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1. ence ceeesesenusecenesdvessacenseceececaseenceders 53 25 EQUIPMENT FURNISHINGS 2 ccce iren eec orsa coceseeccuactecectssesdsadcetcere 57 27 FEIGHT CONTROES Lie Eee en Leurs ree 58 28 FUEL SYSTEM ur u Cau Fe eser eo 59 31 INDICATING RECORDING 5 67 32 LANDING GEAR DD 69 34 NAVIGATION AND PITOT 80 BS audies 90 55 STABILIZERS bi 94 GAss 95 M PROPELLERS uu u EE 96 11 POWER PLANT asa ua a Suysa sus DEED 108 72 ENGINE MAINTENANGCGE 1 iecit hinteren inet eroe uina EE saec aapa ainiaan saeara iaa inisa 110 73 ENGINE FUEL SYSTEMS ceinture entren etae re Ein niai ture tenias aano epe Da 112 TAIGNITION 113 176 ENGINE CONTROLES seeusenstccetentecpdeeuncnuetetsevesensenur seees ie 114 77 ENGINE INDICATING U U innen nnns nnn ns nn nn u u 116 y ol
2. 26 Table 14 Requirements for Rotax 912 Time Between 26 Table 15 General Aircraft Dimensions a enne nenne 30 Table 174 Fuel Specifications SS ua AR 38 Table 18 Torque Table caer cene desee HR AERE 49 Table 19 Excerpt from GJP 141 Complete List of Tie Wire locations 50 Table 20 Features of the Instrumentation 67 Table 21 Drum Brake Wear Limits 72 Table 22 Disk Brake Dimensions and 74 Table 23 Parts List anioe enden iae ER XE HER Ede e ERR 97 Table 24 Propeller Pitch Setting and Gearbox 100 Table 25 Rotax Gear Set Part Numbers a r rrssssssssssa 100 Table 26 Propeller Torque Settings 103 Table 27 Monitored Operations sse nnne nnne 116 Table 28 Drawings List see appendix A 122 Table 29 Parts List from A4 5904 Sheet 2 een eene a nnne nnn 122 LIST OF FIGURES Figure 1 Main Structural Members enne nn
3. Figure 11 Tie on Rear Wheel Figure 12 Trike on Trailer The above photo shows the trike correctly secured upon a trailer and ready for transport Issue 2 0 May 2007 Page 34 AirBorne WindSports Pty Ltd XT 912 Maintenance Manual 10 PARKING AND MOORING 10 00 00 General This chapter provides information concerning the correct procedures for parking securing storage and transport of the aircraft without packing the trike up If any maintenance is to be performed on the trike base it is recommended that the wing is removed For derigging and storage see sections 9 2 and 9 3 of the pilots handbook 10 10 00 Parking Wing Down Park Park the trike at 90 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 shock cord and fastener are then used to secure the base bar to the front mast pole This method of parking the aircraft allows the wind to flow spanwise across and over the wing For other situations such as strong winds pack up and hangaring consult the pilots handbook Figure 13 Securing of Base Bar with Shock Cord Figure 14 Parking of Trike Upwind Wing Down NOTE The wing tip may be pinned to the ground using a peg such as a tent peg This will stop the wing from shifting Issue 2 0 May 2007 Page 35 AirBorne WindSports Pty Ltd XT 912 Maintenance Manual Tail To Wind
4. 119 LOMEEULCHM ste 120 95 SPECIAL PURPOSE menn nnn J 120 APPENDIX A Condition Inspection Record 134 APPENDIX B Feedback u nenne nennen tnnt 135 Issue 2 0 May 2007 Page 9 AirBorne WindSports Pty Ltd XT 912 Maintenance Manual LIST OF TABLES Table 1 XT 912 Data Package edi oes erede ie rere ae eee 2 Table 2 Amendment Record Sheet nn ssrsssssssss 3 Table Log Of All Effective Pages a 4 Table 4 Imperial Metric Conversions enne nennen nnne 8 Table 5 Initial Assembly Procedure GJP144 a 13 Table 6 100 hour service kit and typical consumables 14 Table 7 Airframe Limitations n nsn nnne 18 Table 8 Time Limits of Components enne 19 Table 9 Maintenance Privileges r 21 Table 10 Power Plant Maintenance Schedule r 25 Table 11 Trike Base frame Maintenance Schedule
5. 0 O gt Q D 3 S lt Line Ok Find overhead support suitable to lift approx 200kg Caution Mast has an air strut and will move quickly when untethered Remove straps and box Remove and unwrap all parts Remove mast support screws from the crate leave the mast strap attached to base tube Remove front axle tie down bolts from the crate Loosen gearbox support rope 7 Un bolt base tube support frame from the crate Use lifting mechanism such as a small hand winch to lift rear of trike to allow assembly of rear end Attach lifting device to gearbox hub using a soft sling Have someone hold trike in case of roll over Attach struts ensuring mast safety wire is attached Fit rear shocks to struts Fit rear wheels and spat outer brackets Maintenance Manual Section 20 Lower trike wheels to the ground and remove lifting device Whilst holding down on mast remove strap and raise mast slowly Remove crate top mast support leave mast attached to base tube and vertical legs Remove crate base Attach mast brace inner tube to mast and tighten bolt ing Nut Safety Pin Raise front of trike using sling around base tube Tighten all nuts and bolts in accordance to standard practice see maintenance manual Carry out pre flight inspection in accordance with the pilot handbook Ensure the production flight test has been performed Flight testing must be performed by an authorised Airborne Dealer Airbo
6. AirBorne WindSports Pty Ltd XT 912 Maintenance Manual Limitations Due to Registered Category S LSA Maintenance on a Special LSA 100 hourly and annual inspections are to be performed by the holder of a LSA Repairman Maintenance certificate or an appropriately rated A amp P mechanic Note owners and pilots are permitted to perform preventative maintenance tasks as prescribed by FAR document Part 43 Appendix A Sec A43 1 E LSA The owner of an aircraft registered as an Experimental LSA has operations limited to private use and has additional maintenance privileges During the transition period commercial operations may be conducted until 31 January 2010 Where an experimental registered aircraft is used for compensation training or towing during the transition period the option c below does not apply to 100 hourly inspections The 100 hourly or annual inspections on an E LSA are to be performed by a the holder of a LSA Repairman Maintenance certificate or b an appropriately rated A amp P mechanic or c the owner when the owner is the holder of a LSA Repairman Inspection certificate The pilot of the E LSA aircraft is responsible to see that the maintenance and inspection has been performed on this aircraft as per the maintenance schedules prescribed in this maintenance manual The maintenance schedule tasks remain applicable where there is no minimum level of qualification required to perform maintenance on E LSA howev
7. AirBorne WindSports Pty Ltd XT 912 Maintenance Manual AitrBorne AUSTRALIA XT 912 Light Sport and Primary Category Aircraft MAINTENANCE MANUAL ISSUE 2 0 Manufacturer AirBorne WindSports Pty Ltd Unit 22 30 Kalaroo Rd Redhead NSW 2290 Australia Phone 612 4944 9199 Fax 612 4944 9395 Website http www airborne com au Part 108346 Issue 2 0 May 2007 Page 1 AirBorne WindSports Pty Ltd XT 912 Maintenance Manual DATA PACKAGE This manual constitutes one part of the complete data package that accompanies the aircraft Following is a list of each of the components which are required e Pilot s Operator s Handbook or Aircraft Operating Handbook e XT 912 Maintenance Manual e XT 912 Illustrated Parts Catalogue e Wing Maintenance Manual Wing Illustrated Parts Catalogue e Rotax Owners Manual e Rotax Maintenance Compact Disk e Radio Manual If Installed e BRS Parachute Manual If Installed e Transponder Manual If Installed Table 1 XT 912 Data Package Issue 2 0 May 2007 Page 2 AirBorne WindSports Pty Ltd XT 912 Maintenance Manual REVISION HISTORY January 2007 combined Primary Category Maintenance manual with LSA maintenance skills requirements Insert LSA maintenance privileges section Introduction of the XT Outback rubber cushion front end suspension maintenance schedule and description added May 2007 Addition of hydraulic brake Addition o
8. see drawing A4 5904 Appendix A The canister is located on the parachute bracket by the deployment rocket attachment boss Parachute canister Mount bracket Mountina bolt Profile clamp ____ Profile clamp bolts Figure 81 Parachute Bracket Attachment Once the canister is attached to the bracket attach the bracket to the rear of the trike The steel base tube has a aluminium mounting tube protruding see Figure 82 below Enaine mount Enaine mount Parachute bracket attachment Figure 82 Parachute Mount Attachment Tube Issue 2 0 May 2007 Page 123 AirBorne WindSports Pty Ltd XT 912 Maintenance Manual oe Figure 69 Side View Parachute Attached to Trike Rocket Assembly and Installation Using the data supplied by BRS remove canister plastic end cap and assemble the rocket and cables onto the parachute canister Adjust rocket angle Ensure the rocket is angled downward at an angle of approximately 25 Sight along the rocket it should be aimed to traject below the RHS wheel spat Parachute bridle to trike base Carabineer Canister end cap Canister Parachute bridle Deployment rocket Figure 83 Rocket Angle Parachute Bridle Attachment and Routing Attach the end of the bridle around the engine mount uprights as shown in Figure 84 and Figure 85 Loop the end of the bridle through itself in the direction shown Cable tie the bridle back in
9. 5923 FUEL LEVEL FINGER FILTER GRADUATIONS DRAIN STOPCOCK BOTTOM LHS FUEL CAP OUTLET HOSE FITTING nr BREATHER FITTING CONNECTION TOP RHS BREATHER OUTLET FUEL FILTER CARBURETTORS Figure 29 Fuel Tank Schematic Issue 2 0 May 2007 Page 59 AirBorne WindSports Pty Ltd XT 912 Maintenance Manual 28 00 10 General Precautions and Procedures WARNING DO NOT PERFORM ANY MAINTENANCE ON THE FUEL SYSTEM IN CONJUNCTION WITH MAINTENANCE ON THE ELECTRICAL SYSTEM NO SMOKING OR IGNITION SOURCES WITHIN 50FT OR 15M FROM THE BASE FUEL WILL DEGRADE WING MATERIAL AND UPHOLSTERY IN THE TRIKE CARE SHOULD BE TAKEN TO PREVENT ANY SPILLAGES 28 10 00 Fuel Storage Tank The storage system consists of a single fuel tank located underneath to the sides and to the rear of the passengers seat Note The actual fuel tank has no provision for repair if the fuel tank is damaged in any way that makes it unsafe it should be replaced contact Airborne Fuel Cap The fuel cap has a one way valve attached which allows air to enter the tank while preventing fuel escaping Fittings The tank has a draincock two ventilation fittings and the main supply fitting attached to it Sealant The fittings are attached to the fittings using Loctite 567 Thread Sealant If for any reason the fittings have to be removed then the same sealant should be used to ensure compatibility and correct sealing The Loctite number for ord
10. Ltd XT 912 Maintenance Manual 76 20 00 Emergency Shutdown Emergency shutdown 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 fuel NOTE There will still be some fuel remaining in the float system of the carburettors if the engine is not starved of fuel to shut it down Issue 2 0 May 2007 Page 115 AirBorne WindSports Pty Ltd XT 912 Maintenance Manual 77 ENGINE INDICATING 77 00 00 General The engines operation is monitored by the SkyDAT electronic display system mounted on the instrument panel The engine operations monitored are RPM engine revolutions per minute Battery Voltage Flight duration in hours minutes 2xCHT cylinder head temperature Celsius or seconds Fahrenheit Engine Hours in hours minutes 2xEGT exhaust gas temperature Celsius or Fahrenheit Oil Temperature Oil Pressure bars or PSI Table 27 SkyDAT Monitored Operations The normal and maximum operating range for the oil temperature exhaust temperature cylinder head temperature and oil pressure are indicated on the instrumentation and the alarm Flashing Red Light will go off if any of the settings are exceeded The tachometer does not have an alarm however the maximum sustained level is 5500rpm and 5800 rpm should not be run for more than five minutes The pi
11. the outer diameter of the propeller the equation for the allowable dent is as follows 1 Measure the location from the prop hub mm 2 Depth 3 0 00847 x Location from Centre 250 Issue 2 0 May 2007 Page 106 AirBorne WindSports Pty Ltd XT 912 Maintenance Manual The number of dents allowable depends upon their size It is suggested that two or three per propeller blade would be maximum 61 20 40 Repair To repair all dents and scratches a slow cure EPOXY resin must be used Available from Airborne is a General Purpose Epoxy 180 360 and 1000gm packs Damage over 3mm MUST be filled with slurry made from a suitable Epoxy plus fine milled glass fibres Available from Airborne is a BOS Repair Kit containing the appropriate epoxy Glass Powder and instructions For cosmetic scratches and dents use Talc with 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 For a Dura Tuff or Nickel insert leading edge propeller these propellers are relatively maintenance free in the event that a leading edge is damaged it is likely that the propeller is damaged as well Leading edge inserts may be fitted to existing propellers and as replacement inserts the propeller manufacturer must perform this procedure NOTE If in doubt or if the propeller has more damage than is able to be fixed by the maintainer then return the
12. to ground at the CHT sender and a message short circuit should show on the screen for that CHT This test determines that the wires between the CHT sensor and the SkyDAT are intact If there is no Short Circuit Signal If the SkyDAT does not show 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 Simply checking the resistance of the wires between each section as well as to earth to check for short circuit will determine the circuit s integrity Full electrical system analysis instruction is beyond the scope of this manual Cylinder Head Temperature CHT A good CHT sender measures approximately 800 Ohms resistance at room temperature when measured between the brass terminal and the block of the engine remove the red wire from the sender to perform this test See attached photograph Figure 77 Earthing of CHT Sender to Check the Wire to the SkyDAT Issue 2 0 May 2007 Page 117 AirBorne WindSports Pty Ltd XT 912 Maintenance Manual Exhaust Gas Temperature EGT If an EGT sender is suspected to be faulty then the best method to check the actual sender is to swap the leads that go into the SkyDAT data box When the engine is operated if the opposite display then shows the same reading as before this will confirm a faulty sender To change the wires use the follow
13. 2007 Page 126 AirBorne WindSports Pty Ltd XT 912 Maintenance Manual 3 16 SS rivet Bracket l bolt Figure 89 Release Handle Exploded View Cable Routing and Adjustment Route the release cable around the side of the trike as shown below Using the hose bush and cable tie attach the cable to the oil tank as shown in Figure 90 Ensure the cable is routed as close to the trike as possible to avoid it being caught without over stressing or kinking the cable Attachment to oil tank Cable routing ees Figure 90 Cable Routing Thread cable tie through hose bush and around the oil tank bolt and between soft side and fuel tank The other end goes around the cable as shown Pull the cable tie up tight to lock cable onto hose bush Cut off the excess cable tie end Hose bush and cable tie y Figure 91 Cable Attachment to Oil Tank Issue 2 0 May 2007 Page 127 AirBorne WindSports Pty Ltd XT 912 Maintenance Manual Safety Tag Attachment and Placement The red safety tag comes as part of the BRS parachute Sew the 50 x 40 mm piece of Velcro loop onto the tag as shown in the figure below Attach one end of the safety wire to the release tag and the other to the release pin see drawing A4 6553 Sheet 3 for instructions Release pin Velcro Safetv taq Safety wire Figure 92 Safety Tag Assembly Attach the sticky back
14. AS IT IS UNNECESSARY WHEN ATTACHED TO THE SPAT Figure 26 Muffler Safety Wire and Springs The muffler components are attached to each other via a spring which is in turn safetied with wiring Soft Side Safetying Each of the soft side securing bolts are loctited into position This is necessary because if they were to come loose they may impact the propeller Mast Top The wing wing heart bolt not shown wing safety strap and front pole are locked in place with wing nuts and safety clips as shown below Figure 27 Mast Top Safetying Self Locking Nuts Issue 2 0 May 2007 Page 51 AirBorne WindSports Pty Ltd XT 912 Maintenance Manual Self locking nuts are used at joints that subject neither the nut or the bolt to rotation in service Self locking nuts may be reused but not if they can be run on the thread by hand without using tools After a self locking nut has been tightened at least one full thread pitch of the male thread must protrude through the nut locking feature 20 30 00 Control Cables And Terminals Control cables on the trike base include throttle cables choke cables and brake cables These need to be checked regularly for excessive friction and wear The cables 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 been treated with rust proo
15. BRS for repack 12 years Rocket life Replace rocket http www brsparachutes com Table 8 Time Limits of Components 5 20 00 Scheduled Maintenance Checks Airborne microlights have been designed to permit easy inspection and operators should have no difficulty in assessing problems or recognising damage if visual checks are carried out correctly Maintenance checks may require partial disassembly of the aircraft Inspection should include a thorough visual check of the condition of the component and the attachment point in adequate lighting conditions Cleaning of the component may be required for proper inspection Significant scratches cracks galling or any other mechanical wear of the component is reason for replacement Issue 2 0 May 2007 Page 19 AirBorne WindSports Pty Ltd XT 912 Maintenance Manual General care should include Washing down the tube work with warm water and a mild detergent followed by rinsing with fresh water Fabric sponged with warm water and a mild detergent and rinsed with fresh water The pod and wheel spats washed and polished using commercially obtainable shampoos and polishes Treat all exposed metal components including the engine on the trike base only with a dewatering compound such as WD40 or CRC spray This guards against corrosion and makes cleaning much easier Lubricate the throttle cables regularly using light machine oil The cockpit area shou
16. Maintenance Manual CAUTION ELIMINATE IGNITION SOURCES AND BE AWARE OF THE FUMES THAT EMANATE FROM THE FUEL TANK Breather Lines The breather lines are attached to the breather fittings without adhesives the interference fit is used to secure them The breather lines are made from 6mm ID PVC tubing which may be replaced if necessary Finger Filter A horizontal finger filter is installed into the tank where the main fuel line is attached The length of the finger filter is necessary so that a minimum amount of fuel is left in the tank The condition of the finger filter may be visually inspected through the fuel cap hole with an empty tank this may be assisted by jacking the back of the trike and tilting it to the pilots right see Jacking Section 7 10 00 Cleaning Main Tank Finger Filter NOTE The removal of the finger filter has been simplified with a non structural change to the engine mount Check the serial number of the trike which you are performing maintenance on and follow the relevant instructions Serial Numbers from 61 onwards should use the following instructions 1 Remove the fuel from the tank Turn the main fuel tap to the off position Remove the fuel hose from the 90 degree brass fitting that attaches to the finger filter Unscrew the brass fitting from the aluminium finger filter Unscrew the finger filter from the tank and remove Remove any accumulated debris from the filter and flush the bottom of
17. NOTE The Inner Spat Bracket is intentionally bent inwards at each end Locking Bolt Head Figure 23 View of Locking Bolt head Spat Installation 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 for this reason they do not need to be tightened to the point of crushing the composite fibreglass Issue 2 0 May 2007 Page 48 AirBorne WindSports Pty Ltd XT 912 Maintenance Manual General Torquing Procedures General Torquing Exceptions 1 Joints with hinges or bearings where the specified torque value would prevent free operation 2 Bolts nuts and screws that attach plastic or fibreglass or aluminium tube components where the softer material would be damaged by specified torques 3 Engine bolts are to be torqued to the engine manufacturers specifications and may need to be sequenced Applicable to the following BOLTS and SCREWS AN3 thru AN20 AN42 thru AN49 AN73 thru AN8I AN173 thru AN186 NAS1303 thru NAS1320 NAS6600 thru NAS6608 AN509 AN525 MS20073 MS20074 524694 MS27039 NAS1300 NAS6605 Applicable to the following NUTS Tension Nuts AN310 AN315 AN363 AN365 MS20365 MS20500 MS21042 MS21045 NAS679 NAS1021 Shear Nuts AN316 AN320 AN364 BOLTS LOADED PRIMARILY IN SHEAR FINE THREAD SERIES Tension Type
18. Part Number 100268 15 600x6 4K01 TL Rib TRE 2 aie ARD Part Number 156006RIB TUBE INNER 6 SUIT RIM 100369 156006TU13 6 00X6 103138 480 400x8 Hiway Part TYRE 8 X 4 00 Number Kend4008JT TUBE INNER 8 RIGHT 103139 4008TU87 ANGLE VALVE 105244 CARLISLE 8 00 6 4 PR TYRE 6IN X 8 00 TUNDRA TITAN TURF GLIDE 9042T AIR FILTER XT 912 105685 105284 K amp N filter oil spray K amp N Filter oil 99 1131 897 870 Table 6 100 hour service kit and typical consumables list Additional consumables are applicable to engine maintenance and heavy maintenance Refer to the Rotax Maintenance Manual section 05 00 00 page 10 A detailed illustrated parts catalogue provided with this aircraft contains reference to the consumables on this aircraft 00 20 00 Component Overview Important areas of the Trike base have been identified in this section to aid maintenance personnel These photos and list of names are not comprehensive Issue 2 0 May 2007 Page 14 AirBorne WindSports Pty Ltd XT 912 Maintenance Manual Aircraft Structure Mast Front pole Mast Seat block Seat frame Enaine mount sub frame Base Tube Front end assemblv Rear landing gear Figure 1 Main Structural Members Cockpit i Windscreen Seats Soft side Pod Figure 2 Cockpit Issue 2 0 May 2007 Page 15 AirBorne WindSports Pty Ltd XT 912 Maintenance Manual Under Seat Ba
19. Pty Ltd XT 912 Maintenance Manual 2 2 Outback variant The ground plane is readily constructed from 2mm aluminium sheet Cut a disk of 6 150mm radius or larger Place a tangential 20 fold at 35mm from the edge of the disk Holes are located at the centre 1 2 and 5 16 hole at 34 19mm from the disk edge Mount the ground plane on the bottom of the front mast brace using the existing nut and bolt on the front mast brace Mount the ground plane disk such that it is horizontal The ground plane disk need not be insulated from the frame The aerial is mounted in the central hole of the ground plane 3 Run a coaxial cable such as an RG 223 U or RG 58C U cable with one female BNC and one female TNC connector from the antenna BNC to the TNC connector on the back of the transponder Notes for installation on the Outback The Outback has access the instrument housing on the bottom right hand side the coaxial cable is tied to the base beam using zip ties Run the cable through the centre of the forks 4 Mount the Mode C encoder in a location where the adjustment screws will be readily accessible The altitude encoder may be mounted atop whichever avionics unit the radio or transponder is mounted higher in the console Alternatively the altitude encoder may be mounted to the bottom of the lower unit Affix the encoder s mounting tray to the case of the avionics unit using a strip of hook and loop fastener e g Velcro Secure the ins
