Sirius TL-3000 AIRCRAFT MAINTENANCE MANUAL

TL-3000

Sirius

AIRCRAFT MAINTENANCE MANUAL

Author:

Ing. Martin Zahálka Ph.D

THIS DOCUMENT AND TECHNICAL DATA HEREON DISCLOSED ARE PROPRIETARY

TO TL-ULTRALIGHT AND SHALL NOT BE USED, RELEASED OR DISCLOSED IN WHOLE

OR IN PART WITHOUT EXPRESS WRITTEN PERMISSION FROM TL-ULTRALIGHT.

(THIS PAGE BLANK)

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Dear Sirius Owner:

Congratulations on the purchase of your Sirius! You will find your new

TL-ULTRALIGHT aircraft very enjoyable, extremely economical, and easy to maintain. The Sirius is the ideal Light Sport Airplane. It is fast, economical, pleasing to the eye, and user friendly. We at TL-ULTRALIGHT Sport Aircraft are certain that your Sirius will give you hours and hours of leisure flying and enjoyment. With this Aircraft Maintenance Manual (AMM), we hope to help inform you about the support and operation of your aircraft. Should there be any questions or errors found in your reading this manual please contact us immediately and we will issue a clarification.

Thank you again for your business. We look forward to a continuing satisfied customer relationship. Feel free to contact us if you have any questions or comments regarding your Sirius.

Fly safe! Fly fun!

Jiri Tlusty

TL-ULTRALIGHT, s.r.o.

Airport 515, Pouchov

503 41 Hradec Kr

álové

CZECH REPUBLIC www.tl-ultralight.com

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0.1 Table of Content

0. ITRODUCTION

0.1. Table of Content

0.2. Notes, Cautions, and Warnings

0.3. List of Revisions

1. GENERAL INFORMATION

1.1. Introduction

1.1.1 Scope

1.1.2 Safety

1.1.3 Referenced Documents

1.1.4 Definitions

1.1.5 Maintenance and Repair

1.1.6 Line Maintenance and Repairs

1.1.7 Heavy Maintenance and Repairs

1.1.8 Overhaul

1.1.9 Alternation, Modification or Major Repair

1.1.10 Task – Specific Training

1.1.11 Safety Directives

1.1.12 Views, dimensions

1.1.13 Aircraft Specifications

1.1.14 Engine Specifications

1.1.15 Propeller Specifications

1.1.16 Structural Materials

1.1.17 List of disposable replacement parts

1.1.18 Aircraft and engine approved equipment

1.1.19 Weight and Balance Information

1.1.20 Tire Inflation Pressure

1.1.21 Approved Oils and Capacities

1.1.22 Recommended Fastener Torque Values

1.1.23 General Safety Information

1.1.24 Report „Feed Back“ Forms

2. INSPECTIONS

2.1. Introduction

2.2 Airplane Files

2.3 Washing and Cleaning the Airplane

2.4. Filling the Fuel Tank

2.5 Engine Visual Inspection

2.6 First 25h / 50h / 100h / Annual Inspection

2.6.1 FAA Required Inspections

2.6.2 First 25 hour Inspection

2.6.3 Every 50h / 100h / Annual Inspection

2.7 Every 300 hour Inspection

2.8 Alternations or Major repairs

2.9 Lubrication program figures

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3. STRUCTURES

3.1 Introduction

3.2 Wing

3.2.1 Wings Installation

3.2.2 Wings Removal

3.2.3 Verification Required

3.3 Empennage

3.3.1 Horizontal tail Installation

3.3.2 Horizontal tail Removal

3.3.3 Elevator Installation

3.3.4 Elevator Removal

3.3.5 Verification Required (horizontal tail and elevator

3.3.6 Rudder Installation – partially adjustable foot pedals version

3.3.7 Rudder Installation – full adjustable foot pedals version

3.3.8 Rudder Removal

3.3.9 Verification Required (rudder)

3.4 Landing Gear

3.4.1 Nose gear Installation – 400 x 100 mm wheel

3.4.2 Nose gear Installation – 11 x 4 wheel

3.4.3 Nose gear Removal

3.4.4 Nose gear Bottom attachement Installation

3.4.5 Nose gear Bottom attachement Removal

3.4.6 Nose wheel Installation – 400 x 100 mm wheel

3.4.7 Nose wheel Installation – 11 x 4 wheel

3.4.8 Nose wheel Removal

3.4.9 Main wheel assembly Installation – 400 x 100 mm wheels

3.4.10 Main wheel assembly Installation – 15 x 6 wheels

3.4.11 Main wheel assembly Removal

3.4.12 Main undercarriage leg Installation

3.4.13 Main undercarriage leg Removal

3.4.14 Verification Required (Landing gear)

3.4.15 Brake system description

3.4.16 Filling Brake System with Fluid – 400 x 100 mm wheels

3.4.17 Filling Brake System with Fluid – 15 x 6 wheels

3.4.18 Verification Required (Filling Brake System with Fluid)

3.4.19 Replacing/removal of the Brake pads – 400 x

100 mm wheels

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3.4.20 Replacing/removal of the Brake pads – 15 x 6 wheels

3.4.21 Verification Required (Replacing/removal of the Brake pads)

3.5 Structural Control Surfaces

3.5.1 Flap installation

3.5.2 Flap Removal

3.5.3 Verification Required (flap installation / removal)

3.5.4 Setting Flap „Zero“ Position

3.5.5 Verification Required (flap „Zero“ position)

3.5.6 Aileron installation

3.5.7 Aileron Removal

3.5.8 Verification Required (aileron installation / removal)

3.5.9 Setting Aileron „Zero“ Position

3.5.10 Verification Required (aileron „Zero“ position)

3.6. Engine

3.7. Fuel System

3.7.1 Wing fuel tanks filters inspection / cleaning

3.7.2 Verification Required (Fuel tanks filters inspection / cleaning)

3.7.3 Gascolator Inspection / cleaning

3.7.4 Verification Required (Gascolator Inspection / cleaning)

3.8. Propeller

3.9. Utility Systems

3.9.1 Heating System

3.9.2 Venting System

3.9.3 Seats

3.9.4 Cabin doors

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

3.10.8 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

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3.11.5 Inspection and operation checks

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

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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.

NOTE

This text box emphasizes specific operating conditions, steps in a procedure, helpful hints or useful advice.

CAUTION

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.

WARNING

WARNING

RNING 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.

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CAUTION

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 -11, 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

NOTE

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

s.r.o

Customer Service

10401 West Markham Street

Little Rock, AR 72205

Phone: 501.228.7777

Fax: 501.227.8888

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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

0 30 August 2010

02 September

2015

Revised

Pages

None

1 21 March 2013 All pages

2 11 June 2015

3

All pages

From 3-203 to 3-214

Type of Revision Posted

By

- Original Issue

New type of undercarriage, brake and foot pedal system

Introductions, disposable replacement parts, inspections, engine specification

Other colouring of aircraft information

TL-ULTRALIGHT

TL-ULTRALIGHT

TL-ULTRALIGHT

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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 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.

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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 to the applicable ASTM standards that is not described in the TL-ULTRALIGHT 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 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 and is specified in TL-

ULTRALIGHT´s maintenance manual.

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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 that specifies all maintenance or repairs authorized by TL-ULTRALIGHT.

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 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 to the applicable ASTM standards that is not described in the TL-ULTRALIGHT 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 or component manufacturer to overhaul the product originally produced by that manufacturer.

Repair facility

—facility specifically authorized by the FAA or TL-ULTRALIGHT or component manufacturer to repair the product originally produced by that manufacturer.

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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 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 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)

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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 . 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 service directive when the repairman is listed as an authorized person to accomplish the work described.

1.1.7 Heavy Maintenance and Repairs


—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

LSA aircraft.

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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


—Only TL-ULTRALIGHT 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 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 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.

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No changes may be made to any TL-ULTRALIGHT aircraft without prior written approval of TL-ULTRALIGHT. Any changes made without TL-ULTRALIGHT written approval will void the aircraft airworthiness certificate.

TL-ULTRALIGHT may authorize another TL-ULTRALIGHT 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 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 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 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 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 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 will issue any directive as outlined in the applicable ASTM continued airworthiness specification.

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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, T TL-ULTRALIGHT 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 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.

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1.1.12 Views, dimensions

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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 ft

2

……….. 14.21 ft

2

……….. 4.46 ft

2

……….. 21.64 ft

2

…………… 7,92

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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 steerable or non-steerable nose wheel (depends on version). 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.

CAUTION

For actual and complete information resd the Maintenance Manual for ROTAX Engine

Type 912 Series supplied with the aircraft.

Operating speeds and limits:

ROTAX

912 ULS

ROTAX

912 iS

Engine Type

Performance (ISA): (International Standard Atmosphere)

59,6 kW

Take-off performance

(80 HP)

Maximum continuous performance

58 kW

(77,8 HP)

Speed:

ROTAX

912 UL

Take-off speed

5800 ot/min

(5 min.)

73,5 kW

(100 HP)

69 kW

(93 HP)

5800 ot/min

(5 min.)

73,5 kW

(100 HP)

69 kW

(93 HP)

5800 ot/min

(5 min.)

Maximum continuous speed 5500 ot/min 5500 ot/min 5500 ot/min

Oil pressure:

Maximum

Minimum

7 bar (102 psi) 7 bar (102 psi) 7 bar (102 psi)

0,8 bar (12 psi) 0,8 bar (12 psi) 0,8 bar (12 psi)

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Oil temeprature:

Maximum

Minimum

Cylinder head temperature

140°C (285°F) 130°C (266°F) 130°C (266°F)

50°C (120°F) 50°C (120°F) 50°C (120°F)

Maximum cylinder head temperature

150°C

(300°F)

135°C

(284°F)

-

Coolant temperature:

Maximum coolant temperature

120°C

(248°F)

120°C

(248°F)

120°C

(248°F)

Engine start, operating temperature

Maximum

50°C (120°F) 50°C (120°F) 50°C (120°F)

Minimum - 25°C (- 13°F) - 25°C (- 13°F) - 25°C (- 13°F)

Fuel pressure:

Maximum

Minimum

0,4 bar (5,8 psi) 0,4 bar (5,8 psi) 3,2 bar (45 psi)

0,15 bar 0,15 bar 2,8 bar

(2,2 psi) (2,2 psi) (42 psi)

1.1.15 Propeller Specifications

CAUTION

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

Propeller Diameter

Propeller Type

Recommended Blade Pitch Angle Setting ( Rotax 912 UL)

Recommended Blade Pitch Angle Setting ( Rotax 912 ULS)

3

1660 mm (65.51 in)

˝Constant speed˝ - variable pitch

20°

24°

1 - 12

1.1.16 Structural Materials

Non-metal materials

No.

11

12

13

14

7

8

9

10

15

16

17

1

2

3

4

5

6

18

19

20

21

22

23

24

Material Description Supplier

Epoxy resin L-285

Hardener 285

Hardener 287

Skolil kompozit s.r.o.



Hardener C Havel Composites CZ s.r.o.

Epoxy flokes BAUMWOLLEFLOCKEN Skolil kompozit s.r.o.

Epoxy flokes GLASS Bubbles Q-Cell 2106 Skolil kompozit s.r.o.

Helmipur 46 022

Harter 49533

Fiber glass fabric SKLOTEX st. 1080

Fiber glass fabric SKLOTEX st. 0235

Fiber glass fabric Interglas 90070

Fiber glass fabric 92110

Fiber glass fabric 92125

Fiber glass fabric 92145 UD Interglass

Carbon fabric UD 177gr.

Carbon fabric CT – U 175

Carbon fabric 41090 1K š

Carbon fabric 43 200 TT kepr

Carbon fabric 200 g/m2 – kepr 2/2

Roving glass EC 12 2340 816(45)

Roving carbon T 700SC 12k-50C

Divinycell H60

Alkamid

Poly JARID (Silon)

FH Technik spol. s.r.o.

FH Technik spol. s.r.o.



GRM Systems s.r.o.





GRM Systems s.r.o.



GRM Systems s.r.o.

Skloplast a.s. Trnava



PolyPLASTY s.r.o.

1 - 13

Supplier article number

L+R0025

L+R0026

146022.0110.01

149534.0324.01

112

119.1

117.11

116.4

052.39

40045

042

040.012

20011

3H4008000000

VV 08197

Metal materials

No. Material Description

1 Steel 11 323

2 Steel 11 353

3 Steel 11 523

4 High-tensile steel 15 130.1

5 Chromium – molybdenum steel

6 Stainless steel 17 153

7 Stainless steel EN ISO 9445

8 Aluminium alloy 42 4201.61

9 Aluminium alloy 42 4254.61

10 Bronze EN CW-617N CuZn40Pb2

11 Bronze EN CW-CuSn8

Source of mechanical properties

ČSN 41 1323

ČSN 41 1353

ČSN 41 1523

ČSN 41 5130.1

4130

ČSN 41 7153

EN 10088-2

ČSN 42 4201.61

ČSN 42 4254.61

ČSN EN 1412

ČSN EN 1412

1.1.17 List of disposable replacement parts

Type of component

Filters

Hoses

Rubber parts

Component

Air filter

Fuel filter

Oil filter

Fuel system hoses

Engine cooling system hoses

Oil hoses

Engine mount rubber blocks

Carb. bracket rubber blocks

Ignition rubber block

Wheel tires

Components marking

Rotax 825 551

Rotax 825 711

KN Filters R -

1060

Gascolator ACS

10580

Rotax 825012

FUB 386 5/11

FUB 386 6/12

FUB 386 8/14

Rubena 402529

Rotax 956 390

Rubena 40757 /

042757

Rubena 40795

Rotax size 400 x 100 size 300 x 100 size 15 x 6 size 11 x 4

Airplane variant

all variants all variants all variants all variants all variants all variants all variants all variants all variants all variants all variants size 400 x 100 wheels size 300 x 100 wheels size 15 x 6 wheels size 11 x 4 wheels

Replacement

after every 300 hours after every 300 hours after every 300 hours on condition after every 100 hours after every 5 yaers after every 5 yaers after every 5 yaers after every 5 yaers after every 5 yaers after every 5 yaers on condition on condition on condition on condition

1 - 14

Brake system parts

Metal parts

Engine parts

Fluids

Brake pads

Brake disc

Brake pads

Brake disc

Metal plates under the engine

Passage screw in nose leg

Ignition sparks

Oil

Cooling fluid

Braking fluid

DIAFRICT

2057163605590

TL

400 x 100 mm wheels

400 x 100 mm wheels on condition on condition

DIAFRICT

2057163607170 and

2057163607180

400 x 100 mm size wheels on condition

S4-350_000_00-1

DOT 4 or DOT 5

15 x 6 size wheels all variants on condition

STING-15-2-2 all variants after every 300 hours

Screw M8 x 55 after every 100 all variants

DIN 912 hours see the current Operator´s Manual for all version of

ROTAX 900 series see the current Operator´s Manual for all version of

ROTAX 900 series see the current Operator´s Manual for all version of

ROTAX 900 series after every 2 yaers

CAUTION

For the current and complete information regarding list of disposable replacement engine and propeller parts see the Maintenance Manual for ROTAX Engine Type 900

Series and the Manual for Propeller supplied with the aircraft.

1.1.18 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

1 - 15

approved under the written authority of TL-ULTRALIGHT or the U. S. Field Technical

Director.

Item Description

Engine

Engine

Engine

Engine

Engine Oil Filter

Engine Oil Drain Filter

Engine Air Filter

Engine Air Filter

Engine Air Filter

Engine Air Filter

Engine Hour Meter

TL 3000 Sirius Master Equipment List

Engine

Manufacturer

Rotax

Rotax

Rotax

Rotax

Rotax (No Substitutes!)

TL-ULTRALIGHT

K&N

K&N

K&N

K&N

Hobbs

Model

912UL

912

912ULS

912S

825-701

12MM-1.75T

R-1060

SP2704

SP2706

RU2760

85000

Engine Hour Meter Sensor

Radiator

Oil cooler

Oil thermostat

TL-ULTRALIGHT

TL-ULTRALIGHT

Rotax

Rotax

N/A

N/A

886029

000923

Carburetor Drip pans

Carburetor Brackets

Carburetor Heating Systems

Auxiliary Fuel Pump

Battery

TL-ULTRALIGHT

TL-ULTRALIGHT

Rotax

Facet

Varta

TL-ULTRALIGHT

N/A

N/A

000814

40105

12V 8Ah 80A(EN)

N/A Auxiliary Electrical System


Propeller


Propeller DUC ˝Constant speed˝ - variable pitch

Manufacturer

DUC Helices

Model

DUC

S/O

S

1 - 16

O

S

S

O

O

O

O

O

S

O

O

O

O

O

S

O

S

S/O

S

O

O

O


Towing Bar

Parachute System

Door Lock (2x)

Seat (2x)

3-points safety belts (2x)

Cockpit Upholstery

Baggage Area Upholstery

Cargo Net

Cabin Heating

Co-Pilot Toe Brake System


Equipment

Manufacturer

TL-ULTRALIGHT

Galaxy

TL-ULTRALIGHT

TL-ULTRALIGHT

Schroth

TL-ULTRALIGHT

TL-ULTRALIGHT

Model

N/A

GRS 6–1350SD LSA

N/A

N/A

Rallye 3 asm

N/A

N/A

TL-ULTRALIGHT

TL-ULTRALIGHT

TL-ULTRALIGHT

N/A

N/A

N/A

Brake Shoes

Parking Brake

Wheel Rims/Tires/Tubes

Wheel Pants

Aerial Towing System

Landing/Taxi Light

Strobe lights (2x)

Navigation Lights (3x)

Cabin Light

Fatique Meter

Flap Actuator

TL-ULTRALIGHT

TL-ULTRALIGHT

TL-ULTRALIGHT

TL-ULTRALIGHT

TL-ULTRALIGHT

KONS

KONS

Autolamp CZ

TL-ULTRALIGHT

TL Elektronic

Microel

N/A

N/A

N/A

N/A

N/A

UL 184RL6

UL 131 strobe

12 V

N/A

TL-4324

ALI2FCM – I = 100

1 - 17

O

O

O

O

O

O

S

O

O

S

O

S

S

S

S

S/O

S

S

S

S

O

O


VHF Radio

VHF Radio

VHF Radio

VHF Radio

VHF Radio

VHF Antenna

VHF Antenna

Transponder

Transponder

Transponder

Transponder

Altitude Encoder

Transponder Antenna

Transponder Antenna

Emergency Locator Transmitter

ANC Headsets (2x)

Intercom

Intercom

Airspeed Indicator


Communication and Instrumentation

Manufacturer

Icom

Icom

MicroAir

Becker

Funkwerk

KONS

Comant

Garmin

Garmin

Garmin

MicroAir

Ameri-King

Comant

Comant

Airspeed Indicator

Artificial Horizon

Artificial Horizon

Artificial Horizon

Altimeter, Hg

Turn & Bank

Turn & Bank

Tachometer

Vertical Velocity

Magnetic Compass

Oil Temperature Gauge


Oil Pressure Gauge


Cylinder Temperature Gauge

Cylinder Temperature Gauge

Exhaust Temperature Gauge

Flap driver

Ameri-King

FlightCom

PS Engineering

PS Engineering

TL-ULTRALIGHT

Winter

Tru Trak

Tru Trak

RC Allen

TL-ULTRALIGHT

Tru Trak

Tru Trak

Rotax

TL-ULTRALIGHT

TL-ULTRALIGHT

Star Company

Road

Star Company

Road

Star Company

Road

Rotax

Microel

C101

C105

450

4DLX

PS1000

PS3000

3.125˝

2.25˝

3.125˝

2.25˝

3.125˝

3.125˝

3.125˝

2.25˝

2.25˝

3.125˝

CM-24L

2.25˝

2.25˝

2.25˝

2.25˝

2.25˝

2.25˝

2.25˝

2.25˝

Model

200A

210A

2.25˝

AR4201

ATR833

ULA 1L 18

CI-121

GTX320

GTX327

GTX328

2.25˝

AK 350

1 - 18

O

O

O

O

S

O

O

O

O

S/O

O

O

O

O

O

O

O

O

O

O

S

O

S

S

O

S

O

S

O

O

O

O

O

O

O

O

O

O


Communication and Instrumentation


AutoPilot System, Steering

Manufacturer

Tru Trak

AutoPilot System, Altitude

AutoPilot System, Altitude

GPS Navigation System

Tru Trak

Dynon Avionics

Garmin





Garmin

Garmin

Garmin

Garmin

GPS Navigation System AvMap

EIS-Engine Information System Grand Rapids Technologies

EIS-Engine Information System

XM Entertainment Receiver

EFIS/XMWX

IK Technology

TL-ULTRALIGHT

True Flight

EFIS/EMS

EFIS/EMS

EFIS/EMS

EFIS/EMS/XMWX

Dynon Avionics

Dynon Avionics

Green line

Blue Mountain Avionics

EFIS/EMS/XMWX Grand Rapids Technologies

Model

ADI P1

ADI P2

AP74

295

296

396

496

695

EKPIV

2/4000

AIM Sport

N/A

FL210 series

D10/A series

D100/120/180 series

AIM - 1

Lite G3/G4 Sport series

Sport series

O

O

O

O

O

O

O

O

S/O

O

O

O

O

O

O

O

O

O

1 - 19

1.1.19 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 envelo pe. 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.

NOTE

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 - 20

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 - 21

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 - 22

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 - 23

EMPTY WEIGHT CENTER OF GRAVITY CALCULATIONS

Item

a b c

MAC

Dimension (inches)

32.49

25.98

1.38

48.43

Read the G

1

and G

2

values from the scales (G

2

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:

G

EmptyAircr aft



G

1



G

2

Calculate the empty aircraft centre of gravity distance from the referenc datum plane

(wing leading edge):

x

C

.

G

.



b



G

1



(

a



b

G

EmptyAircr aft

)

1 - 24

Calculate the empty aircraft centre of gravity position in %MAC:

x

%

EmptyAircr aft





x

C

.

G

.



MAC c





100



%

MAC



LOADED WEIGHT AND BALANCE CALCULATIONS

Find the empty aircraft weight G

EmptyAircraft

and empty aircraft centre of gravity position x

%EmptyAircraft

.

Determine the weight of the onboard items for the required configuration:


G

Crew

G

Fuel

G

Baggage

Crew weight

Fuel weight

Baggage weight in the luggage compartment

1 - 25

x

%

Calculate the empty aircraft centre of gravity for the required configuration (by inserting the values):

Aircraft



G

EmptyAircr aft



x

%

EmptyAircr aft



G

EmptyAircr aft

G



Crew

G



35

Crew



, 4

G



G

Fuel



Fuel



23 , 2

G

Baggage



G

Baggage



101 , 5



%

MAC



WARNING

WARNING

RNING

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 - 26

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

1.1.20 Tire Inflation Pressure

Main wheels (400 x 100 mm): 30 PSI (2,1 bar)

Main wheels (15 x 6): 44 PSI (3 bar)

Nose wheel (400 x 100 mm): 30 PSI (2,1 bar)

Nose wheel (11 x 4): 70 PSI (4,8 bar)

1.1.21 Approved Oils and Capacities

NOTE

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 - 27

Fuel

Fuel content: (2 wing fuel tanks for 65 l) 34.32 U.S. gal (130l)

Maximum fuel available:

Fuel consumption:

33.79 U.S. gal (128 l) max. 7.13 U.S. gal/h

(27 l/h)

Braking fluid: DOT 4 or DOT 5 Brake fluid, it depends on type of brake cylinders (see chapter 3.4.15)

Cooling fluid: Antifreeze Extra

CAUTION

Different coolants cannot not mixed, if doubt, drain and replace all of the coolant.

