Maintenance Manual LEGEND 600

At tip 3,15 feet Wing flaps surface 11.83 ft2 Flaps deflections 15° / 30° / 40° Tail Horizontal tail plane span 9.19 feet Horizontal tail plane surface 24.1ft2 Vertical tail plane surface 11.2ft2 7 July 2016 Revision 1.0 6 Weights Empty weight, per UL–2 739 lbs Take-off weight, maximum 1320 lbs Engine Type (brief description): Rotax 912ULS 100HP – four-stroke, four-cylinder engine, air-cooled cylinders with water- cooled heads, integrated reduction gearbox, dual electronic ignition and tuned inlet manifold. Engine Displacement 1400ccm Take-off power, max. 98.99HP@5800rpm Cruising power, max. 93.81HP@5500rpm Dry weight 123 lbs (Including accessories) 159lbs Fuel (fuel grade, octane index) MOGAS 91 Octane min, 100LL AVGAS Oil (type) SHELL HELIX H x 7 AV 10 W - 40 Oil capacity 3L Reduction gear (gear ratio) 2.43:1 Fuel tank volume – main tank 33 gal (130L) Propeller Diameter / pitch at 75% Woodcomp ‘Klassic’ ground adjustable Weight 11 lbs (5kg) Material Wood/Composite 7 July 2016 Revision 1.0 7 Equipment List A preliminary list of factory-installed equipment is provided. A parachute recovery system is installed from the factory, and is included in the factory weight and balance calculation form. Instruments Instrument Type Serial Number Speed Indicator Winter TBD Altimeter Winter TBD Compass Winter Model CM24 TBD Kanardia Nesis III EFIS TBD DIGI Engine Management System Engine Management System TBD GPS AVMap EKPV TBD Radio GARMIN GTR 225A TBD Transponder GARMIN GTX 328 TBD TBD Kanardia AH panel Horis AD-AHRS TBD Parachute Rescue System Model, manufacturer, serial No. GALAXY 5/560 Activation By pulling the handle on central panel Descent speed, max. (m/s) 6,6m/s At take‐off weight 600 kg Maximum Speed at activation, max. 170kt (310km/h) Battery Type 508 901 Voltage 12 V Ah rating 8 Weight 2.9 kg Location On firewall, at the highest point of engine compartment 7 July 2016 Revision 1.0 8 Sources to Purchase Parts Sources to purchase spare parts and disposable parts are given. When in doubt, ask your distributor or contact the factory first. Disposable Replacement Parts A list of disposable replacement parts which shall be replaced if necessary at regular servicing intervals is given below. A list where to purchase replacement parts is shown below. When damage is determined to any part of the aircraft please contact your AEROPILOT distributor when in doubt about replacement or repair. No repairs must be done to any of the listed parts due to flight safety! Part Description or Location Part Description Engine Compartment………………………… Oil Filter Element Gasket for Oil Filter Gasket for Oil Drain Screw Air Cleaner Element All Gaskets in General Exhaust System Retaining Springs Self-Locking Nuts in General Propeller Screws Part Description Source to buy Airframe and Engine Components…………… AEROPILOT S.R.O. 2016-Čáslav (Czech Republic) e-mail: info@aeropilotcz.com web: www.light-sport- aircraft.cz AEROPILOT USA, Inc. 3915 W. Commonwealth Blvd. Fullerton, CA 92833 e-mail: i n f o @ a e r o p i l o t u s a .c o m Engine Components………………………… Refer to ROTAX Engine Operator’s Manual 912 Series, Section 14 7 July 2016 Revision 1.0 9 Engine Specifications The ROTAX 912 Series engines are 4-stroke, 4 cylinder horizontally opposed, spark ignition engines, featuring one central camshaft with push rods OHV. Cylinder heads are liquid cooled. Lubrication system is a dry sump forced type. It is equipped with dual breakerless capacitor discharge ignition and two constant velocity carburetors. Prop drive is via reduction gear with integrated shock absorber and overload clutch. Specific engine data are shown below. Description 912 UL/S Dimensions Bore…………………………………………………………………. Stroke……………………………………………………………….. Displacement………………………………………………………. Compression ratio………………………………...………………. Weight (without exhaust, radiator, air intake System)………………… Speed 3.31 in 2.40 in 82.5 in3 10.5 : 1 134 lb Take-off speed…………………………………………………….. Continuos speed (max.)………………………….………………. Idle speed (approx.)………………………………………………. Gear Ratio…………………………………………………………………. Performance Take-off performance…………………………………………….. Continuous performance…………………………………………. 