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!

date of issue:
11/46
VL-3E-1 Maintenance Manual
3. Structures
3.1 Fuselage
3.1.1 Fuselage design
The fuselage is designed as sandwich shell with transverse cross bulkheads. Engine-compartment
is separated from cockpit by sandwich firewall. Engine bed is fastened on the firewall, which is protected
against fire and heat by a steel sheet. Upper and lower engine cowlings are produced from carbon-glass
composite. Front part of fuselage and cockpit for crew are from hybrid kevlar-carbon composite. Behind
both pilot seats is luggage space. Canopy with carbon frame is covered by transparent acrylic glass which
provides excelent all-round view. The rear part of the fuselage is desined as carbon sandwich shell.
fig.5 –Fuselage design
3.1.2 Allowable maintenance
Washing:
For the first stage of washing use plenty of water with addition of car shampoo. Wipe down the
impurities by water with a soft sponge. Remove water with dissolved detergent by plenty of fresh
water and dry fuselage by suitable soft cloth or synthetrical buckskin.
Greasing:
For the purpose of greasing any semisolid grease (NO SILICONE) can be used, e.g. plastic grease
ISO 6743/9 CCEB2, (DIN 51502 KP2K-30). For application use a small brush (diameter 1cm). The
grease must be applied on the next points of fuselage:
4 bearings - main tennons of both wing

date of issue:
12/46
VL-3E-1 Maintenance Manual
3.2 Wing
3.2.1 Wing design
Wing is designed as a sandwich shell from carbon fabric without any ribs. There are two integral
fuel tanks in the base part of the wings. Connection of both wings with the fuselage is accomplished by
two pegs in the base ribs of wings. The wings are connected together with cantilever beams which extend
the meain beams of the wings and which are connected and fastened down with a plug. Balancing and
portly lifting flaps are hanged on subsidiary beams.
fig.6 –Wing design
3.2.2 Allowable maintenance
Washing:
For the first stage of washing use plenty of water with addition of car shampoo. Wipe down the
impurities by water with a soft sponge. Remove water with dissolved detergent by plenty of fresh
water and dry wings by suitable soft cloth or synthetrical buckskin.
Greasing:
For the purpose of greasing any semisolid grease (NO SILICONE) can be used, e.g. plastic grease
ISO 6743/9 CCEB2, (DIN 51502 KP2K-30). For application use a small brush (diameter 1cm).
Greasing is best done if the wings are removed from the fuselage. The grease must be applied on
the next points of wing:
5 hinges of wing flaps
2 hinges of ailerons
bearings in control pushrods of wing flap
bearings in control pushrods of aileron

date of issue:
13/46
VL-3E-1 Maintenance Manual
3.2.3 Disassembly of wings
For disassembly of wings are needed 3 persons. At least one of them must be trained for this
purpose by the aeroplane producer or aeroplane local dealer.
Procedure of wings disassembly:
1. By wings drain valves drain fuel from both main wings fuel tanks
2. Buttress the ends of both wings by 2 supports
3. Remove upholstery of both pilot seats
4. Dismount both composite seats
5. Remove upholstery on both sides of cockpit (front of the seats) and remove side covers
6. Cut all plastic tapes for fixation fuel hoses and electrical cables of main fuel tanks on both
sides
7. Dismount cover of the main wings pin on the right side of tunnel between seats
8. Remove the tapes covers the connections wings-fuselage
9. Secure the ailerons in neutral position by glue tape for further disassembly
10. Disconnect ailerons long pushrods of control lines of both ailerons under the seats. Then
secure the ailerons in neutral position by a tape prior to further disassembly
11. Disconnect the control lines of both flaps –open the flaps into the position for landing and
disconnect the both short pushrods near by flaps. Then close both flaps by hand and
secure the flaps in closed position by a tape prior to further disassembly
12. Using the steel mounting rod, turn the safety pin of the wings for angle 180 deg.
13. Using the steel mounting rod, by oscillating motion pull out the safety pin rearwards
14. Both wings pull out approx. 20 cm from the fuselage
15. Disconnect all cables of electric installation and all fuel hoses of both main fuel tanks
16. Blind ends of the all fuel hoses in the fuselage and in both wings and secure all the blinds
by clips –see fig.6 (1)
17. Disconnect 2 hoses of the pitostatic system between the left wing and the fuselage and
blind all free ends of Pittot.static hoses and fuel hoses by tape –see fig.6 (2)
18. Secure spacers on the 2 main wings tenons by plastic tapes –see fig.6 (3)
19. Pushrod of aileron wrapped by foam material –see fig.6 (4)
20. Remove both wings from the fuselage and place them into a supports –by leading edge of
wings downwards
fig.6 –Left wing after disassembly
(1)
(3)
(3)
(2)
(4)

