Air Creation IXess 13 User manual

GDMMIX13-1G Version 0010 1
Maintenance Manual
Wing Type :
I
IX Xe es ss s 1 13 3
Aérodrome de Lanas, 07200 Aubenas, France
Telephone: [phone] • Fax: [phone]
[email protected] • http://www.aircreation.fr

1 Table of Contents
1Table of Contents....................................................................2
2Amendment Record Sheet .....................................................4
2.1Table of Amendments.......................................................................... 4
2.2Amendments........................................................................................ 4
3Introduction .............................................................................5
3.1Skills..................................................................................................... 5
3.2Tools .................................................................................................... 5
3.3Air Creation Directives ......................................................................... 6
3.4Units..................................................................................................... 6
3.4.1Use of Metric/Imperial Units...................................................................................6
3.5Main Airframe Description.................................................................... 6
3.5.1Keel ........................................................................................................................7
3.5.2Nose Plates............................................................................................................7
3.5.3U-Bracket................................................................................................................7
3.5.4King Post................................................................................................................7
3.5.5Tensioning U-channel ............................................................................................7
3.5.6Control Frame.........................................................................................................7
3.5.7Leading Edge .........................................................................................................7
3.5.8Cross Bars..............................................................................................................8
3.5.9Battens ...................................................................................................................8
3.5.10Top and Bottom Side Wires ...................................................................................8
3.5.11Top and Bottom Front Back Wires.........................................................................8
3.5.12Reflex Bridles .........................................................................................................8
3.5.13Trim ........................................................................................................................9
3.5.14Sail..........................................................................................................................9
3.5.15Special purpose equipment....................................................................................9
3.6Assembling from Shipping Crate........................................................ 10
3.6.1Reassembly Guide.............................................................................................. 10
3.7Ground Handling................................................................................ 11
3.8Transportation & Storage................................................................... 11
4Maintenance Checks.............................................................12
4.1General .............................................................................................. 12
4.2Time Limits......................................................................................... 12
4.3Scheduled Maintenance..................................................................... 13
4.3.1Wing Maintenance Schedule............................................................................... 13
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4.4Unscheduled Maintenance................................................................. 14
4.4.1General................................................................................................................ 14
4.4.2Inspection after Heavy Landing........................................................................... 14
4.4.3Inspection after Heavy Turbulence...................................................................... 14
5Standard Practices – Airframe.............................................15
5.1Torque and Safety procedures........................................................... 15
5.1.1Torque Procedures.............................................................................................. 15
5.1.2Safety Procedures............................................................................................... 15
5.2Sail Removal...................................................................................... 16
5.2.1Wing Dismantling Procedure............................................................................... 17
5.2.2Wing Reassembly Procedure.............................................................................. 18
5.2.3Sail Reinstallation................................................................................................ 23
5.3Inspection Notes ................................................................................ 30
5.3.1Tubing.................................................................................................................. 30
5.3.2Bolts..................................................................................................................... 31
5.3.3Cables & Terminals............................................................................................. 32
5.3.4Sail....................................................................................................................... 32
5.3.5Special Purpose Equipment................................................................................ 33
6Tuning ....................................................................................34
6.1General .............................................................................................. 34
6.2Adjustments ....................................................................................... 34
7Appendix................................................................................37
7.1Wing Inspection Forms ...................................................................... 37
7.1.1iXess 13 Wing Frame Stage Inspection (1)......................................................... 37
7.1.2iXess 13 Wing Final Assembly Stage Inspection (2)........................................... 39
7.2Method for Folding the Sail ................................................................ 41
7.3Maintenance Operation Board ........................................................... 43
GDMMIX13-1G Version 0010 3

2 Amendment Record Sheet
2.1 Table of Amendments
Amendment date Affected sections Affected pages Date inserted Signature
2.2 Amendments
The information in this manual is based on the data that was available at the time of its
publication. The latest amendments to this manual will be issued on the Air Création
website (http://www.aircreation.fr) in PDF format. This should be printed out and added
to the manual. The amendment table should at that time be updated with the appropriate
details and date. Therefore it is important for operators to check the website regularly for
any amendments that have been made. If any errors or omissions are found in this manual
please advise the factory.
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3 Introduction
This manual contains factory recommended procedures and instructions for servicing,
inspecting and maintaining the iXess wing. The procedures described are to be used in
addition to the particular governing body regulations for each country where the aircraft
is flown.
