Diamond Aircraft - Diamond Aircraft Industries

Transcription

"Diamond
"'1P'
AIRCRAFT
AIRPLANE MAINTENANCE MANUAL
FOR THE POWERED SAILPLANE MODELS
HK 36 R SUPER DIMONA
HK 36 TS
HK 36 TC
HK 36 TTS
HK 36 TTC
HK 36 TTC-ECO
Engine
: Rotax 912 A
: Rotax 91 4 F
Models
: H K 36 R Super Dimona
H K 36 TS
H K 36 TC
H K 36 TTS
H K 36 TTC
HK 36 TTC - ECO
Doc. No.
: 3.02.21
Date of Issue
: 1 7 May 1 993
DIAMOND AIRCRAFT INDUSTRIES GMBH
N.A. OTTO-STR. 5
A-2700 WIENER NEUSTADT
AUSTRIA
Cover Sheet Rev. 1 0
HK 36 R, TS, TC, TTS, TTC, TTC-ECO
.Diamond
AIRCRAFT
AIRPLANE MAI NTENANCE MANUAL
General
SECTION 0
GENERAL
0.1 LOG OF REVISIONS
Pages
Rev.
No.
Source
1 thru 5
Date
Inserted by
1 994-1996
covered by
SB 50/1
6
all
SB 50/1
July 1 996
-
7
all
SB 50/2
1 0 Mar 1 997
-
8
0.2
3.2, 3.3, 3.9, 3.26, 3.27, 3.30
4.25 thru 4.35
SB 50/3
20 May 1 997
covered by
SB 50/5
9
0.2 thru 0.4, 0. 1 1
1 . 1 thru 1 .7
2 . 1 thru 2.3, 2 . 1 7, 2 . 1 8, 2.25, 2.60
3.2, 3.26
4.20
6. 1 , 6 . 1 0, 6. 1 1
SB 50/4
25 Aug 1 997
covered by
SB 50/5
10
all
SB 50/5
1 5 Jun 1 998
-
--
Doc. No.
Issue
Rev. No.
Date
Source
Page No.
3.02.21
17 May 1 993
10
1 5 Jun 1 998
SB 50/5
0.2
HK 36 R, TS, TC, TIS, TIC, TIC-ECO
•Diamond
AIRCRAFT
General
0.2 TABLE OF CONTENTS
SECTION 0: GENERAL
0. 1 LOG OF REVISIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.2
0.2 TABLE OF CONTENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.3
0.3 EXPLANATIONS
0.3.1 ABBREViATIONS . . . . . . . . . . . . . . . . . . . . . . . . . .
0.3.2 PHYSICAL UN ITS . . . . . . . . . . . . . . . . . . . . . . . . . .
0.3.3 PARTS OF THE WING-FUSELAGE CONNECTION
0.3.4 BU LKHEADS AND STIFFENERS IN FUSELAGE . .
0.3.5 METRIC THREADS . . . . . . . . . . . . . . . . . . . . . . . . .
0.3.6 FABRIC DESIG NATION . . . . . . . . . . . . . . . . . . . . .
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0. 1 0
0.10
0.12
0. 1 2
0.13
0 13
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SECTION 1 : RIGGING AND DE-RIGGING, CARE
1.1 RIGGING AND DE-RIGGING
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1 . 1 . 1 GENERAL . . . . . . . .. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1 . 1 .2 WING INSTALLATION WITHOUT WING FOLDING MECHANISM
1 . 1 . 3 WING INSTALLATION WITH WING FOLDING MECHANiSM . . .
1 . 1 .4 WING REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1 . 1 . 5 WING LET INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1 . 1 .6 WING LET REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1 . 1 .7 HORIZONTAL STABILIZER I NSTALLATION . . . . . . . . . . . . . . . .
1 . 1 .8 HORIZONTAL STABILIZER REMOVAL . . . . . . . . . . . . . . . . . . . .
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1.2 ROAD TRANSPORT
1 . 3 STORAGE
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1 .4 CLEANING AND CARE
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1.1
1.1
1 .3
1 .4
1 .5
1 .5
1 .6
1 .6
1 .6
1 .7
1 .8
1 .8
Doc. No.
Issue
Rev. No.
Date
Source
Page No.
3.02.21
17 May 1 993
10
1 5 Jun 1 998
SB 50/5
0.3
IIfIII
V Ii. Diamond
AIRCRAFT
General
SECTION 2: SYSTEMS DESCRIPTION
2.1 FLIGHT CONTROL SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2. 1 . 1 GENERAL . . .
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....
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2 . 1 .2 ELEVATOR CONTROL SYSTEM . . . . .
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2.1 .3 RUDDER CONTROL SYSTEM .
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2 . 1 .4 AI LERON CONTROL SYSTEM
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2 . 1 .5 AIR BRAKE CONTROL SYSTEM
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. . . .
REMOVAL
OF
ALL
PRIMARY
CONTROL
SYSTEM
PARTS
2 . 1 .6
UNDER THE SEATS
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2.1 .7 ELEVATOR TRIM CONTROL SYSTEM
2.1 .8 ELEVATOR AND ELEVATOR TRIM CONTROL SYSTEM (SKETCH)
2 . 1 .9 RUDDER AND TAI L WHEEL CONTROL SYSTEM (SKETCH) .
. . .
2. 1 . 1 0 AILERON CONTROL SYSTEM I N FUSELAGE (SKETCH)
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2. 1 . 1 1 AILERON CONTROL SYSTEM IN WING (SKETCH)
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2 . 1 . 1 2 AIR B RAKE CONTROL SYSTEM AND
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WHEEL BRAKE SYSTEM IN FUSELAGE (SKETCH) .
2. 1 . 1 3 A I R BRAKE CONTROL SYSTEM I N WING (SKETCH) .
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2.2 LANDING GEAR
2 . 2 . 1 MAIN LANDI N G GEAR WITH GFRP STRUT
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2.2.2 TAI L WHEEL
2.2.3 MAIN LANDING GEAR WITH M ETAL STRUTS
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2.2.4 NOSE LAN DING GEAR
2.2.5 WHEEL BRAKE SYSTEM, VERSION 1 . . . . . . . . . . . . . . . . .
2.2.6 WHEEL BRAKE SYSTEM, VERSION 2 . . . . . . . . . . . . . . . . .
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' 2.8
2.9
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2. 1 1
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2. 1
2.1
2.1
2.3
2.4
2.6
. ·
2.12
2. 1 3
2.14
2.14
2.15
2.15
2.16
2.18
2.19
2.3 FUEL SYSTEM I N AIRPLANES WITH FUSELAGE TANK . . . . . . . . . . . . . . . . . . , 2.20
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' 2.20
2.3.1 FUEL SYSTEM DESCRIPTION
2.3.2 FUEL TANK EMPTY I NG
.
2.25
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. , 2.25
2.3.3 FUEL TANK REMOVAL .
' 2.26
2.3.4 REMOVAL OF FUEL FI LTERS I NSTALLED I N AI RFRAME
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' 2.27
2.3.5 FUEL QUANTITY I NDICATOR CALIBRATION
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2.4 FUEL SYSTEM IN AIRPLANES WITH WING TANKS . .
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. . . 2.28
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2.4.1 FUEL SYSTEM DESCRIPTION . . . .
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' 2.35
2.4.2 FUEL SYSTEM EMPTY I NG
2.4.3 CENTRAL FUEL RESERVOIR R EMOVAL . . . . . . . . . . . . . . . . . . . . . . 2.35
2.4.4 REMOVAL OF FUEL FILTERS INSTALLED I N AIRFRAME . . . . . . . . 2.35
2.36
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2.4.5 FUEL QUANTITY INDICATOR CALIBRATION .
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2.5 POWER-PLANT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.37
2.5.1 ENGINE DESCRIPTION
2.37
CARBURETOR
DESCRIPTION
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'
2.41
2.5.2
2.5.3 DESCRIPTION OF THE OF THE TURBOCHARGING
OF THE ROTAX 9 14 F ENGINE
, 2.42
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Doc. No.
Issue
Rev. No.
Date
Source
Page No.
3.02.21
1 7 May 1 993
10
1 5 Jun 1 998
SB 50/5
0.4
.Diamond
AIRCRAFT
2.5.4
2.5.5
2.5.6
2.5.7
POWER-PLANT REMOVAL AND I NSTALLATION
ENGINE SPARE PARTS . . . . . . . . . . . . . . . . . . .
PROPELLER DESCRIPTION . . . . . . . . . . . . . . .
PROPELLER INSTALLATION AND REMOVAL . .
General
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2.44
2.46
2.47
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 . . . . . . . . . . . .
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. . . . . .. . . . . . . . . . . . . . . . . . . . . , 2.75
Doc. No.
Issue
Rev. No.
Date
Source
Page No.
3.02.21
17 May 1 993
10
1 5 Jun 1 998
SB 50/5
0.5
HK 36 R, TS, TC, TIS, TIC, TIC- ECO
•Diamond
AIRCRAFT
General
SECTION 3: MAINTENANCE AND INSPECTIONS
3.1 SCHEDULED INSPECTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 . 1
.
3.1
3. 1 . 1 INSPECTION INTERVALS A N D TOLERANCES
3. 1 .2 ACCOMPLISHMENT OF MAINTENANCE WORK . . . . . . . . . . . . . . . . 3.2
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A.
B.
C.
D.
E.
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INSPECTION CH ECKLISTS FOR THE POWER PLANT
INSPECTION CHECKLISTS FOR THE AI RFRAME
GENERAL MAINTENANCE WORK AND CONFIRMATION
LUBRICATION SCHEDULE
CHECK FLIGHT AFTER MAINTENANCE
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3.2 DESCRIPTION OF SCHEDULED INSPECTIONS.
3.2 . 1 ENGINE
3.2.2 PROPELLER . . . . . . . . . . . . . . . . . . .
3.2.3 CABI N . . . . . . . . . . . . . . . . . . . . . . . .
3.2.4 STRUCTURE
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3.2.5 LANDING GEAR
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3.3
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3.30
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3.33
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3.35
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. . . . . . . . . . . . . . . . . . . . . . . . . 3.36
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3.39
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3.3 NON-SCHEDULED INSPECTIONS
3.3.1 ENGINE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3.3.2 PROPELLER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3.3.3 AIRFRAME . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
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3.45
. . . 3.45
. . . 3.48
. . . 3.48
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3.4 TORQUES
3.51
3.4. 1 STANDARD TORQUES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.51
3.4.2 SPECIAL TORQUES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.52
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Doc. No.
Issue
Rev. No.
Date
Source
Page No.
3.02.21
1 7 May 1 993
10
1 5 Jun 1 998
S B 50/5
0.6
�Diamond
V
AIRCRAFT
General
SECTION 4: OTHER WORK
4. 1 PROCEDURES FOR TOPPING UP OPERATING
4.1 . 1 FUEL . . . . . . . . . . . . . . . . . . . . . . . .
4. 1 .2 ENGI NE OIL . . . . . . . . . . . . . . . . . .
4. 1 . 3 COOLANT . . . . . . . . . . . . . . . . . . . .
4. 1 .4 BRAKE FLUID . . . . . . . . . . . . . . . . .
4. 1 .5 REFILLING THE BATI ERY . . . . . . .
FLUIDS
.. . . . . .
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4. 1
4.1
4.2
4.2
4.3
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 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4.8.1 EXPLANATION OF THE DIAGRAM . . . . . . . . . . . . . . . . . . . . . . . . .
4.8.2 MASS AND BALA NCE DIAGRAM, STANDARD TANK (MASTER) . .
4.8.3 MASS AND BALA NCE DIAGRAM, LONG RANGE TANK (MASTER)
4.9 PERMISSIBLE EMPTY MASS C.G. RANGE
AND MINIMUM USEFUL LOAD ON SEATS . . . . . . . . . . . . . . .
4.9. 1 PERMISSIBLE EMPTY MASS C.G. POSiTION . . .
4.9.2 MINIMUM USEFUL LOAD ON SEATS
WITH STANDARD FUEL TANK . . . . . . . . . . . . . .
4.9.3 MINIMUM USEFUL LOAD ON SEATS
WITH LONG RANGE FUEL TANK . . . . . . . . . . . . .
4.9.4 MINIMUM USEFUL LOAD ON SEATS WITH WING
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4. 1 0
4. 1 0
4. 1 1
4. 1 2
. . . . . . . . . . . . . . . 4: 1 3
. . . . . . . . . . . . . . . 4. 1 3
. . . . . . . . . . . . . . . 4.14
. . . . . . . . . . . . . . , 4. 1 4
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.
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Date
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10
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SB 50/5
0.7
�Diamond
v
AIRCRAFT
General
SECTION 5: REPAIR INSTRUCTIONS
5.1 DESCRIPTION OF THE GFRP PARTS . . . . . . . . . .
5 . 1 . 1 Wi NG . . . . . . . . . . . . . . . . . . . . . . . . . .
5. 1 .2 AI LERONS . . . . . . . . . . . . . . . . . . . . . .
5. 1 . 3 RUDDER . . . . . . . . . . . . . . . . . . . . . . . .
5. 1 .4 HORIZONTAL TAI L . . . . . . . . . . . . . . . .
5. 1 . 5 FUSELAGE . . . . . . . . . . . . . . . . . . . . . .
5 . 1 .6 MAIN LANDING GEAR MADE OF GFRP
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5. 1
5.1
5.4
5.6
5.8
5.10
5.12
'
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
5.2 1
5.5 PAINTING
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
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0.8
.Diamond
AIRCRAFT
General
SECTION 6 : AIRWORTHINESS LIMITATIONS
6.1 LIFE LIMITED PARTS ... . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . . . . . . .
6. 1 . 1 ENGINE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . .
6. 1 .2 SILENTBLOCS OF ENGI N E MOUNT . . . . . . . . . . . . . . . . . . . . . . . . .
6.1.3 OTHER RUBBER COMPONENTS I N THE ENG INE COMPARTMENT
6.1.4 COOLANT . . . .. . . . . . . . . . .. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
6. 1 .5 PROPELLER . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . . . . . . . . . . . . .
6 . 1 .6 PROPELLER GOVERNOR . . . . . . . .. . . . . . . . . . . . . . . . . . . . . . . . .
6 . 1 .7 AIRFRAME . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
6 . 1 .8 ALUMINUM MAI N LANDING GEAR STRUTS . . . . . . . . . . . . . . . . . . .
6 . 1 .9 ELECTRIC FUEL PUMPS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
6.1 . 1 0 HOSES I N TH E AIRFRAME . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . .
6. 1 . 1 1 RUDDER CONTROL CABL ES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
6 . 1 . 1 2 OUTER ROD END BEARI NGS OF ELEVATOR ATTACHMENT . . . . .
6.1.1 3 BRAKE FL UiD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ... . . . . . . . . . .
6.1.1 4 E LT BATTERY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
6 . 1 . 1 5 IGNITION SWiTCH . . . .. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
6 . 1 . 1 6 SAFETY HARNESSES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
6. 1 . 1 7 TOWING DEVICE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . '
6.2
6.2
6.2
6.3
6.3
6.4
6.4
6.5
6.5
6.6
6.6
6.7
6.7
6.7
6.8
6.8
6.8
6.8
6.2 SURFACE COLOR. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . . . . . . . . . . . . . . 6.9
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0.9
.Diamond
AIRCRAFT
General
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
NOTE
In many, mostly older manuals, the mass is referred to as
''weig hf'. 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).
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0. 1 0
.Diamond
AIRCRAFT
51
units
U5
General
conversions
units
length
[mm]
[cm]
[m]
millimeters
centimeters
meters
[in.]
[ft.]
velocity
[km/h]
kilometers per
hour
meters per
second
[kts.] knots
[mph] miles per hour
[fpm] feet per minute
[km/h] I 1 .852 = [kts.]
[ km/h] I 1 .609 = [mph]
[m/s] " 1 96.85 = [fpm]
[m/s]
[mm] I 25.4 = [in.]
[cm] I 2.54 = [in.]
[m] 1 0. 3048 = [ft.]
inches
feet
rotary
speed
[min"]
revolutions per
minute
[RPM] revolutions per
minute
[min"]
capacity
[ I]
liters
[US gaL]
U.S. gallons
[Imp. gaL]
Imperial gallons
[1] 1 3.785
mass
density
[kg/m3 ]
kilograms per
cubic meter
=
[ RPM]
[US gaL]
=
[1] 1 4.546 = [Imp. gaL]
3
[kg/m ] I 27680
= [Ibs.lcu. in.]
[Ibs.lcu.in.]
pounds per
cubic inch
[Ibs.lcu.ft.]
pounds per
cubic foot
3
[kg/m ] I 1 6.02
= [Ibs.lcu.in.]
mass
[kg]
kilograms
[Ibs.]
pounds
[kg] " 2.2046 = [Ibs.]
force,
weight
[N]
[daN]
Newtons
Decanewtons
[Ibs.]
pounds
[ N] • 0.2248 = [ Ibs.]
[daN] • 2.248 = [I bs.]
power
Kilowatts
[kW]
[DIN-hp.] DIN-horsepowers
(German horsep. ,
non-SI unit)
[h.p.]
horse powers
[kW] " 1 . 36 = [DIN-hp.]
[kW] " 1 .341 = [h.p.]
pressure
[hPa]
[mbar]
[bar]
Hectopascal
millibar
bar
[inHg] inches mercury
column
[ psi]
pounds per
square inch
[hPa] = [mbar]
[hPa] I 33.865 = [inHg]
[bar] " 14.504 = [psi]
temperature
[0 C]
degrees Celsius
[O F]
[ 0 C] " 1 .8 + 32
current
intensity
[A]
Ampe res
-
current
capacity
[Ah]
Ampere hours
-
voltage
[V]
degrees
Fahrenheit
=
[ 0 F]
-
Volts
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0. 1 1
IfII>Diamond
AIRCRAFT
General
0.3.3 PARTS OF THE WING-FUSELAGE CONNECTION
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.
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.Diamond
AIRCRAFT
General
0.3.5 METRIC THREADS
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.
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�
AIRCRAFT
Rigging and
AI RPLANE MAINTENANCE MANUAL
De-Rigging, Care
SECTION
1
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:
Other models;
A locking pin is inserted through both bolt
A spring loaded hook is placed over the bolt
handles, thereby securing them.
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.
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1.1
�Diamond
"''W'
AIRCRAFT
HK 36 R, TS, TC, TTS, TT C, TT C-ECO
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.
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�Diamond
"T
AIRCRAFT
1 . 1 .2
Rigging and
De-Rigging, Care
WING INSTALLATION WITHOUT WING FOLDING MECHANISM
NOTE
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.
7.
Screw the B-bolt locking unit onto the B-bolt and tighten it by hand.
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.
3.02.21
Issue
17 May
1 993
Rev. No.
Date
Source
Page No.
10
1 5 Jun 1 998
SB 5015
1.3
•Diamond
AIRCRAFT
Rigging and
De-Rigging, Care
1 . 1 .3 WING INSTALLATION WITH WING FOLDING MECHANISM
NOTE
When installing the wings, prevent the airplane from falling onto its
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 N m (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.
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1 .4
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"'-W
AIRCRAFT
Rigging and
De-Rigging, Care
1.1.4 WING REMOVAL
NOTE
When removing the wings, prevent the airplane from falling onto its
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.
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1 .5
.Diamond
AIRCRAFT
Rigging and
De-Rigging, Care
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.
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.
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1 5 Jun 1 998
SB 50/5
1 .6
•Diamond
AIRCRAFT
H K 36 R, TS, TC, TTS, TTC, TTG-ECO
Rigging and
De-Rigging, Care
1 .2 ROAD TRANSPORT
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.
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�Diamond
v�
AIRCRAFT
Rigging and
De-Rigging, Care
1 .3 STORAGE
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!
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�
AIRCRAFT
Systems
Description
SECTION
2
SYSTEMS DESCRIPTION
2.1 FLIGHT CONTROL SYSTEM
2.1.1 GENERAL
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.
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May 17, 1993
10
15 Jun 1998
SB 50/5
2.1
•Diamond
AIRCRAFT
Systems
Description
Removal and installation
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).
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•Diamond
AIRCRAFT
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
15 ± 2
33.7 ± 4.5
36.505 and subsequent
12 ±2
27.0 ± 4.5
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lilftDiamond
AIRCRAFT
Systems
Description
Adjustment of rudder stops
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
-
push-rods under the seats. These push-rods are connected to a
AILERON
BElLCRANK
AILERON
POCKET
FUSE
LAGE
-
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
@
-
LEVEL
POSITION
movement is finally transmitted to the left and right aileron pocket
through two more push-rods. The design of the aileron pockets
Bell crank engaging in
aileron pocket
enables the automatic connection of the ailerons during wing
installation.
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.
The forward aileron control system is accessible after removing the seats. For removal, refer to
Article 2. 1 .6.
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Iiift6.
""<W' lJiamond
AIRCRAFT
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.
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•Diamond
AIRCRAFT
Systems
Description
2.1 .5 AIR BRAKE CONTROL SYSTEM
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.
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S8 50/5
2.6
.Diamond
AIRCRAFT
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.
11.
Remove both control sticks.
12.
Remove primary control torque tube and air brake torque tube.
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�Diamond
""<W'
AIRCRAFT
Systems
Description
2.1.7 ELEVATOR TRIM CONTROL SYSTEM
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.
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.
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10
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SB 5015
2.8
•Diamond
AIRCRAFT
H K 36 R, TS, TC, TIS, TIC, TIC-ECO
Systems
Description
2.1.8 ELEVATOR AND ELEVATOR TRIM CONTROL SYSTEM
'.
,
,
\
..
\
,
,
\
-
-_.
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�Diamond
v
AIRCRAFT
Systems
Description
2. 1 . 9 RUDDER AND TAIL WHEEL CONTROL SYSTEM
/
/
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S8 50/5
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IIftDiamond
AIRCRAFT
Systems
Description
2.1.10 AILERON CONTROL SYSTEM IN FUSELAGE
I
[
2.1.11 AILERON CONTROL SYSTEM IN WING
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S8 50/5
2. 1 1
.Diamond
AIRCRAFT
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
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2.12
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::
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.Diamond
AIRCRAFT
Systems
Description
2.2 lANDING GEAR
2.2.1 MAIN LANDING GEAR WITH GFRP STRUT
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.
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2.14
Systems
Description
Removal and Installation
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.
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•Diamond
AIRCRAFT
Systems
Description
Removal of strut
1 . Unload main wheel.
2. Remove wheel fairing.
3. Remove brake caliper.
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
: 0.5° to 1 . 5°
Camber
: 1 ° to 6° at empty mass (empty weight)
2.2.4 NOSE LANDING GEAR
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.
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S8 5015
2.16
.Diamond
AIRCRAFT
Systems
Description
Removal of nose landing gear
1.
Remove engine cowlings.
2. Unload nosewheel.
1
3. Disconnect damper on its upper end from
t
I
DIRECTION
OF FLIGHT
engine mount.
4. Remove
safety
bolt
(1)
from joumal
assembly in fuselage bottom (see sketch).
5. Compress journal assembly, extract from
·_·-·_·
bearings.
.1
I
i
1
1
i
- · _ · _· _ · _ · _ · _ · _ · _ · _ ·
•
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.
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 pullin g 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).
APPLY ADHESIVE IN THIS AREA ONLY
Doc. No.
Issue
Rev. No.
Date
Source
Page No.
3.02.21
May 17, 1 993
10
1 5 Jun 1 998
SB 50/5
2.17
•Diamond
AIRCRAFT
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
Serial Nos. 36. 350 through 36. 516
The brake master cylinder is actuated by the
The brake master cylinder is actuated by a
right hand push-rod between the bellcrank
short push-rod between the bellcrank and
and the air brake pocket.
the left hand fuselage root rib.
