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Texan top class 580 ISR
Maintenance Manual
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Fly Synthesis Texan top class 580 ISR Maintenance Manual

FLY SYNTHESIS
15/02/11
Placard updated
C. Cosatto
C. Cosatto
C. Cosatto
20/12/10
Propeller auto pitch contr.
C. Cosatto
C. Cosatto
C. Cosatto
18/11/10
New manual issue
C. Cosatto
C. Cosatto
C. Cosatto
Num.
Date
Description
Issued
Verified
Approved
REVISION
FlySynthesis s.r.l. Reserves in terms of law the exclusive ownership of this manual and also forbids the whole or partial reproduction of it.
TEXAN TOP CLASS 580 ISR
MAINTENANCE MANUAL
(For Rotax 912 ULS)
2
Provincial Road n.78 Km 12.150 33050 Mortegliano (UD) – Italy Tel. +39.(0)432.992482 – +39.(0)432.993557 Fax +39.(0)432.931280 Sito web: www.flysynthesis.com e-mail: info@flysynthesis.com
Maintenance Manual
FLY SYNTHESIS TEXAN
TOP CLASS 580 ISR
(For Rotax 912 ULS
versions)
Identification: MM_TC_580_Rev.2 Page: 2 of 77 Date: 15/02/11 Issued: C. Cosatto Verified: C. Cosatto Approved: C. Cosatto
Revision Description: Placard update
WARNING
Procedures or instructions that if not followed correctly may result in injury or
death
CAUTION
Procedures or instructions that if not followed correctly may result in damage to
the aircraft or its parts
SCOPE
This manual contains the necessary information for safe and efficient Maintenance of the
FLYSYNTHESIS TEXAN TOP CLASS 580 ISR.
NOTE
This manual may be revised in the future and pages/or sections re-issued in part or whole. Revisions will be available on the Fly Synthesis website www.flysynthesis.com. Any revisions and/or sections should be printed and replaced in the manual at the earliest possible time for flight safety. The revisions added to the manual should be logged and recorded in the table under log of Revisions of this manual, by the owner/user.
DEFINITIONS
Definitions used in this handbook such as WARNING, CAUTION and NOTE are employed
in the following context.
NOTE: Procedures or instructions that is essential to highlight
INTELLECTUAL PROPERTY
The data and information contained in this document is the property of FLYSYNTHESIS SRL. This document may not be reproduced or transmitted to a third party, in any form or by any means. Any unauthorised copy or distribution is illegal as per international agreements relating to property rights.
THIS AIRCRAFT WAS MANUFACTURED IN ACCORDANCE WITH THE FOLLOWING LIGHT SPORT AIRCRAFT AIRWORTHINESS STANDARDS BCAR Section S, CS-VLA, F2279, F2295 AND F2483 AND DOES NOT CONFORM TO STANDARD CATEGORY AIRWORTHNESS REQUIREMENTS.
3
Provincial Road n.78 Km 12.150 33050 Mortegliano (UD) – Italy Tel. +39.(0)432.992482 – +39.(0)432.993557 Fax +39.(0)432.931280 Sito web: www.flysynthesis.com e-mail: info@flysynthesis.com
Maintenance Manual
FLY SYNTHESIS TEXAN
TOP CLASS 580 ISR
(For Rotax 912 ULS
versions)
Identification: MM_TC_580_Rev.2 Page: 3 of 77 Date: 15/02/11 Issued: C. Cosatto Verified: C. Cosatto Approved: C. Cosatto
Revision Description: Placard update
Revision No.
Revision
Date
Signature
01
Propeller automatic pitch control system
20/12/10
Cosatto C.
02
Limitations placard updated
15/02/11
Cosatto C.
