STORCH HS-CL MAINTENANCE MANUAL (ALID FOR ROTAX 912 UL AND JABIRU 2200 ENGINES) 00 28/05/07 New manual issue Num. Date Description Issued erify Approvation REISION The FlySynthesis s.r.l. it reserves him to terms of law the exclusive ownership of the present and it also forbids the partial reproduction of it.
SCOPE Page: 2/24 erified: This manual contains the necessary information for safe and efficient Maintenance of the FLYSYNTHESIS STORCH HS and CL versions. NOTE This manual may be revised in the future and pages/or sections re-issued in part or whole. Revisions will be available on the Fly Synthesis website www.flysynthesis.com. Any revisions and/or sections should be printed and replaced in the manual at the earliest possible time for flight safety. The revisions added to the manual should be logged and recorded in the table under log of Revisions of this manual, by the owner/user. LOG OF REISION Revision number Revision Date Signature INTELLECTUAL PROPERTY The data and information contained in this document is the property of FLYSYNTHESIS SRL. This document may not be reproduced or transmitted to a third party, in any form or by any means. Any unauthorised copy or distribution is illegal as per international agreements relating to property rights.
Page: 3/24 erified: LOG OF EFFECTIE PAGES Section Page Date Revision Section Page Date Revision
Page: 4/24 erified: INDEX Title LOG OF REISION 2 LOG OF EFFECTIE PAGES 3 1.1 PRE-FLIGHT INSPECTION 5 1.2 DAILY INSPECTION 5 25 HOURS INSPECTION 7 Page 100 HOURS INSPECTION 11 200 HOURS INSPECTION 15 300 HOURS INSPECTION 19 2 MAINTENANCE PER PERIOD OF TIME 24 3 UNSCHEDULED MAINTENANCE 24
Page: 5/24 erified: 1.1 PRE-FLIGHT INSPECTION Refer to related paragraph of Flight Manual - last issue. 1.2 DAILY INSPECTION Accomplish a complete Pre-Flight Inspection and the following additional operations: 1. Ensure that the ignition key is REMOED. 2. Remove the upper and lower engine cowlings. 3. Drain the fuel tanks as written in Flight Manual. 4. Inspect the carburettor rubber socket or rubber -flange for damage and security of attachment. 5. Remove the floating chamber from the carburettor and inspect for cleanliness and absence of water. 6. erify the air filter for security of attachment. 7. Inspect the ignition cable terminals for security of connections to spark plugs.inspect. all other electrical connections for security. 8. erify the electrical starter for security of attachment. 9. erify the battery for security of attachment. 10. Inspect the rubber shock absorbers and of engine mount for condition. 11. erify the fuel pump, the fuel filter and relevant hoses for security of attachment and fuel 12. erify the attaching bolts of drive reduction unit supporting plate for tightening. 13. Turn the propeller by hand and inspect for abnormal noise. 14. erify engine control cables for security. 15. Check tires pressure for proper- inflation: a. Main wheels 2.2-2.4 bar b. Nose wheel 0.8 bar For aircraft equipped with ROTAX 912 UL engine: In addition to inspections/checks listed in the previous item (1) through (15), accomplish the following additional operations: 1. erify the oil and water radiator mounting -For security. Inspect the radiator for damage and leaks. Check the coolant level and security of filling cap. 2. Inspect the coolant hoses for security, leaks and chafing. 3. Inspect the cylinder heads cylinders and water pump for leaks. 4. erify the lubrication oil content and security of filling cap. 5. Inspect the oil hoses relevant to gear lubrication and oil injection systems for security, leaks and chafing. 6. erify drain and oil level plugs. 7. By pushing and pulling the engine shaft along its axis, check the bearings for abnormal play.
