legend cub maintenance manuallegend cub aircraft uses standard aircraft quality parts and materials....

American Legend AL18 Super

Legend

Maintenance Manual

Rev 2.0

Date of Revision: 9/27/2013

American Legend Document #: 500-MS1014

Legend Aircraft Maintenance Manual – AL18 2

© American Legend Aircraft Company Rev 2.0


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. Three-View Drawing ................................................................................................................... 10

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

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

1.6. Source to Purchase Parts ............................................................................................................ 10

1.7. List of Disposable Replacement parts ......................................................................................... 10

1.8. Engine Specifications .................................................................................................................. 11

1.9. Weight and Balance Information ................................................................................................ 12

1.10. Tire Inflation ............................................................................................................................ 12

1.11. Approved Oils and Capacities ................................................................................................. 13

1.11.1. Lycoming YO-233 ................................................................................................................ 13

1.12. Recommended Fastener Torque Values ................................................................................. 13

1.13. General Safety Information..................................................................................................... 13

1.14. Instructions for Reporting Possible Safety of Flight Concerns during Inspections/Maintenance ....................................................................................................................... 13

2. Inspections ......................................................................................................................................... 14

3. Structures ........................................................................................................................................... 15

3.1. Wing ............................................................................................................................................ 15

3.1.1. Wing Removal ..................................................................................................................... 15

3.1.2. Wing Installation ................................................................................................................. 16

3.2. Empennage ................................................................................................................................. 18

3.2.1. Trim Jackscrew Mechanism Removal/Installation .............................................................. 18

3.2.2. Required Tools: ................................................................................................................... 18

3.2.3. Torque Tube Removal/Installation ..................................................................................... 18

3.3. Landing Gear ............................................................................................................................... 20

3.3.1. Landing Gear Removal/Installation ..................................................................................... 20

3.4. Tailwheel Removal/Installation .................................................................................................. 22

3.5. Structural Control Surfaces ......................................................................................................... 24




3.5.1. Aileron Removal .................................................................................................................. 24

3.5.2. Aileron Installation and Rigging .......................................................................................... 26

3.5.3. Elevator Removal ................................................................................................................ 27

3.5.4. Elevator Installation and Rigging......................................................................................... 28

3.5.5. Rudder Removal .................................................................................................................. 29

3.5.6. Rudder Installation .............................................................................................................. 31

3.5.7. Stabilizer Removal ............................................................................................................... 32

3.5.8. Stabilizer Installation and Rigging ....................................................................................... 32

3.5.9. Flap Removal/Installation ................................................................................................... 33

3.5.10. Flap Control Mechanism Removal/Installation................................................................... 36

4. Engine ................................................................................................................................................. 37

4.1. Engine (Lycoming YO-233) .......................................................................................................... 37

4.1.1. Engine Removal/Installation ............................................................................................... 40

4.1.2. Exhaust Removal ................................................................................................................. 40

4.1.3. Exhaust Installation ............................................................................................................. 43

4.1.4. Alternator Removal/Installation ......................................................................................... 43

4.1.5. Spark Plug Removal/Installation ......................................................................................... 45

4.1.6. Oil Change ........................................................................................................................... 45

4.1.7. Other Engine Maintenance and Repair ............................................................................... 46

5. Fuel System ........................................................................................................................................ 47

5.1. Fuel Tank Removal/Installation .................................................................................................. 49

5.1.1. Required Tools: ................................................................................................................... 49

5.1.2. Parts Required: .................................................................................................................... 49

5.1.3. Level of Maintenance: Line ................................................................................................. 49

5.1.4. Certification Required: A&P or LSA Repairman Maintenance ............................................ 49

5.1.5. Verification .......................................................................................................................... 49

5.2. Gascolator Removal/Installation ................................................................................................ 49

5.2.1. Required Tools: ................................................................................................................... 51

5.2.2. Parts Required: .................................................................................................................... 51

5.2.3. Level of Maintenance: Preventive ...................................................................................... 51

5.2.4. Certification Required: Sport Pilot Certificate or higher ..................................................... 51

5.3. Fuel Gauge Removal ................................................................................................................... 51

5.4. Fuel Gauge Installation ............................................................................................................... 52

5.4.1. Required Tools: ................................................................................................................... 52

