1. Manuals
  2. Brands
  3. SkyReach Manuals
  4. Engine
  5. BushCat
  6. Maintenance manual

SkyReach BushCat Maintenance Manual

Nose-wheel and tail-dragger
Hide thumbs
Table of Contents

Advertisement

Quick Links

Download this manual

Advertisement

Table of Contents
loading
Need help?

Need help?

Do you have a question about the BushCat and is the answer not in the manual?

Questions and answers

Summary of Contents for SkyReach BushCat

  • Page 2 NOSE-WHEEL AND TAIL-DRAGGER FITTED WITH ROTAX 912UL/ULS ENGINE APPROVED FLIGHT MANUAL PART NUMBER: BCMM-NT-008-001 AIRCRAFT TYPE: CHEETAH – BUSHCAT* DATE OF ISSUE: 28 JUNE 2017 NOTE: THIS DOCUMENT MUST BE KEPT IN THE AIRCRAFT DURING OPERATION *Refer to the POH for more information on aircraft type.

  • Page 3: Issues And Revisions

    If revisions are published you will be notified by SkyReach or by your distributer as they will apply to the correctness of your manual. It should be noted that all revisions and revisions are available on the SkyReach website as downloadable PDF files.

  • Page 4: Record Of Issues And Revisions

    RECORD OF ISSUES AND REVISIONS The following issues have led to this current issue: Issues Number Date Published Notable Changes 28/10/2013 Original 05/12/2013 Electrical system schematic moved to A/C supplement 07/07/2014 New Zealand distributer address added 08/07/2014 Several changes 19/11/2014 Fuel line inspection added 01/04/2015 MTOW increased to 600kg...

  • Page 5: Feedback Form

    In addition, please keep a copy of the completed form in your Maintenance Manual. Name: Email: Phone Number: Date: BushCat Serial Number: Registration number: Feedback information: Issue 8, Revision 1 Page 5 of 338 BCPH-NT-008-001...
  • Page 6 Email or fax to: South African Address: USA Address: New Zealand Address: Rainbow SkyReach (PTY) Ltd AeroSport, LLC BushCat Aviation NZ LTD P.O. Box 3408, 198 Lynne Drive, Ngaruawahia, Dalview 1544, Twin Lakes, Waikato, Gauteng, WI 53181, 3720, South Africa.

  • Page 7: Table Of Contents

    TABLE OF CONTENTS ISSUES AND REVISIONS ........................... 3 RECORD OF ISSUES AND REVISIONS ....................... 4 FEEDBACK FORM ............................. 5 TABLE OF CONTENTS ..........................7 CHAPTER 1. GENERAL ........................12 1.1. INTRODUCTION TO THE MANUAL ..................12 1.2. INTRODUCTION TO THE CHEETAH SERIES ................12 1.3.
  • Page 8 3.9.11. CARBURETTOR HEAT ..................... 24 3.9.12. ENGINE PERFORMANCE CURVES .................. 24 3.10. PROPELLER ..........................28 3.11. IGNITION SYSTEM ......................... 29 3.12. ELECTRICAL SYSTEM ......................33 3.13. WEIGHT AND BALANCE INFORMATION ................41 3.13.1. MAXIMUM GROSS MASS ....................41 3.13.2. CENTRE OF GRAVITY POSITION ..................42 3.13.3.
  • Page 9 4.2.5. ENGINE ADDITIONAL ITEM 1000 HOUR CHECK ............77 CHAPTER 5. UNSCHEDULED MAINTENANCE INSPECTION / SERVICE ITEMS ........78 5.1. WING STRIKE INSPECTION ....................79 5.2. TAIL STRIKE INSPECTION ....................... 80 5.3. HARD LANDING INSPECTION ....................81 5.4. EXCEEDANCE OF OPERATING LIMITATIONS OF THE ENGINE ..........82 5.4.1.
  • Page 10 6.4.5. AILERON BALANCE TABS INSTALLATION / REMOVAL ..........157 6.4.6. CONTROL SURFACE RIGGING ..................159 6.4.7. ELEVATOR SETUP ......................167 6.4.8. RUDDER SETUP ......................173 6.4.9. AILERON SETUP ......................177 6.4.10. FLAP SETUP ......................... 181 6.5. ROTAX 912 ENGINE ......................184 6.5.1.
  • Page 11 6.9.1. HEATING AND VENTILATION SYSTEMS ............... 278 6.10. INSTRUMENTS AND AVIONICS .................... 279 6.10.1. INSTRUMENT PANEL INTALLATION ................279 6.10.2. INSPECTION OF THE PITOT STATIC SYSTEM ..............282 6.11. IGNITION SYSTEM ....................... 285 6.11.1. IGNITION SYSTEM INSPECTION ................... 285 6.12. ELECTRICAL SYSTEM ......................286 6.12.1.

  • Page 12: Chapter 1. General

    1.2. INTRODUCTION TO THE CHEETAH SERIES It should be noted that the term ‘BushCat’ refers to the third (and most current) variant of Cheetah aircraft; The Cheetah-BushCat. Original production acceptance certification with the SACAA was obtained under the name of ‘Cheetah’. The two main upgrades to the aircraft were approved as ‘Cheetah-XLS’...

  • Page 13: Supplied Documentation

    1.5. SUPPLIED DOCUMENTATION The following manuals are supplied in either hardcopy or electronic format as part of your BushCat aircraft in addition to any pertinent avionics and equipment manuals 1. The Rotax 912 ULS engine operators manual 2. The BushCat Pilots Operating Handbook 3.

  • Page 14: Terminology

    1.6. TERMINOLOGY Detailed inspection accomplished once a year in accordance with Annual Condition Inspection instructions provided in the maintenance manual supplied with the aircraft to ensure continued safe operation. Airframe and Power plant mechanic as defined by 14 CFR Part 65 in A&P the U.S.
  • Page 15 Facility specifically authorized by the aircraft or component Overhaul Facility manufacturer to overhaul the product originally produced by that manufacturer. Facility specifically authorized by the aircraft or component Repair Facility manufacturer to repair the product originally produced by that manufacturer. Same as an annual condition inspection, except the interval of 100-h inspection inspection is 100 h of operation instead of 12 calendar months.

  • Page 16: Chapter 2. Authorisations

    CHAPTER 2. AUTHORISATIONS This section details the personnel permitted to accomplish each task as detailed in section 6. It should be noted that modifications to the airframe or engine are not permitted WARNING without written approval from the manufacturer. Level of Authorization Classification of tasks to be performed Qualification required to perform the tasks.

  • Page 17: Chapter 3. General Specifications

    CHAPTER 3. GENERAL SPECIFICATIONS This section details general aircraft specifications, capacities and basic instructions for handling the aircraft on the ground. For more detailed specifications, please refer to the accompanying BushCat “Pilot’s Operating Handbook”. 3.1. DIMENSIONS Dimensions of the BushCat nose-wheel and tail-dragger variants are shown on the followings pages.

  • Page 20: Baggage Space

    3.2. BAGGAGE SPACE The aircraft is fitted with two storage areas as standard: 59 litres Capacity: (2 ft Upper baggage area behind seats: 23.2 kg Maximum load: (51 lbs) 150 litres Capacity: (5.3 ft Lower luggage area behind seats: 6.8 kg Maximum load: (15 lbs) This combination results in a maximum baggage weight of 30kg (66lbs).

  • Page 21: Ground Turning Clearance

    GROUND TURNING CLEARANCE Radius for wingtip: 20.1 meters (66 feet). 3.6. EQUIPMENT LIST The standard equipment installed on the BushCat includes the following:  Rotax 912 ULS Engine with Kiev composite three blade propeller  Aerodynamic compensators, ventral Fin, sun shield ...

  • Page 22: List Of Disposable Replacement Parts

    3.8. LIST OF DISPOSABLE REPLACEMENT PARTS Item Comments Air filter If cleaning of the filters is not possible, they can be replaced with new ones and old ones disposed of in accordance with local laws. All parts can be obtained from the aircraft distributer / manufacturer (see page 5 for the contact details of your distributer.)* Battery When the sealed maintenance free battery is to be replaced, the old battery should be recycled in accordance with local laws.

  • Page 23: Engine Specifications

    3.9. ENGINE SPECIFICATIONS The BushCat is available with a choice of two engines that are ASTM compliant: 1. ROTAX 912UL (80HP at maximum RPM), or 2. ROTAX 912ULS (100HP at maximum RPM). Both engines are part of the ROTAX 912 series of engines and have the following basic specifications: ...

  • Page 24: Exhaust Gas Temperature

    Minimum value 50°C (120°F) Normal range 90°C to 110°C (190°F -230°F) 3.9.5. EXHAUST GAS TEMPERATURE: Maximum value 880°C (1616°F) 3.9.6. CYLINDER HEAD TEMPERATURE: Maximum value* 150°C (330°F) 135°C (330°F) 3.9.7. COOLANT TEMPERATURE: Maximum value* 120°C (248°F) 3.9.8. FUEL PRESSURE: Maximum value 0.4 bar (5.8 psi) 0.5 bar (7.26 psi)** Minimum value...
  • Page 25 912UL 912ULS 3000 3500 4000 4500 5000 5500 6000 Engine Speed (rpm) Issue 8, Revision 0 Page 25 of 338 BCPH-NT-008-000...
  • Page 26 912ULS 912UL 3000 3500 4000 4500 5000 5500 6000 Engine Speed (rpm) Issue 8, Revision 0 Page 26 of 338 BCPH-NT-008-000...
  • Page 27 912UL 912ULS 3000 3500 4000 4500 5000 5500 6000 Engine Speed (rpm) Issue 8, Revision 0 Page 27 of 338 BCPH-NT-008-000...

  • Page 28: Propeller

    3.10. PROPELLER The standard propeller used on the BushCat with either engine option is a Kiev-Prop with the following data: Make: Kiev Prop Model: #283 Construction: Composite (glass fibre reinforced plastic) Pitch: Ground adjustable Number of blades: 3 Disk diameter: 1800mm (70.9”)

  • Page 29: Ignition System

    3.11. IGNITION SYSTEM The Rotax 912 series engines are equipped with a breakerless dual ignition system (DCDI - Dual Capacitor Discharge Ignition). The ignition unit needs no external power supply. Each of the two independent charging coils (1) located on the generator stator supplies one of the two ignition circuits.
  • Page 30 Figure 3: Internal Generator: old version as per ROTAX IPC 24-20-00 Issue 8, Revision 0 Page 30 of 338 BCPH-NT-008-000...
  • Page 31 Figure 4: Internal Generator: new version as per ROTAX PIC 24-20-00 Issue 8, Revision 0 Page 31 of 338 BCPH-NT-008-000...
  • Page 32 Figure 5: Electric Starter / Starter Relay as per ROTAX IPC Fig. 80-10-00-1 Issue 8, Revision 0 Page 32 of 338 BCPH-NT-008-000...

