czech sport aircraft SportCruiser Reference manual

SERVICE
BULLETIN
Czech Sport Aircraft a.s.
Na Záhonech 212,
686 04 Kunovice
Czech Republic
[email protected]
No.: SB-SC-055
Date: 2018-08-20
Rev.: -
Page: 1 of 25
Date: -
MODEL
AFFECTED: SportCruiser
SUBJECT: Installation of Fuel return line
AIRCRAFT
AFFECTED:
All SportCruiser aircraft up to S/N 09SC273 inclusive without fuel return line
installed, as applicable.
COMPLIANCE: Apply this Service Bulletin upon the next scheduled annual inspection or till
May 31, 2019, at the latest.
DESCRIPTION:
This Service Bulletin follows the Safety Alert / Safety Directive No. SA-SC-006 dated October 16, 2017.
This Service Bulletin contains instructions for mandatory fuel return line installation that is required to be
incorporated within the aircraft fuel system design as per the Rotax Installation Manual 912 Series, the latest
revision, Chapter 73-00-00, Fuel system. Application of this Service Bulletin is mandatory for all SportCruiser
aircraft without the fuel return line installed. For checking the fuel return line installation on the respective
aircraft, refer to the SA-SC-006. The Service Alert No. SA-SC-006 remains in effect and mandatory for all
respective SportCruiser aircraft without fuel return line installed until this Service Bulletin accomplishment.
AUTHORISATION TO PERFORM:
Repairman (LS-M) or Mechanic (A&P), Aircraft Maintenance Organization
REASON:
Implementation of the fuel return line is required by the Rotax Company. The purpose of the fuel return line
is to bleed off any vapors that may form within the fuel system that could cause vapor lock resulting in
a possible loss of engine power.
MANPOWER:
Approximately 30 manhours.
SPECIAL TOOLS AND TEST EQUIPMENT:
•Direct drilling machine (chuck up to a diameter of 10 mm)
•Corner drilling machine (chuck up to a diameter of 10 mm)
•Riveting pliers with a rotary head for pop rivets
•Pliers for cleco fasteners
•Drill bit, diameter of 2.4 mm ( .094 inch)
•Drill bit, diameter of 4.1 mm ( .161 inch)
•Drill bit, diameter of 6 mm ( .240 inch)
•Drill bit, diameter of 9 mm ( .360 inch)
•Step drill bit 3/4 inch or reamer 3/4 inch
•Cleco fasteners, diameter of 2.4 mm (10 pcs)
•Cleco fasteners, diameter of 4 mm (4 pcs)
•Hot air gun
•Vacuum cleaner designed for working in an explosive environment
•Portable light designed for working in an explosive environment
•Telescopic mirror
•Test equipment for the test of fuel system installation leakage
•Test equipment for the test of pitot-static system leakage

