EVEKTOR-AEROTECHNIK EV-97? EUROSTAR ?model 2000 version R Installation and operation manual

EVEKTOR - AEROTECHNIK
Airport, Kunovice
686 04 Kunovice
Czech Republic
tel.: [phone]
fax: [phone]
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© EVEKTOR - AEROTECHNIK , 2001

EVEKTOR - AEROTECHNIK
Airport, Kunovice
686 04 Kunovice
Czech Republic
tel.: [phone]
fax: [phone]
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Model: EV-97  EUROSTAR 
model 2000 version R
Serial Number:
Registration:
Owner: ................................................................
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The manufacturer invites suggestions and reminders concerning this manual,
and appreciates proposals for corrections.
We invite you to share your experiences with us during operation of your
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1. GENERAL
1-1
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1.1 Record of revisions
Any revisions or amendments to this manual shall be issued in the form of bulletins with attached
new pages. It is in the interests of every user to enter such revision into the table of revisions and
to replace the existing page by the new one. The revised or corrected text shall be indicated by a
vertical line on the page fore-edge and the page shall bear a revision number and date of its issue.
Rev.
No. Affected Section Affected Pages Date of Issue Bulletin No. Date of Approval Date Inserted Signature
MB1 1 2, 3 06/2001 EV97-004a 12.6.2001 Airplane
3 10, 20 Manufacturer
4 9, 10
1 2, 3 10/2001 Airplane
2 6, 42, 43 Manufacturer
3 23
2
4 16
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1.2 List of Effective Pages
Sec. Page Date Sec. Page Date Sec. Page Date Sec. Page Date Sec. Page Date
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01/2001 3-2 01/2001 4-2 01/2001 5-2 01/2001
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1.3 Contents
1. GENERAL.......................................................................................................................................1-1
1.1 RECORD OF REVISIONS ....................................................................................................................... 1-2
1.2 LIST OF EFFECTIVE PAGES .................................................................................................................. 1-3
1.3 CONTENTS ......................................................................................................................................... 1-4
2. TECHNICAL DESCRIPTION..........................................................................................................2-1
2.1 BASIC AND GENERAL INFORMATION ...................................................................................................... 2-2
2.1.1 Designation ...............................................................................................................................2-2
2.2 BASIC TECHNICAL DATA....................................................................................................................... 2-3
2.2.1 Airplane views...........................................................................................................................2-3
2.2.2 Three-view drawing...................................................................................................................2-4
2.2.3 Basic dimensions......................................................................................................................2-5
2.2.4 Weight.......................................................................................................................................2-6
2.2.5 Center of gravity........................................................................................................................2-6
2.2.6 Operating limitations .................................................................................................................2-6
2.3 TECHNICAL DESCRIPTION OF THE AIRPLANE.......................................................................................... 2-7
2.3.1 General......................................................................................................................................2-7
2.3.2 Fuselage....................................................................................................................................2-7
2.3.3 Wing..........................................................................................................................................2-7
2.3.4 Horizontal tail unit......................................................................................................................2-8
2.3.5 Vertical tail unit..........................................................................................................................2-8
2.3.6 Landing gear .............................................................................................................................2-9
2.3.7 Cockpit ....................................................................................................................................2-16
2.3.8 Equipment...............................................................................................................................2-19
2.3.9 Avionics...................................................................................................................................2-21
2.3.10 Additional equipment...............................................................................................................2-22
2.3.11 Control system........................................................................................................................2-25
2.3.12 Powerplant ..............................................................................................................................2-33
2.3.13 Fuel system.............................................................................................................................2-42
2.3.14 Engine lubrication system scheme .........................................................................................2-44
2.3.15 Cooling system description.....................................................................................................2-45
2.3.16 Heating....................................................................................................................................2-45
2.3.17 Ventilation................................................................................................................................2-46
2.3.18 Wiring......................................................................................................................................2-47
2.3.19 Pitot-static system...................................................................................................................2-48
2.3.20 Placards ..................................................................................................................................2-49
3. OPERATION ...................................................................................................................................3-1
3.1 OPERATION OUTLINES......................................................................................................................... 3-2
3.2 AIRPLANE ASSEMBLY........................................................................................................................... 3-3
3.2.1 Wing..........................................................................................................................................3-3
3.2.2 Horizontal tail unit....................................................................................................................3-10
3.2.3 Vertical tail unit........................................................................................................................3-11
3.2.4 Landing gear ...........................................................................................................................3-12
3.2.5 Cockpit canopy........................................................................................................................3-15
3.2.6 Installation and reinstallation of instruments...........................................................................3-15
3.3 LEVELING ......................................................................................................................................... 3-16
3.4 MEASUREMENT OF CONTROL SURFACES DEFLECTIONS ....................................................................... 3-17
3.4.1 Required deflections ...............................................................................................................3-17
3.4.2 Aileron deflection measurement .............................................................................................3-18
3.4.3 Flap deflection measurement..................................................................................................3-18
3.4.4 Elevator deflections measurement..........................................................................................3-19
3.4.5 Rudder deflection measurement.............................................................................................3-19
3.4.6 Trim tab deflections measurement..........................................................................................3-20
3.5 PERMISSIBLE TOLERANCES ............................................................................................................... 3-21
3.6 WEIGHING THE AIRPLANE AND C.G. CALCULATION .............................................................................. 3-22
