Diamond HK 36 R, TS, TC, TIS, TIC, TIC-ECO AIRPLANE MAINTENANCE MANUAL

2.3.3 FUEL TANK REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . , 2.25 2.3.4 REMOVAL OF FUEL FI LTERS I NSTALLED I N AI RFRAME . . . . . . . . ' 2.26 2.3.5 FUEL QUANTITY I NDICATOR CALIBRATION . . . . . . . . . . . . . . . . . . ' 2.27 2.4 FUEL SYSTEM IN AIRPLANES WITH WING TANKS . . . . . . . . . . . . . . . . . . . . . . 2.28 2.4.1 FUEL SYSTEM DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . , 2.28 2.4.2 FUEL SYSTEM EMPTY I NG . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ' 2.35 2.4.3 CENTRAL FUEL RESERVOIR R EMOVAL . . . . . . . . . . . . . . . . . . . . . . 2.35 2.4.4 REMOVAL OF FUEL FILTERS INSTALLED I N AIRFRAME . . . . . . . . . 2.35 2.4.5 FUEL QUANTITY INDICATOR CALIBRATION . . . . . . . . . . . . . . . . . . . 2.36 2.5 POWER-PLANT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.37 2.5.1 ENGINE DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.37 2.5.2 CARBURETOR DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ' 2.41 2.5.3 DESCRIPTION OF THE OF THE TURBOCHARGING OF THE ROTAX 9 14 F ENGINE- . . . . . . . . . . . . . . . . . . . . . . . . . . . . , 2.42 Doc. No. Issue Rev. No. Date Source Page No. 3.02.21 1 7 May 1 993 1 0 1 5 Jun 1 998 SB 50/5 0.4 .Diamond HK 36 R, TS, TC, TIS, TIC, TIC-ECO AIRCRAFT AIRPLANE MAINTENANCE MANUAL General 2.5.4 POWER-PLANT REMOVAL AND I NSTALLATION . . . . . . . . . . . . . . . 2.44 2.5.5 ENGINE SPARE PARTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ' 2.46 2.5.6 PROPELLER DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.47 2.5.7 PROPELLER INSTALLATION AND REMOVAL . . . . . . . . . . . . . . . . . . 2.48 2.6 ELECTRICAL SY STEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.50 2.6. 1 POWER SUPPLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.50 2.6.2 ELECTRIC INSTRUMENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.51 2.6.3 ELECTRIC FUEL PUMP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.52 2.6.4 IGN ITION SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.52 2.6.5 Wi RING . . . . . . . . . . . . . . . . . . .. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.53 2.6.6 CIRCUIT BREAKERS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.53 2.6.7 SWiTCHES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.54 2.6.8 AIR TRAFFIC CONTROL (ATC) EQUIPMENT . . . . . . . . . . . . . . . . . . ' 2.54 2.6.9 ANTENNAS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.55 2.6. 1 0 RADIO LOUDSPEAKER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.55 2.6. 1 1 ANTI COLLISION LIG HTS (ACL'S) . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.56 2.6. 1 2 POSITION LIGHTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.56 2.6. 1 3 WIRING DIAGRAM - INSTRUMENT PANEL HK 36 R . . . . . . . . . . . . . 2.57 2.6. 1 4 WIRING DIAGRAM - ENGINE COMPARTMENT HK 36 R . . . . . . . . . ' 2.58 2.6. 1 5 WIRING DIAGRAM - FUSELAGE HK 36 R . . . . . . . . . . . . . . . . . . . . . 2.59 2.6. 1 6 ABBREVIATIONS USED I N THE HK 36 R WIRING DIAGRAMS . . . . ' 2.60 2.6. 1 7 NUMBERING OF THE WIRES IN THE HK 36 R WIRING DIAGRAMS . 2.61 2.6. 1 8 WIRING DIAGRAM - ENGINE COMPARTMENT HK 36 TS, HK 36 TC .2.62 2.6. 1 9 WIRING DIAGRAM - FLIGHT COMPARTMENT HK 36 TS, HK 36 TC . 2.63 2.6.20 WIRING DIAGRAM - ENGINE COMPARTMENT HK 36 TIS, HK 36 TIC . . . . . . . . . . . . . . . 2.64 2.6.21 WIRING DIAGRAM - FLIGHT COMPARTMENT H K 36 TIS, HK 36 TIC . . . . . . . . . . . . . . . 2.65 2.6.22 WIRING DIAGRAM - FUEL SYSTEM HK 36 TIS, HK 36 TIC .. . . . . ' 2.66 2.6.23 WIRING DIAGRAM - ENGINE COMPARTMENT HK 36 TIC-ECO . . , 2.67 2.6.24 WIRING DIAGRAM - INSTRUMENT PANEL HK 36 TIC-ECO . . . . . . 2.68 2.6.25 WIRING DIAGRAM - FUSELAGE HK 36 TIC-ECO . . . . . . . . . . . . . . . 2.69 2.6.26 WIRING DIAGRAM - WING TANKS HK 36 TIC-ECO . . . . . . . . . . . . . 2.70 2.6.27 WIRING DIMENSIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.71 2.6.28 POWER CONSUMPTION OF ELECTRICAL EQUIPMENT . . . . . . . . . 2.72 2.6.29 INSTALLATION OF ADDITIONAL ELECTRICAL EQUIPMENT . . . . . ' 2.73 2.6.30 G ENERAL RULES FOR WORKING ON THE ELECTRICAL SYSTEM . 2.74 2.7 STALL WARNING SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . , 2.75 2.8 MINIMUM EQUIPMENT LIST . . . . . . . . . . . . . . . . . . .. . . . . . . . . . . . . . . . . . . . . , 2.75 Doc. No. Issue Rev. No. Date Source Page No. 3.02.21 17 May 1 993 1 0 1 5 Jun 1 998 SB 50/5 0.5 •Diamond HK 36 R, TS, TC, TIS, TIC, TIC- ECO AIRCRAFT AIRPLANE MAINTENANCE MANUAL SECTION 3: MAINTENANCE AND INSPECTIONS General 3.1 SCHEDULED INSPECTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 . 1 3. 1 . 1 INSPECTION INTERVALS A N D TOLERANCES . . . . . . . . . . . . . . . . . 3 . 1 3. 1 .2 ACCOMPLISHMENT OF MAINTENANCE WORK . . . . . . . . . . . . . . . . 3.2 A. INSPECTION CH ECKLISTS FOR THE POWER PLANT . . . . . . . . . . . . . . 3.3 B. INSPECTION CHECKLISTS FOR THE AI RFRAME . . . . . . . . . . . . . . . . . . 3.20 C. GENERAL MAINTENANCE WORK AND CONFIRMATION . . . . . . . . . . . . 3.30 D. LUBRICATION SCHEDULE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.31 E. CHECK FLIGHT AFTER MAINTENANCE . . . . . . . . . . . . . . . . . . . . . . . . . 3.33 3.2 DESCRIPTION OF SCHEDULED INSPECTIONS. . . . . . . . . . . . . . . . . . . . . . . . . . 3.35 3.2 . 1 ENGINE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.35 3.2.2 PROPELLER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.35 3.2.3 CABI N . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.36 3.2.4 STRUCTURE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.39 3.2.5 LANDING GEAR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.43 3.3 NON-SCHEDULED INSPECTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.45 3.3.1 ENGINE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.45 3.3.2 PROPELLER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.48 3.3.3 AIRFRAME . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.48 3.4 TORQUES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.51 3.4. 1 STANDARD TORQUES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.51 3.4.2 SPECIAL TORQUES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.52 Doc. No. Issue Rev. No. Date Source Page No. 3.02.21 1 7 May 1 993 1 0 1 5 Jun 1 998 S B 50/5 0.6 �Diamond HK 36 R, TS, TC, TIS, TIC, TIC-ECO V AIRCRAFT AIRPLANE MAINTENANCE MANUAL SECTION 4: OTHER WORK General 4. 1 PROCEDURES FOR TOPPING UP OPERATING FLUIDS . . . . . . . . . . . . . . . . . . . 4. 1 4.1 . 1 FUEL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.1 4. 1 .2 ENGI NE OIL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.2 4. 1 . 3 COOLANT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.2 4. 1 .4 BRAKE FLUID . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ' 4.3 4. 1 .5 REFILLING THE BATI ERY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.3 4.2 DETERMINING EMPTY MASS C.G. POSITION . . . . . . . . . . . . . . . . . . . . . . . . . . , 4.4 4.3 TABLE OF THE MOST IMPORTANT LEVER ARMS . . . . . . . . . . . . . . . . . . . . . . ' 4.6 4.4 WEIGHING REPORT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.7 4.5 EMPTY MASS AND CORRESPONDING C.G . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.7 4.6 MASS OF ALL NON-LIFTING PARTS AND USEFUL LOAD . . . . . . . . . . . . . . . . . 4.8 4.7 MASS AND BALANCE FORM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.9 4.8 MASS AND BALANCE DIAGRAM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4. 1 0 4.8.1 EXPLANATION OF THE DIAGRAM . . . . . . . . . . . . . . . . . . . . . . . . . . . 4. 1 0 4.8.2 MASS AND BALA NCE DIAGRAM, STANDARD TANK (MASTER) . . . , 4. 1 1 4.8.3 MASS AND BALA NCE DIAGRAM, LONG RANGE TANK (MASTER) . . 4. 1 2 4.9 PERMISSIBLE EMPTY MASS C.G. RANGE AND MINIMUM USEFUL LOAD ON SEATS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4: 1 3 4.9. 1 PERMISSIBLE EMPTY MASS C.G. POSiTION . . . . . . . . . . . . . . . . . . 4. 1 3 4.9.2 MINIMUM USEFUL LOAD ON SEATS WITH STANDARD FUEL TANK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 . 1 4 4.9.3 MINIMUM USEFUL LOAD ON SEATS WITH LONG RANGE FUEL TANK . . . . . . . . . . . . . . . . . . . . . . . . . . . , 4. 1 4 4.9.4 MINIMUM USEFUL LOAD ON SEATS WITH WING TANKS . . . . . . . . 4. 1 5 4.10 WEIGHING REPORT (MASTER) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4. 1 5 4.11 ADJUSTMENT DIAGRAM - HORIZONTAL ALIGNMENT, ELEVATOR, ANGLE OF INCIDENCE, DIHEDRAL . . . . . . . . . . . . . . . . . . . . . . . . 4. 1 8 4. 1 2 ADJUSTMENT DIAGRAM - AILERONS, RUDDER, SWEEP . . . . . . . . . . . . . . . . 4. 1 9 4 . 1 3 MASSES AND RESIDUAL MOMENTS O F THE CONTROL SURFACES 4. 1 3 . 1 GENERAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.20 4.1 3.2 MEASUREMENT OF RESIDUAL MOMENTS . . . . . . . . . . . . . . . . . . . 4.20 4. 1 3.3 PERMISSIBLE MASSES AND RESIDUAL MOMENTS OF THE CONTROL SURFACES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.21 4.14 PITOT-STATIC SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ' 4.22 4.15 PARKING FOR OVER 30 DAYS 4. 1 5 . 1 PRESERVATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.25 4. 1 5.2 RETURNING TO OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.25 4. 1 6 PLACARDS AND INSCRIPTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.26 Doc. No. Issue Rev. No. Date Source Page No. 3.02.21 1 7 May 1 993 1 0 1 5 Jun 1 998 SB 50/5 0.7 �Diamondv AIRCRAFT HK 36 R, TS, TC, TIS, TIC, TIC-ECO AIRPLANE MAINTENANCE MANUAL SECTION 5: REPAIR INSTRUCTIONS General 5.1 DESCRIPTION OF THE GFRP PARTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5. 1 5 . 1 . 1 Wi NG . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.1 5. 1 .2 AI LERONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.4 5. 1 . 3 RUDDER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.6 5. 1 .4 HORIZONTAL TAI L . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . , 5.8 5. 1 . 5 FUSELAGE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 . 1 0 5 . 1 .6 MAIN LANDING GEAR MADE OF GFRP . . . . . . . . . . . . . . . . . . . . . . . 5 . 1 2 5.2 REPAIR WORK, GENERAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .' . . . . . . . . . . ' 5. 1 3 5.2.1 DAMAGE CLASSI FICATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . , 5. 1 3 5.2.2 REPAIR OF FIBER COMPOSITE PARTS, GEN ERAL . . . . . . . . . . . . . 5 . 1 4 5 . 3 DAMAGE TO GFRP SANDWICH PARTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5. 1 6 5.3. 1 DAMAGE TO THE OUTER SKIN . . . . . . . . . . . . . . . . . . . . . . . . . . . . , 5. 1 6 5.3.2 DAMAGE TO THE ENTIRE SANDWiCH . . . . . . . . . . . . . . . . . . . . . . . 5. 1 7 5.4 DAMAGE TO ALL-GFRP PARTS 5.4. 1 CRACKS I N LEADING EDGE BONDS . . . . . . . . . . . . . . . . . . . . . . . . . 5 . 1 9 5.4.2 OTHER DAMAGE TO ALL-GFRP PARTS . . . . . . . . . . . . . . . . . . . . . ' 5.20 5.5 PAINTING 5.2 1 5.6 REPAIR O F THE CANOPY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.2 1 5.7 REPAIR OF FITTINGS AND CONTROL SYSTEM PARTS . . . . . . . . . . . . . . . . . . ' 5.22 5.8 PROPELLER REPAIR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . , 5.22 5.9 MATERIALS USED AND SOURCES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . , 5.23 Doc. No. Issue Rev. No. Date Source Page No. 3.02.21 1 7 May 1 993 1 0 1 5 Jun 1 998 S8 50/5 0.8 .Diamond HK 36 R, TS, TC, TTS, TTC, TTC-ECO AIRCRAFT AIRPLANE MAINTENANCE MANUAL SECTION 6 : AIRWORTHINESS LIMITATIONS General 6.1 LIFE LIMITED PARTS ... . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . . . . . . . 6.2 6. 1 . 1 ENGINE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . . 6.2 6. 1 .2 SILENTBLOCS OF ENGI N E MOUNT . . . . . . . . . . . . . . . . . . . . . . . . . 6.2 6.1.3 OTHER RUBBER COMPONENTS I N THE ENG INE COMPARTMENT 6.3 6.1.4 COOLANT . . . .. . . . . . . . . . .. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.3 6. 1 .5 PROPELLER . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . . . . . . . . . . . . . 6.4 6 . 1 .6 PROPELLER GOVERNOR . . . . . . . .. . . . . . . . . . . . . . . . . . . . . . . . . 6.4 6.1.7 AIRFRAME . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.5 6 . 1 .8 ALUMINUM MAI N LANDING GEAR STRUTS . . . . . . . . . . . . . . . . . . . 6.5 6 . 1 .9 ELECTRIC FUEL PUMPS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.6 6.1 . 1 0 HOSES I N TH E AIRFRAME . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . . 6.6 6. 1 . 1 1 RUDDER CONTROL CABL ES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.7 6 . 1 . 1 2 OUTER ROD END BEARI NGS OF ELEVATOR ATTACHMENT . . . . . 6.7 6.1.1 3 BRAKE FL UiD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ... . . . . . . . . . . 6.7 6.1.1 4 E LT BATTERY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.8 6 . 1 . 1 5 IGNITION SWiTCH . . . .. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.8 6 . 1 . 1 6 SAFETY HARNESSES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.8 6. 1 . 1 7 TOWING DEVICE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ' 6.8 6.2 SURFACE COLOR. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . . . . . . . . . . . . . . 6.9 Doc. No. Issue Rev. No. Date Source Page No. 3.02.21 1 7 May 1 993 1 0 1 5 Jun 1 998 SB 5015 0.9 .Diamond HK 36 R, TS, TC, TIS, TIC, TIC-ECO AIRCRAFT AIRPLANE MAINTENANCE MANUAL 0.3 EXPLANATIONS 0.3. 1 ABBREVIATIONS AC Advisory Circular AD Airworthiness Directive CFRP Carbon fiber reinforced plastic DP Datum Plane (for CG Calculations) CG Center of g ravity FAA Federal Aviation Administration GFRP Glass fiber reinforced plastiC SB Service Bulletin 0.3.2 PHYSICAL UNITS Doc. No. 3.02.21 NOTE In many, mostly older manuals, the mass is referred to as ''weighf'. In order to ensure physical correctness, the term "mass" is used in this manual. NOTE A body with a mass of one kilogram (kg) has a weight of 9.80665 Newtons (N). Issue Rev. No. Date Source 1 7 May 1 993 1 0 1 5 Jun 1 998 SB 5015 General Page No. 0. 1 0 .Diamond HK 36 R, TS, TC, TIS, TIC, TIC-ECO AIRCRAFT AIRPLANE MAI NTENANCE MANUAL 51 units U5 units length [mm] millimeters [in.] inches [cm] centimeters [ft.] feet [m] meters velocity [km/h] kilometers per [kts.] knots hour [mph] miles per hour [m/s] meters per [fpm] feet per minute second rotary [min"] revolutions per [RPM] revolutions per speed minute minute capacity [ I] liters [US gaL] U.S. gallons [Imp. gaL] Imperial gallons mass [kg/m3] kilograms per [Ibs.lcu.in.] density cubic meter pounds per cubic inch [Ibs.lcu.ft.] pounds per cubic foot mass [kg] kilograms [Ibs.] pounds force, [N] Newtons [Ibs.] pounds weight [daN] Decanewtons power [kW] Kilowatts [h.p.] horse powers [DIN-hp.] DIN-horsepowers (German horsep. , non-SI unit) pressure [hPa] Hectopascal [inHg] inches mercury [mbar] millibar column [bar] bar [ psi] pounds per square inch temper- [0C] degrees Celsius [O F] degrees ature Fahrenheit current [A] Ampe res intensity current [Ah] Ampere hours capacity - voltage [V] Volts General conversions [mm] I 25.4 = [in.] [cm] I 2.54 = [in.] [m] 1 0. 3048 = [ft.] [km/h] I 1 .852 = [kts.] [km/h] I 1 .609 = [mph] [m/s] " 1 96.85 = [fpm] [min"] = [ RPM] [1] 1 3.785 = [US gaL] [1] 1 4.546 = [Imp. gaL] [kg/m3] I 27680 = [Ibs.lcu. in.] [kg/m3] I 1 6.02 = [Ibs.lcu.in.] [kg] " 2.2046 = [Ibs.] [ N] • 0.2248 = [ Ibs.] [daN] • 2.248 = [I bs.] [kW] " 1 . 36 = [DIN-hp.] [kW] " 1 .341 = [h.p.] [hPa] = [mbar] [hPa] I 33.865 = [inHg] [bar] " 14.504 = [psi] [ 0 C] " 1 .8 + 32 = [ 0 F] - - - Doc. No. Issue Rev. No. Date Source Page No. 3.02.21 1 7 May 1 993 1 0 1 5 Jun 1 998 S8 50/5 0. 1 1 IfII>Diamond HK 36 R, TS, TC, TIS, TIC, TIC-ECO AIRCRAFT AIRPLANE MAINTENANCE MANUAL 0.3.3 PARTS OF THE WING-FUSELAGE CONNECTION General The wing attach hardware is identified in Paragraph 1 . 1 , RIGGING AND DE-RIGGING. 0.3.4 BULKHEADS AND STIFFENERS IN FUSELAGE A picture indicating the location of all bulkheads and stiffeners can be fo und in Article 5.1 .5, FUSELAGE. Doc. No. Issue Rev. No. Date Source Page No. 3.02.21 1 7 May 1 993 1 0 1 5 J un 1 998 SB 50/5 0 . 1 2 .Diamond HK 36 R, TS, TC, TIS, TIC, TIC-ECO AIRCRAFT AIRPLANE MAINTENANCE MANUAL 0.3.5 METRIC THREADS General Metric threads are specified in tenns of their major diameter in mill imeters. Example: an M6 bolt is one with a thread major diameter of 6 mm = 0.236 in. 0.3.6 FABRIC DESIGNATION Glass and carbon fabri cs (92 1 1 0, 92125, etc.) are specified in tenns of the type numbers used by the main manufacturer (Interglas). Other fabrics may be used only if they meet the WLB standards specified in Paragraph 5.9, MATERIALS USED AND SOURCES. Doc. No. Issue Rev. No. Date Source Page No. 3.02.21 1 7 May 1 993 1 0 1 5 Jun 1 998 SB 5015 0. 1 3 �Diamond� AIRCRAFT HK 36 R, TS, TC, TIS, TIC, TIC-ECO AI RPLANE MAINTENANCE MANUAL SECTION 1 Rigging and De-Rigging, Care RIGGING AND DE-RIGGING, CARE 1 .1 RIGGING AND DE-RIGGING 1.1.1 GENERAL Each wing is connected to the fuselage by three bolts. The two main bolts are located at the center of the spar tunnel. They are accessible between the backrests and can be inserted from the front side. HK 36 R: A locking pin is inserted through both bolt handles, thereby securing them. Other models; A spring loaded hook is placed over the bolt handles to secure the bolts. The A- and B-bolts are fixed to the fuselage at the wing root. The A-bolt is placed in front of the spar tunnel and the B-bolt lies near the trailing edge. The B- bolt locking units are special fasteners with a 17 mm (approxi mately 0.67 in.) hexagon head. They are screwed onto the B-bolts and are accessible through handholes on the upper surface of the wing. Locking rings are integrated in the B- bolt locking units, which therefore do not require any further safetying. The wing folding mechanism is optional equipment. It consists of a telescopic tube in side the wing which is attached to the A-bolt by means of two spring dowel sleeves. Doc. No. Issue Rev. No. Date Source Page No. 3.02.21 17 May 1 993 1 0 1 5 Jun 1 998 SB 5015 1 . 1 �Diamond"''W' AIRCRAFT HK 36 R, TS, TC, TTS, TT C, TT C-ECO AIRPLANE MAINTENANCE MANUAL Rigging and De-Riggin g, Care The horizontal stabilizer is attached to th e verti cal stabilizer by means of three bolts. The two bolts at the rear are fi xed to the mount in the vertical stabilizer. The threaded bolt located at the front is fitted with a hexagonal socket. When screwed in, it is automatically secured by means of a locking ring integrated into the horizontal stabilizer. Doc. No. Issue Rev. No. Date Source Page No. 3.02.21 1 7 May 1 993 1 0 1 5 J u n 1 998 SB 50/5 1 .2 �Diamond"T AIRCRAFT HK 36 R, TS, TC, TIS, TIC, TIC-ECO AIRPLANE MAINTENANCE MANUAL 1 . 1 .2 WING INSTALLATION WITHOUT WING FOLDING MECHANISM NOTE Rigging and De-Rigging, Care When installing the wings, prevent the airplane from falling onto its nosewheel or tail skid due to the CG movement. 1 . Clean all bolts and bushes and the B-bolt locking unit and apply a light coat of grease. 2 . Lift one wing (two persons at the root rib, one at the wing tip) and insert spar stump into spar tunnel. Leave a gap of approximately 30 cm (1 ft.). Connect position and strobe lights (optional). 3. HK 36 TTC-ECO only: Screw fuel hose to tank connector. Route tank vent line, fuel quantity signal wire and fuel tank ground strap into fuselage th rough fuselage root rib. 4. I nsert wing completely (ensure t he smooth insertat ion of t he A- and B-bolts). 5. Insert main bolt while moving the wing tip in small circles. The aileron and air brake control systems are automatically connected. Do not release the wing before the main bolt has been completely inserted. The wide track of the landing gear supports the attached wing; no support of the wing tip is required. 6. Screw the B-bolt locking unit onto the B-bolt and tighten it by hand. 7. HK 36 TTC-ECO only: Connect fuel tank ground strap under seat. Connect fuel tank vent line to T-fitting under seat. Connect fuel quantity signal wire under seat. F asten fuel line to deSignated rings with ty-rap (line loops around elbowed airbrake lever in order to avoid squeezing of hose). 8. Install the other wing in a similar manner. 9. Tighten both B-bolt locking units with a wrench (size 1 7 mm), applying moderate hand torque (approximately 6 Nm (4.5 ft.lbs.)). 1 O. Secure main bolts with locking pin (HK 36 R) or spring loaded hook (other models). 1 1 . Apply water resist ant adhesive tape to the gap between fuselage and wing and to the covers on the access holes. Doc. No. Issue Rev. No. Date Source Page No. 3.02.21 17 May 1 993 1 0 1 5 Jun 1 998 SB 5015 1 . 3 •DiamondAIRCRAFT HK 36 R, TS, TC, TIS, TIC, TIC-ECO AIRPLANE MAI NTENANCE MANUAL 1 . 1 .3 WING INSTALLATION WITH WING FOLDING MECHANISM NOTE Rigging and De-Rigging, Care When installing the wings, prevent the airplane from falling onto its nosewheel or tail skid due to the CG movement. 1 . Clean all bolts, bushes and the 8-bolt locking unit and apply a light coat of grease, remove lid over 8 -bolt handhole. 2 . Unhook one wing from its hanging mount and pull it rearward to the stop. A second person should stand between the wing and fuselage and relieve the load on the telescopic tube by lifting the wing at the spar stump. 3. Walk forward until the wing is 90" from line of flight; rotate the wing until the root ribs are parallel; keep wing in its correct position. 4. Introduce spar stump into spar tunnel while ensuring the smooth insertion of A- and 8 -bolts. Connect position and strobe lights (optional) when the gap between the fuselage and wing is just wide enough to reach the wires. 5. Insert main bolt. The aileron and air brake control systems are automatically connected. Do not release the wing before the main bolt has been completely inserted. The wide track of the landing gear supports the attached wing; no support of the wing tip is required. 6. Screw the 8 -bolt locking unit onto the 8 -bolt and tighten it by hand. 7. Install the other wing in a similar manner. 8. Tighten both 8 -bolt locking units with a wrench (size 17 mm), applying moderate hand torque (approximately 6 Nm (4.5 ft.lbs.)). 9. Secure main bolts with locking pin (HK 36 R) or spring loaded hook (other models). 1 0. Apply water resistant adhesive tape to the gap between the fuselage and wing and to the covers on the access holes. Doc. No. Issue Rev. No. Date Source Page No. 3.02.21 1 7 May 1 993 1 0 15 Jun 1 998 S850/5 1 .4 "Diamond"'-W AIRCRAFT HK 36 R, TS, TC, TIS, TIC, TIC-ECO AIRPLANE MAINTENANCE MANUAL Rigging and De-Rigging, Care 1.1.4 WING REMOVAL NOTE When removing the wings, prevent the airplane from falling onto its nosewheel or tail skid due to the CG movement. CAUTION Before removing the wings from an HK 36 TIC-ECO, empty the fuel tanks. To remove the wings, reverse the installation procedure. If the Powered Sailplane is equipped with the optional wing-folding mechanism, the wings will remain connected to the fuselage with the telescopic tube after de-rigging. For a complete removal of the wings, remove the two spring dowel sleeves from the joint of the A-bolt and the telescopic tube. For wing folding, refer to Paragraph 1 .3 , STORAGE. 