Zenair CH2000 User manual

CH2000 TRAINER
with LYCOMING 0-235-N2C
SERVICE MANUAL
ZENAIR Ltd.
Huronia Airport
Midland, Ontario
Canada L4R 4K8
[phone]
November 2002

ZENAIR CH2000 SERVICE MANUAL
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TABLE OF CONTENTS
SECTION I INTRODUCTION SECTION VI POWERPLANT
SECTION II HANDLING AND SERVICING SECTION VII SURFACE CONTROLS
SECTION III INSPECTION SECTION VIII FUEL SYSTEM
SECTION IIIA AIRWORTHINESS LIMITATIONS SECTION IX INSTRUMENTS
SECTION IV STRUCTURE SECTION X ELECTRIC SYSTEM
SECTION V LANDING GEAR AND BRAKES SECTION XI HEATER /VENTILATION
SECTION XII CABIN DOORS
LIST OF EFFECTIVE PAGES
Section
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3A
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May 2011 0.1

ZENAIR CH2000 SERVICE MANUAL
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SERVICE MANUAL UPDATE LOG
REV. NO.
DATE ISSUED
DATE
INCORPORATED
INSERTED BY
9
May 2011
May 2011
Note: 0.1 and 0.2 with Update sheet(s) are replaced for each new update.
0.2 May-2011

ZENAIR CH2000 SERVICE MANUAL
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SECTION 1
INTRODUCTION
GENERAL
This manual contains service and maintenance instructions for the Zenair CH2000,
designed and manufactured as a versatile two-seat aircraft in the personal and training
aviation field.
SCOPE OF MANUAL
Sections II and III comprise the service part of this manual, whereas Sections IV through
XI comprise the maintenance instructions. The service instructions include ground
handling, servicing, and inspection periods. The maintenance instructions for each system
include troubleshooting, removal and installation of components, and corrective
maintenance and testing; each major system of the aircraft is covered in a separate section.
Only qualified personnel should perform the operations described in this manual.
In the text, reference is made to the following publications:
- General: Owner’s Manual or Aircraft Flight Manual CH2000 - ZENAIR
Parts Catalogue CH2000 - ZENAIR
- Engine: Operator’s Manual and overhaul manual Series O-235 engines - Textron Lycoming
- Propeller: Prop. Logbook (instructions for use and care) - Sensenich Prop. Co.
AC-43.13.1B Aircraft Inspection, Repair and Alteration
is a useful handbook published by the FAA.
“Aircraft Powerplants”, published by McGraw-Hill
(ISBN #0-07-035569-X) is the standard reference for the mechanic
working on the engine.
The description of the aircraft included in this section is limited to general information;
however, the figure gives specific external dimensions.
Nov-02 1.1

ZENAIR CH2000 SERVICE MANUAL
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DESCRIPTION - Fig. 1
The Zenair CH2000 is a single engine, two-seat, low-wing monoplane of all-metal
construction.
WING: The wing is of all-metal stressed-skin, full cantilever, low-wing design, consisting
of two wing panels bolted to a spar box assembly in the fuselage. The ailerons are cable
and push rod controlled. The wing trailing edge split flaps are electrically operated.
EMPENNAGE: The empennage consists of the rudder, stabilator, and stabilator trim tabs.
The stabilator is dynamically balanced.
FUSELAGE: The fuselage consists of three basic sections: the engine section, the cabin
section, and the sheet-metal tail cone.
LANDING GEAR: The tricycle landing gear is of the fixed type, consisting of a nose
wheel and two main wheels.
HYDRAULIC SYSTEMS: The dual brake system is operated by master cylinders.
ENGINE: The aircraft is powered by one horizontally opposed Lycoming Model 0-235-
N2C four-cylinder air-cooled engine. The engine employs a wet sump oil system with oil
temperature and pressure indicators.
PROPELLER: The propeller used is a Sensenich fixed pitch, all metal, aluminum alloy,
Model 72-CK series.
FUEL SYSTEM: The fuel system on the Zenair CH2000 consists of one rear aluminum
tank or tanks in the wings, one engine-driven pump, and one electrical auxiliary pump.
FLIGHT CONTROLS: The flight controls are conventional equipment, consisting of a
control wheel which operates the ailerons and stabilator, and pedals which operate the
rudder. Duplicate controls are provided for the co-pilot.
RADIO: Provisions for radio installations consist of microphone and headset jacks and
mounting brackets, necessary wiring, and panel space for extra radios.
CABIN HEATER, DEFROSTER, AND FRESH AIR SYSTEM: Heated air for the cabin
and defroster is obtained directly from the exhaust system muffler shroud. Fresh air is
supplied to the cabin through two individual and orientable air inlet vents in the right and
left door window.
INSTRUMENTS: Provisions for optional instruments are provided, including full IFR
equipment.
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CH 2000 GENERAL DIMENSIONS
- Fig. 1 -
3 Apr 95 1.3

