AMD Zodiac 601XL SLSA, Maintenance Manual

Page 1: ...ZODIAC 601XL 601XLi 650LS 650LSi SLSA Continental 0 200 Engine MAINTENANCE MANUAL Aircraft Manufacturing Design LLC P O Box 639 Eastman GA 31023 USA Tel 478 374 2759 Fax 478 374 2793 July 09...

Page 2: ...1 July 09 2 2 2 July 09 8 8 2 July 09 2 2 3 Nov 09 8 8 3 Nov 09 3 3 1 July 09 9 9 1 July 09 3 3 2 Nov 09 9 9 2 July 09 3 3 3 July 09 9 9 3 July 09 3 3 4 Nov 09 9 9 4 July 09 3 3 5 July 09 9 9 5 July 0...

Page 3: ...__________________________________________________________________ SERVICE MANUAL UPDATE LOG REV NO DATE ISSUED DATE INCORPORATED INSERTED BY 0 July 2009 AT ISSUE 1 November 2009 Note 0 1 and 0 2 with...

Page 4: ...l Airframe parts are listed in the parts assembly drawings Engine Operator s Manual from the engine manufacturer Engine Maintenance and overhaul Manual from the engine manufacturer Propeller Prop book...

Page 5: ...y master cylinders ENGINE The aircraft is powered by one horizontally opposed Continental 0 200 four cylinder air cooled engine PROPELLER The propeller used is a two blade wood fixed pitch propeller F...

Page 6: ...AMD 601XL 601XLI 650LS 650LSi SLSA MAINTENANCE MANUAL ________________________________________________________________________ GENERAL DIMENSIONS AMD 601XL 601XLi 650LS 650LSi July 09 1 3...

Page 7: ...e left and right wing fuel drain valves Oil door is located on the top engine cowling Engine top and bottom cowlings must be removed for engine access Seats and cabin side upholstery can be removed Ac...

Page 8: ...geron See Weight Balance drawing in Pilots Operating Handbook To put the airplane in a longitudinally level position either on scales or on the floor deflate the nose wheel tire until the proper posit...

Page 9: ...brakes DRAINING BRAKE SYSTEM To drain the brake system disconnect the hydraulic brake lines from the brake assembly of the main gear and place the end of each line in a suitable container Slowly pump...

Page 10: ...t list of above documents Manufacturer can be contacted by telephone at 478 374 2759 or by fax at 478 374 2793 or by mail at 415 Airport Road Eastman GA 31023 USA For engine and propeller Service Bull...

Page 11: ...ntervals are listed in Table 1 The tasks are placed in seven groups Propeller Engine Cabin Landing Gear Wing Fuselage and Empennage The first column of Table 1 states the task to be performed the seco...

Page 12: ...ck for particles on oil suction screen and sump drain plug 3 Drain oil and refill Safety plug 4 Perform cylinder compression test 5 Clean the spark plugs Adjust gap 6 Check and set magneto timing See...

Page 13: ...nspect the vacuum pump lines and separator if installed 21 Change the Oil filter 22 Inspect the oil radiator oil lines and attaching brackets if installed 23 Clean and flush oil radiator if installed...

Page 14: ...turnbuckles pulleys and guides for wear damage and safeties 6 Check elevator trim tab switch indicator for correct operation 7 Inspect the flap motor actuator extension tube actuator lever interconnec...

Page 15: ...urity condition etc 18 Inspect electrical wiring for condition security routing damage etc 19 Check condition and security of all bonding wires 20 Inspect antenna installations for condition security...

Page 16: ...nections for damage corrosion leaks etc Service the master brake cylinders 7a Inspect the rubbers at the main landing gear attachments for condition and abrasion damage and position 8 When removing wh...

Page 17: ...wear damage safeties etc 5 Inspect aileron bellcranks stops cable ends and pulley assembly for cracks damage corrosion safeties etc 6 Inspect upper and lower wing skins and leading edges for cracks l...

Page 18: ...corrosion damaged fasteners etc 3 Inspect flight control cables for routing fraying corrosion and tension 4 Inspect flight control turnbuckles pulleys and guides for wear damage and safeties 5 Check f...

Page 19: ...ns up 30 down 15o or 20 2 2 Note early models may have 30 up and down Change to 15o or 20 2 3 Check aileron deflections 10 5 2 up down 4 Check flap deflections up 0 down 20 2 5 Note early models may h...

