ZLIN AIRCRAFT ass Z 24a2L koe DOC. No. 003.032.1 Maintenance Manual-Vol. II CHAPTER 7 SUPPLEMENTARY INFORMATION FOR ACCOMPLISHMENT OF INSPECTIONS CONTENTS Strana 7.1. AIRFRAME PARTS REPLACEMENT 7-3 7.2. BOLTS, SCREWS, PINS AND BUSHINGS FOR REPAIRS 7-5 7.3. INSTRUMENTS AND APPLIANCES 7-9 7.4. SUMMARY OF MATERTALS Jou 7.5. | TIGHTENING THREADED JOINTS, TENSIONING CONTROL CABLES 7-19 7.6. SPECIAL TOOLS AND JIGS 7-27 May 1, 1998 7-1 SUPPLEMENTARY INFORMATIONZ 242 ZLIN AIRCRAFT a.s Maintenance Manual-Vol. II DOC. No. 003.032.1 Otrokovice INTENTIONALLY LEFT BLANK 7-2 May 1, 1998 SUPPLEMENTARY INFORMATIONZLIN AIRCRAFT a.s. Z 2424 Otrokovice DOC. No. 003.0321 Maintenance Manual-Vol. IT qeted May 1, REPLACEMENT OF AIRCRAFT PARTS MANDATORY REPLACEMENT 1) 2) Parts with limited service life The List of parts having the service life limited, fre- quency of their replacements inclusive, is provided in MM I, Chapter 9. Hoses Requirements for replacement of hoses are defined in MMI, subsect. 5.2.16: a) as to hoses of fuel, oil and brake systems - in the explanatory note (1), b) as to hoses of pitot-static system and hoses of en- gine manifold gauge - in the explanatory note (38). CAUTION: RUBBER HOSES MOUNTED ON THE AIRCRAFT MAY NOT BE OLDER THAN 5 YEARS SINCE THE DATE OF THEIR MANUFACTURE INDI- CATED ON HOSES SURFACE. REPLACEMENT PER CONDITION 1) Airframe parts Parts, not mentioned in the preceding subsect. 7.1.1, are to be replaced at their excessive wear, damage or malfunction. Their service lives are time-unlimited. Instructions for judging the airframe parts condition are outlined in Chapter 3 of this Manual. 2) Instruments and appliances Information on service lives of instruments and appli- ances is given in sect. 7.3 of this Manual. 1998 7-3 SUPPLEMENTARY INFORMATION 08Z 242 ZLIN AIRCRAFT as. Maintenance Manual-Vol. II DOC. No. 003.032.1 ‘Otrokovice 7.1.3 MODIFICATIONS OF AIRFRAME PARTS AT THEIR FIRST INSTALLING Name Designation —_| Modification Fuselage: Fuselage frame (NOTE)| L 242.1100-00.00 aL outer body L 242.1500-00.00 a2 Wings: Wing L.H., equipped | 2 242.0210-00.00 a3 Wing R.H., equipped | Z 242.0220-00.00 a3 Empennage: Stabilizer 2% 242.3100-00.00 aa controls: Segment Z 42.4310-00.11 as NOTE: The fuselage framework is delivered as the assembly inclu- ding welded-on and installed parts L 242.1200-00.00. Explanatory notes to the "Modification" column AL a2 a3 aa AS T-4 Check diameters of holes in the fuselage frame sus- pensions and, if necessary, rerean them to be identi- €al with hole diameters in’ appropriate counterparts: a) wing attachment fittings subsect. 7.2.2 b) main gear legs attachments = subsect. 7.2.5 ¢) engine mount suspensions - subsect. 7.2.7 Adapt the body as required. If necessary, adapt attachment bottom covers by cut- ting into proper shape. If necessary, adapt the stabilizer-to-fuselage inter- section (see CAUTION at beginning of subsect. 4.2.9 of this Manual). Set the segment into attachment in the cockpit and drill it together with appropriate counterpart. Re- xean holes for fitted bolts to the diameter 6 H 8 (dia. in inches is shown in subsect. 7.2.8 hereof). Fig. in the Z 242L Catalog: © 142.4320-00.00 for aircraft up to S/N 0655, Z 143.4310-00.00 for aircraft from $/N 0656. Parts: the segment - item 5 (1 pc) the fitted bolt - item 16 (2 pcs) May 1, 1998 SUPPLEMENTARY INFORMATIONZLIN AIRCRAFT as, Z 242 Otrokovice DOC. No. 003.032.2 Maintenance Manual-Vol. IT 7,2, BOLTS, SCREWS, PINS AND BUSHINGS FOR REPAIRS This Supplement provides the summary of important joints on the airframe together with appropriate Drwg. Nos. and diameters of bolts, screws, pins or bushings. First the original part dimension (mounted by the Manufacturer) is given, then equivalents of abnormal diameters determined for repairs Abnormal bolts, screws and pins determined for repairs are identified by the numerical code (diameter without decimal point) on heads (e.g. numerical code 121 denotes dia. 12.1 mm (0.476 in), code 122 denotes dia. 12.2 mm (0.480 in), etc.). Millimeters to inches ‘conversion is given in subsect. 