The Airplane Factory Sling 4 User manual

DOCUMENT No.: REVISION: 1.2 DATE: 2014/11/10
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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 THE AIRPLANE FACTORY (AIRCRAFT MANUFACTURER) ON CHANGE
OF OWNERSHIP OF THE AIRCRAFT
NOTICE
AIRCRAFT WHICH DIFFER FROM THE PRODUCTION STANDARD, IN WHATEVER WAY, ARE NOT
ADDRESSED IN THIS MANUAL, EXCEPT 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.

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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 –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.
APPENDICES
Provides useful additional information.

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REVISION RECORD
REVISION
NUMBER
DATE
DESCRIPTION OF CHANGE
PARAGRAPHS
SIGN
1.0
2013/12/01
Original document
N/A
1.1
2014/05/16
All.
All
1.2
2014/11/10
1. Corrected servo motor body
orientation in Figure 14 and Figure
28.
2. Updated wiring diagrams.
3. Updated front occupant(s) safety
harness(es) removal
4. Changed wing rear attachment bolt
torque from 20 Nm to 18 Nm.
5. Correct bolt size from AN7-25A to
AN7-26A in Figure 5.
6. Added M4 metal washers to fuel
sender mounting plate installation.
7. Updated fuel pump labelling.
1.5,
4.1.1.1, 4.1.2.4,
4.2.1.7,
6.5, 6.6, 6.9,
12.2.1
13

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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
Auxilliary
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

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NC
Normally Closed
NGL
Normal Ground Line
NO
Normally Open
NRV
Non Return Valve
PASS
Passenger
POH
Pilot Operating Handbook
PTT
Push To Talk
QFE
Setting on altimeter subscale equal to ambient atmospheric pressure at a
specified datum
QNH
Barometric pressure adjusted to sea level
RDAC
Remote Data Acquisition Computer
RSA
Republic of South Africa
RON
Research Octane Number
RS232
Recommended Standard 232
RX
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

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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
1
FAA Advisory Circular AC43.13-1B: Acceptable Methods, Techniques and Practices - Aircraft
Inspection and Repair.
2
AP3 Series and AP4 Series Constant Speed Propeller Operator’s Manual.
3
Rotax Service Information SI-914-019.
4
Maintenance Manual (Heavy Maintenance) for Rotax Engine Types Rotax 912 and Rotax 914 Series
(Reference no. MMH-914).
5
Maintenance Manual (Line Maintenance) for Rotax Engine Type 914 Series.
6
Operators Manual for Rotax Engine Type 914 Series (Reference no. OM-914).
7
Installation Manual for Rotax Engine Type 914 Series (Reference no, IM-914).
8
MGL Avionics EFIS Integrated Autopilot user and Installation Manual.
9
ASTM D7547: Standard Specification for Hydrocarbon Unleaded Aviation Gasoline.
10
ASTM D910: Standard Specification for Aviation Gasolines.
11
ASTM D4814: Standard Specification for Automotive Spark-Ignition Engine Fuel.
12
DIN EN 228: Automotive Fuels - Unleaded Petrol - Requirements and Test Methods.
13
RDAC XF Installation Manual (MGL Avionics).
14
MIL-G-3278: Military Specification - Grease, Aircraft and Instrument (For Low and High
Temperatures).
15
MIL-C-16173: Military Specification –Corrosion Preventive Compound, Solvent Cutback, Cold
Application.
16
MIL-C11796: Military Specification - Corrosion Preventive Compound, Petrolatum, Hot Application
17
AMS-S-8802: Sealing Compound, Temperature Resistant, Integral Fuel Tanks and Fuel Cell Cavities,
High Adhesion.
18
MGL Avionics iBOX V1 Installation Manual.
19
MIL-G-81322: Military Specification –Grease, Aircraft, General Purpose, Wide Temperature Range.
20
iEFIS Panel Installation Manual (MGL Avionics).