  • Page 33: Electrical System

    3.12. ELECTRICAL SYSTEM The BushCat electrical system is simplistically separated into the charging circuit and the working circuit as depicted in the logic schematic in figure 6 below. In the charging circuit, the aircraft rectifier converts the alternating current received from the engine into a 12 volt direct current output.
  • Page 36 Figure 8 – Aircraft wiring diagram type 1 (Analogue instruments) Panel design under development Issue 8, Revision 0 Page 36 of 338 BCPH-NT-008-000...
  • Page 40 Figure 12 – Aircraft wiring diagram type 5 (DYNON glass cockpit) Panel design under development Issue 8, Revision 0 Page 40 of 338 BCPH-NT-008-000...

  • Page 41: Weight And Balance Information

    WEIGHT AND BALANCE INFORMATION 3.13.1. MAXIMUM GROSS MASS The maximum gross mass of the BushCat varies depending on the country of the individual registration, and the category of aircraft under which the individual aircraft is registered. The following table details the maximum allowable masses for each of the legislation groups in which the BushCat is approved.

  • Page 42: Centre Of Gravity Position

    3.13.2. CENTRE OF GRAVITY POSITION The centre of gravity position limits are given below as distances aft from the wing leading edge: Forward limit: 19% of MAC 286.5mm 11.28 inches Aft limit: 39% of MAC 588.12mm 23.15 inches Issue 8, Revision 0 Page 42 of 338 BCPH-NT-008-000...

  • Page 43: Mass And Balance Form

    3.13.3. MASS AND BALANCE FORM It is a legal requirement that a mass and balance calculation be performed before each flight for the particular load case of the aircraft. The following form should be used, in conjunction with the empty aircraft data in section 12.5 of the POH.

  • Page 44: Tyre Inflation Pressures

    3.14. TYRE INFLATION PRESSURES The following list of tires and pressures applies to standard tires used on the BushCat nose-wheel and tail-dragger. Tyre make and size Recommended pressure Trac-Gard 2.80 x 2.50 – 4 (4 ply) tail wheel 1.3 – 2.0 bar (20 –...

  • Page 45: Fuel System

    3.16.1. FUEL SYSTEM DESCRIPTION The BushCat fuel system makes use of a single 94 litre (25 US gallons), of which 88 litres (23 gallons) are useable. The tank is located aft of the crew seats and is equipped with dual pickups and dual fuel filters.

  • Page 48: Fuel System Capacities

    3.16.2. FUEL SYSTEM CAPACITIES Total fuel tank capacity: 94 Litres* 24.8 US Gallons Total useable fuel: 88 Litres* 23.2 US Gallons *Assuming an average fuel density of 0.734kg/L 3.16.3. APPROVED FUELS Fuel Type Rotax 912UL Rotax 912ULS Knock Resistance Min. RON90 Min.

  • Page 49: Oil Cooling And Lubrication System

    – one above and one below the engine. The second radiator allows the BushCat to be operated in climates where the ambient temperate reaches the maximum operating temperature of the Rotax 912 series engines. The additional cooling of the...

  • Page 51: Liquid Cooling System

    3.18. LIQUID COOLING SYSTEM Cylinder head cooling is achieved thought a liquid cooling system which makes use of one large radiator. The system is based on the standard Rotax 912 liquid cooling system with a modification to incorporate the carburettor heat system. The flow of coolant fluid through the system is shown in the exploded schematic view in the figure overleaf.

  • Page 53: Braking System

    A brake fluid reservoir is located against the firewall just forward of the co-pilot’s pedals and is plumbed to the master cylinders. Some nose-wheel variants of the BushCat may have a hand operated master cylinder located on the control stick as opposed to toe brake pedals. In this case, the brake fluid reservoir is built into the hand operated brake lever assembly.

  • Page 55: Recommended Fastener Torque Values

    3.20. RECOMMENDED FASTENER TORQUE VALUES Do not exceed the values set out in this table as this will lead to inadvertent crushing of the aluminium tubing. STANDARD AVIATION TORQUE VALUES - METRIC SYSTEM In the absence of specific torque values, the following chart can be used as a guide to the maximum safe torque for a particular size/grade of fastener. There is no torque difference for fine or course threads.

  • Page 56: Ground Handling

    GROUND HANDLING The BushCat can be manoeuvred by hand on the ground safely as long as care is taken to avoid injury and/or damage to the aircraft. The aircraft should not be handled if the engine is running or if there is an occupant in the cockpit who is not a qualified pilot current on the type.

  • Page 57: Instructions For Reporting Possible Safety Of Flight Concerns Found During Inspection / Maintenance

    6. Always be sure to inform spectators and other people near the aircraft that you will be starting the aircraft. 7. Never attempt to change a tire outside in the open when the wind is above 5 MPH. 8. When servicing the engine oil, make sure to clean spilled oil to prevent fire or environmental contamination.

  • Page 58: Chapter 4. Scheduled Maintenance Inspection / Service Items

    CHAPTER 4. SCHEDULED MAINTENANCE INSPECTION / SERVICE ITEMS The following detailed inspection sheets can be photocopied, signed off and stored separately from the body of the file as a record of the completion of each of the tasks. All maintenance and/or inspections conducted on an aircraft must be logged in a suitable logbook (eg: the aircraft maintenance logbook, an airframe or engine logbook, a journey log, etc) as per the requirements of the country of registration.
  • Page 59 Inspection / service item Intervals - hours 1000 100 hour airframe inspection 100 hour engine inspection 200 hour engine inspection 500 hour airframe inspection 600 hour engine inspection 1000 hour engine inspection Oil change** * In order to demonstrate continued airworthiness, an engine must be inspected after the first 25 hours of operation. The checks performed at the 25hr inspection are the same as for the 100 hour inspection. This applies to both newly delivered engines and to overhauled engines.

  • Page 60: Airframe Periodic Inspections / Services

    4.1. AIRFRAME PERIODIC INSPECTIONS / SERVICES The airframe manufacturer requires periodic inspections and service items which must be performed at 100 hour intervals or annually, whichever comes first, in accordance with the procedures detailed below. This means that every 100 hours of operation (provided the date limit is not exceeded), a 100 hour inspection must be carried out. Additional inspections and service items are also tabulated below.

  • Page 61: Airframe 100 Hour / Annual Inspection

    Each person performing the inspection shall complete paragraphs A through J. Pre- Inspection action PASS FAIL Each person to carry out the BushCat 100 hour inspection will open the cockpit doors, baggage area and wing inspection area zippers and remove centre console inspection panels. Fuselage and Hull...
  • Page 62 pitot static connections are secure. Complete a detailed inspection including: Check the operation of the throttle levers. Check the operation of the choke lever. Check operation of the elevator trim lever in response to 5) Controls control input. Check the aileron movement in response to control input. Check the flap movement in response to control input.
  • Page 63 3. Check the engine ignition switches. Inspect for cracks, chafing marks, condition of fasteners and signs of 9) Cowling overheat. Fuel System PASS FAIL Inspect for leakage from fuel drains. Check for sail stains (In flight leakage 1) Fuel tank will stain fuselage sail).
  • Page 64 Check that the torque seal on all critical fasteners is intact. Check the free movement of control surfaces. Check that control cables do not rub against structure (unless protection is fitted. Check that aileron deflections are equal on both sides. Check that flap deflections are equal on both sides.
  • Page 65 Avionics and Electrical Systems PASS FAIL Inspect for correct installation and security of attachment. 1. Check intercom and radio squelch of com radio. Endure no 1) Radio and feedback is heard. Electronics 2. Check all lights, fuel pump and other installed electronics devices. Conduct a detailed inspection including: 1.

  • Page 66: Airframe Additional Item / 500 Hour Inspection

    4.1.2. AIRFRAME ADDITIONAL ITEM / 500 HOUR INSPECTION SCOPE AND DETAILS OF THE BUSHCAT AIRFRAME 100 HOUR / ANNUAL INSPECTION & SERVICE Each person performing the inspection shall complete paragraphs A through B. Elevator Control Hinge Bolt Inspection PASS FAIL...

  • Page 67: Airframe 100 Hour / Annual Service

    4.1.3. AIRFRAME 100 HOUR / ANNUAL SERVICE SCOPE AND DETAILS OF THE BUSHCAT AIRFRAME 100 HOUR / ANNUAL SERVICE Each person performing the inspection shall complete paragraph A Replacement items Spark plugs Replace on 100 hour inspection Complete an oil change and replace the oil as per section 6.7.5...

  • Page 68: Engine Periodic Inspections

    4.2. ENGINE PERIODIC INSPECTIONS The engine manufacturer requires periodic inspections which must be performed at 25, 100, 200 and 600 hours in accordance with the ROTAX Line Maintenance Manual, Ch 05-20-00*. This means that every 100 hours of operation a 100 hour check must be carried out. Every 200 hours of operation, a 100 hour inspection and the additional 200 hr inspection items must be carried out.
  • Page 69 Each person performing the inspection shall complete paragraphs A through Q PRE- Inspection action PASS FAIL Each person to carry out the BushCat Rotax Engine 100 hour inspection will remove the engine cowling to conduct the inspection. Engine Visual Inspection PASS...
  • Page 70 3. Hardening from heat 4. Porosity 5. Security of connections and attachments. Verify the routing is free of kinks and restrictions. Inspect all fuel lines in accordance with the ROTAX line maintenance manual, Ch. 12-20-00, section 4. Check for: 1. Damage Fuel line 2.
  • Page 71 Engine cleaning PASS FAIL Engine Clean engine in accordance with the ROTAX line maintenance manual, Ch. Cleaning. 12-20-00, section 1. Checking the air filter PASS FAIL filter Check the air filter in accordance with the ROTAX line maintenance manual, inspection Ch.
  • Page 72 _____________________________________________________________ Sealing lip findings: (wear, cracks, missing material) _____________________________________________________________ _____________________________________________________________ Spring of bypass valve (small) findings: _____________________________________________________________ _____________________________________________________________ Positioning springs (large) findings: _____________________________________________________________ _____________________________________________________________ Refill the oil tank with approximately 3 litres of oil in accordance with the Oil Refill ROTAX line maintenance manual, Ch.
  • Page 73 4. Inspect carburettor heat system. 5. Hit the preheating and make a note of speed drop. Speed drop _______rpm. 6. Preheating “OFF”, engine idle running and make a note of idle speed running _____________rpm. 7. After engine test run, re-tighten the oil filter by hand (once the engine is cold).

  • Page 74: Engine Additional Item 200 Hour Check

    4.2.3. ENGINE ADDITIONAL ITEM 200 HOUR CHECK SCOPE AND DETAILS OF ROTAX ENGINE 200 HOUR ADDIONAL ITEM ANNUAL INSPECTION & SERVICE Each person performing the annual inspection shall complete paragraph A. ROTAX ENGINE CHECKS PASS FAIL Check the compression by the differential pressure method in accordance with the ROTAX line maintenance manual, Ch.
  • Page 75 Inspection findings: _______________________________________________________________________________________________ _______________________________________________________________________________________________ _______________________________________________________________________________________________ _______________________________________________________________________________________________ _______________________________________________________________________________________________ COMPLETED BY STAMP SIGNATURE Issue 8, Revision 0 Page 75 of 338 BCPH-NT-008-000...

