Cub Crafters CARBON CUB SS CC11-160 Maintenance Manual
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Cub Crafters CARBON CUB SS CC11-160 Maintenance Manual

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CC11-160 AIRCRAFT
MAINTENANCE MANUAL
S/N: CC11-00XXX
Registration Number: NXXXXX
CUB CRAFTERS, INC.
TH
1918 SOUTH 16
AVENUE
YAKIMA, WASHINGTON 98903 USA
509-248-9491
877-484-7865
www.cubcrafters.com
support@cubcrafters.com

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Summary of Contents for Cub Crafters CARBON CUB SS CC11-160

  • Page 1 CC11-160 AIRCRAFT MAINTENANCE MANUAL S/N: CC11-00XXX Registration Number: NXXXXX CUB CRAFTERS, INC. 1918 SOUTH 16 AVENUE YAKIMA, WASHINGTON 98903 USA 509-248-9491 877-484-7865 www.cubcrafters.com support@cubcrafters.com...
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  • Page 3 CUB CRAFTERS, INC. CC11-160 MAINTENANCE MANUAL Record of Revisions Rev. Change Date Prepared By Approved By NC Initial Issue 04/24/2009 List of Effective Pages updated. Revised Sections 1, 3, 4, 5.2, 5.3, 5.4.7, 5.4.8, 5.4.9, 5.4.10, 5.4.13, 5.4.14, 5.6, 6.1, 6.2, 6.3.1, 10/28/2010 6.3.4, 6.3.5, 6.3.8, 6.3.10, 6.3.11, 6.3.12, 6.3.13,...
  • Page 4 CUB CRAFTERS, INC. CC11-160 MAINTENANCE MANUAL INTENTIONALLY LEFT BLANK Manual number SSC10000AMM Page: ii Date: 04/18/2013...
  • Page 5 CUB CRAFTERS, INC. CC11-160 MAINTENANCE MANUAL List of Effective Pages Prepared Approved Pages Change Date 04/24/2009 Initial Issue 1 Pg 1 Revised name to "Carbon Cub". 10/28/2010 3 Pg 1 Added "Part" to 1.a. 5.2 Pg 3 Updated Figure 5.2.1.
  • Page 6 CUB CRAFTERS, INC. CC11-160 MAINTENANCE MANUAL 6.3.18 Pg 3 Added Ignition Backup Battery section. Updated Electronic Ignition Information 6.3.19 and Figure 6.3.18.1. Pg 2 - 4 Reformatted Sections to Landing and Taxi Lights, Incandescent NAV/Anti- 6.3.23 Collision, and LED NAV/Anti-Collision.
  • Page 7 CUB CRAFTERS, INC. CC11-160 MAINTENANCE MANUAL Pg 4 Added schematics for additional drain. 04/18/2013 Pg All Revision Date Updated. 6.3.16 Pg 3 Revised step (c) for electronic ignition. Pg All Revision Date Updated. 6.3.17 Pg 4 Added Hartzell starter image.
  • Page 8 CUB CRAFTERS, INC. CC11-160 MAINTENANCE MANUAL THIS PAGE INTENTIONALLY LEFT BLANK Manual number SSC10000AMM Page: vi Date: 04/18/2013...
  • Page 9 CUB CRAFTERS, INC. CC11-160 MAINTENANCE MANUAL TABLE OF CONTENTS SCOPE 5.4.11 PROPELLER REFERENCE DOCUMENTS 5.4.12 UTILITY SYSTEMS TERMINOLOGY 5.4.13 AVIONICS AND SIGNIFICANCE & USE INSTRUMENT SYSTEMS AIRCRAFT MAINTENANCE MANUAL 5.4.14 ELECTRICAL SYSTEMS FORMAT & GUIDANCE FOR THE 5.4.15 SEATS USE OF THIS MANUAL STRUCTURAL REPAIRS 5.1.1...
  • Page 10 CUB CRAFTERS, INC. CC11-160 MAINTENANCE MANUAL 6.3.22 LEVELING COMPONENTS PLANNED FOR 6.3.23 WEIGHING OVERHAUL 6.3.24 PARKING AND MOORING 8.3.1 ENGINE REPAIR OF STRUCTURE & 8.3.2 PROPELLER COMPONENTS 8.3.3 CARBURETOR 6.4.1 GENERAL 8.3.4 CARBURETOR AIR BOX 6.4.2 PATCHING OF HOLES IN 8.3.5...
  • Page 11 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 12 7 through 9, or in this maintenance manual, are authorized at this time, for this Carbon 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 SSC10000AMM...
  • Page 13 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 SSC10000AMM Date: 04/18/2013 Page: 3...
  • Page 14 CUB CRAFTERS, INC. CC11-160 MAINTENANCE MANUAL INTENTIONALLY LEFT BLANK Manual number SSC10000AMM Page: 4 Date: 04/18/2013...
  • Page 15 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 SSC10000AMM Date: 04/18/2013 Page: 5...
  • Page 16 CUB CRAFTERS, INC. CC11-160 MAINTENANCE MANUAL INTENTIONALLY LEFT BLANK Manual number SSC10000AMM Page: 6 Date: 04/18/2013...
  • Page 17 CUB CRAFTERS, INC. CC11-160 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 18 CUB CRAFTERS, INC. CC11-160 MAINTENANCE MANUAL INTENTIONALLY LEFT BLANK Manual number SSC10000AMM Page: 2 Date: 10/28/2010...
  • Page 19 CUB CRAFTERS, INC. CC11-160 MAINTENANCE MANUAL TERMINOLOGY DEFINITIONS LSA Airplane (Light Sport Aircraft Airplane) – a powered fixed wing aircraft designed per Specification F2245 that is manufactured and delivered ready to fly. The Light Sport Aircraft is also defined by 14 CFR Part 1.1 Annual Condition Inspection –...
  • Page 20 CUB CRAFTERS, INC. CC11-160 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 21 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 CC11-160 Carbon Cub Light Sport Aircraft. Manual number SSC10000AMM...
  • Page 22 CUB CRAFTERS, INC. CC11-160 MAINTENANCE MANUAL INTENTIONALLY LEFT BLANK Manual number SSC10000AMM Page: 2 Date: 10/28/2010...
  • Page 23 CHAPTER AIRCRAFT MAINTENANCE MANUAL...
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  • Page 25 CUB CRAFTERS, INC. CC11-160 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 26 CUB CRAFTERS, INC. CC11-160 MAINTENANCE MANUAL INTENTIONALLY LEFT BLANK Manual number SSC10000AMM Page: ii Date: 04/24/2009...
  • Page 27 CUB CRAFTERS, INC. CC11-160 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 SSC10000AMM...

  • Page 28: General

    CC11-160 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 29: Revision Service

    CUB CRAFTERS, INC. CC11-160 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.
  • Page 30 CUB CRAFTERS, INC. CC11-160 MAINTENANCE MANUAL INTENTIONALLY LEFT BLANK Manual number SSC10000AMM Page: 4 Date: 04/24/2009...

  • Page 31: Table Of Contents

    CUB CRAFTERS, INC. CC11-160 MAINTENANCE MANUAL 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 32: General

    CUB CRAFTERS, INC. CC11-160 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 33 CUB CRAFTERS, INC. CC11-160 MAINTENANCE MANUAL Figure 5.2.1: Aircraft Geometry * - Optional 3X3 Landing Gear F.S. is 59.50 Manual number SSC10000AMM Date: 04/18/2013 Page: 3...

  • Page 34: Main Dimensions

    CUB CRAFTERS, INC. CC11-160 MAINTENANCE MANUAL MAIN DIMENSIONS Span ......................411 in. Length (level flight attitude) ................. 273 in. Length (three point attitude) ................ 290 in. Height ......................111 in. Height (tail wheel on ground, propeller blade vertical at top)* ..... 84.5 in.

  • Page 35: Control Surface Travels And Cable Tension Settings

    CUB CRAFTERS, INC. CC11-160 MAINTENANCE MANUAL (7) 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 36: Equipment List

    CUB CRAFTERS, INC. CC11-160 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 6.3.7...

