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Zenair CH2000 Service Manual

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CH2000 TRAINER
with LYCOMING 0-235-N2C
SERVICE MANUAL
ZENAIR Ltd.
Huronia Airport
Midland, Ontario
Canada L4R 4K8
(705) 526-2871
November 2002

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  • Page 1 CH2000 TRAINER with LYCOMING 0-235-N2C SERVICE MANUAL ZENAIR Ltd. Huronia Airport Midland, Ontario Canada L4R 4K8 (705) 526-2871 November 2002...
  • Page 2 ZENAIR CH2000 SERVICE MANUAL _______________________________________________________________________ TABLE OF CONTENTS SECTION I INTRODUCTION SECTION VI POWERPLANT SECTION II HANDLING AND SERVICING SECTION VII SURFACE CONTROLS SECTION III INSPECTION SECTION VIII FUEL SYSTEM SECTION IIIA AIRWORTHINESS LIMITATIONS SECTION IX INSTRUMENTS SECTION IV STRUCTURE...
  • Page 3 ZENAIR CH2000 SERVICE MANUAL _______________________________________________________________________ SERVICE MANUAL UPDATE LOG REV. NO. DATE ISSUED DATE INSERTED BY INCORPORATED May 2011 May 2011 Note: 0.1 and 0.2 with Update sheet(s) are replaced for each new update. May-2011...
  • Page 4 ________________________________________________________________________ SECTION 1 INTRODUCTION GENERAL This manual contains service and maintenance instructions for the Zenair CH2000, 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.
  • Page 5 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.
  • Page 6 ZENAIR CH2000 SERVICE MANUAL ________________________________________________________________________ CH 2000 GENERAL DIMENSIONS - Fig. 1 - 3 Apr 95...
  • Page 7 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.
  • Page 8 ZENAIR CH2000 SERVICE MANUAL ________________________________________________________________________ CH2000 ACCESS PANELS - Fig. 2 - Oct-00...
  • Page 9 ZENAIR CH 2000 SERVICE MANUAL ________________________________________________________________________ HOISTING - Fig. 3 Nose Gear Hoisting - Remove the cowl and lift the aircraft with a hoist 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.
  • Page 10 ZENAIR CH2000 SERVICE MANUAL ________________________________________________________________________ LOCKING AIRCRAFT The cabin doors are provided with key locks on the outside. MAIN GEAR / WHEEL HOISTING NOSE GEAR / WHEEL HOISTING Nov 02...
  • Page 11 ZENAIR CH2000 SERVICE MANUAL ________________________________________________________________________ AIRCRAFT LEVELING Fig. 4 – Oct-00...
  • Page 12 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.
  • Page 13 ZENAIR CH2000 SERVICE MANUAL ________________________________________________________________________ FUEL DRAINS - Fig. 5 - 3 Apr 96...
  • Page 14 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.
  • Page 15 ZENAIR CH2000 SERVICE MANUAL ________________________________________________________________________ LUBRICATION CHART - Fig. 6 - Feb-00...
  • Page 16 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. LIFE LIMITED PARTS Following is the list of the parts which must be replaced at the frequencies indicated.
  • Page 17 When replacing the fuel lines rear of firewall, replace original fuel lines SAE-30R type with the Parker SUPER-FLEX FL type. When replacing the brakes lines and Pitot Static Lines, use Zenair nylon tube type 11 #487-4 or similar with minimum working preasure of 250 P.S.I. Tube O.D. ¼”, I.D. 0.175 with wall thickness of 0.040. Equivilant fittings to be used.
  • Page 18 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.
  • Page 19 TABLE 1 – ZENAIR INSPECTION FORM Make / Model Serial No. Airframe Hours Type of Inspection ZENAIR CH2000 (Circle One) Registration No: Engine Hours 1000 Symbols: Indicates perform task, - Indicates do not perform task Intervals (Flight Hours) Task Refer to...
  • Page 20 TABLE 1 – ZENAIR INSPECTION FORM Make / Model Serial No. Airframe Hours Type of Inspection ZENAIR CH2000 (Circle One) Registration No: Engine Hours 1000 Symbols: Indicates perform task, - Indicates do not perform task Intervals (Flight Hours) Task Refer to...
  • Page 21 TABLE 1 – ZENAIR INSPECTION FORM Make / Model Serial No. Airframe Hours Type of Inspection ZENAIR CH2000 (Circle One) Registration No: Engine Hours 1000 Symbols: Indicates perform task, - Indicates do not perform task Intervals (Flight Hours) Task Refer to...
  • Page 22 TABLE 1 – ZENAIR INSPECTION FORM Make / Model Serial No. Airframe Hours Type of Inspection ZENAIR CH2000 (Circle One) Registration No: Engine Hours 1000 Symbols: Indicates perform task, - Indicates do not perform task Intervals (Flight Hours) Task Refer to...
