10. Lower Fuselage Assembly Undercarriage

Transcription

1 10. Lower Fuselage Assembly Undercarriage Undercarriage

2 Jabiru Undercarriage Configurations There are four combinations of tyres available, utilising two sets of hubs (standard and heavy duty) and rim reinforcements with two different bolt combinations. Refer to Photo 10.27(a). The 400/4 and 500/6 nose tyres use a shorter noseleg and a larger nose leg yoke. Undercarriage Configuration Description Tyre Rim Hub Rim Reinforcements Standard Nose 260/4 4" STD Nil Main 400/4 4" STD Nil Medium A Nose 400/4 4" STD Nil Main 500/6 6" HD 2 (4 Bolts) Medium B Nose 500/6 6" HD 2 (4 Bolts) Main 500/6 6" HD 2 (8 Bolts) BigFoot Nose 500/6 6" HD 2 (4 Bolts) Main 600/6 6" HD 2 (8 Bolts) Photo 10.27(a) - Rims, Hubs, Reos and Tyres Undercarriage

3 Assemble Main Hubs, Rims, Tyres and Brake Disc Reference: Drawing /2, /3 Photo 10.27(a), 10.27(b) Parts Required: Standard Medium A and B BigFoot Description Qty Brake Disk (2) Wheel Hub (2) N N Rim - Main Wheel (4) AN4-6A AN4-10A AN4-10A Bolt - Wheel Halves (8) MS MS MS Nut - Wheel Halves (8) AN AN AN Washer - Wheel Halves (8) PB0029N PB0029N PB0029N Bearing (4) AN3-6A AN3-6A AN3-6A Bolt - Disk Brake (8) MS MS MS Nut - Disk Brake (8) AN AN AN Washer - Disk Brake (8) PU0019N(400/4) PU0099N (500/6) PU0079N (660/6) Tyre (2) PU0029N (400/4) PU0109N (500/6) PU0089N (600/6) Tube (2) N/A Plate Reinforcements (4) N/A AN3-10A AN3-10A Bolt - Reinforcements (16) N/A MS MS Nut - Reinforcements (16) N/A AN AN Washer - Reinforcements (16) Material Required: Nil Procedure: 1. Press 2 bearings (PB0029N) into each hub ensuring they are properly bottomed. Note: The outer bearing will be 1-2mm inside hub, not flush. 2. Insert tube into tyre and inflate lightly to avoid pinching in rim halves. 3. (a) Assemble tyre tube and wheel laves to hubs as per drawings /2 (standard), /3 (Med A, Med B and BigFoot). Refer to Photo 10.27(b). 3. (b) Med A, Med B and BigFoot only - Bolt rim reinforcements to both sides of rims as per drawing /3. Refer to Photo 10.27(b). Note: Four 3/16" holes will have to be drilled in rims. 4. Bolt brake disc to hubs as per drawing /2 and /3. Assemb Hubs, Rims, Tyres And brake Discs

4 Photo 10.27(b) - BigFoot showing Rim Reo & Photo 10.27(c) - Showing Brake Disc position Assemb Hubs, Rims, Tyres And brake Discs

