Pelican Sport 450 S - Ballard Sport Aircraft Ltd.

Pelican Sport 450 S - Ballard Sport Aircraft Ltd.
Ballard Sport Aircraft Ltd.
THE PELICAN SPORT 450 S
OPERATOR MANUAL
All rights reserved:
Ballard Sport Aircraft Ltd.
2696 rue du Pimbina,
Sherbrooke, Québec,
Canada, J1R 0G3
Phone: 819-563-5847
Fax:
819-829-5677
www.ballardsportaircraft.com
Revision 2008-01
Ballard Sport Aircraft Ltd. 2696 du Pimbina, Sherbrooke, Qc, Canada J1R 0G3 Phone: 819 563-5847.
© Copyright 2007-2008 Ballard Sport Aircraft Ltd. – All rights reserved --.
Ballard Sport Aircraft Ltd.
Table of content
Pelican Sport 450 Technical descriptive..................................................................................................5
1.1 General ..............................................................................................................................................5
1.2 Technical description ........................................................................................................................5
1.3 3-view drawing..................................................................................................................................7
1.4 Technical specifications and performance ........................................................................................8
1.4.1
Spécifications...........................................................................................................................8
1.4.2
Performance with BRP Rotax 912ULS ...................................................................................8
1.4.3
Performance on floats with BRP Rotax 912UL.......................................................................8
2 FLIGHT ENVELOPE .............................................................................................................................9
3 PLACARD SPEEDS AND LIMITATIONS.........................................................................................10
4 PLACARDS AND INSTRUMENT MARKINGS................................................................................11
5 POWERPLANT OPERATING SPEEDS AND LIMITS......................................................................11
5.1 AIRSPEED INDICATOR MARKINGS.........................................................................................12
5.2 WEIGHT LIMITS AND FLIGHT LOAD FACTOR LIMITS .......................................................12
5.3 CENTER OF GRAVITY LIMITS ..................................................................................................12
6 WEIGHT AND BALANCE ..................................................................................................................13
6.1 WEIGHT AND BALANCE CHECK .............................................................................................13
6.2 PROCEDURE, SAMPLE CALCULATION AND DATA.............................................................14
6.3 WEIGHT AND BALANCE CALCULATIONS ............................................................................16
7 NORMAL PROCEDURES...................................................................................................................18
7.1 PRE-FLIGHT INSPECTION..........................................................................................................18
7.2 ENGINE PRE-START VERIFICATION.......................................................................................20
7.3 START ............................................................................................................................................20
7.4 CHECK BEFORE TAXIING .........................................................................................................20
7.5 TAXI ...............................................................................................................................................20
7.6 RUN-UP OF PRE-TAKE-OFF CHECK.........................................................................................21
7.7 TAKE-OFF .....................................................................................................................................22
7.8 ENGINE STOP ...............................................................................................................................22
AIRFRAME MAINTENANCE GUIDE .......................................................................................................23
1 MAINTENANCE OF COMPOSITE - General ..................................................................................23
2 MAINTENANCE OF FABRIC - GENERAL.......................................................................................24
3 HARDWARE ........................................................................................................................................24
4 MAINTENANCE OF STEEL PARTS - General..................................................................................25
5 MAINTENANCE OF ALUMINIUM PARTS - General .....................................................................25
6 ACCESSORIES - General.....................................................................................................................25
MAINTENANCE SCHEDULE ....................................................................................................................26
1 Check before first flight:........................................................................................................................26
2 Check after initial 10 hours: ..................................................................................................................26
3 Check after initial 25 hours....................................................................................................................27
4 Check at every 50 hours ........................................................................................................................27
5 100 hours or annual inspection:.............................................................................................................27
6 WINTER OPERATION ........................................................................................................................32
CONFORMITY INSPECTION CHECK-LIST ............................................................................................33
1
Ballard Sport Aircraft Ltd. 2696 du Pimbina, Sherbrooke, Qc, Canada J1R 0G3 Phone: 819 563-5847.
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Ballard Sport Aircraft Ltd.
PELICAN SPORT 450 S
WARNING
While designed and tested to meet and exceed the
TP10141 Design Standards for Advanced Ultralight
and Sportplane category airplanes,
THIS AIRCRAFT IS NOT TYPE CERTIFICATED
AND ITS OPERATOR HAS THE SOLE RESPONSIBILITY
OF ITS AIRWORTHINESS
Flying is fun only if you put safety first.
3
Ballard Sport Aircraft Ltd. 2696 du Pimbina, Sherbrooke, Qc, Canada J1R 0G3 Phone: 819 563-5847.
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Ballard Sport Aircraft Ltd.
PELICAN SPORT 450 S
INTRODUCTION
This operator’s and maintenance manual was put together only as a guide to the operation and maintenance
of your Pelican.
It does not cover all that is required to do or know to safely operate your airplane.
Read it carefully and make sure you have the required skills and competence to safely operate your aircraft.
Your comments and suggestions to improve this manual will always be welcome.
Note: The Rotax engine operator manual should be considered as a part of this manual and supersedes any
information given in Ballard Sport Aircraft’s manual relating to the operation and maintenance of the
engine.
4
Ballard Sport Aircraft Ltd. 2696 du Pimbina, Sherbrooke, Qc, Canada J1R 0G3 Phone: 819 563-5847.
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Ballard Sport Aircraft Ltd.
PELICAN SPORT 450 S
1
Pelican Sport 450 Technical descriptive
1.1
General
Design Standard:
TP 10141
The Pelican Sport 450 S is manufactured by :
1.2
Aéronefs Sportifs Ballard Ltée.
2696 rue du Pimbina,
Sherbrooke, Québec,
Canada, J1R 0G3
Technical description
General
The Pelican Sport 450 is a two place single-engine, high wing airplane of conventional
configuration consisting of a composite fuselage and metal wings. It is equipped with a
fixed tricycle landing gear.