  • Page 23 TABLE 1 – ZENAIR INSPECTION FORM Make / Model Serial No. Airframe Hours Type of Inspection ZENAIR CH2000 (Circle One) Registration No: Engine Hours 1000 Symbols: Indicates perform task, - Indicates do not perform task Intervals (Flight Hours) Task Refer to...
  • Page 24 TABLE 1 – ZENAIR INSPECTION FORM Make / Model Serial No. Airframe Hours Type of Inspection ZENAIR CH2000 (Circle One) Registration No: Engine Hours 1000 Symbols: Indicates perform task, - Indicates do not perform task Intervals (Flight Hours) Task Refer to...
  • Page 25 TABLE 1 – ZENAIR INSPECTION FORM Make / Model Serial No. Airframe Hours Type of Inspection ZENAIR CH2000 (Circle One) Registration No: Engine Hours 1000 Symbols: Indicates perform task, - Indicates do not perform task Intervals (Flight Hours) Task Refer to...
  • Page 26 TABLE 1 – ZENAIR INSPECTION FORM Make / Model Serial No. Airframe Hours Type of Inspection ZENAIR CH2000 (Circle One) Registration No: Engine Hours 1000 Symbols: Indicates perform task, - Indicates do not perform task Intervals (Flight Hours) Task Refer to...
  • Page 27 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.
  • Page 28 ZENAIR CH2000 SERVICE MANUAL ________________________________________________________________________ REPLACEMENT OF WING ASSEMBLY REMOVAL 1. Drain the gas. (wing tank option only) 2. Disconnect the flap push rod. 3. Remove the seat bottoms. 4. Disconnect the aileron balance cables and aileron control cables (center of fuselage).
  • Page 29 ZENAIR CH2000 SERVICE MANUAL ________________________________________________________________________ MATERIAL THICKNESS MATERIAL THICKNESS FIBERGLASS 6061-T6 0.025 6061-T6 0.025 6061-T6 0.016 6061-T6 0.025 6061-T6 0.025 6061-T6 0.025 6061-T6 0.040 CARBON FIBRE 6061-T6 0.025 CARBON FIBRE 6061-T6 0.025 6061-T6 0.025 6061-T6 0.025 FIBERGLASS FIRE RESISTANT FIBERGLASS...
  • Page 30 ZENAIR CH2000 SERVICE MANUAL ________________________________________________________________________ STRUCTURE (cont’d). REPLACEMENT OF RUDDER - Fig. 8 REMOVAL 1. Disconnect the two control cables from the rudder horn. 2. Disconnect the grounding cable and the tail light wiring. 3. Remove the lower hinge bolt.
  • Page 31 ZENAIR CH2000 SERVICE MANUAL _______________________________________________________________________ TAIL REMOVAL - Fig. 8 - Oct-00...
  • Page 32 LANDING GEAR AND BRAKE SYSTEM GENERAL The landing gear incorporated on the CH2000 is a fixed, tricycle type of gear, fitted with three 500-5 wheels (or optional 600-6 main gear wheels), using four ply tires with tubes. The nose gear is steerable through the rudder pedals.
  • Page 33 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.
  • Page 34 ZENAIR CH2000 SERVICE MANUAL ________________________________________________________________________ NOSE GEAR - Fig. 9 - Nov-02...
  • Page 35 ZENAIR CH2000 SERVICE MANUAL ________________________________________________________________________ BRAKE MAINTENANCE REPLACEMENT OF BRAKE MASTER CYLINDER - Fig. 11 1. 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.
  • Page 36 ZENAIR CH2000 SERVICE MANUAL ________________________________________________________________________ MAIN GEAR - Fig. 10 - Older Style Main Gear Nov-02...
  • Page 37 ZENAIR CH2000 SERVICE MANUAL ________________________________________________________________________ BRAKE SYSTEM - Fig. 11 - Nov-02...
  • Page 38 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.
  • Page 39 ZENAIR CH2000 SERVICE MANUAL ________________________________________________________________________ POWERPLANT - Fig. 12 - Nov-02...
  • Page 40 ZENAIR CH2000 SERVICE MANUAL ________________________________________________________________________ REMOVAL OF ENGINE - Fig. 12 1. Remove the propeller. 2. Remove top and bottom cowl. 3. Disconnect the heat hose from the muffler and front baffle. 4. Disconnect the mechanical fuel pump inlet line.
  • Page 41 ZENAIR CH2000 SERVICE MANUAL ________________________________________________________________________ CARBURETOR - Fig. 13 - Feb-00...
  • Page 42 ZENAIR CH2000 SERVICE MANUAL ________________________________________________________________________ ENGINE MAINTENANCE PROCEDURES: See 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...
