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SERVICE MANUAL - Long Island Flying

1. 39V T3Snd yNYL T3043 38 ALLLNVAOO 1905 STANDARD FUEL SYSTEM REAR TANK Fig 19 3 Apr 96 8 4 ZENAIR CH2000 SERVICE MANUAL NOILdO SATIVA 1303 HIVONV NO1V109SV9 OL 9 SH 9 99 621 ONIM 1431 OL ONIM NIYW 3 2 0253 gt 8 5 9 89 42 YyOLSYNEYVO ONILLIS TANS TIVMV 3314 S lt N SNIM 4 5 OL 9 SH 9 89 651 5946 ONIM 1005 9 TANVd SS399V 335 H39NIJ dnd 1303 33O 1H9I8 1331 N3339S H39NIJ NOlO313S 3nd 197470 1903 S3Nn and a104INVW e Jans 3ATVA T1303 ONISN N3HM dVdS GNIH38 H3AO 585059 SANIT 1905 ALON LHOW H3ON3S ALILNVND 13nd ANVL 1303 1303 TVOINVHO3W een OPTIONAL FUEL SYSTEM WING TANKS Fig 20 8 5 3 Apr 96 ZENAIR CH2000 SERVICE MANUAL SECTION IX INSTRUMENTS GENERAL The instrumentation in the CH2000 is designed to give a quick and actual indication of the attitude performance and condition of the airplane The instrument panel has been arranged to accommodate all the advanced flight instruments in front of the pilot Fig 21 The two types of instruments installed in the CH2000 have been classified in this section as standard and optional The first part of this section will pertain to maintenance and troubleshooting
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3. 12109 NOLLVIOSI NOLLVUALA SSY PNOIYS Jodse Z 1 dg 229913 JoUSeAA 7 2 WIH OL OL 1 814 205 A NNI QED 7 POWERPLANT Fig 12 Nov 02 6 2 ZENAIR CH2000 SERVICE MANUAL REMOVAL OF ENGINE Fig 12 Remove the propeller Remove top and bottom cowl Disconnect the heat hose from the muffler and front baffle Disconnect the mechanical fuel pump inlet line Disconnect the fuel inlet line at the carburetor Disconnect the starter lead Disconnect the alternator leads Disconnect the grounding wire Disconnect the control cables from the engine components throttle mixture carb heat 10 Disconnect the tachometer cable from the rear of the engine 11 Disconnect the hoses from the vacuum pump option 12 Disconnect the magneto P leads Insert a protective cover over the connection 13 Disconnect the oil pressure wire Disconnect manifold pressure line from the left rear cylinder of the engine option 14 Attach a 1 500 Lbs minimum hoist to the hoisting hook and relieve the tension on the engine mount 15 Place a tail stand under the tail of the aircraft before removing the engine 16 Check the engine for any attachments remaining to obstruct its removal 17 Remove the cotter pins nuts washers rear rubber m
4. 727 ws ES n 1 3 20414 2 612837105 nonN utes NN 52346 W 3 0 QXTNASN SDINOIAY SV AYVA 33 358 ILON 270w EH 5 72 401075 2 WOLDSNNGD WOI23NNO2 9 Su ELECTRIC WIRING Fig 24 10 3 Oct 00 ZENAIR CH2000 SERVICE MANUAL REPLACEMENT OF THE BATTERY Remove the rear fuselage side access panel See Fig 2 2 Remove the bolts holding the battery tie down brackets Caution Always remove the ground cable first and install it last to prevent accidental short circuit 3 Remove the two battery terminals from the battery post 4 Remove the battery with its container from the aircraft 5 Remove battery from container REINSTALL in reverse order SERVICING THE BATTERY The battery should be checked for proper fluid level but must not be filled above the baffle plates A hydrometer check should be performed to determine the specific gravity of the electrolyte 1 268 standard and 1 285 for better cold weather cranking capacity All connections must be clean and tight If battery is not up to normal charge recharge starting with a charging rate of 4 amperes and finishing with 2 amperes The normal charged battery will indicate 11 5 Volts or more CHARGING SYSTEM The charging system consists of a 3 phase delta connected alternator with integral silicone diode rectifiers rated 14
5. Security and defects 28 Perform operational checks of all Section VI systems fuel oil heating etc 3 4 Nov 02 TABLE 1 ZENAIR INSPECTION FORM Make Model Serial No Airframe Hours Type of Inspection ZENAIR CH2000 Circle One Registration No Engine Hours 50 100 500 1000 Symbols Indicates perform task Indicates do not perform task Intervals Task Refer to Flight Hours Initials 50 100 500 1000 CABIN GROUP 1 Inspect the control wheels linkages Section VII column and torque tube assemblies for cracks distortion etc 2 Check controls for ease of operation Section VII and correct travel 3 Check operation cockpit lights and Section X external lights 4 Check operation of all circuit breakers Section X and switches 5 Check flight control cables for routing Section VII fraying corrosion and tension Inspect flight control turnbuckles Section VII pulleys and guides for wear damage and safeties 6 Check stabilator trim tab indicator for Section VII correct operation 7 Inspect the flap motor actuator Section VII extension tube actuator lever interconnect tubes control levers and control rods for cracks distortion security etc 7a flap indicator cable and Section VII indicator f
6. corrosion damage etc Manual 3 Inspect spinner and backing plate Engine Group Danger Ground magneto primary circuit before working on engine Section X 1 Check for oil fuel leaks 2 Check for particles on oil suction screen Lycoming Operator s and sump drain plug Manual Section 7 3 Drain oil and refill Lycoming Operator s Manual Section 7 4 Perform cylinder compression test 5 Clean the spark plugs Adjust gap at 018 to 022 6 Check and set magneto timing at 20 Lycoming Operator s Manual Section 5 7 Check magneto breaker points and Lycoming Operator s lubricate breaker point felt Manual Section 4 8 Clean oil suction and oil pressure Lycoming Operator s Screens Manual Section 4 Section VI 9 Inspect the wet type foam air filer 10 Inspect the exhaust manifold for cracks Section XI carb and cabin heat shroud removed 150 HR INTERVALS Ref AD CF 90 03R2 11 Inspect the heat shrouds for cracks etc 12 Inspect the motor mount fuselage and Section VI engine attachment points and braces 13 Inspect the rubber engine vibration isolating mounts for cracks damage etc 3 3 02 TABLE 1 ZENAIR INSPECTION FORM Make Model Serial No ZENAIR CH2000 Airframe Hours Type
7. 847 the filler neck to wing skin joint 4 Check all connections for conditions leaks and safety CAUTION With wing tanks option verify that the fuel lines cross over behind the spar as illustrated on Fig 20 FINGER SCREENS Fig 19 and Fig 20 The finger screens are easily accessible at the tank outlet 1 Drain the tank 2 Disconnect the fuel lines 3 Unscrew the finger screen fitting REINSTALL in reverse order after inspection and cleaning Check the connection for condition leaks and safety FUEL VALVE Fig 19 and Fig 20 The fuel valve is situated between the seats and is attached with two bolts to the underside of the seat panel REMOVAL 1 Drain fuel from rear tank if installed 2 Disconnect fuel lines from fuel valve 3 Remove bolts securing the fuel valve REINSTALL in reverse order of removal and check all connections for conditions leaks operation and safety NOTE To gain access to the fuel sender unit the wing tanks must be removed For sender removal see page 8 1 AUXILIARY FUEL PUMP Fig 19 and Fig 20 The auxiliary fuel pump is bolted to the front of the firewall REMOVAL 1 Ensure fuel valve is in OFF position 2 Disconnect fuel lines from pump 3 Disconnect electrical wiring from pump 4 Remove pump attachment bolts REINSTALL in the reverse order of removal and check all connections for conditions and safety Open the fuel valve and run the pump check for leaks CAUTION Verify
8. bearings 7 Inspect the master and slave brake Section V cylinders brake lines connections for damage corrosion leaks etc Service the master brake cylinders Inspect the rubbers at the main landing Section V gear attachments for condition and abrasion damage and position 8 When removing wheel the airplane Section V hoisted remove the nose wheel and inspect wheel for cracks corrosion etc 9 Inspect the nose gear lower front bearing plate cam centering steering connections strut strut supports and stop plate for cracks distortion corrosion etc 10 Inspect the steering rods for security distortion etc 11 Inspect the shock cord for damaged Section V threads and weakness 12 Inspect the lower shock ring supportfor Section V cracks distortion etc 13 Check tire pressure 30 PSI Section V 14 When removing wheel inspect the nose Section V wheel axle bolt spacers and axle for wear damage corrosion etc Nov 02 3 7 TABLE 1 ZENAIR INSPECTION FORM Make Model Serial No Airframe Hours Type of Inspection ZENAIR CH2000 Circle One Registration No Engine Hours 50 100 500 1000 Symbols Indicates perform task Indicates not perform task Intervals Task Refer to Flight Hours Initials 50 100 500 1000 Wing Group 1 Check the
9. designed and manufactured as a versatile two seat aircraft in the personal and training aviation field SCOPE OF MANUAL Sections II and III comprise the service part of this manual whereas Sections IV through XI comprise the maintenance instructions The service instructions include ground handling servicing and inspection periods The maintenance instructions for each system include troubleshooting removal and installation of components and corrective maintenance and testing each major system of the aircraft is covered in a separate section Only qualified personnel should perform the operations described in this manual In the text reference is made to the following publications General Owner s Manual or Aircraft Flight Manual CH2000 ZENAIR Parts Catalogue CH2000 ZENAIR Engine Operator s Manual and overhaul manual Series O 235 engines Textron Lycoming Propeller Prop Logbook instructions for use and care Sensenich Prop Co AC 43 13 1B Aircraft Inspection Repair and Alteration is a useful handbook published by the FAA Aircraft Powerplants published by McGraw Hill ISBN 0 07 035569 15 the standard reference for the mechanic working on the engine The description of the aircraft included in this section is limited to general information however the figure gives specific external dimensions Nov 02 1 1 ZENAIR CH2000 SERVICE MANUAL DESCRIPTION Fig 1 The Zenair CH2000 is a s
10. r M 930 1 930 rL 93094V 930 GLC O30 936 k 6 94 33S NYOH ONIN331S tiv39 ISON u3oans D vod SavaTHlvd SOY 9NId33l1S 8 33S SNIHSn8 Fig 18 7 1 Nov 02 ZENAIR CH 2000 SERVICE MANUAL SECTION VIII FUEL SYSTEM GENERAL The CH2000 has two fuel tank options one rear tank Fig 19 two wing tanks Fig 20 The Figures show the line routing and accessories When work is performed on the fuel system assure good ventilation no smoking ready availability of fire fighting equipment TROUBLE SHOOTING See Table p 8 3 REAR TANK SYSTEM Fig 19 The rear tank is held in place under the baggage shelf by two straps A rubber hose with hose clamps connects the filler to the tank Vent is through the cap The strainer finger screen is at the tank outlet The larger fuel hose connected to the easy drain beside the gascolator under the fuselage left side near the wing leading edge is the fuel tank sump The fuel valve is of the ON OFF position type REPLACEMENT OF REAR TANK Drain the fuel from tank Disconnect the filler neck Disconnect the wiring from sender unit See Fig 19 and Fig 2 Disconnect the fuel lines at the tank outlet bottom of tank Disconnect the grounding left side bottom of tank Disconnect the straps bolts and remove the tank QA O REINSTALL in the r
