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Lightwing AC4 Maintenance Manual

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LightWing AC4
Maintenance Manual
LightWing AC4
Maintenance Manual
Doc N° LW-RL-Z-004
LW-RL-Z-004
Rev.:1
Page 1

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  • Page 1 LightWing AC4 Maintenance Manual LightWing AC4 Maintenance Manual Doc N° LW-RL-Z-004 LW-RL-Z-004 Rev.:1 Page 1...
  • Page 2 LightWing AC4 Maintenance Manual Intentionally left blank. LW-RL-Z-004 Rev.:1 Page 2...
  • Page 3 LightWing AC4 Maintenance Manual Amendments Issue Date Revised Description pages First Edition Original TC under ADxC-48-001- Edition 12-May-2014 all (1..123) Transfer from ADxC-48-001-AMM 1stEdt. to LW- Rev.:0 23-Sep-2014 all (1..123) RL-Z-004 with detail rework All (1…109) Rev.:1 19-Sep-2017 Detail Rework to V02 All (1…109...

  • Page 4: Table Of Contents

    Table of Contents Chapter Title ...................... Page Introduction ..............9 General .................... 9 01-00 Coverage..................9 01-10 Guidelines ..................9 01-20 Related Publications ................9 01-30 Addresses ..................10 01-40 How to Use the Manual ..........11 General ..................11 02-00 Notes .....................
  • Page 5 Dimensions and Areas ..........50 General ..................50 06-00 Coordinate System ................50 06-00-01 Main Data ..................50 06-10 External Dimensions ................ 50 06-10-01 Internal Dimensions ................. 50 06-10-02 Wing ....................50 06-10-03 Aileron ................... 51 06-10-04 Flap ....................51 06-10-05 Horizontal Tail .................
  • Page 6 Baggage Compartment..............63 25-50 Controls ..............65 Ailerons ..................65 27-10 Rudder ................... 67 27-20 Elevator and Tab ................68 27-30 Flap System ..................70 27-50 Fuel ................ 72 Indicating and Recording Systems ......74 Instrument & Control Panels .............. 74 31-10 Landing Gear ............
  • Page 7 Windows ..............91 Wing ..............92 Propeller ..............95 Power Plant ............. 96 Cowling ..................96 71-10 Engine Mount ................. 98 71-20 Fire Seals ..................98 71-30 Engine ..............100 Air ................ 102 Cooling System ................102 75-20 Engine Controls ............. 104 Exhaust ..............
  • Page 8 List of Effective Pages Page Date Page Date Page Date 1 Cover Rev. 1 24.07.17 2 thru 109 LW-RL-Z-004 Rev.:1 Page 8...

  • Page 9: Introduction

    General This Maintenance Manual provides educated maintenance staff information necessary for servicing, maintenance and repair of the LightWing AC4 CS- LSA Type aircraft. It contains a detailed description of systems including time limits for the particular components and instructions for the performance of inspections and maintenance.

  • Page 10: Addresses

    PowerFLARM FTD-033 PowerFLARM Core installation manual 01-40 Addresses Contacts for service bulletins, general information and for ordering parts: Firm Address Light Wing AG Riedenmatt 1 6370 Stans Switzerland E-mail: info@lightwing.ch Rotax Refer to Rotax Service network LW-RL-Z-004 Rev.:1 Page 10...

  • Page 11: How To Use The Manual

    How to Use the Manual 02-00 General The format and contents of this manual have been prepared in accordance with the GENERAL AVIATION MANUFACTURERS ASSOCIATION (GAMA) Specification No. 2. The contents of this manual are organized in three levels:  Group ...
  • Page 12 three words are emphasized by a safety sign. The text of the note or safety note is printed in bold. See the following examples: Danger Represents a dangerous situation. The non-observation of this safety note will result in death or serious injuries. Warning Represents a dangerous situation.

  • Page 13: General Description

    General Description 03-00 General The LightWing AC4 aircraft is a  Conventional high strutted wing configuration;  Conventional strutted tail;  Single Rotax piston tractor engine with fixed pitch propeller;  2 seat side by side;  Fixed tricycle landing gear with steerable nose wheel airplane.
  • Page 14 Figure 2: AC4 side view Figure 3: AC4 top view LW-RL-Z-004 Rev.:1 Page 14...
  • Page 15 Figure 4: AC4 front view LW-RL-Z-004 Rev.:1 Page 15...