5800 rpm 5500 rpm 1700 rpm 2.43 :1 100 hp 92 hp Engine Mount Screws Engine Shock Mounts Throttle Control Cables Other specific Engine Components………… Refer to ROTAX Engine Maintenance Manual. Propeller………………………………………. Refer to Woodcomp ‘Klassic’ Operators Manual Landing Gear…………………………………. Tires and Tubes Cotter Pins in General Hydraulic Line Fittings Self Locking Nuts in General Brake Pads Brake Discs All Wheel and Landing Gear Components when damaged in General. Airframe………………………………………. Self Locking Nuts in General 7 July 2016 Revision 1.0 10 Max. negative "g" for 5 seconds…………………… Oil Pressure Max. for short period at cold start………………… Min. (below 3500 rpm)…………………………….. Normal (above 3500 rpm)………………………… Deviation from Bank Angle max…………………………. Oil Temperature Max………………………………………………….. Min…………………………………………………... Normal………………………………………………. Cylinder Head Temperature Max. (observation at hottest cylinder, #2 or #3)… Normal………………………………………………. Engine Start, Operating Temperature Max………………………………………………….. Min…………………………………………………… Fuel Pressure Max………………………………………………….. Min…………………………………………………... - 0.5 g 100 psi 12 psi 29 - 73 psi 40° 266° F 120° F 190-230° F 275° F 167-230°F 120° F -13° F Electric Starter……………………………………………… Generator…………………………………………………… 5.8 psi 2.2 psi 12V, 0.6 kW 12V, 7 July 2016 Revision 1.0 11 Weight and Balance Information To perform a successful weight and balance calculation, the center of gravity "C.G." has to be determined with all installed equipment, including engine oil, cooling liquid and unusable fuel. Method for C.G. determination is shown in this section. All measurements including a listing of all installed equipment have to be noted in the separate weight and balance calculation form, supplied TBD. This form has to be placed in the aircraft, so every pilot will be able to conduct his specific weight and balance calculation prior to each flight. Weight and Balance, and Equipment List The following information will enable operation of the Legend 600 within prescribed weight and balance and center of gravity limitations. The methodology and calculations for the determination of the C.G. limits are shown in the Weight and Balance Record of the Legend 600 Aircraft section. This shows the movement of the C.G. from empty weight to gross weight Required Tools: Weighing scales, OTHER TBD Parts required: None Level of Maintenance: Line Certification required: A&P Mechanic or LSA Repairman Maintenance Weighing for aft center of gravity Move seats to rearmost position Fill baggage compartment with maximum allowed load Empty fuel tanks Weighing for forward center of gravity Empty baggage compartment Move seats to foremost position Full fuel tanks Weight and balance record of the aircraft LEGEND 600 Config uration Aircraft Engine Propeller Rescue system TYPE LEGEND 600 ROTAX 912 ULS Woodcomp ‘Klassic’17013R Galaxy 6/473SD Serial number 1531 6785375 16003-683R 7455 Center of gravity determination 7 July 2016 Revision 1.0 12 To get the correct values, it is necessary to put the aircraft on three weighing scales placed on a level surface. Before conducting the weighing procedure, it is important to achieve a level wing main chord, TBD CG-Calculation A specific C.G.-calculation recommendation which has to be carried out prior to each flight is provided in the Pilot Operating Handbook. C.G. position calculation C.G. Centre of gravity calculation LA [mm] = 746 LAR = 710 b SAT[mm] = 1200 bk = 1300 mm Load Nose wheel G P Main gear G HL Total weight G CELK C.G. from the wing leading edge [lbs] [lbs] [lbs] X T [inch] X T [%] Crew/Fuel/Baggage 166 574 738.68 13.7 29 Crew/Fuel/Baggage 221 927 1146.60 15.7 33 Crew/Fuel/Baggage 252 1040 1296.54 15.63 33 Calculated position of C.G. is within a permitted range of 21.6-35.6 % bSAT.. To calculate weight and balance for an actual flight, follow the process shown in the Sample Loading Problem shown below. Loading Provisions and Calculations G[ CELK ] = GP + GHL XT[mm] XT[%]= - -------- * 100 BSAT XT[mm] = LAR - - GP * LP Gtotal 7 July 2016 Revision 1.0 13 The included table shows the distance or “ARM” from the datum point, (set at the leading edge of the aircraft) for the Pilot/Passenger seats, the Fuel Tank and the Aft Baggage Compartment. (NOTE: Items stored in the armrest will be added to the Pilot/Passenger weight. Weight (lbs) Arm (inches) Moment (weight x Arm) (Inch‐lbs) Maximum Allowable (inch‐lbs) Pilot and Passenger 21.8 Baggage 60.8 2128 Fuel 13.2 2614 Aircraft Typical Empty Weight (includes oil and unusable fuel) 739 10.2 7538.7 Total Calculation of C.G. Position C.G.