The air brake lever position at which the
The air brake lever position at which the
wheel brake starts taking effect can be
wheel brake starts taking effect can be
adjusted by moving the plate connecting the
adjusted by opening the locking nut on one
push-rod to the brake master cylinder.
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
10
1 5 Jun 1 998
SB 50/5
2.18
•Diamond
AIRCRAFT
Systems
Description
2.2.6 WHEEL BRAKE SYSTEM. VERSION 2
Applies to tail wheel models with Serial Nos. above 36. 5 1 6 and tricycle models.
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.
Date
Source
Page No.
3.02.21
May 17, 1 993
10
1 5 Jun 1 998
SB 50/5
2.19
.Diamond
AIRCRAFT
Systems
Description
2.3 FUEL SYSTEM I N AIRPLANES WITH FUSELAGE TANK
Applies to all models except for the HK 36 TIC-ECO.
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
10
1 5 Jun 1 998
SB 50/5
2.20
"Diamond
""<W'
AIRCRAFT
Systems
Description
Models with Rotax 9 1 2 A
Models with Rotax 9 1 4 F
A short hose line runs from the finger filter
A short hose line runs from the finger filter
to the electric fuel pump with integrated
to the filter box with integrated strainer.
filter.
A quick release coupling is built into this
A quick release coupling is built into this
line. By opening it, a shut-off mechanism
line. By opening it, a shut-off mechanism
stops the outflow of fuel.
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
10
1 5 Jun 1 998
SB 50/5
2.21
.Diamond
AIRCRAFT
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.
A hose line leads from the firewall breach to
A hose line leads from the firewall breach to
the mechanical fuel pump with built in filter.
the fuel pressure regulator on top of the
This pump is driven by the cam shaft. From
airbox. Through steel pipes the regulator
here, the fuel reaches a cross-shaped fitting
supplies the two carburetors with fuel under
and finally the two carburetors.
a pressure which is always 0.25 bar (3.63
psi) higher than in the airbox.
From the cross-shaped fitting, a return line
The connection for the airbox pressure is
runs to the tank. In the case of the HK 36 R,
located on the underside of the regulator
the opening for the return line is marked by
and the connection for the return line to the
an "R" on the cross. In the case of other
tank is located on top.
models, the uppermost opening is that of
the return line.
A fuel pressure sensor is mounted on the
A fuel pressure sensor is mounted at the
cross. As soon as the fuel pressure (above
entrance to the regulator. As soon as the
atmospheric) falls below 0 . 1 bar ( 1 .45 psi),
fuel pressure (above airbox pressure) falls
the fuel pressure warning light illuminates in
below 0 . 1 bar ( 1 .45 psi), the fuel pressure
the cockpit.
waming light illuminates in the cockpit.
Doc. No.
Issue
Rev. No.
Date
Source
Page No.
3.02.21
May 1 7, 1 993
10
1 5 Jun 1 998
SB 50/5
2.22
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CHECK VALVES
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�Diamond
T
AIRCRAFT
Systems
AIRPLA NE MAINTE NANCE MANUA L
Description
2.3.2 FUEL TANK EMPTYING
Method 1
1.
Open the handhole lid in the fuselage underside.
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
10
1 5 Jun 1 998
SB 50/5
2.25
�D;amond
V�
AIRCRAFT
Systems
Description
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
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
Doc. No.
Issue
Rev. No.
Date
Source
Page No.
3.02.21
May 1 7 , 1 993
10
1 5 Jun 1 998
S 8 50/5
2.26
• Diamond
AIRCRAFT
Systems
Description
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.
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
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.
Date
Source
Page No.
3.02.21
May 17, 1 993
10
1 5 Jun 1 998
SB 5015
2.27
.Diamond
AIRCRAFT
Systems
Description
2.4 FUEL SYSTEM IN AIRPLANES WITH WING TANKS
Applies to HK 36 TIC-ECO only.
General
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
10
1 5 Jun 1 998
SB 50/5
2.28
.Diamond
AIRCRAFT
Systems
Description
Tank filler:
A tank filler is located on the upper side of each wing tank.
Drainage:
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.
3.02.21
May 17, 1 993
10
Date
15
Jun 1 998
Source
Page No.
S8 50 / 5
2.29
•Diamond
AIRCRAFT
Systems
Description
Central fuel reservoir
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
10
1 5 Jun 1 998
SB 50/5
2.30
.,Diamond
AIRCRAFT
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.
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.
Doc. No.
Issue
Rev. No.
Date
Source
Page No.
3.02.21
May 17, 1 993
10
1 5 Jun 1 998
SB 5015
2.31
HK 36 R, TS, TC, TTS, TIC, TIC-ECO
Systems
Description
Fuel pressure regulator
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
10
1 5 Jun 1 998
SB 50/5
2.32
"Diamond
AIRCRAFT
HK 36 R, TS, TC, TIS, HC, TIC-ECO
Systems
AI RPLANE MAI NTENANCE MANUAL
Description
Fuel System Ventilation
Also see sketch on the next page.
The fuel system has four vents:
•
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
Page No.
3.02.21
May 17, 1 993
10
1 5 Jun 1 998
SB 50/5
2.33
"Diamond
v
AIRCRAFT
Systems
Description
.------:
centro!
ru;;; i
l o w fU e I
10 c o u t io n !ig h T
9 liters
reservoir
(:; 1,-ff-I---IV]
.
,
-/
-1[', -----'
re t u rn
line
fUel
s h u t - o ff
volve II
T T
II
LJ
firevv o f '--l
-I
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1[ 1'tJ
Tor
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TeU
i
Fuel system of the H K 36 TIC-ECO
Doc. No.
Issue
Rev. No.
Date
Source
Page No.
3.02.21
May 1 7, 1993
10
1 5 Jun 1 998
S8 50/5
2.34
iA.Diamond
W@Y
AIRCRAFT
I
Systems
Description
2.4.2 FUEL SYSTEM EMPTYING
( 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
Doc. No.
Issue
Rev. No.
Date
Source
Page No.
3.02.21
May 1 7, 1 993
10
1 5 Jun 1 998
S8 50/5
2.35
•Diamond
AIRCRAFT
Systems
Description
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
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.
(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.
(11)
Re-install fuel quantity indicator.
( 1 2)
Re-install instrument panel top cover.
Doc. No.
Issue
Rev. No.
Date
Source
Page No.
3.02.21
May 17, 1 993
10
1 5 Jun 1 998
SB 50/5
2.36
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
Rotax 9 1 4 F
The engine is firmly connected on its four
The engine is firmly connected on its four
rear fixture points to two branched engine
rear fixture points to the annular engine
mount adapters.
mount
mount adapter. This engine mount adapter
adapter is connected to the engine mount by
is connected to the engine mount at four
a rubber damper (silentbloc).
points by rubber dampers (silentblocs).
Each of the two forward engine fixture
The two forward engine fixture pOints are
points is connected directly to the engine
not used.
Each
engine
mount by two rubber dampers (silentblocs).
The engine mount has four fixture points on
The engine mount has six fixture points on
the firewall.
the firewall.
The rubber dampers are designed in such a way that the connection still is maintained if the
rubber is damaged.
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AIRCRAFT
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.
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AIRCRAFT
Systems
Description
Rotax 9 1 2 A
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Systems
Description
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V�
Systems
Description
AIRCRAFT
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.
VACUUM CHAMBER
PISTON
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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):
M eaning
Color
Signal
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
steady on
EGT above 950 'C (1 742 'F) or airbox temp.
above 72 'C (162 'F)
Light
Temperature
amber
The "Turbo' and "Manifold Pressure" lights are controlled by the TCU.
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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.
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Description
2.5.4 POWER-PLANT REMOVAL AND INSTALLATION
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).
11.
Rotax 914 F only. disconnect control cable for waste gate flap from actuator.
12.
Disconnect flexible shaft of RPM indicator (if installed) from engine.
1 3.
Disconnect hose for cabin heat from hot end of exhaust heat exchanger.
14.
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.
16.
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.
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Description
AIRCRAFT
To install the engine, reverse the procedure.
For the sake of safety, all bolts and nuts must be secured either with self-locking nuts or with lock
wire.
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.
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AIRCRAFT
Systems
Description
2.5.5 ENGINE SPARE PARTS
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.
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AIRCRAFT
2.5.6 PROPELLER 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
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Systems
AIRPu\NE MAINTENANCE MANUAL
Description
2.5.7 PROPELLER INSTALLATION AND REMOVAL
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).
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
14° ± 1 °
190 ± 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).
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Systems
Description
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.
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AIRCRAFT
Systems
Description
2.6 ELECTRICAL SYSTEM
2.6.1 POWER SUPPLY
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.
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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.
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Description
2.6.3 ELECTRIC FUEL PUMP
The Powered Sailplane is equipped with a
The Powered Sailplane is equipped with
mechanical fuel pump and also an electric
two independent electric fuel pumps. The
fuel pump, which is operated by a switch
main fuel pump has no switch. It promotes
on the instrument panel.
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 circuit breaker for the electric fuel
The fuse for the main fuel pump is located
pump is located in the center section of the
in the engine compartment. The circuit
instrument panel.
breaker for the fuel booster pump is located
in the instrument panel (HK 36 TIC-ECO:
far right, other models: central section).
2.6.4 IGNITION SYSTEM
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.
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!
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AIRCRAFT
2.6.5 WIRING
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.
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AIRCRAFT
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 (A TC) 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.
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Systems
Description
2.6.9 ANTENNAS
Folded-top antenna located in the vertical stabilizer, standard
Radio antenna:
equipment.
Serial Nos. 36.301 through 36.305, 36.307, 36.308, 36. 3 1 0
VOR antenna:
through 36.314, 36.316, 36. 3 1 7, 36.3 1 9 and 36.320:
Located in the fuselage behind the fuel tank on the upper side.
Serial Nos. 36.306, 36.309, 36.3 1 5, 36.3 1 8 , 36.321 and
subsequent:
Located in the horizontal stabilizer.
ADF antenna:
Located under the fuselage.
TransponderlDME antenna:
Located under the fuselage at the below the seats or below
the main bulkhead. The counterweight is a copper foil which
is bonded to the inner side of the fuselage skin.
Located in the fuselage behind the baggage compartment on
ELT-antenna:
the half-bulkhead.
2.6.10 RADIO LOUDSPEAKER
The radio loudspeaker is installed on the upper edge of the backrest between the seats or in
the upper rear of the baggage compartment.
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Systems
Description
2.6.11 ANTI COLLISION LIGHTS IACL 'Sj
The switch and breaker are located on the switch panel of the instrument panel. ACLs should
be mounted to the wing tips in combination with the position lights, or to the horizontal stabilizer.
We recommend not to use ACLs with filament bulbs, since their power consumption is high in
relation to their benefit.
2.6.12 POSITION LIGHTS
The position lights (optional) are mounted on the wing tips. The switch and breaker are located
on the switch panel of the instrument panel.
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Description
2.6.13 WIRING DIAGRAM - INSTRUMENT PANEL HK 36 R
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Doc. No.
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2.57
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Systems
Description
AIRCRAFT
-
2.6.14 WIRING DIAGRAM - ENGINE COMPARTMENT HK 36 R
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Doc. No.
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Systems
Description
AIRCRAFT
2.6.15 WIRING DIAGRAM - FUSELAGE HK 36 R
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Doc. No.
Issue
Rev. No.
Date
Source
Page No.
3.02.21
May 17, 1 993
10
1 5 Jun 1 99B
S8 50/5
2.59
•Diamond
Systems
Description
AIRCRAFT
2.6.16 ABBREVIATIONS USED IN THE HK 36 R WIRING DIAGRAMS
A
Ammeter
B1
Main breaker
B2
Generator breaker
B3, B4, ...
Breakers for various consumers
CHT
Cylinder head temperature indicator
Ext. Pwr.
External power plug
FQ
Fuel quantity indicator
IS
Ignition/starter switch
K1 , K2,
"
.
Switches for various consumers
Md
Mode select switch
MS
Master switch
Pr
Oil pressure indicator
Relay A
Battery relay
StM
Starter motor
Te
Oil temperature indicator
Doc. No.
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Rev. No.
Date
Source
Page No.
3.02.21
May 17, 1 993
10
1 5 Jun 1 998
SB 50/5
2.60
�Diamond
v
AIRCRAFT
Systems
Description
2.6. 17 NUMBERING OF THE WIRES IN THE H K 36 R WIRING DIAGRAMS
1
Positive terminal battery to ammeter (terminal B+) - ammeter (terminal L+) - battery relay
(terminal 87)
2
Positive terminal battery to starter
3
Negative terminal battery to engine block
5
Fuel quantity sensor
6
Cylinder head temperature sensor
7
Oil temperature sensor
8
Starter relay
9
Ignition short-circuiting cable
10
Oil pressure transducer
12
Electric fuel pump
15
Regulator C+
16
Generator breaker to regulator B+, to regulator R
17
Battery relay terminal 3 0 to main breaker 5 0 A
18
Radio loudspeaker
19
Transmit buttons
25
Anti collision lights
26
COM
27
NAV
28
Transponder
29
ADF
30
Attitude gyro
31
Direction gyro
33
Position lights
39
DME
Doc. No.
Issue
Rev. No.
Date
Source
Page No.
3.02.21
May 1 7 , 1 993
10
1 5 Jun 1 998
SB 50/5
2.61
•Diamond
Systems
Description
AIRCRAFT
2.6.18 WIRING DIAGRAM - ENGINE COMPARTMENT HK 36 TS. HK 36 TC
F�n £!p..aI't.B.l-
......
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Doc. No.
Issue
Rev. No.
Date
Source
Page No.
3.02.21
May 17, 1 993
10
1 5 Jun 1 998
S8 50/5
2.62
1993
•Diamond
Systems
Description
AIRCRAFT
2.6.19 WIRING DIAGRAM - FLIGHT COMPARTMENT HK 36 TS. HK 36 TC
4
X
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Doc. No.
Issue
Rev. No.
Date
Source
Page No.
3.02.21
May 17, 1 993
10
1 5 Jun 1 998
S8 50/5
2.63
.,Diamond
AIRCRAFT
Systems
Description
2.6.20 WIRING DIAGRAM - ENGINE COMPARTMENT HK 36 TTS. HK 36 TTC
F�n �EW�!...l ___
cOcMfo n" HO'A"
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Doc. No.
Issue
Rev. No.
Date
Source
Page No.
3.02.21
May 1 7 , 1 993
10
1 5 Jun 1 998
S8 50/5
2.64
•Diamond
AIRCRAFT
Systems
Description
2.6.21 WIRING DIAGRAM - FLIGHT COMPARTMENT HK 36 TTS. HK 36 TTC
�
,
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FUEL Pllt.lP
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Doc. No.
Issue
Rev. No.
Date
Source
Page No.
3.02.21
May 17, 1 993
10
1 5 Jun 1 998
S8 50/5
2.65
.Diamond
AIRCRAFT
2.6.22 WIRING DIAGRAM
Systems
Description
-
FUEL
SYSTEM HK 36 TTS. HK 36 TTC
Doc. No.
Issue
Rev. No.
Date
Source
Page No.
3.02.21
May 1 7, 1 993
10
1 5 Jun 1 998
SB 5015
2.66
.,Diamond
AIRCRAFT
Systems
Description
2.6.23 WIRING DIAGRAM - ENGINE COMPARTMENT HK 36 TIC-ECO
F'!Q!IT E.J.!l.E: W�l "-..
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Doc. No.
Issue
Rev. No.
Date
Source
Page No.
3.02.21
May 1 7 , 1 993
10
1 5 Jun 1 998
SB 50/5
2.67
•Diamond
AIRCRAFT
Systems
AI RPIJ\NE MAINTENANCE MANUAL
Description
2.6.24 WIRING PIAGRAM - INSTRUMENT PANEL HK 36 TTC-ECO
I
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Rev:
V:dld on SIN:
Dm::l7OS.1900
Doc. No.
Issue
Rev. No.
Date
Source
Page No.
3.02.21
May 17, 1 993
10
1 5 Jun 1 998
S8 50/5
2.68
�Diamond
"'�
AIRCRAFT
Systems
Description
I I� �
"
•
2.6.25 WIRING DIAGRAM - FUSELAGE HK 36 TIC-ECO
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Doc, No,
Issue
Rev, No,
Date
Source
Page No,
3.0221
May 17, 1 993
10
1 5 Jun 1 998
S8 50/5
2.69
•Diamond
AIRCRAFT
Systems
Description
2.6.26 WIRING DIAGRAM - WING TANKS HK 36 TIC-ECO
..
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Doc. No.
Issue
Rev. No.
Date
Source
Page No.
3.02.21
May 1 7, 1 993
10
1 5 Jun 1 998
S8 50/5
2.70
4ftDiamond
AIRCRAFT
Systems
Description
2.6.27 WIRING DIMENSIONS
Designation
AN 4
AN 1 0
AN 1 4
AN 1 6
Cross Sectional Area [mm']
22.0
5.3
1 , 94
1 .2
Length [m]
30
15
6
3
[ft.]
98
49
20
10
Current Intensity [A]
1
2
5
10
Permitted loading on AN 1 6 wire:
Doc. No.
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�Diamond
"'�
AIRCRAFT
Systems
Description
2.6.28 POWER CONSUMPTION OF ELECTRICAL EQUIPMENT
Power Consumption
[A]
Appliance
.approximately 2.0
Engine instruments, including propeller speed control (for
electrically variable propeller)
Battery relay
0.8
Turbo Control Unit (Rotax 914 F only)
0.3
Actuator for waste gate flap (Rotax 914 F only)
average 0.3
approximately 1 . 5
Fuel booster pump for Rotax 9 1 2 A: intermittent consumption,
depending o n fuel pressure and flow rate
Fuel pumps for Rotax 9 1 4 F
Main pump alone
2.7
Main and booster pump
4.0
maximum 1�0.0
Electric starter
ACL
approximately 3.0
Position lights
approximately 7.5
Landing lights
approximately 7.5
Direction gyro
approximately 0.8
Attitude gyro
approximately 0.8
Doc. No.
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.
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SB 50/5
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4&Diamond
"'�
AIRCRAFT
Systems
Description
2.6.29 INSTALLATION OF ADDITIONAL ELECTRICAL EQUIPMENT
The following rules must be followed when installing additional electrical equipment:
•
The total mass (total weight) of the instrument panel, including the instruments, must not
exceed 1 7 kg (37.5 Ibs.). The total mass (total weight) of the instrument panel including
standard equipment (without COM, NAV, etc.) is 7 kg ( 1 5.4 Ibs.).
I
•
Do not rearrange the avionics panel (center section of the instrument panel). In each model,
except for the HK 36 TTC-ECO, the switch panel in the upper center section of the
instrument panel provides additional cooling for the avionics. It must not be displaced, and
the free space behind it must be maintained.
•
The maintenance of the 1 5 Amps limit (see CAUTION) can be checked using the table in
Article 2.6.28. Operating times of equipment with a high power consumption must be
restricted.
CAUTION
The average power consumption of the aircraft electrical system
must not exceed 1 5 Amps, since sufficient battery charging can
otherwise not be ensured.
WARNING
Only applicable to models with Rotax 914 F: The engine only
uses electric fuel pumps. In the case of a generator failure, the
entire fuel supply depends on the battery. Consequently, the
charging of the battery is crucial for flight safety.
•
After the installation of additional equipment, the empty mass (weight) and empty mass CG
position must be established by calculation or weighing in accordance with Section 4.
Doc. No.
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.Diamond
AIRCRAFT
Systems
Description
2.5.30 GENERAL RULES FOR WORKING ON THE ELECTRICAL SYSTEM
•
Throw master switch in OFF position. If necessa ry, disconn ect the ground cable from the
battery to avoid short-circuits.
•
Follow repair procedures set forth in FAA AC 43. 1 3-1A (Aircraft Inspection and Repair).
•
Use approved material only (aviation cables, fully insulated connectors). Use the special
tools of the respective manufacturers .
•
•
Avoid soldered joints.
Wires must have the sizes set forth in FAA AC 43. 1 3-1A, Chapter 1 1 , and must be routed
safely. The maximum permissible voltage drop is 0.5 V during continuous operation.
Consequently, when the battery is fully charged (14 V), the voltage available to the appliance
must be 1 3.5 V or higher.
Doc. No.
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3.02.21
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•Diamond
AIRCRAFT
Systems
Description
2.7 STAll WARNING SYSTEM
The serial numbers equipped with an aural stall warning system have a plastic hose running
from a bore in the leading edge of the left wing to a horn installed in the cockpit near the pilot's
feet. The bore is located 0.9 meters (approximately 3 ft.) outboard of the wing root.
2.8 MINIMUM EQU I PMENT LIST
The Minimum Equipment List can be found in the Airplane Flight Manual, Paragraph 6.9.
NOTE
The tenm 'Minimum Equipment List' is not meant to include the
'Master Minimum Equipment List" which is developed by the
FAA.
Doc. No.
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IIIftDiamond
AIRCRAFT
Maintenance &
Inspections
SECTION 3
MAINTENANCE AND INSPECTIONS
3.1 SCHEDULED INSPECTIONS
3.1.1 INSPECTION INTERVALS AND TOLERANCES
Inspection of Airplanes Serviced in Accordance with FAR 91
The 1 D O hour inspection checklist in this section shall be accomplished for compliance with the
1 DO Hour and Annual Inspections required by FAR 9 1 .
The 200 hour and 600 hour inspections s pecified i n this section shall be accomplished in
addition to the 1 00 Hour and Annual Inspections required by FAR 9 1 .
NOTE
Prior to any inspection, the airframe and the propeller must be
cleaned thoroughly. The engine must be cleaned after the check
for oil leakage (see Inspection Checklist for the engine).
Inspection of Airplanes NOT Serviced in Accordance with FAR 91
Engine and propeller inspections must be performed every 1 D O , 200, and 600 engine operating
hours.
Airframe inspections must be performed every 1 00, 200, and 600 flight hours.
If the airplane is operated less than 200 hours per year, a 200 hour inspection must be
performed once a year.
Doc. No.
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3. 1
.Diamond
AIRCRAFT
Maintenance &
Inspections
The intervals between the inspections must be adhered to within a tolerance of ± 1 0 hours.
These tolerances must not be added up. Example: if the 1 00 hour inspection was carried out at
1 1 0 hours, the next inspection is due at 200 ± 1 0 hours, not at 2 1 0 ± 1 0 hours.
If an inspection is carried out more than 1 0 hours ahead of schedule, all subsequent inspection
intervals are counted from that inspection. Example: if the 1 00 hour inspection was carried out
at 83 hours, the next inspection is due at 1 83 ± 1 0 hours.
3.1.2 ACCOMPLISHMENT OF MAINTENANCE WORK
The inspections are performed on the basis of Inspection Checklists which show the procedures
and extent of the maintenance work in key-words.
NOTE
All items marked with a circle (0) must be performed at these
intervals on any airplane.
I n addition, all items marked with an asterisk (*) must be
performed at these intervals on airplanes serviced in accordance
with FAR 91 and on airplanes registered in Russia.
Photocopies of Tables 1 , 2 and 3 must be made and filled out. After each item has been
completed it must be confirmed over the corresponding circle or asterisk with the initials of the
Aircraft Maintenance Engineer. After the inspection, these pages must be filed in the airplane's
Maintenance Log, and the inspection must be confirmed in the airplane's log book.
The maintenance and inspection work must be carried out by authorized personnel only.
Doc. No.
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3.2
•Diamolld
AIRCRAFT
Maintenance &
Inspections
TABLE 1 , PAGE 1 OF 28
A. INSPECTION CHECKLISTS FOR THE POWER PLANT
1. ENGINE
Type
: 0
Rotax 9 1 2 A
: 0
1 00 h
o Rotax 9 1 4 F
Serial number
Running time meter count
Flight hours
Scope
0
200 h
0
600 h
Items of maintenance carried out are to be confirmed by the initials of the AME.