1.1.5 WINGLET INSTALLATION This Article does not apply to the HK 36 R. 1 . Clean the bolts and bushes if necessary. CAUTION Do not lubricate the bolt threads! 2. Install winglet with washers and self locking-Duts. 3. Tighten self locking nuts with moderate hand torque (approximately 6 Nm (4.5 ft.lbs.)). 4. Apply water resistant adhesive tape to the gap. Doc. No. Issue Rev. No. Date 3.02.21 1 7 May 1 993 1 0 1 5 Jun 1 998 Source Page No. SB 50/5 1 . 5 .Diamond HK 36 R, TS, TC, TIS, TIC, TIC-ECO AIRCRAFT AIRPLANE MAINTENANCE MANUAL 1 . 1 .6 WINGLET REMOVAL This article does not apply to the HK 36 R. To remove the winglet, reverse the installation procedure. 1 . 1 . 7 HORIZONTAL STABILIZER INSTALLATION 1 . Clean all bushes and bolts and apply a light coat of grease. 2. Move the trim knob to full NOSE DOWN position. 3. Remove the Pitot tube. Rigging and De-Rigging, Care 4. Position the horizontal stabilizer over the stabilizer mount; the elevator control rod must be connected by a second person. WARNING The elevator control system is not connected automatically! 5. Slip the horizontal stabilizer onto both rearward bolts. 6. Screw in the fastening bolt to the stop with an 8 mm hexagon key, applying moderate hand torque (approximately 6 Nm (4.5 ft.lbs.». 7. Check the horizontal stabilizer for insecure attachment and inspect load transmission of elevator control system. 8. Install the Pitot tube. 9. Apply water resistant adhesive tape to the gap between the horizontal stabilizer and the vertical stabilizer. 1 . 1 .8 HORIZONTAL STABILIZER REMOVAL To remove the horizontal stabilizer, reverse the installation procedure. Doc. No. Issue Rev. No. Date Source Page No. 3.02.21 17 May 1 993 1 0 1 5 Jun 1 998 SB 50/5 1 .6 •DiamondAIRCRAFT H K 36 R, TS, TC, TTS, TTC, TTG-ECO AIRPLANE MAINTENANCE MANUAL 1 .2 ROAD TRANSPORT Rigging and De-Rigging, Care An open trailer is recommended for road transport. The components should be cushioned and protected against slippage. The fuselage is transportable standing on all three wheels. It must be prevented from moving forward, rearward or vertically. Ensure sufficient propeller clearance in the trailer to prevent damage due to fuselage movement. If the powered sailplane is equipped with the optional wing folding mechanism, the wings need not be removed completely for road transportation. They remain attached to the fuselage by the telescopic tubes (optional equipment). However, the wing must be supported by a 400 mm ( 1 6 in.) wide and 500 mm (20 in.) high profile cushion under the root rib. This will prevent damage to the telescopic tube and its guide. Another profile cushion should be placed about 4 m ( 1 3 ft.) behind the root rib. The cushion should be at least 300 mm ( 1 2 in.) wide and 350 mm ( 1 4 in.) high. The wings must be prevented from moving rearward. The B-bolt must be padded to prevent damage to the wing skin. Lay the horizontal stabilizer flat on the trailer and tie it down or place it vertically on the leading edge, and secure it using profiles cushioned with felt or cellular rubber. Doc. No. Issue Rev. No. Date Source Page No. 3.02.21 1 7 May 1 993 1 0 1 5 Jun 1 998 SB 50/5 1 . 7 �Diamond v� AIRCRAFT 1 .3 STORAGE HK 36 R, TS, TC, TIS, TIC, TIC-ECO AIRPLANE MAINTENANCE MANUAL Rigging and De-Rigging, Care If your airplane is furnished with the optional wing folding mechanism, the wings can be folded for storage in a narrow space. The wing outboard ends can be hung from the horizontal stabilizer with the provided support fixtures. The horizontal stabilizer must be supported with the appropriate diagonal struts. The B-bolts must be padded to protect the wing skin from damage. Should the airplane be stored for a prolonged period (e.g. during winter break), it is recommended that profile cushions be placed under the wings as described above. The storage room or hangar should have good air-circulation. 1 .4 CLEANING AND CARE The entire surface of the Powered Sailplane is painted with a white weather proof two component paint. Nevertheless, the airplane should be protected against moisture and dampness. The airplane should not be stored outdoors for extended periods of time. Water that has accumulated must be removed by storing the affected parts in a dry place and turning them over several times. Dirt, insects, etc. can be removed with water and, if necessary, with a mild detergent. An automotive paint cleaner can be used for stubborn spots. For best results, clean the airplane after the day's flying is ended, so that the dirt will not become eng rained. Oil stains, exhaust stains etc. on the fuselage underside can be removed with a cold detergent. Before starting, make sure the detergent does not harm the paint finish. Use commercial automotive preservatives to conserve the paint finish. Canopy and windows should be cleaned with an acrylic glass detergent if available; otherwise use lukewarm water. Final cleaning should be done with a clean piece of doeskin or soft cloth. Never rub or polish dry acrylic glass! Doc. No. Issue Rev. No. Date Source Page No. 3.02.21 17 May 1 993 1 0 15 Jun 1 998 SB 50/5 1 .8 �Diamond� AIRCRAFT HK 36 R, TS, TC, TIS, TIC, TIC-ECO AIRPLANE MAINTENANCE MANUAL SECTION 2 SYSTEMS DESCRIPTION 2.1 FLIGHT CONTROL SYSTEM 2.1.1 GENERAL Systems Description The flight control system, the engine control system and the engine block are electrically connected by ground straps. When working on these systems, always ensure that the straps are attached and intact. 2.1.2 ELEVATOR CONTROL SYSTEM Description The elevator control system is a torque tube type. Both control sticks are mounted to a 35 mm (approximately 1 '/8 in.) diameter torque tube, coupling the sticks in the longitudinal direction. A shackle joint which is welded to the lower side of the tube 11 mm (approximately 71,6 in.) to the left of the center connects the elevator push-rod to the torque tube. The push-rod consists of two parts connected by a joint between the main bulkhead and the B bulkhead. The rearward part of the push-rod is guided in the half-bulkhead and in the second ring frame, the forward part is guided in the sickle shaped bulkhead. A bellcrank is fixed to the vertical stabilizer web. This bellcrank and the elevator hom are coupled through a vertical push-rod in the vertical stabilizer. This vertical rod has no intermediate bearing. Doc. No. Issue Rev. No. Date Source Page No. 3.02.21 May 17, 1993 10 15 Jun 1998 SB 50/5 2 . 1 •DiamondAIRCRAFT Removal and installation HK 36 R, TS, TC, TIS, TIC, TIC-ECO AIRPLANE MAINTENANCE MANUAL Systems Description The forward elevator control system is accessible after removing the seats. The rear elevator control parts are accessible after removing the rudder. For removal of the control system components located under the seats, refer to Article 2.1 .6. To remove the rearward horizontal push-rod from the fuselage tube, remove the rudder, disconnect push-rods on both ends, mark position of forward rod end bearing, remove forward rod end bearing, remove push-rod in rearward direction. To remove the forward horizontal push-rod, remove the rear push-rod, disconnect rod on forward end, mark position offO/ward rod end bearing, remove forward rod end bearing, mark positions of clamps for trim springs, loosen clamps, remove push-rod in rearward direction. Vertical push-rod in vertical stabilizer: The push-rod can be removed after disconnecting it from the bellcrank on the lower end and the elevator horn on the upper end. After re-installation of elevator push-rods, check trim adjustment (see Article 2 . 1 .7) and elevator deflection (see Paragraph 4. 1 1 ). For removal and installation of the horizontal stabilizer, refer to Articles 1 . 1 .7 and 1 . 1 .8. Adjustment of elevator stops The stops for the elevator are placed on the left side of the forward transverse stiffener. Adjust maximum elevator deflection with the two screws and locking nuts on the transverse stiffener (accessible from outside). Doc. No. Issue Rev. No. Date Source Page No. 3.02.21 May 17, 1 993 1 0 1 5 Jun 1 998 SB 50/5 2.2 •DiamondAIRCRAFT HK 36 R, TS, TC, TIS, TIC, TIC-ECO AIRPLANE MAINTENANCE MANUAL Systems Description 2.1.3 RUDDER CONTROL SYSTEM Description The rudder is deflected through control cables by means of foot pedals. The four forward cables run from the pedals to the rudder lever which is mounted to the B-bulkhead. The outer cables are guided by rollers which are mounted to the root rib of the fuselage (tail wheel models with Serial Nos. through 36.516) or to the transverse stiffeners (tail wheel models with Serial Nos. above 36.156 and tricycle models). The cables are partly guided through Teflon hoses. The two rearward control cables are guided by Teflon tubes from the rudder lever through the fuselage tube to the rudder. Adjustment of forward rudder control cables Lock all four rudder pedals in neutral position. Lock rudder lever in B-bulkhead in neutral position (perpendicular to airplane centerline). In front of each pedal there is a fitting with six mounting holes. Attach cables to appropriate mounting holes. Adjustment of rearward rudder control cables The tensile force of these cables can be adjusted with tumbuckles. These are accessible through the B-bulkhead. In case of airplanes with fuselage mounted fuel tank, the l atter must be removed. Serial Numbers Nominal Tensile Force of Rearward Rudder Control Cables [daN] [lbs.] 36.301 through 36.504 1 5 ± 2 33.7 ± 4.5 36.505 and subsequent 1 2 ± 2 27.0 ± 4.5 Doc. No. Issue Rev. No. Date Source Page No. 3.02.21 May 1 7, 1 993 1 0 1 5 Jun 1 998 SB 50/5 2.3 lilftDiamond HK 36 R, TS, TC, TIS, TIC, TIC-ECO AIRCRAFT AIRPLANE MAINTENANCE MANUAL Adjustment of rudder stops Systems Description The stops for the rudder are located on the inside surface of the lower rudder mounting plate. Adjust maximum rudder deflection with the two screws and locking nuts. 2.1.4 AILERON CONTROL SYSTEM Description In lateral direction, the two control sticks are coupled through two WING AILERON AILERON BElLCRANK POCKET FUSE LAGE push-rods under the seats. These push-rods are connected to a bellcrank which is mounted to the rearward transverse stiffener. From this bellcrank, another push-rod runs through the center console to a second bellcrank behind the main bulkhead. The movement is finally transmitted to the left and right aileron pocket through two more push-rods. The design of the aileron pockets enables the automatic connection of the ailerons during wing installation. - - - LEVEL @ POSITION Bell crank engaging in aileron pocket At the wing root rib, a bellcrank engages in the aileron pocket. The aileron pocket is connected to the differentiator lever through a push-rod in the wing. A short push-rod transmits the movement to the aileron horn. Removal and installation The forward aileron control system is accessible after removing the seats. For removal, refer to Article 2. 