American Legend AL18 Super Legend 2019 User manual

American Legend AL18 Super
Legend
Maintenance Manual
Rev 2.0
Date of Revision: 9/27/2013
American Legend Document #: 500-MS1014

Legend Aircraft Maintenance Manual –AL18 2
© American Legend Aircraft Company Rev 2.0
Date of Revision: 9/27/2013
Table of Contents
Table of Contents.......................................................................................................................................... 2
Table of Figures............................................................................................................................................. 7
1. General................................................................................................................................................. 9
1.1. Manufacturer................................................................................................................................ 9
1.2. Physical Dimensions...................................................................................................................... 9
1.3. Three-View Drawing ...................................................................................................................10
1.4. Materials .....................................................................................................................................10
1.5. Equipment List ............................................................................................................................10
1.6. Source to Purchase Parts ............................................................................................................ 10
1.7. List of Disposable Replacement parts......................................................................................... 10
1.8. Engine Specifications .................................................................................................................. 11
1.9. Weight and Balance Information................................................................................................ 12
1.10. Tire Inflation............................................................................................................................12
1.11. Approved Oils and Capacities .................................................................................................13
1.11.1. Lycoming YO-233 ................................................................................................................13
1.12. Recommended Fastener Torque Values................................................................................. 13
1.13. General Safety Information..................................................................................................... 13
1.14. Instructions for Reporting Possible Safety of Flight Concerns during
Inspections/Maintenance.......................................................................................................................13
2. Inspections ......................................................................................................................................... 14
3. Structures ...........................................................................................................................................15
3.1. Wing ............................................................................................................................................ 15
3.1.1. Wing Removal ..................................................................................................................... 15
3.1.2. Wing Installation ................................................................................................................. 16
3.2. Empennage .................................................................................................................................18
3.2.1. Trim Jackscrew Mechanism Removal/Installation.............................................................. 18
3.2.2. Required Tools: ................................................................................................................... 18
3.2.3. Torque Tube Removal/Installation ..................................................................................... 18
3.3. Landing Gear ............................................................................................................................... 20
3.3.1. Landing Gear Removal/Installation..................................................................................... 20
3.4. Tailwheel Removal/Installation .................................................................................................. 22
3.5. Structural Control Surfaces......................................................................................................... 24

Legend Aircraft Maintenance Manual –AL18 3
© American Legend Aircraft Company Rev 2.0
Date of Revision: 9/27/2013
3.5.1. Aileron Removal..................................................................................................................24
3.5.2. Aileron Installation and Rigging ..........................................................................................26
3.5.3. Elevator Removal ................................................................................................................ 27
3.5.4. Elevator Installation and Rigging.........................................................................................28
3.5.5. Rudder Removal.................................................................................................................. 29
3.5.6. Rudder Installation..............................................................................................................31
3.5.7. Stabilizer Removal...............................................................................................................32
3.5.8. Stabilizer Installation and Rigging ....................................................................................... 32
3.5.9. Flap Removal/Installation ................................................................................................... 33
3.5.10. Flap Control Mechanism Removal/Installation................................................................... 36
4. Engine................................................................................................................................................. 37
4.1. Engine (Lycoming YO-233) .......................................................................................................... 37
4.1.1. Engine Removal/Installation ...............................................................................................40
4.1.2. Exhaust Removal................................................................................................................. 40
4.1.3. Exhaust Installation.............................................................................................................43
4.1.4. Alternator Removal/Installation .........................................................................................43
4.1.5. Spark Plug Removal/Installation .........................................................................................45
4.1.6. Oil Change ........................................................................................................................... 45
4.1.7. Other Engine Maintenance and Repair............................................................................... 46
5. Fuel System ........................................................................................................................................ 47
5.1. Fuel Tank Removal/Installation .................................................................................................. 49
5.1.1. Required Tools: ................................................................................................................... 49
5.1.2. Parts Required:.................................................................................................................... 49
5.1.3. Level of Maintenance: Line .................................................................................................49
5.1.4. Certification Required: A&P or LSA Repairman Maintenance ............................................49
5.1.5. Verification..........................................................................................................................49
5.2. Gascolator Removal/Installation ................................................................................................49
5.2.1. Required Tools: ................................................................................................................... 51
5.2.2. Parts Required:.................................................................................................................... 51
5.2.3. Level of Maintenance: Preventive ......................................................................................51
5.2.4. Certification Required: Sport Pilot Certificate or higher..................................................... 51
5.3. Fuel Gauge Removal ...................................................................................................................51
5.4. Fuel Gauge Installation ............................................................................................................... 52
5.4.1. Required Tools: ................................................................................................................... 52
5.4.2. Parts Required:.................................................................................................................... 52

