Light Sport Aviation EV-97 EUROSTAR SL MICROLIGHT User manual

EV-97 EUROSTAR SL
MICROLIGHT
MAINTENANCE MANUAL
GEN/EUR/04
Light Sport Aviation Tel. Office: 01494 524020
Wycombe Air Park, Email: [email protected]
Hangar 1 Web: www.lightsportaviation.org.uk
Booker
Marlow
Buckinghamshire
SL6 3DP

EV-97 Eurostar SL Microlight Maintenance Manual GEN/EUR/04 Issue 3 2
Amendment Record
Issue
Details of Change
Date
Authorised
1
First Issue
12/05/14
2
Changes to electrical circuit diagrams (Appendix 5)
15/07/14
Change to trim tab deflection (pages 29 and 42)
15/07/14
3
Change to cockpit instruments (page 9 sect 2.12)
01/09/14

EV-97 Eurostar SL Microlight Maintenance Manual GEN/EUR/04 Issue 3 3
Table of Contents
1. Introduction...............................................................................................................................5
2. Aircraft Technical Description...................................................................................................5
2.1 General..............................................................................................................................5
2.2 Dimensions – Drawings......................................................................................................5
2.3 Basic dimensions...............................................................................................................6
2.4 Weight................................................................................................................................6
2.5 Centre of Gravity................................................................................................................6
2.6 Wing...................................................................................................................................7
2.7 Horizontal Tail Unit.............................................................................................................7
2.8 Vertical Tail Unit.................................................................................................................7
2.9 Landing Gear.....................................................................................................................7
2.10 Wheels...............................................................................................................................7
2.10.1 Wheel Brakes..............................................................................................................8
2.11 Tyres..................................................................................................................................8
2.12 Cockpit...............................................................................................................................9
2.13 Additional Equipment List...................................................................................................9
2.14 Control Systems.................................................................................................................9
2.15 Flap Control .....................................................................................................................10
2.16 Elevator Trim....................................................................................................................11
2.17 Power Plant......................................................................................................................11
2.18 Engine Operational Limits................................................................................................13
2.19 Engine Mount...................................................................................................................13
2.20 Engine Cowlings ..............................................................................................................13
2.21 Fuel System.....................................................................................................................14
2.22 Cooling System................................................................................................................14
2.23 Cockpit Heating System...................................................................................................14
2.24 Ventilation........................................................................................................................15
2.25 Electrical System..............................................................................................................15
2.26 Pitot-Static System...........................................................................................................15
2.27 Galaxy Balistic Rescue System GRS 6 473 SD B2..........................................................15
2.28 Stall Warner.....................................................................................................................16
3. Aircraft Assembly and Disassembly of Major Parts.................................................................16
3.1 Wing.................................................................................................................................16
3.2 Horizontal Tail Unit (HTU)................................................................................................18
3.3 Vertical Tail Unit...............................................................................................................18
4. Inspections and Scheduled Maintenance ...............................................................................18
4.1 Pre-Flight Inspection ........................................................................................................18
4.2 Post-flight inspection........................................................................................................19
4.3 Periodic inspections.........................................................................................................19
4.3.1 Periodic inspection intervals ......................................................................................19
4.3.2 Periodic maintenance and inspection work sheets.....................................................19
4.3.3 Periodic Maintenance and Inspections......................................................................20
5. Maintenance Procedures........................................................................................................27
5.1 Rotax 912 UL engine .......................................................................................................27
5.2 Oil ....................................................................................................................................27
5.3 Oil Draining......................................................................................................................27
5.4 Oil Filter Replacement......................................................................................................27
5.5 Coolant ............................................................................................................................27
5.6 Brake System...................................................................................................................28
5.6.1 Fluid Type..................................................................................................................28
5.6.2 Brake fluid refilling .....................................................................................................28
5.6.3 Brake fluid emptying..................................................................................................28
5.6.4 Brake Pad Replacement............................................................................................28
5.6.5 Bleeding ....................................................................................................................29
5.7 Control Surface Deflection Setting ...................................................................................29
5.7.1 Aileron.......................................................................................................................31