SERVICE
BULLETIN
Czech Sport Aircraft a.s.
Na Záhonech 212,
686 04 Kunovice
Czech Republic
[email protected]
No.: SB-SC-055
Date: 2018-08-20
Rev.: -
Page: 2 of 25
Date: -
WEIGHT AND BALANCE:
Affected.
ELECTRICAL LOAD DATA:
Not affected.
REFERENCES:
ROTAX Installation Manual 912 Series, latest revision
ROTAX Maintenance Manual, latest revision
ROTAX Operators Manual 912 Series, latest revision
ROTAX Service Instruction SI912 i 001R4, SI-912-016R9
PUBLICATIONS AFFECTED:
SportCruiser / Piper Sport Airplane Maintenance Manual SC-AMM-1-0-00
MATERIAL AND SPECIAL JIGS:
The following parts and jigs are needed for execution of this service bulletin:
Description:
Part number:
Qty:
Return line connection
CE0271N
1 pc
T6 distributor without jet
3800D084
1 pc
Restriction jet, diameter of 0.35 mm
3800D054
1 pc
Straight coupling - GS6
3436V002
1 pc
Hose clamp 7/32"- 5/8"
HC5-4TB (3330A001)
7 pcs
Gasoline hose FUB 386 6/12 MM
131060 (512K2101)
5 m
Hose thermofit CGPT 25.4/12.7-4-FSP yellow
512O2122
0.4 m
Pyrojacket 13 MM
66501001
2 m
Grommet 13 X 1
930-913011 (3251A131)
2 pcs
Cable tie CB 200/3.5 NATUR
3331A003
20 pcs
Pop rivet, WATERTIGHT SR 4.0 x 9.5 Al/St ZH
12014009 (3171T047)
6 pcs
Pop rivet, AVEX 3.2 X 9.5 Al/St ZH 1604-0412
16040412 (3171T018)
15 pcs
Sealant for hermetic sealing, resistant to the
action of aircraft fuels, applicable between
sheet metals
TM1 sealant is recommended (the sealant
applied between sheet metals) = two-
component sealant PR1770C - 8 or
two-component sealant PR1770C - 12.
0.03 kg
Sealant for hermetic sealing resistant to the
action of aircraft fuels, applicable for rivets
TM2 sealant is recommended (the sealant for
application on rivets) = two-component
sealant PR1440A - 1/2 or two-component
sealant PR1440A – 2
0.02 kg
Agent for degreasing the surfaces intended for
hermetic sealing
Use agent recommended by the manufacturer
of the respective sealants used
Versatile water-resistant contact adhesive
HELCAR 17027 adhesive is recommended
100 g
Drilling jig
1-111-0028
1 pc
COSTS:
To be covered by the aircraft owner.

SERVICE
BULLETIN
Czech Sport Aircraft a.s.
Na Záhonech 212,
686 04 Kunovice
Czech Republic
[email protected]
No.: SB-SC-055
Date: 2018-08-20
Rev.: -
Page: 3 of 25
Date: -
ACCOMPLISHMENT INSTRUCTIONS:
Caution - initial instructions:
Works according to this Service Bulletin SB-SC-055 can only be performed by aircraft mechanic authorized
for works on SportCruiser aircraft and experienced in installation of power units.
When installing the hoses in compliance with this Service Bulletin, the following requirements must be met:
•It is necessary to ensure a sufficient radius of hose bending in order to avoid the breaking of the hoses.
•A free movement of the hoses must be eliminated by means of grommets, fastening elements and cable
ties.
•Under all circumstances, a sufficient play between the hoses, fixed parts of the aircraft structure and the
movable parts of the aircraft system, with the exception of the fastening elements of holes, must be
ensured.
Warning:
During the works performed according to this Service Bulletin, it is necessary strictly to keep the rules for
working in an explosive environment and the rules of fire protection. The wing and the fuselage
of the airplane must be electrically grounded and the extinguishers must be within reach.
Technological procedure:
1) Drain all the fuel from the left fuel tank and from the right fuel tank of the airplane.
2) Remove the upper engine cowling from the airplane.
3) Disconnect all the hoses from the lower engine cowling. Remove the cowling from the airplane.
4) Remove the wing from the fuselage in compliance with SC-AMM-1-0-00, Chapter 4 - Wing.
5) On the upper side of the left wing, carefully drill off the rivet heads attaching the fuel gauge cap, knock
out the rivets, remove the cap from the wing (see Fig. 01 and 02).
Note:
Drilling of the rivet heads can be facilitated by using a stopper tube of the appropriate length that is
pushed to the drill bit, which reduces the depth of the drilled hole to about 3mm.
Fig. 01
Fig. 02

