MAINTENANCE MANUAL for use with the hot air balloon

Model: ...................................................................................

Serial No.: .............................................................................

Registration: .........................................................................

Date of Issue: .......................................................................

Registered copy No.: ............................................................

This balloon is to be preserved in an airworthy condition in compliance with instructions and informationcontained herein.

MAINTENANCE MANUALfor use with the hot air balloon

B.0202

BALÓNY KUBÍÈEK spol. s r.o.Francouzská 81, 602 00 BrnoCzech Republictel.: +420 5 45211917fax: +420 5 4521 [email protected]

Pages identified by �Appr.�are approved by:

Signature:

Authority:

Stamp:

Original date of approval:

Civil Aviation Authority of the Czech Republic

10. 10. 2001

INTENTIONALLY LEFT BLANK


B.0202

Issue: 10. 10. 2001 Change: 0 (i)

0.1 Record of RevisionsAny revision of the present manual, except actual weighing data, must be recorded in the followingtable and in case of approved Sections endorsed by the responsible airworthiness authority.The new or amended text in the revised page will be indicated by a black vertical line in the lefthand margin, and the Revision No. and the date will be shown on the bottom of the page.

Rev. No.

Affected Section

Affected Pages

Date of Issue

Approval Date of Approval

Date of Insertion

Signature

Change: 0 Issue: 10. 10. 2001

BALÓNY KUBÍÈEK spol. s r.o.Francouzská 81, 602 00 Brno

(ii)

0.2 List of Effective Pages

NOTE:The pages, approved by the CAA and involved on the list above, are identified as �Appr.�.

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B.0202

Issue: 10. 10. 2001 Change: 0 (iii)

0.3 Table of Contents

Section

General .................................................................................................................. 1(a non-approved section)

Technical Description ........................................................................................... 2(a non-approved section)

Inspections and Operating Periods ..................................................................... 3(an approved section)

Airworthiness ........................................................................................................ 4(a partly approved section)

Balloon Handling and Maintenance ................................................................... 5(a non-approved section)

Repairs ................................................................................................................... 6(a non-approved section)

Instructions ........................................................................................................... 7(a non-approved section)

Supplements .......................................................................................................... 8


1 - 1


B.0202

Issue: 10. 10. 2001 Change: 0

SECTION 1

1. General

1.1 Introduction ................................................................................................................... 21.2 Applicability .................................................................................................................. 21.3 Warnings, Cautions and Notes ...................................................................................... 21.4 Revisions ....................................................................................................................... 21.5 Definitions and Abbreviations of Terms ....................................................................... 31.6 Index Plates ................................................................................................................... 3

1 - 2


Change: 0 Issue: 10. 10. 2001

1. General

1.1 Introduction

The Maintenance Manual (the manual only hereafter) has been prepared to provide informationand instructions for safe operation of a BALÓNY KUBÍÈEK spol. s r.o. (formerly Kubíèeks.r.o.) or 114 (714) ZO Svazarmu, Aerotechnik, Aerotechnik p.o.s. and Aerotechnik s.r.o. hot-airballoon. This manual contains basic technical and descriptive data of hot-air balloons, scope ofwork during a flight day, instructions for common care and maintenance of the balloon includingannual inspections with determined by both 100 flight hours and 12 calendar months limitations.

1.2 Applicability

The information contained within this Maintenance Manual applies to all standard BB balloonsand standard balloons of AEROTECHNIK AB, AB2, AB2a or AB8 type.This manual in conjunction with a supplement (see Section 8 - Supplements) refers to the pertinentand in the Supplement mentioned special shaped balloon with the identification by letters �BB�and designation (or abbr.) of the special shaped balloon (e.g. BB PNEU).

1.3 Warnings, Cautions and Notes

The following definitions apply to Warnings, Cautions and Notes used in the manual:

WARNING:Warns that in all probability the non-observation of corresponding instructions and prescribedlimits leads to an injury or danger of fatal accident.

CAUTION:Warns that the non-observation of corresponding instructions and prescribed limits could leadto object damage.

NOTE:Draws the attention to any special item not directly related to safety but which is important orunusual.

1.4 Revisions

This manual is kept up to date by manufacturer revisions consisting of a bulletin - optionallywith loose-leaf pages and inclusive of the new list of effective pages, requiring the registeredmanual holder to amend existing information or add new information.

The continued worthiness of your manual should be observed as follows:1. Accomplish the change according to bulletin instructions or replace original pages with new/

amended ones.2. Insert up-to-date �List of Effective Pages�.3. Record the change of issue number in the table of �Record of Revisions�, section 0.1, page (i).

1 - 3


B.0202

Issue: 10. 10. 2001 Change: 0

NOTE:All changes and appendices of the Maintenance Manual elaborated before the date of the issuestated on the title page are incorporated in this manual by the manufacturer.

1.5 Definitions and Abbreviations of Terms

Natural shaped envelopeThe envelope shape is designed so that vertical load tapes will carry the whole basket weight andloading. The textile carries only horizontal acting forces of overpressure.

Special shaped envelopeThe envelope shape that does not correspond to any of mentioned standard types. The envelopeis produced individually (on request) in form of various eye-catching creatures and imitations.

OperatorThe person responsible for the technical condition, proper implementation of all prescribedperiodic inspections and repairs (in accordance with procedures approved) carried out by personswith appropriate qualification mandated by the local aviation authority; and for carrying out alltasks assigned by bulletins issued by either the manufacturer or Airworthiness Directives releasedby the local aviation authority (in compliance with the manufacturer�s/operator�s country)concerning all balloons he/she operates.

Approved organisationThe producer or organisation commissioned by the relevant national aviation authority to carryout prescribed periodical inspections.Periodical inspectionsThe mandatory preventative inspection in a range assigned by the manufacturer and operator�snational aviation authority.

Parts/ComponentsAny instrument, mechanism, equipment, accessory or assembly appointed or used during balloonoperating or handling contained herein.

Approved typeThe part supplied by the manufacturer or authorised by the local aviation authority.

/The sign used as expression of various text explanations, e.g. : and, or, and/or.

1.6 Index Plates

Index plates for each balloon type, their photos and placement are inserted in the Flight Manual.


2 - 1


B.0202

Issue: 10. 10. 2001 Change: 0

SECTION 2

2. Technical Description

2.1 Envelope ....................................................................................................................... 22.1.1 Envelope body.................................................................................................................. 22.1.2 Deflation System .............................................................................................................. 32.1.3 Envelope equipment ......................................................................................................... 5

2.2 Basket ............................................................................................................................ 62.2.1 Basket body ...................................................................................................................... 62.2.2 Basket load cables ............................................................................................................ 62.2.3 Burner rods ....................................................................................................................... 62.2.4 Prescribed basket equipment ............................................................................................ 6

2.3 Burner............................................................................................................................ 72.3.1 Main flight burner ............................................................................................................ 72.3.2 Pilot burner ....................................................................................................................... 72.3.3 Whisper burner ................................................................................................................. 72.3.4 Burner frame .................................................................................................................... 72.3.5 Burner descriptive data .................................................................................................... 8

2.4 Fuel Cylinders ............................................................................................................... 92.4.1 Cylinder descriptive data ................................................................................................. 9

2.5 Balloon Equipment ..................................................................................................... 102.5.1 Prescribed balloon equipment ........................................................................................ 10

2 - 2

BALÓNY KUBÍČEK spol. s r.o.Francouzská 81, 602 00 Brno

Change: 0 Issue: 10. 10. 2001

2. Technical Description

2.1 Envelope

An envelope is the major balloon part. Theaircraft component is identified by a serialnumber and a registration. Each envelopeshould be only accompanied by parts/components meeting requirements specifiedand approved by the Flight Manual for thepertinent balloon type. All envelopes, exceptspecial shaped ones, are of natural shape inthe upper part and conical shape applicationin the lower part. The envelope form isdesigned so that good flight characteristics,high factors of safety and textile life will beprovided.Basic dimensions and data on envelopes arementioned in the Flight Manual.The envelope consists of the main components:1. Envelope body2. Deflation System (DS)3. Envelope equipment

2.1.1 Envelope bodyThe envelope body is sewed from high tenacity polyester or polyamide base textile, which iscoated to make it airtight. The natural envelope shape is designed so that every basket weightand loading will be carried by vertical load tapes (the fabric provides only a horizontal load-carrying element) after envelope hot inflation. A gore is the section of fabric, which lies betweentwo adjacent vertical load tapes. Each gore is constructed from individual panels, i.e. textileparts. The first panel above the mouth of the balloon - the lower part of the envelope body, ismade from heat-resistant fabric. Natural shaped envelopes of vertical ‚N‘ type and horizontal‚O‘ type are used as type approved balloons. The ‚N‘ type has narrow and moderately gibbousgores to give a near-smooth surface with vertical load tapes sewed in their centres. The ‚O‘ typeis characteristic of wider bulbous gores with noticeable curvature and vertical load tapes situatedalong their edges. A network of vertical and horizontal webbing, called load tapes, encapsulatesthe envelope body. The vertical load tapes are attached to a crown ring at the top of the balloon.They extend down to the mouth of the envelope where attachment is made to the stainless steelflying wires by a loop. The wires are fixed to the burner frame by means of locking carabiners.Horizontal load tapes appear mostly on every horizontal seam of panel edges to strengthen themand are provided to increase resistance to great rips or tears by large surface dividing. The specialshaped envelope body is created from panels in order to reach the required form. Vertical loadtapes carry the basket weight and loading. The tapes are sewed towards the envelope body surfaceor attached to the envelope by shaped load ribs, according to the envelope shape and tapeplacement on it.

Balloon nomenclature

burnerrod basket

crownline

verticalload tape

envelopemouth

burner

scoop

horizontalload tape

index plates

rotationvent

DS gore

2 - 3


B.0202

Issue: 10. 10. 2001 Change: 0

2.1.2 Deflation System (DS)In flight venting of hot air and finalenvelope deflation is normallyachieved using a parachute vent or rippanel, prospectively in combination.An optional envelope feature iscommonly double rotation vents. Therotation vent provides controlledvertical balloon rotation and functionsas a DS addition. The Smart Vent is arapid deflation system for envelopesizes above 3699 m3, where one ofits functions serves for central ventingduring landing and final venting.