LOG OF REVISIONS
4
Provincial Road n.78 Km 12.150 33050 Mortegliano (UD) – Italy Tel. +39.(0)432.992482 – +39.(0)432.993557 Fax +39.(0)432.931280 Sito web: www.flysynthesis.com e-mail: info@flysynthesis.com
Maintenance Manual
FLY SYNTHESIS TEXAN
TOP CLASS 580 ISR
(For Rotax 912 ULS
versions)
Identification: MM_TC_580_Rev.2 Page: 4 of 77 Date: 15/02/11 Issued: C. Cosatto Verified: C. Cosatto Approved: C. Cosatto
Revision Description: Placard update
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LOG OF EFFECTIVE PAGES
5
Provincial Road n.78 Km 12.150 33050 Mortegliano (UD) – Italy Tel. +39.(0)432.992482 – +39.(0)432.993557 Fax +39.(0)432.931280 Sito web: www.flysynthesis.com e-mail: info@flysynthesis.com
Maintenance Manual
FLY SYNTHESIS TEXAN
TOP CLASS 580 ISR
(For Rotax 912 ULS
versions)
Identification: MM_TC_580_Rev.2 Page: 5 of 77 Date: 15/02/11 Issued: C. Cosatto Verified: C. Cosatto Approved: C. Cosatto
Revision Description: Placard update
SECTION PAGE
1. GENERAL SAFETY INFORMATION 6
1.1 GENERAL SAFETY INFORMATION 7
1.2 OWNERS MAINTENANCE 7
1.3 AIRFRAME 7
1.4 FLIGHT CONTROL SYSTEM 8
1.5 SEATS AND SAFETY BELTS 8
1.6 BAGGAGE COMPARTMENT 8
1.7 PLACARD REPLACEMENT 9
1.8 GROUND HANDLING 9
1.9 TIE DOWN 9
2. EQUIPMENT LIST 10
2.1 TOOLING 11
2.2 OTHER POSSIBLE REQUIRED ITEMS 11
2.3 SOURCES TO PURCHASE PARTS 11
2.4 LIST OF DISPOSABLE PARTS 12
3. ENGINE SPECIFICATIONS 13
3.1 ENGINE SPECIFICATIONS 14
3.2 ROTAX 912 S/ULS 14
3.3 ENGINE OVERHAUL 15
3.4 ENGINE CONTROLS 15
3.5 ENGINE INDICATIONS 15
4. WEIGHT AND BALANCE 17
4.1 INTRODUCTION 18
4.2 WEIGHT LIMITATIONS 18
4.3 CENTRE OF GRAVITY LIMITATIONS 18
4.4 WEIGHING PROCEDURE 18
5. TIRE INFLATION PRESSURE 21
5.1 INTRODUCTION 22
5.2 TIRE INFLATION PRESSURE 22
5.3 CHANGING THE TIRE AND TUBE REPLACEMENT 22
6. APPROVED OILS, FUEL AND QUANTITY 23
6.1 ENGINE OIL 24
6.2 FUEL 24
6.3 FUEL TANK CAPACITY 24
7. FASTENER TORQUE VALUES 25
7.1 RECOMMENDED FASTNER TORQE VALUES 26
7.2 FUSELAGE 26
7.3 ENGINE ASSEMBLY 27
7.4 PROPELLER ASSEMBLY 27
7.5 WING ASSEMBLY 28
7.6 RUDDER/STABILATOR ASSEMBLY 28
7.7 CANOPY ASSEMBLY 29
8. REPORTING POSSIBLE SAFETY OF FLIGHT CONCERNS 30
8.1 REPORTING INSTRUCTIONS 31
8.2 FEEDBACK FORM EXAMPLE 31
9. INSPECTION PROCEEDURES 32
9.1 INSPECTIONS 33
9.2 DAILY INSPECTIONS 33
9.2.1 REFUELING 33
9.2.2 FUEL DRAINING 34
9.3 SCHEDULED INSPECTIONS 34
9.3.1 TIME LIMITED COMPONENTS 34
INDEX
6
Provincial Road n.78 Km 12.150 33050 Mortegliano (UD) – Italy Tel. +39.(0)432.992482 – +39.(0)432.993557 Fax +39.(0)432.931280 Sito web: www.flysynthesis.com e-mail: info@flysynthesis.com
Maintenance Manual
FLY SYNTHESIS TEXAN
TOP CLASS 580 ISR
(For Rotax 912 ULS
versions)
Identification: MM_TC_580_Rev.2 Page: 6 of 77 Date: 15/02/11 Issued: C. Cosatto Verified: C. Cosatto Approved: C. Cosatto
Revision Description: Placard update
9.3.2 PROPELLER 34
9.3.3 MAIN LANDING GEAR 34
9.4 PRE-FLIGHT INSPECTIONS 35
9.4.1 NOSE WHEEL 35
9.4.2 PROPELLER 35
9.4.3 ENGINE 35
9.4.4 MAIN LANDING GEAR 35
9.4.5 WINGS 36
9.4.6 FUSELAGE 36
9.4.7 TAIL 36
9.4.8 STABILATOR 36
9.4.9 COCKPIT CHECKS 36
9.5 SCHEDULED INSPECTION CHART 37
10. LANDING GEAR SYSTEM 44
10. LANDING GEAR 45
10.1 BRAKE SYSTEM 45
11. FUEL SYSTEM 46
11.1 FUEL SYSTEM OPERATION 47
11.2 FUEL SYSTEM SCHEMATIC DIAGRAM 48
12. PROPELLER SYSTEM 49
12.1 PROPELLER 50
12.2 APPROVED PROPELLER TYPES 50
13. INSTRUMENTS AND AVIONICS 51
13.1 INSTRUMENTS AND AVIAONICS 52
13.2 BASIC MINIMUM FLIGHT AND ENGINE INSTRUMENTS. 52
13.3 INSTRUMENT PANEL LAYOUT AND LEGEND 53
