AMM A22LS - SR No 204 - A6 MPL

Aeroprakt Ltd.
24, Polevaya str., Kiev, Ukraine

Tel: 0038 044 496-77-21
Fax: 0038 044 496-77-31
e-mail: [email protected]
www.aeroprakt.kiev.ua
AEROPRAKT-22LS
Airplane Maintenance Manual
A22LS-AMM-02
Airplane Model: AEROPRAKT-22LS (A-22LS)
Airplane Registration Number:
Airplane Serial Number: 204
Date of issue: 26.12.2013
Approved by: Yuriy Yakovlyev
Position: Chief designer
Date of approval: 26.12.2013
This manual must be carried in the airplane at all times.

This airplane is to be serviced and maintained in compliance with information and instructions
contained herein.
1
AEROPRAKT-22LS Airplane Maintenance Manual A22LS-AMM-02
RECORD OF REVISIONS
No part of this manual may be reproduced or changed in any manner without a written
consent of the Manufacturer.
Any revision of the present manual must be recorded by the Manual holder in the following
table according to information from the Manufacturer.
New or amended text in the revised pages must be marked by a black vertical line on the
left hand margin. The Revision No. and the date must be shown on the bottom left hand
side of the page.
Rev. No. Notice/Bulletin No. Affected Pages Date Issued Date Inserted Signature
2
Contents
1 General ......................................................................................................................... 4
1.1 SOURCES TO PURCHASE PARTS ......................................................................................................................... 5
1.2 EQUIPMENT LIST ............................................................................................................................................... 5
1.3 DISPOSABLE REPLACEMENT PARTS ................................................................................................................... 5
1.4 ENGINE SPECIFICATIONS ................................................................................................................................... 6
1.5 WEIGHT AND BALANCE INFORMATION ............................................................................................................. 7
1.6 TIRE INFLATION PRESSURE ............................................................................................................................... 7
1.7 APPROVED FUEL, OILS AND CAPACITIES ........................................................................................................... 7
1.8 RECOMMENDED FASTENER TORQUE VALUES .................................................................................................... 8
1.9 GENERAL SAFETY INFORMATION ...................................................................................................................... 8
1.10 REPORTING MAINTENANCE, SERVICE, AND SAFETY DIFFICULTIES .................................................................... 9
2 Inspections ................................................................................................................ 10
3 Structures .................................................................................................................. 13
4 Landing gear .............................................................................................................. 17
5 Brake system ............................................................................................................. 22
6 Engine and its control system ................................................................................. 26
7 Cooling system .......................................................................................................... 31
8 Lubrication system.................................................................................................... 33
9 Fuel system ................................................................................................................ 34
10 Exhaust system ......................................................................................................... 37
11 Propeller ..................................................................................................................... 39
12 Airplane control system ............................................................................................ 40
13 Electrical system ....................................................................................................... 45
14 Cockpit heating system ............................................................................................ 52
15 Instruments and Avionics ......................................................................................... 53
16 Full and static pressure system ............................................................................... 55
17 Pilot seats and harness belts ................................................................................... 57
18 Cockpit doors ............................................................................................................ 58
19 Recovery system ....................................................................................................... 59
20 Structural repair......................................................................................................... 60
18.1 GENERAL........................................................................................................................................................ 60
18.2 FUSELAGE GLAZING REPAIR ........................................................................................................................... 60
18.3 FABRIC COVERING REPAIR .............................................................................................................................. 61
18.3 COMPOSITE PARTS’ REPAIR ............................................................................................................................ 62
18.4 RESTORING OF DAMAGED PAINT/COATING ..................................................................................................... 64
21 Feedback Form .......................................................................................................... 65
3
1 General
NOTE: This manual is subject to change by the notifications or safety bulletins published
at the official website of Aeroprakt company http://www.aeroprakt.kiev.ua.
This manual describes the procedures of proper aircraft handling and servicing
recommended by the aircraft manufacturer. It also specifies the requirements to inspection
and maintenance that are required for keeping the flight performance and reliability at a
level of a new airplane. It is recommended to adhere to the scheduled periods of
greasing/lubrication and preventive maintenance taking into account the climate and
operating conditions.
Each of the inspection or service/maintenance action outlined in this manual specifies:
̶ recommended special tools (if any) to accomplish the task,
̶ the parts needed to perform the task,
̶ type of maintenance, for example, line, heavy, or overhaul,
̶ the level of certification needed to accomplish the task, for example, owner, A&P,
LSA repairman with inspection (or maintenance) rating, and repair station,
̶ detailed instructions and diagrams as needed to perform the task,
̶ method to test/inspect to verify the task was accomplished properly.
The types of the maintenance (TM) tasks specified in this manual are marked with the
following one-letter abbreviation and are defined as follows:
Line maintenance (L) – any repair, maintenance, scheduled checks, servicing,
inspections, or alterations not considered heavy maintenance that is approved by the
manufacturer and is specified in this maintenance manual.
Heavy maintenance (H) – any maintenance, inspection, repair, or alteration which
manufacturer has designated that requires specialized training, equipment, or facilities.
Overhaul (O) – maintenance, inspection, repair, or alterations that are only to be
accomplished by the manufacturer or a facility approved by the original manufacturer of
the product.
The levels of certification (LC) needed to accomplish the maintenance tasks specified in
this manual are marked with the following three-letter abbreviation and are defined as
follows:
OWN (owner) – items that can be expected to be completed by a responsible owner who
holds a pilot certificate but who has not received any specific authorized training.
LRI (LSA repairman inspection) – items that can be expected to be completed on an
ELSA by a responsible owner, which holds an FAA repairman certificate (light sport
aircraft), with an inspection rating or equivalent.
LRM (LSA repairman maintenance) – items that can be expected to be completed on a
SLSA by a responsible individual, which holds a FAA repairman certificate (light sport
aircraft), with a maintenance rating or equivalent.
A&P (airframe and powerplant mechanic) – items that can be expected to be completed
by a responsible individual who holds a mechanic certificate with airframe or powerplant
ratings, or both, or equivalent.
TSP (task specific) – items that can be expected to be completed by a responsible
individual who holds either a mechanic certificate or a repairman certificate and has
received task specific training to perform the task.
4
1.1 Sources to purchase parts

For purchasing any parts or spares for this airplane contact your local dealer/distributor or
address the aircraft Manufacturer: Aeroprakt Ltd., Polyova str. 24, 03056, Kyiv, UKRAINE,
e-mail: [email protected] or [email protected], web: www.aeroprakt.kiev.ua.
1.2 Equipment list

This aircraft has the following equipment:
Flight instruments:
̶ BK-3 airspeed indicator
̶ BG-3E altimeter
̶ BC-2A vertical speed indicator
̶ CHY1 slip indicator
̶ CM13L compass
Engine instruments:
̶ XIF4000803 tachometer
̶ HOBBS hour meter
̶ XIH4002500 cylinder head temperature gauge
̶ XIE4001000 oil temperature gauge
̶ XIE4001300 oil pressure gauge
̶ 2 VAZ2104-3827010 fuel level indicators
Avionics:
̶ Dynon EFIS D6 electronic flight information system
̶ Filser ATR-500 radio transceiver
̶ Filser TRT800H-OLED transponder
Miscellaneous equipment
̶ LEOCH DJW12-18 battery
̶ red position and strobe light
̶ green position and strobe light
̶ white/red position and strobe light
1.3 Disposable replacement parts

The manual (see Sections 3 through to 16) contains the check lists with information about
check periods, recommended change out (RCO) times as well as references to inspection
and servicing/maintenance instructions for the airplane components and systems.
Before expiration of the recommended change out time of separate airplane parts or when
it is not specified their operation shall be performed on condition (OC). Such parts must be
inspected and replaced, if necessary, before expiration of the RCO (if specified).
If inspections and checks arouse any issues not covered in this manual contact the
Manufacturer for additional information.
Upon detecting corrosion on airplane structural elements contact the Manufacturer for the
required technical support. In this case further operation of the airplane may be
dangerous!
5
1.4 Engine specifications

WARNING! On all issues of engine operation see Rotax engine Operator's Manual.
Follow its instructions to ensure safe and efficient operation of the engine.
Engine data and operational limitations are given in the table below:
Engine manufacturer: BOMBARDIER-Rotax-GmbH (Austria)
Engine model: Rotax-912UL Rotax-912ULS
Engine type: Flat-four, four-stroke
Maximum takeoff power: 80 h.p. 100 h.p.
Time limit at full power: 5 min (5800 rpm)
Max. revolutions (no time limit) 5500 rpm
Min. revolutions at idle 1400 rpm
Maximum cylinder head 150 ºC (300 ºF) 135 ºC (284 ºF)
temperature at pick-up point:
Oil temperature, normal 90-110 ºC (190-250 ºF) 90-110 ºC (190-250 ºF)
minimum 50 ºC (120 ºF) 50 ºC (120 ºF)
maximum 140 ºC (285 ºF) 130 ºC (266 ºF)
Exhaust gas temperature:
- maximum at takeoff 880 ºC (1620 ºF)
- maximum 850 ºC (1560 ºF)
- normal 800 ºC (1470 ºF)
Oil pressure, normal 2,0-5,0 bar (29-73 psi) (above 3500 RPM)
minimum 0,8 bar (12 psi) (below 3500 RPM)
maximum 7 bar (100 psi) (at cold start, allowed for a short time)
Fuel pressure, normal 0,15-0,4 bar (2,2-5,8 psi)
maximum 0,4 bar (5,8 psi)
Ambient air temperature range from -25 ºC to +50 ºC
6
1.5 Weight and balance information

The airplane CG position must be between 1.47 m and 1.78 m or between 19% and 37%
of the wing MAC (mean aerodynamic chord) see Fig. 1.
Fig. 1 CG location of the empty airplane, pilots, fuel and baggage

Compute the airplane CG position using the example in the table below:
Item Weight, kg × Arm, m = Moment, kg·m
Empty aircraft 309.4 × 1.504 = 465.3
Pilot(s) 180 × 1.6 = 288
Baggage 20 × 2.3 = 46.0
Fuel (0.72 kg/l) 64.8 × 2 = 129.6
Total 574.2 1.618 928.9
Airplane CG: Total moment / Total weight = 928.9 / 574.2 = 1.618 (m)
1.6 Tire inflation pressure

Normal inflation pressure for both main and nose wheels is 1.6 kg/cm2 (22.8 psi).
1.7 Approved fuel, oils and capacities

WARNING! On all issues of engine operation see Rotax engine Operator's Manual.
Follow its instructions to ensure safe and efficient operation of the engine.
Fuel
Approved grade: unleaded MOGAS min. RON 95 or AVGAS 100LL
Maximum capacity of the fuel tanks: 2 × 45 = 90 liters
7
“Fuel Low” warning light at: approx. 6 liters per tank

Unusable fuel: approx. 0.5 liter
Oil
Approved grade: any automotive oil of API classification “SF” or “SG”
Oil tank capacity: 3 liters (NOTE: check correct oil level in the tank using the oil probe.)
Coolant
Approved grade: Mobil Antifreeze Advanced Concentrate
Quantity: 3 liters (NOTE: check the correct level using the overflow bottle marks.)
Braking fluid
Approved grade: Mobil ATF 220
Quantity: 0.2 liter (NOTE: check the correct level using the overflow bottle marks.)
1.8 Recommended fastener torque values

In A-22LS all fasteners in front of the firewall and in the electrical system is metric and rear
of the firewall – inch. The bolts, screws and nuts (unless specified otherwise) must be
tightened (using appropriate torque wrenches) to the following torque:
Metric fasteners Inch fasteners Torque, N·m (lb·ft)
М5 10-32 6 (0.9)
М6 1/4 10 (1.5)
М8 5/16 15 (2.3)
М10 3/8 25 (3.8)
WARNING! All bolts, nuts (except for self-locking ones), pins, turnbuckles must be locked
reliably.
1.9 General safety information

Aircraft owner/operator responsibilities:
Each owner/operator of the Aeroprakt LSA must read and comply with the maintenance
and continued airworthiness information and instructions provided by the Manufacturer.
Each owner/operator of the Aeroprakt LSA is responsible for providing the Manufacturer
with current contact information where the Manufacturer may send the owner/operator
supplemental notification bulletins.
The owner/operator of the Aeroprakt LSA is responsible for notifying the Manufacturer of
any safety of flight issue or significant service difficulty upon discovery.
The owner/operator of the Aeroprakt LSA is responsible for complying with all notices of
corrective action issued by the Manufacturer and for complying with all applicable aviation
authority regulations in regard to maintaining the airworthiness of the LSA.
The owner/operator of the Aeroprakt LSA must ensure that any needed corrective action
be completed as specified in a notice, or by the next scheduled annual inspection.
Should the owner/operator of the Aeroprakt LSA not comply with any mandatory service
requirement, the LSA shall be considered not in compliance with applicable ASTM
standards and may be subject to regulatory action by the presiding aviation authority.
8
1.10 Reporting maintenance, service, and safety difficulties