  • Page 37: Purchase Parts Source Lists

    3. PURCHASE PARTS SOURCE LISTS Consumable or Frequently Replaced Items Description Part Number (Reference purpose) Source Brake Fluid MIL-H-5606G (Aeroshell #41) Cub Crafters or Aircraft Parts Store Air Filter PC54108-001 Cub Crafters 4. ENGINE SPECIFICATIONS AND DATA Engine Model CC340 Number of Cylinders Bore &...

  • Page 38: Weight And Balance Data

    CUB CRAFTERS, INC. CC11-160 MAINTENANCE MANUAL 5. WEIGHT AND BALANCE DATA Refer to the Pilot’s Operating Handbook and Airplane Flight Manual, SSC10000AFM, 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 39: Use Of Torque Wrenches And Adapters

    CUB CRAFTERS, INC. CC11-160 MAINTENANCE MANUAL Nuts shall not be loosened to obtain the required alignment. The maximum torque shall not be exceeded. Threaded fasteners which have been torqued above the maximum value specified shall not be backed off and re-torqued but shall be removed, rejected and rendered unserviceable.

  • Page 40: Torquing Patterns

    CUB CRAFTERS, INC. CC11-160 MAINTENANCE MANUAL Dimensions must be measured in the same units (i.e. both in inches, both in feet, etc.) for each calculation. Different units must not be mixed. Torquing Patterns Figure 5.2.3: Torque Pattern Whenever applicable, the following pattern must be followed when torquing fasteners:...

  • Page 41: General Torque Values

    CUB CRAFTERS, INC. CC11-160 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. CC11-160 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

    The information may also be sent by e-mail to: support@cubcrafters.com or by telephone to 509 248-9491 (note that Cub Crafters is on US Pacific Time and office hours are from 8:00 am to 5:00 pm) Manual number SSC10000AMM Date: 04/18/2013 Page: 13...
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  • Page 45 CUB CRAFTERS, INC. CC11-160 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 SSC10000AMM...

  • 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. CC11-160 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. CC11-160 MAINTENANCE MANUAL Manual number SSC10000AMM Page: 4 Date: 10/28/2010...

  • Page 49: Condition Inspection Tasks

    CUB CRAFTERS, INC. CC11-160 MAINTENANCE MANUAL LEGEND: LOWER ENGINE COWLING INSPECTION COVER (2) INSPECTION COVER WING TRIM EDGE (2) UPPER ENGINE COWLING WING TRIM STRIP (2) COWL FLAP (2) WING TRIM END (2) INSPECTION RING (5 INCH) (9) BELLY ELECTRICAL PANEL...
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  • Page 51 CUB CRAFTERS, INC. CC11-160 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 ........................
  • Page 52 CUB CRAFTERS, INC. CC11-160 MAINTENANCE MANUAL INTENTIONALLY LEFT BLANK Manual number SSC10000AMM Page: ii Date: 04/24/2009...
  • Page 53 CUB CRAFTERS, INC. CC11-160 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. CC11-160 MAINTENANCE MANUAL INTENTIONALLY LEFT BLANK 5.4.1 Manual number SSC10000AMM Page: 2 Date: 04/24/2009...
  • Page 55 CUB CRAFTERS, INC. CC11-160 MAINTENANCE MANUAL 5.4.2 FUSELAGE TABLE OF CONTENTS GENERAL ..........................2 MAINTENANCE ........................2 5.4.2 Manual number SSC10000AMM Date: 04/24/2009 Page: 1...
  • Page 56 CUB CRAFTERS, INC. CC11-160 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. CC11-160 MAINTENANCE MANUAL 5.4.3 WINGS TABLE OF CONTENTS GENERAL ..........................2 MAINTENANCE ........................2 5.4.3 Manual number SSC10000AMM Date: 04/24/2009 Page: 1...
  • Page 58 CUB CRAFTERS, INC. CC11-160 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. CC11-160 MAINTENANCE MANUAL 5.4.4 EMPENNAGE TABLE OF CONTENTS GENERAL ..........................2 MAINTENANCE ........................2 5.4.4 Manual number SSC10000AMM Date: 10/28/2010 Page: 1...
  • Page 60 CUB CRAFTERS, INC. CC11-160 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. CC11-160 MAINTENANCE MANUAL 5.4.5 FLIGHT CONTROLS TABLE OF CONTENTS GENERAL ..........................2 MAINTENANCE ........................2 5.4.5 Manual number SSC10000AMM Date: 04/24/2009 Page: 1...
  • Page 62 CUB CRAFTERS, INC. CC11-160 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. CC11-160 MAINTENANCE MANUAL 5.4.6 LANDING GEAR TABLE OF CONTENTS GENERAL ..........................2 MAINTENANCE ........................2 5.4.6 Manual number SSC10000AMM Date: 04/24/2009 Page: 1...
  • Page 64 CUB CRAFTERS, INC. CC11-160 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. CC11-160 MAINTENANCE MANUAL 5.4.7 WHEEL AND BRAKE ASSEMBLIES TABLE OF CONTENTS GENERAL ..........................2 MAINTENANCE ........................2 5.4.7 Manual number SSC10000AMM Date: 10/28/2010 Page: 1...
  • Page 66 CUB CRAFTERS, INC. CC11-160 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” Airstreak, and 29” Airstreak.
  • Page 67 CUB CRAFTERS, INC. CC11-160 MAINTENANCE MANUAL 5.4.8 ENGINE MOUNT TABLE OF CONTENTS GENERAL ..........................2 MAINTENANCE ........................2 5.4.8 Manual number SSC10000AMM Date: 10/28/2010 Page: 1...
  • Page 68 CUB CRAFTERS, INC. CC11-160 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. 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. CC11-160 MAINTENANCE MANUAL 5.4.9. ENGINE TABLE OF CONTENTS GENERAL ..........................2 ENGINE MAINTENANCE ...................... 2 5.4.9 Manual number SSC10000AMM Date: 10/28/2010 Page: 1...
  • Page 70 CC11-160 MAINTENANCE MANUAL GENERAL The aircraft is powered by a Cub Crafters, Inc CC340 engine. This is an air-cooled, four cylinder powerplant that is capable of delivering up to 180 hp at 2700 RPM for less than 5 minutes, and a constant 80 hp at given altitude and RPM settings.
  • Page 71 CUB CRAFTERS, INC. CC11-160 MAINTENANCE MANUAL 5.4.10. FUEL SYSTEMS TABLE OF CONTENTS GENERAL ........................... 2 MAINTENANCE ........................3 5.4.10 Manual number SSC10000AMM Date: 04/18/2013 Page: 1...
  • Page 72 CUB CRAFTERS, INC. CC11-160 MAINTENANCE MANUAL GENERAL The fuel system has a sump and drain located in the bottom right side of the fuselage aft of the door opening. Some aircraft have an additional sump and drain located on the bottom left side of the aircraft just aft of the firewall.
  • Page 73 CUB CRAFTERS, INC. CC11-160 MAINTENANCE MANUAL FIGURE 5.4.10.1 - STANDARD FUEL TANK CONFIGURATION FIGURE 5.4.10.2 - OPTIONAL EXTENDED RANGE FUEL TANK CONFIGURATION 5.4.10 Manual number SSC10000AMM Date: 04/18/2013 Page: 3...
  • Page 74 CUB CRAFTERS, INC. CC11-160 MAINTENANCE MANUAL 3. 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 schematics for these aircraft are shown below.
  • Page 75 CUB CRAFTERS, INC. CC11-160 MAINTENANCE MANUAL FIGURE 5.4.10.4 - OPTIONAL EXTENDED RANGE 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 76 CUB CRAFTERS, INC. CC11-160 MAINTENANCE MANUAL THIS PAGE INTENTIONALLY LEFT BLANK 5.4.10 Manual number SSC10000AMM Page: 6 Date: 04/18/2013...
  • Page 77 CUB CRAFTERS, INC. CC11-160 MAINTENANCE MANUAL 5.4.11. PROPELLER TABLE OF CONTENTS GENERAL ..........................2 MAINTENANCE ........................2 5.4.11 Manual number SSC10000AMM Date: 04/24/2009 Page: 1...
  • Page 78 CUB CRAFTERS, INC. CC11-160 MAINTENANCE MANUAL GENERAL The standard aircraft comes with a Catto Propellers Wood/Fiberglass Composite Propeller. MAINTENANCE Refer to Section 6.3.16 or to the manufacturer’s instructions for the maintenance of all propellers. 5.4.11 Manual number SSC10000AMM Page: 2...
  • Page 79 CUB CRAFTERS, INC. CC11-160 MAINTENANCE MANUAL 5.4.12. UTILITY SYSTEMS TABLE OF CONTENTS GENERAL ..........................2 MAINTENANCE ........................2 5.4.12 Manual number SSC10000AMM Date: 04/24/2009 Page: 1...
  • Page 80 CUB CRAFTERS, INC. CC11-160 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. There is a small ram air scoop in the cowling inlet that provides air for the cabin heat system.
  • Page 81 CUB CRAFTERS, INC. CC11-160 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 82: General

