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SLSA 582 Dragonfly Maintenance Manual rev.5

1. Appendix Page 1 Page 86 Appendix Page 2 Page 87 Moster cinder Appendix B Page 3 Page 88 TE E 88 x p el e Notes Double Calliper Paris on Axle Caliper up and One Aft of axle Elbow changes to DFN 003 Bolts go up one size through bulkhead elbow and axle EET TERT um CAPT NET i aira alpa rin 4 han re cha Forced oka 2 em 528655 T L 5258 T Appendix B Page 4 Page 89 SECION AA 3 T 3 201 RU A LIE im sio as n 8 THRU insanos cd 6829 sus nan Wheel hub 3 4 anle ares psp 1 Mount Tire Se Spl for Ri edn fn as ta
2. TEAS A CORE CD HT STS TT 1 9 washer ANA half Washer COT ST SOE TEATS UK COTE ATW ST SSS TTS UT 1 4 washer ANS Loos ANE S N wae Wing 5878898555 WOT ANT TB ANT TRS ACE COND fut 50 ANT TWAT ST SES lt 59857 ing como strut saddle 114 washer ANA hal nd comp strut inboard DFC ona Ba ANE 7R Ta washer wg DIRT DORE wi comp sa chanel boa Lt washer ANS half NE Ba ANTE SORT Wa TH MAR TT AN HT Tant SANCTI WaT WT GG SHATTER TS RO 4 0 washer ANA hall nut aT ARE washer OT ST CTT UT washer ANA Looser 20 AER WESE Ep wing spar ang edge vut plate YA washer ANA Tus Tight Check to be sure wing comp stut ends wth 2 holes are to aft of wing and ht Unused in bent Bel onboard Sand off rough edges of wing edge ao damage sal labio Cut omar of box selections in ling edge win hacksaw Sand curved ol hres trailing dee To remove wax Testit aling edge 6 at wing trame Appl appro Ral ube of Liquid porton of aling eig one bead down e mi
3. Section 17 Maintenance 8 Inspection Dragonfly 582 WING BATTENS AND SAILS T INSTRUCTIONS or Assembly or Disassemby reverse order PRAT WO ETRGETERT tape wang edge pace Ural wing par DFR oT rasa wing starboard DFR 002 lay leading edge mylar at on ground Using scissors inside sall cut the upper porton ot ho batten pocket 1 0 tud ofthe mylar edge This 6 away rom the Zippers Sade ing carey Into sa Proceed slowly snage aa not attempt Find ha s caught ro 9 continuing Rotae sal bottom sde o um inside seam to Return outside eam o cene faf ralling edge Turn Inside seem of vinto se before puling ight Put a penal mark on wing apar leading edge 4 tam nbeari end Pu a penc mark baton of wing apar waling 4 inboard ra V or screwdriver Ou hole af eg spar leading edge Pu used rivet Shank through end of pul oop or rough ogee alle way othe and ct Threads a loop ot Place around vet shank overtop of rod another rod and cart pul to board Crank ut inboard o sal touches pencil marka take sure seam le stl tumed to boom side Cane rommet on edge Dri 62 hie wing spar leading edge rough grommet
4. OFT SIE grommet oul loop wing spar leading edge Tight Remove cord and vet shank Place 114 Tad diagonal wing spar rang edpe s0 catches against mar bushing Put used vet shank rough pl oo In previous step Wrap cord round rod and tighten umtii fabrie reaches pencl mark Certe grommet on 88 wing spar ling edge Dil 552 hoe in wing sper ling rough grommet Tay TOES QUITE Wing Spar T cranking process to 3 Sew e IU ST omma pu cg wg sperare 2058 ana upper IT 88 025 lt Probe Ine fud end ot batten upper DFF 003 Stand wing on leading edge and secure Staring at wingtip nsec batten though sta side ot wing ana ino pocket side tot may need ta be cut or enrped to banene 6 Most pockets may be reached trough o zippers you may use tee hand a hel banen Push banen approx 34 of way in Inser balen end aft DFP 046 of baten Continue pushing etl baten exta hud end of pocket Remove hte Srt appar i banen end twa DFP Cl Push aluminum aver leading edge spar Push batten down uni Do not pop into place yet Repeal procos moving iird batten rom tp s the most dictt acess 02 needle piere to remove tp and baton end wa ol wood or tubing used aluminum piece over spar Ret
5. tab aft ube conn saddle end threaded 966 715 x 10 32 Vay ign stab HATS a GATE MIU oA stabelevatr port DER 008 Side horiz stab 1 3 In and put horiz stab comp strut outboard DFF 007 n Piace Side tame 23 nana put horiz stab comp strut Inboard DFF cos n place Push al the way ito sall Push inside seam to bonom screwdriver ar lang Ser rad na i and of nariz stab att Loop engi of cor around sab compr Sinut and botas snow Crank bor round or whatever nales I you nave any roble geting bon stars use a 10 32 Tap 10 align par Bolt ANS ISA hinge hor sta al tube conn saddle end 1 vended 7116x 10132 Very fate Repeal above procedure tor bol slab elevator Winch bt ends at same time to avoid sale damage DFR oo TER Washer 885 589 TET TORE 3 Siete 966278 765 9802 EEE pT SEG To T BAT elevator hinge b herz tab inge 40 hinge b t hare stab 3 16 washer ANS fase nd coner Loose ARS TUTE TESTS TE OAT stab hinge b vat inge bt ANS caso ru coner Libres Putus pop rivet stainless steel 1 8 x e levator comp strut Pullivet ight Do nat pop Bend shank 1801 far hook Piace rubber
6. TST RUCTIONS Tor RESERV revers rir PARTNO T ETAGE TEGTANEZEK TE Washer Wing Spar easing 5 85 tum rue heads wingtip Insert wing up wing tip wing spar leading edge 1 4 washer ANS halt Tight DER DIE DFP 006 6666 Bot ANE ASR washer umet heads wing Spar eae ming p ser weg t Wig tio Insert wing spar 595 14 washer ANA hal nu 586928 RU CIOST SES ing coss brace wing comp strut saddle channel bit Ming wing comp stt saddle channel 1 4 washer ANA Vl mat Tigh 88005 Sat RESORT washer Wg Spa ing Wg UM We TOS TICE CE WU ross brace cable ANA ul ut Tigh washer Wig SI Canna 895588 TT lend wih 2 holes goes to af on al comp Site ing comp sin ade channel bikt threaded insert 12 x 14 28 PL Very taht Tom In insert wt paralel wing comp str oro ote wing Gey STU Shane RT WD WaT TO 10 washer ANA na nut Loose wl appear to be 100 long bu he aleron support tube ataches nere aler washer mhg Spar ead wing 53896 channel wed cros ANT Mna Bo AN SOR wing TOSS HACE WG 98 RTT DAT WN faa
7. T Bol ANF 2TA 1 4 washer 131 plate mount Block 014 boom tube truss assembly DFW 041 tail plate load tube DFC 024 Very taht Z Bal ANE SER THUG 2756 5989 88801988 582 OFT OOS saddle aft root supp brkt 582 DFP 020 boom tube 1 4 washer ANA fll nut Very tight 3 Bolt 84 55 through oot supp Tower 582 TaN TOOT supp bi Tower OTE alt root supp brkt 582 saddle root supp brkt 912 boom tube Spacer main boom wire 875 x 75 x 25 DFP 025 tang three hole DFO 032 ANA full nut Very tight 3 Tio Bolt through 318 washar each of Twa push rod guide OFP OOS boom tube Very tight Maximum 0 090 space around Push Rod 300hr Note Apply dry lube fo pushrod where it passes through guide every 100 hrs or Annual 5 Eye bolt ANA2 aA OFT OT through boom tube Flat end of eye 98 is at right angle with boom tube when tight 100 ne Tight Replacement merenan cable 2977 Using old cable o pull new cable through tape the now release cable to the old cable and pull through Bring te a end ot the release through the 1 2 hale to align with the 79659 boom Recommended Special Tools Nome 2 The parts needed to perform the task Replace worn damaged parts as needed listed above Max Wear defined 1 1 5 3 Type of maintenance Inspection Line amp Replacement Heavy when involves replacement of structu
8. 9 7 ESO DFW 002 2 AN3 16A 3 16 washer aileron main spar aileron torsion Tube aileron main spar 3 16 washer ANS halt nut Very tight TT Recommended Special Tools None 2 The parts needed to perform the task Replace worn damaged parts as needed listed above Max Wear defined 1 1 Type of maintenance Inspection Line amp Replacement Heavy when it involves replacement of structural components 4 Certification needed to accomplish the task Line LSRI Inspection or above Heavy LSRM Maintenance or above Level of Certification in this manual 8 1 75 Detailed instructions and diagrams as needed To perform The ask ted above and adjacent page Every Annual or 100 Hrs Inspect for Cracks Corrosion Elongation of holes amp Fasteners for Wear amp Security See 1 3 8 Fabric Coverings For more inspection and testing information on fabric coverings 6 Method to testinspect to verify the task was accomplished properly Insure that all procedures were followed correctly and there is proper non binding movement to moving parts and that fasteners were tightened as instructed When flight controls are involved assure that they are operating properly Section 15 38668 Sails Section 16 Page 50 LEFT AILERON Drawing 15 Page 51 Section 16 Maintenance amp Inspection Dragonfly 582 WING
9. TIT Recommended Special Tools None 2 The parts needed to perform the task Replace worn damaged parts as needed listed above Max Wear defined 1 1 8 1 3 Type of maintenance Inspection Line amp Replacement Heavy when involves replacement of structural compone 4 Certification needed to accomplish the task LSRI Inspection or above Heavy LSRM Maintenance or above see 3 Level of Certification in this manual 5 Detailed instructions and diagrams as needed to perform the task listed above and adjacent page Every Annual or 100 Hrs Inspect for Cracks Corrosion Elongation of holes amp Fasteners for Wear amp Security V Fabric Coverings For more inspection and testing information on fabric coverings See Cables Thimbles and Tangs Page 16 6 Method testlinspect to verify the task was accomplished properly Insure that all procedures were followed correctly and there is proper non binding movement to moving parts and that fasteners were tightened as instructed When flight controls are involved assure that they are operating properly Section 12 Horiz Stabilizer amp Elev Sails Section 12 Page 44 24 HORIZONTAL STABILISER ELEVATOR SAILS I DRAGONFLY __ ya p d SEE UTE Drawings 12A amp 128 Page 45 Section 13 Maintenance 8 Inspection Dragonfly 582 CONTROLS
10. 4 Certification needed to accomplish the task Line LSRI Inspection or above Heavy LSRM Maintenance or above sec Level of Certification in this manual 5 Detailed instructions and diagrams as needed to perform the task listed above and adjacent page Every Annual or 100 Hrs Inspect for Cracks Corrosion Elongation of holes amp Fasteners for Wear amp Security 1 Inspect this tube to insure Rudder Cables are not cutting tube amp Bolt ANA 21A is not loose both sides 6 Method to test inspect to verily the task was accomplished properly Insure that all procedures were followed correctly and there is proper non binding movement to moving parts and that fasteners were tightened as instructed When flight controls are involved assure that they are operating properly Section 6 Pilot Seat Section 6 Page 32 DRAGONFLY 08 PILOT SEAT uddar maybe cating fs ute Section 7 Maintenance amp Inspection Dragonfly 582 FWD WHEEL THROTTLE amp BRAKE Note Hydraulic Brakes see Appendix T RSTRUCTORS Yor for Disassembly reverse The order PRR OE Ta aS aT TTT TORE FONT We BOD and ing a S o t a out mourning hole for rake drum Bolt hex head x 18 TPX 114 DFT 007 brake drum
11. system tor chating and improper operation ot switches C wnest tor cracks detects and condilion of bearings Ties tor wear and cuts scares tor improper ausiment 0 Each person performing an Annual or 100 hour inspection land center section assembly for poor general condition tab insecunty ot attachment J inspect where applicable all components of the wing kin deterioration distortion evidence of allure and 9 Each person pertorming an Annual or 100 hour Inspection shal inspect where applicable all components and systems of tare insecure atachment improper component installation and improper component operation 2 Each person performing an Annual or 100 hour Inspection shall inspect where applicable the following components of propeller group C Propeler assembiy tor cracks nicks binds and oll leakage Lots tor improper torqueing and lack ot sate tying person performing an annual or 100 hour inspection shall inspect where applicable the following components of Me redo group Rado and electronic equipment tor improper instalation and insecure mounting C wiring and conduits tor improper routing insecure mounting and obvious detects Conaing and shielding tor improper installation and poor condition incuding antenna or poor condition insecure mounting and improper operation Each person pertorming an annual or 100 hour inspection shall inspec
12. wheel in 8020 ru 6167 x SETPL Very Hohe 5878858827 UFTUTY ana Trant tube DFS 008 ana onte DFS 054 it as tar as posse ning up vale with notch Line up wheel halves wih bots and push tont wesi im 020 as ye as posse You may ue a screw or simlar ol inserted nga betwen haves o help push ro place You wil ony be able to push tyre apro 12 Pu Inner ube eam he way mne tube becomes pched between hes Raves E wia leak nen head SE ia TPI 14 font wheel im 8021 ront whae rm B020 put 51 18 TPL Very gt Pat yes are feito fom i Working You way around and around the seems to Work Do mor take 1 10 stre they wit Dre he rm 3 Bar ANS TIR E washer DFN 003 whe equipped w DC brakes 508652 DEN OT ANI IAA and washers when equipped with Dual Caliper Brakes and 3i Axle adie Don 8 loriya gear 3 18 washer ANS hal Tight Most Ror bto ou on ead TENIS Brae 55588 OPT TES 100 hr gear bow e washar ANG hal night one et nd one 5 ang 12 8 dra gear sbon Ba ARES bos 14 washer ANA hal nut brake Ea BPE 558 DOT BI OFT S4 washer hati nut Vey Alan biki paralel gear elbow EET ARETE STE washer oath gato VG washer ARTI VETOT JANITSA amp 14 and w
13. GA 20259 ON IT Scr Maling P O Box 4000 Corona CA 92878 4000 Free Order Line Outside USA Order ne Order Line 6774777505 55 372555 877 705 2278 al Free Fax Line USA Fax Line Canada Far Ln 200 329 3020 351 372 55 519 750 0064 Customer Serice Page 11 1 1 3 List of disposable replacement parts Air filters fuel filters tires tubes ete 1 1 3 1 Engine Parts refer to Rotax Engine Manuals and Authorized Rotax Parts Distributor or Rotax Service Center 1 1 2 Airframe and System All Parts can be purchased direct from Pitman Air alternate suppliers listed below A Fuel Lines 2100686 Ether Based Superthane Only NOT Ester Based Industries Ine 115 James Way Southampton PA 18966 3817 Phone 00 506 3024 215 526 2300 Fax 800 837 1836 or 2155262100 E mail ples newageindusries com B Fuel Line Primer Bulb bypass line Check Valve Check Valve EW 98553 00 http w ww colepar mer com catalog product_view asp sku 0855300 Cole Parmer 625 East Bunker Court Vernon Hills Ilinois 60061 Phone 1 800 323 4340 Fax 1 847 247 2020 E Mail info com C Fuel Line Primer Bulb Quality Primer Bulb from any Marine or Parts Supplier D Fuel In Line Strainer Filler No Paper Filters Any Strainer that meets Rotax requirements from any Marine or Auto Pars Supplier Es Tires See Aircraft Spruce Above Any quality tires commonly used o
14. with a maintenance rating LSRM or equivalent 34 see 41 5 1 661 Tems that be expected to be completed by a responsible individual who holds a mechanic certificate with airframe power plant ratings or both or equivalent 3 5 Task Specific see 4 1 5 1 6 1 and Appendix D of this manual Items that be expected to he completed hy a responsible individual who holds either a mechanic certificate or a repairman certificate and has received task specific training to perform the task 3 51 Rotax Engines and Gearboxes Rotax requires their own Specific Certification in 2 and 4 cycle engines Because of the high compression high RPM s very tight tolerances the extreme need for cleanliness from dust amp dirt while inside the engine and methods ot commonly found in aircraft engines As well as features in their gearboxes which are unique to Rotax General aircraft engine experience may not be sufficient to correctly maintain or service these engines and related components Therefore We agree with Rotax That the technician must have the appropriate Rotax training experience and certificates to work on these engines and their components Rotax is continually making changes in th engines and components which justifies their requirement for recurrent training and certification of such 3 6 Multiple descriptors and modifiers may be used For example manufacturer may list under level
15. 1 1 washer full nut Very ight also tighten bolts 34 5 7 Bar hal top cane Tibe plug 5 EEE 88807 Atach cable clamp DFT 431 T krom af end Sie paste sleeve trough bukhesd Serew pan head 1075347 DFO 009 Tom ant end Side plastic sleeve through row pan 5 cable clamp 1 4 tube plug 875 x 75 x 25 DESIR 3 Face Us Spacer DFG OOF main boom supp iube DFG 014 You may squeeze the lube sighty wih 1o faciitate Be sure wrap ube lo preveni maring use just enough pressure to avoid deioming ub Bol ANA 16A washer channel bt 1 19500 main boom supp toe spacer i ube spacer 575 375 main boom supp tube channel bit 1 1 4 washer ANA hal ul 100 hr Very tight Re tighten every 100 His Look for elongation of holes Bolt Boom supp TA TEE DO TOE A washer ANA hall nat Trough boom supp hae saddle 1 DFP 031 tang mid root DFO 030 boom tube tang mid root saddle 1 main boom supp tube 1 4 washer Very tight Loosening 2 or 5 may assist in assembly T Recommended Special Tools None 2 The parts needed to perform the task Replace worn damaged parts as needed listed above Wear defined 1 1 8 1 Type of maintenance Inspection Line amp Replacement Heavy when involves replacement a structural components 4 Certification needed to
16. 95 901 in Asa percentage of MAC Empty Weight Mas Moment Am Moments 10h 906 506 8768 1960in Moments 494008 9590 86 56 The empty weight CG position from the Leading Edge is then 3596 sss 1153 1 MAX AFT CG WITH 1338 PILOT AND FUEL example Weight Arm Moment 9596 49388 Sin Ib Fuel 6606 6600in Ib Pilot 133b 350in 4655 Din Ib 6598 lb ca MOMENT 290 8 MASS 65 Asa percentage of MAC mn 38 3 MAC 1 1532 WITH MAX FUEL amp TWO 90 KG 199 Ib PILOTS example Weight Arm Moment 952 40388 sin 1b Fuel E 1989 1b Pilot m 3508 por Co Plor 1996 808 nere 746368 ca MOMENT MASS 95 Asa percentage of MAC oa no m MAC DE 11533 WITH MAX FUEL amp 100 221 Ib PILOT FOR MAX FORWARD CG example Weight Moment Aircraft 9596 49388 Sin Ib Fuel 1989 0in Ib Pilot 22115 350in 350in lb Toib 92 88 ca MOME s Sim MASS 7 Asa percentage of MAC 7685 660 1685 1645 wl MAC 11 53 4 AIRCRAFT SPECIFIC WEIGHT AND CG POSITION NOTE Retrieve these numbers from your POH Pilot Operating Handbook Dragonfly Serial No Weight wheel
17. ANS castle nut cotier pin Loose 2 Side two SPRCGFBUIRRERI 875 25 DFP 025 into bukhead Insert bolt boom bulkhead assembly DFW O11 though cross tube n the boom Install boom end plug DFP 027 Wrap packing tape around bolt assembly and cross tube to secure bolts Slide release cable through boom end plug and drive plug into boom tube Bulkhead spacer bulkhead 175 8 25 x 1 25 bulkhead 14 washer high temp nut Very tight 3 Side gear Block DFPOTT into bulkhead Bot AN4 23A 1 4 washer bulkhead gear block bulkhead 1 4 washer ful nut Loose 3875919882 into gear block align with hol in bulkhead Bolt AN4 23A 14 washer bulkhead gear leg bulkhead 147 washer AN4 high temp nut Very tight Using a sharp 174 dr square wih surface of bulkhead d il gear 8668 halfway through Repeat other side holes wil ind each other in the middle LLP500 ANA 26A 1500 1 4 washer cockpit channel brkt lower DFI 011 LLP500 bulkhead gear block bulkhead channel brkt 1 12500 DFL 016 114 washer ANA al nut Loose 5 Toot supper twa DFE 00T into bulkhead Hole may be fled but keep the fi as snug as possible Side spacer 1 8 25 x 125 DFP 028 between each side of root supp fwd and bulkhead Bolt AN4 24A 1 4 washer cockpit channel bt lower bulkhead spacer 17 x 257 125 root support fd spacer T x 25 125 bulkhead
18. Red Bull CA 96080 OR Online at wine pitmanaircomidragonty Check One of Concern Safety of Flight Service Difficult Reporting Party Contact Information Name Address City Zip Code Day Phone FAX email address Check Appropriate Owner Operator LSRI LSRM Other Explain Aircraft Specific Information Aircraft Information Engine Information Make Make Model Model Serial Number Serial Number N Number Gearbox Ratio Date of Mig Propeller Mfg Propeller Serial Date of Problem Discovery Description Comments Signature_ 06 Page 150 Safety of Flight amp Service Difficulty Report Form Mail to Pitman Air 1840 Airport Blvd Red Bluff CA 96080 OR Online at wine pitmanaiccomidragonty Tem of Service Check one Concem Safety of Flight Difficult Reporting Party Contact Information Name Address City ST Zip Code Day Phone FAX email address Check Appropriate Owner Operator LSRI LSRM ARP Other Explain Aircraft Specific Information Engine Aircraft Information Information Make Make Model Model Serial Number Serial Number N Number Gearbox Ratio Date of Mfg Propeller Mfg Propeller Serial Date of Problem Discovery ddimmiyyyy Description Comments Signature
19. When On this display will toggle between the wo EGTs every 2 seconds allowing you 1o observed both without switching pages CHT Toggle When the highest CHT is displayed combination sereen 1 When On this display will toggle between the two CHTs every 2 seconds allowing you to observed Both CHTs without switching pags Combo Page Selets whether coolant temperature Cool o outside air temperature OAT is displayed on the combination pages The OAT selection is useful when coolant temperature is not being monitored TachiPIR Indicates the number of pulses per revolution of the engine Tor tachometer sensing Rotax CDI engines require a setting The Rotax 912 requires a sening of L Fuel SF FueLOM Fuc level input scaling Nomal settings are 5 0 and Forvard respectively When using Princeton Electronics fuel level probe set the Fuel SF to hall of the desired full tank reading For example i you want to display the fuet level as 0 1009 set the Fuel SF 1o 50 Messages at Power Up Non Rotax Tach Setting This indicates the TachPIR setting is not standard for Rotax engine This is a reminder that it may be set The instrument wil not change the TachP R sting however Limits Reset This indicates that a limit may have been altered unintentionally The instrument will reset all limits the initial factory Appendix C Page 8 Page 102 Troubleshooting Common
20. located on the ELT Main Unit and Remote Switch Unit and a buzzer are to indicate when the ELT is transmitting Both ELT Main Unit and Remote Unit are sf powered by their internal batteries Automatic activation is remained regardless whether the Cable Interconnect between the Main Unit and the Remote Unit is open or shortened Appendix F Page 3 Page 134 n PE Figure 1 Mounting Tray for ELT P N 450 013 Figure 2 Holder for ELT P N 450 014 Figure 3 Mounting Tray with Velcro Holder and Portable Antenna for Appendix F Page 4 Page 135 ELT Figure 4 Battery Pack Replacement for ELT Main Unit Actual View Figure 5 Battery Cell Replacement for ELT Main Unit Actual View AK 450 has 6 D Cell Alkaline Batteries MECHANICAL INSTALLATION The ELT is designed with the installer in mind accessories which are required for complete ELT system installation are provided including Mounting Tray Velcro Holder Coaxial Cable Assembly and Wiring Cable Assembly Because of the critical nature of an ELT is very important that the installation be performed according to the following instructions Installation of the ELT is somewhat unique as is the installation of any TSO CI26 and 50 51 ELT requires experience in sheet metal work and avionics Only licensed technicians should install the ELT Many problems assoc
21. system to be done as preventive maintenance and subject to the provisions of Sections 43 13 a and b FAR 4313 Performance rules general Appendix D Page 6 Page 113 Each person performing maintenance alteration or preventive maintenance on an aircraft engine propeller appliance shall use the methods techniques and practices prescribed in the current manufacturer s maintenance manual or Instructions for Continued Airworthiness prepared by its manufacturer or other methods techniques and practices acceptable to the Administrator except as noted in 43 16 He shall use the tools equipment and test apparatus necessary to assure completion of the work in accordance with accepted industry practices special equipment or test apparatus is recommended by the manufacturer involved he must use that equipment or apparatus or its equivalent acceptable to the Administrator b Each person maintaining or altering performing preventive maintenance shall do that work in such manner and use materials of such a quality that the condition of the aircraft airframe aircraft engine propeller or appliance worked on will be at least equal to its original or properly altered condition with regard to aerodynamic function structural strength resistance to vibration and deterioration and other qualities affecting airworthiness c Special provisions for holders of air carrier operating certificates
22. Appendix E2 Page 12 End of Appendix E2 Page 131 Appendix GENERAL INFORMATION Ameri King 451 6 AK 450 SCOPE contains most information necessary for the instalation test and operation of the model AK 481 Emergency Locator Transmitter manufactured by Ameri King Corporation California U S A For more detailed informatio refer to appropriate manuals on Ameri King website hitp www ameri king com Important Note In the event your aireraft is equipped with an AK 450 Apply these difference 1 Batteries are 6 D Cell Alkaline batteries 2 Lights Only one Red Light instead of 2 green 3 No Sell Test Mode 4 Only 121 5 MHz and 243 MHz transmission 8 No audible buzzer tone OVERVIEW Description The Ameri King 451 0 Series isa FAA TSO d approved EASA ETSO d approved 406 MHz ELT Emergency Locator Transmitter Types AF Automatic Fixed AP Automatic Portable S Survival It transmits aircraft GPSINAV position data immediately and accurately on triple 406 Satellite 243 Military 1215 Civilian MHz frequencies The supreme advantage feature is the aircraft GPS NAV Latitude Longitude exact position shall be transmitted within 1 minute on the very first burst without waiting for Polar Orbiting Satellite could be up to 4 hours Enhance the accuracy significantly for the ground search arca from 1 2 kilometers non GPS NAV Position to 22 meters typical with GPS NAV Position Hav
23. Coolant Temperature be monitored No Remember that EGT reflects the fuel air ratio and the internal temperatures of the engine The CHT and coolant reflect how well the engine is being cooled and the overall temperature of the engine When an engine is damaged due to high EGT lean mixture it is typical for the CHT or coolant temperature to remain normal When an engine is damaged due to high CHT and or coolant lack of cooling itis typical for the to remain normal They measure different aspects of the engine that do not necessarily react together Area for Owner to make Notes Appendix Page 4 Page 98 Operating Instructions for the EIS Model 20006 The Model 2000 is specifically designed for the powered parachute type aircraft requires very tle input from the pilot Before using the Model 2000 for the first time Set the units for temperature altitude and fuel quantity if used as desired The instruments are set at the factory to Fahrenheit Feet and Gallons for temperature altitude and fuel respectively Read the section on Automatic Altimeter operation Set this as desired Engine limits are pre set at the factory You may review these limits and change them at any time if you desire AI settings in the instrument may be set back to the initial factory settings by holding the right button Display when tuning on the instrament Before Each Flight 1 If the altimeter is operated in the Manual mode
24. Insert tube conn fat and Loose 3 Bolt ANG 20K washer elevator horn saddle 1 elevator T conn starboard 3 16 washer ANS halt Tighten bolts 4 and 5 Very tight Bolt 520 3776 washer elevator 096269 inser 7167 10 2 Sfevalor levator conn port DFJ 005 3 16 washer ANS hee tube conn tiat end Loose 7 Balt 20 316 washer elevator saddle 1 elevator conn 86 87 Washer nut Tighten bolts 6 and 7 Very tight 888888 DFO TET tube conn fiat end threaded insert 7 16 x 10 32 Very tight Pop rivet sluminium 387 587 UFT 413 3 2 tube insert angled DFP 017 horiz stab twd Set vet Do not TU Pop rivet aluminium 376 58 TF tube inser DFP OTT horiz stab aft DEB 00 Sat rivet do not por TT Pop rivet aluminum 38 TE stab tension tube BFF 005 horiz stab aft Poo the rivet Put first vet in centre hole and pop Gate one end of tube centre horiz stab tension tube using hole in end of horiz stab as visual guide Tape or hold in place Dril 3 16 hole through hole in hariz stab tension lube Remove tape repeat al other end Place rivets and TIT Recommended Special Tool None 2 The parts needed to perform the task Replace worn damaged parts as needed listed above Max Wear defined 1 1 8 1 13 of maintenance Inspection Line
25. Problems One EGT or CHT is One WIES TE 556 89556 Tho nemen ard Tw probe MOST commonly a crimp connection on the quick disconnect onthe probe or the cable it plugs into is loose A visual inspection will usualy be enough to find the problem Another imple test is to use a continuity tester and verily each pin at the instrument end of he Cable has good continuity to the engine case since each probe 6 grounded to he engine The pins numbers are isted on the wiring diagram in the back of hs manual TEST aR CHT are 65 5627 an OPEN connectar To cass OT Ws Gmgine 8 68855 888 de nol include an electric starter Coolant Temperature shows 59 deg F al he time The connection to the coolant temperature probe TE open or 86 case af The coolant temperature sensor isnot grounded A quick test is to touch the coolant temperature sensor lead to ground If the EIS show a high temperature the connection to the instrument is good If it does not change check the wire between the instrument and the Coolant temperature sensor especially the crimp on the quic disconnect that plugs onto the coolant temperature sensor Tach Readings orate or zero when one mag is tumed of Tis is normal as The tach signals generated by one oF The mags Sometimes Wis possible to gel a good reading if the mag test is perlormed at higher RPM 3500 or Tach reading TE steady but teo low
26. T Weight at right main wheel 1b Weight at let main wheel Th Empty weight with standard equipment Th Maximum take off weight 169 1b Maximum load Th Empty weight CG postion inch CG position MAC Date Inspector 14 535 Load Sheet EMPTY WEIGHT CALCULATIONS WEIGH MOMENT MOMENT ARM pos inch 30 EJ Rear Wheel Tad Pilot 35 Totals W Totals M CG position MIW Page 15 1 1 5 4 Installed optional equipment list affecting weight and balance or reference as to where this information can be found NOTE Retrieve and or Update this information in your POH Pilot Operating Handbook Also hem Location Moment Weight 1 1 6 Tire inflation pressures 1010 20 PSI NOTE NEVER EXCEED 22 PSI 1 1 7 Approved 688 and capacities NOTE Refer lo Rotax Manual and Rotax Website for current recommendations as this information is chan 1 1 8 Recommended fastener torque values NOTE Each Specific Fastener has its own Tightening Instructions because of its location and function reference the appropriate Section in this manual or Ilustrated Parts amp Kit Assembly Manual for the instructions each fastener Bolt Tightening amp Lubricate Terms Defined mah re pak Note Observation is required to ensure that no tubes or pars are deformed or crushed A Loose In place but waiting for tightening afier section is tota
27. amp Replacement Heavy when it involves replacement of structural components 4 Certification needed to accomplish the task Line LSRI Inspection or above Heavy LSRM Maintenance or above sce Level of Certification in this manual 737 Detailed instructions and diagrams as needed Wo perform We 5552 above and alfacent page Every Annual or 100 Hrs Inspect for Cracks Corrosion Elongation of holes amp Fasteners for Wear amp Security Sec 35 Fabric Coverings For more inspection and testing information on fabrie coverings 6 Method to testinspect to verify the task was accomplished properly Insure that all procedures were followed correctly and there is proper non binding movement to moving parts and that fasteners were tightened as instructed When flight controls are involved assure that they are operating properly Section TI Horiz Stabilizer amp Elev Frame Section 11 Page 42 6 66 49 peus 1881118 18 TV INOZINOH Drawing 11 Page 43 Section 12 Maintenance amp Inspection Dragonfly 582 HORIZONTAL STABILIZER amp ELEVATOR SAILS T INSTRUCTIONS for Assembly Disassembly reverse ta ode PRAT NOW STAGE CERT ELS spacersleron GE TTT 07102 in end of hariz stab aft Bot 15 hinge bikt horiz stab spacer aderon hinge 1 125
