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czech sport aircraft SportCruiser Service Bulletin
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czech sport aircraft SportCruiser Service Bulletin

Installation of fuel return line
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No.: SB-SC-055
Date: 2018-08-20
Page: 1 of 25
MODEL
SportCruiser
AFFECTED:
Installation of Fuel return line
SUBJECT:
AIRCRAFT
All SportCruiser aircraft up to S/N 09SC273 inclusive without fuel return line
AFFECTED:
installed, as applicable.
Apply this Service Bulletin upon the next scheduled annual inspection or till
COMPLIANCE:
May 31, 2019, at the latest.
DESCRIPTION:
This Service Bulletin follows the Safety Alert / Safety Directive No. SA-SC-006 dated October 16, 2017.
This Service Bulletin contains instructions for mandatory fuel return line installation that is required to be
incorporated within the aircraft fuel system design as per the Rotax Installation Manual 912 Series, the latest
revision, Chapter 73-00-00, Fuel system. Application of this Service Bulletin is mandatory for all SportCruiser
aircraft without the fuel return line installed. For checking the fuel return line installation on the respective
aircraft, refer to the SA-SC-006. The Service Alert No. SA-SC-006 remains in effect and mandatory for all
respective SportCruiser aircraft without fuel return line installed until this Service Bulletin accomplishment.
AUTHORISATION TO PERFORM:
Repairman (LS-M) or Mechanic (A&P), Aircraft Maintenance Organization
REASON:
Implementation of the fuel return line is required by the Rotax Company. The purpose of the fuel return line
is to bleed off any vapors that may form within the fuel system that could cause vapor lock resulting in
a possible loss of engine power.
MANPOWER:
Approximately 30 manhours.
SPECIAL TOOLS AND TEST EQUIPMENT:
•
Direct drilling machine (chuck up to a diameter of 10 mm)
•
Corner drilling machine (chuck up to a diameter of 10 mm)
•
Riveting pliers with a rotary head for pop rivets
•
Pliers for cleco fasteners
•
Drill bit, diameter of 2.4 mm ( .094 inch)
•
Drill bit, diameter of 4.1 mm ( .161 inch)
•
Drill bit, diameter of 6 mm ( .240 inch)
•
Drill bit, diameter of 9 mm ( .360 inch)
•
Step drill bit 3/4 inch or reamer 3/4 inch
•
Cleco fasteners, diameter of 2.4 mm (10 pcs)
•
Cleco fasteners, diameter of 4 mm (4 pcs)
•
Hot air gun
•
Vacuum cleaner designed for working in an explosive environment
•
Portable light designed for working in an explosive environment
•
Telescopic mirror
•
Test equipment for the test of fuel system installation leakage
•
Test equipment for the test of pitot-static system leakage
SERVICE
BULLETIN
Czech Sport Aircraft a.s.
Na Záhonech 212,
686 04 Kunovice
Czech Republic
office@czechsportaircraft.com
Rev.: -
Date: -

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Summary of Contents for czech sport aircraft SportCruiser

  • Page 1 Rotax Installation Manual 912 Series, the latest revision, Chapter 73-00-00, Fuel system. Application of this Service Bulletin is mandatory for all SportCruiser aircraft without the fuel return line installed. For checking the fuel return line installation on the respective aircraft, refer to the SA-SC-006.

