The Airplane Factory Sling 4 Maintenance Manual Download

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Summary of Contents for Sling 4

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Page 2: ...FORM THE AIRPLANE FACTORY AIRCRAFT MANUFACTURER ON CHANGE OF OWNERSHIP OF THE AIRCRAFT NOTICE AIRCRAFT WHICH DIFFER FROM THE PRODUCTION STANDARD IN WHATEVER WAY ARE NOT ADDRESSED IN THIS MANUAL EXCEPT...

Page 3: ...l inspection considerations inspection schedules and inspection procedures SECTION 3 SERVICE This section provides information regarding general service considerations and service schedules SECTION 4...

Page 4: ...1 Corrected servo motor body orientation in Figure 14 and Figure 28 2 Updated wiring diagrams 3 Updated front occupant s safety harness es removal 4 Changed wing rear attachment bolt torque from 20 N...

Page 5: ...soline AWG American Wire Gauge BATT Battery BNC Bayonet Neill Concelman connector type C Common CAN Controller Area Network CG Centre of Gravity DC Direct Current EFIS Electronic Flight Information Sy...

Page 6: ...e at a specified datum QNH Barometric pressure adjusted to sea level RDAC Remote Data Acquisition Computer RSA Republic of South Africa RON Research Octane Number RS232 Recommended Standard 232 RX Rec...

Page 7: ...GL Avionics EFIS Integrated Autopilot user and Installation Manual 9 ASTM D7547 Standard Specification for Hydrocarbon Unleaded Aviation Gasoline 10 ASTM D910 Standard Specification for Aviation Gasol...

Page 8: ...AND PRESSURES 12 1 8 GROUND HANDLING 12 1 9 JACKING 13 1 10 PARKING AND TIE DOWN 14 1 11 AIRCRAFT LEVELLING 14 1 11 1 LONGITUDINAL LEVELLING 15 1 11 2 TRANSVERSE LEVELLING 17 1 12 AIRCRAFT ALIGNMENT...

Page 9: ...SCHEDULE 43 2 3 1 ENGINE 43 2 3 2 PROPELLER 43 2 3 3 AIRFRAME AND SYSTEMS 43 2 4 CONDITION INSPECTION 100 HOUR ANNUALLY 44 2 4 1 INSPECTION PANELS AND INITIAL INSPECTION AND CLEANING 44 2 4 2 FUSELAG...

Page 10: ...AP ADJUSTMENT 97 4 1 3 4 FLAP ACTUATOR MOTOR REMOVAL INSTALLATION 99 4 2 EMPENNAGE 102 4 2 1 HORIZONTAL TAIL AND ELEVATOR 102 4 2 1 1 ELEVATOR CONTROL SYSTEM 103 4 2 1 2 ELEVATOR REMOVAL INSTALLATION...

Page 11: ...ATION 163 4 4 2 2 NOSE WHEEL REMOVAL INSTALLATION 164 4 4 2 3 NOSE WHEEL DISASSEMBLY ASSEMBLY 167 4 4 2 4 NOSE WHEEL BEARING REMOVAL REPLACEMENT 170 4 4 2 5 NOSE GEAR REMOVAL INSTALLATION 171 5 POWER...

Page 12: ...MOVAL INSTALLATION 225 6 4 FUEL SELECTOR UNIT ASSEMBLY DISASSEMBLY 228 6 5 FUEL PUMP ASSEMBLY REMOVAL INSTALLATION 230 6 6 FUEL PUMP REMOVAL INSTALLATION FROM INTO FUEL PUMP ASSEMBLY 236 6 7 FUEL TANK...

Page 13: ...CIRCUIT BREAKERS AND OR SWITCHES 282 10 5 REGULATOR RECTIFIER REMOVAL AND REPLACEMENT 285 11 EXTERIOR LIGHTING 287 11 1 NAVIGATION LIGHTS 287 11 1 1 NAVIGATION LIGHT REMOVAL INSTALLATION 288 11 2 LAND...

Page 14: ...GATION LIGHTS WIRING DIAGRAM 317 13 12 RDAC TO OIL PRESSURE TRANSDUCER WIRING DIAGRAM 318 13 13 DUAL EFIS INSTALLATION WIRING DIAGRAM 319 13 14 TRANSPONDER WIRING DIAGRAM 320 13 14 1 TRIG TT21 TRANSPO...

Page 15: ...15 Aileron autopilot servo pushrod control stick torque tube end 89 Figure 16 Flap control system 90 Figure 17 Flap hinges 93 Figure 18 Flap pushrod to flap connection 94 Figure 19 Flap pushrod to fla...

Page 16: ...vacuum pump fitted 215 Figure 51 Propeller installation external alternator fitted 216 Figure 52 Fuel system 220 Figure 53 Fuel selector unit installation 227 Figure 54 Fuel selector port allocation a...

Page 17: ...rvo wiring diagram 313 Figure 77 EFIS back up battery charge circuit 314 Figure 78 Headphone radio GARMIN GTR 200 intercom wiring diagram 315 Figure 79 Headphone radio GARMIN GTR 225 intercom wiring d...

Page 18: ...ing definitions apply to warnings cautions and notes as used in this aircraft maintenance manual Indicates an action necessary to prevent injury or death Indicates an action necessary to prevent damag...

Page 19: ...1 GENERAL This section provides general information capacities and general procedures and specifications 1 GENERAL 1 1 DESCRIPTION The Airplane Factory Sling 4 is a four seat single engine tricycle f...

Page 20: ...DOCUMENT No REVISION 1 2 DATE 2014 11 10 DC MAM 001 X C 2 Page 2 1 2 AIRCRAFT SPECIFICATIONS AND DATA 1 2 1 AIRCRAFT 3 VIEW DRAWING Note that dimensions in this drawing are in millimetres metric...

Page 21: ...ect ratio 7 52 Dihedral 5 Tip washout 2 Aileron area 0 62 m 6 7 ft Flap area 1 26 m 13 6 ft HORIZONTAL STABILIZER Span 2 820 mm 9 252 ft Area 1 05 m 11 3 ft Aspect ratio with elevator 3 69 Angle of in...

Page 22: ...R Wheel track 1 95 m 6 4 ft Wheel base 1 68 m 5 51 ft 1 2 3 AIRCRAFT WEIGHTS MAXIMUM WEIGHTS Maximum take off weight 920 kg 2028 25 lb Maximum landing weight 920 kg 2028 25 lb Maximum baggage weight 3...

Page 23: ...d cooling water cooled heads and air cooled cylinders twin carburettors and integrated reduction gearbox with torque damper Maximum power 85 85 kW 115 hp at 5 800 rpm maximum 5 minutes 74 6 kW 100 hp...

Page 24: ...fluids NOTE AVGAS 100LL places greater stress on the valve seats due to its lead content and forms increased deposits in the combustion chamber and lead sediments in the oil system Thus it should only...

Page 25: ...3 litres 6 34 pints BRAKE FLUID Grade type Automatic Transmission Fluid ATF AIR FILTER OIL Type K N filter oil spray or K N filter oil GLUE FUEL FUEL TANK SEALANT FUEL LEAK REPAR Type AMSS8802 Class...

Page 26: ...in the centre of wing MIL G 3278 type grease or equivalent Flap torque tube supports Q20 or equivalent Flap actuator ends MIL G 3278 type grease or equivalent Rudder pedal bushes Q20 or equivalent Co...

Page 27: ...rim motor installation screws Propeller extension bolts securing propeller hub assembly to the propeller extension VHF antenna retaining screws Instrument panel retaining screws Navigation light retai...

Page 28: ...4 37 5 to 41 7 5 8 NOTE Torque values in above table are for dry not oiled threads 1 5 2 SPECIFIC ITEM TORQUE VALUE Nm ft lb Wing mounting bolts front AN7 55 40 566 Wing mounting bolts rear AN5 18 13...

Page 29: ...peed Indicator analogue WARNING LIGHTS AND INDICATORS Alternator Charge Warning Light MGL EFIS Warning Light Turbocharger Warning Lights x2 CONTROLS Dual Control Sticks Dual Rudder Pedals Centre Posit...

Page 30: ...he aircraft can be steered using the rudder pedals with a capable person in the cockpit or for sharp turns by lowering the tail to raise the nose wheel off the ground In this case press down on the re...

Page 31: ...he wheel strut so as to prevent slippage If it is necessary to lift the nose gear the engine cowling should be removed and the aircraft lifted using the engine mount as the attachment point The nose w...

Page 32: ...ie down to ground anchors at the outer wing 1 and rear fuselage 2 tie down points Aircraft tie down is essential in severe weather and high wind conditions In such conditions it is also preferable to...

Page 33: ...calibrated torque wrench with adequate range and the correct size as implied by the above tool list accessories sockets etc are implied for torqueing bolts nuts if applicable Refer to paragraph 1 5 f...

Page 34: ...irit water or electronic level with second row of rivets down from below the canopy frame edge on the aircraft fuselage side above the wing Figure 1 Longitudinal leveling reference position 2 Adjust t...

Page 35: ...calibrated torque wrench with adequate range and the correct size as implied by the above tool list accessories sockets etc are implied for torqueing bolts nuts if applicable Refer to paragraph 1 5 fo...

Page 36: ...ph 4 3 2 1 3 Place a spirit water or electronic level across the top of the centre carry through spar from one side to the other and at right angles to the longitudinal axis of the aircraft Figure 2 T...