28. as needed 6 Method totestinspect to verily the task was accomplished properly Insure that all procedures were followed correctly and there is proper non binding movement to moving parts and that fasteners were tightened as instructed When flight controls are involved assure that they are operating proper Section 24 583 Engine Mount Plate Section 24 Page 68 ATANODVUG 31v d LNNOW SNIONA 286 Drawing 24 Page 69 Section 25 Maintenance amp Inspection Dragonfly 582 582 MUFFLER INSTALLATION STEP INSTRUCTIONS Assorby Tor Disassembly reverse 88 60987 PARTNO J STAGETERT T Remove magneto end engine cover from engine by removing four 8 x 1 bolts 2 Dril through 4 holes as shown Gal 3 install four AN3 25A 5685 as shown with head inside cover Tour 68 TE washers on each boit to achieve flange clearance muffler mount and engine stabiliser assembly DFW 005 3 16 washer ANS full nut 4 Re pasion magneto end cover on engine ightan Gram x Tmm 8605 wit 66 6 amp Position exhaust elbow and attach springs io exhaust 8 Position Rotax muffler attach springs to exhaust elbow Bend twa muffler band clamps DFO 021 around muffler and muffler mount fasten with AN3 11A AN3 high temp nut 7 completed afier Section 26 ANS 24A 5 16 lock was
29. band around levator comp strut outboard DFF 65 levator comp strut inboard DFF cos through hole in struts Pu rubber band out end of te and hook nal as Show drawing 128 Outboard end goes n of bot 59605 11 rand end goes over bot Secion 11 Tighten bota 4 and Saug but tee _Stop now if you intend to paint DFE Ola aT ANETTA SA ans HG Ee SD ST aue T PANE T STE ANG TT E R TORTE SET SPR FI stab 31 washer ANS rut Tr FP Bit ANSA 218 washer elevator pori ET 986586 378 Was ANS HG emp nut ight Burm hale In lare fa oot 3 Tupper hon stab wd ANS high temp nut Tight To aust tension move washers lom nas te outage of ang on bali 13 scion B gap 72 V2 7 314 1 18 23 1 2 gap cover on elevator cene belueen bis and leave a bea cover and ver stab Draw on tne horiz stab 890 5 gap cover and varsler above messuremenss stab At each from ine to cente of comp su The strut beer due fabric so each wil be slighty diferent Tansey hese measurements an 10 gap cover cene up cover and det marka win 1 8 da Pop vet sanies tee 18 x YA gap cover hor rab comp shui Pop the het
30. bolt nut torque levels Daily before the first flight of the day lt Make sure the ignition is not active gt Check visually for any signs of wear cracks or corrosion in the hub components or blades Take note any sharp nicks cuts or scratches as these are stress points from which further problems may occur Act on them if required Replace the LE Tape if damaged Check that all blades are firmly mounted This is best done by holding 2 blades at the same time whilst pulling the tips towards each other If any movement is detected immediately check for a problem and rectify Also check the overall propeller assembly is firmly attached Check the 2 faces of the hub grip MUST have a gap between them The hub grip must be in contact with the blade shank not each other Atthe 2 amp 10 flights Check the bolt amp nut torque levels If retightening is needed rare check the tip run out Every 75 hours Perform all the above checks thoroughly including the torque levels and check that alignment tolerance levels have remained the same If any changes are detected investigate and correct reasons Appendix E2 Page 2 Page 121 A1450 hours Perform a full strip down and is Replace all nylon lock nuts The rebuilt prop needs to go through the appropriate inspections from the first flight to 450hrs maintenance sheet record should be kept in your aircraft logbook spection Annual Ins
31. correct frequency Stent is 520 ms ang message burst on dhe 406 MEL signal S elf test is then 121 243 MHz VHF Continuous Wave du ynchronization pattern is 011 010 000 yg the external GPS to the Appendix F Page 11 Page 142 6 PERIODIC MAINTENANCE INSTRUCTIONS FOR CONTINUED AIRWORTHINESS REFERENCES FAR Part 91 207 Part 43 Appendix D i FAR Part 91 207 Paragraph d FAR Part 91407 PURPOSE To insure continued reliability of your ELT it must be inspected for damage and wear which could be caused by age exposed elements vibrations ete Even the best designed equipment if not properly maintained and cared for will eventually fail IMPORTANT NOTES The following inspections must be performed a minimum of one time every year 6 1 Secure Inspection Inspect the ELT Main Unit and Mounting Tray to insure all fasteners and mechanical assemblies are secure 62 Corrosion Inspection for Coaxial Cable Inspect the Coaxial Cable connecting the ELT Main Unit to the Antenna for cuts or abrasions on its outer jacket Disconnect the BNC connectors on each end Examine both the BNC connectors and the mating plug on the Antenna and the ELT Main Unit for any signs of corrosion Modular Cable Inspect the Remote Wiring Modular Cable connecting the ELT Main Uni of signs of wear or abrasion on outer jacket Remove the GA Expiration Date Check Check the expiration date of th
32. engine in your airplane One that comes to mind is Aveo Lycoming 80 04 03 R2 which requires using an additive in the engine and inspection ofthe filter Only an A amp P mechanic sign this AD off and retum the airplane to service Many people today are doing oil analyses One oil analysis will tell you very litle about your engine You will need to develop a history of oil analyses taking oil samples from the same location and after the same number of hours cach time you collect the samples Then you will start to develop a history on what s happening inside the engine Another good idea is cutting the oil filter open and rinsing the filter element in a bucket of Varsol or a similar material Appendix D Page 1 Page 108 Use a magnet to extract ferrous particles and save them for later examinations Filter the remaining solvent through a coffee filter and examine the remains You should ask your A amp P mechanic for advice on what you see the first couple of times Many people will save the coffee filter and particles until the next engine oil change for comparison Type of Contamination Quantty Suggested Course of Action Small shiny nonmagnetic flakes of metal and or hairlike magnetic slivers Fewer than 40 pieces total of filter after 25 hours Place aircraft back in service and recheck screen As above 40 to 60 Clean screen drain oil pieces tol refill Run engine on ground for 20 to 30 minutes then rec
33. in accordance with ASTM standards under the jurisdiction of Committee F37 Light Sport Aircraft for example Specification F 2244 for powered parachutes Specification F 2245 for airplanes and Specification F 2582 for gyroplanes LSA Repairman Inspection LSRI US FAA cerificated repairman light sport aircraft with an inspection rating as defined by 14 CFR Part 65 authorized to perform the annual condition inspection on their Experimental Light Sport Aircraft ELSA or an equivalent rating issued hy other civil aviation authorities Discussion Experimental LSA do not require the individual performing maintenance to hold any FAA Airman Certificate in the USA LSA Repairman Maintenance LSRM US FAAcerificated repairman light sport aircraft with a maintenance rating as defined by 14 CFR Part 65 authorized to perform line maintenance on aireraft certificated as Special Light Sport Aircraft 51 54 Authorized to perform the annual condition 100 hr inspection on an SLSA or ELSA an equivalent rating issued by other civil aviation authorities Maintenance Manual s manual provided by an LSA manufacturer or supplier that specifies all inspections maintenance repairs and alterations authorized by the manufacturer Page 83 Major Repair Alteration or Maintenance any alteration maintenance for which instructions to complet the task excluded from the maintenance manwal s supplied to the consumer are c
34. of G s Find and file the QA sheet and confirm all components are enclosed This sheet is included in the aircraft paperwork that came with your from Pitman The Digital Weight is accompanied by a color dot which signifies a matched set On 4 blade propellers there can be 2 matched sets of 2 blades each The set must be opposing each other in the hub to maintain balance DIGITAL WEIGHT Weight Matching of Bolly blade sets All Bolly props feature a blade number weight number amp digital weight number Our weight matching apparatus gives a reading which combines the weight and center of gravity of any individual propeller blade It can easily detect a 1 4 gram added to the prop tp The blade number is engraved on the hub end and a sticker recording the digital weight For example 067 B blade and mold number and X 772 digital weight balance number Appendix E2 Page Page 120 With this system we can match a new blade to any set at any time Ifa customer replaces damaged blade or adds another blade to make a from a 2B etc then they only need tellus the number blade or balance and we can supply near perfect match All sets of blades Bolly ships are matched to within a tolerance level And Bolly maximum tolerance is comparable to 1 Serams of tip weight comparable to per meter The digital number will not show this directly So do not be alarmed if the digital w
35. of certification required for the replacement ofa piston engine valve A amp P or LSA Repairman Maintenance Task Specific 4 Line Maintenance Repairs and Alterations 4 1 Authorization to Perform The holder of an LSA Repairman Certificate with eher an Inspection LSRI or Maintenance LSRM rating is generally considered the minimum level of certification to perform Line Maintenance of Light Sport Aircraft LSA NOTE Many of the tasks listed are also authorized by the FAA to be performed by the Owner of the SLSA who holds Sport Pilot Certificate The examples listed below should not be considered as restrictions against the performance of the tasks by an Owner that is authorized to perform said task by the FAA See Appendix D 42 Typical Tasks Considered as Line Maintenance Jor SESA s and Persons who hold a LSRM rating or above may include See Note 4 1 above 42 1 100 4 inspection 42 2 Annual condition inspection 423 Servicing of fluids 424 Removal and replacement of components for which instructions are provided inthe maintenance manual such 424 1 Fuel pumps 3242 Bateries 4243 Instruments switches lights and circuit breakers Page 80 4244 Starterslgeneratorsaltemators may require additional Rotax ratings 42 45 Exhaust manifoldstmufflers may require additional Rotax ratings 42 46 Wheel and brake assemblies 42 47 Propellers may require additional ratings see manufacturers manual 42 4
36. only applies to SLSA Dragonfly Aircraft and ELSA Dragonfly Kits Manufactured by Pitman Air in the United States of America Copyright Ed Pitman Rhett Radford Bobby Bailey amp Bill Moyes 2012 Page 5 Contents Page 1 1 General LLL Eg n 1 1 2 Sources to purchase parts n 1 1 3 List of disposable replacement parts 1 1 3 1 Engine Parts 1 1 3 2 Airframe and Systems 1 14 Engine specificatio Performance Combustion chambers Weight _ 1 5 Weight and balance information 1 1 5 1 Weight and Balance Chart 13 1 1 5 2 Operating weights and loading 13 1 153 Center of gravity CG range and determination 13 1 1 5 4 Installed optional equipment list 16 1 1 6 Tire inflation pressures 16 1 1 7 Approved oils and capacities 16 1 18 Recommended fastener torque values 16 Lubricate defined Error Bookmark not defined 1 19 General safety information Error Bookmark not defined 1 1 10 Instructions for reporting possible Safety of Flight concerns found during Inspection or Maintenance Error Bookmark not defined 1 1 11 Standard Tools needed for the maintenance and repair of the aircraft and it s components Error Bookmark not defined 1142 Special Tools needed for the maintenance and repair of the aircraft and it s components Error Bookmark not defined 1 2 Inspections Annual and or 100 hour Inspections Error Bookmark not defin
37. opposite direction the pitch setting will appear different to the figure above rotate the propeller blade to the desired angle apply gentle torque with one hand With the other hand move the blade tip around in a circular motion Repeat for the other blades Repeat the procedure for the other blades check thoroughly and then follow the sequence and torque procedure Appendix E2 Page Page 127 Torques Propeller Flange Bolt Torque be performed ONLY the pitch has been set and confirmed Use a calibrated torque wrench and evenly side to side tighten grip bolts Evenly tighten the bolts in sequence Apply the torque to the bolts not the jam nuts WARNING ALWAYS TIGHTEN THE BOLTS IN THE CORRECT SEQUENCE AND TO THE SPECIFIED TORQUE Figure 6 Propeller M8 Bolt Tightening Sequence Numbers Torque the 7 grip bolts outer bolts on hub as depicted in section 61 20 60 in increments of approximately 3 Newton meter 20 inch pounds up to the recommended torque The bolts should be tensioned in sequence as per the figure above Tighten MS bolts to gearbox output drive plate in increments of approximately 3 Newton meter 20 inch pounds up to the recommended torque The bolts should be tensioned in sequence as per the figure above Return your attention to the grip bolts to check the tension again Ensure that the washer plate is installed it is part of the engineered system If the washer plate is not i
38. periodic or specialized inspection maintenance and Intervals Refer to the component manufacturer s manual s or this information ie Rotax www llyrotax com 1 2 1 Checklist for Annual amp 100 hour Inspections How to perform an Annual and or 100 Hour Inspection Go through Sections of 2 2 Detailed Instructions and Diagrams for Inspection and or Repair cf this manua contd next page Page 17 7852 88 Special oi None The puts pedes eom tc tan Replace wornldamagtd parts as needed sted above Man Wear defined LA Tope o nearer Inspection Line amp Replacement components Corian needed accompli the ak ESRI Level of Cortfication in this mana 15 Dati and diagrams as needed the ik Ta shove and alles page very Annu 100 Inspect for Cracia Corrosion Elongation of holes 6 Fasteners for Wear amp Security See LAS Fabri Coverings For more inspect See Cables Thimble and Tangs Page 16 Section 9 Vertical Stabilizer 5 and 6 contain things that may require special attention during the Inspection Note Each Section 1 through 20 of the Maintenance Instructions must be consulted to identity areas 6 Special Interest or Life Limited Parts LLP to identify part needs special attention or replacement See 2 2 ofthis manual page 21 APPENDIX D TO FAR PART 43 SCOPE AND DETAIL OF ITEMS AS APPLICABLE TO
39. position Whenever and the Remote Switch Unit flash and the Buzzer sound periodically they the ELT is transmitting Ifthe ELT be accidentally activated by turbulence hard landing ec than an accident requiring immediate assistance pressing the RESET button on the Remote S cate this occur under any conditions other iteh Unit If the Aircraft is on the ground and the RESET button on the Remote Unit does not cause the Green ON light to extinguish the RESET button on the Main Unit should be pressed If airborne and the RESET button on the Remote unit does not cause the Green ON LIGHT to extinguish the main switch on the ELT should be set to the OFF position if the ELT is accesible Ifthe ELT is not accessible in flight you should land at the nearest suitable airport and set the Main Switch to the OFF position In either cas the unit should be inspected by qualified facility as soon as possible The Aircraft may be operated with the ELT removed for inspection or repair subject to the condi 91 207 Tn the event of an accident Push the Unit The ELT will be ON immediately IN button on the Cockpit Remote Tn the event of an accident ensure that the External Aircraft Antenna has no damage Important Ifthe ELT is accessible after the accident place the Main Switch in the ON position and monitor it on 121 5 MHZ for proper operation if possible If the Antenna is broken of the Aircraft t
40. safety Multiple damage at the max allowed levels is not acceptable to be repaired If in doubt return to BOLLY AVIATION for evaluati and possible repair or replacement Leading Edge Damage General The Bolly Dura Tuff propeller leading edge has been developed to provide additional protection against water gravel stones and other foreign bodies that are occasionally ingested into and damaging to propellers It is great value for money product in effect eliminating LE repair and the servicing of urethane LE tapes Technical The Dura tuff material is a high density toughened urethane It is not an inlay nor is it an add on it is a genuine molded inset part of the propeller The toughness of the urethane used is just 1 step below that used for most roller blade wheels This provides exceptional wear resistance without being fragile Use The Dura tuff LE will take all normal wear and tear Constant abrasion ie dust etc will dull the surface in time Hits from gravel and stones will sometimes leave a small mark If in time a blades has been sufficiently marked as to require replacement it be redone Using conventional urethane leading edge tape as applied to the standard Bolly prop blades is not necessary Damage An object such as a large stone when do you call it a rock 7 or a passenger s dropped camera can be expected to do significant damage We would suggest that if a hit is big enough to badly damage
41. set the altimeter appropriately the altimeter is set to the automatic mode no action is required Detailed Description of the Features Auomatic Manual Altimeter Setting The altimeter can be set manually by the pilot or automatically by the instrument This option is selected on the SET LIMITS pages Automatic Altimeter Operation In this mode the altimeter will automatically be set to zero at 45 and 75 seconds after the instrument tumed if the engine is running and has not exceeded 4100 RPM If the RPM goes above 4100 the instrument assumes airplane is in the air thus does not alter the altimeter setting The intent of this logic is to allow the instrument to automatically zero the altimeter when the engine is being warmed up on the ground but hopefully not cause the instrument to reset the altimeter when the instrument is tumed on and off in the air The automatic mode of the altimeter should not be used when You wish to set the altimeter to the airport s elevation This is often done when flying to another airport especially when the airports are at different elevations J you anticipate turing off the instrument in flight and then tuming it back on when the engine is below 4100 This could be the case when stopping the engine in flight and restarting Manual Altimeter Operation Use the SET LIMITS pages to set the altimeter as desired Flight Timer The fight timer shows you
42. shin aruna aT STD IE renta 1 in ma boom holes blind nut should be side of tube half ru washer vert stab att 14 5 625 DFO 002 oom tibe ver stab af boom tube 14 washer ANA hal Tigh 27 Assen ial whee 665 7 procedure 8 sinlar Bor 2 221 T water OFP SS rear tube OFS 005 Tear tire OFS 008 tall heel hall bot 1 4 20 x 2 114 washer tal wheel hal tube and tyre assembly tai wheel hal 20 Te ack nu in CEU through whee and put spacer tall wheel axe 1 25 34 tube DFD 009 er side ANE MA V washer tall wheel fork DFW O26 Spacer tal 5 525x1878 wheel axle spacer tal wheel 1 5 8 1875 Sa wee fr T washer ANA Very Ty 7 ok wheat pivot DEF TIT grease steering arm DFK O10 spacer washer 1 75 x 625 x 1875 DFP 05 steering grease spacer washer 1 78x 825 187 grease spacer washer 1 754 625 1925 ease al block lower DFP oo apacer tali pivot 20mm x Smm x 1 860 DFS 010 grease nut ser hatina but free iali block upper DFP 002 7188865379 washer seg 8895 starboard DFT OO and all wheel release arm port DEJ 003 steering am 3167 washer ANS caste rut cotter pin Snug but te hee release arms ae ant Jang on purpose to acc
43. shown in fig 1 by entering the engine plate from below J Mount the engine plate the crank by removing the Tour TOmm studs replace with bolt hex head 10mm x 1 5mm x 50mm GRADE 8 8 DFT 002 washer lock washer 10mm x 3 5mm x 2 2mm DFT 031 engine piate spacer engine mount DFC 026 engine block Use LOCTITE 221 on bolts Tight 3 To be completed afar Sections 258 25 7 The engine now ready for installation Lift the engine package into position Install by fiting six off bolts ANA ITA washer SS 1 1 4 x 1 4 16 032 engine lord mount engine supp bri 1 4 washer full TT Recommended Special Tools None 2 The parts needed to perform the task Replace worn damaged parts as needed listed above Max Wear defined 1 1 81 3 Type af maintenance Inspection Line amp Replacement Heavy when it involves replacement structural To Rotax Manual for guidance on Engine amp Engine 4 Certification needed to accomplish the task sec Level of Certification this manual LSRI inspection or above Heavy LSRM Maintenance or above led to perform the task listed above and adjacent pa holes amp Fasteners for Wear amp Securit 5 Detailed instructions and diagrams as ne Every Annual or 100 Hrs Inspect for Cracks Corrosion Elongati Note Check for eracks in both plates security of fasteners and quality of lord mounts Replace
44. stab alt Find hole tne other side and dril Bolt ANS 22A hinge brkt vert stab alt 3 16 washer ANS hall nut Using short handled 3 16 wrench You can buy a cheap wrench and with hacksaw Very TT Bot AZOR DFR vert stab tllupper ANS halt nut Tight TIT Recommended Special Toots None 2 The parts needed to perform the tsk Replace worn damaged parts as needed listed above Max Wear defined 1 1 8 1 3 Type of maintenance Inspection Line amp Replacement Heavy when it replacement of structural components 4 Cerification needed to accomplish the task Line LSRI Inspection or above Heavy LSRM Maintenance or above see 3 Level of Certification in this manual 15 Detailed instructions and diagrams as needed perform he ask Tisted above and adjacent Every Annual or 100 Hrs Inspect for Cracks Corrosion Elongation of holes amp Fasteners for Wear amp Security See 1 35 Fabric Coverings For more inspection and testing information on fabric coverings Sec Cables Thimbles and Tangs Page 16 6 Method to test inspect to verify the task was accomplished properly Insure that all procedures were followed correctly and there is proper non binding movement to moving parts and that fasteners were tightened as instructed When flight controls are involved assure that they are operating properly Section 9 Vertical Stabilizer Sec
45. task was accomplished properly 3 3 Service Directives are considered as mandatory tasks in order to maintain a condition of sale operation and compliance with the applicable original ASTM design specification NOTE Service Directives are not considered mandatory for Transitioned Experimental LSA s prior to Jan 31 2008 in the US 10 Terminology 10 1 Definitions Annual Condition Inspection detailed inspection accomplished once a year on a LSA in accondance with instructions provided in the maintenance manual supplied with the The purpose of the inspection i to ook for any wear corrosion or damage that would cause an 10 not be in a condition for safe operation A amp P airirame and power plant mechanic as defined by 14 CFR Part 65 in the U S or equivalent certification in other FAA United States Federal Aviation Administration Heavy Maintenance any maintenance inspection repair or alteration a manufacturer has designated that requires specialize training equipment or facilities Line Maintenance repair maintenance scheduled checks servicing inspections or alterations not considered heavy maintenance that is approved by the manufacturer and is specified in the manufacturer s Maintenance Manual LLP Life Limited Part Life Limited Parts are paris known to have a limited amount of use before replacement is required LSA Light Sport Aircraft aircraft designed
46. used as the units on the GPS pages Has no effect if GPS Page is off 102 Messages at Power Up 102 Troubleshooting Common Problems 103 Appendix Page 13 End of Appendix CAppendix D Items Permitted Under the Privileges of Preventive Maintenance 107 Advisory Circular 43 12 112 Preventive Maintenance 7 un SFARASI3 Performance rules general Appendix El KievProp Installation ns 1 Disassemble prop hub us 2 Inspect each blade us 3 Install shoulder bolts us 4 On Rotax 912 applications SECURING ASSEMBLED PROP TO ENGIN 116 5 Secure finger tight the propeller 116 6 With all bolts slightly tightened 116 8 Fit the aluminum end of the protractor 116 9 For Pusher aircraft 10 When all blade angles have been set 11 A static check of rpm s ns 12 Re check torque of prop bolts after first hour 18 Appendix E2 Bolly Propeller Instructions 120 GENERAL INFORMATION 120 DIGITAL WEIGHT 120 Propeller Service amp Inspections m Annual Inspection m Propeller Assembly Procedure 12 Mount Propeller 14 Re Pitching Instructions 126 rques 128 Care amp Cleaning 130 Page 9 BLADE DAMAGE REPAIR Appendix F GENERAL INFORMATION Ameri King 451 amp 450 SCOPE OVERVIEW Description Automatic Fixed ELT AF Automatic Portable ELT AF AP with dual antennas Application and Equipment Limitation PHYSICAL CHARACTERISTICS GENERAL SPECIF
47. 75 wire should not fit between bolt and edge of hole Between 4132 and 417 Safety Wire sizes Cables Thimbles and Tangs Any significant wear of Thimbles fraying of cables lose or broken strands corrosion of cables or NICO Press Sleeves deformation of Tangs REQUIRE RPLACEMENT with new OEM Cable Assemblies Be aware of and learn about Hydrogen Embritlement and how hard itis to detect the amount of damage that it cause When you can see corrosion on Nico Press Sleeves the stainless cables have been affected but don t show signs as well as the Tin plated Copper sleeves WHEN IN DOUBT REPLACE WITH NEW Lubricate defined Dry Film Lubricant that will not leave any sticky residue that will hald dust dirt that will prematurely wear out parts 1 ic Super Lube Dri Film Lubricant by Synco Chemical Corp ww super ube com NOTE DO NOT LUBRICATE after prevent paints from sticking ting fabrie surfaces of the sails ete 1 1 9 General safety information Always use proper PPE Personal Protective Equipment and Work Safety Practices suitable for the work you are performing Information on this can be found in the OSHA Regulations b and or the Occupational Health Authority in your State 1 1 10 Instructions for reporting possible Safety of Flight concerns found during Inspection or Maintenance NOTE See Appendix A in the back ofthis manual amp in the beginning of the POH Pilot
48. 8 Replenishing hydraulic uid in the hydraulic reservoir MIL H 5606 is the common type of hydraulic fluid used in light airplane brakes and hydraulic gear systems Use of other than recommended fluid can cause damage to seals O rings and other pars of the system Be sure you add only the same kind of fluid as that already in the system follow instructions in the service manual 9 Refinishing decorative coating of fuselage balloon baskets wing tail group surfaces excluding balanced control surfaces fairings cowlings landing gear cabin or cockpit interior when removal or disassembly of any primary Structure or operating system is not required Refinishing decorative coating At first glance this sounds like a simple task but it becomes complicated very fast You should start by checking the service manual for recommended procedures and material to be used Then discuss your intentions with your mechanic and a reputable paint shop attendant You will need a place to buy those materials and dispose of the unused materials and remains and they may prove to be excellent sources Many aircraft manufacturers require control surfaces o be balanced after painting so leave those parts to the professionals Remember The quality of paint and workmanship will affect not only the value of your airplane but performance as well Check with your mechanic prior to applying preservatives protective materials to ensure their lasting eff
49. 8 1 3 of maintenance Inspection Line amp Replacement Heavy when involves replacement of structural components 4 Certification needed to accomplish the task Line LSRI Inspection or above Heavy LSRM Maintenance or above 3603 Leve of Certification this manual Detaled and dignam as tak above Every Annual or 100 Hrs Inspect for Cracks Corrosion Elongation of holes amp Fasteners foe Wear amp Security See LAS Fabrie Coverings For more inspection and testing information on fabric coverings Method to sestinspect to verify the task was accomplished properly Insure that all procedures were followed corre non binding movement to moving parts and that fastes they are operating properly and there is proper id instructed When fight controls are Involved assure that jection 20 Struts amp Wing Connection Section 20 Page 60 Section 21 Maintenance amp Inspection Dragonfly 582 CABLE BRACING STEP INSTRUCTIONS Tor Assembly or Disassembly eversa The arder PARTNO STAGE CERT mirror mount brki DEL OTT over cockpit tube lower port Slide mirror tube 3 4 tube DFD 007 through mirror mount brkt and Spacer mirror brkt DFD 008 with approx 1 8 of mirror tube showing below mirror mount br dil 3 16 hole through spacer mirror brkt and
50. 8 Sparkplugs ignition wires and electronic ignition models components limited to the use of mechanical connections may require additional Rotax ratings 4249 Hoses and lines may require additional Rotax ratings 424 10 Sallcloth covering may be heavy Maintenance depending on area 424 11 Ballistic recovery system may require additional ratings see manufacturers manual 42 412 Floats may require additional ratings see manufacturers manual 42413 Skis may require additional ratings see manufacturers manual 4 2 5 Repair of components and structure for which instructions are provided in the maintenance manual and which may not require additional specialized training such as 42 51 Patching of a hole in a fabric metal or composite non structural component and 42 52 Stop dnlling of cracks 4226 Alterations for which specific instruction are provided in the maintenance manual but may require additional rings in Avionics such as 4 26 1 Installation of a communications radio transponder GPS and antenna 4 2 62 Installation of a strobe light system and 4 263 Compliance with a manufacturer Service Directive or Safety Directive when the repairman is listed as an authorized person to accomplish the alteration 5 Heavy Maintenance Repairs and Alterations 5 1 Authorization to Perform The holder of a mechanic certificate with airframe or power plant rating s or both an LSA Repairman Maintenance LSRM that has received addi
51. 8 Supp 869860 07097 582 only oot tube 582 OF 002 engine supp brit starboard DFJ 008 114 washer ANA full nut Very tight Z Balt ANE STA washer Tap adjuster assembly DFW TEE 182 only engine supp root ube engine supp brkt starboard adjuster assembly washer ANA tull nun Tint a Erana aTa TT wash Wing mounting 5888887886 5897 tube wing mounting channel bt 147 washer ANA fll Tight 3 Bolt ANA ZAR washer aft root supp Brkt upper rook tube 14 washer ANS ful nut Tight TIT Recommended Special Tools None 2 The parts needed to perform the task Replace worn damaged parts as needed listed above Max Wear defined 1 1 8 1 3 of maintenance Inspection Line amp Replacement Heavy when it involyes replacement of structural components 4 Certification needed to accomplish the task Line LSRI Inspection or above Heavy LSRM Maintenance or above see 3 Level of Certification in this manual 5 Detailed instructions and diagrams as needed to perform the task listed above and adjacent page Every Annual or 100 Hrs Inspect for Cracks Corrosion Elongation of holes amp Fasteners for Wear amp Security 6 Method to testispect to verify the task was accomplished properly Insure that all procedures were followed correctly and there is proper non binding movement to moving parts and that fasteners were tig
52. A Loose eer a ws er I TAE T5 VI Waser V 25 ea Washer PaT PUE ive rice flesh a eel fa af wad e oom tle 58 585 BGT AN hal bots 62 7 ae Tall wheel kick out DOS between steering ams notice angle with release boom bend tal whos kick out in vice near ip s0 paralel win release oom Bol ANS20A 316 washer release boom ta whoa 316 washer BN hall nut TE 57 TOTO Wa ANS case nut coner pn Snug but fee 77 Recommended Special Toole Nowe 2 The pars needed to perform the task Replace worn damaged parts as needed listed above Max Wear defined 1 1 81 4 Type of maintenance Inspection Lie Replacement Heay when involves replacement o structural components 4 Cenif euion needed to accomplish the tack Line L SRI Inspection or above Heavy LSRM Maintenance or above so Level of Certification this manual ry Anal ic Ie rne Cien eno Wear RS Condition every part is stil in good working condition o last until next ar 100 hour Inspection Note On Condition Provisian ving parte ud Ma fasteners were hend as When conr arc lve sre be operating proper S
