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19.05Mb - Airborne Australia

1. 52 APPENDIX Condition Inspection 53 APPENDIX Feedback cute cnn tie 54 Figures Figure 1 Insertion Of Rear Leading daa 10 Figure 2 Locating Sail Webbing On Rear Leading 11 Figure Setting Tip tersa 11 Figure 4 De Tensioninig the 22 Figure 5 Removing Hear Leading Edges ri ts dd 23 Figure 6 Unbolting Side Wires cornisa 23 Figure 7 Unbolting Crossbar Junction urea e cre t 24 Figure 8 Removing Quick Clip 24 Figure 9 Removing Top Front To Back 4 44 4 24 Figure TO Urol sella 5 to io e doti te olg tote at etatis 25 Figure 11 Removing Nose Webbing 2 50 2 5 en e re A Een e ERREUR RUE 25 Figure 12 Unbolting Top Front Wire iei etr 25 Figure 13 Removing AAA 26 Figure 14 Frame Preparation For Sail 20022 00 27 Figure 15 Sliding Sail Frame Step 1 27 Figure 16 Sliding Sail Onto Frame Step Llista a ere e eter p o rer is een 28 Figure 17 Inser
2. May perform only if the modification is included in the aircrafts Maintenance Manual or if the repairman is authorized to do so by the manufacturer May perform if the Repairman Inspector is the owner of the aircraft and not using the aircraft for compensation training or towing or When using the Experimental aircraft for compensation training or towing until January 31 2010 the inspection must be performed by an LS M A amp P or part 145 repair facility Not authorized to perform Table 4 Maintenance Privileges Issue 1 0 2007 16 AirBorne WindSports Pty Ltd Wizard lll Maintenance Manual Note that owners and pilots are permitted to perform preventative maintenance tasks as prescribed by FAR document Part 43 Appendix A Sec A43 1 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 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
3. Table 10 Condition Inspection Checklist Issue 1 0 2007 Page 53 WindSports Pty Ltd Wizard Maintenance Manual APPENDIX B Feedback Form Operation and Maintenance Feedback Form AUSTRALIA Please use a copy of this form to provide notification to the manufacturer about issues or anomalies identified during the operation or maintenance of the aircraft or in the content of the manual Return to AirBorne WindSports Pty Ltd PO Box 7042 Redhead New South Wales 2290 Australia Fax 61 2 4944 9199 Email trikesupport 2airborne com au Please provide your own contact details below Issue Description If you have a proposal to remedy the issue please provide it here Number of pages submitted including this cover page Table 11 Feedback Form Issue 1 0 2007 54 WindSports Pty Ltd Wizard Maintenance Manual End Wizard Maintenance Manual Issue 1 0 2007 55 WindSports Pty Ltd Wizard Maintenance Manual This page 15 left blank intentionally Issue 1 0 2007 Page 56 irBottie AUSTRALIA WIZARD 3 ILLUSTRATED PARTS CATALOGUE Version 1 Issue Date 15 02 05 Applicability Wizard 3 Unit 22 30 Kalaroo Rd Redhead 2290 New South Wales Australia Phone 61 2 49449199 Fax 61 2 49449399 Part 106971 Co
4. 92 78 379 02 002 0 E 2 000 2 000 2 000 2 000 36 003 003 eoo o o 004 003 0328 00595 E Elo 2 0 gt lt 8 100026 9 El O AirBorne WindSports Pty Ltd 2004 file LNMANUALSWPCWizard3WorkingM623 htm 7 09 04 ALL PARTS ASSEMBLED MAKE AIRFRAME Top Front to Rear Wire Top Front to Rear Wire over Top Side Wire 174 over Side Wire p it ROUND KINGPOST REAR VIEW FAIRED KINGPOST AMENDMENTS O BOTES POT SCALE DATE ADD WIZARD 16 05 00 Peter H HALF SIZE 25 05 99 ADD KING POST PLACARD 27 09 01 AIRBORNE WINDSPORT Pry TRIKE WING KING POST ASEMMBLY TYPE 2 A4 4752 Trike Wing K post Assembly Type 2 Page 1 of 1 Trike Wing K Post Assembly Type 2 Trike Wing K Post Assembly Type 2 Dwg No A4 4752 07 09 2004 103862 K POST WIZARD 2 3 STREAK 1 2 1150MM 103825 K POST TOP PLUG TRIKE WING POP RIVET SS 5 32 SHORT 5 2 02
5. 1000 100 1 000 1000 03699 1 000 308 1 000 1 000 360 200 2 000 2 000 08 6 000 6 000 325 ____ 2 000 9 2 4 88 2000 2 000 200 200 s 326 7 38 200 __ 2 000 ____ Y io pis Me ME 1000 1 000 1200 2000 200 22000 2 000 2000 2 000 2000 2000 200 2000 2001 2 000 6 000 4 000 4 000 4 000 0 240 0 240 2 000 2 000 EDGE FRONT WIZARD EDGE FRONT STREAK 123 CRUZE BAR MOUNT CHANNEL 2 000 ADDLE 60MM TUBE 6 000 IDE BOTT WIRE FWD WIZZ 2475 DE BOTT WIRE FWD STRK 14 DE BOTT WIRE FWD WIZZ 118111 247 IDE BOTT WIRE AFT WIZZ 2485 DE BOTT WIRE AFT 181 IDE BOTT WIRE AFT WIZZ 118 111 2485 OP WIRE SET WIZARD OP SIDE WIRE SET STREAK amp OP SIDE WIRE SET WIZARD 118111 OLT 5 36 OLT 5 40 OLT AN5 21A AP CHAIR LEG 19MM PLASTIC UT NYLOC AN5 FULL UT NYLOC 5 HALF 2 000 ASHER SS 5 16 X 1IN X 168 2 000 ASHER NYLON M 8 XOD 6 000 OLT AN4 32A 4 000 SHER AN4 4 000 UT NYLOC AN4 FULL 4 000 ELCRO 50MM LOOP BLACK ADHESIVE 0 240 ASHER NYLON 8 STD 2 000 1 000 1 000 elo E 00 gt o 4 zm gt 1 000 2 000 6 000 2 000 6 000 2 000 o 40 2 000 2 000 A 40 ND 40 1 000
6. 126191 818 SI19W1d34 928468 Nid did E SN 31VNH3L V 9c ONIM OL 1 1355 SLEVd 11 Trike Wing A frame Corner Assembly Page 1 of 1 Trike Wing A frame Corner Assembly Trike Wing A frame Corner Assembly Dwg No A3 2310 07 09 2004 103261 FLYING WIRE 2599 1 19 FLYING WIRE WIZZ peo __ SIDE BOTT WIRE FWD WIZZz478 rosso SIDE BOTT WIRE FWD Wzz __ SIDE BorT WIRE 2486 1000 ossso SIDE BOTT WIRE AFT Wizz Wa 2485 E 14 100595 WASHER NYLON ME STD 40 400 4090 5 4 16 102872 WINGNUT 1 000 _ _____ 1000 1 000 T 27 Pie O AirBorne WindSports Pty Ltd 2004 file LAMANUALS IPC Wizard3 W orking 23 10 htm 7 09 04 257 002 SINN JONVHO 6 11 0 0 80 11 343NNvHO OL ec9v vV 20 20 81 9 ZIM SAYLIWITIIN NI SNOISN3AIG 11 00 S0 v0 SONVL 11 5 dav SLHOdSGINIA ANYOYY IV 66 20 10 21 8 15
7. LJ TUBE TRIKE SIEVER 2 _ 267 FRAME AL BRACKET Jo 2000 _ 4 100054 NUT NYLOG AN FULL 5 ioo4e WASHERANA A 1251 7 isie DOWNTUBEPROTECTORTW E Y 00 0 100714 SS L 29 iooose NUTNVLOC ANS 0172 gt 100624 WASHER MYLAR ____ 2000 100012 2 2 14 100035 NUT NYLOC ANAHALE E299 157100022 ROLLER TWO 2000 102062 5 SCREW UNF MANN 22 2000 BRACKET NEG LOAD PLATE 120 ALUMIN 1 TUBE ASSEM 2 1 103887 ASSEMBLY TRIKE WING 20102358 SERIAL NO PLATE 100 25 32104712 QUIOK CUP ASMANE ITA T 1 1 33100950 8PLH RING 12MM 24 100055 WASHER SS X 7 16 34 FLAT 35 100804 KEEL WZARDIIa STREAK 0 as ieree orevisPINamexe row _ 103212 FLYING WI
8. SININONINV TANNVWHO SS Wwe MAN LON 24 5 P 51709 143 s3903 ONIGVAT OML NO 1108 ONVL IYS 15814 1333 NO 55080 1337 LH3SNI I SNOILONYLSNI 55 1 6 6 S31OH 1VOILH3A JHL 01 138330 5 FHL OS TANNVHO 3HfISN3 8 6 22 H3HSVM LAN 1108 uv3u ONVL 38IM dOL 7 H3HSVM ON EA J1VH 401 1709 cb v 6 Wizard Nose Junction Assembly Page 1 of 1 Wizard Nose Junction Assembly Wizard Nose Junction Assembly Dwg No A4 4622 07 09 2004 4 000 2 000 2 000 1 000 1 000 4 000 4 000 2 000 2 000 1 000 1 000 Fe 100761 NOSE CATCH CHANNEL 0858 ooo 1000 1000 1 000 5278 CATCH CHANNEL 1000 1000 1 000 1000 TUBE _ _________ TUBE ASSEM FRONT WIZARD SK _ 05602 TUBE ASSEMFRONTSTREAK _ 1 TUBE ASSEM FRONT wizano i 5042 TUBE ASSEM FRONTSTREAKI _ 5043 TUBE ASSEM FRONT WIZARD __ __ Fs wsos uEbsEFRoNrWzaARD ps El EH 1 000
9. Maintenance Manual Other Categories of Registration This aircraft is certified as a Primary Category aircraft and when supplied with this manual and associated placards is a Light Sport eligible aircraft This manual is created to be compliant to the standards applicable to Special Light Sport Aircraft The category of registration may be quite varied as such the maintenance requirements of this aircraft are to be applied in conjunction with the requirements of the National Airworthiness Authority NAA of the country of registration Any NAA maintenance requirement takes precedence over this manual In the event that the owner 15 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 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 Inst
10. 101672 COVER FOLDING BARKNUGKLE 2 E O AirBorne WindSports Pty Ltd 2004 file LNMANUALSWPCWizard3 Working V5323 htm 7 09 04 Alg8WNassv ADVWITINA 20 21 21 39NIH HV8 X Q8 VZIMb3u NI SNOISN3WIG T1V SLAOdSANIM 401 ls 46 3INVHJHIV Q3 18W3SSV 51 5 Wizard Iii Cross Bar Hinge Pull Back As Page 1 of 1 Wizard Cross Bar Hinge Pull Back As Wizard Ill Cross Bar Hinge Pull Back As Dwg No A4 5333 07 09 2004 PartNo Details 6 100003 1000 9 02021 SHACKLE POLL BAR WASHER NYLON 1 4 OBA THICK O AirBorne WindSports Pty Ltd 2004 file LAMANUALS IPC Wizard3 W orking 5333 htm 7 09 04 PART NO USE BOLT PRT NO QUICK CLIP ASSEMBLY 60MM 106151 QUICK CLIP BOLT 60MM 103273 QUICK CLIP ASSEMBLY 65MM 103278 QUICK CLIP BOLT 65MM 103274 QUICK CLIP ASSEMBLY 75MM 106152 QUICK CLIP BOLT 75MM 103275 QUICK CLIP ASSEMBLY 80MM 104045 QUICK CLIP BOLT 80MM 104044 QUICK CLIP ASSEMBLY 85MM 101740 QUICK CLIP BOLT 85MM 103276 QUICK CL
