Direct Fly ALTO 912 TG Aircraft Maintenance Manual Download Page 3

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AIRCRAFT MAINTENANCE MANUAL

DFE-AMM-AR1

Rev. 1 – 07/24/2014

iii

Section 0 - INTRODUCTION

0.1.

CONTACT INFORMATION

Company headquarters:
Direct Fly s.r. o.
Špitálka 8
602 00 Brno,
Czech Republic

www.directfly.cz

[email protected]

The Manufacturing Facility:
Direct Fly s.r.o.
Cihelní 573
687 25 Hluk
Czech Republic

Brazilian Dealer:

Erres Industria Aeronautica Ltda.
Rua Baden Powel, 43 - Bairro São José
Santa Maria – RS – 79110-120
www.erresaeronautica.com.br

[email protected]

0.2.

RECORD OF MANUAL REVISIONS

Refer to Section 12 of this Aircraft Maintenance Manual.

0.3.

LIST OF EFFECTIVE PAGES

Refer to Section 12 of this Aircraft Maintenance Manual.

Summary of Contents for ALTO 912 TG

Page 1: ...Direct Fly ERRES ALTO 912 TG AIRCRAFT MAINTENANCE MANUAL DFE AMM AR1 ...

Page 2: ...ANCE MANUAL DFE AMM AR1 Rev 1 07 24 2014 ii Aircraft model modification ALTO Manufacturer Direct Fly s r o Airplane Serial Number Airplane Registration Number Issued on July 24 2014 Revision 1 Owner DF051 PU RJR 912 TG ...

Page 3: ...he Manufacturing Facility Direct Fly s r o Cihelní 573 687 25 Hluk Czech Republic Brazilian Dealer Erres Industria Aeronautica Ltda Rua Baden Powel 43 Bairro São José Santa Maria RS 79110 120 www erresaeronautica com br contato erresaeronautica com br 0 2 RECORD OF MANUAL REVISIONS Refer to Section 12 of this Aircraft Maintenance Manual 0 3 LIST OF EFFECTIVE PAGES Refer to Section 12 of this Aircr...

Page 4: ...RIODIC INSPECTION TASKS 2 2 2 4 ACCESS WINDOWS 2 2 2 5 SCHEDULE OF INSPECTIONS 2 2 3 SECTION 3 STRUCTURES 3 1 3 1 GENERAL 3 1 3 2 FUSELAGE 3 1 3 3 WING 3 5 3 4 EMPENNAGE 3 8 3 5 LANDING GEAR 3 11 3 6 STRUCTURAL CONTROL SURFACES 3 21 3 7 PERMISSIBLE TOLERANCES 3 33 4 SECTION 4 ENGINE 4 1 4 1 GENERAL 4 1 4 2 ENGINE 4 1 4 3 ENGINE BED 4 5 4 4 ENGINE COWLINGS 4 6 5 SECTION 5 FUEL SYSTEM 5 1 5 1 GENERA...

Page 5: ...14 v 11 2 DESCRIPTION 11 1 11 3 INSTRUCTIONS FOR AUTHORIZED MAINTENANCE REPAIR OR ALTERATIONS 11 6 12 SECTION 12 REVISIONS 12 1 12 1 GENERAL 12 1 12 2 REVISION NOTES 12 1 12 3 LIST OF EFFECTIVE PAGES 12 2 13 SECTION 13 FEEDBACK FORM 13 1 13 1 GENERAL 13 1 ...

Page 6: ...to determine the applicability of any regulatory limitations prior to use 0 6 PILOT OWNER SERVICING AND MAINTENANCE This manual identifies servicing and maintenance actions which can be performed by the owner pilot as identified in ASTM F2483 and who holds a light sport aircraft pilot s certificate or greater and who may not have received any specific authorized Direct Fly S R O training The maint...

Page 7: ...Paragraph 0 1 on this Section 0 10 OWNER CHANGE OF ADRESS NOTICE Each owner operator of a LSA is responsible for providing the manufacturer with current contact information where the manufacturer may send the owner operator supplemental notification bulletins The following form may be used sent to Direct Fly S R O by email or fax to the addresses listed on Paragraph 0 1 on this Section CHANGE OF O...

Page 8: ...red heavy maintenance that is approved by the manufacturer and is specified in the manufacturer s maintenance manual Typical tasks considered as line maintenance for LSA s include 1 100 hour inspection 2 Annual Condition Inspection 3 Servicing of fluids 4 Removal and replacement of components for which instructions are provided in the maintenance manual 5 Repair of components and structure for whi...

Page 9: ...required from the manufacturer in order to overhaul a SLSA or component Typical components that are overhauled include Engines Carburetors fuel injection systems Starters alternators generators Instruments Overhaul Facility A facility specifically authorized by the aircraft or component manufacturer to overhaul the product originally produced by that manufacturer Annual Condition Inspection A deta...

Page 10: ...tive maintenance Sport pilot or higher Sport pilot or higher Maintenance Owner maintained Repairman LS M Mechanic A P Part 145 Repair station Inspections Annual condition Repairman LS I and LS M Mechanic A P Part 145 Repair station 100 hour condition Repairman LS M Mechanic A P Part 145 Repair station Annual condition Repairman LS I and LS M Mechanic A P Part 145 Repair station 100 hour condition ...

Page 11: ...ic instruction are provided in the maintenance manual 7 Compliance with a manufacturer service directive Typical tasks 1 Removal and replacement of components for which instructions are provided in the maintenance manual or service directive instructions such as Complete engine removal and reinstallation in support of an engine overhaul or to install a new engine Primary flight control cables comp...