Engine
The engine is a BRP Rotax, Type 912 S, 4 cylinder, 4 stroke featuring opposed cylinders,
dual electronic ignition, dry sump with oil pump, liquid cooled heads, and an integrated
gearbox. It is equipped with a 12V/250 Watt generator, two Bing 32 mm carburettors, a
0,6 KW electric starter and a mechanical fuel pump. The Rotax 912 S develops 100 HP at
5800 RPM and 94 HP at 5500 RPM.
Instruments
Airspeed indicator, altimeter, magnetic compass, engine tachometer, cylinder head
temperature gauge, oil pressure gauge, oil temperature gauge, one electrical fuel gauge
Propeller
Three blade or four blade, ground adjustable.
Fuselage
Vacuum molded composite structure consisting of a S-glass vinylester resin laminate
with rigid PVC foam core.
Cockpit
Two seats, side by side, foam seat cushions, dual sticks, dual pedals, center console,
Lexan windshield and baggage compartment windows. The baggage compartment behind
the seats has a capacity of 50 lbs. (23 kg) without a ballistic chute and 20 lbs (9 kg) with
a ballistic chute.
Three-points seat belts - shoulder harness system for both seats.
Wings
The all-metal wing is a single-strut, single spar construction, covered with aluminum
skins. Wing tips are made of molded fiberglass. The ailerons and flaps are fabric covered.
Tail
The fin and the cantilever stabilizer are all aluminum construction, covered with
aluminum skins. Rudder and elevators are made of aluminum structures covered with
fabric. Elevator and rudder tips have molded fiberglass tips.
5
Ballard Sport Aircraft Ltd. 2696 du Pimbina, Sherbrooke, Qc, Canada J1R 0G3 Phone: 819 563-5847.
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Ballard Sport Aircraft Ltd.
PELICAN SPORT 450 S
Controls
The airplane features a dual control stick system, dual rudder pedal system and
differential braking system. Ailerons are deflected through a bellcrank/push-rod
mechanism mounted on ball bearings. A torque tube connected to a mechanical lever in
the console operates flaps. The ailerons deflect 12° with full flaps. Rudder and elevators
are cable operated. The elevator trim is mechanically operated. Fixed trims are used for
the rudder and the ailerons.
Flaps
Mechanically operated by a Johnson bar - type lever located in the console. They offer 5
positions from 0° to 45°.
Elevator trim
One elevator trim mechanically operated by a lever on the console.
Fuel system
Fuel is stored in one 15 USG (60 li) composite tank located behind the seat.
Landing gear
The main landing gear legs are made of heat-treated 4130-springsteel tubing. The system
consists of a right and a left leg, connected by a center tube. Aluminium blocks bolted
inside the aluminium gear box support the legs. The nosegear leg is made of 4130 tubing
with an aluminium fork. A bungee chord provides the nosegear suspension. The
nosewheel is steerable via push rods connected to the pedals and it locks in flight. The
tail dragger is also available.
Wheels and brakes
The main wheels are Matco 6 inch wheels and disk brakes with 15 * 600 tires. The nose
wheel is an Azuza 6-inch wheel with a 13 * 600 tire.
Optional equipment (not included in empty weight)
• Upholstery and Carpet
• Cabin heat & ventilation system
• Strobe and naviguation lights system
• Speed fairings
• Wheel pants
• Propeller spinner
• Radios
• Ballistic recovery chute
6
Ballard Sport Aircraft Ltd. 2696 du Pimbina, Sherbrooke, Qc, Canada J1R 0G3 Phone: 819 563-5847.
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Ballard Sport Aircraft Ltd.
PELICAN SPORT 450 S
Pélican Sport 450 F
98-01-27
3 view 450
3-view drawing
Ballard Sport Aircraft Ltd.
1.3
7
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Ballard Sport Aircraft Ltd.
PELICAN SPORT 450 S
1.4
1.4.1
Technical specifications and performance
Spécifications
Wingspan:
9,75 m
Wing area:
10,9 m2
Wing loading:
41,2 kg/m2
Aspect ratio:
8,7
Lenght tricycle:
6,07 m
Fin height tricycle:
2,59 m
Cabin width (at hips):
1,02 m
Cabin width (at elbows):
1,17 m
Cabin headroom:
1,04 m
Structural gross (+4.5/-2.5 limit load): 450 kg
Structural gross (+4.0/-2.0 limit load): 523 kg
Dry empty weight tricycle:
[280:290] kg
Baggage capacity (including parachute):23 kg
Fuel capacity:
60 litres
1.4.2
Performance with BRP Rotax 912ULS
Horsepower:
Never exceed speed Vne:
Cruising speed 75%@6 500 ft:
Cruising speed 65%@6 500 ft:
Maximum range @65% no reserve:
Fuel consumption @65%:
Rate of climb, sea level:
Service ceiling:
Stall speed (flaps up) C.A.S.:
Stall speed (flaps down) C.A.S.:
Take-off ground run:
Take-off over 50 ft (15 m) obstacle:
1.4.3
32,0 ft
117,3 sq ft
8,44 lbs/sq ft
8,7
19,9 ft
8,5 ft
40 in
46 in
41 in
990 lbs
1 150 lbs
[615:638] lbs
50 lbs
15 USG
73,5 kW
228 km/h
205 km/h
195 km/h
725 km
15,5 L/h
7,6 m/s
4 900 m
70 km/h
63 km/h
90 m
150 m
100 HP
123 kts
110 kts
105 kts
450 sm
4,1 gph
1 500 fpm
16 000 ft
38 kts
34 kts
300 ft
500 ft
59 kW
228 km/h
195 km/h
185 km/h
1 000 km
14,4L/h
6,6 m/s
4 900 m
70 km/h
63 km/h
105 m
185 m
80 HP
123 kts
105 kts
100 kts
635 sm
3,8 gph
1 300 fpm
16 000 ft
38 kts
34 kts
350 ft
600 ft
Performance on floats with BRP Rotax 912UL
Horsepower:
Never exceed speed Vne
Cruising speed 75%@6 500 ft:
Cruising speed 65%@6 500 ft:
Maximum range @65% no reserve:
Fuel consumption @65%:
Rate of climb, sea level:
Service ceiling:
Stall speed (flaps up) C.A.S.:
Stall speed (flaps down) C.A.S.:
Take-off ground run:
Take-off over 50 ft (15 m) obstacle:
8
Ballard Sport Aircraft Ltd. 2696 du Pimbina, Sherbrooke, Qc, Canada J1R 0G3 Phone: 819 563-5847.
