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streak 2b & merlin maintenance manual and

1. PART NO 106445 RHS PART NO 106443 LHS LAST ACESSED Wednesday 21 April 2010 ALL DIMENSIONS IN MILLIMETERS UNLESS STATED OTHERWISE Rev AMENDMENTS Date L EDGE REAR TW S2B S3 CRUZE ASM Drawn By Simon FOURTH MARK ISOMETRIC OVERVIEW SCALE 1 10 PHILLIPS HEAD SCREW MUST FACE AWAY FROM THE SAIL THIS ALLOWS ADJUSTMENT B 1 ASSY Scale Date Born 13 02 03 03 Air AUSTRALIA 6486 SHEET 1 of 1 ITEM NO DWG PART NO QTY TEM NO DWG PART NO QTY 1 L EDGE REAR TW S SERIES 6403 106303 1 1 L EDGE REAR TW S SERIES 6403 106303 1 2 TRIKE WING L EDGE TENSIONER LHS 5172 104669 1 2 TRIKE WING L EDGE TENSIONER RHS 5172 104740 1 3 CLEVIS PIN 3 16 X 2 25 32 5536 105239 1 3 CLEVIS PIN 3 16 X 2 25 32 5536 105239 1 4 WASHER NYLON 1 4IN 5540 102424 1 4 WASHER NYLON 1 4IN THICK 5540 102424 1 5 WASHER 55304 3 16 X 7 16IN 5540 100055 1 5 WASHER 55304 3 16 X 7 16IN 5540 100055 1 6 SPLIT RING 11MM RF114 5720 100950 1 6 SPLIT RING 11MM RF114 5720 100950 1 7 SKT BUTTON SCREW M5 X 10 SS 304 5677 106172 2 7 SKT BUTTON SCREW M5 X 10 SS 304 5677 106172 2 8 NUT UNF 1 4lN ZINC PLATED 5506 103157 1 8 NUT UNF 1 4lN ZINC PLATED 5506 103157 1 9 EYEBOLT WITH HEAT SHRINK 6545 106631 1 9 EYEBOLT WITH HEAT SHRINK 6545 106631 1 ADJUST TENSIONER TO VWIIVHLSNYV ANDOWLVS SLYVd GALVYLSNTII NIHAN 8 15 OUIOG
2. en ns 29 Figure 23 Attach Front Top wires showing Top front wire being pushed through the sail slot 29 Figure 24 dimos 29 Figure 25 Locate tip WODDIirIt 30 Elgure 26 FIL RIAD od mde dc EP CI A NS ELE 30 eser do P e 30 Figure 28 Insert patern E 31 Figure 29 Tension es ee eee 31 Figure 30 Locate Folding Tip Struts aea tha aa entendent dima tentes 31 Figure 1 NOSE WEDDING sm RC IE 32 Issue 3 0 2010 Page 9 AirBorne WindSports Pty Ltd Streak 2B amp MERLIN Maintenance Manual Figure 32 Major dimensions of net 34 Figure 33 Bettsometer Instrument an example supplier http www conairsports co Uk 45 Figure 34 Adjusting Tip Angle Sail not fitted 48 Figure 35 Adjusting Batten ne oe ecc pa Revel roc ies ea e dace ede 48 Figure 36 LHS Training Bar Attachment eei cope epe easi 50 Tables Table 1 Amendment Record Sheets sci e e Sek eee ep 3 Table 2 Log Or Effective Pales xe etae Hp Erat 4 Table 3 Imperial Metric Conversions xe ca et ERR err nn tnt n 8 Table 4 Airframe Limitations Dr 13 Table 5 Maintenance Privileges see 16 T
3. 8L 0102 Pr Ald SHOdSPUIM OI F0 IcC 072 91551 ITEM DWG PART NO QTY ITEM NO NAME DWG PART NO QTY 1 WING ADJUSTER INNER TUBE 5168 104665 1 1 WING ADJUSTER INNER TUBE 5168 104665 1 2 WING ADJUSTER WEBBING CAP RHS TYPE 2 5169 109859 1 2 WING ADJUSTER WEBBING CAP LHS TYPE 2 5169 109858 1 3 BOLT TRIKE WING TIP ADJUSTER 5233 104733 1 3 BOLT TRIKE WING TIP ADJUSTER 5233 104733 1 4 ADJUSTER DOWL 5170 104667 1 4 TIP ADJUSTER DOWL 5170 104667 1 5 DRI LUBE SOLID LUBE 5637 106432 1 5 DRI LUBE SOLID LUBE 5637 106432 1 6 SCREW SELF TAPPING 1 4X8G 30455 5909 105140 2 6 SCREW SELF TAPPING 1 4X8G 30455 5909 105140 2 7 SPRING WASHER 8 mm ZINC 5679 101366 1 7 SPRING WASHER 8 mm ZINC 5679 101366 1 3 EXPLODED RHS ASSY SCALE 1 2 INSTRUCTIONS NB THERE ARE TWO DIFFERENT 1 SPRING WASHER PLACED ONTO M8 BOLT LEFT RIGHT COMPONENTS 2 HAMMER SPRING WASHER INTO WEBBING CAP FOR THE WEBBING CAP USING SPECIAL PUNCH POSITION INDICATOR HOLE THIS SIDE Er 104669 SCALE 1 2 RHS PART NO 104740 Rev AMENDMENTS pae LHS PART NO 104669 1 2163 ADDED LOCTITE 10 08 05 TW LEADING EDGE TENSIONER ASSYS DCR CHG TO INTERNAL DES 09 LAST ACESS
4. 2010 21 AirBorne WindSports Pty Ltd Streak 2B amp MERLIN Maintenance Manual Special Requirements and Tips When installing or removing the sail you will need a large unobstructed area of approximately 12 metres by 3 metres Make sure the surface is clean and not abrasive Rough concrete will damage the sail a grass area will not damage the wing but will provide many hiding places for bolts nuts and washers short carpet is ideal It is a good practise to note the order of washers and other fittings prior to disassembly and to have a small container to put the hardware in The Illustrated Parts Catalogue should be referenced for correct assembly NOTE Wherever possible perform an operation on one side of the wing and completely reassemble it before continuing with the other side This method gives an easy reference to the reassembly sequence that is required for correct and safe operation De Tension the Tip Undo hook and loop retaining straps at rear leading edge Wind tip tensioner inward clockwise to de tension the tip webbing Remove sail webbing from rear leading edge Figure 4 De Tensioning the Tip Issue 3 0 2010 22 AirBorne WindSports Pty Ltd Streak 2B amp MERLIN Maintenance Manual Remove Rear Leading Edges Spread leading edges approximately 1 12 metres apart Remove rear leading edge from airframe Figure 5 Removing Rear Leading Edges Unbolt Side W
5. As directed 2 R 2 R 2 R 2 R 2 R 2 R 2 R 2 R 2 R 2 RI Batten fitting latch secure As directed 3 R 3 R 3 R 3 R Ce care 57 40 00 2 R 2 R 2 R 2 R 2 R 2 R 21 2 R 218 2 R As directed SIP 3 R 4 R 3 R 6 R As directed 3IR 3 4 R 3 R 3 R 6 Leading edges keel b dd As directed 2 R 2 R 2 R 2 R 4 R 2 R 2 R AIR 2 R e R dents and corrosion Remove frame for sail disassemble and check for fatigue cracks 5 50 50 4 R 6 R radiating from drilled holes Loose bolts nuts 20 10 00 2 R 2 R 2 R 2 R 2 21 2 R 218 2 6 Universal joint keel roller free moving and in good As directed 2 R 2 R 2 R 2 R AIR 2 R 2 R 2 R 2 6 order As directed 6 R 6 R 6 R 6 R 6 R 6 R e R e R 6 R 6 R Tri bl ton 28 As directed 2 R 2 R 2 R 2 R 2 R 2 R 2 R 2 R 21 2 R PI ds Tri Kingnost and Data niai As directed 3 R 3 R 3 R 3 R 3 R 3 R 3 R 3 R 3 R 3 R Table 6 Scheduled Maintenance April 2010 Issue 3 0 20 AirBorne WindSports Pty Ltd Streak 2B amp ME
6. 100002 100001 100003 100547 101333 100559 100967 100004 105330 100006 100549 109929 100587 100009 100010 100011 100631 100012 101363 100850 100013 100014 100713 102273 103668 Date 1 2428 REV DEV ADD 109929 20 11 09 Design Table for hex bolt an NAME BOLT 4 6 BOLT 4 7 BOLT AN4 11a BOLT AN4 12 a BOLT AN4 13 a BOLT AN4 14 a BOLT AN4 15 a BOLT AN4 16 BOLT AN4 20 BOLT AN4 20 a BOLT AN4 22 a BOLT 4 23 BOLT 4 24 BOLT 4 26 BOLT 4 27 BOLT 4 30 BOLT 4 31 BOLT 4 32 BOLT AN4 33 a BOLT AN4 34a BOLT AN4 35 a BOLT AN4 36 a BOLT AN4 40 a BOLT AN4 41 a BOLT 4 42 a H Le LENGTH 19 84 23 02 29 37 32 54 35 72 38 89 42 07 45 24 51 59 51 59 57 94 61 12 64 29 70 64 73 82 76 99 80 17 83 34 86 52 89 69 92 87 96 04 102 39 105 57 108 74 ALL DIMENSIONS IN MILLIMETERS UNLESS STATED OTHERWISE DIMENSIONED TO ANSI B18 2 1 1981 STANDARD HEX AND HEAVY BOLTS TABLE 2 PG 1049 AND 1047 MACHINERERY S HANDBOOK 22ND ED INDUSTRIAL PRESS LTD NEW YORK AN4 BOLT DESIGN TABLE Drawn By Scale Simon 24 Date 21 03 03 AirBo e AUSTRALIA 5450 SHEET 1 of 1 VWIIVHLSNYV ANDOWLVS SLYVd GALVYLSNTII NHAN AVAYLS AOF 6 0102 PT Ald suodspurA OI F0 IcC 072 Design Table for AN5 hex bolt an PART NO 102743 109637 100015 100553 10963
7. AirBorne WindSports Pty Ltd Streak 2B amp MERLIN Maintenance Manual This page is left blank intentionally Issue 3 0 April 2010 Page 54 STREAK 2B amp MERLIN AirBorne ILLUSTRATED PARTS CATALOGUE AUSTRALIA AUSTRALIA STREAK 2B amp MERLIN ILLUSTRATED PARTS CATALOGUE Applicability Streak 2B Merlin Unit 22 30 Kalaroo Rd Redhead 2290 New South Wales Australia Phone 61 2 49449199 Fax 61 2 49449399 Part 106812 AirBorne WindSports Pty Ltd 2010 Issue 2 0 21 04 10 STREAK 2B amp MERLIN AirBorne ILLUSTRATED PARTS CATALOGUE AUSTRALIA Copyright Notice Copyright Airborne Windsports Pty Ltd 2006 All rights reserved Except where the Copyright Act otherwise allows no part of this parts catalogue may be reproduced stored in a retrieval system in any form or transmitted by any means without prior permission in writing of Airborne Windsports pty Ltd AirBorne WindSports Pty Ltd 2010 Issue 2 0 21 04 10 STREAK 2B amp MERLIN AirBorne ILLUSTRATED PARTS CATALOGUE AUSTRALIA WARNING SOME PARTS WHICH ARE LISTED ARE COMPONENTS OF PARTS WHICH ARE NOT USER SERVICABLE ONLY MAINTENANCE WHICH IS SPECIFIED IN THE MAINTENANCE MANUAL SHOULD BE ATTEMPTED AND ONLY THE EXACT SPARE SHOULD BE USED TO REPLACE PARTS THE FOLLOWING DRAWINGS ARE PROVIDED AS A CONVIENIENCE TO AID IDENTIFICATION OF PARTS WHICH ARE USER MAINTAINABLE INTRODUCTION This manual should be
8. PROFILE STREAK 6622 105028 1 37 LABELS2B CRUZE MERLIN REAR L E LHS 6846 107255 1 38 SER REAR RHS 6846 107254 1 9 gt WING STREAK 2B COLOURS TBA Drawn By Scale Date OTIN W Simon 14 26 01 05 A irB 2 of3 VWIIVHLSNYV ANDOWLVS SLYVd GALVYLSNTII 15 suog LE 0102 PIT Ald suodspurA OI F0 IcC 072 91551 BOTTOM SIDE WIRE VIEW OF RHS LEADING EDGE SHOWING WIRE POSITIONS AFT BOTTOM SIDE WIRE THE LHS LEADING EDGE HAS BEEN HIDDEN DETAIL VIEW SCALE 1 25 SO THAT IT IS POSSIBLE TO VIEW THE PARTS BEING ASSEMBLED AMENDMENTS PART NO 106440 1 AIRFRAME PRE ASSY S SERIES 1 CHANGED TO S SERIES DCR 2109 LAST ACESSED Wednesday 21 April 2010 Drawn By Scale Date A irRoorne 6484 ALL DIMENSIONS IN MILLIMETERS UNLESS STATED OTHERWISE Simon 09 06 04 SHEET 1 of 2 UsTRALIA ITEM NO NAME DWG PART NO QTY 1 NOSE JUNCTION ASSY S SERIES 6474 106426 1 X BAR WITH HINGE 6483 106439 1 BOLT 5 21 5493 100819 2 WASHER NYLON M 8 XOD 5540 100820 6 SADDLE 60MM TUBE 7166 100080 2 WASHER NYLON M 8 STND 5540 100595 2 WASHER SS304 5 16 X 1IN X 16G 5540 100714 10 NUT NYLOC AN5 FULL 5535 100036
9. 20 STANDARD PRACTICES AIRFRAME 20 00 00 General This chapter gives details for each of the bolts that are used on the wing This is because there are few fittings which require standard torques 20 10 00 Torquing Procedures Correct torquing of fasteners is critical If a bolt or fastener is too loose it may cause unnecessary movement resulting in wear or fatigue damage while over tightening may cause tensile failure of the bolt or crushing of components Specific torques should be determined using an accurate torque wrench The torque required after the nut is fully on the shaft but not against the mating surface should be added to the final torque value WARNING THE CORRECT TORQUING OF THE BOLTS FOR THE WING SECTION OF THE AIRFRAME IS ESPECIALLY IMPORTANT FOR THE SAFETY AND LONGEVITY OF THE WING IN GENERAL STANDARD TORQUING VALUES WILL NOT BE APPLICABLE BECAUSE OF THE NATURE OF THE THIN WALL ALUMINIUM TUBING THAT HAS BEEN USED TO CONSTRUCT THE MAJORITY OF THE WING STRUCTURE NEVER TIGHTEN NUTS SO THAT THE ALUMINIUM TUBING IS DEFORMED FROM ITS CIRCULAR CROSS SECTIONAL SHAPE ALWAYS HAVE AT LEAST ONE FULL THREAD SHOWING PAST ANY NYLOK NUT THAT IS USED NEVER REPLACE COMPONENTS WITH A SUB STANDARD PART TO REITERATE OTHER GRADES OF BOLTS SUCH AS GRADE 8 DO NOT HAVE THE SAME STRENGTH FATIGUE CHARACTERISTICS AS AN AERONAUTICAL GRADE BOLTS Special Torquing Procedures Special Notes for each of the bolts on the wing are given
10. Screws Drawing 5668 6 OPTIONS 6 1 Training Bars Type 3 Round Drawing 4634 AirBorne WindSports Pty Ltd 2010 Issue 2 0 21 04 10 STREAK 2B amp MERLIN AirBorne ILLUSTRATED PARTS CATALOGUE AUSTRALIA HOW TO USE THIS CATALOGUE The pieces that make up a trike or wing are called Parts or Assemblies ASM Each drawing in this manual contains a mixture of Parts and ASM s at different levels of manufacture This manual contains the Highest Level Drawing at the front and divides into Main Sub Chapters The Sub Chapter Drawings become simpler and simpler until they show only Parts or simple ASM s These are the items that are SOLD On each Drawing items that are SOLD are identified by CIRCLES Parts identified by BOXES are NOT SOLD and are used for factory purposes only See Figure 1 for examples of circles and boxes Use this manual by identifying the Highest Level Drawing that contains the item you re interested in and then by using the identifier circles look at the next level of Drawings listed in the Bill Of Materials box Continue until you find your item where it is listed on a Drawing where it is identified using a Circle This will be the item to ORDER EXAMPLE For example if you were to require a new handle for the trimmer assembly Step 1 Identify that it is a part of the control frame assembly which means that it is in chapter 1 ITEM NOJNAME PART NO 53 CRUZE PRE ASS
11. Slide the rest of the sail up to the nose Figure 20 Position Keel pocket forward of rear wires Spread Wings Spread each wing apart 1 4 of the way alternately on each side until fully open making sure sail is loose and free at all times Figure 21 Spread the wings apart Issue 3 0 April 2010 AirBorne WindSports Pty Ltd Streak 2B amp MERLIN Maintenance Manual Join Zip p Connect sail safety strap at nose junction Slide on zip slider making sure strike marks on the zipper align Fasten zip tie through eyelet holes around the zipper Figure 22 Join centre zipper Attach Front Top Wires Lay king post assembly out at the back of the wing Feed top front wire back through the nose cone then back through the sail Attach tang to nose bolt Figure 23 Attach Front Top wires showing Top front wire being pushed through the sail slot Fit Side Wires Feed bottom and topside wires back through sail slots Bolt side wires to cross bar Figure 24 Fit side wires CAUTION MAKE SURE BOTTOM SIDE WIRES ARE IN THE CORRECT FWD AND AFT SLOTS Issue 3 0 2010 Page 29 AirBorne WindSports Pty Ltd Streak 2B amp MERLIN Maintenance Manual Locate Tip Webbing Locate tip webbing over rear leading edge and secure retaining Velcro Figure 25 Locate tip webbing Fit King Post Feed pull back wires and pull back handle back through king post hole Insert king post into
12. Figure 13 Unbolting top front wire Issue 3 0 April 2010 AirBorne WindSports Pty Ltd Streak 2B amp MERLIN Maintenance Manual Remove Airframe from Sail Leave control frame attached and carefully slide frame out through the nose of the sail Figure 14 Removing Airframe CAUTION DO NOT FORCE SAIL IF IT SNAGS STOP AND FIND WHAT IT S CAUGHT ON Issue 3 0 April 2010 Page 26 AirBorne WindSports Pty Ltd Streak 2B amp MERLIN Maintenance Manual 5 50 60 Frame Reinsertion After the frame has been removed for inspection the frame must be properly reinstalled to maintain a high level of safety Particular attention must be paid to the correct orientation of bolts and washers It is advisable that all nuts that are removed are replaced with new ones or as a rule Nylok nuts should not be reinstalled more than twice WARNING REFER TO SECTION 20 STANDARD PRACTICES FOR CORRECT TORQUING PROCEDURES FAILURE TO READ AND UNDERSTAND THE SPECIFIC TORQUING METHODS THAT ARE NECESSARY FOR THIS THIN WALLED TUBULAR STRUCTURE WILL RENDER THE AIRFRAME UNSAFE TO FLY Reinstall Bungie Tie pull back handle bungie to pulley temporarily using a bowline knot Figure 15 Tie pull back bungie to pulley Prepare Frame for Sail Reinstallation Insert quick clip bolt attach rear flying wires and tighten wars nut finger tight it needs to be removed again to allow the keel pocket past Insert rear leading edges into
13. Issue 3 0 2010 Page 6 AirBorne WindSports Pty Ltd Streak 2B amp MERLIN Maintenance Manual WARNING THE INFORMATION IN THIS MANUAL NEEDS TO BE FOLLOWED AND IT IS NOT ACCEPTABLE TO MAKE CHANGES TO THE MATERIALS AND OR PHYSICAL FEATURES OF THIS AIRCRAFT IN PARTICULAR THE GRADES OF BOLTS THAT HAVE BEEN UTILISED IN THE MANUFACTURE OF THIS AIRCRAFT ARE CRITICAL FOR ITS CONTINUING AIRWORTHINESS NEVER REPLACE BOLTS WITH ANY OTHER SIZE OR GRADE GRADE 8 BOLTS ARE NOT INTERCHANGEABLE WITH AIRCRAFT AN GRADE BOLTS THE FATIGUE CHARACTERISTICS OF AIRCRAFT GRADE BOLTS ARE SUPERIOR TO OTHER BOLTS AND ALLOW LONGER SAFE SERVICE LIFE UNDER CYCLIC LOADS LIKE THOSE EXPERIENCED IN AIRCRAFT THE LENGTH OF THE BOLT IS IMPORTANT IF A SHORTER BOLT IS USED THE THREAD MAY ENCROACH ON THE LOAD BEARING AREA WHICH INCREASES THE STRESSES EXPERIENCED BY IT MANDATORY SERVICE BULLETINS AS THE SERVICE HISTORY OF THE AIRFRAME EVOLVES AIRBORNE WILL FROM TIME TO TIME ISSUE AIRBORNE DIRECTIVES WHICH DETAIL ANY CHANGES TO THE MAINTENANCE MANUALS PILOT S OPERATING HANDBOOK OR ANY OTHER DETAILS THAT AIRBORNE DEEMS NECESSARY FOR OWNERS TO BE NOTIFIED OF THE WEB ADDRESS FOR AIRBORNE DIRECTIVES IS HTTP WWW AIRBORNE COM AU IT IS THE RESPONSIBILITY OF THE OPERATOR TO KEEP UP TO DATE WITH ANY ROTAX DIRECTIVES THROUGH THE ROTAX WEBSITE Issue 3 0 2010 Page 7 AirBorne WindSports Pty Ltd Streak 2B amp MERLIN Maintenance Manua
14. 2 BOLT AN5 36A 5493 100026 2 NUT NYLOC AN5 HALF 5561 100037 2 STRAP PULL BACK 20MM WITH TANGS 160 6463 104754 1 ROPE PRESTRETCHED 4 X 1270 6493 106452 1 SHOCK CORD 4MM X 2200 6493 106451 1 TOP SIDE WIRE FORWARD ANDOWLVS SLYVd GALVYLSNTII NHAN HVIHLS sou VWIIVHLSNYV 0102 PIT Ald suodspurA 01 00 10 O Rev AMENDMENTS PHOTOGRAPHS ROPE AND SHOCK CORD ROUTING PRIOR TO FINAL ASSEMBLY PULL BACK STRAP LOCATION ALSO SHOWN Date PART NO 106440 LAST ACESSED Wednesday 21 April 2010 ALL DIMENSIONS IN MILLIMETERS UNLESS STATED OTHERWISE ITEM NO NAME DWG PART NO QTY 1 NOSE JUNCTION ASSY S SERIES 6474 106426 1 2 X BAR WITH HINGE 6483 106439 1 3 BOLT AN5 21a 5493 100819 2 4 WASHER NYLON M 8 XOD 5540 100820 6 5 SADDLE 60MM TUBE 7166 100080 2 6 WASHER NYLON M 8 STND 5540 100595 2 7 WASHER 55304 5 16 X 1IN X 16G 5540 100714 10 8 NUT NYLOC 5 FULL 5535 100036 2 9 BOLT AN5 36A 5493 100026 2 10 NUT NYLOC AN5 HALF 5561 100037 2 11 STRAP PULL BACK 20MM WITH TANGS 160 6463 104754 1 12 ROPE PRESTRETCHED 4 X 1270 6493 106452 1 SHOCK CORD 4MM X 2200 6493 106451 1 AIRFRAME PRE ASSY S SERIES Drawn By Scale Date 6484 Simon 1 50 17 06 04 4 irBorne UsTRALIA SHEET 2 of 2 ANDOWLVS SLYVd GALVYLSNTII NHAN 8 HVIHLS suog I OIOC PT Ald suodspurA O