Page 12: ... schematics that have been included in the manual are for general information purposes only Aircraft will have optional equipment for which there will be specific drawings that will either be included with the aircraft s documentation on delivery 1 2 LAYOUT OF THE MANUAL This maintenance manual is divided into Sections The Section numbers appear at the foot of each page 1 3 WARNINGS CAUTION AND NO...

Page 13: ...g tips empennage tips and wheel covers are made of composite materials The Alto is powered by the ROTAX 912 ULS engine 100 HP and PROPULS 174 3 R three blade ground adjustable propeller The two seats are arranged in a side by side configuration The tricycle landing gear features a steerable nose wheel and hydraulic brakes on main wheels 1 4 1 Basic Technical Data 1 4 1 1 Side Top and Front Views F...

Page 14: ...py max width 3 9 ft 1 180 m HTU Span 8 4 ft 2 56 m HTU area 20 88 sq ft 1 768 sq m Elevator area 8 4 sq ft 0 8 sq m VTU Height 4 21 ft 1 28 m VTU area 10 99 sq ft 1 03 sq m Rudder area 4 67 sq ft 0 44 sq m Landing gear Wheel track 5 57 ft 1 70 m Wheel base 4 57 ft 1 395 m Main wheel diameter 15 in 380 mm Nose wheel diameter 15 in 380 mm 1 4 1 3 Weight Empty weight This is an average wt Actual wt i...

Page 15: ...ipment 21 25 MAC Operating CG 25 35 MAC MAC Mean Aerodynamic Chord 1 4 1 5 Operating limitations Refer to the PILOT S OPERATING HANDBOOK POH Section 2 for more details about the following operating limits Airspeed limits Weight limits CG Range limits Approved maneuvers Additional rules are of a more common character and result from generally valid flight regulations It is in every user s interest ...

Page 16: ... storing it at indoor temperature Avoid parking airplane especially airplane with dark design on the direct sunshine during warm climate then can effect or wave can arise on the upper skin of the wing and fuselage It disappears when airplane is parked in the hangar in the shadow or during taxiing or in flight when airplane surface is cooled with air flow This can effect or wave arise during parkin...

Page 17: ... or supports to support the aircraft Aircraft fuselage can be supported on the places marked by the black triangles in the figure below The aircraft should be lifted by the following parts Press down on the rear of the fuselage in front of the fin to lift the front and then support under the firewall To lift the wings push on the wings lower surface at the main spar Do not lift by the wing tips Fi...

Page 18: ...in the cockpit during fueling A fuel tank filler is located on the upper side of each wing see figure below Fig 1 3 Fuel tank filler Cap Tools needed None Parts needed None Type of maintenance Preventive maintenance Level of Certification needed Sport pilot or higher Instructions 1 Connect the aircraft to the ground 2 Open fuel tank filler 3 Insert fuel delivery nozzle or a funnel into the filler ...

Page 19: ...Premium plus or AVGAS100LL Fuel according to FAA Standard Spec for Automotive Spark Ignition Engine Fuel ASTM D 4814 or AVGAS 100 LL Fuel according to DOT CAN CGSB 3 5 Quality 3 min AKI 91 or AVGAS 100 LL Refer to the BRP ROTAX engine Operator s Manual Section 2 4 1 6 2 Oil Filling The oil reservoir is located in the engine compartment and is accessible when engine upper cowling is removed Oil qua...

Page 20: ...in mark insert a funnel and fill oil 5 Remove funnel screw oil reservoir cap check cap proper attachment 6 Mount upper cowling Task proper accomplishment check check the fuel tank cap is home screwed and required amount of fuel is in the tank according to fuel gauge 1 6 2 1 Approved Oil Grades and Specifications Motor oil tested and released from BRP Rotax for use with unleaded fuel or MOGAS Shell...

Page 21: ... use of antifreeze concentrate during cold weather operation Castrol Radicool NF can also be used Refer to the BRP ROTAX engine Operator s Manual Section 2 3 1 6 4 Brake Fluid Filling A brake fluid is filled into reservoir located below the central panel between the seats see C on the picture below For the minimum and maximum brake fluid level see picture below Brake fluid refilling is necessary w...

Page 22: ...AIRCRAFT MAINTENANCE MANUAL DFE AMM AR1 Rev 1 07 24 2014 1 11 Fig 1 6 Brake Fluid Reservoir Location Fig 1 7 Brake Fluid Reservoir Fig 1 8 Brake Fluid Level Marks ...

Page 23: ...system parts inside the wings and fuselage which have been cleaned and lubricated during airplane assembly Lubrication of these will be performed during a periodic inspection There are some parts e g landing gear which are exposed to external conditions and to varying loads These parts will be inspected during pre flight and during periodical inspections These should be lubricated as is necessary ...

Page 24: ...foreign greases Flaps hinges x x MOGUL MOLYKA G foreign greases all movable joints under the quadrant cover between the seats x MOGUL MOLYKA G foreign greases All movable joints under the baggage compartment bottom cover x MOGUL MOLYKA G foreign greases Flaps control pins at a flap root x MOGUL MOLYKA G foreign greases HTU elevator hinge x MOGUL MOLYKA G foreign greases swivel bearing in the eleva...

Page 25: ... 5 Check attachment of wing ailerons flaps and tail units lubricate per Lubricating Chart Engine Refer to the Engine Manual for more details The following should be done 1 Add Anti freeze to the cooling system as required usually a 50 50 mix 2 Change the oil see Engine Manual or Service instructions 3 Check the spark plug gaps If low cylinder head or oil temperatures occur during operation under l...

Page 26: ...side air temperature is not below 5 C Pre heat the engine and oil if air temperature falls below 41 F 5 C Use suitable air heater or a dryer NEVER USE OPEN FIRE TO PRE HEAT AN ENGINE Blow hot air from the front into the hole around the prop engine covered with fiberglass cowlings The temperature of the hot air should not exceed 212 F 100 C at air heater output Warm up the oil tank along with the o...