5.4.2. Parts Required: .................................................................................................................... 52






5.4.5. Verification .......................................................................................................................... 52

6. Propeller ............................................................................................................................................. 53

6.1. Propeller Removal, Installation, and Repair ............................................................................... 53

6.1.1. Required Tools .................................................................................................................... 53

6.1.2. Required Parts ..................................................................................................................... 53



6.1.5. Other Propeller Maintenance and Repair ........................................................................... 55

7. Utility Systems (Heater/Vent) ............................................................................................................ 56

7.1. Description .................................................................................................................................. 56

7.2. Heater System ............................................................................................................................. 57

7.2.1. Removal of Heat Shroud ..................................................................................................... 57

7.2.2. Installation of Heat Shroud ................................................................................................. 57

7.3. Removal of cabin heat box .......................................................................................................... 57

7.3.1. Required Tools: ................................................................................................................... 57

7.3.2. Parts Required: .................................................................................................................... 57



7.4. Installation of cabin heat box...................................................................................................... 58

7.4.1. Required Tools: ................................................................................................................... 58

7.4.2. Parts Required: .................................................................................................................... 58

7.4.3. Level of Maintenance: Line ................................................................................................ 58


7.4.5. Verification .......................................................................................................................... 58

7.5. Ventilation System ...................................................................................................................... 59

7.6. Removal of Vents ........................................................................................................................ 59

7.6.1. Required Tools: ................................................................................................................... 59

7.6.2. Parts Required: .................................................................................................................... 59

7.6.3. Level of Maintenance: Line ................................................................................................ 59


7.7. Installation of Vents .................................................................................................................... 59

7.7.1. Required Tools: ................................................................................................................... 59

7.7.2. Parts Required: .................................................................................................................... 59





7.7.4. Verification .......................................................................................................................... 59

8. Instruments and Avionics ................................................................................................................... 60

8.1. Description .................................................................................................................................. 61

8.2. Removal ...................................................................................................................................... 61

8.2.1. Required Tools: ................................................................................................................... 61

8.2.2. Parts Required: .................................................................................................................... 61



8.3. See owner’s manual .................................................................................................................... 61

8.4. Installation .................................................................................................................................. 61

8.4.1. Required Tools: ................................................................................................................... 61

8.4.2. Parts Required: .................................................................................................................... 61



8.5. Verification .................................................................................................................................. 61

9. Electrical System ................................................................................................................................ 62

9.1. Description .................................................................................................................................. 62

9.2. Schematic .................................................................................................................................... 62

10. Structural Repair ............................................................................................................................. 64

11. Painting and Coating ....................................................................................................................... 65

12. Revisions ......................................................................................................................................... 66

13. Feedback Form ................................................................................................................................ 67

14. Misc. ................................................................................................................................................ 68

14.1. Overhaul .................................................................................................................................. 68

14.2. Major Repairs and Alterations ................................................................................................ 68

14.3. Task-Specific Training .............................................................................................................. 69

14.4. Safety Directives...................................................................................................................... 69

14.5. Safety Alert .............................................................................................................................. 69

14.6. Service Bulletin ........................................................................................................................ 69

14.7. Notification ............................................................................................................................. 69

14.8. Reporting Forms and 100 Hour/Annual Checklist .................................................................. 70

Appendix A. Equipment List ........................................................................................................................ 71

Appendix B. Reporting Forms .................................................................................................................... 73

