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.