FLY SYNTHESIS STORCH HS-CL

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FLY SYNTHESIS STORCH HS-CL

MAINTENANCE MANUAL

(VALID FOR ROTAX 912 UL AND JABIRU 2200 ENGINES)

00 28/05/07 New manual issue M. Fiorindo M. Fiorindo C. Pinzana Num. Date Description Issued Verify Approvation

REVISION

The FlySynthesis s.r.l. it reserves him to terms of law the exclusive ownership of the present and it also forbids the partial reproduction of it.

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SCOPE

This manual contains the necessary information for safe and efficient Maintenance of the FLYSYNTHESIS STORCH HS and CL versions.

NOTE

This manual may be revised in the future and pages/or sections re-issued in part or whole.

Revisions will be available on the Fly Synthesis website www.flysynthesis.com. Any revisions and/or sections should be printed and replaced in the manual at the earliest possible time for flight safety. The revisions added to the manual should be logged and recorded in the table under log of Revisions of this manual, by the owner/user.

LOG OF REVISION

Revision number Revision Date Signature

INTELLECTUAL PROPERTY

The data and information contained in this document is the property of FLYSYNTHESIS SRL.

This document may not be reproduced or transmitted to a third party, in any form or by any means. Any unauthorised copy or distribution is illegal as per international agreements relating to property rights.

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LOG OF EFFECTIVE PAGES

Section Page Date Revision Section Page Date Revision

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INDEX

Title Page

LOG OF REVISION 2

LOG OF EFFECTIVE PAGES 3

1.1 PRE-FLIGHT INSPECTION 5

1.2 DAILY INSPECTION 5

25 HOURS INSPECTION 7

2 MAINTENANCE PER PERIOD OF TIME 24

3 UNSCHEDULED MAINTENANCE 24

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1.1 PRE-FLIGHT INSPECTION

Refer to related paragraph of Flight Manual - last issue.

1.2 DAILY INSPECTION

Accomplish a complete Pre-Flight Inspection and the following additional operations:

1. Ensure that the ignition key is REMOVED.

2. Remove the upper and lower engine cowlings.

3. Drain the fuel tanks as written in Flight Manual.

4. Inspect the carburettor rubber socket or rubber -flange for damage and security of attachment.

5. Remove the floating chamber from the carburettor and inspect for cleanliness and absence of water.

6. Verify the air filter for security of attachment.

7. Inspect the ignition cable terminals for security of connections to spark plugs.Inspect. all other electrical connections for security.

8. Verify the electrical starter for security of attachment.

9. Verify the battery for security of attachment.

10. Inspect the rubber shock absorbers and of engine mount for condition.

11. Verify the fuel pump, the fuel filter and relevant hoses for security of attachment and fuel

12. Verify the attaching bolts of drive reduction unit supporting plate for tightening.

13. Turn the propeller by hand and inspect for abnormal noise.

14. Verify engine control cables for security.

15. Check tires pressure for proper- inflation:

a. Main wheels 2.2 - 2.4 bar b. Nose wheel 0.8 bar

For aircraft equipped with ROTAX 912 UL engine:

In addition to inspections/checks listed in the previous item (1) through (15), accomplish the following additional operations:

1. Verify the oil and water radiator mounting -For security. Inspect the radiator for damage and leaks. Check the coolant level and security of filling cap.

2. Inspect the coolant hoses for security, leaks and chafing.

3. Inspect the cylinder heads cylinders and water pump for leaks.

4. Verify the lubrication oil content and security of filling cap.

5. Inspect the oil hoses relevant to gear lubrication and oil injection systems for security, leaks and chafing.

6. Verify drain and oil level plugs.

7. By pushing and pulling the engine shaft along its axis, check the bearings for abnormal play.

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25 HOURS INSPECTION

Legenda: V = only a visual check, C = complete check, necessary tools General

Ensure that ignition key is REMOVED V

Open all inspection opening in the fuselage and wings. V

Remove Engine cowling. V

Inspect wings and flight surface condition for defect, to become crooked. And another sign of defect.

V Inspect in the Tail all flight surface condition for defect, to become crooked. And another sign of defect.

