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FK-Lightplanes FK 9 Mk IV Maintenance Manual

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AIRCRAFT MAINTENANCE

MANUAL
FK 9 Mk IV / Mk V ELA
Certified as Ultralight Aircraft according to
Kennblatt Nr. 61102.1 and Nr. 61102.2
BFU 95 / LTF-UL 2003
(Germany)
Type Certificate: US-SLSA
Model: FK9 Mk IV 
FK9 Mk V ELA 
Serial Number:
Registration :
Date of manufacture:
Manufacturer and exclusive Distributor:
FK-Lightplanes Krosno - Poland
Design Organisation and Owner of IP Rights:
B & F Technik Vertriebs GmbH Speyer – Germany
document code: des.003
revision date: 01.of november 2013

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Summary of Contents for FK-Lightplanes FK 9 Mk IV

  • Page 1: Aircraft Maintenance

    AIRCRAFT MAINTENANCE MANUAL FK 9 Mk IV / Mk V ELA Certified as Ultralight Aircraft according to Kennblatt Nr. 61102.1 and Nr. 61102.2 BFU 95 / LTF-UL 2003 (Germany) Type Certificate: US-SLSA Model: FK9 Mk IV  FK9 Mk V ELA ...
  • Page 2 Anton-Dengler-Str. 8 D-67346 Speyer Phone:+49(0)6232 / 720 76 Fax:+49(0)6232/720 78 E-mail:info@fk-lightplanes.com Service / parts only via service@fk-lightplanes.com www.fk-servicecenter.com This manual is issued by B&F Technik Vertriebs GmbH and no part of this manual may be reproduced or changed in any manner without written consent.

  • Page 3: Table Of Contents

    Maintenance Manual FK 9 B&F Technik Vertriebs GmbH Revision 2 Section 0 Introduction page 1 TABLE OF CONTENTS 0. INTRODUCTION ............................0-6 0.1. Revisions ............................. 0-6 0.2. Record of Revisions ........................0-6 0.3. List of effective Pages ........................ 0-7 1. GENERAL ..............................1-1 1.1.
  • Page 4 Maintenance Manual FK 9 B&F Technik Vertriebs GmbH Revision 2 Section 0 Introduction page 2 2.4. Hard Landing Inspection ......................2-3 2.4.1. Required Tools .......................... 2-3 2.4.2. Parts/materials required ......................2-3 2.4.3. Level of maintenance ........................ 2-3 2.4.4. Certification required ......................... 2-3 2.4.5.
  • Page 5 Maintenance Manual FK 9 B&F Technik Vertriebs GmbH Revision 2 Section 0 Introduction page 3 3.7. Control Surface Deflection ...................... 3-10 3.8. Jacking / Towing / Storage ...................... 3-10 3.8.1. Jacking ............................ 3-10 3.8.2. Towing ............................. 3-11 3.8.3. Flyable Storage ........................3-12 3.8.4.
  • Page 6 Maintenance Manual FK 9 B&F Technik Vertriebs GmbH Revision 2 Section 0 Introduction page 4 7.4. Windscreen and Windows ......................7-2 7.5. Hydraulic brake system ......................7-3 7.5.1. Brake bleeding .......................... 7-4 7.5.2. Required Tools .......................... 7-4 7.5.3. Parts required..........................7-4 7.5.4.
  • Page 7 Maintenance Manual FK 9 B&F Technik Vertriebs GmbH Revision 2 Section 0 Introduction page 5 11. PAINTING AND COATINGS ........................11-1 11.0.1. Required Tools ........................11-1 11.0.2. Parts required ........................11-1 11.0.3. Level of maintenance ......................11-1 11.0.4. Certification required ......................11-1 11.1.

  • Page 8: Introduction

    Maintenance Manual FK 9 B&F Technik Vertriebs GmbH Revision 2 Section 0 Introduction page 6 Introduction 0.1. Revisions The owner/operator is responsible for keeping all pages of this manual to the revision status indicated in the table, by exchanging the relevant pages as and when a new revision is published. For updates regularly check the technical service site of B &...

