Page 1 Maintenance Manual XA41/XA42 AMM-XA42-0040-001 C.00 Aircraft Maintenance Manual XA41 / XA42 S/N: Manufacturer: _________________ XtremeAir GmbH Harzstraße 2 Registration: Am Flughafen Cochstedt _____________________ 39444 Hecklingen Document Number: Germany AMM-XA42-0040-001 This Manual includes the material required to be furnished to the maintenance personal by EASA regulations, additional information provided by the manufacturer, and in Chapter 4 the EASA approved Airworthiness Limitations.
Page 2: Log Of Revisions
Maintenance Manual XA41/XA42 AMM-XA42-0040-001 C.00 LOG OF REVISIONS Issue Date Changed Pages Reason Of Change Manual rewritten in Simplified Technical English (ASD-STE 100). Inclusion of the following modifications: General Corrections Grove and Beringer Brake C.00 25.09.2018 system improvement Canopy seal treatment...
Page 3 Maintenance Manual XA41/XA42 AMM-XA42-0040-001 C.00 LOG OF EFFECTIVE PAGES Pages Date Issue: Pages Date Issue: Title 25.09.2018 C.00 Ch. 10 Page 4 25.09.2018 C.00 Ch. 00 Page I through XII 25.09.2018 C.00 Ch. 11 Page 1 25.09.2018 C.00 Ch. 01 Page 1 25.09.2018...
Page 4 Maintenance Manual XA41/XA42 AMM-XA42-0040-001 C.00 Pages Date Issue: Pages Date Issue: Ch. 27 Page 15 25.09.2018 C.00 Ch. 33 Page 2 25.09.2018 C.00 Ch. 27 Page 16 25.09.2018 C.00 Ch. 34 Page 1 25.09.2018 C.00 Ch. 27 Page 17 25.09.2018 C.00...
Page 5 Maintenance Manual XA41/XA42 AMM-XA42-0040-001 C.00 Pages Date Issue: Pages Date Issue: Ch. 61 Page 3 25.09.2018 C.00 Ch. 79 Page 2 25.09.2018 C.00 Ch. 61 Page 4 25.09.2018 C.00 Ch. 79 Page 3 25.09.2018 C.00 Ch. 72 Page 1 25.09.2018 C.00...
Page 6: Table Of Contents
Engine change ....................05-14 05-20-07 Maintenance Checks Performed ..............05-15 05-50-00 UNSCHEDULED MAINTENANCE CHECKS ............05-17 CHAPTER 06 DIMENSIONS ..................06-1 06-10-00 DIMENSIONS XA41 / XA42 ................. 06-2 06-10-01 Primary Data ....................06-3 06-10-02 Wing ......................06-3 Page date: 25.09.2018...
Page 7 Maintenance Manual XA41/XA42 AMM-XA42-0040-001 C.00 06-10-03 Horizontal Tail (with Elevator) ................ 06-3 06-10-04 Elevator ......................06-3 06-10-05 Trim Tab ....................... 06-3 06-10-06 Vertical Tail (with Rudder) ................06-4 06-10-07 Rudder ......................06-4 CHAPTER 07 LIFTING AND SHORING ................. 07-1 07-00-00 GENERAL ......................
Page 8 Maintenance Manual XA41/XA42 AMM-XA42-0040-001 C.00 20-10-01 Types of Bolts ....................20-2 20-10-02 Standard Torque Values ................. 20-3 20-10-03 Special Torque Values ..................20-3 20-10-04 Torque Measurement ..................20-4 20-10-05 Check for Delamination .................. 20-4 20-10-06 Flexible Hoses ....................20-4 20-10-07 Fittings......................
Page 9 ELECTRIC/ELECTRONIC PANELS & MULTIPURPOSE PARTS ....39-1 39-00-00 GENERAL ......................39-2 39-10-00 INSTRUMENT AND CONTROL PANELS ..............39-2 39-10-01 XA41 Instrument Panel .................. 39-3 39-10-02 XA42 Rear Instrument Panel ................39-4 39-10-03 XA42 Front Instrument Panel................39-5 39-20-00 ELECTRICAL SWITCH PANEL ................39-6 39-30-00 THROTTLE AND TRIM CONTROL ................
Page 10 Maintenance Manual XA41/XA42 AMM-XA42-0040-001 C.00 51-70-13 Repair guidelines ..................51-12 51-70-15 Painting of Composite Parts ................51-14 51-70-20 Repair of Aluminum and Steel Components ............ 51-14 51-70-25 Aluminum and Steel Components Refinishing ..........51-14 CHAPTER 52 CANOPY ....................52-1 52-00-00 GENERAL ......................
Page 11 Maintenance Manual XA41/XA42 AMM-XA42-0040-001 C.00 CHAPTER 91 CHARTS ....................91-1 91-00-00 MAIN WIRING DIAGRAMS ..................91-2 91-01-00 MVP-50 ....................... 91-11 91-02-00 WIRING WING ....................91-21 91-03-00 RADIO ........................ 91-23 91-04-00 TRANSPONDER ....................91-28 91-05-00 TRIM ........................91-33 91-06-00 SMOKE SYSTEM ....................91-34 91-07-00 ELT ........................
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Page 13: Chapter 00 Table Of Contents
Maintenance Manual XA41/XA42 AMM-XA42-0040-001 C.00 Chapter 01 Introduction Table of Contents Chapter Title Page 01-00-00 GENERAL 01-2 01-00-01 Revision Service 01-2 01-00-02 Warnings, Cautions and Notes 01-2 01-00-03 Log of Revisions 01-2 01-10-00 SAFETY 01-3 Page date: Page 25.09.2018 Chapter 01...
Page 14: General
01-00-00 GENERAL This Aircraft Maintenance Manual (AMM) includes the necessary data to do the maintenance of the XA41 and the XA42. The structure is as follows: Description of the systems, troubleshooting procedures, removal and installation procedures and maintenance instructions. Use the AMM with these (and other) manuals and the related service bulletins: •...
Page 15: Safety
SAFETY Obey these precautions to prevent injury and/or damage during the maintenance procedures on the XA41 and the XA42: • Only approved personnel must do the maintenance work and inspections. • Read the maintenance manual before you start the maintenance work.
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Page 17: Organization And Handling Of This Manual
Maintenance Manual XA41/XA42 AMM-XA42-0040-001 C.00 Chapter 02 Organization and Handling of this Manual Table of Contents Chapter Title Page 01-00-00 GENERAL 01-2 01-00-01 Revision Service 01-2 01-00-02 Warnings, Cautions and Notes 01-2 Page date: Page 25.09.2018 Chapter 02...
Page 18: General
Maintenance Manual XA41/XA42 AMM-XA42-0040-001 C.00 02-00-00 GENERAL This AMM agrees with the Air Transport Association of America, ATA Specification No. 100. For data about a special system, refer to the list of chapters and find the chapter number. The first page of each chapter shows the table of contents.
Page 19: Conversion Factors
Maintenance Manual XA41/XA42 AMM-XA42-0040-001 C.00 02-00-02 Conversion Factors Dimension Conversion Factor Unit SI to US/Imperial US/Imperial to SI Length Millimeter (mm) (mm)/25.4 = (in) Meter (m)/0.3048 = (ft) Kilometer (km) (km)/1.852 = (nm) Inch (in) (in)*25.4 = (mm) Foot (ft) (ft)*0.3048 = (m)
Page 20 Maintenance Manual XA41/XA42 AMM-XA42-0040-001 C.00 (continued) Dimension Conversion Factor Unit SI to US/Imperial US/Imperial to SI Volume Liter (l)/3.7854 = (US gal) (l)/0.9464 = (USqt) (l)/61.024 = (in³) US gallon (US gal) (US gal)*3.7854 = (l) US quart (USqt) (USqt)*0.9464 = (l) Cubic inch (in³)
Page 21: General Description Of The Aircraft
Maintenance Manual XA41/XA42 AMM-XA42-0040-001 C.00 Chapter 03 General Description of the Aircraft Table of Contents Chapter Title Page 03-00-00 GENERAL 03-2 03-10-00 DESCRIPTION 03-2 03-10-01 Construction 03-2 03-10-02 Flight Control System 03-2 03-10-03 Brake System 03-2 03-10-04 Powerplant 03-3 03-10-05...
Page 22: General
03-00-00 GENERAL The Xtreme XA42 is a two-seat unlimited aerobatic aircraft with a tailwheel. The XA41 is a one-seat variant. All parts of the structure are made from carbon/honeycomb sandwich. The two models have the certification in the utility and aerobatic category, as specified in the EASA CS-23.
Page 23: Powerplant
Maintenance Manual XA41/XA42 AMM-XA42-0040-001 C.00 03-10-04 Powerplant Engine: Manufacturer: Textron Lycoming Williamsport Division 652 Oliver Street Williamsport, PA17701, USA Type: AEIO-580-B1A • 6-cylinder air cooled • fuel injection • inverted flight oil system • independent dual magneto ignition system Rated power:...
Page 24: Instruments
Maintenance Manual XA41/XA42 AMM-XA42-0040-001 C.00 03-10-07 Instruments Standard equipment (minimum) installed: Instrument XA42 XA41 Primary glass panel engine monitor - MVP-50P Airspeed indicator Altimeter Magnetic compass G-Meter Page Page date: Chapter 03 25.09.2018...
Page 25: Airworthiness Limitations
Maintenance Manual XA41/XA42 AMM-XA42-0040-001 C.00 Chapter 04 Airworthiness Limitations Record of Revisions Chapter 04 Rev. Date of Revised Description of EASA Approval Date and Revision Pages Revision Sign of Approval B.01 12.12.2011 First edition 01 February 2012 B.03 13.10.2012 FAA approval statement 18 October 2012 B.07...
Page 26 Maintenance Manual XA41/XA42 AMM-XA42-0040-001 C.00 Table of Contents Chapter Title Page 04-00-00 GENERAL 04-3 04-00-01 Operating Time 04-4 04-10-00 LIFE LIMITED COMPONENTS 04-4 04-10-01 General 04-4 04-10-02 Replacement Time 04-4 04-10-03 Service Life Limited Components 04-4 Page Page date: Chapter 04...
Page 27: General
Maintenance Manual XA41/XA42 AMM-XA42-0040-001 C.00 04-00-00 GENERAL The Airworthiness Limitations Section is EASA approved and specifies inspection and maintenance required according to CS-23 Appendix G, 23.4 unless an alternative program has been EASA approved. The Airworthiness Limitations Section is FAA approved and specifies maintenance required under §§43.16 and 91.403 of the Federal Aviation Regulation unless an alternative program has been FAA...
Page 28: Operating Time
Bolts XA42-5300-210, installed on XA41 MSN 04 and on, and XA42 MSN 107 and on, are not life limited. 04-10-03 Service Life Limited Components The service life of the XA41 and XA42 composite structure as listed in chapter 04-10-02 has been set to 6000 flight hours. Page Page date: Chapter 04 25.09.2018...
Page 29: Time Limits And Maintenance Checks
Maintenance Manual XA41/XA42 AMM-XA42-0040-001 C.00 Chapter 05 Time Limits and Maintenance Checks Table of Contents Chapter Title Page 05-00-00 GENERAL 05-2 05-10-00 TIME LIMITS 05-2 05-10-01 General 05-2 05-10-02 Overhaul Schedule 05-2 05-10-03 Recommended Replacement Times 05-3 05-20-00 SCHEDULED MAINTENANCE CHECKS...
Page 30: General
This chapter gives charts and schedules for time limits and maintenance procedures. Thus, approved personnel can do correct inspections on the XA41/XA42. The periodic inspections in this chapter are minimum requirements to keep the aircraft in an airworthy condition. If more frequent maintenance services are necessary to operate the aircraft, it is possible to decrease the time periods.
Page 31: Recommended Replacement Times
Maintenance Manual XA41/XA42 AMM-XA42-0040-001 C.00 05-10-03 Recommended Replacement Times This list shows the replacement times for the items. Only the applicable national authority is permitted to change the replacement times. Item Replacement Time Battery (Genesis 12 V / 16Ah) on condition on condition, if no other instructions are Bolts and nuts (DIN 931, DIN 933, LN 9037, AN…)
Page 32: Scheduled Maintenance Checks
Shorter intervals can become necessary because of the condition of the aircraft. If damage occurs, repair or replace the part immediately. Remove these items before the inspection: Seats Footrest (XA41) or footrest/cover of the front compartment (XA42) Inspection hole covers in the cockpit Baggage compartment Cowling top and bottom...
Page 33: First 25 Hour Inspection
Maintenance Manual XA41/XA42 AMM-XA42-0040-001 C.00 05-20-02 First 25 Hour Inspection For new aircraft, the procedures which are defined in the 50 Hour inspection (Chapter 05- 20-03) must be performed after the first 25 hours of operation. 05-20-03 50 Hour Inspection...
Page 34 Maintenance Manual XA41/XA42 AMM-XA42-0040-001 C.00 Description Action Signature Front seat - Rudder pedal assemblies RH and LH The assemblies move freely from stop to stop CHECK The split pins are correctly installed in the castle nuts CHECK The pulleys are correctly installed and not worn...
Page 35 Maintenance Manual XA41/XA42 AMM-XA42-0040-001 C.00 Description Action Signature Push the trim circuit breaker in. The trim position indicator light CHECK must come on, and the trim motor must operate correctly Push the GPS circuit breaker in. The GPS screen must come CHECK Push in the COM circuit breaker.
Page 36 Maintenance Manual XA41/XA42 AMM-XA42-0040-001 C.00 Description Action Signature There is no leakage from the smoke oil tank CHECK Aileron bellcranks in fuselage, LH and RH The bellcranks move freely from stop to stop CHECK The bellcranks and the split pins are correctly installed...