11. 3 mark for Wizard 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 28 Tension Tip 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 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 Dive Stick Strut Insert into leading edge Ensure that the dive strut locates correctly Figure 29 Insert Dive Stick Into Leading Edge Attach Swan Catch Attach swan catch Secure and tighten nose webbing tangs Issue 1 0 2007 32 AirBorne WindSports Pty Ltd Wizard Maintenance Manual Figure 30 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 in
12. 18 AirBorne WindSports Pty Ltd Wizard lll 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 Code Oil lubricate clean and service Check as directed Check for insecurity cracks wear legibility and faulty operation Remove inspect and replace if necessary Recommend replacement or overhaul Mandatory Replacement Refer to Rotax maintenance manual and Rotax maintenance logbook Certification required to perform Light Sport Aircraft maintenance tasks 0 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 complete both the maintenance manual and the log book should be filled out A copy of the Service Bulletin form should be sent to the factory to be stored with the aircraft QA papers A separate maintenance manual is supplied with the trike base The wing maintenance log should be filed out in the wing maintena
13. RHS 103085 LHS 103085 RHS 103085 Rear Leading Edge 103087 103087 103086 104101 104100 104101 104100 NA 104 003 104669 104740 103088 Keel Tube 102960 103088 103088 103600 103088 103 103088 828 103088 103088 105043 Keel Extension NA 103603 103 603 103603 Washout Rods 101870 101870 101870 101870 101870 104722 104722 Washout Rod Mounts 102625 CONTROL FRAME 102625 102625 102625 102625 104720 104720 Down Tubes Inc Knuckle 103209 103209 103209 103209 103209 103209 103209 Base Bar 103207 103207 103 207 103207 King Post 103264 862 103862 103261 103261 103261 104040 104040 104040 104040 103212 103212 103212 103212 103212 103212 103212 103259 103889 103889 103504 103889 103504 103889 103504 103790 103788 103790 103788 Top Front Side Set Reflex Bridles _________ j See A4 6712 for Details Bungie Bungie Bungie Spring Hinge SAIL WZIII Hinge Battens from 830 102962 104079 104079 104745 103156 NA NA 103211 103211 105038 MODIFICATION HISTORY WIZARD SK Introduced for US trike wing market Allowed removable keel extension Shorter keel pocket allowing pull back wires over top of
14. THE THIN WALL ALUMINIUM TUBING THAT HAS BEEN USED TO CONSTRUCT THE MAJORITY OF THE WING STRUCTURE NEVER TIGHTEN NUTS SO THAT THE ALUMINIUM TUBING IS DEFORMED FROM ITS CIRCULAR CROSS SECTIONAL SHAPE ALWAYS HAVE AT LEAST ONE FULL THREAD SHOWING PAST ANY NYLOC 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 1 4 turn more should be made The resulting fit should not allow any axial movement of the bolt in its location but will allow rotation using fingers of a held component to be achieved with approximately 20mm of lever arm eg a
15. e 100912 O AirBorne WindSports Pty Ltd 2004 file LNMANUALSWPCWizard3WorkingM752 htm 7 09 04 Meamassv 1339 uvau 605052 SSHISWITIIW NI SNOISNAWIG TIV 8 dOL AWVH V aed 9 QquvZIM 2002 HOO SNOILONLYSNI 70 80 90 3111007 3807 SLYOdSGNIM 20 21 0 17109 dav aed SLNAWONAWV 365 TES 1108 4015 1335 icr 9v vi vt gt 7 op N ev 2 LNOHJ sa Sa SNId NOISN31X3 133 1H3SNI 9 N 1no any 133 MATA 2015 H 1 311901 44 27 1708 183SNI NO y si 1 INN NO JANS Na 133 OL 387 2 1108 LH3SNI 133 1 SNOILONYLSNI ATENISSV 1NOyW3 Wizard li Top And Rear Assembly Page 1 of 1 WIZARD A Frame Top and Rear Keel Assembly WIZARD A Frame Top and Rear Assembly Dwg No A4 4759 07 09 2004 a PartNo Detalls 2 E
16. AirBorne WindSports Pty Ltd Wizard Ill Maintenance Manual amp Illustrated Parts Catalogue A Boie AUSTRALIA N WIZARD MAINTENANCE MANUAL AND ILLUSTRATED PARTS CATALOGUE Manufacturer AirBorne WindSports Pty Ltd Unit 22 30 Kalaroo Rd Redhead NSW 2290 Australia Phone 61 2 4944 9199 Fax 61 2 4944 9395 Website http www airborne com au AirBorne WindSports Pty Ltd 2007 Part 108608 2007 WindSports Pty Ltd Wizard Ill Maintenance Manual amp Illustrated Parts Catalogue This aircraft should only be flown with a certified wing and base combination 2007 AirBorne WindSports Pty Ltd Wizard Maintenance Manual AitBorne AUSTRALIA WIZARD MAINTENANCE MANUAL Manufacturer AirBorne WindSports Pty Ltd Unit 22 30 Kalaroo Rd Redhead NSW 2290 Australia Phone 612 4944 9199 Fax 612 4944 9395 Website http www airborne com au O AirBorne WindSports Pty Ltd 2007 Part 108628 Issue 1 0 2007 1 WindSports Pty Ltd Wizard 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 s Operator s Handbook e Applicable Base Maintenance Manual e Applicable Base Illustrated Parts Catalogue e Wing Maintenance Manual Wing I
17. 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 the owner when the owner is the holder of a LSA Repairman Inspection certificate The pilot of the E LSA aircraft is responsible to see that the maintenance and inspection has been performed on this aircraft as per the maintenance schedules prescribed in this maintenance manual The maintenance schedule tasks remain applicable where there is no minimum level of qualification required to perform maintenance on E LSA however a minimum skill level continues to apply to tasks Only people with an adequate skill level should perform maintenance on this aircraft sound understanding of mechanical systems and good experience with the necessary tools and procedures is required as the continuing airworthiness of the aircraft relies on the competence of the person performing the maintenance Assessment and judgement of the condition of each individual component is required which necessitates a sound understanding of the purpose of each component in the system If there are any doubts regarding the required and appropriate maintenance then the safety of the aircraft may be jeopardised in continuing with self maintenance
18. 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 8 2 R 2 R 2 R 2 218 2 8 218 2 6 8 Universal joint keel roller free moving and in good As directed 288 2 R 2 R 28 4 2 R 21 2 R 21 6 order E AN As directed 6 R 6 R 6 R 6 R 6 6 8 6 6 6 8 6 8 ds Tri and alas As directed 3 R 3 R 3 R 3 R 3 R 3 R 318 318 318 Table 5 Scheduled Maintenance May 2007 Issue 1 0 20 AirBorne WindSports Pty Ltd Wizard lll Maintenance Manual 5 50 00 Unscheduled Maintenance Checks Unscheduled maintenance 15 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
19. short packed configuration An approved dealer is responsible for assembly from the short packed configuration The short packed wing has had the rear leading edges removed to reduce the packed size for transport The correct reassembly of the wing is critical for safety and performance of the wing If there are any doubts about the correct procedure for assembly after shipping contact AirBorne 00 10 00 Reassembly Guide Remove wing from box Ensure that all staples are removed before pulling the wing from the box Damage to the sail may result if caught on box staples Unzip bag Remove padding from the nose of the wing Remove all wing straps Remove padding from control bar and rear leading edges Assemble the control frame Assemble control frame and rotate the wing so that it is lying flat on the ground Spread Leading Edges Spread both leading edges approximately 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 The rear leading edges are located with their slots and held in place by the sail loops Note that the dive stick must go through the sail Figure 1 Insertion Of Rear Leading Edges Issue 1 0 2007 Page 10 AirBorne WindSports Pty Ltd Wizard Maintenance Manual CAUTION VELCRO TABS AND
20. side wires back through sail slots Bolt side wires to cross bar Figure 22 Fit Side Wires CAUTION MAKE SURE BOTTOM SIDE WIRES ARE IN THE CORRECT FWD AND AFT SLOTS Reattach Cross Bars Reattach crossbar ensuring washers are on correctly Figure 23 Reattach Cross Bar Locate Tip Webbing Locate tip webbing over rear leading edge and secure retaining Velcro Figure 24 Locate Tip Webbing Issue 1 0 2007 30 AirBorne WindSports Pty Ltd Wizard Maintenance Manual Fit King Post Feed pull back wires back through king post hole Insert king post into locating hole Although there may be two holes visible there is one hole available that 15 large enough for the king post locating bush When installed the machined fitting should be flush with the keel Bolt top front to back wire to the pull back shackle Figure 25 Fit King Post Fit Reflex Bridle Reattach bridles to sail using Loctite 243 on the shackle Screws Head of the shackle screw faces to the rear of the sail Figure 26 Fit Reflex Bridle Insert Battens and Tension Cross Bar Insert battens and pull cross bar tension on Figure 27 Shows Crossbar Pull Back In Place Issue 1 0 2007 31 AirBorne WindSports Pty Ltd Wizard Maintenance Manual Reset Tip Adjusters Tension the sail using a 6mm Allen key The tip fitting should be adjusted until the leading edge 15 positioned on the