  • Page 9: List Of Effective

    Maintenance Manual FK 9 B&F Technik Vertriebs GmbH Revision 2 Section 0 page 7 0.3. List of effective Pages Date: 1. of November 2013 Page Revision Date Page Revision Date Page Revision Date Rev 2 01.11.13 Rev 2 01.11.13 Rev 2 01.11.13 Rev 2 01.11.13...

  • Page 11: General

    This manual must be read carefully by the owner and operator in order to become familiar with the maintenance of the FK 9 Mk IV and Mk V (ELA). The manual presents suggestions and recommendations to help obtain safe and maximum It does not replace procedures or limitations mentioned in the Pilot’s Operating...

  • Page 12: Placards

    D-67346 Speyer, Germany Tel.:+49(0)6232/72076 Fax:+49(0)6232/72078 Email: service@fk-lightplanes.com  Note: Please use the relevant form to order spare parts. All spare part orders are processed and delivered in the quickest possible time. Ask your local dealer to maintain a spare parts inventory, it might be better and faster (especially outside Europe) to purchase orders from the local FK dealer.

  • Page 13: List Of Disposable Replacement Parts

    Disk brake M.I. 42354-6 Brake pads M.I 42176 Fuselage: Seat cover FK-Lightplanes 1.4. Engine specifications refer to the respective engine manual Exhaust system (ROTAX): The engine is delivered optionally with a Rotax steel or with a stainless steel exhaust system.

  • Page 14: Weight And Balance

    Maintenance Manual FK 9 B&F Technik Vertriebs GmbH Revision 2 Section 1 General page 4 1.5. Weight and Balance 1.5.1. Abbreviations and Terminology Reference Datum An imaginary vertical plane from which all horizontal distances are measured for balance purposes The horizontal distance from the reference datum to the center of gravity of an item Moment The product of the weight of an item multiplied by its arm...

  • Page 15: Weighing

    Maintenance Manual FK 9 B&F Technik Vertriebs GmbH Revision 2 Section 1 General page 5 Arms (Datum: wing leading edge): See actual Form “Wägebericht” For the tail wheel version, following applies: L 1 = from datum to the axle of the main wheels L 2 = from datum to the axle of the tail wheel 1.5.3.

  • Page 16: Tire Inflation Pressure

    Maintenance Manual FK 9 B&F Technik Vertriebs GmbH Revision 2 Section 1 General page 6 1.6. Tire Inflation Pressure Wheel Size Pressure Main 6.00 x 6, 4.00 x 6 1.8 to 2 bar 17 – 29 psi 8.00 x 6 Front 4.00 x 4 1.5 - 2 bar...

  • Page 17: Recommended Fastener Torque Values

    The illustrations of this Manual show the typical construction. They may not represent in full detail or the exact shape of the parts, which have the same or similar function. 1.10. Instructions for Reporting Email to service@fk-lightplanes.com the following information: Aircraft Make, Model, Serial Number Engine Make, Model, Serial Number Date of Inspection...

  • Page 19: Inspections

    Maintenance Manual FK 9 B&F Technik Vertriebs GmbH Revision 2 Section 2 Inspections page 1 Inspections 2.1. Inspections Light Sport Aircraft (LSA) aircraft are designed to be lighter than normal aircraft but must withstand similar loads. The structure and the engine must be inspected regularly to maintain airworthiness. If there is any damage it is recommended to consult a certified maintenance facility or contact the manufacturer.

  • Page 20: Regular Maintenance And Lubrication Schedule

    Maintenance Manual FK 9 B&F Technik Vertriebs GmbH Revision 2 Section 2 Inspections page 2 2.3. Regular Maintenance and Lubrication Schedule The following actions must be performed after certain flight hours or time intervals as applicable. There are some actions which must be done for the first time after the very first 2 / 10 / 25 flight hours. The regular maintenance intervals are 100 / 200 / 500 flight hours or every year / every 2 / every 4 years.

  • Page 21: Hard Landing Inspection

    Maintenance Manual FK 9 B&F Technik Vertriebs GmbH Revision 2 Section 2 Inspections page 3 2.4. Hard Landing Inspection After a hard landing or any other abnormal strain on the landing gear, thoroughly examine all affected components and connection points. Damages can be detected after the accident or during the pre-flight checks. Note: An indication for an overload on the landing gear can be: Abnormal taxi behavior...