    CUB CRAFTERS, INC. CC11-160 MAINTENANCE MANUAL 1 GENERAL The aircraft is equipped with an instrument panel containing all flight, navigation, and engine instruments that are required for VFR operations. Table 5.4.6 summarizes the equipment installed on the aircraft. NOTE: All instrument panel configurations shown with Right Ignition Backup Battery installed.
  • Page 83 CUB CRAFTERS, INC. CC11-160 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 SSC10000AMM Date: 04/18/2013 Page: 3...
  • Page 84 CUB CRAFTERS, INC. CC11-160 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 SmartMonitor (S/N 00237 and on) Air Speed Indicator Oil Pressure / Temperature Gauge...

  • Page 85: Instruments

    CUB CRAFTERS, INC. CC11-160 MAINTENANCE MANUAL INSTRUMENTS/GAUGES AVIONICS SYSTEM Performance VFR (II) 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 SmartMonitor (S/N 00237 and on)

  • Page 86: Com System

    CUB CRAFTERS, INC. CC11-160 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 87: Becker Com

    CUB CRAFTERS, INC. CC11-160 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 88: Navigation System

    CUB CRAFTERS, INC. CC11-160 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 89: Becker Mode-C Transponder

    CUB CRAFTERS, INC. CC11-160 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 90: D180 Flightdek

    CUB CRAFTERS, INC. CC11-160 MAINTENANCE MANUAL The Garmin GPSMAP 695/696 is the ultimate portable MFD. This portable GPS navigator has a bright 7-inch diagonal high-definition sunlight readable display. You can quickly find and view all U.S. NACO departure procedures a built-in base map, and Jeppesen aviation database.

  • Page 91: Antennas

    CUB CRAFTERS, INC. CC11-160 MAINTENANCE MANUAL 5 ANTENNAS 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 92 CUB CRAFTERS, INC. CC11-160 MAINTENANCE MANUAL THIS PAGE INTENTIONALLY LEFT BLANK 5.4.13 Manual number SSC10000AMM Page: 12 Date: 04/18/2013...
  • Page 93 CUB CRAFTERS, INC. CC11-160 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 SCHEMATICS ....................... 9 EMERGENCY SYSTEMS: ELT ................... 11 GENERAL ........................

  • Page 94: General

    CUB CRAFTERS, INC. CC11-160 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 95: Schematics

    CUB CRAFTERS, INC. CC11-160 MAINTENANCE MANUAL (2) SCHEMATICS Figure 5.4.14.1: Electrical System Schematic without Ignition Backup Battery 5.4.14 Manual number SSC10000AMM Date: 10/28/2010 Page: 3...
  • Page 96 CUB CRAFTERS, INC. CC11-160 MAINTENANCE MANUAL Figure 5.4.14.2: Electrical System Schematic with Ignition Backup Battery 5.4.14 Manual number SSC10000AMM Page: 4 Date: 10/28/2010...
  • Page 97 CUB CRAFTERS, INC. CC11-160 MAINTENANCE MANUAL Figure 5.4.14.3: PM1200 Intercom System Schematic w/ Intercom 5.4.14 Manual number SSC10000AMM Date: 10/28/2010 Page: 5...
  • Page 98 CUB CRAFTERS, INC. CC11-160 MAINTENANCE MANUAL Figure 5.4.14.4: Performance Avionics System Schematic w/ Intercom 5.4.14 Manual number SSC10000AMM Page: 6 Date: 10/28/2010...
  • Page 99 CUB CRAFTERS, INC. CC11-160 MAINTENANCE MANUAL Figure 5.4.14.5: PM3000 Intercom System Schematic Figure 5.4.14.6: Active Noise Reduction Intercom Systems 5.4.14 Manual number SSC10000AMM Date: 10/28/2010 Page: 7...
  • Page 100 CUB CRAFTERS, INC. CC11-160 MAINTENANCE MANUAL Figure 5.4.14.7: Dynon Schematic 5.4.14 Manual number SSC10000AMM Page: 8 Date: 10/28/2010...

  • Page 101: Lighting Systems

    CUB CRAFTERS, INC. CC11-160 MAINTENANCE MANUAL LIGHTING SYSTEMS (1) GENERAL 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.
  • Page 102 CUB CRAFTERS, INC. CC11-160 MAINTENANCE MANUAL Figure 5.4.14.9: LED Lighting System Schematic (S/N 00107 and on) 5.4.14 Manual number SSC10000AMM Page: 10 Date: 10/28/2010...

  • Page 103: Emergency Systems: Elt

    CUB CRAFTERS, INC. CC11-160 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 in a bracket directly underneath the pilot’s seat and may be accessed through an opening on the forward side of the seat column.
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  • Page 105 CUB CRAFTERS, INC. CC11-160 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 SSC10000AMM Date: 01/31/2011 Page: 1...

  • Page 106: General

    CUB CRAFTERS, INC. CC11-160 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 107 CUB CRAFTERS, INC. CC11-160 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 108: Rear Seat Stowage

    CUB CRAFTERS, INC. CC11-160 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 109 CUB CRAFTERS, INC. CC11-160 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 110: Rear Seat Installation

