Page 1 CC11-100 AIRCRAFT MAINTENANCE MANUAL Serial Number: CC11-XXXXX Registration Number: NXXXXX CUB CRAFTERS, INC. 1918 SOUTH 16TH AVENUE, YAKIMA, WA 98903 U.S.A. 509-248-9491 877-484-7865 www.cubcrafters.com support@cubcrafters.com...
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Page 3 CUB CRAFTERS, INC. CC11-100 MAINTENANCE MANUAL Record of Revisions Rev. Change Date Prepared By Approved By NC Initial Issue 07/06/2006 Reformatted to meet ASTM F2483-05. 08/09/2006 Revised Section 6.1 to clarify maintenance 01/29/2008 authorization. Entire Manual Revised 04/27/2009 Revised 6.A. Revised Chapter 11.
Page 4 CUB CRAFTERS, INC. CC11-100 MAINTENANCE MANUAL List of Effective Pages Prepared Approved Pages Change Date 07/06/2006 Initial Issue 08/09/2006 Reformatted to meet ASTM F 2483-05. Added Maintenance Table and 01/29/2008 clarification Entire Manual Revised 04/27/2009 6.A.A3 Added Exhaust Bolt Check to Engine Group.
Page 5 CUB CRAFTERS, INC. CC11-100 MAINTENANCE MANUAL Prepared Approved Pages Change Date Pg 3 Added note to Figure 5.2.1. 10/01/2010 Pg 4 Added Amphib Gross Weight. Added Wheel Base with 3X3 Gear. 5.3 Pg 3 & 5 Corrected typo to 6.A.
Page 6 CUB CRAFTERS, INC. CC11-100 MAINTENANCE MANUAL INTENTIONALLY LEFT BLANK Manual number SC10000AMM Page: iv Date: 04/18/2013...
Page 7 CUB CRAFTERS, INC. CC11-100 MAINTENANCE MANUAL TABLE OF CONTENTS SCOPE 5.4.12 UTILITY SYSTEMS REFERENCE DOCUMENTS 5.4.13 AVIONICS AND TERMINOLOGY INSTRUMENT SYSTEMS SIGNIFICANCE & USE 5.4.14 ELECTRICAL SYSTEMS AIRCRAFT MAINTENANCE MANUAL 5.4.15 SEATS FORMAT & GUIDANCE FOR THE STRUCTURAL REPAIRS USE OF THIS MANUAL 5.5.1...
Page 8 CUB CRAFTERS, INC. CC11-100 MAINTENANCE MANUAL 6.3.23 WEIGHING 8.3.1 ENGINE 6.3.24 PARKING AND MOORING 8.3.2 PROPELLER REPAIR OF STRUCTURE & 8.3.3 CARBURETOR COMPONENTS 8.3.4 CARBURETOR AIR BOX 6.4.1 GENERAL 8.3.5 STARTERS, GENERATORS, 6.4.2 PATCHING OF HOLES IN AND ALTERNATORS FABRIC, METAL, OR 8.3.6...
Page 9 Cub Crafters may also be contacted by telephone at (509) 248-9491. (note that Cub Crafters is on US Pacific Time and office hours are from 8:00 am to 5:00 pm.) Service Alerts, Service Bulletins and the latest versions of the Pilot’s Operating Handbook and Maintenance Manual Supplements for this aircraft may be found on Cub Crafters’...
Page 10 7 through 9, or in this maintenance manual, are authorized at this time, for this Sport Cub aircraft. Any heavy maintenance, major repairs, or major alterations, as outlined in ASTM F2483 Sections 7 through 9, can only be performed by Cub Crafters, Inc. or only as provided by Cub Crafters’ approved engineering data. Manual number SC10000AMM...
Page 11 Number and Street Number and Street City City State/Province Postal Code State/Province Postal Code Country Country TELEPHONE NUMBER(S) TELEPHONE NUMBER(S) SIGNATURE DATE FOR CUB CRAFTERS' USE ONLY Change of Ownership/Address Log Number: Date Received: Manual number SC10000AMM Date: 04/18/2013 Page: 3...
Page 12 CUB CRAFTERS, INC. CC11-100 MAINTENANCE MANUAL INTENTIONALLY LEFT BLANK Manual number SC10000AMM Page: 4 Date: 04/18/2013...
Page 13 Postal Code AIRCRAFT SERIAL NUMBER CC11-_________________ Country AIRCRAFT REGISTRATION NUMBER TELEPHONE NUMBER(S) DESCRIPTION OF SAFETY OF FLIGHT ISSUE OR SIGNIFICANT SERVICE DIFFICULTY: SIGNATURE DATE FOR CUB CRAFTERS' USE ONLY COS Log Number: Date Received: Manual number SC10000AMM Date: 04/18/2013 Page: 5...
Page 14 CUB CRAFTERS, INC. CC11-100 MAINTENANCE MANUAL INTENTIONALLY LEFT BLANK Manual number SC10000AMM Page: 6 Date: 04/18/2013...
Page 15 CUB CRAFTERS, INC. CC11-100 MAINTENANCE MANUAL REFERENCE DOCUMENTS ASTM F2483 – Standard Practice for Maintenance and the Development of Maintenance Manuals for Light Sport Aircraft ASTM F2245 – Specification for the Design and Performance of a light Sport Aircraft. ASTM F2295 – Practice for Continued Operational Safety Monitoring of a Light Sport Aircraft 14 CFR Part 43 –...
Page 16 CUB CRAFTERS, INC. CC11-100 MAINTENANCE MANUAL INTENTIONALLY LEFT BLANK Manual number SC10000AMM Page: 2 Date: 04/27/2009...
Page 17 CUB CRAFTERS, INC. CC11-100 MAINTENANCE MANUAL TERMINOLOGY DEFINITIONS LSA Airplane (Light Sport Aircraft Airplane) – a powered fixed wing aircraft designed per Specification F 2245 that is manufactured and delivered ready to fly. The Light Sport Aircraft is also defined by 14 CFR 1.1 Annual Condition Inspection –...
Page 18 CUB CRAFTERS, INC. CC11-100 MAINTENANCE MANUAL Maintenance Manual(s) – manual provided by an LSA manufacturer or supplier that specifies all maintenance, repairs, and alterations authorized by the manufacturer. Major Repair, Alteration, or Maintenance – any repair, alteration, or maintenance for which instructions to complete the task excluded from the maintenance manual(s) supplied to the consumer are considered major.
Page 19 The purpose of this maintenance manual is to provide guidance to owners, mechanics, airports, regulatory officials, and aircraft and component manufacturers who may accomplish maintenance, repairs, and alterations on the Cub Crafters CC11-100 Light Sport Aircraft. Manual number SC10000AMM Date: 04/27/2009...
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Page 21 CHAPTER AIRCRAFT MAINTENANCE MANUAL...
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Page 23 CUB CRAFTERS, INC. CC11-100 MAINTENANCE MANUAL AIRCRAFT MAINTANENCE MANUAL 5.1 ........... FORMAT & GUIDANCE FOR THE USE OF THIS MANUAL 5.2 ................... GENERAL: SPECIFICATIONS & DATA 5.3 ............PERIODIC & ANNUAL INSPECTION REQUIREMENTS 5.4 ......MAINTENANCE, REPAIR & ALTERATIONS of PRIMARY STRUCTURES 5.5 ......................
Page 24 CUB CRAFTERS, INC. CC11-100 MAINTENANCE MANUAL INTENTIONALLY LEFT BLANK Manual number SC10000AMM Page: ii Date: 04/27/2009...
Page 25 CUB CRAFTERS, INC. CC11-100 MAINTENANCE MANUAL FORMAT & GUIDANCE FOR THE USE OF THIS MANUAL TABLE OF CONTENTS GENERAL ..........................2 LAYOUT OF THE MANUAL ....................2 WARNINGS, CAUTION AND NOTES ................... 2 REVISION SERVICE ......................3 Manual number SC10000AMM...
Page 26: General
CC11-100 MAINTENANCE MANUAL GENERAL Cub Crafters, Inc. prepared this aircraft maintenance manual. It contains the information that a trained mechanic will need to maintain the aircraft in an airworthy condition. The Aircraft Maintenance Manual was prepared to meet the ASTM F2483 Standard Specification requirements.
Page 27: Revision Service
CUB CRAFTERS, INC. CC11-100 MAINTENANCE MANUAL REVISION SERVICE The Maintenance Manual will be made available to aircraft owners and repair shops on a subscription basis. Revisions will be sent to registered subscribers as they become available. Revisions may also be obtained by submitting a request to: Cub Crafters, Inc.
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Page 29: Table Of Contents
CUB CRAFTERS, INC. CC11-100 MAINTENANCE MANUAL 5.2 GENERAL: SPECIFICATIONS AND DATA TABLE OF CONTENTS GENERAL ..........................2 MAIN DIMENSIONS ...................... 4 WINGS .......................... 4 AILERONS ........................4 FLAPS ........................... 4 HORIZONTAL STABILIZER ..................4 FIN AND RUDDER ......................4 LANDING GEAR ......................4 CONTROL SURFACE TRAVELS AND CABLE TENSION SETTINGS ......
Page 30: General
CUB CRAFTERS, INC. CC11-100 MAINTENANCE MANUAL 1. GENERAL The location of any point on the aircraft is identified in a three axis grid as follows (Reference Figure 5.2.1):  FS - Fuselage Station is a horizontal reference designation starting in front of the nose of the airplane at a point 60 inches ahead of the wing leading edge.
Page 31 CUB CRAFTERS, INC. CC11-100 MAINTENANCE MANUAL Manual number SC10000AMM Date: 10/01/2010 Page: 3...
Page 32: Main Dimensions
CUB CRAFTERS, INC. CC11-100 MAINTENANCE MANUAL MAIN DIMENSIONS Span ......................411 in. Length (level flight attitude) ................273 in. Length (three point attitude) ................. 290 in. Height ....................114 in. Max Height (tail wheel on ground, propeller blade vertical at top)* ..... 84.5 in.
Page 33: Control Surface Travels And Cable Tension Settings
CUB CRAFTERS, INC. CC11-100 MAINTENANCE MANUAL (8) CONTROL SURFACE TRAVELS AND CABLE TENSION SETTINGS (a) Aileron Aileron Up ....................18° ± 2° Aileron Down ..................... 18° ± 2° Aileron Cable Tension ................40 ± 5 lbs. (b) Flaps First Notch ....................15° ± 3°...
Page 34: Equipment List
CUB CRAFTERS, INC. CC11-100 MAINTENANCE MANUAL 2. EQUIPMENT LIST This section provides a list of components and equipment that the operator is likely to change on the aircraft. Description Ref. In AMM 6.00x6, 8.00x6, 8.50x6, 26”x6, 29”x6 main wheel and tires 5.4.6 or...
Page 35: Purchase Parts Source Lists
CUB CRAFTERS, INC. CC11-100 MAINTENANCE MANUAL 3. PURCHASE PARTS SOURCE LISTS Consumable or Frequently Replaced Items Description Part Number (Reference purpose) Source Engine Oil Filter (if equipped) K&N HP1008 Cub Crafters or Local Auto Parts Store Brake Fluid MIL-H-5606G (Aeroshell #41)
Page 36: Engine Specifications And Data
CUB CRAFTERS, INC. CC11-100 MAINTENANCE MANUAL 4. ENGINE SPECIFICATIONS AND DATA Engine Model O-200-A Number of Cylinders Bore & Stroke 4.062 in x 3.875 in Compression Ratio 7.0:1 Piston Displacement 201 in Rated Power at Sea Level 100 HP @ 2750 RPM Maximum Pressure at Rated RPM 29.3 in.
Page 37: Weight And Balance Data
CUB CRAFTERS, INC. CC11-100 MAINTENANCE MANUAL 5. WEIGHT AND BALANCE DATA Refer to CC11 Pilot’s Operating Handbook and Airplane Flight Manual, SC10000AFM, Section 6 for the Weight and Balance Data. 6. TIRE INFLATION Refer to section 6.2.3 of this manual for the tire inflation data.
Page 38 CUB CRAFTERS, INC. CC11-100 MAINTENANCE MANUAL When nuts are to be secured to fasteners by means of cotter pins or lock wire, the low side of the specified torque range shall be approached for tightening. If necessary, tightening shall be continued until the next slot aligns with the hole.
Page 39: Use Of Torque Wrenches And Adaptors
CUB CRAFTERS, INC. CC11-100 MAINTENANCE MANUAL Use of Torque Wrenches and Adaptors All final torquing shall be carried out with certified torque wrenches or torque screwdrivers. When adaptors or extensions are used on manually operated torque wrenches, they shall be aligned as shown in Figure 5.2.2 and the dial reading required shall be calculated from the...
Page 40: Torquing Patterns
CUB CRAFTERS, INC. CC11-100 MAINTENANCE MANUAL Torquing Patterns Figure 5.2.3: Torque Pattern Whenever applicable, the following pattern must be followed when torquing fasteners: Specific Torque Requirements Minimum Dry Maximum Dry Chapter/Section Item Torque Torque Reference Inch Pounds Inch Pounds Sensenich Wood Propeller 6.3.16...
Page 41: General Torque Values
CUB CRAFTERS, INC. CC11-100 MAINTENANCE MANUAL General Torque Values BOLTS - STEEL TENSION BOLTS - STEEL TENSION BOLTS - ALUMINUM AN3 THRU AN 20 MS20004 THRU MS20024 AN3DD THRU AN20DD AN42 THRU AN49 NAS 144 THRU NAS158 AN173DD THRU AN186DD...
Page 42: General Safety Information
CUB CRAFTERS, INC. CC11-100 MAINTENANCE MANUAL GENERAL SAFETY INFORMATION There are many hazards inherently present when performing any maintenance task on this aircraft. To minimize the risk to both yourself and others, begin by thinking through each task that is to be performed before starting any work. Using common sense, think of ways to avoid these hazards.
Page 43: Flight Safety Reporting Instructions
ASTM F2295. Additional forms may be obtained by writing or calling Cub Crafter’s customer service department at 509-248-9491. It is the responsibility of the owner/operator to notify Cub Crafters of any safety of flight issue or significant service difficulty upon discovery.
Page 44 CUB CRAFTERS, INC. CC11-100 MAINTENANCE MANUAL INTENTIONALLY LEFT BLANK Manual number SC10000AMM Page: 16 Date: 10/01/2010...
Page 45 CUB CRAFTERS, INC. CC11-100 MAINTENANCE MANUAL PERIODIC AND CONDITION INSPECTION REQUIREMENTS TABLE OF CONTENTS GENERAL ..........................2 Visual Inspection ......................2 Operational Inspection ....................3 Functional Inspection ....................3 CONDITION INSPECTION TASKS ..................5 PERIODIC INSPECTION TASKS ..................5 Manual number SC10000AMM...
Page 46: General
This guide will not make reference to revision levels of vendor publications. This guide will be applicable to the aircraft in the configuration it left Cub Crafters when it was first delivered and it may not cover modifications made to the aircraft subsequently.
Page 47: Operational Inspection
CUB CRAFTERS, INC. CC11-100 MAINTENANCE MANUAL (D) Fuel and Hydraulic Oil Lines and Hoses Cracks, dents, kinks, loss of flexibility, deterioration, obstruction, chaffing, improper bend radius, cleanliness, security, and any other apparent damage. (E) Electrical Wiring Cleanliness, loose, corroded, or broken terminals, chaffed, broken, or worn insulation;...
Page 48 CUB CRAFTERS, INC. CC11-100 MAINTENANCE MANUAL Manual number SC10000AMM Page: 4 Date: 10/01/2010...
Page 49: Condition Inspection Tasks
CUB CRAFTERS, INC. CC11-100 MAINTENANCE MANUAL 1. LOWER ENGINE COWLING INSPECTION COVER (2) 2. INSPECTION COVER INSPECTION COVER (2) 3. SCREW WING TRIM EDGE (2) 4. WASHER WING TRIM STRIP (2) 5. UPPER ENGINE COWLING WING TRIM END (2) 6. INSPECTION RING (5 INCH) (9) BELLY ELECTRICAL PANEL 7.
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Page 51 CUB CRAFTERS, INC. CC11-100 MAINTENANCE MANUAL 5.4 LINE MAINTENANCE, REPAIRS, AND ALTERATIONS OF PRIMARY STRUCTURES 5.4.1 ..........................GENERAL 5.4.2 ..........................FUSELAGE 5.4.3 ............................ WINGS 5.4.4 ......................... EMPENNAGE 5.4.5 ......................FLIGHT CONTROLS 5.4.6 ........................LANDING GEAR 5.4.7 ................... WHEEL & BRAKE ASSEMBLIES 5.4.8 ........................
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Page 53 CUB CRAFTERS, INC. CC11-100 MAINTENANCE MANUAL 5.4.1 GENERAL No major repair or alterations, as outlined in ASTM F2483, FAR 43, or in this manual are authorized at this time. To obtain engineering approvals for any major repairs or alterations, please contact Cub Crafters at: Cub Crafters, Inc.
Page 54 CUB CRAFTERS, INC. CC11-100 MAINTENANCE MANUAL INTENTIONALLY LEFT BLANK 5.4.1 Manual number SC10000AMM Page: 2 Date: 04/27/2009...
Page 55 CUB CRAFTERS, INC. CC11-100 MAINTENANCE MANUAL 5.4.2 FUSELAGE TABLE OF CONTENTS GENERAL ..........................2 MAINTENANCE ........................2 5.4.2 Manual number SC10000AMM Date: 04/27/2009 Page: 1...
