Aircraft Maintenance Manual

3.10 Instrument and Avionics 3.10.1 Airspeed indicator markings 3.10.2 Engine instruments 3.10.3 Pitot – static system 3.10.4 Airspeed indicator 3.10.5 Altimeter 3.10.6 Vertical speed indicator 3.10.7 Magnetic compass ……………………………………………..3-93 …………………………………………..…3-94 ………………………………………..……3-98 …………………………………………..…3-98 …………………………………………..…3-98 ……………………………………………3-104 ……………………………………………3-104 ……………………………………………3-109 ………………………………………....…3-109 ………………………………………....…3-109 ……………………………………..…......3-114 ………………………………………...….3-115 ……………………………………………3-116 …………………………………………....3-117 ……………………………………………3-120 …………………………...…………..…...3-120 ………………………………………..…..3-122 …………………………………...…..…...3-123 ………………………………..………..…3-123 ……………………………………………3-123 ……………………………………..…..…3-126 ……………………………………………3-126 ………………………………..………..…3-128 ……………………………………………3-131 ……………………………………………3-131 ……………………………………………3-132 ……………………………………………3-133 …………………………………..……..…3-136 ……………………………………………3-136 ……………………………………………3-137 …………………………………………....3-137 3.10.8 Avionics equipment 3.11. Electrical System 3.11.1 Exterior lighting 3.11.2 Generator 3.11.3 Circuit breakers and fuses 3.11.4 Battery 3.11.5 Inspection and operation checks ………………………………...……….....3-138 ………………………………..………......3-138 ………………………………………....…3-141 ……………………………………………3-144 …………………...……………………….3-144 ……………………………………………3-145 …………………………...…………..…...3-150 0 - 6 3.12 Structural Repair 3.12.1 Repair of Laminate parts 3.13 Painting and Coating 3.13.1 Paint repairs 3.13.2 Paint repairs – Method of Verification 3.14 Securing bolted connections 3.14.1 General 3.14.2 Cotter Pins 3.14.3 Safety Wire 3.14.4 Inspection of Rod ends 3.14.5 Inspection of push pull tube connections 3.15 Cable inspections Swaged Nicopress clamp installation 3.15.1 Cable system Inspections …………………………………………....3-151 ……………………………………..……..3-151 ……………………………………...….…3-154 ……………………………………………3-154 ……………………………………………3-159 ……………………………………………3-159 ……………………………………………3-159 ……………………………………………3-159 ……………………………………………3-160 ……………………………………………3-163 ………………………………………....…3-163 ………………………………………....…3-164 ……………………………………………3-164 0 - 7 0.2 Notes, Cautions, and Warnings Throughout this manual, small boxes are inserted reading Note, Caution, or Warning. These are items which require particularly close attention for special conditions or procedures. This text box emphasizes specific operating conditions, steps in a procedure, helpful hints or useful advice. This text box represents danger to equipment or operation. By not observing the cautions, the result could be the destruction of equipment and possibly personal danger and injury. This text box represents a hazardous situation. Warnings are used to call attention to operating procedures or conditions which, if not strictly observed, may result in personal injury or death. Every owner, pilot, operator, or maintainer of the Sirius should become familiar with the entire text of this Aircraft Maintenance Manual (AMM) It also incorporates only some references from Rotax®, the engine manufacturer, Woodcomp®, the propeller supplier, and Galaxy®, the installed aircraft parachute system. Please refer to the latest edition of those manufacturer manuals for specific and complete detailed maintenance procedures of each aircraft system. 0 - 8 NOTE CAUTION WARNING WARNING RNING The Sirius is intended for sport and recreational purposes only. This aircraft meets the standard specification Design and Performance (D&P) established by the American Society for Testing and Materials (ASTM) Document F 2245-04, and it is therefore restricted by that guideline. The aircraft does not comply with any FAA Part 22, or 23 certification processes. Compliance with regulations placed upon the airplane category should be strictly adhered to by the owner and any operator This AMM is valid only if the user complies with any changes that may be issued at a later date. Any pages affected by a change should be removed and replaced with the effective pages immediately. If this manual is found not to be current, revisions missing or pages removed contact our USA Customer Service location for replacements. TL Ultralight, sro Customer Service 10401 West Markham Street Little Rock, AR 72205 Phone: 501.228.7777 Fax: 501.227.8888 0 - 9 CAUTION NOTE 0.3 List of Revisions The Revisions pages are updated by TL – ultralight each time revision issued. They contain a list of all revisions made to the Maintenance Manual since its original issue. Nr. Date Revised Pages Type of Revision Posted By 0 30 August 2010 None Original Issue 0 – 10 (THIS PAGE BLANK) 0 - 11 SECTION 1 GENERAL INFORMATION 1.1 Introduction Section 1 contains general information regarding manual organization, descriptive data, abbreviations, the Master Equipment List, ‗feed-back‘ forms for the aircraft and this manual as well as current warranty information. This manual is written to conform to the ASTM F2483-05, Maintenance and the Development of Maintenance Manuals for Light Sport Aircraft. Maintenance and operation of major components, engine, emergency parachute system, propeller, avionics or other installed equipment is provided in the appropriate manufacturer manuals which are included with the aircraft. Any conflicts in this manual should be superseded by the appropriate manufacturer‘s manual. 1.1.1 Scope This document defines the content and structure of the maintenance manual for the TL Ultralight, sro Sirius aircraft and it‘s components while operated as light sport aircraft. It also establishes guidelines for the qualifications to accomplish the various levels of maintenance on U.S. certificated Sirius Special (SLSA) Light Sport Aircraft. 