V Inspect fuselage for condition and other sing of defect. V Lubricant all movable part and hinges. V Propeller

Inspect the prop blade for crack, stone blow and other defect, small defect smooth with fine glass paper and apply lack.

V

Check prop. Bolts tight. Torque 18 Nm V - C Tail & flight surface

Check all flight control surface for condition and smooth movement and play.

V Check all self-locking nut for condition and security. V Inspect the push-pull control cables and trim control cable for general condition and in particular for cleaning and attachments security.

V

Check tightening of self-locking nuts attaching the push- pull Control cable to the rudder and stabilator (elevator)

V Check all nuts attaching the rudder and stabilator to hinge V Check anti-tab tab tension/regulator device and operation rod abnormal play. All the self-locking nuts.

V Fusolage

Check all the airframe condition look for defect, if is not become crooked, and other sign of defect. Loose bolt and rivet.

V

Check antenna attachment, check for crack. and loose bolt, and antenna condition

V Check self-locking nuts and wing attachment to the

airframe. Check self-locking nuts and struts to the airframe, V Check the main landing gear struts attachment to lower

frame and bolt securing.

V Check all windows for condition and loss rivet. V Check nose landing gear attachment and bolt secreting. V Check door condition and lock operation. V Cockpit

Remove seats. V

Check all fuel line and valve for leak and wear and secure. V

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Check fuel filter if necessary replace cartridge. Check pipes and band for Security. Check all line attachment to the frame.

V

Check hydraulic brake line and brake actuator. V Using a flashlight and mirror carefully inspect the flight

linkages located behind the fuselage main frame (just behind seats) and under the cabin floor. Ensuring that all self-locking nuts are securely tightened.

V

Check tightened of Self-locking nuts securing the stabilator pivot plates supporting

V Check tightened of pedals hinge bolts and retaining screw. V - C Check Engine control cable, and Engine control liver. V Check all electric wire. And electric component, for

security. And condition.

V Check the electrolyte level in the battery. Battery stand and cleans. Look for evident of electrolyte leak. Check battery attachment. Battery cable.

V

Inspect pilot harness. And floor cleanliness. V Check instrument panel security. All the instruments

connection, static and dynamic line.

V - C Check radio and navigation instrument, and antenna line. V

Reassembly seat. V

Wings

Inspect wings and flight surface condition for defect, for

deformation, or other sign of defect V

Check for loose rivets. In upper and lower surface, check

wings tip. V

Check tightening of self-locking nuts securing wings brace

struts. Tank venting tube and pitot tube, V - C Check tank outlet for security and leak. Check the tube. V Check tightening of self-locking nuts securing the aileron

and flap Control linkages. V - C

Check tightening of self-locking nuts securing the aileron

and flap hinge pins. V

Check freedom of movement for aileron and flap. V Landing Gear

Check the shock strut piston for abnormally vowel: both transversal and longitudinal ply. Should be 2 - 3 mm max.

Check for no tensional play between pedals and nose wheel.

V Check wheel and tire for condition. Check air pressure.

Check tightening all self-locking nuts securing. V - C Check main landing gear RH and LH struts connection for

security. Check hydraulic line condition, and attachment to struts.

V - C Check brake disc connection, and security. Check wheel V

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and tire condition. Check air pressure. Check self-locking nuts for tightening

Engine

All Engine maintenance is according to ROTAX maintenance manual, used free lead fuel only. All maintenance preformed according to that manual.

Any other operation that is not mentioned in that manual well be according to that.

Check all the fuel line. To condition, and attachment for

security. V

Check the fuel pump be sure filter is clean. V Check Engine control cables for proper tension and

interference with other equipments: Clean and lubricate as necessary: on the carburetor: verify the rpm and choke operating levers for freedom of movement.

V

Check the carburetor for cleaning and proper adjustment accordingly with engine operator's manual-last issue. Check air filter.

V Check for proper torque the self-locking nuts and securing

the engine to its housing and to the engine mount respectively. Nuts (3) 8Nm Nuts (8) 22Nm

V - C Check for proper torque the self-locking nuts securing the

engine mount to fuselage. Torque load required 10Nm V - C Check for proper torque the self-locking nuts securing the

shock absorbers to the engine mount. V - C

- Check the shock absorbers of the 5^th point, if they have loosened,

- Screw the nut (on the side of shock absorber loosened) until the shock absorber and the washer will be in contact and they can’t relatively rotate,

- Screw the nut for 360° with the key.

