Page 2 GENERAL INFORMATION Equipment fitted to the aircraft must be done so in accordance to the requirements of the national regulations of the country of registration. PLEASE INFORM THE AIRPLANE FACTORY (AIRCRAFT MANUFACTURER) ON CHANGE OF OWNERSHIP OF THE AIRCRAFT NOTICE...
Page 3 PRESENTATION This manual is divided into the following sections: SECTION 1 – GENERAL: This section provides general information, capacities and general procedures and specifications. SECTION 2 – INSPECTION: This section provides information regarding general inspection considerations, inspection schedules and inspection procedures. SECTION 3 –...
Page 4 REVISION RECORD REVISION DATE DESCRIPTION OF CHANGE PARAGRAPHS SIGN NUMBER 2013/12/01 Original document 2014/05/16 All. Corrected servo motor body 1.5, orientation in Figure 14 and Figure 4.1.1.1, 4.1.2.4, 4.2.1.7, Updated wiring diagrams. 6.5, 6.6, 6.9, Updated front occupant(s) safety 12.2.1 harness(es) removal 2014/11/10 Changed wing rear attachment bolt...
Page 5 LIST OF ACRONYMS Alternating Current Aircraft Ampere Hour AHRS Attitude and Heading Reference System Anti-Knock Index Angle Of Attack American Petroleum Institute Authority To Fly Automatic Transmission Fluid Auxilliary AVGAS Aviation Gasoline American Wire Gauge BATT Battery Bayonet Neill Concelman (connector type) Common Controller Area Network Centre of Gravity...
Page 6 Normally Closed Normal Ground Line Normally Open Non Return Valve PASS Passenger Pilot Operating Handbook Push To Talk Setting on altimeter subscale equal to ambient atmospheric pressure at a specified datum Barometric pressure adjusted to sea level RDAC Remote Data Acquisition Computer Republic of South Africa Research Octane Number RS232...
Page 7 REFERENCED DOCUMENTS The following documents are referred to / mentioned in this document and should be read in conjunction with this document, as applicable. DOCUMENT / TITLE FAA Advisory Circular AC43.13-1B: Acceptable Methods, Techniques and Practices - Aircraft Inspection and Repair. AP3 Series and AP4 Series Constant Speed Propeller Operator’s Manual.
Page 8: Table Of Contents
TABLE OF CONTENTS GENERAL ............................1 1.1. DESCRIPTION ..........................1 1.2. AIRCRAFT SPECIFICATIONS AND DATA ..................2 1.2.1 AIRCRAFT 3-VIEW DRAWING ......................2 1.2.2 AIRCRAFT GEOMETRIC DIMENSIONS ..................3 1.2.3 AIRCRAFT WEIGHTS ........................4 1.3. ENGINE ............................5 1.4. APPROVED SUBSTANCES, FLUIDS, LUBRICANTS AND CAPACITIES ........6 1.5.
Page 9 1.16.5 EMPTY WEIGHT CENTRE OF GRAVITY DETERMINATION ............24 1.17. CORROSION PREVENTION ......................26 1.18. AIRCRAFT STORAGE ........................28 1.18.1 SHORT TERM STORAGE ......................28 1.18.2 MEDIUM LONG TERM STORAGE ....................28 1.18.3 OUTSIDE STORAGE ........................29 1.18.4 RETURNING THE AIRCRAFT TO SERVICE ................29 1.19.
Page 10 3.3.5 FIRST 25 HOURS .......................... 65 3.3.6 FIRST 50 HOURS .......................... 66 3.3.7 EVERY 50 HOURS / ANNUALLY ....................66 3.3.8 EVERY 100 HOURS / ANNUALLY ....................67 AIRFRAME ............................. 68 WING .............................. 69 4.1.1 MAIN WING SECTION ........................69 4.1.1.1 WING REMOVAL / INSTALLATION ....................
Page 11 4.3.2.1 FRONT SEAT REMOVAL AND INSTALLATION ................. 138 4.3.2.2 REAR SEAT REMOVAL AND INSTALLATION ................140 4.3.2.3 CANOPY AND WINDSHIELD CLEANING ................... 142 4.3.2.4 UPHOLSTERY CLEANING ......................142 4.3.3 FORWARD FUSELAGE AND FIREWALL ................... 143 LANDING GEAR .......................... 144 4.4.1 MAIN GEAR..........................
Page 12 5.2.14 ENGINE CONTROL SYSTEM (THROTTLE AND CHOKE) ............200 5.2.14.1 THROTTLE LEVER FRICTION ADJUSTMENT ................201 5.2.14.2 THROTTLE LEVER FRICTION DISC REPLACEMENT .............. 202 PROPELLER ..........................204 5.3.1 GENERAL MAINTENANCE AND SERVICE ................204 5.3.2 PROPELLER HUB AND PROPELLER EXTENSION TORQUE PATTERN ........ 204 5.3.3 SPINNER REMOVAL / REPLACEMENT ..................
Page 13 7.6.1 VHF COMMUNICATION ANTENNA .................... 263 7.6.1.1 VHF ANTENNA REMOVAL / INSTALLATION ................263 7.6.2 GPS ANTENNA ..........................265 7.6.2.1 GPS ANTENNA REMOVAL / INSTALLATION ................265 UTILITY SYSTEMS ........................267 CABIN HEATING AND COOLING ....................267 8.1.1 HEAT EXCHANGER ASSEMBLY REMOVAL AND INSTALLATION.......... 267 BRAKE SYSTEM ..........................
Page 14 13.3 EXTERNAL ALTERNATOR WIRING DIAGRAM ................. 305 13.4 FLAP SYSTEM WIRING DIAGRAM ..................... 306 13.4.2 INOTEC ............................307 13.4.3 E-FLAPS ............................308 13.5 ELEVATOR TRIM MOTOR WIRING DIAGRAM ................309 13.5.1 DUAL STICK TRIM ........................309 13.5.2 SINGLE STICK TRIM ........................310 13.6 EFIS SYSTEM / COMMUNICATIONS BUS LAYOUT ..............
Page 15 LIST OF FIGURES Figure 1: Longitudinal leveling reference position....................... 16 Figure 2: Transverse leveling reference position......................18 Figure 3: Aircraft alignment............................19 Figure 4: Moment arms..............................22 Figure 5: Front wing spar to fuselage connection....................... 73 Figure 6: Rear wing spar to fuselage connection......................74 Figure 7: Aileron pushrod-to-control stick connection.
Page 16 Figure 34: Vertical stabilizer to fuselage connection....................131 Figure 35 : Rudder cable tension adjustment......................135 Figure 36: Main landing gear.............................144 Figure 37: Main wheel axle installation........................153 Figure 38: Main gear installation..........................161 Figure 39: Nose gear..............................162 Figure 40: Nose wheel installation..........................166 Figure 41: Front wheel hub assembly.
Page 17 Figure 71: Flap system wiring diagram - E-Flaps...................... 308 Figure 72: Elevator trim motor wiring diagram – dual control sticks................309 Figure 73: Elevator trim motor wiring diagram – single control stick................. 310 Figure 74: EFIS system / communications bus layout....................311 Figure 75: AHRS and compass wiring diagram.
Page 18 WARNINGS, CAUTIONS AND NOTES The following definitions apply to warnings, cautions and notes as used in this aircraft maintenance manual: WARNING Indicates an action necessary to prevent injury or death. CAUTION Indicates an action necessary to prevent damage to the aircraft, aircraft parts or property. NOTE Provides valuable additional information DOCUMENT No.:...
Page 19: General
This section provides general information, capacities and general procedures and specifications. GENERAL 1.1. DESCRIPTION The Airplane Factory Sling 4 is a four seat, single engine, tricycle fixed undercarriage aluminum aircraft with a conventional low wing design. DOCUMENT No.: REVISION: 1.2...
Page 20: Aircraft Specifications And Data
1.2. AIRCRAFT SPECIFICATIONS AND DATA 1.2.1 AIRCRAFT 3-VIEW DRAWING Note that dimensions in this drawing are in millimetres (metric). DOCUMENT No.: REVISION: 1.2 DATE: 2014/11/10 DC-MAM-001-X-C-2 Page 2...
Page 21: Aircraft Geometric Dimensions
1.2.2 AIRCRAFT GEOMETRIC DIMENSIONS WING Span: 9 930 mm / 32.68 ft. Area (gross): 13.12 m² / 141.22 ft². Aspect ratio: 7.52. Dihedral: 5° Tip washout: 2° Aileron area: 0.62 m² / 6.7 ft². Flap area: 1.26 m² / 13.6 ft². HORIZONTAL STABILIZER Span: 2 820 mm / 9.252 ft.
Page 22: Aircraft Weights
FUSELAGE Length: 6 220 mm / 20.41 ft. Width: 1 188 mm / 3.9 ft. Total aircraft length: 7 125 mm / 23.36 ft. LANDING GEAR Wheel track: 1.95 m / 6.4 ft. Wheel base: 1.68 m / 5.51 ft. 1.2.3 AIRCRAFT WEIGHTS MAXIMUM WEIGHTS...
Page 23: Engine
1.3. ENGINE Manufacturer: Bombardier-Rotax GmbH. Model: 914 UL. Type: Turbo charged 4-cylinder horizontally opposed, 1211.2 cm (73.91 inch displacement, mixed cooling (water-cooled heads and air-cooled cylinders), twin carburettors and integrated reduction gearbox with torque damper. Maximum power: 85.85 kW (115 hp) at 5 800 rpm (maximum 5 minutes). 74.6 kW (100 hp) at 5 500 rpm (continuous).
Page 24: Approved Substances, Fluids, Lubricants And Capacities
1.4. APPROVED SUBSTANCES, FLUIDS, LUBRICANTS AND CAPACITIES It is recommended to refer to and comply with the latest Rotax 914 UL engine operator and / or maintenance manuals, as applicable, and with service instructions (as issued from time to time), with regard to recommended lubricants, coolant fluids and fuels, and their usage.
Page 25 COOLANT Water-free propylene glycol based coolant concentrate. DO NOT MIX THESE Grade / type TWO TYPES OF COOLANT. 1:1 Ethylene glycol based coolant and distilled water mixture. Cooling capacity 3 litres (6.34 pints). BRAKE FLUID Grade / type Automatic Transmission Fluid (ATF). AIR FILTER OIL Type K&N filter oil spray or K&N filter oil.
Page 26 LUBRICANTS / GREASE Canopy hinges Q20 or equivalent. Canopy latches Q20 or equivalent. Rudder and pedal control cable terminals MIL-G-3278 type grease or equivalent. Rudder cable guides Q20 or equivalent. Elevator pushrod (in centre) guide MIL-G-3278 type grease or equivalent. Elevator torque tube bushes Q20 or equivalent.
Page 27 MAIN WHEEL BEARING CLEANING SOLVENT Type Paraffin. CANOPY / WINDSHIELD CLEANING FLUIDS / POLISH Suitable for polymethyl methacrylate (Perspex / Plexiglass). Never use Type gasoline, alcohol, alcohol based products or chemical solvents. THREAD LOCKING SEALANT Inspection panel screws, elevator trim motor installation screws. Propeller extension (bolts securing propeller hub / assembly to the propeller extension).
Page 28: Fastener Torque Values And Wrench Sizes
1.5. FASTENER TORQUE VALUES AND WRENCH SIZES 1.5.1 GENERAL Use these values unless indicated otherwise STANDARD NUTS AN BOLT SIZE THREAD SIZE AN310, AN315, AN364. AN365 (MS20365) WRENCH SIZE ft.lb 3/8 “ 10-32 2.0 to 2.7 1.475 to 1.991 7/16 “ 1/4-28 5.7 to 7.9 4.2 to 5.827...
Page 29: Equipment List
1.6. EQUIPMENT LIST AVIONICS / ENGINE INSTRUMENTS MGL Challenger iEFIS incorporating: Moving Map GPS, GLS, Autopilot Operating System, Artificial Horizon, Airspeed Indicator, Altimeter, Vertical Speed Indicator, Angle of Attack Indicator, Compass, Tachometer, Oil Pressure, Fuel Pressure, Fuel Flow, Oil Temperature, Cylinder Head Temperature (x2), Exhaust Gas Temperature (x4), Hour Meter, Fuel Quantity, Volt Meter, Trim Indicator, Flap Indicator, G Meter, Artificial Horizon, Turn and Slip indicators, Time, Flight Time, Time Since Start-up, Range, Endurance.
Page 30: Tyre Specification And Pressures
1.7. TYRE SPECIFICATION AND PRESSURES WHEEL TYPE PRESSURE Main wheel (s) 15.00 x 6.00-6 (6-ply) 2.5 bar (36.26 psi) Nose wheel 5.00-5 (6-ply) 1.8 bar (26.1 psi) 1.8. GROUND HANDLING WARNING MASTER / IGNITION SWITCHES OFF. CAUTION AS A GENERAL RULE, APPLY FORCE TO AIRCRAFT STRUCTURE ONLY ON MAIN STRUCTURAL ELEMENTS SUCH AS FRAMES OR SPARS.
Page 31: Jacking
1.9. JACKING WARNING A LIFTED AIRCRAFT MUST BE SECURELY SUPPORTED BY STATIC STANDS (OTHER THAN A / THE JACKING DEVICE). THE AIRCRAFT MAY NOT MOVE FROM AN ATTEMPT TO SHAKE IT HORIZONTALLY OR VERTICALLY. Following removal of the main wheel fairings (refer to paragraph 4.4.1.1), the aircraft can be jacked from under the ends of the main wheel struts, just inside of the wheels.
Page 32: Parking And Tie Down
1.10. PARKING AND TIE DOWN It is recommended that chocks are used when parking outdoors or in a hanger. If chocks are not available, use the park brake. If possible, park the airplane facing into the wind. Tie down (to ground anchors) at the outer wing (1) and rear fuselage (2) tie down points.
Page 33: Longitudinal Levelling
1.11.1 LONGITUDINAL LEVELLING TOOLS / EQUIPMENT REQUIRED ITEM QUANTITY NOTES Shims. As needed. Spirit, water or electronic level. The above list is not necessarily a complete list of all required tools and equipment needed. A calibrated torque wrench (with adequate range) and the correct size (as implied by the above tool list) accessories (sockets etc.) are implied for torqueing bolts / nuts, if applicable.
Page 34: Figure 1: Longitudinal Leveling Reference Position
PROCEDURE 1. To take measurement rest (align) a spirit, water or electronic level with second row of rivets down from (below) the canopy frame edge, on the aircraft fuselage side, above the wing. these rivets reference. Figure 1: Longitudinal leveling reference position. 2.
Page 35: Transverse Levelling
1.11.2 TRANSVERSE LEVELLING TOOLS / EQUIPMENT REQUIRED ITEM QUANTITY NOTES Shims As needed. Spirit, water or electronic level The above list is not necessarily a complete list of all required tools and equipment needed. A calibrated torque wrench (with adequate range) and the correct size (as implied by the above tool list) accessories (sockets etc.) are implied for torqueing bolts / nuts, if applicable.
Page 36: Figure 2: Transverse Leveling Reference Position
PROCEDURE 1. Open the canopy. 2. Remove a front seat (refer to paragraph 4.3.2.1). 3. Place a spirit, water or electronic level across the top of the centre carry through spar, from one side to the other, and at right angles to the longitudinal axis of the aircraft. Figure 2: Transverse leveling reference position 4.
Page 37: Aircraft Alignment
1.12. AIRCRAFT ALIGNMENT The aim of the alignment control is mainly to compare the measures taken on both sides and to check if the difference between them, if any, is within the tolerances reported below Measurement Nominal Distances (mm) A - B 5 067 mm (±20 mm) B - E 5 0704 mm (±20 mm)
Page 38: Control Surface Deflection / Travel
1.13. CONTROL SURFACE DEFLECTION / TRAVEL DEFLECTION CONTROL SURFACE REFERENCE TOLERANCE UP / DOWN / LEFT RIGHT Ailerons Starting from the tips lined 22° 22° ± 3° up with the wing tips. Elevator Starting from the horn lined 28° 20° ±...
Page 39: Aircraft Rigging
1.15. AIRCRAFT RIGGING 1.15.1 RUDDER CABLE TENSION ADJUSTMENT Refer to paragraph 4.2.2.5. 1.15.2 ELEVATOR ADJUSTMENT Refer to paragraph 4.2.1.5. 1.15.3 ELEVATOR TRIM TAB ADJUSTMENT Refer to paragraph 4.2.1.6. 1.15.4 AILERON ADJUSTMENT Refer to paragraph 4.1.2.3. 1.15.5 FLAP ADJUSTMENT Refer to paragraph 4.1.3.3. DOCUMENT No.: REVISION: 1.2 DATE: 2014/11/10...
Page 40: Weight And Balance Information
1.16. WEIGHT AND BALANCE INFORMATION 1.16.1 REQUIREMENT / SCHEDULE Weight and balance measurements need to be performed according to the following schedule:  Upon completion of manufacture and before the first flight.  Whenever new equipment is fitted or a modification is done which influences the weight of the aircraft.
Page 41: Centre Of Gravity Formulae
1.16.3 CENTRE OF GRAVITY FORMULAE (metric) (imperial) 1.16.4 EMPTY WEIGHT CENTRE OF GRAVITY TABLE ITEM WEIGHT MOMENT [kg] / [lb] [mm] / [inch] [weight x arm] = 2 236 mm / 88.032 ” Right Main Wheel = 2 236 mm / 88.032 ” Left Main Wheel = 548 mm / 21.575 ”...
Page 42: Empty Weight Centre Of Gravity Determination
1.16.5 EMPTY WEIGHT CENTRE OF GRAVITY DETERMINATION TOOLS / EQUIPMENT REQUIRED ITEM QUANTITY NOTES Calibrated scales, minimum 250 kg (551 lb) capacity. Calibrated scale, minimum 250 kg (551 lb) capacity. Alternative to item 1 Blocks with same height as scales (able to bear aircraft weight). Calculator.
Page 43 PROCEDURE Carry out weighing procedure inside a closed building, so as to exclude influence from wind. Remove any unnecessary objects (inadvertently) left on board aircraft. Ensure that all legally required paperwork is on board (e.g. POH, ATF, etc.). Drain fuel. Align nose wheel.
Page 44: Corrosion Prevention