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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
1.4. 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 ........................................................................................................................................ 13
1.10. PARKING AND TIE DOWN............................................................................................................ 14
1.11. AIRCRAFT LEVELLING................................................................................................................. 14
1.11.1 LONGITUDINAL LEVELLING ........................................................................................................ 15
1.11.2 TRANSVERSE LEVELLING........................................................................................................... 17
1.12. AIRCRAFT ALIGNMENT................................................................................................................ 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

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1.16.5 EMPTY WEIGHT CENTRE OF GRAVITY DETERMINATION...................................................... 24
1.17. CORROSION PREVENTION......................................................................................................... 26
1.18. AIRCRAFT STORAGE................................................................................................................... 28
1.18.1 SHORT TERM STORAGE............................................................................................................. 28
1.18.2 MEDIUM LONG TERM STORAGE................................................................................................ 28
1.18.3 OUTSIDE STORAGE..................................................................................................................... 29
1.18.4 RETURNING THE AIRCRAFT TO SERVICE................................................................................ 29
1.19. SOURCES FOR THE PURCHASING OF PARTS......................................................................... 30
1.20. DISPOSABLE REPLACEMENT PARTS........................................................................................ 30
1.21. AIRCRAFT PLACARDS AND EQUIPMENT LABELLING ............................................................. 31
1.21.1 MARKINGS AND PLACARDS ....................................................................................................... 31
2. INTRODUCTION............................................................................................................................ 39
2.1. GENERAL CONSIDERATIONS REGARDING INSPECTION....................................................... 39
2.2. INSPECTION PANELS .................................................................................................................. 42
2.3. INSPECTION SCHEDULE............................................................................................................. 43
2.3.1 ENGINE.......................................................................................................................................... 43
2.3.2 PROPELLER.................................................................................................................................. 43
2.3.3 AIRFRAME AND SYSTEMS.......................................................................................................... 43
2.4. CONDITION INSPECTION (100 HOUR / ANNUALLY)................................................................. 44
2.4.1 INSPECTION PANELS AND INITIAL INSPECTION AND CLEANING......................................... 44
2.4.2 FUSELAGE GROUP ...................................................................................................................... 44
2.4.3 CABIN AND COCKPIT GROUP..................................................................................................... 44
2.4.4 ENGINE AND COWLING GROUP................................................................................................. 45
2.4.5 LANDING GEAR GROUP.............................................................................................................. 45
2.4.6 WING AND CENTRE SECTION ASSEMBLY................................................................................ 46
2.4.7 EMPENNAGE ASSEMBLY............................................................................................................ 46
2.4.8 PROPELLER GROUP.................................................................................................................... 46
2.4.9 RADIO GROUP / AVIONICS / ELECTRONIC EQUIPMENT......................................................... 47
2.4.10 OPTIONAL EQUIPMENT............................................................................................................... 47
2.5. 25 HOUR, 100 HOUR AND ANNUAL SERVICE INSPECTION CHECKLIST............................... 48
3.1 LUBRICATION POINTS, LUBRICANTS AND INTERVALS .......................................................... 62
3.2 SERVICE BULLETINS / INSTRUCTIONS / LETTERS.................................................................. 62
3.3 SERVICE SCHEDULE................................................................................................................... 62
3.3.1 SERVICE PERIOD ADJUSTMENT................................................................................................ 63
3.3.2 ITEMS WITH CALENDAR BASED SERVICING............................................................................ 64
3.3.3 DAILY ............................................................................................................................................. 65
3.3.4 AS NEEDED................................................................................................................................... 65