    CUB CRAFTERS, INC. CC11-160 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 111 CUB CRAFTERS, INC. CC11-160 MAINTENANCE MANUAL 5.5 STRUCTURAL REPAIRS GENERAL ..........................2 Manual number SSC10000AMM Date: 04/24/2009 Page: 1...
  • Page 112 CUB CRAFTERS, INC. CC11-160 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 113 CUB CRAFTERS, INC. CC11-160 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 114 CUB CRAFTERS, INC. CC11-160 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 115 CHAPTER LINE MAINTENANCE, REPAIRS, AND ALTERATIONS...
  • Page 116 INTENTIONALLY LEFT BLANK...
  • Page 117 CUB CRAFTERS, INC. CC11-160 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 ..........................
  • Page 118 CUB CRAFTERS, INC. CC11-160 MAINTENANCE MANUAL INTENTIONALLY LEFT BLANK Manual number SSC10000AMM Page: ii Date: 10/28/2010...
  • Page 119 CUB CRAFTERS, INC. CC11-160 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 SSC10000AMM Date: 10/28/2010 Page: 1...
  • Page 120 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. CUB CRAFTERS CARBON CUB SS MAINTENANCE BREAKDOWN REPAIRMAN-I, REPAIRMAN-M,...
  • Page 121 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 Plasma III Electronic Ignition System Carburetor Starter Propeller –Spinner...
  • Page 122 STATION STATION Fuel Filter 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 123 CUB CRAFTERS, INC. CC11-160 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 Garmin GPS (Removal) COM Radio (Removal) Intercom (Removal) Transponder (Removal Bose Headset Wiring...
  • Page 124 CUB CRAFTERS, INC. CC11-160 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 125 CUB CRAFTERS, INC. CC11-160 MAINTENANCE MANUAL 6.2 LINE MAINTENANCE TASKS TABLE OF CONTENTS 100 HOUR INSPECTION ...................... 2 CONDITION INSPECTION ....................2 SERVICING OF FLUIDS ....................... 2 Manual number SSC10000AMM Date: 05/02/2011 Page: 1...
  • Page 126 CUB CRAFTERS, INC. CC11-160 MAINTENANCE MANUAL 1. 100 HOUR INSPECTION Refer to section 5.3.3 of this manual for 100 Hour Inspection requirements 2. CONDITION INSPECTION Refer to section 5.3.2 of this manual for Condition Inspection requirements 3. SERVICING OF FLUIDS This information gives the general servicing procedures and maintenance practices that are to be used when servicing the airplane.
  • Page 127 CUB CRAFTERS, INC. CC11-160 MAINTENANCE MANUAL Item Specifications Capacity Single Tank per 25 US Gallons Total Wing 24 US Gallons Usable Aviation Grade Fuel 100/100LL 44 US Gallons Total Interconnected 40 US Gallons Usable Tanks per Wing 6 Quarts Maximum 3.5 to 5 Quarts...
  • Page 128 CUB CRAFTERS, INC. CC11-160 MAINTENANCE MANUAL LUBRICATION CHART ITEM SUGGESTED SPEC ENGINE Engine Oil Phillips XC 20W50 Spark Plug Thread Champion Aerospace # Lubricant 2612 Oil Filter Gasket Dow Corning 4 Lubricant MIL-S-8660C COCKPIT Hydraulic Fluid (Brake) Any Brand MIL-H-5606...
  • Page 129 CUB CRAFTERS, INC. CC11-160 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 130 CUB CRAFTERS, INC. CC11-160 MAINTENANCE MANUAL INTENTIONALLY LEFT BLANK Manual number SSC10000AMM Page: 6 Date: 05/02/2011...
  • Page 131 CUB CRAFTERS, INC. CC11-160 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 AND BRAKE ASSEMBLIES 6.3.9 ........................
  • Page 132 CUB CRAFTERS, INC. CC11-160 MAINTENANCE MANUAL INTENTIONALLY LEFT BLANK Manual number SSC10000AMM Page: Date: 04/18/2013...
  • Page 133 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 134 CUB CRAFTERS, INC. CC11-160 MAINTENANCE MANUAL REF. IN ITEM INTERVAL REPLACE OVERHAUL THIS NOTES MANUAL Emergency After 1 hour of Chapter Refer to Manufacture’s Locator cumulative 5.4.7 Transmitter transmitting. Installation and Batteries Date Marked Operation Manual on the Batteries by Duracell.
  • Page 135 CUB CRAFTERS, INC. CC11-160 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 136 CUB CRAFTERS, INC. CC11-160 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 137 CUB CRAFTERS, INC. CC11-160 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 138 CUB CRAFTERS, INC. CC11-160 MAINTENANCE MANUAL INTENTIONALLY LEFT BLANK 6.3.2 Manual number SSC10000AMM Page: 4 Date: 08/31/2011...
  • Page 139 CUB CRAFTERS, INC. CC11-160 MAINTENANCE MANUAL 6.3.3 FUSELAGE TABLE OF CONTENTS FUSELAGE ..........................2 INSPECTION ........................ 2 REPAIR ......................... 2 6.3.3 Manual number SSC10000AMM Date: 04/24/2009 Page: 1...
  • Page 140 CUB CRAFTERS, INC. CC11-160 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 141 CUB CRAFTERS, INC. CC11-160 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 142: Servicing

    CUB CRAFTERS, INC. CC11-160 MAINTENANCE MANUAL SERVICING Figure 6.3.4.1: Wing Installation 6.3.4 Manual number SSC10000AMM Page: 2 Date: 09/03/2010...
  • Page 143 CUB CRAFTERS, INC. CC11-160 MAINTENANCE MANUAL Figure 6.3.4.1: Wing Installation (Continued) 6.3.4 Manual number SSC10000AMM Date: 09/03/2010 Page: 3...

  • Page 144: Removal

    CUB CRAFTERS, INC. CC11-160 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). Disconnect the fuel supply and gauge lines inboard ends at the wing root.

  • Page 145: Installation

    CUB CRAFTERS, INC. CC11-160 MAINTENANCE MANUAL (j) With a person holding the wing and one 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 146 CUB CRAFTERS, INC. CC11-160 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 147: Rigging The Wings

    CUB CRAFTERS, INC. CC11-160 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: Dihedral Angle and Washout...

  • Page 148: Washout Angle

    CUB CRAFTERS, INC. CC11-160 MAINTENANCE MANUAL attachment fittings as illustrated in Figure 6.3.4.2. The bubble should be approximately centered. Check the opposite wing panel in the same manner. (e) If the dihedral angle is not equal for both wing panels, adjust the threaded fork on the lower end of the front strut until the dihedral angle is the same.

  • Page 149: Vortex Generators

    CUB CRAFTERS, INC. CC11-160 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 151 CUB CRAFTERS, INC. CC11-160 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 152: Inspection

    CUB CRAFTERS, INC. CC11-160 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 153: Rudder

    CUB CRAFTERS, INC. CC11-160 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 154: Installation

    CUB CRAFTERS, INC. CC11-160 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 155: Elevator Removal

    CUB CRAFTERS, INC. CC11-160 MAINTENANCE MANUAL (d) Hook each tail wheel steering spring (1) to a rudder arm. Lubricate the hinge pins and pivot points with LPS-2 oil. (e) Install the rectangular inspection cover. 3. HORIZONTAL STABILIZERS AND ELEVATORS (1) ELEVATOR REMOVAL 1 –...

  • Page 156: Horizonal Stabilizers Removal

    CUB CRAFTERS, INC. CC11-160 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 and 9).

  • Page 157: Right Horizontal Stabilizer Installation

    CUB CRAFTERS, INC. CC11-160 MAINTENANCE MANUAL (a) Unbolt the upper and lower tail brace wire assemblies. (b) Unbolt the left stabilizer from the tubes and carefully pull it off. (c) Carefully slide the right stabilizer, together with the tubes, out of the mounting points in the fuselage.
  • Page 158 CUB CRAFTERS, INC. CC11-160 MAINTENANCE MANUAL (b) If the tail surfaces have been changed and new tubes are to be installed, complete the following steps;  Make a line around the front stabilizer tube (6), 2-7/8 inches from one end with a fine tip felt pen.

  • Page 159: Left Horizontal Stabilizer Installation

    CUB CRAFTERS, INC. CC11-160 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 160: Installing Tail Brace Wires

    CUB CRAFTERS, INC. CC11-160 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 161: Rigging The Tail Brace Wires

    CUB CRAFTERS, INC. CC11-160 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 162: Elevator Installation

    CUB CRAFTERS, INC. CC11-160 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 163 CUB CRAFTERS, INC. CC11-160 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 164: 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 165: Maintenance

    CUB CRAFTERS, INC. CC11-160 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 166 CUB CRAFTERS, INC. CC11-160 MAINTENANCE MANUAL INTENTIONALLY LEFT BLANK 6.3.5 Manual number SSC10000AMM Page: 16 Date: 04/18/2013...
  • Page 167 CUB CRAFTERS, INC. CC11-160 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 168: General

    CUB CRAFTERS, INC. CC11-160 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 169: Ailerons

    CUB CRAFTERS, INC. CC11-160 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 170: Installation

    CUB CRAFTERS, INC. CC11-160 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 and 3), nuts (4) and cotter pins (5).
  • Page 171 CUB CRAFTERS, INC. CC11-160 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 172: Rigging

    CUB CRAFTERS, INC. CC11-160 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 173 CUB CRAFTERS, INC. CC11-160 MAINTENANCE MANUAL (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). Alternatively use the single wrap method with .032 stainless safety wire. Figure 6.3.6.6: Safety of Turnbuckles...

  • Page 174: Flaps

    CUB CRAFTERS, INC. CC11-160 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: Flap Hinge...

  • Page 175: Installation

    CUB CRAFTERS, INC. CC11-160 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 Figure 6.3.6.7 and Figure 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 176: Rigging The Position Of The Flaps

    CUB CRAFTERS, INC. CC11-160 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 (c) At the inboard hinge (1 Figure 6.3.6.9), install washers, nut and cotter pin (4 and...

  • Page 177: Flap Handle Lock Replacement

    CUB CRAFTERS, INC. CC11-160 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 178: Maintenance

    CUB CRAFTERS, INC. CC11-160 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 179 CUB CRAFTERS, INC. CC11-160 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 ....................8 REMOVAL ........................8 INSPECTION ......................