14. ELECTRICAL SYSTEM 54
14.1 ELECTRICAL SYSTEM 55
14.2 ELECTRICAL POWER SYSTEM SCHEMATIC DIAGRAM 56
14.3 ELECTRICAL BUS SYSTEM SCHEMATIC DIAGRAM 57
14.4 FLAP SYSTEM 58
14.5 FLAP SYSTEM SCHEMATIC DIAGRAM. 59
15. PITOT-STATIC SYSTEM 60
15.1 PITOT-STATIC SYSTEM 61
15.2 PITOT-STATIC WATER TRAPS 61
15.3 PITOT-STATIC INSPECTIONS. 61
15.4 PITOT-STATIC SCHEMATIC DIAGRAM 62
16. STRUCTURAL REPAIRS AND ALTERATIONS 63
16.1 STRUCTURAL REPAIRS AND ALTERATIONS 64
16.2 DAMAGE TO THE COMPOSITE STRUCTURES 64
16.3 LINE MAINTENACE 64
16.4 HEAVY MAINTENANCE 64
16.5 MAJOR REPAIR, ALTERATION OR MAINTENACE 64
16.6 HEAVY LANDING 64
16.7 EXCEEDING ENGINE LIMITS 64
16.8 EXCEEDING AIRPLANE LIMITS 65
16.9 ENGINE MOUNT CHECKS 65
17 PAINTING AND COATINGS 65
17.1 PAINTINGS AND COATING 68
17.2 PLACARDS 68
18. APPENDIX 70 A. DEFINITIONS 71 B. ABBREVIATIONS 72 C. SUPPLEMENTRY APPROVED OPTIONAL EQUIPMENT 74 D. FEEDBACK FORM 76
7
Provincial Road n.78 Km 12.150 33050 Mortegliano (UD) – Italy Tel. +39.(0)432.992482 – +39.(0)432.993557 Fax +39.(0)432.931280 Sito web: www.flysynthesis.com e-mail: info@flysynthesis.com
Maintenance Manual
FLY SYNTHESIS TEXAN
TOP CLASS 580 ISR
(For Rotax 912 ULS
versions)
Identification: MM_TC_580_Rev.2 Page: 7 of 77 Date: 15/02/11 Issued: C. Cosatto Verified: C. Cosatto Approved: C. Cosatto
Revision Description: Placard update
SECTION 1
GENERAL SAFETY INFORMATION
Title Page
1.1 General Safety Information 8
1.2 Owner maintenance 8
1.3 Airframe 8
1.4 Flight control system 9
1.5 Seats and safety belts 9
1.6 Baggage compartment 9
1.7 Placard replacement 10
1.8 Ground handling 10
1.9 Tie down 10
8
Provincial Road n.78 Km 12.150 33050 Mortegliano (UD) – Italy Tel. +39.(0)432.992482 – +39.(0)432.993557 Fax +39.(0)432.931280 Sito web: www.flysynthesis.com e-mail: info@flysynthesis.com
Maintenance Manual
FLY SYNTHESIS TEXAN
TOP CLASS 580 ISR
(For Rotax 912 ULS
versions)
Identification: MM_TC_580_Rev.2 Page: 8 of 77 Date: 15/02/11 Issued: C. Cosatto Verified: C. Cosatto Approved: C. Cosatto
Revision Description: Placard update
1.1 GENERAL SAFETY INFORMATION
This manual contains recommended procedures and instructions for ground handling, servicing and maintaining the TEXAN TOP CLASS 580 ISR. The procedures described are to be used in addition to the particular governing body‘s regulations for each country where the aircraft is being flown. Where a maintenance procedure contravenes local regulations, the procedures of the local governing body will take precedence. This manual may refer you to the engine manual(s) for maintenance required for the relevant engine. Maintenance instructions are divided to scheduled and unscheduled tasks. Scheduled tasks are carried at fixed intervals, either flight hours or periods of time, e.g. at each 100hrs, or once a year which ever comes first. Unscheduled tasks are those required when the airplane condition if affected after damage is discovered or some unusual event like a heavy landing.
1.2 OWNER MAINTENACE
The Texan Top Class 580 ISR has been designed as a simple aircraft that can be maintained by owners. Fly Synthesis allows normal maintenance up to 100 hourly servicing to be carried out by the owner. This includes:
Oil and Oil filter changes Fuel filter changes Brake pad changes Spark plug changes Tire changes
Fly Synthesis recommends that any aircraft being used for flight training or for hire/reward operation be maintained by an approved maintenance person or organisation.
