CubCrafters CC11-100 Sport Cub Aircraft Maintenance Manual SC10000AMM Rev H 2013

CubCrafters CC11-100 Sport Cub Aircraft Maintenance Manual SC10000AMM Rev H 2013

The CubCrafters CC11-100 Sport Cub Aircraft Maintenance Manual SC10000AMM Rev H 2013 is the Cub Crafters, Inc. maintenance document prepared to ASTM F2483 for servicing and maintaining the CC11-100 Sport Cub Light Sport Aircraft. It tells a qualified owner, LSA repairman, or mechanic who may work on this airplane what inspections to run, which line tasks are authorized, how to remove and reinstall major components, and where the airframe, powerplant, and systems specifications live. The Revision H issue is dated April 18, 2013 and carries manual number SC10000AMM.

File Details

• Manual type: Aircraft Maintenance Manual (ASTM F2483 LSA practice)
• Brand / model: Cub Crafters CC11-100 Sport Cub
• Document number: SC10000AMM
• Revision / date: Revision H, April 18, 2013
• Language: English
• Page count: 360
• File format: PDF

Airplane Covered by This Manual

The CC11-100 is an externally braced high-wing light sport airplane with fabric-covered structure, conventional landing gear, and a Teledyne-Continental Motors O-200 series engine. Cub Crafters identifies locations on a three-axis grid of fuselage stations, water lines, buttock lines, and wing stations, illustrated in the aircraft geometry figure. Design gross weight is 1320 lbs on wheels and 1430 lbs as a seaplane or amphibian. Span is 411 in, length is 273 in in level-flight attitude and 290 in in three-point attitude, and maximum height is 114 in. With the Sensenich Wood Propeller Company W72GK-44 wood composite propeller and 6.00×6 wheels, tail-down height with a blade vertical is 84.5 in and propeller ground clearance is 23 in.

The wing uses a USA 35B Mod airfoil at root and tip, 63 in root chord, 0.75° dihedral measured on the underside of the front spar, 179 sq ft area, and 6.50 aspect ratio. Combined aileron area is 19.25 sq ft and combined flap area is 12.60 sq ft. The horizontal stabilizer spans 118 in with a 27 in maximum chord, -2.5° incidence in the neutral position, and 14.10 sq ft including elevators. Fin and rudder area is 11.22 sq ft. Wheel track is 75.74 in; wheelbase is 199.4 in standard and 202.4 in with 3×3 landing gear.

Powerplant, Propellers, and Servicing Data

Engine data in the CubCrafters CC11-100 Sport Cub Aircraft Maintenance Manual SC10000AMM Rev H 2013 lists the O-200-A: four cylinders, 4.062 in x 3.875 in bore and stroke, 7.0:1 compression, 201 in³ displacement, 100 hp at 2750 rpm at sea level, 29.3 in Hg maximum pressure at rated rpm, 30–60 psi cruise oil pressure, 10 psi minimum idle oil pressure, 75°F minimum oil temperature, 240°F maximum oil temperature with detergent oil, 525°F maximum cylinder head temperature, 190 lb dry weight, 6 quart oil sump, 1800-hour recommended TBO, and 180–190 in-lbs engine-mount torque. Operating limits are referred to the Teledyne-Continental Motors engine operator’s manual. The airframe text also describes the powerplant as an air-cooled four-cylinder Teledyne-Continental Motors O-200 capable of up to 100 hp.

Approved or listed propellers include the Sensenich W72GK-44 72 in wood composite, McCauley 71-41 and 75-38 metal propellers, a Sensenich 72 in ground-adjustable composite propeller, and Catto wood/fiberglass composite propellers. Dry propeller-bolt torque ranges given in the specific-torque table are 175–225 in-lbs for the W72GK-44, 300–360 in-lbs for the McCauley metal propeller, 340–360 in-lbs for the Sensenich composite propeller, and 300–360 in-lbs for spark plugs.

