P92 Echo Super Maintenance Manual

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U#$#""! 8&*&A)A&=.!<3)G)'92!#########################################################################################################################################!HP! ! ! ! ! 6 Revision Date: 10-29-2007 Revision Number: 3.01 Downloaded from www.Manualslib.com manuals search engine 7 Revision Date: 10-29-2007 Revision Number: 3.01 ! P92 Echo Super Maintenance Manual ! ! ! 1 Introduction Before servicing the aircraft, we recommend careful reading of this manual, the flight manual, the propeller manual, and the engine‟s service manual. A thorough knowledge of the aircraft, of its qualities, and of its limitations will allow you to operate with greater safety. The P92 Echo Super is an uncomplicated and sturdy machine whose features include simple servicing and superior flying qualities. This manual describes time and modes for correct servicing procedures. Scrupulously following instructions will insure that your P92 Echo Super will accompany you dependably for a long time with optimal performance in absolute safety. This manual consists of 8 sections; a table of contents in section 1 will allow you to reach any selection quickly. Information contained herein is based on available data at time of publication; possible variations shall be presented in service directives. This manual describes correct servicing of parts manufactured by TECNAM and, in subordinate measure, of the list of components purchased from external suppliers; for more complete information on individual components it is necessary to refer to the component‟s manufacturer‟s manual. ! Downloaded from www.Manualslib.com manuals search engine P92 Echo Super Maintenance Manual ! 2 Descriptions & General Characteristics The Echo Super is an all metal, high wing, two-place, single-engine airplane equipped with tricycle landing gear. It is an ASTM compliant airplane designed to be flown by sport pilot rated pilots as well as higher rated pilots. This aircraft is designed and built in Italy and as such, was built using the metric system. Therefore, the primary numbers are in metric and the US conversion is in parenthesis for your information. Figure 2-1 shows a Three View drawing of the aircraft while tables below report main technical features and dimensions. The Maintenance Manual contains the following sections: 1. Introduction 2. General 3. Inspection and Servicing 4. Airframe 5. Powerplant 6. Systems 7. Markings and Placards 2.1 Certification Basis This aircraft complies with ASTM standards and is certificated as a Special Light Sport Aircraft. Figure 2-1 General Views 8 Revision Date: 10-29-2007 Revision Number: 3.01 ! ! ! ! SECTION 2 GENERAL Downloaded from www.Manualslib.com manuals search engine P92 Echo Super Maintenance Manual 9 Revision Date: 10-29-2007 Revision Number: 3.01 ! ! ! ! 2.2 Descriptive Data ! 2.2.1 Airframe ! 2.2.1.1 Wing ! Wing span 8.70 m (28.54‟) Wing area 12 m2 (129 sq ft) Aspect ratio 6.31 Taper ratio 1.0 Wing chord 1.400 m (4.6‟) Flap span 1.970 m (6.463‟) Flap chord 0.390 m (15.35”) Aileron span 1.505 m (4.937‟) Aileron chord 0.385 m (1.263‟) ! 2.2.1.2 Fuselage ! Overall length 6.4 m (21‟) Overall width 1.1 m (43”) Overall height 2.5 m (8.2‟) ! 2.2.1.3 Empennage ! Stabilator span 2.900 m (9.5‟) Stabilator area 1.972 m2 (21.2 ft2) Stabilator cord 0.680 m (26”) Vertical tail span 1.230 m (3.9‟) Vertical Stabilizer area 0.720 m2 (2.36 sq ft) Rudder area 0.350 m2 (1.48 sq ft) ! 2.2.1.4 Landing Gear ! Wheel track: 1.800 m (5.9‟) Wheel base: 1.600 m (5.2‟) Main gear tire: Air Trac 5.00-5 Wheel brakes: Marc Ingegno 199 - 102 Nose gear tire: Sava 4.00-6 Downloaded from www.Manualslib.com manuals search engine P92 Echo Super Maintenance Manual 10 Revision Date: 10-29-2007 Revision Number: 3.01 ! ! ! ! 2.3 Systems ! 2.3.1 Engine ! Manufacturer: Bombardier-Rotax GmbH Model 912 ULS or 912 S2 (optional) Certification basis ASTM F2239 or FAR 33 Austrian T.C. No. TW 9-ACG dated 27th November 1998 Type: 4 cylinder horizontally opposed twins with overall displacement of 1352 c.c. mixed cooling, (water-cooled heads and air-cooled cylinders), twin carburetors, integrated reduction gear with torque damper. Maximum rating: 98.6hp (73.5kW) @ 5800 rpm/min (2388 rpm/min. prop). Gear reduction ratio - 2.4286:1 Max oil consumption Max: 0.1 liters/hour ! 2.3.2 Propeller ! Manufacturer: GT Tonini Model: GT-2/173/VRR- FW101 SRTC Number of blades: 2 Diameter: 1730 mm (68”) (no reduction permitted) Type: Fixed pitch – wood / composite ! 2.3.3 Fuel ! Fuel grade: Min. RON 95 Auto Fuel (AKI 91 Premium USA) AVGAS 100LL Fuel tanks: 2 integrated wing tanks Capacity of each wing tank 35 liters (9.2 gal) (optional 45 liters) (11.9 gal) Total capacity 70 liters (18.49 gal) (optional 90 liters) (23.8 gal) Total usable fuel 66.8 liters. (17.64 gal) (86.8 liters) (22.93 gal) ! 2.3.4 Oil System ! Oil system: Forced, with external oil reservoir Oil: See Rotax operator‟s manual Oil Capacity: Max. 3.0 liters (3.2 qt) – min. 2.0 liters (2.1 qt) ! 2.3.5 Cooling ! Cooling system: Mixed air and liquid pressurized closed circuit system Coolant: See Rotax operator‟s manual Downloaded from www.Manualslib.com manuals search engine P92 Echo Super Maintenance Manual 11 Revision Date: 10-29-2007 Revision Number: 3.01 ! ! ! ! 2.4 Weights ! 2.4.1 Maximum Weights ! Maximum take-off weight: 600 kg (1320 lbs) Maximum landing weight: 600 kg (1320 lbs) Maximum baggage weight 20 kg (44 lbs) ! 2.4.2 Standard Weights ! Empty weight 325 kg (716 lb) Maximum payload weight 275 kg (604 lb) ! 2.4.3 Specific Loadings ! Wing Loading 50 kg/m2 (10.2 lb/ft2) Power Loading 6 kg/hp (13.2 lb/hp) ! NOTE Standard weights are estimates based on standard equipment. ! 2.5 Instructions for Reporting Possible Safety of Flight Concerns Email to info@tecnam.co.nz the following information: ! Aircraft Make, Model, Serial Number ! Engine Make, Model, Serial Number ! Date of Inspection ! Total Time: ! Airframe ! Engine ! Description of the un-airworthy items found ! Owner of Aircraft ! ! 2.6 Source to Purchase Parts Spare parts can be ordered from Tecnam Australasia Ltd. info@tecnam.co.nz or from your local dealer. ! 