1.17. CORROSION PREVENTION The information supplied here is as a general guideline only, and is by no means intended to be exhaustive, complete or authoritative. For more in depth information refer to an applicable and authoritative publication, such as the FAA Advisory Circular AC43.13-1B: Acceptable Methods, Techniques and Practices - Aircraft Inspection and Repair.
Page 45 After cleaning surface corrosion, parts must be treated with an anti-corrosion finish consisting of a 4 litre solution of water, 10% chromic acid and 20 drops of battery electrolyte. Leave the chromic acid solution on the part for at least five minutes and then remove the excess with water or a damp cloth.
Page 46: Aircraft Storage
1.18. AIRCRAFT STORAGE 1.18.1 SHORT TERM STORAGE Refer to and comply with the storage instructions as stipulated by the latest revision of the Rotax 914 UL engine operator and maintenance manuals, as applicable. If the aircraft is to be stored outside, follow the guidelines outlined in paragraph 1.18.3. 1.18.2 MEDIUM LONG TERM STORAGE Refer to and comply with the storage instructions as stipulated by the latest revision of the Rotax 914 UL engine operator and maintenance manuals, as applicable.
Page 47: Outside Storage
1.18.3 OUTSIDE STORAGE  Tie-down the aircraft in accordance with paragraph 1.9.  Install protective covers on the pitot tube, static vents (if seperate from pitot tube), air vents, openings in the engine cowling and any applicable openings in fuselage. This is important as it prevents the ingress of rain, dust and foreign material.
Page 48: Sources For The Purchasing Of Parts
1.19. SOURCES FOR THE PURCHASING OF PARTS Spare parts can be ordered from the Airplane Factory at www.airplanefactory.co.za, or from your local dealer. 1.20. DISPOSABLE REPLACEMENT PARTS ITEM DESCRIPTION PART NUMBER Air filter. Cylindrical air filter. K&N RU0800 EN-FIL-005-X-X-0 Fuel filter.
Page 49: Aircraft Placards And Equipment Labelling
1.21. AIRCRAFT PLACARDS AND EQUIPMENT LABELLING 1.21.1 MARKINGS AND PLACARDS MAGNETIC COMPASS COMPENSATION TABLE To compensate for the deviation errors of the magnetic compass, the following correction table is located just below the compass: Steer Steer DATE: BRAKE The brake lever is located on the central tunnel between the two front seats and is indicated by a BRAKE label.
Page 50 CABIN HEAT The cabin heat control knob is located on the instrument panel central area and is labelled CABIN HEAT. TRIM SWITCH The elevator trim motor control is located on the top of the control stick and is labelled UP and DN. CIRCUIT BREAKERS Fuses are located on the lower right side of the instrument panel and each breaker is individually labelled.
Page 51 TURBOCHARGER / TCU WARNING LIGHTS Two turbocharger TCU lights are located on the upper left side of the instrument panel and are labelled BOOST and CAUTION. EFIS WARNING LIGHT An EFIS warning light is located on the upper left side of the instrument panel and is labeled EFIS WARNING.
Page 52 The following stainless steel placard is located on the central console inside the aircraft cabin (where ### denotes data unique to each individual aircraft): ZU-### CONSTRUCTOR – THE AIRPLANE FACTORY MODEL – SLING 4 AIRCRAFT SERIAL NUMBER – ### ENGINE ROTAX 914 UL 115 HP MANUFACTURED: ### DOCUMENT No.:...
Page 53 LIMITATION PLACARDS: Located on the instrument panel are the following placards: OPERATE UNDER VMC ONLY MAXIMUM PERMISSIBLE AIRSPEED 135 KIAS MAXIMUM PERMISSIBLE RPM 5 800 RPM FOR 5 MINUTES MAXIMUM CONTINUOUS RPM 5 500 MAXIMUM PERMISSIBLE MASS 920 KG / 2 024 LB WARNING NON TYPE CERTIFIED AIRCRAFT THIS AIRCRAFT IS NOT REQUIRED TO COMPLY WITH ALL THE...
Page 54 1.22. GENERAL SAFETY INFORMATION / CONSIDERATIONS Ensure that the ballistic parachute (if fitted) lever lock mechanism is in place during all repair and servicing work. Never work on an aircraft if the appropriate safety equipment (fire extinguisher, first aid kit, etc.) is not present and serviceable.
Page 55 Never disassemble a wheel or release the wheel assembly bolts before the tyre has not been completely deflated, as explosive separation of the wheel assembly may occur if done so before the pressure is relieved. Never attempt to remove the valve core before the tyre is completely deflated. The core may eject at high velocity if unscrewed before the pressure is relieved.
Page 56 1.23. INSTRUCTIONS FOR CONCERNS REGARDING SAFETY OF FLIGHT If any person should have any concerns regarding the safety of an Airplane Factory Sling 4 for flight, these should be emailed to sales@airplanefactory.co.za. The following information should be included in the email: ...
Page 57: Introduction
SECTION 2 INSPECTION This section provides information regarding general inspection considerations, inspection schedules and inspection procedures. INTRODUCTION This section should be read in conjunction with section 3. 2.1. GENERAL CONSIDERATIONS REGARDING INSPECTION Inspections performed on an aircraft should be performed in accordance with acceptable standards, such as described in, for example, the FAA Advisory Circular AC43.13-1B: Acceptable Methods, Techniques and Practices - Aircraft Inspection and Repair.
Page 58 MOVING PARTS: Lubrication, security of attachment, safety’ing of bolts, binding, excessive play, excessive wear, proper adjustment, correct travel, condition of attachments and hinges, absence of corrosion, deformation, condition of bearings, sealing, rivet slackening, cleanliness, tension (cables), cracks. COMPOSITE PARTS: Inspect for cracks, dents and delamination. FLUID LINES, HOSES, TUBES AND CONNECTIONS: Inspect for leaks, cracks, kinks, nicks, cuts, twisting, any form of collapse, chafing, proper radius, any form of deterioration, security of attachment, corrosion of fitments / couplings.
Page 59 ELECTRICAL WIRING, BONDING, CONNECTION, CIRCUIT BREAKERS AND SWITCHES: Inspect for security of attachment, any sign of arcing, fraying, burning, defective (brittle, nicked, cracked, cut or penetrated in any manner) insulation , loose or broken terminals, heat deterioration, discolouration and corroded terminals. Inspect bonding connections for proper attachment and corrosion.
Page 60: Inspection Panels
DOCUMENTATION: Verify that the documents required by the current national regulations are present, correct and up to date. PLACARDS, LABELLING AND INSTRUCTIONS: Inspect for the presence and correctness of any placards or notices which are required by the current national regulations. Inspect for the proper labelling of equipment, switches and control levers.
Page 61: Inspection Schedule
2.3. INSPECTION SCHEDULE The Airplane Factory considers the inspection schedule outlined below as compulsory for the safe operation of the airframe and systems over an extended period of time. The described servicing requirements pertain to operation in non-extreme climatic conditions.
Page 62: Condition Inspection (100 Hour / Annually)
2.4. CONDITION INSPECTION (100 HOUR / ANNUALLY) Follow the inspection checklist in paragraph 2.4.10 and rectify any shortcomings. 2.4.1 INSPECTION PANELS AND INITIAL INSPECTION AND CLEANING Each person performing an annual or 100 hour inspection shall, before that inspection: Remove or open all necessary inspection panels, access doors, fairings and cowlings. Clean the aircraft and aircraft engine, after an initial visual inspection for oil, exhaust or other leaks.
Page 63: Engine And Cowling Group
2.4.4 ENGINE AND COWLING GROUP Inspect the engine section for visual evidence of excessive oil, fuel or hydraulic leaks, and sources of such leaks. Inspect studs and nuts for improper torque and obvious defects. Inspect entire engine mount for cracks, looseness of mounting, and looseness of the engine to mount connection.
Page 64: Wing And Centre Section Assembly
2.4.6 WING AND CENTRE SECTION ASSEMBLY Inspect for: Poor general condition. Skin deterioration. Distortion. Evidence of failure. Insecurity of attachment. 2.4.7 EMPENNAGE ASSEMBLY Inspect all components and systems for: General condition. Skin deterioration. Distortion. Evidence of failure. Insecurity of attachment. Improper component installation.
Page 65: Radio Group / Avionics / Electronic Equipment
2.4.9 RADIO GROUP / AVIONICS / ELECTRONIC EQUIPMENT Inspect radio and electronic equipment for improper installation, insecure mounting and correct operation and functionality. Inspect wiring and conduits for improper routing, insecure mounting and obvious defects. Inspect bonding and shielding for improper installation and poor condition. Inspect antenna/e for poor condition and insecure mounting.
Page 66: Hour, 100 Hour And Annual Service Inspection Checklist
2.5. 25 HOUR, 100 HOUR AND ANNUAL SERVICE INSPECTION CHECKLIST This checklist must be read / performed in conjunction with the applicable engine and propeller checklists as found in the latest revision of the Rotax 914 UL engine operator’s manual and / or maintenance manuals, as applicable, and the latest revision of the Airmaster 332 operation manual.
Page 67 Verify coolant level and type. Verify coolant hose routing and heat shielding. Coolant system and Verify security of all coolant hose clamps. radiator Verify security of overflow bottle. Verify that overflow bottle breather hole is clear. Brakes Verify fluid level and breather washer correct. Verify security of cable lock-nuts.
Page 68 Free nose wheel rotation. Verify lubrication and ease of rotation of nose gear strut. Verify security of all bolts / nuts in nose gear assembly / nose gear attachment points Verify that air valve grommet is in place on spat. Verify security of spat retaining screws.
Page 69 Verify integrity and security of attachment of air hose Cabin heat between heat exchanger / muffler and air splitter box on firewall. Exhaust / muffler Verify integrity and security of attachment. Placards All required placards present, legible and correct. Front seat security, integrity and correct operation of Seats adjustment lever / mechanism.
Page 70 Security of the steering linkage rod ends. Verify deflection (left and right). Verify steering linkage rod end free play at full deflection, in both directions. Verify rudder stops secure and not catching. Verify integrity and security of attachment of rudder centering springs.
Page 71 Input lever friction correct. Throttle stops (bolts) correct and secure. Control stick pivot / pivot bolts secure and pivot bracket securely riveted to longitudinal torque tube. Control sticks Control stick tube securely riveted to bracket. Switch labeling correct. Verify integrity and security of longitudinal torque tube mounting brackets and integrity and security of bushes and locking rings.
Page 72 Flap torsion bar and connector tube bolts secure. Verify integrity of belt canvass and stitching. Safety harness Buckle free play. Verify operation. Belts not twisted. Seat belt anchors secure. Jacks secure. Headphones Wiring to jacks secure and correct. Secure. Instruments secure and correctly installed. Switches secure.
Page 73 Inspect root / mounting bolts and verify correct torque. Security and integrity of fuel pipes and fittings. Verify correct and symmetric flap deflection: First stage: 10°, Second stage: 20, Third stage: 30° Up: 0° Flap hinge points / bolts secure. Flap system rod ends secure.
Page 74 Security attachment brake lines main undercarriage legs. Verify security of fitment of fuel filler caps. Fuel Fuel drains secure. Verify operation of fuel drains. Verify presence of fuel type / quantity decals at filler openings. Hinges and hinge bolts / lock-nuts secure. Rod end secure and pushrod locknut secure.
Page 75 SECTION 3 SERVICE This section provides information regarding general service considerations and service schedules. SERVICE - INTRODUCTION This section should be read in conjunction with Section 2. GENERAL CONSIDERATIONS REGARDING SERVICE AND MAINTENANCE Work, maintenance and servicing conducted on aircraft should be performed in accordance with acceptable standards, such as described in, for example, the FAA Advisory Circular AC43.13-1B: Acceptable Methods, Techniques and Practices - Aircraft Inspection and Repair.
Page 76 LUBRICATION: Periodic lubrication of moving parts ensures proper operation and extends part lifetimes considerably. Avoid excessive lubrication as this may cause external surfaces of hinges and bearings to collect dirt and dust. If a part is lubricated by hand, remove excess grease. MOVING PARTS: Lubricate as required with the correct lubricant, as specified for the part.
Page 77 BOLTS, NUTS, WASHERS, SAFETY WIRE, SPLIT PINS AND ATTACHMENTS: Lock-nuts, lock-washers, split pins and safety wire should not be reused after removal. Fit new. If in need of replacement, replace bolts, nuts, washers and connecting hardware with items of the same specification. Ensure bolt and nut threads are clean and dry before fitment, unless otherwise specified by the manufacturer.
Page 78 FILTERS Replace as required. FLUIDS: Replenish fluids as required with the correct specification fluid. Do not mix hydraulic / brake fluid and / or coolant fluid of different specifications or from different manufacturers complying to the same specification. Drain the system, flush and replenish.
Page 79 PLACARDS, LABELLING AND INSTRUCTIONS Inspect for the presence and correctness of any placards or notices which are required by the current national regulations. Inspect for the proper labelling of equipment, switches and control levers. ENGINE Refer to and comply with the service schedule, requirements and procedures as stipulated in the latest revision of the engine manufacturer operator’s manual and / or maintenance manuals and / or service instructions, service letters and service bulletins, as applicable.
Page 80: Lubrication Points, Lubricants And Intervals
LUBRICATION POINTS, LUBRICANTS AND INTERVALS LUBRICATION POINT LUBRICANT INTERVAL Canopy door hinges. As needed. Canopy door latches. As needed. Rudder and pedal control cable terminals. 100 Hours / yearly. Rudder cable guides. 100 Hours / yearly. Elevator pushrod (in centre) guide. 100 Hours / yearly.
Page 81: Service Period Adjustment
Refer to and comply with the service schedule and requirements as stipulated in the latest revision of the propeller operator’s manual. 3.3.1 SERVICE PERIOD ADJUSTMENT This paragraph lists items which may have their normal service intervals adjusted due to external influences or circumstances, or changes in operating conditions and / or procedures.
Page 82: Items With Calendar Based Servicing
3.3.2 ITEMS WITH CALENDAR BASED SERVICING This paragraph lists items which must be serviced at specified calendar periods, calculated from the last date of being serviced. Refer to and comply with the latest revision of the 914 UL operator’s and / or maintenance manuals, as applicable, with regard to calendar based items, if any.
Page 83: Daily
DAILY 3.3.3 The following service requirements should be met on each day that the aircraft is operated:  Pitot and static ports - Inspect for obstructions.  Oil - Verify oil level. Refer to paragraph 5.2.6.  Coolant -Verify coolant level. ...
Page 84: First 50 Hours
FIRST 50 HOURS 3.3.6 The following service requirements should be complied with after the first 50 hours of operation:  Perform all propeller service requirements, if any, in accordance with the provisions of the latest revision of the propeller manufacturer operator’s manual. ...
Page 85: Every 100 Hours / Annually
EVERY 100 HOURS / ANNUALLY 3.3.8 The following service requirements should be complied with after every 100 hours of operation or on an annual basis, whichever comes first:  Complete the inspection checklist in paragraph 2.5 and rectify any shortcomings. ...
Page 86: Airframe