Page 27: ...tion Clean the airplane thoroughly hinges especially the suspensions Lubricate airplane per Lubricating Chart Check and adjust the control system 1 7 EQUIPMENT LIST Direct Fly S R O retains the approval authority of any items installed in all ALTO aircrafts Therefore the following master list of equipment must be enforced as the only approved items for installation on the aircraft without further ...

Page 28: ...ct Fly S Cowling Lower Section Direct Fly S Avionics Instruments VHF Icom IC A210 S Transponder Garmin GTX 327 S GPS Garmin Aera 500 S ASI PRC BK 15 S Altimeter Mikrotechna LUN 1128 S Climb PRC BC10 1B S Compass PRC CM 24S S Slip Indicator Winter WIQM2 S Tachometer Road IF61 2B S Hourmeter Honneywell 85094 S Oil Pressure Road IE61 2B S Oil Temperature Road IH61 2B S CHT Road IH71 2B S Fuel Level I...

Page 29: ...Landing Gear Main Landing Gear Direct Fly Dealers or Comlet Nose Landing Gear Direct Fly Dealers Brakes Direct Fly Dealers Wheel Pants Direct Fly Dealers Airframe Canopy Key Lock Direct Fly Dealers Canopy parts Direct Fly Dealers Towing Hook System parts Direct Fly Dealers Electric Trim Direct Fly Dealers or Ray Allen comp Strobe Lights Direct Fly Dealers or Kunzelman SimplePack Direct Fly Dealers...

Page 30: ...er Aircraft Parts Stores Brake parts Aerospool DF dealer Rubber shock absorber Direct fly DF dealer Brake Fluid Castrol Castrol Brake Fluid DOT 4 Castrol Dealers Direct Fly Dealers Aircraft Parts Stores 1 10 ENGINE SPECIFICATIONS ALTO aircraft is powered by ROTAX 912ULS engine rated at 100 hp Engine Type Normally aspirated liquid air cooled dry sump mechanical reduction drive dual carburetor equip...

Page 31: ...ta 1 11 1 Definition The removal or addition of equipment may result in changes to the center of gravity and empty weight of the aircraft The permissible useful load can also be affected In such case a new weight and balance is necessary to determine the new empty weight and center of gravity position The new empty weight and C G position should be recorded in the Pilot s Operating Handbook Sectio...

Page 32: ...building to prevent errors due to wind 3 Place the scales calibrate zero 4 Place the airplane on the scales use boards to run on the scales or lift the airplane see airplane jacking 5 Place the airplane in a level flight position use suitable rests under the wheels 6 Check the configuration for weighing e g empty weight 7 Weigh the airplane and record the values in Weight and Balance Record make a...

Page 33: ...117 67 12 00 164 75 16 80 196 13 20 00 M16 N m kg m 93 16 9 50 107 87 11 50 164 75 16 80 225 55 23 00 274 58 28 00 M18 N m kg m 137 29 14 00 171 61 17 50 245 16 25 00 343 23 35 00 411 87 42 00 M20 N m kg m 176 51 18 00 225 55 23 00 313 81 32 00 441 29 45 00 539 36 55 00 M22 N m kg m 225 55 23 00 284 39 29 00 392 26 40 00 558 97 57 00 676 65 69 00 M24 N m kg m 313 81 32 00 392 26 40 00 549 17 56 00...

Page 34: ...ch as neckties and scarves Tuck in your shirt and secure any long hair to prevent them from becoming tangled in power tools Remove all jewelry Not only can items such as rings watches and necklaces become caught in rotating tools they can also conduct electricity and may cause a short circuit This could result in burns or damage to electrical circuits Disconnect the negative lead from the battery ...

Page 35: ... configuration it left Direct Fly S R O when it was first delivered and it may not cover modifications made to the aircraft subsequently Inspection Groups and Criteria Visual Inspection Visual inspections will normally apply to those areas surfaces and or items that become visible by the removal or opening of access doors panels fairings or cowlings Visual Inspection criteria will normally consist...

Page 36: ...nterval to the next condition inspection may not exceed twelve calendar months 2 3 PERIODIC INSPECTION TASKS If the aircraft is operated commercially for hire in the United States or other country following the same or similar regulation it must also have an inspection every 100 flight hours The 100 hour interval between inspections should never be exceeded by more than 10 hours and then only if a...

Page 37: ... pilot or higher Instructions Refer to Pilot s Operating Handbook section 4 Paragraph 4 1 Task proper accomplishment check None Post flight inspection is performed at the end of each flight day the post flight inspection events are the same as the preflight ones If possible failures damages and malfunctions should be recorded and repaired immediately It is recommended to clean and or wash the airp...

Page 38: ...odical Inspection Checklists are intended for copying and serve as the Maintenance Records It is also recommended to include small repairs damages and their remedy or replacement Some parts of the airplane engine propeller etc may have special time limits refer to the appropriate manuals for maintenance time limits and procedures ...

Page 39: ...ttachment bolts engine engine mounting engine mounting firewall 3 2 2 Visually check condition of rubber isolators replace those cracked and excessively deformed 3 3 Engine induction system 3 3 1 Check operation and condition of carburetor heat and induction air box 3 3 2 Visually check condition of induction tubing 3 3 3 Check carburetor condition control cables attachment lubricate cables and ca...

Page 40: ...eaks attachment and security replace damaged hoses 3 8 4 Check oil quantity add or change oil acc to the engine manual if needed 3 9 Exhaust system 3 9 1 Visually check exhaust system for condition cracks deformations or damage repair replace Check left front pipe clearance from radiator hose approx 0 8 in 20 mm 3 9 2 Visually check condition and attachment of the muffler repair replace as needed ...