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




Table of Figures Figure 1-1 Aircraft Specification ............................................................................................................. 9 Figure 1-2 Aircraft Three View Drawing ..................................................................................................... 10 Figure 1-3 Engine Specifications .......................................................................................................... 11 Figure 1-4 Sample Loading Problem .................................................................................................... 12 Figure 1-5 Center of Gravity Limits ...................................................................................................... 12 Figure 1-6 Main Tire Inflation ............................................................................................................... 12 Figure 1-7 Tailwheel Tire Inflation ....................................................................................................... 12 Figure 1-8 Lycoming YO-233 Approved Oils / Capacities ..................................................................... 13 Figure 3-1 Wing View .................................................................................................................................. 15 Figure 3-2 Jackscrew .................................................................................................................................. 18 Figure 3-3 Jackscrew Access ....................................................................................................................... 18 Figure 3-4 Torque Tube Rear ...................................................................................................................... 19 Figure 3-5 Torque Tube Front ..................................................................................................................... 19 Figure 3-6 Landing Gear .............................................................................................................................. 20 Figure 3-7 – Landing Gear Cabane / Struts ................................................................................................. 21 Figure 3-8 Landing Gear Leg ....................................................................................................................... 21 Figure 3-9 Tailwheel Rear View .................................................................................................................. 23 Figure 3-10 Tailwheel Side View ................................................................................................................. 23 Figure 3-11 Aileron Balance Cable .............................................................................................................. 24 Figure 3-12 Aileron Lower View ................................................................................................................. 25 Figure 3-13 Aileron Upper View .................................................................................................................. 25 Figure 3-14 Elevator .................................................................................................................................... 27 Figure 3-15 Rudder ..................................................................................................................................... 30 Figure 3-16 Control Surface Travels ....................................................................................................... 31 Figure 3-17 Flap, Lower View ...................................................................................................................... 34 Figure 3-18 Flap, Upper View ...................................................................................................................... 35 Figure 4-1 Lycoming YO-233 Installation Top View .................................................................................... 37 Figure 4-2 YO-233 Gascolator ..................................................................................................................... 38 Figure 4-3 YO-233 Side View ....................................................................................................................... 38 Figure 4-4 YO-233 Front View ..................................................................................................................... 39 Figure 4-5 Exhaust, Right Side ..................................................................................................................... 41 Figure 4-6 Exhaust, Left Side ....................................................................................................................... 41 Figure 4-7 Exhaust, Rear ............................................................................................................................. 42 Figure 4-8 YO-233 Alternator ...................................................................................................................... 44 Figure 5-1 Fuel Tank Caps / Covers ............................................................................................................. 47 Figure 5-2 Fuel Sight Gauges ....................................................................................................................... 47 Figure 5-3 Fuel System Diagram ................................................................................................................. 48 Figure 5-4 Gascolator .................................................................................................................................. 50 Figure 5-5 Fuel Sight Gauges ....................................................................................................................... 51 Figure 6-1 .................................................................................................................................................... 54 Figure 6-2 .................................................................................................................................................... 55 Figure 6-3 .................................................................................................................................................... 55 Figure 7-1 Cabin Heat Inlet ......................................................................................................................... 56 Figure 7-2 Cabin Heat Outlet ...................................................................................................................... 56 Figure 8-1 Instrument Panel ....................................................................................................................... 60 Figure 9-1 Battery Installation .................................................................................................................... 62 Figure 9-2 Electrical System Block Diagram ................................................................................................ 63




Figure 9-3 Electrical Bus Diagram ............................................................................................................... 63




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

AL18

Continental YO-233 Wing Span 35’ 6”

Length 22’ 8” Height

(standard wheels and

prop)

7’ 6”

Empty Weight (standard airplane)

845 lbs

Design Gross Weight (land)

1320

Design Gross Weight (sea)

1430

Useable Fuel Capacity

30 U.S. Gallons

Seating 2 Persons, Tandem

Figure 1-1 Aircraft Specification




1.3. Three-View Drawing

Figure 1-2 Aircraft Three View Drawing

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 according to the Star Gloss covering system.

1.5. Equipment List

See Appendix A for the equipment list for this aircraft.

1.6. Source to Purchase Parts

Parts can be procured directly from the component manufacturer or

American Legend Aircraft Company. For example, for avionics replacement

with the same model, aircraft owner can purchase from off the shelf

suppliers.

Our part suppliers include Garmin, TruTrak, AeroLED, and JDI. For contact

information on alternate suppliers for individual components or for more

information on the supplier of a specific component, please contact American

Legend.

1.7. List of Disposable Replacement parts

See YO-233 Lycoming Illustrated Parts Catalog for list of engine related

disposable parts.




