Handling, Servicing and Maintenance
General
The airplane should be moved using a tow bar which connects to the nose wheel. The airplane may be pushed or pulled from the inboard portions of the prop blades. Do not push on the spinner!
Ground Handling
The airplane has three tie-down rings:
- One on each wing (near outboard bellcrank access panel)
- One on the tail
The tie-down rings are removable and may be kept inside the baggage compartment.
Jacking
The airplane can be jacked from:
- Tie-down ring locations
- Main spar just outboard of fuselage (protect with padded boards)
Engine Air Filter
| Specification | Value |
|---|---|
| Filter Type | Van’s FAB-540 filtered air box (VFR only) |
| Modified Alt Air Door | Aluminum sliding gate, cable-actuated from cabin (open/close) |
| Service | Inspect and clean filter per FAB-540 installation guide |
Detailed reference: sys-71-engine.md — Alt Air Door
Brake Service
| Specification | Value |
|---|---|
| Brake Fluid | Royco 782 (MIL-PRF-83282) |
| Brake Type | Hydraulic disc, Matco WHLWI600XLT-2 |
Warning: Use only MIL-PRF-83282 specification hydraulic fluid (Royco 782). Do not substitute automotive brake fluid — it will damage the seals.
Brake lining part numbers and replacement procedure: see Matco WI600 Series manual referenced in sys-61-brakes.md.
Landing Gear Service
Wheels: Matco WHLWI600XLT-2 main, Beringer AV-VANS-102-01 nose.
Tires: Desser retreads on the mains (no inner tubes). Tire size and operating pressure are not currently logged — record at next servicing in sys-61-brakes.md.
Wheel Bearings
Repack main wheel bearings with Aeroshell #5 grease at annual condition inspection.
Propeller Service
The Whirlwind WWA-RV10 is a sealed propeller — no field lubrication required. Inspect leading edges for nicks/erosion, hub for oil weeps, and spinner attachment at each preflight and condition inspection.
A 5-year manufacturer maintenance clock started at first engine run on 2025-11-18; next major prop maintenance event due 2030-11-18.
Detailed reference: sys-84-propeller.md
Oil System Service
| Item | Specification |
|---|---|
| Oil Type | SAE 15W-50 or 20W-50 (multi-grade aviation) |
| Sump Capacity (max) | 12 quarts |
| Minimum for Operation | 8 quarts |
| Recommended Quantity | 9 quarts (extended flight) |
| Oil Drain Plug | Aircraft Spruce 05-12373 magnetic super plug, 1/2“ NPT |
| Oil Quick Drain | Saf-Air P5000 |
| Oil Separator | Antisplat Aero ASA |
| Change Interval | 50 hours / 4 calendar months (Lycoming SB 480), whichever first |
Oil Change Procedure
- Change oil and filter every 50 hours / 4 months (whichever first).
- Remove and inspect oil suction screen for metal.
- Cut filter and inspect for metal.
- Replace crush washers as required.
- Refill with 9 quarts (8 minimum for operation; do not exceed 12).
- Run engine briefly and check for leaks.
50-Hour Companion Tasks
Perform these at every oil change:
Spark plugs: Remove, clean, inspect electrodes, re-gap, rotate top↔bottom.
Oil analysis: Take sample for Blackstone Labs before draining old oil.
Anti-Splat oil separator evacuation tube: Inspect where the evacuation tube enters the exhaust pipe. Remove any carbon coking or buildup that could block crankcase blowby flow. The evacuation tube is saddle-mounted to the exhaust pipe with two stainless steel clamps — look up into the tube entry point and scrape/clean any deposits. If excessive buildup is found, shorten the inspection interval. The safety bypass (0.5 PSI pop-off valve) provides a backup path if the tube blocks, but does not eliminate the need for inspection. See Anti-Splat installation guide.
PLX O2 sensor health: Check sensor health percentage on the DM-6 gauge (requires firmware V2.0+). Replace the wideband sensor if health drops below 50%. Also check reaction time — below 150ms is excellent, above 251ms indicates a degraded sensor. 100LL avgas poisons the sensor faster than mogas; expect 300-500 hours of life on avgas. See PLX Gen4 sensor diagnostics.
Fuel System Service
Fuel Strainer
Drain fuel strainer:
- Before first flight of day
- After each refueling
- Check for water and sediment
Fuel Tank Sumps
Drain each tank sump and check for water/contamination:
- Before first flight of day
- After refueling
Generator Service
Monkworkz MZ-30
| Item | Specification |
|---|---|
| Type | Permanent-magnet generator |
| Mount | Engine vacuum pad (1.3:1 crankshaft ratio) |
| Output | ~14.4 VDC, 30A max |
| RPM Limit | 3572 crankshaft RPM |
| Regulator | MZ Regulator (mounted on engine mount) |
The MZ-30 requires no brushes or field winding — maintenance is minimal.
Condition inspection items:
- Inspect generator mount bolts and silicon/fiberglass gasket
- Check 12 AWG phase wires from generator to regulator for chafe, routing clear of exhaust, and no tension from engine movement
- Check regulator mounting on engine mount
- Inspect Pico-Lock connectors (input and output) for security — add maintenance loops if missing
- Verify cooling ducts (3/4“ corrugated nylon) are intact and connected to both generator and regulator
- Check regulator blink code LED (4 flashes/sec = enabled and normal)
- Verify shear coupling is intact: generator should NOT rotate freely. If it does, the shear coupling has split — contact Monkworkz for replacement.
- Keep ferrous metal shavings away from generator exterior (permanent magnets)
Operational check:
With engine running and enable switch on, Battery 2 voltage should show a charging indication. The BOSCH relay (0332019155) should be energized (audible click when enable switch is toggled with ignition on).