15. 21 April 2010 ALL DIMENSIONS IN MILLIMETERS UNLESS STATED OTHERWISE ITEM NO NAME DWG NO QTY 1 BOLT AN5 40 a 5493 100028 1 2 A FRAME AL BRACKET TRIKE WING 6599 103267 2 3 WASHER NYLON M 6 XOD 5540 101055 4 4 WASHER 4 5540 100042 2 5 BOLT 4 20 a 5450 100006 2 6 NUT NYLOC AN4 FULL 5535 100034 2 7 WASHER 55304 5 16 X 1IN X 16G 5540 100714 2 8 NUT NYLOC AN5 FULL 5535 100036 1 9 WASHER MYLAR 22 7 5540 100624 2 11 D TUBE PROTECTOR TW 6600 104318 2 13 D TUBE TW MERLIN LHS WITH WIRES 7550 108965 1 14 D TUBE TW MERLIN RHS WITH WIRES 7551 108966 1 VIEW OF COMPLETE ASSEMBLY STORED ON WALL IN WING ASSEMBLY AREA CONTROL FRAME MERLIN PRE ASM Drawn By Scale Date orn 2 www Air ia Simon AUSTRALIA SHEET 1 of 1 VWIIVHLSNYV ANDOWLVS SLYVd GALVYLSNTII NHAN 15 AOF 0102 PT Ald suodspurA ITEM NO DWG PART NO QTY 1 D TUBE TW ROUND SILVER WITH KNUCKLE 6602 103209 1 2 D TUBE BTM KNUCKLE ROUND TRIKE 3077 100779 1 3 BOLT 4 26 5450 100009 1 4 WASHER 55304 1 4 X 3 4IN 5540 102018 4 5 FRNT FLYING WIRE MERLIN 6601 108858 1 6 REAR FLYING WIRE MERLIN 6604 108859 1 7 NUT NYLOC AN4 FULL 5535 100034 1 8 WASHER MYLAR 22X 7 5540 100624 1 9 C BAR KNUCKLE TW RND D TUBES TYPE 2 7593 109135 1 10 WASHER NYLON 8 STND 5540 100595 2 11 SHACKL
16. 3 0 2010 Page 17 AirBorne WindSports Pty Ltd Streak 2B amp MERLIN Maintenance Manual Heavy Maintenance Tasks that require a repairman rating with specialized training or Mechanic with A amp P rating such as major engine work repair of landing gear assemblies It also includes alterations to structure where instructions are provided in the manual such as fitment of an undercarriage kit or a tow kit 5 20 03 Qualification Descriptions Certification Required to Perform Light Sport Aircraft Maintenance Tasks O Owner ltems that can be expected to be completed by a responsible owner who holds a pilot certificate but who has not received any specific authorized training R E LSA Repairman Inspection Applicable to E LSA registration Repairman Inspection ltems that can be expected to be completed on an ELSA by a responsible owner who holds an FAA repairman certificate light sport aircraft with an inspection rating or equivalent R S LSA Repairman Maintenance Applicable to S LSA registration Repairman Maintenance Items that can be expected to be completed on a S LSA or E LSA by a responsible individual who holds a FAA repairman certificate light sport aircraft with a maintenance rating or equivalent A amp P Mechanic Certificate with Airframe and or Powerplant Training A amp P Items that be expected to be completed by a responsible individual who holds a mechanic certificate with airframe or pow
17. 5 Removing Rear Leading Edges e ie em ra E tenes Hae 23 Figure 6 Unbolting Side Wires er eii n eet SER eoe ned etin eons Gaede eode iesus 23 Figure 7 Removing Quick Clip Nt run aee Ge aec 23 Figure 8 Removing top Front to Back Wire ss 24 Eigure Sah one e Iac meiste 24 eile lM c ai KO Untying 24 Figure 11 Removing centre lt 25 Figure 12 Removing nose webbing ieri eoe eet hens bna veux eee 25 Figure 13 Unbolting top front wire see 25 Figure 14 Removing NM 26 Figure 15 Tie pull back bungie to 27 Figure 16 Frame preparation for Sail 27 Figure 17 Sliding sail onto frame Step 1 ee terret ent etant 27 Figure 18 Sliding sail onto frame Second Step 28 Figure 19 Inserting keel into Sall seco utc eeu 28 Figure 20 Position Keel pocket forward of rear 8 28 Figure 21 Spread the wings Danse cio d ttem dena d den Rat ed 28 Fig re 22 J in GTI GZ de
18. ACESSED Monday 29 November 2004 DramnBy Scale Date n re 3 6 DCR 29 485 10 06 04 2 nc 3 DCR2054 CHANGED TO PIP FIN 25 04 11 04 DIMENSIONS IN MILLIMETERS UNLESS STATED OTHERWISE Simon 11 SHEET 199 Figure 1 Highest Level Drawing AirBorne WindSports Pty Ltd 2010 Issue 2 0 21 04 10 STREAK 2B amp MERLIN AirBorne ILLUSTRATED PARTS CATALOGUE AUSTRALIA Step 2 So now if you go to that drawing 6482 then you may use the balloon identifiers to find the next drawing number that is required ITEM NO NAME PART NO 1 BOLT 5 41 100965 2 DOWN TUBE 53 53 CRUZE LHS WITH WIRES 106433 3 NUT NYLOC ANS HALF 100037 4 5 WASHER NYLON M8 XOD 100820 DOWN TUBE 53 CRUZE RHS WITH WIRES 106437 Use Balloon Identifier for the 1st Level Drawing In this case Item 5 Down Tube RHS D 1 2 5 Drawing 6481 PRE ASSEMBLY STAGE STORED ABOVE WING ASSEMBLY AREA READY FOR FINAL WING ASSEMBLY NB ALL WIRES ARE LABELLED 4 Rev AMENDMENTS PART 106438 0 CONTROL FRAME PRE ASSEMBLY LAST ACESSED Tuesday 30 Novem ber 2004 DrawnBy Scale Date 5 Ta Sion sss lt dirBorite 9 ALL DIMENSIONS IH MILLIMETERS UNLESS STATED OTHERWISE 4A Figure 2 Chapter 1 Control Frame Assembly Drawing 6482 AirBorne WindSports Pty Ltd 2010 Issue 2 0 21 04 10 STREAK 2B amp MERLIN AirBorne ILLUSTRA
19. ANDOWLVS GALVYLSNTII NHAN 15 AOF VWIIVHLSNv 0S 0102 PT Ald suodspurA OI F0 IcC 072 91551 Design Table for 5668 PART NO NAME 106344 SKT CSK SCREW 5 16 SS 105453 SKT CSK SCREW M6x45 101823 SKT CSK SCREW BSW 2 5x0 25 105997 SKT CSK SCREW BSW 1 4 MOD 58L 106319 5 CSK SCREW BSW 1 4 MOD 47L 102062 SKT CSK SCREW UNF 1 4 x 1 109488 SKT CSK SCREW UNF 1 4IN X1IN BLACK 6 35 12 5 40 25 4 106275 SKT CSK SCREW M6x16 SS HEAD DIA DIA HEAD 5 11 2 45 16 6 13 44 45 45 6 35 11 4 45 2 5 25 4 6 35 11 4 45 58 6 35 11 4 45 47 6 35 12 5 40 25 4 6 13 44 45 16 THREAD LENG HEAD ANGLE HEXDEPTH LENGTH AMENDMENTS Date UPDATED AND REMOVED PARTS 04 06 04 1 WITH NO PART NUMBERS IN THE SYSTEM 2 ADDED 109488 DIA CHAM LENGTH 21 11 08 LAST ACESSED Wednesday 21 April 2010 ALL DIMENSIONS IN MILLIMETERS UNLESS STATED OTHERWISE CHAM LENGTH LENGTH 0 5 0 5 0 5 0 5 0 5 0 5 0 5 DIA A A A A A A A O THREAD HEX THREAD MINOR DEPTH L DIA MATERIAL MATL NO 10 4 2 NA NA 3 35 5 NA NA 3 32 4 8 NA NA 3 23 4 8 SKT CSK SCREW BSW 2 5x0 25 101823 3 23 4 8 SKT CSK SCREW BSW 2 5x0 25 101823 3 19 4 8 NA NA 3 19 4 8 SKT CSK SCREW UNF 1 4 x 1 102062 3 10 5 NA NA HEAD DIA MINOR THREAD DIA SKT CAP SCREW COUNTERSINK DESIGN TABLE Drawn By Scale Date A irRorne 5668 Cris 2
20. AirBorne WindSports Pty Ltd Streak 2B amp Merlin Maintenance Manual amp Illustrated Parts Catalogue Botte AUSTRALIA STREAK 2B amp MERLIN MAINTENANCE MANUAL AND ILLUSTRATED PARTS CATALOGUE Manufacturer AirBorne WindSports Pty Ltd Unit 22 30 Kalaroo Rd Redhead NSW 2290 Australia Phone 612 4944 9199 Fax 61 2 4944 9395 Website http www airborne com au AirBorne WindSports Pty Ltd 2007 Part 108606 Issue 3 0 April 2010 AirBorne WindSports Pty Ltd Streak 2B amp Merlin Maintenance Manual amp Illustrated Parts Catalogue This wing should only be used in conjunction with a certified base combination maintenance requirements in this manual override requirements of the Edge X manual Issue 3 0 April 2010 AirBorne WindSports Pty Ltd Streak 2B amp MERLIN Maintenance Manual A Botte AUSTRALIA N STREAK 2B amp MERLIN MAINTENANCE MANUAL Manufacturer AirBorne WindSports Pty Ltd Unit 22 30 Kalaroo Rd Redhead NSW 2290 Australia Phone 61 2 4944 9199 Fax 61 2 4944 9395 Website http www airborne com au AirBorne WindSports Pty Ltd 2007 Part 106813 Issue 3 0 2010 Page 1 AirBorne WindSports Pty Ltd Streak 2B amp MERLIN Maintenance Manual DATA PACKAGE This manual constitutes one part of the complete data package that accompanies the aircraft Following is a list of each of the components which are required Pilot s Oper
21. Dealer should be contacted for the correct procedures and or servicing Tooling There are no specialised tools needed for the maintenance described in this manual following is a list of the type of tools that may be required NOTE Loctite will be required in certain locations and should always be replaced after disassembly Loctite 243 and 262 for the frame Open ended Imperial Spanner set Open ended Metric Spanner set Torque wrench Dry Lubricant lubricant that doesn t attract dust after application Hex key set Bettsometer Instrument Various general care items specified where needed This list may not be comprehensive Format The manual has been prepared using the ATA format which provides a standard layout of the chapters to be included and their content Some of the chapters are not included as they are deemed to be not applicable to this aircraft The information in this manual is based on the data that was available at the time of its publication The latest amendments to this manual will be issued on the Airborne website in PDF format This should be printed out and added to the manual Therefore it is important that operators keep a regular check on the website for any amendments that have been made If any errors or omissions are found in this manual please advise the factory Service Difficulty Reporting Any service difficulties or defects should be reported to Airborne using the form contained in appendix A
22. OI F0 IcC 070 NOTE THE U BRACKET IS POSITIONED IN THE REAR HOLE FOR THE MERLIN POSITION IS 1245MM FROM THE FRONT AMENDMENTS VIRTUAL PARTS STOCK COLOUR PART LIST 108846 COLOUR TBA 108844 CUSTOM COLOURS 108844 STOCK COLOURS E 051 052 KEEL POCKET BLUE WHITE RED YELLOW RED YELLOW GREY BLACK RED BLUE WHITE YELLOW WHITE BLACK BLUE Date PART NO 108844 LAST ACESSED Wednesday 21 April 2010 ALL DIMENSIONS IN MILLIMETERS UNLESS STATED OTHERWISE Stuart ITEM NO DWG PART QTY 1 SAIL MERLIN 7558 108501 1 2 MYLAR L E INSERT MERLIN 7556 108848 2 3 AIRFRAME S SERIES 6484 106440 1 4 L EDGE REAR TW MERLIN LHS ASM 7630 109214 1 5 LABEL S2B CRUZE MERLIN REAR L E LHS 6846 107255 1 6 L EDGE REAR TW MERLIN RHS ASM 7630 109215 1 7 LABEL S2B CRUZE MERLIN REAR RHS 6846 107254 1 8 K POST TW ASM MERLIN 7547 108852 1 9 CONTROL FRAME MERLIN PREASM 7553 108855 1 10 C BAR TW INCL GRIPS AND WIRE RND D TUBE 3057 103207 1 11 QUICK CLIP BLOCK 7002 106153 1 12 BOLT QUICK CLIP AN5 31A TYPE 3 6453 106405 1 18 SPRING QUICK CLIP BOLT SS 6468 101203 1 14 QUICK CLIP BOLT PIN AL 6467 103277 1 15 WASHER AN5 5540 100043 1 16 NUT NYLOC AN5 FULL 5535 100036 1 17 BOLT AN4 15A 5450 100967 1 18 WASHER AN4 5540 1
23. Rev AMENDMENTS ITEM DWG PART NO 1 BOLT AN5 40 5493 100028 1 2 A FRAME AL TOP BRACKET TRIKE WING 6599 103267 2 3 WASHER NYLON M 6 XOD 5540 101055 4 4 WASHER AN4 5540 100042 2 5 BOLT 4 20 5450 100006 2 6 NUT NYLOC AN4 FULL 5535 100034 2 7 WASHER 55304 5 16 X X 16G 5540 100714 2 8 NUT NYLOC AN5 FULL 5535 100036 1 9 WASHER MYLAR 22X 7 5540 100624 2 10 D TUBE TW STREAK 2B LHS WITH WIRES 6605 106799 1 11 D TUBE PROTECTOR TW 6600 104318 2 12 D TUBE TW STREAK 2B RHS WITH WIRES 6606 106800 1 12 Date DETAIL A PART NO 106801 LAST ACESSED Wednesday 21 April 2010 ALL DIMENSIONS IN MILLIMETERS UNLESS STATED OTHERWISE VIEW OF COMPLETE ASSEMBLY STORED ON WALL IN WING ASSEMBLY AREA CONTROL FRAME STREAK 2B PRE ASSY pue 2 5 AirBorne 6607 AUSTRALIA SHEET 1 of 1 ANDOWLVS SLYVd GALVYLSNTII NHAN HVIHLS AOF VWIIVHLSNYV Lc 0102 PT Ald suodspurA OI F0 IcC 072 91551 DETAIL A NOTE 1 LHS DOWN TUBE HAS THE SHACKLE BOLT THROUGH FROM THE D TUBE BOTTOM KNUCKLE SIDE 2 AFT BOTTOM SIDE WIRE IS NEAREST THE HEAD OF THE SHACKLE BOLT Rev AMENDMENTS Date PART NO 106799 LAST ACESSED Wednesday 21 April 2010 ALL DIMENSIONS IN MILLIMETERS UNLESS STATED O
24. completely Protection Ultraviolet radiation from strong sunlight ultimately reduces the strength of Dacron but this may be reduced to an acceptable level by careful consideration of the wings use and exposure In its bag the wing is fully protected Sunlight will eventually cause it to fail the required Bettsometer tests KEEP THE SAIL COVERED WHEN NOT IN USE AS CONTINUED EXPOSURE TO ULTRAVIOLET RADIATION DRAMATICALLY REDUCES SAIL LIFE NEVER USE CHEMICAL SOLVENTS OR APPLY WATER REPELLENT COMPOUNDS 57 30 10 Bettsometer Testing Bettsometer testing is a method of determining the tensile strength of the sail fabric and stitching which is known to degrade during the life of the sail The Dacron sailcloth may be cleaned with warm soapy water Strong detergents must not be used Thoroughly rinse with plenty of clean water Hour or Time Related Check Limits Annual Bettsometer test with a 1 2mm diameter needle with wing sails fitted and tensioned for flight is to be carried out to Upper amp lower surface 1360 grams Stitches 1360 grams using a 1mm or 1 2mm diameter hook pull upwards As well as the annual check there are several criteria for testing of sails which are highly dependent on the conditions that the sail fabric is exposed to The pilot operator of the aircraft is responsible for determining the level of exposure that the sail experiences Generally the method used for fabric testing is a Bettsometer test
25. each mandatory replacement time structural inspection interval and related structural inspection procedure required for type certification 4 20 00 Airframe Limitations Component Life hours Requirement Heart Bolt 1 off 100 Mandatory Replacement Wires 961 Check For Service Life Announcements Replace if there are no revisions Tubes 961 Check For Service Life Announcements Replace if there are no revisions Sail 1000 Mandatory Replacement Table 4 Airframe Limitations The airframe was analysed using FAA fatigue analysis Fatigue Evaluation Of Wing and Associated Structure on Small Airplanes FAA Report AFS 120 73 2 In order to estimate the time life limits for the major components of the airframe this is detailed in Airborne report 04 144ds The estimates that have been made do not take into account any extreme loads which will reduce the fatigue life of the airframe The fatigue life of these components is dependent upon rigid adherence to maintenance schedules As the service history of the airframe evolves these time life estimates are expected to be revised Amendments should be checked for regularly Issue 3 0 April 2010 Page 13 AirBorne WindSports Pty Ltd Streak 2B amp MERLIN Maintenance Manual 5 TIME LIMITS MAINTENANCE CHECKS 5 00 00 General The time limits and maintenance schedule provided are in addition to any regulation of the governing body where the aircraft is b
26. most UV degradation and will give a better indication of the strength left in the thread than that on the under surface Figure 33 Bettsometer Instrument an example supplier http www conairsports co uk 57 30 20 Minor tears or rips in the sail Minor sail repairs are a Line Maintenance task which Sport Pilots are suitable to perform unless local regulations prohibit owner maintenance for sails A repair is classified as minor if tears are less than 30mm long provided that no free edges such as the wing trailing edge are broken and that the tear is isolated and not within 50mm of an existing seam line or 100mm of the trailing edge Also abraded holes no more than 15mm in diameter Such damage may be replaced with self adhesive patch material Often called sail tape or sticky back sail repair tape such as used for registration letters If possible a patch should be applied to both sides of the fabric Reference BMAA TIL No 015 Issue 1 The tape is available from Airborne as a spare part Any other significant damage should be discussed with Airborne or a dealer for an assessment of the best repair option Issue 3 0 2010 Page 45 AirBorne WindSports Pty Ltd Streak 2B amp MERLIN Maintenance Manual 57 40 00 Tuning Roll Tuning Your aircraft was test flown and delivered to you in good flying order WARNING EXPERIENCED PERSONNEL SHOULD ONLY CARRY OUT ADJUSTMENTS TO THE WING IDENTIFICATION OF A TURN SHOULD
27. on the maintenance schedule The minimum qualification required to perform that task is prescribed A simple explanation of maintenance privileges permitted according to LSA category of registration is described in the table below Experimental LSA Sport Owner LS M LS M Pilot Sport A amp P A amp P Pilot part 145 part 145 repair repair Daily Inspections Preventative Maintenance Repairs Major Maintenance 100 hour inspection Annual Inspection Authorized to perform May perform only if the Repairman Inspector is the owner of the aircraft May perform only if the modification is included in the aircrafts Maintenance Manual or if the repairman is authorized to do so by the manufacturer May perform if the Repairman Inspector is the owner of the aircraft and not using the aircraft for compensation training or towing or When using the Experimental aircraft for compensation Training or towing until January 31 2010 the inspection must be performed by an LS M A amp P or part 145 repair facility Not authorized to perform Table 5 Maintenance Privileges Note that owners and pilots are permitted to perform preventative maintenance tasks as prescribed by FAR document Part 43 Appendix A Sec A43 1 Issue 3 0 2010 Page 16 AirBorne WindSports Pty Ltd Streak 2B amp