(inches) = MOMENT TOTAL WEIGHT Calculation of Percent of Mean Aerodynamic Chord %MAC = C.G. 47.244 (inches) The %MAC is then plotted on the Allowable C.G.Envelope chart. If the point on the chart falls within the shaded area, the aircraft is within C.G. Limits and is legal to fly. Maximum Gross Weight 1320 lbs Minimum %MAC (Forward C.G.) 21.6 % Maximum %MAC (Aft C.G.) 35.6 % 7 July 2016 Revision 1.0 14 Tire Inflation Pressure Tricycle landing gear with steerable nose wheel. Main wheels - size 15x6-6 - are provided with hydraulic disc brakes. These are carried on an all-composite leg. The nose wheel is fitted with spring and hydraulic shock absorber. The front wheel has size 12 x 4 – 4. All wheels provided with fairings. Tire inflation of all wheels is for 2.3 bar (33psi) pressure Approved Oils and Capacities In general we recommend referring to the latest ROTAX 912 Series engine operator's manual to check for suitable engine oil. Nevertheless, general recommendations about lubricants are shown below. If engine is mainly run on AVGAS more frequent oil changes will be required. See ROTAX Service Information SI-18-1997, latest edition. At the selection of suitable lubricants also refer to the ROTAX Service Information SI-18-1997 latest edition. The use of multi-grade oils is recommended. Multi-viscosity grade oils are less sensitive to temperature variations than single-grade oils. They are suitable for use in all seasons, ensure rapid lubrication of all engine components at cold start and multi- viscosity oils get less fluid at higher temperatures. Oil specification Motorcycle oil of a registered brand with gear additives. No aircraft engine oil should be used. - Use only oil with API classification "SF" or "SG" - Due to high stresses in the reduction gears, oils with gear additives such as high performance motorcycle oils are required. - Because of the friction clutch incorporated in the gearbox, oils with friction modifier additives are unsuitable as this could result in a slipping clutch during normal operation. - Heavy duty 4-stroke motorcycle oils meet all the requirements. These oils are normally not mineral oils but semi- or full-synthetic oils. - Oils primarily for Diesel engines are generally unsuitable due to insufficient high temperature properties and additives which favor clutch slipping. 7 July 2016 Revision 1.0 15 General Safety Information TBD Reporting possible Safety of Flight Concerns During Inspection TBD Inspections Introduction This section includes exact procedures for aircraft handling on ground and maintenance recommended by the manufacturer. It defines periodical inspections and prerequisites for the required performance and reliability of aircraft. Passing mandatory inspections required by the manufacturer is one of warranty conditions. Periodical Inspections Regular and thorough maintenance is a prerequisite of reliability and safe handling of the aircraft. Warranty inspection and inspections at 50, 100, 300, and 1000 operating hours must be recorded in Table of lubricants Since the temperature range of neighboring SAE grades overlap, there is no need for change of oil viscosity for a short duration of ambient temperature fluctuation. Climatic conditions Multi-grade oils Tropical…………………………………… SAE 20W-50, SAE 20W-40 SAE 15W-50, SAE 15W-40 SAE 10W-40 SAE 5W-50, SAE 5W-40 Temperate……………………………….. SAE 20W-50, SAE 20W-40 SAE 15W-50, SAE 15W-40 SAE 10W-40 SAE 5W-50, SAE 5W-40 Arctic……………………………………… SAE 10W-40 SAE 5W-50, SAE 5W-40 7 July 2016 Revision 1.0 16 aircraft logbook. For privately operated aircraft, an annual inspection is required on a yearly basis and must be performed by a fully licensed FAA Certified Mechanic. For aircraft operated for hire, the items included in the annual inspection must be conducted every 100 hours, as prescribed by FAA regulations Periodical Inspections of Aircraft This section describes intervals of aircraft inspections and maintenance, not including the engine and propeller. The intervals and items for maintenance listed below are not to preclude any as needed repairs due to normal wear and tear, unexpected parts degradation or accident. All inspections are cumulative, in that, all 50 hours items will also be conducted at the 100 hour inspection. Name of inspection Aircraft hours flown - interval Managed (controlled by) Warranty inspection After the first 25 operating hours