Page 1 Sting TL-2000 AIRCRAFT MAINTENANCE MANUAL Ing. Martin Zahálka Authors: Lukáš Tláskal THIS DOCUMENT AND TECHNICAL DATA HEREON DISCLOSED ARE PROPRIETARY TO TL-ULTRALIGHT AND SHALL NOT BE USED, RELEASED OR DISCLOSED IN WHOLE OR IN PART WITHOUT EXPRESS WRITTEN PERMISSION FROM TL-ULTRALIGHT.
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Page 4 ¨Dear Sting Owner: Congratulations on the purchase of your Sting S4! You will find your new TL- ULTRALIGHT aircraft very enjoyable, extremely economical, and easy to maintain. The Sting S4 is the ideal Light Sport Airplane. It is fast, economical, pleasing to the eye, and user friendly.
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Page 6: Table Of Contents
0 INTRODUCTION 0.1 Table of content INTRODUCTION Table of content Notes, Cautions, and Warnings List of Revisions 0-10 GENERAL INFORMATION Introduction 1.1.1 Scope 1.1.2 Safety 1.1.3 Referenced Documents 1.1.4 Definitions 1.1.5 Maintenance and repair 1.1.6 Line maintenance and repairs 1.1.7 Heavy maintenance and repairs 1.1.8 Overhaul...
Page 7 STRUCTURES Introduction Wing 3.2.1 Wing installation 3.2.2 Wings removal 3.2.3 Verification required (wings) Empennage 3.3.1 Installation of horizontal tail 3.3.2 Horizontal tail removal 3-17 3.3.3 Elevator installation 3-17 3.3.4 Elevator removal 3-24 3.3.5 Verification required (horizontal tail and elevator) 3-25 3.3.6 Rudder installation 3-25...
Page 8 3.5.8 Verification required (aileron installation / removal) 3-94 Setting aileron “zero” position 3.5.9 3-94 Verification required (aileron “zero” position) 3.5.10 3-100 Engine 3-101 Fuel system 3-102 3.7.1 Fuel tanks filter inspection / cleaning 3-104 3.7.2 Verification required (fuel tanks filters inspection / cleaning) 3-105 3.7.3 Gascolator inspection / cleaning...
Page 9: Notes, Cautions, And Warnings
0.2 Notes, Cautions, and Warnings Throughout this manual, small boxes are inserted reading Note, Caution, or Warning. These are items which require particularly close attention for special conditions or procedures. NOTE This text box emphasizes specific operating conditions, steps in a procedure, helpful hints or useful advice.
Page 10 Any pages affected by a change should be removed and replaced with the effective pages immediately. If this manual is found not to be current, revisions missing or pages removed contact our USA Customer Service location for replacements. TL Ultralight, sro Customer Service 8222 Remount Road KORK Municipal Airport North Little Rock, AR 72118 Phone: 501.228.7777...
Page 11: List Of Revisions
0.3 List of Revisions The Revisions pages are updated by TL–ULTRALIGHT each time revision issued. They contain a list of all revisions made to the Maintenance Manual since its original issue. Revised Date Type of Revision Posted By pages 27 September 2011 None Original Issue Added additionally...
Page 12: General Information
TL Ultralight, sro Sting S4 aircraft and it’s components while operated as light sport aircraft. 1.1.2 Safety TL Ultralight, sro cannot address all of the safety concerns associated with the use of this document. It is the responsibility of the user of this document to establish appropriate safety and health practices and to determine the applicability of any regulatory limitations prior to use.
Page 13: Definitions
Alteration—any change to the airframe or aircraft component part after the initial design and production acceptance testing by TL Ultralight, sro to the applicable ASTM standards that is not described in the TL Ultralight, sro maintenance manual. Annual condition inspection—detailed inspection accomplished once a year on an LSA aircraft in accordance with instructions provided in the maintenance manual.
Page 14: Maintenance And Repair
ASTM standards that is not described in the TL Ultralight, sro maintenance manual. Overhaul—maintenance, inspection, or repair that is only to be accomplished by the TL Ultralight, sro or a facility approved by the original manufacturer of the product. Overhaul facility—facility specifically authorized by the FAA or TL Ultralight, sro or component manufacturer to overhaul the product originally produced by that manufacturer.
Page 15: Line Maintenance And Repairs
5. Repair of components and structure for which instructions are provided in the maintenance manual and which do not require additional specialized training. 6. Compliance with a TL Ultralight, sro service directive when the repairman is listed as an authorized person to accomplish the work described.
Page 16: Heavy Maintenance And Repairs
1.1.8 Overhaul (OV) Authorization to Perform—Only TL Ultralight, sro or the FTD may overhaul an LSA component or they may authorize the overhaul of an LSA component to be performed by a competent facility. No FAA certification is required to be an LSA approved overhaul facility.
Page 17: Alternation, Modification Or Major Repair
The instructions must be approved by TL Ultralight, sro or the local FTD and must include ground and flight testing that complies with the original ASTM production...
Page 18: Safety Directives
If an AD is issued against a type-certificated product that may be incorporated into special light sport aircraft, TL Ultralight, sro will issue a safety directive in accordance with ASTM Standard F 2295 to provide instructions on how to address the safety defect outlined in the AD on component in the specific SLSA.
Page 19: Views, Dimensions
1.1.12 Views, dimensions All dimensions are in millimeters...
Page 20: Aircraft Specification
1.1.13 Aircraft Specification The TL-2000 Sting S4 is a full three axis, low wing, two place, side-by-side seating, tricycle landing gear aircraft with a steerable nose wheel. The primary aircraft structure is carbon fiber and fiberglass UV resistant reinforced laminate with an inner foam core creating a ‘sandwich’...
Page 21 Operating speeds and limits: Engine Type Rotax 912 UL Rotax 912 ULS Speed: Take-off speed 5800 1/min 5800 1/min min.) min.) Maximum continuous speed 5500 1/min 5500 1/min Idle speed ca. 1400 1/min ca. 1400 1/min Performance (ISA): (International Standard Atmosphere) Take-off performance 59,6 kW (80 BHP) 73,5...
Page 22: Propeller Specifications
1.1.15 Propeller Specifications CAUTION For actual and complete information read the Maintenance Manual for DUC Propeller supplied with the aircraft. DUC Hélices company Propeller Manufacturer Propeller Model Number Three-blade SWIRL, Right Number of Blades Propeller Diameter 1660 mm (65.51 in) ˝Ground Adjustable˝...
Page 23: Aircraft And Engine Approved Equipment
Fiber glass fabric 92145 Skolil kompozit s.r.o. UD Interglass Carbon fabric UD 177gr. Skolil kompozit s.r.o. 052.39 Carbon fabric CT – U 175 GRM Systems s.r.o. 40045 Carbon fabric 41090 1K Skolil kompozit s.r.o. Carbon fabric 43 200 TT Skolil kompozit s.r.o. 040.012 kepr Carbon fabric 200 g/m2 –...
Page 24: List Of Disposable Replacement Parts
TL Ultralight must remain and retain the approval authority of any items installed in the TL2000 Sting S4 series aircraft. Therefore the latest edition of the Master Equipment List must be enforced as the only approved items for installation on the aircraft without further authority.
Page 25: Weight And Balance Information
DIAFRICT 2057163607170 400 x 100 mm Brake pads on condition size wheels Brake system 2057163607180 parts S4-350_000_00- 15 x 6 size Brake disc on condition wheels Metal plates after every 300 Metal parts under the STING-15-2-2 all variants hours engine see the current Operator´s Manual for all version of Engine parts Ignition sparks...
