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: 05-Aug-12 This Manual is Approved on the Basis of Manufacturer Self Declaration THIS DOCUMENT IS THE PROPERTY OF FLIGHT DESIGN AND MAY NOT BE CITED, REPRODUCED, DISCLOSED OR DISTRIBUTED IN WHOLE OR IN PART WITHOUT PRIOR EXPRESS WRITTEN PERMISSION OF FLIGHT DESIGN...
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RECORD OF SUPPLEMENT REVISIONS Supplement revisions are provided by Flight Design GmbH as available. The updates shall be manually entered to the individual printed version of the AMM by the Pilot/Owner of the aircraft. Supplement updates are provided in electronic format (pdf file) directly to aircraft Pilots/Owners, when the Pilot/Owner leaves the correct contact information with Flight Design GmbH.
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TABLE OF CONTENTS RECORD OF SUPPLEMENT REVISIONS LIST OF EFFECTIVE SECTIONS TABLE OF CONTENTS CHAPTER 01 – INTRODUCTION CHAPTER 02 – ORGANIZATION AND HANDLING OF THE SUPPLEMENT CHAPTER 04 – AIRWORTHINESS LIMITATIONS CHAPTER 05 – TIME LIMITS AND MAINTENANCE CHECK SECTION 05-10 –...
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CHAPTER 01 – INTRODUCTION Contents 01-00.1 General 01-00.2 Approval 01-00.3 Certification Basis 01-00.4 Manufacturer Contact 01-00.5 Recovery of Certification Data 01-00.6 General Safety Information 01-00.7 Source to Purchase Parts 01-00.8 List of Disposable Replacement Parts 01-00.9 Recommended Torque Values 01-00.1 General This Supplement to the Airplane Maintenance Manual (AMM) contains the data necessary to carry out the maintenance of the CTLS-LSA with ROTAX 912 iS, ROTAX 912 iS Sport or ROTAX 912 iSc Sport installed.
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Required Product Information per ASTM F2745. The revision level of the standards applicable to the specific S/N is identified on the aircraft’s Statement of Compliance. 01-00.4 Manufacturer Contact The aircraft is manufactured by: Flight Design GmbH Zum Tower 4 01917 Kamenz Germany Web: www.flightdesign.com...
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Flight Design distributor or service center that is responsible for your area. You can find contact details of the distributors and service centers on the Flight Design web page. 01-00.8 List of Disposable Replacement Parts...
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CHAPTER 02 – ORGANIZATION AND HANDLING OF THE SUPPLEMENT Contents 02-00.1 Supplement Structure 02-00.1.1 Chapter and Subchapter Structure 02-00.1.2 Page Numbering System 02-00.1.3 Figures 02-00.1.4 Warnings, Cautions and Notes 02-00.1.5 Abbreviations 02-00.2 Supplement Handling 02-00.2.1 Record of Revisions 02-00.2.2 List of Effective Sections 02-00.2.3 Feedback Template 02-00.1 Supplement Structure...
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02-00.1.4 Warnings, Cautions and Notes Please pay attention to the following symbols which are used throughout this document to emphasize certain information: ▲Warning: Used to identify an instruction which if not followed may cause serious injury or even death. ■ Caution: Used to identify an instruction which if not followed may damage the aircraft severely or lead to the warranty suspension.
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Limitations provided in the basic aircraft AMM remain valid. 04-00.4 Life Limited Components The engine installation does not include life limited components. Time limits as listed in CHAPTER 05 shall be used to ensure continued airworthiness of the Flight Design CTLS- LSA. Document Title Document No.
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CHAPTER 05 – TIME LIMITS AND MAINTENANCE CHECK Contents 05-00.1 General 05-00.2 Levels of Certification SECTION 05-10 – TIME LIMITS 05-10.1 General 05-10.2 Scheduled Maintenance Time Limits 05-10.3 Component Time Limits 05-10.3.1 Time between Overhaul 05-10.3.2 Time between Replacement SECTION 05-20 – SCHEDULED MAINTENANCE CHECK 05-20.1 General 05-20.2...
