30221-r10-hk36-amm.

Transcript

"Diamond "'1P' AIRCRAFT AIRPLANE MAINTENANCE MANUAL FOR THE POWERED SAILPLANE MODELS HK 36 R SUPER DIMONA HK 36 TS HK 36 TC HK 36 TTS HK 36 TTC HK 36 TTC-ECO Engine : Rotax 912 A : Rotax 91 4 F Models : H K 36 R Super Dimona H K 36 TS H K 36 TC H K 36 TTS H K 36 TTC HK 36 TTC - ECO Doc. No. : 3.02.21 Date of Issue : 1 7 May 1 993 DIAMOND AIRCRAFT INDUSTRIES GMBH N.A. OTTO-STR. 5 A-2700 WIENER NEUSTADT AUSTRIA Cover Sheet Rev. 1 0 HK 36 R, TS, TC, TTS, TTC, TTC-ECO .Diamond AIRCRAFT AIRPLANE MAI NTENANCE MANUAL General SECTION 0 GENERAL 0.1 LOG OF REVISIONS Pages Rev. No. Source 1 thru 5 Date Inserted by 1 994-1996 covered by SB 50/1 6 all SB 50/1 July 1 996 - 7 all SB 50/2 1 0 Mar 1 997 - 8 0.2 3.2, 3.3, 3.9, 3.26, 3.27, 3.30 4.25 thru 4.35 SB 50/3 20 May 1 997 covered by SB 50/5 9 0.2 thru 0.4, 0. 1 1 1 . 1 thru 1 .7 2 . 1 thru 2.3, 2 . 1 7, 2 . 1 8, 2.25, 2.60 3.2, 3.26 4.20 6. 1 , 6 . 1 0, 6. 1 1 SB 50/4 25 Aug 1 997 covered by SB 50/5 10 all SB 50/5 1 5 Jun 1 998 - -- Doc. No. Issue Rev. No. Date Source Page No. 3.02.21 17 May 1 993 10 1 5 Jun 1 998 SB 50/5 0.2 HK 36 R, TS, TC, TIS, TIC, TIC-ECO •Diamond AIRCRAFT General AIRPLANE MAINTENANCE MANUAL 0.2 TABLE OF CONTENTS SECTION 0: GENERAL 0. 1 LOG OF REVISIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.2 0.2 TABLE OF CONTENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.3 0.3 EXPLANATIONS 0.3.1 ABBREViATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . 0.3.2 PHYSICAL UN ITS . . . . . . . . . . . . . . . . . . . . . . . . . . 0.3.3 PARTS OF THE WING-FUSELAGE CONNECTION 0.3.4 BU LKHEADS AND STIFFENERS IN FUSELAGE . . 0.3.5 METRIC THREADS . . . . . . . . . . . . . . . . . . . . . . . . . 0.3.6 FABRIC DESIG NATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0. 1 0 0.10 0.12 0. 1 2 0.13 0 13 . SECTION 1 : RIGGING AND DE-RIGGING, CARE 1.1 RIGGING AND DE-RIGGING . 1 . 1 . 1 GENERAL . . . . . . . .. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 . 1 .2 WING INSTALLATION WITHOUT WING FOLDING MECHANISM 1 . 1 . 3 WING INSTALLATION WITH WING FOLDING MECHANiSM . . . 1 . 1 .4 WING REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 . 1 . 5 WING LET INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 . 1 .6 WING LET REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 . 1 .7 HORIZONTAL STABILIZER I NSTALLATION . . . . . . . . . . . . . . . . 1 . 1 .8 HORIZONTAL STABILIZER REMOVAL . . . . . . . . . . . . . . . . . . . . . 1.2 ROAD TRANSPORT 1 . 3 STORAGE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 .4 CLEANING AND CARE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.1 1.1 1 .3 1 .4 1 .5 1 .5 1 .6 1 .6 1 .6 1 .7 1 .8 1 .8 Doc. No. Issue Rev. No. Date Source Page No. 3.02.21 17 May 1 993 10 1 5 Jun 1 998 SB 50/5 0.3 HK 36 R, TS, TC, TIS, TIC, TIC-ECO IIfIII V Ii. Diamond AIRCRAFT General AIRPLANE MAINTENANCE MANUAL SECTION 2: SYSTEMS DESCRIPTION 2.1 FLIGHT CONTROL SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2. 1 . 1 GENERAL . . . .. . . . . . . . . . . . .... . 2 . 1 .2 ELEVATOR CONTROL SYSTEM . . . . . . . . . . . 2.1 .3 RUDDER CONTROL SYSTEM . . . . . . . .. . . . . . . . 2 . 1 .4 AI LERON CONTROL SYSTEM . . . . . . . .. . . . 2 . 1 .5 AIR BRAKE CONTROL SYSTEM . . . . . . REMOVAL OF ALL PRIMARY CONTROL SYSTEM PARTS 2 . 1 .6 UNDER THE SEATS . . . . 2.1 .7 ELEVATOR TRIM CONTROL SYSTEM 2.1 .8 ELEVATOR AND ELEVATOR TRIM CONTROL SYSTEM (SKETCH) 2 . 1 .9 RUDDER AND TAI L WHEEL CONTROL SYSTEM (SKETCH) . . . . 2. 1 . 1 0 AILERON CONTROL SYSTEM I N FUSELAGE (SKETCH) . . 2. 1 . 1 1 AILERON CONTROL SYSTEM IN WING (SKETCH) . . 2 . 1 . 1 2 AIR B RAKE CONTROL SYSTEM AND . . . WHEEL BRAKE SYSTEM IN FUSELAGE (SKETCH) . 2. 1 . 1 3 A I R BRAKE CONTROL SYSTEM I N WING (SKETCH) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.2 LANDING GEAR 2 . 2 . 1 MAIN LANDI N G GEAR WITH GFRP STRUT . . . . . . . . . . 2.2.2 TAI L WHEEL 2.2.3 MAIN LANDING GEAR WITH M ETAL STRUTS . 2.2.4 NOSE LAN DING GEAR 2.2.5 WHEEL BRAKE SYSTEM, VERSION 1 . . . . . . . . . . . . . . . . . 2.2.6 WHEEL BRAKE SYSTEM, VERSION 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ' . ' 2.7 ' 2.8 2.9 , 2.10 2. 1 1 , 2. 1 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ' . .... ... ......' . . . . . 2. 1 2.1 2.1 2.3 2.4 2.6 . · 2.12 2. 1 3 2.14 2.14 2.15 2.15 2.16 2.18 2.19 2.3 FUEL SYSTEM I N AIRPLANES WITH FUSELAGE TANK . . . . . . . . . . . . . . . . . . , 2.20 . ' 2.20 2.3.1 FUEL SYSTEM DESCRIPTION 2.3.2 FUEL TANK EMPTY I NG . 2.25 . . . . . . , 2.25 2.3.3 FUEL TANK REMOVAL . ' 2.26 2.3.4 REMOVAL OF FUEL FI LTERS I NSTALLED I N AI RFRAME . ' 2.27 2.3.5 FUEL QUANTITY I NDICATOR CALIBRATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.4 FUEL SYSTEM IN AIRPLANES WITH WING TANKS . . . . . . . . 2.28 ... . . , 2.28 .. . . 2.4.1 FUEL SYSTEM DESCRIPTION . . . . . . . . . ' 2.35 2.4.2 FUEL SYSTEM EMPTY I NG 2.4.3 CENTRAL FUEL RESERVOIR R EMOVAL . . . . . . . . . . . . . . . . . . . . . . 2.35 2.4.4 REMOVAL OF FUEL FILTERS INSTALLED I N AIRFRAME . . . . . . . . 2.35 2.36 . . .. 2.4.5 FUEL QUANTITY INDICATOR CALIBRATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.5 POWER-PLANT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.37 2.5.1 ENGINE DESCRIPTION 2.37 CARBURETOR DESCRIPTION . . ' 2.41 2.5.2 2.5.3 DESCRIPTION OF THE OF THE TURBOCHARGING OF THE ROTAX 9 14 F ENGINE , 2.42 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Doc. No. Issue Rev. No. Date Source Page No. 3.02.21 1 7 May 1 993 10 1 5 Jun 1 998 SB 50/5 0.4 .Diamond AIRCRAFT 2.5.4 2.5.5 2.5.6 2.5.7 HK 36 R, TS, TC, TIS, TIC, TIC-ECO AIRPLANE MAINTENANCE MANUAL POWER-PLANT REMOVAL AND I NSTALLATION ENGINE SPARE PARTS . . . . . . . . . . . . . . . . . . . PROPELLER DESCRIPTION . . . . . . . . . . . . . . . PROPELLER INSTALLATION AND REMOVAL . . General . . . . . . . . . . . .. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ' . . 2.44 2.46 2.47 2.48 2.6 ELECTRICAL SY STEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.50 2.6. 1 POWER SUPPLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.50 2.6.2 ELECTRIC INSTRUMENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.51 2.6.3 ELECTRIC FUEL PUMP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.52 2.6.4 IGN ITION SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.52 2.6.5 Wi RING . . . . . . . . . . . . . . . . . . .. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.53 2.6.6 CIRCUIT BREAKERS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.53 2.6.7 SWiTCHES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.54 2.6.8 AIR TRAFFIC CONTROL (ATC) EQUIPMENT . . . . . . . . . . . . . . . . . . ' 2.54 2.6.9 ANTENNAS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.55 2.6. 1 0 RADIO LOUDSPEAKER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.55 2.6. 1 1 ANTI COLLISION LIG HTS (ACL'S) . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.56 2.6. 1 2 POSITION LIGHTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.56 2.6. 1 3 WIRING DIAGRAM - INSTRUMENT PANEL HK 36 R . . . . . . . . . . . . . 2.57 2.6. 1 4 WIRING DIAGRAM - ENGINE COMPARTMENT HK 36 R . . . . . . . . . ' 2.58 2.6. 1 5 WIRING DIAGRAM - FUSELAGE HK 36 R . . . . . . . . . . . . . . . . . . . . . 2.59 2.6. 1 6 ABBREVIATIONS USED I N THE HK 36 R WIRING DIAGRAMS . . . . ' 2.60 2.6. 1 7 NUMBERING OF THE WIRES IN THE HK 36 R WIRING DIAGRAMS . 2.61 2.6. 1 8 WIRING DIAGRAM - ENGINE COMPARTMENT HK 36 TS, HK 36 TC .2.62 2.6. 1 9 WIRING DIAGRAM - FLIGHT COMPARTMENT HK 36 TS, HK 36 TC . 2.63 2.6.20 WIRING DIAGRAM ENGINE COMPARTMENT HK 36 TIS, HK 36 TIC . . . . . . . . . . . . . . . 2.64 2.6.21 WIRING DIAGRAM FLIGHT COMPARTMENT H K 36 TIS, HK 36 TIC . . . . . . . . . . . . . . . 2.65 2.6.22 WIRING DIAGRAM - FUEL SYSTEM HK 36 TIS, HK 36 TIC .. . . . . ' 2.66 2.6.23 WIRING DIAGRAM - ENGINE COMPARTMENT HK 36 TIC-ECO . . , 2.67 2.6.24 WIRING DIAGRAM - INSTRUMENT PANEL HK 36 TIC-ECO . . . . . . 2.68 2.6.25 WIRING DIAGRAM - FUSELAGE HK 36 TIC-ECO . . . . . . . . . . . . . . . 2.69 2.6.26 WIRING DIAGRAM - WING TANKS HK 36 TIC-ECO . . . . . . . . . . . . . 2.70 2.6.27 WIRING DIMENSIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.71 2.6.28 POWER CONSUMPTION OF ELECTRICAL EQUIPMENT . . . . . . . . . 2.72 2.6.29 INSTALLATION OF ADDITIONAL ELECTRICAL EQUIPMENT . . . . . ' 2.73 2.6.30 G ENERAL RULES FOR WORKING ON THE ELECTRICAL SYSTEM . 2.74 . 2.7 STALL WARNING SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . , 2.75 2.8 MINIMUM EQUIPMENT LIST . . . . . . . . . . . . . . . . . . .. . . . . . . . . . . . . . . . . . . . . , 2.75 Doc. No. Issue Rev. No. Date Source Page No. 3.02.21 17 May 1 993 10 1 5 Jun 1 998 SB 50/5 0.5 HK 36 R, TS, TC, TIS, TIC, TIC- ECO •Diamond AIRCRAFT General AIRPLANE MAINTENANCE MANUAL SECTION 3: MAINTENANCE AND INSPECTIONS 3.1 SCHEDULED INSPECTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 . 1 . 3.1 3. 1 . 1 INSPECTION INTERVALS A N D TOLERANCES 3. 1 .2 ACCOMPLISHMENT OF MAINTENANCE WORK . . . . . . . . . . . . . . . . 3.2 . . A. B. C. D. E. . . . INSPECTION CH ECKLISTS FOR THE POWER PLANT INSPECTION CHECKLISTS FOR THE AI RFRAME GENERAL MAINTENANCE WORK AND CONFIRMATION LUBRICATION SCHEDULE CHECK FLIGHT AFTER MAINTENANCE . . . . . . . . . . . . 3.2 DESCRIPTION OF SCHEDULED INSPECTIONS. 3.2 . 1 ENGINE 3.2.2 PROPELLER . . . . . . . . . . . . . . . . . . . 3.2.3 CABI N . . . . . . . . . . . . . . . . . . . . . . . . 3.2.4 STRUCTURE . . 3.2.5 LANDING GEAR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.3 . . . . . . . . . 3.20 3.30 . . 3.31 . 3.33 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.35 3.35 . . . . . . . . . . . . . . . . . . . . . . . . . 3.35 . . . . . . . . . . . . . . . . . . . . . . . . . 3.36 . . . 3.39 . . . . . . . . . . . . . . . . . . . . . . . . . 3.43 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.3 NON-SCHEDULED INSPECTIONS 3.3.1 ENGINE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.3.2 PROPELLER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.3.3 AIRFRAME . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.45 . . . 3.45 . . . 3.48 . . . 3.48 . . 3.4 TORQUES 3.51 3.4. 1 STANDARD TORQUES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.51 3.4.2 SPECIAL TORQUES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.52 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Doc. No. Issue Rev. No. Date Source Page No. 3.02.21 1 7 May 1 993 10 1 5 Jun 1 998 S B 50/5 0.6 �Diamond V AIRCRAFT HK 36 R, TS, TC, TIS, TIC, TIC-ECO AIRPLANE MAINTENANCE MANUAL General SECTION 4: OTHER WORK 4. 1 PROCEDURES FOR TOPPING UP OPERATING 4.1 . 1 FUEL . . . . . . . . . . . . . . . . . . . . . . . . 4. 1 .2 ENGI NE OIL . . . . . . . . . . . . . . . . . . 4. 1 . 3 COOLANT . . . . . . . . . . . . . . . . . . . . 4. 1 .4 BRAKE FLUID . . . . . . . . . . . . . . . . . 4. 1 .5 REFILLING THE BATI ERY . . . . . . . FLUIDS .. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ' . 4. 1 4.1 4.2 4.2 4.3 4.3 4.2 DETERMINING EMPTY MASS C.G. POSITION . . . . . . . . . . . . . . . . . . . . . . . . . . , 4.4 4.3 TABLE OF THE MOST IMPORTANT LEVER ARMS . . . . . . . . . . . . . . . . . . . . . . ' 4.6 4.4 WEIGHING REPORT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.7 4.5 EMPTY MASS AND CORRESPONDING C.G . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.7 4.6 MASS OF ALL NON-LIFTING PARTS AND USEFUL LOAD . . . . . . . . . . . . . . . . . 4.8 4.7 MASS AND BALANCE FORM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.9 4.8 MASS AND BALANCE DIAGRAM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.8.1 EXPLANATION OF THE DIAGRAM . . . . . . . . . . . . . . . . . . . . . . . . . 4.8.2 MASS AND BALA NCE DIAGRAM, STANDARD TANK (MASTER) . . 4.8.3 MASS AND BALA NCE DIAGRAM, LONG RANGE TANK (MASTER) 4.9 PERMISSIBLE EMPTY MASS C.G. RANGE AND MINIMUM USEFUL LOAD ON SEATS . . . . . . . . . . . . . . . 4.9. 1 PERMISSIBLE EMPTY MASS C.G. POSiTION . . . 4.9.2 MINIMUM USEFUL LOAD ON SEATS WITH STANDARD FUEL TANK . . . . . . . . . . . . . . 4.9.3 MINIMUM USEFUL LOAD ON SEATS WITH LONG RANGE FUEL TANK . . . . . . . . . . . . . 4.9.4 MINIMUM USEFUL LOAD ON SEATS WITH WING . . . . . . . , . 4. 1 0 4. 1 0 4. 1 1 4. 1 2 . . . . . . . . . . . . . . . 4: 1 3 . . . . . . . . . . . . . . . 4. 1 3 . . . . . . . . . . . . . . . 4.14 . . . . . . . . . . . . . . , 4. 1 4 TANKS . . . . . . . . 4. 1 5 4.10 WEIGHING REPORT (MASTER) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4. 1 5 4.11 ADJUSTMENT DIAGRAM - HORIZONTAL ALIGNMENT, ELEVATOR, ANGLE OF INCIDENCE, DIHEDRAL . . . . . . . . . . . . . . . . . . . . . . . . 4. 1 8 4. 1 2 ADJUSTMENT DIAGRAM - AILERONS, RUDDER, SWEEP . . . . . . . . . . . . . . . . 4. 1 9 4 . 1 3 MASSES AND RESIDUAL MOMENTS O F THE CONTROL SURFACES 4. 1 3 . 1 GENERAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.20 4.1 3.2 MEASUREMENT OF RESIDUAL MOMENTS . . . . . . . . . . . . . . . . . . . 4.20 4. 1 3.3 PERMISSIBLE MASSES AND RESIDUAL MOMENTS OF THE CONTROL SURFACES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.21 4.14 PITOT-STATIC SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ' 4.22 4.15 PARKING FOR OVER 30 DAYS 4. 1 5 . 1 PRESERVATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.25 4. 1 5.2 RETURNING TO OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.25 4. 1 6 PLACARDS AND INSCRIPTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.26 Doc. No. Issue Rev. No. Date Source Page No. 3.02.21 1 7 May 1 993 10 1 5 Jun 1 998 SB 50/5 0.7 �Diamond v AIRCRAFT HK 36 R, TS, TC, TIS, TIC, TIC-ECO General AIRPLANE MAINTENANCE MANUAL SECTION 5: REPAIR INSTRUCTIONS 5.1 DESCRIPTION OF THE GFRP PARTS . . . . . . . . . . 5 . 1 . 1 Wi NG . . . . . . . . . . . . . . . . . . . . . . . . . . 5. 1 .2 AI LERONS . . . . . . . . . . . . . . . . . . . . . . 5. 1 . 3 RUDDER . . . . . . . . . . . . . . . . . . . . . . . . 5. 1 .4 HORIZONTAL TAI L . . . . . . . . . . . . . . . . 5. 1 . 5 FUSELAGE . . . . . . . . . . . . . . . . . . . . . . 5 . 1 .6 MAIN LANDING GEAR MADE OF GFRP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . .. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . , . . 5. 1 5.1 5.4 5.6 5.8 5.10 5.12 ' 5.2 REPAIR WORK, GENERAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ' 5. 1 3 5.2.1 DAMAGE CLASSI FICATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . , 5. 1 3 5.2.2 REPAIR OF FIBER COMPOSITE PARTS, GEN ERAL . . . . . . . . . . . . . 5 . 1 4 5 . 3 DAMAGE TO GFRP SANDWICH PARTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5. 1 6 5.3. 1 DAMAGE TO THE OUTER SKIN . . . . . . . . . . . . . . . . . . . . . . . . . . . . , 5. 1 6 5.3.2 DAMAGE TO THE ENTIRE SANDWiCH . . . . . . . . . . . . . . . . . . . . . . 5. 1 7 . 5.4 DAMAGE TO ALL-GFRP PARTS 5.4. 1 CRACKS I N LEADING EDGE BONDS . . . . . . . . . . . . . . . . . . . . . . . . . 5 . 1 9 5.4.2 OTHER DAMAGE TO ALL-GFRP PARTS . . . . . . . . . . . . . . . . . . . . . ' 5.20 5.2 1 5.5 PAINTING 5.6 REPAIR O F THE CANOPY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.2 1 5.7 REPAIR OF FITTINGS AND CONTROL SYSTEM PARTS . . . . . . . . . . . . . . . . . . ' 5.22 5.8 PROPELLER REPAIR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . , 5.22 5.9 MATERIALS USED AND SOURCES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . , 5.23 Doc. No. Issue Rev. No. Date Source Page No. 3.02.21 1 7 May 1 993 10 1 5 Jun 1 998 S8 50/5 0.8 .Diamond AIRCRAFT HK 36 R, TS, TC, TTS, TTC, TTC-ECO AIRPLANE MAINTENANCE MANUAL General SECTION 6 : AIRWORTHINESS LIMITATIONS 6.1 LIFE LIMITED PARTS ... . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . . . . . . . 6. 1 . 1 ENGINE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . . 6. 1 .2 SILENTBLOCS OF ENGI N E MOUNT . . . . . . . . . . . . . . . . . . . . . . . . . 6.1.3 OTHER RUBBER COMPONENTS I N THE ENG INE COMPARTMENT 6.1.4 COOLANT . . . .. . . . . . . . . . .. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6. 1 .5 PROPELLER . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . . . . . . . . . . . . . 6 . 1 .6 PROPELLER GOVERNOR . . . . . . . .. . . . . . . . . . . . . . . . . . . . . . . . . 6 . 1 .7 AIRFRAME . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 . 1 .8 ALUMINUM MAI N LANDING GEAR STRUTS . . . . . . . . . . . . . . . . . . . 6 . 1 .9 ELECTRIC FUEL PUMPS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.1 . 1 0 HOSES I N TH E AIRFRAME . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . . 6. 1 . 1 1 RUDDER CONTROL CABL ES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 . 1 . 1 2 OUTER ROD END BEARI NGS OF ELEVATOR ATTACHMENT . . . . . 6.1.1 3 BRAKE FL UiD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ... . . . . . . . . . . 6.1.1 4 E LT BATTERY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 . 1 . 1 5 IGNITION SWiTCH . . . .. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 . 1 . 1 6 SAFETY HARNESSES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6. 1 . 1 7 TOWING DEVICE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ' 6.2 6.2 6.2 6.3 6.3 6.4 6.4 6.5 6.5 6.6 6.6 6.7 6.7 6.7 6.8 6.8 6.8 6.8 6.2 SURFACE COLOR. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . . . . . . . . . . . . . . 6.9 Doc. No. Issue Rev. No. Date Source Page No. 3.02.21 1 7 May 1 993 10 1 5 Jun 1 998 SB 5015 0.9 .Diamond AIRCRAFT HK 36 R, TS, TC, TIS, TIC, TIC-ECO AIRPLANE MAINTENANCE MANUAL General 0.3 EXPLANATIONS 0.3. 1 ABBREVIATIONS AC Advisory Circular AD Airworthiness Directive CFRP Carbon fiber reinforced plastic DP Datum Plane (for CG Calculations) CG Center of g ravity FAA Federal Aviation Administration GFRP Glass fiber reinforced plastiC SB Service Bulletin 0.3.2 PHYSICAL UNITS NOTE In many, mostly older manuals, the mass is referred to as ''weig hf'. In order to ensure physical correctness, the term "mass" is used in this manual. NOTE A body with a mass of one kilogram (kg) has a weight of 9.80665 Newtons (N). Doc. No. Issue Rev. No. Date Source Page No. 3.02.21 1 7 May 1 993 10 1 5 Jun 1 998 SB 5015 0. 1 0 .Diamond AIRCRAFT 51 HK 36 R, TS, TC, TIS, TIC, TIC-ECO AIRPLANE MAI NTENANCE MANUAL units U5 General conversions units length [mm] [cm] [m] millimeters centimeters meters [in.] [ft.] velocity [km/h] kilometers per hour meters per second [kts.] knots [mph] miles per hour [fpm] feet per minute [km/h] I 1 .852 = [kts.] [ km/h] I 1 .609 = [mph] [m/s] " 1 96.85 = [fpm] [m/s] [mm] I 25.4 = [in.] [cm] I 2.54 = [in.] [m] 1 0. 3048 = [ft.] inches feet rotary speed [min"] revolutions per minute [RPM] revolutions per minute [min"] capacity [ I] liters [US gaL] U.S. gallons [Imp. gaL] Imperial gallons [1] 1 3.785 mass density [kg/m3 ] kilograms per cubic meter = [ RPM] [US gaL] = [1] 1 4.546 = [Imp. gaL] 3 [kg/m ] I 27680 = [Ibs.lcu. in.] [Ibs.lcu.in.] pounds per cubic inch [Ibs.lcu.ft.] pounds per cubic foot 3 [kg/m ] I 1 6.02 = [Ibs.lcu.in.] mass [kg] kilograms [Ibs.] pounds [kg] " 2.2046 = [Ibs.] force, weight [N] [daN] Newtons Decanewtons [Ibs.] pounds [ N] • 0.2248 = [ Ibs.] [daN] • 2.248 = [I bs.] power Kilowatts [kW] [DIN-hp.] DIN-horsepowers (German horsep. , non-SI unit) [h.p.] horse powers [kW] " 1 . 36 = [DIN-hp.] [kW] " 1 .341 = [h.p.] pressure [hPa] [mbar] [bar] Hectopascal millibar bar [inHg] inches mercury column [ psi] pounds per square inch [hPa] = [mbar] [hPa] I 33.865 = [inHg] [bar] " 14.504 = [psi] temperature [0 C] degrees Celsius [O F] [ 0 C] " 1 .8 + 32 current intensity [A] Ampe res - current capacity [Ah] Ampere hours - voltage [V] degrees Fahrenheit = [ 0 F] - Volts Doc. No. Issue Rev. No. Date Source Page No. 3.02.21 1 7 May 1 993 10 1 5 Jun 1 998 S 8 50/5 0. 1 1 IfII>Diamond AIRCRAFT HK 36 R, TS, TC, TIS, TIC, TIC-ECO AIRPLANE MAINTENANCE MANUAL General 0.3.3 PARTS OF THE WING-FUSELAGE CONNECTION The wing attach hardware is identified in Paragraph 1 . 1 , RIGGING AND DE-RIGGING. 0.3.4 BULKHEADS AND STIFFENERS IN FUSELAGE A picture indicating the location of all bulkheads and stiffeners can be fo und in Article 5.1 .5, FUSELAGE. Doc. No. Issue Rev. No. Date Source Page No. 3.02.21 1 7 May 1 993 10 1 5 J un 1 998 SB 50/5 0.12 .Diamond AIRCRAFT HK 36 R, TS, TC, TIS, TIC, TIC-ECO AIRPLANE MAINTENANCE MANUAL General 0.3.5 METRIC THREADS Metric threads are specified in tenns of their major diameter in mill imeters. Example: an M6 bolt is one with a thread major diameter of 6 mm = 0.236 in. 0.3.6 FABRIC DESIGNATION Glass and carbon fabri cs (92 1 1 0, 92125, etc.) are specified in tenns of the type numbers used by the main manufacturer (Interglas). Other fabrics may be used only if they meet the WLB standards specified in Paragraph 5.9, MATERIALS USED AND SOURCES. Doc. No. Issue Rev. No. Date Source Page No. 3.02.21 1 7 May 1 993 10 1 5 Jun 1 998 SB 5015 0. 1 3 �Diamond � AIRCRAFT HK 36 R, TS, TC, TIS, TIC, TIC-ECO Rigging and AI RPLANE MAINTENANCE MANUAL De-Rigging, Care SECTION 1 RIGGING AND DE-RIGGING, CARE 1 .1 RIGGING AND DE-RIGGING 1.1.1 GENERAL Each wing is connected to the fuselage by three bolts. The two main bolts are located at the center of the spar tunnel. They are accessible between the backrests and can be inserted from the front side. HK 36 R: Other models; A locking pin is inserted through both bolt A spring loaded hook is placed over the bolt handles, thereby securing them. handles to secure the bolts. The A- and B-bolts are fixed to the fuselage at the wing root. The A-bolt is placed in front of the spar tunnel and the B-bolt lies near the trailing edge. The B- bolt locking units are special fasteners with a 17 mm (approxi mately 0.67 in.) hexagon head. They are screwed onto the B-bolts and are accessible through handholes on the upper surface of the wing. Locking rings are integrated in the B- bolt locking units, which therefore do not require any further safetying. The wing folding mechanism is optional equipment. It consists of a telescopic tube in side the wing which is attached to the A-bolt by means of two spring dowel sleeves. Doc. No. Issue Rev. No. Date Source Page No. 3.02.21 17 May 1 993 10 1 5 Jun 1 998 SB 5015 1.1 �Diamond "''W' AIRCRAFT HK 36 R, TS, TC, TTS, TT C, TT C-ECO Rigging and AIRPLANE MAINTENANCE MANUAL De-Riggin g, Care The horizontal stabilizer is attached to th e verti cal stabilizer by means of three bolts. The two bolts at the rear are fi xed to the mount in the vertical stabilizer. The threaded bolt located at the front is fitted with a hexagonal socket. When screwed in, it is automatically secured by means of a locking ring integrated into the horizontal stabilizer. Doc. No. Issue Rev. No. Date Source Page No. 3.02.21 1 7 May 1 993 10 1 5 J u n 1 998 SB 50/5 1 .2 �Diamond "T AIRCRAFT 1 . 1 .2 HK 36 R, TS, TC, TIS, TIC, TIC-ECO Rigging and AIRPLANE MAINTENANCE MANUAL De-Rigging, Care WING INSTALLATION WITHOUT WING FOLDING MECHANISM NOTE When installing the wings, prevent the airplane from falling onto its nosewheel or tail skid due to the CG movement. 1. Clean all bolts and bushes and the B-bolt locking unit and apply a light coat of grease. 2. Lift one wing (two persons at the root rib, one at the wing tip) and insert spar stump into spar tunnel. Leave a gap of approximately 30 cm (1 ft.). Connect position and strobe lights (optional). 3. HK 36 TTC-ECO only: Screw fuel hose to tank connector. Route tank vent line, fuel quantity signal wire and fuel tank ground strap into fuselage th rough fuselage root rib. 4. I nsert wing completely (ensure t he smooth insertat ion of t he A- and B-bolts). 5. Insert main bolt while moving the wing tip in small circles. The aileron and air brake control systems are automatically connected. Do not release the wing before the main bolt has been completely inserted. The wide track of the landing gear supports the attached wing; no support of the wing tip is required. 6. 7. Screw the B-bolt locking unit onto the B-bolt and tighten it by hand. HK 36 TTC-ECO only: Connect fuel tank ground strap under seat. Connect fuel tank vent line to T-fitting under seat. Connect fuel quantity signal wire under seat. F asten fuel line to deSignated rings with ty-rap (line loops around elbowed airbrake lever in order to avoid squeezing of hose). 8. Install the other wing in a similar manner. 9. Tighten both B-bolt locking units with a wrench (size 1 7 mm), applying moderate hand torque (approximately 6 Nm (4.5 ft.lbs.)). 1 O. Secure main bolts with locking pin (HK 36 R) or spring loaded hook (other models). 1 1 . Apply water resist ant adhesive tape to the gap between fuselage and wing and to the covers on the access holes. Doc. No. 3.02.21 Issue 17 May 1 993 Rev. No. Date Source Page No. 10 1 5 Jun 1 998 SB 5015 1.3 •Diamond AIRCRAFT HK 36 R, TS, TC, TIS, TIC, TIC-ECO Rigging and AIRPLANE MAI NTENANCE MANUAL De-Rigging, Care 1 . 1 .3 WING INSTALLATION WITH WING FOLDING MECHANISM NOTE When installing the wings, prevent the airplane from falling onto its nosewheel or tail skid due to the CG movement. 1. Clean all bolts, bushes and the 8-bolt locking unit and apply a light coat of grease, remove lid over 8 -bolt handhole. 2. Unhook one wing from its hanging mount and pull it rearward to the stop. A second person should stand between the wing and fuselage and relieve the load on the telescopic tube by lifting the wing at the spar stump. 3. Walk forward until the wing is 90" from line of flight; rotate the wing until the root ribs are parallel; keep wing in its correct position. 4. Introduce spar stump into spar tunnel while ensuring the smooth insertion of A- and 8 -bolts. Connect position and strobe lights (optional) when the gap between the fuselage and wing is just wide enough to reach the wires. 5. Insert main bolt. The aileron and air brake control systems are automatically connected. Do not release the wing before the main bolt has been completely inserted. The wide track of the landing gear supports the attached wing; no support of the wing tip is required. 6. Screw the 8 -bolt locking unit onto the 8 -bolt and tighten it by hand. 7. Install the other wing in a similar manner. 8. Tighten both 8 -bolt locking units with a wrench (size 17 mm), applying moderate hand torque (approximately 6 N m (4.5 ft.lbs.)). 9. Secure main bolts with locking pin (HK 36 R) or spring loaded hook (other models). 1 0. Apply water resistant adhesive tape to the gap between the fuselage and wing and to the covers on the access holes. Doc. No. Issue Rev. No. Date Source Page No. 3.02.21 1 7 May 1 993 10 15 Jun 1 998 S850/5 1 .4 "Diamond "'-W AIRCRAFT HK 36 R, TS, TC, TIS, TIC, TIC-ECO Rigging and AIRPLANE MAINTENANCE MANUAL De-Rigging, Care 1.1.4 WING REMOVAL NOTE When removing the wings, prevent the airplane from falling onto its nosewheel or tail skid due to the CG movement. CAUTION Before removing the wings from an HK 36 TIC-ECO, empty the fuel tanks. To remove the wings, reverse the installation procedure. If the Powered Sailplane is equipped with the optional wing-folding mechanism, the wings will remain connected to the fuselage with the telescopic tube after de-rigging. For a complete removal of the wings, remove the two spring dowel sleeves from the joint of the A-bolt and the telescopic tube. For wing folding, refer to Paragraph 1 .3 , STORAGE. 1.1.5 WINGLET INSTALLATION This Article does not apply to the HK 36 R. 1. Clean the bolts and bushes if necessary. CAUTION Do not lubricate the bolt threads! 2. Install winglet with washers and self locking-Duts. 3. Tighten self locking nuts with moderate hand torque (approximately 6 Nm (4.5 ft.lbs.)). 4. Apply water resistant adhesive tape to the gap. Doc. No. Issue Rev. No. Date Source Page No. 3.02.21 1 7 May 1 993 10 1 5 Jun 1 998 SB 50/5 1 .5 .Diamond AIRCRAFT HK 36 R, TS, TC, TIS, TIC, TIC-ECO Rigging and AIRPLANE MAINTENANCE MANUAL De-Rigging, Care 1 . 