In case of encountering any maintenance or service or safety difficulties not covered by
this Manual report about it to the aircraft Manufacturer by e-mail or by fax using the
Feedback Form (see Appendix A). If necessary enclose sketches or photos showing the
problem items in sufficient detail.
9
2 Inspections
This section contains the instructions and checklist for inspection and servicing for the
completion of periodic and annual condition/100-h inspections with references to the
sections containing detailed instructions for the inspection/servicing action.
1000
2000
100
200
500
25
50
Inspection/Servicing action  and its interval in hours →
Structures (section 3)
Inspect fuselage for damage (fatigue cracks, loose rivets, etc.) X
Inspect fuselage glazing for damage (silvering, cracks, etc.) X
Inspect wings for damage (fatigue cracks, loose rivets, torn fabric covering, etc.) X
Inspect wing attachment points for play X
Remove the wings and inspect its spherical bearings for play and hinge brackets for
X
cracks
Inspect the wing struts for fatigue cracks, deformation and loose rivets X
Inspect the sealing fabric tape of the wing strut fairings X
Check the wing attachment bolts’ torque and locking X
Inspect the stabilizer for fatigue cracks, deformation, loose rivets and play in
X
joints
Check the stabilizer attachment bolts/nuts torque and locking X
Inspect the tail wheel for damage and play X
Check the tail wheel attachment bolt/nut torque and locking X
Inspect engine cowlings for damage (cracks, ruptures, damaged paint, etc.) X
Landing gear (section 4)
Inspect the nose leg for fatigue cracks, deformation and play X
Check the nose leg bellcrank bolt/nut torque and locking X
Check the shock absorber condition and pressure X
Inspect the MLG springs and attachment beam for fatigue cracks1, deformation
X
and play
Check the MLG spring attachment bolts/nuts torque and locking X
Remove the wheel fairings and inspect the wheel tires for cracks, cuts and wear. X
Inspect the wheel fairings for cracks, ruptures and damaged paint X
Check the torque and locking of the fairing attachment bolts/nuts X
Inspect the mud-screens for fatigue cracks and deformation2 X
Check the torque and locking of the mud-screen attachment bolts/nuts2 X
Inspect the skis for damage3 X
Check the torque and locking of the ski attachment bolts/nuts3 X
Brake system (section 5)
Inspect expansion tank for leaks, cracks, secure attachment. Check fluid level. X
Inspect the master cylinder for leaks of braking fluid X
Inspect the parking brake valve for leaks of the braking fluid X
Inspect the brake unit for the leaks of the braking fluid X
Measure the brake disks' wear X
Inspect the brake system tubing and joints for leaks and damage X
Engine and its control system (section 6)
Inspect the engine mount for fatigue cracks and deformation X
1
After 5000 landings the MLG springs must be removed and inspected carefully for fatigue cracks
2
For an aircraft version on wheels with mud-screens
3
For an aircraft version on skis
10
1000
2000
100
200
500
25
50
Check the torque of the engine mount attachment bolts X

Inspect the shock absorbers for damage (deep cracks, etc.) X
Inspect the engine attachment fitting for the fatigue cracks X
4
Check the intake airbox function, condition and attachment X
Inspect the throttle and choke cables and cable sheath for wear, damage, kinks X
Check the torque of the throttle lever bolt (axle) X
Cooling system (section 7)
Check the radiator clamps integrity and torque X
Inspect the overflow tank for leaks of coolant, cracks; check coolant level X
Inspect lines for leaks, damage (chaffing, cracks), loose joints X
Lubrication system (section 8)
Inspect the oil tank plug for oil leaks; verify vent line is intact and secured X
Inspect lines for leaks and damage (chaffing, cracks), loose joints X
Fuel system (section 9)
Remove fuel tanks and inspect them for fuel leaks and damage X
Inspect the shut-off and drain fuel valves for leaks of fuel X
Check condition and replace fuel filter (if necessary) X
Inspect fuel lines for leaks, damage (chaffing, cracks), loose joints X
Check condition and replace fuel lines (if necessary) X
Exhaust system (section 10)
Inspect exhaust pipes and muffler for cracks X
Verify attachment springs are intact X
Propeller (section 11)
Inspect propeller hub for fatigue cracks; check pitch angles X
Inspect propeller blades for damage X
Check torque and locking of the propeller bolts/nuts X
Check torque of the spinner bolts X
Airplane control system (section 12)
Inspect control surfaces for fatigue cracks, deformation, loose rivets, torn fabric X
Check the play in the hinges of control surfaces/linkages X
Check tightness/locking of the nuts of control surfaces/linkages X
Check tightness/locking of the nuts and play in hinges of control rods/shafts X
Extend flaps and inspect flap extension (play in hinges, nuts tightness/locking) X
Grease the slide bearings of all control surfaces/linkages (where necessary) X
Inspect rudder control cables for wear, check cable tension X
Inspect rudder pedals for fatigue cracks and deformation X
Check condition of the control cable pulleys and fairleads X
Check trim tab attachment bolts/nuts for corrosion, replace if necessary X
Inspect the trim tab control cables and sheath for damage (wear, kinks, etc.) X
Electrical system (section 13)
Verify battery charges/discharges properly, otherwise replace X
Clean starter terminals and starter relay connector of corrosion, if any X
Verify starter relay and cables are connected and attached reliably X
Verify power cables have good contact with battery, starter and ground X
4
For an aircraft version equipped with intake airbox
11
1000
2000
100
200
500
25
50
Clean rectifier-regulator and condenser terminals/connectors of corrosion, if any X

Check condition of electric switches and warning lights X
Clean fuse block terminals of corrosion, if any. Check fuses X
Verify correct function of the fuel level sensors/indicators (check readings) X
Check landing light function and attaching nut torque X
Clean engine sensors' terminals and connectors of corrosion, if any X
Inspect electrical harness for damage (chaffing, broken wires, bad insulation) X
Cockpit heating system
Inspect warm air scoop for damage. Repair or replace if necessary X
Inspect warm air shutter and its housing for damage. Repair or replace if
X
necessary
Inspect warm air duct for damage. Replace if necessary X
Check condition and operation of the warm air shutter actuator. Replace if
X
necessary
Instruments and Avionics (section 15)
Check condition of the switches and lights. Replace defective ones, if any X
Check operation of the instruments and avionics. Replace defective ones, if any X
Check condition of the full and static pressure system X
Pilot seats and harness belts (section 16)
Inspect the seats framework for the fatigue cracks and loose rivets X
Inspect the seat cushions upholstery for damage X
Verify harness belts’ locks function properly X
Cockpit doors (section 17)
Inspect door glass, framework and sealing for damage X
Verify the gas struts function properly X
Recovery system (section 19)
Check attachment of the suspension cables to fuselage and parachute lanyard X
12
3 Structures
The airframe of A-22LS airplane includes the following parts: fuselage with polycarbonate
glass windscreen and rear skin panels, wings, wing struts, horizontal and vertical tail units
(HTU and VTU), wing fillets, strut fairings and engine cowling. Fuselage with fin, wing
struts and stabilizer are made of aluminum alloys. Wing framework including leading edge
section and top skin are all-metal and bottom skin is fabric. Framework of flaperons,
elevator and rudder is all-metal, their rear skin (aft of spar) is fabric. The rear fuselage skin
panels (top and two side ones) depending on airplane configuration may be made of PVC
glass, all-metal or combined. The fairings and engine cowling are made of fiberglass.
When servicing the airplane a special care shall be taken to protect the airframe from
corrosion and to protection of the paint coating. Protection of the airframe parts from
corrosion consists mainly of keeping the protective coatings intact. Care of the fabric skin
consists mainly of care of its paint coating. Correct care of the paint coating is one of the
conditions of preserving the airplane strength and aerodynamic characteristics. To keep
the paint coating of the airplane in good condition the dust and moisture must be removed
in time, the paint must be protected from scratches, and spilling oil products, solvents,
alkalis and acids on paint must be avoided.
INSPECTION CHART
Instr.
Part No. Description Interval RCO TM LC
No.
A22LS-0-0100-00 Fuselage 100 h OC 3.1 L LRI
A22L-0-1300-00 Windscreen glass 100 h OC
A22L-0-1320-00 Rear fuselage skin panel, top 100 h OC
3.2 L OWN
A22L-0-1330-01 Rear fuselage skin panel, right 100 h OC
A22L-0-1330-02 Rear fuselage skin panel, left 100 h OC
A22LS-0-2000-00 Wing 500 h OC 3.3 L OWN
COM-5 Spherical bearings, 4 pcs. 2000 h OC 3.4 L LRI
A22LS-1-2920-01 Wing strut, right 500 h OC
3.5 L LRI
A22LS-1-2920-02 Wing strut, left 100 h OC
A22LS-0-2950-01 Wings strut fairing, top, right 200 h OC
A22LS-0-2950-02 Wings strut fairing, top, left 200 h OC
3.6 L LRI
A22LS-0-2940-01 Wings strut fairing, bottom, right 200 h OC
A22LS-0-2940-02 Wings strut fairing, bottom, left 200 h OC
AN 175-11 Wing attachment bolts, 4 pcs. 100 h OC
1.8 L OWN
AN 175-12 Wing attachment bolts, 4 pcs. 100 h OC
A22LS-0-3100-00 Stabilizer 100 h OC 3.7 L LRI
AN 174-6 Stabilizer attachment bolts, 2 pcs. 100 h OC
1.8 L OWN
AN 310-5 Stabilizer attachment nut 100 h OC
- Tail wheel 100 h OC 3.8 L LRI
AN 5-32 Tail wheel bolt 100 h OC 1.8 L OWN
A22L-2-6920-00 Engine cowling panel, top 100 h OC
3.9 L LRI
A22L-2-6910-00 Engine cowling panel, bottom 100 h OC
13
Instructions:
3.1 Remove the engine cowling, doors, wing strut fairings (undo the screws fixing the
fairings and 'slide' them along the strut), pilot seats, and rugs. Inspect the fuselage
for cracks and deformation, paying special attention to primary structural elements,
areas of their connection and rivet joints (frames No. 1, 4, 5, 6, longitudinal,
transverse and vertical beams of the cockpit, undercarriage beam, fuselage tubes,
tail boom and fin skin).
Inspection for fatigue cracks. Use torch or any other suitable source of light. When
detecting very thin cracks remove the paint in the area of the suspected crack for a
closer flaw detection. If possible apply load in this area in a manner that will 'open up' the
crack. If the closer inspection confirmed the crack existence contact the manufacturer
for required technical support. If the suspected crack was not detected repaint this
area.
Inspection for loose rivets. When inspecting rivet joints look at the area around
river heads. The paint around the rivet heads must have no cracks or black stains
that indicate on loose and corroded rivet joint. When detecting such flaws contact the
manufacturer for the required technical support.
If no flaws were detected reinstall everything in the reversed order. Apply Loctite 222
on the thread of the attachment screws of the wing strut fairings before reinstalling
them.
Recommended special tools: magnifying glass, electric torch.
Necessary parts/materials: paint, Loctite 222.
3.2 Inspect the glass from outside and inside for cracks. In case if any cracks are found
that protrude beyond the glass attachment strips, the glass must be replaced.
Contact your local dealer for glass replacement instructions.
WARNING! The glazing material is not resistant to fuels, oils and solvents. Spilling
those liquids on glazing may cause its dimness and cracking. Washing the glass with
any agents that may damage PET-G glass is strictly forbidden!
Recommended special tools: electric drill, 3 mm drill.
Necessary parts/materials: none.
3.3 Drain fuel from the fuel tanks. Remove the wing strut fairings and fuel tanks. Inspect
the wing for fatigue cracks, deformation and loose rivets as described in 3.1 (2nd and
3rd paragraph). Pay special attention to the strut-to-wing attachment points, rivet
joints of the wing leading edge section and top skin.
Inspect the fabric skin for damage and detachment from the wing framework. It is
allowed to repair small cuts/ruptures (shorter 50 mm or 2 in) covering them with
ORACAL permanent sticking film. Upon detecting bigger damages and delaminating
of the fabric skin from the framework contact manufacturer for the required technical
support.
Verify that there is no play in attachment points of the wing and strut by holding the
wingtip gently and moving it up and down with an amplitude of 300 mm (1 ft). The
movement in the attachment points due to loose joint (play) is not allowed. When
detecting insignificant radial play (less than 0.2 mm or 0.01 in) in the strut attachment
points it must be eliminated by tightening its bolt joint. In case if the play is more than
0.2 mm (0.01 in) contact the manufacturer for the required technical support.
14
In case if no defects are found re-assemble everything in the reversed order. Before
re-installing the screws attaching the fuel tanks and strut fairings apply Loctite 222 on
the thread.
Necessary parts/materials: ORACAL permanent sticking film, Loctite 222.
3.4 Detach the wings by doing the following:
- detach the doors;
- drain fuel from the fuel tanks;
- disconnect the fuel lines from the fuel valves, close the valves, plug the fuel lines
and pull them out of cockpit through the rubber sealing rings in fuselage beams;
CAUTION! Be careful while working with the fuel system, the fuel remaining in the
fuel lines is highly fire-hazardous and when spilled on the cockpit glass may cause
glass dimness and cracking.
- disconnect the electric connectors of the navigation lights and fuel level probes at
wing root and take the cables out of fuselage;
- detach the strut fairings (undo the screws attaching the fairings and slide fairings
along the struts);
- detach the Cardan rings from the flaperon shafts by removing the vertical bolts;
- remove the split pins and undo the nuts from wing and strut attachment points;
- while holding the wing by the tip and strut carefully take out the strut attachment
bolts and remove the struts;
- while holding the wing by the tip and at the root take out the wing attachment bolts
and slowly move the wing away from fuselage carefully pulling the navigation light
from the wing fillets;
Inspect the wing and strut attachment fittings for fatigue cracks. Check the spherical
bearing for axial and radial play. When detecting play in bearings, as well as
corrosion and fatigue cracks in the attachment fittings contact the manufacturer for
the required technical support.
If no defects were detected re-assemble everything in the reversed order. Before
reinstalling the screws attaching the fuel tanks and strut fairings apply Loctite 222 on
the thread.
Necessary parts/materials: screw clamps, Loctite 222.
3.5 Remove the strut fairings (undo the screws attaching the fairings and slide fairing
along the strut). Inspect the struts for fatigue cracks, deformation (bend) and loose
rivets as described in 3.1 (2nd and 3rd paragraph).
If no defects were found re-install the fairing applying Loctite 222 on the thread of the
attaching screws.
Recommended special tools: none.
3.6 Undo the screws attaching the fairings and slide the fairings along the strut. Inspect
the sealing fabric tape in the inner side. If necessary use double-sided sticking tape
to fix the tape.
Re-install the fairings applying Loctite 222 on the thread of the attaching screws.
15
3.7 Inspect the stabilizer for fatigue cracks, deformation and loose rivets as described in
3.1 (2nd and 3rd paragraph). Pay special attention to the areas near the stabilizer
attachment fittings and leading edge near the hole for elevator trim tab cable.
Verify that there is no play in the stabilizer attachment joints by gently moving the
stabilizer by its tip up and down with an amplitude not more than 50 mm (2 in).
CAUTION! The applied load may not exceed 30 N (7 lb).
There must be no movement due to the play in the attachment joints. When detecting
insignificant play (less than 0.2 mm or 0.01 in) it must be eliminated by tightening the
relevant bolted joint. In case if the play exceeds 0.2 mm (0.01 in) contact the
3.8 Inspect the tail wheel for damage and play. When detecting a serious damage
replace the wheel. When detecting play below 0.5 mm (0.02 in), tighten its axle nut. If
the play exceeds 0.5 mm (0.02 in), insert a washer of appropriate thickness between
the wheel hub and fuselage. Tighten the axle nut until it stops the free rotation of the
wheel.
3.9 Remove the top and bottom engine cowling and inspect for cracks, ruptures, as well
as damaged paint coating. When detecting damaged paint coating sand the
damaged area with sandpaper and re-paint. When detecting cracks and ruptures
sand the damaged area from inside with sandpaper and cover it with a patch of
fiberglass cloth with epoxy resin. After the resin solidifies properly, sand the damaged
area outside with sandpaper and re-paint.
Recommended special tools: rubber gloves.
Necessary parts/materials: fiberglass cloth, epoxy adhesive, paint.
16
4 Landing gear
A-22LS may have the landing gear (LG) of one of the following three types: wheels, skis or
floats. This manual contains the information for servicing the wheel and ski LG. The float
type LG is not included in this manual. For obtaining additional information contact the
manufacturer.
When put on wheels the airplane is equipped with wheels of Matco mfg.
NOTE! When installing wheels tighten the axle nut as follows: first tighten the nut to
remove the axial play, then turn it back until its slots alight with the hole for the split pin in
the axle. Then lock the nut using the split pin.
The nose LG leg is steerable, of trailing link type with spring shock absorber. The leg
structure consists of the strut, trailing link, bellcrank, wheel fork, spring shock absorber,
axle, spacing sleeves, wheel/ski and fairing/mud-screen. The steering is achieved using
the rudder pedals via the rods connected to the bellcrank on the strut. The leg is attached
to the firewall at two points – lower and upper supports. The upper support is made of
aluminum alloy plate, the lower support is an assembly. The supports contain bronze
bearings.
Main landing gear (MLG) is of cantilever spring type. The MLG leg consists of the spring, axle,
wheel (or ski), brake unit with supporting plate, and fairing (or mud-screen). The MLG spring is
made of aluminum alloy. It is bolted at two points to the lower beam of the frame No.2.
Maintenance of the brake unit with supporting plate is described in "Brake system" section.
INSPECTION CHART
Part No. Description Interval RCO Instr. No. TM LC
A22LS-0-4310-00 Nose leg 100 h OC 4.1 L LRI
AN 4-22A Bellcrank bolt 100 h OC 1.8 L OWN
165x40 mm Spring shock absorber 100 h OC 4.2 L LRM
A22LS-3-4110-00 Main leg, right 100 h OC 4.3
H LRM
A22LS-3-4110-00 Main leg, left 100 h OC 4.3
AN 6-37 Spring bolts, upper, 2 pcs. 100 h OC
1.8 L OWN
AN 7-41 Spring bolts, lower, 2 pcs. 100 h OC
See Matco P/N Nose wheel assembly 200 h OC 4.4
See Matco P/N Right wheel assembly 200 h OC 4.4 L LRI
See Matco P/N Left wheel assembly 200 h OC 4.4
A22LS-0-4410-00 Nose wheel fairing 25 h OC 4.5
A22LS-0-4420-01 Right wheel fairing 25 h OC 4.5 L LRI
A22LS-0-4420-02 Left wheel fairing 25 h OC 4.5
A22LS-0-4510-00 Nose wheel mud-screen* 50 h OC 4.6
A22LS-0-4520-01 Right wheel mud-screen* 50 h OC 4.6 L LRI
A22LS-0-4520-02 Left wheel mud-screen* 50 h OC 4.6
A22LS-0-4710-00 Nose ski** 100 h OC 4.7
A22LS-0-4610-01 Right ski** 100 h OC 4.7 L LRI
A22LS-0-4610-02 Left ski** 100 h OC 4.7
* – for wheel version with mud-screens;
** – for ski version.
17
Instructions:
4.1 Remove the nose wheel fairing. Inspect the nose leg for fatigue cracks, deformation
and play. When inspecting follow the instructions of 3.1 (2 and 3 paragraph) of
“Structures” section.
Pay special attention to the areas of the nose leg attachment near its upper and
lower supports as well as weld seams of the nose leg.
Check the nose leg supports for play. The radial play in the supports may not exceed
1 mm (0.04 in). No axial play is allowed.
If the radial play in the upper support exceeds the above specified value then the
bronze bearing in the support must be replaced. If the radial play in the lower support
exceeds the above specified value then the support with bearing must be replaced.
Contact manufacturer to obtain the instructions on replacement of the bearing and
support.
Upon detecting axial play in the supports tighten the upper support nut until play is
eliminated, if necessary, insert a washer of an appropriate thickness.
WARNING! Tightening the nut must eliminate the play while ensuring free rotation of
the leg in the supports. Do not over-tighten the nut!
Check the torque of all bolted joints with self-locking nuts.
Lubricate all surfaces of the nose leg trailing link subjected to friction depending on
their condition as follows:
- set parking brake to ON;
- disconnect the control rods from the nose leg bellcrank;
- remove the split pin and undo the nut of the upper support of the nose leg;
- undo the nut and take out the bellcrank bolt;
- while holding the nose leg carefully push down the airplane tail near the stabilizer
attachment points till the airplane sets on the tail wheel and hold it in this position
till the nose leg is re-installed back (this operation must be done by two persons);
- carefully take out the nose leg from the supports simultaneously removing the
bellcrank from it;
CAUTION! Do not lower the fuselage nose while the nose leg is removed! This may
cause damage to the airframe and propeller.
- remove the old grease from the surfaces of the nose leg trailing link subjected to
friction;
- apply thin layer of new grease;
- re-install the leg in the reversed order;
- squirt grease into the nose leg hinge till grease comes out;
- remove the excessive grease with rags.
Any lubricating grease for bearings may be used for the nose leg.
After servicing the nose leg re-install the nose wheel fairing.
Necessary parts/materials: grease gun, grease.
If the spring shock absorber is seriously damaged, then it must be removed for repair
or replacement.
To remove the shock absorber do the following:
18
- set the parking brake to ON;