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Ballard Sport Aircraft Ltd.
PELICAN SPORT 450 S
2
FLIGHT ENVELOPE
n
5
4
3
2
1
Vf
0
10
20
30
40
50
60
70
80
Va
Vc
90
100
Vd
110
120
130
140
-1
-2
-3
Vd: 137 KEAS
Vne:123 KEAS
Vc: 98 KEAS
Va: 85 KEAS
Vf: 70 KEAS
9
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V KEAS
Ballard Sport Aircraft Ltd.
PELICAN SPORT 450 S
3
PLACARD SPEEDS AND LIMITATIONS
There should be a placard in clear view of the pilot stating:
1)
2)
NO AEROBATIC MANEUVERS, INCLUDING SPINS, APPROVED
Speed limit
Indicated speed
Notes
Vne (max speed)
123 kts
Do not exceed this speed under any
consideration
Vno (max level speed)
98 kts
Do not exceed this speed except in
smooth air and then only with caution
Va (manoeuver speed)
85 kts
No full or abrupt control movements
above this speed
Vf (max speed for flaps)
70 kts
No flaps above this speed
10
Ballard Sport Aircraft Ltd. 2696 du Pimbina, Sherbrooke, Qc, Canada J1R 0G3 Phone: 819 563-5847.
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Ballard Sport Aircraft Ltd.
PELICAN SPORT 450 S
4
PLACARDS AND INSTRUMENT MARKINGS
The following information should be displayed in full view of the pilot.
Aerobatics prohibited
Limits:
5
Maneuvering speed ( I.A.S.)
Structural gross weight
Flight load factors:
Flaps up
Flaps down
85 kts
1150 lbs
+4.0 / -2.0
+2
POWERPLANT OPERATING SPEEDS AND LIMITS
Refer to the engine manufacturer operator’s manual to fill out the following table.
Instruments in the aircraft should be marked accordingly:
Instrument
Red line
(minimum limit)
Green arc
(up to warn limit)
Red line
(maximum limit)
Tachometer
Cylinder head temp
Oil pressure
Oil temperature
Exhaust gas temp
Water temp
11
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Ballard Sport Aircraft Ltd.
PELICAN SPORT 450 S
5.1
AIRSPEED INDICATOR MARKINGS
Marking
I.A.S. value or range
White arc
30 - 70 kts
Full flaps operating range
Lower limit: Vso at maximum weight in landing
configuration
Upper limit: maximum speed permissible with flaps extended
Green arc
40 – 98 kts
Normal operating range
Lower limit: Vs at maximum weight with flaps retracted
Upper limit: maximum structural cruising speed
Yellow arc
98 – 123 kts
Operations must be conducted with caution and only in
smooth air
Red line
5.2
123 kts
Significance
Maximum speed for all operations
WEIGHT LIMITS AND FLIGHT LOAD FACTOR LIMITS
Maximum take-off weight
1 150 lbs (523 kg)
Flight load factors (limit): * flaps up
* flaps down
+4.0 / -2.0 G
+2.0 G
* Design load factors are 150% of the above
5.3
CENTER OF GRAVITY LIMITS
Center of gravity range:
Forward 8.0 inches aft of datum (20,3 cm)
Aft
13.2 inches aft of datum (33,5 cm)
Reference datum:wing leading edge
12
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Ballard Sport Aircraft Ltd.
PELICAN SPORT 450 S
6
WEIGHT AND BALANCE
It is mandatory that you check the weight and balance of your aircraft before flight-testing.
The Pelican was designed to minimize the risk of exceeding the limits of the weight and balance envelope
if properly built and loaded. However, if the center of gravity is not well located versus the wing chord, the
flight characteristics of your aircraft might be dangerously altered:
•
•
6.1
If the C.G, is too far forward, you will lack elevator power on landing
If the C.G. is too far aft, the aircraft will be unstable and dangerous to fly
WEIGHT AND BALANCE CHECK
1.
Place the aircraft on three scales.
2.
FIRST:
Check the position of the center of gravity with the empty aircraft (no fuel, no baggage,
no passenger). Make a list of the equipment and note if there is oil and coolant.
3.
SECOND: Check the foremost position of the center of gravity (light pilot, no fuel, no baggage)
4.
THIRD:
5.
You may also check the weight and balance of your aircraft in any other loading condition by
measuring the weight, computing the moment and checking the new figure with the weight and
balance envelope.
Check the rearmost position of the center of gravity (2 pilots, full fuel, full baggage).
13
Ballard Sport Aircraft Ltd. 2696 du Pimbina, Sherbrooke, Qc, Canada J1R 0G3 Phone: 819 563-5847.
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Ballard Sport Aircraft Ltd.
PELICAN SPORT 450 S
6.2
PROCEDURE, SAMPLE CALCULATION AND DATA
DATA:
•
•
•
•
Place the aircraft on 3 scales
The aircraft must be level (rear top of fuselage is level)
Take note of the Lnose and Lmain measures (note the distance between the plumb line shown
below and the center of the wheel axles)
Write these figures in Table 1
14
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Ballard Sport Aircraft Ltd.
PELICAN SPORT 450 S
EMPTY WEIGHT C.G.
