Bailey Moyes 912 Dragonfly User manual

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Instructions for Printing & Binding
This page gets wasted, to maintain orientation of pages throughout the manual when viewing
online, To allow viewing 2 Pages Up.
Begin printing on Page 1 (the Cover) and print both sides of paper.
Page orientation is important. This can be seen when you get to Pages 22 & 23 which should be
facing you when the Manual is open, as well as many more as you progress through the manual.
This has the Narrative and the proper Drawing facing you at the same time.
Print on 20 Lb (Min.) Premium Paper or better, Printing both sides of paper.
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This allows the manual to be opened and folded back leaving the desired page exposed and lays
flat when opened to expose 2 pages while doing Inspections or Maintenance.
I generally get them printed at Staples or Office Depot where it costs as little as $15.00 USD per
manual in Black & White, printing only the Front Cover (page1) in Color.
Some of the pictures are in Color for the benefit of online viewing, but we print them in black &
white.
Thank you for your interest in our products! Be Safe & Have Fun!! Ed Pitman
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Page 1
Publication Number DF-MM-912 rev 2 05/11/2014 dd/mm/yyyy
Maintenance Manual 912 Dragonfly
&
Kit Assembly Manual 912 Dragonfly
This Manual only applies to SLSA Dragonfly Aircraft and ELSA Dragonfly Kits
Manufactured by Pitman Air, in the United States of America.
Copyright Ed Pitman, Rhett Radford, Bobby Bailey & Bill Moyes 2014

Page 2

Page 3

Page 4

Page 5
Record of Manual Revisions
Note* A current version of this manual is always available
on the internet at: http://www.pitmanair.com/dragonfly
or www.safety-directives.org
# dd/mm/yyyy
Revision Number & Date Purpose Paragraph Page numbers
Rev.0
04/04/2013
Original All All
Rev 1
31/05/2014
Safety Directives ¾” Axle Bolts DF-
1402 & Horz Stab Bolt , DF-1401 34 & 38
Rev 2
05/11/2014
Update Table of Contents All All
Serial Number Information
PA or PAK -____ ____ ____ -____ ____ ____
Pitman Air or Pitman Air Kit – Engine – Production Number
Example: PA-912-126
This Manual only applies to SLSA Dragonfly Aircraft and ELSA Dragonfly Kits
Manufactured by Pitman Air, in the United States of America.
Copyright Ed Pitman, Rhett Radford , Bobby Bailey & Bill Moyes 2013