Page 37 Maintenance Manual XA41/XA42 AMM-XA42-0040-001 C.00 Description Action Signature The ends of the aileron control rod turn freely at the left and right stops WARNING CHECK Make sure that the aileron control rod is correctly adjusted. Incorrect adjustment can cause damage to the rod end housing...
Page 38 Maintenance Manual XA41/XA42 AMM-XA42-0040-001 C.00 Description Action Signature The alternator is correctly installed CHECK The magneto P-lead is correctly connected CHECK The starter is correctly installed and connected CHECK The propeller, the spinner and the safety wiring are correctly CHECK...
Page 39 Maintenance Manual XA41/XA42 AMM-XA42-0040-001 C.00 Description Action Signature Front left compartment The electric fuel pump is correctly installed on the bracket CHECK The electrical connector of the fuel pump is correctly connected CHECK The vent line of the electric fuel pump is correctly installed...
Page 40 Maintenance Manual XA41/XA42 AMM-XA42-0040-001 C.00 Description Action Signature ELT installation The mounting bracket is correctly installed CHECK The ELT is safely attached to the mounting bracket CHECK The remote control and the antenna cable are correctly CHECK connected The routing of the antenna and of the remote control cables is...
Page 41: 100 Hour Inspection
Maintenance Manual XA41/XA42 AMM-XA42-0040-001 C.00 05-20-04 100 Hour Inspection Do all steps of the 50h inspection plus these steps: Description Action Signature Electrical system Alternator maintenance iaw ICA-BC410 or ICA-BC462-H. PERFORM Regulator maintenance iaw ICA-LR3C PERFORM Fuel selector switch The aft universal joint and the mounting bracket are correctly...
Page 42: 1000 Hour Inspection
Maintenance Manual XA41/XA42 AMM-XA42-0040-001 C.00 05-20-05 1000 Hour Inspection Disassemble the aircraft and do a full inspection of all components. Description Action Signature Remove the wings CHECK Remove the ailerons CHECK Remove the elevator CHECK Remove the rudder CHECK Remove the stabilizer...
Page 43: Maintenance Checks Performed
Maintenance Manual XA41/XA42 AMM-XA42-0040-001 C.00 05-20-07 Maintenance Checks Performed Flight Date Place Signature time 25 h 50 h 100 h 150 h 200 h 250 h 300 h 350 h 400 h 450 h 500 h 550 h 600 h...
Page 44 Maintenance Manual XA41/XA42 AMM-XA42-0040-001 C.00 (continued) Flight Date Place Signature time 1050 h 1100 h 1150 h 1200 h 1250 h 1300 h 1350 h 1400 h 1450 h 1500 h 1550 h 1600 h 1650 h 1700 h 1750 h...
Page 45: Unscheduled Maintenance Checks
Maintenance Manual XA41/XA42 AMM-XA42-0040-001 C.00 05-50-00 UNSCHEDULED MAINTENANCE CHECKS Hard landing Description Action Signature Remove the landing gear fairings and the cowling EXAMINE Engine mount EXAMINE Landing gear legs EXAMINE Wheels and axles EXAMINE Tail wheel strut straight? EXAMINE Rudder impact from tail wheel assembly?
Page 46 Maintenance Manual XA41/XA42 AMM-XA42-0040-001 C.00 Hail damage Description Action Signature Upper / exposed surfaces: Damage (coin tapping inspection) EXAMINE Dents (visual inspection) EXAMINE Propeller blades: Damage Page Page date: Chapter 05 25.09.2018...
Page 47: Dimensions
Maintenance Manual XA41/XA42 AMM-XA42-0040-001 C.00 Chapter 06 Dimensions Table of Contents Chapter Title Page 06-10-00 DIMENSIONS XA41 / XA42 06-2 06-10-01 Primary Data 06-3 06-10-02 Wing 06-3 06-10-03 Horizontal Tail (with Elevator) 06-3 06-10-04 Elevator 06-3 06-10-05 Trim Tab 06-3...
Page 48: Dimensions Xa41 / Xa42
Maintenance Manual XA41/XA42 AMM-XA42-0040-001 C.00 06-00-00 GENERAL The XA41 and the XA42 use the System International (SI) for dimensions and areas. For the conversion factors of SI units and US imperial units, refer to Chapter 02. 06-10-00 DIMENSIONS XA41 / XA42...
Page 49: Primary Data
Maintenance Manual XA41/XA42 AMM-XA42-0040-001 C.00 06-10-01 Primary Data Dimensions in mm XA42 XA41 Length overall 6670 6422 Height overall (ground attitude) 2542 Span 7500 Wheel track 2000 06-10-02 Wing Wing planform Trapezoid Wing span 7500 mm Wing area 11.25 m²...
Page 50: Vertical Tail (With Rudder)
Maintenance Manual XA41/XA42 AMM-XA42-0040-001 C.00 06-10-06 Vertical Tail (with Rudder) Planform Trapezoid Height 1100 mm Area 1.54 m² Airfoil DU86-MOD1 06-10-07 Rudder Height 1400 mm Area 0.82 m² Deflection ± 30 ° Page Page date: Chapter 06 25.09.2018...
Page 51: Lifting And Shoring
Maintenance Manual XA41/XA42 AMM-XA42-0040-001 C.00 Chapter 07 Lifting and Shoring Table of Contents Chapter Title Page 07-00-00 GENERAL 07-2 07-10-00 JACKING 07-2 07-20-00 SHORING 07-2 07-20-01 Shoring the front 07-2 07-20-02 Shoring the tail 07-3 Page date: Page 25.09.2018 Chapter 07...
Page 52: General
Maintenance Manual XA41/XA42 AMM-XA42-0040-001 C.00 07-00-00 GENERAL The XA41 and the XA42 have no special hoist points. Refer to chapter 07-10-00. 07-10-00 JACKING To lift the aircraft, remove the top cowling. Attach the straps to the left and right side of the engine mount as near as possible to the fuselage.
Page 53: Shoring The Tail
Maintenance Manual XA41/XA42 AMM-XA42-0040-001 C.00 07-20-02 Shoring the tail The dimensions of the tail support must be 500x300x300 mm. CAUTION Put a cushion on top of the tail support to prevent damage to the fuselage. To lift the tail: Use wheel chocks to safety the main wheels.
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Page 55: Leveling And Weighing
Maintenance Manual XA41/XA42 AMM-XA42-0040-001 C.00 Chapter 08 Leveling and Weighing Table of Contents Chapter Title Page 08-00-00 GENERAL 08-2 08-10-00 LEVELING 08-2 08-20-00 MASS & BALANCE 08-3 08-20-01 Weighing 08-3 08-20-02 Center of Gravity 08-4 Page date: Page 25.09.2018 Chapter 08...
Page 56: General
Maintenance Manual XA41/XA42 AMM-XA42-0040-001 C.00 08-00-00 GENERAL This chapter gives information on the tools for leveling, weighing and how to calculate the center of gravity. NOTE Do the leveling and weighing procedure only on a flat surface. Do the leveling and weighing procedure in a hangar to prevent incorrect measurements because of wind.
Page 57: Mass & Balance
Maintenance Manual XA41/XA42 AMM-XA42-0040-001 C.00 08-20-00 MASS & BALANCE Refer to the Form in Appendix 2. 08-20-01 Weighing To measure the aircraft empty mass: Make sure that the aircraft has the necessary equipment, refer to the equipment list of the Aircraft Flight Manual. Make sure that the equipment is correctly installed in the specified positions.
Page 58: Center Of Gravity
Figure 08-2: Center of Gravity calculation The moment arms A and B are constant values: XA42: A = 112 (mm) B = 4475 (mm) XA41: A = 120 (mm) B = 4225 (mm) For mass M and the weighing procedure, refer to chapter 08-20-01.
Page 59: Towing And Taxiing
Maintenance Manual XA41/XA42 AMM-XA42-0040-001 C.00 Chapter 09 Towing and Taxiing Table of Contents Chapter Title Page 09-00-00 GENERAL 09-2 09-10-00 TOWING 09-2 09-20-00 TAXIING 09-2 Page date: Page 25.09.2018 Chapter 09...
Page 60: General
AMM-XA42-0040-001 C.00 09-00-00 GENERAL This chapter gives information how to move the aircraft on the ground. It is possible to tow and taxi the XA41 / XA42 on the ground. WARNING Only qualified personnel are permitted to taxi the aircraft. 09-10-00...
Page 61: Parking, Mooring, Storage And Return To Service
Maintenance Manual XA41/XA42 AMM-XA42-0040-001 C.00 Chapter 10 Parking, Mooring, Storage and Return to Service Table of Contents Chapter Title Page 10-00-00 GENERAL 10-2 10-10-00 PARKING AND STORAGE 10-2 10-10-01 Parking 10-2 10-10-02 Storage 10-2 10-20-00 TIEDOWN 10-3 10-30-00 RETURN TO SERVICE...
Page 62: General
Maintenance Manual XA41/XA42 AMM-XA42-0040-001 C.00 10-00-00 GENERAL Always park or tie down the aircraft when it is not in operation. If the aircraft is parked for a longer period of time, we recommend that you tie it down. Always tie down the aircraft if strong winds are possible.
Page 63: Tiedown
Maintenance Manual XA41/XA42 AMM-XA42-0040-001 C.00 10-20-00 TIEDOWN CAUTION If you must put the aircraft into storage outdoors for a long time, do the tiedown procedure. Strong winds or gusts can cause damage to the aircraft when it is not tied down.
Page 64: Return To Service
Maintenance Manual XA41/XA42 AMM-XA42-0040-001 C.00 10-30-00 RETURN TO SERVICE If the aircraft was parked for more than 30 days, we recommend that you do a 50 hour Inspection, refer to chapter 05-20-04. Also do the procedure to return the engine to service, refer to Lycoming Service Letter L180, newest issue.
Page 65: Placards And Markings
Maintenance Manual XA41/XA42 AMM-XA42-0040-001 C.00 Chapter 11 Placards and Markings Table of Contents Chapter Title Page 11-00-00 GENERAL 11-2 11-20-00 EXTERNAL PLACARDS AND MARKINGS 11-2 11-30-00 INTERNAL PLACARDS AND MARKINGS 11-2 Page date: Page 25.09.2018 Chapter 11...
Page 66: General
Maintenance Manual XA41/XA42 AMM-XA42-0040-001 C.00 11-00-00 GENERAL Placards are used for identification and indication. They show the function, operation and operating limits of systems and equipment. WARNING Do not remove, replace or change placards and markings without approval of the airworthiness authority.
Page 67: Servicing
Maintenance Manual XA41/XA42 AMM-XA42-0040-001 C.00 Chapter 12 Servicing Table of Contents Chapter Title Page 12-00-00 GENERAL 12-2 12-10-00 REPLENISHING 12-3 12-10-01 Refueling 12-3 12-10-02 Defueling 12-4 12-10-03 Fuel Drainage 12-4 12-10-04 Replenishment of Engine Oil 12-4 12-10-05 Engine Oil Change...
Page 68: General
Maintenance Manual XA41/XA42 AMM-XA42-0040-001 C.00 12-00-00 GENERAL This chapter gives information about the servicing of the aircraft. Shorter service and maintenance intervals are recommended when the aircraft operates in unusual conditions, such as: • Very high or low temperature ranges •...
Page 69: Replenishing
Maintenance Manual XA41/XA42 AMM-XA42-0040-001 C.00 12-10-00 REPLENISHING The procedures of this chapter give information how to add fuel, engine oil and brake fluid. Information about tire inflation is also included. Chapter 12-10-08 gives an overview of all fluids that are necessary for replenishing.
Page 70: Defueling
Maintenance Manual XA41/XA42 AMM-XA42-0040-001 C.00 12-10-02 Defueling WARNING Before you defuel the aircraft, make sure that it is electrically grounded. Incorrectly grounded aircrafts can cause accidents. Also obey the safety precautions in chapter 12-10-01. To defuel the tanks, use containers with applicable dimensions. Use pumps or siphons to remove the fuel from the tanks through the filler ports.
Page 71 Maintenance Manual XA41/XA42 AMM-XA42-0040-001 C.00 Remove the dipstick. Examine the oil level on the dipstick and compare the level with the markings on the dipstick. If it is necessary to add oil, do the instructions below. Put the dipstick back into the filler port and tighten it with your hand.
Page 72: Engine Oil Change
Maintenance Manual XA41/XA42 AMM-XA42-0040-001 C.00 12-10-05 Engine Oil Change For the engine oil change intervals, refer to chapter 05-20-00. To replace the engine oil, refer to chapter 12-10-04 and the newest revision of Lycoming Service Instruction No.1014. To replace the engine oil: Remove the cowling.
Page 73: Replenishment Of Brake Fluid
Maintenance Manual XA41/XA42 AMM-XA42-0040-001 C.00 12-10-06 Replenishment of Brake Fluid WARNING Be careful with brake fluid. Do not get brake fluid on your skin or in your mouth to prevent damage to health. Remove spilled brake fluid immediately to prevent damage to paint and other materials.
Page 74: Tire Inflation
Maintenance Manual XA41/XA42 AMM-XA42-0040-001 C.00 12-10-07 Tire Inflation The specified tire pressure of the main landing gear wheels is 3.5 (bar) / 50 (psi). The tailwheel is made of solid rubber. You cannot inflate it. 12-10-08 Overview of Fluids for Replenishing FUEL Use AvGas 100 or 100LL only.
Page 75: Scheduled Servicing
Maintenance Manual XA41/XA42 AMM-XA42-0040-001 C.00 BRAKE FLUID Use Mil-H-5606 red hydraulic fluid only. Total brake fluid capacity: 2 x 0.10 (L) / 0.11 (USqt) 12-20-00 SCHEDULED SERVICING 12-20-01 Cleaning of the external surfaces The external surfaces have an automotive acrylic finish. The applicable procedure for these surfaces is to clean them with water first and then to polish them.
