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SST AND ARROW MAINTENANCE MANUAL

1. ITEM NO NAME DWG PART NO QTY 43 ACTUAL SIZE BATTEN END HINGE THREADED CLIP 5343 104976 1 7 BATTEN END HINGE PIVOT BEAK 5342 104977 1 iC TT E 85 R12 2 11 4 p TH Hf uuo fi HIME j AO Uu 1 Di NUUAM o 010 Hn NI ME i Hr 1 11 4 18 24 8 Q7 BATTEN END ASM HINGED PUR PURCHASED NON QA PART TO BE INSPECTED PART NO 108707 AS PER ENGINEERING REPORT 07 044 FOR ACCEPTANCE BATTEN END HINGE ASM PART NO 104975 BATTEN END HINGE ASM Rev AMENDMENTS Date 1 NEW PURCHASED PART NO 31 07 07 LAST ACESSED Tuesday 6 September 2011 Drawn By Scale Date 5321 2 REFORMAT FOR USE IN IPC 06 09 11 ALL DIMENSIONS IN MILLIMETERS UNLESS STATED OTHERWISE CRIS 21 12 12 02 AirBortie SHEET 1 of 1 MOHUV LSS VIIVELSNY s i ggup AirBof e SST AND ARROW IPC AUSTRALIA 4 3 Over Centre Tip Lever Asm T Series Drawing 7842 Airborne Windsports 2012 Issue 1 1 ZLOZ suodspurM L L enss NOTE MAKE IN PAIRS AND MAKE IN EQUAL AMOUNTS NOTE THE DIRECTION OF THE BOLT FOR EACH ASSEMBLY THIS IS SO THE NUT FACES DOWNWARDS WH
2. 24 110825 COLOUR CUSTOM 111046 COLOUR STOCK Rev AMENDMENTS Date 111045 COLOUR TBA 1 2520 U SERIES DEV 20 01 12 LAST ACESSED Wednesday 30 May 2012 ALL DIMENSIONS IN MILLIMETERS UNLESS STATED OTHERWISE ITEM NO NAME DWG PART NO QTY 1 SAIL ARROW 12 9 8426 110831 1 2 MYLAR L E INSERT U SERIES 8424 110829 2 3 AIRFRAME T SERIES 7785 109635 1 4 L EDGE REAR TW U SERIES LHS ASM 8425 109633 1 5 L EDGE REAR TW U SERIES RHS ASM 8425 109634 1 6 LABEL S3 SST AND ARROW REAR L E LHS 6846 107257 1 7 LABEL S3 SST AND ARROW REAR RHS 6846 107256 1 8 NOSE CATCH SWAN 2140 100085 1 9 SHACKLE SHGF04 6338 100954 1 10 BOLT AN4 11A 5450 100003 1 11 NUT NYLOC AN4 FULL 5535 100034 2 12 BOLT QUICK CLIP AN5 31A TYPE 3 6453 106405 1 13 QUICK CLIP BLOCK 7002 106153 1 14 QUICK CLIP BOLT PIN AL 6467 103277 1 SPRING QUICK CLIP BOLT SS 6468 101203 1 WASHER AN5 5540 100043 1 NUT NYLOC AN5 FULL 5535 100036 1 CONTROL FRAME SST PREASM 7798 109653 1 C BAR TW INCL GRIPS ARROW 12 9 7790 111040 1 PIP PIN 38 5719 102146 1 PIP PIN CAP WITH WIRE 5718 101418 1 BOLT AN4 15A 5450 100967 1 WASHER AN4 5540 100042 1 STRUT ASM LHS T SERIES 7742 109543 1 SIRUT ASM RHS T SERIES 7742 109575 1 SPROG ASM INBOARD T SERIES 7755 109570 2 HEATSHRINK CLR 38MM X
3. Rev AMENDMENTS Date PART NO 109716 WING ATTACHMENT KIT T SERIES 1 DCR 2402 T SERIES DEV 18 06 09 LAST ACESSED Wednesday 23 May 2012 Drawn By Scale Date orn 7839 ALL DIMENSIONS IN MILLIMETERS UNLESS STATED OTHERWISE Stuart 12 18 06 09 A irB SHEET 1 of 3 AUSTRALIA MOHUV LSS sou VIIVELSNY ZLOZ suodspurM L L enss ITEM NO NAME DWG PART NO QTY 1 MAST TUBE EDGE XT WITH INT SLEEVE TY7859 109774 1 DETAIL MAST TOP MAST SAFETY 2 MAST SAFETY WIRE ASM XT TYPE 2 WITH 7867 109812 1 SCALE 1 4 TANG ASPXOE 3 BOLT SAE 5 UNF 3 8X 4 1 2IN DRILLED 7846 109729 1 4 SPACER ALLOY OD 18X ID 25 64X 16L 4013 109732 1 4 0 6 5 WASHER AN6 5540 100044 3 m P 6 NUT NYLOC AN6 FULL 5535 100038 1 7 WINGNUT AN6 5534 101065 2 8 SAFETY PIN 5545 100920 2 9 BOLT AN6 41 5494 100033 1 NOTE 10 RETAINER ASM BOLT HEAD 5218 104739 1 BOLT MUST GO THRU 11 WASHERSS304 3 8 X 3 4 5540 100924 2 MAST SAFETY WIRE 12 WASHER NYLON M10 STND 5540 100619 2 13 TRIMMER MAST ASM T SERIES 7868 109816 1 ATTACH 14 _ MANUAL PAGES XT 912 S3 CZ AOI 6582 107605 1 15 CABLE TIE SHORT 100 X 2 5MM BLACK 5605 101192 1 NOTE Ladi 13 MAST SAFETY TANG MAST TUBE NO
4. AirBorne WindSports Pty Ltd SST and ARROW 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 f a wing is flown and or left in the open for a 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 most UV degradation and will give a better indication of the strength left in the thread than that on the under surface e Bettsometers are available from Airborne Windsports Figure 30 Bettsometer Instrument 57 30 20 Minor tears or rips in the sail Minor sail repairs are a Line Maintenance task w
5. 36 27 FLIGHT CONTROLS 57 1 nanena annn iamai a nna a rien rien aa ge era 39 ccp 40 95 SPECIAL PURPOSE EQUIPMENT eeeeeeeeseeeeeseeeeene nenne nnne nen nn nnn nn nnne nns nn nnne nanenane 53 APPENDIX A Condition Inspection Checklist ee 54 APPENDIX B Feedback Fortm eerte raapi aaa datadi eae tan ainda niaaa aaa dakita aneradi TEE 55 Figures Figure 1 Insertion of Rear Leading Edges 11 Figure 2 Locating Sail Webbing on Rear Leading 12 Figure 3 Setting Tip Adj sters iie nete eene ke Bere UR e HERR ee Xe aste ERR XR enun 12 Figure 4 De tensioning the Tip sise 23 Figure 5 Removing Rear Leading Edges ssssssssssssssseseeeeee nennen nnne nnns 24 Figure 6 Removing Rear Leading Edges ii 24 Figure 7 Removing Centre Zipper sisi 24 Figure 8 Removing Nose Webbing iii 25 Figure 9 Removing Rear Wires siennes 25 Figure 10 Removing Airframe iii 25 Figure 11 Tie Pull Back Bungie To Pulley sis 26 Figure 12 Frame Preparation for Sail Reinstallation 26 Figure 13 Sliding Sail Onto Fram
6. Airborne Windsports 2012 Issue 1 1 AirBotne SST AND ARROW IPC AUSTRALIA INTRODUCTION 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 This manual should be 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 effect the airworthiness of the Airborne T Series SST 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 Most of the parts listed are available as spare parts If a component is not listed then it may only be available as a complete part For example spare parts are not available for the base bar only the entire base bar assembly is supplied as a spare part 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
7. AirBorne WindSports Pty Ltd SST and ARROW Maintenance Manual A irBorfie AUSTRALIA SST AND ARROW MAINTENANCE MANUAL Manufacturer Phone Fax Website Issue 1 1 AirBorne WindSports Pty Ltd Unit 22 30 Kalaroo Rd Redhead NSW 2290 Australia 61 2 4944 9199 61 2 4944 9395 http www airborne com au AirBorne WindSports Pty Ltd 2012 May 2012 Page 1 AirBorne WindSports Pty Ltd SST and ARROW 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 e Pilot Operator s Handbook Aircraft Operating Instructions e Applicable Base Maintenance Manual e Applicable Base Illustrated Parts Catalogue Wing Maintenance Manual e Wing Illustrated Parts Catalogue e Rotax Owners Manual e Rotax Maintenance Compact Disk e Radio Manual If Installed e BRS Parachute Manual If Installed Issue 1 1 May 2012 Page 2 AirBorne WindSports Pty Ltd SST and ARROW Maintenance Manual AMENDMENT RECORD SHEET Amendment Date Affected Sections Affected Pages Date Inserted Signature 24 05 2012 All to issue 1 1 All to issue 1 1 24 05 2012 Airborne Table 1 Amendment Record Sheets NOTE Airborne data packages will be revised from time to time
8. ITEM NO PART NO NAME MATERIAL DESCRIPTION MATL NO REQD 1 109757 LABEL SST STRUT LEFT SIDE BOTTOM NA NA NA ITEM NO PART NO NAME MATERIAL DESCRIPTION MATL NO REQD 1 109758 LABEL SST STRUT RIGHT SIDE BOTTOM NA NA NA NOTE TO PRINT USE P TOUCH EDITOR 4 2 NAVIGATE TO L Foxpro25 STOCK Labels 7857 AND OPEN FILE 7857 10 TO EDIT DATA USE EXCEL NAVIGATE TO N Cad Drawings 7800 7857 AND OPEN FILE strut leftrighttop labels xls AUSTRALIA AUSTRALIA THIS SIDE UP THIS SIDE UP LEFT HAND SIDE RIGHT HAND SIDE BOTTOM MODEL SST ARROW STRUT MODEL SST ARROW STRUT A Bo e CAUTION AirBoiie CAUTION 2 a PIN 109758 NOTE VIRTUAL PARTS ONLY MADE FOR INCLUDING IN BOM S PART NO 109757 LHS PART NO 109758 RHS LABEL SST STRUT LEFT amp RIGHT SIDE TOP 1 DCR 2402 T SERIES DEV 23 07 09 2 DCR 2520 ARROW DEV 29 05 12 LAST ACESSED Tuesday 29 May 2012 Drawn By Scale Date orn 7857 Stuart 21 23 07 09 A irB e SHEET 1 of 1 ALL DIMENSIONS IN MILLIMETERS UNLESS STATED OTHERWISE AUSTRALIA MOHUV LSS guy VIIVHLSNVv AirBotne SST AND ARROW IPC AUSTRALIA 3 8 TRIKE WING L EDGE TENSIONER Drawing 5172 Airborne Windsports 2012 Issue 1 1 ZLOZ suodspurM L L enss ITEM NO NAME DWG PART NO QTY 1 WING ADJUST
9. FOR THE WEBBING CAP HOLE THIS SIDE 104669 SCALE 1 2 POSITION INDICATOR LHS PART NO 104669 TW LEADING EDGE TENSIONER ASSYS LAST ACESSED Thursday 9 June 2011 Drawn By Scale Date ALL DIMENSIONS IN MILLIMETERS UNLESS STATED OTHERWISE Simon 14 20 05 04 AirBorie AUSTRALIA 5172 SHEET 1 of 2 Odi MOHUV LSS VIIVHLSNv sou ZLOZ suodspurM L L enss ITEM NO NAME DWG PART NO QTY 1 WING ADJUSTER WEBBING CAP LHS TYPE2 5169 109858 1 2 BOLT TRIKE WING TIP ADJUSTER 5233 104733 1 3 DRI LUBE SOLID LUBE 5637 106432 1 4 SCREW SELF TAPPING 1 4X8G 304SS 5909 105140 2 5 SPRING WASHER 8MM ZINC 5679 101366 1 ITEM NO NAME PART NO QTY 1 WING ADJUSTER WEBBING CAP RHS TYPE 2 5169 109859 1 2 BOLT TRIKE WING TIP ADJUSTER 5233 104733 1 3 DRI LUBE SOLID LUBE 5637 106432 1 4 SCREW SELF TAPPING 1 4X8G 304SS 5909 105140 2 5 SPRING WASHER 8MM ZINC 5679 101366 1 Rev AMENDMENTS Date PART NO 110028 LHS RETROFIT KIT PART NO 110029 RHS RETROFIT KIT LAST ACESSED Thursday 9 June 2011 ALL DIMENSIONS IN MILLIMETERS UNLESS STATED OTHERWISE TRIKE WING WEBBING CAP TYPE 2 RETRO LHS Drawn By Scale Simon 14 a L AirBot ne AUSTRALIA 5172 S
10. 109564 1 8 PIVOT SPROG HORIZONTAL 33MM 7727 109514 1 9 SPLIT RING 11MM RF114 5720 100950 1 10 NUT NYLOC AN4 HALF 5561 100035 2 11 CLEVIS PIN 3 16 X 29 32IN 5536 104572 1 12 WASHER NYLON M 6 XOD 5540 101055 1 13 DRI LUBE SOLID LUBRICANT 27GRAMS 5637 106432 3 14 POP RIVET 3 16 SHORT 6 4 5515 100160 2 15 BOLT 4 27 MODIFIED 2MM HEAD 8116 110178 1 16 MACH SCREW 524694 5106 1 4X1 7 321N 7797 104202 1 17 COVER SPROG MYLAR CLEAR 4985 110367 1 18 CABLE TIE MEDIUM 140MM 5605 101193 1 19 WASHER RED FIBRE 5 16X11 16X1 321N 5540 106400 2 ADJUST TENSIONER 2 TO FOURTH MARK SN NOTE PHILLIPS HEAD SCREW IN TENSIONER OG MUST FACE AWAY FROM THE SAIL TO ALLOW ADJUSTMENT AFTER FITTING DETAIL A SCALE 1 7 5 L EDGE REAR TW T SERIES ASM Scale Date _ 1 10 21 04 09 A irBoriie A of 2 AUSTRALIA MOHUV LSS VIIVELSNY owog ZLOZ suodspurM L L enss NOTE USES APPROX 3GM OF DRI LUBE PER LEADING EDGE NOTE RIGHT HAND SIDE ASSEMBLY SHOWN SEE SHEET 1 FOR LEFT HAND SIDE NOTE WIND IN TILL THERE IS 13MM OF THREAD LEFT DETAIL C SCALE 1 4 16 13 NOTE DRI LUBE THREAD OF SPROG ASSEMBLY PART NO 109634 LAST ACESSED Friday 2 March 2012 ALL DIMENSIONS IN MILLIMETERS UNLESS STATED OTHERWISE Rev AMENDMENTS Date ITEM NO NAM
11. 3 R 3 R 3 R 3 R SIP 3 R 3 R 3 R SIP Table 6 Scheduled Maintenance May 2012 Page 21 Issue 1 1 AirBorne WindSports Pty Ltd SST and ARROW 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 profile and the opportunity should also be t
12. MOHUV LSS VIIVHLSNVv guy SST AND A E I AUSTRALIA 4 MISCELLANEOUS COMPONENTS Airborne Windsports 2012 Issue 1 1 AirBof e SST AND ARROW IPC AUSTRALIA 4 1 Dee Shackle Drawing Drawing 6338 Airborne Windsports 2012 Issue 1 1 ZLOZ suodspurM L L enss PART NO DWG D 100406 6338 4 104305 6338 4 7625 102021 6338 6 35 100067 6338 7 9375 6338 6 4 106315 6338 7 6 100954 6338 6 5 15 5 18 51 22 28 23 5 mi Rev AMENDMENTS Date 1 INSTRUCTIONS FOR MOD MOVED TO DWG 6479 03 06 04 LAST ACESSED Thursday 18 May 2006 ALL DIMENSIONS IN MILLIMETERS UNLESS STATED OTHERWISE 10 11 14 30 14 14 12 2 D1 8 9 13 9 14 9 18 2 17 75 13 6 W4 w5 3 3 2 3 4 3 4 3 4 3 4 5 6 1 2 92 4 34 NOTE FOR MODEL DATA SHACKLE DIMENSIONS NOT ACCURATE CHECK DEFORE USE IN DESIGN SHACKLE PIN NOT SHOWN DEE SHACKLES DESIGN TABLE Drawn By Scale Date 1i Born 6338 Cris 11 13 10 03 1r SHEET 1 of 1 AUSTRALIA MOHUV LSS VIIVELSNY AirBotne SST AND ARROW IPC AUSTRALIA 4 2 Batten End Assembly Drawing 5321 Airborne Windsports 2012 Issue 1 1 ZLOZ suodspurM L L enss
13. SHEET 2 of 2 MOHUV LSS VIIVHLSNVv sou AirBof e SST AND ARROW IPC AUSTRALIA 3 15 D TUBE TW SST RHS WITH WIRES Drawing 7801 Airborne Windsports 2012 Issue 1 1 ZLOZ suodspurM L L enss ITEM NO DWG PART NO arv 1 BOLT AN5 15A 5493 100015 1 2 WASHER MYLAR 22X 7 5540 100624 2 3 _ C FRAME BRACKET TOP AERO D TUBE BUSHED 6893 107503 1 4 NYLOC AN5 FULL 5535 100036 1 5 D TUBE TW ASM RHS T SERIES 7770 109592 1 6 FRNT FLYING WIRE STREAK amp T SERIES 1780 6601 103793 1 7 REAR FLYING WIRE SST 6604 109734 1 8 D TUBE TW SST KNUCKLES BTM ASM RHS 7856 109761 1 9 BOLT AN4 22A 5450 100549 1 10 WASHER SS304 1 4 X 3 4IN 5540 102018 2 11 BUSH SERIES CNTL FRAME BTM 7804 109658 2 12 NUT NYLOC AN4 HALF 5561 100035 1 13 KNUCKLE D TUBE TOP RHS T SERIES 7767 109588 1 14 BUSH T SERIES CNTL FRM AND STRUT 7804 109659 1 15 NUT INTERNAL T SERIES 7776 109603 1 16 BOLT AN4 14A 5450 100559 1 17 VELCRO LOOP 25x50 ADHESIVE 6313 105887 1 DETAIL TOP FRONT 18 VELCRO HOOK 25X50 6312 109870 1 SCALE 1 5 O DETAIL TOP SIDE SCALE 1 5 DETA
14. 109581 1 9 BRACKET X BAR STRUT JUNCT RHS T SERIES 7762 109582 1 10 AN5 5540 100043 4 11 AN5 44A 5493 109628 2 12 WASHER SS304 5 16 X 1 1 4 5540 100045 2 13 PIVOT SPROG HORIZONTAL INNER TW 7727 109636 2 14 RED FIBRE 5 16 X11 16 x1 32 5540 106400 4 15 WASHER NYLON M 8 XOD 5540 100820 4 16 NUT NYLOC AN5 HALF 5561 100037 2 BOLT AN4 31 5450 100631 2 WASHER NYLON M 6 XOD 5540 101055 2 WASHER 55304 1 4 X 3 4IN 5540 102018 2 NUT NYLOC AN4 HALF 5561 100035 2 PIVOT SPROG VERTICAL 7728 109512 2 SPROG ADAPTER OD 28 6MM 7756 109571 2 CLEVIS PIN 3 16 X 29 32IN 5536 104572 2 SPLIT RING 11MM RF114 5720 100950 2 SPROG W5 SPROG WIRE ASM INBOARD T SERIES 7758 109574 2 ASM 36 COVER SPROG T SERIES MYLAR 4985 109746 2 ATTACH 2x SHOCK CORD 4MM X 2200 6493 106451 1 DETAIL 28N _ DRI LUBE SOLID LUBE 5637 106432 2 29 COVER SPROG T SERIES MYLAR BTMLHS7RHS 4985 109814 2 NOTE L EDGE HIDDEN 25 FOR CLARITY BALOONS ARRANGED TOP TO BOTTOM AS ASSEMBLED 28 SPROG 1 5 NOTE DRI LUBE SPROG THREAD LAST ACESSED Wednesday 3 February 2010 ALL DIMENSIONS IN MILLIMETERS UNLESS STATED OTHERWISE AIRFRAME T SERIES Drawn By Scale Date Simon 1 25 24 04 09