Legend Aircraft Maintenance Manual –AL18 4
© American Legend Aircraft Company Rev 2.0
Date of Revision: 9/27/2013
5.4.3. Level of Maintenance: Line .................................................................................................52
5.4.4. Certification Required: A&P or LSA Repairman Maintenance ............................................52
5.4.5. Verification..........................................................................................................................52
6. Propeller............................................................................................................................................. 53
6.1. Propeller Removal, Installation, and Repair ...............................................................................53
6.1.1. Required Tools .................................................................................................................... 53
6.1.2. Required Parts..................................................................................................................... 53
6.1.3. Level of Maintenance: Line .................................................................................................53
6.1.4. Certification Required: A&P or LSA Repairman Maintenance ............................................53
6.1.5. Other Propeller Maintenance and Repair........................................................................... 55
7. Utility Systems (Heater/Vent) ............................................................................................................ 56
7.1. Description.................................................................................................................................. 56
7.2. Heater System.............................................................................................................................57
7.2.1. Removal of Heat Shroud ..................................................................................................... 57
7.2.2. Installation of Heat Shroud .................................................................................................57
7.3. Removal of cabin heat box.......................................................................................................... 57
7.3.1. Required Tools: ................................................................................................................... 57
7.3.2. Parts Required:.................................................................................................................... 57
7.3.3. Level of Maintenance: Line .................................................................................................58
7.3.4. Certification Required: A&P or LSA Repairman Maintenance ............................................58
7.4. Installation of cabin heat box......................................................................................................58
7.4.1. Required Tools: ................................................................................................................... 58
7.4.2. Parts Required:.................................................................................................................... 58
7.4.3. Level of Maintenance: Line ................................................................................................ 58
7.4.4. Certification Required: A&P or LSA Repairman Maintenance ............................................58
7.4.5. Verification..........................................................................................................................58
7.5. Ventilation System ......................................................................................................................59
7.6. Removal of Vents ........................................................................................................................59
7.6.1. Required Tools: ................................................................................................................... 59
7.6.2. Parts Required:.................................................................................................................... 59
7.6.3. Level of Maintenance: Line ................................................................................................ 59
7.6.4. Certification Required: Sport Pilot Certificate or higher..................................................... 59
7.7. Installation of Vents ....................................................................................................................59
7.7.1. Required Tools: ................................................................................................................... 59
7.7.2. Parts Required:.................................................................................................................... 59

Legend Aircraft Maintenance Manual –AL18 5
© American Legend Aircraft Company Rev 2.0
Date of Revision: 9/27/2013
7.7.3. Certification Required: Sport Pilot Certificate or higher..................................................... 59
7.7.4. Verification..........................................................................................................................59
8. Instruments and Avionics...................................................................................................................60
8.1. Description.................................................................................................................................. 61
8.2. Removal ...................................................................................................................................... 61
8.2.1. Required Tools: ................................................................................................................... 61
8.2.2. Parts Required:.................................................................................................................... 61
8.2.3. Level of Maintenance: Line .................................................................................................61
8.2.4. Certification Required: A&P or LSA Repairman Maintenance ............................................61
8.3. See owner’s manual....................................................................................................................61
8.4. Installation .................................................................................................................................. 61
8.4.1. Required Tools: ................................................................................................................... 61
8.4.2. Parts Required:.................................................................................................................... 61
8.4.3. Level of Maintenance: Line .................................................................................................61
8.4.4. Certification Required: A&P or LSA Repairman Maintenance ............................................61
8.5. Verification..................................................................................................................................61
9. Electrical System ................................................................................................................................ 62
9.1. Description.................................................................................................................................. 62
9.2. Schematic.................................................................................................................................... 62
10. Structural Repair ............................................................................................................................. 64
11. Painting and Coating .......................................................................................................................65
12. Revisions .........................................................................................................................................66
13. Feedback Form................................................................................................................................ 67
14. Misc.................................................................................................................................................68
14.1. Overhaul.................................................................................................................................. 68
14.2. Major Repairs and Alterations ................................................................................................68
14.3. Task-Specific Training.............................................................................................................. 69
14.4. Safety Directives......................................................................................................................69
14.5. Safety Alert.............................................................................................................................. 69
14.6. Service Bulletin........................................................................................................................ 69
14.7. Notification .............................................................................................................................69
14.8. Reporting Forms and 100 Hour/Annual Checklist ..................................................................70
Appendix A. Equipment List........................................................................................................................71
Appendix B. Reporting Forms ....................................................................................................................73
Appendix C. 100 Hour / Annual Checklist ...............................................................................................74

Legend Aircraft Maintenance Manual –AL18 6
© American Legend Aircraft Company Rev 2.0
Date of Revision: 9/27/2013