Do not open the regulator box — adhesive inside dampens vibration, and opening risks tearing components off the circuit board.
Fuses: Input and output fuses are internal to the regulator. If either blows, the regulator likely needs service. Fuses can be tested with an ohmmeter (should show near-zero resistance). Contact Monkworkz for replacement.
Battery Service
| Battery | Location | Type | Charging Source |
|---|---|---|---|
| Battery 1 | Tailcone / baggage-area junction (right side) | EarthX ETX900 | Hartzell 60 A primary alternator |
| Battery 2 | Tailcone / baggage-area junction (right side) | EarthX ETX900 | Monkworkz MZ-30 generator |
The two charging systems are fully isolated. Do not charge with non-LiFePO4 chargers — EarthX batteries have an internal BMS and require lithium-specific charging.
Approved chargers (filed in shop):
- OptiMate Lithium 4s 5A (TM-291) — 5A maintainer
- OptiMate TM-275 v2 — 9.5A charger / maintainer / 13.6V power supply (TUNE mode for avionics work without battery drain)
Charger sleep behavior: OptiMate units enter sleep once fully charged and check voltage hourly. If a continuous parasitic load is present (panel powered for configuration), the maintainer may not detect drain and the battery can deplete. Use TM-275 TUNE mode (continuous 13.6 V) for any avionics work session that requires panel power.
Detailed reference: sys-24-electrical.md — EarthX Battery & Chargers
Lubrication Schedule
| Item | Lubricant | Interval |
|---|---|---|
| Wheel Bearings | Aeroshell #5 | Annual |
| Control Hinges | LPS-2 or equivalent | As needed |
| Propeller | None (Whirlwind sealed) | N/A |
Oxygen System Service
Mountain High EDS-4iP system:
- Refill oxygen per Mountain High procedures
- Inspect cannulas and tubing
- Verify pulse delivery operation
Dynon Maintenance Log — Scheduled Items
The following items are configured in the Dynon SkyView maintenance log (SETUP MENU > SYSTEM SETUP > AIRCRAFT INFORMATION > MAINTENANCE LOG). The MAINT LOG page is accessible via MENU > MAINT LOG. Past-due items show in red at startup.
Tach-Based Items
| Slot | Name | Basis | Interval | Notes |
|---|---|---|---|---|
| 1 | OIL CHANGE | TACH | 50 hrs | Oil + filter change, spark plug clean/rotate/re-gap, oil analysis sample (Blackstone). Also: inspect Anti-Splat evacuation tube for coking, check PLX O2 sensor health on DM-6. Also due every 4 calendar months (Lycoming SB 480), whichever comes first. Reset to current tach + 50. |
| 2 | PROP | TACH | 650 hrs | Whirlwind WWA-RV10 inspection. Reset to current tach + 650. |
Date-Based Items
| Slot | Name | Basis | Current Due | Interval | Notes |
|---|---|---|---|---|---|
| 3 | COND INSPECT | DATE | 2026-11-18 | 12 months | Annual condition inspection per 14 CFR 91.409(b). |
| 4 | ELT | DATE | 2026-11-18 | 12 months | ELT inspection per 14 CFR 91.207. Artex ELT 345 S/N 267-02567. |
| 5 | XPDR STATIC | DATE | 2027-12-31 | 24 months | Transponder + pitot-static + altimeter per 14 CFR 91.411/91.413. Front Range Transponder Svc, Broomfield. |
| 6 | MEDICAL | DATE | 2030-10-28 | Per class | Pilot medical certificate expiration. |
| 7 | CO GUARDIAN | DATE | 2031-01-08 | 5-7 years | Guardian Avionics 452-101-012 S/N 112081 overhaul. Installed 2026-01-08. |
| 8 | O2 CYLINDER | DATE | 2031-05-31 | End of life | Mountain High CFFC-048 S/N 602-100814. Hydro test passed 2026-01-15. Cylinder end of life 2031-05-31. |
| 9 | ELT BATTERY | DATE | 2032-11-30 | Per mfr | Artex P/N 8322, S/N 1024675-018 Rev F. Installed 2025-12-08. |
| 10 | (empty) |
Not in Dynon — Track Separately
| Item | Interval | Notes |
|---|---|---|
| Fire extinguishers | 12 months | H3R Aviation A344T (Halon 1211, 1.25 lb). Two installed: right rear passenger seat, co-pilot tunnel side. Inspect gauge (green), weight, and condition at condition inspection. |
| Compression check | 100 hrs (break-in) | Differential compression test. More frequent during break-in, then at each condition inspection. |
| Oil analysis | 50 hrs | Blackstone Labs sample at each oil change. Not yet started — first sample due at first oil change. |
| Oil separator (Anti-Splat) | 50 hrs | Inspect evacuation tube where it enters exhaust pipe — remove coking/buildup. Coincides with oil change. If excessive buildup, shorten interval. See installation guide. |
| O2 sensor health (PLX SM-AFR) | 50 hrs | Check sensor health % on DM-6 gauge (V2.0+). Replace if <50%. Reaction time: <150ms excellent, >251ms poor. 100LL poisons sensor faster — expect 300-500 hrs life on avgas. See Gen4 diagnostics. |
| ELT registration | 2 years | NOAA SARSAT, expires 2027-11-18. Portal: beaconregistration.noaa.gov |
Pitot Heat Check
Verify pitot heat operation before flight into potential icing conditions:
- Turn on PITOT HEAT switch
- Verify pitot tube warms (carefully touch)
- Monitor current draw on VPX display