1 .6 WINGLET REMOVAL This article does not apply to the HK 36 R. To remove the winglet, reverse the installation procedure. 1 . 1 . 7 HORIZONTAL STABILIZER INSTALLATION 1. Clean all bushes and bolts and apply a light coat of grease. 2. Move the trim knob to full NOSE DOWN position. 3. Remove the Pitot tube. 4. Position the horizontal stabilizer over the stabilizer mount; the elevator control rod must be connected by a second person. WARNING The elevator control system is not connected automatically! 5. Slip the horizontal stabilizer onto both rearward bolts. 6. Screw in the fastening bolt to the stop with an 8 mm hexagon key, applying moderate hand torque (approximately 6 Nm (4.5 ft.lbs.». 7. Check the horizontal stabilizer for insecure attachment and inspect load transmission of elevator control system. 8. Install the Pitot tube. 9. Apply water resistant adhesive tape to the gap between the horizontal stabilizer and the vertical stabilizer. 1 . 1 .8 HORIZONTAL STABILIZER REMOVAL To remove the horizontal stabilizer, reverse the installation procedure. Doc. No. Issue Rev. No. Date Source Page No. 3.02.21 17 May 1 993 10 1 5 Jun 1 998 SB 50/5 1 .6 •Diamond AIRCRAFT H K 36 R, TS, TC, TTS, TTC, TTG-ECO Rigging and AIRPLANE MAINTENANCE MANUAL De-Rigging, Care 1 .2 ROAD TRANSPORT An open trailer is recommended for road transport. The components should be cushioned and protected against slippage. The fuselage is transportable standing on all three wheels. It must be prevented from moving forward, rearward or vertically. Ensure sufficient propeller clearance in the trailer to prevent damage due to fuselage movement. If the powered sailplane is equipped with the optional wing folding mechanism, the wings need not be removed completely for road transportation. They remain attached to the fuselage by the telescopic tubes (optional equipment). However, the wing must be supported by a 400 mm ( 1 6 in.) wide and 500 mm (20 in.) high profile cushion under the root rib. This will prevent damage to the telescopic tube and its guide. Another profile cushion should be placed about 4 m ( 1 3 ft.) behind the root rib. The cushion should be at least 300 mm ( 1 2 in.) wide and 350 mm ( 1 4 in.) high. The wings must be prevented from moving rearward. The B-bolt must be padded to prevent damage to the wing skin. Lay the horizontal stabilizer flat on the trailer and tie it down or place it vertically on the leading edge, and secure it using profiles cushioned with felt or cellular rubber. Doc. No. Issue Rev. No. Date Source Page No. 3.02.21 1 7 May 1 993 10 1 5 Jun 1 998 SB 50/5 1 .7 �Diamond v� AIRCRAFT HK 36 R, TS, TC, TIS, TIC, TIC-ECO Rigging and AIRPLANE MAINTENANCE MANUAL De-Rigging, Care 1 .3 STORAGE If your airplane is furnished with the optional wing folding mechanism, the wings can be folded for storage in a narrow space. The wing outboard ends can be hung from the horizontal stabilizer with the provided support fixtures. The horizontal stabilizer must be supported with the appropriate diagonal struts. The B-bolts must be padded to protect the wing skin from damage. Should the airplane be stored for a prolonged period (e.g. during winter break), it is recommended that profile cushions be placed under the wings as described above. The storage room or hangar should have good air-circulation. 1 .4 CLEANING AND CARE The entire surface of the Powered Sailplane is painted with a white weather proof two component paint. Nevertheless, the airplane should be protected against moisture and dampness. The airplane should not be stored outdoors for extended periods of time. Water that has accumulated must be removed by storing the affected parts in a dry place and turning them over several times. Dirt, insects, etc. can be removed with water and, if necessary, with a mild detergent. An automotive paint cleaner can be used for stubborn spots. For best results, clean the airplane after the day's flying is ended, so that the dirt will not become eng rained. Oil stains, exhaust stains etc. on the fuselage underside can be removed with a cold detergent. Before starting, make sure the detergent does not harm the paint finish. Use commercial automotive preservatives to conserve the paint finish. Canopy and windows should be cleaned with an acrylic glass detergent if available; otherwise use lukewarm water. Final cleaning should be done with a clean piece of doeskin or soft cloth. Never rub or polish dry acrylic glass! Doc. No. Issue Rev. No. Date Source Page No. 3.02.21 17 May 1 993 10 15 Jun 1 998 SB 50/5 1 .8 �Diamond � AIRCRAFT HK 36 R, TS, TC, TIS, TIC, TIC-ECO Systems AIRPLANE MAINTENANCE MANUAL Description SECTION 2 SYSTEMS DESCRIPTION 2.1 FLIGHT CONTROL SYSTEM 2.1.1 GENERAL The flight control system, the engine control system and the engine block are electrically connected by ground straps. When working on these systems, always ensure that the straps are attached and intact. 2.1.2 ELEVATOR CONTROL SYSTEM Description The elevator control system is a torque tube type. Both control sticks are mounted to a 35 mm (approximately 1 '/8 in.) diameter torque tube, coupling the sticks in the longitudinal direction. A shackle joint which is welded to the lower side of the tube 11 mm (approximately 71,6 in.) to the left of the center connects the elevator push-rod to the torque tube. The push-rod consists of two parts connected by a joint between the main bulkhead and the B­ bulkhead. The rearward part of the push-rod is guided in the half-bulkhead and in the second ring frame, the forward part is guided in the sickle shaped bulkhead. A bellcrank is fixed to the vertical stabilizer web. This bellcrank and the elevator hom are coupled through a vertical push-rod in the vertical stabilizer. This vertical rod has no intermediate bearing. Doc. No. Issue Rev. No. Date Source Page No. 3.02.21 May 17, 1993 10 15 Jun 1998 SB 50/5 2.1 •Diamond AIRCRAFT HK 36 R, TS, TC, TIS, TIC, TIC-ECO Systems AIRPLANE MAINTENANCE MANUAL Description Removal and installation The forward elevator control system is accessible after removing the seats. The rear elevator control parts are accessible after removing the rudder. For removal of the control system components located under the seats, refer to Article 2.1 .6. To remove the rearward horizontal push-rod from the fuselage tube, remove the rudder, disconnect push-rods on both ends, mark position of forward rod end bearing, remove forward rod end bearing, remove push-rod in rearward direction. To remove the forward horizontal push-rod, remove the rear push-rod, disconnect rod on forward end, mark position offO/ward rod end bearing, remove forward rod end bearing, mark positions of clamps for trim springs, loosen clamps, remove push-rod in rearward direction. Vertical push-rod in vertical stabilizer: The push-rod can be removed after disconnecting it from the bellcrank on the lower end and the elevator horn on the upper end. After re-installation of elevator push-rods, check trim adjustment (see Article 2 . 1 .7) and elevator deflection (see Paragraph 4. 1 1 ). For removal and installation of the horizontal stabilizer, refer to Articles 1 . 1 .7 and 1 . 1 .8. Adjustment of elevator stops The stops for the elevator are placed on the left side of the forward transverse stiffener. Adjust maximum elevator deflection with the two screws and locking nuts on the transverse stiffener (accessible from outside). Doc. No. Issue Rev. No. Date Source Page No. 3.02.21 May 17, 1 993 10 1 5 Jun 1 998 SB 50/5 2.2 •Diamond AIRCRAFT HK 36 R, TS, TC, TIS, TIC, TIC-ECO Systems AIRPLANE MAINTENANCE MANUAL Description 2.1.3 RUDDER CONTROL SYSTEM Description The rudder is deflected through control cables by means of foot pedals. The four forward cables run from the pedals to the rudder lever which is mounted to the B-bulkhead. The outer cables are guided by rollers which are mounted to the root rib of the fuselage (tail wheel models with Serial Nos. through 36.516) or to the transverse stiffeners (tail wheel models with Serial Nos. above 36.156 and tricycle models). The cables are partly guided through Teflon hoses. The two rearward control cables are guided by Teflon tubes from the rudder lever through the fuselage tube to the rudder. Adjustment of forward rudder control cables Lock all four rudder pedals in neutral position. Lock rudder lever in B-bulkhead in neutral position (perpendicular to airplane centerline). In front of each pedal there is a fitting with six mounting holes. Attach cables to appropriate mounting holes. Adjustment of rearward rudder control cables The tensile force of these cables can be adjusted with tumbuckles. These are accessible through the B-bulkhead. In case of airplanes with fuselage mounted fuel tank, the l atter must be removed. Serial Numbers Nominal Tensile Force of Rearward Rudder Control Cables [daN] [lbs.] 36.301 through 36.504 15 ± 2 33.7 ± 4.5 36.505 and subsequent 12 ±2 27.0 ± 4.5 Doc. No. Issue Rev. No. Date Source Page No. 3.02.21 May 1 7, 1 993 10 1 5 Jun 1 998 SB 50/5 2.3 lilftDiamond AIRCRAFT HK 36 R, TS, TC, TIS, TIC, TIC-ECO Systems AIRPLANE MAINTENANCE MANUAL Description Adjustment of rudder stops The stops for the rudder are located on the inside surface of the lower rudder mounting plate. Adjust maximum rudder deflection with the two screws and locking nuts. 2.1.4 AILERON CONTROL SYSTEM Description In lateral direction, the two control sticks are coupled through two WING - push-rods under the seats. These push-rods are connected to a AILERON BElLCRANK AILERON POCKET FUSE­ LAGE - bellcrank which is mounted to the rearward transverse stiffener. From this bellcrank, another push-rod runs through the center console to a second bellcrank behind the main bulkhead. The @ - LEVEL POSITION movement is finally transmitted to the left and right aileron pocket through two more push-rods. The design of the aileron pockets Bell crank engaging in aileron pocket enables the automatic connection of the ailerons during wing installation. At the wing root rib, a bellcrank engages in the aileron pocket. The aileron pocket is connected to the differentiator lever through a push-rod in the wing. A short push-rod transmits the movement to the aileron horn. Removal and installation The forward aileron control system is accessible after removing the seats. For removal, refer to Article 2. 1 .6. Doc. No. Issue Rev. No. Date Source Page No. 3.02.21 May 17, 1 993 10 1 5 Jun 1 998 S8 50/5 2.4 Iiift6. "" U> c CD 0 0 Z !" 0 "U III N co N CD '" z !" U1 !2 U1 OJ (J) � (0 (0 OJ 'C ::l � U1 � 0 '" � (0 (0 � -.J III '< s:: � � N '" � (0 N » W � :::T � :::T CD ;0 U> CD 0, 0.1 3 o· 0' , � CD 3 U> n :::T CD 3 III � '* " c � .::::::Jf-----j FILTER IN FUEL PUMP TO CARBURETOR FUEL PRESSURE TRANSDUCER :L � I FUEL VALVE FIREWALL BREACH FIREWALL - ENGINE DRIVEN FUEL PUMP f----;c:;:=. TO CARBURETOR RETURN_LINE ELECTRIC FUEL PUMP M DRAIN FilTER IN FUEL PUMP QUANTITY INDICATOR SENSOR FOR FUEL FILLER ELECTRIC WIRE ! FUEL QUANTITY INDICATOR HOSE COUPLING FINGER FILTEA I' GND VENTILATION t "U CJ) I ;>;: '" ::l o· :::l. "0 � o CD U> n CD 3 U> � o m _0 s:: » :::j z 0 , C m » 0 r 0 (J) » z :::j � :::j (J) s:: ---I » 0 z --I - m S;; ;o Z --I ;0 » - . �8 Sa D ; � C1J Z � m o g \> "U III <0 CJ) C1J :a. I A CAl (J') :j ro � .I>­ ., (l) III )( 5' 5' C1J ;a g, o a. C1J (j) ;1;, 3 !!!. 0' 0' , � U> o :J" � iii 3 U> !!!. ., c 1'\ 0 C , 0 C1J iii III 0 :< z � ;0 C1J (j) U> C C1J 0 0 " z � -- � .I>- '" (JJ U1 0 Oi CJ) � (l) (l) CD :J C � U1 '- � 0 � (l) (l) CAl _ � ..... III '< s: � � '" � 0 « 0: 5 [!J DO u: � ::i RETURN LINE TO AIR BOX PRESSURE MITTER FOR Teu F������=;i=�,;T;,;R6�; REGULATOR FUEL PRESSURE TO RIGHT ICARBURETOR FUEL PUMPS ELECTRIC CHECK VALVES FUEL VALVE FILTER BOX HOSE COUPLING FINGER FILTER <--- DRAINER AIR PRESSURE LINE FUEL LINE TANK LEGEND CJ) I A CAl (J') ..::-I 0 :J :a. 0' o :J, l? U> r U> iii 3 CJ) '< U> 0 \> m }> 0 C � _ }> 0 Z -I :j � CJ) }> Z :j o 0 m s: :j s: --I }> ;0 "U 5:: Z m �i 1!l eg D m' � �Diamond T AIRCRAFT HK 36 R, TS, TC, TIS, TIC, TIC-ECO Systems AIRPLA NE MAINTE NANCE MANUA L Description 2.3.2 FUEL TANK EMPTYING Method 1 1. Open the handhole lid in the fuselage underside. 2. Remove the lock wire from the quick release coupling under the tank (see WARNING below). 3. Open the quick release coupling. 4. Disable the shut-off mechanism by connecting a hose with a corresponding fitting and a free end. Method 2 1 . Open the hand hole lid in the fuselage underside (only necessary for HK 36 R). 2. Actuate and block the drain device. 2.3.3 FUEL TANK REMOVAL 1. Empty the tank as in Method 1 (see above). 2. Remove the baggage compartment floor. 3. Disconnect the rubber hose from the filler by opening the two hose clamps. 4. Release the tank fastening strap. 5. Disconnect all electric wires. 6. Remove the tank. To install the tank, reverse the procedure. WARN ING The removed lock wires must be replaced. Doc. No. Issue Rev. No. Date Source Page No. 3.02.21 May 1 7 , 1 993 10 1 5 Jun 1 998 SB 50/5 2.25 �D;amond V� AIRCRAFT HK 36 R, TS, TC, TIS, TIC, TIC-ECO Systems AIRPLANE MAINTENANCE MANUAL Description 2.3.4 REMOVAL OF FUEL FILTERS INSTALLED IN AIRFRAME The fuel filters must be removed for cleaning. Finger filter i n the tank bottom 1. Remove the tank (see above). 2. Remove the lock wire from the finger filter. 3. Unscrew the finger filter. To install the finger filter, reverse the procedure. WARNING The removed lock wires must be replaced. Filter in electric fuel pump (only models with Rotax 9 1 2 Al 1. Open the hand hole lid in the fuselage underside. 2. Remove the lock wire from the quick release coupling. 3. Open the quick release coupling. 4. Open the pump lid (bayonet socket, fork wrench 1 6 mm (5/8 in.». 5. Remove the filter. To install the filter in the fuel pump, reverse the procedure. WARNING The removed lock wires must be replaced. Doc. No. Issue Rev. No. Date Source Page No. 3.02.21 May 1 7 , 1 993 10 1 5 Jun 1 998 S 8 50/5 2.26 • Diamond AIRCRAFT HK 36 R, TS, TC, TIS, TIC, TIC-ECO Systems AIRPLANE MAINTENANCE MANUAL Description Fuel strainer in the filter box (onlv models with Rotax 9 1 4 F) 1. Open the handhole lid in the fuselage underside. 2. Remove the lock wire from the lid of the filter box. 3. Unscrew the lid from the filter box by pushing a rod (such as an Allen key) into the hole in the joumal of the lid. 4. Remove the seal and filter. To install the fuel strainer in the filter box, reverse the procedure. WARNING The removed lock wires must be replaced. 2.3.5 FUEL QUANTITY INDICATOR CALIBRATION 1. Drain fuel tank to unusable quantity. 2. Align airplane horizontally as shown in Paragraph 4.2. 3. Remove instrument panel top cover. 4. Remove fuel quantity indicator from instrument panel, leave electric wires in place. 5. Masier switch - ON. 6. Mode select switch - POWER FLIGHT. 7. Wait a few seconds until fuel quantity indicator indicates constant value. 8. On the LH side of the indicator's case, when viewed from the face, there is a small hole covered with tape which must be removed. Use a small common tip screwdriver to adjust to zero position. Replace tape. 9. Mode select switch - SOARING. 1 0. Master switch - OFF. 1 1 . Re-install fuel quantity indicator. 1 2 . Re-install instrument panel top cover. Doc. No. Issue Rev. No. Date Source Page No. 3.02.21 May 17, 1 993 10 1 5 Jun 1 998 SB 5015 2.27 .Diamond AIRCRAFT HK 36 R, TS, TC, TIS, TIC, TIC-ECO Systems AIRPLANE MAINTENANCE MANUAL Description 2.4 FUEL SYSTEM IN AIRPLANES WITH WING TANKS Applies to HK 36 TIC-ECO only. 2.4.1 FUEL SYSTEM DESCRIPTION General The airplane has a fuel tank in each wing. The fuel tank which is selected with the fuel tank selector feeds a central fuel reservoir through gravity feed. From there two electric fuel pumps which are connected in series supply fuel to the engine through the fuel shut-off valve. Wing Tanks The HK 36 TIC-ECO is equipped with two 55 liter (14.5 US gal.) tanks made of GFRP with vinyl ester resin. The usable fuel quantity is 53 liters (14.0 US gal.). The tanks are approximately two meters (approximately 7 ft.) long and are situated in the wings in front of the spar. The inboard edge is near the root rib. A finger filter is installed at this position. From the output port a hose runs through the root rib to the fuel selector valve. When removing the wing, the screwed connection on the tank is opened in order to separate the hose line. Electrical Bonding: The wng tanks are electrically conductive through the use of copper mesh. They are connected to electrical ground using a ground strap. This prevents the build-up of electrostatic charges and thus prevents fuel vapors from igniting. The ground strap has a flat plug connector under the seat shell which is disconnected when removing the wing. Doc. No. Issue Rev. No. Date Source Page No. 3.02.21 May 17, 1 993 10 1 5 Jun 1 998 SB 50/5 2.28 .Diamond AIRCRAFT HK 36 R, TS, TC, TIS, TIC, TIC-ECO Systems AIRPLANE MAINTENANCE MANUAL Description Tank filler: A tank filler is located on the upper side of each wing tank. Drainage: Each wing tank has a quick drain device situated on the bottom side of the wing, near the root rib. Draining is perfonmed by pressing in upward direction. Electrical fuel quantity sensors: Two sensors are installed in the bottom side of each wing tank with 5 screws and one gasket. These are accessible after removing the inspection panels. The two sensors of one tank are connected in series. The fuel quantity signal wire has a connector under the seat shell which is separated when removing the wing. NOTE When installing a new fuel quantity sensor it must be inspected for proper resistance values. In the "full' position the electrical resistance must be o to 3 O. The float lever must reach the stop before the float contacts the upper tank wall. In the position in which the float contacts the lower tank wall the resistance must be between 76 and 82 O. Subsequently the fuel quantity indicator of the affected tank must be calibrated. Fuel tank ventilation: see description at the end of this article Fuel selector valve The fuel selector valve is mounted in the center console. When installed, only the pOSitions LEFT and RIGHT are available. The design of the valve would allow to shut off both fuel lines. This is however prevented by stops in the center console. A fuel line runs from the fuel selector valve to the central fuel reservoir. Doc. No. Issue Rev. No. 3.02.21 May 17, 1 993 10 Date 15 Jun 1 998 Source Page No. S8 50 / 5 2.29 •Diamond AIRCRAFT HK 36 R, TS, TC, TTS, TTC, TTC-ECO Systems AIRPLANE MAINTENANCE MANUAL Description Central fuel reservoir An aluminum receptacle which holds 9 liters (approximately 2.4 US gal.) is installed in the fuselage behind the main bulkhead under the baggage compartment. A finger filter is installed in the output port. From there the fuel is led to the two fuel pumps which are connected in series. Low Fuel caution light (amber): A sensor is installed in the central fuel reservoir which activates the low fuel caution light as soon as less than 5 liters (approximately 1 . 3 US gal.) are left in the reservoir. Electrical bonding: The central fuel reservoir is connected to electrical ground through a ground strap. This prevents the build-up of electrostatic charges and thus prevents fuel vapors from igniting. Drainage: The central fuel reservoir has a quick drain device on the bottom side. It is accessible on the fuselage bottom side and is activated by pressing in upward direction. Ventilation: See description at the end of this article. Doc. No. Issue Rev. No. Date Source Page No. 3.02.21 May 17, 1 993 10 1 5 Jun 1 998 SB 50/5 2.30 .,Diamond AIRCRAFT HK 36 R, TS, TC, TIS, TIC, TIC-ECO Systems AI RPLANE MAINTENANCE MANUAL Description Fuel pumps Each fuel pump has a bypass. A check valve in each bypass prevents the fuel from being pumped back into the central fuel reservoir. A hose line running through the center console leads the fuel to the fuel shut-off valve. NOTE In deviation from the description in the Maintenance Manual for Rotax Engine Type 914 F, the integrated filters have been removed from the fuel pumps. Attention should also be paid to this fact during the replacement of fuel pumps. Fuel shut-off valve The fuel shut-off valve is located on the center console near the pilot's feet and is open when it points in the flight direction. From the fuel shut-off valve, a flexible line runs to the firewall breach. WARNING The fuel shut-off valve should only be closed in the event of an engine fire or during maintenance on the fuel system. Otherwise, there is a risk of taking the airplane into operation with the valve closed, which would lead to engine failure. Doc. No. Issue Rev. No. Date Source Page No. 3.02.21 May 17, 1 993 10 1 5 Jun 1 998 SB 5015 2.31 HK 36 R, TS, TC, TTS, TIC, TIC-ECO Systems AIRPLANE MAINTENANCE MANUAL Description Fuel pressure regulator A hose line leads from the firewall breach to the fuel pressure regulator on top of the airbox. Through steel pipes the regulator supplies the two carburetors with fuel under a pressure which is always 0.25 bar (3.63 psi) higher than in the airbox. Connectors: The connection for the airbox pressure is located on the underside of the regulator. The connection for the return line to the central fuel reservoir is located on top. Fuel pressure warning light (red): A fuel pressure sensor is mounted at the entrance to the regulator. As soon as the fuel pressure (above airbox pressure) falls below 0.1 bar ( 1 .45 psi), the fuel pressure waming light illuminates in the cockpit. Doc. No. Issue Rev. No. Date Source Page No. 3.02.21 May 17, 1 993 10 1 5 Jun 1 998 SB 50/5 2.32 "Diamond AIRCRAFT HK 36 R, TS, TC, TIS, HC, TIC-ECO Systems AI RPLANE MAI NTENANCE MANUAL Description Fuel System Ventilation Also see sketch on the next page. The fuel system has four vents: • The vent under the LH wing mainly vents the LH fuel tank. A short hose leads from the highest and most outboard point of the tank to this vent. • The vent under the RH wing mainly vents the RH fuel tank. A short hose leads from the highest and most outboard point of the tank to this vent. • The vent under the fuselage left of the aircraft centerline mainly vents the LH tank and the central fuel reservoir. - A hose leads from the highest and most outboard point of the LH tank through the wing and the root rib to this vent. - A hose leads from the highest point of the central fuel reservoir through the roll bar to this vent The vent hose itself is also vented in order to cut a continuous stream of fuel which might occur. This prevents the emptying of the fuel system through siphoning. • The vent under the fuselage right of the aircraft centerline mainly vents the RH tank. - A hose leads from the highest and most outboard point of the RH tank through the wing and the root rib to this vent. - A hose connects this vent to the vent left of the aircraft centerline. Doc. No. Issue Rev. No. Date Source Page No. 3.02.21 May 17, 1 993 10 1 5 Jun 1 998 SB 50/5 2.33 "Diamond v AIRCRAFT H K 36 R, TS, TC, TIS, TIC, TIC-ECO Systems AIRPLANE MAINTENANCE MANUAL Description .------: centro! ru;;; i l o w fU e I 10 c o u t io n !ig h T 9 liters reservoir (:; 1,-ff-I---IV] . , -/ -1[', -----' re t u rn line fUel s h u t - o ff volve II T T II LJ firevv o f '--l -I �\ 1[ 1'tJ Tor o ,: r o. o ;< TeU i Fuel system of the H K 36 TIC-ECO Doc. No. Issue Rev. No. Date Source Page No. 3.02.21 May 1 7, 1993 10 1 5 Jun 1 998 S8 50/5 2.34 iA.Diamond W@Y AIRCRAFT I H K 36 R, TS, TC, TIS, TIC, TIC-ECO Systems AIRPLANE MAI NTENANCE MANUAL Description 2.4.2 FUEL SYSTEM EMPTYING ( 1 ) Remove quick drain devices from both fuel tanks and central fuel reservoir. Collect fuel in suitable receptacle. 2.4.3 CENTRAL FUEL RESERVOIR REMOVAL ( 1 ) Empty fuel system. (2) Remove baggage compartment floor. (3) Remove RH aileron and air brake push-rods behind main bulkhead. (4) Disconnect fuel and vent lines from central fuel reservoir. (5) Remove electric wires (Low-Fuel signal wire, ground strap) from central fuel reservoir. (6) Release tank fastening strap. (7) Remove fuel reservoir. 2.4.4 REMOVAL OF FUEL FILTERS INSTALLED IN AIRFRAME The fuel filters must be removed for cleaning. Finger filters in the wing tanks ( 1 ) Empty fuel system. (2) Remove wing. (3) Remove lock wire from finger filter. (4) Remove finger filter. To install the filter reverse the procedure. WARNING The removed lock wires must be replaced. Doc. No. Issue Rev. No. Date Source Page No. 3.02.21 May 1 7, 1 993 10 1 5 Jun 1 998 S8 50/5 2.35 •Diamond AIRCRAFT HK 36 R, TS, TC, TIS, TIC, TIC-ECO Systems AIRPLANE MAI NTENANCE MANUAL Description Finger filter in central fuel reservoir ( 1 ) Remove central fuel reservoir (see Article 2.4.3). (2) Remove lock wire from finger filter. (3) Unscrew finger filter. To install the filter reverse the procedure. WARNING The removed lock wires must be replaced. 2.4.5 FUEL QUANTITY INDICATOR CALIBRATION (1) Drain fuel tank to unusable quantity. (2) Align airplane horizontally as shown in Paragraph 4.2. (3) Remove instrument panel top cover. (4) Remove fuel quantity indicator from instrument panel, leave electric wires in place. (5) Master switch - ON. (6) Mode select switch - POWER FLIGHT. (7) Wait a few seconds until fuel quantity indicator indicates constant value. (8) On the LH side of the indicator's case, when viewed from the face, there is a small hole covered with tape which must be removed. Use a small common tip screwdriver to adjust to zero position. Replace tape. (9) Mode select switch - SOARING. ( 1 0) Master switch - OFF. (11) Re-install fuel quantity indicator. ( 1 2) Re-install instrument panel top cover. Doc. No. Issue Rev. No. Date Source Page No. 3.02.21 May 17, 1 993 10 1 5 Jun 1 998 SB 50/5 2.36 H K 36 R, TS, TC, TIS, TIC, TIC-ECO Systems AIRPLANE MAINTENANCE MANUAL Description 2.5 POWER-PLANT 2.5.1 ENGINE DESCRIPTION Power is provided by a Rotax Model 912 A or 914 F four stroke four cylinder hOrizontally opposed engine. It is installed in the nose and drives the propeller through an integrated speed-reducing gear. Rotax 912 A Rotax 9 1 4 F The engine is firmly connected on its four The engine is firmly connected on its four rear fixture points to two branched engine rear fixture points to the annular engine mount adapters. mount mount adapter. This engine mount adapter adapter is connected to the engine mount by is connected to the engine mount at four a rubber damper (silentbloc). points by rubber dampers (silentblocs). Each of the two forward engine fixture The two forward engine fixture pOints are points is connected directly to the engine not used. Each engine mount by two rubber dampers (silentblocs). The engine mount has four fixture points on The engine mount has six fixture points on the firewall. the firewall. The rubber dampers are designed in such a way that the connection still is maintained if the rubber is damaged. Doc. No. Issue Rev. No. Date Source Page No. 3.02.21 May 1 7 , 1993 10 1 5 Jun 1 998 SB 50/5 2.37 •Diamond AIRCRAFT HK 36 R, TS, TC, TIS, TIC, TIC-ECO Systems AI RPLANE MAINTENANCE MANUAL Description All wires come together in a multi-pin plug which is attached to the firewall in the upper right corner. The plug in models with the Rotax 9 1 2 A has some free pins for additional wires that might be needed. For the sake of fire protection, other breaches of the firewall should not be established. The engine is wholly operated through bowden cables. Three view drawings of the Rotax 9 1 2 A: see following pages. Three view drawings of the Rotax 91 4 F: see the Maintenance Manual for Rotax Engine Type 9 1 4 F. Doc. No. Issue Rev. No. Date Source Page No. 3.02.21 May 17, 1 993 10 1 5 Jun 1 998 SB 5015 2.38 •Diamond AIRCRAFT HK 36 R, TS, TC, TIS, TIC, TIC-ECO Systems AIRPLANE MAINTENANCE MANUAL Description Rotax 9 1 2 A Doc. No. Issue Rev. No. Date Source Page No. 3.02.21 May 1 7, 1 993 10 1 5 Jun 1 998 S8 50/5 2.39 .,Diamond AIRCRAFT HK 36 R, TS, TC, TIS, TIC, TIC-ECO Systems AIRPLANE MAINTENANCE MANUAL Description Uil � � �- -T �! ! , I "I , i , ; - . � - - - --- - - - !l - • 1 ! � ,; , , , , I' 1 i I' .I.: =1 - ' 1 .1 iI 1: = ! ' 1= , ! , , ' , , , , ! -I 1 • ' t !l • • Rotax 9 1 2 A Doc. No. Issue Rev. No. Date Source Page No. 3.02.21 May 17, 1 993 10 1 5 Jun 1 998 S8 50/5 2.40 �Diamond V� HK 36 R, TS, TC, TIS, TIC, TIC-ECO Systems AIRPLANE MAINTENANCE MANUAL Description AIRCRAFT 2.5.2 CARBURETOR DESCRIPTION The BING carburetor is a constant speed or equal pressure carburetor. The engine suction produces a partial vacuum, dependent on the throttle valve position. The vacuum propagates to the vacuum chamber (upper part of the dome). As a result, the differential pressure between the vacuum chamber and the atmosphere increases, and the piston and the attached fuel needle ascend. This d evice provides an almost constant pressure drop and an almost constant velocity of air flow in the Venturi tube. I nformation about carburetor adjustment can be obtained from the Operator's Manual for the Rotax 912 A or the Maintenance Manual for Rotax Engine Type 914 F, respectively. VACUUM CHAMBER PISTON . � . ' . n...;� rt-�....J -.