15. AirBorine AUSTRALIA 7785 SHEET 1 of 2 MOHUV LSS VIIVELSNY ZLOZ suodspurM L L enss Rev AMENDMENTS Date PHOTOGRAPHS OF ROPE AND SHOCK CORD ROUTING PRIOR TO FINAL ASSEMBLY PULL BACK STRAP LOCATION ALSO SHOWN photos to be added when finalised PART NO 109635 LAST ACESSED Wednesday 3 February 2010 Drawn By ALL DIMENSIONS IN MILLIMETERS UNLESS STATED OTHERWISE Simon Scale 1 25 Date 24 04 09 AIRFRAME T SERIES AUSTRALIA 7785 SHEET 2 of 2 MOHUV LSS VIIVHLSNVv guy AirBof e SST AND ARROW IPC AUSTRALIA 3 1 NOSE JUNCTION ASM T SERIES Drawing 7792 Airborne Windsports 2012 Issue 1 1 INSTRUCTIONS 1 ADD SHOCK CORD TO NOSE JUNCTION AFTER IT IS ASSEMBLED SEE 6484 SHEET 2 ZLOZ suodspurM N 1 5 PARTS HIDDEN FOR CLARITY L L enss Rev AMENDMENTS 1 DCR 2402 T SERIES DEV PART NO 109643 1 LAST ACESSED Tuesday 4 August 2009 ALL DIMENSIONS IN MILLIMETERS UNLESS STATED OTHERWISE AUSTRALIA ITEM NO NAME DWG PART NO 1 T SERIES A FRAME TOP REAR KEEL ASM 7793 109644 1 2 L EDGE CHANNEL ASM LHS T SERIES 7787 109505 il 3 L EDGE CHANNEL ASM RHS T SERIES 7787 109593 il 4 BOLT AN4 34A 545
16. 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 and Struts Loctite 262 Red High Strength needs to be used 20 30 00 CONTROL CABLES AND TERMINALS 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 where the wire is bent Issue 1 1 May 2012 Page 38 AirBorne WindSports Pty Ltd SST and ARROW Maintenance Manual 27 FLIGHT CONTROLS 27 00 00 General The SST and ARROW 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 weig
17. LAST ACESSED Wednesday 5 August 2009 ALL DIMENSIONS IN MILLIMETERS UNLESS STATED OTHERWISE ITEM NO NAME DWG PART NO QTY 1 L EDGE FRONT TW S SERIES AND T SERIES 4693 103601 1 2 X BAR CHANNEL T SERIES 7723 109490 1 3 SADDLE 60MM TUBE 7166 100080 1 4 BOLT AN4 32A 5450 100012 2 5 WASHER AN4 5540 100042 2 6 NUT NYLOC AN4 HALF 5561 100035 3 7 VELCRO LOOP 50 120 ADHESIVE 6313 106412 1 8 X BAR BRACKET T SERIES 7722 109489 1 9 WASHER NYLON M 8 XOD 5540 100820 2 10 EYEBOLT X BAR BRACKET T SERIES 7826 109705 il 11 BUSH X BAR BRACKET T SERIES 7827 109706 1 LHS AND RHS COMPONENTS BOM IS THE SAME FOR CONSTRUCTION OF L EDGE CHANNEL ASM LHS AND RHS T SERIES co ie a 7787 AUSTRALIA SHEET 1 of 1 MOHUV LSS VIIVHLSNv auo AirBotne SST AND ARROW IPC AUSTRALIA 3 4 X BAR TW WITH HINGE T SERIES Drawing 7795 Airborne Windsports 2012 Issue 1 1 ZLOZ suodspurM L L enss ITEM NO NAME DWG PART NO QTY 1 X BAR BOLT COVER NO SLOT 6465 100804 1 2 PULL BACK WIRE 1200 T SERIES 4632 109622 2 3 WASHER AN5 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
18. PART NO QTY 1 BOLT AN6 35 5494 106347 1 2 RETAINER ASM BOLT HEAD 5218 104739 1 3 SAFETY PIN 5545 100920 1 4 WINGNUT AN6 5534 101065 1 5 WASHER NYLON M10 STND 5540 100619 1 WING ATTACHMENT 60 7839 Drawn Scale Date orn Sw x som irl e AUSTRA LA SHEET 3 of 3 MOHUV LSS VIIVHLSNV guy AirBof e SST AND ARROW IPC AUSTRALIA 3 24 TRIMMER MAST ASM T SERIES Drawing 7868 Airborne Windsports 2012 Issue 1 1 ZLOZ suodspurM L L enss Rev AMENDMENTS 1 DCR 2402 T SERIES DEV NOTE WHEN FITTING THE DISTANCE OF THE CLAMP IN FLIGHT CHARACTERISTICS WILL CHANGE DEPENDING ON THE PLACEMENT OF THE CLAMP SEE DRAWING A4 7839 FOR MORE INFORMATION Date 12 08 09 PART NO 109816 LAST ACESSED Thursday 1 October 2009 ALL DIMENSIONS IN MILLIMETERS UNLESS STATED OTHERWISE Drawn By Scale Date 1i Born Stuart 13 5 12 08 09 1r Aes r e ITEM NO NAME DWG PART NO QTY 1 WASHER SS304 5 16 X 1IN X 16G 5540 100714 2 2 TRIMMER MAST CLAMP SERIES 7853 109749 1 3 NUT NYLOC M8 ZINC 5604 100915 1 4 WASHER NYLON M 8 STND 5540 100595 2 5 SNAP HOOK 60MM RF2355 7855 100921 1 6 SKT SCREW M 8 X25 ZINC 5603 100980 1 TRIMMER MAST ASM T SERIES 7868 ES E ER AE SHEET 1 of 1
19. QUICK CLIP BOLT PIN AL 6467 103277 1 SPRING QUICK CLIP BOLT SS 6468 101203 1 WASHER AN5 5540 100043 1 NUT NYLOC AN5 FULL 5535 100036 1 CONTROL FRAME SST PREASM 7798 109653 1 C BAR TW INCL GRIPS SST 7790 109641 1 PIP PIN 38 5719 102146 1 PIP PIN CAP WITH WIRE 5718 101418 1 BOLT AN4 15A 5450 100967 1 WASHER AN4 5540 100042 1 STRUT ASM LHS T SERIES 7742 109543 1 STRUT ASM RHS T SERIES 7742 109575 1 SPROG ASM INBOARD T SERIES 7755 109570 2 HEATSHRINK CLR 38MM X 160 5582 109815 2 BATTEN SET SST HINGE 7825 109661 1 CARBON TUBE 12 0MM ID 7802 109656 4 PLACARD TRIMMER STREAK 4711 103817 1 SERIAL NO PLATE TRIKE WING 4501 102358 1 POP RIVET 1 8 5515 100162 2 STICKER AIRBORNE LOGO 2009 BLK 815X115MM 7778 109617 1 BATTEN PROFILE MERLIN _ SST AND ARROW 7629 109213 1 COVERS AND PADDING SET T SERIES 6496 109660 1 MANUAL SPIRAL BOUND IPC MM SST AND ARROW 7824 109703 1 WING ASSEMBLY SST Drawn By Scale Date Simon 1 50 24 04 09 A irBoftre 7800 AUSTRALIA SHEET 1 of 4 MOHUV LSS VIIVELSNY guy SST AND A E I AUSTRALIA 2 WING ASSEMBLY ARROW DRAWING 8422 Airborne Windsports 2012 Issue 1 1 ZLOZ suodspurM L L enss INSTRUCTIONS SEE GJP 256 FOR ASSEMBLY INSTRUCTIONS NOTE A CERTIFICATION KIT MUST BE SUPPLIED WITH THIS WING
20. 1 7 SPROG ASM OUTBOARD T SERIES 7751 109564 1 8 PIVOT SPROG HORIZONTAL 33MM 7727 109514 1 9 SPLIT RING 11MM RF114 5720 100950 1 10 NUT NYLOC AN4 HALF 5561 100035 2 11 CLEVIS PIN 3 16 X 29 32IN 5536 104572 1 12 WASHER NYLON M 6 XOD 5540 101055 1 13 DRI LUBE SOLID LUBRICANT 27GRAMS 5637 106432 3 14 POP RIVET 3 16 SHORT 6 4 5515 100160 2 15 BOLT AN4 27A MODIFIED 2MM HEAD 8116 110178 1 16 MACH SCREW MS24694 8106 1 4X1 7 321N 7797 104202 1 17 COVER SPROG MYLAR CLEAR 4985 110367 1 18 CABLE TIE X LONG 5605 101194 1 19 WASHER RED FIBRE 5 16X11 16X1 32IN 5540 106400 2 Rev AMENDMENTS Date PART NO 109634 RHS 1 DCR 2402 T SERIES DEV 21 04 09 2 DCR 2439 100011 to 110178 21 04 10 LAST ACESSED Friday 2 March 2012 Drawn By 3 DCR 2452 109943 to 110367 27 09 10 ALL DIMENSIONS IN MILLIMETERS UNLESS STATED OTHERWISE Stuart NOTE LEFT HAND SIDE ASSEMBLY SHOWN SEE SHEET 2 FOR RIGHT HAND SIDE NOTE SEE SHEET 2 FOR SPROG ASSEMBLY PART NO 109633 LHS ITEM NO NAME DWG PART NO QTY 1 L EDGE REAR TW T SERIES 7783 109632 1 2 TRIKE WING L EDGE TENSIONER RHS 5172 104740 1 3 SKT BUTTON SCREW M5 X 10 SS 304 5677 106172 2 4 LOCTITE 243 BLUE MID STRENGTH 5637 103706 1 5 SPROG BRACKET TW OUTBOARD T SERIES 7781 109619 1 6 PIVOT SPROG VERTICAL 7728 109512 1 SPROG ASM OUTBOARD T SERIES 7751
21. 2 bd PH MH Date PART NO 109660 LAST ACESSED Tuesday 22 May 2012 ALL DIMENSIONS IN MILLIMETERS UNLESS STATED OTHERWISE NOTE VIRTUAL ASSEMBLY MADE FOR BOM PURPOSES THE T SERIES COVERS AND PADDING IS THE SAME AS THE S SERIES EXCEPT FOR 3 X 101673 WHICH COVER THE STRUT ENDS AND 3 X 106614 WHICH COVER STRUT BRACKETS SEE SHEET 1 AND 2 FOR PICTURES OF INDIVIDUAL PARTS COVERS AND PADDING SET T SERIES Drawn By Scale Date orn 6 496 Simon 1 5 28 04 09 A irB r SHEET 3 of 4 AUSTRALIA MOHUV LSS VIIVHLSNv sou ZLOZ suodspurM L L enss ITEM NO NAME DWG PART NO 1 COVER X BAR SMALL 7146 102730 1 2 TIP SCUFF PAD S SERIES 6548 105139 2 3 COVER CONTROL FRAME BASE GENERIC 4500 101673 1 4 COVER QUICK CLIP 7865 109810 1 5 GLIDER TIE 7153 100139 4 6 COVER REAR KEEL 4499 102436 1 7 COVER TIP BAG ELASTIC 6500 106481 2 8 WING BAG ARROW 12 9 7149 111039 1 9 COVER TRIMMER 6535 106614 3 10 COVER C BAR GENERIC 6501 106482 1 11 COVER U BRACKET TRIKE WING 6497 106478 1 12 COVER D TUBE HG DOUBLE MITT 6948 107779 2 Pro La 6 0 2 r9 I9 o
22. AMENDMENTS Ed PAR E NO106477 s2 COVERS AND PADDING SET S SERIES 2 CHANGED TO S SERIES DCR 2107 08 04 05 3 DCR 2402 ADD T SERIES TO SHEET 3 28 04 09 LAST ACESSED Tuesday 22 May 2012 SEE Drawn Seale 4 irBot e 6496 4 DCR 2520 ADD ARROW 21 05 12 ALL DIMENSIONS IN MILLIMETERS UNLESS STATED OTHERWISE Simon NTS 28 06 04 AUSTRALIA SHEET 1 of 4 MOHUV LSS VIIVHLSNv sou ZLOZ suodspurM L L enss Rev AMENDMEN Date 5 2 PART NO 106477 LAST ACESSED Tuesday 22 May 2012 ALL DIMENSIONS IN MILLIMETERS UNLESS STATED OTHERWISE COVERS AND PADDING SET S SERIES Drawn By Scale Date orn Simon 11 02 03 03 AirB AUSTRALIA 6496 SHEET 2 of 4 MOHUV LSS sou VIIVELSNY ZLOZ suodspurM L L enss Rev AMENDMENTS ITEM NO NAME DWG PART NO 1 COVER X BAR SMALL 7146 102730 1 2 TIP SCUFF PAD S SERIES 6548 105139 2 3 COVER CONTROL FRAME BASE GENERIC 4500 101673 1 4 COVER QUICK CLIP 7865 109810 1 5 GLIDER TIE 7153 100139 4 6 COVER REAR KEEL 4499 102436 1 7 COVER TIP BAG ELASTIC 6500 106481 2 8 WING BAG STREAK CRUZE MERLIN SST 7149 103883 1 9 COVER TRIMMER 6535 106614 3 10 COVER C BAR GENERIC 6501 106482 1 11 COVER U BRACKET TRIKE WING 6497 106478 1 12 COVER D TUBE HG DOUBLE MITT 6948 107779
23. Ai 1 rBorne SHEET ott Figure 3 3rd Level Drawing Airborne Windsports 2012 Issue 1 1 AirBotne SST AND ARROW IPC AUSTRALIA Step 4 Part identified Order On this drawing the pulley is found as ITEM NO 9 and has a circle around it which means the part is sold and is identified Record the PART NUMBER DESCRIPTION AND THE DRAWING in order to make the spare part order E g Part 100728 PULLEY RF661 PULL BACK 7793 SECTION 1 4 ee a H L 12 BOLTAN434A 13 RALF 14 WASHER AN4 15 1 5540 100042 2 15 TANG 14N EYELET HOLE 961 0 5673 103290 1 16 ME NT SEC 5637 105992 2 17 0 IS PLUG ACETAL UBRACKET __ 16562 106672 1 19 0 WIDE SPACER SERIES 7828 109708 2 E sen 100850 nl X BAR PROTECTIVE COVER B 1 4 m zu USED DURING STORAGE PI ICH uud ene PART 100644 T SERIES A FRAME TOP REAR KEEL ASM IB UA Air Botte Im Figure 4 The component is identified 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 Airb
24. Centre Battens Issue 1 1 May 2012 Page 29 AirBorne WindSports Pty Ltd SST and ARROW Maintenance Manual Attach Swan Catch Attach swan catch Secure and tighten nose webbing tangs Figure 23 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 1 1 May 2012 Page 30 AirBorne WindSports Pty Ltd SST and ARROW Maintenance Manual QA Inspection Form ASSEMBLY TRACE WING T SERIES AND GJP 256 pg2 3 ARROW FINAL QA T Series Check Operation Security and Finish Left Hand Side Right Hand Side Nose Assembly Nose Catch Nose webbing secure Nose Batten Nose Cone Keel Roller U Bracket Roller Rear Rear 1 Rear 2 Position SST Down Tubes top assembly D Tube Velcro Cross Bar Hinge Cross Bar Padding Down Tube Bottom Corners Bottom Front Wires Strut Control Frame Universal Base Bar Bolts Cross bar Leading Edg
25. DWG PART NO QTY 1 L EDGE REAR TW U SERIES 8423 110826 1 2 TRIKE WING L EDGE TENSIONER LHS 5172 104669 1 3 SKT BUTTON SCREW M5 X 10 SS 304 5677 106172 2 4 LOCTITE 243 BLUE MID STRENGTH 5637 103706 1 5 SPROG BRACKET TW OUTBOARD T SERIES 7781 109619 1 6 PIVOT SPROG VERTICAL 7728 109512 1 7 SPROG ASM OUTBOARD T SERIES 7751 109564 1 8 PIVOT SPROG HORIZONTAL 33MM 7727 109514 1 9 SPLIT RING 11MM RF114 5720 100950 1 10 NUT NYLOC AN4 HALF 5561 100035 2 11 CLEVIS PIN 3 16 X 29 32IN 5536 104572 1 12 WASHER NYLON M 6 XOD 5540 101055 1 13 DRI LUBE SOLID LUBE 5637 106432 3 14 POP RIVET 3 16 SHORT 6 4 5515 100160 2 15 BOLT AN4 27A MODIFIED 2MM HEAD 8116 110178 1 16 MACH SCREW MS24694 8106 1 4X1 7 321N 7797 104202 1 17 COVER SPROG MYLAR CLEAR 4985 110367 1 18 CABLE TIE X LONG 5605 101194 1 19 WASHER RED FIBRE 5 16X11 16X1 32IN 5540 106400 2 Rev AMENDMENTS Date 1 NOTE LEFT HAND SIDE ASSEMBLY SHOWN SEE SHEET 2 FOR RIGHT HAND SIDE NOTE SEE SHEET 2 FOR SPROG ASSEMBLY PART NO 110827 LHS PART NO 110828 RHS DCR 2520 u SERIES DEV 20 01 12 LAST ACESSED Friday 20 January 2012 ALL DIMENSIONS IN MILLIMETERS UNLESS STATED OTHERWISE ITEM NO DWG PART NO QTY 1 L EDGE REAR TW U SERIES 8423 110826 1 2 TRIKE WING L EDGE TENSIONER RHS 5172 104740 1 3 SKT BUTTON SCREW M5 X 10 SS
26. NUT NYLOC AN5 HALF 5561 100037 1 8 CAP WASHER COVER BLACK M8 5666 100603 1 9 WASHER NYLON 1 4IN OBA THICK 5540 102424 6 10 WASHER AN3 5540 100049 2 11 NUT NYLOC AN4 FULL 5535 100034 2 12 NUT NYLOC AN3 FULL 5535 100051 2 13 X BAR TW STREAK T SERIES 7726 109506 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 3 AIRBORNE 7719 109477 1 17 BOLT AN3 30A 5449 100629 2 ITEM 14 TANG 18 BOLT AN4 30A 5450 100011 2 PULLEY PULL BACK X BAR STREAK 6466 103821 1 SHACKLE BODY 1 4IN PULL BACK 6338 102021 1 BOLT AN4 11A 5450 100003 2 NUT NYLOC AN4 HALF 5561 100035 2 WASHER NYLON M 6 XOD 5540 101055 6 WASHER SS304 1 4 X 3 4IN 5540 102018 2 BUSH OD10 x 1 6 x 6L 5453 101488 2 PULL BACK ADJUSTER PLATE SST 8160 110326 1 COVER PULL BACK NEOPRENE 4789 101900 1 NOTE 101193 1 CABLE TIE MEDIUM 140MM 5605 PULL BACK WIRES ATTACH THROUGH MIDDLE HOLE IE 35MM FROM SHACKLE NOTE DCR 2442 109622 T SERIES PULL BACK WIRE LENGTH INCREASED FROM 1175 TO 1200 FOR B 1 2 5 WING SST SERIAL PLAN OF NO S 50 AND UP SCALE 1 25 PULLBACK X BAR WITH HINGE WIRES TO FULL PLAN VIEW SHACKLE NOTE ASSEMBLY WASHERS SHOWING DETAILS A ANDB PER SIDE NOTE SHACKLE ATTACHES TO PULLBACK AT SINGLE HOLE END COPIED FROM 6483 20 04 09 Rev AMENDMENTS Date PART NO 109650 0 X BAR
