Pitman Air 912 Dragonfly User manual

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Page 1
Publication Number DF-MM-912 rev 2 05/11/2014 dd/mm/yyyy
Maintenance Manual 912 Dragonfly
&
Kit Assembly Manual 912 Dragonfly
This Manual only applies to SLSA Dragonfly Aircraft and ELSA Dragonfly Kits
Manufactured by Pitman Air, in the United States of America.
Copyright Ed Pitman, Rhett Radford, Bobby Bailey & Bill Moyes 2014

Page 2

Page 3

Page 4

Page 5
Record of Manual Revisions
Note* A current version of this manual is always available
on the internet at: http://www.pitmanair.com/dragonfly
or www.safety-directives.org
# dd/mm/yyyy
Revision Number & Date Purpose Paragraph Page numbers
Rev.0
04/04/2013
Original All All
Rev 1
31/05/2014
Safety Directives ¾” Axle Bolts DF-
1402 & Horz Stab Bolt , DF-1401 34 & 38
Rev 2
05/11/2014
Update Table of Contents All All
Serial Number Information
PA or PAK -____ ____ ____ -____ ____ ____
Pitman Air or Pitman Air Kit – Engine – Production Number
Example: PA-912-126
This Manual only applies to SLSA Dragonfly Aircraft and ELSA Dragonfly Kits
Manufactured by Pitman Air, in the United States of America.
Copyright Ed Pitman, Rhett Radford , Bobby Bailey & Bill Moyes 2013

Page 6
Table of Contents
1.1 GENERAL.................................................................................................................................................... 11
1.1.1 Equipment list, .......................................................................................................................................................11
1.1.2 Sources to purchase parts,......................................................................................................................................11
1.1.3 List of disposable replacement parts ............................................................................................................11
1.1.3.1 Engine Parts,...................................................................................................................................................11
1.1.3.2 Airframe and Systems...................................................................................................................................12
1.1.4 Engine specifications, 912ULS & 912 UL..................................................................................................................12
Performance 912 ULS................................................................................................................................................... 12
Combustion Chambers.................................................................................................................................................. 12
Weight.............................................................................................................................................................................. 12
Performance 912 UL..................................................................................................................................................... 13
Combustion Chambers.................................................................................................................................................. 13
Weight.............................................................................................................................................................................. 13
1.1.5 Weight and balance information, ...........................................................................................................................14
1.1.5.1 Weight and Balance Chart ...................................................................................................................................14
1.1.5.2 Operating weights and loading....................................................................................................................14
1.1.5.3 Center of gravity (CG) range and determination ..................................................................................................14
1.1.5.4 Installed optional equipment list .................................................................................................................17
1.1.6 Tire inflation pressures ....................................................................................................................................17
1.1.7 Approved oils and capacities,.........................................................................................................................17
1.1.8 Recommended fastener torque values, ..................................................................................................................17
“Lubricate”defined .....................................................................................................................................................18
1.1.9 General safety information,....................................................................................................................................18
1.1.10 Instructions for reporting possible “Safety of Flight” concerns found during Inspection or Maintenance. ..........18
1.1.11 Standard Tools—needed for the maintenance and repair of the aircraft and it’s components.............................18
1.1.12................................Special Tools—needed for the maintenance and repair of the aircraft and it’s components.
........................................................................................................................................................................................18
1.2 INSPECTIONS—ANNUAL AND/OR 100 HOUR INSPECTIONS............................................. 18
1.2.1 Checklist for Annual & 100 hour Inspections: ........................................................................................................18
1.3 STRUCTURES ............................................................................................................................................ 21
1.3.1 Wings see Sections 14 through 20,.........................................................................................................................21
1.3.2 Empennage see Sections 1, 2, 4, 8 through 13, 21, & 23 .........................................................................................21
1.3.3 Landing gear, see Sections 2, 7, 8, and Appendix B ................................................................................................21
1.3.4 Structural Control Surfaces, see Sections 9 through 21...........................................................................................21
1.3.5 Fabric Coverings: Sections 9 through 20.................................................................................................................21
1.3 Engine......................................................................................................................................................................21
—....................................................................................................................................................................................21
1.5 Fuel System—see Section 27 .....................................................................................................................................21
1.6 Propeller—refer to Propeller Manufacturers Manual................................................................................................21
1.7 Utility Systems— No Utility Systems ........................................................................................................................21
1.8 Instruments and Avionics— See Appendix C EIS....................................................................................................21
1.9 Electrical System—see Section 28 ............................................................................................................................21
1.10 Structural Repair—see 2.1 Repairs and Alterations ................................................................................................21
1.11 Painting and Coatings—Imron Paints also Refer to FAA AC43.13-1B ...................................................................21
1.12 Revisions—Record of Manual Revisions is located in the beginning of this Manual...........................................21
1.13 Feedback Form—.....................................................................................................................................................21
2.1 Repairs and Alterations—defined .............................................................................................................................22
2.1.1 Repairs—................................................................................................................................................................22
2.1.2 Alterations— ..........................................................................................................................................................22
2.2 Detailed Instructions and Diagrams for Inspection and/or Repair. ............................................................................22
How to use this Section of the Manual: ...........................................................................................................................22
Section 1 Boom Tube ......................................................................................................................................................23
Section 2 Bulkhead..........................................................................................................................................................25
Section 3 Root Tube ........................................................................................................................................................27
Section 4 Fuselage...........................................................................................................................................................29
Section 5 Fwd Cockpit .....................................................................................................................................................31

