BRM Aero Bristell B23-915 Maintenance Manual Supplement Download

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Bristell B23-915

Airplane Maintenance Manual

supplement

Chapter 72

Issue: 09.12.2021

Chapter 72 Page 13

Removal

Tools needed:

Wrench size 8, 10
Screwdriver

See Fig. 4.

▶

Remove the upper engine cowling.

▶

Remove cooling air inlet duct (for intercooler)

▶

Disconnect all hoses and electrical connections to the
lower cowling

▶

Disconnect alternate air flap Bowden cable

▶

Remove lower cowling

▶

Disconnect air hoses From/to turbocharger / intercooler
/ airbox. Note correct position of hoses.

▶

Remove mounting strut of intercooler.

▶

Remove throttle valve.

Installation

Tools needed:

Wrench size 8, 10
Screwdriver

see Fig. 4.

▶

Attach throttle valve to the airbox (10).

▶

install intercooler (7)

▶

Connect air hoses accordingly. Ensure correct position.

▶

Install alternate air Bowden cable (3)

▶

Connect all hoses and electrical connections to the lower
cowling

▶

Install cooling air inlet duct (for intercooler)

▶

Install the upper engine cowling.

Summary of Contents for Bristell B23-915

Page 1: ...0 Airplane Maintenance Manual Supplement Bristell B23 915 model Doc N ADxC 73 003 AMM Supplement Edition 1 0 Supplementing ADxC 73 001 AMM 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 915 Chapter 00 supplement Chapter 00 Page 2 Issue 09 12 2021 Intentionally left blank ...

Page 3: ...Bristell B23 915 Airplane Maintenance Manual supplement Chapter 00 Issue 09 12 2021 Chapter 00 Page 3 Amendments Issue Date Revised pages Description Edition 1 0 09 12 2021 first issue DC 003 ...

Page 4: ...ual Bristell B23 915 Chapter 00 supplement Chapter 00 Page 4 Issue 09 12 2021 List of Service Bulletins SB No Date Title Affected Serial no s AD EASA ADxC 73 SB 011 09 12 2021 Retrofit of air tow hook to B23 915 All SN B23 915 ...

Page 5: ...09 12 2021 03 1 2 1 0 09 12 2021 61 1 4 1 0 09 12 2021 04 1 4 x 1 0 09 12 2021 71 1 4 1 0 09 12 2021 05 1 10 1 0 09 12 2021 72 1 16 1 0 09 12 2021 08 1 2 1 0 09 12 2021 73 1 4 1 0 09 12 2021 11 1 2 1 0 09 12 2021 74 1 2 1 0 09 12 2021 12 1 2 1 0 09 12 2021 77 1 2 1 0 09 12 2021 20 1 2 1 0 09 12 2021 78 1 4 1 0 09 12 2021 21 1 2 1 0 09 12 2021 79 1 4 1 0 09 12 2021 24 1 6 1 0 09 12 2021 80 1 2 1 0 ...

Page 6: ...cription 04 Airworthiness Limitations 05 Inspection and Maintenance 08 Leveling and Weighing 11 Placards and Markings 12 Servicing 20 Standard Practices Airframe 21 Air Conditioning 24 Electrical Power 28 Fuel 61 Propeller 71 Power Plant 72 Engine 73 Engine Control and Fuel Indicating 74 Ignition 77 Engine Indicating 78 Exhaust 79 Oil 80 Starting 91 Charts ...

Page 7: ... Aero s r o the manufacturer of BRISTELL B23 airplanes provides in accordance with the CS23 Amdt 5 AMC3 CS VLA airworthiness requirements information necessary to maintain airworthiness of BRISTELL B23 915 model airplanes This Maintenance Manual contains technical description of the design change DC 73 003 information on operation maintenance and repairs description of systems and their functions ...

Page 8: ...B23 915 Aircraft Flight Manual supplement ROTAX Operator s Manual for ROTAX 915 series engine OM 915 i A Maintenance Manual line for ROTAX 915 series engine MML 915 i A Maintenance Manual heavy for ROTAX 915 series engine MMH 915 i A Service Instruction for ROTAX 915 series engine SI 915 i 001 Selection of suitable operating fluids for ROTAX Engine Type 912 i 915 i 912 and 914 Series TOST Air tow ...

