Sling 4 TSi Maintenance Manual Rev 1.3

4 SERIAL NO :
REGISTRATION :
DC-MAM-001-X-F-1.3
MAINTENANCE MANUAL
DATE: 13 DECEMBER 2023 REVISION 1.3
SLING AIRCRAFT | HANGAR 8 TEDDERFIELD AIR PARK, JHB SOUTH,EIKENHOF, 1872

SOUTH AFRICA PO BOX 308, EIKENHOF, 1872, SOUTH AFRICA
Phone :+27 11 948 9898 | Information :technical@slingaircraft.com
___________________________________________
GENERAL INFORMATION
Equipment fitted to the aircraft must be done so in accordance to the requirements of the national regulations of
the country of registration.
PLEASE INFORM SLING AIRCRAFT (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 TO THE EXTENT SAID AIRCRAFT CORRESPOND WITH THE
PRODUCTION STANDARD.
NOTICE
THIS EDITION OF THIS MANUAL IS APPLICABLE TO AIRCRAFT REGISTERED IN THE REPUBLIC OF
SOUTH AFRICA. DEFINITIONS ARE ACCORDINGLY CONSISTENT WITH RSA REGULATIONS ONLY.
DOCUMENT No.: REVISION: 1.3 DATE: 2023/12/13

DC-MAM-001-X-F-1.3 Page ii
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PRESENTATION
This manual is divided into the following sections:
SECTION 1 – GENERAL: This section provides general information, capacities and general procedures and
specifications.
SECTION 2 – INSPECTION: This section provides information regarding general inspection considerations,
inspection schedules and inspection procedures.
SECTION 3 – SERVICE: This section provides information regarding general service considerations and service
schedules.
SECTION 4 – AIRFRAME: This section describes the various structures, substructures, systems and
subsystems comprising the aircraft, and describes maintenance procedures applicable to these structures,
substructures, systems and subsystems, as the case may be.
SECTION 5 – POWER PLANT: This section provides general information, capacities and general procedures
and specifications.
SECTION 6 – AVIONICS AND INSTRUMENTS: This section provides information regarding general inspection
considerations, inspection schedules and inspection procedures.
SECTION 7 – UTILITY SYSTEMS: This section provides information regarding general service considerations
and service schedules.
APPENDICES
Provides useful additional information.

DC-MAM-001-X-F-1.3 Page iii
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REVISION RECORD
REVISION
DATE DESCRIPTION OF CHANGE PARAGRAPHS SIGN
NUMBER
0.0 2018/07/20 Original document N/A
1.0 2020/12/08 1. Updated aileron and elevator 1.13
control surface deflections. 1.2.3
2. Updated standard weights. 1.19
3. Updated contact information. 1.21.1
4. Added operation of flaps with 5.4
spring loaded toggle switch.
5. Updated fuel system schematic.
1.1 2021/07/02 1. Updating of lubrication timeline 1.4 & 3.2
and components needing 4.4.1.1 & 4.4.2.1
lubrication.
2. Updated information on wheel
fairings.
1.2 2023/08/30 1. Updated landing gear 2.5.1
maintenance checkpoint 4.3. 2.5.2
2. Added 2000-hour service
checklist.
1.3 2023-12-13 Inclusion of 916 iS engine and MT 6 1.3.1, 1.3.2,
propeller. 1.3.3, 1.5.2,
1.21.1, 5.2.1. to
5.2.4

DC-MAM-001-X-F-1.3 Page iv
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LIST OF ACRONYMS
AC Alternating Current
A/C Aircraft
A/H Ampere Hour
AHRS Attitude and Heading Reference System
AKI Anti-Knock Index
AOA Angle Of Attack
API American Petroleum Institute
ATF Authority To Fly
ATF Automatic Transmission Fluid
AUX Auxiliary
AVGAS Aviation Gasoline
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 System
EXT External
FAA Federal Aviation Authority
GLS GPS Landing System
GmbH Gesellschaft mit beschränkter Haftung (company with limited liability).
GND Ground
GPS Global Positioning System
ID Inner Diameter
IGN Ignition
KIAS Indicated airspeed (Knots)
LAN Local Area Network
MAC Mean Aerodynamic Chord
MIC Microphone
MOGAS Motorcar Gasoline
NC Normally Closed

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NGL Normal Ground Line
NO Normally Open
NRV Non-Return Valve
PASS Passenger
POH Pilot Operating Handbook
PTT Push To Talk
Setting on altimeter subscale equal to ambient atmospheric pressure at a
QFE
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 Receive
SCN Screen (wire)
SPST Single Pole Single Throw (switch contact(s) configuration)
SW Switch
TCU Turbocharger Control Unit
TX Transmit
US - United States (of America)
USB - Universal Serial Bus
VHF Very High Frequency
VMC - Visual Meteorological Conditions
VSI - Vertical Speed Indicator

DC-MAM-001-X-F-1.3 Page vi
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REFERENCED DOCUMENTS
The following documents are referred to / mentioned in this document and should be read in conjunction with
this document, as applicable.
DOCUMENT / TITLE
FAA Advisory Circular AC43.13-1B: Acceptable Methods, Techniques and Practices - Aircraft
1
Inspection and Repair.
2 AP3 Series and AP4 Series Constant Speed Propeller Operator’s Manual.
3 Rotax Service Information SI-915 I-001.
4 Maintenance Manual (Line Maintenance) for Rotax Engine Type 915 i A Series.
5 Operators Manual for Rotax Engine Type 915 i A Series (Reference no. OM-915).
6 Installation Manual for Rotax Engine Type 915 i A Series (Reference no, IM-915).
7 Garmin G3X installation manual
8 ASTM D7547: Standard Specification for Hydrocarbon Unleaded Aviation Gasoline.
9 ASTM D910: Standard Specification for Aviation Gasolines.
10 ASTM D4814: Standard Specification for Automotive Spark-Ignition Engine Fuel.
11 DIN EN 228: Automotive Fuels - Unleaded Petrol - Requirements and Test Methods.
MIL-G-3278: Military Specification - Grease, Aircraft and Instrument (For Low and High
12
Temperatures).
MIL-C-16173: Military Specification – Corrosion Preventive Compound, Solvent Cutback, Cold
13
Application.
14 MIL-C11796: Military Specification - Corrosion Preventive Compound, Petrolatum, Hot Application
AMS-S-8802: Sealing Compound, Temperature Resistant, Integral Fuel Tanks and Fuel Cell
15
Cavities, High Adhesion.
16 MIL-G-81322: Military Specification – Grease, Aircraft, General Purpose, Wide Temperature Range.

DC-MAM-001-X-F-1.3 Page vii
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TABLE OF CONTENTS
1. GENERAL......................................................................................................................................... 1
1.1 DESCRIPTION ................................................................................................................................. 1
1.2 AIRCRAFT SPECIFICATIONS AND DATA ..................................................................................... 2
1.2.1 AIRCRAFT 3-VIEW DRAWING ........................................................................................................ 2
1.2.2 AIRCRAFT GEOMETRIC DIMENSIONS ......................................................................................... 3
1.2.3 AIRCRAFT WEIGHTS ...................................................................................................................... 4
1.3 ENGINE ............................................................................................................................................ 5
1.3.1 PROPELLER ....................................................................... ERROR! BOOKMARK NOT DEFINED.
1.4 APPROVED SUBSTANCES, FLUIDS, LUBRICANTS AND CAPACITIES ..................................... 6
1.5 FASTENER TORQUE VALUES AND WRENCH SIZES ............................................................... 10
1.5.1 GENERAL....................................................................................................................................... 10
1.5.2 SPECIFIC ....................................................................................................................................... 10
1.6 EQUIPMENT LIST .......................................................................................................................... 11
1.7 TYRE SPECIFICATION AND PRESSURES ................................................................................. 12
1.8 GROUND HANDLING .................................................................................................................... 12
1.9 JACKING ........................................................................................................................................ 14
1.10 PARKING AND TIE DOWN ............................................................................................................ 15
1.11 AIRCRAFT LEVELLING ................................................................................................................. 15
1.11.1 LONGITUDINAL LEVELLING ........................................................................................................ 16
1.11.2 TRANSVERSE LEVELLING........................................................................................................... 17
1.12 AIRCRAFT ALIGNMENT ................................................................................................................ 19
1.13 CONTROL SURFACE DEFLECTION / TRAVEL ........................................................................... 20
1.14 RUDDER CONTROL CABLE TENSION ........................................................................................ 20
1.15 AIRCRAFT RIGGING ..................................................................................................................... 21
1.15.1 RUDDER CABLE TENSION ADJUSTMENT ................................................................................. 21
1.15.2 ELEVATOR ADJUSTMENT ........................................................................................................... 21
1.15.3 ELEVATOR TRIM TAB ADJUSTMENT ......................................................................................... 21
1.15.4 AILERON ADJUSTMENT ............................................................................................................... 21
1.15.5 FLAP ADJUSTMENT ..................................................................................................................... 21
1.16 WEIGHT AND BALANCE INFORMATION .................................................................................... 22
1.16.1 REQUIREMENT / SCHEDULE ...................................................................................................... 22
1.16.2 MOMENT ARMS ............................................................................................................................ 22
1.16.3 CENTRE OF GRAVITY FORMULAE ............................................................................................. 23
1.16.4 EMPTY WEIGHT CENTRE OF GRAVITY TABLE ......................................................................... 23
1.16.5 EMPTY WEIGHT CENTRE OF GRAVITY DETERMINATION ...................................................... 24
1.17 CORROSION PREVENTION ......................................................................................................... 26
1.18 AIRCRAFT STORAGE ................................................................................................................... 27
1.18.1 SHORT TERM STORAGE ............................................................................................................. 27
1.18.2 MEDIUM LONG-TERM STORAGE ................................................................................................ 27
1.18.3 OUTSIDE STORAGE ..................................................................................................................... 28
1.18.4 RETURNING THE AIRCRAFT TO SERVICE ................................................................................ 28
1.19 SOURCES FOR THE PURCHASING OF PARTS ......................................................................... 29
1.20 DISPOSABLE REPLACEMENT PARTS ........................................................................................ 29
1.21 AIRCRAFT PLACARDS AND EQUIPMENT LABELLING ............................................................. 30
1.21.1 MARKINGS AND PLACARDS ....................................................................................................... 30
1.21.2 GENERAL SAFETY INFORMATION / CONSIDERATIONS ......................................................... 35
1.21.3 INSTRUCTIONS FOR CONCERNS REGARDING SAFETY OF FLIGHT .................................... 37
2. INSPECTION .................................................................................................................................. 38
2.1 GENERAL CONSIDERATIONS REGARDING INSPECTION ....................................................... 38
2.2 INSPECTION PANELS .................................................................................................................. 41
2.3 INSPECTION SCHEDULE ............................................................................................................. 42
2.3.1 ENGINE .......................................................................................................................................... 42
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2.3.2 PROPELLER .................................................................................................................................. 42
2.3.3 AIRFRAME AND SYSTEMS .......................................................................................................... 42
2.4 CONDITION INSPECTION (100 HOUR / ANNUALLY) ................................................................. 43
2.4.1 INSPECTION PANELS AND INITIAL INSPECTION AND CLEANING ......................................... 43
2.4.2 FUSELAGE GROUP ...................................................................................................................... 43
2.4.3 CABIN AND COCKPIT GROUP ..................................................................................................... 43
2.4.4 ENGINE AND COWLING GROUP ................................................................................................. 44
2.4.5 LANDING GEAR GROUP .............................................................................................................. 44
2.4.6 WING AND CENTRE SECTION ASSEMBLY ................................................................................ 45
2.4.7 EMPENNAGE ASSEMBLY ............................................................................................................ 45
2.4.8 PROPELLER GROUP .................................................................................................................... 45
2.4.9 RADIO GROUP / AVIONICS / ELECTRONIC EQUIPMENT ......................................................... 46
2.4.10 OPTIONAL EQUIPMENT ............................................................................................................... 46
2.5 MAINTENANCE CHECKS ............................................................................................................. 47
2.5.1 25 HOUR, 100 HOUR AND ANNUAL SERVICE INSPECTION CHECKLIST ............................... 47
2.5.2 2000 HOUR SERVICE CHECKLIST .............................................................................................. 56
3. SERVICE ........................................................................................................................................ 58
3.1 GENERAL CONSIDERATIONS REGARDING SERVICE AND MAINTENANCE ......................... 58
3.2 LUBRICATION POINTS, LUBRICANTS AND INTERVALS .......................................................... 63
3.3 SERVICE BULLETINS / INSTRUCTIONS / LETTERS .................................................................. 64
3.4 SERVICE SCHEDULE ................................................................................................................... 64
3.4.1 SERVICE PERIOD ADJUSTMENT ................................................................................................ 64
3.4.2 ITEMS WITH CALENDAR BASED SERVICING ............................................................................ 65
3.4.3 DAILY ............................................................................................................................................. 65
3.4.4 AS NEEDED ................................................................................................................................... 66
3.4.5 FIRST 25 HOURS .......................................................................................................................... 66
3.4.6 FIRST 50 HOURS .......................................................................................................................... 66
3.4.7 EVERY 50 HOURS / ANNUALLY .................................................................................................. 66
3.4.8 EVERY 100 HOURS / ANNUALLY ................................................................................................ 67
3.4.9 EVERY 2000 HOURS .................................................................................................................... 67
3.4.10 EVERY 5000 HOURS .................................................................................................................... 67
3.4.11 ENGINE AND AIRFRAME TIME BASED OVERHAULS ............................................................... 68
4. AIRFRAME ..................................................................................................................................... 69
4.1 WINGS ............................................................................................................................................ 70
4.1.1 MAIN WING SECTION ................................................................................................................... 70
4.1.1.1. WING REMOVAL / INSTALLATION .............................................................................................. 71
4.1.2 AILERON(S) ................................................................................................................................... 77
4.1.2.1. AILERON CONTROL SYSTEM ..................................................................................................... 77
4.1.2.2. AILERON REMOVAL / INSTALLATION ........................................................................................ 78
4.1.2.3. AILERON ADJUSTMENT ............................................................................................................... 83
4.1.2.4. AILERON AUTOPILOT SERVO / SERVO PUSHROD REMOVAL / INSTALLATION .................. 87
4.1.3 FLAPS ............................................................................................................................................ 91
4.1.3.1. FLAP CONTROL SYSTEM ............................................................................................................ 91
4.1.3.2. FLAP REMOVAL / INSTALLATION ............................................................................................... 92
4.1.3.3. FLAP ADJUSTMENT ..................................................................................................................... 98
4.1.3.4. FLAP ACTUATOR MOTOR REMOVAL / INSTALLATION ............................................................ 99
4.2 FUSELAGE................................................................................................................................... 102
4.2.1 REAR FUSELAGE ....................................................................................................................... 102
4.2.2 CENTRE FUSELAGE ................................................................................................................... 103
4.2.2.1. FRONT SEAT REMOVAL AND INSTALLATION ......................................................................... 103
4.2.2.2. REAR SEAT REMOVAL AND INSTALLATION ........................................................................... 104
4.2.2.3. CANOPY AND WINDSHIELD CLEANING ................................................................................... 106
4.2.2.4. UPHOLSTERY CLEANING .......................................................................................................... 106
4.2.3 FORWARD FUSELAGE AND FIREWALL ................................................................................... 107
4.3 EMPENNAGE ............................................................................................................................... 108
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4.3.1 HORIZONTAL TAIL AND ELEVATOR ......................................................................................... 108
4.3.1.1. ELEVATOR CONTROL SYSTEM ................................................................................................ 109
4.3.1.2. ELEVATOR REMOVAL / INSTALLATION ................................................................................... 110
4.3.1.3. HORIZONTAL STABILIZER REMOVAL / INSTALLATION ......................................................... 114
4.3.1.4. ELEVATOR TRIM TAB MOTOR REMOVAL / INSTALLATION ................................................... 117
4.3.1.5. ELEVATOR ADJUSTMENT ......................................................................................................... 120
4.3.1.6. ELEVATOR TRIM TAB ADJUSTMENT ....................................................................................... 122
4.3.1.7. ELEVATOR AUTOPILOT SERVO / SERVO PUSHROD REMOVAL / INSTALLATION ............. 124
4.3.2 VERTICAL TAIL AND RUDDER .................................................................................................. 128
4.3.2.1. RUDDER CONTROL SYSTEM .................................................................................................... 129
4.3.2.2. RUDDER REMOVAL / INSTALLATION ....................................................................................... 130
4.3.2.3. VERTICAL STABILIZER REMOVAL ............................................................................................ 134
4.3.2.4. RUDDER PEDAL ADJUSTMENT ................................................................................................ 138
4.3.2.5. RUDDER CABLE TENSION ADJUSTMENT ............................................................................... 139
4.4 LANDING GEAR .......................................................................................................................... 142
4.4.1 MAIN GEAR.................................................................................................................................. 142
4.4.1.1. MAIN WHEEL FAIRING REMOVAL / INSTALLATION ................................................................ 143
4.4.1.2. MAIN WHEEL REMOVAL / INSTALLATION ............................................................................... 145
4.4.1.3. MAIN WHEEL AXLE AND BRAKE MECHANISM REMOVAL ..................................................... 148
4.4.1.4. MAIN WHEEL DISASSEMBLY / ASSEMBLY .............................................................................. 152
4.4.1.5. MAIN WHEEL BEARING REMOVAL / INSTALLATION AND LUBRICATION ............................ 155
4.4.1.6. MAIN GEAR REMOVAL / INSTALLATION .................................................................................. 156
4.4.2 NOSE GEAR ................................................................................................................................ 160
4.4.2.1. NOSE WHEEL FAIRING REMOVAL / INSTALLATION .............................................................. 161
4.4.2.2. NOSE WHEEL REMOVAL / INSTALLATION .............................................................................. 162
4.4.2.3. NOSE WHEEL DISASSEMBLY / ASSEMBLY ............................................................................. 165
4.4.2.4. NOSE WHEEL BEARING REMOVAL / REPLACEMENT ........................................................... 168
4.4.2.5. NOSE GEAR REMOVAL / INSTALLATION ................................................................................. 169
5. POWER PLANT ........................................................................................................................... 172
5.1 COWLING..................................................................................................................................... 172
5.1.1 COWLING REMOVAL / INSTALLATION ..................................................................................... 173
5.2 ENGINE ........................................................................................................................................ 176
5.2.1 GENERAL MAINTENANCE AND SERVICING ............................................................................ 176
5.2.2 REPLACING ENGINE OIL ........................................................................................................... 176
5.2.3 REPLACING ENGINE COOLANT................................................................................................ 176
5.2.4 SPARK PLUG REPLACEMENT................................................................................................... 176
5.2.5 VERIFYING ENGINE OIL LEVEL ................................................................................................ 177
5.2.6 AIR FILTER REMOVAL, CLEANING AND REPLACEMENT ...................................................... 178
5.2.7 REMOVAL / INSTALLATION OF OIL AND COOLANT RADIATORS ......................................... 181
5.2.8 OIL COOLER / RADIATOR PIPE CONNECTION / DISCONNECTION ...................................... 182
5.2.9 COOLANT RADIATOR PIPE CONNECTION / DISCONNECTION ............................................. 185
5.2.10 ENGINE REMOVAL / INSTALLATION ........................................................................................ 187
5.2.11 ENGINE CONTROL SYSTEM (THROTTLE) ............................................................................... 193
5.2.11.1. THROTTLE LEVER FRICTION ADJUSTMENT .......................................................................... 193
5.2.11.2. THROTTLE LEVER FRICTION DISC REPLACEMENT .............................................................. 195
5.3 PROPELLER ................................................................................................................................ 197
5.3.1 GENERAL MAINTENANCE AND SERVICE ................................................................................ 197
5.3.2 PROPELLER HUB AND PROPELLER EXTENSION TORQUE PATTERN ................................ 197
5.3.3 SPINNER REMOVAL / REPLACEMENT ..................................................................................... 198
5.3.4 PROPELLER REMOVAL / INSTALLATION ................................................................................. 200
5.3.5 PROPELLER ASSEMBLY / DISASSEMBLY ............................................................................... 204
5.3.6 PROPELLER ADJUSTMENT / SET-UP ...................................................................................... 206
5.3.7 PROPELLER BALANCING .......................................................................................................... 206
5.4 FUEL SYSTEM ............................................................................................................................. 207
5.4.1 GENERAL SERVICE INFORMATION AND CONSIDERATIONS ............................................... 209
5.4.2 FUEL SELECTOR UNIT REMOVAL / INSTALLATION ............................................................... 210
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5.4.3 FUEL SELECTOR UNIT ASSEMBLY / DISASSEMBLY ............................................................. 213
5.4.4 FUEL PUMP ASSEMBLY REMOVAL / INSTALLATION ............................................................. 215
5.4.5 FUEL PUMP REMOVAL / INSTALLATION FROM / INTO FUEL PUMP ASSEMBLY ................ 220
5.4.6 FUEL TANK LEAK REPAIR ......................................................................................................... 222
5.4.7 FUEL TANK DRAIN REMOVAL / INSTALLATION (DRAINING WING TANK) ........................... 223
5.4.8 FUEL LEVEL SENDER ASSEMBLY REMOVAL / INSTALLATION (FROM / TO FUEL TANK) . 225
5.4.9 REPLACING FUEL LEVEL SENDER ASSEMBLY SENSOR ..................................................... 229
5.4.10 FINGER STRAINER (ON FUEL PICK-UP) INSPECTION ........................................................... 233
6. AVIONICS AND INSTRUMENTS ................................................................................................. 235
6.1 GENERAL MAINTENANCE AND SERVICE OF INSTRUMENTS .............................................. 237
6.2 REMOVAL / INSTALLATION OF INSTRUMENT PANEL AND INSTRUMENTS ........................ 237
6.3 PITOT AND STATIC SYSTEMS .................................................................................................. 239
6.3.1 PITOT SYSTEM LEAK TEST ....................................................................................................... 240
6.3.2 STATIC SYSTEM LEAK TEST ..................................................................................................... 241
6.3.3 PITOT AND / OR STATIC SYSTEM CLEANING AND SERVICING ........................................... 242
6.4 MAGNETOMETER ....................................................................................................................... 243
6.4.1 MAGNETOMETER REMOVAL / INSTALLATION ....................................................................... 243
6.5 HEADPHONE SOCKETS ............................................................................................................. 245
6.5.1 HEADPHONE SOCKET REMOVAL / INSTALLATION ............................................................... 245
6.6 ANTENNAE .................................................................................................................................. 247
6.6.1 VHF COMMUNICATION ANTENNA ............................................................................................ 247
6.6.1.1 VHF ANTENNA REMOVAL / INSTALLATION ............................................................................. 247
6.6.2.1 GPS ANTENNA REMOVAL / INSTALLATION ............................................................................ 249
7. UTILITY SYSTEMS ...................................................................................................................... 251
7.1 CABIN HEATING AND COOLING ............................................................................................... 251
7.1.1 HEAT EXCHANGER ASSEMBLY REMOVAL AND INSTALLATION.......................................... 253
7.2 BRAKE SYSTEM .......................................................................................................................... 255
7.2.1 BRAKE FLUID DRAINING, REPLACEMENT AND BRAKE SYSTEM BLEEDING ..................... 256
7.2.2 BRAKE MECHANISM REMOVAL / INSTALLATION ................................................................... 258
7.2.3 BRAKE DISC REPLACEMENT .................................................................................................... 259
7.2.4 BRAKE LINING REPLACEMENT ................................................................................................ 260
7.3 ELECTRICAL SYSTEM ................................................................................................................ 263
7.3.1 BATTERY REMOVAL / INSTALLATION ...................................................................................... 265
7.3.2 EFIS BACK-UP BATTERY REMOVAL / INSTALLATION ........................................................... 267
7.3.3 REPLACEMENT OF CIRCUIT BREAKERS AND / OR SWITCHES ........................................... 269
7.3.4 REGULATOR / RECTIFIER REMOVAL AND REPLACEMENT .................................................. 272
7.4 EXTERIOR LIGHTING ................................................................................................................. 274
7.4.1 NAVIGATION LIGHTS ................................................................................................................. 274
7.4.2 NAVIGATION LIGHT REMOVAL / INSTALLATION .................................................................... 275
7.4.3 LANDING AND TAXI LIGHTS ...................................................................................................... 277
7.4.4 LANDING AND / OR TAXI LIGHT REMOVAL / INSTALLATION ................................................ 277
7.4.5 LANDING AND / OR TAXI LIGHT REPLACEMENT .................................................................... 280
7.4.6 LANDING AND / OR TAXI LIGHT ADJUSTMENT....................................................................... 282
7.4.7 STROBE LIGHT ........................................................................................................................... 283
7.4.8 STROBE LIGHT REMOVAL / INSTALLATION ............................................................................ 283
7.5 EMERGENCY AND SAFETY SYSTEMS .................................................................................... 285
7.5.1 BALLISTIC PARACHUTE ............................................................................................................ 285
7.5.2 GENERAL SERVICE AND MAINTENANCE. ............................................................................... 285
7.5.3 SAFETY HARNESSES ................................................................................................................ 286
7.5.4 REMOVAL / INSTALLATION OF FRONT OCCUPANT SAFETY HARNESS(ES) ...................... 286
7.5.5 REMOVAL / INSTALLATION OF REAR OCCUPANT SAFETY HARNESS(ES) ........................ 289
A. APPENDIX A (AVIONICS AND ELECTRICAL SYSTEM WIRING DIAGRAMS) ......................... 290
B. APPENDIX B (FIREWALL MOUNTED EQUIPMENT) ................................................................. 308

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C. APPENDIX C (GENERAL PROCEDURES AND TECHNIQUES NOT DESCRIBED ELSEWHERE)
309
D. APPENDIX D (AN WASHER AND NUT HARDWARE DESIGNATIONS) ................................... 311

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LIST OF FIGURES
Figure 1: Attachment of Tow Bar. .......................................................................................................................... 13
Figure 2: Longitudinal levelling reference position. ............................................................................................... 16
Figure 3: Transverse levelling reference position. ................................................................................................. 18
Figure 4: Aircraft alignment.................................................................................................................................... 19
Figure 5: Moment arms.......................................................................................................................................... 22
Figure 6: Main landing gear plate machine screws. .............................................................................................. 57
Figure 7: Front wing spar to fuselage connection. ................................................................................................ 74
Figure 8: Rear wing spar to fuselage connection. ................................................................................................. 75
Figure 9: Aileron pushrod-to-control stick connection. .......................................................................................... 75
Figure 10 : Aileron control system. ........................................................................................................................ 77
Figure 11: Bell crank (1) ........................................................................................................................................ 79
Figure 12: Aileron hinge (inboard). ........................................................................................................................ 80
Figure 13: Aileron hinge (outboard). ...................................................................................................................... 81
Figure 14: Aileron pushrod -to-bell crank connection. ........................................................................................... 82
Figure 15: Aileron adjustment - cabin side. ........................................................................................................... 84
Figure 16: Aileron adjustment - wing side. ............................................................................................................ 85
Figure 17: Autopilot aileron servo installation. ....................................................................................................... 89
Figure 18: Aileron autopilot servo pushrod – control stick / torque tube end. ....................................................... 90
Figure 19: Flap control system. ............................................................................................................................. 91
Figure 20: Flap hinges. .......................................................................................................................................... 94
Figure 21: Flap pushrod-to-flap connection. .......................................................................................................... 95
Figure 22: Flap pushrod-to-flap torque tube control arm connection. ................................................................... 97
Figure 23: Flap actuator motor removal. ............................................................................................................. 100
Figure 24: Flap actuator motor installation. ......................................................................................................... 101
Figure 25: Horizontal tail and elevator. ................................................................................................................ 108
Figure 26: Elevator control system. ..................................................................................................................... 109
Figure 27: Elevator pushrod to elevator connection. ........................................................................................... 112
Figure 28: Horizontal stabilizer-to-elevator hinge. ............................................................................................... 113
Figure 29: Horizontal stabilizer to fuselage attachment. ..................................................................................... 116
Figure 30: Elevator adjustment. ........................................................................................................................... 121
Figure 31: Elevator control horn (5) ..................................................................................................................... 123
Figure 32: Autopilot elevator servo installation. ................................................................................................... 126
Figure 33: Autopilot elevator servo pushrod –torque tube end. .......................................................................... 127
Figure 34: Vertical tail and rudder. ...................................................................................................................... 128
Figure 35: Rudder control system. ...................................................................................................................... 129
Figure 36: Rudder cable guide ............................................................................................................................ 131
Figure 37: Rudder to vertical stabilizer hinge connection. ................................................................................... 132
Figure 38: Rudder cable connection. ................................................................................................................... 133
Figure 39: Vertical stabilizer to fuselage connection. .......................................................................................... 136
Figure 40 : Rudder cable tension adjustment. ..................................................................................................... 140
Figure 41: Main landing gear. .............................................................................................................................. 142
Figure 42: Main wheel axle installation. ............................................................................................................... 151
Figure 43: Main gear installation. ........................................................................................................................ 159
Figure 44: Nose gear. .......................................................................................................................................... 160
Figure 45: Nose wheel installation. ...................................................................................................................... 164
Figure 46: Front wheel hub assembly. ................................................................................................................ 167
Figure 47: Nose gear installation. ........................................................................................................................ 171
Figure 48: Engine cowling. .................................................................................................................................. 172
Figure 49: Engine removal. ................................................................................................................................. 190
Figure 50: Engine installation. ................................................................................. Error! Bookmark not defined.
Figure 51: Throttle lever friction disc installation. ................................................................................................ 196
Figure 52: Propeller installation / propeller extension installation torque pattern. ............................................... 197
Figure 53: Airmaster propeller signal wire to slip-ring disc connection. .............................................................. 202

DC-MAM-001-X-F-1.3 Page xiii
___________________________________________
Figure 54: Fuel system. ....................................................................................................................................... 207
Figure 55: Fuel selector unit installation. ............................................................................................................. 212
Figure 56: Fuel selector port allocation and fitting orientation. ............................................................................ 214
Figure 57: Fuel selector fuel fitting alignment. ..................................................................................................... 214
Figure 58: Wing tank fuel drain installation.......................................................................................................... 224
Figure 59: Fuel sender installation into fuel tank. ................................................................................................ 228
Figure 60: Fuel level sender assembly sensor replacement. .............................................................................. 232
Figure 61: Standard instrument panel (refer to key on next page). ..................................................................... 235
Figure 62: Representative pitot and static system. ............................................................................................. 239
Figure 63: Headphone socket installation. .......................................................................................................... 246
Figure 64: VHF antenna installation. ................................................................................................................... 248
Figure 65: Brake system. ..................................................................................................................................... 255
Figure 66: Electrical system (overview). .............................................................................................................. 263
Figure 67 : Landing and taxi light installation. ..................................................................................................... 279
Figure 68: Charge and start system wiring diagram / fuel pump wiring. ............................................................. 290
Figure 69: Switches and circuit breakers wiring diagram. ................................................................................... 291
Figure 70: Flap actuator wiring harness diagram ................................................................................................ 292
Figure 71: Actuonix flap controller wiring diagram. ............................................................................................. 293
Figure 72: Flap actuator wiring ............................................................................................................................ 294
Figure 73: Elevator trim motor wiring diagram – dual control sticks. ................................................................... 295
Figure 74: Elevator trim motor wiring diagram – single control stick. .................................................................. 296
Figure 75: EFIS system / communications bus layout. ....................................................................................... 297
Figure 76: Magnetometer (GMU 11) wiring diagram. .......................................................................................... 298
Figure 77: Autopilot roll servo and pitch servo wiring diagram. ........................................................................... 299
Figure 78: EFIS back-up battery charge circuit. ................................................................................................. 300
Figure 79: Headphone / radio (GARMIN GTR 200) / intercom wiring diagram. .................................................. 301
Figure 80: Headphone / radio (GARMIN GTR 225) / intercom wiring diagram. .................................................. 302
Figure 81: Position / navigation lights wiring diagram. ........................................................................................ 303
Figure 82: GEA 24 to Rotax 915 iS engine wiring diagram and settings. ........................................................... 304
Figure 83:Dual EFIS installation. ......................................................................................................................... 305
Figure 84: GTX 35R transponder wiring diagram. ............................................................................................... 306
Figure 85: Components mounted on Firewall Forward ....................................................................................... 308
Figure 86: Two-ear clamp removal. ..................................................................................................................... 309
Figure 87: Pushrod adjustment. .......................................................................................................................... 309

DC-MAM-001-X-F-1.3 Page xiv
___________________________________________
WARNINGS, CAUTIONS AND NOTES

The following definitions apply to warnings, cautions and notes as used in this aircraft maintenance manual:
WARNING
Indicates an action necessary to prevent injury or death.
CAUTION
Indicates an action necessary to prevent damage to the aircraft, aircraft parts or property.
NOTE
Provides valuable additional information.