1 00
200
600
0
o
o
0
o
o
0
o
o
1 .4 Clean engine.
0
o
o
1 .5 Drain oil with the engine warm.
0
o
o
0
o
o
o
o
o
ITEMS 1.1 THROUGH 1.52 APPLY TO ROTAX 912 A ONLY
1 . 1 Remove upper and lower cowling, check for cracks, overheated
spots, deformation, loose or missing fasteners; clean cowling if dirty.
1 .2 Check engine, gearbox case, hydraulic propeller govemor (if
installed) and pressure accumulator (if installed) for oil leakage.
1 .3 Check oil pressure transducer and oil temperature sensor for
leakage.
1 .6 Replace oil filter, apply a light coat of oil to contact surface of filter.
Cut old filter apart, check for metal pieces and foreign matter.
Check magnetic screw(s) for metal particles.
CAUTION
metal
particles
are
found,
the problem must be corrected by
If
authorized personnel, the oil system must be flushed, and the oil
radiator must be replaced.
1 .7 Refill engine with 3.0 liters (3.2 US quarts) of oil according to AFM;
check oil level.
Doc. No.
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SB 50/5
3.3
"Diamond
�
AIRCRAFT
Maintenance &
I nspections
1.8
1 00
200
600
•
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
Perform compression test o n all four cylinders according to
Operator's Manual for the engine (engine warm, throttle
valves open). Minimum pressure: 6 bar (87 psi).
Cyl. 1 :
Cyl. 2:
Cyl. 3:
Cyl. 4:
1 .9
Check spark plug electrode gap and adjust if necessary (0.7
to 0.8 mm (0.028 to 0.031 in.» .
1 .1 0
Replace spark plugs (type: NGK DCPR7E), mind Item 1 . 1 1 .
1.11
Apply a light coat of appropriate lubricant to spark plug
threads, screw in spark plugs.
CAUTION: the engine must be cold!
Torque: 20 Nm ( 1 4.75 ft.lbs.).
1 . 12
Measure force required to pull off spark plug sockets.
Minimum: 30 N (6.75 Ibs.).
1.13
Check ignition harness for chafing, check fastening for
damage.
1.14
Check coolant for poor condition o r insufficient quantity.
Dispatcher vessel must be full, equalizing reservoir must be
at least '/3 full when the engine is cold (also see Article 4.1 .3).
If loss of coolant is significant, determine reason.
1.15
If engine runs too hot: flush cooling system.
1 . 16
Check chafing protection pad on coolant dispatcher vessel for
damage.
0
0
0
Doc. No.
Issue
Rev. No.
Date
Source
Page No.
3.02.21
May 1 7 , 1 993
10
1 5 Jun 1 998
SB 50/5
3.4
"Diamond
"'�
AIRCRAFT
Maintenance &
Inspections
1 00
200
600
o
1.17
Clean coolant radiator ribs;
check radiator for leakage, damage, insecure mounting and
poor condition of fastening.
o
o
1.18
Check air filter for poor condition;
blow compressed air from inside to outside.
o
o
1.19
Replace air filter.
1 .20
Check airbox for insecure attachment, cracks, leaks,
defonnation, and heat damage.
1 .2 1
*
o
o
o
o
Check carburetor heat flap for looseness and improper
operation (air filter removed).
o
o
o
1 .22
Clean oil radiator ribs;
check oil radiator for leakage, damage, insecure mounting
and poor condition of fastening.
o
o
o
1 .23
Check compensator tube between intake manifolds for
chafing, leaks and improper installation (the tube must not
sag - danger of fuel accumulation).
o
o
o
1 .24
Check oil tank breather for blockage (long term operation at
low engine temperatures in combination with high air
humidity leads to blockage of the breather).
o
o
o
1 .25
Check air guide for cylinder cooling for leakage, cracks,
defonnation and heat damage.
o
o
o
1 .26
Check engine mount for cracks, defonnation , corrosion,
missing fasteners and lack of safetying.
o
o
o
Doc. No.
Issue
Rev. No.
Date
Source
Page No.
3.02.21
May 17, 1 993
10
1 5 Jun 1 998
SB 5015
3.5
.Diamond
AIRCRAFT
Maintenance &
Inspections
1 .27
Check silentblocs for cracks and poor condition.
1 .28
Re-torque bolts attaching engine mount to firewall (torque:
40 Nm (29.5 fUbs.)).
1 .29
I nspect reduction gear (see Operator's Manual for the
engine, Section 7.9).
1 .30
Check starter for insecure attachment.
1 .3 1
Check a l l wires and electric installations for heat damage
and chafing;
check wire attachments and connectors for looseneSS by
slightly pulling by hand.
1 00
200
600
0
0
0
0
0
0
0
0
0
0
0
0
0
o Ground straps
o Generator
o Starter
0 Voltage regulator
0 Oil temperature sensor
o Oil pressure transducer
o Cylinder head temperature sensor
o Ignition coils
0
0
1 .32
Check cabin heat hoses for obvious defects.
0
0
0
1 .33
Check exhaust pipes, seals and clamps for damage.
0
0
0
1 . 34
Check heat exchanger (muffler heating jacket) for cracks
and insecure mounting to the muffler;
check hoses for insecure mounting.
0
0
0
Doc. No.
Issue
Rev. No.
Date
Source
Page No.
3.02.21
May 1 7, 1 993
10
1 5 Jun 1 998
SB 5015
3.6
Maintenance &
Inspections
1 00
200
600
1 .35
Open heat exchanger, check muffler for cracks,
defonmation, and corrosion (the connection sleeves are most
susceptible to cracks).
o
o
1 .36
Remove muffler and check for interior damage through
connection sleeves.
o
o
1 .37
Check all nuts and bolts for looseness and obvious defects.
o
o
o
1 .38
Check firewall breaches
attachment of clamps.
insecure
o
o
o
1 .39
Check fuel lines and all other hoses for leakage, chafing,
kinks and improper routing;
check for expiration;
check clamps for looseness.
o
o
o
1 .40
Open cap of electric fuel pump, clean filter and cap.
o
o
o
1 .4 1
Check electric fuel pump for leakage and insecure mounting.
o
o
o
1 .42
Check engine driven fuel pump for leakage and insecure
mounting.
o
o
o
1 .43
Check both carburetors for insecure mounting;
check rubber connection pieces between intake manifolds
and carburetors for insecure mounting, poor condition and
cracks.
o
o
o
1 .44
Check throttle valves for asynchronous opening (see
Operator's Manual for the engine).
o
o
1 .45
Check drain lines of carburetors , airbox and drip bowls for
insecure attachment and poor condition;
check drip bowl drains for blockage of transverse bores.
HK 36 R only: check drip bowl outlets for dirt in the
transverse holes.
o
o
for
leakage
and
o
Doc. No.
Issue
Rev. No.
Date
Source
Page No.
3.02.21
May 1 7, 1 993
10
1 5 Jun 1 998
SB 50/5
3.7
"Diamond
....'W
AIRCRAFT
Maintenance &
Inspections
1 00
1 .46
Check carburetor needles in accordance with ROTAX SB
No. 9 1 2-04.
1 .47
Check valve springs in accordance with ROTAX SB No.
91 2-04.
1 .48
Check battery mount for poor condition;
check acid level of battery.
1 .49
Check battery for poor charge and poor capacity.
1 .50
Check all control cables for insecure condition, interference
and lack of operating clearance, lubricate;
check cable fixtures for looseness;
check th rottle control friction, adjust if necessary.
200
600
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
o Throttle
o Carburetor heat
o Cabin heat
Choke
Cowl flap
o Propeller govemor
0
1 .5 1
Review Airworthiness Directives and Service Bulletins from
the Engine Manufacturer for compliance.
1 .52
Check for foreign bodies.
Operating fluids used (designation and quantitvl:
Oil:
Coolant:
Parts replaced remarks:
Doc. No.
Issue
Rev. No.
Date
Source
Page No.
3.02.21
May 17, 1 993
10
1 5 Jun 1 998
SB 50/5
3.8
•Diamond
AIRCRAFT
Maintenance &
Inspections
1 00
200
600
Remove upper and lower cowling, check for cracks,
overheated spots, deformation, loose or missing fasteners;
clean cowling if dirty.
o
o
o
1 . 1 02 Check engine, gearbox case, oil temperature sensor, oil
pressure transducer, hydraulic propeller governor (if installed)
and pressure accumulator (if installed) for oil leakage.
o
o
o
1 . 1 03 Clean engine.
o
o
o
1 . 1 04 Drain oil with engine warm.
o
o
o
1 . 1 05 Replace oil filter, apply a light coat of oil to the contact surface
of the filter.
Cut old filter apart, check for metal particles and foreign
matter.
CAUTION
If metal particles are found, the problem must be corrected by
authorized personnel, the oil system must be flushed, and the
oil radiator must be replaced.
o
o
o
o
o
ITEMS 1.101 THROUGH 1 .153 APPLY TO ROTAX 9 1 4 F ONLY
1 . 1 01
1 . 1 06 Check magnetic screw for metal particles. When re-installing:
Torque 25 Nm (1 8.4 ft.lbs.), secure with lock wire. See
CAUTION above.
1 . 1 07 Refill engine with 3.0 liters (3.2 US quarts) of oil according to
Flight Manual;
check oil level.
o
o
o
1 . 1 08 Perform compression test on all four cylinders according to
Maintenance Manual for Rotax Engine Type 914 F (engine
warm, throttle valves open)
Correct value: 9 to 12 bar ( 1 31 to 1 74 psi)
Difference between cylinders: max. 2 bar (29 psi)
•
o
o
CyI. 1 :
CyI. 3:
_
_
_
_
_
_
CyI. 2:
CyI. 4:
_
_
_
_
_
_
Doc. No.
Issue
Rev. No.
Date
Source
Page No.
3.02.21
May 17, 1 993
10
1 5 Jun 1 998
SB 5015
3.9
•Diamond
AIRCRAFT
Maintenance &
I nspections
200
600
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
1 00
1 . 1 09 Replace spark plugs (type: 1 2 mm NO X27EPR-U9).
Apply a light coat of appropriate lubricant to spark plug
threads, screw in spark plugs.
CAUTION: the engine must be cold!
Torque: 20 Nm ( 1 4.75 ft. lbs.)
�o
1 . 1 1 0 Measure force required to pull off spark plug sockets.
Minimum: 30 N (6.75 Ibs.).
1.111
Check ignition hamess for chafing, check fastening for
damage.
1 . 1 1 2 Check coolant for poor condition or insufficient quantity.
Dispatcher vessel must be full, equalizing reservoir must be
at least ' /3 full (also see Article 4. 1 . 3). If loss of coolant is
significant, determine reason.
1 . 1 1 3 Flush cooling system.
1 . 1 1 4 Check chafing protection pad on coolant dispatcher vessel
for damage.
1 . 1 1 5 Check coolant filler cap on d ispatcher vessel for defective
sealing;
check pressure control valve and retum valve for improper
operation.
1 . 1 1 6 Clean coolant radiator ribs;
check radiator for leakage, damage, insecure mounting and
poor condition of fastening.
Doc. No.
Issue
Rev. No.
Date
Source
Page No.
3.02.21
May 17, 1 993
10
1 5 Jun 1 998
SB 50/5
3.10
·Diamond
AIRCRAFT
Maintenance &
I nspections
1 . 1 1 7 Check air filter for poor condition;
blow compressed air from inside to outside.
1 00
200
o
o
1 . 1 1 8 Replace air filter.
600
•
o
1 . 1 1 9 Check airbox for insecure attachment, cracks, leaks,
deformation or heat damage.
o
o
o
1 . 1 20 Check carburetor heat flap for looseness and improper
operation.
o
o
o
1 . 1 2 1 Clean oil radiator ribs,
check oil radiator for leakage, damage, insecure mounting
and poor condition of fastening.
o
o
o
1 . 1 22 Check compensator tube between intake manifolds for
chafing, leaks and improper installation (the tube must not
sag - danger of fuel accumulation).
o
o
1 . 1 23 Check oil tank breather for blockage (long term operation at
low engine temperatures in combination with high air
humidity leads to blockage of the breather).
o
o
o
1 . 1 24 Check air guide for cylinder cooling for leakage, cracks,
defonmation and heat damage.
o
o
o
1 . 1 25 Check engine mount for cracks, deformation, corrosion,
missing fasteners and lack of safetying.
o
o
o
1 . 1 26 Check silentblocs for cracks and poor condition.
o
o
o
o
1 . 1 27 Re-torque bolts attaching engine mount to firewall (torque:
40 Nm (29.5 ft.lbs.)).
Doc. No.
Issue
Rev. No.
Date
Source
Page No.
3.02.21
May 1 7, 1 993
10
1 5 Jun 1 998
SB 50/5
3. 1 1
.Diamond
AIRCRAFT
Maintenance &
Inspections
TABLE 1 , PAGE 1 0 OF 28
1 . 1 28 I nspect reduction gear (See Maintenance Manual for Rotax
Engine Type 9 1 4 F).
1 00
200
600
o
o
o
1 . 1 29 Check cogwheel set for pitting and larger cavities (see
Maintenance Manual for Rotax Engine Type 9 1 4 F).
1 . 1 30 Check starter for insecure attachment.
o
o
o
o
o
o
o
1 . 1 32 Check condensation screen in airbox pressure line for TCU
(between firewall and instrument panel) for water
accumulation and replace if necessary.
o
o
o
1 . 1 33 Check the three glass fuses on the right hand side of the
firewall .
o
o
o
1 . 1 34 Check cabin heat hoses for defects.
o
o
o
1 . 1 31
Check all wires and electric installations for heat damage
and chafing;
check wire attachments and connectors for looseness by
Slightly pulling by hand.
o
o
o
o
o
o
o
o
o
o
o
o
o
o
o
o
o
Ground straps
Generator
Starter
Voltage regulator
All relays
Oil temperature sensor
Oil pressure transducer
Cylinder head temperature sensor
Ignition coils
TCU, actuator (behind instrument panel)
Airbox pressure transducer
Ambient pressure transducer
Airbox temperature sensor
Throttle valve position sensor
Mixture switch valve
__
__
__
__
__
__
__
__
Doc. No.
Issue
Rev. No.
Date
Source
Page No.
3.02.21
May 17, 1 993
10
1 5 Jun 1 998
SB 50/5
3. 1 2
•Diamond
AIRCRAFT
Maintenance &
Inspections
1 00
200
600
1 . 1 35 Check exhaust pipes, seals and clamps for damage.
o
o
o
1 . 1 36 Check heat exchanger (muffler heating jacket) for cracks
and insecure mounting to the muffler;
check hoses for insecure mounting.
o
o
o
o
o
1 . 1 37 Remove heat exchanger and check for damage on the
inside.
Check muffler for cracks and leaks (the connection sleeves
are most susceptible to cracks).
1 . 1 38 Open hose connection between carburetor heat flap and
turbocharger.
Check turbocharger for cracks in the housing and defective
attachment;
check compressor wheel for damage and interference.
o
o
o
1 . 1 39 Check waste gate flap for improper adjustment;
check control cable for damage, wear and defective
connection;
cheCk spring for damage.
o
o
o
1 . 140 Check all nuts and bolts for looseness and obvious defects.
o
o
o
1 .141
o
o
o
Check firewall breaches
attachment of clamps.
for
leakage
and
insecure
Doc. No.
Issue
Rev. No.
Date
Source
Page No.
3.02.21
May 17, 1 993
10
1 5 Jun 1 998
SB 5015
3.13
.Diamond
AIRCRAFT
HK 36 R, TS, TC, TIS, TIC, TIC-EGO
Maintenance &
Inspections
1 . 1 42 Check fuel lines and all other hoses for leakage, chafing,
kinks and improper routing;
check for expiration;
check clamps for looseness.
1 . 1 43 HK 36 ITS and HK 36 ITC only:
Clean fuel strainer in the filter box under the tank.
1 . 1 44 Check both electric fuel pumps for leaks and insecure
mounting.
1 . 1 45 Check both carburetors for insecure mounting;
check rubber connection pieces between intake manifolds
and carburetors for insecure mounting, poor condition and
cracks.
1 00
200
600
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
1 . 1 46 Check carburetor float chambers inside for dirt and defective
seals;
check floats for interference;
check float chamber ventilation lines for kinks and blockage.
1 . 1 47 Check throttle valves for asynchronous opening.
1 . 1 48 Check drain lines of carburetors, airbox and drip bowls for
insecure attachment and poor condition.
1 . 1 49 Check battery mount for poor condition;
check acid level of battery.
Doc. No.
Issue
Rev. No.
Date
Source
Page No.
3.02.21
May 17, 1 993
10
1 5 Jun 1 998
SB 50/5
3.14
Maintenance &
.DiamAo'
,RC"RAFTd AIRPLANE MAINTENANCE MANUAL
I nspections
1 00
200
600
o
o
o
o
o
o
1 . 1 52 Review Airworthiness Directives and Service Bulletins from
the Engine Manufacturer for compliance.
o
o
o
1 . 1 53 Check for foreign bodies.
o
o
o
1 . 1 50 Check battery for poor charge and poor capacity.
1.151
Check all control cables for insecure condition, interference
and lack of operating clearance, lubricate;
check cable fixtures for looseness;
check throttle control friction, adjust if necessary.
o Throttle
(dead travel 1 mm (0.04 in.))
o Carburetor heat
o Cabin heat
o Choke
o Cowl flap
o Propeller govemor
Operating fluids used (designation and quantiM:
Oil:
Coola nt.
__
_
__
__
__
__
__
__
_
------
Parts replaced, remarks:
Doc. No.
Issue
Rev. No.
Date
Source
Page No.
3.02.21
May 17, 1 993
10
1 5 Jun 1 998
SB 50/5
3.15
•Diamond
AIRCRAFT
Maintenance &
Inspections
2. PROPELLER
Type
0
: 0
mt-propeller MTV 1-A/1 70-08
o mt-propeller MTV 21 -A-C-F/CF1 75-05
o Hoffmann HO-V352F-S 1 /S1 70FQ
0
mt-propeller MT 1 70 R 125-2A
Hoffmann H014- 1 70 S 123
Serial number
Flight hours
: 0
Scope
0
1 00 h
200 h
o 600 h
Items of maintenance carried out are to be confirmed by the initials of the Worker.
1 00
200
600
2.1
Review Airworthiness Directives and Service Bulletins from
the Propeller Manufacturer for compliance.
o
o
o
2.2
Clean propeller.
o
o
o
2.3
Check spinner and spinner mount for cracks, dents, runout,
and missing fasteners.
o
o
o
2.4
Check propeller track.
o
o
o
2.5
Check blades for damage and cracks (refer to Propeller
Manual).
o
o
o
2.6
Fixed pitch propellers only
o
o
2.7
Constant speed propellers only: Remove spinner dome,
o
o
o
2.8
Check all parts for insecure mounting and defective
safetying.
o
o
o
2.9
Check propeller hub for cracks and corrosion.
o
o
o
2.10
Tighten propeller flange bolts (refer to Propeller Manual for
proper torque and procedure);
check for lack of safetying.
o
o
o
propeller flange for corrosion.
Remove propeller, check
check spinner backplate for cracks and insecure mounting.
Doc. No.
Issue
Rev. No.
Date
Source
Page No.
3.02.21
May 17, 1 993
10
1 5 Jun 1 998
SB 50/5
3.16
•Diamond
AIRCRAFT
Maintenance &
Inspections
1 00
200
600
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
ITEMS 2.101 THROUGH 2.107 APPLY TO MTV-1 ELECTRIC
CONSTANT SPEED PROPELLER ONLY
2 . 1 01
Check for excessive bladeshake (max. 3 mm ('/8 in.)) and
angular play (max. 2").
2 . 1 02 Check pitch change mechanism for oil and grease leakage.
2 . 1 03 Clean carbon brushes, check for insecure attachment,
unsafe condition and excessive wear (minimum length of
brushes: 7 mm (9/32 in.)).
2. 1 04 Clean slip rings, check for wear.
2 . 1 05 Check brush block brackets for cracks;
check fastening screws for looseness and lack of safetying;
check brush block for improper adjustment according to
Propeller Manual, Paragraph 5.5.
2 . 1 06 Check wires and electric connectors for insecure condition
and looseness;
check electric motor and other parts for insecure mounting.
2 . 1 07 Check electric motor for improper operation with the engine
off.
Remarks:
Doc. No.
Issue
Rev. No.
Date
Source
Page No.
3.02.21
May 1 7 , 1 993
10
1 5 Jun 1 998
SB 5 0/5
3.17
.Diamond
AIRCRAFT
Maintenance &
Inspections
1 00
200
600
0
0
0
2.202 Check low pitch stop nuts for looseness.
0
0
0
2.203 Check pitch change mechanism for oil and grease leakage.
0
0
0
2.204 Check propeller govemor for insecure mounting.
0
0
0
0
0
0
2.206 Check hub and blade root areas for oil and grease leakage.
0
0
0
2.207 Inspect position of counterweights.
0
0
0
ITEMS 2.201 THROUGH 2.207 APPLY TO MTV-2 1 HYDRAULIC
CONSTANT SPEED PROPELLER ONLY
2.201
Check for excessive bladeshake (max. 3 mm C /8 in.)) and
angular play (max. 2").
2.205 Check pressure accumulator for insecure mounting;
check gas pressure, refill if necessary (nitrogen or air,
8.5 bar (125 psi)).
Remarks:
Doc. No.
Issue
Rev. No.
Date
Source
Page No.
3.02.21
May 1 7, 1 993
10
1 5 Jun 1998
SB 50/5
3.18
.Diamond
AIRCRAFT
Maintenance &
Inspections
1 00
200
600
Check for bladeshake (no bladeshake allowable) and
angular play (max. 1 °).
o
o
o
2.302 Check pitch change mechanism for oil and grease leakage.
o
o
o
2.303 Check pitch change mechanism for interference by twisting
the blades by hand (see Propeller Manual).
o
o
o
2.304 Check propeller governor for insecure mounting.
o
o
o
2.305 Check propeller speed control cable for improper operation
and obvious defects.
o
o
o
2.306 Check mechanical feathering device for improper operation
and obvious damage;
check thrust plate for excessive wear (max.: 0.2 mm
(' 1,28 in.))
check all parts of the actuating mechanism and ball bearings
for poor condition.
o
o
o
2.307 Check distance between ball bearings and thrust plate (min.
1 mm (0.04 in.) at minimum pitch).
o
o
o
2.308 Clean thrust plate;
slig htly grease pitch change rods, ball bearings and thrust
plate of mechanical feathering device with Calypsol H 443 or
equivalent.
o
o
o
2.309 Check blade retention nuts for defective sealing.
o
o
o
ITEMS 2.301 THROUGH 2.309 APPLY TO HO-V352 HYDRAULIC
CONSTANT SPEED PROPELLER ONLY.
2.301
Remarks:
Doc. No.
Issue
Rev. No.
Date
Source
Page No.
3.02.21
May 1 7, 1 993
10
1 5 Jun 1 998
SB 50/5
3. 1 9
.Diamond
AIRCRAFT
Maintenance &
I nspections
B. INSPECTION CHECKLISTS FOR THE AIRFRAME
Serial number
Flight hours
: 0
Scope
1 00 h
0
200 h
0
600 h
Items of maintenance carried out are to be confirmed by the initials of the AME.
3. CABIN
3.1
Check canopy for damage;
check locking device for unserviceability.
3.2
Check canopy jettison device for unserviceability.
3.3
Check seat belts and shoulder hamesses and their
fastenings for damage.
