Ekolot KR-030 TOPAZ Handling, Maintenance And Periodic Inspections Manual
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Ekolot KR-030 TOPAZ Handling, Maintenance And Periodic Inspections Manual

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Manufacturer: PPHU
EKOLOT
Type: KR-030 TOPAZ
HANDLING, MAINTENANCE AND PERIODIC
SERIAL NUMBER:
Issue: 1
o
Rev. N
:
INSPECTIONS MANUAL
AIRCRAFT
KR-030 TOPAZ
30 - ...... - ......
Date: July 2010
Date:
Handling, maintenance and periodic inspections
manual
Page
1

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Summary of Contents for Ekolot KR-030 TOPAZ

  • Page 1 Handling, maintenance and periodic inspections Manufacturer: PPHU manual EKOLOT Type: KR-030 TOPAZ HANDLING, MAINTENANCE AND PERIODIC INSPECTIONS MANUAL AIRCRAFT KR-030 TOPAZ SERIAL NUMBER: 30 - ..…. - …... Issue: 1 Date: July 2010 Page Rev. N Date:...

  • Page 2: Table Of Contents

    Handling, Maintenance and Periodic Inspections Manufacturer: PPHU Manual EKOLOT Type: KR-030 TOPAZ CONTENTS PAGE 1 SMALL REPAIRS 2 PREPARATION OF THE AIRCRAFT FOR LONG-TERM SUSPENSION OF OPERATION 3 WORKS TO BE DONE AFTER THE LONG-TERM SUSPENSION OF OPERATION 4 ROUTINE MAINTENANCE LIST...
  • Page 3 Handling, Maintenance and Periodic Inspections Manufacturer: PPHU Manual EKOLOT Type: KR-030 TOPAZ 1. SMALL REPAIRS NOTICE: In case of any damage to the propeller, please read the instructions placed in the Operation Manual for AS Type Propellers. NOTICE: All damages to the fuselage composite structure and methods of repair must be consulted with the aircraft manufacturer.

  • Page 4: Preparation Of The Aircraft For Long-Term Suspension Of Operation

    Manufacturer: PPHU Manual EKOLOT Type: KR-030 TOPAZ Value of the P force required to maintain horizontal position of the aileron must not be greater than 0,02 kG. Force P must be applied in the symmetry plane of one of the fastening point.

  • Page 5: Routine Maintenance List

    Manufacturer: PPHU Manual EKOLOT Type: KR-030 TOPAZ - All parts preserved with grease are to be washed and cleaned. - Put air in tires to the level of 1,8 -2,0 Bar. - Carry out activities 1, 2, 3, 4, 5, 6, in the procedure 8.6.

  • Page 6: Periodical Inspection Schedule

    Handling, Maintenance and Periodic Inspections Manufacturer: PPHU Manual EKOLOT Type: KR-030 TOPAZ PERIODICAL INSPECTION SCHEDULE The following schedule shows inspections that must be carried out after specified periods of time or after incidents mentioned: Period of time Perform inspection/check position:...

  • Page 7: Assembly And Disassembly Of The Aircraft

    Manufacturer: PPHU Manual EKOLOT Type: KR-030 TOPAZ 7. ASSEMBLY AND DISASSEMBLY OF THE AIRCRAFT At least two persons are necessary to perform the assembly described below: All parts and elements that are to be assembled must be checked for any visible damages.
  • Page 8 Handling, Maintenance and Periodic Inspections Manufacturer: PPHU Manual EKOLOT Type: KR-030 TOPAZ Pic. 8-1 Placing the wing on the fuselage Pic. 8-2 Installation of mounting pins to the fuselage Issue: 1 Date: July 2010 Page Rev. N Date:...
  • Page 9 Handling, Maintenance and Periodic Inspections Manufacturer: PPHU Manual EKOLOT Type: KR-030 TOPAZ Pic. 8-3 Flaps drive connection Pic. 8-4 Ailerons drive connection to the fuselage Issue: 1 Date: July 2010 Page Rev. N Date:...
  • Page 10 Handling, Maintenance and Periodic Inspections Manufacturer: PPHU Manual EKOLOT Type: KR-030 TOPAZ Pic. 8-5 Tail without elevator unit 1 - front seat for mounting the elevator unit 2 - rear seat for mounting the elevator unit 3 - elevator rod eye...
  • Page 11 Handling, Maintenance and Periodic Inspections Manufacturer: PPHU Manual EKOLOT Type: KR-030 TOPAZ Pic. 8-7 Bolts for fixing elevator unit to the fuselage Pic. 8-8 Connecting of elevator rod to the elevator lever Issue: 1 Date: July 2010 Page Rev. N...

  • Page 12: Adjustment Points Of The Control System

    Loctite 262. Ailerons control system is adjustable by changing length of push rods (recommended to be carried out in Ekolot workshop) Rudder control system is equipped with neutral position adjustment system with pedals in neutral position, (see Pic. 8 – 10), as well as adjustment of deflection, by means of changing positions of limiters mounted on the push-pull rod.
  • Page 13 Handling, Maintenance and Periodic Inspections Manufacturer: PPHU Manual EKOLOT Type: KR-030 TOPAZ Place a lock washer on the middle lever, screw in a crown nut and secure it with a pin. Free the rudder pedal. Push-pull movement limiters Rudder push-pull...
  • Page 14 Handling, Maintenance and Periodic Inspections Manufacturer: PPHU Manual EKOLOT Type: KR-030 TOPAZ Elevator trimmer adjustment J.12.310.03.00 T.12.121.00.01 Using press buttons on the control stick set the trimmer motor slider in the central position (dimensions „a” should be identical) Loosen the bolt in the clamp J.12.310.03.00 (blue arrow in the above photograph) Move the clamp along the rod T.12.121.00.01 to the point elevator is...

  • Page 15: Front Undercarriage

    Handling, Maintenance and Periodic Inspections Manufacturer: PPHU Manual EKOLOT Type: KR-030 TOPAZ PARTS AND SUBASSEMBLIES TO BE REPLACED OUTSIDE THE MANUFACTURER’S FACTORY FRONT UNDERCARRIAGE 9.1.1 Shock absorber assembly J.13.201.00.00 J.13.201.03.00 Pic. 9.1.1 3 pcs. J.13.201.02.00 J.13.201.01.00 4 pcs. AP.PF 126P J.13.201.01.00...
  • Page 16 Handling, Maintenance and Periodic Inspections Manufacturer: PPHU Manual EKOLOT Type: KR-030 TOPAZ Pic. 9.1.3 J.13.130.01.02 Bearing 6004 ZZ zzZ Bearing 6004 ZZ J.13.200.01.00P J.13.200.02.00 J.13.200.03.00 J.13.200.01.00L J.13.200.02.00 J.13.100.01.02 J.13.200.03.00 1. Bolt M6x50 gat. 8,8 DIN 912 2. Washer Ø6 DIN 1440 3.
  • Page 17 Manufacturer: PPHU Handling, Maintenance and Periodic Inspections Manual EKOLOT Type: KR-030 TOPAZ 9.1.4 Complete assembly: hub, rims, tire, inner tube Pic. 9.1.5 Tyre 4.00x6 6 ply Inner tube 4.00x6 J.13.130.02.01 6 pcs. Washer Ø6 6 pcs. Nut M6 DIN 982 J.13.130.01.02...
  • Page 18 Handling, Maintenance and Periodic Inspections Manufacturer: PPHU Manual EKOLOT Type: KR-030 TOPAZ 9.1.6 Wheel mounted on the fork Pic. 9.1.7 Bolt M8 Washer Ø8 Nut M8 DIN 982 Bolt M5 Washer Ø5 DIN 1440 Nut M5 DIN 982 The other side of the wheel is identical.
  • Page 19 Handling, Maintenance and Periodic Inspections Manufacturer: PPHU Manual EKOLOT Type: KR-030 TOPAZ (installed in the airplane) Pic. 9.1.9 J.13.200.00.04 J.13.122.00.01 T.12.622.00.00 Bolt M5x10, 8,8 DIN 912 9.1.8 Removal of wheel from fork 1. Remove the fairing retaining bolts. Pic. 9.1.10 Bolt M5x10, 8,8 DIN 912 Washer Ø5 DIN 1440...
  • Page 20 Handling, Maintenance and Periodic Inspections Manufacturer: PPHU Manual EKOLOT Type: KR-030 TOPAZ 2. Move the fairing upward, along the pole. Pic. 9.1.11 3. Unscrew the shock absorbers mounting bolts. Pic. 9.1.12 Issue: 1 Date: July 2010 Page Rev. N Date:...
  • Page 21 Handling, Maintenance and Periodic Inspections Manufacturer: PPHU Manual EKOLOT Type: KR-030 TOPAZ 4. Unscrew the rocker mounting bolts. Pic. 9.1.13 5. Remove the wheel and the rocker. Pic. 9.1.14 Issue: 1 Date: July 2010 Page Rev. N Date:...
  • Page 22 Handling, Maintenance and Periodic Inspections Manufacturer: PPHU Manual EKOLOT Type: KR-030 TOPAZ 9.1.9 Wheel removal 1. Unscrew the valve and release air from the inner tube. 2. Remove the 6 bolts that attach the rim to the hub. 3. Remove the rim and the tyre Pic.
  • Page 23 Manufacturer: PPHU Manual EKOLOT Type: KR-030 TOPAZ 4. The lever must be fixed in a position allowing to screw in the locking bolt (Pic. 9.1.7, page 18 – Bolt M5x10, 8,8 DIN 912). The bolt must be secured with LOCTITE 262.