  • Page 22: Time Between Overhaul (Tbo)

    Maintenance Manual FK 9 B&F Technik Vertriebs GmbH Revision 2 Section 2 Inspections page 4 Pos. 1: Inspect nose gear leg for cracks and deformation especially between the fitting (aluminum) for connection of nose gear-leg to fuselage. Pos. 2: Inspect aluminum fittings for connection of nose gear-leg to fuselage, Teflon-insert in aluminum fitting and surrounding structure, for cracks and deformation.

  • Page 23: Structures

    Maintenance Manual FK 9 B&F Technik Vertriebs GmbH Revision 2 Section 3 Structures page 1 Structures 3.1. Ground Handling Park aircraft with the nose facing into the wind and secure by putting chocks in front of the wheels. To tie down the aircraft, attach long straps to the bolts connecting the wing to the strut and also tie down the nose/tail wheel.

  • Page 24: Windshield And Windows

    Maintenance Manual FK 9 B&F Technik Vertriebs GmbH Revision 2 Section 3 Structures page 2 3.2.6. Windshield and Windows The windshield and windows can be cleaned by washing it with lukewarm water and car or mild laundry detergents. Use a clean, soft cloth to soak the all surfaces. After a short soaking time to loosen any dried-on dirt, rinse well with fresh water and wipe clean with chamois leather.

  • Page 25: Wing & Struts Removal / Installation

    Maintenance Manual FK 9 B&F Technik Vertriebs GmbH Revision 2 Section 3 Structures page 3 3.3. Wing & Struts Removal / Installation 3.3.1. Required Tools activator only for ext. mechanism 3.3.2. Parts required None 3.3.3. Level of maintenance Line 3.3.4. Certification required Owner 3.3.5.

  • Page 26: Fuselage Interiors

    Maintenance Manual FK 9 B&F Technik Vertriebs GmbH Revision 2 Section 3 Structures page 4 To disassemble the aircraft follow above mentioned steps in reverse order, observe the following steps. If required, remove the elevator tips install the storing device for the wings at the aft part of the fuselage Note: the screws at the main tube of the folding mechanism (overhead the pilots) are the stop for the folding mechanism;...

  • Page 27: Landing Gear

    Maintenance Manual FK 9 B&F Technik Vertriebs GmbH Revision 2 Section 3 Structures page 5 3.5. Landing Gear 3.5.1. Landing Gear Description The FK9 is available in nose- and tail wheel configuration. Both version have a hydraulic disc brake system. The main landing gear is an one peace multi-layer sandwich construction which has spring characteristics.

  • Page 28: Level Of Maintenance

    Maintenance Manual FK 9 B&F Technik Vertriebs GmbH Revision 2 Section 3 Structures page 6 3.6. Flight Controls 3.6.1. General 3.6.2. Required Tools Standard metric tools 3.6.3. Parts required None 3.6.4. Level of maintenance alteration or maintenance, minor repair and Aircraft Inspection 3.6.5.

  • Page 29: Rudder

    Maintenance Manual FK 9 B&F Technik Vertriebs GmbH Revision 2 Section 3 Structures page 7 3.6.6. Rudder Rudder and nose wheel control is served by dual rudder pedals. The rudder is served by cables, the nose wheel is controlled by a push pull rod connected to the left pedal.

  • Page 30: Flaps And Ailerons

    Maintenance Manual FK 9 B&F Technik Vertriebs GmbH Revision 2 Section 3 Structures page 8 3.6.7. Flaps and ailerons Note; scheme as shown for Mk IV Pickup for Flap Indication (Mk IV) document code: des.003...

  • Page 31: Elevator

    Maintenance Manual FK 9 B&F Technik Vertriebs GmbH Revision 2 Section 3 Structures page 9 3.6.8. Elevator dismantling of tailplane To dismantle the elevator, first remove the rudder. Disconnect cables and hinge bolts of the rudder so the rudder can be taken away. Then dismantle elevator: document code: des.003...

  • Page 32: Trim System

    Maintenance Manual FK 9 B&F Technik Vertriebs GmbH Revision 2 Section 3 Structures page 10 3.6.9. Trim System Aileron & Rudder Trim: Ground-adjustable trim tabs are mounted on both ailerons and on the rudder. Elevator Trim: The elevator has an in-flight, adjustable spring trim. The spring trim determines the neutral position of the elevator by springs whose tension can be adjusted by a control lever on the middle console.