ParachuteThe parachute takes form of aparachute-style disc panel inside thetop of the balloon, sealing a circularopening in the top of the envelope.The lateral position of the parachuteis controlled by centralising lines,which join its edge to the insidesurface of the balloon. Companionvelcro tabs are sewed both at the edgeof vent hole and parachute panels forthe purpose of sealing them together

during inflating. After envelope inflation, the parachuteis held in position by the internal overpressure andcloses tightly the envelope. The parachute is operatedby pulling on a red activation rope in the baskettransferring the vertical downwards force to a pulley,which is at the confluence point of a number of controllines attached to the edge of the parachute panel. Theparachute resets itself to the former closing positionafter activation rope releasing.Rip panelThe velcro rip panel is a partially removing panel ofvent opening to permit faster deflation, held in placearound part of its edge by velcro. One or more riplockswith velcro securing, in accordance with the envelopetype, are fitted around the panel edge to prevent thepanel from inadvertently opening the velcro tapes. Therip panel shape matches up with the vent opening.Pulling the rip line first causes a number of riplocks tobreak, which warns the pilot of the nature of this panel,then causes the panel velcro joint to separate. The rippanel will not reseal itself once the rip line has beenpulled, thus revealing a large opening for the escapeof hot air.

Parachute control

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2 - 4


Change: 0 Issue: 10. 10. 2001

Smart VentThe Smart Vent is a vent hole closingof two different modes of hot airescaping. The Smart Vent deflationsystem is similar in appearance and useto a parachute vent followed up byfurther control lines and an activationrope so that the centre of the panel canbe pulled down into the balloon andreset again. The rigging of the parachutevent consists of centralising lines tokeep the panel in place horizontally andgoing to and through pulleys on theinside surface of the balloon, then backto the vent panel. A stop ball is fittedthere on the centralising lines, behalfwhich the lines have free way throughpulleys and become parachute controllines. When the red/white activationrope is pulled, the stop ball comes upagainst the pulley on the underside ofthe vent, and stops all horizontal forcesand so the vent panel can be openedroutinely. This in effect changes the

rigging into a standard parachute style and in flightventing is the same as a normal parachute.Pulling on the red activation rope, connected bymeans of a tape to the centre of the vent panelunderside, gathers the vent panel down into a columnin the centre of the opening for a rapid deflation. Thecentralising lines are rigged so that the length betweenthe vent edges and attachment envelope point isvariable - the edges of the vent move towards thecrown ring and centralising lines lengthen to allowthis to happen. Then pulling the red/white activationrope spreads the vent panel to the resetting position.Rotation ventThe rotation vent is located around the envelopeequator and consists of a strengthened break in thefabric and a tightly sewed overlap panel with ribs.When the arrangement activated, slits open sendingout air tangentially and the effect causes the necessaryforce for required envelope rotation. Operation is byrotation vent activation ropes (once the force isreleased from the rope, the internal air pressure causesthe vents to reseal).

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2 - 5


B.0202

Issue: 10. 10. 2001 Change: 0

CAUTIONFor operating the Smart Vent, the white activation rope instead of red/white one can be usedregarding the BB balloons up to the including serial No. 177.For operating the rotation vent, the white and black activation rope can be used regarding theBB balloons up to the including serial No. 177.For operating the rotation vent, the yellow and green activation ropes can be used regarding theballoons of the AB2, AB2a, AB8, and AEROTECHNIK AB types.

2.1.3 Envelope equipmentCrown lineThe crown line is a rope or tape attached to the crown ring. The crown line secures the envelopeposition during inflation and landing.

ScoopThe scoop is made of a fabric with very high resistance to heat in the form of a polygon or circle,suspended in hook-up loops at the bottom of the envelope mouth. The scoop protects the burnerflame against wind effects and keeps the sufficient pressure in the envelope under windy conditionsduring inflation.

Envelope bagThe envelope transport bag is sewed in the form of a pouch and serves for the envelope storageand transporting

2 - 6


Change: 0 Issue: 10. 10. 2001

2.2 Basket

The basket serves with the aim of crew/load, fuel cylinders and equipment transporting, to protectpeople during a flight and especially while landing. Flexible rods fit into basket and burnerframe sockets to support the overhead burner frame system.Basic descriptive data of each basket size are tabulated in the Flight Manual.

The basket consists of the main components:1. Basket body2. Basket load cables3. Burner rods4. Basket equipment

2.2.1 Basket bodyBaskets are of a traditional cane-work construction, built on a marine grade plywood floor. Thefloor is reinforced underneath by the addition of wooden or tubular lower frame and hardwoodrunners, to prevent damage on basket cables. The wickerwork is woven between tubular U-frames concerning smaller-sized baskets. These frames provide strength and stability towickerwork and protection for steel load cables. The structural load is taken by stainless or steelcables forming a continuous sling around the basket. Flexible rods fit into sleeved sockets at thebasket rim and burner frame to support the overhead frame system. On the basket walls there areholes providing passages for strapping in fuel cylinders, and footsteps are provided for easyentry into the basket. The top basket rim is strengthened by the upper stainless steel tubes andglass-reinforced plastic poles. The whole top basket rim is covered with dense foam and thentrimmed with suede or leather. The bottom edge is covered with rawhide, which protects thebasket from damage during landing and transit. Along the basket top rim underneath, there areinternal strong rope handles for use by passengers during landing. Within the lower weave of thebasket are included also rope carrying handles externally, which facilitate basket manipulation.

2.2.2 Basket load cablesThe load cables are highly strong steel cables with a wire core. Their eyelet endings are squeezedby means of a ferrule and thimble or spliced.

2.2.3 Burner rodsSupport rods are either provided as separate flexible rods made of alkaline polyamide or as tilt-mounted frames, both inserted into steel basket sockets. The rods, basket load cables and burnerhoses are covered with padded suede covers, to prevent damage or people injury during landing.

2.2.4 Prescribed basket equipment:1. The dropline, rolled up in a textile casing at an

accessible place above the basket floor, is fixed by acarabiner to the basket wall.

2. The (powder) fire extinguisher of min. 1 kg capacity -according to the basket size.

3. Heat-resistant cloth4. First aid kit Basket equipment

2 - 7


B.0202

Issue: 10. 10. 2001 Change: 0

2.3 BurnerThe high-pressure atmospheric diffusion burnerprovides heating and directing air into a hot airballoon envelope, which is from safety pointof view backed up by the separately controlledwhisper burner. These both in company withthe pilot burner comprise the burner unit. Theburner is assembled from one or multiple burnerunits and the burner frame.

The burner consists of the major parts:1. Main flight burner2. Pilot burner3. Whisper burner/Liquid fire4. Burner frame

2.3.1 Main flight burnerThe main flight burner operates with the liquidphase of fuel gas supplied by a main high-pressure armoured liquid hose through a ball valvecommonly referred to as the flight (blast) valve (FV) towards a vaporising coil, where the liquidpropane is vaporised prior to combustion. In case of transfer crossover valve (CV) opening, theliquid fuel is fed from fuel cylinders into the second flight burner coil as well. Then already inthe gas form it flows across jets to the combustion room to be diffusely mixed with the ambientair and burned. The main flight burner ignition is achieved via the pilot burner. The protectionagainst flame and condensate effects is kept by means of cans forming also the burner body.

2.3.2 Pilot burner (PB)The low-pressure atmospheric pilot burner works with the vapour phase of fuel gas conductedvia its private supply hose from the fuel cylinder. The gas is fed by the vapour hose to an on/offball valve/cock and after into a pilot burner jet. The gas pressure is reduced by means of anadjustable vapour pressure regulator situated just on the fuel cylinder or hose entering, providingwith the opportunity of an optimal flame setting. The burner flame is ignited via a fitted piezoelectric igniter, matches or an elongated igniter.

2.3.3 Whisper burner (WB)The whisper burner feeds liquid fuel through a shutoff valve/cock directly to a multi-hole jetbypassing the coil, via the same supply liquid hose utilised for the main burner. It produces astream of liquid propane injected into the combustion room. The combustion efficiency andburner power output are lower, but on the other hand, thus producing less noise approximatelyby one-half than the main burner. The sound spectrum is in the range of low frequencies betteraccepted by people or animals than high ones. In case of the main flight burner malfunction, thewhisper burner serves as a backup burner at the same time.

2.3.4 Burner frameThe burner frame is a solid stainless tube construction carrying horizontal forces of load flyingwires. The burner units are swivel-mounted in the inner burner frame or joints, which in its turnis swivel-mounted in the outer frame. This provides a 2-axis gimballed system allowing circularturns of the burner. At each corner the burner frame has sleeved sockets to accept the supportrods or upper tilt-mounted basket frames.

Nomenclature of burner control

flight valve

valve ofpilot burner

valve ofwhisper burner

liquidhose

jet unitwhisperburner

coil

vapourhose

crossover valve

pilot burner

piezo igniter

manometer

2 - 8


Change: 0 Issue: 10. 10. 2001

NOTE:Concerning the fuel hoses, Rego 7141F and Dynaquip D3 couplings are fitted as standard.

2.3.5 Burner descriptive data

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2 - 9


B.0202

Issue: 10. 10. 2001 Change: 0

2.4 Fuel Cylinders

The liquefied gas - propane fuel,supplied for the burner operation isstored and transported withinpressurised fuel cylinders for in-flightuse, which all have a liquid supply viaa major liquid valve/cock (standardtype), and some also a vapour supplyby a vapour valve/cock (master type).A pressure relief /safety blow-off valveand a maxfill bleed valve serve for thepurpose of checking by volume. Allcylinders have a float fuel quantitygauge. The master cylinders areequipped with a pressure regulator. Allcontrol elements are positioned in a wayto be protected by a cylinder collar. Thecylinders tabulated below are available.

NOTE:The pressure regulator is a component of the connecting vapour coupling as far as relating tothe S23 cylinders.

2.4.1 Cylinder descriptive data

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2 - 10


Change: 0 Issue: 10. 10. 2001

2.5 Balloon equipment

2.5.1 Prescribed balloon equipment:1. Thermometer for inner envelope air measuring2. Altimeter3. Variometer4. Fuel quantity gauge on one major cylinder at least5. Melting linkAll balloon equipment should be of the approved type.Operating, maintenance, repairs and preventativeinspections of equipment have to be carried out incompliance with requirements of the covering technicaldocumentation of the pertinent unit.

A124meltinglink

Warning temperaturestreamer (of theA124 melting link)

3 - 1Issue: 10. 10. 2001 Change: 0


B.0202

SECTION 3

3. Inspections and Operating Periods

3.1 General .......................................................................................................................... 23.2 Periodical Inspections ................................................................................................... 23.3 Qualification ................................................................................................................. 23.4 Annual Inspection ......................................................................................................... 3

3.4.1 Documentation preliminaries ........................................................................................... 33.4.2 Envelope check ................................................................................................................ 33.4.3 Basket check .................................................................................................................... 63.4.4 Burner check .................................................................................................................... 73.4.5 Fuel cylinder check ........................................................................................................ 103.4.6 Equipment check ............................................................................................................ 11

3.5 Irregular Inspections .................................................................................................... 123.5.1 Inspection after overheating ........................................................................................... 123.5.2 Inspection after contact with electric power lines ......................................................... 12Check Lists .................................................................................................................. 13

3 - 2 Change: 0 Issue: 10. 10. 2001


3. Inspections and Operating Periods

3.1 General

The qualification on the balloon continued airworthiness is to keep to prescribed periodicalinspections. Inspections of the balloon parts (e.g. baskets, burners) produced by anothermanufacturer have to be conducted in accordance with the relevant producer�s instructions.