  • Page 16: Limitations

    04-10 Structural Limitations and Inspection Intervals The airframe of the Lightwing AC4 is limited to 6000h, the engine mount to 4000h. In addition, the airframe must undergo a major airframe inspection according to 04-30 at 3000h/10year (whichever comes first) intervals for the airframe and at 2000h/10year (whichever comes first) intervals for the engine.

  • Page 17: Major Inspection

    04-30 Major Inspection 04-30-10 Major inspection airframe The major airframe inspection program is not defined at time of print. Upon reaching this airframe life limit contact Light Wing AG. Critical components are: Main beam 1000-00003 Cross beam 1000-00005 Horizontal stabilizer interface 1000-00063/64/65/66/67 Cross beam to fuselage interface 1000-00059 /60/61/62...

  • Page 18: Software

    Make appropriate airplane log book entry for release to furhter service 04-40 Software Only Software delivered with the airplane, or as mandated by resperctive Service Bulletins are approved to be used in the AC4. This adresses: Software revison Function Unit...

  • Page 19: Inspection And Maintenance

    This chapter contains charts, tables and checklists for time limits, scheduled and unscheduled maintenance, to enable licensed personnel to carry out correct inspections on the LightWing AC4 aircraft. The periodic inspections and checks described and the related intervals are minimum required for maintaining the aircraft in airworthy condition.

  • Page 20: Component Time Limits

    05-10-01 Component Time Limits Time between Overhaul Component Interval Propeller Neuform 1000 h 2000 h (refer to latest ROTAX Rotax 912i Engine documentation applicable to the actual SN of the engine) Time Between Replacement Component Interval ELT Batteries 6 years Depending on annual test Dynon SkyView Batteries result...