  • Page 33: Towing

    Maintenance Manual FK 9 B&F Technik Vertriebs GmbH Revision 2 Section 3 Structures page 11 3.8.2. Towing ▲ WARNING: Ensure that the keys are removed and main switches and ignition switch are turned OFF.  Note: Motorized towing is not recommended. █...

  • Page 34: Flyable Storage

    Maintenance Manual FK 9 B&F Technik Vertriebs GmbH Revision 2 Section 3 Structures page 12 3.8.3. Flyable Storage Flyable storage is defined as a maximum of 30 days non-operational storage. █ CAUTION: Do not set the parking brake as brake seizing can result. Secure the aircraft with wheel chocks Ensure that the engine has been stopped by turning off the fuel valve, so as to not leave any fuel in the carburetor bowl.

  • Page 35: Indefinite Storage

    Maintenance Manual FK 9 B&F Technik Vertriebs GmbH Revision 2 Section 3 Structures page 13 3.8.5. Indefinite Storage █ CAUTION: Do not set the parking brake as brake seizing can result. Secure the aircraft with wheel chocks In addition to the temporary storage we recommend: Cover the instruments panel.

  • Page 37: Engine

    Maintenance Manual FK 9 B&F Technik Vertriebs GmbH Revision 2 Section 4 Engine page 1 Engine Refer to the engine manufacturer’s manual.  Note: All Rotax engines in the FK9 are non-certified engines that meet ASTM F-2339 engine standard. 4.1. Inspections Refer to the corresponding chapter in the engine manufacturer’s manual.
  • Page 38 Maintenance Manual FK 9 B&F Technik Vertriebs GmbH Revision 2 Section 4 Engine page 2 Overview of engine installation and engine systems (ROTAX) Important note: engine and all connected systems and parts should be clear from aircraft cowl, engine mount or any fixed aircraft structure, especially with engine running! pictures show type Mk IV...
  • Page 39 Maintenance Manual FK 9 B&F Technik Vertriebs GmbH Revision 2 Section 4 Engine page 3 Systematic of waterlines connected to water pump Carburetors and throttle activators document code: des.003...

  • Page 41: Fuel System

    General description The FK 9 Mk IV is equipped with fuselage tanks The FK 9 Mk V is equipped either with fuselage (Option 1) or with wing tanks (Option 2). A fuel filter and an electrical fuel pump are installed in the fuel system. The electrical pump is operated by a switch at the main switch panel.

  • Page 42: Option 1: Fuselage Tanks

    Maintenance Manual FK 9 B&F Technik Vertriebs GmbH Revision 2 Section 5 Fuel System page 2 5.1.5. Option 1: Fuselage Tanks The two fuel tanks are mounted behind the pilots seats. The fuel valve (ROTAX only) is located at the center console with positions ON and OFF.

  • Page 43: Additional Flexible Wing Tanks

    Maintenance Manual FK 9 B&F Technik Vertriebs GmbH Revision 2 Section 5 Fuel System page 3 5.1.6. Additional flexible Wing tanks (with fuselage tanks installed, optional) Additional flexible fuel tanks (capacity 20l each) can be installed in the wings of the FK 9. They are connected to the main tank and are filled and emptied by using an additional electrical pump.

  • Page 44: Option 2: Wing Tanks

    Maintenance Manual FK 9 B&F Technik Vertriebs GmbH Revision 2 Section 5 Fuel System page 4 5.1.7. Option 2: Wing Tanks: There are two wing tanks installed. Each tank has a fuel valve and a fuel quantity indication. Fuel caps and vents are on top of the wings.
  • Page 45 Maintenance Manual FK 9 B&F Technik Vertriebs GmbH Revision 2 Section 5 Fuel System page 5 Fuel quantity indication (5) Fuel valve (7) Fuel System Version Wing Tanks (Italy only): Aircraft models for Italy also have a drain valve at the gascolator in the engine compartment. document code: des.003...