1.1.22 Recommended Fastener Torque Values

Join

Dimension

Recommended Torques for class 8.8 (ISO 898) fasteners

For areas with thick bonding seams (cotton + cab-o-sil + resin + hardener)

Parts of PVC

M5

52 lb-in

(5.9 N.m)

49 lb-in

(5.5 N.m)

Bolt – Nut

M6

89 lb-in

(10 N.m)

80 lb-in

(9 N.m)

M8

200 lb-in

(22.5 N.m)

200 lb-in

(22.5 N.m)

Bolt – Nut (countersunk)

M5

52 lb-in

(5.9 N.m)

M6

89 lb-in

(10 N.m)

40 lb-in

(4.5 N.m)

71 lb-in

(8 N.m)

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

Plywood bonded into composite

Glass fiber composite packages

49 lb-in

(5.5 N.m)

40 lb-in

(4.5 N.m)

49 lb-in

(5.5 N.m)

53 lb-in

(6 N.m)

80 lb-in

(9 N.m)

71 lb-in

(8 N.m)

80 lb-in

(9 N.m)

89 lb-in

(10 N.m)

200 lb-in

(22.5 N.m)

200 lb-in

(22.5 N.m)

200 lb-in

(22.5 N.m)

200 lb-in

(22.5 N.m)

49 lb-in

(5.5 N.m)

31 lb-in

(3.5 N.m)

49 lb-in

(5.5 N.m)

53 lb-in

(6 N.m)

80 lb-in

(9 N.m)

62 lb-in

(7 N.m)

80 lb-in

(9 N.m)

89 lb-in

(10 N.m)

Metal parts assemblies

(steel, stainless steel, aluminum alloys)

1 - 28

1.1.23 General Safety Information

WARNING

WARNING

During all service and repair work beware of activating the Ballistic Parachute systém rocket.

RNING

1 - 29

WARNING

WARNING

RNING

An accidental engine start is very dangerous. Ensure that the Ignition Switches and main switch are turned off.

1.1.24

Report ˝Feed Back˝ Forms

The following pages contain ‘feed-back’ reports that are intended to assist the owner in reporting questions, safety issues, service or maintenance issues, parts and assembly performance, incidences and warranty claims which may assist in the safe operation of our aircraft and the use of this manual. Electronic versions are also available by request.

Please copy the form, mail or fax it to the address below. You will receive a confirmation of the receipt and status of your comments.

Send the completed form to: TL-ULTRALIGHT, sro

Customer Service

10401 West Markham Street

Little Rock, AR 72205

Phone: 501.228.7777

Fax: 501.227.8888

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Aircraft / Part / Assembly/ Incident Safety Feed Back Form:

Report Date: Aircraft N Number: Aircraft S/N:

Flight hours: Report Airport: Aircraft Airport:

Conditions:

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1. Periodic Inspection Notes

2. Pre-flight Inspection

3. Engine Start

4. Taxi

5. Take off

6. Climb

7. Level Off

8. Cruise

9. Decent

10. Pattern

11. Approach

12. Landing

13. Other

Detailed Description: (Continue on back if required)

Affected parts/assembly:

Part Name Part Number Time in Service Total Time

Dealer Name:

Owner:

Address:

City, State, Zip

Phone / Fax:

Email:

Warranty Claim Filed: YES - NO

Contact:

Claim Number:

CONTACT INFORMATION

Signature: Date:

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Aircraft Maintenance & Maintenance Manual Feed Back Form:

Report Date:

Manual Section:

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0. Introduction

1. General

2. Inspections

3. Structures

4. Engine

5. Fuel System

6. Propeller

7. Utility Systems

8. Instruments and Avionics

9. Electrical System

10. Painting and Coatings

Page Number:

Subject Heading:

Description: (errata; information conflict; details; photos, etc)

CONTACT INFORMATION

Owner:

Address:

City, State, Zip

Phone / Fax:

Email:

Signature: Date:

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Example of report below, see following page for Warranty Claim Report form.

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INSERT WARRANTY HERE!

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SECTION 2

INSPECTIONS


Section 2 contains information pertaining to light maintenance, the weight and balance calculations and periodic inspection lists for the airplane. Included is a illustrated parts list grouped by category and at the end of this section are detailed checklists of the periodic inspections which are meant to be copied and the copy used as a checklist for the inspection. Return the original to this manual.

2.2 Airplane Files

Certain items must be with the airplane at all times. The following is a list of these items and when they are required:

1. To be carried in the airplane at all times:

1. Aircraft Operating Instructions (AOI)

2. Weight and Balance Data

3. Operating Limitations issued by FAA at airworthiness inspection.

4. Aircraft Airworthiness Certificate (FAA Form 8130-7)

5. Aircraft Registration Certificate (AC Form 8050-3)

2. To be with the pilot during flight

1. Airman Certificate

2. Medical Certificate

3. Aviation Charts

3. To be made available upon request:

1. Airplane Log Book

2. Engine Log Book

3. Propeller Log Book

4. Pilot Log Book

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2.3 Washing and Cleaning the Airplane

Type of Maintenance

Level of Certification Required

Tools Required

Materials Required

Washing and Cleaning Checklist

Propeller. Ensure that the Ignition Switches and

Main Switch are turned off. Wash and rinse sedentary dirt from the blades of the propeller.

Cabin glass. Wash, rinse and polish glass parts of the cabin. Use chamois leather that is rinsed often in clean water.

Wing, Struts and Tail. Wash and rinse the leading edges of the wings, struts and tail areas.

Fuselage. Clean front part of the cowlings. Clean the bottom part of the body behind the front undercarriage leg.

Undercarriage. Remove any grass that may have collected on the undercarriage.

Interior. Clean the interior of the cabin, removing trash from all storage areas.

Other parts. Clean other parts of the airplane, as needed, especially the upper sides of the wings and openings of the engine.

Safeguard the airplane. Safeguard the airplane with cleansing agents used for cleaning nad protecting automobiles, including the propeller and any composite parts.

Clean the cabin. Use a vacuum cleaner to clean the cabin, making sure there are no undersirable objects in the back storage area.

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Vacuum cleaner, Chamois leather

Lukewarm water, Cleansing agents used for cleaning and protecting automobiles

After each flight day Once a mounth

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Use lukewarm water that is changed often to wash the airplane. First, wash the parts and then dry them off. For cleaning insects off of airplane parts, use the same cleaning agents as used for automobiles.

Before waxing a new airplane, let it dry for approximately one month to allow the finish maximum drying time.

Remark: Cover the Pitot tube while washing the airplane to protect it from water.

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2.4 Filling the Fuel Tank

Due to the composite construction of the airplane, static electricity may occur.

CAUTION

Fill the fuel tank only from an approved storage container using a funnel approved for petrol only. The tank should be fastened to the ground with a grounding pin (do not use plastic fuel cans or funnels that are not certified for petrol).

CAUTION

While fueling, do not wear clothing that may cause static electricity (synthetic fibers, etc.).

CAUTION

Do not use a paper fiber filter with the filter refill.

CAUTION

Do not support your hands, the fuel container or any subjects (such as ladder) on the wing, as the laminate surface is not proportioned for high area force.

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Tools Required


The Fuel Tank filling Checklist

Electrical appliances. Turn off all electrical appliances, cell phones, ignition circuits and the main switch.

Fuel Selector. Close the fuel selector switch.

Open Fire. Make sure there is no open fire near the airplane, and that no one is smoking near the airplane.

Fire Extinguisher. Have a fire extinguisher close at hand (one suitable for flammable fuels).

Grounding cable. Make sure the grounding cable placed on the right undercarriage leg is reaching the ground.

Fuel cap(s). Unlock and release the fuel cap(s).

Container grounding. Ground the aircraft to the fuel container by a strap to the exhaust pipe.

Funnel placing. Carefully place the approved funnel in the fuel opening. Use a water separator to prevent contamination of the fuel tank.

Fuel filling. Pour the fuel slowly. Pay particular attention to keep fuel off of the airplane when you remove the funnel.

After fueling. After fueling, remove the funnel, replace the tank cap and lock it. Wipe off any spilled fuel.

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Funnel with water separator

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2.5 Engine Visual Inspection



Tools Required


Engine Visual Inspection Checklist

Switches. Ensure that the Ignition Switches and

Main Switch are turned off.

Engine covers. Remove engine covers

Fuel filter. Check for possible contaminants in the fuel filter using the drain tap, and change it if necessary. If you spot pollution in the engine space, carry out a complete inspection or change the fuel filters of the tanks in the wings.

Oil level. Remove the Oil tank cap. Manually turn the propeller until you hear the sound of air leaking into the oil in the oil tank. Check the level of oil and follow the Operator´s Manual for all versions of ROTAX 912. Close the oil tank.

Cooling fluid level. Check the level of cooling fluid and follow the Operator´s Manual for all versions of ROTAX 912.

Hoses. Look for possible worn places on the hoses especially at places, or where they are connected to or near matallic parts of the engine.

Carburetors. Carefully check the link of the carburetor with the carburetor bowl stirrup.

Looseness or slack in the rubber connector at the neck of the carburetor, is cause for replacement even though it has been tightened, take it off and exchange it according to the carburetor manual.

Engine mount. Inspect for cracks, corrosion, loose hardware, chafing by cables, wires, hoses, etc..

Engine covers. Assembly of the engine covers.

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Screw driver

Fuel filter, Engine Oil, Engine Cooling

Fluid

Before each flight day

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2.6 First 25h / 50h / 100h / Annual Inspection

2.6.1 FAA Required Inspections

As required by Federal Aviation Regulations, all LSA aircraft of U.S. registry must undergo a complete condition inspection (

“annual”) every twelve calendar months, in addition, every 100 hours of operation when operated in commercial use. It is the responsibility of the owner/operator to assure compliance with all applicable aircraft manufacturer directives.

2.6.2 First 25 hour Inspection

The inspection after first 25 flight hours is performed in conjuction with the engine oil and filter change by the airplane owner if he is trained for the airplane´s maintenance or by an FAA qualified inspector following the First 25 hour inspection checklist. If the aircraft is used for commercial operation the inspection is performed by an FAA approved A&P. Otherwise, it is made in the manufacturer´s service center.



First 25 hour Inspection Checklist

Engine cowling. Remove engine cowling

Engine covers. Remove engine covers

Engine. Follow the Operator´s Manual for all versions of ROTAX 912 for instruction of First 25 hours Inspection.

Pipes and Gascolator. Carefully inspect the tightening of the engine pipes and the state of the fuel gascolator and any filter(s). Clean the fuel gascolator. Check all places carefully where the pipes are attached to metal parts of the engine.

Wing tanks filters. Disassembly wings and check both wing tanks filters. (see Chapter 3.7.1)

Wings and Engine covers Assembly. Assembly the wings and engine covers

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After first 25 hour

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The possibility that dust or other debris may be left in the tank or the fuel system during the manufacturing process cannot be overlooked. Rinsing of the tank and the fuel system prior to cleaning the filter can cause major contamination.

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2.6.3 Every 50h / 100h / Annual Inspection

The inspection after every 50 flight hours is performed in conjuction with the engine oil and filter change by the airplane owner if he is trained for the airplane´s maintenance or by an FAA qualified inspector following the 50 hour inspection checklist. If the aircraft is used for commercial operation the inspection is performed by an FAA approved A&P.

Otherwise, it is made in the manufacturer´s service center.

If Used for commercial operations, the Annual Condition Inspection and the 100 hour

Inspection and maintenance after every 100 hours is performed by an FAA approved

A&P. Otherwise, it is made in the manufacturer´s service center.

If not used for commercial operations, the Annual Condition Inspection is performed by the airplane owner if he is trained for the airplane´s maintenance, by an FAA qualified inspector or by an FAA approved A&P. Otherwise, it is made in the manufacturer´s service center.

The maintenance procedure is as follows:

• Condition inspection checklist

• Aircraft Records checklist

• Run-up checklist

• Post-Run-up checklist

• Propulsion System checklist

• Fuselage checklist

• Wings and Struts checklist

• Empennage checklist

• Landing Gear checklist

• Cabin and Baggage Compartment checklist

• Inspection Completion checklist

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Condition inspection checklist

Aircraft Model / Serial Number

Registration Number

Owner´s Name

Inspector´s Name

Date of Inspection

Engine Model / Serial Number

Airframe Hours

Engine Hours

TL – 3000 Sirius /

/

Condition inspection checklist

Inspection Item

Aircraft logbooks. Determine total times, times since overhaul and time since last required or recommended maintenance and record on Inspection Coversheet

Safety Directives (SD´s), Airworthiness Directives

(AD´s) and Service Bulletins. Check SD´s, AD´s, and

Service Bulletins which may need to be complied within the inspection.

Aircraft records. Check for presence and condition of aircraft federal registration form and airworthiness certificate.

Pilot´s Operating Handbook (POH). Make sure that the last revisions of POH, the Equipment List and

Weight and Balance forms are in use.

50 hour 100 hour Annual

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Run-up checklist

Type of Inspection

ELT battery due (if applicabe):

Altimeter/Transponder test due (if applicabe):

Strobe lights test due (if applicabe):

Systems

Starter

Oil pressure (PSI)

Brakes

Instrument and Avionics

Navigation and position lights test

(if applicabe)

Cabin light test (if applicabe)

Ignition ground test (See Chapter of the

Operator´s Manual for all versions of ROTAX)

Oil temperature (°F)

WARNING

WARNING

RNING

Cabin heat

Idle RPM

WARNING

WARNING

RNING

All exterior lights are off

Check for fuel odors in cabin

Check for fuel stains on floor

Check fuel valve off function

50 hour 100 hour Annual

Pre - inspection

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Post - inspection

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Post – Run - up checklist

Inspection Item

Flight controls. Check for smooth operation of all flight controls with flaps in retracted and extended positions.

Flight controls. Check controls within entire range for binding, play, and unusual sounds.

Wash clean and vacuum the aircraft. See Washing and

Cleaning Checklist.

Aircraft exterior. Examine the entire aircraft exterior surface for damage, deformation or abrasion.

Fairings, access panels, seats, carpets, covers, and

spinner. Remove for inspection to ensure access. Check for missing or unscrewed bolts and nuts.


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Propulsion system checklist

Inspection Item

Engine cowlings. Remove and check engine cowlings for signs of heat damage, leaks or cracks.

Engine Compartment. Check all engine compartment components and engine mount for chafing, loose connections, wear, fluid or exhaust leaks.

Cleaning. Clean the engine as required in the

Maintenance Manual for ROTAX Engine Type 912

Series.

Engine. Inspect all systems as required in the

Maintenance Manual for ROTAX Engine Type 912

Series.

Oil cooler. Check oil cooler and radiator for damage or debris.

Cowling ducts. Check cowling ducts for blockage

Engine oil. Check the level of oil and follow the

Operator´s Manual for all versions of ROTAX 912.

Induction system. Check connection of manifold between Air filter box and carburetors. Check for fuel leakage nearby carburetors.

Induction air filter. Inspect for cleanliness and condition of sealing surfaces. Replace filter, if damaged.

Fuel installation. Inspect the fuel installation, hoses, pumps, connections, and supports. Inspect and clean the fuel filters in the engine area.


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Inspection Item

Cabin heater. Check clamps and heater attachments.

Check the manifold for holes and attachments.

Engine mount. Inspect for cracks, corrosion, loose hardware, chafing by cables, wires, hoses, etc., and make sure that any flexing item is secured to the engine mount.

Engine mount bolts. Inspect and check engine mount bolts.

Exhaust system. Check the exhaust springs, the pipe systém and its attachment for leaks, cracks on the exhaust pipe and welds.

Battery attachment. Inspect for security of mounting and condition. Ensure vent holes are clear.

Throttle and choke controls. Check operation of throttle and choke controls.

Spinner. Inspect for cracks, security to propeller. Clean inside of spinner.

Propeller hub. Inspect for cracks, corrosion. Re-torque all mounting bolts, if loos of torque is suspected on any bolt.

Propeller blades. Inspect for play, dents, nicks, craks, corrosion, pitting, and leading odge erosion.

Propeller. Check required inspection items detailed in the technical and operational documents of the propeller manufacturer

Foreign Objects. Check engine compartment for foreign objects.

Fuselage checklist

Inspection Item

Skin surface. Inspect for obvious latent signs of damage, including cracks, holes, buckling. Check drain holes for obstructions. Check condition of paint and cleanliness.

Placards. Inspect for presence and condition.

Windows. Clean Inspect for cleanliness, cracks, condition, and bonding. Check door´s windows vent operating.

Caabin doors. Inspect for operating and fit. Inspect skin, hinges, gas struts, latching mechanisms, and door seals.

Lubricate front and rear latching pins.


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Inspection Item

Static Port. Check static port for evidence of obstructions. Do not apply compressed air to the system, since this will result in damage to the static air flight instruments.

Antennas. Inspect for security and condition.

Aircraft identification tag. Inspect for security and legibility.

Fin. Inspect fin for visible damage and evidence of latent damage.


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Wings and Struts checklist

Inspection Item

Covers. Remove cabin ceiling cover, wing-strut, and fuselage-strut covers in order to struts and wings attachment.

Wings and Struts attachment. Inspect for cracks, corrosion, loose hardware, wings and struts attachment

(bolts, nuts, bearings, tubes and hinges). Lubricate strut´s bearings.

Fuel leaks. Inspect the outer skin tank areas for evidence of fuel stains

Wings. Remove wings.


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200 hours interval

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Fuel tanks. Inspect Check wing leading edge and forward surface of root rib for cracks and fuel leak. Make sure there are no foreign objects within area of the fuel tank. Inspect fuel intake filter for obstruction, the fuel vents, fuel cap, connections for leaks.

Wing and strut skins. Inspect for obvious signs of damage, including cracks, holes, and buckling. Check condition of paint and placards. Check drain holes for obstructions.

Aileron and flaps hinges. Inspect for security of attachment to wing. Inspect bearing for condition.

Lubricate the hinges bearing (see Chapter 2.8).

Ailerons. Inspect skins for damage, looseness, or play in attach bearings, and condition of rod end attachment and lubricate (see Chapter 2.8). Check for obstruction of drain holes.

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Inspection Item

Flaps. Inspect skins for condition and signs of debonding. Check hinges for play and attachment to wing and flap. Check flap rod and rod tips for condition, and lubricate (see Chapter 2.8). Check for obstruction of drain holes.

Flap actuator. Clean and run flaps up and down to check for smooth operation.

Wing interior. Inspect wing spars, ribs and control system attachment through revision holes in the bottom skin of the wing for signs of cracks or debonding. Inspect visible areas of ribs and other structures.

Wings. Assembly wings

Flap deflection. Ensure that flaps extend equally on each side of the airplane in all configurations. Measure the down deflection on each side. The difference in static deflection should not be greater than 1/8 ˝ (3 mm).

Inspect stop switches for operating.

Flight controls. Inspect all push-pull rods, rod end bearings for condition, play, security of attachment and lubricate (see Chapter 2.8). Ensure locking is proper where applicable.

Aileron and flaps hinges. Inspect for security of attachment to wing. Inspect bearing for condition.

Lubricate the hinges bearing (see Chapter 2.8).

Pitot tube. Check condition and pitot tube attachment.

Check cleanness of air inlet holes of pitot tube.


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200 hours interval

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Empennage checklist

Inspection Item

Rudder. Visually check surface condition delaminating, deformation, or cracks. Check suspension and security of the rudder upper/lower hinges. Check attachment and security of rudder cables. Check attachment of rudder bell crank to rudder torque tube.Check for obstruction of drain holes. Check for continuity, full and free travel.

Rudder angles of deflection. Verify rudder angles of deflection.

Rudder lubrication. Lubricate upper rudder hinge (see

Chapter 2.8).


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Inspection Item

Horizontal Stabilizer and Elevator. Inspect for visible damage and evidence of latent damage. Inspect looseness or play in hinges. Check for obstruction of drain holes.

Check suspension and free travel of the elevator.

Elevator angles of deflection. Verify elevator angles of deflection.

Elevator lubrication. Lubricate elevator hinges (see

Chapter 2.8).

Horizontal Stabilizer. Remove aft tail cone and disconnect controls to the tail. Remove horizontal stabilizer. Check for surface corrosion and craks main and rear horizontal stabilizer hinge housings and pins.

Inspect for corrosion, cracks, damage and looseness elevator driver and elevator driver rivets attachments.

Lubricate horizontal stabilizer hinges. Re-install horizontal stabilizer and tail cone.

Trim tab. Check trim tab operation, condition and hinge.

Lubricate hinges (see Chapter 2.8).

Ailerons angles of deflection. Verify ailerons angles of deflection. Check for continuity, full and free travel.

Flight controls. Inspect all push-pull rods, cable, rudder and trim tab control cables, rod end bearings and bellcranks for condition, play, security of attachment and lubricate (see Chapter 2.8).


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Landing Gear

Inspection Item

Visual inspection. Inspect from top to bottom for scratches, cracks, corrosion, signs of overstress and sideloading.

Wheels. Inspect for cracks and corrosion. Check all hardware for signs of loss of torque. Check wheel for free rotation. Inspect tires for splitting, flat spots, wear, and dry-rotting. Check tire pressure, and service as necessary.

Fairings. Ispect for condition, scratches, cracks, and signs of overstress. Clean interior.


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Inspection Item

Wheel bearings. Inspect for damage, wear, and corrosion. Check bearing for play, binding and bearing protection plate for condition. Replace bearings if necessary.

Nose landing gear. Lift up the nose gear and check rotation of the nose gear. Check springs and gas strut of the side vibration damping. Lubricate bearings (see

Chapter 2.8).

Passage screw in nose leg. Check (50 hour) and replace

(100 hour) old screw for new passage screw in milled slot in nose leg.

Nose gear spring. Inspect for binding and unusual noises.

Main landing legs. Remove seats and check condition of landing gear legs and attachment points for cracks or damage.

Hydraulic brake lines. Inspect brake lines. Check for security and evidence of chafing. Check for leaks.

Brake calipers, brake pads and brake discs. Clean and inspect for condition, fluid leakage, for cracks and corrosion, security of components. Inspect brake discs for pitting and signs of overheating. Inspect all hardware for signs of loss of torque. Do not lubricate.

Brake fluid reservoir. Inspect for condition, security, and fluid level. Service, if necessary.


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Cabin and Baggage Compartment

Inspection Item

Seats. Remove seats bases

Seats inspection. Inspect seat structure for general condition and cracks. Inspect cushions and upholstery for condition.

Fire extinguisher. Remove fire extinguisher (if applicable) and inspect.

Safety belts. Inspect belts for wear, cuts, and broken stitching. Check all buckles for proper locking and release. Check belt attachments to structure.

Avionics and instruments. Check general condition, attachment, and function of the instrument panel, instruments, switches and circuit breakers.


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Inspection Item

Magnetics compass. Inspect compass correction card for presence and legibility of all headings. Magnetic tools must not be used during this procedure.

Fuel valve. Inspect for operating and signs of fuel leakage.

Starting carb, fuel pump and ventilation. Check function and condition.

Placards. Inspect for presence and condition of all required interior placards.

Ceiling cover. Check condition and attachment of the ceiling cover.

Rudder pedals. Inspect for security, cracks, and play.

Lubricate

Parking brake. Inspect for security of mounting and signs of leakage.

Upholstery. Inspect for general condition, attachment, and cleanliness.

Baggage compartment. Inspect baggage aera network for condition and attachment. Inspect baggage compartment for cleanliness.

Aircraft Parachute system. Check the condition of the chute handle and safety pin for proper fit. Check for proper clearance and freedom from binding of the chute pull (activation) cable. Check the parachute system in accordance with the manufacturer inspection schedule.

Seats. Instal seats


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Inspection Completion

Inspection Item

Fuselage and wings. Make sure aircraft is free of any tools, parts, and debris, and reinstall all access panels, fairings, seats, and so on, removed for the inspection.

Engine. Verify that there is oil in the oil tank, cooling liquid in the expansion tank and coolant level in overflow bottle take place between min. and max. mark as required by the Operator´s Manual for all versions of ROTAX

912, and engine compartment is free of tools, rags, and debris.

Engine run. Run engine for no more than two minutes at

1400 to 1800. After shutdown, check for leaks at oil filter, and any other components removed during this inspection. Instal cowlings, if no leaks are noted.

Aircraft. Operate engine at 2000 to 2500 RPM to warm it up. Operate all aircraft systems to verify proper operation. As engine warms, operate engine systems at appropriate engine speeds and complete all checks listed on Inspection Coversheet.

Aircraft records. Complete entries in logbooks, AD and

SD compliance lists, and any other required records.


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2.7 Every 300 hour Inspection

This inspection is made after every 300 flight hours, or after five years of operation. The inspection of all stressed parts of the construction is made along with the prescribed repair according to the manufacturer’s guide book.

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The inspection and maintenance include:

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Inspection after 100 hours

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Removing the propeller

Inspection of the construction.