53. CHT measurements are often misunderstood They perform very separate and distinct roles Why monitor Exhaust Gas Temperature EGT EGT reflects the ratio of fuel to air being provided to the cylinder The leaner the mixture the higher the EGT EGT does not provide any indication of how well the engine is being cooled This is the job of coolant and CHT internal parts such as the piston of all two stroke engines will be damaged if they are operated with an EGT that is too high Damage can occur in matter of tens of seconds or less if EGT limits are exceeded What causes high EGT lean fuel air mixture will cause high EGT This can be caused by Misadjusted or a problem with the carburetor Too little load on the engine such as an under pitched propeller This also results in unusually high engine RPM problem with fuel delivery to the engine such as clogged fuel line or filter a malfunctioning fuel pump etc Unbalanced unequally opening carburetors will cause one cylinder to operate with a higher EGT Cooler ambient temperatures and lower altitudes An engine set up for operation in Denver 5000 feet above sea level will operate at higher EGTs when operated at sea level What do you do when you get a high 1f possible reduce engine power If high EGTs persist be prepared for the possibility of sudden engine stoppage If not possible to reduce power try going to full power The carburetor provi
54. Date ddimmiyyyy Page 151
55. Delete This Page before printing To Keep Page Orientation Correct Instructions for Printing amp Binding This page gets wasted to maintain orientation of pages throughout the manual when viewing online To allow viewing 2 Pages Up Begin printing on Page 1 the Cover and print both sides of paper Page orientation is important This can be seen when you get to Pages 22 8 23 which should be facing you when the Manual is open as well as many more as you progress thraugh the manual This has the Narrative and the proper Drawing facing you at the same time Print 20 Lb Min Premium Paper or better Printing both sides of paper prefer Spiral Bound with Clear Front Cover and Heavy Black Back Cover This allows the manual to be opened and folded back leaving the desired page exposed and lays flat when opened to expose 2 pages while doing Inspections or Maintenance 1 generally get them printed at Staples Office Depot where it costs as litle as 15 00 USD per manual in Black amp White printing only the Front Cover in Color Some of the pictures are in Color for the benefit of online viewing but we print them in black 8 white Thank you for your interest in our products Safe 8 Have Fun Ed Pitman Delete This Page before printing To Keep Page Orientation Correct Publeaton Number DF MMSB2 rev 4 31 01 2013 Praet Maintenance Manual 582 Dragonfly amp Assembly Manual 582 Dragonfly
56. ES ARE NOT RESPONSIBLE FOR INSTALLATION ERRORS AND OR ATTACHMENT HARDWARE THE INSTALLER PILOT OWNER MUST ASSUME ALL RISKS ASSOCIATED WITH THE PROPELLER AND ALL RELATED ACCESSORIES AND PARTS IMPORTANT HARDWARE 15 ALSO AVAILABLE FOR THE 912 SERIES OF ROTAX ENGINES IF USING BOLTS WITH DRILLED SHANKS YOU MUST USE CASTLATED NUTS AND COTTER KEYS DO NOT USE NYLOC NUTS ON THESE BOLTS THE BOLTS WILL SNAP OFF AT THE HOLES SETTING THE CORRECT TORQUE AND ALIGNING THE HOLE WITH THE CASTLE NUT MAY REQUIRE ADDITIONAL THIN OR THICK WASHERS Appendix E1 Page 4 Page 118 MOUNTING BOLTS DRILLED MOUNTING BOLTS UNDRILLED SHANK 5 26 SHANK 5 36 THICK WASHERS 960 516 THICK WASHERS AN960 516 CASTLE NUTS AN310 5 JAM NUT MS21045 5 Appendix E1 5 End of Appendix E1 Page 119 Appendix E2 Bolly Propeller Instructions Contents Appendix Bolly Propeller Instructions GENERAL INFORMATIO DIGITAL WEIGHT Propeller Service amp Inspections Propeller Assembly Proceduri Mount Propeller itching Instructions Care amp Cleaning GENERAL INFORMATION WARNING IF THE ENGINE 18 BE ROTATED AT ANY TIME IT SHOULD ONLY BE ROTATED IN THE SAME DIRECTION IT RUNS All blade sets leave the factory as matched sets with full QA paperwork incorporating our digital weight system which takes into account the blades weights and C
57. Elev Sails Section 13 Controls Section 14 Aileron Section 15 Aileron Sails Section 16 Wing Section 17 Wing Battens amp Sails Section 18 Wing Sail Access holes and sealing Section 19 Aileron Support Tubes Mounting Section 20 Struts amp Wing Connection Section 21 Cable Bracing Section 22 Aft Seat Section 23 Aft Seat amp Controls Section 24 583 Engine Mount Plate Section 25 582 Muffler Installation Section 26 582 Radiator Installation Section 27 582 Fuel Pickup Section 28 Electrical System Page7 2 2 20 20 20 20 20 a n n n n 26 282 70 72 74 7 80 80 81 81 82 82 82 83 85 86 95 95 Section 29 Parachute Mount amp ELT 3 Level of Certification 3 1 Owner 3 2 LSA Repairman Inspection LSRI see 4 1 5 1 6 1 and Appendix D of this manual 3 3 LSA Repairman Maintenance LSRM see 4 1 5 1 amp 6 1 34 ARP see 4 1 5 1 amp 61 3 5 Task Specifie see 41 5 1 6 1 and Appendix D of this manual 3 5 1 Rotax Engines and Gearboxes 3 6 Multiple descriptors 4 Line Maintenance Repairs and Alterations 4 1 Authorization to Perform 4 2 Typical Tasks Considered as Line Maintenance 5 Heavy Maintenance Repa
58. ICATIONS STANDARD CONDITIONS MECHANICAL INSTALLATION QUICK OPERATION CHECK Detail Operation Check Detailed Operation Check 3 System Integration Test some parts may not apply to AK 450 TRANSMITTER FUNTIONAL TEST FOR ELT S ONLY 6 PERIODIC MAINTENANCE INSTRUCTIONS FOR CONTINUED AIRWORTHINESS AppendixG Bailey Tow amp Release System FIGURE 1 Bailey Tow Release System Configuration Period of Operations of Release TBO and Inspection Intervals Operational Tests Safety of Flight amp Service Difficulty Report Form Safety of Flight amp Service Difficulty Report Form Note 130 132 132 132 132 132 133 133 1 136 137 137 139 140 142 143 Ts 16 16 The Contents and Structure of this manual are mandated by ASTM Standard F2483 05 6 FAA Regulations requiring the conformity to Consensus Standards ASTM standards used Design amp Performance and Required Equipment F 2245 11 Quality Assurance and Production Acceptance Tests F 2279 06 Continued Operational Safety Monitoring F 2295 06 Maintenance amp Inspection Procedures F 2483 05 Pilot Operating Handbook POH F 2245 11 amp F 2746 09 Terminology for LSA F 2626 07 Airframe Emergency Parachutes F 2316 08 Kit Assembly Instructions F2563 06 Required Product Information F2745 11 18 accordance with 14 CFR part 21 190 Page 10 132 145 150 151 1 1 General 1 1 1 Equipment list Ro
59. LT not a measured check but it does provide confidence that the Antenna is radiating with sufficient power to search and rescue Aircraft s VHF Receiver tuned to 121 5 may also be used This Receiver however is more sensitive and could pick up a weak signal even if the radiating 1 1 Antenna is disconnected Thus does not check the integrity of the ELT System or provide the same level of confidence as does an Radio Note 3 Because the ELT radiates on the emergency frequency the Federal Communications Commission allows these tests to be conducted only within the first 5 minutes alter any hour IMPORTANT NOTE IN NORMAL CONFIGURATION THE MAIN SWITCH LOCATED ON THE ELT MAIN UNIT MUST BE SELECTED AT ARM POSITION AT ALL TIMES Appendix F Page 12 Page 143 68 Verification of Digital Message N This test is not mandatory per FAR 91 207 d however Ameri King strongly recommends that it be performed as part of periodic maintenance least every year Verify the 406 MHz digital message using a Computer Test Set or equivalent capable of receiving and decoding the message Ameri King suggests the Ameri King ELT Computer Test Set P N 15 451 Contact your local Ameri King dealer for availability of the Computer Test Set or call Ameri King Follow instructions provided with the computer test set The AMERL KING 451 has a self test feature which is encoded such that it will be
60. Level of Certification in this manual 2 Detailed instructions and diagrams as needed to perform the task ted above and page Every Annual or 100 Hrs Inspect for Cracks Corrosion Elongation of holes amp Fasteners for Wear amp Coverings For more inspection and testing coverings 6 Method tp tesvnspect to verify the task was accomplished properly Insure that all procedures were followed correctly and there is proper non binding movement to moving parts and that fasteners were tightened as instructed When flight controls are involved assure that they are operating properly Section 17 Wing 888665 amp Salle Section 17 Page 54 rawing Page 55 Section 18 Maintenance 8 Inspection Dragonfly 582 WING SAIL ACCESS HOLES amp SEALING STEP INSTRUCTIONS lor Assembly or Disassembly reverse ha order 88886 STAGE GERT Using a hot knife burn a slot against outboard sides of bent strut plates uni they push through fabric slots long enough so that fabric lays back down fiat around wing comp strut saddle channel brkts on top side of wing unti fabric lays flat Sight down trailing edge to be sure it is stil in place f not gently pull back into position edge normally has a slight upward curve due to greater tension on top of sal Go to outboard comp strut Bum hole for bolt 18 Sect 16 Bum hole for unu
61. NE INFORMATION SYSTEM With GPS Interface Grand Rapids Technologies Incorporated 669 76 St SW Unit 2 Byron Center MI 49315 616 583 8000 Fax 616 583 8001 Rev 07 31 01 Appendix C Page 1 Page 95 Table of Contents Introduction The Importance of the Engine Information System Understanding Why monitor Exhaust Gas Temperature What causes a high 97 and CHT Why they are critical to safe engine operation What do you do when you get a high EGT alarm Why monitor Cylinder Head Temperature CI What causes high CHT and Coolant Temperatures ___ What to do when you get a high CHT andor Coolant alarm Can only EGT or CHT Temperature be monitored Operating Instructions for the EIS Model 20006 and Coolant Temperature Before using the Model 2000 for the first time 99 Before Each Flight 99 Detailed Description of the Features 99 Automatic Altimeter Operation w Manual Altimeter Operation 799 Flight Timer 799 Favorite Page Pressto See Labels 100 GPS Page 100 Saving your Home Position To Using the GPS Page 100 Connecting a GPS and Setting up the GPS Function Peak Recording 101 Warning System Operation 101 Set Limit Pages 102 Configuration Set Pages 102 Messages at Power Up 102 Troubleshooting Common Problems 103 Figure 1 Display Pages Diagram Figur
62. NZ 30R 1 4 washer strut plate A DFL 004 wing spar leading edge strut plate B DFL 005 1 4 washer ANS full nut Very tight Z Bolt ANZ 3UA 1 4 washer wing comp strut saddle channel brk wing comp strut wing comp strut saddle channel brkt fabric wing sail saddle 1 aileron angle DFP 021 supp tube DFC 021 saddle angle aluminium inboard aileron support tube gets wing to main boom cable after saddle angle aluminium AN4 half nut Loose 271868 AN3 21A saddle angie aluminium aileron supp tube fabric wing wing comp strut 3 16 washer ANS half nut Loose 7 868 ANS 21A 316 washer wing comp strut fabric wing aleron Supp tube saddle angle aluminium threaded insert 1 2 x 10 32 TPI DFO 040 hola in insert should be parallel with wing comp strut Very tight Tighten 591572 amp 3 5 Bot ANS 5A cable wing tall upper DFO OOF wing tail lower DFO 001 wing comp strut saddle channel brkt 1 4 washer nut Very fight Bali 4 27 hinge spacer aileron hinge 1 125 DFG 002 aileron supp tube 1 4 washer ANA half nut Very fight TIJ Recommended Special Tools None 12 The parts needed to perform the task Replace worn damaged parts as needed listed above Max Wear defined 1 1 3 Type of maintenance Inspection Line amp Replacement Heavy when it Involves replacement of structural components 4 Certific
63. O 004 seat supp boom tube aft seat supp brkt 1 4 washer half nut 3 Remove ANS half nut and place anchor brit aft seat DFTO7 over seat supp aft and root supp mid replace ANS half and tighten 3 Pass seat bolt af DFA OTT through shackle and seat as shown and around boom tube and buckle as shown 5 Side Joystick aversieave 88 DFC 023 onto joystick aft DFD 005 Bolt AN3 20A 3 16 washer joystick plate aft DFL O13 saddle 1 DFP 031 Joystick oversleeve aft joystick aft joystick oversleeve aft joystick plate aft 3 16 washer ANS nut Slide joystick grip DFS 012 joystick aft Bolt ANS 20 3 16 washer Joystick plata af sadda T push rod aff DFCOT7 saddle 1 joystick plato aft 3 16 washer ANS castle nut cotter pin 7 Bolt ANG 20 3 18 washer joystick plate push rod follow block joystick plato aft 3 16 washer ANS castle nut cotter pin 8 Bolt ANS 14 37167 washer mid push rod conn push rod af mid push rod conn 3 16 washer ANS castle nut cotter 3 Connect Throttle cable 88 DFO 07 TIT Recommended Special Tools None 2 The parts needed perform the task Replace worn damaged parts as needed listed above Max Wear defined 1 1 8 1 3 Type of maintenance Inspection Line amp Replacement Heavy when involves replacement uf structural 4 Certification needed to acc
64. Operating Handbook behind the Table of Contents 1441 Standard Tools seded for the maintenance and repair of aireraft and i s components Wrenches sockets amp Allen wrenches in both SAE and Metric are needed Hammers Safety Wire Pliers needle nose and square pliers screw drivers both straight and Phillips chisels punches feeler gauge sets in both inch and metric Calibrated Torque Wrenches hacksaw Hot Knife or soldering gun with tip heat gun hotter than hair dryer and other tools commonly found in a mechanics tools bax 1 112 Special Tools nerded for the maintenance and repair ofthe aircraft and it s components Note Rotax has numerous Special Tools for engine Repair and Maintenance These ean purchased from most Rotax Parts Distributors as needed of the guidance for Inspection Repair and Overhaul of Engines and Gearbares are deferred the Engine Manufacturer Overhaul of engines and it components can only be performed by a Rotax Authorized Service Centre Refer to Rotax manuals and Website for current information regarding overhaul repairs and alterations 1 Batten Tool Used to push battens mast of the way under Rear Spare Can use a screwdriver if your very careful not to scrateh the tube or tear the sail This tool can be Rented or Purchased through Pitman Air 1 2 Inspections Annual and or 100 hour Inspections Note Engine Gearbox Propeller and Instruments may require
65. Replace worn damaged parts as needed listed above Max Wear defined 1 Line amp Replacement Heavy when it involves replacement of struct SRI Inspection or above Heavy 3 Type of maintenance Inspectie 4 Certification needed to accomplish the task Line sce Level of Certification in this manual 5 Detailed instructions and diagrams as needed to perform the task listed above and adjacent page Every Annual or 100 Hrs Inspect for Cracks Corrosion Elongation of holes amp Fasteners for Wear amp See LAS Fabric Coverings For more inspection and testing i 6 Method to testinspect to verify the task was accomplished properly Insure that all procedures were followed correctly and there is proper non binding movement to moving parts and that fasteners were tightened as instructed When flight controls are involved assure that they are operating properly Section 18 Wing Sail Access holes and sealing Section 18 Page 56 ATSNOOVEG 6 9 S310H SS399V IVS ONIM a 81 monoa nous 6 NORE 0 eo Drawing 18 Page 57 Section 19 Maintenance amp Inspection Dragonfly 582 AILERON SUPPORT TUBES amp MOUNTING STEP INSTRUCTIONS Assembly Disassembly reverse the order PART NO_ STAGE T BGI A
66. S half nut 3 B Bolt AN3 13A 3 16 washer seat brit seat frame lower seat brkt aft 3 16 washer ANS half nut 3 C Bolt AN3 14A throttle mount brktaft DFL O12 eat brkt seat main frame aft seat brkt AN3 half nut D Bolt 23 throttle lever aft DFI 010 spacer throttle lever 7mm DFM 002 throttle lever aft spacer lever aft DFP 047 washer 3 16 x 1 OD throttle mount brk aft seat brkt aft seat frame lower aft seat brkt aft 3 16 washer ANS castle nut cotter pin Seat main frame upper aft DFD 092 into seat main frame AN3 12A seat main frame aft seat main frame upper aft seat main frame aft 3 167 washer AN3 half 5 3716 holes in seat to seat frame lower aft to seat Supp Brkt 004 8 Bolt ANG T6A 3 16 washer aft seat supp brid saddle 1 DFP 031 seat main frame lower aft 3 16 washer AN3 half nut 7 Burn hte for Seat supp 8 078005 Bolt AN4 31A 1 4 washer seat frame lower seat supp 1 4 washer half nut Loose 3 Bum top hole for seat supp Bolt ANG Z3A 29767 washer Seat main frame upper aft seat supp aft 3 16 washer ANS half EJ Knob throttle 015 threaded rod 10 32 TPI x 1 1 4 brake lever spacer throttle lever 7mm brake lever brake knob TT Recommended Special Tools None 2 The parts needed to perfo
67. S was 869590 amos Theware2specd east 150 8 due south 8 9270 is due west reporting you were at he ast orditora you shouldbe avare of inthe erampie home s aimostexaciy oast cf tere you araveresthe yow eaten postion When Pe GPS R prompt with Mumbar 1 hewn recuos yur o 6 569 les tran Sp The determina ef vavo 29 6 qund Aaa no tea je Caton GPS ON po fermen tat magnate aration 515 osemines you are esie rue bearings be provided and a SES be displayed bel the degree symbol 585 ground nat moving You 9005 date wil provide dataan What good is bearing best use ia wih her deploy dure is condition even data as a rdugh checkte veny the home SaveHomePos page on the thoughts poston he EIS ie you Wis MINS sof pagos at any ume Selecting Easa EIS has a hore postion nalis ainos Se bast ofe azpanes curent positon ane 14e mias away ete reasonable You decide Nere nat bearing data shoud not be used fr Seeing E upsets positon to caen postion Eo hk tes beore dong iis Er ie anel Winde cause you to backwards Eis CODD DM rine he io hapering and steering icon core i hia case you on course usinge Heng cota Figure 2 Using the GPS Page Appe
68. TEP INSTRUCTIONS To Resumbi Tr 955557 rusas PART RO STAGE 2 RAN ANTE TTE washer sy TTS washer PUSH Tod Taw BIG OFF ODT washer eyebol 296 masher ANS castle nut but Lubricate TOTEM OFT OAT Take ANA hat Screw and bearing several times to loosen nylon Tum nut around and screw on Backwards washer leron main hom 08 005 bell crank veri DEO O17 Tighten unt threads shaw but not so ight that 865 wil not pass ough side hale ANA half nut Vey gh Te aa 3 Ba ANE STE 8558986968 rod end wth bushing OFT 042 push rod conn 3 16 washer ANS hall Very tight 3 Wrap myar aroun ae Fash io shim Bot ANS 13A 9 16 washer bell crank vert elevator push rod mid bell crank ven 316 washer ANS half nut Very oh Bat ANS 126 7 washer El ngalion oT FATE at pushrod conn 316 washer ANS Wrap liar around eater pas od mito shh ube 868525 Ta BI Fo lvarrpashrod mi mid push rod conn ANS Very Nght eS Te GO POP TET HERTS TFT nd push rod conn cevatrposh rod id pop the rivet T7 Sot ANSEES LLP OO 058 ea om Joystick torsion tube DFO 010 push rod nom 3 6 washer ANS cat cotter pin Snug but tee T
69. THE PARTICULAR AIRCRAFT TO BE INCLUDED IN ANNUAL AND 100 HOUR INSPECTIONS Each person pertorming an Annual or100 hour Inspection shall betore that inspection remove or open ali necessary Inspection plates access door fang and He shall thoroughly clean the and engine 0 Each person performing an Annual or 100 hour Inspection shal Inspect where applicat the fuselage end hut rou C Fberglass Aluminium skin tubes for deterioration distortion other evidence af falure and defective or attachment ot 4 the following components of system and components tor improper installation apparent detecta and unsatstctory operation 0 Each person pertormin the cabin and cockpit group n Annual or 100 hour Inspection shali inspect where applicable the following components ot General Structures Cables Tangs and Ftings uncleaniness sign ot corrosion excess wear loose equipment tat might oul the contol or systems seats safety bets tor poor condition and apparent detects C windows and windshields for deterioration and breakage C instruments tor poor condition mounting marking and where practicabie improper operation right and engine controls tor improper instalation and improper operation C eanenes tor improper instalation and improper charge systems tor improper instatation poor general condition apparent and obvious detecta and ins
70. TOE Wes 319 ANS na Snug 22 85 ANS TAK WE washer push rod Wear elevator pier block spit elevator push rod 3115 washer ANS rut Sm 22 185055 STE washer push UST 5595218588 OFT push rod at 3 16 washer ANG ut Ven igit Put ANA 8 nut on rod end 4 screw rod end 1 ended Ve 2B TP ESSER TA Vi washer TU WEST TERI TT ANT T TUI 752225 SorANS TUR aaron PUSH Tod tended eet 1 2 x 14 28 TPI ANA halt nut Very sight Put ANA hgh temp nut on rod end ace to sod VA threaded Insert 1 2 x 1 4 28 EBS ANE TA VI washer 3052 TM RO WTO TT ANT TE 2 The pasts nede la perform he lask Replace worndamaged at needed ded above Max Wear defined 1 12 1 T amp Replacement when involves replacement ef structural component 4 Coco the task SRE Inspection above Maintenance or aboves Level re lo mering pts and al acces were lightens 56 69 When igh tic ne operetin Section 13 Controls Section 13 Page 46 7713 CONTROLS LiteFlite DRAGONFLY 27 08 08 DFD 002 Push Rod Elbow DFM 005 See Note 15 DFD 004 Dra
71. TTENTION Any evidence of delamination of composite layers requires fact and or repair Fora general guide see the FAA Advisory Circular AC 43 13 18 Par 8 71 through 8 109 The design and construction unlike wood metal and many other composite props is to progressively increased strength from tip to root As such a solid tip strike is not likely to destroy the hub or root of the blade leading to a catastrophic failure indeed it is even possible to loose the tip say last 35mm in a solid ground strike and keep flying until a safe landing can be accomplished It might just save you or the engine s crankshaft one day 4 Damage is far more likely at the tip as tip speed is much higher but less critical at the tip as it has less forces acting upon it compared to the root hub As all forces are focused on the root and hub sections these areas are not to be damaged The inner 200mm 8 of the prop should not be damaged any further than minor nicks and scratches Maximum allowed leading dent varies from 4mm within 250mm 10 of the root to 12mm at the tip lt Be especially wary of any deep scratches that run across the blade When in places the fibers are 9 layers deep deep scratches are bad stress concentration points The final 30 of blade be dinged dented holed amp scratched within the dent tolerance level AND REPAIRED Appendix E2 Page ll Page 130 inspection without unduly affecting
72. TTZ spacer 1 tube spacer side cockpit starboard saddle 1 saddle 1 757 cockpit tube lower starboard 147 washer ANS full nut Tight a The upper holes are nol drilled on e side Cock iubes Because of Bana problems To dril holes 5169 side cockpit tube starboard into tube upper DFB 008 17 past start bend Pin bolt 6 into left side of plane Align fight side one side of ube trough fud hole Remove 6 pin fud hole and dril aft hole Repeat for iett through side cockpit Put seat lube upper through seat Side side cockpit and side cockpit starboard into seat lube upper and align holes Take strap and using a tapered punch or similar tool work through sirap spreading treads bolt wil pass through two inches from buckle Bok 147 washer seat lube upper side cockpit port seat tube upper saddle 1 lank strap Saddle 1 root sup hd tank protector DFP 012 1 4 washer ANA half nut Tight Pull tank strap light on each side 7 14 Tender washer Seat Balt wd cockpit tube lower 147 washer ANA full nut Tight TT Recommended Special Tools None 2 The pars needed to perform the task Replace worn damaged parts as needed listed above Max Wear defined 1 1 8 1 3 Type of maintenance Inspection Line amp Replacement Heayy when it involves replacement of structural components
73. This Manual only applies to SLSA Dragonfly Aircraft and ELSA Dragonfly Kits Manufactured by Pitman Air in the United States of America Copyright Ed Pitman Rbett Radford Bobby Bailey amp Bill Moyes 2012 Page 1 903027 3 68880 884891 N 7 Page 2 809022 202 en rrr 909072 3 68 80 aga Page 3 Note A current version of this manual is always available the internet at _http www pitmanair com dragonfly www safety directives org dd mm yyyy Revision Number amp Date Purpose Paragraph Page numbers Rev 0 15 06 2011 A a Rev UE Adjust Gross Weight Rev 2 Improve Inspection 16 30 34 23 05 2012 Instructions MD 40 44 46 Rev 2 cont d Clarify Ratings Required Bailey Release and Tow 58 221 42 Rev3 Sie ued Section 8 8 thru 43 inserted Reva Bailey Release and Tow 31 01 2013 System to Appendix G Rev 5 Safety Directives Hol DF 8 31 05 2014 102 ete Sub Bolt 34 amp 38 Serial Number Information PA or PAK Pitman Air or Pitman Air Kit Engine Production Number Example 582 111 This Manual
74. To reset the ELT press either RESET switch on the remote control panel or on the main unit pacon to be handled or shipped without nuisance activation the ELT not to move the switch or to allow packing material to Main switch alternate postions Red Light for 450 ON ELT transmits immediately Both Green ON lights on the main unit and remote switch unit flash and the buzzer sound at rate of 1 second ON 4 seconds OFF The ELT swept Tone must be heard on the 121 5 MHz VHF Radio The ELT is turned off SARM ELT self test is confirmed after 24 seconds If the self test is passed the sen ON lights and the buzzer sound must be extinguished The ELT swept The ELT system is then in the ARM mode 2 Transmitter ID Programming and Self Test No Self Test Mode for AK 480 3 Turn the main switch from the OFF position the ARM position The Buzzer sound and the 2 Green ON lights shall illuminate for 4 seconds then extinguish This is to allow coding programming during the next 20 seconds window and self test for 1 second thereafter Note The ELT may be ID coding programming during the aforementioned 20 seconds window period If no programming happened the ELT will then enter the Self Test Mode for 1 second thereafter Self Test takes 25 sec Self test results after 28 seconds steadily extinguished and there s no buzzer sound ELT swept Memory at f
75. accomplish the task Line LSRI Inspection or above Heavy LSRM Maintenance or above Level of Certification in this manual 5 Detailed instructions and diagrams as needed to perform the task listed above and adjacent page Every Annual or 100 Hrs Inspect for Cracks Corrosion Elongation of holes amp Fasteners for Wear amp Security 48590 hours replace Bolt ANA 26A LLPSOO check holes for elongation Inspect 4 Bolt 8 500 hours replace main boom supp tube channel brkt 1 4800 1 1000 hours replace bolt control pivot assembly LLP1000 6 Method to testinspect to verify the task was accomplished properly Insure that all procedures were followed correctly and there is proper non binding movement to moving parts and that fasteners were tightened as instructed When flight controls are involved assure that they are operating properly Section 2 Bulkhead Section 2 Page 24 ATINO VYA eller OVIHY INS a 20 910140 gt 008a T Gig uonefiuoj 2 10 ng Cd JO 55 oquiouu eun tutem uop Bum pue g 995991 Page 25 Drawing 2 Section 3 Maintenance 8 Inspection Dragonfly 582 ROOT TUBE STEP INSTRUCTIONS Tor Assembly for Disassembly reverse ha order PART NO STAGE CERT T Bai ANE 89 6
76. addle mid root supp aluminium DFK 012 root tube saddle mid root supp aluminium ool supp mid 1 4 washer ANA full nut Very tighi a Bot ANA DET washer 8969825558 Spacer stand of 375 OFS 605 oot supp spacer stand of 375 adjuster assembly 1 4 washer ANA half Tight T ri 842 Ra ato cana 8 58625 TG TOOT BUH TES Stopping ToT aT BAT through saddle screw pan head 107 x 314 OFT 512 cable clamp 1 4 DFT 431 saddle mid root supp 1 125 TTT Recommended Special Tools None 2 The pars needed to perform the tsk Replace worn damaged parts as needed listed above Wear defined 1 1 3 Type of maintenance Inspection Line amp Replacement Heavy when it involves replacement of structural components 4 Certification needed to accomplish the task Line LSRI Inspection or above Heavy LSRM Maintenance or above Level of Certification in this manual 5 Detailed instructions and diagrams as needed to perform the task listed above and adjacent page Every Annual or 100 Hrs Inspect for Cracks Corrosion Elongation of holes amp Fasteners for Wear amp Security 6 Method to test inspect to verify the task was accomplished properly Insure that all procedures were followed correctly and there is proper non binding movement to moving parts and that fasteners were tightened as instructed When flight controls are involved assure that th
77. ages contain information that configures the instrument to your engine and selects various options These pages are accessed by pressing and holding the ght and center buttons several seconds until The boim row of the sereen displays Up Down Next While on the configuration set pages the bottom row of the display will show UP Down Next indicating the function of the butions while on these pages As such the left and center buttons allow you to change the seting and the right button takes you to successive seins To leave these pages repeatedly press the right buton or press and hold the right buton the normal display pages retum The items that can are set on these pages are onder a follows Fuel Temp and Altitude show the they using The units for the vertical speed climb rate indicator are feet per minute Gin increment of 100 feet per minute or meters per second corresponding to the selection Tor the altimeter GES Page When On enables the GPS page This page appears after the second combination page See the section GPS Page for a complete description GPS Units Selects whether miles or kilo meters will be used as the units on the GPS pages Has no effect if GPS Page is ff GPS Baud Selects he baud rate for receiving data ftom the GPS Most GPS receivers transmit data at 4800 band nd this setting should be used EGT Toggle When OF the highest EGT is displayed on combination sereen 1
78. and operating certificates issued under the provisions of Part 121 or 135 and Part 129 operators holding operations specifications Unless otherwise notified by the administrator the methods techniques and practices contained in the maintenance manual or the maintenance part of the manual of the holder of an air carrier operating certificate or an operating certificate under Part 121 or 135 and Part 129 operators holding operations specifications that 5 required by operating specifications to provide a continuous airworthiness maintenance and inspection program constitute acceptable means of compliance with this section Notes Appendix D Page 7 End of Appendix D Page 114 Appendix E1 KievProp Installation KievProp INSTALLATION INSTRUCTIONS Www kievpropamerica com For engine type with ROTAX 912 series 75mm Bolt Pattern 8 Ib 1 oz w o 6 mounting bolts CG datum Point 132 1 Disassemble prop hub noting orientation of prop hub halves stamped number on each Hub half must remain adjacent to each other during assembly 2 Inspect each blade and remove any tape glue residue from brass leading edges Install propeller blades into their positions between the hub halves Use caution to not drop or hit blade tips the ground or hard surface The tips are the most fragile area of the prop NOTE There is a tiny hole in the tip that must remain open to expel any moisture or condensation trapped inside the b
79. art numbers Wf name to let NOTE When LLP parts are replaced an Aircraft Logbook Entry must to be made to confirm the Date and Total Time at time of replacement to establish when the next replacement is due 100 hr denotes additional attention the need to laok for elongation of holes and re tighten to Very Tight in this case as defined in Torques 1 1 8 See agi ee EEE 277 mai ooom stpp tube 1 DFC 0141 ourmayaquoazothe ube slighty win pesto 59 5 Eo waptubeto Breventmaringanduse ust enough pressure to avoid deformingtute Bol 1 soon vester 1 LLPS00 msinboom sung tube space be spacer washer Altri Page 21 Section 7 Maintenance amp Inspection Dragonfly 582 BOOM TUBE and external paris e folowing manner Take care sach That passes rough Wve Baam or fuselage tube also passes through an Internal tube or sleeve sa that the boom tube wil not be squeezed out of round when bolis are tensioned An internal steel tussis ited centrally The release cable should be fitted now il the Dragonfly is to have a tow system Take care that i remains in the postion that i is fitted STEP INSTRUCTIONS for Assembly for Disassembly reverse The order PART NO__ STAGE CERT
