Legend Cub Maintenance Manual · American Legend Aircraft . Maintenance Manual . Models AL3, AL11 ....

American Legend Aircraft

Maintenance Manual

Models AL3, AL11

Rev 1.9

Legend Cub Maintenance Manual

Table of Contents

Table of Contents .......................................................................................................................................... 2

Table of Figures ............................................................................................................................................. 7

1. General ................................................................................................................................................. 9

1.1. Manufacturer ................................................................................................................................ 9

1.2. Physical Dimensions ...................................................................................................................... 9

1.3. Physical views .............................................................................................................................. 10

1.4. Materials ..................................................................................................................................... 10

1.5. Equipment List ............................................................................................................................ 10

1.6. Source to Purchase Parts ............................................................................................................ 12

1.7. List of Disposable Replacement parts ......................................................................................... 12

1.8. Engine Specifications .................................................................................................................. 13

1.9. Weight and Balance Information ................................................................................................ 13

1.10. Tire Inflation ............................................................................................................................ 14

1.11. Approved Oils and Capacities ................................................................................................. 15

1.11.1. Continental O‐200 ............................................................................................................... 15

1.11.2. Jabiru 3300A ........................................................................................................................ 15

1.12. Recommended Fastener Torque Values ................................................................................. 15

1.13. General Safety Information .................................................................................................... 15

1.14. Service Difficulty Report ......................................................................................................... 15

2. Inspection Checklist ............................................................................................................................ 16

3. Structures ........................................................................................................................................... 17

3.1. Wing ............................................................................................................................................ 17

3.1.1. Wing Removal and Installation ........................................................................................... 17

3.1.2. Wing Installation ................................................................................................................. 17

3.2. Empennage ................................................................................................................................. 20

3.2.1. Trim Jackscrew Mechanism Removal/Installation .............................................................. 20

3.2.2. Required Tools: ................................................................................................................... 20

3.2.3. Torque Tube Removal/Installation ..................................................................................... 21

3.3. Landing Gear ............................................................................................................................... 22

3.3.1. Landing Gear Removal/Installation ..................................................................................... 22

3.4. Tailwheel Removal/Installation .................................................................................................. 24

3.5. Control Surfaces .......................................................................................................................... 26

© American Legend Aircraft Company Rev 1.9


3.5.1. Aileron Removal .................................................................................................................. 26

3.5.2. Aileron Installation and Rigging .......................................................................................... 28

3.5.3. Elevator Removal ................................................................................................................ 29

3.5.4. Elevator Installation and Rigging ......................................................................................... 30

3.5.5. Rudder Removal .................................................................................................................. 31

3.5.6. Rudder Installation .............................................................................................................. 34

3.5.7. Stabilizer Removal ............................................................................................................... 35

3.5.8. Stabilizer Installation and Rigging ....................................................................................... 35

4. Engines ............................................................................................................................................... 37

4.1. Engine (Continental 0200) .......................................................................................................... 37

4.1.1. Engine Removal/Installation ............................................................................................... 39

4.1.2. Exhaust Removal ................................................................................................................. 39

4.1.3. Exhaust Installation ............................................................................................................. 42

4.1.4. Alternator Removal/Installation ......................................................................................... 42

4.1.5. Spark Plug Removal/Installation ......................................................................................... 44

4.1.6. Oil Change ........................................................................................................................... 44

4.1.7. Other Engine Maintenance and Repair ............................................................................... 45

4.2. Engine (Jabiru 3300) .................................................................................................................... 45

4.2.1. Engine Removal/Installation ............................................................................................... 49

4.2.2. Exhaust Muffler Removal/Installation ................................................................................ 50

4.2.3. Spark Plug Removal/Installation ......................................................................................... 50

4.2.4. Oil Change ........................................................................................................................... 51

4.2.5. Other Engine Maintenance and Repair ............................................................................... 51

5. Fuel System ........................................................................................................................................ 52

5.1. Fuel Tank Removal/Installation .................................................................................................. 53

5.1.1. Required Tools: ................................................................................................................... 53

5.1.2. Parts Required: .................................................................................................................... 53

5.1.3. Level of Maintenance: Line ................................................................................................. 53

5.1.4. Certification Required: A&P or LSA Repairman Maintenance ............................................ 53

5.1.5. Verification .......................................................................................................................... 53

5.2. Gascolator Removal/Installation................................................................................................. 53

5.2.1. Required Tools: ................................................................................................................... 55

5.2.2. Parts Required: .................................................................................................................... 55

5.2.3. Level of Maintenance: Preventive ...................................................................................... 55

5.2.4. Certification Required: Sport Pilot Certificate or higher ..................................................... 55



5.3. Fuel Gauge Removal ................................................................................................................... 55

5.4. Fuel Gauge Installation ............................................................................................................... 56

5.4.1. Required Tools: ................................................................................................................... 56

5.4.2. Parts Required: .................................................................................................................... 56



5.4.5. Verification .......................................................................................................................... 56

6. Propeller ............................................................................................................................................. 57

6.1. Propeller Removal (All Types) ..................................................................................................... 57

6.1.1. Required Tools: ................................................................................................................... 57

6.1.2. Parts Required: .................................................................................................................... 57



6.2. Propeller Installation (Wood/Composite) ................................................................................... 58

6.2.1. Required Tools: ................................................................................................................... 58

6.2.2. Parts Required: .................................................................................................................... 58



6.3. Propeller Installation (Metal) ...................................................................................................... 58

6.3.1. Tools Required: ................................................................................................................... 58

6.3.2. Required Parts: .................................................................................................................... 58



6.4. Propeller Repair .......................................................................................................................... 59

7. Utility Systems (Heater/Vent) ............................................................................................................ 60

7.1. Description .................................................................................................................................. 62

7.2. Heater System ............................................................................................................................. 62

7.2.1. Removal of Heat Shroud ..................................................................................................... 62

7.2.2. Installation of Heat Shroud ................................................................................................. 62

7.3. Removal of cabin heat box .......................................................................................................... 62

7.3.1. Required Tools: ................................................................................................................... 63

7.3.2. Parts Required: .................................................................................................................... 63



7.4. Installation of cabin heat box ...................................................................................................... 63



7.4.1. Required Tools: ................................................................................................................... 63

7.4.2. Parts Required: .................................................................................................................... 63

7.4.3. Level of Maintenance: Line ................................................................................................ 63


7.4.5. Verification .......................................................................................................................... 63

7.5. Ventilation System ...................................................................................................................... 64

7.6. Removal of Vents ........................................................................................................................ 64

7.6.1. Required Tools: ................................................................................................................... 64

7.6.2. Parts Required: .................................................................................................................... 64

7.6.3. Level of Maintenance: Line ................................................................................................ 64


7.7. Installation of Vents .................................................................................................................... 64

7.7.1. Required Tools: ................................................................................................................... 64

7.7.2. Parts Required: .................................................................................................................... 64


7.7.4. Verification .......................................................................................................................... 64

8. Instruments and Avionics ................................................................................................................... 65

8.1. Description .................................................................................................................................. 66

8.2. Removal ...................................................................................................................................... 66

8.2.1. Required Tools: ................................................................................................................... 66

8.2.2. Parts Required: .................................................................................................................... 66



8.3. See owner’s manual .................................................................................................................... 66

8.4. Installation .................................................................................................................................. 66

8.4.1. Required Tools: ................................................................................................................... 66

8.4.2. Parts Required: .................................................................................................................... 66



8.5. Verification .................................................................................................................................. 66

9. Electrical System ................................................................................................................................ 67

9.1. Description .................................................................................................................................. 67

9.2. Schematic .................................................................................................................................... 67

10. Structural Repair ............................................................................................................................. 68

11. Paintings and Coverings .................................................................................................................. 69



Appendix A. Reporting Forms .................................................................................................................... 70

Change of Address Form ........................................................................................................................ 71

Change of Ownership Form .................................................................................................................... 72

Service Difficulty Report ......................................................................................................................... 73

