Direct Fly ALTO 912 TG Aircraft Maintenance Manual
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Direct Fly ALTO 912 TG Aircraft Maintenance Manual

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Direct Fly / ERRES
ALTO 912 TG
AIRCRAFT MAINTENANCE
MANUAL
DFE-AMM-AR1

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  • Page 1 Direct Fly / ERRES ALTO 912 TG AIRCRAFT MAINTENANCE MANUAL DFE-AMM-AR1...
  • Page 2 AIRCRAFT MAINTENANCE MANUAL 912 TG ALTO Aircraft model / modification Manufacturer : Direct Fly s.r.o. DF051 Airplane Serial Number: Airplane Registration Number: PU-RJR Issued on : July 24, 2014 Revision : Owner: DFE-AMM-AR1 Rev. 1 – 07/24/2014...
  • Page 3 AIRCRAFT MAINTENANCE MANUAL Section 0 - INTRODUCTION 0.1. CONTACT INFORMATION Company headquarters: Direct Fly s.r. o. Špitálka 8 602 00 Brno, Czech Republic www.directfly.cz info@directfly.cz The Manufacturing Facility: Direct Fly s.r.o. Cihelní 573 687 25 Hluk Czech Republic Brazilian Dealer: Erres Industria Aeronautica Ltda.

  • Page 4: Table Of Contents

    AIRCRAFT MAINTENANCE MANUAL 0.4. CONTENTS 1. SECTION 1 - GENERAL INFORMATION ....................1-1 1.1. GENERAL ............................1-1 1.2. LAYOUT OF THE MANUAL ......................1-1 1.3. WARNINGS, CAUTION AND NOTES WARNING ................1-1 1.4. SPECIFICATION ..........................1-2 1.5. GROUND HANDLING ........................1-5 1.6.
  • Page 5 AIRCRAFT MAINTENANCE MANUAL 11.2. DESCRIPTION ..........................11-1 11.3. INSTRUCTIONS FOR AUTHORIZED MAINTENANCE, REPAIR OR ALTERATIONS ....11-6 12. SECTION 12 - REVISIONS ........................12-1 12.1. GENERAL ............................12-1 12.2. REVISION NOTES .......................... 12-1 12.3. LIST OF EFFECTIVE PAGES ......................12-2 13.
  • Page 6 Paragraph 0.1 on this Section. Direct Fly S.R.O. cannot through this manual 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.
  • Page 7 Each owner/operator of a LSA is responsible for providing the manufacturer with current contact information where the manufacturer may send the owner/operator supplemental notification bulletins. The following form may be used & sent to Direct Fly S.R.O by email or fax to the addresses listed on Paragraph 0.1 on this Section...
  • Page 8 AIRCRAFT MAINTENANCE MANUAL 0.11. TERMILONOGY A&P: A US FAA certificated Mechanic as defined by 14 CFR Part 65. LSA Repairman Inspection: A US FAA certificated repairman (light-sport aircraft) with and inspection rating as defined by14 CFR part 65, authorized to perform the annual condition inspection on light-sport aircraft, which the repairman owns.
  • Page 9 AIRCRAFT MAINTENANCE MANUAL Repainting of control surfaces Structural repairs 3. Alterations of components and or aircraft structure which instructions are provided in the maintenance manual or service directive instruction such as: Installation of new equipment authorized by the aircraft manufacturer Overhaul –...
  • Page 10 AIRCRAFT MAINTENANCE MANUAL REVIEW OF THE REQUIRED QUALIFICATION FOR MAINTENANCE AND INSPECTIONS: Alto built from a kit Factory-built Alto (ELSA under §21.191 (i) (SLSA under §21.190 1,320 pounds MTOW) 1,320 pounds MTOW) Preventive Sport pilot or higher Sport pilot or higher maintenance •...
  • Page 11 0.12. SIGNIFICANCE AND USE The purpose of this maintenance manual is to provide guidance to owners, mechanics, airports, regulatory officials, and aircraft and component manufacturers who may accomplish maintenance, repairs, and alterations on the Direct Fly ALTO Aircraft. DFE-AMM-AR1 Rev. 1 – 07/24/2014...

  • Page 12: Section 1 - General Information

    1.1. GENERAL Direct Fly S.R.O. prepared this aircraft maintenance manual. It contains the information that a trained mechanic will need to maintain the aircraft in an airworthy condition. The Aircraft Maintenance Manual was prepared to meet the ASTM F2483 Standard Specification requirements.

  • Page 13: Specification

    1.4. SPECIFICATION Direct Fly ALTO 912 TG is an all-metal low wing aircraft with a riveted aluminum structure. Some non-load bearing parts such as the engine cowling, wing tips, empennage tips, and wheel covers are made of composite materials. The Alto is powered by the ROTAX 912 ULS engine (100 HP) and PROPULS 174/3/R three-blade ground-adjustable propeller.
  • Page 14 AIRCRAFT MAINTENANCE MANUAL 1.4.1.2. Basic dimensions Wing Span ..................322.83 in 8.20 m Area ………………………………………………………………..114 sq.ft 10.52 sq.m MAC ………………………………………………………………. 51.77 in 1.315 mm Loading …………………………………………………………… 11.71 lbs/sq.ft 59.18 kg/sq.m Aileron Area ……………………………………………………………… 2.62 sq.ft 0.25 sq.m Flap Area ……………………………………………………………… 5.60 sq.ft 0.52 sq.m Fuselage Length ……………………………………………………………...
  • Page 15 AIRCRAFT MAINTENANCE MANUAL An aircraft’s actual empty weight will vary based on how it is equipped. Each aircraft’s empty weight is listed in its Pilot Operating Handbook 1.4.1.4. Center of gravity Empty weight CG (standard equipment)………………………. 21-25% MAC Operating CG ……………………………………………………. 25-35% MAC (MAC..................

