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Bristell B23

 

Airplane Maintenance Manual

 

 

 

Chapter 03 

 

 

 

Issue: 30-Sep-2020 

Chapter 03 Page 3 

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 

Fuel system 

Fuel strainer 

Additional electric fuel pump 

Luggage 

Luggage compartments in cabin (15 kg) 

Luggage compartments in wings (2 x 20 kg each) 

AEPS  

Ballistic rescue parachute system BRS 5 (ASTM compliant) on forward 
RHS fuselage 

 

Summary of Contents for BRMAERO Bristell B23

Page 1: ... 30 Sep 2020 Chapter 00 Page 1 00 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 ...

Page 2: ...Airplane Maintenance Manual Bristell B23 Chapter 00 Chapter 00 Page 2 Issue 30 Sep 2020 Intentionally left blank ...

Page 3: ... 00 Issue 30 Sep 2020 Chapter 00 Page 3 Amendments Issue Date Revised pages Description Edition 1 30 Sep 2020 approved Chapter 4 and 5 for initial TC Edition 1 16 Nov 2020 Chapter 72 30 First issue of complete AMM incl addition of mass ballast DC 005 ...

Page 4: ...Airplane Maintenance Manual Bristell B23 Chapter 00 Chapter 00 Page 4 Issue 30 Sep 2020 List of Service Bulletins SB No Date Title Affected Serial no s AD EASA ...

Page 5: ... 1 8 1 0 30 09 2020 07 1 2 1 0 30 09 2020 61 1 4 1 0 30 09 2020 08 1 6 1 0 30 09 2020 71 1 4 1 0 30 09 2020 09 1 2 1 0 30 09 2020 72 1 16 1 0 30 09 2020 10 1 2 1 0 30 09 2020 72 17 18 1 0 16 11 2020 11 1 2 1 0 30 09 2020 73 1 6 1 0 30 09 2020 12 1 10 1 0 30 09 2020 74 1 2 1 0 30 09 2020 20 1 20 1 0 30 09 2020 77 1 2 1 0 30 09 2020 21 1 6 1 0 30 09 2020 78 1 4 1 0 30 09 2020 23 1 2 1 0 30 09 2020 7...

Page 6: ...05 Inspection and Maintenance 06 Dimensions and Areas 07 Lifting and Shoring 08 Leveling and Weighing 09 Towing and Taxiing 10 Parking Mooring Storage and Return to Service 11 Placards and Markings 12 Servicing 20 Standard Practices Airframe 21 Air Conditioning 23 Communication 24 Electrical Power 25 Equipment Furnishings 27 Flight Controls 28 Fuel 31 Indicating Recording System 32 Landing Gear 33...

Page 7: ...avigation 51 Standard Practices and Structures General 53 Fuselage 55 Stabilizers 57 Wing 61 Propeller 71 Power Plant 72 Engine 73 Engine Fuel and Control 74 Ignition 77 Engine Indicating 78 Exhaust 79 Oil 80 Starting 90 Emergency Equipment 91 Charts Appendix A Reserved Appendix B AEPS System ...

Page 8: ...Airplane Maintenance Manual Bristell B23 Chapter 00 Chapter 00 Page 8 Issue 30 Sep 2020 Intentionally left blank ...

Page 9: ...Bristell B23 Airplane Maintenance Manual Chapter 01 Issue 30 Sep 2020 Chapter 01 Page 1 01 Introduction Table of Contents Chapter Title Page 01 00 General 2 01 20 Related Publications 2 01 30 Address 4 ...

Page 10: ...ormation are also contained in the following documents issued by the airplane manufacturer and by manufacturers of equipment installed in individual airplane 1 BRM AERO BRISTELL B23 Aircraft Flight Manual ROTAX Operator s Manual for ROTAX 912 series engine Maintenance Manual line for ROTAX 912 series engine Service Instruction for ROTAX 912 series engine SI 912 016 Selection of suitable operating ...

Page 11: ... Systems ESI 500 Standby Instrument System DB1502026 Revision IR Instructions for Continued Airworthiness PS Engineering Inc Intercom 200 193 0005 Revision 9 PM3000 High fidelity Stereo Intercom System Orolia SAS ELT DOC07089H Ref 0144618H ELT KANNAD 406 AF COMPACT Initial installation manual Lambert Electronic 10 Channel Intermediate Dimmer MULTIDIMMER quick manual EN Document version 2 manual Fl...

Page 12: ... 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 Certification GmbH DOA Address Reichensteinstr 48 69151 Neckargemünd Germany Phone 49 176 322 69825 E mail info aircraftdc de Web http www aircraftdc de ...

Page 13: ...ow 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 3 02 10 03 Tables of Inspection Tasks 3 02 20 Terminology and Abbreviations 5 02 40 Safety 7 02 50 Ordering Spare Parts 8 ...

Page 14: ...t systems 20 thru 34 and 90 All systems except power plant Structure 51 thru 57 Structure of fuselage wing stabilizers control surfaces and canopy procedures Propeller 61 Propeller and controls Power plant 71 thru 80 Engine and associated systems controls Miscellaneous 91 Electrical wirings System Chapter Systems are arranged numerically per GAMA Specification 2 ATA 100 recommended number assignme...

Page 15: ...he left margin column The text of the note or safety note is printed in bold See the following definitions DANGER indicates a hazardous situation which if not avoided will result in death or serious injury WARNING indicates a hazardous situation which if not avoided could result in death or serious injury CAUTION indicates a hazardous situation which if not avoided could result in minor or moderat...

Page 16: ...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 The second and third column is prepared for signs of mechanic and inspector ...

Page 17: ...ing System F temperature in degree of Fahrenheit 1 F C x 1 8 32 ft foot feet 1 ft 12 in 0 3048 m 304 8 mm ft min vertical speed in feet per minute GPS Global Positioning System hp power unit 1 hp 0 7457 kW HTU Horizontal Tail Unit IAS Indicated Airspeed IC Intercom IFR Instrument Flight Rules in inch 1 in 25 4 mm ISA International Standard Atmosphere KCAS Calibrated Airspeed in Knots kg kilogram 1...

Page 18: ...andbook psi pressure unit pounds per square inch 1psi 0 0689bar rpm revolutions per minute sec second SM Statute Mile 1SM 1 609 m US gal US gallon 1 US gal 0 83 UK gal 3 785 l V Volt VFR Visual Flight Rules VLA Very Light Airplanes VMC Visual Meteorological Conditions VSI Vertical Speed Indicator VTU vertical tail unit VA maneuvering airspeed VFE maximum flap extended speed VNE never exceed speed ...

Page 19: ...necessary ratings to begin your work These ratings may be differently regulated in different countries Before you start working always contact your respective examiner Do not begin any work before completely having read and understood the contents of this manual In any case of doubt or lack of information contact the manufacturer ...

Page 20: ...ailure detection date day month year format dd mm yy 3 Failure has been detected at 1 Flight 6 Landing run encircle appropriate number 2 Taxiing 7 Daily inspection 3 Take off run 8 Periodical inspection 4 Take off 9 Other 5 Touch down 4 Consequences for operation 1 No consequences 5 Emergency landing encircle appropriate number 2 Airplane put out of operation 6 Occurrence on the ground 3 Airplane ...

Page 21: ...Bristell B23 Airplane Maintenance Manual Chapter 03 Issue 30 Sep 2020 Chapter 03 Page 1 03 Description Table of Contents Chapter Title Page 03 10 Airplane Classification 2 03 20 Airplane Description 2 ...

Page 22: ...eerable nose wheel 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 BRM Airbox carbon BRM Engine interface ring mount Battery lead acid type Propeller MTV 34 1 A 175 200 Governor as approved with propelle...

Page 23: ...ventional crucifix design All aluminum structure design Control system Elevator and Aileron by pushrod system Rudder by cable pulley system Flap by electro mechanic system Fuel system Fuel strainer Additional electric fuel pump Luggage Luggage compartments in cabin 15 kg Luggage compartments in wings 2 x 20 kg each AEPS Ballistic rescue parachute system BRS 5 ASTM compliant on forward RHS fuselage...

Page 24: ...Airplane Maintenance Manual Bristell B23 Chapter 03 Chapter 03 Page 4 Issue 30 Sep 2020 Intentionally left blank ...

Page 25: ... Page 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 3 04 10 03 AEPS System Limitations 6 ...

Page 26: ...Airplane Maintenance Manual Bristell B23 Chapter 04 Chapter 04 Page 2 Issue 30 Sep 2020 Approved Page 04 10 Life Limited Components 04 10 01 Airframe Life Limitation Airframe life is unlimited ...

Page 27: ...elage Vertical bracket bolt AN7 3A Replace at 1 000 hours Horizontal Stabilizer Front spar assy 55B230100N Inspect every 1 000 hours Rear spar assy 55B230200N Inspect every 5 000 hours Bulkhead 12 assy 53B251200N Inspect every 5 000 hours Top bulkhead 13 assy 53B251310N Inspect every 5 000 hours Engine Mount Tubes 71B210000N Inspect every 5 000 hours Replace at 18 000 hours Bolts to airframe AN5 1...

Page 28: ...nspect magnifying glass the rear spar assy for deformation cracks especially the mounting brackets and connecting rivets to the spar Inspect the rest of the spar through the lightening holes and the inspection holes by means of a borescope for deformation damage If a complete inspection from both sides front and rear is not possible remove the outer rear rips 55B230052L R of the stabilizer and ins...

Page 29: ...ding ASTM E1417 Perform dye penetrant testing according ASTM E1417 Replace if damaged Paint with the materials defined below if undamaged and reinstall Lower control stick tube 27B260201L Remove seat pans Remove the control stick and inspect for deformation damage incl bracket Remove any paint according ASTM E1417 Perform dye penetrant testing according ASTM E1417 Replace if damaged Paint with the...

Page 30: ...ved Page 04 10 03 AEPS System Limitations AEPS rocket BRS 601 PN 008418 01 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: ... 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 6 05 20 02 Periodical Inspection after the first 25 Flight Hours 7 05 20 03 Periodical Inspection after the first 50 Flight Hours 8 05 20 04 Annual Periodical Inspection or Inspection after 100 Flight Hours 9 ...

Page 32: ...Bulletin No 1 BRS 05 Ballistic recovery parachute See ADxC 73 C1 012 AEPS Instructions for Continued Airworthiness All other items On condition or as stated in the respective maintenance overhaul manual 05 10 02 Replacement Schedule Items shown here must be replaced at the times indicated Item Replacement AEPS BRS 05 parachute repack interval 6 years AEPS BRS 601 rocket replacement 12 years AEPS m...