3.2 Periodical Inspections

(1) At operating period determination by both flight hours and calendar months limitation, theservice period is applied that starts first. The 100-hour time limit can be exceeded up to max5 hours, under condition that the breach is used for the flight completing started before the100-hour limit reaching. The operating period, exceeding the 100-hour interval, must beincluded as hours flown relating to the next 100-hour inspection.

(2) At operating period determination with calendar month limitations, the revision has to bemade on the balloon or its parts till the last day for the month, in which the last inspectionwas carried out after the defined limit expiration.

3.3 Qualification

Inspections must be carried out by an organisation, which is approved by the relevant nationalairworthiness authority. Inspectors dealing with inspections/repairs must be trained and authorisedby the manufacturer.

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3 - 3Issue: 10. 10. 2001 Change: 0


B.0202

3.4 Annual Inspection

3.4.1 Documentation preliminaries

1. Check completeness of the service-technical documentation. Verify validity of eachcertification, as well as the documentation on maintenance and insurance. Inspect the FlightManual and Maintenance Manual for conformity with the particular balloon, theircomprehensiveness and complete records of revisions.

2. Check serial numbers of all the balloon components listed in the logbook against those to beinspected in accordance with index plates and pertinent certificates.

3. Inspect the logbook management - the number of flying hours, flights and modificationsperformed since the last inspection should be correct and up to date. Check the logbook forrepairs, inspections or/and maintenance entries; implementation of issued bulletins andAirworthiness Directives (AD).

3.4.2 Envelope check

1. Supervise the fabric, on the spread or cold inflated envelope, for damage and performedmodifications and repairs are in compliance with the information contained herein. Concentrateon the DS and equator fabric during checking.

CAUTION:Attached banners or patches deforming the envelope shape are inadmissible.

2. Check envelope fabric strength by a grab test, or alternatively the section of the fabric may beremoved from the envelope and submitted to a textile-testing laboratory by a tearing test inthe horizontal direction (i.e. perpendicularly to the vertical load tapes). The requirement ofthe min strength is mentioned in Section 4.5.4 contained in the manual. Description of thetest carrying out is inserted in Section 7.2. The test should be conducted for each fabriccolour on the panels at about 2-meter distance above the rim of the DS vent hole, min at threepositions and one time over a seam at least. Perform the test concerning all fabric types usedat the load-bearing envelope part if there are more envelope fabric patterns. Check the fabricfor porosity by your mouth trying to blow through it. If the porosity of the fabric is high, aflight test should be considered by the inspector, to assess the fuel consumption and ballooncontrollability (see Section 7.5), or the section of the fabric should be sent to the envelopemanufacturer for reviewing. The fabric of the rotation vent needs to be grab tested as well.

WARNING:In case of not observing the requirement, the in flight tearing or ripping of the envelope canoccur.

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3. Check all load vertical load tapes for security of stitching along the whole length. Pay particularattention to the load tape edges for their potential wear or fraying, and especially around theenvelope crown where load tape loops of turnbacks could be abraded or damaged by thecrown line. The horizontal load tapes should be free of damage along the whole length.

4. Check the figure-8 crown ring for damage, especially for cracks, splits or extensive corrosion.The crown line should be free of damage.

5. The melting link attached to the temperature warning streamer in position, must be ofprescribed type and undamaged. In case of the tempilabel fitting, inspect its condition andwhen the solder link has been melted during exceeding the max admissible temperature (1240C), always record the fact and maximum temperature reached in the log book.

6. Inspect the DS textile for no damage. Pay particular attention to the textile edgings. Checkthe condition of velcro tabs and their proper function. If there is a rip panel, aim yourobservation to its velcro tapes, riplocks and securing. Ensure the DS is functional. Test thesystem function, sealing and necessary activation force.

7. Supervise completeness and condition of the whole centralising lines of the DS. Inspectthem for wear, fraying, stiffness or further damage indicating overheating. Check thecentralising lines for security of attachment at both ends (correct loop stitching of the linesand safety knots), and improper stretching, shrinking or tangling. Concerning the SV system,inspect ball stop attachment on the centralising lines and sufficient slack of the lines at pulleys.

WARNING:Frayed, ruptured or missing the centralising lines, or riplocks and rip panel velcro malfunctioncould cause uncontrolled air leakage out of the envelope while airborne.

8. Check the DS control lines for completeness and no damage, their position and attachmenttowards pulleys of activation ropes. Damaged parts have to be replaced with the new ones.The knots served for repairs or minor damage of the control lines can be tolerated if it isensured that the pulleys/loops are free and running smoothly.

9. Supervise the DS activation ropes for completeness and no damage along the whole length.Pay special attention to the length measuring, the activation ropes should not be worn orfrayed from pulley running or heating - check that by the palpation. Inspect the ropes forcorrectness of colours (according to the DS type) and kinks. Concentrate on the rope connectionto the burner frame.

10. Inspect the whole pulleys of the Deflation System to ensure that they are free and runningand not worn (no loosened screw joints or seized bearings). Check non-metallic componentsof pulleys for wear by activation ropes. Pay particular attention to potential damage by flames/ropes and the proper security and attachment to the envelope. Supervise that the loops providingthe pulleys fixing are in a good condition and also for security of their stitching to the envelope.

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11. Check textile of the rotation vent and ambient localities. Inspect control lines and activationropes of the rotation vent along the whole length for completeness and no fraying, wear orburn damage. Supervise pulleys and their attachment to the envelope. Test the rotation ventfunction, especially its sealing.

12. Supervise the load tapes near by the envelope mouth for no burn damage or fraying.Concentrate on the load tape loops that connect the flying wires to the envelope, whetherthey are not worn or heat damaged. Ensure that the load tapes with stitching are not stiffenedby overheating in the first three-meter distance from the envelope mouth, their threads haveno burn damage at the connections and the load tapes themselves have no edge damage dueto repair of the lower panels, which are often replaced. Inspect the horizontal load tape aroundthe envelope mouth for no damage. Mildly burned places should be tolerated.

13. Inspect the flying wires and envelope carabiners. These should be checked for distortion ordamage and that thimbles and ferrules are intact (a slack thimble ordinarily signals a loosewire at a ferrule). Check wires for corrosion and mechanical damage stages (cracking orbreaking partially). In case of the number of broken wires not higher than 8 per 1-meterlength of a flying wire, this matter can be tolerated under the condition that any strand is nottotally separated and there is no doubt of the flying wire strength. Supervise flying wires forany signs of the heat damage reducing their elasticity. Carabiners should be free of frayingand distortion and the screw gate should operate freely. Concerning the balloons up to the1600 - m3 volume, dural carabiners of Walter-M type can be used. Inspect the carabiners forno scratches deeper than 1 mm. In the event that any damage, as described above, is detected,then the carabiners must be replaced promptly.

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3.4.3 Basket check

1. Steel basket load cables should be inspected for damage along the whole free length.Concentrate on the locations of the basket cable leaving the dural/stainless frame in thebottom and on the basket rim. Check cable wires for corrosion and mechanical damage(cracking or breaking partially) from the cable banding during the basket assembly anddisassembly. In case of the number of broken wires not higher than 8 per 1-meter length of abasket cable, the matter can be tolerated under the condition that any strand is not totallyseparated and there is no doubt of the cable strength. Furthermore, review the condition andoperation of load-bearing carabiners.

2. For situations of basket cable squeezing, check that there is no damage to thimbles or ferrules(a slack thimble ordinarily signals a loose basket cable at a ferrule). Applying to baskets withcable splicing, remove leather covers and inspect the splices.

3. Check strapping for cylinder attachment and locations of their openings providing passageson the basket walls. The passages should be safe enough for strapping in fuel cylinders,especially during landing.

4. Inspect the condition and firmness of the plywood floor, runners / rawhide covers protectingsteel basket cables underneath the basket. Pay particularly attention to any cracks present onthe underside of the floor, at the connection of the floor with the basket body and to anyworn, cracked or slotted locations of protective runners. Ensure that no steel basket cable isuncovered.

5. Supervise the basket body, especially for no unsafe sharp edges with imperfectly covering ordangerous holes in the wickerwork which would cause danger to occupants and throughwhich any object carried by the basket could drop out. Inspect the basket for strong and safeenough internal rope handles for use by passengers during landing.

6. Check the condition of the drop line, its accessibility, compactness and attachment to thebasket.

7. Check the type of the pertinent fire extinguisher (filling capacity should be min of 1 kg,according to the basket size). Inspect the fire extinguisher by weighing, or in accordancewith the instructions for pressure gauge for full filling. Ensure that the last revision of the fireextinguisher has been valid so far. The date of the revision should not be older than prescribedby the producer.

8. The JAA Form One should be completed and distributed as required.

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3.4.4 Burner check

1. Check the burner for completeness thoroughly.

2. Inspect (without overpressure) the manometers/pressure gauges, their general condition,protective glass lens fixing, and condition and legibility of the dial with pointer, which shouldindicate/ read zero under the standstill condition/with no fuel pressure applied.

3. Supervise fuel cylinders are of the correct age from data mentioned on hose squeezed endings.Replace the hose with a new one in case of more than five-year old age of the hose (use onlythe original one produced by the burner manufacturer). Inspect the physical condition ofhoses thoroughly. Pay special attention to the liquid ones. Observe outer covers of hosesalong their entire length to check for no mechanical damage or worn places. Concentrate onbent locations and hose end fittings, if they are not cracked/slack at the squeezed endings. Ifthere are any doubts about the hose perfect condition, replace it with a new one (use only theoriginal hoses produced by the burner manufacturer). During deciding this, please keep specialattention and severity. Minor surface damage to fuel vapour hoses (the hoses supplied thepilot burner) is not critical and can be permitted.

4. Check connecting couplings of both the liquid and vapour phases. Inspect the condition ofcontact surfaces and also entering tapered cones for no mechanical damage. Regarding theRego coupligs/connectors equipped with a self-closing valve, review its function. Checkcolour marking of the couplings (if used).

5. Check welds and the surface of the vaporiser and burner frame, especially at positions ofbands on the upper tube edge of the coil and at the rod inserting sockets on both the burnerand basket frames. Supervise the last strength test conducting of the vaporiser. The timeperiod from the manufacturing or the last test should not be longer than five years. In case ofthe event of the test review, ask the manufacturer for its carrying out.

6. Check all threaded joints and the condition of retaining safety rings. Reject any safety ringshowing a loosening/slack or strain, and replace it with a new one.