  • Page 24: Main Undercarriage

    Handling, Maintenance and Periodic Inspections Manufacturer: PPHU Manual EKOLOT Type: KR-030 TOPAZ MAIN UNDERCARRIAGE 9.2.1 Suspension spring with the wheel axle Pic. 9.2.1 Use LOCTITE 262 J.13.611.00.00 J.13.610.04.0 J.13.610.06.00 J.13.610.05.00 Use epoxy glue for metal surfaces Pic. 9.2.2 Issue: 1...
  • Page 25 Handling, Maintenance and Periodic Inspections Manufacturer: PPHU Manual EKOLOT Type: KR-030 TOPAZ Pic. 9.2.3 J.13.620.00.01 J.13.610.07.00 Axis of the joint is parallel to the wall of the spring J.13.611.00.00 Pic. 9.2.4 Issue: 1 Date: July 2010 Page Rev. N Date:...
  • Page 26 Handling, Maintenance and Periodic Inspections Manufacturer: PPHU Manual EKOLOT Type: KR-030 TOPAZ Pic. 9.2.5 Heat shrink sleeve J.13.620.00.0 Nut M8 AP.PF 126P DIN 982 J.13.611.00.00 Use LOCTITE J.13.610.07.00 J.13.610.08.00 J.13.610.09.00 9.2.2 Disk brake assembly Pic. 9.2.6 1. Part no. 42354-6 www.ulmtechnologie.com...
  • Page 27 Handling, Maintenance and Periodic Inspections Manufacturer: PPHU Manual EKOLOT Type: KR-030 TOPAZ Pic. 9.2.7 Part no. 42354-6 www.ulmtechnologie.com 9.2.3 Wheel - rim and hub assembly Pic. 9.2.8 J.13.613.01.02 6 pcs. Nut M6 DIN 982 6 pcs. Washer Ø 6 DIN 1440 1.
  • Page 28 Handling, Maintenance and Periodic Inspections Manufacturer: PPHU Manual EKOLOT Type: KR-030 TOPAZ 9.2.4 Removal of wheel from the axle 1. Remove the fairing - unscrew the retaining bolts - remove the fairing 2. Remove the 4 bolts (2) that fix the brake disc to the rim Pic.
  • Page 29 Handling, Maintenance and Periodic Inspections Manufacturer: PPHU Manual EKOLOT Type: KR-030 TOPAZ 3. Remove the cotter pin (1) and the circlip (2) Pic. 9.2.10 4. Remove the wheel from the axle. 9.2.5 Removal of the wheel As in the procedure 9.1.9 9.2.6 Tire replacement...
  • Page 30 Manufacturer: PPHU Manual EKOLOT Type: KR-030 TOPAZ 6. Put the rim 42025-1 and the rim 42025-0 with tire (see point 5) on the hub J.13.613.01.02 in the assembly 9.2.3 and the clamp ring 4206 6’’ 7. Screw all the elements with bolts.
  • Page 31 Handling, Maintenance and Periodic Inspections Manufacturer: PPHU Manual EKOLOT Type: KR-030 TOPAZ 9.2.8 Removal of the spring 1. Perform point 3 of the procedure 9.2.7 2. Detach the brake hose from the spring – remove the mounting clamps00 . Pic. 9.2.12...
  • Page 32 Handling, Maintenance and Periodic Inspections Manufacturer: PPHU Manual EKOLOT Type: KR-030 TOPAZ 3. Remove the spring retaining nut (inside the cockpit), remove the washers and the rubber damper AP.PF126P. Pic. 9.2.13 J.13.620.00.0 AP.PF 126P Nut M8 DIN 982 J.13.610.09.00 J.13.610.08.00 4.

  • Page 33: Control Systems

    Handling, Maintenance and Periodic Inspections Manufacturer: PPHU Manual EKOLOT Type: KR-030 TOPAZ CONTROL SYSTEM 9.3.1 Rudder control system Dwg. 9.3.1 Diagram of the rudder control system 1. Main rod T.12.630.00.01 2. Front rod J.12.621.00.01 3. Intermediate lever J.12.620.00.02 4. Drive arm J.12.640.00.02 5.
  • Page 34 Manufacturer: PPHU Handling, Maintenance and Periodic Inspections Manual EKOLOT Type: KR-030 TOPAZ 9.3.1.1 Pedals, front rods and the intermediate lever (items „A”, „B” and „C” in the Dwg. 9.3.1) Pic. 9.3.1 J.12.621.00.01 J.12.612.00.01 J.12.620.01.03 J.12.612.02.00 J.12.612.00.01 J.12.612.01.00 Pic. 9.3.2 Bolt M6x15 DIN 912 Shaft Ø6H7-22...
  • Page 35 Manufacturer: PPHU Handling, Maintenance and Periodic Inspections Manual EKOLOT Type: KR-030 TOPAZ Washer Ø6 DIN 1440 Nut M6 DIN 934 Pic. 9.3.3 Use LOCTITE Bearing 6001 2RS Use LOCTITE J.12.620.01.03 Nut M6 DIN 934 J.12.620.01.03 Bearing 6001 2RS Washer Ø6 DIN 1440...
  • Page 36 Handling, Maintenance and Periodic Inspections Manufacturer: PPHU Manual EKOLOT Type: KR-030 TOPAZ Pic. 9.3.5 J.12.620.03.00 J.10.500.06.04 J.12.620.04.01 Pic. 9.3.6 J.12.612.00.01 J.12.612.00.01 J.12.612.02.00 J.12.612.01.00 „X” (do not remove this bolt from any of the three pedal slide bearings.) Issue: 1 Date: July 2010 Page Rev.
  • Page 37 Handling, Maintenance and Periodic Inspections Manufacturer: PPHU Manual EKOLOT Type: KR-030 TOPAZ Pic. 9.3.7 T.12.622.00.00 J.12.630.00.01 Nut M6 DIN 937 J.12.621.00.01 Washer Ø6 DIN 9021 Cotter pin Ø1.6 DIN 94 Pic. 9.3.8 The left side view Issue: 1 Date: July 2010 Page Rev.
  • Page 38 Manufacturer: PPHU Handling, Maintenance and Periodic Inspections Manual EKOLOT Type: KR-030 TOPAZ Pic. 9.3.9 J.12.621.00.01 J.12.612.02.00 J.12.620.01.03 J.12.612.01.00 T.12.630.00.01 Washer Ø6 DIN 9021 Nut M6 DIN 937 Cotter pin Ø1.6 DIN 94 The right side view 9.3.1.2 Rudder travel limiters. Item „D” (Dwg. 9.3.1) Pic.
  • Page 39 Handling, Maintenance and Periodic Inspections Manufacturer: PPHU Manual EKOLOT Type: KR-030 TOPAZ 9.3.1.3 Rudder drive arm. Item “E” (Dwg. 9.3.1) J.12.642.02.02 Pic. 9.3.11 J.12.642.01.02 J.10.506.00.01 J.12.642.02.02 J.12.641.00.02 use LOCTITE J.12.640.01.00 Nut M6 DIN 934 Pic. 9.3.12 J.12.642.02.02 J.12.642.02.02 J.12.642.01.02 Steel pin Ø5x20 use LOCTITE J.10.506.00.01...
  • Page 40 Handling, Maintenance and Periodic Inspections Manufacturer: PPHU Manual EKOLOT Type: KR-030 TOPAZ Pic. 9.3.13 T.12.630.00.01 Pic. 9.3.14 Issue: 1 Date: July 2010 Page Rev. N Date:...
  • Page 41 Handling, Maintenance and Periodic Inspections Manufacturer: PPHU Manual EKOLOT Type: KR-030 TOPAZ 9.3.1.4 Top hinge of the rudder. Item „F” (Dwg. 9.3.1) Pic. 9.3.15 J.33.000.00.01 J.33.110.00.00 9.3.1.5 Removal of pedals 1. Disconnect the rods J.12.621.00.01 from the pedals lever J.12.612.00.01 (Pic. 9.3.1, 9.3.2 & 9.3.8) 2.
  • Page 42 Handling, Maintenance and Periodic Inspections Manufacturer: PPHU Manual EKOLOT Type: KR-030 TOPAZ 9.3.1.6 Removal of the main rod T.12.630.00.01 (can be performed only after removal of the elevator unit) Pic. 9.3.2 J.12.131.00.01 J.12.630.05.01 T.12.630.01K.0 Nut M6 DIN 934 tył front rod T.12.630.00.01...
  • Page 43 Handling, Maintenance and Periodic Inspections Manufacturer: PPHU Manual EKOLOT Type: KR-030 TOPAZ 5. Unscrew the eye nut J.12.131.00.01 from the front part of the rod T.12.630.00.01 6. Remove the rod in the backward direction, holding the limiters cubes J.12.630.04.01 down not to lose them (Pic. 3.9.10).
  • Page 44 Handling, Maintenance and Periodic Inspections Manufacturer: PPHU Manual EKOLOT Type: KR-030 TOPAZ Rys. 9.3.3 J.12.642.02.02 Rudder J.12.642.01.02 J.10.506.00.01 J.12.630.05.01 J.12.641.00.02 T.12.630.00.01 J.12.640.01.00 9.3.1.9 Removal of the rudder 1. Displace the rudder in one direction as much as possible (Pic. 9.3.18).
  • Page 45 Handling, Maintenance and Periodic Inspections Manufacturer: PPHU Manual EKOLOT Type: KR-030 TOPAZ Pic. 9.3.18 Pic. 9.3.19 Issue: 1 Date: July 2010 Page Rev. N Date:...
  • Page 46 Handling, Maintenance and Periodic Inspections Manufacturer: PPHU Manual EKOLOT Type: KR-030 TOPAZ Pic. 9.3.20 Pic. 9.3.21 J.12.642.02.02 Issue: 1 Date: July 2010 Page Rev. N Date:...

