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

LW-RL-Z-004 Rev.:1 Page 11
02 How to Use the Manual
02-00 General
The format and contents of this manual have been prepared in accordance
with the GENERAL AVIATION MANUFACTURERS ASSOCIATION (GAMA)
Specification No. 2.
The contents of this manual are organized in three levels:
Group
System/Chapter
Subsystem (if needed)
Group
Groups used in this manual are:
Group
Chapters
Definition / Remark
General
01 & 02
General information
Aircraft
03 thru 20
Complete operational unit,
limitations
Airframe systems
24 thru 34
All airframe systems except power
plant
Structures
51 thru 57
All aircraft main structures
Propeller
61
Propeller information
Power Plant
71 thru 80
Power plant information
Miscellaneous
91
Charts
Supplementary information
To be collected in
Appendix
Forms, Advanced maintenance
instructions, Service bulletins etc.
System/Chapter
Systems are arranged numerically per GAMA Specification 2 (ATA 100)
recommended number assignment. The first two numbers indicate the
chapter or system; the second two indicate the sub-system or section (for
example Chapter 02-10).
When a subsystem is further divided into units, a third element is added to
the number sequence, e.g. 53-20-01
The table of content lists only those chapter numbers which are used in this
supplement.
02-10 Notes
Notes and safety notes in this handbook are marked by the words Note,
Important, Caution, Warning or Danger in the left margin column. The latter

LW-RL-Z-004 Rev.:1 Page 12
three words are emphasized by a safety sign. The text of the note or safety
note is printed in bold. See the following examples:
Danger Represents a dangerous situation. The non-observation of this safety
note will result in death or serious injuries.
Warning Represents a dangerous situation. The non-observation of this safety
note may result in death or injuries.
Caution Represents a danger to equipment. The non-observation of this safety
note will result in destruction of equipment. This safety note does not
exclude a possible danger for persons.
Important Represents an important hint.
Note Represents a remarkable hint.

LW-RL-Z-004 Rev.:1 Page 13
03 General Description
03-00 General
The LightWing AC4 aircraft is a
Conventional high strutted wing configuration;
Conventional strutted tail;
Single Rotax piston tractor engine with fixed pitch propeller;
2 seat side by side;
Fixed tricycle landing gear with steerable nose wheel
airplane.
Figure 1: AC4 isometric view

LW-RL-Z-004 Rev.:1 Page 14
Figure 2: AC4 side view
Figure 3: AC4 top view

LW-RL-Z-004 Rev.:1 Page 15
Figure 4: AC4 front view

LW-RL-Z-004 Rev.:1 Page 16
04 Limitations
Rev. No
Description
EASA Approval
Number and date
1st Edition
Initial TC
EASA.A.588 17.6.14
04-00 General
At time of print only a white top surface for the fabric covered parts is
approved. If darker colours shall be used for striping or overall contact Light
Wing AG for approval.
04-10 Structural Limitations and Inspection
Intervals
The airframe of the Lightwing AC4 is limited to 6000h, the engine mount to
4000h.
In addition, the airframe must undergo a major airframe inspection according
to 04-30 at 3000h/10year (whichever comes first) intervals for the airframe
and at 2000h/10year (whichever comes first) intervals for the engine.
The wing, stabilizer and movable control surface cover is limited to 5years of
service live.
Note This limit is initially defined, before exchange of the fabric cover
contact Light Wing AG for potential revised limits
Note Whenever the wing or stabilizer covers are removed the according
major inspection shall be performed. This avoids removing the cover
exclusively for this purpose.
04-20 Placards
For Markings and Placards refer to LightWing AC4 Aircraft Flight Manual,
Section 2, Document N°: LW-RL-Z-002.