date of issue:
14/46
VL-3E-1 Maintenance Manual
3.2.4 Assembly of wings
For assembly of wings are needed 3 persons. At least one of them must be trained for this
purpose by the aeroplane producer or aeroplane local dealer.
Procedure of wings assembly:
1. Remove upholstery of both pilot seats
2. Dismount both pilot seats
3. Remove upholstery on both sides of cockpit (front of the seats) and remove side covers
4. Wing flaps lever in the cockpit move to the position flaps closed
5. Prepare both wings for assembly. Support the both wings tightly and keep it approx. in the
flying position –i.e. buttress the ends of both wings by 2 supports and insert the
crossbeams of both wings into the fuselage. Root ribs of wings are approx. 20 cm from the
fuselage (ailerons must be fasten in neutral and flaps in closed position by plastic tape)
6. Remove all blinds from the fuel hoses in the fuselage and both wings, connect all fuel hoses
by connectors and secure by clamps –see fig.7,8
7. Connect cables of electric installation of both fuel tanks between wings and the fuselage
–see fig.7,8
8. Remove tape from ends of 2 hoses of pitotstatic system in the fuselage and left wing and
connect them by quick coupling –see fig.9
9. Open the flaps lever in the cockpit to the position for landing (55°) and open the right and
left wing flaps on both wings
10. Remove plastic tapes from the spacers on the 2 main wing tenons and put little bit grease
on both main wing tennons –see fig.10
11. Push the both wings tightly into the fuselage, insert the 2 main tenons of the each wing into
the bearings of the fuselage (it is necessary to observe right position of the aileron pushrod
and at the same time push connected fuel hoses and cables of electric installation into the
fuselage) Crossbeams of both wings must clinch through the balls at their ends one into
another!
12. Place the connecting pin of wings into the bushings of the both crossbeams - red mark on
the pin downwards!
13. Using a mounting steel bar and by oscillating motion, push the connecting pin into
bushings of both corssbeams of the wings –until it reaches the end position –see fig.11
14. By mounting steel bar rotate connecting pin by angle 180°- the red mark on the pin must
shows up!
15. Using the safety pin ensure the wings connecting pin to the console, safety pin ensure by
plastic tape –see fig.12
16. Connect the left and right short pushrods of wing flaps control line with pins of flaps and
ensure it by crown nuts with cotter pins only! Ensured joint mark by red color –see fig.13
17. Connect the left and right long pushrods of ailerons control line and ensure it –use crown
nuts with cotter pins only! Ensured joint mark by red color –see fig.14
18. Fasten fuel hoses and cables of electric installation of both wings by using plastic tapes
19. Install all side covers on both sides in front of cockpit and adhere back the upholstery
20. Install the cover of the connecting pin of the wings on the central tunnel
21. Install back both composite seats and adhere cushions of upholstery of both pilot seats
22. Stick on the new tape, that covers the slit between the wings and the fuselage

date of issue:
15/46
VL-3E-1 Maintenance Manual
3.2.5 Pictures of important check points –assembly of wings
fig.7 - Fuel hoses and electric cables fig.8 - Fuel hoses and electric cables
connection in left wing connection in right wing
fig.9 - Hoses of pitotstatic system –connection fig.10 - Main tenons of wings –greasing
fig.11 - Connecting pin of wings - assembly fig.12 - Connecting pin of wing –ensuring