Page 37: ...skin overlays the trailing edge skin B The 12 o clock position on the front face of the engine s propeller flange i e the top of the front face of the engine s propeller flange To get access it is nec...

Page 38: ...TOLERANCE UP LEFT DOWN RIGHT Ailerons Starting from the tips lined up with the wing tips 22 22 3 Elevator Starting from the horn lined up with the leading edge 28 20 2 Trim tab Starting flush with ele...

Page 39: ...1 15 1 RUDDER CABLE TENSION ADJUSTMENT Refer to paragraph 4 2 2 5 1 15 2 ELEVATOR ADJUSTMENT Refer to paragraph 4 2 1 5 1 15 3 ELEVATOR TRIM TAB ADJUSTMENT Refer to paragraph 4 2 1 6 1 15 4 AILERON A...

Page 40: ...be performed according to the following schedule Upon completion of manufacture and before the first flight Whenever new equipment is fitted or a modification is done which influences the weight of th...

Page 41: ...Y WEIGHT CENTRE OF GRAVITY TABLE ITEM WEIGHT kg lb ARM mm inch MOMENT weight x arm AIRCRAFT EMPTY CG Right Main Wheel WR LR 2 236 mm 88 032 Left Main Wheel WL LL 2 236 mm 88 032 Nose Wheel WN LN 548 m...

Page 42: ...ove list is not necessarily a complete list of all required tools and equipment needed A calibrated torque wrench with adequate range and the correct size as implied by the above tool list accessories...

Page 43: ...e aircraft must be weighed in a level attitude 11 Position the scales under each tyre or a scale under one tyre and blocks under the remaining tyres 12 In the case where one scale and two blocks are u...

Page 44: ...sh do not use polishing detergents Original or equivalent corrosion prevention if used must be re applied after any alteration or repair If any trace of corrosion is detected it should be removed as s...

Page 45: ...ectrolyte Leave the chromic acid solution on the part for at least five minutes and then remove the excess with water or a damp cloth Apply protective finish the same day in which treatment begins CAB...

Page 46: ...Remove the fuel completely from the tanks lines and carburettor bowls Ethanol based fuel should not be stored in the tanks or carburettors for extended periods Clean the aircraft thoroughly Clean any...

Page 47: ...IRCRAFT TO SERVICE Inspect tyres for proper inflation refer to paragraph 1 7 Inspect battery for general condition and charge If necessary charge the battery according to the battery manufacturer s in...

Page 48: ...filter 90 Mesh filter EN FIL 005 X X 0 Airplane Factory part no Oil filter Rotax Rotax part no 825010 012 Nose wheel tyre 5 00 5 6 ply UN TYR 001 X A 0 Airplane Factory part no Main wheel tyre 15 00...

Page 49: ...ever is located on the central tunnel between the two front seats and is indicated by a BRAKE label PARKING BRAKE VALVE The park brake shutoff valve is located to the rear of the central tunnel betwee...

Page 50: ...h breaker is individually labelled FLAPS The flap control is located on the instrument panel and is labelled FLAPS Flap positions are labelled as UP 1 2 and 3 from top of controller to bottom IGNITION...

Page 51: ...sole and is labelled OFF LEFT and RIGHT indicating selection The selector lever is labelled FUEL ELECTRIC FUEL PUMPS The electric fuel pumps are activated by switches on the upper left of the instrume...

Page 52: ...the nose wheel fairing is a placard 102 mm x 9 mm indicating tyre pressure 1 8 bar IDENTIFICATION PLATE The following stainless steel placard is located on the central console inside the aircraft cab...

Page 53: ...OPERATE UNDER VMC ONLY MAXIMUM PERMISSIBLE AIRSPEED 135 KIAS MAXIMUM PERMISSIBLE RPM 5 800 RPM FOR 5 MINUTES MAXIMUM CONTINUOUS RPM 5 500 MAXIMUM PERMISSIBLE MASS 920 KG 2 024 LB WARNING NON TYPE CER...

Page 54: ...n an aircraft Wear protective eye wear when working on an aircraft especially when inflating or deflating tyres working with power tools with fluids or when working with pressurized air equipment Alwa...

Page 55: ...tyre It is advisable to inflate the tyre on a newly assembled wheel assembly in a cage built for that purpose Spilled hydraulic fluid brake fluid and fuel represent a safety hazard Blank off disconnec...

Page 56: ...ling 4 for flight these should be emailed to sales airplanefactory co za The following information should be included in the email Aircraft make model and serial number Engine make model and serial nu...

Page 57: ...ion of panel covers ribs frames stringers etc absence of cracks deformation rivet slackening corrosion and any other apparent sign s of damage CABLES AND PUSHRODS Inspect cables for broken strands kin...

Page 58: ...form of collapse chafing proper radius any form of deterioration security of attachment corrosion of fitments couplings In addition to the above metal fluid lines tubing should be free of dents FILTER...

Page 59: ...uit breakers BATTERY Inspect for security of attachment correct rating sufficient charge physical integrity leakage and cracks Inspect the battery terminal connections for security of attachment crack...

Page 60: ...the cabin Small round tail cone side holes provides access to the elevator control horn and pushrod end The vertical and horizontal tail nacelle fairings provide access to vertical and horizontal tai...

Page 61: ...LLER Comply with inspection schedule as indicated in the latest revision of the propeller operator s manual 2 3 3 AIRFRAME AND SYSTEMS The airframe and systems inspection schedule is as follows Inspec...

Page 62: ...of failure and defective or insecure attachment of fittings 2 Inspect systems and components for improper installation apparent defects and unsatisfactory operation 2 4 3 CABIN AND COCKPIT GROUP 1 In...

Page 63: ...tachment 8 Inspect accessories for apparent defects in security of mounting 9 Inspect all systems for improper installation poor general condition defects and insecure attachment 10 Inspect electrical...

Page 64: ...components and systems for 1 General condition 2 Skin deterioration 3 Distortion 4 Evidence of failure 5 Insecurity of attachment 6 Improper component installation 7 Improper component operation 2 4 8...

Page 65: ...correct operation and functionality 2 Inspect wiring and conduits for improper routing insecure mounting and obvious defects 3 Inspect bonding and shielding for improper installation and poor conditi...

Page 66: ...e mounts Inspect engine mount for any signs of distortion or cracks Fuel pumps and hoses Verify fuel pump assembly securely attached to firewall Electrical wire connections to pumps in fuel pump assem...

Page 67: ...opens and close correctly Engine air intake system Verify the security of the clamps and the security and integrity of the air hoses from the intake air distributor air box to the carburettors Visual...

Page 68: ...ery earth on firewall Verify security of starter solenoid mounting lock nuts and wires wire terminals Verify presence and integrity of wire boots on terminals Verify security of all transducers sensor...

Page 69: ...seat Electrical and avionics Verify correct operation of alternator charge light Verify security of landing taxi and navigation strobe light connectors connections iBOX electrical wires and connector...

Page 70: ...lve to filters Verify security of fuel hoses from filters to tanks Verify correct and unobstructed fuel hose routing Verify correct fuel selector valve operation Verify security of fuel selector valve...

Page 71: ...rity and security of lateral torque tube mounting brackets and integrity and security of bushes and locking rings Control arms horns securely riveted to lateral torque tubes Pushrods correctly adjuste...

Page 72: ...n on panel Slip indicator balance ball air bubble not visible Magneto switch guard in place if separate magneto switches Instrument markings correct Altimeter indicates correctly with QNH QFE set All...

Page 73: ...eron system pushrod lock nuts secure Aileron system rod ends free at full deflections Verify pitot tube security Verify correct operation of pitot tube Security of navigation lights and lens integrity...

Page 74: ...m motor electrical connector and wiring Trim tab hinge secure Trim tab pivot secure split pin present Pushrod locked Verify operation Trim tab adjusted correctly deflections correct Rudder Correct def...

Page 75: ...e the FAA Advisory Circular AC43 13 1B Acceptable Methods Techniques and Practices Aircraft Inspection and Repair Removed parts should be replaced with parts with the same part number from the same ma...

Page 76: ...epair cracks dents and delamination as necessary FLUID LINES HOSES TUBES AND CONNECTIONS Fluid lines should be replaced with lines of the same part number material size inner and outer diameter pressu...

Page 77: ...y wire is installed in such a manner as to prevent the loosening of the part to which it is applied Where specified bolts and nuts should be torqued to the indicated value Use a calibrated torque wren...

Page 78: ...Tyres should be inflated to the recommended pressures Incorrect inflation can cause excessive wear and tyre imbalance Tyres should be marked and indexed i e apply creep marks with the wheel rim to ena...

Page 79: ...dures as stipulated in the latest revision of the propeller manufacturer operator s manual and or service instructions service letters and service bulletins as applicable GENERAL CONSIDERATIONS IN THE...

Page 80: ...udder pedal bushes 100 Hours yearly 12 Control stick s 100 Hours yearly 13 Control stick torque tube bushes 100 Hours yearly 14 Nose gear support blocks 100 Hours yearly 15 Main wheel bearings 100 Hou...

Page 81: ...sary Air filter Dusty environment 100 Hours Refer to paragraph 3 3 8 Remove and clean the air filter more frequently than the normal service period Replace if necessary Engine Oil Operating predominan...

Page 82: ...recommended by coolant or engine manufacturer Drain and replace Fire extinguisher As indicated Service Ballistic parachute rocket 6 Years Service Ballistic parachute canopy 6 years Repack Muffler hea...