20. R S3 R 3 R 3 R S R cracking see 4 20 00 for time limits Trike mast for bends or cracking As directed 3 R 3 R S R S3 R 3 R S R S R see 4 20 00 for time limits Drag links and rear struts for As directed 3 R 3 R S R S3 R 3 R S R S R bends or hole elongation see 4 20 00 for time limits Brake system inspect dimensions 32 40 3 R 3 R S R S3 R 3 R S R S R amp wear limits table 18 19 Disk brake fluid level Mast brace for bend or cracking As directed 3 R 3 R S R S3 R 3 R S R S R Should Outer brace should slide freely see 4 20 00 for time limits Rubber cushion Front As directed 3 R 3 R S R S3 R 3 R S R S R suspension on XT outback only Pitot Drain drain amp reseal 34 10 10 2 0 2 O 2 O 2 O 2 O 2 0 2 O Heart bolt see 4 20 00 for time As directed 4 O 6 O 6 O 6 O 6 O 6 O 6 O limits Table 11 Trike Base frame Maintenance Schedule Special Instructions Requirements for TBO Rotech Research Ltd is pleased to join with ROTAX in announcing the extension of the T B O Time Between Overhaul period for Rotax 912 and 914 series of piston aviation aircraft engines The Austrian civil aviation authority Certificate Authority Austro Control GmbH or ACG has now granted all of the necessary approvals to increase the time before overhaul TBO of the Rotax 912 series from 1200 hours to 1500 hours The TBO for the popular turbo
21. Repair WARNING THE PROPELLER IS NOT FIBREGLASS AND SEPARATE INSTRUCTIONS IN SECTION 61 HAVE BEEN INCLUDED FOR THE REPAIR OF THE PROPELLER DO NOT USE FIBREGLASS OR POLYESTER RESIN ON THE PROPELLER AS IT IS STRUCTURALLY INFERIOR FOR THE LOADS ON THE PROPELLER AND THE RESINS MAY BE INCOMPATIBLE AND THERFORE UNSAFE The fibreglass that makes up the pod and spat structures of the trike is made from polyester resin and chopped strand fibreglass The fibreglass components may be repaired using polyester resin and fibreglass mat or chopped strand mat which is probably the preferable choice for easy thickness build up Make sure that the surfaces have been correctly prepared for adhesion of the repair Full repair instructions for the fibreglass components is beyond the scope of this manual there are many good texts available for practical composite repairs Issue 2 0 May 2007 Page 45 AirBorne WindSports Pty Ltd XT 912 Maintenance Manual Some guidelines for repairs e Repair thickness should at least equal original material thickness in all cases preferably half on the inside and half on the outside For attachment points the repair thickness should be increased by half again 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 the original profile or the repair will adversely effect airworthiness 12 20
22. SET TO 50psi REBOUND ADJUSTMENT WIND FULLY IN CW WIND OUT 12 CLICKS NEGATIVE AIR VALVE SET TO 5tpei DIMENSION X SHOCK MODEL AIR HYPER DNM AO 22AR da NOTE USE MOUNTAIN BIKE SHOCK PUMP RELEASE AIR FROM BOTH VALVES Bem POSITIVE AIR VALVE TO 50 PSI PUMPNEGATIV E AIR VALVE TO 50 PSI i J CHECK MEASUREMENT DIMENSION N Z DIMENSION X IS 190 SMM ON EMPTY WEIGHT AIRCRAFT RESTING ON THE GROUND Rav AMENDMENTS Oso PART NO 105349 TT ss SHOCK ABSORBER FRONT XT OLEO 2 PRESSURE NSTRUCTIONS 20306 LAST ACESSED Friday 3 March 2005 Oran By Scale 5602 ALL DVENDONS IN MLLIMETRRS UNLESS STATED CTHERWISS cre t2 08 0603 Ai ir Bore SEET tot Figure 34 Front Shock Set up Rubber cushion suspension is used on the front wheel of the XT Outback 32 20 00 Nose Gear The front steering is foot activated and includes a steering damper system The foot steering system includes a linkage to the rear 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 anticlockwise direction The setting may be adjusted for personal preference WARNING NEVER ADJUST THE DAMPER WHILE IN FLIGHT AS IT POSSIBLE TO MAKE STEERING DIFFICULT WITH A HIGH LEVEL OF DAMPING HEAV Y DAMPING Steering Damper Setting ANTICLOCKWISE LIGHT DAMPING CLOCKWISE HEAVY DAMPING DEFAULT SETTING
23. Service 61 10 10 Inspection The intervals at which the propeller must be removed for inspection are specified in the WARNING Maintenance Schedule WHEN WORKING ON THE PROPELLER With the propeller removed from the aircraft and REMOVE THE SPARK PLUG LEADS FROM each of the components separated the blades THE SPARK PLUGS and boss should be inspected for the sort of damage described below paying particular attention to those areas which are not visible when the propeller is installed e Bolt holes should be examined for out of round rough edges and cracks radiating into the boss e Check the whole surface of the hub especially in all areas where there are corners Make sure the surfaces are clean and there is good lighting A magnifying glass will aid close inspection e Boss faces should be examined for damage where they have been in contact with the hub flanges particularly at the circumference of the flanges e The centre bore should be examined for cracks and delamination of the plies e The mounting hub should be examined for corrosion cracks correct fit on the crankshaft and for condition of the attachment bolts and nuts e Take note of any sharp nicks cuts or scratches as these are stress points from which further problems may occur Act on them if required Replace damaged LE tape Do not operate propellers of carbon fibre leading edge construction without LE tape e Inspect the propeller and hub in the area around wher
24. a draincock on the base of the fuel tank at the left hand side which may be used to check the quality of the fuel and to drain fuel if necessary it is especially important to remove any water form the system Checking the fuel The fuel is checked for water and contaminants by draining a sample of the fuel into a clear glass container Once a sample has been taken the quality of the fuel can be checked by looking for any water at the bottom of the glass and checking for any other visual contaminants If the fuel has been sitting for an extended period without use it may be advisable to replace it with fresh fuel Issue 2 0 May 2007 Page 38 AirBorne WindSports Pty Ltd XT 912 Maintenance Manual Draining the Fuel Ensure that a suitable receptacle is found for the fuel that is to be drained position the trike above the receptacle and depress the draincock Ensure that there are no ignition sources and that the fuel is disposed of correctly 12 10 20 Engine Oil System Replenishment The minimum oil level is with system volume at 3L max at 3 45L This is checked and replenished by removing the oil sump lid Rotax has provided service instructions which detail how to check the oil The sump is drained by removing the sump plug Ensure that the sump plug is correctly replaced and lock wired prior to refilling the engine with oil Measure the amount to be replaced refill check the level run the engine and recheck The opportunity
25. against the mating surface should be added to the final torque value Special Torquing Procedures Seat Mast Block Sub Assembly The seat mast block has special torquing procedures that need to be followed Drawing 5658 is supplied showing the required torque values as well as the Loctite required ITEM NO NAME DWG PART NO arY ASSEMBLY NOTES 1 SEAT MAST BLOCK XT 5234 04734 1 HERR 2 4X TOVERCEN TER SOCKET RHS 5299 104898 1 HORIZONTAL CAP SCREWS 26 N m 19 ft Ibs 6 3 XTOVERCENTER SOCKET LHS 5299 04894 1 VERTICAL M8 CAP SCREWS 34 N m 19 ft Ibs 6 5 _ WASHER SS 1 2 X 1 304 FLAT 5540 00093 4 M12 CAP SCREWS 34 N m 25 ft lbs 4 7 _ AN4 22 a Bolt 5450 00549 2 SEE ENGRPT 03 115 8 AN4NUT HALF NYLOC 561 100035 2 USE LOCTITE 243 ON BOLTS 4 AND 6 9 WASHER 5540 00042 2 TIE WIRE BOLTS TOGETHER 10 WASHER SS 5 16 3 4 5540 02332 4 gt 11 SEARIALNO PLATE TRIKE WING 4500 1023558 1 FY ee SURE IS T7m 12 POPRIVET 1 8 5515 100162 2 13 SKT CAP SCREW M 12X 60 DRILLED 5603 06448 2 14 SKT CAP SCREW M 8X40DRILLED 5603 06449 4 E c LOCTITE amp TORQUE TO 26 md in LOCTITE amp TORQUE TO 34Nm 14 10 PART IS THE SAME BOTH SIDES NOTE GJP FORMS MUST BE UPDATED 13 LOCTITE amp TORQUE TO 34Nm WITH REV CHANGES i AMENDMENT pate PART NO 105446 SEAT MAST BLOCK SUB ASSEM XT LAST ACESSED Tuesday 20
26. all instrumentation cables from the engine 5 After the five engine mounts have been undone the engine may be carefully removed by two people one on each side supporting under the cylinder heads If one 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 correct bolt sizes and methods While the engine is off Check the condition of the engine mount and the engine mount rubbers see section 71 20 00 replace or repair as necessary Installation The installation of the engine is the reverse of removal When the exhaust system is rejoined Loctite Antisieze Lubricant should be used on all of the areas that butt into each other Loctite 76764 71 20 00 Mounts The engine mount is of welded steel RHS construction The engine is supported on the engine mount assembly at five points through rubber shock mounts These shock mounts should be inspected regularly for deterioration excessive sagging and other damage It is recommended but not considered mandatory that these be replaced at 500 hour intervals Any damage or distortion to the engine mount structure should be repaired promptly as apart from any loss of structural integrity distortion or misalignment of the engine mount structure could impose abnormal stresses on the engine itself Figure 74 Engine Mount Rubbers Issue 2 0 M
27. between the uprights so the mast can fold back without difficulty Issue 2 0 May 2007 Page 124 AirBorne WindSports Pty Ltd XT 912 Maintenance Manual Cable ties Bridle loop Cable ties Enaine mount Bridle end loop Bridle attachment RHS upright Wek Figure 86 Side View Bridle Attachment Issue 2 0 May 2007 Page 125 AirBorne WindSports Pty Ltd XT 912 Maintenance Manual Run the bridle down the RHS upright and attach to the carabiner on the parachute canister as shown in Figure 87 below Gather together the remaining bridle and neatly cable tie in place as shown below The bridle can be taped with electrical tape once gathered to assist in installation Enaine mount Cable tie Gathered bridle Cable tie v No Figure 87 Gathered Bridle on Engine Mount Upright Release Handle Attachment If the release handle bracket is not already attached unscrew the LHS seat frame bolt and attach bracket as shown Using the bracket as a guide drill the seat frame using a 4 8mm or 3 16 drill and rivet the bracket in place 3 16 SS rivet supplied Drill and rivet Seat frame bolt Release handle bracket Release handle Bracket l bolt Handle pre assembly Figure 88 Release Handle Attachment Attach the pre assembled handle onto the bracket with the I bolt provided see drawing A4 5904 Sheet 2 for bracket assembly Issue 2 0 May
28. 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 be actuated by both The cables and levers should be checked for free operation and ensure that there are no kinks in the cables Light machine oil may be used to lubricate the cables NOTE If any sign of wear or damage is evident then the cable assembly should be replaced Issue 2 0 May 2007 Page 58 AirBorne WindSports Pty Ltd XT 912 Maintenance Manual 28 FUEL SYSTEM 28 00 00 General Description This section pertains to the components which store and deliver fuel to the engine The XT 912 fuel system is simple and easily visually inspected Fuel rate sensing transmitting and indicating are covered in chapter 73 Features Capacity 70 Litres Useable fuel 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 Meter for electronic fuel usage information Usage information provided by the digital flight display The following schematic should be used to ensure the correct sequence of installation if the fuel lines are being repaired or replaced CAUTION THE FLOW METER AND THE FUEL FILTER ARE DIRECTIONAL THEY MUST BE INSTALLED SO THAT THE FUEL FLOWS IN THE CORRECT DIRECTION FUEL TANK SCHEMATIC ATOPLHG N PLAN VIEW DWG
29. cable securing nut must be tightened with sufficient torque to avoid cable slippage If the attachment point is further towards the end of the cable then the condition of the cable where it was previously clamped should be inspected for deterioration and replaced if necessary Fine adjustment of the brake is made with the fine adjustment screw where the sheath is mounted at the wheel end Thoroughly check for free operation of the wheel and proper operation of the brake after adjustment The condition of the rim spokes and other features of the rim brake assembly should be thoroughly inspected for signs of damage or wear Issue 2 0 May 2007 Page 72 AirBorne WindSports Pty Ltd XT 912 Maintenance Manual Brake Coarse Adjustment Brake Fine Adjustment Nut Figure 37 Front Wheel Assembly Figure 38 Rear Disk Brake Master Cylinder Mounted on Front Fork Rear Disk Brake Operation The rear disk brake is actuated hydraulically via a single common circuit Brakes are operated via the left pedal lower pedal for aerotow equipped aircraft A brake lever lock is provided for short term parking use only For extended periods use wheel chocks Issue 2 0 May 2007 Page 73 AirBorne WindSports Pty Ltd XT 912 Maintenance Manual Rear Disk Brake Dimensions and Fluid Specification Brake disk Thickness 3 2 mm thickness service limit 3 mm Brake pad
30. care not to cross thread Issue 2 0 May 2007 Page 118 AirBorne WindSports Pty Ltd XT 912 Maintenance Manual 78 EXHAUST 78 00 00 General There is one muffler system for the four cylinders Each of the cylinder exhausts have a custom made manifold that routes to the Rotax muffler The exhaust system temperature is indicated by the SkyDAT digital display with the sensors in place at the exit of the two cylinders to the front of the engine 78 10 00 Collector Nozzle The muffler 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 anti seize paste should be used as recommended by Rotax Loctite 76764 See the Rotax manual for Loctite instructions If any minor damage occurs to the exhaust it may be repaired If new components are required contact an Airborne dealer Inspect the general condition of the muffler for corrosion and holes that may be present Ensure that it is correctly secured withal safety and tie wires installed Check the ceramic coating of the exhaust and replace if it is degraded 79 OIL 79 00 00 General The 912 UL engine has an external sump and the entire system is standard to the Rotax 912 engine The oil specification is given in the Rotax Operators Manual Section 10 2 3 Lubricants In general use only synthetic or semi synthetic oil API classification
31. instrument panel When the master switch is on pushing the start button will energise the starter system The starter system is Rotax standard and the Rotax documentation should be used for the maintenance of the system 95 SPECIAL PURPOSE EQUIPMENT 95 10 00 BRS Parachute System If a parachute is fitted to this aircraft a parachute manual will be supplied as a part of the data package The owner must read the manual and the manufacturers instructions followed for the maintenance and use of the parachute The maintenance of the parachute system shall be recorded in the aircraft s log book The BRS system has a single handle that is located just forwards of central on the seat frame The handle is slightly aft of the choke lever to the pilots left Maintenance The maintenance of the system is limited to ensuring that the attachment point is secure and that the cable to the BRS rocket and parachute is free from abrasion and kinking Also check for any other damage The maintenance schedule for the BRS parachute is given in the manual that is supplied with the system and should be followed to ensure reliable operation of the parachute Issue 2 0 May 2007 Page 120 AirBorne WindSports Pty Ltd XT 912 Maintenance Manual 95 10 10 BRS Parachute System Installation This manual section is intended as a guide for installation of the BRS ballistic parachute on the XT 912 trike base The installation details contained should be used
32. is necessary to check with local regulations to ensure installation is permitted The information documented in this report is deemed adequate for a reasonably skilled person to install the BRS parachute system However if you are unsure of some aspect of the installation or fitment process please contact AirBorne WindSports or your nearest Airborne dealer 4 e E re A cv Ec i s a w Figure 80 Ballistic Parachute Installation XT 912 Issue 2 0 May 2007 Page 121 AirBorne WindSports Pty Ltd XT 912 Maintenance Manual Required Data and Kit Contents Below is a list of drawings that accompany this document and provide some of the data for the fitment of the BRS parachute recovery system The installation of the rocket and deployment cables are part of the BRS documentation The list of parts below are as supplied by Airborne for the parachute installation kit DWG SHEET DWG NAME A4 5904 1 PARACHUTE SUB ASSEMBLY BRS XT 2 PARACHUTE MOUNT KIT BRS XT A4 6553 3 IRELEASE TAG SAFETY BRS KIT Table 28 Drawings List see appendix A ITEM NO DWG NAME DWG PARTNO QTY 1 PARACHUTE MOUNT BRS XT COMPONENT 5905 105724 1 2 BOLT AN4 27 a 5450 100010 1 3 WASHER AN4 5540 100042 1 4 NUT NYLOC AN4 HALF 5561 100035 2 5 HOSE BUSH 6ID x 10L 5726 106720 1 6 CABLE TIE MED 5605 101193 5 7 SPLIT RING 12MM PIP PIN 5720 100
33. maintenance is required due to abnormal flight loads such as severe turbulence or heavy landings The pilot will be responsible for identification of these extreme operating conditions and identification of the effected components Where damage is found further checks should be carried out upon areas that may also be effected Thorough checks should also be carried out after transportation of the aircraft and 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 for bending or cracking of paint which may indicate permanent deformation of the area If any permanent deformation is identified then a more rigorous inspection of the rest of the aircraft is necessary as permanent deformation indicates that extreme forces have been experienced by the aircraft 5 50 11 Checking for Deformation A straight edge may be used on the tubing to ascertain straightness For checking the overall condition of straightness a good check is the gap between the front mast and the mast brace Figure 7 Front Mast to Mast Brace Check Issue 2 0 May 2007 Page 27 AirBorne WindSports Pty Ltd XT 912 Maintenance Manual Check Clearance The dimension measured will have some variability but should be in the range of 20 to 15mm NOTE 1 The dimension should be measured with the wing off and no pilot in the
34. point is located As this point is jacked the rear of the trike will rest on one of the rear wheels and the front wheel allowing each of the rear wheels to be maintained in turn CAUTION NOT TO BE PERFORMED IF THE FUEL TANK IS FULL AS LEAKAGE WILL OCCUR FROM THE FUEL TANK BREATHER TUBES Lifting the entire base The entire base may be elevated from the ground using the main attachment point the aircraft should be elevated no more than is necessary Issue 2 0 May 2007 Page 31 AirBorne WindSports Pty Ltd XT 912 Maintenance Manual 9 TOWING AND TAXIING 9 00 00 General Moving the trike is a relatively simple operation due to its light weight and manoeuvrability Moving is easily achievable by one person If the front of the trike is lifted from the ground care should be taken to prevent the propeller from contacting the ground 9 10 00 Towing There are two alternatives for towing the trike Pulling the trike Moving the base with or without the wing is facilitated by lifting the front wheel and walking the base Pushing the trike The trike can be pushed using the base tube and using a hand on the steering pedals inside the pod for directional control The brake 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 trike should never be taxied with excessive speed Taxiing
35. propeller that is used Engine Propeller Reduction Tip Angle Tip angle Drive Ratio Reference to Reference to rear hub face drive shaft 912 UL Bolly 2 43 12 78 912 UL Bolly 2 27 9 81 912 UL Warp Drive 2 43 12 78 912 UL Warp Drive 2 27 9 81 Table 24 Propeller Pitch Setting and Gearbox Ratio The tolerance on this angles specified is 0 5 The blade angles can be set using a digital level or a spirit level protractor The gear set part number stamped on the gearbox housing corresponds to the gearbox ratio at time of manufacture Note that replacement gears are available to change the ratio within the gearbox Rotax Gear Set Part Number 2 27 996 605 2 43 887 680 Table 25 Rotax Gear Set Part Numbers Gearbox Ratio The pitch is determined during the certification of the aircraft Settings outside this specification have an unknown effect on aircraft performance and are not approved 61 10 21 Move the Propellers to the Approximate Pitch Position A part line is visible only on the Bolly Propeller it is a useful approximation of the final pitch setting Approximate the propeller pitch position for the Warp Drive propeller fine adjustment is not required at this stage Figure 66 Propeller Part Lines Issue 2 0 May 2007 Page 100 AirBorne WindSports Pty Ltd XT 912 Maintenance Manual 61 10 22 Ensure Prop Hub is Vertical Le
36. propeller to AirBorne for evaluation possible repair and or overhaul Ground Run After adjustments or maintenance and prior to flight the engine should be run up to check the propeller is functioning normally The tracking of the propeller should be checked The aircraft should be securely chocked and the engine run up to full speed Ensure the engine temperature is at the required operation temperature Check that the propeller is functioning normally with minimum vibration A correctly adjusted propeller should result in the engine being limited to 5400 RPM Issue 2 0 May 2007 Page 107 AirBorne WindSports Pty Ltd XT 912 Maintenance Manual 71 POWER PLANT 71 00 00 General This chapter provides information on the installation of the engine but not the engine itself or its accessories Information on these may be found in successive chapters 71 00 10 Engine Run Up Refer to the pilots operating handbook for run up procedures The engine should be run up to operating temperature any time that parts or fluids are replaced or if the engine has been overhauled follow the Rotax instructions in the Rotax manual 71 00 20 Engine Removal Installation Engine removal and installation is straight forward and obvious but the following procedure may assist Removal 1 Ensure that the emergency fuel shut off valve is OFF 2 Remove the propeller and mount 3 Disconnect all fluid flexible lines cap and identify 4 Disconnect
37. seat as this will alter the dimension NOTE 2 If the two tubes are closer than the recommended distance or interfere with each other this indicates significant deformation of the trike base tube and that the trike has been subjected to significant abnormal loads The base tube should be replaced and this necessitates a thorough checking of the rest of the aircraft Check Alignment The alignment of the mast brace with the top of the mast can be checked by ensuring that the two tubes slide freely over each other NOTE The sliding should be measured with the wing off and no pilot in the 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 necessarily be checked after any heavy landing because the forces are transmitted through to the wing structure Check the main structure including the base tube landing gear attachment points and engine mount Check all other components attached to the base are in place and properly secured Seat Frame If the airframe has experienced unusual loads then the seat frame should be checked thoroughly The weight of the pilot during impacts may deform the seat frame 5 50 20 Inspection after heavy turbulence Check all components attached to the base are in place and properly secured any other items that may have shifted due to in flight movement should also
38. structure of the XT has a relatively simple design There are five main components that define the overall structure of the aircraft base This does not include the landing gear which is included in chapter 32 53 10 00 Main Frame There are five main materials that are used in the structure 6061 T6 mild steel 4130 steel JIS G3445 STKM12C 2011 T6 The five main components from front to back are Fork Carrier The fork carrier attaches to the front end of the base tube to it attaches the front landing gear and the front mast 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 This is the main longitudinal structural beam to which all of the other structures are attached Mast The mast attaches to the rear of the base tube and provides the main tension member for attachment to the aircraft s wing It is constructed from 6061 T6 aluminium Engine Mount Structure The engine mount structure is attached to the rear of the base tube and to the mast It is constructed mainly from mild steel AS 1163 53 40 00 Attach Fittings 53 40 10 General The structures on the fuselage used for the attachment of wings stabilisers landing gear engine and rotor pylons and for the support of equipment within the fuselage including instrument brackets Issue 2 0 May 2007 Page 90 AirBor