  • Page 180: Troubleshooting

    CUB CRAFTERS, INC. CC11-160 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 landing Inspect for weak bungee cords...
  • Page 181 CUB CRAFTERS, INC. CC11-160 MAINTENANCE MANUAL PROBLEM PROBABLE CAUSE REMEDY Brakes drag (continued) Bent or cracked torque plate Replace Corroded anchor bolts and/or Clean and lubricate or torque plate bushings replace Warped brake disc; inspect by Replace and use caution...
  • Page 182 CUB CRAFTERS, INC. CC11-160 MAINTENANCE MANUAL PROBLEM PROBABLE CAUSE REMEDY Rapid disc and lining Incorrect lining and/or disc Replace with correct parts wear (continued) Brakes will not hold Lining worn below minimum Replace linings wear limits Discs worn below minimum...

  • Page 183: Main Landing Gear

    CUB CRAFTERS, INC. CC11-160 MAINTENANCE MANUAL MAIN LANDING GEAR Figure 6.3.7.1: Main Landing Gear Arrangement 6.3.7 Manual number SSC10000AMM Date: 04/29/2009 Page: 5...

  • Page 184: 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 185: Installation

    CUB CRAFTERS, INC. CC11-160 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 186: Landing Gear Leg

    CUB CRAFTERS, INC. CC11-160 MAINTENANCE MANUAL LANDING GEAR LEG (1) REMOVAL Chock the main wheel on the opposite side of the landing gear that is to be worked on. Chock the tail wheel. It is recommended to carry this work in a sheltered hangar.

  • Page 187: Aoss Gear - Optional

    CUB CRAFTERS, INC. CC11-160 MAINTENANCE MANUAL Torque all nuts to 130 in-lbs or if necessary, past this value so that the nuts may be aligned with the nearest hole on the corresponding bolt. Safety the nuts with new cotter pins.

  • Page 188: Tail Landing Gear

    CUB CRAFTERS, INC. CC11-160 MAINTENANCE MANUAL TAIL LANDING GEAR STANDARD STEERABLE TAIL WHEEL (1) REMOVAL i - Nut ii - Washer (4) iii - Long Bolt iv - Clamp v - Small Nut (2) vi - Small Washer (2) vii - Small Bolt (2)

  • Page 189: Disassembly

    CUB CRAFTERS, INC. CC11-160 MAINTENANCE MANUAL (2) DISASSEMBLY 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 190: Inspection

    CUB CRAFTERS, INC. CC11-160 MAINTENANCE MANUAL (4) INSPECTION 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. Replace damaged parts.

  • Page 191: Installation

    CUB CRAFTERS, INC. CC11-160 MAINTENANCE MANUAL (g) Pump the tail wheel bracket assembly and axle full of grease (MIL-G-81322E) then wipe off the excess. (8) INSTALLATION See Figure 6.3.7.2 (a) Position the tail wheel springs on the fuselage with long bolt (iii) and hold in place with a washer (ii) and a nut (i).

  • Page 192: Removal

    CUB CRAFTERS, INC. CC11-160 MAINTENANCE MANUAL 3200-TYPE STEERABLE TAIL WHEEL OPTIONAL (1) REMOVAL A - Nut B - Washer C - Long Bolt D - Clamp E - Small Nut F - Small Washer G - Small Bolt H - Large Area Nut...
  • Page 193 CUB CRAFTERS, INC. CC11-160 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 194: Disassembly

    CUB CRAFTERS, INC. CC11-160 MAINTENANCE MANUAL (2) DISASSEMBLY 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 195: Cleaning

    CUB CRAFTERS, INC. CC11-160 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 196: Reassembly

    CUB CRAFTERS, INC. CC11-160 MAINTENANCE MANUAL (7) REASSEMBLY 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 197: Installation

    CUB CRAFTERS, INC. CC11-160 MAINTENANCE MANUAL (8) INSTALLATION 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). (b) Install the small bolts (G), clamp (D), and small washers (F) with the small nuts (E) only finger tight.
  • Page 198 CUB CRAFTERS, INC. CC11-160 MAINTENANCE MANUAL INTENTIONALLY LEFT BLANK 6.3.7 Manual number SSC10000AMM Page: 20 Date: 04/29/2009...
  • Page 199 CUB CRAFTERS, INC. CC11-160 MAINTENANCE MANUAL 6.3.8 WHEEL AND 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 STANDARD WHEEL .....................

  • Page 200: Main Wheels

    CUB CRAFTERS, INC. CC11-160 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 201 CUB CRAFTERS, INC. CC11-160 MAINTENANCE MANUAL (a) Deflate the tire. (b) Break the tire bead loose from the wheel. (c) Remove the wheel nuts (6) and washers (5). (d) Pull the wheel halves (1, 3) apart being careful with the tubes valve stem.

  • Page 202: Inspection

    CUB CRAFTERS, INC. CC11-160 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 203: Wheel Assembly

    CUB CRAFTERS, INC. CC11-160 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 204: Tail Wheel

    CUB CRAFTERS, INC. CC11-160 MAINTENANCE MANUAL TAIL WHEEL STANDARD WHEEL (a) INSPECTION 1. Inspect the solid rubber tire for excessive wear and any flat areas. 2. Lubricate per Chapter 6.2 3200-TYPE WHEEL 1 – Spacer 2 - Grease Retainer 3 - Inner Spacer...

  • Page 205: Disassembly

    CUB CRAFTERS, INC. CC11-160 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 206: Reassembly

    CUB CRAFTERS, INC. CC11-160 MAINTENANCE MANUAL (6) REASSEMBLY (a) Dust the inside of tire lightly with talcum powder. (b) Place the tube (12) in the tire (10). (c) Insert the wheel hubs (8) with the gasket (9) in between into the tire and tube assembly.

  • Page 207: Brake Calipers

    CUB CRAFTERS, INC. CC11-160 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 208: Removal

    CUB CRAFTERS, INC. CC11-160 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 209: Master Cylinder And Parking Brake Valve

    CUB CRAFTERS, INC. CC11-160 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 210: Removal

    CUB CRAFTERS, INC. CC11-160 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 211: 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 213 CUB CRAFTERS, INC. CC11-160 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.
  • Page 214 CUB CRAFTERS, INC. CC11-160 MAINTENANCE MANUAL INTENTIONALLY LEFT BLANK 6.3.9 Manual number SSC10000AMM Page: 2 Date: 04/24/2009...
  • Page 215 CUB CRAFTERS, INC. CC11-160 MAINTENANCE MANUAL 6.3.10 ENGINE TABLE OF CONTENTS TROUBLESHOOTING, SERVICING, AND MAINTENANCE ..........2 SERVICING – OIL SYSTEM ....................5 2.1. CHANGING ENGINE OIL ................... 5 2.2. OIL SCREEN ......................6 REMOVAL ......................... 6 INSPECTION......................6 INSTALLATION ......................7 2.3.

  • Page 216: Troubleshooting, Servicing, And Maintenance

    CUB CRAFTERS, INC. CC11-160 MAINTENANCE MANUAL TROUBLESHOOTING, SERVICING, AND MAINTENANCE 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 the engine Operator’s Manual and their Maintenance and Overhaul Manual.
  • Page 217 CUB CRAFTERS, INC. CC11-160 MAINTENANCE MANUAL Reference PROBLEM PROBABLE CAUSE REMEDY in this manual Rough Engine mount bolts loose. Tighten. 5.2.5 running - Defective spark plug cables. Test for break-down at high voltage. continued… NOTE Worn cam lobe. Overhaul engine.
  • Page 218 CUB CRAFTERS, INC. CC11-160 MAINTENANCE MANUAL Reference PROBLEM PROBABLE CAUSE REMEDY in this manual Low oil Dirt on oil pressure relief valve Clean plunger and seat. Replace 6.2.3 pressure - seat. dirty oil. continued… Oil pressure relief valve seat Overhaul engine. Refinish valve NOTE worn.

  • Page 219: Servicing - Oil System

    CUB CRAFTERS, INC. CC11-160 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. 2.1. CHANGING ENGINE OIL Warm engine Remove the upper and lower engine cowlings.

  • Page 220: Oil Screen

    CUB CRAFTERS, INC. CC11-160 MAINTENANCE MANUAL 2.2. OIL SCREEN Oil Temp Probe Inserts Here 3 – Screen Housing 1 - Gasket 5 - Plug 2 - Pressure Screen 4 - Gasket * Oil Temp Probe (Not Shown) Figure 6.3.11.1: Oil Screen (1) REMOVAL (a) Drain the oil.