Page 7
Section 6 Pilot Seat..........................................................................................................................................................33
Section 7 Fwd Wheel Throttle & Manual Brake...............................................................................................................35
Section 8 Tail Wheel........................................................................................................................................................37
Section 9 Vertical Stabilizer .............................................................................................................................................39
Section 10 Rudder ...........................................................................................................................................................41
Section 11 Horiz. Stabilizer & Elev. Frame .......................................................................................................................43
Section 12 Horiz. Stabilizer & Elev. Sails ..........................................................................................................................45
Section 13 Controls .........................................................................................................................................................47
Section 14 Aileron ...........................................................................................................................................................49
Section 15 Aileron Sails ...................................................................................................................................................51
Section 16 Wing ..............................................................................................................................................................53
Section 17 Wing Battens & Sails ......................................................................................................................................55
Section 18 Wing Sail Access holes and sealing.................................................................................................................57
Section 19 Aileron Support Tubes & Mounting................................................................................................................59
Section 20 Struts & Wing Connection..............................................................................................................................61
Section 21 Cable Bracing .................................................................................................................................................63
Section 22 Aft Seat ..........................................................................................................................................................65
Section 23 Aft Seat & Controls ........................................................................................................................................67
Section 24 912 Engine Mounting ....................................................................................................................................69
Section 25 912 Exhaust & Muffler Installation................................................................................................................71
Section 26 582 Radiator Installation ...............................................................................................................................73
Section 27 912 Fuel System ............................................................................................................................................75
Section 28 Electrical System ...........................................................................................................................................77
Section 29 Parachute & ELT Mounting............................................................................................................................81
Section 30 Trim Tabs Setup..........................................................................................................................................83
3 LEVEL OF CERTIFICATION—.................................................................................................................. 85
3.1 Owner— ...................................................................................................................................................................85
3.2 LSA Repairman Inspection—(LSRI) see 4.1, 5.1, 6.1, and Appendix D of this manual ............................................85
3.3 LSA Repairman Maintenance—(LSRM) see 4.1, 5.1, & 6.1.....................................................................................85
3.4 A&P—see 4.1, 5.1, & 6.1.........................................................................................................................................85
3.5 Task Specific—see 4.1, 5.1, 6.1, and Appendix D of this manual.............................................................................85
3.5.1 Rotax Engines and Gearboxes.................................................................................................................................85
3.6 Multiple descriptors—...............................................................................................................................................85
4. LINE MAINTENANCE, REPAIRS, AND ALTERATIONS..................................................................... 85
4.1 Authorization to Perform ..........................................................................................................................................85
4.2 Typical Tasks Considered as Line Maintenance..........................................................................................................85
5. HEAVY MAINTENANCE, REPAIRS, AND ALTERATIONS ................................................................ 86
5.1 Authorization to Perform ..........................................................................................................................................86
5.2 Typical Tasks Considered as Heavy Maintenance for SLSA’s Include:......................................................................86
6. OVERHAUL................................................................................................................................................... 86
6.1 Authorization to Perform—.......................................................................................................................................86
6.2 Overhaul Manual—...................................................................................................................................................86
7. MAJOR REPAIRS AND ALTERATIONS ................................................................................................. 87
8. TASK-SPECIFIC TRAINING...................................................................................................................... 87
9. SAFETY DIRECTIVES................................................................................................................................. 87
10. TERMINOLOGY ........................................................................................................................................ 88
10.1 Definitions: ..............................................................................................................................................................88
APPENDIX A -- SAFETY OF FLIGHT REPORTING FORM & COMMENT FORM ............................. 90
APPENDIX B BRAKES MANUAL FOR BX1320 & BX1000 ................................................................. 91
Double Caliper Parts ..................................................................................................................................................94
Elbow changes to DFN 003 ¾ Bolts go up one size through bulkhead, elbow and axle..............................94
APPENDIX C EIS 4000 912/914................................................................................................. 100
MODEL 4000/6000 .................................................................................................................................... 100
ENGINE INFORMATION SYSTEM............................................................................................................ 100