80. as possible and work inside seams to one side I seam fi t wil leave a bume 5 Bol stainless hex head x 20 TED OFTOOT 300 hr 1 4 washer vert stab alt vert stab conn block Tight inspect amp tighten every 100 hrs 8 199 vert stab tension tuba DFC TTS inside sall Tube is asymmetrical Ba sure correct end is in frst Bum elongated holes in fabric at tension tube hole Bolt hex head 1 4 x 20 TPIX 6 OFT 005 1 4 washer main boom vert stab fabric vert stab tension tube ona bolt hen the other to tighten fabric DFT 005 balt does not reach threaded rod may be used I you intend to paint he stop assembly of vert stab hore and continue to next Section 7 Burn holes in fabrie Tor bolts 7 8 9 TT Bol ANTER SG washer Roriz stab Brkt UFOS Spacer 1 x 287 1257 DFP 028 saddle 1 75 DFP 032 wert stab alt saddle 1 75 spacer 1 x 257 x 128 hori stab brkt 3 16 washer ANS Tight 3 Bolt 25 8 washar honz stab BA modiied tbe conn 888 82 vert stab fd saddle 1 tube conn saddle end t horiz stab _ 3 16 washer ANa halt nut Tight Switched trom ANS 24A for Safety Dir DF 1401 a Balt ANS ZUR 898889 stab alt ANS blind nut Very fight TO The har 86710 goes Through is only dled because ot aignment_ 5898 3 16 dil insert int hole one side of vert
81. ashers as needed when equipped with Dual Caliper Brakes end i Axe 8 Star inte 7570 Find prope poser on brake assy tying on Ts ew bol 5 AN4 SA 114 washer brake rake 29 14 washer ANE igh emp Very ight 9 TERRE RTO TET 5555280552 BOT and wheel onto UNF locknut Tan 0 1 TE Ba A STE oT ADRS CET 13 Bar ANS 25 ST RTS ever spacer throne ever 7mm DEM 002 hot lever wa washer en saddle 175 DFP O32 cork ibe lower lef 16 washer ANS 80 pin Adust afer engins is Ta Stans washer cable STS wane ab Tver wa 89866 18 roti iever 316 washer ANS case cater pin Sug T6 Bar NS T STE vaso kr rake pivot rae lever 516 washer ANS case corer pin Srug bu ee TE Bak ANS mw ater pin Snug ut ter pin Snug but fee TSE BRE headed rod 10 32 TP 1 1 4 brake spacer hot lever mm brake lever brake lob Tight Roo WOME OFFS headed rod 10 32 TP 1 1 4 ote lever spacer throtle ever lever twd knob TT Recommended Special Tools None 2 The pars needed to perform the task Type of maintenance Inspect 4 Certification needed to accomplish the task Lin see 3 Level of Ce
82. asket or burner is designated as interchangeable in the balloon type certificate data and the baskets and burners are specifically designed for quick removal and installation You must comply with type certificate data sheet ameter of fuel tank filler openings provided the icate data by the aircraft manufacturer the aircraft manufacturer has provided FAA approved instructions for installation of the specific device and installation does not involve the disassembly of the existing tank filler opening Always comply with the FAA approved instructions from the manufacturer when installing nti misfu airplane ing devices on your 29 Removing checking and replacing magnetic chip detectors Comply with the engine and airframe manufacturers recommendations when removing checking and replacing the magnetic chip detector 30 The inspection and maintenance tasks prescribed and specifically identified as preventive maintenance in a primary category aircraft type certificate or supplemental type certificate holder s approved special inspection and preventive maintenance program when accomplished on a primary category aircraft provided i They are performed by the holder of at least a private pilot certificate issued under part 61 who is the registered owner including co owners of the affected aircraft and who holds a certificate of competency for the affected aircraft 1 issued by a school approved under 147 21 e of this chap
83. ation needed to accomplish the task Line LSRI Inspection or above Heavy LSRM Maintenance or above sce Level of Certification in this manual 5 Detailed instructions and diagrams as needed to perform the task listed above and adjacent page Every Annual or 100 Hrs Inspect for Cracks Corrosion Elongation of holes amp Fasteners for Wear amp See 1 35 Fabric Coverings For more inspection and testing information on fabric coverings See Cables Thimbles and Tangs Page 16 6 Method t esvnspect to verify the task was accomplished properly Insure that all procedures were followed correctly and there is proper non binding movement to moving parts and that fasteners were tightened as instructed When fight controls are involved assure that they are operating properly Section 19 3698 Support Tubes amp Mounting Section 19 Page 58 elongation of holes Watch for Cracks or TUBES amp MOUNTING LiteFlite DRAGONFLY 719 AILERON SUPPORT Drawing 19 Page 59 Section 20 Maintenance amp Inspection Dragonfly 582 STRUTS amp WING CONNECTION STEP INSTRUCTIONS for Ascari or Disassembly reverse he order AHTNG STAGE Push spacer sii 1 iio su using a length c tubing or wood approx s Teal Tong Cut a molem in one end of pusher tube for spacer to so you may twist tube as you work Spacer ends be Hed so they
84. attery use only an approved battery for your make and model airplane You are also permitted to add water distilled water and charge your battery If you need to clean the battery terminals or battery box arcs baking soda works about the best Flush with fresh water when you re completed Don t allow any baking soda to emer the battery Emergency Locator Transmitter battery replacement is also permitted provided you are able to follow the manufacturer s recommendations Don t forget that the new expiration date for replacing or recharging the battery must be legibly marked on the outside of the transmitter and entered in the aircraft maintenance record 25 Cleaning of balloon burner pilot and main nozzles in accordance with the balloon manufacturer s instructions Comply with manufacturer s recommendations 26 Replacement or adjustment of non structural standard fasteners incidental to operations You are permitted to remove and replace non structural standard fasteners which also includes the removal and replacement of screws or rives used to attach fasteners Remember that you must use the approved fasteners screws and rivets for your airplane If you are one of those mechanically gifted people have at it drive those rivets But if you like to put a square peg in a ound hole this may be complex task for you Leave it to the professionals 27 The interchange of balloon baskets and burners on envelopes when the b
85. ault Distress ID stored in Memory at fault Battery voltage is low lt Useful Life Battery Voltage setting Vee supplies for F3 F2 or FI at faul F3 RF power level lt 33 dBm 406 028 MHz 81 82 VHF RF power level 17 dBm 125 243 MHz PLL locked in F3 or FL or F2 at fault jus lash no F3 F2 F1 RF output power ELT shuts down completely Note The self test mode that transmits a 406 MHz test code pulse monitors certain system functions before returning to the ARM mode The 406 MHz test pulse is ignored by any satellite that receives the signal but the ELT uses this output to check output power and Correct frequency self test is 520 ms long message burst on the 406 signal Synchronization pattern is 011 010 000 Aes is then 121 243 VHF Continuous Wave during I During Self Test ELT swept Tone must be silent on the 121 8 MHz VHF Radio IFNo Antenna or No coaxial cable connected the ELT may or may not 5 flashes Appendix F Page 8 Page 139 lo ELT REMOTE UNIT 8 ERLANG CORP ELTNAIN UNIT Figure 6 ELT Front Panels Main Unit and Remote Unit 3 System Integration Test some parts may not apply to AK 450 The test consists of turning the unit ON and then resetting it to verify that the Transmitter Latch Circuit Batteries and associated equipment are operating properly Regulations require that Transmitter tests only be done during the f
86. be performed in accordance with applicable sections of part 91 Appendix D Page 4 Page 111 Advisory Circular 43 124 Preventive Maintenance Subject Preventive Maintenance Initiated by AWS 340 1 PURPOSE This advisory circular AC provides information concerning preventive maintenance who may perform it the standards of performance applicable to it authority for approving aircraft for return to service and the applicable recording requirements This AC also clarifies those areas most frequently misunderstood in the past and explains the recent changes in the rules concerning preventive maintenance 2 CANCELLATION AC 43 12 Preventive Maintenance dated July 16 1976 is canceled 3 RELATED FEDERAL AVIATION REGULATIONS FAR Part 1 Definitions and Abbreviations Section 1 1 Part 43 Maintenance Preventive Maintenance Rebuilding and Alteration Part 61 Certification Pilots and Flight Instructors and Part 145 Repair Stations 4 PREVENTIVE MAINTENANCE The holders of mechanic and repairman certificates persons working under the supervision of these mechanics and Tepairmen repair stations certificated under Part 145 and air carriers certificated under Pars 121 127 and 135 are authorized to perform preventive maintenance These persons also authorized to perform other maintenance Therefore itis of litle consequence to them how a particular function is classified since they are authorize
87. between loor pan and cockpit tube fwd Push pedals to alt position and centre foot DFP 031 rest on pedals Dril 3 16 hole through fot rest and cockpit luba fu rivet stainless steel 316 x 58 floor pan foot rest saddle 1 cockpit tube fwd DFT 404 57159 5558772480 5525 DFG 07 into place Bot AN4 24A 1 4 washer cockpit channel lower cockpit tube lower spacer lower cockpit 1 625 cockpit tube lower cockpit channel brkt lower 1 4 washer Very 7 Sis spacer T abe spacer 8 8758 upper cockpit 68 por DFC 005 upper cockpit tube starboard DFC 004 Bolt 4 1 4 washer upper cockpit tube port spacer 1 tube spacer 8757 875 upper cockpit tube saddle 1 root tube saddle 1 upper cockpit tube starboard spacer 1 tube spacer 875 875 upper Cockpit tube starboard 1 4 washer ANA full nut Very tant TT Sige spacer Tubs spacer 875 878 upper cockpit Tube and starboard Sot ANE washer channel 1 upper cockp tube spacer 1 lube spacer 875 875 upper cockpit tube channel brkt i 14 washer ANA nut Very tight Tighten 3 TY Balt ANS T8 37 washer rudder cabe 216 washer rudder pedal fd 16 washer 8505 nut coller pin Snug but fee TOP ANE 8981888727 x 3257 DEO TOE washar root support twd saddle Y tank brit DEJ 002 100 hr Check these fi
88. bly Procedure NOTE The following section shows photographs of assembly of the Bolly 3 blade Propeller Assemble the propeller components on a flat soft and clean surface Before installing a propeller the propeller shaft and threads should be checked for damage Boss and hub flange faces should be checked for cleanliness lack of rust or corrosion to ensure that maximum friction will be obtained The angular position of the propeller on the hub is not important at this point as the pitch will be set later Important Note All bolts washers and nylon lock nuts used to clamp the hub plates and attach propeller assembly to the engine should be assembled dry without oil or moisture Propeller Material List Part Bolly BOS blade Bolly BOS 4 blade Washer Plate Hub Halves Blades ANA 20A Bolis Nyloc Nus ANI Washers Thin Washers Thick MS X 75 MS Washers MS Nate Appendix E2 Page 3 Page 122 Assemble Forward Hub Block The forward hub block is the one which has the small centering hole in it The hub with the large center hole is to index on the 912 prop flange This allows one set of hubs to fit both Rotax 2 cycle gearboxes and 4 cycle as well NOTE It is best to read the propeller instructions completely before beginning any assembly or disassembly NOTE Read and understar Tracking near the end of this appendix before proceedin
89. bove and adjacent pa Every Annual ar 100 Hrs Inspect for Cracks Corrosion Elongation of holes amp Fasteners for Wear amp Security 6 Method to testinspect to verify the task was accomplished properly Insure that all procedures were followed correctly and there is proper non binding movement to moving parts and that fasteners were tightened as instructed When flight controls are involved assure that they are operating properly ion 26 582 Radiator Installation Section 26 Page 72 26 582 RADIATOR MOUNT LiteFlite DRAGONFLY Drawing 26 Page 73 Section 27 Maintenance amp Inspection Dragonfly 582 582 FUEL PICK UP STEP TINSTRUCTIONS ror Assorby Tor Disassembly reverse 88 order PARTNO J STAGE CERT T Dril 332 through cap Tuel tank DFP 051 for ventilation 271858 Tuel primar 5 8 815 into fuel line DFS 014 making sure itis installed with the arrow pointing upwards fasten with hose clamp 1 4 DFO 051 J Cure engin of Tua ihe natal on Tuel primer and Tasten with hase clamp 114 Tse Tuel Titer DFP 050 through fuel tank and fuel ine fasten with hose clamp 1 4 5 Cut 2 leng n of fuel line install onto fuel ter and fasten with nose clamp 1 5 nsa Tuel tank pick up DFG 609 into fuel line fasten with hose clamp 1 4 TIJ Recommended Special Tools None 2 The parts needed 1o perform the task Replace
90. cific training include 8 2 1 Engine manufacturer heavy maintenance or overhaul school or both 82 Rescue Parachute manufacturer repair course and 82 3 Aircraft manufacturer courses 9 Safety Directives 9 1 An SLSA may have a Safety Directive issued against an aircraft or component part The original aircraft manufacturer issues the directive as outlined in the applicable ASTM Continued Airworthiness specification NOTE SLSA and components installed on SLSA s do not have airworthiness directives AD s issued against them Wan AD is issued against a type cer ficated product that may be incorporated into Special Light Sport Aircraft the manufacturer of the aircraft is required in accordance with ASTM Practices F 2295 and F 2415 and Specification F 2241 issue a Safety Directive providing instruction on how to address the safety defect outlined AD on the specifie SLSA 3 2 The original LSA manufacturer is responsible for providing the applicable instructions to comply with any Safety Directive which will include 9 21 A list of the needed to accomplish the task 922 A list of the needed to perform the task 3 Type of maintenance for example Line Heavy Overhaul eic Page 82 24 The level of certification needed to accomplish the tsk for example A amp P Repairman Inspection ete 9255 Detailed instructions and diagrams as needed to perform the task and 19 2 6 Method to testinspectto verity the
91. d after the switch is held for 25 seconds If the self test is passed the Green ON light must be extinguished ELT swept Tone must be silent on the 1215 MHz VHF Radio The ELTAS system is fully self tested 52 Transmitter Self Test Turn and hold the main switch from the OFF position to the SELF TEST position The Green ON light shall illuminate for 4 seconds then extinguish T during next 20 seconds window and self test for 1 second thereafter The 1 8 may be coding programming during the aforementioned 20 seconds programming happened the ELT will then enter the Self Test Mode for 1 second thereafter Self test results after 442041 225 seconds is F the self test is passed the Green ON LICHT is steadily extinguished ELT swept Tone must be silent on the 121 5 MHz VHF Radio H the self test is failed the Green ON LIGHT flashes as shown below 1 flash Internal Data stored in Memory at fault ires ID stored in Memory at fault Battery voltage is low lt Useful Life Battery Voltage setting Vee supplies for F3 F2 or F1 at fault F3 RF power level lt 33 dBm 406 028 MHz FUF2 VHF RF power level lt 17 dBm 121 5 243 MHz PLL locked in F3 or F1 or F2 at fault sous ash no F3 F2 F1 RF output power ELT shuts down completely the SELF TEST mode The 406 MH test pulse is ignored by any satellite that receives the signal but the 1 1 5 tise this o check output power and
92. d to perform the function as either preventive maintenance or as other maintenance Further the procedures used in approving for return to service and recording identical This AC will therefore consider preventive maintenance from the ownersloperators point of view b FAR Part 1 Section 12 defines preventive maintenance as simple or minor preservation operations and the replacement of small standard parts not involving complex assembly operations 1 EAR Part 43 Appendix paragraph contains the list of those functions determined by the FAA to meet this definition If a function does not appear in this list it is not preventive maintenance Further because of differences in a function may be preventive maintenance on one aircraft and not on another provide for this paragraph contains the limitation provided it does not involve complex assembly operations on the aircraft involved Owners and pilots must use good judgment in determining that a specific function may appropriately be classified as preventive maintenance 2 A pilot may not perform preventive maintenance on aircraft used under Parts 121 127 or 135 even when the pilot owns the aircraft lt Persons authorized to perform preventive maintenance In addition to those persons listed in paragraph 4a of this Section 43 3 g authorizes the holder of a pilot certificate issued under Part 61 to perform preventive maintenance S
93. dar comp strat Snug Sida rudder conp strut owe irto comer ot ruddar Push compression sina place Dra 316 hole trough fwd and into end af rudder comp Sut pan nead 12x 1 112 Iwa der eS 9 Ba AN TO rings Taar inge bk versa hoe 860 ude ORT erst TET washer ANG castle nit caner pin Snug bur Pees Bo AE TO Trg BT WaT Sy Tuer GE 167 8851 ANT calle coer pin Snug out kee TTT EERE TT WaT iS EEL washer hom 1 4 washer AN castle nut cater pin Snug but fee necessary MIS rudder unt cables tront 21211 Sect 9 are Bend tanga cow and luncate TT Recommended Special Tools None 2 The pars needed to perform the task Replace worn damaged parts as needed listed above Max Wear defined 1 1 8 1 3 Type of maintenance Inspection Line amp Replacement Heavy when it involves replacement of structural components 4 Certification needed to accomplish the task Line LSRI Inspection or above Heavy LSRM Maintenance or above see 3 Level of Certification in this manual 15 Detailed instructions and diagrams as needed Yo perform The ask ted above and adjacent page Every Annual or 100 Hrs Inspect for Cracks Corrosion Elongation of holes amp Fasteners for Wear amp Security See 1 35 Fabric Coverings For more inspection and testing informati
94. des the leanes mixture and highest around mid power Going to full power will normally reduce the assuming the engine is otherwise functioning normally Why monitor linder Head Temperature CHT and Coolant Temperature Both CHT and coolant temperature reflect how well the engine is being cooled They revel problems association with insufficient cooling such as poor airflow over the engine and or radiator lack of coolant loose fan belts They do not provide any indication of the mixture being too lean and thus can not give any warning about excessive internal engine temperatures This is the job of EGT For air cooled engines CHT is the only means to measure how well the engine is being cooled For water cooled engines CHT allows detection of uneven coolant flow and provides earlier warning to loss of coolant than water temperature Exceeding these limit may result in damage but not nearly as quickly as exceeding EGT limits Appendix Page 3 Page 97 What causes high CHT and Coolant Temperatures High power settings and high ambient temperatures Problems with the engine s cooling system What to do when you get a high CHT and or Coolant alarm Reduce engine power as soon as practical Reduce the load on the engine by reducing the climb rate If normal temperatures can not be achieved with these actions land as soon as practical and safe and investigate Can only EGT or CHT
95. determination The weight and position of the Center of Gravity CG of the empty aircraft must he established to conduct load sheet calculations The must be weighed and measured in a fixed position and altitude and in windless conditions with wings level Use a plumb line to project the following postions to the ground for measurements The Datum is the point from which all measurements are taken and for the Dragonfly is the nose cockpit front cross tube The attitude selected is lo raise the tail wheel till the Horizontal Stabilizer is level by measurement with a spirit level See 2 1151 The weights and measurements recorded in this postion and results as follows note typical aircraft Use only Ibs and inches Metric Units must be converted first Page 13 The Mean Aerodynamic Chord MAC is calculated by adding the wing and flaperon area and divide by span AREA MEAN SPAN DATUM Pilots Pelvis position Axle Leading Edge of Wing Fuel Tank Cemer Rear Pelvis position Wheel Axe mong 437 6468 Cockpit front ros Pilot CG 3509 Fron Wheels Er pr 1960in EMPTY WEIGHT MEASURED AS FOLLOWS and the Moment Arm ftom DATUM used to calculate moments Note these readings for a typical aircraft Front Rt Whee Fron Lt Wheel Rear Wheel Toral Weight CG fiom Datum The Leading Edge of the wing is 600i of Daum
96. dily extinguished and no buzzer sound ELT swept Tone must be silent on the 1212 MHz VHF Radio H the self test is failed the Green ON light flashes as defined below 1 flash Internal Data stored in Memory at fault shes Distress ID stored in Memory at fault Battery voltage is low lt Useful Life Battery Voltage setting Vee supplies for F3 F2 or F1 at fault F3 RF power level lt 33 dBm 406 028 MHz FUF2 VHF power level lt 17 dBm 125 243 MHz PLL locked in F3 or F1 or F2 at fault sous lash no 83 82 1 RF output power ELT shuts down completely Note The self test mode that transmits a 406 MHz test code pulse monitors certain system functions before returning to the ARM mode The 406 test pulse is ignored by any satel output to check output power and correct frequency Self test is 520 ms long message burst on the 406 MHz signal Synchronization pattern is 011 010 006 then 121 248 MHz VHF Continuous Wave during 1s hat receives the signal but the ELT uses this Antenna or No coaxial cable connected the ELT may or may not 5 flashes ELT Self Test Schedule We recommend that the ELT be tested every month Follow the steps outlined above Total allowable test is 0 minutes as determined by FAR 91 207 and RTCA DO 204 Afer this time has been accumulated a 3 lash error may be presented after the self test The battery must be replaced at this point for the ELT to remain in com
97. e Figure 2 Propeller Part Lines Appendix E2 Page 6 Page 125 Re Pitching Instructio Ensure Prop Hub is Vertical Level the base of the airplane so that the prop hub is vertical This is achieved by using shims under the tail wheel to lift it until the flat surface of the rear of the prop hub is vertical NOTE The ideal reading is 90 but 0 05 is acceptable for practical application Figure 3 Prop Hub at 89 95 Degrees After Correct Shimming of Front Wheel Rotate the Propeller Blade to Horizontal Position The propeller that is to be set should be rotated into position on the pilot s right starboard of the engine The prop hub vertical surface is checked to be 90 to ensure the propeller is in the standard horizontal position Figure 4 Propeller Horizontal Check Appendix E2 Page 7 Page 126 Figure 5 Set Blade Angle Start by making gauge reference mark with masking tpe 3 inches in from the tip and perpendicular to the Made using a square on the leading edge Set the pitch gauge in the same location on each blade With blade pulled 5 outward Tighten back and forth to The angle of the propeller can now be set Place the digital level at the blade tip and adjust pitch of the propeller to the angle as specified in table 21 The figure above is with reference to a Rotax 912 engine the 582 propeller turns in the
98. e 2 Using GPS Page Wiring of Tach Diagrams 104 115 116 117 Important Should only be modified by Factory or Qualified Avionics Tech Questions Call First rand Rapids Technolo 616 583 8000 Appendix C Page 2 Page 96 Incorporated Introduction Importance of the Engine Information System Two stroke engines are lightweight and powerful making them ideally suited for ultralight aircraft Their only potential weakness is their intolerance for operating outside their strict temperature limits Exceeding these limits can cause engine damage in as little as tens of seconds The EIS greatly overcomes this weakness by continuously monitoring all critical engine parameters and alerting you with a bright red flashing light should damaging engine conditions develop With this close monitoring itis nearly impossible to knowingly exceed these limits making the two stroke engine well suited as an ultralight aircraft engine Understanding EGT and CHT Why they are critical to safe engine operation The need for monitoring engine RPM and coolant temperatures water cooled engines is obvious to most pilots The tachometer gives you a measure of the power being produced and allows you to keep RPM within limits to prevent damage from mechanical stresses that result from high RPM The coolant ws detection of high engine temperatures that could result in thermally induced mechanical damage due to ig But often EGT and
99. e ELT Main Unit and the Remote Unit Batteries Replace if necessary 65 Battery Leakage Check Remove the Battery Case and inspect the Battery Compartment for signs of corrosion or battery leakage If any battery leakage is present all batteries must be replaced The Battery useful life BS years 64 G Switch Check Ensure that the Main Switch on the ELT main unit must be selected at ARM posi times Activate the ELT using applied force The direction for mounting and force activation is indicated on the ELT The AK 481 AF AP ELT can be activated by using a rapid forward throwing motion coupled by rapid reversing action Verify that the ELT has been activated by use of the Wattmeter the Airplane s VHF Radio Communications Receiver when tuned to 121 5 MHz other means see Note I The ELT must then be reset by pressing either the RESET push button located on the ELT main unit or the ELT Remote Unit Note not a measured check It only indicates that the G Switeh is working 6 1 Antenna Check A low quality AM Broadeast Radio Receiver or Equivalent Test Equipment should be used to determine if energy is being transmitted from the Antenna When the Antenna of this Radio tuning dial on setting is held about 6 inches from the activated ELT Antenna the ELT Aural tone will be heard see notes 2 and 3 The ELT must be reset by pressing either the RESET push button located on the ELT Main unit or the E
100. e final torque settings for the nuts has been achieved TOLERANCE LEVELS for the blade accuracy lt RULE OF 3 gt 3 on torque settings preferably under not over the maximum ideally identical setings 2 Blade weights 3 grams and 3gm between pairs in 4B prop maximum ideally identical From tip to tip 3mm maximum ideally identical distances Runout height 3mm maximum ideally identical distances Pitch as close as possible ideally within 1 3 of a degree perfectly aligned and balanced prop is definitely a bonus to smooth running and reduced vibration It is well worth taking the time to achieve the best tolerance levels possible Care amp Cleaning As per the rest of your airframe the propeller will benefit from being kept dry and out of the sun If you wish to use blade covers it must be a cotton fabric in contact with the blade To remove bugs dust and exhaust residues use a mild household detergent spray on wipe off cleaner Do not polish the blades as some polishes can cause problems with the surface Prop cleaning kit is available from Bolly Aviation BLADE DAMAGE amp REPAIR Common causes are Water damage including hail stones gravel amp sand bugs amp birds plus loose objects plus of course contact with terra firma Such variety makes it very difficult to specify maximum damage levels before the blade should be discarded rather than repaired A
101. e is proper non binding movement to moving parts and that fasteners were tightened as instructed When fight controls are involved assure that they ure operating properly Section 29 Parachute Mount amp ELT Section 29 Page 78 728 PARACHUTE MOUNT LteFile DRAGONFLY ELT Mount located on the front top of Left Wing Inboard Compression Strut ELT must be inspected every 12 calendar months in accordance with FAR 91 207 d Drawing 29 Page 79 3 Level of Certification 34 Owner Tiems that be expected to he completed hy a responsible owner who holds pilot certificate but who has not received any specifie authorized training May do certain Preventative Maintenance on SLSA as defined in Appendix D of this manual NOTE FAA regulations authorize SLSA aircraft owners who hold at least sport pilot certificate to perform maintenance as outlined in 14 CFR Part 43 Defined in Appendix D of this manual 3 2 LSA Repairman Inspection LSRI sce 41 51 61 and Appendix D of this manual items that be expected to be completed an ELSA by a responsible owner which holds an FAA repairman certificate light sport aircraft with an inspection rating 1 81 or equivalent 3 3 LSA Repairman Maintenance LSRM see 41 5 1 amp 6 1 ems that be expected to he completed SLSA by a responsible individual which holds PAA repairman certificate light sport
102. e sequencing in the torque section The propeller should now hold itself in place Put the full nylon lock nuts on but do not tighten until last If they are not assembled at this stage they will be impossible to get on after the bolts have been torqued Figure 41 Mounting the Propeller Lightly Tighten Bolts to Allow Pitch Adjustment Removing a spark plug from each cylinder 81 allow the prop shaft to turn much easier Appendix E2 Pages Page 124 CAUTION PULL THE BLADE RADIALLY OUTWARDS TO SEAT THE BLADE INTO IT S HUB BLOCK LOCATION WHILE TIGHTENING THE AN4 NUTS BOLTS THIS ENSURES UNIFORM DIAMETRICAL POSITIONING OF THE BLADES RELATIVE THE HUB AND EACH OTHER Tighten the AN4 nuts in sequence in order that the propellers can still be easily rotated by hand but are in securely held condition so that they may be adjusted both easily and precisely Evenly tighten the bolts nuts to keep the hub gap the same on both sides of blade Apply the torque to the nuts not the bolts NOTE Wait after the propeller has been adjusted to fully torque either sets of bolts Figure 1 Propeller AN4 Bolt Tightening Sequence Numbers Propeller Approximate Pitch Angle line is visible only on the Bolly Propeller It is good starting point that will be close to the proper pitch which may be adjusted after the first run up RPM test Part Line pur Lin
103. ect Some problem areas that have been noted are alternator drive belts and autopilot servo clutches 11 Repairing upholstery and decorative furnishings of the cabin cockpit or balloon basket interior when the repairing does not require disassembly of any primary structure or operating system or interfere with an operating system or affect the primary structure of the aircraft When repairing or replacing upholstery you are required to meet the original type design requirements Use only material that has met the burn test requirements The supplier of the aireraft interior vill provide you with the needed paper work for your logbook Do not buy materials from a local upholstery shop because your mechanic may ask you for the certification paperwork at the next annual 12 Making small simple repairs to fairings non structural cover plates cowlings and small patches and reinforcements not changing the contour so as to interfere with proper air flow Be careful what you consider a simple repair may not You should refer to the service manual and then ask for advice from your A amp P mechanic before making a judgment call You must use approved material and procedures to do the repair 13 Replacing side windows where that work does not interfere with the structure or any operating system such as controls electrical equipment ete Remember that we are talking side windows not windshield leave that up to the A amp P mechanic Th