Fuel is Aviation Grade 100/100LL at 25 US gallons total and 24 US gallons usable. Oil capacity is 6 quarts using SAE J-1966 non-dispersant mineral oil and SAE J-1899 ashless-dispersant grades, SAE 40 or SAE 50 above 40°F and SAE 20W-50 or SAE 15W-50 below 40°F. The engine must run mineral (non-detergent) oil, MIL-C-6529 Type II, for the first 25 hours; after break-in, oils must conform to Teledyne-Continental Motors Specification MHS-24. Brake hydraulic fluid is MIL-H-5606G (Aeroshell #41 listed among consumables). Main-tire dry-air pressures are 29 ± 2 psi for 6.00×6, 23 ± 2 psi for 8.00×6, 18 ± 2 psi for 8.50×6, and 6–12 psi for 26 in and 29 in Airstreak tundra tires. Tail-wheel pressures are 50–60 psi for the ABW 3200-Type and 8–20 psi for the ABW-3200B Tundra. Consumable references include K&N HP1008 oil filter (if equipped) and air filter SC54108-001.

Who May Do the Work

Scope chapters in the CC11-100 Sport Cub maintenance manual separate pilot/owner servicing, preventive 100-hour and annual/condition inspections, and line maintenance. Pilot/owner tasks follow the intent of 14 CFR Part 43.3 preventive maintenance for a person holding at least a light-sport pilot certificate. Line maintenance, minor repair, and minor alteration are written for an LSA repairman with an inspection or maintenance rating. Heavy maintenance, major repairs, and major alterations as outlined in ASTM F2483 Sections 7 through 9 are not authorized in this document for the Sport Cub; those tasks may be performed only by Cub Crafters, Inc. or under Cub Crafters approved engineering data. Chapters 7–9 still appear so the reader can see the authorization boundary, overhaul-component list, and alteration documentation path. Type-specific training called out by Cub Crafters includes a Continental O-200 overhaul and heavy-maintenance course and the EAA Sport Air fabric-covering course.

Chapters Covered

• 1 Scope: owner contact duty, safety-of-flight reporting, pilot/owner servicing, preventive and corrective maintenance limits
• 2 Reference Documents: ASTM F2483, F2245, F2295, 14 CFR Part 43
• 3 Terminology: LSA, inspections, line vs. heavy maintenance, repairman ratings, major vs. minor work, overhaul
• 4 Significance and Use
• 5 Aircraft Maintenance Manual: format; specifications and data; periodic and annual inspection requirements; maintenance of primary structures (fuselage, wings, empennage, flight controls, landing gear, wheels and brakes, engine mount, engine, fuel, propeller, utility systems, avionics and instruments, electrical, seats); structural repairs; painting and coatings
• 6 Line Maintenance, Repairs and Alterations: authorization tables; 100-hour and annual/condition inspections; fluid servicing; jacking and lifting; removal and replacement of fuselage, wings, empennage, flight controls, landing gear, wheels and brakes, engine mount, engine, engine controls, induction, exhaust, cowl, fuel, propeller, electrical power, ignition, lighting and electrical, stall warning, hoses and lines; leveling and weighing; parking and mooring; fabric, sheet-metal, and composite non-structural repairs; service-directive and major-repair notes; Appendix A
• 7 Heavy Maintenance, Repairs and Alterations: authorization (none authorized in this issue except through Cub Crafters)
• 8 Overhaul: engine, propeller, carburetor, carburetor air box, starters/generators/alternators, instruments, avionics, oil cooler
• 9 Major Repairs and Alterations: ASTM evaluation, affidavit, test programs, owner records
• 10 Task-Specific Training
• 11 Safety Directives Compliance: continued airworthiness, types of directives, how to obtain safety-of-flight information

Taken together, the CubCrafters CC11-100 Sport Cub Aircraft Maintenance Manual SC10000AMM Rev H 2013 is the working book for keeping a Sport Cub in condition for safe operation: station geometry and torque tables at the front, inspection task lists in Chapter 5.3, then the Chapter 6 procedures a line technician actually uses to jack the airplane, pull a wing or tail surface, service wheels and brakes, change oil and screens, time magnetos, rig cables, and patch non-structural fabric or composite. Weight and balance numbers themselves are referred to the CC11 Pilot’s Operating Handbook and Airplane Flight Manual SC10000AFM Section 6 rather than duplicated here.

