BRISTELL S-LSA, Maintenance And Inspection Procedures Manual

Page 1: ...com e mail 2 aero brm gmail com web http www brmaero com REGISTRATION MARK N101LW SERIAL NUMBER 231 2016 This Manual contains information necessary for operation and maintenance of the airplane in ac...

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Page 3: ...n 0 1 0 CHAPTER DOCUMENT CHANGES 0 1 Record of revisions Rev No Reason for revision Affected Pages Date of Issue Date and Signature Initial Issue All 05 2016 05 2016 Petr Javorsk 1 Change of static po...

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Page 6: ...2016 16 6 05 2016 16 7 05 2016 15 15 1 05 2016 16 8 05 2016 15 2 05 2016 16 9 05 2016 15 3 05 2016 16 10 05 2016 15 4 05 2016 15 5 05 2016 15 6 05 2016 17 17 1 05 2016 15 7 05 2016 17 2 05 2016 15 8...

Page 7: ...E 3 1 4 CHAPTER WING 4 1 5 CHAPTER TAIL UNIT 5 1 6 CHAPTER CONTROLS 6 1 7 CHAPTER EQUIPMENT 7 1 8 CHAPTER LANDING GEAR 8 1 9 CHAPTER FUEL SYSTEM 9 1 10 CHAPTER POWER UNIT 10 1 11 CHAPTER ELECTRICAL SY...

Page 8: ...0 CHAPTER DOCUMENT CHANGES Document SLSA MIP 5 4 0 US Date of Issue 05 2016 Revision 0 6 INTENTIONALLY LEFT BLANK...

Page 9: ...1 CHAPTER GENERAL 1 2 Airplane classification 1 2 1 2 1 Power unit 1 2 1 2 2 Main technical data 1 3 1 3 Airplane manufacturer and type certificate holder 1 5 1 4 Chapter order 1 5 1 4 1 Page numberin...

Page 10: ...steerable nose wheel The airplane is designed for basic and advanced training and for leisure time flying 1 2 1 Power unit The power unit standardly consists of Rotax 912 ULS 4 stroke 4 cylinder engin...

Page 11: ...lb CS VLA LSA 57 14 kg m2 11 68 lb sq ft Aileron area 0 276 m2 2 97 sq ft Flap area 0 7275 m2 7 83 sq ft Fuselage length 6 45 m 21 10 ft width 1 30 m 4 27 ft height 2 28 m 7 48 ft cockpit width 1 30...

Page 12: ...1 CHAPTER GENERAL Document SLSA MIP 5 4 0 US Date of Issue 05 2016 Revision 1 4 Fig 1 1 Three view drawing...

Page 13: ...describes one system or assembly 1 4 1 Page numbering Example 12 CHAPTER POWER UNIT 12 10 Chapter No and Title Chapter No Page No 1 5 Warnings Cautions and Notes WARNING Means that non observation of...

Page 14: ...Positioning System hp power unit 1 hp 0 7457 kW HTU Horizontal Tail Unit IAS Indicated Airspeed IC Intercom IFR Instrument Flight Rules in inch 1 in 25 4 mm ISA International Standard Atmosphere KCAS...

Page 15: ...M 1 609 m US gal US gallon 1 US gal 0 83 UK gal 3 785 l V Volt VFR Visual Flight Rules VMC Visual Meteorological Conditions VSI Vertical Speed Indicator VTU vertical tail unit VA maneuvering airspeed...

Page 16: ...1 CHAPTER GENERAL Document SLSA MIP 5 4 0 US Date of Issue 05 2016 Revision 1 8 INTENTIONALLY LEFT BLANK...

Page 17: ...Airframe life limitation 2 2 2 3 Engine life limitation 2 2 2 3 1 Engine parts with limited life 2 2 2 4 Life limitation of other items 2 2 2 5 Ordering spare parts 2 2 2 6 Terms and list of aircraft...

Page 18: ...as obtained from the supliers manufacturers of installed avionics equipment etc Refer to this documentation for life limitation of installed avionics equipment etc Another source of information is int...

Page 19: ...in Flight Manual section 4 propeller inspection after first 5 20 and 50 flight hours see Technical description of the propeller NOTE To be performed with a newly installed propeller or with the prope...

Page 20: ...all works which are performed during inspection Number of chapter is indicated in the first column of this Maintenance Manual where you can also find more detailed information for performing individu...

Page 21: ...nual Line Maintenance for installed engine List of performed operations for propeller is shown in Technical description and operation instructions for installed propeller Remove and check engine cowli...

Page 22: ...aintenance for installed engine List of performed operations for the propeller is shown in Technical description and in operation instructions for installed propeller Remove and check engine cowlings...

Page 23: ...of the canopy locks Check condition and completeness of emergency equipment Check condition of rubber sealing of the cockpit Check condition of canopy struts 4 Wing Visually check surface condition l...

Page 24: ...free travel of the rudder Check attachment and securing of rudder cables Check conductive connection 6 Control Manual control Check for free travel of control see 6 4 2 Check plays see 6 4 1 Check sec...

Page 25: ...g of bolts Check wheels for free rotation Check function of brakes and parking brake Check condition and attachment of brake hoses Check condition and wear of brake hoses minimum admissible thickness...

Page 26: ...t signs of heat damage or cracks Inspect and check for tightening and securing the bolts on the engine brackets and the engine bed Check the engine bed for occurrence of cracks Check the exhaust syste...

Page 27: ...AFTER 100 FLIGHT HOURS Page 5 of 5 Chpt Prescribed works Made by Checked by Navigation Communication Visually check condition of navigation and communication instruments Check function of navigation...