DC-MAM-001-X-F-1.3 Page xv
SECTION 1
GENERAL
This section provides general information, capacities and general procedures and specifications.
1. GENERAL
1.1 DESCRIPTION
Sling Aircraft’s Sling 4 TSi is a four seat, single engine, tricycle fixed undercarriage aluminium aircraft
with a conventional low wing design.
NOTE
Where no guidance is available in this manual for repairs considered minor (light skin damage,
trailing edge damage, scratches etc.), the guidance provided by FAA AC 43.13 is acceptable. If
the repair work is considered major, or involves any structural element of the aircraft (i.e wing
spars, empennage spars, landing gear, engine mount, stringers etc.), Sling Aircraft must be
contacted for repair approval.

DC-MAM-001-X-F-1.3 Page 1
___________________________________________
1.2 AIRCRAFT SPECIFICATIONS AND DATA
1.2.1 AIRCRAFT 3-VIEW DRAWING
Note that dimensions in this drawing are

in millimetres (metric).

___________________________________________
1.2.2 AIRCRAFT GEOMETRIC DIMENSIONS
WING
Span: 9 544 mm / 31.31 ft.

Area (gross): 11.51 m² / 123.89 ft².
Aspect ratio: 7.79
Taper ratio 0.70
Dihedral: 4.5°
Tip washout: 1.5°
Aileron total area: 0.85 m² / 9.149 ft².
Flap total area: 1.71 m² / 18.41 ft².
HORIZONTAL TAIL
Span: 3 020 mm / 9.91 ft.

Area: 1.065 m² / 11.46 ft².
Aspect ratio (with elevator): 4.09
Angle of incidence: -0.8°
Elevator area: 1.164 m² / 12.53 ft².
VERTICAL TAIL
Span: 1 470 mm / 4.82 ft.

Area: 0.53 m² / 5.73 ft².
Aspect ratio (with rudder): 1.92
Rudder area: 0.60 m² / 6.46 ft².

___________________________________________
FUSELAGE
Length: 6 220 mm / 20.41 ft.

Width: 1 188 mm / 3.90 ft.
Total aircraft length: 7 175 mm / 23.54 ft.
LANDING GEAR
Wheel track: 1.95 m / 6.40 ft.

Wheel base: 1.715 m / 5.64 ft.
1.2.3 AIRCRAFT WEIGHTS
MAXIMUM WEIGHTS
Maximum take-off weight: 950 kg / 2094.39 lb.

Maximum landing weight: 950 kg / 2094.39 lb.
Maximum baggage weight: 35 kg / 77.16 lb.
STANDARD WEIGHTS
Standard empty weight: 500 kg / 1102.31 lb.

Maximum useful load: 450 kg / 992.08 lb.
NOTE: Standard weights are estimates based on standard equipment

___________________________________________
1.3 ENGINE
1.3.1 ROTAX 915 IS
Manufacturer: Bombardier-Rotax GmbH

Model: Rotax 915 iS turbo charged 4 stroke engine
Type: 4-cylinder, turbo charged, horizontally opposed, with an overall
displacement of 1352cc, mixed cooling, fuel injection, integrated
reduction gearbox with torque damper
Maximum power: 104 kW (139.5 hp) @ 5 800 rpm (max 5 mins)
99 kW (133 hp) @ 5 500 rpm (continuous)
Refer to the latest revisions of the Rotax 915 iS technical documentation (e.g. operator and maintenance
manuals), as available from the manufacturer, for comprehensive technical data on the engine.
1.3.2 ROTAX 916 IS
Manufacturer: Bombardier-Rotax GmbH

Model: Rotax 916 iS turbo charged 4 stroke engine
Type: 4-cylinder, turbo charged, horizontally opposed, with an overall
displacement of 1352cc, mixed cooling, fuel injection, integrated
reduction gearbox with torque damper
Maximum power: 117 kW (160 hp) @ 5 800 rpm (max 5 mins)
101 kW (137 hp) @ 5 500 rpm (continuous)
Refer to the latest revisions of the Rotax 916 iS technical documentation (e.g. operator and maintenance
manuals), as available from the manufacturer, for comprehensive technical data on the engine.
1.3.3 PROPELLER
Manufacturer: Airmaster Hub, Whirlwind Blades
Model: AP430CTF-WWR72B (Whirlwind blades)
No of blades: 3 carbon fibre blades with inlaid nickel LE
Diameter: 1.83m (72”)
Type: Constant speed
or
Manufacturer: MT Propeller Hub and Blades
Model: MTV 6 190 69 (MT Propeller)
No of blades: 3 wooden blates covered in a glass fibre epoxy and stainless steel
leading edge
Diameter: 1.90m (75”)
Type: Constant speed

___________________________________________
1.4 APPROVED SUBSTANCES, FLUIDS, LUBRICANTS AND CAPACITIES
It is recommended to refer to and comply with the latest Rotax 915 iS engine operator and / or
maintenance manuals, as applicable, and with service instructions (as issued from time to time), with
regard to recommended lubricants, coolant fluids and fuels, and their usage. Any reference to
lubricants, coolant fluids and fuels appearing in this manual is as a general recommendation only.
Refer to the latest revision of Rotax service instruction instruction titled “Selection of suitable operating
fluids for Rotax Engines” for recommendations regarding engine operating fluids.
FUEL
min. MON 85 / RON 95, min. AKI 91
DIN EN 228 Super, DIN EN 228 Super

MOGAS
Plus, ASTM D4814.
Grade
Leaded AVGAS 100LL (ASTM D910).
AVGAS
Unleaded TOTAL AVGAS UL91.
Capacity 176 litres / 46.49 US gallons (88 litres / 23.25 US gallons per tank)
or
198 litres / 52.31 US gallons (99 litres / 26.15 US gallons per tank).
Total usable fuel 172 litres / 45.44 US gallons (86 litres / 22.72 US gallons per tank)
or
194 litres / 51.25 US gallons (97 litres / 25.62 US gallons per tank).
NOTE: AVGAS 100LL places greater stress on the valve seals due to its lead content and forms
increased deposits in the combustion chamber and lead sediments in the oil system. Thus, it should
only be used in case of problems with vapour lock and when other types of gasoline are unavailable.
ENGINE OIL
Grade Automotive grade API SG (or higher) type oil, preferably synthetic or semi-
synthetic. When operating on unleaded fuels or MOGAS fully synthetic oil is
recommended.
Oil capacity 3 litres (6.34 pints).

___________________________________________
COOLANT
Grade / type 1:1 Ethylene glycol-based coolant and distilled water mixture.
Cooling capacity 1.5 litres (3.17 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 B-2 compliant sealant (e.g. (as used by Sling Aircraft)
FLAMEMASTER CS 3204 Class B-2 fuel tank sealant, Parts A and B. Mix
parts according to manufacturer instructions).
SECURING BRAKE FLUID LINE(S) TO MAIN UNDERCARRIAGE STRUT(S)
Type PRATLEY QUICKSET CLEAR.

___________________________________________
LUBRICANTS / GREASE
Canopy hinges Q20 or equivalent.
Canopy latches Q20 or equivalent.
Rudder and pedal control cable terminals MIL-G-3278 type grease or equivalent.
Rudder cable guides Q20 or equivalent.
Elevator pushrod (in centre) guide MIL-G-3278 type grease or equivalent.
Elevator torque tube bushes Q20 or equivalent.
Trim tab hinge Q20 or equivalent.
Aileron pushrod guide (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.
Control sticks MIL-G-3278 type grease or equivalent.
Control stick torque tube bushes Q20 or equivalent.
Nose gear support blocks MIL-G-3278 type grease or equivalent.
MIL-G- 81322 type grease or equivalent (e.g.

Main wheel bearings
Aeroshell 22).
Refer to the latest revision of the propeller

Propeller
operator’s manual.
Refer to the latest revision of the Rotax 915 iS

Engine engine operator’s manual and / or
maintenance manuals, as applicable.
Use a silicone or Teflon based lubricant
Engine throttle cable Do not use any lubricant containing

solvents (e.g. WD-40) as this will cause the
slick inner sheath of the cable to ‘Gum up’.
Engine choke cable Q20 or equivalent.
Heater activation cables Q20 or equivalent.

___________________________________________
MAIN WHEEL BEARING CLEANING SOLVENT
Type Paraffin.
CANOPY / WINDSHIELD CLEANING FLUIDS / POLISH

Suitable for polymethyl methacrylate (Perspex / Plexiglass). Never use
Type
gasoline, alcohol, alcohol-based products or chemical solvents.
THREAD LOCKING SEALANT
Inspection panel screws, elevator trim motor installation screws.

Propeller extension (bolts securing propeller hub / assembly to the propeller
extension).
VHF antenna retaining screws.
Loctite 222 Instrument panel retaining screws.

Navigation light retaining screws.
Strobe light retaining screws.
Fuselage fairings.
Fuel selector valve retaining screws.
Autopilot aileron and elevator servo mounting screws.

Loctite 243 Propeller extension (bolts securing propeller extension to engine flange).
Bolt securing main wheel fairing to main axle spacer.
Fuel hose and oil pipe fitting threads.

Loctite 557
Brake line fittings.

___________________________________________
1.5 FASTENER TORQUE VALUES AND WRENCH SIZES
1.5.1 GENERAL
Use these values unless indicated otherwise.
STANDARD NUTS
AN BOLT SIZE THREAD SIZE AN310, AN315, AN364. AN365 (MS20365) WRENCH SIZE
Nm ft.lb
AN3 10-32 2.2 to 2.7 1.6 to 2.0 3/8“
AN4 1/4-28 5.7 to 7.9 4.2 to 5.8 7/16“
AN5 5/16-24 11.2 to 15.7 8.3 to 11.6 1/2“
AN6 3/8-24 18.0 to 21.4 13.3 to 15.8 9/16“
AN7 7/16-20 50.84 to 56.54 37.5 to 41.7 5/8“
NOTE: Torque values in above table are for dry (not oiled) threads. When a locking nut is used the
friction torque value (the torque required to only turn the lock nut due to the friction of the lock nut.)
must be accounted for. This friction torque value should be added to the torque values specified
above.
1.5.2 SPECIFIC
TORQUE VALUE
ITEM
Nm ft.lb
Wing mounting bolts (front) (AN7). 55 40.57
Wing mounting bolts (rear) (AN5). 18 13.28
Main spar bolts (AN4). 7 5.16
Main landing gear mounting bolts (M10). 25 18.44
Propeller mounting bolts spacer to
20 14.75
propeller hub (M8). Airmaster AP430CTF-
Propeller mounting bolts spacer to engine WWR72B propeller
24 17.70
flange (M8).
Engine mounting bolts (securing engine
suspension frame to engine mount) (M10).
38 28.023
NOTE: Torque value for these bolts is with
oiled thread.
Engine mount mounting bolts (securing
16 11.80
engine mount to engine firewall) (AN5).

___________________________________________
1.6 EQUIPMENT LIST
AVIONICS / ENGINE INSTRUMENTS
Garmin G3X incorporating:
Moving Map GPS, GLS, Autopilot Operating System, Artificial Horizon, Airspeed Indicator, Altimeter,
Vertical Speed Indicator, Angle of Attack Indicator, Compass, Tachometer, Oil Pressure, Fuel
Pressure, Fuel Flow, Oil Temperature, Cylinder Head Temperature (x2), Exhaust Gas Temperature
(x4), Hour Meter, Fuel Quantity, Volt Meter, Trim Indicator, Flap Indicator, G Meter, Artificial Horizon,
Turn and Slip indicators, Time, Flight Time, Time Since Start-up, Range, Endurance.
GARMIN GTR 200 Panel Mount Aircraft Radio.

Magnetic (Standard) Compass.
Intercom System.
2 1/4-inch Ball Type Slip Indicator.
3 1/8-inch Altimeter (analogue) and Airspeed Indicator (analogue).
WARNING LIGHTS AND INDICATORS
GDU 460 Warning Light.
CONTROLS
Dual Control Sticks, Dual Rudder Pedals, Centre Position Throttle, Electric Flaps, Electric Elevator
Trim, Centre Brake Lever, Hydraulic Disc Brakes, Parking Brake, Fuel Selector Valve, Direct Nose
Wheel Steering.
EXTRAS AND SAFETY EQUIPMENT
Ballistic Recovery System (Parachute), Fire Extinguisher.
INTERIOR
Adjustable Pilot and Co-pilot Seats, Two Passenger Seats, Adjustable Rudder Pedals, Adjustable
Cabin Air Ventilators and Heater, Carbon and Fibreglass Roll Cage, 12 V Power Outlet, Anodized
Aluminium Instrument Panel.
EXTERIOR
All Aluminium Structure, Landing Light (Each Wing), Taxi Light (Each Wing), Strobe Light,
Navigation Lights, Fixed Landing Gear (Steerable Nose Wheel), Nose and Main Wheel Fairings.
POWER PLANT AND ACCESSORIES
Rotax 915 iS Turbocharged Engine and Airmaster AP430CTF-WWR72B Variable Pitch Propeller.

___________________________________________
1.7 TYRE SPECIFICATION AND PRESSURES
WHEEL TYPE PRESSURE

Main wheels 15.00 x 6.00-6 (6-ply) 2.5 bar (36.26 psi)
Nose wheel 5.00-5 (6-ply) 1.8 bar (26.1 psi)
1.8 GROUND HANDLING
WARNING
MASTER / IGNITION SWITCHES OFF.
CAUTION
AS A GENERAL RULE, APPLY FORCE TO AIRCRAFT STRUCTURE ONLY ON MAIN
STRUCTURAL ELEMENTS SUCH AS FRAMES OR SPARS.
Move the aircraft on ground by pulling on the propeller blades, close to hub. The 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 rear upper
fuselage and horizontal stabiliser (place your hands above the main spar, where the rivets are).
Avoid dragging the nose wheel sideways. Do not attempt to counter any movement of the aircraft
by handling it by its wing tips.

___________________________________________
TOW BAR
PROCEDURE (INSTALLATION)
1. Push down on the spring bar (1), in the direction (2) shown, to extend the spring (3).
2. While the spring is extended, line the attachment pins (4) with the attachment holes (5) on the
nose wheel fairing (6).
3. Release the spring bar to contract the spring and attach the tow bar to the nose wheel of the
aircraft.
4. Ensure that the tow bar is securely attached to the nose wheel.
1
2
4 4
6
Figure 1: Attachment of Tow Bar.

___________________________________________
1.9 JACKING
WARNING
A LIFTED AIRCRAFT MUST BE SECURELY SUPPORTED BY STATIC STANDS (OTHER
THAN A / THE JACKING DEVICE). THE AIRCRAFT MAY NOT MOVE FROM AN ATTEMPT TO
SHAKE IT HORIZONTALLY OR VERTICALLY.
Following removal of the main wheel fairings (refer to paragraph 4.4.1.1), the aircraft can be jacked
from under the ends of the main wheel struts, just inside of the wheels. Ensure that steps are taken
to locate the jack sturdily under the bottom edge of the wheel strut, 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 wheel can also easily be lifted by
pressing down on the rear fuselage above a bulkhead and the horizontal stabiliser above the main
spar.

___________________________________________
1.10 PARKING AND TIE DOWN
It is recommended that chocks are used when parking outdoors or in a hanger. If chocks are not
available, use the park brake. If possible, park the airplane facing into the wind. Tie 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 tie down the nose
wheel from the engine mount near the nose wheel strut attachment point.
1
1
2
1
1.11 AIRCRAFT LEVELLING
Occasional levelling of the aircraft may be necessary to ensure proper wing incidence and / or dihedral
or for exact centre of gravity determination.

___________________________________________
1.11.1 LONGITUDINAL LEVELLING
TOOLS / EQUIPMENT REQUIRED

ITEM QUANTITY NOTES
1 Shims. As needed.
2 Spirit, water or electronic level. 1
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 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 any kind on the aircraft or any 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
1. To take measurement rest (align) a spirit, water or electronic level with second row of rivets
down from (below) the canopy frame edge, on the aircraft fuselage side, above the wing.
Use these rivets as

reference.
Figure 2: Longitudinal levelling reference position.
2. Adjust the aircraft’s tilt through shims placed under wheels or by regulating tyre pressure.

___________________________________________
1.11.2 TRANSVERSE LEVELLING

ITEM QUANTITY NOTES
1 Shims As needed.
1 Spirit, water or electronic level 1

___________________________________________
PROCEDURE
1. Open the canopy.
2. Remove a front seat (refer to paragraph 4.2.2.1).
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 3: Transverse levelling reference position.
4. Adjust the aircraft’s tilt through shims placed under wheels or by regulating tyre pressure.

___________________________________________
1.12 AIRCRAFT ALIGNMENT
The aim of the alignment control is mainly to compare the measures taken on both sides and to check if
the difference between them, if any, is within the tolerances reported below.
A E
Figure 4: Aircraft alignment.
Measurement Nominal Distances (mm)
A-B 5 123 mm (±20 mm)
B-E 5 123 mm (±20 mm)
A–C
4 609 mm (±20 mm)
E–C
C D D
C
C-D 1 763 mm (±20 mm)
DATUMS
A, E – On the wing upper surface, the outside edge of the wing skins where the trailing edge of
the leading-edge 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 necessary to remove the
engine upper cowling (refer to paragraph 5.1.1).
C – On the outside rear corner of the horizontal stabilizer upper skin.
D – The upper / aft rivet on the vertical stabilizer skin. It is the highest rivet shared between the
skin and the vertical stabilizer rear spar flanges.

___________________________________________
1.13 CONTROL SURFACE DEFLECTION / TRAVEL
DEFLECTION
CONTROL SURFACE REFERENCE TOLERANCE
UP / DOWN /
LEFT RIGHT
Ailerons Starting from

the tips lined
24° 24° ± 3°
up with the
wing tips.
Elevator Starting from

the horn lined
32° 22° ± 2°
up with the
leading edge.
Trim tab Starting flush

5° 25° ± 3°
with elevator
Rudder 23° 23° ± 2°
Flaps (maximum travel) 0° 34° ± 3°
1.14 RUDDER CONTROL CABLE TENSION
Tension (with rudder straight) 15 N ±3 N (1.5 kg ±0.3 kg).

___________________________________________
1.15 AIRCRAFT RIGGING
1.15.1 RUDDER CABLE TENSION ADJUSTMENT
Refer to paragraph 4.3.2.5.
1.15.2 ELEVATOR ADJUSTMENT
1.15.3 ELEVATOR TRIM TAB ADJUSTMENT
1.15.4 AILERON ADJUSTMENT
1.15.5 FLAP ADJUSTMENT

___________________________________________
1.16 WEIGHT AND BALANCE INFORMATION
1.16.1 REQUIREMENT / SCHEDULE
Weight and balance measurements need to 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 the aircraft.
• Periodically as may be required by national legislation.
1.16.2 MOMENT ARMS
2043 Aft CG
1847 Forward CG
464 NW
1800 Fuel
1902 Front Seats Note that dimensions in this drawing
2236 Main Undercarriage
are in millimetres (metric)
2948 Rear Seats
3288 Luggage
3762 Luggage Extension
Figure 5: Moment arms.

___________________________________________
1.16.3 CENTRE OF GRAVITY FORMULAE
Total Moment
Aircraft CG =
Total Weight
100 (metric)
%MAC = (CG − 1613) x
1 302
100
%MAC = (CG − 63.504) x (imperial)
51.26
1.16.4 EMPTY WEIGHT CENTRE OF GRAVITY TABLE
ITEM WEIGHT ARM MOMENT

[kg] / [lb] [mm] / [inch] [weight x arm]
Right Main WR = LR = 2 236 mm / 88.031”

AIRCRAFT EMPTY CG
Wheel
Left Main Wheel WL = LL = 2 236 mm / 88.031”
Nose Wheel WN = LN = 464 mm / 18.268”
Computed empty Empty weight: CG = …………….. mm / inch Aircraft moment:

Centre of gravity WE = ………………..kg / lb (……………….%.MAC)

___________________________________________
1.16.5 EMPTY WEIGHT CENTRE OF GRAVITY DETERMINATION

ITEM QUANTITY NOTES
1 Calibrated scales, minimum 250 kg (551 lb) capacity. 3
2 Calibrated scale, minimum 250 kg (551 lb) capacity. 1
3 Blocks with same height as scales (able to bear aircraft Alternative to item 1
2
weight).
4 Calculator. 1

___________________________________________
PROCEDURE
1. Carry out weighing procedure inside a closed building, so as to exclude influence from wind.
2. Remove any unnecessary objects (inadvertently) left on board aircraft.
3. Ensure that all legally required paperwork is on board (e.g. POH, ATF, etc.).
4. Drain fuel.
5. Align nose wheel.
6. Make sure that the engine oil, hydraulic fluids and coolants are at operating levels.
7. Adjust seats to the rearmost position(s).
8. Flaps retracted (0°).
9. Ailerons in neutral position, elevator in down position.
10. The 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 used, the scale needs to be alternated between
/ under the wheels.
13. Record the weights from the individual scales (wheels) in the table in paragraph 1.16.4.
14. Calculate the moment for each wheel and record in the table in paragraph 1.16.4.
15. Calculate the total empty weight and record in the table in paragraph 1.16.4.
16. Calculate the total aircraft moment and record in the table in paragraph 1.16.4.
17. Use the information recorded in the table in paragraph 1.16.4 and the formulae listed in
paragraph 1.16.3 to calculate the empty weight centre of gravity.

___________________________________________
1.17 CORROSION PREVENTION
The information supplied here is as a general guideline only, and is by no means intended to be
exhaustive, complete or authoritative. For more in-depth information refer to an applicable and
authoritative publication, such as the FAA Advisory Circular AC43.13-1B: Acceptable Methods,
Techniques and Practices - Aircraft Inspection and Repair.
It is highly advisable that expert advice be sought with regard to corrosion related issues.
Aluminium 6061-T6 (of which the aircraft is constructed) is reasonably corrosion resistant and
accordingly is unlikely to corrode substantially.
It is important to keep the aircraft clean and to remove any collection of corrosive causing agents such
as water, anti-freeze, oil, grease, dregs and other foreign matter. To avoid damage to the finish, 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 soon as possible
and the applicable part should be treated immediately to prevent further corrosion.
Treatment consists of mechanically removing as much as possible of any corrosion by-products,

applying corrosion inhibitor and replacing any original finish.
STRUCTURES
• STEEL PARTS:
With the exception of highly stressed components or stainless steel, it is possible to use
abrasives, steel brushes (if operated manually) and steel wool.
• ALUMINIUM PARTS:
Steel wool, emery cloth or steel wire brushes (unless stainless steel), copper alloy brushes,
rotary wire brushes along with other highly abrasive material should not be used. Steel or
emery particles become embedded in the softer material causing corrosion.
Accurate brushing with a sturdy fibre brush should get rid most of the corrosion and ensures
that the anti-corrosion agent penetrates completely into the cracks.
After cleaning surface corrosion, parts must be treated with an anti-corrosion finish
consisting of a 4-litre solution of water, 10% chromic acid and 20 drops of battery
electrolyte. 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.
CABLES:
Tinned steel cables can be coated with any good grade rust preventative oil. Wipe off any excess.
Corrosion prevention of carbon steel cables can be affected by the application of MIL-C-16173,
grade 4 or MIL-C-11796, Class 1 compounds.

___________________________________________
1.18 AIRCRAFT STORAGE
1.18.1 SHORT TERM STORAGE
Refer to and comply with the storage instructions as stipulated by the latest revision of the Rotax
915 iS engine operator and maintenance manuals, as applicable.
If the aircraft is to be stored outside, follow the guidelines outlined in paragraph 1.18.3.
1.18.2 MEDIUM LONG-TERM STORAGE
Refer to and comply with the storage instructions as stipulated by the latest revision of the Rotax
915 iS engine operator and maintenance manuals, as applicable.
• If the aircraft is to be stored outside, follow the guidelines outlined in paragraph 1.18.3.
• Remove the fuel completely from the tanks and lines. Ethanol based fuel should not be
stored in the tanks or carburettors for extended periods.
• Clean the aircraft thoroughly.
• Clean any oil or grease from tyres and coat tyres with a tyre preservative. Cover tyres to
protect against grease and oil.
• Rotate the wheels approximately every 30 days to prevent the formation of flat spots.
• Seal or cover all openings which could allow moisture and / or dust to enter.
• Remove the battery (refer to paragraph 7.3.1). Store the battery in a safe, cool and dry
location. Charge the battery as needed, according to the battery manufacturer’s
instructions / recommendations.
• Seal all engine openings exposed to the atmosphere with suitable covers or non-
hygroscopic tape. Attach a red warning flag at each point where a cover or tape is fitted.,
to act as a reminder.

___________________________________________
1.18.3 OUTSIDE STORAGE
• Tie-down the aircraft in accordance with paragraph 1.10.
• Install protective covers on the pitot tube, static vents (if separate from pitot tube), air
vents, openings in the engine cowling and any applicable openings in fuselage. This is
important as it prevents the ingress of rain, dust and foreign material.
• It is advisable that a tarpaulin (properly attached) is fitted to the aircraft.
1.18.4 RETURNING THE AIRCRAFT 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 instructions / recommendations.
• Install the battery (if it was removed).
• Verify that the oil sump has the proper quantity of engine oil (refer to pilot operating
handbook, the Rotax 915 iS operator manual and / or maintenance manuals, as
applicable, for instructions).
• Verify correct engine coolant levels.
• Inspect air filter and clean if necessary.
• Remove the materials used to cover openings.
• Perform a thorough pre-flight inspection.
• Start and warm-up the engine. Verify engine readings to be within limits.

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1.19 SOURCES FOR THE PURCHASING OF PARTS
Spare parts can be ordered from Sling Aircraft at www.slingaircraft.com, or from your local dealer.
1.20 DISPOSABLE REPLACEMENT PARTS
ITEM DESCRIPTION PART NUMBER

Air filter. Cylindrical air filter. K&N RC-8390
EN-FIL-005-X-X-0
Fuel filter. 90° Mesh filter.
(Sling Aircraft part no.)
Oil filter. Rotax. Rotax part no.897870
UN-TYR-001-X-A-0
Nose wheel tyre. 5.00-5 (6-ply).
UN-TYR-003-X-A-0
Main wheel tyre. 15.00 x 6.00-6 (6-ply).
UN-TUB-001-X-X-0
Nose wheel inner tube. 4.10/3.50-5.
UN-TUB-002-X-X-0
Main wheel inner tube. 15 x 6.00-6.
Refer to the latest revision of the Rotax 915 iS operator manual
Spark plug(s).
and / or maintenance manuals, as applicable.

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1.21 AIRCRAFT PLACARDS AND EQUIPMENT LABELLING
1.21.1 MARKINGS AND PLACARDS
MAGNETIC COMPASS COMPENSATION TABLE
To compensate for the deviation errors of the magnetic compass, the following correction table
is located just below the compass:
For N 30 60 E 120 150
Steer
For S 210 240 W 300 330
Steer
DATE:
BRAKE
The brake lever is located on the central cabin channel 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 cabin channel between the two
front seats and is indicated by a PARK BRAKE label. ON and OFF labels indicate the setting /
activation.
ENGINE THROTTLE
A throttle control knob is located on the central cabin channel and is labelled FULL THROTTLE
(forward position) and IDLE (rear position).

___________________________________________
CABIN HEAT
The cabin heat control knob is located on the instrument panel central area and is labelled CABIN
HEAT.
TRIM SWITCH
The elevator trim motor control is located on the top of the control stick and is labelled UP and DN.
CIRCUIT BREAKERS
Fuses are located on the lower right side of the instrument panel and each 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 DOWN (from 12 o’clock position to 6 o’clock of the rotary switch). For flaps
with the spring-loaded toggle switch, flaps move up when the switch is toggle up and down when
toggled down. Refer to the latest revision of the Pilot Operating Handbook for details on toggle
switch operation.
IGNITION AND STARTER SWITCH
A key switch located on the upper left side of the instrument panel acts as an ignition and starter
switch. It is marked START.

___________________________________________
EFIS WARNING LIGHT
An EFIS warning light is located on the upper left side of the instrument panel and is labelled EFIS
WARNING.
FUEL SELECTOR VALVE
A fuel selector valve is located on the central channel / console 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 instrument panel and are
labelled MAIN PUMP and AUX PUMP.
BAGGAGE COMPARTMENT
A placard indicating the maximum baggage weight is present on the outside of the baggage door
and on the centre front retainer wall of the baggage compartment.
MAX TOTAL BAGGAGE WEIGHT – 35 KG / 77 LB
FUEL TANKS:
AVGAS
OR
MOGAS
198 LITRES
Next to each fuel tank filler cap is located a placard (73 mm x 35 mm) indicating the type of fuel and
the total tank capacity.