Inspection of the interior of the body and the cabin.

Outer inspection of the entire airframe.

Inspection of the steering components.

Replacement of parts.

A flight test by the pilot.

CAUTION

This inspection is typically made by the manufacturer’s service center or a repair station.

2.8 Alterations or Major repairs

WARNING

Any alterations or major repairs to the airplane must be approved in writing by the aircraft manufacturer. See Chapter 1, General Information, for more details.

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2.9 Lubrication program figures

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SECTION 3

STRUCTURES


Section 3 describes the structure, subsystems and work to be completed in the removal and installation of subsystems and parts drawings specific to the Sirius. Some equipment described in this section may not apply to all Sirius serial numbers.

3.2 Wing

The wing of TL-3000 Sirius consists of right and left wings (made of carbon and fiberglass parts bonded together with structural epoxy resin) and left and right struts.

The wing is attached to the fuselage by two hinges with bolts located in the cabin.

Struts are attached to the wing and to the fuselage by bolts too.

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The wing structure includes the skins (upper and lower), main and rear spar, fuel tank, and ribs. The hinges for aeileron and flap are attached to the lower skin and rear spar along the trailing edge. The aileron and flap control rods runs between the spars. Two fuel filler caps are on the upper wing surface. Two access panels are located on the lower skin of the wing, and inspection holes are in the rear spar and in the root rib. The upper and lower skins are made of epoxy/carbon fiber and foam core. The spar caps of the main spar are made of epoxy/carbon fiber and the spar web is of epoxy/glass fiber and foam core. The rear spar and the ribs are made of epoxy/glass fiber and foam core.

The strut consists of the metal tube with the hinges and composite aerodynamic skin.

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3.2.1. Wings Installation

To install the wings requires two - three persons.

Contact TL-ULTRALIGHT or an authorized dealer for the instructions on wing installation, if installing a replacement wing, or a repaired wing.



Task Specific

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Can be completed only by a responsible individual, which has received TL-

ULTRALIGHT Airplane Operation

Training.

Tools Required

Wrench 10,13,16,17 (1pcs)

Allen wrench 5 (1pcs)

Socket wrench 10,13,16 (1pcs)

Screwdriver (1pcs)

Torque wrench (1pcs)

Cradles for the wings

Self-locking nuts VM5, 6, 8, 10 (3 pcs,


2pcs, 2pcs, 6 pcs)

Plastic grease Mogul G3

F-900 Torque seal

Wings Installation Checklist

1) Aircraft parking. Prior to installation set the aircraft on the parking brake and remove any obstacle within 16ft area from the fuselage.

2) Lubricating. Lubricate all metal details with plastic grease before connecting: Main wing spar suspens. case [s200_577_00-1] with bolt (2 x), Rear wing spar suspens. case [s200_578_00-

1] with bolt (2 x), Struts end hinge bearings with bolts (4 x) and bearings and bolts on the inner pullrod assembly bearings (2 x)

Pos. Part

1 Main wing spar suspens. case

2 Rear wing spar suspens. case

3 Inner pullrod assembly bearing 6

4 Struts end hinge bearing 10

Part number / Norm

s200_577_00-1 s200_578_00-1

ČSN 02 3512

ČSN 02 3512

3 - 3

3) Aerodynamic struts covers. Slip on the struts the Strut – fuselage covers [s200_577_00-1] and Wing – strut covers [s200_577_00-1].

Pos.

1 Strut

2 Wing – strut cover

Part

3 Strut – fuselage cover


s810_000_00-1 s810_300_00-1 s810_400_00-1

4) Fuselage – struts connecting. Fix the bottom struts bearings in the Strut – fuselage fittings

[s200_810_00-1] (2x left and right) with the bolt M10x50 DIN 912. Use only new self-locking nuts VM10.

3 - 4

Pos. Part

1 Strut – fuselage fitting

2 Strut

3 Strut – fuselage cover

4 Screw M10 x 50

5 Washer M10

6 Self – locking nut VM 10


s200_810_00-1 s810_000_00-1 s810_400_00-1

DIN 912

ČSN 02 1721

DIN 980

CAUTION

Keep the struts position. Strut mount with indications arising from the dismantling of the wings.

3 - 5

5) Wing assembly. Put the wing with the hinges into the fuselage holes with clearance aprox.

0.12 ft betweem the fuselage and the wing root rib. Run all fuel hoses and electrical wires into the cabin. Then push the wing into the fuselage.

CAUTION

Keep holding the wing tip or use the cradles for the wings until the strut is conected. Do not touch the transparency wing tip light cover.

3 - 6

.

6) Main and rear pins connection . Fix the main and rear wing hinges to the fuselage with the bolts M10x50 DIN 912 and M8x50 DIN 912. Use only new self-locking nuts VM10 and VM8.

3 - 7

.

Pos.

1 Screw M10 x 50

2 Screw M8 x 32

Part

3 Washer M8

4 Washer M10




DIN 912

DIN 912

ČSN 02 1721

ČSN 02 1721

DIN 980

DIN 980

3 - 8

7) Wing – strut connecting . Fix the upper struts bearings in the Wing – strut fitting

[s110_430_00-1] with the bolt M10x50 DIN 912. Use only new self-locking nuts VM10.

Pos.

1 Wing - strut fitting

Part

2 Strut

3 Wing - strut cover

4 Screw M10 x 50

5 Washer M10



s110_430_00-1 s810_000_00-1 s810_300_00-1

DIN 912

ČSN 02 1721

DIN 980

3 - 9

8) Wing connection control. Note that the screws can be set properly into the bushings by moving of the wing back and forth and up and down.

3 - 10

9) Connecting ailerons control. Fix the Wing inner pullrod assembly [s523_400_00-1] in the

Upper lever pillar assembly [s522_800_00-1] with the screw M6 x 27 DIN 912. Use only new self-locking nuts VM6. Check ailerons deflection.

Pos.

1 Screw M6 x 27

2 Washer M6

Part Part number / Norm

DIN 912

ČSN 02 1721

3 Washer 15 x 6,2 x 0,5


Fabory

DIN 980

Angles of deflection of the aileron are to within the range as follows (± 5 mm / ± 0.2 in).

3 - 11

10) Fuselage-to-wing wiring. Connect all fuselage-to-wing wiring, i.e. connect the flaps actuator, position and strobe lights socket and plug.

11) Fuselage-to-wing grounding. Connect fuselage-to-wing grounding wire.

3 - 12

12) Fuel feed line. Connect the fuel feed line from the wing to the fuselage, i.e. set the fuel hose onto the pipe, having the 12 mm clamp on it. Attach the fuel hose by the 12 mm clamp.

Pos.

1 Fuselage pipe

2 Fuel hose

3 12 mm clamp


-

FUB 386 PN 12bar DN 8

W4 12 Typ Cobra

13) Pitot lines connection. Connect the Pitot lines between the wing and the fuselage, i.e. insert hose jumper into the Pitot lines hoses (for the left wing only).

3 - 13

14) Second wing. Repeat the same previous steps on the second wing.

15) Flaps drive in the fuselage. Link the flaps drive in the wings in the fuselage, i.e. insert

Flaps drive in the fuselage assembly. Match groove on the Flap drive tenon [s541_620_00-1] with the screw M5 x 27 DIN 912 on the Short and Long tube [TR20x1-72 (42 4201.61) and

TR20x1-960 (42 4201.61)]. Keep the flaps drive position. Flaps drive in the fuselage mount with indications arising from the dismantling of the wings. Do not forget on Flaps drive in the fuselage slip center plastic bearing bushing [s542_310_00-1] (see step 18).

Pos.

1 Flap drive tenon

Part

2 Flap drive joint in the fuselage

3 Short tube

4 Long tube

5 Screw M5 x 27


s541_620_00-1 s542_200_00-1

TR20x1–72 (42 4201.61)

TR20x1–960 (42 4201.61)

DIN 912

3 - 14

16) Flaps drive in the fuselage fixing. Fix the Long tube [TR20x1-72 (42 4201.61)] in the Flap drive joint in the fuselage [s542_200_00-1] with the screw M5 x 27 DIN 912. Use only new self-locking nuts VM5.

3 - 15

Pos. Part

1 Flap drive joint in the fuselage

2 Long tube

3 Screw M5 x 27



s542_200_00-1

TR20x1–960 (42 4201.61)

DIN 912

DIN 980

17) Flaps drive screws tightening. Tighten two screws M5 x 27 DIN 912 fixing the Flap drive tenon [s541_620_00-1] and Short and Long tube [TR20x1-72 (42 4201.61) and TR20x1-960 (42

4201.61)]. Use only new self-locking nuts VM5. Torque value for the bolts is only 40 lb-in (4.5

N.m).

18) Center plastic bearning. Instal center plastic bearning assembly, i.e. fix center plastic bearing assembly on the cabin ceiling with the screw M5 x 20 PN 02009 (see schema below).

Lubricate the Center plastic bushing (plastic grease Mogul G3).

3 - 16

Pos. Part

1 Center plastic bearing bushing

2 Center plastic bearing socket

3 Center plastic bearing distance

4 Long tube

5 Screw M5 x 20


s542_310_00-1 s542_320_00-1 s542_330_00-1

TR20x1–960 (42 4201.61)

PN 02009

19) Flaps deflection. Ensure that flaps equally on each side of the airplane in all configurations.

Measure the down deflection on each side. The difference in static deflection should not be greater than 1/8 ˝ (3 mm). Inspect stop switches for operating. Inspect all flaps drive line for vibration and free travel.

3 - 17

20) Securing bolted connections. Secure all bolted connections by the F-900 Torque seal.

21) Canopy ceiling cover. Fix on the Velcro the Ceiling cover – laminate [s200_661_00-1].

Ceiling panel board with the switches and radio run through the hole in the ceiling laminate cover (if is ceiling panel board applicable).

3 - 18

22) Fuel gauge installation. Instal left and right fuel tank fuel gauges, i.e. fix Inner part of the fuel gauge [s200_663_20-1] and Outer part of the fuel gauge [s200_663_30-1] on the Ceiling cover – laminate [s200_661_00-1] with four screws M4 x 12 DIN 965 Zn (insert Fuel gauge transparency cylinder [s200_663_10-1] to the assembly).

Pos. Part

1 Ceiling cover - laminate

2 Fuel gauge transparency cylinder

3 Inner part of the fuel gauge

4 Outer part of the fuel gauge

5 Screw M4 x 12


s200_661_00-1 s200_663_10-1 s200_663_20-1 s200_663_30-1

DIN 965 Zn

3 - 19

23) Canopy ceiling cover fixation. Fix Ceiling cover – laminate [s200_661_00-1] with teen slotted mushroom head screws M4 x 12 (905624).

24) Canopy ceiling cover fixation. Fix Ceiling panel board with switches a radio on the Ceiling cover - laminate [s200_661_00-1] with seven black colored phil. pan head machine screws M4 x

12 DIN 7985 (if is ceiling panel board applicable).

3 - 20

25) Pillar inspection holes covers. Close four inspection holes in the pillar using holes covers.

Fix inspection holes covers on the pillar with screws M2,9 x 10 DIN 7981 Zn (two screws per cover).

3 - 21

26) Aerodynamic struts covers fixation. Fix Strut – fuselage covers [s200_577_00-1] and

Wing – strut covers [s200_577_00-1] on the fuselage and wing with slotted mushroom head screws M4 x 12 (905624).

3.2.2. Wings Removal

Drain all the fuel from the wings and fuel lines. The process of draining the aircraft should be performed in a ventilated area with fire precautions taken.

The rest of the wing removal process goes in reverse to the wings installation process.

During the wings removal make indications arising of interchangeable parts, so when the subsequent assembly was assembled in the correct position (struts, Flaps drive).

3.2.3. Verification Required

Make sure the main bolts are not loose (do not rotate).

Check fuselage and wings for foreign objects.

3 - 22

3.3 Empennage

Sirius empennage consists of a vertical fin with a rudder and horizontal tail. The fin makes up a one piece composite structure with the fuselage and therefore is not considered within this section.

Horizontal tail consists of stabilizer, elevators and trim tab.

3 - 23

3.3.1. Horizontal tail Installation

To installation the horizontal tail requires two person.



Task Specific

Tools Required


Line

L/O, RI, RM, A& P

Can be completed only by a responsible individual, which has received

TL-ULTRALIGHT Airplane Operation

Training.


Socket wrench 5,5 ,8,10 (1pcs)

Screwdriver (1pcs)


Safety wire 0.032“ diameter

Self-locking nuts VM3 (2 pcs)


F-900 Torque seal

Horizontal tail Installation Checklist

1) Aircraft parking. Prior to installation set the aircraft on the parking brake and remove any obstacle within 8ft area from the rear part of fuselage.

2) Lubricating. Lubricate all metal main and rear hinges interfaces with plastic grease before connecting: Elevator main hinge pin [s200_584_00-1] (2 x), Main hinge case [s316_000_00-1]

(2 x), Rear hinge case [s317_000_00-1] and bearing and bolt on the Elevator drive

[s323_000_00-1] .

3 - 24

Pos. Part

1 Elevator main hinge pin

2 Main hinge case

3 Rear hinge case

4 Elevator drive bearing 6


s200_584_00-1 s316_000_00-1 s317_000_00-1

ČSN 02 3512

3) Horizontal tail assembly. Put the Horizontal tail with the Main hinge cases [s316_000_00-1] on Elevator main hinge pins [s200_584_00-1] located in the rear part of fuselage. Then push the horizontal tail forward to the stop face on the main hinge pins.

Pos.

1 Fuselage

Part

2 Front vertical fin bulkhead


s200_000_00-1 s200_582_00-1

3 Elevator main hinge pin

4 Horizontal tail

5 Stabilizator main spar

6 Main hinge case s200_584_00-1 s300_000_00-1 s312_000_00-1 s316_000_00-1

3 - 25

CAUTION

Do not press or do not support any objets on the horizontal stabilizer and rear part of the fuselage skins, as the laminate surface is not proportioned for high area force.

3 - 26

4) Rear horizontal tail hinge. Fix the Horizontal tail [s300_000_00-1] on the fuselage

[s200_000_00-1] with the screw M8 x 87 DIN 912 and wedge Stabilizator washer

[s340_000_00-1]. Secure the screw by the stainless safety wire having diameter of 0.032“.

Pos.

1 Horizontal tail

2 Stabilizator washer

Part

3 Screw M8 x 87

4 Safety wire


s300_000_00-1 s340_000_00-1

DIN 912

0.032“ diameter

3 - 27

5) Elevator control connection. Fix the Rear pullrod assembly [s518_000_00-1] in the Elevator drive [s323_000_00-1] with the screw M6 x 27 DIN 912. Use only castle nut M6 with the cotter pin 1,6.

Pos.

1 Elevator drive

Part

2 Rear pullrod assembly

3 Screw M6 x 27

4 Washer M6

5 Castle nut M6

6 Cotter pin 1,6


s323_000_00-1 s518_000_00-1

DIN 912

ČSN 02 1721

ČSN 02 1411

ČSN 02 1781

3 - 28

6) Elevator deflection. Check angles of deflection of the elevator to within the range as follows

(± 5 mm / ± 0.2 in).

7) Fuselage-to-rudder wiring. Connect all fuselage-to-rudder wiring, i.e. connect the position lights sockets and plug. Fix wires to the bottom skin of the stabilizator. Inspect elevator for free travel.

3 - 29

8) Trim bushing holders. Fix the Trim bushing holder - B [s562_000_00-1] on the bottom skin of the Stabilizator [s310_000_00-1] with two screws M5 x 12 ISO 4014. Fix the Trim bushing holder - C [s563_000_00-1] on the root rib of the Left elevator [s321_000_00-1] with two screws M5 x 12 ISO 4014.

Pos.

1 Stabilizator

2 Left elevator

Part

3 Trim bushing holder - B

4 Trim bushing holder - C

5 Screw M5 x 12


s310_000_00-1 s321_000_00-1 s562_000_00-1 s563_000_00-1

ISO 4014

9) Trim tab control connection. Connect the Trim tab lever [s565_000_00-1] with Trim forks

[MPJ M3], i.e. fix the Trim tab lever [s565_000_00-1] on the Trim forks [MPJ M3] on the end of the trim cable with phil. pan head machine screws M3 x 10 DIN 7985. Use only new selflocking nuts VM3.

3 - 30

Pos.

1 Left elevator

2 Trim tab

3 Trim tab lever

4 Trim cabel

Part

5 Trim fork

6 Phil. pan head machine screws M3 x 10

7 Washer M3



s321_000_00-1 s330_000_00-1 s565_000_00-1 s567_000_00-1

MPJ M3

DIN 7985

ČSN 02 1721

DIN 980

3 - 31

10) Trim tab deflection. Check angles of deflection of the Trim tab. Check Trim tab neutral position. Inspect Trim tab for free travel.

11) Tail cone cover. Fix Tail cone cover [s200_410_00-1] on the fuselage with twelve slotted mushroom head screws M4 x 12 (905624).

3 - 32

3.3.2. Horizontal tail Removal

The rest of the horizontal tail removal process goes in reverse to the horizontal tail installation process.

3.3.3. Elevator Installation

To installation the elevator requires two person.



Task Specific

Line

L/O, RI, RM, A& P



Training.

Tools Required



Socket wrench 8, 10 (1pcs)

Screwdriver (1pcs)




F-900 Torque seal

Elevator Installation Checklist

1) Aircraft parking. Prior to installation set the aircraft on the parking brake and remove any obstacle within 8ft area from the rear part of fuselage if you mount elevator on the aircraft with fixed stabilizator. If you install elevator on non – on the fuselage fixed stabilizator, put stabilizator on the cradles.

2) Lubricating. Lubricate all elevator hinges (on the stabilizator and elevator) with plastic grease before connecting: Elevator hinges [s315_000_00-1 and s321_500_00-1] and bearing and bolt on the Elevator drive [s323_000_00-1] .

3 - 33

Pos.

1 Elevator hinge

2 Elevator hinge

3 Elevator drive


s315_000_00-1 s321_500_00-1 s323_000_00-1

3) Elevator assembly. Insert the elevator [s320_000_00-1] with the hinges into the stabilizator

[s310_000_00-1] from the back side.

Pos.

1 Stabilizator

2 Elevator


s310_000_00-1 s320_000_00-1

4) Elevator assembly. Fix the Elevator [s565_000_00-1] on the Stabilizator with four screws

M6 x 40 DIN 912 and two screws M6 x 30 DIN 912. Use only castle nut M6 with the cotter pin

1,6.

Pos. Part Part number / Norm

1

2

Screw M6 x 30

Screw M6 x 40

3 Washer M6

4 Castle nut M6

5 Cotter pin 1,6

DIN 912

DIN 912

ČSN 02 1721

ČSN 02 1411

ČSN 02 1781

3 - 34

3 - 35

5) Elevator control connection. Fix the Rear pullrod assembly [s518_000_00-1] in the Elevator drive [s323_000_00-1] with the screw M6 x 27 DIN 912. Use only castle nut M6 with the cotter pin 1,6.

Pos.

1 Elevator drive

Part

2 Rear pullrod assembly

3 Screw M6 x 27

4 Washer M6

5 Castle nut M6

6 Cotter pin 1,6


s323_000_00-1 s518_000_00-1

DIN 912

ČSN 02 1721

ČSN 02 1411

ČSN 02 1781

3 - 36

6) Elevator deflection. Check angles of deflection of the elevator to within the range as follows

(± 5 mm / ± 0.2 in).


3 - 37

8) Trim bushing holders. Fix the Trim bushing holder - B [s562_000_00-1] on the bottom skin of the Stabilizator [s310_000_00-1] with two screws M5 x 12 ISO 4014. Fix the Trim bushing holder - C [s563_000_00-1] on the root rib of the Left elevator [s321_000_00-1] with two screws M5 x 12 ISO 4014.

Pos.

1 Stabilizator

2 Left elevator

Part

3 Trim bushing holder - B

4 Trim bushing holder - C

5 Screw M5 x 12


s310_000_00-1 s321_000_00-1 s562_000_00-1 s563_000_00-1

ISO 4014

9) Trim tab control connection. Connect the Trim tab lever [s565_000_00-1] with Trim forks

[MPJ M3], i.e. fix the Trim tab lever [s565_000_00-1] on the Trim forks [MPJ M3] on the end of the trim cable with phil. pan head machine screws M3 x 10 DIN 7985. Use only new selflocking nuts VM3.

3 - 38

Pos.

1 Left elevator

2 Trim tab

3 Trim tab lever

4 Trim cabel

Part

5 Trim fork

6 Phil. pan head machine screw M3 x 10

7 Washer M3



s321_000_00-1 s330_000_00-1 s565_000_00-1 s567_000_00-1

MPJ M3

DIN 7985

ČSN 02 1721

DIN 980

3 - 39

10) Trim tab deflection. Check angles of deflection of the Trim tab. Check Trim tab neutral position. Inspect Trim tab for free travel.


3 - 40

3.3.4. Elevator Removal

The rest of the elevator removal process goes in reverse to the wings installation process.

3.3.5. Verification Required (horizontal tail and elevator)


Check fuselage and horizontal tail for foreign objects.

Check elevator and trim tab for free travel.

Secure all bolted connections by the F-900 Torque seal.

3.3.6. Rudder Installation

– partially adjustable foot pedals version

This chapter is intended only for aircraft equipped with older versions of partially adjustable pedals. These pedals are shown in the following figure. If the airplane is equipped with another type of pedals see chapter 3.3.7.

To installation the rudder requires two person.

3 - 41



Task Specific

Tools Required


Line

L/O, RI, RM, A& P



Training.


Socket wrench 10 (1pcs)

Screwdriver (1pcs)


Hook for rudder springs (1pcs)



F-900 Torque seal

Rudder Installation Checklist – partially adjustable foot pedals version


2) Lubricating. Lubricate rudder upper and bottom hinges with plastic grease before connecting: Bottom mounting axis [s213_100_00-1], bearing on the Upper rudder hinge

[s214_100_00-1] and Upper rudder pin [s214_200_00-1] .

Pos. Part

1 Bottom mounting axis

2 Upper rudder hinge

3 Upper rudder pin


s213_100_00-1 s214_100_00-1 s214_200_00-1

3 - 42

3) Rudder assembly. Slip the Small spacer [s213_200_00-1] on the Bottom mounting axis

[s213_100_00-1]. Put the Rudder [s210_000_00-1] on the Fuselage inserting the Bottom mounting axis [s213_100_00-1] to the ball bearing [ZKL 6002] in the Bottom suspension

[s213_300_00-1]. Then upper rudder attachement, i.e. slip the Upper rudder pin [s214_200_00-

1] on the bearing in the Upper rudder hinge [s214_100_00-1].

3 - 43

Pos.

1 Rudder

Part


3 Small spacer


5 Upper rudder pin


s210_000_00-1 s213_100_00-1 s213_200_00-1 s214_100_00-1 s214_200_00-1

4) Rudder balance beam assembly. Slip the Big spacer [s213_400_00-1] on the Bottom mounting axis [s213_100_00-1]. Fix the Rudder balance beam [s213_500_00-1] on the Bottom mounting axis [s213_100_00-1] with screw M6 x 30 DIN 912. Use only new self-locking nuts

VM6.

3 - 44

Pos. Part


2 Big spacer

3 Rudder balance beam

4 Screw M6 x 30

5 Washer M6



s213_100_00-1 s213_400_00-1 s213_500_00-1

DIN 912

ČSN 02 1721

DIN 980

CAUTION

During the assembly don´t damage the fuselage – to – rudder wiring inside the Bottom mounting axis (especially when inserting the screw M6 x 30).

5) Rudder spring connection. Connect two Rudder springs [s533_000_00-1] to the Pedal leg assembly [s531_300_00-1], i.e. hook the Rudder springs [s533_000_00-1] into the holes on the levers of the Pedal leg assembly [s531_300_00-1]. Use hook for rudder springs.

3 - 45

Pos.

1 Pedal leg assembly


s531_300_00-1

2 Rudder spring s533_000_00-1


7) Rudder deflection. Check angles of deflection of the Rudder to within the range 20° left and right (± 10 mm / ± 0.4 in). Inspect Rudder for free travel.


3 - 46


10) Central console front covers. Install left and right central console front covers with black phil. pan head machine screw M4 x 12 DIN 7985.

3 - 47

Pos.

