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WT9 Dynamic LSA. AIRCRAFT MAINTENANCE MANUAL (AS-AMM-01-000, 22. 05. 2017) - page 9

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PLACARDS
AND MARKINGS

Fig. 11-5 Engine Compartment Placards

CONTENTS

SERVICING

12 SERVICING

CONTENTS

GENERAL ......................................................................... 3

INTRODUCTION ....................................................................... 3

DISPOSABLE REPLACEMENT PARTS ................................... 4

12-10

REPLENISHING ................................................................ 5

DESCRIPTION .......................................................................... 5

MAINTENANCE PRACTICES ................................................... 7

Fuel system ....................................................................... 7

Oil system ........................................................................ 10

Engine cooling system .................................................... 16

Tires ................................................................................ 19

Brake system ................................................................... 20

12-20

SCHEDULED SERVICING .............................................. 21

INTRODUCTION ..................................................................... 21

SPECIAL TOOLS, MATERIALS .............................................. 21

LUBRICATION CHART ........................................................... 22

AIRCRAFT CLEANING ............................................................ 29

Aircraft painted surfaces cleaning ................................... 29

Cabin cleaning ................................................................. 30

Interior cleaning ............................................................... 31

Avionics care ................................................................... 31

Engine cleaning ............................................................... 32

Propeller cleaning ............................................................ 32

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SERVICING

12-30

UNSCHEDULED SERVICING ......................................... 33

DESCRIPTION ........................................................................ 33

MAINTENANCE PRACTICES ................................................. 33

Winter maintenance ........................................................ 33

GENERAL

SERVICING

12-00

GENERAL

1. INTRODUCTION

This chapter provides instructions on how to replenish operating fluids.
ln addition, this chapter provides instructions for scheduled servicing, unscheduled
servicing and recommended materials.

2. RECOMMENDED MATERIALS

Tab. 12-1 shows recommended materials, including required specifications,
recommended by the aircraft manufacturer or the engine manufacturer. Any products
with identical specifications can be used. Products given in Tab. 12-1 have been tested
and approved for usage on aircraft.

MATERIAL DESIGNATION

SPECIFICATION

NOTE

Fuel

MOGAS

NATURAL 95
EN 228 Super

For more specific
information about
usable fuel refer to
Rotax Service
Instruction No. SI-
912-016

–

the latest

issue.

AVGAS

AVGAS 100 LL
ASTM-D910

Engine oil

AeroShell Sport Plus 4

API

–

SAE 10W-40

For more specific
information about
usable oils refer to
Rotax Service
Instruction No. SI-
912-016

–

the latest

issue.

Coolant

Conventional coolant

Mobil Antifreeze
Extra

For more specific
information about
usable coolant refer
to Rotax Service
Instruction No. SI-
912-016

–

the latest

issue.

Hydraulic
fluid

Conventional hydraulic
fluid

DOT-4
Classification J1703c

Brake system

Tab.

12-1

Recommended Materials

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3. DISPOSABLE REPLACEMENT PARTS

Tab. 12-2 shows disposable replacement parts. Components given in Tab. 12-2 have
been approved for usage on aircraft WT9 Dynamic LSA.

COMPONENT

SOURCE

SPECIFICATION

Air filter

Sprint Filter

P102

Fuel filter

MEFILTER

DF12

Oil filter

BRP-Powertrain

825016

Spark plugs

BRP-Powertrain

297656

Main wheel tire

Any source

15x6.00-6

Nose wheel tire

Any source

13x5.00-6

Accumulator 17 h

CSB BATTERY CO., LTD.

GP 12170 (12 V / 17 Ah)

Accumulator 20 Ah

GP 12220 (12 V / 20 Ah)

Primary weak link
(round hole)

TOST GmbH

110107 (300

30 daN)

110106 (400

40 daN)

Reserve weak link
(oval hole)

TOST GmbH

110127 (300

30 daN)

110126 (400

40 daN)

Tow rope RED STAR

TOST GmbH

185400 (40 m, 1100 daN)
185500 (50 m, 1100 daN)
185600 (60 m, 1100 daN)

Connecting ring pair

TOST GmbH

102000 (LN 65091)

Brake pads

Beringer

Part No. ZEA01

Tab.