3.4
1 00
200
600
0
0
.0
0
0
0
0
Check elevator trim control system in center console for
damage, interference, looseness of notch plate and
improper adjustment.
o
o
o
3.5
Check rudder pedals for corrosion and causticization, in
particular in the area of the weld seams.
o
o
o
3.6
Check nudder pedals for looseness, interference, and poor
condition of recuperator springs;
check pedal adjusting device for improper operation;
lubricate if necessary.
o
o
o
Doc. No.
Issue
Rev. No.
Date
Source
Page No.
3.02.21
May 17, 1 993
10
1 5 Jun 1 998
SB 5015
3.20
.Diamond
AIRCRAFT
Maintenance &
Inspections
3.7
1 00
200
600
o
o
o
o
o
o
o
o
o
Tail wheel models above Serial No. 36.516 and tricycle
models only: check brake pedals for interference, play, and
improper operation;
check mechanism for damage and wear.
3.8
models only: check brake cylinders and brake lines for
leakage.
3.9
models only: check brake fluid for poor condition, change if
necessary;
fill brake fluid reservoirs to maximum level ( 1 5 mm (5/8 in.)
below top).
3.10
Check parking brake valve for improper operation and leaky
connectors and check Bowden cable for improper
adjustment.
o
o
o
3.1 1
Check control cables in the area of the S-guides for chafing
and broken strands.
o
o
o
3.12
Check control sticks for interference, defective stops, and
excessive play;
check zero position.
o
o
o
3.13
Measure the play of aileron and elevator control system with
one stick blocked. Max. allowable play: 3 mm ( ' /8 in.),
measured on the trailing edge of the surfaces.
o
o
o
3.14
Check air brake levers for improper locking and unlocking (in
the retracted position);
check air brakes for asynchronous extension.
o
o
o
o
o
o
Tail wheel models through Serial No. 36.516 only:
check for premature o r delayed activation of wheel brakes.
3.15
Check instruments for improper or missing markings.
Doc. No.
Issue
Rev. No.
Date
Source
Page No.
3.02.21
May 17, 1 993
10
1 5 Jun 1 998
SB 5015
3.21
"Diamond
v
AIRCRAFT
Maintenance &
Inspections
1 00
3. 1 6
Check all control knobs and handles for improper or missing
inscriptions and designations.
3. 1 7
Remove instrument panel top cover;
check all electric equipment, switches, instruments, and
breakers for insecure mounting.
3.18
3.19
200
600
0
0
0
0
Check fuel valve for insecure mounting.
0
0
0
HK 3 6 TTC-ECO only:
0
0
0
0
0
0
0
0
0
Check fuel selector valve for interference, improper latching,
defective stops, and looseness.
3.20
Check safetying of main bolts for unserviceability and poor
condition.
3.21
Check main bolts for interference, lubricate if necessary.
Doc. No.
Issue
Rev. No.
Date
Source
Page No.
3.02.21
May 17, 1 993
10
1 5 Jun 1 998
SB 5015
3.22
"'Diamond
v
AIRCRAFT
Maintenance &
Inspections
4. STRUCTURE
1 00
200
600
4.1
Check the skin of the wings, stabilizers, and fuselage for
dents, cracks, holes, etc.
o
o
o
4.2
Check winglets, horizontal stabilizer tips, and tail fins (if
installed) for damage and looseness.
o
o
o
4.3
Check ailerons for defective attachment and excessive play
in hinges;
check slot for imperfect or missing adhesive tape.
o
o
o
4.4
Check aileron bell crank and push-rods through inspection
window for improper connection and improper safetying.
o
o
o
4.5
Check aileron webs for delamination and defective bonds.
4.6
Check air brakes and air brake mechanism in wings and
fuselage for damage, improper connection and improper
safetying.
4.7
HK 36 TTC-ECO only:
o
o
o
o
o
o
o
o
o
o
o
o
o
o
Empty fuel tanks
4.8
Remove wings.
4.9
HK 36 TTC-ECO only:
o
Check fuel tanks, fillers and drainers for damage and
leakage.
4. 1 0
HK 36 TTC-ECO only:
Check fuel tank connectors (fuel hose, vent line, fuel quantity
signal wire, ground strap) for damage.
4. 1 1
Measure forces for locking, unlocking and extending the air
brakes;
lubricate wing connecting bolts in accordance with
Lubrication Schedule.
Doc. No.
Issue
Rev. No.
Date
Source
Page No.
3.02.21
May 1 7, 1 993
10
1 5 Jun 1 998
SB 50/5
3.23
"Diamond
v�
AIRCRAFT
Maintenance &
Inspections
1 00
200
600
4.12
Check main bulkhead inside for damage and delamination.
o
o
4. 1 3
Check wing spar stump for damage and delamination.
o
o
4. 1 4
Check forward and rearward web of wing spar through holes
in root rib and aileron inspection hole for defective bonds,
cracks and delamination.
4. 1 5
Remove horizontal stabilizer, check fittings and locking ring
for insecure attachment and corrosion;
check locking ring for inadequate locking function.
4. 1 6
Only for Serial Nos. through 36. 4 1 6 on which sa 51,
Measure 2 has not been carried out:
o
o
o
o
o
o
Check elevator hom for defective attachment.
4. 1 7
Check horizontal stabilizer and elevator for insecure
mounting;
check elevator hinges for insecure attachment and improper
safetying.
o
o
o
4. 1 8
Check both rudder hinges for insecure attachment and
excessive play;
check rudder control cables for damage, improper
connection and looseness;
check safetying of bolts on rudder lower mounting plate for
damage;
o
o
o
o
o
o
o
o
o
tail wheel models only:
check lower edge of rudder for cracks and rubber marks.
4. 1 9
Tail wheel models only:
check tail wheel steering mechanism and suspension for
improper operation;
check coil springs for play and improper installation.
4.20
Check tail wheel fork and steering shaftror deformation.
Doc. No.
Issue
Rev. No.
Date
Source
Page No.
3.02.21
May 1 7, 1 993
10
1 5 Jun 1 998
SB 5015
3.24
"Diamond
T
AIRCRAFT
Maintenance &
Inspections
I
4.2 1
4.22
Remove rudder; relieve tail wheel (if fitted);
check rudder lower pedestal for defonmation, cracks, and
corrosion.
Tail wheel models
: every 1 00 hours
Tricycle models
: every 200 hours
1 00
200
600
tail
o
o
o
o
o
o
o
o
o
o
o
o
o
o
wheel
models
o
Tail wheel models only: remove tail wheel fork;
check steering shaft for deformation.
4.23
Tail wheel models only: remove dowel pins, extract hub of
the tail wheel fork (on upper edge of the oval fork arms);
check hub for defonmation.
4.24
Tail wheel models only: tighten tail wheel rubber spring
assembly.
4.25
Tricycle
models
only: check tail
skid for defective
attachment and excessive wear.
4.26
Lubricate rudder hinge bushes.
4.27
Check vertical stabilizer stiffener and rearward ring frames
for poor condition, cracks and defective bonds.
4.28
Check rearward parts of elevator control system for insecure
attachment, im proper installation, improper operation,
excessive play, corrosion, and improper safetying.
o
o
o
4.29
Remove baggage compartment floor;
check rudder control cables, rudder lever, and aileron and
air brake control system parts for lack of operational
serviceability, damage, corrosion, improper operation and
improper safetying.
o
o
o
o
Doc. No.
Issue
Rev. No.
Date
Source
Page No.
3.02.21
May 17, 1 993
10
1 5 J un 1 998
S B 50/5
3.25
4fADiamond
T
AIRCRAFT
Maintenance &
Inspections
TABLE 1, PAGE 24 OF 28
1 00
200
600
o
o
o
4.30
Remove panel on rear wall of baggage compartment;
check fuselage tube for deformation and cracks;
check guiding of elevator push-rod for insecure attachment;
check control cables and tumbuckles for corrosion, wear
and lack of safetying.
4.31
Check forward ring frames, B-bulkhead, and sickle shaped
bulkhead for delamination, cracks, and defective bonds.
4.32
Remove seat shells, check for uncleanliness and loose
equipment that might foul the controls.
o
o
o
4.3 3
All models except HK 36 R: check air brake fixture (next to
LH air brake lever) for uncleanliness and wear.
o
o
o
4.34
Check main bulkhead and forward and rearward transverse
stiffener for delamination and defective bonds.
o
o
o
4.35
Check firewall for delamination around engine mount
attachment bolts.
4.36
Tail wheel models through Serial No. 36. 516 only: check
brake fluid for poor condition and insufficient quantity;
check brake master cylinder for leakage.
o
o
o
4.37
Check fuel lines and central fuel reservoir (HK 36 TIC-ECO)
or fuel tank (other models) for leakage;
airplanes registered in Russia only: check vent line and
additional vent bore for blockage;
check central fuel reservoir (HK 36 TIC-ECO) or fuel tank
(other models) for insecure or improper installation.
o
o
o
o
o
Doc. No.
Issue
Rev. No.
Date
Source
Page No.
3.02.21
May 1 7, 1 993
10
1 5 Jun 1 998
SB 5015
3.26
�Diamond
"'71T
AIRCRAFT
Maintenance &
Inspections
1 00
200
600
4.38
Check electrical installation and ground straps for chafing;
check wire attachments and connectors for looseness by
slightly pulling by hand.
o
o
o
4.39
Check Pitot tube, TEC nozzle, and antennas for insecure
attachment.
o
o
o
4.40
Check moisture drain holes and ventilation bores in wings,
fuselage and control surfaces for blockage.
o
o
o
4.41
Check aural stall waming system (if installed) for improper
operation by applying negative pressure to the bore in the
leading edge of the left wing.
o
o
o
4.42
Check for imperfect or missing placards and inscriptions.
Refer to Airplane Flight Manual Supplements for placards for
optional equipment.
o
o
o
4.43
Check aileron and air brake control system parts in root ribs
(wing and fuselage) for insecure mounting and wear,
lubricate if necessary.
o
o
o
4.44
Install wings.
o
o
4.45
HK 36 TTC-ECO only:
o
o
o
o
o
o
Measure electrical resistance between tank filler and engine
block (LH and RH wing, max. admissible: 0.5 0).
Measure electrical resistance between drainer and engine
block (LH and RH wing, max. admissible: 0.5 OJ.
4.4 6
Check fuel quantity indicator for improper indication.
4.47
Towing device and release mechanism (optional): clean and
lubricate, check for poor condition and improper operation;
check towing device mount for deformation, obvious
damage, and defective attachment to the fuselage tube.
o
Doc. No.
Issue
Rev. No.
Date
Source
Page No.
3.02.21
May 1 7, 1 993
10
1 5 Jun 1 998
SB 50/5
3.27
.,Diamond
AIRCRAFT
Maintenance &
Inspections
5. LANDING GEAR
5.1
Clean landing gear; remove wheel fairings.
5.2
Check main landing gear strut for cracks, deformation and
damage;
Tail wheel models only: check strut for delamination;
contact Manufacturer if GFRP strut is damaged.
5.3
Check brake linings for wear, minimum thickness: 3.5 mm
(0. 1 4 in.).
5.4
Check tires for cuts, excessive wear and defective valve
stems;
check creep marks.
5.5
Ensure correct tire inflation pressure
1 00
200
600
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
Tail wheel models:
main gear 2.1 bar (30 psi), tail wheel 3. 1 bar (45 psi)
Tricycle models:
main gear 2.3 bar (33 psi), nosewheel 1 .B bar (26 psi)
5.6
Check rims for cracks;
check bearings for rough running and play;
check brake disks for wear (min. thickness: 3. B mm
(0. 1 5 in.)).
5.7
Tricycle models only: check nosewheel assembly for play,
damage, deformation and cracks;
check bearings in fuselage for play;
check LH and RH journal in damper for play, lubricate.
5. B
Tricycle models only: inspect nosewheel elastomer damper,
5.9
tighten if necessary.
Tricycle models only: unload nosewheel fork, check for play;
check for improper friction (3 to 5 daN (6.7 to 1 1 .2 Ibs.)
along axle) and correct if necessary.
-
Doc. No.
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Rev. No.
Date
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Page No.
3.02.21
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10
1 5 Jun 199B
SB 50/5
3.28
"Diamond
�
AIRCRAFT
Maintenance &
I nspections
1 00
200
600
5.10
Tricycle models only: remove nosewheel fork;
check vertical pivot bearing for corrosion and play, lubricate.
o
5. 1 1
Remove main wheels, clean and lubricate bearings.
o
5.12
Tail wheel models only: check differential wheel braking
system (optional) for poor condition and improper operation.
o
o
o
5. 1 3
Check brake lines and brake cylinders for leaks, damage,
and corrosion.
o
o
o
5. 1 4
I n stall wheels and wheel fairings, ensure a secure
attachment.
o
o
o
Doc. No.
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Rev. No.
Date
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Page No.
3.02.21
May 17, 1 993
10
1 5 Jun 1 998
SB 50/5
3.29
•Diamond
AIRCRAFT
Maintenance &
Inspections
C. GENERAL MAINTENANCE WORK AND CONFIRMATION
6. GENERAL
1 00
200
600
o
o
o
o
o
6.1
Review Airplane Flight Manual Supplements for optional
equipment that requires inspection.
6.2
Check Pitot and static pressure system for leakage and dirt.
6.3
Lubricate parts according to Lubrication Schedule.
o
o
o
6.4
Review Airworthiness Directives and Service Bulletins for
compliance.
o
o
o
6.5
Check components listed in Paragraph 6.1 for expiration.
o
o
o
6.6
If necessary re-determine empty mass (weight) and
corresponding CG position (see Paragraph 4.4).
o
o
o
6.7
Enter inspection in log book.
o
o
o
6.8
Perform check flight, carry out and confirm all items in the
form "Check Flight".
o
o
o
Observations and Remarks:
The powered sailplane with the call sign
_____
a
hour inspection on the engine,
a
hour inspection on the propeller, and
a
hour inspection on the airframe
properly performed at a total flight time of
a running time meter count of
___
_
_
_
has had
hours and
hours.
The airplane is airworthy with respect to maintenance.
Date
Place
Signature
Stamp
Doc. No.
Issue
Rev. No.
Date
Source
Page No.
3.02.21
May 1 7, 1 993
10
1 5 Jun 1 998
SB 5015
3.30
•Diamond
AIRCRAFT
Maintenance &
Inspections
D. LUBRICATION SCHEDULE
With a few exceptions, the whole flight control system and all other mechanical systems are
provided with maintenance free rod end bearings and rigid ball bearings. However, the bearings
should be observed constantly, (especially in the case of tough climatic conditions such as
wind-borne sand, saline air, etc.) and, if necessary, cleaned and lubricated:
Beside the lubrication during rigging, lubrication is necessary at the times shown with a circle in
Table 2.
All commercial greases are appropriate. However, lubricants containing MoS2 must not be
combined with common all-purpose grease.
Doc. No.
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Rev. No.
Date
Source
Page No.
3.02.21
May 17, 1 993
10
1 5 Jun 1 998
SB 5015
3.31
•Diamond
AIRCRAFT
Maintenance &
Inspections
LUBRICATION SCHEDULE
1.
Engine operating cable fixtures (oil).
2.
All rod end bearings (grease).
3.
Rudder control cables in area of pedals, S-guides (oil).
4.
Rudder bearings (2 pieces) after removing rudder (grease).
5.
1 00
200
600
0
0
0
0
0
0
Eye bolt in tail wheel elastomer package (oil).
0
0
0
0
0
0
0
6.
Cable eyes on rudder lever beneath baggage compartment
(grease).
7.
Telescopic tubes of wing folding mechanism (optional), main
bolts, A- and B- bolts (grease).
B.
Rollers in the bellcranks for aileron and air brake control
systems (in wing root rib, grease).
9.
Main landing gear bearings (grease).
0
10.
Tricycle models only:
0
11.
0
0
0
0
0
Vertical pivot bearing of nosewheel fork (grease).
LH and RH bearing journal in connection of nosewheel leg
and damper (oil).
1 2.
Locking rings in horizonal tail and in the two B-bolt fastening
units (oil).
1 3.
HO-V352 constant speed propeller only:
Rollers, thrust plate, pitch change rods (grease).
0
0
0
0
0
0
0
0
0
-
Doc. No.
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Rev. No.
Date
Source
Page No.
3.02.21
May 1 7, 1 993
10
1 5 Jun 1 99B
SB 5015
3.32
�Diamol1d
T
AIRCRAFT
Maintenance &
AIRPu\NE MAINTENANCE MANUAL
Inspections
E. CHECK FLIGHT AFTER MAINTENANCE
Call sign:
Pilot
Date:
Start:
Aerodrome:
Landing:
Performance checks, flying characteristics
Observations
no
yes
Functioning check of warning and caution lights
Fuel quantity indicator
Anti collision lights (ACLs)
Position lights
VOR, ADF, XPDR, etc.
COM, transmission test
Electric fuel pump(s)
Electric starter
Engine starting behavior (cold)
Functioning of oil pressure indicator
Functioning of ammeter, functioning of generator, battery charge
Functioning of RPM indicator (comparison with calibrated tachometer)
Functioning of cylinder head temperature indicator
Functioning of wheel brakes I parking brake
Functioning of oil temperature indicator
Taxiing behavior
Take-off
Functioning of airspeed indicator
Doc. No.
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3.02.21
May 1 7, 1 993
10
1 5 Jun 1 998
SB 5015
3.33
"Diamond
'V�
AIRCRAFT
Maintenance &
Inspections
Performance checks, flying characteristics (continued)
Observations
no
yes
Functioning of altimeter I QNH setting
Functioning of vertical speed indicator I TEC
Functioning of magnetic compass
Functioning of Turbo Control Unit (R 914 F only)
Functioning of propeller speed control (if installed)
High speed flying characteristics
Functioning of elevator trim I trim range
Functioning of air brakes
Functioning of cabin heat I cabin air
Carbon monoxide test
In-flight engine stop (constant speed propeller feathered)
Low speed flying characteristics I stall characteristics
Landing
Functioning of fuel valve and fuel pressure waming light (full throttle,
fuel valve CLOSED, fuel pressure waming light must illuminate within 2
seconds).
Engine starting behavior (warm)
Remarks:
--
Pilot's signature
Doc. No.
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Rev. No.
Date
Source
Page No.
3.02.21
May 17, 1993
10
1 5 Jun 1 998
SB 50/5
3.34
i(A,Diamond
T
AIRCRAFT
Maintenance &
Inspections
3.2 DESCRIPTION OF SCHEDULED INSPECTIONS
3.2.1 ENGINE
Detailed descriptions of maintenance work which must be carried out during scheduled
inspections can be found in the O perating Manual for the Rotax 912 A Engine or the
Maintenance Manual for Rotax Engine Type 914 F, respectively.
3.2.2 PROPELLER
Detailed descriptions of the maintenance work which must be carried out during scheduled
inspections can be found in the respective Propeller Manual (see Article 2.5.6).
Doc. No.
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Rev. No.
Date
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Page No.
3.02.21
May 17, 1 993
10
1 5 Jun 1 998
SB 50/5
3.35
�Diamond
�
AIRCRAFT
Maintenance &
Inspections
3.2.3 CABIN
3.1
The canopy and the two rear windows (optional) are checked for cracks and pressure
cracks. Should a crack be found, refer to the instructions in Paragraph 5.6. The locking
mechanism must not be loose, but also should not jam. The connecting rods to the
locking pins must not be deformed.
3.2
The canopy locking levers are swung fully rearward when checking the canopy jettison
device, i.e. approximately 180°. The canopy is separated from the four locking pins and
the canopy brackets are disconnected from the canopy frame.
To avoid inadvertent canopy jettison during flight, the levers are blocked by means of
lock wires in the mechanism. In the event of canopy jettison, or in this test, the lock wire
tears off and must be replaced (available from the Manufacturer).
CAUTION
The breaking strength of the lock wire must not exceed 20 daN
(45 Ibs.). Otherwise the force required to jettison the canopy
would be too great.
3.3
The condition of the seat hamesses must be inspected. The harnesses must be free
from chafing, rips, dry-rot and kinks. The fasteners must be installed and secured
properly. The fittings must be free from cracks on the painted surfaces.
Doc. No.
Issue
Rev. No.
Date
Source
Page No.
3.02.21
May 1 7, 1 993
10
1 5 Jun 1 998
SB 5015
3.36
4'M>Diamond
�
AIRCRAFr
3.4
Maintenance &
Inspections
The elevator trim control system must operate smoothly and the lever must remain
snapped in, even at full elevator deflection. Inspect the condition of the notched plate
and its fastening. Inspect the elevator trim control system as prescribed in Article 2 . 1 .7.
3.5
Should corrosion or causticization be detected on the rudder pedals, the pedals and the
forward control cables must be replaced.
3.6
Rudder pedals: the pedal adjustment must function smoothly. During the 1 00 hour
inspection, the S-shaped cable guides must be lubricated with a few drops of engine oil.
The cable itself must not have any kinks or defective strands. In the case of visible
damage or wear, the cable must be replaced (refer to FAA AC 43. 1 3- 1 A) .
3.12
The control sticks must b e easy to move i n every direction and must not rest against
anything but the travel stops. Check zero position.
3.13
Check for play between control stick and control surfaces. It is important to block-only
one stick in order to be able to detect excessive play between the two sticks.
3.14
The point where the wheel brake starts taking effect i s adjusted correctly when the air
brakes are extended from 65 to 1 05 mm (2.6 to 4.1 in.) over the wing upper surface.
3.15
The markings of the instruments must be well identifiable, confusions of the arcs
(especially on the airspeed indicator) must be impossible. The proper markings are
specified in the Flight Manual.
Doc. No.
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Rev. No.
Date
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Page No.
3.02.21
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10
1 5 Jun 1 998
SB 50/5
3.37
"Diamond
AIRCRAFT
3.20
Maintenance &
Inspections
HK 36 R: The locking pin of the main bolts must be easy to insert.
Other models: The locking hook for the main bolts must not jam. There must be a spring
load on the hook even when it is fully retracted, i.e. there must not be any dead travel.
3.21
The main bolts must be easy to move when the wings are supported,. no matter whether
the wing is removed or installed. If the bolts do not move easily, either the lubrication is
insufficient and the bolts have seized up in their guides, or the bolts or bushes are
deformed due to inappropriate wing installation (releasing the wing when the bolt is
inserted half-way). A deformed bolt must be replaced.
Doc. No.
Issue
Rev. No.
Date
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3.02.21
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10
1 5 Jun 1 998
S8 50/5
3.38
�Diamond
v�
AIRCRAFT
Maintenance &
Inspections
3.2.4 STRUCTURE
4.1
Minor repairs are described in Section 5. In the case of uncertainty, contact the
manufacturer.
Generally, cracks along leading or trailing edge bonds must be reported to the
manufacturer and repaired according to the Instructions given by the manufacturer to
prevent moisture from entering.
Each aileron is attached to the wings with five CFRP hinges. Check the areas around
4.3
the hinges for cracks and defective bonds. Self-lubricating bushes are bonded into the
hinges fixed to the ailerons. Pivots, which are secured by cross pins, are inserted in the
wing mounted hinges.
4.4
All bolts must be secured with self-locking nuts and all rod end bearings must have
locking nuts. Check bolts and nuts for corrosion.
I
4. 1 2
The forces for locking, unlocking, and extending the air brakes are measured o n the
bellcranks in the LH and RH wing root rib. The wing should be placed on its leading
edge and a spring scale is hooked onto the roller bearing, perpendicular to the bellcrank
arm.
The extension forces are measured in order to check the condition of the air brake
damper. The force that is measured shortly before the air brake reaches the stop is
relevant.
CORRECT AIR BRAKE OPERATING FORCES
Unlocking force
Locking force
Extension force
before reaching
stop
[daN]
[daN]
[daN]
H K 36 R
min. 7
max. 24
min. 7
H K 36 TS, TC, TIS, TIC,
TIC-ECO,
SIN 36. 5 1 7 and subsequent
min. 1 2
max. 24
min. 7
others
min. 1 0
max. 1 8
min. 7
Model
-
Doc. No.