Page 9: ...Letecká 255 686 04 Kunovice Czech Republic Phone 420 773 984 338 E mail 1 info brmaero com E mail 2 aero brm gmail com Web http www brmaero com or for occurrence reporting Aircraft Design 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 10: ...Airplane Maintenance Manual Bristell B23 915 Chapter 01 supplement Chapter 01 Page 4 Issue 09 12 2021 Intentionally left blank ...

Page 11: ...U controlled 141hp engine 915iSc3A featuring Turbocharger Injection Intercooler 2nd water cooler o New engine mount to fit the suspensions frame from Rotax New upper lower cowling o New repositioned openings for air inlet cooling exhaust o Upper cowling featuring two access hatches for oil and coolant level control New inspection access hatch on the fuselage belly skin for the main and auxiliary f...

Page 12: ...Airplane Maintenance Manual Bristell B23 915 Chapter 03 supplement Chapter 03 Page 2 Issue 09 12 2021 Intentionally left blank ...

Page 13: ...er 04 Issue 09 12 2021 Chapter 04 Page 1 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 Class I Parts Limitations 2 ...

Page 14: ...00 hours Replace at 18 000 hours Bolts to airframe AN5 26A AN5 32A Replace at 1 000 hours Bolts suspension frame to engine mount AN7 42A Replace at 1 000 hours Table 1 Class I Parts Visual inspection for ovalisation of bracket holes on fuselage side 04 10 03 Air Tow Hook Limitations if installed optional equipment Air tow hook TOST E85 time between overhaul is 10000 actuations This corresponds to ...

Page 15: ...rk No of takeoffs Prescribed works Made by Checked by Engine Mount Tubes 71B510000N Remove engine cowlings Remove the engine with suspension frame and the engine mount Inspect the engine mount for deformation damage Remove any paint according ASTM E1417 Perform dye penetrant testing according ASTM E1417 Replace if damaged Paint with the materials defined in the main manual if undamaged and reinsta...

Page 16: ...Airplane Maintenance Manual Bristell B23 915 Chapter 04 supplement Chapter 04 Page 4 Issue 09 12 2021 Intentionally left blank ...

Page 17: ...itle Page 05 00 Standard Practice 2 05 10 Time Limits 3 05 10 01 Overhaul Schedule 3 05 10 02 Replacement Schedule 3 05 20 Scheduled Maintenance 4 05 20 01 Lubrication Plan 4 05 20 02 Inspection after the first 25 Flight Hours 5 05 20 03 Periodical Inspection after 50 Flight Hours 6 05 20 04 Annual Periodical Inspection or Inspection after 100 Flight Hours 7 ...

Page 18: ...tercooler air inlet The air duct on intercooler is not attached to the engine or airframe and can be removed without tools When reinstalling make sure the form fit is applied correctly For removing the lower cowling Disconnect all hoses and connections attached to the lower cowling including sensor connectors to the inlet airbox and the alternate air Bowden cable After reinstallation verify the co...

Page 19: ...shown here must be overhauled at the times indicated Item Overhaul Motor ROTAX 915 iSc3A Refer to Maintenance Manual Line 915 Series latest edition 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 Fuel fine filter every 100h Fuel coarse filter on condition ...

Page 20: ...Maintenance 05 20 01 Lubrication Plan Unit Area of lubrication Every 100 hours Lubricant Engine Throttle control cable on the inlet into terminal in the engine compartment X Engine oil If towing system installed Unit Area of lubrication Every 100 hours Lubricant Tow hook Bowden cable and release mechanism X Engine oil ...

Page 21: ...k tightening and securing bolts on the engine brackets the engine suspension frame and the engine mount Check the engine mount for occurrence of cracks as well as the engine mount rubber shock absorbers Check the exhaust system and its attachment for occurrence of cracks on the exhaust system and welds see Chapter 78 00 Check Remove heat exchanger for full inspection of the muffler surface Inspect...

Page 22: ... Made by Checked by Engine and Propeller 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 full inspection of the muffler surface Inspect and clean the coarse fuel filter insert Inspect and if required replace the fine fuel filter If installed Clean and lubricate the tow release system Clean the...

Page 23: ...ture ref to the operation manual of the tow hook Check straightness of the Bowden cable holder on the tow hook structure Restore straightness or replace if necessary Check tension of the Bowden cable manually If excessive slack is present retighten by use of the Bowden cable terminals Check wear of the Bowden cable and crimp connections to both end terminals release handle in the cockpit and relea...

