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

Effectivity:

ALL

28. 04. 2021

POWER PLANT
- GENERAL

–

Right carburettor

–

N/A

–

Left carburettor

–

Bracket

–

Left intake manifold

–

Secure clamp

–

Bolt M10 x 110

–

Bolt

–

Bolt M10 x 10

–

Bolt

–

Magnetic plug

–

Bolt of the pressure regulator

–

Spring washer ø10

–

Banjo fitting

Fig. 71-5 New Engine

ENGINE ATTACHMENT

POWER PLANT

- GENERAL

(2) Engine installation:

Advance preparation of the new engine:

(a) Remove carburettors (1; 2, Fig. 71-5) (see Rotax Maintenance

Manual).

(b) Remove left intake manifold (3) (see Rotax Maintenance Manual).
(c) Remove the bolt (4) from top right engine mount attachment point

together with washer (7).

(d)

Drill holes ø1

.6 mm for lockwire on bolts (10; 11; 12).

(e) Check magnetic plug (6) for foreign objects. Clean it and refit. Tighten

it to torque 25 Nm. Secure the magnetic plug (6) with lockwire.

WARNING:

IF METAL CONTAMINATION IS FOUND ON PLUG
(FIG. 12-4, CHAPTER 12-10), CONTACT AIRCRAFT
MANUFACTURER!

(f)

On the starter secure the clamp (10, Fig. 71-5) with lockwire.

(g) On oil pump secure the bolt of the pressure regulator (13)

with lockwire.

(h)

On oil pan, loosen and turn the banjo fitting (14) approximately 10°

clockwise (in direction towards propeller). Tighten the banjo bolt
to torque 35 Nm and secure it with lockwire.

(i)

On engine gear, put the bracket (9), washer (7) and tighten bolt (5).

(j)

Install the baffle for cylinders cooling on engine for towing version
of aircraft (Chapter 75-20).

Connecting engine systems to engine:

(k) Lift engine with hoist, put engine on engine mount and simultaneously

connect upper exhaust pipes (2; 3, Fig. 78-2) to engine.

(l)

Install distance rollers (9, Fig. 71-4), washers (10) and tighten bolts
(6; 7; 8) to torque 40 Nm.

(m) On drip trays (4; 5), clean holes i

n the hose sockets with drill ø

3 mm;

carefully bend hose socket, 30° to the rear, 20° to the

centre

as in (Fig. 71-6).

(n)

Carry out the same on the right drip tray 30° to rear and 20°

to the centre.

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Fig. 71-6 Left drip tray

(o) Install and connect intake manifold (2, Fig. 71-4), lubricated seal

papers (3); drip trays (4; 5), carburettors (1) (see Rotax Maintenance
Manual), and install airbox (Chapter 71-60) for correct positioning
intake manifolds with carburettors.

(p) Remove Airbox (Chapter 71-60).
(q) Install lower exhaust pipes (4; 5, Fig. 78-2) and secure upper exhaust

pipes (2; 3) (Chapter 78-10).

(r) Connect oil system (13, Fig. 71-4) with oil pump and oil pan,

by connecting hoses (14; 15) and securing with safety clamp (19),
gasket rings (18) and elbow (16) with the adapter (17); tighten
to torque moment 30 Nm and secure with lockwire.

(s) Shorten the water hose (1, Fig. 71-7) about 15 mm and water hose (2)

pull out, so that the hose socket output of expansion tank was parallel
with upper strut of engine mount.

(t)

Connect cooling system to engine, by connecting hoses (14; 17; 19,
Fig. 75-2) and securing them with hose clamps (6; 27).

(u) Install air hose (22, Fig. 21-5 (Chapter 21-40).
(v) Connect the fuel hoses (1; 2; 3; 5, Fig. 28-7) to fuel pump

and carburettors (Chapter 28-20).

(w) Connect and adjust control cables of throttle controller (20, Fig. 76-3)

and choke (22) to carburettors (Chapter 76-10).

(x) Connect drain hoses (3; 6, Fig. 71-14) to drip trays and fuel pump

(Chapter 71-60).

Connecting electric system:

NOTE

See Aircraft Wiring Manual (Doc. No. AS-AWM-01-000).

ENGINE ATTACHMENT

POWER PLANT

- GENERAL

–

Hose

–

Hose

–

Hose

–

Safety clamp 14.5

–

Expansion tank

Fig. 71-7 Cooling System

(y) On engine cylinder head No.2, connect the grounding wires 221A

and 222A.

(z)  On engine cylinder head No.3 connect the grounding wire 222A.
(aa)  On engine mount connect wire 221A.
(bb)  On  SMD-Electronic  module,  remove  the  connectors  from  holder

and connect wires B30, WH-113B, WH-114B to connectors.