  • Page 21: Scheduled Maintenance

    05-20 Scheduled Maintenance 05-20-01 Scheduled Inspection plan Scheduled Inspection Report Make Model Serial Number Registration LightWing Owner Date Type of Inspection Airframe time (logbook) 100 h/ Scheduled Inspection 50 h annual specified Preparatory Activities ○ ○ ○ Review of aircraft logbook ○...
  • Page 22 100 h/ Scheduled Inspection 50 h annual specified Inspect top empennage panel and tail cone for delamination, ○ discoloration, cracks and damage, and condition of paint. ○ ○ Check control stick sleeve for condition. Remove bottom empennage panel, middle console, baggage ○...
  • Page 23 100 h/ Scheduled Inspection 50 h annual specified Clean fuel filter next to shut-off valve and inspect for foreign ○ particles. Cabin Heat System (if installed) ○ ○ Inspect hoses for attachment, leaks and wear. ○ ○ Inspect air scoop at radiator for cleanness ○...
  • Page 24 100 h/ Scheduled Inspection 50 h annual specified Engine Controls Check throttle control for proper attachment, full travel, freedom and ○ ○ ○ smoothness of movement. Clean and lubricate Bowden cable. Refer to Section 05-20-02 500h/ 5 Years Lubrication Chart. Inspect all wiring connected to the engine, regulators and ○...
  • Page 25 100 h/ Scheduled Inspection 50 h annual specified Inspect mounting bolts. Re-torque mounting bolts according to ○ ○ ○ chapter 61 Inspect propeller blades for cracks, dents, nicks, scratches, erosion ○ ○ or other damage. Inspect propeller blade mounting for wear and play (no play allowed at blade tip in any direction).
  • Page 26 100 h/ Scheduled Inspection 50 h annual specified Inspect front and rear cross beam struts ("base brace"; V struts facing FWD and aft from cross beam to main beam) for deformation ○ and cracks. Check rivets for condition. No gaps between tube and rod ends allowed.
  • Page 27 100 h/ Scheduled Inspection 50 h annual specified ○ Check instrument panel for condition and proper attachment. Seats and Restraint System ○ Check seat support structure for condition Check seat adjustment, lubricate per Section 05-20-02 ○ Lubrication Chart. ○ Check seat upholstery and cushions for condition and attachment ○...
  • Page 28 100 h/ Scheduled Inspection 50 h annual specified Check all internal wing batten holders on front and rear spar, as well ○ as wing batten distance holders for cracks. Horizontal Stabilizer Attachment ○ Check condition of mounting flanges. ○ Check rivets for condition. ○...
  • Page 29 100 h/ Scheduled Inspection 50 h annual specified Control Surface Hinges Lubricate hinges as per Section 05-20-02 Lubrication Chart. ○ Check saddle pieces of hinges for condition and safety of ○ attachment. (Wing hinges have saddle pieces only on the control surface side.) ○...
  • Page 30 100 h/ Scheduled Inspection 50 h annual specified ○ Check condition and security of travel stops. ○ Check condition, security and tension (100-200 N) of control cables. ○ Check condition, free movement and security of pulleys. ○ Check central bellcrank for condition. ○...
  • Page 31 100 h/ Scheduled Inspection 50 h annual specified Elevator Flettner Tab System ○ ○ Check for condition, security, free movement and operation. Check deflections. Refer to Section 06-10-09 Flettner Tab for nominal values. actual …….. Elevator Up (tab at -26°), ○...
  • Page 32 100 h/ Scheduled Inspection 50 h annual specified Check shut-off valve function by closing while fuel pumps are running (START POWER ON). Check fuel pressure indication drop, ○ reopen shut off valve and check fuel pressure regain. Switch START POWER OFF. Fuel Tank ○...
  • Page 33 100 h/ Scheduled Inspection 50 h annual specified Perform Pitot-static system leak test: Pitot: pressurize to 240km/hIAS, allowable drop 20km/h/min Static: evacuate to 10000ft, allowable drop 100ft/min. ○ Note: allow vertical speed indicator (if installed) to stabilize before taking measurement. Most likely points of leakage are the instruments themselves and hose connections.
  • Page 34 100 h/ Scheduled Inspection 50 h annual specified Landing Gear & Brakes Main Landing Gear Attachment ○ Check bayonet bolts for proper attachment of security bolts. ○ Inspect bearing roller for fretting, wear and damage. Check rubber buffer for condition and proper attachment. Inspect for ○...
  • Page 35 100 h/ Scheduled Inspection 50 h annual specified ○ ○ Check brake lines and hoses for proper routing and attachment. ○ Check brake filling state according AFM, refill as required. ○ ○ Check park brake action. Replace brake system fluid as per Chapter 12-10-01 Replenishment 200h/ of Brake Fluid 2 years...
  • Page 36 100 h/ Scheduled Inspection 50 h annual specified Fuel pressure within limit over complete RPM range both pumps ○ ○ ○ individual and in combination. ○ ○ ○ Check battery and power generation. ○ ○ ○ Install upper cowling Perform maintenance check flight according to 05-20-04 ○...

  • Page 37: Lubrication Chart

    05-20-02 Lubrication Chart Three types of lubricants are used which are  "oil", meaning any general purpose mineral oil according to MIL-PRF-7870 or similar  "grease" meaning any water free general-purpose grease according to MIL-PRF-81322 or similar.  "copper paste" meaning any high temperature copper anti-seize according to MIL-PRF-907E or similar Interval Item...
  • Page 38 Figure 5 Drain holes cowling area Figure 6 Drain holes belly panel area (view from RH side) LW-RL-Z-004 Rev.:1 Page 38...
  • Page 39 Figure 7 Drain hole tail Figure 8 Drain holes horizontal stabilizer fabric Figure 9 Drain holes wing fabric (infront rear spar) LW-RL-Z-004 Rev.:1 Page 39...