Page 28: ...ngs of the control tubes X X Lubrication Grease Two arm control lever in the outer wing and control lever in the center wing X X Lubrication Grease Torque tube bearings in center console in fuselage X...

Page 29: ...0 or 1 month whichever is the lesser More than 1 year but not exceeding 3 years 2 months More than 3 years 3 months Items Controlled by Landing Cycles Maximum Variation 500 landings cycles or less 10...

Page 30: ...2 CHAPTER LIMITATIONS MAINTENANCE CHECKS Document SLSA MIP 5 4 0 US Date of Issue 05 2016 Revision 2 14 INTENTIONALLY LEFT BLANK...

Page 31: ...ear part of the fuselage 3 2 3 2 3 Cockpit 3 4 3 2 4 Luggage compartment 3 4 3 2 5 Crew canopy 3 4 3 2 5 1 Canopy 3 4 3 2 5 2 Rear fixed canopy windows 3 4 3 3 Removal Installation 3 5 3 3 1 Canopy re...

Page 32: ...ing 2 consists from the main spar attachments located as bulkheads No 3 and the rear spar attachments located on the bulkhead No 5 main landing gear attachment points 3 are located behind main center...

Page 33: ...MIP 5 4 0 US Date of Issue 05 2016 Revision 3 3 Fig 3 1 Fuselage monocoque 1 Nose land gear attachment 2 Center section of wing 3 Main landing gear attachments 4 Engine mount attachments 5 Stabilizer...

Page 34: ...py see Fig 3 2 has a semi drop shape and enables access to the cockpit The canopy consists of carbon frame on which the windscreen is attached The canopy is suspended in two swivel hinges on front sid...

Page 35: ...removing of the canopy Open the canopy 1 Remove securing springs from the gas strut rod ends 2 Disconnect gas struts 3 on both sides of canopy 1 Disconnect hinge bolt nuts 4 Remove the hinge bolts 5...

Page 36: ...6 of the canopy 1 Tighten up the joint Insert ends of gas strut in to the pin 7 in the fix frame of the canopy and on the foldable frame secure it with the securing spring 8 3 3 3 Gas strut removal Ty...

Page 37: ...Securing spring 3 3 4 Gas strut installation Type of maintenance line Authorization to perform Sport pilot or LSA mechanic Tools needed pliers At installation of the gas strut follow Fig 3 3 and Fig 3...

Page 38: ...s a covered access hole behind the seat Demount the access hole cover 3 use Allen wrench to unscrew the screws 4 which attach the cover to a composite structure behind the seats Fig 3 5 Canopy lock le...

Page 39: ...driver Follow the Fig 3 5 and Fig 3 6 at installation of the canopy lock Insert the lock 1 with rod 6 from behind through a cutout in the luggage compartment front at the fuselage side Connect the rod...

Page 40: ...3 CHAPTER FUSELAGE Document SLSA MIP 5 4 0 US Date of Issue 05 2016 Revision 3 10 INTENTIONALLY LEFT BLANK...

Page 41: ...g 4 2 4 2 2 Wing flaps 4 3 4 2 3 Ailerons 4 3 4 2 4 Fuel tanks 4 4 4 2 5 Wing lockers 4 4 4 3 Removal Installation 4 4 4 3 1 Wing removal 4 4 4 3 2 Wing installation 4 5 4 3 3 Wing flap removal 4 6 4...

Page 42: ...ng edge fuel tanks 1 on the rear spar there are hinged ailerons 2 and flaps 3 The winglets 4 produced from fiberglass are riveted on the wing ribs No 12 On winglets are installed the position lights a...

Page 43: ...n connected Fig 4 2 Wing flap left 1 Flap skin 2 Flap spar 3 Flap ribs 4 Flap hinges 5 Control pin 4 2 3 Ailerons Ailerons Fig 4 3 are of aluminum structure consisting of the aluminum skin 1 and ribs...

Page 44: ...Authorization to perform LSA mechanic or A P mechanic Airframe and Power plant Tools needed wrench size 7 8 in 3 4 in 1 2 in 7 16 in screwdriver cutting pliers hammer Removal of the wing according to...

Page 45: ...hments by means of lubricating grease Set the wing about 4 in to the fuselage side The first person will hold the wing on the wing tip the second person near the root on the leading edge and the third...

Page 46: ...connect all three flap hinges Remove the flap from the wing Store the removed flap on a safe place and prevent it from damage 4 3 4 Wing flap installation Type of maintenance line Authorization to per...

Page 47: ...on a safe place so that it cannot be damaged 4 3 6 Aileron installation Type of maintenance heavy Authorization to perform LSA mechanic or A P mechanic Airframe and Power plant Tools needed wrench siz...

Page 48: ...4 CHAPTER WING Document SLSA MIP 5 4 0 US Date of Issue 05 2016 Revision 4 8 INTENTIONALLY LEFT BLANK...

Page 49: ...r with trim tab 5 2 5 2 3 Fin 5 3 5 2 4 Rudder 5 3 5 3 Removal Installation 5 4 5 3 1 Horizontal stabilizer removal 5 4 5 3 2 Horizontal stabilizer installation 5 4 5 3 3 Elevator removal 5 5 5 3 4 El...

Page 50: ...ttachments consist of two pins which are riveted on bulkhead No 13 and bushings riveted on front stabilizer spar The rear attachments consist of four hinges bolted on top and bottom part of bulkhead N...

Page 51: ...made from fiberglass On the spar are two rudder hinges bottom one 3 which is integral part of control lever and upper one 4 5 2 4 Rudder Rudder 2 is a fiberglass sandwich structure and consists of spa...

