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64 

 

 

 

 

Provincial Road n.78 Km 12.150 
33050 Mortegliano (UD) – Italy 
Tel. +39.(0)432.992482 – +39.(0)432.993557 
Fax +39.(0)432.931280 
Sito web: 

www.flysynthesis.com

 

e-mail: 

[email protected]

 

 

Maintenance Manual 

FLY SYNTHESIS TEXAN 

TOP CLASS 580 ISR 

(For Rotax 912 ULS 

 versions)

 

Identification:           MM_TC_580_Rev.2 
Page:                                           64 of 77 
Date:                                         15/02/11 
Issued:                                   C. Cosatto 
Verified:                                C. Cosatto 
Approved:                              C. Cosatto 

 
Revision Description:

 

Placard update 

SECTION 16  

 

STRUCTURAL REPAIRS AND ALTERATIONS

 

Title   

 

 

 

 

 

 

 

 

         Page 

 

16.1  Structural repairs and alterations  

 

 

 

 

65 

16.2  Damage to composite structures  

 

 

 

 

65 

16.3    Line maintenance   

 

 

 

 

 

 

65 

16.4  Heavy maintenance  

 

 

 

 

 

 

65 

16.5  Major repair, alteration, or maintenance  

 

 

 

65 

16.6  Heavy landing 

 

 

 

 

 

 

 

65 

16.7  Exceeding engine limits 

 

 

 

 

 

 

66 

16.8  Exceeding airplane limits   

 

 

 

 

 

66 

16.9  Engine mount checks 

 

 

 

 

 

 

66 

 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 

 
 

 

Summary of Contents for Texan top class 580 ISR

Page 1: ...atto 01 20 12 10 Propeller auto pitch contr C Cosatto C Cosatto C Cosatto 00 18 11 10 New manual issue C Cosatto C Cosatto C Cosatto Num Date Description Issued Verified Approved REVISION FlySynthesis...

Page 2: ...s added to the manual should be logged and recorded in the table under log of Revisions of this manual by the owner user DEFINITIONS Definitions used in this handbook such as WARNING CAUTION and NOTE...

Page 3: ...Manual FLY SYNTHESIS TEXAN TOP CLASS 580 ISR For Rotax 912 ULS versions Identification MM_TC_580_Rev 2 Page 3 of 77 Date 15 02 11 Issued C Cosatto Verified C Cosatto Approved C Cosatto Revision Descri...

Page 4: ...0 18 11 10 0 12 50 18 11 10 0 2 11 18 11 10 0 12 51 21 12 10 1 2 12 18 11 10 0 13 52 18 11 10 0 2 13 18 11 10 0 13 53 18 11 10 0 3 14 18 11 10 0 13 54 18 11 10 0 3 15 18 11 10 0 14 55 18 11 10 0 3 16...

Page 5: ...ARTS 12 3 ENGINE SPECIFICATIONS 13 3 1 ENGINE SPECIFICATIONS 14 3 2 ROTAX 912 S ULS 14 3 3 ENGINE OVERHAUL 15 3 4 ENGINE CONTROLS 15 3 5 ENGINE INDICATIONS 15 4 WEIGHT AND BALANCE 17 4 1 INTRODUCTION...

Page 6: ...2 APPROVED PROPELLER TYPES 50 13 INSTRUMENTS AND AVIONICS 51 13 1 INSTRUMENTS AND AVIAONICS 52 13 2 BASIC MINIMUM FLIGHT AND ENGINE INSTRUMENTS 52 13 3 INSTRUMENT PANEL LAYOUT AND LEGEND 53 14 ELECTR...

Page 7: ...tax 912 ULS versions Identification MM_TC_580_Rev 2 Page 7 of 77 Date 15 02 11 Issued C Cosatto Verified C Cosatto Approved C Cosatto Revision Description Placard update SECTION 1 GENERAL SAFETY INFOR...

Page 8: ...intenance up to 100 hourly servicing to be carried out by the owner This includes Oil and Oil filter changes Fuel filter changes Brake pad changes Spark plug changes Tire changes Fly Synthesis recomme...

Page 9: ...s greater then the angular movement down Directional control is by a rudder installed on the vertical fin stabilizer Rudder pedal motion is transmitted via flexible steel cables to the rudder bell cra...

Page 10: ...the hub For rearward motion holding onto the rear vertical fin allows for easy rearward motion WARNING Do not spin the propeller whilst the engine is hot as it may fire when the propeller is moved an...