  • Page 40: Maintenance Check Flight

    05-20-04 Maintenance Check Flight The maintenance check flight is intended to check whether the aircraft can be released for service. Reasons for performing a maintenance check flight can be different. Examples include restoring to operation after the aircraft has been stored for a long period, with yearly maintenance, or aircraft modifications.
  • Page 41 Performance Tests The goal of the performance tests is to have a spot check of three relevant flight conditions in the envelope. Climb, cruise, and full throttle level flight are checked. Both flight performance and engine performance are monitored. Climb Fly the aircraft at a speed between 105 and 115 km/h IAS using a full throttle and flaps retraced.
  • Page 42 speed do not stall the aircraft. Check controls with all possible flap settings. The maximum speed with flaps intermediate and full flaps is 165 km/h IAS. Longitudinal Trim Operate the trim through the full range. It should be possible to trim the aircraft in a speed range above 90km/h IAS at Full throttle and flap up as well as 100km/h IAS at 3000RPM and flap up.
  • Page 43 Skyview System General Verify that the database is current. Verify that software settings are applicable to the AC4 and unchanged versus the information contained in the flight manual. Artificial Horizon Check the logical functioning of the artificial horizon. It should be possible to see the effects from both roll and pitch on the instrument instantaneous and reflecting actual pitch and roll.
  • Page 44 conditions, the temperature will increase with increasing altitude (inversion). If needed consult the meteo office for further information on the day of the test. OAT indication should not change with any change electric power or environment situation. Changed or erratic OAT while transmitting on the Com radio indicates a degradation of the sensor wire shielding.
  • Page 45 EGT Indication Check the functioning of the EGT indication on the EMU display by changing the throttle setting. In idle conditions, the EGT of the various cylinders will have a significant spread, in stabilized conditions above 4000RPM the difference between the four EGT signals should be no more than 50°C. CHT Indication The CHT indication should remain relatively unaffected by the flight condition due to the thermostat employed in the coolant system.

  • Page 46: Unscheduled Maintenance

    Normal Flight In this item the pilot should comment on the normal flight handling. He can base his judgement on the experience gained on the type in previous flights. He should base his judgment on all items tested so far in the maintenance check flight.
  • Page 47 Line Theoretical Acceptable measure tolerance 1868mm ±0.5% 5364mm ±0.5% 4241mm ±0.5% 4593mm ±0.5% 5940mm ±0.5% 2083mm ±0.5% Figure 10 Check distances, overview, side and front view Line 1, 1856mm: The measurement is taken from the frontend center of the lower wing strut attachment bolt to the forward corner of the nose gear strut.
  • Page 48 Figure 11 Line 1, 1856mm Line 2 / 5348mm: Measurment is taken from the lower center of the outer wing tip bolt to the front edge of the nose gear strut. Figure 12 Line 2, 5348mm Line 3 / 4226mm: Measurment is taken from the lower center of the outer wing tip bolt to the center of the lower wing strut bolt.
  • Page 49 Figure 14 Line 4, 4584mm Line 5 / 5932mm: Measurement is taken from the upper center of the outer wing tip bolt to the edge of the vertical tail tube (shortest distance). Figure 15 Line 5, 5932mm Line 6 / 2083mm: Measurement is taken from the edge of the horizontal tail spar tube to the edge of the vertical tail tube (shortest distance).

  • Page 50: Dimensions And Areas

    Dimensions and Areas 06-00 General 06-00-01 Coordinate System An artificial datum point in front and below of the aircraft is defined. All data in this Manual refer to this datum in EX, EY and EZ coordinates. Level attitude is defined by the orientation of the lower door frame. Axis System ...

  • Page 51: Aileron

    Sweep angle Leading edge: 0 06-10-04 Aileron Area: (each) 0.435 m Span: (each) 1.829 m Displacement: Up 22° +-2° Down 20° +-2° 06-10-05 Flap Area: (each) 0.660 m Span: (each) 2.290 m Positions: Down 0/ 10 /24 +-2° 06-10-06 Horizontal Tail Area: 2.250 m Span:...

  • Page 52: Flettner Tab

    Span 900 mm Chord 65 mm Displacement up (for nose down) with elevator at zero +5° +/-2° Displacement down (for nose up) -27° +/-2° Root & Tip Incidences1.2° Trim range REF = X-axis +5° -27° Main beam 4° dwn relative to WRT Reference System Figure 18 Trim range 06-10-09...

