JMB VL-3E-1 User manual

Maintenance Manual for
aeroplane VL-3E-1
Registration number:
Serial number: VL-3-
Date:

date of issue:
2/46
VL-3E-1 Maintenance Manual
0. Table of contents
0. Table of contents ........................................................................................................................................ 2
1. General ........................................................................................................................................................4
1.1 General safety information...............................................................................................................4
1.2 Equipment list .................................................................................................................................... 4
1.2.1 Propellers........................................................................................................................................4
1.2.2 Engines............................................................................................................................................4
1.2.3 Engine specifications - Rotax 912 ULS........................................................................................5
1.2.4 Engine specifications - Rotax 914 F Turbo .................................................................................5
1.3 List of disposable replacement part and operational fluids ........................................................ 6
1.3.1 Engine components.......................................................................................................................6
1.3.2 Landing gears components ..........................................................................................................6
1.3.3 Operational fluids .........................................................................................................................6
1.3.4 Fuel..................................................................................................................................................6
1.4 Recomended tightening torque values ...........................................................................................7
1.5 Weight and balance informations....................................................................................................7
1.5.1 Aeroplane empty weight and centre of gravity ........................................................................7
1.5.2 Instructions how to fill out the „Weighting protocol“ .............................................................8
1.5.3 Aeroplane operating weight and centre of gravity ..................................................................9
2. Inspections of aeroplane ......................................................................................................................... 10
2.1 Pre-flight inspection ........................................................................................................................ 10
2.2 Periodical inspections...................................................................................................................... 10
2.2.1 Instructions for filling out the Maintenance Checklist ........................................................... 10
3. Structures .................................................................................................................................................. 11
3.1 Fuselage............................................................................................................................................. 11
3.1.1 Fuselage design............................................................................................................................ 11
3.1.2 Allowable maintenance .............................................................................................................. 11
3.2 Wing .................................................................................................................................................. 12
3.2.1 Wing design ................................................................................................................................. 12
3.2.2 Allowable maintenance .............................................................................................................. 12
3.2.3 Disassembly of wings ................................................................................................................. 13
3.2.4 Assembly of wings ...................................................................................................................... 14
3.2.5 Pictures of important check points –assembly of wings....................................................... 15
3.3 Tail units ...........................................................................................................................................16
3.3.1 Tail units design .......................................................................................................................... 16
3.3.2 Allowable maintenance .............................................................................................................. 17
3.3.3 Disassembly of tail units.............................................................................................................17
3.3.4 Assembly of tail units ................................................................................................................. 19
3.4 Cockpit and seats............................................................................................................................. 22
3.4.1 Allowable maintenance .............................................................................................................. 22
3.4.2 Dissasembly and assembly of seats .......................................................................................... 22
3.5 Canopy .............................................................................................................................................. 23
3.5.1 Allowable maintenance .............................................................................................................. 23
3.6 Aeroplane control lines................................................................................................................... 24
3.6.1 Allowable maintenance .............................................................................................................. 25
3.7 Landing gears................................................................................................................................... 26
3.7.1 Allowable maintenance .............................................................................................................. 26
3.7.2 Disassembly and assembly of wheels....................................................................................... 26
3.7.2.1 Replacement of tire on main wheels.........................................................................................26
3.7.2.2 Replacement of tire on nose wheel ...........................................................................................27
3.8 Brake system..................................................................................................................................... 29
3.8.1 Filling of the brakes circuit by brake liquid and venting.......................................................30
3.8.2 Replenish of the brake liquid.....................................................................................................31
3.8.3 Clearence and exchange of the brake disc and pads ..............................................................31