1 Central console

Part

2 Right central console front cover


s200_630_00-1

-

3.3.7. Rudder Installation

– full adjustable foot pedals version

This chapter is intended only for aircraft equipped with newer versions of full adjustable pedals. These pedals are shown in the following figure. If the airplane is equipped with another type of pedals see chapter 3.3.6.

3 - 48

To installation the rudder requires two person.



Task Specific

Tools Required


Line

L/O, RI, RM, A& P



Training.



Screwdriver (1pcs)


Hook for rudder springs (1pcs)



F-900 Torque seal

Rudder Installation Checklist – full adjustable foot pedals version


2) Lubricating. Lubricate rudder upper and bottom hinges with plastic grease before connecting: Bottom mounting axis [s213_100_00-1], bearing on the Upper rudder hinge

[s214_100_00-1] and Upper rudder pin [s214_200_00-1] .

Pos. Part



3 Upper rudder pin


s213_100_00-1 s214_100_00-1 s214_200_00-1

3 - 49

3) Rudder assembly. Slip the Small spacer [s213_200_00-1] on the Bottom mounting axis

[s213_100_00-1]. Put the Rudder [s210_000_00-1] on the Fuselage inserting the Bottom mounting axis [s213_100_00-1] to the ball bearing [ZKL 6002] in the Bottom suspension

[s213_300_00-1]. Then upper rudder attachement, i.e. slip the Upper rudder pin [s214_200_00-

1] on the bearing in the Upper rudder hinge [s214_100_00-1].

3 - 50

Pos.

1 Rudder

Part


3 Small spacer


s210_000_00-1 s213_100_00-1 s213_200_00-1


5 Upper rudder pin s214_100_00-1 s214_200_00-1

4) Rudder balance beam assembly. Slip the Big spacer [s213_400_00-1] on the Bottom mounting axis [s213_100_00-1]. Fix the Rudder balance beam [s213_500_00-1] on the Bottom mounting axis [s213_100_00-1] with screw M6 x 30 DIN 912. Use only new self-locking nuts

VM6.

3 - 51

Pos. Part


2 Big spacer

3 Rudder balance beam

4 Screw M6 x 30

5 Washer M6



s213_100_00-1 s213_400_00-1 s213_500_00-1

DIN 912

ČSN 02 1721

DIN 980

CAUTION

During the assembly don´t damage the fuselage – to – rudder wiring inside the Bottom mounting axis (especially when inserting the screw M6 x 30).

5) Rudder spring connection. Connect two Rudder springs [sn533_000_00-1] to the fuelage

Bulkhead, i.e. hook two Rudder springs [sn533_000_00-1] into the eyes of the holders on the fuselage Bulkhead. Use hook for rudder springs.

3 - 52

6) Nose leg connection strainers. Use two Turnbuckles assembly for applyings a tension in the

Cables connecting the Nose leg. Secure the Turnbuckle barrels and Turnbuckle cable eye via the safety wire (see chapter 3.14.3.)

CAUTION

Datums of the Nose gear and Rudder must be parallel in the neutral position.

3 - 53

7) Foot pedals connection strainers. Use for Turnbuckles assembly for applyings a tension in the Cables connecting the Foot pedals and rudder control system. The Turnbuckles assemblies are situated behind the crew seats. Secure the Turnbuckle barrels and Turnbuckle cable eye via the safety wire (see chapter 3.14.3.)

CAUTION

All the Foot pedal legs must be parallel in the neutral position.

3 - 54


9) Rudder deflection. Check angles of deflection of the Rudder to within the range 20° left and right (± 10 mm / ± 0.4 in). Inspect Rudder for free travel.



3 - 55


3 - 56

Pos. Part

1 Central console



s200_630_00-1

-

3.3.8. Rudder Removal

The rest of the rudder removal process goes in reverse to the rudder installation process (chapter 3.3.6 or 3.3.7).

3.3.9. Verification Required (rudder)


Check fuselage for foreign objects.

Check elevator, trim tab and rudder for free travel.


3 - 57

3.4 Landing Gear

TL - 3000 is equipped with conventional tricycle landing gear. The main gear legs made of carbon and glass fiber composite are attached to the undercarriage bulkhead trestle located under the pilot seats. The nose gear is equipped with a shock absorber and attached to the firewall.

There are existing two variants of the undercarriage which differ from undercarriage wheels. First variant has its nose gear and main gear wheels with dimension 400 x 100 mm. The nose gear is non-steerable and it is equipped with shimmy dumper.

Second variant has its nose gear wheel smaller than first variant, the diameter of nose gear wheel is 11 x 4 and main gear wheels have dimension 15 x 6. This nose gear is steerable by steel cabels connected to the rudder pedal system.

3 - 58

Both undercarriage options have different type of laminate wheel covers. It is not possible to combine these two undercarriage variants.

CAUTION

First of all, it is necessary to recognize the undercarriage version of your aircraft in order to follow all instructions related to your type of undercarriage that are described in this AMM.

3.4.1. Nose gear Installation

– 400 x 100 mm wheel

To installation the nose gear requires two person.



Task Specific

Tools Required

Line

L/O, RI, RM, A& P

Can be completed only by a responsible individual, which has received TLultralight Airplane Operation Training.

Allen wrench 5, 6 (1pcs)


Screwdriver (1pcs)


Support for the fuselage

3 - 59

3 – 59


Self-locking nuts VM6, 8 (1 pcs, 3 pcs)


F-900 Torque seal

Nose gear Installation Checklist – 400 x 100 mm wheel

1) Preparation. Before starting, set the parking brake. Check wheel version. The size of the front wheel must be 400 x 100 mm. If the size of the front wheel is 11 x 4 see chapter 3.4.2.

Remove cowlings, make sure the tail area is clear. Lift the forward fuselage by pushing down the tail at the over horizontal tail main hinge so that is possible insert the support under engine mount firewall attachement. Insert the support securely under engine mount firewall attachement.

2) Lubricating. Lubricate all metal surfaces with plastic grease before connecting: Bearning on the Upper attachement [s424_000_00-1] , bearings and Bottom suspension case [s423_200_00-

1] on the bottom attachement and inner tube surface of the Fork [s422_100_00-1] .

3 - 60

Pos.

1 Fork

Part

2 Bottom suspension case

3 Upper attachement

4 Upper attachement bearing 6


s422_100_00-1 s423_200_00-1 s424_000_00-1

ČSN 02 3512

3) Nose gear tube installation. Slide in the Nose gear tube [s424_000_00-1] from the bottom side. Don´t forget to install the Ball bearing [ZKL 51108A] under the Bottom attachement

[s423_000_00-1] and Roll bearing [ZINTM - 2435], Balance spacer [s428_000_00-1], Balance beam [s427_100_00-1] into the area above Bottom attachement [s423_000_00-1]. Under the

Upper attachement [s424_000_00-1] insert the Upper distance ring [s429_000_00-1].

3 - 61

Pos.

1 Nose gear tube

Part

2 Bottom attachement

3 Balance beam

4 Balance spacer

5 Upper distance ring

6 Ball bearing

7 Roll bearing


s421_000_00-1 s423_000_00-1 s427_100_00-1 s428_000_00-1 s429_000_00-1

ZKL 51108A

ZINTM - 2435

3 - 62

CAUTION

The balance beam must be situated into the arm position in direction to the front and down (see photo). If proceeded other way round the springs would not tense properly and the nose gear system could be blocked in the outer position due spring slipping away.

3 - 63

4) Mounting the Balance beam screw. Fix the Balance beam [s427_100_00-1] on the Nose gear tube [s421_000_00-1] with screw M6 x 55 DIN 912. Use only new self-locking nuts VM6.

Pos.

1 Nose gear tube

Part


3 Balance beam

4 Balance spacer

5 Screw M6 x 55

6 Washer M6



s421_000_00-1 s423_000_00-1 s427_100_00-1 s428_000_00-1

DIN 912

ČSN 02 1721

DIN 980

3 - 64

5) Mounting the screw of nose gear deflection stop. Install the screw M8 x 15 DIN 912 to the

Nose gear tube [s421_000_00-1]. Screw is located in the slot on the front face of Bottom attachement [s423_000_00-1].

Pos.

1 Nose gear tube

Part


3 Screw M8 x 15


s421_000_00-1 s423_000_00-1

DIN 912

3 - 65

6) Mounting the nut of Upper attachement. Install the self – locking nut VM8 DIN 980 with washer of Upper attachement of nose gear. Use only new self-locking nuts VM8. Proceed this installation from pilot area which was developed by dismounting the Central console front covers.

Pos.

1 Nose gear tube

Part


3 Washer M8



s421_000_00-1 s423_000_00-1

ČSN 02 1721

DIN 980

CAUTION

Make sure that nothing falls into the aircraft control system. Check control system inside central console for free parts.

3 - 66


Pos.

1 Central console

Part



s200_630_00-1

-

8) Connecting the Dumper. Fix the piston of the Dumper TOBY [15Cy40] on the Balance beam [s427_100_00-1] with screw M8 x 32 ISO 4014. Use only new self-locking nuts VM8.

After connecting make sure that when Nose gear tube [s421_000_00-1] is turning into the outer deflections (up to the stop) that the piston is not sliding out from the dumper.

Pos.

1 Balance beam


s427_100_00-1

2

3

4

5

6

Dumper TOBY

Screw M8 x 32

Washer M8

Washer M8

Self – locking nut VM 8

15Cy40

ISO 4014

ČSN 02 1721

DIN 9021

DIN 980

3 - 67

3 - 68

9) Shimmy springs installation. Pull on the pair of Shimmy springs. Springs must be pulled from Adjustable eye for spring [s427_300_00-1] on the engine mount and the other side of springs must by pulled on into the hole in the Balance beam [s427_100_00-1].

Pos.

1 Balance beam

Part

2 Adjustable eye for spring

3 Shimmy spring


s427_100_00-1 s427_300_00-1

-

3 - 69

CAUTION

Springs must be pulled on as shown on following photos. The spring must be pulled on with eye interruped part in direction down. Otherwise the spring could be dragged. Consequently it is necessary to centre the zero position of the nose leg. The length of of spring (from eye to eye) must be 100 mm (the measurement is described in the following pictures) and the leg must be freely returning back itself into zero position. After connecting check the nose leg function, make sure that springs are not being lossed (dragged).

3 - 70

10) Nose gear fork installation. Fix the Nose gear fork [s422_000_00-1] on the Nose gear tube

[s421_000_00-1] slot with screw M8 x 55 DIN 912. Use only new self-locking nuts VM8.

Check the Nose gear spring [s422_600_00-1] and Spring insert inside Fork [s422_100_00-1] presence.

Pos.

1 Nose gear tube

2 Nose gear fork

3 Screw M8 x 55

Part

4 Washer M8



s421_000_00-1 s422_000_00-1

DIN 912

ČSN 02 1721

DIN 980

3 - 71


12) Cowlings installation. Check engine area for free parts and install cowlings.

13) Nose gear control. After finishing the installation check the correct function and behaviour of nose gear while taxing.

3.4.2. Nose gear Installation

– 11 x 4 wheel

To installation the nose gear requires two person.



Task Specific

Tools Required


Line

L/O, RI, RM, A& P



Training.

Allen wrench 5, 6 (1pcs)


Screwdriver (1pcs)



Self-locking nuts VM6, 8 (1 pcs, 2 pcs)


F-900 Torque seal

Nose gear Installation Checklist – 11 x 4 wheel

1) Preparation. Before starting, set the parking brake. Check wheel version. The size of the front wheel must be 11 x 4. If the size of the front wheel is 400 x 100 mm see chapter 3.4.1.

Remove cowlings, make sure the tail area is clear. Lift the forward fuselage by pushing down the tail at the over horizontal tail main hinge so that is possible insert the support under engine mount firewall attachement. Insert the support securely under engine mount firewall attachement.

3 - 72

2) Lubricating. Lubricate all metal surfaces with plastic grease before connecting: Bearning on the Upper attachement [s424_000_00-1] , bearings and Bottom suspension case [s423_200_00-

1] on the bottom attachement and inner tube surface of the Fork [s422_100_00-1] .

Pos.

1 Fork

2

3

4

Part

Bottom suspension case

Upper attachement

Upper attachement bearing 6


S4-220_000_00-1 s423_200_00-1 s424_000_00-1

ČSN 02 3512

3 - 73

3) Nose gear tube installation. Slide in the Nose gear tube [S4-220_000_00-1] from the bottom side. Don´t forget to install the Ball bearing [ZKL 51108A] under the Bottom attachement

[s423_000_00-1] and Roll bearing [ZINTM - 2435], Balance spacer [S4-260_000_00-1],

Balance beam [S4-250_000_00-1] into the area above Bottom attachement [s423_000_00-1].

Under the Upper attachement [s424_000_00-1] insert the Upper distance ring [s429_000_00-1].

Pos.

1 Nose gear tube

Part



s421_000_00-1 s423_000_00-1

3 Balance beam

4 Balance spacer

5 Upper distance ring

6 Ball bearing

7 Roll bearing

S4-250_000_00-1

S4-260_000_00-1 s429_000_00-1

ZKL 51108A

ZINTM - 2435

3 - 74

4) Mounting the Balance beam screw. Fix the Balance beam [ S4-250_000_00-1] on the Nose gear tube [s421_000_00-1] with screw M6 x 55 DIN 912. Use only new self-locking nuts VM6.

3 - 75

Pos.

1

2

3

4

5

6

Nose gear tube

Balance beam

Balance spacer

Screw M6 x 55

Washer M6

Part



s421_000_00-1

S4-250_000_00-1

S4-260_000_00-1

DIN 912

ČSN 02 1721

DIN 980

5) Nose leg strainers connection. Fix the Balance beam [ S4-250_000_00-1] to the Rudder system cables (to two Turnbuckles assembly) via two M6 x 20 screws. Use only M6 Castle nuts and M6 washers. Then secure the castle nuts with a cotter pins.

3 - 76

Pos.

1 Nose gear tube

2 Balance beam

Part

3 Turnbuckles assembly / U – end eye

4 Screw M6 x 20

5 Washer M6

6 Castle nut M 6

7 Cotter pin


s421_000_00-1

S4-250_000_00-1

-

DIN 912

ČSN 02 1721

ČSN 02 1411

-

6) Nose leg connection strainers. Use two Turnbuckles assembly for applyings a tension in the

Cables connecting the Nose leg. Secure the Turnbuckle barrels and Turnbuckle cable eye via the safety wire (see chapter 3.14.3.)

3 - 77

CAUTION

Datums of the Nose gear and Rudder must be parallel in the neutral position.

7) Mounting the nut of Upper attachement. Install the self – locking nut VM8 DIN 980 with washer of Upper attachement of nose gear. Use only new self-locking nuts VM8. Proceed this installation from pilot area which was developed by dismounting the Central console front covers.

3 - 78

Pos.

1 Nose gear tube

Part


3 Washer M8



s421_000_00-1 s423_000_00-1

ČSN 02 1721

DIN 980

CAUTION

Make sure that nothing falls into the aircraft control system. Check control system inside central console for free parts.

After connecting make sure that when Nose gear tube [s421_000_00-1] is free turning in the ball bearings into the pedals assembly deflections range (up to the stop).


Pos.

1 Central console

Part



s200_630_00-1

-

3 - 79

9) Nose gear fork installation. Fix the Nose gear fork [S4-220_000_00-1] on the Nose gear tube [s421_000_00-1] slot with screw M8 x 55 DIN 912. Use only new self-locking nuts VM8.

Check the Nose gear spring [s422_600_00-1] and Spring insert inside Fork [S4-220_000_00-1] presence.

Pos.

1 Nose gear tube

2 Nose gear fork

Part

3 Screw M8 x 55

4 Washer M8



s421_000_00-1

S4-220_000_00-1

DIN 912

ČSN 02 1721

DIN 980

3 - 80


11) Cowlings installation. Check engine area for free parts and install cowlings.

12) Nose gear control. After finishing the installation check the correct function and behaviour of nose gear while taxing.

3.4.3. Nose gear Removal

The rest of the nose gear removal process goes in reverse to the nose gear installation process.

Before starting the Nose gear Removal process execute step 1. of Nose gear

Installation Checklist.

3.4.4. Nose gear Bottom attachement Installation

To installation the bottom attachement requires two person.



Task Specific

Tools Required

Line

L/O, RI, RM, A& P



Training.


Combination wrench 10 (1pcs)

Screwdriver (1pcs)






F-900 Torque seal

Bottom attachement Installation Checklist

1) Preparation. Before starting, set the parking brake. Remove cowlings, make sure the tail area is clear. Lift the forward fuselage by pushing down the tail at the over horizontal tail main hinge so that is possible insert the support under engine mount firewall attachement. Insert the support securely under engine mount firewall attachement (see pictures in step 1. of the Nose gear

Installation Checklist).

3 - 81

2) Central console front covers removing. Remove left and right central console front covers fixed by black phil. pan head machine screw M4 x 12 DIN 7985.

Pos.

1 Central console

Part



s200_630_00-1

-

3) Bottom attachement installation. Fix the Bottom attachement [s423_000_00-1] on the fuselage with six screws M6 x 22 ISO 4014. Use only new self-locking nuts VM6. Proceed this installation from pilot area (nuts and washers) which was developed by dismounting the Central console front covers.

Pos. Part


2 Screw M6 x 22

3 Washer M6



s423_000_00-1

ISO 4014

ČSN 02 1721

DIN 980

3 - 82

3 - 83

4) Central console front covers. Install back left and right central console front covers with black phil. pan head machine screw M4 x 12 DIN 7985.

NOTE

If you follow the installation the Nose gear according Chapter 3.4.1 or 3.4.2., do not apply this step.

3.4.5. Nose gear Bottom attachement Removal

The rest of the bottom attachement removal process goes in reverse to the bottom attachement installation process.

Before starting the Bottom attachement Removal process execute step 1. of Nose gear


3.4.6. Nose wheel Installation

– 400 x 100 mm wheel

To installation the nose wheel requires one person.



Task Specific

Tools Required

Line

L/O, RI, RM, A& P



Training.



Screwdriver (1pcs)






F-900 Torque seal

Nose wheel Installation Checklist – 400 x 100 mm wheel

1) Preparation. Before starting, set the parking brake. Remove cowlings, make sure the tail area is clear. Lift the forward fuselage by pushing down the tail at the over horizontal tail main hinge so that is possible insert the support under engine mount firewall attachement. Insert the support securely under engine mount firewall attachement.

3 - 84

2) Nose wheel installation. Install the Wheel [s422_200_00-1] on the Fork [s422_100_00-1], i.e. insert the Wheel [s422_200_00-1] with the Nose gear insert [s422_400_00-1], Nose gear distance spacers [s422_500_00-1] and Ball bearings [ZKL 6303] to the Fork [s422_100_00-1].

Assembly connect with Nose gear axis [s422_300_00-1], self – locking nuts VM 12 DIN 980 and washers M12 ČSN 02 1721. Use only new self-locking nuts VM12.

Pos.

1 Fork

2 Wheel 400 x 100

3 Nose gear axis

Part

4 Nose gear insert

5 Nose gear distance spacer

6 Washer M12


8 Ball bearing


s422_100_00-1 s422_200_00-1 s422_300_00-1 s422_400_00-1 s422_500_00-1

ČSN 02 1721

DIN 980

ZKL 6303

3 - 85

3) Bottom part of wheel pant. Install the Bottom part of wheel pant [s426_200_00-1] on the

Upper part of wheel pant [s426_100_00-1] with slotted mushroom head screws M4 x 12

(905624). Use F-900 Torque seal for screw connections.

3 - 86

Pos. Part

1 Upper part of wheel pant

2 Bottom part of wheel pant


s426_100_00-1 s426_200_00-1

4) Nose wheel control. Note that the nose wheel can be freely rotating and is sufficient clearance between the wheel pant and the nose wheel. Check tire pressure.

3.4.7. Nose wheel Installation

– 11 x 4 wheel

To installation the nose wheel requires one person.



Task Specific

Tools Required


Line

L/O, RI, RM, A& P



Training.


Screwdriver or allen wrench (1pcs)



F-900 Torque seal

3 - 87

Nose wheel Installation Checklist – 11 x 4 wheel

1) Preparation. Before starting, set the parking brake. Remove cowlings, make sure the tail area is clear. Lift the forward fuselage by pushing down the tail at the over horizontal tail main hinge so that is possible insert the support under engine mount firewall attachement. Insert the support securely under engine mount firewall attachement.

2) Nose wheel installation. Install the Wheel [S4-221_000_00-1] on the Fork [S4-224_000_00-

1], i.e. insert the Wheel [S4-221_000_00-1] with the Middle nose gear insert [S4-222_400_00-

1], Small and Big nose gear distance spacers [S4-222_200_00-1 and S4-222_300_00-1] to the

Fork [S4-224_000_00-1]. Assembly connect with Nose gear axis [S4-222_100_00-1], Nose wheel washer [S4-222_500_00-1] and two Nose wheel axis screws [S4-222_600_00-1].

3 - 88

Pos.

1 Wheel 11 x 4

Part

2 Nose gear axis

3 Small nose gear distance spacer

4 Big nose gear distance spacer

5 Middle nose gear insert

6 Nose wheel washer

7 Nose wheel axis screw

8 Nose wheel fork

9 Ball bearing 55 x 13

10 Ball bearing 47 x 12


S4-221_000_00-1

S4-222_100_00-1

S4-222_200_00-1

S4-222_300_00-1

S4-222_400_00-1

S4-222_500_00-1

S4-222_600_00-1

S4-224_000_00-1

6006 – 2RSR

6005 – 2RSR

3) Nose wheel pant. Install the composite Nose wheel pant [S4-227_000_00-1] on the Nose wheel fork assembly with four slotted mushroom head screws M4 x 12 or four round head screws M4 x 12 with hex socket. Use F-900 Torque seal for screw connections.

CAUTION

The rubber friction element on the Nose wheel fork assembly must be situated on the left side of the aircraft (see picture).

3 - 89

4) Tire inflation hole cover. Check tire pressure. Install the plastic Tire inflation hole cover on the Nose wheel pant [S4-227_000_00-1].

5) Nose wheel control. Note that the nose wheel can be freely rotating and is sufficient clearance between the wheel pant and the nose wheel.

3.4.8. Nose wheel Removal

The rest of the nose wheel removal process goes in reverse to the nose wheel installation process.

Before starting the Nose wheel Removal process execute step 1. of Nose gear


3 - 90

3.4.9. Main wheel assembly Installation

– 400 x 100 mm wheels

To installation the main wheel assembly requires two person.



Task Specific

Tools Required


Line

L/O, RI, RM, A& P



Training.

Socket wrench 10, 13, 24 (1pcs, 1pcs,

1pcs)


Screwdriver (1pcs)


Support for the wing

Modified self – locking nut M16 (1 pcs)


F-900 Torque seal

Main wheel assembly Installation Checklist – 400 x 100 mm wheels

1) Preparation. Before starting, set the parking brake. Set the chocks under the wheels to prevent plane´s rolling. Lift up the wing where the main spar is located and put the support under the wing (where the strut connection is located).

CAUTION

Use only soft surface of the support for the wing. Do not touch the transparency wing tip light cover.

3 - 91

2) Main wheel assembly completation. Assemble the Main wheel assembly (see 3 steps on next images).

3 - 92

Pos. Part

1 Braked wheel 400 x 100

2 Brake disc

3 Brake disc spacer

4 Main wheel axle

5 Main wheel spacer

6 Main wheel bearing spacer

7 Main wheel pant spacer


s411_210_00-1 s411_220_00-1 s411_230_00-1 s411_240_00-1 s411_250_00-1 s411_260_00-1 s411_270_00-1

8 Brake caliper AIP

9 Screw M6 x 14

-

ISO 7380 – 10.9ZN

10

11

12

13

14

Screw M8 x 40

Screw M8 x 16B

Washer M6

Washer M8

Washer M12

15 Ball bearing

3) Installation Inner part of wheel pant. Put the Inner part of wheel pant [s411_520_00-1] on the Main undercarriage leg [s411_100_00-1]. Put the hose of the brake system on the slot in the

Inner part of wheel pant [s411_520_00-1].