  • Page 53: Rudder

    06-10-11 Rudder Area:* 0.576 m² Span:* full Displacement: Left/Right 25 +/-2° 06-10-12 Fuel System Total volume: 90 litres Unusable volume: 4 litres 06-10-13 Landing Gear Direction (zero load) Nose wheel ground 1.460 contact point Main wheel ground tow in 0° 3.303 +/-0.958 contact point...

  • Page 54: Servicing

    Servicing For servicing the engine (oil, water) refer to applicable Rotax instructions (refer to Chapter 01-30 Related Publications). 12-10 Replenishing 12-10-01 Replenishment of Brake Fluid Necessary Tools: square key wrench (11) Allen key Beringer bleeding equipment Brake fluid Transparent hose Procedure 1 Loosen LH and RH filling nipple (do not remove).

  • Page 55: Standard Practices Airframe

    Standard Practices Airframe 20-00 General The design of the airframe is according to standard procedures and generally requires no special tools or procedures for maintenance other than presented in AC 43-13. Specific torque and tension values are given in the following. 20-10 Standard Practices Airframe 20-10-01...
  • Page 56 The structural cables in the wing cannot be adjusted. If their tension is outside limits it is a sign of damage. In this case contact Light Wing AG LW-RL-Z-004 Rev.:1 Page 56...

  • Page 57: Environmental Systems

    Cabin heating Description The AC4 features an optional cabin heating system which uses RAM air aft of the coolant radiator and guides it through an exhaust shroud. The heated air is further guided to a firewall mounted valve which either dumps the air back into the cowling area or, if the valve is selected by the pilot to ON, into the cabin below the instrument panel.

  • Page 58: Electrical Power

    Electrical Power Description The heart of the system is provided by the fuse box of the engine manufacturer. The Rotax generation system provides a 12/14V system voltage. On the airframe side, it further features a lead battery in the engine compartment, with a 16Ah capacity at 12.7 V.
  • Page 59 continues running on the airframe generator which in this mode no longer supplies the airframe. In case of a dual generator failure the engine control is supplied by means of a manual activates back-up system drawing power only from the battery. In this mode, the usable time is limited by battery capacity. Engine ignition is through the Lane A and B which are selectable individual or as automatic combination.
  • Page 60 Figure 22 Electric system schematic LW-RL-Z-004 Rev.:1 Page 60...

  • Page 61: Equipment/Furnishings

    Equipment/Furnishings 25-10 Flight Compartment Description The cabin volume is separated from the rest of the fuselage by the engine bulkhead/instrument panel on the front and a lightweight textile curtain at the rear. 25-10-01 Seats Description Two seats with integrated head rest, with an adjusting range of approx. 8 cm are provided.
  • Page 62 Figure 23: Seat Figure 24: Seat support principle LW-RL-Z-004 Rev.:1 Page 62...

  • Page 63: Baggage Compartment

    25-50 Baggage Compartment Description A maximum of 25kg of baggage can be placed behind the seats, above the fuel tank, and can be secured by rings anchored at the main beam and at the composite fuselage frame. The fuel cell top surface is sized as loading bay to withstand maximum baggage mass g-loads.
  • Page 64 Figure 26: Luggage restraint anchor points on main beam LW-RL-Z-004 Rev.:1 Page 64...

  • Page 65: Controls

    Controls Description The control system is designed with push pull rods and cables. All push pull rods feature spherical rod end bearings allowing system adjustment. The control cables are stainless steel and feature a 3mm diameter. At cockpit level, the control system consists of a central (single) control stick, two sets of rudder pedals, one flap actuator located at the cockpit ceiling, one elevator trim actuator switch.
  • Page 66 pushrods are connected to two chordwise pushrods, actuating both ailerons (see Figure 29). Polyamid control stops are placed on the fuselage centre beam acting at the rocker type bell crank connecting the torsion tube to the cables. The cable part of the system can be adjusted by a turnbuckle in the vertical moving part of the system.

  • Page 67: Rudder

    If the gearing is not correct it is a sign of internal deformations. In this case contact Light Wing AG. 27-20 Rudder Description The rudder is commanded by two sets of non-adjustable rudder pedals connected to control cables which cross each other while moving aft (see Figure 30).

