FlySynthesis Texan top class 580 ISR User manual

FLY SYNTHESIS
TEXAN TOP CLASS 580 ISR
MAINTENANCE MANUAL
(For Rotax 912 ULS)
02
15/02/11
Placard updated
C. Cosatto
C. Cosatto
C. Cosatto
01
20/12/10
Propeller auto pitch contr.
C. Cosatto
C. Cosatto
C. Cosatto
00
18/11/10
New manual issue
C. Cosatto
C. Cosatto
C. Cosatto
Num.
Date
Description
Issued
Verified
Approved
REVISION
FlySynthesis s.r.l. Reserves in terms of law the exclusive ownership of this manual and also forbids the whole or partial reproduction of it.

2
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Maintenance Manual
FLY SYNTHESIS TEXAN
TOP CLASS 580 ISR
(For Rotax 912 ULS
versions)
Identification: MM_TC_580_Rev.2
Page: 2 of 77
Date: 15/02/11
Issued: C. Cosatto
Verified: C. Cosatto
Approved: C. Cosatto
Revision Description:
Placard update
SCOPE
This manual contains the necessary information for safe and efficient Maintenance of the
FLYSYNTHESIS TEXAN TOP CLASS 580 ISR.
NOTE
This manual may be revised in the future and pages/or sections re-issued in part or whole.
Revisions will be available on the Fly Synthesis website www.flysynthesis.com. Any revisions
and/or sections should be printed and replaced in the manual at the earliest possible time for
flight safety. The revisions added to the manual should be logged and recorded in the table
under log of Revisions of this manual, by the owner/user.
DEFINITIONS
Definitions used in this handbook such as WARNING, CAUTION and NOTE are employed
in the following context.
WARNING
Procedures or instructions that if not followed correctly may result in injury or
death
CAUTION
Procedures or instructions that if not followed correctly may result in damage to
the aircraft or its parts
NOTE: Procedures or instructions that is essential to highlight
INTELLECTUAL PROPERTY
The data and information contained in this document is the property of FLYSYNTHESIS
SRL. This document may not be reproduced or transmitted to a third party, in any form or by
any means. Any unauthorised copy or distribution is illegal as per international agreements
relating to property rights.
THIS AIRCRAFT WAS MANUFACTURED IN ACCORDANCE WITH THE FOLLOWING
LIGHT SPORT AIRCRAFT AIRWORTHINESS STANDARDS BCAR Section S, CS-VLA,
F2279, F2295 AND F2483 AND DOES NOT CONFORM TO STANDARD CATEGORY
AIRWORTHNESS REQUIREMENTS.

3
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33050 Mortegliano (UD) –Italy
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Maintenance Manual
FLY SYNTHESIS TEXAN
TOP CLASS 580 ISR
(For Rotax 912 ULS
versions)
Identification: MM_TC_580_Rev.2
Page: 3 of 77
Date: 15/02/11
Issued: C. Cosatto
Verified: C. Cosatto
Approved: C. Cosatto
Revision Description:
Placard update
LOG OF REVISIONS
Revision No.
Revision
Date
Signature
01
Propeller automatic pitch control system
20/12/10
Cosatto C.
02
Limitations placard updated
15/02/11
Cosatto C.