104. ection 43 7 limits the privileges persons holding at least a private pilot certificate and Section 43 5 prohibits operation of the aircraft unless approved for return to service Further pilots may only approve for return to service preventive maintenance which they themselves have accomplished 1 pilot is defined as a person holding at least a private pilot certificate or above 2 pilot may not perform preventive maintenance on aircraft used under PAR Parts 121 127 or 135 even when the pilot owns the aircraft 3 A pilot who owns an aircraft may not work on his her aircraft unless they hold at least a Private pilot certificate 4 Applicable performance standards 1 FAR 43 13 requires preventive maintenance to be done using methods techniques and practices acceptable to the Administrator These are normally set forth in the manufacturer s maintenance manuals however some may be found in ACs published by the INOTE Itis absolutely essential to have the appropriate manuals and data when performing preventive maintenance Appendix D Page 5 Page 112 2 PAR 42 13 requires the use of the tools equipment and test apparatus necessary to assure completion of the work in accordance with accepted industry practices This means that the proper tools and test apparatus must be used Normally these are listed as of any FAA approved manufacturer s maintenance literature EAR 43 13 also requires that any special e
105. ection 8 Tail Wheel Section 8 Page 36 Section 9 Maintenance 8 Inspection Dragonfly 582 VERTICAL STABILIZER STEP INSTRUCTIONS Tor Assembly Disassembly reverse Ihe 6987 PARTNO STAGE CERT T Wrap myar snim around 88 868870 DFC 857 and side into boom tube Align holes hall nut 1 4 washer Bolt vert stab fed 1 4 x 25 DFO 004 cable clamp 1 4 OFT 431 cable clamp 1 4 spacer stand 275 DFG 005 boom tube vert stab fwd boom tube spacer stand off 375 cable clamp 1 4 cable clamp 1 4 washer halt Tight 27 Shave hal af ane end oF TF TBE DFP OT at sight Pop rivet aluminium 3 16 x 587 DFT 413 1 2 angled tube insert vert stab fwd Align tube insert until approx Parallel wil boom tube Sat rivet but do not pop 1 is popped plastic wil expand and tube wil not Squeeze rivet sigh unti inset is ight against tube Shank may be ff with pliers 3 Pop ret aluminium x 5 8 angled V2 tube inser vert slab Sal vel do nal BOD See above 3 BS ANG STIS Waar VET SI 86 Vert stab conn block OFF 827 vert stab 3 167 washer ANS nut Tight Side fabric Vert stab DFR 015 ovar vert stab aft through lower hole Side fabric over ver stab hud through fd lower hole Side fabric hallway down and put Vert stab comp strut OFF 011 in place Side fabric down as far
106. ecurity ot attachment 8 Each person pertorming an Annual or 100 hour Inspection shal inspect wher applicable component of the engine rou engine section tor visual evidence of excessive uel hydraulic leaks and sources ot such leaks studs ana nuts tor improper taming and obvious defects erat engine tor cyinder compression and tor metal particles or foreign matter on screens or in al iter element and magnetic sump ain pugs etes weak cylinder compression or proper intemal condion ed improper vem olerances C Engine mount tor cracks looseness of mounting and looseness of engine to mount viraton dampers tor poor 06 10 and deterioration Engne contots tor detects improper and improper hoses and clamps leaks improper conditio and looseness Saet stacks tor cracks detects and improper attachment Accessories tor apparent detects in security of mounting Page 18 as systems tor improper instataton poor general condition detects and insecure attachment C Coming or Fairings tor cracks and detects Continued nex page 0 Each person pertorming an Annual or100 hour Inspection shali inspect where applicable the following components ot he landing gear group Cas units tor poor condition and insecuity of attachment shock absorbing devices tor improper oleo fuid level linkages russes and members tor undue or excessive wear fatigue and distortion tor leakage
107. ed 121 Checklist for Annual amp 100 hour Inspections Error Bookmark not defined 1 3 Structures 20 1 3 1 Wings see Sections 14 through 20 20 1 32 Empennage see Sections 1 2 4 8 through 13 21 amp 23 20 1 3 3 Landing gear see Sections 2 7 8 and Appendix 20 134 Structural Control Surfaces see Sections 9 through 21 20 1 35 Fabric Coverings Sections 9 through 20 20 13 Engine 20 20 1 5 Fuel System see Section 27 20 1 6 Propeller refer to Propeller Manufacturers Manual 20 Page 6 1 7 Utility Systems No Utility Systems 1 8 Instruments and Avionics See Appendix C EIS 1 9 Electrical System see Section 28 1 10 Structural Repair see 2 1 Repairs and Alterations Painting and Coatings Refer to FAA ACA3 13 1B 2 Revisions Record of Manual Revisions is located in the beginning of this Manual 1 13 Feedback Form 2 1 Repairs and Alterations defined 2 1 1 Repairs 2 2 Alterations 2 2 Detailed Instructions and Diagrams for Inspection and or Repair How to use this Section of the Manual Section 1 Boom Tube Section 2 Bulkhead Section 3 Root Tube Section 4 Fuselage Section 5 Fwd Cockpit Section 6 Pilot Seat Section 7 Fwd Wheel Throttle amp Manual Brake Section 8 Tail Wheel Section 9 Vertical Stabilizer Section 10 Rudder Section 11 Horiz Stabilizer amp Elev Frame Section 12 Horiz Stabilizer amp
108. ed EysickTimge orion tube 3167 washer ANS hal Very tight DEP TE Bak ANGST 4 aser 85860 e Joys DEG OTT torsion tupe 1 washer ANA castle nut coner pin Snug but Side Joystick grip DFS 012 TI BaP ANE TER TTE 5855 ya abo DFT Toys 16 washer ANS at Very tiant EAT ANS TAR Wan SIS BUS TOT T push rod elbow 005 sisstor push rad ud 3 6 washer ANS ha nut Very tight TS Bat ANS Note beow S 5 washer 826 rane 6889 push rod 8 3 16 washer ANG case nut eater pin Snug but fee Fun bungie DFS fom banom ot rudder pedal a rough tang hg to father rur pedal ad This your fight mim Tighter slower Looser taster TE Ba ANSAN EL PUET TOA TAN PT THOT ANS CUBES TU 81500 05 6 Snug pur ree Bolt conve pivot assembly LLPTUOU TT 82 STEN TOON TRE TT 1060 washer ANG easte a carp Snug bur Pee TE jostek hinge Washers 55 SEAT TUDE ANG CTE CONG i 17 S8 STE WEST ANT 166 caste coner pn Snug bur ran O BOE ANS TOR Te wash BN TATE 96 8988 179097 slevelor push rad af 346 washer ANS nalt nut Very ign Bat ANE aR washer Sr Back UFK
109. eight numbers are say 5 points apart i e X 772 and 777 The tolerance is noted on most Quality Assurance sheets supplied with props NOTE When new or reconditioned blades are received inspect the blades hubs and hardware components to make sure no damage has occurred in transit Blade Tip Painting As black props visually disappear when operating at elevated rpm it is highly recommended as a safety feature that not less than the last 220mm of each blade be painted a contrasting color such as yellow white or orange The polyurethane leading edge tape as applied to some props can be painted but be careful to not get a build up on the edges The painted tips can be done as a part of the final balancing process Use a paint which is not degraded by the fuels and oils used by the engine and has some resilience to impact damage This would ideally be one of the special urethane or epoxy paints but a good quality enamel or poly urathane will also do the job To paint the props the surface must be cleaned lightly scuffed with fine steel wool or abrasive paper and painted in accordance to instructions pertinent to the paint you are using Only minor scuffing is needed do not sand into the fibers Again see an appropriate Level Rated Mechanic Propeller Service amp Inspections Before the first flight Run up the engine to check and assure that all is well Take the engine through the full range of throttle settings ete Re check
110. elect baud rate of 4800 If necessary make any selection required to enable the GPRMC output sentence Most GPS receivers will transmit the GPRMC sentence automatically when NMEA 0183 selection is made Verify the EIS is receiving GPS data by checking the GPS page on the EIS If data is being received the X on this sereen will disappear When the GPS locks onto the satellites a groundspeed of 0 will be displayed on the EIS Note Magellan brand GPS receivers do not activate the data output until they have locked onto satellites and are able to provide valid position Garmin brand GPS receivers typically activate data output as soon as they are tumed on even before any position data is available 1E no data is received by the EIS double check your electrical connections verify the GPS setup to transmit NMEA 0183 at 4800 baud and verify the EIS is set to baud rate of 4800 A fluctuating voltage of a couple of volts can be measured between the GPS serial output line and ground to verify it is providing data output Peak Recording The EIS records the peaks maximums for 9 parameters during the flight The recording of these items begins when 3 minutes has elapsed on the flight timer at which time the peaks from the last flight are erased Since the peaks are recorded in non volatile memory the EIS is able to show you the peaks from the previous flight even if the EIS has been turned off since the end of the last flight T
111. eptance specification s 7 2 The manufacturer other entity that performs the evaluation of an alteration or repair shall provide a written affidavit that the aireraft being altered will still meet requirements of the applicable ASTM design and performance specification subsequent to the alteration 7 3 The manufacturer or other entity that performs the evaluation shall provide a Letter of Authorization LOA with written instructions and diagrams on how who and the level of certification needed to perform the alteration repair 73 1 The LOA instructions must include ground and fight testing that complies with the original ASTM Production Acceptance Testing Standard as appropriate to verify the alteration was performed correctly and the aircraft is in a condition for safe operation 7 4 The manufacturer or other entity that performs the evaluation shall provide information LOA to the owner af the aireraft for the documentation of the alteration in the aircraft s records 8 Task Specific Training 8 1 manufacturer of a product may require type specific training in order to accomplish a task in either the maintenance manual or in an authorization for a major repair maintenance or alteration The FAA does not give approval to these task specific training programs for 51 A manufacturer may specify any task specific training it determines is appropriate to accomplish a task 8 2 Examples of task spe
112. erating position press the ON button on the Remote Switch Unit Verify that the Green Red Light for AK 480 ON lights is flashi OFF and is readily visible from the Pilots operating position Verify that the Audio ELT Sweep Tone can be heard on the Com Receiver Push the RESET button on the Remote Unit Verify that the Audio ELT Sweep Tone ceased Verify the two Green ON lights are extinguished and the buzzer sound is silent Red Light for 450 Notez Always perform the tests within the first 5 minutes of the hour Notify any nearby control tower of your intensions in accordance with AC 43 13 2B Section Note 3 If outside of the US always follow ail local or national regulations for testing of ELT s Warning Do not allow test duration to exceed 5 seconds Any time the ELT is activ distress signal If the unit operates for approximately 50 seconds li transmitted and is considered valid by COSPAS SARSAT satellite system Appendix P Page 6 Page 137 12 5 Miz distress signal is 4 ELT Self Test does not apply to AK 450 Place the main switch position from OFF to ARM The buzzer sounds and the 2 ELT Green ON lights Red Light for 450 shall illuminate for 4 seconds then extinguish After 25 seconds 406 MHz test signal is transmitted However it is specially coded as self test signal that is ignored by the COSPAS SARSAT satellites Ver
113. ere are many airplanes there in which replacing a side window is a simple task However be careful As the aircraft systems become more complicated so will the side window installation Appendix D Page 2 Page 109 14 Replacing safety belts You are allowed to replace your seat belts and shoulder harnesses with approved belts for your make and model airplane Tr you elect to change the belts it is strongly suggested that you follow the service manual instructions for installation If the manual calls for two washers and a spacer use them Changing the belts is definitely safety of ight issue which may your well being 15 Replacing seats or seat parts with replacement parts approved for the aircraft not involving disassembly of any primary structure or operating system Once again this should be regarded as a safety of flight issue that can affect your well being The seats are specifically designed Don t modify them to make them stronger or more rigid Replacement seats seat parts must be of an approved design for your make and model airplane 16 Trouble shooting and repairing broken circuits in landing light wiring circuits This doesn t include position and panel lights or similar lighting systems on your airplane If you elect to venture into other systems words of caution Lack of knowledge of the system may cost you more money for needed repairs 17 Repla Replacement ig bulbs reflectors and len
114. eve rudder al Push seam one oe Pop tube con end t on oto of udder ed over rudera Side spacer 1 tube spacer 875 OFG 004 inside 9 banom of Align win ole Winch rudder wd into pation a show centre T you have toute gating bot ted use 28 tap to gn Bol ANETTA 26 washer check Bolt ANA 17A On Prelght and al Inspection Periods for Security udder hor DFL 002 saddle 1 DFP rudder a spacer 1 tube spacer 878 878 udder aft tube conn saddle end 1 threaded insert Very tigne Inspect s HIR TSA NE washer ANS hal nut Tight Bum holes n a or stops 64 7 ET a ASTOR ngs Te ar I PNT RTA VOTE Pop vel summum TSE OPT rudder afk rudder conn sleeve rudder aft Pop the rivet pep vera ITE ETA OFT ATE Ina omer erd ot rudder comp strut upper OFC 027 Pole taht but do aot pop Ts vet keepa over during installation Side rudder comp tut upper nt ave through half moon e sall end af rudder comp st over 1 2 tube reet rom sep 2 Hong mudder up to ight sideways grasp rudder comp su trough fabrie and wark the ater and over V2 be Puan end ol page Through half moon ut out using udder comp DFC 025 Del 3116 hole through rudder d and into end rudder camp pan head 12x112 OFT 521 ruddar fud nud
115. ey are operating properly Section 4 Fuselage Section 4 Page 28 Section 5 Maintenance amp Inspection Dragonfly 582 FWD COCKPIT STEP INSTRUCTIONS or Assembly or Disassembly reverse ha order PARTNO T STAGE CERT spacer spacer 275 DFS TOT into cockpit tube DFC 018 Eye bolt 15A DFT 203 spacer stand off 375 DFG 008 cockpit tuba hud spacer 1 tuba spacer 875 876 cockpit tube fwd 14 washer ANS nut Very tight ZY ANG Fal na poli rudder 8988188977 587 DFO washer eyeball rudder pedal twd DFO 012 eyeball udder pedal twd eyebolt 1 4 washer halt nut Snug but 3 Sie cockpit tube 6 cockpit tube Tawar DFA 005 and other cockpit tube lower and align holes Bolt ANA 23A 1 4 washer channel brit 1 DFL O16 saddle 1 75 DFP 032 cockpit tube lower cockpit tube fad cockpit tube lower 1 4 washer ANA full nut Loose 77 Turo to Section 6 Put bolts 2 and 3 and seat tube into place femporanly to aris xi oor pan 85 67 into place Space evenly around saddles 1 75 Dril out an hole Set Pop rivet stainless steel 3 16 x 1 4 DFT 402 through lor pan and cockpit tibe lower Dril and set remaining checking io be sure pan is square 55 Toot reat Tour 87897 saddle 1
116. fan LSA component NOTE In the U S no FAA certification is given tobe an LSA Approved Overhaul Facili 62 Overhaul Manual separate Overhaul Manual in addition t the manufacturer s Maintenance Manual is required to perform the overhaul of an LSA or LSA component NOTE The form and content of such a manual not governed by ASTM practice or by any FAA regulation NOTE Specifi form and content guidelines not been promulgated here as type specific training and authorization required from the manufacturer in order to overhaul an SLSA or componen Page 81 6 3 Typical components that are overhauled include 6 1 Engines Must be performed hy Rotax Authorized Service Centre refer to Rotax Manuals and website www flyrotax for specifie information 632 Carburettors fuel injection systems refer to Rotax Manuals and website www flyrotaxcom for information 633 Strievalternatoes generators refer to Rotax Manuals and website www flyrota com for specific information 634 Instruments referto Instrument manufacturers manual andlor website to determine who is authorized to perform overhaul andlor repair speci 7 Major Repairs and Alterations 7 1 All major repairs or alterations made to subsequent to its initial design and production acceptance testing to applicable ASTM standards and sale to consumer must be evaluated relative to the requirements of the applicable ASTM design and production acc
117. g Put the THIN AN4 washers onto the bolts and install into the outer holes Figure 1 AN4 Bolts Into Forward Hub Block Place Blades into Forward Hub Block Place the three blades into the forward hub block it is best to align them in the general direction they will je rotating 7 Figure 2 Place Blades into Hub Block IMPORTANT NOTE On 4 blade propellers the blades come in pairs These pairs are ident dots on the base The same color dots must be across from each other to preserve balance by the color Appendix E2 Page 4 Page 123 Assemble the rest of the components The rest of the components that are listed are now added to the forward hub block as sequenced below Place the aft hub block onto the forward hub block and over the bolts Add AN4 thick washers and then the nylon lock nuts to each of the bolts finger tight Align the washer plate with the aft hub block holes add the M8 X 75 drilled bolts and ONE washer per Figure 3 Propeller Wit All The Necessary Components Mount Propeller Carefully grip the two hub blocks together with your hands and lift from the ground to the engines propeller mount The bolts will match the engines mount pattern Mate the bolts to the holes while ensuring that the propeller blades or bolts don t fall While holding everything in place finger lighten the bolts in sequence see th
118. he ELT Unit should be removed and the portable antenna to be used If the ELT Unit is to remain at the Aircraft site it should be placed on a large metallic portion of the airframe with its Antenna pointing skyward The Green ON lights should be flashing after the accident Ifthe ELT is to be taken along as the Portable Unit when leaving the scene of the accident place the Main switch in the ON position and keep the Antenna vertically oriented as much as possible The ELT Green ON light should be Bashing Green ON lights Buzzer sound and Antenna check Red Light amp no buzzer for AK 450 Green ON Lights and Buzzer Sound Functions Red Light amp no buzzer for AK 450 Green ON lights located on the ELT main unit and remote switch unit Red Light for 450 In ON mode Green ON LED flashes continuously 1 second ON 4 second OFF and the Buzzer sound periodically The ELT swept Tone must be heard on the 121 5 MHz VHF Radio This is indicate that the ELT has been manually activated In ARM mode Green ON light flashes continuously 1 second ON 4 second OFF and the Buzzer sound periodically ELT swept Tone is heard on the 121 8 MHz VHF Radio This is to indicate that the ELT has been auto activated by the G switch gt Antenna Check A low quality AM Broadcast Radio Receiver or Equivalent Test Equipment should be used to determine if energy is being transmitted from the Antenna When the Antenna of t
119. heck screen If clean aircraft 1 to 2 hours and recheck If still clean check once more after 10 hours As above or more teaspoon Remove engine from service Investigate to determine cause Chunks of metal magnetic and nonmagnetic the size of a broken pencil point or greater Any quantity Check sump for other pieces Bore scope cylinders to check for possible valve andor Nonmagnetc plating averaging approximately 1 16 inch in diameter May have copperish tint _ teaspoon or more Ground aircraft and investigate cause cannot be found particles to engine manufacturer for analysis Same as above but minus copperish tint Propeller action may be impaired _ teaspoon or more Ground aircraft Mail material to engine manufacturer for analysis Nonmagnetic brass or copper color d material resembling coarse sand in consistency _ teaspoon or more Ground aircraft and investigate If origin cannot be found send particles to engine manufacturer for analysis Any piece of metal of any kind larger than a broken pencil point any quantity Ground aircraft and send particles to engine manufacturer for analysis Chart provided by Kas Thomas ching or the removal of structural parts or control surfaces In the case of balloons the making of small fabric repairs to envelopes as defined in and in accordance with the tructions not requiring load tape repair or replacement Remember no rib stitching or control surface repair
120. her 576 washer root tube muffler mount and engine stabiliser assembly TT Recommended Special Tools None 2 The parts needed perform the task Replace worn damaged parts as needed listed above Max Wear defined 1 18 1 3 Type of maintenance Inspection when it involves replacement of structural 4 Certification needed to accomplish the task Line LSRI Inspection or above Heavy LSRM Maintenance or above sec Level of Certification this manual 5 Detailed instructions and diagrams as needed to perform the task listed above and adjacent page Every Annual or 100 Hrs Inspect for Cracks Corrosion Elongation of holes amp Fasteners for Wear amp Security 6 Method to test inspect to verify the task was accomplished properly Insure that all procedures were followed correctly and there is proper non binding movement to moving parts and that fasteners were tightened as instructed When flight controls are involved assure that they are operating properly jon 25 582 Muller Installation Section 25 Page 70 ite DRAGONFLY 582 MUFFLER MOUNT Drawing 25 Page 71 Section 26 Maintenance amp Inspection Dragonfly 582 582 RADIATOR INSTALLATION STEP TINSTRUCTIONS for Assemb for Disassembly reverse 88 order PARTNO J STAGE CERT T Remove one cylinder head nut and install idiator head stand DFO 050 at position shown Re position cyl
121. hes will be displayed when no valid GPS position has been received in the last 60 seconds Not Used Show Peaks allows you to display the peak values in place of the current values on the various display pages This function is inhibited while the RPM is greater than 4100 See the Show Peaks section for more information Set to NO Max Timer gives you the maximum time before the flight timer will issue an alarm The limit is entered in minutes If you exceed this limit it can be increased easily in flight Not Used Max Cool is the maximum coolant temperature Set to 175 F or 80 Max RPM is the maximum RPM This limit is set in 30 RPM increments Set to 6400 Min Fuel applies to the optional fuel level input Not Used Max Volt is used to wam of overcharging due to a failed regulator A good limit for this 15 0 volts If a battery is not used this alarm is not required Volt Set to 15 volts Min Volt is used to warn of battery discharging A good setting for this is 12 0 12 8 volts Min Volt Set to 12 volts EGT is a very critical alarm as high EGT can destroy an engine in seconds to minutes reflects the fuel air mixture being burned by the engine A typical limit is 1200 1250 degrees F Max EGT Set to 1200 F or 650 C Max CHT warns of inadequate cooling Max CHT Set to 300 F or 150 Display is used to enter your favourite display page Display Set to Page Configuration Set Pages These p
122. hese peaks will not be erased until 3 minutes into the next fight This can be very useful for evaluating the highest RPM generated by your engine peak engine temperatures as well as your maximum altitude and your maximum distance from your home position The peaks that are recorded are as follows Tachometer Cylinder Head Temperature 1 amp 2 Exhaust Gas Temperature 1 amp 2 Coolant Temperature Voltmeter Altimeter GPS Range from your home position To view the peaks select the Set Limits pages and page down to the Show Peaks page Use the UP DOWN to select YES Press and hold the right button to leave the set pages The peak values for the above items will replace their current values on the various display pages The EIS will alternately flash the symbol and the peak data to identify the peaks O This function is function is disabled The Show Peaks function can be turned off returning to the Show Peaks page and selecting also automatically tumed off at power up or whenever the RPM exceeds 4100 The Show Peaks when the RPM is above 4100 Warning System Operation The alarm system is the most important part of the system It allows you to enjoy flying without the need to constantly monitor your instrument Damaging engine conditions are made immediately obvious All alarms cause the warning light to flash and the page to change automatically to labeled screen which incl
123. his Radio Appendix F Page 10 Page 141 tuning dial on any setting is held about ated ELT Antenna the ELT Aural tone will be heard see note below The ELT must be reset by pressing either the RESET push button located on the ELT Main unit or the ELT Remote Unit Note This is not a measured check but it does provide confidence that the Antenna is radiating with sufficient power to aid search and rescue The Aircrafts VHF Receiver tuned to 121 3 may also be used This Receiver however is more sensitive and could pick up a weak s ting Antenna is disconnected Thus it does not check the integrity of the ELT System or provide the same level of confidence as does an AM Radio The ELTAS should be tested every month 5 Main Switch ON OFF SELF TEST Operation The ELT S has an position This allows the beacon to be handled or shipped without nuisance activation Care should be taken when transporting or shipping the ELT S not to move the switch or to allow packing material to become lodged such as to toggle the switch Main Switch alternate alternate momentary positions Alternate position ELT S transmits immediately Green ON light on the Second ON second OFF The ELT swept Tone mist be heard on he 113 Mie VHF Radio OFF Alternate position The ELT4S is turned off unit flashes 1 SELF TEST Momentary position ELT S self test is confirme
124. how long your flight has lasted It resets at power up and starts counting when the engine is running based on the tachometer t displays the previous flight time until the current flight time reaches 3 minutes allowing you to easily recall the length of the previous fight A warning can be set when the timer exceeds your prese limit to remind you to check your fuel Favorite Page The instrument will automatically select your favorite page when the checklist is ended or the right button is double clicked or when leaving the Set Pages Your favorite display page is entered under the DISPLAY setting in the Set Limits pages It is the last setting on these pages Appendix C Page 5 Page 99 Pressing the right button Display when on a combination page that is a page with no labels will replace the numeric data with labels to identify the data Releasing the button returns the numeric data to the page Double clicking the 1 your favorite GPS Page isplay button immediately takes you to your favorite page Normally a combination page used as The GPS page gives you easy to read and easy to understand steering information to get you home It also provides groundspeed as well as the distance and magnetic bearing to home This function requires the connection of a GPS to the EIS to perform these functions Using the GPS page provided on the EIS has several advantages over that of a stand alone GPS namely Au
125. htened as instructed When flight controls are involved assure that they are operating properly Section 3 Root Tube Section 3 Page 26 Section 4 Maintenance 8 Inspection Dragonfly 582 FUSELAGE STEP INSTRUCTIONS for Assembly or Dsassemby reverse Ins order PRAT NO_ STAGE CERT T Bo ANT 23A washer supp at BI ower push rod guido att root 013 oot supp DFH 003 push rod guide root root supp b k lower 1 4 washer ANA tull nut Tight Over tightening this bolt wil keep pushrod trom moving lac e torque afler shrod is in plac Z Bot ANA ATA root Wd TOOT Supp UTI rool tube saddle hud supp aluminum root supp 1 4 washer ANS ul nul Vary dg 1 19 Spacer aT OFS OS into root supp af supp alt can be carefully squeezed in vice Wrap tube Bolt ANAZOA 1 4 washer root supp brk upper spacer root supp 1 x 6 5mm x 3125 DFP 030 root supp spacer strut 1 root supp spacer root supp 1 x x 3126 root supp 3 1 upper 114 washer ANA fll nut Very fight 7 EK bolt mid root tube maunt SA0 x31257 DFO 007 5 16 washer root supp mid DFB 002 saddle mid root supp 1 125 009 tang mid root boom tube tang mid rot saddle mid root supp 1 125 root supp mid 5216 washer ANS tll nut Very ign 55 06 V washer roor upp mid s
126. iated with the older ELTs were due to poor i installation with the AMERI KING ELT may not be acceptable Appendix F Page 5 Page 136 allation Therefore duplicating a previous ELT Installations must be made by qualified personnel in accordance with FAA regulations Duplicating a previous installation may not be acceptable Refer to the Department of Transportation Regional ACO for detailed information Please refer to FAA AC 43 13 for guideline QUICK OPERATION CHECK Note Refer to Appendix A 1 for Quick Operation Check in sequence order 1 ELT Main Switch ON position ELT swept Tone must be heard on the VHF Radio 121 5 MHz The 2 LEDs flashing 4 sec OFF 1 second ON synchronized with the Buzzer sound 4 see OFF 1 sec 2 ELT Main Switch ARM position Both LED extinguish This is to make sure LED and Buzzer are properly powered and Buzzer must illuminate and sound for 4 see then joe Press RESET anytime to turn off unwanted The ELT will then automatically enter Self test mode Self test takes 25 see If ELT Self test is passed No light illuminate no buzzer sound IFELT malfunctions the LED Lights and buzzer Operation Manual paragraph 244 for details Next in order to check Switch Throw the ELT forward and backward 2 3 times the ELT must activate ELT swept Tone must be heard on the VHF Radio 121 MHz The 2 LED lights lashing 4 sec OFF 1 sec ON synchronized with the Buz
127. ify that both the ELT Green ON lights Red Light for AK 450 located on the ELT Main Unit and the ELT Remote Unit must remain extinguished and no buzzer sound after 25 seconds Verify Audio ELT Sweep Tone is silent on the Com Receiver Activate the ELT using applied force The direction forward force activation is indicated on the ELT The 451 AF AP ELT can be activated by using a rapid forward throwing motion coupled by a rapid reversing action Verify that the ELT has been activated by use of the Wattmeter the Airplane s VHF Radio Communications Receiver when tuned to 1215 MHz or other means see Note 1 The ELT must then be reset by pressing RESET push button located on the ELT main unit or the ELT Remote Unit Note 1 This is not a measured check It only indicates that the Detail Test Procedure for ELT ID Programming and Self Test Turn the main switch from the OFF position to the ARM position The Red Light for AK 450 shall illuminate for 4 seconds then extinguish This is to allow coding programming during the next 20 seconds window and self test for 1 second thereafter The ELT may be ID coding programming during the aforementioned 20 seconds window period If no programming happened the ELT will then enter the Self Test Mode for 1 second thereafter Self Test takes 25 sec results after 25 seconds Ifthe self test is passed the Green ON light is stea
128. ignored by the SAR satellite system This 15 digit number is used to register the ELT with the appropriate 406 MHz ELT registrati he National Oceanic and Atmospheric Administration NOAA maintain the database of registered ELT s NOTE For more detailed and thorough instructions see Ameri King website htp iwwwameri king com End Appendix F Appendix F Page 13 End of Appendix Page 144 Appendix G Bailey Tow amp Release System Refer to Pilot Operating Handbook for complete Towing Operation and Limitations Line 24030 Safety Link Tipe Strength Configuration Weak Solely Link Singlo Loop Weak Link i is Brde Line 22 10 rm Alo amp FIGURE 1 Bailey Tow amp Release System Configuration A Bailey Release Mechanism AT B Quick Release and Safety Link Quick Change Pin and Retainer showing configuration of Safety Link CAUTION This picture shows the Line needs to be shortened about 1 because it should not hit the rudder when hanging down lt can be adjusted at the knot shown in D below Appendix G Page 1 Page 145 Top Post Quick Change Line Retainer and Simple Knot Simple Granny Knot with al tucked in tube ahead of Knot Refer to lot Operating Handbook for complete Towing Operat Appendix G Page 2 Page 146 for wind resistance and additi i attachment line val drag to make the untethered li