27. 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 1 1 May 2012 Page 3 AirBorne WindSports Pty Ltd SST and ARROW Maintenance Manual LOG OF ALL EFFECTIVE PAGES Page Issue Date Page Issue Date All 1 1 24 05 2012 All 1 1 24 05 2012 Table 2 Log Of Effective Pages May 2012 Page 4 Issue 1 1 AirBorne WindSports Pty Ltd SST and ARROW Maintenance Manual INTRODUCTION This manual contains factory recommended procedures and instructions for ground handling servicing and maintaining the SST or ARROW 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 airc
28. PULL PROG WIRE ASM INBOARD T SERIES 100574 2 li EE COVER SPROG T SERIES MYLAR z 109746 SHOCK CORD AMM X Z200MM 106451 1 p B37 106432 7 NOTE UEDGE HIDDEN TRIMMER FOR CLARITY ULLEY BALOONS DETAIL ARRANGED TOP TO BOTTOM AS ASSEMBLED SPROG 1 5 30 NOTE DRI LUBE SPROG THREAD XIBAR 1 5 Re AMENDMENTS Dato 1 DCR 2204 T SERIES DEV PART NO 109635 0 AIRFRAME T SERIES LAST ACESSED Tuesday 4 August 2009 Drawn Scalo Dato ALL DIMENSIONS IN MLUMETERS UNLESS STATED OTHERWISE Simon 125 AirBo e BHEET1O2 Figure 2 2nd Level Drawing Step 3 Keep looking for the part of the wing you want In this example it s still not shown as an individual item so it must be part of Item 1 drawing 7793 TIONS 1 ADD SHOCK CORD TO NOSE JUNCTION AFTER IT IS ASSEMBLED SEE 6484 SHEET 2 NAM DWG PART NO OTY NAN KE D e H TOP REAR KEELASM 7793 109644 1 HEDGE CHANNEL ASM LHS T SERIES 7787 GE CHANNEL ASM RHS T SERIES 7787 109593 1 L 3i EOL FEN OMIS TSEHIES Es r N 60MM KI 6469 CATCH CHANN AIRE WIN 1 5 PARTS HIDDEN FOR CLARITY 5718 101418 Rev AMENDMENTS Date eared PART NO 109643 1 NOSE ASSY SERIES LAST ACESSED Tuesday 4 August 2009 7792 ALL DIMENSIONS IN MILLIMETERS UNLESS STATED OTHERWISE Smon 2304 08
29. TOP STATIC T SERIES 7759 109576 1 3 KNUCKLE STRUT TOP STATIC T SERIES 7759 109576 1 4 BUSH STRUT TOP T SERIES 7761 109578 1 4 BUSH STRUT TOP T SERIES 7761 109578 1 5 KNUCKLE STRUT TOP PIVOT T SERIES 7760 109577 1 5 KNUCKLE STRUT TOP PIVOT T SERIES 7760 109577 1 6 BOLT AN4 14 a 5450 100559 4 6 BOLT AN4 14 a 5450 100559 4 7 BUSH T SERIES CNTL FRM AND STRUT 7804 109659 4 7 BUSH T SERIES CNTL FRM AND STRUT 7804 109659 4 8 NUT INTERNAL AN4 T SERIES 7776 109603 4 8 NUT INTERNAL AN4 T SERIES 7776 109603 4 9 BOLT AN5 16 5493 109630 1 9 BOLT AN5 16 5493 109630 1 10 WINGNUT AN5 5534 102454 2 10 WINGNUT AN5 5534 102454 2 11 SAFETY PIN 5545 100920 2 11 SAFETY PIN 5545 100920 2 12 BOLT AN5 14 5493 109637 1 12 BOLT AN5 14 5493 109637 1 13 LABEL SST STRUT LEFT SIDE BOTTOM 7857 109757 1 13 LABEL SST STRUT RIGHT SIDE BOTTOM 7857 109758 1 14 LOCTITE 262 RED HIGH STRENGTH 5637 103723 4 14 LOCTITE 262 RED HIGH STRENGTH 5637 103723 4 15 LOCTITE 7471 PRIMER 5637 104448 4 15 LOCTITE 7471 PRIMER 5637 104448 4 NOTE BOLTS MUST BE INSERTED TOP TO BOTTOM WHEN ASSEMBLING NOTE ONCE NUTS AND BOLTS ARE FASTENED USE A MARKER TO DRAW A LINE ACROSS END OF BOLTS AN4 14A AND NUTS INTERNAL TO MAKE IT EASIER TO SEE IF THE NUTS BECOME LOOSE NOTE APPLY PRIMER ON ALL INTERNAL NUTS BEFORE ASSEMBLY NOTE PLACE
30. 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 on the tension can be increased on the ends clockwise to reduce tension or left wing The tension on the right right wing The tension on the left rotate batten ends anti clockwise to can be decreased can be decreased increase tension Note Tip batten tuning has more effect on tuning than the root battens Note Maximum 30 Deg angle during install See Fig 24 MILD TURN Tip Angle Adjustment The angle of the tip can be adjusted Rotate the left tip down clockwise Rotate the right tip down anti by rotating the angle of the end cap 1 hole and re install screw If more clockwise 1 hole and re install Adjustment requires removal of the adjustment is required rotate the screw If more adjustment is stainless screw which secures the tip right tip up clockwise 1 hole and required rotate the left tip up webbing bung The tip bung is rotated re install screw anticlockwise 1 hole and re install and the screw is re installed in the Screw appropriate hole Reduction in leading edge tension will simplify procedure Ensure correct tension is applied after adjustment See Section 0 Assembly After Shipping for tip adjustment details If after tuning the turn persists consult your authorised dealer or the factory An ad
31. 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 IS 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 r
32. 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 Issue 1 1 May 2012 Page 6 AirBorne WindSports Pty Ltd SST and ARROW 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 SER
33. 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 apply to tasks Only people with an adequate skill level should perform maintenance on this aircraft A 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 in
34. 0 100850 4 5 NOSE CATCH CHANNEL 3 0MM 6394 106278 id 6 NOSE PLATE TRIKE WING 60MM KEEL 6469 103205 1 7 WASHER NYLON M 6 XOD 5540 101055 16 8 WASHER NYLON M12 STD 5540 100611 4 9 WASHER AN4 5540 100042 4 10 NUT NYLOC AN4 HALF 5561 100035 5 11 BOLT AN4 11A 5450 1000038 1 12 NOSE PLATE TRIKE WING T SERIES 7780 109618 1 13 BUSH NOSE PLATE SLIDER T SERIES 7794 109649 2 14 WASHER SS304 1 4 X 3 4IN 5540 102018 2 15 25 5719 106702 1 16 PIP PIN WITH WIRE 5718 101418 1 NOSE JUNCTION ASSY T SERIES Drawn By Scale Date 11 23 04 09 AirBortie T192 MOHUV LSS sou VIIVELSNY SHEET 1 of 1 AirBof e SST AND ARROW IPC AUSTRALIA 3 2 T SERIES A FRAME TOP REAR KEEL ASM Drawing 7793 Airborne Windsports 2012 Issue 1 1 ZLOZ suodspurM L L enss MOHUV LSS ITEM NO NAME DWG PART NO QTY UNE OEE ROLLER BUNGS SECTION 1 4 1 KEEL TUBE ASM T SERIES 7779 109621 1 2 KEEL ROLLER TWO PIECE HALF 63MM KEEL 7810 109667 2 lt RE A ES ONSETCAR SCREWS 3 U BRACKET WIDE 63MM KEEL 7809 109666 1 Bacche STD ORAVITY SRD HOLE 4 U BRACKET NEG LOAD PLATE 120 ALUMINIUM 5124 104607 1 5 SKT CSK SCREW UNF 1 4IN X1IN ZINC 5568 102062 2 6 KEEL EXTENSION STREAK WIZARD 2 3 4792 103603 1 7 CLEVIS PIN 3 16X2 13 32IN 5536 102796 1 8 SPLIT RING 11MM RF
35. 114 5720 100950 1 9 PULLEY RF661 PULL BACK 6442 100728 1 10 POP RIVET 5 32 LONG 5 8 5515 102417 1 11 BOLT AN4 36A 5450 100014 1 12 BOLT AN4 34A 5450 100850 1 A CE 13 NUT NYLOC AN4 HALF 5561 100035 2 14 WASHER 5540 100042 2 TANG 1 4IN EYELET HOLE 5673 103290 1 DRI LUBE SOLID LUBRICANT 27GRAMS 5637 106432 2 U BRACKET SPACER T SERIES 7828 109708 2 LOCTITE 262 RED HIGH STRENGTH 5637 103723 2 PULLEY LEAD BLOCK RF917 7850 109736 1 POPRIVET 3 16 SHORT 6 4 5515 100160 2 REG C o C 1 4 17 NOTE TANG FACES TO THE FRONT REVISIONS PART NO 109644 T SERIES A FRAME TOP REAR KEEL ASM DCR Rev AMENDMENTS Date 2402 1 T SERIES DEV 16 04 09 LAST ACESSED Tuesday 21 February 2012 Drawn By Scale Date 1 B 7793 2524 2 MOVE TANG 2 02 1 2 ALL DIMENSIONS IN MILLIMETERS UNLESS STATED OTHERWISE Simon 1 12 16 04 09 1r Sete 5 SHEET 1 of 1 VIIVHLSNVv AirBof e SST AND ARROW IPC AUSTRALIA 3 3 L EDGE CHANNEL ASM LHS AND RHS T SERIES Drawing 7787 Airborne Windsports 2012 Issue 1 1 ZLOZ suodspurM L L enss Rev AMENDMENTS 1 DCR 2402 T SERIES DEV DETAIL A SCALE 1 2 Date 12 03 09 PART NO 109505 LHS PART NO 109593 RHS
36. 160 5582 109815 2 BATTEN SET ARROW 12 9 HINGE 8168 110830 1 CARBON TUBE 12 0MM ID 7802 109656 4 PLACARD TRIMMER STREAK 4711 103817 1 SERIAL NO PLATE TRIKE WING 4501 102358 1 POP RIVET 1 8 5515 100162 2 BATTEN PROFILE MERLIN SST AND ARROW 7629 109213 1 COVERS AND PADDING SET ARROW 6496 111048 1 MANUAL SPIRAL BOUND IPC MM SST AND ARROW 7824 109703 1 LABEL TRIMMER ARROW 8468 111052 1 WING ASSEMBLY ARROW DrawnBy Scale Date 11 Born Simon 1 50 20 01 12 1r r AUSTRALIA 8422 SHEET 1 of 2 MOHUV LSS VIIVELSNY guy SST AND A E I AUSTRALIA 3 AIRFRAME T SERIES Drawing 7785 Airborne Windsports 2012 Issue 1 1 ZLOZ suodspurM L L enss FULL VIEW OF KEEL AND X BARS ASSEMBLED SCALE 1 25 STRUT TRIMMER PULLEY DETAIL Rev AMENDMENTS al 1 DCR 2204 T SERIES DEV 16 04 09 PART NO 109635 0 ITEM NO NAME DWG PART NO QTY 1 NOSE JUNCTION ASM T SERIES 7792 109643 1 2 TW WITH HINGE T SERIES 7795 109650 1 3 BOLT AN5 34A 5493 100025 2 4___ SADDLE 60MM TUBE 7166 100080 4 5 NYLOC AN5 FULL 5535 100036 2 6 STRAP PULL BACK 20MM WITH TANGS 160 6463 104754 1 7 ROPE PRESTRETCHED 4 X 1270 6493 106452 1 8 X BAR STRUT JUNCT LHS T SERIES 7762
37. 304 5677 106172 2 4 LOCTITE 243 BLUE MID STRENGTH 5637 103706 1 5 SPROG BRACKET TW OUTBOARD T SERIES 7781 109619 1 6 PIVOT SPROG VERTICAL 7728 109512 1 7 SPROG ASM OUTBOARD T SERIES 7751 109564 1 8 PIVOT SPROG HORIZONTAL 33MM 7727 109514 1 9 SPLIT RING 11MM RF114 5720 100950 1 10 NUT NYLOC AN4 HALF 5561 100035 2 11 CLEVIS PIN 3 16 X 29 321N 5536 104572 1 12 WASHER NYLON M 6 XOD 5540 101055 1 13 DRI LUBE SOLID LUBE 5637 106432 3 14 POP RIVET 3 16 SHORT 6 4 5515 100160 2 15 BOLT AN4 27A MODIFIED 2MM HEAD 8116 110178 1 16 MACH SCREW MS24694 S106 1 4X1 7 321N 7797 104202 1 17 COVER SPROG MYLAR CLEAR 4985 110367 1 18 CABLE TIE MEDIUM 140MM 5605 101193 1 19 WASHER RED FIBRE 5 16X11 16X1 321N 5540 106400 2 ADJUST TENSIONER TO FOURTH MARK NOTE PHILLIPS HEAD SCREW IN TENSIONER MUST FACE AWAY FROM THE SAIL TO ALLOW 4 ADJUSTMENT AFTER FITTING DETAIL A SCALE 1 7 5 L EDGE REAR TW U SERIES ASM Drawn By Scale Date Simon 1 10 20 01 12 A ir Borie 8425 2 AUSTRALIA MOHUV LSS VIIVELSNY owog ZLOZ suodspurM L L enss ITEM NO NAME DWG PART NO QTY 1 L EDGE REAR TW U SERIES 8423 110826 1 55 2 TRIKE WING L EDGE TENSIONER RHS 5172 104740 1 3 SKT BUTTON SCREW M5 X 10 SS 304 5677 106172 2 4 LOCTITE 243 BLUE MID STRENGTH 5637 103706 1 5 SPROG BRACKET TW OUTBOARD T SERIES 7781 109619 1 6 PIVOT SPROG VERTICAL 7728 109512 1 7 SPROG ASM OUTBOARD T SERIE
38. 35 12 5 40 25 4 0 5 4 3 19 4 8 NA NA 102063 TOW RELEASE FIXING SCREW 6 35 10 35 40 24 25 0 5 4 2 19 4 8 SKT CSK SCREW UNF 1 4 x 1 102062 109488 SKT CSK SCREW UNF 1 4IN X1IN BLACK 6 35 12 5 40 25 4 0 5 4 3 19 4 8 SKT CSK SCREW UNF 1 4 x 1 102062 106275 SKT CSK SCREW M6x16 SS 6 13 44 45 16 0 5 4 3 10 5 NA NA THREAD LENGTH HEAD DIA HEAD ANGLE MINOR THREAD DIA DIA HEX DEPTH CHAM LENGTH ewer PART 105997 MADE FROM PART 101823 PART 106319 MADE FROM PART 101823 NOTE MOVED 102063 FROM A4 4414 WHICH IS NOW SUPERSEDED 11 08 10 EE ee AS 1 SKT CAP SCREW COUNTERSINK DESIGN TABLE WITH NO PART NUMBERS IN THE SYSTEM 2 ADDED 109488 3 ADDED 102063 FROM A4 4414 21 11 08 LAST ACESSED Wednesday 11 August 2010 Drawn By Scale Date 1 irBot e 5668 11 08 10 DIMENSIONS IN MILLIMETERS UNLESS STATED OTHERWISE Cris 21 22 05 03 AUSTRALIA SHEET 1 of 1 MOHUV LSS VIIVELSNY AirBotne SST AND ARROW IPC AUSTRALIA 5 OPTIONS 5 1 NIL Airborne Windsports 2012 Issue 1 1 SST AND A E I AUSTRALIA END OF CATALOGUE Airborne Windsports 2012 Issue 1 1
39. 61 103755 Tip Tip Leach Line D OMC MONO ON ENONCE 0 Used gt Left gt waste m gt 5160 8820 waste total mm USAGE FOR 1 SET Note Includes BATTEN BAG DOUBLE PART 106479 ASSEMBLY DETAIL CUT 10MM 7075 T6 TUBE TO LENGTH AND DEBURR Batten Set Part No 109661 BEND USING JIG REFERRING TO APPROPRIATE CO ORDINATES SHAPE TO APPROPRIATE PROFILE INSERT TIP IN FRONT CURVED SECTION INSERT THREADED PLUG amp CRIMP SCREW HINGE FITTING IN THIS DRAWING IS AN EXCEL WORKSHEET DCR 2402 T SERIES DEV 27 05 09 COPIED FROM DRAWING A4 7557 Scale Dae HINGED BATTENS A4 7825 MOHUV LSS guy VIIVHLSNVv ZLOZ suodspurM L L enss ITEM NO DWG PARTNO 3 BATTEN SET SST HINGE 7825 109661 1 CREAR m 109785 109797 Thread Insert 109787 109799 Thread Insert 109794 109806 Thread Insert xa 103758 103752 zm Leach Line 103759 103753 Tip Leach Line 110252 110253 ue Leach Line THIS MODEL IS A VIRTUAL ASSEMBLY OF THE MATERIALS USED TO CREATE THE BATTENS NO ACTUAL ASSEMBLY HAS BEEN CREATED THEYARE DEFINED BY THE EXCEL SPREADSHEET 7825 AND IN NOTE FOXPRO FOR ALL OF THE ADDITIONAL THE NUMBER 1 BATTENS ARE CLOSEST TO THE KEEL COMPONENTS NOTE DWG COPIED FROM A4 7557 Rev AMENDMENTS Date PART NO 109661 BATTEN SE
40. 7 109572 1 2 CLEVISPIN 1 4X 1 9 32IN 5536 109747 1 3 SPLIT RING 14MM RF686 5720 109756 1 4 CLEVIS PIN 3 16X 1 9 32IN 5536 109652 1 5 SPLIT RING 11MM RF114 5720 100950 1 6 HEATSHRINK CLR 38MM X 220 5582 109868 1 NOTE HEATSHRINK NOT SHOWN COVERS CLEVIS PIN TIP OF TUBE PART NO 109570 SPROG ASM INBOARD T SERIES LAST ACESSED Tuesday 29 September 2009 Drawn By Scale Date ALL DIMENSIONS IN MILLIMETERS UNLESS STATED OTHERWISE Simon 1 5 07 03 09 A 1 rBorne 7795 AUSTRALIA SHEET 1 of 1 MOHUV LSS VIIVHLSNVv guy AirBotne SST AND ARROW IPC AUSTRALIA 3 11 CONTROL FRAME SST PHEASM Drawing 7798 Airborne Windsports 2012 Issue 1 1 ZLOZ suodspurM L L enss DETAIL A SCALE 1 2 Rev AMENDMENTS Date PART NO 109653 1 DCR 2402 T SERIES DEV 30 04 09 LAST ACESSED Wednesday 5 August 2009 ALL DIMENSIONS IN MILLIMETERS UNLESS STATED OTHERWISE ITEM NO NAME DWG PART NO QTY 1 BOLT AN5 44A 5493 109628 1 D TUBE TW SST LHS WITH WIRES 7799 109654 1 NUT NYLOC AN5 HALF 5561 100037 1 WASHER NYLON M 8 XOD 5540 100820 2 D TUBE TW SST RHS WITH WIRES 7801 109655 1 CONTROL FRAME SST PREASM SPREAD Drawn By Scale Date Stuart 1 10 30 04 09 4 irE3orne 7798 AUSTRALIA SHEET 1 of 1 MOHUV LSS VIIVELSNY sou AirBotne SST AND A