4
Provincial Road n.78 Km 12.150
33050 Mortegliano (UD) –Italy
Tel. [phone]
Fax [phone]
Sito web: www.flysynthesis.com
e-mail: [e-mail]
Maintenance Manual
FLY SYNTHESIS TEXAN
TOP CLASS 580 ISR
(For Rotax 912 ULS
versions)
Identification: MM_TC_580_Rev.2
Page: 4 of 77
Date: 15/02/11
Issued: C. Cosatto
Verified: C. Cosatto
Approved: C. Cosatto
Revision Description:
Placard update
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5
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33050 Mortegliano (UD) –Italy
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Maintenance Manual
FLY SYNTHESIS TEXAN
TOP CLASS 580 ISR
(For Rotax 912 ULS
versions)
Identification: MM_TC_580_Rev.2
Page: 5 of 77
Date: 15/02/11
Issued: C. Cosatto
Verified: C. Cosatto
Approved: C. Cosatto
Revision Description:
Placard update
INDEX
SECTION PAGE
1. GENERAL SAFETY INFORMATION 6
1.1 GENERAL SAFETY INFORMATION 7
1.2 OWNERS MAINTENANCE 7
1.3 AIRFRAME 7
1.4 FLIGHT CONTROL SYSTEM 8
1.5 SEATS AND SAFETY BELTS 8
1.6 BAGGAGE COMPARTMENT 8
1.7 PLACARD REPLACEMENT 9
1.8 GROUND HANDLING 9
1.9 TIE DOWN 9
2. EQUIPMENT LIST 10
2.1 TOOLING 11
2.2 OTHER POSSIBLE REQUIRED ITEMS 11
2.3 SOURCES TO PURCHASE PARTS 11
2.4 LIST OF DISPOSABLE PARTS 12
3. ENGINE SPECIFICATIONS 13
3.1 ENGINE SPECIFICATIONS 14
3.2 ROTAX 912 S/ULS 14
3.3 ENGINE OVERHAUL 15
3.4 ENGINE CONTROLS 15
3.5 ENGINE INDICATIONS 15
4. WEIGHT AND BALANCE 17
4.1 INTRODUCTION 18
4.2 WEIGHT LIMITATIONS 18
4.3 CENTRE OF GRAVITY LIMITATIONS 18
4.4 WEIGHING PROCEDURE 18
5. TIRE INFLATION PRESSURE 21
5.1 INTRODUCTION 22
5.2 TIRE INFLATION PRESSURE 22
5.3 CHANGING THE TIRE AND TUBE REPLACEMENT 22
6. APPROVED OILS, FUEL AND QUANTITY 23
6.1 ENGINE OIL 24
6.2 FUEL 24
6.3 FUEL TANK CAPACITY 24
7. FASTENER TORQUE VALUES 25
7.1 RECOMMENDED FASTNER TORQE VALUES 26
7.2 FUSELAGE 26
7.3 ENGINE ASSEMBLY 27
7.4 PROPELLER ASSEMBLY 27
7.5 WING ASSEMBLY 28
7.6 RUDDER/STABILATOR ASSEMBLY 28
7.7 CANOPY ASSEMBLY 29
8. REPORTING POSSIBLE SAFETY OF FLIGHT CONCERNS 30
8.1 REPORTING INSTRUCTIONS 31
8.2 FEEDBACK FORM EXAMPLE 31
9. INSPECTION PROCEEDURES 32
9.1 INSPECTIONS 33
9.2 DAILY INSPECTIONS 33
9.2.1 REFUELING 33
9.2.2 FUEL DRAINING 34
9.3 SCHEDULED INSPECTIONS 34
9.3.1 TIME LIMITED COMPONENTS 34

