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Air Creation BioniX2 13 Maintenance Manual

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Maintenance Manual
Telephone: +33 (0)4 75 93 66 66 • Fax: +33 (0)4 75 35 04 03
GDMMBi²13-1G
Wing Type :
B
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B
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615 Route de l'Aérodrome, 07200 Lanas, France
info@aircreation.fr
Version 0010
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http://www.aircreation.fr
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  • Page 1 Maintenance Manual Wing Type : ² ² 615 Route de l’Aérodrome, 07200 Lanas, France Telephone: +33 (0)4 75 93 66 66 • Fax: +33 (0)4 75 35 04 03 • info@aircreation.fr http://www.aircreation.fr GDMMBi²13-1G Version 0010...

  • Page 2: Table Of Contents

    Amendment Record Sheet ............ 4 Table of Amendments ................4 Amendments ..................4 Introduction ................5 Skills ..................... 5 Tools ....................5 Air Creation Directives ................. 6 Units ..................... 6 3.4.1 Use of Metric/Imperial Units ................... 6 Main Airframe Description ..............6 3.5.1 Keel ........................
  • Page 3 Unscheduled Maintenance ..............15 4.4.1 General .........................15 4.4.2 Inspection after Heavy Landing ................15 4.4.3 Inspection after Heavy Turbulence...............15 Standard Practices – Airframe ..........16 Torque and Safety procedures ............16 5.1.1 Torque Procedures ....................16 5.1.2 Safety Procedures ....................16 Sail Removal ..................17 5.2.1 Wing Dismantling Procedure ................18 5.2.2...

  • Page 4: Amendment Record Sheet

    Amendment Record Sheet Table of Amendments Amendment date Affected sections Affected pages Date inserted Signature Amendments The information in this manual is based on the data that was available at the time of its publication. The latest amendments to this manual will be issued on the Air Création website (http://www.aircreation.fr) in PDF format.

  • Page 5: Introduction

    – as the continuing airworthiness of the aircraft depends on the competence of the person performing the maintenance. If there are any doubts regarding the required and appropriate maintenance then an Air Creation technical station should be contacted for the correct procedures and/or servicing.

  • Page 6: Air Creation Directives

    The information in this manual needs to be followed, and it is not acceptable to make changes to the materials and or physical features of this aircraft. Air Creation will from time to time issue airworthiness directives, which detail any changes to the maintenance manuals, pilot’s operating handbook, or any other details that air creation deems necessary for owners to be notified of.

  • Page 7: Nose Plates

    3.5.2 Nose Plates The nose plates are bolted to the keel and provide attachment points from the leading edges to the keel. They are attached to the keel with bolts. The nose plate bolts also fasten the U-channel to the keel. The gooseneck catch fastens the front wires to the U-channel. 3.5.3 U-Bracket The U-bracket is the major junction for the three main components of the aircraft, the...

  • Page 8: Leading Edge

    The battens help to maintain the profile of the wing during flight, and are important to the correct and stable operation of the wing. Do not fly the wing with any other batten profile than that supplied by Air Creation, as variation may have serious effects on flight performance and stall characteristics of the wing.

  • Page 9: Corset

    Reflex bridles produce longitudinal stability when the wing is at zero or negative angles of attack. The reflex bridles work by preventing the trailing edge of the wing from moving downward, as they are tethered to the king post assembly. When the wing has any negative load on the top surface the rest of the lifting surface will move downward relative to the trailing edge, effectively creating elevator type control surfaces that produce a positive pitching moment, helping to restore level flight.

  • Page 10: Assembling From Shipping Crate

    Assembling from Shipping Crate This procedure is to be followed if the wing arrives in a short packed configuration. An approved dealer is responsible for assembly from the short packed configuration. The short packed wing has had the rear leading edges removed to reduce the packed size for transport.
  • Page 11 11. Gradually open the leading edges to the maximum, while checking that the lateral cables tighten correctly at the ends without loops nor blocking the neoprene openings in the sail. Proceed in small steps, returning to the nose of the wing to pull the sail forward and insure that the central battens remain in the right position on the screws of the leading edges.

