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BRISTELL BRMAERO B23 Maintenance Manual

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Airplane Maintenance Manual
Bristell B23
Doc. N°
ADxC-73-001-AMM Edition 1.0
The technical content of this document is approved under the authority of the DOA ref. EASA.21J.411
Issue: 30-Sep-2020
Chapter 00 Page 1

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Summary of Contents for BRISTELL BRMAERO Bristell B23

  • Page 1 Airplane Maintenance Manual Bristell B23 Doc. N° ADxC-73-001-AMM Edition 1.0 The technical content of this document is approved under the authority of the DOA ref. EASA.21J.411 Issue: 30-Sep-2020 Chapter 00 Page 1...
  • Page 2 Airplane Maintenance Manual Bristell Chapter 00 Intentionally left blank Chapter 00 Page 2 Issue: 30-Sep-2020...
  • Page 3 Bristell B23 Airplane Maintenance Manual Chapter 00 Amendments Issue Date Revised pages Description Edition 1 30-Sep-2020 approved Chapter 4 and 5 for initial Edition 1 16-Nov-2020 [Chapter 72- First issue of complete AMM incl. addition of mass ballast (DC-005) Issue: 30-Sep-2020...
  • Page 4 Airplane Maintenance Manual Bristell Chapter 00 List of Service Bulletins SB No Date Title Affected Serial no.’s (EASA) Chapter 00 Page 4 Issue: 30-Sep-2020...
  • Page 5 Bristell B23 Airplane Maintenance Manual Chapter 00 List of Effective Pages Date Rev. Date Rev. 30.09.2020 30.09.2020 1-16 30.09.2020 30.09.2020 30.09.2020 30.09.2020 30.09.2020 30.09.2020 1-12 30.09.2020 30.09.2020 1-10 30.09.2020 1-14 30.09.2020 30.09.2020 30.09.2020 30.09.2020 30.09.2020 30.09.2020 30.09.2020 30.09.2020 30.09.2020 1-16 16.11.2020...
  • Page 6 Airplane Maintenance Manual Bristell Chapter 00 Table of Contents Chapter Title Introduction How to Use the Manual Description Airworthiness Limitations Inspection and Maintenance Dimensions and Areas Lifting and Shoring Leveling and Weighing Towing and Taxiing Parking, Mooring, Storage and Return to Service...
  • Page 7 Bristell B23 Airplane Maintenance Manual Chapter 00 Navigation Standard Practices and Structures - General Fuselage Stabilizers Wing Propeller Power Plant Engine Engine Fuel and Control Ignition Engine Indicating Exhaust Starting Emergency Equipment Charts Appendix A Reserved Appendix B AEPS System...
  • Page 8 Airplane Maintenance Manual Bristell Chapter 00 Intentionally left blank Chapter 00 Page 8 Issue: 30-Sep-2020...
  • Page 9 Bristell B23 Airplane Maintenance Manual Chapter 01 Introduction Table of Contents Chapter Title Page 01-00 General ..................2 01-20 Related Publications ................ 2 01-30 Address ..................4 Issue: 30-Sep-2020 Chapter 01 Page 1...
  • Page 10 Bristell Chapter 01 01-00 General BRM Aero, s.r.o., the manufacturer of BRISTELL B23 airplanes, provides in accordance with the CS23 Amdt. 5 (AMC3 - CS-VLA) airworthiness requirements, information necessary to maintain airworthiness of BRISTELL B23 airplanes. This Maintenance Manual contains technical description of the airplane, information on operation, maintenance, and repairs, description of airplane particular systems and their functions.
  • Page 11 Bristell B23 Airplane Maintenance Manual Chapter 01 ADxC-73-C1-011 AEPS Parachute Installation Manual • ADxC-73-C1-012 AEPS Instructions for Continued Airworthiness • Garmin 190-02472-02 Revision 4 G3X System: Maintenance Manual G3X • Touch EFIS Part 23 AML STC Transponder: 190-01499-02 GTX 3X5 Transponder TSO Installation •...
  • Page 12 Airplane Maintenance Manual Bristell Chapter 01 01-30 Address BRM AERO, s.r.o. Address: 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 or for occurrence reporting Aircraft Design Address: Reichensteinstr. 48 Certification 69151 Neckargemünd...

  • Page 13: Table Of Contents

    Bristell B23 Airplane Maintenance Manual Chapter 02 How to Use the Manual Table of Contents Chapter Title Page 02-00 General ..................2 Group ......................2 System/Chapter ..................... 2 02-10 Standard Elements ................3 02-10-01 General Text Elements ............... 3 02-10-02 Notes ....................

  • Page 14: General

    Airplane Maintenance Manual Bristell Chapter 02 02-00 General The format and contents of this manual have been prepared in accordance with the GENERAL AVIATION MANUFACTURERS ASSOCIATION (GAMA) Specification No. 2. The contents of this manual are organized in three levels: Group •...

  • Page 15: Standard Elements

    Bristell B23 Airplane Maintenance Manual Chapter 02 02-10 Standard Elements 02-10-01 General Text Elements The following text elements are generally used within this manual: Normal text Itemization • ▶ Instructions ▶ Instructions within a safety note Head Lines Head Lines...
  • Page 16 Airplane Maintenance Manual Bristell Chapter 02 The headlines in the first column of this Maintenance Manual correspond to the headlines of the different Chapters, where you can find more detailed information for performing individual works. The description of works, which are to be performed during inspection, is also outlined in the first column.

  • Page 17: Terminology And Abbreviations

    Bristell B23 Airplane Maintenance Manual Chapter 02 02-20 Terminology and Abbreviations Term Meaning ACCU Accumulator AEPS Airframe Emergency Parachute System 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)
  • Page 18 Airplane Maintenance Manual Bristell Chapter 02 max. maximum min. minimum or minute speed in statute miles per hour MTOW Maximum Take-Off Weight Newton - force unit (1 N = 0.225 lbf) Nautical Mile (1 NM = 1852 m) Outside Air Temperature...

  • Page 19: Safety

    Bristell B23 Airplane Maintenance Manual Chapter 02 02-40 Safety ▶ Make sure that you have all necessary ratings to begin your work. These ratings may be differently regulated in different countries. ▶ Before you start working, always contact your respective examiner.

  • Page 20: Ordering Spare Parts

    Airplane Maintenance Manual Bristell Chapter 02 02-50 Ordering Spare Parts ▶ Order spare parts using the following Form: 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.
  • Page 21 Bristell B23 Airplane Maintenance Manual Chapter 03 Description Table of Contents Chapter Title Page 03-10 Airplane Classification ..............2 03-20 Airplane Description ............... 2 Issue: 30-Sep-2020 Chapter 03 Page 1...
  • Page 22 The airplane is designed for basic and advanced training and for leisure time flying. 03-20 Airplane Description Some of the basic characteristics of BRISTELL B23 aircraft are listed below. Power plant - Rotax 912 S3 Without airflow cap BRM exhaust...
  • Page 23 Bristell B23 Airplane Maintenance Manual Chapter 03 Fuselage/Hull Design All-aluminum structure design two side-by-side seats Wing low-wing monoplane Empennage Conventional crucifix design All-aluminum structure design Control system Elevator and Aileron by pushrod system Rudder by cable / pulley system Flap by electro-mechanic system...
  • Page 24 Airplane Maintenance Manual Bristell Chapter 03 Intentionally left blank Chapter 03 Page 4 Issue: 30-Sep-2020...
  • Page 25 Bristell B23 Airplane Maintenance Manual Chapter 04 Airworthiness Limitations The Airworthiness limitations Section is approved and variations must also be approved. Table of Contents Chapter Title ................... Page 04-10 Life Limited Components..............2 04-10-01 Airframe Life Limitation ..............2 04-10-02 Class I Parts Limitations ..............
  • Page 26 Airplane Maintenance Manual Bristell Chapter 04 04-10 Life Limited Components 04-10-01 Airframe Life Limitation Airframe life is unlimited. Approved Page Chapter 04 Page 2 Issue: 30-Sep-2020...
  • Page 27 Bristell B23 Airplane Maintenance Manual Chapter 04 04-10-02 Class I Parts Limitations The following parts must be replaced or inspected as described below at the intervals specified in Table 1. Inspection for welded steel components must include dye-penetrant or similar method.
  • Page 28 Airplane Maintenance Manual Bristell Chapter 04 Mandatory Inspection procedure for Class I limited parts as per Table 1 ………………… ………… Aircraft S/N.: Total flight hours: ………………… ………… Registration mark: No. of takeoffs: Prescribed works Made by Checked by Horizontal Stabilizer...
  • Page 29 Bristell B23 Airplane Maintenance Manual Chapter 04 Prescribed works Made by Checked by Engine Mount Tubes 71B210000N Remove engine cowlings. Remove the engine and the engine mount. Inspect the engine mount for deformation/damage. Remove any paint according ASTM E1417. Perform dye-penetrant testing according ASTM E1417.
  • Page 30 Airplane Maintenance Manual Bristell Chapter 04 04-10-03 AEPS System Limitations PN 008418-01 AEPS rocket (BRS 601; ) life is 12 years. Replace or uninstall (see Chapter 90-10-00) after reaching lifetime. The BRS system must be marked “Inoperative” in the case the instructions for continued airworthiness (see Chapter 90-10-00) are not followed.
  • Page 31 Bristell B23 Airplane Maintenance Manual Chapter 05 Inspection and Maintenance Table of Contents Chapter Title Page 05-10 Time Limits ..................2 05-10-01 Overhaul Schedule ................2 05-10-02 Replacement Schedule ............... 2 05-20 Scheduled Maintenance ..............4 General ......................4 05-20-01 Lubrication Plan ................

  • Page 32: Time Limits

    Airplane Maintenance Manual Bristell Chapter 05 05-10 Time Limits For Information about life limitation of installed avionics/equipment 01-20 Related Publications not listed herein refer to Chapter 05-10-01 Overhaul Schedule Items shown here must be overhauled at the times indicated. Item...
  • Page 33 Bristell B23 Airplane Maintenance Manual Chapter 05 Item Replacement Back-Up battery L3-ESI No specific replacement interval, but recalibration minimum 1time per (unit indicating year or on condition “Battery Failed” or “EOL” (end of life) warrants battery replacement) air-bleeding hoses of...

  • Page 34: Scheduled Maintenance

    05-20 Scheduled Maintenance General Maintenance system serves to maintain flight airworthiness of BRISTELL B23 airplane. Maintenance system is composed of periodic inspections, which must be performed at least in the following intervals: NOTE The intervals of engine inspections and the list of works are shown in Maintenance Manual (Line Maintenance) for installed engine.
  • Page 35 Bristell B23 Airplane Maintenance Manual Chapter 05 Periodical inspection after 100+5 flight hours - airframe and • propeller inspections, engine inspection according to maintenance system, which is described in Maintenance Manual (Line Maintenance) for installed engine. For MTV-34 refer to 6.2 100 flight hours inspection, in the Operation,...