Page 76: Engine Cleaning
Maintenance Manual XA41/XA42 AMM-XA42-0040-001 C.00 12-20-03 Engine Cleaning Remove dirt and oil from the engine. This is necessary to decrease the temperature and to prevent fire. But the applicable maintenance and service procedures are also necessary for a clean engine. Make sure that there is a good airflow in the work area during the cleaning procedure.
Page 77: Standard Practices - Airframe
Maintenance Manual XA41/XA42 AMM-XA42-0040-001 C.00 Chapter 20 Standard Practices - Airframe Table of Contents Chapter Title Page 20-00-00 GENERAL 20-2 20-10-00 STANDARD PRACTICES - AIRFRAME 20-2 20-10-01 Types of Bolts 20-2 20-10-02 Standard Torque Values 20-3 20-10-03 Special Torque Values...
Page 78: General
Maintenance Manual XA41/XA42 AMM-XA42-0040-001 C.00 20-00-00 GENERAL This chapter contains data about standard threaded fasteners. Always tighten the nut or bolt to the torque shown in chapters 20-10-02 and 20-10-03 unless other instructions are applicable. Always use the correct locking device for the nut or the bolt.
Page 79: Standard Torque Values
Maintenance Manual XA41/XA42 AMM-XA42-0040-001 C.00 20-10-02 Standard Torque Values To tighten the nuts and bolts, use these torque values: Table: Standard maximum torque values for DIN and LN bolts and nuts Torque value Thread size (metric) (Nm) (ft.lb) 18.0 37.0 63.0...
Page 80: Torque Measurement
Maintenance Manual XA41/XA42 AMM-XA42-0040-001 C.00 20-10-04 Torque Measurement For self-locking nuts, add the torque value of the locking device (friction or brake torque) to the value in the tables above. Read the friction value from the torque wrench when the nut touches the washer.
Page 81: Fittings
Maintenance Manual XA41/XA42 AMM-XA42-0040-001 C.00 20-10-07 Fittings All installed fittings for the oil lubrication, the fuel system, the brake system and the smoke system are made of aluminum alloy. Most fittings are AN-fittings. The dash number that follows the AN number shows the dimension of the hose for which the fitting is made, in 16 of an inch.
Page 82: Assembly And Disassembly Instructions
Maintenance Manual XA41/XA42 AMM-XA42-0040-001 C.00 20-20-00 ASSEMBLY AND DISASSEMBLY INSTRUCTIONS 20-20-01 General For transportation or storage it is possible to disassemble the aircraft, refer to chapter 20- 20-03. To assemble the aircraft, obey the instructions of chapter 20-20-02. Only approved personnel are permitted to do the assembly and the disassembly.
Page 83: Assembly Instructions
Maintenance Manual XA41/XA42 AMM-XA42-0040-001 C.00 20-20-02 Assembly Instructions Unless specified differently, torque all bolts and nuts as given in chapters 20-10-02 and -03. Assemble the aircraft in the sequences as follows: Remove the rudder if it is installed to the fuselage; refer to chapter 55-60-00.
Page 84 Maintenance Manual XA41/XA42 AMM-XA42-0040-001 C.00 Figure 20-2: Access hatches location in the cockpit Install the battery cover. Install the LH and RH foot rests for the front cockpit (PH 2 screwdriver). Seal the gap at the wing-fuselage intersection with transparent PU protection tape.
Page 85: Disassembly Instructions
Maintenance Manual XA41/XA42 AMM-XA42-0040-001 C.00 20-20-03 Disassembly Instructions It is possible to remove the wing and the stabilizer for transportation and storage. To disassemble the aircraft, do these steps: Fully drain fuel from all tanks. Remove the foot rests from the front cockpit (PH 2 screwdriver).
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Page 87: Environmental Systems
Maintenance Manual XA41/XA42 AMM-XA42-0040-001 C.00 Chapter 21 Environmental Systems Table of Contents Chapter Title Page 21-00-00 GENERAL 21-2 21-20-00 DISTRIBUTION 21-2 21-20-01 Air Vents 21-2 21-20-01 Canopy Defog 21-3 Page date: Page 25.09.2018 Chapter 21...
Page 88: General
Maintenance Manual XA41/XA42 AMM-XA42-0040-001 C.00 21-00-00 GENERAL This chapter includes the system description and operation of the air ventilation and the canopy defog system of the aircraft. You can operate the air intakes on the external side of the canopy with the lever that is shown in Figure 21-1. The levers are installed in the canopy.
Page 89: Canopy Defog
On the XA41, an air intake on the center front part of the canopy lets the air in for the canopy defogging. To adjust the quantity of air for defogging, move the lever in the top center of the instrument panel.
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Page 91: Communication
Maintenance Manual XA41/XA42 AMM-XA42-0040-001 C.00 Chapter 23 Communication Table of Contents Chapter Title Page 23-00-00 GENERAL 23-2 23-10-00 VHF COMMUNICATION TRANSCEIVER 23-2 23-40-00 INTERCOM 23-2 23-50-00 HEADPHONES / HELMETS 23-2 Page date: Page 25.09.2018 Chapter 23...
Page 92: General
23-40-00 INTERCOM The XA42 and XA41 have a voice-controlled intercom which is a part of the ATR833 OLED radio or similar. The intercom can connect a maximum of 2 headsets. An ON / OFF switch is installed between the radio and the transponder in the center console.
Page 93: Electrical Power
Maintenance Manual XA41/XA42 AMM-XA42-0040-001 C.00 Chapter 24 Electrical Power Table of Contents Chapter Title Page 24-00-00 GENERAL 24-2 24-30-00 DC GENERATOR 24-2 24-50-00 ELECTRICAL LOAD DISTRIBUTION 24-2 Page date: Page 25.09.2018 Chapter 24...
Page 94: General
Maintenance Manual XA41/XA42 AMM-XA42-0040-001 C.00 24-00-00 GENERAL For the wiring diagram, refer to chapter 91. 24-30-00 DC GENERATOR The aircraft has a BC410-H or a BC462-H gear-driven DC generator. Both are a spline-driven alternator with high performance. The rated outputs of the alternators are: BC410-H: 30 amps @ 2500 RPM of the engine crankshaft.
Page 95 Maintenance Manual XA41/XA42 AMM-XA42-0040-001 C.00 Power Bus 2*: Smoke, ACL, Fuel Boost, Avionics Master (Switches) Avionics Master: XPDR, COM, GPS, Instr., Copilot Instr., Other options (Circuit breakers) *Power Bus 1 and 2 are not connected when a large alternator is installed. S/N 145 and subsequent have two alternative circuit breaker configurations in the center console for the Power Bus: ...
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Page 97: Equipment And Furnishing
Maintenance Manual XA41/XA42 AMM-XA42-0040-001 C.00 Chapter 25 Equipment and Furnishing Table of Contents Chapter Title Page 25-10-00 COCKPIT 25-2 25-10-01 Seats 25-2 25-10-02 Harnesses 25-2 25-10-03 Document Bag 25-4 25-50-00 CARGO COMPARTMENTS 25-4 25-60-00 EMERGENCY 25-5 25-60-01 Emergency Locator Transmitter...
Page 98: Cockpit
25-10-00 COCKPIT The cockpit of the XA42 has two seats in a tandem layout. The cockpit of the XA41 has one seat. Special aerobatic harnesses are installed on all seats. The aircraft flight manual and the log book are kept in a document bag on the left side wall.
Page 99 Maintenance Manual XA41/XA42 AMM-XA42-0040-001 C.00 Figure 25-2: Installation of the Harness system. Page date: Page 25.09.2018 Chapter 25...
Page 100: Document Bag
• The Aircraft Flight Manual • The Maps. 25-50-00 CARGO COMPARTMENTS The XA41 and the XA42 have a cargo compartment which you can use during non-aerobatic flight. WARNING The cargo compartment must be empty for aerobatic flight. If there are items in the cargo compartment during a utility flight, make sure that they cannot move.
Page 101: Emergency
Maintenance Manual XA41/XA42 AMM-XA42-0040-001 C.00 25-60-00 EMERGENCY 25-60-01 Emergency Locator Transmitter This chapter includes the description of the KANNAD 406 AF-Compact Emergency Locator Transmitter (ELT) and its remote control RC200. Refer to the manufacturer's Operator’s Manual for more data. NOTE We recommend that you set the switch of the ELT to OFF when the aircraft is parked for a long period or for maintenance.
Page 102: Parachutes
Maintenance Manual XA41/XA42 AMM-XA42-0040-001 C.00 DIN 12 socket for the connection of the remote control, a programming dongle or a programming equipment BNC connector for the antenna. For a functional description and operating modes, refer to the manufacturer’s Installation Manual/ Operation Manual.
Page 103: Flight Controls
Maintenance Manual XA41/XA42 AMM-XA42-0040-001 C.00 Chapter 27 Flight Controls Table of Contents Chapter Title Page 27-00-00 GENERAL 27-2 27-00-01 Control Sticks 27-3 27-00-02 Torque Tube 27-4 27-00-03 Control Rods 27-7 27-10-00 AILERONS 27-10 27-20-00 RUDDER 27-17 27-20-01 Rudder Pedals 27-18...
Page 104: General
It also includes the assembly of the flight controls. Refer to the related chapter for the data on a specified system. The standard flight control system of the aircraft is as follows: XA41 with single stick control and XA42 with dual stick control. An elevator on the horizontal stabilizer gives pitch control. Ailerons on the trailing edge of each wing give roll control.
Page 105: Control Sticks
Maintenance Manual XA41/XA42 AMM-XA42-0040-001 C.00 27-00-01 Control Sticks To remove the control sticks for maintenance or overhaul: Disconnect the electronic wires from the lower part of the stick. Remove the tie wraps. Remove the bolt from the lower part of the stick.
Page 106: Torque Tube
Maintenance Manual XA41/XA42 AMM-XA42-0040-001 C.00 27-00-02 Torque Tube The front bearing block is assembled with a taper roller bearing. The rear bearing is a needle roller bearing. To remove the torque tube: Remove the control sticks, refer to chapter 27-00-01.
Page 107 Maintenance Manual XA41/XA42 AMM-XA42-0040-001 C.00 Quantity Component Front bearing shell XA42-2790-251 Outer race A2120D Rear bearing shell XA42-2790-252 Taper roller bearing A2037 Cotter pin DIN94 2,5x22 Castle nut AN320-6 Hexagon head screw DIN7991 M8x100 Washer DIN125-A M8 Self-locking nut DIN985 M8...
Page 108 Maintenance Manual XA41/XA42 AMM-XA42-0040-001 C.00 Figure 27-3: Torque tube installation Page Page date: Chapter 27 25.09.2018...
Page 109: Control Rods
Maintenance Manual XA41/XA42 AMM-XA42-0040-001 C.00 27-00-03 Control Rods To remove the control rods: Remove the applicable access panels and seats. Remove the bolt connection which connects the rod ends to other parts. Refer to the applicable section in chapter 27 for details.
Page 110 Maintenance Manual XA41/XA42 AMM-XA42-0040-001 C.00 Table 27-2: Control rod lengths [mm] Control rod XA41 XA42 1- Elevator rod FWD as necessary as necessary 2- Elevator rod CFRP 1835 1900 3- Aileron rod inboard 4- Aileron rod CFRP 1595 1595 5- Aileron rod outboard...
Page 111 Maintenance Manual XA41/XA42 AMM-XA42-0040-001 C.00 Install the access panels. Figure 27-6: Maximum adjustment length Page date: Page 25.09.2018 Chapter 27...
Page 112: Ailerons
Maintenance Manual XA41/XA42 AMM-XA42-0040-001 C.00 27-10-00 AILERONS The ailerons are mechanically connected to the control sticks with these components: Quantity Component Torque tube See 27-00-02 Aileron rod inboard XA42-2710-109 Aileron bellcrank fuselage XA42-2710-050 Aileron rod CFRP XA42-2710-114 Aileron bellcrank wing...
Page 113 Maintenance Manual XA41/XA42 AMM-XA42-0040-001 C.00 To adjust the ailerons neutral position and/or deflection: Lock one control stick in the neutral position with a temporary fixture. Measure the length of the aileron rod inboard. Adjust the length, if necessary (refer to chapter 27-00-03).
Page 114 Maintenance Manual XA41/XA42 AMM-XA42-0040-001 C.00 Quantity Component Aileron bonded assy lh XA42-5760-101 Spade arm XA42-5760-193 Spade plate XA42-5760-196 opt. 632 cm² spade plate XA42-5760-197 585 cm² undersized spade opt. XA42-5760-198 plate Screw AN4-14A Washer AN960-416L MS21083N4 Spade arm shim plate 1,5 opt.
Page 115 Maintenance Manual XA41/XA42 AMM-XA42-0040-001 C.00 27-10-02 Aileron bellcrank fuselage The aileron bellcrank in the fuselage is installed against the side wall on each side behind the side panel. The bellcrank is connected to the fuselage from the outside with screws on the interface surface between wing and fuselage.
Page 116 Maintenance Manual XA41/XA42 AMM-XA42-0040-001 C.00 Figure 27-9: Fuselage bellcrank installation Page Page date: Chapter 27 25.09.2018...