Page: 6/24 erified: 25 HOURS INSPECTION Legenda: = only a visual check, C = complete check, necessary tools General Propeller Tail & flight surface Fusolage Cockpit Ensure that ignition key is REMOED Open all inspection opening in the fuselage and wings. Remove Engine cowling. Inspect wings and flight surface condition for defect, to become crooked. And another sign of defect. Inspect in the Tail all flight surface condition for defect, to become crooked. And another sign of defect. Inspect fuselage for condition and other sing of defect. Lubricant all movable part and hinges. Inspect the prop blade for crack, stone blow and other defect, small defect smooth with fine glass paper and apply lack. Check prop. Bolts tight. Torque 18 Nm Check all flight control surface for condition and smooth movement and play. Check all self-locking nut for condition and security. Inspect the push-pull control cables and trim control cable for general condition and in particular for cleaning and attachments security. Check tightening of self-locking nuts attaching the pushpull Control cable to the rudder and stabilator (elevator) Check all nuts attaching the rudder and stabilator to hinge Check anti-tab tab tension/regulator device and operation rod abnormal play. All the self-locking nuts. Check all the airframe condition look for defect, if is not become crooked, and other sign of defect. Loose bolt and rivet. Check antenna attachment, check for crack. and loose bolt, and antenna condition Check self-locking nuts and wing attachment to the airframe. Check self-locking nuts and struts to the airframe, Check the main landing gear struts attachment to lower frame and bolt securing. Check all windows for condition and loss rivet. Check nose landing gear attachment and bolt secreting. Check door condition and lock operation. Remove seats. Check all fuel line and valve for leak and wear and secure. - C
Page: 7/24 erified: Wings Landing Gear Check fuel filter if necessary replace cartridge. Check pipes and band for Security. Check all line attachment to the frame. Check hydraulic brake line and brake actuator. Using a flashlight and mirror carefully inspect the flight linkages located behind the fuselage main frame (just behind seats) and under the cabin floor. Ensuring that all self-locking nuts are securely tightened. Check tightened of Self-locking nuts securing the stabilator pivot plates supporting Check tightened of pedals hinge bolts and retaining screw. Check Engine control cable, and Engine control liver. Check all electric wire. And electric component, for security. And condition. Check the electrolyte level in the battery. Battery stand and cleans. Look for evident of electrolyte leak. Check battery attachment. Battery cable. Inspect pilot harness. And floor cleanliness. Check instrument panel security. All the instruments connection, static and dynamic line. Check radio and navigation instrument, and antenna line. Reassembly seat. Inspect wings and flight surface condition for defect, for deformation, or other sign of defect Check for loose rivets. In upper and lower surface, check wings tip. Check tightening of self-locking nuts securing wings brace struts. Tank venting tube and pitot tube, Check tank outlet for security and leak. Check the tube. Check tightening of self-locking nuts securing the aileron and flap Control linkages. Check tightening of self-locking nuts securing the aileron and flap hinge pins. Check freedom of movement for aileron and flap. Check the shock strut piston for abnormally vowel: both transversal and longitudinal ply. Should be 2-3 mm max. Check for no tensional play between pedals and nose wheel. Check wheel and tire for condition. Check air pressure. Check tightening all self-locking nuts securing. Check main landing gear RH and LH struts connection for security. Check hydraulic line condition, and attachment to struts. Check brake disc connection, and security. Check wheel - C - C - C - C - C - C
Page: 8/24 erified: Engine and tire condition. Check air pressure. Check self-locking nuts for tightening All Engine maintenance is according to ROTAX maintenance manual, used free lead fuel only. All maintenance preformed according to that manual. Any other operation that is not mentioned in that manual well be according to that. Check all the fuel line. To condition, and attachment for security. Check the fuel pump be sure filter is clean. Check Engine control cables for proper tension and interference with other equipments: Clean and lubricate as necessary: on the carburetor: verify the rpm and choke operating levers for freedom of movement. Check the carburetor for cleaning and proper adjustment accordingly with engine operator's manual-last issue. Check air