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● Note: Participation in training described in this manual shall not be construed as an implicit authorization by Flight Design to perform inspections or repairs beyond the limitations set forth in the applicable regulations of the governing aviation authority.
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SECTION 05-10 – TIME LIMITS 05-10.1 General All scheduled maintenance checks have time limits. You shall do the scheduled maintenance within the time limits. 05-10.2 Scheduled Maintenance Time Limits The table below contains scheduled maintenance time limits recommended by the manufacturer.
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Chapter Item Overhaul Replacement 2000 h or with engine 71-00.3.2 Engine shock mount replacement, whichever comes first All engine rubber parts, such as: 28-00 All rubber hoses of the cooling system All rubber hoses of the fuel system (incl. Teflon hoses, 75-00 5 years fuel pump and insulating flange if this is fixed with fuel...
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SECTION 05-20 – SCHEDULED MAINTENANCE CHECK 05-20.1 General Perform the scheduled maintenance checks in this Section at the intervals (operating hours and calendar time) marked in SECTION 05-20 with a “ ” or at the time specified. ● Note: Only persons authorized by the National Aviation Authority of the country where the airplane is registered may perform these checks.
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05-20.2.2 Aircraft Records This chapter of AMM is not affected by this Supplement 05-20.2.3 Run-Up Run-up shall be performed before any inspection. ▲Warning: Run-up shall continue until all temperatures are acceptable for take-off. ▲Warning: Minimum Inspection and/or Required Maintenance Initials / Level of Checklist Remarks...
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Minimum Inspection and/or Required Maintenance Initials / Level of Checklist Remarks Certification Check fuel valve off function Notes: 05-20.2.4 Post Run-Up, Pre-inspection and Preparations Minimum Inspection and/or Required Maintenance Initials / Level of Checklist Remarks Certification Airframe, engine, propeller Perform a walk around to detect damage, fluid leaks or other abnormalities, Pilot/Owner Check visual the installation geometry between...
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Minimum Inspection and/or Required Maintenance Initials / Level of Checklist Remarks Certification Engine. Conduct 200 hrs inspection as per Maintenance Manual for A&P ® ROTAX Engine Type 912 iS Series. Engine. Conduct 600 hrs inspection as per Maintenance Manual for A&P ®...
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Minimum Inspection and/or Required Maintenance Initials / Level of Checklist Remarks Certification Refer to Section 28-00.3 Gascolator. Open the gascolator, remove the filter and check for cleanliness. Clean filter and re- install. Check gascolator drain valve for correct Pilot/Owner function and leakage. Refer to Section 28-00.3 Fuel shut off valve.
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Minimum Inspection and/or Required Maintenance Initials / Level of Checklist Remarks Certification Refer to CHAPTER 78 ▲Warning: Failure to inspect Muffler for leaks could result in Carbon monoxide entering the cabin, leading to serious injury or death! Firewall. Inspect for cracks, delamination, buckling, and other signs of damage.
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05-20.2.6 Return to Service Minimum Inspection and/or Required Maintenance Initials / Level of Checklist Remarks Certification Engine Compartment. Make sure that engine compartment is free of any tools, parts, and foreign Pilot/Owner objects. Reinstall all access panels, fairings, etc., which were removed for the inspection. Engine.
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05-20.3 Flight-Line Check 05-20.3.1 General The flight-line checks include the pre-flight and post-flight checks. Do these checks each day the airplane is used. 05-20.3.2 Pre-Flight Check Perform all Preflight Inspection items as defined in the aircraft POH and POH Supplement(s) before the first flight of the day to make sure that the general condition of the airplane and of the engine is good.
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SECTION 05-30 – UNSCHEDULED MAINTENANCE CHECK Please contact the aircraft manufacturer for further instructions. Document Title Document No. Revision Date Section Supplement S3 to the AMM CTLS-LSA – AF 0480 0011 05-Aug-12 05-30-1 CTLS-LSA with ROTAX 912iS Approval Ref.: Approved on the Basis of Manufacturer Self Declaration...
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CHAPTER 11 – PLACARDS AND MARKINGS Contents 11-00.1 General 11-00.2 Placards and Markings 11-00.1 General This chapter provides you with information about exterior and interior placards and markings. 11-00.2 Placards and Markings The aircraft is equipped with the following markings and placards: Item Location Adjacent to each fuel tank filler cap...