Page 6
Table of Contents
1.1 GENERAL.................................................................................................................................................... 11
1.1.1 Equipment list, .......................................................................................................................................................11
1.1.2 Sources to purchase parts,......................................................................................................................................11
1.1.3 List of disposable replacement parts ............................................................................................................11
1.1.3.1 Engine Parts,...................................................................................................................................................11
1.1.3.2 Airframe and Systems...................................................................................................................................12
1.1.4 Engine specifications, 912ULS & 912 UL..................................................................................................................12
Performance 912 ULS................................................................................................................................................... 12
Combustion Chambers.................................................................................................................................................. 12
Weight.............................................................................................................................................................................. 12
Performance 912 UL..................................................................................................................................................... 13
Combustion Chambers.................................................................................................................................................. 13
Weight.............................................................................................................................................................................. 13
1.1.5 Weight and balance information, ...........................................................................................................................14
1.1.5.1 Weight and Balance Chart ...................................................................................................................................14
1.1.5.2 Operating weights and loading....................................................................................................................14
1.1.5.3 Center of gravity (CG) range and determination ..................................................................................................14
1.1.5.4 Installed optional equipment list .................................................................................................................17
1.1.6 Tire inflation pressures ....................................................................................................................................17
1.1.7 Approved oils and capacities,.........................................................................................................................17
1.1.8 Recommended fastener torque values, ..................................................................................................................17
“Lubricate”defined .....................................................................................................................................................18
1.1.9 General safety information,....................................................................................................................................18
1.1.10 Instructions for reporting possible “Safety of Flight” concerns found during Inspection or Maintenance. ..........18
1.1.11 Standard Tools—needed for the maintenance and repair of the aircraft and it’s components.............................18
1.1.12................................Special Tools—needed for the maintenance and repair of the aircraft and it’s components.
........................................................................................................................................................................................18
1.2 INSPECTIONS—ANNUAL AND/OR 100 HOUR INSPECTIONS............................................. 18
1.2.1 Checklist for Annual & 100 hour Inspections: ........................................................................................................18
1.3 STRUCTURES ............................................................................................................................................ 21
1.3.1 Wings see Sections 14 through 20,.........................................................................................................................21
1.3.2 Empennage see Sections 1, 2, 4, 8 through 13, 21, & 23 .........................................................................................21
1.3.3 Landing gear, see Sections 2, 7, 8, and Appendix B ................................................................................................21
1.3.4 Structural Control Surfaces, see Sections 9 through 21...........................................................................................21
1.3.5 Fabric Coverings: Sections 9 through 20.................................................................................................................21
1.3 Engine......................................................................................................................................................................21
—....................................................................................................................................................................................21
1.5 Fuel System—see Section 27 .....................................................................................................................................21
1.6 Propeller—refer to Propeller Manufacturers Manual................................................................................................21
1.7 Utility Systems— No Utility Systems ........................................................................................................................21
1.8 Instruments and Avionics— See Appendix C EIS....................................................................................................21
1.9 Electrical System—see Section 28 ............................................................................................................................21
1.10 Structural Repair—see 2.1 Repairs and Alterations ................................................................................................21
1.11 Painting and Coatings—Imron Paints also Refer to FAA AC43.13-1B ...................................................................21
1.12 Revisions—Record of Manual Revisions is located in the beginning of this Manual...........................................21
1.13 Feedback Form—.....................................................................................................................................................21
2.1 Repairs and Alterations—defined .............................................................................................................................22
2.1.1 Repairs—................................................................................................................................................................22
2.1.2 Alterations— ..........................................................................................................................................................22
2.2 Detailed Instructions and Diagrams for Inspection and/or Repair. ............................................................................22
How to use this Section of the Manual: ...........................................................................................................................22
Section 1 Boom Tube ......................................................................................................................................................23
Section 2 Bulkhead..........................................................................................................................................................25
Section 3 Root Tube ........................................................................................................................................................27
Section 4 Fuselage...........................................................................................................................................................29
Section 5 Fwd Cockpit .....................................................................................................................................................31