11. Lycoming Manual In particular LUBRICATION See Lycoming Manual pages 4 3 4 4 and 5 8 MAGNETO TIMING If timing is required see Lycoming Manual pages 4 4 and 5 1 IDLE SPEED and MIXTURE ADJUSTMENT If idle RPM needs adjustment see Lycoming Manual page 5 7 for the procedure and Fig 13 in the present Manual for the location of the adjusting screws ENGINE TROUBLE SHOOTING See Lycoming Manual Section 6 NOTE The magneto wiring is shown in the Lycoming Manual on Fig 5 1 Feb 00 6 5 ZENAIR CH2000 SERVICE MANUAL SECTION VII FLIGHT CONTROL SYSTEM GENERAL Fig 15 through 18 The CH2000 is controlled in flight by the use of the three standard primary flight control surfaces consisting of the ailerons stabilator and the rudder Operation of these controls is through the movement of the control wheel and rudder pedals The individual surfaces are connected to their control components by the use of cables and push pull rods Provision for longitudinal trim control is provided by an anti servo trim tab The flaps are electrically operated through an interconnecting tube and adjustable rods This section describes the replacement and rigging of the control cables See Section IV for the control surface replacement The movable surfaces have stops as well as adjustments on their cable or control rod connections so that their range of movement can be altered The positions and travel as well as cable tension of the various sur
12. b Check prop flange re crankshaft damage Lightning Strike a Check ELT for inadvertent activation b Check skins for damages Check control connections for damages Bird Strike Check the area for damages Exceedence of Operational Limits Refer to applicable manuals INSPECTION AFTER SPECIFIED MAINTENANCE ACTIONS Inspections are to be performed one time only following the performance of the following tasks Installation of new alternator Check belt for condition and tension at 25 hours of belt drive belt operation Ref Lycoming Service Instruction 114 Installation of new Perform a 50 hour engine inspection Ref Section 4 of re manufactured or overhauled engine Lycoming Operator s Manual CORROSION CONTROL To avoid the deterioration of the CH2000 aircraft due to the effects of corrosion monitor the condition of protective coatings on exterior and interior surfaces If damage to coatings is found restore surfaces prior to the occurrence of damage caused by environmental effects INSPECTION SCHEDULE The required inspection tasks and their intervals are listed in Table 1 The tasks are placed in seven groups Propeller Engine Cabin Landing Gear Wing Fuselage and Empennage The first column of Table 1 states the task to be performed the second column states the applicable references s The third column is divided into four sub columns each of which corresponds to an inspection interval The last column m
13. for the co pilot RADIO Provisions for radio installations consist of microphone and headset jacks and mounting brackets necessary wiring and panel space for extra radios CABIN HEATER DEFROSTER AND FRESH AIR SYSTEM Heated air for the cabin and defroster is obtained directly from the exhaust system muffler shroud Fresh air is supplied to the cabin through two individual and orientable air inlet vents in the right and left door window INSTRUMENTS Provisions for optional instruments are provided including full IFR equipment 1 2 3 Apr 96 ZENAIR CH2000 SERVICE MANUAL 1950 6 57 7140 23 5 1420 567 1167 467 8780 28 10 CH 2000 GENERAL DIMENSIONS Fig 1 3 Apr 95 1 3 ZENAIR CH2000 SERVICE MANUAL SECTION II HANDLING AND SERVICING GENERAL This section provides ground handling and servicing instructions Recommended ground handling procedures and recommended methods of servicing are provided in following paragraphs If trouble or damage to the aircraft is discovered during ground handling or servicing refer to the appropriate section for the system concerned Lubrication is treated as a separate function ACCESS PROVISIONS Fig 2 The figure shows the location and identity of the access doors and panels that provide access for purposes of service and maintenance GROUND HANDLING GENERAL The aircraft must not be pushed pulled or lifted by any other
14. gt d jji iii nj AXLE BRACKET lt o 4 s Nc 1 777 AXLE BOLT Bg A Dl 7 7 FRWD PARKER HANNIFIN BRAKE ASSEMBLY SEE FIG 11 MAIN GEAR Fig 10 COTTFR PIN TAPERED PIN Z N Older Style Main Gear Nov 02 5 5 ZENAIR CH2000 SERVICE MANUAL Savd 5 4 L104 NO JAIM AL3JVS 9 oA 4 3M V 00600 08 AXTHINGISS V NIJINNVH EJM IVd SANTI HM Vad NIJINNVH XANAYA WATT IVQ3Id 3X V IH BRAKE SYSTEM Fig 11 Nov 02 5 6 ZENAIR CH2000 SERVICE MANUAL SECTION VI POWER PLANT GENERAL The CH2000 is powered by a Lycoming engine Model O 235 N2C rated at 116 BHP at 2800 RPM The engine has a compression ratio of 8 1 to 1 and requires 100 100LL octane fuel The engine has a light weight starter 60 amp 12 volt alternator voltage regulator shielded ignition vacuum pump drive fuel pump and a carburetor with air intake box and filter The exhaust system is stainless steel with heater shrouds to supply heat for both the cabin and carburetor The engine is equipped with a Sensenich fixed pitch all metal propeller Model 72 CK 0 46 or 48 TROUBLESHOOTING Troubles peculiar to the power plant are listed in the Lycoming manual See Section I along with their probable causes and suggested remedies When troubleshooting the engine ground the
15. instrument Barometric scale and reference Slippage of mating parts Replace instrument markers out of synchronism Barometric scale and reference Drift in mechanism Reset pointers markers out of synchronism with pointers e PITOT STATIC SYSTEM See Owner s Manual Section 7 REMOVAL OF PITOT STATIC Remove the three retaining screws 2 Remove the lines from the barbed fittings REINSTALL in reverse order Check for leaks proper installation operation and safety Tygon splice for pitot static connection at wing root must be replaced with new material whenever removed ALTIMETER VERTICAL SPEED OPTIONAL AIR SPEED INDICATOR DYNAMIC PRESSURE ALTERNATE STATICY IFR OPTION 7 PITOT STATIC HEATED IFR OPTION 7 Jul 95 9 3 ZENAIR CH2000 SERVICE MANUAL e MAGNETIC COMPASS GENERAL The magnetic compass installed in the CH2000 is a self contained instrument and is mounted at the windshield top The compass correction card is located in the card holder mounted on the instrument panel TROUBLESHOOTING See following table Excessive card error Excessive oscillation Sluggish Liquid leakage Discolored markings 9 4 MAGNETIC COMPASS Compass not properly compensated External magnetic interference Improper mounting on instrument panel Insufficient liquid Weak card magnet Excessive pivot friction or broken jewel Instrument too he
16. key locks on the outside 1500 Ibs MIN CAPACITY HOIST NOSE GEAR WHEEL HOISTING 2 4 Nov 02 ZENAIR CH2000 SERVICE MANUAL 24 LEVEL DOOR SILL 48 LEVEL RIGHT ur UPPER LONGERON SECTION AIRCRAFT LEVELING Fig 4 Oct 00 2 5 ZENAIR CH2000 SERVICE MANUAL SERVICING FUEL SYSTEM FILLING FUEL TANKS Observe all required precautions for handling gasoline Fill the fuel tanks with the fuel specified in the engine Operator s Manual DRAINING FUEL VALVE AND STRAINER Fig 5 The Gascolator is located under the fuselage near the left wing leading edge It has a Curtis type easy drain valve and can be opened to clean the fuel filter Note fuel shut off valve should be in the OFF position when opening the Gascolator The Gascolator should be drained regularly to check for water REAR FUEL TANK SYSTEM The fuel tank and sump are drained through the Curtis valve beside the Gascolator The fuel strainer at the tank outlet is accessed for removal and cleaning through the large access door under the fuselage see page 7 9 of Owner s Manual or AFM WING TANKS OPTION The fuel tanks and sumps are drained through the Curtis valves under the wings just rear of the wheels The fuel strainers at the tank outlets are accessed for removal and cleaning through the access panels beside the Curtis valves see next page F 5 Also page 9 6 of Owner s Manual or AFM 2 6 Feb 00 ZENAIR CH20
17. means than those described Procedures are given for the proper execution of all necessary handling operations and if the instructions are followed damage to the aircraft or its equipment will be prevented Caution Use the utmost care at all times during ground handling operations STEP HANDHOLD AND WALKWAYS A fixed step is located on each side below and aft of the inboard end of the wing trailing edge and fixed handholds are located on the sides of the fuselage above the aft upper corner of the rear window The walkway is made up of a non skid compound applied to the wing surface Caution Walk on the walkways only to avoid damage to the wings 3 Apr 95 2 1 ZENAIR CH2000 SERVICE MANUAL NOLLdO TAN V 5 SUANALSVA ONIAOWAY MNVL ONIM TANA NOLLAVO NOLLdO ONIM 3LLV Id NOLLOGIdSNI MNV2OTT3S IN Vd SSAQOV 850 TAIN Vd SS320V SIETO LLS 7 S TANVd ACIS NOLLdO 3 LV Id 350V95 TANA ONIM NOLLdO SONT2HIVA TAOJ AAMOT INTO NGHE NOLLdO 9 IMOD NOLLO IdSNI suood NIIVO J AO 30V L TANA CH2000 ACCESS PANELS Fig 2 Oct 00 22 ZENAIR CH 2000 SERVICE MANUAL HOISTING Fig 3 Nose Gear Hoisting Remove the cowl and lift the aircraft with a hoi
18. of Inspection Circle One Registration No Engine Hours 50 100 500 1000 Symbols Indicates perform task Indicates do not perform task Intervals Task Refer to Flight Hours Initials 50 100 500 1000 14 Inspect engine for security of all attaching hardware nuts bolts screw etc 15 Perform valve clearance check 0 010 Lycoming Operator s Manual Section 5 16 Inspect the ignition harnesses for general condition 17 Inspect the carburetor air intake box for leaks 18 Drain carburetor and clean carburetor Section VI fuel strainer and strainer bowl 19 Inspect engine cowlings for cracks Section VI damage loose rivets etc 20 Inspect the vacuum pump lines and Section VI separator 21 Change the Oil filter Section VI 22 Inspect the oil radiator oil lines and attaching brackets 23 Clean and flush oil radiator Section VI 24 Inspect engine firewall and firewall seals for deterioration cracking etc 25 Inspect cabin heat control box for Section XI cracks condition etc 26 Inspect engine controls for defects Section VI safeties etc Check control travels 27 Check starter alternator fuel pump Section VI and vacuum pump for proper mounting