SECTION 4 STRUCTURES, SYSTEMS AND PROCEDURES This section describes the various structures, substructures, systems and subsystems comprising the aircraft, and describes maintenance procedures applicable to these structures, substructures, systems and subsystems, as the case may be. 4. AIRFRAME The airframe consists of the following main groups: ...
Page 87: Wing
WING MAIN WING SECTION 4.1.1 The wing main spar comprises of an aluminium web with spar caps solid riveted to the top and bottom to form a composite I-beam. The caps are made from sheet material bent into angles. The rear spar comprises an aluminium C-channel with the flanges facing forward.
Page 88: Wing Removal / Installation
As needed. Inspection panels and wing-to-fuselage fairing screws. The above list is not necessarily a complete list of all material needed. Refer to the Sling 4 construction manual. AUTHORISED PERSONNEL Any person performing maintenance of any kind on the aircraft or any component thereof must do so in accordance with national legislation.
Page 89 PROCEDURE Retain any bolts, nuts (except lock-nuts) spacers, screws and washers (with the exception of lock- washers) for reassembly. Set the fuel selector (in the cockpit) to OFF. Drain fuel from the wing via the fuel drain valve. If the tank is nearly full a substantial amount of fuel can be siphoned through the filler cap hole.
Page 90 Disconnect the fuel quantity sensor, navigation lights and landing / taxi light wiring (6). Cut any tie wraps which would prevent the wing-side wiring from moving free of the aircraft when the wing is moved away. Disconnect the flap torsion bar connector (7) from inside the fuselage by removing the two AN3 bolts (8) closest to the wing.
Page 91: Figure 5: Front Wing Spar To Fuselage Connection
While supporting the wing, remove all the main spar wing retaining bolts, except for the outside top bolt and the outside bottom bolt. Remove the locknuts from the remaining two bolts in the main spar and from the bolt in the rear spar, but do not remove the bolts. While supporting the wing remove the three remaining bolts and then carefully remove the wing by pulling the main spar directly out of the centre-spar.
Page 92: Figure 6: Rear Wing Spar To Fuselage Connection
 Tighten the rear spar bolt to the recommended value (refer to paragraph 1.5.2). Observe the correct placement of washers (refer to Figure 6). AN5-10A bolt AN5 washer (1.6 mm / 0.063”) AN5 lock-nut (Nyloc) Refer to paragraph 16 for hardware designations Figure 6: Rear wing spar to fuselage connection.
Page 93  Tighten the two AN3 lock-nuts on the bolts connecting the wing flap torsion bar sufficiently and observe the correct placement of washers.  Apply tie wraps as required. 2. Paint orange creep marks on the bolts and nuts. 3. Inspect for security of attachment. 4.
Page 94: Aileron(S )
AILERON(S ) 4.1.2 The aileron is a conventional stressed-skin semi-monocoque structure comprising of ribs and riveted sheet metal skin, without a spar. An aluminium tube running inside the leading edge serves as a balancing weight. Aileron hinges (on the aileron side) comprise of sealed ball bearings pressed into shaped plates attached to the aileron.
Page 95: Aileron Removal / Installation
As needed. Inspection panel screws. The above list is not necessarily a complete list of all material needed. Refer to the Sling 4 construction manual. AUTHORISED PERSONNEL Any person performing maintenance of any kind on the aircraft or any component thereof must do so in accordance with national legislation.
Page 96 PROCEDURE (REMOVAL) Retain any bolts, nuts (except lock-nuts) spacers, screws and washers (with the exception of lock- washers) for reassembly. Remove the aileron bellcrank (1) inspection cover (2) from the (underside of) the wing. Support the aileron and unfasten and remove the bolt (3) securing the pushrod (4) to the bellcrank.
Page 97: Figure 9: Aileron Hinge (Inboard)
PROCEDURE (INSTALLATION) Reverse the above procedure (removal), paying close attention to the following:  Inspect all bolts, nuts and screws for damage. Replace if necessary.  Do not reuse lock-nuts. Fit new.  Tighten the lock-nut on the bolt through the inboard aileron hinge sufficiently, observe the correct placement of washers (refer to Figure 9) and note that the bolt is installed with its head facing the wingtip.
Page 98: Figure 10: Aileron Hinge (Outboard)
 Tighten the lock-nut on the bolt through the outboard aileron hinge sufficiently, observe the correct placement of washers (refer to Figure 10) and note that the bolt is installed with its head facing the wingtip. WINGTIP WINGTIP AIRCRAFT SIDE AILERON SIDE AN4-7A bolt AN4 washer (0.8 mm / 0.032”)
Page 99: Figure 11: Aileron Pushrod -To-Bellcranck Connection
 Tighten the lock-nut on the bolt through the aileron pushrod rod-end bearing sufficiently, observe the correct placement of washers (refer to Figure 11) and note that the bolt is installed with its head facing the wing upper surface. AN4 washer (1.6 mm / 0.063”) AN4-11A bolt.
Page 100: Aileron Adjustment
As needed. Inspection panel screws. The above list is not necessarily a complete list of all material needed. Refer to the Sling 4 construction manual. AUTHORISED PERSONNEL Any person performing maintenance of any kind on the aircraft or any component thereof must do so in accordance with national legislation.
Page 101: Figure 12: Aileron Adjustment - Cabin Side
PROCEDURE The procedure is identical for both ailerons. Remove the front seat(s). Refer to paragraph 4.3.2.1. Remove the inspection paneling to gain access to the control mechanism(s). Remove the bellcrank inspection panel(s) under the wing(s). Ensure that the control sticks move freely left and right. If the roll autopilot servo is attached it will create some resistance.
Page 102: Figure 13: Aileron Adjustment - Wing Side
Test the stops (2) so that when moving the sticks left the stops (under the 2 seats) for both sticks touch simultaneously and when moving the sticks right the stops for both sticks touch simultaneously. Tighten the lock-nuts on both ends of the joining pushrod (1) without turning the pushrod. Loosen the lock-nuts on the long in-wing pushrod (4).
Page 103 Paint orange creep marks on the pushrod lock-nuts. Ensure that no tools and / or foreign materials remain in the wing and under the seats Apply thread locking sealant to the inspection panel screws and close the panel(s). Fit the front seat(s). DOCUMENT No.: REVISION: 1.2 DATE: 2014/11/10...
Page 104: Aileron Autopilot Servo / Servo Pushrod Removal / Installation
Tie wraps. As needed. The above list is not necessarily a complete list of all material needed. Refer to the Sling 4 construction manual. AUTHORISED PERSONNEL Any person performing maintenance of any kind on the aircraft or any component thereof must do so in accordance with national legislation.
Page 105 PROCEDURE (REMOVAL) Retain any bolts, nuts (except lock-nuts) spacers, screws and washers (with the exception of lock- washers) for reassembly. Remove the left front seat (refer to paragraph 4.3.2.1). Undo the screws retaining the inspection panels to gain access to the servo. Undo the bolt (1) connecting the servo (2) control arm to the pushrod.
Page 106: Figure 14: Autopilot Aileron Servo Installation
 Observe the correct placement of washers (refer to Figure 14). AN3-10A bolt AN4 washer (thick)(1.6 mm) AN3 washer (thick)(1.6 mm) AN3 washer (thin)(0.8 mm) AN3 lock-nut (Nyloc) Refer to paragraph 16 for hardware designations Figure 14: Autopilot aileron servo installation ...
Page 107: Figure 15: Aileron Autopilot Servo Pushrod - Control Stick / Torque Tube End
REMOVAL AND INSTALLATION OF AILERON SERVO PUSHROD Retain any bolts, nuts (except lock-nuts) spacers, screws and washers (with the exception of lock- washers) for reassembly. REMOVAL If the servo is not already disconnected / removed, undo the bolt and nut connecting the pushrod to the servo arm.
Page 108: Flaps
FLAPS 4.1.3 A flap comprises a conventional stressed-skin semi-monocoque structure comprising ribs and riveted sheet metal skin, without a spar. Flap hinges (on the aileron side) comprise of sealed ball bearings pressed into shaped plates attached to the flaps. 4.1.3.1 FLAP CONTROL SYSTEM Figure 16: Flap control system.
Page 109: Flap Removal / Installation
As needed. Inspection panel screws. Option2 only. The above list is not necessarily a complete list of all material needed. Refer to the Sling 4 construction manual. AUTHORISED PERSONNEL Any person performing maintenance of any kind on the aircraft or any component thereof must do so in accordance with national legislation.
Page 110 PROCEDURE (REMOVAL) (OPTION 1) Retain any bolts, nuts (except lock-nuts) spacers, screws and washers (with the exception of lock- washers) for reassembly. Extend the flaps fully. Disconnect the bolt (1) attaching the flap pushrod (2) the flap (3). WING Support the flap and remove the bolts, washers and locknuts (4) from the hinges (5). Wingtip Support the disconnected pushrod and carefully pull the flap away from the wing and the hinges.
Page 111: Figure 17: Flap Hinges
PROCEDURE (INSTALLATION) (OPTION 1) Reverse above procedure (removal), paying close attention to the following:  Inspect all bolts, nuts and screws for damage. Replace if necessary.  Do not reuse lock-nuts. Fit new.  Tighten the lock-nuts on the bolts through the flap hinges sufficiently, observe the correct placement of washers (refer to Figure 17) and note that the bolts are installed with their heads facing the wingtip.
Page 112: Figure 18: Flap Pushrod-To-Flap Connection
 Tighten the lock nut on the bolt through the flap pushrod rod end bearing sufficiently, observe the correct placement of washers (refer to Figure 18) and note that the bolt is installed with its head facing the wingtip. AN4-11A bolt AN4 washer (1.6 mm / 0.063”) AN4 lock-nut (Nyloc) Refer to paragraph 16 for hardware...
Page 113 PROCEDURE (REMOVAL) (OPTION 2) Retain any bolts, nuts (except lock-nuts) spacers, screws and washers (with the exception of lock- washers) for reassembly. Remove the flap inspection cover (1) from the (underside of) the wing. Support the flap and disconnect the bolt (2) connecting the flap pushrod (3) to the flap torque tube (4) control arm.
Page 114: Figure 19: Flap Pushrod-To-Flap Torque Tube Control Arm Connection
PROCEDURE (INSTALLATION) (OPTION 2) 1. Reverse above procedure (removal)(option 2), paying close attention to the following:  Inspect all bolts, nuts and screws for damage. Replace if necessary.  Do not reuse lock-nuts. Fit new.  Tighten the lock-nuts on the bolts through the flap hinges sufficiently, observe the correct placement of washers (refer to Figure 17) and note that the bolts are installed with their heads facing the wingtip.
Page 115: Flap Adjustment
As needed. Inspection panel screws. The above list is not necessarily a complete list of all material needed. Refer to the Sling 4 construction manual. AUTHORISED PERSONNEL Any person performing maintenance of any kind on the aircraft or any component thereof must do so in accordance with national legislation.
Page 116 Tighten the locknuts on both ends of the flap pushrods without turning the pushrods. Paint orange creep marks on the pushrod lock-nuts. Verify (before flight) correct travel for the flap (refer to paragraph 1.13). Ensure that no foreign material or tools remain inside the wing, apply thread locking sealant to the flap inspection panel screws and fit the panel.
Page 117: Flap Actuator Motor Removal / Installation
As needed. Actuator cable. The above list is not necessarily a complete list of all material needed. Refer to the Sling 4 construction manual. AUTHORISED PERSONNEL Any person performing maintenance of any kind on the aircraft or any component thereof must do so in accordance with national legislation.
Page 118: Figure 20: Flap Actuator Motor Removal
PROCEDURE (REMOVAL) Retain any bolts, nuts (except lock-nuts) spacers, screws and washers (with the exception of lock- washers) for reassembly. Remove the pilot seat (refer to paragraph 4.3.2.1). Remove the central side panel under the instrument panel (next to pilot’s legs / calves) to gain access to the flap actuator motor’s signal cable plug.
Page 119: Figure 21: Flap Actuator Motor Installation
PROCEDURE (INSTALLATION) Reverse above procedure (removal), paying close attention to the following:  Inspect all bolts, nuts and screws for damage. Replace if necessary.  Do not reuse split pins. Fit new.  Observe correct placement of washers (refer to Figure 21). AN5-13 bolt AN5 washer (1.6 mm / 0.063”) AN5 castle nut...
Page 120: Empennage
EMPENNAGE HORIZONTAL TAIL AND ELEVATOR 4.2.1 Figure 22: Horizontal tail and elevator. Refer to Figure 22. The horizontal stabiliser consists of a conventional semi-monocoque all-metal light alloy structure with front and rear spars. The elevator has a similar structure, though with only a front spar.
Page 121: Elevator Control System
4.2.1.1 ELEVATOR CONTROL SYSTEM Figure 23: Elevator control system. Refer to Figure 23. The elevator control system is push/pull type, controlled from the cabin via the control columns. Control is transmitted through a push/pull rod and bellcrank arrangement. All significant transmission elements such as bellcranks, pushrods, supports and hinges can be easily accessed and inspected.
Page 122: Elevator Removal / Installation
Orange paint. As needed. The above list is not necessarily a complete list of all material needed. Refer to the Sling 4 construction manual. AUTHORISED PERSONNEL Any person performing maintenance of any kind on the aircraft or any component thereof must do so in accordance with national legislation.
Page 123 PROCEDURE (REMOVAL) Retain any bolts, nuts (except lock-nuts) spacers, screws and washers (with the exception of lock- washers) for reassembly. Remove the vertical stabiliser (refer to paragraph 4.2.2.3). Support the elevator and disconnect the elevator pushrod from the elevator control horn (located inside the rear fuselage tail cone).
Page 124: Figure 24: Elevator Pushrod To Elevator Connection
PROCEDURE (INSTALLATION) Reverse the above procedure (removal), paying close attention to the following:  Inspect all bolts, nuts and screws for damage. Replace if necessary.  Do not reuse lock-nuts. Fit new.  Tighten the lock-nut on the bolt through the elevator pushrod rod-end bearing sufficiently, observe the correct placement of washers and note that the bolt is installed with its head facing to the port side of the aircraft.
Page 125: Figure 25: Horizontal Stabilizer-To-Elevator Hinge
 Tighten the lock-nuts on the bolts through the elevator hinges sufficiently. Observe the correct placement of washers (refer to Figure 25). Note that the outer hinge bolts are installed with their heads facing outward, towards the elevator tips and the inner hinge bolts are installed with their heads facing inward, towards the fuselage/ tail cone.
Page 126: Horizontal Stabilizer Removal / Installation
Orange paint. As needed. The above list is not necessarily a complete list of all material needed. Refer to the Sling 4 construction manual. AUTHORISED PERSONNEL Any person performing maintenance of any kind on the aircraft or any component thereof must do so in accordance with national legislation.
Page 127 PROCEDURE (REMOVAL) Retain any bolts, nuts (except lock-nuts) spacers, screws and washers (with the exception of lock- washers) for reassembly. Remove the vertical stabilizer. Refer to paragraph 4.2.2.3. Disconnect the trim tab motor cable connection plug (1). Support the horizontal stabilizer and unfasten and remove the bolts (2) retaining it to the fuselage.
Page 128: Figure 26: Horizontal Stabilizer To Fuselage Attachment