filter. Check for proper torque the self-locking nuts and securing the engine to its housing and to the engine mount respectively. Nuts (3) 8Nm Nuts (8) 22Nm Check for proper torque the self-locking nuts securing the engine mount to fuselage. Torque load required 10Nm Check for proper torque the self-locking nuts securing the shock absorbers to the engine mount. - Check the shock absorbers of the 5 th point, if they have loosened, - Screw the nut (on the side of shock absorber loosened) until the shock absorber and the washer will be in contact and they can t relatively rotate, - Screw the nut for 360 with the key. Check the nuts securing the exhaust pipe to cylinder. Check all exhaust system for gas leaks cracks. And serviceability of retaining spring and rubber buffers. Check security of oil tank attachment to the frame and mount. Exhaust muffler oil radiator and cooling radiator to mounting. Check all oil pipe and cooling pipe and clamps for security and condition. Check all the electrical system and wire in the engine compartment. Check cooling liquid and oil level. Check engine for evident of leaks. Check engine cowling for Proper condition. Check all fuel and oil hose connection for security. - C - C - C - C
Page: 9/24 erified: Finishing Check all cooling hose and expansion tank for security Check all components attacking to fire wall for security. Check operation of cockpit ventilation. Check all instrument attachment to Engine pick-up for proper condition. Check all electric harness for proper condition. Assembly Engine cowling. Closed all inspection opening in the fuselage and wings. Check if all the tools are removed from airplane. Check if all system, operate properly. Run the engine. Signed and fill all the documents. - C
Page: 10/24 erified: 100 HOURS INSPECTION Legenda: = only a visual check, C = complete check, necessary tools General Propeller Tail & flight surfaces Fuselage Ensure that ignition key is REMOED Open all inspection opening in the fuselage and wings. Remove Engine cowling. Inspect wings and flight surface condition for defect, to become crooked. And other sign of defect. The max play in flight moving flight control surface is 0.6 mm Check all rivets for detect loose rivets. Any loose rivet shell be replace with oversize rivet. Any crack must be stop by drilling small hole in the edge. Inspect in the Tail. All flight surface condition for defect, To become crooked. And another sign of defect. Inspect fuselage for condition and other sing of defect. Lubricate all movable part and hinges. Inspect the prop blade for crack, stone blow and other Defect, small defect smooth with fine glass paper and Apply lack. Check prop. Bolts tight. Torque 18 Nm Check all flight control surface for condition and smooth Movement and play. Check all self-locking nut for condition and security. Inspect the push-pull control cables and trim control cable For general condition and in particular for cleaning and Attachments security. Pull Control cable to the rudder and stabilator (elevator) Check all nuts securing the rudder and stabilator to hinge, And to hinges supporting plates. Check anti-tab tab tension/regulator device and operation rod abnormal play. All the self-locking nuts. Check control surface angles (rudder elevator and trim) Check all the airframe condition look for defect, if is not Become crooked, and other sign of defect. Loose bolt and Rivet. Check antenna attachment, check for crack. And loose bolt, and antenna condition. Check self-locking nuts and wing attachment to the airframe. Check self-locking nuts and struts to the airframe Check the main landing gear struts attachment to lower Frame and bolt securing. C
Page: 11/24 erified: Cockpit Wings Check all windows for condition and loss rivet. Check nose landing gear attachment and bolt secreting. Check door condition and lock operation. Remove seats. Check all control cables and check for wear and Broken wires: check terminals for security. Carefully inspect all handles for cleanliness, damage wear (abnormal play) and security of attachment. Check all fuel line and valve for leak and wear and secure. Replace fuel filter, replace cartridge. Check Pipes and band for Security. Check all line attachment to the frame. Check hydraulic brake line and brake actuator. Using a flashlight and mirror carefully inspect the flight Linkages located behind the fuselage main frame (just Behind seats) and under the cabin floor. Ensuring that all Self-locking nuts are securely tightened. Thoroughly clean the control stick and examine the assembly for damage and wear. erify that all components are secured and the articulation movements are smooth. Lightly lubricate all moving parts and rod end bearings without rubber protection