Page 33: ... every 5 years all rubber hoses of engine oil system every 5 years carburettor flanges refer to Rotax instructions latest issue of Manufacturer s Service Bulletin and Maintenance and Overhaul Manual carburettor diaphragms refer to Rotax instructions latest issue of Manufacturer s Service Bulletin and Maintenance and Overhaul Manual rubber hoses of the compensation tube connecting carburettors ever...

Page 34: ...hour inspection is performed after 87 flight hours then the following 100 hour inspection must be performed at the latest after 187 flight hours Pre flight inspection is performed within the scope given in Flight Manual section 4 For MTV 34 pre flight inspection refer to 6 1 Daily inspection in the Operation Installation and Maintenance Manual Ground adjustable and Hydraulically Controlled Variabl...

Page 35: ...r installed engine For MTV 34 refer to 6 2 100 flight hours inspection in the Operation Installation and Maintenance Manual Ground adjustable and Hydraulically Controlled Variable Pitch Propeller MTV NOTE Time limits can only be exceed in accordance with the applicable regulations Annual inspection contains works of 100 hour inspection and other specified works inspections of airframe engine and p...

Page 36: ...ushings in the bearings if used X Lubrication Grease Two arm control lever in the outer wing and control lever in the center wing X Lubrication Grease Torque tube bearings in center console in fuselage X Lubrication Grease Flaps Hinges X Lubrication Grease Rod end bearings on actuator X Lubrication Grease HTU Elevator hinges X Lubrication Grease Rod end bearing of the elevator control tubes X Lubr...

Page 37: ...lly Controlled Variable Pitch Propeller MTV Remove and check engine cowlings for evident signs of heat damage or cracks Inspect and check tightening and securing bolts on the engine brackets and the engine mount Check the engine mount for occurrence of cracks Check the exhaust system and its attachment for occurrence of cracks on the exhaust system and welds see Chapter 78 00 Check Remove heat exc...

Page 38: ...d Variable Pitch Propeller MTV Remove and check engine cowlings for evident signs of heat damage or cracks Inspect and check tightening and securing bolts on the engine mount and the engine brackets Check the engine mount for occurrence of cracks Check the exhaust system and its attachment for occurrence of cracks on the exhaust system and on welds see Chapter 78 00 Check Remove heat exchanger for...

Page 39: ...uselage Visually check surface condition including composite parts loosened rivets deformation cracks and some other damage Check condition of fuselage wing fairings Check condition and attachment of the tailskid Check condition and attachment of the canopy Check condition and functions of vents Check condition and function of the canopy locks Check condition and completeness of emergency equipmen...

Page 40: ...mation cracks and some other damage Check for free travel Check hinges Check condition of the control rods and servo Check conductive connection Tail Unit HTU 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 Visually check con...

Page 41: ...ance chafing at fuel lines below fuel selector access thru armrest Flap Control Check for free travel of the control lever Check securing of links and conductive connection Check function of control servo Check function of travel limit switch Control of the Elevator Trim Tab Check the control servo Check plays see Chapter 20 60 03 Check securing of links and conductive connection Check trim tab ne...

Page 42: ...e rotation Check function of brakes and parking brake Check condition and attachment of brake hoses Check condition and wear of brake hoses brake pads minimum admissible thickness of brake pad is 2 mm and brake disk Check brake fluid leakage brake fluid hoses brake pumps brake cylinders Replenish brake fluid as needed see Chapter 12 10 40 Exchange brake fluid annual inspection only see Chapter 12 ...

Page 43: ...eck engine cowlings for evident signs of heat damage or cracks Inspect and check for tightening and securing the bolts on the engine brackets and the engine bed Check the engine bed for occurrence of cracks Check the exhaust system and its attachment for occurrence of cracks on the exhaust system and on welds see Chapter 78 Check Remove heat exchanger for full inspection of the muffler surface Che...

Page 44: ...t exchanger Check condition of the cabin heat mixer mounted to the firewall Check closing function secure of heat shut off valve at firewall visual inspection with removed heating hose Navigation Communication Visually check condition of navigation and communication instruments Check function of navigation and communication instruments annual inspection only Check altimeter function annual inspect...

Page 45: ... Issue 30 Sep 2020 Chapter 06 Page 1 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 3 06 20 05 Landing Gear 4 ...

Page 46: ...he 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 EZ 0 is defined by the forward plane of the engine flange to the propeller upward positive Figure 1 Coordinate System ...

Page 47: ...ron span 1 145 m Aileron area each 0 29 m2 Flap span 2 3 m Flap area 0 828 m2 06 20 02 Fuselage Total length 6 58 m Maximum height approx static gear loading empty 2 36 m Maximum fuselage width 1 3 m 06 20 03 Horizontal Tail Span 3 2 m Area 2 4 m2 Elevator span 3 1 m Elevator area 0 842 m2 06 20 04 Vertical Tail Height 1 28 m Area 1 19 m2 Rudder span 1 13 m Rudder area 0 47 m2 ...

Page 48: ...Airplane Maintenance Manual Bristell B23 Chapter 06 Chapter 06 Page 4 Issue 30 Sep 2020 06 20 05 Landing Gear Wheel base 1 47 m Wheel track 2 04 m Tires tubeless 5 00 5 ...

Page 49: ...Bristell B23 Airplane Maintenance Manual Chapter 06 Issue 30 Sep 2020 Chapter 06 Page 5 Figure 1 Three View Drawing ...

Page 50: ...Airplane Maintenance Manual Bristell B23 Chapter 06 Chapter 06 Page 6 Issue 30 Sep 2020 Intentionally left blank ...

Page 51: ...Bristell B23 Airplane Maintenance Manual Chapter 07 Issue 30 Sep 2020 Chapter 07 Page 1 07 Lifting and Shoring Table of Contents Chapter Title Page 07 00 General 2 07 10 Jacking 2 07 20 Shoring 2 ...

Page 52: ...ely 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 Figure 1 Airplane Jacking Points Item Description Item Description 1 Front fuselage jacking point 2 Rear fuselage jacking points 07 20 Shoring For shoring the jacking points are used Refer to Figure 1 ...

Page 53: ...8 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 5 08 20 Leveling 6 Definitions 6 Procedure 6 ...

Page 54: ...defined in Chapter 08 10 02 Weight and Balance Envelope Limits Definitions The basic airplane empty weight is defined as the empty aircraft with full engine operational required fluids oil and coolant as well as with the amount of unusable fuel in the fuel tanks 2 x 1 0 liter The centre of gravity lever arms relates to the airplane datum located at the plane of engine propeller flange Airplane lev...

Page 55: ...fuel Replenish unusable fuel 1 0 Litre each wing tank Level airplane on scales refer to Chapter 08 20 Determine individual weight on all three gears W_N W_L W_R Check gear lever arms X_N X_L X_R reference propeller flange X 0 0m or firewall X 0 960m Calculate Empty Weight W_empty W_N W_L W_R Calculate Empty airplane moment M_empty WN X_N W_L X_L W_R X_R Calculate Empty Airplane CG CG_empty M_empty...

Page 56: ...le is intended to record continuous history of weighings and changes of equipment affecting weight and balance Basic weight of empty airplane Moment kg m Weight kg Weight change Removed Moment kg m Arm m Weight kg Added Moment kg im Serial No Arm m Weight kg BRISTELL B23 Description of part or modification Manufactured airplane Item No Type Date ...

Page 57: ...Bristell B23 Airplane Maintenance Manual Chapter 08 Issue 30 Sep 2020 Chapter 08 Page 5 08 10 02 Weight and Balance Envelope Limits ...

Page 58: ...selage top rivet row just below the canopy frame The identical distances of wing tips to an even floor are the reference for lateral leveling Procedure Place aircraft on an even floor Measure distances of wing tips to an even floor Align a spirit level towards the fuselage top rivet row just below the canopy frame Place suitable wooden strips under the respective tires ...

Page 59: ...Bristell B23 Airplane Maintenance Manual Chapter 09 Issue 30 Sep 2020 Chapter 09 Page 1 09 Towing and Taxiing Table of Contents Chapter Title Page 09 00 General 2 09 10 Towing 2 09 20 Taxiing 2 ...

Page 60: ... 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 The airplane may be moved by gripping the propeller root never the blades gripping the main legs by pushing it forward with open hands on the reinforced wing root by using a tow bar 09 20 Taxiing For taxiing refer to flight manual ADxC...

Page 61: ...B23 Airplane Maintenance Manual Chapter 10 Issue 30 Sep 2020 Chapter 10 Page 1 10 Parking Mooring Storage and Return to Service Table of Contents Chapter Title Page 10 10 Parking 2 10 20 Anchoring 2 Procedure 2 ...

Page 62: ... not use the parking brake and apply the wheel chocks instead 10 20 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 pa...

Page 63: ...Bristell B23 Airplane Maintenance Manual Chapter 11 Issue 30 Sep 2020 Chapter 11 Page 1 11 Placards and Markings Table of Contents Chapter Title Page 11 00 General 2 ...

Page 64: ...Airplane Maintenance Manual Bristell B23 Chapter 11 Chapter 11 Page 2 Issue 30 Sep 2020 11 00 General No limitations to outer paintjob For placards and markings refer to flight manual ADxC 73 001 AFM ...

Page 65: ...efilling 4 Oil Draining 5 Refilling Oil 5 Venting of the Lubrication System 5 12 10 30 Coolant 5 Drainage of Coolant 6 Refilling Coolant 6 12 10 40 Brake Fluid 6 Refilling Bleeding 6 12 20 Scheduled Servicing 6 12 20 21 Oil Filter 6 Exchange Check 6 12 20 61 Battery 7 Charging 7 12 30 Unscheduled Servicing 7 12 30 31 Air Filter 7 Cleaning 7 12 30 41 Nose Gear Shock Absorber 8 Replacement 8 12 30 4...

Page 66: ...ine Oil3 AeroShell SPORT PLUS 4 Piston Engine Oil Coolant4 Standard Ethylene glycerin based coolant with 50 water dilution acc to Rotax Service Instruction SI 912 016 Selection of suitable operating fluids for ROTAX Engine Type 912 i 915 i 912 and 914 Series 2 For general information product data and safety data refer to latest general information product data and safety data sheets released by ma...

Page 67: ...le with open fire nor allow any person to do so Ensure airplane is grounded NOTE When filling fuel in the airplane use only approved kinds of fuel mentioned in this Manual Chapter 72 00 03 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 Ground the airplane The airplane ground point is located on the exhaust pipe Open the fuel tan...