7. Inspect the tightness of burner couplings and the manometer function. Connect up the burnerby the supplying hose to the pressure source with the checking manometer/pressure gauge(nitrogen cylinder) and adjust the pressure at 12 bar. Pressurise the fitting/coupling unit andconduct the leakage test of all connections by means of lather solution (see Section 7.3).Check the pressure level on the burner unit manometer.

CAUTION:The leakage test conducted by means of the open flame is not permitted. There is a fire risk.

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8. Realise the maintenance of the main flight (blast) valve/burner (FV). Follow the steps fordisassembly of FV relevant to the burner certain type used - see Section 6.5.3. Remove theFV head, then the lever/cam of the lever and pull out the stem. All the parts should bethoroughly cleaned with a soft cloth and all the O-rings should be put apart. After checkingthe guide surfaces of the stem, bush and opening to the lever pin / cam of the lever, the O-rings and the face sealing should be replaced with new ones. Review the safe position of theretaining screw that dimensions the face sealing. While replacing the sealing keep onprocedures according to the right re-change of the FV sealing relevant to the pertinent burnertype mentioned in Section 6.5.3. Check the state and condition of the FV spring free length.The minimum admissible length of the free spring is 24 ± 1 mm for the HB2, H3 or H3-Dburner. The minimum admissible length of the free spring is 27 mm concerning the KOMETburners. In case the length is not standard it is necessary to install a new spring. Supervisethe working surface of the lifting lever cam/ control lever and its functioning. Also the slidingshim must be checked and if any of the mentioned parts is somehow damaged it is to bereplaced. All the movable components should be covered with vaseline and then FV can beassembled altogether. Assembling and taking up the clearance of the lever/ lever cam werecommend following the instructions for building up the FV burner of certain type - seeSection 6.5.3.

9. Maintain the whisper burner (WB) valve. There is the same procedure as for the FV burnermaintenance regarding the KOMET type mentioned above. The HB2, H3 and H3-D burnersshould be inspected, especially the age of the ball control valve/cock and its functioning,respectively no leakage in the shut off position. If there are any doubts concerning the conditionof any parts and if the valve/cock is aged more than 5 years, the new one must be applied.

10. Maintain the pilot burner (PB).KOMET type:

Put aside the supply hose and remove the fuel filter. Wash up the filter in a petrol bath, thenfan it up with compressed unpolluted air and perfectly clean and dry reinstall it. Get out thelever/handle of the PB control and also the PB head from the fitting unit. All componentsshould be cleaned properly with a soft cloth and inspected to see if their friction areas do notsuffer from mechanical damage. New O-ri ngs and face sealing should be installed. All movingparts must be lubricated with silicon grease. The PB head can be assembled and screwed upinto the fitting unit, then the controlling lever should be set and its position adjusted.Disassembling, assembling and adjusting procedures of PB must be ruled with respect to thedirections for PB of KOMET type as shown in Section 6.5.3. Observe the body of PB andcheck the condition of the scatter. Burned scatter must be replaced.

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HB2, H3 and H3-D types:

Remove the body of PB and also its jet. Wash up the jet in the petrol bath, than wipe or fan itup with compressed cold air to be perfectly clean and dry. Open up the ball valve/cock of PBand use the compressed air to clean up the fitting. Then your PB can be built up again.Disassembling, assembling and adjusting procedures must be ruled with respect to theassembling directions for PB of HB2, H3 and H3-D types as shown in Section 6.5.3.

11. Supervise the functioning of the piezo igniter and also the distance setting of ignition electrodecontacts. Conduct the test for ignition and stability of PB heating. Concerning types HB2, H3and H3-D firstly clean up the carbon on the ceramic insolator that is the part of the ignitionelectrode. Re-inspect the safe position of connectors of the conductor. Check the function ofthe pressure regulator and install the new O-rings if necessary with the old type of ÈSNcouplings (only with the older type of burners).

12. Final burner leakage test of fittings should be carried out. Connect the pilot burner by meansof the supply hose to the pressure source with the checking manometer/pressure gauge(nitrogen cylinder). Then adjust the pressure to the level of 12 bar. The fitting unit should bepressurised and inspected for tightness. Draw attention to all connections and apply the lathersolution (see Section 7.3).

CAUTION:The leakage test conducted by means of the open flame is not permitted. There is a fire risk.

13. The final burning test and the test of the burner basic functions must be conducted. Concentrateon the heat power output values of the flight burner and whether these corresponds to thestandard fuel pressure in the fuel system. Minimise the losses of the burner outputs caused bycarbon layers (blockage) on the vaporiser. If the vaporiser is highly carbonated, pay attentionto the thorough check of FV shutting off in all positions of the control lever/handle. In casethe shutting up represents problems including too long dying out of the flame you mustchange the face sealing and the spring of the FV head. If you think that the burner causesproblems concerning the fuel pressure and it loses appropriate output, conduct the minutetest of the fuel consumption under special conditions: gas overpressure is equal to 6 bar.Heat power output can be deducted easily using the equation: P [MW] = (heating capacity[kJ/kg] multiplied by 0.001factor and then multiplied again by the fuel consumption [kg])divided by 60 [sec]. The value of the G35 propane-butane heating capacity is taken as 50 000kJ/kg. In case the power output is more than 10% lower than standard values mentioned inSection 2.3.5, the burner should be repaired by an approved organisation. Supervise thetightness of connections of the descending tube and fitting body and also the connectiontightness of the crossover valve while intensive burning by means of using the lather solution.Review the possibility of the heating intensity control of PB.

14. The JAA Form One should be completed and distributed as required.

3 - 10 Change: 0 Issue: 10. 10. 2001


3.4.5 Fuel cylinder check

1. Verification of the validity of the periodical inspection prescribed by the cylinder producershould be carried out after comparison with data imprinted on the cylinder index label.Cylinders are not permitted to service without the current periodical inspection.

2. Carry out the external inspection of the cylinder free of its padded cover. Draw particularattention to any damage to the locations of longitudinal welds of the lateral area of the cylinderbody, deeper scratches or abrasions, prospective dents, denoting a heavy impact/misuseaccident or any corrosion.

3. Check the valves and fittings for correct operation and no leakage. The leakage test shouldbe conducted in accordance with Section 7.3. When working on cylinders, it is possible thatthey are completely empty, or with only residual pressure. To achieve the required overpressure,utilise compressed nitrogen. Check the fuel quantity gauge for correct operation and signs ofleakage. About the cylinders equipped with the (vapour) pressure regulator within the vapourphase, inspect then for proper functioning.

CAUTION:The leakage test conducted by means of the open flame is a fire hazard and is not permitted.

Validity of the inspections prescribed by the manufacturer concerningfuel cylinders:

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3.4.6 Equipment check

1. Review that the last inspection, in compliance with the Technical description (presentsubmitted documentation), of the relevant ancillary instrument/equipment is current. Youshould also check the result of the inspection and supervise their extra standard operatingperiods. Regarding the BALÓNY KUBÍÈEK spol. s r.o. instruments, the JAA Form One isapplied to certify and release them for operating.

2. Ensure that the condition, function, conspicuous data legibility and exactness concerningeach instrument keep the rules contained in the Technical description/service and maintenancemanual.

3. Check all the supply and by-passing hoses applied in compliance with Section 3.4.4 - 3.

WARNING:Applying different than approved hoses could lead to the hose loosening out from the couplingby corrosion and an ensuing fire hazard.If there is any noticeable damage to the hose external surface or couplings applied, this factcould cause fuel leakage and a fire risk.

Validity of the inspections prescribed by the manufacturerconcerning instruments:

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3.5 Irregular Inspection

3.5.1 Inspection after overheatingThe balloons are fitted with a temperature-warning streamer, which will descend or be damagedwhen the melting link melts after exceeding the maximum allowable temperature in the envelope.If this occurs, the location of tempilabels should be inspected.Tempi-label: If the maximum temperature indicated on thetempilabel is greater than 124 0C, add a new tempilabel alongsidethe original label and inspect the top of the envelope for signs ofoverheating.Envelope fabric: Then a fabric strength test should be conductedby means of a Grab test at various positions of about 2-meterdistance from the envelope top DS edge. The envelope fabricshould be grab tested perpendicularly to the vertical load tapes. In case of the fabric tearing, submitthe envelope to the manufacturer for further inspection.Lines: Ensure that the lines are in good condition with no burn damage, stiffness or length reduction.Replace the stiff lines with new ones.Envelope mouth: Supervise the load tapes at the envelope mouth and the locations that connect theload tapes to the flying wires for any signs of heat damage. If there are any doubts concerning thecondition of any parts, a new component must be applied.Log book: Record the maximum temperature reached, result of the tests and ensuing repairs in thelogbook.

NOTE:Excessive heat on fabric tends to cause cracking due to stiffness.

3.5.2 Inspection after contact with electric power linesIf the envelope or basket touches electric power lines, the inspection should be carried out in scope ofthe annual inspection with concentration on the checks described below.Envelope textile: Review all envelope textiles, especially for signs of any damage to the load tapesby the electric discharge. The damaged parts must be repaired.Crown ring: When supervising the crown ring, draw attention to any noticeable damage. In case ofthis matter, a new crown ring should be installed.Flying wires: Perform the inspection of the flying wires along their whole length including thimblesand ferrules. In the event that any damage from the electric current is detected, then the flying wiremust be replaced.Basket cables: These should be checked for electric damage along the whole length and that thethimble and ferrule are in good condition as well. After removing the basket protective runners/rawhide, pull out .the cables. Replacement of damaged basket cables should be carried out. In theevent that any problem of the whole length checking of the cable occurs, a new basket cable must beinstalled.Fuel cylinders: Remove the padded jackets/covers and inspect the cylinders bodies for externaldamage from the electric discharge. After detecting any damaging effect the pressure test of thecylinder should be performed. If the cylinder has been deemed unsuitable for further service inaccordance with the test results, put the cylinder out of operation. The failed cylinder must be markedand secured against accidental filling.Logbook: The accident concerning the contact with power lines and the following tests/repairsshould be entered in the balloon�s log book.

Tempilabel

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3 - 17Issue: 10. 10. 2001 Change: 0


B.0202

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4 - 1


B.0202

Issue: 10. 10. 2001 Change: 0

SECTION 4

4. Airworthiness

4.1 Airworthiness ................................................................................................................ 24.2 Airworthiness Limitations ............................................................................................ 24.3 Mandatory Standards for Continued or Improved Airworthiness ................................. 24.4 Airworthiness Control ................................................................................................... 2

4.4.1 Information collecting for the airworthiness control ....................................................... 24.4.2 Annual failure summary ................................................................................................... 2

4.5 Service Life ................................................................................................................... 34.5.1 Qualifications of time limits in terms of envelope or burner textile parts ....................... 3Failure Report ............................................................................................................... 4Questionnaire to a balloon operator .............................................................................. 5

4 - 2


Change: 0 Issue: 10. 10. 2001

4. Airworthiness

4.1 Airworthiness

The balloon airworthiness contained herein means the reliability, i.e. the ability of all componentsof the particular balloon to operate under the conditions defined by the covering technicaldocumentation during the defined period.