19. provided by an air heater installed on the exhaust manifold Fresh air enters the engine compartment through the nose cowling and is vented to the heater muff through a flexible hose located on the baffling at the front of the engine The air is then heated and vented into the cabin area through a valve which can be controlled from the instrument panel When the valve is completely closed off the heated air is vented back into the engine compartment The heater outlet in the cabin is located in front of the pilot s feet The windshield is kept clear of frost by a defroster system which operates from the heater Fresh air is supplied to the cabin by adjustable vents in the right and left door windows HEATER MAINTENANCE 1 Disconnect the hoses of the cabin heat shroud 2 Remove the heat shroud and inspect the outer surface of the inner core exhaust pipe for signs of combustion products 3 Thoroughly clean the exhaust pipe of all dirt and corrosion 4 Carefully inspect the exhaust pipe using a hand held magnifying glass and light mirror for signs of cracks and pinholes Pay particular attention to welds seams and their adjacent areas 5 Any suspect areas are to be further evaluated by a pressure test or other means 6 Repair or replace before further flight exhaust pipe containing cracks or holes REINSTALL the heat shroud and hoses in reverse order of removal CABIN HEAT CONTROL Check the operation of the push pull control
20. rivets and pulling it out Reinstall with blind rivets at the same location to obtain the warning buzzer 5 kts above the stall speed LANDING LIGHT REPLACEMENT Located in the right wing Leading edge near the wing tip Remove the polycarbonate cover 2 Remove the four screws of the retaining ring 3 Change light bulb GE 4509 4 Reassemble and install in reverse order 10 6 3 Apr 95 ZENAIR CH2000 SERVICE MANUAL TABLE ELECTRICAL SYSTEM TROUBLESHOOTING BATTERY Discharged battery Battery worn out Replace battery Charging rate not set right Reset Standing too long Remove and recharge battery if left in unused airplane for too long Equipment left on Remove and recharge accidentally Impurities in electrolyte Replace electrolyte Short circuit ground in Check wiring wiring Broken cell partitions Replace battery Battery life 1 short Overcharge due to level of Maintain electrolyte electrolyte being below top of plates Sulfation due to disuse Replace battery Impurities in electrolyte Replace battery Cracked cell jars Hold down bracket loose Replace battery and tighten Frozen battery Replace battery Excessive corrosion inside Spillage from overfilling Use care in adding water container Battery freezes Discharged battery Replace battery Water added and battery Always recharge battery not charged immediately for 1 2 hour following addition of water in freez
21. torque and safeties of the Section IV front spar main spar and rear spar wing to fuselage attachment bolts 2 Inspect the external surfaces of the ailerons and flaps for cracks deformation etc 3 Inspect the aileron and flap hinge pins Section Il 5 for corrosion wear safeties and adequate lubrication 4 Inspect flap and aileron rods and rod Section VII attachment bolts for wear damage safeties etc 5 Inspect aileron bellcranks stops Section VII cable ends and pulley assembly for cracks damage corrosion safeties etc 6 Inspect upper and lower wing skins and leading edges for cracks loose fasteners damage etc Section 7 Lubricate the aileron and flap hinges control rod ends bellcranks etc 8 Inspect the dual landing taxi lights for security clean lenses etc Section n 9 Drain water from wing fuel tanks if applicable using sump drains Check sump drains for leaks Clean fuel strainers 10 Check fuel tank filler caps if installed for security condition etc 2 11 Perform an operational check of the stall warning system 3 8 Nov 02 TABLE 1 ZENAIR INSPECTION FORM Make Model Serial No Airframe Hours Type of Inspection ZENAIR CH2000 Circle One Registration No Engine Hours 50 100 5
22. 0 025 9 FIBERGLASS FIRE RESISTANT 29 FIBERGLASS 10 FIBERGLASS FIRE RESISTANT 30 6061 T6 0 016 11 6061 T6 0 025 31 6061 T6 0 016 12 6061 T6 0 025 32 6061 T6 0 032 13 6061 T6 0 025 33 6061 T6 0 032 14 6061 T6 0 025 34 6061 T6 0 025 15 6061 T6 0 025 35 6061 T6 0 016 16 6061 T6 0 025 36 FIBERGLASS 17 6061 T6 0 025 37 6061 T6 0 016 18 6061 T6 0 025 38 FIBERGLASS OPTIONAL 19 6061 T6 0 025 39 FIBERGLASS OPTIONAL 20 6061 T6 0 025 40 6061 T6 0 016 CH2000 SKIN SPECIFICATIONS Fig 7 Nov 02 4 3 ZENAIR CH2000 SERVICE MANUAL STRUCTURE d REPLACEMENT OF RUDDER Fig 8 REMOVAL O Disconnect the two control cables from the rudder horn Disconnect the grounding cable and the tail light wiring Remove the lower hinge bolt Remove the upper hinge bolt and remove the rudder Caution Do not lose the hinge bushings REINSTALL the rudder in reverse order of removal Check all bolts for safety REPLACEMENT OF STABILATOR Fig 8 REMOVAL ON A 4 Remove the rudder Remove the side panels See 1 Fig 8 Remove the gap filler See 2 Fig 8 Remove the bolt at trim actuator and fork See 3 Fig 8 Disconnect the electric wiring if aircraft equipped with electric trim Remove the upper and lower trim actuator support screws and remove the trim actuator assembly Disconnect the grounding cable Disconnect the control cables from the horn Note Attach
23. 00 1000 Symbols Indicates perform task Indicates not perform task Intervals Task Refer to Flight Hours Initials 50 100 500 1000 12 Perform operational check of the pitot static heater if installed 13 Perform operational check of fuel Section IX quantity indicating system Fuselage Group 1 Inspect the outer fuselage skin for cracks corrosion loose rivets damage etc 2 Inspect fuselage bulkheads stiffeners and internal structure for cracks corrosion damaged fasteners etc 3 Inspect flight control cables for routing Section VII fraying corrosion and tension 4 Inspect flight control turnbuckles pulleys and guides for wear damage and safeties 5 Check flight control torque tube bearings for wear 6 Inspect electrical wiring for condition 2 security routing damage etc 7 Inspect fuel lines for security damage and leaks 8 Inspect the battery for condition fluid 2 level and clean terminals Inspect the battery box 9 Drain water from fuselage fuel tank Section Il using sump drain if applicable Check sump drain for leaks Clean gascolator fuel filter 10 Check fuel tank filler cap if installed for security condition etc Empennage Group 1 Inspect the vertical stabilizer rudder stabilator and trim tab skins for cracks loose
24. 00 SERVICE MANUAL SUMP DRAIN FUSELAGE TANK OPTIONAL WING TANK DRAIN GASCOLATOR 2 SIDES DRAIN ACCESS TO uw FUEL STRAINER OPTIONAL WING TANK ACCESS PANEL FUEL DRAINS Fig 5 3 Apr 96 2 7 ZENAIR CH2000 SERVICE MANUAL LUBE OIL SYSTEM FILLING ENGINE SUMP Fill the engine sump with the specified lubricating oil See Owner s Manual or Engine Manual Access door on right top cowl Fig 2 DRAINING ENGINE SUMP Remove the cowl Drain the engine sump by means of the oil drain plugs at the bottom of the oil sump BRAKE SYSTEM Fig 11 on page 5 6 FILLING BRAKE CYLINDER RESERVOIRS The brake cylinder reservoirs are an integral part of the master cylinders on pilot side They must be checked at every 50 hour inspection and replenished when necessary No adjustment of brake clearance is necessary on the brakes DRAINING BRAKE SYSTEM To drain the brake system disconnect the hydraulic brake lines from the brake assembly of the main gear and place the end of each line in a suitable container Slowly pump the brakes until fluid ceases to flow To clean the brake system flush with denatured alcohol LUBRICATION Fig 6 See the chart for lubrication instructions regarding the locations time intervals and types of lubricant used Where light lubricating oil is specified but unavailable clean engine oil is a satisfactory substitute Avoid excess application of lubricants Excess lubric
25. CH2000 TRAINER with LYCOMING 0 235 N2C SERVICE MANUAL ZENAIR Ltd Huronia Airport Midland Ontario Canada LAR 4K8 705 526 2871 November 2002 ZENAIR CH2000 SERVICE MANUAL TABLE OF CONTENTS SECTION I INTRODUCTION SECTION VI POWERPLANT SECTIONII HANDLING AND SERVICING SECTION VII SURFACE CONTROLS SECTION III INSPECTION SECTION VIII FUEL SYSTEM SECTION AIRWORTHINESS LIMITATIONS SECTION IX INSTRUMENTS SECTIONIV STRUCTURE SECTIONX ELECTRIC SYSTEM SECTION V LANDING GEAR AND BRAKES SECTION XI HEATER VENTILATION SECTION CABIN DOORS LIST OF EFFECTIVE PAGES Nov 02 Nov 02 Nov 02 Apr 96 Apr 95 Apr 95 Oct 00 Nov 02 Nov 02 Oct 00 Feb 00 Apr 96 Feb 00 Feb 00 1 Sep 95 Nov 02 Oct 00 Nov 02 Nov 02 Nov 02 Nov 02 Nov 02 Nov 02 Nov 02 Nov 02 Nov 02 Apr 95 Nov 02 Oct 00 Oct 00 NO NO NO o NNN O CA CA CA 1 1 1 2 2 2 2 2 2 2 2 2 3 3 3 3 3 3 3 3 3 3 3 4 4 4 4 4 Nov 02 0 1 ZENAIR CH2000 SERVICE MANUAL SERVICE MANUAL UPDATE LOG REV NO DATE ISSUED DATE INSERTED BY INCORPORATED Nov 2002 AT ISSUE Note 0 1 and 0 2 with Update sheet s are replaced for each new update 0 2 Nov 02 ZENAIR CH2000 SERVICE MANUAL SECTION 1 INTRODUCTION GENERAL This manual contains service and maintenance instructions for the Zenair CH2000
26. HORIZON INDICATOR Bar fails to respond Check pump and tubing Bar does not settle Excessive vibration Check shock mounts Replace if necessary Insufficient vacuum Check line and pump Adjust regulator Defective instrument Replace Bar oscillates or shimmies Excessive vibration Check shock mounts continuously Replace if necessary Vacuum too high Adjust regulator Defective mechanism Replace instrument ELECTRIC TURN AND BANK INDICATOR GENERAL The turn and bank indicator is an electric instrument used for making correctly controlled turns The turn portion of the indicator is an electrically driven gyroscope while the bank portion is a ball sealed in a curved glass tube filled with damping fluid TROUBLESHOOTING ELECTRIC TURN AND BANK INDICATOR Pointer fails to respond Foreign matter lodged in Replace instrument instrument Incorrect sensitivity Misadjustment of sensitivity Adjust by means of sensitivity spring spring screw If this pulls the pointer from zero replace instrument 9 12 3 Apr 95 ZENAIR CH2000 SERVICE MANUAL MANIFOLD PRESSURE GAUGE GENERAL The manifold pressure gauge is a vapor proof absolute pressure type instrument Pressure from the intake manifold of the engine is transmitted to the instrument through a line A pointer indicates the manifold pressure available at the engine in inches of mercury TROUBLESHOOTING MANIFOLD PRESSURE GAUGE Trouble barometric pres
