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Zenair CH 601 XL ZODIAC 2002 Flight Manual

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Summary of Contents for Zenair CH 601 XL ZODIAC 2002

  • Page 1 Í É Í É...
  • Page 2 represented by: ........................and as the organization authorized by the Ministry of Transportation and Communications of the Czech Republic to prove compliance with the microlight airplane category airworthiness requirements, certifies, that the airplane design, used materials, flight performance and characteristics comply with the Czech UL-2 airworthiness requirements and the airplane is categorized to the following group of microlight airplanes: Signature:...
  • Page 3 Record of revisions Any revision of the present manual, except actual weighing data, must be recorded in the following table. The new or amended text in the revised pages will be indicated by a black vertical line in the left hand margin, and the Revision No. and Date will be shown on the bottom of the page.
  • Page 4 List of Effective Pages Section Page Date of Section Page Date of Issue Issue 12/2002 12/2002 12/2002 12/2002 12/2002 12/2002 12/2002 12/2002 12/2002 12/2002 12/2002 12/2002 12/2002 12/2002 12/2002 12/2002 12/2002 12/2002 12/2002 12/2002 12/2002 12/2002 12/2002 12/2002 12/2002 12/2002 12/2002 12/2002 12/2002...
  • Page 5 Section Page Date of Section Page Date of Issue Issue 12/2002 12/2002 12/2002 12/2002 12/2002 12/2002 12/2002 12/2002 12/2002 12/2002 12/2002 12/2002 12/2002 12/2002 12/2002 12/2002 12/2002 12/2002 12/2002 12/2002 12/2002 12/2002 12/2002 12/2002 12/2002 4/2001 12/2002 12/2002 12/2002 12/2002 12/2002 12/2002 12/2002...

  • Page 6: Table Of Contents

    Table of Contents Section GENERAL.................1 LIMITATIONS ..............2 EMERGENCY PROCEDURES.........3 NORMAL PROCEDURES ..........4 PERFORMANCE ..............5 WEIGHT AND BALANCE ..........6 AIRCRAFT AND SYSTEMS DESCRIPTION ....7 AIRCRAFT HANDLING, CARE AND MAINTENANCE ..8 SUPPLEMENTS ...............9 Date of Issue: Document No.: Revision: 12/2002 Z601XLFMEN...

  • Page 7: General

    SECTION 1 1. GENERAL 1.1 Introduction 1.2 Certification basis 1.3 Warnings, cautions and notes 1.4 Descriptive data 1.4.1 Aircraft description 1.4.2 Technical data Date of Issue: Revision: Document No.: 12/2002 Z601XLFMEN...
  • Page 8 Introduction The airplane Flight Manual has been prepared to provide pilots with information for the safe and efficient operation of It also contains supplemental data supplied by the airplane manufacturer. Certification basis This aircraft type has been approved in compliance with UL-2 regulation, which is mandatory certification basis for Microlight category airplanes approved by Light Aircraft Association of the Czech Republic (LAA CR).
  • Page 9 Warnings, cautions and notes The following definitions apply to warnings, cautions and notes in the flight manual. WARNING Means that the non-observation of the corresponding procedure leads to an immediate or important degradation of the flight safety. CAUTION Means that the non-observation of the corresponding procedure leads to a minor or possible long term degradation of the flight safety.
  • Page 10 Descriptive data 1.4.1 Aircraft description microlight airplane intended especially recreational and cross-country flying, with a limitation to non-aerobatics operation. is a single-engine, all metal, low-wing monoplane of semimonocoque construction with two side-by-side seats. The airplane is equipped with a fixed tricycle undercarriage with steerable nose wheel. The powerplant is composed of ROTAX 912 (80 hp or 100 hp), four cylinder, four stroke engine and optional propeller by customer’s request.
  • Page 11 1.4.2 Technical data Wing span ............8.23 m Wing area .............12.3 Length ............6.1 Cockpit width ..........1.12 m Height1.98 .............m Date of Issue: Revision: Document No.: 12/2002 Z601XLFMEN...
  • Page 12 Three-view drawing Date of Issue: Revision: Document No.: 12/2002 Z601XLFMEN...