  • Page 16: Ground Handling

    AIRCRAFT MAINTENANCE MANUAL 1.5. GROUND HANDLING All ground handling activities described below are considered as Line Maintenance and may be performed by Sport Pilot or higher (or Aircraft owner for ELSA). 1.5.1. Towing It is easy to tow the airplane a short distance by holding the propeller blade root, since the empty weight of this airplane is relatively low.
  • Page 17 AIRCRAFT MAINTENANCE MANUAL 1.5.4. Jacking the airplane Because the empty weight of this airplane is relatively low it is easy to lift the airplane using 2 people. First prepare two suitable jacks or supports to support the aircraft. Aircraft fuselage can be supported on the places marked by the black triangles in the figure below.

  • Page 18: Servicing

    AIRCRAFT MAINTENANCE MANUAL 1.6. SERVICING 1.6.1. Fueling No smoking or open flames during fueling! Fire extinguisher should be within reach! Under no circumstances add fuel with the engine running! Connect the aircraft to ground prior fueling. No person in the cockpit during fueling! A fuel tank filler is located on the upper side of each wing (see figure below).
  • Page 19 AIRCRAFT MAINTENANCE MANUAL • Task proper accomplishment check: check the fuel tank cap is home screwed and required amount of fuel is in the tank (according to fuel gauge). It is highly recommended to pour gasoline through a filter if it was not tested for water content. After fueling, allow 20 min.
  • Page 20 AIRCRAFT MAINTENANCE MANUAL 1. Remove upper cowling. 2. Unscrew oil reservoir cap. 3. Verify the oil level. The total oil quantity in the Rotax 912 ULS lubricating system amounts to 0.9 U.S. gall (3.5 liters). Prior to oil check, turn the propeller in the normal direction of rotation by hand (ignition switched off!) several times to pump oil from the engine into the oil tank, or leave the engine idle for 1 minute.
  • Page 21 AIRCRAFT MAINTENANCE MANUAL • Tools needed: Screwdriver to remove upper cowling • Parts needed: recommended coolant • Type of maintenance: Preventive maintenance • Level of Certification needed: Sport pilot or higher • Instructions: 1. Remove upper engine cowling. 2. Check coolant quantity The total coolant quantity is about 0.4 U.S.
  • Page 22 AIRCRAFT MAINTENANCE MANUAL Fig 1-6: Brake Fluid Reservoir Location Fig 1-7: Brake Fluid Reservoir Fig 1-8: Brake Fluid Level Marks DFE-AMM-AR1 Rev. 1 – 07/24/2014 1-11...
  • Page 23 AIRCRAFT MAINTENANCE MANUAL • Task proper accomplishment check: Check proper attachment of brake fluid tank cap after refilling. 1.6.4.1 Recommended Type of Brake Fluid ONLY DOT 4 or DOT 5.1 fluid should be used. 1.6.5. Lubrication • Tools needed: Screwdriver to remove upper cowling, wheel pants and access windows, grease gun, oiler.
  • Page 24 AIRCRAFT MAINTENANCE MANUAL 1.6.5.3. Lubricating Points after the Every Every Unit Lubricating point Lubricant first 50 hrs. 100 hrs 25 hrs. • Engine carburetor control cable at inlet into the WD40 Bowden (in engine compartment) • WD40 choke control cable at inlet into the termination (in engine compartment) •...
  • Page 25 AIRCRAFT MAINTENANCE MANUAL 1.6.6. Winter operation 1.6.6.2. Definition It is considered a winter operation, if the outside temperature falls below 41°F (+5 °C). 1.6.6.2. Preparing the aircraft for winter operation • Tools needed: Screwdriver to remove upper cowling, wheel pants and access windows, grease gun, oiler.
  • Page 26 AIRCRAFT MAINTENANCE MANUAL 1.6.6.3. Additional Preflight inspection In addition to the Pre-flight inspection described in the POH – Section 4, the following must be done: • Remove all snow from the airplane surfaces, and remove any icing using hot air •...

  • Page 27: Equipment List

    1.7. EQUIPMENT LIST Direct Fly S.R.O. retains the approval authority of any items installed in all ALTO aircrafts. 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 written approval by the Manufacturer.
  • Page 28 Master/Start Key CZ - VDO Some items in the previous list are described as “Direct Fly”, which does not mean that Direct Fly is the manufacturer. For their nature, and availability, instruments can be of different brands: the substitution of one instrument for one of another brand but analog technology and specifications, can provide satisfactory results.

  • Page 29: Sources To Purchase Parts

    Spare parts can be ordered from different sources depending on its nature. We list here a simplified list of sources, and we encourage the owner to contact Direct Fly or its Dealers anytime a question arises about the compatibility of a product or consumable.

  • Page 30: List Of Disposable Replacement Parts

    The following table shows a list of commonly replaced parts with its source. ITEM BRAND REFERENCE # / SOURCE SPECIFICATION Engine and accessories Rotax Dealers / Direct Fly Dealers / Oil Filter Rotax 825012 Aircraft Parts Stores Rotax Dealers / Direct Fly Dealers / Air Filter K&N...