___________________________________________
TYRE PRESSURE:
On each main wheel fairing is a placard (102 mm x 9 mm) indicating tyre pressure (2.5 bar).
On 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 cabin
(where ### denotes data unique to each individual aircraft):
ZU-###
CONSTRUCTOR – SLING AIRCRAFT
MODEL – Sling 4 TSi
AIRCRAFT SERIAL NUMBER – ###
ENGINE ROTAX 915 iS - 141 HP
MANUFACTURED: ###

___________________________________________
LIMITATION PLACARDS:
Located on the instrument panel are the following placards:
OPERATE UNDER VMC ONLY

MAXIMUM PERMISSIBLE AIRSPEED 155 KIAS
MAXIMUM PERMISSIBLE RPM 5 800 RPM FOR 5 MINUTES
MAXIMUM CONTINUOUS RPM 5 500
MAXIMUM PERMISSIBLE MASS 950 KG / 2 094 LB
WARNING
NON-TYPE CERTIFIED AIRCRAFT
THIS AIRCRAFT IS NOT REQUIRED TO COMPLY WITH ALL THE
REGULATIONS FOR TYPE CERTIFIED AIRCRAFT
YOU FLY IN THIS AIRCRAFT AT YOUR OWN RISK
NO SMOKING
WARNING
AEROBATICS AND INTENTIONAL SPINS ARE
PROHIBITED
Located on each flap is a placard (223 mm x 26 mm) that identifies the no-step area:
NO STEP

___________________________________________
1.21.2 GENERAL SAFETY INFORMATION / CONSIDERATIONS
Ensure that the ballistic parachute (if fitted) lever lock mechanism is in place during all repair and
servicing work.
Never work on an aircraft if the appropriate safety equipment (fire extinguisher, first aid kit, etc.) is not
present and serviceable.
Always use appropriate safety attire when working on 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.
Always use the correct tools for a specific task.
Always ensure that the lane / ignition switches are OFF before working on a propeller or the engine.
Ensure that the Master switch is OFF / electrical equipment switches are OFF before removing or fitting
electrical wiring, electrical equipment or electrical / electronic instruments. Consider disconnecting the
battery earth wire before working on electrical equipment.

___________________________________________
Never disassemble a wheel or release the wheel assembly bolts before the tyre has not been completely
deflated, as explosive separation of the wheel assembly may occur if done so before the pressure is
relieved.
Never attempt to remove the valve core before the tyre is completely deflated. The core may eject at
high velocity if unscrewed before the pressure is relieved.
Never use oxygen to inflate a wheel / 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 disconnected fluid lines to
prevent drip / spillage and / or contamination. Clean up any spilled fluid before continuing with work.
Ensure adequate lighting when working on an aircraft.
Always work in well-ventilated areas, especially when working with chemicals / fluids.
Ensure that the aircraft is stable and cannot inadvertently / unexpectedly move (e.g. pitch forward or
backward or fall off jacks or supports) before starting work.
Never smoke when working on or in the vicinity of an aircraft.

___________________________________________
1.21.3 INSTRUCTIONS FOR CONCERNS REGARDING SAFETY OF FLIGHT
If any person should have any concerns regarding the safety of a Sling Aircraft Sling 4 TSi for flight,
these should be emailed to technical@slingaircraft.com. The following information should be included in
the email:
• Aircraft make, model and serial number.
• Engine make, model and serial number.
• Date of last inspection.
• Airframe total time.
• Engine total time.
• Description of the un-airworthy items found.
• Aircraft owner.
Alternatively, write to:
Sling Aircraft, PO Box 308, Eikenhof, 1872, South Africa.

___________________________________________
SECTION 2
INSPECTION
This section provides information regarding general inspection considerations, inspection schedules and
inspection procedures.
2. INSPECTION
This section should be read in conjunction with section 3.
2.1 GENERAL CONSIDERATIONS REGARDING INSPECTION
Inspections performed on an aircraft should be performed in accordance with acceptable standards,

such as described in, for example, the FAA Advisory Circular AC43.13-1B: Acceptable Methods,
Techniques and Practices - Aircraft Inspection and Repair.
STRUCTURE(S) IN GENERAL:
Inspect for the condition 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, kinks, excessive wear, corrosion, security of attachment, binding
and correct tension.
Inspect pushrods for alignment, freedom of movement and security of attachment of rod-end
bearings.
SAFETY EQUIPMENT:
Inspect seat belts / safety harnesses for security of attachment, correct operation of buckles and
couplings and integrity of the webbing and webbing-to-coupling connections.
Inspect fire extinguisher(s) for correct type, currency (inspection / service period), correct pressure
indication, security of attachment and correct disengagement from mounting bracket.
Inspect first-aid kit for currency and compliance with national regulations.
MOVING PARTS:
Lubrication, security of attachment, safety of bolts, binding, excessive play, excessive wear, proper
adjustment, correct travel, condition of attachments and hinges, absence of corrosion, deformation,
condition of bearings, sealing, rivet slackening, cleanliness, tension (cables), cracks.
COMPOSITE PARTS:
Inspect for cracks, dents and delamination.

___________________________________________
FLUID LINES, HOSES, TUBES AND CONNECTIONS:
Inspect for leaks, cracks, kinks, nicks, cuts, twisting, any 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.
FILTERS:
Inspect for cleanliness, damage and security of attachment.
FLUIDS:
Inspect for contamination.
BOLTS, NUTS, SAFETY WIRE, SPLIT PINS AND ATTACHMENTS:
Inspect for proper tightening and safe tying, absence of cracks or nicks, corrosion, damage to
thread, wear and excessive play.
Ensure that safety wire is installed in such a manner as to prevent the loosening of the part to which
it is applied.
Verify the use of correct specification of bolts, nuts and connecting hardware.
Observe creep marks for any indication of creep.
ELECTRICAL WIRING, BONDING, CONNECTION, CIRCUIT BREAKERS AND SWITCHES:
Inspect for security of attachment, any sign of arcing, fraying, burning, defective (brittle, nicked,
cracked, cut or penetrated in any manner) insulation, loose or broken terminals, heat deterioration,
discolouration and corroded terminals.
Inspect bonding connections for proper attachment and corrosion.

Inspect switches for any abnormal side-to-side movement. Inspect switches for security of
attachment.
Consider the possibility that an incorrect switch substitution could have been made during
maintenance (i.e. inspect for the correct switch rating).
Consider the possibility that an incorrect circuit breaker substitution could have been made during
maintenance (i.e. inspect for the correct circuit breaker rating).
Inspect for the correct labelling of switches and circuit 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, cracks and corrosion.

___________________________________________
TYRES AND WHEELS:
Verify for correct inflation of tyres.
Inspect for worn spots, bulges in the tyre sidewall, cracks, cuts or embedded objects.
Inspect for tread wear.
Inspect the wheel hub for cracks, nicks, warping or for any kind of damage.
INSTRUMENTS:
Inspect instruments for security of attachment, sensible indication, absence of cracks in viewing
glass of the instrument and absence of moisture behind the viewing the glass of the instrument.
Inspect for cracks in instrument enclosures / bodies / frames.
Inspect for proper connection of instruments to electrical wiring and / or pneumatic tubes and
couplings.
Consider the possibility that an analogue instrument could have been replaced by an instrument
with incorrect markings (e.g. the colours speed range markings on an airspeed indicator), incorrect
range or alternative units of measurement.
Verify the correct settings on electronic instruments.
DOCUMENTATION:
Verify that the documents required by the current national regulations are present, correct and up to
date.
PLACARDS, LABELLING AND INSTRUCTIONS:
Inspect for the presence and correctness of any placards or notices which are required by the
current national regulations.
Inspect for the proper labelling of equipment, switches and control levers.

___________________________________________
2.2 INSPECTION PANELS
Inspection points / locations that are not in plain view may be accessed through specific inspection holes
and inspection hatches and / or by the removal of panels or fairings, as detailed below:
• Inspection hatches on the wing underside provide access to the aileron bell crank and flap
torque tube and pushrod.
• Covers on the underside of the wing and at the wing to-fuselage connection points provide
access to engine fuel supply and return line connections to the tank, tank level sender, tank
level sender-wiring connectors, flap and aileron control pass-throughs and rear spar
connections (the front spar connection is accessed inside the cabin).
• Small round tail cone side holes provide access to the elevator control horn and pushrod
end.
• The vertical and horizontal tail nacelle / fairings provide access to vertical and horizontal tail
mounting and connections.
• The elevator left lower (under elevator) inspection panel allows access to trim tab motor and
trim tab pushrod.
• Inspection panels on the ventral rear fuselage allows for inspection of the elevator cable
guides.
• A rear cabin central floor inspection panel provides access to the brake line T-piece divider,
brake lines; the elevator control system pushrod.
• Baggage compartment floor inspection panels provide access to the cables for rudder
control.
• Cabin longitudinal divider side inspection hatches provide access to fuel lines, rudder
cables and throttle cables.
• The instrument panel cover provides access to the aircraft instrumentation and the related
wiring and pneumatic connections.
• The engine cowling provides access to the engine and related systems, access to the
components of the electrical system located forward of the firewall and access to the nose
gear strut and steering assembly mechanism.
• The propeller spinner provides access to the propeller hub.
• A clear lens in each wing provides access to the landing and taxi lights.

___________________________________________
2.3 INSPECTION SCHEDULE
Sling Aircraft considers the inspection schedule outlined below as compulsory for the safe operation of
the airframe and systems over an extended period. The described servicing requirements pertain to
operation in non-extreme climatic conditions.
2.3.1 ENGINE
Comply with the inspection schedule as indicated in the latest revision of the Rotax 915 iS or 916 iS
engine maintenance and / or operator manuals, as applicable.
2.3.2 PROPELLER
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 are as follows:
• Inspection for airworthiness before the first flight of the day, as specified in the Pilot Operating
Handbook.
• Condition inspection at every 100 hours. Refer to paragraph 2.4.
• Special inspections, added to normal periodic inspections, e.g. annual inspections which may be
required by national legislation.
• Singular inspection(s), when the aircraft has been exposed to conditions that may have
damaged one or more of its components.
• If the aircraft is used infrequently a 100-hour inspection must be performed annually. Refer to
paragraph 2.4.

___________________________________________
2.4 CONDITION INSPECTION (100 HOUR / ANNUALLY)
Follow the inspection checklist in paragraph 2.5 and rectify any shortcomings.
2.4.1 INSPECTION PANELS AND INITIAL INSPECTION AND CLEANING
Each person performing an annual or 100-hour inspection shall, before that inspection:
1. Remove or open all necessary inspection panels, access doors, fairings and cowlings.
2. Clean the aircraft and aircraft engine, after an initial visual inspection for oil, exhaust or other
leaks.
2.4.2 FUSELAGE GROUP
1. Inspect skin for deterioration, distortion, other evidence 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. Inspect for cleanliness and for loose equipment that might foul the controls.
2. Inspect the seats and safety belts / harnesses for condition and / or any defects.
3. Inspect canopy and windows for deterioration and breakage.
4. Inspect instruments for poor condition, mounting, marking, and (where applicable) improper
operation.
5. Inspect flight and engine controls for improper issues.
6. Inspect all systems for improper installation, poor general condition, apparent and obvious
defects and insecurity of attachment.
7. Inspect the fire extinguisher for security of attachment, correct pressure and currency of
service period.

___________________________________________
2.4.4 ENGINE AND COWLING GROUP
1. Inspect the engine section for visual evidence of excessive oil, fuel or hydraulic leaks, and
sources of such leaks.
2. Inspect studs and nuts for improper torque and obvious defects.
3. Inspect entire engine mount for cracks, looseness of mounting, and looseness of the engine
to mount connection.
4. Inspect flexible vibration dampeners for poor condition and deterioration.
5. Inspect engine control linkages for defects, improper travel and improper safe tying.
6. Inspect lines, hoses and clamps for leaks, improper condition and looseness.
7. Inspect exhaust stacks for cracks, defects and improper attachment.
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 and instrumentation wiring for proper attachment and any signs of defects.
11. Inspect cowling for cracks and defects.
12. Comply with any inspection requirements as stipulated in the latest revision of the Rotax 915
iS or 916 iS operator’s manual and / or maintenance manuals, as applicable.
2.4.5 LANDING GEAR GROUP
1. Inspect all parts for poor condition and insecurity of attachment.

2. Inspect shock absorbing devices (spring on nose gear) for damage.
3. Inspect members for undue or excessive wear, fatigue and distortion.
4. Inspect hydraulic lines for leakage.
5. Inspect wheels for cracks, defects and condition of bearings.
6. Inspect tyres for wear, cuts and slippage.
7. Inspect brakes for improper adjustment.

___________________________________________
2.4.6 WING AND CENTRE SECTION ASSEMBLY
Inspect for:
1. Poor general condition.

2. Skin deterioration.
3. Distortion.
4. Evidence of failure.
5. Insecurity of attachment.
2.4.7 EMPENNAGE ASSEMBLY
Inspect all 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 PROPELLER GROUP
Inspect propeller assembly for:
1. Cracks.
2. Nicks.
3. Improper torque and lack of safe tying on propeller attachment bolts.
4. Comply with any inspection requirements as stipulated in the latest revision of the propeller
manufacturer operator’s manual.

___________________________________________
2.4.9 RADIO GROUP / AVIONICS / ELECTRONIC EQUIPMENT
1. Inspect radio and electronic equipment for improper installation, insecure mounting and
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 condition.
4. Inspect antenna/e for poor condition and insecure mounting.
2.4.10 OPTIONAL EQUIPMENT
Check all optional equipment for proper operation. Refer to optional equipment manufacture’s
manuals / documentation.

___________________________________________
2.5 MAINTENANCE CHECKS
2.5.1 25 HOUR, 100 HOUR AND ANNUAL SERVICE INSPECTION CHECKLIST
This checklist must be read / performed in conjunction with the applicable engine and propeller
checklists as found in the latest revision of the Rotax 915 iS or 916 iS engine operator’s manual and
/ or maintenance manuals, as applicable, and the latest revision of the Airmaster AP430CTF-
WWR72B or MT Propeller operation manual.

___________________________________________
SLING AIRCRAFT AMO MPI & SERVICE CHECKLIST
This checklist must be completed in conjunction with the applicable engine and propeller.
Checklists. (See latest revision of engine maintenance manuals and the latest revision of the
propeller. Maintenance manual. See also SA-CATS 44.01.06 Annexure A for minimum
maintenance requirements).
Any provisions set out in this check list that are not applicable to the work being performed should
be marked “N/A” and signed in confirmation. (No entries should be left blank.)
NOTE
DAMAGED PARTS MUST BE REPLACED ON CONDITION THAT THEIR
DAMAGE INTERFERES WITH NORMAL OPERATION OF THE AIRCRAFT
AC/ TYPE: _______________________________________________________________
A/C SERIAL NO: __________________________________________________________
A/C REGISTRATION: ______________________________________________________
DATE: __________________________________________________________________
A/C HOBBS: _____________________________________________________________
JOB CARD NO: ___________________________________________________________
Technician Name: _______________________ Inspector Name: ____________________
AIRCRAFT DOCUMENTATION
1. AIRCRAFT DOCUMENTATION
No. Work To Be Done Technician Inspector

1.1 Verify all documentation is in aircraft and valid.
AIRFRAME AND INSTALLED EQUIPMENT
1. FUSELAGE OR HULL

1.1 Open all access panels, clean aircraft, engine and propeller.
1.2 Carefully inspect the fuselage or hull for general condition.
1.3 Check the skin covering for condition and security.
1.4 Check installed systems and components for proper installation,
security, defects and satisfactory functioning.
1.5 Check registration markings for conformity.
1.6 Ensure all drain holes are open.

___________________________________________
2. CABIN AND COCKPIT

2.1 Inspect the cabin and cockpit for cleanliness and loose or displaced
articles that might interfere with the operation of controls.
2.2 Check seats, seat rails, seat locking mechanisms, safety harness and
tie-down fittings for security and conditions.
2.3 Check condition of forward flooring at rudder pedals and aft at the main
gear mounting channel.
2.4 Check windscreens and windows for security, condition and where
applicable, satisfactory operation.
2.5 Check exits for proper installation, condition, legibility of operating
instructions and other markings and for satisfactory functioning.
2.6 Check flight, engines and propeller controls for correct installation,
security of connections, condition, proper operation and where
applicable legibility of markings. As per the manufacturers manual.
2.7 Check all systems and their controls in the cockpit or cabin for proper
installation, security, satisfactory operation and legibility of markings.
2.8 Check for smoking rivets on control tubes.
2.9 Ensure that all required placards and registration letter are correctly
installed and positioned, are legible and in good condition.
2.10 Check wing steps for excessive play and security of attachment.
2.11 Check currency of ballistic parachute system.
3. INSTRUMENTS AND INSTRUMENT SYSTEMS

3.1 Check instruments for proper installation, security, obvious defects and
legibility and correctness of markings.
3.2 Check instruments operating systems for proper installation, security
and condition.
3.3 Check that filter elements of vacuum operated instruments are cleaned
or replaced in accordance with the manufacturer’s recommendations.
3.4 Check altimeter and airspeed indicators for accuracy by performing the
test on the last page of this check list.
4. LANDING GEAR

4.1 Check the landing gear for general condition and security of attachment
of all components.
4.2 Check trusses and other members for condition and security of
attachments.
4.3 Check steering mechanisms for condition and bearings for condition,
lubrication and correct adjustment. Ensure compliance with SB0020
Rev1.
4.4 Check tyres for condition and creep, check tyre pressure.
4.5 Check brakes for condition, correct adjustment and operation.

___________________________________________
5. WINGS AND CENTRE SECTION

5.1 Check wing attachment and bracing for security, condition, correct
assembly and where applicable, correct torqueing of attachment bolts.
1. Front mounting bolts torqued to - Nm
2. Rear mounting bolts torqued to - Nm
3. Main Spar attachment bolts torqued to - Nm

5.2 Check movable surfaces for condition, security, proper attachment,
correct travel and operation and security of all control connections.
5.3 Check installed systems and components for proper attachment, correct
travel and operation and security of all control connections.
5.4 Inspect condition of skin along main spar. Ensure compliance with
SB0014 Rev1 (Compliance not required for aircraft with serial numbers
above 232sk).
6. EMPENNAGE

6.1 Check attachment of all components for security and correct assembly.
6.2 Check moveable surfaces for condition, security, proper attachment,
correct travel and operation and security of all control connections.
6.3 Check installed systems and components for proper installation,
security, condition and satisfactory functioning.
7. ELECTRICAL AND RADIO EQUIPMENT INSTALLATIONS.

7.1 Inspect batteries for condition, corrosion and venting and for correct
installation.
7.2 Check electrical installations and components for condition, security of
mounting and satisfactory functioning.
7.3 Check electrical wiring and conduits for condition and security
mounting.
7.4 Check bonding and shielding for correct installation, security and
condition.
7.5 Check radio equipment for correct functioning and for correct
installation and security of mountings.
7.6 Check radio antenna systems for condition, correct installation and
security, and trailing aerials for satisfactory operation.
7.7 Check for unacceptable interference from electrical and ignition
systems on applicable radio equipment.
7.8 Perform a transponder test as per the transponder manufacture
checklist, read with SA CATS 43.02.10.
7.9 Perform the ELT test as per the manufacturers manual, read with SA
CATS 43.02.11.

___________________________________________
8. FUEL SYSTEMS

8.1 Check fuel tanks and fuel systems for the presence of water or other
foreign matter, condition, security, correct installation, freedom from
leaks and satisfactory functioning of components.
8.2 Check fuel lines, wires and cables beneath the floor for condition.
8.3 Inspect RIGHT, LEFT, OFF fuel selector for condition and proper
operation.
8.4 Close all access panels and inspect each of them for correct installation
and security.
POWER PLANTS AND INSTRUMENTS RELATING THERETO
1. ENGINE AND ENGINE INSTALLATIONS.

1.1 Perform the relevant ROTAX engine maintenance checklist.
1.2 Check all studs, nuts and other fasteners for security, condition and
correct torque.
1.3 Check the internal condition of the engine by means of cylinder
compression or blow-by checks, oil filter and sump drain plugs for
evidence of metal particles. (refer to ROTAX engine maintenance
checklist)
1/ 2/ 3/ 4/
1.4 Check engine shock mounts for condition, security and correct
installation.
1.5 Check engine controls for correct installation, operation, condition and
security.
1.6 Check fluid-carrying lines for security, correct installation and condition.
1.7 Check security and condition of exhaust manifold assemblies, heat
exchangers and heat mufflers.
1.8 Check engine driven accessories for condition and security of
mountings.
1.9 Check condition of engine mount frame.
1.10 Check engine mountings for condition and security of attachment to the
main structure.
1. Engine mount onto firewall torqued to - Nm
2. Engine onto engine mount torqued to - Nm

1.11 Check cooling baffles and seals for condition, security and correct
installation.
1.12 Check engine cowling for condition, security and correct installation.
1.13 Check cooling gills or other cooling devices for condition, security,
correct installation and proper operation.
1.14 Check ignition systems for condition, check all wiring and security of
terminals.
1.15 Inspect the engine for evidence of fuel, oil or any other fluid leaks and
for the source of any such leaks.

___________________________________________
2. PROPELLERS

2.1 Perform the relevant propeller maintenance manual checklist.
2.2 Check propeller hub bolts are correctly torqued and leading-edge caps
are properly secured.
1. Propeller mounting bolts spacer to propeller hub torqued to- Nm
2.3 Check security of attachment of propeller to the engine.
1. Propeller mounting bolts spacer to engine flange torqued to - Nm
2.4 Check propeller for oil leaks and for satisfactory operation.
2.5 Check propeller control systems for condition and satisfactory
operation.
2.6 Check the propeller track is within specified limits.
2.7 Check metal and composite propeller blades for nicks and damage.
2.8 Check spinner screws for security.
3. POWERPLANT INSTRUMENTS AND INSTRUMENT SYSTEMS

3.1 Check instruments for proper installation, security, obvious defects and
legibility and correctness of markings.
3.2 Check powerplant instruments before and during engine runs.
4. ENGINE OPERATION / ENGINE RUNS

4.1 Verify power out-put is sufficient (static & idle RPM).
4.2 Verify RPM drop on each magneto is within limits.
4.3 Verify fuel and oil pressures.
4.4 Satisfactory operation of any engine-driven accessory or other items not
specifically mentioned above.
Compass swing
5. COMPASS SWING (EVERY 12 MONTHS, READ WITH SA CATS 43.02.18)

5.1 Verify by means of a compass swing the accuracy of the compass fitted
in the aircraft.
Mass & Balance
6. MASS & BALANCE (EVERY 5 YEARS, READ WITH SA CATS 43.02.07.)

6.1 Perform the mass and balance check.

___________________________________________
Pitot static system test
7. PITOT STATIC TEST PERFORMED AT ANNUAL INSPECTION.
INSEPCTED AND FOUND SATISFACTORY

INSTRUMENT MPI
INITIAL INSPECTION FINAL INSPECTION
1 Test the pitot static for freedom from obstructions
and leaks. Drain water traps if applicable.
2 Test all warning unit and pitot heater.
3 Inspect the compass for discolouration and
bubbles, check for freedom or rotation and ensure
that the compass has been swung in accordance
with the requirements and periods specified in SA-
CATS 43.02.18
4 Check altimeters and airspeed indicators for
accuracy. Carry out pitot static check if applicable.
5 Inspect and check the autopilot for correct
functioning during the flight test.
6 Inspect all instruments for proper installation
security, obvious defects, legibility and legibility of
markings.
7 Inspect and test pneumatic operated instruments
for correct functioning.
8 Inspect VSI for proper function and zero pointer.
AIRSPEED INDICATOR
AIRSPEED SCALE ERROR FRICTION

READING ON L/H READING ON R/H
INDICATOR TOLERANCE TOLERANCE
40 +/-2.5 +/-3
60 +/-2.5 +/-3
80 +/-2.5 +/-3
100 +/-2.5 +/-3
120 +/-2.5 +/-3
140 +/-2.5 +/-3

___________________________________________
ALTIMETER
EQUIVELANT
ALTITUDE TOLERANCE READING ON L/H READING ON R/H
PRESSURE
-1000 1050.36 20
0 1013.25 20
1000 977.15 20
2000 942.10 30
3000 908.10 30
4000 875.09 35
6000 811.97 40
8000 752.61 60
10000 696.12 80
12000 644.38 90
14000 595.21 100
TEST READING L/H READING R/H TOLERANCE
Case leak test 100
Hysteresis test
75
First test point (50% of
maximum altitude)
Second test point
(40% 75
of maximum altitude)
After effect test 30

___________________________________________
ALTITUDE (feet) TOLERANCE (feet) READING L/H READING R/H
1000 70
2000 70
3000 70
5000 70
10000 80
15000 90
Pressure altitude test
PRESSURE IN
ALTITUDE (feet) READING L/H READING R/H
MILLIBARS
951.55 1727
965.10 1340
982.03 863
998.96 392
1013.25 0
1032.82 +531
1046.37 +893
1049.41 +974
The signature below will be used as a statement in confirming all maintenance has been performed as
per this checklist as well as in accordance with SA-CATS & CARS in accordance with the relevant
manufacturers manuals set out in this checklist.
Inspector’s name: _______________________________________________________________
Inspector’s signature & stamp: _____________________________________________________
Date: _________________________________________________________________________

___________________________________________
2.5.2 2000 HOUR SERVICE CHECKLIST
This checklist must be completed / performed in conjunction with the 100 hours MPI & service checklist and
applicable engine and propeller checklists.
1. FUSELAGE OR HULL

Check the rudder cable at the marked inspection points in Figure 35:
1.1 Rudder control system. Replace any cables with broken strands or
indications of corrosion.
Inspect the rudder cable guide for signs of wear. Replace the guide if
1.2 the rudder cable wears through the rear fuselage skin. See Figure 36:
Rudder cable guide.
Inspect the fuselage, paying particular attention to the vertical and
1.3 horizontal stabiliser attachments to the fuselage. See Figure 39 and
Figure 29: Horizontal stabilizer to fuselage attachment.
Check for excessive play in elevator control system. Replace smoking
1.4
rivets. See Figure 26: Elevator control system.
2. WINGS AND CENTRE SECTION

Remove wings as per 4.1.1.1 for detailed inspection of front and rear
spar root.
Inspect the centre spar, main and rear spar attachment holes and
adjacent structure for cracks or damage, paying particular attention to
the main spar bottom cap.
2.1
The AN5-10A rear spar bolt must be replaced with AN6-10A bolt. The
rear spar bolt hole should be drilled to 9.0mm then reamed to 9.45mm
for the correct interference fit. Ensure the bolt is torqued as per 1.5.1.
Replace main spar attachment hardware.

Check flap and aileron hinge brackets for cracks or damage, paying
2.2
particular attention to unwanted play of all control connections.
Inspect bell cranks for cracks and security of mounting to wing structure.
2.3
See Figure 11: Bell crank (1) for details.
3. EMPENNAGE

3.1 Inspect elevator and rudder hinge brackets for cracks or damage.
Replace elevator trim tab control horn as illustrated in Figure 31:
3.2
Elevator control horn (5).
4. LANDING GEAR

Follow the procedure outlined in 4.4.1.6 to remove the main landing
gear. Thoroughly examine the main landing gear for cracks spanning its
4.1 entire length up to the centreline. Check condition of screws on the main
landing gear plate outlined in Figure 6: Main landing gear plate machine
screws. Replace main undercarriage attachment hardware.

___________________________________________
Figure 6: Main landing gear plate machine screws.

___________________________________________
3. SERVICE
This section should be read in conjunction with Section 2.
3.1 GENERAL CONSIDERATIONS REGARDING SERVICE AND MAINTENANCE
Work, maintenance and servicing conducted on aircraft should be performed in accordance with
acceptable standards, such as described in, for example, 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 manufacturer,
to ensure correct specification and safe operation. Refer to the current manufacturer documentation in
this regard.
STRUCTURES IN GENERAL:
Any structural repair to the aircraft should be performed by qualified and trained personnel. Refer to the
aircraft manufacturer.
CABLES AND PUSHRODS:
Service as required.
SAFETY EQUIPMENT:
Service according to any applicable national regulations, calendar-based requirements and

manufacturer recommendations and instructions.

___________________________________________
LUBRICATION:
Periodic lubrication of moving parts ensures proper operation and extends part lifetimes considerably.
Avoid excessive lubrication as this may cause external surfaces of hinges and bearings to collect dirt
and dust.
If a part is lubricated by hand, remove excess grease.
MOVING PARTS:
Lubricate as required with the correct lubricant, as specified for the part.
COMPOSITE PARTS:
Repair 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), pressure rating and length (of the line to be replaced).
Allow enough slack in flexible hoses for stretch when pressure is applied / removed.
Do not twist flexible hoses and metal lines.
Metal end fittings should not be considered as part of the flexible section of a flexible hose.
Keep the bend radius of installed flexible hoses as large as possible to avoid collapse.
When installing seals into end fittings, ensure that the seal is not scratched, cut or damaged.

___________________________________________
BOLTS, NUTS, WASHERS, SAFETY WIRE, SPLIT PINS AND ATTACHMENTS:
Lock-nuts, lock-washers, split pins and safety wire should not be reused after removal. Fit new.
If in need of replacement, replace bolts, nuts, washers and connecting hardware with items of the same
specification.
Ensure bolt and nut threads are clean and dry before fitment, unless otherwise specified by the
manufacturer.
Inspect all bolts, nuts and screws for damage and corrosion before reinstallation. Replace if necessary.
Apply safety wire and / or split pins as required.
Do not overstress safety-wire, as it will break under vibration if twisted too tightly. It is preferable to twist
safety wire with locking pliers. If safety wire is to be twisted by hand, ensure 6 to 8 twists per inch (25.4
mm).
Ensure that safety 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
wrench with adequate range. Where possible, apply the torque to the nut and not the bolt. This will
prevent rotation of the bolt in the hole and will reduce wear on the bolt hole.
Where applicable apply creep marks to bolts and nuts.
ELECTRICAL WIRING, BONDING, CONNECTION, CONNECTORS, CIRCUIT BREAKERS AND

SWITCHES:
Electrical wiring and cables must be replaced with wire and cables of the same rating and specification.
Replace defective switches with switches of equivalent rating.
Circuit breakers should be replaced with circuit breakers of identical rating.
Circuit breakers (if of the type operable by hand) should be periodically cycled with NO LOAD (i.e. with
the electrical system turned off) to enhance contact performance.
Electrical connectors should be replaced with connectors of the same mechanical specification and
electrical rating.

___________________________________________
FILTERS:
Replace as required.
FLUIDS:
Replenish fluids as required with the correct specification fluid.
Do not mix hydraulic / brake fluid and / or coolant fluid of different specifications or from different
manufacturers complying to the same specification. Drain the system, flush and replenish.
TYRES AND WHEELS:
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 enable the detection
of tyre slippage.
INSTRUMENTS:
Service instruments according to any applicable national regulations (if any) and the manufacturer
recommendations and instructions. Refer to the latest revision of the instrument manufacturer
documentation.
DOCUMENTATION:
Verify that the documents required by the current national regulations are present, correct and up to
date.