28. perform line maintenance and inspections to be completed on an E LSA by a responsible owner who holds an FAA repairman certificate light sport aircraft with an inspection rating or equivalent There are no requirements for minimum certification to perform any other task on an experimental aircraft However Airborne recommend that only people with an adequate skill level should perform maintenance on this aircraft as described at the start of this section Issue 3 0 2010 Page 5 AirBorne WindSports Pty Ltd Streak 2B amp MERLIN Maintenance Manual Other Categories of Registration This aircraft is certified as a Primary Category aircraft and when supplied with this manual and associated placards is a Light Sport eligible aircraft This manual is created to be compliant to the standards applicable to Special Light Sport Aircraft The category of registration may be quite varied as such the maintenance requirements of this aircraft are to be applied in conjunction with the requirements of the National Airworthiness Authority NAA of the country of registration Any NAA maintenance requirement takes precedence over this manual In the event that the owner is permitted to perform maintenance in their country and category of registration if there are any doubts regarding the required and appropriate maintenance then the safety of the aircraft may be jeopardised in continuing with self maintenance In this situation an Airborne
29. tips can be wound in clockwise The sail nose tangs be removed to allow the sail to move back It is however extremely important to check that the sail at the nose does not foul on the frame when the wing is being tensioned Ensure that the nose tangs are replaced and secured Locate Folding Tip Strut Ensure strut is on top of the leading edge Streak 2B only Figure 30 Locate Folding Tip Strut Issue 3 0 2010 31 AirBorne WindSports Pty Ltd Streak 2B amp MERLIN Maintenance Manual Attach Swan Catch Attach swan catch Secure and tighten nose webbing tangs Figure 31 Nose webbing Quality Assurance After this procedure is completed recheck all nuts bolts and connections make sure that there are no parts left over or missing from the assembly NOTE It is good practice to have an independent person check the airframe AirBorne WindSports always uses a different person for checking the assembly process Following is the Final assembly QA sheet which may assist in performing the final inspection process This QA is used by trained personnel and does not represent all of the instructions that are necessary for a safe aircraft It is to be used as a reference only Issue 3 0 2010 32 AirBorne WindSports Pty Ltd Streak 2B amp MERLIN Maintenance Manual QA Inspection Form applicable to Streak 2B Merlin Streak 3 amp Cruze wings AIRBORNE WINDSPORTS PTY LTD WIN
30. used in conjunction with the correct maintenance manual and repairs should only be carried out by competent people Read the Maintenance manual before proceeding This parts catalogue has been prepared to aid in the identification of components that may affect the airworthiness of the Airborne Streak 2 B and Merlin Series of Wings Drawings with various levels of detail are supplied that include all of the spare parts available specific to the serial number identification of the wing Parts identified in drawings by CIRCLES are available as spare parts If a component is identified by a box or not listed then it may only be available as individual parts All parts available are named and have part numbers this is the identification system that should be used to order spares eg Shackle RF615 4mm Part Number 100406 and the quantity required NB Some parts may have been used from other wings and therefore have other model names in the title The most important thing in ordering spare parts is the part number NOTE Airborne data packages will be revised from time to time Owners registered on AirBorne s data base will be notified of any changes to data and directed to the AirBorne web site http www airborne com au for the applicable pages The amended pages should be printed and the prior page replaced in the folder as soon as possible The amendment table should at that time be updated with the appropriate details and date Revised p
31. 0 103296 101244 100016 100819 100017 100019 100588 104713 100020 100021 100022 100023 100024 100025 100026 106618 100027 100028 100965 109628 104500 100029 100960 100420 100018 AMENDMENTS NAME CHANGED TO MATCH FP AN5 24A BOLT ADDED DCR 2243 DCR 2402 T SERIES DEV NAME 5 11 5 14 5 15a 5 16a 5 16 DIMENSIONED TO ANSI B18 2 1 1981 5 17 STANDARD HEX AND HEAVY BOLTS 517a TABLE 2 1049 AND 1047 5 20 MACHINERERY S HANDBOOK 22ND ED 521a INDUSTRIAL PRESS LTD NEW YORK 5 22a 5 25a 5 26 BOLTA BOLTA BOLTA BOLTA BOLTA BOLT A BOLTA BOLTA BOLTA BOLTA BOLTA BOLTA BOLT AN5 26 a BOLT AN5 27 BOLT AN5 31 a BOLT AN5 32 a BOLT AN5 33 BOLT AN5 34 a BOLT AN5 36 a BOLT AN5 36 BOLT AN5 37 BOLT AN5 40 a BOLT AN5 41 a i BOLT AN5 44 a BOLT AN5 46 LENGTH BOLT 5 46 BOLT AN5 53 a BOLT AN5 56 a BOLT AN5 24A N N N N N N N N N N N N N N BOLT AN5 30 HEAD N N N N N N N N N N N N N N PARTS WITH AN X BESIDE MAY NOT BE STOCKED BY AIRBORNE THIS TABLE DOES NOT INCLUDE ALL PARTS THAT HAVE BEEN MADE OBSOLETE CHECK FOR EXISTING OBSOLETE PARTS PRIOR TO ALLOCATING NEW PART NUMBERS 2 AN 5 BOLT DESIGN TABLE 19 10 04 270406 LAST ACESSED Wednesday 21 April 2010 Dran Ey scale Dale A irBot e 5493 08 04 09 ALL DIMENSIONS IN MILLIMETERS UNLESS STATED OTHERWISE Simon 1 1 02 03 03 SHEET 1 of 1
32. 00042 1 19 NUT NYLOC AN4 FULL 5535 100034 2 20 BOLT 4 16 5450 100004 1 21 WINGNUT AN4 5534 102472 1 22 SAFETY PIN 5545 100920 1 23 NOSE CATCH SWAN 2140 100085 1 24 SHACKLE SHGF04 6338 100954 1 25 BOLT AN4 11A 5450 100003 1 26 PIP PIN 25 5719 106702 1 27 PIP PIN CAP WITH WIRE 5718 101418 1 28 SHACKLE RF615 4MM 6338 100406 8 29 BATTEN SET MERLIN HINGE 7557 108851 1 30 SERIAL NO PLATE TRIKE WING 4501 102358 1 31 POP RIVET 1 8 5515 100162 2 32 PLACARD KING POST WIRE CHECK 4711 104622 1 33 COVERS AND PADDING SET MERLIN 7626 109209 1 34 MANUAL SPIRAL BOUND IPC MM STREAK 2B 6619 108606 1 35 BATTEN PROFILE MERLIN AND SST 7629 109213 1 COPIED FROM DWG A4 6618 WING MERLIN STOCK COLOURS Drawn By Scale Date 01 11 07 A irBorne 3 VWIIVHLSNYV ANDOWLVS SLYVd GALVYLSNTII NHAN 15 OUIOG 6c 0102 PT Ald suodspurA OI F0 IcC OT 91551 VIEW FROM END FOURTH MARK ISOMETRIC OVERVIEW SCALE 1 10 PHILLIPS HEAD SCREW MUST FACE AWAY FROM THE SAIL THIS ALLOWS ADJUSTMENT 1 2 AFTER ASSEMBLY PART NO 109214 L EDGE REAR MERLIN LHS ASM PART NO 109215 L EDGE REAR MERLIN RHS ASM L EDGE REAR MERLIN PREASM LAST ACESSED Tuesday 20 April 2010 Drawn By Scale Date 1 Born 7630 ALL DIMENSIONS IN MILLIMETERS UNLESS STATED OTHERWISE Stuart 28 05 08
33. 03603 103603 103603 103603 103603 103603 Washout Rods 103870 103870 104721 104721 104721 104721 NA NA NA NA Washout Rod Mounts 104720 104720 104720 104720 NA NA NA NA OIOC PT Ald suodspurA CONTROL FRAME Dow n Tubes Inc Knuckle 103209 103823 103209 103823 103209 103823 103209 103209 106312 106311 106312 106311 103209 103209 7 Base Bar 103207 103207 103207 103207 106317 106317 King Post 103887 103887 103887 103887 106427 106427 WIRES FLYING LX ur 10320 107298 NHAN 8c 15 07 OI v0 Ic 072 Front 103793 103793 103793 103793 103793 103793 103793 103793 106335 106335 107122 107122 108858 108858 Rear 103212 103212 103212 103212 103212 103212 103212 103212 106334 106334 107123 107123 108859 108859 Forw ard Side 103791 103791 103791 103791 104881 104881 106377 106377 106377 106377 106377 106377 108856 108856 Aft Side 103792 103792 103792 103792 104880 104880 106378 106378 106378 106378 106378 106378 108857 108857 Pull Back 103818 103818 103818 103818 103818 103818 103818 103818 103818 103818 103818 103818 103818 103818 11111111111 1 WIRES NEGATIVE Top Side 103789 103789 108044 108044 108044 108044 108853 Top Front 103787 103787 103787 106970 106305 106 1069 305 70 Reflex Bridl
34. 1 22 05 03 SHEET 1 of 1 ANDOWLVS SLYVd GALVYLSNTII NHAN 15 suog STREAK 2B amp MERLIN AirBorne ILLUSTRATED PARTS CATALOGUE AUSTRALIA 6 OPTIONS 6 1 Training Bars Type 3 Hound Drawing 4634 AirBorne WindSports Pty Ltd 2010 Issue 2 0 21 04 10 51 2 0102 PT Ald suodspurA OI F0 Ic 072 91551 5 Date 1 ITEM NO NAME DWG PART NO QTY 1 TRAINING BAR BLANK TYPE 3 6503 103295 2 2 HAND GRIP XT 5579 105311 2 3 CAP ROUND TUBE CLOSURE 1 1 8IN 5633 103226 2 4 TRAINING BAR TUBE TYPE 3 2 HOLES 6506 106518 2 5 TRAINING BAR TUBE TYPE 3 1 HOLE 6506 106523 2 6 SAFETY PIN 5545 100920 2 7 WINGNUT AN5 5534 102454 2 8 BOLT 5 17 5493 103296 2 9 TRAINING BAR CLAMP ROUND INCL H SHRINK 8112 103298 2 10 HEATSHRINK CLR 20MM X 150 5582 110093 2 11 BOLT AN4 14 a 5450 100559 2 12 NUT NYLOC AN4 HALF 5561 100035 2 13 PIP PIN 38 5719 102146 1 14 PIP PIN CAP 5717 105506 1 15 PIP PIN WIRE 5718 105507 1 16 SPLIT RING 10MM PIP PIN 5720 105508 1 FITTING INSTRUCTIONS REMOVE BASE BAR REMOVE OUTER BASE BAR SLEEVE FROM EACH END SLIDE ADAPTORS OVER BASE BAR FIX IN PLACE USING BOLTS REMOVED FROM BASE BAR ENSURE THAT THE CABLE INSIDE THE BASE BAR IS FIXED PLACE BY INNER BOLT REFIT TO WING
35. 109209 COVERS AND PADDING SET MERLIN LAST ACESSED Wednesday 21 April 2010 Drawn By Scale Date 1 Born 7626 ALL DIMENSIONS IN MILLIMETERS UNLESS STATED OTHERWISE Stuart 11 01 11 07 1r SHEET 1 of 2 AUSTRALIA ANDOWLVS SLYVd GALVYLSNTII NHAN 15 AOF VWIIVHLSNYV 96 0102 PT Ald suodspurA OI F0 Ic 072 91551 Copies AUSTRALIA AA STREAK 2B MAINTENANCE MANUAL ND ILLUSTRATED P ARTS C ATALOGUE veo MANUAL 108606 COMBINES 106813 amp 106812 THEY ARE SPIRAL BOUND TOGETHER BY THE SUPPLIER Rev AMENDMENTS Date PART NO 106812 LAST ACESSED Wednesday 21 April 2010 ALL DIMENSIONS IN MILLIMETERS UNLESS STATED OTHERWISE ITEM NO PART NO NAME MATERIAL DESCRIPTION MATL NO REQD 1 108606 MANUAL SPIRAL BOUND IPC MM STREAK 2B NA NA NA ITEM NO PART NO NAME MATERIAL DESCRIPTION MATL NO REQD 1 106812 MANUAL PAGES IPC STREAK 2B NA NA NA ITEM NO PART NO NAME MATERIAL DESCRIPTION MATL NO REQD 2 106813 MANUAL MAINTENANCE STREAK 2B NA NA NA irBorm AirBorn AUSTRALIA AUSTRALIA 1 STREAK 2B ILLUSTRATED PARTS CATALOGUE Applicability Streak 2B xm STREAK 2B Phone 981 2 MAINTENANCE MANUAL Tar LOT 249049399 x PARTS 106812 AND 106813 A
36. 1r SHEET 1 of 1 AMENDMENTS Date ITEM NO NAME DWG PART NO arv ITEM NAME DWG PART NO QTY 1 LEDGE REAR TW S SERIES 6403 106303 1 1 LEDGE REAR TW S SERIES 6403 106303 1 2 WING L EDGE TENSIONER RHS 5172 104740 1 2 WING L EDGE TENSIONER LHS 5172 104669 1 3 SKT BUTTON SCREW 5 X 10 SS 304 5677 106172 2 3 SKT BUTTON SCREW M5 X 10 SS 304 5677 106172 2 ADJUST TENSIONER TO VWIIVHLSNYV ANDOWLVS SLYVd GALVYLSNTII NHAN 15 AOF 0 0102 PT Ald suodspurA OI F0 IcC 072 AMENDMENTS 1 2402 ADD T SERIES TO 53 NO PART NO NAME MATERIAL DESCRIPTION MATL NO REQD 1 107254 LABEL S2B CRUZE MERLIN REAR L E RHS LABEL BROTHER 24MM WHITE 107258 0 045 ITEM NO NO NAME MATERIAL DESCRIPTION MATL NO REQD 1 107255 LABEL S2B CRUZE MERLIN REAR LHS LABEL TAPE BROTHER 24MM WHITE 107258 0 045 ITEM NO NO NAME MATERIAL DESCRIPTION MATL NO REQD 1 107256 LABEL S3 AND SST REAR L E RHS LABEL TAPE BROTHER 24MM WHITE 107258 0 045 ITEM NO NO NAME MATERIAL DESCRIPTION MATL NO REQD 1 107257 LABEL S3 AND SST REAR L E LHS LABEL TAPE BROTHER 24MM WHITE 107258 0 045 INSTRUCTIONS TO PRINT LABELS USE LBL FILE 6846 AND THE P TOUCH EDITOR PROGRAM COUPLED WITH IT S ASSOCIATED EXCEL FILE TH
37. 2 91551 DWG D L Ww D1 W4 W5 100406 6338 4 15 5 10 8 9 3 3 2 104305 6338 4 7625 18 11 13 9 3 4 102021 6338 6 35 43 14 14 9 3 4 100067 6338 7 9375 51 30 18 2 3 4 6338 6 4 22 14 3 4 106315 6338 7 6 28 14 17 75 5 6 1 100954 6338 6 5 23 5 12 2 13 6 2 92 4 34 NOTE FOR MODEL DATA SHACKLE DIMENSIONS NOT ACCURATE CHECK DEFORE USE IN DESIGN L SHACKLE PIN NOT SHOWN D1 Rev AMENDMENTS Date DEE SHACKLES DESIGN TABLE 1 INSTRUCTIONS FOR MOD MOVED TO DWG 6479 03 06 04 LAST ACESSED Wednesday 21 April 2010 Drawn By Scale Date 6338 416 ALL DIMENSIONS IN MILLIMETERS UNLESS STATED OTHERWISE Cris 11 13 10 03 SHEET 1 of 1 AUSTRALIA ANDOWLVS SLYVd GALVYLSNTII NHAN 15 AOF VIIVELSNXY 144 0102 PT Ald suodspurA OI F0 IcC 072 9nss 43 ACTUAL SIZE R12 Le 11 4 Rev AMENDMENTS 1 NEW PURCHASED PART NO ITEM NO DWG PART NO QTY 1 BATTEN END HINGE THREADED CLIP 5343 104976 1 2 BATTEN END HINGE PIVOT BEAK 5342 104977 1 11 4 Date 31 07 07 BATTEN END ASM HINGED PUR PART NO 108707 BATTEN END HINGE ASM PART NO 104975 ALL DIMENSIONS IN MILLIMETERS UNLESS STATED OTHERWISE 7 PURCHASED NON PART TO BE INSPECTED AS PER ENGINEERING
38. 43 1 107290 4 K POST TW ASM STREAK 2B 6609 106805 1 107291 5 CONTROL FRAME STREAK 2B PREASM 6607 106801 1 107292 6 C BAR TW INCL GRIPS AND WIRE RND D TUBE 3057 103207 1 107293 7 TIP STRUT STREAK 2 3 RHS FOLDING 5368 105124 1 107288 8 TIP STRUT STREAK 2 3 LHS FOLDING 5368 105123 1 9 COVERS AND PADDING SET STREAK 2B 6620 106814 1 10 SET STREAK 2B 3 HINGE 6402 106453 1 11 MANUAL PAGES IPC STREAK 2B 6619 106812 1 12 MANUAL MAINTENANCE STREAK 2B 6619 106813 1 13 NOSE CATCH SWAN 2140 100085 1 14 _ MYLAR LE INSERT S SERIES 6488 106446 2 15 SAIL STREAK IIB 6621 106796 1 16 PLACARD KING POST WIRE CHECK 4711 104622 1 17__ SERIAL NO PLATE TRIKE WING 4501 102358 1 18 QUICK CLIP AN5 31A TYPE 3 6453 106405 1 19 QUICK CLIP BLOCK 7002 106153 1 20 QUICK CLIP BOLT PIN AL 6467 103277 1 21 SPRING QUICK CLIP BOLT SS 6468 101203 1 22 BOLT AN4 16 5450 100004 1 28 WINGNUT AN4 5534 102472 1 24 SAFETY PIN 5545 100920 1 25 PIP PIN 25 5719 106702 1 26 PIP PIN CAP WITH WIRE 5718 101418 1 27 BOLT AN4 15A 5450 100967 1 28 BOLT 4 11 5450 100003 1 29 NUT NYLOC FULL 5535 100034 2 30 NUT NYLOC AN5 FULL 5535 100086 1 31 WASHER AN5 5540 100043 1 32 WASHER AN4 5540 100042 1 33 SHACKLE SHGF04 6338 100954 1 34 SHACKLE RF615 4MM 6338 100406 8 35 POP RIVET 1 8 5515 100162 2 36
39. 53 SERIAL 1 Current LHS 104980 106464 106465 106466 106467 106468 106469 106470 106471 106472 106473 105123 103757 103758 103759 NOTE DOUBLE NOSE BATTENS FOLDING STRUTT SETSAME AS SIII MAIN SAIL BATTENS UNDERSURFACE BATTENS STREAK II pw g 6402 Set 106453 Nose 1 2 3 4 5 6 7 8 9 10 11 Strutt 1 2 3 HINGE RHS 104981 106454 106455 106456 106457 106458 106459 106460 106461 106462 106463 105124 103751 103752 103753 SERIAL 1 Current LHS 104980 106464 106465 106466 106467 106468 106469 106470 106471 106472 106473 105123 103757 103758 103759 NOTE DOUBLE NOSE BATTENS FOLDING STRUTT SET SAME AS SIIB MAIN SAIL BATTENS UNDERSURFACE BATTENS CRUZE Dw g 6274 Set 106891 Nose 1 2 3 4 5 6 7 8 9 10 11 Strutt 1 2 3 HINGE RHS 104981 106881 106882 106883 106884 106885 106886 106887 106888 106889 106890 107130 103751 103752 103753 SERIAL 1 Current LHS 104980 106871 106872 106873 106874 106875 106876 106877 106878 106879 106880 107129 103757 103758 103759 NOTE DOUBLE NOSE BATTENS FOLDING STRUTT MAIN SAIL BATTENS UNDERSURFACE BATTENS MERLIN Dw g 7557 Set 108851 Nose 1 2 3 4 5 6 7 8 9 10 11 Strutt 1 2 3 HINGE RHS 109329 109331 109332 109333 109334 109335 108982 108983 108984 108985 108986 108992 SERIAL 1 Current LHS 109330 109336 109337 109338 109339 109340 108987 108988 1089
40. 89 108990 108991 108993 NOTE DOUBLE NOSE BATTENS FOLDING STRUTT NOTE THIS DRAWING IS A COPY OF 7615 XLS pae AND IS CREATED FOR IPC PURPOSES ONLY 11 11 08 LAST ACESSED Wednesday 21 April 2010 ALL DIMENSIONS IN MILLIMETERS UNLESS STATED OTHERWISE TRIKE WING BATTEN INTERCHANGE TABLE AUSTRALIA Scale Date Simon NTS 11 09 06 Drawn By 6712 SHEET 1 of2 VWIIVHLSNYV ANDOWLVS SLYVd GALVYLSNTII NITHJMW 15 STREAK 2B amp MERLIN AirBorne ILLUSTRATED PARTS CATALOGUE 4 TRIKE WING FRAME INTERCHANGE S SERIES DRAWING 6715 AirBorne WindSports Pty Ltd 2010 Issue 2 0 21 04 10 39 Streak 1 amp A Streak Il Streak Il XT Streak IIB Streak Ill Cruze Merlin LHS RHS LHS RHS LHS RHS LHS RHS LHS RHS LHS RHS MAIN FRAME Front Leading Edge 103601 103601 103601 103601 103601 103601 103601 103601 103601 103601 103601 103601 Rear Leading Edge 105125 105126 105125 105126 106303 106303 106303 106303 106303 106303 Leading Edge Tensioners Note 1 104669 104740 104669 104740 104669 104740 104669 104740 Cross Bar 103699 103699 103699 103699 103699 103699 103699 103699 103699 103699 Keel Tube 103602 105042 105042 106304 106304 Keel Extension 103603 104669 104740 104669 103699 103699 103699 106304 106304 1
41. AIL BATTENS UNDERSURFACE BATTENS EDGE Nose 1 2 3 4 5 6 7 8 9 10 11 Strutt 1 2 3 BUNGIE BATTENS RHS 102546 102547 102548 102549 102550 102551 102552 102553 102554 102555 102556 102576 102567 102568 102569 SERIAL 1 337 LHS OneOny 102557 102558 102559 102560 102561 102562 102563 102564 102565 102566 102575 102571 102572 102573 MAIN SAIL BATTENS UNDERSURFACE BATTENS STREAK Nose 1 2 3 4 5 6 7 8 9 10 11 Strutt 1 2 3 BUNGIE BATTENS RHS 103750 103730 103731 103732 103733 103734 103735 103736 103737 103738 103739 102576 103751 103752 103753 SERIAL 1 228 LHS One Only 103740 103741 103742 103743 103744 103745 103746 103747 103748 103749 102575 103757 103758 103759 MAIN SAIL BATTENS UNDERSURFACE BATTENS STREAK II amp Il XT Nose 1 2 3 4 5 6 7 8 9 10 11 Strutt 1 2 3 SPRING BATTENS RHS 104981 104983 104985 104987 104989 104991 104993 104995 104997 104999 105001 105124 103751 103752 103753 SERIAL 250 321 LHS 104980 104982 104984 104986 104988 104990 104992 104994 104996 104998 105000 105123 103757 103758 103759 NOTE DOUBLE NOSE BATTENS FOLDING STRUTT MAIN SAIL BATTENS UNDERSURFACE BATTENS STREAKIIB Dw g 6402 Set 106453 Nose 1 2 3 4 5 6 7 8 9 10 11 Strutt 1 2 3 HINGE RHS 104981 106454 106455 106456 106457 106458 106459 106460 106461 106462 106463 105124 103751 103752 1037