1.3 AIRFRAME
The fuselage, wings and tail are constructed from composite materials. Carbon fibre is used in highly loaded parts of all the structure, like wing spars. The fuselage is made using a composite skin, bulkheads and stringer construction. Sandwich honeycomb is used where required, from the firewall to the tail. The engine is installed on a steel engine mount connected to the firewall. The engine cowling is achieved with two composite material parts, an upper and lower cowling, fixed together with the cam-lock system. The engine compartment is made from steel firewall. The wings are made of a composite skin and ribs with one main spar, connecting both wings together in the centre of the fuselage. Wing-fuselage loads are transmitted through four bolts from the root ribs of each wing to two cross antitorsional tubes in the fuselage construction. An aerodynamic fairing, called Karman, covers the fuselage / wing root area. The cockpit canopy is made of two parts. The forward fixed windshield is installed on the cockpit roll bar, designed to protect the occupants in case of turn over. The aft part of the canopy is designed to move backwards to open the cockpit. When closed, the canopy is held in place by two locks on each side, four locks all together.
WARNING: The four locks must be engaged and locked during flight.
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Provincial Road n.78 Km 12.150 33050 Mortegliano (UD) – Italy Tel. +39.(0)432.992482 – +39.(0)432.993557 Fax +39.(0)432.931280 Sito web: www.flysynthesis.com e-mail: info@flysynthesis.com
Maintenance Manual
FLY SYNTHESIS TEXAN
TOP CLASS 580 ISR
(For Rotax 912 ULS
versions)
Identification: MM_TC_580_Rev.2 Page: 9 of 77 Date: 15/02/11 Issued: C. Cosatto Verified: C. Cosatto Approved: C. Cosatto
Revision Description: Placard update
1.4 FLIGHT CONTROL SYSTEM
The airplane has standard three axis controls, with dual stick and dual rudder pedals. All control surfaces are made from composite material. The control surfaces are mounted on metal hinges and in-turn operated by metal mechanisms. All three control surfaces mass weight balanced to prevent flutter. The pitch is controlled by the stabilator, commonly known as flying tail. There is no fixed elevator section and a negatively geared trim tab is used to position the stabilator in the correct pitch and also to trim the aircraft. The two control sticks in the cockpit are inter-connected and push-pull aluminium rods transfer the movement to the stabilator. The mechanical trim is achieved by changing the zero position of the geared tab. The manual trim lever is positioned between the seats and it moves the trim through a push-pull flexible cable, an optional electric trim is also available. Roll control is by ailerons. Push-pull rods operate the ailerons. These are differential ailerons where the angular movement up is greater then the angular movement down. Directional control is by a rudder installed on the vertical fin stabilizer. Rudder pedal motion is transmitted via flexible steel cables to the rudder bell-crank. The rudder pedals are connected at the front of the aircraft to the steerable nose wheel, which completes the rudder control loop. A spring system help to centralize the rudder and improve pilot‘s control feel.
CAUTION
Do not operate rudder pedals whilst stationary. Excessive pressure applied to rudder pedals may result in damage to the rudder control pedal structure.
1.5 SEATS AND SAFETY BELTS
Pilot and passenger seats are made from composite materials and installed on the cockpit floor. The seat bottom can be removed to enable inspection of the controls below the seat. Each seat vertical back is adjustable on the ground before flight in 1 of 5 positions, to suit pilot and passenger‘s size. Seat covers are fastened via Velcro strips and easily removed for cleaning and inspection.
Each seat is equipped with safety belts, which are locked together with a bayonet quick release latching system. The safety belts are attached to the main structure and each can be adjusted for occupant comfort. Belts should be replaced if frayed, cut, stitching is broken or latching defective.
1.6 BAGGAGE COMPARTMENT
WARNING: Never try to change seat adjustment in flight!
The baggage compartment is located behind the seats. Maximum baggage weight when distributed evenly is 16 kg. Loose Items stored in the baggage area must be secured to prevent unwanted movement during flight in turbulent conditions. An optional bigger baggage compartment is available on request.
10
Provincial Road n.78 Km 12.150 33050 Mortegliano (UD) – Italy Tel. +39.(0)432.992482 – +39.(0)432.993557 Fax +39.(0)432.931280 Sito web: www.flysynthesis.com e-mail: info@flysynthesis.com
Maintenance Manual
FLY SYNTHESIS TEXAN
TOP CLASS 580 ISR
(For Rotax 912 ULS
versions)
Identification: MM_TC_580_Rev.2 Page: 10 of 77 Date: 15/02/11 Issued: C. Cosatto Verified: C. Cosatto Approved: C. Cosatto
Revision Description: Placard update
1.7 PLACARD REPLACEMENT
If placards need to be replaced you can order them through Flysynthesis Srl at
www.flysynthesis.com or contact your local representative.
1.8 GROUND HANDLING
The TEXAN aircraft is very light and should always be moved by hand. Moving the aircraft is accomplished by using the prop hub to pull the aircraft forward, it is best to position the propeller in the horizontal position and hold the propeller close to the hub. For rearward motion holding onto the rear vertical fin allows for easy rearward motion.