Page 56 CUB CRAFTERS, INC. CC11-100 MAINTENANCE MANUAL GENERAL The structure of the fuselage consists of a truss made of high-strength steel tubing. The members are joined together using inert gas fusion welding. The steel structure is powder coated to protect it from corrosion.
Page 57 CUB CRAFTERS, INC. CC11-100 MAINTENANCE MANUAL 5.4.3 WINGS TABLE OF CONTENTS GENERAL ..........................2 MAINTENANCE ........................2 5.4.3 Manual number SC10000AMM Date: 04/27/2009 Page: 1...
Page 58 CUB CRAFTERS, INC. CC11-100 MAINTENANCE MANUAL GENERAL The wing is covered with fabric, has two extruded aluminum spars, pressed aluminum ribs, and aluminum leading and trailing edge skins. Rigidity is provided by drag wires and drag braces. The left wing panel houses an optional landing light. A stall warning vane is installed on the leading edge of the left wing.
Page 59 CUB CRAFTERS, INC. CC11-100 MAINTENANCE MANUAL 5.4.4 EMPENNAGE TABLE OF CONTENTS GENERAL ..........................2 MAINTENANCE ........................2 5.4.4 Manual number SC10000AMM Date: 04/27/2009 Page: 1...
Page 60 CUB CRAFTERS, INC. CC11-100 MAINTENANCE MANUAL GENERAL The stabilizers, elevators, and rudder are constructed of tubular steel with steel channel ribs. Stainless steel tie rods and fittings brace the horizontal stabilizers to the vertical stabilizer and fuselage. The aircraft is trimmed in flight by changing the stabilizer’s angle of incidence. The pitch trim is controlled by an electric servo, which moves the leading edge of the horizontal stabilizer up and down.
Page 61 CUB CRAFTERS, INC. CC11-100 MAINTENANCE MANUAL 5.4.5 FLIGHT CONTROLS TABLE OF CONTENTS GENERAL ..........................2 MAINTENANCE ........................2 5.4.5 Manual number SC10000AMM Date: 04/27/2009 Page: 1...
Page 62 CUB CRAFTERS, INC. CC11-100 MAINTENANCE MANUAL GENERAL The aircraft has conventional Friese-type ailerons that are operated with a stick and actuated with cables. The surfaces have an aluminum structure and are covered with aluminum sheet. The flaps are operated mechanically by moving a lever located in the upper, left-hand side of the cockpit ahead of the pilot.
Page 63 CUB CRAFTERS, INC. CC11-100 MAINTENANCE MANUAL 5.4.6 LANDING GEAR TABLE OF CONTENTS GENERAL ..........................2 MAINTENANCE ........................2 5.4.6 Manual number SC10000AMM Date: 04/27/2009 Page: 1...
Page 64 CUB CRAFTERS, INC. CC11-100 MAINTENANCE MANUAL GENERAL The conventional landing gear is fixed (i.e. not retractable) and has a tailwheel. The main landing gear has bungee type shock absorbers or the optional Alpha Omega Suspension System. The landing gear legs are made from welded high strength steel tubing. Both main wheels are fitted with hydraulically operated disc brakes, actuated by pressing toe brakes at each crew position.
Page 65 CUB CRAFTERS, INC. CC11-100 MAINTENANCE MANUAL 5.4.7 WHEEL AND BRAKE ASSEMBLIES TABLE OF CONTENTS GENERAL ..........................2 MAINTENANCE ........................2 5.4.7 Manual number SC10000AM Date: 10/01/2010 Page: 1...
Page 66 CUB CRAFTERS, INC. CC11-100 MAINTENANCE MANUAL GENERAL The main wheels are of aluminum construction and are designed to be used with tires and tubes. The approved tire sizes are 6.00 x 6, 8.00 x 6, 8.50 x 6, 26” LSA Tundra, and 29” LSA Tundra.
Page 67 CUB CRAFTERS, INC. CC11-100 MAINTENANCE MANUAL 5.4.8 ENGINE MOUNT TABLE OF CONTENTS GENERAL ..........................2 MAINTENANCE ........................2 5.4.8 Manual number SC10000AMM Date: 08/02/2010 Page: 1...
Page 68 CUB CRAFTERS, INC. CC11-100 MAINTENANCE MANUAL GENERAL The structure of the mount is made of high-strength steel and the engine is attached to the mount through rubber mounts that help reduce vibration. ENGINE MOUNT ENGINE MAINTENANCE No major repair or alterations, as outlined in ASTM F2483, FAR 43, or in this manual are authorized at this time.
Page 69 CUB CRAFTERS, INC. CC11-100 MAINTENANCE MANUAL 5.4.9. ENGINE TABLE OF CONTENTS GENERAL ..........................2 ENGINE MAINTENANCE ...................... 2 5.4.9 Manual number SC10000AMM Date: 04/27/2009 Page: 1...
Page 70 CUB CRAFTERS, INC. CC11-100 MAINTENANCE MANUAL GENERAL The aircraft is powered by a Teledyne-Continental Motors O-200 engine. This is an air-cooled, four cylinder powerplant that is capable of delivering up to 100 hp at 2750 RPM. A throttle controls power to the engine. Each crew member is provided with a throttle on the left side of the cockpit.
Page 71 CUB CRAFTERS, INC. CC11-100 MAINTENANCE MANUAL 5.4.10. FUEL SYSTEMS TABLE OF CONTENTS GENERAL ........................... 2 MAINTENANCE ........................3 5.4.10 Manual number SC10000AMM Date: 04/18/2013 Page: 1...
Page 72 CUB CRAFTERS, INC. CC11-100 MAINTENANCE MANUAL GENERAL The aircraft is equipped with two 12.5 US gallon fuel tanks located within the wings. The total usable fuel is approximately 12.0 US gallons per tank. The tank is made of aluminum. The fuel system has a sump and drain located in the bottom right side of the fuselage aft of the door opening.
Page 73 CUB CRAFTERS, INC. CC11-100 MAINTENANCE MANUAL FIGURE 5.4.10.1 - STANDARD FUEL TANK CONFIGURATION 1. FUEL SYSTEM WITH ADDITIONAL DRAIN (S/N 00264 – AND ON) Aircraft, starting with S/N 00264, have an additional sump and drain located on the bottom left side of the aircraft, just aft of the firewall on the boot cowl. The fuel system schematic for these aircraft is shown below.
Page 74 CUB CRAFTERS, INC. CC11-100 MAINTENANCE MANUAL FIGURE 5.4.10.2 - STANDARD FUEL TANK CONFIGURATION WITH ADDITIONAL DRAIN MAINTENANCE Refer to Section 6.3.15 for the maintenance of fuel system. No major repair or alterations, as outlined in ASTM F2483, FAR 43, or in this manual are authorized at this time.
Page 75 CUB CRAFTERS, INC. CC11-100 MAINTENANCE MANUAL 5.4.11. PROPELLER TABLE OF CONTENTS GENERAL ..........................2 MAINTENANCE ........................2 5.4.11 Manual number SC10000AMM Date: 08/02/2010 Page: 1...
Page 76 CUB CRAFTERS, INC. CC11-100 MAINTENANCE MANUAL GENERAL The standard aircraft comes with a Sensenich Wood Propeller Company model W72GK-44 72- inch diameter, 54-44-inch pitch Wood Propeller. Other propeller options are:  McCauley 71-41 Metal Propeller  McCauley 75-38 Metal Propeller ...
Page 77 CUB CRAFTERS, INC. CC11-100 MAINTENANCE MANUAL 5.4.12. UTILITY SYSTEMS TABLE OF CONTENTS GENERAL ..........................2 MAINTENANCE ........................2 5.4.12 Manual number SC10000AMM Date: 04/27/2009 Page: 1...
Page 78 CUB CRAFTERS, INC. CC11-100 MAINTENANCE MANUAL GENERAL The aircraft is equipped with a cabin heat system. Hot air for heating the cabin is supplied by a heat exchanger located around the engine exhaust. On newer models, there is a small “ram air”...
Page 79 CUB CRAFTERS, INC. CC11-100 MAINTENANCE MANUAL 5.4.13 INSTRUMENTS AND AVIONICS SYSTEMS TABLE OF CONTENTS GENERAL ........................... 2 INSTRUMENTS ........................5 COM SYSTEM ........................6 3.1. Garmin SL40 COM ...................... 6 3.2. Becker COM ........................ 7 3.3. PM1200 Intercom ......................7 3.4.
Page 80: General
CUB CRAFTERS, INC. CC11-100 MAINTENANCE MANUAL 1 GENERAL The aircraft is equipped with the instrument panel that contains all flight, navigation, and engine instruments that are required for VFR operations. Table 5.4.6 summarizes the equipment installed on the aircraft. Figure 5.4.6.1: Standard Instrument Panel Figure 5.4.6.2: Deluxe VFR Instrument Panels...
Page 81 CUB CRAFTERS, INC. CC11-100 MAINTENANCE MANUAL Figure 5.4.6.3: Deluxe VFR II Instrument Panel Figure 5.4.6.4: Performance VFR Instrument Panel Figure 5.4.6.5: Deluxe Flat Instrument Panel 5.4.13 Manual number SC10000AMM Date: 04/18/2013 Page: 3...
Page 82 CUB CRAFTERS, INC. CC11-100 MAINTENANCE MANUAL Figure 5.4.6.6: Executive Glass Instrument Panel Figure 5.4.6.7: MyPanel Instrument Panel INSTRUMENTS/GAUGES AVIONICS SYSTEM Standard Instrument Panel Tachometer Garmin SL40 COM Altimeter Air Speed Indicator Oil Pressure / Temperature Gauge Inclinometer (skid/slip indicator) Deluxe VFR (II) Instrument Panel...
Page 83: Instruments
CUB CRAFTERS, INC. CC11-100 MAINTENANCE MANUAL INSTRUMENTS/GAUGES AVIONICS SYSTEM Performance VFR Instrument Panel Airspeed Indicator Becker COM Digital Tachometer Becker Transponder Altimeter Garmin GPS (695, 696, GDU370 or GDU375) Inclinometer (skid/slip indicator) PM1200 Intercom Fuel Flow Vertical Speed Indicator Digital Oil Pressure/Temperature...
Page 84: Com System
CUB CRAFTERS, INC. CC11-100 MAINTENANCE MANUAL 3 COM SYSTEM No major repair or alterations, as outlined in ASTM F2483, FAR 43, or in this manual are authorized at this time. To obtain engineering approvals for any major repairs or alterations, please contact Cub Crafters at: Cub Crafters, Inc.
Page 85: Becker Com
CUB CRAFTERS, INC. CC11-100 MAINTENANCE MANUAL 3.2. Becker COM The Becker AR 4201 is an extremely small and light-weight transceiver which offers 760 channels. A standby frequency and 99 memories can be easily programmed and recalled. The AR 4201 has an intercom, panel-lighting, voltage indicator, an AF-input as well as an automatic test-routine as standard functions.
Page 86: Navigation System
CUB CRAFTERS, INC. CC11-100 MAINTENANCE MANUAL 4 NAVIGATION SYSTEM No major repair or alterations, as outlined in ASTM F2483, FAR 43, or in this manual are authorized at this time. To obtain engineering approvals for any major repairs or alterations, please contact Cub Crafters at: Cub Crafters, Inc.
Page 87: Becker Mode-C Transponder
CUB CRAFTERS, INC. CC11-100 MAINTENANCE MANUAL NOTE The GTX 330 meets the requirements of Level 2 Mode-S to satisfy the upcoming European Mode-S mandate for Elementary Surveillance. 4.3. Becker Mode-C Transponder The Becker ATC 4401 has a sunlight readable display. In addition to the transponder code, the display shows the current flight level if an encoding altimeter is connected and Mode-C is selected.
Page 88 CUB CRAFTERS, INC. CC11-100 MAINTENANCE MANUAL The Garmin aera™ 550/560 is easy-to-use with a 4.3 inch QVGA wide-format display with touchscreen interface. This portable GPS navigator features a high-resolution 9 arc-second terrain graphics. It is preloaded with SafeTaxi charts and AOPA Airport Directory.
Page 89: D180 Flightdek
CUB CRAFTERS, INC. CC11-100 MAINTENANCE MANUAL NEXRAF radar, lightning, METARs, TAFs, TFR, and more. In addition, these units offer XM Satellite Radio capabilities, featuring more than 150 digital channels of commercial free music; more than 30 channels of news, sports, talk and entertainment; and more than 20 dedicated channels of XM Instant Traffic and Weather.
Page 90: Antenna Locations
CUB CRAFTERS, INC. CC11-100 MAINTENANCE MANUAL 5.1. Antenna Locations COM Antenna The COM antenna is attached to the belly panel directly underneath the pilot on the underside of the aircraft. Transponder Antenna The transponder antenna is a 3" long antenna located directly in front of the COM antenna.
Page 91 CUB CRAFTERS, INC. CC11-100 MAINTENANCE MANUAL 5.4.14. ELECTRICAL SYSTEMS TABLE OF CONTENTS GENERAL..........................2 ELECTRICAL POWER SYSTEMS ..................2 GENERAL ........................2 SCHEMATICS ....................... 3 LIGHTING SYSTEMS ......................9 GENERAL ........................9 SCHEMATIC ......................... 9 EMERGENCY SYSTEMS: ELT ................... 11 GENERAL ........................
Page 92: Electrical Systems
CUB CRAFTERS, INC. CC11-100 MAINTENANCE MANUAL GENERAL Refer to Chapters 6.3.17 and 6.3.19 for servicing of the electrical systems. No major repair or alterations, as outlined in ASTM F2483, FAR 43, or in this manual are authorized at this time.
Page 93: Schematics
CUB CRAFTERS, INC. CC11-100 MAINTENANCE MANUAL (2) SCHEMATICS Figure 5.4.14.1: Electrical System Schematic 5.4.14 Manual number SC10000AMM Date: 08/02/2010 Page: 3...
Page 94 CUB CRAFTERS, INC. CC11-100 MAINTENANCE MANUAL Figure 5.4.14.2: Standard and VFR Avionics System Schematic w/ Intercom 5.4.14 Manual number SC10000AMM Page: 4 Date: 08/02/2010...
Page 95 CUB CRAFTERS, INC. CC11-100 MAINTENANCE MANUAL Figure 5.4.14.3: Performance Avionics System Schematic 5.4.14 Manual number SC10000AMM Date: 08/02/2010 Page: 5...
Page 96 CUB CRAFTERS, INC. CC11-100 MAINTENANCE MANUAL Figure 5.4.14.4: Executive Glass Avionics System Schematic 5.4.14 Manual number SC10000AMM Page: 6 Date: 08/02/2010...
Page 97 CUB CRAFTERS, INC. CC11-100 MAINTENANCE MANUAL Figure 5.4.14.5: PM1200 Intercom System Figure 5.4.14.6: PM3000 Intercom Systems 5.4.14 Manual number SC10000AMM Date: 08/02/2010 Page: 7...
Page 98 CUB CRAFTERS, INC. CC11-100 MAINTENANCE MANUAL Figure 5.4.14.7: Dynon Schematic 5.4.14 Manual number SC10000AMM Page: 8 Date: 08/02/2010...
Page 99: Lighting Systems
Optional anti-collision light assemblies may be installed on each wingtip. These consist of navigation light and a strobe light. There is also a position light on the tail of the aircraft. CC11-100 S/N 00001 through S/N 00017 may have a beacon on top of the vertical stabilizer. CC11-100 S/N 00018 and on may have either a Strobe Beacon or Navigation Light on the vertical edge of the rudder.
Page 100 CUB CRAFTERS, INC. CC11-100 MAINTENANCE MANUAL Figure 5.4.14.9: LED Lighting System Schematic (S/N 00107 and on) 5.4.14 Manual number SC10000AMM Page: 10 Date: 08/02/2010...
Page 101: Schematic
CUB CRAFTERS, INC. CC11-100 MAINTENANCE MANUAL EMERGENCY SYSTEMS: ELT (1) GENERAL The aircraft is supplied with an emergency locator transmitter (ELT) that meets TSO C91a. The ELT is mounted directly underneath the pilot’s seat and may be accessed through an opening on the forward side of the seat column. RCPI Unit is optional and wiring may not be present.
Page 102 CUB CRAFTERS, INC. CC11-100 MAINTENANCE MANUAL INTENTIONALLY LEFT BLANK 5.4.14 Manual number SC10000AMM Page: 12 Date: 08/02/2010...
Page 103 CUB CRAFTERS, INC. CC11-100 MAINTENANCE MANUAL 5.4.15 SEATS TABLE OF CONTENTS GENERAL ..........................2 REAR SEAT STOWAGE ....................... 4 REAR SEAT INSTALLATION ....................6 MAINTENANCE ........................6 5.4.15 Manual number SC10000AMM Date: 01/31/2011 Page: 1...
Page 104: General
CUB CRAFTERS, INC. CC11-100 MAINTENANCE MANUAL GENERAL The front seat is made from composite with a foam cushion and covered with either canvas or leather material. It is attached to the seat base at the front with screws on both sides. There are two quick-release T-Handle pins, one on each side, at the rear of the seat to adjust the seat position.