Check tightened of Self-locking nuts securing the Stabilator pivot plates supporting Check tightened of pedals hinge bolts and retaining screw. Check Engine control cable, and Engine control liver. Check tightening of pedals hinge bolts and retaining Screws. Check all electric wire. And electric component, for Security. And condition. Check the electrolyte level in the battery. Battery stand And cleans. Look for evident of electrolyte leak. Check Battery attachment. Battery cable. Inspect pilot set belts. Check tightening of self-locking Nuts securing the set belts. And floor cleanliness. Check instrument panel security. All the instruments Connection, static and dynamic line. Check radio and navigation instrument, and antenna line. Replace seat. Inspect wings and flight surface condition for defect, for Deformation, or other sign of defect. Check for loose rivets. In upper and lower surface, check Wings tip. Check tightening of self-locking nuts securing wings Brace - C
Page: 12/24 erified: Landing Gear Engine struts. Tank venting tube and pitot tube, Check tank outlet for security and leak. Check the tube. Check tightening of self-locking nuts securing the aileron And flap Control linkages. Check tightening of self-locking nuts securing the aileron And flap hinge pins. Check aileron and flaps angles. Check freedom of movement for aileron and flap. Check main and nose wheel for freedom of rotation. Ensure that bearings are not noisy and without abnormal play. Check the oil level in the hydraulic shock strut of nose landing gear. Check wheel alignment. Check the hydraulic shock strut function. By pressing the nose down and release. Check the shock strut piston for abnormally vowel: both Transversal and longitudinal ply. Should be 2-3 mm max. Check for no tensional play between pedals and nose wheel. Check wheel and tire for condition. Check air pressure. Check tightening all self-locking nuts securing. Check main landing gear RH and LH struts connection for Security. Check hydraulic line condition, and attachment to Support the fuselage Remove the main landing gear wheel and check the brake Linings for wear ore stiffness. Replace if necessary. Renewed the oil. Reassembly the wheels. Check security of bolts. All Engine maintenance is according to ROTAX Check all the fuel line for wear and stiffness. And check all attachment for Security. Check the fuel pump be sure filter is clean. Check Engine control cables for proper tension and Interference with other equipments: Clean and lubricate As necessary: On the carburetor: verify the RPM and CHOKE operating levers for freedom of movement. Check the carburetor for cleaning and proper adjustment Accordingly with Engine operator's manual-last issue. Replace or clean the air filter. Replace carburetor mounting flanges. Using a 10X magnifying glass inspect all welding of Engine mount for cracks. Check for proper torque the self-locking nuts and Securing the engine to its housing and to the engine - C - C - C - C - C
Page: 13/24 erified: Finishing Mount respectively. Nuts (3) 8Nm Nuts (8) 22Nm - C Check for proper torque the self-locking nuts securing the Engine mount to fuselage. Torque load required 10Nm - C Check for proper torque the self-locking nuts securing the Shock absorbers to the engine mount. - C - Check the shock absorbers of the 5 th point, if they have loosened, - Screw the nut (on the side of shock absorber loosened) until the shock absorber and the washer will be in contact - C and they can t relatively rotate, - Screw the nut for 360 with the key. Check the nuts securing the exhaust pipe to cylinder. Check all exhaust system for gas leaks cracks. And Serviceability of retaining spring and rubber buffers. Replace exhaust system-retaining springs (28) Replace the 3 ea. Muffler buffers. Check security of oil tank attachment to the frame and Mount. Exhaust muffler oil radiator and cooling radiator to mounting Check all oil pipes and cooling pipe for wear and stiffness Check clamps for security and condition. Change coding fluid Check all the electrical system and wire in the engine compartment. Check cooling liquid and oil level. Check engine for evident of leaks. Check engine cowling for proper condition. Check all fuel and oil hose connection for security. Check all cooling hose and expansion tank for security Check all components attacking to fire wall for security. Engine Check operation of cockpit ventilation. Check all instrument attachment to Engine pick-up for proper condition. Check all electric harness for proper condition. Assembly Engine cowling. Closed all inspection opening in the fuselage and wings. Check if all the tools are removed from airplane. Check if all system, operate properly. Run the engine.