Page 52: ...h a way that a damage cannot occur 5 3 2 Horizontal stabilizer installation Type of maintenance heavy Authorization to perform LSA mechanic or A P mechanic Airframe and Power plant Tools needed wrench...

Page 53: ...ame and Power plant Tools needed wrench size 7 16 in pliers Put the elevator in the piano hinge on the stabilizer Insert the trim tab actuator wires 3 see Fig 6 9 going from the stabilizer to the elev...

Page 54: ...ic Airframe and Power plant Tools needed wrench size 3 8 in 7 16 in Remove horizontal stabilizer see 5 3 1 Remove the nuts from bolts on both hinges of the rudder Remove top bolt from the hinge and li...

Page 55: ...5 CHAPTER TAIL UNIT Document SLSA MIP 5 4 0 US Date of Issue 05 2016 Revision 5 7 5 5 Exchanges Service information No procedures included...

Page 56: ...5 CHAPTER TAIL UNIT Document SLSA MIP 5 4 0 US Date of Issue 05 2016 Revision 5 8 INTENTIONALLY LEFT BLANK...

Page 57: ...aileron control lever behind main center wing spar 6 11 6 3 9 Installation of aileron control lever behind main center wing spar 6 11 6 3 10 Removal of aileron control bell crank in the wing 6 12 6 3...

Page 58: ...deflections 6 19 6 4 4 Adjustment of control surface deflections 6 19 6 4 4 1 Adjusting aileron deflections 6 20 6 4 4 2 Adjusting wing flap deflections 6 20 6 4 4 3 Adjusting elevator deflections 6...

Page 59: ...icks Movement of control sticks is synchronized by push rod lead between them inside of torque tube From control sticks lead two push rods installed behind main wing spar This two push rods lead to th...

Page 60: ...adjustable terminals with spherical bearings on the ends enabling elevator deflection adjustment Fig 6 2 Longitudinal control scheme 6 2 3 Directional control rudder control The rudder control is cont...

Page 61: ...instrument panel Fig 6 4 Trim tab control 6 2 5 Wing flap control Wing flaps are controlled by an electric flaps actuator connected with flaps per torque tube with push rods on each end The flaps actu...

Page 62: ...a Teleflex rod which bottom end is connected on the top of the nose wheel fork and upper end is connected to a lever welded on the pedals connecting tube Fig 6 6 Nose leg control 1 Nose wheel pant 2...

Page 63: ...1 2 Orientation of bolts and cotter pins Put the bolts to the joint on the basis of top down rule or From the front to the back with regard to the flight direction This rule decreases possibility of s...

Page 64: ...torque tube hinges 8 Connect electric wire 5 for trim tab switches and PTT Put aileron control tube push rods 3 on the sticks 4 Put elevator control tube push rod 1 in to the torque tube fork 2 Inser...

Page 65: ...between the seats Disconnect flap lever 3 from the flap actuator 4 Disconnect flap actuator wire 5 Disconnect the flap actuator 4 from the actuator hinge 6 Remove flap actuator 4 Fig 6 8 Disassembly A...

Page 66: ...ic or A P mechanic Airframe and Power plant Tools needed wrench size 5 screwdriver wire nippers pliers The trim tab control actuator is located in the elevator and the left aileron see Fig 6 9 Remove...

Page 67: ...the access hole with cover 1 6 3 8 Removal of aileron control lever behind main center wing spar Type of maintenance heavy Authorization to perform LSA mechanic or A P mechanic Airframe and Power plan...

Page 68: ...perform LSA mechanic or A P mechanic Airframe and Power plant Tools needed wrench size 7 16 in screwdriver The bell crank is located on the bracket in the position of the main spar next to the rear r...

Page 69: ...ondition and lubrication of bell crank bearings If the bearings are contaminated then carefully eliminate the contamination and grease them with lubricant oil Set the bell crank 7 to the position see...

Page 70: ...bail arm lever 3 and lever hinge 4 remove the cotter pin unscrew the castle nut put out the bolt Remove the bail arm lever 3 Fig 6 12 Two arm lever front fuselage 1 Cover on the bottom skin 2 Push ro...

Page 71: ...s hole on the bottom skin under the luggage compartment Check elevator deviations see 6 4 3 3 and check control plays see 6 4 1 2 6 3 14 Removal of bail arm in rear fuselage Type of maintenance heavy...

Page 72: ...Check of plays in control Admissible plays in control are mentioned in the following table Control Admissible plays Area to measure play longitudinal 4 mm max 5 32 in at the end of the control stick i...

Page 73: ...tick 6 4 1 4 Plays in foot control pedals Measure play at the end of pedals by the measuring instrument from the inner wall of the bulkhead No 1 at the blocked rudder at neutral position and with the...

Page 74: ...t s feet by means of the spring scale attached to the foot control pedal Measure force at the moment of rudder deflection from the neutral position Max force can be 4 kg 8 8 lbs 6 4 3 Checking control...

Page 75: ...r deflections that is slid on the vertical tail unit and it is possible directly to read the rudder deflection If you do not have this special jig use the alternative procedure Set the rudder to neutr...

Page 76: ...ust flap deflection by means of the terminals on push rods connected flaps with control torque tube The terminal is accessible on fully deployed flaps 6 4 4 3 Adjusting elevator deflections Range of e...

Page 77: ...e wires evidence of sleeves deformation and damage on cable surface evidence of cable corrosion cable distortion Check cable tension by cable tensioner prescribed cable stress in the operation is 33 1...

Page 78: ...10 Connect new cable with turnbuckle 6 installed on rudder pedal 7 Set the rudder and the pedal and secure them in neutral position Set on rear end of cable thimble 5 and connect it with rudder lever...