Page 83: ...s as required Maintain proper tyre pressure If unusual tolerance is found along the transmission route of the elevator control system replace those parts displaying excessive wear 3 3 5 FIRST 25 HOURS...

Page 84: ...ce manuals as applicable 3 3 7 EVERY 50 HOURS ANNUALLY The following service requirements should be complied with after every 50 hours of operation or on an annual basis whichever comes first Carburet...

Page 85: ...st revision of the Rotax 914 UL operator and or maintenance manuals as applicable Brake fluid Verify the level of the brake fluid in the master cylinder located on the left upper side of the engine si...

Page 86: ...on describes the various structures substructures systems and subsystems comprising the aircraft and describes maintenance procedures applicable to these structures substructures systems and subsystem...

Page 87: ...the wing one providing access to the aileron bellcrank and the other providing access to the flap control arm attached to the flap torque tube Fore and aft inspection panels are located on the undersi...

Page 88: ...are implied for torqueing bolts nuts if applicable Refer to paragraph 1 5 for torque values CONSUMABLE MATERIAL REQUIRED ITEM QUANTITY NOTES 1 Orange paint As needed 2 Loctite 577 As needed Fuel tank...

Page 89: ...removed refer to paragraph 4 3 2 1 4 Remove the matting 5 Remove the inspection panelling by unfastening the button head screws retaining them 6 Remove the wing to fuselage fairings by unscrewing all...

Page 90: ...which would prevent the wing side wiring from moving free of the aircraft when the wing is moved away 11 Disconnect the flap torsion bar connector 7 from inside the fuselage by removing the two AN3 bo...

Page 91: ...he centre spar Take care not to damage the pushrod and torsion bar as they exit the fuselage PROCEDURE INSTALLATION 1 Reverse the above procedure removal for reinstallation paying close attention to t...

Page 92: ...correct placement of washers refer to Figure 7 and note that the bolt is installed with its head facing the nose of the aircraft Figure 7 Aileron pushrod to control stick connection A AN5 10A bolt B...

Page 93: ...ables pneumatic tubes which may cause chaffing 5 Before flight verify alignment and free and correct travel for the ailerons and flaps Refer to paragraph 1 13 6 Ensure that no loose objects foreign ma...

Page 94: ...heet metal skin without a spar An aluminium tube running inside the leading edge serves as a balancing weight Aileron hinges on the aileron side comprise of sealed ball bearings pressed into shaped pl...

Page 95: ...ERIAL REQUIRED ITEM QUANTITY NOTES 1 Orange paint As needed 2 Loctite 222 As needed Inspection panel screws The above list is not necessarily a complete list of all material needed Refer to the Sling...

Page 96: ...bellcrank 1 inspection cover 2 from the underside of the wing 2 Support the aileron and unfasten and remove the bolt 3 securing the pushrod 4 to the bellcrank 3 Support the aileron and unfasten and re...

Page 97: ...reuse lock nuts Fit new Tighten the lock nut on the bolt through the inboard aileron hinge sufficiently observe the correct placement of washers refer to Figure 9 and note that the bolt is installed...

Page 98: ...bserve the correct placement of washers refer to Figure 10 and note that the bolt is installed with its head facing the wingtip Figure 10 Aileron hinge outboard A AN4 7A bolt B AN4 washer 0 8 mm 0 032...

Page 99: ...sure that with the control column vertical the aileron trailing edge is aligned with wing trailing edge and that the aileron bellcrank is in the neutral position i e the inside arm the arm closest to...

Page 100: ...etc are implied for torqueing bolts nuts if applicable Refer to paragraph 1 5 for torque values CONSUMABLE MATERIAL REQUIRED ITEM QUANTITY NOTES 1 Orange paint As needed 2 Loctite 222 As needed Inspe...

Page 101: ...inspection panel s under the wing s 4 Ensure that the control sticks move freely left and right If the roll autopilot servo is attached it will create some resistance Without it attached the control s...

Page 102: ...to the pushrod 4 and lines up exactly with the edges of the inspection hatch Use a straight edge to help with alignment Figure 13 Aileron adjustment wing side 9 Tighten the lock nuts at both ends of...

Page 103: ...Page 85 14 Paint orange creep marks on the pushrod lock nuts 15 Ensure that no tools and or foreign materials remain in the wing and under the seats 16 Apply thread locking sealant to the inspection p...

Page 104: ...TITY NOTES 1 Orange paint As needed 2 Loctite 222 As needed Inspection panel screws 3 Loctite 243 As needed Servo mounting screws 4 Tie wraps As needed The above list is not necessarily a complete lis...

Page 105: ...the bolt 1 connecting the servo 2 control arm to the pushrod 4 Unscrew the screws retaining the connector 3 to the servo and disconnect it 5 Undo the screws 4 retaining the servo to the fuselage struc...

Page 106: ...cable does cannot chafe against airframe parts 2 Ensure the applicable aircraft control s is are free and does not bind with the servo installed 3 Follow any applicable procedures in the latest revisi...

Page 107: ...tube arm s and remove the pushrod INSTALLATION 1 Reverse the above procedure removal paying close attention to the following Inspect all bolts nuts and screws for damage Replace if necessary Do not re...

Page 108: ...ure 16 The flap control system is push pull type with a linking torque tube torsion bar An actuator motor is installed in the centre channel between the front seats It controls an arm attached to a to...

Page 109: ...REQUIRED ITEM QUANTITY NOTES 1 Orange paint As needed 2 Loctite 222 As needed Inspection panel screws Option2 only The above list is not necessarily a complete list of all material needed Refer to th...

Page 110: ...ers with the exception of lock washers for reassembly 1 Extend the flaps fully 2 Disconnect the bolt 1 attaching the flap pushrod 2 the flap 3 3 Support the flap and remove the bolts washers and lockn...

Page 111: ...f necessary Do not reuse lock nuts Fit new Tighten the lock nuts on the bolts through the flap hinges sufficiently observe the correct placement of washers refer to Figure 17 and note that the bolts a...

Page 112: ...t of washers refer to Figure 18 and note that the bolt is installed with its head facing the wingtip Figure 18 Flap pushrod to flap connection 2 Verify the flap for alignment and correct travel refer...

Page 113: ...1 Remove the flap inspection cover 1 from the underside of the wing 2 Support the flap and disconnect the bolt 2 connecting the flap pushrod 3 to the flap torque tube 4 control arm 3 Support the flap...

Page 114: ...hten the lock nut on the bolt through the flap pushrod rod end bearing sufficiently observe the correct placement of washers refer to Figure 19 and note that the bolt is installed with its head facing...

Page 115: ...so in accordance with national legislation This is the responsibility of the aircraft owner and any person who is to perform any maintenance on the aircraft PROCEDURE The procedure is identical for t...

Page 116: ...turning the pushrods 9 Paint orange creep marks on the pushrod lock nuts 10 Verify before flight correct travel for the flap refer to paragraph 1 13 11 Ensure that no foreign material or tools remain...

Page 117: ...nspection panel screws 3 Tie wraps As needed Actuator cable The above list is not necessarily a complete list of all material needed Refer to the Sling 4 construction manual AUTHORISED PERSONNEL Any p...

Page 118: ...actuator motor s signal cable plug Disconnect the plug Remove tie wraps where necessary 3 Remove the central console panel next to the front seat by loosening the button head screws retaining it 4 Ope...

Page 119: ...f washers refer to Figure 21 Figure 21 Flap actuator motor installation 2 Tie wrap the cable where necessary 3 Verify alignment and correct flap movement refer to paragraph 1 13 before closing up the...

Page 120: ...re with front and rear spars The elevator has a similar structure though with only a front spar Bearings are again as with all other control surface bearings inch sealed bearings Elevator horns carry...

Page 121: ...rol system Refer to Figure 23 The elevator control system is push pull type controlled from the cabin via the control columns Control is transmitted through a push pull rod and bellcrank arrangement A...

Page 122: ...NSUMABLE MATERIAL REQUIRED ITEM QUANTITY NOTES 1 Orange paint As needed The above list is not necessarily a complete list of all material needed Refer to the Sling 4 construction manual AUTHORISED PER...

Page 123: ...sconnect the elevator pushrod from the elevator control horn located inside the rear fuselage tail cone The pushrod rod end bearing is accessed through the two small round access holes on the left and...

Page 124: ...cessary Do not reuse lock nuts Fit new Tighten the lock nut on the bolt through the elevator pushrod rod end bearing sufficiently observe the correct placement of washers and note that the bolt is ins...

Page 125: ...one The bolt in the centre hinge is fitted with its head towards the larger clearance side of the elevator cut out Figure 25 Horizontal stabilizer to elevator hinge Tighten the lock nut on the bolt th...

Page 126: ...pplicable Refer to paragraph 1 5 for torque values CONSUMABLE MATERIAL REQUIRED ITEM QUANTITY NOTES 1 Orange paint As needed The above list is not necessarily a complete list of all material needed Re...

Page 127: ...e exception of lock washers for reassembly 1 Remove the vertical stabilizer Refer to paragraph 4 2 2 3 2 Disconnect the trim tab motor cable connection plug 1 3 Support the horizontal stabilizer and u...

Page 128: ...use lock nuts Fit new Tighten the lock nuts sufficiently observe the correct placement of washers refer to Figure 26 and note that the bolts are installed with the bolt heads head facing to the nose o...

Page 129: ...queing bolts nuts if applicable Refer to paragraph 1 5 for torque values CONSUMABLE MATERIAL REQUIRED ITEM QUANTITY NOTES 1 2 4 mm Heat shrink As needed 2 6 4 mm Heat shrink As needed 3 Solder As need...