  • Page 76: Engine Additional Item 600 Hour Check

    4.2.4. ENGINE ADDITIONAL ITEM 600 HOUR CHECK SCOPE AND DETAILS OF ROTAX ENGINE 600 HOUR ADDITIONAL ITEM ANNUAL INSPECTION & SERVICE Each person performing the annual inspection shall complete paragraph A. ROTAX ENGINE CHECKS PASS FAIL For gearboxes with an overload clutch, the overload clutch must be inspected in accordance with the ROTAX line Overload clutch inspection maintenance manual, Ch.

  • Page 77: Engine Additional Item 1000 Hour Check

    4.2.5. ENGINE ADDITIONAL ITEM 1000 HOUR CHECK SCOPE AND DETAILS OF ROTAX ENGINE 1000 HOUR ADDITIONAL ITEM ANNUAL INSPECTION & SERVICE Each person performing the annual inspection shall complete paragraph A. ROTAX ENGINE CHECKS PASS FAIL Propeller gearboxes with an overload clutch must be Prop gearbox inspection inspected in accordance with the ROTAX line maintenance manual, Ch.

  • Page 78: Chapter 5. Unscheduled Maintenance Inspection / Service Items

    CHAPTER 5. UNSCHEDULED MAINTENANCE INSPECTION / SERVICE ITEMS The following detailed inspection sheets can be photocopied, signed off and stored separately from the body of the file as a record of the completion of each of the tasks. All maintenance and/or inspections conducted on an aircraft must be logged in a suitable logbook (eg: the aircraft maintenance logbook, an airframe or engine logbook, a journey log, etc) as per the requirements of the country of registration.

  • Page 79: Wing Strike Inspection

    5.1. WING STRIKE INSPECTION SCOPE AND DETAILS OF THE BUSHCAT AIRFRAME WING STRIKE INSPECTION Each person performing the inspection shall complete paragraphs A through B. Detailed Wing Inspection PASS FAIL 1. Inspect the condition of the wing and centre section components for general condition, distortion, evidence of failure, security of attachment and installation.

  • Page 80: Tail Strike Inspection

    5.2. TAIL STRIKE INSPECTION SCOPE AND DETAILS OF THE BUSHCAT AIRFRAME TAIL STRIKE INSPECTION Each person performing the inspection shall complete paragraphs A through B. Detailed Wing Inspection PASS FAIL Inspect the condition of the vertical and horizontal tail components for...

  • Page 81: Hard Landing Inspection

    5.3. HARD LANDING INSPECTION SCOPE AND DETAILS OF THE BUSHCAT AIRFRAME HARD LANDING INSPECTION Each person performing the inspection shall complete paragraphs A through D. Detailed Undercarriage Inspection PASS FAIL Inspect the condition of the undercarriage components for general condition, distortion, evidence of failure, security of attachment and Undercarriage installation.

  • Page 82: Exceedance Of Operating Limitations Of The Engine

    5.4. EXCEEDANCE OF OPERATING LIMITATIONS OF THE ENGINE An inspection of the engine must be performed if the operating limits of the engine have been exceeded (for example engine overspeed, excessive temperature etc.), or if unusual operating conditions have occurred during operation (e.g.

  • Page 83: Exceedance Of Maximum Permissible Engine Rpm

    In most cases an overhaul is necessary and the engine needs to be sent without delay to an authorized ROTAX overhaul facility via the airframe distributer. 5.4.4. EXCEEDANCE OF MAXIMUM PERMISSIBLE ENGINE RPM Any exceedance of the maximum permissible engine RPM must be entered by the NOTE: pilot into the engine log book stating the duration and extent of over-speed and pertinent details.
  • Page 84 SCOPE AND DETAILS OF MAX ENGINE RPM EXCEEDANCE INSPECTION Each person performing the prop strike inspection shall complete A, B, C or D as applicable in accordance with the chart above. Engine Inspection Procedure PASS FAIL No action needed. Check that the pushrods are straight. 1.

  • Page 85: Exceedance Of Maximum Permissible Cooling System Temperature

    5.4.5. EXCEEDANCE OF MAXIMUM PERMISSIBLE COOLING SYSTEM TEMPERATURE If the maximum cooling system temperature is exceeded, other limits are also NOTE: often exceeded (e.g. max oil temperature limit) Please observe the relevant instructions for other exceedances simultaneously. Any exceedance of the maximum admissible cooling system temperature must be NOTE: entered by the pilot into the engine log book, stating duration and extent of excess temperature and all other pertinent details.
  • Page 86 SCOPE AND DETAILS OF MAX COOLANT TEMPERATURE EXCEEDANCE INSPECTION – ALL ENGINES WITH SERIAL NUMBER WITHOUT SUFFIX-01 Each person performing the prop strike inspection shall complete A or B as applicable in accordance with the chart above. Engine Inspection Procedure PASS FAIL 1.
  • Page 87 5.4.5.2. EXCEEDANCE OF MAX CYLINDER HEAD TEMPERATURE (ENGINE SERIAL NUMBERS WITH SUFFIX -01) NOTE: See SB-912-068, latest issue. The maximum permissible operating temperature limit for coolant is defined in the ROTAX Operators Manual, section 2.1 or 2.2 (as applicable), Operating limits. (275) Temperature Operating limit...
  • Page 88 SCOPE AND DETAILS OF MAX COOLANT TEMPERATURE EXCEEDANCE INSPECTION – ALL ENGINES WITH SERIAL NUMBER WITH SUFFIX-01 Each person performing the prop strike inspection shall complete A or B as applicable in accordance with the chart above. Engine Inspection Procedure PASS FAIL 1.

  • Page 89: Exceedance Of Maximum Permissible Oil Temperature

    5.4.6. EXCEEDANCE OF MAXIMUM PERMISSIBLE OIL TEMPERATURE If the maximum permissible oil temperature is exceeded, other limits are also NOTE: often exceeded (e.g. coolant system temperature limit). Please observe the relevant instructions for other exceedances simultaneously. Any exceedance of the maximum admissible oil temperature must be entered by NOTE: the pilot into the engine log book, stating duration and extent of excess temperature and all other pertinent details.
  • Page 90 SCOPE AND DETAILS OF MAX OIL TEMPERATURE EXCEEDANCE INSPECTION Each person performing the prop strike inspection shall complete A or B as applicable in accordance with the chart above. Engine Inspection Procedure PASS FAIL 1. The whole oil system must be inspected, repaired or overhauled in accordance with the BRP-Powertrain instructions for continued airworthiness.

  • Page 91: Propeller Sudden Stoppage

    5.5. PROPELLER SUDDEN STOPPAGE A propeller sudden stoppage is defined as any incident while the engine is stationary or running which makes it necessary to perform repairs on the propeller. This includes, but is not limited to, a prop strike incidence. In the event of a propeller sudden stoppage, additional to the repair / replacement of the propeller in accordance with the Kiev prop manual, an inspection on the engine and overload clutch must be accomplished.
  • Page 92 Fuel pump & gearbox Remove the fuel pump and gearbox. Remove the roller bearing in the crankcase for the propeller Prop shaft shaft. The whole gearbox must be inspected, repaired or overhauled accordance with BRP-Powertrain instructions for continued airworthiness; including but not limited to: Gearbox inspection 1.

  • Page 93: Exceedance Of Aircraft G-Limitations / Speed Limitations

    5.6. EXCEEDANCE OF AIRCRAFT G-LIMITATIONS / SPEED LIMITATIONS SCOPE AND DETAILS OF THE BUSHCAT AIRFRAME G-LIMIT EXCEEDANCE / SPEED LIMIT EXCEEDENCE INSPECTION Each person performing the inspection shall complete paragraphs A through B. Detailed Wing Inspection PASS FAIL Inspect the condition of the wing and centre section components for general condition, distortion, evidence of failure, security of attachment and installation.

  • Page 94: Chapter 6. Detailed Maintenance Procedures

    CHAPTER 6. DETAILED MAINTENANCE PROCEDURES The following section can be photocopied in separate sections, signed off and stored separately from the body of the file as a record of the completion of each of the tasks. All maintenance and/or inspections conducted on an aircraft must be logged in a suitable logbook (eg: the aircraft maintenance logbook, an airframe or engine logbook, a journey log, etc) as per the requirements of the country of registration.

  • Page 95: Procedure For Weighing And Determining The Centre Of Gravity Position

    6.1. PROCEDURE FOR WEIGHING AND DETERMINING THE CENTRE OF GRAVITY POSITION WEIGHING AND C.G. DETERMINATION PROCEDURE Shims, spirit level, carpenter’s square, tape measure, masking Special tooling required. tape, calculator, 3 scales and a custom stand (tail-dragger only). Level of Maintenance* Level 2 Reference documents MM, POH (Mass &...
  • Page 96 7. With the aircraft still level, drop a plumb line from leading edge of the wing, 100mm outboard from the wing strut top mounting bolt, and mark the floor at this point. 8. Repeat this step on the other side. 9.
  • Page 97 COMPLETED BY STAMP SIGNATURE Issue 8, Revision 0 Page 97 of 338 BCPH-NT-008-000...

  • Page 98: Wing

    6.2. WING 6.2.1. REMOVAL AND INSTALLATION WING REMOVAL/INSTALLATION PROCEDURE Special tooling required 2 x custom made padded stands for the wings for removal. Level of Maintenance* Level 3 Reference documents BCAM-NT-001-001 * Refer to Chapter 2 for the description of the levels authorisation to perform the task. Parts list: Description Part No:...
  • Page 99 3. Undo the aileron cables on both sides of the butterfly bell crank in the central console by removing the safety devices and pushing the tie pins out. When the cable has been removed, replace the tie pins for safekeeping. This is depicted in detail A of the figure below. 4.
  • Page 101 Use masking tape to mark the cable position prior to removal to facilitate installation. 5. Undo the flap control push-pull rod after marking the position with masking tape. 6. Gain access to the inside of the L/H wing by opening the sipper behind the forward wing strut attachment.
  • Page 103 12. Remove the jury struts at the points where they attach to the wing. 13. Undo the wings struts at the points where they attach to the wing. 14. With one person supporting the wingtip and another person supporting the inboard section the wing, lift it away from the airframe.
  • Page 106 Final Inspection: 1. Confirm the aileron cables are installed correctly by performing a functional check. Ensure that when the control stick is moved to the left, the L/H aileron moves up and the R/H aileron moves down. Conduct the check in reverse to ensure that when the control stick moves to the right, the R/H aileron moves up and the L/H aileron moves down.

  • Page 107: Landing Gear

    6.3. LANDING GEAR 6.3.1. TAIL WHEEL INSTALLATION PROCEDURE – TAIL-DRAGGER VARIANTS ONLY TAIL WHEEL INSTALLATION PROCEDURE – TAIL-DRAGGER ONLY Special tooling required Nil. Level of Maintenance* Level 3 Reference documents BCAM-NT-001-001 * Refer to Chapter 2 for the description of the levels authorisation to perform the task. Parts list: Description Part No:...
  • Page 109 Final Inspection: Once work on the landing gear is complete, perform one taxi without the intention to take-off prior to operating again. COMPLETED BY STAMP SIGNATURE Issue 8, Revision 0 Page 109 of 338 BCPH-NT-008-000...