WARNING
Do not spin the propeller whilst the engine is hot as it may fire when the propeller is moved and result in injury. Always ensure that master and Ignition are OFF. Always treat the propeller as LIVE! IT KILLS! Never approach the propeller when someone is in the aircraft. Never use any of the control surfaces to move the aircraft for ground handling.
1.9 TIE DOWN
When mooring the aircraft in the open, head into wind if possible. Secure control surfaces by tying the control stick back firmly with a latched seat belt. Tie ropes to the designated wing attachment points located underneath the wing nearest the wing tip. Anchor the rope approximately 30 degrees to the vertical, outboard of the wing attachment point. Ensure sufficient slack as not to place strain on the wing in the event of tire deflation whilst in the tied down position. A third rope is anchored around the Stabiltator hinge and secured rearward in the same manner as the wings.
11
Provincial Road n.78 Km 12.150 33050 Mortegliano (UD) – Italy Tel. +39.(0)432.992482 – +39.(0)432.993557 Fax +39.(0)432.931280 Sito web: www.flysynthesis.com e-mail: info@flysynthesis.com
Maintenance Manual
FLY SYNTHESIS TEXAN
TOP CLASS 580 ISR
(For Rotax 912 ULS
versions)
Identification: MM_TC_580_Rev.2 Page: 11 of 77 Date: 15/02/11 Issued: C. Cosatto Verified: C. Cosatto Approved: C. Cosatto
Revision Description: Placard update
SECTION 2
EQUIPMENT AND PARTS LIST
Title Page
2.1 Tooling 12
2.2 Other possible required items 12
2.3 Sources to purchase parts 12
2.4 List of disposable replacement parts 13
12
Provincial Road n.78 Km 12.150 33050 Mortegliano (UD) – Italy Tel. +39.(0)432.992482 – +39.(0)432.993557 Fax +39.(0)432.931280 Sito web: www.flysynthesis.com e-mail: info@flysynthesis.com
Maintenance Manual
FLY SYNTHESIS TEXAN
TOP CLASS 580 ISR
(For Rotax 912 ULS
versions)
Identification: MM_TC_580_Rev.2 Page: 12 of 77 Date: 15/02/11 Issued: C. Cosatto Verified: C. Cosatto Approved: C. Cosatto
Revision Description: Placard update
Component
Source
Composite airframe parts
Flysynthesis Srl or local distributor.
Non Composites hardware eg Bolts screws etc.
Flysynthesis Srl or local distributor. Other aircraft specialty hardware shops.
Avionics and Instruments
Flysynthesis Srl or local distributor. Other aircraft avionic and instrument
specialty shops.
Propeller Parts
Flysynthesis Srl or local distributor. Propeller manufacturer eg. DUC France, GT
Tonini (Italy) or Pipistrel (Slovenia).
2.1 TOOLING
Tooling required to do maintenance on this aircraft is listed below. Please note that the list may not be comprehensive
Loctite (243, 567 and Antisieze Lubricant # 76764) for the frame section. Open ended Metric Spanner set Torque wrench Air Pump Various petroleum lubricants Dry Lubricant – lubricant that doesn‘t attract dust after application. UV Resistant Tie wraps, and tooling Metric Hex key set Gasoline resistant thread sealant tape Various general care items Metric Socket Wrench Set Pliers and Wise Grips Phillips and Regular Screw Driver Set Flexible neck funnel
2.2 OTHER POSSIBLE REQUIRED ITEMS
Safety wire and Safety Pins WD-40, CRC or another water displacement compound Telescopic mirror Good flash light 5x and 10x magnifying glass and or video inspection equipment
2.3 SOURCES TO PURCHASE PARTS
Parts can be purchased from the following sources
13
Provincial Road n.78 Km 12.150 33050 Mortegliano (UD) – Italy Tel. +39.(0)432.992482 – +39.(0)432.993557 Fax +39.(0)432.931280 Sito web: www.flysynthesis.com e-mail: info@flysynthesis.com
Maintenance Manual
FLY SYNTHESIS TEXAN
TOP CLASS 580 ISR
(For Rotax 912 ULS
versions)
Identification: MM_TC_580_Rev.2 Page: 13 of 77 Date: 15/02/11 Issued: C. Cosatto Verified: C. Cosatto Approved: C. Cosatto
Revision Description: Placard update
Part
Comment
Fuel Filters
Disposable fuel filters or metal mesh non-disposable ones specified by the respective engine manufacture‘s manual must be used.
Air Filters
Disposable air and fuel filters are available from local distributor. If soiled they will be replaced with new ones and old ones discarded. Old filters should be disposed of as per local laws
Tires
Standard front tires: 4x4-ply (100/75-5) Standard rear tires: 13x5x6-ply Large rear tires: 15x6x6-ply Tires and tubes available from local distributor. Worn tires should be disposed of as per local laws.
Oil Filters
Oil filters should be properly disposed of along with the oil at each oil change, according to local laws.
Landing light
Automotive and auto-electrical shop.