Page 11: ...al FLY SYNTHESIS TEXAN TOP CLASS 580 ISR For Rotax 912 ULS versions Identification MM_TC_580_Rev 2 Page 11 of 77 Date 15 02 11 Issued C Cosatto Verified C Cosatto Approved C Cosatto Revision Descripti...

Page 12: ...V Resistant Tie wraps and tooling Metric Hex key set Gasoline resistant thread sealant tape Various general care items Metric Socket Wrench Set Pliers and Wise Grips Phillips and Regular Screw Driver...

Page 13: ...lters should be disposed of as per local laws Tires Standard front tires 4x4 ply 100 75 5 Standard rear tires 13x5x6 ply Large rear tires 15x6x6 ply Tires and tubes available from local distributor Wo...

Page 14: ...tenance Manual FLY SYNTHESIS TEXAN TOP CLASS 580 ISR For Rotax 912 ULS versions Identification MM_TC_580_Rev 2 Page 14 of 77 Date 15 02 11 Issued C Cosatto Verified C Cosatto Approved C Cosatto Revisi...

Page 15: ...cement Compression ratio 84mm 3 31in 61 0mm 2 4 in 1352cm 82 6 cu in 10 5 1 3 3 ENGINE OVERHAUL Rotax After 1500 hours for Rotax 912ULS 3 4 ENGINE CONTROLS Engine control is by one throttle control op...

Page 16: ...osatto Approved C Cosatto Revision Description Placard update The fuel pressure indicator indicates fuel pressure with the engine pump and or aux electric fuel pump in use This fuel pressure indicator...

Page 17: ...Sito web www flysynthesis com e mail info flysynthesis com Maintenance Manual FLY SYNTHESIS TEXAN TOP CLASS 580 ISR For Rotax 912 ULS versions Identification MM_TC_580_Rev 2 Page 17 of 77 Date 15 02 1...

Page 18: ...tenance Manual FLY SYNTHESIS TEXAN TOP CLASS 580 ISR For Rotax 912 ULS versions Identification MM_TC_580_Rev 2 Page 18 of 77 Date 15 02 11 Issued C Cosatto Verified C Cosatto Approved C Cosatto Revisi...

Page 19: ...crease to below acceptable values when exceeding the maximum Take Off Weight Operation at weights above the limits may thus lead to unsafe conditions and could result in a serious accident Exceeding t...

Page 20: ...heel each Up to 120 kgs 1 Put the airplane on the three scales 2 Block the wheels to prevent the airplane from rolling off the scales 3 Check that the airplane is level The check is done by measuring...

Page 21: ...the airplane X1 is the distance from nose wheel axle centerline to projection of RD X2 is the distance from main wheel axle centerline to projection of RD The standard distance is X1 925mm 0 5 X2 655m...

Page 22: ...m Maintenance Manual FLY SYNTHESIS TEXAN TOP CLASS 580 ISR For Rotax 912 ULS versions Identification MM_TC_580_Rev 2 Page 22 of 77 Date 15 02 11 Issued C Cosatto Verified C Cosatto Approved C Cosatto...

Page 23: ...eel tire 4 00x6 or 13x5x6 inflation pressure 2 2 2 4 bar 32 35 psi Large main wheel tire 15x6x6 inflation pressure 2 2 2 4 bar 32 35 psi Nose wheel tire 4 00x4 100 75 5 inflation pressure 1 8 bar 26 1...

Page 24: ...lysynthesis com Maintenance Manual FLY SYNTHESIS TEXAN TOP CLASS 580 ISR For Rotax 912 ULS versions Identification MM_TC_580_Rev 2 Page 24 of 77 Date 15 02 11 Issued C Cosatto Verified C Cosatto Appro...

Page 25: ...ng on Unleaded Auto Fuel Oil Capacity 3 0 Litres MOBIL 1 5w 30 or 15W 50 SHELL Advance VSX 4 10W 40 or 15W 50 SHELL Advance Ultra 4 10W 40 VALVOLINE Dura blend Synthetic 10W 40 PENNZOIL Motorcycle Mot...

Page 26: ...ASS 580 ISR For Rotax 912 ULS versions Identification MM_TC_580_Rev 2 Page 26 of 77 Date 15 02 11 Issued C Cosatto Verified C Cosatto Approved C Cosatto Revision Description Placard update SECTION 7 F...