  • Page 12: Ground Handling

    18. Assemble the last straight battens at the ends of the wing nor the tip fins. 19. Complete assembly of the wing as indicated in the Pilot’s Handbook. A thorough and complete preflight check is especially necessary after reassembly. Pay special attention to potential transport damage.

  • Page 13: Maintenance Checks

    The fatigue life of these components is dependent upon rigid adherence to maintenance schedules. Air Creation will from time to time amend these maintenance checks as the service history of the aircraft evolves. It is the responsibility of the pilot to ensure compliance with new directives.

  • Page 14: Scheduled Maintenance

    Scheduled Maintenance 4.3.1 Wing Maintenance Schedule Hours of Operation Item Maintenance Requirement 1 yr 2 yrs 3 yrs Wing fabric deterioration and tears Wing Sail Wing fabric stitching condition and abrasion Wing fabric attachments points Straps retaining central battens to keel Straps retaining luff lines on the upper surface Condition of tension straps on batten clasps Zippers of inspection and assembly of the central neoprene junction and...

  • Page 15: Unscheduled Maintenance

    Code: Oil, lubricate, clean and service Check as directed Check for security, cracks, wear and faulty operation Remove, inspect and replace if necessary Recommended replacement or overhaul Mandatory replacement Unscheduled Maintenance 4.4.1 General Unscheduled maintenance is required due to abnormal loads such as heavy landings. If any abnormal loads are encountered during transport or storage then the airframe needs to be checked.

  • Page 16: Standard Practices - Airframe

    Standard Practices – Airframe Torque and Safety procedures This chapter provides standard torque and safety procedures that are to be used in all areas of the aircraft unless otherwise specified. The use of these procedures will ensure the security of installation and prevent overstressing the components. 5.1.1 Torque Procedures Correct Torque of fasteners is critical.

  • Page 17: Sail Removal

    It is mandatory that the sail should be removed from the frame every 300 hours to check for any signs of fatigue or damage from general wear and tear. The removal of the sail may only be performed by an approved Air Creation technical station. The main points to check are: ...

  • Page 18: Wing Dismantling Procedure

    5.2.1 Wing Dismantling Procedure Wing folded on the under surface on a pair of trestles, one at the nose, and the other at the tips:  Check and mark or trace the rotation setting of the sleeves at the ends of the wing and the tension of the sail on the adjustable sleeves on each side of the wing.

  • Page 19: Wing Reassembly Procedure

    5.2.2 Wing Reassembly Procedure Frame Reinsertion After the frame has been dismantled for inspection the frame must be properly reassembled to maintain a high level of safety. Particular attention must be paid to the correct orientation of bolts and washers. Refer to drawings of the “Illustrated Parts Catalogue”...
  • Page 20  The crossbar securing lugs (I220010) are attached to the crossbar protection sleeve (D074329), do not fit them at this stage.  The crossbar attachment bolts screw BHC 6-94/10 (B069410) have the nuts up, assemble with 6-14 nylon washers (B820610) between the stainless steel plates and the aluminum tubes but do not tighten the nuts yet.
  • Page 21  Nylon stop washers (D274080-M) are positioned under the Nylstop of the assembly screws of the leading edge to serve as a rest for each of the central battens.  Note that the rear keel bolt, screw FHC 6-85-15 (B168710) is longer than the front one, screw FHC 6-80-12 (B168310), with two 6x14 stainless steel washers (B810610) on top of the upper nose plate to hold the upper rigging cable later.
  • Page 22  Note that the upper wing wire, kingpost head (D206563) connected to the head of the kingpost should not be attached yet, therefore do not tighten the nut on this bolt. Lateral lower cable N1 (D203674) is the inner wing wire, numbered 1. Lateral lower cable N2 (D203675) is the outer wing wire, numbered 2.