  • Page 43 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.
  • Page 44 ZENAIR CH2000 SERVICE MANUAL ________________________________________________________________________ FIXED AILERON TRIM TAB - Fig. 15 For the purpose 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 1.
  • Page 45 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.
  • Page 46 ZENAIR CH2000 SERVICE MANUAL ________________________________________________________________________ AILERON AND CONTROLS - Fig. 15 - Feb-00...
  • Page 47 ZENAIR CH2000 SERVICE MANUAL ________________________________________________________________________ FLAPS CONTROL SYSTEM - Fig. 16 - Feb-00...
  • Page 48 ZENAIR CH2000 SERVICE MANUAL STABILATOR CONTROL SYSTEM - Fig. 17 - Oct-00...
  • Page 49 ZENAIR CH2000 SERVICE MANUAL ________________________________________________________________________ RUDDER CONTROL SYSTEM Fig. 18 – Nov-02...
  • Page 50 ________________________________________________________________________ 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...
  • Page 51 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.
  • Page 52 ZENAIR CH2000 SERVICE MANUAL ________________________________________________________________________ FUEL SYSTEM TROUBLESHOOTING Trouble Cause Remedy Fuel gauge fails to indicate Broken wiring Check and repair Gauge not operating Replace Float partially or Replace float completely filled with fuel Float touching tank Bend float arm...
  • Page 53 ZENAIR CH2000 SERVICE MANUAL ________________________________________________________________________ STANDARD FUEL SYSTEM (REAR TANK) - Fig. 19 - 3 Apr 96...
  • Page 54 ZENAIR CH2000 SERVICE MANUAL OPTIONAL FUEL SYSTEM (WING TANKS) - Fig. 20 - 3 Apr 96...
  • Page 55 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.
  • Page 56 ZENAIR CH2000 SERVICE MANUAL INSTRUMENT PANEL Note: Position of optional instruments may vary according to owner’s specifications. - Fig. 21 - Oct-00...
  • Page 57 ZENAIR CH2000 SERVICE MANUAL _______________________________________________________________________  ALTIMETER TROUBLESHOOTING See following table: ALTIMETER Trouble Cause Remedy Excessive scale error. 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.
  • Page 58 _______________________________________________________________________  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:...
  • Page 59 ZENAIR CH2000 SERVICE MANUAL _______________________________________________________________________  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.
  • Page 60  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.
  • Page 61 ZENAIR CH2000 SERVICE MANUAL ________________________________________________________________________  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:...
  • Page 62 ZENAIR CH2000 SERVICE MANUAL ________________________________________________________________________ OPTIONAL INSTRUMENTS - Fig. 21  RATE OF 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.
  • Page 63 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.
  • Page 64 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.
  • Page 65 ZENAIR CH2000 SERVICE MANUAL ________________________________________________________________________ GYRO SYSTEM (OPTIONAL) - Fig. 22 - 3 Apr 95 9.11...
  • Page 66 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.
  • Page 67 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.
  • Page 68 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 is a schematic of the different electrical circuits used in this airplane and Fig. 24 shows the wiring.
  • Page 69 ZENAIR CH2000 SERVICE MANUAL _______________________________________________________________________ ELECTRIC SCHEMATICS - Fig. 23 - 10.2 Oct-00...
  • Page 70 ZENAIR CH2000 SERVICE MANUAL ________________________________________________________________________ ELECTRIC WIRING - Fig. 24 - Oct-00 10.3...
  • Page 71 ZENAIR CH2000 SERVICE MANUAL ________________________________________________________________________ REPLACEMENT OF THE BATTERY 1. 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.
  • Page 72 ZENAIR CH2000 SERVICE MANUAL ________________________________________________________________________ CHARGING SYSTEM (cont’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;...
  • Page 73 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.
  • Page 74 ZENAIR CH2000 SERVICE MANUAL ________________________________________________________________________ TABLE - ELECTRICAL SYSTEM TROUBLESHOOTING Trouble Cause Remedy 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.
  • Page 75 ZENAIR CH2000 SERVICE MANUAL ________________________________________________________________________ TABLE. ELECTRICAL SYSTEM TROUBLESHOOTING (cont'd) Trouble Cause Remedy 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.
  • Page 76 CABIN HEATER AND VENTILATION SYSTEM GENERAL - Fig. 25 Heat for the cabin of the CH2000 is 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.
  • Page 77 ZENAIR CH2000 SERVICE MANUAL _______________________________________________________________________ CABIN HEAT AND VENTILATION - Fig. 25 - 11.2 Nov-02...
  • Page 78 ZENAIR CH2000 SERVICE MANUAL _______________________________________________________________________ SECTION XII CABIN DOORS 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 the handle.

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