Page 24: ...contained in Maintenance Manual Line Maintenance for installed engine Inspect and check tightening and securing bolts on the engine brackets and between the engine suspension frame and the engine mount Check the engine mount for occurrence of cracks as well as the engine mount rubber shock absorbers Check the engine bed for occurrence of cracks Check the exhaust system and its attachment for occur...

Page 25: ...tenance Manual supplement Chapter 05 Issue 09 12 2021 Chapter 05 Page 9 Prescribed works Made by Checked by Finalization Close all access hatches remount fairings and cowling Perform ground run and check flight Notes Date Signature ...

Page 26: ...Airplane Maintenance Manual Bristell B23 915 Chapter 05 supplement Chapter 05 Page 10 Issue 09 12 2021 Intentionally left blank ...

Page 27: ... 08 Leveling and Weighing Table of Contents Chapter Title Page 08 10 Weighing and Balancing 1 08 10 02 Weight and Balance Envelope Limits 1 08 10 Weighing and Balancing The weight and balance limits and procedures of the aircraft is not affected by the change 08 10 02 Weight and Balance Envelope Limits ...

Page 28: ...Airplane Maintenance Manual Bristell B23 915 Chapter 08 supplement Chapter 08 Page 2 Issue 09 12 2021 Intentionally left blank ...

Page 29: ...ement Chapter 11 Issue 09 12 2021 Chapter 11 Page 1 11 Placards and Markings Table of Contents Chapter Title Page 11 00 General 1 11 00 General Surface paint is not affected by the change For placards and markings refer to flight manual ADxC 73 003 AFM ...

Page 30: ...Airplane Maintenance Manual Bristell B23 915 Chapter 11 supplement Chapter 11 Page 2 Issue 09 12 2021 Intentionally left blank ...

Page 31: ...e Manual supplement Chapter 12 Issue 09 12 2021 Chapter 12 Page 1 12 Servicing Table of Contents Chapter Title Page 12 10 Replenishing 2 12 10 30 Coolant 2 Refilling Coolant 2 12 30 Unscheduled Servicing 2 12 30 31 Air Filter 2 Cleaning 2 ...

Page 32: ...n addition to this there is an overflow bottle which collects coolant in case of engine overheating and is attached to the firewall For bleeding of the coolant system refer to the ROTAX manuals 12 30 Unscheduled Servicing 12 30 31 Air Filter Cleaning Disconnect all hoses and connections attached to the lower cowling including sensor connectors to the inlet airbox and the alternate air Bowden cable...

Page 33: ...rol Surface Deflections 1 20 50 Adjustments and Tests For procedure instruction and other relevant data refer to basic aircraft Maintenance Manual ADxC 73 001 AMM 20 50 01 Control Surface Deflections 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 20 2 up 13 2 down Wing flap 0 2 10 2 25 2 Difference between L R flap de...

Page 34: ...Airplane Maintenance Manual Bristell B23 915 Chapter 20 supplement Chapter 20 Page 2 Issue 09 12 2021 Intentionally left blank ...

Page 35: ...al supplement Chapter 21 Issue 09 12 2021 Chapter 21 Page 1 21 Air Conditioning Table of Contents Chapter Title Page 21 00 General 1 21 40 Heating 2 21 00 General Changes to the heating system introduced by DC 003 are described in the following ...

Page 36: ...nto the cockpit by air hose 2 Quantity of hot air is regulated by CabinHeat knob 11 on the instrument panel Behind the firewall a up down mixture flap 7 is located which splits hot air flow into the canopy bubble outlet 9 and into the crew legs outlet 8 The mixture flap is controlled by the UP DOWN knob 10 Fig 3 Heating System Item Description Item Description 1 Air inlet cowling connection 2 Muff...

Page 37: ... 2021 Chapter 24 Page 1 24 Electrical Power Table of Contents Chapter Title Page 24 00 General 2 24 30 DC Generation 3 24 30 01 Internal Generators 3 24 30 02 Auxiliary Alternator 3 24 60 DC Electrical Load Distribution 4 24 60 01 Switches and Circuit Breakers 4 24 60 02 Fuses 5 ...

Page 38: ...ition 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 switch ON activating Lane A and Lane B switching the main fu...

Page 39: ...tem EMS and the airframe with power management of electrical power distribution of GEN A GEN B is automatically controlled via the EMS Conversion into DC power is through the fusebox with regulators feeding nominal 14V into the system 24 30 02 Auxiliary Alternator The auxiliary generator ALT C is mounted to the LHS of the engine and supplies electric current through the rectifier Regulator supplie...

