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AirBorne WindSports XT 582 Maintenance Manual

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XT 582 Maintenance Manual
XT 582

MAINTENANCE MANUAL

ISSUE 1.0
Manufacturer:
AirBorne WindSports Pty Ltd
Unit 22/30 Kalaroo Rd
Redhead, NSW
Australia
Phone :
+ 61 2 4944 9199
Fax :
+ 61 2 4944 9395
Website :
www.Airborne.com.au
Part # 107282
Issue 1.0
September 21st 2005
Page 1

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  • Page 1: Maintenance Manual

    © orne ports XT 582 Maintenance Manual XT 582 MAINTENANCE MANUAL ISSUE 1.0 Manufacturer: AirBorne WindSports Pty Ltd Unit 22/30 Kalaroo Rd Redhead, NSW Australia Phone : + 61 2 4944 9199 Fax : + 61 2 4944 9395 Website : www.Airborne.com.au...

  • Page 2: Table 1 Xt 582 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. • Pilot’s Operator’s Handbook • XT 582 Maintenance Manual • XT 582 Illustrated Parts Catalogue • Wing Maintenance Manual • Wing Illustrated Parts Catalogue • Rotax Owners Manual •...

  • Page 3: Table 2 Amendment Record Sheet

    © orne ports XT 582 Maintenance Manual AMMENDMENT RECORD SHEET Affected Amendment Date Affected Pages Date Inserted Signature Sections Issue 1.0 All of initial issue 1 to 102 September 21 September 21 2005 2005 Table 2 Amendment Record Sheet NOTE AirBorne’s data packages will be revised from time to time.

  • Page 4: Table 3 Log Of All Effective Pages, Issue 1

    XT 582 Maintenance Manual 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.
  • Page 5 This manual contains factory recommended procedures and instructions for ground handling, servicing and maintaining the XT 582 Base section of this aircraft. The procedures described are to be used in conjunction with the National Airworthiness Authority (NAA) of the country of registration. Any NAA maintenance requirement takes precedence over this manual.
  • Page 6 © orne ports XT 582 Maintenance Manual 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...

  • Page 7: Table 4 Imperial / Metric Conversions

    © orne ports XT 582 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.

  • Page 8: Table Of Contents

    © orne ports XT 582 Maintenance Manual CONTENTS 0. ASSEMBLY AND TEST FLIGHT / COMPONENT OVERVIEW ............11 4. AIRWORTHINESS LIMITATIONS....................15 5. TIME LIMITS/MAINTENANCE CHECKS ..................16 6. DIMENSIONS AND AREAS ......................24 7. LIFTING AND SHORING ........................ 26 9.

  • Page 9: Issue 1.0 September 21St 2005

    XT 582 Maintenance Manual LIST OF TABLES Table 1 XT 582 Data Package....................... 2 Table 2 Amendment Record Sheet......................3 Table 3 Log Of All Effective Pages, Issue 1 ................... 4 Table 4 Imperial / Metric Conversions....................7 Table 5 Initial Assembly Procedure (GJP144) ..................
  • Page 10 © orne ports XT 582 Maintenance Manual Figure 36 Front Wheel Assembly......................63 Figure 37 Dynamic Port (Pitot Entry) ....................65 Figure 38 Top of Mast, attached to the wing ..................68 Figure 39 Front Landing Gear Attachment................... 69 Figure 40 Front Fork to Wheel Attachment ..................69 Figure 41 Rear Landing Gear and Engine Mount Attachment to Mast Block........

  • Page 11: Assembly And Test Flight / Component Overview

    © orne ports XT 582 Maintenance Manual 0. ASSEMBLY AND TEST FLIGHT / COMPONENT OVERVIEW 00.00.00 Trike Base Assembly. Line Description Caution: Mast has an air strut and will move quickly when untethered. Remove straps and box. Remove and unwrap all parts.

