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Aeros -2 Service Manual

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Aeros-2/Cross Country
ultralight
OWNER /SERVICE MANUAL
Wing: PROFI
Engine: Rotax 912 UL/Rotax 912 ULS
Manufactured by:
AEROS Ltd
Tel: (380 44) 455 41 20
Post-Volynskaya St.5
Fax: (380 44) 455 41 16
Kiev 03061
E-mail: aerosint@aerosint.kiev.ua
UKRAINE
http://www.aeros.com.ua

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Summary of Contents for Aeros Aeros-2

  • Page 1 Aeros-2/Cross Country ultralight OWNER /SERVICE MANUAL Wing: PROFI Engine: Rotax 912 UL/Rotax 912 ULS Manufactured by: AEROS Ltd Tel: (380 44) 455 41 20 Post-Volynskaya St.5 Fax: (380 44) 455 41 16 Kiev 03061 E-mail: aerosint@aerosint.kiev.ua UKRAINE http://www.aeros.com.ua...

  • Page 2: Table Of Contents

    The operating procedures outlined in this Manual are the result of Aeros knowledge and experience gained since 1991. Aeros data packages will be revised from time to time. It is therefore important that you visit us regularly at http://www.aeros.com.ua In case of any doubts or questions contact your local dealers or Aeros.
  • Page 3 AMENDMENT RECORD SHEET Amendment Date Affected Sections Affected Pages Date Inserted Signature...

  • Page 4: General Information

    1. GENERAL INFORMATION 1.1 Symbols Abbreviations and Terminology In this Manual: CG means the centre of gravity. IAS means the airspeed indicated on the cockpit mounted airspeed indicator. Landing Approach Speed means the airspeed that allows control in turbulence, wind gradient or sudden engine failure during landing.
  • Page 5 1.5.2 Wing The Profi wing is the result of continued refinement of Aeros trike wings over the years since 1991. The wing is designed for two-seater trikes. It is the result of an extensive design and development program aimed at optimizing your level of safety and satisfaction as a pilot, through high performance and strength of construction.

  • Page 6: Limitations

    An airfoiled aluminium section is used for the down tubes and king post to achieve minimum drag. 1.5.3 Ultralight The Aeros-2/Cross Country combined with the Profi wing has proven to be an excellent combination. The total fuel capacity is 54 litres and combined with the Rotax 912 delivering a smooth 80/100 HP allows long cross country flights.
  • Page 7 The Aeros-2/Cross Country is therefore not critical in regards to centre of gravity although distribution of load in the trike has an affect on the in-flight attitude of the ultralight.

  • Page 8: Ultralight & Systems Description

    2.5.4 Flight Load Factor Limits Max positive maneuvering load factor: 4.0 G. Negative load factors prohibited. Load factors below 1.0 G to be avoided. 2.5.5 Kinds of Operation Limits The ultralight is only to be flown under visual flight rules (VFR), and the minimum equipment required to operate under VFR conditions are an Air speed indicator, Altimeter and instruments required by the engine manufacturer.
  • Page 9 - front bracket; - joint unit; -electric wiring with connectors, control switch and safety fuse. The control switch is mounted on the right side of the cockpit (Aeros-2 trike) or on the seat frame bottom bracket ( Cross Country trike).
  • Page 10 NOTE: In case of the trim device failure in most forward position it is recommended to use flat, with no obstacles landing field which is long enough for landing due to increased landing approach speed. 3.4 Instrument panel The instrument panel consists of: air speed indicator;...
  • Page 11 Closed flap valves restrict the warm air intake and open the ambient air to supply into the carburetor. Control switch is mounted on the right side of the cockpit(Aeros-2 trike) or on the central part of the dash(Cross Country trike).
  • Page 12 3.9 Brake System A front wheel disk brake system or rear wheels hydraulic disk brake system is used on the ultralight. Parking brake operating: -in case of the front wheel disk brake system, press the brake lever, lift up the rack and fix the brake lever; -in case of the rear wheels hydraulic disk brakes, press the brake lever, lift up the brake valve handle.