41. AND HEAVY BOLTS TABLE 2 PG 1049 AND 1047 MACHINERERY S HANDBOOK 22ND ED INDUSTRIAL PRESS LTD NEW YORK HEAD lt DIA FLATS LENGTH 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 AN 5 BOLT DESIGN TABLE 020341 LAST ACESSED Wednesday 2 March 2011 Drawn By Scale Date 1 Born 5493 ALL DIMENSIONS IN MILLIMETERS UNLESS STATED OTHERWISE Simon 11 02 03 03 1r AUSTRALIA SHEET 1 of 1 MOHUV LSS VIIVELSNY AirBotne SST AND ARROW IPC AUSTRALIA 4 7 Socket Cap Screws Drawing 5668 Airborne Windsports 2012 Issue 1 1 ZLOZ suodspurM L L enss Design Table for 5668 PART HEAD CHAM HEX THREA THREAD MATL NO NAME DIA DIA HEAD LENGTH LENGTH DIA DEPTH DL MINOR DIA MATERIAL NO 106344 SKT CSK SCREW 5 16 SS 5 11 2 45 16 3 10 4 2 NA NA 105453 SKT CSK SCREW M6x45 6 13 44 45 45 0 5 4 3 35 5 NA NA 101823 SKT CSK SCREW BSW 2 5x0 25 6 35 11 4 45 2 5 25 4 0 5 4 3 32 4 8 NA NA 105997 SKT CSK SCREW BSW 1 4 MOD 58L 6 35 11 4 45 58 0 5 4 3 23 4 8 SKT CSK SCREW BSW 2 5x0 25 101823 106319 SKT CSK SCREW BSW 1 4 MOD 47L 6 35 11 4 45 47 0 5 4 3 23 4 8 SKT CSK SCREW BSW 2 5x0 25 101823 102062 SKT CSK SCREW UNF 1 4 x 1 6
42. ASM LHS RHS Drawing 7856 D TUBE TW SST RHS WITH WIRES Drawing 7801 C BAR TW SST ARROW INCL GRIPS Drawing 7790 STRUT ASM T SERIES Drawing 7742 BATTEN SET SST HINGE Drawing 7825 BATTEN SET ARROW HINGE Drawing 8168 BATTEN PROFILE MERLIN SST AND ARROW Drawing 7629 MANUAL SPIRAL BOUND IPC MM SST ARROW Drawing 7824 COVERS AND PADDING SET T SERIES ARROW Drawing 6496 WING ATTACHMENT KIT T SERIES Drawing 7839 TRIMMER MAST ASM T SERIES Drawing 7868 4 MISCELLANEOUS COMPONENTS 4 1 Dee Shackle Drawing Drawing 6338 4 2 Batten End Assembly Drawing 5321 4 3 Over Centre Tip Lever Asm T Series Drawing 7842 4 4 Bolts Drawing 5449 4 5 Bolts Drawing 5450 4 6 AN5 Bols Drawing 5493 4 7 Socket Cap Screws Drawing 5668 5 OPTIONS 5 1 NIL 6 END OF CATALOGUE Airborne Windsports 2012 Issue 1 1 AirBof e SST AND ARROW IPC AUSTRALIA NAVIGATING 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
43. BATTENS MUST ALWAYS BE CORRECTLY INSTALLED WITH RED BATTENS IN THE LEFT HAND SIDE AND GREEN IN THE RIGHT HAND SIDE OF THE WING BATTENS MAY BE DELIBERATELY DIFFERENT FROM SIDE TO SIDE Batten end fittings When inserting batten end fittings prior to closing batten fittings should sit inserted in the trailing edge The angle before loading is applied should not exceed 30 Figure 25 Inserted Batten End Unloaded Angle Check Issue 1 1 May 2012 Page 41 AirBorne WindSports Pty Ltd SST and ARROW Maintenance Manual Latch fittings should be sharp and not rounded Rounded edges can occur from unloading without depressing the latch Check the unloaded measurement of latch to body of the outer fitting is not less than 2mm to maintain loaded retaining force Figure 26 Batten End Fitting Dimension Check WARNING ALWAYS ENSURE THE BATTEN END FITTINGS ARE CLOSED AND LOADED SECURELY BEFORE TAKE OFF BATTEN ENDS BECOMING UNLOADED DURING FLIGHT AT HIGHER AIRSPEEDS MAY HAVE SERIOUS EFFECTS ON THE FLIGHT PERFORMANCE AND STABILITY CHARACTERISTICS OF THE WING Struts The control frame is constructed mainly from 6061 T6 aluminium and are attached to the cross bars and the control frame through fittings that allow them to rotate The struts work mainly in tension through the loads from the crossbars and leading edges Front and Back Wires The front and back wires are stainless steel braided wires that have swage
44. Bome Wind Sports Pry Itd Unit 22 30 Kalaroo Rd Redhead NSW 2290 Australia Phe 612 49449199 Fax 61249449395 Website http Z erorer airbome com au ArBome WindSports Pty Ltd 2007 Int 100905 This wing should only be wed in conjmitionwrifh a certified base combivtion Date PART NO 109703 18 06 09 22 05 12 LAST ACESSED Tuesday 29 May 2012 Drawn By Scale Date ALL DIMENSIONS IN MILLIMETERS UNLESS STATED OTHERWISE Stuart 1 2 25 05 09 AirBorne AUSTRALIA MANUAL SPIRAL BOUND IPC_MM SST AND ARROW 7824 SHEET 1 of 1 MOHUV LSS sou VIIVELSNY AirBotne SST AND ARROW IPC AUSTRALIA 3 22 COVERS AND PADDING SET SERIES ARROW Drawing 6496 Airborne Windsports 2012 Issue 1 1 ZLOZ suodspurM L L enss ITEM NO DWG PART NO 1 COVER X BAR SMALL 7146 102730 1 2 TIP SCUFF PAD S SERIES 6548 105139 2 3 COVER CONTROL FRAME BASE GENERIC 4500 101673 1 4 COVER QUICK CLIP K POST BASE 6499 106480 1 5 GLIDER TIE 7153 100139 4 6 COVER REAR KEEL 4499 102436 1 7 COVER TIP BAG ELASTIC 6500 106481 2 8 WING BAG STREAK CRUZE MERLIN SST 7149 103883 1 9 COVER TRIMMER 6535 106614 1 10 COVER C BAR GENERIC 6501 106482 1 11 COVER U BRACKET TRIKE WING 6497 106478 1 NUMBERS POINTING TO THE FRAME SHOW APPROXIMATE LOCATIONS OF THIS ASSEMBLY IS MADE FROM VIRTUAL PARTS Fev
45. E 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 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 14 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 m
46. E CLIP 8 5667 100604 2 12 NUT NYLOC AN4 HALF 5561 100035 1 13 LOCTITE 243 BLUE MID STRENGTH 5637 103706 1 14 PLACARD TRIMMER STREAK 4711 103817 1 15 POP RIVET 1 8 5515 100162 1 16 TRIMMER ROPE amp SHOCK CORD ASM SST 7887 109845 1 DETAIL RIVET NOTE DRILL 1 8 RIVET WITH HOLE SCALE 2 5 TOWARD TO THE FRONT OF THE DOWN TUBE USE SMALL BOLT WITH WINGNUT TO HOLD SADDELS WHILE DRILLING AND RIVETTING D TUBE TW ASM RHS T SERIES far eme Ain orire 7770 USTRALIA SHEET 2 of2 MOHUV LSS VIIVELSNY owog AirBof e SST AND ARROW IPC AUSTRALIA 3 14 D TUBE TW SST KNUCKLES BTM ASM LHS RHS Drawing 7856 Airborne Windsports 2012 Issue 1 1 ZLOZ suodspurM L L enss REAR VIEW AS FITTED TO AIRFRAME ITEM NO NAME DWG PART NO QTY 1 KNUCKLE D TUBE BTM T SERIES 7765 109585 1 2 WASHER AN6 5540 100044 2 3 BOLT AN6 26A 5494 109627 1 4 WASHER NYLON M10 STND 5540 100619 3 5 KNUCKLE STRUT BASEBAR PIVOT T SERIES 7764 109584 1 6 KNUCKLE STRUT BTM PIVOT T SERIES 7763 109583 1 7 NUT NYLOC AN6 FULL 5535 100038 1 8 C BAR KNUCKLE T SERIES 7769 109590 1 9 WASHER NYLON M 8 XOD 5540 100820 2 10 NUT NYLOC AN5 FULL 5535 100036 1 RIGHT 11 BOLT AN5 15A 5493 100015 1 VIEW NOTE LHS NURSE TE NUT FA Rev AMENDMENTS Date PAR
47. E DWG PART NO QTY 1 L EDGE REAR TW T SERIES 7783 109632 1 2 TRIKE WING L EDGE TENSIONER RHS 5172 104740 1 3 SKT BUTTON SCREW M5 X 10 SS 304 5677 106172 2 4 LOCTITE 243 BLUE MID STRENGTH 5637 103706 1 5 SPROG BRACKET TW OUTBOARD T SERIES 7781 109619 1 6 PIVOT SPROG VERTICAL 7728 109512 1 7 SPROG ASM OUTBOARD T SERIES 7751 109564 1 8 PIVOT SPROG HORIZONTAL 33MM 7727 109514 1 9 SPLIT RING 11MM RF114 5720 100950 1 10 NUT NYLOC AN4 HALF 5561 100035 2 11 CLEVIS PIN 3 16 X 29 32IN 5536 104572 1 12 WASHER NYLON M 6 XOD 5540 101055 1 13 DRI LUBE SOLID LUBRICANT 27GRAMS 5637 106432 3 14 POP RIVET 3 16 SHORT 6 4 5515 100160 2 15 BOLT AN4 27A MODIFIED 2MM HEAD 8116 110178 1 16 MACH SCREW MS24694 S106 1 4 1 7 3213 7797 104202 1 17 COVER SPROG MYLAR CLEAR 4985 110367 1 18 CABLE TIE MEDIUM 140MM 5605 101193 1 19 WASHER RED FIBRE 5 16X11 16X1 32IN 5540 106400 2 PHOTO SHOWS WIRE ATTACHMENT POSITION ALSO AMOUNT OF THREAD SHOWING IS 13MM L EDGE REAR TW T SERIES RHS ASM Drawn By Scale Date 1 Borm 7784 Stuart 1 10 01 11 07 1r SHEET 2 of 2 AUSTRALIA MOHUV LSS VIIVHLSNVv AirBotne SST AND ARROW IPC AUSTRALIA 3 6 L EDGE REAR TW U SERIES ASM Drawing 8425 Airborne Windsports 2012 Issue 1 1 ZLOZ suodspurM L L enss ITEM NO NAME
48. EN INSTALLED IN THE WING LEFT HAND SIDE PART NO 109723 LHS PART NO 109727 RHS Rev AMENDMENTS Date DCR 2402 T SERIES DEV 9 06 09 LAST ACESSED Friday 29 January 2010 ITEM NO NAME DWG PART NO QTY 1 OVER CENTRE TIP LEVER PIVOT AL T SERIES 7841 109722 1 2 OVER CENTRE LEVER AL SERIES 7840 109721 1 3 POP RIVET 1 8 5515 100162 1 4 OVER CENTRE TIP LEVER ROLLER T SERIES 7845 109725 2 5 SKT BUTTON SCREW M5 X 16 SS 304 5677 103182 1 6 NUT NYLOC M 5 ZINC 5604 101365 1 RIGHT HAND SIDE NOTE THESE PARTS ARE USUALLY SOLD AS A COMPLETE ASSEMBLY OVER CENTRE TIP LEVER ASM T SERIES 7842 Drawn By Scale Date 5 Borm ALL DIMENSIONS IN MILLIMETERS UNLESS STATED OTHERWISE Stuart 22 06 09 L 1 1r AUSTRALIA SHEET 1 of 1 MOHUV LSS VIIVHLSNVv sq AirBotne SST AND ARROW IPC AUSTRALIA 4 4 AN3 Bolts Drawing 5449 Airborne Windsports 2012 Issue 1 1 ZLOZ suodspurM L L enss LT LENGTH Design Table for AN3 hex bolt PART NO NAME AN3 10a 102927 Bolt AN3 10 a AN3 11 a 109626 Bolt AN3 11 a AN3 12 a 100050 Bolt AN3 12 a AN3 13 a 100584 Bolt AN3 13 a AN3 14 a 109629 Bolt AN3 14 a AN3 15 a 100735 Bolt AN3 15 a AN3 21 a 101184 Bolt AN3 21 a AN3 23 a 100558 Bolt AN3 23 a AN3 30 a 100629 Bolt AN3 30 a R
49. ER INNER TUBE 5168 104665 1 2 WING ADJUSTER WEBBING CAP RHS TYPE 2 5169 109859 1 3 BOLT TRIKE WING TIP ADJUSTER 5233 104733 1 4 TIP ADJUSTER DOWL 5170 104667 1 5 DRI LUBE SOLID LUBE 5637 106432 1 6 SCREW SELF TAPPING 1 4X8G 30455 5909 105140 2 7 SPRING WASHER 8MM ZINC 5679 101366 1 ITEM NO NAME DWG PART NO QTY 1 WING ADJUSTER INNER TUBE 5168 104665 1 2 WING ADJUSTER WEBBING CAP LHS TYPE 2 5169 109858 1 3 BOLT TRIKE WING TIP ADJUSTER 5233 104733 1 4 TIP ADJUSTER DOWL 5170 104667 1 5 DRI LUBE SOLID LUBE 5637 106432 1 6 SCREW SELF TAPPING 1 4X8G 30455 5909 105140 2 7 SPRING WASHER 8MM ZINC 5679 101366 1 Er SCALE 1 2 INSTRUCTIONS 1 SPRING WASHER PLACED ONTO M8 BOLT 2 HAMMER SPRING WASHER INTO WEBBING CAP USING SPECIAL PUNCH 5 Sloe al a a ama ce REV DCR Rev AMENDMENTS Date 2163 1 ADDED LOCTITE 10 08 05 2425 2 CHG TO INTERNAL DES 21 09 09 2433 3 ADD RETRO KITS 21 01 10 2472 4 ADD ITEM 7 BALLOON 09 06 11 1 1 1 1 1 1 1 1 1 1 1 I 1 1 1 1 __ sense ET L J RHS PART NO 104740 EXPLODED RHS ASSY NB THERE ARE TWO DIFFERENT LEFT RIGHT COMPONENTS
50. ERSECTIONS DRAWING LAST ACESSED Thursday 24 May 2012 Drawn By Scale Date rne ALL DMENSIONS IN MLLMETERS UNLESS STATED OTHERWISE ae uo es A irBor ne me Figure 24 Major Dimensions of Airframe Issue 1 1 May 2012 Page 32 AirBorne WindSports Pty Ltd SST and ARROW Maintenance Manual 6 30 00 Significant Dimensions and Areas General The Major dimensions of the wing are listed below SST Metric Imperial Metric Imperial Sail Area 13 54 m 145 7 ft 12 9 m 138 9 ft Control Frame 73 73 73 73 Rake Angle Wingspan 10m 32 8 ft 9 5m 31 1 ft Control Frame 1 590 m 5 22 ft 1 590 m 5 22 ft Height From Keel Nose Angle With 131 2 131 2 131 2 131 2 Sail Installed 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 be 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 struts The wing should be moved with the nose facing into the wind CAUTION ENSURE THAT WHEN MOVING THE WING IN WINDY CONDITION
51. FACING OUT DETAIL BOTTOM FRONT SCALE 1 5 D TUBE TW SST LHS WITH WIRES Drawn Scale Date 1 B 7 ALL DIMENSIONS IN MILLIMETERS UNLESS STATED OTHERWISE Stuart 1 2 01 11 07 1r AUSTRALIA 7799 SHEET 1 of 1 MOHUV LSS VIIVELSNY guy AirBotne SST AND ARROW IPC AUSTRALIA 3 13 D TUBE TW ASM T SERIES Drawing 7770 Airborne Windsports 2012 Issue 1 1 ZLOZ suodspurM L L enss ITEM NO NAME DWG PART NO QTY 1 D TUBE TW AIRFOIL T SERIES LHS 7820 109697 1 2 TRIMMER ROPE amp SHOCK CORD ASM SST 7887 109845 1 DETAIL BOTTOM SCALE 1 4 SEE SHEET 2 FOR FITTING TRIMMER HANDLE PART NO 109592 RHS Rev AMENDMENTS pae PART NO 109591 LHS 1 DCR 2402 T SERIES DEV 12 03 09 LAST ACESSED Monday 29 March 2010 ALL DIMENSIONS IN MILLIMETERS UNLESS STATED OTHERWISE ITEM NO NAME DWG PART NO QTY 1 D TUBE TW AIRFOIL T SERIES RHS INC WIRE 7820 109698 1 2 SADDLE TRIMMER T W AERO D T 6397 106284 1 3 TRIMMER SPOOL T W AERO D T 6398 106287 1 4 HAND LEVER TYPE 2 COUNTERSINK 4410 106476 1 5 KNOB HAND PLASTIC 40 6433 106531 1 6 SKT CSK SCREW M 6X 16 SS 304 5568 106275 1 7 BOLT AN4 26A 5450 100009 1 8 WASHER SS304 M6 X12 5 BELLEVILLE 6421 106346 2 9 WASHER SS 304 M10 X20 BELLEV
52. H 19 84 23 02 29 37 32 54 35 72 38 89 42 07 45 24 51 59 51 59 DIMENSIONED TO ANSI 18 2 1 1981 57 94 STANDARD HEX AND HEAVY BOLTS 61 12 TABLE 2 PG 1049 AND 1047 64 29 MACHINERERY S HANDBOOK 22ND ED jen INDUSTRIAL PRESS LTD NEW YORK 76 99 80 17 83 34 86 52 89 69 92 87 96 04 102 39 105 57 108 74 0 Le ri ANE ET AN4 BOLT DESIGN TABLE Drawn By Scale Date 1 Born 5450 ALL DIMENSIONS IN MILLIMETERS UNLESS STATED OTHERWISE Simon 21 21 03 03 1r AUSTRALIA SHEET 1 of 1 MOHUV LSS VIIVHLSNv Sup AirBotne SST AND ARROW IPC AUSTRALIA 4 6 AN5 Bolts Drawing 5493 Airborne Windsports 2012 Issue 1 1 ZLOZ suodspurM L L enss Rev AMENDMENTS AN5 11a AN5 14 AN5 15a AN5 16a AN5 16 AN5 17 AN5 17 a AN5 20 a AN5 21 a AN5 22 a AN5 25 a AN5 26 AN5 26 a AN5 27 a AN5 30 a AN5 31 a AN5 32 AN5 32 a AN5 33 AN5 33 a AN5 34 a AN5 36 a AN5 36 AN5 37 AN5 40 a AN5 41 a AN5 43 AN5 44 a AN5 46 AN5 46 a AN5 53 a AN5 56 a AN5 24 a 3 DCR 2402 T SERIES DEV 4 DCR 2446 N SERIES DEV 102743 109637 100015 100553 109630 103296 101244 100016 100819 100017 100019 100588 104713 100020 100021 100022 110556 100023 110555 100024 100025 100026 106618 100027 100028 100965 110557 109628 104500 100029 100960 100420 100018 Date 08 04 09 DIMENSIONED TO ANSI B18 2 1 1981 STANDARD HEX
