Grumman American GA-7 COUGAR Maintenance Manual Download

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Summary of Contents for GA-7 COUGAR

Page 1: ...NCE MANUAL MODEL GA 7 COUGAR GRUMMAN OMllL O lftfl ISSUED July 15 1977 REVISED July 10 1978 GRUMMAN AMERICAN AVIATION CORPORATION P O Box 2206 Savannah Georgia 31402 GRUMMAN AMERICAN AVIATION CORPORAT...

Page 2: ...reproduce this publication No part may be reproduced stored in any retrieval system or trans mitted in any part or form or by any means electronic photocopying microfilm microfiche mechanical or other...

Page 3: ...77 20 1 0 July 10 78 20 2 0 July 15 77 20 24 July 15 77 21 July 15 77 214 July 10 78 21 2 1 July 15 77 21 2 2 July 15 77 21 4 1 July 10 78 21 4 1 21 4 1 July 15 77 July 15 77 22 July 15 77 22 1 1 22...

Page 4: ...77 24 3 2 101 and 102 July 15 77 30 14 2 thru 4 July 15 77 24 3 2 201 thru 205 July 15 77 30 14 201 July 15 77 24 3 2 206 July 10 78 30 1 1 1 July 15 77 24 3 2 207 July 15 77 30 1 1 101 July 15 77 24...

Page 5: ...4 1 1 1 and 2 July 15 77 55 1 1 201 and 202 July 15 77 34 1 1 101 July 15 77 55 2 1 1 July 15 77 34 1 1 201 thru 203 July 15 77 55 2 1 201 thru 203 July 15 77 34 1 2 1 July 15 77 34 1 2 101 July 15 77...

Page 6: ...ly 15 77 74 1 1 201 thru 204 July 15 77 74 2 1 1 July 15 77 74 2 1 201 thru 203 July 15 77 77 1 and 2 July 15 77 774 1 July 15 77 77 1 1 1 and 2 July 15 77 77 1 1 101 July 15 77 77 1 1 201 and 202 Jul...

Page 7: ...BRUMMAN A RtfmBM iM i MM vWlM GA 7 COU6AR MAINTENANCE MANUAL RECORD OF REVISIONS REV NO ISSUE DATE DATE INSERTED BY REV NO ISSUE DATE DATE INSERTED BY REV NO ISSUE DATE DATE INSERTED BY i i i i...

Page 8: ...igP JP N BRUMMAN Mfldr Otg WIl Tfl IM GA 7 COUGAR MAINTENANCE MANUAL RECORD OF TEMPORARY REVISIONS TEMPORARY REV NO PAGE NUMBER ISSUE DATE BY DATE REMOVED BY...

Page 9: ...king and Mooring Placards and Markings Servicing AIRFRAME SYSTEMS Standard Practices Airframe Air Conditioning Auto Flight Communications Electrical Power Equipment Furnishings Flight Controls Fuel Ic...

Page 10: ...C0UGAR MAINTENANCE MANUAL TITLE PROPELLER Propellers POWER PLANT Power Plant General Engine Fueland Control Ignition Engine Indicating Exhaust Oil Starting CHARTS Charts CHAPTER NO 61 71 73 74 77 78...

Page 11: ...s and distribution equipment for the electrical system There is not a chapter in this manual specifically designated for instruments Details of individual branch electrical or instrument systems will...

Page 12: ...e first page ofeach block is placed on aright hand page FIGURE IDENTIFICATION Figures illustrations are numbered consecutively within each topic subject as follows Figures in Description 1 2 3 4 5 etc...

Page 13: ...dded to theinitial manual will beidentified by thedate of revision atthebottom of the page Pages issued with theoriginal manual are identified with theissue date of themanual Each revision also contai...

Page 14: ...TS Description Operation General Inspection Details 5 2 1 SCHEDULED MAINTENANCE CHECKS Description Operation General Maintenance Practices Annual or 100 Hour Inspection Procedures 5 5 1 UNSCHEDULED MA...