Page 41: ...3 1 Visually check shock cord and suspension stop and flexible washer for deformation cracks excessive wear replace if needed 5 4 Tire 5 4 1 Check tires for condition cuts uneven or excessive wear and slippage replace if needed 5 4 2 Check tire pressure inflate to required pressure 5 5 Wheel 5 5 1 Visually check for cracks permanent deformations if damaged replace 5 5 2 Check valve condition aroun...

Page 42: ...t deformations replace wheel rim in case of cracks 6 4 2 Check valve condition around the hole in the disc 6 4 3 Check condition of bearings wheel free rotation play 6 5 Brakes 6 5 1 Check attachment of brake system plastic hoses to the main leg 6 5 2 Visually check condition of pads steady and symmetry abrasion of pads replace pads if needed 6 5 3 Check wear of the disc and overheating 6 5 4 Chec...

Page 43: ...bricating Chart 7 4 Pitot static tube 7 4 1 Check pitot static tube attachment 7 4 2 Check pitot static system for leaks the airplane manufacturer uses KPU 3 instrument 7 4 3 Check hoses under pitot static tube in bend 7 4 4 Check fall sensor of AOA system if installed 7 4 5 Check safety system of AOA system if installed 7 5 Wing suspensions 7 5 1 Remove wing fillets 7 5 2 Visually check condition...

Page 44: ... TAIL UNIT 9 1 Visually check condition For loose rivets deformation cracks deep scratches and any other damage ref maintenance manual or contact the manufacturer for instructions 9 2 Visually check condition and attachment of fiberglass tips 9 3 Check elevator free movement 9 4 Check elevator hinge 9 5 Check play move the stabilizer frontward rearward upward downward contact the airplane manufact...

Page 45: ...11 2 4 Visually check main landing gear legs attachment inside the fuselage 11 3 Safety harness 11 3 1 Visually check condition attachment and security 11 4 Hand control 11 4 1 Remove aileron rod covers inside the cockpit 11 4 2 Check hand control free movement 11 4 3 Check play 11 4 4 Check joints security 11 4 5 Check stops for condition 11 4 6 fuel lines for condition 11 4 7 Lubricate per Lubri...

Page 46: ...te lubricating per Lubricating Chart 11 8 Install seats upholstery and covers 11 9 Engine Test Run see FM idling throttle and choke levers operation acceleration deceleration r p m drop with either magneto switched off max r p m test brake system efficiency 11 10 Test flight as required for level of service check compliance with service directives for aircraft and installed components check all re...

Page 47: ...tructure consisting of reinforcements and duralumin skin Fuselage section is rectangular in the lower part and ecliptic in the upper part The fin is an integral part of fuselage The two place cockpit is located in the middle part of the fuselage that is accessible after forward opening sliding canopy The engine compartment in the front part of the fuselage is separated from the cockpit by the stai...

Page 48: ...ing assembly attached to a aluminum tube frame Rear side windows are made of plexi glass perspex The canopy is attached to the fuselage by two sliding rails allowing it to slide forward For ease of maintenance the canopy can be removed completely by depressing two locking pins on the forward section of the canopy rail The canopy is equipped with a latch on the upper rear section of the frame Figur...

Page 49: ... each equipped with four point seatbelts The waist belt is attached alongside the seat and shoulder belts behind the seats Baggage compartment The baggage compartment is situated behind the seats It is equipped with the net optional to prevent baggage movement Maximum baggage weight is stated on a placard located near the compartment Figure 3 6 Safety Seat Belts and Baggage Compartment 1 Outside l...

Page 50: ...or higher Aircraft owner only for ELSA Instructions Canopy Removal 2 people required 1 Slide the canopy forward 2 One person will press the black plastic lock located on the inner side of the canopy frame and the second will press the black plastic lock located on the inner side of the other side of the canopy Both people have to press the plastic lock at the same time which will allow the canopy ...

Page 51: ...ith suspended ailerons and wing flaps Riveting is used for connecting individual structural elements Fiber glass wing tips are riveted on the wing ends There is an integral fuel tank inside each wing in front of the main spar in the leading edge of the wing Ailerons The ailerons are of rectangular shape on each half of the wing and are attached to the wing with hinges An aileron is formed with the...

Page 52: ...pin When sliding the wings on the attachments take increased care so that damage to hoses of pitot static system left half of the wing and electric system cables cannot occur 4 Set the wing so that the attachments on the wing and on the fuselage are concentric 5 The person keeping the wing on the leading edge will insert the bolts into the upper main attachment the bolt head is in flight direction...

Page 53: ...e wing fairings 2 Drain all fuel from tanks Push airplane tail down almost to the ground to allow drainage of the unusable fuel 3 Prior to removal of the left wing disconnect the pitot static hoses 4 Disconnect fuel hoses from beaks on the fuselage 5 Disconnect cable plugs and sockets of electrical system 6 Disconnect aileron control pull rod 7 The first person will hold onto the wing tip the seco...

Page 54: ...n shape and formed with a duralumin cover and ribs The elevator is attached to the stabilizer with a hinge There is also a hinged trim tab on the left elevator Trim tab The left elevator is equipped with a servo controlled trim tab of rectangular shape The tab is formed with duralumin plate Vertical tail unit VTU The VTU consists of the fin and rudder The rudder is attached to the fin by two hinge...

Page 55: ...king nut 5 Connect trim tab wires 6 Adjust the elevator and trim tab deflections see 3 6 2 2 Task proper accomplishment check Check proper attachment of trim control wires Check HTU proper attachment and securing of all joints Check elevator and trim tab deflection 3 4 2 2 HTU From Fuselage Disassembly Tools needed Metric Wrench Parts needed None Type of maintenance Heavy Level of Certification ne...