Legend Aircraft Maintenance Manual –AL18 7
© American Legend Aircraft Company Rev 2.0
Date of Revision: 9/27/2013
Table of Figures
Figure 1-1 Aircraft Specification............................................................................................................. 9
Figure 1-2 Aircraft Three View Drawing..................................................................................................... 10
Figure 1-3 Engine Specifications .......................................................................................................... 11
Figure 1-4 Sample Loading Problem ....................................................................................................12
Figure 1-5 Center of Gravity Limits ......................................................................................................12
Figure 1-6 Main Tire Inflation............................................................................................................... 12
Figure 1-7 Tailwheel Tire Inflation ....................................................................................................... 12
Figure 1-8 Lycoming YO-233 Approved Oils / Capacities..................................................................... 13
Figure 3-1 Wing View.................................................................................................................................. 15
Figure 3-2 Jackscrew ..................................................................................................................................18
Figure 3-3 Jackscrew Access .......................................................................................................................18
Figure 3-4 Torque Tube Rear ...................................................................................................................... 19
Figure 3-5 Torque Tube Front ..................................................................................................................... 19
Figure 3-6 Landing Gear.............................................................................................................................. 20
Figure 3-7 –Landing Gear Cabane / Struts ................................................................................................. 21
Figure 3-8 Landing Gear Leg ....................................................................................................................... 21
Figure 3-9 Tailwheel Rear View.................................................................................................................. 23
Figure 3-10 Tailwheel Side View ................................................................................................................. 23
Figure 3-11 Aileron Balance Cable .............................................................................................................. 24
Figure 3-12 Aileron Lower View................................................................................................................. 25
Figure 3-13 Aileron Upper View..................................................................................................................25
Figure 3-14 Elevator....................................................................................................................................27
Figure 3-15 Rudder ..................................................................................................................................... 30
Figure 3-16 Control Surface Travels ....................................................................................................... 31
Figure 3-17 Flap, Lower View...................................................................................................................... 34
Figure 3-18 Flap, Upper View...................................................................................................................... 35
Figure 4-1 Lycoming YO-233 Installation Top View .................................................................................... 37
Figure 4-2 YO-233 Gascolator .....................................................................................................................38
Figure 4-3 YO-233 Side View....................................................................................................................... 38
Figure 4-4 YO-233 Front View.....................................................................................................................39
Figure 4-5 Exhaust, Right Side.....................................................................................................................41
Figure 4-6 Exhaust, Left Side.......................................................................................................................41
Figure 4-7 Exhaust, Rear ............................................................................................................................. 42
Figure 4-8 YO-233 Alternator...................................................................................................................... 44
Figure 5-1 Fuel Tank Caps / Covers............................................................................................................. 47
Figure 5-2 Fuel Sight Gauges....................................................................................................................... 47
Figure 5-3 Fuel System Diagram ................................................................................................................. 48
Figure 5-4 Gascolator.................................................................................................................................. 50
Figure 5-5 Fuel Sight Gauges....................................................................................................................... 51
Figure 6-1 ....................................................................................................................................................54
Figure 6-2 ....................................................................................................................................................55
Figure 6-3 ....................................................................................................................................................55
Figure 7-1 Cabin Heat Inlet .........................................................................................................................56
Figure 7-2 Cabin Heat Outlet ......................................................................................................................56
Figure 8-1 Instrument Panel .......................................................................................................................60
Figure 9-1 Battery Installation ....................................................................................................................62
Figure 9-2 Electrical System Block Diagram................................................................................................ 63

Legend Aircraft Maintenance Manual –AL18 8
© American Legend Aircraft Company Rev 2.0
Date of Revision: 9/27/2013
Figure 9-3 Electrical Bus Diagram ............................................................................................................... 63

Legend Aircraft Maintenance Manual –AL18 9
© American Legend Aircraft Company Rev 2.0
Date of Revision: 9/27/2013
1. General
1.1. Manufacturer
Legend Cub aircraft are manufactured by the American Legend Aircraft
Company in Sulphur Springs, Texas. USA.
1.2. Physical Dimensions
AL18
Continental YO-233
Wing Span
35’ 6”
Length
22’ 8”
Height
(standard
wheels and
prop)
7’ 6”
Empty Weight
(standard
airplane)
845 lbs
Design Gross
Weight (land)
1320
Design Gross
Weight (sea)
1430
Useable Fuel
Capacity
30 U.S. Gallons
Seating
2 Persons, Tandem
Figure 1-1 Aircraft Specification

Legend Aircraft Maintenance Manual –AL18 10
© American Legend Aircraft Company Rev 2.0
Date of Revision: 9/27/2013
1.3. Three-View Drawing
Figure 1-2 Aircraft Three View Drawing
1.4. Materials
Legend Cub aircraft uses standard aircraft quality parts and materials.
Fuselages are made from Chromalloy 4130 tubing. Wings are built with spars
and ribs made from 6061 aluminum extrusion. Fuselage, wings and control
surfaces are covered according to the Star Gloss covering system.
1.5. Equipment List
See Appendix A for the equipment list for this aircraft.
1.6. Source to Purchase Parts
Parts can be procured directly from the component manufacturer or
American Legend Aircraft Company. For example, for avionics replacement
with the same model, aircraft owner can purchase from off the shelf
suppliers.
Our part suppliers include Garmin, TruTrak, AeroLED, and JDI. For contact
information on alternate suppliers for individual components or for more
information on the supplier of a specific component, please contact American
Legend.
1.7. List of Disposable Replacement parts
See YO-233 Lycoming Illustrated Parts Catalog for list of engine related
disposable parts.