date of issue:
16/46
VL-3E-1 Maintenance Manual
fig.13 - Short pushrod of wing flaps –ensuring fig.14 - Long pushrod of ailerons –ensuring
After final assembly of wings check the freedom of movement and limit angles of ailerons and wing flaps!
Wing ailerons
limit angle –up
28°± 1°
limit angle –down
17°± 1°
Wing flaps
limit angle –small
15°± 1°
limit angle –middle
37°± 1°
limit angle –large
54°± 1°
Protocol of Aeroplane leveling and angles of control surface is listed in chapter 11.Attachements
3.3 Tail units
3.3.1 Tail units design
Tail units (stabilizator, elevator and rudder) are designed as a sandwich shell from carbon and
glass fabrics without any ribs. Connection of stabilizator with the fuselage is accomplished by two tenons
in the base rib of stabilizator. The elevator and ruder are connected together with stabilizator and fin by
hinges.
fig.15 - Rudder and elevator with trim

date of issue:
17/46
VL-3E-1 Maintenance Manual
3.3.2 Allowable maintenance
Washing:
For the first stage of washing use plenty of water with addition of car shampoo. Wipe down the
impurities by water with a soft sponge. Remove water with dissolved detergent by plenty of fresh
water and dry wings by suitable soft cloth or synthetrical buckskin.
Greasing:
For the purpose of greasing any semisolid grease (NO SILICONE) can be used, e.g. plastic grease
ISO 6743/9 CCEB2, (DIN 51502 KP2K-30). For application use a small brush (diameter 1cm).
Greasing is best done if the elevator and rudder are removed from the fuselage. The grease must
be applied on the next points:
6 hinges of elevator
2 hinges of rudder
3.3.3 Disassembly of tail units
For disassembly of tail units are needed 2 persons. At least one of them must be trained for this
purpose by the aeroplane producer or aeroplane local dealer.
Procedure of tail units disassembly:
Rudder:
1. Remove the 2 pcs of cotter nuts M6 from foot control ropes on the rudder. To release the
right rope of foot control is necessary to deflect the rudder to the right, to release the left
rope of foot control is necessary to deflect the rudder to the left. Bolts M6x25 to pull out
and release both ropes of foot control - see fig.16
2. By socket wrench remove the self-locking nut M6 from lower hinge of rudder - see fig.17
3. By pendulum motion and by pressure upward pull of the rudder from hinges - see fig.18
4. Rudder impose to the stand.
Elevator left:
1. Remove the 2pc of M6 self-locking nuts from control lever of the left elevator - see fig.19
2. By pendulum motion and by pressure to the left to pull out left half of elevator from
stabilizer hinges.
3. Remove 2pcs of washers 6x1mm and elevator save to the stand.
4. Elevator control lever adjust in stabilizer hinge by assembly pins. - see fig.20
Elevator right:
1. Remove the stops of control ropes from trim tab on the right half of the elevator.
2. Remove the 2pc M6 self-locking nuts from control lever of the right elevator. see fig.19
3. By pendulum motion and by pressure to the right to pull out right half of elevator from
stabilizer hinges.
4. Remove 2pcs of washers 6x1mm and elevator save to the stand.
5. Elevator control lever adjust in stabilizer hinge by assembly pin. - see fig.20
Stabilizer:
1. Remove elevator control lever from main hinges of stabilizer. Do not lose 2pcs of the
bronze washers 6x0,5mm between main stabilizer hinges and elevator lever!
2. To cut and pull out the safety wire, which ensures 12pcs hexagon screws M4x20 of the
stabilizer composite cross - see fig.21
3. Step by step dismantle all hexagon screws and remove the composite cross from the
stabilizer.
4. By pressure to the back pull out the stabilizer from the fuselage. Bowden with ropes of trim
tab pull out from the plastic hoses of stabilizer.
5. Stabilizer impose to stand.