Page 117 Maintenance Manual XA41/XA42 AMM-XA42-0040-001 C.00 27-10-03 Wing bellcrank Aileron bellcrank wing aileron rod is installed on the third wing end rib. It connects the CFRP aileron rod outboard and the . See Figure 27-10 for details on the connection. Figure 27-10: Wing bellcrank installation...
Page 118 Maintenance Manual XA41/XA42 AMM-XA42-0040-001 C.00 Quantity Component Aileron bellcrank wing XA42-2710-104 Ailleron bracket XA42-2710-106 Aileron-Rod CFRP XA42-2710-114 Aileron rod Outboard XA42-2710-119 Bearing KP4A MS27641-4 Screw AN4-30 Washer AN960-416 AN310-4 Cotter pin DIN 94 2x12 Washer AN960-10 MS21044N3 Screw AN4-10 Washer...
Page 119: Rudder
27-20-00 RUDDER The rudder operates with a single (XA41) or dual (XA42) pedal system which is connected to the rudder with control cables. The travel stops of the rudder control system are attached to the fulcrum lever. For maintenance of the fulcrum lever, remove the rudder.
Page 120: Rudder Pedals
Maintenance Manual XA41/XA42 AMM-XA42-0040-001 C.00 To remove the rudder, refer to chapter 55-60-00 To adjust the neutral position of the rudder: Remove the side inspection cover in the cockpit. Remove the upper cowling, refer to chapter 71-10-01. Remove the upper firewall inspection cover. Refer to chapter 71-30-00.
Page 121 Maintenance Manual XA41/XA42 AMM-XA42-0040-001 C.00 To remove the front rudder pedals (XA42 only): Disconnect the forward control cable loop. Disconnect the middle control cable. Remove the bolt connection from the hinge point of the front rudder pedal. Refer Figure 27-15, pos. 1.
Page 122 Maintenance Manual XA41/XA42 AMM-XA42-0040-001 C.00 To remove the pedal cart: Applicable to XA42: Disconnect the brake cylinder from the pedal cart. Remove the front connection of the length adjustment rod. Refer to Figure 27-19. Remove the bolts from the two bottom rollers.
Page 123 Maintenance Manual XA41/XA42 AMM-XA42-0040-001 C.00 Put the two (2) concentric rollers in the upper locations of the cart and hold the rail bridge in position at the same time. Make sure that the arrow on the rail bridge points forward.
Page 124 Maintenance Manual XA41/XA42 AMM-XA42-0040-001 C.00 Figure 27-19: Connection bolt AN4-7A of the length adjustment rod to the pedal cart. Page Page date: Chapter 27 25.09.2018...
Page 125: Control Cables
Maintenance Manual XA41/XA42 AMM-XA42-0040-001 C.00 27-20-02 Control Cables These assembled control cables are available in sets:  The control cables in the rear fuselage  The loop of the control cable in the front fuselage  The control cables that connect the front part with the rear part of the rudder control system.
Page 126 Maintenance Manual XA41/XA42 AMM-XA42-0040-001 C.00 Remove all lateral access panels in the cockpit to get a better access. Install the other control cable end on the lever in the side wall of the rear cockpit, refer to Figure 27-21. To adjust the correct length of the cable: Move the rudder to the right. Put the lever in the side wall with a minimum distance of 5mm to the frame directly aft of it.
Page 127 Maintenance Manual XA41/XA42 AMM-XA42-0040-001 C.00 Assemble the forward control cable loop left (XA42-2720-251) and the forward control cable loop right (XA42-2720-252) with the turnbuckle (XA42-2720-260). Refer to Figure 27-22. Use the turnbuckle to apply a tension of 110 N (25 lb) ± 10% to the cable system.
Page 128: Elevator And Trim Tab
Maintenance Manual XA41/XA42 AMM-XA42-0040-001 C.00 27-30-00 ELEVATOR AND TRIM TAB The elevator operates through push/pull rods, a bell crank and an actuator arm. The actuator arm is part of the elevator. The push/pull rod that connects the actuator arm is made of carbon fiber.
Page 129: Trim Tab
Maintenance Manual XA41/XA42 AMM-XA42-0040-001 C.00 27-30-01 Trim Tab The trim tab operates through an electric actuator. You can control the actuator with a switch on the left side panel of the rear cockpit. The trim tab is attached at two hinge points on the right side of the trailing edge of the elevator.
Page 130 Maintenance Manual XA41/XA42 AMM-XA42-0040-001 C.00 Figure 27-23: Trim control installation. Detail L from S/N 08 and S/N 144 on or after performing SB-2016-006. Page Page date: Chapter 27 25.09.2018...
Page 131: Elevator Bellcrank
Maintenance Manual XA41/XA42 AMM-XA42-0040-001 C.00 27-30-02 Elevator bellcrank The Elevator bellcrank is installed between the rear seat frames with an AN5-53A bolt. Refer to Figure 27-24. To disassemble the elevator bellcrank: Remove the rear seat, refer to chapter 25-10-01. Elevator control rod FWD...
Page 132: Elevator Control Rod Cfrp
Maintenance Manual XA41/XA42 AMM-XA42-0040-001 C.00 27-30-03 Elevator control rod CFRP For the connection of the elevator control rod CFRP to the elevator, refer to Figure 27-25. Quantity Component Elevator control rod CFRP XA42-2730-101 Elevator XA42-5520-051 Screw AN4-13 Washer DIN 9021 6,4 (M6)
Page 133: Fuel
Maintenance Manual XA41/XA42 AMM-XA42-0040-001 C.00 Chapter 28 Fuel Table of Contents Chapter Title Page 28-00-00 GENERAL 28-2 28-10-00 STORAGE 28-3 28-10-01 Acro Tank 28-3 28-10-02 Flop Tube 28-4 28-10-03 Wing Tanks 28-6 28-10-04 Ventilation Lines 28-6 28-20-00 DISTRIBUTION 28-7 28-20-01...
Page 134: General
Maintenance Manual XA41/XA42 AMM-XA42-0040-001 C.00 28-00-00 GENERAL The fuel system has these components:  The acro tank  Two integral wing tanks  A fuel selector valve  A fuel filter  An electrically operated auxiliary fuel pump (boost pump) ...
Page 135: Storage
Maintenance Manual XA41/XA42 AMM-XA42-0040-001 C.00 For refueling, defueling or fuel drainage instructions; refer to chapters 12-10-01 thru 12-10- 03. Obey the warnings and cautions of the related chapters. WARNING Obey these instructions during all maintenance procedures on the fuel system. Fuel and fuel tank vapors can cause accidents.
Page 136: Flop Tube
Maintenance Manual XA41/XA42 AMM-XA42-0040-001 C.00 Remove the four bolts on top of the acro tank which attach the tank to the tank compartment structure. If shims are available, identify the position of the shims. This helps to install them in the same position during the installation. Refer to Figure 28-2.
Page 137 Maintenance Manual XA41/XA42 AMM-XA42-0040-001 C.00 To remove the flop tube: Drain the main tank, refer to chapter 12-10-03. Remove the cowling, refer to chapters 71-10-01 and 71-10-02. Remove the lower access panel from the fire wall, refer to chapter 71-30-00.
Page 138: Wing Tanks
Maintenance Manual XA41/XA42 AMM-XA42-0040-001 C.00 28-10-03 Wing Tanks Two integral wing tanks are in front of the main spar between the root rib and the third outboard rib of the wing. The wing tanks are sealed with a sealant, refer to chapter 51-30- 06.
Page 139: Distribution
Maintenance Manual XA41/XA42 AMM-XA42-0040-001 C.00 28-20-00 DISTRIBUTION Flexible hoses connect the components of the fuel system. Three input fuel lines are connected to the fuel selector valve. One output fuel line goes through a fuel filter first and through the electrically-operated auxiliary/boost pump before it goes into the engine fuel pump.
Page 140 Maintenance Manual XA41/XA42 AMM-XA42-0040-001 C.00 To disassemble the fuel selector control rods in order to remove the wing: Drain all fuel tanks, refer to chapter 12-10-03. Remove the front seat, refer to chapter 25-10-01. Remove the wing spar cover if installed.
Page 141 Maintenance Manual XA41/XA42 AMM-XA42-0040-001 C.00 Figure 28-7: Fuel selector mechanism assembly Page date: Page 25.09.2018 Chapter 28...
Page 142: Fuel Lines
Maintenance Manual XA41/XA42 AMM-XA42-0040-001 C.00 28-20-02 Fuel Lines For general information on the fuel lines and the fittings, refer to chapters 20-10-06 and 20- 10-07. If it is necessary to replace the fuel lines: Replace all seals on the fire wall with RTV 106 sealant.
Page 143: Auxiliary/Boost Pump
Maintenance Manual XA41/XA42 AMM-XA42-0040-001 C.00 28-20-04 Auxiliary/Boost Pump If the engine-operated fuel pump does not operate correctly, an auxiliary/boost pump supplies sufficient fuel to the engine. The auxiliary/boost pump also operates as a primer during the start of the engine.
Page 144: Indicating
Maintenance Manual XA41/XA42 AMM-XA42-0040-001 C.00 Install the auxiliary/boost pump in the opposite sequence. Do the engine run-up procedure to make sure that the engine operates correctly. Do a fuel leakage check. 28-40-00 INDICATING 28-40-01 Fuel Quantity Indicator For fuel quantity indication, the main tank has a capacitive quantity sensor. Each wing tank has a lever-type sensor.
Page 145 Maintenance Manual XA41/XA42 AMM-XA42-0040-001 C.00 Calibration of the Acro Tank. On the “Fuel Tank” option, select “ACRO”. Fill 10 liters (2.64 US Gallons) of fuel into the tank. The fuel quantity sensor does not measure the first 10 liters. Set the “Use Current Count?” for 0 US Gallons to “Yes”.
Page 146 Maintenance Manual XA41/XA42 AMM-XA42-0040-001 C.00 Set the “Use Current Count?” for 27.5 US Gallons to “Yes” for each wing. Push “EXIT” some times to go back to the main screen. Page Page date: Chapter 28 25.09.2018...
Page 147: Landing Gear
Maintenance Manual XA41/XA42 AMM-XA42-0040-001 C.00 Chapter 32 Landing Gear Table of Contents Chapter Title Page 32-00-00 GENERAL 32-2 32-10-00 MAIN LANDING GEAR 32-2 32-20-00 TAIL GEAR 32-4 32-40-00 WHEELS AND BRAKES 32-10 32-40-01 Wheels 32-10 32-40-02 Brakes 32-17 32-50-00 MAIN LANDING GEAR FAIRINGS...
Page 148 Maintenance Manual XA41/XA42 AMM-XA42-0040-001 C.00 32-00-00 GENERAL The aircraft has a standard landing gear that cannot retract. It has two main wheels and one tail wheel. 32-10-00 MAIN LANDING GEAR Each main wheel is attached to a landing gear strut. The landing gear struts are attached to the engine mount.
Page 149 Maintenance Manual XA41/XA42 AMM-XA42-0040-001 C.00 Pull the fuel vent lines and the breather lines out from the landing gear fairing. Remove the safety wire from the retaining bolt on the engine mount. Remove the bolt, refer to Figure 32-1. Pull the gear strut out together with the gear fairing. If you cannot remove the leg easily, turn the wheel around the yaw axis.
Page 150: Tail Gear
Maintenance Manual XA41/XA42 AMM-XA42-0040-001 C.00 32-20-00 TAIL GEAR The tail wheel is connected to a spring-type strut. This strut is attached to the frame in the tail of the fuselage. A tail wheel lock locks the wheel in a straight position for these functions: ...
Page 151 Maintenance Manual XA41/XA42 AMM-XA42-0040-001 C.00 Figure 32-3: Tail gear strut assembly Page date: Page 25.09.2018 Chapter 32...
Page 152 Maintenance Manual XA41/XA42 AMM-XA42-0040-001 C.00 To remove the tail wheel strut assembly: Lift the tail of the aircraft, refer to chapter 07-20-02. Remove the rudder, refer to chapter 27-20-00. Disconnect the Bowden cable of the tail wheel lock. Remove the bolt that connects the tail wheel swing arm to the mounting bracket.
Page 153 Maintenance Manual XA41/XA42 AMM-XA42-0040-001 C.00 To remove the tail wheel assembly: Remove the split pin. Remove the nut on top of the tail wheel assembly. Refer to Figure 32-3, detail Y. Remove the tail wheel assembly. Assemble the tail wheel assembly in the opposite sequence with a new split pin.
Page 154 Maintenance Manual XA41/XA42 AMM-XA42-0040-001 C.00 Quantity Component Tail wheel lock cable bracket XA42-3261-100 Tail wheel lock clamp XA42-3261-208 Cylinder head screw M5x10 XA42-6110-205 Elevator bell crank XA42-2730-100 Tail wheel lock idler bushing XA42-3261-206 Tail wheel lock slotted link XA42-3261-204 Tail wheeel lock slider bushing...
Page 155 Maintenance Manual XA41/XA42 AMM-XA42-0040-001 C.00 Figure 32-6: Installation of the control assembly of the tail wheel lock. To adjust the tail wheel lock: Disconnect the forward end of the Bowden cable. Lift the elevator leading edge 90mm and temporarily lock it in this position. Refer to Figure 32-7.
Page 156: Wheels And Brakes
Maintenance Manual XA41/XA42 AMM-XA42-0040-001 C.00 Do a functional test as follows: Push the control stick forward. The lock must disconnect. The tail wheel must move freely when the top of the control stick is approximately 25 mm (1 inch)/ aft of the forward stop.