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3.3.5 FIRST 25 HOURS .......................................................................................................................... 65
3.3.6 FIRST 50 HOURS .......................................................................................................................... 66
3.3.7 EVERY 50 HOURS / ANNUALLY .................................................................................................. 66
3.3.8 EVERY 100 HOURS / ANNUALLY ................................................................................................ 67
4. AIRFRAME ..................................................................................................................................... 68
4.1 WING.............................................................................................................................................. 69
4.1.1 MAIN WING SECTION................................................................................................................... 69
4.1.1.1 WING REMOVAL / INSTALLATION............................................................................................... 70
4.1.2 AILERON(S ) .................................................................................................................................. 76
4.1.2.1 AILERON CONTROL SYSTEM ..................................................................................................... 76
4.1.2.2 AILERON REMOVAL / INSTALLATION......................................................................................... 77
4.1.2.3 AILERON ADJUSTMENT............................................................................................................... 82
4.1.2.4 AILERON AUTOPILOT SERVO / SERVO PUSHROD REMOVAL / INSTALLATION .................. 86
4.1.3 FLAPS ............................................................................................................................................ 90
4.1.3.1 FLAP CONTROL SYSTEM ............................................................................................................ 90
4.1.3.2 FLAP REMOVAL / INSTALLATION ............................................................................................... 91
4.1.3.3 FLAP ADJUSTMENT...................................................................................................................... 97
4.1.3.4 FLAP ACTUATOR MOTOR REMOVAL / INSTALLATION............................................................ 99
4.2 EMPENNAGE............................................................................................................................... 102
4.2.1 HORIZONTAL TAIL AND ELEVATOR......................................................................................... 102
4.2.1.1 ELEVATOR CONTROL SYSTEM................................................................................................ 103
4.2.1.2 ELEVATOR REMOVAL / INSTALLATION................................................................................... 104
4.2.1.3 HORIZONTAL STABILIZER REMOVAL / INSTALLATION ......................................................... 108
4.2.1.4 ELEVATOR TRIM TAB MOTOR REMOVAL / INSTALLATION................................................... 111
4.2.1.5 ELEVATOR ADJUSTMENT ......................................................................................................... 114
4.2.1.6 ELEVATOR TRIM TAB ADJUSTMENT ....................................................................................... 117
4.2.1.7 ELEVATOR AUTOPILOT SERVO / SERVO PUSHROD REMOVAL / INSTALLATION............. 119
4.2.2 VERTICAL TAIL AND RUDDER .................................................................................................. 123
4.2.2.1 RUDDER CONTROL SYSTEM.................................................................................................... 124
4.2.2.2 RUDDER REMOVAL / INSTALLATION....................................................................................... 125
4.2.2.3 VERTICAL STABILIZER REMOVAL............................................................................................ 129
4.2.2.4 RUDDER PEDAL ADJUSTMENT ................................................................................................ 133
4.2.2.5 RUDDER CABLE TENSION ADJUSTMENT............................................................................... 134
4.3 FUSELAGE................................................................................................................................... 137
4.3.1 REAR FUSELAGE........................................................................................................................ 137
4.3.2 CENTRE FUSELAGE................................................................................................................... 138

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4.3.2.1 FRONT SEAT REMOVAL AND INSTALLATION......................................................................... 138
4.3.2.2 REAR SEAT REMOVAL AND INSTALLATION........................................................................... 140
4.3.2.3 CANOPY AND WINDSHIELD CLEANING................................................................................... 142
4.3.2.4 UPHOLSTERY CLEANING.......................................................................................................... 142
4.3.3 FORWARD FUSELAGE AND FIREWALL................................................................................... 143
4.4 LANDING GEAR .......................................................................................................................... 144
4.4.1 MAIN GEAR.................................................................................................................................. 144
4.4.1.1 MAIN WHEEL FAIRING REMOVAL / INSTALLATION................................................................ 145
4.4.1.2 MAIN WHEEL REMOVAL / INSTALLATION ............................................................................... 147
4.4.1.3 MAIN WHEEL AXLE AND BRAKE MECHANISM REMOVAL..................................................... 150
4.4.1.4 MAIN WHEEL DISASSEMBLY / ASSEMBLY.............................................................................. 154
4.4.1.5 MAIN WHEEL BEARING REMOVAL / INSTALLATION AND LUBRICATION............................ 157
4.4.1.6 MAIN GEAR REMOVAL / INSTALLATION.................................................................................. 158
4.4.2 NOSE GEAR ................................................................................................................................ 162
4.4.2.1 NOSE WHEEL FAIRING REMOVAL / INSTALLATION .............................................................. 163
4.4.2.2 NOSE WHEEL REMOVAL / INSTALLATION.............................................................................. 164
4.4.2.3 NOSE WHEEL DISASSEMBLY / ASSEMBLY............................................................................. 167
4.4.2.4 NOSE WHEEL BEARING REMOVAL / REPLACEMENT ........................................................... 170
4.4.2.5 NOSE GEAR REMOVAL / INSTALLATION................................................................................. 171
5. POWER PLANT ........................................................................................................................... 174
5.1 COWLING..................................................................................................................................... 174
5.1.1 COWLING REMOVAL / INSTALLATION..................................................................................... 175
5.2 ENGINE........................................................................................................................................ 178
5.2.1 GENERAL MAINTENANCE AND SERVICING............................................................................ 178
5.2.2 CARBURETTOR SYNCHRONISATION...................................................................................... 178
5.2.3 REPLACING ENGINE OIL........................................................................................................... 178
5.2.4 REPLACING ENGINE COOLANT................................................................................................ 178
5.2.5 SPARK PLUG REPLACEMENT................................................................................................... 178
5.2.6 VERIFYING ENGINE OIL LEVEL ................................................................................................ 179
5.2.7 AIR FILTER REMOVAL, CLEANING AND REPLACEMENT ...................................................... 180
5.2.8 MUFFLER / HEAT EXCHANGER ASSEMBLY REMOVAL / REPLACEMENT........................... 183
5.2.9 MUFFLER / HEAT EXCHANGER DISASSEMBLY / ASSEMBLY............................................... 185
5.2.10 REMOVAL / INSTALLATION OF OIL AND COOLANT RADIATORS......................................... 187
5.2.11 OIL COOLER / RADIATOR PIPE CONNECTION / DISCONNECTION...................................... 188
5.2.12 COOLANT RADIATOR PIPE CONNECTION / DISCONNECTION............................................. 191
5.2.13 ENGINE REMOVAL / INSTALLATION ........................................................................................ 193