5 Assemb Hubs, Rims, Tyres And brake Discs

6 Assemb Hubs, Rims, Tyres And brake Discs

7 Assemble Main Undercarriage Brakes and Wheels References: Drawing /2 (see Section 10.27) Photo 10.28(a) and 10.28(b) Parts Required: Extension Axle Stub (2) AN3-12A Bolt (2) Axle Stub (2) Mounting Plate Inner (2) PX0029N Spring (4) AN4-16A Bolt (4) Piston Body Arm (2) Piston Disk Brake (2) PD0049N Piston Seal (2) Nipple (2) Nipple (2) Piston Body (2) Brake Pad (4) PD0029N Rivet (6) PD0019N Rivet (6) Mounting Plate Outer (2) AN4-16A Bolts (4) AN4-17A Bolts (4) MS /16" Nyloc Nuts (10) MS /4" Nyloc Nuts (8) AN Metal Lock Nuts (4) Suspension Leg LS (1) N Suspension Leg RS (1) Mount Bracket Spat (2) Preassembled Main Wheel Assembly (1) Materials Required: Anti-seize or grease Rubber Grease Loctite Pipe Sealant Procedure: 1. Using shorter rivets, attach brake pads to both inner mounting plates, also using longer rivets attach brake pads to both outer mounting plates. 2. Using two AN4-16A bolts on top holes and two AN4-17A bolts on bottom holes, insert bolts through inner mounting plate, axle and main undercarriage (suspension) leg, ensuring inner brake pad is in front of the axle. As per Drawing /2 refer Photo (a) and (b). Note: Left and right undercarriage legs must be properly identified as they are not interchangeable. The mount plate is on the outside of axle flange (not between flange and leg) and facing forward. 3. Fit spat mount bracket on bottom AN4-17A bolts and bolt axle assembly together. Refer to photo 10.28(a) and 10.28(b). 4. Assemble outer brake pad mounting plate by inserting two AN4-16A bolts and placing return spring (PX0029N) on each bolt. Lightly grease axle, fit pre-assembled wheel assembly onto axle while installing outer brake pad mounting plate assembly at the same time. Refer Drawing /2 and Photo 10.28(a). 5. Secure wheel assembly by mounting extension stub axle to end of axle using AN3-12A Bolt. Refer Drawing /2 and Photo 10.28(b). 6. Thoroughly clean brake piston body, place piston body through piston body arm. 7. Screw in brake hose nipple using thread sealant. 8. Screw in bleed nipple, locking up tight several times to bed seal. Assem Main Undercarriage Brakes and Wheels

8 9. Grease piston seal and piston with rubber grease and insert into piston body as per drawing /2. Note: Use care when inserting piston into piston body as it can mark piston body if not aligned properly. 10. Mount brake piston body and arm assembly to main undercarriage as per drawing Connect brake hose to piston body nipple. Photos 10.28(a) - Main Undercarriage showing brake and axle assembly Assem Main Undercarriage Brakes and Wheels

9 Fit Undercarriage Backing Plates References: Drawings (Proc 10.30) Photo 10.29(a) Parts Required: Backing Plate - Rad (2) Materials Required: Backing Plate - Rec (4) LC3600 Resin LC3600 Hardener Fibre Flock 2" x 5/16" Steel Rod or Tube (6) Procedure: 1. Sand and trim area around the six predrilled 5/16" undercarriage mount holes in preparation for backing plates. Note and Caution: A flatter area around the top of undercarriage hole will ensure a lower fitting backing plate and removal of some glass may be desirable. However strength in this area is important and any glass removal must be kept to a minimum. 2. Grease 5/16" steel rods and insert in undercarriage holes. 3. Trial fit undercarriage backing plates over steel rods to sit as low as possible. Radius edges and reshaping of undercarriage plates may be necessary. Sand backs of undercarriage plates to provide bond key. Note: The four rectangular undercarriage plates fit over holes in front of seat backs (Photo 10.29(a)) and two radius undercarriage plates fit over holes behind seat backs. Refer to Photos 10.29(a) and Drawing Mix epoxy resin/hardener/fibreflock and place sufficient amount around steel rods to form a bed. Press undercarriage backing plates into position. Shape flock bed and smooth off with resin/hardener mix. 5. Cure and remove steel 5/16" rods. Photo 10.29(a) - Showing Front (rec) Undercarriage Backing Plate Fit Main Undercarriage Backing Plate

10 Fit Main Undercarriage Legs Reference: Drawing Photo 10.30(a) and (b) Parts Required: Suspension Leg Rear LS N Suspension Leg Rear RS Bush Suspension Leg (4) Washer Undercarriage (2) Clamp Bar Undercarriage (2) N Rubber Strip (2) AN5-26A Bolt - Leg Inner (2) AN5-31A Bolt - Leg Outer Rear (2) AN5-33A Bolt - Leg Outer Front (2) MS Nut Nyloc (6) Washer (as required) Materials Required: Nil Procedure: 1. Run a 5/16 drill through Undercarriage mount holes to make sure they are clear. 2. Position suspension legs using AN5-26A bolt, undercarriage washer and two suspension leg bushes in inner leg hole. The outer leg is held in place using clamp bar, AN5-31A bolt front, AN5-33A bolt rear, and rubber strip between leg and fuselage. Refer to Drawing assembly details. Photo 10.30(a) shows the rubber strip and undercarriage clamp bar in place. Note: The length of bolts required to mount suspension legs may vary, depending how undercarriage backing plates have been positioned. If more than three washers on each bolt is required, a shorter bolt is recommended. Fit Main Undercarriage Legs