  • Page 2: Service Bulletin

    ROTAX Operators Manual 912 Series, latest revision ROTAX Service Instruction SI912 i 001R4, SI-912-016R9 PUBLICATIONS AFFECTED: SportCruiser / Piper Sport Airplane Maintenance Manual SC-AMM-1-0-00 MATERIAL AND SPECIAL JIGS: The following parts and jigs are needed for execution of this service bulletin:...
  • Page 3 Works according to this Service Bulletin SB-SC-055 can only be performed by aircraft mechanic authorized for works on SportCruiser aircraft and experienced in installation of power units. When installing the hoses in compliance with this Service Bulletin, the following requirements must be met: •...
  • Page 4 Czech Sport Aircraft a.s. Na Záhonech 212, SERVICE 686 04 Kunovice Czech Republic No.: SB-SC-055 BULLETIN office@czechsportaircraft.com Date: 2018-08-20 Rev.: - Page: 4 of 25 Date: - On the fuel gauge that is installed in the left wing tank and on the left wing cabling, mark appropriate contacts and plugs.
  • Page 5 Czech Sport Aircraft a.s. Na Záhonech 212, SERVICE 686 04 Kunovice Czech Republic No.: SB-SC-055 BULLETIN office@czechsportaircraft.com Date: 2018-08-20 Rev.: - Page: 5 of 25 Date: - Cap between ribs No. 4 and No. 2a Fig. 05 9) On the left wing on rib No. 1 and rib No. 2a, measure the position of the holes with a diameter of 4.1 mm ( .161 inch ).
  • Page 6 Czech Sport Aircraft a.s. Na Záhonech 212, SERVICE 686 04 Kunovice Czech Republic No.: SB-SC-055 BULLETIN office@czechsportaircraft.com Date: 2018-08-20 Rev.: - Page: 6 of 25 Date: - Rib No. 2a Fig. 07 10) In the left wing perform the following works: a) Carefully remove the sticker from the appropriate area of the right side of the tank if the sticker is located at the position designated for the CE0271N connection installation (see Fig.
  • Page 7 Czech Sport Aircraft a.s. Na Záhonech 212, SERVICE 686 04 Kunovice Czech Republic No.: SB-SC-055 BULLETIN office@czechsportaircraft.com Date: 2018-08-20 Rev.: - Page: 7 of 25 Date: - b) Set the drilling jig 1-111-0028 on the rib No. 4 (see Fig. 05) and on the right side of the fuel tank so that the bolt of the jig is inserted into the technological hole made in the nose part of the rib No.
  • Page 8 Czech Sport Aircraft a.s. Na Záhonech 212, SERVICE 686 04 Kunovice Czech Republic No.: SB-SC-055 BULLETIN office@czechsportaircraft.com Date: 2018-08-20 Rev.: - Page: 8 of 25 Date: - c) Drill two holes Ø 2.4 mm in the right side of the fuel tank according to the drilling jig (see Figures 11, 12).
  • Page 9 Czech Sport Aircraft a.s. Na Záhonech 212, SERVICE 686 04 Kunovice Czech Republic No.: SB-SC-055 BULLETIN office@czechsportaircraft.com Date: 2018-08-20 Rev.: - Page: 9 of 25 Date: - d) Remove the drilling jig 1-111-0028 from the wing, the pre-drilled hole Ø 2.4 mm intended for the sleeve of the connection CE0271N to be drilled to Ø...
  • Page 10 Czech Sport Aircraft a.s. Na Záhonech 212, SERVICE 686 04 Kunovice Czech Republic No.: SB-SC-055 BULLETIN office@czechsportaircraft.com Date: 2018-08-20 Rev.: - Page: 10 of 25 Date: - Fig. 15 Fig. 16 f) According to the holes in the connection flange drill the 3 remaining holes Ø 2.4 mm in the right side...
  • Page 11 Czech Sport Aircraft a.s. Na Záhonech 212, SERVICE 686 04 Kunovice Czech Republic No.: SB-SC-055 BULLETIN office@czechsportaircraft.com Date: 2018-08-20 Rev.: - Page: 11 of 25 Date: - Fig. 17 g) Drill the holes Ø 2.4 mm made in the connection CE0271N and in the right side of the fuel tank by use of cleco fasteners to Ø...
  • Page 12 Czech Sport Aircraft a.s. Na Záhonech 212, SERVICE 686 04 Kunovice Czech Republic No.: SB-SC-055 BULLETIN office@czechsportaircraft.com Date: 2018-08-20 Rev.: - Page: 12 of 25 Date: - 11) Turn the left wing in such a way that the lower side of wing is located on the assembly supports. Carefully clean the inner space of left wing fuel tank by means of vacuum cleaner.