  • Page 46: Fuel Low Pressure Warning

    Maintenance Manual FK 9 B&F Technik Vertriebs GmbH Revision 2 Section 5 Fuel System page 6 5.1.8. Fuel Low Pressure Warning One fuel pressure warning light or the MID indicate fuel pressure below minimum. 5.1.9. Fuel Quantity Indication Beside the gauges at the respective tanks (see Option 1 & 2), there is a fuel quantity display at the MID. This display derives the information from two different sources, depending on the system installed: a) the pilots enters the fuel quantity before takeoff and the MID computes the remaining fuel using the fuel flow sensor .

  • Page 47: Electrical Fuel Pump Removal And Installation

    Maintenance Manual FK 9 B&F Technik Vertriebs GmbH Revision 2 Section 5 Fuel System page 7 5.1.12. Electrical Fuel Pump Removal and Installation Before starting make sure that the tanks have been emptied or the fuel lines are compressed with the fuel line clamp tool to prevent fuel spill.

  • Page 49: Propeller

    Maintenance Manual FK 9 B&F Technik Vertriebs GmbH Revision 2 Section 6 Propeller page 1 Propeller 6.1. Inspections Different propellers can be installed. Regularly check the symmetry of the angle of attack for the propeller installed. The propeller manufacturer may indicate a method for quick checking without dismantling of any part and is not included in this manual.

  • Page 50: Required Tools

    Maintenance Manual FK 9 B&F Technik Vertriebs GmbH Revision 2 Section 6 Propeller page 2 6.1.2. Required Tools angle of attack tool 6.1.3. Parts required new lock nuts 6.1.4. Level of maintenance Line; Overhaul; alteration or maintenance, Inspection 6.1.5. Certification required A&P Mechanic document code: des.003...

  • Page 51: Fuselage, Interior And Utility Systems

    Maintenance Manual FK 9 B&F Technik Vertriebs GmbH Revision 2 Section 7 Fuselage, Interior & Utility Systems page 1 Fuselage, Interior and Utility Systems 7.1. Rescue system The FK 9 can be equipped with a rescue system BRS 1050 or 1350 (depending on MTOW) mounted into the fuselage behind the seats.

  • Page 52: Required Tools

    Maintenance Manual FK 9 B&F Technik Vertriebs GmbH Revision 2 Section 7 Fuselage, Interior & Utility Systems page 2 7.3.2. Required Tools None 7.3.3. Parts/materials required None 7.3.4. Level of maintenance Line 7.3.5. Certification required Owner 7.4. Windscreen and Windows The door, roof and aft windows are LEXAN (polycarbonate) type 1.0mm.

  • Page 53: Hydraulic Brake System

    Maintenance Manual FK 9 B&F Technik Vertriebs GmbH Revision 2 Section 7 Fuselage, Interior & Utility Systems page 3 7.5. Hydraulic brake system Brakes are controlled by a handle at the center console and are applied to both main wheels at the same time. The brake fluid reservoirs (master brake cylinder) is located under the pilot's seat.

  • Page 54: Brake Bleeding

    Maintenance Manual FK 9 B&F Technik Vertriebs GmbH Revision 2 Section 7 Fuselage, Interior & Utility Systems page 4 7.5.1. Brake bleeding █ CAUTION: We recommend wearing protective gloves and safety glasses while working with brake fluid. Brake fluid is toxic, and must be handled carefully and professionally recycled. All FK9 are delivered ex-factory with FMVSS 116-DOT4 - SAE J 1073 (synthetic) brake fluid, which may be mixed with DOT 3, but DOT 5 is silicone based and not compatible with DOT 3 or 4.

  • Page 55: Parts Required

    Maintenance Manual FK 9 B&F Technik Vertriebs GmbH Revision 2 Section 7 Fuselage, Interior & Utility Systems page 5 7.6. Heating and Ventilation The FK 9 is optionally equipped with cabin heating. By pulling the lever below the instrument panel, heated air is allowed to enter the cabin through the front of the pilots feet.

  • Page 56: Tie-Down

    Maintenance Manual FK 9 B&F Technik Vertriebs GmbH Revision 2 Section 7 Fuselage, Interior & Utility Systems page 6 7.8. Tie-Down The main tie-down points are on each wing located under the upper strut fairing. For frequent use of tie-down points, the fairings may have a cutout hole to ease the access to the tie-down rings For flight these openings can be closed with PVC tape.