  • Page 13: Limitations

    SECTION 2 2. LIMITATIONS 2.1 Introduction 2.2 Airspeed 2.3 Airspeed indicator markings 2.4 Powerplant 2.5 Powerplant instrument markings 2.6 Miscellaneous instrument markings 2.7 Weight 2.8 Center of gravity 2.9 Approved maneuvers 2.10 Maneuvering load factors 2.11 Crew 2.12 Kinds of operation 2.13 Fuel 2.14 Maximum passenger seating 2.15 Other limitations...
  • Page 14 Introduction Section 2 includes operating limitations, instrument markings and basic placards necessary for the safe operation of the aircraft, its engine, standard systems and standard equipment. Limitations for optional systems and equipment are shown in Section 9. Supplements. Airspeed Airspeed limitations and their operational significance are shown below: Speed KIAS Remarks...
  • Page 15 Airspeed indicator markings Airspeed indicator markings and their color-code significance are shown below: Marking IAS value or range Significance [km/h] KIAS White 55÷120 30-65 Positive Flap Operating Range. Green 70÷210 38-113 Normal Operating Range. Maneuvers must be conducted Yellow 210÷260 113-140 with caution and only in smooth air.
  • Page 16 Powerplant , S/N: , S/N is fitted with ROTAX 912 and prop, Type / S/N Engine Model: ROTAX 912A (or UL) ROTAX 912S (or ULS) Engine Manufacturer: Bombardier-Rotax GMBH 59.6 kW / 80 hp 73.5 kW / 100 hp Max Take-off: at 5800 rpm, max.5 min.
  • Page 17 Powerplant instrument markings Analogue engine instruments markings and their color-code significance are shown below. Normal Minimum Caution Maximum Function Operating Limit Range Range Range Engine speed 1400 1400-5500 5500-5800 5800 [RPM] R 912 100-150 °C Cylinder 150 °C (80 hp) 212-302 °F Head 302 °F...
  • Page 18 Miscellaneous instrument markings Date of Issue: Document No.: Revision: 12/2002 Z601XLFMEN...
  • Page 19 Weight Empty weight (standard equipment)..270 kg 595 lbs. NOTE Actual empty weight is shown in SECTION 6, par. 6.2 Max. take-off weight ........450 kg lbs. Max landing weight........450 kg 992 lbs. Max. weight of fuel .........65 kg 143 lbs.
  • Page 20 2.10 Maneuvering load factors Maximum positive limit load factor........+4 g Maximum negative limit load factor ........-2 g 2.11 Crew Number of seats............2 Minimum crew weight.........55 kg 121 lb. Maximum crew weight........see 6.2 WARNING Do not exceed Maximum takeoff weight 450 kg (992 lbs.) ! 2.12 Kinds of operation There are permitted day VFR (Visual Flight Rules) flights only.
  • Page 21 2.13 Fuel EUROSUPER RON 95 unleaded according to EN 228 or DIN 51607 AVGAS 100 LL or 100/130 Due to higher lead content in AVGAS, the wear of valve seats and deposits in the combustion chamber will increase. Therefore, use AVGAS only if other fuel types are not available.
  • Page 22 2.16 Limitation placards The airplane must be placarded with: All fuses Ignition switches Choke Starter Trim: Nose heavy and Tail heavy Fuel quantity indicator according to the engine manual Maximum baggage weight Instruments Cockpit opening Fuel type and its quantity – at filler neck Identification plate located on the fuselage port side below stabilizer (plate must show required information) Operating data and Limitations...