27. PLY LUBRICANT TO RUBBER PARTS NE SAF 15W 50 20 W 50 SEE LYCOMING SERVICE INSTRUCTIONS NO 1014 FOR USE OF DETERGENT OIL LUBRICATION CHART Fig 6 Feb 00 2 9 ZENAIR CH2000 SERVICE MANUAL SECTION IIIA AIRWORTHINESS LIMITATIONS GENERAL This Airworthiness Limitation section is accepted by the FAA It can only be revised with prior FAA approval Saure Z fo Federal Aviation Administration Des Plaines Il SEP 3 Original date of approval 7 995 Date of Issue SEP 3 7 1995 LIFE LIMITED PARTS Following is the list of the parts which must be replaced at the frequencies indicated Fuel line hoses rear of firewall 5 years or 2400 hours whichever occurs first Brakelines 7 years Pitot static lines 7 years Electric Trim actuator 2400 hours 3A 1 Sep 95 ZENAIR CH2000 SERVICE MANUAL SECTION III INSPECTION GENERAL This section provides instructions for conducting scheduled inspections unscheduled inspections replacement of time limited parts and corrosion control Repair or replacement instructions for those components found to be unserviceable are in the sections covering the applicable aircraft system Refer to Section II for lubrication and servicing instructions Lubrication and servicing intervals should be adjusted to take into account the aircraft operating conditions Refer to Section IIIA for Airworthiness Limitations All of the inspections are general
28. SERVICE MANUAL REPLACEMENT OF WING ASSEMBLY REMOVAL Drain the gas wing tank option only Disconnect the flap push rod Remove the seat bottoms Disconnect the aileron balance cables and aileron control cables center of fuselage Disconnect the fuel lines center of fuselage wing tank option only Disconnect the pitot and static lines left wing only Disconnect the electric wirings Remove the bolts on front and rear spar and the six main spar bolts Pull the wing out REINSTALL the wing in reverse order of removal REPLACEMENT OF FLAPS REMOVAL 1 Disconnect the flap push rod 2 Remove the hinge pins and the flap will be loose REINSTALL the flap in reverse order of removal safety the hinge pins and bolt REPLACEMENT OF AILERON REMOVAL 1 Disconnect the aileron push rod at the inboard end of the aileron 2 Remove the hinge pin and the aileron will be loose REINSTALL the aileron in reverse order of removal safety the hinge pin and bolts 4 2 3 Apr 95 ZENAIR CH2000 SERVICE MANUAL THE COWL 9 10 IS FIRE RESISTANT w 2 MATERIAL THICKNESS NO MATERIAL THICKNESS 1 FIBERGLASS 21 6061 T6 0 025 2 6061 T6 0 025 22 6061 T6 0 016 3 6061 T6 0 025 23 6061 T6 0 025 4 6061 T6 0 025 24 6061 T6 0 040 5 CARBON 25 6061 T6 0 025 FIBRE 6 CARBON 26 6061 T6 0 025 FIBRE 27 6061 T6 0 025 28 6061 T6
29. STER BKR MASTER SWITCH MAGNETO SWITCH CARB HEAT FIELD SWITCH ALTERNATOR BKR SWITCH AUX FUEL PUMP BKR SWITCH FLAP SWITCH FLAP INDICATOR ZENAIR CH2000 SERVICE MANUAL INSTRUMENT CLUSTER 1 OIL PRESS 2 OIL TEMP 3 FUEL PRESSURE 4 FUEL QTY REAR OR LEFT TANK 5 BLANK OR RIGHT TANK 6 AMPS AUX MIC PHONE etc 7 VOLTS RADIOS RADIO BREAKERS OPTION CABIN HEAT HR METER AUX CABIN LIGHT BKR TURN amp BANK BKR OIL P LIGHT STROBES START SOL FUEL BKR R LANDING STALL WARNING BKR L LANDING OIL T FUEL P BKR NAVIGATION FLAP MOTOR BKR MIXTURE e PRESSURE BKR LIGHT MASTER D VOLTMETER TRIM INDICATOR MANUAL OPT SHOWN TRIM WHEEL MANUAL OPT SHOWN INSTRUMENT PANEL Note Position of optional instruments may vary according to owner s specifications 9 2 Fig 21 Oct 00 ZENAIR CH2000 SERVICE MANUAL e ALTIMETER TROUBLESHOOTING See following table ALTIMETER Improper calibration adjustment Replace instrument Excessive pointer oscillation Defective mechanism Replace instrument High reading Improper venting Eliminate leak in static pressure system and check alignment of airspeed tube lubrication move when setting knob is rotated Setting knob set screw loose or Excessive vibration Tighten instrument screw if missing loose Replace instrument if screw is missing Cracked or loose cover glass Replace instrument Dull or discolored markings Replace
30. V D C at 60 amp continuous output and a voltage regulator which delivers a constant frequency pulse with modulated field power control to maintain the alternator output voltage The over voltage protection is provided within the regulator it will trip off the regulated output after the regulator fails to maintain the correct level Note the regulator will remain locked off until the power is momentarily removed and reinstated The regulator is internally protected against damage to the output stage in the event of a ground fault to the field wire It will be locked off until the power is momentarily removed and reinstated The alternator and regulator are easily checked individually 10 4 3 Apr 96 ZENAIR CH2000 SERVICE MANUAL CHARGING SYSTEM d If the battery is fully charged and the charging rate remains high disconnect the lead from F terminal of the regulator if charging rate is high with engine at medium speed 1200 R P M the alternator field or field wire is grounded if the output drops off the regulator is faulty and should be checked for high voltage setting or internal grounding If the battery is low and the charging rate is low ground F terminal of the alternator momentarily and increase speed if output does not increase alternator to regulator wiring is faulty if output increases the alternator is operating properly If the ammeter indicates a heavy discharge with engine off or the alternator
31. VICE MANUAL ADJUST FLAP UP DOWN LIMIT SWITCHES THE FLAP POSITION INDICATOR MAY ADJUSTED WITH AN ALLEN SCREW LOCATED BEHIND THE CENTER CABIN CONSOLE BAGGAGE EXTENSION LEVER 50 DEG DOWN 3 DEG FAIRING AT CONTROL LEVER WING ROOT ACTUATOR LEVER CONTROL ROD CONTROL ROD IS SDJUCTED TO SET RIGHT LEFT FLAP IN THE UP POSITION FLAPS CONTROL SYSTEM Fig 16 Feb 00 7 5 ZENAIR CH2000 SERVICE MANUAL 6yz 6N 81 5816 Sg10 NOISN3L 318V2 YOLVIISVLS 930 S o 93096 930 90 930 ZI ape L NO33ONO1T AOVISSNA NO339NO1 OL T3TIVHVd N3HA Nid 331100 Ni TJ TY 9 TWALNIN SI CL H YL TVLNOZIHOH A3Tind 1308415 A3TInd LH 18 0 CS SNIuvY38 930 7 5 930 c 4 4 ISON 0001 MBIA 301 930 S 930 56 NMOQ TING 93a A j MM NA OQ 3SON 11014 930 01 a Qvam 318Vv2 HSnd T NHOH 71031405 Fd T33HM 1081NOO NI ONIONS I1H9I3M 3ONVWS 79139 TL dvdls 5 TYL TCLNOZIHOH WWNOILLdO 15 N31 g 64 335 A SSV STABILATOR CONTROL SYSTEM Fig 17 Oct 00 7 6 ZENAIR CH2000 SERVICE MANUAL Z 01 S81 S ZZ NOISN3L 318v9 H3aans
32. ant on exterior surfaces of bearings tends to attract dirt and grit and may lead to malfunction of the unit 2 8 Feb 00 ZENAIR CH2000 SERVICE MANUAL LUBRICATION CHART FOR ZENAIR CH2000 HOURS LUBRICANT LUBRICANT HOURS HORIZONTAL TAIL 250 PULLEYS HORIZONTAL TAIL 100 HINGES HORIZONTAL TAIL CABIN DOOR HINGES AND TRIM TAB SUPPORT RUDDER HINGES AND HORN SEAT 100 ADJUSTMENT CONTROL 100 COLUMN amp YOKES TRIM TAB MECHANISM ACCESS DOOR HINGES 100 BRAKE MASTER 50 CYLINDERS MAINTAIN FLUID AILERON AND FLAP RUDDER PEDALS TORQUE TUBE PULLEYS BELLCRANK NOSE WHEEL FLAP 100 100 STEERING MECHANICAL LEFT AND RIGHT HINGES NOSE WHEEL BEARING SEE SECTION V INSIDE CONTROL COLUMN ENGINE OIL TANK 100 DRAIN AND 50 REFILL 6 QTS MAIN WHEEL BEARINGS LEFT AND RIGHT SEE SECTION V LEGEND CAUTIONS v MIL L 7870 OIL GENERAL PURPOSE LOW TEMP LUBRICATION 1 DO NOT USE A HYDRAULIC FLUID WITH A CASTOR OIL NOTE OR ESTER BASE A MIL L 7711 GREASE LUBRICATION MISCELLANEOUS DURING ROUTINE MAINTENANCE CHECKS GENERAL PURPOSE APPLY LUBRICATION TO MISCELLANEOUS LINKAGES AND ALL PARTS WITH RELATIVE MOTION AIRCRAFT 2 DO NOT OVER LUBRICATE D MIL L 3545 GREASE LUBRICATION HIGH TEMP MIL 0 5604 HYDRAULIC FLUID RED 3 DO NOT AP
33. avily compensated Loose bezel screws Broken cover glass Defective sealing gaskets Age Compensate instrument Locate magnetic interference and eliminate if possible Align instrument Replace instrument Replace instrument Replace instrument Remove excess compensation Replace instrument Replace instrument Replace instrument Replace instrument 3 Apr 96 ZENAIR CH2000 SERVICE MANUAL e TACHOMETER GENERAL The tachometer is connected to the engine accessory by a flexible cable and provides an indication of crankshaft speed in revolutions per minute The instrument has a recording mechanism for recording the time that the engine is in actual operation TROUBLESHOOTING See following table TACHOMETER Trube Cause No reading on indicator either Broken shaft Replace permanent or intermittent Weak spring Replace instrument Pointer oscillates excessively Rough spot on or sharp bend Repair or replace in shaft Excess friction in instrument Replace instrument e ENGINE OIL PRESSURE GAUGE GENERAL The oil pressure gauge is mounted in the cluster on the instrument panel This gauge will indicate the amount of oil pressure in PSI available at the pressurized engine oil passage TROUBLESHOOTING ENGINE OIL PRESSURE GAUGE Excessive error at zero Pointer loose on shaft Replace instrument Overpressure or seasoning of bourdon tube Excessive scale err
34. ay be used to verify that a task has been completed Perform the stated tasks at the intervals shown when a plus symbol is shown in an interval column A minus symbol indicates no maintenance action is required Tasks may be performed sooner but not later than the stated intervals If done sooner tasks must next be performed at the stated interval e g at 790 flight hours airframe time a 100 hour task is performed 10 flight hours before it is due It must next be performed 100 hours later at 890 flight hours or sooner Operational checks are tasks that determine that an item is fulfilling its intended purpose No verification of meeting tolerances is required Functional checks are tasks which determine if one or more functions of an item are performing within specified limits Quantitative checks must be performed Useful Note The 50 hour inspection has a tolerance of 16 ie between 42 and 58 hours Oct 00 3 2 TABLE 1 ZENAIR INSPECTION FORM Make Model Serial No ZENAIR CH2000 Airframe Hours Type of Inspection Circle One Registration No Engine Hours 50 100 500 1000 Symbols Indicates perform task Indicates do not perform task Intervals Task Refer to Flight Hours Initials 50 100 500 1000 Propeller Group 1 Check propeller bolts for torque and Sensenich Prop safeties Manual 2 Inspect blades and hub for cracks Sensenich Prop
35. breaker off when the master is on the diodes in the alternator are shorted repair or replace the alternator For procedures and specifications concerning testing and adjustment of the alternator and voltage regulator refer to manufacturer s service manual CAUTION If the battery terminals have been reversed the alternator diodes have shorted and need replacement VOLTMETER Fig 23 The voltmeter indicates the level of the battery 11 5 or more volts engine off and master on AMPMETER Fig 23 The amp meter is mounted in series with the battery and bus bar s It shows in positive or out negative current to from the battery With a charged battery the ammeter should read near zero when the engine is running and has recharged 3 to 5 minutes the battery previously discharged by the starter current and no other loads are applied lights radios etc off 1 Sep 95 10 5 ZENAIR CH2000 SERVICE MANUAL STALL WARNING Right bottom of Fig 23 The stall warning system consists of an electric buzzer located behind the roll over bar on the cabin ceiling and activated by the airflow closing the contact on the right wing leading edge when the aircraft operates at a high angle of attack near the stall of the wing If the buzzer does not operate when lifting the contact check the contact the buzzer and the breaker for proper operation The contact element on the wing leading edge is replaced by removing the blind