11 Photo 10.30(a) - Undercarriage Leg Attachment Details Note: A better fit of outter clamp to undercarriage leg can be obtained by placing some resin/fibreflock mix between clamp and undercarriage leg. Photo 10.30(b) - Inner Undercarriage Mount Note: Suspension bush flange between suspension leg and undercarriage washer to be compressed to approximately half original thickness. Bolts on undercarriage clamp bar (outer mount) must be sufficiently tightended to stop later bending. Fit Main Undercarriage Legs

12 Fit Main Undercarriage Legs

13 Bleed Brake Cylinders Reference: Photo Parts Required: Material Required: Nil Brake Fluid Procedure: 1. Close bleed nipples, (Photo 10.31) and fill brake master cylinder reservoir to full mark. 2. Open one of either nipples, depress brake handle and hold depressed. 3. Close open nipple and release brake handle. 4. Repeat steps 2 and 3 until all air has been removed from line. 5. Repeat procedure for both sides. Note: Ensure master cylinder level does not drop to low during bleeding process. Photo Brake Bleed Nipple Bleed Brake Cylinders

14 Assemble Nose Wheel and Hub References: Drawing , (see 10.34) Photo Parts Required: Standard Med A Med B Description PU0009N (260 x 4) PU0019N (400 x 4) PU0099N (500/6) Tyre (1) PU0029N (260 x 4) PU0029N (400 x 4) PU0109N (500/6) Tube (1) N Rim (2) Hub (1) PB0029N PB0029N PB0029N Bearing (2) Spacer Bearing Hub (2) Front Axle (1) Materials Required: Loctite 480 Procedure: 1) Press Bearings into Hub 2) Loctite 480 Bearing Spacers ( Standard) ( Med A, Med B, Big Foot) into Bearings 3) Loctite 480 Front Axle ( Standard) ( Big Foot, Med A, Med B) into Bearing Spacers ensuring axle end flush with, or protruding slightly from spacers. (Ref Drawing Section AA, Section AA, Standard), ( Med A, Med B, Photo Big Foot). Note: If spacers protrude past axle, bearings will be side loaded and bind when wheel is mounted in yokes. Spacers must be ground back to make a flush surface with axle if necessary. 4) Assemble rims, tyre and tube on hub as per Drawing Standard, Med A, Med B and Big Foot. Photo Med A, Med B, Big Foot, Hub and Axle & Tyre assy Assemble Nose Wheel & Hub

15 SECTION ASSEMBLE RUBBER SPACER SET (This item is now supplied complete by Jabiru Aircraft) Assemble Rubber Spacer Set

16 Assemble and Fit Nose Leg References: Drawing , , Photo (a), (b) Parts Required: Standard Med A, Med B, Big Foot Description Quantity MS MS Nut (3) N/A MS Nut (4) AN3-22A AN3-22A Bolt (2) Retaining Collar Leg (1) Suspension Leg w/assy (1) Tube Suspension Rubber (1) Retaining Collar Suspension (1) Steering Link (1) AN3-6A AN3-6A Bolt (1) MS MS Bolt (1) Shaft Suspension Tensioner (1) N/A Suspension Bracket Washer (1) AN4-53A AN4-63A (AN4-72A spats) Bolt Axle (1) AN AN Washer (3) N/A AN4-7A Bolt (4) MS MS Nut (2) AN310-4 AN310-4 Castled Nut (1) AN AN Cotter Pin (1) N Bush Suspension (1) AN5-31 AN5-42 Bolt Yoke Pivot (1) Wheel Yoke RH (1) N Wheel Yoke LH (1) AN4-42A AN4-42A Bolt (1) N N Bush Suspension (1) Pre Assembled Parts Required: Proc Nose Wheel and Hub (1) Proc Rubber Spacer Set (1) Materials Required: Grease Rubber Grease Loctite 480 Procedure: 1) Grease and insert nylon front pivot bush into mount tube, welded into bottom of leg. Note: Standard Bush 50mm long, Med A, Med B, and Bigfoot, 75mm long with 5/16" hole. Bush must be able to pivot freely in mounts, some reaming of mounts may be necessary. 2) Attach yokes to front pivot bush using AN5-32 bolt standard and AN5-42 Bolt Med A, Med B and Bigfoot use castle nut. Do Not Tighten. Ref Drawings , and Photos (a), (b). Assemble & Fit Noseleg