  • Page 110: Spring Gear Attachment Installation

    6.3.2. SPRING GEAR ATTACHMENT INSTALLATION SPRING GEAR ATTACHMENT INSTALLATION PROCEDURE Special tooling required Gear stop-shift pin jig Level of Maintenance* Level 3 Reference documents BCAM-NT-001-001 * Refer to Chapter 2 for the description of the levels authorisation to perform the task. Parts list: Nose-wheel: Description Part No:...
  • Page 111 8. Fit the stop-shift pins with the bolts supplied in items 5 and 7. Ensure Loctite is applied to these bolts. 9. Apply torque seal to all fastened nuts Issue 8, Revision 0 Page 111 of 338 BCPH-NT-008-000...
  • Page 113 Parts list: Tail-dragger: Description Part No: Section 26 (Main assembly) Section 26, item 19 (M12 x 110mm bolt) Spring gear BC-00-42101 Bracket BT-00-42121 Protection BC-00-42104 Gear stop-shift pin BC-00-42105 Gear stop-shift pin jig BC-J0-42105 M6 x 35mm bolt M12 x 24mm washer M12 Nylock nut M6 Hole tap Contact adhesive...
  • Page 115 Final Inspection: 1. Perform a once-over check of all fastenings to ensure that they are tight. 2. Ensure that torque-seal is evident on all fastenings. COMPLETED BY STAMP SIGNATURE Issue 8, Revision 0 Page 115 of 338 BCPH-NT-008-000...

  • Page 116: Matco Wheel Assembly

    Description Part No: Matco 6" MH wheel hub, with calliper assembly, STD-000397 and A3C axle (preassembled) 6.00x6 (BushCat mini) tyre STD-000429 6.00x6 bent valve tube STD-000434 Procedure: 6” hub with tubed 600x6 AirTrac Tyres 1. Assemble as per the exploded view overleaf.
  • Page 118 Description Part No: Matco 6" MH wheel hub, with caliper assembly, STD-000397 and A3C axle (preassembled) 8.00-6 Carlisle Turf-Glide 4 ply tyres (BushCat standard) STD-000428 8.00x6 bent valve tube STD-000436 Matco brake disk offset kit for A3C axle (MHESL-KIT) STD-000513 Procedure: 6”...
  • Page 119 Parts List: 6” hub with tubed 850x6 AirTrac Tyres Description Part No: Matco 6" MH wheel hub, with caliper assembly, STD-000397 and A3C axle (preassembled) 8.50x6 (BushCat-T multi-role) tyre STD-000430 8.50x6 bent valve tube STD-000438 Matco brake disk offset kit for A3C axle (MHESL-KIT) STD-000513 Procedure: 6”...
  • Page 120 Matco 8" hub tubeless kit (MH83-121) STD-000408 27.5/10-8 Aero Classic 4 ply tundra tyre STD-000431 (BushCat tundra balloon) Procedure: 8” hub with tubeless 27” Desser Tyres 1. Assemble as per the exploded view above. 2. Apply torque seal to all fastened nuts.
  • Page 121 Final Inspection: 1. Perform a once over inspection of all fastenings to ensure that they have been tightened. 2. Check for evidence of torque seal wherever required. COMPLETED BY STAMP SIGNATURE Issue 8, Revision 0 Page 121 of 338 BCPH-NT-008-000...

  • Page 122: Axle, Calliper, And Main Wheel Installation

    6.3.4. AXLE, CALLIPER, AND MAIN WHEEL INSTALLATION AXLE, CALLIPER AND MAIN WHEEL INSTALLATION PROCEDURE Special tooling required Trolley Jacks Level of Maintenance* Level 3 Reference documents BCAM-NT-001-001 * Refer to Chapter 2 for the description of the levels authorisation to perform the task. Parts list: Installation without spacer: Description Part No:...
  • Page 124 Parts list: Installation with spacer: Description Part No: Main assembly Wheel assembly (hub and tyre) Calliper assembly A3C axle with nut and split pin Matco A3C axle spacer (0.625”) STD-000491 3/8-16 x 3 1/4” bolt STD-000503 5/16-18 x 3” bolt STD-000505 M8 x 16 x 1.6mm washer STD-000532...
  • Page 126 Procedure: Wheel Removal Place the aircraft in a controlled environment where it is guarded against strong winds. It is further recommended that the floor by covered with a carpet to CAUTION protect parts from minor damages. The facility should be well lit from multiple sources.

  • Page 127: Nose Wheel Assembly - Nose-Wheel Variants Only

    6.3.5. NOSE WHEEL ASSEMBLY – NOSE-WHEEL VARIANTS ONLY NOSE WHEEL ASSEMBLY PROCEDURE Special tooling required Compressed Air, dishwashing liquid. Level of Maintenance* Level 3 Reference documents BCAM-NT-001-001 * Refer to Chapter 2 for the description of the levels authorisation to perform the task. Parts list: Description Part No:...
  • Page 128 8. Inflate the wheel to the pressure specified in section 3.12. 9. Apply torque seal to all fastened nuts. Issue 8, Revision 0 Page 128 of 338 BCPH-NT-008-000...
  • Page 130 Final Inspection: 1. Once work on the landing gear is complete, perform one taxi without the intention to take- off prior to operating again. COMPLETED BY STAMP SIGNATURE Issue 8, Revision 0 Page 130 of 338 BCPH-NT-008-000...

  • Page 131: Front Fork And Wheel Assembly - Nose-Wheel Variants Only

    6.3.6. FRONT FORK AND WHEEL ASSEMBLY – NOSE-WHEEL VARIANTS ONLY FRONT FORK AND WHEEL ASSEMBLY PROCEDURE – NOSE-WHEEL ONLY Special tooling required Level of Maintenance* Level 3 Reference documents BCAM-NT-001-001 * Refer to Chapter 2 for the description of the levels authorisation to perform the task. Parts List: Description Part No:...
  • Page 133 Final Inspection: 1. Once work on the landing gear is complete, perform one taxi without the intention to take- off prior to operating again. COMPLETED BY STAMP SIGNATURE Issue 8, Revision 0 Page 133 of 338 BCPH-NT-008-000...

  • Page 134: Front Fork Installation (Part 1) - Nose Wheel Variants Only

    6.3.7. FRONT FORK INSTALLATION (PART 1) – NOSE WHEEL VARIANTS ONLY FRONT FORK INSTALLATION (PART 1) PROCEDURE – NOSE-WHEEL ONLY Special tooling required Level of Maintenance* Level 3 Reference documents BCAM-NT-001-001 * Refer to Chapter 2 for the description of the levels authorisation to perform the task. Parts List: Description Part No:...

  • Page 136: Front Fork Installation (Part 2) - Nose Wheel Variants Only

    6.3.8. FRONT FORK INSTALLATION (PART 2) – NOSE WHEEL VARIANTS ONLY FRONT FORK INSTALLATION (PART 2) PROCEDURE – NOSE-WHEEL ONLY Special tooling required Front spring compression jig Level of Maintenance* Level 3 Reference documents BCAM-NT-001-001 * Refer to Chapter 2 for the description of the levels authorisation to perform the task. Parts List: Description Part No:...

  • Page 138: Front Fork Installation (Part 3) - Nose Wheel Variants Only

    6.3.9. FRONT FORK INSTALLATION (PART 3) – NOSE WHEEL VARIANTS ONLY FRONT FORK INSTALLATION (PART 3) PROCEDURE – NOSE-WHEEL ONLY Special tooling required Front spring compression jig Level of Maintenance* Level 3 Reference documents BCAM-NT-001-001 * Refer to Chapter 2 for the description of the levels authorisation to perform the task. Parts List: Description Part No:...
  • Page 140 Final Inspection: 1. Perform a once-over check of all fastenings to ensure that they are tight. 2. Ensure that torque-seal is evident on all fastenings. COMPLETED BY STAMP SIGNATURE Issue 8, Revision 0 Page 140 of 338 BCPH-NT-008-000...

  • Page 141: Brake Bleeding Procedure

    8. Close the bleed nipple and do the same for the other side brake system 9. Replace the brake disk and wheel, and secure the wheel bolt with a torque of 25in.lbs/2.8Nm. 10. Lower the BushCat slowly to the ground. Final inspections: 1. Press on the toe brakes and ensure positive pressure.
  • Page 142 3. Ensure that no leaks are evident. WARNING Test the brakes on the first taxi to confirm correct functionality. COMPLETED BY STAMP SIGNATURE Issue 8, Revision 0 Page 142 of 338 BCPH-NT-008-000...

  • Page 143: Control Surfaces

    6.4. CONTROL SURFACES 6.4.1. FLAP AND AILERON INSTALLATION / REMOVAL PROCEDURE FLAP AND AILERON INSTALLATION / REMOVAL PROCEDURE Special tooling required Level of Maintenance* Level 3 Reference documents BCAM-NT-001-001 * Refer to Chapter 2 for the description of the levels authorisation to perform the task. Parts List: Description Part No:...
  • Page 145 Final Inspection: 1. Perform a once over inspection of all fastenings to ensure that they have been tightened. COMPLETED BY STAMP SIGNATURE Issue 8, Revision 0 Page 145 of 338 BCPH-NT-008-000...

  • Page 146: Elevator Installation / Removal Procedure

    6.4.2. ELEVATOR INSTALLATION / REMOVAL PROCEDURE ELEVATOR INSTALLATION / REMOVAL PROCEDURE Special tooling required Level of Maintenance* Level 3 Reference documents BCAM-NT-001-001 * Refer to Chapter 2 for the description of the levels authorisation to perform the task. Parts List: Description Part No: each...
  • Page 149 Final Inspection: 1. Perform a once over inspection of all fastenings to ensure that they have been tightened. COMPLETED BY STAMP SIGNATURE Issue 8, Revision 0 Page 149 of 338 BCPH-NT-008-000...

  • Page 150: Elevator Trim Tab Installation / Removal Procedure

    6.4.3. ELEVATOR TRIM TAB INSTALLATION / REMOVAL PROCEDURE ELEVATOR TRIM TAB INSTALLATION / REMOVAL PROCEDURE Special tooling required Level of Maintenance* Level 3 Reference documents BCAM-NT-001-001 * Refer to Chapter 2 for the description of the levels authorisation to perform the task. Parts List: Description Part No:...
  • Page 152 Final Inspection: 1. Perform a once over inspection of all fastenings to ensure that they have been tightened. COMPLETED BY STAMP SIGNATURE Issue 8, Revision 0 Page 152 of 338 BCPH-NT-008-000...

  • Page 153: Rudder Installation / Removal Procedure

    6.4.4. RUDDER INSTALLATION / REMOVAL PROCEDURE RUDDER INSTALLATION / REMOVAL PROCEDURE Required tooling Level of Maintenance* Level 3 Reference documents BCAM-NT-001-001 * Refer to Chapter 2 for the description of the levels authorisation to perform the task. Parts List: Description Part No: each Total...
  • Page 156 Final Inspection: 1. Perform a once over inspection of all fastenings to ensure that they have been tightened. COMPLETED BY STAMP SIGNATURE Issue 8, Revision 0 Page 156 of 338 BCPH-NT-008-000...