36. d component parts with a suitable solvent After inspecting the parts for any defects replace the O rings Note Use a small amount of hydraulic fluid on the O rings and component parts to prevent damage during reassembly REASSEMBLE the master cylinder in the reverse order given for disassembly being careful not to damage the O rings Reinstall the master cylinder and bleed the brake system BLEEDING PROCEDURE If the brake line has been disconnected for any reason it will be necessary to bleed the brake and line as described below Connect the bleeding unit hose to the fitting at the bottom of the brake unit and pressure fill the brake system with MIL H 5606 fluid Remove the bleeding unit hose after tightening the fitting Repeat the bleeding procedure on the other gear BRAKE PADS REPLACEMENT When the brake pads become worn excessively 1 16 pad thickness they are replaced with new pads REMOVAL Remove the wheel see page 5 2 Replacement of main wheel Remove the two bolts holding the pads Remove the pads REINSTALL in reverse order Check for safeties and operation Note No adjustment of brake clearance is necessary on the brakes The brake disc should not necessarily be replaced because of circumferential grooving 5 4 3 Apr 95 ZENAIR CH2000 SERVICE MANUAL FUSELAGE GEAR FITTINGS MAIN GEAR SPRING TEs LATERAL STOP amp BOLTS BRAKE LINE HOSE CLIPS BEHIND TIEWRAP
37. electrical equipment is powered with the exception of the starter which receives its power from the load side of the battery The master switch located on the switch panel below the instruments controls the battery relay The master switch must be on before any electrical equipment will operate The CH2000 can be equipped with the standard navigation lights strobes and dual landing lights located in the wing leading edge TROUBLESHOOTING Troubles peculiar to the CH2000 electrical system are listed in a Table at the end of this section along with their probable causes and suggested remedies Fig 23 1 a schematic of the different electrical circuits used in this airplane and Fig 24 shows the wiring After the trouble has been corrected check the entire electrical system for security and operation of its components ELECTRICAL POWER SUPPLY The electrical power is supplied by one 12 volt battery and one 12 volt direct current alternator The alternator is located on the front lower right side of the engine and utilizes a belt drive from the engine crankshaft A voltage regulator is incorporated to prevent overloading of the battery and electrical circuits 3 Apr 95 10 1 ZENAIR CH2000 SERVICE MANUAL CV3H gt 243 lt a 2 RA 1 1 THT 390 MIQV31 22 n ll T 7 9 3 E wer 4 ae iz 1
38. en removing the wheel s perform Table 1 inspections Landing Gear Group 3 6 8 and 14 or annually whichever comes first There is no set inspection interval period for this between inspection annuals REPLACEMENT OF NOSE GEAR Fig 9 Remove upper and lower engine cowl Hoist the airplane See Section II Remove the upper stop plate Disconnect the steering Remove the shock ring from the forward upper support Remove the lower front bearing Remove the whole nose gear assembly RUF REINSTALL the nose gear assembly in reverse order of removal Safety all connections Note If for any reason the steering rod length was changed the alignment of the nose wheel must be checked as follows ALIGNMENT OF NOSE GEAR 1 Hoist the airplane See Section ID 2 Locate the center line of the fuselage directly behind the nose wheel assembly and attach a plumb bob also attach a plumb bob to the tail skid Using the two plumb bobs as a guide snap a chalk line extending several feet beyond each bob on the ground 3 Stand in front of the nose wheel and orient the tire with the chalk line Sight along the center rib of the tire 4 Adjust both rod ends at the end of the nose gear steering rod assemblies to align the cockpit rudder pedals Do not attempt to make the adjustment by means of one rod end but divide the adjustment between the two rod ends 3 8 10mm minimum thread engagement must be mai
39. everse order after checking the cork padding for damage and proper position All upper edges top and sides and under the straps adhesive 3M Scotch Grip 847 Check all connections for condition leaks and safety FUEL SENDER UNIT under the fuel gauge cover plate see Fig 2 REMOVE the sender after removing the five screws REINSTALL with the cork seal ring and the five screws Feb 00 8 1 ZENAIR CH2000 SERVICE MANUAL WING TANK SYSTEM Fig 20 The wing tanks are installed behind the wing spar outside the walkway and held in place by the bottom wing panels The filler neck and vent tube are integral parts of the tank Each tank has a sump easy drain The finger screen is at the tank outlet and accessible through the small inspection plate See Fig 20 Each tank feeds the selector shut off valve REPLACEMENT OF WING TANK Fig 20 CAUTION Do not loosen tank support panel unless tanks have been defueled 1 Drain fuel from tank 2 Disconnect the fuel line at tank outlet CAUTION Removing the tank support panel will allow the tank to drop be careful to let the tank down slowly to prevent ripping off the wiring 3 Remove tank cover plate 4 Remove the fuel sender and the ground wires 5 Remove the tank INSTALLATION 1 Verify that the cork padding is not damaged and is in proper position all edges adhesive 3M Scotch Grip 847 2 Follow the steps for removal in inverse order 3 Seal with sealer 3M ref
40. f the suspicious area Remove wheel bearings from the wheel hub and clean thoroughly with a suitable solvent When repacking with grease be sure the lubricant enters the space between the rollers in the retainer ring Do not pack the grease into the wheel hub REINSTALL in reverse order using the shims to prevent lateral floppiness Safetie the nut Note Bolt torque values are given in AC 43 13 1B 5 2 Nov 02 ZENAIR CH2000 SERVICE MANUAL UPPER NOSE GEAR SUPPORT UPPER STOP PLATE NOSE GEAR LEG UPPER NOSE GEAR BEARING UPPER SUPPORT SHOCK RING STEERING CONNECTION SEE DETAIL A NOSE GEAR LEG v WHEEL AXEL SHIMS AS BUSHING LOWER NOSE GEAR BEARING SAFETY WIRE NOSE GEAR Fig 9 Nov 02 5 3 ZENAIR CH2000 SERVICE MANUAL BRAKE MAINTENANCE REPLACEMENT OF BRAKE MASTER CYLINDER Fig 11 Remove the master cylinder from the mounting bracket by removing the brake lever pivot bolt and the master cylinder pivot pin and disconnect 2 Remove the cylinder from the airplane REINSTALL the master cylinder in reverse of removal instructions Check all connections for security and leaks REPLACEMENT OF O RINGS IN MASTER CYLINDER Fig 11 Remove the brake master cylinder 2 Disassemble the master cylinder by removing the snap ring and extracting the plunger assembly from the cylinder housing 3 Thoroughly clean the cylinder housing an
41. faces are shown in the figures Perform a functional check control rigging of the affected flight control system whenever re connection of the cables is completed Ref Figure 15 17 or 18 REMOVAL INSTALLATION OF AILERON CONTROL CABLES Fig 15 REMOVAL Open fuselage access panel Fig 2 Remove the balance cable pulley Fig 15 Remove aileron bellcrank inspection plate Fig 2 Disconnect cables from bellcrank at S Fig 15 Attach Fish line to cable ends to facilitate reinstallation Remove the cables To remove the bellcrank disconnect the rod from the bellcrank and remove the nut and bolt remove the bellcrank Q REINSTALL in reverse order of removal and check the rigging as follows AILERON CONTROL RIGGING Fig 15 1 With control wheel in neutral adjust cable length turnbuckles so that the bellcranks are neutral parallel to the wing rib 2 Adjust the aileron rods so that both aileron trailing edges are 3 8 lower than the inboard wing trailing edge Adjust cable tension to 32 Ibs Safetie all turnbuckles 5 Verify that when the bellcrank hits the stops the control wheel arms in front of the instrument panel have a minimum of 1 8 3mm clearance with the structure 6 Check all components and connections for condition proper installation operation and safety AU Feb 00 7 1 ZENAIR CH2000 SERVICE MANUAL FIXED AILERON TRIM TAB Fig 15 For the p
42. fasteners damage etc Nov 02 3 9 TABLE 1 ZENAIR INSPECTION FORM Make Model ZENAIR CH2000 Serial No Airframe Hours Type of Inspection Circle One Registration No Engine Hours 50 100 500 1000 Symbols Indicates perform task Indicates do not perform task Intervals Task Refer to Flight Hours Initials 50 100 500 1000 2 Inspect stabilator trim actuator wheel for security wear damage etc 3 Perform operational check of stabilator Section VII trim System 4 Inspect rudder stabilator and trim tab Section VII hinges for wear and excessive play 5 Lubricate the rudder and stabilaor trim Section II tab hinges the stabilator hinge points and the trim actuator 6 Inspect the stabilator balance weight Section VII stops and grounding strap for security condition damage etc 3 10 Nov 02 ZENAIR CH2000 SERVICE MANUAL SECTION IV STRUCTURE GENERAL Figure 7 identifies the type and thickness of skin used in the construction of the CH2000 No structural repairs are recommended without contacting the manufacturer however minor repairs such as patching the skin welding etc may be made in accordance with the regulations It may be necessary to cut access holes to make skin repairs in some areas of the aircraft Caution Skin repairs must result in a surface wh
43. g section Check all lines and fittings Normal pressure indication Instruments air filter Remove and clean or but sluggish operation of elements dirty replace instruments High system pressure Vacuum regulator valve Adjust in accordance with incorrectly adjusted Adjustments as per above Vacuum regulator valve sticking or dirty screen Clean and check operation of regulator valve 3 Apr 95 9 9 ZENAIR CH2000 SERVICE MANUAL DIRECTIONAL GYRO INDICATOR Fig 22 GENERAL The directional gyro is a flight instrument incorporating an air driven gyro stabilized in the vertical plane The gyro is rotated at high speed by lowering the pressure in the airtight case and simultaneously allowing atmospheric air pressure to enter the instrument against the gyro buckets Due to gyroscopic inertia the spin axis continues to point in the same direction even though the aircraft yaws to the right or left This relative motion between the gyro and the instrument case is shown on the instrument dial which is similar to a compass card The dial when set to agree with the airplane magnetic compass provides a positive indication free from swing and turning error TROUBLESHOOTING See following table DIRECTIONAL GYRO INDICATOR Excess drift in either Excessive vibration with Check shock mounts direction amplitude more than 0 006 inch Insufficient vacuum If vacuum below 3 75 inch Hg check for the following a Regulator impro
