AirBorne WindSports XT 582 Maintenance Manual Download Page 3

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XT 582 Maintenance Manual

Issue 1.0

September 21st 2005

Page 3

AMMENDMENT RECORD SHEET

Amendment Date

Affected

Sections

Affected Pages

Date Inserted

Signature

Issue 1.0
September 21

2005

All of initial issue

1 to 102

September 21

2005

Table 2 Amendment Record Sheet

NOTE

AirBorne’s data packages will be revised from time to time. Owners registered on AirBorne’s data base
will be notified of any changes to data and directed to the AirBorne web site
(

<http://www.airborne.com.au/>

) for the applicable pages. The amended pages should be printed and

Summary of Contents for XT 582

Page 1: ...e Manual Issue 1 0 September 21st 2005 Page 1 XT 582 MAINTENANCE MANUAL ISSUE 1 0 Manufacturer AirBorne WindSports Pty Ltd Unit 22 30 Kalaroo Rd Redhead NSW Australia Phone 61 2 4944 9199 Fax 61 2 494...

Page 2: ...ccompanies the aircraft Following is a list of each of the components which are required Pilot s Operator s Handbook XT 582 Maintenance Manual XT 582 Illustrated Parts Catalogue Wing Maintenance Manua...

Page 3: ...e Issue 1 0 September 21st 2005 All of initial issue 1 to 102 September 21st 2005 Table 2 Amendment Record Sheet NOTE AirBorne s data packages will be revised from time to time Owners registered on Ai...

Page 4: ...placed in the folder as soon as possible The amendment table should at that time be updated with the appropriate details and date Revised pages will be sent by mail if requested LOG OF ALL EFFECTIVE P...

Page 5: ...nt in the system If there are any doubts regarding the required and appropriate maintenance then the safety of the aircraft may be jeopardised in continuing with self maintenance In this situation an...

Page 6: ...NDING GEAR STRUTS OTHER MINOR REPAIRS CAN BE CARRIED OUT IN ACCORDANCE WITH FAA AC 43 13 1B WARNING THE INFORMATION IN THIS MANUAL NEEDS TO BE FOLLOWED AND IT IS NOT ACCEPTABLE TO MAKE CHANGES TO THE...

Page 7: ...ion factors that have been used in this manual 1 Pound Ib 0 4536 Kilogram kg 1 Pound per sq in psi 6 895 Kilopascal kPa 1 Inch in 25 4 Millimetres mm 1 Foot ft 0 3048 Metre m 1 Statute mile 1 609 Kilo...

Page 8: ...IRED PLACARDS 32 12 SERVICING 33 20 STANDARD PRACTICES AIRFRAME 40 23 COMMUNICATIONS 47 24 ELECTRICAL POWER 48 25 EQUIPMENT FURNISHINGS 49 27 FLIGHT CONTROLS 50 28 FUEL SYSTEM 51 28 FUEL SYSTEM 51 31...

Page 9: ...k 22 Figure 8 Major Dimensions XT912 Shown 24 Figure 9 Tie Down Hook Location 28 Figure 10 Front wheel with tie downs 28 Figure 11 Tie on Rear Wheel 29 Figure 12 Trike on Trailer 29 Figure 13 Parking...

Page 10: ...74 Figure 47 Place Blades into Hub Block 75 Figure 48 Propeller with all the necessary components 75 Figure 49 Mounting the Propeller Photo shows 912 engine 76 Figure 50 Propeller AN4 Bolt Tightening...

Page 11: ...embly of rear end Attach lifting device to the rear of the trike base tube and the top of the crate 8 Fit Compression Struts Rear end assembly 9 Attach drag links ensuring they pass through the soft s...

Page 12: ...e been identified in this section to aid maintenance personnel These photos and list of names are not comprehensive Aircraft Structure Figure 1 Main structural members Cockpit Figure 2 Cockpit XT 912...

Page 13: ...ember 21st 2005 Page 13 Under seat bags Figure 3 Under seat bags Mast Block Area Figure 4 Mast Block Area XT 912 shown in photo Under seat bag rhs Under seat bag lhs Inertia reel retractors mast paddi...