17 Note: For Med A, Med B, and Bigfoot, Yoke Spacer ( ) is bolted between yokes at this stage. Redrilling of 3/16" mount holes may be necessary due to distortion during bending of yoke. Do Not Tighten Bolts. Ref Drawing Photo (b). 3) Assemble rubber suspension tube into suspension shaft tensioner ( ) as per Drawings and Note: Long end to hole of suspension tube goes into suspension shaft tensioner. 4) Grease and insert suspension tensioner bush into suspension tensioner (75mm long with 1/4" hole). Note: Ensure free movement, ream tensioner if necessary. 5) Bolt suspension tensioner to yokes leaving bolt untightened. 6) Fit preassembled nose wheel to yokes. Tighten all bolts. Remove nose wheel. 7) Place curved suspension bracket washer ( ) and rubber spacer set on suspension tensioner shaft. Clamp bottoms of yokes in vice and using a lever on top of nose suspension leg compress rubber spacers to fit top suspension rubber, 3mm washer and retaining collar. Retaining collar held in place with AN3-6A bolt. Ref Drawings and Re fit nose wheel, fit retaining collar ( ). 8) Re fit nose wheel, fit retaining collar ( ). 9) Fit nose leg into suspension leg housing, fit steering link onto top of leg. Note: Only one hole is provided in steering link. The second one must be drilled in situe. 10) With upward pressure on nose leg and downward pressure on steering link, drill 3/16" hole through collar. Note: A series of holes 1mm off set is provided in bottom retaining collar to provide adjustment. Increments of 0.55mm are available by inverting collar. 11 Remove nose leg, lubricate, re assemble. Assemble & Fit Noseleg

18 Assemble & Fit Noseleg

19 Photo (a) - Noseleg Assembly (Right Side) Standard Photo (b) Noseleg Assembly (Med B) Showing Yoke Spacer ( ) Assemble & Fit Noseleg

20 Assemble & Fit Noseleg

21 Assemble & Fit Noseleg

22 Assemble & Fit Noseleg

23 Fit Steering Link and Firewall Steering Grommet Reference: Photo 10.35(a) and (b) Sketch Drawing (Proc 10.19, Page 5), 30070J1 (Proc 10.24) Parts Required: N Firewall Steering Grommet (1) N Steering Push Rod (1) PB0009N Male Ball End (2) AN316-3 Nut Lock (2) AN3-12A Bolt (1) AN Washer 3/16" (2) AN Washer 1/4" (2) Spacer 3/16" ID x 3mm (1) Rivets (6) Washer 1/8" (8) Material Required: Silicon Sealant 240mm x 150mm x 4mm Ply Procedure: Note: This procedure completed after procedure Fitting Firewall Metal Sections and procedure Fit Housing Suspension Leg. 1. Cut out drilling jig from 4mm ply as per drawing 30070J1 (Proc 10.24) 2. Place drilling jig over top of nose leg housing and against firewall. Mark and drill 3/16" pilot hole for steering pushrod. Drill out pushrod hole to 3/4". 3. Assemble ball ends and locknuts to steering pushrod. Insert pushrod through firewall and bolt to bellcrank and steering link. Ref Drawing Photo Note: Spacer is used on bellcrank to provide clearance from bearing flange. AN /4" washers used on top of ball ends to provide security in case of ball end failure. 4. Move rudder pedals through full range of travel to ensure pedals are not fouling pushrod and pushrod is not fouling on firewall. Elongation of hole in firewall will probably be necessary. 5. Punch 3/8" hole in centre of steering grommet. Fold grommet in half over hole and insert 1/8" rivets using washer either side top and bottom of grommet, approx, 10mm back from front and 10mm in from edges. Ref sketch & photo 10.35a&b 6. Remove pushrod from nose leg steering link, place grommet over pushrod with loose ends to firewall. Refit pushrod to steering link. 7. Spread grommet ends onto firewall, drill 1/8" holes through four corners into firewall. Note: A long shank drill will be necessary. Cut a gap in grommet to fit over rudder stop. Rivets do not go through firewall. Seal gap between grommet and firewall with silicon and rivet into position with washers under rivet heads. Ref sketch Fit Steering Link &Firewall Steering Grommet