53. HEET 2 of 2 MOHUV LSS VIIVELSNY sou AirBotne SST AND ARROW IPC AUSTRALIA 3 9 SPROG ASM OUTBOARD T SERIES Drawing 7751 Airborne Windsports 2012 Issue 1 1 ZLOZ suodspurM L L enss Rev AMENDMENTS 1 DCR 2402 T SERIES DEV Date 06 03 09 PART NO 109564 LAST ACESSED Friday 25 September 2009 ALL DIMENSIONS IN MILLIMETERS UNLESS STATED OTHERWISE AUSTRALIA ITEM NO NAME DWG PART NO QTY 1 SPROG TUBE OUTBOARD T SERIES 7753 109566 1 2 SPROG WIRE ASM OUTBOARD T SERIES 7754 109568 1 3 SPROG ADAPTER OUTBOARD T SERIES 7752 109565 1 4 CLEVIS PIN 3 16 X 1 1 32 5536 104209 1 5 SPLIT RING 11MM RF114 5720 100950 1 6 CLEVIS PIN 1 4 X 1 1 32 5536 104001 1 7 SPLIT RING 14MM RF686 5720 109756 1 8 HEATSHRINK CLR 25 X 200 5582 109569 1 HEATSHRINK NOT SHOWN COVERS CLEVIS PIN END SPROG ASM OUTBOARD T SERIES Drawn By Scale Date Simon 1 3 06 03 09 of 1 MOHUV LSS VIIVHLSNVv guy AirBof e SST AND ARROW IPC AUSTRALIA 3 10 SPROG ASM INBOARD T SERIES Drawing 7755 Airborne Windsports 2012 Issue 1 1 ZLOZ suodspurM L L enss Rev AMENDMENTS 1 DCR 2402 T SERIES DEV Date 07 03 09 ITEM NO NAME DWG PART NO QTY 1 SPROG TUBE INBOARD T SERIES 775
54. IL BOTTOM FRONT SCALE 1 5 REVISIONS PART NO 109655 D TUB TW SST RHS WITH WIRES DOR Rev AMENDMENTS Date LAST ACESSED Monday 27 June 2011 Drawn y Scale Date 7801 A DART NAME CLARIFICATION orn ALL DIMENSIONS IN MILLIMETERS UNLESS STATED OTHERWISE D 12 29 04 08 A irBorne SHEET 1 of 1 Odi MOHUV LSS VIIVELSNY AirBotne SST AND ARROW IPC AUSTRALIA 3 16 C BAR TW SST ARROW INCL GRIPS Drawing 7790 Airborne Windsports 2012 Issue 1 1 ZLOZ suodspurM L L enss ITEM NO NAME DWG PART NO QTY 1 C BAR TW SST BASE TUBE INNER ONLY 7791 109646 1 2 C BAR TW SST BASE TUBE OUTER ONLY 7791 109642 1 3 HAND GRIP XT DETAIL 5579 105311 2 4 POP RIVET 5 32 SHORT 5 3 5515 102418 2 5 C BAR PROTECTOR WHEEL SPACER 28 6617 100141 2 1600 300 15 jig 350 xd N Le 15 gt A D17 64 D17 64 THRU xs THRU 2 1 4 Rev AMENDMENTS 1 DCR 2402 T SERIES DEV 2 DCR 2422 REFLECT MAN 3 DCR 2520 ARROW DEV Date 20 04 09 PART NO 109641 02 09 09 LAST ACESSED Friday 18 May 2012 18 05 12 ALL DIMENSIONS IN MILLIMETERS UNLESS STATED OTHERWISE C BAR TW INCL GRIPS SST Drawn By Scale Date Stuart 1 4 20 04 09 A irBorite AUSTRALIA 7790 SHEET 1 of 2 MOHUV LSS VIIVHLSN
55. ILLE 6421 102367 10 CAP WASHER COVER BLACK M8 5666 1006 11 CAP WASHER BASE CLIP M8 5667 604 12 NUT NYLOC AN4 HALF 55624 100035 14 PLACARD TRIMMER STREAK 4711 103817 13 LOCTITE 243 BLUE MID STRENGTH PLU 103706 15 POP RIVET 1 8 5515 100162 mn n 16 TRIMMER ROPE amp SHOCK CORD ASM SST 7887 109845 DETAIL TOP SCALE 1 4 D TUBE TW ASM T SERIES Scal Dat e uw Airborne 7770 Simon 1 10 12 03 09 a SHEET 1 of 2 USTRALIA MOHUV LSS VIIVELSNY ZLOZ suodspurM L L enss DETAIL LEVER SCALE 2 5 13 Jel i 1 ol 8 Q 09 DETAIL TRIMMER Rev AMENDMENTS Date PART NO 109592 LAST ACESSED Monday 29 March 2010 ALL DIMENSIONS IN MILLIMETERS UNLESS STATED OTHERWISE ITEM NO NAME DWG PART NO QTY 1 D TUBE TW AIRFOIL T SERIES RHS INC WIRE 7820 109698 1 2 SADDLE TRIMMER T W AERO D T 6397 106284 1 3 TRIMMER SPOOL T W AERO D T 6398 106287 1 4 HAND LEVER TYPE 2 COUNTERSINK 4410 106476 1 5 KNOB HAND PLASTIC 40 6433 106581 1 6 SKT CSK SCREW M 6X 16 SS 304 5568 106275 1 7 BOLT AN4 26A 5450 100009 1 8 WASHER SS304 M 6 X12 5 BELLEVILLE 6421 106346 2 9 WASHER SS 304 M10 X20 BELLEVILLE 6421 102367 1 10 CAP WASHER COVER BLACK M8 5666 100603 2 11 WASHER BAS
56. IN Al 6467 103277 1 den 15 SPRING QUICK CLIP BOLTSS 6468 101203 1 EY 16 WASHERANS 5540 100043 1 i 17 NUTNYLOCANSFULL 5535 100036 1 Qe 18 CONTROL FRAME SST PREASM 7708 109ess 1 o E NS 19 C BARTWSSTINCLGRIPS 7790 109641 1 N 20 PiPPiINsa igs P Ca The Balloon Identifier p d 22 BOLT AN4 13A 26 p x wrmnocawd IS Used for all levels of NX T Rs the Drawings Only Sw gt E circled numbers are N YS ES 2 jeaTrensersst sold not squares In D 29 BATTENSSTTRA 44 4 Qa SSK Sear mame this example we re N ln ae femer lookingforlitem3 la Lux butit sinasquareso L5 panasea Cannot be purchased The next drawing 109605 COLOUR TBA must be used 109606 COLOUR STOCK en dirBo tte mm Figure 1 Highest Level Drawing Airborne Windsports 2012 Issue 1 1 AirBof e SST AND ARROW IPC AUSTRALIA Step 2 So now if you go to that drawing 7785 then you may use the identifiers to find the next drawing number that is required The keel is part of Item 1 drawing DWG PAHT I NAME 6 O UNCTION ASM T SER X BAR TW WITH HINGE T SERIES PRIT FULL VIEW OF KEEL AND BOLT ANS 344 X BARS ASSEMBLED SADDLE 60MM TUBE SCALE 1 25 NUT NYLOC ANS FULL SAP
57. LABEL ONCE STRUTS MOHUV LSS L L enss Rev AMENDMENTS Date DCR 2402 T SERIES DEV 09 03 09 1 PART NO 109543 LHS PART NO 109575 RHS LAST ACESSED Monday 23 November 2009 ALL DIMENSIONS IN MILLIMETERS UNLESS STATED OTHERWISE ARE IN PLACE STRUT ASM LHS AND RHS T SERIES Drawn By Scale Date 1 irBot e 7742 Simon 13 09 03 09 a SHEET 1 of 1 OSTRALIA VWIIVHLSNVv owog AirBof e SST AND ARROW IPC AUSTRALIA 3 18 BATTEN SET SST HINGE Drawing 7825 Airborne Windsports 2012 Issue 1 1 ZLOZ suodspurM L L enss HINGED BATTENS 4000 mm blank length SST Batch Size NB NO REFLEX Bend Bundle LHS RHS ASSEMBLY Batten Co ordinates Bas Tubes Made Batch To Go PART No PART No FRONT REAR Gf 2 2 109784 109796 45 Cut Spectra Tip 109785 109797 Tip Thread Insert 109786 109798 Tip Thread Insert 109787 109799 Tip Thread Insert 109788 109800 Tip Thread Insert 109789 109801 Tip Thread Insert 109790 109802 Tip Thread Insert 109791 109803 Tip Thread Insert 109792 109804 Tip Thread Insert 109793 109805 Tip Thread Insert 109794 109806 Tip Thread Insert 109795 109807 Tip Tip Over centre lever m m m m m m m mo o io S 103757 103751 Tip Tip Leach Line 103758 103752 Tip Tip Leach Line 103759 103753 Tip Tip Leach Line 110252 110253 Tip Tip Leach Line 1037
58. LL OF THE ADDITIONAL COMPONENTS NOTE DWG COPIED FROM A4 7825 BATTEN SET ARROW 12 9 HINGE Drawn By Scale Date Simon 14 20 01 12 A irBoi e e 1 AUSTRALIA MOHUV LSS VIIVHLSNVv sou AirBotne SST AND ARROW IPC AUSTRALIA 3 20 BATTEN PROFILE MERLIN SST AND ARROW Drawing 7629 Airborne Windsports 2012 Issue 1 1 ZLOZ suodspurM L L enss Rev AMENDMENTS Date PART NO 109213 ESTEE bot a mE MERLIN _ SST AND ARROW DOR 250 ADD ARROW 21 05 12 LAST ACESSED Monday 21 May 2012 Drawn By Scale Date orn 7629 ALL DIMENSIONS IN MILLIMETERS UNLESS STATED OTHERWISE Stuart 12 28 05 08 A irBc Ilic SHEET 1 of 1 ITEM NO PART NO NAME MATERIAL DESCRIPTION MATL NO REQD 1 109213 BATTEN PROFILE MERLIN _ SST AND ARROW NA NA NA MOHUV LSS VIIVHLSNVv sou AirBof e SST AND ARROW IPC AUSTRALIA 3 21 MANUAL SPIRAL BOUND IPC MM SST ARROW Drawing 7824 Airborne Windsports 2012 Issue 1 1 ZLOZ suodspurM L L enss Rev AMENDMENTS 1 DCR 2402 T SERIES DEV 2 DCR 2520 ARROW DEV ITEM NO PART NO NAME MATERIAL DESCRIPTION MATL NO REQD 1 109703 MANUAL SPIRAL BOUND IPC MM SST AND ARROW NA NA NA AUSTRALIA AT SST MAINTENANCE MANUAL AND ILLUSTRATED PARTS CATALOGUE Manufacturer Air
59. Pty Ltd SST and ARROW Maintenance Manual 5 TIME LIMITS MAINTENANCE CHECKS 5 00 00 General The time limits and maintenance schedule provided are in addition to any regulation of the governing body where the aircraft is being flown 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 Aircraft Operating Instructions outlines checks required prior to each flight Extreme operating conditions may reduce the time limits for components Unsc
60. RROW IPC AUSTRALIA 3 12 D TUBE TW SST LHS WITH WIRES Drawing 7799 Airborne Windsports 2012 Issue 1 1 ZLOZ suodspurM L L enss REVISIONS DCR Rev AMENDMENTS 2402 1 T SERIES DEV 2475 2 PART NAME CLARIFICATION 18 ITEM NO NAME DWG PART QTY 1 BOLT AN5 15A 5493 100015 1 2 WASHER MYLAR 22X 7 5540 100624 2 3 C FRAME BRACKET TOP AERO D TUBE BUSHED 6893 107503 1 4 NUT NYLOC AN5 FULL 5535 100036 1 5 D TUBE TW ASM LHS T SERIES 7770 109591 1 6 FRNT FLYING WIRE STREAK amp T SERIES 1780 6601 103793 1 7 REAR FLYING WIRE SST 6604 109734 1 8 D TUBE TW SST KNUCKLES BTM ASM LHS 7856 109760 1 9 BOLT AN4 22A 5450 100549 1 10 WASHER SS304 1 4 X 3 4IN 5540 102018 2 11 BUSH T SERIES CNTL FRAME BTM 7804 109658 2 12 NUT NYLOC AN4 HALF 5561 100035 1 13 KNUCKLE D TUBE TOP LHS T SERIES 7767 109587 1 14 BUSH T SERIES CNTL FRM AND STRUT 7804 109659 1 15 NUT INTERNAL AN4 T SERIES 7776 109603 1 16 BOLT AN4 14A 5450 100559 1 17 VELCRO LOOP 25x50 ADHESIVE 6313 105887 1 18 VELCRO HOOK 25X50 6312 109870 1 DETAIL TOP SIDE SCALE 1 5 DETAIL TOP FRONT SCALE 1 5 PART NO 109654 LAST ACESSED Monday 27 June 2011 NOTE TOP BOLT HAS THREAD FACING IN BOTTOM BOLT HAS THREAD
61. S 7751 109564 1 8 PIVOT SPROG HORIZONTAL 33MM 7727 109514 1 NOTE RIGHT HAND SIDE 9 SPLIT RING 11MM RF114 5720 100950 1 ASSEMBLY SHOWN SEE 10 NUT NYLOC AN4 HALF 5561 100035 2 SHEET 1 FOR LEFT HAND 11 CLEVIS PIN 3 16 X 29 32IN 5536 104572 1 SIDE 12 WASHER NYLON M 6 XOD 5540 101055 1 13 DRI LUBE SOLID LUBE 5637 106432 3 14 POP RIVET 3 16 SHORT 6 4 5515 100160 2 15 BOLT AN4 27A MODIFIED 2MM HEAD 8116 110178 1 16 MACH SCREW MS24694 S106 1 4 1 7 321N 7797 104202 1 17 COVER SPROG MYLAR CLEAR 4985 110367 1 18 CABLE TIE MEDIUM 140MM 5605 101193 1 COVER 19 WASHER RED FIBRE 5 16X11 16X1 32IN 5540 106400 2 MYLAR SPROG DETAIL C SCALE 1 4 13 OF SPROG ASSEMBLY NOTE DRI LUBE THREAD NOTE USES APPROX 3GM OF DRI LUBE PER LEADING EDGE MOHUV LSS PART NO 110828 Rev AMENDMENTS Date L EDGE REAR TW U SERIES RHS ASM LAST ACESSED Friday 20 January 2012 DrawnBy Scale Date orn 8425 ALL DIMENSIONS IN MILLIMETERS UNLESS STATED OTHERWISE Simon 1 10 20 01 12 A irB SHEET 2 of 2 AUSTRALIA guy VIIVHLSNVv AirBotne SST AND ARROW IPC AUSTRALIA 3 7 LABEL SST ARROW STRUT LEFT amp RIGHT SIDE TOP Drawing 7857 Airborne Windsports 2012 Issue 1 1 ZLOZ suodspurM L L enss
62. S 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 should be transported with the control frame down U Bracket on top 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 1 1 May 2012 Page 33 AirBorne WindSports Pty Ltd SST and ARROW 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 applicable Issue 1 1 May 2012 Page 34 AirBorne WindSports Pty Ltd SST and ARROW 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
63. SST SERIAL 20 SHACKLE BODY 1 4IN PULL BACK 6338 102021 1 NO S 50 AND UP 21 BOLT AN4 11A 5450 100003 2 22 NUT NYLOC AN4 HALF 5561 100035 2 23 WASHER NYLON M 6 XOD 5540 101055 6 24 WASHER 55304 1 4 X 3 4IN 5540 102018 2 25 BUSH OD10 x 1 6 x 6L 5453 101488 2 26 PULL BACK ADJUSTER PLATE SST 8160 110326 1 27 COVER PULL BACK NEOPRENE 4789 101900 1 28 CABLE TIE MEDIUM 140MM 5605 101193 1 X BAR STRAP TANG 250 IS BOLTED THROUGH HERE SCALE 1 25 X BAR WITH HINGE FULL ELEVATION VIEW SHOWING DETAIL C NB THE PARTS ARE EXPLODED UP FROM T THEIR ACTUAL wap POSITION RE He 1 D AMENDMENTS Dae PART NO 109650 0 X BAR TW WITH HINGE T SERIES LAST ACESSED Tuesday 1 March 2011 Drawn By Scale Date 22 04 09 AirBofrtie 7795 ALL DIMENSIONS IN MILLIMETERS UNLESS STATED OTHERWISE Simon ti AUSTRALIA SHEET 2 of 2 MOHUV LSS VIIVELSNY guy AirBotne SST AND ARROW IPC AUSTRALIA 3 5 L EDGE REAR TW T SERIES ASM Drawing 7784 Airborne Windsports 2012 Issue 1 1 ZLOZ suodspurM L L enss ITEM NO NAME DWG PART NO QTY 1 L EDGE REAR TW T SERIES 7783 109632 1 2 TRIKE WING L EDGE TENSIONER LHS 5172 104669 1 3 SKT BUTTON SCREW M5 X 10 SS 304 5677 106172 2 4 LOCTITE 243 BLUE MID STRENGTH 5637 103706 1 5 SPROG BRACKET TW OUTBOARD T SERIES 7781 109619 1 6 PIVOT SPROG VERTICAL 7728 109512
64. ST and ARROW Maintenance Manual 4 Check inner sprogs With the access zips to the inner sprogs closed place the protractor level on the underside of the washout struts so that it sits with good contact pressing through the sail as shown in the following photograph Avoid the zip and sew line which will interfere with a correct reading Measure and record at both inner washout strut locations as described in the table below Figure 28 Measuring the inner Washout Strut Angle 5 Check outer sprogs To check the outer sprogs the zips must be opened in order to be able to place the protractor against the sprog correctly Issue 1 1 May 2012 Page 44 AirBorne WindSports Pty Ltd SST and ARROW Maintenance Manual Figure 29 Checking the Outer sprog angle The table below indicates the minimum differential angle for each of the washout struts referenced to the keel at zero degrees Compare the measurements taken to the certified angles in the applicable table Make adjustments to raise or lower the struts as required As a guide for the magnitude of adjustment the inboard struts change approximately 0 5 per revolution of the threaded strut cone the outboard struts change approximately 1 per revolution of the threaded strut cone Strut Inboard Outboard Wing model SST 8 0 10 0 ARROW 8 0 10 0 Table 9 Washout Strut Angles Making changes to the angle of a washou
65. 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 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 Socket Set Imperial and Metric 6mm T Allen Wrench Allen Key Set Imperial and Metric Protractor with built in spirit level Available from Airborne part number 108624 Digital level Protractor with plumb bob This list may not be