  • Page 157: Aileron Balance Tabs Installation / Removal

    6.4.5. AILERON BALANCE TABS INSTALLATION / REMOVAL CONTROL SURFACE RIGGING PROCEDURE Special tooling required. Pedals adjustment jig. Level of Maintenance* Level 4 Reference documents BCAM-NT-001-001 * Refer to Chapter 2 for the description of the levels authorisation to perform the task. Parts List: Description Part No:...
  • Page 158 FIGURE 6.4.5...

  • Page 159: Control Surface Rigging

    6.4.6. CONTROL SURFACE RIGGING CONTROL SURFACE RIGGING PROCEDURE Special tooling required. Pedals adjustment jig. Level of Maintenance* Level 4 Reference documents BCAM-NT-001-001 * Refer to Chapter 2 for the description of the levels authorisation to perform the task. Parts List: Control system cables installation – Nose-wheel only (Part 1) Description Part No: each...
  • Page 161 Parts List: Control system cables installation – Nose-wheel only (Part 2) Description Part No: each Total Section 78.1 / 78.2 (Main assembly) Section 29, item 2 (Rudder pedals installation) Section 23, item 2 (Joystick assembly) Section 72.2, item 2 (Elevator bracket) Section 76, item 10 (Rudder push lever bracket) Turnbuckle CH-00-12260...
  • Page 163 Parts List: Control system cables installation – Tail-dragger only (Part 1) Description Part No: each Total Section 77 (Main assembly) Section 1, item 1 (Bottom fuselage central bracket) Section 59, item 10 (Rear aileron control cable -LH) Section 59, item 11 (Rear aileron control cable -RH) Section 59, item 8 (Front aileron control cable) Rudder cable CH-00-61230...
  • Page 165 Parts List: Control system cables installation – Tail-dragger only (Part 2) Description Part No: each Total Section 78.1 / 78.2 (Main assembly) Section 29, item 2 (Rudder pedals installation) Section 23, item 2 (Joystick assembly) Section 72.2, item 2 (Elevator bracket) Section 76, item 10 (Rudder push lever bracket) Turnbuckle CH-00-12260...

  • Page 167: Elevator Setup

    6.4.7. ELEVATOR SETUP ELEVATOR SETUP PROCEDURE Special tooling required. Nil. Level of Maintenance* Level 4 Reference documents BCAM-NT-001-001 * Refer to Chapter 2 for the description of the levels authorisation to perform the task. Parts List: Description Part No: each Total Section 111 (Main assembly) Ø0.82 x 440mm safety wire...
  • Page 168 Figure 43: Neutral position of elevator Issue 8, Revision 0 Page 168 of 338 BCPH-NT-008-000...
  • Page 170 Figure 45: Measurement of horizontal distance between tube surface and stick centre Issue 8, Revision 0 Page 170 of 338 BCPH-NT-008-000...
  • Page 171 Figure 46: Full nose-down deflection Figure 47: Full nose-up deflection Issue 8, Revision 0 Page 171 of 338 BCPH-NT-008-000...
  • Page 172 COMPLETED BY STAMP SIGNATURE Issue 8, Revision 0 Page 172 of 338 BCPH-NT-008-000...

  • Page 173: Rudder Setup

    6.4.8. RUDDER SETUP RUDDER SETUP PROCEDURE Special tooling required. Control surface alignment jig, rudder pedal alignment jig. Level of Maintenance* Level 4 Reference documents BCAM-NT-001-001 * Refer to Chapter 2 for the description of the levels authorisation to perform the task. Parts List: Description Part No:...
  • Page 174 Figure 48: Installation of pedal alignment jig Figure 49: Neutral position of rudder Issue 8, Revision 0 Page 174 of 338 BCPH-NT-008-000...
  • Page 175 Figure 50: Control surface alignment jig Figure 51: Full left deflection Issue 8, Revision 0 Page 175 of 338 BCPH-NT-008-000...
  • Page 176 Figure 52: Full right deflection COMPLETED BY STAMP SIGNATURE Issue 8, Revision 0 Page 176 of 338 BCPH-NT-008-000...

  • Page 177: Aileron Setup

    6.4.9. AILERON SETUP AILERON SETUP PROCEDURE Custom made clamps to align ailerons with wings. Rudder rigging Special tooling required. jig. Level of Maintenance* Level 4 Reference documents BCAM-NT-001-001 * Refer to Chapter 2 for the description of the levels authorisation to perform the task. Parts List: Description Part No:...
  • Page 178 Figure 53: Alignment of aileron with wingtip Issue 8, Revision 0 Page 178 of 338 BCPH-NT-008-000...
  • Page 180 COMPLETED BY STAMP SIGNATURE Issue 8, Revision 0 Page 180 of 338 BCPH-NT-008-000...

  • Page 181: Flap Setup

    6.4.10. FLAP SETUP FLAP SETUP PROCEDURE Special tooling required. Control surface alignment jig, rudder pedal alignment jig. Level of Maintenance* Level 4 Reference documents BCAM-NT-001-001 * Refer to Chapter 2 for the description of the levels authorisation to perform the task. Parts List: Description Part No:...
  • Page 182 Figure 55: Pushrod adjustment Figure 56: Deflection angles Figure 57: Deflection distances Issue 8, Revision 0 Page 182 of 338 BCPH-NT-008-000...
  • Page 183 COMPLETED BY STAMP SIGNATURE Issue 8, Revision 0 Page 183 of 338 BCPH-NT-008-000...

  • Page 184: Rotax 912 Engine

    6.5. ROTAX 912 ENGINE All maintenance procedures in this section were included from the ROTAX maintenance manuals for line maintenance / heavy maintenance / installation / overhaul 2012 for the reader’s convenience. While every effort has been made to provide a true and up to date representation of the ROTAX inspections, should the ROTAX manual differ from the instructions presented here, the ROTAX manual supersedes this manual in all cases.
  • Page 185 4. After cleaning, dry all electrical components using compressed air including: a. Battery b. Ignition unit c. Spark plug connector d. Clamp connections e. Plug connections Final Inspection: Ensure that all openings that were blanked for cleaning are opened prior to operation. Ensure that all electrical components are dry prior to operation.

  • Page 186: Air Filter Inspection

    6.5.2. AIR FILTER INSPECTION AIR FILTER INSPECTION PROCEDURE Special tooling required K&N filter cleaner, ROTAX air filter oil. Level of Maintenance* Level 3 Reference documents BCAM-NT-001-001 * Refer to Chapter 2 for the description of the levels authorisation to perform the task. Parts List: Description Part No:...
  • Page 187 6. If the filter mat is damaged, replace the air filter. Inspection Findings: __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ COMPLETED BY STAMP SIGNATURE Issue 8, Revision 0 Page 187 of 338 BCPH-NT-008-000...

  • Page 188: Air Filter Replacement

    6.5.3. AIR FILTER REPLACEMENT AIR FILTER REPLACEMENT PROCEDURE Special tooling required Level of Maintenance* Level 3 Reference documents BCAM-NT-001-001 * Refer to Chapter 2 for the description of the levels authorisation to perform the task. Parts List: Description Part No: each Total Air filter...

  • Page 189: Engine Initial Preparation

    3. Place the engine on a table without removing its base plates. 4. Remove the exhaust brackets already fitted to the engine, as shown. Ensure that the openings are plugged. These brackets will not be required if using the BushCat exhaust system.
  • Page 190 Figure 58: Strap locations Figure 59: Removal of Rotax exhaust manifolds Issue 8, Revision 0 Page 190 of 338 BCPH-NT-008-000...
  • Page 191 Figure 60: Grounding wire Figure 61: Bolt removal Issue 8, Revision 0 Page 191 of 338 BCPH-NT-008-000...

  • Page 192: Starter Motor Rotation

    6.5.5. STARTER MOTOR ROTATION STARTER MOTOR ROTATION PROCEDURE Special tooling required Level of Maintenance* Level 3 Reference documents BCAM-NT-001-001 * Refer to Chapter 2 for the description of the levels authorisation to perform the task. Parts List: Description Part No: each Total Section 83.1...
  • Page 193 Figure 62: Starter motor clamp Figure 63: Starter motor retaining nuts Issue 8, Revision 0 Page 193 of 338 BCPH-NT-008-000...
  • Page 194 Figure 64: Removal of starter motor Figure 65: Correct orientation of starter motor Issue 8, Revision 0 Page 194 of 338 BCPH-NT-008-000...
  • Page 195 Figure 66: Rotation of clamp to correct position Figure 67: Clamp fastened with new starter motor position Issue 8, Revision 0 Page 195 of 338 BCPH-NT-008-000...
  • Page 196 Figure 68: Tighten bolts secure starter motor Issue 8, Revision 0 Page 196 of 338 BCPH-NT-008-000...

  • Page 197: Magneto Box Remount

    6.5.6. MAGNETO BOX REMOUNT MAGNETO BOX REMOUNT PROCEDURE Special tooling required Level of Maintenance* Level 3 Reference documents BCAM-NT-001-001 * Refer to Chapter 2 for the description of the levels authorisation to perform the task. Parts List: Description Part No: each Total Section 82.2 (Rotax 912 preparation assy)
  • Page 198 Figure 69: Original assembly Figure 70: Original removed bracket Issue 8, Revision 0 Page 198 of 338 BCPH-NT-008-000...
  • Page 199 Figure 71: Machining of bracket Figure 72: Modified bracket Issue 8, Revision 0 Page 199 of 338 BCPH-NT-008-000...
  • Page 200 Figure 73: P-clamp Figure 74: After p-clamp removal Issue 8, Revision 0 Page 200 of 338 BCPH-NT-008-000...
  • Page 201 Figure 75: Order of parts for mounting assembly Figure 76: Magneto box remounting 1 Issue 8, Revision 0 Page 201 of 338 BCPH-NT-008-000...
  • Page 202 Figure 77: Magneto box completed mounting Issue 8, Revision 0 Page 202 of 338 BCPH-NT-008-000...

  • Page 203: Engine Mounting Attachment

    6.5.7. ENGINE MOUNTING ATTACHMENT ENGINE MOUNTING ATTACHMENT PROCEDURE Special tooling required Engine hoist. Level of Maintenance* Level 3 Reference documents BCAM-NT-001-001 * Refer to Chapter 2 for the description of the levels authorisation to perform the task. Parts List: Description Part No: each Total...
  • Page 204 8. After locating the upper right hand side, locate the upper left hand mount using the method shown. 9. Continue fitting the engine mount, and fasten all 4 bolts. 10. Reconnect all the lower cooling system pipes which were removed in step 3. The 4 complete mounting points are shown as well as the complete routing of the cooling system pipes.
  • Page 205 Figure 78: Cooling pipe removal Figure 79: Leaking coolant Issue 8, Revision 0 Page 205 of 338 BCPH-NT-008-000...
  • Page 206 Figure 80: Bush assembly on mount Figure 81: Application of Loctite to the bolts Issue 8, Revision 0 Page 206 of 338 BCPH-NT-008-000...
  • Page 207 Figure 82: Upper right hand mounting bolt (long bolt) Figure 83 Lever method of inserting washer on upper left mounting position Issue 8, Revision 0 Page 207 of 338 BCPH-NT-008-000...
  • Page 208 Figure 84: Right hand mounting Issue 8, Revision 0 Page 208 of 338 BCPH-NT-008-000...
  • Page 209 Figure 85: Left hand mounting Issue 8, Revision 0 Page 209 of 338 BCPH-NT-008-000...
  • Page 210 Figure 86: Secured magneto box Issue 8, Revision 0 Page 210 of 338 BCPH-NT-008-000...