  • Page 36: Lubrication Plan

    Airplane Maintenance Manual Bristell Chapter 05 05-20-01 Lubrication Plan Every 100 Unit Area of lubrication Lubricant hours Throttle control cable on the inlet into Engine Engine oil terminal (in the engine compartment). Choke control cable on the inlet into Engine oil terminal (in the engine compartment).

  • Page 37: Periodical Inspection After The First 25 Flight Hours

    Bristell B23 Airplane Maintenance Manual Chapter 05 05-20-02 Periodical Inspection after the first 25 Flight Hours ………………… ………… Aircraft S/N.: Total flight hours: ………………… ………… Registration mark: No. of takeoffs: Prescribed works Made by Checked by Engine and Propeller List of performed operations for engine is shown in...

  • Page 38: Periodical Inspection After The First 50 Flight Hours

    Airplane Maintenance Manual Bristell Chapter 05 05-20-03 Periodical Inspection after the first 50 Flight Hours ………………… ………… Aircraft S/N.: Total flight hours: Registration mark: ………………… No. of takeoffs: ………… Made by Prescribed works Checked by Engine and Propeller List of performed operations for the engine is shown in Maintenance Manual (Line Maintenance) for installed engine.

  • Page 39: Annual Periodical Inspection Or Inspection After 100 Flight Hours

    Bristell B23 Airplane Maintenance Manual Chapter 05 05-20-04 Annual Periodical Inspection or Inspection after 100 Flight Hours ………………… ………… Aircraft S/N.: Total flight hours: Registration mark: ………………… No. of takeoffs: ………… Prescribed works Made by Checked by AIRFRAME Preparation Perform aircraft daily inspection and engine start up, run up and shut down per AFM.
  • Page 40 Airplane Maintenance Manual Bristell Chapter 05 Prescribed works Made by Checked by Check cleanliness of optical components of landing lights and clean if needed; check mechanical integrity of product and replace in case the product is damaged Aileron Visually check surface condition loosened rivets, deformation, cracks and some other damage.
  • Page 41 Bristell B23 Airplane Maintenance Manual Chapter 05 Prescribed works Made by Checked by Flight Controls Manual Control Check for free travel of control (see Chapter 20-60-04). Check plays (see Chapter 20-60-03). Check securing of links and conductive connection. Check condition of the stops.
  • Page 42 Airplane Maintenance Manual Bristell Chapter 05 Prescribed works Made by Checked by Check function and condition of throttle controller, choke, Fuel selector valve, heating and ventilation Check condition of labels. Check cleanness and condition of upholstering. Check condition of seats.
  • Page 43 Bristell B23 Airplane Maintenance Manual Chapter 05 Prescribed works Made by Checked by Check condition and integrity of electrical fuel pump and hose sleeves in the engine compartment. Visually check for fuel system tightness. Check tightness and condition of fuel pump for occurrence of...
  • Page 44 Airplane Maintenance Manual Bristell Chapter 05 Prescribed works Made by Checked by Check for pitot-static system tightness (see Chapter 34-10-10 Checks) Heating and Ventilation System Check cleanness and passage of air inlet holes. Check line and integrity of the heating and ventilation system hoses.
  • Page 45 Bristell B23 Airplane Maintenance Manual Chapter 06 Dimensions and Areas Table of Contents Chapter Title Page 06-10 Coordinate System ................2 06-20 Main Data ..................3 06-20-01 Wing ....................3 06-20-02 Fuselage .................... 3 06-20-03 Horizontal Tail .................. 3 06-20-04 Vertical Tail ..................

  • Page 46: Coordinate System

    Airplane Maintenance Manual Bristell Chapter 06 06-10 Coordinate System The airplane is defined in metric (mm) EX, EY, EZ coordinates. EX =0 is defined by the forward plane of the engine flange to the propeller, aft positive. EY =0 lies in the airplane centre plane, RHS positive.

  • Page 47: Main Data

    Bristell B23 Airplane Maintenance Manual Chapter 06 06-20 Main Data 06-20-01 Wing Wing span (incl. wing tips): 9.16 m Area (projected): 11.75 m Aileron span: 1.145 m Aileron area: (each) 0.29 m Flap span: 2.3 m Flap area: 0.828 m...

  • Page 48: Landing Gear

    Airplane Maintenance Manual Bristell Chapter 06 06-20-05 Landing Gear Wheel base: 1.47 m Wheel track: 2.04 m Tires (tubeless): 5.00-5” Chapter 06 Page 4 Issue: 30-Sep-2020...
  • Page 49 Bristell B23 Airplane Maintenance Manual Chapter 06 Figure 1 Three View Drawing Issue: 30-Sep-2020 Chapter 06 Page 5...
  • Page 50 Airplane Maintenance Manual Bristell Chapter 06 Intentionally left blank Chapter 06 Page 6 Issue: 30-Sep-2020...
  • Page 51 Bristell B23 Airplane Maintenance Manual Chapter 07 Lifting and Shoring Table of Contents Chapter Title Page 07-00 General ..................2 07-10 Jacking ................... 2 07-20 Shoring ..................2 Issue: 30-Sep-2020 Chapter 07 Page 1...
  • Page 52 Airplane Maintenance Manual Bristell Chapter 07 07-00 General 07-10 Jacking The airplane jacking can be carried out by two persons due to relatively low empty weight of the airplane. There are three jacking points (see Fig. 1), two of them are under upper ends of main landing gear legs (2) and the third one is under the nose wheel leg (1).
  • Page 53 Bristell B23 Airplane Maintenance Manual Chapter 08 Leveling and Weighing Table of Contents Chapter Title Page 08-10 Weighing and Balancing ..............2 Introduction ....................2 Definitions ..................... 2 Airplane Weighing Procedure ................. 3 08-10-01 Empty Aircraft Weight and Balance Record ......... 4 08-10-02 Weight and Balance Envelope Limits ..........

  • Page 54: Weighing And Balancing

    Airplane Maintenance Manual Bristell Chapter 08 08-10 Weighing and Balancing Introduction This section contains information about the aircraft empty weight and centre of gravity as well as the procedure for its determination. The range within the airplane may be safely operated is defined in Chapter 08-10-02 Weight and Balance Envelope Limits.

  • Page 55: Airplane Weighing Procedure

    Bristell B23 Airplane Maintenance Manual Chapter 08 Nominal Geometric Lever Arms and Lengths Nose gear ground contact X_N....... 0.588 m Main gear ground contact X_L, X_R......2.062 m MAC..............1.343 m MAC Leading edge (MAC )........1.377 m Airplane Weighing Procedure ▶...

  • Page 56: Empty Aircraft Weight And Balance Record

    Airplane Maintenance Manual Bristell Chapter 08 08-10-01 Empty Aircraft Weight and Balance Record The table is intended to record continuous history of weighings and changes of equipment affecting weight and balance. Chapter 08 Page 4 Issue: 30-Sep-2020...

  • Page 57: Weight And Balance Envelope Limits

    Bristell B23 Airplane Maintenance Manual Chapter 08 08-10-02 Weight and Balance Envelope Limits Issue: 30-Sep-2020 Chapter 08 Page 5...

  • Page 58: Leveling

    Airplane Maintenance Manual Bristell Chapter 08 08-20 Leveling Definitions The reference line for longitudinal leveling is the fuselage top rivet row just below the canopy frame. The identical distances of wing tips to an even floor are the reference for lateral leveling.
  • Page 59 Bristell B23 Airplane Maintenance Manual Chapter 09 Towing and Taxiing Table of Contents Chapter Title Page 09-00 General ..................2 09-10 Towing ................... 2 09-20 Taxiing ................... 2 Issue: 30-Sep-2020 Chapter 09 Page 1...
  • Page 60 Airplane Maintenance Manual Bristell Chapter 09 09-00 General 09-10 Towing DANGER The engine could start unintentionally. ▶ Switch off ignition before handling the airplane on the ground! NOTICE Damage to the airplane skin possible. ▶ Avoid excessive pressure on the airframe structure, especially on the wing ends, flaps, ailerons, HTU, VTU etc.
  • Page 61 Bristell B23 Airplane Maintenance Manual Chapter 10 Parking, Mooring, Storage and Return to Service Table of Contents Chapter Title Page 10-10 Parking ................... 2 10-20 Anchoring ..................2 Procedure ....................... 2 Issue: 30-Sep-2020 Chapter 10 Page 1...
  • Page 62 Airplane Maintenance Manual Bristell Chapter 10 10-10 Parking The airplane should be preferably placed in the hangar, possibly in another covered space with stable temperature, good ventilation, low humidity and dust free environment. In case of parking outside the hangar it is necessary to anchor the airplane and to cover the canopy or the whole airplane with suitable tarpaulins for long–term parking.
  • Page 63 Bristell B23 Airplane Maintenance Manual Chapter 11 Placards and Markings Table of Contents Chapter Title Page 11-00 General ..................2 Issue: 30-Sep-2020 Chapter 11 Page 1...
  • Page 64 Airplane Maintenance Manual Bristell Chapter 11 11-00 General No limitations to outer paintjob. For placards and markings refer to flight manual ADxC-73-001-AFM. Chapter 11 Page 2 Issue: 30-Sep-2020...
  • Page 65 Bristell B23 Airplane Maintenance Manual Chapter 12 Servicing Table of Contents Chapter Title Page 12-10 Replenishing ................... 2 12-10-01 Operating Liquids ................2 12-10-10 Fuel ....................3 Refueling ......................3 Draining ......................4 12-10-20 Oil ..................... 4 Exchange/Refilling ..................4 Oil Draining....................

  • Page 66: Replenishing

    Airplane Maintenance Manual Bristell Chapter 12 12-10 Replenishing 12-10-01 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 Engine Oil AeroShell SPORT PLUS 4...

  • Page 67: Fuel

    Bristell B23 Airplane Maintenance Manual Chapter 12 12-10-10 Fuel Refueling Safety Instructions DANGER Explosion and fire hazard! ▶ Replenishing is only allowed to persons who are fully instructed and familiarized with safety instructions. ▶ Do not refuel aircraft during rain and storm...

  • Page 68: Draining

    Airplane Maintenance Manual Bristell Chapter 12 Draining The fuel tank draining points are on bottom side of the wings, and at the gascolator on the firewall. ▶ Open the drain valve by pressing up. ▶ Drain required quantity of fuel.