1.8. Engine Specifications

AL18

Lycoming YO-233 Rating 115 hp

Disposition

Normally aspirated, direct drive, air cooled, horizontally opposed,

carbureted, four cylinder engine with 233 cu. in. displacement

Time Between Overhaul

2200 hours

Oil Specification

SAEJ189 or MIL-L-2285

Oil Quantity 6 quarts maximum, 4 quarts minimum Fuel Grade (minimum)

100LL Aviation Fuel

Figure 1-3 Engine Specifications




1.9. Weight and Balance Information

Sample Airplane Actual Airplane

Weight Station Moment Weight Station Moment

Empty weight

845 11.6 9800

Front Seat

190 11 2090 11

Back Seat

140 37 5180 37

Fuel (6.0 x 20 gal)

120 24 2880 24

Baggage (75 lbs max)

20 57 1140 57

Total

Aircraft

1320

16.0

21,090

Figure 1-4 Sample Loading Problem

Gross Weight Forward Limit Aft Limit

1320 lbs 10.5” 21.0” Figure 1-5 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 1-6 Main Tire Inflation

Tailwheel Tire Pressure

Alaska Bushwheel TBD TBD Figure 1-7 Tailwheel Tire Inflation




1.11. Approved Oils and Capacities

1.11.1. Lycoming YO-233

Temperature SAEJ189 OR MIL-L-2285 Capacity

Above 80°F SAE 15W-50, SAE 20W-50 or SAE

60 4 – 6 quarts

Above 60°F SAE 40 or SAE 50 4 – 6 quarts

Between 30°F and 90°F SAE 40 4 – 6 quarts

Between 0°F and 70°F SAE 30, SAE 40, or SAE 20W-40 4 – 6 quarts

Below 10°F SAE 30 or SAE 20W-30 4 – 6 quarts

Figure 1-8 Lycoming YO-233 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 Lycoming, Sensenich and 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. Instructions for Reporting Possible Safety of Flight Concerns during

Inspections/Maintenance The Service Difficulty Report is included in Appendix B of this manual. The form may also be found at www.legend.aero.

http://www.legend.aero/




2. Inspections The 12-Month Condition / 100 Hour Inspection Checklist is included in Appendix C 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

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 3.5.1, Aileron Removal)

Remove flaps and flap mechanism (See items 3.5.9, Flap

Removal/Installation, and 3.5.10, Flap Control Mechanism

Removal/Installation)

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.

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.

Figure 3-1 Wing View




3.1.2. Wing Installation


½ inch socket/wrench

3/8 inch socket/wrench


diagonal cutters

pliers

Large Hammer

Phillips Screwdriver


None



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 3.5.2, Aileron Installation and Rigging).

Install and rig flap (See items 3.5.9, Flap Removal/Installation, and 3.5.10,

Flap Control Mechanism Removal/Installation)

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

3.2.2. Required Tools:

½ inch wrench/socket

diagonal cutters

pliers

9/16 inch wrench/socket




None


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

3.2.3. Torque Tube Removal/Installation

Figure 3-2 Jackscrew

Figure 3-3 Jackscrew Access




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


Cotter Keys



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.


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


MS24665-498 Cotter Pins.



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.


All fasteners tight

All cotters keys installed

3.4. Tailwheel Removal/Installation




Figure 3-9 Tailwheel Rear View

Figure 3-10 Tailwheel Side View





9/16 wrench/socket

7/16 wrench/socket

diagonal cutters

pliers


AN380-2-2 cotter pins (4)


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.


All fasteners tight

Verify rudder pedals move tail wheel and verify “break away”

All cotter keys installed

3.5. Structural 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


None



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

Spring Scale

Pliers


3.5.2.2. 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.

From upper zero butt line, adjust the cable tension on aileron balance cable

to 1.5 ± .25 inches of cable deflection with 5 lbs of pressure.


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





Diagonal cutters

Pliers


9/16 inch socket wrench



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


Diagonal cutters

Pliers



Spring scale


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.


After proper travels are verified, insure that both cables are tensioned

equally at 2.75 ± .25 in deflection with 4 pounds of pressure measured from

bottom of jack screw.

Also ensure 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




3.5.5.1. Tools Required


diagonal cutters

pliers

hammer

punch


None



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



diagonal cutters

pliers

hammer

punch


None



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.


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 Travels Elevator 25 Up 29 Down Rudder 32 Left 32 Right Aileron 18 Up 18 Down Stabilizer 2.5 Up 4 Down

Figure 3-16 Control Surface Travels




3.5.7. Stabilizer Removal




½ inch wrench/socket.