___________________________________________
PLACARDS, LABELLING AND INSTRUCTIONS:
Inspect for the presence and correctness of any placards or notices which are required by the current
national regulations.
Inspect for the proper labelling of equipment, switches and control levers.
ENGINE:
Refer to and comply with the service schedule, requirements and procedures as stipulated in the latest
revision of the engine manufacturer operator’s manual and / or maintenance manuals and / or service
instructions, service letters and service bulletins, as applicable.
PROPELLER:
Refer to and comply with the service schedule, requirements and procedures 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 ROUTING AND SECURING OF FLEXIBLE FUEL, OIL AND
HYDRAULIC PIPES AND ELECTRICAL CABLE / SIGNAL WIRES
In general, flexible fuel, oil and hydraulic pipes and electrical cables and signal wires can be tie wrapped
to fuselage structures, and to each other, with the aid of stand-offs / spacers cut from rubber pipe or
clear pneumatic pipe, to ensure clearance and prevent chaffing.
Tie wraps should not be tightened to such an extent that distortion of the cross-sectional area of flexible
pipes occur, or that electrical wire insulation is pinched. Tighten only to the extent necessary to prevent
relative movement and chaffing and to ensure secure installation.

___________________________________________
3.2 LUBRICATION POINTS, LUBRICANTS AND INTERVALS
LUBRICATION POINT LUBRICANT INTERVAL

1 Canopy door hinges. As needed.
2 Canopy door latches. As needed.
3 Rudder and pedal control cable terminals. 100 Hours / yearly.
4 Rudder cable guides. 100 Hours / yearly.
5 Elevator pushrod (in centre) guide. 100 Hours / yearly.
6 Elevator torque tube bushes. 100 Hours / yearly.
7 Trim tab hinge. 100 Hours / yearly.
8 Aileron pushrod guide (in the centre of wing). 100 Hours / yearly.
Refer to the list of
9 Flap torque tube bushes. 100 Hours / yearly.
approved lubricants
10 Flap actuator ends. 100 Hours / yearly.
in paragraph 1.4.
11 Rudder 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 Hours / yearly.
16 Engine throttle cable 300 Hours.
17 Engine choke cable 300 Hours.
18 Heater activation cables 300 Hours.
Refer to the latest revision of the propeller
19 Propeller
operator’s manual.
Refer to the latest revision of the Rotax 915
20 Engine iS or 916 iS engine operator’s manual and /
or maintenance manuals, as applicable.

___________________________________________
3.3 SERVICE BULLETINS / INSTRUCTIONS / LETTERS
In addition to the service information contained herein, any service / inspection / modification
bulletins, letters and instructions issued by the engine, propeller or aircraft manufacturer should be
complied with.
3.4 SERVICE SCHEDULE
Refer to and comply with the service schedule and requirements as stipulated in the latest revision
of the Rotax 915 iS or 916 iS operator and / or maintenance manuals, as applicable.
Refer to and comply with the service schedule and requirements as stipulated in the latest revision
of the propeller operator’s manual.
3.4.1 SERVICE PERIOD ADJUSTMENT
This paragraph lists items which may have their normal service intervals adjusted due to external
influences or circumstances, or changes in operating conditions and / or procedures.
REASON FOR
NORMAL SERVICE
ITEM ADJUSTING SERVICE ACTION
PERIOD
PERIOD
Perform a battery check
100 Hours. Refer to more frequently than the
Battery Extreme climates.
paragraph 3.4.8. normal service period.
Replace if necessary.
Remove and clean the air
100 Hours. Refer to filter more frequently than
Air filter Dusty environment.
paragraph 3.4.8. the normal service period.
Replace if necessary.
Operating predominantly on
leaded AVGAS. The engine
is considered to be operated
predominantly on leaded
AVGAS when run for more
than 30% of engine More frequent oil changes
operating time on leaded required (recommended
AVGAS fuel. every 25 hours).
Engine
Oil
Refer to the latest revisions Oil filter change
of the Rotax service recommended every 50
instruction titled “Selection hours.
of suitable operating fluids
for Rotax Engines” and
Rotax 915 iS operator and
maintenance manuals for up
to date information.
As may be stipulated in the latest revision of the Rotax 915 iS or 916 iS engine operator’s manual
and / or maintenance manuals, as applicable.
As may be stipulated in the latest revision of the propeller operator’s manual.

___________________________________________
3.4.2 ITEMS WITH CALENDAR BASED SERVICING
This paragraph lists items which must be serviced at specified calendar periods, calculated from the
last date of being serviced.
Refer to and comply with the latest revision of the 915 iS or 916 iS operator’s and / or maintenance
manuals, as applicable, with regard to calendar-based items, if any.
Refer to the propeller operator’s manual with regard to calendar-based items, if any.
ITEM PERIOD ACTION

As
recommended
Engine coolant by coolant or Drain and replace.
engine
manufacturer.
Fire extinguisher. As indicated. Service.
Magnum 901 6 years. Service.
Ballistic parachute rocket.
BRS 12 years. Service.
Ballistic parachute Magnum 901 6 years. Repack.
(canopy). BRS 6 years. Repack.
Disassemble and inspect. Refer
Muffler / heat exchanger assembly. 5 Years. to paragraphs 7.1.1 for removal
and disassembly instructions.
Any items (if any) as stipulated in the
latest revision of the Rotax 915 iS or 916
iS engine operator’s manual and / or As indicated. As described / indicated.
maintenance manuals, as applicable, and
/ or any relevant service instruction.
Any items (if any) as stipulated in the
latest revision of the propeller operator’s
As indicated. As described / indicated.
manual and / or any relevant service
instruction.
3.4.3 DAILY
The following service requirements should be met on each day that the aircraft is operated:
• Pitot and static ports - Inspect for obstructions.

• Oil - Verify oil level. Refer to paragraph 5.2.5.
• Coolant - Verify coolant level.
• Fuel - Drain some fuel from tanks and inspect for any water and / or sediment.
• Fuel tank vents - Inspect for obstructions.
• Tyres - Inspect for wear, damage and correct pressure.

___________________________________________
3.4.4 AS NEEDED
The following service requirements should be complied with on an as required basis:
• Lubricate the applicable (as needed) items in paragraph 3.2.

• Replace and maintain tyres 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.
3.4.5 FIRST 25 HOURS
The following service requirements should be complied with after the first 25 hours of operation:
• Complete the inspection checklist in paragraph 2.5 and rectify any shortcomings.
• Oil change - Refer to the latest revision of the Rotax 915 iS or 916 iS engine operator’s
manual and / or maintenance manuals, as applicable.
• Perform all propeller service requirements (if any) in accordance with the provisions of the
latest revision of the propeller manufacturer operator’s manual.
• Perform all engine service requirements (if any) in accordance with the provisions of the latest
revision of the Rotax 915 iS or 916 iS engine operator and / or maintenance manuals, as
applicable.
3.4.6 FIRST 50 HOURS
The following service requirements should be complied with after the first 50 hours of operation:
• Perform all propeller service requirements, if any, in accordance with the provisions of the
latest revision of the propeller manufacturer operator’s manual.
• Perform all engine service requirements, if any, in accordance with the provisions of the latest
revision of the Rotax 915 iS or 916 iS engine operator’s and / or maintenance manuals, as
applicable.
3.4.7 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:
• Engine - perform all engine service requirements, if any, in accordance with the provisions of
the latest revision Rotax 915 iS or 916 iS engine operator and / or maintenance manuals, as
applicable.
• Propeller – perform all propeller service requirements, if any, in accordance with the
provisions of the latest revision of the propeller manufacturer operator’s manual.

___________________________________________
3.4.8 EVERY 100 HOURS / ANNUALLY
The following service requirements should be complied with after every 100 hours of operation or
on an annual basis, whichever comes first:
• Complete the inspection checklist in paragraph 2.5.1 and rectify any shortcomings.
• Battery - Inspect for leakage, loosening of tie in strap, proper charge, integrity of terminal
connections and general condition. Perform a battery check using a high-quality testing
device designed for the purpose.
• Engine oil - Change engine oil and replace oil filter element (refer to the latest revision of the
Rotax 915 iS or 916 iS operator and / or maintenance manuals, as applicable).
• Engine - perform all engine service requirements, if any, in accordance with the provisions of
the latest revision of the Rotax 915 iS or 916 iS 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 side of the firewall).
• Fuel filter and lines - Visually inspect all fuel lines. Remove and visually inspect the fuel
filters. Replace the fuel filters if necessary.
• Lubricate the applicable items as listed in paragraph 3.2.
• Air filter - Remove and clean or replace the air filter, as may be appropriate.
• Propeller - Inspect the attachment bolts for integrity and torque (refer to paragraph 1.5) and
safe tying. Comply with the requirements of the propeller manufacturer maintenance manual.
• Ailerons, flaps, rudder and elevator - Inspect visually for condition and for absence of cracks,
wear etc.
• Tyres - Inspect for condition and maintain proper pressures (refer to paragraph 1.7).
• Inspection for condition - Comply in full with the requirements of the 100 hour / annual
inspection and correct all faults or failings.
• Inspect for condition all air ducting (CAT tubing, SCAT tubing, etc). Replace after every 300
hours.
• Parachute. Examine textile components in the parachute bay for any signs of moisture
seepage.
3.4.9 EVERY 2000 HOURS
The service requirements in paragraph 2.5.2 should be complied with after every 2000 hours of
operation during engine overhaul.
3.4.10 EVERY 5000 HOURS
Sling Aircraft is continuously monitoring the Sling 4 TSi fleet, especially aircraft with the highest
airframe hours. Presently, none of the aircraft have surpassed 3000 airframe hours. The 5000-hour
checklist will be issued when service life limits are established for Sling 4 TSi parts as the 100- and
2000-hour checklists are sufficiently comprehensive to ensure thorough inspection and continued
airworthiness of the aircraft.

___________________________________________
3.4.11 ENGINE AND AIRFRAME TIME BASED OVERHAULS
• ENGINE – Rotax engines fitted to the Sling 4 TSi aircraft are governed by the Rotax Engine
Manuals as amended by Rotax. Extension or exceeding of the TBO by 5% or 6 months is
allowed whichever comes first.
• AIRFRAME – Components fitted to the Sling 4 TSi aircraft are subject to the component
manufacturer’s maintenance recommendations and need to be adhered to.

___________________________________________
SECTION 4
STRUCTURES, SYSTEMS AND PROCEDURES
This section describes the various structures, substructures, systems and subsystems comprising the
aircraft, and describes maintenance procedures applicable to these structures, substructures, systems
and subsystems, as the case may be.
4. AIRFRAME
The airframe consists of the following main groups:
• Wings.
• Fuselage.
• Empennage.
• Landing gear.

___________________________________________
4.1 WINGS
4.1.1 MAIN WING SECTION
The wing main spar comprises of an aluminium web with spar caps solid riveted to the top and bottom
to form a composite I-beam. The caps are made from sheet material bent into angles. The rear spar
comprises an aluminium C-channel with the flanges facing forward.
Each wing is connected to the fuselage by means of nine bolts (eight on the front spar, one on the rear
spar).
Two inspection panels are located on the underside of the wing, one providing access to the aileron
bell crank 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 underside of the wing) at the wing-to-fuselage
connection points.
A fuel filler cap is located on upper side of each tank / wing.
Fuel tanks vent by means of a tube exiting the underside of the wing, on the outer tank rib immediately
in front of the main spar.
A fuel drain is located on the underside of each wing.
Aileron and flap hinges (on the wing side) comprise of shaped plates mounted on the wing trailing
edge.
Wing tips are moulded epoxy resin reinforced with glass fibre.
A pitot tube is located on the underside of the left wing.

___________________________________________
4.1.1.1. WING REMOVAL / INSTALLATION

ITEM QUANTITY NOTES
1 Calibrated torque wrench, at least 60 Nm range. 1
2 ½” inch Socket, to fit torque wrench in 1. 1
3 16 mm Socket, to fit torque wrench in 1. 1
4 ½” inch Spanner. 2
5 16 mm Spanner. 2
6 3/8” Spanner. 2
7 7/16” Spanner. 2
8 2 mm Allen key / hex drive. 1
9 17 mm Spanner. 1
Fuel line couplings.
10 9/16" Spanner. 1
CONSUMABLE MATERIAL REQUIRED
ITEM QUANTITY NOTES
1 Orange paint. As needed.
2 Loctite 577. As needed. Fuel tank outlet / return line couplings.
3 Tie wraps. As needed. Installation only.
4 Loctite 222. As needed. Inspection panels and wing-to-fuselage fairing screws.
The above list is not necessarily a complete list of all material needed. Refer to the Sling 4 TSi construction
manual.
CAUTION
BE PREPARED WITH A HELPER OR SUPPORT STAND TO HANDLE THE WEIGHT
AND / OR AWKWARDNESS OF THE OBJECT TO BE REMOVED.

___________________________________________
PROCEDURE (REMOVAL)
Retain any bolts, nuts (except lock-nuts) spacers, screws and washers (with the exception of lock-
washers) for reassembly.
1. Set the fuel selector (in the cockpit) to OFF.

2. Drain fuel from the wing via the fuel drain valve. If the tank is nearly full a substantial amount of
fuel can be siphoned through the filler cap hole.
3. Remove the front seat on the side of the wing that is being removed (refer to paragraph 4.2.2.1).
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 the button head screws).
7. Remove the fuel tank outlet / return line inspection panel (1) from under the wing, by unscrewing
the button head screws.
8. Disconnect the fuel hoses (2) from the tank outlet and the return line by unfastening the
couplings (3). Place / insert temporary caps on / in the fuel lines to prevent spillage and drip.
1 3
3
2
1
Disconnect fuel lines here
9. For the left wing disconnect the two plastic pitot tubes (4) at the couplings (5).
6
5
5
5 4
6
4

___________________________________________
10. Disconnect the fuel quantity sensor, navigation lights and landing / taxi light wiring (6). Cut any
tie wraps 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
bolts (8) closest to the wing.
WING
6
8
6
12. Disconnect the aileron pushrod (9) (inside the fuselage) by removing the AN4 bolt (10) from the
rod end bearing (11).
10, 11
9
Aircraft nose
13. While supporting the wing, remove all the main spar wing retaining bolts, except for the outside
top bolt and the outside bottom bolt. Remove the locknuts from the remaining two bolts in the
main spar and from the bolt in the rear spar, but do not remove the bolts.
___________________________________________
14. While supporting the wing remove the three remaining bolts and then carefully remove the wing
by pulling the main spar directly out of the centre-spar. Take care not to damage the pushrod
and torsion bar as they exit the fuselage.
1. Reverse the above procedure (removal) for reinstallation, paying close attention to the following:
• Apply Loctite 577 on the threads of the fuel line couplings and tighten sufficiently.
• Tighten the main (front) spar bolts to the recommended value (refer to paragraph 1.5.2).
Observe the correct placement of washers (refer to Figure 7). Note that the top bolt is
mounted with its head facing the aircraft tail.
B A AN7-26A bolt
B AN7-23A bolt
C AN7 washer (1.6 mm / 0.063”)
D AN7 lock-nut
Refer to paragraph D for hardware
D designations
A
C
Figure 7: Front wing spar to fuselage connection.

___________________________________________
• Tighten the rear spar bolt to the recommended value (refer to paragraph 1.5.2). Observe
the correct placement of washers (refer to Figure 8).
B
B
A
A AN5-10A bolt
B AN5 washer (1.6 mm / 0.063”)
C AN5 lock-nut (Nyloc)
designations
Figure 8: Rear wing spar to fuselage connection.
• Tighten the lock nut on the bolt through the aileron pushrod rod end bearing sufficiently,
observe the correct placement of washers (refer to
• Figure 9) and note that the bolt is installed with its head facing the nose of the aircraft.
A B
Note: Only the pushrod entering the wing is shown
on this drawing. The pushrod linking the two control
sticks is not shown.
A AN4-16A bolt
B AN4 washer (thick) (1.6 mm)
B C Bush
D AN4 lock-nut (Nyloc)
C Refer to paragraph D for hardware
designations
Figure 9: Aileron pushrod-to-control stick connection.

___________________________________________
• Tighten the two AN3 lock-nuts on the bolts connecting the wing flap torsion bar
sufficiently and observe the correct placement of washers.
• Apply tie wraps as required.
2. Paint orange creep marks on the bolts and nuts.

3. Inspect for security of attachment.
4. Inspect for play on cables / 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 materials or tools are left behind in the wing before closing
the fuel tank inlet / outlet inspection panel.
7. Ensure that no loose objects, foreign materials or tools are left behind under the cabin floor /
seat before closing the panel(s).
8. Apply thread locking sealant to the inspection panel(s) and wing-to-fuselage fairing(s) screws
before fitting.

___________________________________________
4.1.2 AILERON(S)
The aileron is a conventional stressed-skin semi-monocoque structure comprising of ribs and

riveted sheet 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 plates
attached to the aileron.
4.1.2.1. AILERON CONTROL SYSTEM
Figure 10 : Aileron control system.
Refer to Figure 10. The aileron control system uses push-pull rods and bell cranks throughout.

___________________________________________
4.1.2.2. AILERON REMOVAL / INSTALLATION

ITEM QUANTITY NOTES
2 7/16” Spanner. 2
ITEM QUANTITY NOTES
2 Loctite 222. As needed. Inspection panel screws.
manual.
CAUTION
AND / OR AWKWARDNESS OF THE OBJECT TO BE REMOVED / INSTALLED.
CAUTION
CONTROL SURFACE WILL FALL FREE WHEN THE CONTROL LINKAGE CONNECTED TO IT IS
DISCONNECTED.

___________________________________________
PROCEDURE (REMOVAL)
1. Remove the aileron bell crank (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 bell
crank.
Wingtip
2
4 2
Figure 11: Bell crank (1)
3. Support the aileron and unfasten and remove the bolts securing the aileron to the aileron hinges.
4. Carefully pull the aileron away from the aircraft and hinges, supporting and guiding the
disconnected aileron pushrod as it exits the wing.

___________________________________________
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 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 12) and note that the bolt is installed
with its head facing the wingtip.
B
B
WINGTIP
C A
WINGTIP
AIRCRAFT SIDE AILERON SIDE
A AN4-6A bolt
B AN4 washer (0.8 mm / 0.032”)
C AN4 lock-nut (low profile) (Nyloc)
Refer to paragraph D for hardware designations
Figure 12: Aileron hinge (inboard).

___________________________________________
• Tighten the lock-nut on the bolt through the outboard aileron hinge sufficiently, observe
the correct placement of washers (refer to Figure 13) and note that the bolt is installed
with its head facing the wingtip.
D
WINGTIP
B
A
WINGTIP
AILERON SIDE
AIRCRAFT SIDE
A AN4-7A bolt
B AN4 washer (0.8 mm / 0.032”)
C AN4 washer (1.6 mm / 0.063”)
Figure 13: Aileron hinge (outboard).

___________________________________________
• Tighten the lock-nut on the bolt through the aileron pushrod rod-end bearing sufficiently,
observe the correct placement of washers (refer to Figure 14) and note that the bolt is
installed with its head facing the wing upper surface.
B
A
A C A
A AN4 washer (1.6 mm / 0.063”)

B AN4-11A bolt.
Figure 14: Aileron pushrod -to-bell crank connection.
2. Ensure that with the control column vertical the aileron trailing edge is aligned with wing trailing
edge and that the aileron bell crank is in the neutral position, i.e. the inside arm (the arm closest
to the cabin) is perpendicular with the spar axis.
3. Verify for alignment and correct travel (refer to paragraph 1.13).
4. Apply creep marks to the bolts / nuts with orange paint.
5. Apply thread locking sealant and replace the inspection panel.

___________________________________________
4.1.2.3. AILERON ADJUSTMENT

ITEM QUANTITY NOTES
1 7/16” Spanner. 1
2 2 mm Allen key. 1
3 Straight edge. 1
ITEM QUANTITY NOTES
manual.

___________________________________________
PROCEDURE
The procedure is identical for both ailerons.
1. Remove the front seat(s). Refer to paragraph 4.2.2.1.
2. Remove the inspection panelling to gain access to the control mechanism(s).
3. Remove the bell crank 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 sticks must move freely with
absolutely no resistance.
5. Loosen the lock-nuts and turn the small connecting pushrod (1) in or out so that with the left
stick completely vertical, the right-hand stick is also completely vertical.
Figure 15: Aileron adjustment - cabin side.

___________________________________________
6. Test the stops (2) so that when moving the sticks left the stops (under the 2 seats) for both
sticks touch simultaneously and when moving the sticks right the stops for both sticks touch
simultaneously.
7. Tighten the lock-nuts on both ends of the joining pushrod (1) without turning the pushrod.
8. Loosen the lock-nuts on the long in-wing pushrod (4). Hold both sticks completely vertical
and line up the bell crank (3) by turning the main long in-wing pushrod (4) in or out until the
bell crank is exactly 90 to the pushrod (4) and lines up exactly with the edges of the
inspection hatch. Use a straight edge to help with alignment.
To aileron
To control stick(s)
Figure 16: Aileron adjustment - wing side.
9. Tighten the lock-nuts at both ends of the main long in-wing pushrod (4) without turning the
pushrod.
10. Verify again that when the sticks are vertical the bell crank lines up with the edge of the
inspection hatch.
11. Loosen the lock-nuts on the short aileron pushrod (5). While holding the sticks in the centre
vertical position, screw the short aileron pushrod (5) in or out until the aileron lines up with
the flap and the wingtip.
12. Tighten the lock-nuts of the short aileron pushrod (5) without turning the pushrods.
13. Verify correct aileron travel (refer to paragraph 1.13).
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 panel screws and close the panel(s).
17. Fit the front seat(s).

___________________________________________
4.1.2.4. AILERON AUTOPILOT SERVO / SERVO PUSHROD REMOVAL / INSTALLATION

ITEM QUANTITY NOTES
1 3/8” Spanner. 2
2 4 mm Allen key. 1
3 2 mm Allen key 1 Inspection panel screws.
4 Flat screwdriver. 1
ITEM QUANTITY NOTES
3 Loctite 243. As needed. Servo mounting screws.
4 Tie wraps. As needed.
manual.
WARNING
ENSURE MASTER AND ELECTRICAL EQUIPMENT SWITCHES ARE OFF.
IT MAY BE EXPEDIENT TO DISCONNECT THE BATTERY GROUND TERMINAL WHILE WORKING ON
ELECTRICAL EQUIPMENT.
CAUTION
AND / OR AWKWARDNESS OF THE OBJECT (SEAT) TO BE REMOVED.

___________________________________________
PROCEDURE (REMOVAL)
1. Remove the left front seat (refer to paragraph 4.2.2.1).
2. Undo the screws retaining the inspection panels to gain access to the servo.
3. Undo the bolt (1) connecting the servo (2) control arm to the pushrod.
4
4 3
2 4
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 structure and remove the servo motor.
• Observe the correct placement of washers (refer to Figure 17).

___________________________________________
A AN3-10A bolt
C AN3 washer (thin) (0.8 mm)

designations
A B
B
1
Figure 17: Autopilot aileron servo installation.
• Paint orange creep marks on the bolts / lock-nuts.
• Apply thread locking sealant to the servo mounting screws before fitting.
• Secure the cable to the aircraft frame with tie wraps, in the manner it was before
removal, using spacers as applicable. Ensure 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 revision of the Garmin G3X (GSA 28 section)
user and installation manual to complete installation of the servo.
4. Before flight, test the servo for correct operation (refer to the latest revision of the Garmin G3X
(GSA 28 section) user and installation manual).

___________________________________________
REMOVAL AND INSTALLATION OF AILERON SERVO PUSHROD
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 to the control stick torque tube
arm(s) and remove the pushrod.
INSTALLATION
• Inspect all bolts, nuts and screws for damage. Replace if necessary. Do not reuse lock-
nuts. Fit new. Paint orange creep marks on the bolt(s) / lock-nut(s).
2. Move the control stick across its full roll command extent and observe free movement without
binding.
A AN3-11A bolt

designations
B
C
B
Figure 18: Aileron autopilot servo pushrod – control stick / torque tube end.

___________________________________________
4.1.3 FLAPS
A flap comprises a conventional stressed-skin semi-monocoque structure comprising ribs and

riveted sheet metal skin, without a spar. Flap hinges (on the aileron side) comprise of sealed ball
bearings pressed into shaped plates attached to the flaps.
4.1.3.1. FLAP CONTROL SYSTEM
Figure 19: Flap control system.
Refer to Figure 19. 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 torque tube. Control arms are connected to each extremity of the torque tube. Each
control arm is connected to a pushrod, which in turn is connected to a wing flap.
Micro-switches positioned within the actuator motor automatically interrupt the electric current when
the flaps reach extreme (up/down) positions, shutting off the actuator motor. The flap controller is
located on the instrument panel.

___________________________________________
4.1.3.2. FLAP REMOVAL / INSTALLATION

ITEM QUANTITY NOTES
1 2 mm Allen key. 1 Option 2 only.
2 7/16” Spanner. 2
ITEM QUANTITY NOTES
2 Loctite 222. As needed. Inspection panel screws. Option2
only.
manual.
CAUTION
AND / OR AWKWARDNESS OF THE OBJECT TO BE REMOVED
CAUTION
CONTROL SURFACE WILL ROTATE / FALL FREE WHEN THE CONTROL LINKAGE CONNECTED TO IT
IS DISCONNECTED.

___________________________________________
PROCEDURE (REMOVAL) (OPTION 1)
1. Extend the flaps fully.

2. Disconnect the bolt (1) attaching the flap pushrod (2) the flap (3).
WING
2
1
1
1 3
1
3. Support the flap and remove the bolts, washers and locknuts (4) from the hinges (5).
Wingtip
5
4 4
1 1
4. Support the disconnected pushrod and carefully pull the flap away from the wing and the
hinges.

___________________________________________
PROCEDURE (INSTALLATION) (OPTION 1)
1. Reverse above procedure (removal), paying close attention to the following:
• Tighten the lock-nuts on the bolts through the flap hinges sufficiently, observe the
correct placement of washers (refer to Figure 20) and note that the bolts are installed
with their heads facing the wingtip.
C A
AIRCRAFT SIDE FLAP SIDE
A AN4-6A bolt
B AN4 washer (0.8 mm / 0.032”)
C AN4 lock-nut (low profile) (Nyloc)

designations
Figure 20: Flap hinges.

___________________________________________
• Tighten the lock nut on the bolt through the flap pushrod rod end bearing sufficiently,
observe the correct placement of washers (refer to
• Figure 21) and note that the bolt is installed with its head facing the wingtip.
A
A AN4-11A bolt
B
B AN4 washer (1.6 mm / 0.063”)
C

designations
Figure 21: Flap pushrod-to-flap connection.
2. Verify the flap for alignment and correct travel (refer to paragraph 1.13).
3. Paint orange creep marks on the bolts / nuts.

___________________________________________
PROCEDURE (REMOVAL) (OPTION 2)
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.
2
1 3
1
4
1
1
1
3. Support the flap and remove the bolts, washers and locknuts from the hinges.
4. Carefully pull the flap away from the aircraft and hinges, supporting and guiding the
disconnected flap pushrod as it exits the wing.

___________________________________________
PROCEDURE (INSTALLATION) (OPTION 2)
1. Reverse above procedure (removal) (option 2), paying close attention to the following:
• Tighten the lock-nuts on the bolts through the flap hinges sufficiently, observe the
with their heads facing the wingtip.
• Tighten the lock nut on the bolt through the flap pushrod rod end bearing sufficiently,
observe the correct placement of washers (refer to Figure 22) and note that the bolt is
installed with its head facing the wingtip.
C
B
B
A AN4-11A bolt
A
B AN4 washer (1.6 mm / 0.063”)

designations
Figure 22: Flap pushrod-to-flap torque tube control arm connection.
2. Verify the flap for alignment and correct travel (refer to paragraph 1.13).
4. Apply thread locking sealant to the screws and replace the flap inspection panel. Ensure no
tools or foreign materials are left inside the wing before closing the panel.

___________________________________________
4.1.3.3. FLAP ADJUSTMENT

ITEM QUANTITY NOTES
1 2 mm Allen key. 1 Option 2 only.
2 7/16” Spanner. 2
ITEM QUANTITY NOTES
manual.
PROCEDURE
The procedure is identical for the port and starboard flaps.
1. Flaps retracted to full up position.
2. Take a straight edge and place it flat underneath the wing against the 3rd hinge bracket
(from the root) and along the rib rivets (but not on the rivets). If correctly adjusted the flap
should just touch the straight edge.
3. To adjust, remove the flap inspection panel under the wing, lower the flaps and undo the
locknuts on both end of the flap pushrod. Retract the flaps.
4. Take the straight edge and place it flat underneath the wing against the 3rd hinge bracket
(from the root) and along the rib rivets (but not on the rivets). Clamp the straight edge to the
bracket in this position, such that it stays flat underneath the wing.
5. Turn the pushrod until the flap just touches the straight edge.
6. Remove the straight edge.
7. Lower the flaps to gain access to the flap side pushrod connection.
8. Tighten the locknuts on both ends of the flap pushrods without turning the pushrods.
10. Verify (before flight) correct travel for the flap (refer to paragraph 1.13).
11. Ensure that no foreign material or tools remain inside the wing, apply thread locking sealant
to the flap inspection panel screws and fit the panel. Do not over tighten the screws.

___________________________________________
4.1.3.4. FLAP ACTUATOR MOTOR REMOVAL / INSTALLATION

ITEM QUANTITY NOTES
1 2.5 mm Allen key / hex driver 1
2 ½ inch Spanner. 2
3 2 mm Allen key / hex driver. 1
ITEM QUANTITY NOTES
1 Split pin. 2
3 Tie wraps. As needed. Actuator cable.
manual.
CAUTION
IS DISCONNECTED.
WARNING
CAUTION

___________________________________________
PROCEDURE (REMOVAL)
1. Remove the pilot seat (refer to paragraph 4.2.2.1).

2. Remove the central side panel under the instrument panel (next to pilot’s legs / calves) to gain
access to the flap 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. Open the rear panel of the centre console by unscrewing the button head screws retaining it.
5. Support the flap actuator motor (1) and undo the bolts (2) retaining the motor to the forward
fuselage bracket (3) and the flap torque tube (4) control arm (5). Be aware that the flaps will
fall / rotate down unless supported.
2
5
2 1
3
1
1
3 2
2 5
Figure 23: Flap actuator motor removal.

___________________________________________
1. Reverse above procedure (removal), paying close attention to the following:
• Do not reuse split pins. Fit new.
• Observe correct placement of washers (refer to Figure 24).
E A
A AN5-13 bolt
B AN5 washer (1.6 mm / 0.063”)

B
C AN5 castle nut
D AN5 washer (0.8 mm / 0.032”)

B
A E Split pin

designations
Figure 24: 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
centre console and before flight.
4. Apply thread locking sealant to the inspection panel screws before fitment. Do not over tighten.