  • Page 23: Emergency Procedures

    SECTION 3 EMERGENCY PROCEDURES 3.1 Introduction 3.2 Engine failure 3.2.1 Engine failure during take-off run 3.2.2 Engine failure during take-off 3.2.3 Engine failure in flight 3.3 In-flight Engine Starting 3.4 Smoke and fire 3.4.1 Fire on ground at engine starting 3.4.2 Fire on ground with engine running 3.4.3...
  • Page 24 Introduction Section 3 provides checklists and amplified procedures for coping with various emergencies that may occur. Emergencies caused by aircraft or engine malfunction are extremely rare if proper pre-flight inspections and maintenance are practiced. However, should an emergency arise, the basic guidelines described in this section should be considered and applied as necessary to correct the problem.
  • Page 25 3.2.3 Engine failure in flight 1. Push control stick forward 2. Speed - gliding at 120 km/h (65 KIAS) 3. Altitude - below 50 m (160 ft): land in take-off direction over 50 m (160 ft): choose a landing area 4.
  • Page 26 In-flight Engine Starting 1. Electric pump - ON 2. Fuel cock - switch to second fuel tank 3. Starter - switch on Smoke and fire 3.4.1 Fire on ground at engine starting 1. Starter - keep in starting position 2. Fuel cock - close 3.
  • Page 27 3.4.3 Fire during take-off Speed - 120 km/h (65 KIAS) Heating - close Fuel cock - close Throttle - full power Ignition - switch off Land and stop the airplane Leave the airplane Extinguish fire by yourself or call for a fire-brigade if you cannot do it. 3.4.4 Fire in flight 1.
  • Page 28 3.4.5 Fire in the cockpit 1. Master switch - switch off 2. Heating - close 3. Use an extinguisher fire Glide An example of the use of gliding is in the case of engine failure Speed recommended gliding speed 120 km/h (65 KIAS) Landing emergencies 3.6.1 Emergency landing...
  • Page 29 3.6.2 Precautionary landing A precautionary landing is generally carried out in the cases where the pilot may be disorientated, the aircraft has no fuel reserve or possibly in bad weather conditions. 1. Choose landing area, determine wind direction 2. Report your intention to land and land area location if a COMM is installed in the airplane 3.
  • Page 30 Recovery from unintentional spin WARNING Intentional spins are prohibited! There is no uncontrollable tendency of the airplane to enter into a spin provided the normal piloting techniques are used. Unintentional spin recovery technique: 1. Throttle idle 2. Lateral control ailerons neutralized 3.
  • Page 31 Other emergencies 3.8.1 Vibration If any forced aircraft vibrations appear, it is necessary: 1. To set engine speed to such power rating where the vibrations are lowest. 2. To land on the nearest airfield or to perform a precautionary landing according to 3.6.2.

  • Page 32: Normal Procedures

    SECTION 4 4. NORMAL PROCEDURES 4.1 Introduction 4.2 Assembly and disassembly 4.3 Pre-flight inspection 4.4 Normal procedures 4.4.1 Before engine starting 4.4.2 Engine starting 4.4.3 Engine warm up, Engine check 4.4.4 Taxiing 4.4.5 Before take-off 4.4.6 Take-off 4.4.7 Climb 4.4.8 Cruise 4.4.9 Descent...
  • Page 33 Introduction Section 4 provides checklists and amplified procedures for the conduct of normal operation. Normal procedures associated with optional systems can be found in section 9. Assembly and disassembly Refer to the Technical Description, Operating, Maintenance and Repair Manual. Pre-flight inspection Carry out the pre-flight inspection every day prior to the first flight or after airplane assembly.
  • Page 34 Inspection Check List Ignition - OFF Master switch - OFF Avionics - check condition Fuel gauge ind. - check fuel quantity Control system - visual inspection, function, clearance, free movement up to stops - check wing flaps operation Canopy - condition of attachment, cleanness Check cockpit for loose objects Engine cowling condition Propeller and spinner condition...
  • Page 35 Normal procedures 4.4.1 Before engine starting Control system - free movement Canopy - clean Brakes - fully applied Safety harness - tighten 4.4.2 Engine starting Start the engine according to its manual procedure Master switch - switch on Fuel cock - open Choke (cold engine) - pull to open and gradually release after...
  • Page 36 4.4.3 Engine warm up, Engine check Prior to engine check block the main wheels using chocks. Initially warm up the engine to 2000 rpm then continue to 2500-2750 rpm till oil temperature reaches 50°C (122 °F). The warm up period depends on ambient air temperature.
  • Page 37 4.4.5 Before take-off Altimeter - set Trim - set neutral position Control system - check free movement Cockpit canopy - closed Safety harness - tighten Fuel - open Ignition - switched on Wing flaps - 1/2 4.4.6 Take-off Brakes - apply to stop wheel rotation Take-off power - throttle fully forward Engine speed...
  • Page 38 4.4.7 Climb 1. Best rate-of-climb speed - 130 km/h (70 KIAS) 2. Throttle - Max. take-off power (max. 5800 rpm for 5 minutes) - Max. cont.power 5500 rpm 3. Trim - trim the airplane 4. Instruments - oil temperature and pressure, cylinder temperature within limits CAUTION If the cylinder head temperature or oil temperature exceed their limits,...
  • Page 39 4.4.11 Balked landing 1. Throttle - full power (max.5800 rpm) 2. Wing flaps - 1/2 3. Trim - adjust as needed 4. Wing flaps - retract at 50 m height (150 ft) after reaching 120 km/h (65 KIAS) 5. Trim - adjust 6.
  • Page 40 4.4.15 Anchoring Ignition check - OFF Master switch check - OFF Anchor the airplane NOTE Use anchor eyes on the wings and fuselage rear section to fix the airplane. Move control stick forward and fix it together with the rudder pedals.