  • Page 69: Oil Draining

    Bristell B23 Airplane Maintenance Manual Chapter 12 Oil Draining Drain oil from the oil tank by unscrewing the plug (wrench size No.17) on the lower side of the oil tank. It is possible to drain oil from the engine after unscrewing the plug in the lower part of the engine at the hose of the return branch of oil flow.

  • Page 70: Drainage Of Coolant

    Airplane Maintenance Manual Bristell Chapter 12 Drainage of Coolant Disconnect the hose supplying liquid from the radiator to the pump (at the lowest point of the system) and drain cooling liquid into the prepared vessel. Refilling Coolant Refill coolant into the expansion tank in the engine compartment. In addition to this there is an overflow bottle which collects coolant in case of engine overheating and is attached to the firewall.

  • Page 71: Battery

    Bristell B23 Airplane Maintenance Manual Chapter 12 disassemble and check for metal chips, foreign corpuscles and contamination. NOTE If you detect an increased quantity of metal particles (brass or bronze chips or bearing abrasive), find out the reason and eliminate it.

  • Page 72: Nose Gear Shock Absorber

    Airplane Maintenance Manual Bristell Chapter 12 12-30-41 Nose Gear Shock Absorber Replacement Tools needed: wrench size: 1/2 in See Figure 1. ▶ Jack and support the airplane (see Chapter 07). ▶ Use wrench size ½ in to release both upper and lower self–locking nut (1).

  • Page 73: Tires

    Bristell B23 Airplane Maintenance Manual Chapter 12 12-30-42 Tires Change Refer to BERINGER Instructions (see Chapter 01-20). 12-30-43 Brake Pads Replacement Tools needed: Allen wrench size: T40 See Figure 2. NOTE Always replace both brake pads! ▶ Jack and support the airplane (see Chapter 07).
  • Page 74 Airplane Maintenance Manual Bristell Chapter 12 Item Description Item Description Brake caliper Brake pads Chapter 12 Page 10 Issue: 30-Sep-2020...
  • Page 75 Bristell B23 Airplane Maintenance Manual Chapter 20 Standard Practices - Airframe Table of Contents Chapter Title Page 20-10 Bolt Joints ..................3 20-10-01 Torque Moments ................3 20-10-02 Orientation of Bolts and Cotter Pins ........... 3 20-10-03 Securing the Bolt Joints ..............4 General ......................
  • Page 76 Airplane Maintenance Manual Bristell Chapter 20 Plays in Foot Control Pedals ................. 17 Play in Trim Tab Control ................17 Play in Wing Flap Control ................17 20-60-04 Friction in Control System..............18 Friction in the Longitudinal Control System ..........18 Friction in Lateral Control System ..............

  • Page 77: Bolt Joints

    Bristell B23 Airplane Maintenance Manual Chapter 20 20-10 Bolt Joints 20-10-01 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.

  • Page 78: Securing The Bolt Joints

    Airplane Maintenance Manual Bristell Chapter 20 20-10-03 Securing the Bolt Joints General Bolt joint securing is used in order to prevent from their loosening due to vibration or force action on the connected parts, which could result in the damage of the connected parts. Three ways of bolt joint securing are used on the airplane: locking wire, cotter pin and locking washer.
  • Page 79 Bristell B23 Airplane Maintenance Manual Chapter 20 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.

  • Page 80: Securing Bolt Joint By Cotter Pin

    Airplane Maintenance Manual Bristell Chapter 20 Securing Bolt Joint by Cotter Pin Securing by cotter pin is used for independent bolt joints where securing by locking wire could not be used. It is used for securing castle nuts. Cotter pin removal is very easy: by means of a flat screwdriver straighten up the bent ends of the cotter pin and take out the cotter pin of the hole by means of pliers.

  • Page 81: Rivet Joints

    20-20 Rivet Joints General Riveted parts are used in design of BRISTELL B23 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 B23 airplane structure.

  • Page 82: Riveting

    Airplane Maintenance Manual Bristell Chapter 20 Fig. 4 Drilling of Rivets (solid rivet shown) Riveting ▶ Fit the parts being connected and drill them together. Hole diameter must be of 0.1 mm (0.004 in) bigger than rivet shank. NOTICE When drilling, fix by clamps or clecos mutual position of assembled parts.
  • Page 83 Bristell B23 Airplane Maintenance Manual Chapter 20 apply on the cloth only and wipe it off from the surface before its evaporating. ▶ Apply bonding sealant on one of the surfaces, which should be sealed together. Apply the adhesive directly...

  • Page 84: Nicopress Clamps

    Airplane Maintenance Manual Bristell Chapter 20 20-30 Nicopress Clamps Installing Clamps by Nicopress Pliers Procedure of clamp installation by Nicopress pliers is shown on Fig. 5. 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...

  • Page 85: Lubrication

    Bristell B23 Airplane Maintenance Manual Chapter 20 20-40 Lubrication At assembling parts grease al joints and friction surfaces (bolts, pins, and threads) after mechanical or chemical cleaning by lubricant grease. 20-50 Adjustments and Tests 20-50-01 Control Surface Deflections The control surface deflections are shown in the following table: 24°...

  • Page 86: Adjusting Aileron Deflections

    Airplane Maintenance Manual Bristell Chapter 20 NOTE After adjustment of control surface deflections, ensure push rod terminals overreach the inspection hole in the push rod. Adjusting Aileron Deflections ▶ Adjust range of deflections 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.

  • Page 87: Adjusting Rudder Deflections

    Bristell B23 Airplane Maintenance Manual Chapter 20 Adjusting Rudder Deflections ▶ Carry out correction of rudder deflection setting by adjusting the turnbuckles on the foot pedal side in the cockpit. Adjusting Trim Tab Deflections Trim tab deflections are given by control actuator and they are fixed.

  • Page 88: Measuring Elevator Deflections

    Airplane Maintenance Manual Bristell Chapter 20 Measuring Elevator Deflections ▶ Set the protractor with the deflecting pointer on the trailing edge of the elevator by means of the clamps. ▶ Set the elevator to neutral position. ▶ Set the protractor to 0° – starting value of measuring.

  • Page 89: Play In Control System

    Bristell B23 Airplane Maintenance Manual Chapter 20 in the area of cable attachment on the rudder control pedals in the area of cable attachment on rudder lever in the area of cable inlet on rear fuselage ▶ Check for the following defects on the cable:...

  • Page 90: Measuring Procedure

    Airplane Maintenance Manual Bristell Chapter 20 max. 5 mm on pedals in longitudinal axis of the directional 3/16 in) airplane max. 3 mm trim tabs at the end of the trim tab 1/8 in max. 5 mm wing flaps at the end of the wing flap...

  • Page 91: Lateral Control

    Bristell B23 Airplane Maintenance Manual Chapter 20 Figure 6 Control Stick Play Lateral Control Measure total play at the end of the control stick with ailerons blocked in the neutral position. First block the right aileron and measure total play on the control stick, then measure total play at the blocked left aileron.

  • Page 92: Friction In Control System

    Airplane Maintenance Manual Bristell Chapter 20 control on the wing flap trailing edge. Max play of the wing flap measured on the trailing edge must not exceed 5 mm (3/16 in). 20-60-04 Friction in Control System Control system must function smoothly within the whole scope of deflections.

  • Page 93: Friction In Lateral Control System

    Bristell B23 Airplane Maintenance Manual Chapter 20 ▶ Place control stick in neutral position. The down spring is thus released from the bracket (3). ▶ Measure force by a dynamometer attached on the end of the control stick. Maximum force limit is 0.1 kg (0.2 lbs.).
  • Page 94 Airplane Maintenance Manual Bristell Chapter 20 Intentionally left blank Chapter 20 Page 20 Issue: 30-Sep-2020...
  • Page 95 Bristell B23 Airplane Maintenance Manual Chapter 21 Air Conditioning Table of Contents Chapter Title Page 21-00 General ..................2 21-20 Distribution ..................2 21-20-01 Eye Ball Vent..................2 Removal ......................2 Installation ..................... 3 21-40 Heating ..................3 21-40-01 Control Knobs ................... 4 Removal ......................

  • Page 96: General

    Airplane Maintenance Manual Bristell Chapter 21 21-00 General 21-20 Distribution Cockpit ventilation is ensured by two eyeball air vents located in the cockpit on side panels of the instrument panel (see 2, Fig. 1). Air inlets – Naca scoops (1) are located on both fuselage sides in front of the canopy.

  • Page 97: Installation

    Bristell B23 Airplane Maintenance Manual Chapter 21 Fig. 2 Removal / Installation of the Vents Item Description Item Description Glare shield Hose Vent Securing nut Instrument panel Installation see Fig. 2. ▶ Insert the vent (3) into the instrument panel (5).

  • Page 98: Removal

    Airplane Maintenance Manual Bristell Chapter 21 (7) is located, which splits hot air flow into the canopy bubble outlet (1) and into the crew legs outlet (8). The mixture flap is controlled by the MIXTURE knob (9). Fig. 3 Heating System...

  • Page 99: Installation

    Bristell B23 Airplane Maintenance Manual Chapter 21 ▶ Disconnect the control cable on the heating flap lever (6, Fig. 3) and mixture flap lever (7, Fig. 3). ▶ Remove the nuts (1) thus releasing the flexible housing (3) with the control knob (2).
  • Page 100 Airplane Maintenance Manual Bristell Chapter 21 ▶ After adjustment of the control, mark the mutual position of the Bowden cable terminal and the flap controller with red color. Chapter 21 Page 6 Issue: 30-Sep-2020...
  • Page 101 Bristell B23 Airplane Maintenance Manual Chapter 23 Communication Table of Contents Chapter Title Page 23-00 General ..................2 Issue: 30-Sep-2020 Chapter 23 Page 1...
  • Page 102 Airplane Maintenance Manual Bristell Chapter 23 23-00 General The communication system consists of: Transponder • Radio communication • Intercom • • Additionally, the powered headsets plugs of the Bose system are installed: Bose headset power supply • Maintenance for these parts are “on condition”, for detailed maintenance instructions refer to the respective manufacturer manuals (see Chapter 01-20).
  • Page 103 Bristell B23 Airplane Maintenance Manual Chapter 24 Electrical Power Table of Contents Chapter Title Page 24-00 General ..................2 24-30 DC Generation ................3 24-30-01 Generator ..................3 24-30-02 Auxiliary Generator ................3 24-30-03 Battery ....................3 Removal ......................4 Installation .....................
  • Page 104 Airplane Maintenance Manual Bristell Chapter 24 24-00 General The airplane is equipped with 14V DC electrical installations with grounded negative pole. The primary DC electrical sources are an AC alternator in combination with an external electronics full-wave rectifier regulator and an auxiliary generator. The secondary source of electrical energy is the 12V battery, which is located on the firewall.