Page 56: ...a safety pin 4 Attach the rudder control cables Tighten the castle nut and secure with safety pins Task proper accomplishment check Check rudder proper attachment and securing of all joints 3 4 2 3 Rudder Disassembly Tools needed Metric Wrench Parts needed None Type of maintenance Heavy Level of Certification needed Repairman LS M or Mechanic A P both with the minimum level of certification to per...

Page 57: ...s controlled by a hand lever in the central console between the seats The wheels can be covered with the fiberglass fairings wheel pants Nose wheel landing gear The steerable nose landing gear consists of a front landing gear leg a rubber bungee suspension unit and a suspension stop The nose leg is made of a steel tube attached to the firewall by two bearings The axle with wheel attached is connec...

Page 58: ...m composite fiberglass Figure 3 15 3 16 Auxiliary tail skid Wheel brakes Both wheels on the main landing gear are equipped with hydraulic disc brakes The brake system consists of the hydraulic master cylinder plastic hoses calipers with cylinder brake pads and the brake disc which is bolted onto the inner part of the rim Figure 3 17 The Aerospool brake on the wheel 1 Brake caliper with the hydraul...

Page 59: ...ke control The brakes on both wheels are controlled by a hand lever mounted on the central console between the seats Parking Brake function is available by locking the lever on the right side recess on the plate Figure 3 19 Brake Control 1 1 Brake Control Lever 2 Recess for the parking brake lock 2 ...

Page 60: ...2014 3 14 Wheels All the wheels consist of a two part casting rim with a tire and tube The main wheels are on an axle attached to the main gear leg fastened by the nuts Figure 3 20 Main Landing Gear Wheel Layout Figure 3 21 Nose Landing Gear Wheel Layout ...

Page 61: ... 2 1 Disassembly of main wheel pants Tools needed Metric Allen Wrenches Parts needed None Type of maintenance Line Level of Certification needed Aircraft owner only for ELSA Sport pilot or higher Instructions Main wheel pants are attached with 8 bolts to a bracket mounted on the main landing gear leg and with one bolt from outside to the wheel axle Figure 3 22 Wheel Pants Bracket 1 Remove 8 bolts ...

Page 62: ...ner side of the wheel pant shift the spacing tube on the bolt and screw the bolt into nut hole in the wheel center Secure the bolt head with locking wire in order to prevent from its turning Task proper accomplishment check Visually check that all inside bolts are inserted and secured properly Visually check if the outside bolt is secured by the locking wire 3 5 2 3 Disassembly of nose wheel pant ...

Page 63: ...3 Assembly of nose wheel pant Tools needed Screwdriver Metric Allen Wrench Parts needed Bolts and washers Type of maintenance Line Level of Certification needed Aircraft owner only for ELSA Sport pilot or higher Instructions 1 Assemble the bracket connected to the nose leg 2 Screw the bolt from the left side of the wheel axle 3 Screw the bolts of the side cover 4 Screw the bolt from the right side...

Page 64: ... tube into a tire and pump up slightly put easy powder on the tube and or in the tire Task proper accomplishment check none 3 5 2 5 Assembly of main landing gear wheel Tools needed Metric wrench Screwdriver Parts needed split pins self locking mats Type of maintenance Line Repairman LS M or Mechanic A P both with the minimum level of certification to perform heavy maintenance of SLSA in the U S FA...

Page 65: ...move the wheel and the distance ring from the axle 5 Take the brake disc off leave the brake on a main leg 6 Remove the cotter pins shift the pins out and remove the brake pads 7 Mount a new brake pad secure the pins with cotter pins diam 2mm length14mm part No 039 300 8 Put the brake disc on the wheel 9 Put the distance ring and the wheel on the axle adjust the distance ring between bearings 10 S...

Page 66: ...ccording to 1 6 4 2 Check maximum level of brake fluid 3 Push back repeatedly on the braking lever and setup the lever in parking position 4 Slowly open bleeding screw outgoing brake fluid with air bubbles put down in the plastic bottle 5 Tighten the screw 6 Repeat several times 2 5 7 close the central panel install parking T grip Task proper accomplishment check check braking function Figure 3 24...

Page 67: ...ontrol sticks have a common push down stop on the center section and each control stick has a pull up stop formed with a reinforcement riveted on the front edge of each seat The rods have adjustable ends and swivel bearings to adjust the elevator deflections Lateral control system The ailerons are controlled by control sticks with connecting rods and arms A control stick lateral motion is transfer...

Page 68: ...tached to the cockpit floor There are toe brake pedals on both the pilot and copilot side to operate the main wheel brakes The cables are connected to the hinges in the lower part of the rudder spar The cables are pre stressed by means of nose wheel control rods The rudder control is connected to the nose wheel landing gear to control the nose wheel by the adjustable rods Rudder stops are located ...

Page 69: ...AIRCRAFT MAINTENANCE MANUAL DFE AMM AR1 Rev 1 07 24 2014 3 23 Figure 3 27 Rudder stops on the nose wheel leg Figure 3 28 Longitudinal and directional control system layout ...

Page 70: ... of a rod behind the seats torsional tube Then to an angular displacement of a lever onto a tube connecting left and right flap Figure 3 29 Flap control system layout Elevator Trim tab control system description A electric elevator trim control is located between the seats Trim tab position indicator is displayed on the indicator on the panel A servo on the elevator is interconnected to the trim t...

Page 71: ...ptional The aircraft is equipped with steerable nose wheel landing gear The wheel control system is connected to the rudder pedals The nose wheel control system consists of the rods connecting pedals and a two armed lever welded to the nose landing gear leg Figure 3 32 Nose wheel control system layout ...