Page 8
USER’S MANUAL .......................................................................................................................................... 100
GRAND RAPIDS TECHNOLOGIES INCORPORATED .......................................................................... 100
1. READ THIS FIRST! .................................................................................................................................. 105
2. AN OVERVIEW OF INSTALLATION & SETUP ................................................................................. 105
3. USING THE ENGINE INFORMATION SYSTEM ................................................................................ 105
3.1 The Basics of the Engine Information System Operation .........................................................................................106
3.2Before Each Flight.....................................................................................................................................................106
4. SET PAGES – SETTING ENGINE LIMITS AND OTHER USER ENTRIES..................................... 107
4.1Set Page Table of Limits. [Brackets denote Dragonfly Factory Settings] N/U = not used..........................................108
5. INSTALLATION........................................................................................................................................ 110
5.1 Mounting the Instrument – Position and other considerations ...............................................................................110
5.2Wiring ......................................................................................................................................................................111
5.2.1 Outside Air Temperature Sensor....................................................................................................................... 112
5.2.2 Water Coolant/Oil Temperature Sensor ........................................................................................................... 112
5.2.3 Voltmeter .......................................................................................................................................................... 112
5.2.4 Oil Pressure Sender ........................................................................................................................................... 112
5.2.5 Magnetic Tachometer Sensor ........................................................................................................................... 112
5.2.6 External Alarm Output ...................................................................................................................................... 113
5.2.7 Auxiliary Inputs.................................................................................................................................................. 113
5.2.8 Cylinder Head Temperature Probe Installation................................................................................................. 113
5.2.9 Exhaust Gas Temperature Probe Installation.................................................................................................... 113
5.2.10 Carburetor Temperature Probe.................................................................................................................... 114
5.2.11 EGT & CHT Extension Wire ........................................................................................................................... 114
5.3 Verify the Wiring – A Quick Check ...........................................................................................................................115
6. CHECK-OUT .............................................................................................................................................. 115
6.1 Initial Application of Power to the Instrument ........................................................................................................115
6.2 Tachometer Initial Test............................................................................................................................................115
6.2.1 Testing Tachometer Inputs................................................................................................................................ 115
6.2.2 Testing Tachometer Accuracy ........................................................................................................................... 116
6.3 Other Checks ...........................................................................................................................................................116
7. CONFIGURING THE EIS FOR YOUR AIRPLANE. ............................................................................ 116
7.1 Setting up your Auxiliary Inputs – Labels and Scaling ..............................................................................................117
7.1.1 Aux1, Aux2, Aux3, Aux4, Aux5, Aux6................................................................................................................. 117
7.1.2 Dual TIT Option and Aux5/Aux6........................................................................................................................ 117
7.1.3 Auxiliary Scale Factors and Offsets (1SF, 1OFF, 2SF, 2OFF…) ............................................................................ 117
7.1.4 Configuring an Auxiliary Input for a Fluid Temperature Sensor........................................................................ 117
7.1.5 Auxiliary Forward/Reverse Sensing Selection (+/-) ........................................................................................... 118
7.1.6 Auxiliary Decimal/Integer Selection (D/I).......................................................................................................... 118
7.1.7 Transfer function............................................................................................................................................... 119
7.2 Units – (Fahrenheit/Celsius and Gallons/Liters).......................................................................................................119
7.3 FC1 & FC2 (Fuel Flow Activation Codes)...................................................................................................................119
7.4 FloCal (Fuel Flow Calibration) ..................................................................................................................................119
7.5 FloCalR (Return Fuel Flow Calibration)....................................................................................................................120
7.6 TachP/R - Setting for Correct Tachometer Readings ...............................................................................................120
7.6.1 Tach Connections to Magneto P-leads, Ignition Coils or Tach Outputs ............................................................ 120
7.6.2 Tach Connections to Lighting Coils (Jabiru, Rotax, and others) ........................................................................ 121
7.6.3 Rotax 912 Engine............................................................................................................................................... 121
7.6.4 TachP/R Table.................................................................................................................................................... 121
7.7 TachSen...................................................................................................................................................................122
7.8 Peak – Leaning Function Sensitivity Adjustment ( Not Used for Dragonfly )...........................................................122
7.9 Max Fuel – (Fuel Capacity Entry for Fuel Flow Option) ( Not Used for Dragonfly )..................................................122
7.10 Hours (Setting Hourmeter) ...................................................................................................................................122
7.11 Tim-RPM (Hourmeter & Flight Timer RPM Threshold)...........................................................................................122
7.12 AspdLo, AspdHi, TachLo, TachHi (Landing Checklist Reminder/RPM Range Limit) .................................................122
7.12.1 Landing Checklist Reminder ( Not Used for Dragonfly ) ............................................................................. 122
7.12.2 RPM Range Limit .......................................................................................................................................... 123
7.13 AltCor (Calibrating the Altimeter/Barometric Pressure) ........................................................................................123
7.14 AltSF, 1 (10k), 2 (20k), 3 (30k), 4 (40k) Altimeter Adjustments (SW Version 5.8 and above) ..................................124
7.14.1 Precision Altimeter Calibration Procedure ................................................................................................... 124