  • Page 105: Dc Generation

    Bristell B23 Airplane Maintenance Manual Chapter 24 24-30 DC Generation 24-30-01 Generator The generator is a part of the engine which supplies electric current through the rectifier. Regulator supplies electric current of 14V voltage to onboard network. Technical parameters of generator:...

  • Page 106: Removal

    Airplane Maintenance Manual Bristell Chapter 24 Fulfils JIS standard • Spill and leak-proof at angles up to 45° • Features Absorbent Glass Mat (AGM) technology, enabling the battery • to be repeatedly charged and discharged without affecting performance Removal Tools needed:...

  • Page 107: 24-30-04 External Power

    Bristell B23 Airplane Maintenance Manual Chapter 24 24-30-04 External Power Description NOTE The functionality of the external power is limited to supply the engine starter motor and the indication light. The external power cannot be used for re-charging. The external power plug is located on the lower side of the firewall on the engine side left of the nose landing gear.
  • Page 108 Airplane Maintenance Manual Bristell Chapter 24 DANGER Death or serious injury possible due to propeller strike. ▶ Never start the engine if a person is next to the propeller working area. ▶ Never connect or disconnect external power when the engine is running.

  • Page 109: Dc Electrical Load Distribution

    Bristell B23 Airplane Maintenance Manual Chapter 24 24-60 DC Electrical Load Distribution 24-60-01 Switches and Circuit Breakers The switches serve for switching ON/OFF individual electrical circuits. There are two kinds of switches: Switches–Circuit Breakers switching ON/OFF and protecting the electrical circuit from •...
  • Page 110 Airplane Maintenance Manual Bristell Chapter 24 24-60-02 Fuses Fuses serve for protecting individual electrical circuits from overloading. Every fuse is marked by the placard with a fuse designation (see following Table). Fuses are located on the right instrument panel. Wiring diagrams are shown in CHAPTER 91 –...
  • Page 111 Bristell B23 Airplane Maintenance Manual Chapter 25 Equipment/Furnishings Table of Contents Chapter Title Page 25-00 General ..................2 25-10 Flight Compartment ................ 2 25-10-01 Seats ....................2 Servicing ......................3 25-10-02 Safety Harness .................. 3 Removal ......................3 Installation ..................... 3 Check ......................

  • Page 112: General

    Arm rest with a box 25-10-01 Seats Seats (4) of the BRISTELL B23 airplane are attached to the gear channel on Velcro and are equipped with an upholstered cushions. The seat backs (2) are attached by means of hook and loop fasteners (Velcro) to the bulkhead No.5.

  • Page 113: Servicing

    Bristell B23 Airplane Maintenance Manual Chapter 25 Servicing Cleaning Seat Covers and Upholstery ▶ Take upholstered seats and seat backs out of the airplane. ▶ Brush impurities, possibly clean with warm water with addition of a suitable detergent. ▶ Before reinstalling upholstered seats in the airplane, let it thoroughly dry.

  • Page 114: Check

    Airplane Maintenance Manual Bristell Chapter 25 Figure 2 Safety Harness Removal/Installation Item Description Item Description Top attachment bracket Bolt Side attachment bracket Check ▶ 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 115 Bristell B23 Airplane Maintenance Manual Chapter 27 Flight Controls Table of Contents Chapter Title Page 27-00 General ..................3 27-00-01 Push-pull Rods .................. 3 Adjustment ....................3 27-00-02 Control Sticks ..................4 Removal ......................4 Installation ..................... 4 27-00-03 Trim Tab Control Actuator ..............6 Removal ......................
  • Page 116 Airplane Maintenance Manual Bristell Chapter 27 27-30-02 Trim Tab ..................20 Removal ....................... 20 Installation ....................21 27-30-03 Bail Arm lever (front) ............... 21 Removal ....................... 21 Installation ....................22 27-30-04 Bail arm lever (rear) ................. 23 Removal ....................... 23 Installation ....................

  • Page 117: General

    Bristell B23 Airplane Maintenance Manual Chapter 27 27-00 General The airplane is equipped with dual controls. Airplane control includes: lateral control (aileron & trim tab control) • directional control (rudder control) • longitudinal control (elevator & trim tab control) •...

  • Page 118: Control Sticks

    Airplane Maintenance Manual Bristell Chapter 27 27-00-02 Control Sticks Removal Tools needed: wrench size: 7/16 in, 3/8 in wire nippers Refer to Figure 1. ▶ Disconnect electric wire (2) for trim tab switches and PTT. ▶ Disconnect elevator control rod (5) from torque tube (10).
  • Page 119 Bristell B23 Airplane Maintenance Manual Chapter 27 Figure 1 Control Sticks and Torque Tube Item Description Item Description Control stick Electric wire Aileron travel stops Elevator control stops Aileron control rods Control stick bearing bolts Elevator control rod Main center wing spar...

  • Page 120: Trim Tab Control Actuator

    Airplane Maintenance Manual Bristell Chapter 27 27-00-03 Trim Tab Control Actuator The trim tab control actuator is located in the elevator and the left aileron. Removal Tools needed: wrench size: 5 screwdriver wire nippers, pliers ▶ Place trim tab to neutral position.

  • Page 121: Installation

    Bristell B23 Airplane Maintenance Manual Chapter 27 Installation Tools needed: wrench size: 5 screwdriver pliers ▶ Insert trim tab actuator (6) in to the elevator or aileron through access hole (3). ▶ Connect the actuator (6) to the elevator or aileron reinforcement angle.

  • Page 122: Aileron Control

    Airplane Maintenance Manual Bristell Chapter 27 27-10 Aileron Control Ailerons are actuated with 2 control sticks located between the pilot’s and co-pilot’s legs. Movement of the control sticks is synchronized via pushrod lead between them inside of the elevator control torque tube.

  • Page 123: Aileron

    Bristell B23 Airplane Maintenance Manual Chapter 27 27-10-01 Aileron Removal Tools needed: wrench size: 7/16 in cutting pliers ▶ Disconnect the control rod with control lever. ▶ Remove the cover (2) from the hole (3) for access to trim tab actuator (6) on left aileron (see Fig. 2).

  • Page 124: Removal

    Airplane Maintenance Manual Bristell Chapter 27 Removal Tools needed: wrench size: 7/16 in See Figure 4. ▶ Remove access hole cover on bottom skin. ▶ Disconnect both push rods (1) from the control lever (2) by unscrewing the bolts. ▶ Remove the cotter pin – unscrew the nut (3).

  • Page 125: Aileron Control Bell Crank

    Bristell B23 Airplane Maintenance Manual Chapter 27 Item Description Item Description Push rods Control lever Cotter pin & castle nut 27-10-03 Aileron Control Bell Crank The bell crank is located on the bracket in the position of the wing main spar next to the rear rib No. 9.

  • Page 126: Aileron Travel Stops

    Airplane Maintenance Manual Bristell Chapter 27 NOTE The bell crank must not show axial play after installing and its travel must be continuous without dragging. ▶ According to the Fig. 5 connect push rods (2) to the bell crank. ▶ Check aileron deflections (see Chapter 20-50-01) and check plays in the control (see Chapter 20-60-03).

  • Page 127: Rudder Control

    Bristell B23 Airplane Maintenance Manual Chapter 27 27-20 Rudder Control The rudder is controlled by means of foot control pedals. Pedal deflections are transferred to the rudder by a cable-pulley system. Foot control pedals can be set individually to two positions by means of a lock-pin mechanism on the side wall of fuselage under the instrument panel.

  • Page 128: Rudder

    Airplane Maintenance Manual Bristell Chapter 27 27-20-01 Rudder Removal Tools needed: wrench size: 3/8 in, 7/16 in ▶ Remove horizontal stabilizer (see Chapter 55-10). ▶ Remove the nuts from bolts on both hinges of the rudder. ▶ Remove top bolt from the hinge and lift the rudder from lower hinge.

  • Page 129: Rudder Control Cable

    Bristell B23 Airplane Maintenance Manual Chapter 27 27-20-02 Rudder Control Cable Figure 7 Rudder Control Cables Item Description Item Description Control cable Rudder pedal Cable thimble Nicopress sleeve Turnbuckle Pulley Rudder control lever Issue: 30-Sep-2020 Chapter 27 Page 15...

  • Page 130: Removal

    Airplane Maintenance Manual Bristell Chapter 27 Removal See Figure 7. ▶ Remove rudder as per Chapter 27-20-01 to get access to the aft control cable attachment. Access to the front control cable attachment is possible through the front gear channel.
  • Page 131 Bristell B23 Airplane Maintenance Manual Chapter 27 ▶ Connect the forward part of the control cable to the rudder torque tube lever. ▶ Thread the forward part of the control cable through the main spar lead-through. ▶ Secure the rudder and the pedal in neutral position.

  • Page 132: Rudder Travel Stops

    Airplane Maintenance Manual Bristell Chapter 27 27-20-03 Rudder Travel Stops Rudder travel stops (2, Figure 8) are made of a bolted spacer, limiting the travel of the tube (1), which is welded on the rudder bottom tube. Figure 8 Rudder Stops...

  • Page 133: Elevator Control

    Bristell B23 Airplane Maintenance Manual Chapter 27 27-30 Elevator Control The elevator is controlled by moving the control sticks forward and aft. A system of transmission levers and pushrods transfers the movement of control sticks to the elevator. Pushrods are led through the central channel between the seats to the two-arm lever which is located on the fin spar.

  • Page 134: Elevator

    Airplane Maintenance Manual Bristell Chapter 27 27-30-01 Elevator Removal Tools needed: wrench size: 7/16 in wire nippers ▶ Remove the cover (2) from the trim tab access hole (3, Fig. 2). ▶ Disconnect the electrical trim tab actuator wires (1).

  • Page 135: Installation

    Bristell B23 Airplane Maintenance Manual Chapter 27 ▶ Drill out the rivets connecting the piano hinge with elevator. ▶ Remove the trim tab with piano hinge from elevator. Installation Tools needed: pliers wire nippers riveting pliers ▶ Insert the trim tab with piano hinge into the elevator.
  • Page 136 Airplane Maintenance Manual Bristell Chapter 27 Figure 10 Bail Arm (front) Removal/Installation Item Description Item Description Cover on the bottom skin Push rod end Bail arm lever Installation Tools needed: wrench size: 7/16 in screw driver pliers Refer to Figure 10.