Inspections, Rigging, and Line Procedures

Periodic and condition inspection requirements spell out annual condition inspection tasks and the 100-hour inspection used when the airplane is flown for hire. Line-maintenance servicing warns against mixing brands of oil or lubricant and against unapproved fluids, and it tells operators to shorten intervals in salt, dust, humidity, or unimproved-field use. A lubrication chart assigns products such as LPS 2, Mobilgrease 28, Champion Aerospace 2612 spark-plug thread lubricant, Dow Corning 4, and EZ TURN to engine, cockpit, fuselage, and landing-gear points.

Control-surface travels and cable tensions are printed in the specifications chapter: ailerons 18° ± 2° up and down at 40 ± 5 lbs cable tension; flaps 15° ± 3°, 35° ± 3°, and 50° ± 3° at the three notches; stabilizer neutral -2.5° relative to the longitudinal axis, 2.5° ± 0.5° up and 4° ± 0.5° down; elevators 25° ± 2° up and 15° ± 2° down at 60 ± 2 lbs; rudder 25° ± 2° left and right. Chapter 6.3 then walks through aileron and flap hinge hardware, turnbuckle safety (no more than three threads showing), elevator and rudder clevis-pin installations, and tail-brace-wire rigging revised in Revision H.

IMAGES PREVIEW

Jacking instructions cover raising the tail onto a sawhorse, jacking from a main axle, and jacking from the wing one side at a time. Wing work includes dihedral and washout checks (3 in ± 0.13 in string measurement at the inboard front spar cap). Landing-gear coverage includes standard and optional 3200-type steerable tail wheels, leaf springs, and wheel-and-brake disassembly with exploded views. Engine line tasks cover oil drain and spin-on filter K&N HP1008, oil-pressure screen, oil cooler, pin-vice and heavy-duty throttle cables, mixture cable, air filter SC54108-001, carburetor heat, standard and performance exhaust, and composite cowl removal. Fuel work includes tank configurations with an additional drain added in Revision H, strainer bowl service, carburetor inlet screen, and fuel-selector overhaul. Ignition text describes dual impulse-coupled magnetos, firing order, and Slick 4001 non-adjustable magnetos on some O-200 engines. Electrical power identifies a B&C Specialty Products BC433-H 30-ampere externally regulated gear-driven alternator, a matching 3-phase permanent-magnet regulator, and a 12-volt high-torque starter; lighting and ELT schematics include the ME-406 ELT and an incandescent lighting schematic applicable to S/N 00001 through S/N 00106. Instrument coverage includes Standard, Deluxe VFR, Deluxe VFR II, Executive Glass, and MyPanel layouts.

Structure, Fabric, and Records

The fuselage is a welded steel frame, powder coated against corrosion. Non-structural repair chapters cover fabric hole patches and rib lacing (square knot start, modified seine knot, splice knot), non-structural sheet metal, composite patches, and a fabric-rivet section added in Revision H. Painting and coatings are treated separately. Parking and mooring specify propeller position for storage, wing tie-down rings at the forward lift struts, and chocking. Owner forms include change of address/ownership and the Continued Operational Safety reporting form required under ASTM F2295. Safety-of-flight notices, service alerts, and later manual supplements are directed to Cub Crafters at 1918 South 16th Avenue, Yakima, WA 98903.

Use This Manual on the Job

With the CubCrafters CC11-100 Sport Cub Aircraft Maintenance Manual SC10000AMM Rev H 2013 in hand, an authorized person can plan and record 100-hour and annual condition inspections, service 100LL fuel and six quarts of approved oil, set tire pressures for 6.00×6 through tundra mains and both tail-wheel types, torque propeller bolts and airframe fasteners to the printed dry-torque tables, rig flight-control travels and cable tensions, jack and level the airframe, R&R wings, empennage, landing gear, wheels, engine accessories, fuel components, and electrical units, and make the non-structural fabric, metal, and composite repairs the line chapters allow. Correct travels, tensions, torque values, and fluid specs matter on a 1320 lb LSA because a few degrees of aileron or a few pounds of cable tension change how the Sport Cub flies, and over-torque or the wrong oil shows up as cracked mounts or an engine that will not stay within the 30–60 psi / 240°F limits. Download the PDF immediately after purchase—no shipping—open it on any device, and print the inspection, torque, and rigging pages you need in the hangar.