-.. ' " _ :. • .. : .f . . . ;.. � . PARTIAL VACUUM ,, . . /. :; � '$-" ' r -... : . .. . -:. .. , _ .. f� FUEL NEEDLE Doc. No. Issue Rev. No. Date Source Page No. 3.02.21 May 17, 1 993 10 1 5 Jun 1 998 SB 50/5 2.41 HK 36 R, TS, TC, TIS, TIC, TIC-ECO Systems AIRPLANE MAINTENANCE MANUAL Description 2.5.3 DESCRIPTION OF THE TURBOCHARGING OF THE ROTA){ 914 F ENGINE General The exhaust turbocharger it installed undemeath the engine on the right. The TCU (Turbo Control Unit) and the actuator for the waste gate flap are mounted between the instrument panel and the firewall on the right hand side. Working principle of the turbocharger: see Maintenance Manual for Rotax Engine Type 914 F. Manifold pressure regulation Function of the TCU: see Maintenance Manual for Rotax Engine Type 914 F. A switch marked "TCU ON' is located under a flap in the right hand section of the instrument panel. With this switch, the actuator for the waste gate flap can be switched off. Warning and caution lights for engine monitoring Three lights are located in the instrument panel (HK 36 TIC-ECO: left hand section, top; other models: center section): M eaning Color Signal Turbo amber flashing Defect in the sensor, sensor wiring or TCU area, or leakage in the airbox Manifold Pressure red flashing Time limit for max. take off power exceeded steady on Max. permissible manifold pressure exceeded steady on EGT above 950 'C (1 742 'F) or airbox temp. above 72 'C (162 'F) Light Temperature amber The "Turbo' and "Manifold Pressure" lights are controlled by the TCU. Doc. No. Issue Rev. No. Date Source Page No. 3.02.21 May 1 7 , 1 993 10 1 5 Jun 1 998 S8 50/5 2.42 .,Diamond AIRCRAFT HK 36 R, TS, TC, TIS, TIC, TIC-ECO Systems AIRPLANE MAINTENANCE MANUAL Description The 'Temperature' caution light receives its signal from a monitoring box, which is located on the right hand side of the firewall. The electronics in the box are protected by a fuse, which is also located in the box. At three measuring terminals on the monitoring box, the voltages relative to ground can be measured using a voltmeter, from which the temperature values can be calculated directly. Temperature values and corresponding voltage values are displayed directly on the box. Intermediate values can be evaluated by linear interpolation. With this, the three sensors can be checked. It is also possible to check the exhaust gas and airbox temperatures during operation. Doc. No. Issue Rev. No. Date Source Page No. 3.02.21 May 1 7, 1 993 10 1 5 Jun 1 998 S8 50/5 2.43 4ff/tDiamond AIRCRAFT HK 36 R, TS, TC, TIS, TIC, TIC-ECO Systems AIRPLANE MAINTENANCE MANUAL Description 2.5.4 POWER-PLANT REMOVAL AND INSTALLATION The engine must be removed for overhaul and repair. The following procedure is recommended: 1. Disconnect bowden cable from the cowl flap actuating device. 2. Remove upper and lower engine cowling. 3. Disconnect ignition cables. 4. Remove propeller. 5. Disconnect battery (negative terminal first) and remove. 6. Disconnect fuel lines from firewall breach. 7. Disconnect multi-pin plug on the firewall. 8. Rotax 914 F only: disconnect temperature monitoring box connector. g. Only if 28 V system (optional) is installed: remove connector for generator from 28 V voltage regulator. 1 0. Disconnect Bowden cables and control cables: throttle, choke, carburetor heat, cable for mechanical propeller feathering device (if installed), Bowden cable for propeller governor (if installed). 11. Rotax 914 F only. disconnect control cable for waste gate flap from actuator. 12. Disconnect flexible shaft of RPM indicator (if installed) from engine. 1 3. Disconnect hose for cabin heat from hot end of exhaust heat exchanger. 14. Disconnect manifold pressure hose from firewall. 1 5. Rotax 914 F only. disconnect air pressure line which leads to airbox pressure sensor (behind instrument panel) from firewall. 16. Elevate engine (e.g. with nylon ropes at the propeller shaft and the manifolds) until the engine mount is relieved; remove all fastening bolts of the engine mount; push back fuselage. 1 7. Remove exhaust, turbocharger, coolers, oil tank, ignition box, engine mount and engine mount adapters. Should the engine be sent to the manufacturer or to a service station, it must be sent there together with the exhaust, the coolers, the oil tank,Jhe ignition box, propeller governor (if fitted), turbocharger with TCU (if fitted) and the engine logbook. Doc. No. Issue Rev. No. Date Source Page No. 3.02.21 May 17, 1 993 10 1 5 Jun 1 998 SB 50/5 2.44 •Diamond H K 36 R, TS, TC, TIS, TIC, TIC-ECO Systems AIRPLANE MAINTENANCE MANUAL Description AIRCRAFT To install the engine, reverse the procedure. For the sake of safety, all bolts and nuts must be secured either with self-locking nuts or with lock wire. CAUTION After the installation of the Rotax 914 F, the TCU must be adjusted (to the sensors, etc.). A PC, dongle and appropriate software are necessary. This adjustment work may only be carried out by people who have been trained by the manufacturer. Doc. No. Issue Rev. No. Date Source Page No. 3.02.21 May 1 7 , 1 993 10 1 5 Jun 1 998 SB 50/5 2.4 5 •Diamond AIRCRAFT H K 36 R, TS, TC, TIS, TIC, TIC-ECO Systems AI RPLANE MAINTENANCE MANUAL Description 2.5.5 ENGINE SPARE PARTS Aircraft engines are certified in accordance with detailed airworthiness requirements. Every part of an aircraft engine is subjected to an incoming inspection carried out by the engine manufacturer. All spare parts (gaskets, spark plugs, etc.) used in the maintenance of the engine must also be approved by the engine manufacturer. If other spare parts are used or the Original state of the engine is altered in any way, incidents may have legal consequences. Since the aviation authorities distinctly point out this fact, we suggest that you proceed accordingly i n your own interest. Doc. No. Issue Rev. No. Date Source Page No. 3.02.21 May 1 7, 1 993 10 1 5 Jun 1 998 S8 50/5 2.46 .Diamond HK 36 R, TS, TC, TIS, TIC, TIC-ECO Systems AIRPLANE MAINTENANCE MANUAL Description AIRCRAFT 2.5.6 PROPELLER DESCRIPTION The most important features of the available propeller models are shown below and the respective manuals are referred to. mt-propeller MTV- 1 -A/1 70-08 * Electric constant speed propeller * mt-propeller P-1 20-A electronic control unit Blade pitch change mechanism actuated by electric DC-motor and threaded spindle * * Manual: Operation and Installation Manual No. E-1 1 8 mt-propeller MTV-21 -A-C-F/CF1 75-05 * Hydraulically controlled constant speed propeller * Oil pressure is used to reduce propeller pitch * Feathering device operated through counterweights and spring forces Pressure accumulator to move the blades from the feathered position to low pitch * * Govemor : Woodward A 2 1 0790 (for Rotax R 912 A and Rotax R 9 1 4 F) or McCauley DCFU 290 D 1 70/T1 (for Rotax 9 1 2 A) or McCauley DCFU 290 D 1 701T2 (for Rotax 914 F) * Manual: Operation and Installation Manual No. E-124 Hoffmann HO-V352F-S1/S1 70FQ Hydraulically controlled constant speed propeller * * Mechanical feathering device * Governor Woodward A 2 1 0786 A * Manual: Instruction Manual No. E 540 mt-propeller MT170R1 25-2A * Fixed pitch propeller with wooden blades * Manual: Operation and Installation Manual No. E-203 Hoffmann H014-170S123 * * Fixed pitch propeller with wooden blades Manual: Owner's Manual No. E 0 1 1 0.74 Doc. No. Issue Rev. No. Date Source Page No. 3.02.21 May 1 7, 1 993 10 1 5 Jun 1 998 SB 5015 2.47 •Diamond AIRCRAFT HK 36 R, TS, TC, TIS, TIC, TIC-ECO Systems AIRPu\NE MAINTENANCE MANUAL Description 2.5.7 PROPELLER INSTALLATION AND REMOVAL The in stallation and removal of the propeller is carried out in accordance with the Propeller Manual (see Article 2.5.6 for the appropriate manual). CAUTION The MTV-2 1 -A-C-F/CF1 75-05 has two variants with differing adjustment values, of which one is intended for the Rotax 9 1 2 A and the other for the Rotax 9 1 4 F. Therefore, it is absolutely necessary to ascertain, before installing a new propeller, whether the engine can be operated with that propeller. There are three possibilities: (a) The JAA Tag of the propeller explains expliCitly for which engine it is intended. (b) The angles of adjustment of the propeller are given on the "Geratelaufkarte". It can be determined, by comparison with the following table, for which engine the propeller is intended. Adjustment Value On Rotax 912 A On Rotax 9 1 4 F Stop for low pitch 12° ± 0.20 1 6. 5 0 ± 0.2 ° Stop for high pitch 23° ± 1 ° 28° ± 1 0 Stop for starting pitch 14° ± 1 ° 190 ± 1 0 Stop for feathering 830 ± 1 0 83 0 ± 1 0 Ctrwts. at low pitch 280 ± 1 0 32.5° ± 1 0 (c) Measure the propeller adjustment. When stationary, the propeller blades rest at the stop for starting pitch (see above table). Doc. No. Issue Rev. No. Date Source Page No. 3.02.21 May 1 7 , 1 993 10 1 5 J u n 1 998 SB 50/5 2.48 .Diamond AIRCRAFT HK 36 R, TS, TC, TIS, TIC, TIC-ECO Systems AIRPLANE MAINTENANCE MANUAL Description During an engine ground run after the installation, the use of the wrong propeller variant can be recognized by the following signs: (1) Propeller for Rotax 9 1 4 F o n 9 1 2 A: Maximum attainable engine speed at take off power during ground run is more than 1 00 RPM below correct value (2550 RPM). (2) Propeller for Rotax 912 A on 914 F: At take off power during ground run, the governor reduces the engine speed upon the slightest movement of the propeller speed control away from the foremost position (no "quasi­ dead travel" of the propeller speed control). If the wrong propeller variant has been used, the propeller must be exchanged. A change to the propeller settings can only be made by the propeller manufacturer. Doc. No. Issue Rev. No. Date Source Page No. 3.02.21 May 17, 1 993 10 1 5 Jun 1 998 SB 50/5 2.49 "'Diamond v AIRCRAFT HK 36 R, TS, TC, TTS, TTC, TTC-ECO Systems AIRPLANE MAINTENANCE MANUAL Description 2.6 ELECTRICAL SYSTEM 2.6.1 POWER SUPPLY The power supply of the electrical system consists of a 1 2 V lead-acid battery and a generator which is integrated in the engine. The standard rechargeable battery has a capacity of 1 8 Amp-hours (optional 30 Amp-hours). The battery has a central ventilating system to allow vapors to be externally vented. The generator is a permanently excited ten-pole single phase alternator. Voltage regulation and rectification are performed by an electronic regulator with a full-wave bridge rectifier, fabricated by Ducati, Rotax Part No. 965345 with connector shell 965335. The battery is separated from the network by means of a battery relay. The cable that runs from the battery to the starter is not protected and is therefore coated with glass fabric in compliance with LN 9251 B standards. This cable must be routed properly to prevent short-circuits. All other wires meet LN 9251 A standards. With the exception of the starter, all electrical consumers are protected with thermal overload breakers or glass fuses. When triggered, the main breaker separates the network from the battery. The generator supplies the electrical network with power via the generator breaker. Doc. No. Issue Rev. No. Date Source Page No. 3.02.21 May 1 7, 1 993 10 1 5 Jun 1 998 SB 50/5 2.50 .Diamond AIRCRAFT HK 36 R, TS, TC, TIS, TIC, TIC-ECO Systems AIRPLANE MAINTENANCE MANUAL Description A mode selection switch for the different operation modes (power flight, soaring) is connected in series with the master switch. When the master switch is closed (ON) and the mode select switch is open (i.e. in SOARING position), only the radio equipment and the optional electric vertical speed indicator are supplied with power. When the master switch is closed (ON) and the mode select switch is closed (i.e. in POWER FLI GHT position), the pallet of the battery relay is attracted, and all electrical consumers are supplied with power. When the master switch is open (OFF), all electrical consumers are disconnected from the battery and the generator. The electrical network is thereby currentless. 2.6.2 ELECTRIC INSTRUMENTS An ammeter is used to monitor the electrical system. It indicates how quickly the battery is being charged (+ range) or discharged (- range). The following electric engine instruments are installed: - Electric oil pressure indicator - Electric oil temperature indicator - Electric fuel quantity indicator(s) - Electric cylinder head temperature indicator Essentially, all the instruments function in a similar manner: The sensors contain resistors, whose resistances change through changes in the measured variable. The indicators convert these resistance values into needle d eflections. Doc. No. Issue Rev. No. Date Source Page No. 3.02.21 May 17, 1 993 10 1 5 Jun 1 998 S8 50/5 2.51 HK 36 R, TS, TC, TIS, TIC, TIC-ECO Systems AIRPLANE MAINTENANCE MANUAL Description 2.6.3 ELECTRIC FUEL PUMP Models with Rotax 9 1 2 A Models with Rotax 9 1 4 F The Powered Sailplane is equipped with a The Powered Sailplane is equipped with mechanical fuel pump and also an electric two independent electric fuel pumps. The fuel pump, which is operated by a switch main fuel pump has no switch. It promotes on the instrument panel. fuel flow as soon as the generator delivers current. The fuel booster pump is dependent on the electrical network and is operated by a switch on the instrument panel. The circuit breaker for the electric fuel The fuse for the main fuel pump is located pump is located in the center section of the in the engine compartment. The circuit instrument panel. breaker for the fuel booster pump is located in the instrument panel (HK 36 TIC-ECO: far right, other models: central section). 2.6.4 IGNITION SYSTEM The engine is equipped with a non-contacting reactor-capacitor dual ignition. To cut off the ignition, the ignition system must be short-circuited. Therefore, it is very important to ensure proper connection between the ignition system and the ignition switch, and in particular proper ground connection of the switch. WARNING If the ignition system is not short-circuited properly, the ignition is on. When working on the ignition system, the propeller must be secured against moving by hand, otherwise the engine might fire DANGEROUS TO LIFE! Doc. No. Issue Rev. No. Date Source Page No. 3.02.21 May 17, 1 993 10 1 5 Jun 1 998 S8 50/5 2.52 •Diamond HK 36 R, TS, TC, TIS, TIC, TIC-ECO Systems AIRPLANE MAINTENANCE MANUAL Description AIRCRAFT 2.6.5 WIRING Wires in fuselage and wings are fastened with clamps and bindings in a way that prevents chafing. The entire wiring complies with aeronautical requirements (LN 9251 and others). These requirements must also be followed in the case of repairs or subsequent installations. As far as possible, crimp connections are used. Soldered connections should used as little as possible. Connectors must have a so-called insulation support (i.e. a copper bush that grips the wire insulation). Only tinned, insulated copper cable sockets are used. A crimped connection has more strength than the wire itself when proper crimping tools are used. It is advisable to use crimping tools with a self-locking mechanism. 2.6.6 CIRCUIT BREAKERS The circuit breakers operate on thenmal overload (bimetal). They have an absorption capacity of 200 A. They cannot be reset unless the reason for the cut-out is eliminated. HK 36 TTC-ECO: Other models: Main breaker (50A) , the generator breaker Located in the right hand section of the (25 A) and breakers for electrical consumers instrument panel are: the main breaker (engine instruments, ATC equipment, fuel (50 A), the generator breaker (HK 36 R: 50 pump, ACL, position lights, landing light, A, other models: 25 A), the breakers for the etc.) are located in the top RH section of the power-plant instruments and the breakers for instrument panel. the air traffic control equipment. The switch panel in the center section of the instrument panel includes breakers for the corresponding switches (fuel pump, ACL, --position lights, landing lights, etc.). Doc. No. Issue Rev. No. Date Source Page No. 3.02.21 May 17, 1993 10 1 5 Jun 1 998 S8 50/5 2.53 .Diamond AIRCRAFT HK 36 R, TS, TC, TIS, TIC, TIC-ECO Systems AIRPLANE MAINTENANCE MANUAL Description The circuit breaker for the electric variable pitch propeller (if installed) is located beside the control unit. Additional fuses for models with the Rotax 9 1 4 F The fuses for the main fuel pump, the generator relay and the generator control relay are located at the rear of the engine compartment on the right hand side. 2.6.7 SWITCHES For general purposes, single and double pole rocker type switches (HK 36 TIC-ECO) or toggle type switches (other models, switching capacity: 20 Amps per contact) are used. The ignition/starter switch is a key switch. It must not be replaced by any other (unspecified) commercial switch. 2.6.8 AIR TRAFFIC CONTROL (A TC) EQUIPMENT Any ATC equipment must be installed in the center section of the instrument panel. Installation must be carried out by appropriately rated personnel in accordance with the regulations of the respective manufacturers. Doc. No. Issue Rev. No. Date Source Page No. 3.02.21 May 17, 1 993 10 1 5 Jun 1 998 SB 50/5 2.54 •Diamond AIRCRAFT HK 36 R, TS, TC, TIS, TIC, TIC-ECO Systems AIRPLANE MAINTENANCE MANUAL Description 2.6.9 ANTENNAS Folded-top antenna located in the vertical stabilizer, standard Radio antenna: equipment. Serial Nos. 36.301 through 36.305, 36.307, 36.308, 36. 3 1 0 VOR antenna: through 36.314, 36.316, 36. 3 1 7, 36.3 1 9 and 36.320: Located in the fuselage behind the fuel tank on the upper side. Serial Nos. 36.306, 36.309, 36.3 1 5, 36.3 1 8 , 36.321 and subsequent: Located in the horizontal stabilizer. ADF antenna: Located under the fuselage. TransponderlDME antenna: Located under the fuselage at the below the seats or below the main bulkhead. The counterweight is a copper foil which is bonded to the inner side of the fuselage skin. Located in the fuselage behind the baggage compartment on ELT-antenna: the half-bulkhead. 2.6.10 RADIO LOUDSPEAKER The radio loudspeaker is installed on the upper edge of the backrest between the seats or in the upper rear of the baggage compartment. Doc. No. Issue Rev. No. Date Source Page No. 3.02.21 May 17, 1 993 10 1 5 Jun 1 998 S8 50/5 2.55 HK 36 R, TS, TC, TIS, TIC, TIC-ECO Systems AIRPLANE MAINTENANCE MANUAL Description 2.6.11 ANTI COLLISION LIGHTS IACL 'Sj The switch and breaker are located on the switch panel of the instrument panel. ACLs should be mounted to the wing tips in combination with the position lights, or to the horizontal stabilizer. We recommend not to use ACLs with filament bulbs, since their power consumption is high in relation to their benefit. 2.6.12 POSITION LIGHTS The position lights (optional) are mounted on the wing tips. The switch and breaker are located on the switch panel of the instrument panel. Doc. No. Issue Rev. No. Date Source Page No. 3.02.21 May 1 7 , 1 993 10 1 5 Jun 1 998 S8 50/5 2.56 H K 36 R, TS, TC, TIS, TIC, TIC-ECO Systems AI RPLANE MAINTENANCE MANUAL Description 2.6.13 WIRING DIAGRAM - INSTRUMENT PANEL HK 36 R sUld VZ 'sauas . ..OdO.. dV\lV ·Z # Bnld $ � � � = 2 � � � � 'I-----j;g \15"£/58 r-�-I-- � r� C L + ",,0 1-../ I " � , 14B!l'OUiPue l , S � , O� N\I O� N\I \l05n8 u , NV - \. � � _ '- 0 0 / f;:: ... J ,- -, r 1- ---1 L .t._, J g� I-- - -...J: .J r L __ - , - - , r '<-��'" 1----1 .J L - ....J \...- --� L 6 � E o '" 0.. = Doc. No. Issue Rev. No. Date Source Page No. 3.02.21 May 17, 1 993 10 1 5 Jun 1 99B S8 50/5 2.59 •Diamond HK 36 R, TS, TC, TIS, TIC, TIC-ECO Systems AIRPLANE MAINTENANCE MANUAL Description AIRCRAFT 2.6.16 ABBREVIATIONS USED IN THE HK 36 R WIRING DIAGRAMS A Ammeter B1 Main breaker B2 Generator breaker B3, B4, ... Breakers for various consumers CHT Cylinder head temperature indicator Ext. Pwr. External power plug FQ Fuel quantity indicator IS Ignition/starter switch K1 , K2, " . Switches for various consumers Md Mode select switch MS Master switch Pr Oil pressure indicator Relay A Battery relay StM Starter motor Te Oil temperature indicator Doc. No. Issue Rev. No. Date Source Page No. 3.02.21 May 17, 1 993 10 1 5 Jun 1 998 SB 50/5 2.60 �Diamond v AIRCRAFT H K 36 R, TS, TC, TIS, TIC, TIC-ECO Systems AIRPLANE MAINTENANCE MANUAL Description 2.6. 17 NUMBERING OF THE WIRES IN THE H K 36 R WIRING DIAGRAMS 1 Positive terminal battery to ammeter (terminal B+) - ammeter (terminal L+) - battery relay (terminal 87) 2 Positive terminal battery to starter 3 Negative terminal battery to engine block 5 Fuel quantity sensor 6 Cylinder head temperature sensor 7 Oil temperature sensor 8 Starter relay 9 Ignition short-circuiting cable 10 Oil pressure transducer 12 Electric fuel pump 15 Regulator C+ 16 Generator breaker to regulator B+, to regulator R 17 Battery relay terminal 3 0 to main breaker 5 0 A 18 Radio loudspeaker 19 Transmit buttons 25 Anti collision lights 26 COM 27 NAV 28 Transponder 29 ADF 30 Attitude gyro 31 Direction gyro 33 Position lights 39 DME Doc. No. Issue Rev. No. Date Source Page No. 3.02.21 May 1 7 , 1 993 10 1 5 Jun 1 998 SB 50/5 2.61 •Diamond HK 36 R, TS, TC, TIS, TIC, TIC-ECO Systems AIRPLANE MAINTENANCE MANUAL Description AIRCRAFT 2.6.18 WIRING DIAGRAM - ENGINE COMPARTMENT HK 36 TS. HK 36 TC F�n £!p..aI't.B.l- ...... - P240Q·01 g � � VDLTA-liE REliULATDR ".1\2HO-C1 liErIER.ATOR liEti2.�O.Ql � � lG G ..� o ,� , --�� LlRI�----�I� I "�">-� 4- . v , , 0 > R •• '" � rI;; 0 0 > � cJ � ��--� L-�------ filf I t � JWL' � '" " C2�JO·Cl '-"""-' £' '-1!!.J1lL.J; � .,l;: �� � � .J; � .w. , � POWHl (OPTIO'I) EXT "AU;.Q� J.!'_G_'�'L'!� ��!g�G_ Srsn" , C, ry 1- .. ___ _ _ .� HH�" J · l _ AW� n t. 00 � 'L= � = -b = -L .", , ,.'e.,.. , " On ''''�''''' "'�'"t"' ,.." '".<�,.. " �."O" " r"' ",�.".,,,... , O. "',fl, 1 '""C� "'3"""'1 = . HOAC Auatritl D._,"" 's. '�" O"'-" .�, " """' " " '''�'� " = = ""w�. to •• I "llSU" . i"''''W'''' "''' ' w_n". " A"O"!l OS" n HKl6 rs I I Engone 00 " A-2700 Wr.Neustadt EI.eln,al W""'9 O,"g'�'" ... A"w"",0, �. '""',a'L "'''' �" AWG ,O """.. 0."'.". "_, '" " Aoo� I Co", Pa"",eni n SiN , Dar. n Vn"� o 01 Doc. No. Issue Rev. No. Date Source Page No. 3.02.21 May 17, 1 993 10 1 5 Jun 1 998 S8 50/5 2.62 1993 •Diamond HK 36 R, TS, TC, TIS, TIC, TIC-ECO Systems AIRPLANE MAINTENANCE MANUAL Description AIRCRAFT 2.6.19 WIRING DIAGRAM - FLIGHT COMPARTMENT HK 36 TS. HK 36 TC 4 X e-------------� �--------_h ::��-lI1 FUEl. P;IES.StJRE; WARNUIG -01 DSn�-lI1 " " . - - � '" " ' lln I ltD I "U 'V'Uu,c. fi�O�»O i "Il 'W ' "p J r.-> � . ... ". . .".".•..,." ,... "......"'... .. .."'''"'' ,,... HOAC Austria I A-2700 Wr.Neuslndl E IOClMcal l'lonng D,"�r,,," n'ghl Carnp.,lm�"t ! TO ,114{)O_OIIF ;., , " o. " '-lllil-' I KJ5TIl <;n, n t� n o t 19BB ; v "EI n� Doc. No. Issue Rev. No. Date Source Page No. 3.02.21 May 17, 1 993 10 1 5 Jun 1 998 S8 50/5 2.63 .,Diamond AIRCRAFT HK 36 R, TS, TC, TIS, TIC, TIC-ECO Systems AIRPLANE MAINTENANCE MANUAL Description 2.6.20 WIRING DIAGRAM - ENGINE COMPARTMENT HK 36 TTS. HK 36 TTC F�n �EW�!...l ___ cOcMfo n" HO'A" "" P2400-01 U "'IO",f r------=���--� � LAN Dill G LlIHIT 1124JO.o\ GEIIER.A1DR. GEtl24.l11.!l1 n II � " • 0 : , 5f�Rl"'G . '� � �r E"'::: , . " ' ' H : .."�' <"""� : " .11_11 Y-D-- y , : c .... aE : : : ...L -= I ,... L, ' � DOa'Q·OI E7B01.Ql EIlTIIDJ( , . ",SH " " § � , ! , � srSI[" 2 · c n AWe '" " � 'L. = J,. = J,. = � '''" '" .�." • • ". 0. .,.<.�. "m'" I ... . .. " " ."'.,.. ,,, ' .... �" ..,,"' .'''''"' �" "" "' . ,",....,,, i '"'''' ",n,,, , , , = 0••• ...... ", """.��. ,'0"" "" " "''"'0" CL> AHw ••• on ." .. w",a"",", a . "We; J" ."� . 0"",.'" '0'.. = Mw", " " C:"!�" DAIG Austria ", I " " En�m� c; o "' p a"m�n' . i SM ••! I ,,,,,w lln. " I ,,',,' �"•• IIK36 TTSrrTC i An � A-2700 W L N e u stadt E.1�etncal w""'� DlOgfOm .. . " '" I 1 012 i QjlI� n G1 1g�� Vnhd o n &11< Doc. No. Issue Rev. No. Date Source Page No. 3.02.21 May 1 7 , 1 993 10 1 5 Jun 1 998 S8 50/5 2.64 •Diamond AIRCRAFT HK 36 R, TS, TC, TIS, TIC, TIC-ECO Systems AI RPLANE MAINTENANCE MANUAL Description 2.6.21 WIRING DIAGRAM - FLIGHT COMPARTMENT HK 36 TTS. HK 36 TTC � , B2B:Q..Q \ 02-­ FUEL Pllt.lP " >'WG ! ---., .. '" " � t------n 'II , �=��----, . 'W " " C, '' ______________________________________--c __ = -L ",,,o.r- == .. "'�" co '''''''" 0" "","",'0",' I A-2700 Wr.N eustadt DAIG Austria EloMmoi w""'� D,ag" 1TI flight C .J,. = J.. = � " '� " " .,�'". o. "'".�-; "'�""... ,,,,, '"'�" .. ,m..' "" "''"' " ' => OAIG Austria O"�" " h.. " . . ."".,, �" .'"' "' .".,,,.." . �,, "', . . . . . . . ." . . """'.3"''' ..' ." AWl> lo ""� .. o"".,.. "ot., D"" i..l'li' ' . B20-240Q-;1O·OO A'f«!«lto'"",r-.J lJ:>:J1l == DAlGAUstria A-2700W.Nrusladt Slet!t:l of21 E«IIi :alWrinU[)ag ., " � , n �� '. s " w � lJ W ' � in Ti, "1" i d � ,; " � - � c ' . . . . . ... .. I r" ( N N " -I -'I Doc, No, Issue Rev, No, Date Source Page No, 3.0221 May 17, 1 993 10 1 5 Jun 1 998 S8 50/5 2.69 •Diamond AIRCRAFT HK 36 R, TS, TC, TIS, TIC, TIC-ECO Systems AIRPLANE MAI NTENANCE MANUAL Description 2.6.26 WIRING DIAGRAM - WING TANKS HK 36 TIC-ECO .. j Ij • � 6 � I� g jf � � ii U ,---1 : ,; � I � ] I� � '" !i � m 8 i - � -&2] I Doc. No. Issue Rev. No. Date Source Page No. 3.02.21 May 1 7, 1 993 10 1 5 Jun 1 998 S8 50/5 2.70 4ftDiamond AIRCRAFT HK 36 R, TS, TC, TIS, TIC, TIC-ECO Systems AIRPLANE MAINTENANCE MANUAL Description 2.6.27 WIRING DIMENSIONS Designation AN 4 AN 1 0 AN 1 4 AN 1 6 Cross Sectional Area [mm'] 22.0 5.3 1 , 94 1 .2 Length [m] 30 15 6 3 [ft.] 98 49 20 10 Current Intensity [A] 1 2 5 10 Permitted loading on AN 1 6 wire: Doc. No. Issue Rev. No. Date Source Page No. 3.02.21 May 1 7, 1 993 10 1 5 Jun 1 998 S8 50/5 2.71 �Diamond "'� AIRCRAFT HK 36 R, TS, TC, TIS, TIC, TIC-ECO Systems AIRPLANE MAINTENANCE MANUAL Description 2.6.28 POWER CONSUMPTION OF ELECTRICAL EQUIPMENT Power Consumption [A] Appliance .approximately 2.0 Engine instruments, including propeller speed control (for electrically variable propeller) Battery relay 0.8 Turbo Control Unit (Rotax 914 F only) 0.3 Actuator for waste gate flap (Rotax 914 F only) average 0.3 approximately 1 . 