  • Page 137: Removal

    Bristell B23 Airplane Maintenance Manual Chapter 27 NOTE The lever after installing must not show axial play and its travel must be smooth without hitching. ▶ Connect both push rod ends (2) with the bail arm lever (3). ▶ Close the access hole (1) on the bottom skin under the luggage compartment.
  • Page 138 Airplane Maintenance Manual Bristell Chapter 27 Figure 11 Bail Arm (rear) Removal/Installation Item Description Item Description Cover Push/Pull rods Bail arm lever Lever bolt Installation Tools needed: wrench size: 7/16 in (11) screw driver pliers Refer to Figure 11. ▶ Check condition of the lever (3). Grease bearings if necessary and assemble installing the bolts, nuts and cotter pins.

  • Page 139: Elevator Travel Stops

    Bristell B23 Airplane Maintenance Manual Chapter 27 ▶ Check elevator deflections (see Chapter 20-50-01) and check plays in control (see Chapter 20-60-03). 27-30-05 Elevator Travel Stops See Items 4 in Figure 1. Nuts are welded to the upper and lower elevator control arms (positioned on the torque tube) and bolts are screwed down to these nuts.

  • Page 140: Flaps

    Airplane Maintenance Manual Bristell Chapter 27 27-50 Flaps Wing flaps are controlled by one central electric actuator connected to the flaps by a lateral torque tube with transfer pushrods on each side of the wing. The flap actuator is located in the centre channel of fuselage between the seats and is controlled by programmable control unit with three positions switch (including “up”) located on the centre...

  • Page 141: Wing Flap Control Actuator

    Bristell B23 Airplane Maintenance Manual Chapter 27 Installation Tools needed: wrench size: 7/16 in ▶ Set the flap in to the hinges. ▶ Insert the bolts in to the hinges and screw the nuts on them. ▶ Connect control push rod.

  • Page 142: Removal

    Airplane Maintenance Manual Bristell Chapter 27 Removal Tools needed: wrench size: 7/16 in, 172 in. screw driver Refer to Figure 13. ▶ Open the glove box cover on center console (1) between the seats. ▶ Disconnect flap lever (3) from the flap actuator (4).
  • Page 143 Bristell B23 Airplane Maintenance Manual Chapter 28 Fuel Table of Contents Chapter Title Page 28-00 General ..................2 Checking Fuel System Tightness ..............3 28-10 Storage ..................4 28-10-01 Fuel Tank ..................4 28-20 Distribution ..................6 28-20-01 Electric Fuel Pump ................7 Check ......................

  • Page 144: General

    Chapter 28 28-00 General The fuel system of Bristell B23 airplane consists of the following parts: two fuel tanks, fuel tubing, selector valve, gascolator with integrated fuel filter, mechanical fuel pump (located on the engine), and back up electrical fuel pump, fuel level gauges, fuel pressure gauge and drain valves on the fuel tanks.

  • Page 145: Checking Fuel System Tightness

    Bristell B23 Airplane Maintenance Manual Chapter 28 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 –...

  • Page 146: Storage

    Airplane Maintenance Manual Bristell Chapter 28 28-10 Storage Fuel is stored in airplane in two fuel tanks. The fuel tanks are integrated part of the wing from Aluminum sheet and their volume is standardly 60 liters (15.85 US gal, 13.2 UK gal) each.
  • Page 147 Bristell B23 Airplane Maintenance Manual Chapter 28 Figure 3 Fuel Tank (left) Item Description Item Description Pick-up line Fuel level sender Drain valve Issue: 30-Sep-2020 Chapter 28 Page 5...
  • Page 148 Airplane Maintenance Manual Bristell Chapter 28 28-20 Distribution Fuel flows from the tanks through the pick-up line (3, Figure 4) and fuel lines (4, 10) to the fuel selector valve (1) and from there to the gascolator (7), electrical fuel pump (9) to the mechanical fuel pump (6) located on the engine.

  • Page 149: Check

    Bristell B23 Airplane Maintenance Manual Chapter 28 28-20-01 Electric Fuel Pump Check Check for Cracks ▶ Check the fuel pump body for cracks, including the inlet and the outlet hose. ▶ If cracks are detected, immediately exchange the fuel pump with new pump.

  • Page 150: Fuel Drain

    Airplane Maintenance Manual Bristell Chapter 28 28-20-03 Fuel Drain Removal Tools needed: wrench size: 1/2 in ▶ Drain the fuel from the tank or gascolator. ▶ Unscrew the drain valve from the tank or gascolator and remove it. ▶ Check “O” ring and the spring.

  • Page 151: Installation

    Bristell B23 Airplane Maintenance Manual Chapter 28 Installation Tools needed: screwdriver ▶ Set sealing on the fuel tank flange. ▶ Set position and length of the fuel level sender lever according to Fig. 5. ▶ Carefully put the fuel level sender into the tank and attach it using bolts with washers –...
  • Page 152 Airplane Maintenance Manual Bristell Chapter 28 Intentionally left blank Chapter 28 Page 10 Issue: 30-Sep-2020...
  • Page 153 Bristell B23 Airplane Maintenance Manual Chapter 31 Indicating/Recording System Table of Contents Chapter Title Page 31-00 General ..................2 31-10 Instrument & Control Panels ............2 31-40 Garmin G3X system ................ 3 Issue: 30-Sep-2020 Chapter 31 Page 1...
  • Page 154 Airplane Maintenance Manual Bristell Chapter 31 31-00 General 31-10 Instrument & Control Panels The compass rose is positioned on the rotary and swinging pivot inside the compass (if installed / compass optional). Chapter 31 Page 2 Issue: 30-Sep-2020...
  • Page 155 Bristell B23 Airplane Maintenance Manual Chapter 31 31-40 Garmin G3X system For servicing/repair/replacing of components of the Garmin G3X system (excl. TSO’ed parts: NAV/COM and XPDR) uninstall the equipment and send to aircraft manufacturer BRM AERO s.r.o. . The reinstallation process with the corresponding Form1 (“spare part” from aircraft manufacturer) is done acc.
  • Page 156 Airplane Maintenance Manual Bristell Chapter 31 Intentionally left blank Chapter 31 Page 4 Issue: 30-Sep-2020...
  • Page 157 Bristell B23 Airplane Maintenance Manual Chapter 32 Landing Gear Table of Contents Chapter Title Page 32-00 General ..................2 32-10 Main Gear ..................3 32-10-01 Main Gear Leg ................... 3 Removal ......................3 Installation ..................... 4 32-20 Nose Gear ..................5 32-20-01 Nose Gear Leg ...................

  • Page 158: Landing Gear

    Chapter 32 32-00 General The Bristell B23 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.

  • Page 159: Main Gear

    Bristell B23 Airplane Maintenance Manual Chapter 32 32-10 Main Gear The main landing gear (see Fig. 1) consists of the composite landing gear legs (1), wheel axle and wheel (3) equipped with disc brakes (4). 32-10-01 Main Gear Leg The landing gear legs (1, Figure 2) are inserted in the gear channel (4) under the seats, where they are attached by two bolts (3) and stirrup (2).

  • Page 160: Installation

    Airplane Maintenance Manual Bristell Chapter 32 ▶ Disconnect main gear leg (1), stirrup (2) and attachment bolts (3). ▶ Remove the bolts (3) and stirrup (2) from the gear channel (4). ▶ Remove the landing gear leg (1) from the attachment channel and put it on a suitable place.

  • Page 161: Nose Gear

    Bristell B23 Airplane Maintenance Manual Chapter 32 32-20 Nose Gear See Figure 3. The nose landing gear is steerable and consists of 4130 steel welded landing gear leg (2) with cover (3), 4130 steel welded fork, shock absorber and the wheel (4). The landing gear is attached to brackets installed in the nose gear channel (1) located between bulkhead No.

  • Page 162: Nose Gear Leg

    Airplane Maintenance Manual Bristell Chapter 32 32-20-01 Nose Gear Leg Figure 4 Nose Gear Leg Item Description Item Description Gear leg attachment bolt Nose gear leg axle Nose gear leg Nose gear channel Teleflex Shock Absorber Removal Tools needed: wrench size 1/2 in, No. 17 wrench size 10 and 20 See Figure 4.

  • Page 163: Installation

    Bristell B23 Airplane Maintenance Manual Chapter 32 ▶ Remove the gear leg (3) from the fuselage and put it on a suitable place. Installation Tools needed: wrench size 1/2 in, No. 17 wrench size 10 and 22 See Figure 4.

  • Page 164: Wheels And Brakes

    Wheels and Brakes Refer to applicable BERINGER documentation and instructions for further detailed information about wheels and brakes used on the Bristell B23 airplane (see Chapter 01-20). 32-40-01 Wheel Pants The airplane is equipped with composite wheel pants which reduce air drag and improve aerodynamic properties of the airplane.

  • Page 165: Main Wheel

    Bristell B23 Airplane Maintenance Manual Chapter 32 32-40-10 Main Wheel See Figure 5. Also refer to BERINGER documents (refer to Chapter 01- 20). Main landing gear wheel rims (1, 2) are machined of aluminum. Wheel rims are split in order to facilitate assembly and disassembly of tires.

  • Page 166: Installation

    Airplane Maintenance Manual Bristell Chapter 32 ▶ Disconnect the brake disc from the wheel rim (Refer to Chapter 01-20). ▶ Remove the cover (6) and the behind nut from wheel axle. ▶ Remove the wheel from the wheel axle. Installation Tools needed: socket wrench vel.

  • Page 167: Nose Wheel

    Bristell B23 Airplane Maintenance Manual Chapter 32 32-40-20 Nose Wheel The nose landing gear wheel rim is machined of aluminum. In order to facilitate assembly and disassembly of tires, the rim is split. Both halves are connected by bolts. The wheel is equipped with a tubeless tire.

  • Page 168: Installation

    32-40-30 Brake System The Bristell B23 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. 7), master brake cylinder, hoses for brake fluid supply, brake calipers and brake pads.

  • Page 169: Brake Pump

    Bristell B23 Airplane Maintenance Manual Chapter 32 32-40-32 Brake Pump Figure 7 Brake Pump Removal/Installation Item Description Item Description Rudder pedal Brake hoses Bracket on cross channel Fittings Brake master cylinder Rudder pedal bracket Removal Tools needed: wrench size 3/8 in, 10 mm, Allan wrench 5 mm See Figure 7.