date of issue:
3/46
VL-3E-1 Maintenance Manual
3.9 Engine................................................................................................................................................ 32
3.9.1 Exchange of engine oil and oil filter: ........................................................................................32
3.9.2 Refilling of coolant liquid...........................................................................................................33
3.9.3 Cleaning of the engine ................................................................................................................ 34
3.10 Fuel system .......................................................................................................................................34
3.10.1 Exchange of fuel filter:............................................................................................................35
3.11 Hydraulic system.............................................................................................................................35
3.11.1 Replenish of the hydraulic fluid ...........................................................................................37
3.12 Propeller............................................................................................................................................38
3.12.1 Washing of the propeller ....................................................................................................... 38
3.12.2 Inspection of the propeller.....................................................................................................38
4. Utility Systems .........................................................................................................................................39
4.1 Pitot-static system............................................................................................................................ 39
5. Instruments and Avionics....................................................................................................................... 40
5.1 Cleaning of the instrument panel .................................................................................................. 40
5.2 Instrument panel and avionics....................................................................................................... 40
6. Electrical System ...................................................................................................................................... 40
6.1 Electrical system of airplane........................................................................................................... 40
6.1.1 Test of back-up battery (plane on the ground) –applies for EFIS Garmin only.................40
6.2 Electrical system of the engine....................................................................................................... 41
7. Painting and Coatings .............................................................................................................................42
8. Structural Repair ...................................................................................................................................... 42
9. Revisions of Maintenance Manual......................................................................................................... 43
9.1 List of revisions ................................................................................................................................43
9.2 List of effective pages ...................................................................................................................... 43
10. Attachements ........................................................................................................................................ 44

date of issue:
4/46
VL-3E-1 Maintenance Manual
1. General
1.1 General safety information
For maintenance of the aeroplane VL-3E-1, it is necessary to accept all technical instruction given
by the following documentation:
Maintanance Manual for aeroplane VL-3E-1
Pilot Operating Handbook for aeroplane VL-3E-1
Maintenance Manual and service instructions for engine ROTAX 912ULS
Maintenance Manual and sevice instructions for used propeller
All other documentation delivered with the aeroplane VL-3E-1 if appropriate
Airworthiness of the aeroplane VL-3E-1 depends on observance of suggested maintenance
technique. Intervals between annual aeroplane inspections is necessary to adapt according current status
of operation of the individual aeroplane, independently on the prescribed annual inspection system. Such
things as climatic effects, manner of hangaring, used runways quality and all possible other factors must
be respected. This Maintenance Manual describes servicing and maintaining procedures corresponding
with average conditions under which are operated aeroplanes of UL category.
1.2 Equipment list
1.2.1 Propellers
Technical description of propellers and instruction for the maintenance and annual repairs of the
propellers are listed in the propellers Maintenance Manuals.
Fixed propeller:
PESZKE 1700/1950-A-3B (3-blades)
DUC Flash El-912-15 (3-blades)
Hydraulically adjustable propeller:
Woodcomp KW-20W (2-blades)
DUC H-FSH-2-D-PV-I-1730 (2-blades)
MT Propeller MTV-33-1-A/175-200 (2-blades)
Electrically adjustable propeller:
Woodcomp SR3000/2WN (2-blades)
1.2.2 Engines
Aeroplane VL-3E-1 is powered by aircraft engines produced by Bombardier-Rotax GmbH
company. Technical description of engines and instruction for the maintenance and annual inspection
and repairs of the engines are listed in the engines operating manuals.
ROTAX 912ULS
Rotax 912 ULS is 4-cylinder, 4-stroke liquid/air-cooled engine with opposed cylinders, with dry
sump forced lubrication, with separate oil tank, automatic adjustment by hydraulic valve tappet
and 2 carburetors. The engine is equipped by mechanical fuel pump, dual-electronic ignition,
electric starter, propellers speed reduction unit and air intake system.
ROTAX 914 ULS
Rotax 914 UL/F is 4-cylinder, 4-stroke liquid/air-cooled engine with opposed cylinders with turbo
charger, with automatic waste gate control. The engine has dry sump forced lubrication with
separate oil tank, automatic adjustment by hydraulic valve tappet, 2 carburetors dual electronic
ignition-electric starter, propeller speed reduction unit, engine mount assembly, air intake system
and exhaust system.