39. tasks and checklists to be filled when conducting engine maintenance 5 20 05 Maintenance Task Legend Your microlight should be maintained in accordance with the following schedules When registered under LSA the following schedules are mandatory The following codes are used in these schedules 1 Oil lubricate clean and service 2 Check as directed 3 Check for insecurity cracks wear legibility and faulty operation 4 Remove inspect and replace if necessary 5 Recommend replacement or overhaul 6 Mandatory replacement 7 Refer to Rotax maintenance manual and Rotax maintenance logbook Certification required to perform Light Sport Aircraft maintenance tasks O Owner R E LSA Repairman Inspection experimental registered aircraft only R S LSA Repairman Maintenance A amp P Mechanic Certificate Airframe and or Powerplant TS Task Specific 5 20 06 Log Book When maintenance is performed always fill out the appropriate check sheet supplied in Appendix A at the rear of this maintenance manual The aircraft logbook should also be filled out when maintenance has been done When Service Bulletins have been completed both the maintenance manual and the log book should be filled out A copy of the Service Bulletin form should be sent to the factory to be stored with the aircraft QA papers A separate maintenance manual is supplied with the wing The wing maintenance log should be filed out in the wing maintenance manual a
40. the electrical system should include periodic inspection of the wiring loom for chafing and other damage throughout its entire length Pay special attention to the areas that are subject to possible wear points such as sharp corners or proximity to parts which move It should be noted that the electrical wires may be subject to wear through vibration in flight Wiring that is damaged should be replaced and if any wear points are identified then a product such as spiral wrap should be used to cover the area The advantage with the use of spiral wrap is that it allows inspection of the wires even after it is installed Issue 2 0 May 2007 Page 56 AirBorne WindSports Pty Ltd XT 912 Maintenance Manual 25 EQUIPMENT FURNISHINGS 25 00 00 General Section 5 20 00 contains general care instructions which should be referred to for washing and treating surfaces 25 10 00 Flight compartments The structural integrity of the webbing on this aircraft is critical for safe operation All of the webbing should be inspected for signs of wear fraying cuts or other mechanical damages as well as any significant UV damage that may have occurred NOTE It is preferable to store the aircraft away from direct sunlight 25 10 10 Seats The seat structure consists of a seat frame assembly which is attached to the mast block and through two steel welded lugs onto the base tube The seats themselves structurally consist of webbing which is attached to t
41. the tank thoroughly you may need to lift the front of the base for this Check the condition of the filter replace if damaged Installation is the reverse of removal Check hose and fittings use Loctite 567 on the connections between the filter and brass fitting and the two brass fittings Do not allow excess to enter the fuel line 9osom oO M Serial Numbers from 0 to 61 should use the following instructions Remove the fuel from the tank Turn the main fuel tap to the off position Remove the fuel hose from the 90 degree brass fitting that attaches to the finger filter Unscrew the brass fitting from the aluminium finger filter Remove the front two locating bolts on the fuel tank underneath at the front Remove the lower rear centre fuel tank bolt Removing these bolts temporarily allows the fuel tank to move enough so that the finger filter may get past the engine mount Unscrew the finger filter from the tank move the tank slightly to allow removal Remove any accumulated debris from the filter and flush the bottom of the tank thoroughly you may need to lift the front of the base for this Check the condition of the filter replace if damaged 10 Installation is the reverse of removal Check hose and fittings use Loctite 567 on the connections between the filter and brass fitting and the two brass fittings Do not allow excess to enter the fuel line Use Loctite 243 on the three fuel tank screws ensure that the spli
42. 00 6 Nylon Pressure 15 PSI Outback All Tyres Carlisle 8 00 6 Titan Turf Glide Pressure 15 PSI When operating on smooth surfaces increased pressure may be desirable operator experience and tyre wear pattern may be used as a guide to determine variations to the specified pressures When checking tyre pressures the opportunity should be taken to examine the tyres for wear cuts bruises slippage and other defects 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 done before the tyre becomes worn 32 70 00 Supplementary Gear The brake locking mechanism is used to stop any unwanted movement of the trike while it is on the ground This is actuated by depressing the brake and moving the latch into one of the grooves The next time that the brake is depressed the latch will disengage The latch mechanism should be lubricated with a dry lubricant periodically The disk brake model is operated only via hydraulics the same brake lever locking mechanism is employed It is not advisable to leave the aircraft for an extended period of time reliant on the hydraulics to keep the aircraft from moving Use wheel chocks on the hydraulic actuated model when leaving the aircraft unattended for a period of time Issue 2 0 May 2007 Page 79 AirBorne WindSports Pty Ltd XT 912 Maintenance Manual 3
43. 3 785 Litres 1 0 946 Litre I 28 317 Litres 1 1 8 X C 32 0 113 Newton Metres Nm 1 356 Newton Metres Nm Page 8 AirBorne WindSports Pty Ltd XT 912 Maintenance Manual CONTENTS DATA PACKA GE mm EE 2 INTRODUCTION wsccscenntectecvesssececies cebecessccccecceeeechdansceedietceantnedeneeseddpehencsedvecedsesaedunenerteseesaeeancuest s 5 MANDATORY SERVICE BULLETINS ticcceie ceccccsnccctiedcedesessectectentesvacecdceeceessdecncatoceives sssesseeceersies 7 LIST OF TABLES 1 nre SS a ha eee ea 10 BiiWeduciliq 10 0 ASSEMBLY AND TEST FLIGHT COMPONENT OVERVIEVW 13 4 5 18 5 TIME LIMITS MAINTENANCE 19 6 DIMENSIONS AND AREAS U U u u u u 29 7 LIFTING AND SHORING g seccccesecectecececssaseecsteecediececcsteeecveseencacenesteeedauencccceretscensstneendecerea cece 31 9 TOWING AND TAXIING 6 reete cuerno eranan raahaa tessa sectecerzseeseveaes 32 10 PARKING AND MOORINGQ U U 35 11 REQUIRED PLACARDS U nee u u 37 j PAzdelcm 38 23
44. 4 NAVIGATION AND PITOT STATIC 34 00 00 General This chapter provides information on those systems that provide the aircraft navigational data such as the Pitot static system airspeed indicator altimeter outside air temperature gauge and transponder 34 10 00 Flight Environment Data Pitot Static The Pitot static system for the aircraft has a single entrance at the extreme front of the pod A single 6mm ID tube travels rearward to a tee intersection From the splitter a 6mm ID tube continues to the pilots left and to the analogue 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 order to ensure that any moisture that may be in the tubes will tend to drain out of the front of the Pitot tubes The other function of the length of the tubes is to ensure that there is less possibility of kinking the tubing Interference fits are used to keep the tubing in place and some stretching may be required to get new 3mm ID tubing onto the tee intersection fitting 34 10 10 Maintenance Practices Figure 40 Dynamic Port Pitot Entry Check that the Pitot port is free from obstruction or insect nests The lines may be visually checked from the inside of the Pod for obstructions as the tubing is clear CAUTION ENSURE THAT THE PITOT SYSTEM IS NOT PAINTED OR COVERED OVER AS THE AIRSPEED INDICATORS W
45. 82 0042 Order disk brake kit part number 108469 Previous models require a more extensive replacement parts list Skill Level LSA Repairman Maintenance Begin the procedure at Removal and installation of Brake Pads step 1 6 T 8 9 10 Attach fittings to master cylinders and callipers Clean disc rotors with solvent Bolt rear disc callipers to hubs and fit discs and wheels ensure washer is between calliper and rim inner bearing Bolt master cylinder to pre drilled hole in left hand front fork vertical or mark out to drawing supplied and drill hole Route hoses through struts and along base tube to front fork and cable tie Figure 42 Attach Fittings to Callipers LH Calliper Shown 11 Install triple sleeving over the compression fitting connections The large diameter tubing goes over both the sheath and the brass compression fitting nut This is used to protect the hydraulic tube from bending at the junctions Issue 2 0 May 2007 Page 76 AirBorne WindSports Pty Ltd XT 912 Maintenance Manual Figure 43 Master Cylinder Push Triple Sleeving Over the Compression Fitting Nut 12 Fit brake lever do not tighten the hinge bolt Lock with a split pin Brake Bleed Procedure 13 Have piston adjusting bolt set as to give 0 5 to 1mm of free play on the pedal approximately 25 mm of piston rod is required to protrude out of the master cylinder housing this is important to allow fluid to re charge between stro
46. 90 Paint Repair Colour matched touch up paint is available through the Airborne Dealer network Frame components are powdercoated and the fibreglass fairings are 2 pack acrylic eurothane enamel Repair methods on small damaged areas are the same for both paint systems Repair of small chips may be performed using brush touch of acrylic paint Repair of larger areas may be performed by e Scuffing to provide key e Apply epoxy based etch primer rub back e Apply acrylic lacquer final coat Application may be by spray or brush depending on the desired finish Paint repairs may be referred to your local automotive smash repair shop Issue 2 0 May 2007 Page 46 AirBorne WindSports Pty Ltd XT 912 Maintenance Manual 20 STANDARD PRACTICES AIRFRAME 20 00 00 General This chapter provides standard torque values and safetying procedures that are to be used in all areas of the aircraft unless otherwise specified The use of these standard values and procedures will ensure the security of installation and prevent overstressing of components 20 10 00 Torquing Procedures Correct torquing of fasteners is critical if a bolt or fastener is too loose it may cause 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 during installation The torque required after the nut is fully on the shaft but not
47. 950 1 8 VELCRO LOOP 50x40 6313 106664 1 9 PARACHUTE RELEASE TAG CABLE XT 6553 106773 1 10 VELCRO HOOK 25x120 ADHESIVE 6313 106774 1 11 NUT NYLOC M 6 FULL 5604 102132 1 12 RIVET SS 3 16 5515 102205 1 13 EYEBOLT AN43b 4a 6538 100056 1 14 WASHER NYLON M6 XOD 5540 101055 2 15 BRACKET PARACHUTE HANDLE XT 6537 106624 1 16 ISKT BUTTON SCREW M6 x 16 5677 101752 1 17 PLACARD EMERGENCY PARACHUTE BRS 5900 106647 1 Table 29 Parts List from A4 5904 Sheet 2 Skills Repairman Maintenance qualifications are required for installation and maintenance works on the BRS on Light Sport aircraft In categories of registration where this is not applicable the following skills are applicable as a minimum A sound understanding of mechanical systems and good experience with the necessary tools and procedures is required as the continuing airworthiness of the aircraft relies on the competence of the person performing the maintenance Issue 2 0 May 2007 Page 122 AirBorne WindSports Pty Ltd XT 912 Maintenance Manual Installation Procedure The BRS ballistic parachute should be installed in accordance with the instructions from the BRS documentation and this document Note the installation of the BRS falls outside the scope of the certification for this aircraft refer to Pilot Operators Handbook for further details BRS Mount and Parachute Mounting The parachute canister is attached to the mounting bracket by means of large profile clamps
48. Authority NAA of the country of registration Any NAA maintenance requirement takes precedence over this manual This manual will be used in conjunction with a certified wing and therefore the operator is directed to reference the wing maintenance manual for any issues that are related to the wing component of the aircraft Skills Only people with an adequate skill level should perform maintenance on this aircraft A sound understanding of mechanical systems and good experience with the necessary tools and procedures is required as the continuing airworthiness of the aircraft relies on the competence of the person performing the maintenance Assessment and judgement of the condition of each individual component is required which necessitates a sound understanding of the purpose of each component in the system All maintenance and repairs must be carried out in accordance with good aeronautical practices Skills and authorisations specific to Special Light Sport Aircraft Maintenance tasks are rated in the categories listed below according to the applicable category of registration and skill levels required to perform those tasks Owner FAA regulations authorize SLSA aircraft owners who hold at least a sport pilot certificate to perform maintenance as outlined in 14 CFR Part 43 To perform inspections on aircraft condition functional checks and maintenance in between inspections carried out by LSA Repairman Maintenance certificate hold
49. E OF GASOLINE RESISTANT THREAD SEALANT TAPE AND SPECIAL CARE IS REQUIRED TO PREVENT ANY OF THE TAPE ENTERING THE FUEL LINE THE WRAP OF THE TAPE NEEDS TO BE IN THE SAME DIRECTION AS THE THREAD AND MUST BEGIN AWAY FROM THE START OF THE THREAD THIS PROCEDURE CAUSES THE TAPE TO ONLY BE FORCED FURTHER ONTO THE THREAD DURING INSTALLATION AND PRECLUDES ANY STRANDS FROM ENTERING THE FUEL LINE TEM NO NAME DWGPART NO PTY 1 j BracketFuel Tap XT Fwd 5447 105240 1 NOTE TAP SHOWN 2 Bracket Fuel Tap Xt Aft 5448 105241 1 IN THE ON POSITION 3 SKT CAP SCREW SS M 6 X 20 5603 105752 1 4 AN4 15 a Bolt 5450 100967 1 5 ANANUT HALF NYLOC 5561 100035 1 6 WASHER AN4 5540 100042 1 7 FUEL HEX 5672 105346 1 8 ELBOW TANK SUCTION 1 4 BSP 5528 100982 2 9 TAPE THREAD YELLOW GAS 5637 106603 1 10 Locitite 567 Thread Sealant 5637 103705 1 ASSEMBLY INSTRUCTIONS 1 APPLY THREAD TAPE TO ELBOWS APPROX 5 TURNS IN THE THREAD DIRECTION START 1 5 THREADS IN FROM THE END 2 APPLY A SMALL AMOUNT OF THREAD SEALANT 3 ALIGN ELBOW ENDS FOR HOSE ATTACHMENT UPDATE GJP FORMS WITH REV CHANGE Rev AMENDMENTS Date DART NO 105454 amp 1 BOLTCHANGEDTOSS amp ANAi8 200 48 FUEL TAP BRACKET SUB ASSEMBL Y XT 2 THREAD TAPE AND NOTE ADDED 460804 LAST ACESSED Monday 16 August 2004 Drawn By Scale Dat
50. ED POSITIONS OF THE PLACARD Handle Make sure that the valve s actuating handle is secure Flow Checks Should there be any doubts about the fuel supply to the engine i e a lack of power at any RPM range then the Safety Cut Off Valve as well as all other fuel line components should be checked to ensure that they allow the free flow of fuel At least one side of the valve should be disconnected and the valve visually inspected in both the open and closed positions When the valve is open it should be large enough that it will in no way restrict the flow of the fuel When installed the valve should be closed to starve the engine of fuel to ensure that the valve closes fully perform this test while on the ground only Stiff Operation Should the valve become stiff to operate it may be dismantled and cleaned as required however should there be any damage or wear evident it should be replaced Reinstallation The Loctite thread sealant should only be applied from approximately halfway from the end to the start of the thread again keeping it from entering the fuel line Issue 2 0 May 2007 Page 65 AirBorne WindSports Pty Ltd XT 912 Maintenance Manual Loose Operation Ensure that the Safety Valve is not too loose in its operation The valve must be firm enough that it requires a positive closing force and will not be able to vibrate to the closed position WARNING THE REINSTALLATION OF THE FUEL TAP REQUIRES THE US
51. FROM TIME TO TIME ISSUE MANDATORY SERVICE BULLETINS WHICH DETAIL ANY CHANGES TO THE MAINTENANCE MANUALS PILOT S OPERATING HANDBOOK OR ANY OTHER DETAILS THAT AIRBORNE DEEMS NECESSARY FOR OWNERS TO BE NOTIFIED OF THE WEB ADDRESS FOR SERVICE BULLETINS IS HTTP WWW AIRBORNE COM AU IT IS THE RESPONSIBILITY OF THE OPERATOR TO KEEP UP TO DATE WITH ANY ROTAX DIRECTIVES THROUGH THE ROTAX WEBSITE Issue 2 0 May 2007 Page 7 AirBorne WindSports Pty Ltd XT 912 Maintenance Manual USE OF METRIC IMPERIAL UNITS This Service Manual uses the metric unit system as the basic system of measurement Where common usage or available instrumentation refer to the Imperial system both units are quoted The following conversion factors are presented as a ready reference to the conversion factors that have been used in this manual 1 Pound Ib Pound per sq in psi Inch in Foot ft Statute mile Nautical mile NM Millibar mb Millibar mb k Imperial gallon US gallon US quart Cubic foot ft Degree Fahrenheit F Inch Pound in Ib Foot Pound ft Ib Table 4 Imperial Metric Conversions Issue 2 0 May 2007 0 4536 Kilogram kg 6 895 Kilopascal kPa 25 4 Millimetres mm 0 3048 Metre m 1 609 Kilometres km 1 852 Kilometres km 1 Hectopascal hPa 0 1 Kilopascal kPa 4 546 Litres 1
52. ILL CEASE TO FUNCTION Issue 2 0 May 2007 Page 80 AirBorne WindSports Pty Ltd XT 912 Maintenance Manual Leaks moisture and obstructions are the major problems associated with Pitot static systems Provided these problems are adequately addressed the Pitot static system is essentially maintenance free If it becomes necessary to blow through either the Pitot or the static system in order to clear blockages etc the system should be disconnected at both the instrument ends and blown out with clean dry air from that end ensure that all lines tee ed into the static system are disconnected Avoid blowing through by mouth as this will introduce moisture Never blow air through from the source end particularly with the instruments connected or they will be ruined The full cockpit model XT has a self draining Pitot system The Outback model XT has a Pitot sump and drain valve to remove water from the Pitot system Outback models require a maintenance action to check the sump for water and to drain and re seal Figure 41 Pitot Drain Valve Location 34 10 20 Testing the Pitot System The Pitot system is to be tested for leaks by applying a pressure at the Pitot head sufficient to cause the airspeed indicator to read 90 knots There shall be no indication of restrictions in the application of the pressure and no decrease in the reading when the system is sealed for at least 10 seconds Issue 2 0 May 2007 Page 81 Ai
53. ING Propeller may not be turned in reverse of the normal direction of rotation The process is finished when crankcase air can be heard being forced back to the oil tank This will be noticed as a gurgle sound coming from the oil tank with the cap removed verifying the crankcase is purged of residual oil The oil level in the oil tank should be between the two marks max min on the dip stick but must never fall below the min mark Remove the oil dipstick and clean it Return the oil dipstick to the tank NOTE Hold dipstick a few seconds in position to allow an accurate reading Pull out dipstick and check the oil level 3 1 2 Replenishing of oil quantity For normal engine operation maintain the oil level midway between the two marks CAUTION For longer flights replenish oil to max mark to warrant more oil reserve Do not overfill oil tank as an excessive oil level over the max mark will allow oil to escape via the venting Difference between max and min 0 45 I 0 95 lig ptsL If engine is equipped with the genuine ROTAX oil dipstick part no 956151 Check compliance with Service Bulletin SB 912 040 SB 914 026 Introduction of a new oil dipstick current issue to verify your engine has the proper dipstick WARNING Non compliance with this recommendations could result in engine damage personal injury or death Restore aircraft to original operating configuration 3 2 Test run Conduct test run including ignit
54. INOL ONIN Inds 2 9 seo soss 9 1 02901 9Z zS j0ixaimHsna3asoH s z s000 i955 PNY OOTAN LAN tf 19 loves 1 E 2901 15 ON Lava ANTON TEN Sheet 2 Figure 85 Parachute Mount Assembly Drawing A4 5404 Page 132 February 2006 Issue 1 3 AirBorne WindSports Pty Ltd XT 912 Maintenance Manual TOT 133 5 558 Hsp 20 60 00 911 su T aes ag aex g umeig LIM SH8 AL134vS OVL 3S vga 39 Y3 10 031V15 55314n SYJLJATIUA H SHOASHIAIA 77 taz 18quis2a q gp 035530 1S v1 ag SIN3WON3 x ONIA 11195 TWAS HLIAA Z Nid 3Sv3 dd OLNO 3alA JO ONS H3HIO H YLLY E 8 LI1dS HLIAA Z3 ALSAVS HOVLIV Z OWL ALBIS JO MOVES OLNO Gs HOO 1 OHO I3A ANAS 1 SNOILINALSN A THI ASSSv ALD 107901 221901 799901 805601 875901 959901 ON Lad ATESWASSY OL LON WO8 ALON A1345 ASVIAISY SHE ONIS Ll 1dS 548 318 9 AL33VS OWL 353195 310HOvdvd OFxOS dOOT108H2 13A Nid did WWOL ONIS 1 5 S48 Nid 38V3 13H J LAH OYA Yd OVLAL33VS 3Sv3 13H 310HOvHYd ON WALI Figure 86 Parachute Mount Assembly Drawing A4 6553 Sheet3 Page 133 February 2006 Issue 1 3 AirBorne WindSports Pty Ltd XT 912 Maintenance Manual APPENDIX A Condition Inspection Record Aircraft Airborne Edge XT912 B Engine Ro
55. IS WOUND TO THE LEFT FOR FULLY LIGHT DAMPING SETTING Figure 35 Steering Damper Setting Dwg 5610 Issue 2 0 May 2007 Page 71 AirBorne WindSports Pty Ltd XT 912 Maintenance Manual 32 40 00 Wheels and Brakes Two alternate brake systems are available on the XT series o Front wheel drum brake only with leading lagging shoes and actuated by cable o Rear wheel disk brake only with hydraulic actuation Both configurations use a brake lock mechanism the drum brake configuration is shown in the following figure Depress brake and raise lock lever to lock Depress brake to unlock Figure 36 Brake Lock Lever Drum Brake Description The drum brakes on the XT are cable actuated leading lagging shoe type The drum brake is the same as have been in service on Airborne trikes for many years and have provided extremely reliable service The brake pads should be inspected during the 100 hourly inspection of the front wheel bearings The pads should be replaced if necessary Brake drum Internal diameter 90 0 mm Internal diameter service limit 91 0 mm Brake shoe pads Thickness of lining 4 mm Thickness service limit 2 mm Table 21 Drum Brake Wear Limits Drum Brake Adjustment and Maintenance The brake system free play depression distance until the brake actuates may be coarse adjusted by loosening the cable clamping point and moving the position of the cable The
56. July 2004 Drawn By Scale Date gt 5658 ALL DIMENSIONS MILLIMETERS UNLESS STATED OTHERWISE Cris 11 8 20 05 08 4 1 rEX T ne SHEET aft Figure 20 Seat Mast Block Sub Assembly Front wheel The front wheel axle bolts should be torqued to 27Nm on each side before the locking bolts are tightened Rear Wheels The rear wheels need to be set up in a special way because of the spat brackets Issue 2 0 May 2007 Page 47 AirBorne WindSports Pty Ltd XT 912 Maintenance Manual Procedure after Shipping The inside two nuts and bolts are preset at the factory The outer bolt and bracket should tighten sufficiently and at the same time be near to parallel to the ground for the correct spat installation Do not over tighten and make sure that the wheel is fully seated on the inside If not then the full procedure should be followed Full 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 Deg to the ground higher end at the rear Make sure that the split washer is included 2 Tighten the inside bolt be careful not to over tighten to protect the bearings Make sure that there is at least one full thread pitch showing 3 Tighten the locking bolt Make sure that there is at least one full thread pitch showing Figure 22 Inside Nut and Inner Spat Bracket