1.1.2 Safety TL Ultralight, sro can not address all of the safety concerns associated with the use of this document. It is the responsibility of the user of this document to establish appropriate safety and health practices and to determine the applicability of any regulatory limitations prior to use. 1 – 1 1.1.3 Referenced Documents ASTM Standards: F 2245 Specification for Design and Performance of a Light Sport Airplane F 2295 Practice for Continued Operational Safety Monitoring of a Light Sport Airplane Federal Standards: 14 CFR Part 21.190 Issue of a Special Airworthiness Certificate for a Light-Sport Category Aircraft 14 CFR Part 43 Maintenance, Preventive Maintenance, Rebuilding, and Alteration 14 CFR Part 65 Certification: Airmen Other Than Flight Crewmembers 1.1.4 Definitions 14 CFR—Code of Federal Regulations Title 14 Aeronautics and Space also know as the ―FARs‖ or Federal Aviation Regulations. 100-hour inspection—same as an annual condition inspection, except the interval of inspection is 100 hours of operation instead of 12 calendar months. This inspection is utilized when an LSA aircraft is being used for commercial operations such as flight instruction or rental, or both. Alteration—any change to the airframe or aircraft component part after the initial design and production acceptance testing by TL Ultralight, sro to the applicable ASTM standards that is not described in the TL Ultralight, sro maintenance manual. Annual condition inspection—detailed inspection accomplished once a year on an LSA aircraft in accordance with instructions provided in the maintenance manual. The purpose of the inspection is to look for any wear, corrosion, damage or conditions of use that would cause an aircraft to not be in a condition for safe operation. A&P—airframe and power plant mechanic as defined by 14 CFR Part 65. FAA—United States Federal Aviation Administration. Heavy maintenance—any maintenance, inspection, or repair, that TL Ultralight, sro has designated that requires specialized training, equipment, or facilities. Line maintenance—any repair, maintenance, scheduled checks, servicing, inspections not considered heavy maintenance that is approved by TL Ultralight, sro and is specified in TL Ultralight, sro‘s maintenance manual. 1 - 2 LSA (light sport aircraft)—aircraft designed in accordance with ASTM standards under the jurisdiction of Committee F37 Light Sport Aircraft. LSA repairman inspection—U.S. FAA-certificated repairman (light sport aircraft) with an inspection rating as defined by 14 CFR Part 65, authorized to perform the annual condition inspection on experimental light sport aircraft, or an equivalent rating issued by other civil aviation authorities. Experimental LSA aircraft do not require the individual performing maintenance to hold any FAA airman certificate in the U.S. LSA repairman maintenance—U.S. FAA-certificated repairman (light sport aircraft) with a maintenance rating as defined by 14 CFR Part 65, authorized to perform line maintenance on aircraft certificated as special LSA aircraft. Authorized to perform the annual condition/100-h inspection on an LSA, or an equivalent rating issued by other civil aviation authorities. Maintenance manual—manual provided by an TL Ultralight, sro that specifies all maintenance or repairs authorized by TL Ultralight, sro. Major repair or maintenance—any repair or maintenance for which instructions to complete the task are excluded from the maintenance manual supplied to the consumer are considered major. Manufacturer—any entity engaged in the production of an LSA or component used on an LSA. Minor repair or maintenance—any repair or maintenance for which instructions are provided in the TL Ultralight, sro maintenance manual are considered minor. Modification—any change to the airframe or aircraft component part after the initial design and production acceptance testing by TL Ultralight, sro to the applicable ASTM standards that is not described in the TL Ultralight, sro maintenance manual. Overhaul—maintenance, inspection, or repair that is only to be accomplished by the TL Ultralight, sro or a facility approved by the original manufacturer of the product. Overhaul facility—facility specifically authorized by the FAA or TL Ultralight, sro or component manufacturer to overhaul the product originally produced by that manufacturer. Repair facility—facility specifically authorized by the FAA or TL Ultralight, sro or component manufacturer to repair the product originally produced by that manufacturer. 1 - 3 1.1.5 Maintenance and Repair Inspection or Repair, —Each of the inspections or repairs outlined in the maintenance manual specifically list: (1) Recommended special tools to accomplish the task, if any (2) The parts needed to perform the task, if any (3) Type of maintenance, line (L), heavy (H), or overhaul (OV) (4) The level of certification needed to accomplish the task, owner (O), (light sport aircraft) inspection (RI), (light sport aircraft) repairman (RM), FAA approved A&P (A&P), FAA or TL Ultralight repair station, (5) Detailed instructions and diagrams if needed to perform the task, and (6) Confirmation by signature to verify the task was accomplished properly. Repairs and Alterations—TL Ultralight, sro may refer to other repair and alteration manuals such as the FAA‘s AC for the detailed instructions to accomplish tasks outlined in the maintenance manual. Level of Certification—When listing the level of certification needed to perform a task, TL