Page 105 CUB CRAFTERS, INC. CC11-100 MAINTENANCE MANUAL The rear seat is made of fabric with inserted composite stringers. The seat is attached in front by a steel cross bar. The steel cross bar is held in place to the floorboard by two cinched nylon straps.
Page 106: Rear Seat Stowage
CUB CRAFTERS, INC. CC11-100 MAINTENANCE MANUAL REAR SEAT STOWAGE Disconnect the two cinched nylon straps holding the seat cross bar in place. Unscrew and push the screw in to allow the tab to rotate and slide pin out of seat base connector. See Figure 4.
Page 107 CUB CRAFTERS, INC. CC11-100 MAINTENANCE MANUAL Rear Seat Cushion Left Side Fuselage Cross Bar Slot Right Side Fuselage Cross Bar Slot Cross Bar Rear Seat Cross Bar Sleeves Figure 5 - Rear Cross Bar and Strap Attachment Fold rear seat up and stow in sling seat holder. Place seat cushion and cross bar straps in sling seat holder.
Page 108: Rear Seat Installation
CUB CRAFTERS, INC. CC11-100 MAINTENANCE MANUAL REAR SEAT INSTALLATION Slide the seat straps and nylon straps on to the cross bar in the correct order. Install the cross bar in to the fuselage slots. See Figure 5. Connect the two cinched nylon straps to the floorboard to hold the seat cross bar in place. See Figure 4.
Page 109 CUB CRAFTERS, INC. CC11-100 MAINTENANCE MANUAL 5.5 STRUCTURAL REPAIRS GENERAL ..........................2 Manual number SC10000AMM Date: 04/27/2009 Page: 1...
Page 110 CUB CRAFTERS, INC. CC11-100 MAINTENANCE MANUAL GENERAL No major repair structural repairs or structural alterations, as outlined in ASTM F2483, FAR 43, or in this manual are authorized at this time. To obtain engineering approvals for any major repairs or alterations, please contact Cub Crafters at: Cub Crafters, Inc.
Page 111 CUB CRAFTERS, INC. CC11-100 MAINTENANCE MANUAL PAINTING AND COATINGS Table of Contents GENERAL ..........................2 PAINTING ..........................2 Preparation ........................2 PREPARATION OF METAL ..................2 PREPARATION OF COMPOSITES ................2 PREPARATION OF FABRIC ..................2 Painting ........................... 2 GENERAL ........................2...
Page 112: General
CUB CRAFTERS, INC. CC11-100 MAINTENANCE MANUAL GENERAL For repair and maintenance of painting in details, refer to Poly-Fiber, Inc.’s “How to Cover An Aircraft Using the Poly-Fiber System” Procedure Manual. PAINTING Preparation (1) PREPARATION OF METAL (a) Sand surfaces with 180-320 grit sandpaper & very fine red Scuffpads.
Page 113 CHAPTER LINE MAINTENANCE, REPAIRS, AND ALTERATIONS...
Page 114 INTENTIONALLY LEFT BLANK...
Page 115 CUB CRAFTERS, INC. CC11-100 MAINTENANCE MANUAL 6 LINE MAINTENANCE, REPAIRS, AND ALTERATIONS 6.1 .. AUTHORIZATION TO PERFORM LINE MAINTENANCE, REPAIRS, AND ALTERATIONS 6.2 ....................LINE MAINTENANCE TASKS 6.3 ..............REMOVAL & REPLACEMENT OF COMPONENTS 6.4 ................REPAIR OF STRUCTURE & COMPONENTS 6.5 ..........................
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Page 117 CUB CRAFTERS, INC. CC11-100 MAINTENANCE MANUAL 6.1 GENERAL TABLE OF CONTENTS AUTHORIZATION TO PERFORM LINE MAINTENANCE, REPAIRS, ALTERATIONS, AND INSPECTIONS ........................2 FAA AUTHORIZATION FOR PILOT/OWNER TO PERFORM LINE MAINTENANCE TASKS ........................... 6 Manual number SC10000AMM Date: 08/02/2010 Page: 1...
Page 118 ALTERATIONS, AND INSPECTIONS Table 6.1.1 shows the certifications required to perform line maintenance, repairs, alterations, and inspections on CubCrafters CC11-100 SPORT CUB aircraft, as defined by ASTM F2483 Section 3.1.12. Guidance for accomplishing such maintenance, repairs, alterations, and inspections is contained in this manual; and is to be accomplished in accordance with the practices contained in FAA Advisory Circular 43.13.
Page 119 Rear Wing Strut Ailerons Flaps Pitot Tube Stall Warning Fuel Tanks Wing Assembly ENGINE INSTALLATION Engine Assembly Cub Crafters or Cub Crafters Delegate Air Filter Exhaust System Oil Cooler Oil Filter and Oil Change Alternator Magnetos Carburetor Starter Propeller –Spinner...
Page 120 OR ABOVE STATION STATION STATION Fuel Drain Front Seat Assembly Front Seat Shoulder Harness Cub Crafters or Cub Crafters Delegate Rear Seat Assembly Rear Seat Shoulder Harness Cub Crafters or Cub Crafters Delegate Brake Master Cylinder Brake Lines and Fittings Windshield...
Page 121 CUB CRAFTERS, INC. CC11-100 MAINTENANCE MANUAL REPAIRMAN-I, REPAIRMAN-M, REPAIRMAN-M, HEAVY- OWNER / A&P, OR A&P, OR A&P OR OPERATOR REPAIR REPAIR REPAIR DESCRIPTION OR ABOVE STATION STATION STATION Radio Antenna Garmin GPS (Removal) COM Radio (Removal) Intercom (Removal) Bose Headset Wiring...
Page 122 CUB CRAFTERS, INC. CC11-100 MAINTENANCE MANUAL FAA AUTHORIZATION FOR PILOT/OWNER TO PERFORM LINE MAINTENANCE TASKS The tasks listed in this Manual, and considered to be Minor Maintenance, Repairs, or Alteration tasks - as defined in ASTM F2483 Section 3.1.12 - and may be performed by the Pilot/Owner and who is the holder of an FAA Sport Pilot, Recreational Pilot, Private Pilot, Commercial, or Airline Transport Pilot Certificate.
Page 123 CUB CRAFTERS, INC. CC11-100 MAINTENANCE MANUAL 6.2 LINE MAINTENANCE TASKS TABLE OF CONTENTS 100 HOUR INSPECTION ...................... 2 CONDITION INSPECTION ....................2 SERVICING OF FLUIDS ....................... 2 Manual number SC10000AMM Date: 08/02/2010 Page: 1...
Page 124 CUB CRAFTERS, INC. CC11-100 MAINTENANCE MANUAL 100 HOUR INSPECTION Refer to section 5.3.3 of this manual for 100 Hour Inspection requirements CONDITION INSPECTION Refer to section 5.3.2 of this manual for Condition Inspection requirements SERVICING OF FLUIDS This information gives the general servicing procedures and maintenance practices that are to be used when servicing the airplane.
Page 125 CUB CRAFTERS, INC. CC11-100 MAINTENANCE MANUAL Item Specifications Capacity 25 US Gallons Total Fuel Aviation Grade 100/100LL 24 US Gallons Usable SAE J-1966 non-dispersant Average (See note below) mineral oil and Ambient SAE J-1899 ashless- Temperature 6 Quarts dispersant oil grades Above 40ºF...
Page 126 CUB CRAFTERS, INC. CC11-100 MAINTENANCE MANUAL LUBRICATION CHART ITEM SUGGESTED SPEC ENGINE Engine Oil Appropriate for temperature See Table 6.2.1 Spark Plug Thread Champion Aerospace # Lubricant 2612 Oil Filter Gasket Dow Corning 4 Lubricant MIL-S-8660C COCKPIT Hydraulic Fluid (Brake)
Page 127 CUB CRAFTERS, INC. CC11-100 MAINTENANCE MANUAL LUBRICATION CHART ITEM SUGGESTED SPEC Main Landing Gear Pivot LPS 2 MIL-C-16173E GRADE 3 Points CLASS I Main Wheel Bearings Mobilgrease 28 MIL-G-81322E Tail Wheel Swivel Mobilgrease 28 MIL-G-81322E Tail Wheel Bearings Mobilgrease 28...
Page 128 CUB CRAFTERS, INC. CC11-100 MAINTENANCE MANUAL INTENTIONALLY LEFT BLANK Manual number SC10000AMM Page: 6 Date: 08/02/2010...
Page 129 CUB CRAFTERS, INC. CC11-100 MAINTENANCE MANUAL 6.3 REMOVAL & REPLACEMENT OF COMPONENTS 6.3.1 ..........................GENERAL 6.3.2 ....................... JACKING AND LIFTING 6.3.3 ........................... FUSELAGE 6.3.4 ..........................WINGS 6.3.5 ........................EMPENNAGE 6.3.6 ......................FLIGHT CONTROLS 6.3.7 ........................LANDING GEAR 6.3.8 ..................WHEEL & BRAKE ASSEMBLIES 6.3.9 ........................
Page 130 CUB CRAFTERS, INC. CC11-100 MAINTENANCE MANUAL INTENTIONALLY LEFT BLANK Manual number SC10000AMM Page: ii Date: 04/18/2013...
Page 131: General
For maintenance and repair of primary structures, see Section 5.4. This section also lists the components that Cub Crafters recommends be replaced at specified intervals. Whenever this is carried out, ensure that the following information is properly recorded in the airplane maintenance log: ...
Page 132 CUB CRAFTERS, INC. CC11-100 MAINTENANCE MANUAL REF. IN ITEM INTERVAL REPLACE OVERHAUL THIS NOTES MANUAL Emergency After 1 hour of Chapter Refer to ACK Locator cumulative 5.4.7 Technologies Model E- Transmitter transmitting. 01 or Artex ME-406 Batteries Date Marked Installation and...
Page 133 CUB CRAFTERS, INC. CC11-100 MAINTENANCE MANUAL 6.3.2 Jacking the Airplane (1) TOOLS EQUIPMENT AND SUPPLIES Description P/N or Spec. Supplier Purpose Floor Jack Any Source Jack Main Wheels Wooden Saw Horse or Bench Any Source Place Under Tail Wing Jack...
Page 134 CUB CRAFTERS, INC. CC11-100 MAINTENANCE MANUAL (3) RAISING THE AIRCRAFT FROM THE LANDING GEAR Use this method to service the wheels and brakes. Place a chock under the opposite main wheel and tail wheel. Place a jack under the main axle as shown in Figure 6.3.2.2.
Page 135 CUB CRAFTERS, INC. CC11-100 MAINTENANCE MANUAL (4) RAISING THE AIRCRAFT FROM THE WING Use this method for complete removal of landing gear leg. Place chock under opposite main wheel and tail wheel. Place jack between the main lift strut wing attachment point and the tie down (Refer to 6.3.2.3).
Page 136 CUB CRAFTERS, INC. CC11-100 MAINTENANCE MANUAL INTENTIONALLY LEFT BLANK 6.3.2 Manual number SC10000AMM Page: 4 Date: 08/02/2010...
Page 137 CUB CRAFTERS, INC. CC11-100 MAINTENANCE MANUAL 6.3.3 FUSELAGE TABLE OF CONTENTS FUSELAGE ..........................2 INSPECTION ........................ 2 REPAIR ......................... 2 6.3.3 Manual number SC10000AMM Date: 04/27/2009 Page: 1...
Page 138 CUB CRAFTERS, INC. CC11-100 MAINTENANCE MANUAL FUSELAGE (1) INSPECTION See inspection forms in Appendix 6.A to perform periodic inspection tasks. (2) REPAIR No major repair or alterations, as outlined in ASTM F2483, FAR 43, or in this manual are authorized at this time.
Page 139 CUB CRAFTERS, INC. CC11-100 MAINTENANCE MANUAL 6.3.4 WINGS TABLE OF CONTENTS SERVICING ........................2 REMOVAL ........................ 4 INSTALLATION ......................5 RIGGING THE WINGS ....................... 7 PREPARATION ......................7 DIHEDRAL ANGLE ....................7 WASHOUT ANGLE ....................8 VORTEX GENERATORS ....................9 MAINTENANCE ........................
Page 140: Servicing
CUB CRAFTERS, INC. CC11-100 MAINTENANCE MANUAL SERVICING Figure 6.3.4.1 Wing Installation 6.3.4 Manual number SC10000AMM Page: 2 Date: 10/01/2010...
Page 141 CUB CRAFTERS, INC. CC11-100 MAINTENANCE MANUAL Figure 6.3.4.1 Wing Installation (Continued) 6.3.4 Manual number SC10000AMM Date: 10/01/2010 Page: 3...
Page 142: Removal
CUB CRAFTERS, INC. CC11-100 MAINTENANCE MANUAL (1) REMOVAL CAUTION Before removing the wings, set the parking brakes and chock the wheels. (a) Remove the front wing root, rear wing root, wing/root panel interface, skylight, and turtle deck. (b) Drain the fuel tank(s) and disconnect the fuel supply and gauge lines inboard ends at the wing root.
Page 143: Installation
CUB CRAFTERS, INC. CC11-100 MAINTENANCE MANUAL (j) With a person holding the wing and on person holding the rear lift strut, remove the lower and upper rear lift strut bolts and separate the strut from the fuselage. (k) Remove the nuts from the wing and strut attachment bolts.
Page 144 CUB CRAFTERS, INC. CC11-100 MAINTENANCE MANUAL (k) Support the outboard end of the wing and remove the lower strut bullets. Insert the proper bolts. Torque the nut to 95 in. lbs, torque up to the nearest castellation, and safety with a cotter pin.
Page 145: Rigging The Wings
CUB CRAFTERS, INC. CC11-100 MAINTENANCE MANUAL RIGGING THE WINGS (1) PREPARATION The aircraft must be level longitudinally and laterally prior to setting or adjusting the dihedral or the washout angles. Refer to the leveling procedure described in Section 6.3.22. (2) DIHEDRAL ANGLE Figure 6.3.4.2...
Page 146: Washout Angle
CUB CRAFTERS, INC. CC11-100 MAINTENANCE MANUAL (a) Remove the front wing root fairings. (b) Stretch a string from wing tip to wing tip above the front spar and pull tight and secure. (c) Measure down from the string to the top of the inboard edge of the front spar cap (Figure 6.3.4.2).
Page 147: Vortex Generators
CUB CRAFTERS, INC. CC11-100 MAINTENANCE MANUAL VORTEX GENERATORS Each wing has 36 vortex generators on the top leading edge. The aircraft is allowed to fly with the following number of vortex generators missing:  Not more than three vortex generators missing on an aircraft ...
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Page 149 CUB CRAFTERS, INC. CC11-100 MAINTENANCE MANUAL 6.3.5 EMPENNAGE TABLE OF CONTENTS INSPECTION ........................2 FUSELAGE ........................ 2 TAIL SURFACES ....................... 2 RUDDER ..........................3 REMOVAL ........................3 INSTALLATION ......................4 ELEVATOR REMOVAL ....................5 HORIZONAL STABILIZERS REMOVAL ..............6 RIGHT HORIZONTAL STABILIZER INSTALLATION ..........7 LEFT HORIZONTAL STABILIZER INSTALLATION............
Page 150: Inspection
CUB CRAFTERS, INC. CC11-100 MAINTENANCE MANUAL INSPECTION (1) FUSELAGE (a) Visually inspect the fuselage longeron tubing and stringers for damage and corrosion. (b) Inspect all pulleys, guides, and fairleads for damage, cracks, or misalignment. (c) Check that the pulleys turn freely.
Page 151: Rudder
CUB CRAFTERS, INC. CC11-100 MAINTENANCE MANUAL RUDDER 1 - Springs 2 - Cables 3 - Wiring 4 - Hinge pins Figure 6.3.5.1 Rudder Installation (1) REMOVAL Refer to Figure 6.3.5.1 (a) Unhook the tail wheel steering springs (1) from the rudder arm.
Page 152: Installation
CUB CRAFTERS, INC. CC11-100 MAINTENANCE MANUAL (2) INSTALLATION Figure 6.3.5.2: Installation of Clevis Pins at Rudder Hinges (a) Position the rudder hinges inline with the hinges on the fin and fasten with two clevis pins, wire pull bracket (top only), washers, and cotter pin. (Figure 6.3.5.2) (b) Reconnect the electrical wiring to the lights in the light (3).
Page 153: Elevator Removal
CUB CRAFTERS, INC. CC11-100 MAINTENANCE MANUAL 3. HORIZONTAL STABILIZERS AND ELEVATORS (1) ELEVATOR REMOVAL 1 – Clevis Bolts 2 – Washers 3 – Castle Nuts 4 – Cotter Pins 5 – Bolt 6 – Washers 7 – Lock Nut 8 – Elevator Assembly – Left (Horn) 9 –...
Page 154: Horizonal Stabilizers Removal
CUB CRAFTERS, INC. CC11-100 MAINTENANCE MANUAL Refer to Figure 6.3.5.4 (a) Remove left hand and right hand tail inspection covers. (b) Remove the cotter pin (4), nut (3), and washer (2) on the top side of the elevator horns (8 & 9).
Page 155: Right Horizontal Stabilizer Installation
CUB CRAFTERS, INC. CC11-100 MAINTENANCE MANUAL (3) RIGHT HORIZONAL STABILIZER INSTALLATION 1 - Long Bolt 4 - Thick Washer 7 - Rear Stabilizer Tube 2 - Bolt 5 - Nut 3 - Thin Washer 6 - Front Stabilizer Tube Figure 6.3.5.6 Horizontal Stabilizer Installation 6.3.5...