42. ALSO BE CARRIED OUT BY AN EXPERIENCED PERSON ANY ADJUSTMENTS SHOULD BE RECORDED IN THE MAINTENANCE LOG CHANGES REQUIRED FOR TUNING ARE SMALL AND INCRIMENTAL MAJOR CHANGES WILL CAUSE THE WING TO PERFORM BADLY AND MAY BE DANGEROUS If you feel that the wing requires adjustment to trim in the roll or the pitch axis you should check that the problem is not caused by something asymmetrical in the frame or the battens In order of priority check the following e Ensure that the wires especially the reflex bridles are correctly routed e Check the battens against the template e Check that the sail webbing is correctly mounted on the leading edges and tensioned to the correct mark e Check the keel is straight e Check that the leading edges are straight and that the rear leading edges are located correctly To check your battens use the following procedure e Remove the battens from the wing after the wing is de tensioned as required during the pack up phase See Pilot s Operating Handbook for pack up procedures e Lay the template out on a flat surface e Note whether the battens have been reflexed Do not change the reflex initially The battens may have already been reflexed to correct a turn e Start with the keel batten lining the nose of the batten up with the start of the line The line should be above the batten e f the batten does not line up gently apply pressure using your hand or knee to get a smooth curve After checking as not
43. ATTEN SET STREAK 2B 3 HINGE 6402 106453 BATTEN SET STREAK 2B 3 HINGE AirBorrie AUSTRALIA Drawn By Simon Scale 1 2 6402 SHEET 1 of 2 ANDOWLVS SLYVd GALVYLSNTII VWIIVHLSNYV NIHAN 15 AOF Ge 0102 PT Ald suodspurA OI F0 Ic 072 91551 Copies AUSTRALIA AA STREAK 2B MAINTENANCE MANUAL ND ILLUSTRATED P ARTS C ATALOGUE veo MANUAL 108606 COMBINES 106813 amp 106812 THEY ARE SPIRAL BOUND TOGETHER BY THE SUPPLIER Rev AMENDMENTS Date PART NO 106812 LAST ACESSED Wednesday 21 April 2010 ALL DIMENSIONS IN MILLIMETERS UNLESS STATED OTHERWISE ITEM NO PART NO NAME MATERIAL DESCRIPTION MATL NO REQD 1 108606 MANUAL SPIRAL BOUND IPC MM STREAK 2B NA NA NA ITEM NO PART NO NAME MATERIAL DESCRIPTION MATL NO REQD 1 106812 MANUAL PAGES IPC STREAK 2B NA NA NA ITEM NO PART NO NAME MATERIAL DESCRIPTION MATL NO REQD 2 106813 MANUAL MAINTENANCE STREAK 2B NA NA NA irBorm AirBorn AUSTRALIA AUSTRALIA 1 STREAK 2B ILLUSTRATED PARTS CATALOGUE Applicability Streak 2B xm STREAK 2B Phone 981 2 MAINTENANCE MANUAL Tar LOT 249049399 x PARTS 106812 AND 106813 ARE VIRTUAL PARTS AND ARE NOT SOLD IND
44. E BODY 5 16 SIDE WIRE 6338 100067 1 12 WASHER AN5 5540 100043 2 13 BOLT 5 20 5493 100016 1 14 NUT NYLOC AN5 HALF 5561 100037 1 15 SIDE BTM WIRE FWD MERLIN 6440 108856 1 16 SIDE BTM WIRE AFT MERLIN 6440 108857 1 ANDOWLVS GALVYLSNTII NHAN 15 OI v0 Ic 072 a DETAIL A NN NOTE 1 LHS DOWN TUBE HAS THE SHACKLE BOLT THROUGH FROM THE D TUBE BOTTOM KNUCKLE SIDE 2 AFT BOTTOM SIDE WIRE IS NEAREST THE HEAD OF THE SHACKLE BOLT DETAIL B PART NO 108965 AMENDMENTS Date D TUBE TW MERLIN LHS WITH WIRES LAST ACESSED Wednesday 21 April 2010 Drawn By Scale Date ALL DIMENSIONS IN MILLIMETERS UNLESS STATED OTHERWISE Simon 13 5 20 01 05 4 irBorne SHEET 1 of 1 EX OUSTRALIA DETAIL C suog VWIIVHLSNYV 0102 PT Ald suodspurA OI v0 Ic 072 DETAIL A NOTE 1 RHS DOWN TUBE HAS THE SHACKLE BOLT THROUGH FROM THE CONTROL BAR KNUCKLE SIDE 2 AFT BOTTOM SIDE WIRE IS NEAREST THE HEAD OF THE SHACKLE BOLT PART NO 108966 AMENDMENTS Date ITEM NAME DWG NO QTY 1 D TUBE TW ROUND SILVER WITH KNUCKLE 6602 103209 1 2 D TUBE BTM KNUCKLE ROUND TRIKE 3077 100779 1 3 BOLT AN4 26A 5450 100009 1 4 WASHER 55304 1 4 X 3 4IN 5540 102018 4 5 FRNT FLYING WIRE MERLIN 6601 108858 1 6 R
45. EAR FLYING WIRE MERLIN 6604 108859 1 4 NUT NYLOC AN4 FULL 5535 100034 1 8 WASHER MYLAR 22X 7 5540 100624 1 9 C BAR KNUCKLE TW RND D TUBES TYPE 2 7593 109135 1 10 WASHER NYLON M 8 STND 5540 100595 2 11 SHACKLE BODY 5 16IN SIDE WIRE 6338 100067 1 12 WASHER 5 5540 100043 2 13 BOLT AN5 20A 5493 100016 1 14 NUT NYLOC AN5 HALF 5561 100037 1 15 SIDE BTM WIRE FWD MERLIN 6440 108856 1 16 SIDE BTM WIRE AFT MERLIN 6440 108857 1 DETAIL B ZZN CCP TRIS D TUBE TW MERLIN RHS WITH WIRES ANDOWLVS SLYVd GALVYLSNTII VWIIVHLSNYV NHAN 15 AOF LAST ACESSED Tuesday 20 April 2010 Drawn By Scale Date 1 Born 7551 ALL DIMENSIONS IN MILLIMETERS UNLESS STATED OTHERWISE Simon 1155 20 01 05 1r p SHEET 1 of 1 X ST mre A 0102 PIT Ald suodspurA ve OI F0 IcC 072 ITEM NO NAME DWG PART NO QTY 1 COVER CONTROL FRAME BASE 4500 101673 1 2 COVER QUICK CLIP K POST BASE 6499 106480 1 3 COVER U BRACKET TRIKE WING 6497 106478 1 4 COVER X BAR NEOPRENE 6852 107336 1 5 GLIDER TIE 7153 100139 4 6 COVER REAR KEEL 4499 102436 1 7 COVER ELASTIC 6500 106481 2 8 WING BAG STREAK CRUZE MERLIN 7149 103883 1 9 COVER C BAR GENERIC 6501 106482 1 10 TIP SCUFF PAD S SERIES 6548 105139 1 a Rev AMENDMENTS Date PART NO
46. ED Wednesday 21 April 2010 Drawn By Scale Date 5 DCR ADD RETRO KITS ALL DIMENSIONS IN MILLIMETERS UNLESS STATED OTHERWISE Simon 1 1 20 05 04 A irB 51 72 Pere SHEET1of2 SLYVd GALVYLSNTII NHAN 15 AOF VWIIVHLSNYV 61 0102 PT Ald suodspurA OI F0 IcC OT 91551 ET 2e DETAIL A SCALE 1 2 5 N LL lal DETAIL B SCALE 1 2 Rev AMENDMENTS Date PART NO 106805 1 DCR 2171 NEW ASSEM NO CHANGE 09 09 05 2 DCR 2292 CHG ARCUS PART 30 03 07 LAST ACESSED Wednesday 21 April 2010 ALL DIMENSIONS IN MILLIMETERS UNLESS STATED OTHERWISE ITEM NO NAME DWG PART NO QTY 1 TOP SIDE WIRE SET STREAK IIXT amp III 6439 108044 1 2 TOP FRNT WIRE S2I B MERLIN 6721 106970 1 3 REFLEX BRIDLE SUB ASM S2B 6612 106808 1 4 K POST TOP CAP ROUND TRIKE 6614 103827 1 5 SCREW PHILIPS CSK 10GX 3 4IN 304 5909 100912 4 6 K POST TW ROUND T3 6850 107298 1 ISOMETRIC COMPONENT STORED IN WING ASSEMBLY BAY FOR FINAL ASSY K POST TW ASM STREAK 2B D B l g me AirBorire 6609 Simon 1 12 02 03 03 SHEET 1 of 1 AUSTRALIA SLYVd GALVYLSNTII NHAN 15 AOF VWIIVHLSNYV 0 0102 PT Ald suodspurA OI v0 Ic 072
47. ED OTHERWISE ITEM NO NAME DWG PART NO 1 X BAR BOLT COVER NO SLOT 6465 100804 1 2 PULL BACK WIRE 1125 STREAK 4632 103818 2 3 WASHER 5 5540 100043 1 4 WASHER NYLON M 8 STND 5540 100595 3 5 CAP WASHER BASE CLIP M8 5667 100604 1 6 BOLT AN5 15A 5493 100015 1 7 NUT NYLOC 5 HALF 5561 100037 1 8 CAP WASHER COVER BLACK M8 5666 100603 1 9 WASHER NYLON 1 4IN 5540 102424 6 10 WASHER ANS 5540 100049 2 11 NUT NYLOC AN4 FULL 5535 100034 2 12 NUT NYLOC AN3 FULL 5535 100051 2 13 X BAR TW STREAK S SERIES 4703 103699 2 14 STRAP X BAR 25MM TANG 250 6464 103819 1 15 X BAR BALL TYPE 3 AIRBORNE 7718 109478 1 16 X BAR BALL SKT TYPE AIRBORNE 7719 109477 1 17 BOLT AN3 30A 5449 100629 2 18 BOLT 4 30 5450 100011 2 19 PULLEY PULL BACK X BAR STREAK 6466 103821 1 20 SHACKLE BODY 1 4IN PULL BACK 6338 102021 1 21 BOLT 4 11 5450 100003 1 22 NUT NYLOC AN4 HALF 5561 100035 1 SCALE 1 25 X BAR WITH HINGE FULL PLAN VIEW SHOWING DETAILS A ANDB X BAR TW WITH HINGE S3 CRUZE AUSTRALIA Scale Date 07 06 04 Drawn By 6483 Simon 11 SHEET 1 of 2 VWIIVHLSNYV ANDOWLVS SLYVd GALVYLSNTII 15 AOF 2 0102 PT Ald suodspurA OI F0 IcC 072 91551
48. ERSAL U BRACKET WIDE 4746 103799 1 4 U BRACKET NEG LOAD PLATE 120 ALUMINIUM 5124 104607 1 5 SKT CSK SCREW UNF 1 41 X1IN ZINC 5568 102062 2 i 6 KEEL EXTENSION STREAK WIZARD 2 3 4792 103603 1 7 CLEVIS PIN 3 16 X 2 13 32 5536 102796 1 8 SPLIT RING 11MM RF114 5720 100950 1 9 PULLEY RF661 PULL BACK 6442 100728 1 EDS t ipi 10 POPRIVET 5 32 LONG 5 8 5515 102417 1 11 BOLT AN4 32A 5450 100012 1 INSTRUCTIONS 12 BOLT AN4 34A 5450 100850 1 5 EIE Bae 13 NUT NYLOC AN4 HALF 5561 100035 2 14 WASHER AN4 5540 100042 2 3 CRUZE STD GRAVITY CENTER HOLE 15 TANG 1 4IN EYELET HOLE 5673 103290 1 4 STREAK STD GRAVITY CENTER HOLE 16 DRI LUBE SOLID LUBE 5637 106432 2 18 PLUG ACETAL U BRACKET 6562 106672 1 1 C 19 LOCTITE 648 HIGH TEMP 5637 105992 2 o b redo jo Legi ct 2 9 2 T LR ELEVATION LEVATION 8 Rev AMENDMENTS Date PART NO 106423 4 3 1 REPLACED SPLIT RING WITH NEW MODEL 02 06 04 S SERIES A FRAME TOP REAR KEEL ASM 2 ADDED RED LOCTITE AND DRI LUBE DCR 2004 11 08 04 LAST ACESSED Wednesday 21 April 2010 Drawn Scale Date Born 6470 3 ADDED PLUG U BRACKET DCR 2028 22 10 04 ALL DIMENSIONS IN MILLIMETERS UNLESS STATED OTHERWISE Simon 142 26 05 04 1 1r SHEET 1 of 1 4 CHANGED DCR 2110 08 04 05 AUSTRALIA VWIIVHLSNYV ANDOWLVS SLYVd GALVYLSNT
49. ESE ARE BOTH IN THE DRAWINGS SUB DIRECTORY USE 24mm BLACK ON WHITE TAPE AirBofie CAUTION TRALIA TOP LEFT HAND SIDE MODEL STREAK 2B CRUZE MERLIN TENSIONER 3RD MARK REFER TO MAINTENANCE MANUAL SECTION 0 AirBorne CAUTION STRALIA RIGHT HAND SID MODEL STREAK 2B CRUZE MERLIN TENSIONER 3RD MARK REFER TO MAINTENANCE MANUAL SECTION 0 AirBorie CAUTION AirBorne CAUTION AUSTRALIA pe TRALIA s TOP RIGHT HAND SID sTOP LEFT HAND SID K3 i STREAK 3 AND SST STREAK 3 AND SST TENSIONER 4TH MARK TENSIONER 4TH MARK REFER TO MAINTENANCE MANUAL SECTION 0 REFER TO MAINTENANCE MANUAL SECTION 0 a PART NO 107254 LABEL S2B CRUZE MARLIN L E RHS THESE ARE VIRTUAL PARTS PART NO 107255 LABEL S2B CRUZE MARLIN L E LHS PART NO 107256 LABEL S3 SST REAR L E RHS p PART NO 107257 LABEL S3 SST REAR L E LHS LABELS REAR L E CAUTION LAST ACESSED Wednesday 21 April 2010 DrawnBy Scale Date a 6846 ALL DIMENSIONS IN MILLIMETERS UNLESS STATED OTHERWISE Stuart 14 01 11 07 AirBorne peer aN SHEET 1 of 1 ANDOWLVS SLYVd GALVYLSNTII NHAN HVIHLS LE 0102 PT Ald suodspurA OI v0 Ic 072 Rev AMENDMENTS Date DETAIL A PART NO 108855 LAST ACESSED Wednesday
50. G iren iere er rene eicit i mie 11 0 ASSEMBLY AFTER SHIPPING ere ha en escaso tra cese ne nn te nn etienne 11 AIRWORTHINESS LIMITATIONS 2 5 pde 13 5 TIME LIMITS MAINTENANGE CHECKS 2 ds 14 6 DIMENSIONS ANB AHEAGS eine cene atii E EL LUIS IE 34 9 GROUND HANDLING a teens ete 35 aoee e A T E 36 5 37 20 STANDARD PRACTICES AIRFRAME 38 PLE 41 a E 42 95 SPECIAL PURPOSE EQUIPMENT 5555 ne usos 50 APPENDIX Condition Inspection Checklist esse 51 APPENDIX B Feedback lt Eee ei ence 52 Figures Figure 1 Insertion of Rear Leading Edges se 11 Figure 2 Locating Sail Webbing on Rear Leading 12 Figure TIp AO JUSEBIS sees cuoc oorr eerte pe eee te ene ie e e 12 Figure 4 De Tensioning the ae oct e pieta e o ede eden d Cete at eis 22 Figure
51. G FINAL QUALITY INSPECTION GJP 163 Production Order No Check Operation Security and Finish Left Hand Side Nose Assembly Nose Catch Nose webbing secure Nose Battens Nose Cone Keel Roller U Bracket Down Tubes top assembly D Tube Stops King Post Base Cross Bar Hinge Cross Bar Padding Undersurface Zip Down Tube Bottom Corners Trimmer Placard Bottom Front Wires Side Wire Shackles Base Bar Bolts Cross bar Leading Edge Junction Top Side Wires Bottom Side Wires X Bar L Edge Zip Tip Webbing Located Correctly Tip Tension Adjusted Streak 2B Merlin on 3 Mark D AB Tip Strut Adjusted Locknut secure Streak 2B only Tip Zips Tip Scuff Pads Main Sail Batten Fittings Leech line Cleat Reflex Bridle Shackles Pull Back Wires Quick Clip Bottom Rear Wires MININ NISJA nininini l N al a oo CO NIM oy J pr wo King Post Top Assembly King Post Base Placard Co A Trimmer Handle where fitted Trimmer Cable where fitted wo Downtube Pulley Bottom I Downtube Pulley Serial number placard 5 Signature Completed By Checked By Issue Date 9 August 2005 Table 7 Airborne Final QA Inspection Sheet Issue 3 0 April 2010 Page 33 AirBorne WindSports Pty Ltd Streak 2B amp MERLIN
52. GLIDER TIE 7153 100139 4 6 COVER REAR KEEL 4499 102436 1 7 BATTEN BAG DOUBLE 6498 106479 1 8 COVER BAG ELASTIC 6500 106481 2 9 WING BAG STREAK CRUZE MERLIN 17149 103883 1 10 COVER C BAR GENERIC 6501 106482 1 11 TIP SCUFF PAD S SERIES 6548 105139 1 ANDOWLVS SLYVd GALVYLSNTI NIHAN 4V3HlS NUMBERS POINTING TO THE FRAME SHOW APPROXIMATE LOCATIONS OF COVERS WHEN STORING GLIDER fo sou VWIIVHLSNYV Dae PART NO 106814 0 COVERS AND PADDING SET STREAK 2B LAST ACESSED Wednesday 21 April 2010 Drawn By Scale Date 62 5 AirB ELE ALL DIMENSIONS IN MILLIMETERS UNLESS STATED OTHERWISE Simon NTS 26 01 05 SHEET 1 of 2 UsTRALIA ve 0102 PT Ald suodspurA OI F0 IcC 072 91551 Rev AMENDMENTS 1 CHANGED NAME DCR 2091 2 DCR 2402 TSERIES DEV SHEET 2 LHS RHS PART No PART No 104980 104981 106464 106454 106465 106455 106466 106456 106467 106457 106468 106458 106469 106459 106470 106460 106471 106461 106472 106462 106473 106463 103757 103751 103758 103752 103753 105004 105005 103761 103755 NOTE THE NUMBER 1 BATTENS ARE CLOSEST TO THE KEEL ADD DRI LUBE TO THREADED FITTINGS WHEN ASSEMBLING Date PART NO 106453 09 03 05 28 04 09 LAST ACESSED Wednesday 21 April 2010 ALL DIMENSIONS IN MILLIMETERS UNLESS STATED OTHERWISE ITEM NO NAME DWG PART NO QTY 1 B
53. I v0 Ic 072 EXPLODED DETAIL A 1 5 Rev AMENDMENTS 1 CHANGED NAME DCR 2112 INSTRUCTIONS 6484 SHEET 2 1 ADD SHOCK CORD TO NOSE JUNCTION AFTER IT IS ASSEMBLED SEE ITEM NO NAME DWG PART NO QTY 1 S SERIES A FRAME TOP REAR KEEL ASM 6470 106423 1 2 L EDGE CHANNEL ASM S SERIES 6473 106425 2 3 BOLT AN4 32A 5450 100012 4 5 NOSE PLATE TRIKE WING 60MM KEEL 6469 103205 2 6 WASHER 4 5540 100042 3 7 NUT NYLOC AN4 HALF 5561 100035 5 9 WASHER NYLON M 6 XOD 5540 101055 12 10 BOLT 4 11 5450 100003 1 11 CHANNEL SS NOSE CATCH DWG 4 6394 6394 107416 1 NOSE JUNCTION ASSY S SERIES LAST ACESSED Wednesday 21 April 2010 DrawnBy Scale Date 6474 DIMENSIONS MILLIMETERS UNLESS STATED OTHERWISE Bone Simon 41 270504 A irE3c 1 1 1 e AUSTRALIA SHEET 1 of 1 VWIIVHLSNYV ANDOWLVS SLYVd GALVYLSNTII NIHAN AVAYLS AOF vL OIOC PT Ald suodspurA OI v0 Ic 072 DWG PART NO QTY 1 KEEL TUBE ASM S SERIES 6405 106304 1 2 KEEL ROLLER TWO PIECE HALF 60MM KEEL 6471 103822 2 3 UNIV
54. II NIHAN 8c 15 suog GE 0102 PT Ald SHO SPUIM OI v0 Ic 072 MATERIAL DESCRIPTION MATL NO REQD 7 106412 VELCRO LOOP 50x120 ADHESIVE 50mm LOOP BLK ADHV 103289 120 Rev AMENDMENTS 1 NAME CHANGE DCR 2111 08 04 05 ITEM NO NAME DWG PART NO 1 L EDGE FRONT TW S SERIES AND 4693 103601 1 2 X BAR MOUNT CHANNEL TYPE 1 7009 102006 1 3 SADDLE 60MM TUBE 7166 100080 2 4 BOLT 4 32 5450 100012 2 5 WASHER AN4 5540 100042 2 6 NUT NYLOC AN4 FULL 5535 100034 2 7 VELCRO LOOP 50x120 ADHESIVE 6313 106412 1 Date PART NO 106425 1 LAST ACESSED Wednesday 21 April 2010 ALL DIMENSIONS IN MILLIMETERS UNLESS STATED OTHERWISE dw L EDGE CHANNEL ASM S SERIES Drawn By Simon soe ZAirb3orrne AUSTRALIA 6473 SHEET 1 of 1 VWIIVHLSNYV ANDOWLVS SLYVd GALVYLSNTI NHAN 15 AOF 91 OIOC PT Ald suodspurA OI F0 IcC 072 91551 B 1 2 5 PLAN OF PULLBACK WIRES TO SHACKLE ASSEMBLY Rev AMENDMENTS Date 1 DCR 2412 CHANGED XBAR BALL SKTS 05 02 09 14 TANG PART NO 106439 0 LAST ACESSED Wednesday 21 April 2010 ALL DIMENSIONS IN MILLIMETERS UNLESS STAT
55. IVIDUALLY SELL PART 108606 DATA PACKAGE COMPONENTS S2B Drawn By Scale Date otie 6619 Simon 26 01 05 A SHEEP TO AUSTRALIA VWIIVHLSNYV ANDOWLVS SLYVd GALVYLSNTII AVAYLS suog 9c 0102 PT Ald suodspurA OI F0 IcC 072 91551 Rev AMENDMENTS PART MATERIAL DESCRIPTION MATL NO REQD 1 105028 BATTEN PROFILE STREAK II III NA NA NA Date PART NO 105028 eT LAST ACESSED Wednesday 21 April 2010 ALL DIMENSIONS IN MILLIMETERS UNLESS STATED OTHERWISE sr LA M BATTEN PROFILE STREAK Drawn By Scale Simon 12 4 irBorm c UsSsTRALIA 6622 SHEET 1 of 1 ANDOWLVS SLYVd GALVYLSNTI NIHAN HVIHLS suog STREAK 2B amp MERLIN AirBorne ILLUSTRATED PARTS CATALOGUE AUSTRALIA 2 MERLIN WING ASSEMBLY DRAWING 7546 2 1 L Edge Rear Merlin Preasm Drawing 7630 2 2 Labels Rear L E Caution Drawing 6846 2 3 Control Frame Merlin Preasm Drawing 7553 2 3 1 D Tube TW Merlin LHS With Wires Drawing 7550 2 3 2 D Tube TW Merlin RHS With Wires Drawing 7551 2 4 Covers And Padding Set Merlin Drawing 7626 2 5 Data Package Components Drawing 6619 2 6 Batten Profile Drawing 7629 AirBorne WindSports Pty Ltd 2010 Issue 2 0 21 04 10 27 8c 0102 PT Ald suodspurA
56. MERLIN Maintenance Manual Limitations Due to Registered Category S LSA Maintenance on a Special LSA 100 hourly and annual inspections are to be performed by the holder of a LSA Repairman Maintenance certificate or an appropriately rated A amp P mechanic Note owners and pilots are permitted to perform preventative maintenance tasks as prescribed by FAR document Part 43 Appendix A Sec A43 1 E LSA The owner of an aircraft registered as an Experimental LSA has operations limited to private use and has additional maintenance privileges During the transition period commercial operations may be conducted until 31 January 2010 Where the experimental registered aircraft is used for compensation training or towing during the transition period the option c below does not apply to 100 hourly inspections The 100 hourly or annual inspections on an E LSA are to be performed by a the holder of a LSA Repairman Maintenance certificate or b an appropriately rated A amp P mechanic or C the owner when the owner is the holder of a LSA Repairman Inspection certificate The pilot of the E LSA aircraft is responsible to see that the maintenance and inspection has been performed on this aircraft as per the maintenance schedules prescribed in this maintenance manual The maintenance schedule tasks remain applicable where there is no minimum level of qualification required to perform maintenance on E LSA however a minimum skill level continues to