Page 9
7.15 User Definable Combination Pages........................................................................................................................124
7.15.1 1D1, 1P1, … GD9, GP9 .................................................................................................................................. 124
7.15.2 Table of User-Definable Page Entries. .......................................................................................................... 125
7.16 Example Worksheet for setting up your custom pages..........................................................................................128
BAR GRAPHS USE THE FIRST 8 CHARACTER POSITIONS. ( SHOWN AS SET
AT PITMAN AIR ) ...................................................................................................................................... 130
8. DISABLING PAGES ( PITMAN AIR DISABLES PAGES 0, 4, 6, 7, 9, 11, 12, 13, 14, & 15 ). 131
9. ENGINE ANALYSIS FUNCTIONS ......................................................................................................... 131
9.1 The EGT Tracking Function.......................................................................................................................................131
10. DETAILED DESCRIPTION OF OTHER FUNCTIONS .................................................................... 134
10.1 Flight Timer ...........................................................................................................................................................134
10.2 Unit Temperature..................................................................................................................................................134
10.3 H2O (Water Temperature Function) ......................................................................................................................134
11. USE WITH PRECISION AIRMOTIVE EAGLE ENGINE CONTROLLER...................................... 134
12. UPDATING THE EIS SOFTWARE..................................................................................................... 135
13. CHECK ENTRIES MESSAGE............................................................................................................... 135
14. TROUBLESHOOTING COMMON PROBLEMS............................................................................... 135
15. WARRANTY........................................................................................................................................... 136
Appendix D: Items Permitted Under the Privileges of Preventive Maintenance............................................................141
Advisory Circular 43-12a ...............................................................................................................................................145
Preventive Maintenance ................................................................................................................................................. 145
§ FAR 43.13 Performance rules (general).....................................................................................................................146
APPENDIX E1 KIEVPROP INSTALLATION......................................................................................... 148
1. Disassemble prop hub........................................................................................................................................148
2. Inspect each blade...............................................................................................................................................148
3. Install shoulder bolts ..........................................................................................................................................148
4. On Rotax 912 applications.................................................................................................................................149
SECURING ASSEMBLED PROP TO ENGINE:.....................................................................................................................149
5. Secure (finger tight) the propeller ....................................................................................................................149
6. With all bolts slightly tightened..........................................................................................................................149
8. Fit the aluminum end of the protractor............................................................................................................149
9. For Pusher aircraft................................................................................................................................................150
10. When all blade angles have been set..............................................................................................................150
11. A static check of rpm’s......................................................................................................................................151
12. Re-check torque of prop bolts after first hour...............................................................................................151
APPENDIX E2 POWERFIN INSTALLATION........................................................................................ 153
APPENDIX F AMERI-KING AK-451 & AK-450 .................................................................................. 164
SCOPE ...........................................................................................................................................................................164
OVERVIEW ....................................................................................................................................................................164
Description....................................................................................................................................................................164
Automatic Fixed-ELT (AF): .............................................................................................................................................164
Automatic Portable-ELT (AF) (AP) with dual antennas:..................................................................................................164
Application and Equipment Limitation..........................................................................................................................165
PHYSICAL CHARACTERISTICS: ........................................................................................................................................165
•......................................................................................... GENERAL SPECIFICATIONS (STANDARD CONDITIONS):
......................................................................................................................................................................................166
MECHANICAL INSTALLATION.........................................................................................................................................168
QUICK OPERATION CHECK.............................................................................................................................................169
Detail Operation Check: ................................................................................................................................................169
Detailed Operation Check: ............................................................................................................................................171
3 System Integration Test: (some parts may not apply to AK-450)............................................................................172
5.............................................................................................. TRANSMITTER FUNTIONAL TEST FOR ELT-(S) ONLY
......................................................................................................................................................................................174
6 PERIODIC MAINTENANCE (INSTRUCTIONS FOR CONTINUED AIRWORTHINESS):........................................................175

Page 10
APPENDIX G – BAILEY RELEASE AND TOW SYSTEM....................................................................... 177
1. General Information.................................................................................................................................................177
1.1 Introduction............................................................................................................................................................... 177
1.2 Warnings, Cautions and Notes Explained:................................................................................................................. 177
1.3 Description of Bailey Release and Tow System ......................................................................................................... 177
1.4 Perspective Views and Photos................................................................................................................................... 177
FIGURE 1 (Bailey Release & Tow System Configuration)................................................................................................. 177
2. Limitations ................................................................................................................................................................181
2.1 Introduction............................................................................................................................................................... 181
2.2 Installation ................................................................................................................................................................. 181
2.3 Loads.......................................................................................................................................................................... 181
FIGURE 2 Knots used for Safety Links .............................................................................................................................. 182
2.4 Angles ........................................................................................................................................................................ 182
2.5 Forces ........................................................................................................................................................................ 182
2.6 Specifications............................................................................................................................................................. 183
2.7 Period of Operations of Release, TBO and Inspection Intervals................................................................................ 183
3. Checklists ..................................................................................................................................................................183
3.1 Pre-Flight (second person needed)........................................................................................................................... 183
3.2 Pre-Tow ..................................................................................................................................................................... 183
3.3 Post-Flight.................................................................................................................................................................. 184
4. Maintenance and Service ..........................................................................................................................................184
4.1 General ...................................................................................................................................................................... 184
4.2 Installation ................................................................................................................................................................. 184
4.3 Inspections................................................................................................................................................................. 184
4.4 Operational Tests....................................................................................................................................................... 184
5. Signals and Communications for Tow Operations......................................................................................................185
FIGURE 3 Common Signals.............................................................................................................................................. 186
6. Safety Bulletins .........................................................................................................................................................188
7. Operational and Service Difficulty Reporting.............................................................................................................188
SAFETY OF FLIGHT & SERVICE DIFFICULTY REPORT FORM ....................................................... 189
SAFETY OF FLIGHT & SERVICE DIFFICULTY REPORT FORM ....................................................... 190
Note:
The Contents and Structure of this manual are mandated by ASTM Standard F2483-05 &
FAA Regulations requiring the conformity to “Consensus Standards”.
ASTM standards used
Design & Performance and Required Equipment: F 2245-11
Quality Assurance and Production Acceptance Tests: F 2279-06
Continued Operational Safety Monitoring F 2295-06
Maintenance & Inspection Procedures F 2483-05
Pilot Operating Handbook (POH) F 2245-11 & F 2746-09
Terminology for LSA F 2626-07
Airframe Emergency Parachutes F 2316-08
Kit Assembly Instructions F2563-06
Required Product Information F2745-11
In accordance with 14 CFR part 21.190