21. the optimal positions for flight 6 10 00 Major Dimensions of the X Series Airframe EDGE WING WIZARD WING STREAK WING 3 995M 3 745M 3 785M 3 885M 4 600M 4 600M 2 930M 2 830M 2 830M 10 140M 9 960M 9 970M 3 812M 3 360M 3 200M A4 2331 TCW Figure 31 Major Dimensions Of Airframe Issue 1 0 2007 35 AirBorne WindSports Pty Ltd Wizard Maintenance Manual 6 30 00 Significant Dimensions and Areas General The Major dimensions of the wing are listed below Wizard Metric Imperial Sail Area 16 8 181 f Control Frame Rake Angle 67 67 9 96 32 7 ft Control Frame Height From Keel 15m 4 92ft Nose Angle With Sail Installed 123 5 123 5 Table 7 Dimensions And Areas Issue 1 0 2007 Page 36 WindSports Pty Ltd Wizard lll Maintenance Manual 9 GROUND HANDLING 9 00 00 General The wing should only be moved in the packed up condition or if necessary when attaching to the base When moving the wing in the assembled position it is recommended that the wing is lifted with the shoulders whilst standing in the control frame lt 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 th
22. wire tang Issue 1 0 2007 40 AirBorne WindSports Pty Ltd Wizard Maintenance Manual No Area Instructions 1 Nose Assembly Central bolts Just Not Loose Outer bolts to leading edges may be slightly tighter make sure that the sail tangs are in place with approximately two threads showing This area may be slightly tighter than Just Not Loose because there is a bush in the leading edge see Illustrated Parts Catalogue 2 Nose Catch Just not loose See Illustrated Parts Catalogue 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 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 Illustrated Parts Catalogue 6 Down Tube The side wire D shackle and base bar fit
23. 2 000 2 000 103601 FRONT 123 026 200 200 12200 1 102787 FANT WIRE TRIKE 3220 STREAK 100 1 00 _ 586 FRNT WIRE TRIKE 3585 WIZARD Fir FLYING wine wizzzoio wosres FRvrFLYiNG WIRE STAK 160 4040 FLYING WIRE wizz 1000 12 000 12 000 O AirBorne WindSports Pty Ltd 2004 file LAMANUALS IPC Wizard3 W orking 4622 htm 7 09 04 26 11 60 8215 OTIOIN 1813881 3903 EMH sa Aq 01 1 9 QuVZIM SLAOASUNIM SSYLAWITIIN NI SNOISN3WIG TIV 20 21 81 1115 8 SHO 1708 8 00 60 20 VLZ SNV 01 66 20 10 MVAYLS 8 quVZIM aav SININONINV SQV3H 1104 43409 ADGA ONIGVAT OL 31 3AIS3HQV 4135 40017 NINOS ININOZL 5 55 LHOIH ANY 1431 JHL SIVLOL 3S3H1 SLON AWVYSAYIV 3 VIN GATEWASSV SLEVd 11 Wizard Cross Bar Leading Edge Assembly Page 1 of 1 Wizard Cross Bar Leading Edge Assembly Wizard Cross Bar Leading Edge Assembly Dwg No A4 4623 07 09 2004 0 77 pene nme eoe 1 WIZARD
24. 9 700901 22090 020901 810901 910901 10801 210901 010401 5 311789 5NIHdS 6 2 5 311 unas 9 9 2 2 SN3 LLVG IVS QHVZIAN 22080 72090 220 206601 816601 906601 216601 506601 116601 06601 016601 606601 806601 206601 106601 1 unas 9 9 2 2 21 5 SN3 LLV8 1195 NIVIN 792 002 620401 18601 616601 216601 116601 016601 606601 euo 78 18 5 72090 206601 906601 506601 06601 806601 206601 106601 SN3L1Vg AS 5 311 1195 NIVIN 620401 16601 816601 216601 116601 016601 606601 euo 211 700901 206601 906601 206601 06601 806601 206601 106601 3I9Nn8 6 2 5 unas 9 9 v E L IVS NIV GYVZIM Wizard 1 Wizard Il Wizard III LHS Front Leading Edge 103085 103085 Wizard SK RHS LHS RHS LHS 103085 103085
25. CS OF AIRCRAFT GRADE BOLTS ARE SUPERIOR TO OTHER BOLTS AND ALLOW LONGER SAFE SERVICE LIFE UNDER CYCLIC LOADS LIKE THOSE EXPERIENCED IN AIRCRAFT THE LENGTH OF THE BOLT IS IMPORTANT IF A SHORTER BOLT IS USED THE THREAD MAY ENCROACH ON THE LOAD BEARING AREA WHICH INCREASES THE STRESSES EXPERIENCED BY IT MANDATORY SERVICE BULLETINS AS THE SERVICE HISTORY OF THE AIRFRAME EVOLVES AIRBORNE WILL FROM TIME TO TIME ISSUE AIRBORNE DIRECTIVES WHICH DETAIL ANY CHANGES TO THE MAINTENANCE MANUALS PILOT S OPERATING HANDBOOK OR ANY OTHER DETAILS THAT AIRBORNE DEEMS NECESSARY FOR OWNERS TO BE NOTIFIED OF THE WEB ADDRESS FOR AIRBORNE DIRECTIVES IS HTTP WWW AIRBORNE COM AU IT IS THE RESPONSIBILITY OF THE OPERATOR TO KEEP UP TO DATE WITH ANY ROTAX DIRECTIVES THROUGH THE ROTAX WEBSITE Issue 1 0 2007 6 AirBorne WindSports Pty Ltd Wizard 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 gallo
26. FAA Report AFS 120 73 2 In order to estimate the time life limits for the major components of the airframe this is detailed in Airborne report 04 144ds The estimates that have been made do not take into account any extreme loads which will reduce the fatigue life of the airframe The fatigue life of these components is dependent upon rigid adherence to maintenance schedules As the service history of the airframe evolves these time life estimates are expected to be revised Amendments should be checked for regularly Issue 1 0 2007 13 WindSports Pty Ltd Wizard 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 an
27. IP ASSEMBLY AN5 22A104709 QUICK CLIP BOLT AN5 26A102024 QUICK CLIP ASSEMBLY 5 26 104710 QUICK CLIP BOLT 5 264104707 QUICK CLIP ASSEMBLY 5 104711 QUICK CLIP BOLT AN5 30A104708 QUICK CLIP ASSEMBLY 5 31 104712 QUICK CLIP BOLT 5 304102025 QUICK CLIP ASSEMBLY 5 34 104714 QUICK CLIP BOLT 5 344101734 ID DESCRIPTION DWG NO PART NO 1 BOLT PIN AL A4 7043 103277 2 Q C BOLT SPRING 157A 101203 Q CBOLT A4 7043 SEE LIST 4 Q CBLOCK SS A4 7002 106153 Rev AMENDMENTS epar by Scale Date BOLT FOR 57MM LIEDEGE ADD Sports PEER 2004 HALF SIZE 13 2 91 TYPE 2 ASSEMBLIES ADDED 02 11 97 ADDED 80MM ASSEMBLY 10 04 00 AIRBORNE WINDSPORTS on ADDED AN ASSEMBLIES 14 05 02 QUICK CLIP BLOCK ASSEMBLY 4 7048 2 50202 swa ra wen SINOdSQNIM 133HSMHOM 130 3 SIHL 620401 606901 206901 106901 006901 668901 868901 600901 069 1 6 72090 unas 268901 968901 968901 768901 868901 268901 010401 5 311 5 11958 NIVIN 620401 120901 610501 210801 810801 810801 110801 600801 62
28. In this situation an Airborne Dealer should be contacted for the correct procedures and or servicing All maintenance and repairs must be carried out in accordance with good aeronautical practices 5 20 02 Description of Task Classification Preventative Maintenance The preventative maintenance that is permissible to be performed by pilot certificate holders is defined in FAR document Part 43 Appendix A Sec A43 1 Line Maintenance Includes inspections servicing of fluids Tasks where specific instructions are described in the manual that do not require specialized training for replacement repair of parts and structure or alterations described in the manual Includes compliance with service directives that prescribe repairmen as the minimum qualification to perform the task Issue 1 0 2007 17 AirBorne WindSports Pty Ltd Wizard Maintenance Manual Heavy Maintenance Tasks that require a repairman rating with specialized training or Mechanic with A amp P rating such as major engine work repair of landing gear assemblies It also includes alterations to structure where instructions are provided in the manual such as fitment of an undercarriage kit or a tow kit 5 20 03 Qualification Descriptions Certification Required to Perform Light Sport Aircraft Maintenance Tasks 0 Owner ltems that can be expected to be completed by responsible owner who holds a pilot certificate but who has not received a
29. O 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 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 Tip strut locators should be on top of the rear leading edges when inserted Lay sail out at the tips inline with the airframe Figure 14 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 15 Sliding Sail Onto Frame Step 1 Issue 1 0 2007 Page 27 AirBorne WindSports Pty Ltd Wizard Ill Maintenance Manual Reinstall Sail Step 2 Hold the leading edge up approximately 1 2 metre off the ground while you slide the sail up oe FM Slide sail up half a side at a time 17 Pull sail on slowly as damage can result if sail is caught on internal ribs Figure 16 Sliding Sail Onto Frame Step 2 Insert Keel into Sail When sail is approximately halfway up insert the keel into the keel pocket Slide sail up until the keel pocket hits the quick clip bolt Figure 17 Inserting Keel Int
30. R 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 0 2007 Page 46 AirBorne WindSports Pty Ltd Wizard 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 hang
31. RE tO 19 104075 WIZARD 17 21 gt EXTENSION STREAKWIZRD23 _ 2 10519 WASHERNYLONMIGSTD 10456 WASHER SS M10 X2IMM 7 2 100920 ___________ itoss WINGNUT ANS 1o00se BOLT AN amp 36 O AirBorne WindSports Pty Ltd 2004 file LNMANUALSWPCWizard3WorkingM759 htm 7 09 04 NOISNSL 318 V1SAFOV 20 50 16 8228 AT8N3SSV 3903 9NIQV31 83813117 NI SNOISN3HIQ TIV SS3OX3 LNO OL JAINJ LOH ASN 8 85 man JONA GNVH H3AO 6 181 Sued SLAOdSANIM aan HONOYHL 31108 2 ONISN OL IIL 1 e 55 008 LNOHSVM 1511 LYN NO HL9N41 119 338 3IONR8 8 dv34 3903 n ONIQv31 AYNOAS OL LIMY GAONV14 ASN ANY AIINISSV QOY 1 5 LYASNI 6 3111901 30189 ONISN SM3HOS AYAH 9IN X 2 5 HOVLIV 2 OL AIAWASSV H3NOISN3 3903 SNIGV3 LH3SNI L A18IN3SSV Leading E