DIN 912

DIN 7991 – 8.8ZN

ČSN 02 1721

ČSN 02 1721

ČSN 02 1721

ZVL 6004

Pos. Part

1 Main undercarriage leg

2 Inner part of wheel pant


s411_100_00-1 s411_520_00-1

3 - 93

4) Brake system connection. Connect the hose of the brake system to the Brake caliper [AIP].

Brake caliper is located in the Main wheel assembly. Use F-900 Torque seal.


-

-

Pos.

1 Brake caliper AIP

Part

2 Hose of the brake system

5) Main wheel assembly installation. Fix the Main wheel assembly [s411_200_00-1] on the

Main undercarriage leg [s411_100_00-1]. Install the Main gear wedge washer [s411_400_00-1] between the Main wheel assembly [s411_200_00-1] and Main undercarriage leg [s411_100_00-

1]. Use only new self-locking nut VM8 and Modified nut M16 [s411_700_00-1].

Pos. Part


2 Main wheel assembly

3 Main gear wedge washer

4 Main wheel axis washer

5 Modified nut M16

6 Screw M8 x 60

7 Washer M8



s411_100_00-1 s411_200_00-1 s411_400_00-1 s411_600_00-1 s411_700_00-1

DIN 912

ČSN 02 1721

DIN 980

3 - 94

6) Filling Brake system with Fluid. Fill the Brake system with Fluid. See Chapter 3.4.16.

7) Outer part of wheel pant. Install the Outer part of wheel pant [s411_510_00-1] on the Inner part of wheel pant [s411_520_00-1] with slotted mushroom head screws M4 x 12 (905624) and screw M6 x 22 DIN 912. Use F-900 Torque seal for screw connections.

Pos.

1

2

3

4

5

Screw M6 x 22

Washer M6

Part

Main wheel pant spacer

Outer part of wheel pant

Inner part of wheel pant


s411_270_00-1 s411_510_00-1 s411_510_00-1

DIN 912

ČSN 02 1721

3 - 95

3 - 96

3.4.10. Main wheel assembly Installation

– 15 x 6 wheels

To installation the main wheel assembly requires two person.



Task Specific

Tools Required


Line

L/O, RI, RM, A& P



Training.

Socket wrench 10, 13 (1pcs, 1pcs)

Allen wrench 6 (1 pcs)


Screwdriver (1pcs)




F-900 Torque seal

1 mm diameter wire

Main wheel assembly Installation Checklist – 15 x 6 wheels


CAUTION


3 - 97

2) Installation Inner part of wheel pant. Put the Inner part of wheel pant [sn411_520_00-1] on the Main undercarriage leg [s411_100_00-1]. Put the hose of the brake system on the slot in the

Inner part of wheel pant [sn411_520_00-1].

Pos. Part




s411_100_00-1 sn411_520_00-1

3) Main wheel axis assembly completation. Assemble the Main wheel axis assembly with

Brake caliper assembly [sn411_220_00-1] and fix it on the Main undercarriage leg

[s411_100_00-1]. Fix the Brake caliper assembly [sn411_220_00-1] on the Main wheel axis

[sn411_240_00-1] via M6 x 20 screw in the first step. Then attach the Main wheel axis

[sn411_240_00-1], Wedge washer [sn411_230_00-1] and Centering pin [sn411_260_00-1] on the Main undercarriage leg [s411_100_00-1] via M8 x 60 (top pair) and M8 x 65 (lower pair) screws with four Self-locking nuts VM8 (4 pcs) and M8 washers (4 pcs). Use only new selflocking nut VM8.

Pos. Part


2 Brake caliper assembly

3 Wedge washer


s411_100_00-1 sn411_220_00-1 sn411_230_00-1

4 Main wheel axis

5 Centering pin

6 Screw M6 x 20 (flat head)

7 Screw M8 x 60 (cap head) sn411_240_00-1 sn411_260_00-1

DIN 7991

DIN 912

3 - 98

Pos. Part

8 Screw M8 x 65 (cap head)

9 Washer M 8

10 Self-locking nut VM8


DIN 912

ČSN 02 1721

DIN 980

3 - 99

4) Main wheel installation. Put the Brake disc [sn411_250_00-1] between the inner and outer brake pads. Then slide the Main wheel [sn411_210_00-1] on the main wheel axis

[sn411_240_00-1]. Secure the main wheel [sn411_210_00-1] on the axis [sn411_240_00-1] via the Main wheel nut [sn411_270_00-1], Main wheel spacer [sn411_280_00-1] and Cotter pin.

Part Pos.

1 Main wheel

2 Main wheel axis

3 Brake disc


sn411_210_00-1 sn411_240_00-1 sn411_250_00-1

4 Main wheel nut

5 Main wheel spacer

6 Cotter pin 2 x 30 sn411_270_00-1 sn411_280_00-1

ČSN 02 1781

5) Brake disc securing. Secure the Brake disc [sn411_250_00-1] in the main wheel hub via 1 mm diameter wire. Install the securing wire to the slot in the inner part of the main wheel hub.

Check that the Brake disc [sn411_250_00-1] is freely sliding in the space between the brake pads.

3 - 100

6) Filling Brake system with Fluid. Fill the Brake system with Fluid. See Chapter 3.4.17.

7) Completion of Inner part of wheel pant installation. Fix the Inner part of wheel pant to the

Centering pin [sn411_260_00-1] via screw M6 x 16 with washer M6. Use F-900 Torque seal.

Pos.

1 Centering pin

Part


3 Screw M6 x 16

4 Washer M 6


sn411_260_00-1 sn411_520_00-1

ISO 4018

ČSN 02 1721

3 - 101

8) Outer part of wheel pant. Install the Outer part of wheel pant [sn411_510_00-1] on the

Inner part of wheel pant [sn411_520_00-1] with slotted mushroom head screws M4 x 12

(905624), the Wheel pant distance spacer [sn411_300_00-1], washers M6 and screw M6 x 50

ISO 4018. Use F-900 Torque seal for screw connections.

Pos. Part

1 Wheel pant distance spacer

2 Outer part of wheel pant

3 Screw M6 x 50

5 Washer M6


sn411_300_00-1 sn411_510_00-1

ISO 4018

ČSN 02 1721

3 - 102

9) Tire inflation hole cover. Check tire pressure. Install the plastic Tire inflation hole cover on the Outer part of wheel pant [sn411_510_00-1].

10) Main undercariage wheel control. Note that the main wheel can be freely rotating and is sufficient clearance between the wheel pant and the nose wheel. Check function of braking system.

3.4.11. Main wheel assembly Removal

The rest of the Main wheel assembly removal process goes in reverse to the Main wheel assembly installation process (without step no. 6).

3 - 103

Before starting the Main wheel assembly Removal process execute step 1. of Main wheel assembly Installation Checklist.

After disconnection the line of the Brake system prevent draining of brake liquid out of the hose by plugging it up.

3.4.12. Main undercarriage leg Installation

To installation the main undercarriage leg requires two person.

Contact TL-ULTRALIGHT or an authorized dealer for the instructions on main undercarriage leg installation, if installing a replacement main undercarriage leg, or a repaired main undercarriage leg.



Task Specific

Tools Required

Line

L/O, RI, RM, A& P



Training.


Screwdriver (1pcs)




Main undercarriage leg Installation Checklist

F-900 Torque seal


CAUTION


3 - 104

2) Seat removal. Remove the Back seat [s200_621_00-1] and the Bottom seat [s200_622_00-1] over installed main undercarriage leg. See chapter 3.4.13.

3) Main undercarriage leg installation. Insert the Main undercarriage leg [s411_100_00-1] to the main undercarriage leg cases in the Fuselage.

Pos.

1 Fuselage

Part



s200_000_00-1 s411_100_00-1

3 - 105

4) Main undercarriage leg fixation. Fix the Main undercarriage leg [s411_100_00-1] on the

Inner main undercarriage leg case in the Fuselage with Screw M8 x 50 DIN 912. Self-locking nuts VM8 are laminated under the Inner main undercarriage leg case in the Fuselage.

Pos. Part


2 Inner main undercarriage leg case in fusel.

3 Laminated nut VM 8

4 Screw M8 x 50

5 Washer M8


s411_100_00-1

-

-

DIN 912

ČSN 02 1721

3 - 106

5) Undercarriage cover installation. Put the Undercarriage cover – left [s200_431_00-1] or

Undercarriage cover – right [s200_432_00-1] on the Main undercarriage leg [s411_100_00-1].

Fix the Undercarriage cover – left [s200_431_00-1] or Undercarriage cover – right

[s200_432_00-1] on the Fuselage [s200_000_00-1] with slotted mushroom head screws M4 x 12

(905624).

Pos.

1 Fuselage

Part

2 Undercarriage cover - left



s200_000_00-1 s200_431_00-1 s411_100_00-1

3.4.13. Main undercarriage leg Removal

The rest of the Main undercarriage leg removal process goes in reverse to the Main undercarriage leg installation process.

Before starting the Main undercarriage leg Removal process execute Main wheel assembly Removal (see chapter 3.4.11).

Before starting the Main undercarriage leg Removal process execute step 1. of Main undercarriage leg installation Checklist.

3.4.14. Verification Required (Landing gear)


3 - 107

Check fuselage and wheel pants for foreign objects.

Check wheels for free travel.


3.4.15. Brake system description

The aircraft has two single-rotor, hydraulically-actuated brakes located on the main landing gear, one on each wheel. Each brake is connected to a brake piston cylinder attached to the toe pedals of the rudder pedals. When the operator presses the left brake pedal, hydraulic pressure is sent down hydraulic line to the left wheel brake pads, which in turn press on both sides of the rotor. The same process also applies the right brake pedal pressure to the right brake rotor.

There are existing two variants of the brake system differ from undercarriage wheels

(brake calipers) and foot pedals. First (early) variant has its main gear wheels with dimension 400 x 100 mm with AJP type brake calipers. This brake system version use partially adjustable foot pedals and brake fluid reservoir is located directly on the pedals assembly.

3 - 108

Brake system (early variant with partially adjustable foot pedals and 400 x 100 mm wheels, AJP brake calpers):

Second (late) variant has its main gear wheels with dimension 15 x 6 with TL type brake calipers. This brake system version use full adjustable foot pedals and brake fluid reservoir is located directly on the pedals assembly or on the firewall (from the engine side).

3 - 109

Brake system (late variant with full adjustable foot pedals and 15 x 6 wheels, TL brake calipers):

Both variants of the braking system may be equipped with a parking brake, which is located under the crew seat.

3 - 110

CAUTION

Use only the correct type of brake fluid. If are mounted the master cylinders AJP or TL type on the pedal assembly, use DOT 4 brake fluid. When are used the brake master cylinders MATCO type, use DOT 5 brake fluid (see the following figures).

3.4.16. Filling Brake System with Fluid

– 400 x 100 mm wheels

To filling Brake System with Fluid requires one person.



Task Specific

Tools Required


Line

L/O, RI, RM, A& P



Training.


Socket wrench 8, 10 (1 pcs, 1pcs)

Screwdriver (1pcs)


Auxiliary tank


Bottle with the stand for brake fluid


F-900 Torque seal

DOT 4 Brake fluid (if AJP brake cylinders are used)

Filling Brake system with Fluid Checklist – 400 x 100 mm wheels

3 - 111

1) Preparation. Before starting, set the chocks under the wheels to prevent plane´s rolling.

Visually check the system for integrity and tightness. Make sure the aircraft is not set on parking brake, i.e. the parking brake valve is open and the handle of the valve is aligned to aircraft longitudinal axle.

2) Outer part of wheel pant Removing. Remove the Outer part of wheel pant [s411_510_00-1] from the Inner part of wheel pant [s411_520_00-1] .Outer part of wheel pant [s411_510_00-1] is fixed with slotted mushroom head screws M4 x 12 (905624) and screw M6 x 22 DIN 912.

Pos. Part



s411_270_00-1



4

5

Screw M6 x 22

Washer M6 s411_510_00-1 s411_510_00-1

DIN 912

ČSN 02 1721

3 - 112

3) Seats Removing. Remove left and right Bottom seats [s200_622_00-1]. See chapter 3.9.3

for instructions

4) Brake line interruption. Disconnect hoses joints under the crew seats. Blind disconnected hoses.

5) Bottle with the stand for brake fluid connection. Connect hose line from the bottle with the stand for brake fluid to the Brake fluid bottle assembly [s531_700_00-1] on the Foot pedal assembly [s531_200_00-1] (left pilot side for the left wheel line or right pilot side for the right wheel line). Bottle on the stand must be filled by brake fluid and this bottle must be the highest point of the system.

Pos. Part

1 Foot pedal assembly

2 Brake fluid bottle assembly

3 Brake fluid

4 Bottle with the stand for brake fluid

5 Hose line for brake fluid


s531_200_00-1 s531_700_00-1

DOT 4

-

-

CAUTION

Brake fluid is an aggressive substance, be careful avoid the contact with composite structure and cabin upholstery, otherwise it would damage them.

3 - 113

6) Left pedal brake cylinder venting. Remove the Brake cylinder [AJP 128.00.052C] with the

Brake fluid bottle assembly [s531_700_00-1] from the Foot pedal assembly [s531_200_00-1]

(left pilot side for the left wheel line or right pilot side for the right wheel line). Remove blanking from disconnected hoses (blinded in step 4) and hoses end insert into the auxiliary tank so that the brake fluid can freely flow from Bottle on the stand through the brake cylinders on the pedals to the auxiliary tank situated under the crew seats. Let the brake fluid to flow through the removed brake cylinder and by tilting with the brake cylinder to different positions try to remove any air bubbles from the Brake cylinder. Several times press on the brake toe pedal and try to remove any air bubbles form the brake line. Then install the Brake cylinder [AJP

128.00.052C] back on the Foot pedal assembly [s531_200_00-1]. Use only new self-locking nut

VM6.

Pos.

1

2

Foot pedal assembly

Brake cylinder

3 Screw M6 x 22

4 Washer M6

5

Part



s531_200_00-1

AJP 128.00.052C

DIN 912

ČSN 02 1721

DIN 980

3 - 114

7) Right pedal brake cylinder venting. Remove the Brake cylinder [AJP 128.00.052C] without the Brake fluid bottle assembly [s531_700_00-1] from the Foot pedal assembly [s531_200_00-

1] (right pilot side for the left wheel line or left pilot side for the right wheel line). Remove blanking from disconnected hoses (blinded in step 4) and hoses end insert into the auxiliary tank so that the brake fluid can freely flow from Bottle on the stand through the brake cylinders on the pedals to the auxiliary tank situated under the crew seats. Let the brake fluid to flow through the removed brake cylinder and by tilting with the brake cylinder to different positions try to remove any air bubbles from the Brake cylinder. Several times press on the brake toe pedals and try to remove any air bubbles form the brake line.Then install the Brake cylinder [AJP

128.00.052C] back on the Foot pedal assembly [s531_200_00-1]. Use only new self-locking nut

VM6.

Pos. Part


2 Brake cylinder

3 Screw M6 x 22

4 Washer M6



s531_200_00-1

AJP 128.00.052C

DIN 912

ČSN 02 1721

DIN 980

3 - 115

8) Parking brake venting. Remove the Parking brake [Aignep 100302] from the fuselage bulkhead. Remove blanking from disconnected hoses (blinded in step 4) and hoses end insert into the auxiliary tank so that the brake fluid can freely flow from Bottle on the stand through the brake cylinders on the pedals and Parking brake to the auxiliary tank situated under the crew seats. Let the brake fluid to flow through the removed Parking brake cylinder and by tilting with the Parking brake cylinder to different positions try to remove any air bubbles from the Parking brake cylinder. Several press on the brake toe pedals and try to remove any air bubbles form the brake line. Then install the Parking brake cylinder [Aignep 100302] back to the fuselage.

Pos.

1 Fuselage


s200_000_00-1

2 Parking brake

3 Screw M4 x 12

Aignep 100302

DIN 7985

NOTE

Parking brake is situated only in the line for the left main wheel.

3 - 116

NOTE

Completion of this step is ventinged braking system part from brake cylinders to the end of the disconnected hose.

9) Hose blinding. Under the crew seats location blind the brake system hose leading from the parking brake cylinder [Aignep 100302] .

10) Bottle with the stand for brake fluid connection. Connect hose line from the bottle with the stand for brake fluid to under crew seat disconnected Brake line leading to the main wheel

Brake caliper [AJP] (left pilot side for the left wheel line or right pilot side for the right wheel line). Bottle on the stand must be filled by brake fluid and this bottle must be the highest point of the system.

Pos.

2 Brake fluid

Part

1 Brake system line (from disconnected hose to the wheel Brake caliper)


-

3

4


Hose line for brake fluid

DOT 4 (if AJP brake cylinders are used)

-

-

3 - 117

11) Wheel brake system line venting. Remove the Drain bolt M8 from the Brake caliper [AJP] and let the brake fluid freely flow from Bottle on the stand to the auxiliary tank situated under the Brake caliper drain bolt M8. By tilting with the Brake caliper cylinder [AJP] to different positions try to remove any air bubbles from the Brake caliper.

NOTE

Brake caliper [AJP] is fixed on the wheel assembly. To remove air bubbles is possible gently tilt the aircraft. If this method fails to remove all air bubbles from the Brake caliper is necessary to remove the wheel assembly [s411_200_00-1] (see Chapter 3.4.8.) and just tilt with it.

Then install the Brake caliper drain bolt M8 back on the Brake caliper [AJP].

Pos.

1 Brake caliper

Part

2 Brake caliper drain bolt M8


AJP

-

3 - 118

12) Brake line connection. Connect back hoses joints under the crew seats.

3 - 119

NOTE

During this operation protect both hoses line against intrusion of air bubbles. If during the hoses connection penetrated air bubbles, remove them.

13) Bottle with the stand for brake fluid connection. Connect hose line from the bottle with the stand for brake fluid to the Brake fluid bottle assembly [s531_700_00-1] on the Foot pedal assembly [s531_200_00-1] (left pilot side for the left wheel line or right pilot side for the right wheel line). Bottle on the stand must be filled by brake fluid and this bottle must be the highest point of the systém (see step 5). Remove the Drain bolt M8 from the Brake caliper [AJP] and let again the brake fluid freely flow from Bottle on the stand trough the brake systém line to the auxiliary tank situated under the Brake caliper drain bolt M8. Several times press on the brake toe pedals. Then install back the Brake caliper drain bolt M8 and remove bottle with the stand system.

14) Brake system function verification. Check the Brake system function. Check the Parking brake system function. Visually check the system for integrity and tightness.

15) Seats and wheel pants installation. Install back the Outer part of wheel pant

[s411_510_00-1], left and right Bottom seats [s200_622_00-1]. Use F-900 Torque seal for wheel pant screw connections.

NOTE

Repeat on the other side of the brake system (Second main wheel brake system).

3.4.17. Filling Brake System with Fluid

– 15 x 6 wheels

To filling Brake System with Fluid requires one person.



Task Specific

Line

L/O, RI, RM, A& P



Training.

3 - 120

Tools Required



Socket wrench 10, 13, 32 (1 pcs, 1pcs,

1pcs)

Screwdriver (1pcs)


Auxiliary tank



Self-locking nuts VM6, VM 8 (8 pcs, 8 pcs)

F-900 Torque seal

1 mm diameter wire

DOT 4 or DOT 5 Brake fluid (see page 3 -

111)

Filling Brake system with Fluid Checklist – 15 x 6 wheels


Visually check the system for integrity and tightness. Make sure the aircraft is not set on parking brake, i.e. the parking brake valve is open and the handle of the valve is aligned to aircraft longitudinal axle.

2) Outer part of wheel pant. Remove the Outer part of wheel pant [sn411_510_00-1] from the

Inner part of wheel pant [sn411_520_00-1] The Outer part of wheel pant [sn411_510_00-1] is fixed with slotted mushroom head screws M4 x 12 (905624), the Wheel pant distance spacer

[sn411_300_00-1], washers M6 and screw M6 x 50 ISO 4018.

Pos. Part



3 Screw M6 x 50

4 Washer M6


sn411_300_00-1 sn411_510_00-1

ISO 4018

ČSN 02 1721

3 - 121

3) Brake line interruption. Disconnect hoses joints under the wheel pant. Blind disconnected hoses.

4) Wing support. Lift up the wing where the main spar is located and put the support under the wing (where the strut connection is located).

CAUTION


3 - 122

5) Inner part of wheel pant removal. Remove the Inner part of wheel pant [sn411_520_00-1], which is fixed to the Centering pin [sn411_260_00-1] via screw M6 x 16 with washer M6.

Pos.

1 Centering pin

Part


3 Screw M6 x 16

4 Washer M 6


sn411_260_00-1 sn411_520_00-1

ISO 4018

ČSN 02 1721

6) Brake disc releasing. Release the Brake disc [sn411_250_00-1] in the main wheel hub removing 1 mm diameter wire.

7) Main wheel removal. Remove the Main wheel [sn411_210_00-1] and the Brake disc

[sn411_250_00-1] from the main wheel axis [sn411_240_00-1]. The main wheel

[sn411_210_00-1] is fixed via the Main wheel nut [sn411_270_00-1], Main wheel spacer

[sn411_280_00-1] and Cotter pin on the axis [sn411_240_00-1].

Pos.

1 Main wheel

2 Main wheel axis


sn411_210_00-1 sn411_240_00-1

3 Brake disc

4 Main wheel nut

5 Main wheel spacer

6 Cotter pin 2 x 30 sn411_250_00-1 sn411_270_00-1 sn411_280_00-1

ČSN 02 1781

3 - 123

8) Brake caliper assembly removal. Remove the Main wheel axis assembly with Brake caliper assembly [sn411_220_00-1] from the Main undercarriage leg [s411_100_00-1]. The Main wheel axis [sn411_240_00-1] is attached via M8 x 60 (top pair) and M8 x 65 (lower pair) screws with four Self-locking nuts VM8 (4 pcs) and M8 washers (4 pcs).

3 - 124

Pos.

1

Part

Brake caliper and Main wheel axis assembly

2 Centering pin



5 Washer M 8

6 Self-locking nut VM8


sn411_220_00-1 and sn411_240_00-1 sn411_260_00-1

DIN 912

DIN 912

ČSN 02 1721

DIN 980

9) Brake fluid filling. Fill brake fluid to the Brake fluid reservoir (bottle) on the Firewall (on the left side) or directly on the foot pedal assembly. Brake fluid reservoir is the highest point of the system. Use only the correct type of brake fluid. If are mounted the master cylinders AJP or TL type on the pedal assembly, use DOT 4 brake fluid. When are used the brake master cylinders

MATCO type, use DOT 5 brake fluid (see page 3 – 111).

Brake fluid reservoir on the foot pedal assembly Brake fluid reservoir on the Firewall

CAUTION

Brake fluid is an aggressive substance, be careful avoid the contact with composite structure and cabin upholstery, otherwise it would damage them.

3 - 125

10) Left pedal brake cylinder venting. Remove the Brake cylinder from the left Foot pedal assembly (left pilot side for the left wheel line or right pilot side for the right wheel line).

Remove blanking from disconnected hoses (blinded in step 3) and hoses end insert into the auxiliary tank so that the brake fluid can freely flow from Brake fluid reservoir through the brake cylinders on the pedals to the auxiliary tank situated under the disconnected hose. Let the brake fluid to flow through the removed brake cylinder and by tilting with the brake cylinder to different positions try to remove any air bubbles from the Brake cylinder. Several times press on the brake toe pedal and try to remove any air bubbles form the brake line. Then install the Brake cylinder back on the Foot pedal assembly. Use only new self-locking nut VM6.

Pos. Part


2 Brake cylinder

3 Screw M6 x 25

4 Washer M6



S4-100_000_00-1

AJP / TL / MATCO

DIN 912

ČSN 02 1721

DIN 980

11) Right pedal brake cylinder venting. Remove the Brake from the right Foot pedal assembly

(right pilot side for the left right line or left pilot side for the left wheel line). Remove blanking from disconnected hoses (blinded in step 3) and hoses end insert into the auxiliary tank so that the brake fluid can freely flow from Brake fluid reservoir through the brake cylinders on the pedals to the auxiliary tank situated under the disconnected hose. Let the brake fluid to flow through the removed brake cylinder and by tilting with the brake cylinder to different positions try to remove any air bubbles from the Brake cylinder. Several times press on the brake toe pedals and try to remove any air bubbles form the brake line. Then install the Brake cylinder back on the Foot pedal assembly. Use only new self-locking nut VM6. Blind disconnected hoses under the wheel pant (see step 3).