Page 7
Section 6 Pilot Seat..........................................................................................................................................................33
Section 7 Fwd Wheel Throttle & Manual Brake...............................................................................................................35
Section 8 Tail Wheel........................................................................................................................................................37
Section 9 Vertical Stabilizer .............................................................................................................................................39
Section 10 Rudder ...........................................................................................................................................................41
Section 11 Horiz. Stabilizer & Elev. Frame .......................................................................................................................43
Section 12 Horiz. Stabilizer & Elev. Sails ..........................................................................................................................45
Section 13 Controls .........................................................................................................................................................47
Section 14 Aileron ...........................................................................................................................................................49
Section 15 Aileron Sails ...................................................................................................................................................51
Section 16 Wing ..............................................................................................................................................................53
Section 17 Wing Battens & Sails ......................................................................................................................................55
Section 18 Wing Sail Access holes and sealing.................................................................................................................57
Section 19 Aileron Support Tubes & Mounting................................................................................................................59
Section 20 Struts & Wing Connection..............................................................................................................................61
Section 21 Cable Bracing .................................................................................................................................................63
Section 22 Aft Seat ..........................................................................................................................................................65
Section 23 Aft Seat & Controls ........................................................................................................................................67
Section 24 912 Engine Mounting ....................................................................................................................................69
Section 25 912 Exhaust & Muffler Installation................................................................................................................71
Section 26 582 Radiator Installation ...............................................................................................................................73
Section 27 912 Fuel System ............................................................................................................................................75
Section 28 Electrical System ...........................................................................................................................................77
Section 29 Parachute & ELT Mounting............................................................................................................................81
Section 30 Trim Tabs Setup..........................................................................................................................................83
3 LEVEL OF CERTIFICATION—.................................................................................................................. 85
3.1 Owner— ...................................................................................................................................................................85
3.2 LSA Repairman Inspection—(LSRI) see 4.1, 5.1, 6.1, and Appendix D of this manual ............................................85
3.3 LSA Repairman Maintenance—(LSRM) see 4.1, 5.1, & 6.1.....................................................................................85
3.4 A&P—see 4.1, 5.1, & 6.1.........................................................................................................................................85
3.5 Task Specific—see 4.1, 5.1, 6.1, and Appendix D of this manual.............................................................................85
3.5.1 Rotax Engines and Gearboxes.................................................................................................................................85
3.6 Multiple descriptors—...............................................................................................................................................85
4. LINE MAINTENANCE, REPAIRS, AND ALTERATIONS..................................................................... 85
4.1 Authorization to Perform ..........................................................................................................................................85
4.2 Typical Tasks Considered as Line Maintenance..........................................................................................................85
5. HEAVY MAINTENANCE, REPAIRS, AND ALTERATIONS ................................................................ 86
5.1 Authorization to Perform ..........................................................................................................................................86
5.2 Typical Tasks Considered as Heavy Maintenance for SLSA’s Include:......................................................................86
6. OVERHAUL................................................................................................................................................... 86
6.1 Authorization to Perform—.......................................................................................................................................86
6.2 Overhaul Manual—...................................................................................................................................................86
7. MAJOR REPAIRS AND ALTERATIONS ................................................................................................. 87
8. TASK-SPECIFIC TRAINING...................................................................................................................... 87
9. SAFETY DIRECTIVES................................................................................................................................. 87
10. TERMINOLOGY ........................................................................................................................................ 88
10.1 Definitions: ..............................................................................................................................................................88
APPENDIX A -- SAFETY OF FLIGHT REPORTING FORM & COMMENT FORM ............................. 90
APPENDIX B BRAKES MANUAL FOR BX1320 & BX1000 ................................................................. 91
Double Caliper Parts ..................................................................................................................................................94
Elbow changes to DFN 003 ¾ Bolts go up one size through bulkhead, elbow and axle..............................94
APPENDIX C EIS 4000 912/914................................................................................................. 100
MODEL 4000/6000 .................................................................................................................................... 100
ENGINE INFORMATION SYSTEM............................................................................................................ 100