57. Maintenance Manual Type 912 Series Edition 0 of 1998 09 01 72 00 30 Radiator If it is necessary to replace the radiator hoses it is important that the replacement hoses are identical to that supplied with the aircraft The engine coolant is circulated rapidly through the cooling system and the fitting of hoses other than those supplied can increase flow resistance leading to excessive coolant temperatures Refer to the Rotax Maintenance Manual for detailed radiator maintenance and specific fluids and replacement specifications Issue 2 0 May 2007 Page 111 AirBorne WindSports Pty Ltd XT 912 Maintenance Manual 73 ENGINE FUEL SYSTEMS 73 00 00 General The XT fuel system consists of one fuel tank centrally located underneath and to the rear of the passenger seat of the aircraft There is one fuel supply line that runs from the left rear of the fuel tank and through to the mechanical fuel pump of the engine All of the components for the engine are standard as per the Rotax manuals which should be consulted for maintenance information 73 20 00 Controlling The control of the throttle and choke systems for the engine are cable actuated by the pilot The throttle is situated on the right hand side of the aircraft and has a double system that is actuated 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 T
58. Mark out and cut hole in console as per Dwg A4 5756 2 Mark and drill holes for mounting of the Lynx Radio Interface unit 3 Mount the Intercom Interface Unit if used on the side of the console prior to fitting the radio 4 Connect the power supply leads of the Lynx Radio Interface and Radio in parallel use the male spade connectors make the joint 5 Slide heat shrink over the power supply lead and connect to the Radio and Lynx power supply leads Cover with heat shrink 6 Run power lead and aerial cable along the base bar and cable tie in place Leave a generous loop of slack at the bottom of the mast to facilitate mast folding The cables route around the back of the mast pivot axle Terminate the electrical cable at the Starting Solenoid and replace Nut on Solenoid with the slender M6 nut supplied nut has 2mm of the hex section removed to make a slender self locking nut 7 Run Aerial Lead through slot in Mast Block and cable tie in place Cable tie the remainder of the aerial cable to the rear of the mast 8 Remove the king post top plate 9 Install aerial into the new king post top plate install the assembly on the king post 10 Connect the aerial cable to the aerial 11 Install the LYNX PTT SWITCH BAR MOUNT a common position is by hook and loop fastener onto the control bar 12 Check wiring installation and switch power on 13 Test the transmit and receive functionality using a second radio 14 Store the following
59. Nuts Shear Type Nuts Nm Thread Min Max Max 8 36 1 4 1 7 9 10 32 2 3 2 8 15 1 4 28 5 6 7 9 40 5 16 24 11 3 15 8 85 3 8 24 18 1 21 5 110 7 16 20 50 8 56 5 300 1 2 20 54 2 78 410 9 16 18 90 4 113 600 5 8 18 124 3 146 9 780 3 4 16 259 9 282 5 1500 COARSE THREAD SERIES Tension Type Nuts Nm Thread Min Max Max 8 32 1 4 1 7 9 10 24 2 3 2 8 15 1 4 20 4 5 5 6 30 5 16 18 9 10 2 55 3 8 16 18 14 20 9 110 7 16 14 26 6 28 8 155 1 2 13 45 2 54 2 290 Table 18 Torque Table NOTE Castellated nuts requiring cotter pins should be tightened initially to the lower value Torque can then be increased up to the maximum limit in order to install the cotter pin A thick or thin washer may be added under the nut as required in order to maintain within tolerances Issue 2 0 May 2007 Page 49 AirBorne WindSports Pty Ltd XT 912 Maintenance Manual 20 20 00 Safetying Procedures All bolts and nuts except the self locking type should be safetied after installation This prevents them from loosening in flight due to vibration Lock Wiring Lock wiring is the most positive and satisfactory method of safetying nuts bolt heads and turnbuckle barrels that cannot be safetied by any other practical means Two or more units are wired together in such a manner that any tendency of one to loosen is counteracted by the tightening of the wire This is especially important for trikes in flight as the propeller is located downstream of the fli
60. Park CAUTION THIS METHOD SHOULD ONLY BE USED WHEN THERE IS LITTLE OR NO WIND BE AWARE THAT WIND DIRECTION AND SPEED MAY CHANGE RAPIDLY Park the trike at 180 to the wind direction propeller towards the wind and set the brake lock on Attach the base bar to the front mast pole and secure with the shock cord same method as above except at the centre This method causes the wind to flow over the back of the wing This method is only recommended for very short periods of time and in constant and light wind conditions Figure 15 Parking Trike Tail to the Wind 10 20 00 Mooring A trike should not be left in the open in fully set up 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 handbook section 9 3 should be consulted for the correct preparation and mooring procedures for trailers and transportation 10 30 00 Long term Hangarage Long term hangarage will require the supplied air filter covers to be put in place to prevent foreign objects contaminating the air intake area Full covers for the base are advisable which are available as after market items from Airborne The Rotax manual should be consulted for long term storage practices for the engine Issue 2 0 May 2007 Page 36 AirBorne WindSports Pty Ltd XT 912 Maintenance Manual 11 REQUIRED PLACARDS 11 00 00 Genera
61. SF or SG or higher quality oils Multigrade oil is recommended These oil types are detergent types Consult the current Rotax manual for the correct grade of oil for the ambient operating temperature Refer to Rotax service instruction 51 18 1997 R5 or the latest version Oil system capacity with oil cooler is 3 5 litre 0 92 Us gal Dipstick level Difference between maximum and minimum oil levels is 0 45 Litre 0 95 liq pt 79 10 00 Storage The oil level is checked by removing the cap on the top of the oil sump and then removing the dip stick type oil level indicator The oil level should be checked prior to each flight Refer to Section 12 10 20 Engine Oil System Replenishment for instructions and replacement information 79 20 00 Distribution The distribution of the oil is standard to the 912 engine the Rotax manual should be consulted for maintenance information The oil filter that is fitted is a Rotax RB C3068 the filter should be changed at regular intervals as per the maintenance schedules section of this manual in chapter 5 79 30 00 Indicating The SkyDAT system has an oil pressure and temperature indicating system and the information is displayed on the SkyDAT Digital readout Issue 2 0 May 2007 Page 119 AirBorne WindSports Pty Ltd XT 912 Maintenance Manual 80 STARTING 80 00 00 General The electrically driven starter motor is mounted on the front left of the engine A key start is located on the
62. Velcro hook onto the inside of the soft side under the red safety tag as shown in the following two figures Safetv taq Sticky back Velcro applied to soft side Figure 93 Safety Tag Placement Ensure the release handle fits neatly between the seat frame and the soft side It should be able to be reached by both occupants Parachute release handle Figure 94 Release Handle Issue 2 0 May 2007 Page 128 AirBorne WindSports Pty Ltd XT 912 Maintenance Manual Placard Attachment Attach the BRS warning placard on the inside of the pod as shown in figure 82 Figure 95 Placard Placement For XT Outback the Figure 96 Placard Placement Placards are listed from top to bottom Parachute placard Step Placard Limitations Placard Issue 1 3 February 2006 placards are located on the base keel beam as shown in figure 83 Page 129 AirBorne WindSports Pty Ltd XT 912 Maintenance Manual Final Inspection 1 Ensure mount bracket and internal tube is tight 2 Ensure canister clamps are tight 3 Ensure rocket is clamped up tight unable to rotate and facing downwards aim to clear the RHS spat 4 Check routing of release cable close to the side of the trike and ensure there are no kinks or sharp bends 5 Check angle and placement of release handle The handle can be rotated ensure it is within reach of both occupants 6 Release handle safety attached pin in pl
63. ace 7 Placard attached to pod as shown Issue 1 3 February 2006 Page 130 LAE E LE ZL AT31vIATXOSddv 913 51 4 5 JI NYH 3Sv3 3d SNIGCTTONI LHOI2AA NAKOHS Sv 1108 H LIAA 6595 335 JAHL NO 380 1 TvNH3INI LNNOW 310HO va vd ONS SIHL Ld AirBorne WindSports Pty Ltd XT 912 Maintenance Manual Q7 Q Odd XOJ NI doN3dadad adv 5501 dN 343H NANOHS S1Hvd FDes v Odd XO NI GIANNI FCSSDL ON Lad 213 3sv3l3d 1319038 S3ilSINv2 SSdNTONI 0501 S88 LHONOYSIW 31nHOvavd Lad ndr ri 24 zz gl su 3586 M43 410 034V45 SS31H n S33 130110 H S amp O0 S63ALQ 065 ces uneg l toog 1 quusosq gp Mepsiny q35532v 15 PEW ROSAOKEY S 1 Z I33HS 03007 14 1 A 18A 3ssv ans 31nHO vevd 21601 ON Ld Vd m SINJWON3 W 39NvH2 33 HLIAASW3O4 dro 31v dr AINO S3SOdufnd OILVINHOS JjH3H NAROHS LON 30149 31nHovdvd 3Sv3138 5907723 AlaWassv ans 139023 D OLJ 318 2 t elio soos EME O vi 1 102901 sczs 701 xamseuHsna3soH el 5 0001 1955 JIvH PNY OOTAN LAN zi z zezo 7098 TINS SW IOTAN LAN i 8 020 forss WE XPLSS H3HSVM e Feno ss OLE DS z zazor 2295 M3HOS NOLINA DIS 1098 NV CG 055901 2159 SH8 div 19 31nHOvivd g 955901 ecsa 3dA 1 A dH2S gxwuwwz H3NIBvHyO S 159901 8159 1xsHa8aldiHg83inHO
64. ach for the drag link rear strut and suspension member Figure 54 Front Landing Gear Attachment Figure 55 Front Fork to Wheel Attachment Figure 56 Rear Landing Gear and Engine 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 engine mount attachment to the mast block can be seen in section 53 30 00 landing gear above NOTE There are special torques associated with the mast block and section 20 10 00 Torquing Procedures should be consulted 53 40 60 Support of equipment within the Fuselage 1 Seat Attachment The seats are attached to the mast block and to the base tube of the trike At the mast block they are clamped and on the base tube the seats are bolted to a bracket which is welded to the base tube 2 Instrument Brackets Issue 2 0 May 2007 Page 92 AirBorne WindSports Pty Ltd XT 912 Maintenance Manual All of the instruments are attached to the aircraft via the fibreglass instrument panel which is attached to the pod fairing area This panel is attached to the frame using brackets and Nyloc bolts to hold it in place 53 40 70 Pod Attachment The pod is attached to the structure using bolts and brackets and is located on the front mast pole These attachment points are shown in the photos below Figure 57 Pod Front Attachme
65. aks Leave the park brake engaged over a period nominal 10 minute With the brake lever lock engaged depress the brake all the way to the stop Note any change in resistance from prior tests due to oil leakage Figure 46 Inspect All Junctions for Oil Leakage 28 Re adjustment of the piston may be required to maintain the specified free play clearance from the brake lever Brake Run In Period 29 For initial braking taxi around on safe open area exaggerating brake usage you may find that brakes do not work to full efficiency until they bed in Bearing Inspection and Replacement The bearings may be inspected by removing the rear removing the rear wheel and rotating the inner race with a finger Feel for smooth operation Replacement is performed by misaligning the internal spacer and using a drift to drive the opposite bearing out Support the rim using wood or similar to protect the rim during the procedure Replace bearings by evenly driving the outer race with a drift Removal of the front wheel The front wheel should be elevated and the axle nuts removed care should be taken to note the sequence of removal and subsequent reassembly The front brake mounting bolt and cable attachment may also need to be removed to release the wheel Issue 2 0 May 2007 Page 78 AirBorne WindSports Pty Ltd XT 912 Maintenance Manual Tyres Front Tyre Kenda 4 4 X 4 8 8 Nylon Pressure 15 PSI Rear Tyres Deestone 15 X 6
66. annot be overstressed The condition of the air filter should be checked as per the maintenance schedule and if extreme operating conditions are experienced they should be checked more frequently Also check the condition of the air filter after any extended hangarage 12 20 60 Air Filter Service Instructions These service instructions apply to K amp N air filters 1 Tap the element to dislodge any large embedded dirt then gently brush with a soft bristle brush 2 Spray K amp N air filter cleaner liberally onto the entire element and let soak for 10 minutes Issue 2 0 May 2007 Page 43 AirBorne WindSports Pty Ltd XT 912 Maintenance Manual CAUTION DO NOT USE PETROL STEAM DETERGENTS OR OTHER CLEANING SOLUTIONS OR SOLVENTS ANY OF THESE PRODUCTS CAN CAUSE HARM TO THE COTTON FILTER OR SHRINKAGE OR HARDENING OF THE RUBBER END CAPS 3 Rinse off the element with low pressure water Tap water is OK Always flush from the clean side to the dirty side This removes the dirt and does not drive it into the filter 4 Shake off all excess water and let the element dry naturally CAUTION DO NOT USE COMPRESSED AIR AN OPEN FLAME OR OTHER HEAT SOURCES COMPRESSED AIR WILL CREATE HOLES IN THE ELEMENT WHILE EXCESS HEAT WILL CAUSE THE COTTON FILTER TO SHRINK Apply K amp N air filter oil to the filter after it is dry Apply the oil along the top and bottom of each pleat Wait 20 minutes and re oil any white spots still showi
67. ask to be performed on the maintenance schedule The minimum qualification required to perform that task is prescribed A simple explanation of maintenance privileges permitted according to LSA category of registration is described in the table below Experimental LSA Special LSA Sport Owner LS M Owner LS Pilot Sport A amp P Sport A amp P Pilot part 145 Pilot part 145 repair repair Modifications Daily Inspections Preventative Maintenance Repairs Major Maintenance 100 hour inspection Annual Inspection Authorized to perform May perform only if the Repairman Inspector is the owner of the aircraft May perform only if the modification is included in the aircrafts Maintenance Manual or if the repairman is authorized to do so by the manufacturer May perform if the Repairman Inspector is the owner of the aircraft and not using the aircraft for compensation training or towing or When using your aircraft as an Experimental aircraft for compensation training or towing until January 31 2010 the inspection must be performed by an LS M A amp P or part 145 repair facility Not authorized to perform Table 9 Maintenance Privileges Note that owners and pilots are permitted to perform preventative maintenance tasks as prescribed by FAR document Part 43 Appendix A Sec A43 1 Issue 2 0 May 2007 Page 21
68. ation instructions The documentation contains factory recommended procedures and instructions The procedures described are to be used in conjunction with the National Airworthiness Authority NAA of the country of registration Skills FAA licensed repair shops or Repairman Maintenance qualifications are required for installation and maintenance works on the transponder on Special Light Sport aircraft Authorized AirBorne distributors have training to perform this installation Where permitted by the local Aviation Authority the installation may be performed by suitably competent owners In categories of registration where this is not applicable the following skills are applicable as a minimum A sound understanding of mechanical systems and good experience with the necessary tools and procedures is required as the continuing airworthiness of the aircraft relies on the competence of the person performing the maintenance Calibration Calibration of the installation and installation inspection is required to be performed by an avionics service centre licensed by the local Aviation Authority This must be performed prior to operation Issue 2 0 May 2007 Page 82 AirBorne WindSports Pty Ltd XT 912 Maintenance Manual Installation Procedure 1 Install the transponder in the console below the dash the picture below shows a Becker transponder mounted above an XCOM VHF radio by using the template supplied by the manufacture
69. ay 2007 Page 108 AirBorne WindSports Pty Ltd XT 912 Maintenance Manual Figure 75 Top Rubber Link To Gearbox 71 40 00 Attach Fittings The engine set up is standard as per Rotax specifications however there are some simply attached fittings that are extra or necessary The SkyDAT data collection The SkyDAT box is mounted to the top tie rod using a small mounting plate sticky back Velcro and two zip ties Radiator The radiator is attached to the engine mount assembly via four rubber mounts These rubber mounts should be checked for any wear of the rubber and replaced as necessary Oil Radiator The oil radiator is attached to the rear of the engine mount with two bolts Oil Sump The oil sump bracket has two bolts attaching it to the engine mount Coolant Overflow The coolant overflow 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 engine s system including the start system and the SkyDAT wiring loom The wiring loom is easy to find and access The harness should be checked for security and ensure no wear points The electrical schematic can be found in the POH AOI section 7 14 1 71 70 00 Engine Drains In addition to the fuel tank draincock and the oil sump drain plug there are two engine drains The oil sump has a drain which is routed to the rear of the engine
70. be checked on a regular basis Turbulence is more likely to structurally effect the wing of the aircraft rather than the base The Wing Maintenance manual should be consulted for instructions that pertain to the wing Issue 2 0 May 2007 Page 28 AirBorne WindSports Pty Ltd XT 912 Maintenance Manual 6 DIMENSIONS AND AREAS 6 00 00 General This section gives general dimensions for the base of the aircraft Imperial and Metric 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 wheels would rest on level ground 6 10 00 Major Dimensions of the 912 Rev AMENDMENTS Date PART NO 105485 XT 912 TRIKE BASE LAST ACESSED Wednesday 25 August 2004 Drawn By Scale Date G 5703A 08 07 04 AirB EET 1 oft ALL DIMENSIONS IN MILLIMETERS UNLESS STATED OTHERWISE Simon 1 40 ARP E tar SHI Figure 8 Major Dimensions of the XT 912 Issue 2 0 May 2007 Page 29 AirBorne WindSports Pty Ltd XT 912 Maintenance Manual 6 20 00 Significant Dimensions and Areas General Overall Length full cockpit XT level attitude Nose Cone to Edge of Rotax Propeller Mou nt XT OutBack front of wheel to rear propeller Overall Width Edges of Rear Spats Height Without Wing Ground to Main Bolt Centre Undercarria
71. borne recommend that only people with an adequate skill level should perform maintenance on this aircraft as described at the start of this section Other Categories of Registration This aircraft is certified as a Primary Category aircraft and when supplied with this manual and Special Light Sport placards is a Light Sport eligible aircraft This manual is created to be compliant to the standards applicable to Special Light Sport Aircraft Skill levels required to perform tasks are applicable to Special Light Sport registered aircraft The category of registration may be quite varied as such the maintenance requirements of this aircraft are to be applied in conjunction with the requirements of the National Airworthiness Authority NAA of the country of registration Any NAA maintenance requirement takes precedence over this manual In some countries the owner is permitted to perform maintenance on their own aircraft 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 Airborne Dealer should be contacted for the correct procedures and or servicing Tooling There are no specialised tools except for the air shocks needed for the maintenance described in this manual following is a list of the type of tools that may be required NB Loctite will be required in certain locations and should always be replaced after disas
72. calibrated by a qualified avionics shop Until you do the transponder must be marked with an INOP label and may not be turned on in flight Inspection A thorough inspection of the installation and functionality of instruments is to be performed after completion and before flight Issue 2 0 May 2007 Page 88 o Check the installation compared to the plumbing schematic Check that the transponder and altitude encoder are both secured o Ensure that all wires are secured and free from chafing hazards such as sharp edges and long free unsecured lengths Check that the power supply leads are well insulated protected from weather and from chafing AirBorne WindSports Pty Ltd XT 912 Maintenance Manual o Check that fuses installed to power the transponder are of the correct capacity Operation of the Avionics Use the main avionics switch to operate the Skydat prior to start up this is required to watch the oil pressure rise on starting Switch on the transceiver and transponder after start up and switch both off shut down to protect them from voltage fluctuations Other Instruments Other instruments that need to be tested such as the air speed indicator and the altimeter should be calibrated against an independent instrument or sent to a service agent for checking and calibration Issue 2 0 May 2007 Page 89 AirBorne WindSports Pty Ltd XT 912 Maintenance Manual 53 FUSELAGE 53 00 00 General The fuselage
73. cause them to come loose Issue 2 0 May 2007 Page 94 AirBorne WindSports Pty Ltd XT 912 Maintenance Manual 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 windshield becomes damaged it should be replaced Contact an Airborne distributor Issue 2 0 May 2007 Page 95 AirBorne WindSports Pty Ltd XT 912 Maintenance Manual 61 PROPELLERS 61 00 00 General The XT propeller is a carbon fibre composite three bladed propeller Two alternate propeller hub assemblies are available on the aircraft Bolly Blade Description BOS 3 68 X 58 SL 3B Hub Engine Type BOS 3 to suit Rotax 912 True Propeller size 66 1676mm Warp Drive Blade Description Warp Drive 68 INCH 3 blades Hub Engine Type HPL R 914 Pattern True Propeller size 67 7 1720mm Other standard components described in this manual refer to Hub Block Base Hub Block Top Associated bolts washers nyloc nuts and washer plate The Propeller is supplied with a product information package that should be read in addition to these instructions WARNING IF THE ENGINE IS TO BE ROTATED AT ANY TIME IT SHOULD ONLY BE ROTATED IN THE SAME SENSE DIRECTION AS IT RUNS ROTATING THE ENGINE AGAINST THE WAY THAT IT RUNS MAY INTRODUCE AIR INTO THE OIL SUPPLY AND CAUSE DAMAGE TO THE ENGINE 61 10 00 Propeller
74. charged 914 engine has been increased from 1000 hours to 1200 hours These TBO increases are effective immediately and apply to both new engines and existing engines subject to compliance with applicable service bulletins Please refer to Service Bulletins SB 912 041 SB 914 027 and SB 912 041UL SB 914 027UL for complete compliance information Reference _http www rotec com whatnew htm Table 14 Requirements for Rotax 912 Time Between Overhaul 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 below See Rotax Maintenance Manual Section 05 10 00 Operating Hours Related Checks Time Limit for Coolant and Oil See Rotax Maintenance Manual Section 05 20 00 Operating Hours Related Checks See section 12 10 30 for Coolant details and section 12 10 20 for Oil details NOTE There are Special Instructions when using Avgas Consult the Rotax Service Information 18 UL 97 D E Issue 2 0 May 2007 Page 26 AirBorne WindSports Pty Ltd XT 912 Maintenance Manual Special Instructions Fatigue The fatigue life calculations given in Section 4 Airworthiness Limitations give life estimates for the masts attachments to the wing and base tube structure of 953 hours Service announcements may increase the fatigue life as the service history of the airframe evolves 50 00 00 Unscheduled Maintenance Checks Unscheduled