Page 68: ...otax engine Operator s manual para 10 2 3 in Service Instructions SI 912 016 and SI 18 1997 R5 Type of oil used by aircraft manufacturer is shown in Chapter 12 10 01 Oil Quantity Total oil quantity in the lubrication system of Rotax 912 S3 engine is approximately 3 6 liters 1 US gal 0 84 UK gal Check oil Quantity preferably after running the propeller by hand in the sense of engine rotation so tha...

Page 69: ...for ROTAX Engine Refilling Oil Refill oil in the oil tank that is located on the firewall Venting of the Lubrication System After short idling stop engine and replenish oil to maximum mark on dipstick Never overfill otherwise oil would escape through the vent tube during operation At oil level inspect do not exceed the maximum mark 12 10 30 Coolant Refer to the Rotax engine Maintenance manual chap...

Page 70: ...0 40 Brake Fluid Refilling Bleeding NOTE Refer to Chapter 12 10 01 for brake fluid recommended by the airplane manufacturer Use BERINGER Pressure Bleeder PN ONC01 and follow the BERINGER Tech Tip 9 How to bleed your brakes to be found on BERINGER Youtube Tutorials If there is no need to change brake fluid and brake fluid reservoir is not below minimum simply refill the reservoir 12 20 Scheduled Se...

Page 71: ...ttery Charging NOTE 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 t...

Page 72: ...igure 1 Jack and support the airplane see Chapter 07 Use wrench size in to release both upper and lower self locking nut 1 Remove bolts 2 and distance washers 5 Remove the shock absorber Install a new shock absorber in reverse steps Figure 1 Nose Gear Shock Absorber Replacement Item Description Item Description 1 Nut 2 Bolt 3 Shock absorber 4 Nose leg 5 Distance washers ...

Page 73: ... Figure 2 NOTE Always replace both brake pads Jack and support the airplane see Chapter 07 Demount the main wheel see Chapter 32 40 10 if needed Unscrew the bolts holding the brake pads 2 on the brake caliper 3 a remove the brake pads and brake disc Insert new pads insert the brake disc and screw it down to the caliper 3 Re install main wheel if demounted see Chapter 32 40 10 Check brake function ...

Page 74: ...Airplane Maintenance Manual Bristell B23 Chapter 12 Chapter 12 Page 10 Issue 30 Sep 2020 Item Description Item Description 1 Brake caliper 2 Brake pads ...

Page 75: ... Nicopress Pliers 10 20 40 Lubrication 11 20 50 Adjustments and Tests 11 20 50 01 Control Surface Deflections 11 Adjusting Aileron Deflections 12 Adjusting Wing Flap Deflections 12 Adjusting Elevator Deflections 12 Adjusting Rudder Deflections 13 Adjusting Trim Tab Deflections 13 20 60 Inspections and Checks 13 20 60 01 Control Surface Deflections 13 Measuring Aileron Deflections 13 Measuring Wing...

Page 76: ...Issue 30 Sep 2020 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 19 Friction in Directional Control System 19 ...

Page 77: ...eeded Bolt size Torque limits recommended Max allowable torque limits Nm in lb Nm in lb AN3 2 3 2 8 20 25 4 5 40 AN4 5 7 7 9 50 70 11 3 100 AN5 11 3 15 8 100 140 25 4 225 AN6 18 1 21 5 160 190 44 1 390 AN7 50 9 56 5 450 500 94 9 840 AN8 54 2 78 480 690 124 3 1100 AN9 90 4 113 800 1000 180 8 1600 Tab 1 Recommended Torque Values for Oil free Cadmium plated Threads 20 10 02 Orientation of Bolts and C...

Page 78: ...orce 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 Securing Bolt Joints by Locking Wire Procedure of bolt joint securing is shown on Fig 1 and Fig 2 The zinc coated or stainless steel wire having diameter of 0 8 mm 0 032in is used for securing Figure 1 Ways ...

Page 79: ...bolt head and then by the other end of the wire Make sure that the wire is properly tightened around the head 8 Hold the twisted end by pliers and twist it tight 4 Twist the wire to the hole in the next bolt as tight as possible 6 Pull the upper wire through the hole in the other bolt Hold the wire end by pliers tighten it firm 5 Tighten the wire and at the same time continue its twisting unless p...

Page 80: ...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 NOTICE When securing joints always use new cotter pins Shift the new cotter into the hole in the bolt and bent the cotter pin ends according to Fig 3 Fig 3 Securing the Castle Nut by U...

Page 81: ...Tab 2 Survey of Rivets Used in Airplane Structure Removal of Rivets Remove rivets from the side of the rivet which is more accessible Drill out the rivet head and drive out the shank NOTE Center dot heads of solid rivets which shall be drilled off Use a drill bit of 0 5 mm 0 025 in smaller diameter than the rivet shank and drill up to the depth of 2 3 of the total depth riveted parts Remove the dr...

Page 82: ...ngle e g the head with angle of 100 will have countersinking of 95 1 After countersinking the cylindrical part of hole with min length of 0 3 mm 0 012 in must remain in material Countersinking must be performed in such a way that the rivets head overruns the area before riveting max by 0 2 mm 0 008 in the rivet head must not be under the surface level sunk Before applying the bonding sealant caref...

Page 83: ...ered areas The optimum thickness of the applied coat is 0 3 mm 0 01 in NOTICE The surfaces that are to be connected must be dry and clean before application of bonding sealant After applying bonding sealant connect both parts together fix them by clecos and rivet them NOTICE After proper riveting the continual bur of adhesive is created on the edge of connected surfaces If this bur is big it is po...

Page 84: ...ould overlap by about 32 mm 1 25 in from the clamp after its puling through The overlapping will ensure that the cable end will not be pulled back into the clamp during the clamp squeezing Before actual squeezing the clamp it is also necessary to verify which cable terminal will be used whether thimble or suspension eye because some terminals must be put into the cable before actual clamp squeezin...

Page 85: ...ections The control surface deflections are shown in the following table Aileron 24 2 up 16 3 down Rudder 30 2 right 30 2 left Elevator 19 1 up 15 2 down Wing flap 0 2 10 2 25 2 Difference between L R flap deflections 1 2 Elevator trim tab 15 2 up 25 2 down Aileron trim tab 15 2 up 20 2 down Table 3 Control Surface Deflections Adjust control surface deflections to the values shown in the Table 3 W...

Page 86: ... rod leading from bell crank to the control lever on the aileron The terminal is accessible on the aileron lower side after lifting the aileron Adjusting Wing Flap Deflections Wing flap deflections are given by the torque tube and actuator positioning in the fuselage It is possible to adjust flap deflection by means of the terminals on push rods connected flaps with control torque tube The termina...

Page 87: ... of the clamp Measuring Aileron Deflections Attach the protractor with the deflecting pointer on the upper skin of the aileron by means of the clamp Set the aileron to neutral position Set the protractor to 0 starting value for measuring Deflect aileron to the lower possibly upper extreme position and read the deflection value Check deflection values according to the Tab 3 Measuring Wing Flap Defl...

Page 88: ...is special jig use the alternative procedure Set the rudder to neutral position Put the rod to the trailing edge of the rudder and mark the lower margin of the rudder trailing edge Deflect the rudder to extreme positions and with the rule measure distance from the sign to the lower margin of the rudder trailing edge Calculate angle and compare it with the value mentioned in Tab 3 Measuring Trim Ta...

Page 89: ...stress maximum 70 lbs 32 kg minimum 50 lbs 23 kg cable stress in the operation is 33 lbs 15 kg Exchange the cable in cases as follows broken any wire wear of cable surface resulted in permanent deformation of cable section it is not possible to tension the cable to the prescribed value see above it is not possible to set the rudder to neutral position see Chapter 20 50 01 Adjusting Rudder Deflecti...

Page 90: ...ing Measuring Procedure Measure all plays three times and write down average values Perform measuring with the blocked control surfaces Push on the control stick or the pedal by force of 3 kg 6 6 lbs Push the controlling element to one side and read the deflection Then push the controlling element to the other side and read the deflection The sum of deflections represents the total play in the res...

Page 91: ...stick see Fig 6 Plays in Foot Control Pedals Measure play at the end of pedals with the blocked nose landing gear wheel against lateral slewing Mutual total play between pedals must not exceed 5 mm 3 16 in on the pedal end Play in Trim Tab Control Measure play in elevator neutral position Set the balance tab to neutral position and measure play at the end of the trim tab Max total play of the trim...

Page 92: ...n or hitching in the control system Always measure in two opposite directions and note the higher value In case of failure detection find out the cause and eliminate the defect Friction in the Longitudinal Control System Prior to friction measurement the elevator down spring must be deactivated Refer to Figure 7 Figure 7 Elevator Down Spring Item Description Item Description 1 Torque tube 2 Spacer...

Page 93: ...ve spacer 2 Carefully release control stick to neutral position Check function of elevator control Friction in Lateral Control System Set ailerons to neutral position Measure force at the moment of aileron deflection from neutral position by the dynamometer attached on the end of the control stick Maximum force limit is 0 1 kg 0 2 lbs Friction in Directional Control System Raise nose wheel over th...

Page 94: ...Airplane Maintenance Manual Bristell B23 Chapter 20 Chapter 20 Page 20 Issue 30 Sep 2020 Intentionally left blank ...

Page 95: ...sue 30 Sep 2020 Chapter 21 Page 1 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 4 Installation 5 Adjustment 5 ...

Page 96: ... on both fuselage sides in front of the canopy There is a composite part connected to the Naca scoop from inside the cockpit and a flexible hose is used to connect the air vent with the composite part Fig 1 Venting System Item Description Item Description 1 Naca scoop 2 Eye ball vent 21 20 01 Eye Ball Vent Removal see Fig 2 Remove glare shield 1 from the instrument panel Remove hose 2 from the ven...

Page 97: ...crew securing nut 4 on the vent 3 Plug the hose 2 into the vent 3 Install glareshield 1 21 40 Heating Cockpit heating is ensured by hot air from the heat exchanger see Fig 3 The heat exchanger 4 is located on the muffler 5 Ambient inlet air 3 taken by the muffler is heated in the heat exchanger and supplied through heating flap 3 located on the firewall into the cockpit by air hose 2 Quantity of h...

Page 98: ...ew legs outlet 8 The mixture flap is controlled by the MIXTURE knob 9 Fig 3 Heating System Item Description Item Description 1 Canopy bubble outlet 2 Air hose 3 Air inlet 4 Heat exchanger 5 Muffler 6 Heating flap 7 Mixture flap 8 Crew legs outlet 9 Mixture knob 10 Heating knob 21 40 01 Control Knobs Removal Tools needed wrench size in 9 16 in pliers cutting pliers See Fig 4 ...