Appendix B. 100 Hour / Annual Checklist ............................................................................................... 74



Table of Figures Figure 1‐1 Aircraft Specification ............................................................................................................. 9 Figure 1‐2 Aircraft Side View ...................................................................................................................... 10 Figure 1‐3 Equipment List .................................................................................................................... 10 Figure 1‐4 Engine Specifications .......................................................................................................... 13 Figure 1‐5 Sample Loading Problem .................................................................................................... 13 Figure 1‐6 Center of Gravity / Moment Graph .................................................................................... 14 Figure 1‐7 Center of Gravity Limits ...................................................................................................... 14 Figure 1‐8 Main Tire Inflation ............................................................................................................... 14 Figure 1‐9Tailwheel Tire Inflation ............................................................................................................... 14 Figure 1‐10 Continental O‐200 Approved Oils / Capacities ................................................................... 15 Figure 1‐11 Jabiru 3300A Approved Oils / Capacities ............................................................................ 15 Figure 3‐1 Wing View .................................................................................................................................. 17 Figure 3‐2 Jackscrew .................................................................................................................................. 20 Figure 3‐3 Jackscrew Access ....................................................................................................................... 20 Figure 3‐4 Torque Tube Rear ...................................................................................................................... 21 Figure 3‐5 Torque Tube Front ..................................................................................................................... 21 Figure 3‐6 Landing Gear .............................................................................................................................. 22 Figure 3‐7 – Landing Gear Cabane / Struts ................................................................................................. 23 Figure 3‐8 Landing Gear Leg ....................................................................................................................... 23 Figure 3‐9 Tailwheel Rear View .................................................................................................................. 25 Figure 3‐10 Tailwheel Side View ................................................................................................................. 25 Figure 3‐11 Aileron Balance Cable .............................................................................................................. 26 Figure 3‐12 Aileron Lower View ................................................................................................................. 27 Figure 3‐13 Aileron Upper View .................................................................................................................. 27 Figure 3‐14 Elevator .................................................................................................................................... 29 Figure 3‐15 Rudder ..................................................................................................................................... 32 Figure 3‐16 Rudder ..................................................................................................................................... 33 Figure 3‐17 Control Surface Travels ....................................................................................................... 34 Figure 4‐1 O‐200 Installation Top View ...................................................................................................... 37 Figure 4‐2 O‐200 Gascolator ....................................................................................................................... 37 Figure 4‐3 O‐200 Side View ......................................................................................................................... 38 Figure 4‐4 O‐200 Front View ....................................................................................................................... 38 Figure 4‐5 Exhaust, Right Side ..................................................................................................................... 40 Figure 4‐6 Exhaust, Left Side ....................................................................................................................... 40 Figure 4‐7 Exhaust, Rear ............................................................................................................................. 41 Figure 4‐8 O‐200 Alternator ........................................................................................................................ 43 Figure 4‐9 Jabiru Front View ....................................................................................................................... 46 Figure 4‐10 Jabiru Left Front View ............................................................................................................. 46 Figure 4‐11 Jabiru Left Rear View ............................................................................................................... 47 Figure 4‐12 Jabiru Airbox ............................................................................................................................ 47 Figure 4‐13 Jabiru Right Rear View ............................................................................................................. 48 Figure 5‐1 Fuel Tank Caps / Covers ............................................................................................................. 52 Figure 5‐2 Fuel Sight Gauges ....................................................................................................................... 52 Figure 5‐3 Gascolator .................................................................................................................................. 54 Figure 5‐4 Fuel Sight Gauges ....................................................................................................................... 55 Figure 7‐1 Cabin Heat Inlet ......................................................................................................................... 60 Figure 7‐2 Window Vents ............................................................................................................................ 60




Figure 7‐3 Cabin Heat Outlet ...................................................................................................................... 61 Figure 8‐1 Instrument Panel ....................................................................................................................... 65 Figure 9‐1 Battery Installation .................................................................................................................... 67


1. General

1.1. Manufacturer • Legend Cub aircraft are manufactured by the American Legend Aircraft

Company in Sulphur Springs, Texas. USA.

1.2. Physical Dimensions

AL3

Continental O‐200AL11


Jabiru 3300Wing Span 35’ 6” 35’ 6” 35’ 6” Length 22’ 5” 22’ 5” 22’ 9” Height

(standard wheels and

prop)

7’ 6” 7’ 6” 7’ 6”

Empty Weight (standard airplane)

835 lbs 845 lbs 815 lbs

Design Gross Weight (land) 1320 1320 1320

Design Gross Weight (sea) 1430 1430 1430

Useable Fuel Capacity 20 U.S. Gallons 20 U.S. Gallons 20 U.S. Gallons

Seating 2 Persons, Tandem 2 Persons, Tandem 2 Persons, Tandem

Figure 1‐1 Aircraft Specification



1.3. Physical views

Figure 1‐2 Aircraft Side View

1.4. Materials • Legend Cub aircraft uses standard aircraft quality parts and materials.

Fuselages are made from Chromalloy 4130 tubing. Wings are built with spars and ribs made from 6061 aluminum extrusion. Fuselage, wings and control surfaces are covered with aircraft grade Dacron fabric and finished with Air-Tech, PolyFiber, Ranthane or SuperFlite finishing systems.

1.5. Equipment List Figure 1‐3 Equipment List

Item Description Model Number

Propeller (wood) Sensenich W72GK‐44U

Propeller (Metal) Sensenich 69CK‐0‐48L

Propeller (Metal) ) Sensenich 69CK‐0‐44L

Propeller (Composite) ) Sensenich W72GK‐46GU

Propeller (Metal)McCauley 1A90 CF7535

Propeller (Metal)McCauley 1A90 CF7538

Propeller (Wood) ) Sensenich W68CK‐36

Propeller (Wood) ) Sensenich W68CK‐38

Propeller (Composite) ) Sensenich W68CK‐36G

Propeller (Composite) ) Sensenich W68CK‐38G

Tires 4 ply 6.00 x 6.00



Tires 6 ply 6.00 x 6.00

Tires 4 ply 8.00 x 6.00

Tires 6 ply 8.00 x 6.00

Tail Wheel 6” Maule SFSA‐1‐4

Tail Wheel 6” Alaskan Bushwheel ABI 3224 A

Tail Wheel 6“ Matco T‐6

Air/Oil Separator 300‐PP0047

Std. Landing Light Wagner 4609

HID Landing Light 300‐WG0100

Strobe and Tip Lights 300‐EL0044

ELT 121.5 MHZ AK‐450

ELT 406.0 MHZ ME‐406

A/Horizon. Sporty’s

D/Gyro True Track

Compass SIRS

Airspeed Legend

Tachometer Legend

Oil Pressure Legend

Oil Temp. Legend

Radio Garmin 250XL

Radio Garmin SL40

Transponder Garmin 320A

Transponder Garmin 327A

Transponder Garmin 330

Intercom PS ENG. 1200

Intercom Sigtronics 200S

EFIS D‐100

EFIS D‐180

EMS D‐10



GPS ( carry on ) Garmin 296



1.6. Source to Purchase Parts • Parts can be procured directly from the component manufacturer or

American Legend Aircraft Company.

1.7. List of Disposable Replacement parts • Air Cleaner; Factory installed air cleaners can be cleaned and re used, The

following disposable filters have been approved for use on the Continental Engine, Brakett air filter pn; BA 4106 and Challenger pn; CP 1150 .

• Oil Filter; Continental engine-Champion pn. AC 48108. Jabiru engine-WIX pn. 51394

• Spark Plug; Continental engine-Champion pn. REM 37BY. Jabiru engine- NGK D9EA.