5 Fuel booster pump for Rotax 9 1 2 A: intermittent consumption, depending o n fuel pressure and flow rate Fuel pumps for Rotax 9 1 4 F Main pump alone 2.7 Main and booster pump 4.0 maximum 1�0.0 Electric starter ACL approximately 3.0 Position lights approximately 7.5 Landing lights approximately 7.5 Direction gyro approximately 0.8 Attitude gyro approximately 0.8 Doc. No. Issue Rev. No 3.02.21 May 17, 1 993 10 . Date Source Page No. 1 5 Jun 1 998 SB 50/5 2.72 4&Diamond "'� AIRCRAFT HK 36 R, TS, TC, TIS, TIC, TIC-ECO Systems AIRPLANE MAINTENANCE MANUAL Description 2.6.29 INSTALLATION OF ADDITIONAL ELECTRICAL EQUIPMENT The following rules must be followed when installing additional electrical equipment: • The total mass (total weight) of the instrument panel, including the instruments, must not exceed 1 7 kg (37.5 Ibs.). The total mass (total weight) of the instrument panel including standard equipment (without COM, NAV, etc.) is 7 kg ( 1 5.4 Ibs.). I • Do not rearrange the avionics panel (center section of the instrument panel). In each model, except for the HK 36 TTC-ECO, the switch panel in the upper center section of the instrument panel provides additional cooling for the avionics. It must not be displaced, and the free space behind it must be maintained. • The maintenance of the 1 5 Amps limit (see CAUTION) can be checked using the table in Article 2.6.28. Operating times of equipment with a high power consumption must be restricted. CAUTION The average power consumption of the aircraft electrical system must not exceed 1 5 Amps, since sufficient battery charging can otherwise not be ensured. WARNING Only applicable to models with Rotax 914 F: The engine only uses electric fuel pumps. In the case of a generator failure, the entire fuel supply depends on the battery. Consequently, the charging of the battery is crucial for flight safety. • After the installation of additional equipment, the empty mass (weight) and empty mass CG position must be established by calculation or weighing in accordance with Section 4. Doc. No. Issue Rev. No. Date Source Page No. 3.02.21 May 17, 1 993 10 1 5 Jun 1 998 S8 50/5 2.73 .Diamond AIRCRAFT HK 36 R, TS, TC, TIS, TIC, TIC-ECO Systems AI RPLANE MAINTENANCE MANUAL Description 2.5.30 GENERAL RULES FOR WORKING ON THE ELECTRICAL SYSTEM • Throw master switch in OFF position. If necessa ry, disconn ect the ground cable from the battery to avoid short-circuits. • Follow repair procedures set forth in FAA AC 43. 1 3-1A (Aircraft Inspection and Repair). • Use approved material only (aviation cables, fully insulated connectors). Use the special tools of the respective manufacturers . • • Avoid soldered joints. Wires must have the sizes set forth in FAA AC 43. 1 3-1A, Chapter 1 1 , and must be routed safely. The maximum permissible voltage drop is 0.5 V during continuous operation. Consequently, when the battery is fully charged (14 V), the voltage available to the appliance must be 1 3.5 V or higher. Doc. No. Issue Rev. No. Date Source Page No. 3.02.21 May 17, 1 993 10 1 5 Jun 1 998 S8 50/5 2.74 •Diamond AIRCRAFT HK 36 R, TS, TC, TIS, TIC, TIC-ECO Systems AIRPLANE MAINTENANCE MANUAL Description 2.7 STAll WARNING SYSTEM The serial numbers equipped with an aural stall warning system have a plastic hose running from a bore in the leading edge of the left wing to a horn installed in the cockpit near the pilot's feet. The bore is located 0.9 meters (approximately 3 ft.) outboard of the wing root. 2.8 MINIMUM EQU I PMENT LIST The Minimum Equipment List can be found in the Airplane Flight Manual, Paragraph 6.9. NOTE The tenm 'Minimum Equipment List' is not meant to include the 'Master Minimum Equipment List" which is developed by the FAA. Doc. No. Issue Rev. No. Date Source Page No. 3.02.21 May 17, 1 993 10 1 5 Jun 1 998 SB 5015 2.75 IIIftDiamond AIRCRAFT HK 36 R, TS, TC, TIS, TIC, TIC-ECO Maintenance & AIRPLANE MAINTENANCE MANUAL Inspections SECTION 3 MAINTENANCE AND INSPECTIONS 3.1 SCHEDULED INSPECTIONS 3.1.1 INSPECTION INTERVALS AND TOLERANCES Inspection of Airplanes Serviced in Accordance with FAR 91 The 1 D O hour inspection checklist in this section shall be accomplished for compliance with the 1 DO Hour and Annual Inspections required by FAR 9 1 . The 200 hour and 600 hour inspections s pecified i n this section shall be accomplished in addition to the 1 00 Hour and Annual Inspections required by FAR 9 1 . NOTE Prior to any inspection, the airframe and the propeller must be cleaned thoroughly. The engine must be cleaned after the check for oil leakage (see Inspection Checklist for the engine). Inspection of Airplanes NOT Serviced in Accordance with FAR 91 Engine and propeller inspections must be performed every 1 D O , 200, and 600 engine operating hours. Airframe inspections must be performed every 1 00, 200, and 600 flight hours. If the airplane is operated less than 200 hours per year, a 200 hour inspection must be performed once a year. Doc. No. Issue Rev. No. Date Source Page No. 3.02.21 May 17, 1 993 10 1 5 Jun 1 998 S8 50/5 3. 1 .Diamond AIRCRAFT HK 36 R, TS, TC, TIS, TIC, TIC-ECO Maintenance & AIRPLANE MAINTENANCE MANUAL Inspections The intervals between the inspections must be adhered to within a tolerance of ± 1 0 hours. These tolerances must not be added up. Example: if the 1 00 hour inspection was carried out at 1 1 0 hours, the next inspection is due at 200 ± 1 0 hours, not at 2 1 0 ± 1 0 hours. If an inspection is carried out more than 1 0 hours ahead of schedule, all subsequent inspection intervals are counted from that inspection. Example: if the 1 00 hour inspection was carried out at 83 hours, the next inspection is due at 1 83 ± 1 0 hours. 3.1.2 ACCOMPLISHMENT OF MAINTENANCE WORK The inspections are performed on the basis of Inspection Checklists which show the procedures and extent of the maintenance work in key-words. NOTE All items marked with a circle (0) must be performed at these intervals on any airplane. I n addition, all items marked with an asterisk (*) must be performed at these intervals on airplanes serviced in accordance with FAR 91 and on airplanes registered in Russia. Photocopies of Tables 1 , 2 and 3 must be made and filled out. After each item has been completed it must be confirmed over the corresponding circle or asterisk with the initials of the Aircraft Maintenance Engineer. After the inspection, these pages must be filed in the airplane's Maintenance Log, and the inspection must be confirmed in the airplane's log book. The maintenance and inspection work must be carried out by authorized personnel only. Doc. No. Issue Rev. No. Date Source Page No. 3.02.21 May 1 7, 1 993 10 1 5 Jun 1 998 S8 50/5 3.2 •Diamolld AIRCRAFT HK 36 R, TS, TC, TIS, TIC, TIC-ECO Maintenance & AIRPLANE MAINTENANCE MANUAL Inspections TABLE 1 , PAGE 1 OF 28 A. INSPECTION CHECKLISTS FOR THE POWER PLANT 1. ENGINE Type : 0 Rotax 9 1 2 A : 0 1 00 h o Rotax 9 1 4 F Serial number Running time meter count Flight hours Scope 0 200 h 0 600 h Items of maintenance carried out are to be confirmed by the initials of the AME. 1 00 200 600 0 o o 0 o o 0 o o 1 .4 Clean engine. 0 o o 1 .5 Drain oil with the engine warm. 0 o o 0 o o o o o ITEMS 1.1 THROUGH 1.52 APPLY TO ROTAX 912 A ONLY 1 . 1 Remove upper and lower cowling, check for cracks, overheated spots, deformation, loose or missing fasteners; clean cowling if dirty. 1 .2 Check engine, gearbox case, hydraulic propeller govemor (if installed) and pressure accumulator (if installed) for oil leakage. 1 .3 Check oil pressure transducer and oil temperature sensor for leakage. 1 .6 Replace oil filter, apply a light coat of oil to contact surface of filter. Cut old filter apart, check for metal pieces and foreign matter. Check magnetic screw(s) for metal particles. CAUTION metal particles are found, the problem must be corrected by If authorized personnel, the oil system must be flushed, and the oil radiator must be replaced. 1 .7 Refill engine with 3.0 liters (3.2 US quarts) of oil according to AFM; check oil level. Doc. No. Issue Rev. No. Date Source Page No. 3.02.21 May 17, 1 993 10 1 5 Jun 1 998 SB 50/5 3.3 "Diamond � AIRCRAFT HK 36 R, TS, TC, TIS, TIC, TIC-ECO Maintenance & AIRPLANE MAINTENANCE MANUAL I nspections TABLE 1 , PAGE 2 OF 28 1.8 1 00 200 600 • 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 Perform compression test o n all four cylinders according to Operator's Manual for the engine (engine warm, throttle valves open). Minimum pressure: 6 bar (87 psi). Cyl. 1 : Cyl. 2: Cyl. 3: Cyl. 4: 1 .9 Check spark plug electrode gap and adjust if necessary (0.7 to 0.8 mm (0.028 to 0.031 in.» . 1 .1 0 Replace spark plugs (type: NGK DCPR7E), mind Item 1 . 1 1 . 1.11 Apply a light coat of appropriate lubricant to spark plug threads, screw in spark plugs. CAUTION: the engine must be cold! Torque: 20 Nm ( 1 4.75 ft.lbs.). 1 . 12 Measure force required to pull off spark plug sockets. Minimum: 30 N (6.75 Ibs.). 1.13 Check ignition harness for chafing, check fastening for damage. 1.14 Check coolant for poor condition o r insufficient quantity. Dispatcher vessel must be full, equalizing reservoir must be at least '/3 full when the engine is cold (also see Article 4.1 .3). If loss of coolant is significant, determine reason. 1.15 If engine runs too hot: flush cooling system. 1 . 16 Check chafing protection pad on coolant dispatcher vessel for damage. 0 0 0 Doc. No. Issue Rev. No. Date Source Page No. 3.02.21 May 1 7 , 1 993 10 1 5 Jun 1 998 SB 50/5 3.4 "Diamond "'� AIRCRAFT H K 36 R, TS, TC, TIS, TIC, TIC-ECO Maintenance & AIRPLANE MAINTENANCE MANUAL Inspections TABLE 1 , PAGE 3 OF 28 1 00 200 600 o 1.17 Clean coolant radiator ribs; check radiator for leakage, damage, insecure mounting and poor condition of fastening. o o 1.18 Check air filter for poor condition; blow compressed air from inside to outside. o o 1.19 Replace air filter. 1 .20 Check airbox for insecure attachment, cracks, leaks, defonnation, and heat damage. 1 .2 1 * o o o o Check carburetor heat flap for looseness and improper operation (air filter removed). o o o 1 .22 Clean oil radiator ribs; check oil radiator for leakage, damage, insecure mounting and poor condition of fastening. o o o 1 .23 Check compensator tube between intake manifolds for chafing, leaks and improper installation (the tube must not sag - danger of fuel accumulation). o o o 1 .24 Check oil tank breather for blockage (long term operation at low engine temperatures in combination with high air humidity leads to blockage of the breather). o o o 1 .25 Check air guide for cylinder cooling for leakage, cracks, defonnation and heat damage. o o o 1 .26 Check engine mount for cracks, defonnation , corrosion, missing fasteners and lack of safetying. o o o Doc. No. Issue Rev. No. Date Source Page No. 3.02.21 May 17, 1 993 10 1 5 Jun 1 998 SB 5015 3.5 .Diamond AIRCRAFT HK 36 R, TS, TC, TIS, TIC, TIC-ECO Maintenance & AIRPLANE MAINTENANCE MANUAL Inspections TABLE 1 , PAGE 4 OF 28 1 .27 Check silentblocs for cracks and poor condition. 1 .28 Re-torque bolts attaching engine mount to firewall (torque: 40 Nm (29.5 fUbs.)). 1 .29 I nspect reduction gear (see Operator's Manual for the engine, Section 7.9). 1 .30 Check starter for insecure attachment. 1 .3 1 Check a l l wires and electric installations for heat damage and chafing; check wire attachments and connectors for looseneSS by slightly pulling by hand. 1 00 200 600 0 0 0 0 0 0 0 0 0 0 0 0 0 o Ground straps o Generator o Starter 0 Voltage regulator 0 Oil temperature sensor o Oil pressure transducer o Cylinder head temperature sensor o Ignition coils 0 0 1 .32 Check cabin heat hoses for obvious defects. 0 0 0 1 .33 Check exhaust pipes, seals and clamps for damage. 0 0 0 1 . 34 Check heat exchanger (muffler heating jacket) for cracks and insecure mounting to the muffler; check hoses for insecure mounting. 0 0 0 Doc. No. Issue Rev. No. Date Source Page No. 3.02.21 May 1 7, 1 993 10 1 5 Jun 1 998 SB 5015 3.6 HK 36 R, TS, TC, TIS, TIC, TIC-ECO Maintenance & AIRPLANE MAINTENANCE MANUAL Inspections TABLE 1 , PAGE 5 OF 28 1 00 200 600 1 .35 Open heat exchanger, check muffler for cracks, defonmation, and corrosion (the connection sleeves are most susceptible to cracks). o o 1 .36 Remove muffler and check for interior damage through connection sleeves. o o 1 .37 Check all nuts and bolts for looseness and obvious defects. o o o 1 .38 Check firewall breaches attachment of clamps. insecure o o o 1 .39 Check fuel lines and all other hoses for leakage, chafing, kinks and improper routing; check for expiration; check clamps for looseness. o o o 1 .40 Open cap of electric fuel pump, clean filter and cap. o o o 1 .4 1 Check electric fuel pump for leakage and insecure mounting. o o o 1 .42 Check engine driven fuel pump for leakage and insecure mounting. o o o 1 .43 Check both carburetors for insecure mounting; check rubber connection pieces between intake manifolds and carburetors for insecure mounting, poor condition and cracks. o o o 1 .44 Check throttle valves for asynchronous opening (see Operator's Manual for the engine). o o 1 .45 Check drain lines of carburetors , airbox and drip bowls for insecure attachment and poor condition; check drip bowl drains for blockage of transverse bores. HK 36 R only: check drip bowl outlets for dirt in the transverse holes. o o for leakage and o Doc. No. Issue Rev. No. Date Source Page No. 3.02.21 May 1 7, 1 993 10 1 5 Jun 1 998 SB 50/5 3.7 "Diamond ....'W AIRCRAFT HK 36 R, TS, TC, TIS, TIC, TIC-ECO Maintenance & AIRPLANE MAINTENANCE MANUAL Inspections TABLE 1 , PAGE 6 OF 28 1 00 1 .46 Check carburetor needles in accordance with ROTAX SB No. 9 1 2-04. 1 .47 Check valve springs in accordance with ROTAX SB No. 91 2-04. 1 .48 Check battery mount for poor condition; check acid level of battery. 1 .49 Check battery for poor charge and poor capacity. 1 .50 Check all control cables for insecure condition, interference and lack of operating clearance, lubricate; check cable fixtures for looseness; check th rottle control friction, adjust if necessary. 200 600 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 o Throttle o Carburetor heat o Cabin heat Choke Cowl flap o Propeller govemor 0 1 .5 1 Review Airworthiness Directives and Service Bulletins from the Engine Manufacturer for compliance. 1 .52 Check for foreign bodies. Operating fluids used (designation and quantitvl: Oil: Coolant: Parts replaced remarks: Doc. No. Issue Rev. No. Date Source Page No. 3.02.21 May 17, 1 993 10 1 5 Jun 1 998 SB 50/5 3.8 •Diamond AIRCRAFT HK 36 R, TS, TC, TIS, TIC, TIC-ECO Maintenance & AIRPLANE MAINTENANCE MANUAL Inspections TABLE 1 , PAGE 7 OF 28 1 00 200 600 Remove upper and lower cowling, check for cracks, overheated spots, deformation, loose or missing fasteners; clean cowling if dirty. o o o 1 . 1 02 Check engine, gearbox case, oil temperature sensor, oil pressure transducer, hydraulic propeller governor (if installed) and pressure accumulator (if installed) for oil leakage. o o o 1 . 1 03 Clean engine. o o o 1 . 1 04 Drain oil with engine warm. o o o 1 . 1 05 Replace oil filter, apply a light coat of oil to the contact surface of the filter. Cut old filter apart, check for metal particles and foreign matter. CAUTION If metal particles are found, the problem must be corrected by authorized personnel, the oil system must be flushed, and the oil radiator must be replaced. o o o o o ITEMS 1.101 THROUGH 1 .153 APPLY TO ROTAX 9 1 4 F ONLY 1 . 1 01 1 . 1 06 Check magnetic screw for metal particles. When re-installing: Torque 25 Nm (1 8.4 ft.lbs.), secure with lock wire. See CAUTION above. 1 . 1 07 Refill engine with 3.0 liters (3.2 US quarts) of oil according to Flight Manual; check oil level. o o o 1 . 1 08 Perform compression test on all four cylinders according to Maintenance Manual for Rotax Engine Type 914 F (engine warm, throttle valves open) Correct value: 9 to 12 bar ( 1 31 to 1 74 psi) Difference between cylinders: max. 2 bar (29 psi) • o o CyI. 1 : CyI. 3: _ _ _ _ _ _ CyI. 2: CyI. 4: _ _ _ _ _ _ Doc. No. Issue Rev. No. Date Source Page No. 3.02.21 May 17, 1 993 10 1 5 Jun 1 998 SB 5015 3.9 •Diamond AIRCRAFT HK 36 R, TS, TC, TIS, TIC, TIC-ECO Maintenance & AIRPLANE MAINTENANCE MANUAL I nspections TABLE 1 , PAGE 8 OF 28 200 600 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 1 00 1 . 1 09 Replace spark plugs (type: 1 2 mm NO X27EPR-U9). Apply a light coat of appropriate lubricant to spark plug threads, screw in spark plugs. CAUTION: the engine must be cold! Torque: 20 Nm ( 1 4.75 ft. lbs.) �o 1 . 1 1 0 Measure force required to pull off spark plug sockets. Minimum: 30 N (6.75 Ibs.). 1.111 Check ignition hamess for chafing, check fastening for damage. 1 . 1 1 2 Check coolant for poor condition or insufficient quantity. Dispatcher vessel must be full, equalizing reservoir must be at least ' /3 full (also see Article 4. 1 . 3). If loss of coolant is significant, determine reason. 1 . 1 1 3 Flush cooling system. 1 . 1 1 4 Check chafing protection pad on coolant dispatcher vessel for damage. 1 . 1 1 5 Check coolant filler cap on d ispatcher vessel for defective sealing; check pressure control valve and retum valve for improper operation. 1 . 1 1 6 Clean coolant radiator ribs; check radiator for leakage, damage, insecure mounting and poor condition of fastening. Doc. No. Issue Rev. No. Date Source Page No. 3.02.21 May 17, 1 993 10 1 5 Jun 1 998 SB 50/5 3.10 ·Diamond AIRCRAFT HK 36 R, TS, TC, TIS, TIC, TIC-ECO Maintenance & AIRPLANE MAINTENANCE MANUAL I nspections TABLE 1 , PAGE 9 OF 28 1 . 1 1 7 Check air filter for poor condition; blow compressed air from inside to outside. 1 00 200 o o 1 . 1 1 8 Replace air filter. 600 • o 1 . 1 1 9 Check airbox for insecure attachment, cracks, leaks, deformation or heat damage. o o o 1 . 1 20 Check carburetor heat flap for looseness and improper operation. o o o 1 . 1 2 1 Clean oil radiator ribs, check oil radiator for leakage, damage, insecure mounting and poor condition of fastening. o o o 1 . 1 22 Check compensator tube between intake manifolds for chafing, leaks and improper installation (the tube must not sag - danger of fuel accumulation). o o 1 . 1 23 Check oil tank breather for blockage (long term operation at low engine temperatures in combination with high air humidity leads to blockage of the breather). o o o 1 . 1 24 Check air guide for cylinder cooling for leakage, cracks, defonmation and heat damage. o o o 1 . 1 25 Check engine mount for cracks, deformation, corrosion, missing fasteners and lack of safetying. o o o 1 . 1 26 Check silentblocs for cracks and poor condition. o o o o 1 . 1 27 Re-torque bolts attaching engine mount to firewall (torque: 40 Nm (29.5 ft.lbs.)). Doc. No. Issue Rev. No. Date Source Page No. 3.02.21 May 1 7, 1 993 10 1 5 Jun 1 998 SB 50/5 3. 1 1 .Diamond AIRCRAFT HK 36 R, TS, TC, TIS, TIC, TIC-ECO Maintenance & AIRPLANE MAINTENANCE MANUAL Inspections TABLE 1 , PAGE 1 0 OF 28 1 . 1 28 I nspect reduction gear (See Maintenance Manual for Rotax Engine Type 9 1 4 F). 1 00 200 600 o o o 1 . 1 29 Check cogwheel set for pitting and larger cavities (see Maintenance Manual for Rotax Engine Type 9 1 4 F). 1 . 1 30 Check starter for insecure attachment. o o o o o o o 1 . 1 32 Check condensation screen in airbox pressure line for TCU (between firewall and instrument panel) for water accumulation and replace if necessary. o o o 1 . 1 33 Check the three glass fuses on the right hand side of the firewall . o o o 1 . 1 34 Check cabin heat hoses for defects. o o o 1 . 1 31 Check all wires and electric installations for heat damage and chafing; check wire attachments and connectors for looseness by Slightly pulling by hand. o o o o o o o o o o o o o o o o o Ground straps Generator Starter Voltage regulator All relays Oil temperature sensor Oil pressure transducer Cylinder head temperature sensor Ignition coils TCU, actuator (behind instrument panel) Airbox pressure transducer Ambient pressure transducer Airbox temperature sensor Throttle valve position sensor Mixture switch valve __ __ __ __ __ __ __ __ Doc. No. Issue Rev. No. Date Source Page No. 3.02.21 May 17, 1 993 10 1 5 Jun 1 998 SB 50/5 3. 1 2 •Diamond AIRCRAFT HK 36 R, TS, TC, TIS, TIC, TIC-ECO Maintenance & AIRPLANE MAINTENANCE MANUAL Inspections TABLE 1 , PAGE 1 1 OF 28 1 00 200 600 1 . 1 35 Check exhaust pipes, seals and clamps for damage. o o o 1 . 1 36 Check heat exchanger (muffler heating jacket) for cracks and insecure mounting to the muffler; check hoses for insecure mounting. o o o o o 1 . 1 37 Remove heat exchanger and check for damage on the inside. Check muffler for cracks and leaks (the connection sleeves are most susceptible to cracks). 1 . 1 38 Open hose connection between carburetor heat flap and turbocharger. Check turbocharger for cracks in the housing and defective attachment; check compressor wheel for damage and interference. o o o 1 . 1 39 Check waste gate flap for improper adjustment; check control cable for damage, wear and defective connection; cheCk spring for damage. o o o 1 . 140 Check all nuts and bolts for looseness and obvious defects. o o o 1 .141 o o o Check firewall breaches attachment of clamps. for leakage and insecure Doc. No. Issue Rev. No. Date Source Page No. 3.02.21 May 17, 1 993 10 1 5 Jun 1 998 SB 5015 3.13 .Diamond AIRCRAFT HK 36 R, TS, TC, TIS, TIC, TIC-EGO Maintenance & AIRPLANE MAINTENANCE MANUAL Inspections TABLE 1 , PAGE 12 OF 28 1 . 1 42 Check fuel lines and all other hoses for leakage, chafing, kinks and improper routing; check for expiration; check clamps for looseness. 1 . 1 43 HK 36 ITS and HK 36 ITC only: Clean fuel strainer in the filter box under the tank. 1 . 1 44 Check both electric fuel pumps for leaks and insecure mounting. 1 . 1 45 Check both carburetors for insecure mounting; check rubber connection pieces between intake manifolds and carburetors for insecure mounting, poor condition and cracks. 1 00 200 600 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 1 . 1 46 Check carburetor float chambers inside for dirt and defective seals; check floats for interference; check float chamber ventilation lines for kinks and blockage. 1 . 1 47 Check throttle valves for asynchronous opening. 1 . 1 48 Check drain lines of carburetors, airbox and drip bowls for insecure attachment and poor condition. 1 . 1 49 Check battery mount for poor condition; check acid level of battery. Doc. No. Issue Rev. No. Date Source Page No. 3.02.21 May 17, 1 993 10 1 5 Jun 1 998 SB 50/5 3.14 Maintenance & HK 36 R, TS, TC, TIS, TIC, TIC-ECO .DiamAo' ,RC"RAFTd AIRPLANE MAINTENANCE MANUAL I nspections TABLE 1 , PAGE 1 3 OF 28 1 00 200 600 o o o o o o 1 . 1 52 Review Airworthiness Directives and Service Bulletins from the Engine Manufacturer for compliance. o o o 1 . 1 53 Check for foreign bodies. o o o 1 . 1 50 Check battery for poor charge and poor capacity. 1.151 Check all control cables for insecure condition, interference and lack of operating clearance, lubricate; check cable fixtures for looseness; check throttle control friction, adjust if necessary. o Throttle (dead travel 1 mm (0.04 in.)) o Carburetor heat o Cabin heat o Choke o Cowl flap o Propeller govemor Operating fluids used (designation and quantiM: Oil: Coola nt. __ _ __ __ __ __ __ __ _ ------ Parts replaced, remarks: Doc. No. Issue Rev. No. Date Source Page No. 3.02.21 May 17, 1 993 10 1 5 Jun 1 998 SB 50/5 3.15 •Diamond AIRCRAFT HK 36 R, TS, TC, TIS, TIC, TIC-ECO Maintenance & AIRPLANE MAINTENANCE MANUAL Inspections TABLE 1 , PAGE 14 OF 28 2. PROPELLER Type 0 : 0 mt-propeller MTV 1-A/1 70-08 o mt-propeller MTV 21 -A-C-F/CF1 75-05 o Hoffmann HO-V352F-S 1 /S1 70FQ 0 mt-propeller MT 1 70 R 125-2A Hoffmann H014- 1 70 S 123 Serial number Running time meter count Flight hours : 0 Scope 0 1 00 h 200 h o 600 h Items of maintenance carried out are to be confirmed by the initials of the Worker. 1 00 200 600 2.1 Review Airworthiness Directives and Service Bulletins from the Propeller Manufacturer for compliance. o o o 2.2 Clean propeller. o o o 2.3 Check spinner and spinner mount for cracks, dents, runout, and missing fasteners. o o o 2.4 Check propeller track. o o o 2.5 Check blades for damage and cracks (refer to Propeller Manual). o o o 2.6 Fixed pitch propellers only o o 2.7 Constant speed propellers only: Remove spinner dome, o o o 2.8 Check all parts for insecure mounting and defective safetying. o o o 2.9 Check propeller hub for cracks and corrosion. o o o 2.10 Tighten propeller flange bolts (refer to Propeller Manual for proper torque and procedure); check for lack of safetying. o o o propeller flange for corrosion. Remove propeller, check check spinner backplate for cracks and insecure mounting. Doc. No. Issue Rev. No. Date Source Page No. 3.02.21 May 17, 1 993 10 1 5 Jun 1 998 SB 50/5 3.16 •Diamond AIRCRAFT HK 36 R, TS, TC, TIS, TIC, TIC-ECO Maintenance & AIRPLANE MAINTENANCE MANUAL Inspections TABLE 1 , PAGE 1 5 OF 28 1 00 200 600 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 ITEMS 2.101 THROUGH 2.107 APPLY TO MTV-1 ELECTRIC CONSTANT SPEED PROPELLER ONLY 2 . 1 01 Check for excessive bladeshake (max. 3 mm ('/8 in.)) and angular play (max. 2"). 2 . 1 02 Check pitch change mechanism for oil and grease leakage. 2 . 1 03 Clean carbon brushes, check for insecure attachment, unsafe condition and excessive wear (minimum length of brushes: 7 mm (9/32 in.)). 2. 1 04 Clean slip rings, check for wear. 2 . 1 05 Check brush block brackets for cracks; check fastening screws for looseness and lack of safetying; check brush block for improper adjustment according to Propeller Manual, Paragraph 5.5. 2 . 1 06 Check wires and electric connectors for insecure condition and looseness; check electric motor and other parts for insecure mounting. 2 . 1 07 Check electric motor for improper operation with the engine off. Remarks: Doc. No. Issue Rev. No. Date Source Page No. 3.02.21 May 1 7 , 1 993 10 1 5 Jun 1 998 SB 5 0/5 3.17 .Diamond AIRCRAFT HK 36 R, TS, TC, TIS, TIC, TIC-ECO Maintenance & AI RPLANE MAINTENANCE MANUAL Inspections TABLE 1 , PAGE 1 6 OF 28 1 00 200 600 0 0 0 2.202 Check low pitch stop nuts for looseness. 0 0 0 2.203 Check pitch change mechanism for oil and grease leakage. 0 0 0 2.204 Check propeller govemor for insecure mounting. 0 0 0 0 0 0 2.206 Check hub and blade root areas for oil and grease leakage. 0 0 0 2.207 Inspect position of counterweights. 0 0 0 ITEMS 2.201 THROUGH 2.207 APPLY TO MTV-2 1 HYDRAULIC CONSTANT SPEED PROPELLER ONLY 2.201 Check for excessive bladeshake (max. 3 mm C /8 in.)) and angular play (max. 2"). 2.205 Check pressure accumulator for insecure mounting; check gas pressure, refill if necessary (nitrogen or air, 8.5 bar (125 psi)). Remarks: Doc. No. Issue Rev. No. Date Source Page No. 3.02.21 May 1 7, 1 993 10 1 5 Jun 1998 SB 50/5 3.18 .Diamond AIRCRAFT H K 36 R, TS, TC, TIS, TIC, TIC-ECO Maintenance & AIRPLANE MAINTENANCE MANUAL Inspections TABLE 1 , PAGE 1 7 OF 28 1 00 200 600 Check for bladeshake (no bladeshake allowable) and angular play (max. 1 °). o o o 2.302 Check pitch change mechanism for oil and grease leakage. o o o 2.303 Check pitch change mechanism for interference by twisting the blades by hand (see Propeller Manual). o o o 2.304 Check propeller governor for insecure mounting. o o o 2.305 Check propeller speed control cable for improper operation and obvious defects. o o o 2.306 Check mechanical feathering device for improper operation and obvious damage; check thrust plate for excessive wear (max.: 0.2 mm (' 1,28 in.)) check all parts of the actuating mechanism and ball bearings for poor condition. o o o 2.307 Check distance between ball bearings and thrust plate (min. 1 mm (0.04 in.) at minimum pitch). o o o 2.308 Clean thrust plate; slig htly grease pitch change rods, ball bearings and thrust plate of mechanical feathering device with Calypsol H 443 or equivalent. o o o 2.309 Check blade retention nuts for defective sealing. o o o ITEMS 2.301 THROUGH 2.309 APPLY TO HO-V352 HYDRAULIC CONSTANT SPEED PROPELLER ONLY. 2.301 Remarks: Doc. No. Issue Rev. No. Date Source Page No. 3.02.21 May 1 7, 1 993 10 1 5 Jun 1 998 SB 50/5 3. 