Page 26 NOTE Units of measurements and weights must be consistent for each set of calculations and in the same system of units, i.e., pounds and inches, or kilograms and centimeters. Ballast: A specific amount of weight attached in a specific location, which can be temporarily or permanently installed in an aircraft, to help bring its Center of Gravity within the required limits.
Page 27 Maximum and Minimum Weights: Due to balance, structural and aerodynamic considerations, maximum, or minimum, weights for certain locations on the aircraft are specified. For example, the pilot’s minimum (100Lbs) and maximum (240Lbs) weight is be specified for some operations. The same is true for baggage, cargo, fuel, and any other disposable or variable loads.
Page 28 Major Alteration or Modification results from the addition, deletion, or redistribution of existing equipment and accessories, or from a repair which results in a significant increase of weight of the airframe or engine. For example, addition or removal of floats, skis, battery, radios, installation of a additional fuel tank(s) or engine change, painting the airframe, installation of heavier wheels and tires, etc.
Page 29 For best results, weigh indoors. The scales must be calibrated correctly and must be set on level ground. Any equipment placed on the scales when weighing the aircraft, such as chocks or blocks, should be weighed separately and the weight deducted from the scale reading.
Page 30 Loaded weight and balance calculations Complete the Loaded CG calculations as was done in the Sample Weight CG Chart. The Empty Weight, the Empty Weight Arm, and the Empty Moment are shown in the Loading Chart Weight and Balance Work Sheet. Write in the actual Fuel weight for each tank location for your aircraft load condition.
Page 31 Be sure all loaded items are placed in approved locations aboard the aircraft. Maximum Pilot1 + Pilot2 Weight, with: Full Usable Fuel, Maximum Baggage Full Usable Fuel, Zero Baggage Zero Usable Fuel, Maximum Baggage Zero Usable Fuel, Zero Baggage Minimum Pilot Weight, (100lbs), with: Full Usable Fuel, Maximum Baggage Full Usable Fuel, Zero Baggage Zero Usable Fuel, Maximum Baggage...
Page 32 Sting moment arm data sheet 1-21...
Page 33 Sample weight & balance data Sting S4 (NXXXN) SAMPLE WEIGHT & BALANCE DATA Date: 31.12.10 Item Weight Moment Nose Wheel 32.8 4986 Left Gear 95.2 31130 Right Gear 95.2 31035 Empty A/C 83.4 67151 Instruments 59.5 Main Fuel 68.4 7387 Wing Fuel 80.1 Pilot 1...
Page 34 Weight & balance data work sheet Sting S4 (NXXXN) WEIGHT & BALANCE DATA SHEET Date: Item Weight Moment Nose Wheel 32.8 Left Gear 95.2 Right Gear 95.2 Empty A/C 83.4 Instrument 59.5 Main Fuel 68.4 Wing Fuel 80.1 Pilot 1 90.1 Pilot 2 90.1...
Page 35: Tire Inflation Pressure
1.1.20 Tire inflation pressure Main wheels: 44 PSI (3,0 bar) Nose wheel: 70 PSI (4,8 bar) 1.1.21 Approved Oils and Capacities NOTE For approved oil see the current Operator´s Manual for all version of ROTAX 900 series. Do not use oil additives. Use quaility motorcycle or automotive motor oil.
Page 36 CAUTION 100LL Avgas is to be used only as an alternate fuel type if 91 octane auto fuel is not available. The use of 100LL Avgas is restricted to less than 30% of engine operation time without additional engine maintenance management. To best protect your engine, change the engine oil and replace the oil filter every 25 hours of engine operating time or after cross-country operation with 100LL Avgas.
Page 37: Recommended Fastener Torque Values
CAUTION Different coolants cannot not mixed, if doubt, drain and replace all of the coolant. 1.1.22 Recommended Fastener Torque Values Bolt – Nut Bolt – Nut Join (countersunk) Dimension Recommended 52 lb-in 89 lb-in 200 lb-in 52 lb-in 89 lb-in Torques for class 8.8 (5.9 N.m) (10 N.m)
Page 38: General Safety Information
1.1.23 General Safety Information WARNING WARNING RNING During all service and repair work beware of activating the Ballistic Parachute systém rocket. Ballistic parachute system activating pin. 1-27...
Page 39: Report "Feed Back" Forms
Please copy the form, mail or fax it to the address below. You will receive a confirmation of the receipt and status of your comments. Send the completed form to: TL Ultralight, sro Customer Service 8222 Remount Road KORK Municipal Airport North Little Rock, AR 72118 Phone: 501.228.7777...
Page 40 Aircraft / Part / Assembly/ Incident Safety Feed Back Form: Report Date: Aircraft N Number: Aircraft S/N: Flight hours: Report Airport: Aircraft Airport: Conditions: 1. Periodic Inspection Notes (circle ) 2. Pre-flight Inspection 3. Engine Start 4. Taxi 5. Take off 6.
Page 41 Aircraft Maintenance & Maintenance Manual Feed Back Form: Report Date: Manual Section: 0. Introduction 1. General (circle) 2. Inspections 3. Structures 4. Engine 5. Fuel System 6. Propeller 7. Utility Systems 8. Instruments and Avionics 9. Electrical System 10. Painting and Coatings Page Number: Subject Heading: Description: (errata;...
Page 42 Example of report below, see following page for Warranty Claim Report form. 1-31...
Page 43 1-32...
Page 44: Inspections
Return the original to this manual. 2.2 Airplane files Certain items must be with the TL-2000 Sting S4 airplane at all times. The following is a list of these items and when they are required:...
Page 45: Filling The Fuel Tank
□ Propeller. Ensure that the Ignition Switches and Main Switch are turned off. Wash and rinse sedentary dirt from the blades of the propeller. □ Canopy. Wash, rinse and polish canopy. Use chamois leather that is rinsed often in clean water. □...
Page 46  It is prohibited to fill the fuel tank during rain, storm, in closed space, when engine is operating or with electric system switched on.  The person filling the fuel tank must not be wearing polyester clothing or any clothing from a material which creates static electricity.
Page 47: Engine Visual Inspection
□ Fuel Selector. Close the fuel selector switch. □ Open Fire. Make sure there is no open fire near the airplane, and that no one is smoking near the airplane. □ Fire Extinguisher. Have a fire extinguisher close at hand (one suitable for flammable fuels).
Page 48: First 25H / 50H / Annual Inspection
□ Oil level. Remove the Oil tank cap. Manually turn the propeller until you hear the sound of air leaking into the oil in the oil tank. Check the level of oil and follow the Operator´s Manual for all versions of ROTAX 912.
Page 49: Every 50H / 100H / Annual Inspection
Type of Maintenance Line Level of Certification Required L/O, RI, RM, A& P First 25 hour Inspection Checklist After first 25 hour □ Engine cowling. Remove engine cowling □ Engine covers. Remove engine covers Engine. Follow the Operator´s Manual for all □...
Page 50 The maintenance procedure is as follows: • Condition inspection checklist • Aircraft Records checklist • Run-up checklist • Post-Run-up checklist • Propulsion System checklist • Fuselage checklist • Wings checklist • Empennage checklist • Landing Gear checklist • Cabin and Baggage Compartment checklist •...
Page 51 Run-up checklist Type of Inspection 50 hour 100 hour Annual ELT battery due (if applicabe): Altimeter/Transponder test due (if applicabe): Strobe lights test due (if applicabe): Systems Pre - inspection Post - inspection □ □ Starter □ □ Oil pressure (PSI) □...
Page 52 Post – Run - up checklist Inspection Item 50 hour 100 hour Annual □ □ □ Flight controls. Check for smooth operation of all flight controls with flaps in retracted and extended positions. □ □ □ Flight controls. Check controls within entire range for binding, play, and unusual sounds.