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Maintenance Manual
FLY SYNTHESIS TEXAN
TOP CLASS 580 ISR
(For Rotax 912 ULS
versions)
Identification: MM_TC_580_Rev.2
Page: 6 of 77
Date: 15/02/11
Issued: C. Cosatto
Verified: C. Cosatto
Approved: C. Cosatto
Revision Description:
Placard update
9.3.2 PROPELLER 34
9.3.3 MAIN LANDING GEAR 34
9.4 PRE-FLIGHT INSPECTIONS 35
9.4.1 NOSE WHEEL 35
9.4.2 PROPELLER 35
9.4.3 ENGINE 35
9.4.4 MAIN LANDING GEAR 35
9.4.5 WINGS 36
9.4.6 FUSELAGE 36
9.4.7 TAIL 36
9.4.8 STABILATOR 36
9.4.9 COCKPIT CHECKS 36
9.5 SCHEDULED INSPECTION CHART 37
10. LANDING GEAR SYSTEM 44
10. LANDING GEAR 45
10.1 BRAKE SYSTEM 45
11. FUEL SYSTEM 46
11.1 FUEL SYSTEM OPERATION 47
11.2 FUEL SYSTEM SCHEMATIC DIAGRAM 48
12. PROPELLER SYSTEM 49
12.1 PROPELLER 50
12.2 APPROVED PROPELLER TYPES 50
13. INSTRUMENTS AND AVIONICS 51
13.1 INSTRUMENTS AND AVIAONICS 52
13.2 BASIC MINIMUM FLIGHT AND ENGINE INSTRUMENTS. 52
13.3 INSTRUMENT PANEL LAYOUT AND LEGEND 53
14. ELECTRICAL SYSTEM 54
14.1 ELECTRICAL SYSTEM 55
14.2 ELECTRICAL POWER SYSTEM SCHEMATIC DIAGRAM 56
14.3 ELECTRICAL BUS SYSTEM SCHEMATIC DIAGRAM 57
14.4 FLAP SYSTEM 58
14.5 FLAP SYSTEM SCHEMATIC DIAGRAM. 59
15. PITOT-STATIC SYSTEM 60
15.1 PITOT-STATIC SYSTEM 61
15.2 PITOT-STATIC WATER TRAPS 61
15.3 PITOT-STATIC INSPECTIONS. 61
15.4 PITOT-STATIC SCHEMATIC DIAGRAM 62
16. STRUCTURAL REPAIRS AND ALTERATIONS 63
16.1 STRUCTURAL REPAIRS AND ALTERATIONS 64
16.2 DAMAGE TO THE COMPOSITE STRUCTURES 64
16.3 LINE MAINTENACE 64
16.4 HEAVY MAINTENANCE 64
16.5 MAJOR REPAIR, ALTERATION OR MAINTENACE 64
16.6 HEAVY LANDING 64
16.7 EXCEEDING ENGINE LIMITS 64
16.8 EXCEEDING AIRPLANE LIMITS 65
16.9 ENGINE MOUNT CHECKS 65
17 PAINTING AND COATINGS 65
17.1 PAINTINGS AND COATING 68
17.2 PLACARDS 68
18. APPENDIX 70
A. DEFINITIONS 71
B. ABBREVIATIONS 72
C. SUPPLEMENTRY APPROVED OPTIONAL EQUIPMENT 74
D. FEEDBACK FORM 76

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Maintenance Manual
FLY SYNTHESIS TEXAN
TOP CLASS 580 ISR
(For Rotax 912 ULS
versions)
Identification: MM_TC_580_Rev.2
Page: 7 of 77
Date: 15/02/11
Issued: C. Cosatto
Verified: C. Cosatto
Approved: C. Cosatto
Revision Description:
Placard update
SECTION 1
GENERAL SAFETY INFORMATION
Title Page
1.1 General Safety Information 8
1.2 Owner maintenance 8
1.3 Airframe 8
1.4 Flight control system 9
1.5 Seats and safety belts 9
1.6 Baggage compartment 9
1.7 Placard replacement 10
1.8 Ground handling 10
1.9 Tie down 10