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5.2.14 ENGINE CONTROL SYSTEM (THROTTLE AND CHOKE) ........................................................ 200
5.2.14.1 THROTTLE LEVER FRICTION ADJUSTMENT .......................................................................... 201
5.2.14.2 THROTTLE LEVER FRICTION DISC REPLACEMENT.............................................................. 202
5.3 PROPELLER ................................................................................................................................ 204
5.3.1 GENERAL MAINTENANCE AND SERVICE................................................................................ 204
5.3.2 PROPELLER HUB AND PROPELLER EXTENSION TORQUE PATTERN................................ 204
5.3.3 SPINNER REMOVAL / REPLACEMENT..................................................................................... 205
5.3.4 GENERAL CONSIDERATIONS WHEN FITTING PROPELLER EXTENSION TO ENGINE FLANGE
................................................................................................................................................... 207
5.3.5 PROPELLER REMOVAL / INSTALLATION................................................................................. 208
5.3.6 PROPELLER ASSEMBLY / DISASSEMBLY............................................................................... 217
5.3.7 PROPELLER ADJUSTMENT / SET-UP....................................................................................... 219
5.3.8 PROPELLER BALANCING .......................................................................................................... 219
6. FUEL SYSTEM............................................................................................................................. 220
6.1 GENERAL SERVICE INFORMATION AND CONSIDERATIONS............................................... 222
6.2 FUEL FILTER REPLACEMENT................................................................................................... 223
6.3 FUEL SELECTOR UNIT REMOVAL / INSTALLATION............................................................... 225
6.4 FUEL SELECTOR UNIT ASSEMBLY / DISASSEMBLY.............................................................. 228
6.5 FUEL PUMP ASSEMBLY REMOVAL / INSTALLATION............................................................. 230
6.6 FUEL PUMP REMOVAL / INSTALLATION FROM / INTO FUEL PUMP ASSEMBLY................ 236
6.7 FUEL TANK LEAK REPAIR......................................................................................................... 238
6.8 FUEL TANK DRAIN REMOVAL / INSTALLATION (DRAINING WING TANK)............................ 239
6.9 FUEL LEVEL SENDER ASSEMBLY REMOVAL / INSTALLATION (FROM / TO FUEL TANK). 241
6.10 REPLACING FUEL LEVEL SENDER ASSEMBLY SENSOR...................................................... 245
6.11 FINGER STRAINER (ON FUEL PICK-UP) INSPECTION........................................................... 249
7. AVIONICS AND INSTRUMENTS................................................................................................. 251
7.1 GENERAL MAINTENANCE AND SERVICE OF INSTRUMENTS .............................................. 252
7.2 REMOVAL / INSTALLATION OF INSTRUMENT PANEL AND INSTRUMENTS........................ 253
7.3 PITOT AND STATIC SYSTEMS .................................................................................................. 255
7.3.1 PITOT SYSTEM LEAK TEST....................................................................................................... 256
7.3.2 STATIC SYSTEM LEAK TEST..................................................................................................... 257
7.3.3 PITOT AND / OR STATIC SYSTEM CLEANING AND SERVICING ........................................... 258
7.4 AHRS AND COMPASS................................................................................................................ 259
7.4.1 AHRS AND / OR COMPASS SENSOR REMOVAL / INSTALLATION........................................ 259
7.5 HEADPHONE SOCKETS............................................................................................................. 261
7.5.1 HEADPHONE SOCKET REMOVAL / INSTALLATION................................................................ 261
7.6 ANTENNAE .................................................................................................................................. 263