1 9 .Diamond AIRCRAFT HK 36 R, TS, TC, TIS, TIC, TIC-ECO Maintenance & AIRPLANE MAINTENANCE MANUAL I nspections TABLE 1 , PAGE 1 8 OF 28 B. INSPECTION CHECKLISTS FOR THE AIRFRAME Serial number Running time meter count Flight hours : 0 Scope 1 00 h 0 200 h 0 600 h Items of maintenance carried out are to be confirmed by the initials of the AME. 3. CABIN 3.1 Check canopy for damage; check locking device for unserviceability. 3.2 Check canopy jettison device for unserviceability. 3.3 Check seat belts and shoulder hamesses and their fastenings for damage. 3.4 1 00 200 600 0 0 .0 0 0 0 0 Check elevator trim control system in center console for damage, interference, looseness of notch plate and improper adjustment. o o o 3.5 Check rudder pedals for corrosion and causticization, in particular in the area of the weld seams. o o o 3.6 Check nudder pedals for looseness, interference, and poor condition of recuperator springs; check pedal adjusting device for improper operation; lubricate if necessary. o o o Doc. No. Issue Rev. No. Date Source Page No. 3.02.21 May 17, 1 993 10 1 5 Jun 1 998 SB 5015 3.20 .Diamond AIRCRAFT HK 36 R, TS, TC, TIS, TIC, TIC-ECO Maintenance & AIRPLANE MAINTENANCE MANUAL Inspections TABLE 1 , PAGE 19 OF 21 3.7 1 00 200 600 o o o o o o o o o Tail wheel models above Serial No. 36.516 and tricycle models only: check brake pedals for interference, play, and improper operation; check mechanism for damage and wear. 3.8 Tail wheel models above Serial No. 36.516 and tricycle models only: check brake cylinders and brake lines for leakage. 3.9 Tail wheel models above Serial No. 36.516 and tricycle models only: check brake fluid for poor condition, change if necessary; fill brake fluid reservoirs to maximum level ( 1 5 mm (5/8 in.) below top). 3.10 Check parking brake valve for improper operation and leaky connectors and check Bowden cable for improper adjustment. o o o 3.1 1 Check control cables in the area of the S-guides for chafing and broken strands. o o o 3.12 Check control sticks for interference, defective stops, and excessive play; check zero position. o o o 3.13 Measure the play of aileron and elevator control system with one stick blocked. Max. allowable play: 3 mm ( ' /8 in.), measured on the trailing edge of the surfaces. o o o 3.14 Check air brake levers for improper locking and unlocking (in the retracted position); check air brakes for asynchronous extension. o o o o o o Tail wheel models through Serial No. 36.516 only: check for premature o r delayed activation of wheel brakes. 3.15 Check instruments for improper or missing markings. Doc. No. Issue Rev. No. Date Source Page No. 3.02.21 May 17, 1 993 10 1 5 Jun 1 998 SB 5015 3.21 "Diamond v AIRCRAFT H K 36 R, TS, TC, TIS, TIC, TIC-ECO Maintenance & AIRPLANE MAINTENANCE MANUAL Inspections TABLE 1 , PAGE 20 OF 28 1 00 3. 1 6 Check all control knobs and handles for improper or missing inscriptions and designations. 3. 1 7 Remove instrument panel top cover; check all electric equipment, switches, instruments, and breakers for insecure mounting. 3.18 3.19 200 600 0 0 0 0 Check fuel valve for insecure mounting. 0 0 0 HK 3 6 TTC-ECO only: 0 0 0 0 0 0 0 0 0 Check fuel selector valve for interference, improper latching, defective stops, and looseness. 3.20 Check safetying of main bolts for unserviceability and poor condition. 3.21 Check main bolts for interference, lubricate if necessary. Doc. No. Issue Rev. No. Date Source Page No. 3.02.21 May 17, 1 993 10 1 5 Jun 1 998 SB 5015 3.22 "'Diamond v AIRCRAFT HK 36 R, TS, TC, TIS, TIC, TIC-ECO Maintenance & AIRPLANE MAINTENANCE MANUAL Inspections TABLE 1 , PAGE 21 OF 28 4. STRUCTURE 1 00 200 600 4.1 Check the skin of the wings, stabilizers, and fuselage for dents, cracks, holes, etc. o o o 4.2 Check winglets, horizontal stabilizer tips, and tail fins (if installed) for damage and looseness. o o o 4.3 Check ailerons for defective attachment and excessive play in hinges; check slot for imperfect or missing adhesive tape. o o o 4.4 Check aileron bell crank and push-rods through inspection window for improper connection and improper safetying. o o o 4.5 Check aileron webs for delamination and defective bonds. 4.6 Check air brakes and air brake mechanism in wings and fuselage for damage, improper connection and improper safetying. 4.7 HK 36 TTC-ECO only: o o o o o o o o o o o o o o Empty fuel tanks 4.8 Remove wings. 4.9 HK 36 TTC-ECO only: o Check fuel tanks, fillers and drainers for damage and leakage. 4. 1 0 HK 36 TTC-ECO only: Check fuel tank connectors (fuel hose, vent line, fuel quantity signal wire, ground strap) for damage. 4. 1 1 Measure forces for locking, unlocking and extending the air brakes; lubricate wing connecting bolts in accordance with Lubrication Schedule. Doc. No. Issue Rev. No. Date Source Page No. 3.02.21 May 1 7, 1 993 10 1 5 Jun 1 998 SB 50/5 3.23 "Diamond v� AIRCRAFT HK 36 R, TS, TC, TIS, TIC, TIC-ECO Maintenance & AI RPLANE MAINTENANCE MANUAL Inspections TABLE 1 , PAGE 22 OF 28 1 00 200 600 4.12 Check main bulkhead inside for damage and delamination. o o 4. 1 3 Check wing spar stump for damage and delamination. o o 4. 1 4 Check forward and rearward web of wing spar through holes in root rib and aileron inspection hole for defective bonds, cracks and delamination. 4. 1 5 Remove horizontal stabilizer, check fittings and locking ring for insecure attachment and corrosion; check locking ring for inadequate locking function. 4. 1 6 Only for Serial Nos. through 36. 4 1 6 on which sa 51, Measure 2 has not been carried out: o o o o o o Check elevator hom for defective attachment. 4. 1 7 Check horizontal stabilizer and elevator for insecure mounting; check elevator hinges for insecure attachment and improper safetying. o o o 4. 1 8 Check both rudder hinges for insecure attachment and excessive play; check rudder control cables for damage, improper connection and looseness; check safetying of bolts on rudder lower mounting plate for damage; o o o o o o o o o tail wheel models only: check lower edge of rudder for cracks and rubber marks. 4. 1 9 Tail wheel models only: check tail wheel steering mechanism and suspension for improper operation; check coil springs for play and improper installation. 4.20 Tail wheel models only: Check tail wheel fork and steering shaftror deformation. Doc. No. Issue Rev. No. Date Source Page No. 3.02.21 May 1 7, 1 993 10 1 5 Jun 1 998 SB 5015 3.24 "Diamond T AIRCRAFT HK 36 R, TS, TC, TIS, TIC, TIC-ECO Maintenance & AIRPLANE MAINTENANCE MANUAL Inspections TABLE 1 , PAGE 23 OF 28 I 4.2 1 4.22 Remove rudder; relieve tail wheel (if fitted); check rudder lower pedestal for defonmation, cracks, and corrosion. Tail wheel models : every 1 00 hours Tricycle models : every 200 hours 1 00 200 600 tail o o o o o o o o o o o o o o wheel models o Tail wheel models only: remove tail wheel fork; check steering shaft for deformation. 4.23 Tail wheel models only: remove dowel pins, extract hub of the tail wheel fork (on upper edge of the oval fork arms); check hub for defonmation. 4.24 Tail wheel models only: tighten tail wheel rubber spring assembly. 4.25 Tricycle models only: check tail skid for defective attachment and excessive wear. 4.26 Lubricate rudder hinge bushes. 4.27 Check vertical stabilizer stiffener and rearward ring frames for poor condition, cracks and defective bonds. 4.28 Check rearward parts of elevator control system for insecure attachment, im proper installation, improper operation, excessive play, corrosion, and improper safetying. o o o 4.29 Remove baggage compartment floor; check rudder control cables, rudder lever, and aileron and air brake control system parts for lack of operational serviceability, damage, corrosion, improper operation and improper safetying. o o o o Doc. No. Issue Rev. No. Date Source Page No. 3.02.21 May 17, 1 993 10 1 5 J un 1 998 S B 50/5 3.25 4fADiamond T AIRCRAFT HK 36 R, TS, TC, TIS, TIC, TIC-ECO Maintenance & AIRPLANE MAINTENANCE MANUAL Inspections TABLE 1, PAGE 24 OF 28 1 00 200 600 o o o 4.30 Remove panel on rear wall of baggage compartment; check fuselage tube for deformation and cracks; check guiding of elevator push-rod for insecure attachment; check control cables and tumbuckles for corrosion, wear and lack of safetying. 4.31 Check forward ring frames, B-bulkhead, and sickle shaped bulkhead for delamination, cracks, and defective bonds. 4.32 Remove seat shells, check for uncleanliness and loose equipment that might foul the controls. o o o 4.3 3 All models except HK 36 R: check air brake fixture (next to LH air brake lever) for uncleanliness and wear. o o o 4.34 Check main bulkhead and forward and rearward transverse stiffener for delamination and defective bonds. o o o 4.35 Check firewall for delamination around engine mount attachment bolts. 4.36 Tail wheel models through Serial No. 36. 516 only: check brake fluid for poor condition and insufficient quantity; check brake master cylinder for leakage. o o o 4.37 Check fuel lines and central fuel reservoir (HK 36 TIC-ECO) or fuel tank (other models) for leakage; airplanes registered in Russia only: check vent line and additional vent bore for blockage; check central fuel reservoir (HK 36 TIC-ECO) or fuel tank (other models) for insecure or improper installation. o o o o o Doc. No. Issue Rev. No. Date Source Page No. 3.02.21 May 1 7, 1 993 10 1 5 Jun 1 998 SB 5015 3.26 �Diamond "'71T AIRCRAFT HK 36 R, TS, TC, TIS, TIC, TIC-ECO Maintenance & AIRPLANE MAINTENANCE MANUAL Inspections TABLE 1 , PAGE 25 OF 28 1 00 200 600 4.38 Check electrical installation and ground straps for chafing; check wire attachments and connectors for looseness by slightly pulling by hand. o o o 4.39 Check Pitot tube, TEC nozzle, and antennas for insecure attachment. o o o 4.40 Check moisture drain holes and ventilation bores in wings, fuselage and control surfaces for blockage. o o o 4.41 Check aural stall waming system (if installed) for improper operation by applying negative pressure to the bore in the leading edge of the left wing. o o o 4.42 Check for imperfect or missing placards and inscriptions. Refer to Airplane Flight Manual Supplements for placards for optional equipment. o o o 4.43 Check aileron and air brake control system parts in root ribs (wing and fuselage) for insecure mounting and wear, lubricate if necessary. o o o 4.44 Install wings. o o 4.45 HK 36 TTC-ECO only: o o o o o o Measure electrical resistance between tank filler and engine block (LH and RH wing, max. admissible: 0.5 0). Measure electrical resistance between drainer and engine block (LH and RH wing, max. admissible: 0.5 OJ. 4.4 6 Check fuel quantity indicator for improper indication. 4.47 Towing device and release mechanism (optional): clean and lubricate, check for poor condition and improper operation; check towing device mount for deformation, obvious damage, and defective attachment to the fuselage tube. o Doc. No. Issue Rev. No. Date Source Page No. 3.02.21 May 1 7, 1 993 10 1 5 Jun 1 998 SB 50/5 3.27 .,Diamond AIRCRAFT HK 36 R, TS, TC, TIS, TIC, TIC-ECO Maintenance & AIRPLANE MAINTENANCE MANUAL Inspections TABLE 1 , PAGE 26 OF 28 5. LANDING GEAR 5.1 Clean landing gear; remove wheel fairings. 5.2 Check main landing gear strut for cracks, deformation and damage; Tail wheel models only: check strut for delamination; contact Manufacturer if GFRP strut is damaged. 5.3 Check brake linings for wear, minimum thickness: 3.5 mm (0. 1 4 in.). 5.4 Check tires for cuts, excessive wear and defective valve stems; check creep marks. 5.5 Ensure correct tire inflation pressure 1 00 200 600 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 Tail wheel models: main gear 2.1 bar (30 psi), tail wheel 3. 1 bar (45 psi) Tricycle models: main gear 2.3 bar (33 psi), nosewheel 1 .B bar (26 psi) 5.6 Check rims for cracks; check bearings for rough running and play; check brake disks for wear (min. thickness: 3. B mm (0. 1 5 in.)). 5.7 Tricycle models only: check nosewheel assembly for play, damage, deformation and cracks; check bearings in fuselage for play; check LH and RH journal in damper for play, lubricate. 5. B Tricycle models only: inspect nosewheel elastomer damper, 5.9 tighten if necessary. Tricycle models only: unload nosewheel fork, check for play; check for improper friction (3 to 5 daN (6.7 to 1 1 .2 Ibs.) along axle) and correct if necessary. - Doc. No. Issue Rev. No. Date Source Page No. 3.02.21 May 1 7, 1 993 10 1 5 Jun 199B SB 50/5 3.28 "Diamond � AIRCRAFT HK 36 R, TS, TC, TIS, TIC, TIC-ECO Maintenance & AIRPLANE MAINTENANCE MANUAL I nspections TABLE 1 , PAGE 27 OF 28 1 00 200 600 5.10 Tricycle models only: remove nosewheel fork; check vertical pivot bearing for corrosion and play, lubricate. o 5. 1 1 Remove main wheels, clean and lubricate bearings. o 5.12 Tail wheel models only: check differential wheel braking system (optional) for poor condition and improper operation. o o o 5. 1 3 Check brake lines and brake cylinders for leaks, damage, and corrosion. o o o 5. 1 4 I n stall wheels and wheel fairings, ensure a secure attachment. o o o Doc. No. Issue Rev. No. Date Source Page No. 3.02.21 May 17, 1 993 10 1 5 Jun 1 998 SB 50/5 3.29 •Diamond AIRCRAFT HK 36 R, TS, TC, TIS, TIC, TIC-ECO Maintenance & AI RPLANE MAINTENANCE MANUAL Inspections TABLE 1 , PAGE 28 OF 28 C. GENERAL MAINTENANCE WORK AND CONFIRMATION 6. GENERAL 1 00 200 600 o o o o o 6.1 Review Airplane Flight Manual Supplements for optional equipment that requires inspection. 6.2 Check Pitot and static pressure system for leakage and dirt. 6.3 Lubricate parts according to Lubrication Schedule. o o o 6.4 Review Airworthiness Directives and Service Bulletins for compliance. o o o 6.5 Check components listed in Paragraph 6.1 for expiration. o o o 6.6 If necessary re-determine empty mass (weight) and corresponding CG position (see Paragraph 4.4). o o o 6.7 Enter inspection in log book. o o o 6.8 Perform check flight, carry out and confirm all items in the form "Check Flight". o o o Observations and Remarks: The powered sailplane with the call sign _____ a hour inspection on the engine, a hour inspection on the propeller, and a hour inspection on the airframe properly performed at a total flight time of a running time meter count of ___ _ _ _ has had hours and hours. The airplane is airworthy with respect to maintenance. Date Place Signature Stamp Doc. No. Issue Rev. No. Date Source Page No. 3.02.21 May 1 7, 1 993 10 1 5 Jun 1 998 SB 5015 3.30 •Diamond AIRCRAFT HK 36 R, TS, TC, TIS, TIC, TIC-ECO Maintenance & AIRPLANE MAINTENANCE MANUAL Inspections D. LUBRICATION SCHEDULE With a few exceptions, the whole flight control system and all other mechanical systems are provided with maintenance free rod end bearings and rigid ball bearings. However, the bearings should be observed constantly, (especially in the case of tough climatic conditions such as wind-borne sand, saline air, etc.) and, if necessary, cleaned and lubricated: Beside the lubrication during rigging, lubrication is necessary at the times shown with a circle in Table 2. All commercial greases are appropriate. However, lubricants containing MoS2 must not be combined with common all-purpose grease. Doc. No. Issue Rev. No. Date Source Page No. 3.02.21 May 17, 1 993 10 1 5 Jun 1 998 SB 5015 3.31 •Diamond AIRCRAFT HK 36 R, TS, TC, TIS, TIC, TIC-ECO Maintenance & AI RPLANE MAINTENANCE MANUAL Inspections TABLE 2, PAGE 1 OF 1 LUBRICATION SCHEDULE 1. Engine operating cable fixtures (oil). 2. All rod end bearings (grease). 3. Rudder control cables in area of pedals, S-guides (oil). 4. Rudder bearings (2 pieces) after removing rudder (grease). 5. 1 00 200 600 0 0 0 0 0 0 Tail wheel models only: Eye bolt in tail wheel elastomer package (oil). 0 0 0 0 0 0 0 6. Cable eyes on rudder lever beneath baggage compartment (grease). 7. Telescopic tubes of wing folding mechanism (optional), main bolts, A- and B- bolts (grease). B. Rollers in the bellcranks for aileron and air brake control systems (in wing root rib, grease). 9. Main landing gear bearings (grease). 0 10. Tricycle models only: 0 11. 0 0 0 0 0 Vertical pivot bearing of nosewheel fork (grease). Tricycle models only: LH and RH bearing journal in connection of nosewheel leg and damper (oil). 1 2. Locking rings in horizonal tail and in the two B-bolt fastening units (oil). 1 3. HO-V352 constant speed propeller only: Rollers, thrust plate, pitch change rods (grease). 0 0 0 0 0 0 0 0 0 - Doc. No. Issue Rev. No. Date Source Page No. 3.02.21 May 1 7, 1 993 10 1 5 Jun 1 99B SB 5015 3.32 �Diamol1d T AIRCRAFT HK 36 R, TS, TC, TIS, TIC, TIC-ECO Maintenance & AIRPu\NE MAINTENANCE MANUAL Inspections TABLE 3, PAGE 1 OF 2 E. CHECK FLIGHT AFTER MAINTENANCE Call sign: Pilot Date: Start: Aerodrome: Landing: Performance checks, flying characteristics Observations no yes Functioning check of warning and caution lights Fuel quantity indicator Anti collision lights (ACLs) Position lights VOR, ADF, XPDR, etc. COM, transmission test Electric fuel pump(s) Electric starter Engine starting behavior (cold) Functioning of oil pressure indicator Functioning of ammeter, functioning of generator, battery charge Functioning of RPM indicator (comparison with calibrated tachometer) Functioning of cylinder head temperature indicator Functioning of wheel brakes I parking brake Functioning of oil temperature indicator Taxiing behavior Take-off Functioning of airspeed indicator Doc. No. Issue Rev. No. Date Source Page No. 3.02.21 May 1 7, 1 993 10 1 5 Jun 1 998 SB 5015 3.33 "Diamond 'V� AIRCRAFT HK 36 R, TS, TC, TIS, TIC, TIC-ECO Maintenance & AIRPLANE MAINTENANCE MANUAL Inspections TABLE 3, PAGE 2 OF 2 Performance checks, flying characteristics (continued) Observations no yes Functioning of altimeter I QNH setting Functioning of vertical speed indicator I TEC Functioning of magnetic compass Functioning of Turbo Control Unit (R 914 F only) Functioning of propeller speed control (if installed) High speed flying characteristics Functioning of elevator trim I trim range Functioning of air brakes Functioning of cabin heat I cabin air Carbon monoxide test In-flight engine stop (constant speed propeller feathered) Low speed flying characteristics I stall characteristics Landing Functioning of fuel valve and fuel pressure waming light (full throttle, fuel valve CLOSED, fuel pressure waming light must illuminate within 2 seconds). Engine starting behavior (warm) Remarks: -- Pilot's signature Doc. No. Issue Rev. No. Date Source Page No. 3.02.21 May 17, 1993 10 1 5 Jun 1 998 SB 50/5 3.34 i(A,Diamond T AIRCRAFT HK 36 R, TS, TC, TIS, TIC, TIC-ECO Maintenance & AIRPLANE MAINTENANCE MANUAL Inspections 3.2 DESCRIPTION OF SCHEDULED INSPECTIONS 3.2.1 ENGINE Detailed descriptions of maintenance work which must be carried out during scheduled inspections can be found in the O perating Manual for the Rotax 912 A Engine or the Maintenance Manual for Rotax Engine Type 914 F, respectively. 3.2.2 PROPELLER Detailed descriptions of the maintenance work which must be carried out during scheduled inspections can be found in the respective Propeller Manual (see Article 2.5.6). Doc. No. Issue Rev. No. Date Source Page No. 3.02.21 May 17, 1 993 10 1 5 Jun 1 998 SB 50/5 3.35 �Diamond � AIRCRAFT HK 36 R, TS, TC, TIS, TIC, TIC-ECO Maintenance & AIRPLANE MAINTENANCE MANUAL Inspections 3.2.3 CABIN 3.1 The canopy and the two rear windows (optional) are checked for cracks and pressure cracks. Should a crack be found, refer to the instructions in Paragraph 5.6. The locking mechanism must not be loose, but also should not jam. The connecting rods to the locking pins must not be deformed. 3.2 The canopy locking levers are swung fully rearward when checking the canopy jettison device, i.e. approximately 180°. The canopy is separated from the four locking pins and the canopy brackets are disconnected from the canopy frame. To avoid inadvertent canopy jettison during flight, the levers are blocked by means of lock wires in the mechanism. In the event of canopy jettison, or in this test, the lock wire tears off and must be replaced (available from the Manufacturer). CAUTION The breaking strength of the lock wire must not exceed 20 daN (45 Ibs.). Otherwise the force required to jettison the canopy would be too great. 3.3 The condition of the seat hamesses must be inspected. The harnesses must be free from chafing, rips, dry-rot and kinks. The fasteners must be installed and secured properly. The fittings must be free from cracks on the painted surfaces. Doc. No. Issue Rev. No. Date Source Page No. 3.02.21 May 1 7, 1 993 10 1 5 Jun 1 998 SB 5015 3.36 4'M>Diamond � AIRCRAFr 3.4 H K 36 R, TS, TC, TIS, TIC, TIC-ECO Maintenance & AIRPLANE MAINTENANCE MANUAL Inspections The elevator trim control system must operate smoothly and the lever must remain snapped in, even at full elevator deflection. Inspect the condition of the notched plate and its fastening. Inspect the elevator trim control system as prescribed in Article 2 . 1 .7. 3.5 Should corrosion or causticization be detected on the rudder pedals, the pedals and the forward control cables must be replaced. 3.6 Rudder pedals: the pedal adjustment must function smoothly. During the 1 00 hour inspection, the S-shaped cable guides must be lubricated with a few drops of engine oil. The cable itself must not have any kinks or defective strands. In the case of visible damage or wear, the cable must be replaced (refer to FAA AC 43. 1 3- 1 A) . 3.12 The control sticks must b e easy to move i n every direction and must not rest against anything but the travel stops. Check zero position. 3.13 Check for play between control stick and control surfaces. It is important to block-only one stick in order to be able to detect excessive play between the two sticks. 3.14 The point where the wheel brake starts taking effect i s adjusted correctly when the air brakes are extended from 65 to 1 05 mm (2.6 to 4.1 in.) over the wing upper surface. 3.15 The markings of the instruments must be well identifiable, confusions of the arcs (especially on the airspeed indicator) must be impossible. The proper markings are specified in the Flight Manual. Doc. No. Issue Rev. No. Date Source Page No. 3.02.21 May 17, 1 993 10 1 5 Jun 1 998 SB 50/5 3.37 "Diamond AIRCRAFT 3.20 HK 36 R, TS, TC, TIS, TIC, TIC-ECO Maintenance & AIRPLANE MAINTENANCE MANUAL Inspections HK 36 R: The locking pin of the main bolts must be easy to insert. Other models: The locking hook for the main bolts must not jam. There must be a spring load on the hook even when it is fully retracted, i.e. there must not be any dead travel. 3.21 The main bolts must be easy to move when the wings are supported,. no matter whether the wing is removed or installed. If the bolts do not move easily, either the lubrication is insufficient and the bolts have seized up in their guides, or the bolts or bushes are deformed due to inappropriate wing installation (releasing the wing when the bolt is inserted half-way). A deformed bolt must be replaced. Doc. No. Issue Rev. No. Date Source Page No. 3.02.21 May 1 7, 1 993 10 1 5 Jun 1 998 S8 50/5 3.38 �Diamond v� AIRCRAFT HK 36 R, TS, TC, TIS, TIC, TIC-ECO Maintenance & AIRPLANE MAINTENANCE MANUAL Inspections 3.2.4 STRUCTURE 4.1 Minor repairs are described in Section 5. In the case of uncertainty, contact the manufacturer. Generally, cracks along leading or trailing edge bonds must be reported to the manufacturer and repaired according to the Instructions given by the manufacturer to prevent moisture from entering. Each aileron is attached to the wings with five CFRP hinges. Check the areas around 4.3 the hinges for cracks and defective bonds. Self-lubricating bushes are bonded into the hinges fixed to the ailerons. Pivots, which are secured by cross pins, are inserted in the wing mounted hinges. 4.4 All bolts must be secured with self-locking nuts and all rod end bearings must have locking nuts. Check bolts and nuts for corrosion. I 4. 1 2 The forces for locking, unlocking, and extending the air brakes are measured o n the bellcranks in the LH and RH wing root rib. The wing should be placed on its leading edge and a spring scale is hooked onto the roller bearing, perpendicular to the bellcrank arm. The extension forces are measured in order to check the condition of the air brake damper. The force that is measured shortly before the air brake reaches the stop is relevant. CORRECT AIR BRAKE OPERATING FORCES Unlocking force Locking force Extension force before reaching stop [daN] [daN] [daN] H K 36 R min. 7 max. 24 min. 7 H K 36 TS, TC, TIS, TIC, TIC-ECO, SIN 36. 5 1 7 and subsequent min. 1 2 max. 24 min. 7 others min. 1 0 max. 1 8 min. 7 Model - Doc. No. Issue Rev. No. Date Source Page No. 3.02.21 May 1 7, 1 993 10 1 5 Jun 1 998 SB 50/5 3.39 �Diamond T AIRCRAFT HK 36 R, TS, TC, TIS, TIC, TIC-ECO Maintenance & AIRPLANE MAINTENANCE MANUAL Inspections CAUTION The necessity to adjust the air brake control system may indicate damage to the structure (e.g. due to overstressing). Therefore contact the Manufacturer before adjusting. 4.16 The bolts on the horizontal stabilizer mount must fit tightly and must be secured with self-locking nuts. The locking ring must be secured against twist by means of two cross­ pins on the forward horizontal tail mount. CAUTION The elevator is not automatically connected to the elevator control system! Be aware of this when installing or removing the horizontal tail! 4. 1 7 Elevator horns which a re constructed from plywood must be checked for defective attachment to the elevator as follows: (a) Remove horizontal tail. (b) Fix together elevator horn and horizontal stabilizer. (c) Apply a force of 1 5 daN (34 Ibs.) to elevator at trailing edge in upward and downward direction. Check for play. 4. 1 9 The rudder is held in place by a pin which is fixed to the vertical stabilizer at the top and a bolt in the mounting plate at the bottom. The rudder control cables are also attached to the mounting plate with one bolt each. All three bolts must be secured with lock wire. The rudder control cables, eye stiffeners and nicopress sleeves should be checked for poor condition. Doc. No. Issue Rev. No. Date Source Page No. 3.02.21 May 1 7, 1 993 10 1 5 Jun 1 998 SB 50/5 3.40 "Diamond T AIRCRAFT 4.20 HK 36 R, TS, TC, TIS, TIC, TIC-ECO Maintenance & AIRPLANE MAINTENANCE MANUAL Inspections When the rudder is held firmly and the tail wheel is twisted, a positive spring load must be perceptible in either direction. Play in the assembly indicates a defective spring. Fu rthermore, verify that the tail wheel moves to neutral position if the rudder is being brought to neutral. For this test the fuselage is elevated right in front of the tail wheel. If the tail wheel has exceeded the maximum resiliency travel due to overload (e.g. nose over, extremely unfavorable ground), it presses the weak lower edge of the rudder. The rudder hinges will not be damaged, and the rudder will still function. However, the rudder hinges, tail wheel, and tail wheel suspension must be inspected thoroughly. If necessary, repair the rudder lower edge in accordance with Section 5. 