66. T NO 109760 DCR 2402 T SERIES DEV 13 08 09 LAST ACESSED Thursday August 13 2009 ALL DIMENSIONS IN MILLIMETERS UNLESS STATED OTHERWISE D TUBE TW SST KNUCKLES BTM ASM LHS Drawn By Scale Date 12 23 07 09 A irBoi e Stuart AUSTRALIA 7856 SHEET 1 of2 MOHUV LSS VIIVELSNY ZLOZ suodspurM L L enss REAR VIEW AS FITTED TO AIRFRAME Rev AMENDMENTS LEFT VIEW PART NO 109761 LAST ACESSED Thursday August 13 2009 ALL DIMENSIONS IN MILLIMETERS UNLESS STATED OTHERWISE ITEM NO NAME DWG PART NO 1 KNUCKLE D TUBE BTM T SERIES 7765 109585 1 2 WASHER AN6 5540 100044 2 3 BOLT AN6 26A 5494 109627 1 4 WASHER NYLON M10 STND 5540 100619 3 5 KNUCKLE STRUT BASEBAR PIVOT TSERIES 7764 109584 1 6 KNUCKLE STRUT BTM PIVOT T SERIES 7763 109583 1 7 NUT NYLOC AN6 FULL 5535 100038 1 8 C BAR KNUCKLE T SERIES 7769 109590 1 9 WASHER NYLON M 8 XOD 5540 100820 2 10 NUT NYLOC AN5 FULL 5535 100036 1 11 BOLT AN5 15A 5493 100015 1 NOTE RHS CONFIGURATION NUT FACES TO FRONT D TUBE TW SST KNUCKLES BTM ASM RHS D 7856 rawn By Scale Date orn Stuart 1 2 23 07 09 A irB AUSTRALIA
67. T SST HINGE 1 2402 T SERIES DEV 27 05 09 LAST ACESSED Tuesday 29 June 2010 Drawn By Scale Date 1i Borne 7825 ALL DIMENSIONS IN MILLIMETERS UNLESS STATED OTHERWISE Stuart 27 05 09 1r PR E A EA SHEET 1 of 1 MOHUV LSS sou VIIVELSNY AirBof e SST AND ARROW IPC AUSTRALIA 3 19 BATTEN SET ARROW HINGE Drawing 8168 Airborne Windsports 2012 Issue 1 1 ZLOZ suodspurM L L enss Rev AMENDMENTS Date 1 LHS RHS Batten PART No PART No ASSEMBLY FRONT REAR 45 Cut Spectra Tip Tip Thread Insert Thread Insert Thread Insert Tip Tip Thread Insert Po Tip 109784 109796 111066 111067 111068 111069 111059 111070 111060 111071 111061 111072 111074 111075 103751 103758 103752 110253 103755 Thread Insert Tip Over centre lever Tip Leach Line Tip Leach Line MASTER INCLUDES BATTEN BAG DOUBLE PART 106479 NOTE THE NUMBER 1 BATTENS ARE CLOSEST TO THE KEEL PART NO 110830 LAST ACESSED Thursday 31 May 2012 ALL DIMENSIONS IN MILLIMETERS UNLESS STATED OTHERWISE DCR 520 U SERIES DEV 20 01 12 ITEM NO DWG PART NO 1 BATTEN SET ARROW 12 9 HINGE 8168 110830 1 THIS MODEL IS A VIRTUAL ASSEMBLY OF THE MATERIALS USED TO CREATE THE BATTENS NO ACTUAL ASSEMBLY HAS BEEN CREATED THEYARE DEFINED BY THE EXCEL SPREADSHEET 8168 AND IN FOXPRO FOR A
68. T THE BLACK MAST TOP SAFETY TANG ADAPTER WITH THE SNAP HOOK FACING REARWARD AND OPENING GATE DOWN 2 IF THE CENTRE OF GRAVITY IS MOVED EXPLODED FORWARD ON THE WING KEEL THE MAST TRIMMER NEEDS BE RAISED UP THE CLAMP MAST BY 20MM IF THE CoG IS MOVED REARWARD THE MAST CLAMP WILL NEED ATTACHMENT TO BE LOWERED BY 20MM Rev AMENDMENTS Date PART NO 109718 LAST ACESSED Wednesday 23 May 2012 Drawn By Scale Date ALL DIMENSIONS IN MILLIMETERS UNLESS STATED OTHERWISE Stuart 1 3 01 11 07 1 SAFETY WIRE NEEDS TO BE CUT AND DISCARDED WHEN RETROFITTING ITEM 2 MAST SAFETY WIRE 2 WHEN FITTING THE MAST SAFETY WIRE GUIDE THE RUBBER CAP INTO THE MAST TOP ADAPTER SO THAT IT HELPS HOLD THE WIRE IN PLACE WHILE FITTING THE SECURING BOLT 9 CHECK THAT MAST SAFETY WIRE IS HELD IN PLACE AFTER ASSEMBLY BY PULLING FIRMLY ON WIRE AT BASE END OF MAST NOTE 1 MOUNT TRIMMER CLAMP TO MAST 500MM DOWN FROM TOP OF SILVER MAST 13 DETAIL TRIMMER ATTACH SCALE 1 4 WING ATTACHMENT KIT SST RETRO 7839 AirBorne SHEET 2 of 3 AUSTRALIA MOHUV LSS VIIVHLSNVv sou ZLOZ suodspurM L L enss Rev AMENDMENTS Date PART NO 109827 LAST ACESSED Wednesday 23 May 2012 ALL DIMENSIONS IN MILLIMETERS UNLESS STATED OTHERWISE ITEM NO NAME DWG
69. TW WITH HINGE T SERIES 1 DCR 2402 T SERIES DEV 20 04 09 2 DCR 2442 INC WIRE LENGTH 109622 17 05 10 LAST ACESSED Tuesday 1 March 2011 Drawn By Scale Date a 3 DCR 2449 ADD PULL BACK ADJUSTER 16 08 10 DIMENSIONS IN MILLIMETERS UNLESS STATED OTHERWISE Simon Ti 20 04 09 A irB e AUSTRALIA 7795 SHEET 1 of 2 MOHUV LSS VIIVHLSNVv ZLOZ suodspurM L L enss ITEM NO NAME DWG PART NO QTY 1 X BAR BOLT COVER NO SLOT 6465 100804 1 2 PULL BACK WIRE 1200 T SERIES 4632 109622 2 8 3 WASHER AN5 5540 100043 1 4 WASHER NYLON M 8 STND 5540 100595 3 5 CAP WASHER BASE CLIP M8 5667 100604 1 1 2 5 6 BOLT AN5 15A 5493 100015 1 ELEVATION OF 7 NUT NYLOC AN5 HALF 5561 100037 1 X BAR STRAP TANG 250 PIVOT BOLT TO 8 CAP WASHER COVER BLACK M8 5666 100603 1 E D cc Num d GERI IE PR ASSEMBLY 11 NUT NYLOC AN4 FULL 5535 100034 2 12 NUT NYLOC AN3 FULL 5535 100051 2 13 X BAR TW STREAK T SERIES 7726 109506 2 NOTE 14 STRAP X BAR 25MM TANG 250 6464 103819 1 DCR 2442 109622 15 X BAR BALL TYPE 3 AIRBORNE 7718 109478 1 T SERIES PULL 16 X BAR BALL SKT TYPE 3 AIRBORNE 7719 109477 1 BACK WIRE LENGTH 17 BOLT AN3 30A 5449 100629 2 INCREASED FROM 18 BOLT AN4 30A 5450 100011 2 1175 TO 1200 FOR 19 PULLEY PULL BACK X BAR STREAK 6466 103821 1 WING
70. VICE 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 1 1 May 2012 Page 7 AirBorne WindSports Pty Ltd SST and ARROW Maintenance Manual USE OF METRIC IMPERIAL UNITS This Service Manual uses the metric unit system as the basic system of measurement Where common usage or available instrumentation refer to the Imperial system both units are quoted The following conversion factors are presented as a ready reference to the conversion factors that have been used in this manual 1 Pound Ib Pound per sq in psi Inch in Foot ft Statute mile Nautical mile NM Millibar mb Millibar mb Imperial gallon US gallon US quart Cubic foot ft k Degree Fah
71. Vv sou ZLOZ suodspurM L L enss ITEM NO NAME DWG PART NO QTY 1 TC BAR TW ARROW BASE TUBE INNER ONLY 7791 111042 1 2 TC BAR TW ARROW BASE TUBE OUTER ONLY 7791 111043 1 3 HAND GRIP XT DETAIL 5579 105311 2 4 POP RIVET 5 32 SHORT 5 3 5515 102418 2 5 C BAR PROTECTOR WHEEL SPACER 28 6617 100141 2 6 LABEL ARROW BASEBAR 8468 111044 1 1500 ADD PHOTO OF STICKER POSITION 350 60 300 0517 64 THRU 2 1 M 4 PART NO 111040 LAST ACESSED Friday 18 May 2012 ALL DIMENSIONS IN MILLIMETERS UNLESS STATED OTHERWISE 05 32 x RIVET X2 C BAR TW INCL GRIPS ARROW 12 9 0517 64 THRU mm ons lt Airksorire 79 AUSTRALIA SHEET 2 of 2 MOHUV LSS VIIVHLSNVv guy AirBof e SST AND ARROW IPC AUSTRALIA 3 17 STRUT ASM T SERIES Drawing 7742 Airborne Windsports 2012 Issue 1 1 ZLOZ suodspurM ITEM NO NAME DWG PART NO QTY ITEM NO NAME DWG PART NO QTY 1 TUBE AIRFOIL STRUT T SERIES 6475 109542 1 1 TUBE AIRFOIL STRUT T SERIES 6475 109542 1 2 KNUCKLE STRUT BTM LHS T SERIES 7740 109541 1 2 KNUCKLE STRUT BTM RHS T SERIES 7740 109580 1 3 KNUCKLE STRUT
72. 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 serve 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 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 Battens should always be inserted into the same side of the wing red is always inserted on the left hand side green is always inserted on the right hand side A useful mnemonic is red is never right 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
73. aken 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 points for structures These include the front and rear wires the struts 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 Strut attachment points Straightness of the tubes Elonga
74. and replace if necessary 5 Recommend replacement or overhaul 6 Mandatory Replacement 7 Refer to Rotax maintenance manual and Rotax maintenance logbook Certification required to perform Light Sport Aircraft maintenance tasks O Owner R E LSA Repairman Inspection experimental registered aircraft only R S LSA Repairman 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 completed 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 1 1 May 2012 Page 20 AirBorne WindSports Pty Ltd SST and ARROW 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 Bett
75. ay be slightly tighter make sure that the sail tangs are in place with at least one thread showing This area may be slightly tighter than Just Not Loose because there is a bush in the leading edge see drawing 7792 Illustrated Parts Catalogue 2 Nose Catch Just not loose See Drawing 7800 Illustrated Parts Catalogue Issue 1 1 May 2012 Page 36 AirBorne WindSports Pty Ltd SST and ARROW Maintenance Manual 3 Keel Roller U The socket countersunk cap screws which locate in the Neg Plate Bracket horizontal aluminium plate with serial number riveted to it should be tightened to approximately 25 Nm Red Loctite 262 must be used see Drawing 7793 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 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 7795 Illustrated Parts Catalogue 6 Down Tube The base bar fitting bolt should be slightly tighter than just not loose but Bottom Corners base bar knuckle should
76. be able to be rotated by hand Loctite is not required as there is a locking bolt installed T Base Bar Bolts Just not loose 8 Cross Bar Just not loose Leading Edge Junction NOTE The vertical bolt will have approximately four threads showing See Drawing 7792 Illustrated Parts Catalogue 9 Struts Strut top swivel should be lubricated with a lanolin based product to prevent corrosion The bolts and nuts connecting the strut airfoil to the knuckle top and bottom must have Loctite 262 applied The nut internal and bolts should have a marker line drawn across the end to help see if they become loose See Drawing 7742 Illustrated Parts Catalogue 10 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 7795 Illustrated Parts Catalogue there will be two wires in the pull back shackle 11 Quick Clip Bolt Just not loose see drawing 7800 Illustrated Parts Catalogue 12 Trimmer Tighten nut until the faces of the saddle and trimmer spool come in contact Attachment to see drawing 7770 sheet 2 Illustrated Parts Catalogue Down Tube 13 Trimmer Handle Firm with Loctite 243 see drawing 7770 sheet 2 Illustrated Parts Catalogue Table 8 Torque settings for the wing Issue 1 1 May 2012 Page 37 AirBorne WindSports Pty Ltd SST and ARROW Maintenance Manual 20 20 00 SAFETYING PROCEDURES
77. 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 1 1 May 2012 Page 17 AirBorne WindSports Pty Ltd SST and ARROW 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
78. d fitting at each end for attachment to the nose catch control frame and keel Issue 1 1 May 2012 Page 42 AirBorne WindSports Pty Ltd SST and ARROW Maintenance Manual Sprog Washout Struts The sprogs are mainly 6061 T6 aluminium tubes that do not operate in normal flight They attach at the bottom of the leading edges and are connected by stainless steel wire to the top of the leading edges Sprogs become active at low angles of attack the rear of the sprog tubes act upwards on transverse battens that serve to keep the trailing edge of the sail raised providing dive recovery function Checking the SST ARROW Stability System This method is used to check the sprog angle relative to the keel angle of the wing Angles may be measured using one of the following tools 1 Protractor with built in spirit level these are available from Airborne part number 108624 PROTRACTOR SPIRIT LEVEL 2 Digital level 3 Protractor with plumb bob Inspection steps 1 Fully assemble the wing ready for flight 2 On a level piece of ground raise the rear keel to horizontal as 0 is a convenient reference point Using a stand to support the keel extension 3 Place the protractor level on the underside of the keel between the cross bar straps as shown in the following photograph Do not move the wing from this position Figure 27 Setting Reference Keel Angle Issue 1 1 May 2012 Page 43 AirBorne WindSports Pty Ltd S
79. e 1 1 May 2012 Page 23 AirBorne WindSports Pty Ltd SST and ARROW 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 Untie Bungie Untie bungie from pull back handle When the wings are folded in the handle is accessed through the undersurface center zip Figure 6 Removing Rear Leading Edges Remove Zip Cut off zip tie at nose junction Remove zip slider from zip and unclip sail safety webbing Figure 7 Removing Centre Zipper Issue 1 1 May 2012 Page 24 AirBorne WindSports Pty Ltd SST and ARROW Maintenance Manual Remove Nose Webbing Undo sail webbing nut and remove sail webbing Replace nut finger tight Figure 8 Removing Nose Webbing Remove Rear Wires Remove sail Tang and quick clip Figure 9 Removing Rear Wires Remove Airframe from Sail Leave control frame attached and carefully slide frame out through the nose of the sail Figure 10 Removing Airframe CAUTION DO NOT FORCE SAIL IF IT SNAGS STOP AND FIND WHAT IT S CAUGHT ON Issue 1 1 May 2012 Page 25 AirBorne WindSports Pty Ltd SST and ARROW 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 Particu
80. e 1 1 May 2012 Page 46 AirBorne WindSports Pty Ltd SST and ARROW 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 ARROW wing has a large portion of the top surface made from Mylar whereas the SST is all dacron except the leading edge 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 sail strength 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 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 B