2.6.1 List of Disposable Replacement Parts Air filter........................... Rotax PN 825551 Fuel filter ......................... Facet filter, Aircraft Spruce PN 479729 Oil filter ........................... Rotax PN 924420 Nose wheel tire ................ Sava 4.00-6 type tire and tube or may be replaced with a similar size aircraft tire or tube Main gear tire .................. Air Trac 5.00-5 type tire and tube or may be replaced with a similar size aircraft tire or tube Oil.................................... See Rotax manual Coolant ............................ See Rotax manual Downloaded from www.Manualslib.com manuals search engine P92 Echo Super Maintenance Manual 12 Revision Date: 10-29-2007 Revision Number: 3.01 ! ! ! ! ! 2.6.2 Standard Equipment ! Flight Instruments Airspeed Indicator, Altimeter, Vertical Speed Indicator, Compass Engine instruments Tachometer, Oil Pressure, Fuel Pressure, Oil Temperature, Cylinder Head Temperature, Hour Meter, Left and Right Fuel Quantity, Volt Meter Warning Lights and Indicators Trim Indicator, Flap Indicator, Generator Warning Light Controls Dual Stick Flight Controls, Rudder Pedals, Dual Throttles, Throttle Friction Control, Engine Choke, Electric Flaps, Hydraulic Disc Brakes with Parking Brake, Left and Right Fuel Selector Valves, Direct Nose Wheel Steering Interior Adjustable Pilot and Copilot Seats, Acoustic Cabin Soundproofing, Adjustable Cabin Air Ventilators, Steel Roll Cage, Cabin Heat and Windshield Defrost, 12V Power Outlet, Metal Instrument Panel Exterior All Aluminum structure, Landing Light, Strobe Light, Fixed Landing Gear, Nose Gear Strut Fairing, Nose and Main Wheel Fairings Powerplant and Accessories Rotax 912 ULS Engine (100 hp), Composite Covered Wood Propeller with Spinner, 12Volt 18 Ah Battery, internal 18 Amp AC generator, Engine Driven Fuel Pump, Electric Starter, Engine Exhaust Muffler, Gascolator with Quick Drain, Integral Wing Fuel Tanks, All Electric Circuits Fuse Protected Downloaded from www.Manualslib.com manuals search engine P92 Echo Super Maintenance Manual 13 Revision Date: 10-29-2007 Revision Number: 3.01 ! ! ! ! ! ! ! ! SECTION 3 INSPECTION & SERVICING ! ! ! ! 3 Inspection and Servicing ! 3.1 Ground Handling Move the aircraft on the ground by pushing on the wing struts close to wing attachments or by pulling on the propeller blades close to hub. It is preferable to use a tow bar. A tow bar can be attached to fittings provided on nose gear fork. Aircraft can be steered using the rudder or, for sharp turns, by lowering the tail to raise the nosewheel off the ground. In this case, owing to the favorable CG location, a gentle push on the tailcone just ahead of empennage surfaces is all that is needed. Avoid dragging nosewheel sideways and do not attempt to counter any movement of the aircraft by handling it by its wing tips. ! 3.2 Parking and Tie-down As a general precaution for outdoor parking, it is wise to position aircraft into the wind and to set the par king brakes or chock the wheels if chocks are available. In severe weather and high wind conditions, aircraft tie-down is recommended. Tie ropes should be secured to the wing tie- down fittings located at the upper end of each wing strut. Secure opposite end of ropes to ground anchors. Nose gear fork may be used as fixing for forward tie-down. Aircraft control stick should be locked using safety belts to prevent possible wind damage to control surfaces. ! 3.3 Jacking Given the light empty weight of the aircraft, lifting one of the main wheels can be easily accomplished even without the use of hydraulic jacks. Remove the aluminum panel located between the steel springs and, while one person lifts one half-wing by acting on the wing spar immediately before the wingtip, another person will place a suitable stand with protect ive cover under the steel spring attachment. If one of the steel springs needs to be removed, the support stand must be positioned in the specific location along the landing gear support beam (do not place support against lower aluminum panel as doing so would deform and damage the panel). Prevent possible tip-over of the aircraft by placing a suitable stand to rear of aircraft. ! WARNING ! As a general rule, apply force to aircraft structure only on main structural elements such as frames, ribs or spars. Downloaded from www.Manualslib.com manuals search engine P92 Echo Super Maintenance Manual 14 Revision Date: 10-29-2007 Revision Number: 3.01 ! ! ! ! 3.4 Leveling Occasional leveling of aircraft may be necessary to insure proper wing incidence and/or dihedral or for e xact CG location. The aircraft is level when the cabin floor and, in a transversal direction, the landing gear bulkhead are horizontal. Level the aircraft using a simple spirit or water level and adjust the aircraft‟s tilt through shims placed under wheels or by regulating tire pressure. ! 3.4.1 Control surface settings Adjustment of control surfaces must not exceed travel limits reported in table below. The zero reference mark for stabilator is on left side of aircraft (see figure below). ! AILERONS (starting from tip line-up) Up 20° Down 15° " 2° STABILATOR Up 16° Down 3° " 1° TRIM (Stab. at 0° , see fig. below) 2° 12° " 1° RUDDER RH 25° LH 25° " 1° FLAPS (max travel) 0° 38° " 1° CONTROL CABLE TENSION (for all) 20 daN (45#) ! " 2 daN (" 4#) ! ! ! ! ! REFERENCE MARK ! ! ! ! ! ! ! ! ! ! ! FIGURE 3-1 STABILATOR ADJUSTMENT. ! ! 3.4.2 Trim-tab adjustment Travel adjustment of trim tab on stabilator should be carried out as follows: ! Move stabilator to neutral (0 degrees) and lock in position; (this is accomplished by aligning the leading edge of the stabilator with the reference rivet located on the left side of tail cone); ! Turn Master Switch ON ! Trim to maximum pitch-up ! Adjust thread of hinged control rod until tab is deflected downwards 12° (use a protractor or measure downward displacement of trailing edge - 12° is approximately 24mm (.945”) ! Trim to maximum pitch-down ! Tighten lock-nut for adjustment thread and fasten connecting pin of control rod to trim-tab Downloaded from www.Manualslib.com manuals search engine P92 Echo Super Maintenance Manual 15 Revision Date: 10-29-2007 Revision Number: 3.01 ! ! 