Page 40: ...ed with a placard with designation of the circuit see following Table The switches are located on the instrument panel and on the middle channel The buttons for aileron and elevator trim are on the grip of control stick Wiring diagrams are shown in Chapter 91 Switches Switch Breaker Designation Description MAIN PUMP Electric fuel pump switch LANE A LANE A LANE B LANE B START POWER Start power togg...

Page 41: ... are shown in CHAPTER 91 WIRING DIAGRAMS FUSES Designation Description Rating GEN A B Generator A B int generators 30 GEN A B CTRL GEN A B Overvoltage Protection 5 BCK BAT Backup Battery 5 BUS TIE Connecting GEN A B and ALT C 20 ALT C Alternator C ext alternator 30 ALT C CTRL ALT C Overvoltage Protection 5 BATTERY Battery 30 BCK PWR backup power supply engine 30 PFD Left hand side G3X screen 5 TRI...

Page 42: ...rplane Maintenance Manual Bristell B23 915 Chapter 24 supplement Chapter 24 Page 6 Issue 09 12 2021 XPDR Transponder 3 USB 2 USB plug PED power 3 HEADSET Headset power supply Bose 1 CAM Rear view camera 1 ...

Page 43: ...f Contents Chapter Title Page 28 00 General 2 Checking Fuel System Tightness 3 28 10 Storage 4 28 10 01 Fuel Tank 4 28 20 Distribution 6 28 20 01 Electric Fuel Pump 7 Check 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 Sensor 8 Removal 8 Installation 9 ...

Page 44: ... of Bristell B23 airplane consists of the following parts two fuel tanks fuel tubing dual selector valve main and aux fuel pump electric coarse and fine fuel filter fuel level sensor fuel pressure sensor and drain valves on the fuel tanks Figure 1 Fuel System Scheme green low pressure lines red high pressure lines blue return lines ...

Page 45: ...ctric 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 feed line from fuel rail Disconnect fuel return line from fuel rail...

Page 46: ...tank left 3 Filler caps 4 drain valves 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 l...

Page 47: ...ll B23 915 Airplane Maintenance Manual supplement Chapter 28 Issue 09 12 2021 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 48: ...fuel pressure is measured 7 After the fine filter the fuel is fed 10 into the fuel rail and from there distributed to the fuel injection pumps The excess fuel is returned through the return line 11 into the chosen tank left right 13 A bypass routing 12 feeds the return flow into the RHS tank to prevent overpressure in the return part of the fuel system with closed fuel selector valve The fuel sele...

Page 49: ...skin Check the fuel pump assembly pump bodies hoses etc for cracks especially inlet and the outlet hoses If cracks are detected immediately exchange the fuel pump assembly Checking Fuel Leakage Perform fuel system inspection and visually inspect fuel pump pump bodies hoses etc especially fuel pump inlet and outlet hose for fuel leakage e g droplets wet spots In case of fuel leakage find out the re...

Page 50: ...tallation Tools needed wrench size 1 2 in Set drain valve in the tank use LOCTITE 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 PFD MFD screen The fuel system provides a ...

Page 51: ...t the fuel level sender into the tank and attach it using bolts with washers use LOCTITE 565 or equivalent sealant on bolts thread Connect electrical wires to the fuel level sender electrical connection see 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 indicat...

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Page 53: ...tification outside Item Description Item Description 1 Aileron trim access panel 2 4 LH wing access panels 5 LH wing gap cover 6 fuel pump bay access hatch 7 Oil hatch 8 Coolant overflow bottle hatch 9 AEPS egress panel 10 RH wing gap cover 11 13 RH wing access panels 14 Bottom fuselage access panel 15 Top fuselage access panel 16 Stabilizer access panel 17 Elevator trim access panel ...

Page 54: ...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 wing by means of M4x12 ISO 7380 2 A2 bolts with 5 3 DIN 6798 ZN serrated lock washers screwed into 9407 40300 nuts 51 80 Electrical Bonding Refer to the following drawings presented in Chapter 91 Charts 34B520000N 34B540000N ...

Page 55: ...ell B23 915 Airplane Maintenance Manual supplement Chapter 61 Issue 09 12 2021 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 56: ...ring tolerances CNC machined Vibration approved on the ROTAX 915 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 bel...