7.2.8 of this Supplement. Item Nos. are identical with numbers in the Z 2421 Catalog IN AFTER REAMING, DEBURR HOLE EDGES WITH THE COUNTERBORING TOOL. Pos Diameter (mm) 7.24 “STABILIZER STRUT-FUSELAGE" JOINT sores, | holes Fig. L 242.1300-00,00 in Z 2421 Catalog pins lem 8 Rearclamping bolt 42.1300-00.12 4 |o10.0 n7| 100 He 8A Z 42.1900-00.52 10.1 n7| 10.1 HB 8B 2 42.1300-00.53 102 n7| 10.2 H8 ac 2 42.1300-00.54 103 h7| 103 HE 8D 7 42.1300-00.55 104 n7] 10.4 HB 7.2.2 WING ATTACHMENT FITTINGS (aumbers of pieces are given as a total for both wings) Fig. in Z 2421. Catalog: 1 242.2100-00.00/. 242.2200-00.00 Wing upper attachment Hem 13 Vertical pin 2.42.2181-00.00 141 |@200 n6| 0200 He 438 2 42.2182-00.00 20.1 n6| 20.1 He 138 2 42.2183-00.00 202 n6| 202 H6 13¢ 242.2184-00.00 203 n6] 203 He 13D 2 42.2185-00.00 204 n6] 20.4 HE Wing lower attachment Item 17 Horizontal pin Z-42.2181-00.00 141 |@200 n6| @ 200 He 174 2.42.2182-00.00 20.1 6] 20.1 He 178 .42.2183-00.00 202 ne] 202 H6 176 2 42.2184-00.00 203 6] 20.3 H8 17D 2.42.2195-00.00 204 h6| 20.4 HB Wing rear (auxiliary) attachment tem 19 Pin 2 42.2100-00.22 11 |o120) |0120 H7 419A 2 42.2100-00.23 124 424.7 198 2 42.2100-00.24 12.2 [nee] 12.2 H7 49C 2 42.2100-00.25 123 123 HT 190 2 42.2100-00.28 124 124 H7 NOTE: Tolerance for wing rear attachment pins diameter including mm to in conversion is given in subsect. 7.2.8. of this Manual May 1, 1998 7-5 SUPPLEMENTARY INFORMATIONZ242L ZLIN AIRCRAFT as Maintenance Manual-Vol. II DOC. No. 003.032.1 (Qtokovice Pes Diameter (mm) 7.23, STABILIZER JOINTS bolts, | holes Fig, L242.1300-00.00 orL 242.9100-00.00A in z242L ser Catalog. “Stabilizer rear spar-strut” joint tiem 4 Rearjoint bolt 242:3100-00.10 2 |e100 n7 |o100 HB an 2423100-00.43 to. h7 | 10.1 HB 4B 2423100-00.44 102 n7 | 102 H8 ac 242:3100-00.45 103 n7 | 103 HB pr) 2423100-00.46 104 h7 | 10.4 HB "Stabilizer front spar-strut” joint Item & —Frontjoint bolt 2423100-00.11 2 | e100 n7 |e 100 He 5A 42.3100-00.47 40.1 h7 | 10.1 He 58 2423100-00.48 102 n7 | 102 HB sc 2423100-00.49 103 n7 | 103 He Es) 2423100-00.50 1047 | 104 H8 7.24 RUDDERCONTROLFRONTPART Fig. L242.4230-00.00 in Z 2421 Catalog “Brake pedals-countershaft” joint em 14 Bolt 242.4210-00.16 4 |o60t |o60H8 14a 242.4210-00.15 64 8 148 242.4210-00.14 62 8 1ac 242.4210-00.13 63% | 6348 14D 242.4210-00.12, 648 | 64H8 7.2.5 MAINLANDINGGEARLEG ATTACHMENT (number of bottsis given asa total for both ianding gearlegs) “Landing gear leg-fuselage frame” joint tem 4 Attachment bolt 2143.5100-00.08 11 [012018 |o 12.0 HB 4a 2143.5100-00.13 12118 | 121 HB 4B 2143.5100-00 14 1228 | 122 HB a 2143.5100-00.17 1238 | 123 HB 0 2143,5100-00.18 12418 | 124 HB 7.26 NOSELANDINGGEARSTRUTS Fig. C 142,5210-00.000rZ.42.5210-00.05 inZ.242L Catalog “Nose landing gear-struts (1), (2)"Jolnt tiem 10. Hemmedbushing 242.5210-01.03 141 |2180 ne |o 18.0 H7 410A 2425210.01.17 1818 | 18.1 H7 108 2425210.01.18 192 na | 182 H7 10C 242.5210-01.19 18.3 hB 18.3 H7 10D, 242.5210-01.20 18.4 hB 18.4 H7 REVISION No.4 1-6 ‘Aug 15,2003 INTRODUCTIONZLIN AIRCRAFT as Z 242 Otrokovice DOC. No. 003,032.1 Maintenance Manual-Vol. IT Pes Diameter (mm) ae holes: 7.2.6 NOSE LANDING GEAR STRUTS - cont. screws, "Nose landing gear-strut (2)" joint pins tem 18 Fittedbolt ax43_ oncsi20.4 [t+ |o ote |o 80H 418A 8,1x43 MON 1167 818] 81 H8 188 8,2x43 MON 1167 82% | 82H 18C 8,3x43 MoN 1167 338] 83 HB 180 84x43 MoN 1167 8416] 84 H8 “Loft strut (2)-fuselage” joint and “dual strut (1)-fuselage’ joint tem 19 Fitedbott 8x27_ONL312014 | 142 |o 8018] 8.0 HB ton 8.1227 MoN 1167 ait] 818 198 8,227 MoN 1167 8218 | 82 HB 190 8,3x27 MoN 1167 23fe| 83 He 190 84x27 MON 1167 8418] 8.4 HB “Nose landing gear-dual strut (1)" joint tem 20. Fittedbott 8x49 ONL 9120.14 1 |e 80%]o 80 H8 208 81x49 MoN 1167 818] 81 HB 208 8,2x48 MoN 1167 8218] 82H 20c 8 8x49 MoN 1167 a3] 83 He 200 84x49 MON 1167 a4fe| 848 7.2.7 ENGINE MOUNT Fig. L 242.6300-00.00 in Z 2421 Catalog “Upper struts-fuselage" Item 14 Fitted bolt 8x35 ONL312014 | 1+ |o80% |o80H7 14a 8,1x35 MoN 1167 ait | 81 H7 148 8,2x35 MoN 1167 8218 | 82 H7 140 8,3x35 MoN 1167 a3 | 83 H7 14D 84x35 MON 1167 3418 | 8447 “Lower struts-fuselage” joint tem 15 Fittedbolt x31 onLsi20.14 | t+ [280% |o80H7 15a 8,181 MoN 1167 818 | 81 H7 158 8,2x31 MON 1167 821 | 82 H7 15C 8,3x31 MoN 1167 ass | 8347 15D 8,4x31 MoN 1167 a4 | 84H7 May 1, NOTE: Fitted bolts with abnormal diameters, items 14A through 14D, 154 through 15D are not given in ‘earlier issues of the Z 2421 Iilustrated Parts Catalog (up to the end of series 18, ie. up to SIN (0689). In case of prospective ordering, use bolts designations as mentioned in the paragraph above ited bolts are Identical for all S/N of Z 2421 aircraft. 