Page 99: ...4 Control Knob typical Item Description Item Description 1 Nut 2 Control knob 3 Bowden cable Installation Tools needed wrench size 14 9 16 in pliers cutting pliers See Fig 4 Insert the control knob 2 into the flexible housing and fasten it from both sides of the instrument panel by means of nuts 1 Connect the control cable with flap control levers 6 and 7 Fig 3 Adjust fresh air hot air and mixture...

Page 100: ...ane Maintenance Manual Bristell B23 Chapter 21 Chapter 21 Page 6 Issue 30 Sep 2020 After adjustment of the control mark the mutual position of the Bowden cable terminal and the flap controller with red color ...

Page 101: ...Bristell B23 Airplane Maintenance Manual Chapter 23 Issue 30 Sep 2020 Chapter 23 Page 1 23 Communication Table of Contents Chapter Title Page 23 00 General 2 ...

Page 102: ...sponder Radio communication Intercom ELT 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 For Bose headset power refer to wiring diagrams Chapter 91 ...

Page 103: ... 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 4 24 30 04 External Power 5 Description 5 Procedure 5 24 60 DC Electrical Load Distribution 7 24 60 01 Switches and Circuit Breakers 7 24 60 02 Fuses 8 ...

Page 104: ...upplies the ADAHRS PFD and EIS the glare shield and flap position lights DC voltage is distributed to the individual systems by means of the main bus bar Systems are protected by circuit breakers which are permanently ON and switches circuit breakers which may be turned to ON as needed If one of the circuits is overloaded then the circuit breaker disconnects the circuit After switching the MASTER ...

Page 105: ...1000 250 rpm Range of operation temperatures min 25 C 13 F max 90 C 194 F Weight 0 3 kg 0 66 lbs 24 30 02 Auxiliary Generator The auxiliary generator is mounted to the LHS of the engine and supplies electric current through the rectifier Regulator supplies electric current of 14V voltage to onboard network Technical parameters of generator Maximum output power 14V 30A DC Technical parameters of re...

Page 106: ...ry connectors 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 Installation Tools needed screwdriver wrench size according to installed battery connectors wrench size 8 size 8 Install the battery into the metal box on the firewall Fasten it with draw band so that the battery cannot move in...

Page 107: ...upply is protected by a control diode The continuous current capacity of the external power plug is 50 Amps which is usually exceeded during engine start attempts Therefore even with unlimited electric supply the time of start attempts must be in accordance with the AFM Procedure The procedure can be performed by a single person or with an additional helping person connecting and disconnecting ext...

Page 108: ...erson must always have contact to the left wing leading edge when connecting or disconnecting external power Connect external power to the external power plug NOTICE Starter overheating possible due to start attempts Activate the starter for a maximum of 10 sec followed by 2 min pause for starter starter circuit and external power connection cooling Start engine Run engine as long as necessary to ...

Page 109: ...ith designation of the circuit see following Table The switches are located on the instrument panel and on the middle channel The buttons for ailerons and elevator trim are on the grip of control stick Wiring diagrams are shown in Chapter 91 Switches Switch Breaker Designation Description MASTER Main switch ALT 1 Alternator 1 internal alternator ALT 2 Alternator 2 external alternator AVIONICS G3X ...

Page 110: ...rvoltage Protection 5 BCK BAT Backup Battery 5 BUS TIE Connecting ALT 1 and ALT 2 20 ALT 2 Alternator 2 external alternator 30 ALT 2 CTRL ALT 2 Overvoltage Protection 5 START Starter 5 BATTERY Battery 30 PFD Left hand side G3X screen 5 TRIM Trim system 2 LDG Landing Light 5 FLAPS Flap motor and control 5 ADAHRS G3X system component 2 NAV NAV module 5 COM Radio module 10 USB 1 USB plug PED power 3 ...

Page 111: ...l Chapter 25 Issue 30 Sep 2020 Chapter 25 Page 1 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 4 ...

Page 112: ...10 Flight Compartment Figure 1 Seats and Safety Harness Item Description Item Description 1 Integrated head rest 2 Seat back 3 Safety harness 4 Seat 5 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...

Page 113: ...ety harness lock Length of the lap straps and the shoulder straps is adjustable Removal Tools needed wrench size 17 See Figure 2 Remove shoulder harnesses from the top attachment brackets 1 in luggage compartment Remove the nut with distance washer and the bolt 2 Remove the side harnesses from the side attachment brackets 3 Remove the nut with distance washer and the bolt 2 Installation Tools need...

Page 114: ... 2 Safety Harness Removal Installation Item Description Item Description 1 Top attachment bracket 2 Bolt 3 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: ... Removal 6 Installation 7 27 10 Aileron Control 8 27 10 01 Aileron 9 Removal 9 Installation 9 27 10 02 Aileron Control Lever 9 Removal 10 Installation 10 27 10 03 Aileron Control Bell Crank 11 Removal 11 Installation 11 27 10 04 Aileron Travel Stops 12 27 20 Rudder Control 13 27 20 01 Rudder 14 Removal 14 Installation 14 27 20 02 Rudder Control Cable 15 Removal 16 Installation 16 27 20 03 Rudder T...

Page 116: ...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 24 27 30 05 Elevator Travel Stops 25 27 50 Flaps 26 27 50 01 Wing Flaps 26 Removal 26 Installation 27 27 50 02 Wing Flap Control Actuator 27 Removal 28 Installation 28 ...

Page 117: ...tening and securing is done after setting of neutral position It is necessary to keep the following principles Thread must overlap the inspection hole in the push rod end Thread in rod end of all push rods must be uniformly screwed for setting the neutral position Final tightening and securing after setting of neutral position Grease bearings with lubricant grease before installing the push rods i...

Page 118: ...k s from the torque tube by removing the control stick bearing bolts 6 Installation Tools needed wrench size 7 16 in 3 8 in pliers Refer to Figure 1 Install the control stick s to the torque tube by installing the control stick bearing bolts 6 Connect connection rod 9 to control stick s Connect aileron control rods 5 to control sticks 1 Connect elevator control rod 7 to torque tube 10 Connect elec...

Page 119: ...5 Figure 1 Control Sticks and Torque Tube Item Description Item Description 1 Control stick 2 Electric wire 3 Aileron travel stops 4 Elevator control stops 5 Aileron control rods 6 Control stick bearing bolts 7 Elevator control rod 8 Main center wing spar 9 Connection rod 10 Torque tube ...

Page 120: ...ve the cover 2 from the access hole 3 Disconnect the trim tab actuator wires 1 Disconnect the actuator rod end 4 from the trim tab lever 5 Disconnect the actuator 6 from elevator or aileron reinforcement angle by removing the attachment nuts Remove the actuator 6 from the elevator or aileron through access hole 3 Figure 2 Trim Tab Control Actuator Removal Installation Item Description Item Descrip...

Page 121: ...sert 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 Connect the rod end 4 with the trim tab lever 5 Connect the actuator wires 1 Check correct trim tab operation and adjustment of trim tab deflections see Chapter 20 50 01 Close the access hole with cover 3 ...

Page 122: ...rank installed on the main wing spar next to rib No 7 in the outer wing A pushrod connects bell crank with aileron control lever The pushrods have adjustable rod ends with spherical bearings at the ends enabling aileron deflection adjustment Figure 3 Aileron Control System Lateral control stops are located on the torque tube in the cockpit A control stop consist of a headless screw which is screwe...

Page 123: ... aileron on a safe place so that it cannot be damaged Installation Tools needed wrench size 7 16 in pliers Set the aileron on the wing in to the piano hinge Insert trim tab actuator wires 3 see Fig 2 going out from wing to the aileron Insert piano hinge pin Connect the control rod with aileron control lever Connect trim tab actuator wires 1 on the left aileron see Fig 2 Close the access hole 3 wit...

Page 124: ...om the control lever 2 by unscrewing the bolts Remove the cotter pin unscrew the nut 3 Remove bolt Remove control lever Installation Tools needed wrench size 7 16 in See Figure 4 Insert the control lever 2 in bracket Insert bolt Tighten castle nut by hand on bolt and secure with cotter pin 3 Connect control push rods 1 with control lever Close access hole cover Figure 4 Aileron Control Lever Remov...

Page 125: ...ell crank arm unscrew the nuts and remove the bolts 3 Remove the bell crank 5 from the wing unscrew the nut and remove the bolt 4 Installation Tools needed wrench size 7 16 in The procedure is identical for the right and the left wing see Fig 5 Check condition and lubrication of bell crank bearings If the bearings are contaminated then carefully eliminate the contamination NOTICE Do not grease nor...

Page 126: ...leron deflections see Chapter 20 50 01 and check plays in the control see Chapter 20 60 03 Figure 5 Aileron Control Bell Crank Removal Installation Item Description Item Description 1 Covers 2 Push rods 3 Rod end bolts 4 Bell crank bolt 5 Bell crank 27 10 04 Aileron Travel Stops A bolt with counter nut is screwed to each inboard side of the torque tube brackets supporting the control sticks The co...

Page 127: ...elage under the instrument panel The pedals also control the nose gear steering see Chapter 32 20 The forward end of the cable is connected to the foot control pedals The steel cables are led through the middle channel of the fuselage The cables are guided by pulleys in the aft part of the forward fuselage section to a pulley block installed on the fin spar riveted to bulkhead No 11 and attached t...

Page 128: ...move the rudder and store it in such a way that the damage cannot occur Installation Tools needed wrench size 3 8 in 7 16 in Inspect the attachments on the rudder clean them and apply lubricant grease on them Do the same for the attachments on the fin Set the rudder to the hinges on the fin Put the bolt on top hinge and screw the nut Connect bottom hinge to the rudder control lever Perform check s...

Page 129: ...er 27 Issue 30 Sep 2020 Chapter 27 Page 15 27 20 02 Rudder Control Cable Figure 7 Rudder Control Cables Item Description Item Description 1 Control cable 2 Rudder pedal 3 Cable thimble 4 Nicopress sleeve 5 Turnbuckle 6 Pulley 7 Rudder control lever ...

Page 130: ...r 7 Pull out aft part of the control cable rearward and thus provisionally installing the auxiliary wire Disconnect control cable from auxiliary wire Disconnect the front part of the control cable from rudder torque tube lever Pull out the forward part of the control cable to the front Installation See Figure 7 Pre install cable thimble with Nicopress sleeve to one end of the forward and aft part ...

Page 131: ... the rudder and the pedal in neutral position To receive the correct cutting length of the forward control cable provisionally connect its free end to the turnbuckle 5 using the cable thimble Observe desired cable tension see Chapter 20 60 02 Connect the free end of the forward cable with the turnbuckle 5 by making a Nicopress joint 4 Check and adjust the cable tension see Chapter 20 60 02 Check s...