Manufacturer’s service facility 50-hour inspection Every 50 ±5 operating hours Manufacturer, or aircraft operator trained by the manufacturer 100-hour/Annual inspection a) Every 100 ± 5 operating hours b) 12 months from most recent Annual inspection Manufacturer, or aircraft operator trained by the manufacturer Fuel System Performer Level 50 Hr 100Hr / Annual *  Check Gasculator for sediment or water Owner Inspection Type Propeller Performer Level 50 Hr 100Hr / Annual *  Blades A&P, LSA Maint *  Spinner A&P, LSA Maint *  Space (if used) A&P, LSA Maint 7 July 2016 Revision 1.0 17 Engine Performer Level 50 Hr 100Hr / Annual (Prior to all inspections, a visual review of the compartment for oil and gas leaks shall be conducted. All engine inspections will be conducted in accordance with procedures specified by the Rotax 912 ULS maintenance •  Oil System Components Owner • o Oil level Owner • o Filler cap Owner • o Cooler Owner • o Filter Owner • o Drain plug Owner • o Oil level Owner •  Air Filters Owner •  Engine case and Cylinder heads A&P, LSA Maint. •  Reduction Drive to include mounts and seals A&P, LSA Maint •  Plugs and wiring harness A&P, LSA Maint •  Carburetors A&P, LSA Maint •  Engine mounts A&P, LSA Maint •  Controls and linkage A&P, LSA Maint •  Starter A&P, LSA Maint •  Voltage regulator and wiring A&P, LSA Maint •  Exhaust system A&P, LSA Maint 7 July 2016 Revision 1.0 18 Landing Gear Performer Level 50 Hr 100Hr / Annual • Wheels and Fairings Owner • Tires Owner • Brakes and related assemblies Owner • Struts LSA Maint. Airframe Performer Level 50 Hr 100Hr / Annual • All exterior and interior structure A&P • Windows, windscreen, doors and seats • Control yokes and all connecting cables A&P • Electronic and pneumatic engine and flight instruments A&P • Magnetic Compass/ADHD calibration Owner • Interior/Exterior Lights Owner • Electrical system to include breakers and battery LSA Maint Control Systems Performer Level 50 Hr 100Hr / Annual • Cables and all linkage components LSA Maint • Electric Trim and indicator LSA Maint • Flaps to include motors, linkage and indicator LSA Maint • Rudder Pedals assemblies and linkages LSA Maint 7 July 2016 Revision 1.0 20 300-hour inspection Every 300 ± 5 operating Manufacturer’s service facility 1000-hour inspection (assessment of further operating capability of aircraft) a) Every 300 ±5 operating hours b) 5 years from date of manufacture c) 5 years from most recent 1000- hour inspection d) Date determined by the manufacturer according to his experience and assessment of current condition, based on previous inspection Manufacturer’s service facility Periodical Inspections of Engine See Engine Operating and Maintenance Manual issued by engine manufacturer. Periodical Inspections of Propeller See Propeller Operating and Maintenance Manual issued by propeller manufacturer. Airframe Lifetime Original airframe lifetime is defined as 8000 hours or 5 years from date of manufacture. It will be corrected based on operating experience and current condition of airframe, assessed during service inspection performed in manufacturer’s service facility. Inspections Alterations and Repairs WARNING: It is mandatory to contact aircraft manufacturer before any modification; it is also necessary to inform the Federal Aviation Administration (FAA) before any significant modification or repair (impacting airworthiness). IMPORTANT NOTICE: Any modification influencing aircraft weight requires subsequent 7 July 2016 Revision 1.0 20 weighing and determining of COG of empty aircraft according to section 6, recording of COG of empty aircraft into the table in section 2.8, updating the weight and COG of empty aircraft in the respective protocol, and updating the information stated on labels within the aircraft. Repairs of screw connections Corroded, bent, cracked, or blistered screws must be replaced immediately. In case of stripped thread, screw and nut must be both replaced. Use replacement screws of the same quality and compliant with the same standard. Nyloc nuts are intended for single use only. All-metal screws may only be used thrice after being compressed with securing ring and pincers. Repairs of riveted connections Damaged (loose or cut) rivet must be removed, both surfaces checked for damage, and new rivet fitted. If contact surfaces are damaged, parts must be replaced or possible repair discussed with aircraft manufacturer. Use replacement rivets of the same quality and type. Repairs of control elements Linkages, connecting parts, cable bowdens, bearings, and other control elements must not be damaged. Components may only be replaced with originals supplied by the manufacturer. Any significant damage to control elements and/or excess free play must be repaired in manufacturer’s service facility. Any repair of control elements must be followed by test flight performed by a test pilot. 