Lightwing AC4 User manual

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

LightWing AC4
Maintenance Manual
LW-RL-Z-004 Rev.:1 Page 2
Intentionally left blank.

LightWing AC4
Maintenance Manual
LW-RL-Z-004 Rev.:1 Page 3
Amendments
Issue
Date
Revised
pages
Description
1st Edition
12-May-2014
all (1..123)
First Edition Original TC under ADxC-48-001-
AMM
Rev.:0
23-Sep-2014
all (1..123)
Transfer from ADxC-48-001-AMM 1stEdt. to LW-
RL-Z-004 with detail rework
Rev.:1
19-Sep-2017
All (1…109)
Detail Rework to V02
Rev. 1
15-Nov-2017
All (1…109
Detail Rework 912iS Sport
List of Service Bulletins
SB No
Date
Title
Affected
Serial no.’s
AD
(EASA)

LW-RL-Z-004 Rev.:1 Page 4
Table of Contents
Chapter Title...................................................................................................... Page
01 Introduction................................................................9
01-00 General............................................................................................ 9
01-10 Coverage.......................................................................................... 9
01-20 Guidelines ........................................................................................ 9
01-30 Related Publications .......................................................................... 9
01-40 Addresses ...................................................................................... 10
02 How to Use the Manual .............................................11
02-00 General.......................................................................................... 11
02-10 Notes............................................................................................. 11
03 General Description ..................................................13
03-00 General.......................................................................................... 13
04 Limitations...............................................................16
04-00 General.......................................................................................... 16
04-10 Structural Limitations and Inspection Intervals ..................................... 16
04-20 Placards......................................................................................... 16
04-30 Major Inspection.............................................................................. 17
04-30-10 Major inspection airframe.................................................................. 17
04-30-20 Major Inspection Engine Mount.......................................................... 17
04-40 Software......................................................................................... 18
05 Inspection and Maintenance....................................... 19
05-00 General.......................................................................................... 19
05-10 Time Limits and Inspection Program................................................... 19
05-10-01 Component Time Limits.................................................................... 20
05-20 Scheduled Maintenance ................................................................... 21
05-20-01 Scheduled Inspection plan................................................................ 21
05-20-02 Lubrication Chart............................................................................. 37
05-20-03 Drain Holes..................................................................................... 37
05-20-04 Maintenance Check Flight................................................................. 40
05-50 Unscheduled Maintenance................................................................ 46
05-50-01 Structure Dimension Check............................................................... 46

LW-RL-Z-004 Rev.:1 Page 5
06 Dimensions and Areas.............................................. 50
06-00 General.......................................................................................... 50
06-00-01 Coordinate System.......................................................................... 50
06-10 Main Data....................................................................................... 50
06-10-01 External Dimensions........................................................................ 50
06-10-02 Internal Dimensions......................................................................... 50
06-10-03 Wing.............................................................................................. 50
06-10-04 Aileron........................................................................................... 51
06-10-05 Flap............................................................................................... 51
06-10-06 Horizontal Tail................................................................................. 51
06-10-07 Elevator ......................................................................................... 51
06-10-08 Trim Tab ........................................................................................ 51
06-10-09 Flettner Tab.................................................................................... 52
06-10-10 Vertical Tail .................................................................................... 52
06-10-11 Rudder........................................................................................... 53
06-10-12 Fuel System ................................................................................... 53
06-10-13 Landing Gear.................................................................................. 53
06-10-14 Engine and Propeller ....................................................................... 53
12 Servicing................................................................. 54
12-10 Replenishing................................................................................... 54
12-10-01 Replenishment of Brake Fluid............................................................ 54
20 Standard Practices Airframe...................................... 55
20-00 General.......................................................................................... 55
20-10 Standard Practices Airframe ............................................................. 55
20-10-01 Standard Torque Values................................................................... 55
20-10-02 Cable Tensions............................................................................... 55
21 Environmental systems............................................. 57
21-40 Cabin heating ................................................................................. 57
24 Electrical Power....................................................... 58
25 Equipment/Furnishings ............................................. 61
25-10 Flight Compartment ......................................................................... 61
25-10-01 Seats............................................................................................. 61