Ultralight, sro shall use one of the following descriptors. Owner (O)—Items that can be expected to be completed by a responsible owner who holds a pilot certificate but who has not received any specific authorized training. FAA regulations authorize SLSA aircraft owners who hold at least a sport pilot certificate to perform maintenance as outlined in 14 CFR Part 43. LSA Repairman Inspection (RI)—Items that can be expected to be completed on an ELSA by a responsible owner, which holds an FAA repairman certificate (light sport aircraft), with an inspection rating or equivalent. LSA Repairman Maintenance (RM)—Items that can be expected to be completed on a SLSA by a responsible individual, which holds a FAA repairman certificate (light sport aircraft), with a maintenance rating or equivalent. A&P (A&P)—Items that can be expected to be completed by a responsible individual who holds an FAA mechanic certificate with airframe or power plant ratings, or both, or equivalent. Task Specified—Items that can be expected to be completed by a responsible individual who holds either a mechanic certificate or a repairman certificate and has received task specific training to perform the task. Therefore the symbol (O) indicates a maintenance function that can be performed by an owner or higher skilled level. The symbol (A&P) indicates maintenance to be performed by an A&P or a repair station. Indicated at each task by the designation(s) that remain in the following; (L,H,OV/O-RI-RM-A&P) 1 - 4 Task Not Specified—The aircraft is to be maintained, serviced and repaired in accordance with this manual and the equivalent maintenance manual provided by the manufacturer of all other components not manufactured by TL Ultralight, sro. In the absence of specific instructions for a repair in one of the above mentioned maintenance manuals, and where such repairs are not restricted by these manuals or listed as Overhaul, Alteration, Modification or Major Repair, such repairs may be completed by an FAA qualified A&P mechanic. Such repairs must be coordinated with the TL Ultralight U. S, Field Technical Director, in accordance with standard maintenance practice described by FAA Advisory Circular 43.13 and use all available resources including exploded parts views for guidance. 1.1.6 Line Maintenance and Repairs Authorization to Perform—The holder of an LSA repairman certificate with either an inspection or maintenance rating is generally considered the minimum level of certification to perform line maintenance of TL Ultralight LSA aircraft. The examples listed below are not considered as restrictions against the performance of such tasks by an owner who is authorized to perform said task by the FAA. Typical Tasks Considered as Line Maintenance Include: 1. 100-hour inspection, 2. Annual condition inspection, 3. Servicing of fluids, 4. Removal and replacement of components for which instructions are provided in the maintenance manual. 5. Repair of components and structure for which instructions are provided in the maintenance manual and which do not require additional specialized training. 6. Compliance with a TL Ultralight, sro service directive when the repairman is listed as an authorized person to accomplish the work described. 1.1.7 Heavy Maintenance and Repairs Authorization to Perform—The holder of an FAA mechanic certificate with airframe or power plant rating(s), or both, or an LSA Repairman maintenance that has received additional task specific training for the function to be performed is generally considered the minimum level of certification to perform heavy maintenance of TL Ultralight, sro LSA aircraft. 1 - 5 Typical Tasks Considered as Heavy Maintenance include: Removal and replacement of components for which instructions are provided in the maintenance manual or service directive instructions, such as: 1. Complete engine removal and reinstallation in support of an engine overhaul or to install a new engine, 2. Remove and replacement of engine cylinders, pistons, or valve assemblies, or a combination thereof, 3. Primary flight control cables/components, 4. Landing gear assemblies. 5. Repair of components for which instructions are provided in the maintenance manual or service directive instructions, 6. Structural repairs of components or aircraft structure, or both, for which instructions are provided in the maintenance manual or service directive instructions. 1.1.8 Overhaul Authorization to Perform—Only TL Ultralight, sro or the component to be overhauled on an LSA may perform or authorize to be performed the overhaul of an LSA component. In the U.S., no FAA certification is required to be an LSA approved overhaul facility. Overhaul Manual—A separate overhaul manual in addition to the TL Ultralight, sro maintenance manual is required to perform the overhaul of an LSA aircraft or LSA aircraft component. Typical components that are overhauled include: 1. Engines, 2. Carburetors/fuel systems, 3. Starters/alternators/generators, 4. Instruments, 5. Propellers 6. Ballistic parachute systems. 1.1.9 Alteration, Modification or Major Repair Any alteration, modification or major repair made to TL Ultralight, sro aircraft after the initial design and production acceptance testing to applicable ASTM standards, initial airworthiness inspection and sale to a consumer must be evaluated by TL Ultralight relative to the requirements of the applicable ASTM design and production acceptance specification(s) as well as the aerodynamic, structural, electrical, or flight safety conditions. 