3.4.3 Aircraft alignment Figure 3-2 Alignments 3.4.4 Datum Datum Distances in mm Inches A-B 4690 " 20 184 6” B ! ! ! ! ! ! ! ! SPINNER BACK PLATE UPPER POINT ! ! ! ! ! ! A A' ! LAST RIVET ON THE LOWER SIDE OF THE REAR WING SPAR ! ! ! ! ! ! ! C C' FIRST RIVET BETWEEN THE TUBULAR SPAR AND THE OUTERMOST RIB ! UPPER/REAR RIVET ON ALUMINIUM SKIN. i.e. The rivet in common between the fin's rear spar and the upper rib. G ! ! ! C C' ! ! ! F F' Main Wheels Axle Line ! ! ! ! . A‟-B 4690 " 20 184.6” A-C 4140 " 20 163” A‟-C‟ 4140 " 20 163” C-G 1800 " 20 70.87” C‟-G 1800 " 20 70.87” F-F‟ 1880 " 20 74” Downloaded from www.Manualslib.com manuals search engine P92 Echo Super Maintenance Manual 16 Revision Date: 10-29-2007 Revision Number: 3.01 ! ! ! ! 3.5 Weighing USE GUIDELINES AS FOLLOWS: 1. Carry out weighing procedure inside hangar 2. Remove any objects inadvertently left on board aircraft, excessive dirt, grease, moisture, etc. 3. Make sure that all required items of equipment that is included in the empty weight is onboard 4. Align nose wheel 5. Drain all fuel in level flight attitude 6. Oil, hydraulic fluids, and coolants are at operating levels 7. Move seats to most forward position 8. Flaps retracted (0°) 9. Control surfaces in neutral position 10. Position scales (min. capacity. 200 kg / 440 lbs) under each tire 11. Record weights of individual scales 12. Level the aircraft 13. Record weights of individual scales 14. Calculate empty weight 3.6 Determination of CG 1. Drop a plumb bob tangent to the wing‟s leading edge, (in the un-tapered section of the wing, at about one meter (~ 40”) from the root) trace a reference mark on floor 2. Repeat operation on other half-wing 3. Connect the two reference marks with a taut line 4. Measure distances between reference line and landing gear wheel axles 5. Recorded data allows determination of C.G. location and aircraft‟s moment (see following table) Downloaded from www.Manualslib.com manuals search engine P92 Echo Super Maintenance Manual 17 Revision Date: 10-29-2007 Revision Number: 3.01 ! ! ! 6.1 Weight and CG Table ! ! ! ! ! ! ! ! ! ! ! ! ! ! ! ! ! ! ! ! ! e: ! 1405 mm = 55 31” ! Meters Distance from bob to LH wheel AL = Distance from bob to RH wheel AR = Average distance (AL+ AR)/2 A = 560 mm Distance from bob to nose wheel B = 1062 mm ! DATUM FILO A PIOMBO ! ! ! 3. ! ! ! ! ! 1405 D ! ! ! ! ! ! ! ! RIFERIMENTO ORIZZONTALE ! ! ! W1 W2=WL+WR B A ! Not ! . ! A = 560 mm (22.05”) ! B = 1062 mm (41.8”) Information Only - Adapted from AC 43.13-1B CHG 1 C.G. = D-((F * L) / W) C.G. = Distance from datum to center of gravity of the airplane. W = The weight of the aircraft at the time of weighing. D = The horizontal distance measured from the datum to the main wheel weighing point. L = The horizontal distance measured from the main wheel weighting point to the nose wheel weighing point. F = Weight at nosewheel weighing point D = 1965 mm L = 1622 mm ! Kg Fwd wheel weight W1 = Main wheel left WL = Main wheel right WR = W2=WL+WR ! Empty weight ! Wef =W1 + W2 = W # A $ W # B D % 2 1 % Meters We ! Kg Arm (meters) D Moment (Kg m) D # We Net weight Wef ! ! ! Weight unusable fuel (2.6 liter 2.75 quarts) 1.9 (4.2#) 1.660 (65.35”) 3.2 (274.47 #”) TOTAL We = De = Me/We = Me = ! CG position as wing chord % De%=De/1.4 # 100= Downloaded from www.Manualslib.com manuals search engine P92 Echo Super Maintenance Manual 18 Revision Date: 10-29-2007 Revision Number: 3.01 ! ! ! ! 3.7 Corrosion Prevention ! It is important to keep the aircraft clean and to remove any collection of corrosive agents such as oil, grease, dregs and other foreign matter. To avoid damage to finish, do not use polishing detergents. Original or equivalent corrosion prevention must be re-applied after any alteration or repair. If any trace of corrosion is detected it should be removed as soon as possible and part should be immediately treated to prevent further corrosion. (a) For steel parts, with the exception of highly stressed components or stainless steel, it is possible to use abrasives, power brushes, steel brushes if operated manually and steel wool. Removing corrosion byproducts from highly stressed steel components (main gear steel spring) requires particular care. (b) For aluminum parts, treatment consists in mechanically removing as much as possible corrosion byproducts, applying corrosion inhibitor and replacing original finish. Steel wool, emery or steel brushes (unless stainless steel) along with other highly abrasive material should not be used sinc e steel or emery particles become embedded in the softer material causing corrosion. After cleaning surface corrosion, parts must be treated with an anti-corrosion finish prepared as follows: 4 liter solution containing 10% chromic acid with 20 drops of battery electrolyte. Accurate brushing with a sturdy fiber brush will rid most of the corrosion and insure that the anti-corrosion agent will penetrate completely in the cracks. Leave the chromic acid solution on the part for at least five minutes and then remove excess with water or a damp cloth. Apply protective finish the same day in which treatment begins. ! 3.8 Service Directives ! No. TITLE TYPE ! ! ! ! ! ! ! ! ! ! ! ! ! ! ! ! ! ! ! ! ! ! ! ! ! ! ! ! ! ! ! ! ! ! ! ! ! ! ! ! ! ! ! ! ! ! ! ! ! ! ! Downloaded from www.Manualslib.com manuals search engine P92 Echo Super Maintenance Manual 19 Revision Date: 10-29-2007 Revision Number: 3.01 ! ! ! ! 3.9 Servicing For scheduled servicing on engine refer to manufacturer‟s Operator‟s manual. ! 3.9.1 Daily ! Pitot and static ports – Check for obstructions ! Oil – Check oil level ! Coolant – Check coolant level ! Fuel strainer – Check and drain Gascolator for water or sediment ! Fuel tank vents – Check vents for obstruction ! 3.9.2 As needed ! Tires – Check condition and maintain proper tire pressure ! 3.10 Lubrication (every 100 hours or annually) Periodic lubrication of moving parts insures proper operation and extends parts‟ life considerably. Lubrication type, points and intervals are indicated below. ! Avoid excessive lubrication as this may cause external surfaces of hinges and bearing to collect dirt and dust. ! If part is not lubricated using a grease gun, grease part by hand removing excess. ! To grease main gear wheel bearings, first remove thrust bearings from wheel hubs, then clean surface using solvent, apply grease and re-assemble. ! Use grease type MIL-G-3278 or equivalent (i.e. Mobil grease 27 Synthetic aviation grease) ! 