129. ill use the Up or Down button to select Yes and then press the right button to update your home position Selecting will retain the last home position and is normally done only when on a cross country flight This Page can also be manually accessed on the Set Limits pages to allow you to save the current position as your home positon 9 any time The EIS assumes you are on the ground if the engine RPM has not exceeded 4100 RPM since the EIS was turned an and the GPS indicates you are not moving Using the GPS Page The GPS page is described in detail in figure 2 This page provide steering information to direct you to your bome position as well as RPM altitude groundspeed distance and bearing to home When data can not be calculated or is unavailable it will be replaced with dashes to indicate that no valid data is available Connecting a GPS and Setting up the GPS Function Only 2 electrical connections are required to a GPS These are the serial data output line and ground Refer to the Cable Assembly diagram for an illustration of how these connections are made Go tothe Configuration Set Pages and make the following selections See the section Configuration Set Pages for more details on how this is done GPS Page ON GPS Baud 4800 GPS Units Miles or Kilometers as desired Appendix C Page 6 Page 100 Tum on the GPS Refer to its user s manual to select NMEA 0183 serial on S
130. inder head nut and tighten 2 Screw two rubber Rotax mounts 8 Stainless brackets radiator mounts DFS 007 into engine housing With 6mm x 20mm 1 pitch and washer 88 Bracket DFO 0308 3 Set radiator on rubber mounts fasten wih washer 6mm x 1 pitch nylack nut 3 install pump radiator hose fasten each and with hose clamp 17 DFO 082 5 Cut support hose and fit from radiator head stand to radiator fasten each end with hose clamp 17 5 Cut radiator top hose and vom Thermostat housing to radiator top Tasten each end with hose clamp 17 7 Cui steam hose and rom cylinder head To radiator tank Tasten each end with hose clamp 14 DFO 051 a Fit radiator cap 3 When ol injection Is chosen mount the ol Tank according to Rotax instructions T0 Complete 7 on Section 25 TI Complete step amp on Section 25 TT Reconsmended Special Tools None 2 The parts needed to perform the task Replace worn damaged parts as needed listed above Max Wear defined 3 Type of maintenance Inspection when involves replacement of structural components refer to Rotax Manual for guidance on En 4 Certification needed to accomplish the task Line LSRI Inspection or above Heaw Level of Certification in this manual SRM Maintenance or above 5 Detailed instructions and diagrams as needed to perform the task listed a
131. ing a triple frequency insures your distress message reaches both NOAA Satellite Operation and US Air Force AFSR Ground Operation Search and Rescue Team with 100 fully confidence due to transmitting on both 243 0 MHz Military and 121 5 MHz Civilian bands for immediate ground search dispatch narrowing the searching time The AK 451 ELT Emergency Locator Transmitter is micro controller based equipment It is extremely reliable equipment designed to meet TSO C126 and TSO C91A requirements batteries operated and self contained designed only for emergency use The model AK 481 may be used as The ELT Emergency Locator Transmitte one or more of he following ELT types Automatic Fixed ELT AF The ELT AF is designed to be permanently attached to the aireraft before and after a crash Aural and flashing light monitors are provided to alert the fight crew that the ELT has been activated and is transmitting It is designed to aid the Cospas Sarsat satellite and SAR teams in locating a crash site The model AK 451 AF consists of an ELT main unit an aircraft ixed antenna coaxial cable assembly remote switch unit interconnect wiring assembly a T adapter connector an audible buzzer monitor a mounting tray and Velero holders The ELT AF has an automatic activation G Switeh It is activated automatically upon a crash or manually operated Automatic Portable ELT AF AP with dual a
132. irs and Alterations 5 Authorization to Perform 2 Typical Tasks Considered as Heavy Maintenance for SLSA s Include 6 Overhaul 6 1 Authorization to Perform 62 Overhaul Manual 7 Major Repairs and Alterations 8 Task Specific Training 9 Safety Directives 10 Terminology 10 1 Definitions Appendix Safety of Flight Reporting Form amp Comment Form Appendix B Brakes Manual for BX1320 amp BX1000 Double Caliper Parts 89 Appendix C EIS Model 20006 Grand Rapids Technologies Incorporated 95 Introduction The Importance of the Engine Information System 97 What do you do when you get a high EGT alarm Li Appendix C Page 4 98 Operating Instructions for the EIS Model 20006 99 99 99 Automatic Altimeter Operation _ Manual Altimeter Operation Flight Timer Favorite Page 99 GPS Page 100 The GPS page is described in detail in figure 2 This page provide steering information to direct you to your home position as well as RPM altitude groundspeed distance and bearing to home When data can not be calculated or is unavailable will be replaced with dashes to indicate that no valid data is available 100 Peak Recording 101 Tachometer 10 Warning System Operation 101 Set Limit Pages 102 Configuration Set Pages 102 GPS Units Selects whether miles or kilo meters will be
133. ist 5 minutes of each hour and must not last for more than 3 Audio sweeps 1 5 seconds If you fare ata location where there is an FAA Control Tower or other monitoring facility notify the facility before beginning the tests Never activate the ELT while airborne for reason See Figure 18 for the ELT Front Panels for both ELT Main Unit and Remote Unit Appendix Page 140 Mo tor 121 5 MHz using the main switch on the ELT is on ARM posi JN button on the Cockpit Remote Switch Unit Verify that both the Green ON lights located on the Main Unit and the Cockpit Remote Switch Unit flashing Verily the Buzzer sound periodical ELT audio sweep tone can be heard on the Com Receiver Push the RESET button on the Remote Switch unit Verify that the two Green ON lights are extinguished Verify the Buzzer sound ceased Verify the ELT audio sweep tone ceased G Switch Check Activate the switch by using a rapid forward throwing motion coupled by a rapid reversing action Verify that the ELT has been activated by use of the Wattmeter the Airplane s VHF Radio Communications Receiver when tuned to 121 5 MHz or other means see Note 1 The ELT must then be reset by pressing either the RESET push button located on the ELT main unit or the ELT Remote Unit not a measured check It only indicates that the G Switeh is working T Main Unit must be selected to the ARM
134. lade If itis clogged open by pushing in a straight pin 3 Install shoulder bolts with the washers and Nyloc nuts and tighten slightly to hold blades in place NOTE There may be small machined insert that fits into the hub and or spacer Appendix E1 1 Page 115 4 On Rotax 912 applications the hub does not require the insert to bolt directly onto the prop flange However if you are installing a KievProp Spacer you will need to install the supplied insert into the prop hub IMPORTANT On Pusher configurations with the propeller installed make sure that there is least 3 75 clearance between anything forward of the prop lips If clearance is less you will require a spacer on the gearboxes prop flange before mounting the propeller NOTE On all applications if you are using a Spinner install the backing plate between the spacer and the hub When using the machined insert ALWAYS attach into the HUB and not under the backing plate as pictured above left Install Spinner dome to the backing plate after you have run the engine rechecked the torque as instructed below and are satisfied thal everything is correct Otherwise removal of the Spinner dome will be necessary SECURING ASSEMBLED PROP ENGINE 5 Secure finger tight the propeller to the engine with the supplied 8 8 X 1 25 bolts washers nuts NOTE The supplied bolts are grade 8 6 metric and the nuts are metric Nyloc S
135. le one down ade approx 1 2 trom dge Stand wing rame on leading edge and secure Piace edge on ait wing spar Rotate edge sigh toward bonom side of wing Bont sina pates stek out of bottom Pt straight edge agant botom side at wing spar wing spar and at raling ee 1 Touches al ires Using mylar packing tape secure edge 5 af wing spar Push Valing edge tom sragnt edge approx 1 Atach end ol ape to af weg spar and pull up Top of rame ver ling edge ul ape down very unt ang luces stagne edge again Wrap once mora one tune Move approx ane fot down spar and repeat unti done Sight Gown rng edo 8 5 imeve ours before removing lap Sand edges smooth and round iss 88 05 DFP 024 ur recht Trang Ego e 6 65 Ure up Tag Ter smooth radus centre wing Dnl 1 8 hale in weg tp pop rivet stainless 599118 eije ext wing tp Pop he river DFT a01 ean rben Se Lavet af and Tags Page a nd ht lend When canto aren ley are operon prety Section 16 Wing Section 16 Page 52 LiteFlite DRAGONFLY 745688
136. leges of Preventive Maintenance Taken from an article for your help in determining if you are qualified Special Note Please read carefully the following 32 items that are permitted under the privileges of preventive maintenance and the short brief that follows They will help you beter understand your privileges em number 30 pertains to primary category aircraft only To understand what is required when performing preventive maintenance you should also read thoroughly AC 43 12 which follows those 32 items FAR Part 43 Appendix Paragraph C Preventive Maintenance Preventive maintenance is limited to the following work provided it does not involve complex assembly operations 1 Removal installation and repair of landing gear tires changes may not be as simple as anticipated here are some important consideration Know the proper jacking procedure for your aircraft as outlined in the service manual The aircraft should be jacked in an enclosed hangar If the aircraft must be jacked outside take into consideration wind and proximity to taxiway Consider how the removal of wheel pants will affect other systems Know the type of brake system and how it may affect wheel removal and installation Removal and installation of the whee retaining nut requires a special touch Have your mechanic demonstrate how freely the wheel should rotate after being installed Replace the old cotter pin with a new one of proper size WARNING D
137. lfery into position Mount the solenoid Switch on root tube Mount the regulator rectifier on root tube 3 5 6 Mount the 10 terminal connector Block on The port side of the reat Tuba 7 Mount the switch panel on under side ofthe root tube Connect batiery cables 1o solenoid swiich and starter maior negative ground and engine Run all cables on side of the root tube S Connect seven core cable to engine connector block and terminal BOCK 10 Connect switch panel fo connector block 1 Connect E G T io connector block 12 Connect instruments to connector 77 Recommended Special Tools None 2 The parts needed to perform the task Replace worn damaged parts as needed listed above Max Wear defined 1 Type of maintenance Inspection Line replacement of fuses ec amp Replacement Heavy when involves replace of structural components amp all Electrical Components and Wiri 14 Certification needed to accomplish the task Line LSRI Inspection or above Heavy sce Level of Certification in this manual LSRM Maintenance or above 5 Detailed instructions and diagrams as needed to perform the task listed above and adjacent page Every Annual or 100 Hrs Inspect for Cracks Corrosion Elongation of holes amp Fasteners for Wear amp Security 6 Method totestnspect to verify the task was accomplished pr
138. lly ati assembled 05 18 wee tem sen pin an eh Poh aa Snug Absence of free play or ability to move longitudinally Tight Approximately 40 to 60 of Max Allowable listed below Very Tight Approximately 80 to 100 of Maximum Cc Allowable listed below 1 Bolt Torque lt lt Exceed Values for 0698 809 69 Dragonfly free cuim platei nuts and bolts OS n AN Torque values given in inch Pounds in Table below ANS 10 32 04000 THE FOLLOWING TORQUE VALUES ARE DERIVED FROME TORQUE LIMITS RECOMMENDED FOR INSTALLATION BOLTS LOADED ALLOWABLE TIGHTENING PRIMARILY IX SHEAR paars 1 5 689968 Shear ype mus Sas m MES 510 and ANSIO end ANDO Magsimba 09 59685989 34000 pst 8889 136 nas us en 30060 1 1 8 1 Wear Tolerances of Cable Bolt or Fastener and Hole Elongation Bolts and Fastener Wear Maximum 10 Example 4 0259 09 0225 as the thinnest part of bolt or 14 fastener Hole Elongation Maximum of 15 Example 4 025 LIS 0 2875 Maximum in longest direction of hole Example for feeler gauge while bolt is in hole 127 0 25 0 15 0 03
139. lowed to replace prefabricated fuel lines with approved prefabricated fuel lines for your make and model airplane strai Follow the service manual instructions when cleaning or replacing fuel oil induction air and vacuum filter elements Use only approved strainers and filters when replacing them The one from the automobile parts store is not approved There are several ADs that come to mind when talking about filter changes You should also check with your mechanic for all ADs that apply to your airplane AD 84 26 02 requires replacement of the paper induction filter prior to reaching 500 hours time in service You are allowed to change the filter but only an A amp P can sign off the AD and retum the airplane to service See the appendix for the AD Another AD that comes to mind is Aveo Lycoming AD 80 04 03 R2 which requires at the next engine oil change not to exceed 50 hours adding an additive to the engine examination of the engine suction screen for presence of metal particles and the inspection of the extemal full low filter for metal particles by cutting it open so that the pleated element can unfolded and examined You can change the and make your entry in the logbook but once again only an A amp P mechanic can return the airplane service by signing off the AD See the appendix for the AD Appendix D Page 3 Page 110 24 Replacing and servicing batteries When replacing your airplane s b
140. ls with the assembly of gliders and has been on the list of preventive maintenance for some time The recording requirements are intended to provide continuity in the maintenance record and to ensure that the person performing preventive maintenance assumes responsibility for the work performed An entry for the assembly after required inspection ensures this assumption of responsibility Repeated entries are required each time a person assembles the aircraft for operation The assembly must be recorded and the aircraft approved for retum to service accordance with Section 43 9 by a person authorized in Section 43 1 2 em 28 Part 43 Appendix paragraph c This item deals with the installation of balloon baskets and burners Specifically designed for quick removal and installation Such disassembly and assembly is necessary to facilitate transporting the balloon either to the launch site after flight is terminated The assembly operation is preventive maintenance and subject to the provisions of Sections 43 3 43 7 and 43 9 As required by Section 4341 entries are required for assembly operations on all balloons except those certificated in the experimental category which have not been previously certificated in another category i tems 6 and 23 Part 43 Appendix A paragraph c These items permit the draining and reserving of oil and the removal cleaning and reinstallation oil screens filters and strainers in an aircraft
141. lude ON OFF ARM Main Switch Green ON Light Red Light for AK 450 1 RESET Push Button Switch The Remote Unit features include Red Light for AK 450 2 STON Push Button Switch 5 Green ON Light Red Light for AK 450 1 RESET Push Button Switch All functions of the AK 451 are under micro controller control self test routine checks ELT operation and installation then presents the results as visual and auditory error code to aid in troubleshooting and to indicate status Software is approved per requirements of RTCA DO 1788 for level D software The battery pack consists of four D m and is field replaceable Rated life is S years or one hour of use whichever comes first as specified by FAR 91 2070 has 6 cells D Size DURACELL Installation kts are available that contain all major components needed t Application and Equipment Limitation This manual constitutes FAA approved data as described in AC 43 9 1F paragraph h 2 and AC 43 210 chapter 2 paragraph 201aN6 for major alterations Not all installations are major consult your local FAA ACO for clarification Tn Canada Installation of an ELT in an aeronautical product is carried out under a Supplemental Type Certi STC This is a separate regulatory requirement and should therefore refer to Ameri King Document No 451 for the Operations and Instructions for Continued Airworthiness ICA re
142. m 3 16 x 1 4 DFT 412 aileron main spar ext aileron main spar Pap the rivets Take aleron traling edge insert 1727 tube inserts into aileron Wallng edge comp struts if 1 2 tube inserts are oversized toy may be shaved to fit with razor knife Lubricate and push inboard end of aileron trailing edge into aileron main spar 7 Screw CS 10 x 377 505 aileron trailing edge aileron splice 3 x 10 8mm tube DFG 006 aileron trailing edge aileron frame conn block Tight Put aleron Teading edge over alleron splice shorter bend inTeading edge Ts outboard Lubricate and insert 1 2 tube inserts into aileron leading edge struts i too big inserts may be shaved Lubricate and push inboard end of aileron leading edge into aileron main spar Sight down aileron leading and trailing edges to check for straightness If anything is loose aileron sail will pull into place TIT Recommended Special Took None 2 The parts needed to perform the task Replace worn damaged parts as needed listed above Max Wear defined 1 1 8 1 4 Type of maintenance Inspection Line amp Replacement Heavy when it involves replacement of structural components 4 Cenification needed to accomplish the task Line LSRI Inspection or above Heavy LSRM Maintenance or above see 3 Level of Certification in this manual 5 Detailed instructions and diagrams as needed to perform the task isted above a
143. mality 2 Critical Any Alteration which may affect the Structural and or Aerodynamic Qualities of the aircraft and or its Systems must be thoroughly tested before authorization can be given Additional fees may apply depending upon the extent of testing required NOTE Request for LOA can be made by submitting detailed request for Change or Alteration including Drawings Pictures Diagrams ct which make clear the intended alterations requested Along with complete documentation of the proposed parts and or equipment to be used and methods proposed And a new Weight amp Balance Worksheet which shows the final proposed WEB numbers for that specifie aircraft 22 Detailed Instructions and Diagrams for Inspection and or Repair How to use this Section of the Manual While every part and component gets inspected during the Annual and or 100 hour Inspection we have noted items that are of particular interest and known high wear parts Often called Life Limited Parts LLP or in other cases just high wear areas where you must judge the suitability and airworthiness of the parts Instructions are Assembly therefore Di Assembly would be in reverse order Which may include information from several sections Examples in Figure Below In the left column it says 500 or LLPSQD in some cases which denotes Life Limited Part to be replaced at 300 hours or before LLPIOU would denote 1000hr Life Limited Part ete Right Column shows airframe p
144. mirror tube Pop rivet aluminium 3 16 x 1 4 DFT 412 Spacer mirror brkt mirror tube Pop the rivet Z Bolt ANS 17A 3 16 washer mirror mount 860 mirar mount TE washer ANS half nut Tight Attach mirror to top of mirror support tube T Bo AN 44 aileron crank assembly port grease adjuster assembly grease aileron crank assembly starboard 1 4 washer ANA castle nut Ting safety DEQ 013 Lubricate Snug but free 3 Bali ANG T0A 1 4 washer aileron crank assembly pori starboard 1747 washer rod end bearing high temp nut Very fight Lubricate rod end bearing 5 wing boom DFO 005 tang three hole ANA high temp nut Very tight When attaching second cable have someone pull down on aileron support tube to provide slack Bolt ANA 26A cable wing tail lower tail plate tal plate cable wing fa lower ANS high temp nut Tight 7 Bol ANG 20A cable wing tail upper vart stab a Tow pylon DFA 008 vert stab cable wing tall upper ANS high temp nut Tight Bolt 3 18 washer tow pylon tang hg bent DFO 037 ANS half rut Tight TIT Recommended Special Tools None 2 The parts needed to perform the task Replace worn damaged parts as needed listed above Wear defined 1 1 8 1 3 Type of maintenance Inspection Line amp Replacement Heavy when involves replacement of structu
145. n Greasing I you don t have access to a bearing grease machine get ready to get dirty Take a nice dab of grease and put it into the palm of your hand Force the grease into the side of the bearing until the grease comes the other side Now you have accomplished the ultimate in preventive maintenance 5 Replacing defective safety wiring or cotter keys Always place safety wire in a manner to cause the item to be tightened Use approved safety wire of the thickness specified normally 032 and 041 refer to service manual for recommended safety wire to be used Don t over torque or under torque nuts or bolts in order to align cotter key holes Do not use safety wire bought from a hardware store it s not approved for aircraft use 6 Lubrication not requiring disassembly other than removal of non structural items such as cover plates cowlings and fairings If you going to lubricate moving parts on your aircraft first refer to the lubrication section in the service manual for the type of lubricate and how to apply You should also check with your A amp P mechanic before getting started Many Piper aircraft have Teflon ceated aileron hinges and should not be lubricated Engine change is one of the simplest tasks that pilots are allowed to do under the privileges of preventive maintenance but it s one of the most critical Start by checking with your mechanic for any airworthiness directives that apply when changing
146. n General Aviation Aircraft NO Not for Highway Use Tractor or Cart Tires Note Maximum Pressure 22 PSI because of rims never exceed 25 ps F Airframe Structural Components and Parts including Fabric Coverings These parts must be OEM Pitman Air parts to insure proper quality and fit 1 1 4 Engine specifications poem SIT 5 86575 prs Dos atari 627K LR HL Page 12 1 1 5 Weight and balance information 1 1 5 1 Weight and Balance Chart 1 1 5 2 Operating weights and loading occupants baggage fuel ballast The CG must never be further FORWARD than 76 85in from the Datum nor further APT than 836 from the Datum The aircraft must never be flown solo from the back seat The pilot minimum weight of 60 kg in the font seat is necessary to keep the aircraft in its CG range The CG range as percentage of the chord of the wing is from 35 7 with the lightest pilot to 26 1 with the heaviest The figures shown typical of a Dragonfly fitted with 582 liquid cooled Rotax Engine The limiting figures are still valid if the aireraf is fitted with other engine types Reference should he made to the aircraft specifie figures recorded in section 6 3 4 The empty weight CG should be 95 in from the Datum or 55 65 of the MAC 1 1 5 3 Center of gravity CG range and
147. nces containing data acceptable to the Administrator I documents other than types which are in common use referenced the document should be made a of the maintenance record as required by Section 439 aX1 2 The kind of airman certificate exercised When preventive maintenance is performed as authorized in Section 4338 the certificate may be indicated in any manner which would be clear to the reader For example PP CP or ATP might be used to indicate private commercial or airline transport pilot respectively The certificate number is that number displayed on the certificate being exercised Affixing signature to the entry which describes the work accomplished constitutes approval for return to service as required by Section 43 9414 NOTE Since owners pilots are not authorized to approve work accomplished by others Section 43 9 a 3 is not applicable when preventive maintenance is performed by the holder of a pilot certificate The holder of the pilot certificate doing the work is the only person who can sign the approval for retur to service 1 The changes to Section 43 9 which require preventive maintenance to be recorded became effective October 15 1982 Amendment 43 23 47 FR 41076 September 16 1982 On this same date the list of items considered to be preventive maintenance in Appendix A of Part 43 was expanded Two of the items warrant discussion 1 hem 25 Part 43 Appendix A paragraph c This item dea
148. nd adjacent page Every Annual or 100 Hrs Inspect for Cracks Corrosion Elongation of holes amp Fasteners for Wear amp Security See 1 3 5 Fabric Cov For more inspection and testing information on fabric coverings ify the task was accomplished properly Insure that all procedures were followed correctly htened as instructed When flight controls are involved assure that they are operating properly Section 14 Page 48 L NONTIN Plans Drawing 14 Page 49 Section 15 Maintenance amp Inspection Dragonfly 582 AILERON SAILS STEP INSTRUCTIONS for Assembly or Disassembly reversa the order PART NO STAGE Sprinkle generous amounts of baby powder info fabric aileron port DFR 003 on aileron frame Pull onto frame until just snug Patches aro sewn on top side of sal Twist sail until inside seam is on botlom side of frame and return seam to centre of trailing edge tube All of seam should be bottom side If fips you will have bumps in sail Side frame into sail as tar as possible Block inboard end of aileron against something e g a wall Put on rubber gloves Beginning at outboard end work small amount of fabric at a time to inboard This is a long process generally requiring an hour to pull sail completely Work in small increments When you gat frustrated remembe
149. ndar months in accordance with FAR 91 207 d Banery Replacement Regulations require ELT batteries to be replaced after one hour of operation or afier 50 percent of the battery s useful life The one hour usage requirement is cumulative if the ELT ix used two times for half an hour each then the transmitter has been used for a cumulative total of one hour and the battery must be replaced Battery useful life for the purpose of battery replacement is determined by the battery manufacturer The dale of the next required battery replacement must be marked on the ELT and in the aircraft records Common Exceptions The most common exceptions to the ELT requirements are for aireraf used in training within S0 mile radius of their base of operations aircraft used in aerial application crop dusters and aircraft undergoing certification testing Additionally an exception is made for operation of an aircraft while the ELT is removed for service or replacement the aireraft may then be operated without an ELT providing appropriate entries have been made in the aireraft records and the aireraf is placarded noting thatthe ELT is not installed This exception for operation during periods of service or replacement is only applicable for up to 90 days the date the transmitter was removed for the aircraft Method totestinspect to verify the ask was accomplished properly Insure that all procedures were followed correctly and ther
150. ndix C Page 11 Page 105 101 EET Kg aye eee Contos ip Peri niin Red round uw g macip pod jus cpu rne Ebro want Tel m mmm nan PARS NR eee Male d sub connector Be sure to Perm 82 52 7 mat lent correctly Aircraft Power 10 5 22 Note tument eludes an internal thermal se or protection Any E Amps or less to protect wing Notes Rear View of Connector Housing This view shows the side of the connector housing that the wire TTo alow the most accuracy thie round should b made the cam point where the instruments ground vire 5 connected The serial input and output 2 Toe coolant temperature sensor has a round ipd may be at AH female ick disconnect pushes on are inserted into are ei open not For te Hocel 20006 1o the GPS serai data ver ihis halt make the aieeaa connecten 48 Sensor Exctaton Output Required for some 155 ofthe enable he GPS NLC incieates No Connection Do natu
151. ne igher behind the Tow Plane also protects the Rings or Karabiner are with passed through lop and pulled snug 2 Point Glider Attachment has Single Loop Safety Link attached hy passing it through itself and attaching to Glider Release This provides 2 strands of Safety Link carrying the loads CAUTION Any increase in Safety Link strength or change of configuration can cause structural damage andor allow either or both aircraft to get into unsafe attitudes Safety Links must be installed in the configurations outlined within Appendix G Page 3 Page 147 Release Handle Release Pressure is easly measured with a Digital Postal Scale Normally about 5 Ib 4 oz 4109 Ibs of pressure are acceptable More than 9 Ibs pressure indicates cable and housing needs replacement NOTE The release cable housing should be free of eracks or deterioration UV attacks the outer conting of the housing which can cause failure of the housing and loss of release capability When replacing cable and housing Use the old cable and housing to gently pull the new one into place If any resistance or blockage is encountered gently pull it back in the opposite direction a way and try again There are small holes within the tail boom that mast be navigated when pulling in the new cable Period of Operations of Release TBO and Inspection Intervals Normally at engine change or rebuild approximately 2000 hours o
152. ng way the sails should be replaced 2 Use Maule Fabric Tester when fabric question 60 is the minimum acceptable level Fabric should be tested on areas with the most exposure to elements like UV usually upper surfaces Test close to the battens or area next to a tube where the fabric is stretched tight and held securely If you can get to 60 without making a hole move on to the next test area area punctures at less than 60 the sails should be replaced or parts not in good without fixing it 13 Engine Z kefer to Rots Manual far information regarding engine and Engine mounting see Sections 24 through 26 1 5 Fuel System see Section 27 16 Propeller refer to Propeller Manufacturers Manual 17 Utility Systems No Utility Systems 1 8 Instruments and Avionies See Appendix EIS 19 Electrical System see Section 28 1 10 Structural Repair see 2 1 Repairs and Alterations 1 11 Painting and Coatings Refer to FAA AC43 13 18 1 12 Revisions Record of Manual Revisions is located in the beginning of this Manual 1 13 Feedback Form form is located in Appendix for the aircraft owner or maintainer to provide notification to the manufacturer about issues and anomalies identified during the operation or maintenance of the aircraft or in the content of the manual Page 20 2 Inspection Repair and Alterations 2 1 Repairs and Alterations defined 21 1 Repairs Repairs a