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Rev. No.
Date
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3.02.21
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10
1 5 Jun 1 998
SB 50/5
3.39
�Diamond
T
AIRCRAFT
Maintenance &
Inspections
CAUTION
The necessity to adjust the air brake control system may indicate
damage to the structure (e.g. due to overstressing). Therefore
contact the Manufacturer before adjusting.
4.16
The bolts on the horizontal stabilizer mount must fit tightly and must be secured with
self-locking nuts. The locking ring must be secured against twist by means of two cross
pins on the forward horizontal tail mount.
CAUTION
The elevator is not automatically connected to the elevator
control system! Be aware of this when installing or removing the
horizontal tail!
4. 1 7
Elevator horns which a re constructed from plywood must be checked for defective
attachment to the elevator as follows:
(a) Remove horizontal tail.
(b) Fix together elevator horn and horizontal stabilizer.
(c) Apply a force of 1 5 daN (34 Ibs.) to elevator at trailing edge in upward and
downward direction. Check for play.
4. 1 9
The rudder is held in place by a pin which is fixed to the vertical stabilizer at the top and
a bolt in the mounting plate at the bottom.
The rudder control cables are also attached to the mounting plate with one bolt each. All
three bolts must be secured with lock wire.
The rudder control cables, eye stiffeners and nicopress sleeves should be checked for
poor condition.
Doc. No.
Issue
Rev. No.
Date
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Page No.
3.02.21
May 1 7, 1 993
10
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SB 50/5
3.40
"Diamond
T
AIRCRAFT
4.20
Maintenance &
Inspections
When the rudder is held firmly and the tail wheel is twisted, a positive spring load must
be perceptible in either direction. Play in the assembly indicates a defective spring.
Fu rthermore, verify that the tail wheel moves to neutral position if the rudder is being
brought to neutral. For this test the fuselage is elevated right in front of the tail wheel.
If the tail wheel has exceeded the maximum resiliency travel due to overload (e.g. nose
over, extremely unfavorable ground), it presses the weak lower edge of the rudder. The
rudder hinges will not be damaged, and the rudder will still function. However, the rudder
hinges, tail wheel, and tail wheel suspension must be inspected thoroughly. If
necessary, repair the rudder lower edge in accordance with Section 5.
4.21
It is absolutely necessary for this inspection to relieve the tail wheel completely. In
particular the welds and the adjacent areas must be thoroughly inspected for cracks
from all sides. The entire pedestal must be checked for deformation and corrosion.
4.22
Rudder removal and installation: see in Article 5.1 .3.
I
4.23
To remove the tail wheel fork, first remove the transverse M6 bolt, then extract steering
I
4.25
shaft in a downward direction.
For correct adjustment of the pre-tension of the rubber spring assembly, jack airplane in
front of the vertical tail so that the tail wheel has no ground contact. Tighten nut on
elastomer package until disks cannot be twisted by hand torque.
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Maintenance &
Inspections
4.19, 4.30, 4.31
The control cables must be inspected for wear. If there are signs of wear (see FAA AC
43. 1 3-1A) , the cables must be replaced. Refer to Section 6 for the life limit.
The tension force of two the rearward rudder control cables must be adjusted by means
of the turnbuckles. Correct tensile force: see Article 2.1 .3.
4.37
The brake fluid level must not fall below the minimum marking. If it does, inspect the
brake linings. If they are not worn, determine the reason for the loss of brake fluid.
4.38
Thoroughly check all screwed connections and the drainer valve for leakage. Check
fastening strap for poor condition, defective attachment to the fuselage structure and
chafing on the central fuel reservoir or tank.
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AIRCRAFT
3.2.5 LANDING GEAR
5.2
This inspection should be performed very thoroughly after hard landings or in the case
of operation on aerodromes with extremely rough runways.
5.3
The brake linings may be wom down to a minimum thickness of 3.5 mm (0.14 in.) before
they must be replaced.
To replace the linings, remove the lock wires and the two fixture screws (17). The two
pressure plates (12 and 1 5) can be removed and the new brake linings are affixed with
the provided rivets. Re-install pressure plates. When replacing brake linings, all four
should be replaced at the same time.
1
10
:
--I!J
3
2
3
, ."; -,
�
7
14 1 3
I
b
',.::/
.. ' r:f'
/
15
~
.
,
/'
:�,
./
�-- 1 6
'\
/'
12
5
6
Brake line connector
1.
Brake cylinder
11.
2.
Brake piston
1 2.11 5. Pressure plate
4.
Guide pins
8.
9.
.J 3.
Brake linings
Bleed nipple
16.
Fixture plate
Bleed screw
1 7.
Attach ment bolts (2)
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5.8
Maintenance &
Inspections
When new elastomer elements are installed, Dimension "a" should be 1 95 mm (7.7 in.)
with the nosewheel clear of the ground.
The preload on used elements is adjusted properly when the rubber elements cannot be
twisted by moderate hand torque while the nosewheel is clear of the ground. With the
elastomer package properly preloaded, dimension "a" must not beJess than 1 85 mm
(7.3 in.). Otherwise the rubber elements must be replaced.
a
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Maintenance &
AI RPLA.NE MAINTENANCE MANUAL
Inspections
3.3 NON-SCHEDULED INSPECTIONS
3.3.1 ENGINE
25 hour inspection
A newly installed engine must undergo a non-recurring inspection after 25 operating hours. The
maintenance items are stated in the Operator's Manual for the Rotax 912 A or the Maintenance
Manual for Rotax Engine Type 9 1 4 F, respectively.
As well as these items, the bolts attaching the engine mount to the firewall must be tightened at
the 25 hour inspection (torque: 40 Nm (29.5 ft.lbs.)).
Special inspections
Special inspections (e.g. after propeller strike, excessive temperature, etc.) are described in the
Operator's Manual for the Rotax 912 A, Paragraph 8.2 and Section 1 1 , or the Maintenance
Manual for Rotax Engine Type 9 1 4 F, Paragraph 1 2.4, respectively.
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Maintenance &
Inspections
Amber temperature caution light illuminates (Models with Rotax 9 1 4 F onlY)
Through improper operation (carburetor heat ON with power above 75 %) or a high power
setting with a high OAT, the airbox temperature can exceed 72 "C ( 1 62 "F). If the caution light
illuminates for a short while due to this, and is termin ated by the action of the TCU or by moving
back the carburetor heat control or throttle control, it does not indicate a fault.
If the caution light illuminates under other conditions or for a longer time, an inspection must be
carried out as follows:
(1)
Perform engine ground run, measure airbox temperature a t idle RPM (see Article 2.5.3).
This may not exceed 60 "C (140 "F); a higher temperature indicates a defective airbox
temperature sensor.
(2)
Increase engine power setting. The measured value of the airbox temperature must
thereby increase; deviating behavior indicates a defective airbox temperature sensor.
NOTE
Only airbox temperatures above 0 "C (32 "F) can be measured.
At OATs below 0 "C, the airbox temperature can only be
measured with increased engine power settings.
(3)
Measure LH and RH EGT at take-off power (see Article 2.5.3). Both temperatures
should lie between 850 "C (1 562 "F) and 950 "C (1742 "F).
NOTE
At temperatures above ISA + 1 5 "C (ISA + 27 "F), an airbox
temperature just over 72 "C (162 "F) can be reached during this
test. Subsequently, the caution lignt will illuminate.
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If the indicated values are too low, a defect in the corresponding EGT sensor is likely, but the
defect could also lie in the carburetor system =} proceed to Items (4), (5) and (6).
If the indicated values are too high, a defect in the carburetor system is likely, but the defect
could also lie in the EGT sensor =} proceed to Items (5), (4) and (6).
(4)
Test the two EGT sensors with an electronic thermometer for Type "K" thermocouples.
If the sensors are defective, they must be replaced.
(5)
Examine the carburetor in accordance with the Maintenance Manual for Rotax Engine
Type 914 F, Article 12.3.15. Check the pressure connection lines for blockage, kinks or
other damage.
(6)
If the above measures do not solve the problem, contact the manufacturer.
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3.3.2 PROPELLER
Special inspections (e.g. after excessive RPM) are described in the Propeller Manual (see
Article 2.5.6).
3.3.3 AIRFRAME
Hard landings
After an excessively hard landing or some other unusual loading on the landing gear, even when
no obvious damage is apparent, the following inspection must be carried out:
(1)
Check the fixing parts of the main landing gear for cracks, deformation and other
damage using a light and a mirror.
Check the surrounding GFRP structure for delamination.
(2)
Check the main landing gear strut(s) for cracks, deformation, delamination of GFRP
strut, and other damage.
Measure the track width and compare with the value recorded in the Adjustment Report
(use slide sheets!).
(3)
Check all three tires for cuts in the side.
(4)
Check brake lines, brake cylinders, calipers and brake disks for leakage and damage.
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(5)
Maintenance &
Inspections
Remove rudder and check tail wheel assembly and rudder pedestal for cracks,
deformation, defective attachment to the fuselage and other damage.
(6)
Check entire nosewheel assembly for cracks, deformation and other damage. Unload
the nosewheel and check for excessive play in the bearings.
(7)
Check top hat profile in fuselage underside for delamination, especially in the bonding
areas and around the nosewheel strut bearings.
(8)
Check engine mount for cracks and deformation. In the case of tricycle models, the
nosewheel damper attachment area must be inspected especially thoroughly.
Check shock mounts (silentblocs) and fixture points of the engine mount to the firewall
for damage.
(9)
( 1 0)
Check hinges and attachment of balancing masses on the control surfaces for damage.
Remove wings; check wing leading edge and wing-fuselage connection for damage.
Check main bulkhead for delamination.
(1 1 )
Remove horizontal tail and check horizontal stabilizer leading edge and attachment for
damage.
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( 1 2)
Check avionic equipment and instruments for loose attachment and obvious damage.
( 1 3)
Check fiight instrument indications on the ground: airspeed indicator and vertical speed
indicator (if i nstalled) must indicate zero and altimeter must indicate airfield elevation
when set to aerodrome QNH.
Exceeding of operating limitations
If operating limitations (e.g. VNE) have been exceeded, the manufacturer should be contacted.
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3.4 TORQUES
3.4.1 STANDARD TORQUES
Unless otherwise provided (see Article 3.4.2), nuts and bolts must be tightened with the
following torques:
Nut or Bolt Size
Torque [Nm]
Torque [ft Ibs.]
M5
3.6
2.7
M6
6.4
4.7
MB
1 6.0
1 1 .B
M10
32.0
23.6
M12
57.0
42.0
The number after the "M" indicates the thread major diameter in millimeters. Divide this value by
25.4 to obtain inches. Example: an MB bolt is one with a thread major diameter of 0.315 inches.
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AIRCRAFT
3.4.2 SPECIAL TORQUES
I Nut or Bolt
Torque [Nm]
Torque [ft Ibs ]
Bolts attaching engine mount to firewall
40
29.5
Bolts attaching main landing gear axles to strut
20
14.8
Bolts attaching GFRP main landing gear strut to
fuselage (tail wheel models only)
10
7.4
Bolt in main landing gear fitting at inner end of
steel strut (tricycle models only)
height of spring
washers 4 ± 0.5 mm
0. 1 6 ± 0.02 in.
Bolts in main landing gear fitting next to
fuselage root rib (tricycle models only)
20
1 4.8
15
1 1.1
Nosewheel stop bolts limiting steering angle
(tricycle models only)
see Operator's Manual for Rotax 9 1 2 A or
Maintenance Manual for Rotax Engine
Type 9 1 4 F
Nuts and bolts on engine
see Propeller Manual
(refer to Article 2.5.6 for correct manual)
Nuts and bolts on propeller
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H K 36 R , TS, TC, TIS , TIC, TIC-ECO
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Other Work
SECTION 4
OTHER WORK
4.1 PROCEDURES FOR TOPPING UP OPERATING FLU I DS
4.1.1 FUEL
Approved fuel grades; see Airplane Flight Manual, Section 2 .
During reflJeling, the ground cable must b e electrically connected to the exhaust pipe to prevent
electrostatic charge build up.
Do not top up completely when the weather is hot. The fuel expands when it gets warm and
flows off through the ventilation line.
Maximum quantity
Standard tank
; 55 liters (14.5 US gaL)
Long range tank HK 36 R
; 80 liters (2 1 . 1 US gaL)
Long range tank H K 36 TS, TC, TIS, TIC
; 79 liters (20.9 US gaL)
Wing tanks H K 36 TIC-ECO
; 55 liters each (14.5 US gal. each)
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4. 1 .2 ENGINE OIL
After removing the yellow colored oil filler cap, which is located rearward on the right hand side
of the engine, the engine oil can be topped up. The maximum oil quantity is 3.0 liters (3.2 US
quarts). The lubricant quality according to the API system and the required viscosity range can
be found in the Airplane Flight Manual or the Operator's Manual for the Rotax 9 1 2 A or the
Maintenance Manual for Rotax Engine Type 9 1 4 F.
Before closing the oil filler, check condition of the rubber sealing ring and replace if necessary.
4. 1.3 COOLANT
Before topping up coolant, the reason for the loss of fluid must be found and eliminated (e.g.
leaky hose connections).
Only antifreezes with anti-corrosion additives for light alloy engines (e.g. BASF Glysantin
Antikorrosion) may be used. 1 0 to 20 % water should be added to the coolant.
When the engine is cold, open the pressure cap on the dispatcher vessel on top of the engine
and fill the dispatcher vessel up completely. The equalizing reservoir (transparent vessel next to
oil tank) must be between '/3 and 2/3 full.
After the first top-up, close the pressure cap and let the engine run for approximately 3 minutes
at increased idle speed. Then fill up dispatcher vessel completely. Fill up equalizing reservoir
until it is between '/3 and 2/3 full. The maximum coolant quantity is approximately 2.5 liters (2.6
US quarts).
Before closing the pressure cap, check the condition of the rubber sealing rings.
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4.1.4 BRAKE FLUID
Airplanes with wheel brake system version 1 (see Article 2.2.5) have the brake fluid reservoir
installed behind the main bulkhead under the baggage compartment floor. Airplanes with wheel
brake system version 2 (see Article 2.2.6) have two brake fluid reservoirs mounted to the co
pilot's LH and RH rudder pedal.
Always determine the reason for the loss of brake fluid before filling up (wom brake linings,
leaky brake lines or brake cylinders).
The required brake fluid grade is Mil-H-5606 A (or English DTD 585 or French AIR 3520)
Aeroshell Fluid 4. Brake fluids with equal grades may be mixed.
CAUTION
Avoid contact of brake fluid and paint finish! When closing the
brake fluid reservoir of an airplane with wheel brake system
version 1 (see Article 2.2.5), ensure that the bleed hole is not
blocked.
4.1 .5 REFILLING THE BATTERY
The battery must be filled up with distilled water to the upper marking. It is recommendable to
use a special wash bottle or a large injection syringe. Spilled battery acid can be rendered
harmless by means of an acid neutralizer (e.g. Varta Neutralon Spray) or with much water,
which is, however, hard to remove afterwards. At this time, clean the battery terminals and apply
battery terminal grease or Vaseline.
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4.2 DETERMINING EMPTY MASS CG POSITION
Condition of the Powered Sailplane during weighing:
*
Powered Sailplane completely rigged
*
No seat cushions, equipment as listed in the Equipment Inventory
*
No parachutes, no wing support fixtures, no baggage
*
Canopy closed
*
Fuel system drained down to the unusable quantity. In case of the HK 36 TIC-ECO, both
wing tanks and the central fuel reservoir must be emptied through the drain valves, then 2
liters (0.53 US gal.) of fuel must be filled into each tank.
*
Oil quantity 3.0 liters (3.2 US quarts) (full)
For the determination of the empty mass CG, the powered sailplane is placed upon three
scales, one under each wheel. The fuselage tube must be aligned horizontally as shown in the
s ketch on the next page. Drop a plumb line from the wing leading edge at the root rib to the
ground. This plumb line defines the datum plane (DP). Measure the distances from DP to the
axletrees (x 1 , x2 or x1 , x2L, x2R) and enter them in the Weighing Report. The mass portions
(m 1 , m2 or m 1 , m2L, m2R) are measured with the scales.
The formula
for tail wheel models
for tricycle models
yields the position of the empty mass CG aft of DP. Enter distances in millimeters, masses in
kilograms.
If distances have been measured in inches, multiply their values by 25.4 to obtain millimeters.
If masses have been measured in pounds, divide-their values by 2.2046 to obtain kilograms.
The empty mass is the sum of the mass portions (m 1+ m2 or m1+ m2L+m 2R ).
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DP
,...
J
,J
--
_
x
E
top surface of
wedge aligned
horizontally
�
.;-;zj
�
_
1000
��:riZQntaL
-
-
-
-
mil
-
2t �
m1
&l
mE
x1
Other Work
-
� ;) .
-
m2
x2
Horizontal alignment - tail wheel models
�I--:":":=-:' -+- >---"::":"::+i
top surface of
wedge aligned
---r--t__ OriZ
ontaIIY
h
_
h9!kQ�l
1000
__________
Horizontal alignment - tricycle models
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4.3 TABLE OF THE MOST IMPORTANT LEVER ARMS
Lever arms are given in millimeters, forward ( ) or aft (+) of DP.
-
I
Item
Wings
[mm
:�f CG]
495
Horizontal stabilizer
4860
I
I
Item
[mm
:�f CG]
Avionics
-420
Landing light
-1 370
Long range tank
824
ACL on horizontal tail
4800
Standard tank
727
ACLs on wings
470
Wing tanks
(HK 36 TIC-ECO only)
255
Pilots
143
central fuel reservoir
(HK 36 TIC-ECO only)
680
Oil tank, Rotax 9 1 2 A
-1 060
Seat cushions
110
Oil tank, Rotax 914 F
-990 .
Backrest cushions
390
HK 36 TIC-ECO
Baggage
other models
824
assumed equal
to fuel tank
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H K 36 R , TS, TC, TIS, TIC, TIC-ECO
Other Work
4.4 WEIGHING REPORT
The Weighing Report shows the current empty mass and the current empty mass CG position.
Weighing Report and Equipment Inventory are preserved in the Aircraft Maintenance Log.
A master form can be found in Paragraph 4. 1 0.
NOTE
In case of equipment changes, repairs and repainting, or no later
than 5 years after the last weighing, the airplane must be re
weighed by an authorized person. Afterwards , the new empty
mass CG position must be computed. The values must be
entered in the Mass and Balance Form (see Paragraph 4.7). The
new limits must be drawn on a new Mass and Balance Diagram
(not valid for HK 36 TIC-ECO, see Paragraph 4.8), and the
limitations placard in the cockpit must be updated.
4.5 EMPTY MASS AND CORRESPONDING CG
Empty mass CG limitations depending on the empty mass are given in Paragraph 4.9.
HK 36 TTC-ECO:
Other models:
These limitations guarantee that solo pilots
These limitations guarantee that SOlo-pilots
with a minimum mass (weight) of 70 kg
with a minimum mass (weight) of 70 kg
( 1 54 Ibs.) will not overstep the maximum
( 1 54 Ibs.) will not overstep the maximum
rearward CG when flying with at least 1 0 kg
rearward CG when flying with a full tank and
(22 Ibs.) of fuel and no baggage.
no baggage.
The CG will not exceed the maximum
The CG will not exceed the maximum
forward position if the maximum useful load
_
forward position if the maximum useful load
minus 1 0 kg (22 Ibs.) (fuel for a half hour
minus 1 0 kg (22 Ibs.) (fuel for a half hour
flight) is placed on the seats.
flight) is placed on the seats.
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HK 36 R , TS, TC, TIS, TIC, TIC-ECO
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Another limitation is the minimum flight mass of 600 kg ( 1 323 Ibs.). Consequently, the useful
load must never be less than
minimum useful load
=
(600 kg) - (1 0 kg fuel) - (empty mass)
The empty mass CG position can be shifted rearward using a balance weight mounted to the
vertical stabilizer web (serial nos. through 36.517: x
=
4700 mm (185.0 in.), serial nos. 36.51 8
and subsequent: x = 4490 mm (1 76.8 in.)).
4.6 MASS OF NON-LIFTING PARTS AND USEFUL LOAD
Serial
numbers
36.301
through
36.51 6
36.51 7
and subsequent
Mass of
both wings
Max. mass of nonlifting parts
" 1 80 kg
590 kg
770 kg
minus empty mass
180 kg
590 kg
590 kg
plus mass of both wings
minus empty mass
" 1 60 kg
6 1 0 kg
770 kg
minus empty mass
<
6 1 0 kg
6 1 0 kg
plus mass of both wings
minus empty mass
<
1 60 kg
Maximum permissible useful load
The maximum mass of all non-lifting parts is the sum of:
•
Mass of fuselage and installed parts including canopy
•
Mass of rudder
•
Mass of horizontal tail
•
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4.7 MASS AND BALANCE FORM
The Mass and Balance Fonn in Section 6 of the Flight Manual shows the following values:
I
HK 36 TTC-ECO:
other models:
•
Current empty mass
•
Current empty mass
•
Current empty mass CG position
•
Current empty mass CG position
•
Current maximum pennissible useful
•
Current maximum permissible useful
load
load
•
Minimum useful load on the seats with
•
full tank and no baggage
1 0 kg (22 Ibs.) fuel and no baggage
•
•
1 0 kg (22 Ibs.) fuel and maximum
full tank and maximum baggage mass
baggage mass (30 kg (66 Ibs.))
( 1 2 kg (26 Ibs.)).
Furthermore, the Mass and Balance Form is a record of all weighings carried out.
The Mass and Balance Fonn must be updated by an authorized person in compliance with the
currently effective Weighing Report as follows (from left to right):
•
Date of weighing: taken from the Weighing Report
•
Empty mass (weight): taken from the Weighing Report
•
Empty mass (weight) CG position: taken from the Weighing Report
•
Maximum pennissible useful load under consideration of the maximum mass of all non-lifting
parts (see Paragraph 4.6)
•
Minimum useful load on the seats with no baggage;
Minimum useful load on the seats with maximum baggage
taken from the tables in Articles 4.9.2, 4.9.3, or 4.9.4
•
Signature and stamp of the aircraft maintenance engineer (A.M.E.)
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4.8 MASS AND BALANCE DIAGRAM
NOTE
The CG position of the HK 36 TIC-ECO cannot be determined
using a diagram. It must therefore be determined by calculation.
4.8.1 EXPLANATION OF THE DIAGRAM
As an addition to the Mass and Balance Form, a new Mass and Balance Diagram must be filled
out upon each weighing as follows:
•
Master diagrams are given on Pages 4. 1 1 and 4. 12. There is a separate form for each tank
version (standard or long range). Photocopy the appropriate master.
•
The minimum pilot mass and the maximum total mass of fuel and baggage do not depend on
the weighing. Therefore, these limits are already drawn on the diagram .
•
Two additional limits are drawn following the weighing:
- Draw the line representing the empty mass in a parallel direction between the broken lines
labeled with the corresponding empty mass values. The forbidden loading range lies
above this line and must be hatched.
- The empty mass CG position (depending on propeller model, tank, avionics, etc.) may
req uire an additional limit to the maximum rearward CG position. Draw the line for the
empty mass CG position in a parallel direction between the broken lines labeled with the
corresponding empty mass CG values. The forbidden loading range lies above this line
and must be hatched. If this limitation lies outside the other borders, it is not effective and
thus need not be drawn.
•
Cut out half-sized page using markings, enter correct page no. in footer, insert page into
Section 6 of the Flight Manual.
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4.8.2 MASS AND BALANCE DIAGRAM. STANDARD TANK (MASTER)
r
OIl\MOND
AIRCRAFT
�
0 '1
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FLIGHT MI\NUAL
,
0
,
,
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,
,
0
..