1 - 6 No changes may be made to any TL Ultralight, sro aircraft without prior written approval of TL Ultralight, sro. Any changes made without TL Ultralight, sro written approval will void the aircraft airworthiness certificate. TL Ultralight, sro may authorize another TL Ultralight, sro approved entity to perform the evaluation of an alteration, modification or major repair who shall provide a written affidavit that the aircraft being altered will still meet the requirements of the applicable ASTM design and performance specification after the alteration. TL Ultralight, sro or another TL Ultralight approved entity that performs the evaluation shall provide written instructions and diagrams on how, who, and the level of certification needed to perform the alteration, modification or major repair. The instructions must be approved by TL Ultralight, sro and must include ground and flight testing that complies with the original ASTM production acceptance testing standard, as appropriate, to verify the alteration, modification or major repair was performed correctly and the aircraft is in a condition for safe operation. TL Ultralight, sro or another TL Ultralight approved entity that performs the evaluation shall provide information to the owner of the aircraft for the documentation of the alteration, modification or major repair in the aircraft‘s records. 1.1.10 Task-Specific Training TL Ultralight, sro may require type-specific training in order to accomplish a task in either the maintenance manual or in an authorization for a major repair, maintenance, or alteration. The FAA does not give approval to these task-specific training programs for SLSA. TL Ultralight, sro may specify any task-specific training it determines is appropriate to accomplish a task. Examples of task-specific training include: 1. Engine manufacturer heavy maintenance or overhaul school, or both, 2. Instrument installation or repair course 3. Parachute manufacturer repair course 4. Aircraft manufacturer course. 1.1.11 Safety Directives An SLSA aircraft may have a Safety Directive issued against an aircraft or component part by the manufacturer. TL Ultralight, sro will issue any directive as outlined in the applicable ASTM continued airworthiness specification. 1 - 7 SLSA and components installed on SLSA‘s do not have Airworthiness Directives issued against them. If an AD is issued against a type-certificated product that may be incorporated into special light sport aircraft, TL Ultralight, sro will issue a safety directive in accordance with Document F 2295 41 to provide instruction on how to address the safety defect outlined in the AD on the specific SLSA. TL Ultralight, sro will provide applicable instructions to comply with any safety directive, which will include: 1. A list of the tools needed to accomplish the task, 2. A list of the parts needed to perform the task, 3. Type of maintenance, line, heavy, overhaul, 4. Certification level needed to accomplish the task, RI, RM, A&P. 5. Detailed instructions and diagrams as needed to perform the task, 6. Method to test/inspect to verify the task was accomplished properly. 7. Service directives are considered mandatory tasks in order to maintain a condition of safe operation and compliance with the applicable original ASTM design specification. Service directives are not considered mandatory for experimental LSA‘s in the United States. 1 - 8 1.1.12 Views, dimensions 1 – 9 Basic dimensions: Maximum length Cabin width Wing Span Height Areas: Wing Flaps Rudder Stabilizer Aspect ratio: Wing ………… 22.87 ft. ...………. 3.94 ft. ………… 30.84 ft. ………… 7.38 ft. ..……… 120.06 ft2 ……….. 14.21 ft2 ……….. 4.46 ft2 ……….. 21.64 ft2 …………… 7,92 1 - 10 1.1.13 Aircraft Specifications The Sirius is a full three axis, high wing; two place side-by-side seating, tricycle landing gear aircraft with a non-steerable nose wheel. The primary aircraft structure is carbon fiber and fiberglass UV resistant reinforced laminate with an inner foam core creating a ‗sandwich‘ layered construction between each ply. Various options are available such as the Rotax 912ULS, tinted canopies and other avionics or interior selections. Therefore your aircraft may vary from the descriptions in this manual. Please check with your local dealer if you have any specific questions not addressed here. 1.1.14 Engine Specifications 4-cylinder, 4-stroke liquid/air cooled engine with opposed cylinders, dry sump forced lubrication with seperate oil tank, automatic adjustment by hydraulic valve tappet, 2 carburators, mechanical fuel pump, electronic dual ignition, electric starter, propeller speed reduction unit. For actual and complete information resd the Maintenance Manual for ROTAX Engine Type 912 Series supplied with the aircraft. Operating speeds and limits: Engine Type Rotax 912 UL Rotax 912 ULS Speed: Take-off speed 5800 1/min (5 min.) 5800 1/min (5 min.) Maximum continuous speed 5500 1/min 5500 1/min Idle speed ca. 1400 1/min ca. 1400 1/min Performance (ISA): (International Standard Atmosphere) Take-off performance 59,6 kW (80 BHP) at 5800 1/min 73,5 kW (100 BHP) at 5800 1/min Maximum continuous performance 58 kW at 5500 1/min 69 kW at 5500 1/min Acceleration: Limit of engine operation at zero gravity and in negative ˝g˝ conditions, max 5 seconds at max. -0,5 g 5 seconds at max. -0,5 g Reduction ratio: Crankshaft : propeller shaft 2,27 : 1 2,43 : 1 (optional) 2,43 : 1 1 - 11 CAUTION Engine Type Rotax 912 UL Rotax 912 ULS Oil pressure: Maximum 7 bar 7 bar Minimum 0,8 bar (12 psi) (below 3500 rpm) 0,8 bar (12 psi) (below 3500 rpm) Normal 2,0 ÷ 5,0 bar (29 ÷ 73 psi) (above 