PROCEDURE (INSTALLATION) Reverse the above procedure (removal), paying close attention to the following:  Inspect all bolts, nuts and screws for damage. Replace if necessary.  Do not reuse lock-nuts. Fit new.  Tighten the lock-nuts sufficiently, observe the correct placement of washers (refer to Figure 26) and note that the bolts are installed with the bolt heads head facing to the nose of the aircraft.
Page 129: Elevator Trim Tab Motor Removal / Installation
As needed. Inspection panel and trim tab motor screws. The above list is not necessarily a complete list of all material needed. Refer to the Sling 4 construction manual. AUTHORISED PERSONNEL Any person performing maintenance of any kind on the aircraft or any component thereof must do so in accordance with national legislation.
Page 130 PROCEDURE (REMOVAL) Remove the elevator trim motor inspection cover (1) (under the port elevator) by unscrewing the button head screws (2). Note that this wire (orange / white) is connected to the yellow wire (on the aircraft side) for the MGL SP10 trim system. Refer to the connection table under PROCEDURE (INSTALLATION) below.
Page 131 PROCEDURE (INSTALLATION) Reverse the above procedure (removal), paying close attention to the following:  Inspect all bolts and / or screws for damage. Replace if necessary.  Apply thread locking sealant to the trim tab motor retaining screws before fitment. ...
Page 132: Elevator Adjustment
As needed. Inspection panel screws. The above list is not necessarily a complete list of all material needed. Refer to the Sling 4 construction manual. AUTHORISED PERSONNEL Any person performing maintenance of any kind on the aircraft or any component thereof must do so in accordance with national legislation.
Page 133: Figure 27: Elevator Adjustment
PROCEDURE Retain any bolts, nuts (except lock-nuts) spacers, screws and washers (with the exception of lock- washers) for reassembly. Remove the front seats (refer to paragraph 4.3.2.1). Remove the front floor inspection panels by undoing the button-head screws. Remove the rear cabin floor centre inspection panel.
Page 134 Apply thread locking sealant to the inspection cover screws before fitment. Do not over tighten. Verify correct travel and full and free movement before flight. DOCUMENT No.: REVISION: 1.2 DATE: 2014/11/10 DC-MAM-001-X-C-2 Page 116...
Page 135: Elevator Trim Tab Adjustment
NOTES Split pin. The above list is not necessarily a complete list of all material needed. Refer to the Sling 4 construction manual. AUTHORISED PERSONNEL Any person performing maintenance of any kind on the aircraft or any component thereof must do so in accordance with national legislation.
Page 136 PROCEDURE Turn the Master switch ON. Trim the trim tab to the maximum down deflection (i.e. the aircraft will pitch up in flight). Turn the Master switch OFF. Loosen the lock nut (1), i.e. screw it backward on the threaded rod (2), away from the eye- bolt (3).
Page 137: Elevator Autopilot Servo / Servo Pushrod Removal / Installation
As needed. Servo mounting screws. The above list is not necessarily a complete list of all material needed. Refer to the Sling 4 construction manual. AUTHORISED PERSONNEL Any person performing maintenance of any kind on the aircraft or any component thereof must do so in accordance with national legislation.
Page 138 PROCEDURE (REMOVAL) Retain any bolts, nuts (except lock-nuts) spacers, screws and washers (with the exception of lock- washers) for reassembly. Remove the rear seat (refer to paragraph 4.3.2.2). Undo the bolt (1) connecting the control arm of the servo (2) to the pushrod (3). Undo the screws (4) retaining the servo to the bracket (5).
Page 139: Figure 28: Autopilot Elevator Servo Installation
PROCEDURE (INSTALLATION) Reverse the above procedure (removal), paying close attention to the following:  Inspect all bolts, nuts and screws for damage. Replace if necessary.  Do not reuse lock-nuts. Fit new.  The signal cable connector must be secured to the servo motor before installing the motor, otherwise there may not be enough space to insert and manipulate a tool to tighten the connector securing screws.
Page 140: Figure 29: Autopilot Elevator Servo Pushrod -Torque Tube End
Ensure the applicable aircraft control(s) is (are) free and does not bind with the servo installed. Follow any applicable procedures in the latest revision of the MGL Avionics EFIS integrated autopilot user and installation manual to complete installation of the servo. Before flight, test the servo for correct operation (refer to the latest revision of the MGL Avionics EFIS integrated autopilot user and installation manual).
Page 141: Vertical Tail And Rudder
VERTICAL TAIL AND RUDDER 4.2.2 Figure 30: Vertical tail and rudder. Refer to Figure 30. The vertical (1) stabiliser and rudder (2) consist of all-metal light alloy structures. The rudder horn (3) extends to the vertical stabilizer leading edge and has a composite tip on which navigation lights (4) and an aerial may be fitted.
Page 142: Rudder Control System
4.2.2.1 RUDDER CONTROL SYSTEM Figure 31: Rudder control system. Refer to Figure 31. The control system layout is two steel cables attached to the rudder control horn at the bottom of the rudder. The cables are supported and aligned by cable guides. The cables terminate on two rudder pedal control horns.
Page 143: Rudder Removal / Installation
Orange paint. As needed. The above list is not necessarily a complete list of all material needed. Refer to the Sling 4 construction manual. AUTHORISED PERSONNEL Any person performing maintenance of any kind on the aircraft or any component thereof must do so in accordance with national legislation.
Page 144 PROCEDURE (REMOVAL) Retain bolts, spacers, screws and washers (with the exception of lock-washers), as applicable, for reassembly. Disconnect the control cables (1) from the rudder control horn (2). Push and retain the rudder to one side to gain easier access to the rudder hinges. Support the rudder and loosen and remove the hinge bolts.
Page 145: Figure 32: Rudder To Vertical Stabilizer Hinge Connection
PROCEDURE (INSTALLATION) 1. Reverse the above procedure, paying close attention to the following:  Inspect all bolts, nuts and screws for damage. Replace if necessary.  Do not reuse lock-nuts, lock-washers or split pins, as applicable. Fit new.  Tighten the lock-nuts on the bolts through the rudder hinges sufficiently, observe the correct placement of washers (refer to Figure 32) and note that the bolts are installed with their heads facing upwards.
Page 146: Figure 33: Rudder Cable Connection
 Tighten the lock-nuts on the bolts attaching the rudder cables sufficiently, observe the correct placement of washers (refer to Figure 33) and note that the bolts are installed with their heads facing upwards. AN3-7A bolt AN3 washer (0.8 mm / 0.032”) AN3 washer (1.6 mm / 0.063”) AN3 lock-nut (Nyloc) Refer to paragraph 16 for hardware...
Page 147: Vertical Stabilizer Removal
As needed. Fairing screws. The above list is not necessarily a complete list of all material needed. Refer to the Sling 4 construction manual. AUTHORISED PERSONNEL Any person performing maintenance of any kind on the aircraft or any component thereof must do so in accordance with national legislation.
Page 148: Document No.: Revision
PROCEDURE (REMOVAL Retain bolts, spacers, screws and washers (with the exception of lock-washers), as applicable, for reassembly. Remove the rudder (refer to paragraph 4.2.2.2). Remove the empennage-to-fuselage fairing (1), by unscrewing the button head screws retaining it. Remove the side panel (2) on each side of the fuselage, by unscrewing the button head screws (3) and retaining it.
Page 149: Figure 34: Vertical Stabilizer To Fuselage Connection
Support the vertical tail and unfasten the bolts (5) retaining the vertical tail to the fuselage. Note that the six bottom bolts in the rear support screw into anchor nuts attached to the fuselage. 5, both sides Figure 34: Vertical stabilizer to fuselage connection. AN3 washer (0.8 mm / 0.032”) AN3-4A bolt AN3-5A bolt...
Page 150 PROCEDURE (INSTALLATION) Reverse the above procedure (removal), paying close attention to the following:  Inspect all bolts, nuts and screws for damage. Replace if necessary.  Do not reuse lock-nuts, lock-washers or split pins, as applicable. Fit new.  Observe the correct placement of washers (refer to Figure 34). ...
Page 151: Rudder Pedal Adjustment
4.2.2.4 RUDDER PEDAL ADJUSTMENT TOOLS / EQUIPMENT REQUIRED ITEM QUANTITY NOTES 3/8 Spanner. The above list is not necessarily a complete list of all required tools and equipment needed. A calibrated torque wrench (with adequate range) and the correct size (as implied by the above tool list) accessories (sockets etc.) are implied for torqueing bolts / nuts, if applicable.
Page 152: Rudder Cable Tension Adjustment
As needed. Inspection panels screws. The above list is not necessarily a complete list of all material needed. Refer to the Sling 4 construction manual. AUTHORISED PERSONNEL Any person performing maintenance of any kind on the aircraft or any component thereof must do so in accordance with national legislation.
Page 153: Figure 35 : Rudder Cable Tension Adjustment
PROCEDURE (ADJUSTMENT) Retain bolts, spacers, screws and washers (with the exception of lock-washers), as applicable, for reassembly. Remove the rear seats (refer to paragraph 4.3.2.2). Remove the inspection panels in the baggage compartment floor. Support the aircraft such that the nose wheel is in the air. The nose gear strut must swivel freely.
Page 154 Loosen the screws on the angled brackets (3), adjust the brackets so that when the rudder is straight the cable stops (4) are hard against the angled brackets. Tighten the screws. Verify that with the rudder centred there is only a very slight tension on the rear part of the rudder cable.
Page 155: Fuselage
FUSELAGE REAR FUSELAGE 4.3.1 The aft part of the fuselage (tail cone) is an aluminium alloy semi-monocoque structure. A number of stringers carry through to the centre fuselage for strength and rigidity. Supporting brackets for the vertical and horizontal stabilisers are attached to the rear formers at the tail section. A cross brace with a guide for the elevator push/pull rod is mounted in the rear fuselage.
Page 156: Centre Fuselage
CENTRE FUSELAGE 4.3.2 The centre fuselage accommodates the pilot and passenger seating (x4), the flight controls and instrument panel. Seats are removable. 4.3.2.1 FRONT SEAT REMOVAL AND INSTALLATION AUTHORISED PERSONNEL Any person performing maintenance of any kind on the aircraft or any component thereof must do so in accordance with national legislation.
Page 157 PROCEDURE (REMOVAL) Pull the handle (1) (located at the front of the seat, in the middle of the centre cut-out) towards the nose of the aircraft, to release / operate the catch mechanism securing the seat to the aircraft. Slide the seat clear of its railings and carefully lift the seat clear of the aircraft. PROCEDURE (INSTALLATION) Pull the handle forward, fit the seat into place and release / push back the handle.
Page 158: Rear Seat Removal And Installation
4.3.2.2 REAR SEAT REMOVAL AND INSTALLATION TOOLS / EQUIPMENT REQUIRED ITEM QUANTITY NOTES Flat screwdriver. The above list is not necessarily a complete list of all required tools and equipment needed. A calibrated torque wrench (with adequate range) and the correct size (as implied by the above tool list) accessories (sockets etc.) are implied for torqueing bolts / nuts, if applicable.
Page 159 PROCEDURE (REMOVAL) Unlock the sliding catch (1) (located on the back of the seat upright(s)) retaining the seat upright(s) to the fuselage. Back of rear seat upright. Undo the three Dzus fasteners (passing through three eyelets (2)) retaining the seat assembly to the baggage compartment floor. Remove the seat. PROCEDURE (INSTALLATION) Inspect the Dzus fasteners for damage.
Page 160: Canopy And Windshield Cleaning
4.3.2.3 CANOPY AND WINDSHIELD CLEANING CAUTION Never clean the canopy / windshield under dry conditions and never use petrol, alcohol or chemical solvents. Never dust the canopy under dry conditions. The canopy and windshield may only be cleaned by washing it with a sufficient quantity of lukewarm water and an adequate quantity of detergents suitable for polymethyl methacrylate (Perspex).
Page 161: Forward Fuselage And Firewall
FORWARD FUSELAGE AND FIREWALL 4.3.3 The forward fuselage accommodates the engine mount, engine and firewall forward / firewall mounted equipment and engine cowling. Refer to paragraph 14 for a schematic showing the equipment (and their positions) mounted on the firewall (engine side). Refer to paragraph 5.1 with regard to the engine cowling.
Page 162: Landing Gear
LANDING GEAR MAIN GEAR 4.4.1 Figure 36: Main landing gear. Refer to figure Figure 36. Refer to paragraph 1.7. The main landing gear consists of single section composite struts (1) attached (to the fuselage) using four bolts (2) threaded through bushings laid into the struts.
Page 163: Main Wheel Fairing Removal / Installation
As needed. Bolt retaining fairing to main axle spacer. The above list is not necessarily a complete list of all material needed. Refer to the Sling 4 construction manual. AUTHORISED PERSONNEL Any person performing maintenance of any kind on the aircraft or any component thereof must do so in accordance with national legislation.
Page 164 PROCEDURE (REMOVAL) Retain any bolts, nuts (except lock-nuts) spacers, screws and washers (with the exception of lock- washers) for reassembly. 1. Remove the inside half (1) of the fairing by unscrewing all button head screws (2) that hold the fairing to the support plate and hold the inner and outer fairing sections to one another. 4, 5 2.
Page 165: Main Wheel Removal / Installation
Orange paint. As needed. The above list is not necessarily a complete list of all material needed. Refer to the Sling 4 construction manual. AUTHORISED PERSONNEL Any person performing maintenance of any kind on the aircraft or any component thereof must do so in accordance with national legislation.
Page 166 PROCEDURE (REMOVAL) Retain any bolts, nuts (except lock-nuts) spacers, screws and washers (with the exception of lock- washers) for reassembly. Remove the main wheel fairing. Refer to paragraph 4.4.1.1. Hoist the aircraft onto supports. Unfasten the two bolts (1) holding the brake callipers together and remove the rear (towards the wheel) calliper assembly (2), which will come away in two parts (3).
Page 167 PROCEDURE (INSTALLATION) Reverse the above procedure (removal) for installation, paying close attention to the following:  Inspect all bolts and / or screws for damage. Replace if necessary.  Inspect the rubber o-rings (1) on the spacer. Replace if necessary. ...
Page 168: Main Wheel Axle And Brake Mechanism Removal
As needed. Brake line fittings - if decoupled. The above list is not necessarily a complete list of all material needed. Refer to the Sling 4 construction manual. AUTHORISED PERSONNEL Any person performing maintenance of any kind on the aircraft or any component thereof must do so in accordance with national legislation.
Page 169 PROCEDURE (REMOVAL) Retain any bolts, nuts (except lock-nuts) spacers, screws and washers (with the exception of lock- washers) for reassembly. 1. Remove the wheel fairing (refer to paragraph 4.4.1.1). 2. Remove the wheel (refer to paragraph 4.4.1.2). 3. Ensure that the aircraft cannot roll / move (if only one wheel jacked up) and release the park brake.
Page 170 5. If required, the brake mechanism (2) can be disconnected from the brake line (5). Refer to paragraph 9.1 for draining the brake fluid before disconnecting here. Blank off the brake fluid line to prevent drip and spillage. Disconnect brake line here 6.
Page 171: Figure 37: Main Wheel Axle Installation