  • Page 68: Elevator And Tab

    Figure 31 Rudder pedal mounting Rudder Rigging The first step in rigging of the system is to center the nose gear with left and right rudder pedals aligned. After this the rudder cable length is adjusted such that the rudder is centered. 27-30 Elevator and Tab Description...
  • Page 69 Figure 32 Elevator actuation, (orange=bearings, red = massbalance) A trim tab is employed on the left-hand elevator side and controlled by an electric actuator. The linear servo is mounted in the elevator, near the hinge line pivot. The trim actuation control is on the control stick, the indication by means of a multi LED indicator on the instrument panel.

  • Page 70: Flap System

    Elevator Rigging For all movables on horizontal tail (elevatror, trim, flettner) adjust the respective zero position. If resulting deflections do not correspond to the defined values it is a sign for deformations in the system. In this case contact Light Wing AG. Note that the zero position of the elevator is with respect to the horizontal stabilizer, see Figure 17 27-50...
  • Page 71 Pilot indication Figure 35 Flap actuation unit Flap Rigging Flap (and (aileron) are in zero position with the lower surface aligned with the main wing spar to spar tangent on the lower side. The zero position can be set using rod end adjustment range. If the gearing is not correct it is a sign of internal deformations.

  • Page 72: Fuel

    Fuel Description Fuel is stored in a single composite fuel tank behind the seats. The tank capacity is 90 liter. On the tank bottom, a sump volume is present. Bulkhead penetrations and a fuel strainer are mounted. Figure 36 Fuel tank and its integration Downstream of the fuel tank there is a shut off valve and a filter with a sediment volume (gascollator) and finally the dual fuel pump unit with internal check valves.
  • Page 73 Figure 37 Fuel system schematic The system can be drained through the tank. A (water) contamination collection sump is present in the lower part of the tank. Just above is a 4 liter header volume to ensure uninterrupted fuel supply. The fuel cell ventilation features four pick up points which route high over the cockpit frame and high along the rear luggage volume limitation.

  • Page 74: Indicating And Recording Systems

    " EMUevo SW 1.41". Only this, or later approved revisions as mandated be revision of this handbook or by respective service information issued by Light Wing AG is approved foir use in the AC4 type airplane. Note Changing airframe related software settings, such as speed limits or units used, in the multifunction display "Skyview"...

  • Page 75: Landing Gear

    Landing Gear Description The AC4 has a tricycle landing gear with steerable nose wheel. The nose gear leg passes through the fuselage main beam (Figure 40). An elastomeric insert is used to provide the spring/damping characteristics of the nose gear.
  • Page 76 Figure 41 Nose landing gear wheel fairing The main landing gear leg is a machined steel spring connected by brackets to the fuselage cross beam, see Figure 42. Figure 42 Main landing gear connection to fuselage LW-RL-Z-004 Rev.:1 Page 76...

  • Page 77: Wheels And Brakes

    32-40 Wheels and Brakes Description The wheels and brakes are produced by Berringer. The wheels have a 4.00- 6” aluminium rims and 15*6.00-6 tires (Berringer P/N wheel RF-004(B)). Central braking is present at the main gear wheels, using floating disk brakes, actuated by a single break handle placed on the main control stick (Berringer P/N HAB02 brake cylinder;...

  • Page 78: Navigation

    Navigation 34-10 Flight Environment Data 34-10-01 Pitot/Static System Description The Pitot port is located in the left wing, at the connection of the wing strut. Associated pressure tubing is routed thought the wing, then along the fuselage frame to the centre of the instrument panel. Static pressure is taken from the interior of the fuselage and routed to the instrument panel along the fuselage centre beam.
  • Page 79 Figure 45: Pitot tube, with optional aerodynamic strut cover Figure 46: Pitot/static system drains under Co-pilot seat The pitot-static system serves the airspeed and altimeter instruments but also the ADAHARS and a pressure switch for operation hour counting. LW-RL-Z-004 Rev.:1 Page 79...
  • Page 80 Figure 47: Pitot-static routing LW-RL-Z-004 Rev.:1 Page 80...