Page 15: ...7 COUGAR V MAINTENANCE MANUAL TIME LIMITS MAINTENANCE CHECKS DESCRIPTION OPERATION 1 General This Chapter contains the manufacturer s recommended time limits scheduled and unscheduled maintenance che...

Page 16: ...r these requirements the front spar lower cap at W S 76 60 and W S 22 416 The service livesof these two critical areas as defined by structural analysis are shown in Figure 1 As on going fatigue testi...

Page 17: ...luded in this section may be used by the owner inspector ormechanic to ensure complete and comprehensive coverage of the inspection requirements The format of the procedures can be reproduced for read...

Page 18: ...X LANDING GEAR 1 Main gear strut lubrication strut extension and fluid level 2 Nosegear strut lubrication strut extension and fluid level 3 Nose and main wheel bearing lubrication 4 Perform gear retr...

Page 19: ...iring 15 Oil temperature lines fittings and wiring 16 Manifold pressure lines fittings and wiring 17 Propeller and spinner 18 Alternator belt 19 Cylinders crankcase accessory section and front cranksh...

Page 20: ...lding X m NOTES c d e g h Clean and repack wheel bearings at first 100 hours Inspect wheel bearing grease for contamination and solidification at each annual or 100 hour inspection Do not exceed 500 w...

Page 21: ...pulley contact area for examination If filter has any holes or torn spots or is 50 percent covered with foreign material it should be replaced Do not blow off filter with compressed air or attempt to...

Page 22: ...ce Bulletins Letters for compliance at the time specified thereon 2 Check that the following aircraft documents are presentand in order Aircraft AirworthinessCertificate Form FAA 8100 2 Aircraft Regis...

Page 23: ...erlooked any areas even though he may not have previous experience on this particular model aircraft Once a mechanic becomes familiar with this aircraft he may wish to prepare his own checklist whichm...

Page 24: ...eft Right 3 Oil Temperature Average Ambient Air Above 60 F 30 to90T 0oto70 F Below 10T 4 Manifold Pressure Oil Inlet Temperature Desired Maximum 180 F 82 C 180 F 82T 170 F 77t 160 F 71 C Actual Left 2...

Page 25: ...hes as required Cracks may be welded 4 Inspect front crankshafts sealand blade hub dome areafor oil leaks 5 Inspect propeller governor forcondition andevidence of oilleakage 6 Check propeller mounting...

Page 26: ...Check all controls for clearance and proper operation 11 Check all interior bond lines for any indication of damage peeling corrosion or cracking 12 Check flap actuator push rods limit switches and i...

Page 27: ...ck electricalwiring for condition and secure connections 8 Inspect bond lines for any indication of damage peeling corrosion or cracks 9 Check horizontal and vertical stabilizers for damageand securit...

Page 28: ...wing tips and access panels F MAIN LANDING GEAR GROUP 1 Remove wheels and check for cracks Check condition of brake linings and wheel cylinders Pack wheel bearings reinstall wheels and key axle nuts...

Page 29: ...ication at each annual or 100 hour inspection Do not exceed 500 wheel miles between repacking intervals For operation in dusty areas or areas of high humidity repack every 100hours Perform a complete...

Page 30: ...ting systems for operation 17 Check radio foroperation 18 Check leftand right engine idle speed 600 to 650 rpm and mixture setting 19 Check left and right idle cutoff on carburetor for proper operatio...

Page 31: ...tives complied with 4 Allmanufacturer s Service Letters Bulletins and Alert Bulletins complied with 5 Check for proper Pilot s Operating Handbook availability 6 Aircraft papers in proper order Make lo...

Page 32: ...tilating systems for operation 17 Check radio for operation 18 Check left and right engine idle speed 600 to 650 rpm and mixture setting 19 Check left and right idle cutoff on carburetor for proper op...

Page 33: ...cturer s Service Letters Bulletins and Alert Bulletins complied with 5 Check for properPilot s OperatingHandbook availability 6 Aircraft papersin proper order Make log book entry 7 This aircraft has b...