12-2

List of Disposable Replacement Parts

REPLENISHING

SERVICING

12-10

REPLENISHING

1. DESCRIPTION

This chapter provides replenishing information of all operating fluids of aircraft:

•

Fuel system

•

Oil system

•

Engine cooling system

•

Brake system

For servicing points refer to Fig. 12-1 and Fig. 12-2.

–

Fuel tank caps

–

Overflow bottle cap

–

Nose tire inflation valve

–

Oil tank cap

–

Main tire inflation valve

–

Brake fluid reservoir cap

–

Brake caliper bleeding screw

–

Master cylinder bleeding screw

–

Expansion tank cap

–

Pressure limiter bleeding screw

Fig. 12-1 Servicing Points

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SERVICING

Fig.

12-2

Drain Valves

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SERVICING

2. MAINTENANCE PRACTICES

A. Fuel system

Integral  fuel  tanks  are  located  in  both  wings  and  wing  central  section  in  front
of main spar. Wing and wing central section tanks are interconnected with hose.
Fuel tank cap is located on the top surface of the wing. Drain valves are placed
in  the  lowest  point  of  each  tank  on  the  bottom  surface  of  wings  and  fuselage
(Fig. 12-2).
Fuel tanks capacities are shown in Tab. 12-3.

ITEM

LEFT TANK

RIGHT TANK

TOTAL

U. S. gal

Total fuel

63.0

16.65

63.0

16.65

126.0

33.29

Usable fuel

59.5

15.72

59.5

15.72

119.0

31.44

Unusable fuel

3.5

0.93

3.5

0.93

7.0

1.85

Tab. 12-3 Fuel Quantity

The fuels with min. RON 95 (min. AKI 91) can be used. The fuel specifications
that can be used are listed in Tab. 12-4.

FUEL

DESCRIPTION

MOGAS

EN 228 super
EN 228 super plus

AVGAS

AVGAS 100 LL

Tab. 12-4 Fuel Specifications

The fuels can contain dissolved and suspended water.  The  quantity  of  water
in the fuel depends upon the temperature and type of fuel. The suspended water
is settled  on the bottom of fuel tanks. Dissolved water dispersed in fuel cannot
be filtered from the fuel by a fuel filter, which  is  able  to  catch  only microscopic
solid particles.
The risk of operation with a contaminated fuel can be reduced by:

•

Keeping the fuel servicing equipment and filters of such equipment clean

•

Proper storage of the fuel

•

Regular drainage (prior to drainage, let the fuel in calm position

for a sufficient period of time for impurities and suspended water to settle
down)

•

Regular watching for signs of fuel contamination e.g. fuel filter element

condition, fuel drain sample, visual check of the tank inside etc.

The following safety information should be followed at refueling/defueling,
drainage, and another fuel handling:

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WARNING

GROUND  THE  EXHAUST  PIPE  OUTLET  AND  FUEL  SERVICE
EQUIPMENT PRIOR TO AIRCRAFT REFUELING/DEFUELING!
MAKE SURE THAT A SUITABLE FIRE EXTINGUISHER IS AVAILABLE
AT ALL TIMES DURING AIRCRAFT REFUELING/DEFUELING!
SMOKING  OR  MANIPULATING  WITH  OPEN  FIRE  DURING
REFUELING/DEFUELING AND DRAINING IS PROHIBITED!
MASTER  SWITCH  AND  IGNITION  MUST  BE  SWITCHED  OFF!
NO PERSONS ALLOWED TO BE IN THE COCKPIT!
DO  NOT  USE  THE  MATERIALS  WHICH  CAN  CAUSE  STATIC
ELECTRICITY DURING REFUELING/DEFUELING AND DRAINING!
DO NOT OPERATE ANY ELECTRICAL SWITCHES IN THE AIRCRAFT
DURING REFUELING/DEFUELING OR DRAINING!
IT  IS  PROHIBITED  TO  REFUEL  TANKS  IN  RAIN,  STORM,  CLOSED
AND  INSUFFICIENTLY  AIRED  AREAS  (E.  G.  HANGAR),  AT  ENGINE
RUN, AT ELECTRICAL INSTALLATION ON.