•
•
Read the weight on each scale and write them down in Table 1
Add up the weights and moments. Write the totals in Table 1
Sample calculation:
Lnose
Lmain
-32.75 in
22.75 in
Wnose
185 lbs
Wmain, right
Wmain, left
220 lbs
220 lbs
Wmain, total
440 lbs
W total
625 lbs
Lnose x Wnose
Lmain x Wmain
MOMENT
-32.75 in x 185 lbs = -6059 lbs-in
22.75 in x 440 lbs = 10010 lbs-in
=
Lnose x Wnose + Lmain x Wmain
=
-6 059 in-lbs + 10 010 lbs-in
=
3 951 lbs-in
=
VERIFICATION 3 951 lbs-in
625 lbs
6.32 inches
6.32 inches / 44 inches = 14% of wing chord
Note: If aircraft is taildragger, Ltail x Wtail is + sign
15
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Ballard Sport Aircraft Ltd.
PELICAN SPORT 450 S
6.3
WEIGHT AND BALANCE CALCULATIONS
TABLE 1
(A)
(3)
(4)
(5)
(6)
(7)
(8)
(9)
(10)
(1)
Lnose = _________________
(2)
Lmain = _________________
(minus sign if tricycle)
EMPTY WEIGHT C.G.
A
Weight under the nosewheel: Wnose
Weight under left wheel: Wmain, left
Weight under right wheel: Wmain, right
Total weight under main wheels: Wmain (4 + 5)
Total weight of aircraft: WT (3 + 6)
Lnose x Wnose (2 x 3)
Lmain x Wmain (1 x 6)
Moment (8 + 9)
This is your empty weight C.G.
If you add equipment, you may weigh the equipment, measure the distance from the datum and compute
your new empty weight C.G. without weighing the airplane.
(B)
(C)
(3)
(4)
(5)
(6)
(7)
(8)
(9)
(10)
FOREMOST C.G.
REARMOST C.G.
B
C
Weight under the nosewheel: Wnose
Weight under left wheel: Wmain, left
Weight under right wheel: Wmain, right
Total weight under main wheels: Wmain (4 + 5)
Total weight of aircraft: WT (3 + 6)
Lnose x Wnose (2 x 3)
Lmain x Wmain (1 x 6)
Moment (8 + 9)
Check that the total Weight (7) and Moment (10) coordinates fall within the envelope of the next page with
the loaded aircraft.
16
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Ballard Sport Aircraft Ltd.
PELICAN SPORT 450 S
WEIGHT AND BALANCE ENVELOPE
lbs
1150 , 10800
1150, 15180
1150
1100
1000
990 , 7920
900
800
750, 9900
750, 6000
700
6000
(B)
•
•
•
10000
12000
14000
16000
lbs-in
Load the aircraft with one light pilot, no fuel and no baggage
Take note of the weight on each scale
Compute the weight and moment and check that the coordinates fall in the envelope
(C)
•
8000
Weight of the aircraft: foremost position
Weight of the aircraft: rearmost position
Repeat operations with 2 pilots, full fuel and full baggage
17
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Ballard Sport Aircraft Ltd.
PELICAN SPORT 450 S
7
7.1
NORMAL PROCEDURES
PRE-FLIGHT INSPECTION
Before each flight, the operator must visually inspect the aircraft, as taught in every good flying school.
The following checklist can be used as guide:
18
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Ballard Sport Aircraft Ltd.
PELICAN SPORT 450 S
0.
Before external verification: documents and licenses
1.
Unfasten seat belts to free the controls
Electrical system = OFF
Fuel selector:
ON
2.
Door fasteners, window, struts and fairings, landing gear, brakes, wheel pants, wheels and tires.
Leading edge and wing gap cover in good condition. Remove pitot cover (left side). If wing
tanks: drain, visual check of fuel level, check for leaks.
3.
Struts, leading edge
4.
Wing tip: check screws and mass balance
5.
Ailerons and flaps, including controls and fittings. No unusual play. Fabric, false spar and ribs in
good condition.
6.
External check of airframe
9 to 12
Same as 2 to 5
13.
Windshield in good condition. Cowling secured. Propeller is in good condition. No unusual play
in gearbox.
Winter: Check installation of radiator and oil cooler winter kit
Engine access door: nothing unusual. Check oil and coolant expansion bottle.
14.
With ignition OFF: Turn propeller by hand and observe engine for odd noises or uneasy
movements and proper compression
15.
Cabin: visual check of cables, pulleys and supports, engine mount bolts, pedals, brakes. sticks,
instruments, fuel selector, seat belts, door hinges, etc...
19
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Ballard Sport Aircraft Ltd.
PELICAN SPORT 450 S
7.2
ENGINE PRE-START VERIFICATION
Fuel selector
ON
Master
OFF
Electricals and radio
OFF
Trim
NEUTRAL
Throttle
IDLE (note: if throttle is cracked, choke is inoperative)
Choke
as required
7.3
START
After having looked around the aircraft
Master
Alternator
Brakes
ON
OFF (check light is on)
applied
Start while looking outside.
Activate starter for max 20 sec only, followed by a cooling period of 3 minutes
Reduce engine RPM as required (2000 - 2500 RPM for warming up)
Check engine oil pressure: pressure has to rise within 10 seconds
Alternator: check light is off
7.4
CHECK BEFORE TAXIING
Check instrument panel from left to right and top to bottom
Choke as required
Flaps: up
7.5
TAXI
Try the brakes
Aircraft with nose in the wing for the run-up
20
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Ballard Sport Aircraft Ltd.
PELICAN SPORT 450 S
7.6
RUN-UP OF PRE-TAKE-OFF CHECK
Engine
•
•
•
•
•
Check traffic behind
Pressure and temperature (oil has reached 120°F)
Choke: OFF
Check ignition circuits as per engine operator manual
RPM: idle
Instruments and accessories
•
•
•
•
Compass
Fuel selector ON
Alternator (light is off)
Check instrument panel from left to right and from top to bottom
Controls
•
•
•
Controls
Flaps
Trim
Free
Take-off position
Neutral
Safety
•
•
•
•
•
Seat belts
Baggage secured
Doors locked
Check traffic
Radio call
21
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Ballard Sport Aircraft Ltd.