153. nstalled it is also possible that the bolts will become thread hound before applying pressure to the hub nylon lock nuts should not be reused if they have lost their gripping power After the final full torque check has been completed Nylon lock nuts can be tightened must have at least one full thread showing after they ate installed Grip Bolts 02 318 Engine Bolts PROPELLOR Newton Foot Tach Newton Foot Tuch Metre Pound Pound Mewe Pound BOLLY linm 88 5 1366 95ftlb Propeller Torque Settings Between Hub Halves Note that when the hub is bolted together there is a gap between the halves of nearly Imm This is deliberate and will vary slightly as the blade grips are not perfectly circular generally 0 6mm higher than wide This eccentricity will at times cause a slight mismatch on the outside of the hub walls The advantage of this gap is that at 13Nm torque settings the gap will not close The hub in effect becomes a spring washer further enhancing mounting security At 13Nm there is a designed balance between engine and grip bolt torque settings Appendix E2 Page 9 Page 128 Final Checks Figure 7 Correctly Installed Propeller Recheck the pitch of the propellers after they have been fully torqued Recheck visually that all components are in place Note use thin nylon lock nuts to secure the Bolts propeller hub to gearbox out
154. ntennas The ELT AF AP is designed to be rigidly attached to the aircraft before the crash but readily removable from the aircraft after a crash It functions as an ELT AF during crash sequence The aircraft mounted antenna may be disconnected and a portable antenna mounted on the ELT mounting tray is then attached to the ELT All ntioned procedures require no tools Flashing light indicator on the ELT is provided to alert the user that the ELT has been activated and is transmitting The ELT can be tethered to a survivor or a life raft It is designed to aid the Cospas Sarsat satelite and SAR teams in locating the crash site or survivor s The model 451 AF AP consists of an ELT main unit an aircraft fixed antenna portable antenna coaxial cable assembly remote switch unit interconnect wiring assembly a T adapter connector an audible buzzer mounting tray velero holders and portable soft case Appendix F Page 1 Page 132 The ELT has an automat manually operated activation G Switch It is activated automatically upon a crash oF Iffor any reason a fixed mounting is not required the ELT AF AP can be used as a Portable Device due to it manual operated hand use Portability Check Local and or national regulations for this issue The model 451 49 consists of an ELT main unit with integral antenna and a portable soft case The Main Unit features inc
155. o move it covers the reservoir return hole then starts to add pressure to the system If the piston does not return to the full back position it will not open the reservoir return port Thus becoming a check valve because the fluid pressure from the front brake goes past the Cup Seal on the head of the piston and cannot come back the other way because of the Cup Seal shape Also the piston retainer snap ring is punched out so it has a rounded side and a square side The rounded side has to face the piston so that the square side is holding the piston from coming out We have had the piston pop out of the rear master cylinder because the rounded side was trying to hold the piston in when front brakes are applied Normally this snap ring is a passive retainer But the way we use it it gets a lot of pressure when the front brakes are applied 1 YEAR LIMITED WARRANTY ON ALL PARIS ONLY UNDER CONDITIONS OF NORMAL AND INTENDED USE MISUSE DAMAGE OR ALTERATION OF ANY COMPONENT VOIDS THE WARRANTY BRAKE PADS AND ROTORS ARE EXCLUDED FROM WARRANTY USE OF ANY OTHER FLUID OTHER THAN ATF FLUD VOIDS THIS WARRANTY NO OTHER WARRANTIES WRITTEN VERBAL IMPLIED OR OTHER THAN LISTED HERE WILL BE HONORED 1480 LEGION ROAD DETROIT LAKES MN 6501 PHONE 219 847 2862 800 850 3709 Website Email Notes Appendix B Page 8 End of Appendix 8 Page 94 Appendix C EIS Model 2000G ENGI
156. ole through remaining hole in parachute mount repeat with other side Bolt AN4 23A 1 4 washer parachute mount brkt parachute mount sleeve parachute mount brkt 1 4 washer full nut Tight tighten bolt 1 a Side parachute mount assembly nio end of rooi tube as shown and Butt up against upper cockpit tube bolt Drill 1 4 hole through remaining root tube hola Bolt AN4 23A 1 4 washer root tube parachute mount sleeve root tube 1 4 washor full nut Tight 3 insta BAS 1050 YLS Parachute as BAS instructions TTT Recommended Special Took None 2 The parts needed to perform the task Replace worn damaged parts as needed listed above Max Wear defined 1 1 8 1 Type of maintenance Inspection Line amp Replacement Heavy when involves replacement of structural components amp Parachute Components 4 Certification needed to accomplish the task Line LSRI Inspection above Heavy LSRM Maintenance or above Level of Certification in this manual 5 Detailed instructions and diagrams as needed to perform the task listed above and adjacent page Every Annual or 100 Inspect for Cracks Corrosion Elongation of holes amp Fasteners for Wear amp Security Inspect and maintain BRS bridals in accordance with manufacturer s instructions ELT Mount located on the front top of Left Wing Inboard Compression Strut NOTE ELT must be inspected every 12 cale
157. ome clients prefer using ANS bolts and metal jam nuts or castellated nuts These are available from Aircraft Spruce amp Specially Co or from us at an additional cost 6 With all bolts slightly tightened you can easily adjust the pitch on the blades Make sure at this time that the leading edge of all blades are facing in the correct direction and are not backwards 7 Set the reference scale on the protractor to the recommended arbitrary starting pointand clamp in place Typical ROTAX starting points 91201 between 9 and 10 912015 between 11 and 14 Due to variations more adjustments are usually required to dial in the perfec pitch setting 6 Fit the aluminum end of the protractor into the center hole of the prop hub so that the aluminium ears are both touching the flat face of the hub Be careful to keep the ears flat against the hub for accurate adjustments Appendix E1 Page 2 Page 116 PUSHER TRACTOR 9 For Pusher aircraft place the notched end of the protractor against the trailing edge of each prop blade For Tractor applications the notched end should be on the Leading edge of each blade Rotate the blade until it sits flat against the leading and trailing edge of the protractor IMPORTANT Ensure that the ears on the protractor are flush against the hub when the setting the blade angle To hold the blade setting carefully torque the two nuts on the shoulder bolts to 3 4 foot lbs Repeat procedure f
158. omplish the task Line LSRI Inspection or above Heavy LSRM Maintenance or above Level of Certification in this manual 5 Detailed instructions and diagrams as needed to perform the task listed above and adjacent pa Every Annual or 100 Hrs Inspect for Cracks Corrosion Elongation of holes amp Fasteners for Wear amp Security 6 Method to testfinspect to verify the task was accomplished properly Insure that all procedures were followed correctly and there is proper non binding movement to moving parts and that fasteners were tightened as instructed When flight controls are involved assure that they are operating properly jon 23 AT Seat amp Controls Section 23 Page 66 ATJNOOVHI S 081NOO papasu se 939089 seqni Drawing 23 Page 67 LVIS LAV Section 24 Maintenance amp Inspection Dragonfly 582 582 ENGINE MOUNT PLATE These instructions are Tor instalation ola 582 two stroke engine onio tha engine support brackals as shown Section 3 STEP INSTRUCTIONS Assorby lor Disassembly reverse 88 PARTNO STAGE CERT T Prepare engine lord mounts DFS 008 by driling 3 16 holes through existing 5 32 holes 2 Bait ANS SA engine lord mount engine plate DFLOTS 3 16 washer ANS nut Engine lord mounts are asymmetrical and must installed as
159. on on fabric coverings Sec Cables Thimbles and Tangs Page 16 6 Method to testlinspect to verify the task was accomplished properly Insure that all procedures were followed correctly and there is proper non binding movement to moving parts and that fasteners were tightened as instructed When flight controls are involved assure that they are operating properly Section 10 Rudder Section 10 Page 40 300 0 Drawing 10 Page 41 Section 11 Maintenance 8 Inspection Dragonfly 582 HORIZONTAL STABILIZER amp ELEVATOR FRAME J INSTRUCTIONS tor Assembly for Disassembly reverse The order PART NO STAGE T Bait ANG T3 washer stab comp strut inboard DFC OTE threaded insert 7 16 x 1032 DFO 037 horiz stab comp strut inboard ANS half nul insert tube conn saddle end 1 DFP 034 Tight 2 Balt ANTTIA STE washer Toni stab Twd OFS 007 threaded insert 7 16 x 1032 hori stab fd 316 washer ANG nut Insert tube conn saddle end 1 Tight TT Bol ANT TOA washar 86 80 DFC OO threaded insert 7 167 1032 elevator 3 16 washer ANS halt nut Insert tube conn flat end DFP 033 Tight 3 avatar hor BEL OTO saddle 17 DFP 031 levator threaded insert 7 167 x 10 32 elevator saddle 1 elevator conn starboard DFJ 006 3 16 washer ANS nut
160. onsidate the weld on tat whee Sars ane i Ts supped ara Release DTT Bat ARS TR 316 washer release 529 Telease mounting block DFT OT tow release housing 316 washer ANS half rut Loose IAT Changed to NASGOE T6A 3 iow 6 washer ANG ON TOP Tight Dil 916 nole trough release mounting fr bot B E Bal 8 18 war 695222 release Touring block ease house UTS washer ANT nut Very tar Tighten ver Remove nuts 7 66 ANS TOA 316 washer release mounting block tease cabe 860 release boom DFA 007 AG washer ANS half Very Sie ase TOUGH REESE ard TF 8888 OF OTT now ki Replace nut LN 86865 spring UFIUIT tow k t over release Bot ANS release release release arm ANG hal nut TPB VT wer Jal mourt block pato 114 washer ANA hal Loose EKANA 28A VT wae ve stab af 1 75 ial plate 1 4 washer AN ha Loose you have trouble algning asan bor f Sect incer bot 13 and retten bot TP Bra ara PORTS 079985 il tal ck ner plate 1 4 washer AN
161. onsidered major Manufacturer entity engaged in the production of an LSA or component used on an LSA Minor Repair Alteration or Maintenance any repair alteration or maintenance for which instructions provided for inthe maintenance manuals supplied to the consumer of the product are considered minor Overhaul maintenance inspection repair or alterations that are only to be accomplished by the original manufacturer or a facility approved by the original manufacturer of the product Overhaul Facil facility specifically authorized by the aircraft or component manufacturer to overhaul the product originally produced by that manufacturer Qualified Person A person with the proper Certification Training and Experience in that specific task to perform the task correctly Repair Facility facility specifically authorized by the alreraft or component manufacturer ta repair the product originally produced by that manufacturer Structural Component Any group of parts which are critical to the structure by carrying or distributing lods critical othe safe operation of the aircraft Fabric coverings cable assemblies control linkages electrical and instrumentation are also considered Structural Component critical to safe igh 14 CFR Code of Federal Regulations Tile 14 Aeronautics and Space also know as the FARS or Federal Aviation Regulations 100 inspection same as an annual condition inspec
162. operly Insure that all procedures were followed correctly there is proper non binding movement to moving parts and that fasteners were tightened as instructed When flight controls are involved assure that they are operating properly Section 28 Electrical System Section 28 Page 76 80 eys pue Buia 296 AjuoBeug 10 enueu jo 98 58941 WeisKs 1200919 8 xipueddv enuey 13 ees pu soynboy Suc woy papapiding posou mop ES duo o oim wore peer Soi vez uoneunojur uonoun 1 le EE ES 02 1Se tup enue 2540 LE 49958 le 28968 E ues uogeung pue any ANSP ot 5650 E renuco 4219 Hd mr cox e no ETT py wena a gt vor 1 ET Drawing 28 Page 77 Section 29 Maintenance amp Inspection Dragonfly 582 PARACHUTE MOUNT Optional STEP INSTRUCTIONS for Assembly Tor Disassembly reverse The order PARTNO STAGE CERT T Bolt 23 1 4 washer parachute mount Brit DFJ 014 parachute mount sleeve 018 parachute mount bri 1 4 washer full nut Loose 2 one parachute mount Brkt unii tis parallel wih parachute mount sleeve drill 1 4 h
163. or the other blades 10 When all blade angles have been set and using a calibrated torque wrench tighten the Nyloc nuts sequentially with 5 ft Ib increments to 14 5 foot Ib This will help to insure proper tracking Check the pitch of all blades again and once satisfied begin torquing the center mounting hardware sequentially opposing and with 5 fi Ib increments to 14 5 Ib 12mm crows foot on the end of the Torque wrench works well to access the nuts on the backside of the gearbox prop flange Double check the pitch setting again Do not under torque WARNING DO NOT OVER OR UNDER TORQUE BOLTS NEVER START ENGINE WITHOUT PROPER TORQUE ON BOLTS OR DAMAGES INCLUDING LOSS OF PROPELLER INJURY OR DEATH MAY RESULT Appendix E1 Page 3 Page 117 11 A static check of rpm s must be performed before flight Refer to engine manual for specific instructions With engine off make sure your throttle has full travel and the carburetors are adjusted properly and open fully NOTE DO NOT FLY UNTIL YOU HAVE CHECKED AND RECHECKED YOUR PROPELLER FOR PROPER MOUNTING AND PERFORMED A STATIC CHECK OF R P M s If you cannot reach recommended RPM you may be OVER Pitched Exceeding recommended rpm is an indication of UNDER pitched Do not run in this condition or engine damage may result Once satisfied is good practice to place a painted reference mark on each bolt head and 12 Re check torque of prop bolts after first ho
164. or too high 568 58 Sat Pags 555167 806527 tums By ical TRE batery Ins Gupu OT Ws regulator recer Does mor apply to Key West regulalorrecllrs Area for Owner Notes Appendix C Page 9 Page 103 Oyinder Head Highest Exhaust Gas Tachometer Thiskey advances 5 0 455 4629 The t or 2 idest whieh Press ancha these o keys for several seconds e Confourton St pages Press those uo toys togather Ln Batery ard Air Temperature played ere ie EGT and CHT 25 30 Fun an Fray be et ety fl prostre or Sher vterselesable corny Fgh Tee Tach Coolant or Outside Air Te Su kx Foe CT oy 5280 127 1020 Speed and Highest EST nthe row Veal shonn ol lest per mat vita ooo indor Head Temperature row or descent par Breach yirda Gao the Combination seoens provide 2540 152420434 2526 97 228 1014 1020 parametere Tech and aude 7 nih eau GPS Page This cage thant ted 7 Sisto on con
165. p tut channel brit wing spar eading edge wing strut saddle channel brik 4 washer ANA high temp nut Loose TI Bt ANA Z2 washer sirat piate sii Bock shut piate 1 4 washer ANA RH Temp Loose T2 Bolt AZER T washer piale A SII Back washer ANT gh Temp mu Tighten bots 8 1 Very ant T Sn Turysiioversiesve aft DFP 025 over jury strut aft DFE 001 Side through jury strut conn Bolt AN3 10A 3 6 washer jury strut threaded insert 1 2 x 10 2 DFO 040 jury strut 3167 washer AN nut Very tight Ta Boi ANT TAR STE washer Syebol 315 washer Ty DFE 004 ihreaded insent 1 2 x 10 92 Very tight 3367 x 347 jury strut threaded inser 127 x 10 32 jury strut att Ting safety DEQ 013 TE Chavis pin 3 6 x 34 suf ihreaded insert 12 3 18728 TETI stu Tad ring sally TENSION Bar upper and Wiig ensiom Bar WT wing raps 989 Pull tight of loose ends Put wing cover in place on top of wing and halt way in place an bottom of wing Run seat strap through cut out rough seat beit rastrainer strap and back dawn through cut out Close bottom side ol gap cover TIT Special Tools None 2 The parts needed to perform the task Replace worn damaged parts as needed listed above Max Wear defined 1 1
166. pecified in the Dragonfly Maintenance Manual in order to prevent the accumulation of dirt and dust 47 Tow Lines and Safety Links Weak Links Tovlines and Bridle made of Spectra 1000 or Dyneema UHMWPE 12004 20 due to the dragging of the during landing and taxi we use a more durable line The small diameter and light weight of the towline allows it 1o maintain alignment with les effect from wind amp gravity forces There is almost zero plasticity allowing all forces to get to the Safety Links rapidly NOTE Because of the durable size of the line it ix important to insure Safety Links are properly installed CAUTION Loads are limited by proper installation and used of Safety Links commonly referred to as Weak Links Refer to FIGURE 2 for proper tying and configuration Safety Links are made from 130 b Braided Dacron Fishing Line We use TUF LINE BRAIDED DACRON 130 LB T GREEN SPOT which ean be purchased on the Internet The Single Loop is used to fasten the Towline to the Glider being towed Point E in Figure 1 The Triple Strength Link is used to fasten the Tow Bridle to the Quick Release Point in Figure 1 DOUBLE FISHERMAN S KNOT Single Fisherman s Knot will also work Bowline Knot Used for multiple line strengths Triple Strength Configuration Appendix Pages End of Appendix G Page 149 Safety of Flight amp Service Difficulty Report Form Mail to Pitman Air 1840 Airport Blvd
167. pection The intervals at which the propeller must be removed for inspection are specified in the Maintenance Schedule With the propeller removed from the aircraft and each of the components separated the blades and boss should be inspected for the sort of damage described below paying particular attention to those areas which are not visible when the propeller is installed Bolt holes should be examined for out of round rough edges and cracks radiating into the boss Check the whole surface of the hub especially in all areas where there are corners Make sure the surfaces are clean and there is good lighting A magnifying glass will aid close inspection Boss faces should be examined for damage where they have been in contact with the hub flanges particularly at the circumference of the flanges The centre bore should be examined for cracks and delamination of the plies The mounting hub should be examined for corrosion cracks correct fit on the crankshaft and for condition of the attachment bolts and nuts Take note of any sharp nicks cuts or seratches as these are stress points from which further problems may occur Act on them if required Replace the LE Tape if damaged Do not operate a propeller of carbon fibre leading edge construction without LE tape applied Inspect the propeller and hub in the area around where the prop exits hub Inspect the bolts replace any wear or damage is present Propeller Assem
168. pliance Always follow ELT testing requirements per local or national authorities 6 Antenna Cheek low quality AM Broadcast Radio Receiver or Equivalent Test Equipment should be used to determine if energy t transmitted from the Antenna When the Antenna of this Radio tuning dial on any setting is held about 6 inches from the activated ELT Antenna the ELT Aural tone will be heard sce note below The ELT must be reset by pressing either the RESET push button located on the ELT Main unit or the ELT Remote Unit Note This is not a measured check but it does provide confidence that the Antenna is radiating with sufficient power to aid search and rescue The Aircraft s VHF Receiver tuned to 1215 MHz also be used This Receiver however is more sensitive and could pick up a weak signal even the radiating ELT s Antenna is disconnected Thus it does not check the integrity of the ELT System or provide the same level of confidence as does an AM Radio Appendix F Page 7 Page 138 Detailed Operation Check 1 Main ONIOFE ARM Operatie witch located on the ELT main unit must be in the ARM position In the event Tn normal operation the Mai ELT on automatically when the ELT of a crash an acceleration activated crash censor experiences a change in velocity or decelerati also accomplished by means of the cockpit mounted remote control unit or the ON switch on the ELT main unit
169. put drive plate connection These are shown correctly installed on the X 582 hub Balancing Balancing of the propeller should not be necessary if the damage allowances are adhered to repairs should only be to replace what has been removed If there is any doubt or if propeller balancing is necessary itis best done by a person who is experienced with composites and with Level 2 LAME qualifications or equivalent An epoxy compatible clear spray paint applied at the tips is best with the surface of the propeller prepared gently with 600 grit Sandpaper and cleaned to remove any oil residue Tracking ALIGNMENT amp TOLERANCE 1 While assembling the propeller blade alignment and pitch checks must be carried out After setting the pitch tighten all fittings to half torque settings The following should then be checked and readjusted until correct Pitch Angles this can affect all other measurements so make sure the pitch angles are correct before the other checks Distance from tip to tip of each blade as per the diagram The tracking height or runout of each blade as per the blade This can be checked flat as shown or by comparing each tip to a fixed point on the airframe an Appendix E2 Page 10 Page 129 All Distances the Same Small variations in mounting plates shaft holes bolt tensions and drive flange squareness may ause these alignment variations Make sure all is correct before and after th
170. quipment recommended by the manufacturer or its equivalent must be used in manner acceptable to the Administrator This provision is more directly applicable to maintenance than preventive maintenance However it may come into play Therefore owners and pilots should be avare of it 4 Additionally Section 43 13 requires that the work performed and the materials used are to be such as to ensure that when the work is finished the item worked on is at least equal to its original condition Caution must be exercised because some functions which appear to be simple tasks may in fact be quite complicated Care should be taken to ensure that the manufacturer s instructions are understood the function is within the individual s capability within the definition of preventive maintenance and that it listed in paragraph of Appendix of Part 43 e Recording preventive maintenance Preventive maintenance must be recorded in accordance with Section 43 9 of FAR Part 43 This is done by entering in the maintenance record of the item worked on the following 1 A description or reference to data acceptable to the Administrator of the work performed This should indicate what was done and how it was done This is normally quite simple for preventive maintenance however if the description is extensive reference to documents containing that description is acceptable These may be manufacturer s manuals ACS or other documents or refere
171. r the tighter tho fabric the crisper the roll control With only the gap cover on aileron inboard fabric turned inside out side onto Inboard aileron frame Burn small sis in the pockets of aileron fabric Inboard and outboard on trailing edge side Slide aileron tension bars DFL 008 into pockets sits for tie wraps 10 tie wraps total 1 hole top and bottom evenly spaced aft of aileron main spar 1 hole topside near leading edge 1 hole bottom side near ail main spar Insert tie wraps through inside ot holes around tension bar in outboard then around tension bar aileron Inboard from outside 1 inside Fasten tie wraps and pull snug This puts tie wrap connection on inside so you will be pulling with sail rather than against it Tighten tie wraps Put rubber gloves back on Go to tip of aileron and work out wrinkles Rotate tie wraps so that connection is to outboard so you do not run out of Space while tightening Pull tie wraps tight Work out wrinkles rotate tie wraps tighten Repeat until gap closes to 17 To close gap cover fabric down sido to sido until right side out gap cover stops when it reaches outboard fabric trim outboard fabric leading and trailing edges with a hot knife Stop now if you intend to paint T Bolt ANG T4A 3 16 washer alleron torsion tube Aileron crank assembly port Alleron torsion tubo 3 16 washer ANS half Very fight leron torsion tube 912
172. r 6 000 tows complete and thorough inspection of the release should be performed There is no specific TBO However every Annual or 100 Hour Inspection requires a thorough inspection to insure there are no problems with wear or operation of the Release and all components in the Tow Release and System There are Releases in operation that are more the 20 years old and are still in good working condition Some older units had a zinc plated steel spring that eventually corrodes But the newer Stainless Steel Spring has shown no signs of probleme We have never experienced a broken spring in 20 years but it must be inspected every Annual or 100 Hour Inspection Every 100 Hours or Annual Inspection whichever occurs first 1 Inspect for excessive wear or binding in the system 2 Inspect the Release Handle Cable Housing for cracks which would indicate deterioration of the cable housing 3 Insure that the Release Handle Pressure measured at the top of the handle does not exceed 8 Ibs 14 Insure that the cable moves freely through the cable housing and to the normal position by release spring pressure only 5 Insure that the release L link has not developed a wear notch This notch can be smoothed with file But do not remove more than 10 of the material on the L link and insure that maintains the round shape that matches the Release Arm 5 Inspect all fasteners for proper torque Inspect lines for exces
173. ral components 4 Certification needed to accomplish the task Line LSRI Inspection or above Heavy LSRM Maintenance or above sec Level of Certification in this manual 5 Detailed instructions and diagrams as needed to perform the task listed above and adjacent page Every Annual or 100 Hrs Inspect for Cracks Corrosion Elongation of holes amp Fasteners for Wear amp Security See Cables Thimbles and Tangs Page 16 sct all cables for frays and or corrosion around Nicopress sleeves replace if necessary 6 Method to testinspect to verily the task was accomplished properly Insure that all procedures were followed correctly and there is proper non binding movement to moving parts and that fasteners were tightened as instructed When flight controls are involved assure that they are operating properly tion 21 Cable Bracing Section 21 Page 62 Section 22 Maintenance amp Inspection Dragonfly 582 AFT SEAT STEP INSTRUCTIONS for Assembly or Disassembly eversa 85 order PARTNO STAGE CERT T Algn Seat Brkt aft DFO 045 to back hole Dril 3 16 hole pop rivet stainless steel 3 16 x 1 4 DFT 402 seat brkt seat main frame aft DFC 006 2 seat main rame af ini seat cushion DFR 014 3 Side seat frame lower afi DFC OTT into seat cushion and seat brkt a A Bolt AN3 13A 3 16 washer seat brkt seat main frame aft seat aft 3 16 washer AN
174. ral components 4 Cemification needed to accomplish the task ESRI Inspection or above 55 3 Level of Certification this manual 5 Detailed instructions and diagrams as needed perform the task listed above and adjacent Every Annual or 100 Inspect for Cracks Corrosion Elongation of holes amp Fasteners for Wear amp Security 4 Pushrod Guides maximum af 0 090 slop use 0 040 safety wire on each side as feeler gauge 35 Check fur lose Rivauts Repair needed by using 10 32 Rivnut ue Threaded Insert tol to tighten or replace 4 Appl dry abe to pushrod where passes through guide every 100 rs or Annual 6 Method to testinspect to verify the task was accomplished properly Insure that all procedures were followed correctly and there is proper non binding movement to moving parts and that fasteners were tightened as instructed When flight ontrols are involved assure that they are operating properly ection T Boom Tube Section 1 Page 22 1830239 40 enuuv sinoi 001 42940 65 90 55 8839 WOOB 10 Drawing 1 Page 23 Section 2 Maintenance 8 Inspection Dragonfly 582 BULKHEAD STEP INSTRUCTIONS or Assembly Tor Disassembly reverse ia order PRRTNO STAGE CERT Ts eme dem TTG Seion TT 08888 Bolt control pivot assembly DFW OTS into bulkhead 001001 shown
175. ran ort as 1 Mount Hub To Wheel NM 3 Mount Axle to Frame Appendix Page 5 Page 90 9 Mount the Wheel Black Split Rim Assembly Instructions I EI Appendix Page 6 Page 91 Bottom Left View Brake Line Routing Left Rear Heel Brake Left Main Wheel amp Caliper Appendix 8 Page 7 Page 92 Right Rear Heel Brake Fiber Pads Every 100 hours or Annual Inspection Loosen Set Screw turn and insure there is significant play in Woodruff Kay then tighten 3 Allen Screws that disc floats on are tight that there are no leaks no significant scoring and that fibre pads both sides of disc are at least 3 32 thick The Allen Set Screw is tight WARNING When brakes are set up for front and rear there is a chance the rear cylinder will turn into a check valve if the rear brake is not all the way back out This can happen dirt gets under the snap ring that holds the piston in or if the person in the rear seat applies a litle pressure with enough motion for the cup seal to cover the reservoir return hole cont d next page Appendix Page 8 Page 93 Since these are disc brakes there is no need for a shuttle valve When the brake piston starts t
176. rating Frequencies 406 028 MHz 0 001 MHz not on 450 121 500 20 005 243000 MHZ 2 0 008 Short term stability lt 2 x 10 100ms Medium Medium Residual variant 9 Modulation Audio Sweep Frequenz Download Sweeping 1600 300 Hz Sweep Rates 385 185 Modulation Factor More than 0 33 Occupied Bandwidth Less than 25 Hz Voice Modulation Included Modulation Duty Cycle 33 55 Square Wave AM Continuous Peak Effective Radiateds0mW 121 5 MHz RF Power PERP 9 S mW 125 243 0 MHZ SW 41 LS8W 406 028 35 3 to 38 18 dBm 406 028 MHz Equivalent Isotropic 100mW 10dBW 121 52430 MHz min Radiated Power EIRP 448 406 028 MHz max Emission Designator 16K0G1D for 406 028 MHz 3K20A3X for 121 5 MHz 40 BATTERY REQUIREMENTS Transmitter Main Unit Battery Pack consists of 4 cells LiMn02 or LiSO2 AK 450 has 6 cells D Size DURACELL AUTOMATIC CRASH ACTIVATION Velocity Change of 2 3 0 3 G 4 5 0 5 FPS per TSO C 126 DO 204A and 50 2 126 EUROCAE ED 62 requirement ANTENNA RADIATION CHARACTERISTIC Radiation on 121 5 243 0 MHz and 406 028 MHz Vertically polarized amp Omni directional in the Horizontal Plane CRASHWORTHINESS 1007 23 ms 6 directions Manual ON and RESET functions are located on both ELT Main Unit and Remote Unit The two Green Red Light Tor AK 450 ON lights flashing
177. re o be done in accordance with Manufacturers Instructions for SLSA Aircraft andlor AC 43 13 18 and AC 43 13 2B for ELSA 2 1 2 Alterations NOTE No Alterations may be made to SLSA Aircraft without an LOA Letter of Authorization from the manufacturer Any unauthorized alterations will result in the Airworthiness Certificate reverting to Experimental status and or violation of FAA regulations Any unauthorized Alterations must be reported to the manufacturer and the FAA for change of Airworthiness Certification to Experimental ELSA Prior to Alterations Any LOA issued 1s fora Specific Aircraft and does not apply to other aircraft without the LOA being issued to il Fees may apply The LOA must accompany the logbooks and maintenance records for the life of that aircraft The manufacturer is not responsible for alterations to Experimental after the initial Airworthiness is issued but it stil the responsibility of the owner to report such alterations to the manufacturer immediately forthe parpose of Continued Safety Monitoring of the let There 2 types of changes that can be requested Both may require fee 1 Non Critical Such as Non Structural and or None Aerodynamic Alterations such as Instrumentation Wiring Fabric repair and painting different Tires etc which does not adversely affect the Weight and Balance or Flying Characteristics of the Aircraft or it s systems should submitted as a for
178. re operating properly Section 5 Fwd Cockpit Section 5 Page 30 Drawing 5 31 Section 6 Maintenance 8 Inspection Dragonfly 582 PILOT SEAT STEP INSTRUCTIONS for Assembly or Disassembly reverse ins order 28878 STAGE CERT Side seat tuba Tower fwd OFC 020 through sesbcushion 068014 100 861 ANAZIA 1 4 washer cockpit tube lower seat tube lower twd Tight 2 side seat tube wad OPC OT through seat Bolt AN4 37A 1 4 washer seat tube vd throttle cable seat tube saddle 1 DFP 03 saddle 1 75 DFP 032 cockpit tube lower port saddle 1 757 aft throttle cable anchor brkt DFJ 01 1 47 washer ANA full nut Tight T Fabric on new seats very ght you have you may Tsien around the 1 channel br at front of the plane and the fwd seat tube Pull until have proper alignment Bolt AN4 34A 1 4 washer seat tube spacer be spacer seat luba twd saddle 7 saddle 1 75 cockpit ube lower starboard washer ANA full rut Tight TT Bar ANT 37A washer side cockpit DFC OT spacer 1 tube spacer sida cockpit port saddle 1 saddle 1 75 cockpit tube lower port saddle 1 75 trots cable anchor brkt 1 4 washer ANA ful nut Tight 5 1 Bat ANI SIR 174 washer Side cockpit starboard DFC