  • Page 31: Weight And Balance Information

    AIRCRAFT MAINTENANCE MANUAL Figure 1-3 – Rotax Engine For more detail refer to the Rotax engine manual supplied with your engine. 1.11. WEIGHT AND BALANCE INFORMATION Refer to the Pilot’s Operating Handbook (DFE-POH-AR1), Section 6 for the Weight and Balance Data.

  • Page 32: Tire Inflation Pressure

    AIRCRAFT MAINTENANCE MANUAL NEVER EXCEED THE MAXIMUM TAKEOFF WEIGHT AND C.G. RANGE FOR ANY CONFIGURATION OF CREW, FUEL AND BAGGAGE AS SHOWN IN THE AIRCRAFT OPERATING INSTRUCTIONS. 1.11.2. Empty weight determination • Tools needed: Scales, ramp boards and rests under wheels to level the aircraft. •...

  • Page 33: Recommended Fasterner Torque Values

    AIRCRAFT MAINTENANCE MANUAL 1.14. RECOMMENDED FASTERNER TORQUE VALUES Strength class Metric thread 10.9 12.9 1,67 kg.m 0,17 3,45 kg.m 0,35 5,39 6,86 9,80 13,72 16,67 kg.m 0,55 0,70 1,00 1,40 1,70 8,82 10,78 14,70 20,59 25,49 kg.m 0,90 1,10 1,50 2,10 2,60 12,74...

  • Page 34: General Safety Information

    Please report any service difficulties or any other issue relating to flight safety directly to Direct Fly using the form available on Paragraph 0.9. of this Manual. The form may be sent by email or fax to the addresses listed on Paragraph 0.1 on this Section...

  • Page 35: Section 2 - Inspections

    This guide will not make reference to revision levels of vendor publications. This guide will be applicable to the aircraft in the configuration it left Direct Fly S.R.O. when it was first delivered and it may not cover modifications made to the aircraft subsequently.

  • Page 36: Condition Inspection Tasks

    AIRCRAFT MAINTENANCE MANUAL Operational Inspection An operational inspection is a check intended to determine that a component or system is fulfilling its intended purpose. The operational inspection does not require quantitative tolerance. Functional Inspection When called for by an inspection task, a functional inspection is a quantitative check to determine if one or more functions of a component perform within specified limits.
  • Page 37 AIRCRAFT MAINTENANCE MANUAL 2.5.1. PRE-FLIGHT INSPECTION • Tools needed: Screwdriver to remove upper engine cowling • Parts needed: None • Type of maintenance: Preventive maintenance • Level of Certification needed: Sport pilot or higher • Instructions: Refer to Pilot’s Operating Handbook section 4, Paragraph 4.1 •...
  • Page 38 AIRCRAFT MAINTENANCE MANUAL 2.5.3.1. Periodical Inspection Actions / Checklists The following Periodical Inspection Checklists are intended for copying and serve as the Maintenance Records. It is also recommended to include small repairs, damages and their remedy or replacement. Some parts of the airplane (engine, propeller etc.) may have special time limits - refer to the appropriate manuals for maintenance time limits and procedures.
  • Page 39 AIRCRAFT MAINTENANCE MANUAL Model: S/N.: Hours flown: Date of inspection: Alto Registration: No. of Takeoffs: Inspection Tick off performed inspection Event Carried Inspected Event description every every after the after the first out by: first hrs. hrs. hrs. hrs. Prior to the inspection clean and wash the airplane surfaces, if needed.
  • Page 40 AIRCRAFT MAINTENANCE MANUAL Inspection Tick off performed inspection Event Carried Inspected Event description every every after the after the first out by: first hrs. hrs. hrs. hrs. 3.6.3. Visually check system for leaks 3.7. Cooling system 3.7.1. Visually check radiator for condition and leaks 3.7.2.
  • Page 41 AIRCRAFT MAINTENANCE MANUAL Inspection Tick off performed inspection Event Carried Inspected Event description every every after the after the first out by: first hrs. hrs. hrs. hrs. 4.3. Propeller see manufacturer instructions + 4.3.1. Check prop attachment, security of bolts 4.3.2.
  • Page 42 AIRCRAFT MAINTENANCE MANUAL Inspection Tick off performed inspection Event Carried Inspected Event description every every after the after the first out by: first hrs. hrs. hrs. hrs. 6.1.2. Inspect leg attachment into the fuselage (no play) - Lift the landing gear and move the leg forward-backward, upward-downward;...
  • Page 43 AIRCRAFT MAINTENANCE MANUAL Inspection Tick off performed inspection Event Carried Inspected Event description every every after the after the first out by: first hrs. hrs. hrs. hrs. 7.2. Aileron 7.2.1. Visually check condition 7.2.2. Check free movement 7.2.3. Check aileron hinge Check play 7.2.4.
  • Page 44 AIRCRAFT MAINTENANCE MANUAL Inspection Tick off performed inspection Event Carried Inspected Event description every every after the after the first out by: first hrs. hrs. hrs. hrs. 8.1.5. Visually check condition, attachment and operation of towing mechanism (if installed) and lubricate 8.1.6.
  • Page 45 AIRCRAFT MAINTENANCE MANUAL Inspection Tick off performed inspection Event Carried Inspected Event description every every after the after the first out by: first hrs. hrs. hrs. hrs. 10.6. Check joints security 10.7. Lubricate per Lubricating Chart COCKPIT 11.1. Instrument panel 11.1.1.
  • Page 46 AIRCRAFT MAINTENANCE MANUAL Inspection Tick off performed inspection Event Carried Inspected Event description every every after the after the first out by: first hrs. hrs. hrs. hrs. 11.7. Complete lubricating per Lubricating Chart 11.8. Install seats upholstery and covers Engine Test Run (see FM) 11.9.