  • Page 47: Elevator And Ailerons Control System

    Handling, Maintenance and Periodic Inspections Manufacturer: PPHU Manual EKOLOT Type: KR-030 TOPAZ 9.3.2 ELEVATOR AND AILERONS CONTROL SYSTEM Dwg. 9.3.4 Elevator and ailerons control system diagram 1. Manual controls T.12.110.00.01 2. Main rod T.12.121.00.01 3. Vertical rod of the ailerons T.12.122.00.00 4.
  • Page 48 Handling, Maintenance and Periodic Inspections Manufacturer: PPHU Manual EKOLOT Type: KR-030 TOPAZ Pic. 9.3.23 brake hoses Nut M6 DIN 982 Washer Ø 6 DIN 1440 9.3.2.2 Manual controls J.12.110.00.01, Item „B” Pic. 9.3.24 T.12.121.00.01 T.12.122.00.00 T.12.122.00.00 T.12.120.00.03 Issue: 1 Date: July 2010 Page Rev.
  • Page 49 Handling, Maintenance and Periodic Inspections Manufacturer: PPHU Manual EKOLOT Type: KR-030 TOPAZ Pic. 9.3.25 Pic. 9.3.26 T.12.122.00.00 J.12.210.08.02 Nut M6 DIN 937 Cotter pin Ø1.6 DIN 94 J.12.122.00.00 J.12.210.08.02 T.12.120.00.03 Nut M6 DIN 937 Cotter pin Ø1.6 DIN 94 Issue: 1...
  • Page 50 Handling, Maintenance and Periodic Inspections Manufacturer: PPHU Manual EKOLOT Type: KR-030 TOPAZ Pic. 9.3.27 use LOCTITE 262 J.12.120.02.01 J.12.211.02.00 J.12.110.03.00 T.12.120.03.02 J.12.120.06.00 Bolt M6x22 DIN 912 J.12.120.04.02 J.12.211.02.00 J.12.120.05.00 Fill up with grease Nut M6 DIN 982 Washer Ø 6 DIN 1440 Pic.
  • Page 51 Handling, Maintenance and Periodic Inspections Manufacturer: PPHU Manual EKOLOT Type: KR-030 TOPAZ Pic. 9.3.29 T.12.120.00.03 J.12.120.06.00 Cotter pin Ø2 DIN 94 T.12.121.00.01 hole Ø4 Pic. 9.3.30 T.12.122.01.00 use LOCTITE T.12.122.02.00 Pic. 9.3.31 Both tips of the rod T.12.122.00.00 are identical...
  • Page 52 Handling, Maintenance and Periodic Inspections Manufacturer: PPHU Manual EKOLOT Type: KR-030 TOPAZ Dwg. 9.3.5 Nut M6 DIN 937 Cotter pin Ø1.6 DIN 94 J.12.210.08.02 J.12.210.08.02 T.12.122.00.00 T.12.122.00.00 Top connection of vertical rods with the ailerons control system in the wing.
  • Page 53 Handling, Maintenance and Periodic Inspections Manufacturer: PPHU Manual EKOLOT Type: KR-030 TOPAZ Dwg. 9.3.6 J.12.131.00.01 T.12.121.01K.0 Nut M6 DIN 934 Front Rod T.12.121.00.01 9.3.2.4 Elevator trimmer (Item „D”, Dwg. 9.3.4) Pic. 9.3.33 J.12.310.04.00 J.12.310.00.00 T.12.121.00.01 J.12.300.00.00 Issue: 1 Date: July 2010 Page Rev.
  • Page 54 Handling, Maintenance and Periodic Inspections Manufacturer: PPHU Manual EKOLOT Type: KR-030 TOPAZ Pic. 9.3.34 J.12.310.00.00 Bolt M4x18 DIN 965 Nut M4 DIN 982 Washer Ø 4 DIN 9021 J.12.300.00.00 Pic. 9.3.35 J.12.310.00.00 J.12.310.03.00 T.12.121.00.01 Issue: 1 Date: July 2010 Page Rev.
  • Page 55 Handling, Maintenance and Periodic Inspections Manufacturer: PPHU Manual EKOLOT Type: KR-030 TOPAZ J.12.310.04.00 Pic. 9.3.36 J.12.310.04.00 J.12.310.00.00 J.12.310.03.00 J.12.300.00.00 T.12.121.00.01 Pic. 9.3.37 Bolt M5x22 DIN 912 4 pcs. J.12.310.04.00 J.12.310.04.00 Nut M5 DIN 982 Washer Ø5 DIN 1440 Bolt M5x22 DIN 912 J.12.310.00.00...
  • Page 56 Handling, Maintenance and Periodic Inspections Manufacturer: PPHU Manual EKOLOT Type: KR-030 TOPAZ 9.3.2.5 Removal of the manual controls 1. Remove the central tunnel cover 2. Remove the back wall of the cockpit 3. Disconnect the electric cables of the controls from the main cluster (connector) 4.

  • Page 57: Flaps Drive System

    Handling, Maintenance and Periodic Inspections Manufacturer: PPHU Manual EKOLOT Type: KR-030 TOPAZ 9.3.2.9 Removal of the elevator trimmer spring J.12.310.00.00 1. Disconnect the trimmer spring J.12.310.00.00 from the trimmer actuator slider J.12.300.00.00 (Pic. 9.3.33, arrow „A”) 2. Unscrew the 4 bolts that fix the clamps J.12.310.04.00 to the structure.
  • Page 58 Handling, Maintenance and Periodic Inspections Manufacturer: PPHU Manual EKOLOT Type: KR-030 TOPAZ Pic. 9.3.39 Issue: 1 Date: July 2010 Page Rev. N Date:...
  • Page 59 Handling, Maintenance and Periodic Inspections Manufacturer: PPHU Manual EKOLOT Type: KR-030 TOPAZ Pic. 9.3.40 T.12.125.00.00 T.12.124.00.00 Pic. 9.3.41 Blind rivet Ø4 with steel stem 3 pcs. use LOCTITE 603 T.12.125.00.00 T.12.124.00.00 Issue: 1 Date: July 2010 Page Rev. N Date:...
  • Page 60 Handling, Maintenance and Periodic Inspections Manufacturer: PPHU Manual EKOLOT Type: KR-030 TOPAZ Pic. 9.3.42 T.12.125.00.00 Pic. 9.3.43 Bolt M6x15 DIN 912 Washer Ø 6 DIN 1440 T.12.124.00.00 T.12.125.00.00 Issue: 1 Date: July 2010 Page Rev. N Date:...
  • Page 61 Handling, Maintenance and Periodic Inspections Manufacturer: PPHU Manual EKOLOT Type: KR-030 TOPAZ 9.3.3.2 Removal of the torsion pipe T.12.124.00.00 (can be performed after removal of the wing) Through the inspection holes in the fuselage (Pic. 9.3.43) remove bolts M6x15 that fix the torsion pipe to the actuator lever T.12.210.00.00. Take the pipe out of the fuselage through the side hole.