,
,
0
"
PI
..
,
0
III
!
,
,
0
2
!
"
'I
0
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!)!
,
Mass & Balance
....
--
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<Eo-----
Revision No.
a6e66ea pue lan,:l jO sserlll leJol
Date
Source
Issue
Paqe No .
6-
L
Doc. No.
Issue
Rev. No.
Date
Source
Page No.
3.02.21
May 1 7, 1 993
10
1 5 Jun 1 998
S8 50/5
4. 1 1
�Diamond
'T
AIRCRAFT
Olher Work
4.8.3 MASS AND BALANCE DIAGRAM. LONG RANGE TANK (MASTER)
r
FLIGHT MANUAL
Mas s & Balance
J
L
Doc. No.
Issue
Rev. No.
Dale
Source
Page No.
3.02.21
May 1 7, 1 993
10
1 5 Jun 1 998
S8 50/5
4. 1 2
�Diamond
T
AIRCRAFT
Olher Work
4.9 PERMISSIBLE EMPTY MASS CG RANGE AND
MINIMUM USEFUL LOAD ON SEATS
4 9 1 PERMISSIBLE EMPTY MASS CG POSITION
.
.
Empty mass
[kg]
Permissible empty mass
CG range (standard tank)
Permissible
empty mass
CG range
(long range tank)
Permissible
empty mass
CG range
(wing tanks)
520 - 524
384 - 445
384 - 423
390 - 432
525 - 529
384 - 445
384 - 423
389 - 432
530 - 534
383 - 444
383 - 423
388 - 431
535 - 539
382 - 444
382 - 423
386 - 431
540 - 544
382 - 444
382 - 423
385 - 431
545 - 549
380 - 444
380 - 423
383 - 430
550 - 554
377 - 444
377 - 424
381 - 430
555 - 559
375 - 444
375 - 424
379 - 430
560 - 564
373 - 444
373 - 424
377 - 430
565 - 569
371 - 443
371 - 424
374 - 429
570 - 574
369 - 443
369 - 424
372 - 429
575 - 579
367 - 443
367 - 424
370 - 429
580 - 584
365 - 443
365 - 424
368 - 429
585 - 589
363 - 443
363 - 424
367 - 428
590 - 594
361 - 443
361 - 424
365 - 428
595 - 599
360 - 443
360 - 424
363 - 428
600 - 604
358 - 443
358 - 424
361 - 428
605 - 609
359 - 427
610 - 614
357 - 427
-
615 - 6 1 9
356 - 427
620
354 - 427
Doc. No.
Issue
Rev. No.
Dale
Source
Page No.
3.02.21
May 1 7, 1 993
10
1 5 Jun 1 998
S8 50/5
4. 1 3
.Diamond
AIRCRAFT
Other Work
4.9.2 MINIMUM USEFUL LOAD ON THE SEATS WITH STANDARD FUEL TANK
Empty mass CG position
[mm aft of DP]
Minimum useful load on the
seats with full tank, no
baggage
[kg]
seats with full tank, 12 kg
baggage
[kg]
358 - 430
55
55
431 - 432
55
60
433 - 434
55
65
435 - 437
60
70
438 - 439
65
75
440 - 442
70
80
443 - 444
75
85
4.9.3 MINIMUM USEFUL LOAD ON THE SEATS WITH LONG RANGE FUEL TANK
Empty mass CG position
[mm aft of DP]
seats with full tank. no
baggage
[kg]
seats with full tank, 1 2 kg
baggage
{kg]
358 - 406
55
55
407 - 409
55
60
4 1 0 - 41 1
55
65
4 1 2 - 41 4
55
70
415 - 41 7
60
75
4 1 8 - 420
65
80
421 - 422
70
85
423 - 425
75
90
Doc. No.
Issue
Rev. No.
Date
Source
Page No.
3.02.21
May 1 7, 1 993
10
1 5 Jun 1 998
S8 50/5
4. 1 4
•Diamond
AIRCRAFT
Other Work
4.9.4 MINIMUM USEFUL LOAD ON THE SEATS WITH WING TANK
Empty mass (weight)
CG position
[mm aft of DP]
seats with 1 0 kg (22 Ibs.) fuel.
no baggage
[kg]
seats with 1 0 kg (22 Ibs.) fuel.
30 kg (66 Ibs.) baggage
[kg]
354 - 400
55
55
401 - 402
55
60
403 - 404
55
65
405 - 406
55
70
407 - 408
55
75
409 - 4 1 0
55
80
41 1 - 41 2
55
85
413 - 415
55
90
For conversion to Imperial Units, refer to Article 0.3.2.
4.1 0 WEIGHING REPORT (MASTER)
Doc. No.
Issue
Rev. No.
Date
Source
Page No.
3.02.21
May 1 7, 1 993
10
1 5 Jun 1 998
S8 50/5
4. 1 5
.Diamond
"
Date:
Type:
I
.t
[kg]
RH wing
max. uselul load
fuselage including trim mass
vertical tail
770
max. total mass
mass 01 non-lifting parts
including useful load
rudder
uselul load
tara
[kg]
gross
-[kg
]
scale
Remark:
arm
[mm]
net
[kg]
trim mass on vertical stabilizer web
(see AMM, Paragraph 4.5)
front m1
. h'rizonta1�"""
o
rear m2
X x m2 - X,
2
m,
+
m2
x
m,
DP
=
=
=
[kg]
_� m ,""
LH wing
XE
Call sign:
Serial No.:
: vertical plane, tangential to
edge at root rib
: """dge 52:'lUuu 1278 mm in 'ront of f';••'o� ! lube rear edge
Datum plane DP
=
DAI. Form No. H 1 7-E
WEIGHING REPORT
AIRCRAFT
1'---1
=
!
!
wedge .Ogned
I
mm
lop surface o(
;Q ?"--
harizq!1!BL-_
?"
m1
mE
"
mm aft 01 DP
I
'
kg at x =
I
1278
/
l:l
�
-
m2
"
admissible empty mass CG position according to Airplane Maintenance Manual, Article 4.9.1:
I
I
mm to
I
CORRECTIONS
Modification
I
mm aft olDP
mass
[kg]
arm
[mm]
corrected
xdmm]
date
signatu re
The empty mass CG position detennined above lies within the admissible range. The placard
in the cockpit and the Airplane Flight Manual(Mass & Balance Form, Mass & Balance
Diagram) have been updated. Equipment: see Equipment Inventory dated:
Signature:
Stamp:
Doc. No.
Issue
Rev. No.
Date
Source
Page No.
3.02.21
May 1 7, 1 993
10
1 5 Jun 1 998
SB 50/5
4. 1 6
DAI. Form No. H1 7a-E
WEIGHING REPORT
Date:
Type:
: vertical plane, tangent to wing
: wedge 5;clUuu 1 278 mm in- front
Datum plane DP
Call sign:
Serial No.:
[kg]
edge at root rib
,,,.;;,�, , tube rear edge
. '""
"u, ,-""
[kg]
empty mass
RH wing
max. useful load
LH wing
max. total mass
fuselage including trim mass
vertical tail
mass of non-lifting parts
including useful load
rudder
1=====11 Remark:
useful load
scale
[kg]
[mm]
trim mass on vertical stabilizer web
Paragraph 4.5)
front m1
f--�-+----+-----+----+---�I (see AMM,
rear mZL
--�------+-------+-------+-----�I
�--�
rear m 'R
=
770
I
I
r--�-l
kg m x = 1
mm all of DP
admissible empty mass CG position according to Airplane Maintenance Manual, Article 4.9. 1 :
I
mm to
I
CORRECTIONS
mm all of DP
mass
[kg]
arm
[mm]
corrected
Xe [mm]
date
signature
The empty mass CG position determined above lies within the admissible range. The placard
in the cockpit and the Airplane Flight Manual (Mass & Balance Diagram (not for HK 36 TTC
ECO), Mass & Balance Form) have been updated.
Equipment: see Equipment Inventory dated:
.
______
Signature:
Stamp:
Doc. No.
Issue
Rev. No.
Date
Source
Page No.
3.02 .2 1
May 1 7, 1 993
10
1 5 Jun 1 998
SB 5015
4. 1 7
f"
�
OJ
01
en
CD
01
a
-
�
(0
(0
OJ
:J
'-
C
�
01
�
a
'"
�
-
(0
(0
�
"'-I
OJ
'<
s:
�
'"
'"
�
a
CD
CD
Z
P
-u
OJ
10
en
0
C
,
n
CD
�
OJ
0
::0
CD
:<
Z
p
CD
en
en
c
p
z
0
0
p
ai/eron ---\
A T AILERON INBOARD EDGE
DIHEDRAL WITH WING SUPPORTED
�
1:1
1;1
"I
'P to elevator hinge: 5089 mm /200.35
'Pta rudder hinge: 4715 mm /185.63"
wedge aligned
horizontally
ELEVA TOR
+Smm
-0 mm
+5mm
36.517 & subseq..• 50 mm -0
mm
SIN's thru 36.516: 50 mm ±5 mm
other models:
:7
36.517 & subseq.: 60 mm
I S/N's t/Jru J6.516: 60 mm ±5 mm
other models:
+5 mm
HK 36 TTC-ECO: 6Smm
-O mm
I�
i!:!
I�
z
:!!:
m
g »
::t rm »
c r1:::0
G)
...,(
::t
a
m :::0
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N
(") a
'm
.
z
§
I�
:!!:
;:0 m
z
» ...,(
z
c
»
G)
a
»
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:!!:
c:
en
...,(
m »
rC
1m t...
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I
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5'
CD
,
<;1
m
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r 0
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_
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-I :j
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s: :j
m en
s: --I
>
S;:
].J
Z -I
::0
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>
� a.
Q�
�8
B;'
!
Other Work
4.1 2 ADJUSTMENT DIAGRAM - AILERONS. RUDDER. SWEEP
ful
�
'"
1
I
I
I
I
1
1
I
,
I
,
I
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I
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ili
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.
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I
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I
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1
,
I
I
+1
tg �-
Doc. No.
Issue
Rev. No.
Date
Source
Page No.
3.02.21
May 1 7, 1993
10
1 5 Jun 1 998
SB 5015
4. 1 9
�Diamond
�
AIRCRAFT
Other Work
4.1 3 MASSES AND RESIDUAL MOMENTS
OF THE CONTROL S URFACES
4.13.1 GENERAL
CAUTION
For the flutter safety of the airplane, it is very important that
masses and residual moments of the control surfaces comply
with the following limitations. Therefore, these values must be
re-determined after repairing or repainting a control surface.
4.13.2 MEASUREMENT OF RESIDUAL MO MENTS
The surfaces must be removed from the airplane and supported in their axes of rotation with as
little friction as possible. The force "F" is measured (e.g. with a letter balance or a spring scale)
opposite to the balancing mass while the surface is horizontal. The measuring range of the
balance should be about 1 5 N (3.5 Ibs.). With the lever arm "r" which is equal to the distance
between the hinge line and the force "F", the residual moment 'M' can be computed as follows:
HINGE
M
=
F x r
with F in [N], r in [cm]
[Ibs.] > 4.448
I ..
r ------I
[in.] > 2.54
=
=
[N]
[cm]
Should a surface fail to meet the correct values given in Article 4.1 3.3, a modification of the
mass balancing is necessary.
Doc. No.
Issue
Rev. No.
Date
Source
Page No.
3.02.21
May 1 7, 1 993
10
1 5 Jun 1 998
S8 50/5
4.20
�Diamol1d
'17�
AIRCRAFT
Other Work
4.13.3 PERM ISSIBLE MASSES AND RESIDUAL MOMENTS OF THE CONTROL SURFACES
Permissible mass
(including
balancing mass)
[kgJ
Permissible
residual moment
[N*cm]
HK 36 R, TS, TC, TIS, TIC
horizontal stabilizers no.
HF 1 through HF 1 7
2.45 to 3.00
90 to 1 1 2
H K 36 R , TS, TC, TIS, TIC
horizontal stabilizers no. HF 1 8 and
subsequent
2.25 to 2.80
1 00 to 122
HK 36 TIC-ECO
2.40 to 2.90
76 to 1 06
5.30 to 6.55
1 00 to 1 60
HK 36 TIC-ECO
4.75 to 5.80
120 to 1 50
Serial Nos. 36.301 through 36.516
2 .30 to 2.75
1 00 to 125
Serial Nos. 36.5 1 7 and subsequent
2.80 to 3.50
50 to 83
HK 36 TIC-ECO
2.90 to 3.60
30 to 75
Airplane
Rudder
elevator
rudder
ailerons
WARNING
Contact the manufacturer before modifying the mass balancing!
NOTE
All moments in the above table are tail heavy.
Doc. No.
Issue
Rev. No.
Date
Source
Page No.
3.02.21
May 17, 1 993
10
1 5 Jun 1 998
S8 50/5
4.21
v�
"Diamond
AIRCRAFT
Other Work
4.14 PITOT-STATIC SYSTEM
The instruments in the instrument panel are accessible after removing the instrument panel top
cover. The following sketches illustrate the connections of the instruments.
HK 36 R Serial Nos. through 36.331
Water removal: remove rudder; remove caps from drain tubes. For legend, see Page 4.24.
2
3
8
Doc. No.
Issue
Rev. No.
Date
Source
Page No.
3.02.21
May 1 7, 1 993
10
1 5 Jun 1 998
S8 50/5
4.22
"'Diamoll1d
�
AIRCRAFT
Other Work
HK 36 R, Serial Nos. 36.332 and subsequent
Water removal: open handhole lid on fuselage tube bottom side; disconnect and empty filters.
for legend, see Page 4.24.
Doc. No.
Issue
Rev. No.
Date
Source
Page No.
3.02.21
May 1 7, 1 993
10
1 5 Jun 1 998
S B 5015
4.23
�Diamond
T
AIRCRAFT
Other Work
HK 36 TS, TC, TIS, TIC, TIC-ECO
Water removal: open hand hole lid on fuselage tube bottom side; disconnect and empty bypass
lines.
8
6
Legend
1 Altimeter
2 Airspeed indicator
3 Vertical speed indicator
4 Compensator nozzle and Pitot tube with static pressure sensor
5 Static pressure (blue)
6 Total head (green)
7 Nozzle (total energy; red)
8 Equalizing reservoir 0.45 liters (approximately 1 US pt.) (blue or colorless)
9 Water drain
Doc. No.
Issue
Rev. No.
Date
Source
Page No.
3.02.21
May 1 7 , 1 993
10
1 5 Jun 1 998
SB 5015
4.24
.Diamond
AIRCRAFT
Other Work
4.1 5 PARKING FOR OVER 30 DAYS
4. 15.1 PRESERVATION
For standing periods over 30 days, the following tasks must be carried out:
Once only
( 1 ) Engine . . . . . . . . . . . . . . . . . . . preserve in accordance with the Operator's Manual for
the Rotax 912 A or the Maintenance Manual for Rotax
Engine Type 9 1 4 F, respectively
(2) Fuel system . . . . . . . . . . . . . . . fill up completely
(3) Tires . . . . . . . . . . . . . . . . . . . . . wipe dry and spray with tire protector
(4) Battery . . . . . . . . . . . . . . . . . . . remove
(5) Lubricated areas . . . . . . . . . . . . lubricate in accordance with Lubrication Schedule
(6) Cabin . . . . . . . . . . . . . . . . . . . . ventilate
Weekly
( 1 ) Fuel system . . . . . . . . . . . . . . . remove water deposit using drainer
(2) Wheels . . . . . . . . . . . . . . . . . . . turn through 3-4 revolutions
(3) Tires . . . . . . . . . . . . . . . . . . . . . visually inspect for obvious underinflation
(4) Brakes . . . . . . . . . . . . . . . . . . . operate 3-4 times
4.15.2 RETURNING TO OPERATION
( 1 ) Battery . . . . . . . . . . . . . . . . . . . charge and install
(2) Engine . . . . . . . . . . . . . . . . . . . return to operation in accordance with the Operator's
Manual for the Rotax 912 A or the Maintenance
Manual for Rotax Engine Type 9 1 4 F, respectively
(3) Canry out daily inspection in accordance with the Flight Manual
Doc. No.
Issue
Rev. No.
Date
Source
Page No.
3.02.21
May 1 7, 1 993
10
1 5 Jun 1 998
SB 50/5
4.25
�Diamomi
�
AIRCRAFT
HK 36 R, TS, TC, TIS , TIC, TIC-ECO
Other Work
4.16 PLACARDS AND INSCRIPTIONS
Apart from the fire·resistant identification plate, the following placards are attached:
Placard
Remark
Location
if the airspeed indicator is calibrated in kmJh:
Manoeuvring speed at max. gross weight,
VA =
1 76 kmlh
Min. useful load on the seats,
full tank, no baggage
full tank, 1 2 kg baggage
irthe airspeed indicator is calibrated in Ids.:
instrument panel
all models
except HK 36 TTC-ECO
full tank, no baggage
full 1ank, 12 kg baggage
Doc. No.
Issue
Rev. No.
Date
Source
Page No.
3.02.21
May 1 7, 1 993
10
1 5 Jun 1 998
SB 5015
4.26
"Diamond
v
AIRCRAFT
Other Work
Remark
if the airspeed indicator is calibrated in kmJh:
VA
=
1 76 kmlh
1 0 kg (22 lbs.) fuel. no baggage
Min. useful load on the seals,
10 kg (22 lbs.) fuel. 30 kg (66 lbs.) baggage
Maximum pennisslble useful road
if the airspeed indicator is calibrated in kts.:
instrument panel
H K 36 TIC-ECO only
rearward side of baggage
compartment
all models
except HK 36 TIC-ECO
rearward side of baggage
compartment and outside
next to baggage door
2 pes.
next to air brake levers
tail wheel models through
Serial No. 36.516 only,
2 pes.
next to air brake levers
tail wheel models above
Serial No. 36.516 and tricycle
models only,
2 pes.
Manoeuvring speed at max.. gross weight,
10 kg (22 lbs.) fuel. no baggage
10 kg (22 lbs.) fuel. 30 kg (66lbs.) baggage
Maximum pennissible useful load
Tie baggage down,
max. 1 2 kg (26 Ibs.)
Tie baggage down,
max. 30 kg (66 Ibs.)
Air Brakes - pull through completely
to actuate wheel brakes
Air Brakes
Full Throttle
HK 36 TIC-ECO only.
throttle quadrant
Doc. No.
Issue
Rev. No.
Date
Source
Page No.
3.02.21
May 17, 1 993
10
1 5 Jun 1 998
SB 5015
4.27
•Diamond
AIRCRAFT
Placard
Turbo
Control
ON
I
I
OFF
Carburetor Heat
ON
ON
Choke
8
Propeller Speed Control
Take-Off
Cruise
Feather
Fuel Valve OPEN
Fuel Tank
Selector Valve
colored red,
models with Rolax 9 1 4 F only
instrument panel,
RH side
Choke
pull - ON
I
Remark.
Location
EJ
OFF
I I
Other Work
I
I
throttle quadrant
throttle quadrant
except models with hydraulic
propeller speed control
Instrument panel,
center section
models with hydraulic
propeller speed control only
throttle quadrant
models with HO V<f52
propeller only
throtlle quadrant
models with MTV 21
propeller only
I
next to fuel shut-off valve
�I 0
next to fuel tank selector
valve
CLOSED
H K 36 TIC-ECO only
Doc. No.
Issue
Rev. No.
Date
Source
Page No.
3.02.21
May 1 7, 1 993
10
1 5 Jun 1 998
SB 50/5
4.28
�Diamond
..
AIRCRAFT
Placard
I
LH and RH air vent
Cowl Flap pull to close
I
Master Switch
OFF
instrument panel,
center section
I
I
I
I
Power Flight
Soaring
instrument panel,
center section
ON
ON
ON
ON
ON
ON
ON
ON
ON
Fuel
Pump
ACL
Position
Light!>
Landing
Ught
Horizon
Gym
Tum &
Bank Ind.
ADF
DME
I
.....,
.
Power Fit.
SOllcing
Fuel pro
ON
ON
ON
ON
Fuel Position ACL Landing
Light
Pump Lights
I
ON
IC
Differenlial
B r a k i n g
I
Doc. No.
Issue
Rev. No.
3.02.21
May 1 7, 1 993
10
H K 36 R only
I
instrument panel,
center section
ON
2 pes.
instrument panel,
center section
Cabin Heat
pull - O N
I
I
Remark
Location
I
Cabin Air
Other Work
instnument panel,
center section
Date
1 5 Jun 1 998
H K 36 R only
shaded areas are red on
placards;
uDifferential Braking" is
optional for H K 36 TS
HK 36 TS and
HK 36 TC only
Source
Page No.
S8 50/5
4.29
HK 36 R , TS, TC, TIS, TIC, TIC-ECO
"Diamond
T
AIRCRAFT
Placard
I
ON
PawerPtt.
.......,
&loring
Remark
Location
ON
ON
Pump
Fuel
ACL Position Landing
ON
Turbo
ON
I
shaded areas are red on
placards
H K 36 TISand
H K 36 TIConly
instrument panel,
center section
ACL
ON
Fuel Pump
ON
Pas. Lights
ON
Avionics
ON
Power FIt. Master Switch
ON
ON
I
I
Soaring
instrument panel,
LH section
(next to swilches)
I
Gener.
Fuel Press.
Boost
TCU
H K 36 TIC-ECO only
I
Temp.
Fuel QIy.
Instrument panel,
LH section
(next to waming and caution
lights)
Ba!!e.y
Gener.
GeneT.
Other Work
TCU
Contr.
Fuel
F'ump
Oil Temp.
Fuel LH
Oil FIr., CHT
Fuel RH
ACL
instrument panel,
RH section
(next to circuit breakers)
H K 36 TIC-ECO only
�os.
Lights
XF'OR
COMINAV
H K 36 TIC-ECO only
Doc. No.
Issue
Rev. No.
Date
Source
Page No.
3.02.21
May 17, 1 993
10
1 5 Jun 1 998
SB 5015
4.30
�Diamond
v
AIRCRAFT"
Location
Placard
-
Oil
press.;
Fuel Qty.
-
Oil
temp.
-
-
_
-
-
_
Gener.
-
Other Work
Remark:
XPDR
- VOR
-
instrument panel,
RH section,
next to circuit breakers
H K 36 R only
instrument panel,
RH section,
all models
except H K 36 R
and H K 36 TTC-ECO
Radio
Main
Bus
Fuel Qty.!
Oil Temp.
-
Gener.
Control
Oil
Press.!
CHT
Generator
Batteryl
Main CB
Doc. No.
Issue
Rev. No.
Date
Source
Page No.
3.02.21
May 1 7, 1 993
10
1 5 Jun 1 998
SB 5015
4.31
•Diamond
AIRCRAFT
Placard
-
Attitude
Gyro
-
Other Work
Remark
Location
Direction
Gyro
instrument panel,
RH section,
all models
except HK 36 R,
optional
instrument panel,
RH section,
all models
except HK 36 R,
optional
instrument panel
optional
EJ EJ �
instrument panel,
center section
all models
except HK 36 R,
optional
1 6� 1 8
instrument panel
optional
cylinder head temperature
indicator
models with Rotax912 A only
-
111-
Turn &
Bank
COM
GPS
MKR
I G
1 3
1
t][J t]D
GPS
NAV
1-
XPDR
I
GPS not approved for primary navigation.
I
IC-Volume
I
~
1 50 DC
I
CHT
I
I
cylinder head temperature
indicator
Doc. No.
Issue
Rev. No.
Date
Source
Page No.
3.02.21
May 1 7, 1 993
10
1 5 Jun 1 998
SB 5015
4.32
�Diamond
V�
AIRCRAFT
Placard
I
Gen. Contr.