Page 156 CUB CRAFTERS, INC. CC11-100 MAINTENANCE MANUAL Refer to Figure 6.3.5.6 (a) Identify the right stabilizer (note that the fabric seam should be on the bottom of the surface). Lay the stabilizer on a suitable work surface and apply a thin coat of grease (MIL-G-81322E) to the inside ends of the front and rear tubes.
Page 157: Left Horizontal Stabilizer Installation
CUB CRAFTERS, INC. CC11-100 MAINTENANCE MANUAL (4) LEFT HORIZONTAL STABILIZER INSTALLATION (a) Apply grease (MIL-G-81322E to the inside of the front and rear tubes of the right stabilizer and install it onto the ends of the tubes that protrude from the side of the fuselage.
Page 158: Installing Tail Brace Wires
CUB CRAFTERS, INC. CC11-100 MAINTENANCE MANUAL (5) INSTALLING TAIL BRACE WIRES 1 – Clevis Pin 2 – Washer 3 – Tail Fin 4 – Rudder 5 – Fin Stringer 6 – Washer 7 – Cotter Pin 11 – Clevis Pin 12 –...
Page 159: Rigging The Tail Brace Wires
CUB CRAFTERS, INC. CC11-100 MAINTENANCE MANUAL Refer to Figure 6.3.5.7 (a) Set the tail of the aircraft on a sawhorse or a bench. (b) Remove the inspection cover located on the left side of fuselage beneath the horizontal stabilizer. (c) Position the long tail wires with the fin stringer (5) and insert a clevis pin (1) with washer (2) through the fin (3) and rudder (4).
Page 160: Elevator Installation
CUB CRAFTERS, INC. CC11-100 MAINTENANCE MANUAL (7) ELEVATOR INSTALLATION (a) Identify which are the left and right elevators. The sewn seams are on the bottom trailing edge of each. Figure 6.3.5.8 Clevis Pin Installation on Elevator (b) Install each elevator onto the matching hinges on the stabilizers using clevis pins, wire pull brackets, with a washer at each end of every pin, and then secure each with a cotter pin.
Page 161 CUB CRAFTERS, INC. CC11-100 MAINTENANCE MANUAL 1 – Clevis Bolts 2 – Washers 3 – Castle Nuts 4 – Cotter Pins 5 – Bolt 6 – Washers 7 – Lock Nut 8 – Elevator Assembly – Left (Horn) 9 – Elevator Assembly – Right (Horn) 10 –...
Page 162 CUB CRAFTERS, INC. CC11-100 MAINTENANCE MANUAL Refer to Figure 6.3.5.10 (c) Connect the elevator horns (8 & 9) to the stabilizer and fuselage, and secure with the bolt (5), washers (6) and lock nut (7) at the top of the horns.
Page 163: Rigging The Tail Control Surfaces
Ensure that the rudder can travel through its full range, left and right. Rudder travel may be measured using a special protractor available at Cub Crafters for a nominal fee. The travel is not adjustable in the field. Contact Cub Crafters if adjustments to the travel are required.
Page 164: Maintenance
CUB CRAFTERS, INC. CC11-100 MAINTENANCE MANUAL MAINTENANCE No major repair or alterations, as outlined in ASTM F2483, FAR 43, or in this manual are authorized at this time. To obtain engineering approvals for any major repairs or alterations, please contact Cub Crafters at: Cub Crafters, Inc.
Page 165 CUB CRAFTERS, INC. CC11-100 MAINTENANCE MANUAL 6.3.6 FLIGHT CONTROLS TABLE OF CONTENTS GENERAL ..........................2 TROUBLESHOOTING ......................2 AILERONS ..........................3 REMOVAL ........................3 INSTALLATION ......................4 RIGGING ........................6 FLAPS ........................... 8 REMOVAL ........................8 INSTALLATION ......................9 RIGGING THE POSITION OF THE FLAPS ..............10 FLAP HANDLE LOCK REPLACEMENT ................
Page 166: General
CUB CRAFTERS, INC. CC11-100 MAINTENANCE MANUAL GENERAL The control surfaces of the aircraft must be rigged within the prescribed limits in order to maintain adequate margins of safety. This section specifies the procedures that must be used to rig the flight control surfaces. The flight controls consist of ailerons, rudder, elevators, and flaps.
Page 167: Ailerons
CUB CRAFTERS, INC. CC11-100 MAINTENANCE MANUAL PROBLEM PROBABLE CAUSE REMEDY Stall warning does comes on Stall warning vane not Calibrate stall warning vane at a speed less than 6 mph calibrated properly above the stall Stall warning does not work...
Page 168: Installation
CUB CRAFTERS, INC. CC11-100 MAINTENANCE MANUAL (2) INSTALLATION 1- Bolt 2- Washers 3- Washer 4- Nut 5- Cotter Pin Figure 6.3.6.2 Aileron Hinge Refer to Figure 6.3.6.2 (a) Position the ailerons on the wing panels and secure with the bolts (1), washers (2 &...
Page 169 CUB CRAFTERS, INC. CC11-100 MAINTENANCE MANUAL 1 - Aileron Control Cable 2 – Hinge 3 – Turnbuckle Barrel 4 - Wire-Lock Clip 5 - Turnbuckle Fork 6 - Castle Nut 7 - Cotter Pin 8 - Thin Washer 9 – Hinge Arm 10 –...
Page 170: Rigging
CUB CRAFTERS, INC. CC11-100 MAINTENANCE MANUAL (3) RIGGING Figure 6.3.6.4 Alignment of Aileron Trailing Edge with Flap Trailing Edge (a) The neutral position of the ailerons is found by matching as closely as possible, the trailing edge of the ailerons with the trailing edge of the wing tip.
Page 171 CUB CRAFTERS, INC. CC11-100 MAINTENANCE MANUAL CAUTION Leave no more than 3 threads visible at each end of the turnbuckle barrels. Figure 6.3.6.6 Safety of Turnbuckles (e) Safety each turnbuckle barrel with 2 wire lock clips making sure the clip ends are locked in the hole (Figure 6.3.6.6).
Page 172: Flaps
CUB CRAFTERS, INC. CC11-100 MAINTENANCE MANUAL FLAPS (1) REMOVAL 1 – Flap Hinge 2 – Flap Cone Assembly 3 – Cotter Pin 4 – Castle Nut 5 – Washer 6 – Bolt 7 – Steel Bushing 8 - Bolt 9 - Washers Figure 6.3.6.7...
Page 173: Installation
CUB CRAFTERS, INC. CC11-100 MAINTENANCE MANUAL A – Cotter Pin B – Castle Nut C – Washer D – Flap Hinge E – Washer F – Aileron Hinge G – Washer H – Bolt Figure 6.3.6.8 Flap Hinge (continued) Refer to 6.3.6.7 and 6.3.6.8 (a) Remove the cotter pin (3) and nut (4) holding the bolt (6) on the flap cone (2) and flap hinge (1);...
Page 174: Rigging The Position Of The Flaps
CUB CRAFTERS, INC. CC11-100 MAINTENANCE MANUAL (a) Ensure the flap rod connection eye is installed on the flap. (b) Using two people, slide flap inboard and onto the flap cone attach bolt. Install outboard attachment hardware. Refer to Figure 6.3.6.7, Figure 6.3.6.8, and Figure 6.3.6.9.
Page 175: Flap Handle Lock Replacement
CUB CRAFTERS, INC. CC11-100 MAINTENANCE MANUAL FLAP HANDLE LOCK REPLACEMENT (1) REMOVE RETAINING HARDWARE (2) INSTALL NEW FLAP HANDLE LOCK (3) CHECK FLAP MOVEMENT (a) Ensure all flap positions are obtainable and there is no restriction to free movement in the flap handle system.
Page 176: Maintenance
CUB CRAFTERS, INC. CC11-100 MAINTENANCE MANUAL MAINTENANCE No major repair or alterations, as outlined in ASTM F2483, FAR 43, or in this manual are authorized at this time. To obtain engineering approvals for any major repairs or alterations, please contact Cub Crafters at: Cub Crafters, Inc.
Page 177 CUB CRAFTERS, INC. CC11-100 MAINTENANCE MANUAL 6.3.7 LANDING GEAR TABLE OF CONTENTS TROUBLESHOOTING ......................2 MAIN LANDING GEAR ......................5 BUNGEE ASSEMBLY ....................6 REMOVAL ........................6 INSPECTION ......................6 INSTALLATION ......................7 LANDING GEAR LEG ....................7 REMOVAL ........................7 INSPECTION ......................
Page 178: Landing Gear
CUB CRAFTERS, INC. CC11-100 MAINTENANCE MANUAL TROUBLESHOOTING PROBLEM PROBABLE CAUSE REMEDY Landing Gear Sags Bungees are no longer strong Replace bungee cords enough to return the landing gear to its stops Shocks Bottom on Inspect for weak bungee cords Replace bungee cords...
Page 179 CUB CRAFTERS, INC. CC11-100 MAINTENANCE MANUAL PROBLEM PROBABLE CAUSE REMEDY Bent or cracked torque plate Replace Corroded anchor bolts and/or Clean and lubricate or torque plate bushings replace Brakes drag (continued) Warped brake disc; inspect by Replace and use caution...
Page 180 CUB CRAFTERS, INC. CC11-100 MAINTENANCE MANUAL PROBLEM PROBABLE CAUSE REMEDY Brakes will not hold Lining worn below minimum Replace linings wear limits Discs worn below minimum Replace discs wear limits Contaminated lining Replace lining Brakes will not hold New lining installed with old...
Page 181: Main Landing Gear
CUB CRAFTERS, INC. CC11-100 MAINTENANCE MANUAL MAIN LANDING GEAR Figure 6.3.7.1 Main Landing Gear Arrangement 6.3.7 Manual number SC10000AMM Date: 04/27/2009 Page: 5...
Page 182: Bungee Assembly
Inspect the hydraulic strut for leaking fluid or damage. NOTE The bungees are replaced every five years (see Section 6.A). If the cords need replacement, contact Cub Crafters for further information. Replace any hardware that is excessively corroded or worn.
Page 183: Installation
CUB CRAFTERS, INC. CC11-100 MAINTENANCE MANUAL (3) INSTALLATION Insert the shock assembly in the strut. Insert a bolt with a washer through the shock and strut and place a washer and nut on the end of the bolt. Torque the nut to 160-200 in·lbs.
Page 184: Installation
CUB CRAFTERS, INC. CC11-100 MAINTENANCE MANUAL (3) INSTALLATION Replace any hardware that is excessively corroded or worn. Align the upper landing gear attachment holes with the corresponding ones in the fuselage. If there is a gap between a landing gear leg and the corresponding fuselage ear, fill the gap with washers of the appropriate thickness.
Page 185: Tail Landing Gear
CUB CRAFTERS, INC. CC11-100 MAINTENANCE MANUAL TAIL LANDING GEAR STANDARD STEERABLE TAIL WHEEL (1) Removal of Tail Wheel and Leaf Springs i - Nut ii - Washer (4) iii - Long Bolt iv - Clamp v - Small Nut (2)
Page 186: Disassembly Of Tail Wheel Bracket And Fork
CUB CRAFTERS, INC. CC11-100 MAINTENANCE MANUAL (2) Disassembly of Tail wheel Bracket and Fork Figure 6.3.7.3 Standard Tail Wheel Assembly (a) Remove the tire assembly from the fork by removing the nut and sliding the axle out. (b) Disengage the arm assembly, washers, and nut from the fork and bracket.
Page 187: Inspection Of Tail Wheel Components
CUB CRAFTERS, INC. CC11-100 MAINTENANCE MANUAL (4) Inspection of Tail Wheel Components See Figure 6.3.7.3 (a) Check the leaf springs for damage or twisting. (b) Replace if condition dictates. (c) Inspect the arm assembly, fork, and bracket for excessive wear, cracks or other damage.
Page 188: Reassembly Of Tail Wheel Bracket And Fork
CUB CRAFTERS, INC. CC11-100 MAINTENANCE MANUAL (7) Reassembly of Tail Wheel Bracket and Fork See Figure 6.3.7.3 (a) Hand apply grease to all internal parts and pack the bearing (15) with grease (MIL-G-81322E). (b) Place the arm assembly and washers on the fork and secure with the nut.
Page 189: Optional 3200-Type Steerable Tail Wheel
CUB CRAFTERS, INC. CC11-100 MAINTENANCE MANUAL OPTIONAL 3200-TYPE STEERABLE TAIL WHEEL (1) Removal of Tail Wheel and Leaf Springs A - Nut B - Washer C - Long Bolt D - Clamp E - Small Nut F - Small Washer...
Page 190 CUB CRAFTERS, INC. CC11-100 MAINTENANCE MANUAL (a) Lift the tail section of the airplane and rest the fuselage on a bench so the tail landing gear clears the ground. (b) Disconnect the chain links from the Tail wheel arms. (c) Remove the front tail spring attach nut (A) and washer (B).
Page 191: Disassembly Of Tail Wheel Bracket And Fork
CUB CRAFTERS, INC. CC11-100 MAINTENANCE MANUAL (2) Disassembly of Tail Wheel Bracket and Fork 1 - Cotter Pin 2 - Short Castle Nut 3 - Washer 4 - Fork Assy. 5 - Lower Dust Cap 6 – Pawl 7 - Thrust Washer 8 - Arm Assy.
Page 192: Cleaning
CUB CRAFTERS, INC. CC11-100 MAINTENANCE MANUAL (a) Remove the tire assembly from the fork by removing the cotter pin (1), castle nut (23), and washer (3) then sliding the axle (21) out. (b) At the bottom of the fork (4) remove the cotter pin (1), short castle nut (2), and washer (3).
Page 193: Reassembly Of Tail Wheel Bracket And Fork
CUB CRAFTERS, INC. CC11-100 MAINTENANCE MANUAL (7) Reassembly of Tail Wheel Bracket and Fork See Figure 6.3.7.5 (a) Hand apply grease to all internal parts and pack the bearing (15) with grease (MIL-G-81322E). (b) Place the lower dust cap (5) on the fork (4) and the thrust washer (7) on the fork (4) being sure to align the notch with the locking pin in the fork (4).
Page 194: Installation Of Tail Wheel And Leaf Springs
CUB CRAFTERS, INC. CC11-100 MAINTENANCE MANUAL (8) Installation of Tail Wheel and Leaf Springs See Figure 6.3.7.4 (a) Position the tail wheel springs on the fuselage with long bolt (C) and hold in place with a washer (B) and a nut (A).
Page 195 CUB CRAFTERS, INC. CC11-100 MAINTENANCE MANUAL 6.3.8 WHEEL & BRAKE ASSEMBLIES TABLE OF CONTENTS MAIN WHEELS ........................2 REMOVAL ........................2 WHEEL DISASSEMBLY ....................2 INSPECTION ........................ 4 WHEEL ASSEMBLY ..................... 5 MAIN WHEEL INSTALLATION ..................5 TAIL WHEEL ......................... 6 3200-Type Wheel ......................
Page 196: Main Wheels
CUB CRAFTERS, INC. CC11-100 MAINTENANCE MANUAL MAIN WHEELS (1) REMOVAL (a) Chock the main wheel on the opposite side of the landing gear that is to be worked on. Chock the tail wheel. It is not recommended to carry this work outside in windy conditions.
Page 197 CUB CRAFTERS, INC. CC11-100 MAINTENANCE MANUAL (a) Deflate the tire. (b) Break the tire bead loose from the wheel. (c) Remove the wheel halve nuts (6) and washers (5). (d) Pull the wheel halves (1, 3) apart being careful with the tubes valve stem.
Page 198: Inspection
CUB CRAFTERS, INC. CC11-100 MAINTENANCE MANUAL (3) INSPECTION (a) Axle  Visually inspect the axle to make sure there are no cracks or grooves. (b) Tire and Tube  Visually inspect the tires inside and outside for cuts, uneven or excessive wear, and penetration by foreign objects.
Page 199: Wheel Assembly
CUB CRAFTERS, INC. CC11-100 MAINTENANCE MANUAL (4) WHEEL ASSEMBLY (a) If a new tire or tube is used or the old one is sticky, dust the inside of the tire lightly with talcum powder. (b) Inflate the tube, inside the tire, with enough air to start to fill it out so it will not be pinched between the wheel halves.
Page 200: Tail Wheel
CUB CRAFTERS, INC. CC11-100 MAINTENANCE MANUAL TAIL WHEEL 3200-Type Wheel 1 – Spacer 2 - Grease Retainer 3 - Inner Spacer 4 - Bearing 5 - Bearing Race 6 - Bolt 7 - Nut 8 - Hub 9 - Gasket...
Page 201: Disassembly
CUB CRAFTERS, INC. CC11-100 MAINTENANCE MANUAL Refer to Figure 6.3.8.2 (1) DISASSEMBLY (a) Deflate the tube (12). (b) Break the tire bead loose from the wheel. (c) Remove the wheel half nuts (5) and bolts (6). (d) Pull the wheel hubs (8) apart being careful with the valve stem.
Page 202: Reassembly Of Tail Wheel
CUB CRAFTERS, INC. CC11-100 MAINTENANCE MANUAL (3) REASSEMBLY OF TAIL WHEEL (a) Insert the wheel hubs (8) with the gasket (9) in between into the tire and tube assembly. Make certain the gasket (9) is properly aligned with tube valve and hub bolt holes.
Page 203: Brake Calipers
CUB CRAFTERS, INC. CC11-100 MAINTENANCE MANUAL BRAKE CALIPERS 1 - Safety Wire 2 - Bolts 3 - Brake Line 4 - Caliper 5 - Backing Plate 6 - Anchor Lugs 7 - Brake Back Plates Figure 6.3.8.3 Brake Calipers 6.3.8...