Page 132: ...age 18 Issue 30 Sep 2020 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 Item Description Item Description 1 Tube 2 Travel stop ...

Page 133: ...he elevator Pushrods have adjustable rod ends with spherical bearings at the ends enabling elevator deflection adjustment The elevator deflection is limited by travel stops See Chapter 27 30 05 Figure 9 Elevator Control An electric actuator is installed in the horizontal stabilizer It is used to control the elevator trim tab also working as anti servo tab to which it is connected via a threaded ro...

Page 134: ... from the stabilizer Store the elevator so that its damage cannot occur Installation Tools needed wrench size 7 16 in pliers Put the elevator 2 Fig 1 Ch 55 in the piano hinge on the stabilizer Insert wire in piano hinge 5 Fig 1 Ch 55 Insert electrical trim wires and connect to the trim tab actuator 1 Fig 2 Ch 27 Connect control rod with elevator control lever Check proper trim tab operation and el...

Page 135: ...nect control rod end to the trim tab lever Secure the pins with cotter pin At installation follow instructions in Chapters 20 10 and 20 40 Perform check see Chapter 20 50 01 adjust trim tab deflections if needed 27 30 03 Bail Arm lever front The front bail arm lever is located under the luggage compartment Removal Tools needed wrench size 7 16 in screw driver pliers Refer to Figure 13 Remove the a...

Page 136: ...10 Check condition and lubrication of bail arm lever bushings If the bushing is contaminated then carefully remove contamination NOTICE Do not grease nor rinse the bearings with permanent filling that are covered by metal or plastic covers Prelubricated for life If not pre lubricated for life grease the bearings with lubricant oil Install the bail arm lever 3 to the lever hinge insert the bolt int...

Page 137: ... deviations see Chapter 20 50 01 and check control plays see Chapter 20 60 03 27 30 04 Bail arm lever rear The rear lever is located in the rear fuselage Removal Tools needed wrench size 7 16 in 11 Phillips screw driver pliers Refer to Figure 11 Unscrew the access hole cover 1 attachment screws on the starboard side of the fuselage in front of the fin spar Disconnect push rod ends 2 from the lever...

Page 138: ...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 Tighten the nut slightly and secure it with the cotter pin NOTE The arm must not show after installing any axial play and its travel must be continuous without hitching Connect both push rod ends 2 with the lev...

Page 139: ...ops 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 Counter nuts fix the bolts in the desired position The push stop s travel upper bolt s head is limited by a bolt head screwed in the upper wing spar cap The pull stop s travel lower bolt s end is limited by a bolt head screwed in the lower ...

Page 140: ...olled by programmable control unit with three positions switch including up located on the centre console An LCD indicator is integrated to the control unit for confirmation of the positions and transition blinking Wing flaps deflection can be 0 10 and 25 Figure 12 Flap Control System 27 50 01 Wing Flaps Removal Tools needed wrench size 7 16 in Open the flap in full position Disconnect control pus...

Page 141: ...screw the nuts on them Connect control push rod Close the flap in the zero up position Perform check of the wing flaps operation and their deflections see Chapter 20 50 01 27 50 02 Wing Flap Control Actuator Figure 13 Wing Flap Control Actuator Item Description Item Description 1 Center console 2 Flap 3 Flap lever 4 Flap actuator 5 Actuator wire 6 Actuator hinge 7 Flap position sender 8 Limit swit...

Page 142: ...ver 3 from the flap actuator 4 Disconnect flap actuator wire 5 Disconnect the flap actuator 4 from the actuator hinge 6 Remove flap actuator 4 Installation Tools needed wrench size 7 16 in 172 in screw driver Refer to Figure 13 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 Cha...

Page 143: ...nts 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 7 28 20 02 Pick up Line 7 28 20 03 Fuel Drain 8 Removal 8 Installation 8 28 40 Indicating 8 28 40 01 Fuel Level Sender 8 Removal 8 Installation 9 ...

Page 144: ...em 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 Figure 1 Fuel System Scheme ...

Page 145: ...engine is operating or with electric system switched on Do not work on the fuel system nor allow any person to stay next to the aircraft when wearing polyester clothing or any clothing from a material which creates static electricity Do not smoke or handle with open fire nor allow any person to do so Ensure airplane is grounded Drain fuel system Disconnect fuel line from mech Fuel pump 1 Disconnec...

Page 146: ...ft 3 Filler caps 4 drain valve lower skin not visible 28 10 01 Fuel Tank The tanks 1 2 Figure 2 are located in the outer wings between ribs No 2 and 5 in front of the main spar Each fuel tank has a filler neck with flush head filler cap 3 fuel level sender 2 Figure 3 venting tube finger screen 1 Figure 3 and drain valve 4 Fuel is filled into the each tank through the filler neck which is located o...

Page 147: ...Bristell B23 Airplane Maintenance Manual Chapter 28 Issue 30 Sep 2020 Chapter 28 Page 5 Figure 3 Fuel Tank left Item Description Item Description 1 Pick up line 2 Fuel level sender 3 Rib 4 Drain valve ...

Page 148: ...tor valve 1 works also for interruption of fuel supply in case of engine fire or for airplane long time parking The fuel selector is located on the middle console between the seats in the cockpit The gascolator 7 is located on the firewall in lowest point of fuel system The electrical fuel pump 9 is located on the firewall above the gascolator Figure 4 Distribution Item Description Item Descriptio...

Page 149: ...th new pump Checking Fuel Leakage Perform engine inspection and visually inspect the fuel pump body including inlet and outlet hose for fuel leakage e g droplets wet spots In case of fuel leakage find out the reason and if necessary exchange the fuel pump for the new pump 28 20 02 Pick up Line The pick up line is located on the feed line on root tank rib It isn t removable Figure 5 Pick up Line It...

Page 150: ...ITE 565 or equivalent sealant Fill the tank with fuel and check drain valve tightness 28 40 Indicating Fuel quantity is measured by the fuel float gauges also refer to Fig 3 The float position is converted to an electrical signal and fuel quantity in the tank is indicated on the GDU370 G3X screen The fuel system provides a hard wired low fuel warning light in the instrument panel LED 28 40 01 Fuel...

Page 151: ...d 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 Chapter 91 Install the wing see Chapter 57 20 Check fuel system tightness see Chapter 28 00 Connect the battery switch on the master and avionics switch Check if fuel level is correctly indicated on the Garmin system red range and ad...

Page 152: ...Airplane Maintenance Manual Bristell B23 Chapter 28 Chapter 28 Page 10 Issue 30 Sep 2020 Intentionally left blank ...

Page 153: ...rplane Maintenance Manual Chapter 31 Issue 30 Sep 2020 Chapter 31 Page 1 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 ...

Page 154: ...anual Bristell B23 Chapter 31 Chapter 31 Page 2 Issue 30 Sep 2020 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 ...

Page 155: ...AV 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 Garmin manual ref chapter 01 20 For software update contact BRM AERO s r o do not install public downloadable software versions an aircraft TC holder approved Service Bulletin is required for software upda...

Page 156: ...Airplane Maintenance Manual Bristell B23 Chapter 31 Chapter 31 Page 4 Issue 30 Sep 2020 Intentionally left blank ...

Page 157: ...l 3 Installation 4 32 20 Nose Gear 5 32 20 01 Nose Gear Leg 6 Removal 6 Installation 7 32 40 Wheels and Brakes 8 32 40 01 Wheel Pants 8 Removal 8 Installation 8 32 40 10 Main Wheel 9 Removal 9 Installation 10 32 40 20 Nose Wheel 11 Removal 11 Installation 12 32 40 30 Brake System 12 32 40 31 Parking Brake 12 32 40 32 Brake Pump 13 Removal 13 Installation 14 32 50 Steering 15 32 50 01 Nose Wheel Co...

Page 158: ...equipped with hydraulic disk brakes Figure 1 Landing Gear Item Description Item Description 1 Main landing gear leg 2 Wheel pants 3 Main wheels 4 Disc brake 5 Nose wheel 6 Nose gear leg Type and dimension of main wheels Wheel rim Beringer 5 00 5 Tire tubeless Michelin aviator 5 00 5 8 160 Type and dimension of nose wheel Wheel rim Beringer 5 00 5 Tire tubeless Michelin aviator 5 00 5 8 160 This Ch...

Page 159: ...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 Figure 2 Main Gear Leg Item Description Item Description 1 Main gear leg 2 Stirrup 3 Attachment bolt 4 Gear channel Removal Tools needed wrench size 9 16 in 1 2 in See Figure 2 Jack and support the airplane see Chapter 07 Disc...

Page 160: ...n Tools needed wrench size 9 16 in in See Figure 2 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 Insert the landing gear leg 1 into the gear channel 4 on fuselage Put the bolts 3 and stirrup 2 in gear channel tighten the bolts slightly no clamping force on composite leg AND no app...

Page 161: ...ded 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 1 and main center wing spar Figure 3 Nose Gear Item Description Item Description 1 Nose gear channel 2 Landing gear leg 3 Landing gear leg cover 4 Nose wheel pant 5 Nose landing gear wheel ...

Page 162: ...ed wrench size 1 2 in No 17 wrench size 10 and 20 See Figure 4 Jack and support the airplane see Chapter 07 Disconnect the Teleflex rods 5 from the nose wheel fork use wrench size 10 to unscrew the self locking nut at rod bottom end and then use wrench size 22 to release bottom nut at Teleflex attachment to the nose leg Remove Teleflex from the nose leg Disconnect shock absorber 6 from the shock a...

Page 163: ... leg Insert the gear leg 3 into the attachment brackets in gear channel 4 Put the leg axle 2 into the brackets insert bolts 1 and tighten them slightly Connect shock absorber 6 with the shock absorber attachments Pull the bottom end of the Teleflex rods through the hole on the nose leg lever put on it the nut and use wrench size 22 to tight the nut Then attach the bottom end of Teleflex rod to the...

Page 164: ...plane 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 The wheel pants are installed on the brackets per bolts Removal Tools needed screw driver Remove bolts attaching the wheel pants to the brackets Remove wheel pants Installation Tools needed screw driver Position the wheel pants on...

Page 165: ...s are joined by bolts 5 Main landing gear wheels are equipped with the brake discs 3 which are attached to the inner half of the wheel rims Wheels are equipped with tubeless tires Figure 5 Main Wheel Item Description Item Description 1 Outer rim 2 Main inner rim 3 Brake disc 4 Brake calliper 5 Bolts 6 Axle cover Removal Tools needed socket wrench size 32 mm Allen wrench size 4 mm pliers See Figure...