- remove the nose wheel fairing;
- remove the split pins and undo the nuts of the shock absorber attachment;
- carefully push down the airplane tail near the stabilizer attachment points till the
airplane sets on the tail wheel and remove the shock absorber (this operation must
be done by two persons);
- set the airplane level on a wooden support under its bottom as close to the frame
No. 1 (firewall) as possible (the support width must be equal or bigger than the
fuselage width).
To re-install the spring shock absorber perform the above actions in the reversed
order. Before installation of the spring shock absorber lubricate its attachment bolts
with bearing grease.
WARNING! When installing the shock absorber tighten the nuts as follows: first
tighten to remove the axial play, then rotate a little back to alight the nearest slot of
the castle nut with the hole for the split pin and secure it with a split pin. Tightening of
the shock absorber bolts must not restrict its free motion.
4.2 Remove the pilot seat and wheel fairing. Inspect the MLG attachment beam and
spring for fatigue cracks, deformation and play following the instructions of 3.1 (2nd
and 3rd paragraph) of "Structures" section. Pay special attention to the areas of the
spring attachment to the beam and wheel axle attachment to the spring.
If axial play is detected in the MLG attachment, check the attachment bolts' torque. If
radial play is detected, contact the manufacturer to obtain the required technical
support.
After 5000 landings careful inspection of the MLG spring is required. The MLG leg
must be removed for that.
To remove the MLG leg do the following:
- put the wheel chokes under the nose and opposite main wheel;
- remove the pilot seats;
- remove the wheel fairing;
- cut the plastic cable ties fixing the brake system tube to the MLG spring;
- lift the airplane using a jack placed under a special plate near the opening in the
fuselage bottom skin for the MLG spring;
- remove the safety wire and undo the brake disk screws and wheel axle nut;
- remove the wheel and brake disk;
- leaving the braking system tube assembled, disconnect the braking unit from the
supporting plate (undo two bolts and three screws of the braking unit and move the
brake unit with the tube aside);
WARNING! When handling the brake pads and disk avoid smearing their working
surfaces with any lubricating materials. Do not use braking system with a braking disk
removed.
- remove the split pins and undo the nuts of the upper and lower bolts of the MLG
spring attachment and carefully force the bolts out of the holes;
- remove the spring.
Inspect carefully the spring and fittings of the MLG attachment beam for fatigue
cracks. Pay special attention to the areas around the attachment holes in the beam
19
and spring. Upon detecting fatigue cracks in the MLG spring or MLG attachment
beam contact the manufacturer to obtain the required technical support.
If no defects were detected, install the MLG leg back by doing the above actions in
the reversed order.
Before re-installing the attachment screws of the brake disk and pilot seats apply
Loctite 222 on their thread.
Necessary parts/materials: plastic cable ties.
4.3 Remove the wheel fairing. Inspect the tire for cracks and cuts. Determine the nature
and degree of the tire wear. In case of normal operation the wear will be uniform over
entire operating surface of the tire. Tire operation is allowed until exposure of its cord.
In case if exposed cord or deep cuts are detected the tire must be replaced.
To replace the nose wheel tire do the following:
- set the parking brake to ON;
- remove the split pin of the nose wheel axle nut and undo it;
- carefully push down the airplane tail near the stabilizer attachment points till the
airplane sets on the tail wheel and remove the nose wheel (this operation must be
done by two persons);
- put the airplane’s nose down placing a wooden support under the nose wheel fork;
- replace the tire;
- inflate the wheel (1.6 bar) and install it back on the airplane making the above
actions in the reversed order.
To replace a main wheel tire do the following:
- put wheel chokes under the opposite main wheel and nose wheel;
- remove the split pin of the main wheel axle nut and undo it;
- remove the safety wire and undo the brake disk screws and wheel axle nut;
- remove the wheel;
- replace the tire;
- inflate the wheel (1.6 bar) and install it back on the airplane making the above
actions in the reversed order.
Before re-installing the attachment screws of the brake disk apply Loctite 222 on their
thread.
If no defects were found, check the wheel pressure and inflate if necessary. The
pressure must be equal to 1.6 bar. Install the wheel fairing after servicing.
For more detailed information regarding the servicing (repairing) the wheels visit the
manufacturer’s web site http://www.matcomfg .com.
4.4 Inspect the fairing for cracks, ruptures and paintwork damage. If damaged paint is
detected, remove the fairing, clean the damaged area with sand paper and repaint. If
cracks and ruptures were detected, remove the fairing, clean the damaged area with
sand paper from inside, and apply a patch of fiberglass cloth with epoxy resin. After
the resin solidifies properly, sand the damaged area outside with sandpaper and re-
paint.
20
Check the torque of the fairing attachment bolts/nuts.

Recommended special tools: torque wrench, rubber gloves.
Necessary parts/materials: fiberglass cloth, epoxy adhesive, paint.
4.5 Inspect the mud-screens for fatigue cracks and deformation. Pay special attention to
the areas around the bolt joints and mud-screen framework weld seams. If any
cracks are detected in the mud-screen it must be replaced. If cracks are detected in
the mud-screen framework they must be welded using argon-arc welding or the
framework must be replaced.
Check the torque of the mud-screen attachment bolts/nuts.
Recommended special tools: torque wrench.
4.6 Inspect the ski for mechanical damage. If damage of the paintwork is detected, clean
the damaged area with the sand paper and re-paint. In case of serious damage of
the ski contact the manufacturer for the required technical support.
Check the torque of the ski attachment bolts/nuts.
Necessary parts/materials: paint.
21
5 Brake system
The main wheels are equipped with Matco mfg hydraulic disk brakes. The brake system
includes: expansion tank, master cylinder with lever, parking brake valve, brake units with
supporting plates, brake disks, copper tubes, fittings and reinforced rubber hose. The
brake system is filled with transmission fluid ATF, one of the fluids recommended by Matco
mfg. The amount of the fluid in the system can be checked by its level in the expansion
tank that must be not less than half of the tank.
When servicing the brake system it may be necessary to disconnect its tubes. After such
disconnection air gets into its cavities which is inadmissible. After such action it is
necessary to fill the brake system with fluid to force all air out.
To fill the brake system with braking fluid in the airplane version with yokes, do the
following:
- check the level of the braking fluid in the expansion tank and refill if necessary;
WARNING! Use only the fluid that is recommended by Matco mfg. Do not mix up
the fluids of different grade. This may cause damage to the components and failure
of the brake system.
- remove the cover set the parking brake valve to "OFF";
- remove protecting cap from the brake unit nipple and put on it a transparent PVC
tube with the inner diameter of 3 mm (1/8 in) and minimum length of 300 mm (1 ft).
The other end of the tube put into a container with the braking fluid so that it is
completely submerged into the fluid;
- while holding the tube loosen the nipple by ½ turn;
- pump the braking fluid through the system with the braking lever till air bubbles stop
appearing completely in the transparent tube (they may start appearing after some
time of such pumping); while doing it do not forget to add braking fluid into the
expansion tank to avoid air inflow into the system;
- after air bubbles disappear, tighten the braking unit nipple, remove the PVC tube
and put on the protecting cap;
- repeat above actions for the other wheel.
To fill the brake system with braking fluid in the airplane version with central stick, do the
following:
- remove the stick cover;
- remove the stick from the roll torque tube;
- remove the parking brake;
- remove the clamps holding the brake system tubes;
- put the stick on the longitudinal beams of fuselage with the braking cylinder nipples
up and pump the brake system through as described above for the airplane version
with yokes;
- re-assemble everything in the reversed order.
WARNING! When filling the brake system it is necessary to pump through it braking fluid
in the amount of 1 to 2 volumes of the expansion tank.
For more detailed information about maintenance (repair) of the brake system components
visit its manufacturer web site: http://www.matcomfg.com.