Page 204: Removal
CUB CRAFTERS, INC. CC11-100 MAINTENANCE MANUAL REMOVAL (a) Cut the safety wire (1) and remove the brake back plate bolts (2). (b) Disconnect the brake line (3) from the caliper (4). (c) Separate the caliper (4) from backing plate (5).
Page 205: Master Cylinder And Parking Brake Valve
CUB CRAFTERS, INC. CC11-100 MAINTENANCE MANUAL MASTER CYLINDER AND PARKING BRAKE VALVE Figure 6.3.8.4 Brake Master Cylinder and Parking Brake Valve 1 – Master Cylinder 2 – 90° Male Elbow 3 – Ball Valve 4 – 90° Brass Poly-Flow Fitting 5 –...
Page 206: Removal
CUB CRAFTERS, INC. CC11-100 MAINTENANCE MANUAL REMOVAL (a) Drain hydraulic fluid from system. (b) Disconnect brake line from 90° Brass Poly-Flow Fitting (4). (c) Remove Cotter Pins (10) (11) from Clevis Pins (8) (9). (d) Remove Clevis Pins (8) (9) and AN960-10 Washers (12).
Page 207: Maintenance
If any repairs or alteration tasks should be required to be performed before the release of this section of the manual, it shall be accomplished using approved engineering data that will be provided by Cub Crafters’ Engineering Department. To obtain such data and approvals please contact: Cub Crafters, Inc.
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Page 209 CUB CRAFTERS, INC. CC11-100 MAINTENANCE MANUAL 6.3.9 ENGINE MOUNT (1) INSPECTION See inspection forms in Appendix 6.A to perform periodic inspection tasks. (2) REPAIR No major repair or alterations, as outlined in ASTM F2483, FAR 43, or in this manual are authorized at this time.
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Page 211 CUB CRAFTERS, INC. CC11-100 MAINTENANCE MANUAL 6.3.10. ENGINE TABLE OF CONTENTS TROUBLESHOOTING ......................2 SERVICING – OIL SYSTEM ....................5 2.1. CHANGING ENGINE OIL AND FILTER ................. 5 2.2. OIL SCREEN ........................6 REMOVAL ........................6 INSPECTION ......................7 INSTALLATION ......................7 2.3.
Page 212: Troubleshooting
CUB CRAFTERS, INC. CC11-100 MAINTENANCE MANUAL TROUBLESHOOTING This section is prepared to help the owners / operators diagnose the probable causes and determine appropriate corrective actions. For additional information on more specific trouble shooting procedures, refer to Teledyne-Continental’s Operator’s Manual and their Maintenance and Overhaul Manual.
Page 213 CUB CRAFTERS, INC. CC11-100 MAINTENANCE MANUAL Reference PROBLEM PROBABLE CAUSE REMEDY in this manual Rough Propeller out of balance. Remove and inspect. 6.3.16 running Engine mount bolts loose. Tighten. 5.2.5 Defective spark plug cables. Test for break-down at high voltage.
Page 214 CUB CRAFTERS, INC. CC11-100 MAINTENANCE MANUAL Reference PROBLEM PROBABLE CAUSE REMEDY in this manual Low oil Low oil supply. Replenish. pressure Low oil viscosity. Drain sump. Refill with correct grade. 6.2.3 Plugged oil screen. Remove and clean. 6.3.10 Dirt on oil pressure relief valve Clean plunger and seat.
Page 215: Servicing - Oil System
CUB CRAFTERS, INC. CC11-100 MAINTENANCE MANUAL 2 SERVICING – OIL SYSTEM The oil system is an integral part of the engine, except for the cooler that is mounted on the left side of the firewall. Refer to the latest revision of Teledyne-Continental Motors Service Information Letter SIL99-2B to determine the frequency of oil changes and screen inspections.
Page 216: Oil Screen
CUB CRAFTERS, INC. CC11-100 MAINTENANCE MANUAL the engine to idle for a few minutes and shutdown the engine in accordance with POH procedures. CAUTION If the oil pressure does not rise in 30 seconds, stop the engine and determine the trouble.
Page 217: Inspection
CUB CRAFTERS, INC. CC11-100 MAINTENANCE MANUAL CAUTION Do not damage the temperature probe wire while separating the screen housing from the accessory case. (d) Drain the oil from the housing and remove the screen. (2) INSPECTION (a) Inspect the screen (2) and inside the housing (3) for foreign particles.
Page 218: Oil Cooler
CUB CRAFTERS, INC. CC11-100 MAINTENANCE MANUAL 2.3. OIL COOLER Figure 6.3.10.3 Oil Cooler Installation (1) REMOVAL (a) Disconnect the hose fittings from the elbows that go into the oil cooler. Use a backup wrench on the elbow fittings to prevent damage to the oil cooler.
Page 219: Installation
CUB CRAFTERS, INC. CC11-100 MAINTENANCE MANUAL (2) INSTALLATION Figure 6.3.10.4 Oil Cooler Refer to Figure 6.3.10 (a) Apply thread sealant (EZ TURN Lubricant) to all but the most inner pipe thread on each elbow but not on the flare fitting threads. Screw the elbows into the oil cooler.
Page 220: Engine Maintenance
CUB CRAFTERS, INC. CC11-100 MAINTENANCE MANUAL 3 ENGINE MAINTENANCE No major repair or alterations, as outlined in ASTM F2483, FAR 43, or in this manual are authorized at this time. To obtain engineering approvals for any major repairs or alterations, please contact Cub Crafters at: Cub Crafters, Inc.
Page 221 CUB CRAFTERS, INC. CC11-100 MAINTENANCE MANUAL 6.3.11 ENGINE CONTROLS TABLE OF CONTENTS 1. GENERAL ......................2 2. MAINTENANCE ..................... 2 PIN VICE GRIP THROTTLE CABLE ................2 LEVER ATTACHMENT ....................3 LEVER INTERCONNECT LINKAGE ................3 ATTACHMENT OF THROTTLE CABLE TO SIDE PANEL......... 4 MOTOR MOUNT THROTTLE CABLE ATTACHMENT ..........
Page 222: General
CUB CRAFTERS, INC. CC11-100 MAINTENANCE MANUAL 1. GENERAL Each crewmember is provided with a throttle lever on the left side of the cockpit. The air-to- fuel mixture is adjusted manually with a red control knob located on the left side of the instrument panel.
Page 223: Lever Attachment
CUB CRAFTERS, INC. CC11-100 MAINTENANCE MANUAL (1) LEVER ATTACHMENT Refer to Figure 6.3.11.1 (a) Each lever is installed onto a bolt that is mounted to the throttle lever plate (2) as shown. (b) Each control has spacers (8) which are secured with a AN525 screw (5), washers (4), a bushing (9), and nylon lock nuts (6).
Page 224: Attachment Of Throttle Cable To Side Panel
CUB CRAFTERS, INC. CC11-100 MAINTENANCE MANUAL (3) ATTACHMENT OF THROTTLE CABLE TO SIDE PANEL 1 – Throttle Lever 2 – Side Panel 3 – AN525 Screw 4 – Throttle Plate Figure 6.3.11.3 Attachment of Throttle to Side Panel Refer to Figure 6.3.11.3 The throttle plates (4) are kept from moving by six AN525 screws (3) that are bolted thru the left hand composite side panel (2).
Page 225: Motor Mount Throttle Cable Attachment
CUB CRAFTERS, INC. CC11-100 MAINTENANCE MANUAL (4) MOTOR MOUNT THROTTLE CABLE ATTACHMENT 1 – Throttle Cable 2 – Mixture Cable 3 – Cable Clamp 4 – Mixture Bracket Figure 6.3.11.4 Attachment of Throttle Bracket to Engine Mount Refer to Figure 6.3.11.4 The throttle cable (1) is held in place to the mixture bracket (4) and secured with a cable clamp (3), bolt, washer and nut.
Page 226 CUB CRAFTERS, INC. CC11-100 MAINTENANCE MANUAL 1 – Throttle Cable 2 – Mixture Cable 3 – Clamp 4 – Clamp 5 – Bolt 6 – Washer 7 – Nut Figure 6.3.11.5 Attachment of Throttle Cable to Firewall Refer to Figure 6.3.11.5 The throttle cable is held in place to the firewall with clamps secured with bolts, washers, and nuts.
Page 227: Throttle Cable To Carburetor Arm Attachment
CUB CRAFTERS, INC. CC11-100 MAINTENANCE MANUAL (5) THROTTLE CABLE TO CARBURETOR ARM ATTACHMENT 1 – AN3 Bolt 2 – Castle Nut 3 – Nut 4 – Bushings 5 – Cotter Pin 6 – Washer 7 – Pin Vice Grip 8 – Bearing Rod End Figure 6.3.11.6...
Page 228: Inspection
CUB CRAFTERS, INC. CC11-100 MAINTENANCE MANUAL (6) INSPECTION (a) Ensure that the throttle arm at the carburetor contacts both stops at either extreme of its travel while the throttle levers in the cabin have positive clearance from the panel. (b) Move the throttle to either full open or full closed, inspect cable attachment at the carburetor.
Page 229: Heavy Duty Throttle Cable
CUB CRAFTERS, INC. CC11-100 MAINTENANCE MANUAL HEAVY DUTY THROTTLE CABLE 1 – Throttle Lever 2 – Throttle Lever Plate 3 – Throttle Linkage Rod 4 – Washers 5 – AN525 Screws 6 – Nylon Lock Nut 7 – Cotter Pin 8 –...
Page 230: Lever Interconnect Linkage
CUB CRAFTERS, INC. CC11-100 MAINTENANCE MANUAL (a) Each lever is installed onto a bolt that is mounted to the throttle lever plate (2) as shown. (b) Each control has spacers (8) which are secured with a AN525 screw (5), washers (4), a bushing (9), and nylon lock nuts (6).
Page 231: Attachment Of Throttle Cable To Side Panel
CUB CRAFTERS, INC. CC11-100 MAINTENANCE MANUAL (3) ATTACHMENT OF THROTTLE CABLE TO SIDE PANEL 1 – Throttle Lever 2 – Side Panel 3 – AN525 Screw 4 – Throttle Plate Figure 6.3.11.9 Attachment of Throttle to Side Panel 6.3.11 Manual number SC10000AMM...
Page 232: Motor Mount Throttle Cable Attachment
CUB CRAFTERS, INC. CC11-100 MAINTENANCE MANUAL Refer to Figure 6.3.11.9 The throttle plates (4) are kept from moving by seven AN525 screws (3) that are bolted through the left hand composite side panel (2). (4) MOTOR MOUNT THROTTLE CABLE ATTACHMENT 1 –...
Page 233 CUB CRAFTERS, INC. CC11-100 MAINTENANCE MANUAL 1 - Firewall 2 - Throttle Cable Figure 6.3.11.11 Routing of Throttle Cable through Firewall Refer to Figure 6.3.11.11 The heavy duty throttle cable is directly routed through a hole in the firewall to the mixture bracket.
Page 234: Throttle Cable To Carburetor Arm Attachment
CUB CRAFTERS, INC. CC11-100 MAINTENANCE MANUAL (5) THROTTLE CABLE TO CARBURETOR ARM ATTACHMENT 1, 2, 4, 5, 6 1 – AN3 Bolt 2 – Castle Nut 3 – Nut 4 – Bushings 5 – Cotter Pin 6 – Washer 7 – Bearing Rod End Figure 6.3.11.12...
Page 235: Mixture
CUB CRAFTERS, INC. CC11-100 MAINTENANCE MANUAL MIXTURE (1) MIXTURE CONTROL CABLE TO PANEL ATTACHMENT 1 - Mixture Control Knob 2 - Cushion Space 3 - Panel Nut 4 – Instrument Panel 5 - Lock Washer 6 - Large Nut Figure 6.3.11.13 Mounting of the Mixture Control at the Instrument Panel Refer to Figure 6.3.11.13...
Page 236: Mixture Cable To Carburetor Lever Swivel Attachment
CUB CRAFTERS, INC. CC11-100 MAINTENANCE MANUAL (a) The mixture cable is fastened to the mixture bracket clamp with a bolt, washers, and a nut. (b) The mixture bracket is secured to the engine mount with a bolt, a washer, and a nut.
Page 237: Inspection
CUB CRAFTERS, INC. CC11-100 MAINTENANCE MANUAL Refer to Figure 6.3.11.14 (a) The control cable rod pivots the mixture control lever on the carburetor. The rod is held tight by the mixture swivel fitting. (b) Adjusting the cable rod length at the swivel fitting affects the travel of the mixture control lever.
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Page 239 CUB CRAFTERS, INC. CC11-100 MAINTENANCE MANUAL 6.3.12 INDUCTION SYSTEM TABLE OF CONTENTS GENERAL ..........................2 1.1. AIR FILTER ........................3 REMOVAL ........................3 INSPECTION ........................ 3 INSTALLATION ......................3 1.2. CARBURETOR HEAT ....................4 INSTALLATION OF CABLE TO VALVE ARM SWIVEL FITTING ......... 4 6.3.12...
Page 240: General
CUB CRAFTERS, INC. CC11-100 MAINTENANCE MANUAL 1 GENERAL The induction air for the engine enters through a filter on the lower side of the cowling. Alternatively, the pilot may use the carburetor heat control, which operates a butterfly valve that allows heated, unfiltered air to feed into the carburetor.
Page 241: Air Filter
Air Filter (1) REMOVAL (a) Grasp the filter and pull it straight forward out of the air box. (b) If a new filter is required, contact Cub Crafters and seek replacement filter part number SC54108-001. (1) INSPECTION (a) Inspect the foam filter for any damage, such as tears or large holes.
Page 242: Carburetor Heat
CUB CRAFTERS, INC. CC11-100 MAINTENANCE MANUAL 1.2. CARBURETOR HEAT Figure 6.3.12.2 Carburetor Heat Valve (1) INSTALLATION OF CABLE TO VALVE ARM SWIVEL FITTING (a) Insert the carburetor heat control cable end through the swivel fitting stud. (b) Insert the threaded end of the stud through the swivel fitting and through the carburetor heat valve arm.
Page 243 CUB CRAFTERS, INC. CC11-100 MAINTENANCE MANUAL 6.3.13 EXHAUST SYSTEM TABLE OF CONTENTS GENERAL ..........................2 1.1. ENGINE EXHAUST ....................... 3 REMOVAL ........................3 INSPECTION ........................ 3 INSTALLATION ......................3 6.3.13 Manual number SC10000AMM Date: 04/27/2009 Page: 1...
Page 244: General
CUB CRAFTERS, INC. CC11-100 MAINTENANCE MANUAL 1 GENERAL The exhaust system is one of two options, standard or performance exhaust. The standard exhaust consists of a two-into-one system. The performance exhaust is a four-into-four system. Shrouds mounted on the exhaust lines provide provision for both carburetor heat and cabin heat.
Page 245: Engine Exhaust
(2) INSPECTION (a) Inspect the components of the exhaust system for signs of cracking. Have any cracks repaired by an FAA-approved or Cub Crafters-approved repair facility. If the cracking is excessive, replace the exhaust system component(s). WARNING CRACKS IN THE EXHAUST SYSTEM WILL ALLOW CARBON MONOXIDE TO BE PRESENT INSIDE THE COWL.
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Page 247 CUB CRAFTERS, INC. CC11-100 MAINTENANCE MANUAL 6.3.14 ENGINE COWL TABLE OF CONTENTS GENERAL ..........................2 1.1. ENGINE COWL ......................2 REMOVAL ........................2 INSPECTION ........................ 3 INSTALLATION ......................3 6.3.14 Manual number SC10000AMM Date: 04/27/2009 Page: 1...
Page 248: General
CUB CRAFTERS, INC. CC11-100 MAINTENANCE MANUAL 1 GENERAL The engine cowl is made in two pieces and can be remove without the propeller having to come off. The upper and lower portions are made of composites using fire-resistant resins. 1.1.
Page 249: Inspection
CUB CRAFTERS, INC. CC11-100 MAINTENANCE MANUAL (2) INSPECTION (a) Inspect the cowl for loose rivets, wear points and cracking. (3) INSTALLATION Figure 6.3.14.2 Engine Cowl Installation (a) Carefully position the lower cowl in place. (b) Carefully position the lower cowl in place; secure the cowl to the fuselage with screws.
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Page 251 CUB CRAFTERS, INC. CC11-100 MAINTENANCE MANUAL 6.3.15 FUEL SYSTEMS TABLE OF CONTENTS SERVICING ........................2 DRAINING FUEL ......................2 FUEL TANKS ........................3 TROUBLESHOOTING ....................4 MAINTENANCE ......................5 FUEL FILTERS ........................6 FUEL STRAINER SERVICING ................... 6 CARBURETOR INLET SCREEN SERVICING ............8 FUEL SELECTOR ......................
Page 252: Servicing
CUB CRAFTERS, INC. CC11-100 MAINTENANCE MANUAL SERVICING (1) DRAINING FUEL The aircraft has two fuel drains, one under the fuselage and one on the fuel strainer, located on the engine firewall. Some aircraft (S/N 00264 and on) have a third fuel drain located on the bottom left side of the fuselage, just aft of the firewall on the boot cowl.