Page 157 Maintenance Manual XA41/XA42 AMM-XA42-0040-001 C.00 Quantity Component Welding Group MLG XA42-3210-151 Wheel pant support LH XA42-3210-165 Wheel pant support RH XA42-3210-168 Wheel assembly RF-018(A) Brake assembly HE2 for DOT4 6A-002.2N(A) Tire 5.00-5 10PLY Michelin Aviator TL PAA02 Main wheel axle FUS-009.1...
Page 158 Maintenance Manual XA41/XA42 AMM-XA42-0040-001 C.00 Grove 5.00-5 wheels with 5.00-5 6ply tires Inspection: Make sure that the wheel tie bolts are tight. Visually examine the wheel for corrosion, cracks, or other damage. Visually examine the brake disc for cracks, corrosion, grooves, unusual wear, or other damage.
Page 159 Maintenance Manual XA41/XA42 AMM-XA42-0040-001 C.00 CAUTION Be careful when you remove the rings, seals and bearings. Do not cause damage to the wheel and the bearings. Remove the retaining snap rings, the felt grease seals and the wheel bearings. Inspection and repair: Examine the bearing races for scoring, corrosion, signs of heat damage or other damage.
Page 160 Maintenance Manual XA41/XA42 AMM-XA42-0040-001 C.00 To make sure that the nuts of the wheel tie bolts are serviceable, install them onto the bolts. If you can turn the nut with your hand more than to the self-locking section, replace the nut.
Page 161 Maintenance Manual XA41/XA42 AMM-XA42-0040-001 C.00 Figure 32-10: Installation - bearing race. Push the bearing race fully into the wheel. Remove the wheel from the press. Visually examine the race. Make sure that it is fully and tightly installed in the wheel.
Page 162 Maintenance Manual XA41/XA42 AMM-XA42-0040-001 C.00 Fill the bearings with MIL-G-81 322 grease such as Aeroshell 22 or Mobil 28. With the wheel on a flat work surface, put in a wheel bearing. Before you install the bearing, apply a thin layer of bearing grease to the bearing race.
Page 163: Brakes
Maintenance Manual XA41/XA42 AMM-XA42-0040-001 C.00 Tail wheel: To disassemble the tail wheel: Remove the tail wheel axle. Refer to Figure 32-3, detail Z. Disassemble the tail wheel. Refer to Figure 32-3, detail Z. Assemble the tail wheel in the opposite sequence.
Page 164 Maintenance Manual XA41/XA42 AMM-XA42-0040-001 C.00 Installation of new brake linings: Permitted brake lining types are: Grove 066-111 Rapco RA66-111 Cleveland 66-111 Before you install the new brake linings, clean the surfaces of the back plate and the press plate. Visually examine the back plate and the press plate for corrosion, deformation or other damage.
Page 165 Maintenance Manual XA41/XA42 AMM-XA42-0040-001 C.00 Figure 32-11: Grove brake assembly. If you disconnected the hydraulic lines, bleed the brake system, refer to chapter 12- 10-06. Removal and disassembly of the brake caliper: WARNING Be careful when you drain the brake fluid. Do not spill it. Do not get it on your skin. Remove spilled brake fluid immediately.
Page 166 Maintenance Manual XA41/XA42 AMM-XA42-0040-001 C.00 Inspection and repair: Visually examine the cylinder for cracks, nick, corrosion or other damage. If there are cracks around the torque pins, replace the cylinder. Examine the caliper torque pins for wear, cracks in the caliper body or other damage.
Page 167: Main Landing Gear Fairings
Maintenance Manual XA41/XA42 AMM-XA42-0040-001 C.00 32-50-00 MAIN LANDING GEAR FAIRINGS The main landing gear fairings consist of four parts each leg: The upper strut fairing, the leg fairing, the wheel pants and the brake cover. For installation details on the complete landing gear fairings, refer to Figure 32-12.
Page 168: Brake System
Maintenance Manual XA41/XA42 AMM-XA42-0040-001 C.00 Figure 32-12: Landing gear leg fairing installation 32-60-00 BRAKE SYSTEM The brakes are installed at the wheels (refer to chapter 32-40-01). The brakes are acutated with the top part of the rudder pedals, which actuate brake cylinders. Front master brake cylinders (XA42-3240-213) are installed on the front rudder pedals (refer to Figure 32-13).
Page 169 Maintenance Manual XA41/XA42 AMM-XA42-0040-001 C.00 Figure 32-13: Front brake cylinder (LH) Page date: Page 25.09.2018 Chapter 32...
Page 170 Maintenance Manual XA41/XA42 AMM-XA42-0040-001 C.00 Figure 32-14: Rear brake cylinder (RH). Page Page date: Chapter 32 25.09.2018...
Page 171: Lights
Maintenance Manual XA41/XA42 AMM-XA42-0040-001 C.00 Chapter 33 Lights Table of Contents Chapter Title Page 33-40-00 ANTI-COLLISION LIGHTS (ACL) 33-2 Page date: Page 25.09.2018 Chapter 33...
Page 172: Anti-Collision Lights (Acl)
Maintenance Manual XA41/XA42 AMM-XA42-0040-001 C.00 33-40-00 ANTI-COLLISION LIGHTS (ACL) The aircraft has strobe ACL lights on each wingtip. Each light strip is attached to the wingtip structure with two M3 DIN 7991 screws. When you assemble the strobe lights, seal the connection with silicone.
Page 173: Navigation And Pitot Static System
Maintenance Manual XA41/XA42 AMM-XA42-0040-001 C.00 Chapter 34 Navigation and Pitot Static System Table of Contents Chapter Title Page 34-00-00 GENERAL 34-2 34-10-00 FLIGHT ENVIRONMENT DATA 34-2 34-10-01 Pitot Static System 34-2 34-10-02 Altimeter 34-3 34-10-03 Airspeed Indicator 34-3 34-20-00 DIRECTION...
Page 174: General
Maintenance Manual XA41/XA42 AMM-XA42-0040-001 C.00 34-00-00 GENERAL The aircraft has a pitot/static system to measure the total and static pressure. The pitot tube is at the left wing leading edge. Two static ports measure the static pressure. They are installed behind the canopy on the left and right side of the fuselage. The minimum configuration of the aircraft also has an altimeter, an airspeed indicator and a magnetic compass.
Page 175: Altimeter
Maintenance Manual XA41/XA42 AMM-XA42-0040-001 C.00 34-10-02 Altimeter The altimeter measures the pressure changes of the atmosphere to calculate the altitude. The scale of the altimeter has marks in feet (ft) or in (m). The knob on the bottom left side sets the barometric pressure value. The scale has marks in...
Page 176: Dependent Position Determining
Maintenance Manual XA41/XA42 AMM-XA42-0040-001 C.00 34-50-00 DEPENDENT POSITION DETERMINING 34-50-01 Transponder The standard transponder is the TRT800H-OLED. It has the standard A/C modes of operation and the Mode-S support with an extended squitter function. The transponder antenna is located left under the fuselage. It is forward of the spar, at the wing fuselage intersection.
Page 177: Electric/Electronic Panels & Multipurpose Parts
Maintenance Manual XA41/XA42 AMM-XA42-0040-001 C.00 Chapter 39 Electric/Electronic Panels & Multipurpose Parts Table of Contents Chapter Title Page 39-00-00 GENERAL 39-2 39-10-00 INSTRUMENT AND CONTROL PANELS 39-2 39-10-01 XA41 Instrument Panel 39-3 39-10-02 XA42 Rear Instrument Panel 39-4 39-10-03 XA42 Front Instrument Panel...
Page 178: General
Maintenance Manual XA41/XA42 AMM-XA42-0040-001 C.00 39-00-00 GENERAL All instrument and control panels are made of carbon fiber. The panels are attached to the structure with screws and click bonds. In the XA42, the cover of the rear instrument panel is part of the front seat.
Page 179: Xa41 Instrument Panel
* If other options are installed, the layout of the instrument panel can be different. MVP-50P has these functions:  Fuel pressure Figure 1: XA41 Instrument Panel  Ampere / Voltmeter  EGT / CHT Scanner  Fuel capacity  Tachometer ...
Page 180: Xa42 Rear Instrument Panel
Maintenance Manual XA41/XA42 AMM-XA42-0040-001 C.00 39-10-02 XA42 Rear Instrument Panel * If other options are installed, the layout of the instrument panel can be different. MVP-50P has these functions:  Fuel pressure  Ampere / Voltmeter  EGT / CHT Scanner ...
Page 181: Xa42 Front Instrument Panel
Maintenance Manual XA41/XA42 AMM-XA42-0040-001 C.00 39-10-03 XA42 Front Instrument Panel * If other options are installed, the layout of the instrument panel can be different. Refer to the figure below for the location of each equipment item of the front instrument panel.
Page 182: Electrical Switch Panel
Maintenance Manual XA41/XA42 AMM-XA42-0040-001 C.00 39-20-00 ELECTRICAL SWITCH PANEL The switch panel is on the right side console of the (rear) cockpit. For information on the switches, refer to the figure and the list below. Keyed ignition switch: Part No. 11-03169 Manufacturer: ACS, Supplier: Aircraft Spruce &...
Page 183: Throttle And Trim Control
Maintenance Manual XA41/XA42 AMM-XA42-0040-001 C.00 39-30-00 THROTTLE AND TRIM CONTROL For serial numbers 01 to 07 and 101 to 150: The throttle and trim control is on the left control panel. A control screw for the throttle friction is on the left side of the trim control switch.
Page 184 Maintenance Manual XA41/XA42 AMM-XA42-0040-001 C.00 Assemble the throttle control rod in the opposite sequence. Do a functional check of the throttle control. From serial numbers 08 and 151 on, or after performing SB-2017-014: To remove the panel: Loosen and remove the screws around the panel.
Page 185: Circuit Breaker Panel
Maintenance Manual XA41/XA42 AMM-XA42-0040-001 C.00 39-50-00 CIRCUIT BREAKER PANEL The circuit breaker panel is attached to the right side of the rear cockpit. For the wiring, refer to chapter 91-10-00. The panel also includes the Refill / Smoke switch. This switch changes the...
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Page 187: Standard Practices And Structures - General
Maintenance Manual XA41/XA42 AMM-XA42-0040-001 C.00 Chapter 51 Standard Practices and Structures - General Table of Contents Chapter Title Page 51-30-00 MATERIALS 51-2 51-30-01 Composite Parts 51-2 51-30-02 Steel Parts 51-4 51-30-03 Aluminum Parts 51-5 51-30-04 Titanium Parts 51-5 51-30-05 Paint...
Page 188: Materials
51-30-00 MATERIALS This section includes the descriptions of materials that are necessary to repair composite and metal parts of the XA41 and the XA42. Suppliers are also included. 51-30-01 Composite Parts WARNING Use only approved materials to repair composite parts.
Page 189 Maintenance Manual XA41/XA42 AMM-XA42-0040-001 C.00 Carbon fiber unidirectional: Manufacturer: C. Cramer & Co. EperStraße 45-47 D-48619 Heek, Germany WLB-No. Mass per unit Style (Cramer) US-sytle Weavepatterns area [g/m²] DIN 65147 KDU 1007 – – uni-axial KDU 1002 – – uni-axial Style 763 –...
Page 190: Steel Parts
Maintenance Manual XA41/XA42 AMM-XA42-0040-001 C.00 Core material - Honeycomb: Manufacturer/Supplier: Schütz GmbH & Co. KGaA Schützstraße 12 D-56242 Selters, Germany Type: Aramidwabe Coremaster C1-3,2-29t5 Aramidwabe Coremaster C1-3,2-29t8 Filler material for resin: Manufacturer/Supplier: STW Schwarzwälder Textil-Werke Heinrich Kautzmann GmbH Aue 3...
Page 191: Aluminum Parts
Maintenance Manual XA41/XA42 AMM-XA42-0040-001 C.00 51-30-03 Aluminum Parts WARNING Use only approved materials to repair aluminum parts. If you do not obey this precaution, accidents can occur. Aluminum sheet: Supplier: Thyssenkrupp AG Type: WLB 3.1354 T4 or 2024 T4 WLB 3.1364 T3511 or 2024 T3 WLB 3.3214 T4 or 6061-T4 (SS)
Page 192: Paint
Maintenance Manual XA41/XA42 AMM-XA42-0040-001 C.00 51-30-05 Paint Filler: Manufacturer: Nexa Autocolor Supplier: Nexa Autocolor Düsseldorferstrasse 80 D-40721 Hilden, Germany Type: PE Filler light grey P565-7100 Hardener P275-2500 Thinner P830-1492 Type: Basefiller P565-5301/5305/5307 Hardener P210 Thinner P850-1492/1493/1494 ____________________________________________________________________ Manufacturer: Spies Hecker...
Page 193 Maintenance Manual XA41/XA42 AMM-XA42-0040-001 C.00 WT Beispritz Additive 1050 Type (clearcoat): HS+Clearcoat 8055 Hardener 3240/3230 HS Clearcoat additive 9034 Thinner 3385 Interior: Manufacturer: Nexa Autocolor Supplier: Nexa Autocolor Düsseldorferstrasse 80 D-40721 Hilden, Germany Type: HS+Topcoat P47-xxx Hardener P210-82-xxx Thinner P852-189x...
Page 194: Agents And Sealers
Maintenance Manual XA41/XA42 AMM-XA42-0040-001 C.00 51-30-06 Agents and Sealers Tank Sealer: Manufacturer: PPG Aerospace Supplier: PPG Aerospace Type: PR 1440 A PR 1440 B (Wing Tank bonding area) Alternative: PR 1422 A2 NA PR 1422 B2 NA (Wing Tank bonding area)
Page 195: Exterior Foil
Maintenance Manual XA41/XA42 AMM-XA42-0040-001 C.00 51-30-07 Exterior Foil It is permitted to apply a foil on the aircraft surface after paint. Permitted areas to apply the foil: All external aircraft areas where paint is applied. This does not include: ...