Fuel Line
When fuel line has to be replaced, the old one should be properly disposed of, according to local laws.
Water hoses
When hoses have to be replaced, the old one should be properly disposed of, according to local laws. Replacement hose should be of the same type and grade as the original.
Battery
When the sealed maintenance free battery is to be replaced, the older battery should be properly recycled according to local laws.
Spark plugs
Spark plugs are available from Engine manufacturer Or local distributor.
Brake pads
Brake pads are specially made and available from the aircraft manufacturer or local representative.
2.4 LIST OF DISPOSABLE REPLACEMENT PARTS
Dispose of all disposable parts properly following local laws and regulations
14
Provincial Road n.78 Km 12.150 33050 Mortegliano (UD) – Italy Tel. +39.(0)432.992482 – +39.(0)432.993557 Fax +39.(0)432.931280 Sito web: www.flysynthesis.com e-mail: info@flysynthesis.com
Maintenance Manual
FLY SYNTHESIS TEXAN
TOP CLASS 580 ISR
(For Rotax 912 ULS
versions)
Identification: MM_TC_580_Rev.2 Page: 14 of 77 Date: 15/02/11 Issued: C. Cosatto Verified: C. Cosatto Approved: C. Cosatto
Revision Description: Placard update
SECTION 3
ENGINE
Title Page
3.1 Engine specification 15
3.2 Rotax 912 S/ULS 15
3.3 Engine overhaul 16
3.4 Engine controls 16
3.5 Engine indications 16
15
Provincial Road n.78 Km 12.150 33050 Mortegliano (UD) – Italy Tel. +39.(0)432.992482 – +39.(0)432.993557 Fax +39.(0)432.931280 Sito web: www.flysynthesis.com e-mail: info@flysynthesis.com
Maintenance Manual
FLY SYNTHESIS TEXAN
TOP CLASS 580 ISR
(For Rotax 912 ULS
versions)
Identification: MM_TC_580_Rev.2 Page: 15 of 77 Date: 15/02/11 Issued: C. Cosatto Verified: C. Cosatto Approved: C. Cosatto
Revision Description: Placard update
Version
Performance
Torque
Max.RPM
kw hp rpm
Nm ft.lb rpm
912 S/ULS
69.0 95.0 5500
128 94 5100
Continuous
max.5 min
73.5* 100* 5800*
*with Rotax air box and
exhaust system
5800
Bore
Stroke
Displacement
Compression ratio
84mm ( 3.31in )
61.0mm ( 2.4 in )
1352cm ( 82.6 cu.in.)
10.5 : 1
3.1 ENGINE SPECIFICATION The approved power plant installations for the TEXAN TOP CLASS 580 ISR is the
ROTAX 912 ULS. For full detail of engine construction see ROTAX manuals.
3.2 ROTAX 912 S/ULS
3.3 ENGINE OVERHAUL Rotax: After 1500 hours for Rotax 912ULS
3.4 ENGINE CONTROLS
Engine control is by one throttle control, operating both carburettors simultaneously. A choke is provided for starting a cold engine. The twin-magneto ignition system is controlled by the Master Key. The engine starter is actuated by the Master Key, that control the starter relay, when the master switch is ON. With master switch OFF the starter will not operate. An Electric fuel pump supplies fuel pressure prior to the engine starting and running and is used as back up for the engine driven fuel pump in case of failure.
3.5 ENGINE INDICATIONS
The rpm indicator indicates engine speed (RPM). This is an electronic unit. The cylinder head temperature (CHT) indicator shows engine temperature. The oil pressure indicator indicates oil pressure.
A separate indicator indicates the oil temperature. An Exhaust Gas Temperature system (EGT) is also installed.
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Maintenance Manual
FLY SYNTHESIS TEXAN
TOP CLASS 580 ISR
(For Rotax 912 ULS
versions)
Identification: MM_TC_580_Rev.2 Page: 16 of 77 Date: 15/02/11 Issued: C. Cosatto Verified: C. Cosatto Approved: C. Cosatto
Revision Description: Placard update
The fuel pressure indicator indicates fuel pressure with the engine pump and/or aux electric fuel pump in use. This fuel pressure indicator is a mechanical unit.
A standard sealed accumulating hours-meter (Hobbs meter), counts the total time the ignition key is switched on. An optional air switch may be fitted that accumulates time on an air switch clock when the aircraft attains a speed greater than 30 knots. The air switch time can be used for purposes of airframe and engine maintenance.