V - C

Check the nuts securing the exhaust pipe to cylinder. V Check all exhaust system for gas leaks cracks. And

serviceability of retaining spring and rubber buffers. V Check security of oil tank attachment to the frame and

mount. Exhaust muffler oil radiator and cooling radiator to mounting.

V Check all oil pipe and cooling pipe and clamps for security

and condition. V

Check all the electrical system and wire in the engine

compartment. V

Check cooling liquid and oil level. V

Check engine for evident of leaks. V

Check engine cowling for Proper condition. V Check all fuel and oil hose connection for security. V

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Check all cooling hose and expansion tank for security V Check all components attacking to fire wall for security. V

Check operation of cockpit ventilation. V

Check all instrument attachment to Engine pick-up for

proper condition. V

Check all electric harness for proper condition. V

Assembly Engine cowling. V - C

Finishing

Closed all inspection opening in the fuselage and wings. V Check if all the tools are removed from airplane. V

Check if all system, operate properly. V

Run the engine. V

Signed and fill all the documents. V

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100 HOURS INSPECTION

Inspect wings and flight surface condition for defect, to

become crooked. And other sign of defect. V The max play in flight moving flight control surface is 0.6

mm V

Check all rivets for detect loose rivets. Any loose rivet shell

be replace with oversize rivet. V

Any crack must be stop by drilling small hole in the edge. V Inspect in the Tail. All flight surface condition for defect,

To become crooked. And another sign of defect. V Inspect fuselage for condition and other sing of defect. V

Lubricate all movable part and hinges. V

Propeller

Inspect the prop blade for crack, stone blow and other Defect, small defect smooth with fine glass paper and Apply lack.

V

Check prop. Bolts tight. Torque 18 Nm V – C

Tail & flight surfaces

Check all flight control surface for condition and smooth

Movement and play. V

Check all self-locking nut for condition and security. V Inspect the push-pull control cables and trim control cable

For general condition and in particular for cleaning and Attachments security.

V Pull Control cable to the rudder and stabilator (elevator) V Check all nuts securing the rudder and stabilator to hinge,

And to hinges supporting plates. V

Check anti-tab tab tension/regulator device and operation

rod abnormal play. All the self-locking nuts. V Check control surface angles (rudder elevator and trim) V Fuselage

Check all the airframe condition look for defect, if is not Become crooked, and other sign of defect. Loose bolt and Rivet.

V Check antenna attachment, check for crack. And loose bolt,

and antenna condition. V

Check self-locking nuts and wing attachment to the

airframe. Check self-locking nuts and struts to the airframe V Check the main landing gear struts attachment to lower

Frame and bolt securing. V

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Check all windows for condition and loss rivet. V Check nose landing gear attachment and bolt secreting. V

Check door condition and lock operation. V

Cockpit

Remove seats. V

Check all control cables and check for wear and Broken

wires: check terminals for security. V

Carefully inspect all handles for cleanliness, damage wear

(abnormal play) and security of attachment. V Check all fuel line and valve for leak and wear and secure. V Replace fuel filter, replace cartridge. Check Pipes and band

for Security. Check all line attachment to the frame. V - C Check hydraulic brake line and brake actuator. V Using a flashlight and mirror carefully inspect the flight

Linkages located behind the fuselage main frame (just Behind seats) and under the cabin floor. Ensuring that all Self-locking nuts are securely tightened.

V

Thoroughly clean the control stick and examine the

assembly for damage and wear. Verify that all components are secured and the articulation movements are smooth.

Lightly lubricate all moving parts and rod end bearings without rubber protection

V

Check tightened of Self-locking nuts securing the Stabilator

pivot plates supporting V

Check tightened of pedals hinge bolts and retaining screw. V Check Engine control cable, and Engine control liver. V Check tightening of pedals hinge bolts and retaining

Screws. V

Check all electric wire. And electric component, for

Security. And condition. V

Check the electrolyte level in the battery. Battery stand And cleans. Look for evident of electrolyte leak. Check Battery attachment. Battery cable.