  • Page 57: Instruments And Avionics

    Maintenance Manual FK 9 B&F Technik Vertriebs GmbH Revision 2 Section 8 Instruments and Avionics page 1 Instruments and Avionics The instrument panel contains all required flight, navigation and engine instruments for VFR operations. This describes a standard equipment configuration for Rotax 912 engine type, different options can be provided on request.
  • Page 58 Maintenance Manual FK 9 B&F Technik Vertriebs GmbH Revision 2 Section 8 Instruments and Avionics page 2 Alternative Solution Instruments Avionics air speed indicator Filser ATR833 Radio three-point altimeter (20.000ft/min) 80mm instead of TRT800 Transponder original altimeter climb-indicator (80mm,feet/min) Garmin 695 GPS compass slip indicator oil pressure...
  • Page 59 Maintenance Manual FK 9 B&F Technik Vertriebs GmbH Revision 2 Section 8 Instruments and Avionics page 3 Dynon Solution Instruments Avionics air speed indicator / backup instrument D100 PFD altimeter (5000ft)/ backup instrument D120 EMS climb-indicator (80mm,feet/min) Filser ATR833 Radio compass TRT800 Transponder slip indicator...
  • Page 60 Maintenance Manual FK 9 B&F Technik Vertriebs GmbH Revision 2 Section 8 Instruments and Avionics page 4 Garmin Solution Instruments Avionics air speed indicator / backup instrument duo G3X screens with PFD, MFD, EMS altimeter (5000ft)/ backup instrument Garmin SL40 Radio climb-indicator (80mm,feet/min) Garmin GTX328 Transponder compass...

  • Page 61: Antennas

    Maintenance Manual FK 9 B&F Technik Vertriebs GmbH Revision 2 Section 8 Instruments and Avionics page 5 8.2. Antennas 8.2.1. COM Antenna A rod type COM antenna is mounted on the top of the fuselage behind the cockpit. 8.2.2. Transponder Antenna The transponder antenna is a low profile blade-type antenna mounted directly underneath the co-pilot on the underside of the aircraft.

  • Page 63: Electric

    Maintenance Manual FK 9 B&F Technik Vertriebs GmbH Revision 2 Section 9 Electric page 1 Electric 9.1. Description A 12V engine-driven alternator delivers the electricity required. If the red generator control light lights up above 1800 RPM, (or SmartMIP gives a warning) shut off all electrical equipment not required for flight as the generator is disconnected and the battery is discharged.

  • Page 65: Structural Repair

    Maintenance Manual FK 9 B&F Technik Vertriebs GmbH Revision 2 Section 10 Structural Repair page 1 Structural Repair 10.1. Main Structure The main structure contains of: fuselage structure (metal), tail unit structure, engine mount landing gear (metal/carbon fiber composite) control surfaces (metal) main plane (wing &...

  • Page 67: Painting And Coatings

    Maintenance Manual FK 9 B&F Technik Vertriebs GmbH Revision 2 Section 11 Painting and Coatings page 1 Painting and Coatings All FK planes are painted on the exterior with a 2-components acrylic paint in an RAL color. The standard factory paint is RAL 9016.

  • Page 68: Painting

    Maintenance Manual FK 9 B&F Technik Vertriebs GmbH Revision 2 Section 11 Painting and Coatings page 2 11.2. Painting Color: The surface of the structure (composite structure) must be white or yellow. Local colored decoration is possible. Complete painting in different colors only with agreement of the type certificate holder. ...

  • Page 69: Annex

    Airplane Registration Card In order to enjoy the full benefits of the FK-Lightplanes warranty, please sign and return the airplane registration card (to your local authorized FK-Lightplanes distribution partner) as soon as the airplane goes into service, at the latest 10 days after receipt of the airplane.

  • Page 70: Warranty Claim Report

    Maintenance Manual FK 9 B&F Technik Vertriebs GmbH Revision 2 Section 12 Annex page 2 12.2. Warranty claim report document code: des.003...

  • Page 71: Feedback Form

    Maintenance Manual FK 9 B&F Technik Vertriebs GmbH Revision 2 Section 13 Feedback Form page 1 Feedback Form document code: des.003...

This manual is also suitable for:

Mk v ela

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