  • Page 47: Section 3 - Structures

    9, are authorized at this time, for this ALTO aircraft structures. Any heavy maintenance, major repairs, or major alterations, as outlined in ASTM F2483 Sections 7 through 9, can only be performed by Direct Fly S.R.O. or only as provided by Direct Fly‘s’ approved engineering data.
  • Page 48 AIRCRAFT MAINTENANCE MANUAL Figure 3-2 – Cockpit Layout • Cockpit controls Refer to the PILOT´S OPERATING HANDBOOK – POH- Section 7 - for more details about the Cockpit Controls for the specific aircraft. • Cockpit canopy The plexi-glass (perspex) canopy consists of a single forward sliding assembly, attached to a aluminum tube frame.
  • Page 49 AIRCRAFT MAINTENANCE MANUAL Outside lever Inside lever Figure 3-4 & 3-5 – Cockpit canopy lock Keep the canopy locked during taxing, flying and engine run test. • Seats and safety harness The plane has two side-by-side seats, each equipped with four-point seatbelts. The waist belt is attached alongside the seat and shoulder belts behind the seats.
  • Page 50 AIRCRAFT MAINTENANCE MANUAL 3.2.2. Instructions for Authorized Maintenance, Repair or Alterations 3.2.2.1. Sliding Cockpit Canopy Maintenance • Tools needed: None • Parts needed: None • Type of maintenance: Line • Level of Certification needed: Sport pilot or higher, Aircraft owner (only for ELSA) •...

  • Page 51: Wing

    AIRCRAFT MAINTENANCE MANUAL Canopy Mounting: (2 people) 1. Slide the two fuselage rails as forward as possible. 2. Two people will carry the canopy and will slide the canopy onto the fuselage rails. Move the canopy forward and the black plastic locks will lock the canopy to the sliding rails.
  • Page 52 AIRCRAFT MAINTENANCE MANUAL 3.3.2. Instructions for Authorized Maintenance, Repair or Alterations 3.3.2.1. Wing to Fuselage Assembly The wing assembly procedure for an aircraft is the following: (3 persons are needed to accomplish this task): • Tools needed: Light Hammer, Metric Wrenches, Torque Meter, Screwdriver •...
  • Page 53 AIRCRAFT MAINTENANCE MANUAL • Task proper accomplishment check: Visually check that all bolts are inserted and secured properly. Visually check if the Aileron control pull rod are connected and secure. Visually check if fuel hoses are connected and if the clips are installed Visually check if wiring is connected Visually check if pitot-static hoses are connected.

  • Page 54: Empennage

    AIRCRAFT MAINTENANCE MANUAL 3.4. EMPENNAGE 3.4.1. Description • Horizontal tail unit (HTU) The HTU of conventional type consists of the stabilizer and elevator with the trim tab. Single-spar structure of the HTU consists of duralumin ribs, spar and skin. The top view of HTU is of rectangular shape. Stabilizer The stabilizer is rectangular in shape and formed with a “duralumin”...
  • Page 55 AIRCRAFT MAINTENANCE MANUAL 3.4.2. Instructions for Authorized Maintenance, Repair or Alterations 3.4.2.1. HTU to Fuselage Assembly • Tools needed: Metric Wrench, Torque Meter. • Parts needed: Bolts, nuts, washers and grease. • Type of maintenance: Heavy • Level of Certification needed: −...
  • Page 56 AIRCRAFT MAINTENANCE MANUAL 3.4.2.3. Rudder Assembly • Tools needed: Metric Wrench • Parts needed: Bolts, nuts, washers and safety pins. • Type of maintenance: Heavy • Level of Certification needed: − Repairman (LS-M) or Mechanic (A&P) – both with the minimum level of certification to perform heavy maintenance of SLSA in the U.S.