Main undercarriage strut Main wheel fairing mounting bracket AN4-22A bolt AN4 washer (1.6 mm / 0.063”) AN4 lock-nut (Nyloc) Refer to paragraph 16 for hardware designations Figure 37: Main wheel axle installation. DOCUMENT No.: REVISION: 1.2 DATE: 2014/11/10 DC-MAM-001-X-C-2 Page 153...
Page 172: Main Wheel Disassembly / Assembly
Orange paint. As needed. The above list is not necessarily a complete list of all material needed. Refer to the Sling 4 construction manual. AUTHORISED PERSONNEL Any person performing maintenance of any kind on the aircraft or any component thereof must do so in accordance with national legislation.
Page 173 PROCEDURE (DISASSEMBLY) Retain any bolts, nuts (except lock-nuts) spacers, screws and washers (with the exception of lock- washers) for reassembly. 1. Remove the wheel (refer to paragraph 4.4.1.2). 2. Mark the tyre position on the rim and mark the hub halves for correct realignment during assembly.
Page 174 PROCEDURE (ASSEMBLY) In the procedure below, align according to the marks made during disassembly. Remove the valve cap. Inflate the inner tube slightly to give it shape and insert into the tyre. Seat the tyre (with inner tube inside) on the wheel hub half with the cut-out for the valve tube, taking care that the valve tube fits properly through the cut-out.
Page 175: Main Wheel Bearing Removal / Installation And Lubrication
As needed. Refer to paragraph 1.4. The above list is not necessarily a complete list of all material needed. Refer to the Sling 4 construction manual. AUTHORISED PERSONNEL Any person performing maintenance of any kind on the aircraft or any component thereof must do so in accordance with national legislation.
Page 176: Main Gear Removal / Installation
As needed. Brake line fittings. The above list is not necessarily a complete list of all material needed. Refer to the Sling 4 construction manual. AUTHORISED PERSONNEL Any person performing maintenance of any kind on the aircraft or any component thereof must do so in accordance with national legislation.
Page 177 PROCEDURE (REMOVAL) Note: The procedure below describes removing the main gear with the main wheels attached. That would necessitate disconnecting the brake pipes from the brake assembly and separating the lines from the strut. The main wheel assemblies (wheel, brake assembly and axle) can be removed (from the strut) before the strut is dropped out from the aircraft, which does not require the disconnection of the brake pipes at the brake assembly, but do require the separation of the brake lines from the strut.
Page 178 Remove the cover plates on the underside of the fuselage (cover plates between the wings and the centre fuselage). Drill out the rivets retaining the main gear cover plate on the bottom aircraft fuselage. Support the main gear assembly and undo and remove the four bolts and nuts retaining the gear to the aircraft.
Page 179: Figure 38: Main Gear Installation
PROCEDURE (INSTALLATION) Reverse the above procedure (removal), paying close attention to the following:  Inspect all bolts, nuts and screws for damage. Replace if necessary.  Do not reuse the lock-nuts. Fit new.  Torque the bolts / lock-nuts to the correct value (refer to paragraph 1.5.2), observe the correct placement of washers (refer to Figure 38) and note that the bolts are installed with the bolt heads head facing towards the rear of the aircraft.
Page 180: Nose Gear
NOSE GEAR 4.4.2 Refer to Figure 39. Refer to paragraph 1.7. The nose gear strut is attached to the engine mount (1) with two guide brackets (2). A circular spring (3) provides suspension. The steel strut attaches to a conventional U-shaped fork (4) supporting an axle bolt (5).
Page 181: Nose Wheel Fairing Removal / Installation
As needed. Fairing screws. The above list is not necessarily a complete list of all material needed. Refer to the Sling 4 construction manual. AUTHORISED PERSONNEL Any person performing maintenance of any kind on the aircraft or any component thereof must do so in accordance with national legislation.
Page 182: Nose Wheel Removal / Installation
Orange paint. As needed. The above list is not necessarily a complete list of all material needed. Refer to the Sling 4 construction manual. AUTHORISED PERSONNEL Any person performing maintenance of any kind on the aircraft or any component thereof must do so in accordance with national legislation.
Page 183 PROCEDURE (REMOVAL) Retain any bolts, nuts (except lock-nuts) spacers, screws and washers (with the exception of lock- washers) for reassembly. Remove the nose wheel fairing. Refer to paragraph 4.4.2.1. Lift and support the front of aircraft in such a manner as to lift the nose wheel off the ground. Unfasten the lock-nut (1) retaining the nose wheel.
Page 184: Figure 40: Nose Wheel Installation
PROCEDURE (INSTALLATION) Reverse the above procedure (removal), paying close attention to the following:  Inspect all bolts, nuts and screws for damage. Replace if necessary.  Do not reuse the lock-nut. Fit new.  Take care to place / align the spacers correctly so as not to bend them the when tightening the lock-nut.
Page 185: Nose Wheel Disassembly / Assembly
Orange paint. As needed. The above list is not necessarily a complete list of all material needed. Refer to the Sling 4 construction manual. AUTHORISED PERSONNEL Any person performing maintenance of any kind on the aircraft or any component thereof must do so in accordance with national legislation.
Page 186 PROCEDURE (DISASSEMBLY) Retain any bolts, nuts (except lock-nuts) spacers, screws and washers (with the exception of lock- washers) for reassembly. Remove the wheel (refer to paragraph 4.4.2.2). Mark the tyre position on the rim and mark the hub halves for correct realignment during assembly.
Page 187: Figure 41: Front Wheel Hub Assembly
Secure the two wheel hub halves and bearing mount assembly together. Take care not to catch the inner tube between the two hub halves. Observe correct placement of washers. Note that the nuts are on the side of the valve. Tighten the bolts / nuts sufficiently. Inspect the o-ring for damage.
Page 188: Nose Wheel Bearing Removal / Replacement
4.4.2.4 NOSE WHEEL BEARING REMOVAL / REPLACEMENT TOOLS / EQUIPMENT REQUIRED ITEM QUANTITY NOTES Suitable press for bearings. The above list is not necessarily a complete list of all required tools and equipment needed. A calibrated torque wrench (with adequate range) and the correct size (as implied by the above tool list) accessories (sockets etc.) are implied for torqueing bolts / nuts, if applicable.
Page 189: Nose Gear Removal / Installation
4.4.2.5 NOSE GEAR REMOVAL / INSTALLATION TOOLS / EQUIPMENT REQUIRED ITEM QUANTITY NOTES 3/8 Spanner. 7/16 Spanner. ½ inch Spanner. The above list is not necessarily a complete list of all required tools and equipment needed. A calibrated torque wrench (with adequate range) and the correct size (as implied by the above tool list) accessories (sockets etc.) are implied for torqueing bolts / nuts, if applicable.
Page 190 PROCEDURE (REMOVAL) Retain any bolts, nuts (except lock-nuts) spacers, screws and washers (with the exception of lock- washers) for reassembly. 1. Remove the cowling around the engine area (refer to paragraph 5.1.1). 2. Hoist the aircraft onto supports. 3. Disconnect the two rudder pushrods (1) by loosening the bolts (2) through the rod-end bearings. 4.
Page 191: Figure 42: Nose Gear Installation
PROCEDURE (INSTALLATION) Reverse the above procedure (removal), paying close attention to the following:  Inspect all bolts, nuts and screws for damage. Replace if necessary.  Do not reuse lock-nuts. Fit new.  Tighten the lock-nuts sufficiently, observe the correct placement of washers and bearings (refer to Figure 42) and note that the bolts are installed with the bolt heads head facing up.
Page 192: Power Plant
POWER PLANT This section provides a general description of the power plant section, comprising of the engine, the propeller, radiators and the cowling surrounding it, and provides descriptions of service and maintenance procedures applicable to the power plant and its subsystems. COWLING Figure 43: Engine cowling.
Page 193: Cowling Removal / Installation
COWLING REMOVAL / INSTALLATION 5.1.1 TOOLS / EQUIPMENT REQUIRED ITEM QUANTITY NOTES Flat screwdriver. 5/16 Spanner. 3 mm Allen key / hex drive. The above list is not necessarily a complete list of all required tools and equipment needed. A calibrated torque wrench (with adequate range) and the correct size (as implied by the above tool list) accessories (sockets etc.) are implied for torqueing bolts / nuts, if applicable.
Page 194 PROCEDURE (REMOVAL) TOP COWL: Release the eight Dzus fasteners located on the sides of the top cowling. Release the four Dzus fasteners located on the top of the top cowling, along the upper edge of the firewall. Once all Dzus fasteners are loose, remove the front and then side fasteners from their seating holes prior to removing those over the firewall.
Page 195 Release the four catches (4), one on each side of the coolant (5) and oil radiators (6). Also refer to Figure 43. Support the cowl and remove the six Dzus fasteners located around the firewall and on the bracket behind the nose wheel strut. Carefully move the cowl free from the aircraft.
Page 196: Engine
ENGINE The aircraft is fitted with a Rotax 914 UL engine. Refer to paragraph 1.3. Refer to the latest revision of the Rotax 914 UL operator’s manual and maintenance manuals for an in-depth description of the engine and extensive specifications and technical data. 5.2.1 GENERAL MAINTENANCE AND SERVICING Refer to and comply with the latest revision of the Rotax 914 UL engine operator’s manual and / or...
Page 197: Verifying Engine Oil Level
As needed. If required. Refer to paragraph 1.4. The above list is not necessarily a complete list of all material needed. Refer to the Sling 4 construction manual. AUTHORISED PERSONNEL Any person performing maintenance of any kind on the aircraft or any component thereof must do so in accordance with national legislation.
Page 198: Air Filter Removal, Cleaning And Replacement
Split pin. Only if in need of replacement. The above list is not necessarily a complete list of all material needed. Refer to the Sling 4 construction manual. AUTHORISED PERSONNEL Any person performing maintenance of any kind on the aircraft or any component thereof must do so in accordance with national legislation.
Page 199 PROCEDURE (REMOVAL) Retain the clamps for reassembly. Remove the safety wire (1) safety’ing the air filter housing (2) to the air intake manifold / turbocharger impeller (compressor) intake pipe clamp (3). Loosen the clamp (4) securing the air filter to the air intake manifold / turbocharger (5) opening.
Page 200 PROCEDURE (CLEANING) 1. Wash the filter in a solution of lukewarm water and soap. 2. Rinse in clean water until all soap solution is washed away. 3. Leave the filter to dry out thoroughly. 4. Lightly spray with filter oil (refer to paragraph 1.4). Do not overspray. CAUTION NEVER USE STEAM, CAUSTIC LIQUIDS, GASOLINE, STRONG DETERGENTS, PARTICLE REMOVING AGENTS OR COMPRESSED AIR TO CLEAN THE FILTER.
Page 201: Muffler / Heat Exchanger Assembly Removal / Replacement
5.2.8 MUFFLER / HEAT EXCHANGER ASSEMBLY REMOVAL / REPLACEMENT TOOLS / EQUIPMENT REQUIRED ITEM QUANTITY NOTES ½ inch Spanner. 10 mm Spanner. 9 mm Spanner. Flat screwdriver. The above list is not necessarily a complete list of all required tools and equipment needed. A calibrated torque wrench (with adequate range) and the correct size (as implied by the above tool list) accessories (sockets etc.) are implied for torqueing bolts / nuts, if applicable.
Page 202 PROCEDURE (REMOVAL) Retain any bolts, clamps, spacers, screws and washers (with the exception of lock-washers) for reassembly. 1. Remove the engine cowling (refer to paragraph 5.1.1). 2. Loosen the clamp (1) retaining the air pipe (2) to the assembly shroud (3). 3.
Page 203: Muffler / Heat Exchanger Disassembly / Assembly
As needed. For assembly. The above list is not necessarily a complete list of all material needed. Refer to the Sling 4 construction manual. AUTHORISED PERSONNEL Any person performing maintenance of any kind on the aircraft or any component thereof must do so in accordance with national legislation.
Page 204 PROCEDURE (DISASSEMBLY) Retain any bolts, nuts (except lock-nuts) spacers, screws and washers (with the exception of lock- washers) for reassembly. 1. Remove the heat exchanger / muffler assembly (refer to paragraph 5.2.8). 2. Drill out the line of rivets (1) clamping the shroud (2) plate together. Loosen the clamps (3) clamping the shroud to the muffler and slide the shroud off the muffler.
Page 205: Removal / Installation Of Oil And Coolant Radiators
5.2.10 REMOVAL / INSTALLATION OF OIL AND COOLANT RADIATORS TOOLS / EQUIPMENT REQUIRED ITEM QUANTITY NOTES 5/16 Spanner. 3 mm Allen key. The above list is not necessarily a complete list of all required tools and equipment needed. A calibrated torque wrench (with adequate range) and the correct size (as implied by the above tool list) accessories (sockets etc.) are implied for torqueing bolts / nuts, if applicable.
Page 206: Oil Cooler / Radiator Pipe Connection / Disconnection
Oil cooler fittings. Two-ear clamps (20 mm). The above list is not necessarily a complete list of all material needed. Refer to the Sling 4 construction manual. AUTHORISED PERSONNEL Any person performing maintenance of any kind on the aircraft or any component thereof must do so in accordance with national legislation.
Page 207 PROCEDURE (CONNECTION) Apply thread locking sealant to the threads of couplings (1) and (2) and fit into the radiator (3). Slip a two-ear clamp (4) over each pipe (5), slip the pipes over the couplings (2) and move the two-ear clamps into position. Crimp the two ear plugs.
Page 208 PROCEDURE (DISCONNECTION) Drain fluids as required. Remove the two-ear clamps (refer to paragraph 15.1) and pull the pipes from the fittings. Blank off oil pipes if to be unconnected for a substantial period of time, to prevent drip and entry of foreign material. Unscrew the fittings from the radiator, if required.
Page 209: Coolant Radiator Pipe Connection / Disconnection
Safety wire. As needed. The above list is not necessarily a complete list of all material needed. Refer to the Sling 4 construction manual. AUTHORISED PERSONNEL Any person performing maintenance of any kind on the aircraft or any component thereof must do so in accordance with national legislation.
Page 210 PROCEDURE (CONNECTION) Slip a hose clamp over each pipe before connection Push the pipe(s) over the radiator connection(s). Move the hose clamp(s) into place and tighten. Do not over tighten, as this may damage the pipes. Use safety wire and secure the insulation blanket(s) around the pipe(s). Inspect for security of attachment.
Page 211: Engine Removal / Installation
As / if needed. Loctite 577 for oil pipe fitting threads. The above list is not necessarily a complete list of all material needed. Refer to the Sling 4 construction manual. AUTHORISED PERSONNEL Any person performing maintenance of any kind on the aircraft or any component thereof must do so in accordance with national legislation.
Page 212 PROCEDURE (REMOVAL) The procedures described below are general. Reference must be made to the applicable equipment / system documentation with regard to the connection and disconnection of mechanical cables, electrical wires, signal wires and fluid piping. The following documents have relevance: ...
Page 213 5. Cut the tie wraps (3) retaining the coolant overflow bottle to the firewall. Removing the overflow bottle with the engine has the advantage that the cooling system remains closed. Alternatively remove the pipe (4) from the bottle. 6. Disconnect the fuel supply pipe (between the fuel pump assembly and the engine) either at the fuel pump assembly side or at the engine side.