  • Page 12: Figure 1 Main Structural Members

    © orne ports XT 582 Maintenance Manual 00.10.00 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. Aircraft Structure Mast Front pole...

  • Page 13: Figure 3 Under-Seat Bags

    © orne ports XT 582 Maintenance Manual Under-seat bags Under-seat bag (rhs) Under-seat bag (lhs) 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 (XT 912 shown in photo) Issue 1.0...

  • Page 14: Figure 5 Steering And Foot Levers

    © orne ports XT 582 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 Oil Injection Tank...

  • Page 15: Airworthiness Limitations

    © orne ports XT 582 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...

  • Page 16: Time Limits/Maintenance Checks

    © orne ports XT 582 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 is 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...
  • Page 17 Maintenance of aircraft as per the Maintenance Schedule in this handbook. Modification as detailed in any relevant Service Bulletins. Modification to approved details, obtained from Airborne WindSports Pty. Ltd. Repairs necessary to replace minor damage, wear or ageing. Servicing, replacement and overhaul, inspection and checking in compliance with the Maintenance Schedule.

  • Page 18: Table 8 Propeller And Gearbox Maintenance Schedule

    © orne ports XT 582 Maintenance Manual 5.20.10 Propeller and Gearbox Maintenance Schedule WARNING DISCONNECT SPARK PLUG LEADS FOR ALL MAINTENANCE AND INSPECTION PROCEDURES! ITEM MAINTENANCE REQUIREMENT AIRCRAFT or ITEM - HOURS OF OPERATION 1000 PROPELLER Examine for nicks and abrasions Check security of blades Check security and re-torque mounting bolts, &...
  • Page 19 © orne ports XT 582 Maintenance Manual 5.20.20 Engine Maintenance Schedule NOTE The following Engine Maintenance schedules are of a general overview nature. The Rotax engine Maintenance Manual should be used for specific maintenance required for the engine. WARNING DISCONNECT SPARK PLUG LEADS PRIOR TO ALL MAINTENANCE AND INSPECTION...

  • Page 20: Table 9 Engine Maintenance Schedule

    © orne ports XT 582 Maintenance Manual Oil lubricate, clean and service. Check as directed. Check for insecurity, cracks, legibility wear and faulty operation. Remove, inspect and replace if necessary. Recommend replacement or overhaul. Mandatory Replacement The schedule is to be repeated for each subsequent block of 500 hours...

  • Page 21: Table 10 Trike Base And Landing Gear Maintenance Schedule

    © orne ports XT 582 Maintenance Manual 5.20.30 Trike Base and Landing Gear Maintenance Schedule The procedure should be repeated from 500 to 1000 hours. ITEM MAINTENANCE REQUIREMENT AIRCRAFT OR ITEM - HOURS OF OPERATION TRIKE BASE AND All structural members and attachments...

  • Page 22: Figure 7 Front Mast To Mast Brace Check

    © orne ports XT 582 Maintenance Manual 5.50.00 Unscheduled Maintenance Checks Unscheduled 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.
  • Page 23 © orne ports XT 582 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 seat, as this will alter the dimension.

  • Page 24: Dimensions And Areas

    6.10.00 Major Dimensions (XT912 Shown) Figure 8 Major Dimensions (XT912 Shown) Note: All XT 582 dimensions are approximately the same as the XT 912. See next page for XT 582 dimensions. Issue 1.0 September 21st 2005...
  • Page 25 © orne ports XT 582 Maintenance Manual 6.20.00 Significant Dimensions and Areas General Overall Length (level Attitude) 2850 mm (Nose Cone to Edge of Rotax Propeller Mount) Overall Width 1880 mm (Edges of Rear Spats) Height (Without Wing) 2525 mm...

  • Page 26: Lifting And Shoring

    © orne ports XT 582 Maintenance Manual 7. 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.

  • Page 27: Towing And Taxiing

    © orne ports XT 582 Maintenance Manual 9. TOWING AND TAXIING 9.00.00 General Moving the trike is a relatively simple operation due to it’s 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.