  • Page 14: Ultralight Assembly Procedures

    Your instructor should demonstrate the correct assembly and disassembly procedures for your ultralight. This section is intended as a reference only and assumes prior knowledge of assembly Aeros ultralight. 4.1.1 Set up procedure from the package 4 meters long Having used the specific techniques described in this manual you will perform the set up and break down procedures without any difficulties.
  • Page 15 4.1.1.3. Turn the glider so that the downtubes packed into the safety bags are on the bottom and kingpost is on the top. 4.1.1.4. Unfold the sail along the leading edge. Attach the leading edge tubes N3 to the leading edge tubes N2 according to the marking (L-left, R-right, marks must be on the top).
  • Page 16 #1 battens to the wing. Next step is to install the keel battens. Aeros convention is that red marked battens go in the left wing and green marked battens in the right. But you can feel free to install them the other way around, i.e.
  • Page 17 4.1.1.8. Spread the wings all the way. Pay attention to the nose bottom part of the sail, it has to be located between the keel tube and nose channel! Near the kingpost hole find the shackle of the sweep wire. Pull the shackle out the rear end of the keel pocket, and check that the sweep wire is not wrapped around the keel.
  • Page 18 4.2.2.2. Undo the zipper. Remove the battens and the control bar from the bag. 4.2.2.3. Untie the Velcro straps. 4.2.2.4. Turn the glider so that the downtubes packed into the safety bags are on the bottom and kingpost is on the top.
  • Page 19 4.2.2.7. Remove the protective bags from the downtubes. Spread the downtubes. Install the control bar according to the marking. Fix the control bar using nuts and safety rings. NOTE: Take care that the reflex wires and the top wires are not wrapped around the keel and are free from the keel hardware.
  • Page 20 Aeros convention is that red marked battens go in the left wing and green marked battens in the right. But you can feel free to install them the other way around, i.e. red marked battens go to the right and green marked battens go to the left.
  • Page 21 NOTE: Two longest battens are not removed from the battens pockets during the break down procedure. 4.2.2.10. Install the lever batten tips into the hem of the trailing edge. At each batten, make sure the opening in the underside of the trailing edge hem is spread to accept the tab on the batten tip. Make sure the tab slides fully into the hem.
  • Page 22 4.2.2.11. Check all wires for twisted thimbles or tangs. 4.2.2.12. Attach the shackle of the sweep wire to the hook which is placed on the keel tube. An in-flight disengagement of this attachment will cause a complete loss of structural support of the glider and a total loss of control.
  • Page 23 4.2.2.14 Install the bottom surface battens. The longest bottom surface batten is inboard batten. Push the battens all way into the pocket until the rear end is secure in the batten pocket. The strings on the rear ends of the bottom surface battens are to facilitate removal of the battens from the sail during breakdown.
  • Page 24 4.2.2.15 Install the tip battens through the access zipper in the bottom surface: bend the tip batten with angle approx 60 degrees; install the batten into the sail with bend going towards the wing tip; install flat end of the batten to the angle of the sail tip; straighten it a little bit and guide another end of the batten onto the leading edge batten hook;...
  • Page 25 Carefully check the entire length of the leading edge pocket to insure that the mylar insert is lying flat in the pocket. If any section of the mylar is folded under, de-tension the crossbar, remove the batten closest to the area of distortion, and unfold the mylar.
  • Page 26 Check that the washout tip is properly secured in position supporting the batten, and that the washout tip access zipper is properly closed. Check that the bridles are properly engaged. Check the trailing edge for any cuts, tears or broken stitching. 4.3.5.
  • Page 27 4.3.8.Along the right leading edge Same as for the left leading edge. 4.3.9.Under the wing at the control bar Check the cables at the control bar corners, making sure there are no kinks or twisted thimbles. Inspect each Nico press sleeve for slippage and/or corrosion. Check each thimble for distortion, flattening or wear where it touches a bolt, shackle or tang.
  • Page 28 4.3.10. Fit the nose cone over the front of the keel and attach the Velcro at the top rear of the nose cone. Pull the bottom corners of the nose cone back until the nose cone is tight around the nose and secure the Velcro on the bottom of the nose cone.
  • Page 29 4.4 Attaching Wing to the Trike 4.4.1.Attach the wing part of the rescue system bridle to the wing, as shown on the pictures below. Check the ignition switches are off. Position the wing on its control frame, facing into the wind, with the nose on the ground. The pylon of the trike should be held down.
  • Page 30 4.4.2. Lift the nose of the wing up until high enough to connect the universal junction of the trike to the U- bracket of the wing. and allow the bushing of the U-bracket of the wing to slide into position into the slits on the universal junction of the trike.
  • Page 31 4.4.5. Attach second part of the rescue system bridle as shown on the figure 4.4.6. Lift the nose of the wing to allow the front wheel to be rolled rearward over the control frame so that the base tube is forward of the cockpit and the rear of the keel rests on the pylon. 4.4.7.
  • Page 32 4.4.8 Apply the trike park brake. Go to the nose of the wing. With the mast brace tube in one hand and the control bar in the other hand lift the base tube. Rise the wing up. In strong winds maintain a firm grip on the wing.
  • Page 33 4.4.11. Secure the base tube with the safety belt. Park the ultralight in a crosswind position with the wing base tube secured with a safety belt. The wing should be at approx zero angle of attack to avoid the ultralight to be turned upside down with the wind. 4.4.12.Connect the trim device to the rear bracket on the keel tube using a pin and a safety ring.