None



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



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.


All fasteners tight

All cotter keys in place

3.5.9. Flap Removal/Installation




Figure 3-17 Flap, Lower View




Figure 3-18 Flap, Upper View





2 7/16” wrenches

Side cutters

Needle-nose plyers

Hammer

Punch


None



Remove top and bottom wing to fuselage panels.

Remove AN4 bolt from flap pushrod, unhook spring, remove outboard clevis

pin and inboard bolt and spacers.


For installation, perform above procedures in reverse order.

Before installation of clevis pin and bolt, add lubricant.


All fasteners tight.

All cotter keys in place.

3.5.10. Flap Control Mechanism Removal/Installation


2 3/8” wrenches

2 7/16” wrenches

Rubber hammer


None



Remove wing to body panels.

Remove bolt connecting flap horn to heim joint of flap push pull tube, then

remove bolt connecting flap horn to flap torque tube.

Remove bolt from flap handle to flap torque tube.

Remove bolt which attaches the angle setting flap angle setting linkage.

Remove the flap horns (use rubber hammer if needed).

Remove the bushing at each side of the torque tube which connects the

torque tube to the fuselage tab.

Remove torque rod.

Disconnect pushrod to flap springs.

Remove heim joint from pushrod on each side.




All fasteners tight.

All cotter keys in place.




4. Engine

4.1. Engine (Lycoming YO-233)

Figure 4-1 Lycoming YO-233 Installation Top View




Figure 4-2 YO-233 Gascolator

Figure 4-3 YO-233 Side View




Figure 4-4 YO-233 Front View




4.1.1. Engine Removal/Installation


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 ground cable.

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.



Torque the bolts mounting the engine mount to the airframe and the engine

mount to the engine to 15 foot pounds.


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





½ inch socket and extension

3/8 socket and wrench

1/4 inch drive ratchet


New exhaust gaskets if necessary



Remove eight nuts securing exhaust to engine.

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


½ inch socket and extension

3/8 socket and wrench

1/4 inch drive ratchet.


None



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.

Apply anti seize compound to the inside of the female part. 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.

Tighten the eight exhaust flange nuts should be tightened evenly.


Insure all fasteners are secure

Cotter keys where required

4.1.4. Alternator Removal/Installation




Figure 4-8 YO-233 Alternator





½ wrench

9/16 wrench

5/8 wrench


None



Disconnect the alternator power leads.

Loosen 5/16” bolt, remove the alternator belt, then loosen the 3/8” bolt, and

remove alternator.


Perform removal steps in reverse.

Tighten alternator belt.

Add safety wire to 5/16” bolt


All fasteners secure

All cotter keys and safety wire are place

4.1.5. Spark Plug Removal/Installation


7/8 inch deep socket or specialty spark plug socket

¾ inch wrench

7/16 inch wrench.


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.


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.


Check leads and sparkplugs tight

4.1.6. Oil Change


Diagonal cutters




1 inch wrench/socket


Oil filter CH48114-1 Champion

.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.

After oil is drained, reinstall drain plug gasket and safety wire.

If filter equipped remove filter and replace with new and torque filter in

accordance with filter manufacturer’s instructions.


Run the engine and check for leaks.

4.1.7. Other Engine Maintenance, Repair and Overhaul

All other engine maintenance, repair, and overhaul is deferred to the

manuals listed below.

For all other engine maintenance such as cylinder removal/installation,

internal repair, etc., refer to the latest revision of the YO-233-B2A series of

manuals: Engine Maintenance Manual with revision dated at least 6/1/12 or

later, Engine Installation and Operation Manual with revision dated at least

02/12 or later, and Engine Illustrated Parts Catalog with revision dated

12/10 or later.

Refer to the latest revision of the Direct Drive Overhaul Manual for overhaul

procedures which includes disassembly and assembly procedures and

overhaul checklists.

The latest revisions can be obtained by contacting Lycoming directly, see

their website

http://www.lycoming.com/Lycoming/SUPPORT/TechnicalPublications.aspx for

details.

http://www.lycoming.com/Lycoming/SUPPORT/TechnicalPublications.aspx




5. Fuel System

Figure 5-1 Fuel Tank Caps / Covers

Figure 5-2 Fuel Sight Gauges




Figure 5-3 Fuel System Diagram




5.1. Fuel Tank Removal/Installation


¼ inch socket or flat 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.