  • Page 170: Installation

    Airplane Maintenance Manual Bristell Chapter 32 ▶ Remove the master cylinder (5) from the bracket (3) on the cross channel by unscrewing nut and removing the bolt. ▶ Remove fittings (4) if applicable. Installation Tools needed: wrench size 3/8 in, 10 mm, Allan wrench 5 mm See Figure 7.
  • Page 171 Bristell B23 Airplane Maintenance Manual Chapter 32 32-50 Steering 32-50-01 Nose Wheel Control The NLG / Rudder control has a closed loop system with centring springs (3, Figure 8) located in the nose gear channel (also see Item 2 in Figure 9).
  • Page 172 Airplane Maintenance Manual Bristell Chapter 32 ▶ if necessary, adjust the Teleflex rod lenghts by screwing/unscrewing the fork ends on the upper end (connected to the rudder pedal torque tubes) ▶ Secure by tightening the counter nuts at the fork ends...
  • Page 173 Bristell B23 Airplane Maintenance Manual Chapter 33 Lights Table of Contents Chapter Title Page 33-00 General ..................2 33-10 Flight Compartment ................ 2 33-10-01 Interior Lights ................... 2 33-40 Exterior ..................3 33-40-01 Strobe/Position Lights ............... 3 Removal ......................3 Installation .....................
  • Page 174 Airplane Maintenance Manual Bristell Chapter 33 33-00 General Airplane lighting consists of instrument lighting and external lighting. 33-10 Flight Compartment 33-10-01 Interior Lights Displays, autopilot control, transponder, trim indicator have their own illumination. The Garmin system related brightness can be dimmed manually or automatic by a light sensor (pilot choice).
  • Page 175 Bristell B23 Airplane Maintenance Manual Chapter 33 33-40 Exterior External lighting consists of position and strobe lights and of landing lights. 33-40-01 Strobe/Position Lights Navigation LED-type lights are located in the wing tips and are switched by the switch NAV-L and strobe lights are switched by the switch STROBE.
  • Page 176 Airplane Maintenance Manual Bristell Chapter 33 Removal Tools needed: Allan wrench size 3 mm Screwdriver ▶ Remove acryl cover bubble from the landing light box by unscrewing the screws on top and bottom of the bubble ▶ Unscrew the 4 screws on the light panel ▶...
  • Page 177 Bristell B23 Airplane Maintenance Manual Chapter 34 Navigation Table of Contents Chapter Title Page 34-00 General ..................2 34-10 Flight Environment Data ..............2 34-10-10 Pitot/Static System ................2 Checks ......................3 34-10-11 Pitot Tube ..................4 Removal ......................4 Installation .....................

  • Page 178: General

    Airplane Maintenance Manual Bristell Chapter 34 34-00 General 34-10 Flight Environment Data 34-10-10 Pitot/Static System The Pitot tube to sense total pressure is located under left 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 179: Checks

    Bristell B23 Airplane Maintenance Manual Chapter 34 Fig. 2 Pitot–Static System Item Description Item Description Static pressure port Drains GAP 26 Pitot tube GSU 73 ADAHRS AOA sense line Total pressure line Static pressure line Transponder L3 ESI-500 Checks System Tightness Test Static system ▶...

  • Page 180: Pitot Tube

    Airplane Maintenance Manual Bristell Chapter 34 ▶ Create an under pressure by sucking on the tube/hose corresponding to altitude of 1000 ft ▶ Seal the tube/hose ▶ Drop in the indicated altitude per one minute must not exceed 100 ft.
  • Page 181 Bristell B23 Airplane Maintenance Manual Chapter 34 ▶ Attach the bracket by means of rivet (poprivet 3,2x6,0 type 10013206) to the lower skin of the wing ▶ Carry out check of pitot–static system tightness (see 12.4.1). ▶ Check, that pitot–tube is parallel to bottom wing skin.

  • Page 182: Attitude & Direction

    Airplane Maintenance Manual Bristell Chapter 34 34-20 Attitude & Direction 34-20-11 Electronic Magnetometers Two electronic magnetometers are installed to the aircraft. One on each wing side. The RHS magnetometer is the Garmin GMU22 and the LHS is L3 MAG-500. Both do not require compensation. The access to the magnetometers is provided by hatches close to the wing tips on the lower side of the wing.
  • Page 183 Bristell B23 Airplane Maintenance Manual Chapter 34 ▶ Turn the airplane to "S" heading, reduce the found out deviation to the half–value by "N-S" screw and write down the rest of the deviation. ▶ Turn the airplane to "E" heading, eliminate the deviation by "E-W"...
  • Page 184 Airplane Maintenance Manual Bristell Chapter 34 REPORT OF MAGNETIC COMPASS COMPENSATION Aircraft Serial No. Registration mark Compass Type: Compass Serial No.: All instruments switched on to achieve simulated flight conditions Engine running (throttle in cruise position) Course Measured Deviation Date: Time: YES –...
  • Page 185 Bristell B23 Airplane Maintenance Manual Chapter 51 Standard Practices and Structures - General Table of Contents Chapter Title Page 51-00 General ..................2 51-00-01 Access Panel Identification ..............2 51-30 Materials ..................4 51-30-01 List of Used Materials for Airframe Production ........4 51-60 Control-Surface Balancing ...............
  • Page 186 Airplane Maintenance Manual Bristell Chapter 51 51-00 General 51-00-01 Access Panel Identification Fig. 1, Sheet 1 Access Panel Identification (outside) Item Description Item Description Aileron trim access panel LH wing access panels LH wing gap cover Oil hatch AEPS (egress) panel...
  • Page 187 Bristell B23 Airplane Maintenance Manual Chapter 51 Fig. 1, Sheet 2 Access Panel Identification (inside) Item Description Item Description Aft cabin floor access panel Forward cabin floor access panel LH cabin access panel (ELT) Armrest cover (flap actuator) RH cabin access panel All inside access panels allow access to the elevator and rudder control.

  • Page 188: Materials

    Airplane Maintenance Manual Bristell Chapter 51 51-30 Materials 51-30-01 List of Used Materials for Airframe Production Prescribed Material Designation Material Used in … (example) 6061 T6 Aluminium Fuselage structure, skin 7075-T651 Aluminium Bellcranks in control system 4130 N Steel Welded steel parts:...

  • Page 189: Control-Surface Balancing

    Bristell B23 Airplane Maintenance Manual Chapter 51 51-60 Control-Surface Balancing General The weight and balance of control surfaces needs to be determined after execution of work on the surface with (potential) change of total mass and/or balancing (example: new paint or other repair).
  • Page 190 Airplane Maintenance Manual Bristell Chapter 51 ▶ Install bolts in two control surface ball bearings (flap, rudder). ▶ Install a wire in the piano hinges (aileron, elevator, trim tabs). ▶ Place control surfaces friction free on two mandrels. Bolts in ball bearings need to be in line and aligned horizontally.
  • Page 191 Bristell B23 Airplane Maintenance Manual Chapter 51 Bristell B23 Registration No: Serial number: Reason: Mass Limit Indicated Lever arm Resulting moment Limit OK Y/N W [kg] [kg] value X [m] M [kgm] [kgm] limit limit F [kg] Rudder Rudder Elevator (RH elevator weighing including trim tab)
  • Page 192 Airplane Maintenance Manual Bristell Chapter 51 51-60-01 Elevator and Tab Limits Elevator: Trim tab (both sides together WITH trim tab; (co-acting as anti- Without trim tab actuation rod) servo tab) Max mass 5.863 kg 0.631 kg Min mass 5.805 kg 0.625 kg...

  • Page 193: Aileron And Tab Limits

    Bristell B23 Airplane Maintenance Manual Chapter 51 51-60-02 Aileron and Tab Limits Left aileron Right aileron (with trim tab, actuator and actuation rod) Max mass 1.446 kg 1.126 kg Min mass 1.316 kg 1.026 kg Max static moment 0.159 kgm 0.119 kgm...

  • Page 194: Rudder Limits

    Airplane Maintenance Manual Bristell Chapter 51 51-60-03 Rudder Limits Rudder (including horn and mass balance in horn) Max mass 2.309 kg Min mass 2.099 kg Max static moment 0.274 kgm Min Static moment 0.314 kgm B23 Rudder, mass and static moment...
  • Page 195 Bristell B23 Airplane Maintenance Manual Chapter 51 51-60-04 Flap Limits Flap (each side) Max mass 4.188 kg Min mass 3.808 kg Max static moment 0.303 kgm Min Static moment 0.242 kgm Issue: 30-Sep-2020 Chapter 51 Page 11...

  • Page 196: Electrical Bonding

    Airplane Maintenance Manual Bristell Chapter 51 51-80 Electrical Bonding Refer to the following drawings presented in Chapter 91 Charts: 34B220000N_1 and _4 34B240000N_1 thru _6 Chapter 51 Page 12 Issue: 30-Sep-2020...
  • Page 197 Bristell B23 Airplane Maintenance Manual Chapter 53 Fuselage Table of Contents Chapter Title Page 53-00 General ..................2 53-10 Front Part of the Fuselage ............... 2 53-10-10 Cockpit ..................... 2 53-10-11 Luggage Compartment ..............2 53-10-20 Canopy....................3 Removal ......................4 Installation .....................

  • Page 198: General

    Airplane Maintenance Manual Bristell Chapter 53 53-00 General The fuselage is an all-aluminium structure design formed by bulkheads, stiffeners and surface sheets. The fuselage consists of the front part (between bulkheads No.1 and 6) and the rear part (aft of bulkhead No.6), for bulkhead locations see Figure 1 (circled numbers).
  • Page 199 Bristell B23 Airplane Maintenance Manual Chapter 53 53-10-20 Canopy The canopy (see Figure 2) has a semi drop shape and enables access to the cockpit. The canopy consists of composite structure frame. The canopy is suspended in two swivel hinges on front sides of the composite fixed frame.
  • Page 200 Airplane Maintenance Manual Bristell Chapter 53 Removal Tools needed: socket wrench 10 mm Allan wrench size 5 screwdriver pliers Refer to Figure 3. ▶ Open the canopy (2). ▶ Remove securing springs (3) from the gas strut rod ends ▶ Disconnect gas struts (5) on both sides of canopy.

  • Page 201: Installation

    Bristell B23 Airplane Maintenance Manual Chapter 53 Item Description Item Description Bushing Washer Hinge bolt nut Canopy hinge Installation Tools needed: socket wrench 10 mm Allan wrench size 5 screwdriver pliers Refer to Figure 3. ▶ Set the canopy (2) on the airplane fuselage.

  • Page 202: Installation

    Airplane Maintenance Manual Bristell Chapter 53 Installation Tools needed: pliers Refer to Figure 3. ▶ Ensure the strut is not damaged. ▶ Insert top rod end (1) on the gas strut pin, bottom rod end (1) on the pin on the fixed frame and secure it with securing springs (3).