EV-97 Eurostar SL Microlight Maintenance Manual GEN/EUR/04 Issue 3 4
5.7.2 Flap ...........................................................................................................................31
5.7.3 Elevator.....................................................................................................................31
5.7.4 Rudder.......................................................................................................................32
5.7.5 Trim Tab....................................................................................................................32
6. Fueling ...................................................................................................................................32
6.1 Filling – Precaution...........................................................................................................32
6.2 Fuel emptying ..................................................................................................................33
7. Lubrication..............................................................................................................................33
7.1 Engine..............................................................................................................................33
7.2 Airframe...........................................................................................................................33
7.3 Lubricating Points.............................................................................................................34
7.4 Access Holes for Lubricating & Inspection .......................................................................34
8. Bolt Tightening .......................................................................................................................35
9. Rudder ...................................................................................................................................35
9.1 Rudder Cable Tension Adjustment...................................................................................35
9.2 Rudder Pedal Adjustment ................................................................................................36
10. Trim Tab Control Cable Tension.............................................................................................36
11. Jacking the Aircraft.................................................................................................................36
12.Puncture Repair .....................................................................................................................36
12.1 Main wheel:......................................................................................................................37
12.2 Nose wheel:.....................................................................................................................37
12.3 Puncture Repair – all tyres...............................................................................................37
12.4 Tyre pressures (for tyre size 14 x 4 or 400 x 6)...............................................................37
13. Small Repairs.........................................................................................................................37
14. Care and Cleaning Recommendations...................................................................................38
14.1 External Paint...................................................................................................................38
14.2 Canopy ............................................................................................................................38
14.3 Upholstery........................................................................................................................38
15. Levelling.................................................................................................................................38
16. Control Surface Deflections....................................................................................................38
17. Permissible Tolerances (Play)................................................................................................39
18. Weighing the Aircraft and Centre of Gravity Calculation .........................................................40
18.1 Empty weight determination.............................................................................................40
18.2 Operating c.g. range calculation.......................................................................................41
Appendix 1 - Levelling Record ......................................................................................................42
Appendix 2 - Control Surface Deflection Record...........................................................................43
Appendix 3 - Weight & Balance Record........................................................................................44
Appendix 4 - Flight Test Record....................................................................................................45
Appendix 5 – Electrical Circuit Diagrams ......................................................................................46
Appendix 6 - Additional Equipment List.........................................................................................47

EV-97 Eurostar SL Microlight Maintenance Manual GEN/EUR/04 Issue 3 5
1. Introduction
This Maintenance Manual gives recommended procedures for ensuring the continued
airworthiness of the aircraft. Maintenance requirements will depend on aircraft usage and may
need amending accordingly. The operator should always be alert for developing problems and
attentive to ensuring their timely rectification.
2. Aircraft Technical Description
2.1 General
The Eurostar SL airframe is a metal/composite, semi-monocoque construction formed with metal
reinforcements, bulkheads and Duralumin skins. Both pop (blind) rivets and solid rivets are used
for joints. All Metal parts are primary structures. All composite parts, with the exception of the
undercarriage legs, are non-structural (secondary structures).
2.2 Dimensions – Drawings