Page 14: ...d foot levers Figure 5 Steering and foot levers Power Plant Figure 6 Power plant Brake park latch Foot brake lever Front foot steering pedal Draft stop Rear steering pedal Dual steering linkage Water...

Page 15: ...eturn to service if no SB action required Table 6 Airframe Limitations The airframe was analysed using FAA fatigue analysis Fatigue Evaluation Of Wing and Associated Structure on Small Airplanes FAA R...

Page 16: ...Overhaul or Replace Engine Accessories As Specified by Rotax www rotax aircraft engines com Overhaul or Replace Propeller As Specified by the manufacturer See section 5 20 10 of Maintenance Manual Ov...

Page 17: ...the Airborne Factory The airworthiness of Microlights is only valid provided that all necessary Maintenance Modification and Service requirements are fulfilled These requirements include a Maintenance...

Page 18: ...425 450 475 500 1000 Examinefor nicksandabrasions 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 Checksecurityof blades 2 2 2 2 2 2 2 2 2 2 2 Checksecurityandre torquemountingbolts sandwichplates Re torqu...

Page 19: ...ble Fewdropslight machineoil See Section12 20 40 1 3 1 4 1 3 1 4 1 3 1 4 1 3 1 5 1 3 1 4 Air Filter SeeSection12 20 50 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 5 1 1 1 1 Checkexhaust Portsfor CarbonBuild up 2 2...

Page 20: ...of 500 hours Table 9 Engine Maintenance Schedule Time Limit for Rubber Parts For checking the Engine Mount Rubbers see Mounts Section 71 20 00 for other rubber components related to the engine see bel...

Page 21: ...ending 2 2 2 2 6 Pivot Points 1 1 1 4 1 1 1 4 1 1 1 4 1 1 1 4 1 1 1 4 Rear suspensionswingarmsandshock absorber strut 3 4 3 4 3 4 3 4 3 4 MainandNosewheels 3 4 3 4 3 4 3 4 3 4 Rear suspensionswingarms...

Page 22: ...after extended storage periods 5 50 10 Inspection after heavy landing Check shock absorbers for normal operation Check all attachment points and members of the suspension system Check all welded lugs...

Page 23: ...seat as this will change the alignment of the tubes Attachment Points Check attachment points for the wing to the base including the main hang bolt wheel axles and bearings The wing should also necess...

Page 24: ...tric measurements are included Also included is the overview of the components which make up the Trike Base Ground Line The major line through which points are measured from being the points where the...

Page 25: ...mm Ground to Main Bolt Centre Undercarriage Track 1685 mm Wheel Centres Undercarriage Base 1935 mm Axle to Axle Prop Centreline Height 1165 mm Ground to Centre of Prop Ground Line to the Engine Mount...

Page 26: ...oint allows easy lifting by hand from this point Alternatively a strap may be placed around the base tube for long term elevation of the front end Rear wheels The rear wheel may be lifted from the gro...

Page 27: ...ake is available using this method 9 20 00 Taxiing Taxiing of the trike may be performed with or without the wing attached to the base Braking and steering are achieved through the front wheel The tri...

Page 28: ...re rear on the engine mount section Figure 9 Tie Down Hook Location Front The front of the trike should be secured between the front wheel and the fork on both sides of the axle Make sure that the tie...

Page 29: ...Page 29 The rear wheels may be tied as well Route the tie between the drag link and rear suspension member to help prevent damage to the spat Figure 11 Tie on Rear Wheel Figure 12 Trike on Trailer The...

Page 30: ...Parking Wing Down Park Park the trike at 90 Deg to the anticipated wind direction and set the brake lock on The wing tip should then be placed onto the ground on the side of the prevailing wind The bu...

Page 31: ...p condition for any extended period of time Consult the pilots handbook for instructions on disassembly pack up and or hangarage Additionally if the trike is to be prepared for transport the pilot han...

Page 32: ...e illegible or damaged in service Replacement placards may be purchased from an Airborne dealer or direct In the case of the Vne Placard if the ASI has been disassembled the alignment of the ASI and p...