date of issue:
5/46
VL-3E-1 Maintenance Manual
1.2.3 Engine specifications - Rotax 912 ULS
Engine Manufacturer: ROTAX - BRP Powertrain GmbH Engine
Model: Rotax 912 ULS
Power:
Max. take –off: 73,5 kW / 100 hp
Max. continuous: 69 kW / 95 hp in 5500 RPM
Cruising: 66 kW / 90 hp in 4800 RPM
Engine RPM:
Max. Take-off: 5800 RPM max 5 min
Max. Continuous: 5500 RPM
Cruising: 4800 RPM
Idling: 1400 RPM
Cylinder head temperature:
Minimum: 60 °C
Maximum: 120 °C
Oil temperature:
Minimum: 50 °C
Maximum: 130 °C
Operating: 90 °C – 100 °C
Fuel pressure (if the fuel gauge and sensor are instaled):
Minimum: 0,15 bar
Maximum: 0,40 bar
1.2.4 Engine specifications - Rotax 914 F Turbo
Engine Manufacturer: ROTAX - BRP Powertrain GmbH
Engine Model: Rotax 914F
Power:
Max. take - off: 84,5 kW / 115 HP
Max. continuous: 73,5 kW / 100 HP in 5500 RPM
Cruising: 55,1 kW / 74 HP in 5000 RPM
Engine RPM:
Max. take-off: 5800 RPM max 5 min
Max. continuous: 5500 RPM
Cruising: 5000 RPM
Idling: 1400 RPM
Cylinder head temperature:
Minimum: 75 °C
Maximum: 135 °C
Oil temperature:
Minimum: 50 °C
Maximum: 130 °C
Operating: 90 °C – 110 °C
Fuel pressure: (if the fuel gauge and sensor are instaled):
Minimum: 0,15 bar
Maximum: 0,35 bar
Nominal : 0,25 bar

date of issue:
6/46
VL-3E-1 Maintenance Manual
1.3 List of disposable replacement part and operational fluids
1.3.1 Engine components
1.3.2 Landing gears components
BERINGER main and front wheels:
Landing gear component
Dimension - designation
BERINGER part No.
pcs
Front wheel tubeless tire
4.00-4” Kenda
PAG01
1
Main wheel tubeless tire
4.00-6” 6PLY Sava
PAD01
2
Front wheel tubeless tire
4.00-4” 8PLY Aero Classic
PAG03
1
Main wheel tubeless tire
4.00-6” 6PLY Aero Classic
PAD03
2
Brake pad –main wheels
6” WHEELS –SL RF-004
PQT- 003(A)/004(A)
2 sets
Brake disc –main wheels
6” WHEELS – SL RF-004
DSC - 006(A)
2
Recommended tires inflation pressures for BERINGER wheels:
•main wheel 3,0+-0,3 bars (44+-4 psi)
•front wheel 2,5+-0,3 bars (36+-4 psi)
1.3.3 Operational fluids
For more information about applicable operational fluids see Operators Manual Rotax 912ULS. For
ROTAX engine components contact your Rotax dealer. For other components contact your VL-3 dealer
or directly the VL-3 aeroplane producer:
Customer support JMB Aircraft s.r.o
phone: [phone] (ENG,FR)
e-mail: [e-mail]
1.3.4 Fuel
WARNING!
Based on experience from the operation of aircraft VL-3 we strongly recommend to use
quality prescribed fuel only! Using the poor quality fuel can cause a major failure in the fuel system!
Don’t use fuels than contain more then 10% of ethanol! These fuels have not been tested by
ROTAX company and are not permited for use!
•Automotive premium grade gasoline, leaded, according to DIN 516000,Ö-NORM C 1103
•EUROSUPER RON 95 unleaded accord. to DIN 51607,Ö-NORM 1100
•AVGAS 100 LL. Due to higher lead content in AVGAS, the wear of valve seats and deposits in the
combustion chamber will increase.Therefore, use AVGAS only if other fuel types are not available
Engine component
Designation
Part No.
pcs
Oil filter
Rotax oil filter
825012
1
Air filter
K&N Filters
SP-2704
2
Fuel filter
ALCO FF-005
251307
1
Ingnition plugs
NKG-R
DCPR 8E
4
Operational fluid
Designation
Amount
Engine oil
AeroShell Oil Sports Plus 4
3,5 liters
Engine coolant
Fridex G-Plus (ratio 1:1 with water)
2,5 liters
Hydraulic fluid
AeroShell Fluid 41
1,0 liter
Brake fluid
Valvoline - DOT 4
0,2 liter