Page 130: ...ack wire aircraft side to ease later reconnection 3 Remove the split pin from the trim tab pushrod connected to the motor push out the pin and washer and disconnect the pushrod from the servo 4 Unscre...

Page 131: ...the black and white wires on the aircraft side to the white wires on the trim motor side Activate the trim motor and observe the direction of travel If incorrect reverse the two wire connections White...

Page 132: ...to paragraph 1 5 for torque values CONSUMABLE MATERIAL REQUIRED ITEM QUANTITY NOTES 1 Orange paint As needed 2 Loctite 222 As needed Inspection panel screws The above list is not necessarily a complet...

Page 133: ...front panel Figure 27 Elevator adjustment 4 Hold the elevator in line with the horizontal stabilizer Put an inclinometer on it and zero the inclinometer 5 Undo the lock nuts and adjust pushrods 4 and...

Page 134: ...ISION 1 2 DATE 2014 11 10 DC MAM 001 X C 2 Page 116 9 Apply thread locking sealant to the inspection cover screws before fitment Do not over tighten 10 Verify correct travel and full and free movement...

Page 135: ...cessories sockets etc are implied for torqueing bolts nuts if applicable Refer to paragraph 1 5 for torque values CONSUMABLE MATERIAL REQUIRED ITEM QUANTITY NOTES 1 Split pin 1 The above list is not n...

Page 136: ...b horn 5 6 Adjust the eye bolt on the threaded rod temporarily reattach to the trim tab horn and measure the trim tab deflection downwards relative to the elevator upper surface use a protractor or me...

Page 137: ...TEM QUANTITY NOTES 1 Tie wraps As needed 2 Orange paint As needed 3 Loctite 243 As needed Servo mounting screws The above list is not necessarily a complete list of all material needed Refer to the Sl...

Page 138: ...to paragraph 4 3 2 2 2 Undo the bolt 1 connecting the control arm of the servo 2 to the pushrod 3 3 Undo the screws 4 retaining the servo to the bracket 5 Carefully pull the motor from the bracket It...

Page 139: ...curing screws If applicable secure the servo cable to the aircraft frame with tie wraps in the manner it was before removal using spacers as applicable Apply thread locking sealant to the servo mounti...

Page 140: ...ion of lock washers for reassembly REMOVAL 1 If the servo is not already disconnected removed undo the bolt and nut connecting the pushrod to the servo arm Undo the bolt and nut retaining the pushrod...

Page 141: ...win spars 5 with wrap around stressed skin panelling An attachment plate secures the vertical stabiliser s front spar to a bracket attached to the penultimate tail cone rib The rudder consists of a sp...

Page 142: ...terminate on two rudder pedal control horns Control stops limit movement of the pedal to cable attachment horns These horns are in turn attached to two adjustable pushrods which are attached to a con...

Page 143: ...if applicable Refer to paragraph 1 5 for torque values CONSUMABLE MATERIAL REQUIRED ITEM QUANTITY NOTES 1 Orange paint As needed The above list is not necessarily a complete list of all material need...

Page 144: ...dder control horn 2 2 Push and retain the rudder to one side to gain easier access to the rudder hinges 3 Support the rudder and loosen and remove the hinge bolts 4 Carefully and slowly pull the rudde...

Page 145: ...not reuse lock nuts lock washers or split pins as applicable Fit new Tighten the lock nuts on the bolts through the rudder hinges sufficiently observe the correct placement of washers refer to Figure...

Page 146: ...washers refer to Figure 33 and note that the bolts are installed with their heads facing upwards Figure 33 Rudder cable connection 2 Apply orange creep marks to the bolts nuts 3 Verify for alignment...

Page 147: ...er to paragraph 1 5 for torque values CONSUMABLE MATERIAL REQUIRED ITEM QUANTITY NOTES 1 Orange paint As needed 2 Loctite 222 As needed Fairing screws The above list is not necessarily a complete list...

Page 148: ...k washers as applicable for reassembly 1 Remove the rudder refer to paragraph 4 2 2 2 2 Remove the empennage to fuselage fairing 1 by unscrewing the button head screws retaining it 3 Remove the side p...

Page 149: ...he fuselage Note that the six bottom bolts in the rear support screw into anchor nuts attached to the fuselage Figure 34 Vertical stabilizer to fuselage connection 6 Carefully lift the vertical tail c...

Page 150: ...pins as applicable Fit new Observe the correct placement of washers refer to Figure 34 Tighten the lock nuts on the bolts retaining the vertical stabilizer sufficiently and note that the front mounti...

Page 151: ...ragraph 1 5 for torque values AUTHORISED PERSONNEL Any person performing maintenance of any kind on the aircraft or any component thereof must do so in accordance with national legislation This is the...

Page 152: ...Refer to paragraph 1 5 for torque values CONSUMABLE MATERIAL REQUIRED ITEM QUANTITY NOTES 1 Orange paint As needed 2 Loctite 222 As needed Inspection panels screws The above list is not necessarily a...

Page 153: ...ere must be a minimum of a 3 mm clearance to the bolt heads otherwise the rudder could get jammed 5 Undo the bolts 1 retaining the springs 2 to the fuselage remove the bolts and washers and free the e...

Page 154: ...der is straight the cable stops 4 are hard against the angled brackets Tighten the screws 11 Verify that with the rudder centred there is only a very slight tension on the rear part of the rudder cabl...

Page 155: ...gers carry through to the centre fuselage for strength and rigidity Supporting brackets for the vertical and horizontal stabilisers are attached to the rear formers at the tail section A cross brace w...

Page 156: ...SEAT REMOVAL AND INSTALLATION AUTHORISED PERSONNEL Any person performing maintenance of any kind on the aircraft or any component thereof must do so in accordance with national legislation This is the...

Page 157: ...cut out towards the nose of the aircraft to release operate the catch mechanism securing the seat to the aircraft 2 Slide the seat clear of its railings and carefully lift the seat clear of the aircra...

Page 158: ...ied by the above tool list accessories sockets etc are implied for torqueing bolts nuts if applicable Refer to paragraph 1 5 for torque values AUTHORISED PERSONNEL Any person performing maintenance of...

Page 159: ...t s to the fuselage 2 Undo the three Dzus fasteners passing through three eyelets 2 retaining the seat assembly to the baggage compartment floor Remove the seat PROCEDURE INSTALLATION 1 Inspect the Dz...

Page 160: ...dequate quantity of detergents suitable for polymethyl methacrylate Perspex Use a soft clean cloth sponge or deerskin 4 3 2 4 UPHOLSTERY CLEANING Upholstery and covers may be removed from the cockpit...

Page 161: ...ccommodates the engine mount engine and firewall forward firewall mounted equipment and engine cowling Refer to paragraph 14 for a schematic showing the equipment and their positions mounted on the fi...

Page 162: ...struts Suspension is provided by the flexibility within the struts which is attached transversely via a channel 3 designed for purpose in the lower centre fuselage Wheels 4 are cantilevered on the ma...

Page 163: ...tc are implied for torqueing bolts nuts if applicable Refer to paragraph 1 5 for torque values CONSUMABLE MATERIAL REQUIRED ITEM QUANTITY NOTES 1 Loctite 222 As needed Fairing screws 2 Loctite 243 As...

Page 164: ...e support plate and hold the inner and outer fairing sections to one another 2 Support the outside fairing half 3 and unfasten the retaining bolt 4 Remove the fairing half bolt and washers 5 PROCEDURE...

Page 165: ...by the above tool list accessories sockets etc are implied for torqueing bolts nuts if applicable Refer to paragraph 1 5 for torque values CONSUMABLE MATERIAL REQUIRED ITEM QUANTITY NOTES 1 Split pin...

Page 166: ...fasten the two bolts 1 holding the brake callipers together and remove the rear towards the wheel calliper assembly 2 which will come away in two parts 3 4 Remove the split pin 4 and pull out the spac...

Page 167: ...he wheel bearings Replace if necessary Grease the bearings before installation refer to paragraph 4 4 1 5 Tighten the brake caliper retaining nuts sufficiently Do not over tighten 2 To tighten the ret...

Page 168: ...mplied for torqueing bolts nuts if applicable Refer to paragraph 1 5 for torque values CONSUMABLE MATERIAL REQUIRED ITEM QUANTITY NOTES 1 Orange paint As needed 2 Loctite 577 As needed Brake line fitt...

Page 169: ...ption of lock washers for reassembly 1 Remove the wheel fairing refer to paragraph 4 4 1 1 2 Remove the wheel refer to paragraph 4 4 1 2 3 Ensure that the aircraft cannot roll move if only one wheel j...

Page 170: ...PROCEDURE INSTALLATION 1 Reverse the above procedure for reinstallation paying close attention to the following Inspect all bolts nuts and screws for damage Replace if necessary Do not reuse lock nut...

Page 171: ...DC MAM 001 X C 2 Page 153 A B C Main undercarriage strut Main wheel fairing mounting bracket Figure 37 Main wheel axle installation A AN4 22A bolt B AN4 washer 1 6 mm 0 063 C AN4 lock nut Nyloc Refer...

Page 172: ...by the above tool list accessories sockets etc are implied for torqueing bolts nuts if applicable Refer to paragraph 1 5 for torque values CONSUMABLE MATERIAL REQUIRED ITEM QUANTITY NOTES 1 Orange pai...