Page 79: ...d operation 7 2 7 2 1 Seats 7 2 7 2 2 Safety harness 7 2 7 3 Removal Installation 7 3 7 3 1 Removal of seats 7 3 7 3 2 Removal of safety harness 7 3 7 3 3 Installation of safety harness 7 3 7 4 Check...

Page 80: ...ats Seats 1 of the BRISTELL S LSA airplane are attached to the gear channel on Velcro and are equipped with an upholstered cushions The seat backs 2 are attached on Velcro to the bulkhead No 5 For adj...

Page 81: ...e compartment see Fig 7 2 Remove the nut with distance washer and the bolt 2 Remove the side harnesses from the side attachment brackets 4 remove snap hook 3 7 3 3 Installation of safety harness Type...

Page 82: ...Check harnesses surface for any damages Check the lock system function Check the attachment points of shoulder and side harnesses for any damages or corrosion 7 5 Exchanges Service information 7 5 1 C...

Page 83: ...8 3 5 Removal of nose landing gear wheel 8 6 8 3 6 Installation of nose landing gear wheel 8 6 8 3 7 Removal of the main landing gear leg 8 7 8 3 8 Installation of the main landing gear leg 8 8 8 3 9...

Page 84: ...mation on main landing gear nose landing gear brake system wheel pants 8 2 Description and operation 8 2 1 Main landing gear The main landing gear see Fig 8 1 consists of the composite landing gear le...

Page 85: ...ings 8 2 2 Nose landing gear The nose landing gear of BRISTELL S LSA airplane is steerable and consists of 4130 steel welded landing gear leg 1 4130 steel welded fork 2 shock absorber 3 and the wheel...

Page 86: ...pply brake calipers and brake pads By depressing pedals brake pumps are compressed and pressure generated in the brake circuit and the calipers pushes the brake pads onto the brake disks Braking press...

Page 87: ...olts 8 3 3 Removal of main landing gear wheel Type of maintenance line Authorization to perform Sport pilot or LSA mechanic Tools needed socket wrench vel 1 1 2 in Allen wrench size 3 16 in pliers The...

Page 88: ...l Jack and support the airplane see para 14 2 Disassemble wheel fairing see para 8 3 1 Remove safety wire 4 securing bolts 3 on wheel axle 5 Remove the bolts 3 from wheel axle 5 Release the wheel axle...

Page 89: ...h size 9 16 in 1 2 in Follow Fig 8 5 at removal Jack and support the airplane see 14 2 Disconnect the brake line 1 Disconnect main gear leg 2 stirrup 3 and attachment bolts 4 Remove the bolts 4 and st...

Page 90: ...lightly Connect the brake lines 1 Fill brake system with brake liquid and deareate it see 8 5 4 8 3 9 Removal of nose landing gear leg Type of maintenance heavy Authorization to perform Repairman LS M...

Page 91: ...nt brackets in gear channel 6 Put the leg axle 4 into the brackets insert bolts 3 and tighten them slightly Connect shock absorber with the shock absorber attachments 2 Pull the Teleflex bottom end th...

Page 92: ...low Fig 8 7 at removal Drain brake fluid from the brake system Disconnect the brake system hose from the brake cylinder on the main landing gear wheel and let brake fluid drain to a previously prepare...

Page 93: ...he Bracket 4 on the cockpit floor and assemble the fitting 3 to connect brake hose Connect rod end of the brake pump 1 to the Rudder pedal bracket 5 using the bolt 6 secure with a nut Re connect brake...

Page 94: ...et apart both halves of the rim and remove the tire with the air tube Exchange the air tube or the tire if needed Put the air tube into the tire and inflate it slightly Put the inner tube on that half...

Page 95: ...anic Tools needed wrench size 1 2 in Follow Fig 8 9 to replace the shock absorber Jack and support the airplane see 14 2 Use wrench size in to release both upper and lower self locking nut 4 Remove bo...

Page 96: ...ake pads Follow Fig 8 10 at brake pads replacement Jack and support the airplane see 14 2 Demount the main wheel see 8 3 3 if needed Unscrew the bolts holding the brake pads 2 on the brake caliper 3 a...

Page 97: ...pedal to make brake fluid run out faster 8 5 4 2 Filing brake fluid into brake system NOTE Refer to the paragraph 17 5 to see brake fluid used by the airplane manufacturer Re connect brake hose to th...

Page 98: ...8 CHAPTER LANDING GEAR Document SLSA MIP 5 4 0 US Date of Issue 05 2016 Revision 8 16 INTENTIONALLY LEFT BLANK...

Page 99: ...nder removal 9 5 9 3 6 Fuel level sender installation 9 5 9 3 7 Fuel drain valve removal 9 6 9 3 8 Fuel drain valve installation 9 6 9 4 Check Adjustment 9 7 9 4 1 Checking fuel system tightness 9 7 9...

Page 100: ...each tank through the filler neck 1 which is located on the top skin close to rib No 7 Fuel drain from the tank is possible through the drain valve 5 located in the rear corner of bottom skin close to...

Page 101: ...fuel quantity in the tank is indicated on the fuel indicator on the instrument panel 9 3 Removal Installation 9 3 1 Fuel tank removal Type of maintenance line Authorization to perform Sport pilot or...

Page 102: ...rs and ribs per clecos each second hole with help of securing harnesses Rivet the skin on the ribs and spar Screw back filler cap use LOCTITE 565 to seal the thread and silicon to make connection of f...