4.2 Airworthiness Limitations

The continued airworthiness condition of the balloon/balloon part seems to be keeping theregulation maintenance, inspections, revisions and instructions for handling and operationallimitations designated by the manufacturer.

4.3 Mandatory Standards for Continued or Improved Airworthiness

The manufacturer in agreement with the CAA issues mandatory bulletins so that the sufficientcontinued or improved airworthiness will be achieved. The balloon operator is obliged andresponsible for the accomplishment of all bulletin assignments.On grounds of the continued airworthiness regarding the balloons in service, the manufacturerregisters all operators/owners flying the balloons produced in his factory. In case the operator/ownership of this balloon or its part changes, it is obligatory and important for the new operator/owner to contact the manufacturer and inform the manufacturer up-to date by means of an enclosedquestionnaire. If there is an incomplete or untrue correspondence address, it is not possible toprovide proper distribution of bulletins.

4.4 Airworthiness Control

The manufacturers and operators are responsible for the balloon airworthiness in the CzechRepublic and countries where the local CAA enacted the rule.

4.4.1 Information collecting for the airworthiness controlThe manufacturer gathers the information on balloon failures by the data collecting from theoperators by means of the �Failure Report� (see Section 4.4.3). The operator is obligated to fillin and refer the questionnaire to the manufacturer when any defect is occurred. The operatorshould submit the information mentioned above to the local CAA as well, in compliance withthe applied particular national regulations.

4.4.2 Annual failure summaryThe manufacturer puts together an annual summary on failure incidences of the product and ageneral analysis of the main defect reasons, also determines precautions or measures directingagainst the beginning of malfunctions. Furthermore, you can obtain the annual failure summaryon request.

4 - 3


B.0202

Issue: 10. 10. 2001 Change: 0

4.5 Service Life

The service life period is limited in reference to the components contained in the section. Theother parts not mentioned herein should be replaced in compliance with the Maintenance Manual- Section 6. (e.g. after damage or excessive wear).

4.5.1 Qualification of time limits in terms of envelope or burner textile partsThe service life termination of textile materials is based on their residual strength. The textileslose their strength gradually (degradation) right to the value provided for the minimum prescribedfactor of safety.

The degradation speed could dangerously increase after:1. Frequent envelope overheating during hard or rough flight manoeuvres2. Flying the overloaded balloon3. Leaving the spread balloon exposed to the sunshine effect4. Incorrect sealing of DS5. Frequent packing up of the hot envelope6. Envelope storage in a moist/wet condition or near by heaters

NOTE:The degradation velocity depends on the temperature at which the balloon is mainly operated,storage conditions, operating/flying carefulness and maintenance keeping.

Further materials of time limits

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4 - 4


Change: 0 Issue: 10. 10. 2001

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4 - 5


B.0202

Issue: 10. 10. 2001 Change: 0

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5 - 1Issue: 10. 10. 2001 Change: 0


B.0202

SECTION 5

5. Balloon Handling and Maintenance

5.1 Handling ........................................................................................................................ 25.2 Preventative Maintenance ............................................................................................. 2

5.2.1 Envelope ............................................................................................................... 25.2.2 Basket ................................................................................................................... 25.2.3 Burner and fuel system ......................................................................................... 25.2.4 Balloon storage and road transport ....................................................................... 3

5 - 2 Change: 0 Issue: 10. 10. 2001


5. Balloon Handling and Maintenance

5.1 Handling

Balloons are very simple aircraft. Therefore, the balloon parts not mentioned in this chapter donot solicit any detailed comments on operation than it is described in the Flight Manual.

5.2 Preventative Maintenance

5.2.1 EnvelopeBesides common cleaning and keeping the below mentioned storage instructions (Section 5.2.4),the envelope does not necessitate additional maintenance.Use customary cleaning detergents, water diluted. Soiled areas should be cleaned by means ofdamped swabs. Then, before packing, the envelope should be dried thoroughly.

5.2.2 BasketThe basket necessitates periodical cleaning. The cane and floor should be cleaned with flowingwater and brush, or pressure water as far as possible (protect the upper suede rim against overlywetting through). Preserve cane from overly drying, the matter gets down its fragility resistance.Care about the basket not being exposed to moist storage. Under moist conditions acting for along time, there is a danger of mould and rot inception. Rawhide on the basket bottom andleather/suede on the top rim is recommended be attended to common products for oxhide/leather/suede care. If there is a suede cover on the upper rim, simply restore it by brushing with a specialsuede shoe-brush.

5.2.3 Burner and fuel systemDuring the operation of the burner, there is inevitably an accumulation of carbon deposits, i.e.soot and condensates, within the coil and can of the burner. These deposits may be regularlyremoved by using a dry soft cloth - flannel (the best after each flight day). This has been keepingyour burner appearance in good condition for a long time. While more accumulating, you canclean the carbon deposits by using a weak detergent with hot water soaked cloth. In some instances,when cleaning of burners does not be accomplished efficiently and periodically as specifiedabove, the next continued burner operating may result in the mess burning-in and sticking. Thesecan be removed heavily only.Cleaning and the lubrication of valves, the adjustment of the pilot burner electrodes and furthermaintenance are specified in Section 6.5.3.

5 - 3Issue: 10. 10. 2001 Change: 0


B.0202

5.2.4 Balloon storage and road transportThe rolled up balloon envelope is best stored in a transport bag and at a dry airy place. Pack theenvelope in absolute dry condition and minimise the exposure to the sunshine or heater effect(recommended is storage onto a pallet). In case of the wet envelope after the flight completing,ensure its complete drying without fail and as soon as possible. Spread the envelope on a dryshady field and keep airing. The wet envelope should be gently dried by cold and then hotinflation until the whole moisture has evaporated. Under moist conditions acting for a long time,there is a danger of mould and rot inception.Besides common keeping of the mentioned storage instructions, the burner does not necessitateadditional maintenance. It is recommended to remove accumulation of carbon deposits (sootand condensates) after each flight day. Ensure that no fouling to couplings of fuel hoses canoccur during transport/storage (a connector cover is recommended). Draw close attention to fuelhose storage that any collision with heavy objects, fall or hard object squeeze should not causedamage to them. Moreover, concerning the burner transport, a padded burner bag is recommended,and is available at your balloon dealer or the manufacturer. Ideally the burner should always berestrained from movement during transportation.Follow the procedures recommended by your national regulations valid for transport and storageof liquefied oil gas tanks.


6 - 1


B.0202

Issue: 10. 10. 2001 Change: 0

SECTION 6

6. Repairs

6.1 General .......................................................................................................................... 26.2 Classification of Repairs ............................................................................................... 26.3 Approved Organisations to Provide Repairs ................................................................. 26.4 Identification of Demage/Repair Locations ................................................................. 36.5 Minor/Owner Repairs ................................................................................................... 4

6.5.1 Repairing envelopes ......................................................................................................... 46.5.2 Repairing baskets ............................................................................................................. 76.5.3 Repairing burners ............................................................................................................. 86.5.4 Repairing equipment ...................................................................................................... 186.5.5 Repairing accessories ..................................................................................................... 18

6.6 Major/Special Repairs ................................................................................................. 196.6.1 Repairing envelopes ....................................................................................................... 196.6.2 Repairing burners ........................................................................................................... 21

6 - 2


Change: 0 Issue: 10. 10. 2001

6. Repairs

6.1 General

Balloon components are repaired using common methods except the demanding repairs for whichspecial procedures are given in this Section.Balloon components made by another manufacturer - different from BALÓNY KUBÍČEK spol.s r.o. - must follow the repair procedures given by the certain producer.

CAUTION:If it is not possible to reveal the cause of a damage without any doubts, let the approvedorganisations estimate and realise the repairs.Repairs of the character of re-change can be used within the procedures that are standard forspare parts as shown in the balloon catalogue.Materials and components to be used must be approved by the manufacturer and havecertifications to prove it.

6.2 Classification of Repairs

Common repairs do not include for instance slack lines, unfastened screws or loose cane - theseexamples are taken as a part of daily service and maintenance. The repairs that containreplacements or repairs of damaged or non-functional components are classified into twocategories: simple and special ones. All of them must follow this itinerary marked as Section6.5, 6.6 or you can contact the manufacturer asking for topical repair information concerningsteps to be taken.

6.3 Approved Organisations to Provide Repairs

Minor repairs can be provided by the balloon operator (if it is not set in any other way), specialmajor repairs must be referred to approved organisations. Any major repair is followed by a test/inspection of the repaired component. Tests are taken by the person authorised to provide theannual inspection - see Section 3.3.

6 - 3


B.0202

Issue: 10. 10. 2001 Change: 0

6.4 Identification of Damage/Repair Locations

To locate a damage/repair easily we use number codes in this work. The first number signifiesthe main group, the other number represents its sub-group. (see the table below). Then there is adash and the serial number of a repair. Minor repairs contain maximum two numbers, majorrepairs have three numbers code (see Section 6.6).

Main Group Sub-group No. Term No. Term

1 Envelope body 3 Deflation System

5 Ribs and further inner envelope forming aids

1 Envelope

7 Envelope and basket connections 2 Basket 1 Basket body

1 Main flight burner/valve 3 Pilot burner 5 Whisper burner

3 Burner

7 Burner frame 4 Power unit Not applicable 5 Fuel system 1 Fuel cylinders 6 Electrical system Not applicable

1 Mechanical instruments 2 Electric instruments 4 Electronic instruments

7 Equipment

9 Further 1 Envelope 3 Basket 8 Accessories 5 Burner

9 Appliances 1 Ground aids

6 - 4


Change: 0 Issue: 10. 10. 2001

6.5 Minor/Owner Repairs

6.5.1 Repairing envelopes

11-1 Repairing the fabric of the envelopeIf the coat of the envelope is torn somehow you should take appropriate procedures according tothe size of the holes or damaged section of the fabric.Small tears - maximum 3 cmSmall holes or tears can be covered by a simple „hot cut and overlay“ patch from any material ofeither polyester or polyamide origin. Small holes might be mended by means of sticky-backedpatches that are standard for repairing boat sails. This type of adhesive patches is to be used forrepairing straight torn places of maximum length 10 cm, their edges must be sewn up with theenvelope body using two rows of parallel independent stitching. This kind of repair must befinished before the start of the next flight day. When mending small tears the fabric of the envelopeis not cut away.Larger tears - individual holes of maximum size 1 x 1 m placed in one panel onlyMending bigger holes it is necessary to cut away the damaged fabric close to the tear and replaceit with the new one as mentioned in Section 4.5.1. Orientating of the thread direction of the newinserted fabric must follow the orientation of the original fabric. Keep this recommendation notto overcome fabric because of possible stress or strain in the direction of warp and weft threads.Guidelines to the envelope fabric repairs:Mark out the damaged place on the envelope in the parallel direction that follows the anti-ripgrid in the shortest direction along the whole width or length of a panel between the adjacentvertical or horizontal seams according to the size and location of the damaged place.Mark out the fabric to be cut away to identify the concerned panel relative to the envelopeeasily.Unpick the seams on the fabric, in the rest positions cut off the fabric following your marksusing a hot knife.The damaged fabric from the envelope shall be used as a pattern to create a new part forreplacement. Cut the replacement panel/patch of new fabric that is 8.4 cm larger than the markededges (2.1 cm - additional allowance for one (French) fell seam - see Section 6.6.1) and markout orientation of its location within the envelope. If the fabric is seriously damaged or distorted,it is necessary to take the measures from another undamaged identical panel.The new panel to be sewn up into position of the envelope. Use the technique of the doublestructural fell seam.