3.10.1 Lubrication Points ! 1-2 Rudder hinges 3-4 Rudder control cable terminals 5 Stabilator control rod terminals 6-7 Stabilator support bearings 8-9 Trim-tab hinges 10 Tab control push-rod terminals 11 Stabilator pass-through rod 12 Stabilator control rod (inside cabin) 13-14 Aileron hinges 15 Differential ailerons hinges 16 Aileron control pushrods 17 Aileron control rods pass-trough 18 Flaps control pushrods 19-20 Flaps torque-tube support 21 Flap actuator terminals 22-23 Rudder pedals support 24-25 Rudder pushrods and cable terminals 26-27 Brake lever support 28-29 Control stick lever and support 30-31 Aileron control pulleys 32 Nose gear fork attachment hinge 33 Shock absorber attachment hinge 34 Nose gear strut attachment hinge 35 Steering pushrod terminals ! Grease door hinges and adjustable seat rails when necessary Downloaded from www.Manualslib.com manuals search engine P92 Echo Super Maintenance Manual ! ! ! ! ! ! ! ! ! ! ! ! ! ! ! ! ! ! ! ! ! ! ! ! ! ! ! ! ! ! ! ! Figure 3-3 Lubrication points ! ! Figure 3-4 ! Every 50 hours ! ! ! ! ! ! ! ! 20 Revision Date: 10-29-2007 Revision Number: 3.01 Downloaded from www.Manualslib.com manuals search engine P92 Echo Super Maintenance Manual ! ! ! ! ! ! ! ! ! ! ! ! ! ! ! ! ! ! ! ! ! ! ! ! ! ! ! ! ! ! ! ! ! ! ! ! ! ! ! ! ! ! ! ! ! ! ! ! ! ! ! ! ! ! ! Figure 3-5 Every 100 hours ! ! ! ! ! ! ! ! 21 Revision Date: 10-29-2007 Revision Number: 3.01 Downloaded from www.Manualslib.com manuals search engine P92 Echo Super Maintenance Manual ! ! ! 3.10.2 Inspection panels Inspection points that are not in plain view may be accessed through inspection ports and/or removal of panels or fai rings as detailed below: ! 1. Inspection Ports on wing underside - access to aileron differential bellcrank – main spar and torque box; - inspection of wing-to-strut attachment 2. Upper strut fairing - inspection of strut-to-wing attachment 3. Lower strut fairing - inspection of strut-to-fuselage attachment 4. Tailcone underside portholes - access to: stabilator control rod pass-through; battery relay; front attachment of vertical stabilizer; inspection of aft structure and of cables for rudder control 5. Battery porthole - access to battery (not normally installed) 6. Tailcone end fairing - access to stabilator torque tube and attachments to control lever; -attachment of vertical stabilizer aft spar; -rudder bellcrank; -trim actuator and pushrods 7. Aft cabin bulkhead and baggage compartment floor - inspection of aft fuselage section and attachments; - inspection of stabilator control system and of cable pulleys for rudder control; - access to flap actuator; - access to aileron control cable turnbuckles 8. Forward cabin side panels - access to half-wing‟s forward attachment; -access to fuel line tank outflow 9. Cabin ceiling panel - access to bellcrank joining cabin cable circuit to wing pushrods for aileron control 10. Instrument panel cover - access to instrumentation and radio 11. Engine cowling - access to engine and related systems; - access to main components of electrical system - access to nose gear strut and steering assembly mechanism 12. Propeller spinner - access to propeller hub ! 3.11 Inspection ! 3.11.1 INTRODUCTION TECNAM considers the inspection schedule outlined below compulsory for the safe operation of the airframe and of the systems over an extended period of time. Described servicing requirements pertain to operation in non-extreme climatic conditions. For the Rotax 912 ULS / S engine, unless otherwise stated in the present manual, it is compulsory to adhere to maintenance requirements as reported in the Engine‟s Operator‟s Manual (p/n 899 370). For the GT propeller, refer to manufacturer‟s maintenance manual ! Airframe and systems inspection schedule is as follows: ! Inspections for airworthiness before first flight of day as specified in Flight Manual ! Periodic inspections at 100 hours ! Special inspections added to normal periodic inspections ! Singular inspection, when aircraft has been exposed to conditions that may have damaged one or more of its components ! If aircraft is rarely used, a “100 hour inspection” must be performed yearly ! Replacement of parts subject to usage limitations are specified in par. 3.14 Inspections and checks, unless specifically indicated, apply to the following: ! Structures in general: - Condition of panel covers, ribs, frames, stringers etc., absence of cracks, deformation, rivet slackening, corrosion and any other apparent sign of damage ! Moving parts: - Lubrication, security of attachment, safetying of bolts, absence of excessive play, proper adjustment, proper travel, condition of attachments and hinges, absence of corrosion, deformation, rivet slackening, cleanliness ! Fluid lines and hoses: - Absence of leaks, cracks, dents, chafing, proper radius, deterioration ! Bolts and attachments: - Proper tightening and safetying, absence of cracks or nicks, absence of corrosion and punctiform corrosion, damage to thread, wear and excessive play. ! 22 Revision Date: 10-29-2007 Revision Number: 3.01 Downloaded from www.Manualslib.com manuals search engine P92 Echo Super Maintenance Manual ! ! 3.12 Condition Inspection (100 hour / annual) ! 3.12.1 Inspection Panels Each person performing an annual or 100-hour inspection shall, before that inspection: ! Remove or open all necessary inspection plates, access doors, fairing, and cowling. Clean the aircraft and aircraft engine after initial visual inspection for: ! Oil, exhaust, or other leaks ! 3.12.2 Fuselage group 1. Check fabric and skin-for deterioration, distortion, other evidence of failure, and defective or insecure attachment of .fittings 2. Check systems and components-for improper installation, apparent defects, and unsatisfactory operation ! 