Schempp-Hirth Flugzeugbau GmbH Krebenstrae 25 Postfach 14 43 D-7312 Kirchheim unter Teck

Maintenance Manual for the powered sailplane model Discus bT

Edition: Revision: October 1989 8, January 2011

This manual relates to the powered sailplane Discus bT

Registr.-No. Serial-No.

: : Schempp-Hirth Flugzeugbau GmbH

Manufacturer :

Owner

The translation of this manual has been done by best knowledge and judgment, In any case of doubt the original text in German language is authoritative.

SCHEMPP-HIRTH FLUGZEUGBAU GMBH, KIRCHHEIM/TECK Discus bT 0.1 Rev. No.

6.

MAINTENANCE MANUAL issue October 1989

Record of revisions Reference / short title

Replacing propeller/hub assembly

Page
0.2.1 0.2.2 5.5.1 5.5.2

Date
March 2003

7.

Supplement of equipment and instruments

0.2.3 7.1 7.2.1 7.2.2 7.2.3 7.2.4 0.2.2 0.2.4 5.11 5.12.1 5.12.2 12.9 13.1 Troubleshooting page 5

December 2006

8.

Technical Note 863-21 Engine pylon

January 2011

Note: Cross out revisions which are not included. The list of effective pages must be amended by hand if necessary. 0.1.2

SCHEMPP-HIRTH FLUGZEUGBAU GmbH., KIRCHHEIM/TECK Discus bT MAINTENANCE MANUAL

5.1.1 Removing the power plant

Drain all fuel and, if installed, remove upper auxiliary tank Remove power plant battery from fuselage nose Pull off fuel line and impulse line from fuel pump Detach engine wiring (by disconnecting 3 wires from terminal block inside the engine compartment the yellow/green center wire is the ground connection) Remove cable ties securing the wiring Remove decompression valve interconnecting link (see picture on page 5.12.2), remove pylon-mounted valve actuating lever Remove the nuts from the four bolts attaching the engine to the pylon (see pictures on page 5.12.2) Lift engine (with prop.) free from the pylon fork.

January 2011 Revision 8

TN 863-21 MB 863-1

5.11

SCHEMPP-HIRTH FLUGZEUGBAU GmbH., KIRCHHEIM/TECK Discus bT MAINTENANCE MANUAL

5.12

Re-installation of the power plant Slide down engine (folding prop. mounted) onto the pylon fork, together with the rubber engine shock mounts (vibration isolators, two per each lug). Tighten engine mounting nuts such that the spacing between the rubber shock mounts is as follows (see also picture on page 5.12.2): Upper shock mounts: 26.5 0.5 mm (1.04 0.02 in.)

Secure upper engine mounting nuts with a cotter pin Install and tighten lower stop nuts Re-connect engine wiring Re-connect fuel line and impulse line to fuel pump Attach wiring and lines to pylon (using cable ties as before) Mount metal link connecting the decompression valves (see picture on page 5.12.2), mount valve actuating lever Carry out an inspection according to section 4.3 b) of the Flight Manual Re-install power plant battery into fuselage nose section If desired, the upper auxiliary fuel tank (option) may now be re-installed

Note:

The materials necessary for re-installing the power plant may be obtained from Schempp-Hirth.

January 2011 Revision 8

TN 863-21 MB 863-1

5.12.1

SCHEMPP-HIRTH FLUGZEUGBAU GmbH., KIRCHHEIM/TECK Discus bT MAINTENANCE MANUAL

Pictures for power plant removal and re-installation

January 2011 Revision 8

TN 863-21 5.12.2

Maintenance Manual

Diagram 9

M03 RT 841

January 2011 Revision 8

Techn. Note No. 863-21

12.9

SCHEMPP-HIRTH FLUGZEUGBAU GmbH., KIRCHHEIM/TECK Discus bT

CHECK LIST

MAINTENANCE MANUAL
Registr.: .............................. Ser.-No.: ............................. Date: ..................................

I. Engine mount (pylon) and pivoting mechanism

ITEM TO BE INSPECTED Engine mount (pylon) and pivot shaft Spindle drive KIND OF INSPECTION Check steel tube pylon for cracks, check shaft suspension for proper condition. FINDINGS

1.1

1.2

1.3

1.4

1.5

1.6

1.7 1.8 1.9

Check for play and proper function, check attachment of its lower mounting bracket, check limit switches and their mounts for proper attachment and condition. Gas strut Disconnect spindle drive and check that the weight of the power plant is about counterbalanced by the gas strut while pylon swings up and down. Arresting wires Check steel cables and NICOPRESS sleeves for proper condition. Check tension: With power plant fully extended, cables must be equally taut. Check that cable retaining springs are hooked up. Engine stop block Check that retracted power plant rests firmly against its stop block at the bottom of the engine compartment. Rubber pad firmly adhering to stop block? Engine suspension o Check for proper spacing of the annular rubber engine shock mounts (vibration isolators). o Check condition of rubber elements on lower engine suspension o Check condition of rubber stops (O-rings) at the pylon Diaphragm fuel pump Check that the fuel pump is clear from engine doors while pylon swings up and down. Engine door actuating Check linkage for free movement, check for low mechanism friction in the system. Engine doors and door hinges Decompression valve control Check for damage and proper fit. With power plant retracted, check travel of spring on door actuating rods. When releasing the DECO handle, the bellcrank on the pylon must return to its stop so that a gap of at least 3 mm (0.12 in.) exists between the metal link on the decompression valves and the bellcrank. With the DECO handle pulled fully back, the prop must rotate with ease. Check that all power plant accessories, wires, lines etc. are properly connected and secured. Check that cables , wires and lines do not get caught while power plant ex tends/retracts.

1.10

1.11

General

January 2011 Revision 8

TN 863-21

13.1

TROUBLE SHOOTING
PROBABLE CAUSE REMEDY

Discus bT
Page 5

TROUBLE

III. PYLON AND ENGINE MOUNTS a) Rubber shock mounts at upper engine mounting not tightened properly a) Tighten castellated nut to the correct distance and secure it with a cotter pin Correct distance between outer edges of shock mounts: 26.5 0.5 mm (1.04 0.02 in.) b) Tighten nuts or replace rubber elements

1. Engine mounting too weak

b) Rubber elements at the lower engine mounting loose or broken

2. Play in the pylon suspension 1. Axial play of the pivot shaft caused by defective ball bearings or by bearings displaced sideways -

Remove engine and (upper) fuel tankpower plant Remove electrical spindle drive Remove gas strut Remove pylon pivoting shaft by 1. Removing the two outmost bolts M4 and 2. Pressing the two spigots inwards into pivoting shaft using a bolt M8.

Check spigot bearings for proper condition. If necessary, replace bearings and/or retaining clips. Replace defective shock mount(s) or replace engine mounting bracket

2. Rubber shock mounts defective or engine mounting broken

January 2011

TN 863-21