  • Page 81: Standard Practices And Structures - General

    Standard Practices and Structures – General 51-30 Materials Specification Used on Primary structure & Control system aluminium 6082T6 (AlSi1MgMnT6) fuselage main beam, framework tubes, control system tubes, brackets, wing battens aluminium 2024 control system tubes, structural struts aluminium 7020 structural tubes aluminium 6060T66 fuselage cross beam, brackets aluminium 6005 &...

  • Page 82: Doors

    Doors Description The aircraft has one door on each occupant side. The doors are top hinged (i.e. open upwards) and feature a turning locking mechanism. Figure 48: Door lock actuation (inside) For lubrication the inner part of the mechanism is accessible from the inside after removal of the outer and inner handle parts.

  • Page 83: Fuselage

    Fuselage Description The fuselage is constructed around a central load bearing aluminium tube: the main beam (see Figure 49). Figure 49 Main beam The second load bearing element is an aluminium box section frame: the cross beam (See Figure 50). Figure 50 Cross beam LW-RL-Z-004...
  • Page 84 For the attachment of the wing, an aluminium and steel tube frame is connected to the main and cross beam. This frame consists of (from front to rear) the  base brace  cabin bearing structure  cabin support  rear cabin struts. The complete configuration is shown in Figure 51, including the wing attachment locations.
  • Page 85  The air tow winch and hook connection. The fuselage cross beam acts as structural connection for:  The main landing gear,  The front and rear cross beam struts,  The wing struts,  The pilot seats AFT support, ...
  • Page 86 Figure 52 Fuselage panels The engine cowlings are attached to the engine bulkhead frame plane by means of bolts. A view of the cowling attachment bolts is given in Figure 53. Figure 53 Cowling attachment location The cockpit bottom ‘belly panel’ is connected to the engine bulkhead in the front (Figure 54) and to the cabin composite frame at the cross beam in the rear (Figure 55).
  • Page 87 Figure 54 Belly panel connection to firewall Figure 55 Belly panel connection to cabin composite frame The bottom empennage panel is connected to the bulkhead and framework in the front (Figure 56) and to the horizontal stabiliser main spar supports in the rear (Figure 57).
  • Page 88 Figure 57 Bottom empennage panel to main bean connection The top empennage panel is connected to the aluminium/steel framework and the bottom empennage panel as well as to the wing centre panel. Details are shown in Figure 56 and Figure 57. Figure 58 Top to bottom empennage panel connection When removing or re-installing the top empennage panel care must be...

  • Page 89: Stabilizers

    Stabilizers Description The horizontal and vertical stabilisers consist of an aluminium tube framework covered with thermal shrinking tensioned fabric. They provide mutual support by struts attached to the tubes in front of the hinge line. Figure 59 Tail structure 55-10 Horizontal Stabilizer Description The horizontal stabiliser is connected to the fuselage centre beam via a...

  • Page 90: Vertical Stabilizer

    55-30 Vertical Stabilizer Description The vertical stabiliser’s two main load carrying spars pass through the entire fuselage centre beam. The mounting of the vertical stabilizer tubes is done using riveted stop rings to avoid movement and liquid shim to avoid chaffing. LW-RL-Z-004 Rev.:1 Page 90...

  • Page 91: Windows

    Windows Description Pilot and occupant external vision is provided by a windshield, windows in the doors as well as windows in the top empennage cover. All windows and the windshield are adhesively bonded to the respective supporting composite covers. The windshield is bonded from the outside, all other transparencies from the inside.

  • Page 92: Wing

    Wing Description The AC4 has a thermal shrinking tensioned fabric skin wing. Structurally, the wing consists of two aluminium tube spars, held in place by aluminium tube ribs, tensioning cables and a rear lift truss strut combination. The spars lie on the leading edge and forward of the control surface hinge lines, as can be seen in Figure 62.
  • Page 93 Figure 63 Wing rib battens Rigging/De-rigging For reduction of required hangar space, the wings can be taken off. For this purpose, the following system connections need to be opened and closed:  bolted aileron system connection  bolted flap system connection ...
  • Page 94 Figure 64 Wing structure, secant tool for rigging check The tool is used at stations between the rib battens along the span. The nominal angle determined by the Inclinometer is 0°. The acceptable general tolerance is 0.5°. However, the difference between the average angle left and average right shall not be more than 0.5°, nor should the tolerance within one wing be more than 0.5°.