date of issue:
7/46
VL-3E-1 Maintenance Manual
•Mogas European standart EN 228 Super, EN 228 Super Plus
•BA 95 Natural is recommended for Czech Republic
For other suitable fuel types refer to the engine ROTAX Operator’s Manual and ROTAX
Service instruction SI-912-016 for selection of the correct fuel.
1.4 Recomended tightening torque values
Maximal allowed tightening torque for bolts with mechanic property 5S
metric thread
M (mm)
tightening torque
M max (kpm)
tightening torque
M max (Nm)
4
0,17
1,67
5
0,35
3,45
6
0,60
5,90
8
1,50
14,70
10
3,00
28,40
1.5 Weight and balance informations
WARNING!
Permissible combination of weight the crew, fuel and luggage it is necessary to respect
admissible position of centre of gravity and maximum take-off weight as they are given in Pilot
Operating Handbook –chapter 6. Weight and balance.
1.5.1 Aeroplane empty weight and centre of gravity
Empty weight of the aeroplane is calculated for a plane with full basic equipment, i.e. including
outside painting, battery, flight and navigation instruments and with maximum level of working fluids
(engine oil, hydraulic fluid, brake fluid, engine coolant). The aeroplane is without crew, fuel and baggage.
Procedure of weighting the empty aeroplane:
1. Switch ON scales, put jacks on scales and reset scales - displays of all scales shows zero!
2. Put the aeroplane on three scales with jacks –see fig.1,2
3. Put bubble level on centre of canopy frame –see fig.3
4. Fit the aeroplane into horizontal position by screwing of back jack –see fig.4
(reference level is given by the canopy frame)
5. Check configuration of the aeroplane undercarriage –for retraction of wheels must be available
free space at least 25 cm under all wheels!
6. Read indicated values on the scales, measure requested dimensions and put all data into
“Weighting protocol”for centre of gravity calculation –see chapter 1.5.2.
Empty “Weighting protocol” is listed in chapter 10.Attachements
7. Calculate the weight and CG position of empty aeroplane according to procedure given in the
example of Weighting protocol for wheels extended.
8. Switch on instrument panel and by “Landing gear controler”retract undercarriage
9. Read indicated values on the scales and put all data into new “Weighting Protocol”
Calculate the weight and CG position of empty aeroplane according to procedure given in the
example of “Weighting Protocol”for wheels rectracted.
Empty “Weighting protocol” is listed in chapter 10.Attachements
10. Update empty weight of the aeroplane on the label in the cockpit and calculate useful load of
aeroplane = admissible weight of the crew, considering weight of fuel and weight of baggage.

date of issue:
8/46
VL-3E-1 Maintenance Manual
fig.1 - Two front jacks with scales fig.2 - Back jack with scale
fig.3 - Bubble level on canopy frame fig.4 –Positioning of back jack
1.5.2 Instructions how to fill out the „Weighting protocol“
Filling procedure of weighting protocol:
1. Write down the serial number of the aircraft –see (1)
2. Mark landing gears position for weighting (extended/retracted) - delete as applicable –see (2)
3. Read value on the back of scale –see (3)
4. Read value on the left and right front scales –see (4)
5. Write down all the weights into protocol –see (5)(6)
6. Add together all weights –see (7) and write down sum into protocol –see (8)
7. Measure the distance (a) between front and back jack –see (9)
8. Write down values into a formula –see (10) and calculated center of gravity position write into
protocol –see (11)
9. Measure the distance (b) between front jack and leading edge of wing at the connection point
the wing with fuselage –see (12)
10. Write down values into a formula –see (13) and calculated center of gravity position write into
protocol –see (14)
11. Write down date and sign Weighting protocol