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7.6.1 VHF COMMUNICATION ANTENNA............................................................................................ 263
7.6.1.1 VHF ANTENNA REMOVAL / INSTALLATION............................................................................. 263
7.6.2 GPS ANTENNA............................................................................................................................ 265
7.6.2.1 GPS ANTENNA REMOVAL / INSTALLATION ............................................................................ 265
8. UTILITY SYSTEMS...................................................................................................................... 267
8.1 CABIN HEATING AND COOLING ............................................................................................... 267
8.1.1 HEAT EXCHANGER ASSEMBLY REMOVAL AND INSTALLATION.......................................... 267
9. BRAKE SYSTEM.......................................................................................................................... 268
9.1 BRAKE FLUID DRAINING, REPLACEMENT AND BRAKE SYSTEM BLEEDING..................... 269
9.2 BRAKE MECHANISM REMOVAL / INSTALLATION................................................................... 271
9.3 BRAKE DISC REPLACEMENT.................................................................................................... 272
9.4 BRAKE LINING REPLACEMENT ................................................................................................ 273
10. ELECTRICAL SYSTEM................................................................................................................ 276
10.1 BATTERY REMOVAL / INSTALLATION...................................................................................... 278
10.2 EFIS BACK-UP BATTERY REMOVAL / INSTALLATION ........................................................... 280
10.3 ALTERNATOR MAINTENANCE.................................................................................................. 282
10.4 REPLACEMENT OF CIRCUIT BREAKERS AND / OR SWITCHES........................................... 282
10.5 REGULATOR / RECTIFIER REMOVAL AND REPLACEMENT.................................................. 285
11. EXTERIOR LIGHTING................................................................................................................. 287
11.1 NAVIGATION LIGHTS ................................................................................................................. 287
11.1.1 NAVIGATION LIGHT REMOVAL / INSTALLATION .................................................................... 288
11.2 LANDING AND TAXI LIGHTS...................................................................................................... 290
11.2.1 LANDING AND / OR TAXI LIGHT REMOVAL / INSTALLATION ................................................ 290
11.2.2 LANDING AND / OR TAXI LIGHT REPLACEMENT.................................................................... 293
11.2.3 LANDING AND / OR TAXI LIGHT ADJUSTMENT....................................................................... 295
11.3 STROBE LIGHT ........................................................................................................................... 296
11.3.1 STROBE LIGHT REMOVAL / INSTALLATION............................................................................ 296
12. EMERGENCY AND SAFETY SYSTEMS .................................................................................... 298
12.1 BALLISTIC PARACHUTE ............................................................................................................ 298
12.1.1 GENERAL SERVICE AND MAINTENANCE................................................................................ 298
12.2 SAFETY HARNESSES ................................................................................................................ 299
12.2.1 REMOVAL / INSTALLATION OF FRONT OCCUPANT SAFETY HARNESS(ES)...................... 299
12.2.2 REMOVAL / INSTALLATION OF REAR OCCUPANT SAFETY HARNESS(ES)........................ 302
13. APPENDIX A (AVIONICS AND ELECTRICAL SYSTEM WIRING DIAGRAMS)......................... 303
13.1 CHARGE AND START SYSTEM / FUEL PUMPS WIRING DIAGRAM ...................................... 303
13.2 SWITCHES AND CIRCUIT BREAKERS WIRING DIAGRAM ..................................................... 304