  • Page 28: Figure 9 Tie Down Hook Location

    © orne ports XT 582 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. Tie down hook location 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.

  • Page 29: Figure 11 Tie On Rear Wheel

    © orne ports XT 582 Maintenance Manual The rear wheels may be tied as well. Route the tie between the drag link and rear suspension member to help prevent damage to the spat. Figure 11 Tie on Rear Wheel Figure 12 Trike on Trailer The above photo shows the trike correctly secured upon a trailer and ready for transport.

  • Page 30: Parking And Mooring

    © orne ports XT 582 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.

  • Page 31: Figure 15 Parking Trike Tail To The Wind

    © orne ports XT 582 Maintenance Manual Tail To Wind 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 Deg to the wind direction (Propeller towards the wind) and set the brake lock on.

  • Page 32: Required Placards

    © orne ports XT 582 Maintenance Manual 11. REQUIRED PLACARDS 11.00.00 General 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.

  • Page 33: Servicing

    © orne ports XT 582 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.
  • Page 34 © orne ports XT 582 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.
  • Page 35 © orne ports XT 582 Maintenance Manual 12.40.50 Gear Box The gearbox on the 582XT is inverted and in this configuration requires 400 ml of oil. The gear box is drained by removing the sump plug. Ensure that the sump plug is correctly replaced and lock wired prior to refilling.

  • Page 36: Scheduled Servicing

    © orne ports XT 582 Maintenance Manual 12.20.00 Scheduled Servicing 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.).

  • Page 37: Figure 17 Air Filter Protection During Cleaning

    © orne ports XT 582 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.
  • Page 38 © orne ports XT 582 Maintenance 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...
  • Page 39 © orne ports XT 582 Maintenance Manual 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 •...

  • Page 40: Standard Practices - Airframe

    © orne ports XT 582 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.

  • Page 41: Figure 19 Outside Nut With Spat Bracket

    © orne ports XT 582 Maintenance Manual Rear Wheels The rear wheels need to be set up in a special way because of the spat brackets. Procedure after Shipping: The inside two nuts and bolts are pre set 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.
  • Page 42 © orne ports XT 582 Maintenance Manual 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).

  • Page 43: Table 12 Torque Table

    © orne ports XT 582 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.

  • Page 44: Table 13 Excerpt From Gjp 141, Complete List Of Tie Wire Locations

    © orne ports XT 582 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.

  • Page 45: Figure 24 Muffler Safety Wire And Springs

    © orne ports XT 582 Maintenance Manual WARNING IT IS UNSAFE TO OPERATE THE 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, AS IT IS UNNECESSARY WHEN ATTACHED TO THE SPAT.
  • Page 46 © orne ports XT 582 Maintenance Manual 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.

  • Page 47: Communications

    © orne ports XT 582 Maintenance Manual 23. COMMUNICATIONS 23.00.00 General All maintenance and servicing of communications avionics equipment fitted to the XT should be carried out by approved agents of the avionics manufacturer. The intercom and radio system schematic are shown in the electrical schematic (section 7.13) in the Pilots handbook.

  • Page 48: Electrical Power

    © orne ports XT 582 Maintenance Manual 24. ELECTRICAL POWER 24.00.00 General The 582 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.

  • Page 49: Equipment/Furnishings

    © orne ports XT 582 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.

  • Page 50: Flight Controls

    © orne ports XT 582 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 by pilots in the front or rear of the aircraft.

  • Page 51: Fuel System

    © orne ports XT 582 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 Fuel system is simple and easily visually inspected. Fuel rate sensing transmitting and indicating are covered in chapter 73.

  • Page 52: Fuel Storage

    © orne ports XT 582 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.

  • Page 53: Figure 26 Finger Filter, As Installed, As Well As The Unit Prior Installation

    © orne ports XT 582 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.