V Inspect pilot set belts. Check tightening of self-locking Nuts

securing the set belts. And floor cleanliness. V Check instrument panel security. All the instruments

Connection, static and dynamic line. V

Check radio and navigation instrument, and antenna line. V

Replace seat. V

Wings

Deformation, or other sign of defect. V

Wings tip. V

Check tightening of self-locking nuts securing wings Brace V

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struts. Tank venting tube and pitot tube,

Check tank outlet for security and leak. Check the tube. V Check tightening of self-locking nuts securing the aileron

And flap Control linkages. V

And flap hinge pins. V

Check aileron and flaps angles. V

Check main and nose wheel for freedom of rotation. Ensure

that bearings are not noisy and without abnormal play. V Check the oil level in the hydraulic shock strut of nose

landing gear. V

Check wheel alignment. V

Check the hydraulic shock strut function. By pressing the

nose down and release. V

Check the shock strut piston for abnormally vowel: both Transversal and longitudinal ply. Should be 2 - 3 mm max.

Check for no tensional play between pedals and nose wheel.

V Check wheel and tire for condition. Check air pressure. V Check tightening all self-locking nuts securing. V Check main landing gear RH and LH struts connection for

Security. Check hydraulic line condition, and attachment to Support the fuselage

V Remove the main landing gear wheel and check the brake

Linings for wear ore stiffness. Replace if necessary.

Renewed the oil. Reassembly the wheels.

V

Check security of bolts. V

Engine

All Engine maintenance is according to ROTAX V Check all the fuel line for wear and stiffness. And check all

attachment for Security. V

Check the fuel pump be sure filter is clean. V - C Check Engine control cables for proper tension and

Interference with other equipments: Clean and lubricate As necessary: On the carburetor: verify the RPM and CHOKE operating levers for freedom of movement.

V

Check the carburetor for cleaning and proper adjustment

Accordingly with Engine operator's manual-last issue. V - C

Replace or clean the air filter. V - C

Replace carburetor mounting flanges. V - C Using a 10X magnifying glass inspect all welding of Engine

mount for cracks. V

Check for proper torque the self-locking nuts and Securing

the engine to its housing and to the engine V - C

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Mount respectively. Nuts (3) 8Nm Nuts (8) 22Nm V - C Check for proper torque the self-locking nuts securing the

Engine mount to fuselage. Torque load required 10Nm V - C Check for proper torque the self-locking nuts securing the

Shock absorbers to the engine mount. V - C

- Check the shock absorbers of the 5^th point, if they have loosened,

- Screw the nut (on the side of shock absorber loosened) until the shock absorber and the washer will be in contact and they can’t relatively rotate,

- Screw the nut for 360° with the key.

V - C

Serviceability of retaining spring and rubber buffers. V Replace exhaust system-retaining springs (28) V

Replace the 3 ea. Muffler buffers. V

Check security of oil tank attachment to the frame and Mount. Exhaust muffler oil radiator and cooling radiator to mounting

V Check all oil pipes and cooling pipe for wear and stiffness V Check clamps for security and condition. Change coding

fluid V

Check all the electrical system and wire in the engine

compartment. V

Check cooling liquid and oil level. V

Check engine cowling for proper condition. V Check all fuel and oil hose connection for security. V Check all cooling hose and expansion tank for security V Check all components attacking to fire wall for security. V Engine Check operation of cockpit ventilation. V Check all instrument attachment to Engine pick-up for

proper condition. V

Assembly Engine cowling. V

Finishing

Run the engine. V

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200 HOURS INSPECTION

Check all push-pull control cables and replace if necessary.

V

Check all flexible control cables and replace if necessary. V Inspect wings and flight surface condition for defect, To

become crooked. and other sign of defect V The max play in flight moving flight control surface is0.6

mm V

Check all rivets for detect loose rivets. Any loose rivet shell

be replace with oversize rivet V

To become crooked and other sign of defect V Inspect fuselage for condition and other sing of defect. V

Propeller

Inspect the prop blade for crack, stone blow and other Defect, small defect smooth with fine glass paper and Apply lack

V

Check prop. Bolts tight. Torque 18 Nm V - C

Tail and flight surfaces

For general condition and in particular for cleaning and Attachments security

V Check tightening of self-locking nuts attaching the push-

Pull Control cable to the rudder and stabilator (elevator) V Check all nuts securing the rudder and stabilator to hinge,

Rod abnormal play. All the self-locking nuts. V Check control surface angles (rudder elevator and trim). V Fuselage

Check all the airframe condition look for defect, if is not Become crooked, and other sign of defect. Loose bolt and Rivet.