ZENAIR CH2000 SERVICE MANUAL
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SECTION II
HANDLING AND SERVICING
GENERAL
This section provides ground handling and servicing instructions.
Recommended ground handling procedures, and recommended methods of servicing
are provided in following paragraphs. If trouble or damage to the aircraft is discovered
during ground handling or servicing, refer to the appropriate section for the system
concerned. Lubrication is treated as a separate function.
ACCESS PROVISIONS - Fig. 2
The figure shows the location and identity of the access doors and panels that provide
access for purposes of service and maintenance.
GROUND HANDLING
GENERAL. The aircraft must not be pushed, pulled, or lifted by any other means than
those described. Procedures are given for the proper execution of all necessary handling
operations and, if the instructions are followed, damage to the aircraft or its equipment
will be prevented.
Caution: Use the utmost care at all times during ground handling operations.
STEP, HANDHOLD, AND WALKWAYS
A fixed step is located on each side, below and aft of the inboard end of the wing trailing
edge and fixed handholds are located on the sides of the fuselage, above the aft upper
corner of the rear window. The walkway is made up of a non-skid compound applied to
the wing surface.
Caution: Walk on the walkways only, to avoid damage to the wings.
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CH2000 ACCESS PANELS
- Fig. 2 -
2.2 Oct-00

ZENAIR CH 2000 SERVICE MANUAL
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HOISTING - Fig. 3
Nose Gear Hoisting - Remove the cowl and lift the aircraft with a hoist attached to the
metal loop on top of the engine.
Main Gear Hoisting - Lift the aircraft one side at a time and insert a padded sawhorse or
equivalent under wing at main wing spar and rib rivet line.
LEVELING - Fig. 4
The aircraft may be leveled while the wheels are on the ground or during the weighing
procedure while the wheels are on scales. Leveling the aircraft for purposes of reweighing
or rigging is accomplished as follows:
Position the level on the door sill (upper fuselage longeron)
To put the airplane in a longitudinally level position, either on scales or on the
floor, deflate the nose wheel tire until the proper position is reached (or add
shims under the two main wheels ).
To level the airplane laterally, place a level across the cabin on the right and
left longerons, shim one main wheel as required. (repeat longitudinal leveling).
WEIGHING PROCEDURE - See Owner's Manual or Aircraft Flight Manual Chapter 6
TIEING DOWN
Secure tie-down ropes to the wing tie-down rings and the tail skid at approximately 45
angles to the ground. Leave sufficient slack to avoid damage to the aircraft when the
ropes contract due to moisture.
TOWING
Move the aircraft using the nose wheel optional tow bar hooked into the nose gear strut
rings.
Caution: Remove the tow bar when not in use as the propeller may hit it when engine is
started.
Nov-02 2.3

ZENAIR CH2000 SERVICE MANUAL
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LOCKING AIRCRAFT
The cabin doors are provided with key locks on the outside.
MAIN GEAR / WHEEL HOISTING
NOSE GEAR / WHEEL HOISTING
2.4 Nov 02