Tecnam P92 ECHO, P92-S ECHO User Manual
Maintenance
Manual
Doc. n° 92/115
2nd Issue, September 10th, 2004
1st Revision, October 25th, 2004
Ed
.2
efore flying the aircraft we recommend reading carefully this manual, the flight
B
P92 Echo & P92-S Echo
Maintenance Manual
INTRODUCTION
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
a
1
Traversa via G.Pascoli
TECNAM
s.r.l.
80026 Casoria (NA) - ITALY
081-7583210 081-7584528
Date: Sept. 2004
Page . i
Ed
.2
P92 Echo & P92-S Echo
Maintenance Manual
INTRODUCTION
SECTIONS
General Section A
Inspections and Servicing Section B
Airframe Section C
Powerplant and Propeller Section D
Systems Section E
Date: Sept. 2004
Page . ii
P92 Echo & P92-S Echo
Maintenance Manual
Section A
GENERAL
SECTION A
GENERAL
TABLE OF CONTENTS
1 - DESCRIPTION AND GENERAL CHARACTERISTICS-------------------------------------------- 4
Ed. 2
Page A-1 Date: Sept. 2004
P92 Echo & P92-S Echo
Maintenance Manual
Section A
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
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
AirTrac A-A1D4
5.00-5
Ed. 2
Page A-2 Date: Sept. 2004
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
P92 Echo & P92-S Echo
Maintenance Manual
Section A
GENERAL
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.
Ed. 2
Page A-3 Date: Sept. 2004
1st revision, October 25
th
2004
FUEL
P92 Echo & P92-S Echo
Maintenance Manual
Section A
GENERAL
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.
Ed. 2
Page A-4 Date: Sept. 2004
P92 Echo & P92-S Echo
Maintenance Manual
Section A
GENERAL
1 - DESCRIPTION AND GENERAL CHARACTERISTICS
The
P92 Echo
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
and
P92-S Echo
are a twin seat, single engine, strutted high wing, metal
F
IGURE
A-1 P92 E
CHO - THREE VIEWS
Ed. 2
Page A-5 Date: Sept. 2004
P92-S Echo
GENERAL VIEW
P92 Echo & P92-S Echo
Maintenance Manual
Section A
GENERAL
F
IGURE
A-1
BIS
P92-S E
CHO - THREE VIEWS
Ed. 2
Page A-6 Date: Sept. 2004
P92 Echo & P92-S Echo
Maintenance Manual
Section A
GENERAL
F
IGURE
Ed. 2
A-2 L
ONGITUDINAL SECTION
Page A-7 Date: Sept. 2004
P92 Echo & P92-S Echo
Maintenance Manual
Section A
GENERAL
F
IGURE
A-3 W
ING’S PLANFORM VIEW
Ed. 2
Page A-8 Date: Sept. 2004
P92 Echo & P92-S Echo
Maintenance Manual
Section B
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.
Ed.2
INSPECTION’S POINT .................................................................................................15
14.
INSPECTIONS................................................................................................................16
FOREWORD...................................................................................................................................16
PERIODIC INSPECTIONS............................................................................................................. 17
Page B-1 Date: Sept 2004
P92 Echo & P92-S Echo
Maintenance Manual
Section B
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.
Ed.2
Page B-2 Date: Sept 2004
N THE LEVEL
ON THE INSIDE OF THE
CABIN
P92 Echo & P92-S Echo
Maintenance Manual
Section B
INSPECTIONS
AND SERVICING
F
IGURE
B-1 J
ACKING
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.
POSITIO
Ed.2
F
IGURE
B-2 L
EVELLING
Page B-3 Date: Sept 2004
P92 Echo & P92-S Echo
Maintenance Manual
Section B
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
STABILATOR Up 16o Down 3o
TRIM (
RUDDER RH 25o LH 25o
FLAPS (
(starting from tip line-up
Stab. at 0o , see fig. below
maximum travel
)
)
)
Up 20o Down 15o
2o 12o
0o 35o
Cable tension should be as follows:
CONTROL CABLE TENSION: 20 daN ± 2 for all
REFERENCE RIVET
± 2o
± 1o
± 1o
± 2o
± 2o
F
IGURE
B-3 S
TABILATOR 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 trim-
tab.
Ed.2
Page B-4 Date: Sept 2004
P92 Echo & P92-S Echo
Maintenance Manual
7. AIRCRAFT ALIGNMENT
Section B
INSPECTIONS
AND SERVICING
A
UPPER/REAR RIVET ON ALUMINIUM SKIN.
i.e. The rivet in common between the fin's rear
spar and the upper rib.
C
B
G
SPINNER BACK
PLATE UPPER
POINT
FIRST RIVET BETWEEN THE
TUBULAR SPAR AND THE
C'
OUTERMOST RIB
A'
LAST RIVET ON THE LOWER
SIDE OF THE REAR WING
SPAR
Ed.2
C
C'
Main Wheels
F
Axle Line
F'
F
IGURE
B-4 R
EFERENCES FOR ALIGNMENTS
Page B-5 Date: Sept 2004
P92 Echo & P92-S Echo
Maintenance Manual
Section B
INSPECTIONS
AND SERVICING
Datum length in mm
A -B 5030
A’-B 5030
A -C 4365
A’-C’ 4365
C -G 1860
C’-G 1860
F -F’ 1880
± 25
± 25
± 25
± 25
± 20
± 20
± 20
8. WEIGHING AND DETERMINATION OF THE C.G. VERTICAL
U
SE 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
:
Ed.2
L
EVELLING
a. Level the aircraft (see paragraph 4)
W
EIGHING
a. Record weights of individual scales
b. Calculate empty weight
D
ETERMINATION OF
C.G.
a. Dropping a plumb bob tangent to the wing’s leading edge, (in the un-
tapered 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)
Page B-6 Date: Sept 2004
WAW
B
We
⋅−⋅
P92 Echo & P92-S Echo
Maintenance Manual
TABLE OF WEIGHTS AND DETERMINATION OF C.G.
Section B
INSPECTIONS
AND SERVICING
Kg meters
Wheel weight front
“ “ LH
“ “ RH
W2=WL+WR=
W1 =
WL =
WR =
Distance from bob to nose wheel.
Distance from bob to LH wheel
“ “ RH “
Distance average (AL+ AR)/2
A
=
L
AR =
A =
B =
Empty weight W
e =W1 + W2
=
D
=
2 1
=
___________meters
CG position as wing chord %
De% = De / 1.4 ⋅ 100 =
Ed.2
Page B-7 Date: Sept 2004
P92 Echo & P92-S Echo
Maintenance Manual
Section B
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
Page B-8 Date: Sept 2004
P92 Echo & P92-S Echo
Maintenance Manual
Section B
INSPECTIONS
AND SERVICING
10. SERVICE BULLETINS
The following table must report all servicing bulletins pertaining to the aircraft’s
operating life.
NR. TITLE TYPE
Ed.2
Page B-9 Date: Sept 2004
P92 Echo & P92-S Echo
Maintenance Manual
Section B
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.
D
AILY
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
Page B-10 Date: Sept 2004
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