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Aeropilot LEGEND 600 LSA Maintenance Manual

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Aeropilot LEGEND 600
Serial number: 1531
Maintenance Manual
Rev. 01
JULY 7 2016
7 July 2016
Revision 1.0
1

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Summary of Contents for Aeropilot LEGEND 600 LSA

  • Page 1 Aeropilot LEGEND 600 Serial number: 1531 Maintenance Manual Rev. 01 JULY 7 2016 7 July 2016 Revision 1.0...

  • Page 2: Table Of Contents

    TABLE OF CONTENTS TABLEOF CONTENTS ........................Revision Page ..........................3 GENERAL ............................Equipment List ..........................7 Sources Purchase ......................8 Parts Disposable Replacement Parts ....................8 Engine Specifications ......................... 9 Weight Balance ................... 11 Information Tire Inflation Pressure ......................14 Approved Oils Capacities...

  • Page 3: Revision Page

    Revision Page Subject Number Title Effective Date English Units and Rev 01 7 July 2016 FAA Compliance Data Complies with ASTM F2483-05 7 July 2016 Revision 1.0...
  • Page 4 ASTM standard each task does contain the type of maintenance “Level of Maintenance” and the minimum level of certification needed to accomplish the task “Certification Required”. The AEROPILOT Legend 600 complies with the rules of the Light Sport Aircraft airworthiness standards only 7 July 2016...

  • Page 5: General

    GENERAL The Legend 600 LSA aircraft is a two-seat, strut high-wing monoplane of all-composite structure designed for sport, recreational or tourist flying. Favorable flight characteristics make the aircraft suitable for flight training. The aircraft features spacious crew and baggage compartments. Large doors provide for comfortable boarding of crew and loading of baggage.
  • Page 6 Weights Empty weight, per UL–2 739 lbs Take-off weight, maximum 1320 lbs Engine Type (brief description): Rotax 912ULS 100HP – four-stroke, four-cylinder engine, air-cooled cylinders with water- cooled heads, integrated reduction gearbox, dual electronic ignition and tuned inlet manifold. Engine Displacement 1400ccm Take-off power, max.

  • Page 7: Equipment List

    Equipment List A preliminary list of factory-installed equipment is provided. A parachute recovery system is installed from the factory, and is included in the factory weight and balance calculation form . Instruments Instrument Type Serial Number Speed Indicator Winter Altimeter Winter Compass Winter Model CM24...

  • Page 8: Sources To Purchase

    A list where to purchase replacement parts is shown below. When damage is determined to any part of the aircraft please contact your AEROPILOT distributor when in doubt about replacement or repair. No repairs must be done to any of the listed parts...

  • Page 9: Engine Specifications

    Engine Mount Screws Engine Shock Mounts Throttle Control Cables Other specific Engine Components………… Refer to ROTAX Engine Maintenance Manual. Propeller………………………………………. Refer to Woodcomp ‘Klassic’ Operators Manual Landing Gear…………………………………. Tires and Tubes Cotter Pins in General Hydraulic Line Fittings Self Locking Nuts in General Brake Pads Brake Discs All Wheel and Landing Gear...
  • Page 10 Max. negative "g" for 5 seconds…………………… - 0.5 g Oil Pressure Max. for short period at cold start………………… 100 psi Min. (below 3500 rpm)…………………………….. 12 psi Normal (above 3500 rpm)………………………… 29 - 73 psi Deviation from Bank Angle max…………………………. 40° Oil Temperature Max…………………………………………………..

  • Page 11: Weight And Balance

    Weight and Balance Information To perform a successful weight and balance calculation, the center of gravity "C.G." has to be determined with all installed equipment, including engine oil, cooling liquid and unusable fuel. Method for C.G. determination is shown in this section. All measurements including a listing of all installed equipment have to be noted in the separate weight and balance calculation form, supplied TBD.
  • Page 12 To get the correct values, it is necessary to put the aircraft on three weighing scales placed on a level surface. Before conducting the weighing procedure, it is important to achieve a level wing main chord, TBD CG-Calculation A specific C.G.-calculation recommendation which has to be carried out prior to each flight is provided in the Pilot Operating Handbook.
  • Page 13 The included table shows the distance or “ARM” from the datum point, (set at the leading edge of the aircraft) for the Pilot/Passenger seats, the Fuel Tank and the Aft Baggage Compartment. (NOTE: Items stored in the armrest will be added to the Pilot/Passenger weight. Weight Moment (weight x Maximum...