7 July 2016 Revision 1.0 21 Repairs of airframe WARNING: Wings, struts, tail surfaces, and fuselage are essential design elements. Any modification to essential design elements performed by the user without manufacturer’s permission is prohibited. NOTE: Deeper damage to fuselage must be repaired by the manufacturer, who will evaluate influence on design rigidity, and will determine proper repair method. Repairs of fuel system Leaking or blocked fuel system must be repaired immediately. Visible defects, such as damaged hose connecting flange or blockage of fuel filter (with dirt), may be repaired by the user. All other repairs may only be performed in manufacturer’s service facility. Repairs of engine Any repairs of engine and its accessories may only be performed in manufacturer’s service facility. Repairs of electrical installation and instruments The user may recharge the battery, clean contacts, and reconnect disconnected connectors. All other repairs of electrical installation and instruments may only be performed in manufacturer’s service facility. Ground Handling NOTICE: Do not place platforms, ladders, hands, or fuel containers on aircraft painting; damage could occur . IMPORTANT NOTICE: Use only containers and filter fillers approved for fuel storage and refueling; do not wear static- charge generating clothing. 7 July 2016 Revision 1.0 22 Ground Handling (continued) Refueling - The manufacturer recommends the following procedure of safe refueling:  Do not allow open flames near the aircraft, prohibit smoking in the vicinity.  Have fire extinguisher ready, suitable for flammable liquids.  Check that grounding cable attached to right side of main undercarriage leg touches the ground.  Check that electricity consumers, ignition circuits, and main switch are all switched off.  Check that fuel supply is closed.  It is advisable to use elevated platform during refueling, due to the location of fuel tank hose and filling throat.  Unlock and unscrew filling throat cover.  Insert approved refueling funnel including velvet filter into filling throat.  Slowly pour fuel, minimizing spillage onto aircraft.  When fuel tank is full, remove empty funnel, attach and lock filling throat cover.  Thoroughly dry aircraft surface. Parking  When parking the aircraft, locate it in a hangar or other enclosed space with constant temperature, sufficient air exchange (ventilation), low humidity, and possibly dust-free.  Check that fuel supply is closed.  Check that switches are in off position.  Check that ballistic rescue system is secured.  Close and lock cabin doors.  Protect propeller blade using cloth covers, protect Pitot tube similarly.  Cover cabin using suitable cover. IMPORTANT NOTICE: When parking outside hangar, it is necessary to use anchors, so that the aircraft cannot be damaged by wind gusts . 7 July 2016 Revision 1.0 23 Anchoring When parking outside hangar, it is necessary to use anchors. Use three anchoring lugs on top end of wing strut and bottom part of engine firewall. Use sufficiently strong anchors on the ground. Check that all instruments, switches, and fuel valves are switched off.  Lock control surfaces against movement.  Check that ballistic rescue system is secured and locked.  Close ventilation windows.  Close and lock cabin doors.  Anchor the aircraft to anchors on/in the ground. NOTE When planning long-term anchoring, it is advisable to cover cabin glazing and/or whole aircraft with suitable covers attached to aircraft structure, especially in unfavorable weather and/or climate. Lifting Aircraft can be lifted in the following ways: Front part of fuselage may be lifted by pressing rear part of fuselage down by front part of fixed vertical stabilizer. Subsequently, front part of fuselage may be supported under designated parts of engine mount. These supporting location are accessible after removal of lower engine cowling. IMPORTANT NOTICE: Chock wheels from both sides when supporting aircraft under designated parts . Rear part of fuselage may be lifted by holding fixed vertical stabilizer at bulkhead, and pressing upwards. Subsequently, rear part of fuselage may be supported using bulkhead of rear baggage area. IMPORTANT NOTICE: When lifting rear part of fuselage, do not press the axis (center) of fuselage, nor rear fuselage cover. These parts are not designed for this purpose and could be damaged. 