(cc) Re-route ground wire from forward grounding point on No.3 induction

manifold to the inside of the ignition unit to avoid chafing. Route around
the front between the inlet cables and attach to the rear mounting bolt.
Apply on left side of SMD-Electronic module piece of pyrojacket
(fire sleeve) and secure with cable tie (4.8 mm) as required.

(dd)  On generator, connect wire of generator 220A.
(ee)  On starter, connect wire of starter 101B.
(ff)  Near engine fuel pump, connect the connectors of pressure oil sensor

M101 (red wire with red wire and white wire with white wire). Insulate
them with shrink tubes.

(gg) Near engine cylinder heads No.2, No.3 and near oil filter, connect

wires of temperature sensors M72 and M73; secure wire connectors
with shrink tubes.

(hh) At charging rectifier located on firewall, connect wires of generator

YE-106B and YE-107B (2 pcs).

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(ii) On firewall, connect connector of engine rpm indicator B28.
(jj) Insulate wires of ignition with pyro jacket (fire sleeve) coverings

between intake manifolds 2-4 and 1-3. Secure them with cable ties.

(kk) Fix all hoses and cables to prevent movement and abrasion with cable

ties.

(ll)  Install Airbox (Chapter 71-60).
(mm) Install propeller (Chapter 61-10).
(nn)  Fill with oil (Chapter 12-10).
(oo)  Fill with coolant and fuel (Chapter 12-10).
(pp)  Test to verify the task and check:

•

If all systems are connected and secured.

•

Proper connection of cables.

•

Good connection of joints.

•

Disconnect connector of magnetos. Use the multimeter to check

if  magneto  switches  are  in  OFF  position,  wires  WH-113B,
WH-114B  with  negative  terminal,  circuit  is  closed.  When
the  magneto  switches  are  in  ON  position,  wires  WH-113B,
WH-114B with negative terminal, circuit is open.

•

Torque moments on nuts.

•

If hoses and cables are securely fixed.

•

If all bolts are tight.

•

That no foreign objects remained in aircraft.

(qq) Install engine cowlings (Chapter 71-10).

B. Engine mount

Type of maintenance:

Heavy

Personnel qualification:

Independent certifying staff qualified in accordance

with Part-66 or higher.

Recommended tools, materials, persons and documentation:

ITEM

QUANTITY

Hex key 7

1 pc

Wrench 13

1 pc

Persons

Tab. 71-3 Recommended tools, materials, persons and documentation

(1) Engine mount removal:

(a)  Remove engine (Chapter 71-20).
(b)  Remove drain hoses (Chapter 71-70).
(c)  Remove  nuts  (7,  Fig.  71-8),  washers  (8),  front  plates  (4)  and  front

silentblocks (2).

(d) Remove the mount (1) from the aircraft.
(e) Remove rear silentblocks (2), spacers (5) and aft plates (3)

from the mount.

(f)

Remove bolts (6) from the aircraft.

ENGINE ATTACHMENT

POWER PLANT

- GENERAL

(2) Engine mount installation:

(a)  Inspect the engine mount. Look especially for cracks.
(b)  Inspect silentblocks for damage and cracks.
(c)  Insert bolts (6, Fig. 71-8) to holes on the firewall.
(d)  Put  the  rear  plates  (3),  rear  silentblocks  (2)  and  spacers  (5)

on the bolts (6).

(e) Put the mount (1) in position and put an appropriate support below

the mount.

(f)

On bolts (1) put on silentblocks (2), front plates (4), washers (8),
and tighten nuts (7) to torque 22.5 Nm.

(g) Test to verify the task and check:

•

Torque moments on nuts.

•

That no foreign objects remained in aircraft.

–

Engine mount

–

Spacer

–

Silentblock

–

Bolt M8 x 90

–

Silentblock rear plate

–

Self-locking nut M8

–

Silentblock front plate

–

Washer ø8

.4 x 16 x 1.6

Fig. 71-8 Engine Mount Removal / Installation

ATTACH FITTINGS

POWER PLANT

- GENERAL

71-40

ATTACH FITTINGS

1. DESCRIPTION

There are two attach fittings installed on the engine to which the hoses and wires are
fixed.

2. MAINTENANCE PRACTICES

A. Brackets

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

Hex key 8

1 pc

Loctite 243

Persons

Tab. 71-4 Recommended tools, materials, persons and documentation

WARNING

ENGINE IGNITION MUST BE SWITCHED OFF.

(1) Brackets removal:

(a) Make sure that the

IGNITION

switches are set to

OFF

(b)  Remove the upper engine cowling (Chapter 71-10).
(c)  Remove items attached to the brackets (1, Fig. 71-6)
(d)  Remove bolts (3), washers (2) and brackets (1)

(2) Brackets installation:

(a) Make sure that the

IGNITION

switches are set to

OFF

(b) Attach brackets (1, Fig. 71-6) using washers (2), bolts (3) and secure

by using Loctite 243.