  • Page 203: Canopy Lock

    Bristell B23 Airplane Maintenance Manual Chapter 53 53-10-22 Canopy Lock There are two locks, on the left, and on the right side of the canopy. Removal Tools needed: Allen wrenches screw driver wrench size 8mm Refer to Figure 4. ▶ Remove the seat backrest on the cockpit side you intend to remove the lock as per Chapter 25-10-01.
  • Page 204 Airplane Maintenance Manual Bristell Chapter 53 Figure 4 Canopy Lock, Removal/Installation Item Description Item Description Inner handle Rod pin safety spring Forward rod Cover Lock Outer handle Bracket Aft rod Lock torque tube Handle torque tube Chapter 53 Page 8...

  • Page 205: Installation

    Bristell B23 Airplane Maintenance Manual Chapter 53 Installation Tools needed: screw driver Allen wrenches wrench size 8mm Refer to Figure 4. ▶ Insert the lock mechanism and lock mechanism cover through the access hole ▶ Install the lock mechanism and lock mechanism cover ▶...
  • Page 206 Airplane Maintenance Manual Bristell Chapter 53 and stabilizer attachments is an integral part of the fuselage. The bulkheads No.12 and 13 form the stabilizer attachment points. Chapter 53 Page 10 Issue: 30-Sep-2020...
  • Page 207 Bristell B23 Airplane Maintenance Manual Chapter 55 Stabilizers Table of Contents Chapter Title Page 55-00 General ..................2 55-10 Horizontal Stabilizer ............... 2 Removal ......................3 Installation ..................... 4 55-20 Elevator ..................5 55-20-01 Trim Tab ................... 5 55-30 Vertical Stabilizer ................6 55-40 Rudder ...................

  • Page 208: General

    Bristell Chapter 55 55-00 General The BRISTELL B23 tail unit generally is an all metal design (riveted aluminium). Elevator tips and fuselage/tail cover are composite parts. 55-10 Horizontal Stabilizer The horizontal stabilizer (1) (see Figure 1) is an all-metal structure consisting of two aluminum spars, eight ribs and aluminum skins.

  • Page 209: Removal

    Bristell B23 Airplane Maintenance Manual Chapter 55 Removal Figure 2 Horizontal Stabilizer Removal/Installation Item Description Item Description Bulkhead 12 Mandrel Stabilizer front spar Bolts Brackets Stabilizer rear spar Tools needed: wrench size: 7/16 in screwdriver wire nippers ▶ Remove the screws from top and bottom side of composite cover between fuselage and stabilizer.

  • Page 210: Installation

    Airplane Maintenance Manual Bristell Chapter 55 ▶ Pull out the stabilizer in horizontal direction off the mandrels (2) and store it in such a way that a damage cannot occur. Installation Tools needed: wrench size: , 7/16 in screwdriver pliers ▶...

  • Page 211: Elevator

    Bristell B23 Airplane Maintenance Manual Chapter 55 55-20 Elevator The elevator (2) (see Figure 1) is an all-metal structure and consists of aluminum skin, spars and ribs riveted together. The control lever is riveted between the middle elevator ribs. Elevator composite tips (horns) with mass balance inside (6) are riveted to the outboard ribs.

  • Page 212: Vertical Stabilizer

    Airplane Maintenance Manual Bristell Chapter 55 55-30 Vertical Stabilizer The vertical stabilizer (see Figure 2) is an aluminum structure and is an integral part of the fuselage. The vertical stabilizer consists of stiffeners, spar, ribs and aluminum skin. The Individual parts are riveted together.

  • Page 213: Rudder

    Bristell B23 Airplane Maintenance Manual Chapter 55 55-40 Rudder The rudder (4) is a riveted aluminium structure and consists of a spar, ribs and skin. The rudder is attached to the vertical stabilizer by two hinges (3 and 5). Bottom hinge (5), which is integral part of control lever is riveted on the root rudder rib.
  • Page 214 Airplane Maintenance Manual Bristell Chapter 55 Intentionally left blank Chapter 55 Page 8 Issue: 30-Sep-2020...
  • Page 215 Bristell B23 Airplane Maintenance Manual Chapter 57 Wing Table of Contents Chapter Title Page 57-00 General ..................2 57-10 Centre Wing ..................2 57-20 Outer Wing ..................3 Removal ......................3 Installation ..................... 4 57-20-01 Wing Lockers ..................5 57-30 Wing Tip ..................
  • Page 216 Airplane Maintenance Manual Bristell Chapter 57 57-00 General The wing is an all-metal structure with 2 spars and is equipped with flaps, ailerons, fuel tanks and wing lockers. Figure 1 Wing (left) Item Description Item Description Fuel tank Main upper and lower attachments...

  • Page 217: Outer Wing

    Bristell B23 Airplane Maintenance Manual Chapter 57 57-20 Outer Wing Outer part of the wing consists of 9 ribs and has trapezoid shape (see Figure 1). There are 3 main attachments (positioned on the main spar; one upper & two lower) and one rear attachment (positioned on the rear spar) where outer wing is joined with the center section.

  • Page 218: Installation

    Airplane Maintenance Manual Bristell Chapter 57 Installation Tools needed: wrench size: 7/8 in, 3/4 in, 1/2 in, 7/16 in screwdriver pliers hammer ▶ Before installation clean the attachments and bolts of the outer and center wing from dirt. Preserve bolts and attachments by means of lubricating grease.

  • Page 219: Wing Lockers

    Bristell B23 Airplane Maintenance Manual Chapter 57 57-20-01 Wing Lockers Wings are equipped with wing lockers placed between ribs No.2 and 3 aft of the main spar. Capacity of each wing locker is 20 kg. Access doors are suspended on two hinges. They can be locked with a latch.