Page 57: ...eller Item 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 58: ...seats Propeller control lever is connected through a Teleflex cable 2 with the propeller hydraulic governor 3 Once an engine rpm is selected it will be held constant at variations of airspeed and power 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 Sec...

Page 59: ... 20 Mounts 4 71 00 General Power unit of BRISTELL B23 915 model airplane is the ROTAX 915 iSc3 A 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 915 iSc3A is a turbocharged 4 stroke 4 opposed cylinder engine central cam shaft and OHV mechanism with maximal power of 104 kW 141 hp at 5800 RPM ...

Page 60: ...olant access cover 8 is mirrored on the RHS for preflight check of coolant level in the overflow bottle The lower cowling 2 is attached by means of quick fasteners to the firewall and to the upper cowling 1 The front part of the lower cowling features two large openings for oil radiator 3 and front water cooler 4 Behind these openings a smaller hole supplies the heating system with air 5 A large N...

Page 61: ...gine upper cowling 2 Engine lower cowling 3 Air inlet for oil radiator 4 Front water cooler air inlet 5 Heating air inlet 6 Quick fasteners Camlocks 7 Access hatch to oil tank 8 Access hatch to coolant overflow bottle 9 Rear water cooler intercooler air inlet 10 Primary air inlet 11 Engine cooling air inlet 12 Engine compartment air outlet ...

Page 62: ...attached to the firewall on one side and to the engine suspension frame on the other side by means of bolts Between engine mount and suspension frame the connection is by four bolted attachments through rubber shock absorbers as depicted in Fig 2 Fig 2 Rotax Engine Mount Item Description Item Description 1 Engine mount 2 Engine suspension frame 3 Connection bolts with rubber mounts 4 Attachment bo...

Page 63: ... Issue 09 12 2021 Chapter 72 Page 1 72 Engine Table of Contents Chapter Title Page 72 00 General 2 Removal 6 Installation 7 Checks 9 72 20 Air Inlet Section 12 Removal 13 Installation 13 72 20 10 Engine Cooling System 14 72 20 11 Radiator 15 Removal 15 Installation 15 ...

Page 64: ...5800 rpm max 5 min Max Continuous 5500 rpm Idling 1800 rpm Manifold Air Pressure MAP Minimum 60hPa 1 77 in HG Maximum 1730hPa 51in HG Coolant temperature CT Minimum 50 C 122 F Maximum 120 C 248 F Optimum 80 110 C 176 230 F Oil temperature Minimum 50 C 122 F Maximum 130 C 266 F Optimum 90 110 C 190 230 F Oil pressure Minimum 0 8 bar 12 psi below 3500 rpm Maximum 7 bar 102 psi cold engine start Opti...

Page 65: ... propylene glycol or with additives Modified parts Following parts of Rotax IPC are modified by BRM Expansion tank ROTAX PN 922664 71B520020N Water cooler ROTAX PN 997086 71B520010N Intercooler ROTAX PN 888962 71B550050N Muffler ROTAX PN 979475 71B540001N For replacement of these parts contact the manufacturer BRM Aero NOTICE Modified parts can not be ordered through ROTAX but are custom BRM parts...

Page 66: ...Airplane Maintenance Manual Bristell B23 915 Chapter 72 supplement Chapter 72 Page 4 Issue 09 12 2021 Fuel Type ...

Page 67: ...Bristell B23 915 Airplane Maintenance Manual supplement Chapter 72 Issue 09 12 2021 Chapter 72 Page 5 Oil Type Type of oil used by aircraft manufacturer is shown in Chap 12 00 01 ...

Page 68: ... selector valve possibly drain fuel from the fuel installation in front of fuel selector by opening hose in front of fuel pump assembly Drain oil from the engine see Chapter 12 10 20 of the main manual and cooling liquid see Chapter 12 10 30 Disconnect hoses of the oil and the cooling system Disconnect all air hoses from to turbocharger and intercooler Disconnect water hoses from and to the rear w...

Page 69: ...driver cutting pliers pliers Cobra pliers for clamps If the engine mount itself is removed follow these steps Position the engine mount on the firewall Plug the screws through the corresponding holes from the cockpit side of the firewall Install washers and nuts NOTE USE two washers for the lower connection and only one for the upper connection points Tighten up applying torque moment 22 2Nm Insta...

