FlySynthesis Wallaby Maintenance Manual

MAINTENANCE MANUAL

TWO SEATERS ULTRA LI GHT

WALLABY

EQUIPPED WITH:

ROTAX 503

ENGINE

FLYSYNTHESIS WALLABY SECTION VIII

MAINTENANCE MANUAL

3.1 LOG OF REVISIONS

All revisions to this Maintenance Manual must be recorded in the following table.

Revision Number Revision Highlight and Pages affected Date Signature

English Edition 2003-03-28 Page VIII-2

FLYSYNTHESIS WALLABY SECTION VIII

MAINTENANCE MANUAL

MAINTENANCE manual

TABLE OF CONTENT

Paragraph Page

3.1 LOG OF REVISIONS 2
MAINTENANCE MANUAL 4

3.2 INTRODUCTION 4

3.3 SCHEDULED MAINTENANCE 4

3.4 AIRPLANE PREPARATION FOR FLIGHT 5
REFUELING 5
FUEL DRAINING 5
PRE FLIGHT INSPECTION 5

3.5 DETAILED SCHEDULED I NSPECTIONS 8

3.6 TORQUE FOR BOLTS AND NUTS 13

3.7 MAINTENANCE PER PERI OD OF TIME 13
SCHEDULED INSPECTION 13
TIME LIMITED COMPONENTS 13

3.8 NON SCHEDULED MAINTENANCE 13
HEAVY LANDING 13
DAMAGE TO THE COMPOSITE STRUCTURE 14
EXCEEDING ENGINE LIMITS 14
PAINTING THE AIRPLAN E 14

English Edition 2003-03-28 Page VIII-3

FLYSYNTHESIS WALLABY SECTION VIII

MAINTENANCE MANUAL

MAINTENANCE MANUAL

3.2 INTRODUCTION

In order to maintain the airplane in an airworthy condition, to enjoy a safe flight and
save on repair expenses, maintenance tasks must be carried out.

Maintenance instructions are divided to scheduled and non-scheduled tasks.
Scheduled tasks are carried per time, either flight hours or period, like once a year.

Non -scheduled tasks are per airplane condition after damage is discovered or some
unusual happening like a heavy landing.

3.3 SCHEDULED MAINTENANCE

Scheduled maintenance is composed of the following:
Preparation of the airplane for flight includes refueling, fuel system draining and pre

flight inspection.
Scheduled inspections per flight time are planed in a cycle of 50 flight hours, to match
the engine manufacturer requirements, these are composed of the following
inspection types: 25 hours inspection; 50 hours inspection; 100 hours inspection and
200 hours inspection.

The normal cycle repeats itself per following table:
Flight Time 25 50 100 150 200 250 300 350 400

Inspection Type 25 50 100 50 200 50 100 50 200
Flight Time 450 500 550 600 650 700 750 800

Inspection Type 50 100 50 200 50 100 50 200
Flight Time 850 900 950 1000 1050 1100 1150 1200

Inspection Type 50 100 50 200 50 100 50 Overhaul
The 25 hours inspection should be carried out only once after the first 25 flying hours

of the airplane. It is also done once after an engine change, engine or airplane
overhaul or major repair due an accident or other major damage.

Scheduled maintenance per period is done after one year or two years, if the airplane
did not reach certain time of flight.

Other limited periods for certain equipment are listed separately.

English Edition 2003-03-28 Page VIII-4

FLYSYNTHESIS WALLABY SECTION VIII

MAINTENANCE MANUAL

3.4 AIRPLANE PREPARATION FOR FLIGHT
REFUELING

Magnetos OFF check
Master switch ON
Fuel quantity check
Master switch OFF
Fill the required amount of fuel per flight plan
Master switch ON check
fuel quantity
Master switch OFF
Record amou nt of fuel in airplane log

FUEL DRAINING

Fuel drainage should be carried out once a day before the first flight, and 10 minutes
after each refueling of the tank. Fuel drainage should also be repeated if the airplane
was parked for more than three hours.

CAUTION

Before attempting any service or inspection on the airplane, check that the Magnetos
and Master Switch (key) are OFF

Use transparent container to drain into. If water is found in the drained fuel, repeat
fuel drain operation.

Fuel drainage should be performed before moving the airplane from it’s parking place,
to avoid condensed water present on tank Bottom to emulsify with fuel.

PRE FLIGHT INSPECTION

The pre flight inspection should be carried out BEFORE EACH FLIGHT, even if the
previous fligh t was very short. The pilot should carry out the inspection.
The inspection does not require any tools; only a clean rag is needed. It is important
to verify by sight and touch that there are no failures, defects, excessive clearances
or play.

For the det ailed Pre Flight Inspection see Section IV of the AFM.
If a Daily Inspection was just completed, pre flight Inspection is not required.

English Edition 2003-03-28 Page VIII-5