PELICAN SPORT 450 S
7.7
•
•
•
7.8
TAKE-OFF
Climbing with engine running at peak performance is permissible
Note RPM
Observe oil temperature, cylinder head temperature and oil pressure
ENGINE STOP
In normal conditions, the cooling down of the normally aspirated Rotax engine during descent and taxiing
will be sufficient to allow to stop the engine by switching the ignition OFF
22
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Ballard Sport Aircraft Ltd.
PELICAN SPORT 450 S
AIRFRAME MAINTENANCE GUIDE
1
MAINTENANCE OF COMPOSITE - General
The fuselage and engine cowlings of the Pelican are made from vacuum molded composite materials,
which consist in fiberglass and vinylester resin with a polyvynil chloride (PVC) foam core. These
materials are cured at room temperature.
The composite materials require very little maintenance. It is however important that the structure should
be regularly checked for delaminations, particularly in case of accidents.
A visual check is usually enough to find failures in the composite materials. Any crack, lump, depression
or soft surface should be investigated and repaired. For this, refer to the introductory section of the Pelican
assembly manual.
The composite materials used in the Pelican are stable at outside temperatures ranging from -40°C to
+50°C (-40°F to 120°F). Tolerable surface temperature can however reach over 80°C (180°F).
The color of the fuselage is normalized white, which prevents any risk of surface temperature going beyond
these values. The operator is authorized to paint identification marks and side decorative bands of any
color. There is no restriction on the color of the covering fabric.
Composite materials are also sensitive to ultra-violet rays. The Pelican resin system uses an additive for
UV protection. However, a coat of paint, preferably polyurethane, should protect composite parts.
23
Ballard Sport Aircraft Ltd. 2696 du Pimbina, Sherbrooke, Qc, Canada J1R 0G3 Phone: 819 563-5847.
© Copyright 2007-2008 Ballard Sport Aircraft Ltd. – All rights reserved --.
Ballard Sport Aircraft Ltd.
PELICAN SPORT 450 S
2
MAINTENANCE OF FABRIC - GENERAL
The fabric must be well protected from ultra-violet rays.
After bonding the fabric to the frame and taughtening it with the iron, the fabric should be cleaned, covered
with a good UV barrier. The operator is referred to the « covering » section of the Pelican assembly
manual.
The fabric should be checked regularly. It must be well bonded to the structure and cuts or rips must
immediately be repaired.
Depending on exposure to the sun, the fabric will deteriorate with time and re-covering will then be
required. Experienced mechanics in covering have a special tool to check if the fabric is in good shape or
deteriorated.
3
HARDWARE
The hardware used in the construction of the Pelican (bolts, nuts, cable, turnbuckles, pulleys) is almost
exclusively of aeronautical type (AN, MS or NAS) and treated against corrosion with nickel-cadmium
plating. However, rubbing and exposure to wind and rain may remove this protection and rust will appear.
It is then recommended to change the part to prevent corrosion from spreading. The shackles, clevis pins
and safety pins should namely be changed regularly.
As a general rule, for all bolts, the operator should see 1 to 3 threads exceeding the nut. Bolts which are too
short should be changed for longer bolts and washers should be added for bolts slightly too long.
The operator should regularly check that the nicopress on the cables are in good condition and that the
tension in the cables is adequate. The cables should also be secured in the pulleys, with no excessive play.
The pulley supports (cabin and wings) should be checked regularly for failures.
24
Ballard Sport Aircraft Ltd. 2696 du Pimbina, Sherbrooke, Qc, Canada J1R 0G3 Phone: 819 563-5847.
© Copyright 2007-2008 Ballard Sport Aircraft Ltd. – All rights reserved --.
Ballard Sport Aircraft Ltd.
PELICAN SPORT 450 S
4
MAINTENANCE OF STEEL PARTS - General
A number of parts in the Pelican are made of steel, namely the landing gear, the engine mount, the sticks
and pedals, the fin post, the tailfeather horns, some push-rods, etc...
All steel parts must be protected against the rust at the assembly stage (sanding with fine grit paper, linseed
oil inside tubes and steel primer on the outside). Steel parts must also be checked and cleaned regularly.
Some parts, such as the fin post and the wheel axles, must be taken off and greased regularly.
All steel parts should be checked regularly for failures, namely at the welds.
5
MAINTENANCE OF ALUMINIUM PARTS - General
As specified in the Assembly manual, the aluminium used in the construction of the Pelican is of 2024-T3
Alclad grade for sheeting and of 6061-T6 grade for tubing and extrusion. These materials already offer a
good protection against rust. It is however recommended to the treat the aluminium with specialized
products (such as zinc chromate of vinylwash primers) for marine or salt water operations.
All exposed aluminium parts should be cleaned, primed and painted.
All aluminium parts should be regularly checked for failures, such as cracks and crushed areas.
6
ACCESSORIES - General
The operator should regularly check all accessories and make sure of their proper state of operation.
Particular care should be given to the brakes, the instruments and the accessories in the engine
compartment (electrical system, fuel system, exhaust system, cooling system, battery, spinner, propeller,
etc...).
25
Ballard Sport Aircraft Ltd. 2696 du Pimbina, Sherbrooke, Qc, Canada J1R 0G3 Phone: 819 563-5847.
© Copyright 2007-2008 Ballard Sport Aircraft Ltd. – All rights reserved --.
Ballard Sport Aircraft Ltd.
PELICAN SPORT 450 S
MAINTENANCE SCHEDULE
1
Check before first flight:
As per conformity inspection
2
Check after initial 10 hours:
Something may have been overlooked before the first flight, some bolts may need tightening,
some SS screws may have flown away, some wires may be rubbing in the engine compartment,
you may have some dirt in the fuel tanks, etc.