Page 70: ...l the exhaust system see Chapter 78 00 Installation Connect wiring according to the wiring diagrams see Chapter 78 Install oil cooler see Chapter 79 20 01 Installation Install front water cooler see Chapter 72 20 11 Installation Connect and secure oil system hoses Connect and secure fuel system hoses Connect all air hoses from to turbocharger and intercooler Connect water hoses from and to the rea...

Page 71: ...person performing the engine test must have the corresponding approvals and be familiarized with the aircraft type BRISTELL B23 915 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 Brake the airplane and put chocks un...

Page 72: ...ng up period at 2000 rpm for 2 minutes continue at 2500 rpm duration depending on ambient temperature until oil temperature reaches 50 C 122 F Perform lane check acc to the AFM of Bristell B23 915 Par 4 4 NOTE RPM drop with only one LANE running must not exceed 250 RPM After LANE switch on again wait 3 Seconds until continuing with the next step Write down results into the engine test report see T...

Page 73: ... RPM at steady oil pressure 3bar 43 5psi min 2 minutes 3 1 bar 45 psi 5 Warming up the engine at 2000 2500 RPM smooth running 6 Voltage 12 15 V Engine test 7 Min oil temperature 50 C 122 F 8 Oil pressure 2 5 bar 29 73 psi 9 Max Coolant temperature 120 C 248 F 10 RPM drop during LANE CHECK 4700RPM max 250 RPM 11 Acceleration 2 3 sec 12 Max RPM on the ground 5700 5800 RPM 13 Idle Approx 1800 RPM Def...

Page 74: ...ted air filter is controlled by a Bowden cable leading to the ALT AIR knob 4 in the cockpit compartment The compressed and heated air is chilled in the intercooler 7 to which air from the central upper NACA inlet in the upper cowling is lead through a duct 8 The engine air rate to the manifold air box 10 is controlled via the throttle control Fig 4 Removal Installation of Air Intake System Item De...

Page 75: ...den cable Remove lower cowling Disconnect air hoses From to turbocharger intercooler airbox Note correct position of hoses Remove mounting strut of intercooler Remove throttle valve Installation Tools needed Wrench size 8 10 Screwdriver see Fig 4 Attach throttle valve to the airbox 10 install intercooler 7 Connect air hoses accordingly Ensure correct position Install alternate air Bowden cable 3 C...

Page 76: ...ooling circuit of cylinder heads is made as a closed system containing the pump expansion tank with the pressure cap water coolers and the overflow bottle Fig 5 Engine Cooling System Item Description Item Description 1 Expansion tank BRM Aero part 71B520020N 2 Hose tank RAD1 3 Front water radiator 4 Hose RAD1 RAD2 5 Rear water radiator 6 Hose RAD2 water pump 7 Hose tank overflow bottle 8 Overflow ...

Page 77: ... refer to Rotax manual Disconnect hoses from the water cooler outlets Remove four bolts attaching each water cooler brackets Remove the water coolers Installation Tools needed wrench size 10 screwdriver See Fig 5 Install the water coolers on their brackets Install hoses on the outlets from the radiator and secure them with hose fasteners Fill the cooling system with cooling liquid see Rotax manual...

Page 78: ...Airplane Maintenance Manual Bristell B23 915 Chapter 72 supplement Chapter 72 Page 16 Issue 09 12 2021 Intentionally left blank ...

Page 79: ...3 Issue 09 12 2021 Chapter 73 Page 1 73 Engine Control and Fuel Indicating Table of Contents Chapter Title Page 73 20 Controlling 2 73 20 01 Throttle Control 2 Removal 2 Installation 3 Adjustment 4 73 30 Indicating 4 73 30 01 Fuel Quantity 4 73 30 01 Fuel Pressure 4 ...

Page 80: ...lve If the control lever is fully pushed this position 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 Rem...

Page 81: ...ottle Control Lever Item Description Item Description 1 Throttle control lever 2 Throttle cable 3 Bowden cable 4 Throttle flap lever 5 Throttle flap assy Installation Tools needed wrench size 14 Allen wrench size 2 Screwdriver Cutting pliers See Fig 1 Install the throttle 1 control lever into the middle channel ...

Page 82: ...any slack excessive tensioning on the cable and tighten up the nut or by means of adjustable terminals on Bowden cables by means of the adjustable terminals on Bowden cables To prevent the Bowden cables at the throttle valve from shifting out from the terminals secure the Bowden cables with locking wire Mark all bolted joints with red paint 73 30 Indicating 73 30 01 Fuel Quantity Fuel quantity in ...