3500 rpm) 2,0 ÷ 5,0 bar (29 ÷ 73 psi) (above 3500 rpm) Oil temperature: Maximum 140°C (285°F) 130°C (266°F) Minimum 50°C (120°F) 50°C (120°F) Normal operating temperature ca. 90 ÷ 110°C (190 ÷ 230°F) ca. 90 ÷ 110°C (190 ÷ 230°F) Cylinder head temperature: Maximum – reading at observation point of the hotter cylinder head, either no. 2 or no. 3 150°C (300°F) 135°C (284°F) Engine start, operating temperature: Maximum 50°C (120°F) 50°C (120°F) Minimum - 25°C (- 13°F) - 25°C (- 13°F) Fuel pressure: Maximum 0,4 bar (5,8 psi) 0,4 bar (5,8 psi) Minimum 0,15 bar (2,2 psi) 0,15 bar (2,2 psi) 1.1.15 Propeller Specifications For actual and complete information resd the Maintenance Manual for DUC Propeller supplied with the aircraft. Popeller Manufacturer DUC Hélices company Propeller Model Number Three-blade SWIRL, Right Number of Blades 3 Propeller Diameter 1660 mm (65.51 in) Propeller Type ˝Constant speed˝ - variable pitch Recommended Blade Pitch Angle Setting ( Rotax 912 UL) 20° Recommended Blade Pitch Angle Setting ( Rotax 912 ULS) 24° 1 - 12 CAUTION 1.1.16 Structural Materials Non-metal materials No. Material Description Supplier Supplier article number 1 Epoxy resin L-285 Skolil kompozit s.r.o. 2 Hardener 285 Skolil kompozit s.r.o. 3 Hardener 287 Skolil kompozit s.r.o. 4 Hardener C Havel Composites CZ s.r.o. 5 Epoxy flokes BAUMWOLLEFLOCKEN Skolil kompozit s.r.o. L+R0025 6 Epoxy flokes GLASS Bubbles Q-Cell 2106 Skolil kompozit s.r.o. L+R0026 7 Helmipur 46 022 FH Technik spol. s.r.o. 146022.0110.01 8 Harter 49533 FH Technik spol. s.r.o. 149534.0324.01 9 Fiber glass fabric SKLOTEX st. 1080 Skolil kompozit s.r.o. 112 10 Fiber glass fabric SKLOTEX st. 0235 Skolil kompozit s.r.o. 119.1 11 Fiber glass fabric Interglas 90070 GRM Systems s.r.o. 12 Fiber glass fabric 92110 Skolil kompozit s.r.o. 117.11 13 Fiber glass fabric 92125 Skolil kompozit s.r.o. 116.4 14 Fiber glass fabric 92145 UD Interglass Skolil kompozit s.r.o. 15 Carbon fabric UD 177gr. Skolil kompozit s.r.o. 052.39 16 Carbon fabric CT – U 175 GRM Systems s.r.o. 40045 17 Carbon fabric 41090 1K š Skolil kompozit s.r.o. 042 18 Carbon fabric 43 200 TT kepr Skolil kompozit s.r.o. 040.012 19 Carbon fabric 200 g/m2 – kepr 2/2 GRM Systems s.r.o. 20011 20 Roving glass EC 12 2340 816(45) Skloplast a.s. Trnava 21 Roving carbon T 700SC 12k-50C Skolil kompozit s.r.o. 22 Divinycell H60 Skolil kompozit s.r.o. 3H4008000000 23 Alkamid 24 Poly JARID (Silon) PolyPLASTY s.r.o. VV 08197 1 – 13 Metal materials No. Material Description Source of mechanical properties 1 Steel 11 323 ČSN 41 1323 2 Steel 11 353 ČSN 41 1353 3 Steel 11 523 ČSN 41 1523 4 High-tensile steel 15 130.1 ČSN 41 5130.1 5 Chromium – molybdenum steel 4130 6 Stainless steel 17 153 ČSN 41 7153 7 Stainless steel EN ISO 9445 EN 10088-2 8 Aluminium alloy 42 4201.61 ČSN 42 4201.61 9 Aluminium alloy 42 4254.61 ČSN 42 4254.61 10 Bronze EN CW-617N CuZn40Pb2 ČSN EN 1412 11 Bronze EN CW-CuSn8 ČSN EN 1412 1.1.17 Aircraft and engine approved equipment Changes and additions to this master equipment list will be issued as structural, dynamic, electrical, loading, weight/balance, and system component performance testing and analysis is completed. Manufacturers are encouraged to submit requests to the U. S. Field Technical Director for additions to the equipment list. Such requests must explain proposed benefits to our customers, documentation of all aspects of the item under consideration, samples and anticipated effect on existing components/systems, as well as with a written program describing the methods of both ground and flight testing necessary for approval. TL Ultralight must remain and retain the approval authority of any items installed in the TL3000 series aircraft. Therefore the following master list of equipment must be enforced as the only approved items for installation on the aircraft without further authority. No substitutions are allowed without a proper testing program previously approved under the written authority of TL Ultralight, sro or the U. S. Field Technical Director. 1 - 14 TL 3000 Sirius Master Equipment List Engine Item Description Manufacturer Model S/O Engine Rotax 912UL S Engine Rotax 912 O Engine Rotax 912ULS O Engine Rotax 912S O Engine Oil Filter Rotax (No Substitutes!) 825-701 S Engine Oil Drain Filter TL Ultralight 12MM-1.75T O Engine Air Filter K&N R-1060 S Engine Air Filter K&N SP2704 O Engine Air Filter K&N SP2706 O Engine Air Filter K&N RU2760 O Engine Hour Meter Hobbs 85000 O Engine Hour Meter Sensor TL Ultralight N/A O Radiator TL Ultralight N/A S Oil cooler Rotax 886029 S Oil thermostat Rotax 000923 O Carburetor Drip pans TL Ultralight N/A O Carburetor Brackets TL Ultralight N/A O Carburetor Heating Systems Rotax 000814 O Auxiliary Fuel Pump Facet 40105 O Battery Varta 12V 8Ah 80A(EN) S Auxiliary Electrical System TL Ultralight N/A O TL 3000 Sirius Master Equipment List Propeller DUC ˝Constant speed˝ - variable pitch Item Description Manufacturer Model S/O Propeller DUC Helices DUC S 1 – 15 TL 3000 Sirius Master Equipment List Equipment Item Description Manufacturer Model S/O Towing Bar TL Ultralight N/A S Parachute System Galaxy GRS 6–1350SD LSA S Door Lock (2x) TL Ultralight N/A S Seat (2x) TL Ultralight N/A S 3-points safety belts (2x) Schroth Rallye 3 asm S Cockpit Upholstery TL Ultralight N/A S Baggage Area Upholstery TL Ultralight N/A S Cargo Net TL Ultralight N/A S Cabin Heating TL Ultralight N/A O Co-Pilot Toe Brake System TL Ultralight N/A O Brake Shoes TL Ultralight N/A O Parking Brake TL Ultralight N/A O Wheel Rims/Tires/Tubes TL Ultralight N/A S Wheel