  • Page 34: Flight Preparation

    Connect the pin and socket connector of the trim device. Check the trim device operation in most forward and aft position. Check the trim device operation in take-off position, which is 30 – 35mm from the most aft position. Fix the electrical wire of the trim device with a plastic hose clamp.
  • Page 35 Speeds for Normal Operation Trim speed 65-100 Km/h 40-63 Stall speed at maximum take off weight Km/h 32.5 Take off speed and approach speed with Km/h maximum take off weight Maximum speed in turbulent air Km/h Maximum level speed Km/h 5.2 Complete Ultralight Pre Flight inspection A full pre-flight inspection should precede every flight you make, not just the first flight of the day.
  • Page 36 THE REFUELLING OPERATION 5.5 Helmet Recommendation The open cockpit of the Aeros-2/Cross Country exposes the occupants to the elements during flight and exposes them to objects outside of the ultralight in an emergency situation. Helmets and eye protection are recommended for occupants for protection from precipitation, strike by insects.

  • Page 37: Ultralight Flying

    6. ULTRALIGHT FLYING 6.1 Starting the engine All controls should be checked with the ignition OFF. Passengers should have seat belts secure and be briefed for the flight. CAUTION REMEMBER TO CLEAR PROP! The engine should be started with the pilot in the front seat. The following procedure should be used: - Park Brake is locked in the on position - Hand and foot throttle off...
  • Page 38 During take off and landing the recommended trim device setting is 30 – 35mm from the most aft position. 6.4 Take Off Aeros trike wings have a neutral static balance allowing a safe take-off that is controllable under all suitable flying conditions.
  • Page 39 to the ground. Maintaining airspeed on final is very important for engine-off landings, allowing a margin for round out before touch down. The trike is designed to land with the rear wheels touching down slightly before the nose wheel. Once firmly on the ground aerodynamic braking may be achieved by pulling in the control bar, then applying the front nose wheel brake.
  • Page 40 Carry out safe airmanship whilst flying and be aware of possible emergency landing areas along your flight path. If possible check these areas from the ground as you enter the airfield or flying site. This technique is for safety reasons as engines are susceptible to stopping, no matter how reliably manufactured or maintained. Keep a good lookout for other ultralight, always be thoughtful and show your intentions.
  • Page 41 After landing release seat Belt Release Passenger seat belt Evacuate ultralight 7.7 On Ground Engine Fire For fire occurring whilst in motion on the ground proceed as follows: Maintain control and use remaining speed to clear people, ultralight and buildings. Close the throttle.

  • Page 42: Rigging Procedure

    7.11 Ignition Circuit Failure The Rotax engine requires a short circuit on the ignition circuit to stop the engine. If the ignition circuit is broken using full choke to flood the engine should stop the engine. Do not restart the engine until the fault has been fixed. 7.12 Stalls In practice, in level flight it is only possible to induce a nose down stall of the ultralight in level flight at high take off weights.
  • Page 43 8.2 Wing Break Down Procedure This section assumes that the wing has been removed from the trike. This section is intended as a reference only and assumes prior knowledge of the break down procedure. 8.2.1. With the glider on the A-frame put the protection cover on the U bracket. 8.2.2 Remove undersurface battens.

  • Page 44: Performance

    9. PERFORMANCE 9.1 General The performance data in the following section has been computed from actual flight tests with the ultralight and power plant in good condition and using average piloting techniques. It should be noted that piloting techniques, climatic conditions and ultralight condition will cause significant variation to these performance figures.

  • Page 45: Handling Service And Maintenance

    Initial capacity is 54 liters. The Aeros-2/Cross Country has a single fuel tank. When the tank is being filled there may be a slight pressure differential between the sides of the tank, causing the fuel cap side to fill slightly faster than the other side. Allow time for the breather valves to equalize the pressure to allow complete filling and, check that both sides are sufficiently full.
  • Page 46 Rotax Service bulletin SB-912-043, pg # 1. Some Aeros trikes will have a silicate free type high quality and long life antifreeze coolant (which is yellow), installed in the radiator. This coolant must be changed to the newly recommended coolant.

  • Page 47: Transportation And Storage

    WARNING DO NOT OPEN THE COOLING SYSTEM WHEN THE ENGINE IS HOT. SEVERE SCALDING AND OTHER INJURIES MAY RESULT. WARNING WATER OR WATER CONTAINING COOLANT MUST NOT BE ADDED IN ANY CASE TO THE COOLING SYSTEM WITH THE NEW EVANS NPG+ COOLANT. WARNING DO NOT OPEN THE COOLING SYSTEM WHEN THE ENGINE IS HOT.

This manual is also suitable for:

Cross country ultralight

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