8
Provincial Road n.78 Km 12.150
33050 Mortegliano (UD) –Italy
Tel. [phone]
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Maintenance Manual
FLY SYNTHESIS TEXAN
TOP CLASS 580 ISR
(For Rotax 912 ULS
versions)
Identification: MM_TC_580_Rev.2
Page: 8 of 77
Date: 15/02/11
Issued: C. Cosatto
Verified: C. Cosatto
Approved: C. Cosatto
Revision Description:
Placard update
1.1 GENERAL SAFETY INFORMATION
This manual contains recommended procedures and instructions for ground handling,
servicing and maintaining the TEXAN TOP CLASS 580 ISR. The procedures described
are to be used in addition to the particular governing body‘s regulations for each country
where the aircraft is being flown. Where a maintenance procedure contravenes local
regulations, the procedures of the local governing body will take precedence. This manual
may refer you to the engine manual(s) for maintenance required for the relevant engine.
Maintenance instructions are divided to scheduled and unscheduled tasks. Scheduled
tasks are carried at fixed intervals, either flight hours or periods of time, e.g. at each
100hrs, or once a year which ever comes first.
Unscheduled tasks are those required when the airplane condition if affected after
damage is discovered or some unusual event like a heavy landing.
1.2 OWNER MAINTENACE
The Texan Top Class 580 ISR has been designed as a simple aircraft that can be
maintained by owners. Fly Synthesis allows normal maintenance up to 100 hourly
servicing to be carried out by the owner. This includes:
Oil and Oil filter changes
Fuel filter changes
Brake pad changes
Spark plug changes
Tire changes
Fly Synthesis recommends that any aircraft being used for flight training or for hire/reward
operation be maintained by an approved maintenance person or organisation.
1.3 AIRFRAME
The fuselage, wings and tail are constructed from composite materials. Carbon fibre is
used in highly loaded parts of all the structure, like wing spars. The fuselage is made
using a composite skin, bulkheads and stringer construction. Sandwich honeycomb is
used where required, from the firewall to the tail. The engine is installed on a steel engine
mount connected to the firewall. The engine cowling is achieved with two composite
material parts, an upper and lower cowling, fixed together with the cam-lock system. The
engine compartment is made from steel firewall. The wings are made of a composite skin
and ribs with one main spar, connecting both wings together in the centre of the fuselage.
Wing-fuselage loads are transmitted through four bolts from the root ribs of each wing to
two cross antitorsional tubes in the fuselage construction. An aerodynamic fairing, called
Karman, covers the fuselage / wing root area. The cockpit canopy is made of two parts.
The forward fixed windshield is installed on the cockpit roll bar, designed to protect the
occupants in case of turn over. The aft part of the canopy is designed to move backwards
to open the cockpit. When closed, the canopy is held in place by two locks on each side,
four locks all together.
WARNING: The four locks must be engaged and locked during flight.

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33050 Mortegliano (UD) –Italy
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Maintenance Manual
FLY SYNTHESIS TEXAN
TOP CLASS 580 ISR
(For Rotax 912 ULS
versions)
Identification: MM_TC_580_Rev.2
Page: 9 of 77
Date: 15/02/11
Issued: C. Cosatto
Verified: C. Cosatto
Approved: C. Cosatto
Revision Description:
Placard update
1.4 FLIGHT CONTROL SYSTEM
The airplane has standard three axis controls, with dual stick and dual rudder pedals.
All control surfaces are made from composite material. The control surfaces are mounted
on metal hinges and in-turn operated by metal mechanisms. All three control surfaces
mass weight balanced to prevent flutter. The pitch is controlled by the stabilator,
commonly known as flying tail. There is no fixed elevator section and a negatively geared
trim tab is used to position the stabilator in the correct pitch and also to trim the aircraft.
The two control sticks in the cockpit are inter-connected and push-pull aluminium rods
transfer the movement to the stabilator. The mechanical trim is achieved by changing the
zero position of the geared tab. The manual trim lever is positioned between the seats
and it moves the trim through a push-pull flexible cable, an optional electric trim is also
available. Roll control is by ailerons. Push-pull rods operate the ailerons. These are
differential ailerons where the angular movement up is greater then the angular
movement down. Directional control is by a rudder installed on the vertical fin stabilizer.
Rudder pedal motion is transmitted via flexible steel cables to the rudder bell-crank. The
rudder pedals are connected at the front of the aircraft to the steerable nose wheel, which
completes the rudder control loop. A spring system help to centralize the rudder and
improve pilot‘s control feel.
CAUTION
Do not operate rudder pedals whilst stationary. Excessive pressure applied to
rudder pedals may result in damage to the rudder control pedal structure.
1.5 SEATS AND SAFETY BELTS
Pilot and passenger seats are made from composite materials and installed on the cockpit
floor. The seat bottom can be removed to enable inspection of the controls below the
seat. Each seat vertical back is adjustable on the ground before flight in 1 of 5 positions,
to suit pilot and passenger‘s size. Seat covers are fastened via Velcro strips and easily
removed for cleaning and inspection.
WARNING: Never try to change seat adjustment in flight!
Each seat is equipped with safety belts, which are locked together with a bayonet quick
release latching system. The safety belts are attached to the main structure and each can
be adjusted for occupant comfort. Belts should be replaced if frayed, cut, stitching is
broken or latching defective.
1.6 BAGGAGE COMPARTMENT
The baggage compartment is located behind the seats. Maximum baggage weight when
distributed evenly is 16 kg. Loose Items stored in the baggage area must be secured to
prevent unwanted movement during flight in turbulent conditions. An optional bigger
baggage compartment is available on request.

