Tecnam P92 ECHO, P92-S ECHO Manual

Maintenance

Manual

Doc. n° 92/115

2nd Issue, September 10th, 2004

1st Revision, October 25th, 2004

P92 Echo & P92-S Echo

M a i n t e n a n c e M a n u a l

INTRODUCTION

Before flying the aircraft we recommend reading carefully this manual, the flight manual and the engine’s manuals. A thorough knowledge of the aircraft, of its qualities and of its limitations will allow you to operate with greater safety.

The P92 Echo and P92-S Echo are uncomplicated and sturdy machines whose features include simple servicing and superior flying qualities. This manual describes time and modes for correct servicing procedures. Scrupulously following instructions will insure that your P92 Echo or P92-S Echo will accompany you dependably for a long time with optimal performance in absolute safety.

This manual consists of 5 sections; a table of contents at the beginning of each section will allow you to reach quickly any selection.

Information contained in this manual is based on available data at publication time, possible variations shall be presented with servicing bulletins.

This manual describes correct servicing of parts manufactured by TECNAM and, in subordinate measure, of the list of components purchased from external suppliers; for more complete information on individual components it is necessary to refer to the component’s manufacturer’s manual.

For further information or explanations contact:

COSTRUZIONI AERONAUTICHE TECNAM s.r.l.

1a Traversa via G.Pascoli

80026 Casoria (NA) - ITALY

081-7583210 081-7584528

Ed.2	Date: Sept. 2004	Page . i

P92 Echo & P92-S Echo

M a i n t e n a n c e M a n u a l

INTRODUCTION

SECTIONS

General	Section A
Inspections and Servicing	Section B
Airframe	Section C
Powerplant and Propeller	Section D
Systems	Section E

Ed.2	Date: Sept. 2004	Page . ii

P92 Echo & P92-S Echo	Section A
M a i n t e n a n c e M a n u a l	GENERAL

SECTION A

GENERAL

TABLE OF CONTENTS

1 - DESCRIPTION AND GENERAL CHARACTERISTICS --------------------------------------------

4

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Date: Sept. 2004

Page A-1

P92 Echo & P92-S Echo		Section A
M a i n t e n a n c e	M a n u a l	GENERAL
TABLE I
WING
Wing Span	9.3 m
Wing Area	13 m2
Aspect Ratio	6.6
Taper ratio	1.0
Chord	1.4 m
Flap span	1.97 m
Flap chord	0.385 m
Aileron span	1.97 m
Aileron chord	0.385 m
FUSELAGE
Length (overall)	6.4 m
Width max.	1.06 m
Height max. (vertical tail end)	2.5 m
EMPENNAGES
Stabilator Span	2.90 m
Stabilator Area	1.972 m2
Stabilator chord	0.680 m
Vertical Tail Span	1.230 m
Vertical Stabilizer Area	0.720 m2
Rudder Area	0.350 m2
LANDING GEAR
Wheel Track	1.8 m
Wheel Base	1.6 m
Nose Wheel Tire Sava	4.00-6
Main Wheel Tires AirTrac A-A1D4	5.00-5
WEIGHTS
Maximum Take Off Weight	450 kg
Empty Weight	281 kg
Payload	169 kg
Wing Loading	34.1 kg/m2
Power Loading (Rotax 912 UL)	5.6 kg/hp
Power Loading (Rotax 912 ULS)	4.6 kg/hp

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Date: Sept. 2004

Page A-2

P92 Echo & P92-S Echo	Section A
M a i n t e n a n c e M a n u a l	GENERAL

POWERPLANT:

ROTAX 912 UL

Four stroke, four cylinder

Maximum Power 59.6 kW @ 5800 rpm (max. 5 minutes)

Maximum Continuous Power 58 kW @ 5500 rpm

Reduction Gear 1 : 2.27

ROTAX 912 ULS

Four stroke, four cylinder

Maximum Power 73.5 kW @ 5800 rpm (max. 5 minutes)

Maximum Continuous Power 69 kW @ 5500 rpm

Reduction Gear 1 : 2,43

PROPELLER:

For 912UL: TONINI GT ECHO 92/166/145

Twin blade all-wood 166 cm, fixed pitch.

For 912ULS: TONINI GT ECHO 92/172/164

Twin blade all-wood 172 cm, fixed pitch.