32. 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 fitting should be adjusted until the leading edge is positioned on the 3 mark for Wizard 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 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 p
33. WindSports Pty Ltd Wizard lll Maintenance Manual 57 30 00 Sail The sail comprises the lifting surface of the wing It is mainly constructed of Dacron polyester fabric with some Mylar material making up the leading edge areas The sail is constructed from many individual panels which are sewn together using polyester thread to form the required shape The sail has attachment points sewn into it to attach to the frame at various points and to hold the battens in place The sail also provides zips that facilitate easy preflight inspection of all the members inside the double surface wing The sail should be kept out of the sun as much as possible as sunlight will damage the sail and in time will cause it to fail the required Bettsometer tests Inspection Check for tears in the sailcloth or any loose or unravelled seams 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 Bettsometer tests KEEP THE SAIL COVERED WHEN NOT IN USE AS CONTINUED EXPOSURE TO ULTRAVIOLET RADIATION DRAMATICALLY REDUCES SAIL LIFE NEVER USE CHEMICAL SOLVENTS OR APPLY WATE
34. ach flight they should be checked to ensure that the locking pin is installed correctly and that they are securely attached to the uprights and base bar The welded base bar attachment has been made to be slightly loose for ease of fitment Training bar attachment showing the correct attachment of the bar on the inside of the down tube The detail view shows the sequence of components 1 Bolt head to the inside of the control frame 2 Tube 3 Nylon Washer 4 Down tube clamp both sides 5 Wing nut turned until both sides of the down tube clamp contact Ensure the training bars are held securely 6 Safety pin WARNING WHEN INSTALLING TRAINING BARS ENSURE THAT THE BASEBAR SAFETY WIRE IS REINSTALLED CORRECTLY THE BOLT WHICH ATTACHES THE SAFETY WIRE IS REMOVED AND REINSTALLED WHEN THE TRAINING BARS ARE INSTALLED Notes Photograph shows faired downtubes The attachment to the base bar a pip pin or bolt secures the training bar to the base bar and also secures the control frame knuckle A longer pip pin or bolt is necessary for the larger diameter tube of the training bar Figure 35 LHS Training Bar Attachment Issue 1 0 2007 52 AirBorne WindSports Pty Ltd Wizard Maintenance Manual APPENDIX Condition Inspection Checklist Wing Maintenance Log S N Date Hours Maintenance Work Performed Maintained by Section or Service Bulletin
35. ally trained These tasks are not necessarily included in the Maintenance Manual This Maintenance manual is created with the focus to maintain Special Light Sport Aircraft S LSA This category of registration allows the aircraft to be used for hire and reward Maintenance requirements are given in the maintenance schedule tables Note that the level of qualification is given for each of the tasks Notice that this manual prescribes owner maintenance and repairman maintenance The minimum applicable repairman ratings for each category of registration are as follows E LSA registered LSA Repairman Inspection certificate LS I S LSA registered LSA Repairman Maintenance certificate LS R In both cases of E LSA and S LSA a person who holds a mechanic certificate with A amp P rating or part 145 repair station may perform maintenance and inspections on the LSA The 100 hourly or annual inspections on a S LSA are to be performed by the holder of a LSA Repairman Maintenance certificate an appropriately rated Mechanic with Airframe and Powerplant A amp P rating or a part 145 Repair Station The holder of a sport pilot certificate may perform preventive maintenance on an aircraft owned or operated by that pilot and issued a special airworthiness certificate in the light sport category Items of preventative maintenance that may be performed by an owner are listed in FAR 43 appendix A Section A43 1 Issue 1 0 2007
36. attachment The U bracket has two components a shaped channel and a negative block that is attached in to preclude the keel from moving out the bottom of the bracket The U bracket should be checked thoroughly after any unusual loads Issue 1 0 2007 Page 51 WindSports Pty Ltd Wizard Maintenance Manual 95 SPECIAL PURPOSE EQUIPMENT 95 10 00 Training Bars The training bars are supplied as an option for use by qualified instructors in order to teach people to fly the aircraft and with more experienced students to fly the aircraft from the rear if necessary The training bars attach to the wings base bar and down tubes and provide control extensions toward the back of the aircraft for rear occupant usage 95 10 10 Training Bar Maintenance The training bars are likely to be installed and removed often therefore it is important that the components are accounted for each time that they are removed and installed see drawing number 6505 in the Illustrated Parts Catalogue The bars are specific for the left and right hand sides and need to be installed on the inside of the down tubes They should be inspected for bending and at each of the bolt holes and welds as well as any other wear that may occur each time they are installed If they are permanently affixed to the aircraft they need to be inspected at regular intervals The frequency of inspection will depend on the amount that they are used Prior to e
37. bars and leading edges The control frame 15 bolted to the keel through the U bracket The fittings at the top of the control frame allow relative movement between the U bracket and the control frame This is necessary because of the movement between the base and the wing during the weight shift control actions Leading Edge The leading edges are mainly constructed from 6061 T6 Aluminium The leading edges are mainly loaded in bending and compression and share loading with the cross bars during positive and negative flight loads The leading edges are attached to the keel through the two nose plates at the front of the wing and via a bolt assembly to the cross bars and the outboard wires The rear leading edges fit inside the leading edge tubes which locate onto a horizontal bolt in the leading edge assembly The rear leading edges are a part of the leading edge but are made in order that they may be removed for ease of shipping Cross Bars The cross bars are mainly constructed from 6061 T6 aluminium The cross bars 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 The top and bottom side
38. d or replaced they become illegible or damaged in service Replacement placards may be purchased from an Airborne dealer or direct 11 10 00 Required Placards The placards on the aircraft are designed to provide information regarding general aircraft limitations and other details for the safe operation of the aircraft The placards that are required for operation of this aircraft are available in the Aircraft Operating Instructions Section 4 5 Placards Issue 1 0 2007 Page 39 AirBorne WindSports Pty Ltd Wizard 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 15 critical 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
39. dge Rear Assembly Trike Wing Adjustable Page 1 of 1 Leading Edge Rear Assembly Trike Wing Adjustable Leading Edge Rear Assembly Trike Wing Adjustable Dwg No A4 5228 15 02 2005 jPatNo 144444 25 WzRHS 104669 TRIKE WING LEDGE TENSIONERIHS 1 104740 TRIKE WING L EDGE TENSIONER RHS 1000 2 REAR WIZARD ARS 104101 L EDGE REAR WIZARD II amp IIl LHS 1 000 6 104668 CAPCHAIRLEG 16MM 21 64INHOLE 1000 1000 8 100310 2 0750 0790 file L foxpro25 STOCK export A4 5228 HTM 15 02 05 WASSV JWYHJ4HIY 2002 21 81 SsuD eie Ag ume aie SIMYSHLO SLAOASUNIM umoys 100 AITTA Tr 19 MIEGWASSV H3LSfI QV DNIM Lv vV A T8IN3SSV T1333 HV3H dO L 3I VH cSZv vV 5 1504 ve9r vv A 18N3SSV UVA ONINIVH L 6 8225 ATEWASSYV c9v vv MIEGWASSV NOILONN 3 l HV8 X ATANISSV MOVE Tin id dva x ATANISSV H3NHOO AWVYs V A18IN3SSV NOLLONNP ISON NOILdIHOS3d Wizard Iii Sail Airframe Assembly Page 1 of 1 Wizard Sail Airframe Assembly Wizard Sail Airframe Assembly Dwg No A4 5323 07 09 2004 w PartNo 101506_ HAT AIRBORNE INCL GLIDERLOGO 00 oma REAR WIZARD WRHS ASSEMBLY