  • Page 54: Figure 27 Fuel Line Check Example

    © orne ports XT 582 Maintenance Manual Fuel Hoses 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 27 Fuel Line Check Example Areas that should be checked with extra care are the interfaces between the hose and the motor.

  • Page 55: Figure 28 Fuel Flow Sender Device

    © orne ports XT 582 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.

  • Page 56: Figure 29 Fuel Sender And Tools

    © orne ports XT 582 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.

  • Page 57: Figure 30 Fuel Tap Bracket Sub Assembly

    © orne ports XT 582 Maintenance Manual 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. Loose Operation Ensure that the Safety Valve is not too loose in it’s 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.

  • Page 58: Indicating/Recording Systems

    © orne ports XT 582 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).

  • Page 59: Independent Instruments

    © orne ports XT 582 Maintenance Manual WARNING IT IS PROHIBITED TO FLY THIS AIRCRAFT WITH THE AMPTRONIC SKYDAT GX2 ALARM THRESHOLDS SET OUTSIDE THE ENGINE MANUFACTURER’S LIMITS. Changing the units of the SkyDAT 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.

  • Page 60: Landing Gear

    © orne ports XT 582 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.

  • Page 61: Figure 33 Rear Shock Dimension Check

    © orne ports XT 582 Maintenance Manual Rear Shocks WARNING THE REAR AIR SHOCKS ARE UNDER VERY HIGH PRESSURE, THEY ARE PRE SET 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.

  • Page 62: Figure 34 Front Shock Set Up

    © orne ports XT 582 Maintenance Manual Figure 34 Front Shock Set up 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.

  • Page 63: Figure 36 Front Wheel Assembly

    © orne ports XT 582 Maintenance Manual 32.40.00 Wheels and Brakes The trike has a single drum style brake on the front wheel. The front wheel and brake assembly is manufactured by Gremica. The brake is cable actuated, and operated via a foot pedal on the left hand side of the steerer.
  • Page 64 © orne ports XT 582 Maintenance Manual Rear Tyres Deestone 15 X 6.00 –6 (Nylon) 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.

  • Page 65: Navigation And Pitot Static

    © orne ports XT 582 Maintenance Manual 34. 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.
  • Page 66 © orne ports XT 582 Maintenance Manual CAUTION ENSURE THAT THE PITOT SYSTEM IS NOT PAINTED ORCOVERED OVER AS THE AIRSPEED INDICATORS WILL CEASE TO FUNCTION. 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.

  • Page 67: Fuselage

    © orne ports XT 582 Maintenance Manual 53. FUSELAGE 53.00.00 General The fuselage 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.

  • Page 68: Figure 38 Top Of Mast, Attached To The Wing

    © orne ports XT 582 Maintenance Manual 53.40.20 Wings Heart Bolt Mast Brace Safety Loop Bolt Figure 38 Top of Mast, attached to the wing The trike base is attached to the wing using an aircraft grade bolt, that attaches to the Wings U bracket.

  • Page 69: Figure 39 Front Landing Gear Attachment

    © orne ports XT 582 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 each for the Drag Link, Rear Strut and Suspension member.

  • Page 70: Figure 42 Pod Front Attachment

    © orne ports XT 582 Maintenance Manual 2. Instrument Brackets 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.

  • Page 71: Stabilizers

    © orne ports XT 582 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.

  • Page 72: Windows

    © orne ports XT 582 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 dealer.

  • Page 73: Propellers

    © orne ports XT 582 Maintenance Manual 61. PROPELLERS 61.00.00 General The XT propeller is a carbon fibre composite, three bladed propeller. Blade Description: BOS 3 , 68 X 58 SL 3B Hub/Engine Type: Rotax 58 True Propeller size: 66” (1676.4mm) Other standard components include: Hub Block “Base”...

  • Page 74: Figure 46 An4 Bolts Into Forward Hub Block

    © orne ports XT 582 Maintenance Manual 61.20.00 Propeller Assembly Procedure 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.