Necessary parts/materials: 300 mm of Ø3.0 mm PVC tubing, brake fluid.
22
INSPECTION CHART
- Expansion tank 100 h OC 5.1 L LRM
See Matco P/N Master cylinder 200 h OC 5.2 L LRM
See Matco P/N Parking brake valve 200 h OC 5.3 L LRM
See Matco P/N Brake unit assembly, right 200 h OC 5.4
L LRM
See Matco P/N Brake unit assembly, left 200 h OC 5.4
See Matco P/N Brake disk, right 200 h OC 5.5
L LRM
See Matco P/N Brake disk, left 200 h OC 5.5
- Copper tubes 200 h OC 5.6
L LRM
- Reinforced rubber hose 200 h OC 5.6
Instructions:
5.1 Remove the top engine cowling. Inspect the expansion tank for leaks of braking fluid,
cracks in its housing and cap. If the tank is damaged it must be replaced, then the
brake system must be filled with braking fluid, following the instructions described in
the beginning of this section.
Check the fluid level in the tank and refill if necessary. The required level is at least
half of the tank. Make sure the tank attachment to the firewall is secure. Replace the
plastic cable ties if necessary.
5.2 Remove handles from the control levers of the throttle, trim tab, brake and remove
the horizontal panel. Inspect the master cylinders for leaks of braking fluid. If leaks
are detected, it must be removed for repair or replacement.
In order to remove the master cylinders, do the following:
- remove the left seat;
- remove the panel between pilot seats;
- disconnect the control cables of the engine and elevator trim tab (first from the
engine and trim tab ends, and then from the control levers);
- undo the screws of the control lever unit (9 pcs.);
- block the reinforced rubber hose near the master cylinders by squeezing it with a
clamp and disconnect it from the master cylinders;
- disconnect the copper tube connecting the parking brake valve with brake units;
WARNING! When disconnecting the brake system tubes some amount of braking
fluid may spill out.
- remove the control lever unit assembled with the master cylinder;
- detach the master cylinder from the control lever unit;
To install the master cylinder perform the above actions in the reversed order. After
re-assembling fill the brake system following the instructions given in the beginning of
this section. Then adjust the control systems of the engine and elevator trim tab as
described in the corresponding sections of this manual.
If no defects were detected in the master cylinder re-assemble everything in the
reversed order.
23

5.3 Remove the handles from the control levers of the throttle, elevator trim tab, brakes
and the horizontal panel. Inspect the parking brake valve for leaks of the braking
fluid.
If any leak is detected the valve must be removed for repair or replacement.
In order to remove the parking brake valve do the following:
- block the reinforced rubber hose connecting the expansion tank with the master
cylinder by squeezing the hose with a clamp;
- cut the plastic cable ties fixing the valve;
- undo the screws attaching the valve;
- disconnect the copper tubes from the valve.
To install the parking brake valve back perform the above actions in the reversed
order. After assembling fill the brake system with the braking fluid following the
instructions described in the beginning of this section.
If no defects are detected in the parking brake valve, re-assemble everything in the
reversed order.
5.4 Remove the wheel fairing. Inspect the brake unit for the leaks of the braking fluid. If
any leak is detected the brake unit must be removed for repair or replacement.
To remove the brake unit, do the following:
- put the wheel chokes under the nose and opposite main wheel;
- unlock and undo the brake disk screws and wheel axle nut;
- remove the wheel and brake disk;
- disconnect the copper tube from the brake unit;
- disconnect the brake unit from the supporting plate (undo two bolts and three
screws of the brake unit) and remove the braking pads from it.
To re-install the brake unit perform the above actions in the reversed order. After
assembling fill the brake system following the instructions described in the beginning
of this section.
Check the brake pads for integrity and wear. The minimum thickness of the pad is
2.54 mm (0.1 in). The wear may be checked using a special depression in the butt of
the braking pad. In case of serious wear or loss of integrity the pads must be
replaced. In order to do that, detach the brake unit as described above and replace
the brake pads (the braking system tubes need not to be disconnected from the
brake unit). For more detailed instructions on servicing and replacement of the brake
pads contact the manufacturer (Matco mfg).
If the wear is within the permissible limits, re-assemble everything in the reversed
order. Before re-installing the attachment screws of the brake disk apply Loctite 222
on their thread.
Necessary parts/materials: Loctite 222.
24
5.5 Define the nature and degree of the brake disk wear. For that remove the brake disk
as described in 0. Measure the brake disk thickness at its working surface. It must be
at least 3.3 mm (0.13 in). If the disk thickness is less than that, the brake disk must
be replaced. For more detailed instructions on servicing and replacement of the
brake disk contact the manufacturer (Matco mfg).
If the wear is within the permissible limits, re-assemble everything in the reversed
order. Before re-installing the attachment screws of the brake disk apply Loctite 222
on their thread.
5.6 Remove the handles from the control levers of the throttle, elevator trim tab and
brakes, horizontal panel, main wheel fairings and pilot seats. Inspect the tubing of the
brake system for leaks and damage. Pay special attention to the joints. If leaks and
damage is detected replace the corresponding portion of the tubing. To obtain
additional technical support contact the manufacturer.
After re-assembly fill the brake system following the instructions described in the
beginning of this section.
After inspection (repair) re-assemble everything in the reversed order. Before re-
installing the pilot seats apply Loctite 222 on the thread of the attaching bolts.
25
6 Engine and its control system