Page 53 □ □ □ Fuel installation. Inspect the fuel installation, hoses, pumps, connections, and supports. Inspect and clean the fuel filters in the engine area. □ Cabin heater. Check clamps heater attachments. Check the manifold for holes and attachments. □ □ Engine mount.
Page 54 □ □ □ Fuel leaks. Inspect the outer skin tank areas for evidence of fuel stains □ □ Static Port. Check static port for evidence of obstructions. Do not apply compressed air to the system, since this will result in damage to the static air flight instruments.
Page 55 □ Wings. Assembly wings hours interval □ □ Flap deflection. Ensure that flaps extend equally on each side of the airplane in all configurations. hours Measure the down deflection on each side. The interval □ difference in static deflection should not be greater than 1/8 ˝...
Page 56 Horizontal Stabilizer. Remove aft tail cone and disconnect controls to the tail. Remove horizontal hours stabilizer. Check for surface corrosion and craks interval □ main and rear horizontal stabilizer hinge housings and pins. Inspect for corrosion, cracks, damage and looseness elevator driver and elevator driver rivets attachments.
Page 57 □ □ Brake calipers, brake pads and brake discs. Clean and inspect for condition, fluid leakage, for cracks and corrosion, security of components. Inspect brake discs for pitting and signs of overheating. Inspect all hardware for signs of loss of torque. Do not lubricate. □...
Page 58 □ Baggage compartment. Inspect baggage aera network for condition and attachment. Inspect baggage compartment for cleanliness. Aircraft Parachute systém. Check the condition □ of the chute handle and safety pin for proper fit. Check for proper clearance and freedom from binding of the chute pull (activation) cable.
Page 59: Every 300 Hour Inspection
2.7 Every 300 hour Inspection This inspection is made after every 300 flight hours, or after five years of operation. The inspection of all stressed parts of the construction is made along with the prescribed repair according to the manufacturer’s guide book. The inspection and maintenance include: ...
Page 60: Alterations Or Major Repairs
2.8 Alterations or Major repairs WARNING Any alterations or major repairs to the airplane must be approved in writing by the aircraft manufacturer. See Chapter 1, General Information, for more details. 2.9 Lubrication program figures Typical location bearings on the rod end and levers 2-17...
Page 61 Annual Periodic Unit (100 Lubricant Area of lubrication 25 hours hour) Engine Throttle control cable into the engine Light Oil compartment. Choke control cable into the engine Light Oil compartment. Nose gear Nose gear leg insertion of the upper Lubrication strut into the lower yoke.
Page 62: Structures
3.2 Wing The wing of TL-2000 Sting S4 consists of right and left wings (made of carbon and fiberglass parts bonded together with structural epoxy resin). The wings are attached to the fuselage by two, interlocking, box-type spars that cross beneath the cockpit and interlock with the opposite wing.
Page 63 Wings Installation Checklist 1) Aircraft parking. Prior to installation set the aircraft on the parking brake and remove any obstacle within 16ft area from the fuselage. 2) Wing preparing. Insert the wing root spar into the hole in the fuselage. Add support for the end of the wing as shown below.
Page 64 2) Lubricating. Lubricate all metal details with plastic grease before connecting.
Page 65 3) Wing inserting. Slide the wing into the fuselage. Ball on the root spar must fit into the hole. NOTE Pay attention to flap drive fit into the backdrop drive flap.
Page 66 4) Pin inserting. In the hole in the root spar insert the secure pin as shown. Insert in hole and rotate about 180°.
Page 67 5) Aileron control connect. Connect aileron pull rod control. 6) Connect all wiring. Connect all electric fuselage – wing wiring if applicable (eg. light electrical wiring) 7) Connect fuel hose (if wing fuel tank applied). Connect fuel hose from wing tank to fuselage.
Page 68: Wings Removal
3.2.2 Wings Removal Drain all the fuel from the wing tanks (if applied) and fuel lines. The process of draining the aircraft should be performed in a ventilated area with fire precautions taken. The rest of the wing removal process goes in reverse to the wings installation process.
Page 69 Type of Maintenance Line Level of Certification Required L/O, RI, RM, A& P Task Specific completed only responsible individual, which has received TL-Ultralight Airplane Operation Training. Tools Required Allen wrench 5 (1pcs) Socket wrench 5,5 ,8,10 (1pcs) Screwdriver (1pcs) Torque wrench (1pcs) Safety wire 0.032“...
Page 70 4) Rear horizontal tail hinge. Fix the Horizontal tail on the fuselage with the screw M8 x 87 DIN 912 and wedge Stabilizer washer. Secure the screw by the stainless safety wire having diameter of 0.032“. The hole for screw is highlighted red.
Page 71 3-10...
Page 72 5) Elevator control connection. Connect the elevator control connection as shown. Use screw M5 x 25 DIN 912 with washer M6 and castle nut with cotter pin 1,6. 3-11...
Page 73 6) Elevator deflection. Check angles of deflection of the elevator to within the range as follows (± 10 mm / ± 0.4 in). 7) Fuselage-to-rudder wiring. Connect all fuselage-to-rudder wiring, i.e. connect the position lights sockets and plug. Fix wires in the fuselage as shown. Access to the wires is through the rear inspection hole 3-12...
Page 74 8) Trim tab connection. Connect the Trim tab lever with elevator trim tab as shown. Use phil. Head machine screws M3 x 10 DIN 7985. Use only new self-locking nuts VM3. 9) Trim tab control connection. Connect the trim tab with trim tab pull rod drive as shown.
Page 75 3-14...
Page 76 10) Trim tab deflection. Check angles of deflection of the Trim tab. Check Trim tab neutral position. Inspect Trim tab for free travel. 11) Tail cone cover. Fix Tail cone cover on the fuselage with twelve slotted mushroom head screws M4 x 12 (905624). Two screws are under the horizontal tail stabilizer and two screws are in the fuselage accessible through the rear inspection hole.
Page 77 3-16...
Page 78: Horizontal Tail Removal
3.3.2 Horizontal tail removal The rest of the horizontal tail removal process goes in reverse to the horizontal tail installation process. 3.3.3 Elevator installation To installation the elevator requires two person. Type of Maintenance Line Level of Certification Required L/O, RI, RM, A& P Task Specific completed only...
Page 79 3) Elevator assembly. Insert the elevator with the hinges into the stabilizer from the back side. 4) Elevator assembly. Fix the Elevator on the Stabilizator with five elevator pins. Use only castle nut M6 with the cotter pin 1,6. 3-18...
Page 80 5) Elevator control connection. Connect the elevator control connetcion as shown. Use screw M5 x 25 DIN 912 with washer M6 and castle nut with cotter pin 1,6. 3-19...
Page 81 6) Elevator deflection. Check angles of deflection of the elevator to within the range as follows (± 10 mm / ± 0.4 in). 7) Fuselage-to-rudder wiring. Connect all fuselage-to-rudder wiring, i.e. connect the position lights sockets and plug. Fix wires in the fuselage as shown. Access to the wires is through the rear inspection hole 3-20...
Page 82 8) Trim tab connection. Connect the Trim tab lever with elevator trim tab as shown. Use phil. Head machine screws M3 x 10 DIN 7985. Use only new self-locking nuts VM3. 9) Trim tab control connection. Connect the trim tab with trim tab pullrod drive as shown.
Page 83 3-22...
Page 84 10) Trim tab deflection. Check angles of deflection of the Trim tab. Check Trim tab neutral position. Inspect Trim tab for free travel. 11) Tail cone cover. Fix Tail cone cover on the fuselage with twelve slotted mushroom head screws M4 x 12 (905624). Two screws are under the horizontal tail stabilizer and two screws are in the fuselage accessible through the rear inspection hole.