179. re to haee They for tare growth Figure 5 Connector A Wiring Model 2000 for 2 Stroke engines Ext CJ Appendix Page 12 Page 106 Arni Making Se achomear conection lO IT CO b DE Cr MONDE apa state nga go 12 6 Red Instrument Power Regul Ground mr ing c r ones pom E ne ring els soe anv mages Figure 76 Tachometer Connections to Lighting Coil Equipped Engines Rotax Jabiru Hirth Zenoah etc Electronic ignition 1 k Ohm 1 2W resistor To Points Connect iret tach own back rom anton system it eee mme Rotax 912 914 Connect tach input one af the acheter output ee Cone he oor lach ou wre Ignition Magneto Equipped Engines Coil such Lyeoming Continental Franklin etc Point Type wed Ton F lagneto Switch ons ELI ou Nick primary lead e Asch ry beet slem YN cen l4 Engine TET 1 8 Mag 84659 ae m indie Ga Figure 7b Other Tachometer Spare Lighting Connections Model 2000 4000 6000 EIS Appendix C Page 13 End of Appendix Page 107 Appendix D Items Permitted Under the Privi
180. rm the task Replace worn damaged parts as needed listed above Max Wear defined 1 1 8 1 3 Type of maintenance Inspection Line amp Replacement 4 Certification needed to accomplish the task Line LSRI Inspection or above Hea sec Level of Certification in this manual 5 Detailed instructions and diagrams as needed to perform the task listed above and adjacent page Every Annual or 100 Hrs Inspect for Cracks Corrosion Elongation of holes amp Fasteners for Wear amp Security 6 Method to testinspect to verify the task was accomplished properly Insure that all procedures were followed correctly and there is proper non binding movement to moving parts and that fasteners were tightened as instructed When flight controls are involved assure that they are operating properly Section 22 Page 64 722 AFT SEAT LiteFlite DRAGONFLY 27 08 08 Drawing 22 Page 65 Section 23 Maintenance 8 Inspection Dragonfly 582 AFT SEAT amp CONTROLS STEP INSTRUCTIONS for Assembly or Disassembly eversa Wie order PARTO STAGE CERT T Seat bolt aft DFR OTT into shackle large 1 4 x 1 14 DFT 602 Bolt AN4 23A root supp brkt upper shackle large 1 4 x 1 1 4 seat supp aft shackle large 1 4 x 1 1 4 aft root supp brkt upper half nut 2 Position assembled aft seat on boom tube ANA half nut 1 4 washer vert stab fwd 1 4 x 6 25 DF
181. rtification in this manual Replace worn damaged parts as needed listed above Max Wear defined 1 amp Replacement Heavy when it involves replacement of structural components SRI Inspection or above Heavy LSRM Maintenance or above 5 Detailed instructions and diagrams as needed to perform the task listed above and adjacent page ry Annual or 100 Hrs Inspect for Cracks Corrosion Elongation of holes amp Fasteners for Wear amp Security Check Brake Shoe Retainer Pin to insure it is not getting loose Every 100 Hrs Important See Warning in last part of Hydraulic Brakes Appendix B of this manual 6 Method to tesinspect to verily tbe task was accomplished properly Insure that all procedures were followed correctly and there is proper non binding movement to moving parts and that fasteners were tightened as instructed When flight controls are involved assure that they are operating properly Section 7 Fwd Wheel Throtile amp Manual Brake Section 7 Page 34 Note Hydraulic Brakes see Appendix 3111095441 3 20 4331 Jenuew oeq g xipuaddy aos 19801 1994 seyelg uepuedepu onepAH Drawing 7 Page 35 Section 8 Maintenance 8 Inspection Dragonfly 582 TAIL WHEEL TEP STRUCTIONS Tor Resembiy or Disassembly reverse 85 order PART HOSTAGE T Wap mar
182. sed hole in outboard comp strut Move inboard to next comp strut and repeat for bolts 10 and amp Sect 16 Stand wing on trailing edge and secure Go to wingtip Burn hole for bolt 15 16 start burning on bottom side of bolt Fabric will move up and wrinkles in upper surface wil disappear Move inboard to next comp strut and repeat for bolts 7 and 4 Sect 16 Just inboard of 4 Sect 16 burn two holes for strut plates Using template provided mark and burn slot for strut plate Move inboard to 5 Sect 16 Bum hole for threaded insert 1 2 x 1 4 28 1 1 4 Using dimensions provided in drawing burn cut outs inboard section of wing cut outs are approx 1 1 2 1 1 27 Bend wing tension bar upper DFK 003 shape of upper batten Bur slot in pocket on inboard fabric just above leading edge spar Slide wing tension bar upper into place Bend forward part of wing tension bar lower DFK 002 to match lower batten 5166 into fwd cut out in lower sail Put fwd end into pocket and slide fwd Hold aileron up to light Locate and burn holes through patches over hinge points Burn small hole first to make sure hinge point 6 centred finished hole should be approx 3 4 span wise 1 1 2 cordwise staring just fwd of where fabric touches main spar If you intend to paint tho sail now is the time Do not forget wing gap cover TTT Recommended Special Tools None 12 The parts needed to perform the task
183. ses of position and his allowed in these two systems as well as in the anticollision lighting system 18 Replacis involved Enough sai ig wheels and skis where no weight and balance computation i 19 Replacing any cowling not requiring removal of the propeller or disconnection of flight controls Pilots are permitted to remove and replace cowlings and flaps on the aireraf they own or operate However don t forget that only certified mechanics may remove a propeller 20 Replacing or cleaning spark plugs and setting of spark plug gap clearance Some important items to consider when changing spark plugs Have available and use the proper manuals tools and equipment needed for the job which includes torque wrench Use the proper spark plugs for the engine Know the plug rotation sequence for the engine Many people use a simple process of rotating the plugs from top to bottom and then next in firing order 21 Replacing any hose connection except hydraulic connections Owners are allowed to replace any hose or hose connection except hydraulic connections which also includes broken lines You are also allowed to change such lines as 2 Cabin air hoses Carburetor heat hoses Owners may replace static pressure lines except when used for IFR flight see FAR 91 411 however it is strongly suggested that you leave those to the A amp P mechanic 22 Replacing prefabricated fuel lines You are al
184. side into lace more easily T Jurysir conn aft DFO UTE saddle 1 relieved DFP 038 Strut afl DEH 001 strut 1 4 washer ANA tull nut Very tight spacer strut 17 DFG 003 27 18 5 0 865 5 rut fwd 002 UA washer ANA full nut Very tight 3 Bai ANS TSA 516 washer sut a spacer strat Block DFP 040 strut block DFK 001 spacer strut block strut alt 567 washer ANS nut Very taht Tubo may bo squeezed in vice Jo get parts into place 3 Bal ARET Tang stu DFO TET siru twd spacer strut block strut block spacer strut block strut fd tang srt ANS half nut Very m da ang Sru Tud Tang Sul ANE rut 3 858 washer 588888 18 5 Strut hud strul plate C 1 4 washer ANA half nut Very tight Bolt ANS 17A S76 washer sii plate su fwd spacer sini BIER Sirul spacerstui block strut hwd strut plate 516 washer ANS hall ut Very ligh 7_ Bali ANA 17A washer plate strut spacer Strut sit alt 5897 plate C 1 washer ANA nut Very ANE 2 washer TUT BIGER BUTE UA washer ANT Rh Temp ru Loose ESS Balt ANE AEA T washer Wing channe BRL Spar 8888 BOGE Wing comp strut saddle channel 844 147 washer ANG high temp nut Loose TU Bolt 32 Ta washer wing com
185. sive wear fraying kinks or knots than would weaken the line 7 Insure slider has not developed wear spots or sharp edges that would cut or bind the line 8 Replace any parts that exhibit excessive wear friction or damage in accordance with the Maintenance Manual and use only factory replacement paris Operational Tests 1 Without pressure on Bridle insure Release Locking Arm on Release Assembly and Handle retur to Normal Positions 2 With pull being applied to bridle test thar line releases properly and with smooth motion of the release handle 3 Insure that Safety Links are proper size material and installed properly Links are in good condition Both the Bridle Safety Link and Safety Links to be used on the glider end Appendix Page 4 Page 148 4 1 Operational Forces Operational Forces are limited by the Safety Links CAUTION Proper materials and installation of Safety Links are required 45 Corrosion Wear and Breakage The components in the Bailey Release and Towing System are made of materials that resist corrosion Any excessive Corrosion Cracks Breakage or Wear of parts or assemblies requires replacement of bad parts or assemblies with factory supplied pars or assemblies Refer to Dragonfly Maintenance Manual 46 Care and Cleaning The components of the Tow and Release System should be kept Clean and free of dirt and sand There should be no need for lubrication If lubrication is applied it should be Dry Lubricant as s
186. sponsibility of those desiring to install this article specific type or class of aireraft installation cond ithin the TSO standards TSO articles must have separate approval for installation in an aircraft The article may be installed only if further evaluation by the applicant documents an acceptable installation and it is approved by the FAA Administrator The article may be installed only if performed under 14 CFR parts 43 or the applicable airworthiness requirement For installations outside of the US contact your local Evil aviation authority for guidance Ref TSO CI26 paragraph Lithium battery safety concerns include the possibility of fire ve TSO CI26 paragraph 54 0 t violently and venting of toxic gases Ref PHYSICAL CHARACTERISTICS AND WEIGHT 4 27 929 7 5 bs 140z AK 450 3 Ibs 1 1 58 W x 0 65 H x 200 L 1 0 oz Transport Blade type 451 017 3 600 Knots Ibs Business Rod type 451 017 2 350 Knots airspeed 0 5 Ib General Aviation whip type 481 017 1 300 Knots airspeed 0 25 Ib Portable Antenna 451 017 4 I L 4 0 02 Mounting Tray amp Velero holder 4 51 W x 0 75 H x 5 87 40 oz CASEAND COLOR No Sharp Edges High Impact Flame Retorted Fire Resistant Waterproof High Temperature ABS Plastic Safety International Orange Color Appendix F Page 2 Page 133 GENERAL SPECIFICATIONS STANDARD CONDITIONS TRANSMITTER Ope
187. t where applicable each installed miscellaneous tem that ls not otherwise covered by this listing lor improper Installation and Improper operation 61 Specific ems that require addtional attention and inspection such as Limited Parts LLP 5 6 1 toms ass section 2 tems 1 568 section Tat Wheel Assembly most Parts section 13 tems 10 168 19 Rotax Engines amp Components Comply with all Rotax Service and Inspection Butetins and Procedures see Rotax Manuals for complete Inspection Intervals and Procedures wiw Reserved tor use Note Make appropriate Logbook Entries Weight 8 Balance Adjustments Upcoming time or wear limit items to watch that may occur before next Annual or 100 Hr Inspection is due Name Signature Cert Date Aircraft Hours Total Time Airframe Engine Time Page 19 1 3 Structures Sections 1 through 29 and Appendix s of this 1 34 Wings see Sections 14 through 20 1 32 Empennage see Sections 1 2 4 8 through 13 21 amp 23 1 3 3 Landing gear see Sections 2 7 8 and Appendix 1 34 Structural Control Surfaces see Sections 9 through 21 1 3 5 Fabric Coverings Sections 9 through 20 Every Annual and or 100 hour Inspection check for these items 1 Loose or broken vigilance to assure it is not growin ching on fabric particularly on the leading and trailing edge seams Any loose small areas require PIE the stitching givi
188. tax 582 DCDI Engine w E Gearbox 4 1 ratio Propeller EIS 2000 1ea M2STD 01 Lea OPT IntAlt 2a EGT CI 01 2ea CHT 14 01 lea FT 1827402 Lea CAB A 02 1 1 2 Sources to purchase parts Note The use of Used Overhauled or Reconditioned Parts or Components is Strictly Prohibited unless otherwise authorized in this manual or a Letter of Authorization LOA is obtained from Pitman Air All Components including Engine Gearbox Propeller Airframe and Fabric Materials ete America s Manufacturer Airframe Parts Manufacturer Pitman Air Lite Flite Py Lid 1840 Airport Blvd 1144 Botany Rond Red Bluff CA 96080 Botany NSW 2019 Ph 530529 3030 Email ed_pitman hotmail com Australia Ed Pitman 530 945 1860 9 5 Pacific Time Ph 461 29316 5543 Ace Hardware Sherline Products PTFE Dry Lubricant Super Lube NO Film left to hold dust or dirt Or Equivalent EIS and Sensors Grand Rapids Technologies Inc 2133 Madison Ave Wyoming MI 49548 1211 PH 616 245 7700 FAX 616 245 7707 s Engine and Gearbo Lociwood AVaton Supply 1 Lockwood Lane Sebring FL 33870 Prone 6558555100 Fax 6632559225 Bolts Nuts Wire Misc Hardware Tools etc NOTE Be sure to ask for Documentation when ordering parts keep with permanent records amp logbooks for your aircraft Spruce WEST Spruce EAST Spruce CANADA 225 Aport 422 Drive 150 Ave Corona CA 92880
189. ter 2 issued by the holder of the production certificate for that primary category aircraft that has a special training program approved under 21 24 of this Subchapter or 3 issued by another entity that has a course approved by the Administrator and ii The inspections and maintenance tasks are performed in accordance with instructions contained by the special inspection and estive maintenance program approved as part of ara type design or supplemental ype jesign 31 Removing and replacing self contained front instrument panel mounted navigation and communication devices that employ tray mounted connectors that connect the unit when the unit is installed into the instrument panel excluding automatic flight control systems transponders and microwave frequency distance measuring eq DME The approved unit must be designed to be readily and repeatedly removed and replaced and pertinent instructions must be provided Prior to the unit s intended use an operational check must be performed in accordance with the applicable sections of part 91 32 Updating self contained front instrument panel mounted Air Traffic Control ATC navigational software data bases excluding those of automatic flight control systems transponders and microwave frequency distance measuring equipment DME provided no disassembly of the unit is required and pertinent instructions are provided Prior to the unit s intended use an operational check must
190. tgurebon ages The top row shows ach Geen tine nome poston and femore botom fov Seo fouro 2 formare infomation aboa hs page Engine Hour Meter Show on ogne Flight mer snow win ower and una S minutes othe hes ft shows ofthe lat ight mis key tome you carter key sequences he order Figure 1 Display Pages for the Model 200065 Appendix C Page 10 Page 104 Steering date updates wth Steering The 14R 14 degree Distance to home The distanco in mies ey of dals tombe Auto e rights rered to on sou by e symbol o 509 Some GPS receiver Suse deep er hom a KN tom year 36 ones erect The 098 E athe data it te sieering de tia when steering data 1s ome Eu ME e ae EX ey 4750 1487 14 5 2500 91 27 RN mince really we ae aja How to use this page to get nome Simple felon he seorng data Trat Isal Bearing to home This is the deection to home Where is the home postion Zero Gees presents uo North 80 degrees is hs tho here e GP
191. the dura tuff edge then the complete blade is likely to be damaged and should be scrapped There no special care instructions beyond that applicable to normal prop as per our existing instructions Preflight Every relight inspection should check a prop s integrity Repairs For a standard configuration propeller to repair all dents and scratches slow cure EPOXY resin must be used The epoxy types are NOT acceptable Available fom is a General Purpose Epoxy 180 360 and 000em packs Damage over 3mm MUST be filed ih slurry made fom a suitable Epoxy plus fine milled glass fibres For cosmetic scratches Ind dents use tale with the epoxy Always follow resin instructions and apply clean diy surface de geasing with MEK or single solvent When cured carefully sand the filler back to match the blade apply new LE Tape For a Nickel insert leading edge propeller these propellers are relatively maintenance free in the event that a leading edge is damaged it is likely that the propeller is damaged as well Leading edge inserts may be fitted to existing propellers and as replacement inserts the propeller manufacturer must perform this procedure Note If in doubt or if the propeller has more damage than is able to be fixed by the maintainer then return the propeller to Pitman Air or Bolly for evaluation possible repair and or overhaul End of Bolly Propeller Instructions
192. tion except the interval of inspection is 100 hour of operation instead of 12 Calendar months This inspection 8 utilized when the LSA is being used for commercial operations such as fight ineriction or rental or both Page 84 Appendix A make ies page as needed safety of Flight Reporting Form amp Comment Form Safety of Flight amp Service Difficulty Report Form Pitman Air 1840 Aiport Bia Rad 8 96080 and or Online at www pitmanair com dragontiyi Check One Tam of Concern Safety of Fight Difficulty Reporting Party Contact Information Address Ciy sr Zip Code Day Phono FAX email address Check Appropriate Owner Operator LSRI LSRM Other Explain Aircraft Specific Information Aircraft Information Engine Information Make Model Modal Serial Number Serial Number N Number Gearbox Ratio Date of Mig Propeller Mig Date of Problem Discovery Description Propeller Serial 6 Comments End Appendix A Page 85 Appendix B Brakes Manual for BX1320 amp BX1000 PLEASE READ THROUGH THE ENTIRE MANUAL BEFORE INSTALLING YOUR BRAKE SYSTEM WARNING DO NOT USE BRAKE FLUID USE ATF HYDRAULIC FLUID ONLY
193. tion 9 Page 38 4540 fusos woog arua ATHNOOVG 81891 u3sniavis 3 3 80 Drawing 9 Page 39 Section 10 Maintenance amp Inspection Dragonfly 582 RUDDER TEP T INSTRUCTIONS Tor Assembiy Tor Disassembly reverse the 00057 PARTNO 588588 868 DED TE inside udder twd DFC 008 ingert temporarly screw into ANS blind nut Using dril rudder hug and conn sieeve through bid nut Hold ead with wrench so bind nut stays place while dn Pop rivet stainless steet 322 18 Ll ANS rt d uddar con sleeve Pop he rivets and remove 13 Pop TOT TIT TTE ST OPT TIT 12 tube insert DFP 017 he river SO ATT TRIE ET fwa threaded insert 716 x 114 28 TPI DFO 038 9 16 washer ANS half nut Pick any medum enghh 3 16 bot pu through the end of ube conn saddle 8641 DFP and read into threaded insert Line up grooves in tube conn saddle end 1 wi bol 3 Push tube conn saddle end in as lar as possible remove 3 16 Sel ube con 56 end 1 lube and press wno pace 5e 2 into fate though lower fed hole Push inside seam side Side rudder td into fabrie throug lower fud hol push rode conn sle
194. tional task specific training for the function to be performed is generally considered the minimum level of certification to perform heavy maintenance of LSA 5 2 Typical Tasks Considered as Heavy Maintenance for SLSA s Include 521 Removal and replacement of components for which instructions are provided inthe maintenance manual oe service directive instructions such as 52111 Complete engine removal and reinstallation in support of an engine overhaul or to install a new engine 5212 Remove and replacement of engine cylinders pistons or valve assemblies combination thereof may require additional Rotax ratings 52 15 Primary fight control cables eomponents and 52 1 Landing gear assemblies 522 Repair of components or aircraft structure or both for which instructions are provided in the maintenance manual or Service Safety Directive instructions such a 22 1 Repainting of control surfaces 5222 Structural repairs 5223 Recovering of a dope and fabric covered aircraft 523 Alterations of components or aircraft structure or both for which instructions are provided in the maintenance manual or Service Safety Directive instruction such as 52 3 Initial installation of skis or floats 5232 Installation of new additional pito statie instruments 6 Overhaul 6 1 Authorization to Perform Only the manufacturer of an LSA or the component to be overhauled on an LSA may perform or authorize tobe performed the overhaul o
195. tomatic Operation A GPS requires the creation of a waypoint for each location you fly from and also requires that you manually select the correct waypoint as the Goto in onder to get steering information to it The EIS does this automatically Large Readable Display The EIS display is much larger and more easily read than any of the low cost GPS units available today Easy to Understand Steering handheld GPS receivers reviewed to date provide steering information that is sometimes invalid and often hard interpret The EIS provides simple steering information and provides it only when it is valid Convenient Grouping of Information The GPS pages shows all relevant GPS data as well as altitude and tachometer on one screen Although engine temperatures are not shown they Being monitored by the EIS alarms Saying your Home Position At power up the EIS will determine if you are on the ground If you are and the GPS is providing data to the EIS it will determine if you at the same location you flew from last time If the EIS determines you are at a new location it will prompt you to see if you would like to save this as your new home position If you are al the same place you from ovur last light it will not issue this prompt NewHomePox No ME valid GPS position data is lost the No Yes Up Down Next prompt will be replaced with dashes indicating for saving as your home Normally you w
196. ttings for cracks and or decay replace if needed tube conn flat end DFP 033 Lino spacer tank tube OFC 022 lube conn saddle ond 1 end spacer tank tube 1 47 washer hall Very fight TT Balt ANA ZSA 1 4 washer cockpit channel br Tower ruddar pedal DFO 810 through spacer 147 washer ANA halt nut Repeat tor rudder pedal aft right DFO 0138 TIT Recommended Special Tools None 12 The parts needed to perform the task Replace worn damaged parts as needed listed above Max Wear defined 1 1 8 1 3 Type of maintenance Inspection Line amp Replacement Heavy when it involves replacement of structural component tenance or above 4 Certification needed lo accomplish the task Line LSRI Inspection or above Heavy LSRM Mai 3 Level of Certification in this manual 5 Detailed instructions and diagrams as needed to perform the task listed above and adjacent page Every Annual or 100 Hrs Inspect for Cracks Corrosion Elongation of holes amp Fasteners for Wear amp Secur Inspect Hydraulic Brake System for deterioration of line leaks in system and proper functional See Cables Thimbles and Tangs Page 16 6 Method tp tesinspect to verify the task was accomplished properly Insure that all procedures were followed correctly and there is proper non binding movement to moving parts and that fasteners were tightened as instructed When flight controls are involved assure that they a
197. udes the out of limit parameter The offending parameter is flashed on the display along with the warning light unti the problem goes away of until it is acknowledged by pressing the Next Back bution Acknowledged alarms cause the warning light to Stay on steady until the condition ends and does not inhibit other alarms Appendix C Page 7 Page 101 Set Limit Pages The settings on these pages are accessed by pressing the left and centre buttons together This will immediately bring up the set pages displaying cach item listed one at a time While on the set pages the bottom row of the display will show UP Down indicating the function of the buttons while on these pages As such the left and centre butions allow you to change the setting and the right button takes you to successive settings To leave these pages repeatedly press the right button or press and hold the right button until the normal display pages return The items that can are set on these pages are in order as follows Contrast defaults to the best setting at power up may be altered if desired to enhance readability 61 allow you to select Auto or Manual for the altimeter setting function shows the current altimeter setting Altitude is manually set here New Home Pos This setting is only available it the GPS page is turned on Selecting Ves and pressing the right button Stores the current position as your home position Das
198. ue to high air pressure don t forget to deflate the tire prior to disassembly of the wheel halves for tire and tube replacement Another important consideration is the proper toque on the bolts securing the wheels halves together 2 Replacing elastic shock absorber cords on landing gear Shock absorber cords commonly called bungee cords are found on many types of airplanes Examples Cub Aeronca and Pius At first glance changing the bungee cords look like simple task Believe us if you don t have the proper tools it s like going hunting for a grizzly bear with a hickory stick Don t do it 3 Servicing landing gear shock struts by adding oil air or both The allow the adding of and air to air oil or olco struts However many manufacturers recommend the use of nitrogen instead of air which helps to prevent the possibility of corrosion It s also a good idea that dirt and gri removed from the bottom of the shock strut by wiping it down using a clean rag with some MIL H S606 on it This wil help to increase the life of the strut 4 Servicing landing gear wheel bearings such as cleaning and greasing Cleaning and greasing wheel bearings is an There are several very important steps to follow when servicing the wheel bearings Cleaning This must be done thoroughly using a cleaner such as Varsol Inspection Now that the bearing is cleaned inspect the roller and inner and outer races for deterioratio
199. ur of operation and as routine maintenance If there is any sign of the reference marks moving it may be a sign that the Nylocs are loose This indicates that the torque value or clamping force is oo low In this case itis necessary to remove all six mounting bolts and check for wear If wear on the bolt or threads are present DO NOT USE order new hardware It you have followed these instructions exactly and your bolts have stil loosened DO NOT FLY Check the condition of your prop and hardware Have your torque wrench checked for proper calibration Never over torque or STRETCH prop bolts The standard prop bolt for this propeller is a Grade 8 8 X 1 25 metric and will fit the Rotax 75mm bolt pattern AN 5 prop bolts will fit the ROTAX 912 application use the same torque value NEVER OVER TORQUE or exceed established recommended usage of prop bolts Check for wear and deterioration of prop attachment hardware during maintenance and Annual Conditional Inspections Replace if ANY signs of wear or corrosion are present MAXIMUM ALLOWABLE PROP SPEED IS 2700 DISCLAIMER PROPELLER DRIVEN AIRCRAFT ARE EXTREMELY DANGEROUS MAKE SURE THERE ARE NO TOOLS OR LOOSE ITEMS THAT MAY CONTACT THE PROPELLER DURING OPERATION MAKE SURE AREA IS CLEAR BEFORE STARTING THE ENGINE AND NO ONE IS IN THE AREAS OF THE PROPELLER ARC THE PILOT IS FINAL AUTHORITY FOR THE SAFETY OF EACH FLIGHT KIEVPROP AMERICA THEIR DEALERS REPRESENTATIVES AND ASSOCIAT
200. urn owing Pop baton place t Takts a bit o to pop batien Place end of paten tool in of Baten end ress down and in being very cre nol 1o 9159298289 or sal damage may cour Continue process woking Inboard Staring at wingtip insert batien tower DFF 004 Through siat botom wing and wio pocket on boarn sal terior Push batien In 34 ot ne way Daten end altin 2R banen end Push batien stops Do net pop Continue wrung Return to wingtip Push baten down siol Reach n Through zipper or slat and rotate batten enda 180 Insert screwdrver wto stand push bane end wd 059 sub Pop lower Barten o pace Contnue waking board Insert atten end atima Can come loose or fallout wing Up supp OFF 012 Inset wing tip supo through outboard zar Put end of wing supp against high pina aboard baton end aft outboard comp art Meg bp supp be unl most wiles disappear ton wing abi TIT Recommended Special Tools Batten Tool see 1 1 12 Special Took 2 The parts needed to perform the task Replace worn damaged parts as needed listed above Max Wear defined 1 3 Type of maintenance Inspection Line amp Replacement Heavy when involves replacement of structural component 4 Cer lication needed to accomplish the task Line LSRI Inspection or above Heavy LSRM Maintenance or above sce
201. wing 13 Page 47 Section 14 Maintenance 8 Inspection Dragonfly 582 AILERON STEP INSTRUCTIONS lar Assen or Disassembly reverse tha order PART NOW STAGE CERT 2 861 ANS 7 hinge grease hinge point DFK 007 grease hinge brkt 3 16 washer ANS castle nut cotter pin Snug but free Hinge brkt may need to be spread slightly so hinge point turns freely 3_ Bolt AN3 23A 316 washer aileron main spar ext DFA OTT aileron frame conn block DFP 018 aileron main spar ext 3 16 washer ANS half Snug 7 Pop vet aluminium 3718 587 DFT 413 1 2 tube insert DFP 017 Aileron trailing edge DFF 002 Set rivet Do not pop 5 Pop rivet aluminum x 57 172 Tube ser aileron leading edge DFF 00T Set rivet Do not pop Take aileron trailing edge comp strut set OFF OTS and sort from short to long Start at outboard hole of lleron main spar assembly DFW 004 with the shortest strut Push strut through hole until it touches the other sido ofthe tube Insert aileron comp strut assembly DFW 022 into aileron main spar assembly and aileron comp strut Continue inboard with next longest strut and so on 8 aileron main spar ext into aileron main spar assembly and rotate so aileron frame conn block is parallel to comp struts Drill 3 16 hole through aileron main spar aileron main spar ext 1 5 from the joint in the same plane as comp struts Pop rivet aluminiu
202. worn damaged parts as needed listed above Max Wear defined 1 18 1 Type of maintenance Inspection Line amp Replacement Heavy when it involves replacement of structural components amp Replacement of Fuel System Components 4 Certification needed to accomplish the task Level of Certification in this manual Inspection or above Heavy LSRM Maintenance or above 5 Detailed instructions and diagrams as needed to perform the task listed above and adjacent page Every Annual or 100 Hrs Inspect for Cracks Corrosion Elongation of holes amp Fasteners for Wear amp Security Method to testinspect to verify the task was accomplished properly Insure that all procedures were followed correctly and there is proper non binding movement to moving parts and that fasteners were tightened as instructed When flight controls are involved assure that they are operating properly ion 27 582 Fuel Pickup Section 27 Page 74 7 27 FUEL PICK UP LiteFlite DRAGONFLY 270508 Drawing 27 Page 75 Section 28 Maintenance 8 Inspection Dragonfly 582 ELECTRICAL SYSTEM STEP INSTRUCTIONS for Assembiy or Disassembly reverse order PART NO_ STAGE CERT T Mount the battery bracket DFL 025 on the root tube Install rubber cushion pad in of battery bracket Fit battery into position and use a wing strap to buckle The ba
203. zer sound 4 sec OFF sec ON Next Press either RESET Button no ELT swept tone heard on the 121 5 MHz radio Both LED Lights and Buzzer must be extinguished Next Press the ON Switch on the Remote Switch Unit ELT swept Tone must be heard on the VHF Radio 1215 MHZ The 2 LED lights flashing 4 sec OFF 1 sec ON synchronized with the Buzzer sound 4 sec OFF 1 see ON 1 show 1 Bash or 2 flashes or 3 flashes or 4 flashes ete Refer to 3 For normal operation leave the ELT Main Switch ARM position at all times No ELT swept tone heard on the 121 5 MHz VHF radi illuminates No buzzer sound Detail Operation Check w 1215 MHz using the Aircraft Communication Receiver or a Portable Hand Held Receiver The Squelch must be turned all the way UP Max to hear he sweep tone on most receivers iteh on the front of the ELT Main Unit in the ON postion and verify that the Audio Sweep Verify that both the Green ON lights Red Light for AK 450 located on the ELT Main Unit and the ELT Remote Unit are flashing Verify the buzzer is heard at a lash rate and a beeping sound of 1 second ON 4 seconds OFF Place the Main Switch in the OFF po Tone is ceased and the two Green ON ion Verify that the Audio Sweep ts Red Light for AK 480 are extinguished 3 Place the Main Switch on the ELT Main Unit in the ARM position Wait for 25 seconds While seated at the Pilots normal op

SLSA 582 Dragonfly Maintenance Manual rev.5

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