7 July 2016 Revision 1.0 24 Wing may be lifted by pressing up on main spar area. IMPORTANT NOTICE: Do not lift wing by holding leading edge(s). Transporting Aircraft on Ground Towing Aircraft may be towed primarily using tow bar, which may be attached to a hole left by a pin removed from front landing gear leg. The manufacturer also approves the following handling methods:  Press front edge of rectangular part of a wing, to move the aircraft.  Lift front landing gear leg by pressing down rear part of fuselage, to turn the aircraft. IMPORTANT NOTICE: It is important to avoid excess pressure on elements of airframe and propeller, especially on wing tops, struts, tail surfaces, etc. NOTE: Passing through narrow areas requires assistance of trained person at wingtips. 7 July 2016 Revision 1.0 25 Disassembly and assembly of aircraft for road transport Aircraft may be transported on roads, when loaded on trailer. Prior disassembly is necessary. NOTE: Disassembly and assembly of aircraft does not require special qualification. NOTE: After removal of lubricant, all connecting parts must be re- lubricated. Disassembly procedure Disassembly of wings  Remove cabin ceiling trim panel.  Unscrew pins of right and left aileron control cable. Central tensioner  Unscrew peg of connecting aileron rope. 7 July 2016 Revision 1.0 26  Disconnect Pitot tube hoses. Connection of airspeed system  Disconnect electric wires from the wing. 7 July 2016 Revision 1.0 27  Disconnect fuel hoses from the wing. 7 July 2016 Revision 1.0 28  Disconnect and remove flap control bowdens.  Unscrew main and auxiliary wing connections and strut pins. 7 July 2016 Revision 1.0 29  Remove strut pins (wing must be held by a helper).  Press wing out of fuselage.  Disassembly of horizontal stabilizer (elevator)  Disassemble tail section of fuselage. 7 July 2016 Revision 1.0 30  Disassemble trim corrector.   Disassemble elevator linkage.   Unscrew stabilizer out of rear partition   Remove tail surface from front hinges by pulling rearward. Assembly procedure Assembly procedure is the same as disassembly procedure, performed in reverse order. WARNING: After assembly of aircraft, it is necessary to check operation of controls, synchronization of flaps, and check electrical, fuel, and other systems. Aircraft Lubrication Plan Use only oil specified by engine manufacturer in Engine operating manual. Engine oil is replaced every 100 hours flown. Virtually any lubricant, engine or transmission oil, may be used on all other parts. To facilitate lubrication of parts which are hard to access (e.g. hinges), fill a syringe with thicker needle with oil. Apply 1 to 2 drops of oil at each location. Oil also protects some parts from corrosion. Location Lubricant (grease) Lubrication frequency Front landing gear leg Grease Once a year Aileron, flap hinges Transmission oil Every 300 hours flown Elevator hinge, trim surface Transmission oil Every 300 hours flown Control connections (joints) Transmission oil Every 300 hours flown Aileron connections (joints Transmission oil Every 300 hours flown Some of lubricating locations are accessible after removal of seats from cabin. 7 July 2016 Revision 1.0 31 Cleaning and Care This section describes the procedures for cleaning and service of aircraft components. Aircraft skin Use lukewarm water to wash aircraft. Parts listed below must be washed and dried. Automotive preparations may be used to remove dead insects. Treat (protect) aircraft using automotive cleaning and protective preparations approximately once a month. Wait approx. 1 month before the first treatment to allow aircraft skin paint to cure.  