General inspection of engine compartment:
•
•
•
•
•
•
•
•
•
•
25 hour inspection from Rotax manual, except for oil and oil filter change
Engine tight (inspect Lord mounts and bolts)
Exhaust system: secured to engine
Hoses, wires, lines secure (no wear by friction)
Change fuel filter
Clean gascolator
Check carburators and filters for security
Check propeller blade pitch and bolts torque
Check fuel line connections
Check cooling system, including hoses and clamps
General inspection of airframe:
•
•
•
•
•
•
Remove all fairings and covers to inspect all bolts (landing gear, struts, wings to fuselage,
empennage supports, sticks, etc.) for security
Check control cables tension / no chaffing / no slip
Check presence of all Cotter pins
Check brakes: mount leg on support and check that the wheel turns freely
Check all SS screws (fairings and others) for security
Check no friction / no play in all control surfaces
Others: Any vibration must be investigated
26
Ballard Sport Aircraft Ltd. 2696 du Pimbina, Sherbrooke, Qc, Canada J1R 0G3 Phone: 819 563-5847.
© Copyright 2007-2008 Ballard Sport Aircraft Ltd. – All rights reserved --.
Ballard Sport Aircraft Ltd.
PELICAN SPORT 450 S
3
Check after initial 25 hours
Engine:
25 hours from Rotax engine manual + change fuel filter
Check spark plugs for color
Perform compression test (the engine should be run-in and this will be your
reference compression values)
Others: Same as 10 hour inspection
4
Check at every 50 hours
Engine:
As per Rotax manual - 100 hour inspection
Change fuel filter
Clean spark plugs (or change) + gap
Inspect and lubricate nosewheel nylon bearings
Airframe inspection:
5
General
100 hours or annual inspection:
CONFORMITY INSPECTION
27
Ballard Sport Aircraft Ltd. 2696 du Pimbina, Sherbrooke, Qc, Canada J1R 0G3 Phone: 819 563-5847.
© Copyright 2007-2008 Ballard Sport Aircraft Ltd. – All rights reserved --.
Ballard Sport Aircraft Ltd.
PELICAN SPORT 450 S
50 HOUR INSPECTION CHECK-LIST
AIRCRAFT IDENTIFICATION:
Pelican serial N°
Registration
Airframe total time
_____________________
_____________________
_____________________
Engine model
Engine serial N°
Engine total time
Propeller model
Propeller serial N°
______________________
______________________
______________________
______________________
______________________
Owner: ________________________________
Satis
Unsatis
GENERAL
Registration / C of A
Weight and Balance / Equipment list
WINGS
Remove inspection plates / fairings
General inspection of the exterior/interior of wing
Flight control proper attachment (free / no slop)
Flight controls properly rigged / proper tension
Inspect all control stops for security
Skin panels delaminate / voids
Popped rivets / cracked / deformed skins
Fabric/tape condition
Lubrication (WD40 on bushings)
Wing attach points
Struts for security
Corrosion
Check drains
____________________________________________
____________________________________________
FUEL SYSTEM
Corrosion
Fuel lines for chaffing/leaks/security/condition
Fuel caps for security
Fuel placards
Fuel valve / cross feed for operation and security
Inspect fuel tank vent system
____________________________________________
28
Ballard Sport Aircraft Ltd. 2696 du Pimbina, Sherbrooke, Qc, Canada J1R 0G3 Phone: 819 563-5847.
© Copyright 2007-2008 Ballard Sport Aircraft Ltd. – All rights reserved --.
Fixed
Ballard Sport Aircraft Ltd.
PELICAN SPORT 450 S
50 HOUR INSPECTION CHECK-LIST
Satis
Unsatis
FUSELAGE
Inspect for delaminated skin and voids (in and out)
Inspect door latching mechanism
Inspect rudder pedals/brakes for operation/security
Inspect behind firewall for loose wires/chaffing lines
Check control sticks for freedom of movement / no play
Check flap control operation
Check cables and pulleys for security and operation
Inspect instruments, lines, for security / clean
Inspect seats, seatbelts/shoulder harness for security and attachment
Corrosion check
Check drains
_____________________________________________
_____________________________________________
LANDING GEAR
Remove fairings
Inspect legs for attachment / tighten Allen bolts
Check all bushings for wear / free play
Wheels/tires for cracks and serviceability
Inspect for corrosion
Inspect nosegear/tailwheel for cracks and travel / Lubricate nylon bearings and
push-rods
Check tire pressure
Brake linings within limits
Brake disks for cracks/wear/deformity
Brake hydraulic lines for leaks and security (use only automatic transmission oil)
____________________________________________
____________________________________________
TAIL
Inspect rudder attachment points
Inspect elevator/stabilizer attachment points
Inspect hinges/trim tab for attachment and free play
Inspect skins for damage/corrosion
Inspect all control cables, hinges and pulleys
Lubrication (WD40 on bushings)
Inspect all control stops
Check drains
__________________________________________
29
Ballard Sport Aircraft Ltd. 2696 du Pimbina, Sherbrooke, Qc, Canada J1R 0G3 Phone: 819 563-5847.
© Copyright 2007-2008 Ballard Sport Aircraft Ltd. – All rights reserved --.
Fixed
Ballard Sport Aircraft Ltd.
PELICAN SPORT 450 S
50 HOUR INSPECTION CHECK-LIST
Satis
Unsatis
ENGINE
Change oil and filter (check for metal)
Inspect ignition harness for condition and continuity
Check ignition leads cigarettes for condition/cracks
Clean (change) and gap spark plugs
Inspect engine mount/bushings
Check torque of engine mount attachment bolts
Inspect cylinders for cracks/broken fins/exhaust stains
Check for oil leaks
Inspect oil vent lines
Inspect carburator for security/clean filters
Inspect throttle/choke control for proper travel and security / Lubricate
Inspection condition of flexible fuel and oil lines
Inspect oil cooler for leaks and condition
Check exhaust system for attachment and condition
Check muffler for security and attachment
Check cowling for cracks and security
Check radiator/hoses for leaks/security + anti-freeze
Check radiator/oil cooler covers for winter operation
_________________________________________
_________________________________________
_________________________________________
PROPELLER
Check spinner and backplate for cracks
Inspect for cracks / stone damage / nicks (DO NOT FILE)
Repair nicks (resin) - Paint/varnish
Check for delaminations
Check prop bolts torque / Safety wire
Check for oil leaks (crankcase nose seal)
___________________________________________
___________________________________________
ELECTRICALS
Battery and supports/covers for security/corrosion
Check position/strobe lights for operation
Check all antenna mounts and wiring for security
Inspect radios/leads/wires for attachment and security
Inspect circuit breakers/panel for condition
__________________________________________
30
Ballard Sport Aircraft Ltd. 2696 du Pimbina, Sherbrooke, Qc, Canada J1R 0G3 Phone: 819 563-5847.
