DOVA AIRCRAFT DV-1 SKYLARK User manual

MAINTENANCE MANUAL
FOR
DV-1 SKYLARK
Type certificate is registered by LAA ČR under Nb.: ULL 05/2005 amendment ,,A”
Manufacturer: DOVA AIRCRAFT, s.r.o.
Kirilovova 115
739 21 Paskov
Tel./fax: [phone]
Number of sheets: 78
Number of attachment: 2 (32 sheets)
Version: 2
Date of release: 31.10. 2011
Serial Nb.: Nb. of manufacture: Registration mark:

Aircraft Owner:
Name:
Address:
Matriculation sign:
Owner change / Owner:
Date of change:
Name:
Address:
Owner change / Owner:
Date of change:
Name:
Address:
Owner change / Owner:
Date of change:
Name:
Address:
2

CHAPTER 1
1.0 Technical description
1.1. Description of aircraft
1.2. Basic dimensions and aircraft preview
1.3. Weights and performances
1.4. Engine lifetime
1.5. Engines parts with restricted lifetime
1.6. List of parts with restricted lifetime!!!
1.7. Technical description of aircrafts assemblies with drawings – attachment Nb.1
1.8. Controls in cockpit - pictures
CHAPTER 2
2.0 Basic handling
2.1. (Dis) Assembling of wings
2.2. (Dis) Assembling of tail surfaces
2.3. Estimating aircraft weight and center of gravity
2.4. Operational values for engine, tire pressure, deflection of control surfaces, fuses and battery
CHAPTER 3
3.0 Maintenance
3.1. General
3.2. Maintenance list with terms
3.3. Maintenance
3.4. Periodical inspection after first 25 flight hours
3.5. Periodical inspection after 50 flight hours
3.6. Periodical inspection after 100 flight hours
3.7. Lubrication plan
3.8. Ground handling
3.9. Pre-flight inspection - maintenance
3.10. After-flight inspection - maintenance
3.11. Maintenance’s entries
3.12. Instruction for installation of brakes with closed hydraulic circuit
Filling of brake circuit
Brake and brake system control and maintenance
Setting the clearance of brake pads
3.13. Brakes scheme:
- Installation with main brake cylinder (for example on steering rod)
- Installation with main brake cylinder on the pedals – attachment nb.:2
CHAPTER 4
4.0 Repairs:
4.1. General
4.2. Metal skins repair
4.3. Riveting
4.4. Fiberglass parts
4.5. Paint renovation
4.6. Assembling and adjustment after repair
4.7. After-repair first flight
4.8. Spare parts order
CHAPTER 5
5.0. Attachment
– Records of repairs, provided bulletins and other changes
CONTENT

DV-1 SKYLARK aircraft is designed for tourist, recreational or pilot-school nonaerobatic flights. These
Flights are permitted in VFR conditions only.
DV-1 SKYLARK is single engine, full metal, low-wing, two-seater ultra light aircraft. Seats are placed side-by-
side.
Wing surface is trapezoid shaped with semi-monoque construction. As control surface the simple folding
flap and aileron is installed. Each wing is attached to fuselage with three hinges.
The fuselage is semi-monoque construction created by metal skin, longitudinal beams and perpendicular
walls.
Empennage is created as full-metal self-supporting T-tail construction.
Non-structural parts like engine cowlings, wing fairings and winglets are made from composite materials.
The aircraft is equipped with Kaspar’s propellers mostly. Two/three blades fixed or inflight adjustable
propeller is available.
Lift surfaces:
Trapezoid shaped wing is semi-monoque construction. That gives main beam in ¼ of the chord and
auxiliary beam in control surfaces connection. There are fuel tanks installed in the wings. Fuel tanks are
full-metal riveted construction sealed with petrol resistant glue. Wings ends are equipped by pair of
fiberglass winglets. Wing surface is divided into left and right half one, attached with three hinges per
each.
Fuselage:
Fuselage lower cross-section is rectangular with blended corners. The upper crosssection is elliptically
shaped. The vertical fin is designed as a part of fuselage construction. In the middle part of the fuselage,
there is a two pilot’s space covered with canopy from one single piece of organic glass. Engine
compartment is separated with
steel firewall from pilots. Firewall creates important construction point for the front undercarriage leg,
engine bed even for the ballistic rescue system.
Empennages:
Tail surfaces are designed as T-tail. Horizontal tail surfaces are rectangular shaped and they are created by
elevator connected with hinges to stabilizer. Stabilizer is attached through four bolts with fins
construction. On the left side of the elevator, there is an electrical controlled hinged trim surface. Trim
electrical control system is equipped with trim surface position indicator placed on instrument panel. The
rudder is trapezoid shaped and it is attached to vertical fin with two hinges.
Controls:
Aircraft controls are classical doubled system. Controls system for ailerons and elevator are created by
duralumin rods, angle levers and steel control levers. Rudder control is stainless ropes based one. Flaps
control is provided through flap control handle in the middle panel or through electrical servo engine
alternatively. Elevators trim surfaces is controlled through electrical servo engine.
Undercarriage:
Main undercarriage legs are made from composite springs. Wheels of main undercarriage are equipped
with hydraulic brakes. Front undercarriage leg is sprung by rubber shock absorber. Front wheel is
attached through duralumin fork to front leg and it is steering able. Tires size of front and main
undercarriage wheels are the same.
CHAPTER 1 Technical description
1.1. DESCRIPTION OF AIRCRAFT
4