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Maintenance Manual
FLY SYNTHESIS TEXAN
TOP CLASS 580 ISR
(For Rotax 912 ULS
versions)
Identification: MM_TC_580_Rev.2 Page: 17 of 77 Date: 15/02/11 Issued: C. Cosatto Verified: C. Cosatto Approved: C. Cosatto
Revision Description: Placard update
Intentionally left blank
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Provincial Road n.78 Km 12.150 33050 Mortegliano (UD) – Italy Tel. +39.(0)432.992482 – +39.(0)432.993557 Fax +39.(0)432.931280 Sito web: www.flysynthesis.com e-mail: info@flysynthesis.com
Maintenance Manual
FLY SYNTHESIS TEXAN
TOP CLASS 580 ISR
(For Rotax 912 ULS
versions)
Identification: MM_TC_580_Rev.2 Page: 18 of 77 Date: 15/02/11 Issued: C. Cosatto Verified: C. Cosatto Approved: C. Cosatto
Revision Description: Placard update
SECTION 4
WEIGHTS AND BALANCE
Title Page
4.1 Introduction 19
4.2 Weight Limitations 19
4.3 Center of Gravity Limitations 19
4.4 Weighing Procedure 19
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Provincial Road n.78 Km 12.150 33050 Mortegliano (UD) – Italy Tel. +39.(0)432.992482 – +39.(0)432.993557 Fax +39.(0)432.931280 Sito web: www.flysynthesis.com e-mail: info@flysynthesis.com
Maintenance Manual
FLY SYNTHESIS TEXAN
TOP CLASS 580 ISR
(For Rotax 912 ULS
versions)
Identification: MM_TC_580_Rev.2 Page: 19 of 77 Date: 15/02/11 Issued: C. Cosatto Verified: C. Cosatto Approved: C. Cosatto
Revision Description: Placard update
Exceeding the Centre of Gravity limits is
PROHIBITED
Exceeding the maximum weights is
PROHIBITED
4.1 INTRODUCTION
In order to obtain the best flight performance, safety, stability and control, the airplane must be loaded within the Centre of Gravity (balance) inside the prescribed limits. Operation beyond the prescribed limits may cause instability and loss of control, or too much stability with not enough control. Both cases will lead to unsafe conditions and could result in an accident, with serious or fatal personal injury.
Weight limitations are important as the performance and the integrity of the structure will decrease to below acceptable values when exceeding the maximum Take-Off Weight. Operation at weights above the limits may thus lead to unsafe conditions and could result in a serious accident.
4.2 WEIGHT LIMITATIONS
Rotax 912 Maximum Take-Off Weight 580 kg
Maximum Pilot and Passenger Weight 180 kg Minimum Solo Pilot Weight 70 kg Luggage Compartment, 16 kg Minimum Empty Weight 330 kg
4.3 CENTER OF GRAVITY LIMITATIONS Forward Limit: 377 mm behind the reference datum (27% MAC)
Aft Limit: 504 mm behind the reference datum (36% MAC)
The longitudinal location of the Centre of Gravity (CG) is measured as the distance behind a reference datum (RD). The reference datum is defined as the vertical plane of the leading edge of the wing, when the airplane is level. The mean Aerodynamic Chord (MAC) is the average chord of a wing, for this airplane it is 1400 mm. The 0% of the MAC is the reference datum (RD). The location of the CG can be defined by reference to the % MAC.
4.4 WEIGHING PROCEDURE
Weighing must be done in a closed hangar with no chance of wind affecting the measurements. The floor must be level, preferably smooth concrete or any other smooth hard surface.
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Provincial Road n.78 Km 12.150 33050 Mortegliano (UD) – Italy Tel. +39.(0)432.992482 – +39.(0)432.993557 Fax +39.(0)432.931280 Sito web: www.flysynthesis.com e-mail: info@flysynthesis.com
Maintenance Manual
FLY SYNTHESIS TEXAN
TOP CLASS 580 ISR
(For Rotax 912 ULS
versions)
Identification: MM_TC_580_Rev.2 Page: 20 of 77 Date: 15/02/11 Issued: C. Cosatto Verified: C. Cosatto Approved: C. Cosatto
Revision Description: Placard update
The airplane is complete, painted and all instruments and accessories installed. The airplane is serviced with full engine oil, full engine coolant fluid, full brake fluid, fuel tank drained and filled with the specified amount of the unusable fuel (TEXAN-2 litres-with dual tanks). In order to achieve an acceptable accuracy, the scales used for weighing should have the following capacities:
Nose wheel - Up to 100 kgs Main wheel – each - Up to 120 kgs
1. Put the airplane on the three scales,
2. Block the wheels to prevent the airplane from rolling off the scales,
3. Check that the airplane is level. The check is done by measuring on the cockpit sidewall top, which should be 5º nose down when the airplane is level. Place pieces of wood with different thickness under the wheels, as required to have the airplane level. Close the canopy before reading the scales.