Page 20: ...s or stronger than the original skin However flexibility must be retained so that the surrounding areas will not receive extra stress The rivets used on most parts are of the blind rivet type referenc...

Page 21: ...proper hardware See Service Manual Appendix 2 AIRCRAFT PAINTING AND COATINGS Aircraft is painted with basic automotive type paint No special type paint is required when repainting the aircraft In orde...

Page 22: ...e wheel and orient the tire with the chalk line Sight along the center rib of the tire 4 Adjust both rod ends at the end of the nose gear steering rod assemblies to align the cockpit rudder pedals Do...

Page 23: ...erform Landing gear section of Table 1 See Nose Gear Centering on previous page MAIN GEAR 1 Hoist the airplane Lift wings by placing one saw horse under each wing under spar and lift engine 2 Drain th...

Page 24: ...the wheel hub REINSTALL in reverse order using the shims to prevent lateral floppiness Safeties the nut Note Bolt torque values are given in AC 43 13 1B Perform Landing gear section of Table 1 BRAKE...

Page 25: ...owered by a Continental 0 200 engine For engine maintenance refer to the engine manual TROUBLESHOOTING Troubles peculiar to the power plant are listed in the Continental 0 200 Engine Manual along with...

Page 26: ...tio 7 0 1 See engine Operator s Manual for more information SPARK PLUGS Engine is equipped with the Light Speed Engineering spark plug conversion kit Use only Denson Spark plugs W24EMR C Spark plug ga...

Page 27: ...the engine mount 15 Place a tail stand under the tail of the aircraft before removing the engine 16 Check the engine for any attachments remaining to obstruct its removal 17 Remove the cotter pins nu...

Page 28: ...ngitudinal trim control is provided by an electric trim tab The flaps are electrically operated through an interconnecting tube and adjustable rods Use the ZODIAC drawings for installation and removal...

Page 29: ...s on rear spar and the six main spar bolts 9 Pull the wing out REINSTALL the wing in reverse order of removal Torque bolts as per FAA AC 43 13 1B Check aileron and flap deflections See aircraft part d...

Page 30: ...ol system When holding the control stick stationary beyond minor flexing there should be no free play in the system when gently pushing up or down on the aileron trailing edges Note that if the ailero...

Page 31: ...h bob on the ground Draw left and right lines on floor representing full deflection Attach a plumb line at the rear bottom of the rudder Move rudder to stops and check ELEVATOR REMOVAL 1 Remove the ru...

Page 32: ...REMOVAL 1 Remove the rudder 2 Remove elevator 3 Remove fasteners at front of saddle fiberglass center piece 4 Remove the 4 bolts attaching elevator to fuselage REINSTALL the stabilator in reverse orde...

Page 33: ...quired Parts required Rivets as detailed in section IV is required Level of Maintenance Heavy Certification required A P or SLSA Repairman Maintenance REPLACEMENT OF WING TANK 1 Drain the fuel from ta...

Page 34: ...ion leaks and safety ELECTRIC FUEL PUMP The auxiliary fuel pump is bolted to the front of the firewall REMOVAL 1 Ensure fuel valve is in OFF position 2 Disconnect fuel lines from pump 3 Disconnect ele...

Page 35: ...s are not full Incomplete ground Check ground connections at fuel transmitter No fuel pressure indication Fuel valve stuck No fuel in tanks Defective fuel pump Defective gauge Check valve Check fuel f...

Page 36: ...PEED INDICATOR GENERAL The airspeed indicator provides a means of indicating the speed of the airplane passing through the air The airspeed indication is the differential pressure reading between dyna...

Page 37: ...ng knob is rotated Out of engagement Replace instrument Setting knob set screw loose or missing Excessive vibration Tighten instrument screw if loose Replace instrument if screw is missing Cracked or...

Page 38: ...e card error Compass not properly compensated External magnetic interference Compensate instrument Locate magnetic interference and eliminate if possible Excessive oscillation Improper mounting on ins...

Page 39: ...When aircraft is equipped with an EMS see the EMS manufacturers instructions When individual gauges see the following ENGINE OIL PRESSURE GAUGE GENERAL The oil pressure gauge is mounted in the cluster...

Page 40: ...g Dull or discolored luminous marking Age Replace instrument Replace sensor on engine FUEL QUANTITY INDICATOR GENERAL The fuel quantity gauges used on the ZODIAC are mounted in the cluster on the inst...

Page 41: ...ge sensor Pressure low or pressure surges Obstruction in inlet side of pump Faulty bypass valve Faulty diaphragm Trace lines and locate obstruction Replace Replace or rebuild pump Needle fluctuation S...