Page 173: ...done correctly the wheel could be out of balance after assembly 3 Deflate the tyre completely 4 Unfasten the bolts 1 retaining the brake disc 2 to the brake disc spacer 3 to separate the brake disc fr...

Page 174: ...ciently Take care not to catch the inner tube between the two hub halves 4 Inspect the o ring for damage Replace if necessary 5 Push the wheel to one side of the assembled wheel hub slip the o ring ov...

Page 175: ...needed Refer to the Sling 4 construction manual AUTHORISED PERSONNEL Any person performing maintenance of any kind on the aircraft or any component thereof must do so in accordance with national legi...

Page 176: ...eeded Undercarriage channel cover plate 4 3 2 mm x 8 mm Aluminium blind rivets multi grip As needed Undercarriage channel cover plate 5 Glue PRATLEY QUICKSET CLEAR As needed To glue brake line s into...

Page 177: ...4 4 1 3 Retain any bolts nuts except lock nuts spacers screws and washers with the exception of lock washers for reassembly 1 Hoist the aircraft onto supports If necessary balance the sideways moveme...

Page 178: ...e fuselage cover plates between the wings and the centre fuselage 8 Drill out the rivets retaining the main gear cover plate on the bottom aircraft fuselage 9 Support the main gear assembly and undo a...

Page 179: ...ct value refer to paragraph 1 5 2 observe the correct placement of washers refer to Figure 38 and note that the bolts are installed with the bolt heads head facing towards the rear of the aircraft App...

Page 180: ...rk 4 supporting an axle bolt 5 The front wheel 6 is not fitted with a braking mechanism Steering motion is transmitted from the rudder pedal control horns through two adjustable pushrods attached to t...

Page 181: ...Refer to the Sling 4 construction manual AUTHORISED PERSONNEL Any person performing maintenance of any kind on the aircraft or any component thereof must do so in accordance with national legislation...

Page 182: ...ool list accessories sockets etc are implied for torqueing bolts nuts if applicable Refer to paragraph 1 5 for torque values CONSUMABLE MATERIAL REQUIRED ITEM QUANTITY NOTES 1 Orange paint As needed T...

Page 183: ...f lock washers for reassembly 1 Remove the nose wheel fairing Refer to paragraph 4 4 2 1 2 Lift and support the front of aircraft in such a manner as to lift the nose wheel off the ground 3 Unfasten t...

Page 184: ...rve the correct placement of washers and bushes and the correct orientation of the nose wheel refer to Figure 40 Note that the lock nut faces the starboard side of the aircraft Figure 40 Nose wheel in...

Page 185: ...ool list accessories sockets etc are implied for torqueing bolts nuts if applicable Refer to paragraph 1 5 for torque values CONSUMABLE MATERIAL REQUIRED ITEM QUANTITY NOTES 1 Orange paint As needed T...

Page 186: ...ng mount assembly 6 Remove the valve cap 1 To separate the inner tube tyre and o ring from the hubs carefully pull the two hub halves apart taking care not to damage the valve stem as it pulls out of...

Page 187: ...one side of the assembled wheel hub slip the o ring over the other side of the assembled wheel hub and into place in the groove between the two hub halves 7 Inflate the tyre to approximately 2 5 Bar...

Page 188: ...efer to paragraph 1 5 for torque values AUTHORISED PERSONNEL Any person performing maintenance of any kind on the aircraft or any component thereof must do so in accordance with national legislation T...

Page 189: ...THORISED PERSONNEL The above list is not necessarily a complete list of all required tools and equipment needed A calibrated torque wrench with adequate range and the correct size as implied by the ab...

Page 190: ...ts 3 and washers on the bottom nose gear to engine mount attachment 4 Remove the two brackets 5 5 Support the nose gear loosen the bolts 6 and remove the bolts and washers the spacer 7 and the bearing...

Page 191: ...sary Do not reuse lock nuts Fit new Tighten the lock nuts sufficiently observe the correct placement of washers and bearings refer to Figure 42 and note that the bolts are installed with the bolt head...

Page 192: ...owling Refer to Figure 43 The engine cowling is made up of moulded fibreglass upper 1 and lower 2 parts Inspection panels 3 are located in the top cowling and are secured down by two Dzus fasteners Th...

Page 193: ...aragraph 1 5 for torque values AUTHORISED PERSONNEL Any person performing maintenance of any kind on the aircraft or any component thereof must do so in accordance with national legislation This is th...

Page 194: ...g along the upper edge of the firewall 3 Once all Dzus fasteners are loose remove the front and then side fasteners from their seating holes prior to removing those over the firewall BOTTOM COWL 1 Rem...

Page 195: ...N BOTTOM COWL 1 Reverse the above procedure removal to install the bottom cowl paying close attention to the following Ensure that the four catches next to the radiators are properly latched Tighten t...

Page 196: ...nchronisation no other carburettor adjustment is required Refer to the carburettor synchronization procedure in the latest revision of the Rotax 914 UL engine operator s and or maintenance manuals as...

Page 197: ...ensure that there is no residual oil in the crank case Oil is pumped back to the oil reservoir by performing the following procedure Master switch ignition switches OFF Remove the oil reservoir cap R...

Page 198: ...IRED ITEM QUANTITY NOTES 1 Safety wire As needed 2 Split pin 1 Only if in need of replacement The above list is not necessarily a complete list of all material needed Refer to the Sling 4 construction...

Page 199: ...ke pipe clamp 3 2 Loosen the clamp 4 securing the air filter to the air intake manifold turbocharger 5 opening 3 Loosen the clamp securing the air filter housing to the air intake pipe from the cowlin...

Page 200: ...closure is clean and dry on the inside Ensure that the seating area for the air filter enclosure on the air intake manifold is dry and clean Ensure that the air filter enclosure coupling to the air in...

Page 201: ...essories sockets etc are implied for torqueing bolts nuts if applicable Refer to paragraph 1 5 for torque values AUTHORISED PERSONNEL Any person performing maintenance of any kind on the aircraft or a...

Page 202: ...the air pipe 2 to the assembly shroud 3 3 Loosen and remove the ring clamp 4 retaining the exhaust pipe to the engine mount Undo and remove the bolts 5 retaining the assembly to the turbocharger Loos...

Page 203: ...lied by the above tool list accessories sockets etc are implied for torqueing bolts nuts if applicable Refer to paragraph 1 5 for torque values CONSUMABLE MATERIAL REQUIRED ITEM QUANTITY NOTES 1 Alumi...

Page 204: ...rs for reassembly 1 Remove the heat exchanger muffler assembly refer to paragraph 5 2 8 2 Drill out the line of rivets 1 clamping the shroud 2 plate together Loosen the clamps 3 clamping the shroud to...

Page 205: ...queing bolts nuts if applicable Refer to paragraph 1 5 for torque values AUTHORISED PERSONNEL Any person performing maintenance of any kind on the aircraft or any component thereof must do so in accor...

Page 206: ...ool list accessories sockets etc are implied for torqueing bolts nuts if applicable Refer to paragraph 1 5 for torque values CONSUMABLE MATERIAL REQUIRED ITEM QUANTITY NOTES 1 Loctite 577 As needed Oi...

Page 207: ...ds of couplings 1 and 2 and fit into the radiator 3 2 Slip a two ear clamp 4 over each pipe 5 slip the pipes over the couplings 2 and move the two ear clamps into position 3 Crimp the two ear plugs 4...

Page 208: ...1 Drain fluids as required 2 Remove the two ear clamps refer to paragraph 15 1 and pull the pipes from the fittings 3 Blank off oil pipes if to be unconnected for a substantial period of time to preve...

Page 209: ...plied for torqueing bolts nuts if applicable Refer to paragraph 1 5 for torque values CONSUMABLE MATERIAL REQUIRED ITEM QUANTITY NOTES 1 Safety wire As needed The above list is not necessarily a compl...

Page 210: ...the pipes 3 Use safety wire and secure the insulation blanket s around the pipe s 4 Inspect for security of attachment PROCEDURE DISCONNECTION 1 Drain fluid as required 2 Remove the safety wire securi...

Page 211: ...ize as implied by the above tool list accessories sockets etc are implied for torqueing bolts nuts if applicable Refer to paragraph 1 5 for torque values CONSUMABLE MATERIAL REQUIRED ITEM QUANTITY NOT...

Page 212: ...tation Retain any bolts clamps spacers screws and washers with the exception of lock washers for reassembly 1 Support the tail of the aircraft adequately before removing the engine 2 Remove the propel...

Page 213: ...ct the fuel return line from the engine Blank off to prevent drip and or spillage 8 Disconnect the throttle cables from the carburettors 9 Disconnect the choke cables from the carburettors 10 Disconne...

Page 214: ...t exchanger muffler assembly by undoing the clamp or at the firewall 16 Cut any all tie wraps securing pipes connected to the engine and electrical cabling connected to the engine to the engine mount...

Page 215: ...rudder pedals to the nose gear must be disconnected first and the aircraft must be supported adequately in preparation of the absence of the nose gear In this case the exhaust need not be disconnected...

Page 216: ...e installed with the bolt heads facing forward The bottom bolts are installed with the bolt heads facing backward Observe correct placement of washers spacers bushes and vibration dampers refer to Fig...

Page 217: ...ion of electrical wiring 6 Inspect for adequate operating fluid levels in engine Replenish if necessary 7 Inspect all cables electrical wiring and piping for security of attachment 8 If the waste gate...

Page 218: ...achment of the Bowden cable to the carburettor throttle control lever and adjustment refer to the latest revision edition of the Rotax 914 UL engine installation manual and maintenance manuals as appl...