1 .6. Doc. No. Issue Rev. No. Date Source Page No. 3.02.21 May 17, 1 993 1 0 1 5 Jun 1 998 S8 50/5 2.4 Iiift6. lJiamond HK 36 R, TS, TC, TTS, TTC, TTC-ECO ""<W' AIRCRAFT AIRPLANE MAI NTENANCE MANUAL Systems Description The bellcrank behind the main bulkhead and the aileron pockets are accessible after removing the baggage compartment floor. In case of airplanes with fuselage mounted fuel tank, the latter must also be removed. The differentiator lever in the wing is accessible through an inspection window which is attached to the lower wing surface with three screws near the aileron hom. Adjustment of aileron bellcranks in fuselage With the control sticks centered, the arms of the two bellcranks that are connected by the push rod in the center console must be aligned perpendicular to the airplane centerline. The aileron pocket must be parallel with the root rib of the fuselage (see sketch above). Adjustment of aileron bellcranks in wing With the aileron blocked in neutral position, the outboard bellcrank under the inspection window (or differentiator lever) must be aligned in such a way that the outboard rod end bearing of the long transverse push-rod lies on the hypothetical extension of the short push-rod connecting the bellcrank to the aileron hom. The bellcrank at the wing root rib must be parallel with the wing root (see sketch above). Adjustment of aileron stogs The stops are located on the stick bearing unit on either side. Adjust maximum aileron deflection with the two screws with locking nuts. Doc. No. Issue Rev. No. Date Source Page No. 3.02.21 May 1 7, 1 993 1 0 1 5 Jun 1 998 SB 50/5 2.5 •DiamondAIRCRAFT HK 36 R, TS, TC, TIS, TIC, TIC-ECO AI RPLANE MAINTENANCE MANUAL 2.1 .5 AIR BRAKE CONTROL SYSTEM Systems Description The two air brake levers are coupled through a torque tube under the seats. An arm welded to the torque tube drives a push-rod running rearward under the left seat. The push-rod is connected to a bellcrank behind the main bulkhead. The bellcrank transmits the movement to the air brake pockets by means of two push-rods. Like the ailerons, the air brakes are connected automatically during wing installation. A push-rod runs through the wing from the bellcrank at the root rib to the toggle joint. From here a short rod (called "toggle joint connecting rod", see sketch in Article 2 . 1 . 1 3) runs to the first of two air brake levers which are coupled by means of a pus h-rod. A stop on the toggle joint pedestal limits the overbending of the toggle joint and the extension of the air brakes. The toggle mechanism prevents self-extension of the air brakes. The overbending travel is compensated for by means of seven springs between air brake shield and cover plate. All models except for the HK 36 R are equipped with a spring loaded lever, made of polyamide, which is attached to the rearward transverse stiffener and pressed against the LH air brake lever by means of a spring. When the air brakes are half extended, the air brake lever catches in a groove in the polyamide lever. This device allows the air brakes to be fixed in the half extended position. The forward air brake control system is accessible after removing the seats. The parts behind the main bulkhead can be reached when the baggage compartment floor is removed. In case of airplanes with fuselage mounted fuel tank, the latter must also be removed. The air brake control system in the wing can be viewed when the air brakes are extended. Doc. No. Issue Rev. No. Date Source Page No. 3.02.21 May 17, 1 993 1 0 1 5 Jun 1 998 S8 50/5 2.6 .Diamond HK 36 R, TS, TC, TIS, TIC, TIC-ECO AIRCRAFT AIRPLANE MAINTENANCE MANUAL Systems Description The locking and unlocking forces required for the air brake can be adjusted at the toggle joint connecting rod in the wing. See Article 3.2.2 for force measurement. WARNING The necessity for readjusting the air brake control system may indicate damage to the structure (e.g. due to overstressing). Therefore, contact the Manufacturer before readjusting! 2. 1 . 6 REMOVAL OF ALL PRIMARY CONTROL SYSTEM PARTS UNDER THE SEATS 1 . Disconnect the push-rods of elevator, aileron, and air brake control systems from the torque tubes. 2. Remove the fastening screws of the two air brake levers. 3. Push the right hand air brake lever into the air brake torque tube until the right nand bearing joumal lies free. 4. Remove the fastening screws of the left and right primary control pedestal. 5. Gently lift the air brake torque tube, extract right hand air brake lever. 6. Remove left hand air brake lever in a similar manner. 7. Remove both bearing screws of the primary control torque tube. 8. Shift right hand pedestal to the right, tip, remove. 9. Remove left hand pedestal in a similar manner. 1 0. Remove the aileron bellcrank together with its pedestal. 1 1 . Remove both control sticks. 1 2 . Remove primary control torque tube and air brake torque tube. Doc. No. Issue Rev. No. Date Source 3.02.21 May 1 7 , 1 993 1 0 1 5 Jun 1 998 S8 50/5 Page No. 2.7 �Diamond""<W' AIRCRAFT HK 36 R, TS, TC, TIS, TIC, TIC-ECO AIRPLANE MAINTENANCE MANUAL 2.1.7 ELEVATOR TRIM CONTROL SYSTEM Systems Description The elevator trim control system operates on springs. A spring loaded locking mechanism keeps the trim lever in its position. Inspection of the trim adjustment 1 . The elevator control system must operate smoothly and must not be blocked by anything (hamesses, seats, etc.). 2. Move trim lever slowly from full NOSE UP to NOSE DOWN position until the stick reaches its maximum forward position; release trim lever. 3. The lever must catch in index hole no. 1 1 ± 4, counted from the front. 4. Move the trim lever to full NOSE DOWN position, pull stick to the rearward stop. The rearward trim spring must not contract completely. Doc. No. 3.02.21 CAUTION If the result is not satisfactory, check the condition of the trim springs before readjusting the trim lever. In most cases, one of them has been overstretched. Issue Rev. No. Date Source May 17, 1 993 1 0 1 5 Jun 1 998 SB 5015 Page No. 2.8 •DiamondAIRCRAFT H K 36 R, TS, TC, TIS, TIC, TIC-ECO AI RPLANE MAINTENANCE MANUAL 2.1.8 ELEVATOR AND ELEVATOR TRIM CONTROL SYSTEM \ Doc. No. Issue Rev. No. 3.02.21 May 17, 1 993 1 0 '. , ,\ ..\ - -_. Date 1 5 Jun 1 998 ,, Source S8 50/5 Systems Description Page No. 2.9 �Diamondv AIRCRAFT HK 36 R, TS, TC, TTS, TTC, TTC-ECO AIRPLANE MAINTENANCE MANUAL 2. 1 . 9 RUDDER AND TAIL WHEEL CONTROL SYSTEM Doc. No. 3.02.21 Issue May 1 7 , 1 993 Rev. No. 1 0 Date 1 5 Jun 1 998 / Source S8 50/5 / Systems Description Page No. 2 . 1 0 IIftDiamond HK 36 R, TS, TC, TIS, TIC, TIC-ECO AIRCRAFT AI RPLANE MAINTENANCE MANUAL 2.1.10 AILERON CONTROL SYSTEM IN FUSELAGE I [ 2.1.11 AILERON CONTROL SYSTEM IN WING Doc. No. Issue Rev. No. Date Source 3.02.21 May 1 7, 1 993 1 0 1 5 Jun 1 998 S8 50/5 Systems Description Page No. 2. 1 1 .Diamond HK 36 R, TS, TC, TIS, TIC, TIC-ECO AIRCRAFT AIRPLANE MAINTENANCE MANUAL Systems Description 2.1.12 AIR BRAKE CONTROL SYSTEM AND WHEEL BRAKE SYSTEM IN FUSELAGE .� Tail wheel models with Serial Nos. through 36.349 I ____ = Tail wheel models with Serial Nos. 36.350 through 36.5 1 6 Doc. No. Issue Rev. No. Date Source Page No. 3.02.21 May 17, 1 993 1 0 1 5 Jun 1 998 SB 50/5 2 . 1 2 HK 36 R, TS, TC, TIS, TIC, TIC-ECO AI RPLANE MAINTENANCE MANUAL Systems Description Tail wheel models with Serial Nos. above 36. 5 1 6 and tricycle models 2.1 . 1 3 AIR BRAKE CONTROL SYSTEM IN WING "� TOGGLE JOINT CONNECTING .� ROD � ""::s:: Doc. No. Issue Rev. No. Date Source Page No. 3.02.21 May 1 7, 1 993 1 0 1 5 Jun 1 998 SB 50/5 2 . 1 3 .Diamond HK 36 R, TS, TC, TIS, TIC, TIC-ECO AIRCRAFT AIRPLANE MAINTENANCE MANUAL 2.2 lANDING GEAR 2.2.1 MAIN LANDING GEAR WITH GFRP STRUT Description Systems Description The two-legged landing gear with GFRP strut (tail wheel models only) is equipped with 380 by 1 50 mm (1 5 by 6.00 in.) - 5 tires. The wheel fairings are separate parts and are fastened with four screws. The GFRP-stnut consists of three parts. Diagonal torsion plies form the outer skin. The bending loads are absorbed by caps made of UD cloth, embedded in the outer skin. The shear force is absorbed by two diagonally laminated tubes which also form the center web. Steel mounts are inserted in pockets and fastened with four bolts each on the ends of the strut. The axle is attached to the steel mount with four bolts. It also serves as a wheel fairing support. The steel mounts provide a camber of 1 " ± 1 " and a total toe-in (sum of toe-in on left and right side) of 2" ± 1 ° . The landing gear is connected to the fuselage through two bolts. These bolts go through the landing gear tunnel and the bushes which are bonded into the GFRP strut. In the area around the holes there are additional reinforcing plies. Self-lubricating press-fit collar bushes lie within the bushes. Thus, bending of the gear legs is not d isturbed by the mounting at the fuselage. Spacers prevent play of the landing gear strut in the tunnel. Doc. No. Issue Rev. No. Date Source Page No. 3.02.21 May 17, 1 993 1 0 1 5 Jun 1 998 SB 50/5 2 . 1 4 Removal and Installation HK 36 R, TS, TC, TIS, TIC, TIC-ECO AIRPLANE MAINTENANCE MANUAL Systems Description The brake lines run behind the wheel mounts and through the GFRP strut. In the center of the strut they are connected with a T-type fitting. The brake line in the fuselage can be connected through holes in the strut and in the gear tunnel. This line must be disconnected before removing the landing gear. Then the fuselage is jacked up, and the two mounting bolts are removed. When extracting the bolts, mind the spacers. To install the landing gear, reverse the procedure. 2.2.2 TAIL WHEEL The steerable tail wheel (Models HK 36 R, HK 36 TS and HK 36 TIS) is connected to the rudder with two coil-springs and chain links. The chain links penmit the opposite deflection of rudder and tail wheel up to an angle of 60', at which point one spring is completely relieved. An elastomer package provides suspension of the tail wheel. To adjust the pre-tension, unload tail wheel by jacking up fuselage tube and tighten nut on top of elastomer package until the elastomer package cannot be turned with moderate hand torque. 2.2.3 MAIN LANDING GEAR WITH METAL STRUTS Description The main landing gear with metal struts (tricycle models) is equipped with 380 by 1 50 mm ( 1 5 by 6.00 i n . ) - 5 tires. I t comprises of two separate spring steel o r aluminum legs which are attached to the main bulkhead with two fittings each. Polyamide plates in the outer fittings compensate for the bending of the struts. The wheel axle is attached to the strut with four bolts and also serves as a support for the wheel fairing. Doc. No. Issue Rev. No. Date Source Page No. 3.02.21 May 1 7 , 1 993 1 0 1 5 Jun 1 998 S8 50/5 2 . 1 5 •DiamondAIRCRAFT Removal of strut 1 . Unload main wheel. 2. Remove wheel fairing. 3. Remove brake caliper. HK 36 R, TS, TC, TIS, TIC, TIC-ECO AIRPLANE MAINTENANCE MANUAL 4. Disconnect electrical ground strap from landing gear strut. 5. Support strut, remove lower bracket from outer fitting. 6. Remove bolt from inner fitting. 7. Remove strut. I nstallation of strut For installation, reverse the sequence. Adjustment values Toe-in Camber : 0.5° to 1 . 