3 - 126

12) Bottle with the stand for brake fluid connection. Connect hose line from the bottle with the stand for brake fluid to under wheel pant disconnected Brake line leading to the main wheel

Brake caliper assembly [sn411_220_00-1] (left pilot side for the left wheel line or right pilot side for the right wheel line). The Main wheel axis assembly with Brake caliper assembly

[sn411_220_00-1] was removed in step 8 from the Main undercarriage leg [s411_100_00-1] and now you can freely manipulate the entire assembly. Bottle on the stand must be filled by brake fluid and this bottle must be the highest point of the system.

13) Wheel brake system line venting. Remove the Drain bolt M8 [sn411_226_00-1] from the

Brake caliper assembly [sn411_220_00-1] and let the brake fluid freely flow from Bottle on the stand to the auxiliary tank situated under the Brake caliper drain bolt M8. By tilting with the

Brake caliper cylinder to different positions try to remove any air bubbles from the Brake caliper. Then install back the Drain bolt M8 [sn411_226_00-1], disconect hose line from Bottle on the stand and blind hoses.

Pos. Part Part number / Norm

1 Brake caliper and Main wheel axis assembly

2 Drain bolt M8

3 Bottle on the stand sn411_220_00-1 and sn411_240_00-1 sn411_226_00-1

-

3 - 127

14) Brake line connection. Connect back hoses joints under the wheel pant, which were disconected in step 3.

NOTE

During this operation protect both hoses line against intrusion of air bubbles. If during the hoses connection penetrated air bubbles, remove them.

3 - 128

15) Main wheel assembly installation. Install back Main wheel axis assembly with Brake caliper assembly [sn411_220_00-1], Main wheel [sn411_210_00-1] the Brake disc

[sn411_250_00-1] and Inner part of wheel pant [sn411_520_00-1]. For informations see chapter

3.4.10.

NOTE

Do not install the Outer part of wheel pant [sn411_510_00-1] for now.

16) Brake fluid filling. Fill brake fluid to the Brake fluid reservoir (bottle). Brake fluid reservoir is the highest point of the system. Remove the Drain bolt M8 [sn411_226_00-1] from the Brake caliper assembly [sn411_220_00-1] and let again the brake fluid freely flow from the Brake fluid reservoir through the brake system line to the auxiliary tank situated under the Brake caliper drain bolt M8 [sn411_226_00-1]. Several times press on the brake toe pedals. Then install back the Brake caliper drain bolt M8 [sn411_220_00-1].

NOTE

Brake fluid reservoir must be kept constantly full during this step. Otherwise there is a risk of intrusion of air bubbles in the brake system.

17) Brake system function verification. Check the Brake system function. Check the Parking brake system function. Visually check the system for integrity and tightness.





Pos.

Washer M6

Part



3 Screw M6 x 50

5


sn411_300_00-1 sn411_510_00-1

ISO 4018

ČSN 02 1721

3 - 129

NOTE

Repeat on the other side of the brake system (Second main wheel brake system).

3.4.18. Verification Required (Filling Brake System with Fluid)


Check fuselage and wheel pants for foreign objects.

Check wheels and pedals for free travel.


3 - 130

3.4.19. Replacing/removal of the Brake pads

– 400 x 100 mm wheels

To replacing/removal of the Brake pads requires one person.



Task Specific

Tools Required

Line

L/O, RI, RM, A& P



Training.

Socket wrench 10 (1 pcs)

Screwdriver (1pcs)


Needle – nose pliers (1pcs)


F-900 Torque seal

Brake pads for replacing

Replacing of the Brake pads Checklist – 400 x 100 mm wheels


Make sure the aircraft is not set on parking brake, i.e. the parking brake valve is open and the handle of the valve is aligned to aircraft longitudinal axle.

2) Outer part of wheel pant Removing. Remove the Outer part of wheel pant [s411_510_00-1] from the Inner part of wheel pant [s411_520_00-1] .Outer part of wheel pant [s411_510_00-1] is fixed with slotted mushroom head screws M4 x 12 (905624) and screw M6 x 22 DIN 912.

Pos. Part




s411_270_00-1 s411_510_00-1


4 Screw M6 x 22

5 Washer M6 s411_510_00-1

DIN 912

ČSN 02 1721

3 - 131

3) Brake pads retaining pin removing. Remove two Brake pads retaining pins. Retaining pins hold the Brake pads.

3 - 132

Pos.

1 Brake caliper

Part

2 Brake pads retaining pin


AIP

-

4) Brake pads removing. Remove the Brake pads. One on each side of the Brake disc

[s411_220_00-1].

Pos.

1 Brake disc

2 Brake caliper

Part

3 Brake pad

4 Brake pads retaining pin


s411_220_00-1

AIP

-

-

NOTE

File the pads to remove the glaze caused by lightly applying the brakes during ground operations. Replace them if they are excessively worn.

3 - 133

5) Brake pads reinserting. Reinsert the Brake pads and ensure the retaining pins are fully engaged.

6) Brake system function verification. Check the Brake system function. Visually check the system for integrity and tightness.

7) Wheel pants installation. Install back the Outer part of wheel pant [s411_510_00-1]. Use F-

900 Torque seal for wheel pant screw connections.

3.4.20. Replacing/removal of the Brake pads

– 15 x 6 wheels

To replacing/removal of the Brake pads requires one person.



Task Specific

Tools Required


Line

L/O, RI, RM, A& P



Training.

Socket wrench 10, 32 (1 pcs, 1 pcs)

Screwdriver (1pcs)




F-900 Torque seal

Brake pads for replacing

1 mm diameter wire

3 - 134

Replacing/removal of the Brake pads – 15 x 6 wheels


CAUTION


2) Outer part of wheel pant. Remove the Outer part of wheel pant [sn411_510_00-1] from the

Inner part of wheel pant [sn411_520_00-1] The Outer part of wheel pant [sn411_510_00-1] is fixed with slotted mushroom head screws M4 x 12 (905624), the Wheel pant distance spacer

[sn411_300_00-1], washers M6 and screw M6 x 50 ISO 4018.

3 - 135

Pos. Part



3 Screw M6 x 50

4 Washer M6


sn411_300_00-1 sn411_510_00-1

ISO 4018

ČSN 02 1721

3) Brake disc releasing. Release the Brake disc [sn411_250_00-1] in the main wheel hub removing 1 mm diameter wire.

4) Main wheel removal. Remove the Main wheel [sn411_210_00-1] and the Brake disc

[sn411_250_00-1] from the main wheel axis [sn411_240_00-1]. The main wheel

[sn411_210_00-1] is fixed via the Main wheel nut [sn411_270_00-1], Main wheel spacer

[sn411_280_00-1] and Cotter pin on the axis [sn411_240_00-1].

Pos.

1 Main wheel

2 Main wheel axis


sn411_210_00-1 sn411_240_00-1

3 Brake disc

4 Main wheel nut

5 Main wheel spacer

6 Cotter pin 2 x 30 sn411_250_00-1 sn411_270_00-1 sn411_280_00-1

ČSN 02 1781

3 - 136

5) Brake pads replacing. Remove the Brake pads [S4-324_000_00-1 and S4-325_000_00-1].

The Brake pads are fixed via screws M8 x 30 and M8 x 40 and the Brake caliper assembly counterpart [S4-322_000_00-1]. Repalce the brake pads with new parts. Fix back the new Brake pads [S4-324_000_00-1 and S4-325_000_00-1] and the Brake caliper assembly counterpart

[S4-322_000_00-1] via screws M8 x 30 and M8 x 40.

Pos. Part

1 Main wheel axis

2 Brake caliper assembly counterpart

3 Brake pad (fixed)

4 Brake pad (moveable)

5 Screw M8 x 30

6 Screw M8 x 40


sn411_240_00-1

S4-322_000_00-1

S4-324_000_00-1

S4-325_000_00-1

DIN 7984

DIN 7984

3 - 137

6) Insert brake disc. Insert brake disc [sn411_250_00-1] between brake pads [S4-324_000_00-

1 and S4-325_000_00-1] in the Brake caliper assembly [sn411_220_00-1].


sn411_220_00-1 sn411_250_00-1

Pos. Part

1 Brake caliper assembly

2 Brake disc

7) Brake system function verification. Check the Brake system function. Visually check the system for integrity and tightness.

8) Main wheel installation. Slide the Main wheel [sn411_210_00-1] on the main wheel axis

[sn411_240_00-1]. Secure the main wheel [sn411_210_00-1] on the axis [sn411_240_00-1] via the Main wheel nut [sn411_270_00-1], Main wheel spacer [sn411_280_00-1] and Cotter pin.

Part Pos.

1 Main wheel

2 Main wheel axis

3 Brake disc


sn411_210_00-1 sn411_240_00-1 sn411_250_00-1

4 Main wheel nut

5 Main wheel spacer

6 Cotter pin 2 x 30 sn411_270_00-1 sn411_280_00-1

ČSN 02 1781

3 - 138

9) Brake disc securing. Secure the Brake disc [sn411_250_00-1] in the main wheel hub via 1 mm diameter wire. Install the securing wire to the slot in the inner part of the main wheel hub.

Check that the Brake disc [sn411_250_00-1] is freely sliding in the space between the brake pads.

3 - 139





Pos. Part



3 Screw M6 x 50

5 Washer M6


sn411_300_00-1 sn411_510_00-1

ISO 4018

ČSN 02 1721

3 - 140

11) Main undercariage wheel control. Note that the main wheel can be freely rotating and is sufficient clearance between the wheel pant and the nose wheel. Check function of braking system.

3.4.21. Verification Required (Replacing/removal of the Brake pads)


Check wheel pants for foreign objects.

Check wheels for free travel.


3 - 141

3.5 Structural Control Surfaces

TL - 3000 is equipped with conventional plain flaps on the wing trailing edge. Extending flaps increases the camber of the wing airfoil, thus raising tha maximum lift coefficient.

Therefore, extending the flaps reduces the stalling speed of the aircraft.

TL - 3000 is equipped with ailerons on the wing trailing edge. The ailerons are used to control the aircraft roll.

Both flaps and ailerons are made of carbon top and bottom skins, glass fiber sandvich spars and ribs. Flap is hinged to the wing by for simple and one double hinges. Aileron is hinged to the wing by three simple and one double hinges.

3 - 142

3.5.1. Flap installation

To flap installation requires one person.



Task Specific

Line

L/O, RI, RM, A& P



Training.

Tools Required


Allen wrench 5



F-900 Torque seal

SOUDAL Fix All Classic (single component joint sealant)

Flap installation Checklist

1) Lubricating. Lubricate all metal details with plastic grease before connecting: metal insert in the Flap hinges [s110_540_00-1] (4x), Aileron and flaps hinges [s110_710_00-1] (6x) and hole for the bolt in the Flap control hinge [s110_550_00-1] (1x). Lubricate Bearing [ČSN 02 3512] in the Flaps pullrod assembly [s541_200_00-1].

3 - 143

Pos.

1 Left wing

(Right wing)

Part

2 Left flap

(Right flap)

3 Flap hinge

Flap control hinge

Aileron and flap hinge

4 Flaps pullrod assembly

5 Bearing 6


s110_000_00-1

(s120_000_00-1) s110_500_00-1

(s120_500_00-1) s110_540_00-1 s110_550_00-1 s110_710_00-1 s541_200_00-1

ČSN 02 3512

2) Flap installing. Fix the Flap [s110_500_00-1] on the wing [s110_000_00-1] with for bolts

M6 x 32 DIN 912 and one bolt M6 x 58 DIN 912 (in the Flap control hinge location). Use only castle nuts M 6 ČSN 02 1411 with the Cotter pin 1,6 [ČSN 02 1781].

3 - 144

Pos.

1 Screw M6 x 32

2 Screw M6 x 58

3 Washer M6

4 Castle nut M 6

5 Cotter pin 1,6


DIN 912

DIN 912

ČSN 02 1721

ČSN 02 1411

ČSN 02 1781

3) Connecting flap control. Fix the Flaps pullrod assembly [s541_200_00-1] on the Flap control hinge [s110_550_00-1] with screw M6 x 30 DIN 912. Use only castle nuts M 6 ČSN 02

1411 with the Cotter pin 1,6 [ČSN 02 1781].

3 - 145

Pos.

1 Flap control hinge


3 Screw M6 x 30

4 Washer M6

5 Castle nut M 6

6 Cotter pin 1,6


s110_550_00-1 s541_200_00-1

DIN 912

ČSN 02 1721

ČSN 02 1411

ČSN 02 1781



5) Flap pullrod cover installing. Fix the Flap pullrod cover [s110_140_00-1] on the Wing

[s110_000_00-1] with single component joint sealant SOUDAL Fix All Classic.

3 - 146

Pos.

1 Wing

2 Flap pullrod cover


s110_000_00-1 s110_140_00-1

CAUTION

Flap pullrod cover [s110_140_00-1] must be placed in order not to interfere Flap [s110_500_00-

1] and Flaps pullrod assembly [s541_200_00-1] movement. Correct Flap pullrod cover

[s110_140_00-1] position must be determinated by the test of all possible flap positions.

CAUTION

Do not support your hands or any subjects on the wing and flap, as the laminate surface is not proportioned for high area force.

3.5.2. Flap Removal

The rest of the Flap removal process goes in reverse to the Flap installation process.

Use segmented blade utility knife for Flap pullrod cover removing. Remove the Flap pullrod cover without damaging the wing.

3.5.3. Verification Required (flap installation/removal)

Check flaps for free travel.


3.5.4. Setting Flap “ Zero ” Position

To Setting Flap ” Zero ” position requires one person.

“Zero“ position of the Flaps is the position when the flaps are aligned to the centre – section on fuselage.

3 - 147



Task Specific

Line

L/O, RI, RM, A& P



Training.

Tools Required



Combination wrench 13 (1 pcs)



F-900 Torque seal


Setting Flap “Zero” Position Checklist

1) Flap pullrod cover removing. Remove the Flap pullrod cover [s110_140_00-1] from the

Wing [s110_000_00-1]. Flap pullrod cover is glued by the single component joint sealant on the wing. Use segmented blade utility knife for Flap pullrod cover removing. Remove the Flap pullrod cover without damaging the wing skin.

Pos.

1 Wing



s110_000_00-1 s110_140_00-1

2) Flap control disconnecting. Disconnect the Flaps pullrod assembly [s541_200_00-1] and the

Flap control hinge [s110_550_00-1]. Flap pullrod assembly is fixed with screw M6 x 30 DIN

912 and castle nuts M 6 ČSN 02 1411 with the Cotter pin 1,6 [ČSN 02 1781].

3 - 148

Pos.


Part


3 Screw M6 x 30

4 Washer M6

5 Castle nut M 6

6 Cotter pin 1,6


s110_550_00-1 s541_200_00-1

DIN 912

ČSN 02 1721

ČSN 02 1411

ČSN 02 1781

3 - 149

3) Flap pullrod setting. Loosen the nut M8 ISO 4032 on the Adjustable eye M8 [s590_300_00-

1]. Select the correct Adjustable eye M8 position [s590_300_00-1] so that flap [s110_500_00-1] is in the ”zero“ position (Flaps control switch must be in the flaps closed position). Then tighten the nut M8 ISO 4032 on the Adjustable eye M8 [s590_300_00-1] (use F-900 Torque seal).

Pos.

1 Wing

Part

2 Flap


4 Adjustable eye M8

5 Nut M 6


s110_000_00-1 s110_500_00-1 s541_200_00-1 s590_300_00-1

ISO 4032

3 - 150

4) Connecting flap control. Fix the Flaps pullrod assembly [s541_200_00-1] on the Flap control hinge [s110_550_00-1] with screw M6 x 30 DIN 912. Use only castle nuts M 6 ČSN 02

1411 with the Cotter pin 1,6 [ČSN 02 1781].

Pos.


Part


3 Screw M6 x 30

4 Washer M6

5 Castle nut M 6

6 Cotter pin 1,6


s110_550_00-1 s541_200_00-1

DIN 912

ČSN 02 1721

ČSN 02 1411

ČSN 02 1781

3 - 151



6) Flap pullrod cover installing. Fix the Flap pullrod cover [s110_140_00-1] on the Wing

[s110_000_00-1] with single component joint sealant SOUDAL Fix All Classic.

Pos.

1 Wing



s110_000_00-1 s110_140_00-1

CAUTION

Flap pullrod cover [s110_140_00-1] must be placed in order not to interfere Flap [s110_500_00-

1] and Flaps pullrod assembly [s541_200_00-1] movement. Correct Flap pullrod cover

[s110_140_00-1] position must be determinated by the test of all possible flap positions.

3 - 152

CAUTION

Do not support your hands or any subjects on the wing and flap, as the laminate surface is not proportioned for high area force.

3.5.5. Verification Req uired (flap “Zero” position)

Check flaps for free travel.


3.5.6. Aileron installation

To aileron installation requires one person.



Task Specific

Tools Required


Line

L/O, RI, RM, A& P



Training.

Allen wrench 5



F-900 Torque seal


Aileron installation Checklist

1) Lubricating. Lubricate all metal details with plastic grease before connecting: metal insert in the Aileron hinges [s110_640_00-1] (3x), Aileron and flaps hinges [s110_710_00-1] (5x) and hole for the bolt in the Aileron control hinge [s110_650_00-1] (1x). Lubricate Bearing [ČSN 02

3512] in the Pullrod assembly in the aileron [s541_200_00-1].

Pos.

1 Left wing

(Right wing)


s110_000_00-1

(s120_000_00-1)

2 Left aileron

(Right aileron)

3 Aileron hinge

Aileron control hinge

Aileron and flap hinge

4 Pullrod assembly in the aileron

5 Bearing 6 s110_600_00-1

(s120_600_00-1) s110_640_00-1 s110_650_00-1 s110_710_00-1 s523_600_00-1

ČSN 02 3512

3 - 153

2) Aileron installing. Fix the Aileron [s110_600_00-1] on the wing [s110_000_00-1] with three bolts M6 x 32 DIN 912 and one bolt M6 x 58 DIN 912 (in the Aileron control hinge location).

Use only castle nuts M 6 ČSN 02 1411 with the Cotter pin 1,6 [ČSN 02 1781].

Pos.

1 Screw M6 x 32

2 Screw M6 x 58

3

4

5

Washer M6

Castle nut M 6

Cotter pin 1,6


DIN 912

DIN 912

ČSN 02 1721

ČSN 02 1411

ČSN 02 1781

3 - 154

3) Connecting aileron control. Fix the Pullrod assembly in the aileron [s523_600_00-1] on the

Aileron control hinge [s110_650_00-1] with screw M6 x 30 DIN 912. Use only castle nuts M 6

ČSN 02 1411 with the Cotter pin 1,6 [ČSN 02 1781].

Pos. Part

1 Aileron control hinge


3 Screw M6 x 30

4

5

6

Washer M6

Castle nut M 6

Cotter pin 1,6


s110_650_00-1 s523_600_00-1

DIN 912

ČSN 02 1721

ČSN 02 1411

ČSN 02 1781

3 - 155

4) Ailerons deflection. Check ailerons deflection. Angles of deflection of the aileron are to within the range as follows (± 5 mm / ± 0.2 in).

3 - 156

5) Aileron pullrod cover installing. Fix the Aileron pullrod cover [s110_150_00-1] on the

Wing [s110_000_00-1] with single component joint sealant SOUDAL Fix All Classic.

Pos.

1 Wing

Part

2 Aileron pullrod cover


s110_000_00-1 s110_150_00-1

CAUTION

Aileron pullrod cover [s110_150_00-1] must be placed in order not to interfere Aileron

[s110_600_00-1] and Pullrod assembly in the aileron [s523_600_00-1] movement. Correct

Aileron pullrod cover [s110_150_00-1] position must be determinated by the test of all possible ailerons positions.

CAUTION

Do not support your hands or any subjects on the wing and aileron, as the laminate surface is not proportioned for high area force.

3 - 157

3.5.7. Aileron Removal

The rest of the Aileron removal process goes in reverse to the Aileron installation process.

Use segmented blade utility knife for Aileron pullrod cover removing. Remove the

Aileron pullrod cover without damaging the wing.

3.5.8. Verification Required (aileron installation/removal)

Check aileron for free travel.


3.5.9. Setting Aileron “ Zero ” Position

To Setting Aileron ” Zero ” position requires one person.

“Zero“ position of the Ailerons is the position when the ailerons are aligned to the flaps.



Task Specific

Tools Required


Line

L/O, RI, RM, A& P



Training.



Combination wrench 13 (1 pcs)


F-900 Torque seal


Setting Aileron “Zero” Position Checklist

1) Aileron pullrod cover removing. Remove the Aileron pullrod cover [s110_150_00-1] from the Wing [s110_000_00-1]. Aileron pullrod cover is glued by the single component joint sealant on the wing. Use segmented blade utility knife for Aileron pullrod cover removing. Remove the

Aileron pullrod cover without damaging the wing skin.

Pos.

1 Wing

Part



s110_000_00-1 s110_150_00-1

3 - 158

2) Aileron control disconnecting. Disconnect the Pullrod assembly in the aileron

[s523_600_00-1] and the Aileron control hinge [s110_650_00-1]. Pullrod assembly in the aileron is fixed with screw M6 x 30 DIN 912 and castle nuts M 6 ČSN 02 1411 with the Cotter pin 1,6 [ČSN 02 1781].

3 - 159

Pos.

1

2

3

4

5

6 Cotter pin 1,6

Part


Pullrod assembly in the aileron

Screw M6 x 30

Washer M6

Castle nut M 6


s110_650_00-1 s523_600_00-1

DIN 912

ČSN 02 1721

ČSN 02 1411

ČSN 02 1781

3) Flap pullrod setting. Loosen the nut M8 ISO 4032 on the Adjustable eye M8 [s590_300_00-

1]. Select the correct Adjustable eye M8 position [s590_300_00-1] so that aileron

[s110_600_00-1] is in the ”zero“ position. Then tighten the nut M8 ISO 4032 on the Adjustable eye M8 [s590_300_00-1] (use F-900 Torque seal).

3 - 160

Pos.

1 Wing

2 Aileron

Part


4 Adjustable eye M8

5 Nut M 6


s110_000_00-1 s110_600_00-1 s523_600_00-1 s590_300_00-1

ISO 4032

4) Connecting aileron control. Fix the Pullrod assembly in the aileron [s523_600_00-1] on the

Aileron control hinge [s110_650_00-1] with screw M6 x 30 DIN 912. Use only castle nuts M 6

ČSN 02 1411 with the Cotter pin 1,6 [ČSN 02 1781].

3 - 161

Pos.

1

2

3

4

5

6 Cotter pin 1,6

Part


Pullrod assembly in the aileron

Screw M6 x 30

Washer M6

Castle nut M 6


s110_650_00-1 s523_600_00-1

DIN 912

ČSN 02 1721

ČSN 02 1411

ČSN 02 1781

5) Ailerons deflection. Check ailerons deflection. Angles of deflection of the aileron are to within the range as follows (± 5 mm / ± 0.2 in).

6) Aileron pullrod cover installing. Fix the Aileron pullrod cover [s110_150_00-1] on the

Wing [s110_000_00-1] with single component joint sealant SOUDAL Fix All Classic.

Pos.

1 Wing

Part



s110_000_00-1 s110_150_00-1

3 - 162

CAUTION

Aileron pullrod cover [s110_150_00-1] must be placed in order not to interfere Aileron

[s110_600_00-1] and Pullrod assembly in the aileron [s523_600_00-1] movement. Correct

Aileron pullrod cover [s110_150_00-1] position must be determinated by the test of all possible ailerons positions.

CAUTION

Do not support your hands or any subjects on the wing and aileron, as the laminate surface is not proportioned for high area force.

3.5.10. Verification Required (aileron “Zero” position)

Check ailerons for free travel.


3 - 163

3.6 Engine

For engine inspection and maintenance refer to original Rotax manuals supplied with the aicraft:

1) Opera tor´s Manual for ROTAX engine Type 912 Series

2) Documentation for ROTAX aircraft engines (CD

– ROM)

3) Service instruction fur ROTAX Type 912 und 914 (serie)

4) ROTAX service letter Warranty conditions for ROTAX engine types 912 and

914 (series)

5) ROTAX engine Log book

CAUTION

Engine removal, installation and replacement can only done of TL-ULTRALIGHT authorized service center.