Page 219: ...ling 2 construction manual AUTHORISED PERSONNEL Any person performing maintenance of any kind on the aircraft or any component thereof must do so in accordance with national legislation This is the re...

Page 220: ...ol list accessories sockets etc are implied for torqueing bolts nuts if applicable Refer to paragraph 1 5 for torque values CONSUMABLE MATERIAL REQUIRED ITEM QUANTITY NOTES 1 Split pin 1 2 Loctite 222...

Page 221: ...rocedure removal paying close attention to the following Do not re use split pin Fit new Inspect castle nut and bolt for damage Replace if necessary 2 Adjust the throttle lever friction refer to parag...

Page 222: ...on 5 3 1 GENERAL MAINTENANCE AND SERVICE Refer to and comply with the latest revision of the propeller operator s manual for service requirements and procedures 5 3 2 PROPELLER HUB AND PROPELLER EXTEN...

Page 223: ...adequate range and the correct size as implied by the above tool list accessories sockets etc are implied for torqueing bolts nuts if applicable Refer to paragraph 1 5 for torque values AUTHORISED PER...

Page 224: ...the screws 1 retaining the spinner 2 to the spinner bulkhead 3 PROCEDURE INSTALLATION 1 Reverse the above procedure removal to install the spinner paying close attention to the following Inspect all b...

Page 225: ...TED DIRECTLY TO ENGINE FLANGE LUGS SLIP RING DISC OR EXTERNAL ALTERNATOR DRIVE PULLEY FITTED BETWEEN ENGINE FLANGE AND PROPELLER EXTENSION M8 x 40 mm hex bolt Class 8 8 Apply thread locking sealant Lo...

Page 226: ...ied for torqueing bolts nuts if applicable Refer to paragraph 1 5 for torque values CONSUMABLE MATERIAL REQUIRED ITEM QUANTITY NOTES 1 Orange paint As needed 2 Loctite 243 As needed Bolts connecting p...

Page 227: ...curing the propeller extension 2 to the engine flange 3 2 Slowly move the propeller assembly away from the engine flange until the signal wire connections 4 are exposed Disconnect the signal wires 3 A...

Page 228: ...the spinner dome for security of attachment Inspect the balance weight bolt nut for security of attachment Carefully clean and dry the engine flange and propeller extension Ensure that no oil traces a...

Page 229: ...during the installation procedure Apply electrical power and operate the propeller controls to verify correct operation 4 Before flight start and let the engine run for a few minutes operate the prop...

Page 230: ...ller extension 2 2 Carefully and slowly pull the propeller away from the propeller extension 2 until the signal wire connectors are exposed Disconnect the wires REMOVING AT ENGINE FLANGE SIDE WITH PRO...

Page 231: ...efore doing so use coloured stickers or paint to mark the connection of the coloured signal wires to the disc terminals connections or place an alignment mark on the propeller extension and slip ring...

Page 232: ...any signs of damage Inspect the spinner dome for security of attachment Inspect the balance weight bolt nut for security of attachment Carefully clean and dry the engine flange propeller extension and...

Page 233: ...r and before flight inspect for security of attachment of the propeller correct and secure attachment of the signal wires and for any damage which may have been incurred during the installation proced...

Page 234: ...LATION WITH EXTERNAL ALTERNATOR FITTED The procedure is in general the same as that for the standard installation Note that a longer bolt is used to secure the propeller extension to the engine flange...

Page 235: ...ories sockets etc are implied for torqueing bolts nuts if applicable Refer to paragraph 1 5 for torque values CONSUMABLE MATERIAL REQUIRED ITEM QUANTITY NOTES 1 Orange paint As needed 2 Loctite 222 As...

Page 236: ...ion 3 and remove the propeller and spinner bulkhead 4 For further disassembly of the propeller assembly 2 refer to the latest revision of the propeller manufacturer operator s manual for the required...

Page 237: ...assembly before tightening the bolts Observe washer placement refer to Figure 48 Torque the bolts securing the propeller assembly to the propeller extension to the correct value refer to paragraph 1 5...

Page 238: ...ated panels The fuel outlet for each tank is located at the lowest point of the inboard sidewall of the tank A B A Left fuel tank F Rotax 914 UL engine B Right fuel tank G Fuel flow sensor C Fuel filt...

Page 239: ...plits into two separate branches one for each carburettor A fuel pressure transducer H is connected to one fuel pipe branch and is connected to the EFIS via the RDAC unit A fuel flow transducer G is c...

Page 240: ...ely 13 mm 8 mm 14 5 mm approximately 15 mm When tie wrapping fuel pipes to the engine mount other pipes or the aircraft structure to aid in routing security of attachment care should be taken that the...

Page 241: ...if applicable Refer to paragraph 1 5 for torque values CONSUMABLE MATERIAL REQUIRED ITEM QUANTITY NOTES 1 Orange paint As needed 2 Loctite 222 As needed Inspection panel screws The above list is not...

Page 242: ...ilters from the fuel lines and drain any remaining fuel in the lines into a container Replace the filters Note that the fuel filters are installed with the 90 elbow facing the nose of the aircraft 6 T...

Page 243: ...ueing bolts nuts if applicable Refer to paragraph 1 5 for torque values CONSUMABLE MATERIAL REQUIRED ITEM QUANTITY NOTES 1 Loctite 222 As needed Inspection panel screws and four fuel selector unit ret...

Page 244: ...he selector lever 3 to the selector valve unit Loosen the screw and remove slide off the lever 3 Loosen the four button head screws 4 retaining the plate 5 to the selector unit Push the unit towards t...

Page 245: ...e only lines up one way with the holes in the selector unit aiding the correct orientation of the unit on installation For fuel selector port allocation and fuel hose fitting orientation refer to Figu...

Page 246: ...ose fitting threads The above list is not necessarily a complete list of all material needed Refer to the Sling 4 construction manual AUTHORISED PERSONNEL Any person performing maintenance of any kind...

Page 247: ...ALLOCATION A 8 mm From starboard tank feed B 8 mm To engine pumps feed C 8 mm From port tank feed D 6 mm To starboard tank return E 8 mm From engine return F 6 mm To port tank return A B C D E F RETUR...

Page 248: ...BLE MATERIAL REQUIRED ITEM QUANTITY NOTES 1 Safety wire and tie wraps 8 mmx 12 mm x 5 mm seal draft rubber strip As needed 2 Two ear clamps 15 mm 2 3 Tie wraps clear tubing As needed The above list is...

Page 249: ...h the exception of lock washers for reassembly 1 Fuel selector in OFF position 2 Remove the cowlings refer to paragraph 5 1 1 3 Undo the button head screws 1 retaining the fuel pump assembly cover 2 s...

Page 250: ...ull the fuel hoses from the pump frame connections 6 Drain excess fuel in the lines into a container Blank off any fuel lines to be left open for an extended time to avoid drip spillage and contaminat...

Page 251: ...DOCUMENT No REVISION 1 2 DATE 2014 11 10 DC MAM 001 X C 2 Page 233 7 Undo the two clamps 11 retaining the pump assembly to the firewall bracket and remove the assembly Fuel Pump 11...

Page 252: ...over button head screws excessively Ensure that the wires marked GND is connected to the terminals marked on the fuel pump connector blocks and that the wires marked MAIN PUMP and AUX PUMP are connect...

Page 253: ...bracket 2 before fitting the assembly to the firewall 3 Before flight perform an engine ground run and verify correct operation of the fuel pumps and correct fuel flow and pressure After the engine ru...

Page 254: ...es sockets etc are implied for torqueing bolts nuts if applicable Refer to paragraph 1 5 for torque values CONSUMABLE MATERIAL REQUIRED ITEM QUANTITY NOTES 1 Two ear clamps 22 mm 2 Per pump 2 Two ear...

Page 255: ...oses 2 connecting the fuel pump to the surrounding pipe framework 3 and remove the pump 4 from the pipe frame PROCEDURE INSTALLATION 1 Reverse the above procedure removal to install a fuel pump into t...

Page 256: ...nstruction manual AUTHORISED PERSONNEL Any person performing maintenance of any kind on the aircraft or any component thereof must do so in accordance with national legislation This is the responsibil...

Page 257: ...ly a complete list of all material needed Refer to the Sling 4 construction manual AUTHORISED PERSONNEL Any person performing maintenance of any kind on the aircraft or any component thereof must do s...

Page 258: ...ed completely by removing unscrewing the drain PROCEDURE REMOVAL 1 Unscrew the fuel drain from the wing Do not retain fibre washer 2 Drain fuel into suitable container PROCEDURE INSTALLATION 1 Observe...

Page 259: ...fer to paragraph 1 5 for torque values CONSUMABLE MATERIAL REQUIRED ITEM QUANTITY NOTES 1 Loctite 222 As needed Inspection panel 2 Loctite 577 As needed Fuel tank outlet return line couplings The abov...

Page 260: ...s of the wing s to access the fuel tank end rib s 2 Drain the fuel tank completely by removing the fuel drain refer to paragraph 6 8 3 Loosen the fuel line couplings 1 Move the fuel pipes out of the w...

Page 261: ...tted with the edge with the single notch facing the top of the wing and the edge with two notches facing the rear of the wing Apply thread locking sealant to the fuel line couplings before fitting and...

Page 262: ...e 57 Fuel sender installation into fuel tank A M4 x 16 mm hex head stainless steel bolt B M4 thin washer stainless steel plated C M4 Fibre washer D Sender sender bracket mounting plate E Cork mounting...