Page 214 14. Disconnect the two plugs (6) between the TCU and the waste gate servo (7). This allows the servo to be removed with the engine (by undoing the two bolts (8) retaining it to the firewall), keeping the servo-to-waste gate cable connection in place (and negating the need to re-adjust the cable after reconnection).
Page 215: Figure 44: Engine Removal
18. With the engine securely and adequately supported, undo the four bolts (12) and nuts retaining the engine suspension frame (13) to the engine mount (14). Remove the bolts. Figure 44: Engine removal. Carefully move the engine free from the engine mount. Alternatively (to separating the engine suspension frame from the engine mount) the engine can also be removed (as a unit with the nose gear) by undoing the four bolts retaining the engine mount to the firewall.
Page 216: Figure 45: Engine Installation
Reverse the above procedure (removal), paying close attention to the following:  Inspect all bolts, nuts and screws for damage. Replace if necessary.  Do not reuse lock-nuts. Fit new.  Do not over tighten clamps.  Apply thread locking sealant to the oil reservoir pipe fittings (if removed). ...
Page 217 2. Inspect the rubber vibration dampers for damage before fitment. Replace if necessary. 3. Place a drop of oil (engine oil) on the threads before fitment and torque the four bolts and nuts retaining the engine suspension frame to the engine mount to the recommended value (refer to paragraph 1.5.2).
Page 218: Engine Control System (Throttle And Choke)
5.2.14 ENGINE CONTROL SYSTEM (THROTTLE AND CHOKE) Each carburettor throttle control lever is attached to the throttle lever (in cabin) by a separate Bowden cable. Friction on the throttle lever (in cabin) is effected by two friction discs (refer to Figure 46). For attachment of the Bowden cable to the carburettor throttle control lever and adjustment refer to the latest revision / edition of the Rotax 914 UL engine installation manual and maintenance manuals, as applicable.
Page 219: Throttle Lever Friction Adjustment
5.2.14.1 THROTTLE LEVER FRICTION ADJUSTMENT TOOLS / EQUIPMENT REQUIRED ITEM QUANTITY NOTES 3/8 Spanner 2 mm Allen key, 2.5 mm Allen key 1 each Inspection panel screws. The above list is not necessarily a complete list of all required tools and equipment needed. A calibrated torque wrench (with adequate range) and the correct size (as implied by the above tool list) accessories (sockets etc.) are implied for torqueing bolts / nuts, if applicable.
Page 220: Throttle Lever Friction Disc Replacement
5.2.14.2 THROTTLE LEVER FRICTION DISC REPLACEMENT TOOLS / EQUIPMENT REQUIRED ITEM QUANTITY NOTES 3/8 Spanner 2 mm Allen key, 2.5 mm Allen key 1 each Inspection panel screws. The above list is not necessarily a complete list of all required tools and equipment needed. A calibrated torque wrench (with adequate range) and the correct size (as implied by the above tool list) accessories (sockets etc.) are implied for torqueing bolts / nuts, if applicable.
Page 221: Figure 46: Throttle Lever Friction Disc Installation
PROCEDURE (REMOVAL) Retain any bolts, clamps, spacers, screws and washers (with the exception of lock-washers) for reassembly. Remove the centre console side inspection panel. Remove the split pin and discard. Undo the castle nut, support the throttle lever and pull out the bolt, and remove the friction washers. PROCEDURE (INSTALLATION) Reverse the above procedure (removal), paying close attention to the following: ...
Page 222: Propeller
PROPELLER The aircraft is fitted with a three blade Airmaster 332 72” variable pitch / constant speed propeller, controllable from the cabin. Refer to the latest revision of the propeller operator’s manual for detailed information. GENERAL MAINTENANCE AND SERVICE 5.3.1 Refer to and comply with the latest revision of the propeller operator’s manual for service requirements and procedures.
Page 223: Spinner Removal / Replacement
SPINNER REMOVAL / REPLACEMENT 5.3.3 TOOLS / EQUIPMENT REQUIRED ITEM QUANTITY NOTES Phillips screwdriver. The above list is not necessarily a complete list of all required tools and equipment needed. A calibrated torque wrench (with adequate range) and the correct size (as implied by the above tool list) accessories (sockets etc.) are implied for torqueing bolts / nuts, if applicable.
Page 224 PROCEDURE (REMOVAL) Retain any bolts, nuts (except lock-nuts) spacers, screws and washers (with the exception of lock- washers) for reassembly. 1. Undo the screws (1) retaining the spinner (2) to the spinner bulkhead (3). PROCEDURE (INSTALLATION) 1. Reverse the above procedure (removal) to install the spinner, paying close attention to the following: ...
Page 225: General Considerations When Fitting Propeller Extension To Engine Flange
GENERAL CONSIDERATIONS WHEN FITTING PROPELLER EXTENSION TO ENGINE 5.3.4 FLANGE BOLT SIZE / TYPE TO FIT PROPELLER EXTENSION TO ENGINE FLANGE / ENGINE FLANGE LUGS SLIP RING DISC OR EXTERNAL ALTERNATOR PROPELLER EXTENSION FITTED DIRECTLY TO DRIVE PULLEY FITTED BETWEEN ENGINE ENGINE FLANGE / LUGS FLANGE AND PROPELLER EXTENSION M8 x 40 mm hex bolt, Class 8.8.
Page 226: Propeller Removal / Installation
PROPELLER REMOVAL / INSTALLATION 5.3.5 TOOLS / EQUIPMENT REQUIRED ITEM QUANTITY NOTES Calibrated torque wrench, minimum range of at least 25 Nm. Installation. ½ inch Hex socket (to fit item 1). Installation. 13 mm Hex socket (to fit item 1). Installation.
Page 227 PROCEDURE (REMOVAL) (STANDARD) Retain any bolts, nuts (except lock-nuts) spacers, screws and washers (with the exception of lock-washers) for reassembly. Support the propeller and undo the bolts (1) securing the propeller extension (2) to the engine flange (3). Slowly move the propeller assembly away from the engine flange, until the signal wire connections (4) are exposed.
Page 228 PROCEDURE (INSTALLATION) (STANDARD) Reverse the above procedure (removal) to install the propeller onto the engine, paying close attention to the following:  Do not reuse lock-washers. Fit new.  Inspect all bolts, nuts and screws for damage, cracks, corrosion, proper thread and cleanliness.
Page 229: Figure 48: Airmaster Propeller Installation (Standard)
Loctite 222 to bolts (C) Loctite 243 to bolts (B) 2 x 8 mm Wedge lock-washer M8 x 40 mm bolt, Class 8.8. AN5-15A bolt. Figure 48: Airmaster propeller installation (standard). Paint orange creep marks on the bolts. After the correct installation of the propeller and before flight, inspect for security of attachment or any damage which may have been incurred during the installation procedure.
Page 230 PROCEDURE (REMOVAL) (WITH VACUUM PUMP FITTED) Retain any bolts, nuts (except lock-nuts) spacers, screws and washers (with the exception of lock-washers) for reassembly. REMOVING WITHOUT PROPELLER EXTENSION Support the propeller and undo the bolts (1) securing the propeller assembly to the propeller extension (2).
Page 231 If required to separate the slip-ring disc (4) from the propeller extension, undo the nuts (6) securing the signal wires (from the propeller extension) to the slip-ring disc. Before doing so, use coloured stickers or paint to mark the connection of the coloured signal wires to the disc terminals / connections, or place an alignment mark on the propeller extension and slip-ring disc.
Page 232: Figure 49: Airmaster Propeller Signal Wire To Slip-Ring Disc Connection (Vacuum Pump Fitted)
PROCEDURE (INSTALLATION) (WITH VACUUM PUMP FITTED) 1. Reverse the above procedure (removal) to install the propeller onto the engine, paying close attention to the following:  Do not reuse lock-washers and lock-nuts. Fit new.  Inspect all bolts, nuts and screws for damage, cracks, corrosion, proper thread and cleanliness.
Page 233: Figure 50: Airmaster Propeller Installation (Vacuum Pump Fitted)
 Ensure that the propeller extension is correctly aligned with engine flange before tightening the bolts.  Observe washer placement (refer to Figure 50). Torque the bolts to the correct value (refer to paragraph 1.5.2). Torque in a star pattern / sequence as shown in Figure 47.
Page 234: Figure 51: Propeller Installation (External Alternator Fitted)
PROCEDURE (REMOVAL) (WITH EXTERNAL ALTERNATOR FITTED) Retain any bolts, nuts (except lock-nuts) spacers, screws and washers (with the exception of lock-washers) for reassembly. The procedure is in general the same as that for the standard installation removal. When the bolts joining the propeller extension, alternator drive pulley and engine flange / engine flange lugs are removed, the alternator drive pulley can be separated, but cannot be removed from the engine without further disassembly.
Page 235: Propeller Assembly / Disassembly
Loctite 222. As needed. The above list is not necessarily a complete list of all material needed. Refer to the Sling 4 construction manual. AUTHORISED PERSONNEL Any person performing maintenance of any kind on the aircraft or any component thereof must do so in accordance with national legislation.
Page 236 PROCEDURE (DISASSEMBLY) Retain any bolts, nuts (except lock-nuts) spacers, screws and washers (with the exception of lock- washers) for reassembly. 1. Remove the spinner dome (refer to paragraph 5.3.3). 2. Remove the propeller assembly from the aircraft (refer to paragraph 5.3.4). 3.
Page 237: Propeller Adjustment / Set-Up
 Carefully clean and dry the propeller extension and spinner hub. Ensure that no oil traces are present.  Inspect the spinner dome, the spinner bulkhead and propeller extension for cracks, deformations or signs of any damage.  Ensure that the propeller extension is correctly aligned with propeller assembly before tightening the bolts.
Page 238: Fuel System
6. FUEL SYSTEM Left fuel tank Rotax 914 UL engine Right fuel tank Fuel flow sensor Fuel filter(s) Fuel pressure sensor Fuel selector (LEFT, Fuel line to carburettors ( 8 mm inner diameter) RIGHT,OFF) Fuel return line to tanks Electric fuel pumps (6 mm inner diameter from fuel selector to tanks) (8 mm inner diameter from engine to fuel selector) Figure...
Page 239 An inline mesh fuel filter (C) is fitted (in the centre console between the two front seats) in the fuel line from each tank to a fuel selector valve (D), which is mounted on the lower centre instrument panel in the cockpit.
Page 240: General Service Information And Considerations
GENERAL SERVICE INFORMATION AND CONSIDERATIONS FUEL HOSE / PIPE TWO-EAR CLAMPS INNER DIAMETER OUTER DIAMETER 6 mm 12.5 mm (approximately) 13 mm 8 mm 14.5 mm (approximately) 15 mm When tie wrapping fuel pipes to the engine mount, other pipes or the aircraft structure to aid in routing / security of attachment, care should be taken that the inside cross sectional area of the pipe is not distorted to such an extent that it impedes or hampers the flow of fuel in any way.
Page 241: Fuel Filter Replacement
As needed. Inspection panel screws. The above list is not necessarily a complete list of all material needed. Refer to the Sling 4 construction manual. AUTHORISED PERSONNEL Any person performing maintenance of any kind on the aircraft or any component thereof must do so in accordance with national legislation.
Page 242 PROCEDURE Retain any bolts, clamps, spacers, screws and washers (with the exception of lock-washers) for reassembly. Fuel selector to OFF position. Drain the fuel from the wing tank(s) if necessary. Remove the central console side panelling to gain access to the fuel filters. Loosen the clamps (1) retaining the fuel pipes (2) to the fuel filters (3) and move the clamps back along the fuel lines.
Page 243: Fuel Selector Unit Removal / Installation
Two-ear pipe clamps (13 mm). Installation. The above list is not necessarily a complete list of all material needed. Refer to the Sling 4 construction manual. AUTHORISED PERSONNEL Any person performing maintenance of any kind on the aircraft or any component thereof must do so in accordance with national legislation.
Page 244 PROCEDURE (REMOVAL) Retain any bolts, clamps, spacers, screws and washers (with the exception of lock-washers) for reassembly. Access is gained to the unit from behind and below the instrument panel. Removing the centre console side inspection panel might ease access. Pull / raise the safety button (1) to reveal the screw (2) retaining the selector lever (3) to the selector valve unit.
Page 245: Figure 53: Fuel Selector Unit Installation
PROCEDURE (INSTALLATION) Reverse the above procedure (removal), paying close attention to the following:  Inspect all bolts and / or screws for damage. Replace if necessary.  Apply thread locking sealant to the selector unit retaining screws before fitting. Do not over tighten the button head screws. ...
Page 246: Fuel Selector Unit Assembly / Disassembly
As needed. Fuel hose fitting threads. The above list is not necessarily a complete list of all material needed. Refer to the Sling 4 construction manual. AUTHORISED PERSONNEL Any person performing maintenance of any kind on the aircraft or any component thereof must do so in accordance with national legislation.
Page 247: Figure 54: Fuel Selector Port Allocation And Fitting Orientation
The above schematic does not show the correct alignment for the fuel fittings. intended port RETURN SUPPLY / FEED identification only. ALLOCATION PORT FUEL PIPE INSIDE DIAMETER 8 mm From starboard tank (feed) 8 mm To engine / pumps (feed) 8 mm From port tank (feed) 6 mm...
Page 248: Fuel Pump Assembly Removal / Installation
Tie wraps, clear tubing. As needed. The above list is not necessarily a complete list of all material needed. Refer to the Sling 4 construction manual. AUTHORISED PERSONNEL Any person performing maintenance of any kind on the aircraft or any component thereof must do so in accordance with national legislation.
Page 249 PROCEDURE (REMOVAL) Retain any bolts, nuts (except lock-nuts) spacers, screws and washers (with the exception of lock- washers) for reassembly. 1. Fuel selector in OFF position. 2. Remove the cowlings (refer to paragraph 5.1.1). 3. Undo the button head screws (1) retaining the fuel pump assembly cover (2), slide the cover downwards and remove.
Page 250 Disconnect the fuel hoses (5) from the assembly, by removing the safety wire, pulling the fire resistant sleeving back and removing the two-ear clamps (refer to paragraph 15.1). Pull the fuel hoses from the pump frame connections (6) .Drain excess fuel in the lines into a container. Blank off any fuel lines to be left open for an extended time to avoid drip, spillage and contamination.
Page 251 7. Undo the two clamps (11) retaining the pump assembly to the firewall bracket and remove the assembly. Fuel Pump DOCUMENT No.: REVISION: 1.2 DATE: 2014/11/10 DC-MAM-001-X-C-2 Page 233...
Page 252 PROCEDURE (INSTALLATION) Reverse the above procedure (removal), paying close attention to the following:  Do not reuse lock-nuts. Fit new.  Inspect all bolts, nuts and screws for damage. Replace if necessary.  Do not tighten the cover button head screws excessively. ...
Page 253 Fit seal draft rubber strips (1) to the pump assembly bracket (2) before fitting the assembly to the firewall. 8 mm x 12 mm x 5 mm Seal draft rubber strips Before flight, perform an engine ground run and verify correct operation (of the fuel pumps) and correct fuel flow and pressure.
Page 254: Fuel Pump Removal / Installation From / Into Fuel Pump Assembly
Two-ear clamps (15 mm). 2 per pump. The above list is not necessarily a complete list of all material needed. Refer to the Sling 4 construction manual. AUTHORISED PERSONNEL Any person performing maintenance of any kind on the aircraft or any component thereof must do so in accordance with national legislation.