The operator is directed to reference the trike maintenance manual for any issues related
to the trike component of the aircraft.
3.1 Skills
It is assumed that only people with an adequate skill level will perform maintenance on
this aircraft. A sound understanding of mechanical systems, experience with the
necessary tools and procedures and knowledge of the specific flight mechanics of weight-
shift controlled aircraft is required – as the continuing airworthiness of the aircraft
depends on the competence of the person performing the maintenance. If there are any
doubts regarding the required and appropriate maintenance then an Air Creation technical
station should be contacted for the correct procedures and/or servicing.
All maintenance and repairs should be carried out in accordance with good aeronautical
practices.
3.2 Tools
There are no specialized tools needed for the maintenance described in this manual. The
following is a list of the type of tools that may be required.
Loctite® will be required in certain locations and should always be replaced after
disassembly.
•Loctite® 243 for the frame
•Open ended metric spanner set (6, 10, 13, 17mm)
•Dry lubricant – lubricant that doesn’t attract dust after application, like Teflon lubricant.
•Hex key set up to 8mm
•#2 Phillips screwdriver
•Various general care items, specified where needed
This list may not be exhaustive.
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3.3 Air Creation Directives
The information in this manual needs to be followed, and it is not acceptable to make
changes to the materials and or physical features of this aircraft.
Air Creation will from time to time issue airworthiness directives, which detail any
changes to the maintenance manuals, pilot’s operating handbook, or any other
details that air creation deems necessary for owners to be notified of.
The web address for Air Creation directives is:
http://www.aircreation.fr
3.4 Units
3.4.1 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 (lb) = 0.4536 Kilogram (kg)
1 Pound per sq in (psi) = 6.895 Kilopascal (kPa)
1 Inch (in) = 25.4 Millimeters (mm)
1 Foot (ft) = 0.3048 Meter (m)
1 Statute mile = 1.609 Kilometers (km)
1 Nautical mile (NM) = 1.852 Kilometers (km)
1 Millibar (mb) = 1 Hectopascal (hPa)
1 Millibar (mb) = 0.1 Kilopascal (kPa)
1 Imperial gallon = 4.546 Liters (L)
1 US gallon = 3.785 Liters (L)
1 US quart = 0.946 Liter (L)
1 Cubic foot (ft3) = 28.317 Liters (L)
1 Degree Fahrenheit (F) = (1.8 X C)+32
1 Inch Pound (in lb) = 0.113 Newton Meters (Nm)
1 Foot Pound (ft lb) = 1.356 Newton Meters (Nm)
3.5 Main Airframe Description
The wing is a very specific part of the aircraft.
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.
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3.5.1 Keel
The keel of the wing is mainly constructed from 2017A aluminum. Each of the major
components of the wing is attached to the keel. Major components from the front to the
rear of the keel:
3.5.2 Nose Plates
The nose plates are bolted to the keel and provide attachment points from the leading
edges to the keel. They are attached to the keel with bolts. The nose plate bolts also fasten
the U-channel to the keel. The gooseneck catch fastens the front wires to the U-channel.
3.5.3 U-Bracket
The U-bracket is the major junction for the three main components of the aircraft, the
wing (keel attachment), trike (mast attachment) and control frame (top knuckle
attachment). The U-bracket has two components, a U-shaped channel, and an internal
nylon sleeve.
The U-bracket is allowed to rotate around the keel, and is held in position longitudinally
by nylon rings that are bolted to the keel.
The U-bracket should be checked thoroughly after any unusual loads, especially torsional
ones.
3.5.4 King Post
The king post assembly is a vertical post perpendicular to 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 secured to the keel using a locating foot. The main
material is 6082 aluminum.
3.5.5 Tensioning U-channel
The cross bars tensioning U-channel is bolted to the keel with two bolts. These bolts are
used to attach the rear wires.
3.5.6 Control Frame
The control frame is constructed mainly from 6082 and 2017 aluminum. The control
frames down tubes work mainly in compression due to the positive loading of the wing,
which is reacted through the side wires and base bar sections. The base bar works mainly
in tension through the side wire loads from the crossbars and leading edges.
The control frame is bolted to the keel through the U-bracket. The fittings at the top of
the control frame allow relative movement between the U-bracket and the control frame.
This is necessary because of the movement between the base and the wing during the
weight shift control actions.
3.5.7 Leading Edge
The leading edges are mainly constructed from 7075, 2017 and 6082 aluminum. The
leading edges are mainly loaded in bending and compression .they share loading with the
cross bars during positive and negative flight loads.