Page 263: ...fer to paragraph 1 5 for torque values CONSUMABLE MATERIAL REQUIRED ITEM QUANTITY NOTES 1 Fuel fuel tank sealant As needed Refer to paragraph 1 4 2 100 x 2 5 mm tie wrap 1 The above list is not necess...

Page 264: ...e to the terminal stud cut the tie wrap and unwind the signal wire from the bracket 2 3 Undo the screws 3 retaining the sensor 4 to the bracket 2 and remove the sensor 4 Mark the position of the float...

Page 265: ...ntre of bent part of arm on the arm as was over the centre of the spindle of the removed sensor over the centre of the sensor spindle refer to Figure 58 Use the marks made during disassembly on the fl...

Page 266: ...The range measured should be between 0 and 200 approximately 8 to 192 Measuring an open circuit with the float arm flush against any one of the stops indicates that the sensor wiper has moved of the...

Page 267: ...list accessories sockets etc are implied for torqueing bolts nuts if applicable Refer to paragraph 1 5 for torque values AUTHORISED PERSONNEL Any person performing maintenance of any kind on the aircr...

Page 268: ...angled mirror tool and small pencil flashlight light source to inspect the finger strainer on the fuel pick up Under no circumstances use a match flame or cigarette lighter flame or an open bulb to pr...

Page 269: ...he required minimum instrumentation together with typical back up and additional instrumentation supplied with the aircraft The instrument panel in any particular aircraft may differ from that illustr...

Page 270: ...nual propeller pitch control switch 3 Fuel pump switches 20 Ballistic parachute deployment handle 4 Charge warning light 21 Fuel selector valve handle 5 TCU boost warning light 22 Switches EFIS EFIS b...

Page 271: ...bolts nuts if applicable Refer to paragraph 1 5 for torque values CONSUMABLE MATERIAL REQUIRED ITEM QUANTITY NOTES 1 Loctite 222 As needed Instrument panel retaining screws The above list is not neces...

Page 272: ...ting screws before fitment INSTRUMENTS 1 Before installing any electrical instrument ensure that the master switch is OFF 2 When installing instruments follow the recommendations below Do not over tig...

Page 273: ...rpose of determining aircraft angle of attack displayed on the EFIS Flexible plumbing connects the pitot tube and static ports to the pressure instruments being an analogue airspeed indicator altimete...

Page 274: ...so in accordance with national legislation This is the responsibility of the aircraft owner and any person who is to perform any maintenance on the aircraft PROCEDURE 1 Ensure that all instruments th...

Page 275: ...cordance with national legislation This is the responsibility of the aircraft owner and any person who is to perform any maintenance on the aircraft PROCEDURE 1 Ensure that all instruments that utilis...

Page 276: ...onnect the pneumatic tubes lines from the applicable instrument s 3 Blow low pressure air into the tubes lines in the direction of the port and never towards the instrument to clear any possible obstr...

Page 277: ...orqueing bolts nuts if applicable Refer to paragraph 1 5 for torque values CONSUMABLE MATERIAL REQUIRED ITEM QUANTITY NOTES 1 Adhesive lined foam As needed If adhesive foam was removed with removal of...

Page 278: ...sensor to the plate 4 and remove the unit 4 Alternatively mark the location of the sensor foam mounting block s footprint for later replacement in the same location and tear the unit attached to plate...

Page 279: ...tools and equipment needed A calibrated torque wrench with adequate range and the correct size as implied by the above tool list accessories sockets etc are implied for torqueing bolts nuts if applica...

Page 280: ...connections information for each socket headphone position 1 Reverse the above procedure removal for installation paying close attention to the following Observe the correct washer insulator placement...

Page 281: ...if applicable Refer to paragraph 1 5 for torque values CONSUMABLE MATERIAL REQUIRED ITEM QUANTITY NOTES 1 Loctite 222 As needed Antenna mounting screws 2 Clear silicone As needed The above list is not...

Page 282: ...LATION 1 Reverse the above procedure removal paying close attention to the following Inspect the mounting screws for damage before fitting Replace if necessary Ensure that the base of the antenna make...

Page 283: ...mplied for torqueing bolts nuts if applicable Refer to paragraph 1 5 for torque values CONSUMABLE MATERIAL REQUIRED ITEM QUANTITY NOTES 1 Tie wraps As needed Installation The above list is not necessa...

Page 284: ...Cut the tie wraps 1 retaining the antenna 2 to the bracket 3 Cut any tie wraps securing the cable e g to other cables and pull the cable through the rubber grommet 4 in the mounting bracket PROCEDURE...

Page 285: ...vents are found on the left and right sides of the instrument panel each with a shut off valve that can be directed through 180 degrees The heating system is comprised of a heat exchanger on the exhau...

Page 286: ...master cylinder and two disc brakes assemblies An intercept valve activates the parking brake Braking action is through a lever located on the cabin tunnel between seats The hydraulic circuit intercep...

Page 287: ...ories sockets etc are implied for torqueing bolts nuts if applicable Refer to paragraph 1 5 for torque values CONSUMABLE MATERIAL REQUIRED ITEM QUANTITY NOTES 1 Brake fluid As needed Refer to paragrap...

Page 288: ...p feeding from a reservoir filled with the correct brake fluid 4 Use the pump to pump brake fluid until it reaches the bottom of the brake fluid reservoir Tighten the nipple and remove the pipe 5 Top...

Page 289: ...ndependently 1 Pull the brake lever to pressurise the system 2 Loosen the brake calliper nipple to allow the fluid to spurt out 3 Tighten the nipple and release the brake lever 4 Repeat steps 1 to 3 u...

Page 290: ...eof must do so in accordance with national legislation This is the responsibility of the aircraft owner and any person who is to perform any maintenance on the aircraft PROCEDURE REMOVAL Retain any bo...

Page 291: ...t is not necessarily a complete list of all required tools and equipment needed A calibrated torque wrench with adequate range and the correct size as implied by the above tool list accessories socket...

Page 292: ...tached to the strut by the axle mounting bolts Undo the four axle bolts and nuts 5 to release the spat mounting plate 2 Remove the spat mounting plate 3 To obtain the second brake lining mounting plat...

Page 293: ...use Inspect for damage and the formation of cracks which may have resulted from the riveting process Note that the caliper is fitted into plate 1 such that the grooved sides of the brass fixtures 3 in...

Page 294: ...iBOX installation manual Figure 64 Electrical system overview A single phase alternator integral to the engine connected to a regulator rectifier mounted in the cabin supplies DC power to the main bus...

Page 295: ...adio 7 Elevator and Aileron autopilot servos turbocharger waste gate servo 8 Flap actuator motor 9 Flap controller 10 Ignition systems 11 Landing and taxi light switches 12 Landing and taxi lights 13...

Page 296: ...queing bolts nuts if applicable Refer to paragraph 1 5 for torque values AUTHORISED PERSONNEL Any person performing maintenance of any kind on the aircraft or any component thereof must do so in accor...

Page 297: ...er switch OFF All other switches OFF 2 Thoroughly clean and dry the inside and outside of the battery bracket 3 Insert the battery into the bracket Ensure that the battery is inserted the right way ro...

Page 298: ...ble Refer to paragraph 1 5 for torque values CONSUMABLE MATERIAL REQUIRED ITEM QUANTITY NOTES 1 Tie wraps 2 2 Loctite 222 As needed Instrument panel retaining screws The above list is not necessarily...

Page 299: ...RE INSTALLATION 1 Reverse the above procedure removal paying close attention to the following Inspect all bolts nuts and screws for damage Replace if necessary The battery is installed with its positi...

Page 300: ...plicable Refer to paragraph 1 5 for torque values CONSUMABLE MATERIAL REQUIRED ITEM QUANTITY NOTES 1 Loctite 222 As needed Instrument panel retaining screws The above list is not necessarily a complet...

Page 301: ...sher 4 from the instrument panel 4 Slip the new washer 4 supplied with the circuit breaker over the circuit breaker threaded stub and inset the circuit breaker through the instrument panel Ensure that...

Page 302: ...d the instrument panel when fitted 5 Ensure that the switch is inserted correct side up Align the switch body vertically and secure with the front nut 3 Do not over tighten PLEASE NOTE THAT IN CASES W...

Page 303: ...as implied by the above tool list accessories sockets etc are implied for torqueing bolts nuts if applicable Refer to paragraph 1 5 for torque values AUTHORISED PERSONNEL Any person performing mainte...

Page 304: ...assembly 1 Master switch OFF 2 Disconnect the connection plug 1 from the rectifier 2 3 Undo the bolts 3 retaining the rectifier and the ground wire 4 to the firewall Remove the rectifier PROCEDURE INS...

Page 305: ...ding and taxi lights Strobe light 11 1 NAVIGATION LIGHTS Combined navigation and strobe lights are installed on the wing tips All navigation lights are controlled by a single switch located on the ins...

Page 306: ...1 5 for torque values CONSUMABLE MATERIAL REQUIRED ITEM QUANTITY NOTES 1 Loctite 222 As needed Navigation light retaining screws The above list is not necessarily a complete list of all material need...

Page 307: ...move the light away from the wingtip until the wire connection plugs are revealed Disconnect Retain the rubber backing for reassembly PROCEDURE INSTALLATION 1 Reverse the above procedure for reinstall...

Page 308: ...ue wrench with adequate range and the correct size as implied by the above tool list accessories sockets etc are implied for torqueing bolts nuts if applicable Refer to paragraph 1 5 for torque values...