24 Sketch10.35 Fit Steering Link &Firewall Steering Grommet

25 Photo 10.35a Steering pushrod cover Photo 10.35b Steering pushrod cover Fit Steering Link &Firewall Steering Grommet

26 30070J1 Jig Steering Link Fit Steering Link &Firewall Steering Grommet

27 Fit Auxiliary Fuel Pump Reference: Photo 10.36(a), 10.36(b) Parts Required: PM0029N Fuel Pump PZ0069N Hosetail (2) MS Machine Screw (2) AS Tinnerman Washer (2) MS Nut (2) AN Washer (2) Material Required: Fuel Resistant Thread Sealant Procedure: 1. Attach hosetails to the fuel pump using Loctite 262 or a fuel resistant product. 2. Fit Male electrical terminals to wires. 3. Using the base of the fuel pump as a template mark the position of the bolt holes on the lower fuselage approximately 160mm back from undercarriage radius and central between LH mount and spine. Ref Photo 10.36b&c. 4. Drill and countersink 3/16" holes. Attach fuel pump to lower fuselage using machine screws, tinnerman washers, nuts and AN washers as per Photo 10.36b&C. Note: Tinnerman washers under screw heads. Ensure flow direction of pump is forward. 5. Seal hosetail ends to prevent the entry of foreign bodies to the fuel pump. Masking tape is adequate. Underneath view of Fuel pump screws MS24693C51 & tinniminum washers. #A Photo 10.36a Installation of the Auxiliary Fuel Pump Fit Aux Fuel Pump

28 Fuel Pump Note: Make sure direction of flow is facing forward FRONT OF AIRCRAFT Photo 10.36b Fuel Pump Pisition Fit Auxiliary Fuel Pump

29 Fit Fuel Lines, Filter, Fuel Tap and Tap Cover Reference: Photos Drawing /2 Parts Required: PT0019N Fuel Hose PV0019N Hose Clamp (6) PM0009N Fuel Filter (1) Cover Fuel Tap (1) Mount Bracket Fuel Tap (1) PM0019N Fuel Tap (1) PZ0019N Hose Tail 1/4 BSP - 1/4 (2) PH0199N Screw Phillips Pan Head 6g x 1/4 (10) Material Required: Procedure: Fuel Resistant Thread Sealant Loctite Run fuel hose from auxiliary pump through large hole behind seat backs and through 5/8" holes predrilled in seat pan on left hand side of main centre beam. Finish hose 90mm from front hole where fuel line re-enters main beam (Ref Photo 10.37). Connect fuel line to pump. Note: Ensure fuel line is of sufficient length to lie freely. Do not over tighten clamps. 2. Fit hosetails to tap using thread sealant and remove handle. 3. Fit tap to hose from auxiliary pump. 4. Run hose from tap through front beam and exiting rear of two 5/8" holes in top of beam. Note: Position clamps on tap to top of line. This will help secure tap behind mount. 5. Fit fuel filter between main beam and firewall fuel bulkhead fitting. (Ref Drawing ). 6. Drill and file hole to fit fuel tap mount bracket over tap handle shaft and position tap as far forward as possible (Ref Photo 10.37). Secure tap mount with 6g x 1/4" self tapping screws. 7. Refit tap handle using loctite Fit tap cover with handle in upright (OFF) position, using 6g x 1/4" self tapping screws (Ref Photo 10.37, Drawing ). 9. Ensure both ends of fuel system are sealed. Note: The connection to the Fuel Tank and to the Firewall Bulkhead Fitting are completed at a later stage. Fit Fuel Lines, Filter, Fuel Tap & Tap Cover

30 Fit Fuel Lines, Filter, Fuel Tap & Tap Cover

31 Fuel Tap Cover ¼ I.D. Fuel Line Fuel Decal Fuel Tap Photo 10.37a Fuel Tap Cover and Fuel Tap Photo 10.37b Fuel filter Fuel Filter Fuel hose Note: leave enough hose in console so it can be pulled out to change filter. Fit Fuel Lines, Filter, Fuel Tap & Tap Cover