4.21 It is absolutely necessary for this inspection to relieve the tail wheel completely. In particular the welds and the adjacent areas must be thoroughly inspected for cracks from all sides. The entire pedestal must be checked for deformation and corrosion. 4.22 Rudder removal and installation: see in Article 5.1 .3. I 4.23 To remove the tail wheel fork, first remove the transverse M6 bolt, then extract steering I 4.25 shaft in a downward direction. For correct adjustment of the pre-tension of the rubber spring assembly, jack airplane in front of the vertical tail so that the tail wheel has no ground contact. Tighten nut on elastomer package until disks cannot be twisted by hand torque. Doc. No. Issue Rev. No. Date Source Page No. 3.02.21 May 1 7, 1 993 10 1 5 Jun 1 998 SB 5015 3.41 �Diamond v AIRCRAFT HK 36 R, TS, TC, TIS, TIC, TIC-ECO Maintenance & AIRPLANE MAINTENANCE MANUAL Inspections 4.19, 4.30, 4.31 The control cables must be inspected for wear. If there are signs of wear (see FAA AC 43. 1 3-1A) , the cables must be replaced. Refer to Section 6 for the life limit. The tension force of two the rearward rudder control cables must be adjusted by means of the turnbuckles. Correct tensile force: see Article 2.1 .3. 4.37 The brake fluid level must not fall below the minimum marking. If it does, inspect the brake linings. If they are not worn, determine the reason for the loss of brake fluid. 4.38 Thoroughly check all screwed connections and the drainer valve for leakage. Check fastening strap for poor condition, defective attachment to the fuselage structure and chafing on the central fuel reservoir or tank. Doc. No. Issue Rev. No. Date Source Page No. 3.02.21 May 17, 1 993 10 1 5 Jun 1 998 S B 50/5 3.42 �Diamond 'T HK 36 R, TS, TC, TIS, TIC, TIC-ECO Maintenance & AIRPLANE MAINTENANCE MANUAL Inspections AIRCRAFT 3.2.5 LANDING GEAR 5.2 This inspection should be performed very thoroughly after hard landings or in the case of operation on aerodromes with extremely rough runways. 5.3 The brake linings may be wom down to a minimum thickness of 3.5 mm (0.14 in.) before they must be replaced. To replace the linings, remove the lock wires and the two fixture screws (17). The two pressure plates (12 and 1 5) can be removed and the new brake linings are affixed with the provided rivets. Re-install pressure plates. When replacing brake linings, all four should be replaced at the same time. 1 10 : --I!J 3 2 3 , ."; -, � 7 14 1 3 I b ',.::/ .. ' r:f' / 15 ~ . , /' :�, ./ �-- 1 6 '\ /' 12 5 6 Brake line connector 1. Brake cylinder 11. 2. Brake piston 1 2.11 5. Pressure plate 4. Guide pins 8. 9. .J 3. Brake linings Bleed nipple 16. Fixture plate Bleed screw 1 7. Attach ment bolts (2) Doc. No. Issue Rev. No. Date Source Page No. 3.02.21 May 1 7, 1 993 10 1 5 Jun 1 998 SB 50/5 3.43 �Diamond � AIRCRAFT 5.8 HK 36 R, TS, TC, TIS, TIC, TIC-ECO Maintenance & AIRPLANE MAINTENANCE MANUAL Inspections When new elastomer elements are installed, Dimension "a" should be 1 95 mm (7.7 in.) with the nosewheel clear of the ground. The preload on used elements is adjusted properly when the rubber elements cannot be twisted by moderate hand torque while the nosewheel is clear of the ground. With the elastomer package properly preloaded, dimension "a" must not beJess than 1 85 mm (7.3 in.). Otherwise the rubber elements must be replaced. a Doc. No. Issue Rev. No. Date Source Page No. 3.02.21 May 1 7, 1 993 10 1 5 Jun 1 998 SB 5015 3.44 T#/f' lADiamond AIRCRAFT H K 36 R, TS, TC, TIS, TIC, TIC-ECO Maintenance & AI RPLA.NE MAINTENANCE MANUAL Inspections 3.3 NON-SCHEDULED INSPECTIONS 3.3.1 ENGINE 25 hour inspection A newly installed engine must undergo a non-recurring inspection after 25 operating hours. The maintenance items are stated in the Operator's Manual for the Rotax 912 A or the Maintenance Manual for Rotax Engine Type 9 1 4 F, respectively. As well as these items, the bolts attaching the engine mount to the firewall must be tightened at the 25 hour inspection (torque: 40 Nm (29.5 ft.lbs.)). Special inspections Special inspections (e.g. after propeller strike, excessive temperature, etc.) are described in the Operator's Manual for the Rotax 912 A, Paragraph 8.2 and Section 1 1 , or the Maintenance Manual for Rotax Engine Type 9 1 4 F, Paragraph 1 2.4, respectively. Doc. No. Issue Rev. No. Date Source Page No. 3.02.21 May 1 7, 1 993 10 1 5 Jun 1 998 SB 50/5 3.45 •Diamond AIRCRAFT H K 36 R, TS, TC, TIS, TIC, TIC-ECO Maintenance & AIRPLANE MAINTENANCE MANUAL Inspections Amber temperature caution light illuminates (Models with Rotax 9 1 4 F onlY) Through improper operation (carburetor heat ON with power above 75 %) or a high power setting with a high OAT, the airbox temperature can exceed 72 "C ( 1 62 "F). If the caution light illuminates for a short while due to this, and is termin ated by the action of the TCU or by moving back the carburetor heat control or throttle control, it does not indicate a fault. If the caution light illuminates under other conditions or for a longer time, an inspection must be carried out as follows: (1) Perform engine ground run, measure airbox temperature a t idle RPM (see Article 2.5.3). This may not exceed 60 "C (140 "F); a higher temperature indicates a defective airbox temperature sensor. (2) Increase engine power setting. The measured value of the airbox temperature must thereby increase; deviating behavior indicates a defective airbox temperature sensor. NOTE Only airbox temperatures above 0 "C (32 "F) can be measured. At OATs below 0 "C, the airbox temperature can only be measured with increased engine power settings. (3) Measure LH and RH EGT at take-off power (see Article 2.5.3). Both temperatures should lie between 850 "C (1 562 "F) and 950 "C (1742 "F). NOTE At temperatures above ISA + 1 5 "C (ISA + 27 "F), an airbox temperature just over 72 "C (162 "F) can be reached during this test. Subsequently, the caution lignt will illuminate. Doc. No. Issue Rev. No. Date Source Page No. 3.02.21 May 1 7, 1 993 10 1 5 Jun 1 998 SB 50/5 3.46 .Diamond AIRCRAFT HK 36 R, TS, TC, TIS, TIC, TIC-ECO Maintenance & AIRPLANE MAINTENANCE MANUAL Inspections If the indicated values are too low, a defect in the corresponding EGT sensor is likely, but the defect could also lie in the carburetor system =} proceed to Items (4), (5) and (6). If the indicated values are too high, a defect in the carburetor system is likely, but the defect could also lie in the EGT sensor =} proceed to Items (5), (4) and (6). (4) Test the two EGT sensors with an electronic thermometer for Type "K" thermocouples. If the sensors are defective, they must be replaced. (5) Examine the carburetor in accordance with the Maintenance Manual for Rotax Engine Type 914 F, Article 12.3.15. Check the pressure connection lines for blockage, kinks or other damage. (6) If the above measures do not solve the problem, contact the manufacturer. Doc. No. Issue Rev. No. Date Source Page No. 3.02.21 May 17, 1 993 10 1 5 J u n 1 998 SB 5015 3.47 • Diamond AIRCRAFT HK 36 R, TS, TC, TIS, TIC, TIC-ECO Maintenance & AIRPLANE MAINTENANCE MANUAL Inspections 3.3.2 PROPELLER Special inspections (e.g. after excessive RPM) are described in the Propeller Manual (see Article 2.5.6). 3.3.3 AIRFRAME Hard landings After an excessively hard landing or some other unusual loading on the landing gear, even when no obvious damage is apparent, the following inspection must be carried out: (1) Check the fixing parts of the main landing gear for cracks, deformation and other damage using a light and a mirror. Check the surrounding GFRP structure for delamination. (2) Check the main landing gear strut(s) for cracks, deformation, delamination of GFRP strut, and other damage. Measure the track width and compare with the value recorded in the Adjustment Report (use slide sheets!). (3) Check all three tires for cuts in the side. (4) Check brake lines, brake cylinders, calipers and brake disks for leakage and damage. Doc. No. Issue Rev. No. Date Source Page No. 3.02.21 May 1 7, 1 993 10 1 5 Jun 1 998 SB 50/5 3.48 �Diamond v AIRCRAFT (5) H K 36 R, TS, TC, TIS, TIC, TIC-ECO Maintenance & AIRPLANE MAINTENANCE MANUAL Inspections Tail wheel models only: Remove rudder and check tail wheel assembly and rudder pedestal for cracks, deformation, defective attachment to the fuselage and other damage. (6) Tricycle models only: Check entire nosewheel assembly for cracks, deformation and other damage. Unload the nosewheel and check for excessive play in the bearings. (7) Tricycle models only: Check top hat profile in fuselage underside for delamination, especially in the bonding areas and around the nosewheel strut bearings. (8) Check engine mount for cracks and deformation. In the case of tricycle models, the nosewheel damper attachment area must be inspected especially thoroughly. Check shock mounts (silentblocs) and fixture points of the engine mount to the firewall for damage. (9) ( 1 0) Check hinges and attachment of balancing masses on the control surfaces for damage. Remove wings; check wing leading edge and wing-fuselage connection for damage. Check main bulkhead for delamination. (1 1 ) Remove horizontal tail and check horizontal stabilizer leading edge and attachment for damage. Doc. No. Issue Rev. No. Date Source Page No. 3.02.21 May 1 7 1 993 10 1 5 Jun 1 998 S8 50/5 3.49 , �Diamond 'V� AIRCRAFT HK 36 R, TS, TC, TIS, TIC, TIC-ECO Maintenance & AIRPLANE MAINTENANCE MANUAL Inspections ( 1 2) Check avionic equipment and instruments for loose attachment and obvious damage. ( 1 3) Check fiight instrument indications on the ground: airspeed indicator and vertical speed indicator (if i nstalled) must indicate zero and altimeter must indicate airfield elevation when set to aerodrome QNH. Exceeding of operating limitations If operating limitations (e.g. VNE) have been exceeded, the manufacturer should be contacted. Doc. No. Issue Rev. No. Date Source Page No. 3.02.21 May 1 7, 1 993 10 1 5 Jun 1 998 SB 50/5 3.50 ·Diamond AIRCRAFT HK 36 R, TS, TC, TIS, TIC, TIC-ECO Maintenance & AI RPLANE MAINTENANCE MANUAL Inspections 3.4 TORQUES 3.4.1 STANDARD TORQUES Unless otherwise provided (see Article 3.4.2), nuts and bolts must be tightened with the following torques: Nut or Bolt Size Torque [Nm] Torque [ft Ibs.] M5 3.6 2.7 M6 6.4 4.7 MB 1 6.0 1 1 .B M10 32.0 23.6 M12 57.0 42.0 The number after the "M" indicates the thread major diameter in millimeters. Divide this value by 25.4 to obtain inches. Example: an MB bolt is one with a thread major diameter of 0.315 inches. Doc. No. Issue Rev. No. Date Source Page No. 3.02.21 May 1 7, 1 993 10 1 5 Jun 1 99B S8 50/5 3.51 .,Diamond HK 36 R, TS, TC, TIS, TIC, TIC-ECO Maintenance & AIRPLANE MAINTENANCE MANUAL Inspections AIRCRAFT 3.4.2 SPECIAL TORQUES I Nut or Bolt Torque [Nm] Torque [ft Ibs ] Bolts attaching engine mount to firewall 40 29.5 Bolts attaching main landing gear axles to strut 20 14.8 Bolts attaching GFRP main landing gear strut to fuselage (tail wheel models only) 10 7.4 Bolt in main landing gear fitting at inner end of steel strut (tricycle models only) height of spring washers 4 ± 0.5 mm 0. 1 6 ± 0.02 in. Bolts in main landing gear fitting next to fuselage root rib (tricycle models only) 20 1 4.8 15 1 1.1 Nosewheel stop bolts limiting steering angle (tricycle models only) see Operator's Manual for Rotax 9 1 2 A or Maintenance Manual for Rotax Engine Type 9 1 4 F Nuts and bolts on engine see Propeller Manual (refer to Article 2.5.6 for correct manual) Nuts and bolts on propeller Doc. No. Issue Rev. No. Date Source Page No. 3.02.21 May 1 7, 1 993 10 1 5 Jun 1 998 SB 5015 3.52 H K 36 R , TS, TC, TIS , TIC, TIC-ECO •Diamooo AIRCRAFT AIRPLANE MAINTENANCE MANUAL Other Work SECTION 4 OTHER WORK 4.1 PROCEDURES FOR TOPPING UP OPERATING FLU I DS 4.1.1 FUEL Approved fuel grades; see Airplane Flight Manual, Section 2 . During reflJeling, the ground cable must b e electrically connected to the exhaust pipe to prevent electrostatic charge build up. Do not top up completely when the weather is hot. The fuel expands when it gets warm and flows off through the ventilation line. Maximum quantity Standard tank ; 55 liters (14.5 US gaL) Long range tank HK 36 R ; 80 liters (2 1 . 1 US gaL) Long range tank H K 36 TS, TC, TIS, TIC ; 79 liters (20.9 US gaL) Wing tanks H K 36 TIC-ECO ; 55 liters each (14.5 US gal. each) Doc. No. Issue Rev. No. Date Source Page No. 3.02.21 May 17, 1 993 10 15 Jun 1 998 S8 50/5 4.1 .Diamond AIRCRAFT HK 36 R, TS, TC, TIS, TIC, TIC-ECO AIRPLANE MAINTENANCE MANUAL Other Work 4. 1 .2 ENGINE OIL After removing the yellow colored oil filler cap, which is located rearward on the right hand side of the engine, the engine oil can be topped up. The maximum oil quantity is 3.0 liters (3.2 US quarts). The lubricant quality according to the API system and the required viscosity range can be found in the Airplane Flight Manual or the Operator's Manual for the Rotax 9 1 2 A or the Maintenance Manual for Rotax Engine Type 9 1 4 F. Before closing the oil filler, check condition of the rubber sealing ring and replace if necessary. 4. 1.3 COOLANT Before topping up coolant, the reason for the loss of fluid must be found and eliminated (e.g. leaky hose connections). Only antifreezes with anti-corrosion additives for light alloy engines (e.g. BASF Glysantin Antikorrosion) may be used. 1 0 to 20 % water should be added to the coolant. When the engine is cold, open the pressure cap on the dispatcher vessel on top of the engine and fill the dispatcher vessel up completely. The equalizing reservoir (transparent vessel next to oil tank) must be between '/3 and 2/3 full. After the first top-up, close the pressure cap and let the engine run for approximately 3 minutes at increased idle speed. Then fill up dispatcher vessel completely. Fill up equalizing reservoir until it is between '/3 and 2/3 full. The maximum coolant quantity is approximately 2.5 liters (2.6 US quarts). Before closing the pressure cap, check the condition of the rubber sealing rings. Doc. No. Issue Rev. No. Date Source Page No. 3.02.21 May 1 7, 1 993 10 1 5 Jun 1 998 SB 50/5 4.2 "Diamond v AIRCRAFT HK 36 R, TS, TC, TIS, TIC, TIC-ECO AIRPLANE MAINTENANCE MANUAL Other Work 4.1.4 BRAKE FLUID Airplanes with wheel brake system version 1 (see Article 2.2.5) have the brake fluid reservoir installed behind the main bulkhead under the baggage compartment floor. Airplanes with wheel brake system version 2 (see Article 2.2.6) have two brake fluid reservoirs mounted to the co­ pilot's LH and RH rudder pedal. Always determine the reason for the loss of brake fluid before filling up (wom brake linings, leaky brake lines or brake cylinders). The required brake fluid grade is Mil-H-5606 A (or English DTD 585 or French AIR 3520) Aeroshell Fluid 4. Brake fluids with equal grades may be mixed. CAUTION Avoid contact of brake fluid and paint finish! When closing the brake fluid reservoir of an airplane with wheel brake system version 1 (see Article 2.2.5), ensure that the bleed hole is not blocked. 4.1 .5 REFILLING THE BATTERY The battery must be filled up with distilled water to the upper marking. It is recommendable to use a special wash bottle or a large injection syringe. Spilled battery acid can be rendered harmless by means of an acid neutralizer (e.g. Varta Neutralon Spray) or with much water, which is, however, hard to remove afterwards. At this time, clean the battery terminals and apply battery terminal grease or Vaseline. Doc. No. Issue Rev. No. Date Source Page No. 3.02.21 May 1 7, 1 993 10 1 5 Jun 1 998 SB 50/5 4.3 �Diamond T AIRCRAFT HK 36 R, TS, TC, TIS, TIC, TIC-ECO AIRPLANE MAINTENANCE MANUAL other Work 4.2 DETERMINING EMPTY MASS CG POSITION Condition of the Powered Sailplane during weighing: * Powered Sailplane completely rigged * No seat cushions, equipment as listed in the Equipment Inventory * No parachutes, no wing support fixtures, no baggage * Canopy closed * Fuel system drained down to the unusable quantity. In case of the HK 36 TIC-ECO, both wing tanks and the central fuel reservoir must be emptied through the drain valves, then 2 liters (0.53 US gal.) of fuel must be filled into each tank. * Oil quantity 3.0 liters (3.2 US quarts) (full) For the determination of the empty mass CG, the powered sailplane is placed upon three scales, one under each wheel. The fuselage tube must be aligned horizontally as shown in the s ketch on the next page. Drop a plumb line from the wing leading edge at the root rib to the ground. This plumb line defines the datum plane (DP). Measure the distances from DP to the axletrees (x 1 , x2 or x1 , x2L, x2R) and enter them in the Weighing Report. The mass portions (m 1 , m2 or m 1 , m2L, m2R) are measured with the scales. The formula for tail wheel models for tricycle models yields the position of the empty mass CG aft of DP. Enter distances in millimeters, masses in kilograms. If distances have been measured in inches, multiply their values by 25.4 to obtain millimeters. If masses have been measured in pounds, divide-their values by 2.2046 to obtain kilograms. The empty mass is the sum of the mass portions (m 1+ m2 or m1+ m2L+m 2R ). Doc. No. Issue Rev. No. Date Source Page No. 3.02.21 May 1 7, 1 993 10 1 5 Jun 1 99a S B 50/5 4.4 H K 36 R, TS, TC, TIS, TIC, TIC-ECO "Diamond v AIRCRAFT AIRPLANE MAINTENANCE MANUAL DP ,... J ,J -- _ x E top surface of wedge aligned horizontally � .;-;zj � _ 1000 ��:riZQntaL - - - - mil - 2t � m1 &l mE x1 Other Work - � ;) . - m2 x2 Horizontal alignment - tail wheel models �I--:":":=-:' -+- >---"::":"::+i top surface of wedge aligned ---r--t__ OriZ ontaIIY h _ h9!kQ�l 1000 __________ Horizontal alignment - tricycle models Doc. No. Issue Rev. No. Date Source Page No. 3.02.21 May 1 7, 1 993 10 1 5 Jun 1 998 SB 50/5 4.5 �DiamolJd T AIRCRAFT HK 36 R, TS, TC, TIS, TIC, TIC-ECO Other Work AIRPLANE MAINTENANCE MANUAL 4.3 TABLE OF THE MOST IMPORTANT LEVER ARMS Lever arms are given in millimeters, forward ( ) or aft (+) of DP. - I Item Wings [mm :�f CG] 495 Horizontal stabilizer 4860 I I Item [mm :�f CG] Avionics -420 Landing light -1 370 Long range tank 824 ACL on horizontal tail 4800 Standard tank 727 ACLs on wings 470 Wing tanks (HK 36 TIC-ECO only) 255 Pilots 143 central fuel reservoir (HK 36 TIC-ECO only) 680 Oil tank, Rotax 9 1 2 A -1 060 Seat cushions 110 Oil tank, Rotax 914 F -990 . Backrest cushions 390 HK 36 TIC-ECO Baggage other models 824 assumed equal to fuel tank Doc. No. Issue Rev. No. Date Source Page No. 3.02.21 May 1 7, 1 993 10 1 5 Jun 1 998 SB 50/5 4.6 IfIIIA v Diamond AIRCRAFT H K 36 R , TS, TC, TIS, TIC, TIC-ECO AIRPLANE MAINTENANCE MANUAL Other Work 4.4 WEIGHING REPORT The Weighing Report shows the current empty mass and the current empty mass CG position. Weighing Report and Equipment Inventory are preserved in the Aircraft Maintenance Log. A master form can be found in Paragraph 4. 1 0. NOTE In case of equipment changes, repairs and repainting, or no later than 5 years after the last weighing, the airplane must be re­ weighed by an authorized person. Afterwards , the new empty mass CG position must be computed. The values must be entered in the Mass and Balance Form (see Paragraph 4.7). The new limits must be drawn on a new Mass and Balance Diagram (not valid for HK 36 TIC-ECO, see Paragraph 4.8), and the limitations placard in the cockpit must be updated. 4.5 EMPTY MASS AND CORRESPONDING CG Empty mass CG limitations depending on the empty mass are given in Paragraph 4.9. HK 36 TTC-ECO: Other models: These limitations guarantee that solo pilots These limitations guarantee that SOlo-pilots with a minimum mass (weight) of 70 kg with a minimum mass (weight) of 70 kg ( 1 54 Ibs.) will not overstep the maximum ( 1 54 Ibs.) will not overstep the maximum rearward CG when flying with at least 1 0 kg rearward CG when flying with a full tank and (22 Ibs.) of fuel and no baggage. no baggage. The CG will not exceed the maximum The CG will not exceed the maximum forward position if the maximum useful load _ forward position if the maximum useful load minus 1 0 kg (22 Ibs.) (fuel for a half hour minus 1 0 kg (22 Ibs.) (fuel for a half hour flight) is placed on the seats. flight) is placed on the seats. Doc. No. Issue Rev. No. Date Source Page No. 3.02.21 May 1 7, 1 993 10 1 5 Jun 1 998 SB 50/5 4.7 HK 36 R , TS, TC, TIS, TIC, TIC-ECO •Diamond AIRCRAFT AIRPLANE MAINTENANCE MANUAL Other Work Another limitation is the minimum flight mass of 600 kg ( 1 323 Ibs.). Consequently, the useful load must never be less than minimum useful load = (600 kg) - (1 0 kg fuel) - (empty mass) The empty mass CG position can be shifted rearward using a balance weight mounted to the vertical stabilizer web (serial nos. through 36.517: x = 4700 mm (185.0 in.), serial nos. 36.51 8 and subsequent: x = 4490 mm (1 76.8 in.)). 4.6 MASS OF NON-LIFTING PARTS AND USEFUL LOAD Serial numbers 36.301 through 36.51 6 36.51 7 and subsequent Mass of both wings Max. mass of nonlifting parts " 1 80 kg 590 kg 770 kg minus empty mass 180 kg 590 kg 590 kg plus mass of both wings minus empty mass " 1 60 kg 6 1 0 kg 770 kg minus empty mass < 6 1 0 kg 6 1 0 kg plus mass of both wings minus empty mass < 1 60 kg Maximum permissible useful load The maximum mass of all non-lifting parts is the sum of: • Mass of fuselage and installed parts including canopy • Mass of rudder • Mass of horizontal tail • Maximum permissible useful load Doc. No. Issue Rev. No. Date Source Page No. 3.02.21 May 1 7, 1 993 10 1 5 Jun 1 998 S8 50/5 4.8 �Diamond T AIRCRAFT HK 36 R, TS, TC, TIS, TIC, TIC-ECO AI RPLANE MAINTENANCE MANUAL Other Work 4.7 MASS AND BALANCE FORM The Mass and Balance Fonn in Section 6 of the Flight Manual shows the following values: I HK 36 TTC-ECO: other models: • Current empty mass • Current empty mass • Current empty mass CG position • Current empty mass CG position • Current maximum pennissible useful • Current maximum permissible useful load load • Minimum useful load on the seats with Minimum useful load on the seats with • full tank and no baggage 1 0 kg (22 Ibs.) fuel and no baggage • Minimum useful load on the seats with Minimum useful load on the seats with • 1 0 kg (22 Ibs.) fuel and maximum full tank and maximum baggage mass baggage mass (30 kg (66 Ibs.)) ( 1 2 kg (26 Ibs.)). Furthermore, the Mass and Balance Form is a record of all weighings carried out. The Mass and Balance Fonn must be updated by an authorized person in compliance with the currently effective Weighing Report as follows (from left to right): • Date of weighing: taken from the Weighing Report • Empty mass (weight): taken from the Weighing Report • Empty mass (weight) CG position: taken from the Weighing Report • Maximum pennissible useful load under consideration of the maximum mass of all non-lifting parts (see Paragraph 4.6) • Minimum useful load on the seats with no baggage; Minimum useful load on the seats with maximum baggage taken from the tables in Articles 4.9.2, 4.9.3, or 4.9.4 • Signature and stamp of the aircraft maintenance engineer (A.M.E.) Doc. No. Issue Rev. No. Date Source Page No. 3.02.21 May 1 7, 1 993 10 1 5 Jun 1 998 SB 5015 4.9 .Diamond AIRCRAFT HK 36 R, TS, TC, TIS, TIC, TIC-ECO AIRPLANE MAINTENANCE MANUAL Other Work 4.8 MASS AND BALANCE DIAGRAM NOTE The CG position of the HK 36 TIC-ECO cannot be determined using a diagram. It must therefore be determined by calculation. 4.8.1 EXPLANATION OF THE DIAGRAM As an addition to the Mass and Balance Form, a new Mass and Balance Diagram must be filled out upon each weighing as follows: • Master diagrams are given on Pages 4. 1 1 and 4. 12. There is a separate form for each tank version (standard or long range). Photocopy the appropriate master. • The minimum pilot mass and the maximum total mass of fuel and baggage do not depend on the weighing. Therefore, these limits are already drawn on the diagram . • Two additional limits are drawn following the weighing: - Draw the line representing the empty mass in a parallel direction between the broken lines labeled with the corresponding empty mass values. The forbidden loading range lies above this line and must be hatched. - The empty mass CG position (depending on propeller model, tank, avionics, etc.) may req uire an additional limit to the maximum rearward CG position. Draw the line for the empty mass CG position in a parallel direction between the broken lines labeled with the corresponding empty mass CG values. The forbidden loading range lies above this line and must be hatched. If this limitation lies outside the other borders, it is not effective and thus need not be drawn. • Cut out half-sized page using markings, enter correct page no. in footer, insert page into Section 6 of the Flight Manual. Doc. No. Issue Rev. No. Date Source Page No. 3.02.21 May 1 7, 1 993 10 1 5 Jun 1 998 SB 50/5 4. 1 0 HK 36 R, TS, TC, TIS, TIC, TIC-ECO �Diamond v AIRCRAFT Other Work AI RPLANE MAINTENANCE MANUAL 4.8.2 MASS AND BALANCE DIAGRAM. STANDARD TANK (MASTER) r OIl\MOND AIRCRAFT � 0 '1 I "" 'Ul o ' 0 N .Q '" ! FLIGHT MI\NUAL , 0 , , � N , , 0 .. , , 0 " PI .. , 0 III ! , , 0 2 ! " 'I 0 " !)! , Mass & Balance .... -- '" , , 0 .. ',I 010 '"oj .. o o ... o �'-,/<'-I-I-I-j- I!! o \IJ (!J o -t--I--t--I- !2 � +-�-+� t- 0 __ __ "'h'1-l--+-�-+-t--t- � ++-+-t-t--t- � . I ;>; '" Q) ;;!- � o 5' CD , <;1 m > 0 r 0 �C _ - 0 z -I :j � en > z :j o 0 m s: :j m en s: --I > S;: ].J Z -I ::0 -u > � a. Q� �8 B;' ! HK 36 R, TS, TC, TIS, TIC, TIC-ECO AIRPLANE MAINTENANCE MANUAL Other Work 4.1 2 ADJUSTMENT DIAGRAM - AILERONS. RUDDER. SWEEP ful � '" 1 I I I I 1 1 I , I , I I I � ili ::! « � �... �a � '" '" � o 0: . � E E .. I I I I 1 , I I +1 tg �- Doc. No. Issue Rev. No. Date Source Page No. 3.02.21 May 1 7, 1993 10 1 5 Jun 1 998 SB 5015 4. 1 9 �Diamond � AIRCRAFT HK 36 R, TS, TC, TIS, TIC, TIC-ECO Other Work AIRPLANE MAINTENANCE MANUAL 4.1 3 MASSES AND RESIDUAL MOMENTS OF THE CONTROL S URFACES 4.13.1 GENERAL CAUTION For the flutter safety of the airplane, it is very important that masses and residual moments of the control surfaces comply with the following limitations. Therefore, these values must be re-determined after repairing or repainting a control surface. 4.13.2 MEASUREMENT OF RESIDUAL MO MENTS The surfaces must be removed from the airplane and supported in their axes of rotation with as little friction as possible. The force "F" is measured (e.g. with a letter balance or a spring scale) opposite to the balancing mass while the surface is horizontal. The measuring range of the balance should be about 1 5 N (3.5 Ibs.). With the lever arm "r" which is equal to the distance between the hinge line and the force "F", the residual moment 'M' can be computed as follows: HINGE M = F x r with F in [N], r in [cm] [Ibs.] > 4.448 I .. r ------I [in.] > 2.54 = = [N] [cm] Should a surface fail to meet the correct values given in Article 4.1 3.3, a modification of the mass balancing is necessary. Doc. No. Issue Rev. No. Date Source Page No. 3.02.21 May 1 7, 1 993 10 1 5 Jun 1 998 S8 50/5 4.20 HK 36 R, TS, TC, TIS, TIC, TIC-ECO �Diamol1d '17� AIRCRAFT Other Work AIRPLANE MAINTENANCE MANUAL 4.13.3 PERM ISSIBLE MASSES AND RESIDUAL MOMENTS OF THE CONTROL SURFACES Permissible mass (including balancing mass) [kgJ Permissible residual moment [N*cm] HK 36 R, TS, TC, TIS, TIC horizontal stabilizers no. HF 1 through HF 1 7 2.45 to 3.00 90 to 1 1 2 H K 36 R , TS, TC, TIS, TIC horizontal stabilizers no. HF 1 8 and subsequent 2.25 to 2.80 1 00 to 122 HK 36 TIC-ECO 2.40 to 2.90 76 to 1 06 HK 36 R, TS, TC, TIS, TIC 5.30 to 6.55 1 00 to 1 60 HK 36 TIC-ECO 4.75 to 5.80 120 to 1 50 HK 36 R, TS, TC, TIS, TIC Serial Nos. 36.301 through 36.516 2 .30 to 2.75 1 00 to 125 HK 36 R, TS, TC, TIS, TIC Serial Nos. 36.5 1 7 and subsequent 2.80 to 3.50 50 to 83 HK 36 TIC-ECO 2.90 to 3.60 30 to 75 Airplane Rudder elevator rudder ailerons WARNING Contact the manufacturer before modifying the mass balancing! NOTE All moments in the above table are tail heavy. Doc. No. Issue Rev. No. Date Source Page No. 3.02.21 May 17, 1 993 10 1 5 Jun 1 998 S8 50/5 4.21 HK 36 R, TS, TC, TIS, TIC, TIC-ECO v� "Diamond AIRCRAFT AIRPLANE MAINTENANCE MANUAL Other Work 4.14 PITOT-STATIC SYSTEM The instruments in the instrument panel are accessible after removing the instrument panel top cover. The following sketches illustrate the connections of the instruments. HK 36 R Serial Nos. through 36.331 Water removal: remove rudder; remove caps from drain tubes. For legend, see Page 4.24. 