Page 309: ...xi light switches in OFF positions 2 Undo the screws retaining the clear lens to the wing and remove the lens 3 Undo the button head screws 1 which secure the taxi 2 or landing 3 light and remove toge...

Page 310: ...lf facing towards the top of the wing Figure 65 Landing and taxi light installation All connector connections must be covered by heat shrink see below Slide heat shrink over the wires before connectin...

Page 311: ...essories sockets etc are implied for torqueing bolts nuts if applicable Refer to paragraph 1 5 for torque values CONSUMABLE MATERIAL REQUIRED ITEM QUANTITY NOTES 1 Tie wraps As needed The above list i...

Page 312: ...e light to the angled plates 2 front plate 3 and ground wire 4 Cut tie wraps Remove the light PROCEDURE ASSEMBLY 1 Reverse the above procedure disassembly paying careful attention to the following Obs...

Page 313: ...sockets etc are implied for torqueing bolts nuts if applicable Refer to paragraph 1 5 for torque values AUTHORISED PERSONNEL Any person performing maintenance of any kind on the aircraft or any compo...

Page 314: ...c are implied for torqueing bolts nuts if applicable Refer to paragraph 1 5 for torque values CONSUMABLE MATERIAL REQUIRED ITEM QUANTITY NOTES 1 Loctite 222 As needed Strobe light retaining screws The...

Page 315: ...rom the rudder until the wire connection plugs are revealed Disconnect PROCEDURE INSTALLATION 1 Reverse the above procedure for reinstallation paying close attention to the following Inspect all bolts...

Page 316: ...tem The system is designed to enable the pilot or passenger to deploy the parachute in case of emergency in such a manner that the aircraft structure is carried under the parachute to the ground on th...

Page 317: ...nd the correct size as implied by the above tool list accessories sockets etc are implied for torqueing bolts nuts if applicable Refer to paragraph 1 5 for torque values CONSUMABLE MATERIAL REQUIRED I...

Page 318: ...do the bolt retaining the lap strap to the fuselage and remove the belt strap 5 Drill out the rivets retaining the side cover plate to the fuselage and remove the cover plate to gain access to the ine...

Page 319: ...DURE INSTALLATION 1 Reverse the above procedure for reinstallation paying close attention to the following Inspect all bolts nuts and screws for damage Replace if necessary Do not reuse lock nuts Fit...

Page 320: ...y component thereof must do so in accordance with national legislation This is the responsibility of the aircraft owner and any person who is to perform any maintenance on the aircraft PROCEDURE REMOV...

Page 321: ...DATE 2014 11 10 DC MAM 001 X C 2 Page 303 13 APPENDIX A AVIONICS AND ELECTRICAL SYSTEM WIRING DIAGRAMS 13 1 CHARGE AND START SYSTEM FUEL PUMPS WIRING DIAGRAM Figure 66 Charge and start system wiring...

Page 322: ...DOCUMENT No REVISION 1 2 DATE 2014 11 10 DC MAM 001 X C 2 Page 304 13 2 SWITCHES AND CIRCUIT BREAKERS WIRING DIAGRAM Figure 67 Switches and circuit breakers wiring diagram...

Page 323: ...DOCUMENT No REVISION 1 2 DATE 2014 11 10 DC MAM 001 X C 2 Page 305 13 3 EXTERNAL ALTERNATOR WIRING DIAGRAM Figure 68 External alternator wiring diagram...

Page 324: ...UMENT No REVISION 1 2 DATE 2014 11 10 DC MAM 001 X C 2 Page 306 13 4 FLAP SYSTEM WIRING DIAGRAM 13 4 1 MGL SP10 FLAP WITH 4 POSITION ROTARY SWITCH Figure 69 MGL SP 10 Flap trim controller wiring diagr...

Page 325: ...DOCUMENT No REVISION 1 2 DATE 2014 11 10 DC MAM 001 X C 2 Page 307 13 4 2 INOTEC Figure 70 Flap system wiring diagram INOTEC...

Page 326: ...DOCUMENT No REVISION 1 2 DATE 2014 11 10 DC MAM 001 X C 2 Page 308 13 4 3 E FLAPS Figure 71 Flap system wiring diagram E Flaps...

Page 327: ...11 10 DC MAM 001 X C 2 Page 309 13 5 ELEVATOR TRIM MOTOR WIRING DIAGRAM 13 5 1 DUAL STICK TRIM Figure 72 Elevator trim motor wiring diagram dual control sticks RAY ALLEN G205 TYPE STICK GRIP SWITCH 1...

Page 328: ...ION 1 2 DATE 2014 11 10 DC MAM 001 X C 2 Page 310 13 5 2 SINGLE STICK TRIM Figure 73 Elevator trim motor wiring diagram single control stick RAY ALLEN G205 TYPE STICK GRIP SWITCH 1 SWITCH 3 SWITCH 4 S...

Page 329: ...DOCUMENT No REVISION 1 2 DATE 2014 11 10 DC MAM 001 X C 2 Page 311 13 6 EFIS SYSTEM COMMUNICATIONS BUS LAYOUT Figure 74 EFIS system communications bus layout...

Page 330: ...DOCUMENT No REVISION 1 2 DATE 2014 11 10 DC MAM 001 X C 2 Page 312 13 7 AHRS AND COMPASS WIRING DIAGRAM Figure 75 AHRS and compass wiring diagram...

Page 331: ...DOCUMENT No REVISION 1 2 DATE 2014 11 10 DC MAM 001 X C 2 Page 313 13 8 AUTOPILOT ROLL SERVO AND PITCH SERVO WIRING DIAGRAM Figure 76 Autopilot roll servo and pitch servo wiring diagram...

Page 332: ...DOCUMENT No REVISION 1 2 DATE 2014 11 10 DC MAM 001 X C 2 Page 314 13 9 EFIS BACK UP BATTERY CHARGE CIRCUIT Figure 77 EFIS back up battery charge circuit...

Page 333: ...REVISION 1 2 DATE 2014 11 10 DC MAM 001 X C 2 Page 315 13 10 HEADPHONE RADIO INTERCOM WIRING DIAGRAM 13 10 1 GARMIN GTR 200 RADIO Figure 78 Headphone radio GARMIN GTR 200 intercom wiring diagram INTER...

Page 334: ...DOCUMENT No REVISION 1 2 DATE 2014 11 10 DC MAM 001 X C 2 Page 316 13 10 2 GARMIN GTR 225 RADIO Figure 79 Headphone radio GARMIN GTR 225 intercom wiring diagram Circuit breaker on instrument panel...

Page 335: ...DOCUMENT No REVISION 1 2 DATE 2014 11 10 DC MAM 001 X C 2 Page 317 13 11 POSITION NAVIGATION LIGHTS WIRING DIAGRAM Figure 80 Position navigation lights wiring diagram...

Page 336: ...DOCUMENT No REVISION 1 2 DATE 2014 11 10 DC MAM 001 X C 2 Page 318 13 12 RDAC TO OIL PRESSURE TRANSDUCER WIRING DIAGRAM Figure 81 RDAC to oil pressure transducer wiring diagram and settings...

Page 337: ...DOCUMENT No REVISION 1 2 DATE 2014 11 10 DC MAM 001 X C 2 Page 319 13 13 DUAL EFIS INSTALLATION WIRING DIAGRAM Figure 82 Dual EFIS installation...

Page 338: ...DOCUMENT No REVISION 1 2 DATE 2014 11 10 DC MAM 001 X C 2 Page 320 13 14 TRANSPONDER WIRING DIAGRAM 13 14 1 TRIG TT21 TRANSPONDER WIRING DIAGRAM Figure 83 TRIG TT21 transponder wiring diagram XPOND...

Page 339: ...DOCUMENT No REVISION 1 2 DATE 2014 11 10 DC MAM 001 X C 2 Page 321 13 14 2 SANDIA STX 165R TRANSPONDER WIRING DIAGRAM Figure 84 SANDIA STX 165R transponder wiring diagram XPOND MAIN BUS...

Page 340: ...ONTROLLER ELECTRICAL WIRING INFORMATION Refer to the latest revision of the Airmaster AP3 Series and AP4 Series Constant Speed Propeller Operator s Manual 13 18 ROTAX 914 UL ENGINE ELECTRICAL WIRING I...

Page 341: ...ED EQUIPMENT Figure 85 Firewall mounted equipment 1 Oil reservoir 7 TCU 2 Fuel pump assembly 8 GPS antenna 3 Cabin air inlet splitter box 9 Main battery 4 Turbocharger waste gate servo 10 Coolant over...

Page 342: ...oupling length to be adjusted in situ by turning the rod 1 just as one would a turnbuckle Loosen the two lock nuts 2 and adjust the pushrod Once the desired length has been set the pushrod is locked b...

Page 343: ...325 15 3 FITTING OF FIRE RESISTANT SLEEVING Fire resistant sleeving fitted over fuel oil hoses which are secured to fittings couplings with two ear clamps must be secured with safety wire adjacent to...

Page 344: ...m 0 063 AN960 416 AN4 washer 0 8 mm 0 032 AN960 416L AN5 washer 1 6 mm 0 063 AN960 516 AN5 washer 0 8 mm 0 032 AN960 516L AN6 washer 1 6 mm 0 063 AN960 616 AN6 washer 0 8 mm 0 032 AN960 616L AN7 washe...

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The Airplane Factory Sling 4, Maintenance Manual

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