Page 34: ...f the aircraft should be inspected for subsequent damage Applicable groups in Figure 201 Section 5 2 1 should be used as a guideline when performing the unscheduled inspection required as a result of...

Page 35: ...ckled or damaged mount flanges can normally be repaired using the procedures in AC43 2 Inspect horizontal and vertical stabilizer elevator rudder and aileron mounting brackels for damage cracks and sc...

Page 36: ...01 2 Tapping Gently tap the bondline with acoin orsimilar metal object toverify the existence ofa bondline separation Slowly move along the bondline while tapping and listen for a change in tone as th...

Page 37: ...6 DIMENSIONS AND AREAS TABLE OF CONTENTS 6 0 PRINCIPAL DIMENSIONS General Principal Dimensions GA 7 Cougar Aircraft 6 1 1 STATION LOCATIONS General Station Locations GA 7 Cougar Aircraft 6 2 1 SPECIFI...

Page 38: ...Cougar Aircraftare provided in this section Principal Dimensions Principal dimensions of the GA 7 Cougar are shown in Figure 1 Propeller tip to ground clearance areas follows Static 10 inches nominal...

Page 39: ...STATIC GROUND LINE GRUMMAN M lP30 g M VDATDIaJIRfl GA 7 C0UGAR MAINTENANCE MANUAL U 6FT8IN J PrincipalDimensions GA 7 Cougar Aircraft Figure 1 10 FT 4 1 4 IN 6G72 1 6 0 Page 2 July 15 77...

Page 40: ...A 7 COUGAR MAINTENANCE MANUAL STATION LOCATIONS 1 General This section providesstation locations for the GA 7 Cougaraircraft 2 Station Locations Station locations for the GA 7 Cougaraircraftarcshown i...

Page 41: ...ATOOIR GA 7 COUGAR MAINTENANCE MANUAL BL VVS 70 00 23 00 WS 85 50 FS FS fs FS WL 2 00 35 00 50 00 115 00 23 00 Station Locations GA 7 Cougar Aircraft Figure 1 WS 184 38 WS 131 566 FS FS 284 00 319 096...

Page 42: ...wn 30 degrees 2 degrees Horizontal Tail Span 14 00 feet Area 49 21 square feet Aspect Ratio 3 983 to 1 Dihedral 7 degrees 00 minutes Incidence 0 degrees Elevator Travel Up 17 degrees 1 degree Down 16...

Page 43: ...Ambient temperature of 70 F 21 C 118 U S gallons 98 3 Imperial gallons 446 6 liters Each Tank 59U S gallons 49 1 Imperial gallons 223 3 liters Total Usable 114U S gallons 94 9 Imperial gallons 431 5...

Page 44: ...l GA 7 C0UGAR MAINTENANCE MANUAL CHAPTER 7 LIFTING AND JACKING TABLE OF CONTENTS 7 0 LIFTING AND JACKING POINTS General Liftingand Jacking Points 7 1 1 LIFTING AND JACKING PROCEDURES General Jacking P...

Page 45: ...Cougar Aircraft areidentified in this section 2 Lifting and Jacking Points Lifting and jacking points for the GA 7 Cougar Aircraftareshown in Figure 1 1 Forward Jack PadFuselage Station 50 00 Left But...

Page 46: ...Place a minimum 1 ton capacity aircraft jack at each jack pad The forward jack pad is located beneath the forward fuselage The wing jack pads are located just inboard ofthe engine nacelles at the tra...

Page 47: ...cator light isout before proceeding Place the MASTER switch in the OFFposition CAUTION MAKE SURE THE AREA BENEATH THE AIRCRAFT IS CLEAR BEFORE LOWERING 2 Make sure the parking brake is released Releas...

Page 48: ...NTS NUMBER 8 0 AIRCRAFT PREPARATION General Preparation Procedure 8 1 1 LEVELING General Leveling Procedure 8 2 1 WEIGHING General Weighing Procedure 8 3 1 MEASURING ARM General Measuring Procedure 8...