2 3 8 Doc. No. Issue Rev. No. Date Source Page No. 3.02.21 May 1 7, 1 993 10 1 5 Jun 1 998 S8 50/5 4.22 "'Diamoll1d � AIRCRAFT HK 36 R, TS, TC, TIS, TIC, TIC-ECO AI RPLANE MAINTENANCE MANUAL Other Work HK 36 R, Serial Nos. 36.332 and subsequent Water removal: open handhole lid on fuselage tube bottom side; disconnect and empty filters. for legend, see Page 4.24. Doc. No. Issue Rev. No. Date Source Page No. 3.02.21 May 1 7, 1 993 10 1 5 Jun 1 998 S B 5015 4.23 �Diamond T AIRCRAFT H K 36 R, TS, TC, TIS, TIC, TIC-ECO AIRPLANE MAINTENANCE MANUAL Other Work HK 36 TS, TC, TIS, TIC, TIC-ECO Water removal: open hand hole lid on fuselage tube bottom side; disconnect and empty bypass lines. 8 6 Legend 1 Altimeter 2 Airspeed indicator 3 Vertical speed indicator 4 Compensator nozzle and Pitot tube with static pressure sensor 5 Static pressure (blue) 6 Total head (green) 7 Nozzle (total energy; red) 8 Equalizing reservoir 0.45 liters (approximately 1 US pt.) (blue or colorless) 9 Water drain Doc. No. Issue Rev. No. Date Source Page No. 3.02.21 May 1 7 , 1 993 10 1 5 Jun 1 998 SB 5015 4.24 .Diamond AIRCRAFT HK 36 R, TS, TC, TIS, TIC, TIC-ECO AIRPLANE MAINTENANCE MANUAL Other Work 4.1 5 PARKING FOR OVER 30 DAYS 4. 15.1 PRESERVATION For standing periods over 30 days, the following tasks must be carried out: Once only ( 1 ) Engine . . . . . . . . . . . . . . . . . . . preserve in accordance with the Operator's Manual for the Rotax 912 A or the Maintenance Manual for Rotax Engine Type 9 1 4 F, respectively (2) Fuel system . . . . . . . . . . . . . . . fill up completely (3) Tires . . . . . . . . . . . . . . . . . . . . . wipe dry and spray with tire protector (4) Battery . . . . . . . . . . . . . . . . . . . remove (5) Lubricated areas . . . . . . . . . . . . lubricate in accordance with Lubrication Schedule (6) Cabin . . . . . . . . . . . . . . . . . . . . ventilate Weekly ( 1 ) Fuel system . . . . . . . . . . . . . . . remove water deposit using drainer (2) Wheels . . . . . . . . . . . . . . . . . . . turn through 3-4 revolutions (3) Tires . . . . . . . . . . . . . . . . . . . . . visually inspect for obvious underinflation (4) Brakes . . . . . . . . . . . . . . . . . . . operate 3-4 times 4.15.2 RETURNING TO OPERATION ( 1 ) Battery . . . . . . . . . . . . . . . . . . . charge and install (2) Engine . . . . . . . . . . . . . . . . . . . return to operation in accordance with the Operator's Manual for the Rotax 912 A or the Maintenance Manual for Rotax Engine Type 9 1 4 F, respectively (3) Canry out daily inspection in accordance with the Flight Manual Doc. No. Issue Rev. No. Date Source Page No. 3.02.21 May 1 7, 1 993 10 1 5 Jun 1 998 SB 50/5 4.25 �Diamomi � AIRCRAFT HK 36 R, TS, TC, TIS , TIC, TIC-ECO AIRPLANE MAINTENANCE MANUAL Other Work 4.16 PLACARDS AND INSCRIPTIONS Apart from the fire·resistant identification plate, the following placards are attached: Placard Remark Location if the airspeed indicator is calibrated in kmJh: Manoeuvring speed at max. gross weight, VA = 1 76 kmlh Min. useful load on the seats, full tank, no baggage Min. useful load on the seats, full tank, 1 2 kg baggage Maximum permissible useful load irthe airspeed indicator is calibrated in Ids.: instrument panel all models except HK 36 TTC-ECO Manoeuvring speed at max. gross weight, Min. useful load on the seats, full tank, no baggage Min. useful load on the seats, full 1ank, 12 kg baggage Maximum permissible useful load Doc. No. Issue Rev. No. Date Source Page No. 3.02.21 May 1 7, 1 993 10 1 5 Jun 1 998 SB 5015 4.26 "Diamond v AIRCRAFT HK 36 R, TS, TC, TIS, TIC, TIC-ECO AIRPLANE MAINTENANCE MANUAL Other Work Remark if the airspeed indicator is calibrated in kmJh: Manoeuvring speed at max. gross weight, VA = 1 76 kmlh Min. useful load on the seats, 1 0 kg (22 lbs.) fuel. no baggage Min. useful load on the seals, 10 kg (22 lbs.) fuel. 30 kg (66 lbs.) baggage Maximum pennisslble useful road if the airspeed indicator is calibrated in kts.: instrument panel H K 36 TIC-ECO only rearward side of baggage compartment all models except HK 36 TIC-ECO rearward side of baggage compartment and outside next to baggage door 2 pes. next to air brake levers tail wheel models through Serial No. 36.516 only, 2 pes. next to air brake levers tail wheel models above Serial No. 36.516 and tricycle models only, 2 pes. Manoeuvring speed at max.. gross weight, Min. useful load on the seats, 10 kg (22 lbs.) fuel. no baggage Min. useful load on the seats, 10 kg (22 lbs.) fuel. 30 kg (66lbs.) baggage Maximum pennissible useful load Tie baggage down, max. 1 2 kg (26 Ibs.) Tie baggage down, max. 30 kg (66 Ibs.) Air Brakes - pull through completely to actuate wheel brakes Air Brakes Full Throttle HK 36 TIC-ECO only. throttle quadrant Doc. No. Issue Rev. No. Date Source Page No. 3.02.21 May 17, 1 993 10 1 5 Jun 1 998 SB 5015 4.27 HK 36 R, TS, TC, TIS, TIC, TIC-ECO •Diamond AIRCRAFT AIRPLANE MAINTENANCE MANUAL Placard Turbo Control ON I I OFF Carburetor Heat ON ON Choke 8 Propeller Speed Control Take-Off Cruise Feather Fuel Valve OPEN Fuel Tank Selector Valve colored red, models with Rolax 9 1 4 F only instrument panel, RH side Choke pull - ON I Remark. Location EJ OFF I I Other Work I I throttle quadrant throttle quadrant except models with hydraulic propeller speed control Instrument panel, center section models with hydraulic propeller speed control only throttle quadrant models with HO V Landing Ught Horizon Gym Tum & Bank Ind. ADF DME I ....., . Power Fit. SOllcing Fuel pro ON ON ON ON Fuel Position ACL Landing Light Pump Lights I ON IC Differenlial B r a k i n g I Doc. No. Issue Rev. No. 3.02.21 May 1 7, 1 993 10 H K 36 R only I instrument panel, center section ON 2 pes. instrument panel, center section Cabin Heat pull - O N I I Remark Location I Cabin Air Other Work instnument panel, center section Date 1 5 Jun 1 998 H K 36 R only shaded areas are red on placards; uDifferential Braking" is optional for H K 36 TS HK 36 TS and HK 36 TC only Source Page No. S8 50/5 4.29 HK 36 R , TS, TC, TIS, TIC, TIC-ECO "Diamond T AIRCRAFT AIRPLANE MAINTENANCE MANUAL Placard I ON PawerPtt. ......., &loring Remark Location ON ON Pump Fuel ACL Position Landing ON Turbo ON I shaded areas are red on placards H K 36 TISand H K 36 TIConly instrument panel, center section ACL ON Fuel Pump ON Pas. Lights ON Avionics ON Power FIt. Master Switch ON ON I I Soaring instrument panel, LH section (next to swilches) I Gener. Fuel Press. Boost TCU H K 36 TIC-ECO only I Temp. Fuel QIy. Instrument panel, LH section (next to waming and caution lights) Ba!!e.y Gener. GeneT. Other Work TCU Contr. Fuel F'ump Oil Temp. Fuel LH Oil FIr., CHT Fuel RH ACL instrument panel, RH section (next to circuit breakers) H K 36 TIC-ECO only �os. Lights XF'OR COMINAV H K 36 TIC-ECO only Doc. No. Issue Rev. No. Date Source Page No. 3.02.21 May 17, 1 993 10 1 5 Jun 1 998 SB 5015 4.30 �Diamond v AIRCRAFT" HK 36 R, TS, TC, TIS, TIC, TIC-ECO AIRPLANE MAINTENANCE MANUAL Location Placard - Oil press.; Fuel Qty. - Oil temp. - - _ - - _ Gener. - Other Work Remark: XPDR - VOR - instrument panel, RH section, next to circuit breakers H K 36 R only instrument panel, RH section, next to circuit breakers all models except H K 36 R and H K 36 TTC-ECO Radio Main Bus Fuel Qty.! Oil Temp. - Gener. Control Oil Press.! CHT Generator Batteryl Main CB Doc. No. Issue Rev. No. Date Source Page No. 3.02.21 May 1 7, 1 993 10 1 5 Jun 1 998 SB 5015 4.31 •Diamond AIRCRAFT HK 36 R, TS, TC, TIS, TIC, TIC-ECO Placard - Attitude Gyro - Other Work AIRPLANE MAINTENANCE MANUAL Remark Location Direction Gyro instrument panel, RH section, next to circuit breakers all models except HK 36 R, optional instrument panel, RH section, next to circuit breakers all models except HK 36 R, optional instrument panel optional EJ EJ � instrument panel, center section all models except HK 36 R, optional 1 6� 1 8 instrument panel optional cylinder head temperature indicator models with Rotax912 A only - 111- Turn & Bank COM GPS MKR I G 1 3 1 t][J t]D GPS NAV 1- XPDR I GPS not approved for primary navigation. I IC-Volume I ~ 1 50 DC I CHT I I cylinder head temperature indicator Doc. No. Issue Rev. No. Date Source Page No. 3.02.21 May 1 7, 1 993 10 1 5 Jun 1 998 SB 5015 4.32 HK 36 R, TS, TC, TIS, TIC, TIC-ECO �Diamond V� AIRCRAFT AIRPLANE MAINTENANCE MANUAL Placard I Gen. Contr. I Fuel Pressure oil temperature indicator usable 53 1 (14 gal.) on fuel quantity indicators max. difference UR: 50 % = 27 1 (7.1 gal.) next to fuel quantity indicators and next to fuel selector valve Prop. Pitch Control Tow-Rope I propeller only above optional, light is not required caution light for towing in all countries device I Tow-Rope Release Nose Down models with HQ V352 on propeller feather grip I - Trim - Nose Up on release lever for tow-rope I H K 36 TTC-ECO only. 2 pes. only control unit I H K 36 TTC-ECO only. 2 pes. models wUh MTV 1 propeller next to prop. PROPELLER FEATHER I H K 36 R only instrument panel Temp. I Remark Location � I Other Work optional center console next to trim lever CANOPY JETTISON: Pull both handles fully rearward� next to levers for canopy Push canopy up and jettison colored red 2 pes. away, � Doc. No. Issue Rev. No. Date Source Page No. 3.02.21 May 1 7, 1 993 10 1 5 Jun 1 998 S8 50/5 4.33 H K 36 R, TS, TC, TIS, TIC, TIC-ECO �Diamond � AIRCRAFT Placard 55 1 55 1 Aviation Grade 1 00 LL or MOGAS (96 oct. ROZ) usable: 54 [ next to tank filler cap H K 36 R with S8 36 or S 8 36/1 not carried out next to tank filler cap H K 36 R with S8 36 or S 8 36/1 carried out ne>Ct to tank filler cap H K 36 TS, TC, TIS, TIC only next to tank filler caps HK 36 TIC-ECO only, 2 pes. on or next to brake nuid reservoir(s) 1 or 2 pes. Aviation Grade 1 00 LL or MOGAS (96 oct. ROZ) usable: 79 1 Aviation Grade 1 00 LL or MOGAS (96 oct.) or unleaded Auto Super (95 oct.) usable: 54 1 or 80 1 Remark Location or 80 1 Other Work AIRPLANE MAINTENANCE MANUAL AViation Grade 1 00 LL or MOGAS (96 oct.) or unleaded Auto Super (95 oct.) usable: 79 1 79 1 (20.9 US gaL) 55 1 (1 4.5 US gat.) AVGAS 100 LL, MOGAS, Auto Super min. 95 ROZ leaded or unleaded usable: 77 1 (20.3 US gal.) AVGAS 100 LL, MOGAS, Auto Super min. 95 ROZ leaded or unleaded usable: 53 1 (1 4.0 US gaL) Hydraulic Fluid 4 Ultimate load of breaking piece: 300 daN (674 Ibs.) or Ultimate load of breaking piece: 400 daN (899 I bs.) - towing assembly mount models with tOWing assembly only (optional) models with Rotax 912 A: 300 daN models with Rotax 914 F: 400 daN Doc. No. Issue Rev. No. Date Source Page No. 3.02.21 May 1 7, 1 993 10 1 5 Jun 1 998 SB 50/5 4.34 HK 36 R, TS, TC, TIS, TIC, TIC-ECO •Diamond AIRCRAFT Placard I I I I I 2.1 bar 3.1 bar 2.3 bar 1 .8 bar Oil 3.0 I II II II II I 30 psi 45 psi 33 psi 26 psi Other Work AIRPLANE MAINTENANCE MANUAL Remark Location I next to main wheels tail wheel models only I on rudder beside tail wheel tail wheel models only I next to main wheels tricycle models only I next to nose wheel tricycle models only SAE 1 5 W-'IO or according to Flight Manual oil liller cap CAUTIONI DO NOT USE AVIATION GRADE ENGINE OIL! I Coolant Gen. Relay I F 2439-01 I Main Fuel Pump F 2820-02 Gen. C�ntro Relay F 2437-01 Parking Brake - pull oil inspection lid in upper cowling, inside colored red coolant dispatcher vessel; equalizing reservoir 2 pes. I I RH side of firewall, next to glass fuses models with Rolax 914 F only next to parking brake button - Doc. No. Issue Rev. No. Date Source Page No. 3.02.21 May 1 7, 1 993 10 1 5 Jun 1 998 SB 50/5 4.35 �Diamond Y AIRCRAFT HK 36 R, TS, TC, TIS, TIC, TIC-ECO AIRPLANE MAINTENANCE MANUAL Other Work 0 Localiin Remark START CHECK 1. 2. 3. 4. 5. 6. 7. 8. 9. 1 0. 11. 12. 1 3. Mass & Balance checked Main bolts secured Fuel valve OPEN Fuel quantity checked Canopy locked Seat hamess on & secure Propeller check Magneto check Carburetor heat OFF Controls free Trim checked Parking brake released Air brakes locked instrument panel models with Rotax 912 A only START CHECK 1. 2. 3. 4. 5. 6. 7. 8. 9. 1 0. 11. 12. 1 3. 14. 15. Mass & Balance checked Main bolts secured Fuel valve OPEN Fuel quantity checked Canopy locked Seat harness on & secure Propeller check Magneto check Carburetor heat OFF Controls free Trim checked Parking brake released Air brakes locked Turbo control ON Fuel booster pump ON instrument panel H K 36 TIS and H K 36 TIC only Doc. No. Issue Rev. No. Date Source Page No. 3.02.21 May 17, 1 993 10 1 5 Jun 1 998 SB 50/5 4.36 HK 36 R, TS, TC, TIS, TIC, TIC-ECO �Diamond v AIRCRAFT . .. . " .• . • .. .. " ' Placard .' AIRPLANE MAINTENANCE MANUAL . . . .. . . . '" ( . . .. " . ' Location . ' . .. . " , .' Other Work . . ' .··· Remark ' , . .. START CHECK 1. 2. 3. 4. 5. 6. 7. 8. 9. 1 0. 11. 12. 1 3. 1 4. 1 5. 1 6. 1 7. I Mass & Balance checked Main bolts secured Baggage door secured Fuel valve OPEN Fuel quantity checked Fuller tank selected Canopy locked Seat hamess on & secure Propeller check Magneto check Carburetor heat OFF Controls free Trim neutral Parking brake released Air brakes locked Turbo control ON Fuel booster pump ON No smoking instrument panel I HK 36 TIC-ECO only instrument panel Aerobatics and Spin are forbidden! instrument panel Landing Light - max. operation: 25 % of engine operating time, no longer than 5 minutes Landing Light and Position Lights may only be used for 1 0 % of engine operating time instrument panel models with Rotax 912 A only, optional instrument panel models with Rolax 914 F only, optional Doc. No. Issue Rev. No. Date Source Page No. 3.02.21 May 1 7, 1 993 10 1 5 Jun 1 998 SB 50/5 4.37 . " �Diamol1d T AIRCRAFT H K 36 R , TS, TC, TIS, TIC, TIC-ECO AIRPLANE MAINTENANCE MANUAL Placard Other Work Location MANIFOLD PRESSURE max. 30 2500 max. 30 2400 max. 24 2200 max. 22 2000 max. 1 7 1 500 Remark RPM MANIFOLD PRESSURE max. 30 2500 max. 30 2200 max. 27 2 1 00 2000 max. 26 max. 2 1 1 500 instrument panel models with MTV 1 propeller only instrument panel models with HO V352 propeller only RPM The differential bra king system may only be activated during taxiing. I lail wheel models, optional instrument panel Differential Bra king next to differential braking switch tail wheel models, optional WARNING Use air brake fixture (hands off) only up to 150 km/h! AlB may extend beyond fixture at higher speeds. I instrument panel or canopy frame, LH side all models except H K 36 R Doc. No. Issue Rev. No. Date Source Page No. 3.02.21 May 17, 1 993 10 1 5 Jun 1 998 SB 50/5 4.38 HK 36 R, TS, TC, TIS, TIC, TIC-ECO �Diamol1d v AIRCRAFT AI RPLANE MAINTENANCE MANUAL Placard Other Work Remark Location Power connector should be used only on the ground. Maximum load: 2A instrument panel optional This airplane must be operated as a utility category airplane in compliance with the operating limitations as stated in the form of placards, markings, and manuals. MAXIMA: MANEUVERING SPEED (lAS) GROSS WEIGHT FLIGHT LOAD FACTOR 20 m (65 ft.). Flight into imO'Ml 176 kmIh (95 Ids. I 109 mph) no kg (1 698 Ibs.) +5.3/-2.65 No acrobatic maneuvers, including spin, approved. Altitude loss in a stall recovery: icing conditions prohibited. This airplane is certified for lhefuUavving flight operations as of date of original airworthiness certificate: DAY-VFR. canopy frame, LH side required for U.S. registered Serial Nos. only canopy frame, LH side required for U.S. and Canadian registered Serial Nos. only VNE (lAS) [km/h] [kts.] [mph] Altitude [ft.] [m] - 2000 - 6500 - 3000 - 9800 - 4000 - 1 3 1 00 - 5000 - 1 6400 - 6000 - 1 9600 261 246 233 221 210 141 1 33 1 26 1 19 113 1 62 1 53 1 45 137 1 30 Doc. No. Issue Rev. No. Date Source Page No. 3.02.21 May 1 7, 1 993 10 1 5 Jun 1 998 SB 50/5 4.39 •Diamond AIRCRAFT HK 36 R, TS, TC, TIS, TIC, TIC-ECO Repair AIRPLANE MAINTENANCE MANUAL Instructions SECTION 5 REPAIR INSTRUCTIONS 5.1 DESCRIPTION OF THE G FRP PARTS 5.1 . 1 WING Skin The primary structure of the wing consists of a sandwich shell and a spar. The skin is very strong, in order to allow for the high aerodynamic torsion effect on the wing. The skin consists of diagonal glass fabric only. The support structure is Conticell 60 or Divinycell H 60, a mm e/'6 in.) thick. Spar (Serial Nos. 36.301 through 36.51 6) The caps of the I-shaped spar consist of glass rovings. The sandwich web consists of diagonal layers and Rohacell 71 or Divinycell H 60, a mm (5/,6 in.) thick. In the area of the spar, the wing skin sandwich is recessed, so that the spar caps lie on the outer skin. Spar (Serial Nos. 36.51 7 and subsequent) The caps of the I-shaped spar consist of CFRP UD bands. The sandwich web consists of diagonal layers and Divinycell H 60, a mm sandwich is not recessed. (5/'6 in.) thick. In the area of the spar, the wing skin Doc. No. Issue Rev. No. Date 3.02.21 May 1 7 , 1 993 10 1 5 Jun 1 99a Source SB 50/5 Page No. 5.1 •Diamond AIRCRAFT HK 36 R, TS, TC, TIS, TIC, TIC-ECO Repair AIRPLANE MAINTENANCE MANUAL Instructions Wing tanks (H K 36 TIC-ECO only) I n front of the wing spar, a GFRP trough is bonded to the wing upper skin. Copper mesh laminated into the walls provides electrical conductivity. NOTE In deviation from the rest of the structure, vinyl ester resin is used for the wing tanks (instead of epoxy resin). The part of the wing skin that forms the upper wall of the fuel tank is covered with one 92125 layer impregnated with vinyl ester resin. Wing-Fuselage connection The spar stump penetrates the fuselage to the centerline. Each wing is attached to the fuselage with three bolts. The removable main bolt is placed close to the fuselage centerline and lies in the flight direction. A- and B-bolts are attached to the root rib of the fuselage in transverse direction. The main bulkhead of the fuselage serves as a bridge for the two spars. The wing root rib and the spar stump web are fabricated in one piece. Repairs of the wing spar, the spar stump and the root rib may only be carried out by the manufacturer or a repair station authorized by the manufacturer. Wing removal is described in the Flight Manual, Section 4. If the airplane is equipped with the optional wing-folding mechanism, the wings remain connected to the fuselage through the telescopic tubes after de-rigging. Remove the two spring dowel sleeves from the joint of the A­ bolt and the telescopic tube for a complete wing removal. Doc. No. Issue Rev. No. Date Source Page No. 3.02.21 May 1 7 , 1 993 10 1 5 Jun 1 99a SB 5015 5.2 �Diamond � AIRCRAFT HK 36 R, TS, TC, TIS, TIC, TIC-ECO Repair AIRPLANE MAINTENANCE MANUAL Instructions Canticell CC60 ar 1 x 92110 * 2x 92125 lit Canticell CC60 ar Rahacell 71 ar Divin cell H60 Divin cell H60 2x 92125 ,J( .. " -' - � - .�., " . . , . . . . . . �. ," . " . 2 x 92126 'i/I! 2 x 92125 1\1: 1 x 92110;1J( Wing (Serial Nos. 36.301 through 36.516) Fiber direction: ±45° to spar. CFRP UD's 1 x 92110 * " ' " •• - • # - • ,- • . .. . .. .. . . . . , ... . �. .. -. . . -.- - ' . '- .. . . ". . Wing (Serial Nos. 36.517 and subsequent) Fiber direction: ±45° to spar. Doc. No. Issue Rev. No. Date Source Page No. 3.02.21 May 1 7 , 1 993 10 1 5 Jun 1 998 SB 50/5 5.3 •Diamond AIRCRAFT HK 36 R, TS, TC, TIS, TIC, TIC-ECO Repair AIRPLANE MAINTENANCE MANUAL Instructions 5.1.2 AILERONS Construction The aileron consists of two half-shells in sandwich design. Carbon fiber cloth is used beside glass fiber cloth to increase torsional stiffness. The fiber direction is 45 0 to the aileron axis. The aileron is attached to the wing by means of five CFRP hinges. These hinges are bonded to the wing, and integrated into the upper skin of the aileron. Removal and installation Removal of the aileron is only necessary when major damage occurs to the aileron or to the wing in this area. To remove the aileron, the push-rod which is connected to the aileron hom with an M6 bolt must be disconnected. Then remove the adhesive tape and deflect the aileron upward, exposing the hinges. Remove safety pins, extract hinge bolts. To install the surface, reverse the procedure. The gap between aileron and wing must be sealed (e.g. with adhesive cloth tape) with the wing removed from the fuselage and the aileron deflected to its full down position. Doc. No. Issue Rev. No. Date Source Page No. 3.02.21 May 1 7, 1 993 10 1 5 Jun 1 998 SB 50/5 5.4 .fII>Diamond AIRCRAFT HK 36 R, TS, TC, TIS, TIC, TIC-ECO Repair AIRPLANE MAINTENANCE MANUAL Instructions Repair infonnation If the ailerons have been damaged, the areas around the hinges must be inspected thoroughly. After the aileron has been repaired, the mass and the residual moment must be re-detennined before installing the surface. Refer to Paragraph 4. 1 3, Masses and Residual Moments of Control Surfaces. 1 x 92110 * 1 x 98141 , . . . + .. . . Rohacell 51 or Divinycel/ H 60 (3 mm thick) 1 x 92110 Vfl!. 1 x 98141>1!' Doc. No. Issue Rev. No. Date Source Page No. 3.02.21 May 1 7, 1 993 10 1 5 Jun 1 998 S8 50/5 5.5 �Diamond 'V� AIRCRAFT HK 36 R, TS, TC, TIS, TIC, TIC-ECO Repair AIRPLANE MAINTENANCE MANUAL Instructions 5.1.3 RUDDER Construction The rudder consists of two GFRP sandwich skins which have 45° fiber direction only. Two roving stringers (HK 36 R) or two UD bands (other models) run over the whole length of the rudder and from the lower mounting rib rearward to the trailing edge. Several rigid foam ribs reinforce the rudder. The lower edge serves as a buffer and has a very thin skin. The lower rudder mount is a C-shaped metal plate to which the rudder cables and eventually the springs for the tail wheel steering are attached. This mounting plate is screwed to the lower mounting rib which transmits control forces into the rudder. The rudder upper hinge is a brass bush, bonded into the upper rudder mounting rib. The hinge is completed by a 6 mm (,5/64 in.) bolt which is attached to the vertical stabilizer. Removal and installation To remove the rudder, first remove the horizontal stabilizer. Separate the mounting plate from the rudder by removing the two M6-nuts. Swing the rudder approx. 2 em remove it by lifting. ('/4 in.) rearward, then To install the rudder, reverse the procedure. Doc. No. Issue Rev. No. Date Source Page No. 3.02.21 May 1 7, 1 993 10 1 5 Jun 1 998 SB 50/5 5.6 Ififflil. T lJiamond AIRCRAFT HK 36 R, TS, TC, TIS, TIC, TIC-ECO Repair AIRPLANE MAINTENANCE MANUAL Instructions HK 36 R rudder lower edge: only 2*921 1 0, 45' 1 stringer = 51 * EC 9 - 756 tex (K43) or 1 6 · EC 1 0 - 2400 tex (K43) 2 x 921 1 0* H K 36 TS, TC, TIS, TIC and TIC-ECO rudder Doc. No. Issue Rev. No. Date Source Page No. 3.02.21 May 1 7, 1 993 10 1 5 Jun 1 998 SB 5015 5.7 �Diamond T AIRCRAFT HK 36 R, TS, TC, TIS, TIC, TIC-ECO Repair AIRPLANE MAINTENANCE MANUAL I nstructions 5.1.4 HORIZONTAL TAIL Construction The horizontal stabilizer is a sandwich design type. Two root ribs transfer the torsional loads of the skin to the bolts. A spar absorbs bending and shearing loads. Two consoles which are able to hold the wing support fixtures are attached to the spar web. The horizontal stabilizer mount has two bolts lying in flight direction. Two swing bearings mounted in the web of the horizontal stabilizer are slipped onto these bolts. The forward fastening of the horizontal stabilizer is a bolt with hexagon socket head. It goes through the fitting near the nose of the stabilizer and is screwed into a nut which is fixed to the auxiliary web of the vertical stabilizer. This is done after slipping the horizontal stabilizer onto the two bolts. The hexagon socket bolt is secured with a locking ring. The GFRP sandwich elevator is held in place through five hinges, which are attached to the rearward web of the horizontal stabilizer. Elevator removal HK 36 R: Remove lock wires; remove two outer bolts and nut of center hinge; remove elevator in a rearward direction. other models: Remove maintenance hole covers on horizontal stabilizer tips; remove split pins and extract outer joumals; remove both attachment bolts for elevator horn; remove elevator in rearward direction. Elevator installation For installation, reverse the procedure. CAUTION Do not forget the safetying! Doc. No. Issue Rev. No. Date Source Page No. 3.02.21 May 1 7, 1 993 10 1 5 Jun 1 996 SB 5015 5.6 .,Diamond AIRCRAFT HK 36 R, TS, TC, TIS, TIC, TIC-ECO Repair AIRPLANE MAINTENANCE MANUAL Instructions Repair information After repair or repainting of the elevator, mass and residual moment must be re-determined (see Paragraph 4. 1 3). I spar caps: to y = 650 mm (25.6"): 2 stringers 1 stringer to tip: i?':. . . � � l\ \ I 2 x 92 1 1 0 lK Conticell 60, 8 mm (5/1 6') thick 1 x 921 1 0 )JK '" . rearward web: 2 x 92125 )JK j .I , . I V{ • \ ....... 2 x 92125 lK Rohacell 7 1 , 8 mm (5/1 6") thick I 2 x 921 1 0 lK Rohacell 5 1 , 3 mm (1/8") thick 1 x 921 1 0 lK Horizontal tail of the HK 36 R 1 stringer = 51 ' EC 9 - 756 tex (K43) or 1 6 ' EC 1 0 - 2400 tex (K43) spar caps made of GFRP UD's and 92125 )1[( in different lengths 2 x 92110 � Divinycell H60, 8 mm thic 1 x 92110 � 92125 different lengths 2 x 92110 � Divinycell H60, 3 mm thie 1 x 92110 � Horizontal tail of the HK 36 TS, TC, TIS, TIC, TIC-ECO Doc. No. Issue Rev. No. Date Source Page No. 3.02.21 May 1 7, 1 993 10 1 5 Jun 1 99B SB 50/5 5.9 •Diamond AIRCRAFf HK 36 R, TS, TC, TIS, TIC, TIC-ECO Repair AIRPLANE MAINTENANCE MANUAL Instructions 5.1.5 FUSELAGE The fuselage is manufactured in GFRP semi-monocoque construction with several bulkheads but without rigid foam or supporting stringers. The number of layers and their orientation depend on the load in the respective cross sections. Therefore, the fuselage skin has very different laminate thicknesses and fiber orientations. Prior to a repair of the fuselage skin or the built-in parts, contact the manufacturer and order a fuselage layup plan. Doc. No. Issue Rev. No. Date Source Page No. 3.02.21 May 17, 1 993 10 1 5 Jun 1 998 S8 50/5 5. 1 0 w g c en 0 CD O OJ - :" z p ;0 CD CD C III III 0 0 fl z p � � Z P CD -U OJ !Jl co en CD U1 a U1 � CD CD ex> t- C ::J � U1 � a � CD CD W � -.." s: OJ '< � '" '" a ring frame no. 2 ivertical sfilbiliziiiStit'fener (not all Serial Nos.) reinforcement for towing device vertical stabilizer web auxiliary web -; en -; 0 - :::j :::j -en :::j o Q. III _. ::J ::J III " c ' ""0 OJ. _ ;0 CD Q C m >- 0 r 0 �z m _0 z o � >- m s: >z -; I ;>;; w Ol S;: ;o z ;0 -u >- �i. �8 tl s' � 4'ADiamond v AIRCRAFT HK 36 R, TS, TC, TIS, TIC, TIC-ECO Repair AIRPLANE MAINTENANCE MANUAL Instructions 5.1.6 MAIN LANDING GEAR MADE OF GFRP All tail wheel models are equipped with a main landing gear strut made of GFRP. Description: removal and installation See Article 2.2. 1 Repair information Due to the complex structure of the GFRP strut, even the manufacturer cannot repair it in any case. Before repairing the landing gear strut, contact the manufacturer. Doc. No. Issue Rev. No. Date Source Page No. 3.02.21 May 1 7, 1 993 10 1 5 Jun 1 998 SB 50/5 5. 