Page 166: ...tallation Tools needed socket wrench vel 1 1 2 in Allen wrench size 3 16 in pliers See Figure 5 Clear the wheel axle of impurities and apply slight layer of grease on it Put the wheel on the axle Apply securing liquid blue Loctite 243 on the screw threads and attach with it the wheel rim and brake disc Refer to Chapter 01 20 Screw and tighten the nut on the wheel axle Install axle cover 6 Install ...

Page 167: ...nected by bolts The wheel is equipped with a tubeless tire Figure 6 Nose Wheel Item Description Item Description 1 Wheel fork 2 Wheel 3 Bolt 4 Washer 5 Wheel axle 6 Hub 7 Bushing Removal Tools needed wrench size 9 16 in pliers See Figure 6 Jack and support the airplane see para Chapter 07 Disassemble wheel pants see Chapter 32 40 01 Remove the bolts 3 and washers 4 from wheel axle 5 Release the wh...

Page 168: ...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 By applying force on the pedal the master brake cylinder is compressed and pressure is generated in the brake circuit and the caliper pushes the brake pads onto the brake disks Braking pressure can be cont...

Page 169: ...tings 5 Brake master cylinder 6 Rudder pedal bracket Removal Tools needed wrench size 3 8 in 10 mm Allan wrench 5 mm See Figure 7 Drain brake fluid from the respective brake system side by disconnecting the brake hose from the main gear wheel brake and allowing brake fluid to spill to a previously prepared can Disconnect the brake hoses 2 from the brake master cylinder fittings 4 Disconnect the ma...

Page 170: ...llation Tools needed wrench size 3 8 in 10 mm Allan wrench 5 mm See Figure 7 Install fittings 4 to the brake pump if applicable Install the brake pump 5 to the bracket 3 on the cross channel by inserting the bolt and screwing the nut on Connect the brake pump 1 to the rudder pedal bracket 6 Connect brake hoses 2 to the fittings 4 on the brake pump 5 Re fill the brake system with brake liquid and b...

Page 171: ...dder pedals 1 Figure 8 are transferred to the nose wheel fork 8 Figure 9 by means of steering levers 1 welded to the rudder control system and Teleflex cables 5 The Teleflex rods are attached to the nose gear leg 4 by brackets 3 6 The rod attachment to the steering levers is made by fork ends the one to the steering brackets 7 at the nose wheel fork 8 by ball ends Adjustment of Nose gear steering ...

Page 172: ...g 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 Figure 9 Nose Gear Steering Item Description Item Description 1 Steering levers 2 Nose gear channel 3 Brackets upper 4 Nose gear leg 5 Teleflex cable 6 Brackets lower 7 Steering brackets 8 Nose wheel fork ...

Page 173: ... 2020 Chapter 33 Page 1 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 3 33 40 02 Landing Light 3 Removal 4 Installation 4 ...

Page 174: ...s 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 The trim indications can be dimmed by switching on the DAY NIGHT switch To allow clearly readable inscription at night a strip of red LEDs on the bottom side of the glareshield is installed The light intensity is adjustab...

Page 175: ...hts to the wing tip thus releasing the lights Remove strobe position light and disconnect the wire Installation Tools needed screwdriver 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 Seal th...

Page 176: ...ing light box by unscrewing the screws on top and bottom of the bubble Unscrew the 4 screws on the light panel Disconnect the wires on the rear side of the light panel Installation Tools needed Allan wrench size 3 mm screwdriver Reconnect the wires to the light panel Push cables through the corresponding opening in the landing light box Secure with 4 screws Install acryl cover glass ...

Page 177: ...gation 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 4 34 20 Attitude Direction 6 34 20 11 Electronic Magnetometers 6 34 20 12 Magnetic Compass if installed 6 Compensation 6 ...

Page 178: ... sensed through the hole in the pitot tube face Static pressure ports are located on both sides of the fuselage at the tail The pitot tube also contains a second hole for AOA sensing by the G3X system Pressure distribution to individual instruments is performed by means of flexible plastic hoses Static pressure and the total pressure are lead to the GSU73 ADAHRS and to the L3 ESI 500 for independe...

Page 179: ... System Item Description Item Description 1 Static pressure port 2 Drains 3 GAP 26 Pitot tube 4 GSU 73 ADAHRS 5 AOA sense line 6 Total pressure line 7 Static pressure line 8 Transponder 9 L3 ESI 500 Checks System Tightness Test Static system Seal the one static port On the other connect airtight a tube hose ...

Page 180: ...34 10 11 Pitot Tube Removal 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 Remove the tightening strip from hose Disconnect the red hose for total pressure from the Pitot tube Disconnect the green hose for AOA sensor from the Pitot tube Disco...

Page 181: ...34 Issue 30 Sep 2020 Chapter 34 Page 5 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: ...course of the airplane The magnetic compass is positioned on the upper edge of the instrument panel and consists of the vessel filed with non freezing liquid with the little window in the front wall The compass rose is positioned on the rotary and swinging pivot inside the compass Compensation Rules for doing compensation of the magnetic compass Compass compensation must be performed on the approv...

Page 183: ...deviation by E W screw Turn the airplane to W heading reduce the found out deviation to the half value by E W screw and write down the rest of the deviation Turn the airplane by grades indicated in the compensation report see Table 1 and write down individual deviations in the table After finishing compensation of the magnetic compass fill out the deviation card see Fig 3 and place it near the mag...

Page 184: ... mark Serial No Compass Type Compass Serial No All instruments switched on to achieve simulated flight conditions Course Engine running throttle in cruise position Measured Deviation N 030 060 E 120 150 S 210 240 W 300 330 Date Time Compensation conforming YES NO Note Elaborated by Signature Date Checked by Signature Date Table 1 Compensation Report ...

Page 185: ...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 5 General 5 Procedure 5 51 60 01 Elevator and Tab Limits 8 51 60 02 Aileron and Tab Limits 9 51 60 03 Rudder Limits 10 51 60 04 Flap Limits 11 51 80 Electrical Bonding 12 ...

Page 186: ...AEPS egress panel 8 RH wing gap cover 9 11 RH wing access panels 12 Bottom fuselage access panel 13 Top fuselage access panel 14 Stabilizer access panel 15 Elevator trim access panel Except from the oil hatch which has a latching mechanism all access panels are attached to the aircraft skin by means of AN526C832R8 bolts screwed into MS21047L08 anchor nuts The wing gap covers are attached to the wi...

Page 187: ...access panel 3 LH cabin access panel ELT 4 Armrest cover flap actuator 5 RH cabin access panel All inside access panels allow access to the elevator and rudder control Item 3 additionally allows access to the ELT item 4 to the wing flap control actuator item 5 to parts of the static system Except from the armrest cover all inside access panels are attached by means of M4x12 ISO 7380 2 A2 bolts scr...

Page 188: ...s 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 engine mount flap lever assy 1 4301 Stainless steel Firewall sheet ...

Page 189: ...w paint or other repair Refer to the Chapters 51 60 01 thru 51 60 04 for limits of the respective control surfaces Procedure NOTE Check weighing scale currency of calibration If required Remove the respective control surfaces from the aircraft Determine total weight of the control surface and enter in respective column of record form Use balancing support mandrels as shown in the following Figure ...

Page 190: ...ongest moment arm weighing point with the surfaces in level attitude Use a conventional spring balance or table balance Enter the support weights in the table and enter in respective column of record form Measure distances of hinge center line to weighing points and enter the values in record form Calculate the control surface moments and note in record sheet NOTE Limits given in the result form a...

Page 191: ... Wlimit kg Indicated value F kg Lever arm X m Resulting moment M kgm Limit Mlimit kgm OK Y N Rudder Rudder Elevator RH elevator weighing including trim tab Elevator LH Elevator RH Elevatorcompl Aileron RH aileron weighing including trim tab Aileron LH Aileron RH Flaps Flap LH Flap RH Moments M kgm F kg X m Weighing done by Name Date Table 1 Record Sheet ...

Page 192: ... kg Min mass 5 805 kg 0 625 kg Max static moment 0 0322 kgm 0 0119 kgm 1 Min Static moment 0 0318 kgm 0 0121 kgm 1 The effect of the trim tab mass on the elevator static moment is significant and can eat up the selected permissible tolerance range quite fast Therefore the selected tolerances are tight On the other side the static moment of the trim tab itself is almost exclusively driven by the su...

Page 193: ...30 Sep 2020 Chapter 51 Page 9 51 60 02 Aileron and Tab Limits Left aileron with trim tab actuator and actuation rod Right aileron 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 Min Static moment 0 142 kgm 0 106 kgm ...

Page 194: ... 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 0 26 0 27 0 28 0 29 0 3 0 31 0 32 0 33 2 05 2 1 2 15 2 2 2 25 2 3 2 35 Static Moment kgm Mass kg B23 Rudder mass and static moment Limits defined ...

Page 195: ...l B23 Airplane Maintenance Manual Chapter 51 Issue 30 Sep 2020 Chapter 51 Page 11 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 ...

Page 196: ... Maintenance Manual Bristell B23 Chapter 51 Chapter 51 Page 12 Issue 30 Sep 2020 51 80 Electrical Bonding Refer to the following drawings presented in Chapter 91 Charts 34B220000N_1 and _4 34B240000N_1 thru _6 ...

Page 197: ...ral 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 5 53 10 21 Gas Strut 5 Removal 5 Installation 6 53 10 22 Canopy Lock 7 Removal 7 Installation 9 53 10 23 Rear Canopy Windows 9 53 10 30 Wing Centre Section 9 53 10 40 Engine Mounts 9 53 20 Rear Part of the Fuselage 9 ...

Page 198: ...ng fuselage are not interchangeable hardware replacing the wings or the fuselage has to be completed in BRM AERO s r o facilities where the main joints are reamed together in the corresponding jig 53 10 Front Part of the Fuselage 53 10 10 Cockpit The cockpit see Figure 1 is located in the front part of the fuselage between the bulkheads No 1 and 6 The instrument panel is located on the bulkhead No...

Page 199: ...fixed frame The canopy can be opened forward and is lightened by a gas strut 6 each side which keep it in the opened position The canopy outside handles 2 are placed on the fuselage sides below the rear cockpit windows 3 The inside handles 5 are installed inside the fixed frame Figure 2 Canopy and Rear Windows Item Description Item Description 1 Canopy 2 Canopy handle outside left and right 3 Cano...