40. e safetied after installation This prevents them from loosening in flight due to vibration Self Locking Nuts Self locking nuts are used throughout the airframe Self locking nuts may be reused but not if they can be run on the thread by hand without using tools After a self locking nut has been tightened at least one full thread pitch of the male thread must protrude through the nut locking feature Loctite On any bolt that does not have a Nyloc type locking mechanism Loctite 243 should be used to prevent premature loosening On the U bracket Loctite 262 Red High Strength needs to be used Issue 1 0 2007 Page 42 AirBorne WindSports Pty Ltd Wizard lll Maintenance Manual 27 FLIGHT CONTROLS 27 00 00 General The Wizard wing uses weight shift control This means that there is no need for most of the traditional flight control surfaces such as flaps and rudders The pilot uses the control bar to shift weight relative to the attachment point of the base to the wing which in turn causes a reaction in the wing and the control response of the aircraft 27 30 00 Reflex Bridles Reflex bridles produce longitudinal stability when the wing is at zero or negative angles of attack The reflex bridles work by stopping the trailing edge of the wing moving downward as they are tethered to the king post assembly When the wing has any negative load on the top surface the rest of the lifting surface will move downward relative to the trail
41. er the wing will still experience UV degradation e lfawing 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 Figure 32 Bettsometer Instrument example supplier http www conairsports co uk 57 30 20 Minor tears or rips in the sail Minor sail repairs are a Line Maintenance task which Sport Pilots are suitable to perform unless local regulations prohibit owner maintenance for sails A repair is classified as minor if tears are less than 30mm long provided that no free edges s
42. ere is a significant amount of wind it is advisable to have assistants to hold the side wires The wing should be moved with the nose facing into the wind CAUTION ENSURE THAT WHEN MOVING THE WING IN WINDY CONDITIONS THAT THE NOSE IS KEPT LOW WHEN FACING INTO THE WING THE WINDWARD TIP SHOULD ALSO BE KEPT LOWER TO AVOID THE WING RISING 9 10 00 Ground Transportation Avoid damage to your wing by using well padded racks Careless transportation can cause considerable damage to your wing We recommend that you support the wing in at least 3 places to spread the load The wing should be transported with the control frame down to minimise the chance of damage to the cross tubes Flat straps should be used for tie downs to avoid damage to leading edge mylar Store the wing in a dry room off the ground Air the wing out regularly to avoid mildew and never store wet Issue 1 0 2007 37 AirBorne WindSports Pty Ltd Wizard lll Maintenance Manual 10 DERIGGING 10 00 00 General For derigging and storage see Sections 4 of the Aircraft Operating Instructions or Pilots Operating Handbook as appicable Issue 1 0 2007 Page 38 AirBorne WindSports Pty Ltd Wizard 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 repaire
43. ex bridles are correctly routed e Check the battens against the template e Check that the sail webbing is correctly mounted on the leading edges and tensioned to the correct mark e Check the keel is straight e Check that the leading edges are straight and that the rear leading edges are located correctly To check your battens use the following procedure e Remove the battens from the wing after the wing is de tensioned as required during the pack up phase See Pilot s Operating Handbook for pack up procedures e Lay the template out on a flat surface e Note whether the battens have been reflexed Do not change the reflex initially The battens may have already been reflexed to correct a turn Start with the keel batten lining the nose of the batten up with the start of the line The line should be above the batten e f the batten does not line up gently apply pressure using your hand or knee to get a smooth curve After checking as noted above a turn can be remedied by adjustments as outlined in the following table Issue 1 0 2007 48 AirBorne WindSports Pty Ltd Wizard Maintenance Manual Roll Tuning Matrix The following table outlines procedures for tuning a wing to correct a turn applied after adjustment See Section 0 Assembly After Shipping for tip adjustment details Adjustment Method Remedy Left Turn Remedy Right turn Cc gt Batten Tip Ends The main sail batten tip end The ma
44. han 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 degradation of wires requires replacement 5 20 00 Scheduled Maintenance Checks General care should include Washing down the tube with warm water and light detergent followed by rinsing with fresh water Fabric sponged with warm water and 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 microlight
45. hould be used in conjunction with a certified base and therefore the operator is directed to reference the base maintenance manual for any issues that are related to the base component of the aircraft Skills Only people with an adequate skill level should perform maintenance on this aircraft A sound understanding of mechanical systems and good experience with the necessary tools and procedures 15 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 Repairman Maintenance This certification authorizes a certificate holder to perform line maintenance repairs and a
46. in sail batten tip end Unclip batten ends Rotate batten tension can be increased 2 tension can be increased 2 9 ends clockwise to reduce tension 4 turns on the left wing The 4 turns on the right wing rotate batten ends anti clockwise to tension on the right can The tension on the left can increase tension Note Tip batten decreased the same be decreased the same tuning has more effect on turn tuning amount if required amount if required than the root battens Tip Angle Adjustment The angle of the tip can be adjusted Rotate the left tip down Rotate the right tip down by rotating the angle of the tip clockwise 1 hole and re anti clockwise 1 hole and Adjustment requires removal of the install screw more re install screw If more stainless screw which secures the adjustment is required adjustment is required webbing bung The tip bung is rotate the right tip up rotate the left tip up rotated and the screw is re installed clockwise 1 hole and re anticlockwise 1 hole and Q in the appropriate hole Reduction in install screw re install screw leading edge tension will simplify procedure Ensure correct tension is SIGNIFICANT TURN Batten Reflex Adjustment One of the most effective ways to tune a more significant turn is to reflex the root battens Contact the factory for details for reflex tuning The wing needs to be removed from the base and de tensioned The battens sh
47. ing edge effectively creating elevator type control surfaces that produce a positive pitching moment helping to restore level flight Issue 1 0 2007 43 AirBorne WindSports Pty Ltd Wizard lll Maintenance Manual 57 WINGS 57 00 00 General The main structure of the wing comprises of aluminium tubing and stainless steel wire The lifting surface is constructed from Dacron polyester fabric The wing is subject to maintenance checks and preflight procedures that must be carried out prior to flying Any dents crazing bends except for tube bending caused by normal flight and set up loads corrosion or other distortion of the wing structure renders the wing unsafe to fly Secondary structures of the aircraft are limited to extension structure 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 kee
48. l Major components from the front to the rear of the keel Nose Plates The nose plates are bolted to the keel and provide attachment points from the leading edges to the keel They are attached to the keel with bolts The nose plate bolts also attach the stainless U channel where the front wires attach to the swan catch U Bracket The U bracket provides a mounting point for both the control frame and the trike mast the main attachment point for the base to the wing The U bracket is allowed to rotate around the keel and 15 held in position longitudinally with acetal bungs which are bolted to the keel Quick Clip The quick clip is bolted to the keel with the same bolt used to attach the rear wires King Post The king post assembly is a vertical post from the keel of the wing which supports the reflex bridles the top front and back wires and the top side wires The king post works in compression and is located on the keel using a locating pin The main material is 6061 T6 aluminium for both the tubing and the fittings Control Frame The control frame is constructed mainly from 6061 T6 aluminium The control frames down tubes work mainly in compression due to the positive loading of the wing which is reacted through the Side wires Issue 1 0 2007 44 AirBorne WindSports Pty Ltd Wizard Maintenance Manual and base bar sections The base bar works mainly in tension through the side wire loads from the cross