75. condition If the battery is to be replaced a similar sealed lead acid battery may be used please recycle old batteries 12 20 30 Airframe Lubrication This section identifies areas deemed necessary for lubrication and the appropriate frequency of lubrication Most of the pivots on the trike are open bush type pivots On initial assembly the following joints are assembled with a coating of petroleum jelly for ease of disassembly for maintenance or repair fork pivot bolt front and rear wheel axels front suspension hinge bolt mast hinge bolt and brake cable Each of the wheels on the trike has fully sealed bearings in place that should not require user service as they have been lubricated and sealed by the manufacturer If no lubrication interval is specified for a component lubricate as required and when assembled or installed General Lubrication Notes e All lubrication points should be serviced when overhauled e Dry lubricant should be used on the brake latch e Throttle cable and choke cables should be lubricated with a light machine oil every 100 hrs 12 20 40 Cable Lubrication The throttle and choke cables have been lubricated with light machine oil on initial assembly The Brake Cable is lubricated with Vaseline on initial assembly 12 20 50 Air Filter Dust and dirt that make their way into the engine are probably the greatest cause of premature engine wear The value of maintaining the air filter in good condition c
76. design and construction unlike wood metal and many other composite props is to progressively increase strength from tip to root As such a solid tip strike is not likely to destroy the hub or root of the blade leading to a catastrophic failure damage is far more likely at the tip as tip speed is much higher but less critical at the tip as it has less forces acting upon it compared to the root hub As all forces are focused on the root and hub sections these areas are not to be damaged If any doubt exists as to the airworthiness of a propeller have it properly assessed prior to flight 61 20 40 Surface Scratches The inner 250mm of the prop should not be damaged any further than minor nicks and scratches This is because it carries the most forces This area is harder to damage than further out on the radius because the speeds are lower As a guide there should be no more than three scratches of 0 1mm deep and 25 of the chord in this area of a blade From 250mm out from the hub to the tip of the propeller the depth allowance is slightly greater at 0 15mm and extending a maximum of 2596 of the chord Slightly more damage is allowable toward the tip There should not be a concentration of scratches in one area 61 20 50 Leading Edge Damage Maximum allowed leading edge dent in the carbon fibre portion of the propeller is 3mm within 250mm of the root to 8mm at the tip The depth of the dents allowable varies linearly from 250mm to 840mm
77. documents in the Aircraft Maintenance manual MANUAL LYNX RADIO POWER amp GUARANTEE 106746 MANUAL MICROAIR M760 amp WARRANTY 106747 Issue 2 0 May 2007 Page 54 AirBorne WindSports Pty Ltd XT 912 Maintenance Manual NAME _ MATERIAL DESCRIPTION MATLNOTREQD 1 5756 CONSOLE X XT WITH MICRO AIR CUTOUT CONSOLE INST F GLASS X XT MEASURE VERTICAL POSITION LE CENTRE FROM EDGE OF HO OF RIPPLE FINISH 23 3 Le T 2 USE 57MM HOLE SAW f E 3 TO FORM CENTRE HOLE M 1 4 FF USE RADIO FACE PLATE L 04 THAU P No 104630 A4 5133 ALIGNED ON CENTRE HOLE AS TEMPLATE TO DRILL 4MM HOLES Rev AMENDMENTS Dae PART NO 106239 CONSOLE X XT WITH MICRO AIR CUTOUT LAST ACESSED Sunday 19 December 2004 DrawiBy Scale Dae ALL DIMENSIONS IN MILLIMETERS UNLESS STATED OTHERWISE MOLLO 125 051703 A 1 rHorne is Figure 28 Radio Mounting Position Issue 2 0 May 2007 Page 55 AirBorne WindSports Pty Ltd XT 912 Maintenance Manual 24 ELECTRICAL POWER 24 00 00 General The 912 trike base has a 12V electrical system essentially comprising of a 12V battery the Rotax alternator and accessories A detailed description and schematic are available in the pilots handbook section 7 13 The Rotax manual should be consulted for the maintenance of the engines electrical system Rotax 912 UL 24 10 00 Maintenance The maintenance of
78. e of substitutes or other lubricants may cause malfunction or excessive wear 12 10 00 Replenishing 12 10 10 Fuel System Replenishment Fuel Specification The XT has a single fuel tank capacity 70 L NOTE On manufacture the fuel tank has 64 Litre capacity and is known to expand within the first month of use to the specified 70 Litre capacity take note of this fact when planning flight times When the tank is being filled there may be a slight pressure differential between the sides of the tank causing the fuel cap side to fill slightly faster than the other side Allow time for the breather valves to equalise the pressure to allow complete filing and check that both sides are sufficiently full Fill to the neck of the fuel entrance EIER Fuel Type zie MN s Super grade gasoline lead free min Optional Fuel Type AVGAS see note Table 174 Fuel Specifications NOTE Due to higher lead content in AVGAS the wear of the valve seats and deposits in the combustion chamber will increase Therefore use AVGAS only if you encounter problems with vapour lock or if the other fuel types are not available Special instructions and service intervals are specified when using AVGAS If AVGAS is used the Rotax web site should be referenced for maintenance requirements See Rotax service information 18 UL 97 D E which outlines special instructions regarding the oil system when using AVGAS Fuel Sampling Draining There is
79. e or boil before the max permissible cylinder head temperature is reached Rotax Service Bulletin SB 912 043 pg 1 Earlier Airborne trikes have had a silicate free type high quality and long life antifreeze coolant which is red Airborne Part Number 106644 installed in the radiator This coolant must be changed to the newly recommended coolant The directive requires that the new coolant be used and a sticker be placed on the coolant cap which prohibits the use of water in the coolant system Issue 2 0 May 2007 Page 41 AirBorne WindSports Pty Ltd XT 912 Maintenance Manual Older model XT 912 Trikes with the red coolant may have a 0 9 bar radiator cap If this is the case a 1 2 bar radiator cap should be installed when the coolant is replaced with the required Evans Coolant The coolant should be replaced according to the Rotax maintenance manual current issue Please refer to the directive which is available from the Rotax website SB 912 043 September 04 WARNING WATER OR WATER CONTAINING COOLANT MUST NOT BE ADDED IN ANY CASE TO THE COOLING SYSTEM WITH THE EVANS NPG COOLANT If the coolant needs to be replaced for any reason it is recommended that the Rotax manual is read as well as the their service instructions 4 Appendix 41 Sticker The illustrations is document show the ty constructio ey maynotrepresentfull detail or th ep E sanda r specific detail refer Figure 18 Coolant Warning Sticke
80. e p Borie 5669 ALL DIMENSIONS IN MILLIMETERS UNLESS STATED OTHERWISE Cris 11 220503 L 1 1r PNE ANNA SHEETI of 1 Figure 31 Fuel Tap Bracket Sub Assembly 28 40 00 Indicating The main fuel level indication method is a 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 calibrated for use while the trike is level on the ground Zero fuel level is indicated when the fuel is at the bottom of the sight gauge Issue 2 0 May 2007 Page 66 AirBorne WindSports Pty Ltd XT 912 Maintenance Manual 31 INDICATING RECORDING SYSTEMS 31 00 00 General This chapter provides a pictorial coverage of the instruments the instrument panel and all controls mounted on it The instrumentation of the base includes the AMPtronics GX2 Flight instrument and an additional air speed indicator calibrated in knots Figure 32 SkyDAT Console Photo WARNING IT IS PROHIBITED TO FLY THIS AIRCRAFT WITH THE AMPTRONIC SKYDAT GX2 ALARM THRESHOLDS SET OUTSIDE THE ENGINE MANUFACTURER S LIMITS Features of the Instrumentation Standard ASI mph knots or kilometres ALT Altimeter in feet or meters RPM engine revolutions per minute VSI vertical speed indicator in m s or ft min Flight duration 1 in hours minutes Battery Voltage 4 seconds Engine Hours 5 in hours minutes 2x CHT c
81. e the inners correctly connected to the respective engine linkage and be rotationally free so that the linkage 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 Rectify the problems as required If the cable is damaged or kinked in any way it should be replaced Care must be taken during installation not to kink the replacement cable and to ensure that the routing is correct and will not cause damage or kinking in service NOTE The throttle cables that are supplied on the XT912 are not user serviceable though they can be maintained They are constructed in a special way which allows each of the cables to be actuated independently If the throttle cable needs to be replaced and entire throttle cable assembly should be used It is difficult to adequately clean the sliding surfaces of an old Bowden cable It is usually easier to replace them than to attempt maintenance After maintenance is necessary to carefully check the operation of the cables and to ensure that they are correctly secured to the appropriate linkages Check that the control can be easily operated through its full range of operation CAUTION AFTER THROTTLE CABLES HAVE BEEN ADJUSTED OR REPLACED THE CARBURETTOR SYSTEM WILL NEED TO BE RE SYNCHRONISED AS PER THE ROTAX METHOD Issue 2 0 May 2007 Page 114 AirBorne WindSports Pty
82. e the prop exits the hub e Inspect the bolts replace if any wear or damage is present Issue 2 0 May 2007 Page 96 AirBorne WindSports Pty Ltd XT 912 Maintenance Manual 61 20 00 Propeller Assembly Procedure NOTE The following section shows photographs of assembly of the Bolly Propeller Assembly of the Warp drive propeller requires the same procedure unless otherwise specified Assemble the propeller components on a flat soft and clean surface such as a carpet Before installing a propeller the propeller shaft and threads should be checked for damage Boss and hub flange faces should be checked for cleanliness to ensure that maximum friction will be obtained Refer to drawing number 7424 Bolly Prop and 7439 Warp Drive Prop in the Illustrated parts catalogue The angular position of the propeller on the hub is not important as the pitch will be set later Important 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 Check Material List Part Bolly Warp Drive Tie Wire 1 Length as supplied Washer Plate 1 1 Hub Blocks Forward and Aft Blades 3 3 ANA 20A Bolts 6 12 AN4 Nyloc Nuts 6 12 AN4 Washers Thin 6 24 AN4 Washers Thick 6 0 8 X 75 Drilled 6 6 M8 Washers 6 6 Table 23 Parts List 61 20 20 Assemble Forward Hub Block The forward hub block
83. eliable operation of the engine The fuel filter should be removed and checked for debris every 100 hours The filter should be removed and cleaned at any time debris is seen during the preflight inspection If any debris is present the filter may be flushed using fuel to remove the debris If there is any damage to the filter or there are debris lodged in it then it must be replaced to avoid damage to the engine If debris is present the rest of the system should be investigated to ascertain their source Issue 2 0 May 2007 Page 63 AirBorne WindSports Pty Ltd XT 912 Maintenance Manual Fuel Meter CAUTION THE FUEL METERING DEVICE IS DIRECTIONAL THE FUEL FLOW IS GIVEN BY THE ARROW ON THE SIDE OF THE METER NOTE Fuel Flow Arrow which points Downwards in this case Figure 32 Fuel Flow Sender Device The electric fuel meter supplies usage information to the digital readout in the pod The fuel meter has two scales of fuel flow reading capability and if removed or renewed the correct settings must be used for the meter to read correctly This system is able to supply consumption rates and total usage information if the computer is reset after refilling the tank For remaining 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 Pilots Handbook Fuel Meter Maintenance Check
84. er a minimum skill level continues to apply to tasks Only people with an adequate skill level should perform maintenance on this aircraft A sound understanding of mechanical systems and good experience with the necessary tools and procedures is required as the continuing airworthiness of the aircraft relies on the competence of the person performing the maintenance Assessment and judgement of the condition of each individual component is required which necessitates a sound understanding of the purpose of each component 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 Airborne Dealer should be contacted for the correct procedures and or servicing All maintenance and repairs must be carried out in accordance with good aeronautical practices 5 20 02 Description of Task Classification Preventative Maintenance The preventative maintenance that is permissible to be performed by pilot certificate holders is defined in FAR document Part 43 Appendix A Sec A43 1 Line Maintenance Includes inspections servicing of fluids Tasks where specific instructions are described in the manual that do not require specialized training for replacement repair of parts and structure or alterations described in the manual Includes compliance with service directives that prescribe repairmen as the minimum qual
85. ering is 56747 and the instruction supplied with the product should be followed Testing the Fuel Tank The fuel tank has been pressure tested at the factory during manufacture if any suspected leaks are to be tested the tank should be tested to 10 35 kPa 1 50 psi All fuel should be 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 for the pressure test as this may damage the tank 28 10 10 Venting The tank is protected from negative pressures by both the breather valves and the Fuel Cap which allows air in if the pressure is lower inside the tank than out The tank is protected from positive pressure build up by the breather tubes that are present at the top of both the right and left hand sides of the tank at the top 28 10 20 Draining and Checking There is a draincock on the base of the fuel tank at the left hand side which may be used to check the quality of the fuel and to drain fuel if necessary See section 12 10 10 28 20 00 Distribution The fuel supply is taken from the base of the left hand side and is protected from large contaminants by a finger filter The fuel is drawn by the Rotax fuel pump system The Rotax manual should be consulted for maintenance and operating procedures for the fuel pump system Issue 2 0 May 2007 Page 60 AirBorne WindSports Pty Ltd XT 912
86. ers LSA Repairman Maintenance This certification authorizes a certificate holder to perform line maintenance repairs and alterations to S LSA as the task allows Includes 100 hourly and yearly inspections on S LSA A amp P Mechanic Certificate with Airframe and or Powerplant rating To perform heavy Maintenance on airframes or powerplant as the rating allows Task Specific Applicable to the following ratings LSA Repairman Maintenance with appropriate task specific training or A Mechanic Certificate with appropriate task specific training Authorizes the holder of mechanic certificate or a repairman certificate who has received task specific training to perform the tasks approved under that training Allows a repairman certificate holder to perform heavy maintenance repairs and alterations on the SLSA E g The Mechanic Certificate holder may obtain Task Specific training on Rotax engines to allow overhaul etc Issue 2 0 May 2007 Page 5 AirBorne WindSports Pty Ltd XT 912 Maintenance Manual Skills and authorisations specific to Experimental Special Light Sport Aircraft LSA Repairman Inspection To perform line maintenance and inspections to be completed on an E LSA by a responsible owner who holds an FAA repairman certificate light sport aircraft with an inspection rating or equivalent There are no requirements for minimum certification to perform any other task on an experimental aircraft However Air
87. f Warp Drive propeller and pitch setting measurement methodology Minor changes to formatting are made throughout AMENDMENT RECORD SHEET Amendment Affected s Date Sections Affected Pages Date Inserted Signature Table 2 Amendment Record Sheet NOTE Airbornes data packages will be revised from time to time Owners registered on AirBorne s database will be notified of any changes to data and directed to the AirBorne website lt http www airborne com au gt for the applicable pages The amended pages should be printed and the prior page replaced 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 Issue 2 0 May 2007 Page 3 AirBorne WindSports Pty Ltd XT 912 Maintenance Manual LOG OF ALL EFFECTIVE PAGES Page Issue Date Page Issue Date All of issue 2 0 May2007 Table 3 Log Of All Effective Pages Issue 2 0 May 2007 Page 4 AirBorne WindSports Pty Ltd XT 912 Maintenance Manual INTRODUCTION This manual contains factory recommended procedures and instructions for ground handling servicing and maintaining the XT 912 Base section of this aircraft The procedures described are to be used in conjunction with the National Airworthiness
88. fing agent inside the tubing the exterior is protected with powder coat paint Where steel components are removed or inspected the opportunity should be taken to inspect the interior use a high quality rust proofing agent and apply after inspection has been completed If the aircraft is operated in coastal areas and or has had exposure to corrosive environments rust proofing is especially necessary Issue 2 0 May 2007 Page 52 AirBorne WindSports Pty Ltd XT 912 Maintenance Manual 23 COMMUNICATIONS 23 00 00 General All maintenance and servicing of communications avionics equipment fitted to the XT 912 should be carried out by approved agents of the avionics manufacturer Fitment of additional approved instrumentation as listed in this manual may be performed by appropriately qualified maintenance personnel according to the procedures outlined in this manual The intercom and radio system schematic are shown in the electrical schematic section 7 13 in the pilots handbook 23 10 00 Fuses The fuses for the electrical equipment 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 radio are protected at the rear of the aircraft with inline fuses which terminate at the right hand side of the mast block A 5A fuse is to be used for the radio and intercom power supply The fuse holder
89. g the brake fluid Do not remove the fine mesh from the bottom of this reservoir plug Issue 2 0 May 2007 Page 74 AirBorne WindSports Pty Ltd XT 912 Maintenance Manual 7 Figure 40 Remove Reservoir Plug 2 Using a syringe fill reservoir with auto transmission fluid Visually sight the level to be approximately 10mm from top of housing and replace plug A clean matchstick may be a useful dipstick Figure 41 Brake Fluid Top Up 3 Replace the reservoir plug Replace the grit cover cap filling into the reservoir plug to make future access and cleaning easy Issue 2 0 May 2007 Page 75 AirBorne WindSports Pty Ltd XT 912 Maintenance Manual Removal and Installation of Brake Pads Skill Level LSA Repairman Maintenance 1 Lift the rear of the aircraft by one of the means described in Section 6 LIFTING AND SHORING Remove the rear wheel spat wheel nut and wheel Remove the disk from the callipers Remove the pad by pushing it to the centre of the callipers and slide it out Replace pads and reverse the procedure for refitting the wheel Note that wheel nuts are tightened to position the spat bracket Then tighten the inner nut and axle rotation lock screw The axle nuts are designed to be tightened If the brake pads are being replaced replace them as a set of four Installation of a Disk Brake Kit Disk brakes are readily fitted to XT aircraft with serial numbers XT912 0180 XT5
90. ge Track Wheel Centres Undercarriage Base Axle to Axle Prop Centreline Height Ground to Centre of Prop Ground Line to the Engine Mount Mast Block Assembly intersection Edge of Rotax Propeller mount to Engine Mount Mast Block Assembly interse ction 2740 mm 2730 mm 1880 mm 2525 mm 1685 mm 1935 mm 1165 mm 1160 mm 0730 mm Table 15 General Aircraft Dimensions NOTE There may be some differences in these dimensions due to suspension sagging and tyre pressures as well as the particular way the pod and fittings are mounted Issue 2 0 May 2007 Page 30 AirBorne WindSports Pty Ltd XT 912 Maintenance Manual 7T LIFTING AND SHORING 7 00 00 General The base may be lifted using the main attachment point for the wing or alternatively parts of the base may be lifted for local maintenance such as changing tyres There are specific areas that have been designated for these purposes 7 10 00 Jacking Front wheel The front wheel is lifted by hand using the gap between the front wheel and the fibreglass pod This is located underneath and at the front The base s balance point 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 ground using the jacking point located underneath at the rear of the base tube where the welded tie down
91. ght 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 locations of tie wires which need to be checked regularly the engine scheduled maintenance table details the time interval for checks TIE WIRE INSTALLED Oil Pressure Relief Valve Bolt Head Compression Strut Assem to Seat Mast Block LHS Compression Strut Assem to Seat Mast Block RHS Seat Mast Block to Engine Mount LHS 2 off t Mast Block to Engine Mount RHS 2 off Engine Mount Tie Rod to Seat Block Engine Mount Angle Cap Screws LHS Engine Mount Angle Cap Screws RHS Oil Tank Side Clamp Oil Tank Drain Plug Oil Tank Top Clamp Engine Sump Banjo Bolt Exhaust Springs Propeller Bolts x 6 Table 19 Excerpt from GJP 141 Complete List of Tie Wire locations Figure 24 Tie Wires on Propeller Figure 25 Rear Wheels Self Locking Nuts The two photographs above give examples of safetying devices There are special instructions in the propeller section for tie wiring Issue 2 0 May 2007 Page 50 AirBorne WindSports Pty Ltd XT 912 Maintenance Manual WARNING IT IS UNSAFE TO OPERATE THE SPAT EQUIPPED AIRCRAFT WITHOUT THE SPATS INSTALLED THIS IS BECAUSE THE SPAT ATTACHMENT TO THE WHEEL NUT STOPS IT FROM ROTATING AND BECOMING LOOSE DURING OPERATION THE NUT ON THE SHAFT HAS A SPRING WASHER BUT NO NYLOC OR OTHER SAFETYING DEVICE
92. gs Under seat bag rhs Under seat bag Ihs Figure 3 Under Seat Bags Mast Block Area Inertia reel retractors mast padding not shown Mast seat block Over centre lever Seat frame top corner Figure 4 Mast Block Area Issue 2 0 May 2007 Page 16 AirBorne WindSports Pty Ltd XT 912 Maintenance Manual Steering and Foot Levers Foot brake lever Brake park latch Front foot steering pedal Draft stop Dual steering linkage Rear steering pedal Figure 5 Steering and Foot Levers Power Plant _ 4 2 eye Air filter rhs i Carburettor heater rhs Propeller Fuel tank Oil cooler Muffler Water radiator Figure 6 Power Plant Issue 2 0 May 2007 Page 17 AirBorne WindSports Pty Ltd XT 912 Maintenance Manual 4 AIRWORTHINESS LIMITATIONS 4 00 00 General This section sets forth each mandatory replacement time structural inspection interval and related structural inspection procedure required for type certification 4 10 00 Log of Effective pages Airworthiness Limitations 4 20 00 Airframe Limitations Component Life hours Requirement Heart Bolt 100 Mandatory 1 off Replacement Drwg 5564 Front Suspension 500 Remove Inspect and Pivot Bolts 2 off replace if necessary Rear Suspension Drwg 559085787 Pivot bolts 4 off Masts and Base 953 Check Service Tube Bul
93. h Metre Pound Metre Pound Pound 8 ft lb 95 in Ib 13 Nm 9 5 ft lb 115 in Ib 10 ft lb 120 in Ib 20 Nm 15 ft lb 175 in lb Table 26 Propeller Torque Settings 61 10 40 Gap Between Hub Halves It will be noted that when the hub is bolted together there is a gap between the halves of nearly 1mm This is quite deliberate and will vary slightly as the blade grips are not perfectly circular generally 0 6mm higher than wide This eccentricity will at times cause a slight mismatch on the outside of the hub walls The advantage of this gap is that at 13Nm torque settings the gap will not close The hub in effect becomes a spring washer further enhancing mounting assurance At 13Nm there is a good balance between engine and grip bolt torque settings Issue 2 0 May 2007 Page 103 AirBorne WindSports Pty Ltd XT 912 Maintenance Manual 61 10 50 Tie Wire Installation Once the torquing has been completed recheck the pitch of the propellers before moving onto the final tie wire stage Tie wire is supplied as a part Use a tie wire tool to install The bolts are secured in pairs Match a length of the tie wire as shown spin it leaving approx 20mm at the end to join onto the other bolt in the pair Attention should be paid to the length so that there is minimum slack between the two Figure 71 Tie Wiring Step 1 The second step is to thread the last 20mm through the next bolt spin it and trim the excess Leave at least te