Page 85: Elevator Removal
12) Rear inspection hole. Close rear inspection hole by screw M4 x 12 (905624). 3.3.4 Elevator Removal The rest of the elevator removal process goes in reverse to the wings installation process. 3-24...
Page 86: Verification Required (Horizontal Tail And Elevator)
3.3.5 Verification Required (horizontal tail and elevator) Make sure the main bolts are not loose (do not rotate). Check fuselage and horizontal tail for foreign objects. Check elevator and trim tab for free travel. Secure all bolted connections by the F-900 Torque seal 3.3.6 Rudder Installation To installation the rudder requires two person.
Page 87 3-26...
Page 88 3) Rudder assembly. Slip the small spacer on the bottom mounting axis. Put the rudder on the fuselage inserting the bottom mounting axis to the ball bearing the bottom suspension . Then upper rudder attachment, i.e. slip the upper rudder pin on the bearing in the upper rudder hinge.
Page 89 3-28...
Page 90 4) Rudder balance beam assembly. Slip the Big spacer on the Bottom mounting axis. Fix the Rudder balance beam on the Bottom mounting axis with screw M6 x 30 DIN 912. Use only new self-locking nuts VM6. 3-29...
Page 91 Pos. Part Part number / Norm Bottom mounting axis s213_100_00-1 Big spacer s213_400_00-1 Rudder balance beam s213_500_00-1 Screw M6 x 30 DIN 912 ČSN 02 1721 Washer M6 Self – locking nut VM 6 DIN 980 CAUTION During the assembly don´t damage the fuselage – to – rudder wiring inside the Bottom mounting axis (especially when inserting the screw M6 x 30).
Page 92 6) Fuselage-to-rudder wiring. Connect all fuselage-to-rudder wiring, i.e. connect the position lights sockets and plug. Fix wires in the fuselage as shown. Access to the wires is through the rear inspection hole 7) Rudder deflection. Check angles of deflection of the Rudder to within the range 20°...
Page 93: Rudder Removal
10) Central console front covers. Install left and right central console front covers with black phil. pan head machine screw M4 x 12 DIN 7985. 3.3.7 Rudder Removal The rest of the rudder removal process goes in reverse to the wings installation process.
Page 94 Modified self – locking nut M16 (1 Materials Required pcs) Self-locking nuts VM8 (1 pcs) F-900 Torque seal Nose gear leg Installation Checklist 1) Inserting into the bottom hinge. Nose gear leg slide from the bottom side into the bottom nose leg hinge. Don´t forgot under the bottom hinge insert ball bearing. Grease ball bearing and sliding parts.
Page 95 3-34...
Page 96 2) Inserting into the upper hinge. The upper part of the nose gear leg insert into the upper nose leg hinge. Under the upper hinge insert the spacer ring. Above upper nose leg hinge screw self-locking nut VM8 DIN 980 with the washer M8 02 1721. Pos.
Page 97 NOTE Location of the balance beam and preparing the hole for screw in the nose gear leg must be prepared by the hole in the engine firewall before montage start. 4) Mounting rods. Install the tensioner rope control to the balance beam. Screw the tensioner sheets on the both ends of the balance beam, using s screw M6 x 20, crown nut M6 ČSN 02 1411 with washer M6 ŠC 02 1721 with cotter pin.
Page 98: Nose Gear Leg Removal
3.4.2 Nose gear leg removal To the nose gear leg removal process goes in reverse to the nose gear leg installation process. 3.4.3 Nose gear assembly installation Type of Maintenance Line Level of Certification Required L/O, RI, RM, A& P Task Specific completed only...
Page 99 Nose gear assembly Installation Checklist 1) Grease. Grease by plastic grease Mogul G3 the bottom part of the nose gear leg under the bottom attachment. (Part of the nose gear leg with slotted) 2) Spring and cylinder spacer. Into the tube for attaching the fork which is assembled in the assembly, insert the cylinder spacer and steel spring.
Page 100: Nose Gear Assembly Removal
Fork assembly screw by bold M8 x 55 with self-locking nut with washer. Screw through the milled slot in the fixed part of the nose landing gear leg. NOTE For passage screw through the leg must compress the spring. It is necessary to push down on the fuselage.
Page 101 Type of Maintenance Line Level of Certification Required L/O, RI, RM, A& P Task Specific completed only responsible individual, which has received TL-Ultralight Airplane Operation Training. Tools Required Socket wrench 10 (1pcs) Combination wrench 10 (1pcs) Screwdriver (1pcs) Torque wrench (1pcs) Support for the fuselage Materials Required...
Page 102: The Upper Attachment Removal
Pos. Part Part number / Norm Self-locking nutsVM6 DIN 980 ČSN 02 1721 Washer M6 Nose gear upper attachments s424_000_00-1 Screw M6 x 20 ISO 4014 3.4.6 The upper attachment removal To the upper attachment remove process goes in reverse to the upper attachment installation process.
Page 103 Tools Required Socket wrench 10 (1pcs) Combination wrench 10 (1pcs) Screwdriver (1pcs) Torque wrench (1pcs) Support for the fuselage Materials Required Self-locking nuts VM6 (6 pcs) Plastic grease Mogul G3 F-900 Torque seal Bottom attachment Installation Checklist 1) Preparation. Before starting, set the parking brake. Remove cowlings, make sure the tail area is clear.
Page 104 2) Central console front covers removing. Remove left and right central console front covers fixed by black phil. pan head machine screw M4 x 12 DIN 7985. 3-43...
Page 105 NOTE Place where the mounting hole to Access the screws holding bottom attachment is marked in red. 3) Bottom attachment installation. Fix the Bottom attachment on the fuselage with six screws M6 x 22 ISO 4014. Use only new self-locking nuts VM6. Proceed this installation from pilot area (nuts and washers) which was developed by dismounting the Central console.
Page 106: Nose Gear Bottom Attachment Remove
4) Central console front covers. Install back left and right central console front covers with black phil. pan head machine screw M4 x 12 DIN 7985. 3.4.8 Nose gear bottom attachment removal The nose gear bottom attachment removal process goes in reverse to the bottom attachment installation process.
Page 107: Fork Assembly Installation
3.4.9 Fork assembly installation To installation the upper attachment requires one person Type of Maintenance Line Level of Certification Required L/O, RI, RM, A& P Task Specific completed only responsible individual, which has received TL-Ultralight Airplane Operation Training. Tools Required Wrench 5 (1pcs) Allen wrench 5 (1pcs) Screwdriver...
Page 108: Fork Assembly Removal
Fork assembly screw by bold M8 x 55 with self-locking nut with washer. Screw through the milled slot in the fixed part of the nose landing gear leg. NOTE For passage screw through the leg must compress the spring. It is necessary to push down on the fuselage.
Page 109: Main Wheel Assembly Installation
3.4.11 Main wheel assembly Installation To installation the main wheel assembly requires two person. Type of Maintenance Line Level of Certification Required L/O, RI, RM, A& P Task Specific completed only responsible individual, which has received TL-Ultralight Airplane Operation Training. Tools Required Socket wrench 10, 13, 24 (1pcs,...
Page 110 Main wheel assembly Installation Checklist 1) Preparation. Before starting, set the parking brake. Remove cowlings, make sure the tail area is clear. Lift the forward fuselage by pushing down the tail at the over horizontal tail main hinge so that is possible insert the support under engine mount firewall attachment.
Page 111 3-50...
Page 112 2) Main wheel assembly. Assemble the Main wheel assembly according instructions below. Pos. Part Part number / Norm Main wheel sn411_210_00-1 Brake caliper assembly sn411_220_00-1 Main wheel axis sn411_240_00-1 Brake disc sn411_250_00-1 Main wheel nut sn411_270_00-1 Main wheel nut spacer sn411_280_00-1 Screw M6 x 20 ČSN 02 1781...