5° : 1 ° to 6° at empty mass (empty weight) 2.2.4 NOSE LANDING GEAR Description Systems Description The nose landing gear (tricycle models) with castering nosewheel has an elastomer damper. The tire is a Tost-Aero 4.00-4. Stops on the nosewheel fork limit deflection to ±30°. The steering friction (which prevents nosewheel shimmy) is adjustable at the mounting bolt of the nosewheel fork. When the nosewheel is unloaded, the force required to deflect the wheel must be 3 to 5 daN (6.7 to 1 1 .2 Ibs.) (measured along the wheel axle). Adjustment of elastomer damper: see Article 3.2.5. Doc. No. Issue Rev. No. Date Source Page No. 3.02.21 May 17, 1 993 1 0 1 5 Jun 1 998 S8 5015 2 . 1 6 .Diamond HK 36 R, TS, TC, TIS, TIC, TIC-ECO AIRCRAFT AIRPLANE MAINTENANCE MANUAL Removal of nose landing gear 1 . Remove engine cowlings. Systems Description 2. Unload nosewheel. 3. Disconnect damper on its upper end from engine mount. 1 t DIRECTION I OF FLIGHT 4. Remove safety bolt (1) from joumal assembly in fuselage bottom (see sketch). 5. Compress journal assembly, extract from bearings. 6 . Remove nose gear in a downward direction. Installation of nose landing gear For installation reverse the sequence. Removal of damper 1 . Remove engine cowlings. 2. Unload nosewheel. 1 . i · _ · - · _ · 1 - · _ · _ · _ · _ · _ · _ · _ · _ · _ · • 1 I i 3. Disconnect damper on its upper end from engine mount. 4. Disconnect damper on its lower end from nose gear leg: Remove both safety brackets and remove both bearing journals with M5 pulling screw, applying heat, if necessary, to break glue contact. Installation of damper F or installation, reverse the sequence. The bearing joumals must be degreased before they are bonded into the aluminum disk with Loctite 262. Be careful not to apply adhesive to the bronze bushes (see sketch). Doc. No. Issue Rev. No. Date 3.02.21 May 17, 1 993 1 0 1 5 Jun 1 998 APPLY ADHESIVE IN THIS AREA ONLY Source Page No. SB 50/5 2 . 1 7 •DiamondAIRCRAFT HK 36 R, TS, TC, TIS, TIC, TIC-ECO AI RPLANE MAINTENANCE MANUAL Systems Description 2.2.5 WHEEL BRAKE SYSTEM, VERSION 1 Applies to tail wheel models with Serial Nos. through 36. 516. The brake master cylinder is located under the fuel tank. The equalizing reservoir is accessible after removal of the baggage floor. Serial Nos. through 36.349 The brake master cylinder is actuated by the right hand push-rod between the bellcrank and the air brake pocket. The air brake lever position at which the wheel brake starts taking effect can be adjusted by moving the plate connecting the push-rod to the brake master cylinder. Serial Nos. 36. 350 through 36. 516 The brake master cylinder is actuated by a short push-rod between the bellcrank and the left hand fuselage root rib. The air brake lever position at which the wheel brake starts taking effect can be adjusted by opening the locking nut on one end of the push-rod (either on the rod end bearing or on the brake cylinder side) and turning the push-rod. The brake line runs through the center console and the landing gear tunnel to the "T"-fitting inside the landing gear strut and further to either wheel brake cylinder. The parking brake valve on the brake master cylinder is actuated with a Bowden cable. Doc. No. Issue Rev. No. Date Source Page No. 3.02.21 May 1 7 , 1 993 1 0 1 5 Jun 1 998 SB 50/5 2 . 1 8 •Diamond HK 36 R, TS, TC, TIS, TIC, TIC-ECO AIRCRAFT AIRPLANE MAINTENANCE MANUAL 2.2.6 WHEEL BRAKE SYSTEM. VERSION 2 Applies to tail wheel models with Serial Nos. above 36. 5 1 6 and tricycle models. Systems Description The main wheels are equipped with independent disk brakes which are operated through toe pedals integrated into the rudder pedals. The four master brake cylinders are attached to the pedals. The two brake fluid reservoirs are mounted to the pedals on the co-pilot's side. The parking brake valve is located in the center console near the pilot's feet. It is operated through a bowden cable. The brake lines run from the brake master cylinders to the parking brake valve, from where they are routed through the fuselage skin and along the rear edge of the metal struts or inside the GFRP strut to the wheel brake cylinders. Doc. No. Issue Rev. No. 3.02.21 May 17, 1 993 1 0 Date Source Page No. 1 5 Jun 1 998 SB 50/5 2 . 1 9 .Diamond HK 36 R, TS, TC, TIS, TIC, TIC-ECO AIRCRAFT AI RPLANE MAINTENANCE MANUAL 2.3 FUEL SYSTEM I N AIRPLANES WITH FUSELAGE TANK Applies to all models except for the HK 36 TIC-ECO. 2.3.1 FUEL SYSTEM DESCRIPTION Systems Description In its standard version, the HK 36 is equipped with a 55 liter (14.5 US gaL) aluminum tank. A long range tank with a capacity of 79 or 80 liters (20.9 or 2 1 . 1 US gaL) is optional. The tank is mounted between the main bulkhead and the B-bulkhead. It is covered by the floor of the baggage compartment. The filler lies outboard on the left side behind the canopy and is connected to the fuel tank by a rubber hose. The tank vent line runs from the filler through the fuselage underside to the exterior of the airplane. Fuel can be drained off with a drain cup. In the case of the HK 36 R, the hand hole lid in the fuselage underside must be opened first. Since the outlet is placed at the lowest point in the tank, it is possible to remove water that might have deposited. The fuel tank cap is not ventilated. The tank is bonded to all metal parts of the flight control system, the engine and the filler by means of a ground cable. This prevents the build up of electrostatic charges during refueling and thus prevents fuel vapors from igniting. The sensor for the for the electric fuel quantity indicator is built into the upper side of the tank with 5 screws and a gasket. A finger filter, which absorbs coarse impurities, is built into the tank bottom. Doc. No. Issue Rev. No. Date Source Page No. 3.02.21 May 1 7 , 1 993 1 0 1 5 Jun 1 998 SB 50/5 2.20 "Diamond""<W' AIRCRAFT HK 36 R, TS, TC, TIS, TIC, TIC-ECO AIRPLANE MAINTENANCE MANUAL Systems Description Models with Rotax 9 1 2 A A short hose line runs from the finger filter to the electric fuel pump with integrated filter. A quick release coupling is built into this line. By opening it, a shut-off mechanism stops the outflow of fuel. Models with Rotax 9 1 4 F A short hose line runs from the finger filter to the filter box with integrated strainer. A quick release coupling is built into this line. By opening it, a shut-off mechanism stops the outflow of fuel. From the filter box, the fuel reaches the two serially connected fuel pumps. Each fuel pump has a bypass connected in parallel. A check valve in each bypass prevents the fuel from being pumped back into the tank. NOTE In deviation from the description in the Maintenance Manual for Rotax Engine Type 914 F, the integrated filters have been removed from the fuel pumps. Attention should also be paid to this fact during the replacement of fuel pumps. The fuel is carried through a hose line in the center console to the fuel shut-off valve, which is located on the center console near the pilot's feet and is open when it points in the flight direction. From the fuel shut-off valve, a flexible line runs to the firewall breach. Doc. No. Issue Rev. No. Date Source Page No. 3.02.21 May 1 7 , 1 993 1 0 1 5 Jun 1 998 SB 50/5 2.21 .Diamond HK 36 R, TS, TC, TIS, TIC, TIC-ECO AIRCRAFT AIRPLANE MAINTENANCE MANUAL Systems Description WARNING The fuel shut-off valve should only be closed i n the event o f a n engine fire or during maintenance on the fuel system. Otherwise, there is a risk of taking the airplane into operation with the valve closed, which would lead to engine failure. Models with Rotax 9 1 2 A A hose line leads from the firewall breach to the mechanical fuel pump with built in filter. This pump is driven by the cam shaft. From here, the fuel reaches a cross-shaped fitting and finally the two carburetors. From the cross-shaped fitting, a return line runs to the tank. In the case of the HK 36 R, the opening for the return line is marked by an "R" on the cross. In the case of other models, the uppermost opening is that of the return line. A fuel pressure sensor is mounted on the cross. As soon as the fuel pressure (above atmospheric) falls below 0 . 1 bar ( 1 .45 psi), the fuel pressure warning light illuminates in the cockpit. Doc. No. Issue Rev. No. 3.02.21 May 1 7, 1 993 1 0 Models with Rotax 9 1 4 F A hose line leads from the firewall breach to the fuel pressure regulator on top of the airbox. Through steel pipes the regulator supplies the two carburetors with fuel under a pressure which is always 0.25 bar (3.63 psi) higher than in the airbox. The connection for the airbox pressure is located on the underside of the regulator and the connection for the return line to the tank is located on top. A fuel pressure sensor is mounted at the entrance to the regulator. As soon as the fuel pressure (above airbox pressure) falls below 0 . 1 bar ( 1 .45 psi), the fuel pressure waming light illuminates in the cockpit. Date Source Page No. 1 5 Jun 1 998 SB 50/5 2.22 '" 0 � 0 0 N Z � !" s:: III '< � U> -.J U> c � CD (0 (0 '" ;0 CD � :" 0 z !" � U1 '- 0 C ::l III� � CD (0 (0 OJ (J) (J) OJ 0 U1 c !2 Cl U1 CD "U N III co N CD '" z !" " c � '*� CD 3 U> n :::T CD 3 III� o· 0', 3 0 , 0.1 CD U> �:::T � :::T CD ;0 W(0 � N » FUEL PRESSURE TRANSDUCER TO CARBURETOR .::::::Jf-----j FILTER IN FUEL PUMP RETURN _LINE f----;c:;:=. TO CARBURETOR :L - ENGINE DRIVEN FUEL PUMP FUEL QUANTITY INDICATOR ELECTRIC WIRE FILLER FIREWALL SENSOR FOR FUEL QUANTITY INDICATOR � FIREWALL BREACH I FUEL VALVE DRAIN ! FilTER IN FUEL PUMP M ELECTRIC FUEL PUMP VENTILATION I' GND FINGER FILTEA HOSE COUPLING t � D ;. �8 Sa » I - ;>;: ;0 '" "U CJ) S;; ;o Z --I m (J) s:: - » --I - 0 z - --I :::j � (J) » - z :::j o 0 m _ s:: :::j » 0 z , C m » 0 r 0 o CD U> n :::l. "0 � o· ::l �CD 3 U> � 0 0 0 " '" � z � � s: III '< � (j) _ ..... U> C � C1J (l)(l)CAl ;0C1J � :< 0 z � � U1 '- C 0 :J III � iii (l)(l)CD CJ) CJ) (JJ 0 U1 C , 0 0 Oi C1J "U '" III <0 � C1J .I>- Z � -- ., c !!!. U> � iii 3 U> o :J" � !!!. 0' 0', 3 oa.C1J (j) ;1;, 5' 5' C1J ;a g, III )( (l)� ., ro 1'\ C1J :a. I A CAl(J') :j \> m o g FUEL PRESSURE REGULATOR TO RIGHT ICARBURETOR RETURN LINE TO AIR BOX PRESSURE F����������=;i=�,;T;,;R6�; MITTER FOR Teu 5[!J 0: « ::i �DO u: FUEL VALVE CHECK VALVES ELECTRIC FUEL PUMPS LEGEND FUEL LINE AIR PRESSURE LINE TANK <--- DRAINER FINGER FILTER HOSE COUPLING FILTER BOX � D m' eg 1!l �i }> I - A ;0 CAl "U (J') 5:: ..::0 Z -I m CJ) s: - }> -I - 0 Z - -I :j � CJ) }> - Z :j o 0 m _ s: :j � \> C m }> 0 r 0 l?U> o :J, :a. 0':J CJ) '< U> iii 3 U> �Diamond HK 36 R, TS, TC, TIS, TIC, TIC-ECO T AIRCRAFT AIRPLANE MAINTENANCE MANUAL 2.3.2 FUEL TANK EMPTYING Method 1 1 . Open the handhole lid in the fuselage underside. Systems Description 2. Remove the lock wire from the quick release coupling under the tank (see WARNING below). 3. Open the quick release coupling. 4. Disable the shut-off mechanism by connecting a hose with a corresponding fitting and a free end. Method 2 1 . Open the hand hole lid in the fuselage underside (only necessary for HK 36 R). 2. Actuate and block the drain device. 2.3.3 FUEL TANK REMOVAL 1 . Empty the tank as in Method 1 (see above). 2. Remove the baggage compartment floor. 3. Disconnect the rubber hose from the filler by opening the two hose clamps. 