Page 196: Control Surface Balancing
Maintenance Manual XA41/XA42 AMM-XA42-0040-001 C.00 51-60-00 CONTROL SURFACE BALANCING 51-60-01 Weighing and Calculation of the Control Surface Moments To weigh a control surface or to calculate its moment, it is necessary to remove the control surface from the aircraft. You must weigh and calculate the control surface moments after each repair or painting procedure.
Page 197: Repairs
Maintenance Manual XA41/XA42 AMM-XA42-0040-001 C.00 51-70-00 REPAIRS 51-70-10 Repairs of Reinforced Glass and Carbon Fiber Parts This chapter gives the standard practices to repair a composite structure. A certified design organization must prepare a special repair design for each repair. This repair design must include the layup plans with the number of layers and their orientation.
Page 198: Damage Description
Maintenance Manual XA41/XA42 AMM-XA42-0040-001 C.00 51-70-12 Damage description It is very important to make an accurate damage description. This will be the basis for the repair design. To record a damaged area on the aircraft for a repair design, use the forms in Appendix 8.
Page 199 Maintenance Manual XA41/XA42 AMM-XA42-0040-001 C.00 WARNING Be careful when you sand carbon and glass fiber laminates. Do not get dust of these materials on your skin and do not breathe it. Put on protective clothing and use respiratory protection to prevent damage to your health.
Page 200: Painting Of Composite Parts
Maintenance Manual XA41/XA42 AMM-XA42-0040-001 C.00 51-70-15 Painting of Composite Parts WARNING Be careful when you use hardeners and coating materials: Do not get hardeners and coating materials on your skin. Do not breathe the fumes. Make sure that there is sufficient airflow in the work area during and after the procedure.
Page 201 Maintenance Manual XA41/XA42 AMM-XA42-0040-001 C.00 Removal of grease: WARNING Be careful when you use solvents or other liquids to clean the components. These liquids can be dangerous and release flammable fumes. Always obey these precautions: Make sure that there is sufficient airflow in the work area during and after the procedure.
Page 202 Maintenance Manual XA41/XA42 AMM-XA42-0040-001 C.00 Removal of paint: Disassemble the components as necessary for the repair. To remove the paint from the components: WARNING Be careful when you use paint-removing solvents or other liquids to remove the paint from the components. These liquids can be dangerous and release flammable fumes. Always obey...
Page 203: Canopy
Maintenance Manual XA41/XA42 AMM-XA42-0040-001 C.00 Chapter 52 Canopy Table of Contents Chapter Title Page 52-00-00 GENERAL 52-2 Page date: Page 25.09.2018 Chapter 52...
Page 204: General
Maintenance Manual XA41/XA42 AMM-XA42-0040-001 C.00 52-00-00 GENERAL The canopy frame is a carbon-fiber construction and has an acrylic canopy glass. The composite parts have different protective layers: a polyester layer, an acrylic filler and an acrylic paint to prevent damage to the structure because of moisture and UV radiation.
Page 205 Maintenance Manual XA41/XA42 AMM-XA42-0040-001 C.00 Quantity Component Canopy assy XA42-5200-001 option Single seat canopy XA42-5200-002 Canopy hinge pin XA42-5230-150 Countersunk washer A3235-028-193 Screw MS24693S274 Retainer plate XA42-5230-250 Screw AN526-10R10 Shim-washer canopy 1,0 XA42-5230-255 Shim-washer canopy 1,2 XA42-5230-256 Shim-washer canopy 1,5...
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Page 207: Fuselage
Maintenance Manual XA41/XA42 AMM-XA42-0040-001 C.00 Chapter 53 Fuselage Table of Contents Chapter Title Page 53-00-00 GENERAL 53-2 Page date: Page 25.09.2018 Chapter 53...
Page 208: General
53-00-00 GENERAL The fuselage of the XA41 and the XA42 is a carbon-fiber/honeycomb sandwich construction. All composite parts have different protective layers: a polyester layer, an acrylic filler and an acrylic paint to prevent damage to the structure because of moisture and UV radiation.
Page 209: Stabilizers
Maintenance Manual XA41/XA42 AMM-XA42-0040-001 C.00 Chapter 55 Stabilizers Table of Contents Chapter Title Page 55-00-00 GENERAL 55-2 55-10-00 HORIZONTAL STABILIZER 55-2 55-20-00 ELEVATOR 55-4 55-30-00 TRIM TAB 55-6 55-60-00 RUDDER 55-7 Page date: Page 25.09.2018 Chapter 55...
Page 210: General
AMM-XA42-0040-001 C.00 55-00-00 GENERAL The XA41 and the XA42 have a standard empennage with stabilizers and movable control surfaces. The spars are made of carbon fiber rovings, carbon fiber mesh and foam cores. The empennage shells are made of honeycomb sandwich with carbon-fiber laminate.
Page 211 Maintenance Manual XA41/XA42 AMM-XA42-0040-001 C.00 Quantity Component Stabilizer XA42-5510-001 Horizontal tailplane bolt XA42-5510-291 2 (optional) Shim washer DIN988-22x30-A2 Safety wire MS20995-C32 Figure 55-3: Horizontal stabilizer installation To install the horizontal stabilizer: Clean and lubricate the bolts and bushings with grease.
Page 212: Elevator
Maintenance Manual XA41/XA42 AMM-XA42-0040-001 C.00 Safety the stabilizer main bolts against each other with a 0.032” safety wire. Refer to Figure 55-2. Connect the elevator trim electric connector to the right side of the stabilizer. Make sure that the bayonet lock of the connector is “open” (the white dots are aligned).
Page 213 Maintenance Manual XA41/XA42 AMM-XA42-0040-001 C.00 Quantity Component Elevator XA42-5520-051 Stabilizer XA42-5510-001 Control surface hinge pin XA42-5780-150 Figure 55-5: Elevator installation Page date: Page 25.09.2018 Chapter 55...
Page 214: Trim Tab
Maintenance Manual XA41/XA42 AMM-XA42-0040-001 C.00 55-30-00 TRIM TAB To remove the trim tab: Disconnect the control rod of the trim tab. Refer to chapter 27-30-01. Cut the safety wire on the hinge pin. Remove the hinge pin. Refer to Figure 55-6.
Page 215: Rudder
Maintenance Manual XA41/XA42 AMM-XA42-0040-001 C.00 55-60-00 RUDDER To remove the rudder: Cut the safety wires. Remove the bolts of the lower connection of the rudder (AN5H- 6A bolts, ½” wrench) (refer to Figure 55-7). Remove the rudder hinge pin (5mm Allen key).
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Page 217 Maintenance Manual XA41/XA42 AMM-XA42-0040-001 C.00 Chapter 57 Wing Table of Contents Chapter Title Page 57-00-00 GENERAL 57-2 57-10-00 WING 57-2 57-60-00 AILERONS 57-7 57-70-00 SIGHTING DEVICES 57-8 Page date: Page 25.09.2018 Chapter 57...
Page 218: Wing
57-00-00 GENERAL The wing of the XA41 and the XA42 is one part. It has a dual-box main spar which is made of CFRP. The core of the box is foam. The wing shells are a honeycomb sandwich type with carbon-fiber laminates.
Page 219 Maintenance Manual XA41/XA42 AMM-XA42-0040-001 C.00 A fourth person must remove the rear spar bolts as follows: Pull the safety pins out. Push the bolts out with a rubber mallet, refer to Figure 57-5. Remove the main bolts as follows: Pull the safety pins out. Push the bolts out with a rubber mallet (refer to Figure 57-6).
Page 220 Maintenance Manual XA41/XA42 AMM-XA42-0040-001 C.00 aileron rod CFRP aileron Make sure that the fully moves into the wing root when you pull the rod outboard aileron rod CFRP . If they are not in the wing root, damage to the occur.
Page 221 Maintenance Manual XA41/XA42 AMM-XA42-0040-001 C.00 Turn the top and bottom landing gear strut fairing (LH and RH) to the original position. Install the aft screw on both top strut fairings (AN526-10R12). Refer to chapter 32-50-00, Figure 32-12. Install the wheel pants. Refer to chapter 32-50-00.
Page 222 Maintenance Manual XA41/XA42 AMM-XA42-0040-001 C.00 Rear spar bolt washer XA42-5320-344 or DIN 988 20x28x1 A2 or DIN 988 20x28x0,5 A2 DIN94 3.2x40 Rear spar bolts XA42-5320-340 Figure 57-5: Rear spar bolt assembly Main spar bolts bushing XA42-5320-253 Main spar bolts XA42-5320-250 DIN94 3.2x71...
Page 223: Ailerons
Maintenance Manual XA41/XA42 AMM-XA42-0040-001 C.00 XA42-5370-242 Figure 57-9: Fuel lines RH fuselage 57-60-00 AILERONS The construction of the ailerons is the same as the wing, but they have only one spar. The spar is a honeycomb sandwich type with carbon fiber laminate. It is attached at five points.
Page 224: Sighting Devices
Maintenance Manual XA41/XA42 AMM-XA42-0040-001 C.00 Remove the aileron hinge pin. Install the aileron in the opposite sequence. Install the wing in the opposite sequence. Quantity Component Wings assy XA42-5710-001 Aileron complett lh XA42-5760-051 Aileron complett rh XA42-5760-061 Aileron hinge pin...
Page 225: Propeller
Maintenance Manual XA41/XA42 AMM-XA42-0040-001 C.00 Chapter 61 Propeller Table of Contents Chapter Title Page 61-00-00 GENERAL 61-2 61-10-00 PROPELLER 61-2 61-20-00 PROPELLER CONTROL 61-2 Page date: Page 25.09.2018 Chapter 61...
Page 226: General
AMM-XA42-0040-001 C.00 61-00-00 GENERAL The XA41 and the XA42 have a MTV-9-B-C/C203-20d 3-blade, or MTV-14-B-C/C190-130 4- blade constant-speed propeller. For the control, the operation and the maintenance of the propeller, refer to the MT- Propeller Operation and Installation Manual E-124.
Page 227 Maintenance Manual XA41/XA42 AMM-XA42-0040-001 C.00 Quantity Component P-880-5 MT with Propeller governor XA42-6110-210 housing Clamping piece XA42-6110-201 Cylinder screw M5x10 XA42-6110-205 Washer AN960-10L AN310-3 Split pin 1,6-20 DIN94 Figure 61-1: Connection to the propeller governor. S/N 01-07 and 101-150. Quantity...
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Page 229: Power Plant
Maintenance Manual XA41/XA42 AMM-XA42-0040-001 C.00 Chapter 71 Power Plant Table of Contents Chapter Title Page 71-00-00 GENERAL 71-2 71-01-00 MANIFOLD 71-2 71-10-00 COWLING 71-3 71-10-01 Upper Cowling 71-3 71-10-02 Lower Cowling 71-3 71-20-00 ENGINE MOUNT 71-4 71-30-00 FIRE WALL 71-6...
Page 230: General
Maintenance Manual XA41/XA42 AMM-XA42-0040-001 C.00 71-00-00 GENERAL The XA41 and the XA42 have a Lycoming AEIO-580-B1A aircraft engine. For information on the engine, refer to the manufacturer’s manual. 71-01-00 MANIFOLD The engine has six custom manifold pipes. For the installation of the manifolds on the engine, refer to Figure 71-1.
Page 231: Cowling
Maintenance Manual XA41/XA42 AMM-XA42-0040-001 C.00 71-10-00 COWLING WARNING Before you do work on the cowling, make sure that the engine is OFF. If the engine operates, this can cause accidents. For repair of the cowling, refer to chapter 51-70-10 – Repairs of Reinforced Glass and Carbon Fiber Parts.
Page 232: Engine Mount
Maintenance Manual XA41/XA42 AMM-XA42-0040-001 C.00 71-20-00 ENGINE MOUNT The engine mount holds the engine and attaches the engine to the airframe. The engine is attached to the steel tube engine mount at four points with bolts and washers. Each mounting point has a shock absorber to absorb engine vibration. For the installation of the engine on the engine mount, refer to Figure 71-2.
Page 233 Maintenance Manual XA41/XA42 AMM-XA42-0040-001 C.00 The engine mount is attached to the airframe at four points with bolts, washers and self- locking nuts. For the engine mount installation, refer to Figure 71-3. Component Comment Engine mount XA42-7120-151 LH Front pedal...
Page 234: Fire Wall
71-30-00 FIRE WALL The XA41 and the XA42 have a titanium fire wall. It is installed between the engine mount and the airframe. There are two access panels to get access to the main tank. Fire blankets are also installed in the fire wall. Replace the fire blankets if they are damaged.
Page 235 Maintenance Manual XA41/XA42 AMM-XA42-0040-001 C.00 Figure 71-4: Firewall installation Page date: Page 25.09.2018 Chapter 71...
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Page 237 Maintenance Manual XA41/XA42 AMM-XA42-0040-001 C.00 Chapter 72 Engine Table of Contents Chapter Title Page 72-00-00 GENERAL 72-2 72-10-00 ENGINE 72-2 Page date: Page 25.09.2018 Chapter 72...
Page 238: Engine
Maintenance Manual XA41/XA42 AMM-XA42-0040-001 C.00 72-00-00 GENERAL This chapter gives information on the engine and its assemblies that are installed in the aircraft. For operation and maintenance on the engine, refer to the applicable Lycoming Manual as in chapter 01-0-00.