Page 113 3-52...
Page 114 3) Disc – caliper- axis assembly. Assemble disc – caliper – axis assembly as shown, it means put the brake disc to the caliper assembly and crew by M6 x 20 to main wheel axis. Bolted connections secured by F900 Torque seal. 4) Disc –...
Page 115 6) Check and ensure connections. Screw M6 x 20 and main wheel nut secure with cotter pin 2,5 x 50 secure by F900 Torque seal. Check brake disc wire attachment. Check brake disc free moving along the main wheel axis between the uncompressible brake pads.
Page 116 9) Inner main wheel pant installation. Slide the inner part of the main wheel pant to the main undercarriage leg. Put brake hose into the slot on wheel pant. NOTE Inner part of main wheel pant must be strung to the main undercarriage leg before main wheel axis assembly.
Page 117 13) Check freedom of rotation. Check the main wheel free rotation. The wheel must rotate freely without any resistance. 14) Main wheel pant assembly. Assembly inner and outer part of the main wheel pant (as shown), it means spacing tube and washer screw by M6 x 50. Screw inner and outer part of main wheel pant by the 12 screws M4 x 12.
Page 118: Main Wheel Assembly Removal
15) Check freedom of rotation. Check the main wheel free rotation. The wheel must rotate freely without any resistance. Between the main wheel and main wheel pant must be a hole 12 – 20 mm. Check strength of attachment main wheel pant. 3.4.12 Main wheel assembly removal The Main wheel assembly removal process goes in reverse to the Main wheel assembly installation process.
Page 119: Main Undercarriage Leg Removal
3.4.13 Main undercarriage leg removal To remove the main wheel assembly requires two person. Type of Maintenance Line Level of Certification Required L/O, RI, RM, A& P Task Specific completed only responsible individual, which has received TL-Ultralight Airplane Operation Training. Tools Required Socket wrench 10, 13, 24 (1pcs,...
Page 120 3-59...
Page 121 2) Seat removal. Remove the Back seat and the Bottom seat over installed main undercarriage leg. See chapter 3.9.3. 3) Main undercarriage leg removal. Main undercarriage leg is attached in the laminated case. Through the case and leg go two screws M8 x 65 with washers M8 and nuts M8.
Page 122 CAUTION Knocking only on the place indicated by the arrow 3-61...
Page 123: Main Undercarriage Leg Installation
3.4.14 Main undercarriage leg installation Type of Maintenance Line Level of Certification Required L/O, RI, RM, A& P Task Specific completed only responsible individual, which has received TL-Ultralight Airplane Operation Training. Tools Required Socket wrench 10, 13, 24 (1pcs, 1pcs, 1pcs) Combination wrench 13 (1pcs) Screwdriver (1pcs)
Page 124: Verification Required (Landing Gear)
3) Seat installation. Install the Back seat and the Bottom seat back in the cockpit. leg. 4) Gap clog. Clog the gap between the main undercarriage leg and bottom side of the fuselage using the silicone. 3.4.15 Verification Required (Landing gear) Make sure the main bolts are not loose (do not rotate).
Page 125: Filling Brake System With Fluid
When the operator presses the left brake pedal, hydraulic pressure is sent down hydraulic line to the left wheel brake pads, which in turn press on both sides of the rotor. The same process also applies the right brake pedal pressure to the right brake rotor.
Page 126 Filling Brake system with Fluid Checklist 1) Preparation. Before starting, set the chocks under the wheels to prevent plane´s rolling. Visually check the system for integrity and tightness. Make sure the aircraft is not set on parking brake, i.e. the parking brake valve is open and the handle of the valve is aligned to aircraft longitudinal axle.
Page 127 Pos. Part Part number / Norm Main wheel pant spacer s411_300_00-1 Outer part of the main wheel pant s411_510_00-1 Screw M6 x 50 HEX ISO 4014 ČSN 02 1721 Washer M6 3) Brake line interruption. Disconnect hoses joints under the wheel pant. Blind disconnected hoses.
Page 128 CAUTION Brake fluid is an aggressive substance, be careful avoid the contact with composite structure and cabin upholstery, otherwise it would damage them. 3-67...
Page 129 5) Left pedal brake cylinder venting. Remove the Brake cylinder from the left Foot pedal assembly (left pilot side for the left wheel line or right pilot side for the right wheel line). Remove blanking from disconnected hoses (blinded in step 3) and hoses end insert into the auxiliary tank so that the brake fluid can freely flow from Brake fluid reservoir through the brake cylinders on the pedals to the auxiliary tank situated under the disconnected hose.
Page 130 6) Right pedal brake cylinder venting. Remove the Brake from the right Foot pedal assembly (right pilot side for the left right line or left pilot side for the left wheel line). Remove blanking from disconnected hoses (blinded in step 3) and hoses end insert into the auxiliary tank so that the brake fluid can freely flow from Brake fluid reservoir through the brake cylinders on the pedals to the auxiliary tank situated under the disconnected hose.
Page 131 7) Hose blinding. Under the wheel pant location blind the disconnected brake system hose leading from the parking brake cylinder. 8) Bottle with the stand for brake fluid connection. Connect hose line from the bottle with the stand for brake fluid to under wheel pant disconnected Brake line leading to the main wheel Brake caliper (left pilot side for the left wheel line or right pilot side for the right wheel line).
Page 132 Then install the Brake caliper drain bolt M8 back on the Brake caliper . 10) Brake line connection. Connect back hoses joints under the wheel pant. NOTE During this operation protect both hoses line against intrusion of air bubbles. If during the hoses connection penetrated air bubbles, remove them.
Page 133: Verification Required (Filling Brake System With Fluid)
11) Brake fluid filling. Fill brake fluid to the Brake fluid reservoir (bottle) on the Engine mount (on the left side). Brake fluid reservoir is the highest point of the system. Remove the Drain bolt M8 from the Brake caliper and let again the brake fluid freely flow from Bottle on the stand trough the brake system line to the auxiliary tank situated under the Brake caliper drain bolt M8.
Page 134: Replacing/Removal Of The Brake Pads
3.4.19 Replacing/removal of the Brake pads To replacing/removal of the Brake pads requires one person. Type of Maintenance Line Level of Certification Required L/O, RI, RM, A& P Task Specific completed only responsible individual, which has received TL-Ultralight Airplane Operation Training. Tools Required Socket wrench 10 (1 pcs)
Page 135 3-74...
Page 136 2) Remove outer part. Unscrew connecting outer and inner part of the main wheel pant. Remove outer part of the main wheel pant. 3-75...
Page 137 3) Remove inner part. Unscrew the highlighted screw. Slide the inner part of the main wheel pant up to undercarriage leg. 4) Brake disc remove. Cut the wire holding the brake disc. 3-76...
Page 138 5) Remove main wheel. Remove cotter pin 2.5 x 50 and unscrew the nut main wheel. Remove main wheel of the main undercarriage leg. NOTE Main wheel assembly axis to leave installed in the leg. NOTE For more information about wheel remove see "Main wheel assembly" chapter. 6) Release brake pads.
Page 139 7) Replacing brake pads. Replace old brake pads with new ones. 3-78...
Page 140 8) Screw. Complete the caliper assembly. Use the reverse procedure. Screw three screws. 9) Insert brake disc. Insert brake disc between brake pads in caliper. 3-79...
Page 141 10) Brake system function verification. Check the Brake system function. Visually check the system for integrity and tightness. 11) Wheel installation. Slide main wheel to the main wheel axis. 12) Attaching brake disc. Attach the brake disc to the wheel by using wire. 13) Install main wheel.