Page 42: ...scillates Leaks in static lines Defective mechanism Disconnect all instruments connected to the static line Check individual instruments for leaks Reconnect instruments to static line and test install...

Page 43: ...sensitivity Misadjustment of sensitivity spring Adjust by means of sensitivity spring screw If this pulls the pointer from zero replace instrument Not working No power to indicator Check wires fuse p...

Page 44: ...tion Defective mechanism Check shock mounts Replace instrument REPLACEMENT OF INSTRUMENTS GENERAL Since all instruments are mounted in a similar manner a description of a typical removal and installat...

Page 45: ...attery The master switch located on the switch panel below the instruments controls the battery relay The master switch must be on before any electrical equipment will operate The can be equipped with...

Page 46: ...ONAL The amp meter is mounted in series with the battery and bus bar s It shows in positive or out negative current to from the battery With a charged battery the ammeter should read near zero when th...

Page 47: ...e to disuse Impurities in electrolyte Maintain electrolyte Replace battery Replace battery Cracked cell jars Hold down bracket loose Frozen battery Replace battery and tighten Replace battery Excessiv...

Page 48: ...t Low motor and cranking speed Worn rough or improperly lubricated motor or starter gearing Same electrical causes as listed under Motor fails to operate Disassemble clean inspect and relubricate repl...

Page 49: ...hrough the nose cowling and is vented to the heater muff through a flexible hose located at the front of the engine The air is then heated and vented into the cabin area through a valve which can be c...

Page 50: ...2 If the bolts need to be torqued it is suggested all the bolts be loosened for an hour to allow the wood to relax Finger tighten the bolts until snug and tighten the attaching bolts in small increme...

Page 51: ...ading The airspeed needle should remain steady for a minute if the system is sound A fast drop off will indicate a leak in the instrument fittings lines or the test hose attachment NEVER force air in...

Page 52: ...first start of the engine is always a critical operation The engine should be pre oiled in accordance with the manufacturer s instructions After completing the starting engine checklist in the Pilots...

Page 53: ...Request this form from the manufacturer TAXI TESTS a The pilot should spend an hour or more in the cockpit to become accustomed to the aircraft s takeoff position This small but important aspect of tr...

Page 54: ...g heavy braking action to bring the aircraft to a full stop After each take off abort test the brakes must be allowed to COOL DOWN The lining must be examined carefully and replaced if necessary f Aft...

Page 55: ...ment and the error caused by the installation of the system in the aircraft c The airspeed calibrations runs should be made several times in opposite headings for each of the selected airspeeds the pi...

Page 56: ...of gravity limits of the aircraft xii Changes to the basic design of the fuel oil cooling heating electrical hydraulic or exhaust systems xiii Changes to the wing or to fixed or movable control surfa...

Page 57: ...st be evaluated relative to the requirements of the applicable ASTM design and production acceptance specification s The manufacturer or other entity that performs the evaluation of an alteration or r...

Page 58: ...of removable or integral fuel tanks and oil tanks 2 Powerplant major repairs Repairs of the following parts of an engine and repairs of the following types are powerplant major repairs i Separation or...

Page 59: ...maintenance as outlined in 14 CFR Part 43 This maintenance may be performed only on an aircraft which the pilot owns or operates and which is not used in commercial service This list does not supersed...

Page 60: ...shooting and repairing broken circuits in landing light wiring circuits 17 Replacing bulbs reflectors and lenses of position and landing lights 18 Replacing wheels where no weight and balance computa...

Page 61: ...to perform line maintenance of SLSA Typical tasks allowed by Line Maintenance 1 100 hour inspection 2 Annual condition inspection 3 Service of fluids 4 Removal and replacement of components for with i...

Page 62: ...Include 1 Removal and replacement of components for which instructions are provided in the maintenance manual or service directive instructions such as i Complete engine removal and reinstallation in...

Page 63: ...rhaul manual in addition to manufacturers maintenance is required to perform the overhaul of an SLSA or SLSA component 1 Typical components that are overhauled include i Engines ii Carburetors fuel in...

Page 64: ...e last annual inspection completed ______________________________ __________________________________________________________________________________ When and who completed the last 100 hour inspection...

Page 65: ...r Courier Shipping Number _____________ Your Federal Tax I D Number ___________ Visa Card Number ___________________________ Exp Date ________ Ship above items immediately and bill my credit card Fax...