94. he mixer also has two cables from it to the carburettors The throttle system has two cables that are both attached to a hand lever on the left hand side of the seat frame Carburettor actuation is set up opposite to the standard Rotax sense this modification is made with no changes to the parts as Rotax provides provision for this alternative set up Care should be taken to replicate the changes if any carburettor replacements or overhauls are made 73 30 00 Indicating There is a supplementary fuel flow rate sensor that is in line with the fuel supply line An electrical fuel flow sensor supplies information to the SkyDAT data box mounted on the Tie Rod for the engine The digital display at the front of the aircraft displays the fuel consumption rate for the pilot The total usage information is also available if the counter is correctly reset after the fuel tank is filled The remaining fuel indication should be used in addition to the physical tank graduations that are visible on the pilot s right of the fuel tank Issue 2 0 May 2007 Page 112 AirBorne WindSports Pty Ltd XT 912 Maintenance Manual 74 IGNITION 74 00 00 General The power supply of the engine after starting is self sufficient within the engine No external power supply is require for the engine to operate The engine generates excess power with the integrated generator this powers systems which are external to the engine The Rotax maintenance manual should be co
95. he seat frame The padding and other areas 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 checked for wear and correct operation In particular the stitching webbing and all attachments Any worn or damaged belts or fittings should be replaced this includes belts that have been subject to extreme loads during a heavy landing It should be noted that in order to inspect the seatbelts they need to be pulled out as far as possible from their reels Check the shoulder harness inertia reel for corrosion moisture and debris Check that the belt retracts readily and locks when pulled suddenly Check the lap belt connector for proper operation engagement and release Airborne should be contacted for spare parts 25 10 30 Safety webbing The top of the mast has safety webbing for the unlikely event of failure of the main mast bolt 25 10 40 Operation of Seatbelts The Pilot s Operating Handbook should be consulted for correct usage instructions for the seat belts Issue 2 0 May 2007 Page 57 AirBorne WindSports Pty Ltd XT 912 Maintenance Manual 27 FLIGHT CONTROLS 27 00 00 General For information on the flight controls system refer to the relevant wing maintenance manual 27 10 00 Engine Controls The engine is controlled through cable actuated throttle levers which may be actuated
96. i ed ce d Clean rmt oer UTE ere sed iat aede edet 42 Figure 19 Areas be Protected During Cleaning r 44 Figure 20 Seat Mast Block Sub 47 Figure 21 Outside Nut with spat bracket 48 Figure 22 Inside Nut and Inner Spat Bracket 48 Figure 23 View of Locking Bolt head eene nnne 48 Figure 24 Tie Wires on Propeller nr 50 Figure 25 Rear Wheels Self Locking Nuts nar 50 Issue 2 0 May 2007 Page 10 AirBorne WindSports Pty Ltd XT 912 Maintenance Manual Figure 26 Muffler Safety Wire and Springs 51 Figure 27 Mast Top Safetying 51 Figure 28 Radio Mounting Position ssssssssessssseeeeneneeeennemeemennne nennen nnns 55 Figure 29 Fuel Line Check Example nas 63 Figure 30 Fuel Sender and tools enne erret 65 Figure 31 Fuel Tap Bracket Sub Assembly ar 66 Figure 32 SkyDAT Console Photo ns sssssnssssssssssssssa 67 Figure 33 Rear Shock Dimension Check rss 70 Figure 34 Front Shock Set Up ice ren eene ti o rid i e e dee saei er eee 71 Figure 35 Steering Damper Setti
97. ia fittings The fittings are manufactured from 2011 aluminium and AS 1163 steel welded and bolted to the struts and drag link Front The front suspension steering and braking assembly is manufactured from welded AS 1163 steel It is a regular fork type assembly with welded lugs and bushes for all attached parts The fork carrier assembly has two bearings pressed into it for attachment onto the main frame The XT Outback rubber cushion suspension on the front fork requires inspection of the rubber for cuts cracks The bearing surface and pivot bolt require inspection for wear f it is appropriate to reinstall parts clean and lubricate them prior to reassembly Check nylon washers for wear replace as required Damage Both the front and rear undercarriage allow for minor damage that does not result in dimensional changes of the materials permanent deformation Tell tale signs of permanent deformation include chipped paint around highly stressed areas and crazing of the alloy members Any permanent deformation warrants full checking of all possible effected parts 32 10 20 Air Shocks The life of the shocks should exceed that of the aircraft due to the minimal amount of travel they will do on the ground though they still need to be checked regularly for correct operation If one of the shocks has lost air then they will sag a different amount on the ground relative to each other Issue 2 0 May 2007 Page 69 AirBorne WindSports Pt
98. ificate with A amp P rating or a part 145 repair station may perform maintenance and inspections on the LSA The 100 hourly or annual inspections on a S LSA are to be performed by the holder of a LSA Repairman Maintenance certificate an appropriately rated Mechanic with Airframe and Powerplant A amp P rating or a part 145 Repair Station The holder of a sport pilot certificate may perform preventative maintenance on an aircraft owned or operated by that pilot and issued a special airworthiness certificate in the light sport category Items of preventative maintenance that may be performed by an owner are listed in FAR 43 appendix A Section A43 1 c Issue 2 0 May 2007 Page 23 AirBorne WindSports Pty Ltd XT 912 Maintenance Manual 5 20 04 Rotax Engine Periodic Inspections and Maintenance Rotax periodic inspections are scheduled according to 50 100 200 and 600 hour inspection cycles 100 hr Inspections occur at 100hr 300hr 500hr 700hr 900hr 1100hr 200 hr Inspections occur at 200hr 400hr 800hr 1000hr 600 hr Inspection occurs at 600hr For convenience the AirBorne XT base periodic maintenance has been brought into line with the above Rotax schedule New and overhauled engines require an inspection at 25 hours Rotax recommend inspections at 50 hours but state that this is not essential For engines operating on AVGAS 50 hour oil changes are required Refer to Rotax maintenance manual and Rotax maintenance logbook for the
99. ification to perform the task Heavy Maintenance Tasks that require a repairman rating with specialized training or mechanic with A amp P rating such as major engine work repair of landing gear assemblies It also includes alterations to structure where instructions are provided in the manual such as fitment of an undercarriage kit or a tow kit Issue 2 0 May 2007 Page 22 AirBorne WindSports Pty Ltd XT 912 Maintenance Manual 5 20 03 Qualification Descriptions Certification Required to Perform Light Sport Aircraft Maintenance Tasks O Owner ltems that can be expected to be completed by a responsible owner who holds a pilot certificate but who has not received any specific authorized training R E LSA Repairman Inspection Applicable to E LSA registration Repairman Inspection ltems that can be expected to be completed on an ELSA by a responsible owner who holds an FAA repairman certificate light sport aircraft with an inspection rating or equivalent R S LSA Repairman Maintenance Applicable to S LSA registration Repairman Maintenance ltems that can be expected to be completed on a S LSA or E LSA by a responsible individual who holds a FAA repairman certificate light sport aircraft with a maintenance rating or equivalent A amp P Mechanic Certificate with Airframe and or Powerplant Training A amp P lItems that can be expected to be completed by a responsible individual who holds a mechanic certifica
100. in conjunction with the equipment manufacturer s installation instructions Extreme hazard exists from mishandling the rocket system read the original manufacturers manual and understand the hazards before beginning work on the BRS system Fitment may be considered heavy maintenance The documentation contains factory recommended procedures and instructions The procedures described are to be used in conjunction with the National Airworthiness Authority NAA of the country of registration All parts that are not supplied with the ballistic parachute from BRS or already installed on the aircraft should be included with the Airborne parachute mount kit Airborne part numbers vary according to category of registration e PARACHUTE MOUNT KIT BRS XT LSA part number 108068 e PARACHUTE MOUNT KIT BRS XT PRIMARY part number 106374 Depending on the state of the trike when delivered some additional equipment may be required for the fitment If the bracket which holds the parachute handle is not already attached to the trike the seat frame will need to be drilled and the bracket bolted and riveted in place rivet supplied The BRS ballistic parachute is not supplied with the aircraft by AirBorne WindSports for some countries This is due to the deployment rocket being classified as a dangerous good which incurs various shipment penalties Hence Airborne supplies a kit to allow the distributor or owner to complete the BRS installation Note it
101. ing procedure 1 Obtain a flathead screwdriver with an approx 2mm head 2 Note the colour of the wires for each position Write these down and preferably mark the left and right hand side EGT wires to make it easy to replace them 3 Use the small screwdriver to push into the hole above each wire connection do not force This releases the wire and allows each to be removed individually Figure 78 Photo of Screwdriver in Place to Remove Wire 4 Remove both sets of wires and place the Faulty wires into the side which has been receiving a signal 5 Now if there is still no signal then the EGT sender needs to be replaced 6 A further check may be made of the resistance of the sender Use a multimeter to measure the resistance of the sender An open circuit clearly shows that the thermocouple circuit is broken and will need to be replaced Typical values for the resistance of wire are RHS Sender Approximately 1 8 Ohms LHS Sender Approximately 3 Ohms 7 Order the EGT sender note that there is a left and right hand side as they are different lengths Spare Part 106220 SENDER ASM GENERIC XT 912 Figure 79 Spare parts numbers for the XT912 EGT Sender 8 Release the wires from the sender that is to be replaced note the wire routing which is used Undo the EGT 9 Replace the EGT make sure that the copper washer is in place no sealant is required The approximate torque for the EGT is 22Nm Take
102. ion and oil coolant leak checks 3 3 Summary These instructions section 3 have to be conducted in compliance with section 1 5 Approval of translation to best knowledge and judgment in any case the original text in the German language and the metric units Sl system are authoritative APRIL2003 SI 27 1997R1 Copyright ROTAX page 3 of 4 Figure 16 Rotax Oil Replenishment Service Release Issue 2 0 May 2007 Page 40 AirBorne WindSports Pty Ltd XT 912 Maintenance Manual 4 Appendix the following drawings should provide additional information 05489 The illustrations in this document show the typical construction They may not represent full detail or the exact shape of the parts which have the same or similar function Exploded views are not technical drawings and are for reference only For specific detail refer to the current documents of the respective engine type APRIL2003 SI 27 1997R1 Copyright ROTAX page 4 of 4 Figure 17 Rotax Oil Replenishment Service Release 12 10 30 Coolant Replenishment Coolant Specification A MANDATORY Rotax Directive was issued on the 25 of November 2004 which requires a change in the type of coolant that must be used with the Rotax 912 type engine From the 23 Feb 2005 the new coolant Evans NPG waterless coolant is to be used The reason for the change is In some instances conventional coolant mixture ratio of 50 water and 50 antifreeze can vaporiz
103. is a part of the training necessary for flying this aircraft if a maintenance engineer without trike flying experience is working on the trike they should push the trike and not taxi it as the control sense may be different to what they are accustomed to 9 30 00 Ground Transportation The base may be transported overland on a suitable trailer usually custom built for the purpose During transport the trike base should be firmly held at both the front and the rear to prevent movement Tie down straps should be used with a ratchet system so preload can be applied this allows the tyres to be compressed slightly so as to firmly hold the base in place during transport Issue 2 0 May 2007 Page 32 AirBorne WindSports Pty Ltd XT 912 Maintenance Manual Rear The rear of the trike base may be secured from the tie down hook at the centre rear on the engine mount section NY 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 downs are installed correctly so the brake assembly is not interfered with Ensure that the park brake is applied Figure 10 Front wheel with tie downs 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 Issue 2 0 May 2007 Page 33 AirBorne WindSports Pty Ltd XT 912 Maintenance Manual
104. is compliant with the Light Sport Aircraft standard Skill levels required to perform tasks are applicable to the levels of qualification issued under the Light Sport Aircraft System The information in this manual is based on the data that was available at the time of its publication The latest amendments to this manual will be issued on the Airborne website in PDF format This should be printed out and added to the manual Therefore it is important that operators keep a regular check on the website for any amendments that have been made If any errors or omissions are found in this manual please advise the factory WARNING THE INFORMATION IN THIS MANUAL NEEDS TO BE FOLLOWED AND IT IS NOT ACCEPTABLE TO MAKE CHANGES TO THE MATERIALS AND OR PHYSICAL FEATURES OF THIS AIRCRAFT IN PARTICULAR THE GRADES OF BOLTS THAT HAVE BEEN UTILISED IN THE MANUFACTURE OF THIS AIRCRAFT ARE CRITICAL FOR ITS CONTINUING AIRWORTHINESS NEVER REPLACE BOLTS WITH ANY OTHER SIZE OR GRADE GRADE 8 BOLTS ARE NOT INTERCHANGEABLE WITH AIRCRAFT AN GRADE BOLTS THE FATIGUE CHARACTERISTICS OF AIRCRAFT GRADE BOLTS ARE SUPERIOR TO OTHER BOLTS AND ALLOW LONGER SAFE SERVICE LIFE UNDER CYCLIC LOADS LIKE THOSE EXPERIENCED IN AIRCRAFT THE LENGTH OF BOLT IS IMPORTANT IF A SHORTER BOLT IS USED THE THREAD MAY ENCROACH ON THE LOAD BEARING AREA WHICH INCREASES THE STRESSES EXPERIENCED BY IT MANDATORY SERVICE BULLETINS AS THE SERVICE HISTORY OF THE AIRFRAME EVOLVES AIRBORNE WILL
105. is marked with the correct current rating for the fuse 3 The battery charging circuit is protected with a 20A fuse which also terminates at the right hand side of the mast block The fuse holder is marked with the correct current rating for the fuse 23 20 00 Radio Radio installation instructions for XCOM Microair radio including Lynx Interface for Edge XT Tools Required Phillips head screw driver Electrical terminal crimping tool Heat gun Drill Holesaw 56mm 2 2 Crescent file Drill bit 4mm Hex key 2 5mm Hex key 3mm Spanner 10mm Side cutters Eye and breathing protection are recommended for cutting of fibreglass components The dust may cause irritation to exposed skin Bill of Materials 108160 XCOM 760 VHF TRANSCEIVER 106653 WIRING LOOM RADIO XT 106282 AERIAL BRACKET KINGPOST AIRFOIL 102230 CONNECTOR YELLOW SPADE MALE 101780 LYNX RADIO INTERFACE AND POWER ADAP 101786 LYNX POWER SUPPLY LEAD 101781 LYNX PTT SWITCH BAR MOUNT 101194 CABLE TIE LONG 290MM 101192 CABLE TIE SHORT 98MM 105032 AERIAL KIT 102029 HEATSHRINK CLEAR 13 106771 NUT NYLOC M6 FULL TURNED DOWN 100911 NUT NYLOC M 4 105601 SCREW PHILIPS CSK 10GX1IN 304 Issue 2 0 May 2007 Page 53 AirBorne WindSports Pty Ltd XT 912 Maintenance Manual Skill level Light sport maintenance repairman For other categories of registration at a minimum a good understanding and practice on electrical systems is required Procedure 1
106. is the one which has the larger counter bored holes in it Bolly Prop Put the THIN AN4 washers onto the AN4 bolts 6 of each and install into the counter bored holes Warp Drive Put the AN4 washers onto the AN4 bolts 12 of each and install into the counter bored holes Figure 61 AN4 Bolts Into Forward Hub Block Issue 2 0 May 2007 Page 97 AirBorne WindSports Pty Ltd XT 912 Maintenance Manual 61 20 30 Place Blades into Forward Hub Block Place the three blades into the forward hub block it is best to align them in the general direction they will be rotating in Figure 62 Place 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 as sequenced below e Place the aft hub block onto the forward hub block and over the AN4 bolts e Add AN4 thick washers and then the AN4 nuts to each of the bolts finger tight e Align the washer plate with the aft hub block holes add the M8 X 75 drilled bolts and ONE washer per bolt Figure 63 Propeller With All the Necessary Components Issue 2 0 May 2007 Page 98 AirBorne WindSports Pty Ltd XT 912 Maintenance Manual 61 20 50 Place the pre assembled propeller onto the engines mount Carefully grip the two hub blocks together with your hands and lift from the ground to the engines propeller mount The M8 bolts will match the engine s mount pattern Mate
107. kes 14 Remove reservoir plug this is the most rearward plug on the master cylinder accessible by turning steering to the left and approach from the left under side of fairing on full faired versions 15 Using a syringe fill reservoir with auto transmission fluid This will require further top up during the brake bleed procedure every 2 bleed strokes Refer to figure 41 Replenishment of Fluid Figure 44 fill reservoir using a syringe 16 Place clear PVC hose on bleed nipples into small collection containers Figure 45 Bleed Drain Hose Connected 17 Undo RH bleed nipple a half turn 18 Push brake pedal forward and hold in place with last notch on park brake 19 Lock bleed screw 20 Let pedal return to the vertical stop position 21 Repeat several times until fluid reaches nipple top reservoir up every two to three piston stroke 22 Repeat to LH nipple until fluid appears and all visible signs of air removed Issue 2 0 May 2007 Page 77 AirBorne WindSports Pty Ltd XT 912 Maintenance Manual 23 Return to RH side until all visible air removed 24 Top fluid up within 10mm from top of housing and replace plug 25 Adjust free play in piston rod with adjusting bolt then tighten the lock nut Post Installation Brake Inspection 26 Raise each wheel one at a time Rotate each wheel by hand check that there is no substantial drag on each wheel 27 Depress brake pedal and engage park brake checking for oil le
108. l The placards that are present on this aircraft are a legal requirement showing safety information emergency information and identification of the aircraft The placards must be repaired or replaced if they become 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 placard should be checked 11 10 00 Required Placards The placards on the aircraft are designed to provide information regarding general aircraft limitations and other details for the safe operation of the aircraft The placards that are required for operation of this aircraft are available in the Pilot s Operating Handbook Section 2 Placards Issue 2 0 May 2007 Page 37 AirBorne WindSports Pty Ltd XT 912 Maintenance Manual 12 SERVICING 12 00 00 General This chapter provides servicing procedures necessary to replenish or service the aircraft and its equipment as required The operational integrity of the aircraft systems can be seriously impaired if contaminated fuel oil fluids and lubricants are used or if they do not meet the required specifications Mixtures of various brands and types of materials is undesirable and should be avoided wherever possible even though the use of such mixtures may be technically acceptable Specified lubricants will meet requirements for extreme hot or cold temperature operations Us
109. ld have all litter removed to minimise corrosion and to safeguard the propeller Apart from the consequences of heavy landing or of exceeding flight limitations the major factors requiring attention are corrosion fatigue and wear There are no known fatigue problems with Airborne microlights but excessive loads and vibration can weaken the structure Regular inspection for hair line cracks in areas under high stress such as bolt holes tube junctions etc is recommended Many components can be replaced with ease for difficult repairs or if the repair process is not fully understood consult your Airborne distributor or 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 of aircraft as per the Maintenance Schedule in this handbook b Modification as detailed in any relevant Service Bulletins c Modification to approved details obtained from Airborne WindSports Pty Ltd d Repairs necessary to replace minor damage wear or ageing e Servicing replacement and overhaul inspection and checking in compliance with the Maintenance Schedule f Any Airworthiness Directive AD issued by CASA or the NAA of the country of registration Issue 2 0 May 2007 Page 20 AirBorne WindSports Pty Ltd XT 912 Maintenance Manual 5 20 01 Maintenance Privileges This manual lists t
110. letins See note Return to service if no SB action required Trike Structure 8338 Check Service Excluding Masts and Bulletins See note Base Tube Return to service if no Structures SB action required Table 7 Airframe Limitations The airframe was analysed using FAA fatigue analysis Fatigue Evaluation Of Wing and Associated Structure on Small Airplanes FAA Report AFS 120 73 2 in order to estimate the time life limits for the major components of the airframe this is detailed in Airborne report 04 144ds The estimates that have been made do not take into account any extreme loads which will reduce the fatigue life of the airframe The fatigue life of these components is dependent upon rigid adherence to maintenance schedules The bolts that are listed are known through history of operation to be affected more through mechanical wear than through fatigue and therefore the time life for these components is less than the calculated values for the airframe As the service history of the airframe evolves these time life estimates are expected to be revised amendments should be checked for regularly Note See Airborne web site for Service Bulletins Issue 2 0 May 2007 Page 18 AirBorne WindSports Pty Ltd XT 912 Maintenance Manual 5 TIME LIMITS MAINTENANCE CHECKS 5 00 00 General The time limits and maintenance schedule provided are in addition to any regulation of the governing body where the aircraft i
111. lter 12 20 50 2 R 2 R 2 R 2 R 2 2 R 2 R Exhaust system 78 00 00 2 R 2 R 2 R 2 R 2 2 R 2 R Muffler springs and safety As directed 3 R 3 R 3 R SIR SI R 3 R Tie wires 20 20 00 3 R 3 R 3 R 3 R 3 R 3 R 3 R Exhaust Gas Temperature As directed 2 R 2 R 2 R 2 R 2 2 R 2 R Operation Cylinder head Temperature As directed 2 R 2I R 2I R 2IR 2IR 2 R 2 R Operation Engine Tachometer Operation As directed 2 R 2 R 2 R 2 R 2 2 R 2 R Engine Hour Meter Operation As directed 2 R 2 R 2 R 2 R 2 2 R 2 R Engine Oil Temperature As directed 2 R 2 R 2 R 2 R 2 2 R 2 R Operation Propeller bolt torquing 61 10 30 2 R 2 R 2 R 2 R 2 R 5 R 2 R Propeller inspection for nicks and 61 10 10 2 R 2 R 2j R 2 R 2 R 2 R 2 R abrasions see 61 20 00 if repair required Propeller removal disassembly Section 61 4 R and inspection Table 10 Power Plant Maintenance Schedule Issue 2 0 May 2007 Page 25 AirBorne WindSports Pty Ltd XT 912 Maintenance Manual 5 20 20 Trike Base Frame Maintenance Schedule TRIKE BASE FRAME Manual MAINTENANCE SCHEDULE Section AIRCRAFT OR ITEM HOURS OF OPERATION Inspection Items Reference 25 100 200 300 400 500 600 Trike base tube for bend or As directed 3 R 3 R S