SERVICE
BULLETIN
Czech Sport Aircraft a.s.
Na Záhonech 212,
686 04 Kunovice
Czech Republic
[email protected]
No.: SB-SC-055
Date: 2018-08-20
Rev.: -
Page: 4 of 25
Date: -
6) On the fuel gauge that is installed in the left wing tank and on the left wing cabling, mark appropriate
contacts and plugs. Disconnect the fuel gauge from the electrical wiring of the respective wing, remove
the fuel gauge from the tank and from the wing (see Fig. 03).
Caution:
It is necessary to mark the fuel gauge contacts and the appropriate plug contacts in such a way that after
the reinstallation of the fuel gauge to the tank, it is possible to connect each of the above mentioned
plugs to that contact from which it was disconnected based on this section.
7) Turn the left wing and put it on the assembly supports so that the upper side of wing is located
on the assembly supports.
8) From the left wing, remove the cap located on the lower side of leading edge in the area defined
by rib No. 2a and rib No. 4. (see Fig. 04 and 05)
Fig. 03
Fig. 04

SERVICE
BULLETIN
Czech Sport Aircraft a.s.
Na Záhonech 212,
686 04 Kunovice
Czech Republic
[email protected]
No.: SB-SC-055
Date: 2018-08-20
Rev.: -
Page: 5 of 25
Date: -
9) On the left wing on rib No. 1 and rib No. 2a, measure the position of the holes with a diameter of 4.1 mm
( .161 inch ). Drill the holes and deburr them (see Fig. 05, 06 and 07).
Rib No. 1
Fig. 06
Fig. 05
Cap between ribs No. 4 and No. 2a

SERVICE
BULLETIN
Czech Sport Aircraft a.s.
Na Záhonech 212,
686 04 Kunovice
Czech Republic
[email protected]
No.: SB-SC-055
Date: 2018-08-20
Rev.: -
Page: 6 of 25
Date: -
10) In the left wing perform the following works:
a) Carefully remove the sticker from the appropriate area of the right side of the tank if the sticker
is located at the position designated for the CE0271N connection installation (see Fig. 08).
Fig. 08
Fig. 07
Rib No. 2a

SERVICE
BULLETIN
Czech Sport Aircraft a.s.
Na Záhonech 212,
686 04 Kunovice
Czech Republic
[email protected]
No.: SB-SC-055
Date: 2018-08-20
Rev.: -
Page: 7 of 25
Date: -
b) Set the drilling jig 1-111-0028 on the rib No. 4 (see Fig. 05) and on the right side of the fuel tank so
that the bolt of the jig is inserted into the technological hole made in the nose part of the rib No. 4
and that the area of the jig with drilled holes Ø2.4 mm was pressed against the area of the right side
of the fuel tank (see Figures 09, 10).
Caution:
If a cable or hose passes through the hole in the rib No. 4 and prevents the positioning
of the jig 1-111-0028, release the cable or hose and place them into the slot located between the stops
of the jig.
Drilling jig 1-111-0028
Fig. 09
Fig. 10

SERVICE
BULLETIN
Czech Sport Aircraft a.s.
Na Záhonech 212,
686 04 Kunovice
Czech Republic
[email protected]
No.: SB-SC-055
Date: 2018-08-20
Rev.: -
Page: 8 of 25
Date: -
c) Drill two holes Ø 2.4 mm in the right side of the fuel tank according to the drilling jig
(see Figures 11, 12).
Fig. 11
Fig. 12

SERVICE
BULLETIN
Czech Sport Aircraft a.s.
Na Záhonech 212,
686 04 Kunovice
Czech Republic
[email protected]
No.: SB-SC-055
Date: 2018-08-20
Rev.: -
Page: 9 of 25
Date: -
d) Remove the drilling jig 1-111-0028 from the wing, the pre-drilled hole Ø 2.4 mm intended for
the sleeve of the connection CE0271N to be drilled to Ø 6.0 mm and then to Ø 9.0 mm, then deburr
the hole (see Fig. 13).
e) Insert the connection CE0271N (see Fig. 14) into the hole made according to section 10 d),
set the connection to the position shown in Fig. 15, 16 (see the hole for rivet marked with a center
punch and red dot), attach the connection to the rib of the fuel tank by cleco fastener.
Fig. 13
Connection CE0271N
Fig. 14