Page: 14/24 erified: 200 HOURS INSPECTION Legenda: = only a visual check, C = complete check, necessary tools General Propeller Ensure that ignition key is REMOED Open all inspection opening in the fuselage and wings. Remove Engine cowling. Check all push-pull control cables and replace if necessary. Check all flexible control cables and replace if necessary. Inspect wings and flight surface condition for defect, To become crooked. and other sign of defect The max play in flight moving flight control surface is0.6 mm Check all rivets for detect loose rivets. Any loose rivet shell be replace with oversize rivet Any crack must be stop by drilling small hole in the edge. Inspect in the Tail. All flight surface condition for defect, To become crooked and other sign of defect Inspect fuselage for condition and other sing of defect. Lubricate all movable part and hinges. Inspect the prop blade for crack, stone blow and other Defect, small defect smooth with fine glass paper and Apply lack Check prop. Bolts tight. Torque 18 Nm Tail and flight surfaces Check all flight control surface for condition and smooth Movement and play. Check all self-locking nut for condition and security. Inspect the push-pull control cables and trim control cable For general condition and in particular for cleaning and Attachments security Check tightening of self-locking nuts attaching the push- Pull Control cable to the rudder and stabilator (elevator) Check all nuts securing the rudder and stabilator to hinge, And to hinges supporting plates. Check anti-tab tab tension/regulator device and operation Rod abnormal play. All the self-locking nuts. Check control surface angles (rudder elevator and trim). Fuselage Check all the airframe condition look for defect, if is not Become crooked, and other sign of defect. Loose bolt and Rivet. Check antenna attachment, check for crack. And loose Bolt, and antenna condition. - C
Page: 15/24 erified: Cockpit Wings Check self-locking nuts and wing attachment to the Airframe. Check self-locking nuts and struts to the Airframe, Check the main landing gear struts attachment to lower Frame and bolt securing. Check all windows for condition and loss rivet. Check nose landing gear attachment and bolt secreting. Check door condition and lock operation. Remove seats. Check all control cables and check for wear and Broken wires: check terminals for security. Carefully inspect all handles for cleanliness, damage wear (abnormal play) and security of attachment. Check all fuel line and valve for leak and wear and secure. Replace fuel filter, replace cartridge. Check Pipes and band for Security. Check all line attachment to the frame. Check hydraulic brake line and brake actuator. Using a flashlight and mirror carefully inspect the flight Linkages located behind the fuselage main frame (just Behind seats) and under the cabin floor. Ensuring that all Self-locking nuts are securely tightened. Thoroughly clean the control stick and examine the assembly for damage and wear. erify that all components are secured and the articulation movements are smooth. Lightly lubricate all moving parts and rod end bearings without rubber protection Check tightened of Self-locking nuts securing the Stabilator pivot plates supporting Check tightened of pedals hinge bolts and retaining screw. Check Engine control cable, and Engine control liver. Check tightening of pedals hinge bolts and retaining Screws. Check all electric wire. And electric component, for Security. And condition. Check the electrolyte level in the battery. Battery stands And cleans. Look for evident of electrolyte leak. Check Battery attachment. Battery cable. Inspect pilot set belts. Check tightening of self-locking Nuts securing the set belts. And floor cleanliness. Check instrument panel security. All the instruments Connection, static and dynamic line. Check radio and navigation instrument, and antenna line. Replace seat. - C
Page: 16/24 erified: Landing gear Engine Inspect wings and flight surface condition for defect, for Deformation. Or other sign of defect Check for loose rivets. In upper and lower surface, check Wings tip. Check tightening of self-locking nuts securing wings Brace struts. Tank venting tube and pitot tube, Check tank outlet for security and leak. Check the tube. Check tightening of self-locking nuts securing the aileron And flap Control linkages. Check tightening of self-locking nuts securing the aileron And flap hinge pins. Check aileron and flaps angles. Check freedom of movement for aileron and flap. Inspect wings and flight surface condition for defect, for Deformation. Or other sign of defect Ensure that bearings are not noisy and without abnormal Play. Check the oil level in