  • Page 57: Landing Gear

    AIRCRAFT MAINTENANCE MANUAL 3.5. LANDING GEAR 3.5.1. Description • Main landing gear The main landing gear consists of the left and right landing gear legs. The legs are formed from composite / fiberglass and are fixed by means of bolts in the fuselage casing under the seats. Wheel axles are bolted to the lower part of the main landing gear legs.
  • Page 58 AIRCRAFT MAINTENANCE MANUAL • Auxiliary tail skid The auxiliary tail skid is attached at the lower rear part of the fuselage and protects the aircraft from inadvertent damage during tail-down landing conditions. The tail skid is formed from composite/fiberglass. Figure 3-15 & 3-16 – Auxiliary tail skid •...
  • Page 59 AIRCRAFT MAINTENANCE MANUAL Figure 3-18 - The Aerospool brake • Brake control The brakes on both wheels are controlled by a hand lever mounted on the central console between the seats. Parking Brake function is available by locking the lever on the right side recess on the plate. Brake Control Lever Recess for the parking brake lock.
  • Page 60 AIRCRAFT MAINTENANCE MANUAL • Wheels All the wheels consist of a two-part casting rim with a tire and tube. The main wheels are on an axle attached to the main gear leg, fastened by the nuts. Figure 3-20 – Main Landing Gear Wheel Layout Figure 3-21 –...
  • Page 61 AIRCRAFT MAINTENANCE MANUAL • Tires and Tubes All Tires ..........main SAVA 14x4, 4.00-6/6 PR B11 front SHENG SHIN 13x5.00-6 B19 Tubes ..........main 4.00-6 TR 13 front 13x5.00-6 Main wheel rim…………………………..AEROSPOOL 02-A Veral Nose wheel rim………………………...… AEROSPOOL 02-A Veral Master Cylinders……………………..
  • Page 62 AIRCRAFT MAINTENANCE MANUAL 3.5.2.2. Assembly of main wheel pants • Tools needed: Metric Allen Wrenches • Parts needed: Bolts, washers, spacing tubes and locking wire • Type of maintenance: Line • Level of Certification needed: - Aircraft owner (only for ELSA) - Sport pilot or higher •...
  • Page 63 AIRCRAFT MAINTENANCE MANUAL Figure 3-23 – Nose Wheel Pant 1. Unscrew the bolts from the wheel axle 2. Unscrew the bolts from the side cover and remove it. 3. Unscrew the bolts on the bracket connected to the nose leg 4.
  • Page 64 AIRCRAFT MAINTENANCE MANUAL 3.5.2.4. Disassembly of main landing gear wheel • Tools needed: wrench to tighten/remove the M13 , M21 nuts Metric, Screwdriver • Parts needed: new tube • Type of maintenance: Line • Level of Certification needed: − Repairman (LS-M) or Mechanic (A&P) – both with the minimum level of certification to perform heavy maintenance of SLSA in the U.S.
  • Page 65 AIRCRAFT MAINTENANCE MANUAL • Task proper accomplishment check: check tire pressure 3.5.2.6. Brake Pads Replacement • Tools needed: Screwdriver, Metric Wrench • Parts needed: brake pads , Loctite 638 to secure the screws, • Type of maintenance: Line − Repairman (LS-M) or Mechanic (A&P) – both with the minimum level of certification to perform heavy maintenance of SLSA in the U.S.
  • Page 66 AIRCRAFT MAINTENANCE MANUAL 3.5.2.7. Bleeding • Tools needed: Screwdriver, Metric Wrench set, plastic bottle for outgoing brake fluid, • Parts needed: brake fluid • Type of maintenance: Line − Repairman (LS-M) or Mechanic (A&P) – both with the minimum level of certification to perform heavy maintenance of SLSA in the U.S.

  • Page 67: Structural Control Surfaces

    AIRCRAFT MAINTENANCE MANUAL 3.6. STRUCTURAL CONTROL SURFACES 3.6.1. Description • Longitudinal control system The airplane is equipped with a classic dual control system. The elevator is controlled by control sticks, with connecting rods and arms. A control stick push/pull movement is transmitted, by a rod inside the quadrant between the seats to the elevator through a two-armed lever located underneath the baggage compartment floor cover.
  • Page 68 AIRCRAFT MAINTENANCE MANUAL Figure 3-26 – Lateral control system layout (Wing) • Directional control system The rudder is controlled by cables attached to the rudder pedals and guided along the fuselage center to the rudder. The rudder pedals are attached to the cockpit floor. There are toe brake pedals on both the pilot and copilot side to operate the main wheel brakes.
  • Page 69 AIRCRAFT MAINTENANCE MANUAL Figure 3-27 – Rudder stops on the nose wheel leg. Figure 3-28 – Longitudinal and directional control system layout. DFE-AMM-AR1 Rev. 1 – 07/24/2014 3-23...
  • Page 70 AIRCRAFT MAINTENANCE MANUAL • Flap control system description The wing flaps are controlled by an electronic controller located on the vertical quadrant below the instrument panel. The servo push/pull actuator movement is transferred to a longitudinal movement of a rod behind the seats (torsional tube).
  • Page 71 AIRCRAFT MAINTENANCE MANUAL • Nose wheel control system description (optional) The aircraft is equipped with steerable nose wheel landing gear. The wheel control system is connected to the rudder pedals. The nose wheel control system consists of the rods, connecting pedals and a two-armed lever welded to the nose landing gear leg.
  • Page 72 AIRCRAFT MAINTENANCE MANUAL 3.6.2. Instructions for Authorized Maintenance, Repair or Alterations 3.6.2.1. Measurement of control surfaces deflections • Tools needed: Protractor with a deflection hand, a clip to attach protractor to measured control surface. • Parts needed: None • Type of maintenance: Line •...
  • Page 73 AIRCRAFT MAINTENANCE MANUAL If a protractor is not available, the following procedure may be substituted: 1. Insert a stiff cardboard sheet of paper in the space between the aileron and the flap. Hold the drawing paper against the flap. 2. Put the aileron in a neutral position. Then trace its profile (upper surface from the hinge to the trailing edge).
  • Page 74 AIRCRAFT MAINTENANCE MANUAL Elevator deflection measurement The starting position to measure the elevator deflections is the neutral positions of the control stick and elevator. The neutral position of the control stick is set by the aircraft manufacturer, by means of a jig. The distances between the control stick and instrument panel, and between the control stick and fuselage side can be used to set the neutral position.
  • Page 75 AIRCRAFT MAINTENANCE MANUAL Trim Tab deflection measurement The trim tab deflection is measured from the neutral position. When the trim tab profile does not protrude from the elevator profile with elevator set in neutral position. 1. Attach a protractor with a deflection hand at the trim tab 2.
  • Page 76 AIRCRAFT MAINTENANCE MANUAL Aileron deflection adjustment Control stops are on the stick A range of deflections are set using adjustment screws on lateral control stops located on a console of the left/right control column. The aileron neutral position can be adjusted with the adjustable end of the short rod inside the cockpit.
  • Page 77 AIRCRAFT MAINTENANCE MANUAL 3.6.2.3. Steerable nose wheel landing gear adjustment • Tools needed: Metric Wrenches • Parts needed: None. • Type of maintenance: Line • Level of Certification needed: Repairman (LS-M) or Mechanic (A&P) – both with the minimum level of certification to perform heavy maintenance of SLSA in the U.S.
  • Page 78 AIRCRAFT MAINTENANCE MANUAL FUSELAGE FRAME SYSTEM SUSPENSION STOP NOSE WHEEL LEG RUBBER ROPE RUBBER ROPE HOLLOW PIN COTTER PIN 2.5 x 25 ČSN 02 1781.05 Figure 3-33 – Rubber shock absorber. • Task proper accomplishment check: Check function of nose wheel shock absorbing. Check for proper installation of cotter pins.