6 - 5


B.0202

Issue: 10. 10. 2001 Change: 0

13-1 Repairing activation ropes of DSIt is common to replace the whole activation ropes of the DS. Itis possible to extend activation ropes of the DS by using thesame rope type. If more length is needed the additional ropemay be tied in, but any knots must be within max 3 m of the fixattachment point on the envelope body. Lengthening is to bemade by means of safety turnback knots.

13-2 Repairing control lines of DSMending is provided by elongation of the damaged control lines in that way the length betweenthe pulley and the loop on the edge of the vent panel remains the same. Lengthening is to bemade by means of safety turnback knots. If more than three of control lines are damaged it isnecessary to change them for the new ones.

13-3 Repairing centralising lines of DSCentralising lines for both the parachute vent and the Smart Vent fix the right position of the ventpanel and that affects its sealing.Short line pulls the vent panel inside the envelope, it causes dangerous stress or strain to its edgeand afterwards the vent panel possible leakage. The short line is responsible for the characteristictense flat edge of the vent.Long line allows pulling the vent panel inside the load tapes, it increases the force and timenecessary to open and can cause leakage. The long line is typical for the drooping edge of parachutevent.Adjusting the length of the parachute line:1. Join up the velcro panel of parachute vent and the relevant matted gore on which you provide

the adjustment.2. Untie the centralising line from the envelope body. Then stretch out the load tape between

the loop of the vent panel on the envelope and the edge of the deflation/vent hole.3. Tight up the line using the safety turnback knot in that way the distance between the loop on

the envelope body and the velcro panel of the parachute becomes longer by 6 ± 1 cm than thedistance between the loop and velcro panel on the envelope body.

CAUTION:While final securing lines do not forget to use the special turnback knots. Other knots can causeproblems owing to the high force to the lines, and their loosening and undoing leads to the faultysealing of the parachute vent.Damaged or broken cords should be replaced with new ones. When replacing cut off the damagedone close to the edge of the parachute vent so there remains the overlap end of 5cm length asminimum. This loose end shall be heat sealed with a hot knife or lighter. The new line shall beplaced and fastened into the loop on the edge of the vent panel, after adjusting its length it canbe fixed into the loop on the envelope body.

Safety turnback knot

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NOTE:Add the 5cm surplus as minimum, which is the lost while replacing cords with a knot. Conductthe final check of the length after fixing.

There is no need to adjust the length of Smart Vent lines, as there are special heat-resistantvectran lines.

CAUTION:Damaged or broken vectran cords must bereplaced with new ones Knotting in of vectranand control lines is possible by means of adouble fisherman’s knot. Then fix the vectrancord to the edge of the vent panel using abowline knot.

13-4 Repairing pulleys of the envelopeNo repairs just replacement with new ones.When changing do not forget to fasten up theattachment screw properly.

CAUTION:It is prohibited to replace one type of pulley that allows its rotationaround the vertical axis with another type of fixed pulleys and viceversa. Mixing up the types you risk tangling up of line.Pulleys must be of certain type approved by the manufacturer.

13-5 Repairing rotation ventThe damaged fabric of the rotation vent shall be mended as shownabove in procedure 11-1. Faulty activation ropes and control linescan be knotted in by means of turnback knots so they will not causeany jamming problem using them in pulleys.

17-1 Repairing carabinersNo repairs just replacement with new ones of the same type, and ofthe same or even higher loading capacity. Bowline knot

Double fisherman‘s knot

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6.5.2 Repairing baskets

21-1 Repairing basket floor, load-bearing wooden frame and other wooden componentsMending the floor the common techniques are used. If the floor is hardly damaged or the floorhas cracked right through, then it must be replaced totally. If there is a serious crack damage oreven a breakthrough of wooden runners protecting cables and tubes, they must be also replacedwith new ones. After installation the bottom of the basket shall be covered with transparentsynthetic protective varnish for wood.While applying the varnish firstly note that any protective varnish must be completely removedfrom the damaged area by using the wire brush and then the sandpaper and only afterwards puton the re-varnish coat. Before you start to varnish up the coloured part of wickerwork, it isnecessary to use a stain of suitable colour to dye in first. Tidy up dangerous sharp edges ofcertain objects (e.g. parts of screws, floor splinters etc.) according it your own needs to reducerisk of any injury. Other repairs should be provided by approved organisations.

21-2 Repairing upholstery and padded suede/leatherworkWhile mending the soft parts of suede/leatherwork all attainable materials and aids are to beused.To impregnate the thick rawhide/oxhide of brown colour used to protect the bottom basket edgingwe recommend the Elaskon treatment that should be applied after warming to about 50 - 60 0C intwo layers minimally. Before coating with the Elaskon firstly clean up the leather with brush andwash it with hot water and detergent and then let it dry.Basket protective cables and bottom basket rim being covered with the rawhide of white colourso called English it becomes a necessity to cut away the damaged parts and replace them. Whenchanging for new rawhide covering basket cables, the revision of basket load cables is advisable.Maintain the rawhide with a brush or apply shoe treatment for white leather.

21-3 Repairing basket wickerworkDangerous sharp ends, edges or broken canes of the basket should be carefully adjusted/fed byweaving them up and fixing them by means of a cord, string or plastic belt.Repairing of damaged vertical ratan-canes manages only the approved organisations.

NOTE:Completing the repair do not forget to check if the tape of the dropline is tightly fixed up to thebasket by means of a carabiner.

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6.5.3 Repairing burners

31-1 Repairing the main flight (blast) valve (FV) of H3, H3-D, HB2 burnersPut out the nut of the main flight (blast) valve head (50259). Remove the split pin (425) with thewasher (404), lever roll pin of FV head (50261), set out the lever (50263), adjusting sliding shim(50264, 50265) and carefully pick the stem (50260). The stem and bush of FV head (50262)shall be cleaned up, observed and the state of both top and bottom O-rings (420) should bechecked. Protect the O-rings with silicon vaseline and if they are damaged replace them withnew ones. (We recommend re-changing O-rings during every whole dismantling of the FV head).Then install the bottom O-ring firstly and put a thick layer of silicon vaseline into the roominside the head then insert the bush, the top O-ring and the lid (50267). The stem should be alsocoated with silicon vaseline, set the spring and install it into the head. Put together the adjustingsliding shims and the lever, put in the split pin and fix it with the roll pin (see 61-2). Completethe FV head and fix the head roll pin with the split one. Before assembling the head into the FVbody (50222, 50228) check up the state of seat, facestem sealing (50520) and also the right position ofthe screw (423). In case you find up any damage ofthe sealing, replace it with new. (We recommend re-changing it during every whole dismantling of theFV head). The head should be then equipped withthe seal PTFE tape of width 0.1 mm (see Section 7.4)and then installed into the FV body. Check up thelevel clearance and conduct the leakage test with thelather solution (see Section 7.3).

404 - Washer, 4.3 Zn413 - Pressure spring420 - O-ring, 12x8 rubber422 - Washer, 3.2 Zn423 - Screw, M3x10

50222 - Left FV body50228 - Right FV body50259 - Nut of FV head50260 - Stem of FV head50261 - Lever roll pin of FV head

50263 - FV lever50264 - Adjusting shim of FV50265 - Adjusting shim of FV50267 - Lid of FV head50520 - Face seal of FV cone

50260

50264

50259

50262420(2 pc)

423422

Flight valve head of H3,

50222

Dismantling flight valve head of

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31-2 Taking up the clearance of the FV lever of H3, H3-D, HB2 burnersThe minimum clearance between the lever and the adjusting shim must be 0.5 mm.Adjusting the right clearance you should use the sliding shim 1 mm thick (50264) and one 0.5mm thick (50265). Take off the split pin (425) and also the head roll pin (50261) and the lever.Then adjust the right number of sliding shims. Then insert the lever and the roll pin, check theclearance and fix the state with the split pin.

CAUTION:Fixing the roll pin by means of the split pin you should pay attention not to let the split pin tomake spontaneous movement that causes getting stuck/jamming and blocking of the flight ventin the open position.

31-3 Repairing untightness of the H3, H3-D or HB2 descent tube/fitting connectionThe repair starts with fastening of the central nut by means of the specially adjusted open-endwrench. If the positioning is not good enough, ask the manufacturer to replace the lower part ofthe descent tube.

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31-11 Repairing the main FV of KOMET burners

If controlling the vent causes problems or if there is leakage due to untight closed position of theburner, you should:1. Check the quantity of motion of lever mechanism regarding valve control2. Check the state and lubrication of the O-rings that belong to the vent, use silicon vaseline.3. Check the right position of the countersunk lock screw (1116) and of the front face stem

sealing of FV/WB (51133).4. Check possible permanent deformations of the spring (51132).5. Check the state and lubrication of the parallel/roll pin (1160).

Start the repair with unscrewing the screw of the lever (1126) related to the head of FV andscrews (51138). Then getting out the head cover of FV (51116). Using the hook spanner unscrewthe FV nut (51119). After evaluating causes of defects replace the damaged parts including seals(we do recommend re-change the O-rings (1113) and the face sealing while every wholedisassembly of the FV.