Page 72: ...Pos 30 o Neg 20 o Aileron Pos 28 o Neg 25 o Rudder Left 30 o Right 30 o Trim Tab Elevator Pos 15 o Neg 30 o Trim Tab Aileron Pos 25 o Neg 25 o Flap Position I 15 o Position II 25 o Position III 45 o Aileron deflection measurement 1 Attach a protractor with a deflection hand at the aileron upper surface by means of a clamp 2 Set the aileron in neutral position the aileron must fit the wing profile ...

Page 73: ...two nuts are riveted The strip should overhang the flap trailing edge 2 Attach a protractor with a deflection hand at the strip using a clamp 3 Zero the protractor this will be the starting position for measurement with the flaps retracted 4 Extend the flap to the required position using the flap control lever and read the deflection 5 Compare the measured deflections with those specified in the C...

Page 74: ...t the airplane under the tail skid and firewall and set the airplane in a horizontal position a level set on the canopy lower frame can be used to set the airplane in horizontal position 2 Stand a suitable staff close to the elevator trailing edge and mark the neutral position of the elevator 3 Move the control stick and fully deflect the elevator Mark the positions of the elevator while fully def...

Page 75: ...e trim tab to the maximum both directions using the trim tab control lever and trace the profile again 4 Remove the cardboard and measure the deflection from the neutral position using a protractor 5 Compare the deflection with that specified in the Control Surfaces Deflection Requirements If required adjust trim tab deflections Task proper accomplishment check None 3 6 2 2 Control surfaces deflec...

Page 76: ...just the flaps in the position RETRACTED or you can use eccentric pin to set retracted position see figure 3 29 The deflection of the left flap against the right flap may be adjusted when the eccentric pin is moved a slight amount The pin is inserted into the groove of the flap root Elevator deflection adjustment The range of elevator deflection is determined by the control stick stops setting The...

Page 77: ...dals 2 Adjust the nose wheel control using the adjustable rod ends Task proper accomplishment check Check straight taxiing at idle with rudder pedals neutralized 3 6 2 4 Rubber shock absorber replacement Tools needed Metric Wrenches Parts needed New rubber shock absorber cotter pins Type of maintenance Line Level of Certification needed Repairman LS M or Mechanic A P both with the minimum level of...

Page 78: ... HOLLOW PIN COTTER PIN 2 5 x 25 ČSN 02 1781 05 D SUSPENSION STOP NOSE WHEEL LEG RUBBER ROPE FUSELAGE FRAME SYSTEM 1 D Figure 3 33 Rubber shock absorber Task proper accomplishment check Check function of nose wheel shock absorbing Check for proper installation of cotter pins ...

Page 79: ...nce control and Excessive Play Correction Tools needed Dial Indicator Parts needed swivel bearing pins if replacement is necessary to be consulted with aircraft manufacturer Type of maintenance Preventive maintenance Clearance control Line Excessive Play Correction Level of Certification needed Preventive maintenance Clearance control Aircraft owner only for ELSA Sport pilot or higher Level of Cer...

Page 80: ... Move the wing tip and note play in wing suspensions play is measured on the wing tip Check wing suspensions replace pins 0 08 in 2 mm 0 16 in 4 mm HTU attachment Move the stabilizer tip control rearward Replace bearings in suspension points and bearings in control system Check nuts tightening and add distance washers respectively 0 0 08 in 2 mm Rudder hinges Lift the rudder Change swivel bearing ...

Page 81: ...ed in ASTM F2483 Sections 7 through 9 that are not covered by this Maintenance Manual 4 2 ENGINE 4 2 1 Description The Rotax 912 ULS installed on Alto is a 4 stroke 4 cylinder horizontally opposed spark ignition engine and has one central camshaft push rods OHV liquid cooled cylinder heads ram air cooled cylinders dry sump forced lubrication and dual breaker less capacitor discharge ignition The e...

Page 82: ...lubrication system Cooling system description The cooling system uses two forms of cooling The cylinder heads are liquid cooled and the cylinders are ram air cooled The radiator is located in the front of the lower engine cowling The coolant is forced through the radiator by a water pump driven from the crankshaft to the cylinder heads From the top of the cylinder heads the coolant passes on to th...

Page 83: ...ottom of the engine from oil tank is properly connected 4 2 2 3 Oil Filter Replacement Tools needed Phillips Screwdriver Metric Wrenches Parts needed Oil Filter Type of maintenance Line Level of Certification needed Repairman LS M or Mechanic A P both with the minimum level of certification to perform heavy maintenance of SLSA in the U S FAA approved Part 145 Repair station Instructions Remove eng...

Page 84: ...ith the minimum level of certification to perform heavy maintenance of SLSA in the U S FAA approved Part 145 Repair station Instructions 1 Remove upper engine cowling 2 Place suitable container under the engine 3 Check coolant quantity and fill some amount if needed 4 Disconnect the hose going from the radiator into the pump on the lowest part of the cooling system 5 Empty coolant into a container...

Page 85: ...escription The engine mounting bed is welded from chrome molybdenum tubing and is attached to the firewall with 4 bolts The bed is spring mounted with four rubber vibration isolators Figure 4 2 Engine Bed 1 bed 2 rubber vibration isolators Figure 4 3 Rubber vibration isolators details ...

Page 86: ... Level of Certification needed Aircraft owner only for ELSA Sport pilot or higher Instructions UPPER COWLING The disassembly and assembly are both easy just release the quick closing locks The upper cowling is usually removed during engine pre flight inspection to check the engine compartment operating fluids quantity oil coolant and to check the engine installation LOWER COWLING To remove it unsc...

Page 87: ...d by Direct Fly S R O or only as provided by Direct Fly s approved engineering data 5 1 1 Description Each wing contains an integral fuel tank with a capacity of approximately 46 liters 12 1 U S gallons volume Each tank is fitted with an air vent output is under the wing and a drain valve on the bottom side of the wing Fuel flow from the tanks through the hoses to the fuel selector located on a ce...

