AMD Zodiac 601XL SLSA Maintenance Manual
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AMD Zodiac 601XL SLSA Maintenance Manual

AMD Zodiac 601XL SLSA Maintenance Manual

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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

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Summary of Contents for AMD Zodiac 601XL SLSA

  • Page 1: Maintenance Manual

    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: Table Of Contents

    July 09 Copyright AMD The data and information contained in the document is the property of AMD. This document may not be reproduced or transmitted to a third party, in any form or by any means. Any unauthorized copy, distribution is illegal as per international agreements relating to property rights.
  • Page 3 AMD 601XL / 601XLi / 650LS / 650LSi SLSA MAINTENANCE MANUAL _______________________________________________________________________ SERVICE MANUAL UPDATE LOG REV. NO. DATE ISSUED DATE INSERTED BY INCORPORATED July 2009 AT ISSUE November 2009 Note: 0.1 and 0.2 with Update sheet(s) are replaced for each new update.
  • Page 4 AMD 601XL / 601XLI / 650LS / 650LSi SLSA MAINTENANCE MANUAL ________________________________________________________________________ SECTION 1 GENERAL INTRODUCTION This manual contains service and maintenance instructions for the ZODIAC 601XL / 601XLi / 650LS / 650LSi, designed and manufactured as a versatile two-seat aircraft In the text, reference is made to the following publications: - Pilots’...
  • Page 5 AMD 601XL / 601XLI / 650LS / 650LSi SLSA MAINTENANCE MANUAL ________________________________________________________________________ DESCRIPTION The ZODIAC is a single engine, two-seat, low-wing monoplane of all-metal construction. WING: The wing is of all-metal stressed-skin, full cantilever, low-wing design, consisting of two wing panels bolted to a spar box assembly in the fuselage. The ailerons are cable and push rod controlled.
  • Page 6 AMD 601XL / 601XLI / 650LS / 650LSi SLSA MAINTENANCE MANUAL ________________________________________________________________________ GENERAL DIMENSIONS AMD 601XL / 601XLi / 650LS /650LSi July 09...

  • Page 7: July 09

    AMD 601XL / 601XLI / 650LS / 650LSi SLSA MAINTENANCE MANUAL ________________________________________________________________________ SECTION II HANDLING AND SERVICING GENERAL This section provides ground handling and servicing instructions. Recommended ground handling procedures, and recommended methods of servicing are provided in following paragraphs.
  • Page 8 AMD 601XL / 601XLI / 650LS / 650LSi SLSA MAINTENANCE MANUAL ________________________________________________________________________ HOISTING Nose Gear Hoisting - Remove the cowl and lift the aircraft with a hoist attached to the metal loop on top of the engine. Main Gear Hoisting - Lift the aircraft one side at a time and insert a padded sawhorse or equivalent under wing at main wing spar and rib rivet line.
  • Page 9 Oil filter – Cessna 150 type. Order from AMD, Aircraft Spruce & Specialty, etc. Carb. air filter – Cessna 150 type. Order from AMD, Aircraft Spruce & Specialty, etc. Spark plugs – Auto type. Order from AMD, Aircraft Spruce & Specialty, etc. See engine manual for type.
  • Page 10 AMD 601XL / 601XLI / 650LS / 650LSi SLSA MAINTENANCE MANUAL ________________________________________________________________________ SECTION III INSPECTION GENERAL This section provides instructions for conducting scheduled inspections, unscheduled inspections, replacement of time limited parts and corrosion control. Repair or replacement instructions for those components found to be unserviceable are in the sections covering the applicable aircraft system.

  • Page 11: Nov. 09

    AMD 601XL / 601XLI / 650LS / 650LSi SLSA MAINTENANCE MANUAL ________________________________________________________________________ UNSCHEDULED INSPECTIONS Unscheduled inspections must be performed anytime that unusual operating conditions are encountered which may affect the integrity or airworthiness of the aircraft. Actions to be taken following the reporting of such events are as follows: Hard Landing a) Check ELT for inadvertent activation.
  • Page 12 TABLE 1 – ZODIAC INSPECTION FORM Make / Model Serial No. Airframe Hours Type of Inspection ___________________ (Circle One) ____________________ _____________________ Registration No: _________ Engine Hours: __________ 50 100 500 1000 Symbols: Indicates perform task, - Indicates do not perform task Intervals Task Refer to...