  • Page 211: Engine Removal And Installation

    4. Prepare the bolt assemblies to fasten the lower mounting pins, complete with LOCTITE® 243. It is vital to note that if the BushCat exhaust system is to be installed, item 11 from section 86 should be inserted into this bolt assembly now.
  • Page 212 8. Prepare the bolt assemblies to fasten the lower mounting pins, complete with LOCTITE® 243. 9. Permanently fasten the two top mounting points, using the same method as for the lower mounting points. Issue 8, Revision 0 Page 212 of 338 BCPH-NT-008-000...
  • Page 213 Figure 87: Bottom pins loosely located Figure 88: Exploded view of lower mount bolt assemblies Issue 8, Revision 0 Page 213 of 338 BCPH-NT-008-000...
  • Page 214 Figure 89: Method of inserting the rubber bushes into the aircraft mount Issue 8, Revision 0 Page 214 of 338 BCPH-NT-008-000...
  • Page 215 Figure 90: Method of inserting the engine mount into the aircraft mount Issue 8, Revision 0 Page 215 of 338 BCPH-NT-008-000...
  • Page 216 Figure 91: Exploded view of upper mount bolt assemblies Final Inspection: 1. Conduct a stock take of all tools and loose parts to ensure that none remain behind in the engine. 2. Complete an engine test run as per section 6.5.10. COMPLETED BY STAMP SIGNATURE...

  • Page 217: Replacement Of Engine Exhaust

    6.5.9. REPLACEMENT OF ENGINE EXHAUST REPLACEMENT OF ENGINE EXHAUST PROCEDURE Special tooling required Nil. Level of Maintenance* Level 3 Reference documents BCAM-NT-001-001 * Refer to Chapter 2 for the description of the levels authorisation to perform the task. Parts List: Description Part No: each...
  • Page 218 Procedure: 1. A schematic of the overall engine exhaust system is given in figure 86.1 and an exploded view of all pipes is given. 2. Begin fitting the engine exhaust pipes starting from the front engine exhaust manifolds (items 5 and 6) as shown. 3.
  • Page 219 Figure 92: Exploded view Figure 93: Front tubes Issue 8, Revision 0 Page 219 of 338 BCPH-NT-008-000...
  • Page 220 Figure 94: Back tubes with copper compound Figure 95: Spring tensioning tool Issue 8, Revision 0 Page 220 of 338 BCPH-NT-008-000...
  • Page 221 Figure 96: Muffler orientation Figure 97: Muffler attached Issue 8, Revision 0 Page 221 of 338 BCPH-NT-008-000...
  • Page 222 Figure 98: Strap plates Figure 99: Pipe clamps Issue 8, Revision 0 Page 222 of 338 BCPH-NT-008-000...
  • Page 223 Figure 100: Strap installation Figure 101: All springs installed and gasket maker applied Figure 102: Exhaust positioning Issue 8, Revision 0 Page 223 of 338 BCPH-NT-008-000...
  • Page 224 Figure 103: Drilling exhaust pipe Figure 104: Completed clamp assembly Final Inspection: 1. Perform a final audit of all loose parts and check that the clamps are tight. COMPLETED BY STAMP SIGNATURE Issue 8, Revision 0 Page 224 of 338 BCPH-NT-008-000...

  • Page 225: Fuel Pump Inspection / Maintenance Procedure

    6.5.10. FUEL PUMP INSPECTION / MAINTENANCE PROCEDURE FUEL PUMP INSPECTION / MAINTENANCE PROCEDURE Special tooling required Nil. Level of Maintenance* Level 4 Reference documents ROTAX Heavy Maintenance Manual. * Refer to Chapter 2 for the description of the levels authorisation to perform the task. Parts List: Description Part No:...
  • Page 226 Service Bulletins SB-912-049 “Checking eccenters and fuel pump plungers”, latest NOTE: issue must be observed. In the course of continuous development a new fuel pump part no 893115 has been introduced. The fuel pumps part no. 893115 has been introduced. The fuel NOTE: pumps part no.
  • Page 227 Figure 105: Fuel Pump Schematic Issue 8, Revision 0 Page 227 of 338 BCPH-NT-008-000...
  • Page 228 Inspection Findings: __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ COMPLETED BY STAMP SIGNATURE Issue 8, Revision 0 Page 228 of 338 BCPH-NT-008-000...

  • Page 229: Magnetic Plug Inspection

    6.5.11. MAGNETIC PLUG INSPECTION MAGNETIC PLUG INSPECTION PROCEDURE Special tooling required Nil. Level of Maintenance* Level 4 Reference documents ROTAX Line Maintenance Manual. Parts: Description Part No: each Total NO PARTS Procedure: NOTE: The magnetic plug is located on the crankcase between cylinder 2 and gearbox. 1.
  • Page 230 Figure 106: ROTAX Magnetic Plug Inspection. Inspection Findings: __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ COMPLETED BY STAMP SIGNATURE Issue 8, Revision 0 Page 230 of 338 BCPH-NT-008-000...

  • Page 231: Bing Constant Depression Carburettor Inspection

    6.5.12. BING CONSTANT DEPRESSION CARBURETTOR INSPECTION BING CONSTANT DEPRESSION CARBURETTOR INSPECTION PROCEDURE Special tooling required Level of Maintenance* Level 4 Reference documents ROTAX Heavy Maintenance Manual. Parts List: Description Part No: each Total NO PARTS Procedure: The determination of the main jet is carried out by the manufacturer on a test bed at 300 m (1000 ft) above Mean Sea Level.
  • Page 232 If the pressure drops, this indicates leakage which may cause fuel overflow and in consequence engine damage due to hydraulic shock. Replacement of the float CAUTION valve seat is not permissible. Issue 8, Revision 0 Page 232 of 338 BCPH-NT-008-000...
  • Page 233 Figure 107: Float Needle Valve Leakage Test Schematic Issue 8, Revision 0 Page 233 of 338 BCPH-NT-008-000...
  • Page 234 Figure 108: Individual Components of the Carburettor as per ROTAX IPC 73-00-00-2 Issue 8, Revision 0 Page 234 of 338 BCPH-NT-008-000...
  • Page 235 Diaphragm: 1. The plunger (carburettor piston) (8) is attached to the diaphragm (6). Depending on the pressure prevailing, the plunger is moved up or down. 2. To inspect a. Remove the two M5x12 counter sunk screws (1) b. Take off the chamber top (2) c.
  • Page 236 Figure 109: Carburettor Diaphragm and Needle Maintenance Schematic Issue 8, Revision 0 Page 236 of 338 BCPH-NT-008-000...
  • Page 237 Float chamber, floats: 1. Release the spring clip (39). 2. Remove and clean the float housing (11) with the seal (12). 3. Check both floats (9) for free movement on the guide pin (3). 4. When the float is at its lowest position, it must still have radial clearance and must not stick on the float chamber wall (10).
  • Page 238 Figure 110: Carburettor Float and Float Chambers Schematic. Issue 8, Revision 0 Page 238 of 338 BCPH-NT-008-000...
  • Page 239 Carburettor jets: Always maintain high standards of cleanliness when performing any work on the CAUTION carburettor. 1. Remove the float chamber. 2. Unscrew the main jet (14), the mixing tube (15), the needle jet (16), the idle jet (17), the starting jet (18) and the idle mixture screw (19).
  • Page 240 Float needle valve inspection: 1. Remove the float chamber. 2. Remove the bearing pin (4) of the float bracket (5) and pull out the float needle. 3. Check fuel inlet for free passage. 4. Inspect the viton tip (1). 5. Inspect clip end for visible wear to the beaded edge (2) of the sprung pin (3) 6.
  • Page 241 Starting Carburettor (Choke) 1. Remove the 4 M4x14 countersunk screws and remove the complete rotary disc valve housing. The shafts for the rotary disc valve have two markings, L and R. The shaft marked NOTE: R is for the carburettors for cylinders 2/4, the shaft marked : for the carburettor for cylinders 1/3.
  • Page 242 Carburettor Assembly: The carburettor with new O-rings and gaskets is assembled in reverse order. Figure 114: Carburettor Assembly Schematic. Issue 8, Revision 0 Page 242 of 338 BCPH-NT-008-000...
  • Page 243 Inspection Findings: __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ COMPLETED BY STAMP SIGNATURE Issue 8, Revision 0 Page 243 of 338 BCPH-NT-008-000...

  • Page 244: Engine Test Run

    6.5.13. ENGINE TEST RUN ENGINE TEST RUN PROCEDURE Aircraft anchor point and chains / ballistic chute chords to secure Special tooling required the aircraft. Level of Maintenance* Level 3 Reference documents ROTAX Line Maintenance Manual. * Refer to Chapter 2 for the description of the levels authorisation to perform the task. Parts List: Description Part No:...
  • Page 245 12. After a full-load run, conduct a short cooling run to prevent steam locks in the cooling and fuel system after shut-down. 13. Shut engine down. NOTE: On switching off the engine, switch off ignition and withdraw the ignition key. 14.

  • Page 246: Fuel System

    6.6. FUEL SYSTEM 6.6.1. REFUELLING PROCEDURE REFUELLING PROCEDURE Special tooling required Funnel, refuelling pip, cleaning rags. Level of Maintenance* Level 1 Reference documents ROTAX 912 ULS MANUAL * Refer to Chapter 2 for the description of the levels authorisation to perform the task. Parts List: Description Part No:...

  • Page 247: Fuel Filter Inspection / Replacement

    In-line fuel filters STD-000314 Procedure: The BushCat makes use of 2 diesel inline fuel filters positioned on the fuel lines leaving the tank. The use of two on separate lines provides redundancy until such NOTE: a time as the fuel drops below the minimum level in the tank that allows the fuel to move from one side to the other.
  • Page 248 Figure 115: Fuel Filter Inspection Issue 8, Revision 0 Page 248 of 338 BCPH-NT-008-000...
  • Page 249 Inspection findings: __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ COMPLETED BY STAMP SIGNATURE Issue 8, Revision 0 Page 249 of 338 BCPH-NT-008-000...