49. le that some tubes may be bent therefore close inspection of all the tubes is necessary It is suggested that the sail should be removed from the frame every 500 hours to check for any signs of fatigue or damage from general wear and tear The main points to check are Cross bar hinge joint Cross bar leading edge joint deformation in the bushes Leading edge nose joint deformation in the bushes Nose plates Straightness of the tubes Elongation of boltholes Damaged wires Damage to bolts Damage to sail NOTE If any part of the aircraft has any signs of damage the part should be replaced prior to re installing the frame Issue 1 0 2007 21 WindSports Pty Ltd Wizard 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 15 ideal It is a good practise to note the order of washers and other fittings prior to disassembly and to have small container to put the hardware in The Illustrated Parts Catalogue should be referenced for correct assembly NOTE Wherever possible perform an operation on one side of the wing and completely reassemble it before continuing wi
50. llustrated Parts Catalogue e Rotax Owners Manual e Rotax Maintenance Compact Disk Radio Manual If Installed BRS Parachute Manual If Installed Issue 1 0 2007 Page 2 AirBorne WindSports Pty Ltd Wizard Maintenance Manual AMENDMENT RECORD SHEET Affected Affected Pages Date Inserted Signature Sections Amendment Date Table 1 Amendment Record Sheets NOTE Airborne s data packages will be revised from time to time Owners registered on AirBorne s database will be notified of any changes to data and directed to the AirBorne web site http www airborne com au for the applicable pages The amended pages should be printed and the prior page replaced in the folder as soon as possible The amendment table should at that time be updated with the appropriate details and date Revised pages will be sent by mail if requested Issue 1 0 2007 3 AirBorne WindSports Pty Ltd Wizard Maintenance Manual INTRODUCTION This manual contains factory recommended procedures and instructions for ground handling servicing and maintaining the Wizard 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 s
51. lterations 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 on airframes or powerplant as the rating allows Task Specific Applicable to the following ratings LSA Repairman Maintenance with appropriate task specific training or A Mechanic Certificate with appropriate task specific training Authorizes the holder of mechanic certificate or a repairman certificate who has received task specific training to perform the tasks approved under that training Allows a repairman certificate holder to perform heavy maintenance repairs and alterations on the SLSA E g The Mechanic Certificate holder may obtain Task Specific training on Rotax engines to allow overhaul etc Skills and authorisations specific to Experimental Special Light Sport Aircraft LSA Repairman Inspection To 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 0 2007 4 AirBorne WindSports Pty Ltd Wizard
52. main bolt or the keel as well as all of the other effected components If the landing resulted in contact with the ground then obviously these parts will require extra attention The tubing relies on being intact in perfect condition for full strength If tubing is bent or kinked in any way then it should be replaced prior to flying This includes its attachment point to bolts The battens should be checked against the supplied batten profiles and the opportunity should also be taken to inspect the batten fittings 5 50 20 Inspection after heavy turbulence The main areas of wing structure that require attention after severe turbulence are the attachment points for structures These include the front and rear wires the side wires and the main hang point The sail should also be inspected for any strain or tearing that may have occurred though this is very unlikely All of the tubing should be inspected for bending including the battens against the supplied batten profiles The opportunity should be taken to inspect the batten fittings at the same time If the base bar has made contact with the mast brace at any time during flight then they should both be checked 5 50 50 Sail removal The sail should be removed for close inspection of the airframe if the frame is suspected of suffering any damage for example having bent tubes following a heavy landing blow over or crash If the wing suddenly develops a turn after severe turbulence it is possib
53. n US quart Cubic foot ft k Degree Fahrenheit F Inch Pound in Ib Foot Pound ft Ib Table 2 Imperial Metric Conversions Issue 1 0 2007 0 4536 Kilogram kg 6 895 Kilopascal 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 1 28 317 Litres 1 1 8 X C 32 0 113 Newton Metres Nm 1 356 Newton Metres Nm Page 7 AirBorne WindSports Pty Ltd Wizard Maintenance Manual CONTENTS 0 ASSEMBLY AFTER SHIPPING op api 10 4 AIRWORTHINESS LIMITATIONS ese tto eiie tee eoi te 13 5 TIME LIMITS MAINTENANCE 5 14 6 DIMENSIONS AND AREAS Eee sip DE M 35 9 GROUND HANDLING 12 pine orto season 37 38 11 REQUIRED PLACARDS 2 39 20 STANDARD PRACTICES AIRFRAME 40 2T ELIGHDECONTHROES itti toilet 43 57 WINGS A ME 44 95 SPECIAL PURPOSE
54. nce manual and aircraft log book Issue 1 0 2007 19 AirBorne WindSports Pty Ltd Wizard Maintenance Manual 5 20 10 Wing Airframe Maintenance Schedule WING Manual MAINTENANCE Section AIRCRAFT OR ITEM HOURS OF OPERATION SCHEDULE Inspection Items Reference 100 200 300 400 500 600 700 800 900 1000 Sail Bettsometer testing 57 30 00 2 R 2 R 2 R 2 R 2 R 573000 2 R 2R 2R 218 2IRI 2IRI 2 R 28 218 2 R 573000 2 R 2R 2R 218 2 2IRI 2 8 218 218 2 R Tip assembly and webbing Correct tension 00 10 00 2 R 2 R 2 R 2 R 2 R 2 R 2 R 2 R 2 R 2 R set As directed 218 2 R 2 R 2 R 218 218 218 2 2 8 218 Batten fitting latch secure As directed 3 R 3 R 3 R 3 R 574000 218 2R 2 R 208 2 R 218 218 2 8 218 21R As directed 3 R 318 41 6 As directed 418 3 R 3 R 6 R Leading edges keel cross bars and down As directed 2 R 2 R 2 R 2 R 418 2 8 2 8 48 218 6 R dents and corrosion Remove frame for
55. ny specific authorized training R E LSA Repairman Inspection Applicable to E LSA registration Repairman Inspection ltems that can be expected to be completed on an ELSA by a responsible owner who holds an FAA repairman certificate light sport aircraft with an inspection rating or equivalent R S LSA Repairman Maintenance Applicable to S LSA registration Repairman Maintenance Items that can be expected to be completed on a S LSA or E LSA by a responsible individual who holds a FAA repairman certificate light sport aircraft with a maintenance rating or equivalent A amp P Mechanic Certificate with Airframe and or Powerplant Training A amp P lItems 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 specific
56. o Sail Position Keel Pocket forward of Rear Wires Have someone hold the nose of the wing up so the bottom rear flying wires are loose Remove quick clip nut and bottom rear flying wires Slide keel pocket up until the sail tang aligns with the quick clip bolt hole Re insert quick clip bolt and attach washer sail tang and rear flying wires tighten nut see drawing 6485 in Illustrated Parts Catalogue Let the nose down Slide the rest of the sail up to the nose Insert dive sticks through their holes Figure 18 Position Keel Pocket Forward Of Rear Wires Issue 1 0 2007 Page 28 AirBorne WindSports Pty Ltd Wizard Maintenance Manual Guide Cross Bars Through the undersurface Once the sail is 34 onto the frame insert the cross bars into the neoprene holes Figure 19 Cross Bars Inserted Through Sail Spread Wings Spread each wing apart 1 4 of the way alternately on each side until fully open making sure sail is loose and free at all times Figure 20 Spread the Wings Apart Attach Front Top Wires Lay king post assembly out at the back of the wing Feed top front wire back through the nose cone then back through the sail Attach tang to nose bolt see illustrated parts catalogue 25 8 2004 Figure 21 Attach Front Top Wires Issue 1 0 2007 29 AirBorne WindSports Pty Ltd Wizard Ill Maintenance Manual Fit Side Wires Feed bottom and top