EV-97 Eurostar SL Microlight Maintenance Manual GEN/EUR/04 Issue 3 6
2.3 Basic dimensions
Wing span...............................................26.57 ft. 8.1m
Wing area.............................................105.92 sq. ft. 9.84m2
MAC .........................................................4.10 ft. 1.25m
Wing loading (MTOW, 1030 lb, 472.5 kg) 9.72 lb./sq. ft. 48 kg/m2
Aileron area..............................................2.26 sq. ft. 0.21m2
Flap area ...............................................5.60 sq. ft. 0.52m2
Fuselage length......................................19.62 ft. 5.98m
Fuselage width .........................................3.41 ft. 1.04m
Fuselage height........................................7.68 ft. 2.34m
Horizontal Tail Unit (HTU)
Span.........................................................8.20 ft. 2.5m
HTU area................................................20.99 sq. ft. 1.95m2
Elevator area............................................8.61 sq. ft. 0.8m2
Vertical Tail Unit (VTU)
Height.......................................................4.21 ft. 1.28m
VTU area................................................10.93 sq. ft. 1.02m2
Rudder area..............................................4.67 sq. ft. 0.43m2
Landing gear
Wheel track...............................................5.25 ft. 1.6m
Wheel base...............................................4.42 ft. 1.35m
Main wheel diameter................................. 14 in 350mm
Nosewheel diameter................................. 14 in 350mm
2.4 Weight
Empty weight will vary with selection of options and small manufacturing variations. However there
is a maximum limit to the aircraft’s dry empty weight, as shown below.
Empty weight max.(standard equipment) 290.5kg + 0, - 3%
Maximum Take-off weight 472.5kg
Maximum Landing weight 472.5kg
Max. fuel weight, (standard 65 l fuel tank) 47kg
Maximum weight in Baggage Compartment 15kg
NOTE
Actual empty weight is stated on the placard “LOAD LIMITS,“
located on the instrument panel.Empty weight includes 2.9 litres of unusable
fuel.
2.5 Centre of Gravity
Empty weight CG (standard equipment) 18 ±2% Mean Aerodynamic Chord (MAC)
200 – 250mm AoD
Operating CG 20-34% MAC
250 – 410mm AoD

EV-97 Eurostar SL Microlight Maintenance Manual GEN/EUR/04 Issue 3 7
ANGLE REINFORCEMENT
MAIN LEG
MAIN LEG ATTACHMENT
MAIN LEG ATTACHMENT
2.6 Wing
The rectangular wing has a single, aluminium main spar and rear spar to which are attached
ailerons and flaps. All components are riveted. The composite wing tips are attached by rivets.
2.7 Horizontal Tail Unit
The rectangular HTU comprises a stabilizer and elevator with trim tab. It has a semi-monocoque
construction (i.e. the skins bear part of the load), consisting of Duralumin pressed ribs, spar and
skins. The HTU width of 2.5m permits transport by road without removal.
The stabilizer is attached to the fuselage by two pins at the leading edge and secured with two
screws at the trailing edge.
2.8 Vertical Tail Unit
The trapezoidal VTU comprises fin and rudder. The rudder is attached to the fin by two hinges
consisting of spherical joints bolted into the fin’s trailing edge spar.
A composite fairing is fitted immediately forward of the fin, blending its surface with that of the
fuselage top.
Neither composite tip, nor forward fairing takes significant structural loads.
2.9 Landing Gear
The fixed gear consists of:
•a steerable nose wheel on a leg sprung on a rubber rope suspension. The nose leg is
constructed from steel tube and mounted on the firewall on two bearings. The nose wheel
is steered by two push rods connected to the rudder pedals.
•hydraulically braked main wheels and composite spring legs attached to the fuselage cross
member under the seats. These legs are designed to deflect to reduce landing impact.
The leg’s attachment to the fuselage is shown below:
2.10 Wheels
1
7
°
NOSE WHEEL
CONTROL ROD
FOOT PEDAL
SUSPENSION STOP
NOSE WHEEL LEG
RUBBER ROPE SUSPENSION
FUSELAGE FRAME
WHEEL AXLE
WASHER
E 54-04 21
NUT 765 155
WASHER 765 478
NOSE WHEEL ASSEMBLY
COTTER PIN 4x40
ČSN 02 1781.04
1

EV-97 Eurostar SL Microlight Maintenance Manual GEN/EUR/04 Issue 3 8
Each wheel consists of a two-part cast alloy rim with tyre and inner tube. The main wheels are
mounted on an axle secured to the composite leg by 4 bolts. Cross sections of the main and nose
wheels and their axles are shown below:
2.10.1 Wheel Brakes
Both wheels on the main landing gear are equipped with hydraulic disc brakes. The brake
system consists of the brake pedals (pilot standard, co-pilot as an option), hydraulic brake
master cylinders, plastic hoses, brake caliper with the hydraulic brake cylinder, brake pads and
the brake disc which is bolted onto the inner part of the rim.
The brakes on both wheels are controlled independently by toe brake pedals mounted on the
pilot’s and the co-pilot’s rudder pedals.
Fig. The brake control with toe brake pedals
1 – ruder pedals, 2 – brake cylinder, 3 – nose wheel steering rod
2.11 Tyres
SAVA 14 x 4 (standard), all three wheels.
NOSE WHEEL LEG
WHEELAXLE
WASHER
E 54-04 21
NUT 765 155
WASHER 765 478
NOSE WHEELASSEMBLY
COTTER PIN 4x40
ČSN 02 1781.04
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
2
3
2
1
1
3
1
2
2
1
WARNING
When adjusting the rudder pedals, if the plungers are not fully engaged in one of the
three holes in the plate, the pedal may rotate backwards and prevent rudder movement.
See Brake Pedal Adjustment section 9.2