  • Page 95: Propeller

    Propeller Description Propeller Neuform Make: Neuform Composites GmbH & Co Type: CR3-75 3-blade Diameter: 1.75m Blade angle: 25° measured 365mm from hub center using the Neuform tool, which determines the gaugeable angle (Secant). Refer to Figure 66. Torque Bolts: 25Nm Figure 66 Definition of the gaugeable angle LW-RL-Z-004...

  • Page 96: Power Plant

    Power Plant 71-10 Cowling Description The cowling is made from glass fibre composite in an upper and lower part. Both are removable from the airplane as a whole using bolted hardware. For pre-flight inspection a hatch giving access to the oil and coolant water reservoir is provided.
  • Page 97 Figure 68 Cowling inlet for engine air and oil radiator Figure 69 Cowling inlet for cylinder cooling and coolant radiator (note: inlet of optional cabin heating system is right aft of coolant radiator) LW-RL-Z-004 Rev.:1 Page 97...

  • Page 98: Engine Mount

    Fire Seals Description The engine cowling area is the only designated fire zone of the AC4 airplane. The basic firewall is a 0.4mm stainless steel sheet. It is installed along the separation line of cowling and fuselage covers in a self stiffening Z-shape.
  • Page 99  Electric cables sealed with high temperature silicone;  Fuselage centre beam tube opening is closed with stainless steel plates  Fuselage centre beam surface is protected by by textile aluminized glass fibre heat shield  Fuselage centre beam and engine mount interfaces are sealed with high temperature silicone;...

  • Page 100: Engine

    Approved software revision for the engine control unit (ECU) is designated "130". Only this, or later approved revisions as mandated be revision of this handbook or by respective service information issued by Light Wing AG is approved for use in the AC4 type airplane LW-RL-Z-004 Rev.:1...
  • Page 101 Figure 72 Rotax 912iSc/iS Sport LW-RL-Z-004 Rev.:1 Page 101...

  • Page 102: Air

    Description The engine takes its air from a separate NACA inlet on the right cowling side, see Figure 73. The air enters a separated volume into which the induction filter and engine air data sensor are mounted. Figure 73 Air filter installation Engine inlet air temperature is sensed next to the inlet filter.
  • Page 103 The radiator is supplied with cooling air from the cowling centre front inlet. LW-RL-Z-004 Rev.:1 Page 103...

  • Page 104: Engine Controls

    Engine Controls Description The engine side of the engine control is thought the engine manufacturer supplied engine control unit (ECU). The airframe side engine control compromises the following:  A throttle vernier control for the pilot in the left side of the instrument panel, mechanically driving directly the throttle valve;...

  • Page 105: Exhaust

    Exhaust Description The exhaust system is mounted to the engine bock. The muffler is located below the engine such that the length of all four exhaust discharge stacks is similar. The design of the engine exhaust is shown in Figure 74. Figure 74 Exhaust system The exhaust discharges to the left through the lower main air dump opening.

  • Page 106: Oil

    Description The engine is provided with a dry sump oil system, which includes a pump and an oil pressure regulator. The oil pump is driven by the crankshaft. The oil pump sucks the oil from the sump, and delivers the oil through a filter to the moving components requiring lubrication.

  • Page 107: Charts

    Charts Figure 75 Wire routing (Power) LW-RL-Z-004 Rev.:1 Page 107...
  • Page 108 Figure 76 Wire routing (RF) LW-RL-Z-004 Rev.:1 Page 108...
  • Page 109 AC-4 Maintenance Check Flight Form Date: Tacho: QNH: Empty mass: Pilot: Serial number: Take Off: Wind: Take off mass: C Landing: OAT: Fuel: liter Registration: Observer: Duration: Remarks: Performance tests Configuration Altitude Altitude Elapsed Oil press. Oil temp Fuel press. (km/h) begin (ft) end (ft)

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