V Check antenna attachment, check for crack. And loose Bolt,

and antenna condition. V

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Check self-locking nuts and wing attachment to the Airframe. Check self-locking nuts and struts to the Airframe,

V Check the main landing gear struts attachment to lower

Check all windows for condition and loss rivet. V Check nose landing gear attachment and bolt secreting. V

Check door condition and lock operation. V

Cockpit

Remove seats. V

for Security. Check all line attachment to the frame. V - C Check hydraulic brake line and brake actuator. V Using a flashlight and mirror carefully inspect the flight

V

Thoroughly clean the control stick and examine the

assembly for damage and wear. Verify that all components are secured and the articulation movements are smooth.

V

Check tightened of Self-locking nuts securing the Stabilator

pivot plates supporting V

Screws. V

Check the electrolyte level in the battery. Battery stands And cleans. Look for evident of electrolyte leak. Check Battery attachment. Battery cable.

V Inspect pilot set belts. Check tightening of self-locking Nuts

securing the set belts. And floor cleanliness. V Check instrument panel security. All the instruments

Connection, static and dynamic line. V

Replace seat. V

Wings

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Deformation. Or other sign of defect V

Wings tip. V

Check tightening of self-locking nuts securing wings Brace

struts. Tank venting tube and pitot tube, V Check tank outlet for security and leak. Check the tube. V Check tightening of self-locking nuts securing the aileron

Check freedom of movement for aileron and flap. V Inspect wings and flight surface condition for defect, for

Deformation. Or other sign of defect V

Landing gear

Ensure that bearings are not noisy and without abnormal

Play. V

Check the oil level in the hydraulic shock strut of nose

Landing gear. V

Remove the upper screw located in the strut. The oil must

fill the treaded hole of upper screw Reinstall upper screw. V

Check wheel alignment. V

Check the hydraulic shock strut function. By pressing The

Check the shock strut piston for abnormally vowel: both Transversal and longitudinal ply. Should be 2 - 3 mm Max.

Check for no tensional play between pedals and Nose wheel. Reinstall the main landing gear struts and check the self- Locking nuts for tightening.

V

Check wheel and tire for condition. Check air pressure. V Check tightening all self-locking nuts securing. V Check main landing gear RH and LH struts connection for

Security. Check hydraulic line condition, and attachment to Struts.

V Engine

All Engine maintenance is according to ROTAX

Maintenance manual 899 372, Section. 50-20-00 Used free lead fuel only. All maintenance preformed According to that manual. Any other operation that is not mentioned in that manual Will be according to that.

V - C

Check the fuel pump be sure filter is clean. V Check Engine control cables for proper tension and

Interference with other equipments: Clean and lubricate V As necessary: On the carburettor: verify the RPM and V

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CHOKE operating levers for freedom of movement.

Check the carburettor for cleaning and proper adjustment V - C Accordingly with Engine operator's manual-last issue.

Replace or clean the air filter. V – C

Replace carburettor mounting flanges. V – C

Using a 10X magnifying glass inspect all welding of Engine

mount for cracks. V

Check for proper torque the self-locking nuts and Securing the engine to it's housing and to the engine Mount

respectively. Nut (3) 8Nm Nut (8) 22Nm

V – C Check for proper torque the self-locking nuts securing the

Engine mount to fuselage. Torque load required 10Nm V – C Check for proper torque the self-locking nuts securing the

Shock absorbers to the engine mount. V – C

Check security of oil tank attachment to the frame and Mount. Exhaust muffler oil radiator and cooling radiator To mounting.

V Replace all oil pipes and cooling pipes, check clamps for

Security and condition. Change cologne fluid V Check all the electrical system and wire in the engine

Compartment. V

Check cooling liquid and change oil V - C

Check engine cowling for Proper condition. V Check all fuel and oil hose connection for security. V Check all cooling hose and expansion tank for security V Check all components attacking to fire wall for security. V

Proper condition. V

Assembly engine cowling V

Finishing

Closed all inspection opening in the fuselage and wings. V Check if all the tools are removed from airplane. V Check if all system, operate properly. V

Run the engine. V

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300 HOURS INSPECTION

Check all push-pull control cables and replace if necessary.