Page 142 15) Install outer part. Install outer part of the main wheel pant, i.e. screw screws connecting outer and inner part of the main wheel pant. 3-81...
Page 143: Verification Required (Replacing/Removal Of The Brake Pads)
3.4.20 Verification Required (Replacing/removal of the Brake pads) Make sure the main bolts are not loose (do not rotate). Check wheel pants for foreign objects. Check wheels for free travel. Secure all bolted connections by the F-900 Torque seal. 3-82...
Page 144: Structural Control Surfaces
3.5 Structural control surfaces TL - 2000 Sting S4 is equipped with electrically operated split flaps on the wing trailing edge. Extending flaps increases the camber of the wing airfoil, thus raising the maximum lift coefficient. TL - 2000 Sting S4 is equipped with ailerons on the wing trailing edge.
Page 145: Flap Installation
3.5.1 Flap installation To flap installation requires one person Type of Maintenance Line Level of Certification Required L/O, RI, RM, A& P Task Specific completed only responsible individual, which has received TL-Ultralight Airplane Operation Training. Tools Required Allen wrench 6 Socket wrench 10 (1 pcs) Torque wrench...
Page 146 Connection flap control. Insert the flap drive into the backdrop drive flap, Stick must fit into the forks as shown below. 3-85...
Page 147: Flap Removal
4) Flaps deflection. Ensure that flaps equally on each side of the airplane in all configurations. Measure the down deflection on each side. The difference in static deflection should not be greater than 1/8 ˝ (3 mm). Inspect stop switches for operating.
Page 148: Verification Required (Flap Installation/Removal)
3.5.3. Verification Required (flap installation/removal) Check flaps for free travel. Secure all bolted connections by the F-900 Torque seal. 3.5.4 Setting Flap “ Zero ” Position To Setting Flap ” Zero ” position requires one person. “Zero“ position of the Flaps is the position when the flaps are aligned to the center – section on fuselage.
Page 149 3) Flaps setting: Using the one of the two highlighted forks set correct position of flaps. Flaps with higher measured value set on the same value, which has a flaps with lower measured value. CAUTION Both flaps must have the same deflection. 3-88...
Page 150 4) Close flaps and check position. Fully close flaps using FLYBOX. Check position of booth flaps. 5) Fly Box flaps settings. CAUTION Both flaps must have the same deflection before FlyBox setting. How to save the positions of flaps using an instrument FlyBox 1) Device powered OFF.
Page 151: Verification Required (Flap "Zero" Position)
3.5.5. Verification Required (flap “Zero” position) Check flaps for free travel. Secure all bolted connections by the F-900 Torque seal. 3.5.6 Aileron installation To aileron installation requires one person. Type of Maintenance Line Level of Certification Required L/O, RI, RM, A& P Task Specific completed only...
Page 152 3) Pull rod connecting. Connect the pull rod and aileron drive by the bold M6 x30 DIN 912. Use castle nut M6 with cotter pin 1,6 and 8 washers M6. Assemble as shown bellow. 3-91...
Page 153 Pos. Part Part number / Norm Aileron control hinge s110_650_00-1 Pull rod assembly in the aileron s523_600_00-1 Screw M6 x 30 DIN 912 ČSN 02 1721 Washer M6 ČSN 02 1411 Castle nut M 6 ČSN 02 1781 Cotter pin 1,6 3-92...
Page 154 4) Ailerons deflection. Check ailerons deflection. Angles of deflection of the aileron are to within the range as follows (± 5 mm / ± 0.2 in). 5) Aileron pull rod cover installing. Fix the Aileron pull rod cover on the Wing with single component joint sealant SOUDAL Fix All Classic.
Page 155: Aileron Removal
CAUTION Do not support your hands or any subjects on the wing and aileron, as the laminate surface is not proportioned for high area force. 3.5.7. Aileron Removal The rest of the Aileron removal process goes in reverse to the Aileron installation process.
Page 156 Setting Aileron “Zero” Position Checklist 1) Aileron pull rod cover removing. Remove the Aileron pull rod cover from the Wing. Aileron pull rod cover is glued by the single component joint sealant on the wing. Use segmented blade utility knife for Aileron pull rod cover removing. Remove the Aileron pull rod cover without damaging the wing skin.
Page 157 Pos. Part Part number / Norm Aileron control hinge s110_650_00-1 Pull rod assembly in the aileron s523_600_00-1 Screw M6 x 30 DIN 912 ČSN 02 1721 Washer M6 ČSN 02 1411 Castle nut M 6 ČSN 02 1781 Cotter pin 1,6 3) Aileron pull rod setting.
Page 158 4) Pull rod connecting. Connect the pull rod and aileron drive by the bold M6 x30 DIN 912. Use castle nut M6 with cotter pin 1,6 and 8 washers M6. Assemble as shown bellow. Pos. Part Part number / Norm Aileron control hinge s110_650_00-1 Pull rod assembly in the aileron...
Page 159 5) Pull rod connecting. Connect the pull rod and aileron drive by the bold M6 x30 DIN 912. Use castle nut M6 with cotter pin 1,6 and 8 washers M6. Assemble as shown below. Pos. Part Part number / Norm Aileron control hinge s110_650_00-1 Pull rod assembly in the aileron...
Page 160 6) Ailerons deflection. Check ailerons deflection. Angles of deflection of the aileron are to within the range as follows (± 5 mm / ± 0.2 in). 7) Aileron pull rod cover installing. Fix the Aileron pull rod cover on the Wing with single component joint sealant SOUDAL Fix All Classic.
Page 161: Verification Required (Aileron "Zero" Position)
CAUTION Aileron pull rod cover must be placed in order not to interfere Aileron and pull rod assembly in the aileron movement. Correct Aileron pull rod cover position must be determinated by the test of all possible ailerons positions. CAUTION Do not support your hands or any subjects on the wing and aileron, as the laminate surface is not proportioned for high area force.
Page 162: Engine
3.6 Engine For engine inspection and maintenance refer to original Rotax manuals supplied with the aircraft: Operator´s Manual for ROTAX engine Type 912 Series Documentation for ROTAX aircraft engines (CD – ROM) Service instruction fur ROTAX Type 912 und 914 (series) ROTAX service letter Warranty conditions for ROTAX engine types 912 and 914 (series) ROTAX engine Log book...
Page 163: Fuel System
3.7 Fuel System The TL-2000 Sting S4 has one main fuel tank in fuselage and can also be equipped with tanks in the wings. Main tank has capacity 20.5 US Gals. Wing tanks, if installed, has a 6 US Gals each.
Page 164 NOTE The aircraft could be equipped with two different types of Fuel Shut-Off Valve. Older aircraft models are fitted with two-way valve type 22MB. The latest aircraft are equipped with two-way valve type TL-ultralight. 3-103...
Page 165: Fuel Tanks Filter Inspection/Cleaning
3.7.1 Fuel tanks filter inspection/cleaning To inspection/cleaning wing tanks fuel filters requires two persons. Type of Maintenance Line Level of Certification Required L/O, RI, RM, A& P Task Specific completed only responsible individual, which has received TL-Ultralight Airplane Operation Training. Tools Required Socket wrench 22 (1 pcs)
Page 166: Verification Required (Fuel Tanks Filters Inspection/Cleaning)
5) Screw the cover. Install back the main fuel tank cover with fuel tanks filters. 6) Install covers. Install back the side covers of the central console. Screw all bolts attached the side covers. 7) Screw the drain valve. Screw the drain valve back. 3.7.2.