AIR INTAKES

POWER PLANT

- GENERAL

71-60

AIR INTAKES

1. DESCRIPTION

Cooling air is received through the two upper engine cowling intakes and is distributed
to the engine compartment.
Air intake is located on the left side of spinner. The cold air flows through the ram air
tunnel  (glued  at  the  lower  engine  cowling),  air  hose,  air  filter  holder  and  air  filter
to  the  airbox.  The  air  filter  holder  receives  warm  air  from  a  shroud  installed
on  the  muffler  (Chapter  78)  and  cold  air  from  the  ram  air  tunnel  and  mixes  them
depending  on  preheating  control  setting.

CARBUR. PREHEATING

controller

is located on the instrument panel.

2. MAINTENANCE PRACTICES

A. Airbox and air filter holder

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 10

1 pc

Special wrench 14

1 pc

Screwdriver 5

1 pc

Hex key 4

1 pc

Hex key 5

1 pc

Oetiker pliers- Crimping pliers

1 pc

Knife

1 pc

Pliers

1 pc

Cable tie 2.6

7 pcs

Lockwire

0.8 mm

Loctite 243

Persons

Tab. 71-5 Recommended tools, materials, persons and documentation

WARNING

ENGINE IGNITION MUST BE SWITCHED OFF. DISCONNECT
NEGATIVE TERMINAL OF AIRCRAFT BATTERY.

Effectivity:

ALL

28. 04. 2021

POWER PLANT
- GENERAL

(1) Airbox and air filter holder removal:

(a) Make sure that the

IGNITION

switches are set to

OFF

(b) Remove the engine cowlings (Chapter 71-10).
(c) Disconnect negative terminal of battery (Chapter 24-30).

Air filter holder removal:

(d) Disconnect air hoses (4; 5, Fig. 71-10), by loosening hose clamps

(13; 14).

(e) Disconnect control cable (3) from the air filter holder (2).
(f)

Unplug the connector of temperature sensor (21).

(g) Remove safety pins (20) and unclip the latches on upper and lower

side of air filter holder (2).

(h) Remove air filter holder (2) with air filter (6).

Airbox removal:

(i)

Disconnect drain hoses (9; 10; 11; 12), by removing cable ties.

(j)

Loosen hose clamps (13) on hoses (7; 8).

(k) Unscrew nuts (19), remove washers (16; 17; 18) and bolt (15).
(l)

Remove the airbox (1).

(2) Airbox and air filter holder installation:

(a) Make sure that the

IGNITION

switches are set to

OFF

(b) Thoroughly clean and lubricate all movable parts of the air induction

system before each assembling (Chapter 12-20).

filter holder (2) and check the air hoses for cracks; if cracks are found
use new air hoses.

(d) Apply two layers of adhesive tape on each end of hoses.

Airbox installation:

(e) Connect airbox (1) with carburettors using hoses (7; 8).

NOTE

Hose (7) is longer than hose (8).

(f)

Attach the airbox (1) to engine mount (24) by using bolts (15), washers
(16; 17; 18) and nuts (19).

(g) Secure hoses (7; 8) to the airbox (1) by hose clamps (13).
(h) Slide drain hoses (9; 10; 11; 12) on airbox (1) and secure them using

cable ties.
Air filter holder installation:

(i)

Fit clean air filter (6) to the air filter holder (2).

(j)

Attach them (2; 6) to the airbox (1), clip two latches and secure them
with safety pins (20).

(k) Connect the temperature sensor connector (21).
(l)

Connect the control cable (3) to the air filter holder (2).

AIR INTAKES

POWER PLANT

- GENERAL

(m) Connect air hoses (4; 5) and secure them with hose clamps (13; 14).
(n) Carry out test and check:

•

If all bolts connections are tight.

•

If hoses are firmly secured and sealed.

•

That the latches are secured with safety pins.

•

Operation of air filter holder flaps (fully open and fully close

position).

•

That no foreign objects remain in the aircraft or engine

compartment.

(o) Install the engine cowlings (Chapter 71-10).