10
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33050 Mortegliano (UD) –Italy
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Maintenance Manual
FLY SYNTHESIS TEXAN
TOP CLASS 580 ISR
(For Rotax 912 ULS
versions)
Identification: MM_TC_580_Rev.2
Page: 10 of 77
Date: 15/02/11
Issued: C. Cosatto
Verified: C. Cosatto
Approved: C. Cosatto
Revision Description:
Placard update
1.7 PLACARD REPLACEMENT
If placards need to be replaced you can order them through Flysynthesis Srl at
www.flysynthesis.com or contact your local representative.
1.8 GROUND HANDLING
The TEXAN aircraft is very light and should always be moved by hand.
Moving the aircraft is accomplished by using the prop hub to pull the aircraft forward, it is
best to position the propeller in the horizontal position and hold the propeller close to the
hub. For rearward motion holding onto the rear vertical fin allows for easy rearward
motion.
WARNING
Do not spin the propeller whilst the engine is hot as it may fire when the propeller is
moved and result in injury.
Always ensure that master and Ignition are OFF.
Always treat the propeller as LIVE! IT KILLS!
Never approach the propeller when someone is in the aircraft.
Never use any of the control surfaces to move the aircraft for ground handling.
1.9 TIE DOWN
When mooring the aircraft in the open, head into wind if possible. Secure control surfaces
by tying the control stick back firmly with a latched seat belt.
Tie ropes to the designated wing attachment points located underneath the wing nearest
the wing tip. Anchor the rope approximately 30 degrees to the vertical, outboard of the
wing attachment point. Ensure sufficient slack as not to place strain on the wing in the
event of tire deflation whilst in the tied down position. A third rope is anchored around the
Stabiltator hinge and secured rearward in the same manner as the wings.

11
Provincial Road n.78 Km 12.150
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Maintenance Manual
FLY SYNTHESIS TEXAN
TOP CLASS 580 ISR
(For Rotax 912 ULS
versions)
Identification: MM_TC_580_Rev.2
Page: 11 of 77
Date: 15/02/11
Issued: C. Cosatto
Verified: C. Cosatto
Approved: C. Cosatto
Revision Description:
Placard update
SECTION 2
EQUIPMENT AND PARTS LIST
Title Page
2.1 Tooling 12
2.2 Other possible required items 12
2.3 Sources to purchase parts 12
2.4 List of disposable replacement parts 13