Page 167: Gascolator Inspection/Cleaning
3.7.3 Gascolator Inspection/cleaning To inspection/cleaning Gascolator requires one person. Type of Maintenance Line Level of Certification Required L/O, RI, RM, A& P Task Specific completed only responsible individual, which has received TL-Ultralight Airplane Operation Training. Tools Required Screwdriver (1pcs) Safety wire 0.032“ diameter Materials Required Gascolator inspection/cleaning Checklist 1) Engine covers removing.
Page 168 5) Fuel filter tank removing. Remove Fuel filter tank from the Fuel gascolator. Pos. Part Part number / Norm Fuel filter cap ACS 10580 Fuel filter sealing ACS 10580 Fuel filter tank ACS 10580 6) Fuel gascolator inspection/cleaning. Clean Fuel gascolator fuel strainer and sediment bowl.
Page 169: Verification Required (Gascolator Inspection/Cleaning)
9) Leakage inspection. Make the Fuel Selector Valve to the Left or Right tank position. Inspect Fuel Gascolator for leakage. 10) Cowlings installation. Install back the Upper cowling and Bottom cowling. 3.7.4 Verification Required (Gascolator Inspection/cleaning) Make sure the nuts are not loose (do not rotate). Check engine and gascolator area for foreign objects.
Page 170: Utility Systems
3.9 Utility systems 3.9.1 Heating System To minimize the chances for carbon monoxide entering the cockpit, heated air is drawn from the water radiator not from a heat exchanger on the muffler. Ambient inlet air taken through the radiator is heated and supplied through a control flap into the cockpit by a air hose.
Page 171 Pos. Part Part number / Norm Heating flap s700_910_00-1 Heating cover s700_920_00-1 Heating hose Hose clamp TORRO 35 - 50 3) Heating flap inspection. Make sure the Heating flap on the firewall is in closed position. 4) Cowlings installation. Install back the Upper cowling and Bottom bowling. To removal of the Cabin Heat control knob one person is required.
Page 172: Venting System
Cabin Heat control knob removal Checklist 1) Upper engine cover removing. Remove Upper cowling. 2) Control cable disconnecting. Disconnect the control cable on the control flap lever located on the firewall (on the Heating flap). 3) Nut removing. Remove the nuts thus releasing the heating control knob. 4) Control knob removing.
Page 173: Seats
Type of Maintenance Line Level of Certification Required L/O, RI, RM, A& P Task Specific completed only responsible individual, which has received TL-Ultralight Airplane Operation Training. Tools Required Materials Required Cabin air vents removal and installation Checklist 1) Cabin air vents removal/installation. The two rotating air vents mounted in the canopy can be removed or installed by slightly squeezing the interior edge of the vent scoop from the exterior and rotating the scoop slightly as it is removed or replaced.
Page 174 To removal and installation of the seats one person is required. Type of Maintenance Line Level of Certification Required L/O, RI, RM, A& P Task Specific completed only responsible individual, which has received TL-Ultralight Airplane Operation Training. Tools Required Screwdriver (1pcs) Cross-screwdriver (1pcs) Materials Required...
Page 175 2) Bottom seat unscrewing. Remove the screws M5 x 16 located in the rear part of the bottom seat. 3-114...
Page 176 3) Remove bottom seat. Slide backwards the bottom seat out from the lower cockpit frame in the direction on arrow. 4) Bottom seat install. Slide the bottom seat back on the lower cockpit frame in the arrow direction as shown. 3-115...
Page 177 5) Bottom seat screw. Screw M5 x 16 is located in the rear part of the bottom seat. Screw the bottom seat. 3-116...
Page 178: Canopy
6) Back seat installs. Install the back seat: back seat is attached to the cockpit bulkhead by Velcro. Slide the bottom part of the seas in the middle of the cockpit bulkhead and rear part of the bottom seat. Then press the back seat on the cockpit bulkhead to attach.
Page 179 CAUTION Be careful. If the cover fall down and quickly closed, can cause injury. CAUTION With the canopy handled with care. Be careful to do not break. Type of Maintenance Line Level of Certification Required L/O, RI, RM, A& P Task Specific completed only...
Page 180 2) Unscrew bold. Unscrew two bolds M8 x 40 (with nut M8) attached the canopy in the fuselage. 3-119...
Page 181 3-120...
Page 182 3) Canopy removing. Remove carefully canopy from the fuselage. CAUTION With the canopy handled with care. Be careful to do not break. The canopy installation process goes in reverse to the canopy removal process. NOTE Canopy is not designed for frequent assembly and disassembly, so these operations be performed only if necessary.
Page 183: Airspeed Indicator Markings
3.10 Instruments and Avionics The specific instruments and/or the configuration in which they are arranged may vary slightly from aircraft to aircraft. The magnetic compass is centered on top of the glare shield behind the utility tray. Sting S4 flight instruments are arranged in the basic “T” configuration on the pilot (left) side of the aircraft.
Page 184: Engine Instruments
3.10.2 Engine instruments The Engine Information System (EIS) is the primary display for monitoring engine operation. The EIS displays the following data: RPM, manifold pressure, fuel pressure, oil temperature, oil pressure, 2 cylinder head temperatures, 4 exhaust gas temperatures, voltage, elapsed engine time, and total engine time. Individual input limitations are preprogrammed into the system.
Page 185: Pitot - Static System
16. Set Min Volt to 11.0 and push Next, 17. Set Max CHT to 238 and push Next, 18. Set Max EGT to 1600 and push Next, 19. Set Display to 3 and push Next. 20. This will then exit the main program. Prior to entering the SECONDARY program mode, you must read the static amount of the Fuel Pressure display with the power on but the engine off and the aux pump off.
Page 186 To removal and installation of the pitot – static tube one persons is required. Type of Maintenance Line Level of Certification Required L/O, RI, RM, A& P Task Specific completed only responsible individual, which has received TL-ultralight Airplane Operation Training. Tools Required Screwdriver (1pcs)
Page 187 Materials Required Pitot – static tube removal Checklist 1) Screw removing. Remove the screw attaching the Pitot – static tube with Pitot – static tube attachment to the wing. 2) Pitot – static tube removing. Remove the Pitot – static tube by gently pulling front and rotating the tube to expose the total pressure hose.
Page 188: Airspeed Indicator
To inspect pitot – static system tightness one persons is required. Type of Maintenance Line Level of Certification Required L/O, RI, RM, A& P Task Specific completed only responsible individual, which has received TL-ultralight Airplane Operation Training. Pitot – static system tightness inspection Checklist 1) Static pressure line.
Page 189: Vertical Speed Indicator
3.10.6 Vertical speed indicator The vertical speed indicator (VSI) provides the operator with rate of climb and rate of descent. It acts quite similar to the altimeter. Atmospheric pressure is supplied by the static ports on the fuselage, and this air is sent into a holding chamber. However, unlike the altimeter, this chamber also has a metered leak attached to it that allows the pressure inside the chamber to eventually equalize with the pressure outside of the chamber.
Page 190: Avionics Equipment
4) Turn the airplane to “E” heading, eliminate the deviation by “B” screw. 5) Turn the airplane to “W” heading, reduce any deviation by half – value by “B” screw and write down the corrected heading. 6) Enter the individual corrected headings to maintain in the magnetic direction on the compass compensation card and position it in the airplane near the magnetic compass.
Page 191 3-130...
Page 192 3-131...
Page 193: Exterior Lighting
Two 12 VDC auxiliary power ports are installed in the lower right and left vertical surface of each seat. The ports are directly “hot-wired” to the battery and can be used to charge the battery without the operator having to connect additional leads directly to the battery.