44. he forks Check all components and connections for condition proper operation and safety 7 2 Nov 02 ZENAIR CH2000 SERVICE MANUAL REMOVAL INSTALLATION OF RUDDER CONTROL CABLES Fig 18 REMOVAL 1 Disconnect both rudder control cables by removing the nuts and bolts at the rudder horn and rudder pedals 2 Open the fuselage access panel Fig 2 3 Remove the fairleads 4 Remove the cables REINSTALL the controls in reverse order of removal Check the rigging RUDDER CONTROL RIGGING Fig 18 1 Adjust cable tension to 22 165 2 With the nose wheel centered and pedals in line at 170mm from Firewall Fig 18 see also nose wheel alignment in Section V The rudder is centered Check travel limits 21 5 1 5 left and right For non spinable airplanes see Fig 18 Check all components and connections for condition proper installation operation and safety Rudder Turnbuckles can be adjusted for level flight S A FLAP CONTROLS Fig 16 REMOVAL Lower the flaps Remove the fairings Disconnect the control rods Open the fuselage access panel Fig 2 Disconnect the actuator lever by removing the four bolts on the interconnecting tubes and indicator cable liberating the actuator lever 6 Pull the interconnecting tubes out thes REINSTALL in reverse order of removal FLAP CONTROL RIGGING The relative position of the control levers and the actuator lever is shown on Fig 16 1 Adjust t
45. he handle Inspect the bearing in 20 F 32 3 and make sure that it is not worn through that it rotates freely and that it is greased The schematic shows 10 32 rivnut located front rear of each door with washers and countersunk screw When the door handle is in the closed position the front rear countersunk screws must be tight against 20 M 82 3 channel on top of Upper Longeron Make sure that the door handle position is as per schematic in the closed position and that it has positive locking pressure Make sure that handles crew MS24693 S274 is tight and that locktite has been applied Nov 02 12 1
46. he rod length for flaps up 2 Check the full flaps down travel limit 509 35 3 Check all components and connections for condition proper installation operation and safety FLAP ACTUATOR UNIT REMOVAL 1 Open the fuselage access panel 2 Disconnect the electric connector 3 Remove the bolts at bottom and top of actuator 4 Remove the actuator REINSTALL in reverse order of removal Check all connections for proper condition installation and safety Check for proper operation CONTROL SYSTEM WEAR OF JOINTS The wear tolerance on hinges etc is maximum 5mm 020 which is easily measured In particular 5mm 3 32 floppiness maximum at the stabilator tip 3mm 1 87 maximum at rudder tip When the wear reaches above limits replace the bushings See Section IV Nov 02 7 3 ZENAIR CH2000 SERVICE MANUAL 15 DEG 1 DEG LINKAGE BOLT NUT BUSHING BELLCRANK EUN 34 DEG 3 DEG AILERON STOP CONTROL COLUMN AILERON PULLEY ASSY Z CENTER GEAR FLOOR STIFFENER TORQUE TUBE ROLL TRIM 77f AIRCRAFT CENTER LINE BELLCRANK AILERON ROD gt LENGTH AS PIN REQUIRED MAX 300mm LEFT 30 DEG AILERON AILERON PULLEY ASSEMBLY RIVETS A4 PITCH 50 ROLL TRIM DETAIL MAY BE ADDED LATER AILERON CABLE TENSION TO LEFT OR RIGHT AILERON 32 LBS 5 LBS 15 Kg 5 AILERON AND CONTROLS Fig 15 7 4 Feb 00 ZENAIR CH2000 SER
47. he system VACUUM GAUGE The vacuum gauge is mounted above the gyro instruments This gauge is calibrated in inches of mercury and indicates the amount of vacuum created by the engine driven vacuum pump 9 8 3 Apr 95 ZENAIR CH2000 SERVICE MANUAL VACUUM REGULATOR VALVE Fig 22 One vacuum regulator valve is incorporated in the system to control vacuum pressure to the gyro instruments The regulator valve is located under the instrument panel access to the valve for maintenance and adjustment is gained from below the instrument panel ADJUSTMENTS OF VACUUM REGULATOR VALVE Unlock the nut under the Regulator valve and turn the adjusting screw to obtain the proper vacuum Safety after adjustment TROUBLE SHOOTING OF VACUUM SYSTEM See following table VACUUM SYSTEM No vacuum pressure gauge Pump inoperative Replace pump Locate indication Disconnected Broken or trouble and correct restricted lines indication at instrument gauge leaking or restricted connections No vacuum suction gauge Faulty gauge Check operation of indication at either Malfunctioning regulator instruments If operation is instrument or source valve or vacuum pump normal replace gauge If instruments are inoperative check operation of vacuum pump or regulator valve Low vacuum system Vacuum regulator valve Adjust regulator valves in pressure incorrectly adjusted accordance with Leaking of the system lines Adjustments of this or fittin
48. ich is as strong as or stronger than the original skin However flexibility must be retained so that the surrounding areas will not receive extra stress The rivets used on most parts are of the blind rivet type Zenair reference A 4 1 8 dia or A 5 5 32 dia to be set with the hand tool Zenair reference 4 5 Aircraft quality aluminum Cherry rivets are an approved substitute Standard MS20470 rivets may be used where access is possible ZENAIR MANUFACTURED _ HAND TOOL HEAD RIVET HEAD TIGHT ON SURFACE K lt gt SSSSSS SoS AN lt gt ESSSSSSSSSSSGSSS lt lt lt lt lt 7 4 AS RIVET Repair Carbon Fiber and Fiberglass parts with standard typical Fiberglass type resin and woven Fiberglass cloth Using the Aircraft Inspection and Repair manual AC43 13 1B Chapter 3 is also acceptable When nylon Locknuts are removed the installation of new Locknuts is highly recommended Bolt torque valves are given in AC 43 13 1B NOTE Modifications to the fuselage are permissible if they do not involve alterations to its main structure The manufacturer must be contacted for approval regarding specific alterations proposed in accordance with approved data Following list gives the primary structural parts Wing Spars Spar box assembly in fuselage Stabilator spar and mass balance attachment Rudder spar Nov 02 4 1 ZENAIR CH2000
49. ing weather Leaking battery jar Frozen Replace battery Battery polarity reversed Connected backwards on Battery should be slowly airplane or charger discharged completely and then charged correctly and tested Battery consumes Cracked jar one cell only Replace battery excessive water 3 Apr 95 10 7 ZENAIR CH2000 SERVICE MANUAL TABLE ELECTRICAL SYSTEM TROUBLESHOOTING contd STARTER Motor fails to operate Low battery charge Check and recharge if necessary Defective or improper Refer to electrical wiring wiring or loose diagram and check all connections wiring Defective starter solenoid Replace faulty unit or control switch Low motor and cranking Worn rough or Disassemble clean speed improperly lubricated inspect and relubricate motor or starter gearing replacing ball bearings if Same electrical causes as worn listed under Motor fails to Same remedies listed for operate these troubles ELECTRICAL LOADS AMPS Intermittent Battery solenoid Voltage Regulator Clock Hour meter Fuel Gauge Fuel Pressure Oil Temperature Voltmeter Ammeter Aux fuel pump Flap Actuator Trim Actuator if applicable Stall Warning Options Turn and Bank Position Lights Strobes Instrument Lights Landing Lights Pitot Heat 10 8 Oct 00 ZENAIR CH2000 SERVICE MANUAL SECTION XI CABIN HEATER AND VENTILATION SYSTEM GENERAL Fig 25 Heat for the cabin of the CH2000 is
50. ingle engine two seat low wing monoplane of all metal construction WING The wing is of all metal stressed skin full cantilever low wing design consisting of two wing panels bolted to a spar box assembly in the fuselage The ailerons are cable and push rod controlled The wing trailing edge split flaps are electrically operated EMPENNAGE The empennage consists of the rudder stabilator and stabilator trim tabs The stabilator is dynamically balanced FUSELAGE The fuselage consists of three basic sections the engine section the cabin section and the sheet metal tail cone LANDING GEAR The tricycle landing gear is of the fixed type consisting of a nose wheel and two main wheels HYDRAULIC SYSTEMS The dual brake system is operated by master cylinders ENGINE The aircraft is powered by one horizontally opposed Lycoming Model 0 235 N2C four cylinder air cooled engine The engine employs a wet sump oil system with oil temperature and pressure indicators PROPELLER The propeller used is a Sensenich fixed pitch all metal aluminum alloy Model 72 CK series FUEL SYSTEM The fuel system on the Zenair CH2000 consists of one rear aluminum tank or tanks in the wings one engine driven pump and one electrical auxiliary pump FLIGHT CONTROLS The flight controls are conventional equipment consisting of a control wheel which operates the ailerons and stabilator and pedals which operate the rudder Duplicate controls are provided
51. is position is transmitted electrically to the indicator gauge to show the amount of fuel in the tank TROUBLESHOOTING See following table FUEL QUANTITY INDICATORS Fuel gauge fails to indicate Broken wiring Check and repair Gauge not operating Replace Float partially or completely Replace float filled with fuel Circuit breaker out Reset and check Float touching tank Bend float arm Fuel gauge indicates full when Incomplete ground Check ground connections at tanks are not full fuel transmitter 9 6 Nov 02 ZENAIR CH2000 SERVICE MANUAL e FUEL PRESSURE GAUGE GENERAL The fuel pressure gauge instrument is mounted in the cluster on the instrument panel This gauge is connected to the sender at the carburetor fuel inlet fitting TROUBLESHOOTING See following table FUEL PRESSURE GAUGE No fuel pressure indication Fuel valve stuck Check valve No fuel in tanks Check fuel fill Defective fuel pump Check pump for pressure build up Check diaphragm and relief valves in engine pump Check for obstruction in electric pump Defective gauge sender Replace gauge sender Pressure low or pressure Obstruction in inlet side of Trace lines and locate surges pump obstruction Faulty bypass valve Replace Faulty diaphragm Replace or rebuild pump with fuel AMMETER GENERAL The ammeter is mounted in the instrument cluster located on the instrument panel This instrument measures the amount of c
52. magneto primary circuits before performing any checks on the engine by connecting an electric wire from magneto terminal to the screw marked GD Ground on the magneto Refer to following paragraphs for procedures for removal and replacement of engine components REMOVAL OF PROPELLER Fig 12 1 Optional Remove the screws and remove the spinner 2 Remove the six propeller bolts and remove the propeller 3 Optional Remove the spinner mounting plate REINSTALL the propeller with the plate between the propeller and crankshaft flange See Fig 12 Tighten the six propeller bolts See Sensenich manual for torque Before installing the spinner check the propeller for track Safety the propeller bolts Screw the optional spinner to its plate PROPELLER TRACKING CHECK 1 Place a box or other fixed object at the lower tip while the propeller 15 vertical 2 Mark the line of one tip on the box 3 Rotate the propeller 180 degrees and compare the location of the other tip with respect to the first 4 They must pass within 1 16 inch or 2mm of the same line If they are further apart loosen and tighten the propeller bolts until the tracking is satisfactory Feb 00 6 1 ZENAIR CH2000 SERVICE MANUAL V 6 IS COA Usruosuag puondo 9t 0 NOCL CS COA 65 lguotdO oig 5419196 oeg 8 4 SSY JOLBNIA 8 Suruoo amp