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3.6.1 Empty weight determination ................................................................................................... 3-22
3.6.2 Operating C.G. Range calculation.......................................................................................... 3-23
3.7 GROUND HANDLING .......................................................................................................................... 3-24
3.7.1 Towing the airplane................................................................................................................. 3-24
3.7.2 Parking the airplane................................................................................................................ 3-24
3.7.3 Tieing-Down............................................................................................................................ 3-24
3.7.4 Jacking the airplane................................................................................................................ 3-25
3.8 ROAD TRANSPORT ............................................................................................................................ 3-25
4. MAINTENANCE.............................................................................................................................. 4-1
4.1 OVERALL MAINTENANCE SURVEY ......................................................................................................... 4-2
4.2 PRE-FLIGHT INSPECTION ..................................................................................................................... 4-2
4.3 POST-FLIGHT INSPECTION ................................................................................................................... 4-2
4.4 PERIODICAL INSPECTIONS ................................................................................................................... 4-3
4.4.1 Periodical inspection intervals .................................................................................................. 4-3
4.4.2 Periodical inspections Sign off sheets...................................................................................... 4-3
4.4.3 Periodical inspections - events................................................................................................. 4-4
4.4.4 List of periodical inspections of Rotax 912 UL engine............................................................ 4-11
4.5 FLUIDS............................................................................................................................................. 4-12
4.5.1 Engine oil ................................................................................................................................ 4-13
4.5.2 Coolant.................................................................................................................................... 4-14
4.5.3 Brake fluid............................................................................................................................... 4-15
4.5.4 Fuel......................................................................................................................................... 4-16
4.6 LUBRICATION.................................................................................................................................... 4-18
4.6.1 Lubrication fundamentals........................................................................................................ 4-18
4.6.2 Recommended lubricants....................................................................................................... 4-18
4.7 MECHANISM ADJUSTMENTS ............................................................................................................... 4-20
4.7.1 Torque moments..................................................................................................................... 4-20
4.8 NECESSARY MAINTENANCE TOOLS..................................................................................................... 4-21
4.9 ACCESS HOLES ................................................................................................................................ 4-21
4.10 BRAKE SYSTEM EFFICIENCY ADJUSTMENT .......................................................................................... 4-22
4.10.1 Brake pad replacement........................................................................................................... 4-22
4.10.2 Bleeding.................................................................................................................................. 4-23
4.11 CONTROL SURFACES DEFLECTION SETTING........................................................................................ 4-24
4.11.1 Aileron deflection adjustment.................................................................................................. 4-24
4.11.2 Flap deflection adjustment...................................................................................................... 4-24
4.11.3 Elevator deflection adjustment................................................................................................ 4-24
4.11.4 Rudder deflection adjustment................................................................................................. 4-25
4.11.5 Trim tab adjustment................................................................................................................ 4-25
4.12 STEERABLE NOSEWHEEL LANDING GEAR ADJUSTMENT........................................................................ 4-26
4.12.1 Rubber block replacement...................................................................................................... 4-26
4.13 ENGINE IDLE ADJUSTMENT ................................................................................................................ 4-27
4.14 TIRE INFLATION PRESSURE................................................................................................................ 4-27
4.15 CLEANING AND CARE ........................................................................................................................ 4-28
4.15.1 Airplane care outlines ............................................................................................................. 4-28
4.15.2 External surfaces cleaning...................................................................................................... 4-28
4.15.3 Interior cleaning ...................................................................................................................... 4-28
4.15.4 Cockpit canopy cleaning......................................................................................................... 4-28
4.15.5 Engine maintenance............................................................................................................... 4-29
4.15.6 Propeller maintenance............................................................................................................ 4-29
4.15.7 Winter operation...................................................................................................................... 4-30
5. REPAIRS ........................................................................................................................................ 5-1
5.1 REPAIR GUIDELINES............................................................................................................................ 5-2
5.2 DAMAGE CLASSIFICATION.................................................................................................................... 5-2
5.3 MATERIALS USED................................................................................................................................5-3
5.3.1 List of skin sheets ..................................................................................................................... 5-3
5.4 SKIN REPAIR....................................................................................................................................... 5-4
5.4.1 Riveting..................................................................................................................................... 5-5
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5.5 FIBERGLASS PARTS REPAIRS ............................................................................................................... 5-6
5.6 PAINT REPAIRS ................................................................................................................................... 5-6
5.7 AIRPLANE ASSEMBLY AND LEVELING AFTER A REPAIR ............................................................................ 5-6
5.8 FIRST FLIGHT AFTER A REPAIR ............................................................................................................. 5-7
5.9 SPARE PARTS ORDER.......................................................................................................................... 5-7
6. APPENDICES.................................................................................................................................6-1
6.1 LIST OF APPENDICES .......................................................................................................................... 6-2
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2. TECHNICAL
DESCRIPTION
2-1
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2.1 Basic and general information
The EV-97 „EUROSTAR“ model 2000 version R is a single engine, all metal, low-wing
monoplane of semimonocoque construction with two side-by side seats. The aircraft is equipped
with fixed, tricycle landing gear.