Page 200: ... springs 3 from the gas strut rod ends 1 Disconnect gas struts 5 on both sides of canopy Disconnect hinge bolt nuts 9 and washer 8 Remove the hinge bolts 6 and bushing 7 Remove the canopy and store it in a safe place so that windscreen damage cannot occur Figure 3 Canopy Removal Installation Item Description Item Description 1 Gas strut rod end 2 Canopy 3 Securing spring 4 Gas strut ball joint 5 G...

Page 201: ...ts 6 bushings 7 washers 8 and the nuts 9 into the hinges 10 of the canopy Tighten up the joint Insert ends of gas strut 1 in to the pins in the fix frame of the canopy and on the foldable frame secure the ball joints 4 with the securing spring 3 53 10 21 Gas Strut Removal Tools needed screwdriver pliers Refer to Figure 3 Open the canopy and fix it against closing after gas strut removal Remove the...

Page 202: ... 53 Chapter 53 Page 6 Issue 30 Sep 2020 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: ...backrest on the cockpit side you intend to remove the lock as per Chapter 25 10 01 Use Allen wrench to unscrew the screws and remove the access hole cover Put your hand inside the access hole and disconnect the safety wire of the ball joint connected to the outer handle lever Disconnect the aft rod 8 by disconnecting the ball joint Use wrench to remove the bolt on the cover of the control handle a...

Page 204: ...hapter 53 Page 8 Issue 30 Sep 2020 Figure 4 Canopy Lock Removal Installation Item Description Item Description 1 Inner handle 2 Rod pin safety spring 3 Forward rod 4 Cover 5 Lock 6 Outer handle 7 Bracket 8 Aft rod 9 Lock torque tube 10 Handle torque tube ...

Page 205: ...ted and glued SCS2000E Silpruf on the fuselage side skins 53 10 30 Wing Centre Section The centre section of the wing is an integral part of the fuselage and contains the main spar attachments located at bulkhead No 3 and the rear spar attachments located on the bulkhead No 5 Main landing gear attachment points are located behind the main spar 53 10 40 Engine Mounts Top engine mount attachment poi...

Page 206: ...e Maintenance Manual Bristell B23 Chapter 53 Chapter 53 Page 10 Issue 30 Sep 2020 and stabilizer attachments is an integral part of the fuselage The bulkheads No 12 and 13 form the stabilizer attachment points ...

Page 207: ...pter 55 Issue 30 Sep 2020 Chapter 55 Page 1 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 7 ...

Page 208: ...ips are made from composite The horizontal stabilizer is mounted to the fuselage by means of front and rear attachments see Figure 2 The front attachments consist of two mandrels 2 which are riveted on bulkhead No 12 and bushings riveted on front stabilizer spar The rear attachments consist of two brackets 5 riveted on rear stabilizer spar which is bolted on top and bottom part of bulkhead No 13 F...

Page 209: ...Brackets 6 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 Remove the composite covers top and bottom Remove bolts 4 washer and nuts and afterwards the brackets 5 on the bulkhead No 13 Disconnect trim tab actuator wires see Chapter 27 00 03 located between stabilizer and fus...

Page 210: ...stabilizer from behind to the fuselage so that it slides on two mandrels on bulkhead No 12 Install the brackets 5 and secure with the 4 bolts 4 install washers and secure with nuts Connect the trim tab actuator wires see Chapter 27 00 03 located between the stabilizer and fuselage Connect the elevator control rod with the control lever Install the composite covers on bulkhead No 13 Screw back the ...

Page 211: ... 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 The elevator is attached to the rear spar by means of piano hinge 5 55 20 01 Trim Tab The elevator is equipped with a trim tab 3 made from aluminum sheet It is attached to the elevator rear spar by means of a piano hinge 4 ...

Page 212: ...ral part of the fuselage The vertical stabilizer consists of stiffeners spar ribs and aluminum skin The Individual parts are riveted together The tip is made from fiberglass The vertical stabilizer spar features to hinges 3 and 5 for rudder attachment Figure 2 Vertical Stabilizer with Rudder Item Description Item Description 1 Fin 2 Fin tip 3 Top rudder hinge 4 Rudder 5 Bottom rudder hinge ...

Page 213: ... 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 The top attachment 3 is located on the spar ...

Page 214: ...Airplane Maintenance Manual Bristell B23 Chapter 55 Chapter 55 Page 8 Issue 30 Sep 2020 Intentionally left blank ...

Page 215: ...pter 57 Issue 30 Sep 2020 Chapter 57 Page 1 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 5 57 50 Wing Flaps 6 57 60 Ailerons 7 ...

Page 216: ...s of the wing 3 Wing locker 4 Rear attachment of the wing 5 Flap 6 Aileron trim tab 7 Aileron 8 Position strobe light 9 Winglet Rib numbering NOTE Wing fuselage are not interchangeable hardware replacing the wings or the fuselage has to be completed in BRM AERO s r o facilities where the main joints are reamed together in the corresponding jig 57 10 Centre Wing Centre section of the wing is an int...

Page 217: ... cutting pliers hammer Remove the access cover plates between outer and center wing Disconnect aileron control push rod on the control lever between center wing tip rib and root outer wing rib Extend the flaps to maximum and disconnect rear attachment bolts on rear spar and flap control push rods Disconnect fuel lines wiring and on left wing also pitot tube hoses and trim tab wire Remove all 4 nut...

Page 218: ... the leading edge will insert the first bolt into the upper main attachment the bolt head is on the flight direction side and shift it by means of slight hammering until the bolt is completely inserted shifting can be facilitated by slight moving the wing tip up and down Insert the bolts 2x into the lower main attachment and shift them by slight hammering until the bolts are completely inserted In...

Page 219: ... 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 57 30 Wing Tip Winglets are produced from composite and are partially enclosed by and riveted to the wing skin Position lights and anti collision beacons are installed on the winglets ...

Page 220: ... 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 There is a control plate 3 on the flap root rib where the flap control pin is connected Figure 2 Wing Flap left Item Description Item Description 1 Flap 2 Flap spar 3 Control pin 4 Flap hinges 5 Flap ribs ...

Page 221: ...ded on the rear spar by means of piano hinges 2 A trim tab 5 is installed on the left aileron Control lever 3 is installed on the root aileron rib Figure 3 Aileron left Item Description Item Description 1 Aileron skin 2 Aileron piano hinge 3 Aileron control lever 4 Aileron ribs 5 Aileron trim tab Figure 4 Aileron right Item Description Item Description 1 Aileron skin 2 Aileron piano hinge 3 Ailero...

Page 222: ...Airplane Maintenance Manual Bristell B23 Chapter 57 Chapter 57 Page 8 Issue 30 Sep 2020 Intentionally left blank ...

Page 223: ...Bristell B23 Airplane Maintenance Manual Chapter 61 Issue 30 Sep 2020 Chapter 61 Page 1 61 Propeller Table of Contents Chapter Title Page 61 00 General 2 Removal 2 Installation 3 61 20 Controlling 4 ...

Page 224: ...olerances CNC machined Vibration approved on the ROTAX 912 series EASA certified Refer to the documentation supplied with the propeller for more details Removal Tools needed wrench size No 16 5 8 in Refer to Fig 2 Disconnect the board battery and remove spark plugs from the engine Loosen the bolt 1 from the tension bar 2 and the upper connecting bolt 1 of the external alternator Remove V belt 3 Un...

Page 225: ...tem Description Item Description 1 Alternator Bolts 2 Tension bar 3 V belt 4 Propeller Bolts 5 Pulley carrier 6 Pulley Installation Tools needed wrench size No 16 5 8 in NOTE Follow the instructions in the Operation Installation and Maintenance Manual Section 5 Installation and Operation Instructions to install the MTV propeller ...

Page 226: ...ropeller 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 Fig 3 Propeller control Item Description Item Description 1 Propeller control lever 2 Teleflex cable 3 hydraulic governor NOTE Follow the instructions in the Installation Manual Chapter 61 00 00 Section 3 ...

Page 227: ...Bristell B23 Airplane Maintenance Manual Chapter 71 Issue 30 Sep 2020 Chapter 71 Page 1 71 Power Plant Table of Contents Chapter Title Page 71 00 General 2 71 10 Cowling 3 71 20 Mounts 4 ...

Page 228: ...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 at 5800 RPM ...

Page 229: ...he oil tank without removing the upper cowling and without the use of tools The lower cowling 2 is attached by means of quick fasteners to the firewall and to the upper cowling 1 In the front part of the lower cowling 2 there is an oval hole 3 for air inlet to the oil radiator In the bottom part of the lower cowling 2 is NACA scoop for air intake to the water cooler 7 Fig 1 Engine Cowling Item Des...

Page 230: ...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 2 Fig 2 Rotax Engine Mount Item Description Item Description 1 Firewall 2 Engine mount 3 Attachment bolts with shock absorbers 4 Nyloc nut ...

Page 231: ...e 1 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 15 72 20 11 Radiator 16 Removal 16 Installation 16 72 30 Mass ballast 17 Removal 17 Installation 18 ...

Page 232: ... Cruising 5000 rpm Idling 1400 rpm Cylinder head temperature CHT Older engines S N without Suffix 01 Minimum 50 C 122 F Maximum 135 C 275 F conventional coolant permanent monitoring of coolant temperature and CHT is necessary Waterless coolant permanent monitoring of CHT is necessary Optimum 80 110 C 176 230 F Coolant temperature CT New engines S N with Suffix 01 Minimum 50 C 122 F Maximum 120 C 2...

Page 233: ... 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 Type of coolant used by aircraft manufacturer is shown in Chapter 12 10 01 ...

Page 234: ...Airplane Maintenance Manual Bristell B23 Chapter 72 Chapter 72 Page 4 Issue 30 Sep 2020 Fuel Type ...

Page 235: ...Bristell B23 Airplane Maintenance Manual Chapter 72 Issue 30 Sep 2020 Chapter 72 Page 5 Oil Type Type of oil used by aircraft manufacturer is shown in Chapter 12 00 01 ...

Page 236: ...r 12 10 20 and cooling liquid see Chapter 12 10 30 Disconnect hoses of the oil and the cooling system Remove the oil cooler see Chapter 79 20 01 Removal and the radiator Chapter 72 20 11 Removal Disconnect control of carburetors and carburetors heating Remove air intake see Chapter 72 20 Removal Remove the exhaust system see Chapter 78 00 Removal Blind all the holes on the engine so that no impuri...

Page 237: ...the engine mount according to Fig 1 Put the engine on the engine mount by the crane or with 2 assistants and attach it by the screws 2 Fig 2 with washers 3 Fig 2 Tighten up applying torque moment 4 146 kg m 30 lbf Secure the screw heads by cotter pins 1 Fig 2 Fig 1 Engine Mount Attachment to the Engine and Firewall Item Description Item Description 1 Engine mount 2 Screws holes for screws Install ...