53. ments for security Section IX markings condition and perform operational check 22 Inspect fuel sender unit for security Section VIII leaks etc 23 Inspect fuel primer if installed for security condition leaks etc 24 Check brake fluid level section V 25 Inspect the aft side of the firewall from inside the cabin for cracks around any rivets In case of repair see Zenair Service bulletin No 00 03 section B and C Landing Gear Group 1 Inspect the main landing gear Section V mainspring attachment bolts for proper torque safeties etc 3 6 Nov 02 TABLE 1 ZENAIR INSPECTION FORM Make Model Serial No Airframe Hours Type of Inspection ZENAIR CH2000 Circle One Registration No Engine Hours 50 100 500 1000 Symbols Indicates perform task Indicates do not perform task Intervals Task Refer to Flight Hours Initials 50 100 500 1000 2 Check security condition etc of lateral Section V stop and bolts and axle bolts 3 When removing wheels inspect the Section Section V brake assemblies axles pins and Spacers for security condition leaks etc 4 Check the brake pads and brake discs Section V for excessive wear 5 Inspect the main wheels for cracks corrosion etc 6 When removing wheels re pack wheel Section V
54. ntained 5 Check the nose gear steering for travel by measuring the maximum deflection each side from the center of the chalk line Fig 18 Nov 02 5 1 ZENAIR CH2000 SERVICE MANUAL REPLACEMENT OF NOSE WHEEL Fig 9 1 Hoist aircraft up 2 Remove the axle bolt and remove the wheel and tire Caution Do not lose the spacers Check wheel as indicated for the main wheels and grease the wheel bearings REINSTALL in reverse order of removal REPLACEMENT OF MAIN GEAR Fig 10 1 Hoist the airplane 2 Drain the fluid from the brake system see Fig 11 and disconnect the brake lines from gear assembly 3 Remove the four bolts which attach the spring to the fuselage 4 Remove the gear assembly REINSTALL the main gear in reverse order of removal safety the bolts Note Torque value on the four bolts Tighten snug approximately 110 LB IN Do not bend bracket 20 L 3 3 when tightening Make sure that the rubber padding HH 16 top bottom are in place before tightening the four bolts REPLACEMENT OF MAIN WHEEL Fig 10 1 Hoist aircraft up 2 Remove the axle nut disassemble the brake assembly and remove the wheel and tire Check the wheel casting for visible signs of cracks corrosions loose or broken bolts and any defects which may impair its operation Note If there are any indications of defects deflate the tire remove the three wheel bolts remove the tire and tube and perform a thorough inspection o
55. of all the standard instruments and their systems The remaining portion of this section is directed to maintenance and troubleshooting of optional instruments STANDARD INSTRUMENTS Fig 21 e AIRSPEED INDICATOR GENERAL The airspeed indicator provides a means of indicating the speed of the airplane passing through the air The airspeed indication is the differential pressure reading between dynamic air pressure and static air pressure This instrument has the diaphragm vented to the dynamic air source and the case is vented to the static air system As the airplane increases speed the dynamic air pressure increases causing the diaphragm to expand A mechanical linkage picks up this motion and moves the instrument pointer to the indicated speed The instrument dial is calibrated in knots and also has the necessary operating range markings for safe operation of the airplane TROUBLESHOOTING See following table AIRSPEED TUBES AND INDICATOR Pointers of static Leak in instrument case or Check for leak and seal instruments do not indicate in lines properly Pointer of instrument Leak in instrument case Check for leak and seal oscillates 3 Apr 95 9 1 OPT INTERCOM SWITCH OPT VOR TACHOMETER ADF ALTIMETER INDICATOR VACUUM GAUGE VERTICAL SPEED INDICATOR HORIZONTAL GYRO DIRECTIONAL GYRO AIRSPEED INDICATOR EL TURN amp BANK CLOCK FUEL PRIMER TACHOMETER RADIO MIC ALTERNATE STATIC CONTROL WHEEL MA
56. or Improper calibration Replace instrument adjustment Excessive pointer oscillation Improper damping or rough Disconnect line and drain engine relief valve Check for leaks If trouble persists clean and adjust relief valve Sluggish operation or pointer Engine relief valve open Check and clean or pressure fails to build up 3 Apr 95 9 5 ZENAIR CH2000 SERVICE MANUAL e ENGINE OIL TEMPERATURE INDICATOR GENERAL The oil temperature indicator is mounted in the instrument cluster on the instrument panel This instrument will provide a temperature indication of the engine oil in degrees Fahrenheit The instrument has a temperature sender located on the engine accessory section TROUBLESHOOTING See following table ENGINE OIL TEMPERATURE INDICATORS reading Wiring open to instrument adjustment Pointer fails to move as engine Broken or damaged capillary Check engine unit and wiring is warmed up or open wiring Dull or discolored luminous Age Replace instrument marking e FUEL QUANTITY INDICATOR GENERAL The fuel quantity gauge s used on the CH2000 is are mounted in the cluster on the instrument panel These instruments are calibrated in fractional divisions of one fourth one half three fourths and full A transmitter unit is installed in each fuel tank This unit contains a resistance strip and a movable control arm The position of this arm is controlled by a float in the fuel tank and th
57. or security and correct operation 8 Perform functional check of the flap Section VII System 9 Inspect all windows for cracks cleanliness etc 10 Check cabin finish for damage 4 4 deterioration etc 11 Perform operational check of the fuel Section VIII selector valve and safety lock 12 Inspect door fit and latching Section XII mechanisms 13 Check upholstery for condition Nov 02 3 9 TABLE 1 ZENAIR INSPECTION FORM Make Model Serial No Airframe Hours Type of Inspection ZENAIR CH2000 Circle One Registration No Engine Hours 50 100 500 1000 Symbols Indicates perform task Indicates do not perform task Intervals Task Refer to Flight Hours Initials 50 100 500 1000 14 Inspect safety belts attaching hardware etc for condition Security 15 Verify appropriate compass correction card is in aircraft 16 Clean or replace filters in the gyro Section IX vacuum system if installed 17 Inspect radio installations and Section IX mounting hardware for security condition etc 18 Inspect electrical wiring for condition 4 4 security routing damage etc 19 Check condition and security of all bonding wires 20 Inspect antenna installations for condition security etc 21 Inspect instru
58. ount and bolt from each engine mounting Swing the engine free being careful not to damage any attached parts REINSTALLATION OF ENGINE Attach a one half ton hoist to the hoisting hook and lift the engine Position the mounting lugs of the engine so that they align with the engine mount attaching points Insert the front rubber mounts and the spacers between engine and engine mount Position the rear rubber mounts and insert the bolts Install a washer and castellated nut on each mounting bolt Tighten the nuts until the inner spacer is tight then align castle nut with cotter pin hole in the bolt approx 40 inch pounds and install cotter pins Reconnect all engine connections in the reverse order they were removed See reverse of removal items 13 to 1 above Note Adjust all controls to provide full travel in particular when the throttle control is full forward it must contact the stop on the carburetor before it bottoms 3 Apr 96 6 3 ZENAIR CH2000 SERVICE MANUAL S5NIHSh8 TOMLNOD TInd HSnd WAV JILLOYHL TOULNOD TInd HSnd 5 JILLOYHL TTINA WUV TOULNOD ATLLOUHL WAV TOULNOSD 4015 ATLLOUHL LNAWLSALACV Q334S 3A3T3HnLXIN N INIALLSOf GV 4 4 NOLLV2ETTAOOV SHOLLXIIN TLLLOHH L TOULNOD TInd HSnd TLLLOSH L 320 18 ANIONA CARBURETOR Fig 13 Feb 00 6 4 ZENAIR CH2000 SERVICE MANUAL ENGINE MAINTENANCE PROCEDURES See
59. perly a Adjust see Fig 22 adjusted b Incorrect gauge reading b Recalibrate c pump failure c Repair or replace d Vacuum line kinked or d Check and repair leaking Check for collapsed inner wall of hose Defective instrument Replace instrument Dial spins continuously Defective mechanism 9 10 3 Apr 95 ZENAIR CH2000 SERVICE MANUAL Vacuum Pump Instrument Panel ex Gauge Gyro Horizon 90 4 Indicator Adjusting Screw Directional Gyro Filter Electric Turn amp Bank Indicator AIR FLOW o 2A Breaker GYRO SYSTEM OPTIONAL Fig 22 3 Apr 95 9 11 ZENAIR CH2000 SERVICE MANUAL GYRO HORIZON INDICATOR GENERAL The gyro horizon is essentially an air driven gyroscope rotating in an horizontal plane and is operated by the same principal as the directional gyro Due to the gyroscopic inertia the spin axis continues to point in the vertical direction providing a constant visual reference to the altitude of the airplane relative to pitch and roll axis A bar across the face of the indicator represents the horizon A miniature adjustable airplane is mounted to the case and aligning the miniature airplane to the horizon bar simulates the alignment of the airplane to the actual horizon Any deviation simulates the deviation of the airplane from the true horizon The gyro horizon is marked for different degrees of bank TROUBLESHOOTING See following table GYRO
60. ructions Ref SPRM 590 C Overhaul the magnetos every 2 400 flight hours in accordance with the manufacturer s instructions Ref Unison Industries Slick manual L 1363 sect 4 d Overhaul the horizontal stabilator trim electric actuator every 2400 flight hrs in accordance with the manufacturer s overhaul instructions Replacement of Time Limited Parts The following parts are subject to the effects of aging and environmental deterioration and must be replaced at the time indicated Fuel Line Hoses rear of firewall 5 years or 2400 hours whichever comes first Brake Lines 7 years Pitot Static Lines 7 years Nov 02 3 1 ZENAIR CH2000 SERVICE MANUAL Calendar Inspection Requirements a Perform a visual inspection of the pitot static system connection Tygon splice at the wing root for security and condition every 12 months b Perform a visual inspection of the wing fuel tank compartments if wing fuel tanks are installed for corrosion cracking etc every 5 years UNSCHEDULED INSPECTIONS Unscheduled inspections must be performed anytime that unusual operating conditions are encountered which may affect the integrity or airworthiness of the aircraft Actions to be taken following the reporting of such events are as follows Hard Landing a Check ELT for inadvertent activation b Check main gear spring for deformation c Check nose gear and firewall for damage Propeller Strike a Check propeller for damages