Power plants:
Aircraft is powered by ROTAX 912UL and ROTAX 912ULS mostly. The engine is attached through shock
absorbers to engine bed welded from steel rods. The engine bed is attached to firewall through
strengthened points. The engine compartment is covered with two fiberglass cowlings (lower and upper
one). Cowlings are one-side painted to match the aircraft and they are both removable. The upper one is
attached with cam-locks.
Fuel system:
Two integral fuel tanks are mounted in wings, with 45L volume each. They are made from duralumin
sheets riveted and sealed together. Each fuel tank is equipped with filling intake, outlet valve, sludge valve,
air-bleeding valve and fuel-meter. Fuel system itself is equipped with three-ways fuel valve, fuel filters and
electrical fuel pump.
Interior:
Aircraft is equipped with two upholstered seats placed side-by-side. Position of each seat is adjustable
with position lock. Further equipment are four-point safety belts, baggage compartment placed behind
the seats and safety net for fixing luggage.
Canopy:
Canopy is made from one single part of organic glass. This glass is riveted and glued to welded frame from
duralumin tubes. Canopy opens with forward sliding movement. Canopy frame is attached to fuselage
through metal pull-out system. The canopy latch is placed in the top of the canopy and it is lock-able.
Ventilate system:
Ventilation is provided through rounded valve in front of the canopy. As an option, there are side sliding
windows.
Electrical installation:
Electrical system is single phase 12V system with negative pole grounded. As a source, there is a duty-free
battery and engine alternator. Each electrical circuit is protected with fuse or circuit breaker placed on
instrument panel.
Labels:
Ready-to-fly aircraft delivered from manufacture is equipped with given labels. In case of kit the labels are
delivered, but the owner had to placed them into correct positions. Warning: owner of the aircraft is
responsible for readability of the label during the aircraft lifetime.
Instruments:
Minimal instruments equipment:
- in-flight instruments: air speed indicator, altimeter, vertical speed indicator, slide-ball
indicator, compass, fuel gauges
- engine instruments: tachometer, oil temperature indicator, engine head temperature
indicator, oil pressure indicator
Radio: ICOM 200
Servo: for elevator trim surface Ray Allen T10A
Options: fuel pressure indicator, manifold pressure indicator, GPS AvMap EKP IV,
transponder Garmin , artificial horizon, landing light 100W.
Signal lights: position lights placed in winglets and strobe lights (2pcs in winglets ad
2pcs on fuselage)
Additional equipment:
There is a preparation for installation of ballistic rescue systems already provided.

Previews DV–1 SKYLARK
6

1.2. BASIC DIMENSIONS AND AIRCRAFT PREVIEW
2288 /90,08/
2863 /112,72/
5°
1092 /42,99/
1486 /58,49/
776 /30,56/
8136 /320,32/
1756 /69,12/
6624,3 /260,80/
ø1 090 /42,92/
ø1 620 /63,78/
1367 /53,81/
4315 /161,89/

Fuselage:
Length 6,62 m
Width 1,09 m
Height 2,28 m
Wings:
Wingspan 8,14 m
2
Wing surface 9,44 m
Empennage:
2
Horizontal tail surface 1,47 m
2
Vertical tail surface 1,02 m
Undercarriage:
Track 1,70 m
Wheelbase 1,36 m
Empty weight ..................kg ± 2 %
Maximum Take-Off weight 450 kg
Useful load 170 kg
Fuel capacity 90 liters
Maximum baggage weight 20 kg
Maximum loads +4,4 / -2
Stall speed without flaps 79 km/h
Stall speed with flaps 64 km/h
Never exceeded speed 280 km/h
Maximum horizontal speed 240 km/h
Cruise speed 210 km/h
Climb speed 8 m/s
Ceiling 3 650 m
Range (45 min. reserve) 1 200 km
Term of engine overhaul is given as 2000 flight hours or 10 years for ROTAX 912 UL/S
(first reached is valuable). See Rotax Bulletins – operational condition of engine manufacturer
Had to be changed every 5 years:
• air supplying hose for carburetors (AIRBOX)
• all rubber hoses of cooling circuit
1.2. BASIC DIMENSIONS
1.3. WEIGHTS AND PERFORMANCES
1.4. ENGINE LIFETIME
1.5. ENGINE PARTS WITH RESTRICTED LAIFETIME
8

• all rubber hoses of oil circuit
• carburetors flange
• rubber hoses connecting carburetors
• belt attaching alternator
• fuel pump including fuel hoses
Had to be changed every 2 years:
• cooling liquid of engine
– structural:
lifetime for changing parts of structural joint will be estimated by manufacturer,
alternatively authorized service center during estimated inspections. In case that you
will find any sign of rising wear of parts, higher friction or backlashes during your
pre/after flight check, call authorized service center.
– flight, navigate and engine instruments:
DV-1 SKYLARK is equipped with
1.6. LIST OF PARTS WITH RESTRICTED LIFETIME
Item
Basic equipment
Air Speed indicator
Altimeter
Vertical speed indicator
Side slip ball
Compass
Fuel gauges
Tachometer
Oil temperature indicator
Head temperature indicator
Oil pressure indicator
Nb. Overhaul
(flight.
Hours/years)
Date of
installation
(Fl. hours/years)

Item
Options
Fuel pressure indicator
Manifold pressure indicator
Artificial horizon
Transponder Garmin
Ballistic Rescue System
Nb. Overhaul
(flight.
Hours/years)
Date of
installation
(Fl. hours/years)
10