  • Page 14: Tire Inflation Pressure

    Tire Inflation Pressure Tricycle landing gear with steerable nose wheel. Main wheels - size 15x6-6 - are provided with hydraulic disc brakes. These are carried on an all-composite leg. The nose wheel is fitted with spring and hydraulic shock absorber. The front wheel has size 12 x 4 – 4. All wheels provided with fairings.

  • Page 15: Climatic Conditions

    Table of lubricants Since the temperature range of neighboring SAE grades overlap, there is no need for change of oil viscosity for a short duration of ambient temperature fluctuation. Climatic conditions Multi-grade oils Tropical…………………………………… SAE 20W-50, SAE 20W-40 SAE 15W-50, SAE 15W-40 SAE 10W-40 SAE 5W-50, SAE 5W-40 Temperate………………………………..
  • Page 16 aircraft logbook. For privately operated aircraft, an annual inspection is required on a yearly basis and must be performed by a fully licensed FAA Certified Mechanic. For aircraft operated for hire, the items included in the annual inspection must be conducted every 100 hours, as prescribed by FAA regulations Periodical Inspections of Aircraft This section describes intervals of aircraft inspections and maintenance, not...
  • Page 17 Engine Performer Level 100Hr Annual (Prior to inspections, visual review of compartment leaks shall conducted. engine inspections will conducted accordance with procedures specified Rotax maintenance  • System Components Owner • Owner level • Filler Owner • Cooler Owner • Filter Owner •...
  • Page 18 Landing Gear Performer Level 100Hr Annual • Wheels and Fairings Owner • Tires Owner • Brakes and related assemblies Owner • Struts Maint. Airframe Performer Level 100Hr Annual • exterior interior structure A&P • Windows, windscreen, doors seats • Control yokes connecting cables A&P...

  • Page 19: Inspections Alterations And Repairs

    Every 300 ± 5 operating 300-hour inspection Manufacturer’s service facility a) Every 300 ±5 operating hours Manufacturer’s service facility 1000-hour inspection (assessment of further operating b) 5 years from date of manufacture capability of aircraft) c) 5 years from most recent 1000- hour inspection d) Date determined by the manufacturer according to his...
  • Page 20 weighing and determining of COG of empty aircraft according to section 6, recording of COG of empty aircraft into the table in section 2.8, updating the weight and COG of empty aircraft in the respective protocol, and updating the information stated on labels within the aircraft.

  • Page 21: Important Notice

    Repairs of airframe WARNING: Wings, struts, tail surfaces, and fuselage are essential design elements. Any modification to essential design elements performed by the user without manufacturer’s permission is prohibited. NOTE: Deeper damage to fuselage must be repaired by the manufacturer, who will evaluate influence on design rigidity, and will determine proper repair method.
  • Page 22 Ground Handling (continued) Refueling - The manufacturer recommends the following procedure of safe refueling:  Do not allow open flames near the aircraft, prohibit smoking in the vicinity.  Have fire extinguisher ready, suitable for flammable liquids.  Check that grounding cable attached to right side of main undercarriage leg touches the ground.
  • Page 23 Anchoring When parking outside hangar, it is necessary to use anchors. Use three anchoring lugs on top end of wing strut and bottom part of engine firewall. Use sufficiently strong anchors on the ground. Check that all instruments, switches, and fuel valves are switched off. ...
  • Page 24 Wing may be lifted by pressing up on main spar area. IMPORTANT NOTICE: Do not lift wing by holding leading edge(s). Transporting Aircraft on Ground Towing Aircraft may be towed primarily using tow bar, which may be attached to a hole left by a pin removed from front landing gear leg.
  • Page 25 Disassembly assembly aircraft road transport Aircraft may be transported on roads, when loaded on trailer. Prior disassembly is necessary. NOTE: Disassembly and assembly of aircraft does not require special qualification. NOTE: After removal of lubricant, all connecting parts must be re- lubricated.
  • Page 26  Disconnect Pitot tube hoses Connection of airspeed system  Disconnect electric wires from the wing 7 July 2016 Revision 1.0...
  • Page 27  Disconnect fuel hoses from the wing. 7 July 2016 Revision 1.0...
  • Page 28  Disconnect and remove flap control bowdens  Unscrew main and auxiliary wing connections and strut pins 7 July 2016 Revision 1.0...
  • Page 29  Remove strut pins (wing must be held by a helper).  Press wing out of fuselage.  Disassembly of horizontal stabilizer (elevator)  Disassemble tail section of fuselage 7 July 2016 Revision 1.0...