  • Page 23: Sail Reinstallation

    5.2.3 Sail Reinstallation Preparation for Fitting the Sail  At this stage a workspace large enough to open the wings fully is required.  Place the airframe crossbar uppermost on a pair of trestles, one at the nose, the other at the crossbar ends.
  • Page 24 Figure 5-11 Figure 5-12  Slide the rest of the sail onto the leading edges.  Place another trestle under the end of the leading edges and remove the trestle from the crossbar end area.  Remove the nose weight. ...
  • Page 25  Insert the upper wing wires through the openings in the top surface of the sail close to the cross-boom/leading edge junctions.  The wing wire can now be attached on top of the crossbar as per drawings UO28271-M050.  Apply threadlock to bolt, screw BHC 8-96-11 (B090960), and tighten gently, allowing rotation of the cable tang.
  • Page 26 Figure 5-18 Figure 5-17  Position the nose battens on the nuts of the fastening bolts of the leading edge above the nose plates, against the stop washers D274080. Figure 5-19.  Open the leading edge progressively to the maximum, while checking that the lateral cables deploy properly at their ends without loops or knots at the neoprene openings of the sail.
  • Page 27 Figure 5-21 Figure 5-22 Pull Back Attachment  Refer to drawings OP10-24ET & U028271-M010.  Pull the pull back cables (D204591) back behind the kingpost.  Check that the pull back cables are not crossed or wrapped around the keel. ...
  • Page 28  Assemble the luff lines on the pulley block (D255520). (Refer to drawing OP10-26CA.) The doubled interior luff line, luff line N°1 D207006, should be placed in the groove of the front pulley and the exterior luff line, luff line N°2 D207007, in the groove of the back pulley. Figure 5-25.
  • Page 29 Figure 5-27 Figure 5-28  Secure the back-up pull back bridle webbing to the main pull back cables with a ziptie to keep it close to the hang point. This will ease access when rigging, as the hang point back up cable also threads through this back-up loop.
  • Page 30  Pop the plastic covering caps (P201610) over the tips. Figure 5-29 Figure 5-30 15. Front Lower Rigging  Refer to drawing U028271-M030.  To maintain the correct tension of the front lower longitudinal cables the goose-neck catch bolt screw CHC 6-30-10 (B063210) should be placed in the second rearmost hole in the tensioning rail (D251010) when the hang point bracket is in the standard middle position.
  • Page 31 Figure 5-31 Figure 5-32 18. CORSET  Refer to drawing Y153020 & OP10-35CO.  Reassemble the pulley blocks of the CORSET hoist. Check that all of the pulleys are perfectly free to turn without friction. Figure 5-33.  Secure the CORSET pulley blocks to the central battens by means of the straps and stainless steel loops and wrapping them around the central battens in the 3 openings made in the pockets.
  • Page 32 Figure 5-35 Figure 5-36  Refer to drawings Y153030 & UO28271-M100.  The fine cord of the CORSET has a knot on the end near the control lever. Thread the cord in the hole on the flat surface of the cone-shaped pulley D274011 of the control lever by the free end and pull it until the knot is blocked in its housing.
  • Page 33 Figure 5-40 Inspection after Reassembly It is good practice to have an independent person check the airframe. Air Creation always uses a different person for checking the assembly process. Included in 7.1.2 is the Final QA sheet, which may assist in performing the final inspection process.

  • Page 34: Inspection Notes

    The tubes can be washed down with warm water and a light detergent followed by rinsing with fresh water. There are no known fatigue problems with Air Creation wings, but excessive loads and vibration can weaken the structure. Regular inspection for hairline cracks in areas under high stress, such as bolt holes and tube junctions is recommended.

  • Page 35: Bolts

    Replacement Aluminum tubing comes in many different sizes and grades. As sections of the airframe are manufactured from tubing made specifically to Air Creation specification, it is mandatory that only genuine replacement parts, supplied by Air Creation are used. Never attempt to repair tubing. Always replace with a genuine new part.