Propeller blade and spinner  Wings and tail surfaces  Wing struts  Landing gear  Engine cowling air suction holes  Fuselage Glazed aircraft parts Wash, dry, and polish glazing, using velvet (deer skin), frequently washed in clean water. IMPORTANT NOTICE: Do not clean glazing without previous wetting, and do not use chemicals, thinner, nor benzene. Aircraft interior Clean all debris from cabin, remove rubbish from baggage area. Seats may be removed from cabin, brushed or washed using domestic cleaner (cleaning / washing solution). Assembly and disassembly of LEGEND aircraft Assembly of LEGEND aircraft at airfield after transport on a trailer (in a container) Assembly of wings 7 July 2016 Revision 1.0 32  Thread aerodynamic covers onto wing strut.  Push in and screw in bottom pin of strut (use new Nyloc nut).  Lift wing and position it on its attachments. At the same time, thread aileron control cables, flap Bowden, and Pitot-static system hoses into fuselage.  Insert main and rear wing attachment pin.  Turn strut upwards into position and insert its main pin.  Threat and tighten nuts on wing pins and upper pin of strut. 7 July 2016 Revision 1.0 33  Repeat the procedure with the other wing. Connect aileron control cables. Central tensioner 7 July 2016 Revision 1.0 34  Check that cables are taut, and check free movement of aileron control.  Connect flap bowdens and check operation of flaps in all positions.  Connect connectors of electrical equipment in wings and connectors of fuel senders. 7 July 2016 Revision 1.0 35  Connect Pitot-static system hoses. Connection of airspeed system  Connect suction hoses of fuel tanks. 7 July 2016 Revision 1.0 36  Install aerodynamic covers onto wing struts.  Install cabin ceiling trim. Assembly of horizontal stabilizer (elevator)  Insert horizontal stabilizer from side into center of fuselage.  When in center of fuselage, slide horizontal stabilizer forward onto its pins.  Tighten attachment baffle screws and secure them using locking wire.  Connect control link.  Connect trim connector.  Check free movement of controls, between end stops.  Check trim operation.  Thread rear cover of fuselage into its place. Disassembly of LEGEND aircraft for transport on trailer (in container) Disassembly of wings Drain fuel from wing tanks. Disconnect fuel hoses downstream electrical fuel pump. Install drain hose onto fuel pump and pump all fuel from tanks into jerry cans.  Remove ceiling trim.  Disconnect aileron cables.  Disconnect flap bowdens.  Disconnect wing fuel tanks suction hoses.  Disconnect wing electrical installation connectors.  Disconnect fuel level sender connectors.  Disconnect Pitot-static system connectors.  Unscrew aerodynamic covers of wing struts.  Unscrew nuts from strut pins.  Unscrew nuts from wing pins. 7 July 2016 Revision 1.0 37  Support (hold) wingtip.  Remove upper pin from strut, turn strut towards ground.  Use puller to remove wing pins.  Remove wings from attachments by pulling away from the fuselage.  Pull wing away from the fuselage, carefully remove control cables and bowden from the fuselage, store wing on stand or in transport cover.  Pull bottom pin from strut and store wing strut in transport cover.  Repeat the procedure with the other wing. Disassembly of horizontal stabilizer Horizontal st a bi l i z e r is re m o v e d and tr a n s p o r te d co m p lete wi t h bot h ha l ve s of elevator, including mounting baffle).  Remove rear part of the fuselage.  Disconnect trim connector.  Remove securing wire from mounting bolts.  Disconnect control link.  Disconnect rudder control cables.  Unscrew bolts from mounting baffle.  Pull horizontal stabilizer rearwards to loosen front pins.  Carefully pull horizontal stabilizer sideways.  Store horizontal stabilizer on stand or in transport cover. Inspection Inspection Requirements As required by Federal Aviation Regulations, all civil aircraft of U.S. registry must undergo a complete inspection (annual) each twelve calendar months. In addition to the required Annual Inspection, aircraft operated commercially (for hire) must also have a complete aircraft inspection every 100 hours of operation. Trouble Shooting Refer to Rotax 912 UL/S Maintenance Manual, latest issue. This table should be understood as a general guide to locate engine failures. 