57. Maintenance Manual 6 DIMENSIONS AND AREAS 6 00 00 General This section gives general dimensions for the wing It should be noted that this is a flex wing aircraft and the dimensions that are given will be different depending on the loads on the wing In general the dimensions that have been supplied are those without the sail on the wing which bends the leading edge and slightly reduces the wing span and with the wing on the ground resting on the base bar As the wing is loaded in flight the lower wires will become taut and the amount of anhedral will reduce changing the geometry and dimensions to the optimal positions for flight 6 10 00 Major Dimensions of the S Series Airframe THIS IS A FLEX WING AIRCRAFT THEREFORE REPESENT BASIC DIMENSIONS THAT ELEVATION nme CHANGE DUE TO THE LOADING THAT IS PLACED UPON THE WING SOME OF THE DIMENSIONS SHOWN ARE MEASURED FROM THE WING ON THE GROUND OTHERS ARE MODELLED WITH NO FLEX 4 59 KEEL CENTERLINE B t 50 PLAN Pan AMENDMENTS Dae PART NO 106442 0 REPORT 04051 FRAME INTERSECTIONS DRAWING LAST ACESSED Thursday 22 July 2004 Drawn By Scale Date ork ALL DIMENSIONS IN MILLIMETERS UNLESS STATED OTHERWISE s Simon 1 50 22 07 04 Figure 32 Major dimensions of airframe Issue 3 0 2010 Page 34 AirBorne WindSports Pty Ltd Streak 2B amp MERLIN Maintenance Manual 6 30 00 Significant Dimensions and Areas General The Major dimensions o
58. RE VIRTUAL PARTS AND ARE NOT SOLD INDIVIDUALLY SELL PART 108606 DATA PACKAGE COMPONENTS S2B Drawn By Scale Date otie 6619 Simon 26 01 05 A SHEEP TO AUSTRALIA VWIIVHLSNYV ANDOWLVS SLYVd GALVYLSNTII AVAYLS suog 0102 PT Ald suodspurA 9 OI F0 Ic 072 91551 ITEM NO NO NAME MATERIAL DESCRIPTION MATL NO REQD 1 109213 BATTEN PROFILE MERLIN AND SST NA NA NA ANDOWLVS SLYVd GALVYLSNTII NHAN 8 9 4V3HlS VIIVEHILSNY AMENDMENTS Date PART NO 109213 2402 SERIES DEV Po 1 MERLIN AND SST LAST ACESSED Wednesday 21 April 2010 Drawn By Scale Date 7629 ALL DIMENSIONS IN MILLIMETERS UNLESS STATED OTHERWISE Stuart 12 28 05 08 A irBorne SHEET 1 of 1 NM _ NM STREAK 2B amp MERLIN AirBorne ILLUSTRATED PARTS CATALOGUE 3 TRIKE WING BATTEN INTERCHANGE TABLE DRAWING 6712 AirBorne WindSports Pty Ltd 2010 Issue 2 0 21 04 10 37 8 0102 PT Ald suodspurA OI F0 IcC 072 91551 AMENDMENTS 1 ADDED MERLIN MAIN S
59. REPORT 07 044 FOR ACCEPTANCE BATTEN END HINGE ASM Drawn By Scale Date 1 Born CRIS 2 1 12 12 02 1r AUSTRALIA A4 5321 Sheet1 of 1 ANDOWLVS SLYVd GALVYLSNTII NHAN 15 AOF VWIIVHLSNYV Gv OIOC PT Ald SHO SPUIM OI F0 IcC O AMENDMENTS Date PART NO 109165 LAST ACESSED Wednesday 21 April 2010 ALL DIMENSIONS IN MILLIMETERS UNLESS STATED OTHERWISE ITEM NO NAME DWG PART 1 BATTEN END FOLDING CLIP LHS 7604 109153 1 2 BATTEN END FOLDING CLIP RIVET 7606 109154 1 3 BATTEN END FOLDING CLIP PIVOT AL 7642 109263 1 NOTE PARTS ARE PURCHASED INDIVIDUALLY PARTS ARE CREATED FOR MODELLING PURPOSES AND MAY NOT BE DIMENSIONALLY CORRECT BATTEN END FOLDING CLIP ASM LHS DrawnBy Scale Date orn Stuart ti 18 06 08 A irB AUSTRALIA 7598 SHEET 1 of 1 ANDOWLVS GALVYLSNTII NHAN HVIHLS AOF VWIIVHLSNY OIOC PT Ald SHO SPUIM 9v OI F0 IcC O ITEM DWG PART NO QTY 1 BATTEN END FOLDING CLIP RHS 7605 109156 2 BATTEN END FOLDING CLIP RIVET 7606 109154 mam 3 BATTEN END FOLDING CLIP PIVOT AL 7642 109263 NOTE PARTS ARE PURCHASED INDIVIDUALLY PARTS ARE CREATED FOR MODELLING PURPOSES AND MAY NOT BE DIMENSIONALLY CORRECT AMENDMENTS Dat
60. RLIN Maintenance Manual 5 50 00 Unscheduled Maintenance Checks Unscheduled maintenance is required due to abnormal flight loads such as severe turbulence or heavy landings If any abnormal loads are encountered during transport or storage then the airframe needs to be checked The pilot will be responsible for identification of these extreme operating conditions and identification of the effected components Where damage is found further checks should be carried out upon areas that may also be affected Thorough checks should also be carried out after transportation of the aircraft and after extended storage periods 5 50 10 Inspection after heavy landing The main attachment point for the wing to the aircraft base should be inspected carefully for any permanent deformation of the U bracket the main bolt or the keel as well as all of the other effected components If the landing resulted in contact with the ground then obviously these parts will require extra attention The tubing relies on being intact in perfect condition for full strength If tubing is bent or kinked in any way then it should be replaced prior to flying This includes its attachment point to bolts The battens should be checked against the supplied batten profiles and the opportunity should also be taken to inspect the batten fittings 5 50 20 Inspection after heavy turbulence The main areas of wing structure that require attention after severe turbulence are the attachment poi
61. S TO BE REPLACED IT SHOULD BE REPLACED WITH AIRBORNE SPARE PARTS ONLY 57 10 00 Main Frame Description This section allows the user to understand the main function of each of the components of the wing which should help the operator or maintenance personnel to properly inspect the wing Keel The keel of the wing is mainly constructed from 6061 T6 aluminium Each of the major components of the wing are attached to the keel Major components from the front to the rear of the keel 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 attach the stainless U channel where the front wires attach to the swan catch U Bracket The U bracket provides a mounting point for both the control frame and the trike mast the main attachment point for the base to the wing The U bracket is allowed to rotate around the keel and is held in position longitudinally with acetal bungs which are bolted to the keel Quick Clip The quick clip is bolted to the keel with the same bolt used to attach the rear wires King Post The king post assembly is a vertical post from the keel of the wing which supports the reflex bridles the Top Front and Back wires and the top side wires The king post works in compression and is located on the keel using a locating pin The main material is 6061 T6 aluminium for both the tubing and the fitting
62. TED OTHERWISE ITEM NO NAME DWG PART NO QTY 1 D TUBE TW ROUND SILVER WITH KNUCKLE 6602 103209 1 2 D TUBE BTM KNUCKLE ROUND TRIKE 3077 100779 1 3 BOLT AN4 26A 5450 100009 1 4 WASHER 55304 1 4 X 3 4IN 5540 102018 4 5 FRNT FLYING WIRE 1780 STRK amp T SERIES 6601 103793 1 6 REAR FLYING WIRE WIZARD STREAK 6604 103212 1 7 NUT NYLOC AN4 FULL 5535 100034 1 8 WASHER MYLAR 22X 7 5540 100624 1 9 C BAR KNUCKLE TW RND D TUBES TYPE 1 3079 100781 1 10 WASHER NYLON M 8 STND 5540 100595 2 11 SHACKLE BODY 5 16IN SIDE WIRE 6338 100067 1 12 WASHER 5 5540 100043 2 13 BOLT 5 20 5493 100016 1 14 NUT NYLOC AN5 HALF 5561 100037 1 15 SIDE WIRE FWD STRK3 CRUZE 6440 106377 1 16 SIDE BTM WIRE STRK3 CRUZE 6440 106378 1 DETAIL B D TUBE TW STREAK 2B RHS WITH WIRES Drawn By Scale Date 1 Born Simon 11 5 20 01 05 1r AUSTRALIA 6606 SHEET 1 of 1 VWIIVHLSNYV ANDOWLVS SLYVd GALVYLSNTII NIHAN AVAYLS AOF c 0102 PIT Ald suodspurA OI F0 IcC OT 91551 Rev AMENDMENTS 1 DWG PART NO QTY 1 COVER CONTROL FRAME BASE 4500 101673 1 2 COVER QUICK CLIP K POST BASE 6499 106480 1 3 COVER U BRACKET TRIKE WING 6497 106478 1 4 COVER X BAR SMALL 7146 102730 1 5
63. TED PARTS CATALOGUE AUSTRALIA Step 3 Again identify the next level of drawing that is relevant In this case Item 1 Trimmer Assembly Aero Down Tube Drawing 6409 ITEM NO NAME PART NO TRIMMER ASSEMBLY AERO D TUBE 108313 KNUCKLE AERO 35x85 BOTTOM RHS 106201 KNUCKLE TW AERO 35x85 RHS 106205 TOP BRACKET AERO D T TRIKE 106203 SHACKLE MODIFIED RM 24 HD 106385 ASHER NYLON M8 STD 100595 ISOMETRIC SKT CAP SCREW SS M 4 X8 106322 VIEWS CSK SCREW MBx16 SS 106275 SKT SHOULDER SCREW 5 16x1 1 4 BSW1 4 SCALE 1 2 5 IRE BOTTOM FRONT AERO S3 CRUZE IRE BOTTOM REAR AERO S3 CRUZE IRE BOT SIDE FWD AERO S3 CRUZE IRE BOT SIDE AFT AERO S3 CRUZE LOCTITE 243 Blue Med Strength IDRILUBE SOLID LUBE TUBE PVC CLEAR 6mm x18L KNUCKLE RD BASE BAR AERO D T LOCKTITE 243 ON LOCKING BOLTS 7 AND 8 DRI LUBE ON ROTATING PARTS 9 AND 6 L AMENDMENTS PART NO 106437 DOWN TUBE 53 CRUZE RHS WITH WIRES LAST ACESSED Tuesday 16 November 2004 Drawn Scale Date 64 81 AirB oe C gt ALL DIMENSIONS IN MIL LIMETERS UNLESS STATED OTHERWISE Simon 11 07 08 04 AM ase Figure 3 Identify the next drawing number AirBorne WindSports Pty Ltd 2010 Issue 2 0 21 04 10 STREAK 2B amp MERLIN AirBorne ILLUSTRATED PARTS CATALOGUE AUSTRALIA Step 4 Order Now that the actual component has bee
64. THERWISE ITEM NO NAME DWG PART NO QTY 1 D TUBE TW ROUND SILVER WITH KNUCKLE 6602 103209 1 2 D TUBE BTM KNUCKLE ROUND TRIKE 3077 100779 1 3 BOLT AN4 26A 5450 100009 1 4 WASHER 55304 1 4 X 3 4IN 5540 102018 4 5 FRNT FLYING WIRE 1780 STRK amp T SERIES 6601 103793 1 6 REAR FLYING WIRE WIZARD STREAK 6604 103212 1 7 NUT NYLOC AN4 FULL 5535 100034 1 8 WASHER MYLAR 22X 7 5540 100624 1 9 C BAR KNUCKLE TW RND D TUBES TYPE 1 3079 100781 1 10 WASHER NYLON M 8 STND 5540 100595 2 11 SHACKLE BODY 5 16IN SIDE WIRE 6338 100067 1 12 WASHER 5 5540 100043 2 13 BOLT 5 20 5493 100016 1 14 NUT NYLOC AN5 HALF 5561 100037 1 15 SIDE WIRE FWD STRK3 CRUZE 6440 106377 1 16 SIDE BTM WIRE STRK3 CRUZE 6440 106378 1 DETAIL B D TUBE TW STREAK 2B LHS WITH WIRES Drawn By Scale Date 1 Born Simon 11 5 20 01 05 1r AUSTRALIA 6605 SHEET 1 of 1 VWIIVHLSNYV ANDOWLVS SLYVd GALVYLSNTII NIHAN AVAYLS AOF cc 0102 PT Ald suodspurA OI F0 IcC 072 DETAIL A NOTE 1 RHS DOWN TUBE HAS THE SHACKLE BOLT THROUGH FROM THE CONTROL BAR KNUCKLE SIDE 2 AFT BOTTOM SIDE WIRE IS NEAREST THE HEAD OF THE SHACKLE BOLT Rev AMENDMENTS Date PART NO 106800 LAST ACESSED Wednesday 21 April 2010 ALL DIMENSIONS IN MILLIMETERS UNLESS STA
65. THIS SW DRAWING SUPERCEDES TURBOCAD DRAWING 4634 TCW UPDATED TO AID INCLUSION IN IPC PART NO 103291 INSERT PIP PIN FROM IN FRONT AND ABOVE NUT FACES UPWARD LAST ACESSED Wednesday 21 April 2010 Drawn By Scale Date 1 Born ALL DIMENSIONS IN MILLIMETERS UNLESS STATED OTHERWISE Stuart 1 5 09 09 1r AUSTAR ALIA 4634 SHEET 1 of 1 ANDOWLVS SLYVd GALVYLSNTI NHAN HVIHLS AOF VWIIVHLSNYV
66. The right hand side training bar is secured in the same way and is also attached on the inside of the down tube Figure 36 LHS Training Bar Attachment Issue 3 0 2010 50 AirBorne WindSports Pty Ltd Streak 2B amp MERLIN Maintenance Manual APPENDIX A Condition Inspection Checklist Wing Maintenance Log S N Date Hours Maintenance Work Performed Maintained by Section or Service Bulletin Issue 3 0 2010 Page 51 AirBorne WindSports Pty Ltd Streak 2B amp MERLIN Maintenance Manual APPENDIX B Feedback Form Operation and Maintenance Feedback Form AirBof e AUSTRALIA Please use a copy of this form to provide notification to the manufacturer about issues or anomalies identified during the operation or maintenance of the aircraft or in the content of the manual Return to AirBorne WindSports Pty Ltd PO Box 7042 Redhead New South Wales 2290 Australia Fax 61 2 4944 9199 Email trikesupport airborne com au Please provide your own contact details below Issue Description If you have a proposal to remedy the issue please provide it here Number of pages submitted including this cover page Issue 3 0 2010 52 AirBorne WindSports Pty Ltd Streak 2B amp MERLIN Maintenance Manual End Streak 2B Merlin Maintenance Manual Issue 3 0 April 2010 Page 53
67. Y SPREAD 106440 REAR LEADING EDGE RHS PRE ASSY 106445 REAR LEADING EDGE LHS PRE ASSY 106443 Item 5 KINGPOST AERO S3 CRUZE WITH WIRES 106309 CONTROL FRAME PRE ASSY SPREAD 106438 Control BASE BAR AERO SUB ASSEM 106317 FOLDING STRUT ASSY RHS 105124 Erama TW FOLDING TIP STRUT ASSY LHS 105123 COVERS AND PADDING SET STREAK 3 106477 STREAK 3 BATTEN SET 106453 MANUAL IPC STREAK 3B 106726 MANUAL MAINTENANCE STREAK 3B 105725 ALUMINIUM NOSE CATCH TW 100085 MYLAR INSERT 53 106446 STREAK 3 SAIL 106281 PLACARD TRIMMER STREAK REF CDR 4711 103817 PLACARD KING POST WIRE CHECK 104622 DATA PLATE STREAK 3 B 106646 QUICK CLIP BOLT AN5 30A 108405 QUICK CLIP BLOCK SS 106153 QUICK CLIP PIN AL 103277 PIP PIN 33 102147 PIP PIN CAP WITH WIRE 101418 PIN25 106702 BOLT AN4 13 a 101333 BOLT AN4 11a 100003 NUT NYLOC AN4 FULL 100034 NUT NYLOC AN4 HALF 100035 NUT NYLOC ANS FULL 400036 WASHER ANS 100043 WASHER AN4 100042 ISHACKLE SHGF 09 100954 SHACKLE RF615 4mm 100406 RIVET 1 8 100162 TUBE PVC CLEAR 6 X 11 WITH GROOVE 105693 HEATSHRINK CLR 20mm x 50 106375 SS INSTRUCTIONS SEE GJP 162 FOR ASSEMBLY INSTRUCTIONS VIRTUAL PARTS Rev AMENDMENTS Date PART 106442 0 S ANING ASSEMBLY 1 ADDED NAME PLATE DCR 2022 08 10 04 2 ADDED PVC TRIMMER LOCATOR 27 10 54 LAST
68. able 6 Scheduled 20 Table 7 Airborne Final QA Inspection Sheet uon cer orte 33 Table 8 Torque settings for the Wing iore ie ota ree stern ka Ep ments 39 Table MM 47 Issue 3 0 2010 10 AirBorne WindSports Pty Ltd Streak 2B amp MERLIN Maintenance Manual 0 ASSEMBLY AFTER SHIPPING 00 00 00 Wing Assembly After Shipping 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 The correct reassembly of the wing is critical for safety and performance of the wing If there are any doubts about the correct procedure for assembly after shipping contact AirBorne 00 10 00 Reassembly Guide Remove wing from box Ensure that all staples are removed before pulling the wing from the box Damage to the sail may result if caught on box staples Unzip bag Remove padding from the nose of the wing Remove all wing straps Remove padding from control bar and rear leading edges Assemble the control frame Assemble control frame and rotate the wing so that it is lying flat on the ground Spread Leading Edges Spread both leading edges approximately 1 metre Remove
69. ages will be sent by mail if requested AirBorne WindSports Pty Ltd 2010 Issue 2 0 21 04 10 STREAK 2B amp MERLIN AirBorne ILLUSTRATED PARTS CATALOGUE AUSTRALIA TABLE OF CONTENTS INTRODUCTION TABLE OF CONTENTS HOW TO USE THIS CATALOGUE 1 STREAK 2B WING ASSEMBLY DRAWING 6618 c cl lll Cross Bar Leading Edge Junct Drawing 6484 Rear Leading Edge Assembly Drawing 6486 Kingpost Assembly Drawing 6609 Control Frame Assembly Drawing 6607 Covers and Padding Drawing 6620 Batten List Drawing 6402 Data Package Components Drawing 6619 Batten Profile Drawing 6622 2 MERLIN WING ASSEMBLY DRAWING 7546 2 1 2 2 2 3 2 4 2 5 2 6 L Edge Rear Merlin Preasm Drawing 7630 Labels Rear L E Caution Drawing 6846 Control Frame Merlin Preasm Drawing 7553 Covers And Padding Set Merlin Drawing 7626 Data Package Components Drawing 6619 Batten Profile Drawing 7629 3 TRIKE WING BATTEN TABLE DRAWING 6712 4 TRIKE WING FRAME INTERCHANGE S SERIES DRAWING 6715 5 MISCELLANEOUS COMPONENTS 5 1 Dee Shackle Drawing Drawing 6338 5 2 Batten End Assembly Drawing 5321 5 3 Batten End Folding Clip Asm LHS Drawing 7598 5 4 End Folding Clip RHS Drawing 7609 5 5 ANSBolts Drawing 5449 5 6 Bolts Drawing 5450 5 7 AN5 Bolts Drawing 5493 5 8 Socket
70. apply to tasks Only people with an adequate skill level should perform maintenance on this aircraft sound understanding of mechanical systems and good experience with the necessary tools and procedures is required as the continuing airworthiness of the aircraft relies on the competence of the person performing the maintenance Assessment and judgement of the condition of each individual component is required which necessitates a sound understanding of the purpose of each component in the System If there are any doubts regarding the required and appropriate maintenance then the safety of the aircraft may be jeopardised in continuing with self maintenance In this situation an Airborne Dealer should be contacted for the correct procedures and or servicing All maintenance and repairs must be carried out in accordance with good aeronautical practices 5 20 02 Description of Task Classification Preventative Maintenance The preventative maintenance that is permissible to be performed by pilot certificate holders is defined in FAR document Part 43 Appendix A Sec A43 1 Line Maintenance Includes inspections servicing of fluids Tasks where specific instructions are described in the manual that do not require specialized training for replacement repair of parts and structure or alterations described in the manual Includes compliance with service directives that prescribe repairmen as the minimum qualification to perform the task Issue
71. ator s Handbook Applicable Base Maintenance Manual e Applicable Base Illustrated Parts Catalogue e Wing Maintenance Manual t e Wing Illustrated Parts Catalogue Rotax Owners Manual e Rotax Maintenance Compact Disk Radio Manual If Installed e BRS Parachute Manual If Installed Issue 3 0 2010 Page 2 AirBorne WindSports Pty Ltd Streak 2B amp MERLIN Maintenance Manual AMENDMENT RECORD SHEET Affected Pages Date Inserted Signature Amendment Date Affected Sections Table 1 Amendment Record Sheets NOTE Airborne s data packages will be revised from time to time Owners registered on AirBorne s database will be notified of any changes to data and directed to the AirBorne web site http www airborne com au for the applicable pages The amended pages should be printed and the prior page replaced in the folder as soon as possible The amendment table should at that time be updated with the appropriate details and date Revised pages will be sent by mail if requested Issue 3 0 2010 Page 3 AirBorne WindSports Pty Ltd Streak 2B amp MERLIN Maintenance Manual LOG OF ALL EFFECTIVE PAGES ISSUE 3 0 Page Issue Date Page Issue Date All of issue pages 1 to 54 3 0 April 2010 Table 2 Log Of Effect