  • Page 221: Installation

    CUB CRAFTERS, INC. CC11-160 MAINTENANCE MANUAL (b) Remove the old gasket (1) and make sure the housing and case surfaces are clean. (3) INSTALLATION (c) Assemble the screen (2) in the housing (3), assemble the gasket (1) and the housing (3) on mounting pad.

  • Page 222: Removal

    CUB CRAFTERS, INC. CC11-160 MAINTENANCE MANUAL (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. (b) Loosen the hose clamp and remove the air duct.
  • Page 223 CUB CRAFTERS, INC. CC11-160 MAINTENANCE MANUAL 6.3.11 ENGINE CONTROLS TABLE OF CONTENTS GENERAL ......................2 MAINTENANCE ....................2 PIN VICE GRIP THROTTLE CABLE ................2 LEVER ATTACHMENT ....................3 ATTACHMENT OF THROTTLE CABLE TO SIDE PANEL......... 4 MOTOR MOUNT THROTTLE CABLE ATTACHMENT ..........5 THROTTLE CABLE TO CARBURETOR ARM ATTACHMENT ........

  • Page 224: General

    CUB CRAFTERS, INC. CC11-160 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 225: Lever Attachment

    CUB CRAFTERS, INC. CC11-160 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 226: Attachment Of Throttle Cable To Side Panel

    CUB CRAFTERS, INC. CC11-160 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 227: Motor Mount Throttle Cable Attachment

    CUB CRAFTERS, INC. CC11-160 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 228 CUB CRAFTERS, INC. CC11-160 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 229: Throttle Cable To Carburetor Arm Attachment

    CUB CRAFTERS, INC. CC11-160 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 230: Inspection

    CUB CRAFTERS, INC. CC11-160 MAINTENANCE MANUAL (6) INSPECTION (g) 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. (h) Move the throttle to either full open or full closed, inspect cable attachment at the carburetor.

  • Page 231: Heavy Duty Throttle Cable

    CUB CRAFTERS, INC. CC11-160 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 232: Lever Interconnect Linkage

    CUB CRAFTERS, INC. CC11-160 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 233: Attachment Of Throttle Cable To Side Panel

    CUB CRAFTERS, INC. CC11-160 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 Dual and Single Throttle Attachments Shown 6.3.11...
  • Page 234 CUB CRAFTERS, INC. CC11-160 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 235 CUB CRAFTERS, INC. CC11-160 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 engine mount tube bracket.

  • Page 236: Inspection

    CUB CRAFTERS, INC. CC11-160 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 237: Mixture

    CUB CRAFTERS, INC. CC11-160 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 238: Motor Mount Mixture Cable Attachment

    CUB CRAFTERS, INC. CC11-160 MAINTENANCE MANUAL (3) MOTOR MOUNT MIXTURE CABLE ATTACHMENT Figure 6.3.11.14 - Mounting of the Mixture Cable to Engine Mount Refer to Figure 6.3.11.14 (a) The mixture cable is fastened to the mixture bracket clamp with a bolt, washers, and a nut.

  • Page 239: Mixture Cable To Carburetor Lever Swivel Attachment

    CUB CRAFTERS, INC. CC11-160 MAINTENANCE MANUAL (2) MIXTURE CABLE TO CARBURETOR LEVER SWIVEL ATTACHMENT MIXTURE MIXTURE CABLE 1- Mixture Cable 2- Stud 3- Swivel 4- Mixture Arm 5- Washer 6- Short Castellated Nut 7- Cotter Pin Figure 6.3.11.15 - Attachment of Mixture Cable to Carburetor Swivel Arm Refer to Figure 6.3.11.15...

  • Page 240: Inspection

    CUB CRAFTERS, INC. CC11-160 MAINTENANCE MANUAL (3) INSPECTION (a) Ensure that the mixture lever at the carburetor contacts both stops at either extreme of its travel. At the same time, there should be no more than ¼” cushion between the knob and the panel nut in the full rich position.
  • Page 241 CUB CRAFTERS, INC. CC11-160 MAINTENANCE MANUAL 6.3.12 INDUCTION SYSTEM TABLE OF CONTENTS GENERAL ..........................2 1.1. AIR FILTER ........................2 REMOVAL ........................3 INSPECTION ........................ 3 INSTALLATION ......................3 1.2. CARBURETOR HEAT ....................4 INSTALLATION OF CABLE TO VALVE ARM SWIVEL FITTING ......... 4 6.3.12...

  • Page 242: General

    CUB CRAFTERS, INC. CC11-160 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 243: Removal

    (1) REMOVAL (a) Remove screws holding the lower access panel to the lower cowl. (b) Remove lower access panel with air filter. (c) If a new filter is required, contact Cub Crafters and seek replacement filter part number PC54108-001. (1) INSPECTION (a) Inspect the foam filter for any damage, such as tears or large holes.

  • Page 244: Carburetor Heat

    CUB CRAFTERS, INC. CC11-160 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 245 CUB CRAFTERS, INC. CC11-160 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 SSC10000AMM Date: 10/28/2010 Page: 1...

  • Page 246: General

    CUB CRAFTERS, INC. CC11-160 MAINTENANCE MANUAL 1 GENERAL The exhaust system is a four-into-one system. Shrouds mounted on the exhaust lines provide provision for both carburetor heat and cabin heat. Figure 6.3.13.1: Exhaust System 6.3.13 Manual number SSC10000AMM Page: 2...

  • Page 247: 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 249 CUB CRAFTERS, INC. CC11-160 MAINTENANCE MANUAL 6.3.14 ENGINE COWL TABLE OF CONTENTS GENERAL ..........................2 1.1. ENGINE COWL ......................2 COWL REMOVAL ....................... 2 INSPECTION ......................3 INSTALLATION ......................3 1.2. COWL FLAPS ........................ 4 COWL FLAP POSITIONING ..................4 6.3.14...

  • Page 250: General

    CUB CRAFTERS, INC. CC11-160 MAINTENANCE MANUAL 1 GENERAL The engine cowl is made in two pieces and can be removed without the propeller being removed. The upper and lower portions are made of composites, using fire-resistant resins. 1.1. ENGINE COWL Figure 6.3.14.1:...

  • Page 251: Inspection

    CUB CRAFTERS, INC. CC11-160 MAINTENANCE MANUAL (g) Remove the screws holding the lower cowl to the fuselage. (h) Disconnect the induction tubing. (i) Carefully remove the lower cowl. (2) INSPECTION (a) Inspect the cowl for loose rivets, wear points and cracking.

  • Page 252: Cowl Flaps

    CUB CRAFTERS, INC. CC11-160 MAINTENANCE MANUAL 1.2. COWL FLAPS Figure 6.3.14.3: Cowl Flap Adjustment (1) COWL FLAP POSITIONING NOTE: Position of Cowl Flaps should be determined by the pilot depending on weather conditions. It is recommended the flaps be in the closed position during the winter months.
  • Page 253 CUB CRAFTERS, INC. CC11-160 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 254: Servicing

    CUB CRAFTERS, INC. CC11-160 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 255: Fuel Tanks

    CUB CRAFTERS, INC. CC11-160 MAINTENANCE MANUAL FUEL TANKS Figure 6.3.15.1: Standard Fuel System Schematic Figure 6.3.15.2: Extended Range Fuel System Schematic 6.3.15 Manual number SSC10000AMM Date: 04/18/2013 Page: 3...
  • Page 256 CUB CRAFTERS, INC. CC11-160 MAINTENANCE MANUAL Figure 6.3.15.3: Standard Fuel System Schematic with Additional Drain Figure 6.3.15.4: Extended Range Fuel System Schematic with Additional Drain 6.3.15 Manual number SSC10000AMM Page: 4 Date: 04/18/2013...

  • Page 257: Troubleshooting

    CUB CRAFTERS, INC. CC11-160 MAINTENANCE MANUAL (2) 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 Replace Fuel Cap Seal Inspect and Tighten Leak in Fuel Line...