V

Check all flexible control cables and replace if necessary. V Inspect wings and flight surface condition for defect, To

become crooked. And other sign of defect. V The max play in flight moving flight control surface is0.6

mm V

Check all rivets for detect loose rivets. Any loose rivet

shell be replace with oversize rivet V

For deformation. And another sign of defect. V Inspect fuselage for condition and other sing of defect. V

Propeller

Inspect the prop blade for crack, stone blow and other Defect, small defect smooth with fine glass paper and Apply lack,

V Check prop. Bolts tight. Torque 18 Nm V - C Tail and flight surfaces

For general condition and in particular for cleaning and Attachments security.

V Check tightening of self-locking nuts attaching the push-

Pull Control cable to the rudder and stabilator (elevator) V Check all nuts securing the rudder and stabilator to hinge,

Check all the nuts supporting/connecting of hydraulic-

Damper Condition and security. V

Rod abnormal play. All the self-locking nuts. V Check control surface angles (rudder elevator and trim). V Check all flight control surface for condition and smooth

Fuselage

Check all the airframe condition look for defect, if is not V

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Become crooked, and other sign of defect. Loose bolt and Rivet.

Check antenna attachment, check for crack. And loose

Bolt, and antenna condition. V

Check self-locking nuts and wing attachment to the Airframe. Check self-locking nuts and struts to the Airframe,

V Check the main landing gear struts attachment to lower

Check all windows for condition and loss rivet. V Check nose landing gear attachment and bolt secreting. V Check door condition and lock operation. V Cockpit

Remove seats. V

for Security. Check all line attachment to the frame. V – C Check hydraulic brake line and brake actuator. V Using a flashlight and mirror carefully inspect the flight

V

Thoroughly clean the control stick and examine the assembly for damage and wear. Verify that all components are secured and the articulation movements are smooth.

V

Check tightened of Self-locking nuts securing the

Stabilator pivot plates supporting V

Screws. V

Check the electrolyte level in the battery. Battery stand And cleans. Look for evident of electrolyte leak. Check Battery attachment. Battery cable.

V Inspect pilot set belts. Check tightening of self-locking

Nuts securing the set belts. And floor cleanliness. V Check instrument panel security. All the instruments V

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Connection, static and dynamic line.

Replace seat. V

Wings

Deformation. or other sign of defect V

Wings tip. V

Check tightening of self-locking nuts securing wings Brace

struts. Tank venting tube and pitot tube, V Check tank outlet for security and leak. Check the tube. V Check tightening of self-locking nuts securing the aileron

Check main and nose wheel for freedom of rotation. V Ensure that bearings are not noisy and without abnormal

Play. V

Replace the oil level in the hydraulic shock strut of nose

Landing gear. V – C

Remove the main landing legs V – C

Remove the upper screw located in the strut. The oil must

fill the treaded hole of upper screw. Reinstall upper screw. V – C

Check wheel alignment. V – C

Check the hydraulic shock strut function. By pressing The

Check the shock strut piston for abnormally vowel: both Transversal and longitudinal ply. Should be 2 - 3 mm Max.

Check for no tensional play between pedals and Nose wheel.

V

Support the aircraft and remove the main landing gear RH and LH struts clean the strut housings located in the Tubular framework and in the axle assemblies. Lubricate Strut housings as necessary in accordance with paragraph2 LUBRICATION

V – C

Replace legs of main landing gear. V – C

Reinstall the main landing gear struts and check the self-

Locking nuts for tightening. V – C

Check wheel and tire for condition. Check air pressure.

Check tightening all self-locking nuts securing V – C Check main landing gear RH and LH struts connection for

Security. Check hydraulic line condition, and attachment to V – C

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Struts.

Support the fuselage Remove the main landing gear wheel and check the brake Linings for wear ore stiffness. Replace if necessary Renewed The oil. Reassembly the Wheels.

Check security of bolts.