Page 103: ...uel level sender removal Type of maintenance line Authorization to perform Sport pilot or LSA mechanic Tools needed electric drill drill bit diam 3 2 mm 1 8 in screwdriver cutting pliers pliers Remove...

Page 104: ...unction Install the wing see 4 3 2 Fig 9 4 Float mechanism 9 3 7 Fuel drain valve removal Type of maintenance line Authorization to perform Sport pilot or LSA mechanic Tools needed wrench size 1 2 in...

Page 105: ...ition 9 4 1 2 Checking airplane fuel system tightness by fuel Fill up the fuel tanks with fuel Connect the pressurization equipment to the filler neck Blind the fuel filter and the fuel return line bu...

Page 106: ...5 1 2 Procedure of fuel tank filing Ground the airplane The airplane ground point is located on the nose landing gear leg Open the fuel tank filler cap Fill necessary quantity of fuel CAUTION When fil...

Page 107: ...ne 10 15 10 3 2 Installation of the engine on the airplane 10 15 10 3 3 Removal of the propeller 10 17 10 3 4 Installation of the propeller 10 18 10 3 5 Exhaust system removal 10 19 10 3 6 Exhaust sys...

Page 108: ...ument SLSA MIP 5 4 0 US Date of Issue 05 2016 Revision 10 2 10 5 2 2 Drainage of cooling liquid 10 28 10 5 2 3 Refilling cooling liquid 10 29 10 5 3 Exchange Check of oil filter 10 29 10 5 4 Exchange...

Page 109: ...ve via integrated gearbox with mechanical shock absorber and overload clutch Oil tank electric starter 12 V 0 8 kW fuel pump assy 10 2 1 1 Technical data of the engine Engine Model ROTAX 912 iS Sport...

Page 110: ...t type WARNING The coolant concentrate propylene glycol may not be mixed with conventional glycol water coolant or with additives CAUTION Conventional glycol water coolant reduce to apply the maximum...

Page 111: ...10 CHAPTER POWER UNIT Document SLSA MIP 5 4 0 US Date of Issue 05 2016 Revision 10 5 10 2 1 3 Fuel type...

Page 112: ...10 CHAPTER POWER UNIT Document SLSA MIP 5 4 0 US Date of Issue 05 2016 Revision 10 6 10 2 1 4 Oil type Type of oil used by aircraft manufacturer is shown in 17 5...

Page 113: ...is attached by means of quick fasteners 4 to the firewall and to the lower cowling 2 Unlock the quick fasteners by turning the bolt by 90 counter clockwise The access cover 5 which is located on the...

Page 114: ...d this position corresponds to max take off power of the engine If the control lever is fully pulled this position corresponds to idle Changes in the engine power setting can be made by moving of the...

Page 115: ...ds to the expansion tank 1 Since the standard location of the radiator 3 is below engine level the expansion tank located on top of the engine allows for coolant expansion The expansion tank is closed...

Page 116: ...10 CHAPTER POWER UNIT Document SLSA MIP 5 4 0 US Date of Issue 05 2016 Revision 10 10 Fig 10 5 Rotax 912 iS Sport Cooling system scheme Fig 10 6 Rotax 912 iS Sport Cooling syst m...

Page 117: ...gine oil from oil tank 1 see Fig 10 8 via the oil cooler 3 and forces it through the oil filter to the individual points of lubrication also lubricates the propeller governor The surplus oil emerging...

Page 118: ...controlled by flap on the firewall The heating control flap is controlled by CARB HEAT knob 6 on the instrument panel 10 2 1 12 Exhaust system Exhaust system of BRISTELL S LSA airplane consist of fou...

Page 119: ...tem is powered by the ECU Engine Control Unit and has fully mapped variable timing It is completely doubled up Either of the ECU s can operate the double ignition coils If a fault occurs with the igni...

Page 120: ...performance are needed short field take off high altitude airfield operation etc The Fiti 3LRSE 158 propeller is designed for Rotax 912 80 HP and Rotax 912 ULS 100 HP engines Maximum allowed RPM is 25...

Page 121: ...r see 10 3 7 and the radiator see 10 3 9 Disconnect throttle control bowden cable Remove the exhaust system see 10 3 5 Blind all the holes on the engine so that no impurity can get into the engine Cut...

Page 122: ...l cooler see 10 3 8 Install water radiator see 10 3 10 Connect and secure oil system hoses Connect and secure fuel system hoses Connect throttle control cable 3 to the throttle lever 2 on throttle val...

Page 123: ...e Authorization to perform Sport pilot or LSA mechanic NOTE For the Fiti 3LRSE propeller DISASSEMBLY refer to the OPERATING INSTRUCTIONS AND TECHNICAL DESCRIPTION OF FITI ECO COMPETITION IN FLIGHT ADJ...

Page 124: ...propeller Type of maintenance line Authorization to perform Sport pilot or LSA mechanic NOTE For the Fiti 3LRSE propeller installation refer to the OPERATING INSTRUCTIONS AND TECHNICAL DESCRIPTION OF...

Page 125: ...al blade tips from marking see Fig 10 17 The difference can be max 1 5 mm 0 06 in Possible bigger differences can be corrected by repetition of the procedure from point d or f X distance of the propel...

Page 126: ...e the tubes by means of springs 2 Gradually tighten all nuts of the flanges on the engine necks NOTE Ensure the sufficient space between the exhaust pipes and the other installed parts 10 3 7 Oil cool...

Page 127: ...e 10 17 screwdriver see Fig 10 18 Remove the upper and lower engine cowling Drain the cooling liquid from the cooling system see 10 5 2 2 Disconnect hoses from the radiator outlets Remove four bolts a...

