Tecnam P2002 Sierra User manual

MAINTENANCE
MANUAL
Doc. n° 2002/61
1
st
Edition, April 22
th
2008
Revision, 0
P2002 Sierra
BUILD NUMBER . . . . . . . . . . . .
BUILD YEAR . . . . . . . . . . . .
REGISTRATION MARKINGS . . . . . . . . . . . .

efore flying the aircraft we recommend careful reading of this manual, the flight
manual and the engine’s service manual. A thorough knowledge of the aircraft, of its
qualities and of its limitations will allow you to operate with greater safety.
The P2002 Sierra is an uncomplicated and sturdy machine whose features include simple
servicing and superior flying qualities. This manual describes time and modes for correct
servicing procedures. Scrupulously following instructions will insure that your P2002 Sierra
will accompany you dependably for a long time with optimal performance in absolute safety.
This manual consists of 6 sections; a table of contents at the beginning of each section will
allow you to reach quickly any selection.
Information contained herein is based on available data at time of publication, possible
variations shall be presented in servicing bulletins.
This manual describes correct servicing of parts manufactured by TECNAM and, in
subordinate measure, of the list of components purchased from external suppliers; for more
complete information on individual components it is necessary to refer to the component’s
manufacturer’s manual.
For additional information or explanations contact:
COSTRUZIONI AERONAUTICHE TECNAM s.r.l.
1
a
Traversa via G. Pascoli
80026 Casoria (NA)
081-7583210 081-7584528
www.tecnam.com
B
i

LIST OF VALID PAGES
Section Page Date Section Page Date
0 i 22
th
April 2003 C C-1 22
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April 2003
ii “ C-2 “
iii “ C-3 “
iv “ C-4 “
C-5 “
C-6 “
C-7 “
A A-1 22
th
April 2003 C-8 “
A-2 “ C-9 “
A-3 “ C-10 “
A-4 “ C-11 “
A-5 “ C-12 “
A-6 “ C-13 “
C-14 “
C-15 “
C-16 “
B B-1 22
th
April 2003 C-17 “
B-2 “ C-18 “
B-3 “ C-19 “
B-4 “ C-20 “
B-5 “ C-21 “
B-6 “ C-22 “
B-7 “
B-8 “
B-9 “
B-10 “
B-11 “
B-12 “
B-13 “ D D-1 22
th
April 2003
B-14 “ D-2 “
B-15 “ D-3 “
B-16 “ D-4 “
B-17 “ D-5 “
B-18 “
B-19 “
B-20 “
B-21 “
B-22 “
B-23 “
ii

Sezione Pagina Data Sezione Pagina Data
E E-1 22
th
April 2003 F F-1 22
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April 2003
E-2 “ F-2 “
E-3 “ F-3 “
E-4 “ F-4 “
E-5 “ F-5 “
E-6 “ F-6 “
E-7 “ F-7 “
E-8 “
E-9 “
E-10 “
E-11 “
iii

INDEX OF SECTIONS
General Section A
Inspection & servicing Section B
Airframe Section C
Powerplant Section D
Systems Section E
Electrical systems Section F
iv

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Edition, April 22
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P2002 Sierra
MAINTENANCE MANUAL
SECTION A
GENERAL
pag. A-1
SECTION A
GENERAL
TABLE OF CONTENTS
1 – DESCRIPTION & GENERAL CHARACTERISTICS--------------------------------------------------2
PRIMARY DIMENSIONS -----------------------------------------------------------------------------------------3
ENGINE -------------------------------------------------------------------------------------------------------------4
PROPELLER--------------------------------------------------------------------------------------------------------4
FUEL ----------------------------------------------------------------------------------------------------------------5
O IL S YSTEM ----------------------------------------------------------------------------------------------------------5
COOLING-----------------------------------------------------------------------------------------------------------5
MAXIMUM WEIGHTS --------------------------------------------------------------------------------------------6
STANDARD WEIGHT ---------------------------------------------------------------------------------------------6
SPECIFIC LOADINGS--------------------------------------------------------------------------------------------6

2
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Edition, April 22
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, 2008
P2002 Sierra
MAINTENANCE MANUAL
SECTION A
GENERAL
pag. A-2
1 – DESCRIPTION & GENERAL CHARACTERISTICS
The P2002 Sierra is a twin seat, single engine, low wing, metal structure mono-
plane with tricycle landing gear and steerable nose gear.
Figure A-1 shows a Three View drawing of the aircraft while the following table re-
port main technical features and dimensions.
F IGURE A-1 G ENERAL V IEWS