Pants TL Ultralight N/A O Aerial Towing System TL Ultralight N/A O Landing/Taxi Light KONS UL 184RL6 O Strobe lights (2x) KONS UL 131 strobe O Navigation Lights (3x) Autolamp CZ 12 V O Cabin Light TL Ultralight N/A O Fatique Meter TL Elektronic TL-4324 O Flap Actuator Microel ALI2FCM – I = 100 S 1 – 16 TL 3000 Sirius Master Equipment List Communication and Instrumentation Item Description Manufacturer Model S/O VHF Radio Icom 200A O VHF Radio Icom 210A O VHF Radio MicroAir 2.25˝ O VHF Radio Becker AR4201 O VHF Radio Funkwerk ATR833 O VHF Antenna KONS ULA 1L 18 O VHF Antenna Comant CI-121 O Transponder Garmin GTX320 O Transponder Garmin GTX327 O Transponder Garmin GTX328 O Transponder MicroAir 2.25˝ O Altitude Encoder Ameri-King AK 350 O Transponder Antenna Comant C101 O Transponder Antenna Comant C105 O Emergency Locator Transmitter Ameri-King 450 O ANC Headsets (2x) FlightCom 4DLX O Intercom PS Engineering PS1000 O Intercom PS Engineering PS3000 O Airspeed Indicator TL Ultralight 3.125˝ S Airspeed Indicator Winter 2.25˝ O Artificial Horizon Tru Trak 3.125˝ O Artificial Horizon Tru Trak 2.25˝ O Artificial Horizon RC Allen 3.125˝ O Altimeter, Hg TL Ultralight 3.125˝ S Turn & Bank Tru Trak 3.125˝ O Turn & Bank Tru Trak 2.25˝ O Tachometer Rotax 2.25˝ O Vertical Velocity TL Ultralight 3.125˝ O Magnetic Compass TL Ultralight CM-24L O Oil Temperature Gauge Star Company 2.25˝ O Oil Temperature Gauge Road 2.25˝ S Oil Pressure Gauge Star Company 2.25˝ O Oil Temperature Gauge Road 2.25˝ S Cylinder Temperature Gauge Star Company 2.25˝ O Cylinder Temperature Gauge Road 2.25˝ S Exhaust Temperature Gauge Rotax 2.25˝ O Flap driver Microel 2.25˝ S 1 - 17 TL 3000 Sirius Master Equipment List Communication and Instrumentation Item Description Manufacturer Model S/O AutoPilot System, Steering Tru Trak ADI P1 O AutoPilot System, Altitude Tru Trak ADI P2 O AutoPilot System, Altitude Dynon Avionics AP74 O GPS Navigation System Garmin 295 O GPS Navigation System Garmin 296 O GPS Navigation System Garmin 396 O GPS Navigation System Garmin 496 O GPS Navigation System Garmin 695 O GPS Navigation System AvMap EKPIV O EIS-Engine Information System Grand Rapids Technologies 2/4000 O EIS-Engine Information System IK Technology AIM Sport O XM Entertainment Receiver TL Ultralight N/A O EFIS/XMWX True Flight FL210 series O EFIS/EMS Dynon Avionics D10/A series O EFIS/EMS Dynon Avionics D100/120/180 series O EFIS/EMS Green line AIM - 1 EFIS/EMS/XMWX Blue Mountain Avionics Lite G3/G4 Sport series O EFIS/EMS/XMWX Grand Rapids Technologies Sport series O 1 - 18 1.1.18 Weight and Balance Information Section includes the allowed centre of gravity positioning and weight ranges and centre of gravity position determination procedure allowing safe aircraft operating. All aircraft are structurally and aerodynamically engineered for certain load conditions which result from specific weights and forces anticipated to occur in normal operations within the specified flight envelope. An Aircraft‘s handling qualities and structural integrity may be seriously compromised if the weight and balance limits are exceeded in normal operations. It is the pilot‘s responsibility to make sure the weight and balance limits are not exceeded as to weight, its location, distribution and security prior to any flight. DEFINITIONS Arm: The horizontal distance expressed in inches from the reference datum plane to the center of gravity (CG) of an item or location along the fuselage. Units of measurements and weights must be consistent for each set of calculations and in the same system of units, i.e., pounds and inches, or kilograms and centimeters. Ballast: A specific amount of weight attached in a specific location, which can be temporarily or permanently installed in an aircraft, to help bring its Center of Gravity within the required limits. If temporary ballast must be used for certain operations, the exact amount and its location must be placarded on the instrument panel within clear view of the pilot. The use of Ballast increases Empty Weight and reduces Useful Load. Basic Empty Weight: The standard empty weight plus the weight of any additionally installed or optional equipment. Basic Empty Weight Center of Gravity. The c.g. of an aircraft in its basic empty weight condition, and is an essential part of the weight and balance record. Center of Gravity (CG): A point along an aircraft‘s longitudinal axis at which all the loads and forces are perfectly concentrated and balanced. It is computed by dividing the total moment by the total weight of the airplane. Its distance from the reference datum is found by dividing the total moment by the total weight of the airplane. (Total Moment / Total Weight = Center of Gravity) Center of Gravity Arm is the arm obtained by adding the airplane's individual moments and dividing the sum by the total weight. 