  • Page 220: Wing Flaps

    Airplane Maintenance Manual Bristell Chapter 57 57-50 Wing Flaps The wing flaps (Figure 2) are all-metal structures consisting of the skin (1) aluminum sheet metal, spar (2) and ribs (5) riveted together. The flaps are suspended on the rear spar by means of three hinges (4).
  • Page 221 Bristell B23 Airplane Maintenance Manual Chapter 57 57-60 Ailerons The ailerons (Figure 3 and 4) are of aluminum structure consisting of the skin (1) and ribs (4) riveted together. Ailerons are suspended on the rear spar by means of piano hinges (2). A trim tab (5) is installed on the left aileron.
  • Page 222 Airplane Maintenance Manual Bristell Chapter 57 Intentionally left blank Chapter 57 Page 8 Issue: 30-Sep-2020...
  • Page 223 Bristell B23 Airplane Maintenance Manual Chapter 61 Propeller Table of Contents Chapter Title Page 61-00 General ..................2 Removal ......................2 Installation ..................... 3 61-20 Controlling ..................4 Issue: 30-Sep-2020 Chapter 61 Page 1...
  • Page 224 Airplane Maintenance Manual Bristell Chapter 61 61-00 General The MTV-34-1-A/175-200 is a new high performance, low weight 3 bladed hydraulic constant speed composite propeller for the ROTAX 912series engine. The new MTV-34-1-A/175-200 feature the following: Low Propeller weight - 9 kg (19,8 lbs) for the 3-blade plus Governor •...
  • Page 225 Bristell B23 Airplane Maintenance Manual Chapter 61 Fig. 2 Removal/Installation of Propeller Item Description Item Description Alternator Bolts Tension bar V-belt Propeller Bolts Pulley carrier Pulley Installation Tools needed: wrench size No. 16 (5/8 in) NOTE Follow the instructions in the Operation, Installation, and Maintenance Manual, Section 5.
  • Page 226 Airplane Maintenance Manual Bristell Chapter 61 61-20 Controlling MTV-34-1-A/175-200 propeller control lever (1) is located together with the throttle control on a quadrant between seats. Propeller control lever is connected through a Teleflex cable (2) with the propeller hydraulic governor (3). Once an engine rpm is selected it will be held constant at variations of airspeed and power.
  • Page 227 Bristell B23 Airplane Maintenance Manual Chapter 71 Power Plant Table of Contents Chapter Title Page 71-00 General ..................2 71-10 Cowling ..................3 71-20 Mounts ................... 4 Issue: 30-Sep-2020 Chapter 71 Page 1...
  • Page 228 Bristell Chapter 71 71-00 General Standard power unit of BRISTELL B23 airplane is the ROTAX 912 S3 engine and MTV 34 1 A/175-200 in flight adjustable 3-blade propeller. Both, engine (EASA-TCDS E.121) and propeller (EASA-TCDS P.049) are certified. ROTAX 912 S3 is a 4 stroke, 4 opposed - cylinder engine, central cam shaft and OHV - mechanism with maximal power of 73.5 kW (98.6 hp)
  • Page 229 Bristell B23 Airplane Maintenance Manual Chapter 71 71-10 Cowling Engine cowling (Fig. 1) consists of two parts: upper cowling and lower cowling. The upper cowling (1) is attached by means of quick fasteners - Camlocks (4) to the firewall and to the lower cowling (2).
  • Page 230 Airplane Maintenance Manual Bristell Chapter 71 71-20 Mounts 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.
  • Page 231 Bristell B23 Airplane Maintenance Manual Chapter 72 Engine Table of Contents Chapter Title Page 72-00 General ..................2 Removal ......................6 Installation ..................... 7 Checks ......................9 72-20 Air Inlet Section ................13 Removal ....................... 14 Installation ....................14 72-20-10 Engine Cooling System ..............
  • Page 232 Airplane Maintenance Manual Bristell Chapter 72 72-00 General ROTAX 912 S3 is a four-stroke, four-cylinder, opposed - cylinder engine, central cam shaft and OHV - mechanism with maximal power of 73.5 kW ( 98.6 hp ) at 5 800 RPM.
  • Page 233 Bristell B23 Airplane Maintenance Manual Chapter 72 Coolant Type Ethylene-glycol based with 50% water dilution acc. current version of Rotax Service Instruction SI-912-016. NOTICE The conventional (glycol/water) coolant may not be mixed with coolant concentrate (propylene glycol) or with additives.
  • Page 234 Airplane Maintenance Manual Bristell Chapter 72 Fuel Type Chapter 72 Page 4 Issue: 30-Sep-2020...
  • Page 235 Bristell B23 Airplane Maintenance Manual Chapter 72 Oil Type Type of oil used by aircraft manufacturer is shown in Chapter 12-00- Issue: 30-Sep-2020 Chapter 72 Page 5...
  • Page 236 Airplane Maintenance Manual Bristell Chapter 72 Removal Tools needed: wrench size 8, 9, 10, 12, 17, 9/16 in Allen wrench size 8 screwdriver cutting pliers, pliers Cobra pliers (for clamps) ▶ Remove engine cowling. ▶ Disconnect and remove the board battery.
  • Page 237 Bristell B23 Airplane Maintenance Manual Chapter 72 Installation Tools needed: wrench size 8, 9, 10, 12, 17, 9/16 in Allen wrench size 8 screwdriver cutting pliers, pliers Cobra pliers (for clamps) Install the engine on the engine mount according to Fig. 1: ▶...
  • Page 238 Airplane Maintenance Manual Bristell Chapter 72 ▶ Connect wiring according to the wiring diagrams (see Chapter 78). Installation ▶ Install oil cooler (see Chapter 79-20-01 ▶ Install water radiator (see Chapter 72-20-11 Installation ▶ Connect and secure oil system hoses.
  • Page 239 NOTE The person performing the engine test must have the corresponding approvals and be familiarized with the aircraft type BRISTELL B23. ▶ Perform the test out of the buildings at the place assigned for performing engine tests in broad daylight.
  • Page 240 AOI of Bristell B23 (Par. 4.3) and Rotax engine Operator’s manual (Chapter 10.3). ▶ Start the engine according to the AOI of Bristell B23 (Par. 4.4) and Rotax engine Operator’s manual (Chapter 10.3).: ▶...
  • Page 241 Bristell B23 Airplane Maintenance Manual Chapter 72 exceed 115 rpm. Write down results into the engine test report, see the Tab.10–1. ▶ Test of max. RPM on the ground: Throttle lever fully forward for maximum power NOTE Record max. RPM into the engine test report, see the Table 1.
  • Page 242 Airplane Maintenance Manual Bristell Chapter 72 ENGINE TEST REPORT Aircraft Bristell B23 Registration Engine ROTAX Type 912 S3 Activity Set down values Measured values Starting up the engine Min. oil pressure up to 10 sec. 0.8 bar (12 psi) Max. oil pressure*...
  • Page 243 Bristell B23 Airplane Maintenance Manual Chapter 72 72-20 Air Inlet Section Engine air inlet system ensures supply of sufficient air volume to the engine. Air is supplied to the engine through the NACA inlet (5, Figure 4), the air filter and the airbox (1, 2). Heated air (11) from the heat exchanger, which is attached to the muffler is controlled by flap on the firewall.
  • Page 244 Airplane Maintenance Manual Bristell Chapter 72 Removal Tools needed: Wrench size 8, 10 Screwdriver See Fig. 4. ▶ Remove the upper engine cowling. ▶ Disconnect the control cable (12) from the air intake changeover lever (8) and from the holder.
  • Page 245 Bristell B23 Airplane Maintenance Manual Chapter 72 72-20-10 Engine Cooling System Engine cooling is combined, cylinder heads are liquid cooled, cylinders are air cooled. Cooling circuit of cylinder heads is made as a closed system containing the pump, expansion tank with the pressure cap, radiator and the overflow bottle.
  • Page 246 Airplane Maintenance Manual Bristell Chapter 72 72-20-11 Radiator Removal Tools needed: wrench size 10, screwdriver See Fig. 5. ▶ Remove the upper and lower engine cowling. ▶ Drain the cooling liquid from the cooling system (see Chapter 12-10-30). ▶ Disconnect hoses from the radiator outlets.
  • Page 247 Bristell B23 Airplane Maintenance Manual Chapter 72 72-30 Mass ballast On the two front bottom attachments point of the engine a mass ballast of ~8kg is installed. This mass ballast consists of a close- welded steel tube filled with lead.
  • Page 248 Airplane Maintenance Manual Bristell Chapter 72 Installation Tools needed: wrench size 16, safety wire tools pliers ▶ Install the mass ballast ▶ Tighten the bolts ▶ Secure with safety wire Chapter 72 Page 18 Issue: 16-Nov-2020...
  • Page 249 Bristell B23 Airplane Maintenance Manual Chapter 73 Engine Fuel and Control Table of Contents Chapter Title Page 73-20 Controlling ..................2 73-20-01 Throttle Control ................2 Removal ......................2 Installation ..................... 3 Adjustment ....................4 73-20-02 Choke Control ................... 4 Removal/Installation ..................
  • Page 250 Airplane Maintenance Manual Bristell Chapter 73 73-20 Controlling 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.
  • Page 251 Bristell B23 Airplane Maintenance Manual Chapter 73 Fig. 1 Throttle Control Lever Item Description Item Description Throttle control lever Choke control handle Throttle cable Choke cable Installation Tools needed: wrench size 14 Allen wrench size 2 Screwdriver Cutting pliers See Fig. 1.
  • Page 252 Airplane Maintenance Manual Bristell Chapter 73 Adjustment ▶ Pull the throttle control to the stop. The throttle lever on the carburetor (5) must be on the stop (see Chapter 72- 00, Figure 2). The Bowden cables must be supported in the terminals.
  • Page 253 Bristell B23 Airplane Maintenance Manual Chapter 73 ▶ To prevent the Bowden cables at the carburetor from shifting out of the terminal, secure the Bowden cables with locking wire. Mark al bolted joints with red paint. 73-20-03 Carburetor Heating Knob...
  • Page 254 Airplane Maintenance Manual Bristell Chapter 73 ▶ Put the flexible housing (3) with knob (2) into the hole in the instrument panel and firewall from behind and fasten it from both sides of the instrument panel by the nuts (6).
  • Page 255 Bristell B23 Airplane Maintenance Manual Chapter 74 Ignition Table of Contents Chapter Title Page 74-00 General ..................2 Issue: 30-Sept-2020 Chapter 74 Page 1...
  • Page 256 Airplane Maintenance Manual Bristell Chapter 74 74-00 General Engine is equipped with the double contactless ignition system. Every ignition circuit has its source of energy, control unit, 2–ignition coils and 4–spark plugs. It is fully independent on the other circuit and battery.
  • Page 257 Bristell B23 Airplane Maintenance Manual Chapter 77 Engine Indicating Table of Contents Chapter Title Page 77-00 General ..................2 77-10-01 Tachometer ..................2 77-20-01 Cylinder Head Thermometer .............. 2 Issue: 30-Sept-2020 Chapter 77 Page 1...
  • Page 258 Airplane Maintenance Manual Bristell Chapter 77 77-00 General The engine instruments are included in the Garmin system 77-10-01 Tachometer The RPM indicator is digital (Garmin System) and is controlled by the signal from the RPM sensor on the generator. Working range of the RPM indicator is from 0 to 7000 RPM.
  • Page 259 Bristell B23 Airplane Maintenance Manual Chapter 78 Exhaust Table of Contents Chapter Title Page 78-00 General ..................2 Removal ......................2 Installation ..................... 3 Check ......................3 Issue: 30-Sept-2020 Chapter 78 Page 1...
  • Page 260 Chapter 78 78-00 General Exhaust system of Bristell B23 airplane consist of four exhaust pipes (2) which lead exhaust gases from individual cylinders to the muffler (1). The muffler works at the same time as a silencer. Exhaust gases lead from there by the exhaust end pipe (4) down the airplane.
  • Page 261 Bristell B23 Airplane Maintenance Manual Chapter 78 ▶ Remove the springs (3) from the exhaust pipes (2) attaching to the muffler (1). ▶ Remove individual pipes from the necks on the engine. ▶ Remove springs (3) and release the heat exchanger from the muffler (1).
  • Page 262 Airplane Maintenance Manual Bristell Chapter 78 ▶ Remove the heat exchanger and check muffler area located under it. ▶ Check the whole exhaust pipe between the engine and the muffler including its attachment to the engine. ▶ Check outlet pipe from the muffler.
  • Page 263 Bristell B23 Airplane Maintenance Manual Chapter 79 Table of Contents Chapter Title Page 79-00 General ..................2 79-20 Distribution ..................3 79-20-01 Oil Cooler ..................3 Removal ......................3 Installation ..................... 3 79-30 Indicating ..................4 79-30-01 Oil Thermometer ................4 79-30-02 Oil Pressure Gauge ................
  • Page 264 Airplane Maintenance Manual Bristell Chapter 79 79-00 General Engine lubrication system (see Fig. 1) is made with the dry sump. Engine lubrication system is equipped with the mechanically driven oil pump (3) which ensures oil supply from the oil tank (1) located on the firewall through the oil cooler (4) and the oil pump (5) with oil filter to the lubricated points on the engine.
  • Page 265 Bristell B23 Airplane Maintenance Manual Chapter 79 79-20 Distribution 79-20-01 Oil Cooler Removal Tools needed: wrench size 22, 30 See Fig. 1. ▶ Remove the upper and lower engine cowling (see Chapter 71-10). ▶ Drain oil from the oil system (see Chapter 12-10-20).
  • Page 266 Airplane Maintenance Manual Bristell Chapter 79 79-30 Indicating 79-30-01 Oil Thermometer Oil temperature on the inlet to the engine is measured by the sensor which is located behind the oil pump. Working range of the oil thermometer is 50 to 150 °C (120 to 300 °F).
  • Page 267 Bristell B23 Airplane Maintenance Manual Chapter 80 Starting Table of Contents Chapter Title Page 80-00 General ..................2 Description ....................2 80-10 Cranking ..................2 Issue: 30-Sept-2020 Chapter 80 Page 1...
  • Page 268 Airplane Maintenance Manual Bristell Chapter 80 80-00 General Description The ROTAX engine is equipped with a 12V, 0.6 kW electric starter. The airframe mounted/supplied system consists of the following parts: Ignition switch • starter relay • related wiring • Refer to the ROTAX documentation for detailed information about starting system (see Chapter 01-20).
  • Page 269 Bristell B23 Airplane Maintenance Manual Chapter 90 Emergency Equipment Table of Contents Chapter Title Page 90-10-00 BRS-05 AEPS System ............... 2 Issue: 30-Sept-2020 Chapter 90 Page 1...
  • Page 270 Airplane Maintenance Manual Bristell Chapter 90 90-10-00 BRS-05 AEPS System Refer to Appendix B of this manual for removal and installation instructions of the parachute and the rocket of the AEPS system. If additional information is required contact BRM aero s.r.o requesting further instructions.
  • Page 271 Airplane Maintenance Manual Chapter 91 Charts General Typical wiring diagrams of BRISTELL B23 airplane systems, navigation and communication means are found here (refer to the Table of Content presented below). Further wiring diagrams, relating to additional equipment of the airplane are included in the documentation supplied with the airplane.
  • Page 272 Airplane Maintenance Manual Bristell Chapter 91 Table of Contents 34B200000N Avionics Installation Assembly (Instrument Panel) 34B200001N Pitot-Static System (pneumatic side) 34B220000N ELECTRICAL POWER SYSTEM ROTAX 912 34B220000N_1 ELECTRICAL POWER SYSTEM ROTAX 912 34B220000N_4 ELECTRICAL POWER SYSTEM ROTAX 912 34B220001N Garmin G3X GDU460+ ADAHRS...

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