  • Page 62: Power Plant

    Handling, Maintenance and Periodic Inspections Manufacturer: PPHU Manual EKOLOT Type: KR-030 TOPAZ 9.3.3.3 Installation and adjustment of the torsion pipe T.12.124.00.00 i T.12.125.00.00 (it refers to a new pipe). Fuselage without the wing. 1. The pipe T.12.124.00.00 is to be fixed with bolts M6x15 to the actuator lever T.12.210.00.00 without LOCTITE 262 (Pic.
  • Page 63 Handling, Maintenance and Periodic Inspections Manufacturer: PPHU Manual EKOLOT Type: KR-030 TOPAZ 1. Propeller assembly Pic. 9.4.1.1 M8x100, 8.8 J.15.201.01.00 DIN 912 6 pcs. Nut M8 DIN 6pcs. M4x16 ISO 7318 6pcs. J.15.000.01.00 Propeller AS 1650/1900 J.15.200.01.01 2. Remove the engine cowling.
  • Page 64 Handling, Maintenance and Periodic Inspections Manufacturer: PPHU Manual EKOLOT Type: KR-030 TOPAZ − Remove the upper cowling. Pic. 9.4.1.3 − Disconnect the landing lamp connector. Pic. 9.4.1.4 Connector Issue: 1 Date: July 2010 Page Rev. N Date:...
  • Page 65 Handling, Maintenance and Periodic Inspections Manufacturer: PPHU Manual EKOLOT Type: KR-030 TOPAZ − Using a flat head screwdriver turn all cam locks of the bottom cowling by 90º angle. Pic. 9.4.1.5 − Remove the bottom cowling Pic. 9.4.1.6 Issue: 1...
  • Page 66 Handling, Maintenance and Periodic Inspections Manufacturer: PPHU Manual EKOLOT Type: KR-030 TOPAZ 3. Remove the spinner J.15.000.01.00. − Remove the spinner mounting bolts M4x16 (6 pcs.). Pic. 9.4.1.7 − Remove the spinner J.15.000.01.00 Pic. 9.4.1.8 J.15.000.01.00 Issue: 1 Date: July 2010 Page Rev.
  • Page 67 Handling, Maintenance and Periodic Inspections Manufacturer: PPHU Manual EKOLOT Type: KR-030 TOPAZ 4. Remove the propeller. − Using a box-end wrench 13 mm and Allen wrench 6mm unscrew the hub mounting bolts M8x100 (6 pcs. shown in the below picture).
  • Page 68 Handling, Maintenance and Periodic Inspections Manufacturer: PPHU Manual EKOLOT Type: KR-030 TOPAZ − Remove the propeller and the bolts, remove the disc J.15.201.01.00 and the ring J.15.200.01.01 off of the engine reduction gear. Pic. 9.4.1.11 Propeller 5. Disconnect the engine controls a.
  • Page 69 Handling, Maintenance and Periodic Inspections Manufacturer: PPHU Manual EKOLOT Type: KR-030 TOPAZ - Using a wrench 8 mm and Allen wrench 4 mm unscrew the clamping bolt and pull out the rope from the clamp Pic. 9.4.1.13 b. Choke control cable −...
  • Page 70 Handling, Maintenance and Periodic Inspections Manufacturer: PPHU Manual EKOLOT Type: KR-030 TOPAZ − Using a wrench 10 mm and Allen wrench 4 mm unscrew the clamping bolt and pull out the rope from the clamp Pic. 9.4.1.15 c. Carburetors heating control −...
  • Page 71 Handling, Maintenance and Periodic Inspections Manufacturer: PPHU Manual EKOLOT Type: KR-030 TOPAZ 6. Disconnect the electrical connector − Remove the safety wire from the connector Pic. 9.4.1.17 − Undo the nut in the bottom part of the connector and disconnect the connector.
  • Page 72 Handling, Maintenance and Periodic Inspections Manufacturer: PPHU Manual EKOLOT Type: KR-030 TOPAZ Pic. 9.4.1.19 7. Disconnect the hot air hose. − Using a socket wrench 7 mm, with a flexible extension if available, loosen the steel hose clamp and remove the corrugated hot air hose Pic.
  • Page 73 Handling, Maintenance and Periodic Inspections Manufacturer: PPHU Manual EKOLOT Type: KR-030 TOPAZ − Using a socket wrench 7 mm loosen the clamps on the coolant hose Pic. 9.4.1.21 Hose clamps − Place a clean pan under the hose and drain the coolant Pic.
  • Page 74 Handling, Maintenance and Periodic Inspections Manufacturer: PPHU Manual EKOLOT Type: KR-030 TOPAZ − Using a socket wrench 7 mm loosen the clamp and disconnect the fuel pipe J.15.407.00.00 from the pump Pic. 9.4.1.23 J.15.407.00.00 − Using a socket wrench 7 mm loosen the clamp and disconnect the fuel pipe 15.406.00.00 from the four-way manifold J.15.400.12.00...
  • Page 75 Handling, Maintenance and Periodic Inspections Manufacturer: PPHU Manual EKOLOT Type: KR-030 TOPAZ − Using a wrench 22 mm unscrew the barb fitting fitting from oil tank (oil hose J.15.255.00.00) Pic. 9.4.1.25 J.15.255.00.00 − Using a wrench 7 mm loosen the clamp and disconnect the breather pipe from the oil tank Pic.
  • Page 76 Handling, Maintenance and Periodic Inspections Manufacturer: PPHU Manual EKOLOT Type: KR-030 TOPAZ − Using fork wrench 19 mm and 22 mm replace the hose barb fitting fitting from the oil tank (oil pipe J.15.254.00.00) Pic. 9.4.1.27 J.15.254.00.00 11. Drain oil from the engine −...
  • Page 77 Handling, Maintenance and Periodic Inspections Manufacturer: PPHU Manual EKOLOT Type: KR-030 TOPAZ Pic. 9.4.1.29 12. Put a clean pan under the surge tank. Using a socket wrench 7 mm loosen the hose clamp and disconnect the coolant hose from the surge tank, draining the coolant from the tank simultaneously.
  • Page 78 Handling, Maintenance and Periodic Inspections Manufacturer: PPHU Manual EKOLOT Type: KR-030 TOPAZ 13. Remove the plastic clamps of pipes and control cables. Pic. 9.4.1.31 14. Sling the engine on a crane of safe working load 200 kg, as shown in the below picture.
  • Page 79 Handling, Maintenance and Periodic Inspections Manufacturer: PPHU Manual EKOLOT Type: KR-030 TOPAZ 15. Using a box-end wrench 13 mm undo the nut and disconnect the electrical bonding cable between the fuselage and the engine frame. Pic. 9.4.1.33 J.15.251.11.00 Bonding cable 16.
  • Page 80 Handling, Maintenance and Periodic Inspections Manufacturer: PPHU Manual EKOLOT Type: KR-030 TOPAZ − Disconnect the magneto cables connector that is connected to the dashboard wiring. The connector is located to the left hand behind the dashboard Pic. 9.4.1.35 − Pull the connector through the hole in the diagonal former after removal of the rubber ring J.14.000.06.00 (the below picture shows...
  • Page 81 Handling, Maintenance and Periodic Inspections Manufacturer: PPHU Manual EKOLOT Type: KR-030 TOPAZ Pic. 9.4.1.37 − Do the same on the firewall Pic. 9.4.1.38 Rubber ring Magneto J.14.000.06.00 cables Issue: 1 Date: July 2010 Page Rev. N Date:...
  • Page 82 Manufacturer: PPHU Manual EKOLOT Type: KR-030 TOPAZ 18. Remove the safety wire, and using a box-end wrench 13 mm remove the lower bolts M8 that attach the engine frame to the fuselage. Do the same on the left and the right side of the engine frame.
  • Page 83 Manufacturer: PPHU Manual EKOLOT Type: KR-030 TOPAZ 19. In similar way as in the point 17, remove the upper bolts that attach the engine frame to the fuselage. Observe the position of the engine on the sling and correct the position if necessary.
  • Page 84 Handling, Maintenance and Periodic Inspections Manufacturer: PPHU Manual EKOLOT Type: KR-030 TOPAZ 7. Connect the coolant hose to the surge tank (compare to the picture 9.4.1.30). 8. Connect the oil hose to the surge tank (compare to the picture 9.4.1.25).
  • Page 85 Handling, Maintenance and Periodic Inspections Manufacturer: PPHU Manual EKOLOT Type: KR-030 TOPAZ 12. Connect the electrical connector (compare to the picture 9.4.1.17, 9.4.1.18 and 9.4.1.19). − Twist the connector’s nut − Secure with safety wire 1.2 mm 13. Connect the engine controls (compare to the picture 9.4.1.12, 9.4.1.13, 9.4.1.14, 9.4.1.15, 9.4.1.16).