Page 238: ...he choke and the throttle on the carburetor control levers according to the Fig 2 Adjust the throttle control see Chapter 73 20 01 Adjustment and the choke control see Chapter 73 20 02 Adjustment Connect air hose from the heat exchanger for heating of the airplane cockpit Fill the prescribed amount of oil and cooling liquid quantity Check fuel system tightness see Chapter 28 00 Checking Fuel Syste...

Page 239: ...rol lever Checks Engine Check 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 Test place must be equipped with extinguisher which is suitable for extinguishing burning liquids and electrical installation B...

Page 240: ...sure 7 bar 102 psi for a short period at cold start Fuel pressure has to be in range from 0 15 to 0 4 bar 2 2 to 5 8 psi Engine warm up according to the AOI of Bristell B23 Par 4 4 and Rotax engine Operator s manual Chapter 10 3 As soon as oil pressure will be in range from 2 to 5 bar 29 to 73 psi start warming up period at 2000 rpm for approx 2 minutes continue at 2500 rpm duration depending on a...

Page 241: ...ssue 30 Sep 2020 Chapter 72 Page 11 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: ...Max cylinder head temperature 120 135 C 248 275 F 10 RPM drop between ignition position BOTH and L R at 4000 RPM max 300 115 RPM 11 Acceleration 2 3 sec 12 Max RPM on the ground 5200 100 RPM 13 Idle Approx 1400 RPM Defects During cold start for a short term only RPM drop between ignition position BOTH and position L or R must not exceed 300 RPM Mutual difference between left L and right R ignition...

Page 243: ...eat exchanger which is attached to the muffler is controlled by flap on the firewall The heating control flap is controlled by CARB HEAT knob 13 on the instrument panel Fig 4 Removal Installation of Air Intake System Item Description Item Description 1 Airbox rear half 2 Air box front half 3 Drain hoses 4 Carburettors 5 Naca scoop 6 Hose fastener 7 Air hose cold air 8 Air intake changeover lever 9...

Page 244: ...store it Installation Tools needed Wrench size 8 10 Screwdriver see Fig 4 Attach the outlet pipe of the airbox 1 2 to the carburettor 4 inlet necks by means of hose fasteners Fix the airbox by means of the strut and the silentblock to the engine mount Connect the air intake hoses to the airbox rear half 1 cold air hose 7 to the NACA scoop 5 and hot air hose 11 to the heat exchanger Ensure correct ...

Page 245: ...d 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 The cylinder head cooling system is shown in Fig 5 Fig 5 Engine Cooling System Item Description Item Description 1 Expansion tank 2 Hoses 3 Water Radiator 4 Overflow hose 5 Overflow bottle ...

Page 246: ... 10 30 Disconnect hoses from the radiator outlets Remove four bolts attaching the radiator to the upper and lower brackets Remove the radiator Installation Tools needed wrench size 10 screwdriver See Fig 5 Install the radiator on upper and lower brackets Install hoses on the outlets from the radiator and secure them with hose fasteners Fill the cooling system with cooling liquid see Chapter 12 10 ...

Page 247: ...m 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 Fig 6 Installation of mass ballast on the engine Item Description Item Description 1 Mass ballast 2 bolt Removal Tools needed wrench size 16 pliers Cut the safety wire Unscrew the two bolts ...

Page 248: ...aintenance Manual Bristell B23 Chapter 72 Chapter 72 Page 18 Issue 16 Nov 2020 Installation Tools needed wrench size 16 safety wire tools pliers Install the mass ballast Tighten the bolts Secure with safety wire ...

Page 249: ...le 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 4 Adjustment 4 73 20 03 Carburetor Heating Knob 5 Removal 5 Installing 5 Adjustment 6 73 30 Indicating 6 73 30 01 Fuel Quantity 6 73 30 01 Fuel Pressure 6 ...

Page 250: ...corresponds to max take off power of the engine If the control lever is fully pulled this position corresponds to idle Changes in the engine power setting can be made by moving of the control lever forwards and backwards 73 20 01 Throttle Control Removal Tools needed wrench size 19 Allen wrench size 2 5 Screwdriver Cutting pliers see Fig 1 Remove the cover of the throttle 1 control lever from the ...

Page 251: ...wrench size 2 Screwdriver Cutting pliers See Fig 1 Install the throttle 1 control lever into the middle channel Connect the throttle 3 and choke 4 cables to the throttle 1 and choke 2 control levers and to the carburetors Install the cover of throttle and choke on the middle channel Install the upper engine cowling Check for continuous travel of the throttle and choke control lever Adjust the thro...

Page 252: ...ls on Bowden cables In order to prevent the Bowden cables at the carburetor from shifting out from the terminals secure the Bowden cables with locking wire Mark all bolted joints with red paint 73 20 02 Choke Control The choke control lever is installed next to the switch box key Removal Installation Refer to the procedure outlined in Chapter 73 20 01 Adjustment Set the choke lever to the stops po...

Page 253: ...al Tools needed Wrench size 8 14 Screwdriver Cutting pliers see Fig 2 Remove the upper engine cowling Disconnect the control cable on the changeover lever of the air intake 4 see Chapter 72 00 Figure 3 Remove the inner nut 1 and pull out the knob 2 with the flexible housing 3 from the firewall and instrument panel Fig 2 Carburetor Heating Knob Item Description Item Description 1 Nut 3 Flexible hou...

Page 254: ...top see Fig Chapter 72 00 Figure 3 The Bowden cable must rest on the terminal Release the bolt on the changeover lever 4 slightly stretch the cable and tighten up the bolt Check again whether the knob and the lever on the air intake are on the stops If not carry out adjustment by adjustable Bowden terminals To prevent the Bowden cables from shifting out of the terminal secure the Bowden cable with...

Page 255: ...Bristell B23 Airplane Maintenance Manual Chapter 74 Issue 30 Sept 2020 Chapter 74 Page 1 74 Ignition Table of Contents Chapter Title Page 74 00 General 2 ...

Page 256: ...High voltage current is distributed to the spark plugs by means of high voltage cables The sequence of individual cylinder ignition of the engine is as follows 1 4 2 3 Ignition circuits are controlled by the ignition switch on the instrument panel There are the following positions of the switch box key Position Description OFF Engine ignition is OFF R Only Right ignition circuit ON L Only Left ign...

Page 257: ...23 Airplane Maintenance Manual Chapter 77 Issue 30 Sept 2020 Chapter 77 Page 1 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 ...

Page 258: ... 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 77 20 01 Cylinder Head Thermometer Cylinder head temperature sensor measures temperature of the cylinder No 3 Working range of the cylinder head thermometer is 50 to 150 C 120 to 300 F Indication is by the Garmin System ...

Page 259: ...Bristell B23 Airplane Maintenance Manual Chapter 78 Issue 30 Sept 2020 Chapter 78 Page 1 78 Exhaust Table of Contents Chapter Title Page 78 00 General 2 Removal 2 Installation 3 Check 3 ...

Page 260: ... as a silencer Exhaust gases lead from there by the exhaust end pipe 4 down the airplane On the muffler is heat exchanger from which is taken warm air for the carburetor preheating and for the cockpit The whole exhaust system is welded from the stainless steel sheets and pipes Fig 1 Exhaust System Item Description Item Description 1 Muffler 2 Exhaust pipes 3 Spring 4 End pipe Removal Tools needed ...

Page 261: ... the engine exhaust necks do not tighten the nuts Install the muffler 1 to the exhaust pipes 2 and secure the tubes by means of springs 3 Gradually tighten all nuts of the flanges on the engine necks NOTE Ensure the sufficient space between the exhaust pipes and the other installed parts Check WARNING A burst or leaky exhaust can expose the crew to danger presented by carbon monoxide or can result...

Page 262: ...ter 78 Chapter 78 Page 4 Issue 30 Sept 2020 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: ...ter 79 Issue 30 Sept 2020 Chapter 79 Page 1 79 Oil 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 4 ...

Page 264: ...ted on the firewall through the oil cooler 4 and the oil pump 5 with oil filter to the lubricated points on the engine The oil pump is equipped with the pressure regulator and with the pressure transmitter The oil tank is ventilated by the hose 6 which leads under the airplane Oil pressure and temperature are indicated on the Garmin System Fig 1 Oil Cooling System Item Description Item Description...

Page 265: ...from the oil tank you will remove the hose leading to the oil cooler Engine ignition must be switched off Remove hose fittings from the oil cooler necks After that it is possible to remove nuts from the cooler necks attaching the cooler to the brackets 3 on the engine Installation Tools needed wrench size 22 30 See Fig 1 Set the oil cooler 4 to the bracket 3 on the engine and on the cooler necks g...

Page 266: ...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 79 30 02 Oil Pressure Gauge Oil pressure on the inlet to the engine is measured by the sensor which is located behind the oil filter Oil pressure gauge measure range is 0 to 10 bar 0 to 150 psi ...

Page 267: ...Bristell B23 Airplane Maintenance Manual Chapter 80 Issue 30 Sept 2020 Chapter 80 Page 1 80 Starting Table of Contents Chapter Title Page 80 00 General 2 Description 2 80 10 Cranking 2 ...

Page 268: ...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 80 10 Cranking Cranking is initiated by placing the ignition switch located on the instrument panel to the START position also refer to Chapter 74 00 For detailed procedures refer to the aircraft AFM and to the External Power...

Page 269: ...Bristell B23 Airplane Maintenance Manual Chapter 90 Issue 30 Sept 2020 Chapter 90 Page 1 90 Emergency Equipment Table of Contents Chapter Title Page 90 10 00 BRS 05 AEPS System 2 ...

Page 270: ...nents of the AEPS system rocket parachute the parts have to be send to the aircraft manufacturer BRM aero s r o The reinstallation with the corresponding Form1 spare part provided by the aircraft manufacturer is done acc Appendix B NOTE The aircraft is airworthy without the AEPS being operational not part of MEL It must be marked Inoperative visible to the pilot in accordance with Chapter 04 10 03...

Page 271: ...ing 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 Compass und autopilot are optional equipment ...

Page 272: ...4B220005N G3X CAN BUS Architecture 34B220006N Garmin G3X_Intercom 34B220008N Stanby Instruments ES500 34B220009N Garmin G3X_Discrete_in_out 34B220010N Garmin G3X_Trim_Position 34B220011N G3X_Engine sensors 34B220012N G3X_GPS 34B220013N Transponder_GTX345 34B220015N Fuel 34B220016N Internal lights 34B220017N External lighting 34B220018N Flaps 34B220019N Pitot heat 34B220020N ELT Kannad 34B220200N E...

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