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13.3 EXTERNAL ALTERNATOR WIRING DIAGRAM......................................................................... 305
13.4 FLAP SYSTEM WIRING DIAGRAM............................................................................................. 306
13.4.2 INOTEC ........................................................................................................................................ 307
13.4.3 E-FLAPS....................................................................................................................................... 308
13.5 ELEVATOR TRIM MOTOR WIRING DIAGRAM.......................................................................... 309
13.5.1 DUAL STICK TRIM....................................................................................................................... 309
13.5.2 SINGLE STICK TRIM................................................................................................................... 310
13.6 EFIS SYSTEM / COMMUNICATIONS BUS LAYOUT................................................................. 311
13.7 AHRS AND COMPASS WIRING DIAGRAM................................................................................ 312
13.8 AUTOPILOT ROLL SERVO AND PITCH SERVO WIRING DIAGRAM....................................... 313
13.9 EFIS BACK-UP BATTERY CHARGE CIRCUIT........................................................................... 314
13.10 HEADPHONE / RADIO / INTERCOM WIRING DIAGRAM.......................................................... 315
13.10.1 GARMIN GTR 200 RADIO ........................................................................................................... 315
13.10.2 GARMIN GTR 225 RADIO ........................................................................................................... 316
13.11 POSITION / NAVIGATION LIGHTS WIRING DIAGRAM............................................................. 317
13.12 RDAC TO OIL PRESSURE TRANSDUCER WIRING DIAGRAM ............................................... 318
13.13 DUAL EFIS INSTALLATION WIRING DIAGRAM........................................................................ 319
13.14 TRANSPONDER WIRING DIAGRAM.......................................................................................... 320
13.14.1 TRIG TT21 TRANSPONDER WIRING DIAGRAM....................................................................... 320
13.14.2 SANDIA STX 165R TRANSPONDER WIRING DIAGRAM.......................................................... 321
13.15 ENGINE MONITORING TRANSDUCERS (SENSORS) / RDAC ELECTRICAL WIRING........... 322
13.16 EFIS AND IBOX ELECTRICAL WIRING...................................................................................... 322
13.17 PROPELLER AND PROPELLER CONTROLLER ELECTRICAL WIRING INFORMATION....... 322
13.18 ROTAX 914 UL ENGINE ELECTRICAL WIRING INFORMATION.............................................. 322
14. APPENDIX B (FIREWALL MOUNTED EQUIPMENT)................................................................. 323
15. APPENDIX C (GENERAL PROCEDURES AND TECHNIQUES NOT DESCRIBED ELSEWHERE)
................................................................................................................................................... 324
15.1 REMOVAL OF TWO-EAR CLAMPS............................................................................................ 324
15.2 PUSHROD ADJUSTMENT .......................................................................................................... 324
15.3 FITTING OF FIRE RESISTANT SLEEVING................................................................................ 325
16. APPENDIX D (AN WASHER AND NUT HARDWARE DESIGNATIONS)................................... 326

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LIST OF FIGURES
Figure 1: Longitudinal leveling reference position.......................................................................................................16
Figure 2: Transverse leveling reference position. .......................................................................................................18
Figure 3: Aircraft alignment..........................................................................................................................................19
Figure 4: Moment arms................................................................................................................................................22
Figure 5: Front wing spar to fuselage connection. ......................................................................................................73
Figure 6: Rear wing spar to fuselage connection........................................................................................................74
Figure 7: Aileron pushrod-to-control stick connection. ................................................................................................74
Figure 8 : Aileron control system.................................................................................................................................76
Figure 9: Aileron hinge (inboard).................................................................................................................................79
Figure 10: Aileron hinge (outboard).............................................................................................................................80
Figure 11: Aileron pushrod -to-bellcranck connection.................................................................................................81
Figure 12: Aileron adjustment - cabin side..................................................................................................................83
Figure 13: Aileron adjustment - wing side. ..................................................................................................................84
Figure 14: Autopilot aileron servo installation..............................................................................................................88
Figure 15: Aileron autopilot servo pushrod –control stick / torque tube end. .............................................................89
Figure 16: Flap control system. ...................................................................................................................................90
Figure 17: Flap hinges.................................................................................................................................................93
Figure 18: Flap pushrod-to-flap connection.................................................................................................................94
Figure 19: Flap pushrod-to-flap torque tube control arm connection. .........................................................................96
Figure 20: Flap actuator motor removal. ...................................................................................................................100
Figure 21: Flap actuator motor installation. ...............................................................................................................101
Figure 22: Horizontal tail and elevator.......................................................................................................................102
Figure 23: Elevator control system............................................................................................................................103
Figure 24: Elevator pushrod to elevator connection..................................................................................................106
Figure 25: Horizontal stabilizer-to-elevator hinge......................................................................................................107
Figure 26: Horizontal stabilizer to fuselage attachment. ...........................................................................................110
Figure 27: Elevator adjustment..................................................................................................................................115
Figure 28: Autopilot elevator servo installation..........................................................................................................121
Figure 29: Autopilot elevator servo pushrod –torque tube end. ................................................................................122
Figure 30: Vertical tail and rudder. ............................................................................................................................123
Figure 31: Rudder control system. ............................................................................................................................124
Figure 32: Rudder to vertical stabilizer hinge connection..........................................................................................127
Figure 33: Rudder cable connection..........................................................................................................................128