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SECTION 12-10 – REPLENISHING 12-10.1 General This section provides instructions concerning replenishing procedures. 12-10.2 Replenishing Practices 12-10.2.1 Refueling and Defueling Fuel content: 136 l (36) total, distributed to: - 2 wing tanks each with 65 l (17.2 US.gal) - one header tank with 6 l (1.6 US.gal). Maximum Usable fuel: 130 l (34.3) total, provided by: - 2 wing tanks each with 63 l (16.7 US.gal) - one header tank with 4 l (1.1 US.gal).
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C. Defueling Step Action Reference Turn the engine off. Set parking brake Put a container below the gascolator drain valve. Open the gascolator drain valve. Drain all accessible fuel from the tanks. Close the gascolator drain valve. 12-10.2.2 Fuel Contamination Test 12-10.2.2.1 Type of Maintenance Line 12-10.2.2.2 Minimum Level of Certification...
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12-10.2.3 Fuel Flow Rate Check 12-10.2.3.1 Type of Maintenance Line 12-10.2.3.2 Minimum Level of Certification Repairman, Light Sport Aircraft-Maintenance (RLSA-M) or higher. 12-10.2.3.3 Procedure A. Recommended Special Tools and Parts Item Quantity Unit Transparent container Measuring jug, fuel and ethanol resistant, min. 4 l (1 US.gal). Alternatively, transparent container as above with calibrated volume markings Marking pen that will write on the transparent container...
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CHAPTER 28 – FUEL SYSTEM Contents 28-00.1 General 28-00.2 Description 28-00.3 Maintenance Practices 28-00.3.1 Fuel System Inspections 28-00.3.2 Fuel Pump Removal and Installation 28-00.3.3 Fuel Hoses and Lines Replacement 28-00.1 General This chapter provides description of the Fuel System. 28-00.2 Description The fuel system consists of: integrated in to each wing fuel tank with capacity of 65 l (17.2 US.gal) with sight gauges at the root rib...
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From shutoff valve fuel flows through a fine filter to the injection lines, the injection valves and the fuel pressure regulator. The fuel pressure regulator keeps injection pressure at the desired level and allows surplus fuel to feed back to the header tank. The back-flow line is also blocked when the fuel shut-off valve is closed.
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Fig. 28-00-2 To open the fuel filler cap, the lever in the cap must be raised and turned 90° anti- clockwise. The cap can then be removed. The cap is properly shut when the lever is pressed down into position (Fig. 28-00-3). Incorrect position Correct position Fig.
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Fig. 28-00-4 The tanks are vented via tubes in the outer tank sections, the air coming from NACA inlets on the outer side of each of the upper winglets. The vent tube is led through the outer tank section in a loop. In this way, no fuel can escape into the vent tubes should the aircraft be parked at a slant.
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Fig. 28-00-6 Fuel selector is placed behind occupants at the fuel selector box (Fig. 28-00-7). The fuel selector normal operating position is “both”, a single tank is only selected temporarily to correct a possible fuel imbalance. Selection of a single tank is announced by the EMS to remind the pilot to go back to “both”.
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Fig. 28-00-8 The fuel shutoff valve is located after Fuel pumps, on the tunnel. This valve closes both, feed line and back flow line and therefore completely separates the engine compartment. As an option two fuel flow transducers can be placed after the shutoff valve. Fuel consumption metering is achieved by the difference between the feed line and the back flow line fuel flow.
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Fig. 28-00-10 Document Title Document No. Revision Date Section Supplement S3 to the AMM CTLS-LSA – AF 0480 0011 05-Aug-12 28-00-7 CTLS-LSA with ROTAX 912iS Approval Ref.: Approved on the Basis of Manufacturer Self Declaration...
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28-00.3 Maintenance Practices 28-00.3.1 Fuel System Inspections 28-00.3.1.1 Type of Maintenance Line 28-00.3.1.2 Minimum Level of Certification Repairman, Light Sport Aircraft-Maintenance (RLSA-M) or higher 28-00.3.1.3 Procedure A. Recommended Special Tools and Parts Item Quantity Unit None B. Fuel Filter Inspection Step Action Reference...