112. lumbing 87 Figure 52 Amptronics GMX Case Rear View With Altimeter Static Pressure Tube Exit Hole amp 88 Figure 53 Top of Mast attached to the wing rr 91 Figure 54 Front Landing Gear Attachment ars 92 Figure 55 Front Fork to Wheel Attachment 92 Figure 56 Rear Landing Gear and Engine Mount Attachment to Mast Block 92 Figure 57 Pod Front Attachmentl nn 93 Figure 58 Pod Attachment to Mast Brace n rr 93 Figure 59 Pod Attachment to Seat Frame rara 93 Figure 60 Pod Instrument Panel Attachment 93 Figure 61 AN4 Bolts Into Forward Hub Block rr 97 Figure 62 Place Blades into Hub Block nr 98 Figure 63 Propeller With All the Necessary 98 Figure 64 Mounting the Propeller nr 99 Figure 65 Propeller AN4 Bolt Tightening Sequence Numbers 99 Figure 66 Propeller Part Lines nn nennen nnns 100 Figure 67 Shims under the front wheel na r 101 Fig
113. mount at the bottom near the oil radiator The coolant overflow goes down near the mast and exits at the base of the engine mount in the same position as the fuel tank overflow and breather tube Issue 2 0 May 2007 Page 109 AirBorne WindSports Pty Ltd XT 912 Maintenance Manual 72 ENGINE MAINTENANCE Engine Power Spark plugs should be the type recommended by the manufacturer Adjusting a carburettor is a specialised job and can have a large effect on the power developed by the engine Altitude can also affect the power available When moving to a field with a different elevation it may be necessary to retune the carburettor It is recommended that only a qualified person should tune the engine For Special Light Sport Aircraft maintenance refer this task to a Mechanic with power plant rating 72 00 00 General This aircraft is fitted with a Rotax 912 UL horizontally opposed four cylinder water cooled engine The engine is rated to 59 6 kW maximum take off power with full throttle at 5800 RPM and 58 kW maximum continuous speed of 5500 Rpm 72 00 10 Maintenance and Overhaul Other than any specific procedures specified elsewhere in this manual detailed procedures for the maintenance and overhaul of the Rotax 912 UL engine fitted to the XT 912 aircraft can be found in the following documents Rotax Operator Manual for Rotax Engine Type 912 Series Rotax Documentation CD Documentation for Rotax engines available at www ro
114. n twists of the tie wire at the end Figure 72 Tie Wiring Step 2 Issue 2 0 May 2007 Page 104 AirBorne WindSports Pty Ltd XT 912 Maintenance Manual 61 10 30 Final Checks Figure 73Correctly Installed Propeller Recheck the pitch of the propellers after they have been fully torqued Recheck visually that all components are in place Note the tie wiring WARNING CLEARANCE BETWEEN WING WIRES TUBES AND THE PROPELLER SHOULD ALWAYS BE MAINTAINED THIS SHOULD BE CHECKED IN ALL POSSIBLE CONFIGURATIONS OF PROPELLER AND WING Issue 2 0 May 2007 Page 105 AirBorne WindSports Pty Ltd XT 912 Maintenance Manual 61 20 00 Blade Damage and Repair The condition of a composite propeller is important for safe flight The pilot of the aircraft needs to check the condition of the propeller prior to each flight and ascertain its airworthiness In general deep scratches across the chord of the propeller are most significant along with leading edge dents and damage that may lead to delamination Leading edge damage is repairable as long as it is not larger than the specified sizes and that the propeller is not delaminated In general if the damage size on the surface of the propeller is not exceeded then it will be better to leave the surface alone as filling minor scratches will likely cause more damage The plys of the propeller are approximately 0 15mm thick each If any doubts exist as to the condition
115. nance Manual WARNING DO NOT USE PETROL OR ANY OTHER HIGHLY FLAMMABLE SUBSTANCES FOR WASH DOWN DO NOT ATTEMPT TO WASH AN ENGINE THAT IS STILL HOT OR RUNNING ALLOW THE ENGINE TO COOL FULLY BEFORE CLEANING PERFORM ALL CLEANING OPERATIONS IN A WELL VENTILATED WORK AREA PREFERABLY OUTSIDE AND ENSURE THAT PERSONAL PROTECTIVE CLOTHING IS WORN AND THAT FIRE FIGHTING SAFETY EQUIPMENT IS READILY AVAILABLE CAUTION PARTICULAR CARE SHOULD BE GIVEN TO ELECTRICAL EQUIPMENT BEFORE CLEANING SOLVENT SHOULD NOT BE ALLOWED TO ENTER ANY OF THE ELECTRICAL EQUIPMENT ELECTRICAL COMPONENTS SHOULD BE PROTECTED BEFORE SATURATING THE ENGINE WITH SOLVENT ANY OIL FUEL AND AIR OPENINGS ON THE ENGINE AND ACCESSORIES SHOULD BE COVERED BEFORE WASHING THE ENGINE WITH SOLVENT CAUSTIC CLEANING SOLUTIONS SHOULD BE USED CAUTIOUSLY AND SHOULD BE NEUTRALISED AFTER USE Propeller The propeller should be cleaned occasionally with water and a mild detergent to remove dirt grass and bug stains The opportunity should be taken to visually check the condition of the propeller during cleaning Upholstery and Interior The pod area should be vacuumed out to remove all loose dirt gravel etc All vinyl surfaces can be wiped with a product such as Armourall surface protectant The seat is a structural part of the airframe and care should be taken to avoid any substance that will degrade the webbing material vacuuming is recommended for the upholstery 12 20 80 Fibreglass
116. nd aircraft log book Issue 2 0 May 2007 Page 24 AirBorne WindSports Pty Ltd XT 912 Maintenance Manual 5 20 10 Power Plant Maintenance Schedule WARNING DISCONNECT SPARK PLUG LEADS FOR ALL MAINTENANCE AND INSPECTION PROCEDURES IF THE ENGINE IS ROTATED AT ANY POINT IT SHOULD ONLY BE ROTATED IN THE SAME SENSE AS IT RUNS ROTATING THE ENGINE IN THE OPPOSITE SENSE MAY INTRODUCE AIR INTO THE OIL SUPPLY AND CAUSE DAMAGE TO THE ENGINE POWER PLANT Manual AIRCRAFT OR ITEM HOURS OF OPERATION MAINTENANCE SCHEDULE Section Inspection Items Reference 25 100 200 300 400 500 600 Rotax engine maintenance 72 00 10 2 R 2 R 2 R 2 R 2 2 R 2 R Loose bolts nuts 20 10 10 2 R 2 R 2 R 2 R 2 2 R 2 R Engine rubber mounts 71 20 00 2 R 2 R 2 R 2 R 2 2 R 2 R Engine platform mounting plates 2 R 2I R 2IR 2IR 2IR 2 R 2 R Check for cracks Electrical cable harness 71 50 00 2 R 2 R 2 R 2 R 2 2 R 2 R Fuel lines cracks tight See 28 20 00 3 R S R 3 R S R 3 R 3 R 3 R 5 10 00 for time limits Fuel tank located and secure no As directed 3 S R 3 R 3 R 3 R 3 R 3 R leaks or cracks Fuel filter 28 20 00 2 R 2 R 2 R 2 R 2 2 R 2 R Throttle cable Few drops of light 12 20 40 2 R 2 R 2 R 2 R 2 2 R 2 R machine oil Air fi
117. ne WindSports Pty Ltd XT 912 Maintenance Manual 32 LANDING GEAR 32 00 00 General The XT trike base landing gear assembly consists of a tricycle type undercarriage Both the front and the rear suspension incorporate air shocks that allow pneumatic adjustment of the spring rate and fluid flow damping The XT Outback has rubber cushion suspension on the front fork Rear wheel suspension is common to all XT models 32 10 00 Undercarriage General Maintenance With the weight removed from each wheel check each of the components is not loose Also check each of the bearings tyre wear and the condition of the brake line Where excessive looseness is found the bushes and attachment points should be checked for wear and replaced if necessary In practice this will mean that any pivot point should not have more than 1 2mm of movement when load is applied The main areas that need to be checked for looseness are suspension pivots the mast pivot and the main mast pivot hole For wheel and suspension pivots the wheels should be lifted from the ground when testing the movement 32 10 10 Structure Rear The main rear undercarriage is manufactured from 6061 extruded aluminium tubing which attaches 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 These are attached to the wheels and the frame v
118. ne WindSports Pty Ltd XT 912 Maintenance Manual 53 40 20 Wings Heart Bolt Mast Brace Figure 53 Top of Mast attached to the wing The trike base is attached to the wing using an aircraft grade bolt which attaches to the wings U bracket The attachment arrangement allows the mast to move forwards backwards and sideways relative to the hinge point There is also the safety strap included for the unlikely event of the main attachment failing For instructions regarding the attachment and maintenance of the main bolt refer to the wing maintenance manual and the Pilot s Operating Handbook Aircraft Operating Instructions as applicable 53 40 30 Stabilisers The stabilisers are attached to the frame using the brackets on the inside and outside of the rear wheels These may be clearly seen in section 20 10 00 Torquing Procedures They are held in place with bolts and washers where the washers are important to prevent crushing of the composite AN4 washers on the outside and 3 16 X 7 washers on the inside The Illustrated parts catalogue should be consulted for the correct assembly sequence for the spats Issue 2 0 May 2007 Page 91 AirBorne WindSports Pty Ltd XT 912 Maintenance Manual 53 40 40 Landing Gear The landing gear is non retractable The front landing gear is attached to the main frame through two sealed bearings and bolt assembly The rear is attached through three bushed pivots one e
119. ng 12 20 70 Cleaning Windshield The windshield is made from a polycarbonate material and therefore a certain amount of care is required to keep it clean and in good condition The following procedure is recommended 1 Flush with clean water to remove excess dirt bugs and other loose particles 2 Wash with mild detergent and warm water Use a soft cloth or sponge do not rub excessively 3 Rinse thoroughly then dry with a clean moist chamois Do not use volatile solvents such as gasoline alcohol benzine or most 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 alternatively an automotive liquid detergent may be used Engine An engine and accessories wash down should be performed regularly to remove any oil grease and other residue Periodic cleaning allows proper inspection of the engine components and can be an aid to discovering defects during inspection as well as reducing the potential for an engine fire during aircraft operation The engine may be washed down using a suitable solvent then dried thoroughly During cleaning the air intakes BRS parachute and the electronics should be protected with a thin plastic film as shown in this photograph Figure 19 Areas to be Protected During Cleaning Issue 2 0 May 2007 Page 44 AirBorne WindSports Pty Ltd XT 912 Mainte
120. ng Dwg 5610 sss 71 Figure 36 Brake Lock Lever 72 Figure 37 Front Wheel Assembly nr nennen nennen nnne 73 Figure 38 Rear Disk Brake Master Cylinder Mounted on Front Fork 73 Figure 39 Cap Grit Plug Remove the Plug from the Grub Screw for Allen Key Access 74 Figure 40 Remove Reservoir Plug 75 Figure 41 Brake Fluid Top Up nsn 75 Figure 42 Attach Fittings to Callipers LH Calliper Shown 76 Figure 43 Master Cylinder Push Triple Sleeving Over the Compression Fitting Nut 77 Figure 44 fill reservoir using a syringe nr 77 Figure 45 Bleed Drain Hose Connected 77 Figure 46 Inspect All Junctions for Oil Leakage a 78 Figure 47 Section 34 Transponder Instrument Face and Mounting Detail 83 Figure 48 Section 34 Stubb Antenna Installation sesssemem 84 Figure 49 Altitude Encoder Mounting Detail 85 Figure 50 Transponder Ground Plane and Altitude Encoder Installation 86 Figure 51 Pitot Dynamic and Static Pressure P
121. nm nennen nnne enne 15 Figure 2 15 Figure Under Seat Bags nn 16 Fig re 4 Mast silere qim 16 Figure 5 Steering and Foot Levers 17 Figure 6 Power Plahl 3 nter dating ne etel aepo ce c x ede ER EIER eee an 17 Figure 7 Front Mast to Mast Brace Check r 27 Figure 8 Major Dimensions of the XT 912 29 Figure 9 Tie Down Hook Location 33 Figure 10 Front wheel with tie downs n nnne 33 Figure T1 Tie on Rear Wheel itte De SE Feo eoe XH ederet oce ERE 34 12 Trike on Trailer crede 34 Figure 13 Securing of Base Bar with Shock Cord a 35 Figure 14 Parking of Trike issena ineine nnn nnns enne 35 Figure 15 Parking Trike Tail to the Wind u enne 36 Figure 16 Rotax Oil Replenishment Service 40 Figure 17 Rotax Oil Replenishment Service 41 Figure 18 Coolant Warning Sticker instructions Excerpt from Rotax Service Bulletin SB 912 043 Sept04
122. nsulted for the maintenance of the engines electrical system section 12 60 00 of the maintenance manual 74 30 00 Switching Main Switch The main switch of the aircraft is located on the front instrument panel this is used to start the engine but not to turn it off There are two wires which make a double system that are used to earth the engine stop circuit from the engine The engine s ignition power supply is cut off stopping the engine Issue 2 0 May 2007 Page 113 AirBorne WindSports Pty Ltd XT 912 Maintenance Manual 76 ENGINE CONTROLS 76 00 00 General The fuel supply system of the trike is a cable actuated twin carburettor system 76 10 00 Power Control Power control is achieved in three ways Throttle There are two method to actuate the throttle either with the hand throttle or the foot actuated throttle Both of the cables run through a mixer which allows each to operate independently Fully forwards opens the throttle and fully aft closes the throttle Section 53 00 00 Landing Gear clearly shows a photo of the foot throttle pedal Choke There is also a separate choke control on the left hand side which faces downwards to avoid confusion of the controls 76 10 10 Inspection and Maintenance In order that the Bowden cables operate correctly they must e Not be kinked or damaged e Be adequately lubricated internally and not binding e Have the outer properly and securely clamped at both ends e Hav
123. nt Figure 58 Pod Attachment to Mast Brace 4 Figure 59 Pod Attachment to Seat Frame Figure 60 Pod Instrument Panel Attachment 53 50 00 Aerodynamic Fairings The pod and spat assemblies are the only included aerodynamic fairing on the aircraft They are constructed from fibreglass and polyester composite material and attached to the aircraft via bolts and brackets which attach to the main structure Each of the fairings should be checked regularly to ensure that the Nyloc bolts are secure and that the fibreglass where it is attached is in good condition Issue 2 0 May 2007 Page 93 AirBorne WindSports Pty Ltd XT 912 Maintenance Manual 55 STABILIZERS 55 00 00 General The stabiliser system for the XT trike consists of two fibreglass spats which are attached to the rear wheels of the trike 55 30 00 Vertical Stabilizers The vertical stabiliser spats consist of two wheel spats with fins 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 wheel nut is secure They should be checked every 25 hours as noted in the maintenance schedule as well as after any hangarage or transport to check for impact damage that may have occurred NOTE When checking the spats and other fibreglass areas ensure that they are free from cracks crushing and delamination that may
124. ocedure for the other two blades check thoroughly and then follow the sequence and torquing procedure Issue 2 0 May 2007 Page 102 AirBorne WindSports Pty Ltd XT 912 Maintenance Manual 61 10 30 Propeller Bolt Torquing ONLY after the pitch has been set and confirmed Use a calibrated torque wrench and evenly side to side tighten M8 grip bolts Evenly tighten the bolts in a sequence lt bolt 1 bolt 4 bolt 2 bolt 5 bolt 6 bolt 3 gt WARNING ALWAYS TIGHTEN THE BOLTS IN THE CORRECT SEQUENCE AND TO THE SPECIFIED TORQUE Figure 70 Propeller M8 Bolt Tightening Sequence Numbers Torque the 1 2 grip bolts in increments of approximately Newton metre 20 inch pounds up to the recommended torque The bolts should be tensioned in sequence as per figure 65 Tighten M8 bolts in increments of approximately 3 Newton metre 20 inch pounds up to the recommended torque The bolts should be tensioned in sequence as per figure 70 Return to grip bolts to check tension Ensure that 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 the final full torque check has been completed Nyloc nuts must have at least one full thread showing after they are installed PROPELLOR i M8 Engine Bolts PROPELLOR Inch Newton Foot Inc
125. or repair procedure for the propeller either return the propeller to Airborne or consult a LAME engineer or equivalent who has experience with composite materials 61 20 10 Balancing Balancing of the propeller should not be necessary if the damage allowances are adhered to repairs should only be to replace what has been removed If there is any doubt or if propeller balancing is necessary it is best done by a person who is experienced with composites and with Level 2 LAME qualifications or equivalent An epoxy compatible clear spray paint applied at the tips is best with the surface of the propeller prepared gently with 600 grade sandpaper and cleaned to remove any oil residue 61 20 20 Leading Edge Tape Your standard configuration propeller blade is supplied with a light grade of Urethane LE Protective Tape applied This will help resist the abrasive effects of dust sand amp water etc It will not stop solid objects from damaging the blade although it will help reduce 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 degrees of damage Varieties of damage such as water stones gravel amp sand makes it very difficult to specify maximum damage levels before the blade should be discarded rather than repaired For a guide see the FAA Advisory Circular AC 43 13 1B Par 8 71 through 8 109 The
126. r in the installation instructions The transponder fits into a standard 2 25 hole Use a 2 25 hole saw to make this hole BRCK PRNEL MOUNTING 4 Jmm eee B62in t8 BBB in 3 5mm B 13Bin DIR Figure 47 Section 34 Transponder Instrument Face and Mounting Detail Issue 2 0 May 2007 Page 83 AirBorne WindSports Pty Ltd XT 912 Maintenance Manual 2 Install a ground plane for the antenna Note that both of the following installations require the aerial to be mounted at the front of the aircraft to comply with minimum distance of critical body parts from the radiation source 2 1 Full pod variant Mark and drill an antenna mount hole a 1 2 hole on the bottom centreline of the pod at 190mm in front of nose wheel hole so that the antenna sticks out the bottom Use the stickey back foil ground plane Locate it around antenna hole and smooth it into the compound curves of the pod one panel at a time Push the BNC side of the antenna up through the bottom of the pod and tighten the nut BNC Buchse BNC JACK The 6 aluminum disk or ground plane goes here Flugzevghaut AIRFRAME Zahnscheibe TOOTH WASHER g gt 8 Silikonkoutschuk Dichtung or SILICON RUBBER GASKET pad Montegebohrung MOUNTING HOLE Figure 48 Section 34 Stubb Antenna Installation Issue 2 0 May 2007 Page 84 AirBorne WindSports
127. r instructions Excerpt from Rotax Service Bulletin SB 912 043 Sept 04 NOTE Rotax recommends a two year or 200 hourly replacement interval for coolant 12 10 40 Tyre Inflation The recommended tyre inflation pressures are 15 PSI for both the front and rear tyres When checking the tyre pressures the opportunity should be taken to examine the tyres for wear cuts bruises slippage and other defects Issue 2 0 May 2007 Page 42 AirBorne WindSports Pty Ltd XT 912 Maintenance Manual 12 20 00 Scheduled 12 20 10 General This section provides details necessary to carry out routine scheduled periodic maintenance on the XT airframe and is to be read in conjunction with the XT MAINTENANCE SCHEDULES Section 5 Should any conflict occur between information in this section and the XT Maintenance Schedules the latter will take precedence 12 20 20 Battery Service The battery supplied is a Genesis NP 18 12 12V 17 2AH sealed lead acid battery which requires no maintenance Earlier model XT 912 bases were supplied with a Century PS Series PS12180 12V 18AH which can be replaced by the Genesis battery if a replacement is needed CAUTION WHEN REPLACING BATTERIES USE ONLY SEALED LEAD ACID OR SEALED GEL TYPE BATTERIES TO AVOID THE ESCAPE OF CORROSIVES ONTO THE AIRCRAFT STRUCTURE The SkyDAT system gives voltage readout If the voltage drops below 12V then the battery system should be checked for correct charging and battery
128. r screws at the back and open up the instrument Issue 2 0 May 2007 Page 86 AirBorne WindSports Pty Ltd XT 912 Maintenance Manual Static pressure vented to inside the cockpit ASI ANALOG Static pressure vented to inside the cockpit s Pitot Dynamic pressure from the port at the front of the t ASI ALTITUDE DIGITAL DIGITAL Drill hole in case hole plug Static pressure vented to inside the cockpit y Amptro ics unit ALTITUDE ENCODER Figure 51 Pitot Dynamic and Static Pressure Plumbing Diagram 5 2 Inside the instrument you will see the two pressure sensors with two 1 8 diameter black nipples 5 3 One is already used and a black tube runs from it to the brass nipple on the back of the case this is the dynamic input from the Pitot tube for the ASI running from the nose of the aircraft The sensor without a thin hose connected to it is the static port of the altitude sensor Attach a 1 8 inside diameter vinyl tube to this Issue 2 0 May 2007 Page 87 AirBorne WindSports Pty Ltd XT 912 Maintenance Manual 5 4 On the back of the Skydat case is a plastic plug remove the plug and run the tube through the hole to the outside In the picture below a hole has been drilled through the plastic plug large enough to accommodate a rubber grommet and the vinyl tubing is routed through the grommet This provides a more secure installation than just running the vinyl tube thro
129. rBorne WindSports Pty Ltd XT 912 Maintenance Manual Testing the Static System CAUTION THE PITOT IS A VERY SENSITIVE INSTRUMENT AND IS EASILY DAMAGED READ THE INSTRUCTIONS CAREFULLY BEFORE CONTINUING WITH THE TEST PROCEDURE UNDERSTAND THAT THE AMOUNT OF PRESSURE NEEDED TO TEST THE PITOT IS LOW NEVER USE COMPRESSED AIR OR BLOW INTO A PITOT 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 The amount of pressure is very minimal At 46 3m s 90kts the pressure necessary is only 134mm water head or 1 34kPa 0 194PSl In a 50cc syringe this will equate to somewhere the region of 2 5mm of travel If the flexible tube is long enough the testing can be done from the cockpit while looking at the instruments alternatively a helper will be required Outside Air Temperature Gauge The air temperature reading is taken by the SkyDAT box that is located behind the passenger above the engine 34 50 Transponder The XT may be fitted with a MicroAir or Becker transponder as a factory approved option and modification Fitment may be considered heavy maintenance 34 50 10 Transponder Installation This manual section is intended as a guide for installation of a transponder on an AirBorne XT aircraft The installation details contained should be used in conjunction with the equipment manufacturer s install
130. rne form GJP 170 to be completed and returned to Airborne by an Authorised Dealer 10 12 13 15 17 20 21 22 23 24 2 Table 5 Initial Assembly Procedure GJP144 This list is meant as a guide and is in no way a comprehensive list of instructions Refer to Standard Practices Section 20 for torquing procedures and refer to Illustrated Parts Catalogue to ensure complete and safe assembly is achieved Each of the components that have been disassembled have the required nuts bolts and washers in place ready for fitment this ensures that the reassembly is as easy as possible Issue 2 0 May 2007 Page 13 AirBorne WindSports Pty Ltd XT 912 Maintenance Manual 00 10 00 General Spare Parts Service Spare parts may be purchased from your local dealer Visit the Airborne Website at http www airborne com au pages dealerselect cfm Accessed from the homepage under Microlights Dealer listing Typical Consumables 100 hour service kit Airborne part number 106907 Contents of Rotax 912 100 Hour Service Kit Airborne part number 106907 Consumable Airborne Part Number Rotax Part Number OIL SHELL ADVANCE 15W 106786 50 ENGINE 912 OIL FILTER 105620 825701 Use only Rotax brand filter SPARKPLUG NGK DCPR7E 106816 SILICONE HEAT TRANSFER 106817 897 186 PASTE WASHER 18X12X1 OIL TANK 105936 Gasket Ring C12x18 XT912 250010 Consumable Airborne Part Number External Supplier