I
Fuel Pressure
oil temperature indicator
usable
53 1 (14 gal.)
on fuel quantity indicators
max. difference UR:
50 % = 27 1 (7.1 gal.)
next to fuel quantity
indicators and next to fuel
selector valve
Prop. Pitch
Control
Tow-Rope
I
propeller only
above
optional, light is not required
caution light for towing
in all countries
device
I
Tow-Rope Release
Nose Down
models with HQ V352
on propeller feather grip
I
-
Trim
-
Nose Up
on release lever for tow-rope
I
H K 36 TTC-ECO only.
2 pes.
only
control unit
I
H K 36 TTC-ECO only.
2 pes.
models wUh MTV 1 propeller
next to prop.
PROPELLER FEATHER
I
H K 36 R only
instrument panel
Temp.
I
Remark
Location
�
I
Other Work
optional
center console next to trim
lever
CANOPY JETTISON:
Pull both handles fully
rearward�
next to levers for canopy
Push canopy up and
jettison
colored red
2 pes.
away,
�
Doc. No.
Issue
Rev. No.
Date
Source
Page No.
3.02.21
May 1 7, 1 993
10
1 5 Jun 1 998
S8 50/5
4.33
�Diamond
�
AIRCRAFT
Placard
55 1
55 1
Aviation Grade 1 00 LL or
MOGAS (96 oct. ROZ)
usable: 54 [
next to tank filler cap
H K 36 R with
S8 36 or
S 8 36/1
not carried out
next to tank filler cap
H K 36 R with
S8 36 or
S 8 36/1
carried out
ne>Ct to tank filler cap
H K 36 TS, TC, TIS, TIC
only
next to tank filler caps
HK 36 TIC-ECO only,
2 pes.
on or next to
brake nuid reservoir(s)
1 or 2 pes.
MOGAS (96 oct. ROZ)
usable: 79 1
MOGAS (96 oct.) or
unleaded Auto Super (95 oct.)
usable: 54 1
or
80 1
Remark
Location
or
80 1
Other Work
AViation Grade 1 00 LL or
MOGAS (96 oct.) or
unleaded Auto Super (95 oct.)
usable: 79 1
79 1 (20.9 US gaL)
55 1 (1 4.5 US gat.)
AVGAS 100 LL, MOGAS,
Auto Super min. 95 ROZ
leaded or unleaded
usable: 77 1 (20.3 US gal.)
AVGAS 100 LL, MOGAS,
Auto Super min. 95 ROZ
leaded or unleaded
usable: 53 1 (1 4.0 US gaL)
Hydraulic
Fluid 4
Ultimate load
of breaking piece:
300 daN (674 Ibs.)
or
Ultimate load
of breaking piece:
400 daN (899 I bs.)
-
towing assembly mount
models with tOWing assembly
only (optional)
models with Rotax 912 A:
300 daN
models with Rotax 914 F:
400 daN
Doc. No.
Issue
Rev. No.
Date
Source
Page No.
3.02.21
May 1 7, 1 993
10
1 5 Jun 1 998
SB 50/5
4.34
•Diamond
AIRCRAFT
Placard
I
I
I
I
I
2.1 bar
3.1 bar
2.3 bar
1 .8 bar
Oil 3.0 I
II
II
II
II
I
30 psi
45 psi
33 psi
26 psi
Other Work
Remark
Location
I
next to main wheels
tail wheel models only
I
on rudder beside tail wheel
tail wheel models only
I
next to main wheels
tricycle models only
I
next to nose wheel
tricycle models only
SAE 1 5 W-'IO
or according to
Flight Manual
oil liller cap
CAUTIONI
DO NOT USE AVIATION
GRADE ENGINE OIL!
I
Coolant
Gen. Relay
I
F 2439-01
I
Main Fuel Pump
F 2820-02
Gen. C�ntro Relay
F 2437-01
Parking
Brake - pull
oil inspection lid in upper
cowling, inside
colored red
coolant dispatcher vessel;
equalizing reservoir
2 pes.
I
I
RH side of firewall,
next to glass fuses
models with Rolax 914 F only
next to parking brake button
-
Doc. No.
Issue
Rev. No.
Date
Source
Page No.
3.02.21
May 1 7, 1 993
10
1 5 Jun 1 998
SB 50/5
4.35
�Diamond
Y
AIRCRAFT
Other Work
0
Localiin
Remark
START CHECK
1.
2.
3.
4.
5.
6.
7.
8.
9.
1 0.
11.
12.
1 3.
Mass & Balance checked
Main bolts secured
Fuel valve OPEN
Fuel quantity checked
Canopy locked
Seat hamess on & secure
Propeller check
Magneto check
Carburetor heat OFF
Controls free
Trim checked
Parking brake released
Air brakes locked
instrument panel
models with Rotax 912 A only
START CHECK
1.
2.
3.
4.
5.
6.
7.
8.
9.
1 0.
11.
12.
1 3.
14.
15.
Main bolts secured
Fuel valve OPEN
Canopy locked
Seat harness on & secure
Propeller check
Magneto check
Carburetor heat OFF
Controls free
Trim checked
Air brakes locked
Turbo control ON
Fuel booster pump ON
instrument panel
H K 36 TIS and H K 36 TIC
only
Doc. No.
Issue
Rev. No.
Date
Source
Page No.
3.02.21
May 17, 1 993
10
1 5 Jun 1 998
SB 50/5
4.36
�Diamond
v
AIRCRAFT
. ..
.
"
.•
. • .. .. "
'
Placard .'
. . . ..
. . . '" (
.
.
..
"
. '
Location . ' . .. .
" , .'
Other Work
.
. ' .···
Remark
'
, . ..
START CHECK
1.
2.
3.
4.
5.
6.
7.
8.
9.
1 0.
11.
12.
1 3.
1 4.
1 5.
1 6.
1 7.
I
Main bolts secured
Baggage door secured
Fuel valve OPEN
Fuller tank selected
Canopy locked
Seat hamess on & secure
Propeller check
Magneto check
Carburetor heat OFF
Controls free
Trim neutral
Air brakes locked
Turbo control ON
Fuel booster pump ON
No smoking
instrument panel
I
HK 36 TIC-ECO only
instrument panel
Aerobatics and Spin
are forbidden!
instrument panel
Landing Light - max. operation:
25 % of engine operating time,
no longer than 5 minutes
Landing Light and Position Lights
may only be used for
1 0 % of engine operating time
instrument panel
models with Rotax 912 A
only,
optional
instrument panel
models with Rolax 914 F
only,
optional
Doc. No.
Issue
Rev. No.
Date
Source
Page No.
3.02.21
May 1 7, 1 993
10
1 5 Jun 1 998
SB 50/5
4.37
.
"
�Diamol1d
T
AIRCRAFT
H K 36 R , TS, TC, TIS, TIC, TIC-ECO
Placard
Other Work
Location
MANIFOLD
PRESSURE
max. 30
2500
max. 30
2400
max. 24
2200
max. 22
2000
max. 1 7
1 500
Remark
RPM
MANIFOLD
PRESSURE
max. 30
2500
max. 30
2200
max. 27
2 1 00
2000
max. 26
max. 2 1
1 500
instrument panel
models with MTV 1 propeller
only
instrument panel
models with HO V352
propeller only
RPM
The differential bra king system may only be activated during taxiing.
I
lail wheel models, optional
instrument panel
Differential
Bra king
next to
differential braking switch
tail wheel models, optional
WARNING
Use air brake fixture (hands off) only up to 150 km/h!
AlB may extend beyond fixture at higher speeds.
I
instrument panel
or canopy frame, LH side
all models
except H K 36 R
Doc. No.
Issue
Rev. No.
Date
Source
Page No.
3.02.21
May 17, 1 993
10
1 5 Jun 1 998
SB 50/5
4.38
�Diamol1d
v
AIRCRAFT
Placard
Other Work
Remark
Location
Power connector
should be used
only on the ground.
Maximum load:
2A
instrument panel
optional
This airplane must be operated as a utility category airplane in compliance with the
operating limitations as stated in the form of placards, markings, and manuals.
MAXIMA:
MANEUVERING SPEED (lAS)
GROSS WEIGHT
FLIGHT LOAD FACTOR
20 m (65 ft.). Flight into
imO'Ml
176 kmIh (95 Ids. I 109 mph)
no kg (1 698 Ibs.)
+5.3/-2.65
No acrobatic maneuvers, including spin, approved. Altitude loss in a stall recovery:
icing conditions prohibited. This airplane is certified for
lhefuUavving flight operations as of date of original airworthiness certificate: DAY-VFR.
canopy frame, LH side
required for U.S. registered
Serial Nos. only
canopy frame, LH side
required for U.S. and
Canadian registered
Serial Nos. only
VNE (lAS)
[km/h] [kts.] [mph]
Altitude
[ft.]
[m]
- 2000 - 6500
- 3000 - 9800
- 4000 - 1 3 1 00
- 5000 - 1 6400
- 6000 - 1 9600
261
246
233
221
210
141
1 33
1 26
1 19
113
1 62
1 53
1 45
137
1 30
Doc. No.
Issue
Rev. No.
Date
Source
Page No.
3.02.21
May 1 7, 1 993
10
1 5 Jun 1 998
SB 50/5
4.39
•Diamond
AIRCRAFT
Repair
Instructions
SECTION 5
REPAIR INSTRUCTIONS
5.1 DESCRIPTION OF THE G FRP PARTS
5.1 . 1 WING
Skin
The primary structure of the wing consists of a sandwich shell and a spar. The skin is very
strong, in order to allow for the high aerodynamic torsion effect on the wing. The skin consists
of diagonal glass fabric only. The support structure is Conticell 60 or Divinycell H 60, a mm
e/'6 in.) thick.
Spar (Serial Nos. 36.301 through 36.51 6)
The caps of the I-shaped spar consist of glass rovings. The sandwich web consists of diagonal
layers and Rohacell 71 or Divinycell H 60, a mm
(5/,6 in.) thick. In the area of the spar, the wing
skin sandwich is recessed, so that the spar caps lie on the outer skin.
Spar (Serial Nos. 36.51 7 and subsequent)
The caps of the I-shaped spar consist of CFRP UD bands. The sandwich web consists of
diagonal layers and Divinycell H 60, a mm
sandwich is not recessed.
(5/'6 in.) thick.
In the area of the spar, the wing skin
Doc. No.
Issue
Rev. No.
Date
3.02.21
May 1 7 , 1 993
10
1 5 Jun 1 99a
Source
SB
50/5
Page No.
5.1
•Diamond
AIRCRAFT
Repair
Instructions
Wing tanks (H K 36 TIC-ECO only)
I n front of the wing spar, a GFRP trough is bonded to the wing upper skin. Copper mesh
laminated into the walls provides electrical conductivity.
NOTE
In deviation from the rest of the structure, vinyl ester resin is used
for the wing tanks (instead of epoxy resin).
The part of the wing skin that forms the upper wall of the fuel tank is covered with one 92125
layer impregnated with vinyl ester resin.
Wing-Fuselage connection
The spar stump penetrates the fuselage to the centerline. Each wing is attached to the fuselage
with three bolts. The removable main bolt is placed close to the fuselage centerline and lies in
the flight direction. A- and B-bolts are attached to the root rib of the fuselage in transverse
direction.
The main bulkhead of the fuselage serves as a bridge for the two spars. The wing root rib and
the spar stump web are fabricated in one piece. Repairs of the wing spar, the spar stump and
the root rib may only be carried out by the manufacturer or a repair station authorized by the
manufacturer.
Wing removal is described in the Flight Manual, Section 4. If the airplane is equipped with the
optional wing-folding mechanism, the wings remain connected to the fuselage through the
telescopic tubes after de-rigging. Remove the two spring dowel sleeves from the joint of the A
bolt and the telescopic tube for a complete wing removal.
Doc. No.
Issue
Rev. No.
Date
Source
Page No.
3.02.21
May 1 7 , 1 993
10
1 5 Jun 1 99a
SB 5015
5.2
�Diamond
�
AIRCRAFT
Repair
Instructions
Canticell CC60 ar
1 x 92110 *
2x 92125 lit
Canticell CC60 ar
Rahacell 71 ar
Divin cell H60
Divin cell H60
2x 92125 ,J(
.. "
-' - �
-
.�.,
"
.
. ,
. . .
.
. . �. ," . " .
2 x 92126 'i/I!
2 x 92125 1\1:
1 x 92110;1J(
Wing (Serial Nos. 36.301 through 36.516)
Fiber direction: ±45° to spar.
CFRP UD's
1 x 92110 *
"
' " •• - • #
-
•
,-
•
.
..
.
..
..
.
.
.
.
, ...
.
�. ..
-. .
.
-.-
- '
.
'- ..
.
.
".
.
Wing (Serial Nos. 36.517 and subsequent)
Fiber direction: ±45° to spar.
Doc. No.
Issue
Rev. No.
Date
Source
Page No.
3.02.21
May 1 7 , 1 993
10
1 5 Jun 1 998
SB 50/5
5.3
•Diamond
AIRCRAFT
Repair
Instructions
5.1.2 AILERONS
Construction
The aileron consists of two half-shells in sandwich design. Carbon fiber cloth is used beside
glass fiber cloth to increase torsional stiffness. The fiber direction is 45 0 to the aileron axis.
The aileron is attached to the wing by means of five CFRP hinges. These hinges are bonded to
the wing, and integrated into the upper skin of the aileron.
Removal of the aileron is only necessary when major damage occurs to the aileron or to the
wing in this area.
To remove the aileron, the push-rod which is connected to the aileron hom with an M6 bolt must
be disconnected. Then remove the adhesive tape and deflect the aileron upward, exposing the
hinges. Remove safety pins, extract hinge bolts.
To install the surface, reverse the procedure. The gap between aileron and wing must be sealed
(e.g. with adhesive cloth tape) with the wing removed from the fuselage and the aileron
deflected to its full down position.
Doc. No.
Issue
Rev. No.
Date
Source
Page No.
3.02.21
May 1 7, 1 993
10
1 5 Jun 1 998
SB 50/5
5.4
.fII>Diamond
AIRCRAFT
Repair
Instructions
Repair infonnation
If the ailerons have been damaged, the areas around the hinges must be inspected thoroughly.
After the aileron has been repaired, the mass and the residual moment must be re-detennined
before installing the surface. Refer to Paragraph 4. 1 3, Masses and Residual Moments of
Control Surfaces.
1 x 92110 *
1 x 98141
, . .
.
+
..
.
.
Rohacell 51 or
Divinycel/ H 60 (3 mm thick)
1 x 92110 Vfl!.
1 x 98141>1!'
Doc. No.
Issue
Rev. No.
Date
Source
Page No.
3.02.21
May 1 7, 1 993
10
1 5 Jun 1 998
S8 50/5
5.5
�Diamond
'V�
AIRCRAFT
Repair
Instructions
5.1.3 RUDDER
Construction
The rudder consists of two GFRP sandwich skins which have 45° fiber direction only. Two
roving stringers (HK 36 R) or two UD bands (other models) run over the whole length of the
rudder and from the lower mounting rib rearward to the trailing edge. Several rigid foam ribs
reinforce the rudder. The lower edge serves as a buffer and has a very thin skin.
The lower rudder mount is a C-shaped metal plate to which the rudder cables and eventually the
springs for the tail wheel steering are attached. This mounting plate is screwed to the lower
mounting rib which transmits control forces into the rudder.
The rudder upper hinge is a brass bush, bonded into the upper rudder mounting rib. The hinge
is completed by a 6 mm
(,5/64 in.) bolt which is attached to the vertical stabilizer.
To remove the rudder, first remove the horizontal stabilizer. Separate the mounting plate from
the rudder by removing the two M6-nuts. Swing the rudder approx. 2 em
remove it by lifting.
('/4 in.) rearward, then
To install the rudder, reverse the procedure.
Doc. No.
Issue
Rev. No.
Date
Source
Page No.
3.02.21
May 1 7, 1 993
10
1 5 Jun 1 998
SB 50/5
5.6
Ififflil.
T lJiamond
AIRCRAFT
Repair
Instructions
HK 36 R rudder
lower edge: only 2*921 1 0, 45'
1 stringer = 51
*
EC 9 - 756 tex (K43) or 1 6 · EC 1 0 - 2400 tex (K43)
2 x 921 1 0*
H K 36 TS, TC, TIS, TIC and TIC-ECO rudder
Doc. No.
Issue
Rev. No.
Date
Source
Page No.
3.02.21
May 1 7, 1 993
10
1 5 Jun 1 998
SB 5015
5.7
�Diamond
T
AIRCRAFT
Repair
I nstructions
5.1.4 HORIZONTAL TAIL
Construction
The horizontal stabilizer is a sandwich design type. Two root ribs transfer the torsional loads of
the skin to the bolts. A spar absorbs bending and shearing loads. Two consoles which are able
to hold the wing support fixtures are attached to the spar web.
The horizontal stabilizer mount has two bolts lying in flight direction. Two swing bearings
mounted in the web of the horizontal stabilizer are slipped onto these bolts. The forward
fastening of the horizontal stabilizer is a bolt with hexagon socket head. It goes through the
fitting near the nose of the stabilizer and is screwed into a nut which is fixed to the auxiliary web
of the vertical stabilizer. This is done after slipping the horizontal stabilizer onto the two bolts.
The hexagon socket bolt is secured with a locking ring.
The GFRP sandwich elevator is held in place through five hinges, which are attached to the
rearward web of the horizontal stabilizer.
Elevator removal
HK 36 R:
Remove lock wires; remove two outer bolts and nut of center hinge; remove
elevator in a rearward direction.
other models: Remove maintenance hole covers on horizontal stabilizer tips; remove split pins
and extract outer joumals; remove both attachment bolts for elevator horn;
remove elevator in rearward direction.
Elevator installation
For installation, reverse the procedure.
CAUTION
Do not forget the safetying!
Doc. No.
Issue
Rev. No.
Date
Source
Page No.
3.02.21
May 1 7, 1 993
10
1 5 Jun 1 996
SB 5015
5.6
.,Diamond
AIRCRAFT
Repair
Instructions
Repair information
After repair or repainting of the elevator, mass and residual moment must be re-determined (see
Paragraph 4. 1 3).
I
spar caps: to y = 650 mm (25.6"): 2 stringers
1 stringer
to tip:
i?':.
. .
�
�
l\
\
I
2 x 92 1 1 0 lK
Conticell 60, 8 mm (5/1 6') thick
1 x 921 1 0 )JK
'"
.
rearward web:
2 x 92125 )JK
j
.I , .
I
V{ •
\
.......
2 x 92125 lK
Rohacell 7 1 ,
8 mm (5/1 6") thick
I
2 x 921 1 0 lK
Rohacell 5 1 ,
3 mm (1/8") thick
1 x 921 1 0 lK
Horizontal tail of the HK 36 R
1 stringer = 51 ' EC 9 - 756 tex (K43) or 1 6 ' EC 1 0 - 2400 tex (K43)
spar caps made of GFRP UD's and
92125 )1[( in different lengths
2 x 92110 �
Divinycell H60, 8 mm thic
1 x 92110 �
92125
different
lengths
2 x 92110 �
Divinycell H60, 3 mm thie
1 x 92110 �
Horizontal tail of the HK 36 TS, TC, TIS, TIC, TIC-ECO
Doc. No.
Issue
Rev. No.
Date
Source
Page No.
3.02.21
May 1 7, 1 993
10
1 5 Jun 1 99B
SB 50/5
5.9
•Diamond
AIRCRAFf
Repair
Instructions
5.1.5 FUSELAGE
The fuselage is manufactured in GFRP semi-monocoque construction with several bulkheads
but without rigid foam or supporting stringers.
The number of layers and their orientation depend on the load in the respective cross sections.
Therefore, the fuselage skin has very different laminate thicknesses and fiber orientations. Prior
to a repair of the fuselage skin or the built-in parts, contact the manufacturer and order a
fuselage layup plan.
Doc. No.
Issue
Rev. No.
Date
Source
Page No.
3.02.21
May 17, 1 993
10
1 5 Jun 1 998
S8 50/5
5. 1 0
w
g
c
en
0
CD
O
OJ
-
:"
z
p
;0
CD
CD
C
III
III
0
0
fl
z
p
�
�
Z
P
CD
-U
OJ
!Jl co
en
CD
U1
a
U1
�
CD
CD
ex>
t-
C
::J
�
U1
�
a
�
CD
CD
W
�
-.."
s:
OJ
'<
�
'"
'"
a
ring frame
no. 2
ivertical sfilbiliziiiStit'fener
(not all Serial Nos.)
reinforcement for
towing device
vertical stabilizer web
auxiliary web
-;
en
-;
0
-
:::j
:::j
-en
:::j
o
Q.
III
_.
::J
::J
III
"
c
'
""0
OJ.
_
;0
CD
Q
C m
>- 0
r
0
�z
m _0
z
o
�
>-
m
s:
>z
-;
I
;>;;
w
Ol
S;:
;o
z
;0
-u
>-
�i.
�8
tl
s'
�
4'ADiamond
v
AIRCRAFT
Repair
Instructions
5.1.6 MAIN LANDING GEAR MADE OF GFRP
All tail wheel models are equipped with a main landing gear strut made of GFRP.
Description: removal and installation
See Article 2.2. 1
Repair information
Due to the complex structure of the GFRP strut, even the manufacturer cannot repair it in any
case. Before repairing the landing gear strut, contact the manufacturer.
Doc. No.
Issue
Rev. No.
Date
Source
Page No.
3.02.21
May 1 7, 1 993
10
1 5 Jun 1 998
SB 50/5
5. 1 2
�Diamond
v
AIRCRAFT
Repair
Instructions
5.2 REPAIR WORK, GENERAL
5.2.1 DAMAGE CLASSIFICATION
Should the airplane become damaged, the first thing to do is to detemnine the extent of damage.
White areas indicate damage to GFRP laminate.
After a hard landing, the Powered Sailplane should be inspected, even if no visible damage is
apparent. In particular, cracks in the paint finish indicate possible damage to the outer laminate
or the GFRP parts built in (e.g. bulkheads).
Should there be doubt whether the crack area is damaged, the paint must be removed. Steel
fittings, such as shear bolts, horizontal tail mount, etc. must be inspected thoroughly for cracks
and white spots in the adjacent structure; sometimes the crack continues beneath the surface
where it is invisible.
Should questions relating to the damage arise, contact the manufacturer.
In the follOwing cases, repair work may only be performed by the manufacturer or an authorized
repair station:
•
damage to the primary structure, e.g. wing spar, horizontal stabilizer spar, main bulkhead,
landing gear, root rib;
•
damage to fittings of wing, main bulkhead, stabilizer, landing gear, engine, etc.;
•
two-dimensional damage to the skin of wing, fuselage or stabilizer, if the diameter is greater
than 1 5 cm (57/8 in.);
•
in particular: broken fuselage tube, broken wings, broken control surfaces.
Doc. No.
Issue
Rev. No.
Date
Source
Page No.
3.02.21
May 1 7, 1 993
10
1 5 Jun 1 998
S8 50/5
5. 1 3
�Diamond
v#7fT
AIRCRAFT
Repair
Instructions
5.2.2 REPAIR OF FIBER COMPOSITE PARTS, GENERAL
Repair work must be performed extremely carefully and only by authorized personnel. The outer
skin is a load carrying member. Any failure of this structure can have serious consequences.
It is very important that the resin mixture has the exact proportion (± 0.5 %) and that only clean
vessels are used. Do not use brushes that have been in contact with oil, 'grease or something
similar, even if they have been washed. New brushes are best utilized.
The ratio of glass weight to resin mixture weight should be approximately 50:50. Sand the repair
area shortly before laying the wet laminate to prevent the surface from getting dirty. The sanded
areas must not be touched and must be cleaned thoroughly with a vacuum cleaner after
sanding. Before laying the laminate, lightly coat the repair area with resin.