The standard powerplant consists of the four-cylinder, 4 stroke, ROTAX 912 (80 hp) engine and
the two blade, wooden, V 230 C fixed prop.
2.1.1 Designation
EV-97 „EUROSTAR“ model 2000 version R is an aircraft especially intended for recreational and
cross-country flying with a limitation to non-aerobatic operation.
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2.2 Basic technical data
2.2.1 Airplane views
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2.2.2 Three-view drawing
8.1 m
26.57 ft
2.5 m
8.2 ft
2.34m
7.7ft
19.62 ft
5.98 m
2.25 m
7.38 ft
0.94 m
3.1 ft
4.42 ft
1.35 m 1.6 m
5.25 ft
3.42 ft
1.04 m
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2.2.3 Basic dimensions
Wing
span.................................................................26.57 ft 8.1 m
area ...............................................................105.92 sq ft 9.84 m2
MAC ..................................................................4.10 ft 1.25 m
loading (MTOW 992 lb, 450 kg) ................9.37 lbf/sq ft 45.7 kg/m2
(MTOW 1058 lb, 480 kg) ..............9.99 lbf/sq ft 48,8 kg/m2
Aileron
area.........................................................2.26 sq ft 0.21 m2
Flap
area.........................................................5.60 sq ft 0.52 m2
Fuselage
length...............................................................19.62 ft 5.98 m
width..................................................................3.41 ft 1.04m
height.................................................................7.68 ft 2.34m
HTU
span...................................................................8.20 ft 2.5 m
HTU area.........................................................20.99 sq ft 1.95m2
elevator area .....................................................8.61 sq ft 0.8 m2
VTU
height.................................................................4.07 ft 1.24m
VTU area.........................................................10.76 sq ft 1.0 m2
rudder area........................................................4.30 sq ft 0.4 m2
Landing gear
wheel track ........................................................5.25 ft 1.6 m
wheel base ........................................................4.42 ft 1.35 m
main wheel diameter......................................... 14 in 350 mm
nosewheel diameter.......................................... 14 in 350 mm
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2.2.4 Weight
Empty weight (standard equipment) ..............................................606 lbs± 3% 275 kg ± 3%
Maximum Take-off weight (Czech Rep., Germany..)...............992 lbs 450 kg
(Slovak Republic, Canada)..........1058 lbs 480 kg
Maximum Landing weight (Czech Rep., Germany..)...............992 lbs 450 kg
(Slovak Republic, Canada)..........1058 lbs 480 kg
Maximum fuel weight (65 l fuel tank - standard)...............104 lbs 47 kg
Maximum weight in Baggage Compartment ....................................33 lbs 15 kg
NOTE
Actual empty weight is stated on the placard “LOAD LIMITS,“
located on the cockpit canopy.
2.2.5 Center of gravity
Empty weight CG (standard equipment)......................................18±2 % MAC
Operating CG ............................................................................. 20-34 % MAC
(MAC...Mean Aerodynamic Chord)
2.2.6 Operating limitations
Refer to the PILOT'S OPERATING HANDBOOK (POH), Section 2 for more details about the
following operating limits:
•Airspeed limits
•Weight limits
•CG Range limits
•Approved maneuvers
Additional rules are of a more common character and result from generally valid flight regulations.
It is in every user’s interest to be familiar with these regulations, rules and restrictions.
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2.3 Technical description of the airplane
2.3.1 General
The EV-97 „EUROSTAR“ model 2000 version R airframe is of semi-monocoque construction
formed with metal reinforcements, bulkheads and duralumin cover. Pop-rivets are used for joints
and some non-supporting parts are made from fiberglass.
2.3.2 Fuselage
The fuselage has a semi-monocoque construction formed with reinforcements and duralumin
covers. The fuselage cross-section is rectangular in the lower section and elliptical in the upper
one. The tail fin is an integral part of the fuselage. In the middle section of the fuselage there is a
two-man cockpit which is accessible by unfolding the one-part perspex overlap canopy. The engine
section in the nose is separated from the crew by a firewall which the engine mount is attached to.