  • Page 13: Nov. 09

    TABLE 1 – ZODIAC INSPECTION FORM Type of Inspection (Circle One) 50 100 500 1000 Symbols: Indicates perform task, - Indicates do not perform task Intervals Task Refer to (Flight Hours) Initials 1000 14. Inspect engine for security of all attaching hardware (nuts, bolts, screw, etc.) 15.
  • Page 14 1. Inspect the control stick(s), linkages, column and torque tube assemblies for cracks, distortion, excessive play etc. 2. Check controls for ease of operation and See AMD Safety Alert of correct travel. October 2008 3. Check operation lights. 4. Check operation of all circuit breakers and switches.
  • Page 15 TABLE 1 – ZODIAC INSPECTION FORM Type of Inspection (Circle One) 50 100 500 1000 Symbols: Indicates perform task, - Indicates do not perform task Intervals Task Refer to (Flight Hours) Initials 1000 14. Inspect safety belts, attaching hardware, etc. for condition security. 15.
  • Page 16 TABLE 1 – ZODIAC INSPECTION FORM Type of Inspection (Circle One) 50 100 500 1000 Symbols: Indicates perform task, - Indicates do not perform task Intervals Task Refer to (Flight Hours) Initials 1000 Check security, condition, etc., of lateral stop and bolts and axle bolts. When removing wheels, inspect the brake assemblies, axles, pins and spacers for security, condition, leaks, etc.
  • Page 17 1. Check the torque and safeties of the front AC 43-13-1B Section 3 spar, main spar and rear spar wing to fuselage attachment bolts. 2. Inspect the external surfaces of the See AMD Safety Alert of ailerons and flaps for cracks, deformation, October 2008 etc. See AMD Notification 3.
  • Page 18 TABLE 1 – ZODIAC INSPECTION FORM Type of Inspection (Circle One) 50 100 500 1000 Symbols: Indicates perform task, - Indicates do not perform task Intervals Task Refer to (Flight Hours) Initials 1000 12. Perform operational check of the pitot static heater (if installed).
  • Page 19 TABLE 1 – ZODIAC INSPECTION FORM Type of Inspection (Circle One) 50 100 500 1000 Symbols: Indicates perform task, - Indicates do not perform task Intervals Task Refer to (Flight Hours) Initials 1000 2. Inspect elevator trim lever/fork for security, wear, damage, etc.
  • Page 20 AMD 601XL / 601XLI / 650LS / 650LSi SLSA MAINTENANCE MANUAL ________________________________________________________________________ SECTION IV STRUCTURE GENERAL No structural repairs are recommended without contacting the manufacturer, however, minor repairs such as patching the skin, etc., may be made in accordance with AC43-13- XX for the airframe.
  • Page 21 AMD 601XL / 601XLI / 650LS / 650LSi SLSA MAINTENANCE MANUAL ________________________________________________________________________ PRIMARY STRUCTURAL PARTS Following list gives the “primary structural” parts which cannot be repaired: - Wing Spars - Spar box assembly in fuselage - Stabilator and Elevator spars...
  • Page 22 AMD 601XL / 601XLI / 650LS / 650LSi SLSA MAINTENANCE MANUAL ________________________________________________________________________ SECTION V LANDING GEAR AND BRAKE SYSTEM GENERAL The landing gear incorporated on the ZODIAC is a fixed, tricycle type of gear, fitted with three 500-5 wheels, using four ply tires with tubes. The nose gear is steerable through the rudder pedals.
  • Page 23 AMD 601XL / 601XLI / 650LS / 650LSi SLSA MAINTENANCE MANUAL ________________________________________________________________________ REMOVAL AND INSTALLATION OF GEAR AND WHEELS Tools required: Standard type socket wrenches and tools. Parts required: None Level of Maintenance: Heavy Certification required: A&P or SLSA Repairman Maintenance NOSE WHEEL 1.
  • Page 24 AMD 601XL / 601XLI / 650LS / 650LSi SLSA MAINTENANCE MANUAL ________________________________________________________________________ REPLACEMENT OF MAIN WHEEL 1. Hoist aircraft up. This can be done by placing a floor “jack” under main gear near fuselage. 2. Remove the cotter pin and axle nut, disassemble the brake assembly and remove the wheel and tire.
  • Page 25 AMD 601XL / 601XLI / 650LS / 650LSi SLSA MAINTENANCE MANUAL ________________________________________________________________________ SECTION VI POWER PLANT GENERAL The ZODIACSLSA is powered 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 their probable causes and suggested remedies.
  • Page 26 AMD 601XL / 601XLI / 650LS / 650LSi SLSA MAINTENANCE MANUAL ________________________________________________________________________ ENGINE SPECIFICATIONS - 4 Cylinders Horizontally Opposed - Air Cooled Engine Manufacturer Teledyne Continental Engine Model Number 0-200 Rated Horsepower RPM Rating, standard atmosphere Max. continuous 2750 Recommended cruising RPM 2500 Maximum allowed Pressure in Hg.
  • Page 27 AMD 601XL / 601XLI / 650LS / 650LSi SLSA MAINTENANCE MANUAL ________________________________________________________________________ REMOVAL OF ENGINE Tools required: Standard type socket wrenches and tools. Parts required: None Level of Maintenance: Heavy Certification required: A&P or SLSA Repairman Maintenance 1. Remove the propeller.