___________________________________________
4.2 FUSELAGE
4.2.1 REAR FUSELAGE
The aft part of the fuselage (tail cone) is an aluminium alloy semi-monocoque structure. Several
stringers 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
with a guide for the elevator push/pull rod is mounted in the rear fuselage. The forward portion of
the rear fuselage contains a luggage packing space with an aluminium skin floor supported by
stringers.

___________________________________________
4.2.2 CENTRE FUSELAGE
The centre fuselage accommodates the pilot and passenger seating (x4), the flight controls and
instrument panel. Seats are removable.
4.2.2.1. FRONT SEAT REMOVAL AND INSTALLATION
CAUTION
PROCEDURE (REMOVAL)
1. Pull the handle (1) (located at the front of the seat, in the middle of the centre 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 aircraft.
1
1
1. Pull the handle forward, fit the seat into place and release / push back the handle.
2. Before flight, verify secure attachment of the seat.

___________________________________________
4.2.2.2. REAR SEAT REMOVAL AND INSTALLATION

ITEM QUANTITY NOTES
CAUTION

___________________________________________
PROCEDURE (REMOVAL)
1. Unlock the sliding catch (1) (located on the back of the seat upright(s)) retaining the seat
upright(s) to the fuselage.
Back of rear seat upright.
2. Undo the three Dzus fasteners (passing through three eyelets (2)) retaining the
seat assembly to the baggage compartment floor. Remove the seat.
1. Inspect the Dzus fasteners for damage. Replace if necessary.
2. Reverse the above procedure (removal) for installation.
3. Inspect for security of attachment, before flight.

___________________________________________
4.2.2.3. CANOPY AND WINDSHIELD CLEANING
CAUTION
Never clean the canopy / windshield under dry conditions and never use petrol, alcohol or
chemical solvents.
Never dust the canopy under dry conditions. The canopy and windshield may only be cleaned by
washing it with a sufficient quantity of lukewarm water and an adequate quantity of detergents
suitable for polymethyl methacrylate (Perspex). Use a soft, clean cloth, sponge or deerskin.
4.2.2.4. UPHOLSTERY CLEANING
Upholstery and covers may be removed from the cockpit / cabin, brushed and eventually washed in
lukewarm water with an adequate quantity of detergents. Dry thoroughly before insertion into the
cockpit / cabin.

___________________________________________
4.2.3 FORWARD FUSELAGE AND FIREWALL
The forward fuselage accommodates the engine mount, engine and firewall forward / firewall
mounted equipment and engine cowling.
Refer to paragraph B for a schematic showing the equipment (and their positions) mounted on the
firewall (engine side).
Refer to paragraph 5.1 with regard to the engine cowling.
Refer to paragraph 5.2 with regard to the engine.

___________________________________________
4.3 EMPENNAGE
4.3.1 HORIZONTAL TAIL AND ELEVATOR
Figure 25: Horizontal tail and elevator.
Refer to Figure 25. The horizontal stabiliser consists of a conventional semi-monocoque all-metal
light alloy structure 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, ¼ inch sealed bearings.
Elevator horns carry through to the leading edge of the horizontal tail and the elevator tips consist of
shaped epoxy resin and glass fibre composite.
Elevator mass balancing is located in the two-elevator horn leading edges and in the centre of the
rear channel. To inspect these parts, it is necessary to remove the composite tips and empennage
fairing.

___________________________________________
4.3.1.1. ELEVATOR CONTROL SYSTEM
Figure 26: Elevator control system.
Refer to Figure 26. 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 bell crank arrangement. All
significant transmission elements such as bell cranks, pushrods, supports and hinges can be easily
accessed and inspected.

___________________________________________
4.3.1.2. ELEVATOR REMOVAL / INSTALLATION

ITEM QUANTITY NOTES
1 7/16” Spanner. 2
ITEM QUANTITY NOTES
manual.
CAUTION
CAUTION
IS DISCONNECTED.

___________________________________________
PROCEDURE (REMOVAL)
1. Remove the vertical stabiliser (refer to paragraph 4.3.2.3).

2. Support the elevator and disconnect 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 right sides of the rear fuselage tail cone.
3. Support the elevator and loosen and remove the bolts from the elevator hinges.
4. Carefully and slowly pull the elevator free from the hinges and horizontal stabiliser, until the
trim tab motor cable plug connection is exposed. Disconnect the plug.

___________________________________________
• 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 installed
with its head facing to the port side of the aircraft.
B
A
A AN4-12A bolt
B AN4 lock-nut (Nyloc)
C AN4 washer (1.6 mm / 0.063”)
designations C
Figure 27: Elevator pushrod to elevator connection.

___________________________________________
• Tighten the lock-nuts on the bolts through the elevator hinges sufficiently. Observe the
correct placement of washers (refer to Figure 28). Note that the outer hinge bolts are
installed with their heads facing outward, towards the elevator tips and the inner hinge
bolts are installed with their heads facing inward, towards the fuselage / tail cone. The
bolt in the centre hinge is fitted with its head towards the larger clearance side of the
elevator cut-out.
A
B
B
B
A AN4-10A bolt
B AN4 washer (1.6 mm / 0.063”)
Refer to paragraph D for
hardware designations
Figure 28: Horizontal stabilizer-to-elevator hinge.
• 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 installed
with its head facing to the port side of the aircraft.
2. Apply orange creep marks to the bolts / nuts.

3. Verify for elevator alignment and correct travel (refer to paragraph 1.13).

___________________________________________
4.3.1.3. HORIZONTAL STABILIZER REMOVAL / INSTALLATION

ITEM QUANTITY NOTES
1 7/16” Spanner. 2
ITEM QUANTITY NOTES
manual.
CAUTION

___________________________________________
PROCEDURE (REMOVAL)
1. Remove the vertical stabilizer. Refer to paragraph 4.3.2.3.

2. Disconnect the trim tab motor cable connection plug (1) and the NAV/COM antenna
connection (2) (If installed).
3. Support the horizontal stabilizer and unfasten and remove the bolts (3) retaining it to the
fuselage.
FRONT REAR
3
3
3
3
3, four off
4. Carefully lift the horizontal stabilizer free from the fuselage.

___________________________________________
• Tighten the lock-nuts sufficiently, observe the correct placement of washers (refer
to Figure 29) and note that the bolts are installed with the bolt heads head facing to
the nose of the aircraft.
B D C
A
B
B
C
A
C
D
C B
A C
A
B
B
C D
A AN3-5A bolt
B AN3 washer (0.8 mm / 0.032”)
C AN3 washer (1.6 mm / 0.064”)
designations
Figure 29: Horizontal stabilizer to fuselage attachment.

___________________________________________
4.3.1.4. ELEVATOR TRIM TAB MOTOR REMOVAL / INSTALLATION

ITEM QUANTITY NOTES
2 Electric solder iron. 1
ITEM QUANTITY NOTES
1 2.4 mm Heat shrink. As needed.
2 6.4 mm Heat shrink. As needed.
3 Solder. As needed.
4 Loctite 222. As needed. Inspection panel and trim tab motor screws.
manual.

___________________________________________
PROCEDURE (REMOVAL)
1. Remove the elevator trim motor inspection cover (1) (under the port elevator) by unscrewing
the button head screw (2).
1
1
3 1
1 1
2
1
2. Disconnect the plug connection (3).
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. Unscrew the four button head screws (4) retaining the trim tab motor and remove the motor
from inside the elevator.

___________________________________________
• Inspect all bolts and / or screws for damage. Replace if necessary.
• Apply thread locking sealant to the trim tab motor retaining screws before fitment.
• Reconnect the elevator trim tab motor plug.
2. Verify for trim tab alignment and correct travel (refer to paragraph 1.13).
3. Ensure no loose articles or tools are left in the elevator before refitting the inspection panel.
4. Apply thread locking sealant to the screws and refit the inspection panel.

___________________________________________
4.3.1.5. ELEVATOR ADJUSTMENT

ITEM QUANTITY NOTES
1 7/16” Spanner. 1
2 Inclinometer. 1
ITEM QUANTITY NOTES
manual.
CAUTION
AND / OR AWKWARDNESS OF THE OBJECT (SEATS) TO BE REMOVED / INSTALLED.

___________________________________________
PROCEDURE
1. Remove the front seats (refer to paragraph 4.2.2.1).

2. Remove the front floor inspection panels by undoing the button-head screws. Remove the
rear cabin floor centre inspection panel.
3. Move the control sticks (1) forward until the stops (2) engage. Undo the lock-nuts and
adjust the stick pushrods (3) until the sticks are approximately 25 mm (1) away from the
front panel.
To elevator.
5
1 4
1
4
Note: Pushrod (3) is shown for only one stick (1).

Both pushrods for both sticks are adjusted.
Figure 30: 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 (5) until the elevator is 20° down (from the
zero level in line with the horizontal stabilizer) with the sticks fully forward (with the stops
engaged) and 28° up with the sticks fully backward (i.e. with the stops engaged).
6. Tighten the lock-nuts on the pushrods without turning the pushrods.
7. Paint orange creep marks on the lock-nuts.
8. Ensure that no tools or foreign material is left behind before closing the inspection panels.
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 before flight.

___________________________________________
4.3.1.6. ELEVATOR TRIM TAB ADJUSTMENT

ITEM QUANTITY NOTES
1 ¼ inch Spanner. 1
ITEM QUANTITY NOTES
1 Split pin. 1
manual.

___________________________________________
PROCEDURE
1. Turn the Master switch ON.

2. Trim the trim tab to the maximum down deflection (i.e. the aircraft will pitch up in flight).
3. Turn the Master switch OFF.
4. Loosen the lock nut (1), i.e. screw it backward on the threaded rod (2), away from the eye-
bolt (3).
5. Remove the split pin, pin and washer (4) and disconnect the eye-bolt from the trim tab horn (5).
5
4
2 3
Figure 31: Elevator control 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
measure the downward displacement of the trim tab trailing edge). Repeat step 4 until the
deflection measures equal to 25°.
7. Do not reuse split pin. Fit new. Note that the pin is inserted with the split pin and washer facing
towards the aircraft fuselage.
8. Tighten the lock nut against the eye-bolt.
9. Before flight, verify correct operation and travel (refer to paragraph 1.13) of the elevator trim tab.

___________________________________________
4.3.1.7. ELEVATOR AUTOPILOT SERVO / SERVO PUSHROD REMOVAL / INSTALLATION

ITEM QUANTITY NOTES
1 3/8” Spanner. 2
ITEM QUANTITY NOTES
3 Loctite 243. As needed. Servo mounting screws.
manual.
WARNING
CAUTION

___________________________________________
PROCEDURE (REMOVAL)
1. Remove the rear seat (refer to paragraph 4.2.2.2).

2. Undo the bolt (1) connecting the control arm of the servo (2) to the pushrod (3).
3
4
2
5
6
3. Undo the screws (4) retaining the servo to the bracket (5). Carefully pull the motor from the
bracket. It may be necessary to cut the tie wrap(s) securing the cable to the aircraft frame to
allow adequate play in the cable.
4. Undo the screws securing the connector (6) to the servo motor and disconnect from the servo.

___________________________________________
• The signal cable connector must be secured to the servo motor before
installing the motor, otherwise there may not be enough space to insert and
manipulate a tool to tighten the connector securing 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 mounting screws before fitment. Do
not over tighten.
A AN3-10A bolt
C AN3 washer (thick) (1.6 mm)
D AN3 washer (thin) (0.8 mm)
E AN3 lock-nut (Nyloc)

designations
E A
C D
C B
Figure 32: Autopilot elevator servo installation.
• Paint orange creep marks on the bolts / lock-nuts.
2. Inspect for security of attachment. Ensure servo signal cable will not chafe against the
aircraft frame.
3. Ensure the applicable aircraft control(s) is (are) free and does not bind with the servo
installed.

___________________________________________
4. Follow any applicable procedures in the latest revision of the Garmin G3X (GSA 28
section) user and installation manual to complete installation of the servo.
5. Before flight, test the servo for correct operation (refer to the latest revision of the
Garmin G3X (GSA 28 section) user and installation manual).
REMOVAL AND INSTALLATION OF AILERON SERVO PUSHROD
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 to the control stick torque tube
arm(s) and remove the pushrod.
INSTALLATION
• Inspect all bolts, nuts and screws for damage. Replace if necessary. Do not reuse lock-
nuts. Fit new. Paint orange creep marks on the bolt(s) / lock-nut(s). Observe the correct
placement of washers (refer to
• Figure 33).
A AN3-10A bolt

designations
C
B
A
B
Figure 33: Autopilot elevator servo pushrod –torque tube end.
2. Move the control stick across its full pitch command extent and observe free movement
without binding.

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4.3.2 VERTICAL TAIL AND RUDDER
3 4
10
1
2
5
6
7
6
Figure 34: Vertical tail and rudder.
Refer to Figure 34. The vertical (1) stabiliser and rudder (2) consist of all-metal light alloy structures.
The rudder horn (3) extends to the vertical stabilizer leading edge and has a composite tip on which
navigation lights (4) and an aerial may be fitted. The vertical stabiliser consists of twin 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 spar (6) with formed sheet
metal ribs (7) and sheet-metal skin. The rudder rotates / deflects around three hinges. Rudder control
is affected by steel cables (8) attached to a control horn (9) on the bottom edge of the rudder and
running (with a cross-over) to two control horns attached to the rudder pedal axles. Rudder mass
balancing (10) is placed under the leading edge of the rudder horn, on the top rudder rib.

___________________________________________
4.3.2.1. RUDDER CONTROL SYSTEM
Figure 35: Rudder control system.
Refer to Figure 35. The control system layout is two steel cables attached to the rudder control horn at
the bottom of the rudder. The cables are supported and aligned by cable guides. The cables 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 control
horn on the nose wheel strut (detail B).
The rudder pedals can be adjusted backwards and forwards on tubular slides (to set positions) and
locked in position with bolts and lock-nuts.
In the rear fuselage the rudder cables are attached to a spring load device (detail A) which provides a
centring force on the rudder.

___________________________________________
4.3.2.2. RUDDER REMOVAL / INSTALLATION

ITEM QUANTITY NOTES
1 7/16” Spanner. 2
2 3/8 Spanner. 2
ITEM QUANTITY NOTES
manual.
CAUTION

___________________________________________
PROCEDURE (REMOVAL)
Retain bolts, spacers, screws and washers (with the exception of lock-washers), as applicable, for
reassembly.
1. Disconnect the control cables (1) from the rudder control horn (2).
Rudder cable guide
2
1
Figure 36: Rudder cable guide
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 rudder away from the vertical tail and hinges, until the strobe
light connection plug is exposed. Disconnect the plug.
5. Move the rudder away from the vertical stabilizer. Take care to protect the horn as it
clears the top of the horizontal stabilizer.

___________________________________________
1. Reverse the above procedure, paying close attention to the following:
• Do 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
with their heads facing upwards.
A AN4-10A bolt
B AN4 washer (1.6 mm / 0.063”) B
designations
C B
Figure 37: Rudder to vertical stabilizer hinge connection.

___________________________________________
• Tighten the lock-nuts on the bolts attaching the rudder cables sufficiently, observe the
with their heads facing upwards.
A AN3-7A bolt
B AN3 washer (0.8 mm / 0.032”)
C AN3 washer (1.6 mm / 0.063”)
designations
D
F
Figure 38: Rudder cable connection.
2. Apply orange creep marks to the bolts / nuts.
3. Verify for alignment and correct rudder travel (refer to paragraph 1.13).

___________________________________________
4.3.2.3. VERTICAL STABILIZER REMOVAL

ITEM QUANTITY NOTES
1 3/8” Spanner. 2
ITEM QUANTITY NOTES
2 Loctite 222. As needed. Fairing screws.
manual.
CAUTION

___________________________________________
PROCEDURE (REMOVAL)
Retain bolts, spacers, screws and washers (with the exception of lock-washers), as applicable, for reassembly.
1. Remove the rudder (refer to paragraph 4.3.2.2).

2. Remove the empennage-to-fuselage fairing (1), by unscrewing the button head screws retaining it.
3. Remove the side panel (2) on each side of the fuselage, by unscrewing the button head screws (3) and
retaining it.
3
2
2
1
4. Disconnect the strobe light cable connector (4).
5. Support the vertical tail and unfasten the bolts (5) retaining the vertical tail to the fuselage. Note that the
six bottom bolts in the rear support screw into anchor nuts attached to the fuselage.

___________________________________________
5, both sides
E
A
E
C
A E
B
D
E
E
A
C
D C
Figure 39: Vertical stabilizer to fuselage connection. E

A
A AN3-4A bolt E AN3 washer (0.8 mm / 0.032”)
B AN3-5A bolt Refer to paragraph D for hardware

designations
D AN3 washer (1.6 mm / 0.063”)
6. Carefully lift the vertical tail clear from the fuselage.

___________________________________________
• Do not reuse lock-nuts, lock-washers or split pins, as applicable. Fit new.
• Observe the correct placement of washers (refer to
• Figure 39).
• Tighten the lock-nuts on the bolts retaining the vertical stabilizer sufficiently and note that the
front mounting bolts are installed with their heads facing towards the aircraft nose and the rear
mounting bolts are installed with their heads facing the rear of the aircraft.
• Do not over tighten the button head screws.
2. Apply orange creep marks to the bolts and nuts.

3. Verify for alignment.

___________________________________________
4.3.2.4. RUDDER PEDAL ADJUSTMENT

ITEM QUANTITY NOTES
1 3/8” Spanner. 2
PROCEDURE (ADJUSTMENT)
Retain bolts, spacers, screws and washers (with the exception of lock-washers), as applicable, for reassembly.
1. Undo the bolt and nut (1) securing rudder bar (2) in the pedal tube (3). Slide the rudder bar (2) to the
selected position and reinsert the bolt and washer.
2. Do not reuse the lock-nut. Fit new.
3. Tighten the lock-nut.
1
3
1
2
1

___________________________________________
4.3.2.5. RUDDER CABLE TENSION ADJUSTMENT

ITEM QUANTITY NOTES
1 3/8” Spanner. 1
3 2 mm Allen key. 1
ITEM QUANTITY NOTES
2 Loctite 222. As needed. Inspection panels screws.
manual.
CAUTION

___________________________________________
PROCEDURE (ADJUSTMENT)
Retain bolts, spacers, screws and washers (with the exception of lock-washers), as applicable, for
reassembly.
1. Remove the rear seats (refer to paragraph 4.2.2.2).

2. Remove the inspection panels in the baggage compartment floor.
3. Support the aircraft such that the nose wheel is in the air. The nose gear strut must swivel
freely.
4. Make sure that the stops (in the centre between the pedals) on the pedals are working
correctly and stop the pedal travel approximately equally left and right. Also make sure that
the stops cannot hook on the attaching bolts (there 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 ends of the springs.
2
3
4
2
3 4
Figure 40 : Rudder cable tension adjustment.
6. Verify that when the rudder is in line with the vertical stabilizer, the pedals are in line with each
other. With the rudder lined up with the vertical stabilizer the front wheel must be perfectly
straight.
7. Adjust the tension on the rudder cables and the font wheel alignment by adjusting the two
pedal pushrods. The rudder cables must not be so tight as to impede movement, but also not
so loose that it hangs.
8. Tighten the lock-nuts on the two pedal / front steering pushrods.
9. Reconnect the springs (2) onto the fuselage with the applicable bolts and washers.

___________________________________________
10. Loosen the screws on the angled brackets (3), adjust the brackets so that when the rudder 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 cable.
13. Ensure no foreign objects or tools are left behind. Close the inspection panels. Refit the seats.

___________________________________________
4.4 LANDING GEAR
4.4.1 MAIN GEAR
.
3
2
7
8 1
7
6
4
8 5
Figure 41: Main landing gear.
Refer to Figure 41. Refer to paragraph 1.7. The main landing gear consists of single section
composite struts (1) attached (to the fuselage) using four bolts (2) threaded through bushings laid
into the 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 main gear struts (1) via axles (5). Mounting plates (6) allow for the attachment of
the inner halves of the wheel fairings (7). The system features hydraulically actuated disc brakes (8)
controlled by a lever located on the cabin centre console (between the seats).
Wheel fairings / spats (7) round off the main landing gear.

___________________________________________
4.4.1.1. MAIN WHEEL FAIRING REMOVAL / INSTALLATION

ITEM QUANTITY NOTES
2 2.5 mm Allen key / hex drive. 1
ITEM QUANTITY NOTES
Bolt retaining fairing to main axle
2 Loctite 243 As needed.
spacer.
manual.

___________________________________________
PROCEDURE (REMOVAL)
1. Remove the inside half (1) of the fairing by unscrewing all button head screws (2) that hold the
fairing to the support plate and hold the inner and outer fairing sections to one another.
3
2
4, 5
1 2
2. Support the outside fairing half (3) and unfasten the retaining bolt (4). Remove the fairing half,
bolt and washers (5).
1. Reverse the above procedure for installation, paying careful attention to the following:
• Avoid damage to the fibreglass fairing(s) and rivnuts by not tightening the button head
screws excessively.
• Apply thread locking sealant to the fairing screws and the retaining bolt before fitting.
Note:
The airplane can be operated with any wheel fairings installed or removed
in any combination.

___________________________________________
4.4.1.2. MAIN WHEEL REMOVAL / INSTALLATION

ITEM QUANTITY NOTES
1 38 mm Hex socket. 1
2 Socket wrench + drive (if necessary) to fit item 1. 1
3 7/16” Spanner. 1
ITEM QUANTITY NOTES
1 Split pin. 1
manual.

___________________________________________
PROCEDURE (REMOVAL)
1. Remove the main wheel fairing. Refer to paragraph 4.4.1.1.

2. Hoist the aircraft onto supports.
3. Unfasten 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).
1 1
1
1 2
3
4. Remove the split pin (4) and pull out the spacer (5).
4
6
5
4
5. Unfasten the wheel retaining nut (6). Carefully pull the wheel assembly free from the axle, taking
care not to let the two-wheel bearings fall out and sustain damage.
6. Drop the two-wheel bearings out from the hub assembly. Keep the bearings clear / free of dust,
dirt and moisture.

___________________________________________
1. Reverse the above procedure (removal) for installation, paying close attention to the following:
• Inspect the rubber O-rings (1) on the spacer. Replace if necessary.
1 1
• Do not reuse lock-washers or split pins. Fit new.
• Inspect the 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 retaining nut (large black axle nut): place a little grease on the seal and then
tighten the nut until it is properly finger (hand) tight (check this) and then tighten it further until
the split pin (cotter pin) holes (in nut and axle) line up for insertion of the cotter pin.

4. Verify free rotation for the wheel before operational use.

___________________________________________
4.4.1.3. MAIN WHEEL AXLE AND BRAKE MECHANISM REMOVAL

ITEM QUANTITY NOTES
1 7/16” Spanner. 2
ITEM QUANTITY NOTES
2 Loctite 577 As needed. Brake line fittings - if decoupled.
manual.

___________________________________________
PROCEDURE (REMOVAL)
1. Remove the wheel fairing (refer to paragraph 4.4).

2. Remove the wheel (refer to paragraph 4.4.1.2).
3. Ensure that the aircraft cannot roll / move (if only one wheel jacked up) and release the park
brake.
4. Unfasten and remove the four axle (1), brake mechanism (2) and fairing mounting plate (3)
retaining bolts and nuts (4).
4
2
3
4
4
1
4
1

___________________________________________
5. If required, the brake mechanism (2) can be disconnected from the brake line (5). Refer to
paragraph 7.2.1 for draining the brake fluid before disconnecting here. Blank off the brake fluid
line to prevent drip and spillage.
Disconnect brake line here
4
2
6. Remove the axle, brake assembly and mounting plate. Slide the axle out from the brake
mechanism plate.
1. Reverse the above procedure for reinstallation, paying close attention to the following:
• Do not reuse lock-nuts and / or lock-washers. Fit new.
• Tighten the lock-nuts and bolts mounting the axle, brake assembly and fairing mounting
plate to the undercarriage strut sufficiently. Observe the correct placement of washers
(refer to Figure 42) and note that the bolts are installed with their heads facing the
wheel.
2. Apply creep marks to the bolts / nuts with orange paint.

___________________________________________
Main undercarriage strut
Main wheel fairing mounting bracket
B
C
A AN4-22A bolt
B AN4 washer (1.6 mm / 0.063”)

designations
Figure 42: Main wheel axle installation.

___________________________________________
4.4.1.4. MAIN WHEEL DISASSEMBLY / ASSEMBLY

ITEM QUANTITY NOTES
ITEM QUANTITY NOTES
manual.

___________________________________________
PROCEDURE (DISASSEMBLY)

2. Mark the tyre position on the rim and mark the hub halves for correct realignment during
assembly. If not 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 from the hub.
1 3
NOTE: Tyre not shown mounted on hub in this photograph.
5. Unfasten and remove the bolts and nuts clamping the two-wheel hub halves and brake disc
spacer together. 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 the hole in the
one half.

___________________________________________
PROCEDURE (ASSEMBLY)
In the procedure below, align according to the marks made during disassembly.
1. Remove the valve cap. Inflate the inner tube slightly to give it shape and insert into the tyre.
2. Seat the tyre (with inner tube inside) on the wheel hub half with the cut-out for the valve tube,
taking care that the valve tube fits properly through the cut-out.
3. Move the other wheel hub half into position. Secure the two-wheel hub halves and brake disc
spacer together. Tighten the bolts sufficiently. 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 over the other side of
the assembled wheel hub and into place in the groove between the two hub halves.
6. Secure the brake disc to the assembled wheel hub / brake disc spacer. Tighten the button
head screws sufficiently.
7. Inflate the tyre to 2.8 bar to make it seat properly and then deflate the tyre to normal
pressure. Refer to paragraph 1.7 for tyre pressures.
8. Replace the valve cap.
9. Inspect for air leaks.
11. Index (i.e. apply creep marks) the tyre with the wheel rim to enable the detection of tyre
slippage.

___________________________________________
4.4.1.5. MAIN WHEEL BEARING REMOVAL / INSTALLATION AND LUBRICATION

ITEM QUANTITY NOTES
1 Grease. As needed. Refer to paragraph 1.4.
2 Solvent to clean bearings. As needed. Refer to paragraph 1.4.
manual.
PROCEDURE
1. Remove the main wheel(s) to obtain the bearing(s). Refer to paragraph 4.4.1.2.
2. Clean the bearing(s) with solvent.
3. Apply grease. Do not grease excessively.
4. Install the bearing(s) and wheel(s). Refer to paragraph 4.4.1.2.

___________________________________________
4.4.1.6. MAIN GEAR REMOVAL / INSTALLATION

ITEM QUANTITY NOTES
1 x 4 mm and 1 x 3.2 mm Drill bits with driver
1 1 Set Removal.
(electric or hand drill).
2 17 mm Spanner. 1
3 8 mm Allen key. 1
4 7/1”6 Spanner. 1
6 Blind rivet tool. 1 Installation.
7 Calibrated torque wrench with at least 25 Nm range. 1 Installation.
8 17 mm Hex socket. 1 To fit item 7.
ITEM QUANTITY NOTES
Undercarriage channel cover
3 4 mm x 10 mm Aluminium blind rivets (multi-grip). As needed.
plate.
Undercarriage channel cover
4 3.2 mm x 8 mm Aluminium blind rivets (multi-grip). As needed.
plate.
To glue brake line(s) into
undercarriage leg groove. Mix
5 Glue (PRATLEY QUICKSET CLEAR) As needed.
glue according to manufacturer
instructions.
5 Loctite 577. As needed. Brake line fittings.
manual.
CAUTION

___________________________________________
PROCEDURE (REMOVAL)
Note: The procedure below describes removing the main gear with the main wheels attached. That would
necessitate disconnecting the brake pipes from the brake assembly and separating the lines from the strut. The
main wheel assemblies (wheel, brake assembly and axle) can be removed (from the strut) before the strut is
dropped out from the aircraft, which does not require the disconnection of the brake pipes at the brake assembly
but do require the separation of the brake lines from the strut. Refer to paragraph 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 movement of the aircraft by placing
padded stands under the wings at the hard points (the main spars).
2. Remove the front seats (refer to paragraph 4.2.2.1).
3. Remove the floor inspection panels (by unscrewing the button-head screws that retain them) to gain
access to the bolts / nuts retaining the main gear to the fuselage.
4. Release the brake pressure and drain the brake fluid (refer to paragraph 7.2.1).
5. Disconnect the brake lines (1) at the break assembly (2).
Disconnect brake line here

1
6. Carefully separate the brake lines from the glue securing the brake line to the grooves in the
undercarriage legs.
7. Remove the cover plates on the underside of the 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 and remove the four bolts and nuts retaining the gear to the
aircraft.
10. Drop down the gear underneath the aircraft.

___________________________________________
• Do not reuse the lock-nuts. Fit new.
• Torque the bolts / lock-nuts to the correct value (refer to paragraph 1.5.2), observe the correct
placement of washers (refer to Figure 43) and note that the bolts are installed with the bolt
heads facing towards the rear of the aircraft.
• Apply thread locking sealant to the brake line fittings before connecting.
2. Paint creep marks on the bolts and nuts.

3. Apply thread locking sealant to the inspection panel screws before fitting.
B B
C
A A M10 x 170 mm bolt, Class 12.9
B M10 washer
B
C M10 lock-nut
AIRCRAFT NOSE
Figure 43: Main gear installation.

___________________________________________
4.4.2 NOSE GEAR
Refer to Figure 44. Refer to paragraph 1.7.
The nose gear strut is attached to the engine mount (1) with two guide brackets (2). A circular
spring (3) provides suspension. The steel strut attaches to a conventional U-shaped fork (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 the nose gear strut by means of two control horns. Ease of steering movement (both on the
ground and in the air) is ensured using three needle roller bearings on the weight bearing surfaces
of the strut.
A wheel fairing (7) rounds off the nose gear assembly.
AN3
HARDWARE
4 7
7
AN3
HARDWARE
5
6 M16
HARDWARE
Figure 44: Nose gear.

___________________________________________
4.4.2.1. NOSE WHEEL FAIRING REMOVAL / INSTALLATION

ITEM QUANTITY NOTES
ITEM QUANTITY NOTES
manual.
PROCEDURE (REMOVAL)
1. Separate the front and rear halves of the nose wheel fairing by unscrewing the button head
screws retaining the halves to each other and to the brackets on the nose gear.

• Prevent damage to the fibreglass fairings and rivnuts by not tightening the button head
screws excessively.
Note:
The airplane can be operated with any wheel fairings installed or removed
in any combination.

___________________________________________
4.4.2.2. NOSE WHEEL REMOVAL / INSTALLATION

ITEM QUANTITY NOTES
2 24 mm Spanner. 1
ITEM QUANTITY NOTES
manual.