SERVICE
BULLETIN
Czech Sport Aircraft a.s.
Na Záhonech 212,
686 04 Kunovice
Czech Republic
[email protected]
No.: SB-SC-055
Date: 2018-08-20
Rev.: -
Page: 10 of 25
Date: -
f) According to the holes in the connection flange drill the 3 remaining holes Ø 2.4 mm in the right side
of the fuel tank, using cleco fasteners (see Fig. 17).
Fig. 15
Fig. 16

SERVICE
BULLETIN
Czech Sport Aircraft a.s.
Na Záhonech 212,
686 04 Kunovice
Czech Republic
[email protected]
No.: SB-SC-055
Date: 2018-08-20
Rev.: -
Page: 11 of 25
Date: -
g) Drill the holes Ø 2.4 mm made in the connection CE0271N and in the right side of the fuel tank by use
of cleco fasteners to Ø 4.1 mm. Dismantle the connection CE0271N from the fuel tank, deburr all
the holes (see Fig. 18). Install the CE0271N connection back on the right side of the fuel tank
and fasten it to the rib by cleco fasteners. Check the position of the connection pipe through
the hole in the fuel tank intended for the fuel gauge. The position of the connection pipe must
correspond to the position shown in Fig. 16 (there must be sufficient clearance between
the connection pipe, the rib and the fuel tank cover, the connection pipe must not be in touch with
the fuel tank cover or with the rib). Check the position of the connection pipe by using a portable
light and a telescopic mirror.
Fig. 17
Fig. 18

SERVICE
BULLETIN
Czech Sport Aircraft a.s.
Na Záhonech 212,
686 04 Kunovice
Czech Republic
[email protected]
No.: SB-SC-055
Date: 2018-08-20
Rev.: -
Page: 12 of 25
Date: -
11) Turn the left wing in such a way that the lower side of wing is located on the assembly supports. Carefully
clean the inner space of left wing fuel tank by means of vacuum cleaner. Check the quality of cleaning
by means of the telescopic mirror. Turn the wing back to the initial position and put it on the assembly
supports in such a way that the upper side of wing is located on the assembly supports.
Warning:
During the work according to this section, it is necessary to use the vacuum cleaner designed for working
in an explosive environment.
12) According to the Technical Data Sheets of the used sealants, mix a needed quantity of sealant for
hermetic sealing of the joint of fuel return line connection and the fuel tank, and a needed quantity
of the sealant for application on rivets. Carefully degrease the rivets and the appropriate areas
on the connection flange and on the right side of left wing fuel tank by means of the agent recommended
by the manufacturer of the used sealants. Apply a layer of appropriate sealant on the mentioned
surfaces, position the connection into the appropriate fuel tank hole by using cleco fasteners (see Fig. 15
and 16 and see the hole made in the connection flange and marked with a center punch and a red dot).
Rivet the connection on the tank and apply the sealant intended for rivets on the rivet heads.
Caution:
For the hermetic sealing of the joints made according to this section, use the sealants that are resistant
to the action of aircraft fuels. The following sealants are recommended:
•Sealant TM1 (the sealant applied between sheet metals) = two-component sealant PR1770C - 8
or two-component sealant PR1770C - 12.
•Sealant TM2 (the sealant for application on rivets) = two-component sealant PR1440A - 1/2
or two-component sealant PR1440A - 2
13) On the left side of the firewall (frame No. 1), measure the position of the hole having a diameter
of 19.05 mm (3/4 inch), make the hole, deburr the hole and insert the grommet 13x1 into the hole
(see Fig. 19 and 20 ).
Fig. 19

SERVICE
BULLETIN
Czech Sport Aircraft a.s.
Na Záhonech 212,
686 04 Kunovice
Czech Republic
[email protected]
No.: SB-SC-055
Date: 2018-08-20
Rev.: -
Page: 13 of 25
Date: -
On the left side of the cabin, partly remove (carefully unstick + tear off) the marked upholstery panel
(see Fig. 21). Remove the panel in such a way that it is possible to perform the work according
to Sections 14, 15 and 16.
Fig. 20
Fig. 21