3.12.3 Cabin and cockpit group 1. Check for cleanliness and for loose equipment that might foul the controls 2. Check the seats and safety belts for condition and/or any defects 3. Check windows and windshields for deterioration and breakage 4. Check instruments for poor condition, mounting, marking, and (where practicable) improper operation 5. Check flight and engine controls for improper installation and improper operation 6. Check battery for improper installation and improper charge 7. Check all systems for improper installation, poor general condition, apparent and obvious defects, and insecurity of attachment ! 3.12.4 Engine and nacelle group 1. Check engine section for visual evidence of excessive oil, fuel, or hydraulic leaks, and sources of such leaks 2. Check studs and nuts for improper torque and obvious defects 3. Check engine compression. If there is weak cylinder compression, check for improper internal condition and improper internal tolerances 4. Check for metal particles or foreign matter on screens and sump drain plugs. 5. Check engine mount for cracks, looseness of mounting, and looseness of engine to mount 6. Check flexible vibration dampeners for poor condition and deterioration 7. Check engine controls for defects, improper travel, and improper safetying 8. Check lines, hoses, and clamps for leaks, improper condition and looseness 9. Check exhaust stacks for cracks, defects, and improper attachment 10. Check accessories for apparent defects in security of mounting 11. Check all systems for improper installation, poor general condition, defects, and insecure attachment 12. Check cowling for cracks, and defects ! 3.12.5 Landing gear group 1. Check all units/for poor condition and insecurity of attachment 2. Check shock absorbing devices for damage 3. Check linkages, trusses, and members for undue or excessive wear fatigue, and distortion 4. Check hydraulic lines for leakage 5. Check electrical system for change and improper operation of switches 6. Check wheels for cracks, defects, and condition of bearings 7. Check tires for wear and cuts 8. Check brakes for improper adjustment ! 3.12.6 Wing and center section assembly Check for: 1. Poor general condition ! ! ! ! 23 Revision Date: 10-29-2007 Revision Number: 3.01 Downloaded from www.Manualslib.com manuals search engine P92 Echo Super Maintenance Manual 24 Revision Date: 10-29-2007 Revision Number: 3.01 ! ! ! 2. Fabric or skin deterioration 3. Distortion 4. Evidence of failure 5. Insecurity of attachment ! 3.12.7 Empennage assembly Inspect all components and systems for: 1. General condition 2. Fabric or skin deterioration 3. Distortion 4. Evidence of failure 5. Insecure attachment 6. Improper component installation 7. Improper component operation. ! 3.12.8 Propeller group Check propeller assembly for: 1. Cracks 2. Nicks 3. Binds 4. Bolts for improper torque and lack of safetying ! 3.12.9 Radio group 1. Check radio and electronic equipment for improper installation and insecure mounting 2. Check wiring and conduits for improper routing, insecure mounting, and obvious defects 3. Check bonding and shielding for improper installation and poor condition 4. Check antenna including trailing antenna for poor condition, insecure mounting, and improper operation ! 3.12.10 Optional equipment Check all optional equipment for proper operation ! 3.12.11 ELT Remove and inspect the installed for proper operation of the “G” switch and calendar date currency of the batteries installed in accordance with FAA Advisory Circular 91-44 current revision. Downloaded from www.Manualslib.com manuals search engine P92 Echo Super Maintenance Manual 25 Revision Date: 10-29-2007 Revision Number: 3.01 ! ! ! ! ! SUMMARY OF REFERENCE VALUES Torque settings for connection bolts are a function of their thread (shank) diameter Bolt resistance category: 8.8 & 4 = 3.1 Nm ~ 27 In/Lb & 6 = 10.4 Nm ~ 92 In/Lb & 8 = 24.6 Nm ~ 217 In/Lb & 10 = 50.0 Nm ~ 442 In/Lb Warning: propeller attachment bolts must be fastened to 18 Nm (~159 In/Lb) value even though they have an & 8 diameter. Wing to fuselage fitting bolts & ½” (NAS 1308 – 28) = ~ 100 Nm (~73 Ft/Lb) Control cable tension (for both aileron and rudder) Value : 20 dN " 2 dN (45 # " 4 #) ! Tire pressure: Nose 1.0 bar (15 PSI) Main 1.6 bar (23 PSI) ! ! ! 3.13 Torque Conversion Table Multiply By To obtain foot-pounds 1.3558 Newton-meters foot-pounds 0.1383 kilogram-meters foot-pounds 12.0 inch-pounds inch-pounds 0.0115 kilogram-meters inch-pounds 0.1130 Newton-meters inch-pounds 0.0833 foot-pounds kilogram-meters 7.233 foot-pounds kilogram-meters 86.7964 inch-pounds kilogram-meters 9.8067 Newton-meters Newton-meters 0.7376 foot-pounds Newton-meters 8.8508 inch-pounds Newton-meters 0.1020 kilogram-meter Downloaded from www.Manualslib.com manuals search engine P92 Echo Super Maintenance Manual 26 Revision Date: 10-29-2007 Revision Number: 3.01 ! ! ! ! ! ! ! 3.14 LIMITATIONS TO AIRWORTHINESS! ! COMPONENTS ! Type ! SERVICE LIFE Electric trim actuator T2-10A 1000 hr or 10 yrs Shock absorber rubber discs 92-8-200-1 (QTY 7) 1200 hr or 10 yrs Oil system flexible hose assy TECNAM pn‟s: 21-11-910-001; 21-11-910-002; 21-11-910-003 5 yrs Fuel system flexible hose TECNAM pn‟s: 21-11-311-1; 21-11-311-2; 21-11-340-1; 21-11-324-1; 21-11-330- 2 yrs Liquid cooling system flexible hose 92-11-105-1; 92-11-105-2; 92-11-105-3; 92-11-105-4 2 yrs ! ! ! ! ! ! ! ! ! ! ! ! ! ! ! ! ! ! ! ! ! ! ! ! ! ! ! ! Revision n°1, 2nd February 2009 Downloaded from www.Manualslib.com manuals search engine P92 Echo Super Maintenance Manual 27 Revision Date: 10-29-2007 Revision Number: 3.01 ! ! ! ! ! ! ! ! SECTION 4 AI RFRAME ! ! ! ! 4 Introduction The airframe consists of the following main groups as shown in figure 4-1: ! 1) Wings 2) Fuselage 3) Empennage 4) Landing gear 5) Powerplant ! ! ! ! 