  • Page 86: Engine Control System

    Handling, Maintenance and Periodic Inspections Manufacturer: PPHU Manual EKOLOT Type: KR-030 TOPAZ 9.4.2 ENGINE CONTROL SYSTEM Throttle control diagram in the cockpit Dwg. 9.4.2.2 Dwg. 9.4.2.1 Issue: 1 Date: July 2010 Page Rev. N Date:...
  • Page 87 Handling, Maintenance and Periodic Inspections Manufacturer: PPHU Manual EKOLOT Type: KR-030 TOPAZ 9.4.2.1 Throttle control levers J.12.410.00.03L & J.12.410.00.03P Pic. 9.4.2.1 J.12.411.00.03L J.12.412.00.03L J.12.412.05.03 Bolt M5x5 DIN 913 J.12.432.00.03 Bolt M5X10 DIN 912 The lever on the left side Pic. 9.4.2.2 Bolt M6x15 DIN 965 3 pcs.
  • Page 88 Manufacturer: PPHU Handling, Maintenance and Periodic Inspections Manual EKOLOT Type: KR-030 TOPAZ 9.4.2.2 Intermediate bracket J.12.431.00.03 Pic. 9.4.2.3 J.12.423.05.03 J.12.450.00.03 Nut M6 DIN 934 J.12.412.05.03 Bolt M5x5 DIN 913 J.12.432.00.03 J.12.432.00.03 „N” J.12.420.00.03 J.12.430.01.03 Pic. 9.4.2.4 J.12.420.02.03 J.12.422.00.03 J.12.420.01.03 J.12.423.00.03 Nut M6 DIN 982 J.12.423.05.03...
  • Page 89 Handling, Maintenance and Periodic Inspections Manufacturer: PPHU Manual EKOLOT Type: KR-030 TOPAZ Pic. 9.4.2.5 J.12.431.00.03 J.12.430.01.03 9.4.2.4 Removal of the throttle control system 1. Disconnect the cables J.12.450.00.03 from the carburetors clamps. 2. Remove the cover J.12.400.02.03 of the intermediate bracket.
  • Page 90 Handling, Maintenance and Periodic Inspections Manufacturer: PPHU Manual EKOLOT Type: KR-030 TOPAZ Pic. 9.4.2.7 J.12.450.00.03 Bolt M4x12 DIN 7985 Washer Ø4 DIN 1440 Nut M4 DIN 985 J.12.412.05.03 Bolt M5x5 DIN 913 4. Pull out the cable J.12.450.00.03 from the Bowden conduit.
  • Page 91 Handling, Maintenance and Periodic Inspections Manufacturer: PPHU Manual EKOLOT Type: KR-030 TOPAZ 1. The regulatorJ.12.423.05.03 on the bracket J.12.423.00.03 must be screwed in (Pic. 9.4.3) 2. Put the distance element J.12.420.02.03 (Pic. 9.4.2.4) on the axleJ.12.423.00.03 3. Put the cables J.12.431.00.03 to the bracket J.12.421.00.03 with the tip and the seat J.12.430.01.03 (Pic.
  • Page 92 Handling, Maintenance and Periodic Inspections Manufacturer: PPHU Manual EKOLOT Type: KR-030 TOPAZ J.12.420.00.03, eliminate play and secure the cables with clamping bolts M5x5 in clamps J.12.412.05.03 (Pic. 9.4.2.7). Secure the bolts with LOCTITE 262. 8. The regulators J.12.412.05.03 on the intermediate bracket J.12.420.00.03 should be screwed in gradually until the cables are...
  • Page 93 Handling, Maintenance and Periodic Inspections Manufacturer: PPHU Manual EKOLOT Type: KR-030 TOPAZ Pic. 9.4.2.10 Perform operation test of the system: - The throttle levers should move smoothly, without unnecessary play. - There should not be excessive friction in the Bowden cables.