the hydraulic shock strut of nose Landing gear. Remove the upper screw located in the strut. The oil must fill the treaded hole of upper screw Reinstall upper screw. Check wheel alignment. Check the hydraulic shock strut function. By pressing The nose down and release. Check the shock strut piston for abnormally vowel: both Transversal and longitudinal ply. Should be 2-3 mm Max. Check for no tensional play between pedals and Nose wheel. Reinstall the main landing gear struts and check the self- Locking nuts for tightening. Check wheel and tire for condition. Check air pressure. Check tightening all self-locking nuts securing. Check main landing gear RH and LH struts connection for Security. Check hydraulic line condition, and attachment to Struts. All Engine maintenance is according to ROTAX Maintenance manual 899 372, Section. 50-20-00 Used free lead fuel only. All maintenance preformed According to that manual. Any other operation that is not mentioned in that manual Will be according to that. Check the fuel pump be sure filter is clean. Check Engine control cables for proper tension and Interference with other equipments: Clean and lubricate As necessary: On the carburettor: verify the RPM and - C
Page: 17/24 erified: Finishing CHOKE operating levers for freedom of movement. Check the carburettor for cleaning and proper adjustment Accordingly with Engine operator's manual-last issue. Replace or clean the air filter. Replace carburettor mounting flanges. Using a 10X magnifying glass inspect all welding of Engine mount for cracks. Check for proper torque the self-locking nuts and Securing the engine to it's housing and to the engine Mount respectively. Nut (3) 8Nm Nut (8) 22Nm Check for proper torque the self-locking nuts securing the Engine mount to fuselage. Torque load required 10Nm Check for proper torque the self-locking nuts securing the Shock absorbers to the engine mount. Check the nuts securing the exhaust pipe to cylinder. Check all exhaust system for gas leaks cracks. And Serviceability of retaining spring and rubber buffers. Replace exhaust system-retaining springs (28) Replace the 3 ea. Muffler buffers. Check security of oil tank attachment to the frame and Mount. Exhaust muffler oil radiator and cooling radiator To mounting. Replace all oil pipes and cooling pipes, check clamps for Security and condition. Change cologne fluid Check all the electrical system and wire in the engine Compartment. Check cooling liquid and change oil Check engine for evident of leaks. Check engine cowling for Proper condition. Check all fuel and oil hose connection for security. Check all cooling hose and expansion tank for security Check all components attacking to fire wall for security. Check operation of cockpit ventilation. Check all instrument attachment to Engine pick-up for Proper condition. Check all electric harness for proper condition. Assembly engine cowling Closed all inspection opening in the fuselage and wings. Check if all the tools are removed from airplane. Check if all system, operate properly. Run the engine. - C C C C C C - C
Page: 18/24 erified: 300 HOURS INSPECTION Legenda: = only a visual check, C = complete check, necessary tools General Propeller Ensure that ignition key is REMOED Open all inspection opening in the fuselage and wings. Remove Engine cowling. Check all push-pull control cables and replace if necessary. Check all flexible control cables and replace if necessary. Inspect wings and flight surface condition for defect, To become crooked. And other sign of defect. The max play in flight moving flight control surface is0.6 mm Check all rivets for detect loose rivets. Any loose rivet shell be replace with oversize rivet Any crack must be stop by drilling small hole in the edge. Inspect in the Tail. All flight surface condition for defect, For deformation. And another sign of defect. Inspect fuselage for condition and other sing of defect. Lubricate all movable part and hinges. Inspect the prop blade for crack, stone blow and other Defect, small defect smooth with fine glass paper and Apply lack, Check prop. Bolts tight. Torque 18 Nm Tail and flight surfaces Check all flight control surface for condition and smooth Movement and play. Check all self-locking nut for condition and security. Inspect the push-pull control cables and trim control cable For general condition and in particular for cleaning and Attachments security. Check tightening of self-locking nuts attaching the push- Pull Control cable to the rudder and stabilator (elevator) Check all nuts securing the rudder and stabilator to hinge, And to hinges supporting plates. Check all the nuts supporting/connecting of hydraulic- Damper Condition and security. Check anti-tab tab tension/regulator device and operation Rod abnormal play. All the self-locking nuts. Check control surface angles (rudder elevator and trim). Check all flight control surface for condition and smooth Movement and play. Fuselage Check all the airframe condition look for defect, if is not - C