4.1 Wing Figure 4-1 Main groups Each wing is connected to the fuselage by means of two pin attachments and a single strut brace per side. Wings are made up of a central light alloy torsion box; a light alloy leading edge is attached to the front spar (1) while flap (2) and aileron (3) are attached to rear fake spar through two hinges each. The torsion box, as shown in figure 4-2 and with reference to numbers in parenthesis, consists of a main spar (4) and a fake spar (5) that makes up its front and rear vertical walls; a series of ribs (6) and wrap-around panels complete the structure. Downloaded from www.Manualslib.com manuals search engine P92 Echo Super Maintenance Manual ! Front and aft spars are complete with wing-to-fuselage attachment fittings (7). Wing-to-strut attachment fittings are located approximately in the middle of main spars (8). Aileron uses "piano-hinges" type MS 20001-4 for direct attachment of aileron spar to wing spar. Flap hinges are external to wing torsion box and feature SKF GE10E type ball bearings. ! ! ! ! Figure 4-2 Wing structure The aileron is constructed of an aluminum spar to which a formed sheet metal leading edge and metal ribs are attached; Dacron synthetic material wrap-around aileron structure. Flaps are constructed of a center spar to which front and rear ribs are joined; aluminum skin panels wrap-around flap structure. Wing tips are molded epoxy resin, fiberglass reinforced. At the inboard end of half-wing's leading edge is an integrated aluminum fuel tank with individual filler cap. Fuel tanks vent through light alloy tubes in the area immediately below the tanks. ! 4.1.1 Installing and reinstalling the wing Procedure for removal of wing and strut is as follows: ! Drain fuel tank using drain tank and closing opposite side tank fuel circuit ! Remove panel inside cabin to access and disconnect fuel line ! For the right wing, disconnect stall-warning system wires ! Disconnect position lights wiring if present ! Disconnect flap control (see fig. 4-3) by removing roller bearings (7) that link push-pull rods (6) to flap control plate ! Disconnect aileron control (see fig. 4-4) by removing pins (4) that connect the small bar (3) to the pushrods (5) ! While supporting the wing‟s end (not from wingtip), release strut‟s upper pin, then release lower pin and remove strut ! While supporting the half-wing from below the root area, release the two wing-to-fuselage attachment pins. To expedite release of aft pin, keep flap lifted, then remove wing ! Replace pins in their original location and cap fuel lines ! Reverse above procedure for reinstallation paying close attention to tighten strut‟s bolts to recommended value M8 bolt torque 24.6 Nm (~ 218 inch pounds) ! ! ! 28 Revision Date: 10-29-2007 Revision Number: 3.01 Downloaded from www.Manualslib.com manuals search engine P92 Echo Super Maintenance Manual ! ! 4.2 Flap control Flap control system is push-pull type. The torque tube (1), connects the two moving surfaces and hinges on two braces (2) rigidly attached to fuselage structure. Bolt, nut and cotter pin secure link. Rotation is transmitted through a push-rod (3) whose position is adjusted via an electric linear actuator (4) governed by a switch on instrument panel. Two push-pull rods (6) are connected to the ends of the torque tube (1) and are located in the area between wing and fuselage thus facilitating inspection. The two push-pull rods controlling flap movement feature an adjustable linkage just before the roller bearings allowing trailing edge alignment. ! ! ! ! ! ! ! ! ! ! ! ! ! ! ! ! ! ! ! ! ! ! ! ! ! ! Figure 4-3 Flap control ! ! ! ! ! ! ! ! Figure 4-3a Flap Actuator ! ! ! ! ! ! ! ! ! ! ! ! ! ! ! 29 Revision Date: 10-29-2007 Revision Number: 3.01 Downloaded from www.Manualslib.com manuals search engine P92 Echo Super Maintenance Manual ! ! 4.3 Aileron control Aileron control system uses push-pull rods and bellcranks inside wing and steel cables and pulleys inside fuselage. Layout of flight control system inside cabin includes three pairs of pulleys which transmit movement from the two control sticks (1), linked in parallel by a rod (2), to a small bar (3) located in cabin overhead in correspondence with main pushrod s issuing from half-wings. Main rods are connected to the small bar using two pins (4). The two main rods (5), are routed through the ribs and are attached at opposite end to a bell crank (6) and a push-pull rod (7). The push-pull rod then crosses the wing‟s fake spar to transmit motion. Linkage length is adjustable. ! ! ! ! Figure 4-4 Aileron control To remove aileron, disconnect one end of push-pull rod and remove pins from hinges. Reverse above procedure to reinstall aileron insuring that, with stick vertical, the aileron‟s trailing edge is aligned with wing‟s trailing edge. Through access panels located on wing‟s bottom, check that the bellcrank lever is in neutral position, i.e. the inside arm at right angle with spar axis. To remove half-wings, release pins (4) that secure short bar (3) to main rods (5). The steel cable system is designed to insure proper cable tension without the need to check whenever the half-wings are removed. It is however recommended that periodic checks be carried out and proper tension applied by acting on the two tur nbuckles (8) located behind the cabin‟s aft panel. Also check periodically that pulleys rotate freely and tolerance for entire linkage is within standards (ref. Section B). ! If control stick should feel unusually hard, reduce cable tension as this may be the primary cause for malfunction; also check that pulleys and other parts of the link system positioned under seats are properly greased. If control stiffness persists, check integrity of bellcranks and pulleys and insure that cable has not come off pulleys. Alignment of moving surfaces with wing must be done using outboard trailing edge as reference. Further lateral corrections (aircraft leans to one side) may be carried out adjusting trim tab located on left aileron trailing edge. ! 30 Revision Date: 10-29-2007 Revision Number: 3.01 Downloaded from www.Manualslib.com manuals search engine ! ! 