• Oil screen crush gasket. Pn An 900-28 • Brake Pads; Pn 66-106



1.8. Engine Specifications

“‐‐‐“ indicates same as previous model

AL3



Jabiru 3300 Rating 100 hp 100 hp 120 hp

Disposition Air cooled,4 cylinder,

horizontally opposed‐‐‐

Air cooled, 6 cylinder,

horizontally opposedTime

Between Overhaul

1800 hours ‐‐‐ 2000 hours

Oil Type SAE 40 below 40°F, SAE 50 above 40°F

‐‐‐ SAE 40 below 77ºFSAE 50 at 59‐95ºF SAE 60 above 95ºF

Oil Quantity 6 quarts maximum, 4 quarts minimum

‐‐‐ 3.69 quarts

Fuel Grade (minimum) 80/87 ‐‐‐ 100LL or Auto Gas

Figure 1‐4 Engine Specifications

1.9. Weight and Balance Information

Sample Airplane Actual Airplane Weight Station Moment Weight Station Moment Empty weight

850 11.6 9860

Front Seat

190 11 2090

Back Seat

140 37 5180

Fuel (6.0 x 20 gal)

120 24 2880

Baggage (50 lbs max)

20 57 1140

Total

Aircraft

1320

16.0

21,150

Figure 1‐5 Sample Loading Problem



1000

1050

1100

1150

1200

1250

1300

1350

1400

1450

1500

11.5 12.5 13 14 15 16 17 18 19 20 21

Figure 1‐6 Center of Gravity / Moment Graph

Gross Weight Forward Limit Aft Limit 1200 lbs 11.5” 21.0” 1320 lbs 12.5” 21.0”

Figure 1‐7 Center of Gravity Limits

1.10. Tire Inflation

Main Tire Pressure 6.00 x 6 25 psi 8.00 x 6 15 psi 26” Tundra 8 psi min

Figure 1‐8 Main Tire Inflation

Tailwheel Tire Pressure Alaska Bushwheel TBD TBD

Figure 1‐9Tailwheel Tire Inflation



1.11. Approved Oils and Capacities

1.11.1. Continental O-200

Oil Type Temperature Range Min Qty Max Qty SAE 40 Below 40°F 4.0 qts 6.0 qts SAE 50 Above 40°F 4.0 qts 6.0 qts Figure 1‐10 Continental O‐200 Approved Oils / Capacities

1.11.2. Jabiru 3300A

Oil Type Temperature Range Min Qty Max Qty SAE 40 Below 77°F 3.69 qts SAE 50 59°F ‐ 95°F 3.69 qts SAE 60 Above 95°F 3.69 qts

Figure 1‐11 Jabiru 3300A Approved Oils / Capacities

1.12. Recommended Fastener Torque Values • American Legend uses the standard torque values as referenced in FAA

document AC 43.13 and the Continental, Jabiru, Sensenich and McCauley Service Manuals.

1.13. General Safety Information

CAUTION WHEN PULLING THE PROPELLER THROUGH BY HAND, TREAT THE PROPELLER AS IF THE MAGNETO/START SWITCH WERE ON. DO NOT STAND OR ALLOW ANYONE ELSE TO STAND WITHIN THE ARC OF THE PROPELLER SINCE A LOOSE OR BROKEN WIRE OR A COMPONENT MALFUNCTION COULD CAUSE THE ENGINE TO START. Do not tow or push aircraft by the tail surfaces, Lift handle on the right rear side of fuselage should be used for this purpose. Always check oil cap, fuel caps, cowling, doors and windows for security before flight. Always use and follow the aircraft checklist

1.14. Service Difficulty Report The Service Difficulty Report is included in Appendix A of this manual. The form may also be found at www.legend.aero.


http://www.legend.aero/


2. Inspection Checklist The 12‐Month Condition / 100 Hour Inspection Checklist is included in Appendix B of the Maintenance Manual. The latest revision of the checklist can be found on the American Legend Website at www.legend.aero.




3. Structures

3.1. Wing

3.1.1. Wing Removal and Installation

3.1.1.1. Required tools: • ½ inch socket/wrench • 3/8 inch socket/wrench • #1 and #2 Phillips screwdriver • diagonal cutters • pliers

3.1.1.2. Parts Required: • None

3.1.1.3. Level of Maintenance: Line 3.1.1.4. Certification Required: A&P or LSA Repairman Maintenance 3.1.1.5. Removal

• Drain all fuel from the airplane through the belly sump drain. Both tanks will drain from this location.

• Remove remaining fuel from each tank through the tank sump drains. • Remove all wing root fairings. • Remove aileron (See item 4.5.1, Aileron Removal) • Remove nuts from the wing root attach bolts, lift strut upper attach bolts,

and lift strut lower attach bolts. • Pull the aileron direct cable out of the wing, forward strut pulley, and forward

strut fairleads. • Disconnect aileron balance cable at the link in the cabin and pull cable out of

fuselage fairlead. • If equipped with strobe/position lights or landing light, disconnect wires as

necessary.

Figure 3‐1 Wing View

• Disconnect front and rear fuel pickup lines and both fuel gage connections.

• While supporting the wing at the tip, remove the rear strut starting with bottom attach point first then the front strut starting with the bottom attach point first.

• NOTE • Before removing wing, support

opposite wing to prevent the aircraft from tipping over when wing is removed.

• Support the wing at the root and remove the rear wing attach bolt first then the forward attach bolt.

• Remove wing from airplane.

3.1.2. Wing Installation

3.1.2.1. Required tools:



• ½ inch socket/wrench • 3/8 inch socket/wrench • #1 and #2 Phillips screwdriver • diagonal cutters • pliers • Large Hammer • Phillips Screwdriver


3.1.2.3. Level of Maintenance: Line 3.1.2.4. Certification Required: A&P or LSA Repairman Maintenance 3.1.2.5. Installation

• To facilitate the rigging process, pre-set the forks in the front struts to eight threads past jam nut and five threads past the jam nut on the rear struts.

• Raise wing to bring spar fittings into position in the wing fittings on the fuselage.

• Install the forward bolt first then the rear bolt. • Install the forward strut beginning with the upper attach point first. Make

sure to install the tie-down ring before the strut. • With the forward strut attached to the wing, raise the wing tip and slide the

fork down on the fuselage fitting and install the bolt. • Repeat the above steps for the opposite wing. • To check dihedral angle, first insure that the fuselage is level laterally, then

stretch a string from wing tip to wing tip along the front spar. • Measure down from the string to the top of the fuselage front wing hinge

fitting. The measurement should be three inches plus or minus 1/8-inch.If the measurement is too low, adjust the forks on the front struts an equal amount on each side.

• One half turn adjustment on both forks results in a 1/8 inch change in the height of the string.

• Once the proper measurement is obtained the wings must be checked to insure that they are set square with the fuselage.

• Assemble a tool to check the rigging by using a piece of straight aluminum angle of sufficient thickness to not be flexible. On one end attach a metal or wood block that is 13/22 inches thick. Place this bar with the block facing outboard along the front spar in the area between the jury strut attach fitting and the strut attach fitting. Place the level along this bar. The reading should be the same on each wing. If not, it indicates that one wing is adjusted higher than the other. To correct, shorten the strut on the high wing side and lengthen the strut on the low wing side and equal amount. When the level reading is the same on both sides recheck total dihedral again with the string.

• Once dihedral is set, the rear struts can be installed and the washout of each wing set. Start by installing the rear strut on one wing. To check washout, attach another block 3/8 inch thick to the rigging tool. Check the angle the fuselage is sitting at by placing the digital level along the tube at the lower door sill. This is the baseline number. Hold the tool with the 3/8 inch block toward the rear along the last full rib at the outboard end of the aileron bay. Place the level on the bar. This measurement should match the fuselage



number. If not, adjust the fork in or out until the numbers match. Repeat the process for the opposite wing.

• NOTE • It is very important that the washout of the wings be equal. If washout is

unequal it will cause the airplane to constantly bank and not fly straight. • Repeat the process for the other wing. • Attach the jury struts to the wing and the jury strut clamps to the struts. • Anti-chafe tape should be put on the jury strut clamp where it will make

contact with the strut. • The jury strut lugs and the spreader bar should be attached to the bottom of

both jury struts before attaching the lugs to the clamps on the struts. • Check the jury struts to make sure they are vertical before tightening the

clamp bolts. • Run the aileron direct cable through the fairleads on the front strut, around

the pulley and up into the wing. • Put the aileron balance cable back through the fuselage fairlead and attach

to the opposite wing cable. • Install and rig aileron (See section 4.5).