  • Page 258: Fuel Filters

    CUB CRAFTERS, INC. CC11-160 MAINTENANCE MANUAL FUEL FILTERS (1) FUEL STRAINER SERVICING 1. – Cotter Pin 2. – O-Ring 3. – Screen 4. – Clip 5. – Top Support 6. – Bowl Figure 6.3.15.5: Fuel Strainer Assembly 6.3.15 Manual number SSC10000AMM...
  • Page 259 CUB CRAFTERS, INC. CC11-160 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 260: Carburetor Inlet Screen Servicing

    CUB CRAFTERS, INC. CC11-160 MAINTENANCE MANUAL (2) CARBURETOR INLET SCREEN SERVICING Figure 6.3.15.6: 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 261: Fuel Selector

    CUB CRAFTERS, INC. CC11-160 MAINTENANCE MANUAL FUEL SELECTOR Figure 6.3.15.7: 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 262 CUB CRAFTERS, INC. CC11-160 MAINTENANCE MANUAL 1. – Detent Holes 2. – Snap Ring 3. – Barrel 4. – Detent Balls and Springs 5. – Small O-Ring 6. – Large O-Rings Figure 6.3.15.8: 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 263: Maintenance

    CUB CRAFTERS, INC. CC11-160 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 265 CUB CRAFTERS, INC. CC11-160 MAINTENANCE MANUAL 6.3.16 PROPELLERS TABLE OF CONTENTS CATTO PROPELLER ......................2 TROUBLESHOOTING ....................2 REMOVAL ........................2 INSPECTION......................2 INSTALLATION ......................3 MAINTENANCE ......................... 4 6.3.16 Manual number SSC10000AMM Date: 04/18/2013 Page: 1...

  • Page 266: Catto Propeller

    CUB CRAFTERS, INC. CC11-160 MAINTENANCE MANUAL CATTO PROPELLER (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 267: Installation

    CUB CRAFTERS, INC. CC11-160 MAINTENANCE MANUAL (4) INSTALLATION The following instructions are a general guide. Defer to propeller manufacturers detailed instructions as required. (a) Thoroughly clean the surfaces of the crankshaft flange and pilot stub, the rear/mounting face of the propeller, and the pilot bore. Carefully examine each surface and especially examine the end of the crankshaft pilot stub.

  • Page 268: Maintenance

    CUB CRAFTERS, INC. CC11-160 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 269 CUB CRAFTERS, INC. CC11-160 MAINTENANCE MANUAL 6.3.17 ELECTRICAL POWER SYSTEMS TABLE OF CONTENTS GENERAL ........................... 2 TROUBLESHOOTING ......................3 STARTER ........................... 4 GENERAL ........................4 TROUBLESHOOTING ....................5 REMOVAL ........................5 INSPECTION ....................... 5 INSTALLATION ......................5 ALTERNATOR ........................6 GENERAL ........................

  • Page 270: General

    CUB CRAFTERS, INC. CC11-160 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 271: Troubleshooting

    CUB CRAFTERS, INC. CC11-160 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 Drive belt broken Replace belt Regulator Faulty...

  • Page 272: Starter

    CUB CRAFTERS, INC. CC11-160 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 Figure 6.3.17.2: Hartzell Starter 6.3.17 Manual number SSC10000AMM Page: 4...

  • Page 273: Troubleshooting

    CUB CRAFTERS, INC. CC11-160 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 274: Alternator

    CUB CRAFTERS, INC. CC11-160 MAINTENANCE MANUAL ALTERNATOR (1) GENERAL The alternator is a belt-driven, 40 ampere, internally regulated alternator. Figure 6.3.17.3: Alternator (2) REMOVAL (a) Disconnect the wires (b) Remove the mounting bolts. (3) INSPECTION (c) Inspect the alternator for general condition. Broken wires or damaged connectors may be corrected in the field.

  • Page 275: Main Battery

    CUB CRAFTERS, INC. CC11-160 MAINTENANCE MANUAL MAIN 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 (d) Remove the pins from each side of pilot’s seat base.

  • Page 276: Installation

    CUB CRAFTERS, INC. CC11-160 MAINTENANCE MANUAL (4) INSTALLATION (c) Place the battery in the mounting space. (d) Connect the positive lead. (e) Connect the ground lead. (f) Reinstall the pilot’s seat by securing with the pins. IGNITION BACKUP BATTERY The battery is a 12 Volt lead acid battery. It is sealed and does not require electrolyte replenishment.
  • Page 277 CUB CRAFTERS, INC. CC11-160 MAINTENANCE MANUAL NOTE Do not use greater than 2 ampere battery charger to charge ignition backup battery. (a) The battery may be charged using a 12 volt, 1 ampere battery charger. (4) INSTALLATION (a) Connect negative lead, the black heat shrink covered wire, to battery.
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  • Page 279 CUB CRAFTERS, INC. CC11-160 MAINTENANCE MANUAL 6.3.18 POWERPLANT - IGNITION TABLE OF CONTENTS SPARK PLUGS ......................2 REMOVAL ......................2 INSPECTION ....................2 INSTALLATION ....................2 ELECTRONIC IGNITION ..................3 REMOVAL AND INSPECTION ................. 4 INSTALLATION ....................4 6.3.18 Manual number SSC10000AMM...

  • Page 280: Spark Plugs

    CUB CRAFTERS, INC. CC11-160 MAINTENANCE MANUAL SPARK PLUGS (1) REMOVAL (a) Remove spark plug caps. (b) Remove 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. Clean as needed.

  • Page 281: Electronic Ignition

    CUB CRAFTERS, INC. CC11-160 MAINTENANCE MANUAL ELECTRONIC IGNITION The ignition system on the engine uses two Plasma III ignition modules (from Light Speed Engineering) and a Direct Crank Sensor system with magnets in the ring gear to provide the triggers for timing. The firing order is 1,3,2,4.

  • Page 282: Removal And Inspection

    CUB CRAFTERS, INC. CC11-160 MAINTENANCE MANUAL (1) REMOVAL AND INSPECTION (a) Refer to the CC340 Engine Maintenance Manual and manuals from Light Speed Engineering for the Plasma III ignition system. (2) INSTALLATION (a) Refer to the CC340 Engine Maintenance Manual and manuals from Light Speed Engineering for the Plasma III ignition system.
  • Page 283 CUB CRAFTERS, INC. CC11-160 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 SSC10000AMM...

  • Page 284: General

    CUB CRAFTERS, INC. CC11-160 MAINTENANCE MANUAL 1. 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 285: Landing And Taxi Lights

    CUB CRAFTERS, INC. CC11-160 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 286: Lightweight Led Navigation Lights And Anti-Collision

    CUB CRAFTERS, INC. CC11-160 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 287 CUB CRAFTERS, INC. CC11-160 MAINTENANCE MANUAL 6.3.20 STALL WARNING SYSTEM TABLE OF CONTENTS GENERAL ..........................2 STALL WARNING SWITCH ADJUSTMENT ................. 2 6.3.20 Manual number SSC10000AMM Date: 04/24/2009 Page: 1...
  • Page 288 CUB CRAFTERS, INC. CC11-160 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 289 CUB CRAFTERS, INC. CC11-160 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 SSC10000AMM Date: 04/24/2009 Page: 1...
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  • Page 291 CUB CRAFTERS, INC. CC11-160 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 292 CUB CRAFTERS, INC. CC11-160 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 293 CUB CRAFTERS, INC. CC11-160 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 294 CUB CRAFTERS, INC. CC11-160 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 295 CUB CRAFTERS, INC. CC11-160 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 296: Parking

    CUB CRAFTERS, INC. CC11-160 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 297 CUB CRAFTERS, INC. CC11-160 MAINTENANCE MANUAL Figure 6.3.24.1: Wing Tie Down Figure 6.3.24.2: Tailwheel Tie Down 6.3.24 Manual number SSC10000AMM Date: 10/28/2010 Page: 3...