LW-RL-Z-004 Rev.:1 Page 17
04-30 Major Inspection
04-30-10 Major inspection airframe
The major airframe inspection program is not defined at time of print. Upon
reaching this airframe life limit contact Light Wing AG.
Critical components are:
Main beam 1000-00003
Cross beam 1000-00005
Horizontal stabilizer interface 1000-00063/64/65/66/67
Cross beam to fuselage interface 1000-00059 /60/61/62
Verbindung Dachstrebe vorn 1210-00001
Verbindung Dachstrebe hinten 1220-00001
Kabinenabstützung 1400-0001
Horizontal stabilizer front tube 1500-00003/4
Vertical stabilizer front tube 1600-00003
Wing front spar 2111-00001 / 2211-00001
Wing rear spar 2121-00001 / 2221-00001
Stütze hinten 1007-00001
Struts adjacent to Engine mount 4100-00051
04-30-20 Major Inspection Engine Mount
Relevent P/N Engine mount 4100-00051
The inspection is best performed with the engine removed, which however is
not mandatory.
The inspection is required to be performed each 2000h, but recommended to
be performed whenever the engine is removed from the airframe.
Major Inspection engine mount
2000h
Preparatory Activities
Remove engine (recommended)
○
Clean the engine mount thoroughly
○
Inspection
Visually inspect all engine mount struts for straightness using appropriate
straight ruler lengths.
○
Check torque of all attachment bolts, ref 20-10-02.
○
At locations where bolt torque is below the specified values: remove bolt and
inspect for sights of wear or overload. Discharge the respective (stop) nuts.
If a bent bolt is found the engine mount must be removed from the airframe to
further inspect the respective bearings on airframe and engine mount side.
Report such condition to Light Wing AG.
○

LW-RL-Z-004 Rev.:1 Page 18
Major Inspection engine mount
2000h
Visual inspect entire top coat paint of engine mount for scrathces and cracks.
○
Where top coat cracks are found remove top coat in the affected area and min
10mm further.
○
Perform dye penetrant check at all welding nodes and all identified top coat
crack locations.
○
In case of doubt remove top coat at entire node.
○
If cracks are found report to Light Wing AG before proceeding
○
Finish
Refinish top coat at weld nodes as required. Touch up top coat at all other
identified scatches
○
Reinstall engine (if removed)
○
Make appropriate airplane log book entry for release to furhter service
○
04-40 Software
Only Software delivered with the airplane, or as mandated by resperctive
Service Bulletins are approved to be used in the AC4. This adresses:
Function
Unit
Software revison
(approved at time of print)
Fuel metering and
ignition timing
ECU of Rotax 912iS/iSC
130
Engine indication
EMU 912iS Evo
EMUevo AC41
MFD configuration
Skyview System
15.0.2

LW-RL-Z-004 Rev.:1 Page 19
05 Inspection and Maintenance
05-00 General
This chapter contains charts, tables and checklists for time limits, scheduled
and unscheduled maintenance, to enable licensed personnel to carry out
correct inspections on the LightWing AC4 aircraft. The periodic inspections
and checks described and the related intervals are minimum required for
maintaining the aircraft in airworthy condition.
Specific operation and specific operation environments might require
shortening the intervals.
The regulating airworthiness authority must approve any increase of interval
time.
Important The regulatory authority might require specific (additional) inspection
or calibration items as well as replacement/overhaul intervals not
described in this manual. It is the responsibility of the operator and
maintenance personnel to adhere to national regulations.
05-10 Time Limits and Inspection Program
The LightWing AC4 aircraft scheduled inspection and maintenance program
comprises:
Non repetitive aircraft inspection at 25 hours after delivery of the aircraft or
installation of a new, rebuilt or overhauled engine, including a break-in
inspection and maintenance of the power plant corresponding to the 100
hours/annual inspection.
Recommended repetitive 50 hour inspection mainly covering power plant,
and fuel system (firewall forward).
Mandatory repetitive 100 hour inspection or annual inspection, whichever
comes first, which includes the coverage of the 50 hour inspection plus the
inspection of the aircraft controls, structure landing gear and the fuel system
aft of firewall.
Unless stated otherwise the inspection methods follow standard practice and
are mainly visual. However specific attention shall be paid to the elements
listed in section 04-30-10. In case of doubt consider dye penetrant
inspections at the welding connections and highly stressed areas as
indicated in the inspection list.

LW-RL-Z-004 Rev.:1 Page 20
05-10-01 Component Time Limits
Time between Overhaul
Component
Interval
Propeller Neuform
1000 h
Rotax 912i Engine
2000 h
(refer to latest ROTAX
documentation applicable to
the actual SN of the engine)
Time Between Replacement
Component
Interval
ELT Batteries
6 years
Dynon SkyView Batteries
Depending on annual test
result
Engine mount
4000h
Airframe elements as listed in section
04-30-10
6000h