61. st attached to the metal loop on top of the engine Main Gear Hoisting Lift the aircraft one side at a time and insert a padded sawhorse or equivalent under wing at main wing spar and rib rivet line LEVELING Fig 4 The aircraft may be leveled while the wheels are on the ground or during the weighing procedure while the wheels are on scales Leveling the aircraft for purposes of reweighing or rigging is accomplished as follows Position the level on the door sill upper fuselage longeron To put the airplane in a longitudinally level position either on scales or on the floor deflate the nose wheel tire until the proper position is reached or add shims under the two main wheels To level the airplane laterally place a level across the cabin on the right and left longerons shim one main wheel as required repeat longitudinal leveling WEIGHING PROCEDURE See Owner s Manual or Aircraft Flight Manual Chapter 6 TIEING DOWN Secure tie down ropes to the wing tie down rings and the tail skid at approximately 45 angles to the ground Leave sufficient slack to avoid damage to the aircraft when the ropes contract due to moisture TOWING Move the aircraft using the nose wheel optional tow bar hooked into the nose gear strut rings Caution Remove the tow bar when not in use as the propeller may hit it when engine is started Nov 02 2 3 ZENAIR CH2000 SERVICE MANUAL LOCKING AIRCRAFT The cabin doors are provided with
62. sure engine is running movement adjustment pressure case Dull or discolored luminous Age Replace instrument markings Incorrect reading Moisture or oil in line Disconnect lines and blow out REPLACEMENT OF INSTRUMENTS Fig 21 GENERAL Since all instruments are mounted in a similar manner a description of a typical removal and installation is provided as a guide for the removal and installation of the instruments Special care should be taken when any operation pertaining to the instruments is performed Remove the connections to the instrument and remove the mounting screws of the instrument Note Tag connections for ease of reinstallation Installation of the instruments will be in the reverse order given for removal After the installation is completed check all components for clearance of the control column condition proper operation and safety 3 Apr 95 9 13 ZENAIR CH2000 SERVICE MANUAL SECTION X ELECTRICAL SYSTEM GENERAL Fig 23 and Fig 24 The electrical system of the CH2000 is a 12 volt direct current single wire negative ground system electrical equipment is grounded to the metal structure of the airplane therefore the structure takes the place of the second wire 12 volt battery is incorporated in the system to furnish power for starting and as a reserve power source in case of alternator failure The battery and alternator are both connected to the bus bar from which all the
63. the cables to the fuselage for easy reinstallation Remove the right and left hinge bolts and remove the complete stabilator Caution Do not lose the hinge bushings REINSTALL the stabilator in reverse order of removal 44 Oct 00 ZENAIR CH2000 SERVICE MANUAL ONTHS 184 e DNIHSII9 15 WHOIV IISVIS 22 Neus _ t wmo 2 e i xs SNIHS OS H3HSVM 9NI43201 Javd 03 13 01 1108 Q3diNv19 508 TAIL REMOVAL Fig 8 4 5 Oct 00 ZENAIR CH2000 SERVICE MANUAL SECTION V LANDING GEAR AND BRAKE SYSTEM GENERAL The landing gear incorporated on the CH2000 is a fixed tricycle type of gear fitted with three Cleveland 500 5 wheels using four ply tires with tubes The nose gear is steerable through the rudder pedals The fixed cam automatically centers the nose wheel and rudder in the shock extended position See Fig 9 The main gear shock absorber is a mono leaf metal spring The two main gear wheels are equipped with single disc hydraulic brake assemblies which are actuated by the brake pedals connected to the brake master cylinders located forward of the rudder pedals The brake fluid reservoirs are an integral part of the pilot side master cylinders INSPECTION OF WHEELS Wh
64. the pump will operate in the correct direction Flow direction is indicated by arrow stamped on pump 8 2 3 Apr 95 ZENAIR CH2000 SERVICE MANUAL FUEL SYSTEM TROUBLESHOOTING Fuel gauge fails to indicate Broken wiring Gauge not operating Float partially or completely filled with fuel Float touching tank Circuit breaker out Check and repair Replace Replace float Bend float arm Reset and check Fuel gauge indicates full Incomplete ground Check ground connections when tanks are not full at fuel transmitter No fuel pressure Fuel valve stuck indication No fuel in tanks Defective fuel pump Defective gauge Obstruction in inlet side of pump Pressure low or pressure surges Faulty diaphragm Unidentified leak Fuel lines damaged or improperly installed Fuel valve leaks Worn parts Nov 02 Check valve Check fuel fill Check pump for pressure buildup Check diaphragm and relief valves in engine pump Check for obstruction Air leak in intake lines Replace gauge Trace lines and locate obstruction Replace or rebuild pump Locate and repair or tighten Replace valve 8 3 ZENAIR CH2000 SERVICE MANUAL 30139189395 ONILLIS 1903 779314 HOJIV1O0SV9 1 33S AAO NO 303 N33HOS YAONIS 1031358 1303 LATLNO ANYL dvuls 1304 Y The S3NI1 G IO3INVW 1903 3SOH 1903 15
65. to insure the valve door functions properly when the control is pulled out the door should be completely open to permit full air flow when the control is pushed in the valves should close off all air passage HOT WEATHER USE The slat hose from the engine baffle to muffler heat shroud to cabin can be replaced with a one piece scat hose from engine baffle to cabin This will give additional fresh air in cabin area Nov 02 11 1 ZENAIR CH2000 SERVICE MANUAL 181100 1V3H 24 31899 1O31NOOS 1V3H b s 3SOH X314 131100 1 0433 ASOH X314 15 aNnouv anouHs LVSH 3SOH X314 CABIN HEAT AND VENTILATION Fig 25 Nov 02 11 2 ZENAIR CH2000 SERVICE MANUAL SECTION XII CABIN DOORS DOOR PLACARD FRWD lt 20 2 20 FRONT EDGE OF DOOR DOOR HANDLE 20 F 32 4 24693 274 WITH LOCKTITE 94733 524693 5274 DOOR TRIM PE NS 960 10 AS REQ D e E oce a AN960 416 12 20 F 32 3 TYPICAL DOOR LOWER STOP BEARING INSIDE UPPER LONGERON REQ D FRONT REAR OF EACH DOOR IN 20 F 32 3 IN LOCKED POSITION LEFT DOOR VIEWED FROM INSIDE DOOR HANDLE Fig 26 From inside the aircraft with the gull wing doors closed the door handle is parallel with the arm rest Label 20 E 2 20 with the closed line is lined up with t
66. urpose of changing the lateral trim a fixed tab may be installed on one aileron length as required See Fig 15 REMOVAL INSTALLATION OF STABILATOR CONTROL CABLES AND TRIM TAB Fig 17 REMOVAL Remove the trim motor access plates Fig 2 2 Disconnect the cables at the stabilator horn by removing the two bolts 3 Disconnect the cables at the control column by removing the bolts 4 Open the fuselage access panel Fig 2 5 Remove the two pulleys and remove the cables 6 Remove the cables REINSTALL in reverse order of removal and check the rigging as follows STABILATOR CONTROL RIGGING Fig 17 1 Adjust cable tension to 40 lbs 5 2 With the stabilator trailing edge up on the stop check deflection limit 12 5 3 With the stabilator trailing edge down on the stop check deflection limit 9 5 5 Note Stabilator neutral parallel to upper fuselage longeron See Fig 17 4 Check that when stabilator hits the stops there is 1 2 12mm minimum clearance to any item forward of the instrument panel 5 Check all components and connections for condition proper installation operation and safety ANTISERVO TRIM TAB ADJUSTMENT With the stabilator in neutral position see Fig 17 the trim tab travel is adjusted with the adjustable fork ends so that it deflects 10 up for full nose down trim and 5 down for full nose up trim Caution Ensure that the rod is engaged with 1 4 6mm minimum in t
67. urrent received and the amount of current drain on the battery e VOLTMETER GENERAL The Voltmeter is mounted in the instrument cluster located on the instrument panel This instrument measures the level of the battery or Alternator output 3 Apr 95 9 7 ZENAIR CH2000 SERVICE MANUAL OPTIONAL INSTRUMENTS Fig 21 e RATE CLIMB INDICATOR GENERAL The rate of climb indicator measures the rate of change in static pressure when the airplane is climbing or descending By means of a pointer and dial this instrument will indicate the rate of ascent or descent of the airplane in feet per minute TROUBLESHOOTING See following table RATE OF CLIMB INDICATOR Pointer does not set on zero Aging of diaphragm Reset pointer to zero by means of setting screw Tap instrument while resetting Pointer fails to respond Obstruction in static line Disconnect all instruments connected to the static line Check individual instruments for obstruction in lines Pointer oscillates Leaks in static lines Disconnect all instruments connected to the static line Check individual instruments forleaks Reconnect instruments to static line and test installation for leaks Replace instrument Defective mechanism e VACUUM SYSTEM Fig 21 and Fig 22 GENERAL The vacuum system employed to operate the gyro instruments is comprised of an engine driven dry vacuum pump vacuum regulator valve and the necessary tubing to complete t
68. visual inspections unless otherwise specified They are to be performed by trained and qualified personnel using appropriate tools and adequate lighting Prior to commencing the scheduled inspections listed in Table 1 Thoroughly clean the aircraft and engine b Remove or open the necessary inspection and access panels the engine cowlings the spinner and the optional wheel fairings and c Review the aircraft records for outstanding Airworthiness Directives AD s Airworthiness Limitations AWLs Service Bulletins SBs or other maintenance requirements pitot static system ELT fire extinguisher etc Contact the manufacturer for latest AD SB and Service Letters Note addition to the tasks specified in Table 1 do the preflight inspections described in the Owner s Manual SCHEDULED INSPECTIONS Scheduled inspections include the items listed in Table 1 Inspection Form the overhaul requirements for the engine and propeller the calendar time inspections and the one time inspections done following specified tasks Do the following Inspection Form Requirements Perform the tasks in Table 1 at the intervals shown Refer to Paragraph 6 Overhaul Requirements Overhaul the engine Lycoming 0 235 every 2400 flight hours in accordance with Lycoming Direct Drive Engine Overhaul Manual P N 602947 b Overhaul the propeller Sensenich Model 72 CK Series every 2 000 flight hours in accordance with Sensenich overhaul inst

SERVICE MANUAL - Long Island Flying

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