57. ould be shaped to the template and re installed The battens 3 4 5 amp 6 on the left side should be reflexed as per batten profile The battens 3 4 5 amp 6 on the right side should be reflexed as per batten profile Table 9 Tuning Procedure If after tuning the turn persists consult your authorised dealer or the factory Issue 1 0 2007 Page 49 AirBorne WindSports Pty Ltd Wizard Maintenance Manual Figure 33 Adjusting Tip Angle Sail Not Fitted DECREASE Figure 34 Adjusting Batten Tension Pitch Tuning Trim speed at MTOW 15 Wizard wing 35 37 KIAS If the wing 15 trimming outside the specified trim range a forward movement of the keel roller on the keel tube can be used to trim the wing A one hole adjustment will see a typical change in trim of 5 knots Moving the roller to the forward position will increase the trim speed whilst moving the roller rearward will decrease the trim speed The illustrated parts catalogue should be referenced for correct reassembly Issue 1 0 2007 Page 50 AirBorne WindSports Pty Ltd Wizard Ill 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
58. ports Pty Ltd Wizard Ill Maintenance Manual Unroll Sail Unroll sail enough to access reflex bridles Undo reflex bridle shackles from sail Figure 10 Unrolling Sail Remove Nose Webbing Undo sail webbing nut and remove sail webbing Replace nut finger tight see Drawing 6474 in Illustrated Parts Catalogue 25 8 2004 Figure 11 Removing Nose Webbing Unbolt Top Front Wire Unbolt top front wire from nose junction and replace nut finger tight Raise nose slightly and feed wire back through sail king post will now be detached Remove nose battens if inserted Figure 12 Unbolting Top Front Wire Issue 1 0 2007 25 AirBorne WindSports Pty Ltd Wizard Ill Maintenance Manual Remove Airframe from Sail Leave control frame attached and carefully slide frame out through the nose of the sail Figure 13 Removing Airframe CAUTION DO NOT FORCE SAIL IF IT SNAGS STOP AND FIND WHAT 1175 CAUGHT ON Issue 1 0 2007 Page 26 AirBorne WindSports Pty Ltd Wizard Ill Maintenance Manual 5 50 60 Frame Reinsertion After the frame has been removed for inspection the frame must be properly reinstalled to maintain a high level of safety Particular attention must be paid to the correct orientation of bolts and washers It is advisable that all nuts that are removed are replaced with new ones or as a rule Nyloc nuts should not be reinstalled more than twice WARNING REFER T
59. pyright Notice O Copyright Airborne Windsports Pty Ltd 2004 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 5 1 DISCLAIMER 2 INTRODUCTION 3 WING and AIRFRAME PART DRAWINGS 3 01 Trike Wing A Frame Corner Assembly 3 02 Wizard and Streak Nose Junction Assembly 3 03 Wizard and Streak X Bar to Leading Edge Assembly 3 04 Trike Wing King Post Type 2 3 05 Wizard 2 and Top and Rear Keel Assembly 3 06 Rear Leading Edge Assembly 3 06 Wizard 3 Sail to Airframe Assembly 3 07 Wizard X Bar Hinge Pullback Assembly 3 08 Quick Clip Block 3 09 Batten Interchange Table 3 10 Trike Wing Frame Interchange Table Drawing 2310 Drawing 4622 Drawing 4623 Drawing 4752 Drawing 4759 Drawing 5228 Drawing 5323 Drawing 5333 Drawing 7048 Drawing 6712 Drawing 6713 DISCLAIMER This manual has been prepared to assist in the identification of items that may be required for spare parts Approved changes may have been made to the aircraft prior to and after this set of drawings was created Full comparison and identification must be ensured before use Airborne is in no way responsible for the quality of workmanship of people that use this manual and all persons m
60. rotectors onto the sail at the tip Assemble Assemble in accordance with the Pilot s Operating Handbook Issue 1 0 2007 11 AirBorne WindSports Pty Ltd Wizard Maintenance Manual Preflight CAUTION A THOROUGH AND COMPLETE PREFLIGHT 15 ESPECIALLY NECESSARY AFTER REASSEMBLY THOROUGHLY CHECK ALL NUTS AND BOLTS REFER TO SECTION 5 FOR TORQUING PROCEDURES BEFORE TIGHTENING ANY NUTS WIRE ROUTING SAIL FIT MYLAR SHAPE AND OVERALL SYMMETRY OF THE WING BEFORE FLIGHT Preflight as described in the aircraft flight manual paying particular attention to possible damage to the airframe during transport Issue 1 0 2007 12 AirBorne WindSports Pty Ltd Wizard 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 Wires 961 Check For Service Life Announcements Replace if there are no revisions Tubes 961 Check For Service Life Announcements Replace if there are no revisions Sail 1000 Mandatory Replacement Table 3 Airframe Limitations The airframe was analysed using FAA fatigue analysis Fatigue Evaluation Of Wing and Associated Structure on Small Airplanes
61. rument Various general care items specified where needed This list may not be comprehensive Format The manual has been prepared using the ATA format which provides a standard layout of the chapters to be included and their content Some of the chapters are not included as they are deemed to be not applicable to this aircraft The information in this manual is based on the data that was available at the time of its publication The latest amendments to this manual will be issued on the Airborne website in PDF format This should be printed out and added to the manual Therefore it is important that operators keep a regular check on the website for any amendments that have been made If any errors or omissions are found in this manual please advise the factory Service Difficulty Reporting Any service difficulties or defects should be reported to Airborne using the form contained in appendix A Issue 1 0 2007 Page 5 AirBorne WindSports Pty Ltd Wizard 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 CHARACTERISTI
62. s 50 Figure 34 Adjusting Batten Tension ccs ee qoe ette ea ees de 50 Figure 35 LHS Training Bar Attachment iia 52 Issue 1 0 2007 Page 8 AirBorne WindSports Pty Ltd Wizard Maintenance Manual Tables Table 1 Amendment Record 1 21 2 1 0101000000100000100000 nnne nennen 3 Table 2 Imperial Metric SERERE 7 Table 3 LimitaionS oen da m a m ud end 13 Table 4 Maintenance Prvledes cui att utt eoi te e ite atto ite o det dte eic aie 16 Table 5 Scheduled eor opor cono od boo or DE n P RED DS 20 Table 6 Airborne Final QA Inspection 34 Table 7 Dimensions And Areas 36 Table 8 Torque Settings For The Wing 41 Table 9 Tuning PEIOGSQUEIG a d o idco tero cl a A 49 Table 10 Condition Inspection Checklist ein erra terror ere Fera sepa co nara na 53 Table ti Feedback e PA enden pr ER 54 Issue 1 0 2007 9 AirBorne WindSports Pty Ltd Wizard 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
63. s is only valid provided that all necessary maintenance modification and service requirements are fulfilled These requirements include a Maintenance of aircraft as per the Maintenance Schedule in this manual e b Modification as detailed in any relevant Service Bulletins Modification to approved details obtained from Airborne WindSports Pty Ltd d Repairs necessary to replace minor damage wear or ageing e Servicing replacement and overhaul inspection and checking in compliance with the Maintenance Schedule f Any Airworthiness Directory AD issued by CASA or the NAA of the country of registration Issue 1 0 2007 15 AirBorne WindSports Pty Ltd Wizard Ill 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 l Sport Owner LS M LS M Pilot Sport A amp P A amp P Pilot part 145 part 145 repair repair Daily Inspections Preventative Maintenance Repairs Major Maintenance 100 hour inspection Annual Inspection Authorized to perform May perform only if the Repairman Inspector is the owner of the aircraft
64. sail Drop in King Post WIZARD II Introduced so that same wing Short Keel was suitable for Australian and Export Market Shorter keel pocket allowing pull back wires over top of sail Drop in King Post Shorter Rear Leading Edges to accommodate Leading Edge Tensioners Shim Type Re designed Kpost top to allow seperate top wires WIZARD III Adjustable Leading Edge Tensioners Allen Key Sail rear webbing Dual to suit Tensioners Spring Battens Hinge Battens from WZ 830 Neoprene on XBar holes THIS DRAWING IS AN EXCEL WORKSHEET 14 AIRBORNE WINDSPORTS Pty Ltd TRIKE WING FRAME RD NA 20205 INTERCHANGE WIZARD SERIE 6713
65. structions that are necessary for a safe aircraft lt is to be used as a reference only Issue 1 0 2007 33 AirBorne WindSports Pty Ltd Wizard Maintenance Manual QA Inspection Form applicable to Wizard wings WIZARD WING FINAL QUALITY INSPECTION GJP 129 Work Order No W Line WIZARD Check Operation Security and Finish Left Hand Side Right Hand Side 6 TopFrontWires 8 DownTubestopassembly 2 _______________ D Tube Stops Tip Webbing Located Correctl 27 Reflex Bridle Shackles Pull Back Wires Quick Clip 29 Bottom Rear Wires King Post Top Assembly King Post Base Placard 32 Serial number Placard Include Test Fly Sheet Table 6 Airborne Final QA Inspection Sheet Issue 1 0 2007 Page 34 AirBorne WindSports Pty Ltd Wizard lll Maintenance Manual 6 DIMENSIONS AND AREAS 6 00 00 General This section gives general dimensions for the wing It should be noted that this is a flex wing aircraft and the dimensions that are given will be different depending on the loads on the wing In general the dimensions that have been supplied are those without the sail on the wing which bends the leading edge and slightly reduces the wing span and with the wing on the ground resting on the base bar As the wing is loaded in flight the lower wires will become taut and the amount of anhedral will reduce changing the geometry and dimensions to