Page 253: Fuel Tanks
CUB CRAFTERS, INC. CC11-100 MAINTENANCE MANUAL FUEL TANKS Figure 6.3.15.1 Fuel System Schematic 6.3.15 Manual number SC10000AMM Date: 04/18/2013 Page: 3...
Page 254: Troubleshooting
CUB CRAFTERS, INC. CC11-100 MAINTENANCE MANUAL Figure 6.3.15.2 Fuel System Schematic with Additional Drain (1) TROUBLESHOOTING PROBLEM PROBABLE CAUSE REMEDY Filler Cap Leaks Filler Cap Improperly Installed Install Filler Cap Properly Seal Improperly Installed Replace Fuel Cap Seal Deteriorated Seal...
Page 255: Maintenance
CUB CRAFTERS, INC. CC11-100 MAINTENANCE MANUAL (2) MAINTENANCE No major repair or alterations, as outlined in ASTM F2483, FAR 43, or in this manual are authorized at this time. To obtain engineering approvals for any major repairs or alterations, please contact Cub Crafters at: Cub Crafters, Inc.
Page 256: Fuel Filters
CUB CRAFTERS, INC. CC11-100 MAINTENANCE MANUAL FUEL FILTERS (1) FUEL STRAINER SERVICING 1. – Cotter Pin 2. – O-Ring 3. – Screen 4. – Clip 5. – Top Support 6. – Bowl Figure 6.3.15.3 Fuel Strainer Assembly 6.3.15 Manual number SC10000AMM...
Page 257 CUB CRAFTERS, INC. CC11-100 MAINTENANCE MANUAL (a) Turn fuel selector to “OFF” position. (b) Drain fuel from strainer. (c) Remove the cotter pin (1) that locks the bowl (6). (d) Place a metal container under the bowl to catch the residual fuel.
Page 258: Carburetor Inlet Screen Servicing
CUB CRAFTERS, INC. CC11-100 MAINTENANCE MANUAL (2) CARBURETOR INLET SCREEN SERVICING Figure 6.3.15.4 Carburetor Inlet Screen (a) Turn fuel selector to “OFF” position. (b) Remove the large hex plug in the left side of the float chamber. (c) Clean the screen and flush accumulations of dirt and water from the chamber.
Page 259: Fuel Selector
CUB CRAFTERS, INC. CC11-100 MAINTENANCE MANUAL FUEL SELECTOR Figure 6.3.15.5 Fuel Selector Assembly (1) FUEL SELECTOR OVERHAUL (a) Drain the fuel tanks through the drains located on the underside of the fuselage and fuel strainer. (b) Drain the remaining fuel out the fuel strainer drain.
Page 260 CUB CRAFTERS, INC. CC11-100 MAINTENANCE MANUAL 1. – Detent Holes 2. – Snap Ring 3. – Barrel 4. – Detent Balls and Springs 5. – Small O-Ring 6. – Large O-Rings Figure 6.3.15.6 Fuel Selector Detail Refer to Figure 6.3.15.6 (e) Rotate the shaft so the detent balls (4) are between the detent holes (1).
Page 261: Maintenance
CUB CRAFTERS, INC. CC11-100 MAINTENANCE MANUAL MAINTENANCE No major repair or alterations, as outlined in ASTM F2483, FAR 43, or in this manual are authorized at this time. To obtain engineering approvals for any major repairs or alterations, please contact Cub Crafters at: Cub Crafters, Inc.
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Page 263 CUB CRAFTERS, INC. CC11-100 MAINTENANCE MANUAL 6.3.16 PROPELLERS TABLE OF CONTENTS GENERAL ..........................2 TROUBLESHOOTING ....................2 REMOVAL ........................2 PROPELLER INSPECTION ................... 2 HUB INSPECTION ......................3 INSTALLATION ......................4 REMOVAL ........................5 WOOD PROPELLER ......................5 PROPELLER MAINTENANCE (BOLT TORQUE) ............5 BOLT TORQUE CHECK PROCEDURE: ...............
Page 264: General
CUB CRAFTERS, INC. CC11-100 MAINTENANCE MANUAL GENERAL (1) TROUBLESHOOTING If the propeller-engine combination feels rough in flight; (a) Check that the mounting face of the propeller is tight against the engine flange and check the blade track. (b) Verify that the attaching bolts have reached their required torque and have not bottomed out of the threads.
Page 265: Hub Inspection
CUB CRAFTERS, INC. CC11-100 MAINTENANCE MANUAL (b) Inspect the attaching bolts for worn or damaged threads and heads. Replace damaged bolts with new ones. (c) Inspect the spinner bulkheads for cracks or broken brackets. Replace if any damage is noted.
Page 266: Installation
CUB CRAFTERS, INC. CC11-100 MAINTENANCE MANUAL the tip of the razor easily goes into the crack more than 1/16-inch then the propeller must be returned to the factory for closer inspection. Bolt Hole/Counterbore Elongation The bolt holes and counterbores will naturally elongate since the wood will shrink and expand differently with and against the grain.
Page 267: Removal
CUB CRAFTERS, INC. CC11-100 MAINTENANCE MANUAL McCauley Metal Sensenich Wood Sensenich Catto Propellers Propeller Propeller Composite Propeller Wood/Composite 300-360 in-lbs 175-225 in-lbs 340-360 in-lbs 360 in-lbs (h) Check to make sure the propeller track is within 1/8-inch. (i) Install 0.041-inch diameter stainless steel safety wire in the propeller bolt heads locking bolt heads together in a tightening moment.
Page 268: Bolt Torque Check Procedure
CUB CRAFTERS, INC. CC11-100 MAINTENANCE MANUAL For these reasons, it is important to follow the maintenance schedule below: (a) After First Flight – After the first flight, recheck the bolt torque. Refer to Bolt Torque Check Procedure and Table 6.3.16.1.
Page 269: Maintenance
CUB CRAFTERS, INC. CC11-100 MAINTENANCE MANUAL CAUTION Improper torque values will be obtained by measuring the breaking torque in a loosening direction. The torque should be checked in a tightening direction and adjusted as needed. Actual Torque Required Action Below 117 in-lbs...
Page 270 CUB CRAFTERS, INC. CC11-100 MAINTENANCE MANUAL INTENTIONALLY LEFT BLANK 6.3.16 Manual number SC10000AMM Page: 8 Date: 08/02/2010...
Page 271 CUB CRAFTERS, INC. CC11-100 MAINTENANCE MANUAL 6.3.17 ELECTRICAL POWER SYSTEMS TABLE OF CONTENTS GENERAL ..........................2 TROUBLESHOOTING ......................3 STARTER ..........................4 GENERAL ........................4 TROUBLESHOOTING ....................5 REMOVAL ........................5 INSPECTION ........................6 INSTALLATION ......................6 ALTERNATOR ........................7 GENERAL ........................
Page 272: General
CUB CRAFTERS, INC. CC11-100 MAINTENANCE MANUAL GENERAL No major repair or alterations, as outlined in ASTM F2483, FAR 43, or in this manual are authorized at this time. To obtain engineering approvals for any major repairs or alterations, please contact Cub Crafters at: Cub Crafters, Inc.
Page 273: Troubleshooting
CUB CRAFTERS, INC. CC11-100 MAINTENANCE MANUAL TROUBLESHOOTING PROBLEM PROBABLE CAUSE REMEDY Engine speed too low Check for output at higher speed Blown fuse(s) Replace fuse(s) Bad Wire Connections Replace bad connectors No Operation Shear coupling broken Replace shear coupling Regulator Faulty...
Page 274: Starter
CUB CRAFTERS, INC. CC11-100 MAINTENANCE MANUAL STARTER (1) GENERAL The starter is a 12 Volt High-Torque starter with a built in electro-mechanical pinion to actuate the gear. Figure 6.3.17.1 Starter 6.3.17 Manual number SC10000AMM Page: 4 Date: 08/02/2010...
Page 275: Troubleshooting
CUB CRAFTERS, INC. CC11-100 MAINTENANCE MANUAL (2) TROUBLESHOOTING PROBLEM PROBABLE CAUSE REMEDY - Charge battery Starter turns engine slowly Weak battery - Test when cold - Replace, if necessary Starter turns engine slowly Bad connection, cable, or - Clean connections and/or...
Page 276: Inspection
CUB CRAFTERS, INC. CC11-100 MAINTENANCE MANUAL Figure 6.3.17.2: Needle Bearing Removal (4) INSPECTION (a) Visually inspect the teeth of the starter gear and starter’s housing for damage. (5) INSTALLATION (a) Before installing new starter, five 5/16" cap-head bolts must be removed from the new starter.
Page 277: Alternator
CUB CRAFTERS, INC. CC11-100 MAINTENANCE MANUAL ALTERNATOR (1) GENERAL The alternator is manufactured by B&C Specialty Products. It is a model BC433-H, gear-driven, 30 ampere, externally regulated alternator. Figure 6.3.17.3 Alternator (2) REMOVAL (a) Disconnect the wires (b) Remove the mounting bolts.
Page 278: Regulator
CUB CRAFTERS, INC. CC11-100 MAINTENANCE MANUAL REGULATOR (1) GENERAL The regulator is a B&C Specialty Products 3-phase Permanent Magnetic Regulator. Figure 6.3.17.4 Voltage Regulator (2) REMOVAL (a) Disconnect the electrical connectors. (b) Unscrew the attaching hardware and remove the regulator.
Page 279: Battery
CUB CRAFTERS, INC. CC11-100 MAINTENANCE MANUAL BATTERY The battery is a 12 Volt lead acid battery. It is sealed and does not require electrolyte replenishment. Inspect every 100 hours for physical condition and cleanliness. (1) REMOVAL (a) Remove the pins from each side of pilot’s seat base.
Page 280: Installation
CUB CRAFTERS, INC. CC11-100 MAINTENANCE MANUAL State of Charge Voltage Reading on Voltmeter (Volts) 100% 13.0 12.8 12.5 12.2 12.0 or less Table 6.3.17.1 Battery Voltage Reading using a Voltmeter (4) INSTALLATION (a) Place the battery in the mounting space.
Page 281 CUB CRAFTERS, INC. CC11-100 MAINTENANCE MANUAL 6.3.18 POWERPLANT - IGNITION TABLE OF CONTENTS SPARK PLUGS ........................2 REMOVAL ........................2 INSPECTION ........................ 2 INSTALLATION ......................2 MAGNETOS .......................... 3 REMOVAL ........................4 INSPECTION ........................ 4 INSTALLATION ......................5 6.3.18 Manual number SC10000AMM...
Page 282: Spark Plugs
CUB CRAFTERS, INC. CC11-100 MAINTENANCE MANUAL SPARK PLUGS (1) REMOVAL (a) Unscrew all the spark plug caps. (b) Unscrew all the spark plugs. (2) INSPECTION (a) Inspect the firing end of the spark plugs for any foreign material lodged between electrodes or around the insulator that could be conductive.
Page 283: Magnetos
CUB CRAFTERS, INC. CC11-100 MAINTENANCE MANUAL MAGNETOS The ignition system on the O-200 engine uses two magnetos that generate electricity, which is distributed via a distributor block to the ignition cables. The ignition cables deliver the energy generated by the magnetos to the spark plugs via shielded conductors. The spark plugs then carry the energy from the ignition cables into to the combustion chamber where the spark ignites the air/fuel mixture.
Page 284: Removal
CUB CRAFTERS, INC. CC11-100 MAINTENANCE MANUAL (1) REMOVAL WARNING PRIOR TO REMOVING THE MAGNETOS, MAKE SURE THE FUEL MIXTURE IS IN IDLE CUTOFF POSITION THE AND THE MAGNETOS ARE TURNED OFF (a) Remove spark plug cable terminals from the plugs.
Page 285: Installation
CUB CRAFTERS, INC. CC11-100 MAINTENANCE MANUAL (3) INSTALLATION (a) Turn the engine crankshaft in the direction of engine rotation until No.1 cylinder is in its correct firing position on the compression stroke. See Table 6.3.18.1. Right Magneto Fires Upper Plugs (°B.T.C.) 28°...
Page 286 CUB CRAFTERS, INC. CC11-100 MAINTENANCE MANUAL INTENTIONALLY LEFT BLANK 6.3.18 Manual number SC10000AMM Page: 6 Date: 04/27/2009...
Page 287 CUB CRAFTERS, INC. CC11-100 MAINTENANCE MANUAL 6.3.19 ELECTRICAL TABLE OF CONTENTS GENERAL ..........................2 LANDING AND TAXI LIGHTS ....................3 INCANDESCENT LIGHTING SYSTEM ................. 3 LIGHTWEIGHT LED NAVIGATION LIGHTS AND ANTI-COLLISION ........4 CABIN LIGHTING ........................4 6.3.19 Manual number SC10000AMM...
Page 288: General
CUB CRAFTERS, INC. CC11-100 MAINTENANCE MANUAL GENERAL This chapter contains information for troubleshooting, removal, installation and adjustments of the interior and exterior lighting systems used on the airplane. Exterior lighting is optional. Options are incandescent navigation lights, incandescent navigation lights with anti-collision lights, or lightweight LED Navigation with anti-collision lights.
Page 289: Landing And Taxi Lights
CUB CRAFTERS, INC. CC11-100 MAINTENANCE MANUAL LANDING AND TAXI LIGHTS The landing/taxi light consists of one PAR 36 type lamp mounted in the left wing leading edge. The light is covered with a Plexiglas lens the same shape of the leading edge. A breaker switch on the instrument panel turns on the light.
Page 290: Lightweight Led Navigation Lights And Anti-Collision
CUB CRAFTERS, INC. CC11-100 MAINTENANCE MANUAL (2) REMOVAL (a) Wing tip - Remove the light shield lens and unscrew the bulb. Be careful not to drop the glass lens or the gasket. (b) Tail - Remove the lens retainer and lens and unscrew the bulb. Be careful not to drop the glass lens or the gasket.
Page 291 CUB CRAFTERS, INC. CC11-100 MAINTENANCE MANUAL 6.3.20 STALL WARNING SYSTEM TABLE OF CONTENTS GENERAL ..........................2 STALL WARNING SWITCH ADJUSTMENT ................. 2 6.3.20 Manual number SC10000AMM Date: 04/27/2009 Page: 1...
Page 292 CUB CRAFTERS, INC. CC11-100 MAINTENANCE MANUAL GENERAL The stall warning system is electrically powered and is made up of a horn and an actuating switch. The horn is mounted in the left wing root panel and the switch is on the leading edge of the left wing.
Page 293 CUB CRAFTERS, INC. CC11-100 MAINTENANCE MANUAL 6.3.21 HOSES AND LINES For replacement hoses, please contact: Cub Crafters, Inc. 1918 South 16 Avenue Yakima, WA. 98903 Tel: 509-248-9491 support@cubcrafters.com 6.3.21 Manual number SC10000AMM Date: 04/27/2009 Page: 1...
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Page 295 CUB CRAFTERS, INC. CC11-100 MAINTENANCE MANUAL 6.3.22 LEVELING GENERAL Have a set of calibrated weighing scales available. The range should be 1000 lbs for each main and 250 lbs for the tail. Zero the scales or record the tare, as appropriate.
Page 296 CUB CRAFTERS, INC. CC11-100 MAINTENANCE MANUAL LATERAL LEVELING Place the level on the upper forward cross tube located in the cabin just behind the windshield, as shown in Figure 6.3.22.2. Center the bubble to level the aircraft laterally. Figure 6.3.22.2: Leveling the Aircraft Laterally 6.3.22...
Page 297 CUB CRAFTERS, INC. CC11-100 MAINTENANCE MANUAL 6.3.23 WEIGHING GENERAL This section describes the methods for determining the empty weight of the aircraft and the position of its center of gravity relative to the datum. Weight and balance limits are placed on aircraft for two reasons: ...
Page 298 CUB CRAFTERS, INC. CC11-100 MAINTENANCE MANUAL Line Recorded Actual Number Position Weight Tare Weight Moment Left Main Wheel 62.50 in. Right Main Wheel 62.50 in. Tail Wheel 261.90 in. TOTAL TOTAL WEIGHT MOMENT (Weight in Lines 1+2+3) (Moment in Lines 1+2+3) Table 6.3.23.1: Standard Landing Gear Weighing Form...
Page 299 CUB CRAFTERS, INC. CC11-100 MAINTENANCE MANUAL 6.3.24 PARKING AND MOORING TABLE OF CONTENTS PARKING ..........................2 MOORING ..........................2 STORAGE ..........................4 3.1. GENERAL ......................... 4 3.2. MAINTENANCE PRACTICES ................... 4 TEMPORARY STORAGE - 30 to 90 Days ..............4 INDEFINITE STORAGE ....................
Page 300: Parking