Page 33: ...Allow time for the breather valves to equalise the pressure to allow complete filling and check that both sides are sufficiently full Fill to the neck of the fuel entrance FUEL Preferred Fuel Type En2...

Page 34: ...12 10 30 Rotary Valve Replenishment Rotary valve lubrication is supplied via a small tank mounted on the top right hand side of the engine Oil quantity on a new installation is approximately 310ml Be...

Page 35: ...g Ensure that the sump plug is correctly replaced and lock wired prior to refilling See Rotax Maintenance Manual for further details Oil Specifications Gear oil API GL5 or GL6 SAE 140 EP or 85W 140 EP...

Page 36: ...cturer If no lubrication interval is specified for a component lubricate as required and when assembled or installed 12 20 40 Cable Lubrication The throttle Choke and Brake Cables have been lubricated...

Page 37: ...ost commercial window cleaning sprays as they will adversely affect the plastic Painted Surfaces The painted exterior surfaces of the aircraft can be washed using a mild detergent and water alternativ...

Page 38: ...le for practical composite repairs Some guidelines for repairs Repair thickness should at least equal original material thickness in all cases preferably half on the inside and half on the outside For...

Page 39: ...mber 21st 2005 Page 39 Repairs should overlap damage by at least 35mm on all sides Repairs are prohibited within a radius of 150mm of the pitot tube Repairs in the vicinity of the Pitot must maintain...

Page 40: ...e unnecessary movement resulting in wear or fatigue while over tightening may cause tensile failure of the bolt or crushing of components Torques should be determined using an accurate torque wrench d...

Page 41: ...ull Procedure 1 With the lock bolt and the inside Nyloc nut loose tighten the outside bolt with incorporated spat bracket until it is sufficiently far onto the bolt and is resting at approximately 10...

Page 42: ...nstallation The spats are made from a fibreglass polyester composite material for this reason care should be taken to ensure they are not damaged during their installation They are held by Nyloc nuts...

Page 43: ...s Shear Type Nuts Nm in Ibs Nm in Ibs Thread Min Max Min Max Min Max Min Max 8 36 1 4 1 7 12 15 0 8 1 7 9 10 32 2 3 2 8 20 25 1 4 1 7 12 15 1 4 28 5 6 7 9 50 70 3 4 4 5 30 40 5 16 24 11 3 15 8 100 140...

Page 44: ...e flight direction and any component that becomes loose will tend to be pushed into the propeller and engine Following is an excerpt from a manufacturing Quality Control form giving all of the locatio...

Page 45: ...strap and front pole are locked in place with wing nuts and safety clips as shown below Figure 25 Mast Top Safetying Self Locking Nuts Self locking nuts are used at joints that subject neither the nu...

Page 46: ...may be lubricated with light oil if necessary Wear is most likely to occur at the ends of the cables at the attachment points 20 40 00 Rust Proofing During manufacture all of the steel components have...

Page 47: ...are located in two positions 1 The Lynx intercom system has a 1 5A fuse screwed into the side of the box where the headsets and push to talk cables are plugged in 2 The power supply cables for the ra...

Page 48: ...tenance The maintenance of the electrical system should include periodic inspection of the wiring loom for chafing and other damage through its entire length Pay special attention to the areas that ar...

Page 49: ...s of the seats are non structural components 25 10 20 Occupant Restraint Systems Both the pilot and passenger seats are fitted with both lap and shoulder belts Both of these should be periodically che...

Page 50: ...through cable actuated throttle levers which may be actuated by pilots in the front or rear of the aircraft The foot throttle is only available to the front pilot while the hand throttle is able to b...

Page 51: ...67 Litres Fuel drain tap Breather system Safety fuel tap Fuel Filter The Rotax engine contains the fuel pump Consult the Rotax manual for instructions Sight gauge for remaining fuel Electric Flow Met...

Page 52: ...removed and all fittings disconnected prior to this test being performed so that other components of the system are not effected by the test Do not inflate the tank more than the recommended amount f...