A-22LS is equipped with a 100 hp Rotax-912ULS four-cylinder four-stroke engine with
combined cooling system manufactured by Rotax GmbH (Austria).
WARNING! Maintenance of the engine must be performed according to the current
documentation of ROTAX company on operation and maintenance of Rotax 912 engine.
For more detailed information visit the engine manufacturer’s web site: Ошибка!
Недопустимый объект гиперссылки..
Arrangement and design of the engine systems (fuel, electric, oil, cooling, control, exhaust)
complies with the requirements of the “Installation Manual for Rotax-912 aircraft engine”.
The engine is installed on a mount and is retained on top with a rod. The engine mount
consists of upper and lower parts. The lower mount (truss) is attached to fuselage
structure (firewall), and the upper mount (frame) is attached to the engine. To damp the
vibrations produced by the engine the upper and lower mounts are connected via rubber
shock absorbers. The shock absorbers are installed on the upper mount. The rod connects
a bracket installed on the engine with fuselage structure. The rod is connected to fuselage
structure via a shock absorber as well.
The throttle lever is located between the pilot seats. In the airplane equipped with a central
stick the throttle levers are located outboard of the pilot seats. Two cables run from the
throttle lever(s) to the left and right carburetors. The engine control system also includes
engine start mixture control. The mixture control lever is located between the pilot seats. It
is connected to the carburetors’ chokes with cables.
The engine may be equipped with an intake air box of Aeroprakt design that improves the
engine operating conditions, prevents carburetor icing and increases the engine power
output in hot climate.
INSPECTION CHART
Instr.
No.
Rotax 912 ULS Engine * OC 6.1 H TSP
A22L-3-6402-00 Engine mount, upper 200 h OC 6.2
A22L-2-6401-00 Engine mount, lower 200 h OC 6.2 L LRI
A22L-0-6404-00 Engine retaining rod 200 h OC 6.2
See Gumokov P/N Shock absorbers, 6 psc. 500 h OC 6.3 H LRM
A22-1-6405-00 Engine attachment fitting 2000 h OC 6.4 H LRM
A22L-0-6570-00 Intake airbox assembly** 200 h OC 6.5 H LRM
A22LS-0-6023-01*** Throttle cable right 100 h OC 6.6
A22LS-0-6023-02*** Throttle cable left 100 h OC 6.6
A22LS-0-6013-01 Throttle cable right 100 h OC 6.6
A22LS-0-6013-02 Throttle cable left 100 h OC 6.6
H TSP
A22LS-0-6056-01*** Choke cables right 100 h OC 6.6
A22LS-0-6056-02*** Choke cables left 100 h OC 6.6
A22LS-1-6056-01 Choke cables right 100 h OC 6.6
A22LS-1-6056-02 Choke cables left 100 h OC 6.6
A22LS-0-6021-01*** Throttle cable sheath right 100 h OC 6.7
A22LS-0-6021-02*** Throttle cable sheath left 100 h OC 6.7
A22LS-1-6011-01 Throttle cable sheath right 100 h OC 6.7 H TSP
A22LS-1-6011-02 Throttle cable sheath left 100 h OC 6.7
A22LS-0-6054-01*** Choke cable sheath right 100 h OC 6.7
26
Instr.
No.
A22LS-0-6054-02*** Choke cable sheath left 100 h OC 6.7
A22LS-1-6054-01 Choke cable sheath right 100 h OC 6.7 H TSP
A22LS-1-6054-02 Choke cable sheath left 100 h OC 6.7
A22LS-0-6007-00 Throttle lever 100 h OC 6.8 L OWN
* - see "Maintenance Manual for Rotax Engines. Rotax-912 Serie"
** - in aircraft version equipped with intake airbox.
*** – for the airplane version with central control stick.
Instructions:
6.1 The engine servicing must be performed according to "Maintenance Manual for
Rotax Engines. Rotax-912 Serie". When servicing and repairing the engine it may be
necessary to dismantle it. The plastic cable ties securing the engine system
components must be cut. When disconnecting the tubes and hoses it is
recommended to plug the holes and fittings. When installing the engine back secure
the cables and tubes of the engine systems with the plastic cable ties.
To dismantle the engine, do the following:
- set the fuel valves to CLOSED;
- switch OFF the battery using the battery switch or (if it is not available) disconnect
one of the power lines from the battery;
- remove the top and bottom engine cowlings;
- disconnect the fuel line at its joint behind the firewall;
WARNING! Be careful when working with the fuel system, as remains of fuel in the
fuel lines are highly fire hazardous.
- remove the muffler and exhaust pipes (see “Exhaust system” section);
- disconnect the throttle and choke control cables from the carburetors;
- remove the intake air box (see 0 of this section);
- drain the coolant from the cooling system (see “Cooling system” section);
- disconnect the cooling system hose from the water pump;
- disconnect the cooling system hoses from the expansion tank outlet and overflow
sleeve;
- disconnect the oil system hose from the oil outlet and drain the remaining oil from
the crank case;
- disconnect the oil system hose from the oil inlet and drain the remaining oil from the
system;
- drain oil from the oil tank, if necessary;
- disconnect the oil system hose from the oil tank outlet;
- detach the oil radiator by undoing the attachment fittings’ bolts (4 pcs.);
- take out the senders of oil temperature and cylinder head temperature (or
disconnect the cables from them if possible) and detach the cables from the engine;
- disconnect the cables from the oil pressure sender and untie the cables;
- disconnect the cables from the starter;
- take out the shielded cables of the ignition switches from the ignition system
connector and untie the cables;
- take out the shielded cable of generator from the rectifier-regulator connector and
untie the cable;
- disconnect the tachometer connector from the engine and untie he cable;
- disconnect the engine retaining rod from fuselage;
27
- remove the engine by undoing the bolts of engine attachment to the engine mount
(4 pcs.), use engine hoist for that.
Engine installation is performed in the reversed order following the instructions of the
“Installation Manual for Rotax-912 Aircraft Engine”. After engine installation the
cooling and oil system must be refilled and engine control system must be re-
adjusted.
WARNING! When adjusting the throttle cables ensure 1 mm clearance between the
throttle valve control arm and the idle RPM stop (special feature of A-22LS). When
installing the vent tubes of the carburetors do not let them protrude out of the engine
cowling as this may cause unstable operation of the engine in flight.
Necessary parts/materials: fuel line plugs.
6.2 Remove the top and bottom engine cowling. Check the torque of the engine mount
attachment bolts and tighten if necessary.
Inspect the engine mount for fatigue cracks and deformation. Pay special attention to
the weld seams. If any defects were detected contact the manufacturer for the
required technical support.
Recommended special tools: magnifying glass, electric torch, torque wrench.
6.3 Remove the top and bottom engine cowling. Inspect the shock absorbers for deep
cracks and other damage. If any such defects were detected the shock absorbers
must be replaced.
To replace the shock absorbers do the following:
- remove the safety pin and undo the nut of the rod attaching engine to fuselage;
- remove the bolt while holding the engine;
- remove the shock absorbers of the rod;
- install new shock absorbers;
WARNING! The shock absorbers are asymmetric about their attachment plate. They
must be installed with their bigger halves towards each other in order to ensure 3-5
mm (0.1-0.2 in) clearance between their bushings.
- put a support of an appropriate size under the tail wheel (with the engine removed
the airplane will tend to lower the tail);
- remove the safety pins and undo the nuts of the bolts attaching the upper engine
mount to the lower one (2 pcs.);
- remove the bolts and carefully lift the engine using the hoist;
- remove the shock absorbers;
- install new shock absorbers;
WARNING! The shock absorbers are asymmetric about the plane of their attachment
plate. They must be installed with their bigger side towards each other to ensure the
dimension along the bushing axes equal to 51 mm (2 in).
- re-assemble everything in the reversed order.
Recommended special tools: magnifying glass, electric torch, hoist, torque wrench.
28
6.4 Remove the top cowling. Disconnect the rod from the fitting. Inspect the fitting for the
fatigue cracks.
Check the spherical bearing for play. Permissible radial play is 0.25 mm (0.1 in), axial
– 0.5 mm (0.2 in).
If fatigue cracks or play more than permissible are detected the fitting must be
replaced. Contact manufacturer for the required technical support.
Recommended special tools: magnifying glass, electric torch, torque wrench.
6.5 Remove top and bottom cowling. Check if the shutter actuator functions properly and
the shutter fits tight at its extreme position, adjust if necessary.
To adjust the shutter actuator, do the following:
- set the shutter to ON;
- loosen the cable sheath fixing screws;
- push the shutter to the extreme position with the cable sheath and tighten the
screws.
If the cable sheath travel is insufficient for the adjustment, the shutter must be re-
installed. Remove the top half of the airbox for that (see installation of the airbox
below).
Check the torque of the airbox screws and tighten them if necessary applying Loctite
222 on the thread.
Check the attachment of the shutter actuator, vent tube and corrugated hose and
replace the plastic cable ties if necessary.
Check the integrity and reliable attachment of the sealing ring of the intake manifold.
Install new ring if necessary, using any suitable glue.
It may be necessary to remove the airbox when servicing and repairing the engine.
To remove the airbox do the following:
- remove the carburetor vent tubes;
- undo the screws connecting the airbox halves;
- undo and remove the bolt attaching the engine rod to fuselage;
- remove the top half of the airbox pushing the engine forward if necessary;
- set the airbox shutter to ON;
- unfix and remove the shutter;
- remove the carburetor air filters;
- cut the plastic cable ties fixing the corrugated hose and airbox vent tube;
- loosen the cable sheath clamp screws and take it out from the airbox;
- remove the bottom half of the airbox.
Airbox installation shall be performed in the reversed order. Then while installing the
shutter, set the carburetor heating knob to ON and ensure 33 mm (1.3 in) clearance
between the lower flange and the shutter. After assembling the airbox the shutter can
be adjusted by loosening the cable sheath clamp. When assembling the airbox apply
Loctite 222 on the thread of its fixing screws.
29
6.6 Remove the top cowling. Remove the handles from the control levers of throttle,
elevator trim tab and horizontal panel. Inspect the cables for wear. In case of
significant wear the cables must be replaced. Use 1x19 Ø1.5 mm (0.075 in) cable cut
to the length of the old one. Tin the cable ends before its installation.
WARNING! Using the cable with broken wires is not allowed.
After replacement or disconnection of the cables the engine control system must be
re-adjusted (see Installation Manual for Rotax 912 aircraft engine).
Recommended special tools: soldering iron.
6.7 Remove the top cowling. Inspect the control cables for kinks and damage of their
sheath, paying special attention to the areas where it goes through the firewall.
A damaged portion of the cable sheath may be repaired by setting over it a piece of
thermoshrinkable tube.
If significant kinks in cable sheath were detected that hamper the cable motion, the
sheath must be replaced. After replacement or repair of the cable sheath the engine
control system must be re-adjusted. (see Installation Manual for Rotax-912 aircraft
engine).
WARNING! When adjusting the throttle cables ensure 1 mm clearance between the
throttle valve control arm and the idle RPM stop (special feature of A-22LS).
Recommended special tools: heat gun.
Necessary parts/materials: thermoshrinkable tube.
6.8 Check the torque of the bolt serving as the axle of the throttle lever and adjust if
necessary. The adjustment must ensure that the lever remains at IDLE when engine
is running and the force to move the throttle is not too high.
30
7 Cooling system
Rotax-912 has cooling system of a combined type. The cylinders are air-cooled and the
cylinder heads are liquid-cooled.
The liquid cooling system consists of a water pump, expansion tank – accumulator,
radiator, overflow tank and hoses.
Its servicing consists of systematic inspection of its components, timely replacement of the
coolant and system cleaning, as well as replacement of its parts with expired service life
(hoses, sealing, etc.).
WARNING! Servicing of the cooling system must be performed in accordance with the
latest documentation of Rotax company on operation and maintenance of Rotax 912
engine.
Cooling system capacity is about 3 l (0.8 US gal). Amount of the coolant in the system
must be checked by the coolant level in the expansion and overflow tanks.
WARNING! When the cooling system is filled with coolant, air lock may be formed within
the top portion of the radiator. To remove it from the system, loosen the clamp of the upper
hose and carefully let air out.
To drain coolant from the system remove the top and bottom cowlings, disconnect the
lower hose from the radiator and let coolant out.
INSPECTION CHART
Norma 30-40 Radiator clamps, 2 pcs. 100 h OC 7.1 L LRI
See Rotax P/N Overflow tank 100 h OC 7.2 L LRI
- Hoses 100 h OC 7.3 L LRM
Instructions:
7.1 Check for integrity the clamps attaching the radiator to the engine mount. If any
clamp is damaged it must be replaced. Check the clamp torque and tighten if
necessary.
7.2 Remove the top and bottom cowlings. Inspect the tank for leaks of coolant, cracks in
its housing and cap. If any damage is detected the tank must be replaced.
Check the level of coolant in the tank and refill if necessary. Check the required level
using the marks on the tank.
Make sure the tank is attached reliably to the firewall. Replace the plastic cable ties if
necessary.
Necessary parts/materials: coolant.
7.3 Remove the top and bottom cowlings. Inspect the hoses for leaks and any damage
(chaffing, cracks). Pay special attention to the areas of hose attachment and passing
close to structural elements of engine and its mount.
31
Damaged hoses must be replaced. Drain coolant before replacing the hoses and re-
fill the cooling system with coolant as described in the beginning of this section.
Check torque of the clamps on joints and tighten if necessary. Pay special attention
to tightness of the joints before beginning operation in cold season.
32
8 Lubrication system
The engine lubrication system is of closed type with dry crankcase and forced circulation
of oil. The lubrication system consists of oil pump, oil tank, radiator, filter and connecting
lines.
Servicing of the lubrication system consists of systematic inspection of its components,
timely replacement of oil and oil filter, as well as replacement of the parts with expired
service life (connecting lines, sealing, etc.).
WARNING! Servicing of the lubrication system must be performed in accordance with the
latest documentation of Rotax company on operation and maintenance of Rotax 912
engine.
The lubrication system must be filled with high quality oil for gasoline four-stroke engines,
recommended by Rotax company. Lubrication system capacity is 3 l (0.8 US gal).
INSPECTION CHART
See Rotax P/N Oil tank 100 h OC 8.1 L LRI
- Connecting lines 100 h 1000 h/OC 8.2 H TSP
Instructions:
8.1 Remove top and bottom cowling. Inspect the oil tank plug for oil leaks. If leaks are
detected, tighten and lock the plug with safety wire.
Make sure that the vent line has no kinks, is intact and secured reliably. If the line is
damaged it must be replaced.
Necessary parts/materials: safety wire.
8.2 Remove top and bottom cowling. Inspect the connecting lines for leaks of oil and
damage (chaffing, cracks). Pay special attention to the areas of connecting lines
binding and passing close to engine, its mount and cowling. If damaged connecting
lines are detected, they must be replaced.
WARNING! When disconnecting the lines some oil may be spilled out.
33
9 Fuel system
The fuel system (see Fig. 2) includes two wing fuel tanks 1 (each 45 l capacity, 57 I fuel
tanks are optional) with filler inlets 2 and fuel lines 9 connecting the tanks to each other
and to the engine fuel pump 6 (that is feeding fuel to the engine carburetors 10) via two
fuel valves 3, mud box 11 and fuel filter 5. Fuel can be drained from the tanks using the
drain valve 4. The fuel tanks are connected with the atmosphere via the vent lines 8 in inlet
covers 2.
Fig. 2 Fuel system schematic
34
Servicing of the fuel system consists of systematic inspection of its components, timely
replacement of the fuel filter, as well as replacement of the parts with expired service life
(connecting lines, sealing, etc.).
WARNING! Be careful when working with the fuel system, as the remains of fuel are
highly fire hazardous and when spilled on glass may cause its dimness and cracking.
INSPECTION CHART
A22LS-1-6120-01 Fuel tank, right 500 h OC 9.1
A22LS-1-6120-02 Fuel tank, left 500 h OC 9.1
L LRM
A22LS-6-6120-01* Fuel tank, right 500 h OC 9.1
A22LS-6-6120-02* Fuel tank, left 500 h OC 9.1
Fuel valve х2 100 h OC 9.2
L LRM
Drain fuel valve 100 h OC 9.2
Fuel filter 100 h 200 h/OC - L LRM
Connecting lines 100 h 1000 h/OC 9.3 L LRM
* – larger fuel tank (55L)
Instructions:
9.1 Drain fuel from the tanks.
Remove the tank and inspect it for leaks of fuel. In case of suspected damage of the
tank a more thorough check is necessary. Contact manufacturer for the required
technical support.
If no defects were detected, re-install the tank, applying Loctite 222 on the tread of
the attaching screws.
9.2 Inspect the fuel valve for leaks of fuel. If fuel leaks under fuel valve fittings, do the
following:
- drain fuel from the fuel tanks;
- remove the valve after disconnecting handle and fuel lines from it;
- take out the fittings from the valve and clean their thread from old sealing material;
- put the fitting back after applying Loctite 55 sealing material on their thread;
- install the fuel valve back using Loctite 222.
If any other defect, causing leaks of fuel, was detected, the valves must be replaced.
Necessary parts/materials: Loctite 55, Loctite 222.
9.3 Remove the top cowling. Inspect the fuel lines for leaks of fuel and damage (chaffing,
cracks). Pay special attention to the areas of fuel line binding and passing through
the fuselage structure. If damaged fuel lines are found, they must be replaced. For
replacement of fuel lines use reinforced rubber hoses resistant to fuels and oils with
inside diameter Ø8 mm and Ø12 mm (drain).
35
Make sure the fuel lines are fixed to fuselage structure reliably and replace the plastic
cable ties if necessary.
36
10 Exhaust system
The exhaust system of A-22LS airplane is arranged and installed in accordance with the
recommendations of "Installation manual for Rotax-912 aircraft engine".
The system comprises of the exhaust pipes and muffler. Depending on configuration the
exhaust pipes may be fitted with exhaust gas temperature (EGT) sensors.
Each exhaust pipe is fixed to the engine with two studs and secured with M8 self-locking
nuts. The exhaust muffler is attached to the exhaust pipes via spherical joints and secured
with springs.
WARNING! Servicing of the exhaust system must be performed in accordance with the
current documentation of Rotax company on operation and maintenance of Rotax-912
engine.
INSPECTION CHART
А22-0-6475-04 Muffler 100 h OC 10.1
A22-1-6471-04 Exhaust pipe of cylinder 1 100 h OC 10.1
A22-1.6472-04 Exhaust pipe of cylinder 3 100 h OC 10.1
A22-1-6471-03* Exhaust pipe of cylinder 1 100 h OC 10.1
A22-1-6473-03* Exhaust pipe of cylinder 2 100 h OC 10.1 L LRM
A22-1.6472-03* Exhaust pipe of cylinder 3 100 h OC 10.1
A22-1-6474-03* Exhaust pipe of cylinder 4 100 h OC 10.1
A22-2-6471-03** Exhaust pipe of cylinder 1 100 h OC 10.1
A22-2.6472-03** Exhaust pipe of cylinder 3 100 h OC 10.1
See Rotax P/N Springs, 8 pcs. 100 h OC 10.2 L OWN
* – with nut for egt. temp. probe
** – with hole for egt. temp. probe.
Instructions:
10.1 Remove the top and bottom cowling. Inspect the exhaust system for fatigue cracks.
Pay special attention to the weld seams and the areas around them. Use electric
torch any other suitable source of light for the inspection.
In case of suspicion for fatigue crack the exhaust system must be dismantled for
more thorough flaw detection. In case of a confirmed crack, contact the aircraft
To dismantle the exhaust system, do the following:
- remove the springs retaining the muffler;
- undo the nuts securing the exhaust pipes;
- carefully take out the exhaust pipes and the EGT sensors (if the latter are fitted).
To install the exhaust system, do the following:
- put in place the EGT sensors (if fitted);
37
- put in place the exhaust pipes and nuts attaching them;

- attach the exhaust muffler and tighten the exhaust pipe nuts.
WARNING! When installing the exhaust pipes follow the requirements of "Installation
manual for Rotax-912 aircraft engine".
10.2 Remove the top and bottom cowling. Inspect the springs for integrity. Broken springs
must be replaced.
38
11 Propeller
A-22LS airplane may be fitted with three-blade on-ground adjustable propeller of 1.71 m
(67 in) diameter manufactured by KievProp company (e-mail: [email protected],
web: http://www.kievprop.com).
Propeller servicing comprises of its systematic inspection and timely repair (or
replacement) of the parts with expired service life in accordance with the requirements of
its manufacturer.
INSPECTION CHART
- Propeller hub 200 h 4 years/OC 11.1 L LRM
- Blades, 3 pcs. 25 h 4 years/OC 11.2 L LRI
- Bolts, 6 pcs. 200 h 4 years/OC 1.8 L OWN
А22-4-6481-00 Spinner 200 h OC 11.3 L LRI
Instructions:
11.1 Remove the propeller spinner. Inspect the propeller hub for fatigue cracks. If any
cracks are detected contact propeller manufacturer (KievProp, Ukraine, Kyiv, 04128,
Tupolev str. 19, tel./fax: +38 (044) 443-79-91, e-mail: [email protected]) for necessary
technical support.
Check the pitch angles of the blades and re-adjust the propeller if necessary.
If no defects are detected install the spinner in place applying Loctite 222 on the
thread of the attachment screws.
Recommended special tools: propeller blade angle gauge, torque wrench.
11.2 Inspect the blades for damage, paying special attention to the blade tips and
protecting metal strip on the leading edge. If seriously damaged spots or
delaminations of composite is detected, the blade(s) must be repaired (or replaced).
Contact propeller manufacturer for the required technical support.
11.3 Check the torque of the screws attaching the spinner. Tighten if necessary using
Loctite 222.
39
12 Airplane control system