CUB CRAFTERS, INC. CC11-100 MAINTENANCE MANUAL 1 PARKING (a) Position the airplane on level surface, headed into wind. (b) Set the parking brakes. The parking brake valves are located on the forward portion of the passenger rudder pedals. To engage, press both brake pedals and turn the brake valve to the horizontal position.
Page 301 CUB CRAFTERS, INC. CC11-100 MAINTENANCE MANUAL Figure 6.3.24.1: Wing Tie Down Figure 6.3.24.2: Tailwheel Tie Down 6.3.24 Manual number SC10000AMM Date: 08/02/2010 Page: 3...
Page 302: Storage
CUB CRAFTERS, INC. CC11-100 MAINTENANCE MANUAL STORAGE 3.1. GENERAL The procedures outlined in this section must be followed if it is expected that the aircraft will remain inactive for longer than 30 days. 3.2. MAINTENANCE PRACTICES (1) TEMPORARY STORAGE - 30 to 90 Days (a) Park and moor the airplane.
Page 303: Indefinite Storage
CUB CRAFTERS, INC. CC11-100 MAINTENANCE MANUAL (2) INDEFINITE STORAGE CAUTION Do not set the parking brake as brake seizing can result. (a) Park and moor the airplane. (b) Apply engine preservation. Refer to the latest edition of manufacturer’s service letter.
Page 304: Preparation For Service
CUB CRAFTERS, INC. CC11-100 MAINTENANCE MANUAL (3) PREPARATION FOR SERVICE (a) Engine preparation for service - Refer to the manufacturer’s service letter. (b) Remove all covers, tapes and tags from airplane. (c) Reinstall the engine battery (Refer to Chapter 6.3.14) and the ELT batteries (Refer to Chapter 5.4.14).
Page 305 CUB CRAFTERS, INC. CC11-100 MAINTENANCE MANUAL REPAIR OF STRUCTURE & COMPONENTS TABLE OF CONTENTS GENERAL ........................... 2 PATCHING OF HOLES IN FABRIC, METAL, OR COMPOSITE NON-STRUCTURAL COMPONENT ........................2 Fabric Repairs ......................2 APPROVED FABRIC REPAIR MATERIALS .............. 2 INSPECTION OF FABRIC ..................2 FABRIC REPAIRS ......................
Page 306: General
The aircraft has been covered using a process that is proprietary to Cub Crafters. It is similar to the Poly-Fiber Aircraft coating process, more commonly referred to as the Stits method.
Page 307: Size Of Repair Area
CUB CRAFTERS, INC. CC11-100 MAINTENANCE MANUAL WARNING GROUND THE STRUCTURE BEING IRONED, SANDED OR SPRAYED TO PREVENT STATIC ELECTRICITY FROM IGNITING VAPORS (4) SIZE OF REPAIR AREA  If the length of the damaged area is 8 inches or more, the patch must overlap the old fabric by at least 2 inches.
Page 308: Patch Repair Less Than 8 Inches
CUB CRAFTERS, INC. CC11-100 MAINTENANCE MANUAL (5) PATCH REPAIR LESS THAN 8 INCHES (a) Trim any ragged edges. (b) Lay an un-shrunk piece of material over the hole and trace the outline of the patch with a #2 pencil. Make sure to allow for enough overlap as explained earlier.
Page 309 CUB CRAFTERS, INC. CC11-100 MAINTENANCE MANUAL  Smooth any edges, which may be sticking up, using a small hot iron.  Smooth tape and doubler edges using dry 320 grit sandpaper to remove surface dust bumps.  Blow and tack off the covering to be sure it is as dust free as possible.
Page 310: Patch Repair More Than 8 Inches
CUB CRAFTERS, INC. CC11-100 MAINTENANCE MANUAL (6) PATCH REPAIR MORE THAN 8 INCHES (a) For large fabric repairs such as a wing tip, start at the last good rib, or at a convenient location close to the damaged area, removing the old finish tapes.
Page 311 CUB CRAFTERS, INC. CC11-100 MAINTENANCE MANUAL lace long or thick ribs. Tie off the end of each length with a half hitch as illustrated in Step 10 and 11 (See Figure 6.4.3), or if needed, separate lengths of lacing cord may be joined by using the splice knot illustrated in Figure 6.4.4.
Page 312 CUB CRAFTERS, INC. CC11-100 MAINTENANCE MANUAL Figure 6.4.2 - Rib Stitching, Steps 1 to 4 Manual number SC10000AMM Page: 8 Date: 04/18/2013...
Page 313 CUB CRAFTERS, INC. CC11-100 MAINTENANCE MANUAL Figure 6.4.3 - Rib Stitching, Steps 5 to 8 Manual number SC10000AMM Date: 04/18/2013 Page: 9...
Page 314 CUB CRAFTERS, INC. CC11-100 MAINTENANCE MANUAL Figure 6.4.4 - Rib Stitching, Steps 9 to 11 Manual number SC10000AMM Page: 10 Date: 04/18/2013...
Page 315 CUB CRAFTERS, INC. CC11-100 MAINTENANCE MANUAL The splice knot is made by crossing the ends of the cord, and making four complete wraps with the small end of the free piece around the end of the standing piece. The end is then doubled back through the formed loop.
Page 316: Non-Structural Sheet Metal Repairs
Aircraft Circular 43.13. Chapter 4, Section 4. At this time repairs to primary or secondary structures by others than Cub Crafters’ are not authorized. Description, by Electronic photos or similar means, of damaged primary or secondary structures, or flight control surfaces structures, are to be forwarded to Cub Crafters, Inc.
Page 317 CUB CRAFTERS, INC. CC11-100 MAINTENANCE MANUAL ALTERATIONS TABLE OF CONTENTS 6.5.1 ........COMPLIANCE WITH MANUFACTURER’S SERVICE DIRECTIVE 6.5.2 ................. MAJOR REPAIRS AND/OR ALTERATIONS Manual number SC10000AMM Date: 04/18/2013 Page: 1...
Page 318 6.5.2 MAJOR REPAIRS AND/OR ALTERATIONS All major repairs and/or alterations require an approved MRA (Major Repair and/or Alteration) form from Cub Crafters. Requests for an MRA can be made to Customer Support at Cub Crafters, or through a form on the company website.
Page 319 - Aircraft Log Book - Registration Certificate - Weight and Balance Record - Aircraft Equipment List - FAA Airworthiness Directives - Cub Crafters’ Service Documents 2 Visual Inspection of Aircraft 3 Check Oil Quantity (6 Quarts) 4 Operational Check POH/AFM 5 Perform walk-around to detect fluid leaks.
Page 320 CUB CRAFTERS, INC. CC11-100 MAINTENANCE MANUAL Interval Engine Group Ref. Initials Special 4 Oil Screen 6.3.10 25 hours - Visual inspection for foreign particles. 5 Oil Temperature Sender Unit: - Check for leaks and security. 6 Oil Lines and Fittings: - Check for leaks, security, chafing, dents, and cracks.
Page 321 CUB CRAFTERS, INC. CC11-100 MAINTENANCE MANUAL Interval Engine Group Ref. Initials Special 17 Induction Air Filter: - Remove, inspect, and clean. hours, or - Replace at 500 hours, or when filter is more than 50% covered by foreign material. covered 18 Carburetor: - Drain and clean inlet line fuel strainer.
Page 322 CUB CRAFTERS, INC. CC11-100 MAINTENANCE MANUAL Interval Engine Group Ref. Initials Special 34 Starter: - Visual inspection for condition and security. 35 Engine Controls: - Check travel from stop to stop and lubricate. 36 Engine Cowl: - Install, ensuring good clearance.
Page 323 CUB CRAFTERS, INC. CC11-100 MAINTENANCE MANUAL Interval Cabin Group Ref. Initials Special 4 Upholstery: - Visual inspection for tears and fraying. 5 Seat Belts, Inertia Reel, and Harnesses: - Visual inspection. 6 Seats: - Pilot (Front): Visual inspection and verify T- Handle security.
Page 324 CUB CRAFTERS, INC. CC11-100 MAINTENANCE MANUAL Interval Cabin Group Ref. Initials Special 17 Cabin Heater: - Verify freedom of movement and ensure full travel. 18 Placards and Instrument Markings: - Visual inspection for conformity, security, and condition. 19 Instrument Panel: - Visual inspection for security of lines and wiring.
Page 325 CUB CRAFTERS, INC. CC11-100 MAINTENANCE MANUAL Interval Fuselage and Empennage Group Ref. Initials Special 4 Rudder, Elevator and Stabilizer Trim Cables, Turnbuckles, Guides, and Pulleys: - Inspect for tension, safety, wear, damage, corrosion, and operation. 5 Stabilizer Yoke and Screw: - Visual inspection for end play, security, and excessive wear.
Page 326 CUB CRAFTERS, INC. CC11-100 MAINTENANCE MANUAL Interval Wing Group Ref. Initials Special 10 Flap Attachments and Brackets: - Visual inspection for tightness and damage. 11 Flap Crossbar, Control Rod, Spring Pins, and Blocks: - Visual inspection 12 Lubricate per Chapter 6.2...
Page 327 / functional check: - After completing, perform a walk around to detect fluid leaks or other discrepancies. 6 Verify all Cub Crafters’ Service Letters, Bulletins, and Instructions are complied with. 7 Verify the aircraft's documentation is in order: - Airworthiness Certificate...
Page 328 CUB CRAFTERS, INC. CC11-100 MAINTENANCE MANUAL Operational/Functional Inspection Report Initials Notes 7 Battery Master Switch: - Switch on - Verify voltage - Flag on turn coordinator should disappear. 8 Start engine using procedure in Pilot's Operating Handbook, Section 4. 9 Set 1700 RPM:...
Page 329 CHAPTER HEAVY MAINTENANCE, REPAIRS, AND ALTERATIONS...
Page 330 INTENTIONALLY LEFT BLANK...
Page 331 CUB CRAFTERS, INC. CC11-100 MAINTENANCE MANUAL 7 HEAVY MAINTENANCE, REPAIRS AND ALTERATIONS 7.1 ..........AUTHORIZATION TO PERFORM HEAVY MAINTENANCE, REPAIR, AND ALTERATIONS 7.2 ....................HEAVY MAINTENANCE TASKS Manual number SC10000AMM Date: 04/27/2009 Page: i...
Page 332 CUB CRAFTERS, INC. CC11 MAINTENANCE MANUAL INTENTIONALLY LEFT BLANK Manual number SC10000AMM Page: ii Date: 04/27/2009...
Page 333 CUB CRAFTERS, INC. CC11-100 MAINTENANCE MANUAL 7 HEAVY MAINTENANCE, REPAIRS, AND ALTERATIONS TABLE OF CONTENTS 7.1. AUTHORIZATION TO PERFORM HEAVY MAINTENANCE, REPAIR, AND ALTERATIONS ..........................2 7.2. HEAVY MAINTENANCE TASKS (Not Authorized at this Time) ..........2 7.2.1 Removal and Replacement of Components .............. 2 7.2.2...
Page 334 CUB CRAFTERS, INC. CC11-100 MAINTENANCE MANUAL 7.1. AUTHORIZATION TO PERFORM HEAVY MAINTENANCE, REPAIR, AND ALTERATIONS No heavy maintenance, major repair or alterations, as outlined in ASTM F2483, FAR 43, or in this manual are authorized at this time. To obtain engineering approvals for any major repairs or alterations, please contact Cub Crafters at: Cub Crafters, Inc.
Page 335 CHAPTER OVERHAUL...
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Page 337 CUB CRAFTERS, INC. CC11-100 MAINTENANCE MANUAL 8 OVERHAUL 8.1 ..............AUTHORIZATION TO PERFORM OVERHAULS 8.2 ............OVERHAUL MANUAL FOR LSA OR LSA COMPONENT 8.3 ................COMPONENTS PLANNED FOR OVERHAUL Manual number SC10000AMM Date: 04/27/2009 Page: i...
Page 338 CUB CRAFTERS, INC. CC11-100 MAINTENANCE MANUAL INTENTIONALLY LEFT BLANK Manual number SC10000AMM Page: ii Date: 04/27/2009...
Page 339 CUB CRAFTERS, INC. CC11-100 MAINTENANCE MANUAL 8 OVERHAUL TABLE OF CONTENTS 8.1. AUTHORIZATION TO PERFORM OVERHAULS ..............2 8.2. OVERHAUL MANUAL FOR LSA OR LSA COMPONENTS ..........3 8.3. COMPONENTS PLANNED FOR OVERHAUL ..............3 8.1.1 Engine ........................3 8.1.2 Propeller ........................
Page 340 AUTHORIZATION TO PERFORM OVERHAULS No overhauls as outlined in ASTM F2483, FAR 43, or in this manual are authorized at this time. Overhauls can only be performed by Cub Crafters. To obtain engineering approvals for any major repairs or alterations, please contact Cub Crafters at: Cub Crafters, Inc.
Page 341 CUB CRAFTERS, INC. CC11 MAINTENANCE MANUAL 8.2. OVERHAUL MANUAL FOR LSA OR LSA COMPONENTS 8.3. COMPONENTS PLANNED FOR OVERHAUL Engine 8.1.1 Propeller 8.1.2 Carburetor 8.1.3 Carburetor Air Box 8.1.4 Starters, Generators, and Alternators 8.1.5 Instruments 8.1.6 Avionics Equipment 8.1.7 Oil Cooler 8.1.8...
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Page 343 CHAPTER MAJOR REPAIRS AND ALTERATIONS...
Page 344 INTENTIONALLY LEFT BLANK...
Page 345 CUB CRAFTERS, INC. CC11 MAINTENANCE MANUAL 9 MAJOR REPAIRS AND ALTERATIONS 9.1 ......................ALTERATIONS GENERAL 9.2 ......EVALUATION TO ASTM STANDARD WITH PRODUCTION ACCEPTANCE .......................... SPECIFICATIONS 9.3 ......................ALTERATION AFFIDAVIT 9.4 ........WRITTEN INSTRUCTIONS AND DIAGRAMS FOR CERTIFICATION 9.5 ........OWNER INFORMATION ON ALTERATION DOCUMENTATION FOR ........................
Page 346 CUB CRAFTERS, INC. CC11 MAINTENANCE MANUAL INTENTIONALLY LEFT BLANK Manual number SC10000AMM Page: ii Date: 04/27/2009...
Page 347 CUB CRAFTERS, INC. CC11 MAINTENANCE MANUAL MAJOR REPAIRS AND ALTERATIONS TABLE OF CONTENTS 9.1. ALTERATIONS GENERAL ....................2 9.2. EVALUATION TO ASTM STANDARD WITH PRODUCTION ACCEPTANCE SPECIFICATIONS ......................... 2 9.3. ALTERATION AFFIDAVIT ..................... 2 9.4. WRITTEN INSTRUCTIONS AND DIAGRAMS FOR CERTIFICATION ........ 2 9.4.1...
Page 348 ALTERATIONS GENERAL No major alterations, as outlined in ASTM F2483, FAR 43, or in this manual are authorized at this time. To obtain engineering approvals for any major alterations, please contact Cub Crafters at: Cub Crafters, Inc. 1918 South 16 Avenue Yakima, WA.
Page 349 CHAPTER TASK-SPECIFIC TRAINING...
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Page 351 CUB CRAFTERS, INC. CC11-100 MAINTENANCE MANUAL 10 TASK-SPECIFIC TRAINING 10.1 ..............SPORT CUB SPECIFIC TRAINING – GENERAL 10.2 ........TYPE-SPECIFIC TRAINING REQUIRED BY CUB CRAFTERS, INC. Manual number SC10000AMM Date: 04/27/2009 Page: i...
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Page 353 CC11-100 MAINTENANCE MANUAL TASK-SPECIFIC TRAINING TABLE OF CONTENTS 10.1 SPORT CUB SPECIFIC TRAINING – GENERAL ..............2 10.2 TYPE SPECIFIC TRAINING REQUIRED BY CUB CRAFTERS, INC........2 10.1.2 Continental 0-200 Overhaul and Heavy Maintenance Course ........2 10.2.2 EAA Sport Air Fabric Covering Course ..............2...
Page 354 CUB CRAFTERS, INC. CC11-100 MAINTENANCE MANUAL 10.1 SPORT CUB SPECIFIC TRAINING – GENERAL 10.2 TYPE SPECIFIC TRAINING REQUIRED BY CUB CRAFTERS, INC. 10.1.2 Continental 0-200 Overhaul and Heavy Maintenance Course 10.2.2 EAA Sport Air Fabric Covering Course Manual number SC10000AMM...
Page 355 CHAPTER SAFETY DIRECTIVES COMPLIANCE...
Page 356 INTENTIONALLY LEFT BLANK...
Page 357 CUB CRAFTERS, INC. CC11-100 MAINTENANCE MANUAL 11 SAFETY DIRECTIVES COMPLIANCE 11.1 ..........SAFETY DIRECTIVES FOR CONTINUED AIRWORTHINESS 11.2 ..................TYPES OF SAFETY DIRECTIVES 11.3 ..................MANDATORY SAFETY DIRECTIVES 11.4 ..........OBTAINING LATEST SAFETY OF FLIGHT INFORMATION Manual number SC10000AMM Date: 04/27/2009...
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Page 359 CUB CRAFTERS, INC. CC11-100 MAINTENANCE MANUAL 11 SAFETY DIRECTIVES TABLE OF CONTENTS 11.1. SAFETY DIRECTIVES FOR CONTINUED AIRWORTHINESS........ 2 11.2. TYPES OF SAFETY DIRECTIVES ................2 11.3. MANDATORY SAFETY DIRECTIVES ..............2 11.4. OBTAINING LATEST SAFETY OF FLIGHT INFORMATION ........2...
Page 360 In the event of an aircraft component failure, defect, or other discrepancy on this aircraft, contact Cub Crafters quality department via postal mail, e-mail, fax, or telephone. If the problem relates to safety of flight or is a significant service issue, use the form and procedures specified in section 5.2.11 of this manual to initiate corrective action.