1998 7-7 SUPPLEMENTARY INFORMATIONZ 242n ZLIN AIRCRAFT as Maintenance Manual-Vol. II DOC. No. 003.032.1 Otrokovice 7.2.8 MILLIMETERS TO INCHES CONVERSION TABLE Outer diameters Inner diameters (pins, screws, bushings) (holes for pins, screws, bushings) Diameter Diameter mm in, mm in, 96.0 8 023512 - 0.23583 96.0 18 023622 - 0.23693 61 18 0.23878 - 0.23964 6.4 HB 0.24016 - 0.24087 6218 028272 - 0.24358 62 HB 0.24409 - 0.24480 63 fe 0.24865 - 0.24751 63 HB 0.24803 - 0.24874 64 18 0.25059 _-_ 0.25145 64 HB 0.25197 _- 0.25268 $8.0 18 0.31358 - 0.31445 98.0 HB 0.31496 - 0.31582 81 8 031752 - 0.31898 8.1 HB 0.31880 - 0.31976 82 18 oszs - 032232 82 HB 0.32283 - 0.32370 83 18 032539 - 0.32626 8.3 He 0.32677 - 0.32763 84 18 032923 - 0.33020 84 HB 0.33071 - 0.33187 980 HT 031408 - 0.31555 81 H7 0.31880 - 0.31949 82 HT 0.32283 - 0.32342 83 H7 0.32677 - 0.32736 84 H7 0.33071 - 0.33130 9100 fT 030311 - 0.30370 100 He | 038370 - 0.30657 40.1 h7 0.30693 - 0.30764 101 HB | 0.39764 - 0.39870 402 h7 0.40087 - 0.40157 102 He | 0.40157 - 0.40264 103 h7 0.40480 - 0.40551 10.3 HB 0.40551 - 0.40657 404 hz 0.40874 _- 0.40045 10.4 H8 0.4045 - 0.41051 120 18 0.47075 - 0.47181 912.0 HB 0.47244 - 0.47350 1218 0.47488 - 0.47575 12.4 HB 0.47638 - 0.4744 122 8 0.47862 - 0.47068 12.2 HB 0.48031 - 0.48138 123 8 0.48256 - 0.48362 123 HB 0.48425 - 0.48531 124 18 0.48650 - 0.48756 124 HB 0.48819 - 0.48925 9120 oa7ies - 0.47224 9120 H7 0.47248 - 0.47808 124 0.47578 - 0.47618 121 H7 0.47638 - 0.47697 122 fwore| 0.47072 - 0.48012 122 H7 0.48031 - 0.48080 123 0.48966 - 0.48405 123 H7 0.48425 - 0.48484 124 0.48760 - 0.48790 124 H7 0.48819 - 0.48878 9160 he 0.70760 - 0.70866 e180 ri? | 070866 - O.70957 18.1 n8 0.71130 - 0.71260 1817 | 71260 - 0.71942 18.2 ns 0.71523 - 0.71653 182 H7 0.71653 - 0.71736 18.3 hs 0.71917 - 0.72087 18.3 H7 0.72047 - 0.72130 18.4 hB O.72311_- 0.72441 10.4 H7 072461 = 0.72523 920.0 he 0.76889 - 0.78740 920.6 HE 0.78740 - 0.78781 20.1 6 0.79083 - 0.79134 20.1 HE 079134 - 0.79185 202 n6 0.70476 - 0.79527 202 He 0.79527 - 0.79579 203 n6 0.79870 - 0.79921 203 H6 0.79921 - 0.79972 20.4 h6 0.80263 - 0.80315, 20.4 HE 0.80315 - 0.80366 NOTE: Allpins diametersidentified with “Note” are determined for the wing rearjoint and have the identicaltolerances -0,005 -0,000 197 0,015 -0,000 591 7=8 May 1, 1998 mm, ie, in, SUPPLEMENTARY INFORMATIONZLIN AIRCRAFT ass Z 2a2n Otrokovice DOC. No. 003.032. Maintenance Manual-Vol. 11 7.3, INSTRUMENTS AND APPLIANCES 7.3.1 GENERAL 1) 2) 3) Repairs of instruments and appliances should be carried out in accordance with their condition. The service life of instruments and appliances, if de- termined, is higher than the airframe service life. Instruments, which are checked periodically, are listed in the following Table, intervals for mandatory checks inclusive. 7.3.2 INSTRUMENTS CHECKS Instrument (appliance) check Notes Name Model nh |years Air-speed |LUN 1106.31-8 Check is to be accomp- indicator |LUN 1107.03-8 - | 1¥ |lishea at pitot-static LUN 1107.31-8 system leakage test (MD 6.804) Altimeter |UI 5934 D - [aw Magnetic [27 LUN 1224.02-8| - | 1y |compass compensation is compass carried out (MD 6.904) Fuel LUN 7520.02-8 1500] - |Leakage is to be chec- valve ked within framework of fuel system leakage Fuel LUN 7610-8 1500] - |test (MD 6.703) filter Marking: h = flight hours 1¥ - check is carried out 1x per year NOTES: q) Conditions for accomplishment of the engine and the propeller overhauls are outlined in the "Z 2421 Main- tenance Manual - Vol. I", subsect. 5.1.2 and 5.1.3. (2) Intervals for accomplishment of the nose landing gear overhauls are given in subsect. 