4.4 Horizontal Tail P92 Echo Super Maintenance Manual The horizontal tail is an all-moving type, that is, the stabilizer and elevator form a single, uniform plane called stabilator that rotates about an axis normal to fuselage at the desired pitch setting. The stabilator structure (see fig.4-5) is made-up of an aluminum tubular spar (1) to which a series of ribs (2) and an aluminum leading edge (3) are riveted. Dacron heat-shrink wrap-around material covers structure. A trim tab (4) provides stick force adjustment and longitudinal compensation through an electric actuator co ntrolled by pilot. Tab is split in two parts interconnected at the support brackets (5) and attached to the stabilator through four external hinges (6) that allow for immediate inspection. ! ! ! ! ! ! ! ! ! ! ! ! ! ! ! ! ! ! ! ! ! ! ! ! ! ! ! ! ! ! ! ! ! ! ! Figure 4-5 Stabilator ! ! ! To remove the stabilator, disconnect the two halves of the tab from each other and from the control rod, remove pins (7), and then remove half-planes. To avoid cover damage during operation, handle parts by their rigid components. Reverse procedure for reinstallation applying a small amount of grease to the inside of the torque tube (1) to facilitate insertion and gently tapping parts into position being careful not to deform outward ribs. The stabilator control system is push-pull type (see fig. 4-6) and is controlled from the cabin via the control sticks. Control is transmitted through a push-pull rod (1) linked to a bellcrank (2) and a shaft (3) that runs through the tail cone supported at midsection by a bracket (4) and connected with the stabilator torque tube through the aft bellcrank assembly (5). All significant transmission elements such as bellcranks, pushrods, supports and hinges can be easily accessed and inspected. ! ! ! 31 Revision Date: 10-29-2007 Revision Number: 3.01 Downloaded from www.Manualslib.com manuals search engine P92 Echo Super Maintenance Manual ! ! ! ! Figure 4-6 Stabilator control ! If unusual tolerance is found along transmission, replace parts displaying excessive wear. The aft bellcrank assembly (see fig. 4-7) consists of a steel tube (1) with welded horn assembly (2), attachment for stabilator control shaft (3) and balanced weight bellcrank (4). Counterweight is located at the end of a prong bolted to the torque tube and entering tail cone through the tail-frame cutout. Longitudinal trim is controlled through two switches on the stick handle and is monitored via an indicator located on instrument panel. Control activates the linear actuator (5) connected to supports (6) and horn assembly (7). Actuator‟s motion is transmitted to an adjustable push-pull rod (8) through a bellcrank (9). To remove the stabilator torque tube, disconnect electric actuator frame assembly (7) from support (6), release control shaft (4) from aft bellcrank assembly (3) then release horn assembly (2) from brackets (6). ! ! ! ! ! ! ! ! ! ! ! ! ! ! ! ! ! ! ! ! 32 Revision Date: 10-29-2007 Revision Number: 3.01 Downloaded from www.Manualslib.com manuals search engine P92 Echo Super Maintenance Manual ! ! ! ! ! ! ! ! ! ! ! ! ! ! ! ! ! ! ! ! ! ! ! ! ! ! ! ! ! ! ! ! ! ! ! Figure 4-7 Stabilator control ! ! 4.4.1 Stabilator balance If it becomes necessary to verify stabilator balance (repairs etc.) proceed as follows: Remove the tail fairing and open the inspection hatch located on the bottom of the tailcone (the one closest to tail -end); Disconnect the moving surface from its control rod. To avoid interference with the free rotation of the tailplane, temporarily secure control rod to the stabilator support assembly; Disconnect the trim-tab control rod; Secure trim-tab to stabilator to avoid any relative movement. Use adhesive tape to avoid any influence on balance; Check for excessive friction or lock-ups in the moving parts; The stabilator is balanced when the application of an 800 grams / ~ 28.21 ounces weight at point (1) in figure above brings stabilator to horizontal position. If the stabilator should result “trailing-edge-heavy” it is necessary to add a few small weights to the leading edge near the root. A slight imbalance towards the leading edge is acceptable as it is deemed conservative with respect to stability. ! 4.5 Vertical Tail The vertical tail consists of an all-metal light alloy structure (fig. 4-8). Vertical stabilizer tip is composite with cut-outs for navigation and strobe light. The vertical stabilizer consists of a twin spar with wrap-around stressed skin paneling. An attachment plate (1) secures the stabilizer‟s front spar to the penultimate tailcone frame while the rear spar is extended to attach directly onto the last tailcone ordinate (2). ! ! 33 Revision Date: 10-29-2007 Revision Number: 3.01 Downloaded from www.Manualslib.com manuals search engine P92 Echo Super Maintenance Manual ! The rudder consists of an aluminum alloy torque tube (3), formed sheet metal ribs (4) and sheet -metal panel cover (5) held in place by rivets. The rudder rotates about its torque tube via two, specially designed hinges (parts 6 and 7). The top hinge pin rotates about a bushing embedded in the topmost ordinate of the vertical stabilizer. The bottom hinge pin rotates about a bushing (8) embedded within a support flange attached to vertical stabilizer aft spar. A bellcrank (9) secured to the rudder's lower hing e converts the rudder pedals cable commands. ! Figure 4-8 Vertical stabilizer, rudder and supports ! Rudder mass balancing (10) is via a counterweight attached to a prong coupled, in turn, to the upper end of the rudder torque tube. Weight and prong move within stabilizer tip and within specially designed fairings (one is removable) for overhang. To remove rudder, after removing tail fairing, disconnect cables from bellcrank, unfasten lower support flange from stabilizer and uncouple rudder with downward motion. Control system layout (fig. 4-9) is steel cable driven and circuit terminates on nose wheel steering lever. Rudder pedals (1) are attached to two pushrods (3) that terminate the control circuit (2) for the rudder and transmit steerin g motion to the nose gear leg through a lever. This lever hinges on the engine mount and springs connected to the steeri ng lever via two small plates allow for a more effective realignment of the rudder. Length of pushrods can be mod ified via adjustable ball and socket connections. Cable tension must be checked periodically and adjusted to proper value using the turnbuckles (4) (Tension = 20 daN " 2). Pulley condition (5) and their smooth operation must also be checked. To access levers and rudder pedals support, remove cabin‟s central tunnel; for speedier operation remove seats from railings. ! ! ! ! ! ! ! 34 Revision Date: 10-29-2007 Revision Number: 3.01 Downloaded from www.Manualslib.com manuals search engine P92 Echo Super Maintenance Manual ! ! ! ! ! ! ! ! ! ! ! ! ! ! ! ! ! ! ! ! ! ! ! ! ! ! ! ! ! ! ! ! ! Figure 4-9 Rudder control ! ! ! ! ! ! ! ! ! ! ! ! ! ! ! ! ! ! ! ! ! ! ! ! ! ! ! ! ! ! 