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C. Gascolator Inspection Drain all fuel from the system. Remove lock wire from Gascolator and remove gascolator bowl. Clean gascolator bowl and inspect for damage, cracks and scuffing marks. Clean gascolator filter screen. Assemble gascolator in reverse order. D Shut off valve Inspection Remove lower instrument panel.
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Install the rubber seal ring and press it to the root rib ring. Install the cap plate and press it. Install the washers and the self-locking nuts M6. Do pre-tightening of the nuts, in a sequence shown on picture below, thus the cap plate is not askew.
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28-00.3.2 Fuel Pumps Block Removal and Installation 28-00.3.2.1 Type of Maintenance Line 28-00.3.2.2 Minimum Level of Certification Repairman, Light Sport Aircraft-Maintenance (RLSA-M) or higher 28-00.3.2.3 Procedure A. Recommended Special Tools and Parts Item Quantity Unit None B. Fuel Pumps Block Removal Step Action Reference...
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Fuel pumps Bolts Inspect the Fuel Pumps for damage, corrosion and leakages before re-installation. Install Fuel Pumps in reversed order 28-00.3.3 Fuel Hoses and Lines Replacement 28-00.3.3.1 Type of Maintenance Line 28-00.3.3.2 Minimum Level of Certification Airframe and Powerplant mechanic (A&P) 28-00.3.3.3 Procedure ®...
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CHAPTER 71 – ENGINE Contents 71-00.1 General 71-00.2 Description 71-00.3 Maintenance Practices 71-00.3.1 Engine Cowlings Removal 71-00.3.2 Engine Mount Inspection 71-00.3.3 Air Induction Inspection 71-00.3.4 Starter Replacement 71-00.3.5 Generator Replacement 71-00.3.6 Other Engine Maintenance 71-00.1 General This chapter provides description of the engine systems. 71-00.2 Description ®...
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71-00.3 Maintenance Practices 71-00.3.1 Engine Cowlings Removal The upper and lower cowling cover the engine compartment. The cowlings are connected together and attached to the fuselage. The cowlings are connected with quick fasteners. The upper cowling provides an inspection hatch for access to oil and coolant tanks. The lower cowling provides air-inlets for engine cooling, air induction, cabin heat and mounting position for the optional landing light.
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71-00.3.1.1 Type of Maintenance Line 71-00.3.1.2 Minimum Level of Certification Pilot/Owner 71-00.3.1.3 Procedure A. Recommended Special Tools and Parts Item Quantity Unit None B. Engine Cowlings Removal Step Action Reference Place chocks on the wheels and confirm that the ignition switch is OFF 71.2.1 Unscrew 13 Camlock Studs 7 of upper cowling: Press and turn with the screwdriver to quarter-turn;...
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71-00.3.2 Engine Mount Inspection The engine is attached to the primary aircraft structure by a strong steel engine mount. The small engine mount is attached directly to engine. The small engine mount is attached to the Big Engine mount with rubber shock mounts. Fig.
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71-00.3.2.1 Type of Maintenance Line 71-00.3.2.2 Minimum Level of Certification Repairman, Light Sport Aircraft-Maintenance (RLSA-M) or higher 71-00.3.2.3 Procedure A. Recommended Special Tools and Parts Item Quantity Unit Padded support B. Engine Mount Inspection Step Action Reference Remove upper and lower cowlings 71-00.3.1 Lift the forward fuselage by pushing down the tail at the narrowest part so that the Nose Wheel is at least 25 cm (10 inch) off the ground.
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71-00.3.3.1 Type of Maintenance Line 71-00.3.3.2 Minimum Level of Certification Pilot/Owner 71-00.3.3.3 Procedure A. Recommended Special Tools and Parts Item Quantity Unit None A. Air Intake System Inspection; Airfilter Removal and Installation / Exchange Step Action Reference Remove upper cowling 71-00.3.1 Check Aeroduct hose for damage, security of attachments and condition.