3 - 164

3.7 Fuel System

Aircraft fuel system allows the crew to store, manage, and deliver fuel to the propulsion system of the aircraft.

Sirius have two fuel tanks, one in each wing, and they use additional components as a means of providing fuel to the single engine. The fuel is piped through fuel lines to a Fuel Selector Shutoff

Valve. After the Selector Valve there is a gascolator: the fuel filter that can be drained. Drainage points are in each Wing Fuel tank. Fuel system have the main mechanical and electrical fuel boost pump. The mechanical pump is engine driven and always working. The mechanically driven fuel pump provides positive fuel pressure to the two carburetors. Each tank needs to be vented to allow air in the tank to take the place of burned fuel otherwise the tank would be in negative pressure which in the long run would result in engine fuel starvation. The vent tube are situated on the wing tips and also serves to allow for changes in atmospheric pressure with altitude. Part of the fuel system is also two fuel levels indication systems, which are transparent windows on the tank side situated in the cabin.

CAUTION

Fuel system inspection and maintenance are to be performed in a well-ventilated compartment, away from heaters and flame.

3 - 165

3.7.1. Wing fuel tanks filters inspection/cleaning

To inspection/cleaning wing tanks fuel filters requires two persons.



Task Specific

Tools Required


Line

L/O, RI, RM, A& P



Training.



F-900 Torque seal

3 - 166

Wing fuel tanks filters inspection/cleaning Checklist

1) Remove wings. Remove the left and right wing. See Chapter 3.2.2.

2) Fuel tanks sunctions disassembling. Remove the Fuel tank filter [s111_414_00-1] from the

Fuel sunction base [s111_411_00-1] situated on the Fuel tank [s111_000_00-1]. Fuel tank filtr

[s111_414_00-1] is fixed by the Fuel sunction beak [s111_412_00-1] and two Sealing O – ring

[s111_413_00-1]. Repeat with the second wing.

Pos.

1 Fuel tank

2 Fuel sunction base

3 Fuel sunction beak

Part

4 Sealing O - ring

5 Fuel tank filter


s111_000_00-1 s111_411_00-1 s111_412_00-1 s111_413_00-1 s111_414_00-1

3 - 167

3) Fuel filters inspection/cleaning. Inspect Fuel tank filters [s111_414_00-1] for obstruction and cleanliness. Clean the Fuel tank filters [s111_414_00-1]. Replace Fuel filters, if damaged.

Check Sealing O – rings [s111_413_00-1] for condition, replace them if damaged.

4) Fuel tanks sunctions assembling. Install the Fuel tank filter [s111_414_00-1] to the Fuel sunction base [s111_411_00-1] situated on the Fuel tank [s111_000_00-1]. Fuel tank filtr

[s111_414_00-1] is fixed by the Fuel sunction beak [s111_412_00-1] and two Sealing O – ring

[s111_413_00-1]. Repeat with the second wing.

Pos.

1 Fuel tank

2 Fuel sunction base

3 Fuel sunction beak

Part

4 Sealing O - ring

5 Fuel tank filter


s111_000_00-1 s111_411_00-1 s111_412_00-1 s111_413_00-1 s111_414_00-1

3 - 168

5) Wings installation. Install the left and right wing. See Chapter 3.2.1.

3.7.2. Verification Required (Fuel tanks filters inspection/cleaning)


Check wings and fuel tanks for foreign objects.

Inspect fuel system for fuel leak


3.7.3. Gascolator Inspection/cleaning

To inspection/cleaning Gascolator requires one person.



Task Specific

Line

L/O, RI, RM, A& P



Training.

Tools Required


Gascolator inspection/cleaning Checklist

Screwdriver (1pcs)

Safety wire 0.032“ diameter

1) Engine covers removing. Remove Upper cowling [s200_421_00-1] and Bottom cowling

[s200_422_00-1]

2) Fuel selector valve. Make sure the Fuel Selector Valve is in the off position.

3) Fuel gascolator draining. Drain the Fuel gascolator by the draining vent on the Fuel gascolator tank. Remove all fuel from Fuel gascolator tank.

4) Safety wire removing. Remove the stainless safety wire securing Fuel gascolator tank Nut.

5) Fuel filter tank removing. Remove Fuel filter tank from the Fuel gascolator [ACS 10580]

Part Pos.

1 Fuel filter cap

2 Fuel filter sealing

3 Fuel filter tank


ACS 10580

ACS 10580

ACS 10580

3 - 169

6) Fuel gascolator inspection/cleaning. Clean Fuel gascolator fuel strainer and sediment bowl.

Inspect the Fuel gascolator sealing for condition, replace it if damaged.

7) Fuel filter tank installation. Install back Fuel filter tank from the Fuel gascolator [ACS

10580]. The rest of the Fuel filter tank installation process goes in reverse to the Fuel filter tank removing process (Step 5).

3 - 170

8) Gascolator nut securing. Secure the Fuel gascolator tank Nut by the stainless safety wire having diameter of 0.032“.

Pos.

1 Fuel Gascolator

Part

2 Stainless safety wire


ACS 10580

0.032“ diameter

9) Leakage inspection. Make the Fuel Selector Valve to the Left or Right tank position. Inspect

Fuel Gascolator for leakage.

10) Cowlings installation. Install back the Upper cowling [s200_421_00-1] and Bottom cowling [s200_422_00-1].

3.7.4. Verification Required (Gascolator Inspection/cleaning)

Make sure the nuts are not loose (do not rotate).

Check engine and gascolator area for foreign objects.

Inspect fuel system for fuel leak

3 - 171

3.8 Propeller

For propeller inspection and maintenance refer to original propeller manufacturer´s manuals.

CAUTION

Propeller removal, installation and replacement can only done of TL-ultralight or propeller manufacturer authorized service center.

3.9 Utility Systems

3.9.1. Heating System

To minimize the chances for carbon monoxide entering the cockpit, heated air is drawn from the water radiator not from a heat exchanger on the muffler. Ambient inlet air taken through the radiator is heated and supplied through a control flap into the cockpit by a air hose. The amount of hot air is regulated by the CABIN HEAT knob on the lower throttle quadrant instrument panel.

In case that the aircraft is being operated while OAT is more than 20 °C dismount the carbon Heating cover and Heating air hose.

To dismounting Heating cover and Heating hose one person is required.



Task Specific

Line

L/O, RI, RM, A& P



Training.

Tools Required


Screwdriver (1pcs)

Cross-screwdriver (1pcs)

-

Heating cover and Heating hose dismounting Checklist

1) Engine covers removing. Remove Upper cowling [s200_421_00-1] and Bottom cowling

[s200_422_00-1]

2) Fuel selector valve. Remove two Hose clamps [TORRO 35 - 50], carbon Heating cover

[s700_920_00-1] and Heating hose from the engine area.

3 - 172

Pos.

1 Heating flap

2 Heating cover

3 Heating hose

4 Hose clamp


s700_910_00-1 s700_920_00-1

-

TORRO 35 - 50

3) Heating flap inspection. Make sure the Heating flap [s700_910_00-1] on the firewall is in closed position.

4) Cowlings installation. Install back the Upper cowling [s200_421_00-1] and Bottom cowling

[s200_422_00-1].

3 - 173

To removal of the Cabin Heat control knob one person is required.



Task Specific

Line

L/O, RI, RM, A& P



Training.

Tools Required

Screwdriver (1pcs)


Needle - nose pliers (1pcs)

-


Cabin Heat control knob removal Checklist

1) Upper engine cover removing. Remove Upper cowling [s200_421_00-1].

2) Control cable disconnecting. Disconnect the control cable on the control flap lever located on the firewall (on the Heating flap [s700_910_00-1]).

3) Nut removing. Remove the nuts thus releasing the heating control knob.

4) Control knob removing. Remove the Heating control knob with cable from the flexible housing.

To installation of the Cabin Heat control knob one person is required.



Task Specific

Line

L/O, RI, RM, A& P



Tools Required

Training.

Screwdriver (1pcs)


Needle - nose pliers (1pcs)

F-900 Torque seal


Cabin Heat control knob installation Checklist

1) Upper engine cover removing. Remove Upper cowling [s200_421_00-1].

2) Control knob inserting. Insert the Cabin Heat control knob into the flexible housing and fasten it from both sides of the lower throttle panel by means of nuts.

3) Control cable connecting. Connect the control cable with control flap lever on the Heating flap [s700_910_00-1].

4) Heat control adjusting. Adjust heat control.

3 - 174

3.9.2. Venting System

Cockpit ventilation is ensured by two rotating scoop air vents located on the side windows of the doors. An additional adjustable air inlet is located forward of the glare shield also in the cockpit. Quantity of inlet air is controlled by air scoops which are movable in all clock directions and can be opened or closed to adjust the air volume and air flow direction in our out of the cabin.

To removal and installation of the cabin air vents one person is required.



Task Specific

Line

L/O, RI, RM, A& P



Training.

Tools Required


Cabin air vents removal and installation Checklist

-

-

1) Cabin air vents removal/installation. The two rotating air vents mounted in the doors windows can be removed or installed by slightly squeezing the interior edge of the vent scoop from the exterior and rotating the scoop slightly as it is removed or replaced.

CAUTION

This is should be done carefully to not break the plastic scoop.

3.9.3. Seats

The seats of the Sirius are fixed and are equipped with an upholstered removable back cushions attached to the cockpit bulkhead by Velcro. The seat bases are attached to the lower cockpit frame.

To removal and installation of the seats one person is required.

3 - 175



Task Specific

Tools Required

Line

L/O, RI, RM, A& P



Training.

Screwdriver (1pcs)



Seat removal Checklist

-

1) Back seat removing. Remove the Back seat [s200_621_00-1]. Back seat is attached to the cockpit bulkhead by Velcro.

2) Bottom seat Srew unscrewing. Remove the Screw M 4 located in the rear part of the Bottom seat [s200_622_00-1] under Bottom seat upholstery.

3 - 176

3) Bottom seat removing. Slide the Bottom seat [s200_622_00-1] from the pins to the front direction.

Pos.

1 Cockpit bulkheads

Part

2 Bottom seat


s200_550_00-1 s200_622_00-1

3.9.4. Cabin doors

The cockpit is entered by two large doors which open upwards towards the wing.

To removal and installation of the seats two persons are required.



Task Specific

Tools Required


Line

L/O, RI, RM, A& P



Training.

Screwdriver (1pcs)


-

3 - 177

Cabin door removal Checklist

1) Door opening. Open the Cabin door [s200_210_00-1 or s200_220_00-1].

2) Securing pins removing. Remove the Securing pins (wire) from two doors gas struts.

Pos.

1 Door gasstrut

2 Securing pin


Interex 150N

Interex 150N

3) Gas struts disconnecting. Disconnect two ball joints between the Gas struts [Interex 150N] and the Fuselage [s200_000_00-1]. Hold the door in the opened position.

3 - 178

4) Door removing. Remove the door [s200_210_00-1 or s200_220_00-1]. The door is fixed by four screws M 3,5 on the frame of the door in the Fuselage [s200_000_00-1].

The rest of the Cabin door installation process goes in reverse to the Cabin door removal process.

NOTE

Cabin doors are not designed for frequent assembly and disassembly, so these operations be performed only if necessary.

.

3 - 179

3.10 Instruments and Avionics

The specific instruments and/or the configuration in which they are arranged may vary slightly from aircraft to aircraft. The magnetic compass is centered on top of the glare shield behind the utility tray.

Sirius flight instruments are arranged in the basic “T” configuration on the pilot (left) side of the aircraft. Part of switches can be placed on the ceiling instrument panel.

Exceptions can include the absence of a particular instrument or a variation in the order of the instruments due to after market changes.

3.10.1. Airspeed indicator markings

MARKING

White Arc

Green Arc

Yellow Arc

KIAS

35 - 75

40 - 115

KCAS

38-73

43-111

SIGNIFICANCE

Full-Flap Operating Range. Lower limit is maximum weight V

S0 in landing configuration. Upper limit is maximum speed permissible with flaps extended to stage one (Takeoff) setting.

Normal Operating Range. Lower limit is maximum weight V

S

at most forward C.G. with flaps retracted. Upper limit is maximum structural cruising speed

115 - 138 111-136

Caution Range. Operations must be conducted with caution and only in smooth air

Red Line

138 136

Never Exceed Speed. Maximum speed for all operations.

3 - 180

3.10.2. Engine instruments

The Engine Information System (EIS) is the primary display for monitoring engine operation. The EIS displays the following data: RPM, manifold pressure, fuel pressure, oil temperature, oil pressure, 2 cylinder head temperatures, 4 exhaust gas temperatures, voltage, elapsed engine time, and total engine time. Individual input limitations are preprogrammed into the system. If any of these limits are exceeded, a red EIS alert light will illuminate. The EIS data display will then flash the reading that is in alert.

NOTE

A difference of as much as 200 RPM can exist between the Rotax

®

tachometer and the RPM indication on the EIS. The EIS digital RPM readout is more accurate and should be relied upon when in doubt.

Engine manifold pressure is monitored in the AUX1 display on the EIS. The indication interpreted from the remote sensor is displayed in two digits with a decimal point and one more digit (eg 25.5) which is an indication of induction air manifold pressure, and is measured in inches of mercury.

Fuel pressure is monitored in the AUX2 display on the EIS. The indication interpreted from the remote sensor is displayed in two digits without a decimal point (eg 35) which is an indication of 3.5 and is measured in pounds per square inch (PSI).

Engine Information System (EIS) Setup (1 Nov 05) (L/O,RI,RM,A&P)

1. Hold down both the Next/ACK and Previous buttons at the same time for 5 seconds. The unit will enter the MAIN program

‘set limits mode’ and the alert light will stay on.

2. The left (Next/Ack) button will now increase the setting (Up)

3. The center (Previous) button will now lower the setting (Down)

4. The right (Display) button will enter the setting and advance to the (Next) setting.

5. Set Contrast at 2 and push Next,

6. Set Max timer to 0 and push Next,

7. Set Max Oil P to 92 and push Next,

8. Set Min Oil P to 30 and push Next,

9. Set Max Oil T to 256 and push Next,

10. Set Max RPM to 5700 and push Next,

11. Set Max Aux 1 to 0 and push Next,

12. Set Min Aux 1 to 0 and push Next,

13. Set Max Aux 2 to 56 and push Next,

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14. Set Min Aux 2 to 22 and push Next,

15. Set Max Volt to 14.8 and push Next,

16. Set Min Volt to 11.0 and push Next,

17. Set Max CHT to 238 and push Next,

18. Set Max EGT to 1600 and push Next,

19. Set Display to 3 and push Next.

20. This will then exit the main program.

Prior to entering the SECONDARY program mode, you must read the static amount of the Fuel Pressure display with the power on but the engine off and the aux pump off.

Example to obtain the setting value for minimum fuel pressure on Aux2Off:

1. Turn on power to the EIS display. Read the EIS number shown for Fuel Pressure

(AUX2) with the power on but no fuel pump or engine running.

2. If this number is one digit such as 9, place a decimal in front to read

‘.9’. If the number is two digits such as 11, insert a decimal to read

‘1.1’.

3. Multiply the number shown by 20, such as .9 x 20 = 18. Then subtract 1, the number will always be odd, so the answer is 17 in this example.

4. If the number is 1.1, then the calculation will be 1.1 X 20 = 22, minus 1 = 21

3.10.3. Pitot

– static system

The pitot-static tube is located on the leading edge of the left wing and consists of a ram air duct located inside a cylindrical static air chamber. Total system pressure is sensed through the hole in the pitot-tube face and static pressure is sensed through the holes on the side of the rear part of fuselage. Pressure distribution to individual instruments is received by means of flexible plastic hoses.

The tube supplies dynamic ram air pressure to the airspeed indicator, and the static ports supply outside atmospheric pressure to the airspeed indicator, altimeter, mode C encoder, and vertical speed indicator. If installed, the altitude hold portion of the autopilot is also connected to the pitot system.

Pos. Part

1 Pitot – static tube attachement in the wing

2 Pitot – static tube

3 Pitot – static probe


s611_000_00-1 s612_000_00-1

Aviatik

3 - 182

3 - 183

To removal and installation of the pitot

– static tube one persons is required.



Task Specific

Line

L/O, RI, RM, A& P



Training.

Tools Required

Screwdriver (1pcs)

Linesman´s pliers (1pcs)

-


Pitot – static tube removal Checklist

1) Screw removing. Remove the screw attaching the Pitot – static tube [s612_000_00-1] with

Pitot – static tube attachement [s611_000_00-1] to the wing.

2) Pitot – static tube removing. Remove the Pitot – static tube [s612_000_00-1] by gently pulling front and rotating the tube to expose the total pressure hose.

3) Hose disconnecting. Disconnect the total pressure hose from the Pitot – static probe

[Aviatik].



Line

L/O, RI, RM, A& P

Task Specific



Training.

Tools Required

Screwdriver (1pcs)


F-900 Torque seal


Pitot – static tube installation Checklist

1) Hose inserting. Insert the transparent hose of total pressure line the Pitot – static tube

[s612_000_00-1]. Connect the hose to the outlet of the Pitot – static probe [Aviatik] and secure it with clamp.

WARNING

WARNING

RNING

incorrect connection! Connect the hose to the outlet marked P.

2) Pitot – static probe inserting. Insert the Pitot – static probe [Aviatik] in the Pitot - static tube

[s612_000_00-1].

3 - 184

3) Pitot – static tube mounting. Attach the Pitot – static tube [s612_000_00-1] by means of the screw through the Pitot – static tube attachement [s611_000_00-1] protruding from the leading edge of the left wing. Use F-900 Torque seal for screw connection.

4) Pitot – static system inspection. Carry out check of pitot – static system tightness.

To inspect pitot

– static system tightness one persons is required.



Task Specific

Line

L/O, RI, RM, A& P



Training.

Pitot – static system tightness inspection Checklist

1) Static pressure line. In the static pressure system create the under pressure by means of an appropriate instrument corresponding to an altitude of 1000 ft indicated on the cockpit altimeter.

Drop in the indicated altitude per one minute must not exceed 100 ft.

2) Total pressure line. Create in the total pressure tube, by means of a suitable instrument, an overpressure corresponding to the speed of 120 KT indicated on the ASI. Drop in speed during 3 minutes must not exceed 3 KT.

3.10.4. Airspeed indicator

The airspeed indicator (ASI) is the instrument that displays how fast the aircraft is traveling, in knots, through the air. Ram air pressure and static atmospheric pressure supplied by the pitot tube and static ports are compared by a diaphragm that expands and contracts as the difference between the two varies. Linkages are connected between the diaphragm and the indicator needle gives the operator a visual reading of the indicated airspeed at any given time.

3.10.5. Altimeter

The altimeter (ALT) contains aneroid wafers that expand and contract as atmospheric pressure changes. As altitude increases, the atmospheric pressure decreases, and the aneroid wafers expand. As altitude decreases, the aneroid wafers will contract.

Atmospheric pressure is supplied to the altimeter by the static ports on the fuselage.

Mechanical linkages attached to the aneroid wafers move the needles on the altimeter face. A knob on the altimeter’s face allows the operator to enter the correct barometric pressure into the Kollsman window.

3 - 185

NOTE

When setting the current barometric pressure in the Kollsman window for the first flight of the day, note the difference between the indicated altitude and the known field elevation.

This will give you a correction factor for airborne resetting.

3.10.6. Vertical speed indicator

The vertical speed indicator (VSI) provides the operator with rate of climb and rate of descent. It acts quite similar to the altimeter. Atmospheric pressure is supplied by the static ports on the fuselage, and this air is sent into a holding chamber. However, unlike the altimeter, this chamber also has a metered leak attached to it that allows the pressure inside the chamber to eventually equalize with the pressure outside of the chamber. As the aircraft climbs, pressure decreases and this is displayed by the needle on the VSI as a rate of climb. When the aircraft stops climbing, the metered leak allows the pressures to equalize, and thus the indicator needle returns to zero, or no rate of climb. The same holds true for a descent. The indicator will show a rate of descent so long as the aircraft continues to lose altitude, but will return to zero whenever level flight is reached. Because of the metered leak, there is a small delay in the VSI’s indication and a change in altitude may be noted first from the altimeter.

3.10.7. Magnetic compass

The magnetic compass is designed to determine magnetic course of the airplane. The magnetic compass is positioned on the upper glare shield of the instrument panel and consists of a vessel filed with nonfreezing liquid to dampen movement and has a window in the front wall. The compass rose is positioned on the rotary swinging pivot inside the compass.

To magnetic compass compensation one person is required.



Task Specific

Line

L/O, RI, RM, A& P



Training.

Magnetic compass compensation Checklist

1) Preparatory work. Compass compensation must be performed on the approved compass swinging locations, which are at least 300 ft from steel structures, electric leading or over ground or underground steel equipment or objects. If the compass north is westward from magnetic north, the deviation is westward, i.e. negative. If the compass north is eastward from magnetic north, the deviation is eastward, i.e. positive.

3 - 186

2) Turn the airplane to “N” heading; elininate the deviation by “C” screw.

3) Turn the airplane to “S” heading, reduce any deviation by half – value by “C” screw and write down the corrected heading.

4) Turn the airplane to “E” heading, eliminate the deviation by “B” screw.

5) Turn the airplane to “W” heading, reduce any deviation by half – value by “B” screw and write down the corrected heading.

6) Enter the individual corrected headings to maintain in the magnetic direction on the compass compensation card and position it in the airplane near the magnetic compass.

3.10.8. Avionics equipment

For specific operational and maintenance instructions, see the manufacturer’s manual corresponding to each piece of equipment.

NOTE

The Garmin 295 GPS internal AA batteries should to be replaced at each annual condition inspection. The battery furnished with the Garmin 396 should be checked at each annual condition inspection and replaced in accordance with the manufacturers instructions.

3.11 Electrical System

The aircraft is equipped with a 12-volt, direct-current electrical system with grounded negative pole. The primary source of electrical energy is provided by the engine mounted interior alternator/generator with total power of 750 W. The internal alternator located at the rear of the engine block will charge the battery up to 13.5 VDC. Power is supplied to the electrical and avionics circuits through a main bus bar located behind center instrument panel, this bus bar is energized anytime the Main switch is ON. Each system is protected by circuit breaker which is permanently on. If some circuit is overloaded, then the circuit breaker disconnects that circuit. The ELT is independent from the aircraft electrical system.

3 - 187

3 - 188

3 - 189

Two 12 VDC auxiliary power ports are installed in the lower right and left vertical surface of each seat. The ports are directly

“hot-wired” to the battery and can be used to charge the battery without the operator having to connect additional leads directly to the battery.

CAUTION

Do not attempt to start the engine with a dead battery by using either 12VDC port.

The current load will exceed the wire capacity and a fire may result.

The Instrument Switch activates all avionics equipment tied into the circuit. This instrument switch should always be in the OFF position before the main switch is turned on or before the main switch is turned off.

Main switches on ceiling panel

3.11.1. Exterior lighting

High capacity, anti-collision, safety strobe lights are located on each wingtip and one on the lower aft tail. These lights are encased in a clear-plastic, flush-mounted cover for protection and decreased drag. The center or ceiling panel has an ON/OFF circuit breaker-switch (CBS) for the strobe lights.

LED high intensity position-navigation lights are mounted on each wing tip and on the rudder trailing edge. The ceiling panel has an ON/OFF circuit breaker-switch (CBS) for the position lights.

The HID lamp is used for taxi and landing illumination and is mounted on the left wing leading edge. The ceiling panel has an ON/OFF circuit breaker-switch (CBS) for the landing light.

3 - 190

To wing tip lights installation one person is required.



Task Specific

Line

L/O, RI, RM, A& P



Training.

Tools Required

Screwdriver (1pcs)


F-900 Torque seal


Wing tip lights installation Checklist

1) Light console assembling. Assembly the composite Light console [s621_200_00-1] with the wing tip lights.

Pos.

1 Light console

2 LED light ring

Part

3 LED light spacer

4 LED light 12V

5 LED light 12V socket

6 Strobe light

7 Strobe light socket


s621_200_00-1 s621_300_00-1 s621_400_00-1

-

-

Krčmář

Krčmář

NOTE

Wing tip lights could be mounted according to the customer´s requirement. Aircraft could be fitted with variouse lights.