Page 8
USER’S MANUAL .......................................................................................................................................... 100
GRAND RAPIDS TECHNOLOGIES INCORPORATED .......................................................................... 100
1. READ THIS FIRST! .................................................................................................................................. 105
2. AN OVERVIEW OF INSTALLATION & SETUP ................................................................................. 105
3. USING THE ENGINE INFORMATION SYSTEM ................................................................................ 105
3.1 The Basics of the Engine Information System Operation .........................................................................................106
3.2Before Each Flight.....................................................................................................................................................106
4. SET PAGES – SETTING ENGINE LIMITS AND OTHER USER ENTRIES..................................... 107
4.1Set Page Table of Limits. [Brackets denote Dragonfly Factory Settings] N/U = not used..........................................108
5. INSTALLATION........................................................................................................................................ 110
5.1 Mounting the Instrument – Position and other considerations ...............................................................................110
5.2Wiring ......................................................................................................................................................................111
5.2.1 Outside Air Temperature Sensor....................................................................................................................... 112
5.2.2 Water Coolant/Oil Temperature Sensor ........................................................................................................... 112
5.2.3 Voltmeter .......................................................................................................................................................... 112
5.2.4 Oil Pressure Sender ........................................................................................................................................... 112
5.2.5 Magnetic Tachometer Sensor ........................................................................................................................... 112
5.2.6 External Alarm Output ...................................................................................................................................... 113
5.2.7 Auxiliary Inputs.................................................................................................................................................. 113
5.2.8 Cylinder Head Temperature Probe Installation................................................................................................. 113
5.2.9 Exhaust Gas Temperature Probe Installation.................................................................................................... 113
5.2.10 Carburetor Temperature Probe.................................................................................................................... 114
5.2.11 EGT & CHT Extension Wire ........................................................................................................................... 114
5.3 Verify the Wiring – A Quick Check ...........................................................................................................................115
6. CHECK-OUT .............................................................................................................................................. 115
6.1 Initial Application of Power to the Instrument ........................................................................................................115
6.2 Tachometer Initial Test............................................................................................................................................115
6.2.1 Testing Tachometer Inputs................................................................................................................................ 115
6.2.2 Testing Tachometer Accuracy ........................................................................................................................... 116
6.3 Other Checks ...........................................................................................................................................................116
7. CONFIGURING THE EIS FOR YOUR AIRPLANE. ............................................................................ 116
7.1 Setting up your Auxiliary Inputs – Labels and Scaling ..............................................................................................117
7.1.1 Aux1, Aux2, Aux3, Aux4, Aux5, Aux6................................................................................................................. 117
7.1.2 Dual TIT Option and Aux5/Aux6........................................................................................................................ 117
7.1.3 Auxiliary Scale Factors and Offsets (1SF, 1OFF, 2SF, 2OFF…) ............................................................................ 117
7.1.4 Configuring an Auxiliary Input for a Fluid Temperature Sensor........................................................................ 117
7.1.5 Auxiliary Forward/Reverse Sensing Selection (+/-) ........................................................................................... 118
7.1.6 Auxiliary Decimal/Integer Selection (D/I).......................................................................................................... 118
7.1.7 Transfer function............................................................................................................................................... 119
7.2 Units – (Fahrenheit/Celsius and Gallons/Liters).......................................................................................................119
7.3 FC1 & FC2 (Fuel Flow Activation Codes)...................................................................................................................119
7.4 FloCal (Fuel Flow Calibration) ..................................................................................................................................119
7.5 FloCalR (Return Fuel Flow Calibration)....................................................................................................................120
7.6 TachP/R - Setting for Correct Tachometer Readings ...............................................................................................120
7.6.1 Tach Connections to Magneto P-leads, Ignition Coils or Tach Outputs ............................................................ 120
7.6.2 Tach Connections to Lighting Coils (Jabiru, Rotax, and others) ........................................................................ 121
7.6.3 Rotax 912 Engine............................................................................................................................................... 121
7.6.4 TachP/R Table.................................................................................................................................................... 121
7.7 TachSen...................................................................................................................................................................122
7.8 Peak – Leaning Function Sensitivity Adjustment ( Not Used for Dragonfly )...........................................................122
7.9 Max Fuel – (Fuel Capacity Entry for Fuel Flow Option) ( Not Used for Dragonfly )..................................................122
7.10 Hours (Setting Hourmeter) ...................................................................................................................................122
7.11 Tim-RPM (Hourmeter & Flight Timer RPM Threshold)...........................................................................................122
7.12 AspdLo, AspdHi, TachLo, TachHi (Landing Checklist Reminder/RPM Range Limit) .................................................122
7.12.1 Landing Checklist Reminder ( Not Used for Dragonfly ) ............................................................................. 122
7.12.2 RPM Range Limit .......................................................................................................................................... 123
7.13 AltCor (Calibrating the Altimeter/Barometric Pressure) ........................................................................................123
7.14 AltSF, 1 (10k), 2 (20k), 3 (30k), 4 (40k) Altimeter Adjustments (SW Version 5.8 and above) ..................................124
7.14.1 Precision Altimeter Calibration Procedure ................................................................................................... 124