  • Page 36: Corset

    Inspection of wires should concentrate on any areas where the wires come into physical contact with other components. These areas may cause stress concentration and mechanical wear. Some areas may need to be partially disassembled to fully inspect wires. Kinks created during packing up, transport and storage should also be checked. Any degradation of wires requires replacement.

  • Page 37: Composites

    Figure 5-42 During each overhaul, a strip must be cut off along the lateral stitching and on one of the transversal lines, and sent to the Air Creation factory to be submitted to a test of wear and GDMMBi²13-1G Version 0010...

  • Page 38: Special Purpose Equipment

    “sticky back sail repair tape”) such as used for registration letters, if possible to both sides of the fabric. This tape is available from Air Creation. Any other significant damage should be discussed with Air Creation or a technical station for an assessment of the best repair option. 5.3.7...

  • Page 39: Adjustments

    The batten shape is intrinsic to stability, stall behavior and handling. Some aircraft require batten shape adjustment to correct for turns. This is not necessary for Air Creation wings.
  • Page 40 Tension of the sail on the last carbon battens of the wing tips. It is easy to adjust the symmetry of the wing by differentially adjusting the tension of the sail on the last carbon batten wing tips. To do this, simply rotate the plastic tip of the batten (batten screw P235015) which is fitted with a thread.
  • Page 41 slows the wing down by 5 kph and speeds it up by 5 kph for a 2.5 mm rotation downwards (towards -). The usable speed range adjustment is limited to +5 and -2.5 mm. Beyond these limits, performance and stability of the wing may be affected and unsightly wrinkles may appear on the fabric of the wing tip.
  • Page 42 GDMMBi²13-1G Version 0010...

  • Page 43: Appendix

    Appendix Wing Inspection Forms 7.1.1 BioniX² 13 Wing Frame Stage Inspection (1) Wing serial number and registration: _________________________________________ General This stage inspection should be carried out when the wing frame has been assembled and is ready to be fitted in the sail. It is not possible to properly inspect once the sail has been fitted.
  • Page 44 Check condition & Teflon lubrication of male & female joints __________________ Cross tube to leading edge assembly _________________________________ Sat / Unsat Check general assembly correct (check with drawings M050) __________________ Check rotation of vertical hinge bolts B106517 (free to move but play taken up) ____ Check rotation of horizontal hinge bolts B088515 (free to move but play taken up) ________________________________________________________________ Confirm that internal spacer is fitted in leading edges on bolt B088515 ___________...

  • Page 45: Bionix² 13 Wing Final Assembly Stage Inspection (2)

    7.1.2 BioniX² 13 Wing Final Assembly Stage Inspection (2) Wing serial number and registration __________________________________________ General: This stage inspection should be carried out when the wing assembly is complete. This is the final inspection before the test pilot gets his hands on it, so please look carefully! Inspection schedule: While Rigging Check control frame upright rotates smoothly on upper hinge bolt...
  • Page 46 Retaining straps of the sail secured in the cap at the end of the nose battens, maintaining connectors & batten of the trailing edge in place according to drawing M140 _______________________________________________________ Check the correct fitting of the leather tensioning boot (D074810) _______________ Cross tube to leading edge assembly _________________________________ Sat / Unsat Refer to drawing M050 and check the correct position and assembly of all wires and tightness of all nuts (the tangs should be snug but free to rotate under...

  • Page 47: Method For Folding The Sail

    Method for Folding the Sail Caution: If the Mylar is still installed in the wing, avoid sharp creases in this process or the Mylar may be damaged. 1 Put the wing flat on the ground, upper surface on top. 2 Take the right wing tip and fold it over the left wing tip. 3 Take the two wing tips and bring them on the nose of the wing.

  • Page 49: Maintenance Operation Board

    Maintenance Operation Board Wing Type: ______________________ Serial Number: _________________________ Date Hours Type of Operation Performed Operator Name, Address, Stamp Flown GDMMBi²13-1G Version 0010...
  • Page 50 Date Hours Type of Operation Performed Operator Name, Address, Stamp Flown GDMMBi²13-1G Version 0010...

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