  • Page 28: Nov

    AMD 601XL / 601XLI / 650LS / 650LSi SLSA MAINTENANCE MANUAL ________________________________________________________________________ SECTION VII FLIGHT CONTROL SYSTEM The ZODIACSLSA is controlled in flight by the use of the three standard primary flight control surfaces, consisting of the ailerons, elevator and the rudder. Operation of these controls is through the movement of the control stick and pedals.
  • Page 29 AMD 601XL / 601XLI / 650LS / 650LSi SLSA MAINTENANCE MANUAL ________________________________________________________________________ REMOVAL AND INSTALLATION OF FLYING SURFACES Tools required: Standard type socket wrenches and tools. Parts required: None Level of Maintenance: Heavy Certification required: A&P or SLSA Repairman Maintenance...
  • Page 30 AMD 601XL / 601XLI / 650LS / 650LSi SLSA MAINTENANCE MANUAL ________________________________________________________________________ AILERON REMOVAL 1. Disconnect the aileron push rod at the inboard end of the aileron. 2. Remove the hinge pin and the aileron will be loose. REINSTALL the flap in reverse order of removal, safety the hinge pins, check deflection and control stops Left and Right.
  • Page 31 AMD 601XL / 601XLI / 650LS / 650LSi SLSA MAINTENANCE MANUAL ________________________________________________________________________ Rudder deflection. Locate the center line of the fuselage directly behind the nose wheel assembly and attach a plumb bob, also attach a plumb bob to the lower rudder hinge. Draw exact point on floor at rear.
  • Page 32 AMD 601XL / 601XLI / 650LS / 650LSi SLSA MAINTENANCE MANUAL ________________________________________________________________________ STABILATOR 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.
  • Page 33 SECTION VIII FUEL SYSTEM GENERAL When work is performed on the fuel system, assure good ventilation, no smoking, ready availability of fire fighting equipment. WING TANK SYSTEM The wing tanks are installed behind the wing spar, outside the walkway, and held in place by the bottom wing panels.
  • Page 34 AMD 601XL / 601XLI / 650LS / 650LSi SLSA MAINTENANCE MANUAL ________________________________________________________________________ FINGER SCREENS The finger screens are accessible at the tank outlet, bottom of wing near root. 1. Drain the tank. 2. Open inspection panel. 3. Disconnect the fuel lines.
  • Page 35 AMD 601XL / 601XLI / 650LS / 650LSi SLSA MAINTENANCE MANUAL ________________________________________________________________________ FUEL SYSTEM TROUBLESHOOTING Trouble Cause Remedy Fuel gauge fails to indicate Broken wiring Check and repair Gauge not operating Replace Float partially or Replace float completely filled with fuel...
  • Page 36 AMD 601XL / 601XLI / 650LS / 650LSi SLSA MAINTENANCE MANUAL _______________________________________________________________________ SECTION IX INSTRUMENTS GENERAL The instrumentation in the ZODIACSLSA is designed to give a quick and actual indication of the attitude, performance and condition of the airplane. The instrument panel has been arranged to accommodate all the advanced flight instruments in front of the pilot.
  • Page 37 AMD 601XL / 601XLI / 650LS / 650LSi SLSA MAINTENANCE MANUAL _______________________________________________________________________ ALTIMETER TROUBLESHOOTING See following table: ALTIMETER Trouble Cause Remedy Excessive scale error. Improper calibration adjustment. Replace instrument. Excessive pointer oscillation. Defective mechanism. Replace instrument. High reading. Improper venting.