As when working with plywood, the orientation of the fibers (parallel or diagonal) is very
important to ensure the strength of the laminate. The number of cloth layers that is required to
provide the original strength can be determined from the layup plans which are available from
the manufacturer. A piece of old damaged laminate can be removed and set on fire. The resin
will burn and the glass fabric remains. Cloth types, number of layers and orientations can then
be identified.
Even though chamfering takes effort, the time should be taken to sand until the cloth patches
are flush. They must not be sanded away for aesthetic or other reasons).
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5.14
.Diamond
AIRCRAFT
Repair
I nstructions
In order to reduce hardening time, heat may be applied with a heat fan. Build a small foil tent
over the repair area and blow hot air into it. This will prohibit local overheating, which would
cause blisters in the fabric.
It is important to work up the resin before the potlife is over (at least 20 minutes at 20 °C
(68 OF), see resin manufacturer's specifications). To ensure the full strength of the plastic, it is
necessary to cure the repaired area for 14 hours at 55 °C (131 °F). This may be done as
described above.
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5.15
"Diamond
�
AIRCRAFT
Repair
Instructions
5.3 DAMAGE TO G FRP SANDWICH PARTS
There are two common damages to sandwich parts:
•
only the surface (outer skin) is damaged
•
the whole sandwich construction (outer skin, rigid foam, inner skin) is broken
5.3.1 DAMAGE TO THE OUTER SKIN
The laminate might have separated from the rigid foam around the damage area. This area can
be determined by tapping. The outer skin that has separated is removed with a sanding disk, a
sanding block or a sharp knife. Then chamfer the fabric around the damage area with a sanding
block or a plane iron. The ratio of laminate thickness to chamfer length must be at least 1 :SO. In
case of the cloth 9212S, that means a chamfer of approximately 20 mm
(,3/16 in.) per layer.
After chamfering, the dust must be removed with a vacuum cleaner. The pores of the rigid foam
must also be open and clean. Should the area come in contact with oil or grease, clean.it with
uncontaminated carbon tetrachloride or acetone.
Damage to the rigid foam is repaired with resin and Microballoons using a spatUla. Lay the cloth
patches into the repair area in their respective orientations and impregnate them until the
surface has a matt finish. The largest patch comes first, the smallest is the last. Avoid dust and
grease!
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S.16
4ADiamond
v
AIRCRAFT
Repair
I nstructions
At room temperature, the resin hardens in approximately 24 hours. The area may then be
sanded (not the skin in the center, only the edges), primed, and painted.
5.3.2 DAMAGE TO THE ENTIRE SANDWICH
If the inner skin is damaged, first remove the outer laminate that has separated from the rigid
foam. The foam is then removed to the limits of bonding to the inner skin."ln order to repair the
inner laminate, another area of rigid foam must be removed until a rim of inner laminate at least
3
20 mm (1 /'6 in.) wide is available (chamfer ratio at least 1 :50).
The outer skin is then chamfered as described in Article 5.3. 1 , Damage to the Outer Skin. Clean
the inner skin from the rigid foam and chamfer it carefully.
J.
d
>
=
d
50
c. J - ""f...0 "' � ) o\
o O .;J o o� -- J
min 20 mm ( 1 311 6 " )
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5. 1 7
�Diamond
"'4p'
AIRCRAFT
Repair
I nstructions
For minor repair work, a thin piece of plywood is bonded to the inner skin from inside. The
plywood can be inserted through the skin if the hole has an elongated shape. A nail through the
p lywood aliows it to be held tightly against the inner skin (see sketch). The plywood must lie
close to the skin to prevent kinks in the fabric. Lay the cloth patches of the inner skin. Then fill
the hole with resin and Microbalioons. When hardened, sand the surface and lay the cloth
patches of the outer skin.
For repair of larger holes in a sandwich, it is recommendable to use a piece of rigid foam
(Conticeli 60, Rohaceli 71 , or Divinyceli H60) instead of the Microbalioons in order to save
weight. Prepare a piece of rigid foam that fits the hole exactly. The pores of the inner surface
should be closed with resin and Microbalioons with a spatula. Lay the inner laminate on the
insert. After hardening this insert can still be bent (use a fan heater if necessary). Sand the
insert and paste it in the hole using a mixture of resin and cotton flakes.
Sand the upper surface, close the pores with resin and Microbalioons and lay the outer
laminate. When this has hardened, sand (not the skin in the center, only the edges), prime, and
paint.
When using the foam insert, the plywood piece need not be used.
J
0
0
,..
0
0
. 0 1 ; . " . ', " .
° O D o L· · . · : ·. : . · .
'
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5.18
•Diamond
AIRCRAFr
Repair
Instructions
5.4 DAMAGE TO All-GFRP PARTS
5.4.1 CRACKS IN LEADING EDGE BONDS
CAUTION
Cracks in the paint on a leading edge bond necessitate a
thorough examination of the bond.
Cracks in the leading edge bond of a control surface
Cracks in the leading edge of a control surface are repaired by embedding a 921 1 0 layer,
observing the correct chamfer ratio.
Cracks in the wing leading edge bonds
(1)
Determine crack depth. I f the crack continues under the laminate of the outer skin:
Remove laminate and thickened resin until the end of the crack is reached.
Case 1 :
Crack does not continue under the laminate of the outer skin, no laminate
needed to be removed
Case 2:
A laminate strip with a maximum width of 1 0 mm ('Is in.) (parallel to the wing
leading edge) had to be removed.
Case 3:
A laminate strip wider than 1 0 mm ('Is in.) (parallel to the wing leading edge)
had to be removed.
(2)
Chamfer remaining laminate. Minimum chamfer lengths:
Case 1 :
1 5 mm (sis in.)
Case 2:
30 mm (1 '/4 in.)
Case 3:
60 mm (2'1, in.)
(3)
Remove sanding dust with a vacuum cleaner or compressed air.
(4)
If the repair area has come in contact with dirt or grease, it must be cleaned with
uncontaminated tetrachloride or acetone.
(5)
Fill groove with resin and Microballoons.
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5. 1 9
"Diamond
v�
AIRCRAFT
(6)
Repair
Instructions
Prepare impregnated laminate diagonally on plastic foil. See Item (2) for chamfer
lengths.
x
Case 1 :
2
Case 2:
2
Case 3:
4 x 92125 layers
x
921 1 0 layers
92125 layers
(7)
Apply resin to repair area, lay prepared laminate and remove plastic foil.
(8)
Allow to harden at room temperature, then cure repair area for 1 5 hours at 50 'C
( 1 22 'F).
(9)
( 1 0)
Sand repair area (not the skin in the center, only the edges).
Paint repair area.
5.4.2 OTHER DAMAGE TO ALL-GFRP PARTS
Chamfer the laminate around the hole (chamfer length per layer: 20 mm (13/ ' 6 in.), ratio of
laminate thickness to chamfer length: 1 :50) and clean the area (eventually with uncontaminated
carbon tetrachloride or acetone). Lay the cloth patches into the area, the largest patch first. In
case of larger holes, use a piece of plywood (as described in Article 5.3.2, Damage to the Entire
Sandwich), since wet laminate alone should not bridge more than 20 mm (13/,6 in.).
--L ::: 50
d -
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5.20
.Diamond
AIRCRAFT
I
Repair
Instructions
5.5 PAINTING
When the laminate in the repair area is hardened and cured (see Article 5.2.2), sand the area
with no. 80 sandpaper to remove the major unevenness. Smaller unevennesses are primed.
Then use no. 1 50 sandpaper to create a uniform rough surface. Clear repair area from dust,
parting compounds and other foreign substances. Apply primary coat and paint according to the
paint manufacturer's instructions.
Refer to Paragraph 5.9 for the selection of the proper paint.
I
5.6 REPAIR OF THE CANOPY
If a crack in the canopy is detected, a stop hole should be drilled immediately. This will prevent
the crack from going further. If the crack is longer than 1 0 m m ('/a in.), it should be repaired as
follows:
1 . Make a 3 m m Cia in.) wide V-groove along the crack.
2. Align and fix the edges.
3. Apply acrylic glass cement (e.g. R6hm Acrifix 92) to the groove. Since this cement hardens
only in light, it should be exposed to direct sunlight (hardening time 3 to 6 hours). If this is
not possible, an artificial light source may be used.
4. After the cement has hardened, remove the bead with a small milling cutter, sand the
repair area with smooth sandpaper and finally apply polishing paste.
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5.21
•Diamond
AIRCRAFT
Repair
Instructions
5.7 REPAIR OF FITTINGS AND CONTROL SYSTEM PARTS
Repair of fittings and control system parts must never be carried out without contacting the
manufacturer. The parts mostly consist of aviation steel 1 .7734 or 1 . 72 1 4 , which is only
weldable with T.I.G.-welding. Since the steel quality cannot be identified visually, it is necessary
to refer to the type design.
All major fitting bolts are also made of this material, quenched and tempered to condition 6.
Therefore, only the original bolts made by the manufacturer may be used.
5.8 PROPELLER REPAIR
I
Refer to the appropriate Propeller Manual (see list in Article 2.5.6).
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5.22
�Diamond
V
AIRCRAFT
HK 36 R, TS, TC, TIS, TIC, TIC-EGO
Repair
Instructions
5.9 MATERIALS USED AND SOURCES
Resin system
Resin
: L 285
Hardener
: 286
Mixture
: 1 00 parts resin and 38 parts hardener (by weight)
Supplier
: Scheufler
Am Ostkai 2 1 /22
0-70327 Stuttgart, Germany
Phone: +49/71 1 /323081
Fax: +49/71 1/3280041
Resin system for H K 36 TIC-ECO wing tanks
Resin
: Oerakane 470-36S
Hardener
: Butanox LPT
1 .5 to 2 parts per 1 00 parts resin (by weight)
Accelerator
: NL51 P (cobalt or violet)
0.3 parts per 1 00 parts resin (by weight)
Restrainer
: NLC- 1 0
0.5 parts per 1 00 parts resin (by weight)
Carbon powder : Ketjenblack (only for coloring) max. 2 parts per 1 00 parts resin (by weight)
Supplier
: Polychem HandelsgesmbH
Bahnhofsplatz 5
A-21 1 1 RGckersdorf, Austria
Phone: +43/2264/652 1 -0
Fax.: +43/2264/61 39
Rovings
Vetrotex glass silk rovings EC 1 0 - 2400 tex (K43) or EC 9 - 756 tex (K 43)
Supplier
: Rudolf Usner GmbH
Am Ausfemgenufer 4
A-5400 Hallein, Austria
Phone: +43/6245/81 5 1 6
Fax: +43/6245/8 1 5 1 6-40
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5.23
.Diamond
AIRCRAFT
Repair
Instructions
Glass fiber cloth
WLB No.
(German
aviation
standard)
Weave
8.4548.6
2/2 twill
163
8.455 1 .6
2/2 twill
280
8.4554.6
2/2 twill
390
8.4520.6
UD
220
8.4525.6
UD
425
/nterg/as
Mass per unit
area [g/m2]
Type
Porcher
Type
92110
917
92125
92140
92145
3063
Vorwerk
Type
95290
1 989
92146
All cloth types consist of alkali free E-glass with I 550 or PT 55 finish and comply with LN 9169
(German aviation standard).
Supplier for Interglas fabric
: Rudolf Usner GmbH (see above)
Supplier for Porcher fabric
: Porcher Industrietextilien GmbH
Holzgraben 1 3/ 1 5
0-52062 Aachen, Germany
Phone: +49/241/48225
Fax: +49/241 /48229
Supplier for Vorwerk fabric
: Saertex Wagener GmbH
&
Co KG
Industriestr. 9
0-48369 Saerbeck, Germany
Phone: +49/2574/8051
Fax: +49/2574/8231
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5.24
.Diamond
AIRCRAFT
Repair
Instructions
Carbon fiber cloth
WLB No.
(German
aviation
standard)
Weave
8.3520.8
2/2 twill
Interglas
Mass per unit
area [g/m"l
Porcher
Type
Type
Vorwerk
Type
98141
200
The cloth complies with LN 9 1 69 (German aviation standard).
Supplier: Rudolf Usner GmbH (see above)
Rigid foams
WLB No.
(German
Aviation
Standard)
Density
[kg/m"l
Thickness
[mm]
Divinycell Type
60
8
PVC rigid foam
Divinycell H 60
5.1460. 1
50
3
PMI rigid foam
Rohacell 5 1
5.1460.2
70
8
PMI rigid foam
Rohacell 71
Supplier for Divinycell
Rohacell Type
: Continental
C.U.P Gummi Ges.m.b.H.
Eisgrubengasse 4
A-2334 V6sendorf Sud, Austria
Manufacturer of Rohacell
: R6hm, Darmstadt, Germany
Supplier for Rohacell
: Thun und Hohenstein
Lamezanstr. 1 7
A-1231 Vienna, Austria
Phone: +43/1/61 6751 0-0
Fax: +43/1/61 6751 0-33
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5.25
IIIIfI
V IIIt. Diamond
AIRCRAFT
AIRPLA NE MAINTENANCE MANUAL
Repair
Instructions
Fillers for resin
Cotton flakes FB 1 F, white
Supplier
: Schwarzwalder Textilwerke
Postfach 4, Aue 3
0-77771 Schenkenzell, Germany
Phone: +49/7836/5713
Fax: +49/7836/5737
Silcell 300
Supplier
: Joh. Klinglhuber & S6hne Handelsgesellschaft mbH
Wallgasse 2 1
A-1 062 Vienna, Austria
Phone: +43/1/5974712-0
Fax: +43/1/5974712-16
Aerosil 380
Supplier
: Polychem HandelsgmbH (see above)
Microballoons Q-cell 300
Supplier
: Polychem HandelsgmbH (see above)
Chopped glass fiber
Supplier
: Rudolf Usner GmbH (see above)
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5.26
"Diamond
V
AIRCRAFT
Repair
Instructions
Knifing filler, Primer (acrylic filler), Paint (color RAL 9016)
These products are supplied by Herberts or Sikkens. It is highly recommendable to contact
Diamond Aircraft Industries to inquire about the products used on a specific serial number in
order to avoid such problems as bubbles in the paint finish.
Paint for the instrument panel
Satin paint, color tone 82, with hardener and thinner
Manufacturer: 3M
Fire retardant paint
Fire retardant paint
: no. N 565821T508 (white)
Finishing varnish
: no. 4232-0303
Hardener
: no. N 39/1 327 (4: 1)
Supplier
: Courtaulds Aerospace
c/o ICI Lacke Farben
Lauenburger Landstr. 1 1
0-21 039 86msen, Germany
Phone: +49/40/720031 -75, -74
Fax: +49/40/72041 92
Acrylic glass cement
Polymerization cement Acrifix 92
Manufacturer : R6hm, Darmstadt, Germany
Supplier
: Thun und Hohenstein (see above)
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HK 36
�Diamond
....'0/
AIRCRAFT
R, TS, TC, TIS, TIC, TIC-ECO
SECTION
Airworthiness
Limitations
6
AIRWORTHINESS llNIiTATIONS
This Airworthiness Limitations Section has been approved by the Austro Control GmbH (ACG)
and accepted by the
FAA. Service Bulletins or other documents which contain a statement
that the document is Austro Control GmbH (ACG) approved are considered
FAA approved
and revise this section.
Pages identified by "ACG-appr." are approved by:
Signature
AUSTRO CONTROL GmbH
Abteilung F!ugteclmik
A�i300 V,:icn�Flugi:?l[en, Hcllgar 2
A.uGensteile Ost
Stamp
2 O. Jan. 1999
Date of approval
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6.1
"Diamond
T
AIRCRAFT
Airworthiness
Limitations
6.1 LIFE LIMITED PARTS
6.1.1 ENGINE
•
Rolax 912 A: The TBO is 1200 hours or 1 0 years, whichever comes first. A possible extension
of the TBO will be notified through Service Bulletins.
•
Rolax 914 F: The TBO is 1 000 hours or 1 0 years, whichever comes first. A possible extension
of the TBO will be notified through Service Bulletins.
6.1 .2 SILENTBLOCS OF ENGINE MOUNT
These must be replaced upon engine overhaul.
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6.2
�Diamol1d
v
AIRCRAFT
Airworthiness
Limitations
6. 1 .3 OTHER RUBBER COMPONENTS IN THE ENGINE COMPARTMENT
All elastomer hoses in the engine compartment, as well as the carburetor membranes (see
Operator's Manual for the Rotax 912 A or Maintenance Manual for Rotax Engine Type 9 1 4 F,
respectively), must be replaced every 5 calendar years.
CAUTION
When replacing the oil lines, bear in mind that the coil springs which
prevent kinks must lie within the hoses.
The hose change must be entered and confirmed in the Aircraft Maintenance Log. The date of
installation (quarter and year) must be pennanently marked on the hoses (by engraving in metallic
hose clamps or by means of heat shrinkable tubes specially designed for labeling).
Hoses and tubes made of plastic (e.g. teflon) are exempted from this measure. Original equipment
consists of only elastomer hoses.
6.1.4 COOLANT
The engine coolant must be changed at least once in 2 years.
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6.3
"Diamond
T
AIRCRAFT
Airworthiness
Limitations
6.1.5 PROPELLER
Constant speed propellers
- mt-propeller MTV-1: The current TBO is 1200 hours of operation or 5 calendar years, whichever
comes first.
- mt-propeller MTV-21 : The current TBO is 1200 hours of operation or 5 calendar years, whichever
comes first. The pressure accumulator is overhauled together with the propeller.
- Hoffmann HO-V352: The current TBO is 1200 hours of operation or 5 calendar years, whichever
comes first.
The 5 year period may be extended to the next Annual Inspection, as long as no Service Bulletin
or other technical information contradicts this extension. A period of 6 years may not be exceeded
under any circumstances.
An overhaul is required prior to reaching the above limit:
(a) at engine overhaul, if engine hours and propeller hours are identical, or
(b) upon ground contact, overspeed, leakage, etc.
A possible extension of the TBO will be notified through Service Bulletins. In each case, the last
revision is authoritative.
Fixed pitch propellers
The TBO depends on the condition of the propeller. There is no life limit.
6.1.6 PROPELLER GOVERNOR
The propeller govemor (if fitted) must be overhauled together with the engine.
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6.4
"Diamond
v
AIRCRAFT
Airworthiness
Limitations
6.1.7 AIRFRAME
The current life time of Powered Sailplanes made of GFRP is 6000 flight hours. The results of
operational strength tests on wing spars have proved that the life time of Powered Sailplanes made
of GFRP can be extended to over 6000 flight hours.
(a) As soon as the Powered Sailplane has reached an operation time of 6000 flight hours, an
inspection prescribed in an Inspection Program prepared by the Manufacturer must be carried
out. Upon a positive result or after the detected defects have been removed properly, the
lifetime of the Powered Sailplane can be further extended.
(b) The Inspection Program can be requested from the Manufacturer when required.
(c) The inspection must be perfonned either by the Manufacturer or by a certified repair station,
which means an FAA-approved repair station in case of U.S. registered aircraft.
(d) The results of the checks must be recorded in a Findings Report in which each item is
commented upon. If the checks are not perfonned by the Manufacturer but by an authorized
repair station, a copy of the Findings Report must be sent to the Manufacturer (for the purpose
of analysis and eventual supplementation or modification of the Inspection Program).
(e) The Annual Inspection that must be performed is not affected by this regulation.
6. 1 .8 ALUMINUM MAIN LANDING GEAR STRUTS
Main landing gear struts made from aluminum (only available for tricycle models) must be replaced
after 3000 hours of operation.
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6.5
•Diamond
AIRCRAFT
Airworthiness
Limitations
6.1.9 ELECTRIC FUEL PUMPS
•
Models with Rotax 912 A: The electric fuel pump must be replaced after 3000 hours of
operation.
•
Models with Rotax 914 F: The two electric fuel pumps must both be replaced, together with
the check valves, at each engine overhaul.
6.1 .10 HOSES IN THE AIRFRAME
All elastomer hoses which lie behind the firewall must be replaced after 8 calendar years.
The hose change must be entered and confirmed in the Aircraft Maintenance Log. The date of
installation (quarter and year) must be permanently marked on the hoses (by engraving in metallic
hose clamps or by means of heat shrinkable tubes specially designed for labelling).
Hoses and tubes made of plastic (e.g. teflon) are exempted from this measure. Original equipment
consists of only elastomer hoses.
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6.6
•Diamond
AIRCRAFT
Airworthiness
Limitations
6.1 . 1 1 RUDDER CONTROL CABLES
The rudder control cables can be visually inspected near the pedals and beneath the baggage
compartment over a length of approximately 30 cm (1 tt). If wear (e.g. abrasion or broken strands)
should be detected, the respective control cable must be replaced immediately. Also refer to FAA
AC 43. 1 3 - 1A.
Tail wheel models
Regardless of visible wear, the rudder control cables must be replaced after 1200 flight hours
or 1 0 calendar years, whichever comes first.
Tricvcle models
Regardless of visible wear, the rudder control cables must be replaced after 1 200 flight hours
or 6 calendar years, whichever comes first.
6.1 . 1 2 OUTER ROD END BEARINGS OF ELEVATOR ATTACHMENT
HK 36 R only:
These must be replaced after 3000 flight hours.
6.1 . 1 3 BRAKE FLUID
The hydraulic brake fluid must be changed at least once in 3 years.
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6.7
•Diamond
AIRCRAFT
HK 36 R, TS, TC, TIS , TIC, TIC-ECO
Airworthiness
Limitations
6 . 1 . 1 4 ELT BATIERY
The lifetime of the ELT battery depends on the battery type. The original battery must be replaced
after 2 or 3 calendar years (refer to placard on ELT).
6 . 1 . 1 5 IGNITION SWITCH
Every 2000 flight hours, the ignition switch must be serviced a=rding to HOAC Work Instruction
No. 13.
6. 1 . 1 6 SAFETY HARNESSES
The safety harnesses on the LH and RH seat must be replaced every 1 2 calendar years.
6. 1 . 1 7 TOWING DEVICE
The towing device (optional) must be overhauled by an authorized service station every 4 calendar
years or 2000 tows, whichever comes first.
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Date
Source
Page No.
3.02.21
May 1 7, 1 993
10
1 5 Jun 1 99B
S8 50/5
6.B
M6.Diamond
v
AIRCRAFT
HK 36 R, TS, TC, TIS, TIC, TTC-ECO
Airworthiness
Limitations
6.2 SURFACE COLOR
Since the strength of the fiber composite structure has only been shown up to a temperature of
54 °C (129 OF), the outer surface of the airplane must be painted white.
Exceptions are registration markings and warning marks, which are subject to the following
restrictions (also see drawing on next page):
No registration markings or waming marks may be applied here.
Zone II
Registration markings and warning marks may be applied here. They may have
(a)
any shape, provided that colors with a solar absorptivity not exceeding 0.5
(e.g. light yellow or light green) are used
or
(b)
any color, provided that no area measuring 1 5 cm by 1 5 cm (% ft. by % ft.)
is covered by more than 50 %. One consequence is that the width of
decoration stripes must not exceed 7.5 cm (3 in.).
Zone III
Registration markings and waming marks of any shape and color may be applied
here without restrictions.
NOTE
For both conventional and tricycle landing gear, the wheel fairings
and metal parts are Zone III. The GFRP landing gear strut of the
conventional landing gear is Zoner.
Doc. No.
Issue
Rev. No
Date
Source
Page No.
3.02.21
May 1 7, 1 993
10
1 5 Jun 1 998
SB 50/5
6.9
iiADiamond
T
AIRCRAFT
Airworthiness
Limitations
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Doc. No.
Issue
Rev. No
Date
Source
Page No.
3.02.21
May 1 7, 1 993
10
1 5 Jun 1 998
SB 5015
6. 1 0

Diamond Aircraft - Diamond Aircraft Industries

Transcription

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