___________________________________________
PROCEDURE (REMOVAL)
1. Remove the nose wheel fairing. Refer to paragraph 4.4.1.

2. Lift and support the front of aircraft in such a manner as to lift the nose wheel off the ground.
3. Unfasten the lock-nut (1) retaining the nose wheel.
4
1
4. Support the wheel and remove the axle bolt (2), washers (3) and the two bushes / spacers (4).
2, 3
5. Remove the wheel from the fork (5).

___________________________________________
• Do not reuse the lock-nut. Fit new.
• Take care to place / align the spacers correctly so as not to bend them when tightening
the lock-nut.
• Observe the correct placement of washers and bushes and the correct orientation of the
nose wheel (refer to Figure 45). Note that the lock-nut faces the starboard side of the
aircraft.
A M16 x 175 mm Allen cap bolt, Class 12.9
B M16 washer
C Bush (long)
E
B D Bush (short)
D E M16 lock-nut (Nyloc)
Wheel is mounted in the fork with the 3-

pointed flange (1) of the bearing mount
facing the port side (i.e. the valve facing
starboard).
C
B
A
A
Figure 45: Nose wheel installation.
• Tighten the lock-nut sufficiently.
2. Paint orange creep marks on the bolt and nut.

3. Verify free rotation for the wheel.

___________________________________________
4.4.2.3. NOSE WHEEL DISASSEMBLY / ASSEMBLY

ITEM QUANTITY NOTES
2 13 mm Spanner. 1
ITEM QUANTITY NOTES
manual.
2. Mark the tyre position on the rim and mark the hub halves for correct realignment during
assembly. If not done correctly the wheel could be out of balance after assembly.
3. Deflate the tyre completely.
4. Unfasten and remove the bolts clamping the two-wheel hub halves and bearing mount assembly
together.
5. Pull out the bearing 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 the cut-
out in the one hub half

___________________________________________
In the procedure below, align according to the marks made during disassembly.
1. Remove the valve cap (1). Inflate the inner tube slightly to give it shape and insert into the tyre.
2. Seat the tyre (with inner tube inside) on the wheel hub half with the cut-out (2) for the valve
stem (3), taking care that the valve stem fits properly through the cut-out.
2
3 1
3. Move the other wheel hub half into position and insert the bearing mount assembly through the
centre of the two halves, from the side of the hub not supporting the valve stem.
4. Secure the two-wheel hub halves and bearing mount assembly together. Take care not to catch
the inner tube between the two hub halves. Observe correct placement of washers. Note that the
nuts are on the side of the valve. Tighten the bolts / nuts sufficiently.
5. Inspect the O-ring for damage. Replace if necessary.
6. Push the wheel to 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 to make it seat properly and then deflate to normal
pressure. Refer to paragraph 1.7 for tyre pressures.
8. Replace the valve cap.
9. Inspect for leaks.
11. Index (i.e. apply creep marks) the tyre with the wheel rim to enable the detection of tyre
slippage.

___________________________________________
This bush slides in / out of the bearings /

bearing mount assembly.
Figure 46: Front wheel hub assembly.

___________________________________________
4.4.2.4. NOSE WHEEL BEARING REMOVAL / REPLACEMENT

ITEM QUANTITY NOTES
1 Suitable press for bearings. 1
PROCEDURE (REMOVAL)
1. Disassemble the wheel (refer to paragraph 4.4.2.3) to obtain the bearing mount assembly.
2. Push out the inner bush (refer to Figure 46).
3. Tap the bearings out of the bearing mount.
1. Inspect the bush for damage. Replace if necessary.

2. Press the bearings into the bearing mount.
3. Insert the bush (refer to Figure 46).

___________________________________________
4.4.2.5. NOSE GEAR REMOVAL / INSTALLATION

ITEM QUANTITY NOTES
1 3/8” Spanner. 2
2 7/16" Spanner. 1
WARNING
WARNING
ALLOW THE ENGINE AND APPLICABLE COMPONENTS TO COOL COMPLETELY BEFORE

PERFORMING ANY WORK OR INSPECTION IN THE ENGINE COMPARTMENT. HOT ENGINE
COMPONENTS CAN CAUSE SERIOUS BURNS AND CAN IGNITE SPILLED FLUID / VAPOUR.
CAUTION

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PROCEDURE (REMOVAL)
1. Remove the cowling around the engine area (refer to paragraph 1).
2. Hoist the aircraft onto supports.
3. Disconnect the two rudder pushrods (1) by loosening the bolts (2) through the rod-end bearings.
4. Support the nose gear and undo and remove the bolts, nuts (3) and washers on the bottom nose
gear-to-engine mount attachment (4). Remove the four brackets (5).
6
5
4 5
1 6
7 5
9
5
2
3
5. Support the nose gear, loosen the bolts (6) and remove the bolts and washers, the spacer (7) and
the bearing (8) underneath. Take care not to let the nose gear fall down and strike the rudder control
horns against the bottom engine mount connection.
6. Drop the nose gear out / clear from the top engine mount connection (9), pull it (backward) out from
the bottom engine mount connection and drop it out underneath the aircraft. The spring and the two
lower bearings will remain around the nose gear tube. The bottom bush will split into two pieces.

___________________________________________
• Tighten the lock-nuts sufficiently, observe the correct placement of washers and
bearings (refer to Figure 47) and note that the bolts are installed with the bolt heads
facing up.
1
2
1 AN4-5A bolt
2 AN4 washer
4 3
3 Punched cap
5
10 4 Nose gear yellow spacer bush
10 5 Thrust bearing (NTA3244)
5 10 6 AN3 washer (0.8 mm / 0.032”)

10 7 AN3-23A bolt
8 AN3-14A bolt.
11
9 AN3 lock-nut (Nyloc)
10
10 Thrust bearing washer (TA 3244)
10
5 11 Nose gear spring
designations
Figure 47: Nose gear installation.

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SECTION 5
POWERPLANT
This section provides a general description of the power plant section, comprising of the engine, the
propeller, radiators and the cowling surrounding it, and provides descriptions of service and maintenance
procedures applicable to the power plant and its subsystems.
5. POWER PLANT
5.1 COWLING
3
2
1 3
3 2
2
3
Figure 48: Engine cowling.
Refer to Figure 48. The engine cowling is made up of moulded fibreglass upper (1) and lower (2)
parts. Inspection panels (3) are located on the top cowling and are secured down by two Dzus
fasteners. The cowling houses the engine, air filter, coolant radiator, oil radiator and oil reservoir. Air
to the air filter is provided through the right-side intake. Circulation over the engine is provided by
the front nose intakes. Additional circulatory air is supplied through the coolant and oil radiators.
The outflow area is on the underside of the cowling, by the firewall.

___________________________________________
5.1.1 COWLING REMOVAL / INSTALLATION

ITEM QUANTITY NOTES
2 Philip screwdriver 1
3 5/16” Spanner. 1
WARNING
TURN OFF MASTER / IGNITION SWITCHES.
WARNING

CAUTION

___________________________________________
PROCEDURE (REMOVAL)
TOP COWL:
1. Release the cam lock fasteners located on the sides of the top cowling.
2. Release the cam lock fasteners located on the top of the top cowling, along the upper edge of
the firewall.
3. Once all cam lock fasteners are loose, remove the front and then side fasteners from their
seating holes prior to removing those over the firewall.
BOTTOM COWL:
1. Remove the top cowl (refer to above procedure).

2. Disconnect the air filter supply pipe (1) from the cowl inlet (2) by loosening the clamp (3)
securing it to the inlet.
3. Alternatively, loosen the clamp securing the air pipe at the air filter box.
3
2

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4. Release the four catches (4), one on each side of the coolant (5) and oil radiators (6). Also
refer to Figure 48.
5 6
1
6
1
5. Support the cowl and remove the cam lock fasteners located around the firewall and the Dzus
fasteners on the bracket behind the nose wheel strut.
6. Carefully move the cowl free from the aircraft.
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 the clamp securing the air filter inlet pipe to the cowl air inlet sufficiently, but do not
over tighten, as this may damage the cowl fibreglass inlet.
TOP COWL:
1. Fit the bottom cowl.

2. Reverse the above procedure (removal) to install the top cowl. Ensure that the radiators and
filter air supply pipe are properly connected before closing up the engine compartment.

___________________________________________
5.2 ENGINE
The aircraft is fitted with a Rotax 915 iS or 916 iS engine. Refer to paragraph 1.3.
Refer to the latest revision of the Rotax 915 iS or 916 iS operator’s manual and maintenance
manuals for an in-depth description of the engine and extensive specifications and technical data.
5.2.1 GENERAL MAINTENANCE AND SERVICING
Refer to and comply with the latest revision of the Rotax 915 iS or 916 iS engine operator’s manual
and / or maintenance manuals, as applicable, for procedures and instructions.
5.2.2 REPLACING ENGINE OIL
Refer to the latest revision of the Rotax 915 iS or 916 iS engine operator’s manual and / or
maintenance manuals, as applicable, for the procedures and instructions with regard to changing
the engine oil.
5.2.3 REPLACING ENGINE COOLANT
Refer to the latest revision of the Rotax 915 iS or 916 iS engine operator’s manual and / or
maintenance manuals, as applicable, for the procedures and instructions with regard to changing
the engine coolant.
5.2.4 SPARK PLUG REPLACEMENT
Refer to and comply with the latest revision of the Rotax 915 iS or 916 iS engine operator and / or
maintenance manuals, as applicable.

___________________________________________
5.2.5 VERIFYING ENGINE OIL LEVEL

ITEM QUANTITY NOTES
1 Engine oil. As needed. If required. Refer to paragraph 1.4.
manual.
WARNING
WARNING

PROCEDURE
1. Before verifying the oil level, 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.
• Rotate the propeller counter clockwise (viewing from front of aircraft) until a murmuring /
gurgling sound is heard. This signifies that air is pumped and indicates that all the oil has
been pumped back to the reservoir.
2. Verify the oil level. The oil should be between the MIN and MAX marks on the dipstick.
Replenish as needed.
3. Replace the oil reservoir cap and ensure it fits securely.

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5.2.6 AIR FILTER REMOVAL, CLEANING AND REPLACEMENT

ITEM QUANTITY NOTES
1 10mm Spanner 1
2 Phillips screw driver 1
ITEM QUANTITY NOTES
1 Safety wire. As needed.
manual.
WARNING
WARNING


___________________________________________
PROCEDURE (REMOVAL)
Retain the clamps for reassembly.
1. Remove the upper and lower cowling (see 5.1.1)
2. Loosen the nut (1) securing the air filter cover (2) and remove the cover.
3. Loosen the clamp (3) securing the air filter to the turbocharger (4)
4. Remove the air filter.
1 2 4
1 3 1
5
1
5. If the air filter is to be removed from the engine for an extended period, blank off (5) the air
intake manifold.
5
1
PROCEDURE (CLEANING)
1. Wash the filter in a solution of lukewarm water and soap.
2. Rinse in clean water until all soap solution is washed away.
3. Leave the filter to dry out thoroughly.
4. Lightly spray with filter oil (refer to paragraph 1.4). Do not overspray.
CAUTION
NEVER USE STEAM, CAUSTIC LIQUIDS, GASOLINE, STRONG DETERGENTS, PARTICLE
REMOVING AGENTS OR COMPRESSED AIR TO CLEAN THE FILTER.
NEVER ATTEMPT TO DRY THE FILTER WITH A HEAT SOURCE (E.G. HEAT GUN) OR
COMPRESSED AIR.

___________________________________________
1. Reverse the above procedure (removal) to install the air filter, paying close attention to the
following:
• Inspect the clamps for damage, cracks, corrosion and cleanliness. Replace if
necessary.
• Ensure that the filter enclosure 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 intake manifold)
is clean and dry.
• Inspect the air filter enclosure for damage or cracks. Replace if necessary.
• Use safety wire to secure the filter housing to the air intake manifold pipe clamp.
2. Before flight, start the engine and verify for correct operation, stop the engine and inspect
the air filter housing / air filter for security of attachment.

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5.2.7 REMOVAL / INSTALLATION OF OIL AND COOLANT RADIATORS

ITEM QUANTITY NOTES
1 5/16” Spanner. 1
2 3 mm Allen key. 1
PROCEDURE
1. The radiators (1) are physically separated / attached from / to the bottom cowling (2) by undoing
/ fastening the clamps (3) securing them to the cowl. For radiator pipe disconnection /
connection refer to paragraphs 5.2.8 and 5.2.9.
2
3
2. After installation inspect for security of attachment.

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5.2.8 OIL COOLER / RADIATOR PIPE CONNECTION / DISCONNECTION

ITEM QUANTITY NOTES
1 10B Spanner. 1
2 Shifting spanner. 1
3 Front pincer pliers. 1 To crimp two-ear pipe clamps. Connection.
4 Hacksaw or Dremel tool. 1 Refer to paragraph C.1. Disconnection.
ITEM QUANTITY NOTES
1 Loctite 577. As needed. Oil cooler fittings.
2 Two-ear clamps (20 mm). 2
manual.
WARNING
SPILLED OIL CREATES A SAFETY HAZARD. CLEAN UP SPILLED OIL BEFORE CONTINUING WITH
WORK.

___________________________________________
PROCEDURE (CONNECTION)
1. Apply thread locking sealant to the threads 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.
5
4
2
3. Crimp the two ear plugs.
4. Inspect for security of attachment and correct sense of connection (i.e. the correct pipe to
the correct oil cooler port).

___________________________________________
PROCEDURE (DISCONNECTION)
1. Drain fluids as required.
2. Remove the two-ear clamps (refer to paragraph C.1) and pull the pipes from the fittings.
3. Blank off oil pipes if to be unconnected for a substantial period, to prevent drip and entry
of foreign material.
4. Unscrew the fittings from the radiator, if required.

___________________________________________
5.2.9 COOLANT RADIATOR PIPE CONNECTION / DISCONNECTION

ITEM QUANTITY NOTES
2 Side cutter. 1
3 Locking pliers. 1
ITEM QUANTITY NOTES
1 Safety wire. As needed.
manual.
WARNING
SPILLED COOLANT CREATES A SAFETY HAZARD. CLEAN UP SPILLED COOLANT BEFORE
CONTINUING WITH WORK.

___________________________________________
PROCEDURE (CONNECTION)
1. Slip a hose clamp over each pipe before connection Push the pipe(s) over the radiator
connection(s).
2. Move the hose clamp(s) into place and tighten. Do not over tighten, as this may damage
the pipes.
3. Use safety wire and secure the insulation blanket(s) around the pipe(s).
PROCEDURE (DISCONNECTION)
1. Drain fluid as required.
2. Remove the safety wire securing the insulation blanket to the pipe, fold the blanket back
to expose the hose clamp and loosen the clamp.
3. Pull the pipe of the radiator connection.
4. Blank off coolant pipes if to be unconnected for a substantial period, to prevent drip and
entry of foreign material.

___________________________________________
5.2.10 ENGINE REMOVAL / INSTALLATION

ITEM QUANTITY NOTES
1 17 mm Spanner, 16 mm Spanner. 1 Each
2 Support stand for aircraft tail. 1
3 Calibrated torque wrench, with range of at least 35 to 45 Nm. 1 Installation only.
4 10 mm Spanner. 1
5 9 mm Spanner. 1
6 17 mm Socket. 1 To fit item 3.
7 Side cutter. 1
8 Locking pliers. 1 Installation only.
If oil reservoir not removed
9 22 mm Spanner and 14 mm spanner. 1 Each
with / attached to engine.
If engine mount to be
10 ½ inch Socket (with drive) and spanner. 1 Each
removed from firewall.
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 above tool list) accessories (sockets etc.)
are implied for torqueing bolts / nuts, if applicable. Refer to paragraph 1.5 for torque values.
ITEM QUANTITY NOTES
2 Safety wire, Loctite 577, tie wraps. As / if needed. Loctite 577 for oil pipe fitting threads.
manual.
WARNING
WARNING

___________________________________________
PROCEDURE (REMOVAL)
The procedures described below are general. Reference must be made to the applicable equipment
/ system documentation with regard to the connection and disconnection of mechanical cables,
electrical wires, signal wires and fluid piping. The following documents have relevance:
• Rotax 915 iS or 916 iS installation manual, maintenance manuals and operator’s manual.
• AP3 series and AP4 series or MT constant speed propeller operator’s manual.
• Garmin G3X documentation.
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 propeller (refer to paragraph 5.3.4) if the intention is to remove the engine without
the propeller attached.
3. Remove the top and bottom cowls (refer to paragraph 1).
4. Undo the clamps (1) retaining the oil reservoir to the firewall bracket. Removing the oil reservoir
with the engine (i.e. not disconnecting the piping) has the advantage that the oil system remains
closed and negates the need for refilling. Alternatively, the piping (2) to the oil reservoir can be
disconnected, leaving the oil reservoir behind on the firewall.
1
1
2
1

___________________________________________
5. Cut the tie wraps (3) retaining the coolant overflow bottle to the firewall. Removing the overflow
bottle with the engine has the advantage that the cooling system remains closed. Alternatively
remove the pipe (4) from the bottle.
3
1
4
1
6. Disconnect the fuel supply pipe (between the fuel pump assembly and the engine) either at the fuel
pump assembly side or at the engine side. Blank off to prevent drip and / or spillage.
7. Disconnect the fuel return line from the engine. Blank off to prevent drip and / or spillage.
8. Disconnect the throttle cable.
9. Disconnect the positive (red) cable between the starter solenoid and the starter, Disconnect the
ground (black) cable between the battery and starter.
10. Disconnect all sensor / transducer wires between the engine and GEA 24 unit, either at the engine
side or at the GEA 24 side. Disconnect the propeller controller signal wires.
11. Disconnect the electrical wiring between the engine control unit (ECU) and the engine on the ECU
side.
12. Disconnect the cabin heat feed pipe (6) at the firewall by undoing the clamp.
7
10
13.Cut any / all tie wraps securing pipes (connected to the engine) and electrical cabling (connected to
the engine) to the engine mount and which would prevent the engine and attached piping / cabling
from pulling free of the engine mount.

___________________________________________
14.Support the engine in such a manner that when the bolts attaching the engine suspension frame to
the engine mount are undone they can be removed / pulled out freely. If the engine is supported by
hoisting it with a crane or block and tackle, attachment must be such that the hoisted assembly
(engine, engine with propeller attached, etc.) balances evenly (about its centre of gravity) under the
hoist when freed and moved away from the engine mount.
15. With the engine securely and adequately supported, undo the four bolts (12) and nuts retaining the
engine suspension frame (13) to the engine mount (14). Remove the bolts.
Figure 49: Engine removal.
16. Carefully move the engine free from the engine mount.
17. Alternatively (to separating the engine suspension frame from the engine mount) the engine can
also be removed (as a unit with the nose gear) by undoing the four bolts retaining the engine
mount to the firewall. In that case the pushrods from the 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 piping and cables secured to the engine mount need not be
freed (step 13 above).

___________________________________________
The procedures below are general. Reference must be made to the applicable equipment / system
documentation with regard to the connection and disconnection of electrical wires, signal wires and
fluid piping. The following documents have relevance:
• Rotax 915 iS or 916 iS installation manual, maintenance manuals and operator’s manual.
• AP3 series and AP4 series or MT constant speed propeller operator’s manual.
• Garmin G3X documentation.
• Do not over tighten clamps.
• Apply thread locking sealant to the oil reservoir pipe fittings (if removed).
Note that the two top mounting bolts are 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 Figure 50
• ). Note that the two-bottom lock-nuts seat directly on the turbocharger and exhaust
muffler brackets, without washers.

___________________________________________
•
B A
1 1
C
1
B C
1 1
C
1
B
1
For clarity the engine is

not shown attached to the A
suspension frame. 1
A M10 x 130 bolt, Class 8.8

(shortened to 122 mm)
B M10 washer (thick)
C M10 lock-nut (Nyloc)
Figure 50: Engine installation.

2. Inspect the rubber vibration dampers for damage before fitment. Replace if necessary.
3. Place a drop of oil (engine oil) on the threads before fitment and torque the four bolts and nuts
retaining the engine suspension frame to the engine mount to the recommended value (refer to
paragraph 1.5.2). Torque in increments by alternately tightening opposite pairs of bolts / nuts.
4. Torque the four bolts and nuts retaining the engine mount to the firewall (if that option was
followed) to the recommended value (refer to paragraph 1.5.2). Torque in increments by
alternately tightening opposite pairs of bolts / nuts.
5. Inspect for correct connection 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. Before flight, an adequate ground run must be performed. Follow the preparations for trial run of
the engine as set out in the latest revision of the Rotax 915 iS or 916 iS installation manual.
During the run monitor all engine indications for correctness. Test / monitor all systems which
were disconnected during the removal of the engine (e.g. the propeller, the GEA 24 / EFIS) as
far as possible on the ground.
9. After the ground run inspect for leaks (fluid pipes) and security of attachment (bolts, connectors,
cables, pipes etc.).
5.2.11 ENGINE CONTROL SYSTEM (THROTTLE)
The throttle control lever is attached to the throttle lever (in cabin) by a separate Bowden cable. Friction on
the throttle lever (in cabin) is affected by two friction discs (refer to Figure 51).
For attachment of the Bowden cable to the butterfly valve throttle control lever and adjustment refer to the
latest revision / edition of the Rotax 915 iS or 916 iS engine installation manual and maintenance manuals,
as applicable.
5.2.11.1. THROTTLE LEVER FRICTION ADJUSTMENT

ITEM QUANTITY NOTES
1 3/8” Spanner 2
2 2 mm Allen key, 2.5 mm Allen key 1 each Inspection panel screws.
ITEM QUANTITY NOTES
1 Split pin 1.
2 Loctite 222 As needed Centre console inspection panel.
The above list is not necessarily a complete list of all material needed. Refer to the Sling 2 construction
manual.

___________________________________________
PROCEDURE
1. Remove the centre console side inspection panel.
2. Remove split pin and discard (do not re-use).
3. Inspect all bolts and nuts for damage. Replace if necessary.
4. Adjust castle nut and thickness of washers to attain required friction (refer to Figure 51).
5. To inspect, ground run the engine and move throttle lever to arbitrary positions across its
complete range of travel, and to the extreme rear position, and verify that adequate friction can
be maintained.
6. Fit new split pin (do not use previously used split pin).
7. Apply thread locking sealant to the centre console inspection panel screws before fitting.

___________________________________________
5.2.11.2. THROTTLE LEVER FRICTION DISC REPLACEMENT

ITEM QUANTITY NOTES
1 3/8” Spanner 2
2 2 mm Allen key, 2.5 mm Allen key 1 each Inspection panel screws.
ITEM QUANTITY NOTES
1 Split pin 1.
2 Loctite 222 As needed Centre console inspection panel.
manual.

___________________________________________
PROCEDURE (REMOVAL)
Retain any bolts, clamps, spacers, screws and washers (with the exception of lock-washers) for reassembly.
1. Remove the centre console side inspection panel.

2. Remove the split pin and discard.
3. Undo the castle nut, support the throttle lever and pull out the bolt, and remove the friction washers.
• 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 paragraph 0).
A AN3-7 bolt
THROTTLE
B AN3 washer (0.8 mm / 0.032”) **

BRAKE
C AN3 washer (1.6 mm / 0.064”) **

D AN3 castle nut
E Split pin
F Friction disc
** (Note: thickness of these washers may be varied to
accommodate throttle lever friction adjustment)
E
D C
NOTE: Throttle cables not shown for the sake

of clarity. Throttle lever detent mechanism not
shown.
F
F
Figure 51: Throttle lever friction disc installation.

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5.3 PROPELLER
The aircraft is fitted with a three blade Airmaster AP430CTT-WWR72B 72” or an MTV-6/190-69
variable pitch / constant speed propeller, controllable from the cabin. Refer to the latest revision of
the propeller operator’s manual for detailed information.
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 EXTENSION TORQUE PATTERN
Bolts / nuts should be torqued in the following sequence (as indicated in Figure 52) when securing
the propeller extension to the engine hub or when securing a propeller to the propeller extension.
Figure 52: Propeller installation / propeller extension installation torque pattern.

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5.3.3 SPINNER REMOVAL / REPLACEMENT

ITEM QUANTITY NOTES
1 Phillips screwdriver. 1
WARNING

___________________________________________
PROCEDURE (REMOVAL)
1. Undo the screws (1) retaining the spinner (2) to the spinner bulkhead (3).
3
6
1
6
2
6
1
6
1. Reverse the above procedure (removal) to install the spinner, paying close attention to the
following:
• Inspect all bolts, nuts and screws for damage, cracks, corrosion, proper thread and
cleanliness. Replace if necessary.
• Inspect the spinner bulkhead and spinner dome for cracks, deformations or any signs of
damage.

___________________________________________
5.3.4 PROPELLER REMOVAL / INSTALLATION

ITEM QUANTITY NOTES
1 Calibrated torque wrench, minimum range of at least 1 Installation.
25 Nm.
2 ½ inch Hex socket (to fit item 1). 1 Installation.
3 13 mm Hex socket (to fit item 1). 1 Installation.
4 ½ inch Spanner. 1 Removal.
5 13 mm Spanner 1 Removal.
6 Socket wrench to fit items 2 and 3. 1 Alternative to items 4 and 5.
ITEM QUANTITY NOTES
2 Loctite 243. As needed. Bolts connecting propeller extension and engine flange.
3 Bolts connecting propeller extension and propeller assembly /
Loctite 222. As needed.
hub.
manual.
WARNING
CAUTION
AND AWKWARDNESS OF THE OBJECT TO BE REMOVED.

___________________________________________
PROCEDURE (REMOVAL)
Retain any bolts, nuts (except lock-nuts) spacers, screws and washers (with the exception of
lock-washers) for reassembly.
REMOVING WITHOUT PROPELLER EXTENSION
1. Support the propeller and undo the bolts (1) securing the propeller assembly to the
engine propeller flange (2).
2. Carefully and slowly pull the propeller away from the engine propeller flange (2) until the
signal wire connectors are exposed. Disconnect the wires.
3 4
1 4
1
2
2
1
4
3. If required to separate the slip-ring disc (3) from the propeller extension, undo the
nuts (4) securing the signal wires (from the propeller extension) to the slip-ring disc. Before
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 disc.
4. After removal, do not lay the propeller down on its tip (against a wall for instance) but
always lay the propeller flat and away from sources of humidity, heat or, in any case, away
from areas subject to excessive temperature variations.

___________________________________________
1. Reverse the above procedure (removal) to install the propeller onto the engine, paying
close attention to the following:
• Do not reuse lock-washers and lock-nuts. Fit new.
• Inspect all bolts, nuts and screws for damage, cracks, corrosion, proper thread
and cleanliness. Replace if necessary.
• Apply thread locking sealant to the bolt threads before fitting.
• Inspect the spinner bulkhead and spinner dome for cracks, deformations or 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 slip-ring disc.
Ensure that no oil traces are present.
• Inspect the electrical wire connections terminals for damage and security of
attachment to the wires.
• Ensure that the electrical signal wire connections are secure and correct (i.e. a
specific coloured wire on the propeller / propeller extension side connects to the
correct slip-ring / terminal on the slip-ring disc (as marked upon removal or refer
to Figure 53).
BLACK WIRE
RED WIRE
GREEN WIRE
Figure 53: Airmaster propeller signal wire to slip-ring disc connection.

___________________________________________
• Ensure that the propeller extension is correctly aligned with engine flange before
tightening the bolts.
2. Paint orange creep marks on the bolts.

3. After the correct installation of the propeller 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 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 propeller
controls to verify correct operation, stop the engine and carry out an inspection
(tightness of bolts, spinner security of attachment, overall state, etc.).

___________________________________________
5.3.5 PROPELLER ASSEMBLY / DISASSEMBLY

ITEM QUANTITY NOTES
1 Calibrated torque wrench, with a minimum range of at
1
least 25 Nm.
2 ½ inch Hex socket (to fit item 1). 1
4 Socket wrench to fit item 2. 1 Alternative to item 3.
ITEM QUANTITY NOTES
2 Loctite 222. As needed.
manual.
CAUTION

2
___________________________________________
1. Remove the spinner dome (refer to paragraph 5.3.3).

2. Remove the propeller assembly from the aircraft (refer to paragraph 5.3.4).
3. For further disassembly of the propeller assembly refer to the latest revision of the propeller
manufacturer operator’s manual for the required procedures and instructions.
1. Reverse the above procedure (disassembly) to reassemble the propeller assembly, paying close
attention to the following:
• Do not reuse lock-washers. Fit new.
• Inspect all bolts, nuts and screws for damage, cracks, corrosion, proper thread and
cleanliness. Replace if necessary.
• Apply Loctite 222 to the bolts before fitting to the spacer / propeller assembly.
• Carefully clean and dry the propeller extension and spinner hub. Ensure that no oil traces
are present.
• Inspect the spinner dome, the spinner bulkhead and propeller extension for cracks,
deformations or signs of any damage.
• Ensure that the propeller extension is correctly aligned with propeller assembly before
tightening the bolts.
• Torque the bolts securing the propeller assembly to the propeller extension to the correct
value (refer to paragraph 1.5.2). Torque in a star pattern / sequence as shown in Figure
52).

___________________________________________
5.3.6 PROPELLER ADJUSTMENT / SET-UP
Refer to the latest revision of the propeller manufacturer operator manual for the relevant
procedures and instructions.
5.3.7 PROPELLER BALANCING
Refer to the latest revision of the propeller manufacturer operator manual for the relevant
procedures and instructions.

___________________________________________
5.4 FUEL SYSTEM
A Left fuel tank
B Right fuel tank
C Fuel selector
D ANDAIR gascalator
E Rotax fuel pump
F Fuel pressure sensor
G Bypass pressure valve
H Fuel filter
I Jet T piece
J Rotax 915 iS
AN6 90o bulkhead fitting,
K
flare, nut & 2 washers
AN6 straight female push-on
L
fitting
Male to female AN6 90o
M
fitting
N T-piece 3/8”-5/16”-3/8”
AN6 straight flare bulkhead
O
fitting with nut and washer
P 1/8” NPT female adaptor
Q M14x1.5 AN 6 male
R M12x1.5 AN6 male
S S/S AN6 female barb fitting
90o fitting, ¼”NPT male to
T
3/8”barb, brass
Facet Posi-Flow Electrical
U
Fuel Pump
ANDAIR Check Valve, 0.4–
V
0.7 Psi
90o hose end swivel push on
W
AN6-barb
5/16” fuel hose SAE J30R9
Figure 54: Fuel system.
Refer to
Figure 54 which illustrates the fuel system with a Rotax fuel pump assembly (E). Some aircraft are
alternatively fitted with Andair duplex fuel pumps. The aircraft is equipped with two aluminium fuel tanks
(A, B) within the wing leading edges, accessible for inspection through dedicated panels.
The fuel outlet for each tank is located at the lowest point of the inboard sidewall of the tank (A, B).
___________________________________________
A fuel selector valve (C) is mounted in the lower centre instrument panel in the cockpit.
Fuel feed is through a Gascolator (D) and two electric pumps (E). Each pump has a parallel installed
check valve (NRV).
The main fuel feed from the fuel pumps enters a T-piece (N) where the fuel in split in two directions. Fuel
exits the T-piece to the fuel pressure sensor (F) and to another T-piece (N). At the second T-piece fuel is
supplied to a fuel filter (H) and a bypass pressure valve (G).
The fuel that exits the fuel filter and bypass pressure valve is supplied to the Rotax 915iS engine via a T-
piece (I) equipped with a jet.
Surplus fuel returns from the T-piece with jet (I) to the tank in use (as selected by the selector) via a fuel
return line to the upper inboard section of each tank (A, B).
Fuel drain valves are located under the inner leading edge section of each wing, just forward of the main
spar.
Each fuel tank (A, B) is equipped with an individual float sensor. Fuel level indicators for each tank
appear on the EFIS display.