Page 88: ...AIRCRAFT MAINTENANCE MANUAL DFE AMM AR1 Rev 1 07 24 2014 5 2 Figure 5 2 Fuel system scheme ...

Page 89: ... higher Instructions 1 Put the sump fuel tester or a transparent cup under the drain valve 2 Push open the drain valve 3 Drain required quantity of fuel 4 Release the drain valve and visually check that there is no fuel leaking for the valve 5 Repeat procedure for the opposite tank Figure 5 3 Fuel drain valve Task proper accomplishment check Visually check that the valve is closed and there is no ...

Page 90: ...n Instructions 1 Put the fuel container under the drain valve 2 Open fuel tank cap to speed up draining 3 Using the wrench remove the drain valve 4 Drain the fuel If it is necessary to drain all fuel push airplane tail down almost to the ground to allow draining all of the unusable fuel 5 Reinstall the drain valve 6 Close fuel tank cap 7 Repeat procedure for the opposite tank Task proper accomplis...

Page 91: ...raft propeller Any heavy maintenance major repairs or major alterations as outlined in ASTM F2483 Sections 7 through 9 can only be performed by Direct Fly S R O or only as provided by Direct Fly s approved engineering data 6 2 PROPELLER 6 2 1 Description Manufacturer Woodcomp S R O Model Propuls 174 3 R Type Composite Number of blades 3 Diameter 1740 mm 69 in Pitch Ground Adjustable Max RPM 2600 F...

Page 92: ...authorized at this time for this ALTO aircraft utilities systems Any heavy maintenance major repairs or major alterations as outlined in ASTM F2483 Sections 7 through 9 can only be performed by Direct Fly S R O or only as provided by Direct Fly s approved engineering data 7 2 HEATING 7 2 1 Description A cockpit heating system is standard An air duct collects air from behind the water radiator via ...

Page 93: ...ertification to perform heavy maintenance of SLSA in the U S FAA approved Part 145 Repair station Instructions 1 Remove the engine cowlings release hoses complexes dismantle clamps 2 Change hoses for new ones install strip clamps 3 Attach hoses 4 Install the engine cowlings Task proper accomplishment check Verify if all the clamps are firmly locked to the hoses 7 3 VENTILATION SYSTEM 7 3 1 Descrip...

Page 94: ...enance Line Level of Certification needed Repairman LS M or Mechanic A P both with the minimum level of certification to perform heavy maintenance of SLSA in the U S FAA approved Part 145 Repair station Instructions 1 unscrew screws from plexi take out the rails and window 2 insert the window insert rails 3 screw up the screws highly sensitive tighten a screw without power Task proper accomplishme...

Page 95: ...are authorized at this time for this ALTO aircraft instruments and avionics Any heavy maintenance major repairs or major alterations as outlined in ASTM F2483 Sections 7 through 9 can only be performed by Direct Fly S R O or only as provided by Direct Fly s approved engineering data 8 2 INSTRUMENTS AND AVIONICS 8 2 1 Description The aircraft is equipped with an instrument panel containing flight n...

Page 96: ...s needed Instrument to be replaced or installed for other parts refer to manuals supplied with particular instruments Type of maintenance Line Level of Certification needed Aircraft owner only for ELSA Sport pilot or higher Instructions 1 Dismantle the plexi canopy Remove the top plate of the instrument panel to access the back part of the instruments 2 The installation procedure will depend on th...

Page 97: ...plate of the instrument panel to access the back part of the instruments 2 The installation procedure will depend on the instrument being installed Follow the manufacturer recommendations manuals supplied with particular instruments Task proper accomplishment check Refer to manuals supplied with particular instruments ...

Page 98: ... 2 1 Description The electric system is a single wire type with the negative side connected to the chassis The power source is a single phase generator integral to the engine A 12V 7Ah maintenance free battery is located on the firewall The electrical system is controlled protected by electric circuit breakers E T A installed on the instrument panel The dual engine ignition is a separate part of t...

Page 99: ...AIRCRAFT MAINTENANCE MANUAL DFE AMM AR1 Rev 1 07 24 2014 9 2 Figure 1 Wiring dagram for the standard installation ...

Page 100: ...nections Misalignment of electrically driven equipment Poor electrical bonding broken disconnected or corroded bonding strap and grounding including evidence of corrosion Dirty equipment and connections Improper broken inadequately supported wiring and conduit loose connections of terminals and loose ferrules Poor mechanical or cold solder joints Condition of circuit breaker and fuses Insufficient...

Page 101: ...nt such as motors inverters generators batteries lights protective devices etc 9 2 2 3 Battery electrolyte corrosion cleaning only for NON maintenance free accumulators Tools needed Screwdriver metric wrenches Parts needed Brush sodium bicarbonate solution Type of maintenance Line Level of Certification needed Repairman LS M or Mechanic A P both with the minimum level of certification to perform h...

Page 102: ...med by Direct Fly S R O or only as provided by Direct Fly s approved engineering data 10 2 DESCRIPTION 10 2 1 Repair classification Major repair alteration or maintenance Any repair alteration or maintenance for which instructions to complete the task are excluded from the maintenance manual s supplied to the consumer are considered major Minor repair alteration or maintenance Any repair alteratio...

Page 103: ...ed by a stiffener or a patch from one side of a repaired area to another In some cases the load transmission should be carried out at another structural member and then back to an undamaged part of the original structure 3 The length of overlapping between a reinforcement stiffener or patch and the undamaged part of the original structure should be enough to assure a good joint The length of overl...