  • Page 13 Czech Sport Aircraft a.s. Na Záhonech 212, SERVICE 686 04 Kunovice Czech Republic No.: SB-SC-055 BULLETIN office@czechsportaircraft.com Date: 2018-08-20 Rev.: - Page: 13 of 25 Date: - Fig. 20 On the left side of the cabin, partly remove (carefully unstick + tear off) the marked upholstery panel (see Fig.
  • Page 14 Czech Sport Aircraft a.s. Na Záhonech 212, SERVICE 686 04 Kunovice Czech Republic No.: SB-SC-055 BULLETIN office@czechsportaircraft.com Date: 2018-08-20 Rev.: - Page: 14 of 25 Date: - 14) On the longeron riveted on the fuselage skin (see the left side of cabin), measure the position of 4 holes having a diameter of 4.1 mm (.161 inch).
  • Page 15 Czech Sport Aircraft a.s. Na Záhonech 212, SERVICE 686 04 Kunovice Czech Republic No.: SB-SC-055 BULLETIN office@czechsportaircraft.com Date: 2018-08-20 Rev.: - Page: 15 of 25 Date: - Fig. 24 16) Install the fuel return line into the system of fuel installation located in the fuselage (see the diagram in Fig.
  • Page 16 Czech Sport Aircraft a.s. Na Záhonech 212, SERVICE 686 04 Kunovice Czech Republic No.: SB-SC-055 BULLETIN office@czechsportaircraft.com Date: 2018-08-20 Rev.: - Page: 16 of 25 Date: - Cut the return line hose and the hose PYROJACKET to a needed length. Pull the return line hose through the fuselage, grommet in the firewall and through the grommet in the fuselage skin.
  • Page 17 Czech Sport Aircraft a.s. Na Záhonech 212, SERVICE 686 04 Kunovice Czech Republic No.: SB-SC-055 BULLETIN office@czechsportaircraft.com Date: 2018-08-20 Rev.: - Page: 17 of 25 Date: - f) Using cable ties, attach the hose of fuel return line passing through the cockpit to the longeron riveted on the left side of cabin on the fuselage skin (see Fig.
  • Page 18 Czech Sport Aircraft a.s. Na Záhonech 212, SERVICE 686 04 Kunovice Czech Republic No.: SB-SC-055 BULLETIN office@czechsportaircraft.com Date: 2018-08-20 Rev.: - Page: 18 of 25 Date: - Fig. Fig. 28...
  • Page 19 Czech Sport Aircraft a.s. Na Záhonech 212, SERVICE 686 04 Kunovice Czech Republic No.: SB-SC-055 office@czechsportaircraft.com BULLETIN Date: 2018-08-20 Rev.: - Page: 19 of 25 Date: - Warning: During the works carried out according to section 16 it is necessary to take into account the following facts: •...
  • Page 20 Czech Sport Aircraft a.s. Na Záhonech 212, SERVICE 686 04 Kunovice Czech Republic No.: SB-SC-055 BULLETIN office@czechsportaircraft.com Date: 2018-08-20 Rev.: - Page: 20 of 25 Date: - 17) Turn the left wing in such a way that the lower side of wing is located on the assembly supports. Clean the inner space of the fuel tank of left wing by means of the vacuum cleaner.
  • Page 21 Czech Sport Aircraft a.s. Na Záhonech 212, SERVICE 686 04 Kunovice Czech Republic No.: SB-SC-055 BULLETIN office@czechsportaircraft.com Date: 2018-08-20 Rev.: - Page: 21 of 25 Date: - The tank leak tightness is complying if, after the above mentioned 60 minutes period, there is no reduction of air pressure in the tested tank.
  • Page 22 Czech Sport Aircraft a.s. Na Záhonech 212, SERVICE 686 04 Kunovice Czech Republic No.: SB-SC-055 BULLETIN office@czechsportaircraft.com Date: 2018-08-20 Rev.: - Page: 22 of 25 Date: - Fig. 31 Fig. 32...
  • Page 23 Czech Sport Aircraft a.s. Na Záhonech 212, SERVICE 686 04 Kunovice Czech Republic No.: SB-SC-055 BULLETIN office@czechsportaircraft.com Date: 2018-08-20 Rev.: - Page: 23 of 25 Date: - Fig. 33 21) Perform the complete installation of the wing on the fuselage including the connection of all installations and systems of control according to SC-AMM-1-0-00, Chapter 4 - Wing.
  • Page 24 Czech Sport Aircraft a.s. Na Záhonech 212, SERVICE 686 04 Kunovice Czech Republic No.: SB-SC-055 BULLETIN office@czechsportaircraft.com Date: 2018-08-20 Rev.: - Page: 24 of 25 Date: - Fig. 01 Fig. 02 29) On the left side of the cabin, stick the partly removed upholstery panel by means of versatile water-resistant contact adhesive.