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Date: Sept. 2004

Page A-3

P92 Echo & P92-S Echo	Section A
M a i n t e n a n c e M a n u a l	GENERAL

FUEL

Fuel grade

Rotax 912 UL

∙Min RON 90

∙EN 228 Regular

∙EN 228 Premium

∙EN 228 Premium plus

∙AVGAS 100 LL (*)

Rotax 912 UL

∙Min RON 90

∙EN 228 Premium

∙EN 228 Premium plus

∙AVGAS 100 LL (*)

Fuel tanks	2 wing tanks integrated within the wing's leading
	edge with fuel strainer located in engine cowling
Capacity of each wing tank	35 litres (45 litres – Optional)
Total capacity	70 litres (90 litres – Optional)

(*) Please refer to “Rotax Operator’s Manual”

Oil System
Oil system type	Forced, with external oil reservoir
Oil	Lubricant specifications and grade are detailed into
	the “Rotax Operator’s Manual” and in its related
	documents
Oil Capacity:	max. 3.0 litres – min 2.0 litres

COOLING
Cooling system:	Mixed air and liquid pressurized closed circuit
	system
Coolant:	Coolant type and specifications are detailed into
	the “Rotax Operator’s Manual” and in its related
	documents.

	1st revision, October 25th 2004
Ed. 2	Date: Sept. 2004	Page A-4

P92 Echo & P92-S Echo	Section A
M a i n t e n a n c e M a n u a l	GENERAL

1 - DESCRIPTION AND GENERAL CHARACTERISTICS

The P92 Echo and P92-S Echo are a twin seat, single engine, strutted high wing, metal structure monoplane with tricycle landing gear and steerable nose gear.

Figure A-1 below shows a Three View drawing of the aircraft (P92-S Echo) while table I reports main technical characteristics and dimensions; figure A-2 shows a longitudinal section of the aircraft and figure A-3 shows the wing’s planform view.

P92 Echo

GENERAL VIEW

FIGURE A-1 P92 ECHO - THREE VIEWS

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Date: Sept. 2004

Page A-5

P92 Echo & P92-S Echo	Section A
M a i n t e n a n c e M a n u a l	GENERAL
P92-S Echo
GENERAL VIEW
FIGURE A-1BIS P92-S ECHO - THREE VIEWS

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Date: Sept. 2004

Page A-6

P92 Echo & P92-S Echo

Section A

M a i n t e n a n c e M a n u a l

GENERAL

FIGURE A-2 LONGITUDINAL SECTION

Ed. 2

Date: Sept. 2004

Page A-7

P92 Echo & P92-S Echo	Section A
M a i n t e n a n c e M a n u a l	GENERAL
FIGURE A-3 WING’S PLANFORM VIEW

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Date: Sept. 2004

Page A-8

P92 Echo & P92-S Echo	Section B
M a i n t e n a n c e M a n u a l	INSPECTIONS
	AND SERVICING

SECTION B

INSPECTIONS AND SERVICING

TABLE OF CONTENTS

1.	GROUND HANDLING..........................................................................................................	2
2.	PARKING AND TIE DOWN ................................................................................................	2
3.	JACKING................................................................................................................................	2
4.	LEVELING .............................................................................................................................	3
5.	CONTROL SETTINGS .........................................................................................................	4
6.	TRIM-TAB ADJUSTMENT .................................................................................................	4
7.	AIRCRAFT ALIGNMENT ...................................................................................................	5
8.	WEIGHING AND DETERMINATION OF THE C.G. VERTICAL ................................	6
TABLE OF WEIGHTS AND DETERMINATION OF C.G..............................................................		7
9.	CORROSION PREVENTION ..............................................................................................	8
10.	SERVICE BULLETINS ....................................................................................................	9
11.	SERVICING.....................................................................................................................	10
12.	LUBRICATION...............................................................................................................	11
INTRODUCTION ...........................................................................................................................		11
LUBRICATION POINTS (SEE FIG. B-5)........................................................................................		12
13.	INSPECTION’S POINT .................................................................................................	15
14.	INSPECTIONS ................................................................................................................	16
FOREWORD ...................................................................................................................................		16
PERIODIC INSPECTIONS.............................................................................................................		17

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Date: Sept 2004

Page B-1

P92 Echo & P92-S Echo	Section B
M a i n t e n a n c e M a n u a l	INSPECTIONS
	AND SERVICING

1. GROUND HANDLING

Moving the aircraft on ground is accomplished by pushing on the wing struts close to wing attachments or by pulling on the propeller blades close to hub. Aircraft can be steered using the rudder or, for sharp turns, by lowering the tail to raise nose wheel off the ground. In this case, owing to the favourable CG location, a gentle push on the tail cone just ahead of empennage surfaces is all that’s needed. Avoid dragging nose wheel sideways and do not attempt to counter any movement of the aircraft by handling it by its wing tips.

2. PARKING AND TIE DOWN

As a general precaution for outdoor parking, it is wise to position aircraft into the wind and to set the parking brakes or chock the wheels if chocks are available.