Page 11
1.1 General
1.1.1 Equipment list,
Rotax 912 DCDI Engine w/E Gearbox 4:1 ratio
Propeller
EIS 2000- 1ea.-M2STD-01, 1ea.-OPT-IntAlt, 2ea.-EGT-CF-01, 2ea.-CHT-14-01, 1ea.-FT-1827-02, 1ea.- CAB-A-02
1.1.2 Sources to purchase parts,
Note: The use of Used, Overhauled or Reconditioned Parts or Components is Strictly Prohibited unless otherwise
authorized in this manual or a Letter of Authorization (LOA) is obtained from Pitman Air.
All Components including Engine, Gearbox, Propeller, Airframe and Fabric Materials, etc..:
America’s LSA Manufacturer: many Airframe Parts Manufacturer:
Pitman Air LLC Lite Flite Pty Ltd.
1840 Airport Blvd. Unit 4/5 Clerke Place
Red Bluff, CA 96080 Kurnell NSW 2231
Email: e[email protected]om Australia
Ed Pitman 530-945-1860 9 – 5 Pacific Time Ph. [phone]
Ace Hardware
Sherline Products PTFE Dry Lubricant “Super Lube” (NO Film left to hold dust or dirt)
Or Equivalent
EIS and Sensors:
Grand Rapids Technologies, Inc.
3133 Madison Ave.
Wyoming, MI 49548-1211
PH. [phone]
FAX [phone]
http://www.grtavionics.com/
Engine and Gearbox:
Lockwood Aviation Supply, Inc
1 Lockwood Lane
Sebring, FL 33870
Phone: [phone]
Fax: [phone]
http://www.lockwood-aviation.com/
Bolts, Nuts, Wire, Misc. Hardware, Tools, etc.
NOTE: Be sure to ask for “Documentation” when ordering parts, keep with permanent records & logbooks for
your aircraft.
Aircraft Spruce WEST
225 Airport Circle
Corona, CA 92880
Mailing Address
P.O. Box 4000
Corona, CA 92878-4000
Aircraft Spruce EAST
452 Dividend Drive
Peachtree City, GA 30269
Aircraft Spruce CANADA
150 Aviation Ave.,
Brantford, ON N3T 5L7
Toll Free Order Line:
877-477-7823
Outside USA Order Line:
951-372-9555
Canada Order Line:
877-795-2278
Toll Free Fax Line:
800-329-3020
Outside USA Fax Line:
951-372-0555
Canada Fax Line:
519-759-8964
Customer Service:
800-861-3192
1.1.3 List of disposable replacement parts,
Air filters, fuel filters, tires & tubes, etc.
1.1.3.1 Engine Parts,
refer to Rotax Engine Manuals. and Authorized Rotax Parts Distributor or Rotax Service Center.

Page 12
1.1.3.2 Airframe and Systems:
(All Parts can be purchased direct from Pitman Air, alternate suppliers listed below)
A: Clear Return Fuel Lines, # 2100686 Ether Based Superthane Only, NOT Ester Based
NewAge® Industries, Inc., 145 James Way, Southampton, PA 18966-3817
Phone: [phone] or 215-526-2300 Fax: [phone] or 215-526-2190
E-mail: [e-mail]
B: Fuel Line Electric Pump & bypass line Check Valve *
Electric Fuel Pump NAPA # P60504
Check Valve # EW-98553-00, http://www.coleparmer.com/catalog/product_view.asp?sku=9855300
Cole-Parmer, 625 East Bunker Court, Vernon Hills, Illinois 60061
Phone: [phone], Fax: [phone], E-Mail: [e-mail]
C: Fuel Lines
5/16” Multi Fuel Injection Line Outside lines: Gates # 27340 or 27348
5/16” Submersible Line inside of Fuel Tank Gates # 27093 2” to 3” long
D: Fuel In Line Strainer/Filter *
No Paper Filters Any Clear Strainer that meets Rotax requirements from any Marine or Auto Parts Supplier
E: Tires (See Aircraft Spruce Above)
* Any quality tires commonly used on General Aviation Aircraft, NO “Not for Highway Use” Tractor or Cart Tires.
Note: Maximum Pressure 29 PSI because of rims, never exceed 32 psi.
F: Airframe Structural Components and Parts including Fabric Coverings.
These parts must be OEM ( Pitman Air ) parts to insure proper quality and fit.
1.1.4 Engine specifications, 912ULS & 912 UL
Performance 912 ULS
Maximum Power*
(5 minutes)
100HP / 73.5KW @ 5800 RPM
Maximum Power
(sustained)
95HP / 69.0KW @ 5500 RPM
Maximum Torque
94ft-lb / 128NM @ 5100 RPM
*100HP maximum power when optional air box and tuned exhaust are
installed.
Combustion Chambers
Bore
3.31" / 84mm
Stroke
2.40" / 61.0mm
Displacement
82.6cu.in. / 1352cm³
Compression ratio
10.5:1
Weight
Engine with carburetors
124.7lbs / 56.6Kg
Exhaust System
8.8lbs / 4.0Kg
Air Box
2.9lbs / 1.3Kg
Air Filter
0.7lbs / 0.3Kg
Liquid Radiator
2.2lbs / 1.0Kg
Oil Radiator
1.1lbs / 0.5Kg
Regulator-Rectifier
0.2lbs / 0.1Kg
Installed Weight
140.6lbs / 63.8Kg
Weight/power ratio
1.41lbs/HP / 0.87Kg/KW
912UL next page