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Check conditions of dust filter. Clean Air Filter 2 and Lower Cowling Filter Box 1. Replace Filter if required. Check the drain hole at the bottom of the dust filter box for obstructions or blockage. Check incoming air line for damage, security of attachments and condition. Install air filter in reverse order.
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71-00.3.6.3 Procedure Refer to the maintenance manual provided by the engine manufacturer for the specific engine. Document Title Document No. Revision Date Section Supplement S3 to the AMM CTLS-LSA – AF 0480 0011 05-Aug-12 71-00-8 CTLS-LSA with ROTAX 912iS Approval Ref.: Approved on the Basis of Manufacturer Self Declaration...
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CHAPTER 73 – ENGINE FUEL AND CONTROL Refer to the maintenance manual provided by the engine manufacturer for your engine for description and maintenance instructions on the engine-mounted portion of the fuel system. Document Title Document No. Revision Date Section Supplement S3 to the AMM CTLS-LSA –...
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CHAPTER 74 – IGNITION Refer to the maintenance manual provided by the engine manufacturer for your engine for description and maintenance instructions on the ignition system including spark plugs. Document Title Document No. Revision Date Section Supplement S3 to the AMM CTLS-LSA – AF 0480 0011 05-Aug-12 74-00-1...
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CHAPTER 75 – COOLING Contents 75-00.1 General 75-00.2 Description 75-00.3 Maintenance Practices 75-00.3.1 Cooling Inspection 75-00.3.2 Cooling Hoses and Lines Replacement 75-00.1 General This chapter provides description and information concerning maintenance of engine cooling. 75-00.2 Description The engine is provided with liquid cooling. The coupled water and oil radiators are installed in front of the engine just behind the air-inlet.
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Fig. 75-00-2. Cooling system diagram with thermostat From the top of the cylinder heads the coolant passes on to the expansion tank. Since the standard location of the radiator is below engine level, the expansion tank located on top of the engine allows for coolant expansion. The expansion tank is closed by a pressure cap (with excess pressure valve and return valve).
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Fig. 75-00-3. Cooling System Document Title Document No. Revision Date Section Supplement S3 to the AMM CTLS-LSA – AF 0480 0011 05-Aug-12 75-00-3 CTLS-LSA with ROTAX 912iS Approval Ref.: Approved on the Basis of Manufacturer Self Declaration...
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75-00.3 Maintenance Practices 75-00.3.1 Cooling Inspection 75-00.3.1.1 Type of Maintenance Line 75-00.3.1.2 Minimum Level of Certification Pilot/Owner 75-00.3.1.3 Procedure A. Recommended Special Tools and Parts Item Quantity Unit None B. Cooling Inspection Step Action Reference Inspect connections for leaks. Check coolant level. Replenish if required. Inspect cylinders for dents, cracks and cooling jacket for chafing marks and burn spots.
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Shock mount Fig. 75-00-5. Radiators Unit mounting Remove clamp from overflow bottle hose and disconnect the hose from nipple. Remove clamp from vent tube, and disconnect it from nipple. Inspect overflow bottle vent line for damage and blockage. Replace if required. Drain coolant in clean container.
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CHAPTER 76 – ENGINE CONTROLS Contents 76-00.1 General 76-00.2 Description 76-00.3 Maintenance Practices 76-00.3.1 Throttle Box Inspection 76-00.1 General This chapter provides description and information concerning maintenance of engine controls. 76-00.2 Description The throttle quadrant is located in the center pedestal, just behind the lower instrument panel.
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Detailed view is given in Fig. 76-00-2. Fig. 76-00-2 Document Title Document No. Revision Date Section Supplement S3 to the AMM CTLS-LSA – AF 0480 0011 05-Aug-12 76-00-2 CTLS-LSA with ROTAX 912iS Approval Ref.: Approved on the Basis of Manufacturer Self Declaration...
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Fig. Item Part Name Torque Reference Main Plate KF76000151 Covering Plate KF76000001 Grip KF76000132 Grip KF76000131 Bolt DIN 7991 M6x35 A2-70 C9996219 Grip KF32400010 Grip KF32400012 Bolt DIN 7991 M6x30 A4 C9996218A Countersunk rivet nut, steel, M5 C9996834 Holder DC76000101 Bolt DIN 912 M6x30-8.8 C9996059 Bolt DIN 912 M4x20-8.8...