72. bolt installed 8 Base Bar Bolts Just not loose 9 Cross Bar Just not loose Leading Edge NOTE Junction The vertical bolt will have approximately four threads showing See drawing Illustrated Parts Catalogue 10 Top Side Wires Just not loose 11 Bottom Side Just not loose Wires 12 Reflex Bridle Firm tighten to the end of the thread use Loctite 243 Shackles 13 Pull Back Wires Tighten bolt till 1 2 threads are showing NOTE The wires that locate on the bolt will float slightly from side top side see drawing lllustrated Parts Catalogue there will be three wires in the pull back shackle with the inclusion of the top front back wire 14 Quick Clip Bolt Just not loose see drawing Illustrated Parts Catalogue and Bottom Rear Wires 15 King Post Top The aluminium fitting which attaches to the king post part 106209 should Assembly be tightened to approx 15 Nm firm See drawing lllustrated Parts Catalogue Loctite 243 must be used Locate the wires in their correct position The cover is held in place with four bolts These should be firm with Loctite 243 used 16 Trimmer The procedure that is used for the torque of the trimmer handle ensures that Attachment to the amount of trimmer adjustment will not remain over tightened Install the Down Tube bolt and then turn the handle until the swage is at the top of its adjustment at Streak 2B the top of the stickers arrow Tighten the bolt unt
73. correct right and left hand side and stand airframe onto its A frame The folding tip struts should be on the top of the tube Lay sail out at the tips inline with the airframe Figure 16 Frame preparation for Sail Reinstallation Reinstall Sail Step 1 Slide sail 1 metre up the airframe making sure one leading edge goes in either side of the sail Figure 17 Sliding sail onto frame Step 1 Issue 3 0 April 2010 Page 27 AirBorne WindSports Pty Ltd Streak 2B amp MERLIN Maintenance Manual Reinstall Sail Step 2 Hold the leading edge up approximately 1 2 metre off the ground while you slide the sail up so the leading edges don t hit the cells internal fabric ribs Slide sail up half a side at a time Pull sail on slowly as damage can result if sail is caught on internal ribs Figure 18 Sliding sail onto frame Second Step Insert Keel into Sail When sail is approximately halfway up insert the keel into the keel pocket Slide sail up until the keel pocket hits the quick clip bolt Figure 19 Inserting keel into sail Position Keel Pocket forward of Rear Wires Have someone hold the nose of the wing up so the bottom rear flying wires are loose Remove quick clip nut and bottom rear flying wires Slide keel pocket up until the sail tang aligns with the quick clip bolt hole Re insert quick clip bolt and attach washer sail tang and rear flying wires tighten nut Let the nose down
74. ctory for details for reflex tuning profile profile The wing needs to be removed from gt the base and de tensioned The 5 battens should be shaped to the template and re installed Table 9 Tuning procedure If after tuning the turn persists consult your authorised dealer or the factory Issue 3 0 April 2010 Page 47 AirBorne WindSports Pty Ltd Streak 2B amp MERLIN Maintenance Manual Figure 34 Adjusting Tip Angle Sail not fitted DECREASE TENSION Figure 35 Adjusting Batten Tension Pitch Tuning Trim speed at MTOW is Streak 2B wing 47 52 KIAS centre hole pole position trimmer off Merlin wing 47 52 KIAS centre hole position If the wing is trimming outside the specified trim range a forward or aft movement of the keel roller on the keel tube can be used to trim the wing A one hole adjustment will see a typical change in trim of 5 knots Moving the roller to the forward position will increase the trim speed whilst moving the roller rearward will decrease the trim speed The illustrated parts catalogue should be referenced for correct reassembly Issue 3 0 April 2010 Page 48 AirBorne WindSports Pty Ltd Streak 2B amp MERLIN Maintenance Manual 57 50 00 Attach Fittings U bracket The U bracket is the main attachment point of the wing to the base structure as well as to the keel of the wing It is the major junction for the three main components of the aircraft the w
75. decrease There is a swage on the wire which allows the pilot to see which position the trimmer is in The wire for the trimmer assembly should be periodically inspected for wear and the handle inspected for free operation 27 70 00 Trimmer Knob Inspection Streak 2B only When inspecting the trimmer assembly check that the pulley at the bottom of the base bar has not been worn by the position indicating swage on the wire If the pulley has been worn it will need to be replaced Issue 3 0 April 2010 Page 41 AirBorne WindSports Pty Ltd Streak 2B amp MERLIN Maintenance Manual 57 WINGS 57 00 00 General The main structure of the wing comprises of aluminium tubing and stainless steel wire The lifting surface is constructed from Dacron polyester fabric The wing is subject to maintenance checks and preflight procedures that must be carried out prior to flying Any dents crazing bends except for tube bending caused by normal flight and set up loads corrosion or other distortion of the wing structure renders the wing unsafe to fly Secondary structures of the aircraft are limited to e Keel extension structure e The trimmer assembly e The pull back assisting rope and pulley system CAUTION IT SHOULD BE NOTED THAT ALL OF THE TUBES THAT ARE USED ARE SPECIFIC GRADES OF ALUMINIUM DESIGNED FOR FLEX STRENGTH AND FATIGUE CHARACTERISTICS ALL OF THE TUBES ARE SLEEVED FOR STRENGTH AND WHERE STRESS CONCENTRATIONS EXIST IF ANY TUBING I
76. e PART NO 109166 BATTEN END FOLDING CLIP ASM RHS LAST ACESSED Wednesday 21 April 2010 Drawn By Scale Date orn 7609 ALL DIMENSIONS IN MILLIMETERS UNLESS STATED OTHERWISE Stuart T4 01 11 07 A irB SHEET 1 of 1 AUSTRALIA ANDOWLVS SLYVd GALVYLSNTI NHAN 15 AOF VWIIVHLSNYV 47 0102 PT Ald suodspurA OI F0 IcC 072 91551 AN3 10 11 AN3 12 a AN3 13 a AN3 14 a AN3 15 a 21 AN3 23 a 30 Rev AMENDMENTS 1 DCR 2402 SERIES DEV LT LENGTH Design Table for AN3 hex bolt PART NO NAME 102927 Bolt AN3 10 a 109626 Bolt AN3 11 a 100050 Bolt AN3 12 a 100584 Bolt AN3 13 a 109629 Bolt AN3 14 a 100735 Bolt AN3 15 a 101184 Bolt 21 100558 Bolt 23 100629 Bolt AN3 30 Date 08 04 09 LAST ACESSED Wednesday 21 April 2010 ALL DIMENSIONS IN MILLIMETERS UNLESS STATED OTHERWISE SHANK 26 2 29 4 32 5 35 7 38 9 42 1 54 8 61 1 77 0 DIMENSIONED TO ANSI B18 2 1 1981 STANDARD HEX AND HEAVY BOLTS TABLE 2 1049 AND 1047 MACHINERERY S HANDBOOK 22ND ED INDUSTRIAL PRESS LTD NEW YORK 9 36 CHECK THIS DIMENSION AN3 BOLT DESIGN TABLE Drawn By Scale Date 1 orm Simon 2 1 02 03 03 1r AUSTRALIA ANDOWLVS SLYVd GALVYLSNTII NIHAN 15 suog 8v 0102 PT Ald suodspurA OI F0 IcC 072 91551 Rev AMENDMENTS PART
77. e on the website http www airborne com au 5 00 10 Inspection Notes Installation amp Removal When removing or installing tubing do not bend or force tubes Inspection Inspect tubing for cracks damage from abrasion elongated holes or distortion in tube surface WARNING Inspect holes in tubing and corners radiused NEVER ATTEMPT REPAIR TUBING areas for cracks during scheduled inspections ALWAYS REPLACE WITH A GENUINE NEW Ensure that the areas are clean A 10X magnifying PART glass and good lighting will improve this visual inspection for cracks Corrosion Inspect tubing for corrosion inside and out Discolouration of the metal may indicate corrosion Salt is the most common cause of corrosion during coastal operation Parts affected by salt must be stripped and thoroughly cleaned before reassembly The cause of the corrosion must be identified and eliminated If corrosion pitting or oxidation is present the component must be removed and replaced with a new part Exposed wires may be protected from corrosion by applying a water dispersant such as WD 40 RP7 or Inox using a rag wetted with the water dispersant Such treatment is only required in corrosive environments Preventative treatment may be applied as required Issue 3 0 2010 Page 14 AirBorne WindSports Pty Ltd Streak 2B amp MERLIN Maintenance Manual Replacement Aluminium tube comes in many different sizes and grades As sections of the a
78. ed above a turn can be remedied by adjustments as outlined in the following table Issue 3 0 April 2010 Page 46 AirBorne WindSports Pty Ltd Streak 2B amp MERLIN Maintenance Manual Roll Tuning Matrix The following table outlines procedures for tuning a wing to correct a turn Adjustment Method Remedy Left Turn Remedy Right turn Batten Tip Ends The main sail batten tip end The main sail batten tip end Unclip batten ends Rotate batten tension can be increased 2 tension can be increased 2 ends clockwise to reduce tension or 4 turns on the left wing The 4 turns on the right wing rotate batten ends anti clockwise to tension on the right can The tension on the left can increase tension Note Tip batten decreased the same be decreased the same tuning has more effect on turn tuning amount if required amount if required than the root battens Strut Tension Strut tension on the left Strut tension on the right The over centre strut should be strut should be increased strut should be increased 2 rotated to adjust the tension The by 2 4 turns The tension by 2 4 turns The tension lock nut should be loosened prior to on the right can be on the left can be 5 rotation The strut should be decreased the same decreased the same FH unloaded prior to adjustment amount if required amount if required Q Clockwise adjustment of the strut y reduces tension and anti clockwise adjustment increases t
79. eing flown The pilot of the aircraft must ensure that the required maintenance is carried out and documented in the correct manner Airborne microlights have been designed to permit easy inspection and operators should have no difficulty in assessing problems or recognising damage if visual checks are carried out correctly Maintenance checks may require partial disassembly of the wing Inspection should include a thorough visual check of the condition of the component and the attachment point in adequate lighting conditions Cleaning of the component may be required for proper inspection Significant scratches cracks galling corrosion or any other mechanical wear of the component is reason for replacement The sail requires special attention to the condition of the fabric and Bettsometer tests will be required after significant amounts of environmental exposure to things such as UV radiation chemicals and heat as well as mechanical wear and or tears For instructions on Bettsometer testing see Section 57 30 10 Bettsometer Testing The Pilot s Operating Handbook outlines checks required prior to each flight Extreme operating conditions may reduce the time limits for components Unscheduled maintenance is detailed in Section 5 50 00 AirBorne will from time to time amend these maintenance checks as the service history of the aircraft evolves It is the responsibility of the pilot to ensure compliance with new directives Information is availabl
80. ension gt The above adjustments assume that the trimmer is off when the turn is evident In the case of a tc turn developing when the trimmer is activated the battens adjacent to the reflex bridles should be adjusted an example if a left turn is evident when the trimmer is the battens 3 4 5 amp 6 gt should be tightened on the LHS and vice versa for right turn Tip Angle Adjustment The angle of the tip can be adjusted Rotate the left tip down Rotate the right tip down by rotating the angle of the tip clockwise 1 hole and re anti clockwise 1 hole and Adjustment requires removal of the install screw If more re install screw If more stainless screw which secures the adjustment is required adjustment is required tip webbing bung The tip bung is rotate the right tip up rotate the left tip up gt rotated and the screw is installed clockwise 1 hole and re anticlockwise 1 hole and in the appropriate hole Reduction in install screw re install screw leading edge tension will simplify procedure Ensure correct tension is Q applied after adjustment See Section x 0 Assembly After Shipping for tip adjustment details Batten Reflex Adjustment One of the most effective ways to The battens 3 4 5 amp 6 on The battens 3 4 5 amp 6 on 2 tune a more significant turn is to the left side should be the right side should be reflex the root battens Contact the reflexed as per batten reflexed as per batten Q fa
81. erefore it is important that the components are accounted for each time that they are removed and installed see drawing number 6505 in the Illustrated Parts Catalogue The bars are specific for the left and right hand sides and need to be installed on the inside of the down tubes They should be inspected for bending and at each of the bolt holes and welds as well as any other wear that may occur each time they are installed If they are permanently affixed to the aircraft they need to be inspected at regular intervals The frequency of inspection will depend on the amount that they are used Prior to each flight they should be checked to ensure that the locking pin is installed correctly and that they are securely attached to the uprights and base bar The welded base bar attachment has been made to be slightly loose for ease of fitment Training bar attachment showing the correct attachment of the bar on the inside of the down tube The detail view shows the sequence of components 1 Bolt head to the inside of the control frame 2 Tube 3 Nylon Washer 4 Down tube clamp both sides 5 Wing nut turned until both side of the down tube clamp contact Ensure the training bars are held securely 6 Safety pin Note The attachment to the base bar a pip pin or bolt secures the training bar to the base bar and also secures the control frame knuckle A longer PIP Pin is necessary for the larger diameter tube of the training bar
82. erplant ratings or both or equivalent RS Part 145 Repair Station Items that can be expected to be completed by a responsible organization that holds a part 145 repair Station approval TS Task Specific Items that can be expected to be completed by a responsible individual who holds either a mechanic certificate or a repairman certificate and has received task specific training to perform the task When specifying the task specific level of certification the specific training is also specified where it is appropriate Note that dealers may be authorized by the manufacturer to perform a maintenance or modification task for which they are specifically trained These tasks are not necessarily included in the Maintenance Manual This Maintenance manual is created with the focus to maintain Special Light Sport Aircraft S LSA This category of registration allows the aircraft to be used for hire and reward Maintenance requirements are given in the maintenance schedule tables Note that the level of qualification is given for each of the tasks Notice that this manual prescribes owner maintenance and repairman maintenance The minimum applicable repairman ratings for each category of registration are as follows E LSA registered LSA Repairman Inspection certificate LS I S LSA registered LSA Repairman Maintenance certificate LS R In both cases of E LSA and S LSA a person who holds a mechanic certificate with A amp P rat
83. erve the purpose of holding the leading edges forwards and spread against the sail they share the loading with the leading edges during positive and negative flight loads The cross bars are attached to each other at the keel using a ball joint that allows relative movement They are also tethered to the keel via a webbing loop The cross bars are attached to the leading edges outboard using a bolt assembly The top and bottom side wires are a part of the bolting arrangement Battens The battens are mainly constructed from 7075 T6 aluminium The battens are located with batten pockets sewn into the sail The batten fittings at the trailing edge secure the battens into their pockets The battens help to maintain the profile of the wing during flight and are important to the correct and stable operation of the wing For this reason there is a batten profile that is supplied with each wing for the battens to be checked against WARNING DO NOT FLY THE WING WITH ANY OTHER BATTEN PROFILE THAN THAT SUPPLIED BY AIRBORNE AS VARIATION MAY HAVE SERIOUS EFFECTS ON THE FLIGHT PERFORMANCE STALL AND STABILITY CHARACTERISTICS OF THE WING Top and Bottom Side Wires The bottom side wires are stainless steel braided wires which are attached to the cross bars and the knuckle at the bottom of the control frame through swaged fittings The control frame end is attached via a stainless D shackle while the cross bar end has a fitting that allows a bolt to secure i