Page 83: ...Bristell B23 915 Airplane Maintenance Manual supplement Chapter 74 Issue 09 12 2021 Chapter 74 Page 1 74 Ignition Table of Contents Chapter Title Page 74 00 General 2 ...

Page 84: ... circuit High voltage current is distributed to the spark plugs by means of high voltage cables Being equipped with an injection system and a turbocharger the engine is directly controlled by the Engine Control Unit ECU handling not only the ignition but also the injection power supply turbo actuation etc Being a redundant system both Lanes can be separately activated and are controlled by switche...

Page 85: ... displayed o measured behind the oil pump Oil pressure sensor displayed o measured behind the oil pump Ambient air and temp sensor redundant not shown o measured in the air filter box Manifold air temperature redundant displayed o measured in the airbox Manifold air pressure redundant displayed o measured in the airbox Crank position sensor redundant displayed as RPM o measured at the crankshaft K...

Page 86: ...e of either LANE A or LANE B leads to loss of indication of the sensor indications as follows When Lane A is OFF lamp ON Loss of data for o coolant temperature o Exhaust gas temperatures from cyl 2 4 o Ambient temp o Throttle lever position When Lane B is OFF lamp ON Loss of data for o oil temperature o oil pressure o Exhaust gas temperatures from cyl 1 3 o fuel flow calculated internally by ECU ...

Page 87: ...Bristell B23 915 Airplane Maintenance Manual supplement Chapter 78 Issue 09 12 2021 Chapter 78 Page 1 78 Exhaust Table of Contents Chapter Title Page 78 00 General 2 Removal 3 Installation 3 Check 3 ...

Page 88: ... energy is transferred to the air inlet system by compressing and heating the engine air Connected to this exhaust manifold is the muffler 4 working at the same time as a silencer Exhaust gases lead from there by the exhaust end pipe 6 down the airplane Mounted on the muffler is heat exchanger from which is taken warm air for the heating system of the cockpit see chapter 21 40 The whole exhaust sy...

Page 89: ... 3 by means of bolted connection Reattach muffler to the clamp 5 and tighten NOTE For further removal installation information regarding the exhaust system e g turbocharger maintenance refer to Rotax manual heavy maintenance Check WARNING A burst or leaky exhaust can expose the crew to danger presented by carbon monoxide or can result in engine power loss and possibly fire Check the exhaust system...

Page 90: ...r 78 supplement Chapter 78 Page 4 Issue 09 12 2021 Remove the heat exchanger and check muffler area located under it Check the whole exhaust pipes between the engine and the muffler including its attachment to the engine Check end pipe from the muffler ...

Page 91: ...15 Airplane Maintenance Manual supplement Chapter 79 Issue 09 12 2021 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 ...

Page 92: ...il stream lubricates the turbocharger 5 6 The oil pump is equipped with the pressure regulator and with the pressure transmitter The oil tank is ventilated by the hose 13 which exits the airplane beneath the lower cowling Oil pressure and temperature are indicated on the Garmin System see chapter 77 00 Fig 1 Oil Cooling System Item Description Item Description 1 Oil tank 2 Oil feed line to cooler ...

Page 93: ...propeller whereas 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 on the engine Installation Tools needed wrench size 22 30 See Fig 1 Set the oil cooler 3 to the bracket on the engine and gradual...

Page 94: ...Airplane Maintenance Manual Bristell B23 915 Chapter 79 supplement Chapter 79 Page 4 Issue 09 12 2021 Intentionally left blank ...

Page 95: ...Bristell B23 915 Airplane Maintenance Manual supplement Chapter 80 Issue 09 12 2021 Chapter 80 Page 1 80 Starting Table of Contents Chapter Title Page 80 00 General 2 Description 2 ...

Page 96: ... is equipped with an electric starter The airframe mounted electric power supplied system consists of the following parts Lane switch Start power toggle switch Starter button Internal power supply ECU as control instance related wiring Refer to the ROTAX documentation for detailed information about starting system see Chapter 01 20 and cranking ...

Page 97: ...ring diagrams of BRISTELL B23 915 model 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 98: ...ionics installation assembly 34B520000N Electrical power system Rotax 915 34B520009N Garmin G3X discrete inputs 34B520011N Engine sensors 34B520015N Fuel 34B520016N Internal lights 34B520023N Engine harness interface connectors 34B520200N Electrical grounding 34B540000N Engine wiring assembly 71B500000N Engine installation sheet 5 5 ...

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