Page: 19/24 erified: Cockpit Become crooked, and other sign of defect. Loose bolt and Rivet. Check antenna attachment, check for crack. And loose Bolt, and antenna condition. Check self-locking nuts and wing attachment to the Airframe. Check self-locking nuts and struts to the Airframe, Check the main landing gear struts attachment to lower Frame and bolt securing. Check all windows for condition and loss rivet. Check nose landing gear attachment and bolt secreting. Check door condition and lock operation. Remove seats. Check all control cables and check for wear and Broken wires: check terminals for security. Carefully inspect all handles for cleanliness, damage wear (abnormal play) and security of attachment. Check all fuel line and valve for leak and wear and secure. Replace fuel filter, replace cartridge. Check Pipes and band for Security. Check all line attachment to the frame. Check hydraulic brake line and brake actuator. Using a flashlight and mirror carefully inspect the flight Linkages located behind the fuselage main frame (just Behind seats) and under the cabin floor. Ensuring that all Self-locking nuts are securely tightened. Thoroughly clean the control stick and examine the assembly for damage and wear. erify that all components are secured and the articulation movements are smooth. Lightly lubricate all moving parts and rod end bearings without rubber protection Check tightened of Self-locking nuts securing the Stabilator pivot plates supporting Check tightened of pedals hinge bolts and retaining screw. Check Engine control cable, and Engine control liver. Check tightening of pedals hinge bolts and retaining Screws. Check all electric wire. And electric component, for Security. And condition. Check the electrolyte level in the battery. Battery stand And cleans. Look for evident of electrolyte leak. Check Battery attachment. Battery cable. Inspect pilot set belts. Check tightening of self-locking Nuts securing the set belts. And floor cleanliness. Check instrument panel security. All the instruments C
Page: 20/24 erified: Wings Landing Gear Connection, static and dynamic line. Check radio and navigation instrument, and antenna line. Replace seat. Inspect wings and flight surface condition for defect, for Deformation. or other sign of defect Check for loose rivets. In upper and lower surface, check Wings tip. Check tightening of self-locking nuts securing wings Brace struts. Tank venting tube and pitot tube, Check tank outlet for security and leak. Check the tube. Check tightening of self-locking nuts securing the aileron And flap Control linkages. Check tightening of self-locking nuts securing the aileron And flap hinge pins. Check aileron and flaps angles. Check freedom of movement for aileron and flap. Check main and nose wheel for freedom of rotation. Ensure that bearings are not noisy and without abnormal Play. Replace the oil level in the hydraulic shock strut of nose Landing gear. Remove the main landing legs Remove the upper screw located in the strut. The oil must fill the treaded hole of upper screw. Reinstall upper screw. Check wheel alignment. Check the hydraulic shock strut function. By pressing The nose down and release. Check the shock strut piston for abnormally vowel: both Transversal and longitudinal ply. Should be 2-3 mm Max. Check for no tensional play between pedals and Nose wheel. Support the aircraft and remove the main landing gear RH and LH struts clean the strut housings located in the Tubular framework and in the axle assemblies. Lubricate Strut housings as necessary in accordance with paragraph2 LUBRICATION Replace legs of main landing gear. Reinstall the main landing gear struts and check the self- Locking nuts for tightening. Check wheel and tire for condition. Check air pressure. Check tightening all self-locking nuts securing Check main landing gear RH and LH struts connection for Security. Check hydraulic line condition, and attachment to C C C C C C C C C