12
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33050 Mortegliano (UD) –Italy
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Maintenance Manual
FLY SYNTHESIS TEXAN
TOP CLASS 580 ISR
(For Rotax 912 ULS
versions)
Identification: MM_TC_580_Rev.2
Page: 12 of 77
Date: 15/02/11
Issued: C. Cosatto
Verified: C. Cosatto
Approved: C. Cosatto
Revision Description:
Placard update
2.1 TOOLING
Tooling required to do maintenance on this aircraft is listed below. Please note that the list
may not be comprehensive
Loctite (243, 567 and Antisieze Lubricant # 76764) for the frame section.
Open ended Metric Spanner set
Torque wrench
Air Pump
Various petroleum lubricants
Dry Lubricant –lubricant that doesn‘t attract dust after application.
UV Resistant Tie wraps, and tooling
Metric Hex key set
Gasoline resistant thread sealant tape
Various general care items
Metric Socket Wrench Set
Pliers and Wise Grips
Phillips and Regular Screw Driver Set
Flexible neck funnel
2.2 OTHER POSSIBLE REQUIRED ITEMS
Safety wire and Safety Pins
WD-40, CRC or another water displacement compound
Telescopic mirror
Good flash light
5x and 10x magnifying glass and or video inspection equipment
2.3 SOURCES TO PURCHASE PARTS
Parts can be purchased from the following sources
Component
Source
Composite airframe parts
Flysynthesis Srl or local distributor.
Non Composites hardware eg
Bolts screws etc.
Flysynthesis Srl or local distributor.
Other aircraft specialty hardware shops.
Avionics and Instruments
Flysynthesis Srl or local distributor.
Other aircraft avionic and instrument
specialty shops.
Propeller Parts
Flysynthesis Srl or local distributor.
Propeller manufacturer eg. DUC France, GT
Tonini (Italy) or Pipistrel (Slovenia).

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Maintenance Manual
FLY SYNTHESIS TEXAN
TOP CLASS 580 ISR
(For Rotax 912 ULS
versions)
Identification: MM_TC_580_Rev.2
Page: 13 of 77
Date: 15/02/11
Issued: C. Cosatto
Verified: C. Cosatto
Approved: C. Cosatto
Revision Description:
Placard update
2.4 LIST OF DISPOSABLE REPLACEMENT PARTS
Dispose of all disposable parts properly following local laws and regulations
Part
Comment
Fuel Filters
Disposable fuel filters or metal mesh non-disposable
ones specified by the respective engine
manufacture‘s manual must be used.
Air Filters
Disposable air and fuel filters are available from local
distributor. If soiled they will be replaced with new
ones and old ones discarded. Old filters should be
disposed of as per local laws
Tires
Standard front tires: 4x4-ply (100/75-5)
Standard rear tires: 13x5x6-ply
Large rear tires: 15x6x6-ply
Tires and tubes available from local distributor.
Worn tires should be disposed of as per local laws.
Oil Filters
Oil filters should be properly disposed of along with
the oil at each oil change, according to local laws.
Landing light
Automotive and auto-electrical shop.
Fuel Line
When fuel line has to be replaced, the old one should
be properly disposed of, according to local laws.
Water hoses
When hoses have to be replaced, the old one should
be properly disposed of, according to local laws.
Replacement hose should be of the same type and
grade as the original.
Battery
When the sealed maintenance free battery is to be
replaced, the older battery should be properly
recycled according to local laws.
Spark plugs
Spark plugs are available from Engine manufacturer
Or local distributor.
Brake pads
Brake pads are specially made and available from the
aircraft manufacturer or local representative.

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Maintenance Manual
FLY SYNTHESIS TEXAN
TOP CLASS 580 ISR
(For Rotax 912 ULS
versions)
Identification: MM_TC_580_Rev.2
Page: 14 of 77
Date: 15/02/11
Issued: C. Cosatto
Verified: C. Cosatto
Approved: C. Cosatto
Revision Description:
Placard update
SECTION 3
ENGINE
Title Page
3.1 Engine specification 15
3.2 Rotax 912 S/ULS 15
3.3 Engine overhaul 16
3.4 Engine controls 16
3.5 Engine indications 16