Page 104: ... S A Alclad 2024 Germany DIN 1745 Russia D16AT 10 2 4 2 Materials Thickness 0 032 in 0 8 mm Skin on forward part of fuselage 0 040 in 1 0 mm Other small parts 0 050 in 1 2 mm Wing Spar 0 063 in 1 6 mm Center Section Spar 0 080 in 2 0 mm Control Sticks 0 125 in 3 2 mm Wing Spar 0 250 in 3 2 mm Wing Spar 0 320 in 8 0 mm Center Section Spar 10 2 5 Spare parts order Use the form on Section 13 to order...

Page 105: ...ertification to perform heavy maintenance of SLSA in the U S FAA approved Part 145 Repair station Instructions 1 To prevent small cracks max 0 2 in 5 mm from spreading drill a hole of 0 06 in 1 5 mm diameter at the end of the crack 2 Small holes up to Ø 0 16 in 4 mm can be repaired by a POP rivets More extensive skin damage is repaired by means of a patch Per standard repair procedures Ref AC 43 1...

Page 106: ... up shortly the sealed joint using hot air gun 356 392 F 180 200 C to make it easier to cut In the following table lists the pop rivets and characteristics AVEX Pop rivets supplied by AVDEL Company 1 material Al Mg 2 5 2 Shank material steel zinc chromate coating surface Rivet No Diameter Length Hole diameter Max riveting thickness Head in mm in mm in mm in mm 1691 0410 1691 0414 1691 0512 1691 05...

Page 107: ...res are prepared in a given mass ratio by means of weighing accuracy of scales 1g 10 3 2 2 Parts of external appearance 10 3 2 2 1 Small Damage Tools needed sand paper scissors Parts needed epoxy resin drills fiberglass cloth degreasing agent Type of maintenance Line Level of Certification needed Repairman LS M or Mechanic A P both with the minimum level of certification to perform heavy maintenan...

Page 108: ...name Type Mixing ration Dwelling Rate of setting Time of setting Temperature Fillers HUNTSMAN VANTICO Araldite 2011 AW106 HV953U epoxy A B 100 80 to be processed within 100min for 0 1 kg mixture 40 24 hours 32hrs 20 35 C 17 20 C thickening Aerosil micro balls Grinding Grinding or eventually sealing the surface is made after setting the mixture and possible tearing off the used folia It is suitable...

Page 109: ...n for every damaged stiffener layer smoothly up to the top layer and then about 50 mm 2 in for finishing and mastic application It is convenient to do grinding with grinding material having grain size of 160 It is carried out by dry grinding equipment with suction from grinding area Al203 Aluminum Oxide Power fused corundum can be used as grinding material In case of Carbon Kevlar stiffener Kevlar...

Page 110: ... the grinding area Al2O3 can be used as grinding material It is important not to diminish basic material of the part at grinding Especially in case of Carbon Kevlar stiffener in the basic part there must not be any grinding through up to the stiffener complication see the note about preparatory grinding Finishing See Section 11 Painting and Coatings Task proper accomplishment check Visual check 10...

Page 111: ...rohibited to smoke and anyway handle with free fire in a working area use protective working means such as goggles gloves respirator etc 11 2 2 Recommendation for paint repairs By applying paints weight of airplane is increased and center of gravity position is changed Increase in weight depends on type of coat and its thickness 11 2 2 1 Washing and degreasing It is possible to use both organic so...

Page 112: ...red imperfect elimination of water results in wrong adhesion of paint coats imperfect degreasing of fiberglass parts not possible to use Use for Al alloys surfaces and plastics 11 2 2 2 Bonding rivet heads big irregularities and material transitions In case that airplane surface remains without top coat carry out just rivet head bonding After perfect degreasing carry out bonding of rivet heads big...

Page 113: ... the type air pressure jet diameter Primer should be applied in several sprayings total thickness is not reached at a blow with defined maximum dwell and total drying time till further treatment or handling Primer serves especially for anchoring adhesion to the substrate the top coats and can serve also for eliminating irregularities of the surface function of filler for grinding For surfaces from...

Page 114: ...hesiveness to the used base coat according to manufacturer It is possible to use some of the coat systems for car repairs In our recommendation see the table below there are two types of colors single coat color shade and protection in one double coat one component color shade is formed by the substrate and protection is ensured by two component transparent top coat By single coat paint coat it is...

Page 115: ...er blended In the case that it is not possible to choose the area in this way it is necessary to take into consideration the higher difficulty of the procedure as for the uniformity of shade and elaboration of coat transition Tools needed abrasive coated paper Parts needed materials for primer and for top coat Type of maintenance Line Level of Certification needed Repairman LS M or Mechanic A P bo...

Page 116: ...e primer was not removed by the previous step it is not necessary to apply the primer again The original ground primer with adhesive intercoat is enough Actual application of primer will be carried out in the same way as for the total spray coat see paragraph 11 2 2 3 4 Application of Top Coat For repairing it is necessary to choose the identical type single coat double coat of the repair color as...

Page 117: ...new pages This Section will also be revised in all revisions of this Aircraft Maintenance Manual 12 2 REVISION NOTES Rev No Section Pages Date of Issue Bulletin No Description 0 All All 09 26 2010 Initial Issue 1 All All 07 24 2014 a Layout revised per ASTM F2483 12 b Publication number is now using the Direct Fly Erres Industria Aeronautica pattern c Revised to comply with the Brazilian version o...

Page 118: ...AIRCRAFT MAINTENANCE MANUAL DFE AMM AR1 Rev 1 07 24 2014 12 2 12 3 LIST OF EFFECTIVE PAGES Sec Page Date Sec Page Date Sec Page Date Sec Page Date All all 07 24 2014 ...

Page 119: ...3 1 GENERAL The owner operator of a LSA is responsible for notifying the manufacturer of any safety of flight issue or significant service difficulty upon discovery The following form may be used sent to Direct Fly S R O by email or fax to the addresses listed on Paragraph 0 1 of Section 0 ...

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