  • Page 250: Inspection Of The Fuel Pump, Carburettor, Fuel Lines, And Drip Tray

    6.6.3. INSPECTION OF THE FUEL PUMP, CARBURETTOR, FUEL LINES, AND DRIP TRAY INSPECTION PROCEDURE FOR THE FUEL PUMP, CARBURETTORS, CARBURETTOR SOCKETS, FUEL LINES AND DRIP TRAY. Special tooling required Funnel, refuelling pip, cleaning rags. Level of Maintenance* Level 4 Reference documents ROTAX 912 ULS MANUAL * Refer to Chapter 2 for the description of the levels authorisation to perform the task.
  • Page 251 Flexible fuel line: 1. Each fuel line (5) is supported by a cable clamp (13) on the intake manifold. Each of these clamps is attached with an M8 Allen nut (14), which must be removed. 2. The fuel line is additionally attached with 2 cable straps (15) to the compensation tube (16). 3.
  • Page 254 Inspection findings: __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ COMPLETED BY STAMP SIGNATURE Issue 8, Revision 0 Page 254 of 338 BCPH-NT-008-000...

  • Page 255: Fuel Tank, Fuel Lines, And Fuel Shut-Off Valve Installation

    6.6.4. FUEL TANK, FUEL LINES, AND FUEL SHUT-OFF VALVE INSTALLATION FUEL TANK AND FUEL LINE INSTALLATION PROCEDURE (PART 1) Special tooling required Level of Maintenance* Level 3 Reference documents BCAM-NT-001-001 * Refer to Chapter 2 for the description of the levels authorisation to perform the task. Parts List: Description Part No:...
  • Page 257 FUEL SHUT OFF VALVE INSTALLATION PROCEDURE (PART 2) Special tooling required Level of Maintenance* Level 1 Reference documents BCAM-NT-001-001 Parts List: Description Part No: each Total Section 82.1 (Main assembly) Parts list in development Procedure: 1. Install the fuel shutoff valve in the left hand centre console inspection panel (or preferred position).
  • Page 258 Figure 119: Fuel shutoff valve Issue 8, Revision 0 Page 258 of 338 BCPH-NT-008-000...
  • Page 259 Final Inspection: 1. Perform a final check of the fuel line routing and security of attachments. COMPLETED BY STAMP SIGNATURE Issue 8, Revision 0 Page 259 of 338 BCPH-NT-008-000...

  • Page 260: Oil System

    6.7. OIL SYSTEM 6.7.1. REPLENISHMENT OF OIL REPLENISHMENT OF OIL PROCEDURE Special tooling required Level of Maintenance* Level 1 Reference documents BCAM-NT-001-001 * Refer to Chapter 2 for the description of the levels authorisation to perform the task. Parts List: Description Part No: each...
  • Page 261 Figure 120: Remove the Cap from the Oil Tank Figure 121: Remove the Dipstick Issue 8, Revision 0 Page 261 of 338 BCPH-NT-008-000...
  • Page 262 Figure 122: Pour the Oil Directly in Issue 8, Revision 0 Page 262 of 338 BCPH-NT-008-000...

  • Page 263: Oil Filter Replacement

    6.7.2. OIL FILTER REPLACEMENT OIL FILTER REPLACEMENT Special tooling required ROTAX Oil filter cutting tool Level of Maintenance* Level 3 Reference documents BCAM-NT-001-001 * Refer to Chapter 2 for the description of the levels authorisation to perform the task. Parts List: Description Part No: each...
  • Page 264 Figure 123: (a) Oil Filter Cutting Tool (b) Oil Filter Replacement Process. Issue 8, Revision 0 Page 264 of 338 BCPH-NT-008-000...
  • Page 265 Final Inspection: 1. Perform a final check of fastener tightness and tool inventory. COMPLETED BY STAMP SIGNATURE Issue 8, Revision 0 Page 265 of 338 BCPH-NT-008-000...

  • Page 266: Oil Filter Inspection

    6.7.3. OIL FILTER INSPECTION OIL FILTER REPLACEMENT Special tooling required ROTAX Oil filter cutting tool Level of Maintenance* Level 3 Reference documents BCAM-NT-001-001 * Refer to Chapter 2 for the description of the levels authorisation to perform the task. Parts List: Description Part No: each...
  • Page 267 If an increased amount of metal particles are found (such as brass chips, bronze chips or a sliver of bearing), repair or overhaul the engine in accordance with the NOTE: BRP-Powertrain instructions for continued airworthiness. If the filter mat is clogged by foreign matter, the lube oil reaches the bearing points unfiltered via the by-pass valve in the oil filter.
  • Page 268 Figure 124: ROTAX Oil Filter Issue 8, Revision 0 Page 268 of 338 BCPH-NT-008-000...
  • Page 269 Inspection findings: __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ COMPLETED BY STAMP SIGNATURE Issue 8, Revision 0 Page 269 of 338 BCPH-NT-008-000...

  • Page 270: Oil Changes

    6.7.4. OIL CHANGES OIL CHANGE PROCEDURE Special tooling required K&N filter cleaner, ROTAX air filter oil. Level of Maintenance* Level 3 Reference documents BCAM-NT-001-001 * Refer to Chapter 2 for the description of the levels authorisation to perform the task. Parts List: Description Part No:...
  • Page 271 6. Install new oil filter. 7. Pour in approximately 3.01 litres (0.8 US Gallons) of fresh oil. 8. After carrying out the oil change, the engine should be cranked by hand in the direction of engine rotation (approximately 20 turns) to completely refill the entire oil circuit. When tightening the fasting nut, always support the fitting with a second CAUTION spanner.

  • Page 272: Propeller

    6.8. PROPELLER 6.8.1. INSTALLATION OF THE PROPELLER AND ADJUSTMENT OF THE PROPELLER PITCH ANGLE INSTALLATION OF THE PROPELLER & ADJUSTMENT OF THE PROPELLOR PITCH ANGLE Special tooling required Level of Maintenance* Level 4 Reference documents BCAM-NT-001-001 * Refer to Chapter 2 for the description of the levels authorisation to perform the task. Parts List: Description Part No:...
  • Page 273 6. Fit the blade inclinometer at its correct distance from the blade tip, on a horizontal blade (on the left side), as shown. 7. Adjust the blade pitch to the required setting as shown. 8. Tighten the nuts on the hub either side of the adjusted blade. 9.
  • Page 274 Figure 127: Loosely fasten hub Figure 128: Install composite flange and spacer Issue 8, Revision 0 Page 274 of 338 BCPH-NT-008-000...
  • Page 275 Figure 129: Fit large spacer Figure 130: Install on engine Figure 131: Loosely fasten Issue 8, Revision 0 Page 275 of 338 BCPH-NT-008-000...
  • Page 276 Figure 132: Fit inclinometer to blades Figure 133: Set pitch Issue 8, Revision 0 Page 276 of 338 BCPH-NT-008-000...
  • Page 277 Figure 134: Torque Figure 3: Propeller Installation. Final Inspection: 1. Perform a final check of the propeller blade angle for each of the 3 blades: a. Blade 1: ___________________________ b. Blade 2: ___________________________ c. Blade 3: ___________________________ 2. Perform a final check of fastener security and a final tool inventory. COMPLETED BY STAMP SIGNATURE...

  • Page 278: Utility Systems

    UTILITY SYSTEMS 6.9.1. HEATING AND VENTILATION SYSTEMS The BushCat has vents in the doors which can be opened to increase cabin ventilation. Additionally the aircraft comes with an option to have a cabin heating system included. For information on the installation and maintenance of this system, please consult the heater system installation manual.

  • Page 279: Instruments And Avionics

    6.10. INSTRUMENTS AND AVIONICS Due to the variance of instrument panels used on the BushCat, the operator is referred to the maintenance manuals for the specific equipment installed in the aircraft. Avionics maintenance procedures which relate to the airframe are given in the sections below.
  • Page 281 Final Inspection: 1. Perform a complete functionality check of all instruments. COMPLETED BY STAMP SIGNATURE Issue 8, Revision 0 Page 281 of 338 BCPH-NT-008-000...

  • Page 282: Inspection Of The Pitot Static System

    6.10.2. INSPECTION OF THE PITOT STATIC SYSTEM INSPECTION OF THE PITOT STATIC SYSTEM PROCEDURE Special tooling required Level of Maintenance* Level 2 Reference documents Parts List: Description Part No: each Total NO PARTS Procedure: Remove the cover from the Pitot tube and inspect it visually to ensure that there are no obstructions in the entry to the tube.
  • Page 283 Figure 137: Pitot tube attachment to airspeed Indicator. Figure 138: Pitot tube cover Issue 8, Revision 0 Page 283 of 338 BCPH-NT-008-000...
  • Page 284 Inspection findings: __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ COMPLETED BY STAMP SIGNATURE Issue 8, Revision 0 Page 284 of 338 BCPH-NT-008-000...

  • Page 285: Ignition System

    6.11. IGNITION SYSTEM As the ignition system cannot be repaired, failure of an inspection requires it to be replaced. The basic inspection has been reproduced below from the ROTAX Heavy Maintenance Manual for convenience. While every effort has been made to accurately reproduce the contents, in the case of any discrepancy between this and the ROTAX manuals, the ROTAX manuals take precedence in all cases.

  • Page 286: Electrical System

    6.12. ELECTRICAL SYSTEM 6.12.1. REPLACEMENT OF THE BATTERY BATTERY REPLACEMENTPROCEDURE Special tooling required Nil. Level of Maintenance* Level 3 Reference documents BCAM-NT-001-001 * Refer to Chapter 2 for the description of the levels authorisation to perform the task. Parts List: Description Part No: 390 x 7.8mm tie wrap...
  • Page 287 Final Inspection: 1. Perform a functionality check of the battery prior to operation. COMPLETED BY STAMP SIGNATURE Issue 8, Revision 0 Page 287 of 338 BCPH-NT-008-000...