Page 239 Maintenance Manual XA41/XA42 AMM-XA42-0040-001 C.00 Figure 72-1: Sensor hose of the manifold pressure (cylinder 5). Disconnect the mixture vernier control from the injector body and the engine, refer to chapter 76-20-00. Disconnect the propeller control vernier from the propeller governor. Refer to chapter 61-20-00.
Page 240 Maintenance Manual XA41/XA42 AMM-XA42-0040-001 C.00 NOTE We recommend that you remove the oil lines from the oil valve end and not from the engine end. If necessary, remove the exhaust assembly (78-00-00), the manifold assembly (71-01-00), the baffling and the fittings.
Page 241 Maintenance Manual XA41/XA42 AMM-XA42-0040-001 C.00 Figure 72-3: Rear hoist removed during engine installation. Lift the front end of the engine sufficiently to install the top bolts, washers, and shock mount kits. Torque all four (4) bolts to 51-56 Nm (450–500 in.lb.). Safety the nuts with inspection varnish.
Page 242 Maintenance Manual XA41/XA42 AMM-XA42-0040-001 C.00 Figure 72-5: Oil line 1 and 3. Figure 72-6: Oil lines 5 and 11. Page Page date: Chapter 72 25.09.2018...
Page 243 Maintenance Manual XA41/XA42 AMM-XA42-0040-001 C.00 Figure 72-7: Oil line 4. LH for SN 01-07 and SN 101-136. CENTER from SN 08 and SN 137 on. RH for option with oil filter. Figure 72-8: Oil line 5 Page date: Page 25.09.2018...
Page 244 Maintenance Manual XA41/XA42 AMM-XA42-0040-001 C.00 Fuel system: Figure 72-9 thru Figure 72-11. Refer to Figure 28-5. Firewall Mechanical pump Fuel injection servo Figure 72-9: Fuel lines Fuel pressure transducer Mechanical pump Fuel injection servo Firewall Figure 72-10: Fuel lines (cont.)
Page 245 Maintenance Manual XA41/XA42 AMM-XA42-0040-001 C.00 To fuel divider Fuel injection servo Figure 72-11: Fuel lines (cont.) Install the smoke oil hoses with a T-fitting. Connect the hoses to the exhaust stacks, refer to Figure 72-4. Connect the throttle Bowden cable to the injector body and the engine. Refer to chapter 76-10-00.
Page 246 Maintenance Manual XA41/XA42 AMM-XA42-0040-001 C.00 Connect the mixture control vernier to the injector body and the engine. Connect the hose to the manifold pressure sensor. Connect all electrical cables to the engine and the accessories; refer to chapter 91- 10-00.
Page 247: Engine Controls
Maintenance Manual XA41/XA42 AMM-XA42-0040-001 C.00 Chapter 76 Engine Controls Table of Contents Chapter Title Page 76-00-00 GENERAL 76-2 76-10-00 THROTTLE CONTROL 76-2 76-20-00 MIXTURE CONTROL 76-5 Page date: Page 25.09.2018 Chapter 76...
Page 248: General
Maintenance Manual XA41/XA42 AMM-XA42-0040-001 C.00 76-00-00 GENERAL The engine controls include the throttle control, the propeller control, and the mixture control. 76-10-00 THROTTLE CONTROL The throttle is operated with a throttle lever on the left side of each cockpit and a Bowden cable.
Page 249 Maintenance Manual XA41/XA42 AMM-XA42-0040-001 C.00 Quantity Component Comments Rear lever assy. XA42-7610-111 Front lever assy. XA42-7610-112 Throttle pushrod XA42-7610-116 Friction screw XA42-7610-214 Screw retainer plate XA42-7610-217 For retrofit installed in 1(2) Throttle track 1 XA42-7610-235 front and rear Front throttle traveller...
Page 250 Maintenance Manual XA41/XA42 AMM-XA42-0040-001 C.00 Quantity Component Comments Screw, flat countersunk head XA42-7610-365 Secured with Loctite 243 For retrofit. Secured with Screw, cap socket head MS16998-28 Loctite 243 Figure 76-3: Rear Throttle handle installation on the aircraft. RIGHT after performing SB-2017-014.
Page 251: Mixture Control
Maintenance Manual XA41/XA42 AMM-XA42-0040-001 C.00 76-20-00 MIXTURE CONTROL A vernier on the left side of the rear cockpit and a lever on the right side of the injector body control the mixture. Figure 2: Mixture control linkage. To adjust the mixture control, change the length of the rod end bearing. The rod end bearing connects the forward end of the Bowden cable to the operating lever on the injector body.
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Page 253: Exhaust
Maintenance Manual XA41/XA42 AMM-XA42-0040-001 C.00 Chapter 78 Exhaust Table of Contents Chapter Title Page 78-00-00 GENERAL 78-2 Page date: Page 25.09.2018 Chapter 78...
Page 254: General
Washer STD 35 Lycoming Self-locking nut STD 2233 Lycoming Figure 78-1: Exhaust assembly applicable to these serial numbers: - S/N 07 and subsequent (XA41) - S/N 119 and subsequent (XA42) - Aircraft that accomplished SB-2014-003 and/or SB-2015-003. Page Page date: Chapter 78 25.09.2018...
Page 255: Oil System
Maintenance Manual XA41/XA42 AMM-XA42-0040-001 C.00 Chapter 79 Oil System Table of Contents Chapter Title Page 79-00-00 GENERAL 79-2 79-00-01 Christen Inverted Oil System 79-3 79-40-00 OIL COOLING 79-4 Page date: Page 25.09.2018 Chapter 79...
Page 256: General
79-00-00 GENERAL The XA41 and the XA42 have an inverted oil system for a satisfactory lubrication during all aerobatic maneuvers. The installed system is the Christen inverted oil system. The oil temperature is controlled with two oil coolers (Setrab P/N 50-113-7612). Flexible hoses connect the oil coolers to each other and to the engine.
Page 257: Christen Inverted Oil System
Maintenance Manual XA41/XA42 AMM-XA42-0040-001 C.00 79-00-01 Christen Inverted Oil System The Christen inverted oil system is a gravity oil system. A connection to aircraft power sources is not necessary. The system is applicable for all flight attitudes and also for negative-g flight.
Page 258: Oil Cooling
79-40-00 OIL COOLING The XA41 and the XA42 have two oil coolers (Setrab P/N 50-113-7612). Flexible hoses connect the oil coolers to each other and to the engine. The oil coolers are attached to the engine mount on the left and the right side. Air flow to the oil coolers is supplied through the cowling.
Page 259: Smoke System
Maintenance Manual XA41/XA42 AMM-XA42-0040-001 C.00 Chapter 85 Smoke System Table of Contents Chapter Title Page 85-00-00 GENERAL 85-2 85-10-00 SMOKE OIL TANK 85-2 85-20-00 SMOKE DISTRIBUTION 85-4 Page date: Page 25.09.2018 Chapter 85...
Page 260: General
85-00-00 GENERAL The XA41 and the XA42 have a smoke system that the pilot can operate for aerobatic flight. The smoke system includes a smoke oil tank and smoke oil lines. The smoke oil is injected into the exhaust stacks where the hot exhaust gas evaporates it. Thus, white smoke comes out of the exhaust stacks.
Page 261 Maintenance Manual XA41/XA42 AMM-XA42-0040-001 C.00 Quantity Component Smoke tank XA42-8510-101 Smoke oil pickup line XA42-8510-122 Screw AN3-4A Washer AN960-10 Sealant Epple 33 Figure 85-2: Smoke oil flop tube assembly installation. To fill the smoke tank, change the pump direction of the smoke pump with the switch on the right side panel.
Page 262: Smoke Distribution
Maintenance Manual XA41/XA42 AMM-XA42-0040-001 C.00 Figure 85-4: Smoke system with refill from the right side of the lower cowling. To drain the smoke tank: Put a container of applicable dimensions below the exhaust tubes. Set the battery switch to "ON".
Page 263 Maintenance Manual XA41/XA42 AMM-XA42-0040-001 C.00 Chapter 91 Charts Electrical Charts are provided on demand. Please send a request to support@xtremeair.de Page date: Page 25.09.2018 Chapter 91...
Page 264 Maintenance Manual XA41/XA42 AMM-XA42-0040-001 C.00 APPENDIX Table of Content Chapter Title Page ....Appendix 1 FORM: OCCURRENCE REPORT ....... Appendix 2 FORM: MASS AND BALANCE ....Appendix 3 FORM: COMPASS COMPENSATION ....Appendix 4 FORM: GROUND RUN REPORT ....Appendix 5...
Page 265: Appendix 1
Maintenance Manual XA41/XA42 AMM-XA42-0040-001 C.00 APPENDIX 1 FORM: OCCURENCE REPORT Page Page date: Appendix 24.09.2018...
Page 266 Consecutice No: ___/____ Occurrence Report Issue: _.__ DOA No EASA.21J.360 Page 1 of 2 Design Holder E-Mail: XtremeAir GmbH support@xtremeair.de Contact Data: Fax: Harzstrasse 2 + 49 39267 60999 22 Phone: D-39444 Hecklingen + 49 39267 60999 0 Electronic Report Phone Sundays www.xtremeair.com...
Page 267 Consecutice No: ___/____ Occurrence Report Issue: _.__ DOA No EASA.21J.360 Page 2 of 2 4. Occurrence Summary Detection [_] Maintenance [_] Parking [_] En-Route [_] Aerobatic Phase: [_] Scheduled [_] Taxi [_] Descent [_] Hovering [_] Non-Scheduled [_] Take-off [_] Approach [_] Manoeuvring [_] Operation [_] Climb...
Page 268: Appendix 2 Form: Mass And Balance
Maintenance Manual XA41/XA42 AMM-XA42-0040-001 C.00 APPENDIX 2 FORM: MASS AND BALANCE Page date: Page 24.09.2018 Appendix...
Page 269 Mass and Balance XA42 POA Nr.: DE.21G.0227 Type: Prod.-Nr.: Registration: Job-Nr. XA42 Equipment List from: Reason for M&B: Data according to Airplane Operating Handbook or Type Certificate: Reference Plane (RP): Firewall Levelling reference (LR): Firewall vertical Remaining fuel, comments, configuration MTOM in category 999 kg Utility 850 kg Acrobatic...
Page 270: Appendix 3 Form: Compass Compensation
Maintenance Manual XA41/XA42 AMM-XA42-0040-001 C.00 APPENDIX 3 FORM: COMPASS COMPENSATION Page date: Page 24.09.2018 Appendix...
Page 271 Doc. Nr.:________ XtremeAir GmbH, Harzstr.2, D-39444 Hecklingen Tel: +49 39267 60999 0, Fax: +49 39267 60999 20 Page: 1 of 1 www.xtremeair.de info@xtremeair.de POA-Nr.: DE.21G.0227 Compass compensation Aircraft Type: Registration: Aircraft S/N: Compass type: Compass S/N: Compass manufacturer: Reason for compensation:...
Page 272: Appendix 4 Form: Ground Run Report
Maintenance Manual XA41/XA42 AMM-XA42-0040-001 C.00 APPENDIX 4 FORM: GROUND RUN REPORT Page date: Page 24.09.2018 Appendix...
Page 273 XtremeAir GmbH, Harzstr.2, D-39444 Hecklingen Tel: +49 39267 60999 0, Fax: +49 39267 60999 20 Page: 1 of 1 www.xtremeair.de info@xtremeair.de POA-Nr.: DE.21G.0227 Ground Run report Registration: Aircraft S/N: Aircraft Model: Location: Airfield elevation: Pilot: QNH: Engine: Propeller: Co-Pilot: OAT (°C):...
Page 274: Appendix 5 Form: Check Flight Report
Maintenance Manual XA41/XA42 AMM-XA42-0040-001 C.00 APPENDIX 5 FORM: CHECK FLIGHT REPORT Page date: Page 24.09.2018 Appendix...
Page 275: Form: Control Surfaces Deflections
XtremeAir GmbH Check Flight POA: DE.21G.0227 Type: Aircraft S/N: Registration: Pilot: Location: Airfield elevation: Co-Pilot: Take-off: Landing: QNH: OAT (°C) Date: Flighttime: Weight and Balance Empty mass: (EM) kg Take-off mass (TOM): Crew and crew equipment: kg Empty mass c.g.: Take-off fuel mass (TOFM): kg Take-off c.g.:...
Page 276 Maintenance Manual XA41/XA42 AMM-XA42-0040-001 C.00 APPENDIX 6 FORM: CONTROL SURFACES MASS AND BALANCE Page date: Page 24.09.2018 Appendix...
Page 277 XtremeAir GmbH, Harzstr.2, D-39444 Hecklingen Tel: +49 39267 60999 0, Fax: +49 39267 60999 20 Page: 1 of 1 www.xtremeair.de info@xtremeair.de Control surfaces mass and balance POA-Nr.: DE.21G.0227 XA42 Control surfaces mass and balance Model: Serial Number (S/N): Registration: XA41 / XA42 Refer to AMM chapter 51-60-01 and follow the procedure to determine the mass and balance of the control surfaces.
Page 278: Appendix 7
Maintenance Manual XA41/XA42 AMM-XA42-0040-001 C.00 APPENDIX 7 FORM: CONTROL SURFACE DEFLECTIONS Page date: Page 24.09.2018 Appendix...
Page 279 XtremeAir GmbH, Harzstr.2, D-39444 Hecklingen Tel: +49 39267 60999 0, Fax: +49 39267 60999 20 Page: 1 of 1 www.xtremeair.de info@xtremeair.de POA-Nr.: DE.21G.0227 Control surface deflections Model: Serial Number (S/N): Registration: XA41 XA42 Left wing Right wing Aileron Deflection (° )
Page 280: Damage Description
Maintenance Manual XA41/XA42 AMM-XA42-0040-001 C.00 APPENDIX 8 DAMAGE DESCRIPTION Use the aircraft views below to document the position and dimensions of the damage. In case necessary, attach further sketches and detailed description. Page date: Page 24.09.2018 Appendix...
Page 281 Maintenance Manual XA41/XA42 AMM-XA42-0040-001 C.00 Page Page date: Appendix 24.09.2018...
Page 282 Maintenance Manual XA41/XA42 AMM-XA42-0040-001 C.00 Page date: Page 24.09.2018 Appendix...
Page 283 Maintenance Manual XA41/XA42 AMM-XA42-0040-001 C.00 Page Page date: Appendix 24.09.2018...
Page 284 Maintenance Manual XA41/XA42 AMM-XA42-0040-001 C.00 Page date: Page 24.09.2018 Appendix...