V – C

Engine

All Engine maintenance is according to ROTAX

Maintenance manual 899 372, Section. 50-20-00 Used free lead fuel only. All maintenance preformed According to that manual. Any other operation that is not mentioned in that manual Will be according to that.

V – C

Check all the fuel line for wear and stiffness. And check all

attachment for Security. V

Check the fuel pump be sure filter is clean. V – C Check Engine control cables for proper tension and

Interference with other equipments: Clean and lubricate As necessary: On the carburettor: verify the RPM and CHOKE operating levers for freedom of movement

V

Check the carburettor for cleaning and proper adjustment

Accordingly with Engine operator's manual-last issue. V – C

Replace or clean the air filter. V – C

Replace carburettor-mounting flanges. V – C

Using a 10X magnifying glass inspect all welding of

Engine mount for cracks. V

Check for proper torque the self-locking nuts and Securing the engine to it's housing and to the engine Mount

respectively. Nuts (3) 8Nm Nuts (8) 22Nm

V – C Check for proper torque the self-locking nuts securing the

Engine mount to fuselage. Torque load required 10Nm V – C Check the front and rear engine mount shock absorber And

replace if necessary. Check for proper torque the self- locking nuts securing the Shock absorbers to the engine mount.

V – C

Check security of oil tank attachment to the frame and Mount. Exhaust muffler oil radiator and cooling radiator To mounting.

V Check all oil pipes and cooling pipe for wear and stiffness

Check clamps for security and condition. Change cooling Fluid

V Check all the electrical system and wire in the engine V

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Compartment.

Check cooling liquid and replace oil. V – C

Check engine cowling for Proper condition. V Check all fuel and oil hose connection for security. V Check all cooling hose and expansion tank for security V Check all components attacking to fire wall for security. V

Proper condition. V

Assembly Engine cowling. V

Finishing

Run the engine. V

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2 MAINTENANCE PER PERIOD OF TIME

2.1 SCHEDULED MAINTENANCE

If the airplane does not reach 100 flight hours within consecutive 12 months, a 100 hours inspection must be carried out before renewal of its permit to fly.

If the airplane did not reach 200 flight hours within 24 months, a 200 hours inspection must be carried out

2.2 TIME LIMITED COMPONENETS

The following components must be removed for inspection and complete overhaul after the time specified have expired:

- ROTAX 912 UL: 1500 hours or 10 years, whichever comes first, refer always to Rotax manual.

- ROTAX 582 UL DCDI: refer always to Rotax manual.

- JABIRU 2200: 1000 hours, refer always to Jabiru manual.

- Propeller see propeller manual

- Shock absorbers replace at 300 hours or every 2 years (whichever comes first) - Main landing legs replace at 300 hours (Only alluminium alloy legs)

3 UNSCHEDULE MAINTENANCE

3.1 HEAVY LANDING

Heavy landing event should be recorded in the airplane logbook by the pilot or technician, observing landing gear damage. Following inspection must be carried out:

1. Remove fairing from wheels and struts. Remove cowling.

2. Check nose-landing gear structure for cracks and alignment, attachment and bolt tightness.

3. Check the nose gear hydraulic shock strut function, by pressing the nose down and release, replace failed components.

4. Support the airplane, remove main landing gear wheels, check axle welding, check struts for linearity scratches and cracks. Replace struts if bent or damaged.

5. Install wheels, Check main wheel alignment.

6. Install wheels and struts fairing, install cowling.

7. Check engine mount for distortion.

3.2 DAMAGE TO THE COMPOSITE STRUCTURE Contact Fly Synthesis s.r.l. for this type of problem.

3.3 EXCEEDING ENGINE LIMITS

Any time an engine limit is exceeded, RPM, time limit, pressure or temperature, record the event in the airplane logbook and consult the ROTAX Maintenance Manual.

3.4 EXCEEDING AIRPLANE LIMITS

Any time VNE or G limits are exceeding, must be make 200 flight hours inspection.

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3.5 PAINTING THE AIRPLANE

The airplane when delivered is painted white all over.

It is prohibited to paint the upper surfaces of the wings and fuselage with any dark paint, as this will increase the heat absorption from the sun, which may lead to damage to the composite material structure.

After any painting operation is obligatory verify the weight and balance of the aircraft.