  • Page 288: Overhaul Of Electric Starter

    6.12.2. OVERHAUL OF ELECTRIC STARTER ELECTRIC STARTER OVERHAUL PROCEDURE Special tooling required Nil. Level of Maintenance* Level 4 Reference documents ROTAX Heavy Maintenance Manual. * Refer to Chapter 2 for the description of the levels authorisation to perform the task. Parts List: Description Part No:...
  • Page 289 Figure 139: Dismantling the Electric Starter – Standard Issue 8, Revision 0 Page 289 of 338 BCPH-NT-008-000...
  • Page 290 Electric starter dismantling: HD Starter 1. Remove the M5 hexagonal nuts (1) with lock washers (2) and washers (3) or the cap nut (10) from the rear side of the ignition cover (6). 2. The electric starter (4) can be removed by releasing the tension clamp (5). Issue 8, Revision 0 Page 290 of 338 BCPH-NT-008-000...
  • Page 291 Figure 140: Dismantling the Electric Starter – HD Issue 8, Revision 0 Page 291 of 338 BCPH-NT-008-000...
  • Page 292 Electric starter disassembly: Standard Starter 1. Unscrew combined nut (23) and remove connector sheath (17) with O-ring (19). 2. Pull bearing flange (1) off the starter housing (2). 3. Carefully pull rotor bearing (3) a short way off the starter housing and press the positive carbon brush (23) with the connector sheath (17) out of the rotor bearing.
  • Page 293 Figure 141: Disassembling the Electric Starter – Standard Issue 8, Revision 0 Page 293 of 338 BCPH-NT-008-000...
  • Page 294 Electric starter disassembly: HD Starter 1. Unscrew combined nut (23) and remove connector sheath (17) with O-ring (19). 2. Unscrew M5 allen screw (24) and pull bearing flange (1) off the starter housing (2). 3. Carefully pull rotor bearing (3) a short way off the starter housing and press the positive carbon brush (23) out of the rotor bearing.
  • Page 295 Figure 142: Dismantling the Electric Starter - HD Issue 8, Revision 0 Page 295 of 338 BCPH-NT-008-000...
  • Page 296 Inspection of individual parts (both): After disassembly, check the following parts: Rotor: 1. Clean the commutator 2. Check for run out 3. Carry out visual inspection 4. If necessary, fine machine and undercut commutator ribs (7). NOTE: The insulation should be 0.5mm (.02 inches) lower than the ribs. During this machining process, material particles are released and could possibly WARNING be inhaled.
  • Page 297 Figure 143: Electric Starter Inspection Issue 8, Revision 0 Page 297 of 338 BCPH-NT-008-000...
  • Page 298 Bearings: Check bearing socket (13) and if necessary, replace the complete rotor bearing. Carbon Brushes: 1. Carbon brushes (14) must move freely in their guides (15). 2. Replace too short brushes (min. Length 8mm = 0.32”). 3. Check spring pressure. 4.
  • Page 299 Figure 144: Electric Starter Reassembly Installation of the Electric Starter: Standard (See the Dismantling Diagram) 1. Lightly grease the centring bore (9) in the ignition housing (8). 2. Push the complete electric starter (6) with new 4.7x1.4 O-rings (5) and distance sleeves (4) into the ignition housing (8).
  • Page 300 Installation of the Electric Starter: HD (See the Dismantling Diagram) 1. Lightly grease the centring bore (9) in the ignition housing (6). 2. Push the complete electric starter (4) into the ignition housing (6). 3. Tighten evenly with washer (3), spring (2) and hexagonal nut (1) or only with the M5 cap nut (10) and then attach to the ignition housing with the tension clamp (5).
  • Page 301 Figure 145: Electric Starter Wear Limits. Issue 8, Revision 0 Page 301 of 338 BCPH-NT-008-000...
  • Page 302 Figure 146: Electric Starter Wear Limits. Final Inspection: 2. Perform an engine test run as per section 6.5.10. COMPLETED BY STAMP SIGNATURE Issue 8, Revision 0 Page 302 of 338 BCPH-NT-008-000...

  • Page 303: Structural Installation / Replacement / Minor Repair

    6.13. STRUCTURAL INSTALLATION / REPLACEMENT / MINOR REPAIR 6.13.1. SEAT INSTALLATION SEAT INSTALLATION PROCEDURE Special tooling required Level of Maintenance* Level 1 Reference documents BCAM-NT-001-001 * Refer to Chapter 2 for the description of the levels authorisation to perform the task. Parts List: Description Part No:...
  • Page 306 Final Inspection: 3. Perform a final check that the seatbelts are securely positioned. COMPLETED BY STAMP SIGNATURE Issue 8, Revision 0 Page 306 of 338 BCPH-NT-008-000...

  • Page 307: Seat Belt Nstallation

    6.13.2. SEAT BELT NSTALLATION SEAT BELT INSTALLATION PROCEDURE Special tooling required Level of Maintenance* Level 1 Reference documents BCAM-NT-001-001 * Refer to Chapter 2 for the description of the levels authorisation to perform the task. Parts List: Description Part No: Section 41 (Main assembly) Main belt CH-00-65100...
  • Page 309 Final Inspection: 4. Perform a functionality check of the seatbelts. COMPLETED BY STAMP SIGNATURE Issue 8, Revision 0 Page 309 of 338 BCPH-NT-008-000...

  • Page 310: Cabin Door Replacement

    6.13.3. CABIN DOOR REPLACEMENT CABIN DOOR REPLACEMENT PRODECURE Special tooling required Level of Maintenance* Level 2 Reference documents BCAM-NT-001-001 * Refer to Chapter 2 for the description of the levels authorisation to perform the task. Parts List: Description Part No: each Total Section 99 (Main assembly)
  • Page 312 Final Inspection: 1. Perform a final check that all fittings are secure. COMPLETED BY STAMP SIGNATURE Issue 8, Revision 0 Page 312 of 338 BCPH-NT-008-000...

  • Page 313: Replacement Of The Ballistic Recovery System

    6.13.4. REPLACEMENT OF THE BALLISTIC RECOVERY SYSTEM BALLISTIC RECOVERY SYSTEM REPLACEMENT PROCEDURE Special tooling required Level of Maintenance* Level 3 Reference documents BCAM-NT-001-001 * Refer to Chapter 2 for the description of the levels authorisation to perform the task. Parts List: Description Part No: each...
  • Page 314 Final Inspection: 1. Perform a final check that all fittings are secure. COMPLETED BY STAMP SIGNATURE Issue 8, Revision 0 Page 314 of 338 BCPH-NT-008-000...

  • Page 315: Removal And Replacement Of The Windscreen

    6.13.5. REMOVAL AND REPLACEMENT OF THE WINDSCREEN WINDSCREEN INSTALLATION / REPLACEMENT PROCEDURE Special tooling required Level of Maintenance* Level 3 Reference documents BCAM-NT-001-001 * Refer to Chapter 2 for the description of the levels authorisation to perform the task. Parts List: Part 1 Description Part No: each...
  • Page 317 Parts List: Part 2 Description Part No: each Total Section 97.1 (Main assembly) Support Beam CH-00-10005 M4 x 30mm bolt M4 x 8mm washer M4 Nylock nut Ø3.2 x 10mm pop rivet (St. steel) Torque Seal Procedure: Part 2 1. Assemble as per the assembly steps shown. 2.
  • Page 319 Parts List: Part 3 Description Part No: each Total Section 97.2 (Main assembly) Windscreen CH-00-15001 Centre windscreen batten CH-00-15011 PP110 rubber - 1400mm CH-00-10006 M4 x 16mm machine screws M4 x 8mm washer M4 x 10mm rivet nut Ø3.2 x 10mm pop rivet (Aluminium) Procedure: 1.
  • Page 321 Procedure: Additional notes: In the event of a wing recovery preceding the intended windscreen replacement, this method is no longer valid. NOTE: It is advisable to do any trimming, drilling or finishing of the Lexan screen on a warm day Do not use any chemical cleaners (such as acetone) on or near the Lexan screen Removal accomplishment procedure: 1.
  • Page 322 NOTES: Rev no Date Approval Eddie's brackets for the windscreen battens for the windscreen replacement. 100,0 15,0 20,0 Page TOLERANCE: +0.2, -0.2 CHEETAH Mass Description Date Brackets for windscreen replacement 27/01/2017 Puzilewicz Developer Surname Part no: Scale Material Mild steel Authority Signature...
  • Page 323 6. These brackets are fastened tightly to the leading edge tubes of the wings with 2 cable ties on each after adjustment so that the front of the batten tubes slots between the arms of the bracket as depicted in the schematics that follow. Figure 155: Schematic for bracket placement –...
  • Page 324 2. Fit the 2 M6 bolts through the pre-drilled holes in the rear of the Lexan screen and through the transverse strut. These holes are accurately pre-drilled to ensure correct alignment of the screen. 3. Lift the front of the screen enough to slide the top portion of the screen sides under the leading edge tubes and allow the screen to lie in position against the main fairing.
  • Page 325 16. Manipulate and reposition the fairings as required to get the tightest fit around the leading edge tune and against the windscreen. Hold this position and drill through the holes in the fairing and into the screen. 17. When all the new holes have been drilled, remove the fairings. 18.
  • Page 326 Final Inspection: 1. Check the window for any cracks that have become apparent after fitting. 2. Check that the window is securely fitted. COMPLETED BY STAMP SIGNATURE Issue 8, Revision 0 Page 326 of 338 BCPH-NT-008-000...

  • Page 327: Painting And Coatings

    6.14. PAINTING AND COATINGS 6.14.1. TRI-LAMINATE REPAIR TRILAMINATE REPAIR PROCEDURE Special tooling required Level of Maintenance* Level 2 Reference documents BCAM-NT-001-001 * Refer to Chapter 2 for the description of the levels authorisation to perform the task. Parts List: Description Part No: each Total...

  • Page 328: Placard And Instrument Marking Identification And Replacement

    Throttle placard (left hand side) BC-00-01406 Throttle placard (right hand side) BC-00-01407 Door latch placard (left hand side) BC-00-01408 Door latch placard (right hand side) BC-00-01409 BushCat by SkyReach logo BC-00-01411 Fuel here placard BC-00-01412 Fuel type placard BC-00-01413 Fuel shut-off placard BC-00-01414 Flap 0°...
  • Page 329 4. Note that item 19 and 20 may be used to the preference of the customer, i.e.: Both mounting surfaces may display only metric or only imperial units, or one of each unit could be used on either side. Figure 156: BushCat logo Issue 8, Revision 0 Page 329 of 338...
  • Page 330 Figure 157: Passenger warning and trim/choke decal Figure 158: Operating limits decal Issue 8, Revision 0 Page 330 of 338 BCPH-NT-008-000...
  • Page 331 Figure 159: Aerobatics and spins prohibited decal Figure 160: Baggage limits decal Issue 8, Revision 0 Page 331 of 338 BCPH-NT-008-000...
  • Page 332 Figure 161: Throttle decals Figure 162: Door latch decals Issue 8, Revision 0 Page 332 of 338 BCPH-NT-008-000...
  • Page 333 Figure 163: Fuel location decal Figure 164: Fuel cap decal Issue 8, Revision 0 Page 333 of 338 BCPH-NT-008-000...
  • Page 334 Figure 165: Fuel shut-off valve decal Figure 166: Flap increment decals Figure 167: Light sport decal Issue 8, Revision 0 Page 334 of 338 BCPH-NT-008-000...
  • Page 335 Figure 168: Fuel quantity decals COMPLETED BY STAMP SIGNATURE Issue 8, Revision 0 Page 335 of 338 BCPH-NT-008-000...

  • Page 336: Aircraft Painting

    Paint Procedure: The aluminium tubing making up the primary structure of the BushCat is of aircraft grade and requires no painting of any kind. The tri-laminate covering making up the BushCat skin does not require any paint or dye. The application of inappropriate paint or dye would rapidly deteriorate the life of the tri-laminate covering and is not advisable.

  • Page 337: Aircraft Washing

    6.14.4. AIRCRAFT WASHING AIRCRAFT WASHING PROCEDURE Special tooling required Level of Maintenance* Level 1 Reference documents * Refer to Chapter 2 for the description of the levels authorisation to perform the task. Parts List: Description Part No: each Total NO PARTS Under no circumstances make use of a high pressure hose to wash the aircraft as WARNING this will damage the tri-laminate aircraft covering.

  • Page 338: Appendix 1: Equipment Change Request

    To whom it may concern Subject: BushCat equipment change authorization Manufacturer authorizes repairman, A&P, IA (Authority certificate number) to install the following equipment in LSA BushCat (insert serial number here) Product Name_________________ Model_________________ Part Number_________________ Product Name_________________ Model_________________ Part Number_________________...

Table of Contents

Save PDF