66. th the other side This method gives an easy reference to the reassembly sequence that is required for correct and safe operation De Tension the Tip Undo hook and loop retaining straps at rear leading edge Wind tip tensioner inward clockwise to de tension the tip webbing Remove sail webbing from rear leading edge Figure 4 De Tensioning the Tip Issue 1 0 2007 22 AirBorne WindSports Pty Ltd Wizard Maintenance Manual Remove Rear Leading Edges Spread leading edges approximately 1 12 metres apart Remove rear leading edge from airframe Figure 5 Removing Rear Leading Edges Unbolt Side Wires Unbolt top and bottom side wires from cross bar and feed wires back through sail Figure 6 Unbolting Side Wires Issue 1 0 2007 Page 23 AirBorne WindSports Pty Ltd Wizard Maintenance Manual Unbolt CrossBar Junction Undo bolt remove cross bar from leadind edge channel Replace washers and nut onto the channel Figure 7 Unbolting Crossbar Junction Remove Quick Clip Nut Remove quick clip bolt padding Undo quick clip bolt and remove sail webbing bottom rear wires and bolt from airframe see Drawing 6485 in Illustrated Parts Catalogue Figure 8 Removing Quick Clip Nut Remove Top Front to Back Wire Unbolt top front to back wire from pull back wire shackle Figure 9 Removing Top Front To Back Wire Issue 1 0 2007 AirBorne WindS
67. ting Keel Into t eri Eee rer atur e Saeed pee 28 Figure 18 Position Keel Pocket Forward Of Rear 28 Figure 19 Cross Bars Inserted Through 29 Figure 20 Spread the Wings Coro eos RR 29 Figure 21 Attach Front Wires uuo deir erro rene eene dece rre e per oie 29 22 qu detect d e 30 Figure 23 Reattach Cross uei ea 30 Figure 24 Locate 30 Figure 25 Fit King Post 22555555 A 31 Figure 26 Fit Reflex ee 31 Figure 27 Shows Crossbar Pull Back In Place ass 31 xe usa Morte A A 32 Figure 29 Insert Dive Stick Into Leading Edge 32 Figure 30 Nose Webbing MC Cm 33 Figure 31 Major Dimensions 35 Figure 32 47 Figure 33 Adjusting Tip Angle Sall io
68. ting bolt should be slightly tighter Bottom Corners than just not loose but the D shackle and base bar knuckle should be able to be rotated by hand Loctite is not required 7 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 Illustrated Parts Catalogue 9 Top Side Wires Just not loose 10 Bottom Side Just not loose Wires 11 Reflex Bridle Firm tighten to the end of the thread use Loctite 243 Shackles 12 Pull Back Wires Tighten till 1 2 threads are showing NOTE The wires that locate on the bolt will float slightly from side top side see drawing 6483 Illustrated Parts Catalogue there will be three wires in the pull back shackle with the inclusion of the top front back wire 13 Quick Clip Bolt Just not loose see Illustrated Parts Catalogue and Bottom Rear Wires 14 King Post Top The acetal fitting which attaches to the king post should be tightened to Assembly approx 10 Nm firm see Illustrated Parts Catalogue Locate the wires their correct position The cover is held in place with four self tapping screws Table 8 Torque Settings For The Wing Issue 1 0 2007 Page 41 AirBorne WindSports Pty Ltd Wizard Maintenance Manual 20 20 00 SAFETYING PROCEDURES All bolts and nuts except the self locking type should b
69. tion of the metal may indicate corrosion Salt is the most common cause of corrosion during coastal operation Parts affected by salt must be stripped and thoroughly cleaned before reassembly The cause of the corrosion must be identified and eliminated If corrosion pitting or oxidation is present the component must be removed and replaced with a new part Exposed wires may be protected from corrosion by applying a water dispersant such as WD 40 RP7 or Inox using a rag wetted with the water dispersant Such treatment is only required in corrosive environments Preventative treatment may be applied as required Issue 1 0 2007 14 AirBorne WindSports Pty Ltd Wizard Maintenance Manual Replacement Aluminium tube comes in many different sizes and grades As sections of the airframe manufactured from tube made specifically to Airborne s specification it is important that only genuine replacement parts as supplied by Airborne WindSports Pty Ltd are used Airframe Bolts All airframe bolts are either aircraft quality or high tensile bolts If it necessary to replace any bolts or nuts it is important that the specification of the original bolt are matched when a replacement is selected This applies not only to the grade of the bolts but to the length as well Installation amp Removal e After tightening all bolts should have at least 1 to 2 threads showing e All self locking nuts should not be installed more t
70. uch 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 0 2007 Page 47 WindSports Pty Ltd Wizard 1 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 INCRIMENTAL MAJOR CHANGES WILL CAUSE THE WING TO PERFORM BADLY AND MAY BE DANGEROUS If you feel that the wing requires adjustment to trim in the roll or the pitch axis you should check that the problem is not caused by something asymmetrical in the frame or the battens order of priority check the following Ensure that the wires especially the refl
71. ust abide by local regulations regarding maintenance of aircraft INTRODUCTION 1 1 About This Manual This parts catalogue has been prepared to aid in the identification of components that may effect the airworthiness of the Airborne Wizard Series of Wings Drawings with various levels of detail are supplied that include all of the spare parts available specific to the serial number identification of the wing Each of the parts listed are available as spare parts lf 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 15 the identification system that should be used to order spares eg Shackle RF615 4mm Part Number 100406 and the quantity required 20 90 71 did AV3YLS 8 Xd ZIM 0 Lez ey ATINISSV SSYLAWITIIW NI SNOISNAWIG TIV SEU STE IZ dV 26 11 80 5 8 SHIM UVA 3SV8 56 11 01 LAN 40 SLYOdSUNIM ANYORUV SIN3AGN3IAV 5 1 335 TIV13G 395 MIA LNOdS 1 140 gt V OL quvoaino 3UIM HV3H
72. wires are a part of the bolting arrangement Battens The battens are mainly constructed from 7075 T6 aluminium The battens are located with batten pockets sewn into the sail The batten fittings at the trailing edge secure the battens into their pockets The battens help to maintain the profile of the wing during flight and are important to the correct and stable operation of the wing For this reason there 15 a batten profile that is supplied with each wing for the battens to be checked against WARNING DO NOT FLY THE WING WITH ANY OTHER BATTEN PROFILE THAN THAT SUPPLIED BY AIRBORNE AS VARIATION MAY HAVE SERIOUS EFFECTS ON THE FLIGHT PERFORMANCE STALL AND STABILITY CHARACTERISTICS OF THE WING Top and Bottom Side Wires The bottom side wires are stainless steel braided wires which are attached to the cross bars and the knuckle at the bottom of the control frame through swaged fittings The control frame end 15 attached via a stainless D shackle while the cross bar end has a fitting that allows a bolt to secure it Top and Bottom Front To Back Wires The bottom front back wires are stainless steel braided wires that have swaged fitting at each end for attachment to the nose catch control frame and keel Reflex Bridles The reflex bridles are mainly stainless steel wire swaged together and attached to the top of the king post via the top king post fitting and to the sail using D shackles Issue 1 0 2007 Page 45 AirBorne
73. y other mechanical wear of the component is reason for replacement The sail requires special attention to the condition of the fabric and Bettsometer tests will be required after significant amounts of environmental exposure to things such as UV radiation chemicals and heat as well as mechanical wear and or tears For instructions on Bettsometer testing see Section 57 30 10 Bettsometer Testing The Pilot s Operating Handbook outlines checks required prior to each flight Extreme operating conditions may reduce the time limits for components Unscheduled maintenance is detailed in Section 5 50 00 AirBorne will from time to time amend these maintenance checks as the service history of the aircraft evolves It is the responsibility of the pilot to ensure compliance with new directives Information is 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 Discoloura

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