7 July 2016 Revision 1.0 38 Cleaning The engine may be cleaned with a suitable solvent, then dried thoroughly. Particular care should be given to electrical equipment before cleaning. Solvent should not be allowed to enter magnetos, starter, alternator and the like. Hence, protect these components before saturating the engine with solvent. Cover any fuel, oil and air openings on the engine and accessories before washing the engine with solvent. Caustic cleaning solutions should be used cautiously and should always be properly neutralized after their use. Accessories Removal Removal of engine accessories for overhaul or for engine replacement involves stripping the engine of parts, accessories, and components to reduce the engine assembly to the bare engine. During removal, carefully examine removed items and tag defective parts for repair or replacement by a new part. Items easily confused with similar items should be tagged to provide a means of identification when being installed on a new engine. All openings exposed by the removal of an item should be closed by installing a suitable cover or cap over the opening. This will prevent entry of foreign particles. If suitable covers are not available, tape may be used to cover the opening. Inspection For specific items to be inspected refer to engine manufacturer’s manual.  Visually inspect the engine for loose nuts, bolts, cracks and fin damage.  Inspect brackets for cracks, deterioration and breakage.  Inspect all hoses for internal swelling, chafing through protective plys, cuts, breaks, stiffness, damaged threads and loose connections. Excessive heat on hoses will cause them to become brittle and easily broken. Hoses and lines are most likely to crack or break near the end fittings and support points.  Inspect for color bleaching of the end fittings or severe discoloration of the hoses. All flexible fluid carrying hoses in the engine compartment should be replaced at engine overhaul or every five years, whichever occurs first. For major engine repairs, refer to the manufacturer’s overhaul and repair manual. Note Caution 7 July 2016 Revision 1.0 39 Trouble Shooting Introduction All checks in accordance with the Maintenance Manual (current issue/revision). The following listing should be understood as quick reference guide to locate particular trouble which may occur to the engine oil system. For detailed information refer to the engine manufacturers Maintenance Manual. Starting problems Engine does not start Possible cause Remedy Ignition off. Switch on. Closed fuel valve or clogged filter. Open valve, clean or renew filter, check fuel system for leaks. No fuel in tank. Refuel. Starting speed too low, faulty or discharged battery. Fit fully charged battery. Starting speed too low, start problems on cold engine. Use top quality, low friction oil; allow for sufficient cooling period to counter for performance drop on hot starter; pre- heat engine. Wrong fuel (Jet fuel or Diesel). Change of fuel. Engine run Engine idles rough after warm‐up period, smoky exhaust emission Possible cause Remedy Starting carb (Choke) activated. Close starting carb (Choke). Engine keeps running with ignition off Possible cause Remedy Overheating of engine. Let engine cool down at idling at approx. 2000 rpm. Knocking under load Possible cause Remedy Octane rating of fuel too low. Use fuel with higher octane rating. Oil pressure Low oil pressure Possible cause Remedy Not enough oil in oil tank. Refill oil. Too hot oil. Cool down oil. High oil pressure Possible cause Remedy Too cold oil. Cover oil cooler or install thermostat. Wrong viscosity of oil. Change oil to lower viscosity. 7 July 2016 Revision 1.0 40 Oil level Oil level is increasing Possible cause Remedy Oil too cold during engine operation. Cover oil cooler surface, observe the operating limits. Contamination with diesel fuel. Check fuel Cold engine start Engine hard to start at low temperature Possible cause Remedy Starting speed too low. Preheat engine. Low charge battery. Fit fully charged battery. High oil pressure. At cold start a pressure reading of up to around 7 bar (102 psi) does not indicate a malfunction. Oil pressure too low after cold start. Too much resistance in the oil suction system at low temperatures due to cold oil. Stop engine and preheat oil. After a cold start the oil pressure must be observed and should be above 1.5 bar (22 psi). Otherwise, the speed must be lowered again, because not enough cold oil can be sucked. If oil pressure is lower than 1 bar (15 psi) oils with lower viscosity have to be used. See SI-912-016, current issue. NOTE: Oil pressure must be measured at idle at an oil temperature of minimum 50 °C (120 °F). Be sure the oil pressure does not go below minimum at idle.