Flight valve of KOMET type

1107 - O-ring, 25x2.5 1108 - O-ring, 37x2.5 1113 - O-ring, 7x1.8 1116 - Screw, M3x8 1117 - O-ring, 25x2 1126 - Screw, M6x80 1160 - Roll pin, 4x2851116 - Head cover of KOMET FV51118 - Stem of KOMET FV/WB51119 - Nut of KOMET FV51132 - Spring of KOMET FV/WB51133 - Stem sealing of KOMET FV/WB51134 - Sliding shim I of KOMET burner51135 - Sliding shim II of KOMET burner51138 - Screw of KOMET head cover51184 - Lever of KOMET FV head52013 - Head cam of KOMET FV

51119

51116

51118

51133

51132

51135

52013

51134

51138(2 pc)

51184

1116

1160 1126

1113

11071108

1113

1117

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In case of O-rings (1113)/spring of FV/WB (51132) replacements, you should remove the rollpin (1160) from the head cam of FV (52013) and pull out the stem of FV/WB (51118). Beforesetting the O-rings (1107, 1108, 1113) into the pertinent pits, coat them carefully with siliconvaseline. Then place the sealing of the stem and fix it with the lock screw. Provide the stem withthe spring and put a thick layer of silicon vaseline into the space among O-rings (1113). Usingthe cloth soaked with silicon vaseline clean up the hole inside the FV nut and install there thecompleted stem. Then put on the sliding shim (51134 or 51135) and the head cam of the FV(52013), adjust the openings of the sliding shim, head cam and fix the right position with theparallel pin. The roll pin surfaces shall be coated with silicon vaseline. Screw up the completedhead into the burner fitting and adjust it by means of the hook spanner. Check up the prescribedclearance to be 0.1+0.1 mm between the cam and the sliding shim. If the clearance is not standard,change the shims for new ones of different thickness. Place the head cover with the cam on theFV nut and fix it with screws. Connect the lever of FV using the screw (1126). Check thequantity of motion, tightness (see Section 7.3) and the functioning of the main FV.

NOTE:Cleaning and lubricating the FV with the silicon vaseline should be realised while everydisassembling of the main FV head.

31-12 Repairing untigtness of the descent tube/ fitting connection belonging to KOMETburnersThe connecting screw of KOMET burners must be set into the right position with the elongatedsocket wrench. If the untightness is not solved, let the approved organisation eliminate it.

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419 - O-ring, 6x2 1125 - Adjusting screw, M5x12 1139 - Retaining ring for hole51139 - Stem of KOMET CV51149 - CV control of KOMET type51168 - Bush of KOMET CV51172 - Threaded liner of KOMET type51198 - Ball of KOMET CV51199 - CV seat I of KOMET type52007 - CV seat II of KOMET type52010 - Right CV control of KOMET type

Crossover valve of KOMET burner

51139

51199 51198 52007 51172

1139

51168

5114952010

419(2 pc)

1125

31-13 Repairing the crossover vent/cock of KOMET burnersFuel leakage can be mended after the following steps: disassemble the ball valve control (51149,52010), retaining ring (1139) and stem (51139), then change the O-rings for new ones (419).Putting things back apply the silicon vaseline onto the O-rings, fix the stem with the retainingring and check the position of the ball valve control. Replacing the O-rings (419) you stop fuelloss but not the untightness of the valve. Let the approved organisation repair the untight ballvalve (components 51172, 51198, 51199 a 52007) as well as the pressed in part (51168).

31-14 Repairing mechanical deformations of the vapouriser and burner cansTry to planish by means of the wooden bar (levering or hammering) only the small deformationsof the shape of the maximum deflection of 3 mm. Any repairs of welds or cleaning the innerparts of tubes from carbon must be referred to the manufacturer. While finding the considerablemechanical damage of the tube surface of the vapouriser the strength test must be conductedwith the inner overpressure - submit the burner to the approved organisation.

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31-15 Repairing fuel hosesIf there is any mechanical damage to any of fuel hoses, it is necessary to replace them with newones as soon as possible (see Section 6.6.2). No repairs or shortening of hoses are allowed.If there are any fuel leak on the threaded connection of the DYNAQUIP coupling, then fasten upthe screw junction by the moment of about 25 Nm (regarding hoses of 8 and 10 mm diameters).Damaged seals of the REGO (ČSN) couplings mean you must replace the O-ring with a newone. The procedures how to manage tight connections using the seal PTFE tape are to be foundin Section 7.4.

NOTE:All burners that have been produced until November 8th, 1999 have their connectors coatedwith special adhesive material so their repairs should be managed by approved organizations.

NOTE:Regular re-change of O-rings you should realise yearly.It is recommended to coat the couplings by means of graphite powder.If you have found any other faults, ask an approved organisation to repair them.After finishing the repairs of fuel system the leakage test should be conducted using the lathersolution as mentioned in details in Section 7.3.

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33-1 Repairing pilot burners of H3, H3-D, HB2 typesClean the ceramic insulation of the spark ignition electrode using a cloth with the detergent orusing a hard but non-metal brush. Layers of soot or carbon deposits can cause problems as thepossible source of discharge except of the electrodes of the spark gap. Damaged componentsshoulds be replaced with new ones. Check up the undisturbed state of the conductor between thepiezo igniter and the sparking plug. Adjust the distance between the electrodes of the pilot burneraccording to the picture. The distance between the electrodes (411) or the distance between theelectrodes and the body of the pilot burner (50241) according to the type of the burner should beadjusted. The spark must be as long as possible but it must spark over properly. The recommendeddistance is from 3 to 4 mm. Then review the right functioning of the piezo igniter, if necessary tochange for a new part.

33-2 Repairing the fuel supply of H3, H3-D, HB2 burnersTurn off the conductor (51158) from the spark ignition electrode, unscrew up the body of thepilot burner (50241) and also the jet (50235). The H3 and H3-D types need to remove thewhisper burner body before unscrewing. The jet should be cleaned by using the metal wire 0.7mm thick, then washed in petrol and dried with the pressurised cold air.

Pilot burner H3, H3-D, HB2 types

3 - 4

50241

403404405

52086

167

402

411

50230 50232

502365051550233

50634

51158

50235

50223

50233

50237

3 - 4

50223 - Elbow, G1/8 - G1/450230 - Connector, M14x1,5 - G1/450232 - Support of ball cock50233 - Nut, G3/850235 - Jet of PB50236 - Nut, M26 (H3, H3-D)

50237 - Cover (H3, H3-D)50241 - PB body50515 - Support of HB2 piezo50634 - Piezo igniter cover of HB2 type51158 - Piezo igniter52086 - Hose

167 - Ball cock402 - Nut, M8403 - Screw, M4404 - Washer, 4.3405 - Nut, M4411 - Spark plug

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1103 - Sliding shim, 8x14 1104 - Retaining ring for shaft 1105 - O-ring, 12x2,5 1106 - O-ring, 4x1.75 1109 - Adjusting screw, M6x10 1115 - Adjusting screw, M5x851122 - Stem of KOMET PB51123 - Lower PB tappet of KOMET type51124 - Upper PB tappet of KOMET type51126 - Stem sealing of KOMET PB51127 - Spring of KOMET PB51140 - Jet of KOMET PB51144 - PB control of KOMET type51145 - Piezo igniter of KOMET type51161 - PB body of KOMET type51162 - PB tube of KOMET type52043 - PB scatter of KOMET type

4.5±

1

51140

1103

51126

51161

52043

51145

51124

51127

51123

51122

1106(2 pc)

1105

1115

1109

1104

1109

51144

51162

KOMET pilot burner

33-11 Repairing KOMET pilot burnersStart up with unfastening the adjusting screw (1109), taking off the pilot burner control (51144)and unscrewing the PB control mechanism.Rechanging the O-rings (1106) do not forget to let the retaining ring loose (1104), get out thestem of PB (51122) with the sealing (51126). Replace the original O-rings (1106), clean up thestem from carbon deposits and coat the new O-rings with the silicon vaseline. Then positionthem progressively into the pits. Before re-completing feed the room between the O-rings withthe silicon vaseline.Repairing the flat stem sealing (51126) you should remove the whole stem and change it witha new one (51122) or let an approved organisation manage this repair.

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Positioning the lever of the PB control - follow the photos. While assembling do pay attentionto the right position - Closed/ Open. Turning around increase or reduce the angle. At the positionbetween closed/open, the axis of the control lever should be set perpendicularly to the longitudinalaxis of the fitting unit.

33-12 Repairing the fuel supply of KOMET burnersIf the power output of the pilot burner is inefficient and you are not sure about fuel quality,remove the liquid hose and the fuel filter out of the burner fitting. The filter should be washed intechnical petrol and then fanned and dried with the compressed cold air. After sealing the hosecoupling using the seal PTFE tape (see 7.3) finish the procedure by screwing up the hose into thefitting. If you can ignite the burner but you need too many tries, check up the possible damage orblockage of the scatter (52043). The new scatter must be shaped for the tube step of the pilotburner (51162). Clean the jet of PB (51140) in case the flame is still not stable or sensitive duringthe intensity regulation. While dissasembling/assembling the jet, follow the 33-11 procedure.

33-13 Repairing the piezo igniter of KOMET burnersClean using a dry cloth or with a hard but non-metal brush the ceramic insulation of the ignitionspark electrode. Check it up and if necessary adjust the distance between electrodes of the pilotburner (see 33-11). If there is a serious malfunction, replace the piezo igniter (51145) with a newone.

OpenPosition between closed/openClosed

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35-11 Repairing KOMET whisper burnersIf controlling the vent causes problems or if there is leakage due to the leaky closed position ofthe burner, you should:1. Check the quantity of motion of the lever mechanism regarding the valve control2. Check the state and lubrication of the O-rings that belong to the vent, use silicon vaseline.3. Check the right position of the countersunk lock screw (1116) and of the face sealing of

FV/WB (51133).4. Check possible permanent deformations of the spring (51132).5. Check the state and lubrication of the parallel/roll pin (1160).Start the repair with unscrewing the hex socket screw of the lever (1155) related to the WB headand adjusting screws (1115). Then take out the head cover of WB (51115). Using the hookspanner unscrew the WB nut (51130). After evaluating causes of defects replace the damagedparts including seals (we do recommend re-change the O-rings (1113) and face sealing whileevery the whole disassembly of the valve head of WB).

1102 - O-ring, 18.5x3 1107 - O-ring, 25x2.5 1108 - O-ring, 37x2.5 1113 - O-ring, 7x1.8 1115 - Adjusting screw, M5x8 1116 - Screw, M3x8 1155 - Hex socket screw, M6x40 Zn 1160 - Roll pin, 4x2851113 - WP insert of KOMET type51114 - KOMET WB51115 - Head cover of KOMET WB51118 - Stem of FV/WB of KOMET type51130 - WB nut of KOMET type51132 - Spring of KOMET FV/WB51133 - Stem sealing of KOMET FV/WB51134 - Sliding shim I of KOMET type51135 - Sliding shim II of KOMET type51137 - Head cam of KOMET WB51183 - Lever of WB head of KOMET type

51137

1102

51114

51134

51130

51133

51132

51135

51183

51118

1116

1115(2 pc)

1155 1160

1113

51115

51113

11071108

Whisper burner valve of KOMET type

1113

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In case of O-rings (1113)/spring of FV/WB replacements, you should remove the roll pin (1160)from the cam of WB head (51137) and pull out the stem of FV/WB (51118). O-rings (1107,1108, 1113) should be coated with silicon vaseline and placed into the pits. Then insert the stemsealing and fix it with the screw and fill the room among the O-rings with silicon vaseline. Cleanup the hole in the whisper burner nut by means of the cloth soaked in the silicon vaseline. Theninsert the completed stem. Put on the sliding shim (51134 or 51135) and the WB head cam(51137), position the openings of the sliding shim and the head cam. Fix the position with theparallel pin after lubricating properly. The assembled head should be installed into the burnerfitting and fastened with the hook spanner. Check the standard clearance to be 0.1-0.2 mm betweenthe cam and the sliding shim. If the clearance is not as prescribed, replace the shim with a newshim of different thickness. Place the head cover with the cam on the WB nut and fix it withscrews. Connect the lever of WB using the screw (1126). Check the quantity of motion, tightness(see Section 7.3) and functioning of the WB valve.