The airplane control system consists of control systems of ailerons, elevator, elevator trim
tab, and aileron drooping mechanism. Control systems of ailerons and elevator may be
with either yokes or central stick. The control system of elevator trim tab may be either
mechanical or electrical one.
Control system linkage for ailerons and elevator is rigid, and for the elevator and its trim
tab it is made of cables.
Servicing of the airplane control system comprises of its systematic inspection, lubrication,
detection of worn components, repair and timely replacement of the parts with the expired
service life.
The control system must operate smoothly without jamming and significant play. The
clearances between the movable parts of the control system and fixed structural elements
must be at least 5 mm (0.2 in).
Main components of the system to be checked are:
- fabric covering of the control surfaces;
- spherical bearings;
- slide bearing;
- fairleads;
- cables;
- pulleys;
- fasteners.
The fabric covering must be inspected for damage and delamination from the framework of
the control surfaces. Minor ruptures (less than 50 mm or 2 in) may be repaired by covering
them with ORACAL permanent sticking film. In case of significant damage and
delamination of the fabric covering from the framework contact aircraft manufacturer for
The spherical bearings are installed in hinge brackets of the control surfaces, in control
rods and control system supports. The used hinges do not require any servicing. Their
wear must be checked by their radial and axial play. Maximum radial play is 0.25 mm (0.01
in) maximum axial play – 0.5 mm (0.02 in). If the play is exceeding the above specified
values contact the manufacturer for the required technical support.
Slide bearings are used in hinge brackets of the control surfaces and in control system
supports. They consist of a sleeve and an axle. The sleeves used in this airplane are
either off bronze or off steel. In the hinge brackets the sleeve is press-fitted into the
bracket, fixed to the airframe structure, and the axle is component of the movable control
surface. In the Cardan joints and in the control system supports the sleeves are installed
both in fixed and movable parts, and bolts (or pins) are used as axles. Slide bearing wear
must be checked by the radial play. The maximum radial play is 0.5 mm (0.02 in). If the
play exceeds the specified value contact the manufacturer for the required technical
support.
Slide bearings require periodic lubrication. They may be lubricated by any grease for
bearings every 200 hours or on condition.
The fairleads are used in the control systems of rudder and elevator trim tab and serve to
retain the cables. The fairleads are made of textolite. The fairleads wear must be checked
by the depth of the slot created due to cable friction against them. The slot depth must not
exceed double diameter of the cable. If the wear is exceeding the specified value contact
the manufacturer for the required technical support.
40
The cables are used in the control systems of the rudder and elevator trim tab. The cables
must be inspected for broken wires. Special attention must be paid to the areas where
cables pass through the fairleads, pulleys and to the cable terminations. If broken cable
wires are found than the cable must be replaced. Contact the manufacturer for the
required technical support.
Pulleys are used in the control system of rudder. They do not require any servicing. The
pulley must rotate without jamming and play. If jamming or play appears the pulley must
be replaced.
WARNING! When servicing the control system avoid over-tightening the bolts serving as
slide bearing axles. The tightening must eliminate the axial play however it must allow
unrestricted motion of the movable part of the joint. All bolts, nuts (except for self-locking
ones), pins, turnbuckles must be locked reliably.
Adjustment of the aileron control system is achieved by changing the length of the vertical
and diagonal control rods.
Adjustment of the elevator control system is achieved by changing the length of the aft
control rod.
WARNING! To increase the length of a control rod, loosen the locking nut and screw the
rod end OUT (all treads are right-hand!), to reduce the length – screw it DOWN. After
adjusting the rod length tighten the locking nut applying the Loctite 222 on the thread.
Adjustment of the rudder control system is achieved using the turnbuckles of the rudder
control cables.
Adjustment of the elevator trim tab control system is achieved by fixing the control cable of
the trim tab with a screw in the control arm of the tab at a proper setting.
WARNING! Do not cut the excessive length of the cable beyond the control arm of the tab.
This portion is required for passing the cable through its sheath in the elevator when re-
attaching the elevator to the stabilizer. After adjusting the cable length coil its free end
carefully and secure it to the trim tab control arm with a plastic cable tie but in a manner
that does not hamper the tab deflection while it is being controlled.
Adjustment of the control system must ensure the deflection angles of the control surfaces
specified in the "Pilot Operating Handbook A-22LS".
INSPECTION CHART
Aileron control system
A22LS-0-3700-01 Aileron, right 100 h OC 12.1
L LRI
A22LS-0-3700-02 Aileron, left 100 h OC 12.1
A22LS-0-5165-00 Cardan rings, 2 pcs. 100 h OC 12.2
A22LS-0-5160-01 Aileron shaft, right 100 h OC 12.2 L LRI
A22LS-0-5160-02 Aileron shaft, left 100 h OC 12.2
A22LS-0-5175-00 Rods, vertical, 2 pcs. 100 h OC 12.3
A22LS-0-5150-00* Roll shaft 100 h OC 12.3 L LRI
A22LS-1-5150-00 Roll shaft 100 h OC 12.3
A22LS-1-5172-00 Rod, diagonal 100 h OC 12.2
A22LS-1-5170-00 Rod, horizontal 100 h OC 12.2 L LRI
A22LS-3-5140-01 Yoke, right 100 h OC 12.2
41

A22LS-3-5140-02 Yoke, left 100 h OC 12.2 L LRI
A22LS-1-5130-01 Yoke end, right 100 h OC 12.9
L LRI
A22LS-1-5130-02 Yoke end, left 100 h OC 12.9
A22LS-1-5120-00 Control yoke column 100 h OC 12.3
L LRI
A22LS-0-5120-00* Control stick column 100 h OC 12.3
A22LS-0-5400-00 Aileron drooping mechanism 100 h OC 12.4 L LRI
Elevator control system
A22LS-0-3200-00 Elevator 100 h OC 12.5 L LRI
A22LS-0-5196-00 Rod, aft 100 h OC 12.3
L LRI
A22LS-0-5193-00 Rod, middle 100 h OC 12.3
A22LS-0-5190-00*
Rod, front 100 h OC 12.3 L LRI
A22LS-1-5190-00
A22LS-0-5188-00 Bellcrank unit, aft 100 h OC 12.2
L LRI
A22LS-0-5186-00 Bellcrank unit, front 100 h OC 12.2
Rudder control system
A22LS-0-3300-00 Rudder 100 h OC 12.6 L LRI
A22LS-0-5218-01 Rudder cable, right 200 h OC 12.7
L LRI
A22LS-0-5218-02 Rudder cable, left 200 h OC 12.7
A22LS-0-5210-00 Pedals 100 h OC 12.8 L LRI
A22LS-0-5214-00 Rods, 2 pcs. 100 h OC 12.9 L LRI
- Pulleys, front, 2 pcs. 500 h OC -
A22LS-0-5216-00 Pulley units, aft, 2 pcs. 500 h OC -
L LRI
A22LS-0-5224-00 Fairleads, front 500 h OC -
A22LS-0-5204-00 Fairleads, aft 500 h OC -
Elevator trim tab control system
A22LS-0-4000-00 Trim tab 200 h OC 12.10 L LRM
A22LS-0-5515-00 Cable 200 h OC 12.11 L LRM
A22LS-0-5502-00 Fairleads, 2 pcs. 200 h OC - L LRM
A22LS-0-5504-00 Cable sheath, front 200 h OC 12.12
L LRM
- Cable sheath, aft 200 h OC 12.12
* – for the airplane version with central control stick
Instructions:
12.1 Inspect aileron for fatigue cracks, deformation, loose rivets, as described in 3.1
(paragraphs 2 and 3). Pay special attention to the areas near the aileron hinge
brackets.
Check the play in the aileron hinge brackets and Cardan joint. Grease the slide
bearings if necessary.
Check tightness and locking of the nut of the aileron root hinge bracket.
Inspect the fabric covering as described in the beginning of this section.
42

12.2 Check tightness and locking of the nuts and play in hinged joints. Grease the slide
12.3 Check tightness and locking of the nuts and play in hinged joints.
Inspect the riveted joints for loose rivets as described in 3.1. If loose rivets are
detected contact the manufacturer for the required technical support.
12.4 Remove the housing of the aileron drooping mechanism after extending the flaps to
20°. Check tightness and locking of the nuts and play in hinged joints. Grease the
slide bearings if necessary.
12.5 Inspect the elevator for fatigue cracks, deformation, loose rivets, as described in 3.1
(paragraphs 2 and 3). Pay special attention to the areas near the elevator control arm
and hinge brackets.
Check play in the elevator hinges. Grease the slide bearings if necessary.
Check tightness and locking of the nuts on the center hinge and control rod
attachment.
12.6 Inspect the rudder for fatigue cracks, deformation, loose rivets, as described in 3.1
(paragraphs 2 and 3). Pay special attention to the areas near the rudder control arms
and hinge brackets.
Check play in the rudder hinges. Grease the slide bearings if necessary.
Check tightness and locking of the lower hinge nut and locking of the attachment pins
of the control cables.
12.7 Inspect the cable for wear in the areas where it passes through fairleads and pulleys.
If any cable wire is broken the cable must be replaced. Contact the manufacturer for
Check the cable tension. To do that, apply 30 N (6.7 lb) side load towards the other
cable of in the middle of the cable portion between the pulley supports behind the
luggage container. The cable sag must be equal to 50±5 mm (2±0.2 in). If necessary
adjust the cable tension using the turnbuckles. Lock the turnbuckles with safety wire
after that.
43

12.8 Inspect the pedals for fatigue cracks and deformation. Pay special attention to the
weld seams. In case of detecting cracks contact the manufacturer for the required
technical support.
Check tightness and locking of the nut of the nose wheel control rods.
Check locking of the pins and pedal supports.
Check play in the supports and hinged joints. Grease slide bearings if necessary.
12.9 Check tightness and locking of the nuts and play in hinged joints. Grease the slide
12.10 Check the trim tab fasteners for corrosion. Replace corroded fasteners. Grease
slide bearings if necessary.
12.11 In airplane version with mechanical control system of the elevator trim tab remove
the handles from the control levers of throttle, trim tab, brakes and horizontal panel.
Inspect the cable for wear in the areas where it passes fairleads, cable sheath and
near its attachment to the control lever and trim tab control arm.
In airplane version with electromechanical control system of the elevator trim tab
inspect the cable in the areas where it passes fairleads, sheath and near its
attachment to the control arm of the trim tab.
If any cable wire is broken the cable must be replaced. Contact the manufacturer for
After inspection assemble everything in the reversed order.
12.12 Inspect the cable sheath for kinks and damage. A damaged portion of the cable
sheath may be repaired by setting over it a piece of thermoshrinkable tube.
If significant kinks in cable sheath were detected that hamper the cable motion, the
sheath must be replaced. After replacement or repair of the cable sheath the trim tab
control system must be re-adjusted.
Recommended special tools: heat gun.
Necessary parts/materials: thermoshrinkable tube.
44
13 Electrical system
The major components of the electrical system of A-22LS airplane are: battery (12 V,
minimum 16 Ah), starter relay, rectifier-regulator, condenser (22000 µF, 25 V), warning
light (12 V, 2 W), master switch, ignition and consumer switches, fuse block, electric
harness, fuel level senders and indicators and analog engine instruments. Optionally the
airplane may be also equipped with ground switch, landing light and miscellaneous
consumers.
The battery is located on the left side behind the frame No. 3. The starter relay, rectifier-
regulator and condenser are located on the left side of the firewall. The switches, fuses,
and fuel level indicators – on the lower part of the instrument panel. The warning light – on
the left side of the instrument panel. Fuel level sensors are installed in the fuel tanks. The
landing light – on the lower part of the engine mount.
The electrical system arrangement complies with the requirements of the "Installation
manual of Rotax-912 aircraft engine". Electric system wiring depends on the electric
equipment/instruments installed in the aircraft and therefore have main and additional
(optional) portions. The respective wiring diagrams are shown on Fig. 3, to Fig. 5.
WARNING! Checking the electrical system components belonging to the engine electrical
system (rectifier-regulator, condenser, engine instruments) shall be performed in
accordance with the current documentation of Rotax company on operation and
maintenance of Rotax-912 engine.
Depending to airplane configuration, the electrical system may include miscellaneous
consumers (radio, transponder, engine instruments, navigation lights, etc.). Servicing
those consumers shall be performed in accordance with the current documentation on
their operation and maintenance of their respective manufacturers.
The electrical system of the airplane requires minimum servicing. The main problems that
may arise in the electrical system is corrosion of contacts and chaffing of wires.
To prevent oxidation of the connectors and terminals they must be covered with some
Lithium-based grease.
To minimize the probability of chaffing and prevent breaking (or short circuit) of wiring the
reliable fixation (binding) of harnesses must be ensured. Special attention must be paid to
the areas where wiring is located close to the movable parts of airplane. To fix the wiring
use plastic cable ties.
45
Fig. 3 Wiring diagram of A-22LS electric system (main)
46
Fig. 4. Wiring diagram for installation PTT buttons
Fig. 5. Wiring diagram for installation of strobes
47
Fig. 6. Wiring diagram for installation of FlyDat
48
INSPECTION CHART
- Battery 100 h OC 13.1 L LRM
See Rotax P/N Starter relay 100 h OC 13.2 L LRM
- Power cables 100 h OC 13.3 L LRM
See Rotax P/N Rectifier-regulator 100 h OC 13.4
L LRM
- Condenser 100 h OC 13.4
- Warning light 100 h OC - L OWN
- Master switch 100 h OC - L OWN
- Ignition switches, 2 pcs. 100 h OC - L OWN
- Consumer switches 100 h OC - L OWN
- Fuse block 100 h OC 13.5
L LRM
- Fuses 100 h OC 13.5
- Fuel level sensors, 2 pcs. 200 h OC 13.6
L LRM
- Fuel level indicators, 2 pcs. 200 h OC 13.6
- Landing light 100 h OC 13.7 L LRM
- Engine instruments 100 h OC 13.8 L LRM
- Main harness 100 h OC 13.9 L LRM
- Harness for engine instruments 100 h OC 13.10 L LRM
Instructions:
13.1 Replace the battery when it does not charge or discharge properly. Keep the battery
terminals clean; do not allow corrosion to appear on its surfaces.
13.2 Inspect terminals and connector of the starter relay for corrosion and clean them if
necessary.
WARNING! To prevent starter from inadvertent engagement or short circuit switch
OFF the ground switch (if installed) or disconnect one of the power cables from the
battery.
Make sure the relay and cables connected to it are attached reliably.
13.3 Inspect the terminals of the power cables connecting the battery to the starter and
airplane ground for corrosion and damage at cable terminations. If necessary clean
the terminals from corrosion. Bad contact will cause cable overheating and difficult
engine start.
If the cables are damaged, contact manufacturer for the required technical support.
13.4 Inspect terminals and connectors for corrosion and clean if necessary.
49