3.5.5 of this Manual. (3) Instructions for mandatory replacement of the airframe parts are provided in sect. 7.1 of this Manual. May 1, 1998 7-9 SUPPLEMENTARY INFORMATIONZ 242 ZLIN AIRCRAFT as, Maintenance Manual-Vol. II DOC. No. 003.032.1 Otrokovice INTENTIONALLY LEFT BLANK 7-10 May 1, 1998 SUPPLEMENTARY INFORMATIONZLIN AIRCRAFT as. Z 242 Otrokovice DOC. Wo. 003.032.1 Maintenance Manual-vol. IT 7.4. SUMMARY OF MATERIALS 7.4.1 GENERAL 1) This Supplement provides the summary of chemical compo- sition and mechanical characteristics of metallic mate- rials, used by the Manufacturer at the % 2421 aircraft construction, as well as the summary of recommended fo- reign equivalents. 2) When replacing the original material by equivalent on structural parts, verify and compare the strength cha- racteristics of both materials. Welded parts should be checked also for weldability of equivalent material and connecting parts (e.g. bolts, screws, nuts, rivets, washers) should be checked also for dimensions. Materials given in tables in parentheses are not recom- mended by the Manufacturer as equivalents of used mate- rials. Select the equivalent material in accordance with function and loading of replaced part and respect- ing its manufacture procedure. Values in parentheses are informative. 3) Substitute materials may be used only according to ins- tructions given in the “Table of dimensions, limits and clearances". Following materials and parts ‘must not be substituted by any equivalent: a) Fuselage frame is welded from steel tubes L-cM3.9. After welding, anneal joints with the flame to the strength 588-785 MPa. b) Wing spar flanges are made from light alloy (semi- product profile) 2 42.4203.61. c) Wing skin, leading edge of ailerons and wing flaps, skins of rudder, stabilizer, tail fin and rear fuse~ lage part are made from the light alloy sheet D 16 ATV. d) Rear skin of ailerons and wing flaps, elevator skin, wing spar web, spar of elevator and rudder, ribs of wings ans empennage and rear fuselage part bulkheads are made from aluminium alloy sheet % 42.4253.61. 4) Unless stated otherwise, values given in tables are mi- nimum. 7.4.2 DESIGNATIONS OF MECHANICAL CHARACTERISTICS Ry - the tensile strength is the stress corresponding to the highest load F, before breaking the test speci- men. F, Ro (pa) 8 Ry - the yield point is the stress at which the residual deformation reaches the specified value. The speci- fied value is expressed in percents of the test spe- cimen initial length. The residual deformation value is determined by the marking (e.g. Rp, 0-2). May 1, 1998 7-1 SUPPLEMENTARY INFORMATION mZ 242, ZLIN AIRCRAFT as Maintenance Manual-Vol. II DOC. No. 003.032.1 Otrokovies A HB - the elongation is the ratio of the test specimen elongation at rupture to the initial measured speci- men length and is expressed in percents: Ly - by A= ( ) x 100 The elongation measured Sn the “short” test specimen (determined for extensible material) is indicated by AS, the elongation measured on the "long" test speci- men is indicated by A10 marking. - the Brinell hardness is the ratio of the acting test load to the area of the ball impression. - the Vickers hardness is the ratio of the acting test load to the area of the standard tetrahedral “pyra- nid" impression. 7.4.3 STEELS 1) Comparison of different standards czech Germany | France Great |the united] Inter- Republic Britain |states of | national America. sn DIN NF BS AISI, ASTM Iso 11600 st 60-2 | a 60-2, | (55c) 1044, S (A 65-20) (GRADE 65) 12050 | C45,Ck45, |cc45,xc42) 060a47, 1045, c4sE Cras XC48 (cpsios) | (c1042) 14100 | 100cre (100 cs) | 534 a99,| (52100) R100 (En.31) 15230 - ascvi2 - - - 15231 27Mncrv4 - - (5130) - L-cm3 | 25crMo4 25cp4 70Ba25 | (4130H) | 25crMo4 (cbs110) | (4125) L-ROL, - - - - - L-ROLN - (once) - - - L-scH | (54sicr6) |(60Sc7) | (En4sa) | 9254 - (A401) LW6H c45,Ck45, |cc45,xc42] o60a47, | 1045, c45E cfs, xcas (eps108)| (c1042) 703) May 1, 1998 SUPPLEMENTARY INFORMATIONZLIN AIRCRAFT as, Otrokovice Z 242 Doc. No. 003.032.1 Maintenance Manual-vol. IZ 2) Chemical composition of steels Material Additives (%) design. ec [cr | cu] mn | Mo | wi P ge Site) 11600 min|0.50 0.009] 0.045] 0.045 