1 2 �Diamond v AIRCRAFT H K 36 R, TS, TC, TIS, TIC, TIC-ECO Repair AIRPLANE MAINTENANCE MANUAL Instructions 5.2 REPAIR WORK, GENERAL 5.2.1 DAMAGE CLASSIFICATION Should the airplane become damaged, the first thing to do is to detemnine the extent of damage. White areas indicate damage to GFRP laminate. After a hard landing, the Powered Sailplane should be inspected, even if no visible damage is apparent. In particular, cracks in the paint finish indicate possible damage to the outer laminate or the GFRP parts built in (e.g. bulkheads). Should there be doubt whether the crack area is damaged, the paint must be removed. Steel fittings, such as shear bolts, horizontal tail mount, etc. must be inspected thoroughly for cracks and white spots in the adjacent structure; sometimes the crack continues beneath the surface where it is invisible. Should questions relating to the damage arise, contact the manufacturer. In the follOwing cases, repair work may only be performed by the manufacturer or an authorized repair station: • damage to the primary structure, e.g. wing spar, horizontal stabilizer spar, main bulkhead, landing gear, root rib; • damage to fittings of wing, main bulkhead, stabilizer, landing gear, engine, etc.; • two-dimensional damage to the skin of wing, fuselage or stabilizer, if the diameter is greater than 1 5 cm (57/8 in.); • in particular: broken fuselage tube, broken wings, broken control surfaces. Doc. No. Issue Rev. No. Date Source Page No. 3.02.21 May 1 7, 1 993 10 1 5 Jun 1 998 S8 50/5 5. 1 3 �Diamond v#7fT AIRCRAFT HK 36 R, TS, TC, TIS, TIC, TIC-ECO Repair AIRPLANE MAINTENANCE MANUAL Instructions 5.2.2 REPAIR OF FIBER COMPOSITE PARTS, GENERAL Repair work must be performed extremely carefully and only by authorized personnel. The outer skin is a load carrying member. Any failure of this structure can have serious consequences. It is very important that the resin mixture has the exact proportion (± 0.5 %) and that only clean vessels are used. Do not use brushes that have been in contact with oil, 'grease or something similar, even if they have been washed. New brushes are best utilized. The ratio of glass weight to resin mixture weight should be approximately 50:50. Sand the repair area shortly before laying the wet laminate to prevent the surface from getting dirty. The sanded areas must not be touched and must be cleaned thoroughly with a vacuum cleaner after sanding. Before laying the laminate, lightly coat the repair area with resin. As when working with plywood, the orientation of the fibers (parallel or diagonal) is very important to ensure the strength of the laminate. The number of cloth layers that is required to provide the original strength can be determined from the layup plans which are available from the manufacturer. A piece of old damaged laminate can be removed and set on fire. The resin will burn and the glass fabric remains. Cloth types, number of layers and orientations can then be identified. Even though chamfering takes effort, the time should be taken to sand until the cloth patches are flush. They must not be sanded away for aesthetic or other reasons). Doc. No. Issue Rev. No. Date Source Page No. 3.02.21 May 17, 1 993 10 1 5 Jun 1 998 SB 50/5 5.14 .Diamond AIRCRAFT HK 36 R, TS, TC, TIS, TIC, TIC-ECO Repair AIRPLANE MAINTENANCE MANUAL I nstructions In order to reduce hardening time, heat may be applied with a heat fan. Build a small foil tent over the repair area and blow hot air into it. This will prohibit local overheating, which would cause blisters in the fabric. It is important to work up the resin before the potlife is over (at least 20 minutes at 20 °C (68 OF), see resin manufacturer's specifications). To ensure the full strength of the plastic, it is necessary to cure the repaired area for 14 hours at 55 °C (131 °F). This may be done as described above. Doc. No. Issue Rev. No. Date Source Page No. 3.02.21 May 17, 1 993 10 1 5 Jun 1 998 SB 5015 5.15 "Diamond � AIRCRAFT HK 36 R, TS, TC, TIS, TIC, TIC-ECO Repair AIRPLANE MAINTENANCE MANUAL Instructions 5.3 DAMAGE TO G FRP SANDWICH PARTS There are two common damages to sandwich parts: • only the surface (outer skin) is damaged • the whole sandwich construction (outer skin, rigid foam, inner skin) is broken 5.3.1 DAMAGE TO THE OUTER SKIN The laminate might have separated from the rigid foam around the damage area. This area can be determined by tapping. The outer skin that has separated is removed with a sanding disk, a sanding block or a sharp knife. Then chamfer the fabric around the damage area with a sanding block or a plane iron. The ratio of laminate thickness to chamfer length must be at least 1 :SO. In case of the cloth 9212S, that means a chamfer of approximately 20 mm (,3/16 in.) per layer. After chamfering, the dust must be removed with a vacuum cleaner. The pores of the rigid foam must also be open and clean. Should the area come in contact with oil or grease, clean.it with uncontaminated carbon tetrachloride or acetone. Damage to the rigid foam is repaired with resin and Microballoons using a spatUla. Lay the cloth patches into the repair area in their respective orientations and impregnate them until the surface has a matt finish. The largest patch comes first, the smallest is the last. Avoid dust and grease! Doc. No. Issue Rev. No. Date Source Page No. 3.02.21 May 1 7, 1 993 10 1 S Jun 1 998 S8 SOlS S.16 4ADiamond v AIRCRAFT HK 36 R, TS, TC, TIS, TIC, TIC-ECO Repair AIRPLANE MAINTENANCE MANUAL I nstructions At room temperature, the resin hardens in approximately 24 hours. The area may then be sanded (not the skin in the center, only the edges), primed, and painted. 5.3.2 DAMAGE TO THE ENTIRE SANDWICH If the inner skin is damaged, first remove the outer laminate that has separated from the rigid foam. The foam is then removed to the limits of bonding to the inner skin."ln order to repair the inner laminate, another area of rigid foam must be removed until a rim of inner laminate at least 3 20 mm (1 /'6 in.) wide is available (chamfer ratio at least 1 :50). The outer skin is then chamfered as described in Article 5.3. 1 , Damage to the Outer Skin. Clean the inner skin from the rigid foam and chamfer it carefully. J. d > = d 50 c. J - ""f...0 "' � ) o\ o O .;J o o� -- J min 20 mm ( 1 311 6 " ) Doc. No. Issue Rev. No. Date Source Page No. 3.02.21 May 1 7, 1 993 10 1 5 Jun 1 998 S8 50/5 5. 1 7 �Diamond "'4p' AIRCRAFT HK 36 R, TS, TC, TIS, TIC, TIC-ECO Repair AIRPLANE MAINTENANCE MANUAL I nstructions For minor repair work, a thin piece of plywood is bonded to the inner skin from inside. The plywood can be inserted through the skin if the hole has an elongated shape. A nail through the p lywood aliows it to be held tightly against the inner skin (see sketch). The plywood must lie close to the skin to prevent kinks in the fabric. Lay the cloth patches of the inner skin. Then fill the hole with resin and Microbalioons. When hardened, sand the surface and lay the cloth patches of the outer skin. For repair of larger holes in a sandwich, it is recommendable to use a piece of rigid foam (Conticeli 60, Rohaceli 71 , or Divinyceli H60) instead of the Microbalioons in order to save weight. Prepare a piece of rigid foam that fits the hole exactly. The pores of the inner surface should be closed with resin and Microbalioons with a spatula. Lay the inner laminate on the insert. After hardening this insert can still be bent (use a fan heater if necessary). Sand the insert and paste it in the hole using a mixture of resin and cotton flakes. Sand the upper surface, close the pores with resin and Microbalioons and lay the outer laminate. When this has hardened, sand (not the skin in the center, only the edges), prime, and paint. When using the foam insert, the plywood piece need not be used. J 0 0 ,.. 0 0 . 0 1 ; . " . ', " . ° O D o L· · . · : ·. : . · . ' Doc. No. Issue Rev. No. Date Source Page No. 3.02.21 May 17, 1 993 10 1 5 Jun 1 998 SB 5015 5.18 •Diamond AIRCRAFr H K 36 R, TS, TC, TIS, TIC, TIC-ECO Repair AIRPLANE MAINTENANCE MANUAL Instructions 5.4 DAMAGE TO All-GFRP PARTS 5.4.1 CRACKS IN LEADING EDGE BONDS CAUTION Cracks in the paint on a leading edge bond necessitate a thorough examination of the bond. Cracks in the leading edge bond of a control surface Cracks in the leading edge of a control surface are repaired by embedding a 921 1 0 layer, observing the correct chamfer ratio. Cracks in the wing leading edge bonds (1) Determine crack depth. I f the crack continues under the laminate of the outer skin: Remove laminate and thickened resin until the end of the crack is reached. Case 1 : Crack does not continue under the laminate of the outer skin, no laminate needed to be removed Case 2: A laminate strip with a maximum width of 1 0 mm ('Is in.) (parallel to the wing leading edge) had to be removed. Case 3: A laminate strip wider than 1 0 mm ('Is in.) (parallel to the wing leading edge) had to be removed. (2) Chamfer remaining laminate. Minimum chamfer lengths: Case 1 : 1 5 mm (sis in.) Case 2: 30 mm (1 '/4 in.) Case 3: 60 mm (2'1, in.) (3) Remove sanding dust with a vacuum cleaner or compressed air. (4) If the repair area has come in contact with dirt or grease, it must be cleaned with uncontaminated tetrachloride or acetone. (5) Fill groove with resin and Microballoons. Doc. No. Issue Rev. No. Date Source Page No. 3.02.21 May 17, 1 993 10 1 5 Jun 1 998 S8 50/5 5. 1 9 "Diamond v� AIRCRAFT (6) HK 36 R, TS, TC, TIS, TIC, TIC-ECO Repair AIRPLANE MAINTENANCE MANUAL Instructions Prepare impregnated laminate diagonally on plastic foil. See Item (2) for chamfer lengths. x Case 1 : 2 Case 2: 2 Case 3: 4 x 92125 layers x 921 1 0 layers 92125 layers (7) Apply resin to repair area, lay prepared laminate and remove plastic foil. (8) Allow to harden at room temperature, then cure repair area for 1 5 hours at 50 'C ( 1 22 'F). (9) ( 1 0) Sand repair area (not the skin in the center, only the edges). Paint repair area. 5.4.2 OTHER DAMAGE TO ALL-GFRP PARTS Chamfer the laminate around the hole (chamfer length per layer: 20 mm (13/ ' 6 in.), ratio of laminate thickness to chamfer length: 1 :50) and clean the area (eventually with uncontaminated carbon tetrachloride or acetone). Lay the cloth patches into the area, the largest patch first. In case of larger holes, use a piece of plywood (as described in Article 5.3.2, Damage to the Entire Sandwich), since wet laminate alone should not bridge more than 20 mm (13/,6 in.). --L ::: 50 d - Doc. No. Issue Rev. No. Date Source Page No. 3.02.21 May 1 7, 1 993 10 1 5 Jun 1 998 S8 50/5 5.20 .Diamond AIRCRAFT I HK 36 R, TS, TC, TIS, TIC, TIC-ECO Repair AIRPLANE MAINTENANCE MANUAL Instructions 5.5 PAINTING When the laminate in the repair area is hardened and cured (see Article 5.2.2), sand the area with no. 80 sandpaper to remove the major unevenness. Smaller unevennesses are primed. Then use no. 1 50 sandpaper to create a uniform rough surface. Clear repair area from dust, parting compounds and other foreign substances. Apply primary coat and paint according to the paint manufacturer's instructions. Refer to Paragraph 5.9 for the selection of the proper paint. I 5.6 REPAIR OF THE CANOPY If a crack in the canopy is detected, a stop hole should be drilled immediately. This will prevent the crack from going further. If the crack is longer than 1 0 m m ('/a in.), it should be repaired as follows: 1 . Make a 3 m m Cia in.) wide V-groove along the crack. 2. Align and fix the edges. 3. Apply acrylic glass cement (e.g. R6hm Acrifix 92) to the groove. Since this cement hardens only in light, it should be exposed to direct sunlight (hardening time 3 to 6 hours). If this is not possible, an artificial light source may be used. 4. After the cement has hardened, remove the bead with a small milling cutter, sand the repair area with smooth sandpaper and finally apply polishing paste. Doc. No. Issue Rev. No. Date Source Page No. 3.02.21 May 1 7, 1 993 10 1 5 Jun 1 998 SB 50/5 5.21 •Diamond AIRCRAFT HK 36 R, TS, TC, TIS, TIC, TIC-ECO Repair AIRPLANE MAINTENANCE MANUAL Instructions 5.7 REPAIR OF FITTINGS AND CONTROL SYSTEM PARTS Repair of fittings and control system parts must never be carried out without contacting the manufacturer. The parts mostly consist of aviation steel 1 .7734 or 1 . 72 1 4 , which is only weldable with T.I.G.-welding. Since the steel quality cannot be identified visually, it is necessary to refer to the type design. All major fitting bolts are also made of this material, quenched and tempered to condition 6. Therefore, only the original bolts made by the manufacturer may be used. 5.8 PROPELLER REPAIR I Refer to the appropriate Propeller Manual (see list in Article 2.5.6). Doc. No. Issue Rev. No. Date Source Page No. 3.02.21 May 17, 1 993 10 1 5 Jun 1 998 S8 50/5 5.22 �Diamond V AIRCRAFT HK 36 R, TS, TC, TIS, TIC, TIC-EGO Repair AIRPLANE MAINTENANCE MANUAL Instructions 5.9 MATERIALS USED AND SOURCES Resin system Resin : L 285 Hardener : 286 Mixture : 1 00 parts resin and 38 parts hardener (by weight) Supplier : Scheufler Am Ostkai 2 1 /22 0-70327 Stuttgart, Germany Phone: +49/71 1 /323081 Fax: +49/71 1/3280041 Resin system for H K 36 TIC-ECO wing tanks Resin : Oerakane 470-36S Hardener : Butanox LPT 1 .5 to 2 parts per 1 00 parts resin (by weight) Accelerator : NL51 P (cobalt or violet) 0.3 parts per 1 00 parts resin (by weight) Restrainer : NLC- 1 0 0.5 parts per 1 00 parts resin (by weight) Carbon powder : Ketjenblack (only for coloring) max. 2 parts per 1 00 parts resin (by weight) Supplier : Polychem HandelsgesmbH Bahnhofsplatz 5 A-21 1 1 RGckersdorf, Austria Phone: +43/2264/652 1 -0 Fax.: +43/2264/61 39 Rovings Vetrotex glass silk rovings EC 1 0 - 2400 tex (K43) or EC 9 - 756 tex (K 43) Supplier : Rudolf Usner GmbH Am Ausfemgenufer 4 A-5400 Hallein, Austria Phone: +43/6245/81 5 1 6 Fax: +43/6245/8 1 5 1 6-40 Doc. No. Issue Rev. No. Date Source Page No. 3.02.21 May 1 7, 1 993 10 1 5 Jun 1 998 SB 50/5 5.23 .Diamond AIRCRAFT HK 36 R, TS, TC, TIS, TIC, TIC-ECO AIRPLANE MAINTENANCE MANUAL Repair Instructions Glass fiber cloth WLB No. (German aviation standard) Weave 8.4548.6 2/2 twill 163 8.455 1 .6 2/2 twill 280 8.4554.6 2/2 twill 390 8.4520.6 UD 220 8.4525.6 UD 425 /nterg/as Mass per unit area [g/m2] Type Porcher Type 92110 917 92125 92140 92145 3063 Vorwerk Type 95290 1 989 92146 All cloth types consist of alkali free E-glass with I 550 or PT 55 finish and comply with LN 9169 (German aviation standard). Supplier for Interglas fabric : Rudolf Usner GmbH (see above) Supplier for Porcher fabric : Porcher Industrietextilien GmbH Holzgraben 1 3/ 1 5 0-52062 Aachen, Germany Phone: +49/241/48225 Fax: +49/241 /48229 Supplier for Vorwerk fabric : Saertex Wagener GmbH & Co KG Industriestr. 9 0-48369 Saerbeck, Germany Phone: +49/2574/8051 Fax: +49/2574/8231 Doc. No. Issue Rev. No. Date Source Page No. 3.02.21 May 1 7, 1 993 10 1 5 Jun 1 998 SB 50/5 5.24 .Diamond AIRCRAFT Repair Instructions HK 36 R, TS, TC, TIS, TIC, TIC-ECO AIRPLANE MAINTENANCE MANUAL Carbon fiber cloth WLB No. (German aviation standard) Weave 8.3520.8 2/2 twill Interglas Mass per unit area [g/m"l Porcher Type Type Vorwerk Type 98141 200 The cloth complies with LN 9 1 69 (German aviation standard). Supplier: Rudolf Usner GmbH (see above) Rigid foams WLB No. (German Aviation Standard) Density [kg/m"l Thickness [mm] Divinycell Type 60 8 PVC rigid foam Divinycell H 60 5.1460. 1 50 3 PMI rigid foam Rohacell 5 1 5.1460.2 70 8 PMI rigid foam Rohacell 71 Supplier for Divinycell Rohacell Type : Continental C.U.P Gummi Ges.m.b.H. Eisgrubengasse 4 A-2334 V6sendorf Sud, Austria Manufacturer of Rohacell : R6hm, Darmstadt, Germany Supplier for Rohacell : Thun und Hohenstein Lamezanstr. 1 7 A-1231 Vienna, Austria Phone: +43/1/61 6751 0-0 Fax: +43/1/61 6751 0-33 Doc. No. Issue Rev. No. Date Source Page No. 3.02.21 May 17, 1 993 10 1 5 Jun 1 998 SB 50/5 5.25 IIIIfI V IIIt. Diamond AIRCRAFT HK 36 R, TS, TC, TIS, TIC, TIC-ECO AIRPLA NE MAINTENANCE MANUAL Repair Instructions Fillers for resin Cotton flakes FB 1 F, white Supplier : Schwarzwalder Textilwerke Postfach 4, Aue 3 0-77771 Schenkenzell, Germany Phone: +49/7836/5713 Fax: +49/7836/5737 Silcell 300 Supplier : Joh. Klinglhuber & S6hne Handelsgesellschaft mbH Wallgasse 2 1 A-1 062 Vienna, Austria Phone: +43/1/5974712-0 Fax: +43/1/5974712-16 Aerosil 380 Supplier : Polychem HandelsgmbH (see above) Microballoons Q-cell 300 Supplier : Polychem HandelsgmbH (see above) Chopped glass fiber Supplier : Rudolf Usner GmbH (see above) Doc. No. Issue Rev. No. Date Source Page No. 3.02.21 May 17, 1 993 10 1 5 Jun 1 998 SB 50/5 5.26 "Diamond V AIRCRAFT HK 36 R, TS, TC, TIS, TIC, TIC-ECO AIRPLANE MAINTENANCE MANUAL Repair Instructions Knifing filler, Primer (acrylic filler), Paint (color RAL 9016) These products are supplied by Herberts or Sikkens. It is highly recommendable to contact Diamond Aircraft Industries to inquire about the products used on a specific serial number in order to avoid such problems as bubbles in the paint finish. Paint for the instrument panel Satin paint, color tone 82, with hardener and thinner Manufacturer: 3M Fire retardant paint Fire retardant paint : no. N 565821T508 (white) Finishing varnish : no. 4232-0303 Hardener : no. N 39/1 327 (4: 1) Supplier : Courtaulds Aerospace c/o ICI Lacke Farben Lauenburger Landstr. 1 1 0-21 039 86msen, Germany Phone: +49/40/720031 -75, -74 Fax: +49/40/72041 92 Acrylic glass cement Polymerization cement Acrifix 92 Manufacturer : R6hm, Darmstadt, Germany Supplier : Thun und Hohenstein (see above) Doc. No. Issue Rev. No. Date Source Page No. 3.02.21 May 17, 1 993 10 1 5 Jun 1 998 S8 50/5 5.27 HK 36 �Diamond ....'0/ AIRCRAFT R, TS, TC, TIS, TIC, TIC-ECO AIRPLANE MAINTENANCE MANUAL SECTION Airworthiness Limitations 6 AIRWORTHINESS llNIiTATIONS This Airworthiness Limitations Section has been approved by the Austro Control GmbH (ACG) and accepted by the FAA. Service Bulletins or other documents which contain a statement that the document is Austro Control GmbH (ACG) approved are considered FAA approved and revise this section. Pages identified by "ACG-appr." are approved by: Signature AUSTRO CONTROL GmbH Abteilung F!ugteclmik A�i300 V,:icn�Flugi:?l[en, Hcllgar 2 A.uGensteile Ost Stamp 2 O. Jan. 1999 Date of approval Doc. No. Issue 3.02.21 May 17, 1 993 Rev. 10 No Date Source Page No. 1 5 Jun 1 998 S8 50/5 6.1 "Diamond T AIRCRAFT H K 36 R, TS, TC, TIS, TIC, TIC-ECO AIRPLANE MAINTENANCE MANUAL Airworthiness Limitations 6.1 LIFE LIMITED PARTS 6.1.1 ENGINE • Rolax 912 A: The TBO is 1200 hours or 1 0 years, whichever comes first. A possible extension of the TBO will be notified through Service Bulletins. • Rolax 914 F: The TBO is 1 000 hours or 1 0 years, whichever comes first. A possible extension of the TBO will be notified through Service Bulletins. 6.1 .2 SILENTBLOCS OF ENGINE MOUNT These must be replaced upon engine overhaul. Doc. No. Issue Rev. No Date Source Page No. 3.02.21 May 1 7, 1 993 10 1 5 Jun 1 998 SB 50/5 6.2 �Diamol1d v AIRCRAFT HK 36 R, TS, TC, TIS, TIC, TIC-ECO AIRPLANE MAINTENANCE MANUAL Airworthiness Limitations 6. 1 .3 OTHER RUBBER COMPONENTS IN THE ENGINE COMPARTMENT All elastomer hoses in the engine compartment, as well as the carburetor membranes (see Operator's Manual for the Rotax 912 A or Maintenance Manual for Rotax Engine Type 9 1 4 F, respectively), must be replaced every 5 calendar years. CAUTION When replacing the oil lines, bear in mind that the coil springs which prevent kinks must lie within the hoses. The hose change must be entered and confirmed in the Aircraft Maintenance Log. The date of installation (quarter and year) must be pennanently marked on the hoses (by engraving in metallic hose clamps or by means of heat shrinkable tubes specially designed for labeling). Hoses and tubes made of plastic (e.g. teflon) are exempted from this measure. Original equipment consists of only elastomer hoses. 6.1.4 COOLANT The engine coolant must be changed at least once in 2 years. Doc. No. Issue Rev. No Date Source Page No. 3.02.21 May 1 7, 1 993 10 1 5 Jun 1 998 S8 50/5 6.3 "Diamond T AIRCRAFT H K 36 R, TS, TC, TIS, TIC, TIC-ECO AIRPLANE MAINTENANCE MANUAL Airworthiness Limitations 6.1.5 PROPELLER Constant speed propellers - mt-propeller MTV-1: The current TBO is 1200 hours of operation or 5 calendar years, whichever comes first. - mt-propeller MTV-21 : The current TBO is 1200 hours of operation or 5 calendar years, whichever comes first. The pressure accumulator is overhauled together with the propeller. - Hoffmann HO-V352: The current TBO is 1200 hours of operation or 5 calendar years, whichever comes first. The 5 year period may be extended to the next Annual Inspection, as long as no Service Bulletin or other technical information contradicts this extension. A period of 6 years may not be exceeded under any circumstances. An overhaul is required prior to reaching the above limit: (a) at engine overhaul, if engine hours and propeller hours are identical, or (b) upon ground contact, overspeed, leakage, etc. A possible extension of the TBO will be notified through Service Bulletins. In each case, the last revision is authoritative. Fixed pitch propellers The TBO depends on the condition of the propeller. There is no life limit. 6.1.6 PROPELLER GOVERNOR The propeller govemor (if fitted) must be overhauled together with the engine. Doc. No. Issue Rev. No Date Source Page No. 3.02.21 May 1 7, 1 993 10 1 5 Jun 1 998 SB 50/5 6.4 "Diamond v AIRCRAFT HK 36 R, TS, TC, TIS, TIC, TIC-ECO AIRPLANE MAINTENANCE MANUAL Airworthiness Limitations 6.1.7 AIRFRAME The current life time of Powered Sailplanes made of GFRP is 6000 flight hours. The results of operational strength tests on wing spars have proved that the life time of Powered Sailplanes made of GFRP can be extended to over 6000 flight hours. (a) As soon as the Powered Sailplane has reached an operation time of 6000 flight hours, an inspection prescribed in an Inspection Program prepared by the Manufacturer must be carried out. Upon a positive result or after the detected defects have been removed properly, the lifetime of the Powered Sailplane can be further extended. (b) The Inspection Program can be requested from the Manufacturer when required. (c) The inspection must be perfonned either by the Manufacturer or by a certified repair station, which means an FAA-approved repair station in case of U.S. registered aircraft. (d) The results of the checks must be recorded in a Findings Report in which each item is commented upon. If the checks are not perfonned by the Manufacturer but by an authorized repair station, a copy of the Findings Report must be sent to the Manufacturer (for the purpose of analysis and eventual supplementation or modification of the Inspection Program). (e) The Annual Inspection that must be performed is not affected by this regulation. 6. 1 .8 ALUMINUM MAIN LANDING GEAR STRUTS Main landing gear struts made from aluminum (only available for tricycle models) must be replaced after 3000 hours of operation. Doc. No. Issue Rev. No Date Source Page No. 3.02.21 May 1 7, 1 993 10 1 5 Jun 1 998 S8 50/5 6.5 •Diamond AIRCRAFT HK 36 R, TS, TC, TIS, TIC, TIC-ECO AIRPLANE MAINTENANCE MANUAL Airworthiness Limitations 6.1.9 ELECTRIC FUEL PUMPS • Models with Rotax 912 A: The electric fuel pump must be replaced after 3000 hours of operation. • Models with Rotax 914 F: The two electric fuel pumps must both be replaced, together with the check valves, at each engine overhaul. 6.1 .10 HOSES IN THE AIRFRAME All elastomer hoses which lie behind the firewall must be replaced after 8 calendar years. The hose change must be entered and confirmed in the Aircraft Maintenance Log. The date of installation (quarter and year) must be permanently marked on the hoses (by engraving in metallic hose clamps or by means of heat shrinkable tubes specially designed for labelling). Hoses and tubes made of plastic (e.g. teflon) are exempted from this measure. Original equipment consists of only elastomer hoses. Doc. No. Issue Rev. No Date Source Page No. 3.02.21 May 1 7, 1 993 10 1 5 Jun 1 998 S8 50/5 6.6 •Diamond AIRCRAFT HK 36 R, TS, TC, TIS, TIC, TIC-ECO AIRPLANE MAINTENANCE MANUAL Airworthiness Limitations 6.1 . 1 1 RUDDER CONTROL CABLES The rudder control cables can be visually inspected near the pedals and beneath the baggage compartment over a length of approximately 30 cm (1 tt). If wear (e.g. abrasion or broken strands) should be detected, the respective control cable must be replaced immediately. Also refer to FAA AC 43. 1 3 - 1A. Tail wheel models Regardless of visible wear, the rudder control cables must be replaced after 1200 flight hours or 1 0 calendar years, whichever comes first. Tricvcle models Regardless of visible wear, the rudder control cables must be replaced after 1 200 flight hours or 6 calendar years, whichever comes first. 6.1 . 1 2 OUTER ROD END BEARINGS OF ELEVATOR ATTACHMENT HK 36 R only: These must be replaced after 3000 flight hours. 6.1 . 1 3 BRAKE FLUID The hydraulic brake fluid must be changed at least once in 3 years. Doc. No. Issue Rev. No Date Source Page No. 3.02.21 May 17, 1 993 10 1 5 Jun 1 998 S8 50/5 6.7 •Diamond AIRCRAFT HK 36 R, TS, TC, TIS , TIC, TIC-ECO AIRPLANE MAINTENANCE MANUAL Airworthiness Limitations 6 . 1 . 1 4 ELT BATIERY The lifetime of the ELT battery depends on the battery type. The original battery must be replaced after 2 or 3 calendar years (refer to placard on ELT). 6 . 1 . 1 5 IGNITION SWITCH Every 2000 flight hours, the ignition switch must be serviced a=rding to HOAC Work Instruction No. 13. 6. 1 . 1 6 SAFETY HARNESSES The safety harnesses on the LH and RH seat must be replaced every 1 2 calendar years. 6. 1 . 1 7 TOWING DEVICE The towing device (optional) must be overhauled by an authorized service station every 4 calendar years or 2000 tows, whichever comes first. Doc. No. Issue Rev. No Date Source Page No. 3.02.21 May 1 7, 1 993 10 1 5 Jun 1 99B S8 50/5 6.B M6.Diamond v AIRCRAFT HK 36 R, TS, TC, TIS, TIC, TTC-ECO AIRPLANE MAINTENANCE MANUAL Airworthiness Limitations 6.2 SURFACE COLOR Since the strength of the fiber composite structure has only been shown up to a temperature of 54 °C (129 OF), the outer surface of the airplane must be painted white. Exceptions are registration markings and warning marks, which are subject to the following restrictions (also see drawing on next page): No registration markings or waming marks may be applied here. Zone II Registration markings and warning marks may be applied here. They may have (a) any shape, provided that colors with a solar absorptivity not exceeding 0.5 (e.g. light yellow or light green) are used or (b) any color, provided that no area measuring 1 5 cm by 1 5 cm (% ft. by % ft.) is covered by more than 50 %. One consequence is that the width of decoration stripes must not exceed 7.5 cm (3 in.). Zone III Registration markings and waming marks of any shape and color may be applied here without restrictions. NOTE For both conventional and tricycle landing gear, the wheel fairings and metal parts are Zone III. The GFRP landing gear strut of the conventional landing gear is Zoner. Doc. No. Issue Rev. No Date Source Page No. 3.02.21 May 1 7, 1 993 10 1 5 Jun 1 998 SB 50/5 6.9 HK 36 R, TS, TC, TIS, TIC, TIC-ECO AIRPLANE MAINTENANCE MANUAL iiADiamond T AIRCRAFT Airworthiness Limitations ..: IU W OJ OJ C I '6 I U ..!!! I j I c W i)' - ·c I 0 � w OJ IU C. IJ) ::J 0 � I II . ;; w � c. c 0 W Ia z w w en c s: 0 .c IJ) � I IU W OJ OJ c I 1\I '6 ..!!! c IU C 0 "" c w > C 0 U I ID c 0 N I ID c 0 N I I ID c 0 N I DOl Doc. No. Issue Rev. No Date Source Page No. 3.02.21 May 1 7, 1 993 10 1 5 Jun 1 998 SB 5015 6. 1 0