In severe weather and high wind conditions, aircraft tie-down is recommended. Tie ropes should be secured to the wing tie-down fittings located at the upper end of each wing strut. Secure opposite end of ropes to ground anchors. Nose gear fork may be used as fixing for forward tie-down.

Aircraft control stick should be locked using safety belts to prevent possible wind action from causing control surfaces to hit end travel.

3. JACKING

Given the low empty weight, jacking one of the main gear wheels can be accomplished even without hydraulic jack. In fact, it is sufficient that one person lifts the wing tip in proximity of the spar area before the tip, while another person positions a suitably high support, like a wooden stand or block, under the leaf spring attachment. To avoid scratching the paint, cover the stand or block with rubber or other suitable material.

In the event the leaf spring must be removed, the stand should be positioned under the cabin, just ahead of the leaf spring as shown in figure B-1.

CAUTION

As general rule, apply force to aircraft structure only on main structural elements such as frames, ribs or spars.

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Date: Sept 2004

Page B-2

P92 Echo & P92-S Echo

Section B

M a i n t e n a n c e M a n u a l

INSPECTIONS

AND SERVICING

FIGURE B-1 JACKING

4. LEVELING

Occasional levelling of aircraft may be necessary to insure proper wing incidence and/or dihedral or for exact CG location.

The aircraft is levelled when the lower cabin door sill is horizontal (see fig. B-2) and the main gear support girder is horizontal in a transversal direction. Level the aircraft using a simple level and adjust the aircraft’s tilt through shims placed under wheels or by regulating tire pressure.

POSITION THE LEVEL

ON THE INSIDE OF THE

CABIN

FIGURE B-2 LEVELLING

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Date: Sept 2004

Page B-3

P92 Echo & P92-S Echo	Section B
M a i n t e n a n c e M a n u a l	INSPECTIONS
	AND SERVICING

5. CONTROL SETTINGS

Adjustment of control surfaces must not exceed travel limits reported in table below. Zero reference mark for stabilator is on left side of aircraft (see figure below).

AILERONS (starting from tip line-up)	Up	20o	Down	15o	± 2o
STABILATOR	Up	16o	Down	3o	± 1o
TRIM (Stab. at 0o , see fig. below)		2o		12o	± 1o
RUDDER	RH	25o	LH	25o	± 2o
FLAPS (maximum travel)		0o	35o		± 2o

Cable tension should be as follows:

CONTROL CABLE TENSION: 20 daN ± 2 for all

REFERENCE RIVET

FIGURE B-3 STABILATOR ZERO REFERENCE

6. TRIM-TAB ADJUSTMENT

Travel adjustment of trim tab on tail plane should be carried out as follows:

∙Move stabilator to neutral (0 degrees) and lock in position; (this is accomplished by aligning the stabilator’s leading edge with the reference rivet located on the left side of tail cone);

∙Turn Master-Switch ON;

∙Trim to maximum pitch-up;

∙Adjust thread of hinged control rod until tab is deflected downwards 12° (use a protractor or measure downward displacement of trailing edge - 12° relates to roughly 24mm -);

∙Tighten adjustment thread lock-nut and fasten connecting pin of control rod to trimtab.

Ed.2

Date: Sept 2004

Page B-4

P92 Echo & P92-S Echo	Section B
M a i n t e n a n c e M a n u a l	INSPECTIONS
	AND SERVICING

7. AIRCRAFT ALIGNMENT

SPINNER BACK

BPLATEPOINT UPPER

A	A'

LAST RIVET ON THE LOWER

SIDE OF THE REAR WING

SPAR

C C'

	UPPER/REAR RIVET ON ALUMINIUM SKIN.
	i.e. The rivet in common between the fin's rear	G
	spar and the upper rib.

C

C'

FIRST RIVET BETWEEN THE TUBULAR SPAR AND THE OUTERMOST RIB

Main Wheels

Axle Line

FF'

FIGURE B-4 REFERENCES FOR ALIGNMENTS

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Date: Sept 2004

Page B-5

P92 Echo & P92-S Echo	Section B
M a i n t e n a n c e M a n u a l	INSPECTIONS
	AND SERVICING

Datum	length in mm
A -B	5030	± 25
A’-B	5030	± 25
A -C	4365	± 25
A’-C’	4365	± 25
C -G	1860	± 20
C’-G	1860	± 20
F -F’	1880	± 20

8. WEIGHING AND DETERMINATION OF THE C.G. VERTICAL

USE FOLLOWING GUIDELINES:

a.Carry out weighing procedure inside hangar

b.Remove any objects inadvertently left on board aircraft

c.Align nose wheel

d.Drain fuel

e.Oil, hydraulic fluids and coolants at operating levels

f.Move seats to most forward position

g.Flaps retracted (0°)

h.Control surfaces in neutral position

i.Position scales (min. capacity. 200 kg) under each tire

LEVELLING

a. Level the aircraft (see paragraph 4)