  • Page 79: Permissible Tolerances

    AIRCRAFT MAINTENANCE MANUAL 3.7. PERMISSIBLE TOLERANCES Description The following table indicates the permissible control for critical control the airplane. These values should not be exceeded in operation. Control expected that an operator will system steps if excessive play are found on/in part not listed below.
  • Page 80 AIRCRAFT MAINTENANCE MANUAL Max. Max. Instructions to find an Instructions to correct an System component operational excessive play excessive play play play Ailerons Block ailerons up to the wing and Check condition of bearings 0.08 in 0.2 in control move the control to the left and and replace if needed 2 mm 5 mm...

  • Page 81: Section 4 - Engine

    AIRCRAFT MAINTENANCE MANUAL Section 4 – ENGINE 4.1. GENERAL This Section identifies the line maintenance, minor repair, and minor alteration tasks that can be accomplished in the aircraft engine and correlated items by the Aircraft owner (only for ELSA), a Sport Pilot or higher or a holder of an LSA repairman certificate with either an inspection or maintenance rating.
  • Page 82 AIRCRAFT MAINTENANCE MANUAL Lubrication system description The Rotax 912 engine is provided with a dry sump forced lubrication system. The oil pump pulls the engine oil from the oil tank attached to the firewall via the oil cooler and then forces it through the oil filter to the lubrication points in the engine.
  • Page 83 AIRCRAFT MAINTENANCE MANUAL 4.2.2. Instructions for Authorized Maintenance, Repair or Alterations 4.2.2.1. Oil Filling Refer to the Paragraph 1.6.2 on section 1. 4.2.2.2. Oil Emptying • Tools needed: Phillips Screwdriver, Metric Wrench No. 17, a suitable oil can or sump. •...
  • Page 84 AIRCRAFT MAINTENANCE MANUAL 4.2.2.4. Coolant Filling Refer to the Paragraph 1.6.3 on section 1. 4.2.2.5. Coolant Emptying • Tools needed: Phillips Screwdriver, a suitable container for coolant. • Parts needed: None. • Type of maintenance: Line • Level of Certification needed: Repairman (LS-M) or Mechanic (A&P) –...

  • Page 85: Engine Bed

    AIRCRAFT MAINTENANCE MANUAL 4.3. ENGINE BED 4.3.1. Description The engine mounting bed is welded from chrome-molybdenum tubing and is attached to the firewall with 4 bolts. The bed is spring-mounted with four rubber vibration isolators. Figure 4-2 – Engine Bed (1- bed, 2 - rubber vibration isolators) Figure 4-3 –Rubber vibration isolators details DFE-AMM-AR1 Rev.

  • Page 86: Engine Cowlings

    AIRCRAFT MAINTENANCE MANUAL 4.4. ENGINE COWLINGS 4.4.1. Description There are two fiberglass cowlings (upper and lower) which cover the engine. The interior sides of the cowlings is protected with fire resistant paint, the exterior is painted with aircraft paint. The upper cowling is connected to the lower cowling with quick-closing locks.

  • Page 87: Section 5 - Fuel System

    9, are authorized at this time, for this ALTO aircraft fuel system. Any heavy maintenance, major repairs, or major alterations, as outlined in ASTM F2483 Sections 7 through 9, can only be performed by Direct Fly S.R.O. or only as provided by Direct Fly‘s’ approved engineering data.
  • Page 88 AIRCRAFT MAINTENANCE MANUAL Figure 5-2 – Fuel system scheme. DFE-AMM-AR1 Rev. 1 – 07/24/2014...
  • Page 89 AIRCRAFT MAINTENANCE MANUAL 5.1.2. Instructions for Authorized Maintenance, Repair or Alterations 5.1.2.1. Fueling Refer to the Paragraph 1.6.1. on section 1. 5.1.2.2. Fuel tank draining • Tools needed: None • Parts needed: fuel tester or a transparent cup. • Type of maintenance: Preventive Maintenance •...
  • Page 90 AIRCRAFT MAINTENANCE MANUAL 5.1.2.3. Fuel Emptying • Tools needed: 5/8 inch wrench • Parts needed: a fuel container to be placed under the aircraft. • Type of maintenance: Line • Level of Certification needed: Repairman (LS-M) or Mechanic (A&P) – both with the minimum level of certification to perform heavy maintenance of SLSA in the U.S.