AIR INTAKES

POWER PLANT

- GENERAL

–

Airbox

–

Hose clamp

50-70

–

Air filter holder

–

Bolt M6 x 18

–

Control cable

–

Washer

6.4 x 18 x 1.6

–

Air hose ø63 x 420

–

Rubber washer

6.4

–

Air hose ø51 x 260

–

Washer

6.4 x 12 x 1.6

–

Air filter

–

Self-locking nut M6

–

Hose

50 x 60

–

Safety pin

1.4

–

Hose

50 x 40

–

Electrical connector

–

Drain hose R

For information:

–

Drain hose L

–

Ram air tunnel

–

Upper drain hose R

–

Airbox pre-heat exchanger

–

Upper drain hose L

–

Engine mount

–

Hose clamp

40-60

Fig. 71-10 Airbox Removal / Installation (page 2 of 2)

B. Air filter

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

Air filter

1 pc / AR

Air filter oil

Persons

Tab. 71-5 Recommended tools, materials, persons and documentation

(1) Air filter inspection / check:

Check air filter on each inspection or annually for cleanliness. Air filter can
be cleaned using compressed air and then brushed with air filter oil. Replace
air filter if necessary.

Effectivity:

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28. 04. 2021

POWER PLANT
- GENERAL

C. Carburettor pre-heat control

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 10

1 pc

Special wrench 14

1 pc

Screwdriver 5

1 pc

Hex key 4

1 pc

Hex key 5

1 pc

Solder set

1 pc

Knife

1 pc

Pliers

1 pc

Cable tie 2.6

7 pcs

Cable tie 3.6

5 pcs

Shrink tube

4.8 x 2.4 mm

Adhesive sealing tape TESA FIX 20 mm

Lockwire

0.8 mm

Loctite 243

Persons

Tab. 71-6 Recommended tools, materials, persons and documentation

WARNING

ENGINE IGNITION MUST BE SWITCHED OFF.

AIR INTAKES

POWER PLANT

- GENERAL

(1) Carburettor pre-heat control removal:

(a) Make sure that the

IGNITION

switches are set to

OFF

(b) Remove the engine cowlings (Chapter 71-10).
(c) Unscrew cable end fitting (1, Fig. 71-12), remove shrink tube,

and unsolder thread rod (2).

(d) From the cockpit, remove the inner cable by pulling handle (14)

and remove the nut (15).

(e) Remove parachute container (Chapter 25-60).
(f)

In parachute compartment, remove lockwire (6) and remove
the control cable (7) from firewall.

(g) Remove cable tie (9), unstick adhesive tape (10), pull green sleeve

(11).

NOTE

The ball can drop from green sleeve (10).

(h) Unscrew the nut (12), remove washer (13) and pull out control cable

(7) from central console.

NOTE

For easier removal use special tool (Fig. 71-11) and hex key
inserted on control cable end from cockpit side.

Fig. 71-11 Band Wrench Size 14

(i)

In the engine compartment, unscrew nut (3, Fig. 71-12), remove
washers (4) with the nut (3), screw shackle (5).

Effectivity:

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28. 04. 2021

POWER PLANT
- GENERAL

(2) Carburettor pre-heat control installation:

(a) Make sure that the

IGNITION

switches are set to

OFF

(b) Thoroughly clean and lubricate all movable parts of the air induction

system before each assembling. Refer to lubrication chart
(Chapter 12-20).

(c)  Control cable (7, Fig. 71-12) passes through central console (16).
(d)  Rotate the control cable (7) so the ball is at the top.
(e)  Slide washer (13), tighten the nut (12) and secure using Loctite 243.

NOTE

For better performance use special wrench (Fig. 71-11)
and hex key inserted in control cable end from cockpit side.

(f)

Insert the ball and simultaneously slide on the green sleeve
(11, Fig. 71-12):

•

Push the green sleeve (11) just to first indication of minimal

resistance.

•

Check for correct operation by pulling and pushing handle; the ball

must engage with ratchet, movement must not be free.

(g) Apply two layers of textile adhesive tape (10) and lock it with cable tie

(9).

(h) Assemble screw shackle (5) with nut (3), washer (4) and bowden end

(8); put them on control cable (7) and secure them with lockwire (6).

(i)

Insert the cable with screw shackle through hole in firewall (17), apply
washer (4) and screw on the nut (3), secure with Loctite 243.

(j)

Secure control cable (7) with cable ties (3.6 mm) along the length
as required.

(k) Push handle (14) in, leaving a gap of 2 mm (carburettor pre-heating)

and set air filter holder bellcrank (18) to position with cold air flap fully
open.

(l)

Cut inner wire to correct length, solder thread rod (2), slide shrink tube
and screw on cable end fitting (1), and adjust end fitting to connect
with nipple on bellcrank.

(m)  Shrink the shrink tube on thread rod (3).
(n)  Connect cable end fitting (1) with nipple on bellcrank (18).
(o)  Carry out test and check:

•

If all bolts connections are tight.

•

Operation of air filter holder flaps (fully open and fully close).

•

That no foreign objects remain in the aircraft or engine

compartment.

(p) Install the engine cowlings (Chapter 71-10).

WT9 Dynamic LSA. AIRCRAFT MAINTENANCE MANUAL (AS-AMM-01-000, 22. 05. 2017) - page 40