CAUTION

USE ONLY FUEL SUITABLE FOR THE RESPECTIVE CLIMATIC ZONE.
RISK OF VAPOUR FORMATION IF USING WINTER FUEL FOR SUMMER
OPERATION.

(1) Tanks refueling:

Type of maintenance:

Line

Personnel qualification:

Pilot/Owner

qualified

accordance

with M.A.803 or higher

Recommended tools, materials, persons and documentation:

ITEM

QUANTITY

Fire extinguisher

1 pc

Cotton cloth

Persons

Tab. 12-5 Recommended tools, materials, persons and documentation

(a) Shut down the engine.
(b) Set the brake lever to

PARK

position or install wheel chocks.

of fuel is used (Tab. 12-4).

(d) Electrically ground the aircraft (use the exhaust pipe outlet)

to the grounding point.

(e) Remove the fuel tank cap (1, Fig. 12-1) on wing

’

s upper skin.

(f)

Refuel the tank from the fuel servicing equipment.

REPLENISHING

SERVICING

(g) Install the fuel tank cap and make sure that opening arm directs

rearward.

(h) Make sure that no spilled fuel is on the aircraft; clean if necessary.

NOTE

If refueling only one fuel tank, fill such fuel quantity that in both
tanks will be same amount of fuel.

(i)

Remove the ground cable from the aircraft.

(j)

Remove wheel chocks.

(2) Tanks defueling:

Type of maintenance:

Line

Personnel qualification:

Independent

certifying

staff

qualified

in accordance with Part-66 or higher.

Recommended tools, materials, persons and documentation:

ITEM

QUANTITY

Fire extinguisher

1 pc

Fuel container

1 pc

Defueling tool

1 pc

Cotton cloth

Loctite 577

Persons

Tab. 12-6 Recommended tools, materials, persons and documentation

Fuel  tanks  are  defueled  by  means  of  fuel  drain  valves,  located
in the lowest point of each tank on a wings bottom surface (Fig. 12-2).

(a)  Shut down the engine.
(b)  Set the brake lever to

PARK

position or install wheel chocks.

to the grounding point.

(d) Place a fuel container bellow the drain valve.
(e) Unscrew the drain valve from wing central section tank (A, Fig. 12-2),

install the defueling tool and set it to open.

(f)

Open the fuel tank cap (1, Fig. 12-1) on the wing upper side
to accelerate defueling.

(g) When the fuel stops draining, remove defueling fixture.
(h) Drain the residual fuel from the wing tank (A, Fig. 12-2).
(i)

Clean the drain valves. Apply Loctite 577 on threads and screw the drain
valves.

(j)

Remove the ground cable from the aircraft.

(k) Release

PARK

lever or remove wheel chocks.

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B. Oil system

The engine Rotax 912 ULS2 uses a dry sump lubrication system with total oil
system capacity 3.5 l. A filler cap and dipstick is provided for determining
the amount of oil in the system.

WARNING

ALWAYS ALLOW ENGINE TO COOL DOWN TO AMBIENT
TEMPERATURE BEFORE START OF ANY WORK, OTHERWISE
YOU RISK BURNING FROM HOT PARTS.
ENGINE IGNITION MUST BE SWITCHED OFF.

(1) Oil level check:

Type of maintenance:

Line

Personnel qualification:

Independent

certifying

staff

qualified

in accordance with Part-66 or higher.