  • Page 75: Figure 47 Place Blades Into Hub Block

    © orne ports XT 582 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 47 Place Blades into Hub Block 61.20.40 Add the rest of the components...

  • Page 76: Figure 49 Mounting The Propeller (Photo Shows 912 Engine)

    © orne ports XT 582 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 Engines mount pattern. Mate the bolts to the holes while ensuring that the propellers or bolts don’t fall.

  • Page 77: Figure 51 Propeller Part Lines

    61.10.20 Adjusting Pitch Angle The setting for the XT 582 is 19 degrees measured on the flat section of the blade at a radius of 24 inches and relative to the flat rear face on the propeller hub. The tolerance on this angle is +/- 0.5 Deg.

  • Page 78: Figure 53 Prop Hub At 89.95 Degrees After Correct Shimming Of Front Wheel

    © orne ports XT 582 Maintenance Manual NOTE The ideal reading is 90 Deg but +/- 0.05 Degrees is acceptable for practical application. Figure 53 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 on the pilots right of the engine.

  • Page 79: Figure 55 Radius Measurement

    © orne ports XT 582 Maintenance Manual 61.10.24 Measure 24 Inches Radius The angle of the propeller needs to be checked at 24 inches from the center of the hub. This is the position that the angle of the blade is checked from. Masking tape, or similar should be used to accurately mark the position.

  • Page 80: Figure 57 Propeller M8 Bolt Tightening Sequence Numbers

    © orne ports XT 582 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 grip bolts, and 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 bolts –...

  • Page 81: Figure 60 Correctly Installed Propeller

    Recheck the pitch of the propellers after they have been fully torqued. Recheck visually that all components are in place. Note that while tie wire is required on the XT912 model, the XT582 variant uses Nyloc nuts to secure the M8 Bolts. These are shown correctly installed on the XT 582 hub. Issue 1.0...
  • Page 82 © orne ports XT 582 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.
  • Page 83 © orne ports XT 582 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).

  • Page 84: Power Plant

    © orne ports XT 582 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.

  • Page 85: Engine Drains

    © orne ports XT 582 Maintenance Manual 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 mast block using a small mounting plate.

  • Page 86: Engine Maintenance

    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 582 UL engine fitted to the XT 582 aircraft can be found in the following documents:...

  • Page 87: Engine Fuel Systems

    © orne ports XT 582 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.

  • Page 88: Ignition

    © orne ports XT 582 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 required for the engine to operate. The engine generates excess power with the integrated generator, which powers systems, which are external to the engine.

  • Page 89: Engine Controls

    © orne ports XT 582 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 methods to actuate the throttle either with the hand throttle or the foot actuated throttle.
  • Page 90 © orne ports XT 582 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.

  • Page 91: Engine Indicating

    © orne ports XT 582 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) VSI (vertical speed indicator) in m/s or ft/min Flight duration, in hours;...

  • Page 92: Figure 62 Earthing Of Cht Sender, To Check The Wire To The Skydat

    © orne ports XT 582 Maintenance Manual 77.30.00 Analysers Cylinder Head 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 to ground at the CHT sender and a message short-circuit should show on the screen for that CHT".

  • Page 93: Figure 63 Photo Of Screwdriver In Place To Remove Wire

    © orne ports XT 582 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.
  • Page 94 © orne ports XT 582 Maintenance Manual 78. EXHAUST 78.00.00 General There is one muffler system for the two cylinders. Each of the cylinder exhausts have a custom made manifold that routs 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.

  • Page 95: Starting

    © orne ports XT 582 Maintenance Manual 80. STARTING 80.00.00 General The electrically driven starter motor is mounted on the rear of the engine below the gearbox. A key start is located on the instrument panel. When the master switch is on, pushing the start button will energise the starter system.
  • Page 96 © orne ports XT 582 Maintenance Manual End of XT 582 Maintenance Manual Issue 1.0 September 21st 2005 Page 96...

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