  • Page 41: Performance

    SECTION 5 5. PERFORMANCE 5.1 Introduction 5.2 Performance 5.2.1 Airspeed indicator system calibration 5.2.2 Stall speeds 5.2.3 Take-off performance 5.2.4 Landing distances 5.2.5 Climb performance 5.3 Additional information 5.3.1 Cruise 5.3.2 Endurance and Range 5.3.3 Effect of rain on flight performance and characteristics 5.3.4 Demonstrated crosswind performance 5.3.5...
  • Page 42 Introduction Section 5 provides data for airspeed calibration, stall speeds, take-off performance and additional information. The presented data has been computed from actual flight tests with the aircraft and engine in good conditions and using average piloting techniques. If not stated otherwise, the performance stated in this section is valid for maximum take-off weight and under International Standard Atmosphere (ISA) conditions..
  • Page 43 Performance 5.2.1 Airspeed indicator system calibration IAS [km/h] CAS [km/h] KIAS KCAS Date of Issue: Document No.: Revision: 12/2002 Z601XLFMEN...
  • Page 44 5.2.2 Stall speeds Conditions: Wing Altitude loss flaps at recovery Max.take-off pos. weight [km/h] KIAS [km/h] KCAS [ft] Engine idle run Wing level stall Co-ordinated turn 30 degree bank 5.2.3 Take-off performance Take-off distances shown in the table below are valid at sea level and ambient temperature of 15 °C (59 °F).
  • Page 45 5.2.5 Climb performance Conditions: Best rate-of- Rate of climb Max.Cont.Power –5500 rpm climb speed Weight- 450 kg (992 lb). [km/h] KIAS [m/s] [fpm] 0 ft ISA 1200 3000 ft ISA 6000 ft ISA 9000 ft ISA Date of Issue: Document No.: Revision: 12/2002 Z601XLFMEN...
  • Page 46 Additional information 5.3.1 Cruise Conditions: Valid for ROTAX 912 ULS and prop WOOCOMP Altitude Engine speed [ft ISA] [km/h] KIAS [km/h] KCAS [rpm] 4500 4800 5000 5300 5500 5800 4500 4800 5000 3000 5300 5500 5800 4500 4800 5000 6000 5300 5500 5800...
  • Page 47 5.3.2 Endurance and Range The table below shows fuel consumption, endurance and range at given engine speed. 3000 ft Altitude [ft ISA] Fuel quantity USgal 23,2 Engine speed [rpm] 4500 4800 5000 5300 5500 Fuel consumption [l/h] [km/h] KIAS [km/h] KCAS 07:18 06:14...