Page 49: ...mmended operating pressure and service theshock struts Chapter 12 B Drainall fuel from the tanks and fuel system C Drain all oil from the oil system D Place all controls in the neutral position E Rais...

Page 50: ...on 8 2 B If required placescales minimum1 toncapacity under each wheel NOTE Release air from the tire on the high end to level airplane C Place a level underneath the fuselage at right angles to the a...

Page 51: ...ityto support the aircraft WeighingProcedure A Place the aircraft on scales and level Refer to Section 8 1 1 B Read each scale and record theindicated weight in the Scale Reading column Figure 1 C Rec...

Page 52: ...aircraft centerline beneath the fuselage connect a plumb bob so that it hangs from Fuselage Station 50 00 Fuselage Station 50 00 is the forward side of the forward cabin bulkhead 3 Along the aircraft...

Page 53: ...1000 LBS IN 232076 0 1 932 1 008 233 084 Aircraft Net Weight W Oil 16 Qts at 1 875 Lb Qt Total _ JJ MeJFuel_ 50Gal at 6 LB Gal Equipment Changes Aircraft Licensed Empty Weight 1 F S 22 000 SAMPLE AIR...

Page 54: ...nformation previously recorded calculate the aircraft C G Arm using the formula given in Figure 1 Section 8 3 1 D Enter the Aircraft Net Weight W and C G Arm Step 2 C into the Aircraft Licensed Empty...

Page 55: ...Ku llft GA 7 COUGAR MAINTENANCE MANUAL NUMBER 9 0 TOWING General General Precautions Towing Procedures 9 1 1 TAXI1NC General Taxiing Technique CHAPTER 9 TOWING AND TAXIING TABLE OF CONTENTS PACE 1 1 1...

Page 56: ...t numbers General Precautions A Makesure the parking brake is releasedand remove any chocks B Do not use either propeller for ground handling Serious damage could result especially if pressure is exer...

Page 57: ...e it as far toward the handle as it will go 2 Unfold the towbar and slide the thumbscrew to the other end of the slot Tighten the thumbscrew hand tight B Attach the towbar to the towbar attach points...

Page 58: ...ANE DO NOT EXCEED THE TURN LIMITS 35 MARKED ON THE TRUNNION FOLLOW THE PLACARDED INSTRUCTIONS ON THE NOSE LANDING GEAR C Remove chocks release the parking brakes and tow the aircraft by pushing or pul...

Page 59: ...urns of this type are not recommended 2 Taxiing Technique All taxiing should he done at slow speed the rate depending upon ground conditions proximity of other aircraft ground obstructions and wind co...

Page 60: ...DIRECTION CONTROL POSITION 1 Fwd Wheel Neutral Back 2 Fwd RH Quarter Wheel Right Back 3 Aft RH Quarter Wheel Left Forward 4 Aft Wheel Neutral Forward 5 Aft LH Quarter Wheel Right Forward 6 Fwd LH Quar...

Page 61: ...7 COUGAR MAINTENANCE MANUAL NUMBER 10 0 PARKING General Parking Precautions Parking Practices 10 1 1 MOORING General Normal Tiedown Severe Weather Precautions CHAPTER 10 PARKING AND MOORING TABLE OF C...

Page 62: ...0 1 1 C If heavybraking has been done in landing allowthe brakes to cool before setting the parkingbrakes D Do not set the parking brake when the ambient temperature is near or below freezing Accumula...

Page 63: ...re The wing tiedown fittings are located at the inboard edge ofthe wing tip cap beneath the wing The tail tiedown fitting islocated beneath the fuselage attheforward end of thetail cone CAUTION IF MAN...

Page 64: ...7 C0UGAR MAINTENANCE MANUAL CHAPTER 11 PLACARDS AND MARKINGS TA BLE OF CONTENTS NUMBER PAGE 11 0 PLACARDS AND MARKINGS General I Placard Locution 1 11 1 1 EXTERIOR PLACARDS I 11 2 1 INTERIOR PLACARDS...

Page 65: ...d or flight safety data required by FAA regulations Also covered in this chapter are placards which provide the pilot passengers and maintenance personnel with aircraft operational data 2 Placard Loca...