WEIGHING

a.Record weights of individual scales

b.Calculate empty weight

DETERMINATION OF C.G.

a.Dropping a plumb bob tangent to the wing’s leading edge, (in the untapered section of the wing, at about one meter from the root), trace a reference mark on floor.

b.Repeat operation on other wing.

c.Connect the two reference marks with a taut line

d.Measure distances between reference line and landing gear axes

e.Recorded data allows determination of C.G. location and aircraft’s moment (see following table)

Ed.2

Date: Sept 2004

Page B-6

P92 Echo & P92-S Echo	Section B
M a i n t e n a n c e M a n u a l	INSPECTIONS
	AND SERVICING

TABLE OF WEIGHTS AND DETERMINATION OF C.G.

Kg

Wheel weight front			W1 =
“	“	LH	WL =
“	“	RH	WR =
	W2=WL+WR=

				meters
Distance from bob to LH wheel			AL =
“	“	RH “	AR =
Distance average (AL+ AR)/2			A	=
Distance from bob to nose wheel.			B	=

Empty weight		We =W1 + W2	=	D =	W2	× A -W1	× B	= ___________meters
						We
CG position as wing chord %				De% = De / 1.4 × 100 =

Ed.2

Date: Sept 2004

Page B-7

P92 Echo & P92-S Echo	Section B
M a i n t e n a n c e M a n u a l	INSPECTIONS
	AND SERVICING

9. CORROSION PREVENTION

It is important to keep the aircraft clean and to remove any collection of corrosive agents such as oil, grease, dregs and other foreign matter. To avoid damage to finish do not use polishing detergents.

Original or equivalent corrosion prevention must be re-applied after any alteration or repair.

If any trace of corrosion is detected it should be removed as soon as possible and part should be immediately treated to prevent further corrosion.

(a) For steel parts, with the exception of highly stressed components or stainless steel, it is possible to use abrasives, power brushes, steel brushes if operated manually and steel wool.

Removing corrosion byproducts from highly stressed steel components (main gear steel spring) requires particular care.

(b) For aluminium parts, treatment consists in mechanically removing as much as possible corrosion byproducts, applying corrosion inhibitor and replacing original finish.

Steel wool, emery or steel brushes (unless stainless steel) along with other highly abrasive material should not be used since steel or emery particles become embedded in the softer material causing corrosion.

After cleaning surface corrosion, parts must be treated with anti-corrosion finish.

Ed.2

Date: Sept 2004

Page B-8

P92 Echo & P92-S Echo	Section B
M a i n t e n a n c e M a n u a l	INSPECTIONS
	AND SERVICING

10. SERVICE BULLETINS

The following table must report all servicing bulletins pertaining to the aircraft’s operating life.

NR.	TITLE	TYPE

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Date: Sept 2004

Page B-9

P92 Echo & P92-S Echo	Section B
M a i n t e n a n c e M a n u a l	INSPECTIONS
	AND SERVICING

11. SERVICING

For scheduled servicing on engine Rotax 912, please refer to the Rotax documentations. The list below includes only primary engine maintenance operations.

DAILY

1.Pitot and static ports - Check for obstructions (see section E);

2.Oil - Check oil level in reservoir located on firewall.

3.Coolant - Check coolant level in overflow reservoir located on firewall;

4.Fuel strainer - Drain off any water and sediment by opening tap and collecting an amount of fuel at least equal to cup’s capacity.

5.Fuel tank vents - Check for obstructions.(see section E)

EVERY 100 HOURS

6.Flange carburettor - Visually inspect rubber flange connecting carbs to engine.

7.Battery - Check level of electrolyte.

8.Engine oil - Change engine oil and replace filter element (refer to Operator’s Manual of ROTAX 912); initially after first 25 hours.

9.Brake fluid - Check level of brake fluid in the master cylinder located below the left seat. Add fluid as needed using MIL H5606 standard type UNIVIS J43.

10.Fuel filter – Check and eventually clean the fuel filter of the electric pump (if installed).

11.Fuel line and carburettor air filter - Visually inspect fuel lines. Remove filter and clean accurately. Repeat operation more often in dusty conditions. If aircraft is equipped with carb heat system, scoop filter shall in any case be replaced (automotive type air filter: Autobianchi Y10).

12.Propeller - Check attachment bolts for integrity, tightening torque (18 Nm) and safetying, initially after the first 25 hours.

Ed.2

Date: Sept 2004

Page B-10