  • Page 94: Fuel System

    Handling, Maintenance and Periodic Inspections Manufacturer: PPHU Manual EKOLOT Type: KR-030 TOPAZ 9.4.3 FUEL SYSTEM 9.4.3.1 Fuel system with tanks installed in the wings 1. Fuel system diagram Dwg. 9.4.3.1 Tanks in wings Tanks in the fuselage 1. Tank in left wing 7.
  • Page 95 Handling, maintenance and periodic inspections Manufacturer: PPHU manual EKOLOT Type: KR-030 TOPAZ 2. Replacement of the reserve sensor − Remove the upper and the lower fuel hose clamps Pic. 9.4.3.1 Pic. 9.4.3.2 Pic. 9.4.3.3 Hose clamp W1 13-15 Hose clampW1 −...
  • Page 96 Handling, maintenance and periodic inspections Manufacturer: PPHU manual EKOLOT Type: KR-030 TOPAZ Pic. 9.4.3.4 3. Removal of the left additional fuel tank − Loosen the hose clamp on the fuel pipe and remove the pipe Hose clamp W1 Pic. 9.4.3.5...
  • Page 97 Handling, maintenance and periodic inspections Manufacturer: PPHU manual EKOLOT Type: KR-030 TOPAZ Pic. 9.4.3.6 − Loosen the clamp on the outlet hose from the settling tank side J.15.430.00.01, located in the central tunnel Pic. 9.4.3.7 Hose clamp W1 − Remove the bolts that mount the tank to the brackets in fuselage...
  • Page 98 Handling, maintenance and periodic inspections Manufacturer: PPHU manual EKOLOT Type: KR-030 TOPAZ Pic. 9.4.3.8 − Lift the additional tank and remove the hose clamp from the overflow hose Issue: 1 Date: July 2010 Page Rev. N Date:...
  • Page 99 Handling, maintenance and periodic inspections Manufacturer: PPHU manual EKOLOT Type: KR-030 TOPAZ Pic. 9.4.3.9 Hose clamp W1 Overflow hose − Remove the additional fuel tank Pic. 9.4.3.10 Overflow hose Issue: 1 Date: July 2010 Page Rev. N Date:...
  • Page 100 Handling, maintenance and periodic inspections Manufacturer: PPHU manual EKOLOT Type: KR-030 TOPAZ 4. Removal of the right additional fuel tank − Loosen the hose clamps on the fuel pipe Pic. 9.4.3.11 Opaska W1 13-15 − Move the rubber part upward and remove it from the fuel tank barb fitting connector Pic.
  • Page 101 Handling, maintenance and periodic inspections Manufacturer: PPHU manual EKOLOT Type: KR-030 TOPAZ − Remove the hose clamp on the drain pipe from the side of the sediment bowl J.15.430.00.01, located in the central tunnel Pic. 9.4.3.13 Hose clamp W1 − Remove the mounting bolts of the fuel tank bracket Pic.
  • Page 102 Handling, maintenance and periodic inspections Manufacturer: PPHU manual EKOLOT Type: KR-030 TOPAZ − Lift the additional tank, loosen the hose clamp of the overflow pipe and cut the “no fuel” sensor electric cable Pic. 9.4.3.15 Opaska W1 13-15 Pic. 9.4.3.16...
  • Page 103 Handling, maintenance and periodic inspections Manufacturer: PPHU manual EKOLOT Type: KR-030 TOPAZ 5. Removal of the sediment bowl − Remove the hose clamps from the drain pipes of the additional tanks and remove the pipes from the tanks Pic. 9.4.3.17 J.15.430.00.01...
  • Page 104 Handling, maintenance and periodic inspections Manufacturer: PPHU manual EKOLOT Type: KR-030 TOPAZ − Loosen the clamp on the fuel pipe J.15.400.08.00 and remove the pipe from the barb fitting Pic. 9.4.3.19 Fuel pipe J.15.400.08.00 Clamp W1 13-15 J.15.430.00.01 − Remove the drain valve (see the point 6 below) −...
  • Page 105 Handling, maintenance and periodic inspections Manufacturer: PPHU manual EKOLOT Type: KR-030 TOPAZ Pic. 9.4.3.21 J.15.430.00.01 6. Replacement of the drain valve − Using an open-end wrench 11 mm unscrew the fuel drain valve (ULM 70569) from the sediment tank J.15.430.00.01 Pic.
  • Page 106 Handling, maintenance and periodic inspections Manufacturer: PPHU manual EKOLOT Type: KR-030 TOPAZ − Clean the bottom hole of the bowl if needed − Screw in a new drain valve (ULM 70569) using a Teflon tape to make the connection tight Pic.
  • Page 107 Handling, maintenance and periodic inspections Manufacturer: PPHU manual EKOLOT Type: KR-030 TOPAZ Pic. 9.4.3.24 − Remove the clamp on the fuel pipe between the filter and the valve and take the filter out Pic. 9.4.3.25 Filtr paliwa FILTRON PS 878 −...
  • Page 108 Handling, maintenance and periodic inspections Manufacturer: PPHU manual EKOLOT Type: KR-030 TOPAZ Pic. 9.4.3.26 Clamp W1 13-15 Pic. 9.4.3.27 Clamp W1 13-15 − Remove the fuel pipes from the fuel valve Issue: 1 Date: July 2010 Page Rev. N Date:...
  • Page 109 Handling, maintenance and periodic inspections Manufacturer: PPHU manual EKOLOT Type: KR-030 TOPAZ − Using a screwdriver and an open-end wrench remove the two screws M4x30 DIN 7985 that fix the assembly J.15.440.00.01 to the bracker J.10.500.22.00 Pic. 9.4.3.28 Screw M4x30 J.15.440.00.01...
  • Page 110 Handling, maintenance and periodic inspections Manufacturer: PPHU manual EKOLOT Type: KR-030 TOPAZ 9. Removal of the electric fuel pump − Remove the fuel pipe clamps (the below picture shows the pump dismounted from the airplane) and remove the pipes Pic. 9.4.3.30...
  • Page 111 Handling, maintenance and periodic inspections Manufacturer: PPHU manual EKOLOT Type: KR-030 TOPAZ Pic. 9.4.3.32 J.15.400.16.00 M6 DIN 982 − Remove the pump from the fuselage 10. Removal of the fuel pressure sensor − Disconnect the connector Pic. 9.4.3.33 Hermetic connector...
  • Page 112 Handling, maintenance and periodic inspections Manufacturer: PPHU manual EKOLOT Type: KR-030 TOPAZ − Loosen the fuel pipe clamp on the fuel pressure sensor barb fitting Pic. 9.4.3.34 Clamp W1 13-15 J.15.408.00.00 − Remove the rubber lined clamp that fixes the sensor to the former of the fuselage Pic.
  • Page 113 Handling, maintenance and periodic inspections Manufacturer: PPHU manual EKOLOT Type: KR-030 TOPAZ − Remove the fuel pressure sensor 11. Replacement of the rubber fuel pipes 12. Installation of the additional left fuel tank (compare to the pictures in point 3) −...
  • Page 114 Handling, maintenance and periodic inspections Manufacturer: PPHU manual EKOLOT Type: KR-030 TOPAZ Part no. 70223 www.ulmtechnologie.com Pic. 9.4.3.36 Screw M4x20 J.15.440.01.01 DIN 963 − The fuel valve, together with the element J.15.440.01.01 is to be put on the bracket J.10.500.22.00, cover with the disc J.15.440.03.01 and connect using screws M4x30 DIN 7985 washers Ø4 DIN 1440...
  • Page 115 Handling, maintenance and periodic inspections Manufacturer: PPHU manual EKOLOT Type: KR-030 TOPAZ Pic. 9.4.3.38 Screw M4x30 DIN 7985 J.10.500.22.00 − Connect the fuel pipes J.15.400.09.00 & J.15.400.10.00 to the fuel valve and secure with the clamps W1 13-15 (compare to the pictures of point 8) 16.
  • Page 116 Handling, maintenance and periodic inspections Manufacturer: PPHU manual EKOLOT Type: KR-030 TOPAZ special attention to correct position of the pump - flow direction must be according to the arrow stamped on the pump body (see the below picture) Pic. 9.4.3.40 −...
  • Page 117 Handling, maintenance and periodic inspections Manufacturer: PPHU manual EKOLOT Type: KR-030 TOPAZ J.15.400.17.00 Nut M4 DIN Washer Ø4 DIN 9021 Bolt M4x30 DIN 7985 J.15.408.00.00 Clamp Fuel RUBBER pressure P-CLIP D35 sensor Pic. 9.4.3.41 − Put the fuel pipe on the barb fitting J.15.408.00.00 and secure with the clamp W1 13-15 −...
  • Page 118 Handling, maintenance and periodic inspections Manufacturer: PPHU manual EKOLOT Type: KR-030 TOPAZ − Using a paper band, tape the fairing and then draw a line on it at 35 mm distance from wing surface Pic. 9.4.3.43 Pic. 9.4.3.44 Issue: 1...
  • Page 119 Handling, maintenance and periodic inspections Manufacturer: PPHU manual EKOLOT Type: KR-030 TOPAZ Pic. 9.4.3.45 − Using a small electric saw, cut the fairing along the marked line Pic. 9.4.3.46 Issue: 1 Date: July 2010 Page Rev. N Date:...
  • Page 120 Handling, maintenance and periodic inspections Manufacturer: PPHU manual EKOLOT Type: KR-030 TOPAZ Pic. 9.4.3.47 Pic. 9.4.3.48 Issue: 1 Date: July 2010 Page Rev. N Date:...
  • Page 121 Handling, maintenance and periodic inspections Manufacturer: PPHU manual EKOLOT Type: KR-030 TOPAZ − Unscrew the bolts M5x15 DIN 912 that are fixing the oil pressure sensor. Pic. 9.4.3.49 Bolts M5x15 DIN 912 − Unroll the spiral casing from the wires and remove the heat...
  • Page 122 Handling, maintenance and periodic inspections Manufacturer: PPHU manual EKOLOT Type: KR-030 TOPAZ Pic. 9.4.3.51 Heat shrinkable tubing − Unsolder the electrical wires Pic. 9.4.3.52 Issue: 1 Date: July 2010 Page Rev. N Date:...
  • Page 123 Handling, maintenance and periodic inspections Manufacturer: PPHU manual EKOLOT Type: KR-030 TOPAZ Pic 9.4.3.53 − Remove the hose clamps AML 12 from a rubber pipe Pic. 9.4.3.54 Hose clamp AML12 Issue: 1 Date: July 2010 Page Rev. N Date:...
  • Page 124 Handling, maintenance and periodic inspections Manufacturer: PPHU manual EKOLOT Type: KR-030 TOPAZ − Pull out the ventilation pipe from a rubber pipe Pic. 9.4.3.55 − Remove rubber pipe from a sensor ferrule and pull out from the electrical wires Pic. 9.4.3.56 −...
  • Page 125 Handling, maintenance and periodic inspections Manufacturer: PPHU manual EKOLOT Type: KR-030 TOPAZ Pic. 9.4.3.57 Pic. 9.4.3.58 Issue: 1 Date: July 2010 Page Rev. N Date:...
  • Page 126 Manufacturer: PPHU manual EKOLOT Type: KR-030 TOPAZ − Assemble the new oil pressure sensor by gently putting it in the opening inside the pipe. Pay attention to the position of the ring and make sure that you don’t damage the heat shrinkable tubing when putting it in.
  • Page 127 Handling, maintenance and periodic inspections Manufacturer: PPHU manual EKOLOT Type: KR-030 TOPAZ Pic. 9.4.3.61 − Put on the rubber sector of the ventilation pipe on the oil pressure sensor ferrule. Push the electrical wires through the rubber pipe. Pic. 9.4.3.62 −...
  • Page 128 Handling, maintenance and periodic inspections Manufacturer: PPHU manual EKOLOT Type: KR-030 TOPAZ Pic. 9.4.3.63 LOCTITE 5922 − Slide over the rubber sector on the aluminium tube. Make sure that the electrical wires are not damaged in the process. Pic. 9.4.3.64 −...
  • Page 129 Handling, maintenance and periodic inspections Manufacturer: PPHU manual EKOLOT Type: KR-030 TOPAZ Pic. 9.4.3.65 Hose clamp AML 12 − Protect the end of the rubber sector along with the electrical wires by using preparation LOCTITE 5922 LOCTITE 5922 Pic. 9.4.3.66 −...
  • Page 130 Handling, maintenance and periodic inspections Manufacturer: PPHU manual EKOLOT Type: KR-030 TOPAZ Pic. 9.4.3.67 Heat shrinkable tubing − Solder the electrical wires and secure it with heat shrinkable tubing by heating it up Pic. 9.4.3.68 Issue: 1 Date: July 2010 Page Rev.
  • Page 131 Handling, maintenance and periodic inspections Manufacturer: PPHU manual EKOLOT Type: KR-030 TOPAZ Pic. 9.4.3.70 − Wrap already soldered electrical wires with spiral casing Spiral Pic. 9.4.3.71 casing Issue: 1 Date: July 2010 Page Rev. N Date:...
  • Page 132 Handling, maintenance and periodic inspections Manufacturer: PPHU manual EKOLOT Type: KR-030 TOPAZ − Use abrasive paper to clean and degrease the surfaces of the internal fairing sensor. Pic. 9.4.3.72 − Prepare straps 15x78 from glass panel in thickness 1-1.5 mm and four plates 10x10 mm from a panel in thickness 3 mm Pic.
  • Page 133 Handling, maintenance and periodic inspections Manufacturer: PPHU manual EKOLOT Type: KR-030 TOPAZ − Glue the straps and plates to the internal fairing surface in the way shown below: Plate gr. 3 mm Dwg. 9.4.3.2 Fairing Pic. 9.4.3.74 Issue: 1 Date: July 2010 Page Rev.
  • Page 134 Handling, maintenance and periodic inspections Manufacturer: PPHU manual EKOLOT Type: KR-030 TOPAZ Pic. 9.4.3.75 Pic. 9.4.3.76 − Apply the already cut-off upper part of a faring on the lower one and holding them both together drill four openings Ø3 mm (see the...
  • Page 135 Handling, maintenance and periodic inspections Manufacturer: PPHU manual EKOLOT Type: KR-030 TOPAZ Pic. 9.4.3.77 − Use screw-tap M4 to tap the drilled openings Pic. 9.4.3.78 Issue: 1 Date: July 2010 Page Rev. N Date:...
  • Page 136 Handling, maintenance and periodic inspections Manufacturer: PPHU manual EKOLOT Type: KR-030 TOPAZ Pic. 9.4.3.79 − Put on the upper part of the fairing right on to the lower part and protect the place of contact by using adhesive foil in width 15-20 Pic.
  • Page 137 Handling, maintenance and periodic inspections Manufacturer: PPHU manual EKOLOT Type: KR-030 TOPAZ Adhesive foil Pic. 9.4.3.81 − Secure the fairing by using four M4x10 DIN 7985 screws Pic. 9.4.3.82 Issue: 1 Date: July 2010 Page Rev. N Date:...
  • Page 138 Handling, maintenance and periodic inspections Manufacturer: PPHU manual EKOLOT Type: KR-030 TOPAZ Pic. 9.4.3.83 Pic. 9.4.3.84 Issue: 1 Date: July 2010 Page Rev. N Date:...
  • Page 139 Handling, maintenance and periodic inspections Manufacturer: PPHU manual EKOLOT Type: KR-030 TOPAZ 9.4.3.2 Fuel system installation with the tanks behind pilots’ seats. 1. Fuel system schematic illustration Dwg. 9.4.3.3 1. Left tank 9. Carburettors 2. Right tank 10. Electrical fuel pump 3.
  • Page 140 Handling, maintenance and periodic inspections Manufacturer: PPHU manual EKOLOT Type: KR-030 TOPAZ Pic. 9.4.3.85 Pic. 9.4.3.86 Band clip Issue: 1 Date: July 2010 Page Rev. N Date:...
  • Page 141 Handling, maintenance and periodic inspections Manufacturer: PPHU manual EKOLOT Type: KR-030 TOPAZ − Remove a ventilation pipe from fuel tank venting ferrule J.15.410.09.03 Pic. 9.4.3.87 Ventilation pipe Hose clamp − Undo a hose clamp on a drain pipe from the tank next to fuel trap J.15.430.00.01 situated in the middle tunnel...
  • Page 142 Handling, maintenance and periodic inspections Manufacturer: PPHU manual EKOLOT Type: KR-030 TOPAZ Pic. 9.4.3.89 − Unscrew upper bolts fastening fuel tank with luggage rack Pic. 9.4.3.90 Bolt M5x20 Issue: 1 Date: July 2010 Page Rev. N Date:...
  • Page 143 Handling, maintenance and periodic inspections Manufacturer: PPHU manual EKOLOT Type: KR-030 TOPAZ Pic. 9.4.3.91 − Unscrew a lower bolt fastening bracket with a fuel tank 15.410.13.01L Pic. 9.4.3.92 Bolt M5x25 Issue: 1 Date: July 2010 Page Rev. N Date:...
  • Page 144 Handling, maintenance and periodic inspections Manufacturer: PPHU manual EKOLOT Type: KR-030 TOPAZ − Carefully pull out the fuel tank from a pit behind the seat Pic. 9.4.3.93 4. Left fuel tank disassembly − Undo a hose clamp on a ventilation pipe and slide down...
  • Page 145 Handling, maintenance and periodic inspections Manufacturer: PPHU manual EKOLOT Type: KR-030 TOPAZ Foto 9.4.3.94 Hose clamp − Undo a hose clamp on the overflow pipe and slide down the pipe from a ferrule Pic. 9.4.3.95 Band clip Issue: 1 Date: July 2010 Page Rev.
  • Page 146 Handling, maintenance and periodic inspections Manufacturer: PPHU manual EKOLOT Type: KR-030 TOPAZ − Undo a hose clamp from a ventilation pipe no 14 and slide down the pipe from a ferrule Foto 9.4.3.96 Hose clamp − Undo an upper hose clamp on a filling elbow and slide down the...
  • Page 147 Handling, maintenance and periodic inspections Manufacturer: PPHU manual EKOLOT Type: KR-030 TOPAZ Pic. 9.4.3.97 Hose clamp Pic. 9.4.3.98 Issue: 1 Date: July 2010 Page Rev. N Date:...
  • Page 148 Handling, maintenance and periodic inspections Manufacturer: PPHU manual EKOLOT Type: KR-030 TOPAZ − Undo a hose clamp from a refueling pump pipe and slide down the pipe Pic. 9.4.3.99 Hose clamp W1 13-15 Pic. 9.4.3.100 Issue: 1 Date: July 2010 Page Rev.
  • Page 149 Handling, maintenance and periodic inspections Manufacturer: PPHU manual EKOLOT Type: KR-030 TOPAZ − Undo a lower hose clamp on a filling elbow and remove it from the fuel runner and filling pipe on a tank Pic. 9.4.3.101 Hose clamp Pic. 9.4.3.102...
  • Page 150 Handling, maintenance and periodic inspections Manufacturer: PPHU manual EKOLOT Type: KR-030 TOPAZ − Undo a hose clamp a drain pipe from the tank next to the fuel decanter J.15.430.00.01 situated in the middle tunnel Pic. 9.4.3.103 Trim W1 25-28 − Slide down the drain pipe from a fuel decanter ferrule J.15.430.00.01...
  • Page 151 Handling, maintenance and periodic inspections Manufacturer: PPHU manual EKOLOT Type: KR-030 TOPAZ − Unscrew upper bolts fastening the tank with luggage rack Pic. 9.4.3.105 Bolt M5x20 Pic. 9.4.3.106 Issue: 1 Date: July 2010 Page Rev. N Date:...
  • Page 152 Handling, maintenance and periodic inspections Manufacturer: PPHU manual EKOLOT Type: KR-030 TOPAZ Unscrew a lower bolt fastening the bracket with a fuel tank 15.410.13.01P Pic. 9.4.3.107 Bolt M5x25 − Remove the tank from a pit behind pilot’s seat (see the pictures below) Pic.
  • Page 153 Handling, maintenance and periodic inspections Manufacturer: PPHU manual EKOLOT Type: KR-030 TOPAZ Pic. 9.4.3.109 Pic. 9.4.3.110 Pic. 9.4.3.111 Issue: 1 Date: July 2010 Page Rev. N Date:...
  • Page 154 Manufacturer: PPHU manual EKOLOT Type: KR-030 TOPAZ 5. Fuel decanter disassembly– perform according to the point 5 from chapter 9.4.3.1. Sentence: „Undo band clips on the drain pipes from extra tanks and slide down pipes from the tank” changes into:...