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 5-4 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.


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.


Verify all fasteners are tight

Verify no fuel leaks

5.3. Fuel Gauge Removal

Figure 5-5 Fuel Sight Gauges






diagonal cutters


None



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




Cable ties, if necessary



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, Installation, and Repair

6.1.1. Required Tools

Torque wrench

Socket wrench

6.1.2. Required Parts

None



Attach Mounting Hub Half

o Be certain that the magneto switch is “OFF” and that both magnetos

are grounded. Chock the aircraft wheels to prevent movement. Clean

dirt and oil residue from the engine flange. Refer to Figure 6-1 for

views of the propeller assembly.

o Be certain the two springs are installed in the mounting half of the

hub.

o Place spacer (if applicable), rear spinner bulkhead, and the hub

mount half, as shown in Figure 6-1, on the engine mounting flange.

Vertical orientation of the hub is recommended for ease of assembly.

The hub and spacer (if applicable) must sit flush on the mounting

flange and the rear spinner bulkhead. NOTE: Bolt breakage will occur

if not flush. Place special lock washers, under the bolt heads, on 6

mounting bolts (AN6-XXA) and insert into the 6 mounting holes inside

the hub mount half. Each special lock washer works in pairs with the

“ramped” sides facing each other. See Figure 6-2. Position the hub

mount half, rear bulkhead, and spacer (if applicable) on the engine

flange with the six mounting bolts running through the engine flange.

Torque the 6 mounting bolts using a star pattern similar to Figure

6-3. See Table 1 for mounting bolt torques.

Insert Blades in Hub Mounting Half

o Each blade has a camber, round side (decal) and a flat side. With the

round side facing forward, and the hub in the vertical position, insert

one blade at a time into the hub mounting half. You may need to hold

the upper blade with one hand.

o Place the hub clamp half over the blade shanks. Place special lock

washers, under the heads, on clamp bolts (AN6-15A) and insert into

the hub cover half. Hand tighten the clamp bolts into the threaded

clamp bushings, taking care to start with an even gap between hub

halves on both sides. NOTE: Once fully torqued, the gap will close up

and the hub halves will meet on the hub sides.

o Rotate each blade’s leading edge slightly towards the aircraft. Insert

the pitch cartridge into the slot of the hub clamp half. You should be

able to feel the springs depress and push back when you press on the

cartridge. Take a blade with one hand and depress the pitch

cartridge. Rotate the blade’s leading edge, away from the aircraft,




until it engages the pitch cartridge. Rotate the second blade until it

engages the pitch cartridge. Grab each blade together and rock into

the pitch cartridge. You should hear a click when the blades are

seated properly. Slight play is normal after blades are locked in. Rock

the blades back and forth to center the pitch cartridge in the slot.

o Using a calibrated torque wrench and following the pattern shown in

Figure 6-3. Tighten the bolts in ¼ to ½ turn increments (this will take

several passes) until the proper torque given in Table 1is reached.

o NOTE: Have your tachometer calibrated by a professional before

performing this next operation. With the brakes on, run the engine

full throttle to verify your desired static RPM. CAUTION: YOU

SHOULD NEVER EXCEED THE MAXIMUM RPM RATING FOR

YOUR ENGINE. If you are not seeing your correct static RPM, be

certain the tach was properly calibrated. You may contact Sensenich

to purchase a slightly lower or higher pitch cartridge if you feel this is

the problem due to your density altitude. CAUTION: YOU SHOULD

NEVER MASK AN ENGINE PROBLEM WITH A PITCH CHANGE. If

you are unsure, please contact the factory.

Changing the Pitch

o If changing the pitch is necessary, first loosen the 6 clamp bolts until

the blades are loose, then hand tighten the bolts to maintain an even

hub gap in each side. NOTE: The special lock washers will click

loudly when loosened. Unlock each blade by depressing the pitch

cartridge while rotating each blade’s leading edge towards the

aircraft. Remove the first pitch cartridge. Follow steps 6 and 7 of the

Installation Procedure. NOTE: This is considered a model

change and must be noted in the logbook.