3.1.2.6. Verification • Wing to fuselage bolts secure • Lift struts to wing and fuselage secure and torque sealed



3.2. Empennage

3.2.1. Trim Jackscrew Mechanism Removal/Installation

Figure 3‐2 Jackscrew

3.2.2. Required Tools:

• ½ inch wrench/socket • diagonal cutters • pliers • 9/16 inch wrench/socket • #1 and #2 Phillips screwdriver • 5/16 inch wrench/socket


3.2.2.2. Level of Maintenance: Line 3.2.2.3. Certification Required: A&P or

LSA Repairman Maintenance 3.2.2.4. Trim Jackscrew Removal

• First remove trim cable from the jackscrew pulley by pulling the idler pulley aft to relieve the cable tension.

• Remove stabilizer link from the stabilizer yolk by removing the cotter pin, nut, and bolt on each side. The trim indicator cable will have to be disconnected from the link first.

• Pull the cotter pin from the nut securing the trim pulley to the jackscrew and remove the nut and pulley.

• Take out the key in the bottom of the jackscrew.

• Cut the fabric from the hole in the fairing directly above the jackscrew.

• Lift the jackscrew up through the hole while threading the trim yolk down off the jackscrew.

3.2.2.5. Trim Jackscrew Installation

• Install in the reverse order. • A cover for the hole cut to

remove the jackscrew will have to be fabricated.

3.2.2.6. • Verify all fasteners are tight and cotter keys are installed where required

Figure 3‐3 Jackscrew Access



3.2.3. Torque Tube Removal/Installation

Figure 3‐4 Torque Tube Rear

Figure 3‐5 Torque Tube Front



3.2.3.1. Required Tools • Pliers • 3/8 socket/wrench • 7/16 socket/wrench

3.2.3.2. Parts Required: • Cotter Keys

3.2.3.3. Level of Maintenance: Line 3.2.3.4. Certification Required: A&P or LSA Repairman Maintenance 3.2.3.5. Torque Tube Removal

• Loosen tension on aileron and elevator cables. • Disconnect elevator cables from the torque tube. • Remove upper part of the front and back sticks. • Remove the front and rear torque tube caps. Pay attention to washer

placement to make installation easier. • Pull the aft end of the torque tube up to bring the aileron cables above the

floorboard and remove the aileron cables. • Remove the torque tube from the airplane. • Install in the reverse order.

3.2.3.6. Verification • All fasteners tight • All cotter keys installed

3.3. Landing Gear

3.3.1. Landing Gear Removal/Installation

Figure 3‐6 Landing Gear



Figure 3‐7 – Landing Gear Cabane / Struts

Figure 3‐8 Landing Gear Leg



3.3.1.1. Tools Required: • #2 Phillips screwdriver • 9/16 wrench/socket • diagonal cutters • pliers

3.3.1.2. Parts Required: • MS24665-498 Cotter Pins.

3.3.1.3. Level of Maintenance: Line 3.3.1.4. Certification Required: A&P or LSA Repairman Maintenance 3.3.1.5. Landing Gear Removal

• Raise and support airplane using either lift rings installed on the front wing attach fittings or installed in the special fittings welded just inboard of the wing attach fittings on later model airplanes.

• Removed brake calipers from brake discs. • Remove wheel and tire assemblies. • Disconnect die spring assemblies at the lower end where it connects to the

landing gear axle. • Remove the front and rear bolts of the main landing gear and remove from

airplane. The left gear rear attach bolt supports the forward end of the cabin entry step. The step can be completely removed from the airplane or it can be left on the airplane supported by its aft attach bolt.

• The die springs can be removed from the Cabane or the Cabane and die springs can be removed as an assembly.

3.3.1.6. Landing gear installation • Reverse the process to install.

3.3.1.7. Verification • All fasteners tight • All cotters keys installed

3.4. Tailwheel Removal/Installation



Figure 3‐9 Tailwheel Rear View

Figure 3‐10 Tailwheel Side View



3.4.1.1. Tools Required: • 9/16 wrench/socket • 7/16 wrench/socket • diagonal cutters • pliers

3.4.1.2. Parts Required: • AN380-2-2 cotter pins (4)

3.4.1.3. Level of Maintenance: Line 3.4.1.4. A&P or LSA Repairman Maintenance 3.4.1.5. Tailwheel Removal / Installation

• Disconnect tailwheel springs from the tailwheel. • Remove the 3/8 inch bolt and nut from tailwheel and take it off the leaf

spring. • Remove the two ¼ inch bolts that secure the leaf spring saddle. • Loosen and remove the 3/8 inch bolt on the forward side of the leaf spring.

3.4.1.6. Tail wheel installation • Installation is accomplished in reverse. • When reattaching the tailwheel springs, they should be adjust just enough to

take out the slack and keep the wheel aligned with the rudder. A little slack in the springs is better than having the tailwheel misaligned.

3.4.1.7. Verification • All fasteners tight • Verify rudder pedals move tail wheel and verify “break away” • All cotter keys installed

3.5. Control Surfaces

3.5.1. Aileron Removal

Figure 3‐11 Aileron Balance Cable



Figure 3‐12 Aileron Lower View

Figure 3‐13 Aileron Upper View



3.5.1.1. Required Tools: • Diagonal cutters and pliers


3.5.1.3. Level of Maintenance: Line 3.5.1.4. Certification Required: A&P or LSA Repairman Maintenance

• Using the diagonal cutters and/or pliers, remove the cotter pins and washers securing the three hinge pins.

• Cut the safety clips or safety wire from the upper and lower turnbuckles and disconnect the cables from the ailerons. The fork assembly attached to the upper aileron bell crank can be left in place or removed.

• While supporting the aileron, remove the three hinge pins and remove the aileron from the airplane.

3.5.2. Aileron Installation and Rigging

3.5.2.1. Required tools • Diagonal cutters

3.5.2.2. Pliers 3.5.2.3. 3/8 inch wrench/socket 3.5.2.4. Parts Required

• MS21256-1 Turnbuckle Safety Clips (4) or .041 safety wire • AN394-43 clevis pins (3), • N960-416 washers (3) • AN960-10 washers (4) • AN3-7 bolts (2) • AN310-3 castle nuts (2) • AN380-2-2 cotter pins (5)


• Position the aileron to the wing panel and secure with clevis pins, washers, cotter pins.

• Attach the aileron control cables to the aileron horns with bolt, nut, washers and cotter pin

• Lubricate aileron hinges. • Using the adjustable stops at the aft torque tube support in the cockpit, set

travels to those listed in Table 3-1.After travels are set, tighten jam nuts on stops.

3.5.2.7. Verification • Cable tension should be set so that there is not free play or slack in the

cables but the system should still move freely. • Safety turnbuckles with safety clips or safety wire. Turnbuckles should have

no more than three threads exposed at each end of the turnbuckle barrel.



3.5.3. Elevator Removal

Figure 3‐14 Elevator



3.5.3.1. Required tools • Diagonal cutters • Pliers • 3/8 inch wrench/socket • 9/16 inch socket wrench • #1 Phillips screwdriver

3.5.3.2. Parts Required • None


• Remove LH aft, RH aft and LH rectangular tail inspection panels • Cut safety clips or safety wire from upper and lower turnbuckles and

disconnect control cables. • Remove the bolts and nuts that secure the upper elevator link to the two

elevators and remove the link. • Remove the clevis pin that secures the lower elevator link to the two

elevators and remove the link. • Remove all cotter pins and washers from the two hinge pins securing each

elevator. • Remove one elevator at a time by removing the hinge pins from the hinges.