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P2002 Sierra
MAINTENANCE MANUAL
SECTION A
GENERAL
pag. A-3
PRIMARY DIMENSIONS
WING
Wing span 8.6 m
Wing surface 11.5 m
2
Wing loading 39 kg/m
2
Aspect ratio 6.4
Taper ratio 0.6
Dihedral 5°
FUSELAGE
Length overall 6.61 m
Width overall 1.11 m
Height overall 2.43 m
EMPENNAGE
Stabilator span 2.90 m
Vertical tail span 1.10 m
LANDING GEAR
Wheel track 1.85 m
Wheel base 1.62 m
Main wheel tyres: Air Trac 5.00-5
Nose gear tyre: Sava 4.00-6
CONTROL SURFACE TRAVEL RANGE
Ailerons up 25° down 19 ° ±2°
Stabilator up 15° down 3° ±1°
Trim 2° ; 9° ±1°
Rudder Lh 30° Rh 30° ±2°
Flap 0°; 40° ±1°

2
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Edition, April 22
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P2002 Sierra
MAINTENANCE MANUAL
SECTION A
GENERAL
pag. A-4
ENGINE
Manufacturer Bombardier-Rotax GmbH
Model 912 ULS
4 cylinder horizontally-opposed twins with overall
displacement of 1352 c.c., mixed cooling, (water-
cooled heads and air-cooled cylinders), twin carbu-
retors, integrated reduction gear with torque dam-
per.
Maximum rating 73.5 kW (98.6 hp) @ 5800 giri/min - max. 5 min.
69.0 kW (92.5 hp) @ 5500 giri/min - continuous
PROPELLER
Manufacturer F.lli Tonini Giancarlo & Felice S.n.c.
Model GT-2/173/VRR-SRTC FW101
Number of blades 2
Diameter 1730 mm
Type Fixed pitch - wood

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P2002 Sierra
MAINTENANCE MANUAL
SECTION A
GENERAL
pag. A-5
FUEL
Fuel grade •Min. RON 95
•EN 228 Premium
•EN 228 Premium plus
•AVGAS 100LL (see Flight Manual Sec. 2)
Fuel tanks 2 wing tanks integrated within the wing's
leading edge with fuel strainer located in
engine cowling
Capacity of each wing tank 50 L
Total capacity 100 L
Oil System
Oil system type Forced, with external oil reservoir
Oil Lubricant specifications and grade are
reported into the “Rotax Operator’s
Manual” and in its related documents
Oil Capacity: max. 3.0 litres – min 2.0 litres
COOLING
Cooling system: Mixed air and liquid pressurized
closed circuit system
Coolant: Coolant type and specifications are re-
ported into the “Rotax Operator’s
Manual” and in its related documents.

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Edition, April 22
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P2002 Sierra
MAINTENANCE MANUAL
SECTION A
GENERAL
pag. A-6
MAXIMUM WEIGHTS
Maximum Takeoff weight 450 kg
Maximum Landing weight 450 kg
STANDARD WEIGHT
Standard empty weight 289 kg
SPECIFIC LOADINGS
Wing loading 39 kg/m
2
Power loading 4.6 kg/hp

P2002 Sierra SECTION B
MAINTENANCE MANUAL pag. B-1
2
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Edition, April 22
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, 2008
INSPECTION & SERVICING
SECTION B
INSPECTION & SERVICING
TABLE OF CONTENTS
1 GROUND HANDLING--------------------------------------------------------------------------------------- 2
2 PARKING AND TIE-DOWN-------------------------------------------------------------------------------- 2
3 JACKING------------------------------------------------------------------------------------------------------- 2
4 LEVELLING--------------------------------------------------------------------------------------------------- 4
4.1 L ONGITUDINAL LEVELLING ----------------------------------------------------------------------------------- 4
4.2 T RANSVERSAL L EVELLING ------------------------------------------------------------------------------------- 4
5 MOVING SURFACES CONTROL SETTINGS---------------------------------------------------------- 5
5.1 S TABILATOR SETTING ------------------------------------------------------------------------------------------ 5
5.2 T RIM - TAB ADJUSTMENT --------------------------------------------------------------------------------------- 5
6 AIRCRAFT ALIGNMENTS--------------------------------------------------------------------------------- 6
6.1 D ATUM --------------------------------------------------------------------------------------------------------- 7
6.2 N OMINAL DISTANCES ------------------------------------------------------------------------------------------ 7
7 WEIGHING AND DETERMINATION OF VERTICAL CG ------------------------------------------ 8
8 CORROSION PREVENTION------------------------------------------------------------------------------10
9 SERVICE BULLETINS-------------------------------------------------------------------------------------11
10 SERVICING.------------------------------------------------------------------------------------------------12
11 LUBRICATION---------------------------------------------------------------------------------------------14
11.1 INTRODUCTION -----------------------------------------------------------------------------------------14
11.2 LUBRICATION POINTS (S EE FIG . B-6 & B-7)--------------------------------------------------------14
12 INSPECTION-----------------------------------------------------------------------------------------------17
13 INSPECTION-----------------------------------------------------------------------------------------------18
13.1 INTRODUCTION -----------------------------------------------------------------------------------------18
13.2 PERIODIC INSPECTIONS------------------------------------------------------------------------------19
13.3 SERVICING REQUIREMENTS -------------------------------------------------------------------------19
14 SUMMARY OF REFERENCE VALUES -------ERRORE. IL SEGNALIBRO NON È DEFINITO.