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Maintenance Manual
FLY SYNTHESIS TEXAN
TOP CLASS 580 ISR
(For Rotax 912 ULS
versions)
Identification: MM_TC_580_Rev.2
Page: 15 of 77
Date: 15/02/11
Issued: C. Cosatto
Verified: C. Cosatto
Approved: C. Cosatto
Revision Description:
Placard update
3.1 ENGINE SPECIFICATION
The approved power plant installations for the TEXAN TOP CLASS 580 ISR is the
ROTAX 912 ULS. For full detail of engine construction see ROTAX manuals.
3.2 ROTAX 912 S/ULS
Version
Performance
Torque
Max.RPM
kw hp rpm
Nm ft.lb rpm
912 S/ULS
69.0 95.0 5500
128 94 5100
Continuous
max.5 min
73.5* 100* 5800*
*with Rotax air box and
exhaust system
5800
Bore
Stroke
Displacement
Compression ratio
84mm ( 3.31in )
61.0mm ( 2.4 in )
1352cm ( 82.6 cu.in.)
10.5 : 1
3.3 ENGINE OVERHAUL
Rotax: After 1500 hours for Rotax 912ULS
3.4 ENGINE CONTROLS
Engine control is by one throttle control, operating both carburettors simultaneously. A
choke is provided for starting a cold engine. The twin-magneto ignition system is
controlled by the Master Key.
The engine starter is actuated by the Master Key, that control the starter relay, when the
master switch is ON. With master switch OFF the starter will not operate.
An Electric fuel pump supplies fuel pressure prior to the engine starting and running and is
used as back up for the engine driven fuel pump in case of failure.
3.5 ENGINE INDICATIONS
The rpm indicator indicates engine speed (RPM). This is an electronic unit.
The cylinder head temperature (CHT) indicator shows engine temperature.
The oil pressure indicator indicates oil pressure.
A separate indicator indicates the oil temperature. An Exhaust Gas Temperature system
(EGT) is also installed.

16
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33050 Mortegliano (UD) –Italy
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Maintenance Manual
FLY SYNTHESIS TEXAN
TOP CLASS 580 ISR
(For Rotax 912 ULS
versions)
Identification: MM_TC_580_Rev.2
Page: 16 of 77
Date: 15/02/11
Issued: C. Cosatto
Verified: C. Cosatto
Approved: C. Cosatto
Revision Description:
Placard update
The fuel pressure indicator indicates fuel pressure with the engine pump and/or aux
electric fuel pump in use. This fuel pressure indicator is a mechanical unit.
A standard sealed accumulating hours-meter (Hobbs meter), counts the total time the
ignition key is switched on. An optional air switch may be fitted that accumulates time on
an air switch clock when the aircraft attains a speed greater than 30 knots. The air switch
time can be used for purposes of airframe and engine maintenance.

17
Provincial Road n.78 Km 12.150
33050 Mortegliano (UD) –Italy
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Maintenance Manual
FLY SYNTHESIS TEXAN
TOP CLASS 580 ISR
(For Rotax 912 ULS
versions)
Identification: MM_TC_580_Rev.2
Page: 17 of 77
Date: 15/02/11
Issued: C. Cosatto
Verified: C. Cosatto
Approved: C. Cosatto
Revision Description:
Placard update
Intentionally left blank

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Provincial Road n.78 Km 12.150
33050 Mortegliano (UD) –Italy
Tel. [phone]
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Maintenance Manual
FLY SYNTHESIS TEXAN
TOP CLASS 580 ISR
(For Rotax 912 ULS
versions)
Identification: MM_TC_580_Rev.2
Page: 18 of 77
Date: 15/02/11
Issued: C. Cosatto
Verified: C. Cosatto
Approved: C. Cosatto
Revision Description:
Placard update
SECTION 4
WEIGHTS AND BALANCE
Title Page
4.1 Introduction 19
4.2 Weight Limitations 19
4.3 Center of Gravity Limitations 19
4.4 Weighing Procedure 19