1 - 19 NOTE Center of Gravity Limits are the extreme forward and aft center of gravity locations (limits) within which the airplane must be operated at any given weight. Center of Gravity Range: The horizontal distance, along an aircraft‘s longitudinal axis, within which an aircraft has been found to be fully maneuverable at all specified design speeds, weights and loading configurations. Datum: A convenient vertical reference plane along the longitudinal axis of an aircraft from which all horizontal measurements are taken. Installed Equipment: All optional accessories and equipment permanently installed on an airframe or engine at the time of weighing. These items must be included in the ―Installed Equipment List‖ resulting in the Basic aircraft weight. Additions and deletions must be noted in the list each time they are made and new Weight and Balance calculations performed to determine the magnitude and effect of weight change. Ballast, if permanently installed, must also be listed. Maximum and Minimum Weights: Due to balance, structural and aerodynamic considerations, maximum, or minimum, weights for certain locations on the aircraft are specified. For example, the pilot‘s minimum (100Lbs) and maximum (240Lbs) weight is be specified for some operations. The same is true for baggage, cargo, fuel, and any other disposable or variable loads. Maximum Forward and Maximum Aft C.G. Locations: A specified forward most and rear most Center of Gravity location, along the aircraft longitudinal axis. These Center of Gravity location limits are expressed in inches from a convenient reference (forward tip of the propeller spinner) on the aircraft. Reference or Datum Plane: An imaginary vertical plane located on the forward tip of the propeller spinner from which all horizontal distances are measured for balance purposes. Standard Empty Weight: The weight of a standard airplane, including unusable fuel, full engine operating fluids, and full engine oil reservoir. Station: A vertical location along the airplane fuselage horizontal axis given in terms of the distance from the reference datum plane. Tare: The weight of chocks, blocks, stands, etc. used when weighing an airplane, and is included in the scale readings. Tare is deducted from the scale reading to obtain the actual (net) airplane weight. Useful Load: The total amount of weight available for pilot, passengers, baggage, cargo and in-flight usable fuel. The difference between the maximum ramp weight and the basic empty weight. (Maximum Ramp Weight – Basic Empty Weight = Useful Load) The useful load will be reduced by the installation of additional equipment. 1 - 20 Weight: Actual individual weight of each item such as airframe, crew, fuel, baggage, cargo, etc. in pounds or kilograms Empty Weight: The actual weight of the individual aircraft, including the structure, power plant, fixed equipment, any fixed ballast, unusable (in-flight) fuel, and coolant. Original Empty Weight is determined by actually weighing each new aircraft before it is flown. Any time a Major Alteration, Modification or Repair (WHICH MUST BE APPROVED IN WRITING BY THE MANUFACTURER.) is performed on the aircraft; a new Empty Weight must be determined by either weighing the aircraft again, or by accurate calculation of the weight changes and their effect on Empty Weight Center of Gravity (EWCG) location. Major Alteration or Modification results from the addition, deletion, or redistribution of existing equipment and accessories, or from a repair which results in a significant increase of weight of the airframe or engine. For example, addition or removal of floats, skis, battery, radios, installation of a additional fuel tank(s) or engine change, painting the airframe, installation of heavier wheels and tires, etc. Maximum Gross Weight: The maximum total weight for which an aircraft‘s structure and performance have been approved for normal operations by its manufacturer. It is the maximum weight (Empty Weight plus useful load) at which an aircraft can be safely operated. Maximum Takeoff Weight must never exceed the published Gross Weight. Useful Load: The difference between the maximum ramp weight and the basic empty weight. Maximum Ramp Weight – Basic Empty Weight = Useful Load The total amount of weight available for pilot, passengers, baggage, cargo and in-flight usable fuel. Moment: The product of the weight of an item multiplied by its arm. (Weight x Arm = Moment) Loading Chart: Used to calculate the actual Center of Gravity location of a ready to fly aircraft. Care must be taken not to exceed the Maximum/Minimum Weight and Balance Limits stipulated for the aircraft. These limits are determined by structural, stability and control considerations throughout the aircraft speed range. PROCEDURE All permanent equipment, options and accessories should be installed on the aircraft prior to weighing. All equipment options and accessories installed in the aircraft must be listed on the ―Master Equipment List‖. That list becomes part of Weight and Balance Documents by reference. 1 - 21 Be sure to remove any loose equipment, tools, etc. from the aircraft prior to weighing. Sometimes it is necessary to adjust or reduce fuel, cargo, or passenger weights to remain at or below Maximum Allowable Gross Weight. Temporary or permanent ballast is sometimes necessary to bring the C.G. within specified limits. However, the Maximum Allowable Gross Weight should not be exceeded under any circumstances The fuel tank should be empty except for unusable fuel. If the fuel tank is not empty, then the exact amount of usable fuel in the tank must be determined. Usable fuel weight and its moment must be deducted from the Empty Weight calculations before EWCG. can be accurately determined. Oil and coolant tanks and reservoirs must be properly filled before weighing. These and any other liquids necessary for normal operations are considered part of an aircraft‘s empty weight. If weighing is done outdoors, make sure there is no wind to affect the weight measurements. For best results, weigh indoors. The scales must be calibrated correctly and must be set on level ground. Any equipment placed on the scales when weighing the aircraft, such as chocks or blocks, should be weighed separately and the weight deducted from the scale reading. These weights become Tare and should be noted for reference, if necessary. The aircraft must be weighed in a level flight attitude, both longitudinally (front to back, i.e. the cabin botton edge must be in the horizontal position) and laterally (side to side). Place a scale under each wheel of aircraft for all weighings. If only one scale is used, be sure to level the wheels not being weighed before taking the scale readings. Remember, the aircraft must be in proper level flight attitude to ensure accuracy. 