84. es 103724 104942 104942 106808 106342 106342 108854 BATTENS See A4 6712 for Details Bungie Spring Spring Hinge Hinge Hinge Hinge SAIL 0 108501 Sail 103776 104746 104746 106796 106281 10642 NOTE DRAWING DETAIL COPIED FROM ee 6715 XLS FOR IPC PURPOSES TRIKE WING FRAME INTERCHANGE S SERIES 1 ADDED MERLIN 11 11 08 LAST ACESSED Wednesday 21 April 2010 Drawn By Scale Date 1 Born 6715 ALL DIMENSIONS IN MILLIMETERS UNLESS STATED OTHERWISE Stuie T4 11 02 10 1r SHEET 1 of 2 aA ANDOWLVS SLYVd GALVYLSNTII AOF VWIIVHLSNY OIOC PT Ald suodspurA Lv OI F0 IcC 072 MODIFICATION HISTORY STREAK I NOTE 1 LHS Rear 103866 RHS Rear 103867 Can use Streak Il Rears with Leading Edge Tensioners Shim Type 104043 STREAK14A Shorter Rear Leading Edges to accommodate Leading Edge Tensioners Shim Type 104043 STREAK Il Adjustable Leading Edge Tensioners Allen Key Sail rear webbing Dual to suit Tensioners Spring Battens STREAK II XT Used on early XT 912 Base Increase in length in side wire Di hederal STREAK Ill Introduced for XT 912 Base Faired Control Frame and Kingpost New Trimmer System STREAK IIB Introduced after Streak Illfor Edge X Base Round Down Tubes and King Post No Trimmer Same main frame as Streak Ill CRUZE Introduced as Intermediate wing Same frame as Streak Ill with Control Frame raked rearward MERLIN Introduced as rep
85. etergent and rinsed with fresh water Apart from the consequences of heavy landing or of exceeding flight limitations the major factors requiring attention are corrosion fatigue wear UV exposure and heat There are no known fatigue problems with Airborne microlights 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 Many components can be replaced with ease for difficult repairs or if the repair process is not fully understood consult your Airborne Dealer or the Airborne factory The registration of microlights is only valid provided that all necessary maintenance modification and service requirements are fulfilled These requirements include a Maintenance of aircraft as per the Maintenance Schedule in this manual e b Modification as detailed in any relevant Service Bulletins c Modification to approved details obtained from Airborne WindSports Pty Ltd d Repairs necessary to replace minor damage wear or ageing e Servicing replacement and overhaul inspection and checking in compliance with the Maintenance Schedule f Any Airworthiness Directory AD issued by CASA or the NAA of the country of registration 5 20 01 Maintenance Privileges Issue 3 0 2010 Page 15 AirBorne WindSports Pty Ltd Streak 2B amp MERLIN Maintenance Manual This manual lists task to be performed
86. f the wing are listed below Streak 2B MERLIN Metric Imperial Metric Imperial Sail Area 13 54 m 1457 14 57 1574 Control Frame Rake Angle 65 90 65 9 65 9 65 90 Wingspan 10m 32 8 ft 9 97 m 32 7 ft Control Frame Height From Keel 1 545 m 5 07 ft 1 545 m 5 07 ft Nose Angle With Sail Installed 131 22 131 2 131 20 131 20 Table 8 Dimensions and areas 9 GROUND HANDLING 9 00 00 General The wing should only be moved in the packed up condition or if necessary when attaching to the base When moving the wing in the assembled position it is recommended that the wing is lifted with the shoulders whilst standing in the control frame It is suggested that an assistant is used to support the weight on the rear of the keel tube If there is wind or gusts the wing can easily be caught by the wind without proper handling If there is a significant amount of wind it is advisable to have assistants to hold the side wires The wing should be moved with the nose facing into the wind CAUTION ENSURE THAT WHEN MOVING THE WING IN WINDY CONDITIONS THAT THE NOSE IS KEPT LOW WHEN FACING INTO THE WING THE WINDWARD TIP SHOULD ALSO BE KEPT LOWER TO AVOID THE WING RISING 9 10 00 Ground Transportation Avoid damage to your wing by using well padded racks Careless transportation can cause considerable damage to your wing We recommend that you support the wing in at least 3 places to spread the load The wing
87. here the wire is bent Issue 3 0 April 2010 Page 40 AirBorne WindSports Pty Ltd Streak 2B amp MERLIN Maintenance Manual 27 FLIGHT CONTROLS 27 00 00 General The Streak 2B and Merlin wings use weight shift control This means that there is no need for most of the traditional flight control surfaces such as flaps and rudders The pilot uses the control bar to shift weight relative to the attachment point of the base to the wing which in turn causes a reaction in the wing and the control response of the aircraft 27 30 00 Reflex Bridles Reflex bridles produce longitudinal stability when the wing is at zero or negative angles of attack The reflex bridles work by stopping the trailing edge of the wing 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 27 60 00 Spoiler Drag Devices and Variable Aerodynamic Fairings The only flight control on the wing that is not automatic or weight shift controlled is the trim speed control A pulley device on the right hand down tube gathers wire which is linked to the reflex bridles Turning the trim handle pulls the reflex bridles upward pulling up and effectively creating elevator surfaces causing the trim speed of the wing to
88. il the swaged wire will just remain at the top adjustment point 17 Trimmer Handle Firm with Loctite 243 see drawing Illustrated Parts Catalogue Streak 2B Table 8 Torque settings for the wing Issue 3 0 2010 Page 39 AirBorne WindSports Pty Ltd Streak 2B amp MERLIN Maintenance Manual 20 20 00 SAFETYING PROCEDURES All bolts and nuts except the self locking type should be safetied after installation This prevents them from loosening in flight due to vibration Self Locking Nuts Self locking nuts are used throughout the airframe Self locking nuts may be reused but not if they can be run on the thread by hand without using tools After a self locking nut has been tightened at least one full thread pitch of the male thread must protrude through the nut locking feature Loctite On any bolt that does not have a Nyloc type locking mechanism Loctite 243 should be used to prevent premature loosening On the U bracket Loctite 262 Red High Strength needs to be used 20 30 00 CONTROL CABLES AND TERMINALS Streak 2B only There is a single control cable on the wing used for the trimmer The trimmer wire is routed through the right hand down tube through a pulley to halve the ratio and on to the trimmer reel where the pilot actuates it The trimmer should be checked regularly for excessive friction and wear Wear is most likely to occur at the ends of the cables at the attachment points and the areas w
89. in the table below along with references to the illustrated parts catalogue which should be used to ensure that the components are reinstalled in the correct sequence Definition of Just Not Loose A definition of torque has been made for the assembly of this wing which has been called Just not loose a setting which is used to achieve the best combination of strength characteristics of the tubing while not allowing any vibration or relative movement of the bolt in the axial direction In practice this means that the nut shall be tightened adequately to ensure that each of the components that are held by it are in contact with each other and then approximately 4 turn more should be made The resulting fit should not allow any axial movement of the bolt in its location but will allow rotation using fingers of a held component to be achieved with approximately 20mm of lever arm eg a wire tang No Area Instructions 1 Nose Assembly Central bolts Just Not Loose Outer bolts to leading edges may be slightly tighter make sure that the sail tangs are in place with approximately two threads showing This area may be slightly tighter than Just Not Loose because there is a bush in the leading edge see drawing Illustrated Parts Catalogue 2 Nose Catch Just not loose See drawing Illustrated Parts Catalogue 3 Keel Roller U The socket countersunk cap screws which locate in the Neg Plate Bracke
90. ing keel attachment base mast attachment and control frame top knuckle attachment The U bracket has two components a N shaped channel and a negative block that is attached in to preclude the keel from moving out the bottom of the bracket The U bracket should be checked thoroughly after any unusual loads Streak 2B only Overcenter Battens The overcenter battens are attached to the rear leading edges near the tips They are attached using a clevis pin and with an aluminium eyebolt 57 60 00 Flight Surfaces There is a trim speed control device on the wing The trim control is achieved by a pulley system which raises the reflex bridles Raising the bridles cause the root airfoil of the wing to be reflexed The reflexed section causes the centre of pressure of the airfoil to move forward resulting in a reduction in trim speed Issue 3 0 April 2010 Page 49 AirBorne WindSports Pty Ltd Streak 2B amp MERLIN Maintenance Manual 95 SPECIAL PURPOSE EQUIPMENT 95 10 00 Training Bars The training bars are supplied as an option for use by qualified instructors in order to teach people to fly the aircraft and with more experienced students to fly the aircraft from the rear if necessary The training bars attach to the wings base bar and down tubes and provide control extensions toward the back of the aircraft for rear occupant usage 95 10 10 Training Bar Maintenance The training bars are likely to be installed and removed often th
91. ing or a part 145 repair station may perform maintenance and inspections on the LSA The 100 hourly or annual inspections on a S LSA are to be performed by the holder of a LSA Repairman Maintenance certificate an appropriately rated Mechanic with Airframe and Powerplant A amp P rating or a part 145 Repair Station The holder of a sport pilot certificate may perform preventive maintenance on an aircraft owned or operated by that pilot and issued a special airworthiness certificate in the light sport category Items of preventative maintenance that may be performed by an owner are listed in FAR 43 appendix A Section A43 1 Issue 3 0 2010 Page 18 AirBorne WindSports Pty Ltd Streak 2B amp MERLIN Maintenance Manual 5 20 05 Maintenance Task Legend Your micro light should be maintained in accordance with the following schedules When registered under LSA the following schedules are mandatory The following codes are used in these schedules Code Oil lubricate clean and service Check as directed Check for insecurity cracks wear legibility and faulty operation Remove inspect and replace if necessary Recommend replacement or overhaul Mandatory Replacement Refer to Rotax maintenance manual and Rotax maintenance logbook O1 BR D Certification required to perform Light Sport Aircraft maintenance tasks Owner R E LSA Repairman Inspection experimental registered aircraft only R S LSA Repa
92. ires Unbolt top and bottom side wires from cross bar and feed wires back through sail Figure 6 Unbolting Side Wires Remove Quick Clip Nut Remove quick clip bolt padding Undo quick clip bolt and remove sail webbing bottom rear wires and bolt from airframe Figure 7 Removing Quick Clip Nut Issue 3 0 April 2010 Page 23 AirBorne WindSports Pty Ltd Streak 2B amp MERLIN Maintenance Manual Remove Top Front Back Wire Unbolt top front to back wire from pull back wire shackle Figure 8 Removing top Front to Back Wire Unroll Sail Unroll sail enough to access reflex bridles Undo reflex bridle shackles from sail Cut off heat shrink and undo trimmer wire shackle Feed trimmer wire back through sail Figure 9 Unrolling sail Untie Bungie Untie bungie from pull back handle Figure 10 Untying bungie Issue 3 0 2010 24 AirBorne WindSports Pty Ltd Streak 2B amp MERLIN Maintenance Manual Remove Zip Cut off zip tie at nose junction Remove zip slider from zip and unclip sail safety webbing Figure 11 Removing centre zipper Remove Nose Webbing Undo sail webbing nut and remove sail webbing Replace nut finger tight b e UM i 25 8 2004 Figure 12 Removing nose webbing Unbolt Top Front Wire Unbolt top front wire from nose junction and replace nut finger tight Raise nose slightly and feed wire back through sail king post will now be detached
93. irframe are manufactured from tube made specifically to Airborne s specification it is important that only genuine replacement parts as supplied by Airborne WindSports Pty Ltd are used Airframe Bolts All airframe bolts are either aircraft quality or high tensile bolts If it necessary to replace any bolts or nuts it is important that the specification of the original bolt are matched when a replacement is selected This applies not only to the grade of the bolts but to the length as well Installation amp Removal e After tightening all bolts should have at least 1 to 2 threads showing e All self locking nuts should not be installed more than 2 times e sure not to over torque bolts when installing e Check assembly instructions for correct bolt placement Inspection Check bolts for worn shanks bad threads or corrosion Wire Inspection 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 5 20 00 Scheduled Maintenance Checks General care should include Washing down the tube with warm water and light detergent followed by rinsing with fresh water Fabric sponged with warm water and a mild d
94. irman Maintenance A amp P Mechanic Certificate Airframe and or Powerplant TS Task Specific 5 20 06 Log Book When maintenance is performed always fill out the appropriate check sheet supplied in Appendix A at the rear of this maintenance manual The aircraft logbook should also be filled out when maintenance has been done When Service Bulletins have been complete both the maintenance manual and the log book should be filled out A copy of the Service Bulletin form should be sent to the factory to be stored with the aircraft QA papers A separate maintenance manual is supplied with the trike base The wing maintenance log should be filled out in the wing maintenance manual and aircraft log book Issue 3 0 April 2010 Page 19 AirBorne WindSports Pty Ltd Streak 2B amp MERLIN Maintenance Manual 5 20 10 Wing Airframe Maintenance Schedule WING Manual MAINTENANCE Section AIRCRAFT OR ITEM HOURS OF OPERATION SCHEDULE Inspection Items Reference 100 200 300 400 500 600 700 800 900 1000 Sail Bettsometer testing 57 30 00 2 R 2 R 2 R 2 R 2 R a 57 30 00 2 R 2 R 21 218 2IRI 2IRI 2 R 28 218 2 R cM 57 30 00 2 R 2 R 2 218 2 2IRI 2 R 2 RI 218 2 R Tip assembly and webbing Correct tension 00 10 00 2 R 2 R 2 R 2 R 2 R 2 R 2 R 2 R 2 R 2 R set
95. ive Pages Issue 3 0 2010 Page 4 AirBorne WindSports Pty Ltd Streak 2B amp MERLIN Maintenance Manual INTRODUCTION This manual contains factory recommended procedures and instructions for ground handling servicing and maintaining the Streak 2B Merlin wing section of this aircraft The procedures described are to be used in conjunction with those required by the National Airworthiness Authority NAA of the country of registration Any NAA maintenance requirement takes precedence over this manual This manual should be used in conjunction with a certified base and therefore the operator is directed to reference the base maintenance manual for any issues that are related to the base component of the aircraft Skills Only people with an adequate skill level should perform maintenance on this aircraft sound understanding of mechanical systems and good experience with the necessary tools and procedures is required as the continuing airworthiness of the aircraft relies on the competence of the person performing the maintenance Assessment and judgement of the condition of each individual component is required which necessitates a sound understanding of the purpose of each component in the system All maintenance and repairs must be carried out in accordance with good aeronautical practices Skills and authorisations specific to Special Light Sport Aircraft Maintenance tasks are rated in the categories listed below acc
96. l USE OF METRIC IMPERIAL UNITS This Service Manual uses the metric unit system as the basic system of measurement Where common usage or available instrumentation refer to the Imperial system both units are quoted The following conversion factors are presented as a ready reference to the conversion factors that have been used in this manual 1 Pound Ib Pound per sq in psi Inch in Foot ft Statute mile Nautical mile NM Millibar mb k Millibar mb Imperial gallon US gallon US quart Cubic foot ft k Degree Fahrenheit F Inch Pound in Ib Foot Pound ft Ib Table 3 Imperial Metric Conversions Issue 3 0 April 2010 0 4536 Kilogram kg 6 895 Kilopascal kPa 25 4 Millimetres mm 0 3048 Metre m 1 609 Kilometres km 1 852 Kilometres km 1 Hectopascal hPa 0 1 Kilopascal kPa 4 546 Litres 3 785 Litres 1 0 946 Litre 1 28 317 Litres 1 1 8 X C 32 0 113 Newton Metres Nm 1 356 Newton Metres Nm Page 8 AirBorne WindSports Pty Ltd Streak 2B amp MERLIN Maintenance Manual CONTENTS AMENDMENT RECORD 5 on ade nn din tdi ie en 3 USE OF METRIC IMPERIAL UNITS fo loce tn en tante 8 MONTE evs ce ees ere errem nement unes en IL RU LE DE E E 9 pr DI PEE 10 ASSEMBLY AFTER SHIPPIN