date of issue:
18/46
VL-3E-1 Maintenance Manual
fig.16 –Ropes of foot control connection fig.17 –Lower pin of the rudder ensuring
fig.18 –Rudder disassembly fig.19 –Elevator and pushrod ensuring
fig.20 –Elevator contol lever fig.21 –Imbus screws and safety wire

date of issue:
19/46
VL-3E-1 Maintenance Manual
3.3.4 Assembly of tail units
For assembly of tail units are needed 2 persons. At least one of them must be trained for this
purpose by the aeroplane producer or aeroplane local dealer.
Procedure of tail units assembly:
Stabilizer:
1. Bowdens with ropes of trim tab control put through the plastic tubes in the stabilizer. Be
sure to match the right direction of the trim tabs control! (upper bowden from trim lever
put into lower plastic tube in stabilizer) - see fig.22
2. Stabilizer to put by 2 major pins into the slot of the fusselage.
3. From behind deploy composite cross on the stabilizer and put all 12pcs imbus screws
M4x20. Step by step tighten all screws by torque 1,67Nm.
4. Heads of hexagon screws ensure by safety wire and mark it by red colour - see fig.23
5. All stabilizer hinges and both sides of the elevator lever grease by vaseline - see fig.24
6. Between the 2 main hinges of stabilizer insert the elevator control lever - do not forget to
put 2pcs of the bronze washers diam.8x0,5mm between main stabilizer hinges and both
sides of elevator lever. Elevator control lever adjust in stabilizer hinges by 2 assembly pins
- see fig.25
Elevator right:
1. Put 2pcs of washers 6x1mm on the 2 screws of right elevator. All 3 pins of elevator hinges
grease by vaseline - see fig.26
2. Take the right elevator and put the 2 bowdens with ropes of trim tab control through the
plastic tubes in the right elevator. At the same time the right half of the elevator to put on
the stabilizer. By pendulum motion and pressure to the left, put 3 pins of elevator into
stabilizer hinges - see fig.27
3. Screws of the right elevator put into control lever of the elevator and secure it by 2pcs self-
locking nuts M6. For assembly you must always use new self-locking nuts! Gradually
tighten the self-locking nuts by torque 5,9Nm a mark it by red color. - see fig.28
4. Secure control ropes of trim tab by stops and mark by red color. Check the trim tab
freedom and the right direction of movement.
Elevator left:
Assembly procedure of the left elevator is very similar to assembly procedure of the right.
1. Put 2pcs of washers 6x1mm on the 2 screws of left elevator. All 3 pins of elevator hinges
grease by vaseline - see fig.26
2. Take the left elevator and to deploy it on the stabilizer. By pendulum motion and pressure
to the right put 3 pins of elevator into stabilizer hinges.
3. Screws of the left elevator to put into control lever of the elevator and secure it by 2pcs self-
locking nuts M6. For assembly you must always use new self-locking nuts! Gradually
tighten the self-locking nuts by torque 5,9Nm a mark it by red color. - see fig.28
4. Assembly long pushrod of elevator control line with elevator lever by bolt M6x25. Slightly
tighten the cotter nut, insert split pin and mark it by red colour. - see fig.28
Rudder:
1. The 2 pins of rudder and 2 hinges in the fuselage grease by vaseline –as on the elevator.
2. Rudder put into the fuselage. By pendulum motion and downward pressure to deploy
pins of the rudder into the fuselage hinges. - see fig.29
3. The lower pin of the rudder ensure by self-locking nut M6 –use socket wrench lenght
17cm. During the assembly you must always use new self-locking nuts! The self-locking
nut tighten and check free movement of rudder - see fig.30

date of issue:
20/46
VL-3E-1 Maintenance Manual
4. Connect the ropes of foot control. To hook up the ropes of foot control is necessary to
deflect the rudder to the right for right rope and to the left for left rope assembly. Bolts
M6x25 insert from the top and bottom of the forks fit the washer 6x1mm and cotter nuts
M6. Slightly tighten the nuts, insert cotter pins and mark it by red colour - see fig.31
After final assembly of tail units check the freedom of movement and limit angles of rudder, elevator
and proper function of trim!
Elevator
limit angle –up
25°± 1°
limit angle –down
20°± 1°
Rudder
limit angle –left
30°± 1°
limit angle –right
30°± 1°
Protocol of Aeroplane leveling and angles of control surface is listed in chapter 11.Attachements
fig.22 –Bowdens of trim tab in stabilizer fig.23 –Imbus screws and safety wire
fig.24 –Grease hinges of stabilzer by vaseline fig.25 –Elevator contol lever