  • Page 91: Section 6 - Propeller

    9, are authorized at this time, for this ALTO aircraft propeller. Any heavy maintenance, major repairs, or major alterations, as outlined in ASTM F2483 Sections 7 through 9, can only be performed by Direct Fly S.R.O. or only as provided by Direct Fly‘s’ approved engineering data.

  • Page 92: Section 7 - Utility Systems

    9, are authorized at this time, for this ALTO aircraft utilities systems. Any heavy maintenance, major repairs, or major alterations, as outlined in ASTM F2483 Sections 7 through 9, can only be performed by Direct Fly S.R.O. or only as provided by Direct Fly‘s’ approved engineering data.

  • Page 93: Ventilation System

    AIRCRAFT MAINTENANCE MANUAL 7.2.2. Instructions for Authorized Maintenance, Repair or Alterations 7.2.2.1. Heating hoses replacement • Tools needed: Screwdriver, metric wrenches • Parts needed: hoses, clamps, wires • Type of maintenance: Line • Level of Certification needed: Repairman (LS-M) or Mechanic (A&P) – both with the minimum level of certification to perform heavy maintenance of SLSA in the U.S.
  • Page 94 AIRCRAFT MAINTENANCE MANUAL 7.3.2. Instructions for Authorized Maintenance, Repair or Alterations 7.3.2.1. Sliding Window Substitution • Tools needed: Screwdriver, metric wrenches • Parts needed: spare window, spare rail • Type of maintenance: Line • Level of Certification needed: Repairman (LS-M) or Mechanic (A&P) – both with the minimum level of certification to perform heavy maintenance of SLSA in the U.S.

  • Page 95: Section 8 - Instruments And Avionics

    9, are authorized at this time, for this ALTO aircraft instruments and avionics. Any heavy maintenance, major repairs, or major alterations, as outlined in ASTM F2483 Sections 7 through 9, can only be performed by Direct Fly S.R.O. or only as provided by Direct Fly‘s’ approved engineering data.
  • Page 96 BC10-1B Altimeter Mikrotechna LUN 1128 Airspeed Indicator BK-15 Slip Indicator Winter WIQM2 Low Voltage Annunciator Direct Fly Fuel Pump Annunciator Direct Fly Trim Position Annunciator Ray Allen Company Left Tank Gauge FL314 Right Tank Gauge FL314 Engine Oil Temperature Road IH61.2B...
  • Page 97 AIRCRAFT MAINTENANCE MANUAL • Instructions: 1. Dismantle the plexi canopy. Remove the top plate of the instrument panel to access the back part of the instruments. 2. The installation procedure will depend on the instrument being installed. Follow the manufacturer recommendations (manuals supplied with particular instruments). •...

  • Page 98: Section 9 - Electrical System

    9, are authorized at this time, for this ALTO aircraft fuel system. Any heavy maintenance, major repairs, or major alterations, as outlined in ASTM F2483 Sections 7 through 9, can only be performed by Direct Fly S.R.O. or only as provided by Direct Fly‘s’ approved engineering data.
  • Page 99 AIRCRAFT MAINTENANCE MANUAL Figure -1 – Wiring dagram for the standard installation. DFE-AMM-AR1 Rev. 1 – 07/24/2014...
  • Page 100 AIRCRAFT MAINTENANCE MANUAL Circuit breakers/switches The circuit breakers E.T.A are located on the lower edge of instrument panel 9.2.2. Instructions for Authorized Maintenance, Repair or Alterations 9.2.2.1. Inspection and operation checks of electrical system • Tools needed: Screwdriver • Parts needed: None •...
  • Page 101 AIRCRAFT MAINTENANCE MANUAL • Instructions: Annual cleaning of electrical equipment to remove dust, dirt, and grime is recommended. Suitable solvents or fine abrasives that will not score the surface or remove the plating may be used to clean the terminals and mating surfaces if they are corroded or dirty. Only cleaning agents that do not leave any type of residue must be used.

  • Page 102: Section 10 - Structural Repair

    9, are authorized at this time, for this ALTO aircraft fuel system. Any heavy maintenance, major repairs, or major alterations, as outlined in ASTM F2483 Sections 7 through 9, can only be performed by Direct Fly S.R.O. or only as provided by Direct Fly‘s’ approved engineering data.
  • Page 103 AIRCRAFT MAINTENANCE MANUAL 10.2.2. Repair guidelines Repairs must be performed only by qualified persons – see Section 0 Paragraph 0.12. Dents, cracks and loose rivets are the most frequent problems encountered during the operation of an all-metal airplane. The following guidelines should be considered during repair: 1.
  • Page 104 AIRCRAFT MAINTENANCE MANUAL 10.2.4. Materials used 10.2.4.1. Materials Specifications Z 424253.61 Czech Standard Al Cu Mg 1 Mechanical properties Yield Point 260 MPa (Minimum) Rp 0.2 Tensile strength 400 MPa Ductility [%] (A10) Chemical composition rest Fe max 0.3 - 0.9 3.8 - 4.9 Zn max 1.2 - 1.8...