Page 13
Performance 912 UL
Maximum Power
(5 minutes)
81HP / 59.6KW @ 5800 RPM
Maximum Power
(sustained)
79HP / 58.9KW @ 5500 RPM
Maximum Torque
75.9ft-lb / 103NM @ 4800 RPM
Combustion Chambers
Bore
3.13" / 79.5mm
Stroke
2.40" / 61.0mm
Displacement
73.91cu.in. / 1211.2cm³
Compression ratio
9.0:1
Weight
Engine with carburetors
121.2lbs / 55.0Kg
Exhaust System
8.8lbs / 4.0Kg
Air Filter
0.7lbs / 0.3Kg
Liquid Radiator
2.2lbs / 1.0Kg
Oil Radiator
1.1lbs / 0.5Kg
Regulator-Rectifier
0.2lbs / 0.1Kg
Installed Weight
134.2lbs / 60.9Kg
Weight/power ratio
1.66lbs/HP / 1.0Kg/KW

Page 14
1.1.5 Weight and balance information,
1.1.5.1 Weight and Balance Chart
1.1.5.2 Operating weights and loading (occupants, baggage, fuel, ballast)
The CG must never be further FORWARD than 75.67 inches from the Datum nor further AFT than 80.78
inches from the Datum
The aircraft must never be flown solo from the back seat.
The pilot minimum weight of approx.. 187 to 205 lbs in the front seat is necessary to keep the aircraft in its CG range.
The CG range as a percentage of the chord of the wing is from 35.7% with the lightest pilot to 26.1% with the heaviest
pilot.
(The figures shown are typical of a Dragonfly fitted with a 582 liquid cooled Rotax Engine. The limiting figures are
still valid if the aircraft is fitted with other engine types. Reference should be made to the aircraft specific figures
recorded in section 1.1.5.3.4)
(912) The empty weight CG should be approximately 96.25 in from the Datum or 56.2% of the MAC.
1.1.5.3 Center of gravity (CG) range and determination
The weight and position of the Center of Gravity (CG) of the empty aircraft must be established to conduct load sheet
calculations. The aircraft must be weighed and measured in a fixed position and attitude and in windless conditions
with wings level. Use a plumb line to project the following positions to the ground for measurements. The Datum is
the point from which all measurements are taken and for the Dragonfly is the nose or cockpit front cross tube. The
attitude selected is to raise the tail wheel till the Horizontal Stabilizer is level by measurement with a spirit level. (See
fig. 2) 1.1.5.1 The weights and measurements are recorded in this position and results as follows; - (note typical
aircraft) Use only lbs. and inches, Metric Units must be converted first.

Page 15
The Mean Aerodynamic Chord (MAC) is calculated by adding the wing and flaperon area and divide by span.
MAC = AREA = 183.10 ft sq = 5.37ft / 64.50in
MEAN SPAN 34.08ft
1. DATUM - Cockpit front cross tube 0.00
2. Pilots Pelvis position - Pilot CG 35.0in
3. Front Axle - Front Wheels 50.0in
4. Leading Edge of Wing - 60.0in
5. Fuel Tank Center - 60.0in
6. Rear Seat Pelvis position - Co Pilot CG 82.0in
7. Tail Wheel Axle - 196.0in
EMPTY WEIGHT MEASURED AS FOLLOWS and the Moment Arm from DATUM used to calculate moments. (Note – these
readings for a typical aircraft)
Empty Weight Mass Moment Arm Moments
Front Rt. Wheel 179.0lb 50.0in 8950in lb
Front Lt Wheel 174.5lb 50.0in 8718in lb
Rear Wheel 162.0lb 196.0in 31752in lb
Total Weight 515.5lb Total Moments 49420in lb
CG from Datum = Moment = 49420in lb = 95.90in
Mass 515.5lb
The Leading Edge of the wing is 60.0in aft of Datum. The empty weight CG position from the Leading Edge is then:-
95.90in – 60in = 35.9in
As a percentage of MAC 35.9 = 0.556 55.6%
64.5
1.1.5.3.1 MAX. AFT CG WITH 133lb PILOT AND 11lb FUEL (example)
Weight Arm Moment
Aircraft 515lb 95.9in 49388.5in lb
Fuel 11lb 60.0in 660.0in lb
Pilot 133lb 35.0in 4655.0in lb
659lb 54703.5in lb
CG = MOMENT = 54703 = 83in
MASS 659
As a percentage of MAC
83 -60 = 23 = 23 = 0.357 = 35.7%
MAC 64.5
1.1.5.3.2 CG WITH MAX FUEL & TWO 90 KG / 199 lb. PILOTS
(example)
Weight Arm Moment
Aircraft = 515lb 95.9in 49388.5in lb
Fuel = 33lb 60.0in 1989.0in lb
Pilot = 199lb 35.0in 6965.0in lb
Co Pilot = 199lb 82.0in 16318.5in lb
946lb 74660.5in lb
CG = MOMENT = 74660 = 78.92in
MASS 946
As a percentage of MAC
78.92 –60 = 18.92 = 18.92 = .293 = 29.3%
MAC 64.5