35 Revision Date: 10-29-2007 Revision Number: 3.01 Downloaded from www.Manualslib.com manuals search engine P92 Echo Super Maintenance Manual ! ! 4.6 Fuselage The front part of the fuselage is made up of a mixed structure: a truss structure with special steel members for cabin survival cell (fig. 4-10), and a light-alloy semi-monocoque structure for the cabin's bottom section. The aft part of the fuselage (fig. 4-11) is constructed of an aluminum alloy semi-monocoque structure. Attachment to cabin truss is at the forward fittings of four stringers that run the aft fuselage length (1). Two flanges are located at the aft end of the tail section to support the horizontal tail assembly (2) and the vertical tail forward and aft spars. Forward truss structure drawing (fig. 4-10) shows location of attachment points for half-wing (1), aft section (2), brace-strut (3), main landing gear (4), engine mount (5), flap torque tube (6), stabilator bellcrank (7), throttle support (8) and pulley support for cable driven aileron control (9). Seat supports and safety harness attachment points are also shown. ! ! ! ! ! ! ! ! ! ! ! ! ! ! ! ! ! ! ! ! ! ! ! ! ! ! Figure 4-10 Cabin truss ! Engine mount is constructed of steel tubing and is secured to cabin truss via a four-point attachment. Bolts travel through bushings welded on mount, pass through the firewall and exit through other bushings welded to cabin truss. Nose gear support assembly is attached to engine mount. ! ! ! ! ! ! ! ! ! ! ! ! ! ! ! ! ! ! ! 36 Revision Date: 10-29-2007 Revision Number: 3.01 Downloaded from www.Manualslib.com manuals search engine P92 Echo Super Maintenance Manual ! ! ! Figure 4-11 Tailcone ! Cabin access is through two doors constructed of light alloy square tubing. A synthetic mat erial door panel, shaped for better comfort, is riveted to doorframes. Both doors feature spring lock door handles with inside safety latch. Seats are made out of metal tubing framework with fabric covered foam padding. The two seats can be independently adjusted by sliding backward and forward along rails fixed to cabin truss structure. Seat release levers are located just below seat cushions. Cabin floor is constructed of light alloy and features matting. Entire fuselage, wing and other exposed surfaces are finished with a highly resistant weatherproofing synthetic coating. Wash using only water, mild detergent and chamois. All parts in Perspex material must never be dusted dry, but washed with lukewarm soapy water. In any case, never use, on this kind of surface, products such as gasoline, alcohol or any kind of solvent. ! ! ! ! ! ! ! ! ! ! ! ! ! ! ! ! ! ! ! ! ! ! ! ! 37 Revision Date: 10-29-2007 Revision Number: 3.01 Downloaded from www.Manualslib.com manuals search engine P92 Echo Super Maintenance Manual ! ! 4.7 Landing Gear The main landing gear (see fig. 4-12) consists of two special steel spring-leaf struts (1) positioned crossways to fuselage for elastic cushioning of landing loads. The two steel spring-leaf struts are attached to the fuselage underside via the main girder. Two rawhide liners (2 3) are inserted between each spring-leaf and the girder. Two bolts (5) and nuts secure the individual spring-leaf to the edge of the girder via a light alloy clamp (4) while a single bolt (6) and nut secures the inboard end of the leaf-spring to the girder. ! ! ! ! ! ! ! ! ! ! ! ! ! ! ! ! ! ! ! ! ! ! ! ! ! ! ! ! Figure 4-12 Main landing gear ! Wheels are cantilevered on gear struts and feature hydraulically actuated disc brakes (see fig. 4-13) controlled by a lever (1) located on cabin tunnel between seats. Main gear wheels mount Air-Trac type 5.00-5 tires inflated at 23 psi (1.6 bar). Hydraulic circuit shut-off valve (2) is positioned between seats. With circuit shut off, pulling emergency brake lever activates parking brake function. Braking is simultaneous on both wheels via a “T” shaped joint (6). Control lever (1) activates master cylinder (3) that features built-in brake-fluid reservoir (4). The brake system is equipped with a non-return valve (5), which insures that braking action is always effective even if parking brake circuit should accidentally be closed. ! ! ! ! ! ! ! ! ! ! ! ! ! 38 Revision Date: 10-29-2007 Revision Number: 3.01 Downloaded from www.Manualslib.com manuals search engine P92 Echo Super Maintenance Manual ! ! ! ! Figure 4-13 Brake circuit ! To remove the leaf-spring struts proceed as follows: Remove cabin seats by sliding them forward Hoist aircraft onto supports Disconnect brake fluid line unscrewing the upper link of the external line tract near fuselage bottom. Place temporary caps on lines to prevent spillage Loosen bolts (part.5 fig. 4-12) of the aluminum clamp (part 4 fig. 4-12) that secure spring-leaf to edge of main girder Remove bolt connection between inboard end of spring-leaf (part.6 fig. 4-12) and main girder Remove gear strut by pulling outward from fuselage Reinstall using reverse procedure. It is however necessary to eliminate any trapped air: once the circuit is closed and fluid in reservoir is at normal level, bleed air through dedicated valve. For best results, use external pump to push fluid through valves allowing trapped air to escape through open reservoir. If braking action appears degraded, check and eventually replace main gear brake pads Refer to Periodic Inspection Chart in Section B for any service operation to main gear ! ! ! ! ! ! ! ! ! 39 Revision Date: 10-29-2007 Revision Number: 3.01 Downloaded from www.Manualslib.com manuals search engine P92 Echo Super Maintenance Manual ! ! ! 4.7.1 Main Gear Removal of main gear wheel (see fig. 4-16a and 17) Removal of a single wheel is carried out as follows: ! Hoist aircraft onto supports ! Release parking brake ! Remove fairing (1) by releasing bolt (2) and the three Phillips screws (3) that hold fairing to plate ! Remove bolt (4) and cup (5) ! Remove wheel lock nut (6) ! Unscrew 4 brake disc assembly bolts (See Figure 4-14 and Figure 4-15 (8)) ! Carefully remove wheel assembly with both hands ! ! ! ! ! ! ! ! ! ! ! ! ! Disc bolts ! ! ! ! ! ! Figure 4-14 ! ! ! ! ! ! ! ! ! ! ! ! ! ! ! ! ! ! ! ! ! ! ! ! ! ! ! 40 Revision Date: 10-29-2007 Revision Number: 3.01 Downloaded from www.Manualslib.com manuals search engine