© Copyright 2007-2008 Ballard Sport Aircraft Ltd. – All rights reserved --.
Fixed
Ballard Sport Aircraft Ltd.
PELICAN SPORT 450 S
50 HOUR INSPECTION CHECK-LIST
OPERATIONAL INSPECTION
Visual inspection of the engine/propeller
All inspection panels and fairings secure
Brake system check
Proper fuel in tanks (Super unleaded or 100LL with TCP additive)
Engine start procedures
Oil pressure/oil temperature within limits
Ignition check
Idle RPM check/Choke check
Static RPM check
Electrical system check
Cool down period/engine shut-down
Perform oil, hydraulic and fuel leak check
_____________________________________________
Satis
Unsatis
PAPERWORK
Airworthiness directives
Record findings and sign off inspection and maintenance in aircraft logbooks
_____________________________________________
Inspector signature:
___________________________________
Name (in print) ___________________________________
Date:
___________________________________
31
Ballard Sport Aircraft Ltd. 2696 du Pimbina, Sherbrooke, Qc, Canada J1R 0G3 Phone: 819 563-5847.
© Copyright 2007-2008 Ballard Sport Aircraft Ltd. – All rights reserved --.
Fixed
PELICAN SPORT 450 S
6
WINTER OPERATION
Ultravia offers a very effective cabin heating system with radiator. However, you will not get adequate
heating if the engine’s water temperature is too low.
For winter operation:
•
•
•
•
Check prestone
Check acid in battery
Install fiberglass radiator cover (or cover partly with tape) when outside temperature is below 50°F
(10°C)
Install Lexan cover (drill a few holes in the cover) over oil cooler when oil temperature falls below
green arc
DAMAGE TO THE ENGINE OR ENGINE STOPPAGE
CAN OCCUR IF TEMPERATURES ARE NOT
WITHIN OPERATING LIMITS OR IF THE AIR COMING
FROM THE CABIN HEATING SYSTEM IS NOT WARM ENOUGH
Comes spring and summer, you must remove the fiberglass covers in the radiator and oil cooler inlets. You
may also disconnect the air hose from the side of the cabin to the radiator box and connect directly from the
side of the cabin to the ventilation box behind the instrument panel.
32
Ballard Sport Aircraft Ltd. 2696 du Pimbina, Sherbrooke, Qc, Canada J1R 0G3 Phone: 819 563-5847.
© Copyright 2007-2008 Ballard Sport Aircraft Ltd. – All rights reserved --.
Ballard Sport Aircraft Ltd.
PELICAN SPORT 450 S
CONFORMITY INSPECTION CHECK-LIST
This list was put together as a guide to the Pelican operator. It must in no case be considered as a complete
and infallible list. The assembly manual is a far better guide and each owner and operator must ensure that
he has the required knowledge and competency to perform a valid inspection.
This guide is also very useful before the first flight of the aircraft. In the event the aircraft should be flight
tested by another person than the owner, we remind the latter that the whole responsibility of declaring the
aircraft airworthy lies with the owner who bears the sole responsibility of any accident or incident, which
may be related to the construction of his aircraft.
Human lives are at stake, not to mention the amount of time and money involved.
It is therefore of capital importance that you do a thorough inspection of your aircraft before declaring that
it is airworthy.
33
Ballard Sport Aircraft Ltd. 2696 du Pimbina, Sherbrooke, Qc, Canada J1R 0G3 Phone: 819 563-5847.
© Copyright 2007-2008 Ballard Sport Aircraft Ltd. – All rights reserved --.
Ballard Sport Aircraft Ltd.
PELICAN SPORT 450 S
AIRCRAFT IDENTIFICATION:
Pelican serial N°
Registration
Airframe total time
_____________________
_____________________
_____________________
Engine model
Engine serial N°
Engine total time
Propeller model
Propeller serial N°
______________________
______________________
______________________
______________________
______________________
Owner: ________________________________
Satis
Unsatis
GENERAL
Registration
Aircraft identification plates and placards installed
Weight and Balance / Equipment list
WINGS
Remove inspection plates / fairings
General inspection of the exterior/interior of wing
Flight controls balance weights for security
Flight control proper attachment (free / no slop)
Flight controls properly rigged / proper tension
Check aileron travel
Check flaps operation
Inspect all control stops for security
Skin panels delaminate / voids
Popped rivets / cracked / deformed skins
Fabric/tape condition
Lubrication (WD40 on bushings)
Wing attach points
Struts for security
Corrosion
Pitot line / electrical wires and connectors
Check drains
____________________________________________
____________________________________________
34
Ballard Sport Aircraft Ltd. 2696 du Pimbina, Sherbrooke, Qc, Canada J1R 0G3 Phone: 819 563-5847.
© Copyright 2007-2008 Ballard Sport Aircraft Ltd. – All rights reserved --.
Fixed
Ballard Sport Aircraft Ltd.