LW-RL-Z-004 Rev.:1 Page 6
25-50 Baggage Compartment..................................................................... 63
27 Controls ..................................................................65
27-10 Ailerons.......................................................................................... 65
27-20 Rudder........................................................................................... 67
27-30 Elevator and Tab............................................................................. 68
27-50 Flap System.................................................................................... 70
28 Fuel........................................................................72
31 Indicating and Recording Systems ..............................74
31-10 Instrument & Control Panels.............................................................. 74
32 Landing Gear...........................................................75
32-40 Wheels and Brakes.......................................................................... 77
34 Navigation ...............................................................78
34-10 Flight Environment Data ................................................................... 78
34-10-01 Pitot/Static System........................................................................... 78
51 Standard Practices and Structures –General ...............81
51-30 Materials ........................................................................................ 81
52 Doors......................................................................82
53 Fuselage................................................................. 83
55 Stabilizers................................................................89
55-10 Horizontal Stabilizer......................................................................... 89
55-30 Vertical Stabilizer............................................................................. 90

LW-RL-Z-004 Rev.:1 Page 7
56 Windows................................................................. 91
57 Wing ...................................................................... 92
61 Propeller................................................................. 95
71 Power Plant............................................................. 96
71-10 Cowling.......................................................................................... 96
71-20 Engine Mount ................................................................................. 98
71-30 Fire Seals....................................................................................... 98
72 Engine.................................................................. 100
75 Air........................................................................ 102
75-20 Cooling System............................................................................. 102
76 Engine Controls..................................................... 104
78 Exhaust ................................................................ 105
79 Oil........................................................................ 106
91 Charts .................................................................. 107

LW-RL-Z-004 Rev.:1 Page 8
List of Effective Pages
Page
Date
Page
Date
Page
Date
1 Cover
Rev. 1
24.07.17
2 thru 109

LW-RL-Z-004 Rev.:1 Page 9
01 Introduction
01-00 General
This Maintenance Manual provides educated maintenance staff information
necessary for servicing, maintenance and repair of the LightWing AC4 CS-
LSA Type aircraft. It contains a detailed description of systems including time
limits for the particular components and instructions for the performance of
inspections and maintenance.
All service, maintenance, inspections, repairs and/or modifications shall be
performed by adequate qualified/licensed personnel within approved
maintenance organisations, certified according EASA Part-145/M or other
applicable National Aviation Authority regulations.
For all instruction necessary for major repairs and cases not covered in this
manual, contact Light Wing AG. Instructions necessary for maintenance,
repair and/or overhaul of vendor parts are not incorporated in this
Maintenance Manual, appropriate documentation may be requested from the
vendors or their representatives. For this contact addresses are provided in
Chapter 01-40 Addresses of this manual.
The instructions for installation, service, repair and maintenance of optional
equipment shall be collected with this Manual.
01-10 Coverage
This manual provides servicing and maintenance information for all
LightWing AC4 aircraft.
Maintenance actions that refer to a limited number of aircraft will be
designated by serial numbers of the applicable aircraft.
01-20 Guidelines
For general information on acceptable methods, techniques and practices, if
not presented here, refer to FAA AC 43-13.
01-30 Related Publications
Note If not stated otherwise use the latest revisions of documentation
presented in the following.
LightWing
AC4 Aircraft Flight Manual Doc. N°: LW-RL-Z-002

LW-RL-Z-004 Rev.:1 Page 10
Rotax
Description
Operators's Manual
OM-912 i
Installation Manual
IM-912 i
Maintenance Manual Line
MML-912 i
Maintenance Manuel Heavy
MMH-912 i
Overhaul Manual
OHM-912 i
Overhaul Manual, Appendix
OHMA-912 i
Illustrated Parts Catalog
IPC-912 i
Servive Bulletins, Service Instructions and Service Letters
as issued
Neuform
C3 Series Operating and Maintenance Manual
DYNON AVIONICS
SkyView System Installation Guide
SkyView Pilot’s User Guide
PowerFLARM
FTD-033 PowerFLARM Core installation manual
01-40 Addresses
Contacts for service bulletins, general information and for ordering parts:
Firm
Address
Light Wing AG
Riedenmatt 1
6370 Stans
Switzerland
E-mail: [e-mail]
Rotax
Refer to Rotax Service network