  • Page 38: July 09

    AMD 601XL / 601XLI / 650LS / 650LSi SLSA MAINTENANCE MANUAL _______________________________________________________________________ MAGNETIC COMPASS GENERAL The magnetic compass installed in the ZODIAC is a self-contained instrument and is mounted at the panel. The compass correction card is located in the card holder mounted on the instrument panel.

  • Page 39: July 09

    AMD 601XL / 601XLI / 650LS / 650LSi SLSA MAINTENANCE MANUAL _______________________________________________________________________ TACHOMETER GENERAL The tachometer is connected to the engine regulator which provide rpm data to the indicator. A separate hour meter records engine operation time. Aircraft may have mechanical or Electric Tachometer.

  • Page 40: July 09

    AMD 601XL / 601XLI / 650LS / 650LSi SLSA MAINTENANCE MANUAL ________________________________________________________________________ ENGINE OIL TEMPERATURE INDICATOR GENERAL The oil temperature indicator is mounted in the instrument cluster on the instrument panel. This instrument will provide a temperature indication of the engine oil in degrees Fahrenheit.

  • Page 41: July 09

    AMD 601XL / 601XLI / 650LS / 650LSi SLSA MAINTENANCE MANUAL ________________________________________________________________________ FUEL PRESSURE GAUGE GENERAL The fuel pressure gauge instrument is mounted in the cluster on the instrument panel. This gauge is connected to the sender at the carburetor fuel inlet fitting.

  • Page 42: July 09

    AMD 601XL / 601XLI / 650LS / 650LSi SLSA MAINTENANCE MANUAL ________________________________________________________________________ OPTIONAL INSTRUMENTS RATE OF CLIMB INDICATOR - OPTIONAL GENERAL The rate of climb indicator measures the rate of change in static pressure when the airplane is climbing or descending. By means of a pointer and dial, this instrument will indicate the rate of ascent or descent of the airplane in feet per minute.

  • Page 43: July 09

    AMD 601XL / 601XLI / 650LS / 650LSi SLSA MAINTENANCE MANUAL ________________________________________________________________________ DIRECTIONAL GYRO INDICATOR - ELECTRIC - OPTIONAL GENERAL The directional gyro is a flight instrument incorporating an gyro stabilized in the vertical plane. The gyro is rotated at high speed. Due to gyroscopic inertia, the spin axis continues to point in the same direction even though the aircraft yaws to the right or left.

  • Page 44: July 09

    AMD 601XL / 601XLI / 650LS / 650LSi SLSA MAINTENANCE MANUAL ________________________________________________________________________ TROUBLESHOOTING See following table: HORIZON GYRO INDICATOR Trouble Cause Remedy Bar does not settle. Excessive vibration. Check shock mounts. (Replace if necessary.) Defective instrument. Replace. Not working No power to indicator Check wires / fuse / power Replace instrument.