___________________________________________
5.4.1 GENERAL SERVICE INFORMATION AND CONSIDERATIONS
FUEL HOSE / PIPE

TWO-EAR CLAMPS
INNER DIAMETER OUTER DIAMETER
8 mm 14.5 mm (approximately) 15 mm
9.5 mm 16.0 mm (approximately) 18 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 inside cross-sectional area of the pipe is not distorted
to such an extent that it impedes or hampers the flow of fuel in any way.
For fuel feed and return line hose sizes / diameters refer to Figure 56.

___________________________________________
5.4.2 FUEL SELECTOR UNIT REMOVAL / INSTALLATION

ITEM QUANTITY NOTES
1 2.5 mm Allen key (short nosed). 1
2 2 mm Allen key. 1
3 Front pincer pliers. 1 To crimp two-ear pipe clamps. Installation only.
4 Hacksaw or Dremel tool. 1 Refer to paragraph C.1. Removal only.
ITEM QUANTITY NOTES
Inspection panel screws and four fuel selector
1 Loctite 222. As needed.
unit retaining screws.
2 Two-ear pipe clamps (18 mm). 6 Installation.
manual.
WARNING
SPILLED FUEL CREATES A SAFETY HAZARD. CLEAN UP SPILLED FUEL BEFORE CONTINUING
WITH WORK.

___________________________________________
PROCEDURE (REMOVAL)
Retain any bolts, clamps, spacers, screws and washers (with the exception of lock-washers)
for reassembly.
1. Access is gained to the unit from behind and below the instrument panel. Removing
the centre console side inspection panel might ease access.
2. Pull / raise the safety button (1) to reveal the screw (2) retaining the selector lever (3)
to the selector valve unit. Loosen the screw and remove / slide off the lever.
4
1
2 5
3
4 4
3. Loosen the four button head screws (4) retaining the plate (5) to the selector unit.
Push the unit towards the nose of the aircraft to expose (fuel pipe flexibility should
allow this) and remove the fuel pipes from the unit’s fittings, by removing the two-ear
clamps (refer to paragraph C.1) retaining the pipes to the selector unit. Alternatively
gain access to the fittings via the centre console side inspection panels.
4. Blank off the fuel pipes if to be unconnected for an extended time.

___________________________________________
• Apply thread locking sealant to the selector unit retaining screws before fitting.
Do not over tighten the button head screws.
• The fuel selector lever is keyed to the fuel selector unit shaft.
• The faceplate 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 Figure
56 and
• Figure 57.
2. Before flight, perform an engine ground run and verify correct operation of the selector
unit / correct feed from both fuel tanks.
3. After the engine ground run inspect for leaks. Inspect for security of attachment.
4. Apply thread locking sealant to the inspection panel screws before fitting. Close the
inspection panels, if applicable.
PLATE
LEVER
A M4 x 16 mm button head screw
Lever retaining screw, provided

FUEL SELECTOR UNIT
B
with assembly
Figure 55: Fuel selector unit installation.

___________________________________________
5.4.3 FUEL SELECTOR UNIT ASSEMBLY / DISASSEMBLY

ITEM QUANTITY NOTES
1 15 mm Spanner. 1 Fuel hose fittings.
ITEM QUANTITY NOTES
1 Loctite 577. As needed. Fuel hose fitting threads.
manual.
ASSEMBLY / DISASSEMBLY
1. Fitting (1) is screwed into the fuel selector unit body (2). 9.5 mm inner diameter fuel pipe is fitted to the barb
end of fitting (1) (refer to Figure 56)). Apply thread locking sealant to fitting (1) threads before fitment to the
fuel selector unit body.
2. Align the fuel hose fittings for easy fit and alignment with the fuel hoses (refer to
3. Figure 57).
4. Reverse the above to disassemble the fuel selector unit.

___________________________________________
D
D A
E A
B F
C
E The above schematic does not show
the correct alignment for the fuel
fittings. It is intended for port
identification only.
F C
RETURN SUPPLY / FEED ALLOCATION
PORT FUEL PIPE INSIDE DIAMETER
A 9.5 mm From starboard tank (feed)
B 9.5 mm To engine / pumps (feed)
C 9.5 mm From port tank (feed)
D 9.5 mm To starboard tank (return)
E 9.5 mm From engine (return)
F 9.5 mm To port tank (return)
Figure 56: Fuel selector port allocation and fitting orientation.
Aircraft nose
Aircraft starboard
Aircraft port
Aircraft nose
Figure 57: Fuel selector fuel fitting alignment.

___________________________________________
5.4.4 FUEL PUMP ASSEMBLY REMOVAL / INSTALLATION

ITEM QUANTITY NOTES
1 Flat screwdriver and side cutter. 1 Each
2 Locking pliers. 1 Installation.
11/16” (18 mm) spanner, 10 mm Spanner / hex 1 Each
4
drive, 8 mm spanner / hex drive.
5 Hacksaw or Dremel tool / front pincer pliers. 1 Each Two-ear clamp removal /
installation.
ITEM QUANTITY NOTES
1 Safety wire and tie wraps, 8 mmx 12 mm x 5 mm seal draft rubber As needed.
strip.
2 Two-ear clamps. (18 mm) 2
3 Tie wraps, clear tubing. As needed.
manual.
WARNING
WARNING

WARNING
WITH WORK.

___________________________________________
PROCEDURE (REMOVAL)
1. Fuel selector in OFF position.

2. Remove the cowlings (refer to paragraph 5.1.1).
3. Undo the fittings (1) connecting to the inlet (2) and outlet (3) tube of the fuel pump assembly housing
(4). Drain excess fuel in the lines into a container
4. Remove the fuel pump assembly housing cover (4) by undoing the four Allen Cap screws (5).
2 4
4
1 4
3
1 1
4
4
5
5

___________________________________________
5. Disconnect the electrical wiring from the electrical plug (6) on the two fuel pumps.
6
STARBOARD
6. Remove the fuel pump assembly from the firewall forward by loosening the nuts (7) on the cabin
side of the firewall (8).
6 6
6
6

___________________________________________
• Do not tighten the cover 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 connected
to the terminal marked (+) on the respective fuel pump connector blocks. Note that the
assembly is mounted on the firewall with the MAIN PUMP to starboard and the AUX PUMP
to port.
Auxiliary pump
TOP OF AIRCRAFT wires connect
here.
STARBOARD
AUX
PUMP
MAIN
PUMP
Main pump wires

connect here.
2. Fit seal draft rubber strips (1) to the pump assembly bracket (2) before fitting the assembly to the
firewall.

___________________________________________
8 mm x 12 mm x 5 mm Seal draft rubber strips
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 run inspect for any sign of fuel leaking at the pump-
to-hose connections.

___________________________________________
5.4.5 FUEL PUMP REMOVAL / INSTALLATION FROM / INTO FUEL PUMP ASSEMBLY

ITEM QUANTITY NOTES
1 Front pincer pliers. 1 To crimp two-ear pipe clamps. Installation.
2 Hacksaw or Dremel tool. 1 Refer to paragraph C.1. Removal.
ITEM QUANTITY NOTES
1 Two-ear clamps (22 mm). 2 Per pump.
2 Two-ear clamps (15 mm). 2 per pump.
manual.
WARNING
WITH WORK.

___________________________________________
PROCEDURE (REMOVAL)
1. Remove the fuel pump assembly (refer to paragraph 5.4.4), if required, else disconnect the applicable
pump’s electrical wiring (refer to paragraph 5.4.4).
2. Remove (refer to paragraph C.1) the two-ear clamps (1) on the rubber hoses (2) connecting the fuel pump
to the surrounding pipe framework (3) and remove the pump (4) from the pipe frame.
3 1 From fuel selector

To engine
1 3
1
AUX PUMP
2
MAIN PUMP
PUMP
4 3
4
Remove connecting rubber hosing from here to remove pump.
1. Reverse the above procedure (removal) to install a fuel pump into the pipe framework, paying close
• Inspect the rubber hoses before fitment. Replace if necessary.
2. Inspect for security of attachment (rubber hoses).

___________________________________________
5.4.6 FUEL TANK LEAK REPAIR

ITEM QUANTITY NOTES
1 Sealant. As needed. Refer to paragraph 1.4.
manual.
PROCEDURE
1. Repairs can only be made if cracks are small.

2. Empty the fuel tank.
3. Repeatedly rinse area with water.
4. Apply sealant according to manufacturer instructions.
5. Verify for no leaks using instructions stated in paragraph 5.4.8.

___________________________________________
5.4.7 FUEL TANK DRAIN REMOVAL / INSTALLATION (DRAINING WING TANK)
A fuel drain is installed for each fuel tank. The drain is located under each wing, near the wing root.
The tank can be drained completely by removing (unscrewing) the drain.

ITEM QUANTITY NOTES
1 16 mm Spanner 1
manual.
WARNING
HAVE THE CORRECT TYPE (FOR FUEL FIRES) FIRE EXTINGUISHER AT HAND.
CLEAN UP SPILLED FUEL IMMEDIATELY AS IT CREATES A SAFETY HAZARD.

___________________________________________
A fuel drain is installed for each fuel tank. The drain is located under each wing, near the wing root.
The tank can be drained 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.
1. Observe correct washer placement (refer to Figure 58). Do not reuse fibre washer. Fit new.
2. Fill tank with fuel and inspect for leakage.
A M14 fibre washer
Figure 58: Wing tank fuel drain installation.

___________________________________________
5.4.8 FUEL LEVEL SENDER ASSEMBLY REMOVAL / INSTALLATION (FROM / TO FUEL TANK)

ITEM QUANTITY NOTES
1 2 mm Allen key 1 Inspection panel(s).
Tank cover plate / fuel
2 7 mm Spanner 1 level sender mounting
plate.
3 17 mm Spanner. 1
Fuel line couplings.
4 9/16” Spanner. 1
ITEM QUANTITY NOTES
1 Loctite 222 As needed Inspection panel
2 Loctite 577 As needed Fuel tank outlet / return line couplings.
manual.
WARNING

___________________________________________
The procedure is the same for the left and right tank fuel level sender assembly removal and installation.
PROCEDURE (REMOVAL)
1. Remove the inspection hatch(es) under the leading edge(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 5.4.7).
3. Loosen the fuel line couplings (1). Move the fuel pipes out of the way.
4. Loosen the nut (2) retaining the signal wire to the fuel level sender terminal stud and remove the
signal wire.
5. Undo the button screws (3) retaining the tank cover plate / fuel level sender mounting plate (4).
1
3
3
2
6. Carefully pull the plate / fuel sender assembly away from the wing rib, taking care not to hook
the float arm assembly on the hole (in rib) edges.

___________________________________________
• Ensure no loose material or tools are left in fuel tank cavity before fitting the fuel level
sender / sender mounting plate.
• Do not re-use the cork gasket or fibre washers. Fit new.
• The metal washers are fitted between the bolt heads and the fibre washers.
• Do not re-use Nyloc lock-nut on signal wire-to-terminal connection. Fit new.
• Be careful not to damage the cork gasket during assembly.
• Observe correct plate orientation and placement of washers (refer to Figure 59). The
plate is fitted 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 tightening.
2. Inspect for leaks by pressurizing the tank: Ensure that the fuel filler cap is in place and correctly
closed. Ensure that the fuel drain is replaced and correctly fitted. Place a hose onto the tank
overflow pipe and blow using a hard breath of air. Do not use air pressure from a compressor, as
this may cause the tank to burst from over pressurization. Brush soapy water over the gasket
area, bolts and fuel line fittings to observe for leaks. Dry / swipe away after inspection.
3. Fill the tank completely and verify for leaks or sweating.
4. Close the inspection hatches under the wing.
5. Run the engine at 4000 rpm for 5 minutes before flying the aircraft.

___________________________________________
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 gasket
F M4 lock-nut (Nyloc) (secures signal wire to terminal stud)
B
E
Figure 59: Fuel sender installation into fuel tank.

___________________________________________
5.4.9 REPLACING FUEL LEVEL SENDER ASSEMBLY SENSOR

ITEM QUANTITY NOTES
1 7 mm Spanner 1
2 Side cutter 1
3 Fibre tipped marking pen (fine point) 1 To mark float arm position
4 Pliers 1 To bend float arm stops on sensor
5 Multimeter 1
ITEM QUANTITY NOTES
1 Fuel / fuel tank sealant As needed Refer to paragraph 1.4.
2 100 x 2.5 mm tie wrap 1
manual.
WARNING

___________________________________________
PROCEDURE (REMOVAL)
The procedure is the same for the left and right tank fuel level sender assembly sensor removal and
installation.
1. Remove the fuel level sender from the wing / wing end rib (refer to paragraph 5.4.8).
2. Undo the nut (1) retaining the signal wire to the terminal stud, cut the tie-wrap and unwind the
signal wire from the bracket (2).
Mark position on float arm here.
5
4 6
6
2
4
5 3
1
Mark position on float arm here.
3. Undo the screws (3) retaining the sensor (4) to the bracket (2) and remove the sensor.
4. Mark the position of the float arm (5) where it is secured to the sensor (by screw).
5. Remove the sealant and undo the screw retaining the float arm (5) to the sensor. Retain the float
arm for reassembly onto the replacement sensor.
6. The float arm stops (6) on the replacement sensor must be bent to be identical in position to that
on the removed sensor (refer to Figure 54). Retain the removed sensor for reference.

___________________________________________
• Observe correct washer placement (refer to Figure 60).

• The sensor is fitted to the bracket with the spindle pointing away (in opposite direction)
from the 90-degree bend / plate / part of the bracket attached to the hexagonal tank
cover / sender assembly plate, i.e. spindle will face to rear when level sender assembly
is installed in fuel tank. See Figure 60.
• The float arm is installed onto the sensor spindle so that the (bent) corner will point to
the bottom of the fuel tank.
• (a) The float arm must be fitted to the new sensor with the same point (centre 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 60). Use the marks made (during
disassembly) on the float arm to assist in positioning the float arm before securing it to
the sensor spindle.
• (b) Bend the float arm stops (refer to Figure 60) on the replacement sensor to be
identical to that on the sensor which was removed.
Steps (a) and (b) above are to ensure that the float ball does not touch the tank
edges / skin and should be carefully and accurately applied.
• Wind the signal wire (1) tightly and securely around the bracket (2) and sensor (3) as
shown below, without damaging or distorting / stretching it unnecessarily. Route the
signal wire as shown and tie wrap (4) the bundle as shown. Cut the excess tie wrap
strap off.
1
3
1
• Do not re-use the lock (split) washer on the signal wire terminal stud. Fit lock washer
supplied with sensor.
• Seal / lock (to the sensor spindle) the screw used to secure the float arm to the sensor
spindle with fuel / fuel tank sealant. The fuel sealant must be allowed to dry for 48 hours
before coming into contact with fuel.

___________________________________________
2. Use a multimeter set to measure resistance (set to the 200 Ω range setting, if available or
higher) to measure the range of the sensor, with the float arm first flush against one stop and
then rotated to lie flush against the other stop. The range measured should be between > 0 Ω
and < 200 Ω (approximately 8 Ω to 192 Ω). Measuring an open circuit with the float arm flush
against any one of the stops indicates that the sensor wiper has moved off the sensor board
pick-up and indicates that the stops are not correctly bent. Bend the stops to exactly match
those of the sensor previously removed!
3. Replace the fuel level sender assembly (refer to paragraph 5.4.8).
4. Follow the calibration procedure as outlined in the latest revision of the Garmin G3X installation
manual to calibrate the newly fitted sensor.
A
Bend these stops to be identical to
B that on the removed sensor.
Lock the screw (securing the float arm to the

sensor spindle) with fuel / fuel tank sealant. Allow
48 hours to dry before contact with fuel.
Multimeter probe here (on A Screws supplied with sensor

bracket).
B Washers supplied with sensor
C D
C Lock (split) washer supplied with sensor
D Brass nut supplied with sensor
Multimeter probe here. (on
terminal).
Float arm is secured with this

point (centre of bent arm (as
shown)) over centre of sensor
spindle.
Figure 60: Fuel level sender assembly sensor replacement.

___________________________________________
5.4.10 FINGER STRAINER (ON FUEL PICK-UP) INSPECTION

ITEM QUANTITY NOTES
1 Small angled mirror inspection tool 1
2 Small pencil flashlight 1
3 Source of compressed air (low pressure) 1
WARNING
WORK IN A WELL-VENTILATED AREA.

___________________________________________
A finger strainer (1) forms part of each fuel tank pick-up (2), located just inboard (in the tank) from the
wing root end rib (3), immediately below the fuel level sender mounting plate (4).
PROCEDURE (INSPECTION AND CLEANING)
1. Remove the fuel level sender assembly / assembly mounting plate (refer to paragraph 5.4.8).
2. Use a small 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 provide light!!!!!!
3. Any observed clogging can be washed away and / or blown clear (with low pressure air). Blow
towards end rib to prevent material being CARRIED deeper into tank. Remove the cleared
material from the tank cavity.
4. Ensure that no tools or foreign material remains behind in the tank cavity and refit the fuel level
sender assembly (refer to paragraph 5.4.8) when finished.

___________________________________________
SECTION 6
AVIONICS AND INSTRUMENTS
This section provides a general layout of instrumentation, avionics and supporting systems and provides
descriptions of service and maintenance procedures applicable to the avionics and instruments.
6. AVIONICS AND INSTRUMENTS
The diagram below represents an instrument panel containing the 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 illustrated in the diagram.
Figure 61: Standard instrument panel (refer to key on next page).

___________________________________________
The aluminium instrument panel contains the bulk of the electrical, flight and engine instruments (refer to
Figure 61). They are described as follows:
1 Power ON light 18 GMC 307 control unit
2 Master switch 19 Cabin heat fan speed knob
3 Ignition switch 20 Ballistic rescue parachute activation handle
4 Lane A and Lane B warning lights 21 Cabin heat temperature control knob
5 Lane A and Lane B switches 22 Flap position control knob (rotary)
6 12 V Power port / socket. 23 Propeller control switch
7 Garmin GDU 460 (EFIS) Switches: EFIS, EFIS back-up battery, propeller,
avionics, taxi lights, landing lights, strobe lights,
24
navigation lights, external alternator (if fitted),
8 EFIS warning light
autopilot, etc.
9 Propeller controller 25 Fuel pump switches
10 Garmin G5
11 Radio (GTR 200)
12 RAM mount (Ball type)
13 Cubby hole
14 ACK ELT display unit
15 Circuit breakers
16 Air vent
17 Cabin air flow control knob

___________________________________________
6.1 GENERAL MAINTENANCE AND SERVICE OF INSTRUMENTS
Refer to the applicable instrument manufacturer’s documentation for information regarding

maintenance, service, wiring diagrams and programming / set-up instructions (as applicable).
6.2 REMOVAL / INSTALLATION OF INSTRUMENT PANEL AND INSTRUMENTS

ITEM QUANTITY NOTES
2 As required for each instrument. As required.
ITEM QUANTITY NOTES
1 Loctite 222. As needed. Instrument panel retaining screws.
manual.
WARNING
ENSURE MASTER SWITCH IS OFF.

___________________________________________
PROCEDURE (REMOVAL)
PANEL:
The instrument panel may be removed by unscrewing the button head screws on the outside edge
of the panel. Tilt the panel forward (into the cabin) to reveal the connections to the instruments and
panel mounted equipment.
INSTRUMENTS:
1. Before removing any electrical instrument, ensure that the master switch is OFF.
2. Before removing an individual instrument, carefully disconnect wires, hoses and / or other
cables, as the case may be.
3. Remove the instrument.
PANEL:
Reverse the procedure for installation. Apply thread locking sealant to the instrument panel
mounting 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-tighten bolts / screws as instrument casings may break or crack.

• Ensure hoses are free of any foreign matter and that no tight radius turns are present,
as this may choke the hose or cause malfunction.
• Ensure proper connection and tightening of all instrument electrical connectors.
• Ensure proper connection of pneumatic tubes.
3. Perform a pitot system leak test if any instrument connecting to the pitot system was removed /
installed. Refer to paragraph 6.3.1.
4. Perform a static system leak test if any instrument connecting to the static system was
removed / installed. Refer to paragraph 6.3.2.
5. Verify the operation of any electrical instrument which were replaced / installed.

___________________________________________
6.3 PITOT AND STATIC SYSTEMS
Refer to Figure 62. The system consists of a pitot tube mounted below the left wing and a static port
behind the instrument panel. The pitot tube includes a second port set on an angled bevel below the
main port for the purpose 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, altimeter, vertical speed indicator and the EFIS).
Please note that this drawing is

representative of a pitot and static system
only and may differ from the actual
installation in the aircraft, with regard to, for
example, placement of instruments and
actual instruments installed.
Figure 62: Representative pitot and static system.

___________________________________________
6.3.1 PITOT SYSTEM LEAK TEST
For safety reasons and to ensure correct airspeed readings, it is important to test the system for
leaks.

ITEM QUANTITY NOTES
Rubber hose with inside diameter equal to pitot
1 1
outside diameter, at least 30 cm length.
PROCEDURE
1. Ensure that all instruments (that utilise the pitot system) are connected.
2. Connect a piece of rubber hose approximately 30 centimetres long to the pitot tube, ensure
that there is no leakage at the pitot tube to hose interface.
3. Close off the opposite end of the hose and slowly roll it up until the airspeed indicator shows
cruise speed. Stop rolling up the tube at the cruise speed indication.
4. Observe the airspeed indication for an adequate period.
5. A constant reading is an indication of no leak in the pitot lines.
6. Unroll the tube slowly until fully extended. Remove the tube from the pitot.
7. Fit pitot cover, if required.
CAUTION
AVOID BLOWING AIR THROUGH THE PITOT TOWARDS CONNECTED INSTRUMENTS, AS THIS MAY
CAUSES IMMEDIATE DAMAGE. DO NOT APPLY SUCTION TO CONNECTED PITOT LINES /
INSTRUMENTS.

___________________________________________
6.3.2 STATIC SYSTEM LEAK TEST

ITEM QUANTITY NOTES
1 Vacuum pump. 1
2 Piping to connect vacuum pump to static system T-piece. As needed.
PROCEDURE
1. Ensure that all instruments (that utilise the static system / port) are connected.
2. One of the T-pieces connected into the static system piping (behind the instrument panel)
has a free end, which acts as a static port. Connect the vacuum pump to this free end.
3. Set the altimeter / EFIS to indicate 0 ft (i.e. set QFE on the subscale) or to indicate
elevation above sea level (i.e. set QNH on subscale).
4. Apply a vacuum equivalent to 308.4 m (1000 ft) (differential pressure of approximately
36.2302 mb (1.07“Hg) with ambient) and hold.
5. Monitor the indication on the altimeter or EFIS. Any leak should not exceed 30.48 m (100 ft)
per minute (decrease in differential pressure of approximately 0.3555 mb (0.0105” Hg) per
minute).

___________________________________________
6.3.3 PITOT AND / OR STATIC SYSTEM CLEANING AND SERVICING
PROCEDURE
1. Open the instrument panel (refer to paragraph 6.2).

2. Disconnect 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 obstructions.
4. Reconnect the pneumatic line(s) to the instrument(s).
5. Close the instrument panel (refer to paragraph 6.2).
6. Perform (if applicable) a pitot system leak test before flight. Refer to paragraph 6.3.1.
7. Perform (if applicable) a static system leak test before flight. Refer to paragraph 6.3.2.
CAUTION
AVOID BLOWING AIR THROUGH THE PITOT OR STATIC PORTS TOWARDS CONNECTED
INSTRUMENTS, AS THIS MAY CAUSES IMMEDIATE DAMAGE. DO NOT APPLY SUCTION TO PITOT
LINES / INSTRUMENTS.

___________________________________________
6.4 MAGNETOMETER
The aircraft is equipped with a magnetometer (GMU 11) which provide attitude and heading
information to the EFIS. The sensors are each mounted on a plate which is in turn attached to the
cabin floor with adhesive foam blocks.
6.4.1 MAGNETOMETER REMOVAL / INSTALLATION

ITEM QUANTITY NOTES
1 2.5mm Allen key. 1
WARNING
ENSURE MASTER AND ALL AVIONIC / INSTRUMENT SWITCHES ARE OFF.
CAUTION
AND / OR AWKWARDNESS OF THE OBJECT (SEAT) TO BE REMOVED / INSTALLED.

___________________________________________
PROCEDURE (REMOVAL)
1. Remove the rear fuselage inspection hatch (1)

2. Undo the screws retaining the connector (2) to the GMU 11 (3) and disconnect the
connector.
4
4
5
2 4
1
3 4
2 4
5
3. Undo the four screws (4) retaining the sensor to the plate (5) and remove the unit.
• Inspect the mounting screws for damage before fitting. Replace if necessary.
2. Inspect for alignment, security of attachment and proper connector attachment before
replacing the rear seat.

___________________________________________
6.5 HEADPHONE SOCKETS
The aircraft is equipped with standard aviation specification headphone sockets, located in the rear
of the centre console (for front occupants) and in fuselage former just aft of the rear seat (for rear
occupants).
6.5.1 HEADPHONE SOCKET REMOVAL / INSTALLATION

ITEM QUANTITY NOTES
1 2.5 mm Allen key. 1 If removing front occupant socket(s).
3 Solder iron. 1
4 Heat gun. 1 Installation only.
ITEM QUANTITY NOTES
1 Loctite 222. As / if needed. Inspection panel screws.
2 Heat shrink. As needed.
3 Solder. As needed.
manual.

___________________________________________
PROCEDURE (REMOVAL)
1. Remove the centre console rear inspection panel (for pilot and co-pilot sockets).
2. Undo the nut retaining the socket to the mounting plate and pull the socket from the
plate.
3. Remove the heat shrink on the wire connections and de-solder the wire connections.
Refer to paragraph A.9 for the wiring connections / information for each socket / headphone
position.
• Observe the correct washer / insulator placement (refer to Figure 63).

• Shrink the heat shrink with a suitable heat source (e.g. a heat gun). Do not burn / melt
the heat shrink.
STAINLESS STEEL WASHER
FIBREGLASS WASHER
INSULATOR EXTENDS THROUGH THE

MOUNTING HOLE, SUCH THAT NO METAL PART
OF SOCKET IS IN CONTACT WITH METAL OF
MOUNTING PLATE.
MICROPHONE SOCKET
(ID OF SOCKET: 5.25 mm)
HEADPHONE SPEAKER SOCKET

(ID OF SOCKET: 6.35 mm)
Figure 63: Headphone socket installation.

___________________________________________
6.6 ANTENNAE
6.6.1 VHF COMMUNICATION ANTENNA
The VHF antenna is attached to the rear dorsal fuselage.
6.6.1.1 VHF ANTENNA REMOVAL / INSTALLATION

ITEM QUANTITY NOTES
1 2.5 mm Allen key. 1
ITEM QUANTITY NOTES
1 Loctite 222. As needed. Antenna mounting screws.
2 Clear silicone. As needed.
manual.
WARNING

___________________________________________
PROCEDURE (REMOVAL)
1. Unscrew the four bolts retaining the antenna to the fuselage.
2. Separate the antenna from the fuselage so that the BNC connector is exposed.
3. Undo the BNC connector and separate the cable and antenna.
• Inspect the mounting screws for damage before fitting. Replace if necessary.
• Ensure that the base of the antenna makes proper contact with the fuselage. Clean the area
if necessary.
• Inspect the rubber seal for damage before fitment. Replace if necessary.
• Apply thread locking sealant to the antenna mounting screws before fitting.
2. Apply clear silicone (refer to Figure 64) around the interface between the fuselage and antenna
base. Allow to dry.
Figure 64: VHF antenna installation.
3. Apply power to the radio and perform a communication test.

___________________________________________
6.6.2. GPS ANTENNA
The GPS antenna is mounted in the engine compartment on a bracket attached to the firewall.
Refer to paragraph B.
6.6.2.1 GPS ANTENNA REMOVAL / INSTALLATION

ITEM QUANTITY NOTES
1 7mm Spanner. 1
ITEM QUANTITY NOTES
1
manual.
WARNING

___________________________________________
PROCEDURE (REMOVAL)
1. Unplug the antenna cable (4) from the GA-35 (1) and the GA-56 below the mounting bracket.
2. Loosen the bolts (3) securing the GA-35 and GA-56 to the bracket.
3 3 3 4 3
1 2 4

3. Apply power and verify GPS operation on the EFIS.

___________________________________________
SECTION 7
UTILITY SYSTEMS
This section provides a general description of the utility systems comprising of the cabin heat system,
brake, electrical, lighting and emergency systems and provides descriptions of service and maintenance
procedures applicable to each.
7. UTILITY SYSTEMS
7.1 CABIN HEATING AND COOLING
The Sling 4 TSi is equipped with a fully functional cabin heat system. The airflow into the cabin is
controlled by a fan-heater unit mounted behind the firewall. The fan-heater unit has five exhaust vents
that distributes air throughout the cabin. Two the exhaust vents are positioned on the left and right sides
of the instrument panel, each with a shut-off valve that restricts the airflow. One exhaust vent is
connected to a Y-piece which distributes air to the left and right foot area of the front occupants. The last
exhaust vent is positioned at the bottom of the windshield. This vent is for de-misting. The temperature
of the air flow into the cabin is controlled by a rotary knob on the instrument panel. The fan speed of the
cabin heat unit is controlled by a rotary switch on the instrument panel.

___________________________________________
FRONT OF
AIRCRAFT
FRONT OF
AIRCRAFT

___________________________________________
7.1.1 HEAT EXCHANGER ASSEMBLY REMOVAL AND INSTALLATION

ITEM QUANTITY NOTES
1 2.5mm Allen key 1
2 3mm Allen key 1
ITEM QUANTITY NOTES
1 Loctite 222. As needed. Mounting screws.
manual.
WARNING

___________________________________________
PROCEDURE (REMOVAL)
1. Remove the engine cowling (refer to paragraph 5.1.1)

2. Disconnect the fan heat exchanger fan unit electrical plug.
3. Disconnect water radiator hoses at the radiator side and drain all fluid.
4. Disconnect all air exhaust pipes from the fan unit.
5. Loosen the screws securing the mounting bracket to the firewall and the rear channel.