Page 16
1.1.5.3.3 CG WITH MAX FUEL & 100 KG / 221 lb. PILOT FOR MAX FORWARD CG
(example)
Weight Arm Moment
Aircraft 515lb 95.9in 49388.5in lb
Fuel 33lb 60.0iin 1989.0in lb
Pilot 221lb 35.0in 7735.0in lb
769lb 59112.5in lb
CG = MOMENT = 59112.5 = 76.85in
MASS 769
As a percentage of MAC
76.85 –60.0 = 16.85 = 16.85 = .261 = 26.1%
MAC 64
1.1.5.3.4 AIRCRAFT SPECIFIC WEIGHT AND CG POSITION
NOTE: ( Retrieve these numbers from your POH ( Pilot Operating Handbook )
Dragonfly Serial No:
Weight at tail wheel:
lb
Weight at right main wheel:
lb
Weight at left main wheel:
lb
Empty weight with standard equipment:
lb
Maximum take-off weight:
1080
lb
Maximum load:
lb
Empty weight CG. position
inch
CG position % MAC
MAC
Date:
Inspector:
1.1.5.3.5 Load Sheet EMPTY WEIGHT CALCULATIONS
WEIGH
T
lb
MOMENT
ARM
inch
MOMENT
In/lb
Left Front Wheel
50
Right front Wheel
50
Rear Wheel
196
Fuel
60
Pilot
35
Co-Pilot
82
Totals W = Totals M =
CG position M/W CG =

Page 17
1.1.5.4 Installed optional equipment list affecting weight and balance or a reference as to
where this information can be found.
NOTE—( Retrieve and/or Update this information in your POH ( Pilot Operating Handbook ) Also.
Item Location Moment Weight
1.1.6 Tire inflation pressures,15 to 25 PSI NOTE: (NEVER EXCEED 32 PSI)
1.1.7 Approved oils and capacities, NOTE: Refer to Rotax Manual and Rotax Website for current
recommendations as this information occasionally changes.
1.1.8 Recommended fastener torque values,
NOTE—Each Specific Fastener has its own Tightening Instructions because of its location and function,
reference the appropriate “Section” in this manual or Illustrated Parts & Kit Assembly Manual for the
instructions on each fastener.
Bolt Tightening & Lubricate Terms Defined:
*Note: Observation is required to ensure that no tubes or parts are
deformed or crushed.
Loose= In place but waiting for tightening after section is totally
assembled.
Snug*= Absence of free play or ability to move longitudinally.
Tight*= Approximately 40% to 60% of Max Allowable listed below
Very Tight*= Approximately 80% to 100% of Maximum
Allowable listed below.
AN Bolt Torque <<Never Exceed Values for
Dragonfly>>
**For oil free cadmium plated steel nuts and bolts
AN Torque values given in Inch Pounds in Table below! AN3 = 10-32 etc.