6.5.4 Repairing equipment

71-1 Repairing the tempilabel and the melting linkDo not try to repair and do not even undo the original tempilabel. Sew the new one along theoriginal. Replace the disconnecting melting link with a new one.

6.5.5 Repairing accessories

83-1 Repairing the droplineThe carabiner of the tape shall be replaced with a new one. Damaged or mouldy tape must bechanged with a new one.

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Tape sewing to the crown ring

22

80 cm

1 1 10221221

Tape sewing up

50 cm

6.6 Major/Special repairs

The following repairs concern the most important parts of the balloon that influence the vitalfunctions and its safety. If there is any damage, all repairs must keep to the procedures shownbelow otherwise the balloon should not be operated any more.

6.6.1 Repairing envelopes

11-101 Repairing vertical and horizontal load tapesDamaged or cut load tapes shall be changed or covered witha new one in that way there is the minimum overlap of 500mm in both directions from the damaged area. The sewingshall be secured using 14 rows of parallel stitching along thetape length and two rows of running across ones (see thepicture). Sewing of the load tapes altogether must be finishedbefore their fixing to the fabric of the envelope.

11-102 Repairing the crown ringThe damaged crown ring shall be unpicked and replaced with a new one. The load tapes shall besewn in accordance with the picture and the original overlap should be kept. If the ends aredamaged while undoing stitches, cut off the damaged part and supply it with the brand new loadtape according to the procedure 11-101.

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Double fell seam

7 mm 7 mm

4 4

11-103 Repairing the vent hole sealed with the velcro panelThe repair of the riplocks must be provided by the complete re-change. The seam length andtypes of the knots must be kept, changing the velcro you should use the type supplied by theenvelope producer. The velcro tab must be sewn all along its edges. Load tapes protective coveringmust be followed.

CAUTION:The load protective covering minimises damage to the velcro tabs during the envelope packing.Using other than certified velcro can cause a disconnection influenced by moisture or change oftemperature.

11-104 Repairing textile panelsIf your envelope is seriously damaged, unpick stitching and re-change the whole panel. The old panel should be kept as a patternwhile cutting the new panel for replacement (then the damagedpanel is not distorted overly). Cutting a new panel you must keepthe original orientation of thread in the direction of warp and weftthreads. Always use only double (French) fell seams (see thepicture).

11-105 Repairing load-bearing steel flying wiresLoad-bearing flying wires are never repaired but only replaced. Any squeezing of endings orwicking up the ends of the steel wires is prohibited.

11-106 Repairing connections of flying wires made of steel and load tapes at the envelopemouthUndo the stitches of the tape that needs the repair, then cut off the damaged part, heat seal theends with a hot knife or a lighter and set the tape according to the procedure 11-101. Then insertthe tape into the thimble of the flying wire. Sew up the tapes altogether and then back to theenvelope. It is recommended to cut away the tape leaving it as long as the rim tape sewn aroundthe envelope mouth.

Connection of the flying wire and the envelope load tape

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15-101 Repairing load fabric ribsIf any part of ribs is damaged, you must cut it away and replaced it with new fabric. It is necessaryto keep the original orientation of threads in the direction of warp and weft threads.

CAUTION:The rib shape and its strength influence the stress and strain to the outer envelope textile. Tornribs, especially while the balloon descending or climbing up, can cause serious stress problemsand even the damage to the envelope fabric.

6.6.2 Repairing burners

31-101 Replacing hoses of H3, HB3, H-3D and H4 burnersUnscrew the old hoses and check the new hoses by means of blowing through to see if they haveno blockage problems with the passage. Connecting couplings shall be sealed, set and the hosesshould be fastened (see procedure 31-15). Connect the burner to the pressure source and use thelather solution to inspect the connection tightness (see Section 7.3). Mend possible connectionleakage.

31-111 Replacing hoses of KOMET burnersUnscrew the old hoses and check the new hoses by means of blowing through to see if they haveno blockage problems with the passage. Connecting couplings shall be sealed, set, and the hosesshould be fastened (see procedure 31-15). Connect the burner to the pressure source and use thelather solution to inspect the connection tightness (see Section 7.3). Mend possible untightconnections.

CAUTION:While changing hoses you should use only the hose type compatible to the certain type of fueland approved by the manufacturer.Always review the age of the hose applied. Used hoses must not be older than 5 years (seeSection 4.5.1).


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SECTION 7

7. Instructions

7.1 General .......................................................................................................................... 27.2 Fabric Strength Test ...................................................................................................... 2

7.2.1 Test conduct ..................................................................................................................... 27.2.2 Test evaluation ................................................................................................................. 2

7.3 Leakage Test with Lather Solution ............................................................................... 27.3.1 Preparation of lather solution .......................................................................................... 27.3.2 Application of lather solution .......................................................................................... 2

7.4 Sealing Threaded Joints with PTFE Tape ..................................................................... 37.4.1 Principles, preparations and procedures of seal threaded joints ...................................... 37.4.2 Sealing procedure ............................................................................................................. 3

7.5 Test Flight ..................................................................................................................... 4Certificate on Serial Flight Test/Renewal of Certificate of Airworthiness ................... 5

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7. Instructions

7.1 General

The instructions regarding special procedures during inspections and repairs are contained inthis section. Concerning the instructions involving measurement records in the written form, theparticular certificates are drawn up and enclosed herein. While any certificate varying, its technicalcontent must be retained.

7.2 Fabric Strength Test

The fabric test should be carried out to find out, whether the tested fabric is convenient (airworthy)for the following airborne service. This may be conducted directly on the envelope by using grabtesters (the proprietary clamps are available from the manufacturer).

7.2.1 Test conduct1. The fabric must be gripped with the jaw edges carefully aligned so that the same fibres are

being pulled from each end. The minimum jaw distance of 80 mm must be kept at thesame time (the min textile width of 120 mm). The clamp edges must be parallel so that thefibres are loaded evenly and tightened properly.

2. The envelope fabric should be grab tested to 13 kg. The level of loading could be observedon a spring tensile dynamometer suspended in the hook of the grab tester.

7.2.2 Test evaluation1. If the fabric withstands the specified pull and is not damaged, it is fully airworthy.2. If the fabric fails between 10 and 13 kg fabric may be passed as airworthy with the following

limitations:- The max admissible loading will be reduced by 20 % concerning all types.- The balloon can only fly under favourable weather conditions.- The strength test to be periodically repeated either every 50 flight hours or 6 calendar

months. The limitation of the service period is applied that starts first.3. If the fabric fails below 10 kg then all the weak fabric must be replaced.

7.3 Leakage Test with Lather Solution

7.3.1 Preparation of lather solutionMix 3 units of unpolluted water with one unit of whichever (ecological) detergent.

7.3.2 Application of lather solutionThe leak detection should be carried out using a wide paintbrush (coating no pouring) or asprayer. The spay or paintbrush should be applied to the joint requiring testing when it is underpressure of min 12 bar. Any leaks will be shown by the presence of bubbles. The min observingperiod of the bubble initiation is 5 minutes.

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7.4 Sealing Threaded Joints with PTFE Tape

7.4.1 Principles, preparations and procedures of seal threaded jointsEnsure the threaded surfaces are clean and degreased. The thread upper parts (female and malethreads) should not be sharp or rough. The prospective sharp edges must be rubbed down byusing sandpaper. After roughening the male thread flank tops in the diagonal direction (by usingsteel blade of a metal saw), the PTFE tape is protected against any push while bolting connectionstogether.

7.4.2 Sealing procedureUse a sealing compound of the PTFE tape typeon threads. The 12 x 0.1 mm tape should bewound onto the male thread in order not to bepushed down and following compactnessfailures of connecting sealing surfaces. Windthe tape in the same direction as the thread lead.The PTFE tape beginning and end must be atthe root of the thread lead. The PTFE tape turnsshould be tried on one unit. Proper and impropertape forming before screwing on and includingthe tape deformation after re-screwing off arein the enclosed picture below.The threads must be turned up to about 1/3length after initial thread engagement by hand.Then bolt together the rest part by using anopen-end wrench set. In case of impossibilityto screw on the joint along its first 1/3 length,there are too many layers of the PTFE tapeprobably.

CAUTION:Sealing threaded joints with PTFE tapes are applicable for the operating pressures up to 12bars (1.2 MPa) and further for the standard gas mixture - propane / butane / nitrogen.

NOTE:The leakage test of sealing threaded connections by using PTFE tapes is conducted in compliancewith Section 7.3 of the manual.

CorrectlywoundPTFE tape

Admissibledeformationof the PTFEtape

Inadmissibledeformationof the PTFEtape

IncorrectlywoundPTFE tape

Sealing procedure of threaded joints

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Change: 0 Issue: 10. 10. 2001

7.5 Test/Trial Flight

The approved organisation considers and required possibly the test/trial flight carrying out. Thisdecision is based on the technical balloon condition in accordance with current requirementsand rules of the operator�s local CAA.The range and authorisation of trial flights performing follow the valid regulations of the operator�snational CAA. The manufacturer carries out ordinarily test flights according to the enclosedbellow Certificate on Serial Flight Test/Renewal of Certificate of Airworthiness.

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B.0202

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8 - 1Issue: 10. 10. 2001 Change: 0


B.0202

SECTION 8

8. Supplements

8.1 Introduction ................................................................................................................... 28.2 List of Supplements ...................................................................................................... 2

8.3 Supplements ..................................................................................................................... 2

8 - 2 Change: 0 Issue: 10. 10. 2001


8. Supplements

8.1 Introduction

This Section containes necessary supplemets with information requisite for continuedairworthiness of the balloon differed in further equipment or other deviations from standardballoon realisation.

8.2 List of Supplements

8.3 Supplements

None

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BALÓNY KUBÍÈEK spol. s r.o.e-mail: [email protected] � www.kubicekballoons.cz

Brno 602 00 � Francouzská 81 � Czech Republictel. +420 5 45211917, 45214755 � fax +420 5 45213074

© Copyright BALONY KUBÍÈEK spol. s r.o.2001

Documents

MAINTENANCE MANUAL for use with the hot air balloon