1 - 22 EMPTY WEIGHT CENTER OF GRAVITY CALCULATIONS Item Dimension (inches) a 32.49 b 27.17 c 1.38 MAC 48.43 Read the G1 and G2 values from the scales (G2 represents the sum of the values indicated by the scales under the main wheels). Calculate the total empty aircraft weight by using the following formula: lb G G G aft EmptyAircr 2 1 Calculate the empty aircraft centre of gravity distance from the referenc datum plane (wing leading edge): in G b a G b x aft EmptyAircr G C ) ( 1 . . 1 – 23 Calculate the empty aircraft centre of gravity position in %MAC: MAC MAC c x x G C aft EmptyAircr % 100. . % LOADED WEIGHT AND BALANCE CALCULATIONS Find the empty aircraft weight GEmptyAircraft and empty aircraft centre of gravity position x%EmptyAircraft. Determine the weight of the onboard items for the required configuration: Item Description GCrew Crew weight GFuel Fuel weight GBaggage Baggage weight in the luggage compartment 1 - 24 MAC G G G G G G G x G x Baggage Fuel Crew aft EmptyAircr Baggage Fuel Crew aft EmptyAircr aft EmptyAircr Aircraft % 5 , 101 2 , 23 4 , 35 % % Calculate the empty aircraft centre of gravity for the required configuration (by inserting the values): The calculate x%Aicraft value must fit within the centre of gravity positioning range from 22 to 32,5 %MAC CRITICAL LOADING CONDITIONS Each of the following critical loading conditions should be investigated for each individual aircraft, along with any other possible loading condition which may affect the Weight and Balance envelope of the aircraft. This is particularly important for aircraft operation close to the C.G. limits. Be sure the maximum individual weights and the Gross Weight are not exceeded at any time. Be sure all loaded items are placed in approved locations aboard the aircraft. 1. Maximum Crew (Pilot/Co-Pilot) Weight (480lbs), with: a) Full Usable Fuel, Maximum Baggage b) Full Usable Fuel, Zero Baggage c) Zero Usable Fuel, Maximum Baggage 2. Minimum Crew Weight, (100lbs), with: a) Full Usable Fuel, Zero Baggage b) Zero Usable Fuel, Zero Baggage An aircraft log book entry should be made whenever a Weight Balance calculation is performed, indicating date, and nature of change, results and name of person performing the calculation. (If any changes are made to the instrument panel, an entry moment arm is included in the sample.) This document, in its entirety, becomes a part of the Aircraft Legal Documents. It must be kept aboard the aircraft and made available for inspection upon request 1 - 25 WARNING WARNING RNING WEIGHT & BALANCE DATA WORKSHEET NOTES 1. Datum Plane: Wing leading edge. 2. Maximum Forward CG Limit: 12.03 inches aft of Datum 3. Maximum Aft CG Limit: 17.12 inches aft of Datum 4. Maximum Gross Weight: 1320 pounds 5. Maximum Seat Load: 240 pounds 6. Minimum Pilot Weight: 100 pounds 7. Maximum Fuel: 206 pounds 8. Maximum Baggage Weight: 65 pounds 1.1.19 Tire Inflation Pressure Main wheels: 30 PSI (2,1 bar) Nose wheel: 30 PSI (2,1 bar) 1.1.20 Approved Oils and Capacities For approved oil see the Operator´s Manual for all versions of ROTAX 912. Do not use oil additives. Quality automotive motor oil, not approved for aircraft motor oil – for viscosity see Chapter 10 of the Operator´s Manual for all versions of ROTAX 912. Oil Oil capacity: 7.4 liq pt (3,5 l) Oil consumption: max 0.13 liq pt/h (0,06 l/h) Fuel specification: Premium Automotive Unleaded that conform to ASTM D 4814 Minimum AKI 89 Rotax 912 UL Minimum AKI 91 Rotax 912 ULS 1 - 26 NOTE Fuel Fuel content: (2 wing fuel tanks for 65 l) 34.32 U.S. gal (130l) Maximum fuel available: 33.79 U.S. gal (128 l) Fuel consumption: max. 7.13 U.S. gal/h (27 l/h) Braking fluid: DOT 4 Brake fluid Cooling fluid: Antifreeze Extra Different coolants cannot not mixed, if doubt, drain and replace all of the coolant. 1.1.21 Recommended Fastener Torque Values Join Bolt – Nut Bolt – Nut (countersunk) Dimension M5 M6 M8 M5 M6 Recommended Torques for class 8.8 (ISO 898) fasteners 52 lb-in (5.9 N.m) 89 lb-in (10 N.m) 200 lb-in (22.5 N.m) 52 lb-in (5.9 N.m) 89 lb-in (10 N.m) For areas with thick bonding seams (cotton + cab-o-sil + resin + hardener) 49 lb-in (5.5 N.m) 80 lb-in (9 N.m) 200 lb-in (22.5 N.m) 40 lb-in (4.5 N.m) 71 lb-in (8 N.m) Parts of PVC 49 lb-in (5.5 N.m) 80 lb-in (9 N.m) 200 lb-in (22.5 N.m) 49 lb-in (5.5 N.m) 80 lb-in (9 N.m) Carbon fabric composite packages assemblies 49 lb-in (5.5 N.m) 80 lb-in (9 N.m) 200 lb-in (22.5 N.m) 49 lb-in (5.5 N.m) 80 lb-in (9 N.m) Plywood bonded into composite 40 lb-in (4.5 N.m) 71 lb-in (8 N.m) 200 lb-in (22.5 N.m) 31 lb-in (3.5 N.m) 62 lb-in (7 N.m) Glass fiber composite packages 49 lb-in (5.5 N.m) 80 lb-in (9 N.m) 200 lb-in (22.5 N.m) 49 lb-in (5.5 N.m) 80 lb-in (9 N.m) Metal parts assemblies (steel, stainless steel, aluminum alloys) 53 lb-in (6 N.m) 89 lb-in (10 N.m) 200 lb-in (22.5 N.m) 53 lb-in (6 N.m) 89 lb-in (10 N.m) 1 - 27 CAUTION 1.1.22 General Safety Information During all service and repair work beware of activating the Ballistic Parachute systém rocket. 1 - 28 WARNING WARNING RNING