max| 0.55 0.011] 0.055] 0.055 12050 min|0.42 0.50 0.17 max|0.50/0.25/0.30]0.80 0.30 }0.040/0.04 |0.37 14100 min}0.95/1.25 0.35 0.17 max|1.05]1.50 0.60 0.035|0.035|0.37 15230 min|0.24|2.20 0.40 0.17/0.10 max|0.34|2.50 0.80 0.035|0.085]0.37]0.20 15231 min|0.24|0.60 1.00 0.17/0.10 max|0.30|0.90 1.34 0.035] 0.035]0.37/0.20 L-cm3. min|o.22/0.90 0.50]/0.15 0.17 max|0.29]1.20]0.25|0.80/0.25|0.30 |0.030|0.030/0.37 L-ROL min}0.28|0.80 0.80 0.90 max|0.35}1.10/0.25]1.10 0.30 |0.030|0.030]1.20 L-ROLN min|0,27/0.90 1.00 1.40 0.90 max|0.34/1.20/0.25]1.30 1.80 |0.030/0.030/1-20 L-ScH min|0.50|0.60 1.00 0.17/0.10 max|0.60/0.90 1.34 0.035]0.035|0.37/0.20 L-WeH min|0.42 0.50 0.17 max|0.50/0.30/0.25/0.80 0.30 |0.035]0.035/0.37 998 7-13 May 1, 1! SUPPLEMENTARY INFORMATION meZ 242 ZLIN AIRCRAFT as. Maintenance Manual-vol. II DOC. No. 003.032.1 —_trokovice 3) Mechanical characteristics of steels Material |semi- 2] as [ayo | HB | Note design. | product Ba |*RDa"| 3/78 1160.0 | bar |s90-710 | 335 | 11 274 12050.0 | bar |min, 540 | 325 | a7 225 14100.3 bar min. 780 225 15230.7 | bar [980-1160 | 635 | a2 300-359) 15231.3 bar 880-1030 735 12 269-317 ‘L-CM3.3 bar max. 740 max. 211 1a. | tube |590-900 | 440 @) +33 sheet max. 700 17 =| max.199 L-ROL.3 sheet max.730 (2) te | “bar [930-1080 | 735 | 13 17. | sheet |1080-1270| 930 | 10 | 10 |2es-322 (10¢)} “par 1080-1420] 930 | 12 @) T-ROLN.3| bar |max. 880 max. 253 teweH.6 | bar [640-780 | 390 | 20 192-239 L-SCH.3 strap max. 800 max. 253 (4) te | strap |1470-1670 6 NOTES: (1) Fuselage frame junctions (L-cM3.9 material) are annea- led after welding with the flame to the strength 588- 785 MPa. (2) Wing main attachments (L-ROL.3 material) are heat tre- ated to the condition of L-ROL.7. (3) The Table states mechanical characteristics 10¢ accor- ding to the CSN 02 1005 specification. (4) Landing gear legs (L~SCH.3 material) are after shaping heat treated to the condition of L-SCH.8, HV = 463 - 520. 7-14 May 1, 1998 SUPPLEMENTARY INFORMATIONZLIN AIRCRAFT ass. Zz 242 Ouckowics: Doc. No. 003.032.1 Maintenance Manual-Vol. II 4) Supplementary digits meaning The first supplementary digit following the material designation indicates the type of steel heat treatment: First! Type of heat treatment digit +0 |No heat treatment +1 [Normalizing -2 [Annealing (of determined type) +3 |Soft annealing 4 |Hardening or hardening/tempering at low tempera- tures or after temper annealing (only at auste~ nitic steels) +5 _|Normalizing and tempering +6 |Heat treatment to the lower strength value, usu- al for appropriate type of steel +7 |Heat treatment to the mean strength value, usual for appropriate type of steel +8 |Heat treatment to the upper strength value, usu- al for appropriate type of steel +9 |Heat treatment of other type as per special con- ditions not covered by digits 0 through 8 The second supplementary digit following the material designation is given only at sheets and straps. May 1, 1998 7-15 SUPPLEMENTARY INFORMATIONZ 24a2L ZLIN AIRCRAFT a's, Maintenance Manual-Vol. II DOC. No. 003.032.1 ‘Otrokovice 7.4.4 LIGHT NON-FERROUS METALS 1) Comparison Czech Germany | France Great |the united] Inter- Republic Britain |States of | national America ésn DIN NE BS AISI, ASTM Iso 242 4201 | AlCuMgl 20178 20140 2017 | AlcuaNgsi 3.1325 (a-uae) | Gna) (2014) 242 4203 | AlCuMg2 2024 2024 2024 AlcuaMg1 (3.1355) | (a-u4c) | (197) ZA2 4253 - (a-U4F1)|clad.2024] Al clad - Al 99.5 +2024 clad 242 4400 | AlMgSi1 60s2 6062 (6061) |a1si1mgun (3.2315) | (ase) (112) D 16 AM DINI745 - Clad.2024] Al clad - +2024 D 16 ATV | DINI745 - Clad.2024] Al clad - +2024 42 4911 - - - (4047) - 2) Ch composition of Material Additives (%) alt designation cu | mg] mn| Fe] ni] si] Ti | zn |others 242 4201 min|3.8 /o.4]o.4] - | - | - | - | - - resi- max|4.8 |1.1]1.0/0.5]0.1/0.5/0.2 ]o.2 | 0.15 | due 242 4203 min|3.8 /1.2/0.4] - | - | - | - | - - resi- max|4.8 |1.8]/1.1/0.5|0.1/0.5/0.2 |o.2 | 0.15 | due 242 4206 min|1.8 /0.4/0.4] - | - |0.7/0.02] - - resi~ max|2.6 |0.8/0.8/0.7|0.2/1.2/0.10]0.3 | 0.2 due 242 4253 min|3.8 /1.2/0.4) - | - | - | - | - - resi- max|4.8 [1.8/1.1]0.5]0.2/0.5/0.2 |o.2 | 0.15 | due 7-16 May 1, 1998 