SERVICE
BULLETIN
Czech Sport Aircraft a.s.
Na Záhonech 212,
686 04 Kunovice
Czech Republic
[email protected]
No.: SB-SC-055
Date: 2018-08-20
Rev.: -
Page: 14 of 25
Date: -
14) On the longeron riveted on the fuselage skin (see the left side of cabin), measure the position of 4 holes
having a diameter of 4.1 mm (.161 inch). When measuring, make sure that the holes are distributed
uniformly, drill and deburr the holes (see Fig. 22)
15) On the skin of left side of fuselage in the area between frame No. 1 and frame No. 2, measure the position
of the hole having a diameter of 19.05 mm (3/4 inch), make the hole, deburr the hole and insert
the grommet 13x1 into the hole (see Fig. 23, 24).
Fig. 22
Fig. 23

SERVICE
BULLETIN
Czech Sport Aircraft a.s.
Na Záhonech 212,
686 04 Kunovice
Czech Republic
[email protected]
No.: SB-SC-055
Date: 2018-08-20
Rev.: -
Page: 15 of 25
Date: -
16) Install the fuel return line into the system of fuel installation located in the fuselage (see the diagram
in Fig. 28 + see figures shown in Sections No.16a through 16f). Install the fuel return line according
to the following instructions:
a) In the angle piece riveted on the firewall, drill and deburr the hole having a diameter of 4.1 mm (.161
inch) intended for fastening the fuel return line (see Fig. 26).
b) Cut the hose of fuel system installation pressure line with the protective PYROJACKET hose. Slide
the shrinkable hoses, that were cut before, onto the PYROJACKET hoses. Insert the T-coupler with
the restriction jet into the pressure line of fuel installation. Connect the pressure line hoses
to the above-mentioned T-coupler by means of hose clamps (see Fig. 25).
Fig. 24
Pyrojacket
Fuel hose FUB 386
Typical connection
of fuel system
installation branch
to aggregate or
valve fitting
Fig. 25
Thermofit CGPT
Hose clamp

SERVICE
BULLETIN
Czech Sport Aircraft a.s.
Na Záhonech 212,
686 04 Kunovice
Czech Republic
[email protected]
No.: SB-SC-055
Date: 2018-08-20
Rev.: -
Page: 16 of 25
Date: -
c) Cut the return line hose and the hose PYROJACKET to a needed length. Pull the return line hose
through the fuselage, grommet in the firewall and through the grommet in the fuselage skin.
In the area before the firewall (in the area of engine compartment), slide the protective hose
PYROJACKET onto the return line hose and slide the shrinkable hoses on. Connect the return line
hose to the T-coupler with the restriction jet by means of hose clamps (see Fig. 25).
d) Position the shrinkable hoses on the ends of PYROJACKET hoses (see Section 16 b, 16 c), secure
the position of PYROJACKET hoses by heating the shrinkable hoses by means of hot air gun.
Attach the return line hose to the angle piece of firewall by means of a cable tie and by means
of the hose FUB386 6/12mm cut in advance to a length of 8 mm (see Fig. 25, 26).
e) Attach all the free hoses of fuel installation, that are located between the engine and the firewall,
to suitable fixed structural elements by means of cable ties in order to prevent from their moving
and in order to avoid their chafing and knocking (see Fig. 29).
Fig. 26

SERVICE
BULLETIN
Czech Sport Aircraft a.s.
Na Záhonech 212,
686 04 Kunovice
Czech Republic
[email protected]
No.: SB-SC-055
Date: 2018-08-20
Rev.: -
Page: 17 of 25
Date: -
f) Using cable ties, attach the hose of fuel return line passing through the cockpit to the longeron
riveted on the left side of cabin on the fuselage skin (see Fig. 27).
Fig. 27