  • Page 105: Instructions For Authorized Maintenance, Repair Or Alterations

    AIRCRAFT MAINTENANCE MANUAL 10.2.6. Recommended reading Many useful information you can find in the document: Acceptable Methods, Techniques, and Practices – Aircraft Inspections, Repair & Alternations AC 43.13-1B, AC 43.13-2A 10.3. INSTRUCTIONS FOR AUTHORIZED MAINTENANCE, REPAIR OR ALTERATIONS 10.3.1. SKIN REPAIR •...
  • Page 106 AIRCRAFT MAINTENANCE MANUAL 10.3.1.1. Riveting • Tools needed: drills, riveting pliers • Parts needed: rivets • Type of maintenance: Line • Level of Certification needed: Repairman (LS-M) or Mechanic (A&P) – both with the minimum level of certification to perform heavy maintenance of SLSA in the U.S. FAA approved Part 145 Repair station •...
  • Page 107 AIRCRAFT MAINTENANCE MANUAL 10.3.2. FIBERGLASS PARTS REPAIRS 10.3.2.1. Damage classification Any damage of parts from reinforces plastics with epoxy matrix leads to increased saturation of the matrix with humidity and subsequently to loss of properties. Therefore we recommend carrying out their repair as soon as possible after the damage has occurred. Two kinds of parts are made from these materials in the airplane: •...
  • Page 108 AIRCRAFT MAINTENANCE MANUAL Application of smoothing layer After preparation of mixture (for material recommendation see tab below) 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 spatula. For better distribution of deposited material on irregular surface it is possible to form it through the laid PE or PP transparent folia.
  • Page 109 AIRCRAFT MAINTENANCE MANUAL 10.3.2.2.2. Medium Damage • Tools needed: sand paper, scissors, • Parts needed: epoxy resin, drills, fiberglass cloth , degreasing agent • Type of maintenance: Line • Level of Certification needed: Repairman (LS-M) or Mechanic (A&P) – both with the minimum level of certification to perform heavy maintenance of SLSA in the U.S.
  • Page 110 AIRCRAFT MAINTENANCE MANUAL Putting layers After preparing lamination mixture (for recommendation of material see the Tab. on page 10-4), 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”...

  • Page 111: Section 11 - Painting And Coating

    9, are authorized at this time, for this ALTO aircraft fuel system. Any heavy maintenance, major repairs, or major alterations, as outlined in ASTM F2483 Sections 7 through 9, can only be performed by Direct Fly S.R.O. or only as provided by Direct Fly‘s’ approved engineering data.
  • Page 112 AIRCRAFT MAINTENANCE MANUAL These agents must not be used for degreasing parts from plastics (PC - Lexan, PMMA - Plexiglas) (b) Water-based agents - emulation substances, wetting agents • Applied also by spraying onto washed surfaces or by wiping with wet (by pouring and dipping) textile wad.
  • Page 113 AIRCRAFT MAINTENANCE MANUAL Recommended bonding agents: Surface Manufacturer, Type Other components Drying (grindable) name [min] / 20°C BASF BASF Al-alloys Glasurit 839-10 polyester Glasurit 948-36 (initiator) (base) transitions BASF BASF epoxide-fiberglass + Glasurit 839-45 polyester Glasurit 948-36 (initiator) Al-alloys (base) epoxide Rivet heads DP-190...
  • Page 114 AIRCRAFT MAINTENANCE MANUAL 11.2.2.4. Bonding After total drying of basic coat we recommend to carry out total bonding of irregularities including repairs of bonding. Recommended binders are shown in the table - Recommended bonding agents. After drying perform grinding with emery paper with grain size of 240 until the surface is smooth.

  • Page 115: Instructions For Authorized Maintenance, Repair Or Alterations

    AIRCRAFT MAINTENANCE MANUAL 11.3. INSTRUCTIONS FOR AUTHORIZED MAINTENANCE, REPAIR OR ALTERATIONS 11.3.1. SMALL DAMAGE 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 grinding), of which not all are suitable for (in ageing stage) for good adhesion of paint coats.
  • Page 116 AIRCRAFT MAINTENANCE MANUAL 2 – Degreasing: Refer to paragraph 11.2.2.1 3 – Application of primer: For reaching the satisfactory equal adhesion we recommend to carry out a spray coat of the place to be repaired by adhesive interlayer (see the tab. below). Adhesive interlayer Surface Recommended...

  • Page 117: Section 12 - Revisions

    Date of Issue Description 09/26/2010 Initial Issue a- Layout revised per ASTM F2483- b- Publication number is now using the Direct Fly / Erres Industria 07/24/2014 Aeronautica pattern. c- Revised to comply with the Brazilian version of the ALTO 912 DFE-AMM-AR1 Rev.

  • Page 118: List Of Effective

    AIRCRAFT MAINTENANCE MANUAL 12.3. LIST OF EFFECTIVE PAGES Sec. Page Date Sec. Page Date Sec. Page Date Sec. Page Date 07/24/2014 DFE-AMM-AR1 Rev. 1 – 07/24/2014 12-2...

  • Page 119: Section 13 - Feedback Form

    The owner/operator of a LSA is responsible for notifying the manufacturer of any safety of flight issue or significant service difficulty upon discovery. The following form may be used & sent to Direct Fly S.R.O by email or fax to the addresses listed on Paragraph 0.1 of Section 0.

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