Page 128: ...10 CHAPTER POWER UNIT Document SLSA MIP 5 4 0 US Date of Issue 05 2016 Revision 10 22 Fig 10 18 Attachment of the radiator on the engine...

Page 129: ...LSA mechanic Tools needed wrench size 14 Allen wrench size 2 Screwdriver Cutting pliers see Fig 10 19 Remove the cover of the throttle 3 from the middle channel Remove the upper engine cowling Disconn...

Page 130: ...nic Tools needed wrench size 14 Allen wrench size 2 Screwdriver Cutting pliers see Fig 10 19 Install the control lever of throttle into the middle channel in the cockpit Connect the throttle cable to...

Page 131: ...extinguishing burning liquids and electrical installation Brake the airplane and put the chocks under the landing gear wheels Before performing engine test carry out preflight check of the engine and...

Page 132: ...pressure reaches 2 bar 29 psi 6 Warming up the engine at 2000 2500 RPM smooth running 7 Voltage 12 4 15 1 V Engine test 8 Min oil temperature 50 C 122 F 9 Oil pressure 2 5 bar 29 73 psi 10 Max coolan...

Page 133: ...nal on bowden 4 In order to prevent the bowden from shifting out from the terminal secure the bowden with locking wire Mark all bolted joints with red paint 10 4 3 Checking exhaust system WARNING Chec...

Page 134: ...the oil tank It is possible to drain oil from the engine after unscrewing the plug in the lower part of the engine at the hose of the return branch of oil flow It is recommended to drain oil immediat...

Page 135: ...r metal chips foreign corpuscles and contamination CAUTION If you detect an increased quantity of metal particles brass or bronze chips or bearing abrasive find out the reason and eliminate it Install...

Page 136: ...10 CHAPTER POWER UNIT Document SLSA MIP 5 4 0 US Date of Issue 05 2016 Revision 10 30 INTENTIONALLY LEFT BLANK...

Page 137: ...of the onboard battery 11 6 11 3 2 Installation of the onboard battery 11 6 11 3 3 Removal of the optional strobe position lights 11 6 11 3 4 Installation of the optional strobe position lights 11 6 1...

Page 138: ...ching the idle RPM the generator starts supplying current to the electrical network Information about voltage in the main bus bar is indicated by low voltage red light on the instrument panel The Rota...

Page 139: ...B connect the ECU for the relevant LANE to the EMS power supply If only one LANE is turned ON the engine is powered by one ignition circuit depending on which ignition circuit was chosen LANE B Ignit...

Page 140: ...io 2 5A XPONDER Fuse of transponder 3A GPS Fuse of GPS 3A AVIONICS Fuse of avionics 5A SPARE Spare fuse 10A Tab 11 2 Fuses 11 2 3 Generator Rotax 912 iS internal generator has two isolated coils integ...

Page 141: ...discharged without affecting performance For more information on the battery refer to the http www varta automotive com en gb products powersports agm 518 901 026 Fig 11 1 Battery installation 11 2 5...

Page 142: ...battery into the bracket on the firewall Fasten it with draw band so that the battery cannot move in the bracket Grease the battery contacts with lubricating grease and install the clamps on them fro...

Page 143: ...o prevent water from in leaking under the position light 11 3 5 Removal of the optional landing light Type of maintenance line Authorization to perform Sport pilot or LSA mechanic Tools needed Wrench...

Page 144: ...ing the optional landing light Unscrew turn bolts on the bulb bracket Do adjustment in the horizontal direction according to Fig 11 2 in such a way that the light axis is directed towards the airplane...

Page 145: ...charger manufacturer If the charger curve is unknown it can be assumed that charging will be unregulated i e voltage monitoring via a Voltmeter and manual disconnection at 14 4 V are required The nom...

Page 146: ...trobe position light see 11 3 3 Exchange the discharge tube for the same type CAUTION Do not touch the new discharging tube with bare hands Use the cloth gloves or a cloth Install the strobe position...

Page 147: ...12 2 2 5 Magnetic compass 12 3 12 2 3 Engine instruments 12 4 12 2 3 1 Tachometer 12 4 12 2 3 2 Coolant thermometer 12 4 12 2 3 3 Oil thermometer 12 4 12 2 3 4 Oil pressure gauge 12 4 12 2 3 5 Fuel pr...

Page 148: ...ed through the hole in the pitot tube face Static pressure ports are located on both sides of the fuselage at the tail Pressure distribution to individual instruments is performed by means of flexible...

Page 149: ...d indicator optional instrument located on the left side of instrument panel is classical analogue round pressure gauge Range of measure is up to 2 000 fpm i e 10 m s 12 2 2 4 Inclinometer The inclino...

Page 150: ...linder head thermometer is 50 to 150 C 120 to 300 F 12 2 3 3 Oil thermometer Oil temperature on the inlet to the engine is measured by the sensor which is located behind the oil pump Working range of...

Page 151: ...hole in wing Remove the tightening strip from hose Mark the hose for total pressure by P letter Disconnect the transparent hose of total pressure from the Pitot tube 12 3 2 Installation of the pitot...

Page 152: ...es electric leading or other over ground or underground steel equipment or objects If the compass north is westward from magnetic north the deviation is westward i e negative If the compass north is e...

Page 153: ...istration mark Serial No Compass Type Compass Serial No List of Switched On Radio navigation Course Engine running Engine stopped Measured Deviation Measured Deviation N 030 060 E 120 150 S 210 240 W...

Page 154: ...12 CHAPTER PITOT STATIC SYSTEM INSTRUMENTS Document SLSA MIP 5 4 0 US Date of Issue 05 2016 Revision 12 8 INTENTIONALLY LEFT BLANK...