Page 53: ...l 1 Remove the fuel from the tank 2 Turn the Main Fuel tap to the off position 3 Remove the fuel hose from the 90 Deg brass fitting that attaches to the finger filter 4 Unscrew the brass fitting from...

Page 54: ...ter The first item after the tank is the fuel filter correct operation and maintenance is extremely important for reliable operation of the engine The fuel filter should be removed and checked for deb...

Page 55: ...ning fuel it should be used in addition to the visual check but not instead of The visual check is described in section 28 40 00 The electrical system and schematic is described in section 8 4 of the...

Page 56: ...ncy to starve the engine of its fuel supply Maintenance Handle Make sure that the valves actuating handle is secure Flow Checks Should there be any doubts about the fuel supply to the engine i e a lac...

Page 57: ...visual check of the level on the exposed part of the tank on the right hand side There are graduations imprinted on the plastic in ten litre increments up to 60 litres it should be noted they are cal...

Page 58: ...ay module which is mounted in the dash and the capture module which is located on the engine tie rod The photo shows the layout of the display when set up for the 582 Rotax engine Figure 31 SkyDAT Con...

Page 59: ...centre 31 10 00 Panels The panel for the AMPtronics system is included in the pilots handbook section 3 4 Showing the layout of the display 31 20 00 Independent Instruments The additional air speed i...

Page 60: ...to fittings that in turn attach to the pivot locations The rear suspension layout consists of tubular main struts for the rear suspension an airfoil shaped drag link and airfoil shaped rear strut The...

Page 61: ...for checking the pressures and resetting them if necessary is 1 Check and set the large reservoir At the top nearest the rebound knob to 50 Psi 2 Check and set the small reservoir at the base of the s...

Page 62: ...ear passenger footrest to allow them to steer if they are piloting The default setting for the steering damper is light which is achieved by rotating the shaft of the damper completely in the anticloc...

Page 63: ...e assembly should be thoroughly inspected for signs of damage or wear Figure 36 Front Wheel Assembly The brake depression distance until the brake actuates may be adjusted by loosening the cable attac...

Page 64: ...fects and replaced as necessary Because the tyres on the trike contact the runway in an uneven manner the rear tyres may be swapped with each other in order to utilise all of the tread This should be...

Page 65: ...air speed indicator A second 3mm tube splits to the pilots right and into the SkyDAT readout The tubes are both made of PVC and may be replaced if necessary The length of the tubing is important in o...

Page 66: ...ting the Static System Testing the Pitot can be achieved by carefully using a syringe and flexible tube sealing it to the front of the Pitot entrance and introducing a very small amount of pressure Th...

Page 67: ...brace Front Mast Brace The front mast brace is the stabilising member that joins the front of the trike to the top of the Mast The Front mast brace is mainly constructed of 6061 T6 Aluminium Base Tube...

Page 68: ...ing For instructions regarding the attachment and maintenance of the main bolt refer to the Wing maintenance manual and the Pilot s Operating Handbook 53 40 30 Stabilisers The stabilisers are attached...

Page 69: ...e Mount Attachment to Mast Block 53 40 50 Engine mount The engine is attached to the engine mount which is in turn attached to the mast via the mast block and to the Base Tube of the aircraft The engi...

Page 70: ...mast pole These attachment points are shown in the photos below Figure 42 Pod Front Attachment Figure 43 Pod Attachment to Mast Brace Figure 44 Pod Attachment to Seat Frame Figure 45 Pod Instrument P...

Page 71: ...s which protrude from the top surface and into the airflow providing some yaw stability at speed The structural integrity of the spats is important for the wheel operation and ensuring that the outer...

Page 72: ...21st 2005 Page 72 56 WINDOWS 56 00 00 General The windshield of the XT is basic and should be cared for as per the instructions covered in section 12 20 50 56 40 00 Inspection and Observation If the w...

Page 73: ...d out Bolt holes should be examined for out of round rough edges and cracks radiating into the boss Check the whole surface of the hub especially in all areas where there are corners Make sure the sur...

Page 74: ...t Note All bolts washers and Nyloc nuts used to clamp the hub plates and attach propeller assembly to the engine should be assembled dry without oil or moisture 61 20 10 Propeller Material List Table...