P2002 Sierra SECTION B
MAINTENANCE MANUAL pag. B-2
2
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Edition, April 22
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, 2008
INSPECTION & SERVICING
1GROUND HANDLING
Move the aircraft on ground by pulling on the propeller blades close to
hub. A tow bar can be attached to fittings. Aircraft can be steered using the
rudder or, for sharp turns, by lowering the tail to raise nosewheel off the
ground. In this case, owing to the favorable CG location, a gentle push on
the tailcone just ahead of empennage surfaces is all that is needed. Avoid
dragging nosewheel sideways and do not attempt to counter any movement
of the aircraft by handling it by its wing tips.
2PARKING AND TIE-DOWN
As a general precaution for outdoor parking, it is wise to position aircraft
into the wind and to set the parking brakes or chock the wheels if chocks
are available.
In severe weather and high wind conditions, aircraft tie-down is recom-
mended. Tie ropes should be secured to the wing tie-down fittings located
under each wing. Secure opposite end of ropes to ground anchors. Nose
gear fork may be used as fixing for forward tie-down.
Aircraft control stick should be locked using safety belts to prevent possi-
ble weathervaning damage to control surfaces.
3JACKING
For the jacking of the main landing gear, two lifting points are provided
under the two outer keelsons (see Figure B-1). The lifting point consists of
a small aluminium cylinder fastened to the outer keelsons. Below of it
could be placed either a hydraulic jack or a lifting rod. The lifting point is
realized with a φ 11mm hole which could be used to fit a lifting rod safety
pivot. Given the light empty weight of the aircraft, lifting one of the main
wheels can be easily accomplished even without the use of hydraulic jacks.

P2002 Sierra SECTION B
MAINTENANCE MANUAL pag. B-3
2
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Edition, April 22
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, 2008
INSPECTION & SERVICING
F
IGURE B-1 R EAR LIFTING POINT
In case of it would be necessary to lift the nose gear, we suggest you to
remove the engine’s cowling and then, acting on the engine’s mount, lift
the aeroplane.
As general rule, apply force to aircraft structure only on main struc-
tural elements such as frames, ribs or spars.
WARNING

P2002 Sierra SECTION B
MAINTENANCE MANUAL pag. B-4
2
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Edition, April 22
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, 2008
INSPECTION & SERVICING
4LEVELLING
Occasional levelling of aircraft may be necessary to insure proper wing in-
cidence and/or dihedral or for exact CG location.
F IGURE B-2 L ONGITUDINAL L EVELLING
4.1 LONGITUDINAL LEVELLING
To check the longitudinal levelling act as follows:
•Slide off one of the two seat to get the access to the two seat track’s
supporting trusses.
•Place longitudinally a spirit or water level over the two supporting
trusses using, if necessary, a straight piece of wood as indicated
into figure B-2.
•Adjust the aircraft’s tilt through shims placed under wheels or by
regulating tire pressure.
4.2 TRANSVERSAL LEVELLING
With one seat removed place a level along the forward seat track’s supporting
truss. Level the aeroplane by deflating the main gear tyres.