  • Page 298: Storage

    CUB CRAFTERS, INC. CC11-160 MAINTENANCE MANUAL 3. 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 299: Indefinite Storage

    CUB CRAFTERS, INC. CC11-160 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 300: Preparation For Service

    CUB CRAFTERS, INC. CC11-160 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 301 CUB CRAFTERS, INC. CC11-160 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 302: 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 303: Size Of Repair Area

    CUB CRAFTERS, INC. CC11-160 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 304: Patch Repair Less Than 8 Inches

    CUB CRAFTERS, INC. CC11-160 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 305 CUB CRAFTERS, INC. CC11-160 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 306: Patch Repair More Than 8 Inches

    CUB CRAFTERS, INC. CC11-160 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 307 CUB CRAFTERS, INC. CC11-160 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 6.4.4), or if needed, separate lengths of lacing cord may be joined by using the splice knot illustrated in Figure 6.4.5.
  • Page 308 CUB CRAFTERS, INC. CC11-160 MAINTENANCE MANUAL Figure 6.4.2 - Rib Stitching, Steps 1 to 4 Manual number SSC10000AMM Page: 8 Date: 04/18/2013...
  • Page 309 CUB CRAFTERS, INC. CC11-160 MAINTENANCE MANUAL Figure 6.4.3 - Rib Stitching, Steps 5 to 8 Manual number SSC10000AMM Date: 04/18/2013 Page: 9...
  • Page 310 CUB CRAFTERS, INC. CC11-160 MAINTENANCE MANUAL Figure 6.4.4 - Rib Stitching, Steps 9 to 11 Manual number SSC10000AMM Page: 10 Date: 04/18/2013...
  • Page 311 CUB CRAFTERS, INC. CC11-160 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 312: 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 313 CUB CRAFTERS, INC. CC11-160 MAINTENANCE MANUAL ALTERATIONS 6.5.1 ........COMPLIANCE WITH MANUFACTURER’S SERVICE DIRECTIVE 6.5.2 ................. MAJOR REPAIRS AND/OR ALTERATIONS Manual number SSC10000AMM Date: 04/18/2013 Page: 1...
  • Page 314 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 315 - 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 4 Operational Check POH/AFM 5 Perform walk-around to detect fluid leaks.
  • Page 316 CUB CRAFTERS, INC. CC11-160 MAINTENANCE MANUAL Interval Engine Ref. Initials Special 4 Engine Oil: 6.3.10 25 hours - Drain. 5 Oil Screen 6.3.10 25 hours - Visual inspection for foreign particles. 6 Oil Temperature Sender Unit: - Check for leaks and security.
  • Page 317 CUB CRAFTERS, INC. CC11-160 MAINTENANCE MANUAL Interval Engine Ref. Initials Special 19 Intake Seals: - Visual inspection for leaks and clamps for tightness. 20 Flexible Fuel and Primer Lines: - Visual inspection condition. 21 Throttle, Mixture Controls: - Visual inspection for proper travel and operating condition.
  • Page 318 CUB CRAFTERS, INC. CC11-160 MAINTENANCE MANUAL Interval Propeller Ref. Initials Special 1 Spinner and Bulkheads: - Visual inspection for damage and security. 2 Propeller Blades: - Visual inspection for nicks and cracks. 3 Spinner Mounting Brackets: - Visual inspection for damage and security.
  • Page 319 CUB CRAFTERS, INC. CC11-160 MAINTENANCE MANUAL Interval Cabin Ref. Initials Special - Operational check. 12 Fuel Lines and Gauges: - Visual inspection for leaks, chaffing, obstruction, security, general condition. 13 Flap Lever: - Operational Check - Visual inspection of ratchet and latch through the range of operation - Lubricate Shaft.
  • Page 320 CUB CRAFTERS, INC. CC11-160 MAINTENANCE MANUAL Interval Cabin Ref. Initials Special 25 Transponder (if applicable): - Visual and functional inspection for condition 24 mos and calibration 26 Antennas: - Visual inspection for condition and security. 27 Brake Cylinders and Parking Valves: - Operational and visual inspections for leaks - Fill up with fluid, as required.
  • Page 321 CUB CRAFTERS, INC. CC11-160 MAINTENANCE MANUAL Interval Wing Ref. Initials Special 1 Fabric and Finish: - Visual inspection for cracks and deterioration. 2 Aileron, Flap, and Wing Structure: - Visual inspection for damage. 3 Fuel Tanks, Caps, and Lines: - Visual inspection for damage, leaks and deterioration.
  • Page 322 CUB CRAFTERS, INC. CC11-160 MAINTENANCE MANUAL Interval Landing Gear Ref. Initials Special 4 Shock Absorber and Shock Cords: - Visual inspection for broken bands, threads, and weakness. - If AOSS installed, refer to AOSS information 5 Tires: - Visual inspection for cuts, uneven or excessive wear and slippage.
  • Page 323 Return To Service Ref. Initials Special detect fluid leaks or other discrepancies. 6 Verify all Cub Crafters’ Safety Alerts, Service Bulletins, and Instructions are complied with. 7 Verify the aircraft's documentation is in order: - Airworthiness Certificate - Registration - Pilot's Operating Handbook and Aircraft Flight...
  • Page 324 CUB CRAFTERS, INC. CC11-160 MAINTENANCE MANUAL Operational/Functional Inspection Report Initials Notes 10 Pull Carburetor Heat Knob: - Engine RPM should show a slight drop. 11 Apply a Load to the Electrical System (e.g. switch on landing light): - Observe that voltage remains constant and amperage increases when load is applied (if ammeter installed).
  • Page 325 CHAPTER HEAVY MAINTENANCE, REPAIRS, AND ALTERATIONS...
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  • Page 327 CUB CRAFTERS, INC. CC11-160 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 SSC10000AMM Date: 04/24/2009 Page: i...
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  • Page 329 CUB CRAFTERS, INC. CC11-160 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 330: Authorization To Perform Heavy Maintenance, Repair, And Alterations

    CUB CRAFTERS, INC. CC11-160 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 331 CHAPTER OVERHAUL...
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  • Page 333 CUB CRAFTERS, INC. CC11-160 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 SSC10000AMM Date: 04/24/2009 Page: i...
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  • Page 335 CUB CRAFTERS, INC. CC11-160 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 336 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 337 CUB CRAFTERS, INC. CC11-160 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 339 CHAPTER MAJOR REPAIRS AND ALTERATIONS...
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  • Page 341 CUB CRAFTERS, INC. CC11-160 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...
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  • Page 343 CUB CRAFTERS, INC. CC11-160 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 344: Alterations General

    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 345 CHAPTER TASK-SPECIFIC TRAINING...
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  • Page 347 CUB CRAFTERS, INC. CC11-160 MAINTENANCE MANUAL 10 TASK-SPECIFIC TRAINING 10.1 ............CARBON CUB SS SPECIFIC TRAINING – GENERAL 10.2 ........TYPE-SPECIFIC TRAINING REQUIRED BY CUB CRAFTERS, INC. Manual number SSC10000AMM Date: 04/24/2009 Page: i...
  • Page 348 CUB CRAFTERS, INC. CC11-160 MAINTENANCE MANUAL INTENTIONALLY LEFT BLANK Manual number SSC10000AMM Page: ii Date: 04/24/2009...
  • Page 349 TASK-SPECIFIC TRAINING TABLE OF CONTENTS 10.1 CARBON CUB SS SPECIFIC TRAINING – GENERAL ........... 2 10.2 TYPE SPECIFIC TRAINING REQUIRED BY CUB CRAFTERS, INC......2 10.1.2 EAA Sport Air Fabric Covering Course ..............2 Manual number SSC10000AMM Date: 04/24/2009...
  • Page 350 CUB CRAFTERS, INC. CC11-160 MAINTENANCE MANUAL 10.1 CARBON CUB SS SPECIFIC TRAINING – GENERAL 10.2 TYPE SPECIFIC TRAINING REQUIRED BY CUB CRAFTERS, INC. 10.1.2 EAA Sport Air Fabric Covering Course Manual number SSC10000AMM Page: 2 Date: 04/24/2009...
  • Page 351 CHAPTER SAFETY DIRECTIVES COMPLIANCE...
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  • Page 353 CUB CRAFTERS, INC. CC11-160 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 SSC10000AMM Date: 05/02/2011...
  • Page 354 CUB CRAFTERS, INC. CC11-160 MAINTENANCE MANUAL INTENTIONALLY LEFT BLANK Manual number SSC10000AMM Page: ii Date: 05/02/2011...
  • Page 355 CUB CRAFTERS, INC. CC11-160 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 356 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 a 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.

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