4. Lower two plumb lines from the leading edge of the inboard wing section, left and right wings. Mark the points on the floor and draw a straight line on the floor (parallel to the wing span). This is the reference datum (RD),
5. Measure the longitudinal distance from the RD to the axle of the nose wheel. This is the value X1. Record the value in the weight report. This value should be with a minus sign,
6. Measure the longitudinal distance from the RD to the axle of the main wheels. This is the value X2. Record the value in the weight report,
7. Note the weight of each scale and record in the weight report,
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Maintenance Manual
FLY SYNTHESIS TEXAN
TOP CLASS 580 ISR
(For Rotax 912 ULS
versions)
Identification: MM_TC_580_Rev.2 Page: 21 of 77 Date: 15/02/11 Issued: C. Cosatto Verified: C. Cosatto Approved: C. Cosatto
Revision Description: Placard update
8. Remove the airplane from the scales, record the weight of the supporting wood pieces of each scale as tare weight for that scale,
9. Change the left and right scales for the main wheels, and repeat the weighing procedure again. Record results in the weight report,
10. Calculate the average weight value for each wheel.
11. Calculate the Empty Weight and the Empty Centre of Gravity position for the airplane.
X1 is the distance from nose wheel axle centerline to projection of RD. X2 is the distance from main wheel axle centerline to projection of RD. The standard distance is:
X1 = 925mm (±0.5%) X2 = 655mm (±0.5%).
The formula for CG calculation is as follows: Xt = ML / PT . [CofG position in mm on the wing chord]
Where: ML = (P2DX + P2SX) x X2 - P1 x X1 Xt% = (Xt / MAC) x 100 [CG position in percentage to the wing chord]
ML = Empty weight moment P2DX , P2SX = Weight measured on main wheel P1 = Weight measured on nose wheel
NOTE: DX = RHS SX = LHS The first recording of the Weighing Report & the Center of Gravity Position of the aircraft
is taken at the factory before the delivery of the same aircraft. The Factory Weight and Balance report will accompany the Aircraft on delivery.
Every variation due to the installation of new components or repairs and painting, implicate a new calculation of the empty weight and the relative positioning of the center of gravity. Any weight and Balance changes should be recorded into the aircraft log book.
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Maintenance Manual
FLY SYNTHESIS TEXAN
TOP CLASS 580 ISR
(For Rotax 912 ULS
versions)
Identification: MM_TC_580_Rev.2 Page: 22 of 77 Date: 15/02/11 Issued: C. Cosatto Verified: C. Cosatto Approved: C. Cosatto
Revision Description: Placard update
Title Page
5.1 Introduction 23
5.2 Tire Inflation pressure 23
5.3 Tire and tube replacement procedure 23
SECTION 5
TIRE INFLATION PRESSURE
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Maintenance Manual
FLY SYNTHESIS TEXAN
TOP CLASS 580 ISR
(For Rotax 912 ULS
versions)
Identification: MM_TC_580_Rev.2 Page: 23 of 77 Date: 15/02/11 Issued: C. Cosatto Verified: C. Cosatto Approved: C. Cosatto
Revision Description: Placard update
5.1 INTRODUCTION
It is essential to maintain your tires in good condition. When checking tire pressure, examine for tire wear, cuts, bruises and slippage. Remove oil, grease and mud from tires with soap and water.
NOTE: Recommended tire pressures should be maintained, especially in cold weather. Any drop in temperature of air inside the tire causes a corresponding drop in tire pressure.
5.2 TIRE PRESSURES
Main wheel tire 4.00x6‖ or (13x5x6), inflation pressure 2.2 – 2.4 bar (32 – 35 psi) Large main wheel tire 15x6x6, inflation pressure 2.2 – 2.4 bar (32 – 35 psi) Nose wheel tire 4.00x4‖,(100/75-5) inflation pressure: 1.8 bar (26.1 psi)
5.3 CHANGING THE TIRE AND TUBE REPLACEMENT.
The wheel rims used in this aircraft are of the split rim type and as such generally require an inner tube. Should the tube or tire require replacement the following procedure will be of assistance.
Raise the aircraft to suspend the wheel off the ground Remove the wheel fairing Remove axle from wheel housing Unbolt the disk brake from rim ( rear wheel only) Remove wheel from axle assembly Split rim by undoing the rim bolts
NOTE: ensure no pressure is left in tire prior to splitting the rim.
Replace defective tire or tube Re bolt the rim being careful not to pinch the inner tube Inflate the tire to correct tire pressure Check bearing for smoothness in rotation Submerse the inflated tire in water and check for leaks Re-assemble the wheel to the axle in reverse order.
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Maintenance Manual
FLY SYNTHESIS TEXAN
TOP CLASS 580 ISR
(For Rotax 912 ULS
versions)
Identification: MM_TC_580_Rev.2 Page: 24 of 77 Date: 15/02/11 Issued: C. Cosatto Verified: C. Cosatto Approved: C. Cosatto
Revision Description: Placard update
SECTION 6
APPROVED OILS, FUELS AND QUANTITY
Title Page
6.1 Engine Oil 25
6.2 Fuel 25
6.3 Fuel tank capacity 25
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