SUPPLEMENTARY INFORMATIONZLIN AIRCRAFT as. Z 2425 Otrokovice Doc. No. 003.032.1 Maintenance Manual-Vol. II Material Additives (%) alt designation cu | Mg] Mn} Fel ni] si] Ti | zn |others Cladding material max|o.0s|0.4] - | - | - |0.3|0.05]0.07] - 99.5 za2 4400 min| - | - lo.4}o.7| - |o.7| - | - - resi- max|0.05/0.5/1.0/1.2| - [1.4/0.2 [0.2 | 0.15 | due D16 ATV min|3.8 j1.2/0.3} - | - | - | - | - - resi- max|4.9 [1.8/0.9] - | - |o.5| - jo.3 - due NOTE: 3) Chemical composition of magnesium alloys ‘The D 16 ATV material and the 242 4253 material are alumi- nium-clad on both sides of the sheet. Mate- |Additives % Additival elements % Mg rial design.| al] zn| Mn | si | cul Fe | Be | Ni | zr | Ti |To~ tal 42 4911 min|7.5/0.2/0.15] - | - | - | - | - - - - max|9.0|0.8]0.50/0.25]0.1|0.08/0.01|0.01|0.003]0.002|0.40/Re Marking: Re - residue 4) Mechanical characteristics May 1, 1998 Material | semi- Be Bee lars Note designation| product Se z42 4201.01| sheet 290 a ea a ‘61| sheet 370 as | - | 5 242 4203.61| sheet 430 27s | - | a3 te1] tube 440 315 | - | 10 161] profile| 450 335 | a2 | a2 z42 4206.71| bar 380 275 | a0 | - 242 4253.11] sheet |max. 200 | - | - | 12 clad 161] sheet 440 20s | - | 13 clad 42 4400 .71| bar 270 9s | ar | 9 D 16 AM sheet | 150-225 | - | - | 10 7237 SUPPLEMENTARY INFORMATION42 242 ZLIN AIRCRAFT as. Maintenance Nanual-Vol. IE DOC, No. 003.032.1 _Otrokovice Material | seni- Be | Foe | ts |e Note Gesignation| product| mBa af | D a6 AT sheet 407 20 | - | as Dac atv | sheet 407 ao | - | as clad 5) Supplenentary digit meaning Supplementary digits follo- Material quality wing material designation -00 commercial quality Hot formed product, .02 annealed, guaranteed quality waa non-guaranteed, 8) 0.2: guaranteed qualiey “4 soft |deep-arawing, guaranteed quality 115 guaranteed Rp 0-2 guaranteed qbality cold fornea v2 non-guaranteed Ry 0,2: [product seni-|guaranteea quali hard 125 guaranteed R, 0,27 Guaranteed qbality ert hard [non-guaranteed Ry 0,2) guaranteed qualiky ar spring material hardness -52 spring material hardness-double -62 guaranteed quality Hot or cold for- ned product, 62 guaranteed quality and cold hardened equalized a guaranteed R, 0,2; guaranteed [Hot or cola for- quality med product, hot hardened 7-18 SUPPLEMENTARY INFORMATION May 1, 1998ZLIN AIRCRAFT as. 2 242 Otrokovice Doc. No. 003.032.1 Maintenance Manual-vol. II 7.5, TIGHTENING THREADED JOINTS, TRNSIONING CONTROL CABLES 7.5.1 GENERAL 1) This Supplement provides information for tightening threaded joints on the airframe as well as information for tensioning control cables and for mounting the en- gine, the propeller and the propeller R.P.M. governor. 2) When’ tightening slotted nuts secured by the cotter pin, use the torque moment tolerance to set nuts in the po: sition appropriate for locking; i.e. adjust the nut slot opposite to the screw hole. At tightening nuts and screws secured by the other way (e.g. using the tab washer or the locking wire), adjust the torque wrench to the mean value of prescribed torque moment and then tighten the joint. 3) Determined torque moments are valid on condition of clean, dry and corrosionless threads. They are not ap- plicable to tightening either aluminium alloy or self- locking nuts. 4) At assembly, observe values for tightening threaded joints and for tensioning control cables given in sub- ect. 7.5.2. Values mentioned in subsect. 7.5.3 are re~ commended ones. 7.5.2 DETERMINED VALUES 1) Torque moments Joint nuts~ ‘Torque moment Note pos wm | kpm | ipe.ft | 1pe-in. Attachment of engine on 4 33-35 |3.4-3.6] 24-26 |292-320] (2) engine mount Attachment of propeller on 6 25-90 |8.7-9.2| 63-66 |752-796] (2) engine flange Stabilizer 3x 2| 44-49 |4.5-5.0] 32-36 [390-435] (3) attachment Wing main 242] 23-27 |2.3-2.7| 17-20 |200-240] (4) attachments Engine and propeller con- trol grommets | 4 20 2.0 15 177_—-| (5) through firewall May 1, 1998 7-19 SUPPLEMENTARY INFORMATIONZ 242 ZLIN AIRCRAFT ass. Maintenance Manual-Vol. II DOC. No. 003.032.1 Otrokovice NOTE! The following notes (1) up to (5) mention subsections of this Manual which provide instructions for instal- lation of items listed in the foregoing Table. (1) Installing the engine mount on the engine: subsect. 