3.5.4. Elevator Installation and Rigging

3.5.4.1. Required tools • Diagonal cutters • Pliers • 3/8 inch wrench/socket • 9/16 inch wrench/socket

3.5.4.2. Parts Required • MS21256-1 turnbuckle safety clips (4) or .041 safety wire • 310-TL0023 Link • Elevator Upper (1) • 310-TL0025 Link • Elevator Lower (1) • 350-TL0015 turnbuckle forks • MS21251-B3S turnbuckle barrel (2) • AN3-5 Bolt (1) • AN6-5A bolt (1) • AN393-13 clevis pin (1) • AN394-55 clevis pin (4) • AN960-616 washer (1) • AN960-10 Washer (10) • MS21083N6 nut (1) • AN 310-3 Nut (3) • AN380-2-2 cotter pin (7) • MS24665-208 cotter pin (1)




• Assemble the LH and RH elevator to the stabilizers using four AN394-55 clevis pins, four AN960-10 washers and four AN380-2-2 cotter pins.

• Attach the two 350-TL0015 turnbuckle forks to the two elevator links using one AN3-6 bolt, two AN960-10 washers, one AN310-3 nut, and one AN380-2-2 cotter pin per fork.

• Join the top of the elevator bell cranks together using one 310-TL0023 upper link, one AN3-5 bolt, one AN960-10 washer, one AN310-3 nut, one AN380-2-2 cotter pin, one AN6-5A bolt, one AN960-616 washer, and one MS21083N6 Nut.

• Install the 310-TL0025 lower link using the AN393-13 clevis pin, one AN960-10 washer, and one MS24665-208 cotter pin.

• Attach the cables to the forks threading the ends into the turnbuckle barrel evenly.

• With the elevators against the down stop, tighten the lower cable turnbuckle to pull the rear control stick away from the back of the front seat. The top turnbuckle may need to be loosened during this process. When the back stick is rearward enough to clear the seat, tighten up the top turnbuckle to remove slack from the system. Final tightening will be done later.

• Using a digital level or other suitable device, measure the up and down travel of the elevators. Proper travels are listed in Table 3-1.When using a digital level, there is no need to level the fuselage. Measure the angle of the fuselage at the tube on the lower door sill. This will be the zero point. For example, if fuselage is sitting at 12 degrees tail down from level 25 degrees up travel will be obtained when the level reads 13 degrees up from level. You must add 12 degrees to the number displayed because the zero point is 12 degrees down from level. Likewise to measure down travel you must subtract the 12 degrees from the number displayed because the zero point is 12 degrees down from level. In this case proper down travel is obtained when the level reads 41 degrees down from level. The travels can also be checked using a bubble protractor but the fuselage must be leveled before starting.

3.5.4.5. Verification • After proper travels are verified, insure that both cables are tensioned

equally and that the control stick moves easily. Turnbuckles may not have more than three threads exposed on either end of the barrel. Safety turnbuckles with safety clips or safety wire.

•

3.5.5. Rudder Removal



Figure 3‐15 Rudder



Figure 3‐16 Rudder



3.5.5.1. Tools Required • 3/8 inch wrench/socket • diagonal cutters • pliers • hammer • punch



• Disconnect spring assemblies from the tailwheel rudder arm • Disconnect rudder control cables from rudder bell crank. • Remove cotter pins and washers from the bottom of the rudder hinge pins. • While supporting the rudder remove the hinge pins and take rudder off

airplane.

3.5.6. Rudder Installation

3.5.6.1. Tools Required: • 3/8 inch wrench/socket • diagonal cutters • pliers • hammer • punch



• Put rudder in place on the airplane and install the two hinge pins. • Secure the hinge pins with washers and cotter pins. • Rudder travel is set by the length of the stop tubes at the lower portion of

the tail post, is pre set at the factory, and should not require adjustment. • Attach the rudder cables to the rudder bell crank. The neutral position of the

pedals can be changed by which hole is used on the rudder cable connector. 3.5.6.5. Verification

• After connecting cables make sure that full rudder travel can be achieved by moving the rudder pedals.

• Reconnect the tailwheel springs to the tailwheel rudder arm.

Control Surface TravelsElevator 25 Up 29 DownRudder 32 Left 32 RightAileron 18 Up 18 DownStabilizer 2.5 Up 4 Down

Figure 3‐17 Control Surface Travels



3.5.7. Stabilizer Removal

3.5.7.1. Required Tools • 3/8 inch wrench/socket • 7/16 inch wrench/socket • ½ inch wrench/socket.



• Remove elevators (See step 4.5.3.). • Loosen the jam nuts on the tail brace wires and relieve the tension on the

wires. • Remove the bolts securing the wires and remove the wires. • Take out the bolts that secure the forward and aft end of one of the

stabilizers. • Pull the stabilizer with the bolts removed off of the airplane. Then remove

the other stabilizer. The stabilizer liner tubes will stay installed in this stabilizer.

• Remove the liner tubes if necessary. It is a good idea to mark the liner tubes to make sure they are reinstalled properly.

3.5.8. Stabilizer Installation and Rigging

3.5.8.1. Required Tools: 3.5.8.2. Parts Required:

• Upper Tail brace Wires (2) • Lower Tail brace Wires (2) • Tail brace Wire Hardware Kit (1) • AN3-14 bolt (2) • AN3-16 bolt (2) • AN960-10 Washers (4) • AN365-1032A nuts (4) • Forward liner tube • Aft liner tube


• If new liner tubes are being installed, they will have to be drilled to match the stabilizers. If new stabilizers are being installed you must use new liner tubes.

• To set and drill new liner tubes and stabilizers, first install the tubes in the fuselage with equal amounts extending out on either side. Mark the tubes with a marker for a reference point to maintain positioning while drilling.

• Take each stabilizer and make a mark ¾ inch from the open end of the forward and aft tubes on both sides of the stabilizer.

• Lay a straight edge on the stabilizer so that the ends rest on the marks made in the previous step. Make a mark where the straight edge touches the tubes. This will be the tangent point on the tube ¾ of an inch from the edge of the tube. Drill through the tubes at each of the four points marked using a #12 drill. Do not try to drill straight through the tube from one side. If the



measuring was done properly the holes will be directly across from one another.

• After the stabilizers are drilled, take one stabilizer and install the forward and aft liner tubes in it up to the reference marks made previously.

• Match drill the liner tubes on one side of the stabilizer. • Put a short 3/16 inch diameter bolt in the hole just drilled in the liner tube.

This will keep the tube from moving when drilling the other side. • Flip the stabilizer over and match drill the other side. • Remove the short bolt and install the AN3-14 bolt in the forward side and the

AN3-16 bolt in the aft side. This will create a subassembly to be installed on the airplane.

• Slide the stabilizer onto the fuselage. • Slide the other stabilizer onto the other side of the fuselage. Match drill the

top and bottom of the liner tubes in the same manner described above and install the bolts.

• Next, attach the upper and lower tail brace wires using the appropriate hardware.

• Level the fuselage laterally. • Tighten the upper tail brace wires and check with a level until the stabilizers

are level. • Tight the lower tail brace wires evenly to achieve proper tension and adjust

the upper wires as necessary to make sure that the stabilizers remain level. • Proper tension on both upper and lower tail brace wires are adjusted as

follows. Tail brace wires shall be adjusted to obtain 7/16 deflection (+or- 1/16 inch) with a centered 10 lb. (+or- 1 lb.) load.

• Secure each end of the tail brace wires by tightening the jam nuts. 3.5.8.5. Verification

• All fasteners tight • All cotter keys in place



4. Engines

4.1. Engine (Continental 0200)

Figure 4‐1 O‐200 Installation Top View

Figure 4‐2 O‐200 Gascolator



Figure 4‐3 O‐200 Side View

Figure 4‐4 O‐200 Front View



4.1.1. Engine Removal/Installation

4.1.1.1. Required Tools: • Engine hoist • 3/8 wrench/socket • 9/16 wrench/socket • diagonal cutters • soft-face hammer • torque wrench • flat head screw driver

4.1.1.2. Parts required: • None


• Remove propeller. • Remove engine cowling. • Disconnect throttle cable from carburetor. • Disconnect mixture cable from carburetor. • Remove throttle/mixture bracket from engine. • Disconnect tachometer drive cable or tachometer leads from magneto. • Disconnect EGT, CHT, and carburetor temperature sensor leads (EMS only). • Disconnect alternator power leads. • Disconnect fuel line from carburetor. • Disconnect primer line from intake. • Remove exhaust system (See item 2). • Raise and support tail of airplane at a near level attitude. • Attach engine hoist to engine lift ring. • Support weight of engine with hoist. • Remove the four bolts securing engine mount to the airframe. • Remove the engine, with mount attached, from the airplane.