Page 194 Type of Maintenance Line Level of Certification Required L/O, RI, RM, A& P Task Specific completed only responsible individual, which has received TL-Ultralight Airplane Operation Training. Tools Required Screwdriver (1pcs) Linesman´s pliers (1pcs) Materials Required F-900 Torque seal Wing tip lights installation Checklist 1) Light assembling.
Page 195 NOTE Wing tip lights could be mounted according to the customer´s requirement. Aircraft could be fitted with various lights. 2) LED light 12V. Mount LED light 12V assembly into the light console. Screw the light by a two black screws. 3) Strobe light.
Page 196 4) Mount landing light. Mount the landing light into the light console. 5) Wing-to-wingtip lights wiring. Connect all wing-to-wing tip light wiring, i.e. connect the lights sockets and plug. 6) Light console installing. Install the light console with lights on the wingtip. Use the Philips pan wood screws 3 x 10 with F900 Torque seal.
Page 197: Generator
3.11.2 Generator The 600 W generator is a part of the engine which supplies electric current through the rectifier. Regulator supplies electric current of 14 V voltage to onboard network. The maximum of approximately 18 amps is provided by the regulator, but only 14 amps should be considered available for use.
Page 198: Battery
3.11.4 Battery Both the GPS and the Emergency Locator Transmitter (ELT) contain internal batteries, and therefore can be operated when Main switch is OFF. The Garmin 295GPS contains six AA batteries. The ELT contains eight D-cell batteries, as well as one small battery in the remote control panel. All batteries should be replaced at each annual inspection.
Page 199 NOTE If the airplane is not used for flight for more than one month, remove the battery from the airplane and store it. Always store the battery fully charged at temperature of 68 °F. Daily discharging is less than 0.1 % of battery nominal capacity.
Page 200 Pos. Part Part number / Norm Bottom battery holder s700_710_00-1 Upper battery holder block s700_710_00-1 Battery Varta 12V 8Ah 80A(EN) Screw M4 x 10 ISO 7045 4) Battery removing. Remove the battery from the airplane. CAUTION To reduce the chance of personal injury and possible equipment damage, remove the negative wire before removing the positive wire.
Page 201 To battery installation one person is required. Type of Maintenance Line Level of Certification Required L/O, RI, RM, A& P Task Specific completed only responsible individual, which has received TL-Ultralight Airplane Operation Training. Tools Required Screwdriver (1pcs) Cross-screwdriver (1pcs) Wrench 10 (1pcs) Materials Required Electrical grease for battery contact Battery installation Checklist...
Page 202 3) Additional contacts. Install the additional electrical contacts to the aircraft electrical system. 4) Contacts corrosion protection. Install electrical grease on the battery contacts to minimize corrosion. 5) Clamps installation. Install the clamps on battery contacts from the aircraft electrical +/- system. 6) Engine cowl installation.
Page 203: Inspection And Operation Checks
WARNING WARNING Failure to reconnect the battery connectors properly could result in reversing RNING the polarity of the battery. CAUTION Do not replace the dry cell battery with a wet cell battery. The dry cell battery has the electrolyte immobilized as a paste and the battery can be operated in any random position.
Page 204: Structural Repair
Insufficient clearance between exposed current carrying parts and ground or poor insulation of exposed terminals. Broken or missing safety wire, broken bundle lacing, cotter pins, etc. Operational check of electrically operated equipment such as motors, inverters, generators, batteries, lights, protective devices, etc. Ensure that ventilation and cooling air passages are clear and unobstructed.
Page 205 2) Dust removing Wipe with clean and dry brush or by a vacuum cleaner. 3) Application of smoothing layer After preparation of mixture and its eventual thickening to enhance the non-curtaining capability (for vertical or lower areas) is performed its application onto the repair area by means of a plastic spatula.
Page 206 1) Preparatory Sanding: For good adhesion of repair layers it is necessary to do sanding up to the depth of damage. It is necessary to do surface sanding from the damage area with overrun at the least 1” for every damaged stiffener layer smoothly up to the top layer and then about 2”...
Page 207: Painting And Coating
HEAVY DAMAGE At such damage the part must be replaced. CAUTION When repairing structural parts, it is necessary to pay attention to timely repair see the text about low of properties at humidity effect. CAUTION When repairing small damage, it is necessary to carefully pay attention not to damage any structural part! 3.13 Painting and Coating Task Specific: can be completed a responsible individual, which holds either an FAA...
Page 208 1) Washing and degreasing It is possible to use both organic solvents and water based solvents. CAUTION All paints and solvents must be used only with caution for proper personal and environmental protection and disposal. Organic solvents – (acetone, metyetylketone (MEK), benzine, toluene) Applied by spraying on washed surfaces (e.g.
Page 209 wrong adhesion of paint coats; imperfect degreasing of fiberglass parts (not possible to use) Use: for Al-alloys surfaces and plastics 2) Application of primer (paint) In order to reach a uniform resistance to corrosion and smooth surface, carry out this application by means of spraying (air standard gun with the upper vessel, air HVLP gun, airless electric gun).
Page 210 SMALL DAMAGE General Small damage is a deterioration of corrosion resistance. At repair the situation is made more difficult by the fact that the substrate for repair coats is not a compact surface of basic material but mostly all coats of surface protection (after sanding), of which not all are suitable for (in ageing stage) for good adhesion of paint coats.
Page 211: Paint Repairs - Method Of Verification
CAUTION In case that the primer was not removed by the previous step, it is not necessary to apply the primer again. The original ground primer with adhesive intercoat is enough. Actual application of primer will be carried out in the same way as for the total spray-coat Application of top coat Application of the top coat will be carried out by spraying as for the total spray coat...
Page 212: Safety Wire
Figure: Securing bolts or castle nuts with a cotter pin. Cotter pin removal is very easy: by means of a flat screwdriver straighten up the bent ends of the cotter pin and take the cotter pin out of the hole with small pliers. CAUTION When securing castle nuts, always use new cotter pins.
Page 213 The installation of safety wire is not intended to retain bolt or nut torque. It is installed to prevent disengagement of screws, nuts, bolts, and other parts for added safety. Do not confuse aluminum wire with stainless steel wire. Wire should only be stainless steel, do not use common wire or ferrous metal which can rust or be attracted by magnetic portions of the aircraft.
Page 214 Figure: Safety wire installation to turnbuckles and swaged terminals Safety wire procedures, alignment and installation are shown below: 1. Adjust the correct 6. Pull the upper wire position of holes for safety through the hole in wire. the other bolt. Hold the wire end by pliers tighten it firm.
Page 215: Inspection Of Rod Ends
4. Twist the wire to the hole 9. Bend the end of in the next bolt as tight as the wire under the possible. bolt head. 5. Tighten the wire and at 10. Cut off the the same time continue its surplus wire.
Page 216: Inspection Of Push Pull Tube Connections
3.14.5 Inspection of push pull tube connections Elongated holes are especially prevalent in taper-pin holes and bolt holes or at the riveted joints of torque tubes and push-pull rods. (See figure below) Typical locations for elongation of insert holes in push pull tubes. 3.15 Cable inspections Swaged Nicopress clamp installation 3.15.1 Cable system Inspections The aircraft uses cable only for the rudders and trim system.
Page 217 Figure: Swage terminal shank gauge Nicopress clamp installation procedure is shown below: Pos. Part Part number / Norm Clamp Sequence of squeezing Inspection gauge Gauge No. Accomplish all procedures in accordance with the manufacturer directions. First pull the cable through the clamp, make a loop around the eye and pull the cable end back through the clamp.
Page 218 Before actual squeezing the clamp it is also necessary to verify which cable terminal will be used, whether thimble or suspension eye, because some terminals must be put into the cable before actual clamp squeezing. 3-157...

TL Ultralight TL-2000 Sting S4 Maintenance Manual

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