4.2.1, para 1). Information on recommended torque moments of other screws and nuts on the engine is given in the Tex- tron Lycoming No. SSP 2070 Engine Operator's Manu~ al. (2) Installing the propeller on the engine: subsect. 462.46 (3) Installing the stabilizer on the aircraft: subsect. 4.2.9, para 4). (4) Installing wings on the aircraft: subsect. 4.2.14, para 5). (5) Installing engine and propeller control: subsect. 4.3.13, procedure - see para 1), 4), 5) and sub- sect. 4.3.14. 2) Prestress check asur il s_elongat: Bolts elongation Joint mm in. Rear fuselage part - fuselage /0.12-0.14/0.0047-0.0055) frame (4 attachment bolts) NOTE: Attachment bolts elongation is determined as a diffe- rence between the bolt length measured after mounting and the bolt length measured before mounting. Mounting attachment bolts of the rear fuselage part is described in subsect. 4.3.1 of this Manual. 7 ~ 20 May 1, 1998 SUPPLEMENTARY INFORMATIONom ZLIN AIRCRAFT as. 2242L Otrokovice DOC. No, 003.032.1 Maintenance Manual - Vol. II 3) Tensioning of cables _ TTensioning of cable 1 Name Pos Note N kp. bf Cables of rudder control rearpart| 2 | 350-450 36-45 79-100 | (1) Cables of trim tab control 1+1[ 60-80 6-8 13-18 | @) Distance between spring coils: Nose landing gear control cables | 1+ 1 |up to SIN. 0740: 0.18-0.20 mm (0,006-0.008 in.) (3) from SIN 0741: 0.25-0.35 mm (0.010-0.014 in) Flap control cables in wings 1+1 | Cable sag: 6-10 mm (0.24-0.40 in) @ ‘Subsections of this Manual providing instructions for control cables installation: (1) Mounting the rudder control rear part cables: sub- sect. 4.3.5, para 1) (2) Mounting the trim tab control cables: subsect. 4.3.5, para 4) (3) Mounting the nose landing gear control cables: sub- sect. 43.5, para 2), 2A), (4) Mounting the wing flap control cables: subsect. 4.3.5, para 3) 7.8.3 RECOMMENDED TORQUE MOMENTS as Figure in the Z 2421 Catalog | Torque moment | Locking int : Fig. No. item [Nm | loft | offoint eps, Z 42.2300-00.00 a) Allerons: 18 +, |__bim, ailerons, hinges | 7422400-00.00 ons |7oas| ser ') Wing flaps: Z42.2501-00.00 | 4, hinges 2 42.2601-00.00 fa REVISION No. 3 (Oct 15, 2002 7-21 ‘SUPPLEMENTARY INFORMATIONZz 242 xi ZLIN AIRCRAFT as, Maintenance Manual-Vol. II DOC. No. 003.032.1 Otrokovice Recommended torque moments - continued Figure in the Torque Lock- Joint % 242L Catalog moment ing of joint Fig. No. |Item| Nm |1bf.ft Empennage a) Elevator: outer joints |Z 242.0320-00.00] 23 |9.5-11.5| 7-8.5 |cotter —_——— pins central joint 22 | 23-29 |17-21.4 b) Rudder upper joint 13 |9.5-11.5] 7-8.5 |cotter ————4z 242.0340-00.00 pins lower joint 12 | 23-29 |17-21.4 Control a) Elevator control: cotter pull rod joints 19 |9.5-11.5] 7-8.5 | pins ———_— 2 242.4120-00.00 nuts of forks 22 20 14.8 |was- +} locking in hers pull rods b) Control in wings: cotter pull rod joints|z 242.4130-00.00| 24 |9.5-11.5| 7-8.5 | pins Z 242.4140-00.00 nuts of eyes 14 20 14.8 |was- locking in hers pull rods ¢) stick control in cockpit - joints:counter- 25 | 23-29 |17-21.4 Bhaft-fuselage, cotter control sticks— pins countershaft rod (15) atta- |¢ 142.4150-00.00| 26 |9.5-11.5| 7-8.5 ching to sticks nuts of fork 28 20 14.8 locking was- ——“ hers stop nuts 27 8.5 6.3 7 - 22 May 1, 1998 SUPPLEMENTARY INFORMATIONZLIN AIRCRAFT a.s. Z 242 Otrokovice Doc. No. 003.032.1 Maintenance Manual-Vol. II Recommended torque moments - continued Figure in the ‘Torque Lock= Joint 2% 242L Catalog moment ing of joint Fig. No. Item} Nm |ipf.ft 3.]d) Rudder control rear part: cable turnbuckles, 34 | 6-7.2 |4.4-5.3 joint of cables and sheets (8) | cotter intermediate le~ pins ver, pulley, % 142,4220-00.00 pull rod joints, 35 |9.5-21.5] 7-8.5 cable attachment to rudder lever stop nuts 36 | 8.5 6.3 - nuts of eyes 38 20 14.8 |was- (24) locking hers e) Rudder control front part: cotter turnbuckles, L 242.4230-00.00| 31 |9.5-11.5]7.5-8.5| pins cable attachment f£) Flaps control in fuselag: wing flaps lever|up to S/N 0655: | 22 | 23-29 |17-21.4 © 142.4320-00.00 cotter segment, pulley |fron S/N 0656: | 20 |9.5-11.5| 7-8.5 | pins Z 143.4310-00.00 cable attachment a1 | 6-7.2 |4.4-5.3 to lever g) Flaps control in wings: pull rod attach- 27 |9.5-11.5] 7-8.5 ment to lever cotter (3) or (3A) up to S/N 0656: pins Z 42.4330-00.00 cable attachment|z 42.4340-00.00 | 28 | 6-7.2 |4.4-5.3 to lever (4) from S/N 0657 ————€ 142.4330-00.00 nuts of eye (17)/C 142.4340-00.00] 32 20 14.8 |was- locking her May 1, 1998 7 - 23 SUPPLEMENTARY INFORMATION neZ 2424 ZLIN AIRCRAFT as Maintenance Manual-Vol. II DOC. No. 003.032.1 Otrokovice Recommended torque moments - continued Figure in the Torque Lock- Joint % 2421 Catalog moment ing of joint Fig. No. Item] Nm [1bf.