EV-97 Eurostar SL Microlight Maintenance Manual GEN/EUR/04 Issue 3 9
2.12 Cockpit
Two side by side seats have between them the levers
for elevator trim and flaps. Floor covering is lightweight
removable carpet and interior trim panels can be
removed for cleaning or access.
The canopy has two parts: a fixed part to the rear and a
forward-opening part at the front. Acrylic (Perspex)
transparencies are used in both parts. Two gas struts
aid opening and a lock is fitted to the top rear of the
opening section. The lock mechanism carries a micro-
switch operating a lamp on the panel showing the pilot
when the canopy is properly locked.
The following electronic or analogue instruments are fitted to the panel:
1. Airspeed Indicator (ASI)
2. Altimeter
3. Compass
4. Vertical Speed Indicator(VSI)
5. Tachometer
6. Cylinder Head Temperature (CHT) gauge
7. Oil temperature gauge
8. Oil pressure gauge
9. Fuel pressure gauge
10. Fuel contents gauge
11. Engine hours indicator.
2.13 Additional Equipment List
See additional equipment list Appendix 6 if applicable
2.14 Control Systems
Longitudinal Control (Pitch) – The elevator is controlled by a system of push rods. Movement of the
control stick is passed into a torque tube running along the front of the seats. An arm is attached
to this tube near its centre which connects a push rod to a relay arm mounted beneath the
baggage bay. From here, a second push rod connects to an intermediate relay arm mount half
way along the fuselage rear, and from this point a third push rod connects to the elevator horn; the
system is shown below.
See additional equipment list Appendix 5 if applicable
Elevator trim
Flap lever

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Lateral Control (Roll) – ailerons are also controlled by push rods. Lateral movement of either
control stick is transferred, via a short rod in the cockpit, to a long push rod in the wing,
immediately in front of the main spar. A bell crank, connected to the end of the long push rod,
converts span wise movement to a chord wise one, and a third pushrod terminates on the aileron
horn to deflect it up or down. The short chord wise push rods can be adjusted to achieve the
correct aileron deflections. The control stick base incorporates a stop.
Directional Control (Yaw) – cables, attached to arms at the end of the rudder pedals’ torque tubes,
are guided along the sides of the fuselage to the rudder horn. Stops, in the form of swages
crimped on to the cable, are located at points where the cable passes through fuselage side
stiffeners; adjusters are installed at these points.
Push rods attached to the inboard rudder pedals connect to either side of the steering yoke of the
front wheel, permitting direct steering via the rudder pedals. Since this system and the rudder
cables form a closed loop, rudder cable tension can be adjusted by changing the lengths of the
steering push rods, using the rod ends screwed into their ends.
Toe Brakes - The brakes are controlled independently by hydraulic toe brake pedals mounted on
the pilot’s and the co-pilot’s (optional) rudder pedals.
2.15 Flap Control
Wing flaps are controlled by a gated lever located between the seats; the lever is released by
pressing the lock button on the lever’s end.
Push – pull movement of the lever is translated into a longitudinal movement of a push rod by a
quadrant mounted at its base. The other end of the push rod connects to the arm of a torque tube
passing across the fuselage and exiting the wall at each side adjacent to the flap end. An arm on
each end of the torque tube engages in slots in the flap end to deploy or retract the flaps. Where
the arm engages in the flap end, an eccentric is provided to permit fine adjustment and balance of
the flaps’ deflections. The system is shown below: