BRISTELL S-LSA Maintenance And Inspection Procedures Manual
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BRISTELL S-LSA Maintenance And Inspection Procedures Manual

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REGISTRATION MARK:
SERIAL NUMBER:
This Manual contains information necessary for operation and maintenance
of the airplane in accordance with the European CS-VLA, International ASTM
LSA, and Czech UL – 2 airworthiness requirements.
BRM AERO, Ltd.
Letecká 255
686 04 Kunovice
Czech Republic
phone:
+ 420 773 984 338
e-mail 1:
info@brmaero.com
e-mail 2:
aero.brm@gmail.com
web:
http://www.brmaero.com
N101LW
231/2016

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  • Page 1 BRM AERO, Ltd. Letecká 255 686 04 Kunovice Czech Republic phone: + 420 773 984 338 e-mail 1: info@brmaero.com e-mail 2: aero.brm@gmail.com web: http://www.brmaero.com REGISTRATION MARK: N101LW SERIAL NUMBER: 231/2016 This Manual contains information necessary for operation and maintenance of the airplane in accordance with the European CS-VLA, International ASTM LSA, and Czech UL –...
  • Page 3 CHAPTER – DOCUMENT CHANGES Record of revisions Rev. Date and Reason for revision Affected Pages Date of Issue Signature 05/2016 Initial Issue 05/2016 Petr Javorský 12/2016 0-1, 0-2, 0-3, 12-2 12/2016 Change of static ports Petr Javorský 0.CHAPTER – DOCUMENT CHANGES Document: SLSA-MIP-5-4-0-US Date of Issue: 05/2016 Revision: -...
  • Page 4 List of effective pages Chapter Page Date Chapter Page Date Cover page 05/2016 05/2016 12/2016 05/2016 12/2016 05/2016 12/2016 05/2016 05/2016 05/2016 05/2016 05/2016 05/2016 05/2016 05/2016 05/2016 05/2016 05/2016 05/2016 05/2016 05/2016 05/2016 05/2016 05/2016 05/2016 05/2016 05/2016 05/2016 05/2016 05/2016 05/2016...
  • Page 5 Chapter Page Date Chapter Page Date 10-18 05/2016 10-19 05/2016 05/2016 10-20 05/2016 05/2016 10-21 05/2016 05/2016 10-22 05/2016 05/2016 10-23 05/2016 05/2016 10-24 05/2016 05/2016 10-25 05/2016 05/2016 10-26 05/2016 05/2016 10-27 05/2016 05/2016 10-28 05/2016 8-10 05/2016 10-29 05/2016 8-11 05/2016...
  • Page 6 Chapter Page Date Chapter Page Date 14-1 05/2016 16-1 05/2016 14-2 05/2016 16-2 05/2016 14-3 05/2016 16-3 05/2016 14-4 05/2016 16-4 05/2016 16-5 05/2016 16-6 05/2016 16-7 05/2016 15-1 05/2016 16-8 05/2016 15-2 05/2016 16-9 05/2016 15-3 05/2016 16-10 05/2016 15-4 05/2016 15-5...

  • Page 7: Table Of Contents

    Table of contents CHAPTER – DOCUMENT CHANGES ............. 0-1 CHAPTER - GENERAL ................... 1-1 CHAPTER - LIMITATIONS / MAINTENANCE CHECKS ......... 2-1 CHAPTER - FUSELAGE ................. 3-1 CHAPTER - WING ................... 4-1 CHAPTER – TAIL UNIT ................... 5-1 CHAPTER - CONTROLS ................. 6-1 CHAPTER - EQUIPMENT ................

  • Page 8: Chapter - Document Changes

    INTENTIONALLY LEFT BLANK 0.CHAPTER – DOCUMENT CHANGES Document: SLSA-MIP-5-4-0-US Date of Issue: 05/2016 Revision: -...

  • Page 9: Chapter - General

    CHAPTER - GENERAL Airplane classification ............1-2 1.2.1 Power unit ....................1-2 1.2.2 Main technical data ................. 1-3 Airplane manufacturer and type certificate holder ....1-5 Chapter order ................. 1-5 1.4.1 Page numbering ..................1-5 Warnings, Cautions, and Notes ..........1-5 Definitions and abbreviations ..........

  • Page 10: Airplane Classification

    Introduction BRM Aero, Ltd., the manufacturer of BRISTELL S-LSA airplanes, provides in accordance with the CS-VLA, ASTM LSA, and UL – 2 airworthiness requirements, information necessary to maintain airworthiness of BRISTELL S-LSA airplanes. Information are also contained in the following manuals issued by the airplane manufacturer and by manufacturers of equipment installed in individual airplane: ...

  • Page 11: Main Technical Data

    1.2.2 Main technical data Wing Span ................8.13 26.65 ft Area ................. 10.5 113.02 sq ft Mean aerodynamic chord (MAC) ......1.367 m 53.82 in Wing loading MTOW 450 kg (UL category, no parachute) ... 42.86 kg/m 8.78 lb/sq ft MTOW 472.5 kg (UL, with parachute) .....
  • Page 12 Fig. 1-1 Three-view drawing 1.CHAPTER - GENERAL Document: SLSA-MIP-5-4-0-US Date of Issue: 05/2016 Revision: -...

  • Page 13: Airplane Manufacturer And Type Certificate Holder

    Airplane manufacturer and type certificate holder BRM Aero, Ltd. Letecká 255 686 04 Kunovice Czech Republic Phone: + 420 773 984 338 e-mail 1: info@brmaero.com e-mail 2: aero.brm@gmail.com web page: http://www.brmaero.com Chapter order Chapters in this manual are ordered in ascending sequence from No. 1. Every chapter describes one system or assembly.

  • Page 14: Definitions And Abbreviations

    Definitions and abbreviations ACCU Accumulator Altimeter Air Traffic Control pressure unit (1 bar = 14,5037 psi) BEACON anti-collision beacon °C temperature in degree of Celsius (1°C = (°F - 32) / 1,8) Calibrated Airspeed COMM Communication transmitter EFIS Electronic Flight Instrument System Emergency Locator Transmitter Engine Monitoring System °F...
  • Page 15 system is switched on or control element is in on- position Sport pilot Operating Handbook pressure unit - pounds per square inch (1psi = 0.0689bar) revolutions per minute sec. second Statute Mile (1SM = 1,609 m) US gal US gallon (1 US gal = 0.83 UK gal = 3.785 l) Volt Visual Flight Rules Visual Meteorological Conditions...
  • Page 16 INTENTIONALLY LEFT BLANK 1.CHAPTER - GENERAL Document: SLSA-MIP-5-4-0-US Date of Issue: 05/2016 Revision: -...

  • Page 17: Chapter - Limitations / Maintenance Checks

    CHAPTER - LIMITATIONS / MAINTENANCE CHECKS General ................... 2-2 Airframe life limitation ............2-2 Engine life limitation .............. 2-2 2.3.1 Engine parts with limited life ..............2-2 Life limitation of other items ..........2-2 Ordering spare parts ............. 2-2 Terms and list of aircraft regular maintenance works ..2-3 2.6.1 General .....................
  • Page 18 General This chapter contains information about:  airframe life limitations  engine life limitations  terms and list of aircraft regular maintenance works  lubrication plan Airframe life limitation Initial airframe life is 5000 flight hours. Engine life limitation Time to overhaul of ROTAX 912 engine is 2000 flight hours or 12 years whichever is the sooner or with completed SB-912-057 2000 flight hours or 15 years whichever is the sooner.
  • Page 19 Terms and list of aircraft regular maintenance works 2.6.1 General Maintenance system serves to maintain flight airworthiness of BRISTELL S-LSA airplane. Maintenance system is composed of periodic inspections, which must be performed at least in the following intervals: CAUTION The intervals of engine inspections and the list of works are shown in Maintenance Manual (Line Maintenance) for installed engine.
  • Page 20 2.6.2 Tables of inspection tasks Tables of inspection tasks include the list of all works, which are performed during inspection. Number of chapter is indicated in the first column of this Maintenance Manual where you can also find more detailed information for performing individual works. The description of works, which are performed during inspection, is indicated in the second column.
  • Page 21 PERIODICAL INSPECTION AFTER FIRST 25 FLIGHT HOURS ………………… ………… Aircraft S/N.: Total flight hours: ………………… ………… Registration mark: No. of takeoffs: Page: 1 of 1 Prescribed works Made by Checked by Chpt. Engine and propeller List of performed operations for engine is shown in Maintenance Manual (Line Maintenance) for installed engine List of performed operations for propeller is shown in...
  • Page 22 PERIODICAL INSPECTION AFTER 50 FLIGHT HOURS ………………… ………… Aircraft S/N.: Total flight hours: ………………… ………… Registration mark: No. of takeoffs: Page: 1 of 1 Prescribed works Made by Checked by Chpt. Engine and propeller List of performed operations for the engine is shown in Maintenance Manual (Line Maintenance) for installed engine.
  • Page 23 ANNUAL PERIODICAL INSPECTION OR INSPECTION AFTER 100 FLIGHT HOURS ………………… ………… Aircraft S/N.: Total flight hours: ………………… ………… Registration mark: No. of takeoffs: ………………… Type of inspection: Page: 1 of 5 Prescribed works Made by Checked by Chpt. AIRFRAME Fuselage Visually check surface condition including fiberglass parts - loosened rivets, deformation, cracks and some other damage.
  • Page 24 ANNUAL PERIODICAL INSPECTION OR INSPECTION AFTER 100 FLIGHT HOURS Page: 2 of 5 Prescribed works Made by Checked by Chpt. Check horizontal stabilizer attachment and securing. Visually check surface condition - deformation, cracks and some other damage. Check condition and attachment of the wing tips. Check suspension and free travel of the elevator.
  • Page 25 ANNUAL PERIODICAL INSPECTION OR INSPECTION AFTER 100 FLIGHT HOURS Page: 3 of 5 Prescribed works Made by Checked by Chpt. Check condition and attachment of instruments. Check function and condition of switches and circuit breakers. Check function and condition of throttle controller, Andair valve, heating and ventilation Check condition of labels.
  • Page 26 ANNUAL PERIODICAL INSPECTION OR INSPECTION AFTER 100 FLIGHT HOURS Page: 4 of 5 Prescribed works Made by Checked by Chpt. Check condition and integrity of fuel pumps and hose sleeves in the engine compartment. Visually check for fuel system tightness. Check tightness and condition of fuel pump for occurrence of cracks on the pump body (see 9.4.2) Engine and propeller...
  • Page 27 ANNUAL PERIODICAL INSPECTION OR INSPECTION AFTER 100 FLIGHT HOURS Page: 5 of 5 Prescribed works Made by Checked by Chpt. Navigation/Communication Visually check condition of navigation and communication instruments. Check function of navigation and communication instruments - applied for annual inspection only Check altimeter function - applied for annual inspection only Notes:...
  • Page 28 Lubrication plan After first Every 100 Unit Area of lubrication Lubricant 25 hours hours Engine Throttle control cable on the inlet into Engine oil terminal (in the engine compartment). Nose Landing gear leg in the area of mounting Lubrication landing (lubricator).
  • Page 29 Maximum variation to inspection intervals Items Controlled by Flying Hours. Maximum Variation 5,000 flying hours or less More than 5,000 flying hours 500 flying hours Items Controlled by Calendar Time Maximum variation 1 year or less 10% or 1 month, whichever is the lesser More than 1 year but not exceeding 3 2 months years...
  • Page 30 INTENTIONALLY LEFT BLANK 2.CHAPTER - LIMITATIONS / MAINTENANCE CHECKS Document: SLSA-MIP-5-4-0-US Date of Issue: 05/2016 Revision: - 2-14...

  • Page 31: Chapter - Fuselage

    CHAPTER - FUSELAGE General ................... 3-2 Description and operation ............. 3-2 3.2.1 Front part of the fuselage ............... 3-2 3.2.2 Rear part of the fuselage ................ 3-2 3.2.3 Cockpit ..................... 3-4 3.2.4 Luggage compartment ................3-4 3.2.5 Crew canopy .................... 3-4 3.2.5.1 Canopy ..........................

  • Page 32: General

    General BRISTELL S-LSA fuselage is a semimonocoque structure formed by stiffeners and aluminum sheets. The fuselage consists of the front part with the cockpit and the rear part, the integral part of which is the fin. This chapter describes the following: ...
  • Page 33 Fig. 3-1 Fuselage monocoque 1 - Nose land.gear attachment 2 - Center section of wing 3 - Main landing gear 4 - Engine mount attachments attachments 5 - Stabilizer attachments 6 - Rudder attachments 3.CHAPTER - FUSELAGE Document: SLSA-MIP-5-4-0-US Date of Issue: 05/2016 Revision: -...

  • Page 34: Cockpit

    3.2.3 Cockpit The cockpit (see Fig. 3-1) is located in the front part of the fuselage between the bulkheads No.1 and 5. The instrument panel is located on the bulkhead No.2. In the middle of the cockpit there is a middle console with control elements. The cockpit is equipped with two adjustable seats.

  • Page 35: Removal / Installation

    Removal / Installation 3.3.1 Canopy removal Type of maintenance: line Authorization to perform:  Sport pilot or LSA mechanic Tools needed:  socket wrench 7/16”  screwdriver  pliers Follow the Fig. 3-3 at removing of the canopy: Open the canopy (1). Remove securing springs from the gas strut rod ends (2) Disconnect gas struts (3) on both sides of canopy (1).

  • Page 36: Canopy Installation

    3.3.2 Canopy installation Type of maintenance: line Authorization to perform:  Sport pilot or LSA mechanic Tools needed:  socket wrench 7/16”  screwdriver  pliers At installation of the canopy, follow the Fig. 3-3: Set the canopy on the airplane fuselage. Insert the bolts and the nuts into the hinges (6) of the canopy (1).

  • Page 37: Gas Strut Installation

    Fig. 3-4 Removal of the gas strut 2 - Gas strut rod end 2 - Gas strut 7 - Gas strut ball joint 8 - Securing spring 3.3.4 Gas strut installation Type of maintenance: line Authorization to perform:  Sport pilot or LSA mechanic Tools needed: ...

  • Page 38: Removal Of Canopy Lock

    3.3.5 Removal of canopy lock Type of maintenance: line Authorization to perform:  Sport pilot or LSA mechanic Tools needed:  Allen wrenches Follow the Fig. 3-5 and Fig. 3-6 when demounting canopy lock: Remove from the cockpit a backrest from that seat on which side you intend to replace the lock (there are two locks of the canopy, on the left, and on the right side).

  • Page 39: Canopy Lock Installation

    Fig. 3-6 Canopy lock rod (a rear view through a cutout in the luggage compartment) 5 - Rod pin safety spring 6 - Lock rod 3.3.6 Canopy lock installation Type of maintenance: line Authorization to perform:  Sport pilot or LSA mechanic Tools needed: ...
  • Page 40 INTENTIONALLY LEFT BLANK 3.CHAPTER - FUSELAGE Document: SLSA-MIP-5-4-0-US Date of Issue: 05/2016 Revision: - 3-10...

  • Page 41: Chapter - Wing

    CHAPTER - WING General ................... 4-2 Description and operation ............. 4-2 4.2.1 Wing ......................4-2 4.2.2 Wing flaps ....................4-3 4.2.3 Ailerons ....................4-3 4.2.4 Fuel tanks ....................4-4 4.2.5 Wing lockers .................... 4-4 Removal / Installation ............4-4 4.3.1 Wing removal ...................

  • Page 42: General

    General BRISTELL S-LSA wing is an aluminum structure and is equipped with flaps, ailerons and fuel tanks. This chapter describes the structure of:  wings  wing flaps  ailerons  fuel tanks Description and operation 4.2.1 Wing The wing of the airplane is formed from center section of wing made as main and rear spar, which is integrated part of fuselage (Fig.

  • Page 43: Wing Flaps

    4.2.2 Wing flaps Flaps (Fig. 4-2) are of all-metal structure consisting of the skin (1) aluminum sheet metal, spar (2) and ribs (3) which are connected by means of riveting. Flaps are suspended on the rear spar by means of three hinges (4). There is a control plate (5) on flap root rib where is the flap control pin connected.

  • Page 44: Fuel Tanks

    4.2.4 Fuel tanks Fuel tanks (Fig. 4-4) are of integrated all-metal structure consisting of aluminum sheet metal skin (1) and four ribs (2). There are on each tank filler neck (3), fuel level sender (4), ventilating tube (5), finger screen (6) and drain valve (7). Fig.

  • Page 45: Wing Installation

    One person hold the wing on the winglet side, the second person by the root on the leading edge side and remove top attachment bolt from the main spar, the third person hold the wing by the root on the trailing edge. Move the wing about 4 in out from the fuselage and disconnect fuel lines, cable plugs, sockets of electrical systems and on left wing also Pitot tube and trim tab wire.

  • Page 46: Wing Flap Removal

    4.3.3 Wing flap removal Type of maintenance: line Authorization to perform:  Sport pilot or LSA mechanic Tools needed:  wrench size 7/16 in Removal of the wing flap according to the following procedure: Open the flap in full position. Disconnect control push rod on the flap side Disconnect all three flap hinges.

  • Page 47: Aileron Removal

    4.3.5 Aileron removal Type of maintenance: heavy Authorization to perform: LSA mechanic or A&P mechanic (Airframe and Power plant) Tools needed:  wrench size 7/16 in  cutting pliers Removal of the aileron according to the following procedure: Disconnect the control rod with control lever. Remove the cover (1) from the hole (2) for access to trim tab actuator (6) on left aileron (see Fig.
  • Page 48 INTENTIONALLY LEFT BLANK 4. CHAPTER - WING Document: SLSA-MIP-5-4-0-US Date of Issue: 05/2016 Revision: -...

  • Page 49: Chapter - Tail Unit

    CHAPTER – TAIL UNIT General ................... 5-2 Description and operation ............. 5-2 5.2.1 Horizontal stabilizer ................5-2 5.2.2 Elevator with trim tab ................5-2 5.2.3 Fin ......................5-3 5.2.4 Rudder ...................... 5-3 Removal / Installation ............5-4 5.3.1 Horizontal stabilizer removal ..............5-4 5.3.2 Horizontal stabilizer installation ............

  • Page 50: General

    General The BRISTELL S-LSA tail unit is of mixed structure and is composed of:  All metal horizontal stabilizer  Metal elevator with trim tab  Metal fin surface  Carbon rudder Description and operation 5.2.1 Horizontal stabilizer Horizontal stabilizer (1) (see Fig. 5-1) is of the all-metal structure consisting from two aluminum spars, eight ribs and aluminum skins.

  • Page 51: Fin

    5.2.3 Vertical fin (1) is an aluminum structure and is an integral part with rear part of fuselage. Fin consists of stiffeners, spar, ribs and aluminum skin. Individual parts are assembled by riveting. Fin tip is made from fiberglass. On the spar are two rudder hinges, bottom one (3) which is integral part of control lever and upper one (4).

  • Page 52: Removal / Installation

    Removal / Installation 5.3.1 Horizontal stabilizer removal Type of maintenance: heavy Authorization to perform: LSA mechanic or A&P mechanic (Airframe and Power plant) Tools needed:  wrench size 3/8 in, 7/16 in  screwdriver  wire nippers Remove the screws from top and bottom side of composite cover between fuselage and stabilizer.

  • Page 53: Elevator Removal

    5.3.3 Elevator removal Type of maintenance: heavy Authorization to perform: LSA mechanic or A&P mechanic (Airframe and Power plant) Tools needed:  wrench size 7/16 in  wire nippers Remove the cover (1) from the access hole (2) (see Fig. 6-9). Disconnect the trim tab actuator wires (3).

  • Page 54: Trim Tab Installation

    5.3.6 Trim tab installation Type of maintenance: heavy Authorization to perform: LSA mechanic or A&P mechanic (Airframe and Power plant) Tools needed:  pliers, wire nippers  riveting pliers Insert the trim tab with piano hinge into the elevator. Rivet piano hinge into the elevator. Check for free rotation of the trim tab.

  • Page 55: Exchanges / Service Information

    Exchanges / Service information No procedures included. 5.CHAPTER – TAIL UNIT Document: SLSA-MIP-5-4-0-US Date of Issue: 05/2016 Revision: -...
  • Page 56 INTENTIONALLY LEFT BLANK 5.CHAPTER – TAIL UNIT Document: SLSA-MIP-5-4-0-US Date of Issue: 05/2016 Revision: -...

  • Page 57: Chapter - Controls

    CHAPTER - CONTROLS General ................... 6-3 Description and operation ............. 6-3 6.2.1 Lateral control (aileron control) ............. 6-3 6.2.2 Longitudinal control (elevator control) ..........6-4 6.2.3 Directional control (rudder control) ............6-4 6.2.4 Elevator trim tab control ................. 6-5 6.2.5 Wing flap control ..................
  • Page 58 6.4.3.2 Measuring wing flap deflections ..................6-19 6.4.3.3 Measuring elevator deflections ..................6-19 6.4.3.4 Measuring rudder deflections .................... 6-19 6.4.3.5 Measuring trim tab deflections ..................6-19 6.4.4 Adjustment of control surface deflections ......... 6-19 6.4.4.1 Adjusting aileron deflections ..................... 6-20 6.4.4.2 Adjusting wing flap deflections ..................

  • Page 59: General

    General BRISTELL S-LSA airplane is equipped with dual controls which enables pilot training. Airplane control includes:  lateral control (aileron control)  longitudinal control (elevator control)  directional control (rudder control)  aileron trim tab control  elevator trim tab control ...

  • Page 60: Longitudinal Control (Elevator Control)

    6.2.2 Longitudinal control (elevator control) The elevator is controlled by control sticks. Movement of control sticks is transferred by system of transmission levers and push rods to the elevator. Forward and backward movement of the control stick is transferred by the push rods lead through the central channel between seats to the two-arm lever which is located on the fin spar.

  • Page 61: Elevator Trim Tab Control

    6.2.4 Elevator trim tab control The elevator trim tab is controlled by the electrical actuator installed in elevator and connected per threaded rod with trim tab. Control switches are integrated part of grip on the left control stick (option on both control sticks). A LED position indicator is installed on the instrument panel.

  • Page 62: Nose Leg Control

    6.2.6 Nose leg control Turning of the nose wheel fork is controlled through a Teleflex rod which bottom end is connected on the top of the nose wheel fork and upper end is connected to a lever welded on the pedals connecting tube. Fig.

  • Page 63: 6.3 Removal / Installation

    6.3 Removal / Installation 6.3.1 General principles for work on control system 6.3.1.1 Push-pull rod adjustment Type of maintenance: heavy Authorization to perform: LSA mechanic or A&P mechanic (Airframe and Power plant) Tools needed:  wrench size 7/16 in Set the push rods to the prescribed length before assembling, tighten the nuts slightly, and do not secure them for the time being.

  • Page 64: Control Sticks Installation

    Remove the bolt (11) from the stick (4). Remove the stick (4) from the torque tube (2). 6.3.3 Control sticks installation Type of maintenance: heavy Authorization to perform: LSA mechanic or A&P mechanic (Airframe and Power plant) Tools needed:  wrench size 7/16 in, 3/8 in ...

  • Page 65: Removal Of Wing Flap Control Actuator

    6.3.4 Removal of wing flap control actuator Type of maintenance: line Authorization to perform:  Sport pilot or LSA mechanic Tools needed:  wrench size 7/16 in, 1/2 in,  screwdriver Removal of the flap control actuator is shown on Fig. 6-8. Open the glove box cover on center console (1) between the seats.

  • Page 66: Removal Of The Trim Tab Control Actuator

    Insert flap actuator (4) in to the actuator hinge (6). Connect actuator wire (5). Connect the flap actuator (4) with the flap lever (3). Check the flap operation and deflections (see 6.4.3.2). Insert glove box in the center console. 6.3.6 Removal of the trim tab control actuator Type of maintenance: heavy Authorization to perform:...

  • Page 67: Installation Of The Trim Tab Control Actuator

    6.3.7 Installation of the trim tab control actuator Type of maintenance: heavy Authorization to perform: LSA mechanic or A&P mechanic (Airframe and Power plant) Tools needed:  wrench size 5  screwdriver  pliers Insert trim tab actuator (6) in to the elevator or aileron through access hole (2). Connect the actuator (6) from the elevator or aileron skin.

  • Page 68: Removal Of Aileron Control Bell Crank In The Wing

    Fig. 6-10 Control lever of aileron control behind the main center wing spar 1 - Control lever 2 - Nut 3 - Bushing 4 - Lever bolt 5 - Push rods 6.3.10 Removal of aileron control bell crank in the wing Type of maintenance: heavy Authorization to perform: LSA mechanic or A&P mechanic (Airframe and Power plant)

  • Page 69: Installation Of Aileron Control Bell Crank In The Wing

    Fig. 6-11 Bell crank of aileron control 1 - Cover 3,4 - Push rods 5,6 - Rod end bolts 7 - Bell crank 8 - Bell crank bolt 9 - Aileron control stop 6.3.11 Installation of aileron control bell crank in the wing Type of maintenance: heavy Authorization to perform: LSA mechanic or A&P mechanic (Airframe and Power plant)

  • Page 70: Installation Of Bail Arm Under The Luggage Compartment

    Tools needed:  wrench size 7/16 in  screwdriver  pliers Bail arm attachment is shown on Fig. 6-12. Remove the access hole cover on the bottom fuselage skin under the luggage compartment (1). Disconnect push rod ends (2) from the bail arm (3). Disconnect bail arm lever (3) and lever hinge (4) –...

  • Page 71: Removal Of Bail Arm In Rear Fuselage

    Check condition and lubrication of bail arm lever bushings. If the bushing is contaminated, then carefully remove contamination and grease it with lubricant grease. Set the bail arm lever (3) to the position (see Fig. 6-12), insert the bolt into the hole in the lever and the hinge (4) and secure it with the castle nut and cotter pin.

  • Page 72: Installation Of Bail Arm In Rear Fuselage

    6.3.15 Installation of bail arm in rear fuselage Type of maintenance: heavy Authorization to perform: LSA mechanic or A&P mechanic (Airframe and Power plant) Tools needed:  wrench size 7/16 in (11)  screwdriver  pliers Attachment of bail arm is shown in Fig. 6-13. Check condition of the lever (3).

  • Page 73: Longitudinal Control

    Push on the control stick or the pedal by force of 3 kg (6,6 lbs.). Deflect the controlling element to one side and read the deflection. Then push the control stick to the other side and read the deflection. Sum of deflections presents plays in control. 6.4.1.2 Longitudinal control Measure play at the end of the control stick at the blocked elevator in the neutral position.

  • Page 74: Friction In The Longitudinal Control System

    6.4.2.1 Friction in the longitudinal control system Balance elevator through the pulley to get it to neutral position. Measure force at the moment of elevator deflection from neutral position by the dynamometer attached on the end of the control stick. Max force can be 1.5 kg (3.3 lbs.).

  • Page 75: Measuring Wing Flap Deflections

    Deflect aileron to the lower (possibly upper) extreme position and read the deflection value. Check deflection values according to the Tab. 6-1. 6.4.3.2 Measuring wing flap deflections Attach the protractor with the deflecting pointer on the upper flap skin by means of the clamp.

  • Page 76: Adjusting Aileron Deflections

    6.4.4.1 Adjusting aileron deflections Range of deflections is adjusted by means of rod adjustable ends. Adjust aileron neutral position by setting the terminal of the push rod in the center wing or outer wing. It is possible to adjust the aileron differentiation, i.e. difference in the lower and the upper deflection of the aileron, by means of the terminal on the push rod leading from the control lever in the fuselage to the bell crank in the wing or by means of the terminal of the push rod leading from bell crank to the control lever on the aileron.

  • Page 77: Checking Condition And Tension Of Rudder Control Cables

    6.4.5 Checking condition and tension of rudder control cables Carefully inspect the control cable especially on the following areas:  in the area of cable attachment on the rudder control pedals  in the area of cable attachment on rudder lever ...

  • Page 78: Exchanges / Service Information

    Exchanges / Service information 6.5.1 Exchange of rudder control cable Cut the control cable (1) in the cockpit behind the rudder pedals. Remove cables on the rudder side from the fuselage. NOTE Grease the new cable with lubricant grease before installing it to the fuselage. Insert the new cable from the rudder side into the fuselage.

  • Page 79: Chapter - Equipment

    CHAPTER – EQUIPMENT General ................... 7-2 Description and operation ............. 7-2 7.2.1 Seats......................7-2 7.2.2 Safety harness ..................7-2 Removal / Installation ............7-3 7.3.1 Removal of seats ..................7-3 7.3.2 Removal of safety harness ..............7-3 7.3.3 Installation of safety harness ..............7-3 Check / Adjustment ...............

  • Page 80: General

    7.2.1 Seats Seats (1) of the BRISTELL S-LSA airplane are attached to the gear channel on Velcro and are equipped with an upholstered cushions. The seat backs (2) are attached on Velcro to the bulkhead No.5. For adjusting of seats and seat backs are used fiberglass sandwich boxes attached on Velcro.

  • Page 81: Removal / Installation

    Removal / Installation 7.3.1 Removal of seats Remove the seats from the Velcro 7.3.2 Removal of safety harness Type of maintenance: line Authorization to perform:  Sport pilot or LSA mechanic Tools needed:  wrench size 1/2 in Remove shoulder harnesses from the top attachment brackets (1) in luggage compartment (see Fig.

  • Page 82: Check / Adjustment

    Fig. 7-2 Removal/Installation of safety harnesses 1 - Top attachment 2 - Bolt bracket 3 - Snap-hook 4 - Side attachment bracket Check / Adjustment 7.4.1 Checking of safety harness Check harnesses surface for any damages. Check the lock system function. Check the attachment points of shoulder and side harnesses for any damages or corrosion.

  • Page 83: Chapter - Landing Gear

    CHAPTER – LANDING GEAR General ................... 8-2 Description and operation ............. 8-2 8.2.1 Main landing gear ..................8-2 8.2.1.1 Main wheel .......................... 8-2 8.2.2 Nose landing gear ................... 8-3 8.2.2.1 Nose landing gear wheel ....................8-4 8.2.3 Brake system ................... 8-4 8.2.3.1 Parking brake ........................

  • Page 84: General

    General The BRISTELL S-LSA airplane has tricycle landing gear which consists of the main landing gear and the nose landing gear. The nose landing gear is steerable. The main landing gear wheels are equipped with hydraulic disk brakes. Type and dimension of main wheels: ...

  • Page 85: Nose Landing Gear

    8.2.2 Nose landing gear The nose landing gear of BRISTELL S-LSA airplane is steerable and consists of 4130 steel welded landing gear leg (1), 4130 steel welded fork (2), shock absorber (3) and the wheel (4). The landing gear is attached to the brackets (5) installed in the nose gear channel located between bulkhead No.

  • Page 86: Brake System

    8.2.3 Brake system The BRISTELL S-LSA airplane is equipped with hydraulic disc brakes on the main landing gear wheels. Brake system consists of the brake pedals (part of rudder control pedals, see Fig. 8–7), brake pumps, hoses for brake fluid supply, brake calipers and brake pads. By depressing pedals, brake pumps are compressed and pressure generated in the brake circuit and the calipers pushes the brake pads onto the brake disks.

  • Page 87: Removal / Installation

    Removal / Installation 8.3.1 Removal of wheel pants Type of maintenance: line Authorization to perform:  Sport pilot or LSA mechanic Tools needed:  screwdriver Wheel pants are attached on the brackets by means of bolts. Remove bolts attaching the wheel pants to the brackets. Remove wheel pants.

  • Page 88: Removal Of Nose Landing Gear Wheel

     pliers Follow Fig. 8-2 at installation: Clear the wheel axle (4) of impurities and apply slight layer of grease on it. Put the wheel (2) on the axle. Apply securing liquid (blue Loctite 243) on the screw threads and attach with it the wheel rim and brake disc.

  • Page 89: Removal Of The Main Landing Gear Leg

    8.3.7 Removal of the main landing gear leg Type of maintenance: heavy Authorization to perform: LSA mechanic or A&P mechanic (Airframe and Power plant) Tools needed:  wrench size 9/16 in, 1/2 in Follow Fig. 8-5 at removal: Jack and support the airplane (see 14.2). Disconnect the brake line (1).

  • Page 90: Installation Of The Main Landing Gear Leg

    8.3.8 Installation of the main landing gear leg Type of maintenance: heavy Authorization to perform: LSA mechanic or A&P mechanic (Airframe and Power plant) Tools needed:  wrench size 9/16 in, 1/2 in Follow Fig. 8-5 at installation: Check outer surface of the composite landing gear leg for occurrence of cracks and whether the axle connection is not damaged before installing the landing gear leg.

  • Page 91: Installation Of Nose Landing Gear Leg

    8.3.10 Installation of nose landing gear leg Type of maintenance: heavy Authorization to perform: Repairman (LS-M) or Mechanic (A&P) Tools needed:  wrench size 1/2 in, No.17 Follow Fig. 8-6 at installation. Check the welds of the gear leg for occurrence of cracks and corrosion and whether the bearings are not damaged before installing the gear leg.

  • Page 92: Removal Of Brake Pumps

    8.3.11 Removal of brake pumps Type of maintenance: line Authorization to perform:  Sport pilot or LSA mechanic Tools needed:  wrench size 1/2 in, 3/8 in Follow Fig. 8-7 at removal. Drain brake fluid from the brake system. Disconnect the brake system hose from the brake cylinder on the main landing gear wheel and let brake fluid drain to a previously prepared can from that system line in which you want to remove the brake pump.

  • Page 93: Installation Of Brake Pumps

    8.3.12 Installation of brake pumps Type of maintenance: line Authorization to perform:  Sport pilot or LSA mechanic Tools needed:  wrench size 1/2 in, 3/8 in Follow Fig. 8-7 at installation. Install the brake pump (1) according to Fig. 8-7 to the Bracket (4) on the cockpit floor and assemble the fitting (3) to connect brake hose.

  • Page 94: Exchanges / Service Information

    Exchanges / Service information 8.5.1 Tire change Type of maintenance: line Authorization to perform:  Sport pilot or LSA mechanic Tools needed:  wrench size 1/2 in  Allen wrench size 1/4 in Jack and support the airplane (see 14.2). Remove the wheel fairing (see 8.3.1).

  • Page 95: Exchange Of Nose Landing Gear Shock Absorber

    8.5.2 Exchange of nose landing gear shock absorber Type of maintenance: line Authorization to perform: Sport pilot or LSA mechanic Tools needed:  wrench size 1/2 in Follow Fig. 8-9 to replace the shock absorber. Jack and support the airplane (see 14.2). Use wrench size ½...

  • Page 96: Exchange Of Brake Pads

    8.5.3 Exchange of brake pads Type of maintenance: line Authorization to perform:  Sport pilot or LSA mechanic Tools needed:  wrench size 7/16 in CAUTION Always replace both brake pads! Follow Fig. 8-10 at brake pads replacement. Jack and support the airplane (see 14.2) Demount the main wheel (see 8.3.3) if needed.

  • Page 97: Refilling / Exchanging Brake Fluid

    8.5.4 Refilling / exchanging brake fluid 8.5.4.1 Draining brake fluid from brake system Type of maintenance: line Authorization to perform:  Sport pilot or LSA mechanic Tools needed:  wrench size 7/16 in  plastic hose  a compressible brake fluid filler (or a bigger syringe is also suitable) ...
  • Page 98 INTENTIONALLY LEFT BLANK 8. CHAPTER – LANDING GEAR Document: SLSA-MIP-5-4-0-US Date of Issue: 05/2016 Revision: - 8-16...

  • Page 99: Chapter - Fuel System

    CHAPTER – FUEL SYSTEM General ................... 9-2 Description and operation ............. 9-2 9.2.1 Fuel storage ..................... 9-2 9.2.2 Fuel distribution ..................9-2 9.2.3 Indication of fuel quantity and pressure ..........9-3 Removal / Installation ............9-3 9.3.1 Fuel tank removal ..................9-3 9.3.2 Fuel tank installation................

  • Page 100: General

    Fuel system works for storing fuel in the airplane and its delivering to the engine. The fuel system of BRISTELL S-LSA airplane fitted with Rotax 912 iS Sport engine consists of the following parts: two fuel tanks, fuel tubing, selector valve, gascolator with integrated fuel filter, electrical fuel pumps (MAIN and AUX), fuel level gauges, fuel pressure gauge and drain valves on the fuel tanks.

  • Page 101: Indication Of Fuel Quantity And Pressure

    Fig. 9-2 Fuel system scheme 1 - Fuel tank left 2 - Fuel tank right 3 - Finger screen 4 - Andair selector valve 5 - Gascolator 6 - Electrical fuel pump Rotax 912 iS – 2 electrical pumps) 7 - Mechanical fuel pump (not for Rotax 912iS) 9.2.3 Indication of fuel quantity and pressure Scheme of fuel quantity is shown in Fig.

  • Page 102: Fuel Tank Installation

    Carefully remove the tank and store it. Seal the tank holes as needed. 9.3.2 Fuel tank installation Type of maintenance: line Authorization to perform:  Sport pilot or LSA mechanic Tools needed:  wrench size 8, 1/2 in,  screwdriver ...

  • Page 103: Fuel Level Sender Removal

    At installing proceed according to Fig. 9-3. Screw the finger screen (2) into the root tank rib – use LOCTITE 565 or equivalent sealant. Connect fuel hose (3) on the finger screen. Install the wing – see 4.3.2. Check fuel system tightness (see 9.4.1). Fig.

  • Page 104: Fuel Drain Valve Removal

    Carefully put the fuel level sender into the tank and attach it using bolts with washers – use LOCTITE 565 or equivalent sealant on bolts thread. Connect electrical wires to the fuel level sender (electrical connection – see 16.CHAPTER – WIRING DIAGRAMS). Check fuel system tightness (see 9.4.1).

  • Page 105: Check / Adjustment

    Check / Adjustment 9.4.1 Checking fuel system tightness NOTE Tightness is checked by pressurized air or fuel. When performing a specific tightness check, outside temperature fluctuations must not be bigger than ±13°C (8°F). Reseal found out leakage by a suitable method – by tightening, by using a suitable sealing. 9.4.1.1 Checking airplane fuel system tightness by air Connect an appropriate device to the filing neck for pressurizing.

  • Page 106: Exchanges / Service Information

    Exchanges / Service information 9.5.1 Fuel tank filling CAUTION When filling fuel in the airplane, use only approved kinds of fuel mentioned in this Manual, par. 10.2.1.3, or in the POH Chapter 2, or in Rotax engine Operator’s Manual–Section 10.2.2 and 13 or Service Instruction SI–912–016.

  • Page 107: Chapter- Power Unit

    CHAPTER– POWER UNIT 10.1 General ................. 10-3 10.2 Description and operation ........... 10-3 10.2.1 Engine ....................10-3 10.2.1.1 Technical data of the engine ..................... 10-3 10.2.1.2 Coolant type ........................10-4 10.2.1.3 Fuel type ........................... 10-5 10.2.1.4 Oil type ..........................10-6 10.2.1.5 Engine mount ........................
  • Page 108 10.5.2.2 Drainage of cooling liquid ....................10-28 10.5.2.3 Refilling cooling liquid...................... 10-29 10.5.3 Exchange / Check of oil filter ............. 10-29 10.5.4 Exchange / Check of air filter ............. 10-29 10.CHAPTER– POWER UNIT Document: SLSA-MIP-5-4-0-US Date of Issue: 05/2016 Revision: - 10-2...

  • Page 109: General

    Fiti Eco Competition 3LR 158, 3-bladed, ground adjustable propeller. Optionally other engines (Rotax 912, 914, 912 iS, Jabiru 2200, 3300) and propellers may be installed. BRISTELL S-LSA, S/N 231/2016 is fitted with ROTAX 912 iS Sport and Fiti Eco Competition 3LRSE 158, 3-bladed, in-flight electrically adjustable propeller 10.2 Description and operation 10.2.1...

  • Page 110: Coolant Type

    10.2.1.2 Coolant type WARNING The coolant concentrate (propylene glycol) may not be mixed with conventional (glycol/water) coolant or with additives. CAUTION Conventional glycol/water coolant reduce to apply the maximum permissible cylinder head temperature. Type of coolant used by aircraft manufacturer is shown in 17.5. 10.CHAPTER–...

  • Page 111: Fuel Type

    10.2.1.3 Fuel type 10.CHAPTER– POWER UNIT Document: SLSA-MIP-5-4-0-US Date of Issue: 05/2016 Revision: - 10-5...

  • Page 112: Oil Type

    10.2.1.4 Oil type Type of oil used by aircraft manufacturer is shown in 17.5. 10.CHAPTER– POWER UNIT Document: SLSA-MIP-5-4-0-US Date of Issue: 05/2016 Revision: - 10-6...

  • Page 113: Engine Mount

    10.2.1.5 Engine mount The engine mount connects the power unit to the airplane. It is welded from 4130 steel tubes and is attached to the firewall and to the engine by means of bolts. The engine mount is installed on the firewall by four attachments through rubber shock absorbers. The scheme of engine mount attachment to the firewall and to the engine is shown in the Fig.

  • Page 114: Engine Control

    10.2.1.7 Engine control Rotax 912 iS engine power is controlled by means of the THROTTLE control lever which is positioned on the middle channel between the seats and which controls engine power from idle up to max. take–off power. Throttle lever in the cockpit is mechanically connected (by a bowden cable) to a throttle lever on the throttle valve.

  • Page 115: Engine Cooling System

    10.2.1.9 Engine cooling system The engine cooling system is designed for liquid cooling of the cylinder heads and ram air cooling of the cylinders. The cooling system of the cylinder heads is closed circuit with an expansion tank and overflow bottle.The coolant flow is forced by a water pump, driven from the camshaft, from the radiator to the individual cylinder heads.
  • Page 116 Fig. 10-5 Rotax 912 iS Sport Cooling system scheme Fig. 10-6 Rotax 912 iS Sport Cooling systém 10.CHAPTER– POWER UNIT Document: SLSA-MIP-5-4-0-US Date of Issue: 05/2016 Revision: - 10-10...

  • Page 117: 10.2.1.10 Engine Lubrication System

    10.2.1.10 Engine lubrication system The Rotax 912 iS Sport engine has dry sump forced lubrication. General overview is shown on Fig. 10-7. The oil pump is driven by the camshaft.The main oil pump sucks the engine oil from oil tank (1) –...

  • Page 118: 10.2.1.11 Air Inlet System Of The Engine

    HEAT knob (6) on the instrument panel. 10.2.1.12 Exhaust system Exhaust system of BRISTELL S-LSA airplane consist of four exhaust pipes (3) which lead exhaust gases from individual cylinders to the muffler (1). The muffler works at the same time as a silencer.

  • Page 119: 10.2.1.13 Ignition System

    10.2.1.13 Ignition system Rotax 912 iS Sport ignition system is powered by the ECU (Engine Control Unit and has fully mapped variable timing. It is completely doubled up. Either of the ECU’s can operate the double ignition coils. If a fault occurs with the ignition system the ECU informs the pilot by warning lamps through the display in the instrument panel.

  • Page 120: Propeller

    10.2.2 Propeller FITI ECO COMPETITION 3 LRSE 158 is originally in-flight electrically adjustable, 3-bladed propeller with the composite blades. Since the US Sport Pilot rule prohibits use of in-flight variable propellers for the Light Sport category airplanes, the switch to change propeller blades pitch angle is installed in the engine compartment (see below), out of reach of the pilot in flight.

  • Page 121: Removal / Installation

    10.3 Removal / Installation 10.3.1 Removal of the engine from the airplane Type of maintenance: heavy Authorization to perform: LSA mechanic or A&P mechanic (Airframe and Power plant) Tools needed:  wrench size 8, 9, 3/8 in, 7/16 in, 9/16 in ...
  • Page 122 Secure the screw heads by cotter pins (8). Fig. 10-13 Engine mount attachment to the engine and firewall 1 - engine mount 2 - Screws (holes for screws) Install the exhaust system (see 10.3.6). Connect wiring according to the wiring diagrams (see 16.CHAPTER – WIRING DIAGRAMS).

  • Page 123: Removal Of The Propeller

    Fig. 10-14 Rotax 912 iS throttle control 1 - Throttle valve 2 - Throttle lever 4 – Adjustable terminal 3 - Throttle bowden cable 5 - Nut 10.3.3 Removal of the propeller Type of maintenance: line Authorization to perform:  Sport pilot or LSA mechanic NOTE For the Fiti 3LRSE propeller DISASSEMBLY refer to the OPERATING INSTRUCTIONS AND...

  • Page 124: Installation Of The Propeller

    Unscrew nuts (8), remove bolts (7) and take out the propeller along with other parts from the flange. Put the protective covers on the propeller blades and store the propeller on a safe place so that no damage can occur. Fig.

  • Page 125: Exhaust System Removal

    Fig. 10-16 Bolt tightening sequence Remove spark plugs of the engine and secure the airplane against its movement (see 14.5). Check out, possibly adjust the blades pitch of propeller according to the propeller manual. Tighten up bolts (7) gradually according to the Fig. 10-16, for torque moments refer to the propeller manual, and measure the difference in distance of individual blade tips from marking (see Fig.

  • Page 126: Exhaust System Installation

    see Fig. 10-9. Remove the springs (4) from the exhaust pipes (1) attaching to the muffler (2). Remove individual pipes from the necks on the engine. Remove springs (6) and release the heat exchanger (5) from the muffler (2). 10.3.6 Exhaust system installation Type of maintenance: line Authorization to perform:...

  • Page 127: Removal Of The Radiator

    see . Set the oil cooler to the bracket on the engine and on the cooler necks gradually install and tight the nuts. Install the fittings with oil hoses, screw the fitting nuts. Fill the oil system with oil (see 10.5.1) and check oil system tightness. Install the lower and upper engine cowling.
  • Page 128 Fig. 10-18 Attachment of the radiator on the engine 10.CHAPTER– POWER UNIT Document: SLSA-MIP-5-4-0-US Date of Issue: 05/2016 Revision: - 10-22...

  • Page 129: 10.3.11 Removal Of The Throttle Control Lever

    10.3.11 Removal of the throttle control lever Type of maintenance: line Authorization to perform:  Sport pilot or LSA mechanic Tools needed:  wrench size 14  Allen wrench size 2  Screwdriver  Cutting pliers see Fig. 10-19. Remove the cover of the throttle (3) from the middle channel. Remove the upper engine cowling.

  • Page 130: 10.3.12 Installing Of The Throttle Control Lever

    10.3.12 Installing of the throttle control lever Type of maintenance: line Authorization to perform:  Sport pilot or LSA mechanic Tools needed:  wrench size 14  Allen wrench size 2  Screwdriver  Cutting pliers see Fig. 10-19. Install the control lever of throttle into the middle channel in the cockpit. Connect the throttle cable to the throttle lever (2).

  • Page 131: Check / Adjustment

    Before performing engine test carry out preflight check of the engine and the propeller in the range shown in the AOI of BRISTELL S-LSA (Par. 4.3) and Operators Manual for Rotax engine type 912 i series, 3.1 Daily checks, 3.3 Pre-flight checks Start the engine according to Operators Manual for Rotax engine type 912 i series, 3.4...
  • Page 132 ENGINE TEST REPORT Aircraft Registration BRISTELL S-LSA Engine ROTAX Type 912 iS Sport Activity Set down values Measured values Starting up the engine Check if Warning Lamps illuminate and extinguish after around 3 seconds Min. oil pressure up to 10 sec.

  • Page 133: Adjusting Throttle Control

    10.4.2 Adjusting throttle control Pull the throttle control to the stop. The throttle lever on the throttle valve (5) must be on the stop (see Fig. 10-14). The bowden must be supported in the terminals. Release the nut on the control lever (5) and take up any slack on the cable and tighten up the nut.

  • Page 134: Exchanges / Service Information

    10.5 Exchanges / Service information 10.5.1 Exchange / Refilling oil Refer to the Rotax engine Maintenance manual Chapter 12–00–00 para 5 NOTE Refer to Rotax SI-912 i-001 latest edition for recommended kinds of oil. Type of oil used by aircraft manufacturer is shown in 17.5. 10.5.1.1 Oil volume Total oil volume in the lubrication system of Rotax 912 ULS engine is approximately 3.8 liters...
  • Page 135 10.5.2.3 Refilling cooling liquid Refill cooling liquid into the expansion tank in the engine compartment. In addition to this there is an overflow bottle which collects cooling liquid in case of engine overheating and is attached to the firewall. 10.5.3 Exchange / Check of oil filter Refer to the Rotax engine Maintenance Manual Chapter 12–00–00 para 5.
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  • Page 137: Chapter - Electrical System

    CHAPTER – ELECTRICAL SYSTEM 11.1 General ................. 11-2 11.2 Description and operation ........... 11-2 11.2.1 Switches, circuit breakers ..............11-3 11.2.2 Fuses ...................... 11-4 11.2.3 Generator ....................11-4 11.2.4 Onboard battery ..................11-5 11.2.5 Lighting ....................11-5 11.2.5.1 Optional instrument lighting ....................11-5 11.2.5.2 Optional external lighting ....................

  • Page 138: Description And Operation

    11.1 General Electrical system of BRISTELL S-LSA airplane serves for supplying electrical current to the instruments. 11.2 Description and operation The airplane fitted with Rotax 912 iS engine is equipped with 14V DC electrical installations with grounded negative pole. Primary source of electrical energy is formed by the generator.

  • Page 139: Switches, Circuit Breakers

    NOTE Until the idle speed is reached, the EMS requires an external 12V supply from the onboard system of the aircraft (battery). 11.2.1 Switches, circuit breakers The switches serve for switching ON/OFF individual electrical circuits. There are two kinds of switches: switches–circuit breakers ...

  • Page 140: Fuses

    11.2.2 Fuses Fuses serve for protecting individual electrical circuits from overloading. Every fuse is marked by the placard with a fuse designation (see Tab. 11-2). Fuses are located on the right instrument panel. Wiring diagrams are shown in 16.CHAPTER – WIRING DIAGRAMS. NOTE There are not used classical fuses in the aircraft.

  • Page 141: Onboard Battery

    NOTE If generator B fails, the battery will no longer be charged. The engine still runs on generator A and the instruments will be supplied by the battery. The function of the instruments depends on the state of charge of the battery. The charging of the battery from generator B is not monitored by the EMS.

  • Page 142: Removal / Installation

    11.3 Removal / Installation 11.3.1 Removal of the onboard battery Type of maintenance: line Authorization to perform:  Sport pilot or LSA mechanic Tools needed:  screwdriver  wrench size 8 Remove engine cowlings Disconnect the contacts from the battery. Disconnect the draw band of the battery and remove the battery from the airplane.

  • Page 143: Removal Of The Optional Landing Light

    Connect the strobe/position lights wire. Set the strobe/position light to the wing tip and fasten it with bolts. NOTE Before installing the strobe/position light thoroughly clean the contacting surfaces on the light and on the wing tip of the putty residues. Install the covering glass of the strobe/position lights.

  • Page 144: 11.4 Check / Adjustment

    11.4 Check / Adjustment 11.4.1 Adjusting the optional landing light Unscrew ¼ turn bolts on the bulb bracket. Do adjustment in the horizontal direction according to Fig. 11-2 in such a way that the light axis is directed towards the airplane axis about 45m (150 ft) before the fuselage nose.

  • Page 145: Exchanges / Service Information

    11.5 Exchanges / Service information 11.5.1 Charging the battery CAUTION Please observe the instructions supplied by the charger manufacturer If the charger curve is unknown, it can be assumed that charging will be unregulated, i.e. voltage monitoring via a Voltmeter and manual disconnection at 14.4 V are required. The nominal charger current should be 1/10 of the nominal capacity in Ampere When charging, connect the battery to the charger before switching on the charger.

  • Page 146: Exchange Of The Optional Position Light Lamp

    11.5.2 Exchange of the optional position light lamp Remove the cover of the position lights including the cover glass. Slightly push in the front lamp and turn it counter–clockwise (bayonet closure) and exchange it for the same type. Remove the rear lamp and exchange it for the same type. CAUTION Don’t touch the new lamps with bare hands.
  • Page 147 CHAPTER – PITOT–STATIC SYSTEM / INSTRUMENTS 12.1 General ................. 12-2 12.2 Description and operation ........... 12-2 12.2.1 Pitot–static system ................12-2 12.2.2 Flight instruments ................. 12-3 Airspeed indicator – ASI ....................12-3 12.2.2.1 Altimeter – ALT ......................... 12-3 12.2.2.2 Vertical speed indicator – VSI ................... 12-3 12.2.2.3 12.2.2.4 Inclinometer ........................

  • Page 148: 12.Chapter - Pitot-Static System / Instruments

    12.1 General This chapter provides information about pitot–static system and instruments. 12.2 Description and operation 12.2.1 Pitot–static system The Pitot tube to sense total pressure is located under right wing. The total pressure is sensed through the hole in the pitot–tube face. Static pressure ports are located on both sides of the fuselage, at the tail.

  • Page 149: 12.Chapter - Pitot-Static System / Instruments

    12.2.2 Flight instruments Airspeed indicator – ASI 12.2.2.1 The airspeed indicator located on the left side of instrument panel is classical analogue round pressure gauge. Color marking of the ASI is shown in the Aircraft Operating Instructions. Altimeter – ALT 12.2.2.2 The altimeter located on the left side of instrument panel is classical analogue round pressure gauge.

  • Page 150: Engine Instruments

    12.2.3 Engine instruments The engine instruments located on the right side of instrument panel serve for engine run checking. Color marking of the engine instruments is shown in the Aircraft Operating Instructions, Section 2. 12.2.3.1 Tachometer The RPM indicator is electrical and is controlled by the signal from the RPM sensor on the generator.

  • Page 151: Removal / Installation

    12.3 Removal / Installation 12.3.1 Removal of the pitot tube Type of maintenance: line Authorization to perform:  Sport pilot or LSA mechanic Tools needed:  Electric drill  drill bit diam. 1/8 in  pliers, cutting pliers Drill out rivets attaching the bracket with the Pitot tube to the wing and pull out a bit the Pitot tube with hose from hole in wing.

  • Page 152: 12.4 Check / Adjustment

    12.4 Check / Adjustment 12.4.1 Check of pitot–static system tightness In the static pressure system create the under pressure by means of an appropriate instrument corresponding to altitude of 1000 ft. Drop in the indicated altitude per one minute must not exceed 100 ft. In the system of total pressure create the overpressure corresponding to speed of 140 knots (260 km/h,161 mph) by means of a suitable instrument.
  • Page 153 REPORT OF MAGNETIC COMPASS COMPENSATION Aircraft Registration mark Serial No. Compass Type: Compass Serial No.: List of Switched–On Radio navigation Engine running Engine stopped Course Measured Deviation Measured Deviation Date: Time: YES – NO Compensation conforming: Note: Elaborated by: Signature: Date: Checked by: Signature:...
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  • Page 155: Chapter - Ventilation / Heating

    CHAPTER – VENTILATION / HEATING 13.1 General ................. 13-2 13.2 Description and operation ........... 13-2 13.2.1 Venting system ..................13-2 13.2.2 Heating system ..................13-2 13.3 Removal / Installation ............13-4 13.3.1 Removal of fresh air, hot air and mixture control knob ..... 13-4 13.3.2 Installation of fresh air, hot air and mixture control knob ....
  • Page 156 13.1 General This chapter contains information on crew compartment heating and ventilation system. 13.2 Description and operation 13.2.1 Venting system Cockpit ventilation is ensured by two eyeball (2) or automotive (3) air vents located in the cockpit on side panels of the instrument panel (see Fig. 13-1). Air inlets – Naca scoops (1) are located on both fuselage sides in front of the canopy.
  • Page 157 Fig. 13-2 Heating system 1 - Heat exchanger 2 - Muffler 3 - Control flap 4 - Air hose 5 - Heating knob 6 - Mixture flap 7 - Canopy bubble outlet 8 - Crew legs outlet 13.CHAPTER – VENTILATION / HEATING Document: SLSA-MIP-5-4-0-US Date of Issue: 05/2016 Revision: -...
  • Page 158 13.3 Removal / Installation 13.3.1 Removal of fresh air, hot air and mixture control knob Type of maintenance: line Authorization to perform:  Sport pilot or LSA mechanic Tools needed:  wrench size 14, 9/16 in  pliers, cutting pliers see Fig.
  • Page 159 Unscrew securing nut (4) from the vent (3). Remove the vent (3) from the instrument panel (5). Fig. 13-4 Removal / Installation of the vents 1 - Glareshield 2 - Hose 3 - Vent 4 - Securing nut 5 - Instrument panel 13.3.4 Installation of eyeball vents see Fig.
  • Page 160 INTENTIONALLY LEFT BLANK 13.CHAPTER – VENTILATION / HEATING Document: SLSA-MIP-5-4-0-US Date of Issue: 05/2016 Revision: - 13-6...

  • Page 161: Chapter - Aeroplane Handling

    CHAPTER – AEROPLANE HANDLING 14.1 General ................. 14-2 14.2 Airplane jacking and supporting ........14-2 14.3 Airplane towing ..............14-2 14.4 Airplane parking..............14-2 14.5 Airplane anchoring .............. 14-3 14.CHAPTER – AEROPLANE HANDLING Document: SLSA-MIP-5-4-0-US Date of Issue: 05/2016 Revision: - 14-1...
  • Page 162 14.1 General This chapter contains information on airplane handling – jacking, parking and anchoring. 14.2 Airplane jacking and supporting The airplane jacking can be carried out by two persons due to relatively low empty weight of the airplane. There are three supporting points (see Fig. 14-1), two of them are under upper ends of main landing gear legs (1), third one is under the tail wheel leg (2).
  • Page 163 14.5 Airplane anchoring When parking, the airplane outside the hangar after flight day, the airplane should be anchored to the ground. It is necessary to anchor the airplane in order to protect it from a possible damaging caused by wind and gusts. For this reason the airplane is equipped with anchoring eyes on the lower side of wings and on rear part of fuselage.
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  • Page 165: Chapter - Aeroplane Repairs

    CHAPTER – AEROPLANE REPAIRS 15.1 General ................. 15-3 15.2 Removing rivets ..............15-3 15.3 Riveting ................15-4 15.3.1 General ....................15-4 15.3.2 Riveting procedure................15-4 15.4 Skin repairs ................15-5 15.4.1 Removing damaged skins ..............15-5 15.4.2 Division of damaging into groups ............15-5 15.4.3 Principles for repair method determination ........
  • Page 166 15.9 Bonding repair ..............15-21 15.9.1 General ....................15-21 15.9.2 Removal / Installation ................. 15-21 15.10 Installing clamps by Nicopress pliers........ 15-22 15.CHAPTER – AEROPLANE REPAIRS Document: SLSA-MIP-5-4-0-US Date of Issue: 05/2016 Revision: - 15-2...

  • Page 167: General

    15.1 General This chapter contains information about standard procedures for performing common repairs of the airplane. These repairs can be made by an authorized organization. Other procedures for repairing individual airplane systems you can find in the appropriate chapter describing the system.

  • Page 168: Riveting

    Riveted parts are used in design of BRISTELL S-LSA airplane for whole fuselage, wings, flaps, ailerons and tail unit. In the following table there is a survey of rivets that are used on BRISTELL S-LSA airplane structure. Type of rivets...

  • Page 169: Skin Repairs

    After applying bonding sealant connect both parts together, fix them by clecos and rivet them. NOTE After proper riveting the continual bur of adhesive is created on the edge of connected surfaces. If this bur is big, it is possible to wipe it off with the plastic spatula and finally with cloth dipped in degreasing agent.

  • Page 170: Angle Repair

    Minimum distances of rivets from the edge of sheet metals or inserted bands are shown in Tab. 15-2: Rivet diameter Distance of rivet axis from the edge of the sheet metal (angle minimum recommended 2.4 mm (3/32 in) 5 mm (0.2 in) 7 mm (0.27 in) 3.2 mm (1/8 in) 6 mm (0.24 in)

  • Page 171: 15.4.5.2 Repairing The Skins With Patches

    15.4.5.2 Repairing the skins with patches CAUTION The following procedure is intended for skin repairs only with max. area of the patch up to 200 cm (31 in ) (area of the cut out skin). Before riveting the patch check the adjacent part of the inner structure in the damaged area and find out whether its repair is needed.
  • Page 172 Fig. 15-4 Repair of the punctured skin in the frame area 1 - Skin 2 - Patch 3 - Stiffening frame 15.CHAPTER – AEROPLANE REPAIRS Document: SLSA-MIP-5-4-0-US Date of Issue: 05/2016 Revision: - 15-8...
  • Page 173 Fig. 15-5 Repair of the punctured skin A ... Punctured skin B ... Cutting out and cleaning the damaged skin C ... Repair with the flat patch D ... Repair with the sunk patch 1 ... Patch 2 ... Frame 3 ...

  • Page 174: Repair Of Fiberglass Parts

    15.5 Repair of fiberglass parts 15.5.1 Damage classification Any damage of parts from reinforced plastics with epoxy matrix leads to increased saturation of the matrix with humidity and subsequently to loss of properties. Therefore we recommend carry out their repair as soon as possible after the damage has occurred. Two kinds of parts are made from these materials in the airplane: ...
  • Page 175 Application of smoothing layer After preparation of mixture (for material recommendation see Tab. 15-3) and its eventual thickening to enhance the non-curtaining capability (for vertical or lower areas) is performed its application onto the repair area by means of a plastic spatula. For better distribution of deposited material on irregular surface it is possible to form it through the laid PE or PP transparent polyethylene.

  • Page 176: Major Damage

    Dust removing Dust is removed by wiping with a clean and dry brush or by a vacuum cleaner. Stiffener preparation For this kind of repairs we recommend the stiffener G (glass) with plain weave, 150 g/m (0.037 lb/ft ), with surface protection for epoxy resins. Number of needed stiffener layers depends on depth of damage.

  • Page 177: Paint Repairs

    15.6 Paint repairs 15.6.1 Safety rules When working with paints, thinners and solvents follow the following safety rules:  it is necessary to follow safety rules for working with flammable and volatile substances  working area must be properly aerated ...

  • Page 178: 15.6.2.2 Bonding Rivet Heads, Big Irregularities And Material Transitions

    15.6.2.2 Bonding rivet heads, big irregularities and material transitions CAUTION In case that airplane surface remains without top coat, carry out just rivet head bonding. After perfect degreasing carry out bonding of rivet heads, big irregularities and transitions of fiberglass parts with Al-sheet. Epoxy and polyester bonding agents for car bodies are suitable;...

  • Page 179: Application Of Primer (Paint)

    15.6.2.3 Application of primer (paint) In order to reach a uniform resistance to corrosion and smooth surface, we recommend carry out application by means of spraying (air standard gun with the upper vessel, air HVLP gun, airless electric gun). The adjusting of the used gun (given by manufacturer) differs according to the type - air pressure, jet diameter.
  • Page 180 Type Drying (between other Recommended Manufacturer, Surface Type spraying / total) name mass items thickness 18°C (65°F) color acrylic – single BASF BASF 5.24-8.38 0.00078-0.00157” 15 min / 16 hrs. coat Glasurit polyurethane Glasurit [lb/inch/ft R-68 / shade 922-36 0.02-0.04mm (base) (standard 1-1.6...
  • Page 181 abrasive having grain size of max. 160 and finish with grain size of 400. It is made by the sander equipped with the suction from the area of sanding or by manual sanding under water. CAUTION Anodized coat cannot be destroyed by sanding on the Al-alloy sheet. 15.6.3.3 Degreasing It is carried out in the same way as in the case of the total spray coat - see 15.6.2.1.
  • Page 182 15.6.3.5 Application of top coat CAUTION For repairing it is necessary to choose the identical type (single coat, double coat) of the repair color as on the original surface. Application of the top coat will be carried out by spraying as for the total spray coat (see 15.6.2.3) with the exception of used thinners and hardeners.
  • Page 183 15.7 Torque moments Unless otherwise prescribed, the torque moments shown in the following table can be used. When tightening follow several rules: Unless specifically stated do not grease neither nut nor bolt. If possible always tighten the nut. If for some space reasons it is necessary to tighten the bolt head and the scope of tightening moment is defined.
  • Page 184 1. Adjust the correct position of 6. Pull the upper wire through the holes for locking wire. hole in the other bolt. Hold the wire end by pliers tighten it firm. 2. Pull the locking wire through 7. Hold the free end of wire by the hole in one bolt to be secured.
  • Page 185 15.9.1 General In order to keep the set down values of the transition resistances between some structural parts of the BRISTELL S-LSA airplane structure, the bonding (conductive interconnection) is installed between all important parts of the fuselage structure. 15.9.2 Removal / Installation Before installing the bonding remove the paint coat which protects the joint.
  • Page 186 15.10 Installing clamps by Nicopress pliers Procedure of clamp installation by Nicopress pliers is shown on Fig. 15-9. First pull the cable through the clamp, make a loop around the thumb and pull the cable end back through the clamp. The cable end should overlap by about 32 mm (1.25 in) from the clamp after its puling through.

  • Page 187: Chapter - Wiring Diagrams

    CHAPTER – WIRING DIAGRAMS 16.1 General ................. 16-2 16.2 General wiring diagram ............16-3 16.3 Wiring diagram of trims ............16-4 16.4 Wiring diagram of flaps ............16-5 16.5 Wiring diagrams of the communication system ....16-6 16.6 Wiring diagram of the transponder ........16-7 16.7 Wiring diagram of the GPS ..........

  • Page 188: General

    16.1 General This chapter contains typical wiring diagrams of BRISTELL S-LSA airplane systems, navigation and communication means. Further wiring diagrams, relating to additional equipment of the airplane are included in the documentation supplied with the airplane. 16.CHAPTER – WIRING DIAGRAMS...

  • Page 189: General Wiring Diagram

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

  • Page 190: Wiring Diagram Of Trims

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

  • Page 191: Wiring Diagram Of Flaps

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

  • Page 192: Wiring Diagrams Of The Communication System

    16.5 Wiring diagrams of the communication system Fig. 16-4 Wiring diagram of the radio and intercom (stereo) 16.CHAPTER – WIRING DIAGRAMS Document: SLSA-MIP-5-4-0-US Date of Issue: 05/2016 Revision: - 16-6...

  • Page 193: Wiring Diagram Of The Transponder

    16.6 Wiring diagram of the transponder Fig. 16-5 Wiring diagram of the transponder and encoder 16.CHAPTER – WIRING DIAGRAMS Document: SLSA-MIP-5-4-0-US Date of Issue: 05/2016 Revision: - 16-7...

  • Page 194: Wiring Diagram Of The Gps

    16.7 Wiring diagram of the GPS Fig. 16-6 Wiring diagram of the GPS 16.8 Wiring diagram of the socket Fig. 16-7 Wiring diagram of the socket 16.CHAPTER – WIRING DIAGRAMS Document: SLSA-MIP-5-4-0-US Date of Issue: 05/2016 Revision: - 16-8...

  • Page 195: Wiring Diagram Of The Lighting System

    16.9 Wiring diagram of the lighting system Fig. 16-8 Wiring diagram of the lighting system 16.CHAPTER – WIRING DIAGRAMS Document: SLSA-MIP-5-4-0-US Date of Issue: 05/2016 Revision: - 16-9...
  • Page 196 INTENTIONALLY LEFT BLANK 16.CHAPTER – WIRING DIAGRAMS Document: SLSA-MIP-5-4-0-US Date of Issue: 05/2016 Revision: - 16-10...

  • Page 197: Chapter - Supplements

    CHAPTER – SUPPLEMENTS 17.1 General ................. 17-2 17.2 List of appendices ............... 17-2 17.3 List of used materials for airframe production ....17-2 17.4 Airplane failure card ............17-3 17.5 Operating liquids ..............17-4 17.CHAPTER – SUPPLEMENTS Document: SLSA-MIP-5-4-0-US Date of Issue: 05/2016 Revision: - 17-1...
  • Page 198 17.1 General This chapter contains other information necessary to maintain the BRISTELL S-LSA airplane in the form of appendices 17.2 List of appendices Title 17.3 List of used materials 17.4 Airplane failure card 17.5 Operating liquids 17.3 List of used materials for airframe production...
  • Page 199 17.4 Airplane failure card Letecká 255, 686 04 Kunovice, Czech Republic BRM AERO s.r.o. Airplane Failure Card Dear customer, We would like to ask you for your assistance at obtaining information for continuous increasing reliability of airplanes produced by our company. Please fill out the card in case of any failure on your airplane.
  • Page 200 17.5 Operating liquids Aircrafts manufacturer used this operating liquids Brake fluid Beringer brakes Castrol brake fluid DOT 4 Protector series SAE J1703 & J1704; FMVSS 116 DOT4; JIS K2233 Class 4; ISO 4925 Class 4 General information: http://www.castrol.com/en_au/australia/products/cars/brake-fluids/brake- fluid-dot-4.html Product data: http://msdspds.castrol.com/bpglis/FusionPDS.nsf/Files/AF9FDB842F7E528 780257A3A002E1EBB/$File/BPXE-8WAHL9.pdf Safety Data Sheet:...
  • Page 201 Coolant Castrol Radicool NF Standard General Information: http://www.castrol.com/en_au/australia/products/cars/antifreeze-and- coolants/radicool-nf.html Product Data Sheet: http://msdspds.castrol.com/bpglis/FusionPDS.nsf/Files/3C59D03BDBCFCF B180257EC3002F3E7B/$File/BPXE-A2QEP9.pdf Safety Data Sheet: http://msdspds.castrol.com/ussds/amersdsf.nsf/Files/4626548FE641F4458 0257E1B00528E07/$File/BP%20TransTasman%20CSDS%20- %20Australia%20AU-Lubes%20AsPac-Castrol467186- AE05%20AUXX%20DE40%20ES11%20GB20%20SEXX%20X101en- GB.pdf Velvana G48 Alternative concentrated coolant A concentrated cooling liquid based on ethyleneglycol, it contains highly effective corrosion inhibitors to protect the cooling system. Product Data (Czech language only): http://www.velvana.cz/product/fridex-g-48 Retractable landing gear oil...

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