  • Page 30: Lubrication Plan

     Disassemble trim corrector.   Disassemble elevator linkage.   Unscrew stabilizer out of rear partition   Remove tail surface from front hinges by pulling rearward Assembly procedure Assembly procedure is the same as disassembly procedure, performed in reverse order. WARNING: After assembly of aircraft, it is necessary to check operation of controls, synchronization of flaps, and check electrical, fuel,...
  • Page 31 Cleaning Care This section describes the procedures for cleaning and service of aircraft components. Aircraft skin Use lukewarm water to wash aircraft. Parts listed below must be washed and dried. Automotive preparations may be used to remove dead insects. Treat (protect) aircraft using automotive cleaning and protective preparations approximately once a month. Wait approx.
  • Page 32  Thread aerodynamic covers onto wing strut.  Push in and screw in bottom pin of strut (use new Nyloc nut).  Lift wing and position it on its attachments. At the same time, thread aileron control cables, flap Bowden, and Pitot-static system hoses into fuselage. Insert main and rear wing attachment pin.
  • Page 33  Repeat the procedure with the other wing. Connect aileron control cables. Central tensioner 7 July 2016 Revision 1.0...
  • Page 34  Check that cables are taut, and check free movement of aileron control.  Connect flap bowdens and check operation of flaps in all positions.  Connect connectors of electrical equipment in wings and connectors of fuel senders. 7 July 2016 Revision 1.0...
  • Page 35  Connect Pitot-static system hoses. Connection of airspeed system  Connect suction hoses of fuel tanks. 7 July 2016 Revision 1.0...
  • Page 36  Install aerodynamic covers onto wing struts.  Install cabin ceiling trim. Assembly of horizontal stabilizer (elevator)  Insert horizontal stabilizer from side into center of fuselage.  When in center of fuselage, slide horizontal stabilizer forward onto its pins. ...
  • Page 37  Support (hold) wingtip.  Remove upper pin from strut, turn strut towards ground.  Use puller to remove wing pins.  Remove wings from attachments by pulling away from the fuselage.  Pull wing away from the fuselage, carefully remove control cables and bowden from the fuselage, store wing on stand or in transport cover.
  • Page 38 Cleaning The engine may be cleaned with a suitable solvent, then dried thoroughly. Caution Particular care should be given to electrical equipment before cleaning. Solvent should not be allowed to enter magnetos, starter, alternator and the like. Hence, protect these components before saturating the engine with solvent.

  • Page 39: Trouble Shooting

    Trouble Shooting Introduction All checks in accordance with the Maintenance Manual (current issue/revision). The following listing should be understood as quick reference guide to locate particular trouble which may occur to the engine oil system. For detailed information refer to the engine manufacturers Maintenance Manual.
  • Page 40 levelOil level is increasing Possible cause Remedy Oil too cold during engine Cover oil cooler surface, observe the operation. operating limits. Contamination with diesel fuel. Check fuel Cold engine start Engine hard start temperature Possible cause Remedy Starting speed too low. Preheat engine.
  • Page 41 Safety Safety Directives are issued by AEROPILOT S.R.O., to ensure the safe operation of the aircraft if required. Safety Directives are issued in accordance to the applicable ASTM continued airworthiness specification. 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.

  • Page 42: Appendix - 1 Inspection Checklists

    Appendix – 1 Inspection Checklists 100 Hour / Annual Inspection Checklist Inspection Checklist Related to FAR 43, Appendix D Aircraft Identification SN: 1531 Engine Rotax 912 ULS Date Total Time Airframe Total Time Engine Inspection Preparation Steps (General Review)  Each person performing an annual or 100-hour inspection shall, before that inspection, remove or open all necessary inspection plates, access doors, fairing, and cowling.
  • Page 43 Steps (Engine and Nacelle Inspection) Step Inspection Completion Date Each person performing an annual or 100-hour inspection shall inspect (where applicable) components of the engine and nacelle group as follows: Engine section—for visual evidence of excessive oil, fuel, or hydraulic leaks, and sources of such leaks.
  • Page 44 Steps Propeller Inspection Step Inspection Completion Date Each person performing an annual or 100-hour inspection shall inspect (where applicable) the following components of the propeller group: Propeller assembly—for cracks, nicks and binds. Bolts—for improper torque and lack of safetying. Anti-icing devices—for improper operations and obvious defects. Steps Avionics Inspection Step Inspection...

  • Page 45: Appendix - 2 Flight Acceptance Procedure

    Appendix – 2 Flight Acceptance Procedure Flight Acceptance Procedure 7 July 2016 Revision 1.0...
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