Page 27: ...ty TORQUE MAIN LANDING GEAR STRUCTURE ON FUSELAGE N 24 screws M6 Kg mt 0 75 MAIN LANDING GEAR LEG ATTACH ON GEAR STRUT N 2 screws M8 Kg mt 1 6 WHEEL AXLE ATTACH ON MAIN LANDING GEAR LEG N 2 screws M6...

Page 28: ...FIRE BULKHEAD N 2 screws M5 Kg mt 0 42 AIR FILTER SUPPORT ON FIRE BULKHEAD N 2 screws M5 Kg mt 0 42 ENGINE TO ENGINE MOUNTING PYLON N 4 screws M10 Kg mt 3 5 WATER MANIFOLD ASSEMBLY N 2 screws M6 Kg m...

Page 29: ...8 screws M5 Kg mt 0 42 PIN AIRELONS MECHANISM N 2 screws M6 Kg mt 0 75 PYLON TO WING FLAP AND AIRELONS N 32 screws M5 Kg mt 0 42 FLAP AIRELONS ALLIGNMENT REGULATION BLADES ON WING PYLONS N 16 screws...

Page 30: ..._580_Rev 2 Page 30 of 77 Date 15 02 11 Issued C Cosatto Verified C Cosatto Approved C Cosatto Revision Description Placard update 7 7 CANOPY ASSEMBLY Quantity TORQUE PLEXIGLAS ON ROLL BAR N 12 screws...

Page 31: ...s com Maintenance Manual FLY SYNTHESIS TEXAN TOP CLASS 580 ISR For Rotax 912 ULS versions Identification MM_TC_580_Rev 2 Page 31 of 77 Date 15 02 11 Issued C Cosatto Verified C Cosatto Approved C Cosa...

Page 32: ...del Aircraft Registration No Texan Top Class 580 ISR Registration No 4X XXXX Engine type and Serial number Rotax 912 ULS xxxx xxxx xxxx Date of Manufacture Enter Day Month and year of manufacture Numb...

Page 33: ...ed C Cosatto Approved C Cosatto Revision Description Placard update SECTION 9 INSPECTION PROCEEDURES Title Page 9 1 Inspections 34 9 2 Daily Inspections 34 9 2 1 Refueling 34 9 2 2 Fuel draining 35 9...

Page 34: ...50 200 Flight Time 450 500 550 600 650 700 750 800 Inspection Type 50 100 50 200 50 100 50 200 Flight Time 850 900 950 1000 1050 1100 1150 1200 Inspection Type 50 100 50 200 50 100 50 Overhaul The 25...

Page 35: ...liminate the water in the tank Use transparent container to drain into If water is found in the drained fuel repeat fuel drain operation until the water is completely drained and any trace of water in...

Page 36: ...earance between fairing and tire Tire and wheel Undamaged not worn excessively inflated properly Gear strut No distortion Gear support frame Locking nuts tightened No distortion with pedals centred ru...

Page 37: ...ce fixed tight NO PLAY 9 4 6 FUSELAGE Skin Undamaged no sign of serious chipping swellings or Delamination Inspection doors closed 9 4 7 TAIL Vertical fin Undamaged no serious chipping depressions or...

Page 38: ...py Clean undamaged freedom of movement four locks operate correctly Windshield Clean fixed securely Baggage Not exceeding weight limit weight distributed and load secured Weight and balance Calculate...

Page 39: ...check can be made with special video equipment X X Internal check main landing gear frame steel tube spar to fuselage for condition no cracks Check four points of connection to fuselage structure no...

Page 40: ...er is 0 6 mm Check aileron push pull rods and rod ends for condition no distortion free clearances all around in full movement X X Check elevator push pull rods and rod ends for condition no distortio...

Page 41: ...the fuel lines from the tank to the firewall for condition and support This may be done via the Inspection port O O O COCKPIT Carefully inspect all operating levers for damage wear abnormal play and...

Page 42: ...e the main landing gear RH and LH struts Clean the strut housings in the tubular framework Clean the axle assemblies Lubricate strut housings for corrosion prevention Check struts for alignment X Rein...

Page 43: ...acks Check for distortion X X Check for proper torque of the nuts securing the engine to the engine mount Torque required Nut 6 8Nm Nut 8 22Nm X X X Check for proper torque the self locking nuts secur...