4.1.1.5. Installation • For installation, perform above procedures in reverse order. • Torque the bolts mounting the engine mount to the airframe and the engine

mount to the engine to 15 foot pounds. 4.1.1.6. Verification

• Verify all fasteners are tight • All cotter keys in place • Run engine and check for leaks

4.1.2. Exhaust Removal



Figure 4‐5 Exhaust, Right Side

Figure 4‐6 Exhaust, Left Side



Figure 4‐7 Exhaust, Rear

4.1.2.1. Required Tools: • ½ inch socket and extension • 3/8 socket and wrench • 1/4 inch drive ratchet

4.1.2.2. Parts required: • New exhaust gaskets if necessary


• Remove bolt from slip joint connector. • Remove three bolts from ball joint. • Remove eight nuts securing exhaust to engine. • Remove right side of exhaust system first, then remove center assembly and

finally remove the left side. NOTE

If equipped with spin‐on filter and adapter, the filter must be removed before the left side of the exhaust.



• For closed cowl airplanes, some cowling removal is required. Remove all screws on the lower left U channel support and let bottom cowl piece hang down. Remove the screw securing the left side cowl support strut to the engine mount. Once all the fasteners are removed, the U channel and cowl support strut should come out as an assembly. This will provide the clearance necessary to raise the aft side of the exhaust and remove it from the engine.

4.1.3. Exhaust Installation

4.1.3.1. Required tools: • ½ inch socket and extension • 3/8 socket and wrench • 1/4 inch drive ratchet. • Inspect exhaust gaskets for abnormal deformation and cracking. If

necessary replace gaskets. If using the thin sheet metal gaskets, use two per exhaust stack and the raised beads on the two gaskets must be nested together and the raised side installed facing the exhaust stack.

• Install the left side first and start the nuts just enough to keep the piece in place.

• Install cabin heat shroud on the cross tube portion of the left exhaust. • Install the center assembly onto the left side. • Apply anti seize compound to the inside of the female part of the ball joint.

Next install the right side exhaust and start the nuts just enough to keep the piece in place.

• Install the three bolts, springs, and nuts for the ball joint next. Tighten each bolt until there are two to three threads protruding through the nut.

• After the ball joint has been secured and seated, the eight exhaust flange nuts should be tightened evenly and torque to 100-110 inch pounds.

• Finally, install the bolt and nut on the slip joint connector. Tighten only enough to prevent the bolt from rotating. Do not over tighten.

4.1.3.2. Verification • Insure all fasteners are secure • Cotter keys where required

4.1.4. Alternator Removal/Installation



Figure 4‐8 O‐200 Alternator



4.1.4.1. Required tools: • ½ wrench



• Disconnect the three alternator power leads. • Remove the three nuts retaining the alternator and pull the alternator aft

until it clears the engine. 4.1.4.5. Installation

• Slide alternator into engine case until the alternator flange is against the case. The alternator may need to be rotated to make sure the gears line up.

• Tighten the three mounting nuts. • Reconnect the three alternator power leads.

4.1.4.6. Verification • All fasteners secure • All cotter keys in place

4.1.5. Spark Plug Removal/Installation

4.1.5.1. Required Tools: • 7/8 inch deep socket or specialty spark plug socket • ¾ inch wrench • 7/16 inch wrench.

4.1.5.2. Parts required: • Spark plug anti seize compound

4.1.5.3. Level of Maintenance: Preventive 4.1.5.4. Certification Required: Sport Pilot Certificate or higher

• Open or remove any cowling required to access spark plugs. • Loosen and remove the large nuts on the ends of the spark plug leads while

holding the small nut still to prevent twisting of the lead. • Remove the spark plugs from the cylinders. • Clean spark plugs and set the gap according to the plug manufacturer’s

instructions. 4.1.5.5. Installation

• Put a light coat of anti seize compound on the threads of the spark plugs. • Install plugs in cylinders and torque to 25-30 foot pounds. • Reattach spark plugs leads making sure that the correct lead is attached to

the correct plug. The leads are marked T1 (Top plug cylinder #1), B4 (Bottom plug cylinder #4), etc.

• Reinstall any cowling that was removed. • Run-up the engine to check for correct installation and hook up.

4.1.5.6. Verification • Check leads and sparkplugs tight

4.1.6. Oil Change

4.1.6.1. Tools Required: • Diagonal cutters • 7/8 wrench (no oil quick drain)



• length of 3/8 inch I.D. flexible tubing (with oil quick drain) • 1 inch wrench/socket

4.1.6.2. Parts Required: • AN900-28 Gasket (if not filter equipped) • AN900-XX (if not quick drain equipped) • Champion CH48108-1 filter (if filter equipped) • .032 safety wire

4.1.6.3. Level of Maintenance: Preventive 4.1.6.4. Certification Required: Sport Pilot Certificate or higher.

• Obtain a suitable container to capture old oil. • Run engine to warm oil. Warm oil will drain better. • If quick drain equipped, attach the length of 3/8 tubing to the drain with the

other end in the container, push up and turn to lock open. • If not quick drain equipped, cut safety wire from drain plug and use the 7/8

inch wrench to remove plug and drain oil into the container. • After oil is drained, close drain and remove tubing or reinstall drain plug with

a new AN900-XX gasket (install gasket with parting line against plug), torque to 190-210 inch pounds, and safety with safety wire.

• If filter equipped remove filter and replace with new and torque filter in accordance with filter manufacturer’s instructions. Cut open the old filter to check for metal or other contaminants.

• If not filter equipped remove safety wire from the oil screen. • Disconnect the oil temperature sender wire from the sender. • Remove the filter screen from the engine. • Inspect screen for metal or other contaminants and then clean. • Reinstall the screen using a new AN900-28 gasket with the parting line

against the screen face. Torque screen to 41.6-43.3 foot pounds. • Safety wire screen. • Reconnect the oil temperature sender wire to the sender.

4.1.6.5. Verification • Run the engine and check for leaks.

4.1.7. Other Engine Maintenance and Repair

• For all other engine maintenance such as cylinder removal/installation, internal repair, etc., refer to the latest revision of the Continental Overhaul Manual.

4.2. Engine (Jabiru 3300)



Figure 4‐9 Jabiru Front View

Figure 4‐10 Jabiru Left Front View



Figure 4‐11 Jabiru Left Rear View

Figure 4‐12 Jabiru Airbox



Figure 4‐13 Jabiru Right Rear View



4.2.1. Engine Removal/Installation

4.2.1.1. Required Tools: • Engine hoist • 3/8 wrench/socket • 9/16 wrench/socket • diagonal cutters • soft-face hammer • torque wrench • flat head screw driver



• Remove propeller. • Remove engine cowling. • Removed scat hose from engine. • Disconnect throttle cable from carburetor. • Disconnect wires from coil packs. • Disconnect EGT, CHT, and carburetor temperature sensor leads (if

equipped). • Disconnect alternator power leads. • Disconnect fuel line from carburetor. • Disconnect choke cable from carburetor. • Remove exhaust muffler. • Disconnect oil cooler lines at the oil filter adapter plate. • Raise and support tail of airplane at a near level attitude. • Attach engine hoist to engine lift ring. • Support weight of engine with hoist. • Remove the six bolts securing engine mount to the airframe. • Remove the engine, with mount attached, from the airplane.