Page 18
1.1.8.1 Wear Tolerances of Cable, Bolt or Fastener and Hole Elongation.
Bolts and Fastener Wear: Maximum 10%
Example: ¼” 0.25 * 0.9 = 0.225’as the thinnest part of bolt or ¼” fastener.
Hole Elongation: Maximum of 15%
Example: ¼” 0.25 * 1.15 = 0.2875 Maximum in longest direction of hole.
Example for feeler gauge while bolt is in hole: ¼” 0.25 * 0.15 = 0.0375 wire should not fit between bolt and
edge of hole. (Between .032” and .041” Safety Wire sizes.)
Cables, Thimbles and Tangs
Any significant wear of Thimbles, fraying of cables, loose or broken strands, corrosion of cables or NICO Press
Sleeves, deformation of Tangs, REQUIRE RPLACEMENT with new OEM Cable Assemblies. Be aware of and
learn about “Hydrogen Embrittlement” and how hard it is to detect the amount of damage that it can cause.
When you can see corrosion on Nico Press Sleeves, the stainless cables have been affected but don’t show signs
as well as the Tin plated Copper sleeves. WHEN IN DOUBT, REPLACE WITH NEW.
“Lubricate”defined =Dry Film Lubricant that will not leave any sticky residue that will hold
dust, dirt or sand, that will prematurely wear out parts.
i.e. Super Lube, Dri Film Lubricant by,Synco Chemical Corp. www.super-lube.com
NOTE: DO NOT LUBRICATE until after painting fabric surfaces of the sails etc. Silicones can
prevent paints from sticking
1.1.9 General safety information,
Always use proper PPE (Personal Protective Equipment) and Work Safety Practices suitable for
the work you are performing. Information on this can be found in the OSHA Regulations
and/or the Occupational Health Authority in your State.
1.1.10 Instructions for reporting possible “Safety of Flight” concerns found during Inspection or
Maintenance.
NOTE—See Appendix A in the back of this manual & in the beginning of the POH (Pilot Operating Handbook)
behind the Table of Contents.
1.1.11 Standard Tools—needed for the maintenance and repair of the aircraft and it’s components.
Wrenches, sockets & Allen wrenches in both SAE and Metric are needed, Hammers, Safety Wire Pliers, needle
nose and square pliers, screw drivers in both straight and Phillips, chisels, punches, feeler gauge sets in both
inch and metric, Calibrated Torque Wrenches, hacksaw, Hot Knife or soldering gun with flat tip, heat gun
(hotter than hair dryer), and other tools commonly found in a mechanics tools box.
1.1.12 Special Tools—needed for the maintenance and repair of the aircraft and it’s components.
Note: Rotax has numerous Special Tools for engine Repair and Maintenance. These can be purchased from most
Rotax Parts Distributors as needed. All of the guidance for Inspection, Repair and Overhaul of Engines and
Gearboxes are deferred to the Engine Manufacturer. Overhaul of engines and it components can only be performed
by a Rotax Authorized Service Centre. Refer to Rotax manuals and Website for current information regarding
overhaul, repairs and alterations.
1) Batten Tool -- Used to push battens most of the way under Rear Spare. Can use a screwdriver if your very careful
not to scratch the tube or tear the sail. This tool can be Rented or Purchased through Pitman Air.
1.2 Inspections—Annual and/or 100 hour Inspections
Note: Engine, Gearbox, Propeller, and Instruments may require periodic or specialized inspection/maintenance and
intervals. Refer to the component manufacturer’s manual(s) for this information. i.e. Rotax www.flyrotax.com
1.2.1 Checklist for Annual & 100 hour Inspections:
How to perform an Annual and/or 100 Hour Inspection:
Go through all Sections of 2.2 Detailed Instructions and Diagrams for Inspection and/or Repair of this
manual. (cont’d next page)

Page 19
Items (5) and (6) contain things that may require special attention during the Inspection.
Note: Each “Section” 1 through 30 of the Maintenance Instructions must be consulted to identify areas
of Special Interest or “Life Limited Parts” (LLP) to identify if part needs special attention or replacement. See
2.2 of this manual. (page 21)
APPENDIX D TO FAR PART 43 - SCOPE AND DETAIL OF ITEMS (AS APPLICABLE TO THE
PARTICULAR AIRCRAFT) TO BE INCLUDED IN ANNUAL AND 100-HOUR INSPECTIONS
(a) Each person performing an Annual or 100-hour Inspection shall, before that inspection, remove or open all necessary
inspection plates, access doors, fairing, and cowling. He shall thoroughly clean the aircraft and aircraft engine.
(b) Each person performing an Annual or 100-hour Inspection shall inspect (where applicable) the following components of
the fuselage and hull group:
Fiberglass / Aluminium skin (tubes)- for deterioration, distortion, other evidence of failure, and defective or insecure attachment of
fittings.
Systems and components - for improper installation, apparent defects, and unsatisfactory operation.
(c) Each person performing an Annual or 100-hour Inspection shall inspect (where applicable) the following components of
the cabin and cockpit group:
General Structures, Cables, Tangs and Fittings - for uncleanliness, signs of corrosion, excess wear and loose equipment that might
foul the controls or systems.
Seats and safety belts - for poor condition and apparent defects.
Windows and windshields - for deterioration and breakage.
Instruments - for poor condition, mounting, marking, and (where practicable) improper operation.
Flight and engine controls - for improper installation and improper operation.
Batteries - for improper installation and improper charge.
All systems - for improper installation, poor general condition, apparent and obvious defects, and insecurity of attachment.
(d) Each person performing an Annual or 100-hour Inspection shall inspect (where applicable) components of the engine
group as follows:
Engine section - for visual evidence of excessive oil, fuel, or hydraulic leaks, and sources of such leaks.
Studs and nuts - for improper torquing and obvious defects.
Internal engine - for cylinder compression and for metal particles or foreign matter on screens or in oil filter element and magnetic sump
drain plugs. If there is weak cylinder compression, for improper internal condition and improper internal tolerances.
Engine mount - for cracks, looseness of mounting, and looseness of engine to mount.
Flexible vibration dampers - for poor condition and deterioration.
Engine controls - for defects, improper travel, and improper safetying.
Lines, hoses, and clamps - for leaks, improper condition and looseness.
Exhaust stacks - for cracks, defects, and improper attachment.