13.5 Remove the fuse block cover. Take out the fuses and inspect their sockets. If
corrosion is detected the fuses and sockets must be cleaned. After servicing put in
place the fuses and fuse block cover.
13.6 Verify correctness of the fuel level indicators’ readings. For that do the following:
-close the fuel valves;
-fill a fuel tank fully (57 l or 15.1 US gal);
-switch ON the master switch;
-open the valve of the full fuel tank;
-drain fuel through the drain valve and compare the fuel level indicator readings
against the fuel remaining in the tank:
57 l (15.1 US gal) – «4/4»
28.5 l (7.5 US gal) – «1/2»
6 l (1.6 US gal) – “reserve fuel remains” light ignites
1 l (0.3 US gal) – «0»;
WARNING! Be careful while working with the fuel system, the fuel is highly fire-
hazardous.
- switch OFF the master switch;
- perform the check of the other fuel level sensor and indicator;
If the “reserve fuel remains” light does not ignite it must be replaced. If after
replacement the light still does not ignite, contact the manufacturer for the required
technical support.
If at «4/4» and «1/2» readings the remaining fuel differs from the reading for more
than 5 l (1.3 US gal) and the fuel remaining at ignition of “reserve fuel remains” light
differs for more than 2 l (0.5 US gal), contact the manufacturer for the required
technical support.
13.7 Remove top and bottom cowling. Check torque of the nut attaching the landing light
and tighten it if necessary.
Check landing light functioning and replace the lamp if necessary.
13.8 Inspect the terminals and connectors of the sensors for corrosion and clean if
necessary.
13.9 Remove top cowling. Inspect the electrical harness for damage (chaffing, broken
wires). Restore damaged insulation by setting a piece of thermoshrinkable tube over
it. Connect broken wires by soldering with following insulation of the soldered areas
with thermoshrinkable tube.
50
Special attention must be paid to the areas where harness comes through the firewall
and near the airbox.
After every 1000 hours of flight time the harness must be freed from its fixation inside
the fuselage (cut the plastic cable tie fixing the harness and preventing the harness
extraction and inspection) and moved carefully to 10-15 mm (0.4-0.6 in) away from its
place for inspection. The abraded insulation of wires detected during the inspection
must be restored by covering it with insulating tape or thermoshrinkable tubing. After
that put the harness in its place and fix with plastic cable ties.
Check the integrity of the protective rubber insert in the area where harness passes
close to the airbox and replace the insert if necessary.
Recommended special tools: heat gun, soldering iron.
Necessary parts/materials: thermoshrinkable tube, soldering alloy, cable ties.
13.10 Remove the top cowling. Inspect the electrical harness for damage (chaffing,
broken wires). Restore damaged insulation by setting a piece of thermoshrinkable
tube over it. Connect broken wires by soldering with following insulation of the
soldered areas with thermoshrinkable tube.
Inspect the terminals and connectors of the sensors for corrosion and clean if
necessary.
Recommended special tools: heat gun, soldering iron.
Necessary parts/materials: thermoshrinkable tube, soldering alloy, cable ties.
51
14 Cockpit heating system

Cockpit heating system of A-22LS airplane consists of warm air scoop (located behind the
engine cooling system radiator), warm air duct (flexible corrugated hose), warm air shutter
housing (attached to the firewall inside the engine compartment of the left side) and warm
air shutter actuator. The control handle of the actuator (No. 4 on Fig. 7) is located on the
left side of the instrument panel. The shutter actuator comprises a thick wire and a flexible
conduit. The warm air duct connects the warm air scoop to the warm air shutter housing.
The duct is attached to the scoop and housing with screw clamps. In flight some portion of
the air cooling the engine radiator is forced into the warm air scoop and then is going via
the duct to the shutter housing and (when the cockpit heating handle is in the “ON”
position) through the hole in the firewall into the cockpit. When the cockpit heating handle
is set to “OFF” position, the shutter closes the hole in the firewall and the warm air is not
getting into the cockpit but is released into the engine compartment via an opening in the
shutter housing.
INSPECTION CHART
A22.1.6520.00 Warm air scoop 100 h OC 14.1 L OWN
A22.1.6509.00 Warm air shutter housing 100 h OC
14.2 L A&P
A22.1.6501.00 Warm air shutter 100 h OC
A22.0.6514.00 Warm air duct 50 h OC 14.3 L LRI
A22.1.6515.00 Warm air shutter actuator 100 h OC 14.4 L LRM
Instructions:
14.1 Remove the top and bottom engine cowling. Inspect the warm air scoop for damage.
If it is damaged, remove it from its place, clean the damaged area with sand paper
and apply a patch of fiberglass cloth impregnated with epoxy adhesive.
Recommended special tools: sand paper, rubber gloves.
Necessary parts/materials: fiberglass cloth, epoxy adhesive.
14.2 Remove the top engine cowling. Inspect the warm air shutter housing and shutter for
damage. Check if the shutter closes and opens fully and moves freely and without
jamming. If the shutter or housing is damaged so that the shutter is not functioning
properly, replace the shutter or housing.
Recommended special tools: electric drill, drills, reamers, pop-rivet tool.
Necessary parts/materials: pop-rivets.
14.3 Remove the top and bottom engine cowling. Inspect the warm air duct for damage
and secure attachment to air scoop and shutter housing. If the hose is damaged (i.e.
has holes or ruptures) replace it. If the actuator has kinks or other damage
hampering the shutter control, replace the actuator.
Recommended special tools: electric torch, mirror.
14.4 Remove the top engine cowling. Check the condition of the air shutter actuator in the
engine compartment and in the cockpit (remove the instrument panel if necessary).
Recommended special tools: electric torch.
52
15 Instruments and Avionics

Instrument panel is shown on Fig. 7 below. The list of instruments and avionics are
installed in the airplane is in subsection 1.2 Equipment list.
The instruments and avionics of A-22LS are located on the main and additional (lower)
instrument panels in the cockpit.
Fig. 7 Instrument panel
53
Numbers in Ошибка! Источник ссылки не найден. denote the following:

1. Placard with passenger warning: "THIS AIRCRAFT WAS MANUFACTURED IN
ACCORDANCE WITH LIGHT SPORT AIRCRAFT
AIRWORTHINESS STANDARDS AND DOES NOT
CONFORM TO STANDARD CATEGORY
AIRWORTHINESS REQUIREMENTS"
2. Placard with operating limitations: OPERATE UNDER VFR ONLY
NEVER EXCEED SPEED = 124 KTS IAS
MAX CONTINUOUS ENGINE SPEED = 5500 RPM
MAX TAKEOFF MASS = 600 KG (1320 LB)
LIMIT LOAD FACTOR = +4.0 / -2.0
3. NO CHARGE indicator and marking
4. ALARM indicator and marking
5. Right tank fuel level indicator and marking "FUEL R"
6. Left tank fuel level indicator and marking "FUEL L"
7. LANDING LIGHT marking and switch
8. Strob light switch and marking
9. Navigation light switch and marking
10. IGN A switch
11. IGN B switch
12. Master and starter key
13. ON marking for electric and ignition switches
14. OFF marking for electric and ignition switches
15. IGN A marking
16. IGN B marking
17. Master marking
18. Starter marking
54
16 Full and static pressure system

The full and static pressure system (see Fig. 8) supplies the full (dynamic) and static
pressure of the outside air to the instruments measuring the flight parameters: airspeed,
rate of climb and altitude. The system consists of the full and static pressure probe (1) and
full (2) and static (3) pressure lines connecting the probe to the instruments. Full and static
pressure lines have joints (4) for disconnecting the lines when the left wing is removed
during aircraft disassembly.
The full and static pressure probe (1) is located on the left wing strut. The full and static
pressure lines are connected to the airspeed indicator. The altimeter and vertical speed
indicator are connected to the static pressure line.
Good condition of the full and static pressure system is important for correct measurement
of the flight parameters and therefore for flight safety. Pilots must take all measures
necessary to keep the system in good condition. During the preflight check pilot must
remove the cover from the full and static pressure probe and inspect the probe and lines to
make sure that they are not damaged or blocked (by water, ice, dirt, etc.). After flight pilot
must put the cover back on the probe.
Fig. 8 Full and static pressure system

Maintenance and repair of the instruments together with the full and static pressure system
and avionics consists in periodic checks of its operation and replacement of the
components that failed.
INSPECTION CHART
- Switches 100 h OC 15.1 L LRM
- Lights 100 h OC 15.2 L LRM
- Instruments and avionics 100 h OC 15.3 L LRM
- Full and static pressure system 100 h OC 15.4 L LRM
55
Instructions:
16.1 Switch on the master switch. Check operation of the switches, by switching them ON
one by one. Replace the ones that are not fuctioning properly. To replace a switch
detach the lower panel, remove the switch and replace it for a new one of the same
model/type. Put the panel in place.
16.2 Switch on the master switch. Check operation of the lights. Replace defective ones.
To replace a light detach the main instrument panel to get access to the light to be
replaced. After replacing the light put the instrument panel in place and fix it properly
with its attaching screws.
16.3 Inspect the instrument panel, make sure that arrows of analog instruments are set to
zero. Switch on the master switch. Check indications of the electronic instruments. If
necessary start the engine and check if the instruments are functioning properly. If an
instrument is defective replace it. To replace the instrument detach the instrument
panel to which it is fixed and move it to get access to the instrument to be replaced.
Take care not to damage any wiring behind the instrument panel. If necessary cut the
plastic cable ties, disconnect and put carefully aside the cables that do not allow
removal of the instrument to be replaced. Replace the instrument and fix the electric
cables with cable ties to hold them away from the movable parts of the flight control
system. Put the instrument panel in place.
16.4 Inspect the Pitot tube. Check condition of the full and static pressure lines and of their
joints in the cockpit. The lines must be intact and have no water, dirt or any foreign
objects trapped inside. Replace damaged lines. To remove water, dirt or foreigh
objects from the lines disconnect the lines from the instruments and clean them with
compressed air.
56
17 Pilot seats and harness belts

The pilot seats of A-22LS airplane are adjustable (they have 2 fixed settings) and consist
of an aluminum framework and a cushion.
The harness system is of four-point type. It consists of two sets of harness belts.
INSPECTION CHART
А22LS-0-8010-00 Pilot seat frameworks, 2 pcs. 100 h OC 15.1 L LRM
А22LS-0-8020-00 Pilot seat cushions, 2 pcs. 100 h OC 15.2 L OWN
А22LS-2-7550-00 Harness belts set, 2 pcs. 100 h OC 15.3 L LRI
Instructions:
17.1 Remove the cushions from the seat framework. Inspect the framework for the fatigue
cracks and loose rivets.
Upon detecting cracks with length less than 10 mm (0.4 in) stop the crack
propagation by drilling carefully a Ø3 mm (0.12 in) hole at its end. If the crack is
longer than 10 mm (0.4 in), the framework must be replaced (repaired). To obtain the
instructions on repair of the framework contact the manufacturer.
If loose rivets are detected they must be replaced. For that do as follows:
- remove the pilot seat framework;
- remove the cores from the loose pop-rivets;
- drill out the rivets with a Ø3 mm (0.12 in) drill;
- install new Ø3×6 rivets;
- install the seat framework in place.
If no defects are detected install the seats back. Apply Loctite 222 on the thread of
the attaching bolts.
Recommended special tools: electric drill, Ø3 mm drill.
Necessary parts/materials: Ø3×6 rivets, Loctite 222.
17.2 Inspect the seat cushions for damage of the upholstery and repair it if necessary.
17.3 Check functioning of the harness belts’ locks. For that apply a 300 N (67 lb) tension
to the waist belts. The lock must not unlock spontaneously under the load. Otherwise
the lock must be replaced.
Inspect the belts for damage (cuts, chaffing). Upon detecting any damage contact the
57
18 Cockpit doors
The cockpit doors are made in form of a PVC glass on a riveted metal framework. The
doors may be fitted optionally with locks. The doors are retained in their open position with
a gas strut. The forward part of each door is fitted with a ventilation air scoop.
The doors can be removed quickly. To remove the doors do the following:
- while holding the door open detach the gas strut from fuselage (remove the securing
clamp and move the strut away);
- while holding the door outside remove the pins from the door hinges (first the aft than
the front one);
- remove the door.
To install the door repeat above actions in the reversed order.