PELICAN SPORT 450 S
Satis
Unsatis
Fixed
Satis
Unsatis
Fixed
FUEL SYSTEM
Corrosion
Fuel lines for chaffing/leaks/security/condition
Sump all tanks for water or debris
Fuel caps for security
Fuel placards
Fuel valve / cross feed for operation and security
Change fuel filters / clean gascolator / flush system
Inspect fuel tank vent system
____________________________________________
____________________________________________
FUSELAGE
Remove pulley covers, console top, cable covers
Inspect for delaminated skin and voids (in and out)
Inspect bulkheads for cracked skins
Inspect windows for cracks and fit
Inspect windshield for cracks and fit
Inspect door latching mechanism
Inspect firewall for distortion and cracks
Inspect rudder pedals/brakes for operation/security
Inspect behind firewall for loose wires/chaffing lines
Check control sticks for freedom of movement / no play
Check flap control operation
Check cable and pulleys for attachment and operation
Check aileron cables tension: 50 lbs
Ensure cockpit instruments are properly marked
Compass swing (annual)
Inspect instruments, lines, for security / clean
Inspect cockpit fresh air vents / heater for operation and security
Inspect seats, seatbelts/shoulder harness for security and attachment
Corrosion check
Check drains
_____________________________________________
_____________________________________________
35
Ballard Sport Aircraft Ltd. 2696 du Pimbina, Sherbrooke, Qc, Canada J1R 0G3 Phone: 819 563-5847.
© Copyright 2007-2008 Ballard Sport Aircraft Ltd. – All rights reserved --.
Ballard Sport Aircraft Ltd.
PELICAN SPORT 450 S
Satis
Unsatis
LANDING GEAR
Remove fairings
Inspect legs for attachment
Lift wing and check leg for play / grease pivot points / tighten bolts
Check all bushings for wear / free play
Lubricate wheel axles / Check security of bolts
Inspect wheels for alignment / balance
Wheels/tires for cracks and serviceability
Wheel bearings for lubrication/wear
Inspect for corrosion
Inspect nosegear/tailwheel for cracks and travel / Lubricate nylon bearings and
push-rods
Check tire pressure
Brake linings within limits
Brake disks for cracks/wear/deformity
Brake hydraulic lines for leaks and security (use only automatic transmission oil)
____________________________________________
____________________________________________
____________________________________________
TAIL
Remove covers and fairings
Inspect vertical fin attachment points
Inspect rudder attachment points
Inspect elevator/stabilizer attachment points
Inspect hinges/trim tab for attachment and free play
Inspect skins for damage/corrosion
Inspect all control cables, hinges and pulleys
Check table tension: 50 lbs elevator, 20 lbs rudder
Check elevator travel
Check rudder travel / No interference with elevators
Lubrication (WD40 on bushings)
Inspect all control stops
Flight control balance weights for security
Check drains
__________________________________________
__________________________________________
__________________________________________
36
Ballard Sport Aircraft Ltd. 2696 du Pimbina, Sherbrooke, Qc, Canada J1R 0G3 Phone: 819 563-5847.
© Copyright 2007-2008 Ballard Sport Aircraft Ltd. – All rights reserved --.
Fixed
Ballard Sport Aircraft Ltd.
PELICAN SPORT 450 S
Satis
Unsatis
ENGINE
Perform compression test (yearly or 100 hrs)
#1 __________ #2 ___________ #3 __________ #4 __________
Change oil and filter (check for metal)
Inspect ignition harness for condition and continuity
Check ignition leads cigarettes for condition/cracks
Clean (change) and gap spark plugs
Inspect engine mount/bushings
Check torque of engine mount attachment bolts
Inspect cylinders for cracks/broken fins/exhaust stains
Check for oil leaks
Inspect oil vent lines
Inspect carburator for security/clean filters
Oil air filters
Change carburator intake flanges (200 hrs or yearly)
Inspect throttle/choke control for proper travel and security / Lubricate
Inspection condition of flexible fuel and oil lines
Inspect oil cooler for leaks and condition
Check exhaust system for attachment and condition
Check muffler for security and attachment
Check cowling for cracks and security
Check radiator/hoses for leaks/security + anti-freeze
Check radiator/oil cooler covers for winter operation
_________________________________________
_________________________________________
_________________________________________
_________________________________________
PROPELLER
Check spinner and backplate for cracks
Inspect for cracks / stone damage / nicks (DO NOT FILE)
Repair nicks (resin) - Paint/varnish
Check for delaminations
Check prop bolts torque / Safety wire
Check for oil leaks (crankcase nose seal)
Check prop track/pitch
___________________________________________
___________________________________________
___________________________________________
37
Ballard Sport Aircraft Ltd. 2696 du Pimbina, Sherbrooke, Qc, Canada J1R 0G3 Phone: 819 563-5847.
© Copyright 2007-2008 Ballard Sport Aircraft Ltd. – All rights reserved --.
Fixed
Ballard Sport Aircraft Ltd.
PELICAN SPORT 450 S
Satis
Unsatis
ELECTRICALS
Battery serviced and free of corrosion
Battery supports/covers for security/corrosion
ELT battery free from corrosion and current battery
Check position/strobe lights for operation
Check all antenna mounts and wiring for security
Check all grounding wires (engine to airframe, wing, tail, etc...)
Inspect radios/leads/wires for attachment and security
Inspect circuit breakers/panel for condition
__________________________________________
__________________________________________
OPERATIONAL INSPECTION
Visual inspection of the engine/propeller
All inspection panels and fairings secure
Personnel with fire bottle standing by
Brake system check
Proper fuel in tanks (Super unleaded or 100LL with TCP additive)
Engine start procedures
Oil pressure/oil temperature within limits
Ignition check
Idle RPM check/Choke check
Static RPM check
Electrical system check
Cool down period/engine shut-down
Perform oil, hydraulic and fuel leak check
_____________________________________________
PAPERWORK
Airworthiness directives
Record findings and sign off inspection and maintenance in aircraft logbooks
_____________________________________________
Inspector signature:
___________________________________
Name (in print) ___________________________________
Date:
___________________________________
38
Ballard Sport Aircraft Ltd. 2696 du Pimbina, Sherbrooke, Qc, Canada J1R 0G3 Phone: 819 563-5847.
© Copyright 2007-2008 Ballard Sport Aircraft Ltd. – All rights reserved --.
Fixed
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