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76-00.3 Maintenance Practices 76-00.3.1 Throttle Box Inspection 76-00.3.1.1 Type of Maintenance Line 76-00.3.1.2 Minimum Level of Certification Repairman, Light Sport Aircraft-Maintenance (RLSA-M) or higher 76-00.3.1.3 Procedure A. Recommended Special Tools and Parts Item Quantity Unit None B. Throttle Box Inspection (Fig. 76-00-2). Step Action Reference...
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CHAPTER 77 – ENGINE INDICATING For maintenance instructions regarding the engine indicating system contact the aircraft manufacturer. Document Title Document No. Revision Date Section Supplement S3 to the AMM CTLS-LSA – AF 0480 0011 05-Aug-12 77-00-1 CTLS-LSA with ROTAX 912iS Approval Ref.: Approved on the Basis of Manufacturer Self Declaration...
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CHAPTER 78 – EXHAUST Contents 78-00.1 General 78-00.2 Description 78-00.3 Maintenance Practices 78-00.3.1 Exhaust Muffler and Pipes Removal 78-00.3.2 Exhaust Muffler and Pipes Inspection 78-00.1 General This chapter provides description and information concerning maintenance of engine exhaust. 78-00.2 Description The powerplant exhaust system consists of the muffler and exhaust pipes. The exhaust gases from the cylinders go to the muffler via the exhaust elbows.
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Fig. Item Part Name Torque Reference Forward exhaust pipe, right KF78000010 Rear exhaust pipe, right KF78000020 Forward exhaust pipe, left KF78000030 78-00-1 Rear exhaust pipe, left KF78000040 Muffler KF78000050 Spring Spring 12 Nm C9996035 78-00.3 Maintenance Practices 78-00.3.1 Exhaust Muffler Removal 78-00.3.1.1 Type of Maintenance Line 78-00.3.1.2 Minimum Level of Certification...
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B. Exhaust Muffler and Pipes Inspection Step Action Reference Inspect exhaust system for damage and missing parts. Checks attachment Nuts 7 and Springs 6 for securing and fit. Inspect exhaust pipes and mounting flanges for cracks, corrosion and leakages. Remove heating shroud from Muffler as per instructions in the basic AMM. Inspect muffler for cracks, corrosion and leakages.
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CHAPTER 79 – OIL SYSTEM Contents 79-00.1 General 79-00.2 Description 79-00.3 Maintenance Practices 79-00.3.1 Oil System Inspection 79-00.3.2 Oil Hoses and Lines Replacement 79-00.1 General This chapter provides description and information concerning maintenance of engine oil system. 79-00.2 Description The oil system is available in two variants: −...
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Fig. 79-00-2. Oil System diagram Fig. Item Part Name Torque Reference Engine ROTAX® 912 iS C9997789Z/C9997791Y Oil pump C9993515J Oil filter C9997793R Oil thermostat C9997793Y 79-00-1 Oil tank C9997791I 79-00-2 Radiators Unit KF79000050 Oil hose C9997792D Fuel hose (vent line) C9993184G Oil pressure sensor C9997798O...
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Fig. 79-00-3 79-00.3 Maintenance Practices 79-00.3.1 Oil System Inspection 79-00.3.1.1 Type of Maintenance Line 79-00.3.1.2 Minimum Level of Certification Repairman, Light Sport Aircraft-Maintenance (RLSA-M) or higher 79-00.3.1.3 Procedure A. Recommended Special Tools and Parts Item Quantity Unit None B. Oil System Inspection Step Action Reference...
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Check the securing and conditions of Oil pressure sensor. Tighten sensor with torque 15Nm and secured with Loctite 243. Check the securing and conditions of oil temperature sensors. Check the securing and conditions of magnetic plug. 12-20-00 12 79-00.3.2 Oil Hoses and Lines Replacement For maintenance instructions regarding oil hoses and lines replacement contact the aircraft manufacturer.
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