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7.15 User Definable Combination Pages........................................................................................................................124
7.15.1 1D1, 1P1, … GD9, GP9 .................................................................................................................................. 124
7.15.2 Table of User-Definable Page Entries. .......................................................................................................... 125
7.16 Example Worksheet for setting up your custom pages..........................................................................................128
BAR GRAPHS USE THE FIRST 8 CHARACTER POSITIONS. ( SHOWN AS SET
AT PITMAN AIR ) ...................................................................................................................................... 130
8. DISABLING PAGES ( PITMAN AIR DISABLES PAGES 0, 4, 6, 7, 9, 11, 12, 13, 14, & 15 ). 131
9. ENGINE ANALYSIS FUNCTIONS ......................................................................................................... 131
9.1 The EGT Tracking Function.......................................................................................................................................131
10. DETAILED DESCRIPTION OF OTHER FUNCTIONS .................................................................... 134
10.1 Flight Timer ...........................................................................................................................................................134
10.2 Unit Temperature..................................................................................................................................................134
10.3 H2O (Water Temperature Function) ......................................................................................................................134
11. USE WITH PRECISION AIRMOTIVE EAGLE ENGINE CONTROLLER...................................... 134
12. UPDATING THE EIS SOFTWARE..................................................................................................... 135
13. CHECK ENTRIES MESSAGE............................................................................................................... 135
14. TROUBLESHOOTING COMMON PROBLEMS............................................................................... 135
15. WARRANTY........................................................................................................................................... 136
Appendix D: Items Permitted Under the Privileges of Preventive Maintenance............................................................141
Advisory Circular 43-12a ...............................................................................................................................................145
Preventive Maintenance ................................................................................................................................................. 145
§ FAR 43.13 Performance rules (general).....................................................................................................................146
APPENDIX E1 KIEVPROP INSTALLATION......................................................................................... 148
1. Disassemble prop hub........................................................................................................................................148
2. Inspect each blade...............................................................................................................................................148
3. Install shoulder bolts ..........................................................................................................................................148
4. On Rotax 912 applications.................................................................................................................................149
SECURING ASSEMBLED PROP TO ENGINE:.....................................................................................................................149
5. Secure (finger tight) the propeller ....................................................................................................................149
6. With all bolts slightly tightened..........................................................................................................................149
8. Fit the aluminum end of the protractor............................................................................................................149
9. For Pusher aircraft................................................................................................................................................150
10. When all blade angles have been set..............................................................................................................150
11. A static check of rpm’s......................................................................................................................................151
12. Re-check torque of prop bolts after first hour...............................................................................................151
APPENDIX E2 POWERFIN INSTALLATION........................................................................................ 153
APPENDIX F AMERI-KING AK-451 & AK-450 .................................................................................. 164
SCOPE ...........................................................................................................................................................................164
OVERVIEW ....................................................................................................................................................................164
Description....................................................................................................................................................................164
Automatic Fixed-ELT (AF): .............................................................................................................................................164
Automatic Portable-ELT (AF) (AP) with dual antennas:..................................................................................................164
Application and Equipment Limitation..........................................................................................................................165
PHYSICAL CHARACTERISTICS: ........................................................................................................................................165
•......................................................................................... GENERAL SPECIFICATIONS (STANDARD CONDITIONS):
......................................................................................................................................................................................166
MECHANICAL INSTALLATION.........................................................................................................................................168
QUICK OPERATION CHECK.............................................................................................................................................169
Detail Operation Check: ................................................................................................................................................169
Detailed Operation Check: ............................................................................................................................................171
3 System Integration Test: (some parts may not apply to AK-450)............................................................................172
5.............................................................................................. TRANSMITTER FUNTIONAL TEST FOR ELT-(S) ONLY
......................................................................................................................................................................................174
6 PERIODIC MAINTENANCE (INSTRUCTIONS FOR CONTINUED AIRWORTHINESS):........................................................175