Page 44: ...Check battery cables for connection and cable dressing O O O O Visual inspection the engine shock absorber s spacer must be centred about its seat see Page 66 16 9 for engine mount checks X X X i Dis...

Page 45: ...e mail info flysynthesis com Maintenance Manual FLY SYNTHESIS TEXAN TOP CLASS 580 ISR For Rotax 912 ULS versions Identification MM_TC_580_Rev 2 Page 45 of 77 Date 15 02 11 Issued C Cosatto Verified C...

Page 46: ...eg Each wheel of the main gear is equipped with a disk brake The nose gear is installed on the firewall and connected to a strengthened frame on the front fuselage It is made of a steel construction s...

Page 47: ...ysynthesis com Maintenance Manual FLY SYNTHESIS TEXAN TOP CLASS 580 ISR For Rotax 912 ULS versions Identification MM_TC_580_Rev 2 Page 47 of 77 Date 15 02 11 Issued C Cosatto Verified C Cosatto Approv...

Page 48: ...n and one tank is empty it is possible that fuel pump may suck air instead of fuel Fuel is drawn from the bottom of the tank through a finger strainer and through a fuel valve in the cockpit labelled...

Page 49: ...web www flysynthesis com e mail info flysynthesis com Maintenance Manual FLY SYNTHESIS TEXAN TOP CLASS 580 ISR For Rotax 912 ULS versions Identification MM_TC_580_Rev 2 Page 49 of 77 Date 15 02 11 Iss...

Page 50: ...e mail info flysynthesis com Maintenance Manual FLY SYNTHESIS TEXAN TOP CLASS 580 ISR For Rotax 912 ULS versions Identification MM_TC_580_Rev 2 Page 50 of 77 Date 15 02 11 Issued C Cosatto Verified C...

Page 51: ...procedures see propeller manufacturers manual WARNING Ensure Ignition system is OFF before commencing any work on propeller Failure to adhere may result in injury or death 12 2 APPROVED PROPELLER TYPE...

Page 52: ...al FLY SYNTHESIS TEXAN TOP CLASS 580 ISR For Rotax 912 ULS versions Identification MM_TC_580_Rev 2 Page 52 of 77 Date 15 02 11 Issued C Cosatto Verified C Cosatto Approved C Cosatto Revision Descripti...

Page 53: ...nstruments are located on the RHS panel The central panel is usually used for radio and GPS installation 13 2 BASIC MINIMUM FLIGHT AND ENGINE INSTRUMENTS The basic airplane is delivered with the follo...

Page 54: ...is com e mail info flysynthesis com Maintenance Manual FLY SYNTHESIS TEXAN TOP CLASS 580 ISR For Rotax 912 ULS versions Identification MM_TC_580_Rev 2 Page 54 of 77 Date 15 02 11 Issued C Cosatto Veri...

Page 55: ...LASS 580 ISR For Rotax 912 ULS versions Identification MM_TC_580_Rev 2 Page 55 of 77 Date 15 02 11 Issued C Cosatto Verified C Cosatto Approved C Cosatto Revision Description Placard update SECTION 14...

Page 56: ...regulator rectifier above the battery in the engine compartment The electrical plant is protected by circuit breakers positioned on engine instruments pannel side The switches on central instruments p...

Page 57: ...Page 57 of 77 Date 15 02 11 Issued C Cosatto Verified C Cosatto Approved C Cosatto Revision Description Placard update Generator Failure Warning Light red indicates system voltage is below 12 volts o...

Page 58: ...ysynthesis com e mail info flysynthesis com Maintenance Manual FLY SYNTHESIS TEXAN TOP CLASS 580 ISR For Rotax 912 ULS versions Identification MM_TC_580_Rev 2 Page 58 of 77 Date 15 02 11 Issued C Cosa...

Page 59: ...eats Through a reduction gearbox and a screw jack the flap motor transmits the motion to the flap s interconnecting torque shafts An angular position transducer installed near the gearbox transmits th...

Page 60: ...ww flysynthesis com e mail info flysynthesis com Maintenance Manual FLY SYNTHESIS TEXAN TOP CLASS 580 ISR For Rotax 912 ULS versions Identification MM_TC_580_Rev 2 Page 60 of 77 Date 15 02 11 Issued C...