4.2.1.5. Installation • For installation, perform above procedures in reverse order. • Torque the bolts mounting the engine mount to the airframe and the engine

mount to the engine to 15 foot pounds. 4.2.1.6. Verification

• Verify all fasteners, wires and hoses are secure • Run engine and check for leaks



4.2.2. Exhaust Muffler Removal/Installation

4.2.2.1. Removal 4.2.2.2. Required Tools:

• Pliers • Allen wrench set (standard sizes)

4.2.2.3. Parts Required: None 4.2.2.4. Level of Maintenance: Line 4.2.2.5. Certification Required: A&P or LSA Repairman Maintenance

• Removed top and bottom cowling to access the engine. • Using pliers, remove the four springs securing the exhaust can to the

exhaust tubes. • Remove exhaust muffler by pulling it off of the exhaust tubes. Light tapping

with a soft face mallet will aid in removal. It may be necessary to loosen the cap screws securing the exhaust tubes to the cylinders. This will allow the tubes to move and free the muffler from the engine.

4.2.2.6. Installation • Install in reverse order. • If the exhaust tubes were loosened at the cylinders, consult the Jabiru

service manual for proper torque values. 4.2.2.7. Verification

• Verify all fasteners, wires and hoses are secure • Run engine and check for leaks

4.2.3. Spark Plug Removal/Installation

4.2.3.1. Required Tools: 18mm thin wall, deep socket 4.2.3.2. Parts required: Spark plug anti seize compound 4.2.3.3. Level of Maintenance: Preventive 4.2.3.4. Certification Required: Sport Pilot Certificate or higher

• Remove top cowling and cylinder cooling ducts to access spark plugs. • Pull the leads to disconnect them from the plugs. • Remove the spark plugs from the cylinders using the 18mm socket. • Clean spark plugs and set the gap according to the plug manufacturer’s

instructions. 4.2.3.5. Installation

• Put a light coat of anti seize compound on the threads of the spark plugs. • Install plugs in cylinders and torque to 8 foot pounds (96 inch pounds).

Place CHT thermocouples in the same position as removed. • Reattach spark plugs leads making sure that the correct lead is attached to

the correct plug. • Reinstall cooling ducts and top cowling.

4.2.3.6. Verification • Run the engine to check for correct installation and hook up.



4.2.4. Oil Change

4.2.4.1. Tools Required: Diagonal cutters, ¾ inch wrench 4.2.4.2. Parts Required: Oil, Wix 51394 Oil filter or equivalent, .032

safety wire 4.2.4.3. Level of Maintenance: Preventive 4.2.4.4. Certification Required: Sport Pilot Certificate or higher.

• Obtain a suitable container to capture old oil. • Run engine to warm oil. Warm oil will drain better. • Position container under drain plug and using the ¾ inch wrench, remove

plug. When the oil is warm, it tends to shoot out sideways as well as run down. Position container accordingly.

• After oil is drained, reinstall drain plug and safety with .032 safety wire. • Remove oil filter and replace with new one. Safety with .032 safety wire.

Cut open the old filter to check for metal or other contaminants. • Fill oil sump with the proper quantity, type, and grade of oil. (Refer to

Section 1 of this manual and the Jabiru Maintenance Manual). 4.2.4.5. Verification

• Run the engine and check for proper operation and leaks.

4.2.5. Other Engine Maintenance and Repair

• For all other engine maintenance, refer to Jabiru Instruction and Maintenance Manual, Document No. JEM3304-2, dated October 2006 and Jabiru service documents. All publications are available on the Jabiru website www.jabiru.net.au.


http://www.jabiru.net.au/


5. Fuel System

Figure 5‐1 Fuel Tank Caps / Covers

Figure 5‐2 Fuel Sight Gauges



5.1. Fuel Tank Removal/Installation


• ¼ inch socket or flat screwdriver • 3/8 inch wrench/socket • #1 and #2 Phillips screwdriver • Needle nose pliers • diagonal cutters • pliers

5.1.2. Parts Required:

• None

5.1.3. Level of Maintenance: Line

5.1.4. Certification Required: A&P or LSA Repairman Maintenance

• Drain fuel tanks through the belly sump drain located on the underside of the fuselage.

• Then open the fuel drains on the underside of each tank to remove as much of the residual fuel as possible.

• Remove the wing root fairings and fuel tank covers. • Disconnect the fuel sight gage lines and remove the fittings from the tanks. • Disconnect the forward and aft flexible fuel lines and remove the fittings

from the tanks. • Disconnect both ends of the drag tube that runs through the tank and

remove from the tank. • Remove screws from both tank hold down straps and raise the straps. • Remove the fuel tank.

5.1.4.1. Installation • Installation is done in reverse.

5.1.5. Verification

• Verify lines and clamps are tight. • Verify fuel lines have torque seal applied • Fuel aircraft and check for leaks

5.2. Gascolator Removal/Installation



Figure 5‐3 Gascolator




• Diagonal cutters • safety wire pliers


• .032 safety wire

5.2.3. Level of Maintenance: Preventive

5.2.4. Certification Required: Sport Pilot Certificate or higher

• Turn fuel shut off valve to the OFF position. • Drain remaining fuel in the gascolator. • Cut safety wire from thumb screw. • Loosen thumb screw from bowl and push it aft towards the firewall. • Pull the bowl from the gascolator and inspect contents for debris. • Inspect seal for discoloration and deterioration. • Wipe clean with cloth to remove debris. • Inspect and clean gascolator screen.

5.2.4.1. Installation • Reinstall screen and seal. • While holding the bowl in place position the thumb screw and tighten

securely. • Turn fuel valve back on and check gascolator for any leaks. • Safety wire thumb screw.

5.2.4.2. Verification • Verify all fasteners are tight • Verify no fuel leaks

5.3. Fuel Gauge Removal

Figure 5‐4 Fuel Sight Gauges



5.3.1.1. Required Tools: • #1 and #2 Phillips screwdriver • diagonal cutters



• Drain fuel tanks into fire safe containers (Use belly sump to drain fuel) • Remove wing root fairings. • Disconnect fuel lines from tank to gauge. • Pull fuel gauge from the wing root closeout into cabin.

5.4. Fuel Gauge Installation


• #1 Phillips screwdriver


• Cable ties, if necessary • new fuel gage connecting line (P/N XXXXX)



• Install gage in wing root closeout. • Inspect flexible hose for damage and if necessary replace with new line. • Connect fuel tank to gage with flexible line. • Secure line on each fitting with a cable tie. • Refill fuel tanks and check for leaks. • Reinstall wing root fairings.

5.4.5. Verification

• Verify all fasteners secure • Fuel aircraft and check for fuel leaks



6. Propeller

6.1. Propeller Removal (All Types)


• Phillips head screw driver • Diagonal Cutters • 9/16 inch wrench/socket


• None



• Remove the spinner taking out the Phillips head screw in the center of the spinner.

• Cut all safety wire from bolt heads. • Remove all six bolts and spinner bracket. • Carefully slide propeller off the crankshaft.



6.2. Propeller Installation (Wood/Composite)


• Diagonal cutters or safety wire pliers • #2 Phillips screw driver • 9/16 inch socket • calibrated torque wrench


• one 300-PP0091 Prop Hub Flange Plate • six AN6H41A bolts • ten AN960-616 washers • 0.041 safety wire • one 310-PP0064 Spinner Bracket • one 200-PP0004 Spinner Assembly



• Inspect propeller and hardware before installation for any defects. • Turn crankshaft so that the #1 cylinder is at TDC. • Place propeller on crankshaft with blade number one at the one o’clock

position and blade number two at the 7 o’clock position. • Place the propeller hub flange plate over the crankshaft. • Install four bolts with two washers under each bolt head. • Place the other two bolts with one washer under the head through the

spinner bracket and then in the two remaining bolt holes in the propeller hub.

• Torque all six bolts in an alternating pattern to 175 to 225 inch pounds. Bolt torque must be checked every 50 hrs or seasonally according to the manufacturer’s instructions.