81. e Junction Cross Bar Strut Assembly Inboard Sprog Assembly Inboard Sprog Mylar Cover X Bar L Edge Zip Outboard Sprog Assembly Outboard Sprog Mylar Cover Tip Webbing Located Correctly Tip Tension L Edge 3 Mark 4 Mark Tension SST Tip Scuff Pads Pull Back Wires Bottom Rear Wires Pull Back Wires Shackle Clip Batten Tension Adjusted Tip struts adjusted Inboard Sprog Angle 8 Deg Outboard Sprog Angle 10 Deg Trimmer Sticker Strut LH amp RH Identification Sticker Torque seal applied to Strut and D Tube Nuts Serial number Placard Attach Test Fly Sheet in Plastic Holder Final QA By Appointed Signatory Date As per 03 122 01 Table 7 Airborne Final QA Inspection Sheet Issue 1 1 May 2012 Page 31 AirBorne WindSports Pty Ltd SST and ARROW 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 6 10 00 Major Dimensions of the SST Airframe KEEL CENTERLINE PLAN 1 50 ERES EDU pas PART NO 109605 0 REPORT 04051 FRAME INT
82. e Step 1 iii 26 Figure 14 Sliding Frame Onto Frame Step 2 iii 27 Figure 15 Inserting Keel Into Sail nennen nnne nnne nns 27 Figure 16 Position Keel Pocket Forward Of Rear Wires 27 Figure 17 Spread The Wings Apart sise 27 Figure 18 Join Centre Zipper etico cto eet e temi dee ide der ru eat ot eee o eroe 28 Figure 19 Locate Tip Webbing sienne 28 Eigure 20 Insert Battes inerte ete tendu nb ner ode ea nenas 28 Figure 21 Tension TIS dette pecore aii nen aves dre ee cones ever e 29 Figure 22 Locate Tip Over Centre Battens sis 29 Figure 23 Nose Webbitig oer ce eere b op eere a Eee per deo de aduentu 30 Figure 24 Major Dimensions of Airframe sis 32 Figure 25 Inserted Batten End Unloaded Angle Check 41 Figure 26 Batten End Fitting Dimension Check 42 Figure 27 Setting Reference Keel Angle sis 43 Figure 28 Measuring the inner Washout Strut Angle 44 Figure 29 Checking the Outer sprog angle iii 45 Figure 30 Bettsometer Instrument see 48 Figure 31 Adjusting Tip Angle Sail Not Fitted ssssssssseeeneemmmnnenn 51 Figure 32 Adjusting Batten Tension sise 51 Issue 1 1 May 2012 Page 9 AirBorne WindSports Pty Ltd SST and ARROW Maintenance Manual Tables Table 1 Amendment Record Sheets sise 3 Table 2 Log Of Effective Pages tem Rc
83. enance 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 rating 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 c Issue 1 1 May 2012 Page 19 AirBorne WindSports Pty Ltd SST and ARROW Maintenance Manual 5 20 05 Maintenance Task Legend Your microlight 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 1 Oil lubricate clean and service 2 Check as directed 3 Check for insecurity cracks wear legibility and faulty operation 4 Remove inspect
84. ettsometer 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 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 1 1 May 2012 Page 47
85. ev AMENDMENTS Date 1 DCR 2402 SERIES DEV 08 04 09 LAST ACESSED Wednesday 8 April 2009 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 N MA 9 36 CHECK THIS DIMENSION E NB AT THIS STAGE BOLTS WITH HOLES IN THE SHAFT WITHOUT a DESIGNATION CARE NOT REPRESENTED WITH HOLES IN THE MODELS AN3 BOLT DESIGN TABLE co ar we Air ore 5449 AUSTRALIA SHEET 1 of 1 MOHUV LSS VIIVHLSNv AirBotne SST AND ARROW IPC AUSTRALIA 4 5 AN4 Bolts Drawing 5450 Airborne Windsports 2012 Issue 1 1 ZLOZ suodspurM L L enss Rev AMENDMENTS Design Table for hex bolt an PART NO 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 DCR 2428 REV DEV ADD 109929 20 11 09 NAME BOLT AN4 6 BOLT AN4 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 AN4 23 BOLT AN4 24 a BOLT AN4 26 a BOLT AN4 27 a BOLT AN4 30 a BOLT AN4 31 BOLT AN4 32 a BOLT AN4 33 a BOLT AN4 34a BOLT AN4 35 a BOLT AN4 36 a BOLT AN4 40 a BOLT AN4 41 a BOLT AN4 42 a H LENGT
86. gradation 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 a mild detergent 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 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 Airwo
87. have other model names in the title The most important thing in ordering spare parts is the part number NOTE Airbornes 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 pages will be sent by mail if requested Airborne Windsports 2012 Issue 1 1 AirBotne SST AND ARROW IPC AUSTRALIA TABLE OF CONTENTS 1 WING ASSEMBLY SST DRAWING 7800 2 WING ASSEMBLY ARROW DRAWING 8422 3 AIRFRAME T SERIES Drawing 7785 3 24 NOSE JUNCTION ASM T SERIES Drawing 7792 T SERIES A FRAME TOP REAR KEEL ASM Drawing 7793 L EDGE CHANNEL ASM LHS AND RHS T SERIES Drawing 7787 X BAR TW WITH HINGE T SERIES Drawing 7795 L EDGE REAR TW T SERIES ASM Drawing 7784 L EDGE REAR TW U SERIES ASM Drawing 8425 LABEL SST ARROW STRUT LEFT amp RIGHT SIDE TOP Drawing 7857 TRIKE WING L EDGE TENSIONER Drawing 5172 SPROG ASM OUTBOARD T SERIES Drawing 7751 SPROG ASM INBOARD T SERIES Drawing 7755 CONTROL FRAME SST PREASM Drawing 7798 D TUBE TW SST LHS WITH WIRES Drawing 7799 D TUBE TW ASM T SERIES Drawing 7770 D TUBE TW SST KNUCKLES BTM
88. heduled 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 available 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 TO 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 envi
89. hich 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 1 1 May 2012 Page 48 AirBorne WindSports Pty Ltd SST and ARROW 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 ALSO BE CARRIED OUT BY AN EXPERIENCED PERSON ANY ADJUSTMENTS SHOULD BE RECORDED IN THE MAINTENANCE LOG CHANGES REQUIRED FOR TUNING ARE SMALL AND INCREMENTAL 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 p
90. ht 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 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 through a bungie system and is linked to the keel Turning the trim handle pulls the keel down at the rear acting like a counterweight which has the effect of reducing trim speed 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 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 1 1 May 2012 Page 39 AirBorne WindSports Pty Ltd SST and ARROW 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
91. 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 PULL BACK PULLEY for the KEEL Step 1 Use the main drawing to identify which part or sub assembly it belongs to In this case it is a part of the AIRFRAME T SERIES DRAWING 7785 which means that it is in Chapter 2 cd NAME owG Pant noor 1 samsst o P 5 S rma 1099e 1 Item 3 UE INSERT T SERIES AIRFRAME T SERIES 7785 1 AIRFRAME T SERIES 7785 4 lUEDGEREARTWTISERISLIHSASM 7784 109633 1 s UEDGEREARTWTSERIESRHSASM 7784 109694 1 6 LABELSSANDSSTREARVELHS ese 107257 1 7 LABEL 53 AND SST REAR LE RHS ese 107256 1 8 NosEcarcH swaN 100085 1 9 SHACKLE SHGFo4 O 1 1 6338 100954 1 1 0 BOLTANs 11A 1 1 545 100003 1 1 1 NUT NYLOC AN4 FuLL 5535 100024 1 12 BOLT QUICK CLIP AN5 31A TYPE3 6453 106405 1 1 3 ouckcuPBlOCKk 7002 106153 1 1 4 QUICK CLIP BOLT P
92. ies identified during the operation or maintenance of the aircraft or in the content of the manual AUSTRALIA Return to Please provide your own contact details below AirBorne WindSports Pty Ltd PO Box 7042 Redhead New South Wales 2290 Australia Fax 61 2 4944 9199 Email trikesupport airborne com au Issue Description If you have a proposal to remedy the issue please provide it here Number of pages submitted including this cover page Issue 1 1 May 2012 Page 55 AirBorne WindSports Pty Ltd SST and ARROW Maintenance Manual End SST and ARROW Maintenance Manual Issue 1 1 May 2012 Page 56 AirBorne WindSports Pty Ltd SST and ARROW Maintenance Manual This page left blank intentionally Issue 1 1 May 2012 Page 57 AirBotne SST AND ARROW IPC AUSTRALIA AirBotfie AUSTRALIA SST AND ARROW ILLUSTRATED PARTS CATALOGUE Applicability SST ARROW Unit 22 30 Kalaroo Rd Redhead 2290 New South Wales Australia Phone 61 2 49449199 Fax 61 2 49449399 Airborne Windsports 2012 Issue 1 1 AirBotne SST AND ARROW IPC AUSTRALIA Copyright Notice Copyright Airborne Windsports Pty Ltd 2012 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
93. imming 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 NOTE e If the centre of gravity is moved forward the trimmer mast clamp will need to be moved up the mast the same amount If the C G is moved rearward the trimmer clamp will need to be moved down That is a single hole adjustment of the keel roller will require a 20mm trimmer mast clamp adjustment Issue 1 1 May 2012 Page 51 AirBorne WindSports Pty Ltd SST and ARROW 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 wing keel attachment base mast attachment and control frame top knuckle attachment The U bracket has two components N shaped channel and a negative block that is attached below the keel to preclude the keel from moving out the bottom of the bracket The U bracket should be checked thoroughly after any unusual loads 57 60 00 Flight Surfaces There is a trim speed control device on the wing The t
94. itch 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 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 e Check front and rear wires are routed 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 Aircraft Operating Instructions 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 the batten does not line up gently apply pressure using your hand or knee to get a smooth curve After checking as noted above a turn can be remedied by adjustments as outlined in the following table Issue 1 1 May 2012 Page 49 AirBorne WindSports Pty Ltd SST and ARROW Maintenance Manual Roll Tuning Matrix The following table outlines procedures for tuning a wing to correct a turn VERY MILD
95. justment called torque roll tuning is also used to adjust a small roll off to the right in the wing as it approaches Vne This adjustment has little or no effect at lower speeds It is achieved by reflexing the right hand side tip battens numbers 8 and 9 250mm from the trailing edge upwards to a maximum of 15mm from the straight section of the batten refer batten profile as necessary NOTE The more reflex the more correction effect ADDITIONAL TUNING Table 10 Tuning procedure BATTEN TENSION ADJUSTMENT Over tensioning of battens will cause degradation of handling A mylar sail tends to shrink as it ages so checking of the batten tension periodically is required The correct tension is applied to the batten when loading with minimal pressure applied an angle of 30 is achieved See diagram The last tip batten should be approximately 45 More tension To decrease tension the fitting is rotated clockwise To increase tension the fitting is rotated anticlockwise Figure 31 Standard Batten Tension Issue 1 1 May 2012 Page 50 AirBorne WindSports Pty Ltd SST and ARROW Maintenance Manual Figure 32 Adjusting Tip Angle Sail Not Fitted DECREASE TENSION Figure 33 Adjusting Batten Tension Pitch Tuning Trim speed at MTOW and the trimmer in the off position is WING MODEL TRIM SPEED SST 60 66 KIAS ARROW 60 70 KIAS Table 11 Trim speeds If the wing is tr
96. lar 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 11 Tie Pull Back Bungie To Pulley Prepare Frame for Sail Reinstallation g Insert quick clip bolt attach rear flying wires and tighten nut finger tight it needs to be removed again to allow the keel pocket past Insert rear leading edges into correct right and left hand side and stand airframe onto its A frame Lay sail out at the tips inline with the airframe Ensure rears are located correctly Figure 12 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 13 Sliding Sail Onto Frame Step 1 Reinstall Sail Step 2 Issue 1 1 May 2012 Page 26 SST and ARROW Maintenance Manual AirBorne WindSports Pty Ltd Figure 14 Sliding Frame Onto Frame Step 2 Insert Keel into Sail When sail is approxi
97. mately halfway up insert the keel into the keel pocket Slide sail up until the keel pocket hits the quick clip bolt Figure 15 Inserting Keel Into Sail 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 Position Keel Pocket forward of Rear Wires Figure 16 Position Keel Pocket Forward Of Rear Wires Spread Wings 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 Slide the rest of the sail up to the nose 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 17 Spread The Wings Apart Issue 1 1 May 2012 Page 27 AirBorne WindSports Pty Ltd SST and ARROW Maintenance Manual Join Zip 2 Connect sail safety strap at nose junction Slide on zip slider making sure strike marks the zipper align Fasten zip tie through eyelet holes around the zipper Figure 18 Join Cent
98. n 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 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 1 1 May 2012 Page 5 AirBorne WindSports Pty Ltd SST and ARROW Maintenance Manual Other Categories of Registration This aircraft is a Light Sport eligible aircraft This manual is created to be compliant to the standards applicable to Special Light
99. ne i bet er et Re tese E ceo Ey Ta 4 Table Imperial Metric Conversions iii 8 Table 4 Airframe Limitations issues 14 Table 5 Maintenance Privileges sise 17 Table 6 Scheduled Maintenance iii 21 Table 7 Airborne Final QA Inspection Sheet ss 31 Table 8 Torque settings for the wings 37 Table 9 Washout Strut Angles iii 45 Table 10 Tuning procedure sise 50 Table 11 Trim speeds ed d e de de e RR Ee den d LAN ede Er ARR 51 Issue 1 1 May 2012 Page 10 AirBorne WindSports Pty Ltd SST and ARROW 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 tha