  • Page 45: July 09

    AMD 601XL / 601XLI / 650LS / 650LSi SLSA MAINTENANCE MANUAL ________________________________________________________________________ SECTION X ELECTRICAL SYSTEM GENERAL The electrical system of the is a 12 volt, direct current, single wire, negative ground system. All electrical equipment is grounded to the metal structure of the airplane, therefore the structure takes the place of the second wire.

  • Page 46: July 09

    AMD 601XL / 601XLI / 650LS / 650LSi SLSA MAINTENANCE MANUAL ________________________________________________________________________ SERVICING THE BATTERY The battery should be checked for proper fluid level (not required when using a SEALED LEAD ACID battery), but must not be filled above the baffle plates. A hydrometer check should be performed to determine the specific gravity of the electrolyte (1.268 standard,...

  • Page 47: July 09

    AMD 601XL / 601XLI / 650LS / 650LSi SLSA MAINTENANCE MANUAL ________________________________________________________________________ TABLE - ELECTRICAL SYSTEM TROUBLESHOOTING Trouble Cause Remedy BATTERY Discharged battery. Battery worn out. Replace battery. Charging rate not set right. Reset. Standing too long. Remove and recharge battery if left in unused airplane for too long.

  • Page 48: July 09

    AMD 601XL / 601XLI / 650LS / 650LSi SLSA MAINTENANCE MANUAL ________________________________________________________________________ TABLE. ELECTRICAL SYSTEM TROUBLESHOOTING (cont'd) Trouble Cause Remedy STARTER Motor fails to operate. Low battery charge. Check and recharge if necessary. Refer to electrical wiring Defective or improper wiring or diagram and check all wiring.

  • Page 49: July 09

    AMD 601XL / 601XLI / 650LS / 650LSi SLSA MAINTENANCE MANUAL _______________________________________________________________________ SECTION XI CABIN HEATER AND VENTILATION SYSTEM GENERAL Heat for the cabin of the ZODIAC is provided by an air heater installed on the exhaust. Fresh air enters the engine compartment through the nose cowling and is vented to the heater muff through a flexible hose located at the front of the engine.

  • Page 50: July 09

    AMD 601XL / 601XLI / 650LS / 650LSi SLSA MAINTENANCE MANUAL _______________________________________________________________________ SECTION XII PROPELLER SYSTEM 5. WOOD PROPELLER INSPECTION. Follow the manufactures instructions for maintenance an operations. For the Sensenich wood propellers, Doc# WOOD_CF_REV_A 5-20-04 may be helpful. If instructions are not available from the propeller manufacturer, the following may be used: Inspection of a wood propeller.
  • Page 51 APPENDIX 1 Aircraft Testing INTRODUCTION For a factory new SLSA, use this Appendix when reassembling the aircraft, after performing major alterations or repairs. To prevent errors in assembling and or reassembling the aircraft, follow the instruction. FOLLOW THE MANUFACTURERS DRAWINGS. USE THE ZODIACPARTS DRAWINGS AS YOU ASSEMBLE AND INSPECT YOUR AIRCRAFT.
  • Page 52 2. New/newly overhauled Follow the engine manufacturer’s instructions. These instructions are found either in the manufacturer’s overhaul manuals, service bulletins, or service letters. Following the manufacturer’s instructions is especially important if the engine has chrome cylinders which require special run-in procedures. Also, before running-up the engine, be certain that it has the proper grade oil in the sump.
  • Page 53 8. Mixture and Idle Speed Check: After completing the initial engine ‘‘run-in’’ tests, check the idle speed and mixture settings. To determine if the mixture setting is correct, perform the follow- ing: (a) Warm up the engine until all readings are normal (b) Adjust the engine rpm to the recommended idle rpm (c) Slowly pull the mixture control back to idle cut-off (d) Just before the engine quits, the engine rpm should rise about 50 rpm if the mixture is properly...
  • Page 54 HIGH SPEED TAXI TESTS 1. OBJECTIVE. To determine the aircraft’s high speed handling and braking parameters. a. Propeller rotation will determine which rudder pedal is pressed to compensate for the asymmetrical thrust of the propeller blades. b. Each taxi run should be 5 mph faster than the last run until the aircraft is within 80 percent of the predicted stall speed.
  • Page 55 AIRSPEED IN-FLIGHT ACCURACY CHECK. The following procedure for airspeed calibration is offered for evaluation: a. A measured course should be chosen with readily identifiable landmarks at each end. The land- marks should be a known distance apart, and the length of course should be at least 1 to 2 miles long. b.