97. lacement for Wizard Ill Same frame as Streak Ill with Control Frame raked rearward Leading Edge Rears have a folding clip tip strut ed arom TRIKE WING FRAME INTERCHANGE SERIES LAST ACESSED Wednesday 21 April 2010 Drawn By Scale Date 1 Born 6715 ALL DIMENSIONS IN MILLIMETERS UNLESS STATED OTHERWISE Stuie T4 11 02 10 1r gh SHEET 2 of 2 aA ANDOWLVS SLYVd GALVYLSNTII NHAN 15 AOF VWIIVHLSNYV STREAK 2B amp MERLIN a Air Borne ILLUSTRATED PARTS CATALOGUE AUSTRALIA WARNING THE PARTS WHICH ARE REPRESENTED IN THE FOLLOWING DRAWINGS ARE NOT NECESSARILY PART OF THIS AIRCRAFT SOME PARTS WHICH ARE LISTED ARE COMPONENTS OF PARTS WHICH ARE NOT USER SERVICABLE ONLY MAINTENANCE WHICH IS SPECIFIED IN THE MAINTENANCE MANUAL SHOULD BE ATTEMPTED AND ONLY THE EXACT SPARE SHOULD BE USED TO REPLACE PARTS THE FOLLOWING DRAWINGS ARE PROVIDED AS A CONVIENIENCE TO AID IDENTIFICATION OF PARTS WHICH ARE USER MAINTAINABLE 5 MISCELLANEOUS COMPONENTS 5 1 Dee Shackle Drawing Drawing 6338 5 2 Batten End Assembly Drawing 5321 5 3 Batten End Folding Clip Asm LHS Drawing 7598 5 4 Batten End Folding Clip Asm RHS Drawing 7609 5 5 ANS Bolts Drawing 5449 5 6 4 Bolts Drawing 5450 5 7 AN5 Bolts Drawing 5493 5 8 Socket Cap Screws Drawing 5668 AirBorne WindSports Pty Ltd 2010 Issue 2 0 21 04 10 42 0102 PT Ald suodspurA ev OI F0 IcC 07
98. locating hole Although there may be two holes visible there is one hole available that is large enough for the king post locating bush When installed the machined fitting with velcro should be flush with the keel Bolt top front to back wire to the pull back shackle Figure 26 Fit king post Fit Reflex Bridle Reattach bridles to sail using Loctite 243 on the shackle Screw Feed trimmer cable back through eyelet hole in sail Fit new heat shrink 13mm x 30mmL over trimmer wire Feed shackle back through wires and tighten using Loctite 243 Slide heat shrink over shackle assembly Shrink down using a heat gun Figure 27 Fit reflex bridle Issue 3 0 2010 Page 30 AirBorne WindSports Pty Ltd Streak 2B amp MERLIN Maintenance Manual Insert Battens Insert battens and pull cross bar tension on Tie pull back bungie onto pull back handle using a bowline knot Photo shows the pull back handle being tied on Figure 28 Insert batten Reset Tip Adjusters Tension the sail using a 6mm Allen key The tip fitting should be adjusted until the leading edge is positioned on the 3 mark for Streak 2B Wing 3 mark for Merlin Wing The markings are on the internal tube and should be adjusted until the appropriate mark aligns with the main outer tube Secure Velcro tabs around the leading edge Figure 29 Tension tip NOTE If you find difficulty pulling the sail tension on the leading edge the adjustable
99. mark for Merlin wing The markings are on the internal tube and should be adjusted until the appropriate mark aligns with the main outer tube Secure the hook and loop fastener tabs around the leading edge isi Figure 3 Setting Tip Adjusters NOTE If you find difficulty pulling the sail tension on the leading edge the adjustable tips can be wound in clockwise The sail nose tangs can be removed to allow the sail to move back It is however extremely important to check that the sail at the nose does not foul on the frame when the wing is being tensioned Ensure that the nose tangs are replaced and secured Tip Protectors Install the tip wear protectors secure the hook and loop fasteners to the mylar protectors onto the sail at the tip Assemble Assemble in accordance with section 4 of the Pilot s Operating Handbook Preflight CAUTION A THOROUGH AND COMPLETE PREFLIGHT IS ESPECIALLY NECESSARY AFTER REASSEMBLY THOROUGHLY CHECK ALL NUTS AND BOLTS REFER TO SECTION 5 FOR TORQUING PROCEDURES BEFORE TIGHTENING ANY NUTS WIRE ROUTING SAIL FIT MYLAR SHAPE AND OVERALL SYMMETRY OF THE WING BEFORE FLIGHT Preflight as described in section 4 of the Pilots Operating Handbook paying particular attention to possible damage to the airframe during transport Issue 3 0 2010 Page 12 AirBorne WindSports Pty Ltd Streak 2B amp MERLIN Maintenance Manual 4 AIRWORTHINESS LIMITATIONS 4 00 00 General This section sets forth
100. n found the Part Number AND THE DESCRIPTION can be recorded in order to make the spare part order E g Knob Hand Plastic 30 Part 106530 ITEM PART NO DOWN TUBE S3 CRUZE RHS SUB ASSEM 106311 SADDLE TRIMMER TRIKE AERO D T 06284 TRIMMER SPOOL TRIKE AERO D T 06287 HAND TRIMMER LEVER 06476 KNOB HAND PLASTIC 30 06530 SKT CSK SCREW 6 16 55 106275 BOLT AN4 26 a 00009 NOTE THREAD TRIMMER WIRE WASHER 55 M6x12 5 BELVILLE 06346 WASHER SS M10x20 BELVILLE 02367 CAP WASHER COVER BLK M8 00603 CAP WASHER BASE CLIP M8 100604 NUT NYLOC AN4 HALF 100035 Locitite 243 Blue Med Strength 03706 lt Visually identify the component And match it to the part number given in the Bill of Materials TRIMMER ASSEMBLY AERO D TUBE Drawn By Scale Date Bas 2 Airborne 5409 t etra SHEET 141 Figure 4 Identify the actual component required AirBorne WindSports Pty Ltd 2010 Issue 2 0 21 04 10 STREAK 2B amp MERLIN ILLUSTRATED PARTS CATALOGUE 1 STREAK 2B WING ASSEMBLY 1 1 Cross Bar Leading Edge Junct 1 1 1 Nose Junction Assembly 1 1 1 1 U Bracket and Keel Assembly 1 1 1 2 Leading Edge and Channel 1 1 2 Cross Bar Hinge Assembly 1 2 Rear Leading Edge Assembly 1 2 1 Trike Wing Leading Edge Tensioner 1 3 Kingpost Assembly 1 4 Control Frame Assembl
101. nts for structures These include the front and rear wires the side wires and the main hang point The sail should also be inspected for any strain or tearing that may have occurred though this is very unlikely All of the tubing should be inspected for bending including the battens against the supplied batten profiles The opportunity should be taken to inspect the batten fittings at the same time If the base bar has made contact with the mast brace at any time during flight then they should both be checked 5 50 50 Sail removal The sail should be removed for close inspection of the airframe if the frame is suspected of suffering any damage for example having bent tubes following a heavy landing blow over or crash If the wing suddenly develops a turn after severe turbulence it is possible that some tubes may be bent therefore close inspection of all the tubes is necessary It is suggested that the sail should be removed from the frame every 500 hours to check for any signs of fatigue or damage from general wear and tear The main points to check are Cross bar hinge joint Cross bar leading edge joint deformation in the bushes Leading edge nose joint deformation in the bushes Nose plates Straightness of the tubes Elongation of boltholes Damaged wires Damage to bolts Damage to sail NOTE If any part of the aircraft has any signs of damage the part should be replaced prior to re installing the frame Issue 3 0
102. on an annual basis Annual testing has been found to be adequate for recreational user where the operator takes care to avoid unnecessary exposure to UV More frequent testing 200 operating hours or 750 UV hours is applied where operators exceed these hours prior to the annual test Issue 3 0 April 2010 Page 44 AirBorne WindSports Pty Ltd Streak 2B amp MERLIN Maintenance Manual NOTE e f a wing is stored under a roof but the roof does not have doors on the front i e an open hanger the wing will still experience UV degradation e lfawing is flown and or left in the open for day this will equate to 8 10 hours of UV exposure Where aircraft have been exposed to high levels of UV over an extended period such as being left set up in the open for 3 months or more equivalent to 750 UV hours then testing prior to return to service is recommended The instructions that are supplied with the Bettsometer should be followed to ensure proper testing NOTE Some instructions that may be helpful e The instructions that come with the Bettsometer recommend that any flat section of the sail clear of obstructions is suitable for fabric testing Single layer sections of the sail would give a more relevant test result than patched or multi layered sections and obviously those areas most exposed to UV damage usually the top surface would be the most useful to test e Likewise the stitching exposed on the top surface would show the
103. ording to the applicable category of registration and skill levels required to perform those tasks Owner FAA regulations authorize SLSA aircraft owners who hold at least a sport pilot certificate to perform maintenance as outlined in 14 CFR Part 43 To perform inspections on aircraft condition functional checks and maintenance in between inspections carried out by LSA Repairman Maintenance certificate holders LSA Hepairman Maintenance This certification authorizes a certificate holder to perform line maintenance repairs and alterations to S LSA as the task allows Includes 100 hourly and yearly inspections on S LSA A amp P Mechanic Certificate with Airframe and or Powerplant rating perform heavy Maintenance on airframes or powerplant as the rating allows Task Specific Applicable to the following ratings LSA Repairman Maintenance with appropriate task specific training or A Mechanic Certificate with appropriate task specific training Authorizes the holder of mechanic certificate or a repairman certificate who has received task specific training to perform the tasks approved under that training Allows a repairman certificate holder to perform heavy maintenance repairs and alterations on the SLSA E g The Mechanic Certificate holder may obtain Task Specific training on Rotax engines to allow overhaul etc Skills and authorisations specific to Experimental Special Light Sport Aircraft LSA Repairman Inspection To
104. s Control Frame The control frame is constructed mainly from 6061 T6 aluminium The control frames down tubes work mainly in compression due to the positive loading of the wing which is reacted through the Side wires Issue 3 0 April 2010 Page 42 AirBorne WindSports Pty Ltd Streak 2B amp MERLIN Maintenance Manual and base bar sections The base bar works mainly in tension through the side wire loads from the crossbars and leading edges The control frame is bolted to the keel through the U bracket The fittings at the top of the control frame allow relative movement between the U bracket and the control frame This is necessary because of the movement between the base and the wing during the weight shift control actions Leading Edge The leading edges are mainly constructed from 6061 T6 Aluminium The leading edges are mainly loaded in bending and compression and share loading with the cross bars during positive and negative flight loads The leading edges are attached to the keel through the two nose plates at the front of the wing and via a bolt assembly to the cross bars and the outboard wires The rear leading edges fit inside the leading edge tubes which locate onto a horizontal bolt in the leading edge assembly The rear leading edges are a part of the leading edge but are made in order that they may be removed for ease of shipping Cross Bars The cross bars are mainly constructed from 6061 T6 aluminium The cross bars s
105. should be transported with the control frame down to minimise the chance of damage to the cross tubes Flat straps should be used for tie downs to avoid damage to leading edge mylar Store the wing in a dry room off the ground Air the wing out regularly to avoid mildew and never store wet Issue 3 0 Page 35 April 2010 AirBorne WindSports Pty Ltd Streak 2B amp MERLIN Maintenance Manual 10 DERIGGING 10 00 00 General For derigging and storage see Sections 4 of the Aircraft Operating Instructions or Pilots Operating Handbook as appicable Issue 3 0 April 2010 Page 36 AirBorne WindSports Pty Ltd Streak 2B amp MERLIN Maintenance Manual 11 REQUIRED PLACARDS 11 00 00 General The placards that are present on this aircraft are a legal requirement showing safety information emergency information and identification of the aircraft The placards must be repaired or replaced if they become illegible or damaged in service Replacement placards may be purchased from an Airborne dealer or direct 11 10 00 Required Placards The placards on the aircraft are designed to provide information regarding general aircraft limitations and other details for the safe operation of the aircraft The placards that are required for operation of this aircraft are available in the Aircraft Operating Instructions Section 2 Placards Issue 3 0 April 2010 Page 37 AirBorne WindSports Pty Ltd Streak 2B amp MERLIN Maintenance Manual
106. t Top and Bottom Front Back Wires The bottom front back wires are stainless steel braided wires that have swaged fitting at each end for attachment to the nose catch control frame and keel Reflex Bridles The reflex bridles are mainly stainless steel wire swaged together and attached to the top of the king post via the top king post fitting and to the sail using D shackles The trimmer wire is also attached using a D shackle Issue 3 0 2010 43 AirBorne WindSports Pty Ltd Streak 2B amp MERLIN Maintenance Manual 57 30 00 Sail The sail comprises the lifting surface of the wing It is mainly constructed of Dacron polyester fabric with some Mylar material making up the leading edge areas The sail is constructed from many individual panels which are sewn together using polyester thread to form the required shape The sail has attachment points sewn into it to attach to the frame at various points and to hold the battens in place The Sail also provides zips that facilitate easy preflight inspection of all the members inside the double surface wing The sail should be kept out of the sun as much as possible as sunlight will damage the sail and in time will cause it to fail the required Bettsometer tests Inspection e Check for tears in the sailcloth or any loose or unravelled seams e Check all webbing securing points are not damaged or worn e Check all inspection zippers to see if they function smoothly and close
107. t horizontal aluminium plate with serial number riveted to it should be Issue 3 0 April 2010 38 AirBorne WindSports Pty Ltd Streak 2B amp MERLIN Maintenance Manual tightened to approximately 25 Nm Red Loctite 262 must be used see drawing Illustrated Parts Catalogue 4 Down Tubes The down tubes are also attached to the U bracket The down tubes need to Top Assembly move relative to the U Bracket therefore it is important that they are able to move after tightening This may be slightly tighter than Just Not Loose Ensure that there is no gap between the neg plate and the U bracket there should be approx 2 3 threads showing 5 King Post Base The bolts which attach the fittings to the king post should be tightened to approx 15 Nm firm Loctite 243 must be used The long locating bolt which protrudes vertically from the bottom of the king post should be firm with Loctite 243 see drawing lllustrated Parts Catalogue 6 Cross Bar The central bolt should be tightened to Just not loose the black acetal Hinge cross bar protector should still be able to be rotated by hand see drawing Illustrated Parts Catalogue T Down Tube The side wire D shackle and base bar fitting bolt should be slightly tighter Bottom Corners than just not loose but the D shackle and base bar knuckle should be able to be rotated by hand Loctite is not required as there is a locking
108. the tip bags which have been used as protection on the rear of the front leading edges Insert Rear Leading Edges NOTE Insert rear leading edges in the correct side left and right hand sides are marked with the slot positioned horizontally Streak 2B only Ensure that the tip strut is positioned on the top of the leading edge top of leading edge assumes the wing is in the flying position The rear leading edges are located with their slots and held in place by the sail loops Figure 1 Insertion of Rear Leading Edges CAUTION VELCRO TABS AND SAIL CELLS NEED TO BE POSITIONED AFT OF THE LEADING EDGE ONCE INSTALLED THE REAR LEADING EDGE SLOT SHOULD BE LOCATED ON THE CHANNEL HORIZONTAL BOLT IT IS IMPOSSIBLE TO ROTATE THE LEADING EDGE IF CORRECTLY INSTALLED Issue 3 0 2010 11 AirBorne WindSports Pty Ltd Streak 2B amp MERLIN Maintenance Manual Tension Sail Place one hand on the rear of the leading edge Pull sail firmly until the loops are located on the end of the leading edge fitting This holds both the sail and the rear leading edges in place Ensure the webbing is centrally located with one on each side of the central divider Repeat for the other leading edge Figure 2 Locating Sail Webbing on Rear Leading Edges Set Tip Adjusters Tension the sail using a 6mm Allen key The tip fitting should be adjusted until the leading edge is positioned on the 3 mark for Streak 2B wing 3
109. y 1 4 4 Down Tube LHS Assembly 1 4 2 Down Tube RHS Assembly 1 5 Covers and Padding 1 6 Batten List 1 7 Data Package Components 1 8 Batten Profile AirBorne AUSTRALIA DRAWING 6618 Drawing 6484 Drawing 6474 Drawing 6470 Drawing 6473 Drawing 6483 Drawing 6486 Drawing 5172 Drawing 6609 Drawing 6607 Drawing 6605 Drawing 6606 Drawing 6620 Drawing 6402 Drawing 6619 Drawing 6622 AirBorne WindSports Pty Ltd 2010 Issue 2 0 21 04 10 01 PYT Ald SHO SPUIM OI F0 IcC 072 91551 THE 0 BRACKET IS POSITIONED IN THE REAR HOLE FOR THE STREAK 2 B VIRTUAL PARTS Rev AMENDMENTS 1 2 3 DCR 2173 ADD COLOURS D Date 12 09 05 STOCK COLOUR PART LIST 106795 COLOUR TBA 107306 WHITE RED 107307 WHITE YELLOW 107308 WHITE BLUE 107309 GREY YELLOW 107310 BLACK RED 107311 CUSTOM COLOURS PART NO 106795 0 LAST ACESSED Wednesday 21 April 2010 ALL DIMENSIONS IN MILLIMETERS UNLESS STATED OTHERWISE AUSTRALIA ITEM NO NAME DWG PART NO arv SAIL 1 AIRFRAME S SERIES 6484 106440 1 106796 2 LEDGE REAR TW S3 CRUZE RHS ASM 6486 106445 1 107289 3 L EDGE REAR TW S3 CRUZE LHS ASM 6486 1064

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