100. ng should be adjusted until the leading edge is positioned on the 4 mark for SST ARROW 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 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 OH Book Aircraft Operating Instruction for LSA 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 Issue 1 1 May 2012 Page 12 AirBorne WindSports Pty Ltd SST and ARROW Maintenance Manual Preflight as described in section 4 of the Pilots Operating Handbook Aircraft Operating Instuctions paying particular attenti
101. on to possible damage to the airframe during transport Issue 1 1 May 2012 Page 13 AirBorne WindSports Pty Ltd SST and ARROW Maintenance Manual 4 AIRWORTHINESS LIMITATIONS 4 00 00 General This section sets forth each mandatory replacement time structural inspection interval and related structural inspection procedure required for type certification 4 20 00 Airframe Limitations Component Life hours Requirement Heart Bolt 1 off 100 Mandatory Replacement Struts 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 4 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 1 1 May 2012 Page 14 AirBorne WindSports
102. 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 tems that can be expected to be completed by a responsible individual who holds a mechanic certificate with airframe or powerplant 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 maint
103. orne Windsports 2012 Issue 1 1 SST AND ARROW IPC 2 A E I AUSTRALIA 1 WING ASSEMBLY SST DRAWING 7800 Airborne Windsports 2012 Issue 1 1 ZLOZ suodspurM L L enss INSTRUCTIONS SEE GJP XXXX162XXXX FOR ASSEMBLY INSTRUCTIONS NOTE NOTE A CERTIFICATION KIT MUST 109622 T SERIES PULL BACK WIRE LENGTH BE SUPPLIED WITH THIS INCREASED FROM 1175 TO 1200 FOR WING WING SST SERIAL 50 AND UP 109605 COLOUR TBA 109606 COLOUR STOCK Rev AMENDMENTS Date 109607 COLOUR CUSTOM 1 DCR 2402 T SERIES DEV 24 04 09 LAST ACESSED Tuesday 29 May 2012 ALL DIMENSIONS IN MILLIMETERS UNLESS STATED OTHERWISE TEM NO NAME DWG PART NOQTY 1 SAIL SST 7774 109596 1 2 MYLAR L E INSERT T SERIES 7773 109595 2 3 AIRFRAME T SERIES 7785 109635 1 4 L EDGE REAR TW T SERIES LHS ASM 7784 109633 1 5 L EDGE REAR TW T SERIES RHS ASM 7784 109634 1 6 LABEL S3 SST AND ARROW REAR LHS 6846 107257 1 7 LABEL S3 SST AND ARROW REAR L E RHS 6846 107256 1 8 NOSE CATCH SWAN 2140 100085 1 SHACKLE SHGF04 6338 100954 1 BOLT AN4 11A 5450 100003 1 NUT NYLOC AN4 FULL 5535 100034 2 BOLT QUICK CLIP AN5 31A TYPE 3 6453 106405 1 QUICK CLIP BLOCK 7002 106153 1
104. otate 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 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 struts and base bar sections The base bar works mainly in tension through the strut 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 Issue 1 1 May 2012 Page 40 AirBorne WindSports Pty Ltd SST and ARROW Maintenance Manual 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 struts 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
105. r 1 h oA lo LD Rev AMENDMENTS Date PART NO 111048 LAST ACESSED Tuesday 22 May 2012 ALL DIMENSIONS IN MILLIMETERS UNLESS STATED OTHERWISE NOTE VIRTUAL ASSEMBLY MADE FOR BOM PURPOSES THE T SERIES COVERS AND PADDING IS THE SAME AS THE S SERIES EXCEPT FOR 3 X 101673 WHICH COVER THE STRUT ENDS AND 3 X 106614 WHICH COVER STRUT BRACKETS SEE SHEET 1 AND 2 FOR PICTURES OF INDIVIDUAL PARTS COVERS AND PADDING SET ARROW Drawn By Scale Date orn 6 496 Simon 1 5 28 04 09 A irB r SHEET 4 of 4 AUSTRALIA MOHUV LSS VWIIVHLSNVv guy AirBof e SST AND ARROW IPC AUSTRALIA 3 23 WING ATTACHMENT KIT T SERIES Drawing 7839 Airborne Windsports 2012 Issue 1 1 ZLOZ suodspurM L L enss ITEM NO NAME DWG PART NO QTY 1 BOLT AN6 41 5494 100033 1 NOTE 2 RETAINER ASM BOLT HEAD 5218 104739 1 1 MOUNT TRIMMER CLAMP TO MAST 3 WASHER SS304 3 8 X 3 4 5540 100924 1 500MM DOWN FROM TOP OF SILVER MAST 4 SAFETY PIN 5545 100920 1 TUBE NOT THE BLACK MAST TOP ADAPTER WITH THE SNAP HOOK FACING WINGNUTANS D REARWARD AND OPENING GATE DOWN 2 IF THE CENTRE OF GRAVITY IS MOVED 7 TRIMMER MAST ASM T SERIES 7868 109816 1 FORWARD ON THE WING KEEL THE MAST CLAMP NEEDS TO BE RAISED UP THE MAST BY 20MM IF THE CoG IS MOVED REARWARD THE MAST CLAMP WILL NEED TO BE LOWERED BY 20MM
106. raft Skills Only people with an adequate skill level should perform maintenance on this aircraft A 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 according 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 To perform heavy Maintenance o
107. re Zipper Locate Tip Webbing Attach Struts Locate tip webbing over rear leading edge and secure retaining Velcro Attach Struts Figure 19 Locate Tip Webbing Insert Battens Insert main sail battens and pull cross bar tension on Note the pull back handle should be routed through the top sail hole Tie pull back bungie onto pull back handle using a bowline knot Photo shows the pull back handle being tied on Figure 20 Insert Battens Issue 1 1 May 2012 Page 28 AirBorne WindSports Pty Ltd SST and ARROW Maintenance Manual 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 4 mark for SST ARROW 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 21 Tension Tips 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 Locate Tip Over Centre Battens Locate tip over center battens Insert under surface battens E Figure 22 Locate Tip Over
108. renheit F Inch Pound in Ib Foot Pound ft Ib Table 3 Imperial Metric Conversions Issue 1 1 May 2012 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 1 3 785 Litres 1 0 946 Litre I 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 SST and ARROW Maintenance Manual CONTENTS 0 ASSEMBLY AFTER SHIPPING csscssecsicisssscssconctcbisesevesastcceeastecescesseccersnestdsecaasocssusnecsarsvaecersiaaencesscs 11 4 AIRWORTHINESS LIMITATIONG scsseceeeeseeeeeesseeeeeeeeeeeseeeeaeeeeseseeesensneeeeseeneesenseaeeeeneeeeeeenees 14 5 TIME LIMITS MAINTENANCE CHECKS cc eccceeeeeeeeeeeeeeeneeneeeeneeeeesensneeeeeseneeseaseaeeeenseeeeeenees 15 6 DIMENSIONS AND AREAS iiiecesssssnissssscscescsscressesceecdsvocsstesesncssenscceressancessvenstecusdsoserssuassereescocedansestes 32 9 GROUND HANDLING wesecescccsecedsccccscesdeteccscesssceressvancitsssccesenssscdeessscecesssadieecesacoosatsizetecavssceceaseazencvaas 33 10 uilccdcme 34 11 REQUIRED PLACARDS ceris radica oo a neon neon eran cy ak 35 20 STANDARD PRACTICES AIRFRAME
109. rim control is achieved by a pulley system which gathers rope through a bungie system and is linked to the keel Turning the trim handle pulls the keel down acting like a counterweight which has the effect of reducing trim speed Issue 1 1 May 2012 Page 52 AirBorne WindSports Pty Ltd SST and ARROW Maintenance Manual 95 SPECIAL PURPOSE EQUIPMENT 95 10 00 Training Bars The training bars will be supplied as an option for use by qualified instructors in order to teach people to fly the aircraft they allow 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 Instructions for fitting and maintenance are included as part of the training bar kit Issue 1 1 May 2012 Page 53 AirBorne WindSports Pty Ltd SST and ARROW Maintenance Manual APPENDIX A Condition Inspection Checklist Wing Maintenance Log S N Date Hours Maintenance Work Performed Maintained by Section or Service Bulletin Issue 1 1 May 2012 Page 54 AirBorne WindSports Pty Ltd SST and ARROW Maintenance Manual APPENDIX B Feedback Form Operation and Maintenance Feedback Form Please use a copy of this form to provide notification to the e manufacturer about issues or anomal
110. ronments Preventative treatment may be applied as required Issue 1 1 May 2012 Page 15 AirBorne WindSports Pty Ltd SST and ARROW Maintenance Manual Replacement Aluminium tube comes in many different sizes and grades As sections of the airframe 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 thread protruding out of the nyloc e All self locking nuts should not be installed more than 2 times 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 de
111. rthiness Directory AD issued by CASA or the NAA of the country of registration Issue 1 1 May 2012 Page 16 AirBorne WindSports Pty Ltd SST and ARROW Maintenance Manual 5 20 01 Maintenance Privileges This manual lists task to be performed 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 Pilot Sport Pilot Modifications LS I Sport Pilot LS M A amp P part 145 repair Special LSA Sport Pilot LS M A amp P part 145 repair Owner Sport Pilot 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 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 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 inspection must be performed
112. someter testing 57 30 00 2 R 2 R 2 R 2 R 2 R 57 30 00 2 R 2 R 2 R 2 R 2 R 2 2 R 2 R 2 R 218 ne attachment 57 30 00 2 R 2 R 21 2 R 2 R 2 R 2 R 2 R 2 R 218 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 tion zi As directed 2 R 2 R 2 R 218 21 2 R 21 2 R 218 21 atches 57 10 00 3 R 3 R 3 R 3 R 3 R 3 R 3 R 3 R SIP 3 R a ae 57 40 00 2 R 2IR 2 R 2 RI 21 2 R 218 2 R 2 RI 21 M DUM As directed 3 R 3 R STR 3 R 418 3 R 3 R 3 R 31 6 Leading edges struts keel cross bars and down tubes for As directed 2 R 2 R 2 R 2 R AIR 2 R 2IR 4 R 2 R 6 R straightness dents and corrosion Remove frame from 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 R 21 2 2 R 2IRI 6 Universal joint keel roller free moving in good As directed 2 R 2 R 2 R 2 R 4 R 2IR 2 R 2 R 2 R 6 R order dodo OA TENE As directed 6 R 6 R 6 R e R 6 R e R e R e R 6 R 6 a As directed 2 R 2 R 2 R 2 R 2 R 2 R 2 R 2 R 2 RI 21 PI Tri Scenes ang As directed 3 R
113. spections servicing of fluids Tasks where specific instructions are described in the manual that do not require specialised 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 1 1 May 2012 Page 18 AirBorne WindSports Pty Ltd SST and ARROW Maintenance Manual Heavy Maintenance Tasks that require a repairman rating with specialised 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 Items 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 Items 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
114. t it is lying flat on the ground Spread Leading Edges Spread both leading edges approximately 2 metre Remove 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 As shown on the photo the washout struts or sprogs should be routed through the sail zip as the rear leading edge is pushed inwards The rear leading edges are located with their slots and held in place by the sail loops Figure 1 Insertion of Rear Leading Edges Issue 1 1 May 2012 Page 11 irks AirBorne WindSports Pty Ltd SST and ARROW Maintenance Manual 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 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 fitti
115. t strut Swing the strut out from the sail Remove the split ring from the clevis pin Remove the clevis pin To raise the trailing edge view the washout strut from the rear rotate the threaded cone anticlockwise until the clevis pin hole reappears this occurs in 1 2 turn increments To lower the trailing edge view the washout strut from the rear rotate the threaded cone clockwise until the clevis pin hole reappears this occurs in 1 2 turn increments Replace the clevis pin and split pin Replace the strut in the sail and capture it by doing the zipper up Tap the sail from above to jiggle the strut into its flattest position The strut angle is now ready to be sighted and re measured Issue 1 1 May 2012 Page 45 AirBorne WindSports Pty Ltd SST and ARROW Maintenance Manual WARNING EXPERIENCED PERSONNEL SHOULD ONLY CARRY OUT ADJUSTMENTS TO THE WING STABILITY SYSTEMS ANY ADJUSTMENTS SHOULD BE RECORDED IN THE MAINTENANCE LOG CHANGES REQUIRED FOR TUNING ARE SMALL AND INCREMENTAL MAJOR CHANGES WILL CAUSE THE WING TO PERFORM BADLY AND MAY BE DANGEROUS WHEN MAKING STRUT ADJUSTMENTS IT IS WISE TO VISUALLY SIGHT THE STRUTS TO CHECK FOR GROSS CHANGES BEFORE TEST FLYING TO SIGHT THE STRUT SETTINGS STAND IN FRONT OF THE GLIDER WITH THE KEEL HORIZONTAL amp HOLDING THE NOSE WIRES SLOWLY ROTATE THE NOSE FORWARD AND BACKWARD NOTICE WHEN THE TRAILING EDGE OF EACH OF THE STRUT LOCATIONS COMES INTO AND OUT OF VIEW Issu
116. 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 Section 2 Placards of the Aircraft Operating Instructions or Pilots Operating Handbook as applicable Issue 1 1 May 2012 Page 35 AirBorne WindSports Pty Ltd SST and ARROW Maintenance Manual 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 TH
117. tion 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 1 1 May 2012 Page 22 AirBorne WindSports Pty Ltd SST and ARROW 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 Taking photos before and during disassembly can also help aid the reassembly process 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 Issu

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