SERVICE
BULLETIN
Czech Sport Aircraft a.s.
Na Záhonech 212,
686 04 Kunovice
Czech Republic
[email protected]
No.: SB-SC-055
Date: 2018-08-20
Rev.: -
Page: 18 of 25
Date: -
Fig.
Fig. 28

SERVICE
BULLETIN
Czech Sport Aircraft a.s.
Na Záhonech 212,
686 04 Kunovice
Czech Republic
[email protected]
No.: SB-SC-055
Date: 2018-08-20
Rev.: -
Page: 19 of 25
Date: -
Warning:
During the works carried out according to section 16 it is necessary to take into account the following
facts:
•The fuel system installation corresponding to the diagram shown in Figure 28, which is part of this
service bulletin, is only one of the variants of the fuel system installation that can be actually
installed on the respective airplane.
•The fuel return line of the fuel system installation branch must be always connected to the discharge
line of the mechanical fuel pump, between the mechanical pump and the pressure gauge. If the fuel
installation of the respective airplane includes the flowmeter, then the fuel return line must be
connected to the discharge line of the mechanical fuel pump, behind the mechanical pump, and,
at the same time, in front of the pressure gauge and the flowmeter.
•Figures 25, 29 are to be considered as illustrative only. Their purpose is to show typical elements
of the airplane fuel system installation (eg. fixing the hoses against movement by pulling strips, fixing
the "PYROJACKET" protective hoses on the FUB 386 gas hoses using THERMOFIT CGPT shrink tubing,
fixing the FUB 386 gas hoses to the aggregate sockets and fittings using hose clips, etc.
Hoses to
carburetors
Discharge line of the
mechanical fuel pump
Position the T-coupler with the restriction
jet and the hose of the fuel return line
Installation without flowmeter
– illustrative picture
Discharge line
of electrical fuel
pump
Mechanical
fuel pump
Fig. 29

SERVICE
BULLETIN
Czech Sport Aircraft a.s.
Na Záhonech 212,
686 04 Kunovice
Czech Republic
[email protected]
No.: SB-SC-055
Date: 2018-08-20
Rev.: -
Page: 20 of 25
Date: -
17) Turn the left wing in such a way that the lower side of wing is located on the assembly supports. Clean
the inner space of the fuel tank of left wing by means of the vacuum cleaner. Check the cleaning quality
by means of the telescopic mirror.
Warning:
During the work according to this section, it is necessary to use the vacuum cleaner designed for working
in an explosive environment.
18) Install the fuel gauge transmitter into the fuel tank of left wing. Connect the transmitter to the electrical
wiring of wing (see the marking of fuel gauge contacts and the marking of appropriate plugs of wing
cabling based on Section 6 + see Fig. 03)
19) Check the left wing fuel tank tightness as follows:
a) Hermetically blind the fuel return line connection located on the right side of the left wing fuel tank
and the hose of suction line that is connected to the fuel tank.
b) Connect the test equipment to the hose of venting system of left wing fuel tank (see the area
between ribs No. 8 and No. 9).
c) By means of the test equipment, create and close an air pressure of 10 kPa (1.45 PSI) = 1000 mm
(40 inch ) of water column in the above mentioned fuel tank.
Caution:
•The work according to this section (i.e. Section No. 19 c) must be performed only after
the hardening of the sealants that are hermetically sealing the joint between the fuel return line
connection and the left wing fuel tank. The mentioned sealants must be hardened to the values
shown in the Technical Data Sheets of the used sealants.
•The work according to this section (i.e. Section No. 19 c) must be performed at a constant
ambient temperature.
d) After 10 minutes, adjust the positive air pressure in the left wing fuel tank again to 10 kPa (1.45 PSI)=
= 1000 mm (40 inch) of water column, close the positive air pressure in the tank and after another
60 minutes check the tank for leak-tightness.
Fig. 03