Page: 21/24 erified: Engine Struts. Support the fuselage Remove the main landing gear wheel and check the brake Linings for wear ore stiffness. Replace if necessary Renewed The oil. Reassembly the Wheels. Check security of bolts. All Engine maintenance is according to ROTAX Maintenance manual 899 372, Section. 50-20-00 Used free lead fuel only. All maintenance preformed According to that manual. Any other operation that is not mentioned in that manual Will be according to that. Check all the fuel line for wear and stiffness. And check all attachment for Security. Check the fuel pump be sure filter is clean. Check Engine control cables for proper tension and Interference with other equipments: Clean and lubricate As necessary: On the carburettor: verify the RPM and CHOKE operating levers for freedom of movement Check the carburettor for cleaning and proper adjustment Accordingly with Engine operator's manual-last issue. Replace or clean the air filter. Replace carburettor-mounting flanges. Using a 10X magnifying glass inspect all welding of Engine mount for cracks. Check for proper torque the self-locking nuts and Securing the engine to it's housing and to the engine Mount respectively. Nuts (3) 8Nm Nuts (8) 22Nm Check for proper torque the self-locking nuts securing the Engine mount to fuselage. Torque load required 10Nm Check the front and rear engine mount shock absorber And replace if necessary. Check for proper torque the selflocking nuts securing the Shock absorbers to the engine mount. Check the nuts securing the exhaust pipe to cylinder. Check all exhaust system for gas leaks cracks. And Serviceability of retaining spring and rubber buffers. Replace exhaust system-retaining springs (28) Replace the 3 ea. Muffler buffers. Check security of oil tank attachment to the frame and Mount. Exhaust muffler oil radiator and cooling radiator To mounting. Check all oil pipes and cooling pipe for wear and stiffness Check clamps for security and condition. Change cooling Fluid Check all the electrical system and wire in the engine C C C C C C C C C
Page: 22/24 erified: Finishing Compartment. Check cooling liquid and replace oil. Check engine for evident of leaks. Check engine cowling for Proper condition. Check all fuel and oil hose connection for security. Check all cooling hose and expansion tank for security Check all components attacking to fire wall for security. Check operation of cockpit ventilation. Check all instrument attachment to Engine pick-up for Proper condition. Check all electric harness for proper condition. Assembly Engine cowling. Closed all inspection opening in the fuselage and wings. Check if all the tools are removed from airplane. Check if all system, operate properly. Run the engine. C
Page: 23/24 erified: 2 MAINTENANCE PER PERIOD OF TIME 2.1 SCHEDULED MAINTENANCE If the airplane does not reach 100 flight hours within consecutive 12 months, a 100 hours inspection must be carried out before renewal of its permit to fly. If the airplane did not reach 200 flight hours within 24 months, a 200 hours inspection must be carried out 2.2 TIME LIMITED COMPONENETS The following components must be removed for inspection and complete overhaul after the time specified have expired: - ROTAX 912 UL: 1500 hours or 10 years, whichever comes first, refer always to Rotax manual. - ROTAX 582 UL DCDI: refer always to Rotax manual. - JABIRU 2200: 1000 hours, refer always to Jabiru manual. - Propeller see propeller manual - Shock absorbers replace at 300 hours or every 2 years (whichever comes first) - Main landing legs replace at 300 hours (Only alluminium alloy legs) 3 UNSCHEDULE MAINTENANCE 3.1 HEAY LANDING Heavy landing event should be recorded in the airplane logbook by the pilot or technician, observing landing gear damage. Following inspection must be carried out: 1. Remove fairing from wheels and struts. Remove cowling. 2. Check nose-landing gear structure for cracks and alignment, attachment and bolt tightness. 3. Check the nose gear hydraulic shock strut function, by pressing the nose down and release, replace failed components. 4. Support the airplane, remove main landing gear wheels, check axle welding, check struts for linearity scratches and cracks. Replace struts if bent or damaged. 5. Install wheels, Check main wheel alignment. 6. Install wheels and struts fairing, install cowling. 7. Check engine mount for distortion. 3.2 DAMAGE TO THE COMPOSITE STRUCTURE Contact Fly Synthesis s.r.l. for this type of problem. 3.3 EXCEEDING ENGINE LIMITS Any time an engine limit is exceeded, RPM, time limit, pressure or temperature, record the event in the airplane logbook and consult the ROTAX. 3.4 EXCEEDING AIRPLANE LIMITS Any time NE or G limits are exceeding, must be make 200 flight hours inspection.
Page: 24/24 erified: 3.5 PAINTING THE AIRPLANE The airplane when delivered is painted white all over. It is prohibited to paint the upper surfaces of the wings and fuselage with any dark paint, as this will increase the heat absorption from the sun, which may lead to damage to the composite material structure. After any painting operation is obligatory verify the weight and balance of the aircraft.