date of issue:
9/46
VL-3E-1 Maintenance Manual
1.5.3 Aeroplane operating weight and centre of gravity
WARNING!
Operational weight and CG of the aeroplane must be always newly calculated before each flight.
Allowed aeroplane operational CG limits is: CG = 21 - 34 % M.A.C.
Based on knowledge of empty weight and CG of the aeroplane and knowledge of arms and
weights of individual items (crew, fuel and baggage) calculate operational weight and CG of the
aeroplane for extended and retacted undercarriage. Details are given in Pilot Operating Handbook -
chapter 6.2.2 - CG calculation.
Airplane :
Serial number :
Configuration :
Rr =Gr =
RL =Gleft =
RR =Gright =
=62 +125 +
62,0 ×
xT-b-xsat 814 -533 -
bsat
Date:
Signature:
68
x
100
1236
=
814
PR
310
m
4071
Weighting protocol
=
PL
125,0
62,0
125,0
xT =
Gr × a
xT(mm)
C.G. position
Rear support
=
62,0
Pr
Left front support
=
=
Right front support
Total weight
m = Gr+ Gleft + Gright
Displayed weight
Weight of support
Ri(kg)
Pi (kg)
VL-3-100
empty airplane - undercarriage extended / rectracted
Example of completed Weighting protocol
VL-3E-1
0
Weight
Gi=Ri-Pi (kg)
m (kg)
=
310,0
0
Weighting point
123,0
0
123,0
123
xbsat
=
17,2
%
xbsat =
× 100
=
C.G. position in % of depth of M.A.C.
1
2
3
4
5
6
7
8
10
11
13
14
12
9

date of issue:
10/46
VL-3E-1 Maintenance Manual
2. Inspections of aeroplane
WARNING!
For the safe operation of the aeroplane is necessary to observe prescribed periods and content
of service inspections and maintenance. Failure to observe these inspections reduce airworthiness and
safe operation and may cause serious malfunctions of aeroplane!
2.1 Pre-flight inspection
The pre-flight inspection is very important because an incomplete or careless inspection could
allow aeroplane failure. The pre-flight inspection procedure is given in Pilot Operating Handbook –see
chapter 4.2 Pre-flight inspection.
2.2 Periodical inspections
WARNING!
Observe these periodical inspections, but always respect the current technical condition of
the aeroplane. If you discover damage or other unsafe condition, do not wait for the periodic
inspection, and promptly repair the defect!
The basis of the aeroplane safe operation and airworthiness is thorough care of all aeroplane
components. Maintenance base are regular inspections of aircraft after 25,50,100,1000,2000 flight hours.
The details content of the periodical inspections are described in the “Maintenance Checklist” -
chapter 10.Attachment of this Maintenance Manual.
System of service inspection of the engine is described in the Maintenance Manual issued by
the engine manufacturer.
System of service inspection of the propeller is described in the Maintenance Manual issued
by the propeller manufacturer.
2.2.1 Instructions for filling out the Maintenance Checklist
1. Before making periodic inspection of aerolpane print a new copy the "Maintenance
Checklist" listed in chapter 10.Attachment of this Maintenance Manual
2. Complete details of airplane and date of inspection
3. Select and mark the type of performed inspection
4. Fill in a name of mechanic and quality inspector
5. When performing aeroplane inspection follow step by step items of "Maintenance
Checklist"
6. Each item execution indicate by mark in the appropriate square
7. In the end of „Maintenance Checklist“ to confirm the performed inspection by signatures
(mechanic,quality inspector)
8. Keep the completed „Maintenance Checklist“ for the next service period
9. All found defects of airplane and their elimination write into the Maintenance Log
Book!