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Figure 34: Vertical stabilizer to fuselage connection.................................................................................................131
Figure 35 : Rudder cable tension adjustment............................................................................................................135
Figure 36: Main landing gear.....................................................................................................................................144
Figure 37: Main wheel axle installation......................................................................................................................153
Figure 38: Main gear installation................................................................................................................................161
Figure 39: Nose gear.................................................................................................................................................162
Figure 40: Nose wheel installation.............................................................................................................................166
Figure 41: Front wheel hub assembly. .....................................................................................................................169
Figure 42: Nose gear installation...............................................................................................................................173
Figure 43: Engine cowling. ........................................................................................................................................174
Figure 44: Engine removal.........................................................................................................................................197
Figure 45: Engine installation. ...................................................................................................................................198
Figure 46: Throttle lever friction disc installation. ......................................................................................................203
Figure 47: Propeller installation / propeller extension installation torque pattern......................................................204
Figure 48: Airmaster propeller installation (standard)...............................................................................................211
Figure 49: Airmaster propeller signal wire to slip-ring disc connection (vacuum pump fitted). .................................214
Figure 50: Airmaster propeller installation (vacuum pump fitted).............................................................................215
Figure 51: Propeller installation (external alternator fitted)........................................................................................216
Figure 52: Fuel system. .............................................................................................................................................220
Figure 53: Fuel selector unit installation....................................................................................................................227
Figure 54: Fuel selector port allocation and fitting orientation...................................................................................229
Figure 55: Fuel selector fuel fitting alignment............................................................................................................229
Figure 56: Wing tank fuel drain installation................................................................................................................240
Figure 57: Fuel sender installation into fuel tank.......................................................................................................244
Figure 58: Fuel level sender assembly sensor replacement.....................................................................................248
Figure 59: Standard instrument panel (refer to key on next page)............................................................................251
Figure 60: Representative pitot and static system.....................................................................................................255
Figure 61: Headphone socket installation. ................................................................................................................262
Figure 62: VHF antenna installation. .........................................................................................................................264
Figure 63: Brake system............................................................................................................................................268
Figure 64: Electrical system (overview).....................................................................................................................276
Figure 65 : Landing and taxi light installation. ...........................................................................................................292
Figure 66: Charge and start system wiring diagram /fuel pump wiring. ....................................................................303
Figure 67: Switches and circuit breakers wiring diagram..........................................................................................304
Figure 68: External alternator wiring diagram............................................................................................................305
Figure 69: MGL SP 10 Flap / trim controller wiring diagram. ....................................................................................306
Figure 70: Flap system wiring diagram –INOTEC....................................................................................................307

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Figure 71: Flap system wiring diagram - E-Flaps......................................................................................................308
Figure 72: Elevator trim motor wiring diagram –dual control sticks..........................................................................309
Figure 73: Elevator trim motor wiring diagram –single control stick.........................................................................310
Figure 74: EFIS system / communications bus layout. .............................................................................................311
Figure 75: AHRS and compass wiring diagram. .......................................................................................................312
Figure 76: Autopilot roll servo and pitch servo wiring diagram..................................................................................313
Figure 77: EFIS back-up battery charge circuit........................................................................................................314
Figure 78: Headphone / radio (GARMIN GTR 200) / intercom wiring diagram.........................................................315
Figure 79: Headphone / radio (GARMIN GTR 225) / intercom wiring diagram.........................................................316
Figure 80: Position / navigation lights wiring diagram...............................................................................................317
Figure 81: RDAC to oil pressure transducer wiring diagram and settings. ...............................................................318
Figure 82:Dual EFIS installation................................................................................................................................319
Figure 83: TRIG TT21 transponder wiring diagram...................................................................................................320
Figure 84: SANDIA STX 165 R transponder wiring diagram.....................................................................................321
Figure 85: Firewall mounted equipment. ...................................................................................................................323
Figure 86: Two-ear clamp removal...........................................................................................................................324
Figure 87: Pushrod adjustment. ................................................................................................................................324

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

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SECTION 1
GENERAL
This section provides general information, capacities and general procedures and specifications.
1. GENERAL
1.1. DESCRIPTION
The Airplane Factory Sling 4 is a four seat, single engine, tricycle fixed undercarriage aluminum aircraft
with a conventional low wing design.

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1.2. AIRCRAFT SPECIFICATIONS AND DATA
1.2.1 AIRCRAFT 3-VIEW DRAWING
Note that dimensions in this drawing are
in millimetres (metric).