  • Page 56: July

    Appendix 2 Major Alterations, Major Repairs, and Preventive Maintenance (a) Major alterations. Must be pre-approved by the Manufacturer and performed by an FAA certified A&P (1) Airframe major alterations. (i) Wings. (ii) Tail surfaces. (iii) Fuselage. (iv) Engine mount. (v) Control system. (vi) Landing gear.

  • Page 57: July

    (iv) Removal of accessories that are listed as required equipment on the aircraft or engine specification. (v) Installation of structural parts other than the type of parts approved for the installation. (vi) Conversions of any sort for the purpose of using fuel of a rating or grade other than that listed in the engine specifications.

  • Page 58: July

    (ix) Main seat support braces and brackets. (x) Landing gear brace struts. (xi) Axles. (xii) Wheels. (xiii) Parts of the control system such as control columns, pedals, shafts, brackets, or horns. (xiv) Repairs involving the substitution of material. (xv) The repair of damaged areas in metal stressed covering exceeding six inches in any direction.

  • Page 59: July

    (ix) Replacement of tip fabric. (x) Replacement of plastic covering. (xi) Repairs to deep dents, cuts, scars, nicks, etc., and straightening of blades. (xii) The repair or replacement of internal elements of blades. (4) Appliance major repairs. Repairs of the following types to appliances are appliance major repairs: (i) Calibration and repair of instruments.

  • Page 60: July

    (9) Refinishing decorative coating of fuselage, wings tail group surfaces (excluding balanced control surfaces), fairings, cowlings, landing gear, cabin, or cockpit interior when removal or disassembly of any primary structure or operating system is not required. (10) Applying preservative or protective material to components where no disassembly of any primary structure or operating system is involved and where such coating is not prohibited or is not contrary to good practices.
  • Page 61 Any work accomplished must include an entry in the appropriate logbook. The entry should contain: (a) The date the work was accomplished. (b) Description of the work. (c) Number of hours on the aircraft. (d) The certificate number of pilot performing the work. (e) Signature of the individual doing the work.
  • Page 62 (6) Stop-drilling of cracks (7) Alterations for which specific instructions and provided in the maintenance manual, such as (i.) Installation of communications radios, transponder, GPS, and antenna (ii.) Installation of strobe light system (iii.) Compliance with manufacturer creative directive when repairman is listed as an authorized person to accomplish the alteration (e) Heavy Maintenance, Repairs, and Alterations Authorization to Perform—The holder of a mechanic certificate with airframe or...
  • Page 63 (f) Overhaul Overhaul of components is to be treated the same as typical FAR 23 type aircraft. Overhaul 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 injection systems (iii.) Starters/alternators/generators, and...
  • Page 64 OWNER / OPERATOR REPORTING OF MAINTENANCE, SERVICE, AND SERVICE DIFFICULTIES Aircraft serial number: ___________________ Aircraft model and type: _________________ Date of manufacturing: _______________ Total hours on airframe: ____________________ Total hours on engine (since new or last overhaul): _______ Total hours on propeller (since new or last overhaul): _______ Has the above aircraft had any major repairs: Yes _____ No ____ When and who completed the last annual inspection completed? ______________________________ __________________________________________________________________________________...
  • Page 65 Name of Visa card holder: Date: Signature authorizing all of the above: Complete this form and FAX or mail this form to AMD when ordering parts. AMD – 441 Airport Road, Eastman GA 31023 USA Tel: 478-374-2759 Fax: 478-374-2793 FORM 2...

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