Page 75: ...lace Blades into Hub Block 61 20 40 Add the rest of the components The rest of the components that are listed are now added to the Forward Hub Block 61 20 41 Place the Aft Hub Block onto the Forward H...

Page 76: ...the M8 full nyloc nuts on but do not tighten untill last If they are not assembled at this stage they will be impossible to get on after the bolts have been torqued Figure 49 Mounting the Propeller 61...

Page 77: ...ould separation line on the blade it should be close to the gap between the hub halves at the quoted pitch The blade angles can be set using a digital level There are six steps that are required to pe...

Page 78: ...ront wheel 61 10 23 Rotate the Propeller Blade to be checked to horizontal The propeller that is to be set should be rotated into position on the pilots right of the engine The prop hub vertical surfa...

Page 79: ...d be used to accurately mark the position Figure 55 Radius Measurement 61 10 25 Set the angle of the propeller The angle of the propeller can now be set Place the digital level in the centre of the 24...

Page 80: ...t the washer plate is installed If the washer plate is not installed it is possible that the bolts will become thread bound before applying pressure to the hub Nyloc nuts should not be reused after th...

Page 81: ...58 Correctly Installed Propeller Recheck the pitch of the propellers after they have been fully torqued Recheck visually that all components are in place Note that while tie wire is required on the X...

Page 82: ...e the damage If the LE Tape is damaged it has done its job and will need replacing 61 20 30 Damage Allowances All propellers will eventually suffer damage from a variety of causes and in differing deg...

Page 83: ...h the epoxy Always follow the resin instructions and apply to a clean dry surface When cured carefully sand the filler back to match the blade apply new LE Tape NOTE If in doubt or if the propeller ha...

Page 84: ...e person is to perform the operation or if two willing and capable people are unavailable there are mounting points for a hoist on the top of the engine The Rotax manual should be consulted for the co...

Page 85: ...low bottle is attached to the engine mount using Velcro straps 71 50 00 Electrical Harness The electrical harness for the system is routed between the fuel tank and the engine it incorporates the engi...

Page 86: ...for the maintenance and overhaul of the Rotax 582 UL engine fitted to the XT 582 aircraft can be found in the following documents Rotax Operator Manual for Rotax Engine Type 582 Series Rotax Document...

Page 87: ...tuated either by foot or hand The cables from each of the two are routed through a mixer device which allows each to be depressed independently even if the other is stuck for any reason The mixer also...

Page 88: ...hich powers systems which are external to the engine The Rotax maintenance manual should be consulted for the maintenance of the engines electrical system Section 12 60 00 of the maintenance manual 74...

Page 89: ...nkage can operate correctly through its full travel without causing binding or bending kinking of the inner Any problems with Bowden type controls can usually be traced to one or more of the above Rec...

Page 90: ...of the fuel system is either achieved by shutting the motor down which will stop the mechanical fuel pump or by moving the main fuel supply tap to the off position which will starve the engine of fue...

Page 91: ...The tachometer does not have an alarm however the maximum sustained level is 6500rpm and 6800 rpm should not be run for more than five minutes The pitch of the propeller set up should prevent over spe...

Page 92: ...w a short circuit signal then the wiring between the CHT and the SkyDAT needs to be checked The best place to start the inspection would be the physical connections before tracing the wire through Sim...

Page 93: ...lows each to be removed individually Figure 61 Photo of screwdriver in place to remove wire 4 Remove both sets of wires and place the Faulty EGT wires into the side which has been receiving a signal 5...

Page 94: ...er connections are all of the spring loaded ball joint type to absorb engine vibration Removal and inspection of the exhaust system is simple and obvious When reinstalling the exhaust system Loctite a...

Page 95: ...plied as a part of the data package The manual must be read by the owner and the manufacturers instructions followed for the maintenance and use of the parachute The maintenance of the Parachute syste...

Page 96: ...AirBorne WindSports Pty Ltd XT 582 Maintenance Manual Issue 1 0 September 21st 2005 Page 96 End of XT 582 Maintenance Manual...

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