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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.
3.5.8 Cross Bars
The cross bars are mainly constructed from 7075 aluminum .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 using a bolt assembly. The top and bottom side wires are a part of the
bolting arrangement.
3.5.9 Battens
The battens are mainly constructed from 7075 aluminum. The battens are secured by
batten pockets sewn into the sail. The batten ropes 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.
Do not fly the wing with any other batten profile than that supplied by Air Creation, as
variation may have serious effects on flight performance and stall characteristics of
the wing.
3.5.10 Top and Bottom Side Wires
The bottom side wires are stainless steel braided wires that are attached to the cross bars
and the knuckle at the bottom of the control frame by stainless steel plates, thimbles and
swaged Nicopress sleeves. The top side wires are attached to the kingpost head.
3.5.11 Top and Bottom Front Back Wires
The bottom front back wires are stainless steel braided wires that are attached to the nose
catch, control frame and keel by stainless steel plates, thimbles and swaged Nicopress
sleeves. The top front back wires are attached to the kingpost head.
3.5.12 Reflex Bridles
The reflex bridles are mainly stainless steel wire swaged together using Nicopress sleeves
and attached to the top rear wire via a pulley, and to the sail using shackles.
Reflex bridles produce longitudinal stability when the wing is at zero or negative angles
of attack. The reflex bridles work by preventing the trailing edge of the wing from
moving downward, as they are tethered to the king post assembly. When the wing has
any negative load on the top surface the rest of the lifting surface will move downward
relative to the trailing edge, effectively creating elevator type control surfaces that
produce a positive pitching moment, helping to restore level flight.
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3.5.13 Trim
There is a trim speed control device on all the iXess wings. The trim control is achieved
by a pulley system, which raises the reflex bridles. Raising the bridles causes the root
airfoil of the wing to be reflexed. The reflexed section causes the centre of pressure of the
airfoil to move forward resulting in a reduction in trim speed.
3.5.14 Sail
The sail comprises the lifting surface of the wing. It is mainly constructed of UV
protected Trilam and Dacron polyester fabric, with some ABS and 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 zippers that facilitate easy preflight inspection of
all the members inside the double surface wing.
3.5.15 Special purpose equipment
Training Bars
The training bars are attached to the control bar and uprights in order to extend the
possibility to fly the aircraft from the back seat. They are supplied as an option for use by
qualified flight instructors.
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3.6 Assembling from Shipping Crate
This procedure is to be followed if the wing arrives in a short packed configuration. An
approved dealer is responsible for assembly from the short packed configuration. The
short packed wing has had the rear leading edges removed to reduce the packed size for
transport.
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 Air
Creation factory.
3.6.1 Reassembly Guide
1. Remove wing from box. Take care that no staple damages the bag or the sail during this operation.
2. Unzip bag
3. Remove all wing straps. Remove padding from control bar and rear leading edges.
4. Unfold the ends of the sail
5. Assemble the control bar on the revolving base fixed to the left A-frame strut with the 6mm CHC
bolt, washers, thread locker and Nylstop nut and on the right with the push pin. Close the leather
protections.
6. Rotate the wing so that it is lying flat on the ground
7. Spread both leading edges approximately ½ meter. Remove the tip covers, which have been used
as protection on the rear of the front leading edges.
8. Insert rear leading edges in the tips opening of the sail with the plastic lugs at the rear of the tubes
positioned horizontally and to the inside. Finish sliding the rear leading edges in the front part.
Turn slightly and push in order to line up the half-hole and the horizontal bolt connecting the
crossbars on the front part of the leading edge. Make sure that the plastic lugs at the rear of the
tubes are face-to-face. Once installed the rear leading edge slot should be located on the channel
horizontal bolt. it should be impossible to rotate the leading edge, if correctly assembled.
Figure 3-1
9. Remove the self-tapping screws B 199010 (Refer to drawing OP10-24CA) which hold the sail
on the leading edge at the nose of the wing. This way, the sail will move back easily. Thread a
piece of string through the eyelets on the sail at the nose and tie it to the nose plates. You will have
to replace the nose screws using this string once the wing is fully open and tensioned. (See Figure
3-1.)
10. Attach the sail to the sleeves with the 4 screws FHC 6-70 (B167210). Make sure that the
aluminum guide retainer, which adjusts the tension, is facing the slot of the sleeve, at the tip of the
leading edge.
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