Page 61: ...al FLY SYNTHESIS TEXAN TOP CLASS 580 ISR For Rotax 912 ULS versions Identification MM_TC_580_Rev 2 Page 61 of 77 Date 15 02 11 Issued C Cosatto Verified C Cosatto Approved C Cosatto Revision Descripti...

Page 62: ...PVC tubes should be checked when doing regular maintenance or after flying through rain If water is ever found in the PVC tubes it should be drained immediately The draining procedure consists of rem...

Page 63: ...eb www flysynthesis com e mail info flysynthesis com Maintenance Manual FLY SYNTHESIS TEXAN TOP CLASS 580 ISR For Rotax 912 ULS versions Identification MM_TC_580_Rev 2 Page 63 of 77 Date 15 02 11 Issu...

Page 64: ...580_Rev 2 Page 64 of 77 Date 15 02 11 Issued C Cosatto Verified C Cosatto Approved C Cosatto Revision Description Placard update SECTION 16 STRUCTURAL REPAIRS AND ALTERATIONS Title Page 16 1 Structura...

Page 65: ...be reported to the MANUFACTURER or the APPOINTED AGENT 16 3 Line Maintenance any repair maintenance scheduled checks servicing inspections or alterations not considered heavy maintenance that is appro...

Page 66: ...wheels Check main wheel alignment 6 Install wheels and struts fairing install cowling 7 Check engine mount for distortion 16 7 EXCEEDING ENGINE LIMITS Any time an engine limit is exceeded RPM time li...

Page 67: ...LY SYNTHESIS TEXAN TOP CLASS 580 ISR For Rotax 912 ULS versions Identification MM_TC_580_Rev 2 Page 67 of 77 Date 15 02 11 Issued C Cosatto Verified C Cosatto Approved C Cosatto Revision Description P...

Page 68: ...info flysynthesis com Maintenance Manual FLY SYNTHESIS TEXAN TOP CLASS 580 ISR For Rotax 912 ULS versions Identification MM_TC_580_Rev 2 Page 68 of 77 Date 15 02 11 Issued C Cosatto Verified C Cosatto...

Page 69: ...aint as this will increase the heat absorption from the sun which may lead to damage to the composite material structure Before painting the aircraft it would be wise to consult the manufacturer about...

Page 70: ...ion MM_TC_580_Rev 2 Page 70 of 77 Date 15 02 11 Issued C Cosatto Verified C Cosatto Approved C Cosatto Revision Description Placard update LOCATED IN BAGGAGE COMPARTMENT Located on the Instrument pane...

Page 71: ...nce Manual FLY SYNTHESIS TEXAN TOP CLASS 580 ISR For Rotax 912 ULS versions Identification MM_TC_580_Rev 2 Page 71 of 77 Date 15 02 11 Issued C Cosatto Verified C Cosatto Approved C Cosatto Revision D...

Page 72: ...authorities Discussion Experimental LSA kit aircraft an LSA aircraft with modifications does not require the person performing maintenance to hold any FAA aircraft maintenance certificate in the U S L...

Page 73: ...Standard Atmosphere Kg Kilogram km hr Kilometres per hour MPH Miles per hour kt s Nautical Mile per Hour knot 1 nautical mph 1852 3600 m s lb s Pound s 1 lb 0 4539 kg mm Millimetre cm Centimetre m Me...

Page 74: ...Max Maximum Min Minimum B 2 UNITS Speed Kts Knots 1 15 mph miles per hour 1 84 km hr 1 km hr 1 6 MPH Pressure PSI Pounds per Square Inch in Hg inches of Mercury mb millibar Distances in inches 25 4 mi...

Page 75: ...IL FAIRING LARGE WHEEL SPATS TO SUIT 15X6X6 TYRES AIR SWITCH AND AIR SWITCH METER CABIN HEATING SECOND THROTTLE ELECTRICAL TRIM PANEL MOUNT OR ON CONTROL STICK CONTROLS FOR DISABLED STABILATOR BALANCI...

Page 76: ...proved C Cosatto Revision Description Placard update GT TONINI PROPELLERS GT TONINI TWO PLADE FIXED PITCH PROPELLER ROTAX 912 S 173 P155 ROTAX 912 S 173 P157 ROTAX 912 S 173 P158 DUC PROPELLERS DUC CA...

Page 77: ...o Verified C Cosatto Approved C Cosatto Revision Description Placard update APPENDIX D FEED BACK FORM Model Aircraft and Registration No Engine type and Serial number Date of Manufacture Number of hou...

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