Page 155: ...13 2 13 2 1 Venting system 13 2 13 2 2 Heating system 13 2 13 3 Removal Installation 13 4 13 3 1 Removal of fresh air hot air and mixture control knob 13 4 13 3 2 Installation of fresh air hot air and...

Page 156: ...the Naca scoop from inside the cockpit and a flexible hose is used to connect the air vent with the composite part Fig 13 1 Venting system 1 Naca scoop 2 Eye ball vent 3 Automotive air vent 13 2 2 He...

Page 157: ...N HEATING Document SLSA MIP 5 4 0 US Date of Issue 05 2016 Revision 13 3 Fig 13 2 Heating system 1 Heat exchanger 2 Muffler 3 Control flap 4 Air hose 5 Heating knob 6 Mixture flap 7 Canopy bubble outl...

Page 158: ...move the control knob with cable from the flexible housing 3 Fig 13 3 Control knob typical 1 Nut 2 Control knob 3 Bowden 13 3 2 Installation of fresh air hot air and mixture control knob Type of maint...

Page 159: ...ent panel 13 3 4 Installation of eyeball vents see Fig 13 4 Insert the vent 3 into the instrument panel 5 Screw securing nut 4 on the vent 3 Plug the hose 2 into the vent 3 Install glareshield 1 13 4...

Page 160: ...13 CHAPTER VENTILATION HEATING Document SLSA MIP 5 4 0 US Date of Issue 05 2016 Revision 13 6 INTENTIONALLY LEFT BLANK...

Page 161: ...cument SLSA MIP 5 4 0 US Date of Issue 05 2016 Revision 14 1 14 CHAPTER AEROPLANE HANDLING 14 1 General 14 2 14 2 Airplane jacking and supporting 14 2 14 3 Airplane towing 14 2 14 4 Airplane parking 1...

Page 162: ...s possible to push it forward by open hands pushing on the reinforced wing root also the main legs may be utilized to move the airplane WARNING Ignition to be switched off before handling the airplane...

Page 163: ...eason the airplane is equipped with anchoring eyes on the lower side of wings and on rear part of fuselage Procedure check the FUEL valve is OFF switch OFF all switches ignition and master switch bloc...

Page 164: ...14 CHAPTER AEROPLANE HANDLING Document SLSA MIP 5 4 0 US Date of Issue 05 2016 Revision 14 4 INTENTIONALLY LEFT BLANK...

Page 165: ...of external appearance 15 10 15 5 3 1 Small damage 15 10 15 5 3 2 Medium damage 15 11 15 5 3 3 Major damage 15 12 15 5 4 Structural parts 15 12 15 6 Paint repairs 15 13 15 6 1 Safety rules 15 13 15 6...

Page 166: ...AEROPLANE REPAIRS Document SLSA MIP 5 4 0 US Date of Issue 05 2016 Revision 15 2 15 9 Bonding repair 15 21 15 9 1 General 15 21 15 9 2 Removal Installation 15 21 15 10 Installing clamps by Nicopress p...

Page 167: ...ane Torque moments Securing bolt joints and screwed fittings Repairs of bonding Installing clamps by Nicopress pliers 15 2 Removing rivets Remove rivets from the side of the rivet which is more access...

Page 168: ...or sunk rivets perform conical countersinking of the rivet head by 5 smaller apex angle e g the head with angle of 100 will have countersinking of 95 1 After countersinking the cylindrical part of hol...

Page 169: ...appearance defects of paint coat etc Damage which can be eliminated by airplane operator Methods of elimination are describer further in the text Damage with disturbance of basic structural elements o...

Page 170: ...r Choose the same rivet diameter as in the damaged place Use at least two rivets on each side from the crack At riveting follow 15 3 Fig 15 2 Scheme of angle repair 15 4 5 Skin repair 15 4 5 1 Stoppin...

Page 171: ...cut out Corners of cut out holes in the skin must have minimum radius of 12 7 mm 0 5 in and their edges must be smoothly filled off Size of patch overlapping depends on the cut out of skin area patch...

Page 172: ...15 CHAPTER AEROPLANE REPAIRS Document SLSA MIP 5 4 0 US Date of Issue 05 2016 Revision 15 8 Fig 15 4 Repair of the punctured skin in the frame area 1 Skin 2 Patch 3 Stiffening frame...

Page 173: ...t SLSA MIP 5 4 0 US Date of Issue 05 2016 Revision 15 9 Fig 15 5 Repair of the punctured skin A Punctured skin B Cutting out and cleaning the damaged skin C Repair with the flat patch D Repair with th...

Page 174: ...tiffener thickness damaged big damage We recommend carry out repairs by means of epoxy resin and glass or carbon stiffeners 15 5 2 General Epoxy resin mixtures are prepared in a given mass ratio by me...

Page 175: ...o 160 and finish with grain size of at least 400 It is carried out by dry sanding equipment with suction from the sanding area Al203 or equivalent fused corundum can be used as sanding material Basic...

Page 176: ...When applied properly the layer is without bubbles Repair thickness should exceed surrounding surface in this phase by about 0 5 to 1 mm 0 02 in to 0 04 in for finishing Sanding Carry out sanding and...

Page 177: ...on even from the corners and borders without additional warming Disadvantages it must be used without other dilution expensive not ecological danger of water contamination detrimental to health must b...

Page 178: ...ng agents are applied with plastic spatula after being mixed with initiator Sanding with sanding paper with grain size of 240 is made to smooth surface after drying Remove dust after sanding and clean...

