Zenith ZODIAC 601 XL User manual

ZODIAC
601 XL
Zenith Aircraft Company
www.zenithair.com
FUSELAGE ASSEMBLY
6-B-19 - Page 1 of 12
Revision 2 (08/18/05)
© 2004 Zenith Aircraft Co.
Rear view.
Remove the baggage floor to
install the flap controls.
NOTE: The control tube can
also be installed by access
through the bottom fuselage
access door 6B3-8
Front view.
Electric flap actuator bolted
behind left seat.

ZODIAC
601 XL
Zenith Aircraft Company
www.zenithair.com
FUSELAGE ASSEMBLY
6-B-19 - Page 2 of 12
Revision 2 (08/18/05)
© 2004 Zenith Aircraft Co.
Layout and pre-drill 12 rivets in 2 lines.
6B19-9
FLAP MOUNT GUSSET
Installed on left side.
First drill the O/B flange to the fuselage side.
Top corner even with the top
flange of the seat panel 6B5-1

ZODIAC
601 XL
Zenith Aircraft Company
www.zenithair.com
FUSELAGE ASSEMBLY
6-B-19 - Page 3 of 12
Revision 2 (08/18/05)
© 2004 Zenith Aircraft Co.
6 RIVETS A5
(6B19-9 into 6B16-3)
5 RIVETS A5
(6B19-9 into 6B5-1 & 6B16-5)
3 RIVETS A5
(6B19-9 into 6B5-1 & 6B16-5
& 6B16-3)
Clamp the flap actuator mount 6B19-6 on the back side of the seat
panel angle 6B16-5. Back drill the front holes through the gusset
6B19-9
Remove the seat back side channel 6B16-3 to drill the top flange.
8 RIVETS A5
IN EACH FLANGE of 6B19-6
6B19-6
FLAP ACTUATOR MOUNT
Rear view
Remember to rust paint all
steel part.
“RUSTOLEUM” aerosol spray
paint is adequate protection.

ZODIAC
601 XL
Zenith Aircraft Company
www.zenithair.com
FUSELAGE ASSEMBLY
6-B-19 - Page 4 of 12
Revision 2 (08/18/05)
© 2004 Zenith Aircraft Co.
Left flap.
On the finished aircraft the
piano hinge is in line with the
center of the flap control tube
6B19-1 and 6B19-2.
Bolt and clamp the wing jig 6-B-13 to the spar and attach plate 6B5-4.
With a level, check that the fuselage reference line is level. Adjust the
back of the jib until the top of the jib is level.
CHECK: Ref top right diagram
on drawing 6-S-3, 325mm
from the top edge of the
forward side skins 6B11-2 to
the top of the rear channel
6W7-1

ZODIAC
601 XL
Zenith Aircraft Company
www.zenithair.com
FUSELAGE ASSEMBLY
6-B-19 - Page 5 of 12
Revision 2 (08/18/05)
© 2004 Zenith Aircraft Co.
Clamp a piece of piano hinge to the bottom flange of the rear channel
6W7-1
Trace the position of the hinge
on the side of the fuselage.
Locate the center of the hinge.
Drill a pilot hole.

ZODIAC
601 XL
Zenith Aircraft Company
www.zenithair.com
FUSELAGE ASSEMBLY
6-B-19 - Page 6 of 12
Revision 2 (08/18/05)
© 2004 Zenith Aircraft Co.
Drill the 1” hole in the fuselage side skin for the flap control tube.
Cut and cleco the diagonal L angle, Ref bottom left diagram 6-B-5
Outside view of right side.
Locate and drill the 1” hole to line up with the center of the piano hinge
6W1-4 (pin). Bolt the bearing to the channel.
6B19-5
FLAP CONTROL BEARING
AN3-5A BOLTS
QTY=2

ZODIAC
601 XL
Zenith Aircraft Company
www.zenithair.com
FUSELAGE ASSEMBLY
6-B-19 - Page 7 of 12
Revision 2 (08/18/05)
© 2004 Zenith Aircraft Co.
6B19-2
LEFT FLAP CONTROL TUBE
Welded flap assembly with ¼” rod for flap control plate 6W1-3
8B19-3
FLAP CONTROL ARM
Welded assembly 1” inside
diameter
STEEL SHIM P/N 4088A-416 inside diameter = 1” fits between
welded stop ring and bearing 6B19-5
AN3-14A BOLTS
QTY=2

ZODIAC
601 XL
Zenith Aircraft Company
www.zenithair.com
FUSELAGE ASSEMBLY
6-B-19 - Page 8 of 12
Revision 2 (08/18/05)
© 2004 Zenith Aircraft Co.
Detail of the right O/B side 6B19-1

ZODIAC
601 XL
Zenith Aircraft Company
www.zenithair.com
FUSELAGE ASSEMBLY
6-B-19 - Page 9 of 12
Revision 2 (08/18/05)
© 2004 Zenith Aircraft Co.
Flaps up position: forward micro switch activated
D145-00-36-3
FLAP ACTUATOR
Electric 12V
Flap down position: Rear micro switch activated.
Electrical circuit diagram,
see
Drawing 6-B-20

ZODIAC
601 XL
Zenith Aircraft Company
www.zenithair.com
FUSELAGE ASSEMBLY
6-B-19 - Page 10 of 12
Revision 2 (08/18/05)
© 2004 Zenith Aircraft Co.
Detail of rear micro switch.
Note: The front micro switch is mirror image: the writing in against the
aluminum block (it is not recommended to remove and reinstall the
switch).
CAUTION: The black plastic
material of the micro switch
is very brittle, to not attempt
to bend the connectors; this
could cause the casing to
crack.
FLAP ACTUATOR ROD
6B19-7
Detail of set screw. Open the
set screw to screw the Rod
to the actuator. Tighten the
set screw upon final
installation.

ZODIAC
601 XL
Zenith Aircraft Company
www.zenithair.com
FUSELAGE ASSEMBLY
6-B-19 - Page 11 of 12
Revision 2 (08/18/05)
© 2004 Zenith Aircraft Co.
Insert the FLAP ACTUATOR BUSHING 6B19-8 through the 3/8” hole at
the front of the actuator.
6B19-7
FLAP ACTUATOR ROD
AN6-16A BOLT
QTY=1
(6B19-6 through 6B19-8)
The builder of the aircraft in this photo installed a panel mount flap
indicator; notice the remote servo on the front side of the channel.

ZODIAC
601 XL
Zenith Aircraft Company
www.zenithair.com
FUSELAGE ASSEMBLY
6-B-19 - Page 12 of 12
Revision 2 (08/18/05)
© 2004 Zenith Aircraft Co.
Detail of the flap control arm 6B19-3 in the flap up position.
CHECK: There is some clearance between the front of the arm and the
aft edge of the rear frame channel 6B5-2
Photo of the flaps down:
CHECK: There is some
clearance between the rod
and the top of the channel.
Flaps down, approximately 27 degrees (flap actuator fully extended on
the worm gear).
Neutral