131. s Thickness 5 2 mm Thickness service limit MIN II ZIIII 2 mm Master cylinder Master cylinder piston rod to pedal clearance 0 5 1 5mm Pedalheight fixed Working fluid Power transmission fluid Similar to factory supplied fluid Castrol TQ DEXRON III Automatic transmission fluid Fluid quantity aces 50 mL Table 22 Disk Brake Dimensions and Wear Limits Brake Maintenance Procedure Tools Callipers Allen Keys 5 32 1 4 Spanners open ring 1 4 5 16 3 8 7 16 1 2 Sockets 3 8 7 16 Pliers Cutters Screwdriver Blade Syringe eg 25ml Drill with 13 64 5 16mm bit Required for brake kit installation Disk Brake Inspection Inspect hoses and hose shielding for wear kinks Inspect complete system for oil leaks Measure brake disk thickness replace if required Measure brake pad thickness replace if required Measure the free play in the master cylinder piston rod adjust if required Replenishment of Fluid Skill Level Pilot Certificate 1 Remove reservoir plug this is the most rearward plug on the master cylinder accessible by turning steering to the left and approach from under side of fairing on full faired versions Remove the grit plug from the cap to enable the insertion of the Allen key Figure 39 Cap Grit Plug Remove the Plug from the Grub Screw for Allen Key Access A fine mesh is located below the grit plug to prevent dust from enterin
132. s being flown Some components are subject to overhaul intervals as specified by their manufacturers Table 5 10 00 gives the overhaul or replacement intervals for these components The pilot of the aircraft must ensure that the required maintenance is carried out and documented in the correct manner Extreme operating conditions may reduce the time limits for components unscheduled maintenance is detailed in Section 5 50 00 AirBorne will from time to time amend these maintenance checks as the service history of the aircraft evolves It is the responsibility of the pilot to ensure compliance with new directives information is available on the website http www airborne com au 5 10 00 Time Limits The following components are time limited and should be overhauled or replaced as indicated This table may be updated to include more components in the future as MANDATORY SERVICE BULLETINS are amended Component Life Requirement Engine As specified by Rotax www rotax Overhaul or Replace aircraft engines com Engine Accessories As Specified by Rotax Overhaul or Replace www rotax aircraft engines com Propeller As Specified by the manufacturer See Overhaul or Replace section 5 20 20 of Maintenance Manual Fuel and Oil Hoses Five Years or to be replaced during Replace engine overhaul replacement Rocket BRS As specified by BRS 5 Manual Repack parachute into 6 years return parachute cannister canister only to
133. sembly Loctite 243 567 and Antisieze Lubricant 76764 for the frame section The Rotax Maintenance Manual gives a list of consumable materials in section 2 5 Ring Open ended Imperial Spanner set Ring Open ended Metric Spanner set Torque wrench WARNING SPECIALISED PUMPS MUST BE USED FOR THE AIR SHOCKS PRESSURES UP TO 600 PSI EXIST Air Pump Schrader Style Valve Various petroleum lubricants Dry Lubricant lubricant which doesn t attract dust after application Tie wire and tooling Wire and Swages and tooling Hex key set metric and imperial Petrol resistant thread sealant tape Various general care items This list may not be comprehensive Issue 2 0 May 2007 Page 6 AirBorne WindSports Pty Ltd XT 912 Maintenance Manual Service Difficulty Reporting Any service difficulties or defects should be reported to Airborne using the form contained in appendix A WARNING REPAIRS SHOULD NOT BE CONDUCTED UPON THE FOLLOWING ITEMS AS THEIR STRUCTURAL INTEGRITY IS CRITICAL TO SAFETY THE MAST STRUCTURES HANG POINT BASE BEAM FRONT FORK ATTACHMENT ASSEMBLY LANDING GEAR STRUTS OTHER MINOR REPAIRS CAN BE CARRIED OUT IN ACCORDANCE WITH FAA AC 43 13 1B Format The manual has been prepared using the ATA format which provides a standard layout of the chapters to be included and their content Some of the chapters are not included as they are deemed to be not applicable to this aircraft The content
134. should be taken to replace the oil filter any time that the oil is replaced Use only Rotax oil filters Consult the Rotax manual and Rotax service instruction 18 UL 97 for the correct type and grade of oil for the ambient operating temperature Issue 2 0 May 2007 Page 39 AirBorne WindSports Pty Ltd XT 912 Maintenance Manual Rotax Oil Replenishment Service Release Following is a service announcement released by Rotax regarding the Oil system ROTAX AIRCRAFT ENGINES SERVICE INSTRUCTION OIL LEVEL CHECK FOR ROTAX ENGINE TYPE 912 AND 914 SERIES 51 27 1997 R1 3 1 Instructions Proceed as follows for checking the oil level replenishing of oil level WARNING Assure both ignition circuits are Off grounded before cranking the propeller Anchor the aircraft and ensure the have the is cockpit occupied by a competent person who will be in control of aircraft operation Risk of burns by hot oil and engine parts exists use appropriate safety measures Handle propeller with extreme care and secure engine against unintentional operation 3 1 1 Oil level check a check for oil leaks If leaks are evident check cause of failure and rectify before flight b check of oil quantity Level aircraft for accurate reading Prior to oil level check remove the oil tank cap and turn the propeller by hand in the direction of normal rotation to transfer all the oil from the engine crankcase to the oil tank WARN
135. t washer is also present on each OXgr iQ M Issue 2 0 May 2007 Page 61 AirBorne WindSports Pty Ltd XT 912 Maintenance Manual Figure 30 Finger Filter as installed as well as the unit prior installation NOTE In the photo the components Filter Oring e 90 degree Fitting e Fuel hose and clamp Check that each joint is free from leakage Issue 2 0 May 2007 Page 62 AirBorne WindSports Pty Ltd XT 912 Maintenance Manual Fuel Lines The sequence of the fittings is critical for correct function of the fuel system The fuel lines and components are secured using hose clamps Possible Stress Concentration at Joint Figure 29 Fuel Line Check Example Areas that should be checked with extra care are the interfaces between the hose and the motor These areas are stressed to a greater degree than the rest of the tubing and are more likely to have cracks and or wear If fuel lines need to be replaced contact Airborne for the correct specifications and or replacement components Fuel Filter CAUTION THE FUEL FILTER IS DIRECTIONAL AND HAS IN AND OUT MARKED ON IT WHICH IS VERY IMPORTANT IF THE FUEL FILTER HAS BEEN INSTALLED INCORRECTLY IT SHOULD BE CLEANED PRIOR TO REINSTALLATION OR REPLACED TO AVOID DEBRIS BEING FLUSHED INTO THE ENGINE The first item after the tank is the fuel filter correct operation and maintenance is extremely important for r
136. tachment Tube a enn 123 Figure 83 Rocket Angle 5 iere dedero ep t rai ede RR EE Ida LR Y HERR RED den RR 124 Figure 84 Bridle end Attachment nn 125 Figure 85 Schematic Bridle Attachmentl 125 Figure 86 Side View Bridle Attachmentl a 125 Figure 87 Gathered Bridle on Engine Mount Upright 126 Figure 88 Release Handle 126 Figure 89 Release Handle Exploded View ssssssseessseeeenennn e 127 Figure 90 Cable Routing u u correre eco eet tr ei anata ee sadip ee rv sr ere ena 127 Figure 91 Cable Attachment to Oil Tank 127 Figure 92 Safety Tag Assembly narrar 128 Figure 93 Safety Tag Placement nr 128 Figure 94 Release 128 Figure 95 Placard Placement ito reo eer hne Bre dn ved cn neg eas 129 Figure 96 Placard Placement 129 Issue 2 0 May 2007 Page 12 AirBorne WindSports Pty Ltd XT 912 Maintenance Manual 0 ASSEMBLY AND TEST FLIGHT COMPONENT OVERVIEW S e 3
137. tallation using a pair of cable ties around the altitude encoder and the avionics unit s Mode C altitude encoder mounted on top of the transponder Note the two adjustment screws the avionics technicians need access to Figure 49 Altitude Encoder Mounting Detail Issue 2 0 May 2007 Page 85 AirBorne WindSports Pty Ltd XT 912 Maintenance Manual Altitude encoder installation Ground plane installation Figure 50 Transponder Ground Plane and Altitude Encoder Installation 5 The installation of transceiver and transponder is shown above for the full pod variant Note the forward floor mounted location of the ground plane and antenna the location an orientation of the Pitot tubes for self draining of moisture AmeriKing Encoder is shown black box mounted on the transceiver located with self adhesive hook and loop fasteners and backed up with zip ties around the upper avionics unit transceiver and encoder 6 The calibration of the Mode C encoder installation requires access to the static pressure port inside the Amptronics GMX instrumentation and display unit This section of the instructions may be performed by the Avionics shop as a part of the calibration if desired In this stage of the installation the altitude encoder and the Skydat altimeter have static pressure which are vented into the cockpit joined together and vented into the cockpit Carefully remove the Skydat from the aircraft remove the fou
138. tax 912 UL 2 S N S N XT 912 Date Hours Maintenance Work Performed Maintained by Section or Service Bulletin Issue 1 3 February 2006 Page 134 AirBorne WindSports Pty Ltd XT 912 Maintenance Manual APPENDIX B Feedback Form Operation and Maintenance Feedback Form Please use a copy of this form to provide notification to the e manufacturer about issues or anomalies identified during the operation or maintenance of the aircraft or in the content of the manual AUSTRALIA Return to Please provide your own contact details below AirBorne WindSports Pty Ltd PO Box 7042 Redhead New South Wales 2290 Australia Fax 61 2 4944 9199 Email trikesupport airborne com au Issue Description If you have a proposal to remedy the issue please provide it here Number of pages submitted including this cover page_ Issue 1 3 February 2006 Page 135 AirBorne WindSports Pty Ltd XT 912 Maintenance Manual End of XT 912 Maintenance Manual Issue 1 3 February 2006 Page 136
139. tax aircraft engines com The supplied manuals and documentation are supplemented by Rotax Service letters and Service Bulletins as appropriate The Rotax website should be periodically reviewed for these updates Overhaul of Rotax engines should be performed by a qualified Rotax service centre For Special Light Sport Aircraft maintenance this task must be referred to a Mechanic with powerplant rating and task specific training on Rotax 912 engines Issue 2 0 May 2007 Page 110 AirBorne WindSports Pty Ltd XT 912 Maintenance Manual 72 00 20 Carburettor When checking the carburettor rubbers check for cracks There is a Rotax service announcement 1998 which points out that there is a potential issue with the rubbers Rotax Aircraft Engines MAINTENANCE MANUAL 4 7 Inspection of the Carburettor flange socket Inspection of the carburettor flange socket See fig 14 Compress carburettor socket in the area of the carburettor connection to allow easier detection of existing cracks 1 and 3 also check the area of the inner diameter 2 At suspicion of cracks renew the carburettor flange NOTE The carburettor socket is subject apart from chemical strain due to fuel and UV radiation to stress by vibration Excessive tightening of the clamp may also damage it causing cracks resulting in intake leaks fig 14 00366 Effectivity 912 Series 12 00 00 page 25 Initial issue Sept 01 98 Figure 76 Excerpt from Rotax
140. tch of the propeller set up should prevent over speeding of the engine The preset engine limits can be checked against the limits outlined in section 2 4 2 by noting the position of the larger square bars on the LCD display for the particular gauge 77 10 00 Power The SkyDAT data box collects all of the engine management data Tachometer The tachometer system is connected to the Rotax sensor the Rotax manual should be consulted for maintenance instructions 77 20 00 Temperature Cylinder Head Temperature The cylinder head temperature sensors are supplied with the engine Information for checking the sender can be found in the following section Exhaust Gas Temperature The exhaust temperature sensors are located at the exit of the two front cylinders of the engine Information for checking the sender can be found in the following section Oil Temperature The oil temperature sensor is located near the oil filter at the RHS rear of the engine The Rotax manual should be consulted for maintenance instructions Issue 2 0 May 2007 Page 116 AirBorne WindSports Pty Ltd XT 912 Maintenance Manual 77 30 00 Analysers Oil Pressure The oil pressure indicator sensor is located above the mechanical pump on the LHS at the rear of the engine The SkyDAT instrument will show open when there is an open circuit in the CHT circuit To determine if the problem is the wiring or the sender simply short circuit the sender connection
141. te with airframe or powerplant ratings or both or equivalent RS Part 145 Repair Station Items that can be expected to be completed by a responsible organization that holds a part 145 repair Station approval TS Task Specific Items that can be expected to be completed by a responsible individual who holds either a mechanic certificate or a repairman certificate and has received task specific training to perform the task When specifying the task specific level of certification the specific training is also specified where it is appropriate Note that dealers may be authorized by the manufacturer to perform a maintenance or modification task for which they are specifically trained These tasks are not necessarily included in the Maintenance Manual This Maintenance manual is created with the focus to maintain Special Light Sport Aircraft S LSA This category of registration allows the aircraft to be used for hire and reward Maintenance requirements are given in the maintenance schedule tables Note that the level of qualification is given for each of the tasks Notice that this manual prescribes owner maintenance and repairman maintenance The minimum applicable repairman ratings for each category of registration are as follows E LSA registered LSA Repairman Inspection certificate LS I S LSA registered LSA Repairman Maintenance certificate LS R In both cases of E LSA and S LSA a person who holds a mechanic cert
142. the bolts to the holes while ensuring that the propellers or bolts don t fall While still holding everything in place finger tighten the bolts in sequence see the sequencing in the Torquing section The propeller should now hold itself in place Figure 64 Mounting the Propeller 61 20 60 Nip the AN4 bolts to allow pitch adjustment CAUTION PULL THE BLADE RADIALLY OUTWARDS TO SEAT THE BLADE INTO IT S HUB BLOCK LOCATION WHILE TIGHTENING THE AN4 NUTS BOLTS THIS ENSURES UNIFORM DIAMETRICAL POSITIONING OF THE BLADES RELATIVE TO THE HUB AND EACH OTHER Tighten the AN4 nuts in sequence in order that the blades can still be easily rotated by hand but are in a positively held condition so that they may be adjusted both easily and precisely Evenly tighten the bolts nuts in a sequence bolt 1 bolt 4 bolt 2 bolt 5 bolt 6 bolt 3 Apply the torque to the nuts not the bolts Wait until after the propeller has been adjusted to fully torque either sets of bolts For the Warp Drive Propeller the inner set of bolts should be tightened as described above followed by the outer sets of bolts using the same sequence Figure 65 Propeller AN4 Bolt Tightening Sequence Numbers Issue 2 0 May 2007 Page 99 AirBorne WindSports Pty Ltd XT 912 Maintenance Manual 61 10 20 Adjusting Pitch Angle The setting for the propeller pitch angle is given in the table below according to the gearbox and
143. the fuel meter for proper rotation of the impellor and that there are no blockages or debris present A good time to do this would be during replacement of the fuel lines or filter unit If there is any debris present at any time then a full investigation of the origin as well as investigation of the fuel filter is absolutely necessary The fuel filter should have prevented any debris making its way into the meter Issue 2 0 May 2007 Page 64 AirBorne WindSports Pty Ltd XT 912 Maintenance Manual Replacement of the Fuel Sender Device If the fuel sender device is being replaced then the correct installation of the flow range jet is important Incorrect installation will cause the unit to malfunction The jet must be fully inserted in the inlet port with the smaller diameter end toward the inside Push it to the inner end with a flat ended rod and tap gently to ensure it is fully seated Included is a photograph of a flat ended rod used for installation the meter and vernier callipers the reading for a correctly seated flow range jet is 23 5mm a Figure 30 Fuel Sender and tools Fuel Safety Cut off Valve The final component prior to the engine is the fuel safety cut off valve which is used both during transportation and during any fuel or fire emergency to starve the engine of its fuel supply Maintenance CAUTION MAKE SURE THAT IF THE SAFETY VALVE IS REMOVED IT IS REINSTALLED TO COMPLY WITH THE OPEN AND CLOS
144. ugh the large hole in the back of the Skydat Plastic plug drilled out with grommet installed to secure static port tubing coming out the back of the Skydat Figure 52 Amptronics GMX Case Rear View With Altimeter Static Pressure Tube Exit Hole amp Grommet 1 5 5 The static port tube as installed in the previous step is now connected via a T junction to the altitude encoder The connected pair encoder and Skydat static port are vented together into the cockpit via an open end of the T junction This junction is used by the avionics technicians giving easy access to both the static ports in the Skydat and the Mode C encoder Install the T junction at the lowest point in the plumbing that connects the attitude encoder and the Amptronics Skydat Place the open vent to the bottom to allow any condensate to drain automatically The wiring harness will include a 25 pin plug a 15 pin plug and red black power leads The 25 pin plug goes to the transponder The 15 pin plug goes to the Mode C encoder Attach the red black leads to the positive and negative rails of the radio transceiver power supply This is accessed at a spade connector set at the bottom rear of the console Airborne factory installed radio power supplies are taken from the live side of the starter motor solenoid and have a 5A fuse fitted This completes the installation However before you can use the transponder in the US you must have it checked and
145. ure 68 Prop Hub at 89 95 Degrees after correct shimming of front wheel 101 Figure 69 Propeller Horizontal Check n nnne 102 Figure 70 Propeller M8 Bolt Tightening Sequence 103 Figure 71 Tie Wiring Step Wisc teehee ee heen tet eir tese n Fx ER peo foeda 104 Figure 72 Tie Wiring Step 2 4 ec e eer meet o at E Tee e ev Pers 104 Figure 73Correctly Installed Propeller ssssseeeennnmn e 105 Figure 74 Engine Mount Rubbers 108 Figure 75 Top Rubber Link To Gearbox rr 109 Figure 76 Excerpt from Rotax Maintenance Manual Type 912 Series Edition O of 1998 09 01111 Figure 77 Earthing of CHT Sender to Check the Wire to the SkyDAT 117 Figure 78 Photo of Screwdriver in Place to Remove Wire 118 Figure 79 Spare parts numbers for the XT912 EGT 118 Figure 80 Ballistic Parachute Installation XT 912_ 121 Figure 81 Parachute Bracket Attachment 123 Issue 2 0 May 2007 Page 11 AirBorne WindSports Pty Ltd XT 912 Maintenance Manual Figure 82 Parachute Mount At
146. vHvd F 5795901 2199 1x SHO AISWASSY 134903 31nHOvevd E L 2601 5065 LNSNOdWOO LX S88 LNNOW 31nHOvdvd c 602901 2065 0501 S88 d3lSINvO 31nHOwvavd alofon Jdvd DMO wfo Wall Figure 84 Parachute Assembly Drawing A4 5404 Sheet 1 Page 131 February 2006 Issue 1 3 AirBorne WindSports Pty Ltd XT 912 Maintenance Manual 133 5 FTI sug FDBS ag aex G umeg 1 SH8 LIA 3 LAHO Ve Yd 01 0 LdH9N3 SNOILONHLSNI AdBA3SSv H04 LN3INFIDOQ 310HOvavd 335 01 0 LHOd3H SNIH33NION3 33S W31SAS Ad3 O238 S88 JHL SNOILONYLSNI NOLINCTTvLSNI 9NILNDYOIN 310 HOvavd S49 HO4 aaurniod AAO 138 S1dHvd 39 M43 410 031715 SS31H n 533413Al lh H SHOSHIMIG 17 POO q 91 epsinu q35532v 1S1 2 901 ON Lid su SINJWON3 amp NAAOHS Sv 1109 HOW Li 6595 395 JAHL NO 38f L Tv N 3 INI INNOW 3 10H2vHvd QN3 SIH L Li r9901 poes zsarol 2299 _ 2es9 Ena 95000 BES9 90201 5199 588 ainHovaHvdA2ON3SHa3W3 QquvOvid _ LX 9W Agos NOLING bis gi 1X FIONVH 1340733 SL IA H3HSvAA fl ep dcpNv L1O83A3 L IVE SS 13AlMdOd ci TINS 8 JOTAN LAN 3AIS3HQY 021 952 MOOH OH2T2A egg9 1X 318v2 A13dvS 9vi13sv313H SINHOWvd 6 0905 dOO1ONDTAA 8 805501 l czs Nid did
147. vel the base of the trike so that the prop hub is vertical This is achieved by using shims under the front wheel to lift it until the flat surface of the rear of the prop hub is vertical Figure 67 Shims under the front wheel NOTE The ideal reading is 90 but 0 05 is acceptable for practical application Figure 68 Prop Hub at 89 95 Degrees after correct shimming of front 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 to be on the pilot s right of the engine The prop hub vertical surface is checked to be 90 to ensure the propeller is in the standard horizontal position WARNING IF THE ENGINE IS TO BE ROTATED AT ANY TIME IT SHOULD ONLY BE ROTATED IN THE SAME SENSE DIRECTION AS IT RUNS ROTATING THE ENGINE AGAINST THE WAY THAT IT RUNS MAY INTRODUCE AIR INTO THE OIL SUPPLY AND CAUSE DAMAGE TO THE ENGINE Issue 2 0 May 2007 Page 101 AirBorne WindSports Pty Ltd XT 912 Maintenance Manual 61 10 25 Set the Angle of the Propeller The angle of the propeller can now be set Place the digital level at the blade tip and adjust the pitch of the propeller to the angle as specified in table 24 To rotate the propeller blade to the desired angle apply gentle torque with one hand With the other hand move the blade tip around in a circular motion 61 10 26 Repeat for the other two blades Repeat the pr
148. y Ltd XT 912 Maintenance Manual Rear Shocks WARNING THE REAR AIR SHOCKS ARE UNDER VERY HIGH PRESSURE THEY ARE PRESET AT THE FACTORY TO 40 BAR 580 PSI WHICH WILL REQUIRE SPECIALISED EQUIPMENT TO BE REPRESSURISED IF THESE SHOCKS REQUIRE SERVICE OR PRESSURE TESTING CARE SHOULD BE TAKEN TO ENSURE THAT THE CORRECT EQUIPMENT IS AVAILABLE CONTACT AN AIRBORNE REPRESENTATIVE IF SUCH EQUIPMENT IS NOT AVAILABLE THE SHOCK MAY NEED TO BE REMOVED AND TAKEN TO A SUITABLE SERVICE PROVIDER FOR ADJUSTMENT OR CHECKING The rear shock absorber should be checked every 100 hours to confirm the dimension of the sliding tubes The dimension A should not exceed 2mm difference between the right and left shock when the shocks are completely extended ie there must be no weight on the wheels If the shocks are outside the nominated tolerance AirBorne should be contacted to organise repair replacement of the shock unit Figure 33 Rear Shock Dimension Check Front Shocks The front shocks run more user serviceable pressures There are two reservoirs and a rebound damping adjustment available The correct procedure for checking the pressures and resetting them if necessary is shown on the following diagram The shock absorber should not be adjusted unless it is out of tolerance as indicated on the following diagram Issue 2 0 May 2007 Page 70 AirBorne WindSports Pty Ltd XT 912 Maintenance Manual MAIN POSITIVE AIR VALVE
149. ylinder head temperature Celsius or Fahrenheit Oil Temperature 2x EGT exhaust gas temperature Celsius or Fahrenheit Oil Pressure bars or PSI Air Temperature Additional air speed indicator Fuel flow data instantaneous and cumulative in calibrated in knots gallons or Litres Table 20 Features of the Instrumentation Changing the units of the SkKyDAT The units of the SkyDAT display may be changed to match the units that are used in the country where the display is being used The method is given in the Pilots Handbook or Aircraft Operating Instructions as applicable Section 7 16 Issue 2 0 May 2007 Page 67 AirBorne WindSports Pty Ltd XT 912 Maintenance Manual 31 00 10 Maintenance There are no user serviceable parts in any of the instrumentation for this aircraft any maintenance required should be carried out by an approved service 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 indicator is an instrument included as a fail safe in case of the failure of the electronic system The additional air speed indicator is calibrated in knots and has red tags which indicate the Vne speed for the aircraft the aircraft is placarded in knots so it provides easy reference to Vye information for pilots who prefer other air speed units Issue 2 0 May 2007 Page 68 AirBor

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