Page 179: ...can be also used as filler 15 min 12 hours epoxy fiberglass PC Lexan PMMA Plexiglas Tab 15 5 Recommended primers 15 6 2 4 Bonding After total drying of basic coat we recommend to carry out total bondi...

Page 180: ...ct that the substrate for repair coats is not a compact surface of basic material but mostly al coats of surface protection after sanding of which not all are suitable for in ageing stage for good adh...

Page 181: ...y coat of the place to be repaired by adhesive interlayer see Tab 15 7 surface Manufacturer name type Surface weight Recommended thickness Drying total 18 C 65 F Al alloys BASF Glasurit 934 0 single c...

Page 182: ...in Tab 15 8 Type of color Manufacturer name Type other components Surface mass Recommended thickness Drying between spray coats total 18 C 65 F single coat BASF Glasurit R 68 shade base acrylic polyur...

Page 183: ...s recommended Max allowable torque limits Nm in lb Nm in lb AN3 2 3 2 8 20 25 4 5 40 AN4 5 7 7 9 50 70 11 3 100 AN5 11 3 15 8 100 140 25 4 225 AN6 18 1 21 5 160 190 44 1 390 AN7 50 9 56 5 450 500 94 9...

Page 184: ...bolt head and then by the other end of the wire Make sure that the wire is properly tightened around the head 8 Hold the twisted end by pliers and twist it tight 4 Twist the wire to the hole in the ne...

Page 185: ...elage structure 15 9 2 Removal Installation Before installing the bonding remove the paint coat which protects the joint Principles for repeated installation of the bonding Carefully clean the whole b...

Page 186: ...le end should overlap by about 32 mm 1 25 in from the clamp after its puling through The overlapping will ensure that the cable end will not be pulled back into the clamp during the clamp squeezing Be...

Page 187: ...l 16 2 16 2 General wiring diagram 16 3 16 3 Wiring diagram of trims 16 4 16 4 Wiring diagram of flaps 16 5 16 5 Wiring diagrams of the communication system 16 6 16 6 Wiring diagram of the transponder...

Page 188: ...Revision 16 2 16 1 General This chapter contains typical wiring diagrams of BRISTELL S LSA airplane systems navigation and communication means Further wiring diagrams relating to additional equipment...

Page 189: ...16 CHAPTER WIRING DIAGRAMS Document SLSA MIP 5 4 0 US Date of Issue 05 2016 Revision 16 3 16 2 General wiring diagram Fig 16 1 Wiring diagram of BRISTELL S LSA aircraft...

Page 190: ...16 CHAPTER WIRING DIAGRAMS Document SLSA MIP 5 4 0 US Date of Issue 05 2016 Revision 16 4 16 3 Wiring diagram of trims Fig 16 2 Wiring diagram of the aileron and elevator trim...

Page 191: ...16 CHAPTER WIRING DIAGRAMS Document SLSA MIP 5 4 0 US Date of Issue 05 2016 Revision 16 5 16 4 Wiring diagram of flaps Fig 16 3 Wiring diagram of flaps...

Page 192: ...16 CHAPTER WIRING DIAGRAMS Document SLSA MIP 5 4 0 US Date of Issue 05 2016 Revision 16 6 16 5 Wiring diagrams of the communication system Fig 16 4 Wiring diagram of the radio and intercom stereo...

Page 193: ...16 CHAPTER WIRING DIAGRAMS Document SLSA MIP 5 4 0 US Date of Issue 05 2016 Revision 16 7 16 6 Wiring diagram of the transponder Fig 16 5 Wiring diagram of the transponder and encoder...

Page 194: ...ING DIAGRAMS Document SLSA MIP 5 4 0 US Date of Issue 05 2016 Revision 16 8 16 7 Wiring diagram of the GPS Fig 16 6 Wiring diagram of the GPS 16 8 Wiring diagram of the socket Fig 16 7 Wiring diagram...

Page 195: ...16 CHAPTER WIRING DIAGRAMS Document SLSA MIP 5 4 0 US Date of Issue 05 2016 Revision 16 9 16 9 Wiring diagram of the lighting system Fig 16 8 Wiring diagram of the lighting system...

Page 196: ...16 CHAPTER WIRING DIAGRAMS Document SLSA MIP 5 4 0 US Date of Issue 05 2016 Revision 16 10 INTENTIONALLY LEFT BLANK...

Page 197: ...MIP 5 4 0 US Date of Issue 05 2016 Revision 17 1 17 CHAPTER SUPPLEMENTS 17 1 General 17 2 17 2 List of appendices 17 2 17 3 List of used materials for airframe production 17 2 17 4 Airplane failure c...

Page 198: ...intain the BRISTELL S LSA airplane in the form of appendices 17 2 List of appendices No Title 17 3 List of used materials 17 4 Airplane failure card 17 5 Operating liquids 17 3 List of used materials...

Page 199: ...y month year format dd mm yy 3 Failure has been detected at 1 Flight 6 Landing run encircle appropriate number 2 Taxiing 7 Daily inspection 3 Take off run 8 Periodical inspection 4 Take off 9 Other 5...

Page 200: ...3 20IN12 20MY01 20MY03 20TH01 20TR0 1 20US65 20X101en GB pdf Matco brakes AeroShell FLUID 41 Mineral hydraulic fluid for aircraft AeroShell Fluids 4 and 41 mineral hydraulic fluids the latter has supe...

Page 201: ...es 20AsPac Castrol467186 AE05 20AUXX 20DE40 20ES11 20GB20 20SEXX 20X101en GB pdf Alternative Velvana G48 concentrated coolant A concentrated cooling liquid based on ethyleneglycol it contains highly e...