  • Page 48: Weight And Balance

    SECTION 6 6. WEIGHT AND BALANCE 6.1 Introduction 6.2 Weight and balance record / Permitted payload range Date of Issue: Document No.: Revision: 12/2002 Z601XLFMEN...
  • Page 49 Introduction This sections contains the payload range within which the microlight may be safely operated.. Procedures for weighing the aircraft and the calculation method for establishing the permitted payload range are contained in the Technical Description, Operating, Maintenance and Repair Manual for Microlight Airplane Date of Issue: Document No.:...
  • Page 50 Weight and balance record / Permitted payload range Date of Issue: Document No.: Revision: 12/2002 Z601XLFMEN...
  • Page 51 SECTION 7 7. AEROPLANE AND SYSTEMS DESCRIPTION 7.1 Introduction 7.2 Airframe 7.3 Control system 7.4 Controls in the cockpit Instrument panel 7.5 Landing gear 7.6 Seats and safety harness 7.7 Baggage compartment 7.8 Cockpit 7.9 Powerplant 7.9.1 Throttle 7.9.2 Choke 7.9.3 Carburetor pre-heating 7.9.4...
  • Page 52 Introduction This section provides description and operation of the aircraft and its systems. Refer to section 9, Supplements, for details of optional systems and equipment. Airframe All-metal construction, stressed skin, single curvature metal skins riveted to stiffeners. Construction is of 6061-T6 aluminum sheet metal riveted to aluminum angles with Avex rivets.
  • Page 53 Controls in the cockpit / Instrument panel Date of Issue: Document No.: Revision: 12/2002 Z601XLFMEN...
  • Page 54 Landing gear Tricycle landing gear with steerable nose wheel. Main landing gear uses two fiberglass spring elements. Seats and safety harness Side-by-side seating. Seat cushions are removable to make more easy cleaning and drying. Three-point safety belts provided to each seat.. Optional is an additional seat upholstery to raise the small pilot or move him forward.
  • Page 55 Powerplant ROTAX 912 engine (80 or 100 hp) is standardly installed in . Rotax 912 is 4-stroke, 4 cylinder horizontally opposed, spark ignition engine with one central camshaft-push-rod-OHV. Liquid cooled cylinder heads, ram air cooled cylinders. Dry sump forced lubrication. Dual breakerless capacitor discharge ignition.
  • Page 56 7.10 Fuel system Wing tanks volume 2 X 45 liters Each tank equipped with a vent outlet and screen filter. Drain valve located in the lowest point of the tank and on the bottom edge of the firewall. Main fuel cock on the central console in the cockpit. Electric fuel pump.
  • Page 57 7.11 Electrical system 7.11.1 Battery The battery is mounted on the foreside of the firewall. 7.11.2 Master switch connects the electrical system to the 12 Volt battery and charger/coils, controlled by the regulator and a 15 amp reset breaker for safety. See Engine Manual for electrical system details.
  • Page 58 7.12 Pitot and static pressure system Pitot-static head is located below the left wing. Pressure distribution to the instruments is through flexible plastic hoses. Keep the pitot head clean to ensure proper function of the system. Date of Issue: Document No.: Revision: 12/2002 Z601XLFMEN...
  • Page 59 7.13 Miscellaneous equipment There is installed the following equipment in Date of Issue: Document No.: Revision: 12/2002 Z601XLFMEN...
  • Page 60 7.14 Avionics Flight and NAV instruments: 1 Airspeed indicator 1 Altimeter 1 Magnetic compass 1 Vertical speed indicator 1 Inclinometer NOTE For operating instructions refer to the documentation supplied with the instruments. Engine instruments Tachometer Cylinder Head Temperature indicator Oil temperature indicator Oil pressure gauge Engine hours Fuel gauge(s)
  • Page 61 SECTION 8 8. Airplane handling, servicing and maintenance 8.1 Introduction 8.2 Aircraft inspection periods 8.3 Aircraft alterations or repairs 8.4 Ground handling 8.4.1 Towing 8.4.2 Parking 8.4.3 Mooring 8.4.4 Jacking 8.4.5 Leveling 8.4.6 Road transport 8.5 Cleaning and care Date of Issue: Document No.: Revision: 12/2002...
  • Page 62 Introduction This section contains factory-recommended procedures for proper ground handling and servicing of the airplane. It also identifies certain inspection and maintenance requirements which must be followed if the airplane is to retain that new-plane performance and dependability. Aircraft inspection periods Periods of overall checks and contingent maintenance depends on the condition of the operation and on overall condition of the airplane.
  • Page 63 Ground handling 8.4.1 Towing To handle the airplane on ground the engine mount may be raised or fuselage rear pushed down in the place of a bulkhead. CAUTION Avoid excessive pressure at the airplane airframe - especially at control surfaces. Keep all safety precautions, especially in the propeller area.
  • Page 64 8.4.3 Mooring The airplane should be moored when parked outside a hangar after the flight day. The mooring is necessary to protect the airplane against possible damage caused by wind and gusts. For this reason the aircraft is equipped with mooring eyes located on the lower surfaces of the wings.
  • Page 65 8.4.4 Jacking Since the empty weight of this aircraft is relatively low, two people can lift the aircraft easily. First of all prepare two suitable supports to support the aircraft. It is possible to lift the aircraft by handling the following parts: By pushing the fuselage rear section down in the place of a bulkhead the fuselage front section may be raised and then supported under the firewall.
  • Page 66 Cleaning and care Use efficient cleaning detergents to clean the aircraft surface. Oil spots on the aircraft surface (except the canopy!) may be cleaned with petrol. The canopy may only be cleaned by washing it with a sufficient quantity of lukewarm water and an adequate quantity of a detergents.

  • Page 67: Supplements

    SECTION 9 9. SUPPLEMENTS 9.1 Introduction 9.2 List of inserted supplements 9.3 Supplements inserted Date of Issue: Document No.: Revision: 12/2002 Z601XLFMEN...
  • Page 68 Introduction This section contains the appropriate supplements necessary to safely and efficiently operate the aircraft when equipped with various optional systems and equipment not provided with the standard airplane. List of inserted supplements Date Doc.No. Title of inserted supplement Date of Issue: Document No.: Revision: 12/2002...
  • Page 69 Supplements inserted Date of Issue: Document No.: Revision: 12/2002 Z601XLFMEN...