  • Page 155: Engine Lubrication System

    Handling, maintenance and periodic inspections Manufacturer: PPHU manual EKOLOT Type: KR-030 TOPAZ 9.4.4 ENGINE LUBRICATION SYSTEM 1. Removal of the engine oil tank − Disconnect the oil hoses (see point 10 in procedure 9.4.6) and drain oil from the engine (see point 11 in procedure 9.4.6) −...
  • Page 156 Handling, maintenance and periodic inspections Manufacturer: PPHU manual EKOLOT Type: KR-030 TOPAZ Pic. 9.4.4.2 M4 DIN 982 4 pcs. − Remove the bracket J.15.250.09.00 and remove the oil tank − Drain the oil tank through the inlet 2. Removal of the engine oil cooler −...
  • Page 157 Handling, maintenance and periodic inspections Manufacturer: PPHU manual EKOLOT Type: KR-030 TOPAZ Pic. 9.4.4.4 J.15.256.00.00 − Unscrew the bottom bracket J.15.250.02.00 from the engine block Pic. 9.4.4.5 J.15.250.13.00 J.15.250.02.00 Issue: 1 Date: July 2010 Page Rev. N Date:...
  • Page 158 Handling, maintenance and periodic inspections Manufacturer: PPHU manual EKOLOT Type: KR-030 TOPAZ − Unscrew the bracket J.15.250.03.00 from the reducer body and remove the cooler Pic. 9.4.4.6 J.15.250.03.00 3. Installation of then oil tank − Fix the tank using clamping rings J.15.250.09.00 and brackets J.15.250.08.00 and secure with nuts M4 DIN 982 inside the cockpit...
  • Page 159 Handling, maintenance and periodic inspections Manufacturer: PPHU manual EKOLOT Type: KR-030 TOPAZ − The bracket J.15.250.03.00 should be fixed with bolts M8x20 DIN 931 to the reducer body − The bracket J.15.250.02.00 should fixed with bolts J.15.250.13.00 and washers J.15.250.06.02 to the oil pump body Pic.
  • Page 160 Handling, maintenance and periodic inspections Manufacturer: PPHU manual EKOLOT Type: KR-030 TOPAZ a. Remove the oil hose from the oil tank barb fitting (see point 10 in the procedure 9.4.6) b. Remove the oil hose from the oil cooler barb fitting (see point c.
  • Page 161 Handling, maintenance and periodic inspections Manufacturer: PPHU manual EKOLOT Type: KR-030 TOPAZ Pic. 9.4.4.10 Clamp W1 18-20 J.15.254.00.00 − Oil hose J.15.256.00.00 Pic. 9.4.4.11 Barb fitting Oil hose CONTI-TCH- Rotax OLNS1-12x3.5 AEM/AEM Clamps W1 18-20 J.15.256.01.00 Issue: 1 Date: July 2010 Page Rev.
  • Page 162 Handling, maintenance and periodic inspections Manufacturer: PPHU manual EKOLOT Type: KR-030 TOPAZ a. Remove the oil hose J.15.256.00.00 from the cooler Pic. 9.4.4.12 J.15.256.00.00 b. Remove the oil hose J.15.256.00.00 from the oil pump Pic. 9.4.4.13 J.15.256.00.00 Clamp W1 18-20 c.