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Maintenance Manual
FLY SYNTHESIS TEXAN
TOP CLASS 580 ISR
(For Rotax 912 ULS
versions)
Identification: MM_TC_580_Rev.2
Page: 19 of 77
Date: 15/02/11
Issued: C. Cosatto
Verified: C. Cosatto
Approved: C. Cosatto
Revision Description:
Placard update
4.1 INTRODUCTION
In order to obtain the best flight performance, safety, stability and control, the airplane
must be loaded within the Centre of Gravity (balance) inside the prescribed limits.
Operation beyond the prescribed limits may cause instability and loss of control, or too
much stability with not enough control. Both cases will lead to unsafe conditions and could
result in an accident, with serious or fatal personal injury.
Exceeding the Centre of Gravity limits is
PROHIBITED
Weight limitations are important as the performance and the integrity of the structure will
decrease to below acceptable values when exceeding the maximum Take-Off Weight.
Operation at weights above the limits may thus lead to unsafe conditions and could result
in a serious accident.
Exceeding the maximum weights is
PROHIBITED
4.2 WEIGHT LIMITATIONS
Rotax 912
Maximum Take-Off Weight 580 kg
Maximum Pilot and Passenger Weight 180 kg
Minimum Solo Pilot Weight 70 kg
Luggage Compartment, 16 kg
Minimum Empty Weight 330 kg
4.3 CENTER OF GRAVITY LIMITATIONS
Forward Limit: 377 mm behind the reference datum (27% MAC)
Aft Limit: 504 mm behind the reference datum (36% MAC)
The longitudinal location of the Centre of Gravity (CG) is measured as the distance behind
a reference datum (RD).
The reference datum is defined as the vertical plane of the leading edge of the wing, when
the airplane is level.
The mean Aerodynamic Chord (MAC) is the average chord of a wing, for this airplane it is
1400 mm.
The 0% of the MAC is the reference datum (RD).
The location of the CG can be defined by reference to the % MAC.
4.4 WEIGHING PROCEDURE
Weighing must be done in a closed hangar with no chance of wind affecting the
measurements.
The floor must be level, preferably smooth concrete or any other smooth hard surface.

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Provincial Road n.78 Km 12.150
33050 Mortegliano (UD) –Italy
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Maintenance Manual
FLY SYNTHESIS TEXAN
TOP CLASS 580 ISR
(For Rotax 912 ULS
versions)
Identification: MM_TC_580_Rev.2
Page: 20 of 77
Date: 15/02/11
Issued: C. Cosatto
Verified: C. Cosatto
Approved: C. Cosatto
Revision Description:
Placard update
The airplane is complete, painted and all instruments and accessories installed.
The airplane is serviced with full engine oil, full engine coolant fluid, full brake fluid, fuel
tank drained and filled with the specified amount of the unusable fuel (TEXAN-2 litres-with
dual tanks).
In order to achieve an acceptable accuracy, the scales used for weighing should have the
following capacities:
Nose wheel - Up to 100 kgs
Main wheel –each - Up to 120 kgs
1. Put the airplane on the three scales,
2. Block the wheels to prevent the airplane from rolling off the scales,
3. Check that the airplane is level. The check is done by measuring on the cockpit
sidewall top, which should be 5º nose down when the airplane is level. Place
pieces of wood with different thickness under the wheels, as required to have the
airplane level. Close the canopy before reading the scales.
4. Lower two plumb lines from the leading edge of the inboard wing section, left and
right wings. Mark the points on the floor and draw a straight line on the floor
(parallel to the wing span). This is the reference datum (RD),
5. Measure the longitudinal distance from the RD to the axle of the nose wheel. This
is the value X1. Record the value in the weight report. This value should be with a
minus sign,
6. Measure the longitudinal distance from the RD to the axle of the main wheels. This
is the value X2. Record the value in the weight report,
7. Note the weight of each scale and record in the weight report,