Figure 6-1




Figure 6-2

Figure 6-3

Table 1

6.1.5. Other Propeller Maintenance and Repair

For all other propeller maintenance refer to the latest version of the

Sensenich Propeller Manual.




7. Utility Systems (Heater/Vent)

Figure 7-1 Cabin Heat Inlet

Figure 7-2 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


Common screw driver

5/16 socket and ratchet


None



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


Common screw driver

5/16 socket and ratchet


None



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.


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



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



pliers


None



Remove 4 screws and nuts front the vent

Carefully remove vents from side windows

7.7. Installation of Vents



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

ITEM NUM. ITEM NAME

1 ELT SWITCH

2 HEADSET JACKS

3 AIRSPEED INDICATOR

4 ADI

5 ALTERNATOR OFFLINE

INDICATOR

6 ALTIMETER

7 JPI EMS (OPTIONAL)

8 GARMIN 796 (OPTIONAL)

9 LIGHT SWITCHES, MASTER AND

AVIONICS SWITCHES

10 INTERCOM

11 CABIN HEAT

12 CIRCUIT BREAKERS

13 INSTRUMENT LIGHT DIMMER

14 TRANSPONDER (OPTIONAL)

15 RADIO (OPTIONAL)

16 MIXTURE

17 IGNITION




18 POWER PORT

19 MUSIC IMPUT

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




Figure 9-2 Electrical System Block Diagram

Figure 9-3 Electrical Bus Diagram




10. Structural Repair

No major structural repairs or structural alterations, as outlined in ASTM

F2483, AC 43.13, or in this manual are authorized at this time.

American Legend Aircraft Company must be contacted for guidance on any

repairs required. Please go to American Legend’s website for latest contact

information at http://www.legend.aero

Upon contacting Legend Aero and describing the structural or major repair a

mechanic wants to handle, American Legend Aircraft Company will upon its

sole approval provide guidance to the mechanic or repair shop including

internal work instructions for assembly, assembly drawings if applicable and

technical support and guidance for specific repair and testing through a

letter of authorization (LOA). This LOA needs to be referenced in the repair

aircraft logbook. Items such as repairing covering and painting can be

handled per instructions and guidance in the subsequent section of this

manual and are not considered structural repair. American Legend Aircraft

Company may simply sell replacement parts to the repair facility or mechanic

to replace and install in lieu of guidance for repairing the part to maintain

quality and compliance to applicable design and quality standards.





11. Painting and Coating

All aircraft are covered, maintained, and repaired using the Star Gloss

covering system (STC SA4503NM)

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.




12. Revisions

Revision Number

Change Pages

Effected Approved (signature)

Date

1.0 Original 9/16/2013

2.0 Rewritten 9/27/2013




13. Feedback Form

See Appendix B, Reporting forms for the Feedback form, titled Service

Difficulty Report.




14. Misc.

14.1. Overhaul

Only the manufacturer of an LSA or the component to be overhauled on an

LSA may perform or authorize to be performed the overhaul of an LSA

component.

Overhaul information for the Lycoming YO-233 engine is listed in section

4.1.7

14.2. Major Repairs and Alterations

To meet the relevant ASTM standards, major repairs or alterations have to

be done such that they meet American Legend Aircraft Company’s quality

assurance and production standards. As such, any major alterations are

highly discouraged, and would require approval after testing from American

Legend Aircraft Company at cost to the aircraft owner.

Major repairs may require use of jigs and other tooling that may not be

available in the field. American Legend Aircraft Company requests that repair

stations and mechanics contact American Legend Aircraft Company for

guidance and authorization on major structural repairs.

See ASTM F2483-05 for applicable rules relating to Major Repairs and

Alterations, including concerns about meeting requirements of applicable

ASTM specifications




14.3. Task-Specific Training

No task-specific training is required for the maintenance listed in this

manual, refer to the applicable manuals for information on task-specific

training for overhaul, structural repair, etc.