Recommended tools, materials, persons and documentation:

ITEM

QUANTITY

Cotton cloth

Persons

Tab. 12-7 Recommended tools, materials, persons and documentation

(a) Level the aircraft (Chapter 08-10).
(b) Set the brake lever to

PARK

position or install wheel chocks.

(c) Open inspection door located in engine upper cowling.
(d) Unscrew the cap (2, Fig. 12-3) on oil tank (1), pull out dipstick (3) and

clean it.

(e) Turn the propeller several times by hand in direction of engine rotation

to pump all the oil from the engine to the oil tank. This process is
completed when air flows back to the oil tank. This flow can be
perceived as a murmur.

(f)

Put dipstick back in oil tank and check oil level.

(g) The oil level in the oil tank should be between the two marks (min. /

max.) on the oil dipstick, but must never fall below the min. mark.

(h) If oil is below minimum level, replenish as required.
(i)

Fit the oil dipstick and tighten the oil tank cap by hand.

(j)

Close inspection door at upper engine cowling.

(k) Release

PARK

lever or remove wheel chocks.

REPLENISHING

SERVICING

(2) Oil replenish:

Type of maintenance:

Line

Personnel qualification:

Independent

certifying

staff

qualified

in accordance with Part-66 or higher.

Recommended tools, materials, persons and documentation:

ITEM

QUANTITY

New oil

Cotton cloth

Persons

Tab. 12-8 Recommended tools, materials, persons and documentation

NOTE

For longer flights replenish oil to max. mark to warrant more
reserve. Difference between min. and max. level marks is 0.5 l.

(a) Put the aircraft on leveled surface.
(b) Set the brake lever to

PARK

position or install wheel chocks.

(c) Open inspection door located on engine upper cowling.
(d) Unscrew the cap (2, Fig. 12-3) on oil tank (1), pull out dipstick (3) and

clean it.

(e) Turn the propeller several times by hand in direction of engine rotation

to pump all the oil from the engine to the oil tank. This process is
completed when air flows back to the oil tank. This flow can be
perceived as a murmur.

(f)

Replenish oil to the correct level. Make sure that the corresponding
kind of oil is used (Tab. 12-1).

(g) Put dipstick back in oil tank and check oil level. The oil level in the oil

tank should be between the two marks (min. / max.) on the oil dipstick,
but must never fall below the min. mark.

(h) Fit the oil dipstick and tighten the oil tank cap by hand.
(i)

Close inspection door at upper engine cowling.

(j)

Release

PARK

lever or remove wheel chocks.

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Fig.

12-3

Oil Level Check

(3) Oil change:

Type of maintenance:

Line

Personnel qualification:

Independent

certifying

staff

qualified

in accordance with Part-66 or higher.

Recommended tools, materials, persons and documentation:

ITEM

QUANTITY

Wrench 17

1 pc

Wrench 19

1 pc

Wrench 22

1 pc

Ignition wrench 16

1 pc

Oil filter wrench

1 pc

Jig

1 pc

Rags

2 pcs

Syringe

1 pc

New oil

4 l

New oil filter

1 pc

Cooper gasket ring

14 mm

3 pcs

Safety wire

0.8 mm

Persons

Maintenance Manual (Line Maintenance) for Rotax
Engine Type 912 Series (Ref. No. MML-912)

Tab. 12-8 Recommended tools, materials, persons and documentation

1  Oil tank
2  Oil tank cap
3  Dipstick

REPLENISHING

SERVICING

WARNING

CARELESS  DRAINING  OF  HOT  ENGINE  OIL  MAY  CAUSE
SCALDS.  DISPOSE  OF  USED  OIL  AND  FILTERS
RESPECTING  THE  ENVIRONMENTAL  AND  SAFETY
REGULATIONS.