Page 255 PROCEDURE (REMOVAL) 1. Remove the fuel pump assembly (refer to paragraph 6.5), if required, else disconnect the applicable pump’s electrical wiring (refer to paragraph 6.5). 2. Remove (refer to paragraph 15.1) the two-ear clamps (1) on the rubber hoses (2) connecting the fuel pump to the surrounding pipe framework (3) and remove the pump (4) from the pipe frame.
Page 256: Fuel Tank Leak Repair
As needed. Refer to paragraph 1.4. The above list is not necessarily a complete list of all material needed. Refer to the Sling 4 construction manual. AUTHORISED PERSONNEL Any person performing maintenance of any kind on the aircraft or any component thereof must do so in accordance with national legislation.
Page 257: Fuel Tank Drain Removal / Installation (Draining Wing Tank)
NOTES 16 mm Spanner The above list is not necessarily a complete list of all material needed. Refer to the Sling 4 construction manual. AUTHORISED PERSONNEL Any person performing maintenance of any kind on the aircraft or any component thereof must do so in accordance with national legislation.
Page 258: Figure 56: Wing Tank Fuel Drain Installation
A fuel drain is installed for each fuel tank. The drain is located under each wing, near the wing root. The tank can be drained completely by removing (unscrewing) the drain. PROCEDURE (REMOVAL) Unscrew the fuel drain from the wing. Do not retain fibre washer. Drain fuel into suitable container.
Page 259: Fuel Level Sender Assembly Removal / Installation (From / To Fuel Tank)
As needed Fuel tank outlet / return line couplings. The above list is not necessarily a complete list of all material needed. Refer to the Sling 4 construction manual. AUTHORISED PERSONNEL Any person performing maintenance of any kind on the aircraft or any component thereof must do so in accordance with national legislation.
Page 260 The procedure is the same for the left and right tank fuel level sender assembly removal and installation. PROCEDURE (REMOVAL) Retain any bolts, nuts (except lock-nuts) spacers, screws and washers (with the exception of lock- washers) for reassembly. Remove the inspection hatch(es) under the leading edge(s) of the wing(s) to access the fuel tank end rib(s).
Page 261 PROCEDURE (INSTALLATION) Reverse the above procedure (removal) for installation, paying close attention to the following:  Ensure no loose material or tools are left in fuel tank cavity before fitting the fuel level sender / sender mounting plate.  Do not re-use the cork gasket or fibre washers. Fit new. ...
Page 262: Figure 57: Fuel Sender Installation Into Fuel Tank
M4 x 16 mm hex head stainless steel bolt M4 thin washer (stainless steel / plated) M4 Fibre washer Sender / sender bracket mounting plate Cork mounting gasket M4 lock-nut (Nyloc) (secures signal wire to terminal stud) Figure 57: Fuel sender installation into fuel tank. DOCUMENT No.: REVISION: 1.2 DATE: 2014/11/10...
Page 263: Replacing Fuel Level Sender Assembly Sensor
Refer to paragraph 1.4. 100 x 2.5 mm tie wrap The above list is not necessarily a complete list of all material needed. Refer to the Sling 4 construction manual. AUTHORISED PERSONNEL Any person performing maintenance of any kind on the aircraft or any component thereof must do so in accordance with national legislation.
Page 264 PROCEDURE (REMOVAL) The procedure is the same for the left and right tank fuel level sender assembly sensor removal and installation. Retain any bolts, nuts (except lock-nuts) spacers, screws and washers (with the exception of lock- washers) for reassembly. Remove the fuel level sender from the wing / wing end rib (refer to paragraph 6.9). Undo the nut (1) retaining the signal wire to the terminal stud, cut the tie-wrap and unwind the signal wire from the bracket (2).
Page 265 PROCEDURE (INSTALLATION) Reverse the above procedure (removal) for installation, paying close attention to the following:  Observe correct washer placement (refer to Figure 58).  The sensor is fitted to the bracket with the spindle pointing away (in opposite direction) from the 90 degree bend / plate / part of the bracket attached to the hexagonal tank cover / sender assembly plate, i.e.
Page 266: Figure 58: Fuel Level Sender Assembly Sensor Replacement
 Seal / lock (to the sensor spindle) the screw used to secure the float arm to the sensor spindle with fuel / fuel tank sealant. The fuel sealant must be allowed to dry for 48 hours before coming into contact with fuel. Use a multimeter set to measure resistance (set to the 200 Ω...
Page 267: Finger Strainer (On Fuel Pick-Up) Inspection
6.11 FINGER STRAINER (ON FUEL PICK-UP) INSPECTION TOOLS / EQUIPMENT REQUIRED ITEM QUANTITY NOTES Small angled mirror inspection tool Small pencil flashlight Source of compressed air (low pressure) The above list is not necessarily a complete list of all required tools and equipment needed. A calibrated torque wrench (with adequate range) and the correct size (as implied by the above tool list) accessories (sockets etc.) are implied for torqueing bolts / nuts, if applicable.
Page 268 A finger strainer (1) forms part of each fuel tank pick-up (2), located just inboard (in the tank) from the wing root end rib (3), immediately below the fuel level sender mounting plate (4). PROCEDURE (INSPECTION AND CLEANING) Remove the fuel level sender assembly / assembly mounting plate (refer to paragraph 6.9). Use a small angled mirror tool and small pencil flashlight / light source to inspect the finger strainer on the fuel pick-up.
Page 269: Avionics And Instruments
7. AVIONICS AND INSTRUMENTS The diagram below represents an instrument panel containing the required minimum instrumentation, together with typical back-up and additional instrumentation supplied with the aircraft. The instrument panel in any particular aircraft may differ from that illustrated in the diagram. Figure 59: Standard instrument panel (refer to key on next page).
Page 270: General Maintenance And Service Of Instruments
The aluminium instrument panel contains the bulk of the electrical, flight and engine instruments (refer to Figure 59). They are described as follows: Air vent(s) 18 Transponder Magneto and start switch 19 Manual propeller pitch control switch Fuel pump switches 20 Ballistic parachute deployment handle Charge warning light 21 Fuel selector valve handle...
Page 271: Removal / Installation Of Instrument Panel And Instruments
As needed. Instrument panel retaining screws. The above list is not necessarily a complete list of all material needed. Refer to the Sling 4 construction manual. AUTHORISED PERSONNEL Any person performing maintenance of any kind on the aircraft or any component thereof must do so in accordance with national legislation.
Page 272 PROCEDURE (REMOVAL) PANEL: The instrument panel may be removed by removing the button head screws on the outside edge of the panel. Tilt the panel forward (into the cabin) to reveal the connections to the instruments and panel mounted equipment. INSTRUMENTS: 1.
Page 273: Pitot And Static Systems
PITOT AND STATIC SYSTEMS Refer to Figure 60. The system consists of a pitot tube mounted below the left wing and a static port behind the instrument panel. The pitot tube includes a second port set on an angled bevel below the main port for the purpose of determining aircraft angle of attack (displayed on the EFIS).
Page 274: Pitot System Leak Test
PITOT SYSTEM LEAK TEST 7.3.1 For safety reasons and to ensure correct airspeed readings, it is important to test the system for leaks. TOOLS / EQUIPMENT REQUIRED ITEM QUANTITY NOTES Rubber hose with inside diameter equal to pitot outside diameter, at least 30 cm length. The above list is not necessarily a complete list of all required tools and equipment needed.
Page 275: Static System Leak Test
STATIC SYSTEM LEAK TEST 7.3.2 TOOLS / EQUIPMENT REQUIRED ITEM QUANTITY NOTES Vacuum pump. Piping to connect vacuum pump to static system T-piece. As needed. The above list is not necessarily a complete list of all required tools and equipment needed. A calibrated torque wrench (with adequate range) and the correct size (as implied by the above tool list) accessories (sockets etc.) are implied for torqueing bolts / nuts, if applicable.
Page 276: Pitot And / Or Static System Cleaning And Servicing
PITOT AND / OR STATIC SYSTEM CLEANING AND SERVICING 7.3.3 AUTHORISED PERSONNEL Any person performing maintenance of any kind on the aircraft or any component thereof must do so in accordance with national legislation. This is the responsibility of the aircraft owner and any person who is to perform any maintenance on the aircraft.
Page 277: Ahrs And Compass
As needed. If adhesive foam was removed with removal of sensor(s). The above list is not necessarily a complete list of all material needed. Refer to the Sling 4 construction manual. AUTHORISED PERSONNEL Any person performing maintenance of any kind on the aircraft or any component thereof must do so in accordance with national legislation.
Page 278 PROCEDURE (REMOVAL) Retain any bolts, nuts (except lock-nuts) spacers, screws and washers (with the exception of lock- washers) for reassembly. 1. Remove the rear seat (refer to paragraph 4.3.2.2). 2. Undo the screws retaining the connector (1) to the sensor (2) and disconnect the connector. 3.
Page 279: Headphone Sockets
Solder. As needed. The above list is not necessarily a complete list of all material needed. Refer to the Sling 4 construction manual. AUTHORISED PERSONNEL Any person performing maintenance of any kind on the aircraft or any component thereof must do so in accordance with national legislation.
Page 280: Figure 61: Headphone Socket Installation
PROCEDURE (REMOVAL) Remove the centre console rear inspection panel (for pilot and co-pilot sockets). Undo the nut retaining the socket to the mounting plate and pull the socket from the plate. Remove the heat shrink on the wire connections and desolder the wire connections. PROCEDURE (INSTALLATION) Refer to paragraph 13.10 for the wiring connections / information for each socket / headphone position.
Page 281: Antennae
Clear silicone. As needed. The above list is not necessarily a complete list of all material needed. Refer to the Sling 4 construction manual. AUTHORISED PERSONNEL Any person performing maintenance of any kind on the aircraft or any component thereof must do so in accordance with national legislation.
Page 282: Figure 62: Vhf Antenna Installation
PROCEDURE (REMOVAL) Retain any bolts, nuts (except lock-nuts) spacers, screws and washers (with the exception of lock- washers) for reassembly. 1. Unscrew the four bolts retaining the antenna to the fuselage. 2. Separate the antenna from the fuselage so that the BNC connector is exposed. 3.
Page 283: Gps Antenna
As needed. Installation. The above list is not necessarily a complete list of all material needed. Refer to the Sling 4 construction manual. AUTHORISED PERSONNEL Any person performing maintenance of any kind on the aircraft or any component thereof must do so in accordance with national legislation.
Page 284 PROCEDURE (REMOVAL) Unplug the antenna cable from the iBOX interface (below the instrument panel). Cut the tie wraps (1) retaining the antenna (2) to the bracket (3). Cut any tie wraps securing the cable (e.g. to other cables) and pull the cable through the rubber grommet (4) in the mounting bracket.
Page 285: Utility Systems
UTILITY SYSTEMS CABIN HEATING AND COOLING The heating system exhaust vent is located near the rudder pedals on the passenger side of the cabin. Two fresh air vents are found on the left and right sides of the instrument panel, each with a shut-off valve that can be directed through 180 degrees.
Page 286: Brake System
9. BRAKE SYSTEM Figure 63 Refer to . The brake system consists of a brake fluid reservoir, a master cylinder and two disc brakes assemblies. An intercept valve activates the parking brake. Braking action is through a lever located on the cabin tunnel between seats. The hydraulic circuit intercept valve is also located between seats and, when closed with lever pulled, keeps circuit under pressure and aircraft’s parking brake on Figure 63: Brake system.
Page 287: Brake Fluid Draining, Replacement And Brake System Bleeding
As needed. Refer to paragraph 1.4. The above list is not necessarily a complete list of all material needed. Refer to the Sling 4 construction manual. AUTHORISED PERSONNEL Any person performing maintenance of any kind on the aircraft or any component thereof must do so in accordance with national legislation.
Page 288 PROCEDURE (DRAIN) Open the park brake shut-off valve. Remove the plastic cap (1) and loosen and remove the brake calliper nipple (2). Let the brake fluid drain out in a container. PROCEDURE (FILL) METHOD 1 (PUMP) Remove the brake fluid reservoir cap. Ensure park brake shut-off valve is open.
Page 289: Brake Mechanism Removal / Installation
Apply the brakes and verify for correct operation and the absence of sponginess. PROCEDURE (BLEED) Both main wheels are bled independently. Pull the brake lever to pressurise the system. Loosen the brake calliper nipple to allow the fluid to spurt out. Tighten the nipple and release the brake lever.
Page 290: Brake Disc Replacement
BRAKE DISC REPLACEMENT TOOLS / EQUIPMENT REQUIRED ITEM QUANTITY NOTES 4 mm Allen key / hex drive. The above list is not necessarily a complete list of all required tools and equipment needed. A calibrated torque wrench (with adequate range) and the correct size (as implied by the above tool list) accessories (sockets etc.) are implied for torqueing bolts / nuts, if applicable.
Page 291: Brake Lining Replacement
BRAKE LINING REPLACEMENT TOOLS / EQUIPMENT REQUIRED ITEM QUANTITY NOTES 4 mm Drill bit and drive (electric or hand drill). 1 Set. Axle spat mounting plate 7/16 Spanner retaining nut and bolts. Hammer, punch and anvil / bucking bar (suitable for 1 Set.
Page 292 PROCEDURE (REMOVAL) 1. Remove the main wheel (refer to paragraph 4.4.1.2) and obtain the first brake lining mounting plate / calliper (1). 2. The spat mounting plate (2) prevents the rear calliper (3) from sliding out of plate (4) attached to the strut by the axle mounting bolts.
Page 293 PROCEDURE (REPLACEMENT) Drill out the rivets (1) to remove the linings from the mounting plates (2). Set the new linings in place, insert the brass rivets (supplied with the linings) and set the rivets. PROCEDURE (INSTALLATION) Reverse the above procedure (removal) to install, paying close attention to the following: ...
Page 294: Electrical System
ELECTRICAL SYSTEM This aircraft electrical system consists of a 12 V DC circuit. An 17 Ah lead acid battery provides the energy to drive the starter and acts as an emergency standby supply of electrical power in case of an alternator malfunction.
Page 295 The following table lists typical electrical equipment: Description Alternator Alternator l(charge)l light Battery Circuit breakers Cylinder head temperature sensors and exhaust gas temperature sensors Electrical and electronic instruments and radio Elevator and Aileron autopilot servos, turbocharger waste gate servo Flap actuator motor Flap controller Ignition systems Landing and taxi light switches...
Page 296: Battery Removal / Installation
10.1 BATTERY REMOVAL / INSTALLATION TOOLS / EQUIPMENT REQUIRED ITEM QUANTITY NOTES 8 mm Spanner. The above list is not necessarily a complete list of all required tools and equipment needed. A calibrated torque wrench (with adequate range) and the correct size (as implied by the above tool list) accessories (sockets etc.) are implied for torqueing bolts / nuts, if applicable.
Page 297 PROCEDURE (REMOVAL) Engine stopped. Master switch OFF. Remove the top engine cowling (refer to paragraph 5.1.1). First disconnect the ground (negative) cable (1, black) and then the positive cable (2, red) from the battery terminals (3). Loosen the tie-in strap (4) and remove the battery (5) from the bracket (6). PROCEDURE (INSTALLATION) Master switch OFF.
Page 298: Efis Back-Up Battery Removal / Installation