P2002 Sierra SECTION B
MAINTENANCE MANUAL pag. B-5
2
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Edition, April 22
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, 2008
INSPECTION & SERVICING
5MOVING SURFACES CONTROL SETTINGS
Adjustment of control surfaces must not exceed travel limits reported in
table below.
5.1 STABILATOR SETTING
In order to find the stabilator’s “zero” the aeroplane must be previously
longitudinally levelled. Place a shim 19mm thick over the stabilator’s rear
spar and place the level over the shim and the stabilator’s tubular spar (see
figure B-3), then level the stabilator.
F
IGURE B-3 S TABILATOR SETTING
5.2 TRIM-TAB ADJUSTMENT
The following procedure lists the operation to be carried out to adjust the
trim tab excursion:
•Set the stabilator in its “zero” position and lock it in this position.
•Turn the Master switch ON.
•Trim to maximum pitch-up;
•Adjust thread of hinged control rod until tab is deflected down-
wards 9° (use a protractor or measure downward displacement of
trailing edge - 9° is approximately 16mm);
•Tighten lock-nut for adjustment thread and fasten connecting pin
of control rod to trim-tab.
AILERONS (starting from tip line-up) up 25
o
dwn 19
o
±1
o
STABILATOR up 15
o
dwn 3
o
±1
o
TRIM ( Stab. at 0
o
, see picture below) 2
o
9
o
±1
o
RUDDER Lh 30
o
Rh 30
o
±2
o
FLAPS ( max. travel ) 0
o
40
o
±1
o
CONTROL CABLE TENSION (for all) 20 daN ±2 daN

P2002 Sierra SECTION B
MAINTENANCE MANUAL pag. B-6
2
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Edition, April 22
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, 2008
INSPECTION & SERVICING
6AIRCRAFT ALIGNMENTS
F IGURE B-4 A LIGNMENTS
C'
A
A
B
C
C
D'
D
B
A'
D'
C'
C'

P2002 Sierra SECTION B
MAINTENANCE MANUAL pag. B-7
2
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Edition, April 22
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, 2008
INSPECTION & SERVICING
6.1 DATUM
•A & A’ – On the wing upper surface, is the rivet shared between
the main spar’s and the composite wing tip rivet lines (of the two
tip rivet lines, we are referring to the external one).
•B – The reference pointed in Figure B-4 on the top of the propeller
reduction gearbox. To get the access it is necessary to remove the
engine’s upper cowling.
•C & C’ – On the stabilator upper surface, is the rivet shared be-
tween the composite tip and the tubular spar rivet lines.
•D & D’ – On the fin’s skin is the upper/aft rivet. It shared between
the upper rib and the rear spar rivet lines.
6.2 NOMINAL DISTANCES
The aim of the alignment control is mainly to compare the measures taken
on both sides and to check if the difference between them, if any, is within
the tolerances reported below.
Datum Nominal distances (mm)
A - B 4360
±20
A’- B 4360
±20
A - C 4685
±20
A’- C’ 4685
±20
C - D 1810
±10
C’- D’ 1810
±10

P2002 Sierra SECTION B
MAINTENANCE MANUAL pag. B-8
2
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Edition, April 22
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, 2008
INSPECTION & SERVICING
7WEIGHING AND DETERMINATION OF VERTICAL CG
USE GUIDELINES AS FOLLOWS:
a. Carry out weighing procedure inside hangar
b. Remove any unnecessary objects inadvertently left on board aircraft
c. Make sure of the on-board presence of the Flight Manual.
d. Align nose wheel
e. Drain fuel
f. Oil, hydraulic fluids and coolants at operating levels
g. Move seats to most forward position
h. Flaps retracted (0°)
i. Control surfaces in neutral position
j. Position scales (min. capacity. 200 kg) under each tire
LEVELLING
a. Level the aircraft (see par.4 “Levelling”)
WEIGHING
a. Record weights of individual scales
b. Calculate empty weight
DETERMINATION OF CG
a. Drop a plumb bob tangent to the wing’s leading edge, as indicated into fig-
ure B-5. Trace a reference mark on floor.
b. Repeat operation on other wing.
c. Connect the two reference marks with a taut line
d. Measure distances between reference line and landing gear wheel axles
e. Recorded data allows determination of C.G. location and aircraft’s moment
(see following table)

P2002 Sierra SECTION B
MAINTENANCE MANUAL pag. B-9
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, 2008
INSPECTION & SERVICING
1337 from the propeller's flange (without sapacer)
W2=WL+WR
CMA 1370
D
B
W1
A
15 mm inboard
from rib n°7
4
2
1
3
6
5
7
W2 * A - W1 * B
* 100D% =
D =
D
1370
W1 + W2
Reference line
WEIGHT AND CG DETERMINATION TABLE
Kg
metres
Fwd wheel weight W
1
=
Distance from bob to Lh wheel A
L =
Lh main “ “ W
L
=
“ “ Rh wheel A
R
=
Rh main “ “ W
R
=
Average distance (A
L
+ A
R
)/2 A =
W
2
=W
L
+W
R
=
Distance from bob to nose wheel B =
Empty weight We =W1 + W2=
D
W
A
W
B
We
=
⋅
−
⋅
=
2 1
________meters
C.G. position as wing chord %
D% = D/1.37 ⋅ 100 =
F IGURE B-5 W EIGHT & B ALANCE