4. Release the tank fastening strap. 5. Disconnect all electric wires. 6. Remove the tank. To install the tank, reverse the procedure. WARN ING The removed lock wires must be replaced. Doc. No. Issue Rev. No. Date Source Page No. 3.02.21 May 1 7, 1 993 1 0 1 5 Jun 1 998 SB 50/5 2.25 �D;amond V� AIRCRAFT HK 36 R, TS, TC, TIS, TIC, TIC-ECO AIRPLANE MAINTENANCE MANUAL 2.3.4 REMOVAL OF FUEL FILTERS INSTALLED IN AIRFRAME The fuel filters must be removed for cleaning. Finger filter i n the tank bottom 1 . Remove the tank (see above). 2. Remove the lock wire from the finger filter. 3. Unscrew the finger filter. To install the finger filter, reverse the procedure. WARNING The removed lock wires must be replaced. Filter in electric fuel pump (only models with Rotax 9 1 2 Al 1 . Open the hand hole lid in the fuselage underside. 2. Remove the lock wire from the quick release coupling. 3. Open the quick release coupling. 4. Open the pump lid (bayonet socket, fork wrench 1 6 mm (5/8 in.». 5. Remove the filter. To install the filter in the fuel pump, reverse the procedure. WARNING The removed lock wires must be replaced. Doc. No. Issue Rev. No. Date Source 3.02.21 May 1 7 , 1 993 1 0 1 5 Jun 1 998 S8 50/5 Systems Description Page No. 2.26 • Diamond HK 36 R, TS, TC, TIS, TIC, TIC-ECO AIRCRAFT AIRPLANE MAINTENANCE MANUAL Fuel strainer in the filter box (onlv models with Rotax 9 1 4 F) 1 . Open the handhole lid in the fuselage underside. 2. Remove the lock wire from the lid of the filter box. Systems Description 3. Unscrew the lid from the filter box by pushing a rod (such as an Allen key) into the hole in the joumal of the lid. 4. Remove the seal and filter. To install the fuel strainer in the filter box, reverse the procedure. WARNING The removed lock wires must be replaced. 2.3.5 FUEL QUANTITY INDICATOR CALIBRATION 1 . Drain fuel tank to unusable quantity. 2. Align airplane horizontally as shown in Paragraph 4.2. 3. Remove instrument panel top cover. 4. Remove fuel quantity indicator from instrument panel, leave electric wires in place. 5 . Masier switch - ON. 6. Mode select switch - POWER FLIGHT. 7. Wait a few seconds until fuel quantity indicator indicates constant value. 8. On the LH side of the indicator's case, when viewed from the face, there is a small hole covered with tape which must be removed. Use a small common tip screwdriver to adjust to zero position. Replace tape. 9. Mode select switch - SOARING. 1 0. Master switch - OFF. 1 1 . Re-install fuel quantity indicator. 1 2 . Re-install instrument panel top cover. Doc. No. Issue Rev. No. 3.02.21 May 17, 1 993 1 0 Date Source Page No. 1 5 Jun 1 998 SB 5015 2.27 .Diamond HK 36 R, TS, TC, TIS, TIC, TIC-ECO AIRCRAFT AIRPLANE MAINTENANCE MANUAL 2.4 FUEL SYSTEM IN AIRPLANES WITH WING TANKS Applies to HK 36 TIC-ECO only. 2.4.1 FUEL SYSTEM DESCRIPTION General Systems Description The airplane has a fuel tank in each wing. The fuel tank which is selected with the fuel tank selector feeds a central fuel reservoir through gravity feed. From there two electric fuel pumps which are connected in series supply fuel to the engine through the fuel shut-off valve. Wing Tanks The HK 36 TIC-ECO is equipped with two 55 liter (14.5 US gal.) tanks made of GFRP with vinyl ester resin. The usable fuel quantity is 53 liters (14.0 US gal.). The tanks are approximately two meters (approximately 7 ft.) long and are situated in the wings in front of the spar. The inboard edge is near the root rib. A finger filter is installed at this position. From the output port a hose runs through the root rib to the fuel selector valve. When removing the wing, the screwed connection on the tank is opened in order to separate the hose line. Electrical Bonding: The wng tanks are electrically conductive through the use of copper mesh. They are connected to electrical ground using a ground strap. This prevents the build-up of electrostatic charges and thus prevents fuel vapors from igniting. The ground strap has a flat plug connector under the seat shell which is disconnected when removing the wing. Doc. No. Issue Rev. No. Date Source Page No. 3.02.21 May 17, 1 993 1 0 1 5 Jun 1 998 SB 50/5 2.28 .Diamond HK 36 R, TS, TC, TIS, TIC, TIC-ECO AIRCRAFT AIRPLANE MAINTENANCE MANUAL Tank filler: A tank filler is located on the upper side of each wing tank. Drainage: Systems Description Each wing tank has a quick drain device situated on the bottom side of the wing, near the root rib. Draining is perfonmed by pressing in upward direction. Electrical fuel quantity sensors: Two sensors are installed in the bottom side of each wing tank with 5 screws and one gasket. These are accessible after removing the inspection panels. The two sensors of one tank are connected in series. The fuel quantity signal wire has a connector under the seat shell which is separated when removing the wing. NOTE When installing a new fuel quantity sensor it must be inspected for proper resistance values. In the "full' position the electrical resistance must be o to 3 O. The float lever must reach the stop before the float contacts the upper tank wall. In the position in which the float contacts the lower tank wall the resistance must be between 76 and 82 O. Subsequently the fuel quantity indicator of the affected tank must be calibrated. Fuel tank ventilation: see description at the end of this article Fuel selector valve The fuel selector valve is mounted in the center console. When installed, only the pOSitions LEFT and RIGHT are available. The design of the valve would allow to shut off both fuel lines. This is however prevented by stops in the center console. A fuel line runs from the fuel selector valve to the central fuel reservoir. Doc. No. Issue Rev. No. Date Source Page No. 3.02.21 May 17, 1 993 1 0 1 5 Jun 1 998 S8 50/ 5 2.29 •DiamondAIRCRAFT Central fuel reservoir HK 36 R, TS, TC, TTS, TTC, TTC-ECO AIRPLANE MAINTENANCE MANUAL Systems Description An aluminum receptacle which holds 9 liters (approximately 2.4 US gal.) is installed in the fuselage behind the main bulkhead under the baggage compartment. A finger filter is installed in the output port. From there the fuel is led to the two fuel pumps which are connected in series. Low Fuel caution light (amber): A sensor is installed in the central fuel reservoir which activates the low fuel caution light as soon as less than 5 liters (approximately 1 . 3 US gal.) are left in the reservoir. Electrical bonding: The central fuel reservoir is connected to electrical ground through a ground strap. This prevents the build-up of electrostatic charges and thus prevents fuel vapors from igniting. Drainage: The central fuel reservoir has a quick drain device on the bottom side. It is accessible on the fuselage bottom side and is activated by pressing in upward direction. Ventilation: See description at the end of this article. Doc. No. Issue Rev. No. Date Source Page No. 3.02.21 May 17, 1 993 1 0 1 5 Jun 1 998 SB 50/5 2.30 .,DiamondAIRCRAFT HK 36 R, TS, TC, TIS, TIC, TIC-ECO AI RPLANE MAINTENANCE MANUAL Systems Description Fuel pumps Each fuel pump has a bypass. A check valve in each bypass prevents the fuel from being pumped back into the central fuel reservoir. A hose line running through the center console leads the fuel to the fuel shut-off valve. NOTE In deviation from the description in the Maintenance Manual for Rotax Engine Type 914 F, the integrated filters have been removed from the fuel pumps. Attention should also be paid to this fact during the replacement of fuel pumps. Fuel shut-off valve The fuel shut-off valve is located on the center console near the pilot's feet and is open when it points in the flight direction. From the fuel shut-off valve, a flexible line runs to the firewall breach. Doc. No. 3.02.21 WARNING The fuel shut-off valve should only be closed in the event of an engine fire or during maintenance on the fuel system. Otherwise, there is a risk of taking the airplane into operation with the valve closed, which would lead to engine failure. Issue Rev. No. Date Source Page No. May 17, 1 993 1 0 1 5 Jun 1 998 SB 5015 2.31 Fuel pressure regulator HK 36 R, TS, TC, TTS, TIC, TIC-ECO AIRPLANE MAINTENANCE MANUAL Systems Description A hose line leads from the firewall breach to the fuel pressure regulator on top of the airbox. Through steel pipes the regulator supplies the two carburetors with fuel under a pressure which is always 0.25 bar (3.63 psi) higher than in the airbox. Connectors: The connection for the airbox pressure is located on the underside of the regulator. The connection for the return line to the central fuel reservoir is located on top. Fuel pressure warning light (red): A fuel pressure sensor is mounted at the entrance to the regulator. As soon as the fuel pressure (above airbox pressure) falls below 0.1 bar ( 1 .45 psi), the fuel pressure waming light illuminates in the cockpit. Doc. No. Issue Rev. No. Date Source Page No. 3.02.21 May 17, 1 993 1 0 1 5 Jun 1 998 SB 50/5 2.32 "Diamond HK 36 R, TS, TC, TIS, HC, TIC-ECO AIRCRAFT AI RPLANE MAI NTENANCE MANUAL Fuel System Ventilation Also see sketch on the next page. The fuel system has four vents: Systems Description • The vent under the LH wing mainly vents the LH fuel tank. A short hose leads from the highest and most outboard point of the tank to this vent. • The vent under the RH wing mainly vents the RH fuel tank. A short hose leads from the highest and most outboard point of the tank to this vent. • The vent under the fuselage left of the aircraft centerline mainly vents the LH tank and the central fuel reservoir. - A hose leads from the highest and most outboard point of the LH tank through the wing and the root rib to this vent. - A hose leads from the highest point of the central fuel reservoir through the roll bar to this vent The vent hose itself is also vented in order to cut a continuous stream of fuel which might occur. This prevents the emptying of the fuel system through siphoning. • The vent under the fuselage right of the aircraft centerline mainly vents the RH tank. - A hose leads from the highest and most outboard point of the RH tank through the wing and the root rib to this vent. - A hose connects this vent to the vent left of the aircraft centerline. Doc. No. Issue Rev. No. Date Source 3.02.21 May 17, 1 993 1 0 1 5 Jun 1 998 SB 50/5 Page No. 2.33 "Diamondv AIRCRAFT H K 36 R, TS, TC, TIS, TIC, TIC-ECO AIRPLANE MAINTENANCE MANUAL centro! ru;;;i reservoir Systems Description .--------: 9 liters ,-ff- I ---IV ] l o w f U e I .(:;, 1 10 c o u t io n !ig h T -/ -1['- , -----' Doc. No. 3.02.21 re t u rn l i n e firevv o f l'---- I f U e l s h u t - o ff volve II T T II LJ �\ 1 1[ 't J o ,: r o. o ;< i Fuel system of the H K 36 TIC-ECO Issue Rev. No. Date May 1 7, 1993 1 0 1 5 Jun 1 998 T o r TeU Source Page No. S8 50/5 2.34 iA.Diamond W@Y AIRCRAFT H K 36 R, TS, TC, TIS, TIC, TIC-ECO AIRPLANE MAI NTENANCE MANUAL I 2.4.2 FUEL SYSTEM EMPTYING Systems Description ( 1 ) Remove quick drain devices from both fuel tanks and central fuel reservoir. Collect fuel in suitable receptacle. 2.4.3 CENTRAL FUEL RESERVOIR REMOVAL ( 1 ) Empty fuel system. (2) Remove baggage compartment floor. (3) Remove RH aileron and air brake push-rods behind main bulkhead. (4) Disconnect fuel and vent lines from central fuel reservoir. (5) Remove electric wires (Low-Fuel signal wire, ground strap) from central fuel reservoir. (6) Release tank fastening strap. (7) Remove fuel reservoir. 2.4.4 REMOVAL OF FUEL FILTERS INSTALLED IN AIRFRAME The fuel filters must be removed for cleaning. Finger filters in the wing tanks ( 1 ) Empty fuel system. (2) Remove wing. (3) Remove lock wire from finger filter. (4) Remove finger filter. To install the filter reverse the procedure. WARNING The removed lock wires must be replaced. Doc. No. Issue Rev. No. Date Source 3.02.21 May 1 7, 1 993 1 0 1 5 Jun 1 998 S8 50/5 Page No. 2.35 •DiamondAIRCRAFT HK 36 R, TS, TC, TIS, TIC, TIC-ECO AIRPLANE MAI NTENANCE MANUAL Finger filter in central fuel reservoir ( 1 ) Remove central fuel reservoir (see Article 2.4.3). (2) Remove lock wire from finger filter. (3) Unscrew finger filter. To install the filter reverse the procedure. WARNING The removed lock wires must be replaced. 2.4.5 FUEL QUANTITY INDICATOR CALIBRATION ( 1 ) Drain fuel tank to unusable quantity. (2) Align airplane horizontally as shown in Paragraph 4.2. (3) Remove instrument panel top cover. Systems Description (4) Remove fuel quantity indicator from instrument panel, leave electric wires in place. (5) Master switch - ON. (6) Mode select switch - POWER FLIGHT. (7) Wait a few seconds until fuel quantity indicator indicates constant value. (8) On the LH side of the indicator's case, when viewed from the face, there is a small hole covered with tape which must be removed. Use a small common tip screwdriver to adjust to zero position. Replace tape. (9) Mode select switch - SOARING. ( 1 0) Master switch - OFF. ( 1 1 ) Re-install fuel quantity indicator. ( 1 2) Re-install instrument panel top cover. Doc. No. Issue Rev. No. 3.02.21 May 17, 1 993 1 0 Date Source Page No. 1 5 Jun 1 998 SB 50/5 2.36 H K 36 R, TS, TC, TIS, TIC, TIC-ECO AIRPLANE MAINTENANCE MANUAL Systems Description 2.5 POWER-PLANT 2.5.1 ENGINE DESCRIPTION Power is provided by a Rotax Model 912 A or 914 F four stroke four cylinder hOrizontally opposed engine. It is installed in the nose and drives the propeller through an integrated speed-reducing gear. Rotax 912 A The engine is firmly connected on its four rear fixture points to two branched engine mount adapters. Each engine mount adapter is connected to the engine mount by a rubber damper (silentbloc). Each of the two forward engine fixture points is connected directly to the engine mount by two rubber dampers (silentblocs). The engine mount has four fixture points on the firewall. Rotax 9 1 4 F The engine is firmly connected on its four rear fixture points to the annular engine mount adapter. This engine mount adapter is connected to the engine mount at four points by rubber dampers (silentblocs). The two forward engine fixture pOints are not used. The engine mount has six fixture points on the firewall. The rubber dampers are designed in such a way that the connection still is maintained if the rubber is damaged. Doc. No. Issue Rev. No. Date Source Page No. 3.02.21 May 1 7 , 1993 1 0 1 5 Jun 1 998 SB 50/5 2.37 •Diamond HK 36 R, TS, TC, TIS, TIC, TIC-ECO AIRCRAFT AI RPLANE MAINTENANCE MANUAL Systems Description All wires come together in a multi-pin plug which is attached to the firewall in the upper right corner. The plug in models with the Rotax 9 1 2 A has some free pins for additional wires that might be needed. For the sake of fire protection, other breaches of the firewall should not be established. The engine is wholly operated through bowden cables. Three view drawings of the Rotax 9 1 2 A: see following pages. Three view drawings of the Rotax 91 4 F: see the Maintenance Manual for Rotax Engine Type 9 1 4 F. Doc. No. Issue Rev. No. Date Source Page No. 3.02.21 May 17, 1 993 1 0 1 5 Jun 1 998 SB 5015 2.38 •DiamondAIRCRAFT Doc. No. Issue HK 36 R, TS, TC, TIS, TIC, TIC-ECO AIRPLANE MAINTENANCE MANUAL Rotax 9 1 2 A Rev. No. Date Source 3.02.21 May 1 7, 1 993 1 0 1 5 Jun 1 998 S8 50/5 Systems Description Page No. 2.39 .,DiamondAIRCRAFT -T �- Uil � � �- , - , , I ' 1 i ! I '' 1 = .I.: =1 -' 1.1i 1=1 I : , ! , ' , , ' , , , ! t Doc. No. Issue HK 36 R, TS, TC, TIS, TIC, TIC-ECO AIRPLANE MAINTENANCE MANUAL ; • - � . � - - - --- - - - !l - !l Rotax 9 1 2 A • 1 • !;,,, Rev. No. Date Source 3.02.21 May 17, 1 993 1 0 1 5 Jun 1 998 S8 50/5 Systems Description !! , I "Ii , -I• Page No. 2.40 �Diamond V� AIRCRAFT HK 36 R, TS, TC, TIS, TIC, TIC-ECO AIRPLANE MAINTENANCE MANUAL Systems Description 2.5.2 CARBURETOR DESCRIPTION The BING carburetor is a constant speed or equal pressure carburetor. The engine suction produces a partial vacuum, dependent on the throttle valve position. The vacuum propagates to the vacuum chamber (upper part of the dome). As a result, the differential pressure between the vacuum chamber and the atmosphere increases, and the piston and the attached fuel needle ascend. This d evice provides an almost constant pressure drop and an almost constant velocity of air flow in the Venturi tube. I nformation about carburetor adjustment can be obtained from the Operator's Manual for the Rotax 912 A or the Maintenance Manual for Rotax Engine Type 914 F, respectively. PISTON Doc. No. Issue Rev. No. 3.02.21 May 17, 1 993 1 0 VACUUM CHAMBER � . ' . ' _ : . • .f . . ;. � . PARTIAL . '$ -" _.../. :; � n...;�rt-�....J -.-" .. : . ' ,, :. ... . - VACUUM - .. .. , . r -:.... f�FUEL NEEDLE Date Source 1 5 Jun 1 998 SB 50/5 Page No. 2.41 HK 36 R, TS, TC, TIS, TIC, TIC-ECO AIRPLANE MAINTENANCE MANUAL Systems Description 2.5.3 DESCRIPTION OF THE TURBOCHARGING OF THE ROTA){ 914 F ENGINE General The exhaust turbocharger it installed undemeath the engine on the right. The TCU (Turbo Control Unit) and the actuator for the waste gate flap are mounted between the instrument panel and the firewall on the right hand side. Working principle of the turbocharger: see Maintenance Manual for Rotax Engine Type 914 F. Manifold pressure regulation Function of the TCU: see Maintenance Manual for Rotax Engine Type 914 F. A switch marked "TCU ON' is located under a flap in the right hand section of the instrument panel. With this switch, the actuator for the waste gate flap can be switched off. Warning and caution lights for engine monitoring Three lights are located in the instrument panel (HK 36 TIC-ECO: left hand section, top; other models: center section): Light Color Signal Meaning Turbo amber flashing Defect in the sensor, sensor wiring or TCU area, or leakage in the airbox Manifold Pressure red flashing Time limit for max. take off power exceeded steady on Max. permissible manifold pressure exceeded Temperature amber steady on EGT above 950 'C (1 742 'F) or airbox temp. above 72 'C (162 'F) The "Turbo' and "Manifold Pressure" lights are controlled by the TCU. Doc. No. Issue Rev. No. Date Source Page No. 3.02.21 May 1 7 , 1 993 1 0 1 5 Jun 1 998 S8 50/5 2.42 .,DiamondAIRCRAFT HK 36 R, TS, TC, TIS, TIC, TIC-ECO AIRPLANE MAINTENANCE MANUAL Systems Description The 'Temperature' caution light receives its signal from a monitoring box, which is located on the right hand side of the firewall. The electronics in the box are protected by a fuse, which is also located in the box. At three measuring terminals on the monitoring box, the voltages relative to ground can be measured using a voltmeter, from which the temperature values can be calculated directly. Temperature values and corresponding voltage values are displayed directly on the box. Intermediate values can be evaluated by linear interpolation. With this, the three sensors can be checked. It is also possible to check the exhaust gas and airbox temperatures during operation. Doc. No. Issue Rev. No. Date Source Page No. 3.02.21 May 1 7, 1 993 1 0 1 5 Jun 1 998 S8 50/5 2.43 4ff/tDiamond HK 36 R, TS, TC, TIS, TIC, TIC-ECO AIRCRAFT AIRPLANE MAINTENANCE MANUAL 2.5.4 POWER-PLANT REMOVAL AND INSTALLATION Systems Description The engine must be removed for overhaul and repair. The following procedure is recommended: 1 . Disconnect bowden cable from the cowl flap actuating device. 2. Remove upper and lower engine cowling. 3. Disconnect ignition cables. 4. Remove propeller. 5. Disconnect battery (negative terminal first) and remove. 6. Disconnect fuel lines from firewall breach. 7. Disconnect multi-pin plug on the firewall. 8. Rotax 914 F only: disconnect temperature monitoring box connector. g. Only if 28 V system (optional) is installed: remove connector for generator from 28 V voltage regulator. 1 0. Disconnect Bowden cables and control cables: throttle, choke, carburetor heat, cable for mechanical propeller feathering device (if installed), Bowden cable for propeller governor (if installed). 1 1 . Rotax 914 F only. disconnect control cable for waste gate flap from actuator. 1 2 . Disconnect flexible shaft of RPM indicator (if installed) from engine. 1 3. Disconnect hose for cabin heat from hot end of exhaust heat exchanger. 1 4 . Disconnect manifold pressure hose from firewall. 1 5. Rotax 914 F only. disconnect air pressure line which leads to airbox pressure sensor (behind instrument panel) from firewall. 1 6 . Elevate engine (e.g. with nylon ropes at the propeller shaft and the manifolds) until the engine mount is relieved; remove all fastening bolts of the engine mount; push back fuselage. 1 7. Remove exhaust, turbocharger, coolers, oil tank, ignition box, engine mount and engine mount adapters. Should the engine be sent to the manufacturer or to a service station, it must be sent there together with the exhaust, the coolers, the oil tank,Jhe ignition box, propeller governor (if fitted), turbocharger with TCU (if fitted) and the engine logbook. Doc. No. Issue Rev. No. Date Source Page No. 3.02.21 May 17, 1 993 1 0 1 5 Jun 1 998 SB 50/5 2.44 •DiamondAIRCRAFT H K 36 R, TS, TC, TIS, TIC, TIC-ECO AIRPLANE MAINTENANCE MANUAL To install the engine, reverse the procedure. Systems Description For the sake of safety, all bolts and nuts must be secured either with self-locking nuts or with lock wire. Doc. No. 3.02.21 CAUTION After the installation of the Rotax 914 F, the TCU must be adjusted (to the sensors, etc.). A PC, dongle and appropriate software are necessary. This adjustment work may only be carried out by people who have been trained by the manufacturer. Issue Rev. No. Date Source May 1 7 , 1 993 1 0 1 5 Jun 1 998 SB 50/5 Page No. 2.45 •DiamondAIRCRAFT H K 36 R, TS, TC, TIS, TIC, TIC-ECO AI RPLANE MAINTENANCE MANUAL 2.5.5 ENGINE SPARE PARTS Systems Description Aircraft engines are certified in accordance with detailed airworthiness requirements. Every part of an aircraft engine is subjected to an incoming inspection carried out by the engine manufacturer. All spare parts (gaskets, spark plugs, etc.) used in the maintenance of the engine must also be approved by the engine manufacturer. If other spare parts are used or the Original state of the engine is altered in any way, incidents may have legal consequences. Since the aviation authorities distinctly point out this fact, we suggest that you proceed accordingly i n your own interest. Doc. No. Issue Rev. No. Date Source Page No. 3.02.21 May 1 7, 1 993 1 0 1 5 Jun 1 998 S8 50/5 2.46 .Diamond HK 36 R, TS, TC, TIS, TIC, TIC-ECO AIRCRAFT AIRPLANE MAINTENANCE MANUAL 2.5.6 PROPELLER DESCRIPTION Systems Description The most important features of the available propeller models are shown below and the respective manuals are referred to. mt-propeller MTV- 1 -A/1 70-08 * Electric constant speed propeller * mt-propeller P-1 20-A electronic control unit * Blade pitch change mechanism actuated by electric DC-motor and threaded spindle * Manual: Operation and Installation Manual No. E-1 1 8 mt-propeller MTV-21 -A-C-F/CF1 75-05 * Hydraulically controlled constant speed propeller * Oil pressure is used to reduce propeller pitch * Feathering device operated through counterweights and spring forces * Pressure accumulator to move the blades from the feathered position to low pitch * Govemor : Woodward A 2 1 0790 (for Rotax R 912 A and Rotax R 9 1 4 F) or McCauley DCFU 290 D 1 70/T1 (for Rotax 9 1 2 A) or McCauley DCFU 290 D 1 701T2 (for Rotax 914 F) * Manual: Operation and Installation Manual No. E-124 Hoffmann HO-V352F-S1/S1 70FQ * Hydraulically controlled constant speed propeller * Mechanical feathering device * Governor Woodward A 2 1 0786 A * Manual: Instruction Manual No. E 540 mt-propeller MT170R1 25-2A * Fixed pitch propeller with wooden blades * Manual: Operation and Installation Manual No. E-203 Hoffmann H014-170S123 * Fixed pitch propeller with wooden blades * Manual: Owner's Manual No. E 0 1 1 0.74 Doc. No. Issue Rev. No. 3.02.21 May 1 7, 1 993 1 0 Date 1 5 Jun 1 998 Source SB 5015 Page No. 2.47 •Diamond HK 36 R, TS, TC, TIS, TIC, TIC-ECO AIRCRAFT AIRPu\NE MAINTENANCE MANUAL 2.5.7 PROPELLER INSTALLATION AND REMOVAL Systems Description The in stallation and removal of the propeller is carried out in accordance with the Propeller Manual (see Article 2.5.6 for the appropriate manual). Doc. No. 3.02.21 CAUTION The MTV-2 1 -A-C-F/CF1 75-05 has two variants with differing adjustment values, of which one is intended for the Rotax 9 1 2 A and the other for the Rotax 9 1 4 F. Therefore, it is absolutely necessary to ascertain, before installing a new propeller, whether the engine can be operated with that propeller. There are three possibilities: (a) The JAA Tag of the propeller explains expliCitly for which engine it is intended. (b) The angles of adjustment of the propeller are given on the "Geratelaufkarte". It can be determined, by comparison with the following table, for which engine the propeller is intended. Adjustment Value On Rotax 912 A On Rotax 9 1 4 F Stop for low pitch 12° ± 0.20 1 6. 5 0 ± 0.2 ° Stop for high pitch 23° ± 1 ° 28° ± 1 0 Stop for starting pitch 1 4 ° ± 1 ° 1 9 0 ± 1 0 Stop for feathering 830 ± 1 0 83 0 ± 1 0 Ctrwts. at low pitch 280 ± 1 0 32.5° ± 1 0 (c) Measure the propeller adjustment. When stationary, the propeller blades rest at the stop for starting pitch (see above table). Issue Rev. No. Date Source May 1 7 , 1 993 1 0 1 5 J u n 1 998 SB 50/5 Page No. 2.48 .Diamond HK 36 R, TS, TC, TIS, TIC, TIC-ECO AIRCRAFT AIRPLANE MAINTENANCE MANUAL Doc. No. 3.02.21 During an engine ground run after the installation, the use of the wrong propeller variant can be recognized by the following signs: ( 1 ) Propeller for Rotax 9 1 4 F o n 9 1 2 A: Maximum attainable engine speed at take off power during ground run is more than 1 00 RPM below correct value (2550 RPM). (2) Propeller for Rotax 912 A on 914 F: At take off power during ground run, the governor reduces the engine speed upon the slightest movement of the propeller speed control away from the foremost position (no "quasi dead travel" of the propeller speed control). If the wrong propeller variant has been used, the propeller must be exchanged. A change to the propeller settings can only be made by the propeller manufacturer. Issue Rev. No. Date Source May 17, 1 993 1 0 1 5 Jun 1 998 SB 50/5 Systems Description Page No. 2.49 "'Diamondv AIRCRAFT HK 36 R, TS, TC, TTS, TTC, TTC-ECO AIRPLANE MAINTENANCE MANUAL 2.6 ELECTRICAL SYSTEM 2.6.1 POWER SUPPLY Systems Description The power supply of the electrical system consists of a 1 2 V lead-acid battery and a generator which is integrated in the engine. The standard rechargeable battery has a capacity of 1 8 Amp-hours (optional 30 Amp-hours). The battery has a central ventilating system to allow vapors to be externally vented. The generator is a permanently excited ten-pole single phase alternator. Voltage regulation and rectification are performed by an electronic regulator with a full-wave bridge rectifier, fabricated by Ducati, Rotax Part No. 965345 with connector shell 965335. The battery is separated from the network by means of a battery relay. The cable that runs from the battery to the starter is not protected and is therefore coated with glass fabric in compliance with LN 9251 B standards. This cable must be routed properly to prevent short-circuits. All other wires meet LN 9251 A standards. With the exception of the starter, all electrical consumers are protected with thermal overload breakers or glass fuses. When triggered, the main breaker separates the network from the battery. The generator supplies the electrical network with power via the generator breaker. Doc. No. Issue Rev. No. Date Source Page No. 3.02.21 May 1 7, 1 993 1 0 1 5 Jun 1 998 SB 50/5 2.50 .Diamond HK 36 R, TS, TC, TIS, TIC, TIC-ECO AIRCRAFT AIRPLANE MAINTENANCE MANUAL Systems Description A mode selection switch for the different operation modes (power flight, soaring) is connected in series with the master switch. When the master switch is closed (ON) and the mode select switch is open (i.e. in SOARING position), only the radio equipment and the optional electric vertical speed indicator are supplied with power. When the master switch is closed (ON) and the mode select switch is closed (i.e. in POWER FLI GHT position), the pallet of the battery relay is attracted, and all electrical consumers are supplied with power. When the master switch is open (OFF), all electrical consumers are disconnected from the battery and the generator. The electrical network is thereby currentless. 2.6.2 ELECTRIC INSTRUMENTS An ammeter is used to monitor the electrical system. It indicates how quickly the battery is being charged (+ range) or discharged (- range). The following electric engine instruments are installed: - Electric oil pressure indicator - Electric oil temperature indicator - Electric fuel quantity indicator(s) - Electric cylinder head temperature indicator Essentially, all the instruments function in a similar manner: The sensors contain resistors, whose resistances change through changes in the measured variable. The indicators convert these resistance values into needle d eflections. Doc. No. Issue Rev. No. Date Source Page No. 3.02.21 May 17, 1 993 1 0 1 5 Jun 1 998 S8 50/5 2.51 HK 36 R, TS, TC, TIS, TIC, TIC-ECO AIRPLANE MAINTENANCE MANUAL Systems Description 2.6.3 ELECTRIC FUEL PUMP Models with Rotax 9 1 2 A The Powered Sailplane is equipped with a mechanical fuel pump and also an electric fuel pump, which is operated by a switch on the instrument panel. The circuit breaker for the electric fuel pump is located in the center section of the instrument panel. 2.6.4 IGNITION SYSTEM Models with Rotax 9 1 4 F The Powered Sailplane is equipped with two independent electric fuel pumps. The main fuel pump has no switch. It promotes fuel flow as soon as the generator delivers current. The fuel booster pump is dependent on the electrical network and is operated by a switch on the instrument panel. The fuse for the main fuel pump is located in the engine compartment. The circuit breaker for the fuel booster pump is located in the instrument panel (HK 36 TIC-ECO: far right, other models: central section). The engine is equipped with a non-contacting reactor-capacitor dual ignition. To cut off the ignition, the ignition system must be short-circuited. Therefore, it is very important to ensure proper connection between the ignition system and the ignition switch, and in particular proper ground connection of the switch. Doc. No. 3.02.21 WARNING If the ignition system is not short-circuited properly, the ignition is on. When working on the ignition system, the propeller must be secured against moving by hand, otherwise the engine might fire - DANGEROUS TO LIFE! Issue Rev. No. Date Source May 17, 1 993 1 0 1 5 Jun 1 998 S8 50/5 Page No. 2.52 •DiamondAIRCRAFT 2.6.5 WIRING HK 36 R, TS, TC, TIS, TIC, TIC-ECO AIRPLANE MAINTENANCE MANUAL Systems Description Wires in fuselage and wings are fastened with clamps and bindings in a way that prevents chafing. The entire wiring complies with aeronautical requirements (LN 9251 and others). These requirements must also be followed in the case of repairs or subsequent installations. As far as possible, crimp connections are used. Soldered connections should used as little as possible. Connectors must have a so-called insulation support (i.e. a copper bush that grips the wire insulation). Only tinned, insulated copper cable sockets are used. A crimped connection has more strength than the wire itself when proper crimping tools are used. It is advisable to use crimping tools with a self-locking mechanism. 2.6.6 CIRCUIT BREAKERS The circuit breakers operate on thenmal overload (bimetal). They have an absorption capacity of 200 A. They cannot be reset unless the reason for the cut-out is eliminated. HK 36 TTC-ECO: Other models: Main breaker (50A) , the generator breaker Located in the right hand section of the (25 A) and breakers for electrical consumers instrument panel are: the main breaker (engine instruments, ATC equipment, fuel (50 A), the generator breaker (HK 36 R: 50 pump, ACL, position lights, landing light, A, other models: 25 A), the breakers for the etc.) are located in the top RH section of the power-plant instruments and the breakers for instrument panel. the air traffic control equipment. The switch panel in the center section of the instrument panel includes breakers for the corresponding switches (fuel pump, ACL, --position lights, landing lights, etc.). Doc. No. Issue Rev. No. Date Source Page No. 3.02.21 May 17, 1993 1 0 1 5 Jun 1 998 S8 50/5 2.53 .Diamond HK 36 R, TS, TC, TIS, TIC, TIC-ECO AIRCRAFT AIRPLANE MAINTENANCE MANUAL Systems Description The circuit breaker for the electric variable pitch propeller (if installed) is located beside the control unit. Additional fuses for models with the Rotax 9 1 4 F The fuses for the main fuel pump, the generator relay and the generator control relay are located at the rear of the engine compartment on the right hand side. 2.6.7 SWITCHES For general purposes, single and double pole rocker type switches (HK 36 TIC-ECO) or toggle type switches (other models, switching capacity: 20 Amps per contact) are used. The ignition/starter switch is a key switch. It must not be replaced by any other (unspecified) commercial switch. 2.6.8 AIR TRAFFIC CONTROL (ATC) EQUIPMENT Any ATC equipment must be installed in the center section of the instrument panel. Installation must be carried out by appropriately rated personnel in accordance with the regulations of the respective manufacturers. Doc. No. Issue Rev. No. Date Source Page No. 3.02.21 May 17, 1 993 1 0 1 5 Jun 1 998 SB 50/5 2.54 •Diamond HK 36 R, TS, TC, TIS, TIC, TIC-ECO AIRCRAFT AIRPLANE MAINTENANCE MANUAL Systems Description 2.6.9 ANTENNAS Radio antenna: VOR antenna: ADF antenna: TransponderlDME antenna: ELT-antenna: 2.6.1