This manual is also suitable for:

Xa42

XtremeAIR XA41 Maintenance Manual

Log of Revisions

Chapter 0 1 Introduction

Chapter 00 Table of Contents

Organization and Handling of this Manual

General Description of the Aircraft

Airworthiness Limitations

Time Limits and Maintenance Checks

Dimensions

Lifting and Shoring

Leveling and Weighing

Towing and Taxiing

Parking, Mooring, Storage and Return to Service

Placards and Markings

Servicing

Standard Practices - Airframe

Environmental Systems

Communication

Electrical Power

Equipment and Furnishing

Flight Controls

Fuel

Landing Gear

Lights

Navigation and Pitot Static System

Electric/Electronic Panels & Multipurpose Parts

Standard Practices and Structures - General

Canopy

Fuselage

Stabilizers

Wing

Propeller

Power Plant

Engine

Engine Controls

Exhaust

Oil System

Smoke System

Appendix 1

Chapter 91 Charts

Appendix 2 Form: Mass and Balance

Appendix 3 Form: Compass Compensation

Appendix 4 Form: Ground Run Report

Appendix 5 Form: Check Flight Report

Appendix 5

Appendix 6 Form: Control Surfaces Mass and Moment

Form: Control Surfaces Deflections

Appendix 7

Damage Description

Quick Links

Related Manuals for XtremeAIR XA41

Summary of Contents for XtremeAIR XA41