14.4. Safety Directives

American Legend Aircraft Company will issue a Safety Directive to any

aircraft on any Type Certified or TSO’d (Technical Standard Orders) part

when an Airworthiness Directive (AD) is issued against it as required by the

relevant ASTM standards. In addition, the following will be provided with the

Safety Directive if applicable:

o A list of the tools needed to accomplish the task

o A list of the parts needed to perform the task

o The type of maintenance, for example, line, heavy, or overhaul, etc.

o The level of certification needed to accomplish the task, for example,

A&P, repairman inspection

o Detailed instructions and diagrams as needed to perform he task

o The method to test/inspect to verify the task was accomplished

properly

An AD is issued by the FAA when an unsafe condition is found to exist in a

type-certificated product or component installed in the aircraft. The FAA

processes and issues ADs, however, American Legend Aircraft Company is

responsible for making the corresponding Safety Directive available to

owners of Legend aircraft.

Service directives are considered as mandatory tasks in order to maintain a

condition of safe operation and compliance with the applicable original ASTM

design specification.

Contact American Legend Aircraft Company or visit the website,

www.legend.aero, for the latest information regarding Safety Directives.

14.5. Safety Alert

American Legend Aircraft Company will issue a Safety Alert when an unsafe

condition exists that may also exist in other aircraft in the fleet. All Safety

Alerts will be distributed to all operators and made available to the

appropriate airworthiness authority. Safety Alerts are considered mandatory

and must be performed immediately and documented in the aircraft

permanent records.

14.6. Service Bulletin

When no unsafe condition exists, but a service problem has become

repetitive, American Legend Aircraft Company will develop a design change

that will contribute to the safety of Legend airplanes and issue a Service

Bulletin containing information on the design change for distribution to all

operators of Legend aircraft. Service Bulletins may also be issued for minor

changes considered to be product improvements.

14.7. Notification

American Legend Aircraft Company will issue a Notification on any subject

that is considered helpful to operators. Such Notifications are intended to

maintain a good rapport with the operators, to encourage feedback on

service or other problems, or to circulate items of interest that an operator





may feel would be of value to all operators. Notifications are not considered

mandatory.

14.8. Reporting Forms and 100 Hour/Annual Checklist

See Appendices A and B for more information on the Change of Address

Form, the Change of Ownership Form, the Service Difficulty Report, and the

100 Hour/Annual Checklist




Appendix A. Equipment List

Item Description Model Number

Propeller (76” Ground Adjustable Composite)

Sensenich

2EK/C76AE-0

Tires 26” Airstreak 26126R1 26 x 12 x 6

Tail Wheel 6” Alaskan Bushwheel ABI-3200

Air/Oil Separator 300-PP0125

LED Landing Light 300-EL0278

LED Strobe and Position Lights 300-EL0277

ELT 406.0 MHZ Kannad with Antenna 300-EL0279

TruTrak ADI 3-1/8” Gemini LCD 300-EL0309

3 in 1 (Oil Pressure, Oil Temperature,

Voltmeter)

UMA

Compass, Magnetic SIRS 300-EL0042

Airspeed Indicator 3-1/8” 300-SEL0029

Tachometer 300-SEL0227

Oil Pressure Gauge Legend

Oil Temperature Gauge Legend

Voltmeter Legend

Radio, Garmin SL-40 Comm Radio 300-EL0036

Altimeter UMA 16-310-142 300-EL0091

JPI EDM740-4c w/Fuel Flow 300-EL0213

Transponder, Garmin GTX-327 Mode C 300-EL0136

Intercom , High-Noise PM-1200 300-EL0035

Altitude Encoder ACK-30 300-EL0058

Antenna, Xponder CI-101 (Mode C) 300-EL0018

Antenna, VHF Com CI-121 300-EL0019

GPS (carry on), Garmin 796 300-EL0293

Garmin GPS 796 Connector 300-EL0306

Garmin GPS 796 Panel Dock 300-EL0292

Garmin GPS Antenna GA25MCX 300-EL0246

Headset Jacks Bose 300-EL0141

Hobbs Hour Meter 300-EL0201

Hobbs Oil Pressure Switch 300-EL0202




Inclinometer (Slip Indicator) 300-EL0068

Light, Interior Cockpit LED (dimmable) 300-EL0169

Light, Interior Dimmer LED 300-EL0221

JPI Carb Temp Probe 300-EL0218

JPI Ignition Interface 790969

Battery Lithium VPH750 300-EL0283




Appendix B. 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 C. 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.


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