2.3.3 Wing
The rectangular wing is of a monospar construction with an auxiliary spar for the ailerons and flap
attachments. All the elements are riveted together. Fiberglass wing tips are riveted to the ends of
the wings and the wings can be equipped with an optional folding mechanism for convenient
storing.
2.3.3.1 Ailerons
The ailerons are of rectangular shape on each half of the wing and are attached to the wing with
hinges. An aileron is formed with the ribs and cover, which forms a hollow section.
2.3.3.2 Flaps
Two-third 's of each half of the wing is fitted with a flap. The flaps are of rectangular shape and are
formed with the ribs and cover, which forms a hollow section. The flap is attached to the wing with
a hinge.
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2.3.4 Horizontal tail unit
The rectangular HTU consists of a stabilizer and elevator with a trim tab. The semi-monocoque
construction of the HTU consists of duralumin ribs, spar and cover. The width of 8.2 ft (2.5 m)
enables transport without dismantling.
2.3.4.1 Stabilizer
The stabilizer is rectangular in shape and formed with a duralumin cover and ribs. The stabilizer is
attached to the fuselage with two pins at the leading edge and secured with two screws at the
stabilizer trailing edge.
2.3.4.2 Elevator
The elevator is rectangular in shape and formed with a duralumin cover and ribs. The elevator is
attached to the stabilizer with a hinge. There is also a hinged trim tab at the elevator trailing edge.
2.3.4.3 Trim tab
Each elevator is equipped with the one trim tab of rectangular shape. The tab is formed with
duralumin cover which forms a hollow section. The span of the trim tab is 2/3 of the elevator
spanwise.
2.3.5 Vertical tail unit
The trapezoidal VTU consists of the fin and rudder. The rudder is attached on the fin by two
hinges. The frame of the VTU is composed of a metal sheet spar and a duralumin cover.
2.3.5.1 Fin
The fin is an integral part of the fuselage rear section and is formed with a duralumin spar and
cover. The fin tip is formed with a fiberglass cover, where the anticollision beacon can be installed.
The fillet between the fin and rear upper fuselage part is formed with a fiberglass fillet cover.
2.3.5.2 Rudder
The rudder is of trapezoidal shape and formed with a duralumin spar and cover and attached by
two hinges at the fin. The rudder upper tip is formed with a fiberglass cover.
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EURO
STAR
EV-97
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2.3.6 Landing gear
2.3.6.1 General description
The aircraft is equipped with fixed nosewheel landing gear. The nosewheel is steerable, but as an
option, can be casterable, only.
Fig. EV-97 Eurostar
1 - Steerable nosewheel
2 - Main landing gear
1
2
2.3.6.2 Main landing gear
2.3.6.2.1 Description
The main landing gear consists of the left and right landing gear legs. The legs are formed from
fiberglass springs and are fixed by means of screws in the fuselage casing under the seats. Wheel
axis is screwed at the lower part of the main landing gear legs. The main wheels on both legs are
equipped with hydraulic disc brakes controlled with toe brake pedals mounted on the rudder
pedals. The wheels can be covered with the fiberglass fairings (wheel pants) or mudguards.
2.3.6.3 Nosewheel landing gear
2.3.6.3.1 Description
Steerable nose landing gear consists of front landing gear leg, rubber rope suspension unit and
suspension stop. The nose leg is made of a bended steel tube, attached to the firewall by two
bearings. The axle, with wheel attached, is connected to the welded bushing in the bottom part of
the leg. Two rods are used for the leg steering by the control pedals.
2-9
Document No.:
EV2000RNOEN Date of Issue: 01/2001 Revision:
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A
AI IR RP PL LA AN NE E T TE EC CH HN NI IC CA AL L D DE ES SC CR RI IP PT TI IO ON N, ,
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OP PE ER RA AT TI IN NG G, , M MA AI IN NT TE EN NA AN
NC CE E A AN ND D R RE EP PA AI IR R M MA AN NU UA AL L
EURO
STAR
EV-97
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MO OD DE EL L 2 20 00 00 0
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2.3.6.3.2 Main landing gear layout
ANGLE REINFORCEMENT
MAIN LEG
MAIN LEG ATTACHMENT
MAIN LEG ATTACHMENT
FLIGHT DIRECTION
SCREW 4x40 ČSN 02 1781.04
NUT M16x1.5 ČSN 02 1412.24
WASHER
WHEEL WITH BRAKE
SCREW 5x10 ČSN 02 2150.01
MAIN LEG
Fig. Main leg attachment into fuselage
2-10 Document No.:
EV2000RNOEN Date of Issue:
01/2001 Revision:
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