£t 3.{h) Trim tab control: cotter pull rods joints 13 | 6-7.2 }4.4-5.3] pins ————L 242.4420-00.00 nuts of fork 17 | 6-7.2 |4.4-5.3]was- (16) locking her Landing gear a) Main landing gear: wheel axle 27 | 23-29 |17-21.4] cotter attachment to up to S/N 0670: pins landing gear leg|L 242.5100-00.00 ————— fron s/n 0671: clip (9) L 242.5000-11.00] 26 | 46-58 |34-42.8|was- attachment hers landing gear leg 25 | 80-100 | 59-74 |cotter attachment to pins fuselage b) Nose landing up to S/N 0670: gear: 2 42.5210-00.00 cotter struts attach- |from S/n 0671: | 13 | 23-29 |17-21.4| pins ment © 142.5210-00.00 c) Brakes control from left seat: pedals attach- ment to brake 36 | 6-7.2 |4.4-5.3| cotter actuators 2 142.5310-00.00 pins nuts of fork 37 | 23-29 |a7-2i.a} - (13) locking 4) Brakes control from right seat: pedals attach- ment to brake 25 | 6-7.2 |4.4-5.3|cotter actuators © 142.5320-00.00 pins nuts of fork 24 | 23-29 Ja7-2i.a] (13) locking May 1, 1998 7-24 SUPPLEMENTARY INFORMATIONZLIN AIRCRAFT as, Z 242 Ovokovice DOC. No. 003.032.1 Maintenance Manual-Vol. IT Recommended torque moments - continued Figure in the ‘Torque Lock= Joint % 2421 Catalog moment ing of joint Fig. No. Item| Nm bt. ft 5.|Engine assembly a) Engine mount attachment cotter to fuselage |L 242.6300-00.00| 16 | 23-29 | 17-21.4 | pins b) Exhaust system: L 242.6570-00.00 cotter strut 54 | 17-21 |12.5-15.5| pins nuts of eye (26) locking 55 | 17-21 |12.5-15.5| - clips 51 | 6-7.2 | 4.4-5.3 |cotter 52 pins 6.|Power plant control a) Mixture control: L 242.7500-00.00| 28 | 23-29 | 17-21.4 |was- nut on mixture her pull rod b) Propeller control: L 242.7800-00.00| 26 | 23-29 | 17-21.4 |was- nuts on pull her rod (3) 7.| Safety belts installation: nuts on faste- ning screws L 242.8310-00.00| 19 | 17-21 |12.5-15.5|cotter pins May 1, 1998 7 - 25 SUPPLEMENTARY INFORMATION 5Z 24a2u ZLIN AIRCRAFT as, Maintenance Manual-Vol. II DOC. No. 003.032.1 Otrokovice 7.5.4. TORQUE MOMENTS FOR THE ENGINE AND THE PROPELLER 7 - 26 This subsection provides the summary of torque moments ac- cording to the appropriate Operator's Manuals of the engi- ne and the propeller: 2) -360-ALBS ENGINE Nn ipf.ft | Ibf.in Engine brackets nuts 34-41 | 25-30 | 300-360 Damper nuts 33-35 | 24-26 | 290-310 Spark plugs 33-35 | 24-26 | 290-310 Jets 7 5 60 Oil filter 22-25 | 16-18 | 195-220 Valve rocker arm cham- 6 4.4 50 ber cover screws Fuel strainer in 4-5 3-4 30-40 injection pump 2) =9-B-C/C-188-18a PROPELLE! Nn ipt.tt | ibf.in Propeller flange nuts 85-90 63-66 | 755-795 3) The "“HARTZELL" HC-C3Y-4BF/FC-6890 PROPELLER Nn ibf.ft | 1bf.in Propeller flange nuts 81-95 59-71 | 708-850 4) The Woodward D-210 982 PROPELLER R.P.M. REGULATOR Nn apf.ft | ipf.in Regulator flange nuts as-30 | 18-22 | 217-260 SUPPLEMENTARY INFORMATION May 1, 1998rcs ZLIN AIRCRAFT ass Z242L Otrokovice 06. No. 003,052.1__________Maintenance Manual-Vol Il 7.6. SPECIAL TOOLS AND JIG 1. GENERAL ‘This Supplement provides the basic information on special tools and jigs recommended for checking, repairs, adjustments and for other job. LIST OF SPECIAL TOOLS AND JIGS 242.9210 . Basic tools (delivered for aircrafts to S/N 0740 incl.) .242.9210B Basic tools (delivered for aircrafts from S/N 0741 inc!) 150.0.923.0 Engine and propeller tools (delivered for aircrafts to SIN 0740 incl.) 242.9220 Engine tools (delivered for aircrafts from S/N 0741 incl) NOTE: Detailed specification special tools and jigs is state in llustrated parts catalog Z 242 L, Chapter 9. REVISION No. 6 Jun 20, 2006 7-27 ‘SUPPLEMENTARY INFORMATION.