Cub Crafters CC11-100 Maintenance Manual

Table of Contents

Table of Contents

1 General

2 Equipment List

3 Purchase Parts Source Lists

4 Engine Specifications and Data

5 Weight and Balance Data

6 Tire Inflation

7 Approved Oils and Capacities

8 Recommended Fastener Torques

9 General Safety Information

10 Flight Safety Reporting Instructions

Table of Contents

1 General

2 Condition Inspection Tasks

3 Periodic Inspection Tasks

Table of Contents

1 General

2 Instruments

3 Com System

4 Navigation System

5 Antennas

Table of Contents

1 General

2 Electrical Power Systems

3 Lighting Systems

4 Emergency Systems: Elt

Table of Contents

General/Painting

1 General

2 Painting

Table of Contents

1 Servicing

2 Rigging the Wings

3 Vortex Generators

4 Maintenance

Table of Contents

1 Inspection

2 Rudder

4 Rigging the Tail Control Surfaces

5 Maintenance

Table of Contents

1 General

2 Troubleshooting

3 Ailerons

4 Flaps

5 Flap Handle Lock Replacement

6 Maintenance

Table of Contents

1 Troubleshooting

2 Main Landing Gear

3 Tail Landing Gear

4 Maintenance

Table of Contents

1 Main Wheels

2 Tail Wheel

3 Brake Calipers

4 Master Cylinder and Parking Brake Valve

5 Maintenance

Table of Contents

1 Troubleshooting

2 Servicing - Oil System

3 Engine Maintenance

Table of Contents

Pin Vice Grip Throttle Cable

1 General

2 Maintenance

Heavy Duty Throttle Cable

Mixture

Section 15

Section 16

Section 17

Table of Contents

1 Servicing

2 Fuel Tanks

3 Fuel Filters

4 Fuel Selector

5 Maintenance

Table of Contents