CAUTION

FAILURE TO FOLLOW INSTRUCTIONS BELOW COULD LEAD
TO AIR ENTERING THE OIL SYSTEM AND DEFECTS
ON VALVE TRAIN.

NOTE

Run engine to warm oil before beginning oil change procedure.
Do not drain the oil suction line, oil radiator and return line
to avoid of air entering the oil system.
Carry out the oil and filter change quickly and without interruption
to prevent draining of the oil system from hydraulic tappets.

(a) Put the aircraft on leveled surface.
(b) Set the brake lever to

PARK

position or install wheel chocks.

(c)  Check oil level (see 2.B.(1)).
(d)  Remove engine cowlings (Chapter 71-10).
(e)  Place a suitable container under the oil tank, remove the drain plug

(9, Fig. 12-5) (quick drain valve if fitted) and drain oil out.

(f)

Turn the propeller several times by hand in direction of engine rotation
to pump all the oil from the engine to the oil tank. This process is
completed when air flows back to the oil tank. This flow can be
perceived as a murmur.

(g) On oil cooler (2), remove safety wire and disconnect hoses (4; 5). Suck

oil from oil cooler (2).

(h) Unscrew oil filter.
(i)

Install new oil filter:

•

clean the contact surface of the oil pump housing with a clean cloth

•

apply a thin film of engine oil on the gasket of a new oil filter

•

screw on oil filter until oil filter gasket is seated solidly

•

tighten oil filter with 3/4 turn (270°)

(j)

Cut old oil filter without producing any metal debris and inspect filter
material for foreign objects.

(k) Remove safety wire, unscrew magnetic plug (Fig. 12-4), check

for metal contamination and refit, torque to 25 Nm. Secure magnetic
plug using safety wire.

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WARNING

IF METAL CONTAMINATION IS FOUND ON PLUG
(FIG. 12-4), CONTACT AIRCRAFT MANUFACTURER!

Fig.

12-4

Magnetic Plug

(l)

Fill the oil cooler with new oil. Make sure that the corresponding kind
of oil is used (Tab. 12-1).

(m) Connect hoses (4; 5, Fig. 12-5) on the oil cooler (2); secure them

with safety wire.

(n) On bottom of oil tank screw the drain plug (9) with new gasket ring (10)

torque to 25 Nm. Secure drain plug (9) with safety wire.

NOTE

During tightening of drain plug, hold upper nut with second
wrench.

(o) Remove cap (3), pour approximately 3 l of new oil into oil tank. Make

sure to use corresponding kind of oil (Tab. 12-1); close the oil tank cap
(3).

(p) On oil tank (1) disconnect hose (7); route disconnected hose under

engine and put to suitable container.

(q) Seal up hose socket (10).

REPLENISHING

SERVICING

(r) Remove upper spark plugs from every cylinder head on the engine

(refer to the Maintenance Manual (Line Maintenance) for Engine Type
912 Series, Ref. No.: MML-912 for spark plugs removal information).

(s) On vent hose (8) put on jig making pressure at 0.45 bar.

CAUTION

PRESSURE SHOULD NEVERRISE OVER 1 BAR.

(t)

Rotate the propeller while beginning a continual flow of oil from hose
(7). Add more oil if necessary.

(u) Disconnect jig, connect back hose (7) on oil tank and reinstall spark

plugs; tighten spark plugs on recommended torque moment
(refer to the Maintenance Manual (Line Maintenance) for Engine Type
912 Series, Ref. No.: MML-912 for spark plugs removal information).

(v)  Check oil level (see 2.B.(1)).
(w)  Install engine cowlings (Chapter 71-10).
(x)  Release

PARK

lever or remove wheel chocks

–

Oil tank

–

Oil hose

–

Oil cooler

–

Venting hose

–

Oil tank cap

–

Drain plug

–

Oil hose

–

Cooper gasket ring

14 mm

–

Oil hose

–

Hose socket

–

Oil thermostat

Fig. 12-5 Oil Change

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