• Check propeller track in accordance with AC43.13.1B. • Safety wire all bolts using .041” safety wire. • Attach spinner to spinner bracket with one Phillips screw, ensure spinner is

centered on the prop hub. 6.2.4.1. Verification

• Check prop secure • Check for proper safety wire

6.3. Propeller Installation (Metal)

6.3.1. Tools Required:

• Safety wire pliers • #2 Phillips screw driver • 9/16 inch socket and ratchet • calibrated torque wrench

6.3.2. Required Parts:



• propeller bolt kit (supplied with propeller) • one 310-PP0064 Spinner Bracket • one 200-PP0004 Spinner Assembly



• Inspect propeller and hardware before installation for any defects. • Turn crankshaft so that the #1 cylinder is at TDC. • Place propeller on crankshaft with blade number one at the one o’clock

position and blade number two at the 7 o’clock position. • Install four of the mounting bolts in the prop hub until snug. • Put the remaining two bolts through the spinner bracket and then in the

propeller. • Torque propeller bolts to 23-25 lbs/ft in an alternating pattern. • Check propeller track in accordance with AC43.13.1B. • Safety wire bolts. • Attach spinner to spinner bracket using the Phillips head screw.

6.3.4.1. Verification • Check prop secure • Check for proper safety wire

6.4. Propeller Repair • All minor propeller repairs should be accomplished in accordance with the

manufacturer’s instructions or FAA Advisory Circular AC43.13.1B. • All major propeller repairs must be accomplished by an approved propeller

repair station or the propeller manufacturer.



7. Utility Systems (Heater/Vent)

Figure 7‐1 Cabin Heat Inlet

Figure 7‐2 Window Vents



Figure 7‐3 Cabin Heat Outlet



7.1. Description • The cabin heat and ventilation system comprises the utility systems. • The cabin heat system consists of a heat shroud around the exhaust and a

cabin heat box to control airflow. The heat shroud has two scat hoses, one that connects to the intake at the front of the cowling and on to the cabin heat box located on the firewall. The cabin heat box has a push pull cable that runs in the cabin and to the instrument panel for operation of the cabin heat.

• The ventilation system is an option that installs “vista vents” in the side window or windows. These vents draw in fresh air and can be adjusted and turned off from the inside.

7.2. Heater System

7.2.1. Removal of Heat Shroud

7.2.1.1. Required Tools: • Common screw driver • 5/16 socket and ratchet



• Open or remove cowling as necessary and loosen the two clamps on either end of the shroud on the left hand side of the wye in the exhaust.

• Remove the clamps on the scat hoses and remove the scat hoses. • Pull the clamps off of the shroud. • Spread the heat shroud open and pull it from the exhaust system.

7.2.2. Installation of Heat Shroud

7.2.2.1. Required Tools • Common screw driver • 5/16 socket and ratchet



• Assemble the heat shroud around the exhaust pipe on the left hand side of the exhaust pipe.

• Attach the scat hose from the fresh air intake to the hose fitting on the outboard side of the shroud. Secure with clamps.

• Attach the scat hose from the cabin heat box to the hose fitting on the inboard section of the heat shroud. Secure with clamps.

• Clock the shroud to keep the SCAT hose clear of obstructions and tighten with clamps on the scat hose to keep in place. Install and tighten the clamps on both sides of the shroud.

7.2.2.5. Verification • Make sure shroud is secure to exhaust pipe and will not vibrate.

7.3. Removal of cabin heat box




• Phillips and common screw drivers


• none



• Disconnect scat hose from cabin heat box using a Phillips screw driver • Disconnect control cable from cabin heat box. • Drill out rivets to remove cabin heat box from firewall. • Inspect cabin heat box for cracking or corrosion • Inspect Valve for proper operation

7.4. Installation of cabin heat box


• Phillips and common screw drivers • pop rivet gun


• None



• Assemble cabin heat box to the firewall using four Avex type pop rivets • Assemble control cable to the cabin heat box using the provided bolt and nut • Attach scat hose to the cabin heat box

7.4.5. Verification

• Pull control knob from inside cabin to insure proper installation.



7.5. Ventilation System

7.6. Removal of Vents


• Phillips and common screw drivers • pliers


• None



• Remove 4 screws and nuts front the vent • Carefully remove vents from side windows

7.7. Installation of Vents


• Phillips and common screw drivers • Pliers


• Loc-tite (blue) • Level of Maintenance: Line


• Install vents in reverse order. • Use Loc-tite on screws and tension adjuster knob

7.7.4. Verification

• Verify vents are secure and can be adjusted



8. Instruments and Avionics

Figure 8‐1 Instrument Panel



8.1. Description • Instruments and avionics will vary from aircraft to aircraft depending on

options and configuration of the aircraft. All items are installed using normal aircraft techniques and standards from FAA Advisory Circular 43.13-1B. For detail instructions refer to the manufacturer installation and operation manuals.

8.2. Removal


• # 2 Phillips head and standard screw drivers • 5/16 wrench/socket • 3/8 allen head driver


• None



8.3. See owner’s manual

8.4. Installation


• # 2 Phillips head and standard screw drivers • 5/16 wrench/socket • 3/8 allen head driver


• None



• Reverse removal procedure

8.5. Verification • Verify instruments are secure • Verify proper operation of instruments



9. Electrical System

Figure 9‐1 Battery Installation

9.1. Description Electrical System: Electrical power is supplied by a 14‐volt, direct‐current (DC), 30/20 amp engine‐driven permanent magnet alternator. A 12‐Volt, sealed battery is located on the firewall. Circuit breakers are placed on the lower left hand portion of the instrument panel. Placards clearly label the circuit breakers. The starter switch for the electric starter is located in the left side wing root near the left fuel tank quantity indicator. The master and avionics switches are situated on the lower left hand portion of the instrument panel. Light switches are located on the lower left portion of the instrument panel or on the forward portion of the right wing root closeout panel. A voltmeter or amp meter on the instrument panel gives the pilot information regarding the health of the electrical system. An amber over voltage warning light on the panel warns of an over voltage condition.

9.2. Schematic



1

0. Structural Repair

• Other than standard repairs as listed in FAA Advisory Circular 43.13-1B no Structural Repairs are authorized.

• • American Legend Aircraft Company must be contacted for guidance on any

repairs required.



11. Paintings and Coverings • All aircraft are covered with Dacron fabric and are finished with either

PolyFiber, Air-Tech or Ranthane systems. Paints and primers are two part epoxies.

• Aircraft can be washed with a mild detergent and after 90 days from paint application can be waxed with a quality automotive product.

• Other than normal washing and waxing no maintenance is required. • For more detailed information refer to manufactures covering and painting

manuals. • Inspection Procedure for fabric. The basic concept is that the paint and

coatings should remain in good shape to protect the fabric. • Inspect the overall condition of the paint and coatings • If the fabric is flexible and resilient when pushed hard with a knuckle it is

good and no further inspection is required. • If the paint is brittle, cracked and ring wormed and readily cracks when

pushed hard with a knuckle it is subject to further inspection. As long as there are no big chucks out of the paint, and there is no sun exposed fabric, the airplane is still considered air worthy, but should be monitored for problems continually until the next annual inspection

• If there are significant areas of the paint and coatings missing, advanced peeling, sun-exposed fabric the aircraft could be considered un-airworthy and the American Legend Aircraft company should be contacted for further repair instructions.



Appendix A. Reporting Forms The following forms are to be used to contact American Legend Aircraft. Additional copies as well as updated revisions may be found on the American Legend Website, www.legend.aero



Change of Address Form



Change of Ownership Form



Service Difficulty Report



Appendix B. 100 Hour / Annual Checklist An example of the Annual Condition / 100 Hour Inspection Checklist is included in Appendix B of the Maintenance Manual. The latest revision of the checklist can be found on the American Legend Website at www.legend.aero.



Legend Cub Maintenance Manual · American Legend Aircraft . Maintenance Manual . Models AL3, AL11 ....

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