INSPECTION CHART
A22LS-0-1350-01 Door, right 100 h OC 16.1
L LRI
A22LS-0-1350-02 Door, left 100 h OC 16.1
- Gas struts, 2 pcs. 100 h OC 16.2 L LRI
Instructions:
18.1 Inspect the door glass as described in 3.2.
Inspect and if necessary replace the door sealing. To do that carefully clean the door
from the old sealing and fix the new one.
Inspect the framework, hinges and fasteners of the door for fatigue cracks, damage
and loose rivets, as described in 3.1 (paragraph 2 and 3).
18.2 Check the functioning of the gas strut. Its cylinder rod must move smoothly and
without jamming. The gas strut must retain the door in open position. If not than the
gas strut must be replaced.
58
19 Recovery system
A-22LS airplane can optionally be equipped with a parachute recovery system for the
maximum take-off weight of 600 kg (1320 lb).
The recovery system is installed on the right side behind the luggage container. The
system actuation handle is installed on the panel between the pilot seats.
The system suspension cables are fixed to fuselage in three locations (at firewall and near
the rear attachment points of the wings).
System servicing must be performed in accordance with the current documentation of the
recovery system manufacturer.
WARNING! Before any servicing of the system install the safety pin into its actuation
mechanism.
INSPECTION CHART
- Container with parachute * - L TSP
- Actuation handle with cable * - L TSP
A22LS-0-7010-00 Suspension cable, front 500 h OC 17.1
A22LS-0-7020-01 Suspension cable, right 500 h OC 17.1 L LRI
A22LS-0-7020-02 Suspension cable, left 500 h OC 17.1
* see Maintenance Manual of the respective recovery system
Instructions:
19.1 Check attachment of the suspension cables to the parachute lanyard and to fuselage
structure. If necessary, replace the plastic cable ties fixing the cables.
59
20 Structural repair
18.1 General
This section describes the repairs that can be performed by aircraft owners, LSA repairmen or
aircraft and powerplant mechanics without further consultation with the aircraft manufacturer.
However when planning to perform the particular repair work it is recommended to consult the
aircraft manufacturer in order to verify that the necessary repair was correctly identified and
properly prepared. Before commencing to perform the repairs described in this section study
carefully this section and prepare all necessary tools, parts and materials. Make sure that the level
of certification requirements are met. In case of doubt consult your local dealer or aircraft
manufacturer.
18.2 Fuselage glazing repair

Fuselage glazing (windscreen, door glass, rear windows) is fragile and prone to cracking
due to internal stress, vibration, shock loads and other factors that are likely to occur
during aircraft operation. If any cracks in fuselage glazing were detected when performing
the inspection or maintenance operations described in this manual their propagation must
be stopped by drilling the 3 mm holes at the crack ends as shown on Fig. 9 below.
Typically cracks start from the rivets attaching the glass to the framework (as shown on the
right side of Fig. 9). In that case only one end of the crack has to be stop-drilled. In case of
a crack is located away from the rivet holes then both ends of the crack must be stop-
drilled (as shown on the left side of Fig. 9).
Fig. 9 Fuselage glass crack stop-drilling

Note: detailed instructions for inspection and repair are given in Section 3 (paragraph 3.2).
60
18.3 Fabric covering repair

The fabric covering of the wing, flaperons, elevator and rudder is soft and therefore it may
be damaged accidentally in operation. If minor damage (holes, cuts or rupture of size less
than 50 mm) of the fabric covering is detected during inspection it must be repaired by
covering the damaged area with a patch of ORACAL permanent sticking film of suitable
color, shape and size as shown on Fig. 10 below.
WARNING: this repair is allowed for fabric skin damage (holes, cuts, rupture, etc.) less
than 50 mm in size and located away from the fabric covering edges and airframe parts to
which the fabric covering is attached with adhesive. In case if the damage is greater than
50 mm in size or if the attachment of the fabric covering to airframe parts is damaged
contact aircraft manufacturer.
Fig. 10 Fabric covering repair

This repair operation must be performed indoor (in the workshop or hangar) at a
temperature not below 15°C for the film to stick properly to the fabric covering and dry air.
Before repairing the fabric covering wash the damaged area from any contamination (dust,
greasy stains, etc.) with a piece of soft cloth soaked with warm soapy water, then wipe
away the water and soap with a clean wet cloth and let it dry. Cut a patch of ORACAL film
of suitable color, shape and size and apply it on the damaged are so that the minimum
distance from any edge of the damage to the patch edge is at least 25 mm as shown on
Fig. 10. Apply the patch to the fabric covering evenly over entire damaged area without
wrinkles and bubbles. Make sure that all patch edges stuck reliably to the fabric covering.
Type of maintenance: line.
Level of Certification: owner.
Necessary parts/materials: ORACAL permanent sticking film.
61
18.3 Composite parts’ repair

Some parts of the aircraft such as engine cowlings, wheel fairings, wing tips, fin tip, wing
root fairings are made of composite materials. Those parts may be damaged in operation
accidentally. If during inspection any damage of those parts such as cracks, dents, etc. is
found it can be repaired as described below.
WARNING: this repair is allowed for the composite parts’ damage (holes, cracks, dents,
etc.) less than 50 mm in size and located away from the attachment points (bolt holes,
quick-release locks, etc.). In case if the damage is greater than 50 mm in size or if the
attachment of the composite parts to airframe is damaged contact aircraft manufacturer.
Fig. 11 Composite parts repair

Repair of damaged composite parts must be performed in a premise with temperature not
below 15°C (for the epoxy resin to solidify properly) and some kind of air ventilation (for
health protection). The composite part to be repaired must be removed from the airplane.
The composite parts such as wing root fairings, wing tips, fin tip that are riveted to airframe
structure can not be removed from the airplane and therefore must be brought into the
repair premise together with the airframe component to which they are riveted (wing,
fuselage).
After removing the composite part to be repaired clean and degrease the damaged area
with soapy water and let it dry completely. Sand the damaged area from inside or from
outside (if the inner surface of the part is inaccessible) with sand paper of a medium grain
size and clean thoroughly the damaged area from dust and chips created by sanding.
When sanding the outer surface of the parts with inaccessible inner surface (wing tips,
wing root fairings) make sure to remove the paint from entire area where the repair
patches will be applied later.
62
WARNING! use protective means (rubber gloves, respirator, protective glasses and
clothes) when sanding or working with epoxy adhesive. Make sure the air in the working
area is ventilated properly.
Cut several patches of fiberglass cloth of suitable shape and size that cover the damaged
area as shown on Fig. 11 above (at least 25 mm to the damaged spot from any edge of
the patch). The number of the patches should be such that the total thickness of the
patches is approximately equal to the thickness of the repaired part in the damaged area.
The size of each following patch should be slightly less to form a pack with gradual
increase of the thickness at the edges as shown on Fig. 11.
Prepare the necessary amount of epoxy adhesive by mixing its components in proper
ratio, impregnate the preliminarily cut patches of fiberglass cloth and apply them on the
damaged area as necessary (inside or outside). Apply the patches evenly over entire
damaged area without wrinkles and bubbles. Make sure that all edges of the patches stuck
reliably to the part surface. Fill the cavities of the damaged spot (holes, dents, cracks) with
putty made of the preliminarily prepared epoxy adhesive mixed with some powder filler.
After applying the patches over the damaged spot let the epoxy resin to solidify
completely. Then sand the solidified patches to obtain a smooth surface and restore the
damaged paint on the outer surface of the repaired part.
Level of Certification: LSA repairman maintenance.
Recommended special tools: respirator, protective glasses, rubber gloves, sanding
paper.
Necessary parts/materials: fiberglass cloth, epoxy adhesive, putty, paint.
63
18.4 Restoring of damaged paint/coating

It is recommended to restore the damaged paint/coating in a closed room with ventilation
and temperature sufficient for the paint/coating to dry. The parts/components requiring
restoring of the paint/coating must be removed from the airplane.
WARNING! use protective means (gloves, respirator, protective glasses and clothes)
when sanding or painting. Make sure the air in the working area is ventilated properly.
Restoring of the damaged paint/coating shall be done as follows:
1. Remove the delaminated paint/coating in the damaged area and degrease the area
using tissue and solvent.
2. Sand the damaged area using the sand paper with the grain of not bigger than R360.
3. Small scratches and nicks of paint/coating may be filled with nitro putty. Big scratches
and nicks of paint/coating must be filled with polyether putty. Smooth the surfaces with
dried putty using sand paper. Maximum layer of the putty should not exceed 1 mm.
4. Using a spray gun apply epoxy (for metal parts) or acrylic (for composite parts) primer
on the damaged area.
5. When the primer is dry finish the surface with sand paper. If necessary apply cover with
nitro putty again.
6. Remove the sanding dust and degrease the repaired area.
7. Cover undamaged surface of the part/component with paper/film and sticking tape.
8. Using spray gun apply the paint on the repaired area and let it dry.
9. When the paint is dry remove the protecting paper/film. Polish the repaired area if
necessary.
Level of Certification: LSA repairman maintenance.
Recommended special tools: respirator, spray gun, protective glasses and clothes,
gloves, sanding paper.
Necessary parts/materials: tissue, solvent, epoxy or acrylic putty, paint, sticking tape,
paper or polyethylene film.
64
21 Feedback Form
This section contains a form for the aircraft owner or maintainer to provide notification to
the manufacturer about issues and anomalies identified during the operation or
maintenance of the aircraft or in the content of the manual.
Aeroprakt LSA Feedback Form
Airplane model _______________________ Airplane serial No. _____________________
Airplane registration ___________________ Date of event _________________________
Date of airplane manufacture ____________ Airplane total hours ____________________
Engine model ________________________ Engine serial No. ______________________
Engine total hours ____________________ Engine hours since last overhaul __________
Description of occurrence:
______________________________________________________________________________
______________________________________________________________________________
______________________________________________________________________________
______________________________________________________________________________
______________________________________________________________________________
______________________________________________________________________________
______________________________________________________________________________
______________________________________________________________________________
______________________________________________________________________________
______________________________________________________________________________
______________________________________________________________________________
______________________________________________________________________________
______________________________________________________________________________
______________________________________________________________________________
______________________________________________________________________________
______________________________________________________________________________
Enclose all available data including photos, sketches, etc. and send to: Aeroprakt Ltd., Polyova str. 24,
03056, Kyiv, UKRAINE, phone: +38 (044) 496-77-21, fax: +38 (044) 496-77-21, e-mail: [email protected] or
[email protected], web: www.aeroprakt.kiev.ua.
Owner: _____________________________ Contacts: ___________________________
Address: _________________________________________________________________
65

AMM A22LS - SR No 204 - A6 MPL

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Aeroprakt Ltd.

24, Polevaya str., Kiev, Ukraine

Airplane Model: AEROPRAKT-22LS (A-22LS)

Airplane Registration Number:

Airplane Serial Number: 204

Date of issue: 26.12.2013

Approved by: Yuriy Yakovlyev

Position: Chief designer

Date of approval: 26.12.2013

This manual must be carried in the airplane at all times.

1.1 Sources to purchase parts

1.2 Equipment list

1.3 Disposable replacement parts

1.4 Engine specifications

1.5 Weight and balance information

Fig. 1 CG location of the empty airplane, pilots, fuel and baggage

1.6 Tire inflation pressure

1.7 Approved fuel, oils and capacities

“Fuel Low” warning light at: approx. 6 liters per tank

1.8 Recommended fastener torque values

1.9 General safety information

1.10 Reporting maintenance, service, and safety difficulties

Check the torque of the engine mount attachment bolts X

Clean rectifier-regulator and condenser terminals/connectors of corrosion, if any X

- set the parking brake to ON;

Check the torque of the fairing attachment bolts/nuts.

Recommended special tools: none.

Recommended special tools: none.

6 Engine and its control system

Fig. 2 Fuel system schematic

- put in place the exhaust pipes and nuts attaching them;

12 Airplane control system

Part No. Description Interval RCO Instr. No. TM LC

Necessary parts/materials: none.

Recommended special tools: none.

Fig. 3 Wiring diagram of A-22LS electric system (main)

Fig. 4. Wiring diagram for installation PTT buttons

Fig. 5. Wiring diagram for installation of strobes

Fig. 6. Wiring diagram for installation of FlyDat

Recommended special tools: none.

14 Cockpit heating system

15 Instruments and Avionics

Fig. 7 Instrument panel

Numbers in Ошибка! Источник ссылки не найден. denote the following:

16 Full and static pressure system

Fig. 8 Full and static pressure system

17 Pilot seats and harness belts

To install the door repeat above actions in the reversed order.

* see Maintenance Manual of the respective recovery system

18.2 Fuselage glazing repair

Fig. 9 Fuselage glass crack stop-drilling

18.3 Fabric covering repair

Fig. 10 Fabric covering repair

18.3 Composite parts’ repair

Fig. 11 Composite parts repair

18.4 Restoring of damaged paint/coating

Aeroprakt LSA Feedback Form

Airplane model _______________________ Airplane serial No. _____________________

Airplane registration ___________________ Date of event _________________________

Airplane model ___ Airplane serial No. _

Airplane registration _ Date of event _______

Date of airplane manufacture Airplane total hours ________

Engine model __ Engine serial No.

Owner: ___ Contacts: _