3. Apply power and verify the cabin heat system is operational.

___________________________________________
7.2 BRAKE SYSTEM
Refer to Figure 65. The brake system consists of a brake fluid reservoir, a master cylinder and two-disc
brake assemblies. An intercept valve activates the parking brake. Braking action is through a lever
located on the cabin tunnel between seats. The hydraulic circuit intercept valve is also located between
seats and, when closed with lever pulled, keeps circuit under pressure and aircraft’s parking brake on.
Figure 65: Brake system.

___________________________________________
7.2.1 BRAKE FLUID DRAINING, REPLACEMENT AND BRAKE SYSTEM BLEEDING

ITEM QUANTITY NOTES
1 ¼ inch Spanner. 1
2 Manual pump to pump brake fluid. 1 Pump method of replacement only.
3 Container for drained fluid. As needed.
ITEM QUANTITY NOTES
1 Brake fluid. As needed. Refer to paragraph 1.4.
manual.
WARNING
SPILLED BRAKE FLUID CREATES A SAFETY HAZARD. CLEAN UP SPILLED BRAKE FLUID BEFORE
CONTINUING WITH WORK.

___________________________________________
PROCEDURE (DRAIN)
1. Open the park brake shut-off valve.

2. Remove the plastic cap (1) and loosen and remove the brake calliper nipple (2). Let the brake
fluid drain out in a container.
2
5
1
1
5
1
PROCEDURE (FILL)
METHOD 1 (PUMP)
1. Remove the brake fluid reservoir cap.

2. Ensure park brake shut-off valve is open.
3. Loosen the nipple (2) on the brake calliper enough to allow the passage of fluid. Attach a pipe
over the nipple and to a manually operated pump 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 up the brake fluid reservoir and replace the cap.
6. Apply the brakes and verify for correct operation and the absence of sponginess.
METHOD 2 (GRAVITY)
1. Ensure park brake shut-off valve is open.

2. Loosen the brake calliper nipple (2) slightly to allow the passage of air and the seepage of brake
fluid.
3. Remove the brake fluid reservoir cap.
4. Add brake fluid to the reservoir and let it run down the fluid lines to the main wheel brake
assemblies, until the fluid exits without air bubbles.
5. Apply the brakes and verify for correct operation and the absence of sponginess.

___________________________________________
PROCEDURE (BLEED)
Both main wheels are bled independently.
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 until the fluid comes out smoothly with the absence of air bubbles (no
longer spurts).
5. Top up the brake fluid reservoir.
1
7.2.2 5
BRAKE MECHANISM REMOVAL / INSTALLATION
1

___________________________________________
7.2.3 BRAKE DISC REPLACEMENT

ITEM QUANTITY NOTES
PROCEDURE (REMOVAL)
1. Remove the main wheel (refer to paragraph 4.4.1.2).
2. Unfasten the button head screws retaining the brake disc to the wheel assembly and
remove the brake disc.
• Inspect the brake disc for damage and / or cracks before fitment.
2. Before flight, verify correct operation of the brake mechanism and function.

___________________________________________
7.2.4 BRAKE LINING REPLACEMENT

ITEM QUANTITY NOTES
1 4 mm Drill bit and drive (electric or hand drill). 1 Set.
Axle / spat mounting plate
2 7/16” Spanner 2
retaining nut and bolts.
Hammer, punch and anvil / bucking bar (suitable for
3 1 Set.
rivets supplied with the brake linings).

___________________________________________
PROCEDURE (REMOVAL)
1. Remove the main wheel (refer to paragraph 4.4.1.2) and obtain the first brake lining mounting
plate / calliper (1).
2. The spat mounting plate (2) prevents the rear calliper (3) from sliding out of plate (4) attached 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.
2
5
4
1 5 5
5 6
5 5 5
4
33 4
55 1
5
3. To obtain the second brake lining mounting plate (6), slide the calliper (3) out of plate (4), then
slide the brake lining mounting plate (6) off the calliper. Note that in the photos below the calliper
(3) is shown disconnected from the brake fluid supply line. This is not required.
3 4
6
5
4 6
3 6
6 5 5

___________________________________________
PROCEDURE (REPLACEMENT)
1. Drill out the rivets (1) to remove the linings from the mounting plates (2).
2. Set the new linings in place, insert the brass rivets (supplied with the linings) and set the rivets.
1
1
1 2 2
1
5 5
1
1
1. Reverse the above procedure (removal) to install, paying close attention to the following:
• Inspect the new brake linings for damage before use. Inspect for damage and the
formation of cracks which may have resulted from the riveting process.

3. Before flight, verify correct operation of the brake mechanism and function.

___________________________________________
7.3 ELECTRICAL SYSTEM
This aircraft electrical system consists of a 12 V DC circuit. A 17 Ah lead acid battery provides the energy
to drive the starter and acts as an emergency standby supply of electrical power in case of an alternator
malfunction.
The EFIS is provided with a 5 Ah back-up battery which charges via the back-up battery charging circuit
(refer to Figure 78). Refer to the Garmin G3X installation manual.
Figure 66: Electrical system (overview).
A single-phase internal alternator is connected directly to the main battery, in order to charge the battery.
Power is supplied to the starter motor via the starter relay. The main bus receives power from the main
battery through the master switch. The main bus is used to power all avionic units and lights. The ignition
switch is connected to the main bus and is connected to the fusebox and ECU via 3 relays.
Refer to paragraph A for electrical wiring diagrams.

___________________________________________
The following table lists typical electrical equipment:
Description
1 Main and backup batteries
2 Wiring harness
3 Circuit breakers
4 Radio, intercom, transponder, ELT units
5 Main bus, circuit breakers, fuses
6 Fusebox
Engine electrical system
7 Internal generators
8 Regulator / rectifier
Cylinder head temperature sensors and exhaust gas

9
temperature sensors
10 Manifold temperature and pressure sensors

Engine management sensors
11 Oil temperature and pressure sensor
12 Ambient air temperature and pressure sensors
Elevator and Aileron autopilot servos, turbocharger waste

13
gate servo
Electrical actuators
14 Flap actuator motor
15 Trim tab actuator motor
16 Ignition system
17 Landing / taxi lights
18 Lighting system Navigation / strobe lights
19 Internal cabin lights
20 Electric fuel pumps
21 Master switch
22 Ignition switch
Switches
Lanes, EFIS, EFIS backup, propeller, avionics, lights,

23
autopilot,

___________________________________________
7.3.1 BATTERY REMOVAL / INSTALLATION

ITEM QUANTITY NOTES
1 8 mm Spanner. 2
WARNING
WARNING

COMPONENTS CAN CAUSE SERIOUS BURNS OR CAN IGNITE SPILLED FLUID / VAPOUR.

___________________________________________
PROCEDURE (REMOVAL)
2
1 1
3
3 1
1 4
1 5
1
6
5
1
1. Engine stopped.
2. Master switch OFF.
3. Remove the top engine cowling (refer to paragraph 5.1.1).
4. First disconnect the ground (negative) cable (1, black) and then the positive cable (2, red) from
the battery terminals (3).
5. Loosen the tie-in strap (4) and remove the battery (5) from the bracket (6).
1. Master 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 around, with
the negative (-) terminal towards the starboard wing and the positive terminal (+) towards the
port wing.
4. First connect the positive cable (red) and then the negative cable (black) to the corresponding
battery terminals.
5. Secure the battery with the tie in strap.
6. Inspect for correct connection and security of attachment.
7. Replace the top cowl (refer to paragraph 5.1.1)).

___________________________________________
7.3.2 EFIS BACK-UP BATTERY REMOVAL / INSTALLATION

ITEM QUANTITY NOTES
1 2.5 mm Allen key. 1
ITEM QUANTITY NOTES
manual.
WARNING
CAUTION
EFIS, EFIS BACK-UP AND ALL OTHER AVIONIC / INSTRUMENT SWITCHES OFF.

___________________________________________
PROCEDURE (REMOVAL)
1. Undo the screws retaining the instrument panel and tilt it forward to gain access to the battery.
2. Disconnect the electrical plug (1) from the underside of the battery (2).
3. Loosen the four screws (3) attaching the battery to the airframe (4).
• Mount the battery so that the electrical plug connection faces towards the aircraft floor.
3, FOUR OFF
2
4 2
2. Inspect for security of attachment and for correct polarity of the connections before closing the
instrument panel.
3. Apply thread locking sealant to the instrument panel mount screws before fitment.
4. Verify correct operation of the EFIS from the back-up battery alone before flight.

___________________________________________
7.3.3 REPLACEMENT OF CIRCUIT BREAKERS AND / OR SWITCHES

ITEM QUANTITY NOTES
1 9/16” Spanner. 1 Switches.
2 Phillips screwdriver or flat screwdriver. 1 Circuit breakers.
ITEM QUANTITY NOTES
manual.
WARNING
CAUTION
CIRCUIT BREAKERS AND / OR SWITCHES MUST BE REPLACED BY CIRCUIT BREAKERS AND / OR
SWITCHES WITH IDENTICAL RATING AND SPECIFICATION.

___________________________________________
PROCEDURE (CIRCUIT BREAKER)

2. Unscrew the wire / lug connecting terminals (1) on the circuit breaker (2) and remove the
wires. Note (or mark) the placement / connection of the wires. Wires must be reconnected to
the replacement circuit breaker in the same sense / order.
3. Undo the circuit breaker retaining nut / ring (3) and remove the circuit breaker and lock
washer (4) from the instrument panel.
4. Slip the new washer (4) supplied with the circuit breaker over the circuit breaker threaded
stub and insert the circuit breaker through the instrument panel. Ensure that the circuit
breaker is inserted right side up. Align the circuit breaker body vertically and secure with the
nut / ring (3). Do not over tighten.
5. Reattach the wires to the circuit breaker connecting terminals, in the same order / sense that
they were fitted to the removed circuit breaker.
6. Inspect for security of attachment and correct connection.
7. Apply thread locking sealant to the instrument panel mount screws and close the instrument
panel.
3
1 2 1
3 4 1 5
1 1 1

___________________________________________
PROCEDURE (SWITCH)
2. The electrical wiring connections from the switch connections (1) are shown. Note (or mark)
the placement / connection of the wires. Wires must be reconnected to the replacement switch
in the same sense / order.
3. Undo the front nut (2) securing the switch to the instrument panel and remove the switch.
4. Adjust the rear nut (3) on the replacement switch so that the switch body will be the correct
distance behind 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 (2). Do not over tighten. PLEASE NOTE THAT IN CASES WHERE THE
IGNITION (LANE) SWITCHES ARE SEPARATE FROM THE KEY SWITCH, THE SWITCHES
ARE MOUNTED UPSIDE DOWN, SO THAT THE IGNITION CIRCUITS ARE GROUNDED
WHEN THE SWITCH LEVER IS DOWN.
6. Reattach the wires to the switch connecting terminals, in the same order that they were fitted to
the removed switch.
8. Inspect for security of attachment and correct connection.

9. Apply power and test for correct operation.
10. Apply thread locking sealant to the instrument panel mount screws and close the instrument
panel.
2
5
1
1
5 3
1 1 5
5 1
1

___________________________________________
7.3.4 REGULATOR / RECTIFIER REMOVAL AND REPLACEMENT

ITEM QUANTITY NOTES
1 14 mm Socket. 1
2 Socket wrench + extension (if needed) for item 1. 1
WARNING

___________________________________________
PROCEDURE (REMOVAL)
1. Master switch OFF.

2. Disconnect the connection terminal (1) from the fuse box (2).
2 2 3
3. Undo the bolts (3) retaining the rectifier to the engine mount frame. Remove the rectifier.
1. Reverse the above procedure (removal) to install the regulator / rectifier, paying close
• Tighten the mounting bolts sufficiently. Do not over tighten.

___________________________________________
7.4 EXTERIOR LIGHTING
Exterior lighting consists of:
• Navigation lights.
• Landing and taxi lights.
• Strobe light.
7.4.1 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 instrument panel. Green, white and strobe lights are
located on starboard wing tip. Red, white and strobe lights are located on the port wing tip.

___________________________________________
7.4.2 NAVIGATION LIGHT REMOVAL / INSTALLATION

ITEM QUANTITY NOTES
ITEM QUANTITY NOTES
1 Loctite 222. As needed. Navigation light retaining screws.
manual.
WARNING
ENSURE MASTER AND NAVIGATION LIGHT SWITCHES ARE OFF.

___________________________________________
PROCEDURE (REMOVAL)
Retain any bolts, nuts (except lock-nuts) spacers, screws and washers (with the exception of
lock-washers) for reassembly.
1. Master switch in OFF position. Navigation lights switch in OFF position.
2. Undo the button head screws retaining the navigation light to the wing.
3. Carefully move the light away from the wingtip until the wire connection plugs are
revealed. Disconnect. Retain the rubber backing for reassembly.
• Inspect the rubber backing for damage before fitting. Replace if necessary.
• Apply thread locking sealant to the navigation light retaining screws before
fitment. Do not over tighten.
2. Apply electrical power and verify correct operation of the lights.

___________________________________________
7.4.3 LANDING AND TAXI LIGHTS
A landing light is located in each wing leading edge. The landing lights are activated by a switch
located on the instrument panel. A taxi light is located in each wing leading edge. The taxi lights are
activated by a switch located on the instrument panel.
7.4.4 LANDING AND / OR TAXI LIGHT REMOVAL / INSTALLATION

ITEM QUANTITY NOTES
1 2.5 mm Allen key / hex driver. 1
3 Heat gun. 1
ITEM QUANTITY NOTES
1 9.5 mm Heat shrink. . As needed.
manual.
WARNING
ENSURE MASTER AND LANDING / TAXI LIGHT SWITCHES ARE OFF.

___________________________________________
PROCEDURE (REMOVAL)
1. Master switch in OFF position. Landing light and taxi 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.
Slowly move the light away from the mounting bracket, until the electric wire connectors are
exposed.
Wing tip
1 1
1 1
3
2
1
1 1 1
1
4. Remove the heat shrink from the connectors and disconnect.

___________________________________________
1. Reverse the above procedure (removal) for installation, paying close attention to the
following:

• The light assembly is installed on the wing with the red wire (wired into the circular
extension on the light itself) facing towards the top of the wing.
Figure 67 : Landing and taxi light installation.
• All connector connections must be covered by heat shrink (see below). Slide heat
shrink over the wires before connecting the connectors together. Slide back over the
connected connectors and shrink with a suitable heat source (e.g. a heat gun). Do
not melt / burn the heat shrink.
2. Adjust the light (refer to paragraph 7.4.6).

3. Apply electrical power and verify for correct operation of the light and correct adjustment.
4. Inspect for security of attachment before replacing the clear lens.

___________________________________________
7.4.5 LANDING AND / OR TAXI LIGHT REPLACEMENT

ITEM QUANTITY NOTES
1 3/8” Spanner. 1
ITEM QUANTITY NOTES
manual.

___________________________________________
1. Remove the light assembly from the aircraft (refer to paragraph 7.4.4).
2. Undo the nuts (1) retaining the light to the angled plates (2), front plate (3) and ground wire
(4). Cut tie wraps. Remove the light.
2
5
1 6
2
3
1
1. Reverse the above procedure (disassembly), paying careful attention to the following:
• Observe correct orientation of the angled plates. Also refer to Figure 67.
• Tie wrap the wires together and to the angled plates (through hole (5)) with a plastic
tubular standoff / spacer (6) to distance the wires from the angled plate’s edge.
• Inspect the light for any sign of damage before assembling.

___________________________________________
7.4.6 LANDING AND / OR TAXI LIGHT ADJUSTMENT

ITEM QUANTITY NOTES
PROCEDURE
1. Undo the screws retaining the clear lens to the wing and remove the lens.
2. Adjust the light angle in azimuth and elevation by independently adjusting each button head
screw until the desired result is attained.
3. Replace the lens.

___________________________________________
7.4.7 STROBE LIGHT
A strobe light is installed on the rudder horn. The strobe light is activated by a switch located on the
instrument panel.
7.4.8 STROBE LIGHT REMOVAL / INSTALLATION

ITEM QUANTITY NOTES
ITEM QUANTITY NOTES
1 Loctite 222. As needed Strobe light retaining screws.
manual.
WARNING
ENSURE MASTER AND STROBE LIGHT SWITCHES ARE OFF.

___________________________________________
PROCEDURE (REMOVAL)
1. Master switch in OFF position. Strobe light switch in OFF position.
2. Undo the button head screws retaining the strobe light to the wing.
3. Carefully move the light away from the rudder until the wire connection plugs are revealed.
Disconnect.
• Apply thread locking sealant to the strobe light retaining screws before fitment. Do not
over tighten.
2. Apply electrical power and verify correct operation of the strobe light. Testing of the strobe light
may have to be done with the engine running, since the battery may or may not have enough
voltage to energize the light.

___________________________________________
7.5 EMERGENCY AND SAFETY SYSTEMS
7.5.1 BALLISTIC PARACHUTE
The Sling 4 TSi is designed specifically for convenient fitment of a Magnum 901 or SLI4SI (BRS)
ballistic parachute recovery system. 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 the basis that the occupants will not be injured, and the
aircraft structure suffers minimal damage.
7.5.2 GENERAL SERVICE AND MAINTENANCE.
The ballistic parachute should be serviced by qualified personnel only.
Refer to paragraph 3.4.2.

___________________________________________
7.5.3 SAFETY HARNESSES
The aircraft is fitted with conventional spool type, inertial three-point safety belt-for each front seat
occupant and a lap strap with shoulder harnesses for each rear seat occupant.
7.5.4 REMOVAL / INSTALLATION OF FRONT OCCUPANT SAFETY HARNESS(ES)

ITEM QUANTITY NOTES
1 3.2 mm Metal drill bit+ drive. 1 Set Removal.
2 17 mm Spanner. 2
3 7/16” Spanner. 2
6 Blind rivet tool. 1 Installation.
ITEM QUANTITY NOTES
1 Aluminium blind rivets (3.2 mm) (multigrip) As needed. Installation only.
2 Loctite 222. As needed. Inspection panel / fairing screws.
manual.
CAUTION

___________________________________________
PROCEDURE (REMOVAL)
Retain any bolts, spacers, nuts (except lock-nuts) screws and washers (with the exception of lock-
1. Remove the rear spar attachment inspection panel (on the bottom of the wing, at the wing to
fuselage interface) to gain access to the inertial reel retaining bolt.
2. Remove the front seat (refer to paragraph 4.2.2.1) on the side of the safety belt to be removed.
3. Remove the rear seat (refer to paragraph 4.2.2.2) to gain access to the inertial reel.
4. Remove the centre console rear panel by undoing the button head screws retaining it, undo
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 inertial / diagonal strap front mounting bracket. Undo the bolt retaining the
diagonal belt front bracket to the fuselage.
6. Undo the bolt retaining the diagonal safety belt bracket on the canopy frame.
7. Undo the bolt retaining the inertial reel to the fuselage and remove the reel.
8. Hold the reel (1) with the mounting bracket perfectly vertical and slowly unwind the safety belt
completely from the inertial reel.
9. Lock / hold the inertial reel drum (2) in position to prevent it from rewinding and push / pull the
belt (3) partly through the drum until the belt retaining pin1(4) is comfortably clear of its seat /
recess in the drum. 5
2 1
5 5
1
5 3
5
4
5

___________________________________________
10. Pull / push the pin (4) out of the loop in the belt (3).
3
5
3
5
4 4
5 5
11. Pull the belt back through the drum to separate it from the inertial reel unit.
12. Pull the belt through the fuselage guidance slots. Reattach the belt to the inertial reel drum if
required.
2. Inspect the entire length of the safety belt canvas for damage before fitment.
3. Inspect for security of attachment before riveting the side panel into place, replacing the rear
seat and replacing the inspection panel.
4. Apply thread locking sealant to the inspection panel screws before fitment.

___________________________________________
7.5.5 REMOVAL / INSTALLATION OF REAR OCCUPANT SAFETY HARNESS(ES)

ITEM QUANTITY NOTES
1 7/16” Spanner. 2
manual.
CAUTION
PROCEDURE (REMOVAL)
1. Remove the rear seat (refer to paragraph 4.2.2.2) to gain access to the lap strap attachment
brackets.
2. Undo the nuts and bolts retaining the bracket(s) / strap(s) to the fuselage.
2. Inspect for security of attachment before replacing the rear seat.

___________________________________________
A. APPENDIX A (AVIONICS AND ELECTRICAL SYSTEM WIRING DIAGRAMS)
A.1 CHARGE AND START SYSTEM / FUEL PUMPS WIRING DIAGRAM
Figure 68: Charge and start system wiring diagram / fuel pump wiring.

___________________________________________
A.2 SWITCHES AND CIRCUIT BREAKERS WIRING DIAGRAM
Figure 69: Switches and circuit breakers wiring diagram.

___________________________________________
A.3 FLAP SYSTEM WIRING DIAGRAM
A.3.1 FLAP ACTUATOR HARNESS WIRING DIAGRAM
Figure 70: Flap actuator wiring harness diagram

___________________________________________
A.3.2 ACTUONIX FLAP CONTROLLER WITH 4 POSITION ROTARY SWITCH
Figure 71: Actuonix flap controller wiring diagram.

___________________________________________
A.3.3 FLAP ACTUATOR WIRING
Figure 72: Flap actuator wiring

___________________________________________
A.4 ELEVATOR TRIM MOTOR WIRING DIAGRAM
A.4.1 DUAL STICK TRIM
SWITCH 5
SWITCH 1
SWITCH 2
SWITCH 4 SWITCH 3
RAY ALLEN G205 TYPE STICK GRIP
Figure 73: Elevator trim motor wiring diagram – dual control sticks.

___________________________________________
A.4.2 SINGLE STICK TRIM
SWITCH 5
SWITCH 1
SWITCH 2
SWITCH 4 SWITCH 3
RAY ALLEN G205 TYPE STICK GRIP
Figure 74: Elevator trim motor wiring diagram – single control stick.

___________________________________________
A.5 EFIS SYSTEM / COMMUNICATIONS BUS LAYOUT
Figure 75: EFIS system / communications bus layout.

___________________________________________
A.6 MAGNETOMETER WIRING DIAGRAM
Figure 76: Magnetometer (GMU 11) wiring diagram.

___________________________________________
A.7 AUTOPILOT ROLL SERVO AND PITCH SERVO WIRING DIAGRAM
Figure 77: Autopilot roll servo and pitch servo wiring diagram.

___________________________________________
A.8 EFIS BACK-UP BATTERY CHARGE CIRCUIT
Figure 78: EFIS back-up battery charge circuit.

___________________________________________
A.9 HEADPHONE / RADIO / INTERCOM WIRING DIAGRAM
A.9.1 GARMIN GTR 200 RADIO
INTERCOM PM1000II
Figure 79: Headphone / radio (GARMIN GTR 200) / intercom wiring diagram.

___________________________________________
A.9.2 GARMIN GTR 225 RADIO
Circuit breaker
on instrument panel
Figure 80: Headphone / radio (GARMIN GTR 225) / intercom wiring diagram.

___________________________________________
A.10 POSITION / NAVIGATION LIGHTS WIRING DIAGRAM
Figure 81: Position / navigation lights wiring diagram.

___________________________________________
A.11 GEA 24 TO ROTAX 915 iS ENGINE WIRING DIAGRAM
Figure 82: GEA 24 to Rotax 915 iS engine wiring diagram and settings.

___________________________________________
A.12 DUAL EFIS INSTALLATION WIRING DIAGRAM
Figure 83:Dual EFIS installation.

___________________________________________
A.13 TRANSPONDER WIRING DIAGRAM
A.13.1 GTX 35R TRANSPONDER WIRING DIAGRAM
Figure 84: GTX 35R transponder wiring diagram.

___________________________________________
A.14 ENGINE MONITORING TRANSDUCERS (SENSORS) / GEA 24 ELECTRICAL WIRING
Refer to the latest revision of the GEA 24 installation documentation from Garmin (manufacturer).
Also refer to paragraph A.11.

A.15 EFIS ELECTRICAL WIRING
Refer to the Garmin G3X installation manual.
A.16 PROPELLER AND PROPELLER CONTROLLER ELECTRICAL WIRING INFORMATION
Refer to the latest revision of the Airmaster AP3 Series and AP4 Series Constant Speed Propeller
Operator’s Manual.
A.17 ROTAX 915 iS ENGINE ELECTRICAL WIRING INFORMATION
Refer to the latest revisions of the following Rotax documents, as applicable:
1. Maintenance Manual (Line Maintenance) for Rotax Engine Type 915i Series (Reference no.
MML-915i A)
2. Operators Manual for Rotax Engine Type 915i Series (Reference no. OM-915i A).
3. Installation Manual for Rotax Engine Type 915i Series (Reference no, IM-915i A).

___________________________________________
B. APPENDIX B (FIREWALL MOUNTED EQUIPMENT)
2 3 4
5
1
6
11
10
1 Brake fluid reservoir 7 Shunt with cover

2 Coolant overflow bottle 8 Oil reservoir mounting bracket
3 Main battery 9 Starter solenoid
4 GA-35 10 Rotax 915 iS fuel pumps with cover
5 GA-56 11 Rotax 915 iS pressure control valve
6 Rotax 915 iS fuse box
Figure 85: Components mounted on Firewall Forward

___________________________________________
C. APPENDIX C (GENERAL PROCEDURES AND TECHNIQUES NOT DESCRIBED ELSEWHERE)
C.1 REMOVAL OF TWO-EAR CLAMPS
Use a hacksaw or Dremel tool to cut through the one ear as

shown by the dotted line. Once cut through, pry the clamp
open and remove.
Figure 86: Two-ear clamp removal.
C.2 PUSHROD ADJUSTMENT
1 Threaded fitting (riveted in place on pushrod tube).
Figure 87: Pushrod adjustment.
Pushrods are assembled using one left handed thread fitting and one right handed thread fitting,
allowing the coupling 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 by tightening the two nuts (2) against the pushrod ends. Do not over
tighten the nuts. It is normal procedure to index (i.e. paint creep marks across) the lock-nut and
pushrod interfaces.

___________________________________________
C.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 the two-ear clamp, on both sides of the
clamp.
Two-ear clamp(s)

___________________________________________
D. APPENDIX D (AN WASHER AND NUT HARDWARE DESIGNATIONS)
Reference (this manual) Hardware Designation

WASHERS
AN3 washer (1.6 mm / 0.063”) AN960-10
AN3 washer (0.8 mm / 0.032”) AN960-10L
AN4 washer (1.6 mm / 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 washer (1.6 mm / 0.063”) AN960-716
NUTS / LOCKNUTS
AN3 lock-nut (Nyloc) AN365-1032A
AN4 lock-nut (low profile) (Nyloc) AN364-428A
AN5 castle nut AN310-5


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4 SERIAL NO :

DATE: 13 DECEMBER 2023 REVISION 1.3

SLING AIRCRAFT | HANGAR 8 TEDDERFIELD AIR PARK, JHB SOUTH,EIKENHOF, 1872

PLEASE INFORM SLING AIRCRAFT (AIRCRAFT MANUFACTURER) ON CHANGE

DOCUMENT No.: REVISION: 1.3 DATE: 2023/12/13

This manual is divided into the following sections:

Provides useful additional information.

DOCUMENT No.: REVISION: 1.3 DATE: 2023/12/13

DOCUMENT No.: REVISION: 1.3 DATE: 2023/12/13

DOCUMENT No.: REVISION: 1.3 DATE: 2023/12/13

DOCUMENT No.: REVISION: 1.3 DATE: 2023/12/13

DOCUMENT No.: REVISION: 1.3 DATE: 2023/12/13

DOCUMENT No.: REVISION: 1.3 DATE: 2023/12/13

DOCUMENT No.: REVISION: 1.3 DATE: 2023/12/13

DOCUMENT No.: REVISION: 1.3 DATE: 2023/12/13

DOCUMENT No.: REVISION: 1.3 DATE: 2023/12/13

WARNINGS, CAUTIONS AND NOTES

DOCUMENT No.: REVISION: 1.3 DATE: 2023/12/13

DOCUMENT No.: REVISION: 1.3 DATE: 2023/12/13

1.2 AIRCRAFT SPECIFICATIONS AND DATA

1.2.1 AIRCRAFT 3-VIEW DRAWING

Note that dimensions in this drawing are

DOCUMENT No.: REVISION: 1.3 DATE: 2023/12/13

1.2.2 AIRCRAFT GEOMETRIC DIMENSIONS

Span: 9 544 mm / 31.31 ft.

Span: 3 020 mm / 9.91 ft.

Span: 1 470 mm / 4.82 ft.

DOCUMENT No.: REVISION: 1.3 DATE: 2023/12/13

Length: 6 220 mm / 20.41 ft.

Wheel track: 1.95 m / 6.40 ft.

1.2.3 AIRCRAFT WEIGHTS

Maximum take-off weight: 950 kg / 2094.39 lb.

Standard empty weight: 500 kg / 1102.31 lb.

NOTE: Standard weights are estimates based on standard equipment

DOCUMENT No.: REVISION: 1.3 DATE: 2023/12/13

1.3.1 ROTAX 915 IS

Manufacturer: Bombardier-Rotax GmbH

1.3.2 ROTAX 916 IS

Manufacturer: Bombardier-Rotax GmbH

DOCUMENT No.: REVISION: 1.3 DATE: 2023/12/13

1.4 APPROVED SUBSTANCES, FLUIDS, LUBRICANTS AND CAPACITIES

DIN EN 228 Super, DIN EN 228 Super

Oil capacity 3 litres (6.34 pints).

DOCUMENT No.: REVISION: 1.3 DATE: 2023/12/13

Cooling capacity 1.5 litres (3.17 pints).

Grade / type Automatic Transmission Fluid (ATF).

AIR FILTER OIL

Type K&N filter oil spray or K&N filter oil.

FUEL / FUEL TANK SEALANT / FUEL LEAK REPAR

SECURING BRAKE FLUID LINE(S) TO MAIN UNDERCARRIAGE STRUT(S)

Type PRATLEY QUICKSET CLEAR.

DOCUMENT No.: REVISION: 1.3 DATE: 2023/12/13

Canopy hinges Q20 or equivalent.

Canopy latches Q20 or equivalent.

Rudder cable guides Q20 or equivalent.

Elevator pushrod (in centre) guide MIL-G-3278 type grease or equivalent.

Elevator torque tube bushes Q20 or equivalent.

Trim tab hinge Q20 or equivalent.

Flap torque tube supports Q20 or equivalent.