  • Page 163: Engine Cooling System

    Handling, maintenance and periodic inspections Manufacturer: PPHU manual EKOLOT Type: KR-030 TOPAZ f. Put the barb fitting on the upper rubber hose and secure with the clamp W1 18-20 g. Connect the oil hose J.15.256.00.00 to the oil cooler (see the point „a”)
  • Page 164 Handling, maintenance and periodic inspections Manufacturer: PPHU manual EKOLOT Type: KR-030 TOPAZ Dwg. 9.4.5.2 1. Gasket 6. Sealing ring 2. Cover 7. O-ring 3. Bolt M6x90 – DIN 912 8. Inlet elbow 4. Bolt M6x35 – DIN 912 9. Bolt M6x20 – DIN 912 5.
  • Page 165 Handling, maintenance and periodic inspections Manufacturer: PPHU manual EKOLOT Type: KR-030 TOPAZ Dwg. 9.4.5.4 − The inlet fittings should be secured with LOCTITE 243 − Install the cover with the bolts (3, 4 & 5). Secure the bolts thread with a thread sealant.
  • Page 166 Handling, maintenance and periodic inspections Manufacturer: PPHU manual EKOLOT Type: KR-030 TOPAZ Pic. 9.4.5.2 Self acting clamp − Fix the three-way manifold J.15.505.00.00 to the pump cover with bolts (9) Pic. 9.4.5.3 J.15.505.00.00 Issue: 1 Date: July 2010 Page Rev. N...
  • Page 167 Handling, maintenance and periodic inspections Manufacturer: PPHU manual EKOLOT Type: KR-030 TOPAZ Pic. 9.4.5.4 Bolt M6x20 DIN 912 Install the coolant hoses J.15.500.01.01 & J.15.500.07.00 and secure with clamps W1 25-28 J.15.505.00.00 Pic. 9.4.5.5 J.15.500.07.00 J.15.500.01.01 3. Thermostst − Complete thermostat assembly – diagram...
  • Page 168 Handling, maintenance and periodic inspections Manufacturer: PPHU manual EKOLOT Type: KR-030 TOPAZ Dwg. 9.4.5.5 4. O-ring Ø48x3 1. Thermostst body – J.15.501.01.00 2. Cover – J.15.501.02.00 5. Socket cap bolt M6x18 – DIN 912 6. Washer Ø6 – DIN 1440 3.
  • Page 169 Handling, maintenance and periodic inspections Manufacturer: PPHU manual EKOLOT Type: KR-030 TOPAZ Pic. 9.4.5.7 J.15.500.07.00 J.15.500.02.01 o Remove the hoses from the thermostat and take out the thermostat − Replacement of the thermostat o Remove the thermostat assembly (see the previous...
  • Page 170 Manufacturer: PPHU manual EKOLOT Type: KR-030 TOPAZ o Close the body placing the o-ring Ø48x3 into the groove o Tighten the bolts M6x18 using the thread sealant o Install the coolant hoses 6, 7 & 8 on appropriate inlets of...
  • Page 171 Handling, maintenance and periodic inspections Manufacturer: PPHU manual EKOLOT Type: KR-030 TOPAZ Pic. 9.4.5.10 J.15.502.04.00 J.15.502.03.00 Clamp W1 13-15 Pic. 9.4.5.11 J.15.500.03.00 Clamp W1 13-15 o Remove the springs Issue: 1 Date: July 2010 Page Rev. N Date:...
  • Page 172 Handling, maintenance and periodic inspections Manufacturer: PPHU manual EKOLOT Type: KR-030 TOPAZ Pic. 9.4.5.12 Springs o Remove the clamps that mounts the heating system to the suction manifold and remove the system together with carburetors Pic. 9.4.5.13 Clamp o Remove the bolt M5x8 and remove the heating elements...
  • Page 173 Handling, maintenance and periodic inspections Manufacturer: PPHU manual EKOLOT Type: KR-030 TOPAZ − Installation of the carburetors heating system o Drain the coolant from the engine cooling system o Remove the spring o Loosen the clamps on the suction manifolds and remove...
  • Page 174 Handling, maintenance and periodic inspections Manufacturer: PPHU manual EKOLOT Type: KR-030 TOPAZ o Insert the carburetors with the heaters onto the suction manifolds and secure with the steel clamps. Pic. 9.4.5.17 Clamp o Install the safety springs Pic. 9.4.5.18 Spring o Fix the heating control mechanism J.12.460.02.01 and...
  • Page 175 Handling, maintenance and periodic inspections Manufacturer: PPHU manual EKOLOT Type: KR-030 TOPAZ Pic. 9.4.5.19 J.12.460.02.01 o Connect the heating hose no 9 to the fitting on the three- way manifold J.15.500.04.00 and to the external fitting on the left heating assembly and secure with the clamp W1 13-15 Pic.
  • Page 176 Handling, maintenance and periodic inspections Manufacturer: PPHU manual EKOLOT Type: KR-030 TOPAZ Pic. 9.4.5.21 J.15.502.03.00 Clamp W1 13-15 J.15.502.03.00 Opaska W1 13-15 Pic. 9.4.5.22 o Connect the heating hose no 11 to the external fitting on the right heating assembly and the control system valve...
  • Page 177 Handling, maintenance and periodic inspections Manufacturer: PPHU manual EKOLOT Type: KR-030 TOPAZ J.15.502.04.00 Clamp W1 13-15 Pic. 9.4.5.23 Pic. 9.4.5.24 J.15.502.04.00 Clamp W1 13-15 Valve Issue: 1 Date: July 2010 Page Rev. N Date:...
  • Page 178 Handling, maintenance and periodic inspections Manufacturer: PPHU manual EKOLOT Type: KR-030 TOPAZ 5. Coolant surge tank and connecting hose − Removal of the surge tank o Put a clean pan under the surge tank, loosen the clamp of the hose J.15.500.09.00, remove the hose and drain the coolant from the system and the tank Pic.
  • Page 179 Handling, maintenance and periodic inspections Manufacturer: PPHU manual EKOLOT Type: KR-030 TOPAZ o Remove the surge tank assembly bolts J.15.250.10.00 Pic. 9.4.5.26 o Remove the surge tank with the clamping ring J.15.250.10.00 the nuts inside the cockpit Pic. 9.4.5.27 Issue: 1...
  • Page 180 Handling, maintenance and periodic inspections Manufacturer: PPHU manual EKOLOT Type: KR-030 TOPAZ − Installation of the surge tank o Put the clamping ring on the tank J.15.250.10.00 o Fix the clamp and the tank with bolts M5x15 DIN 912, washers Ø5 DIN 9021 and nuts M5 DIN982 o Connect the hose J.15.500.09.00 to the tank stub pipe...

  • Page 181: Airframe Structure

    Handling, maintenance and periodic inspections Manufacturer: PPHU manual EKOLOT Type: KR-030 TOPAZ 9.5 AIRFRAME STRUCTURE 9.5.1 DOORS (left door is shown in the picture, right door is symmetrically identical) 9.5.1.1 Rear lock of the door Pic. 9.5.1 T.14.200.01.00 T.14.207.00.00 T.14.206.00.00 Bolt M5x5 Pic.
  • Page 182 Handling, maintenance and periodic inspections Manufacturer: PPHU manual EKOLOT Type: KR-030 TOPAZ Pic. 9.5.3 Washer Ø5 DIN 1440 Cotter pin Ø1.6 DIN 94 T.14.207.00.00 T.14.200.01.00 Bolt M5x5 DIN 913 T.14.206.00.00 T.14.205.04.00 9.5.1.2 Upper rear interlock Pic. 9.5.4 T.14.208.00.00 T.14.200.01.00 Issue: 1...
  • Page 183 Handling, maintenance and periodic inspections Manufacturer: PPHU manual EKOLOT Type: KR-030 TOPAZ Pic. 9.5.5 use LOCTITE T.14.208.00.00 T.14.208.03.00 T.14.200.01.00 9.5.1.3 Front upper lock Pic. 9.5.6 Bolt M5x5 DIN 913 T.14.205.00.00 T.14.206.00.00 Issue: 1 Date: July 2010 Page Rev. N Date:...
  • Page 184 Handling, maintenance and periodic inspections Manufacturer: PPHU manual EKOLOT Type: KR-030 TOPAZ Pic. 9.5.7 T.14.206.00.00 T.14.205.04.00 Bolt M5x5 DIN 913 T.14.205.00.00 Pic. 9.5.8 use LOCTITE Bolt M5x5 DIN 913 T.14.205.00.00 T.14.206.00.00 T.14.205.04.00 Issue: 1 Date: July 2010 Page Rev. N...
  • Page 185 Handling, maintenance and periodic inspections Manufacturer: PPHU manual EKOLOT Type: KR-030 TOPAZ 9.5.1.4 Hinge Pic. 9.5.9 Cover of the upper hinge Cover of the lower hinge Pic. 9.5.10 Bolt M6x25 DIN 966 Nut M6 DIN 982 T.14.202.01.00 Bolt M6x20 DIN 912 T.14.202.02.00...
  • Page 186 Handling, maintenance and periodic inspections Manufacturer: PPHU manual EKOLOT Type: KR-030 TOPAZ Pic. 9.5.11 T.14.202.01.00 T.14.202.03.00 T.14.202.02.00 Pic. 9.5.12 T.14.202.01.00 T.14.202.04.00 T.14.202.02.00 Issue: 1 Date: July 2010 Page Rev. N Date:...
  • Page 187 Handling, maintenance and periodic inspections Manufacturer: PPHU manual EKOLOT Type: KR-030 TOPAZ 9.5.1.5 Door travel limiter Pic. 9.5.13 Nut M5 DIN 1587 Washer Ø5 DIN 1440 T.14.210.00.00 Pic. 9.5.14 T.14.210.00.00 Nut M5 DIN 1587 Washer Ø5 DIN 1440 Issue: 1...
  • Page 188 Handling, maintenance and periodic inspections Manufacturer: PPHU manual EKOLOT Type: KR-030 TOPAZ 9.5.1.6 Removal of the doors 1. Remove the hinge covers (Pic. 9.5.9, 9.5.10) 2. Disconnect the door travel limiter T.14.210.00.00 (Pic. 9.5.13) 3. Remove the bolts M6x20 (Pic. 9.5.10) 4.

  • Page 189: Replacement Of Glazing

    Handling, maintenance and periodic inspections Manufacturer: PPHU manual EKOLOT Type: KR-030 TOPAZ 9.5.2 REPLACEMENT OF GLAZING Removal of cracked glazing 1. Using a heat gun heat the edges of the broken glazing in order to make them flexible. Secure the structures bordering the glazing not to destroy painting and composite structure.

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