3 - 191

2) Wing-to-wing tip lights wiring. Connect all wing-to-wing tip lights wiring, i.e. connect the lights sockets and plug.

3) Light console installing. Install the Light console [s621_200_00-1] with lights on the wing tip. Use the Philips pan wood screws 3 x 10 with F-900 Torque seal.


s100_000_00-1 s621_200_00-1

Pos.

1 Wing

2 Light console

Part

4) Transparency light cover installing. Install the Transparency light cover [s621_100_00-1] on the wing tip. Use the Philips pan wood screws 3 x 10 with F-900 Torque seal.

Pos.

1 Wing

Part

2 Transparency light cover


s100_000_00-1 s621_100_00-1

3 - 192

5) Lights inspection. Inspect function of the lights.

The rest of the wing tip lights removal process goes in reverse to the wings tip lights installation process.

3.11.2. Generator

The 600 W generator is a part of the engine which supplies electric current through the rectifier. Regulator supplies electric current of 14 V voltage to onboard network. The maximum of approximately 18 amps is provided by the regulator, but only 14 amps should be considered available for use.

Technical parameters of generator:

Maximum output power: 600 W at 5500 RPM

Technical parameters of rectifier - regulator:

Type: electronic

Output voltage:

14 ± 0.3 V (000 ± 250 RPM)

Range of operation temperatures: min. -

13 °F max. +194 °F

Weight: 0.6 lbs

3.11.3. Circuit breakers and fuses

Circuit breakers and fuses are the best protection for electrical loads and malfunctions.

The most common form of protection for this aircraft is circuit breakers (CB) and circuit breaker-switches (CBS). The CBs cannot manually be pulled out to disconnect the circuit. If a surge or over-loading amperage is placed on a CB switch, the built-in circuit breaker will open turning the switch off, thus protecting the circuit. After reducing the electrical load, turn the switch back to the ON position to reset the breaker.

3 - 193

3.11.4. Battery

Both the GPS and the Emergency Locator Transmitter (ELT) contain internal batteries, and therefore can be operated when Main switch is OFF. The Garmin 295GPS contains six AA batteries. The ELT contains eight D-cell batteries, as well as one small battery in the remote control panel. All batteries should be replaced at each annual inspection. The Garmin 396GPS contains a rechargeable lithium-ion battery pack. The battery furnished with the Garmin 396 should be checked at each annual condition inspection and replaced in accordance with the manufacturers instructions.

The maintenance-free Varta battery or equivalent is installed on firewall. Battery can be charged directly in the airplane after disconnecting from the onboard electrical system.

Aircraft Battery Technical Parameters:

Voltage 12 V

Nominal capacity 24 Ah;

Weight: 17 lbs

Discharging current 1200 mA

Maximum loading 200 A

Range of operation temperatures -

22°F to +122°F

Number of cycles, 100% discharging-charging: more than 200

Service life: 4 to 5 years (Service life occurs at 60% of nominal capacity after full

charging)

NOTE

If the airplane is not used for flight for more than one month, remove the battery from the airplane and store it.

Always store the battery fully charged at temperature of 68 °F.

Daily discharging is less than 0.1 % of battery nominal capacity. Regularly recharge it up to the full capacity once a month.

3 - 194

To battery removal one person is required.



Task Specific

Line

L/O, RI, RM, A& P



Training.

Tools Required

Screwdriver (1pcs)


Wrench 10 (1pcs)

-


Battery removal Checklist

1) Engine cover removing. Remove Upper cowling [s200_421_00-1].

2) Contacts disconnecting. Disconnect the contacts from the battery.

3) Upper battery holder block. Disconnect the Upper battery holder block [s700_710_00-1], i. e. remove two philips mushroom head screws M4 x 10 ISO 7045.

3 - 195

Pos. Part

1 Bottom battery holder

2 Upper battery holder block

3 Battery

4 Screw M4 x 10

4) Battery removing. Remove the battery from the airplane.


s700_710_00-1 s700_710_00-1

Varta 12V 8Ah 80A(EN)

ISO 7045

CAUTION

To reduce the chance of personal injury and possible equipment damage, remove the negative wire before removing the positive wire.

To battery installation one person is required.



Task Specific

Tools Required


Line

L/O, RI, RM, A& P



Training.

Screwdriver (1pcs)


Wrench 10 (1pcs)

Electrical grease for battery contact

3 - 196

Battery installation Checklist

1) Battery inserting. Insert the battery into the Battery holder [s200_421_00-1] on the firewall.

2) Battery fastening. Fasten the battery with fixing the Upper battery holder block

[s200_421_00-1] so that it cannot move in the Bottom battery holder [s200_421_00-1], i.e. fix the Upper battery holder block [s200_421_00-1] with two philips mushroom head screws M4 x

10 ISO 7045.

Pos. Part

1 Bottom battery holder

2 Upper battery holder block

3 Battery

4 Screw M4 x 10


s700_710_00-1 s700_710_00-1

Varta 12V 8Ah 80A(EN)

ISO 7045

3) Additional contacts. Install the additional electrical contacts to the aircraft electrical system.

3 - 197

4) Contacts corrosion protection. Install electrical grease on the battery contacts to minimize corrosion.

5) Clamps installation. Install the clamps on battery contacts from the aircraft electrical +/- system.

6) Engine cowl installation. Reinstall the Upper cowling [s200_421_00-1].

WARNING

WARNING

Failure to reconnect the battery connectors properly could result in reversing the

RNING

polarity of the battery.

CAUTION

Do not replace the dry cell battery with a wet cell baterry. The dry cell baterry has the electrolyte immobilized as a paste and the battery can be operated in any random position.

3 - 198

3.11.5 Inspection and operation checks

L/RI, RM, A&P level of certification required.

The satisfactory performance of an aircraft is dependent upon the continued reliability of the electrical system. Damaged wiring or equipment in an aircraft, regardless of how minor it may appear to be, cannot be tolerated. Reliability of the system is proportional to the amount of maintenance received and the knowledge of those who perform such maintenance. It is, therefore, important that maintenance be accomplished using the best techniques and practices to minimize the possibility of failure.

Inspect equipment, electrical assemblies, and wiring installations for damage, general condition, and proper functioning to ensure the continued satisfactory operation of the electrical system. Adjust, repair, overhaul, and test electrical equipment and systems in accordance with the recommendations and procedures in the component manufacturer’s maintenance instructions. Replace components of the electrical system that are damaged or defective with identical parts from the aircraft manufacturer’s approved equipment, or its equivalent to the original in operating characteristics, mechanical strength, and environmental specifications.

A list of suggested problems to look for and checks to be performed are: a Damaged, discolored, or overheated equipment, connections, wiring, and installations. b c d

Excessive heat or discoloration at high current carrying connections.

Misalignment of electrically driven equipment.

Poor electrical bonding (broken, disconnected or corroded bonding strap) and grounding, including evidence of corrosion. e f g h i j k l m

Dirty equipment and connections.

Improper, broken, inadequately supported wiring and conduit, loose connections of terminals, and loose ferrules.

Poor mechanical or cold solder joints.

Condition of circuit breaker and fuses.

Insufficient clearance between exposed current carrying parts and ground or poor insulation of exposed terminals.

Broken or missing safety wire, broken bundle lacing, cotter pins, etc.

Operational check of electrically operated equipment such as motors, inverters, generators, batteries, lights, protective devices, etc.

Ensure that ventilation and cooling air passages are clear and unobstructed.

Voltage check of system with portable precision equipment.

3 - 199

3.12 Structural Repair

Task Specific: can be completed only by a responsible individual, which holds either an

FAA Mechanic certificate or an FAA LSA Repairman Certificate plus he (or she) must have received TL-ULTRALIGHT Structure Repairing course.

Otherwise all repairs can only be done at TL-ULTRALIGHT authorized service centers.

3.12.1 Repair of Laminate parts

Damage classification

Any damage of parts from reinforced plastics with epoxy matrix leads to increased saturation of the matrix with humidity and subsequently to loss of properties. Carry out their repair as soon as possible after the damage has occurred.

According to the damage extent, it can be divided into repairs of:

1. small damage

2. medium damage (not more than 10% of part damaged)

3. heavy damage

General

Epoxy resin mixtures are prepared in a given mass ratio by means of weighing

(accuracy of scales 0,002 lb)

SMALL DAMAGE (surface defects, not affecting the spars or other structure)

Repair of damage just by application of mastic and by varnish repair.

1) Preparatory Sanding

For a good adhesion of repair layers it is necessary to carry out surface sanding at the utmost up to the depth of contact with the lower surface of fabric (do not damage). It is necessary to do surface sanding with overrun of 2” from the damage location smoothly to the top layer. It is suitable to do sanding with grain size of 160. Dry Sanding equipment with suction from the sanding area is used. Al2O3 or equivalent (fused corundum) can be used as sanding material.

2) Dust removing

Wipe with clean and dry brush or by a vacuum cleaner.

3 - 200

3) Application of smoothing layer

After preparation of mixture and its eventual thickening to enhance the non curtaining capability (for vertical or lower areas) is performed its application onto the repair area by means of a plastic spatula. For better distribution of deposited material on irregular surface it is possible to form it through the laid PE or PP transparent polyethylene. After proper application the layer is without bubbles. Deposit thickness is given by necessary thickness of surrounding layers (leveling

) and ranges from 0.008” to ½” in one deposit.

Manufacturer Type

Mixing

Ratio

MGS,

A: L285

B: Hardener 285

Epoxy

A:B =

100:40

Delay

Rate of

Setting

Process within 50 min (for

0.2kg mixture)

40%

100%

Time of

Setting

16hours

(32hours)

26hours

(72hours)

(2hours)

Temperature

68-9

5°F

(62-

68°F)

68-

95°F

(62-

68°F)

(176°F)

Fillers

Aerosil,

Microballs

4) Sanding

Sanding or eventually sealing the surface is made after setting the mixture and possible tearing of the used polyethylene. It is suitable to start sanding with grain size up to 160 and finish with grain size of at least 400. It is carried out by dry sanding equipment with suction from the sanding area. Al203 or equivalent (fused corundum) can be used as sanding material. Basic material of the part must not be diminished by sanding.

NOTE

Especially in case of carbon stiffener in the basic part, sanding through up to the stiffener must not occur

5) Finishing

MEDIUM DAMAGE

Repair of damage by replacing the stiffener part, by mastic and varnish repair. At such repair it is necessary to distinguish type of used stiffener (especially for sanding):

C (carbon), rovings of fabric of black color

G (glass), rovings from milky white to transparent

3 - 201

1) Preparatory Sanding:

For good adhesion of repair layers it is necessary to do sanding up to the depth of damage. It is necessary to do surface sanding from the damage area with overrun at the least 1” for every damaged stiffener layer smoothly up to the top layer and then about

2” for finishing and mastic application. It is convenient to do sanding with sanding material having grain size of 160. It is carried out by dry sanding equipment with suction from sanding area. Al203 or equivalent (fused corundum) can be used as sanding material.

2) Dust removing

Dust is removed by wiping with a clean and dry brush or by a vacuum cleaner.

3) Stiffener preparation:

For this kind of repairs use the stiffener G (glass) with plain weave, 150g/m2, with surface protection for epoxy resins. Number of needed stiffener layers depends on depth of damage. It is possible to say that each layer of the mentioned fabric represents at proper saturation by matrix resin thickness of 0.020”. Stiffener layers must be prepared (cut out) gradually from the smallest (the lowest) up to the bigger

(upper), each with overrun of ¾”.

4) Putting layers

After preparing lamination mixture, it is applied to the place of repair by means of rigid brush. The first stiffener is laid into the deposit and it is again saturated by brush.

Another layer of stiffener is laid and saturated. When putting the last layer it is necessary to pay attention to a proper saturation and compression of stiffeners so that they cannot

“come up" to the surface and subsequent useless damage at final sanding.

For better saturation of the surface by resin and securing against curtaining it is possible to put PE or PP transparent foil across the surface. When applied properly, the layer is without bubbles. Repair thickness should exceed surrounding surface in this phase by about 0,020” to 0,040” for finishing.

5) Sanding

Carry out sanding and eventually apply mastic on the surface after setting, eventually tearing of the foil. It is suitable to begin sanding by abrasive with grain size of 160 and finish by grain size of at least 400. Dry Sanding equipment is used with suction from the sanding area. Al2O3 or equivalent can be used as sanding material. It is important not to diminish basic material of the part at sanding.

3 - 202

HEAVY DAMAGE

At such damage the part must be replaced.

CAUTION

When repairing structural parts, it is necessary to pay attention to timely repair see the text about low of properties at humidity effect.

CAUTION

When repairing small damage, it is necessary to carefully pay attention not to damage any structural part!

3.13 Painting and Coating

Task Specific: can be completed a responsible individual, which holds either an FAA

Mechanic certificate or an FAA LSA Repairman Certificate or aircraft owner plus he (or she) must have received TL-ULTRALIGHT Structure Repairing course.

CAUTION

It is not allowed by the manufacturer to use any other colouring of aircraft. The dark colour must be confirmed by the manufacturer, he must decide in which parts of aircraft it is allowed or in which size.

3.13.1 Paint repairs

Safety rules

When working with paints, thinners and solvents follow the following safety rules:

1. it is necessary to follow safety rules for working with flammable and volatile

substances

3 - 203

2. working area must be properly aerated

3. it is prohibited to smoke and anyway handle with free fire in a working area

4. use protective working means such as goggles, gloves, respirator, etc.

Recommendation for additional surface treatment of the airplane surface

CAUTION

By applying permanent protective coats weight of airplane is increased and gravity center position is changed. Increase in weight depends on type of coat and its thickness.

1) Washing and degreasing

It is possible to use both organic solvents and water based solvents.

CAUTION

All paints and solvents must be used only with caution for proper personal and environmental protection and disposal.

Organic solvents

– (acetone, metyetylketone (MEK), benzine, toluene)

Applied by spraying on washed surfaces (e.g. mechanical sprayer, jet ejector) or by wiping with wet (by pouring, not by dipping because it would contaminate the whole volume of solvent) textile wad. After applying it, the agent is wiped of by clean absorbing material before solvent evaporation.

Advantages: fast and reliable evaporation even from the corners and borders without additional warming

Disadvantages: it must be used without other dilution (expensive); not ecological

(danger of water contamination); detrimental to health (must be carried out in an aerated area with personal protective means); waste (including dripping from the area) must be eliminated in the incinerating plants.

Use: for Al-alloys surfaces, epoxy fiberglass

CAUTION

These agents must not be used for degreasing parts from plastics (PC -Lexan,

PMMA Plexiglass)

3 - 204

Water-based agents

– (emulgation substances, wetting agents)

Applied also by spraying onto washed surfaces or by wiping with wet (by pouring and dipping) textile wad. After applying it, let it act for some time (see manufacturers recommendation) and then it is rinsed with clear water (by means of sponge dipped in ample amount of water or water jet).

Advantages: (different according to the type of product: it is possible to highly dilute with water (cheap); ecological - waste (including dripping from the surface due to ample amount of water it is necessary to contain it) can be generally eliminated after its additional dilution with water; the least detrimental to health.

Disadvantages: slow and unreliable evaporating from corners and borders, additional warming (drying) mostly required imperfect elimination of water results in wrong adhesion of paint coats; imperfect degreasing of fiberglass parts (not possible to use)

Use: for Al-alloys surfaces and plastics

2) Application of primer (paint)

In order to reach a uniform resistance to corrosion and smooth surface, carry out this application by means of spraying (air standard gun with the upper vessel, air HVLP gun, airless electric gun). The adjusting of the used gun (given by manufacturer) differs according to the type - air pressure, jet diameter. Primer should be applied in several sprayings (total thickness is not reached at a blow) with defined maximum dwell and total drying time till further treatment or handling.

Primer serves especially for anchoring (adhesion to the substrate) the topcoats and can serve also for eliminating irregularities of the surface (function of filer, for sanding).

Surface Manufacturer Type

Carbon fiber BASF Glasurit

Fiberglass

801-1871

(base)

PC (Lexan),

PMMA

(Plexiglass)

Further

Components

Epoxy BASF Glasurit

965-35/2

(hardener)

Glasurit

965-50

(thinner)

Surface

Mass

[lb/inch/ft

2

]

8.49

Recom.

Thickness

[“]

0.00098

(at 0.00197 it can be also used as filler)

Drying

(between spraying / total)

/ 65°F

15 min / 12 hours

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3) Bonding

After total drying of basic coat carry out total bonding of irregularities including repairs of bonding. After drying perform sanding with emery paper with grain size of 240 until the surface is smooth. After sanding clean dust and wipe of with grease remover and perform repairing paint coat by primer (1/3 of coat thickness).

4) Application of top coat

In order to reach smooth surface apply the paint coat only by spraying. Topcoat serves especially for creating the coat resistant to weather and external effects for aesthetic rendering of the unit. Considering the higher loading by external effects use top materials, exclusively two-component ones, on the acrylic-polyurethane or polyurethane basis, always with guaranteed adhesiveness to the used base coat (according to manufacturer).

Small damage

General

Small damage is a deterioration of corrosion resistance. At repair the situation is made more difficult by the fact that the substrate for repair coats is not a compact surface of basic material but mostly all coats of surface protection (after sanding), of which not all are suitable for (in ageing stage) for good adhesion of paint coats. Therefore accomplish such repairs only by a verified system.

It is suitable to choose a defined edge delimited area (e.g. connection of parts, wing edge) for the scope of the place, which is being repaired transition, is then better blended. In the case that it is not possible to choose the area in this way, it is necessary to take into consideration the higher difficulty of the procedure as for the uniformity of shade and elaboration of coat transition.

Sanding

For good adhesion of the repair coats it is necessary to carry out sanding of the old paint coat at least up to such depth as the depth of damage. Ground area must be larger from 2” to 4” than damaged area. With two-coat type of the topcoat it is necessary to add at least 2” for the run-out of the top coat. Sanding can be started with abrasive having grain size of max. 160 and finish with grain size of 400. It is made by the grinder equipped with the suction from the area of sanding or by manual sanding under water.

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Degreasing

It is carried out in the same way as in the case of the total spray coat.

Application of primer

For reaching the satisfactory equal adhesion to carry out a spray coat of the place to be repaired by adhesive interlayer

Surface Manufacturer Type

Surface weight

[lb/inch/ft

2

]

Recomm.

Thickness

[“]

Drying

(total) /

65°F

Al-alloys

Epoxy fiberglass

Old paint coats

BASF

Glasurit 934-0

Singlecomponent

4.19

0.00019-

0.00039 max 15 min

Subsequently the primer is applied according to the table.. Paint coat thickness is given by necessary thickness of surrounding coats (leveling).

CAUTION

In case that the primer was not removed by the previous step, it is not necessary to apply the primer again. The original ground primer with adhesive intercoat is enough. Actual application of primer will be carried out in the same way as for the total spray-coat

Application of top coat

Application of the top coat will be carried out by spraying as for the total spray coat with the exception of used thinners and hardeners. Due to the need of smooth transition to the basic surface it is necessary to use so called

“spraying into the surface" using longer time of drying initiations for a good result of work.

FINISH COATINGS COLORS AND NUMBER

Paint number: Rabbe, RAL9003, Signal White

Silicone number: GE Silicone II, White

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3.13.2 Paint repairs

– Method of Verification

For final inspection touch the painted (or coated) surfaces of parts. Finished surface must be smooth, no dents or bumps are allowed. Ensure original profile of the treated surfaces, if necessary. Inspect painted surface visually from various viewpoints. No paint runs, unpainted areas are allowed. Quality of polishing must be the same of adjacent areas.

3.14 Securing bolted connections

3.14.1 General

Bolt/nut joint securing is used in order to prevent from their loosening due to vibration or force action on the connected parts, which could result in the damage of the connected parts. Three ways of bolt joint securing are used on the airplane: safety wire, cotter pin and locking washer.

3.14.2 Cotter Pins

Securing by cotter pin is used for bolts subject to rotation. They are used because they can be removed and reinstalled quickly. The diameter of the cotter pin should be the largest size that will fit the slot in the castle nut or the hole in the bolt. To prevent injury the ends of the cotter pin should be bent over the nut and firmly flat against each face of the nut then rolled and tucked.

Figure: Securing bolts or castle nuts with a cotter pin.

Cotter pin removal is very easy: by means of a flat screwdriver straighten up the bent ends of the cotter pin and take the cotter pin out of the hole with small pliers.

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CAUTION

When securing castle nuts, always use new cotter pins. Shift the new cotter pin into the hole in the bolt and bend the cotter pin ends as shown in Figure on page 3 - 159.

3.14.3 Safety Wire

Procedure of bolt joint securing is by stainless steel wire having diameter of 0.032”.

Figure: Examples of correct direction for drilled bolt safety wire

The installation of safety wire is not intended to retain bolt or nut torque. It is installed to prevent disengagement of screws, nuts, bolts, and other parts for added safety. Do not confuse aluminum wire with stainless steel wire. Wire should only be stainless steel, do not use common wire or ferrous metal which can rust or be attracted by magnetic portions of the aircraft.

Drilled bolts or screws do not need to be safety wired if they are installed with selflocking nuts. Safety wire must be installed in a manner that will prevent the tendency of the part to loosen or rotate. See Figure on page 3 - 160.

Safety wire ends are a safety hazard unless they are bent under and inward toward the part to avoid sharp or projecting ends. Safety wire must not be nicked, kinked, or mutilated. When cutting off the end of the twisted wire, leave at least four to six completer turns (1/2” to 5/8”) of wound wire to complete a loop.

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Figure: Safety wire pliers Figure: Twisting the wire

Figure: Safety wire installation to turnbuckles and swaged terminals

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Safety wire procedures, alignment and installation are shown below:

1. Adjust the correct position of holes for safety wire.

2. Pull the safety wire through the hole in one bolt to be secured.

6. Pull the upper wire through the hole in the other bolt. Hold the wire end by pliers tighten it firm.

7. Hold the free end of wire by hand, bend it around the bolt head and along with the other end twist it counterclockwise.

8. Hold the twisted end by pliers and twist it tight.

3. Hold the upper end of the wire and wind it around the bolt head and then by the other end of the wire. Make sure that the wire is properly tightened around the head.

4. Twist the wire to the hole in the next bolt as tight as possible.

9. Bend the end of the wire under the bolt head.

5. Tighten the wire and at the same time continue its twisting until perfectly tightened.

The twisted wire can have approximately from 3 to 4 threads on the length of 0,4“.

10. Cut off the surplus wire.

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3.14.4 Inspection of Rod ends

Cracks and subsequent failures of rod ends usually begin at the thread end near the bearing and adjacent to or under the jam nut. (See figure below)

Typical locations for rod end cracks

3.14.5 Inspection of push pull tube connections

Elongated holes are especially prevalent in taper-pin holes and bolt holes or at the riveted joints of torque tubes and push-pull rods. (See figure below)

Typical locations for elongation of insert holes in push pull tubes.

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3.15 Cable inspections Swaged Nicopress clamp installation

3.15.1 Cable system Inspections

The aircraft uses cable only for the rudders and trim system. These cables are subject to many environmental exterior and interior conditions which can result in deterioration over of a long period of time. Wire or stand breakages is easy to visually recognize when bent into a curve. See Figure below. Other deterioration, such as wear, corrosion and distortion are not so easily seen. Therefore the control cables and all critical areas of fatigue, fairleads, pulleys and swaged connections should receive a detailed inspection at the annual condition inspection for signs of such deterioration.

Figure: Wire cable strands exposed by bending the cable.

Figure: Swage terminal shank gauge

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Nicopress clamp installation procedure is shown below.

Pos.

1 Clamp

Part

2 Eye

3 Sequence of squeezing

4 Inspection gauge

5 Gauge No.


-

-

-

-

-

Accomplish all procedures in accordance with the manufacturer directions. First pull the cable through the clamp, make a loop around the eye and pull the cable end back through the clamp.

The cable end should overlap by about 1 ¼” from the clamp after its puling through. The overlapping will ensure that the cable end will not be pulled back into the clamp during the clamp squeezing. Before actual squeezing the clamp it is also necessary to verify which cable terminal will be used, whether thimble or suspension eye, because some terminals must be put into the cable before actual clamp squeezing.

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