As needed. Instrument panel retaining screws. The above list is not necessarily a complete list of all material needed. Refer to the Sling 4 construction manual. AUTHORISED PERSONNEL Any person performing maintenance of any kind on the aircraft or any component thereof must do so in accordance with national legislation.
Page 299 PROCEDURE (REMOVAL) Retain any bolts, nuts (except lock-nuts) spacers, screws and washers (with the exception of lock- washers) for reassembly. Undo the screws retaining the instrument panel and tilt it forward to gain access to the battery. Unplug the electrical wires / lugs from the battery terminals. Cut and remove the tie wraps retaining the battery to the bracket and fuselage frame and remove the battery.
Page 300: Alternator Maintenance
As needed. Instrument panel retaining screws. The above list is not necessarily a complete list of all material needed. Refer to the Sling 4 construction manual. AUTHORISED PERSONNEL Any person performing maintenance of any kind on the aircraft or any component thereof must do so in accordance with national legislation.
Page 301 PROCEDURE (CIRCUIT BREAKER) Open the instrument panel (refer to paragraph 7.2). Unscrew the wire / lug connecting terminals (1) on the circuit breaker (2) and remove the wires. Note (or mark) the placement / connection of the wires. Wires must be reconnected to the replacement circuit breaker in the same sense / order.
Page 302 PROCEDURE (SWITCH) Open the instrument panel (refer to paragraph 7.2). The electrical wiring connections from the switch connections (1). Note (or mark) the placement / connection of the wires. Wires must be reconnected to the replacement switch in the same sense / order. Undo the front nut (2) securing the switch to the instrument panel and remove the switch.
Page 303: Regulator / Rectifier Removal And Replacement
10.5 REGULATOR / RECTIFIER REMOVAL AND REPLACEMENT TOOLS / EQUIPMENT REQUIRED ITEM QUANTITY NOTES 10 mm Socket. Socket wrench + extension (if needed) for item 1. The above list is not necessarily a complete list of all required tools and equipment needed. A calibrated torque wrench (with adequate range) and the correct size (as implied by the above tool list) accessories (sockets etc.) are implied for torqueing bolts / nuts, if applicable.
Page 304 PROCEDURE (REMOVAL) Retain any bolts, nuts (except lock-nuts) spacers, screws and washers (with the exception of lock- washers) for reassembly. Master switch OFF. Disconnect the connection plug (1) from the rectifier (2). Undo the bolts (3) retaining the rectifier and the ground wire (4) to the firewall. Remove the rectifier.
Page 305: Exterior Lighting
11. EXTERIOR LIGHTING Exterior lighting consists of:  Navigation lights.  Landing and taxi lights.  Strobe light. 11.1 NAVIGATION LIGHTS Combined navigation and strobe lights are installed on the wing tips. All navigation lights are controlled by a single switch located on the instrument panel. Green, white and strobe lights are located on starboard wing tip.
Page 306: Navigation Light Removal / Installation
As needed. Navigation light retaining screws. The above list is not necessarily a complete list of all material needed. Refer to the Sling 4 construction manual. AUTHORISED PERSONNEL Any person performing maintenance of any kind on the aircraft or any component thereof must do so in accordance with national legislation.
Page 307 PROCEDURE (REMOVAL) Retain any bolts, nuts (except lock-nuts) spacers, screws and washers (with the exception of lock-washers) for reassembly. Master switch in OFF position. Navigation lights switch in OFF position. Undo the button head screws retaining the navigation light to the wing. Carefully move the light away from the wingtip until the wire connection plugs are revealed.
Page 308: Landing And Taxi Lights
9.5 mm Heat shrink. As needed. The above list is not necessarily a complete list of all material needed. Refer to the Sling 4 construction manual. AUTHORISED PERSONNEL Any person performing maintenance of any kind on the aircraft or any component thereof must do so in accordance with national legislation.
Page 309 PROCEDURE (REMOVAL) Retain any bolts, nuts (except lock-nuts) spacers, screws and washers (with the exception of lock- washers) for reassembly. Master switch in OFF position. Landing light and taxi light switches in OFF positions. Undo the screws retaining the clear lens to the wing and remove the lens. Undo the button head screws (1) which secure the taxi (2) or landing (3) light and remove together with the tension springs.
Page 310: Figure 65 : Landing And Taxi Light Installation
PROCEDURE (INSTALLATION) Reverse the above procedure (removal) for installation, paying close attention to the following:  Inspect all bolts and / or screws for damage. Replace if necessary.  The light assembly is installed on the wing with the red wire (wired into the circular extension on the light itself) facing towards the top of the wing.
Page 311: Landing And / Or Taxi Light Replacement
Tie wraps. As needed. The above list is not necessarily a complete list of all material needed. Refer to the Sling 4 construction manual. AUTHORISED PERSONNEL Any person performing maintenance of any kind on the aircraft or any component thereof must do so in accordance with national legislation.
Page 312 PROCEDURE (DISASSEMBLY) Retain any bolts, nuts (except lock-nuts) spacers, screws and washers (with the exception of lock- washers) for reassembly. Remove the light assembly from the aircraft (refer to paragraph 11.2.1). Undo the nuts (1) retaining the light to the angled plates (2), front plate (3) and ground wire (4).
Page 313: Landing And / Or Taxi Light Adjustment
11.2.3 LANDING AND / OR TAXI LIGHT ADJUSTMENT TOOLS / EQUIPMENT REQUIRED ITEM QUANTITY NOTES 2.5 mm Allen key / hex drive. Phillips screwdriver. The above list is not necessarily a complete list of all required tools and equipment needed. A calibrated torque wrench (with adequate range) and the correct size (as implied by the above tool list) accessories (sockets etc.) are implied for torqueing bolts / nuts, if applicable.
Page 314: Strobe Light
As needed Strobe light retaining screws. The above list is not necessarily a complete list of all material needed. Refer to the Sling 4 construction manual. AUTHORISED PERSONNEL Any person performing maintenance of any kind on the aircraft or any component thereof must do so in accordance with national legislation.
Page 315 PROCEDURE (REMOVAL) Retain any bolts, nuts (except lock-nuts) spacers, screws and washers (with the exception of lock- washers) for reassembly. Master switch in OFF position. Strobe light switch in OFF position. Undo the button head screws retaining the strobe light to the wing. Carefully move the light away from the rudder until the wire connection plugs are revealed.
Page 316: Emergency And Safety Systems
12.1 BALLISTIC PARACHUTE The Sling 4 is designed specifically for convenient fitment of a Magnum 901 ballistic parachute recovery system. The system is designed to enable the pilot or passenger to deploy the parachute in case of emergency, in such a manner that the aircraft structure is carried under the parachute to the ground, on the basis that the occupants will not be injured and the aircraft structure suffers minimal damage.
Page 317: Safety Harnesses
As needed. Inspection panel / fairing screws. The above list is not necessarily a complete list of all material needed. Refer to the Sling 4 construction manual. AUTHORISED PERSONNEL Any person performing maintenance of any kind on the aircraft or any component thereof must do so in accordance with national legislation.
Page 318 PROCEDURE (REMOVAL) Retain any bolts, spacers, nuts (except lock-nuts) screws and washers (with the exception of lock- washers) for reassembly. Remove the rear spar attachment inspection panel (on the bottom of the wing, at the wing to fuselage interface) to gain access to the inertial reel retaining bolt. Remove the front seat (refer to paragraph 4.3.2.1) on the side of the safety belt to be removed.
Page 319 Pull / push the pin (4) out of the loop in the belt (3). Pull the belt back through the drum to separate it from the inertial reel unit. Pull the belt through the fuselage guidance slots. Reattach the belt to the inertial reel drum if required.
Page 320: Removal / Installation Of Rear Occupant Safety Harness(Es)
(with adequate range) and the correct size (as implied by the above tool list) accessories (sockets etc.) are implied for torqueing bolts / nuts, if applicable. Refer to paragraph 1.5 for torque values. The above list is not necessarily a complete list of all material needed. Refer to the Sling 4 construction manual. AUTHORISED PERSONNEL Any person performing maintenance of any kind on the aircraft or any component thereof must do so in accordance with national legislation.
Page 321: Appendix A (Avionics And Electrical System Wiring Diagrams)
13. APPENDIX A (AVIONICS AND ELECTRICAL SYSTEM WIRING DIAGRAMS) 13.1 CHARGE AND START SYSTEM / FUEL PUMPS WIRING DIAGRAM Figure 66: Charge and start system wiring diagram /fuel pump wiring. DOCUMENT No.: REVISION: 1.2 DATE: 2014/11/10 DC-MAM-001-X-C-2 Page 303...
Page 322: Switches And Circuit Breakers Wiring Diagram
13.2 SWITCHES AND CIRCUIT BREAKERS WIRING DIAGRAM Figure 67: Switches and circuit breakers wiring diagram. DOCUMENT No.: REVISION: 1.2 DATE: 2014/11/10 DC-MAM-001-X-C-2 Page 304...
Page 323: External Alternator Wiring Diagram
13.3 EXTERNAL ALTERNATOR WIRING DIAGRAM Figure 68: External alternator wiring diagram. DOCUMENT No.: REVISION: 1.2 DATE: 2014/11/10 DC-MAM-001-X-C-2 Page 305...
Page 324: Flap System Wiring Diagram
13.4 FLAP SYSTEM WIRING DIAGRAM 13.4.1 MGL SP10 FLAP WITH 4 POSITION ROTARY SWITCH Figure 69: MGL SP 10 Flap / trim controller wiring diagram. DOCUMENT No.: REVISION: 1.2 DATE: 2014/11/10 DC-MAM-001-X-C-2 Page 306...
Page 325: Inotec
13.4.2 INOTEC Figure 70: Flap system wiring diagram – INOTEC. DOCUMENT No.: REVISION: 1.2 DATE: 2014/11/10 DC-MAM-001-X-C-2 Page 307...
Page 326: E-Flaps
13.4.3 E-FLAPS Figure 71: Flap system wiring diagram - E-Flaps. DOCUMENT No.: REVISION: 1.2 DATE: 2014/11/10 DC-MAM-001-X-C-2 Page 308...
Page 327: Elevator Trim Motor Wiring Diagram
13.5 ELEVATOR TRIM MOTOR WIRING DIAGRAM 13.5.1 DUAL STICK TRIM SWITCH 5 SWITCH 1 SWITCH 2 SWITCH 4 SWITCH 3 RAY ALLEN G205 TYPE STICK GRIP Figure 72: Elevator trim motor wiring diagram – dual control sticks. DOCUMENT No.: REVISION: 1.2 DATE: 2014/11/10 DC-MAM-001-X-C-2 Page 309...
Page 328: Single Stick Trim
13.5.2 SINGLE STICK TRIM SWITCH 5 SWITCH 1 SWITCH 2 SWITCH 4 SWITCH 3 RAY ALLEN G205 TYPE STICK GRIP Figure 73: Elevator trim motor wiring diagram – single control stick. DOCUMENT No.: REVISION: 1.2 DATE: 2014/11/10 DC-MAM-001-X-C-2 Page 310...
Page 329: Efis System / Communications Bus Layout
13.6 EFIS SYSTEM / COMMUNICATIONS BUS LAYOUT Figure 74: EFIS system / communications bus layout. DOCUMENT No.: REVISION: 1.2 DATE: 2014/11/10 DC-MAM-001-X-C-2 Page 311...
Page 330: Ahrs And Compass Wiring Diagram
13.7 AHRS AND COMPASS WIRING DIAGRAM Figure 75: AHRS and compass wiring diagram. DOCUMENT No.: REVISION: 1.2 DATE: 2014/11/10 DC-MAM-001-X-C-2 Page 312...
Page 331: Autopilot Roll Servo And Pitch Servo Wiring Diagram
13.8 AUTOPILOT ROLL SERVO AND PITCH SERVO WIRING DIAGRAM Figure 76: Autopilot roll servo and pitch servo wiring diagram. DOCUMENT No.: REVISION: 1.2 DATE: 2014/11/10 DC-MAM-001-X-C-2 Page 313...
Page 332: Efis Back-Up Battery Charge Circuit
13.9 EFIS BACK-UP BATTERY CHARGE CIRCUIT Figure 77: EFIS back-up battery charge circuit. DOCUMENT No.: REVISION: 1.2 DATE: 2014/11/10 DC-MAM-001-X-C-2 Page 314...
Page 333: Headphone / Radio / Intercom Wiring Diagram
13.10 HEADPHONE / RADIO / INTERCOM WIRING DIAGRAM 13.10.1 GARMIN GTR 200 RADIO Figure 78: Headphone / radio (GARMIN GTR 200) / intercom wiring diagram. DOCUMENT No.: REVISION: 1.2 DATE: 2014/11/10 DC-MAM-001-X-C-2 Page 315...
Page 334: Garmin Gtr 225 Radio
13.10.2 GARMIN GTR 225 RADIO Circuit breaker on instrument panel Figure 79: Headphone / radio (GARMIN GTR 225) / intercom wiring diagram. DOCUMENT No.: REVISION: 1.2 DATE: 2014/11/10 DC-MAM-001-X-C-2 Page 316...
Page 335: Position / Navigation Lights Wiring Diagram
13.11 POSITION / NAVIGATION LIGHTS WIRING DIAGRAM Figure 80: Position / navigation lights wiring diagram. DOCUMENT No.: REVISION: 1.2 DATE: 2014/11/10 DC-MAM-001-X-C-2 Page 317...
Page 336: Rdac To Oil Pressure Transducer Wiring Diagram
13.12 RDAC TO OIL PRESSURE TRANSDUCER WIRING DIAGRAM Figure 81: RDAC to oil pressure transducer wiring diagram and settings. DOCUMENT No.: REVISION: 1.2 DATE: 2014/11/10 DC-MAM-001-X-C-2 Page 318...
Page 337: Dual Efis Installation Wiring Diagram
13.13 DUAL EFIS INSTALLATION WIRING DIAGRAM Figure 82:Dual EFIS installation. DOCUMENT No.: REVISION: 1.2 DATE: 2014/11/10 DC-MAM-001-X-C-2 Page 319...
Page 338: Transponder Wiring Diagram
13.14 TRANSPONDER WIRING DIAGRAM 13.14.1 TRIG TT21 TRANSPONDER WIRING DIAGRAM Figure 83: TRIG TT21 transponder wiring diagram. DOCUMENT No.: REVISION: 1.2 DATE: 2014/11/10 DC-MAM-001-X-C-2 Page 320...
Page 339: Sandia Stx 165R Transponder Wiring Diagram
13.14.2 SANDIA STX 165R TRANSPONDER WIRING DIAGRAM XPOND + Figure 84: SANDIA STX 165R transponder wiring diagram. DOCUMENT No.: REVISION: 1.2 DATE: 2014/11/10 DC-MAM-001-X-C-2 Page 321...
Page 340: Engine Monitoring Transducers (Sensors) / Rdac Electrical Wiring
13.15 ENGINE MONITORING TRANSDUCERS (SENSORS) / RDAC ELECTRICAL WIRING Refer to the latest revision of the RDAC XF installation documentation from MGL (manufacturer). Also refer to paragraph 13.12. 13.16 EFIS AND IBOX ELECTRICAL WIRING Refer to the iEFIS Panel Installation Manual and the MGL Avionics iBOX V1 Installation Manual. 13.17 PROPELLER AND PROPELLER CONTROLLER ELECTRICAL WIRING INFORMATION Refer to the latest revision of the Airmaster AP3 Series and AP4 Series Constant Speed Propeller...
Page 341: Appendix B (Firewall Mounted Equipment)
14. APPENDIX B (FIREWALL MOUNTED EQUIPMENT) Oil reservoir Fuel pump assembly GPS antenna Cabin air inlet / splitter box Main battery Turbocharger waste gate servo Coolant overflow bottle Starter relay Brake fluid reservoir RDAC Figure 85: Firewall mounted equipment. DOCUMENT No.: REVISION: 1.2 DATE: 2014/11/10 DC-MAM-001-X-C-2...
Page 342: Appendix C (General Procedures And Techniques Not Described Elsewhere)
APPENDIX C (GENERAL PROCEDURES AND TECHNIQUES NOT DESCRIBED ELSEWHERE) 15.1 REMOVAL OF TWO-EAR CLAMPS Use a hacksaw or Dremel tool to cut through the one ear as shown by the dotted line. Once cut through, pry the clamp open and remove. Figure 86: Two-ear clamp removal.
Page 343: Fitting Of Fire Resistant Sleeving
15.3 FITTING OF FIRE RESISTANT SLEEVING Fire resistant sleeving fitted over fuel / oil hoses which are secured (to fittings / couplings) with two- ear clamps must be secured with safety wire adjacent to the two-ear clamp, on both sides of the clamp.
Page 344: Appendix D (An Washer And Nut Hardware Designations)
APPENDIX D (AN WASHER AND NUT HARDWARE DESIGNATIONS) Reference (this manual) Hardware Designation WASHERS AN3 washer (1.6 mm / 0.063”) AN960-10 AN3 washer (0.8 mm / 0.032”) AN960-10L AN4 washer (1.6 mm / 0.063”) AN960-416 AN4 washer (0.8 mm / 0.032”) AN960-416L AN5 washer (1.6 mm / 0.063”) AN960-516...

The Airplane Factory Sling 4 Maintenance Manual

1 General

2 Introduction

Date: 2014/11/10

4 Airframe

5 Power Plant

6 Fuel System

7 Avionics and Instruments

Date: 2014/11/10

8 Utility Systems

9 Brake System

10 Electrical System

11 Exterior Lighting

12 Emergency and Safety Systems

13 Appendix A (Avionics and Electrical System Wiring Diagrams)

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Summary of Contents for The Airplane Factory Sling 4