Page 66: ...SatgAL MflLMTl I GA 7 C0UGAR MAINTENANCE MANUAL GRUMMAN AMERICAN Located on each side of vortical stabilizer Located on eachsideof aft fuselage Exterior Placards Figure 1 Sheet 1 of 4 11G72 1 1 II I I...

Page 67: ...VE 4 EXTEND STRUT HOLD VERT 5 FILL TO OVERFLOW WITH MIL H 5606 HYD FLUID 6 FULLY COMPRESS STRUT TO REMOVE EXCESS OIL 7 REPLACE FILLVALVE 8 WITH NO LOAD ON STRUT INFLATE WITH NITROGEN OR CLEAN AIR TO M...

Page 68: ...AVANNAH QEORGlA 3140 U S A MODEL NO i I SERIAL NO C TYPE CERT NO C PROD CERT NO C J 9 j6 Located on fuselage sideunderleft horizontal stabilizer DO NOT PAINT VANE OR SLOT Located on stall warningswitc...

Page 69: ...ION 12 VOLT DC ONLY MASTER SW MUST BE ON PRIOR TO STARTING ENGINE Located next to auxiliary power receptacle inside of door Located on fuselage above upper entrance doorlatch GRUMMAN AMERICAN AVIATION...

Page 70: ...ocated on instrument panel GRUMMAN AMERICAN yar Located on control wheels o o THROTTLE PROP M XTURE OPEN RPK RICH o ioki Ft LEAN O NOSE O C LEFT 3 O NOSE o RIGHT Located on control quadrant Interior P...

Page 71: ...ebehh Located on instrument panel MICROPHONE JACK Located forward center lower console Located on aft cabin bulkhead TURN OFF STROBE IN CLOUD FOG OR HAZE TAXI WITH STROBE OFF Locatedin view of pilot...

Page 72: ...fT MAINTENANCE MANUAL LDG GEAR EMERGENCY DOWN PULL KNOB Located on left side of control quadrant Located on aileron trim control knob Locatedon instrument panel optional Interior Placards Figure 2 She...

Page 73: ...CAPACITY 175 LBS MAX FOR ADDITIONAL LOADING INSTRUCTIONS SEE WEIGHT a BALANCE DATA NO HEAVY OBJECTS ON HAT SHELF Located on aft cabin bulkhead WARNING TO AVOID DAMAGE LATCH HANDLE MUST BE IN OPEN POSI...

Page 74: ..._SS fIALT O O OFF WARM O O O o OFF RIGHT CABIN AIR Located on instrument panel l WARNING 1 STARTER FLAP PITOT p LEFT i LG GEAR STALL ALT BPRIMER MOTOR HEATER ALT FIELO ooooooooo ooooooooo LG NAV STROB...

Page 75: ...NE RIGHT ENGINE O py0H CROSS SELECT pushCJ TO w SELECT FEEO 5 OFFn_ fj OFF LEFT TANK RIGHT TANK Located on aft console CONTROL LOCK o REMOVE BEFORE STARTING ENGINE Located on left hand control column...

Page 76: ...ENCY EXIT OPEN CLOSE I ROTATE UPPER LEVER TO OPEN 2 PULL LOWER HANDLE IN THEN UP Located on left hand side above emergency exit window GRUMMAN AMERICAN NXXXXX Located on Instrument Panel Interior Plac...

Page 77: ...efueling Defueling Engine Oil Replenishing Brake Fluid Replenishing Tire Inflation Battery Fluid Replenishing Landing Gear OleoStruts Replenishing Servicing 12 2 1 SCHEDULED SERVICING General EngineOi...

Page 78: ...ed Hydraulic Reservoir Landing Gear Servicing Hydraulic Fluid Contamination Check 12 3 1 UNSCHEDULED SERVICING General Ice and Snow Removal Battery Servicingand Charging External Cleaning Internal Cle...

Page 79: ...r maintenance In addition to the normal access provided by the engine cowlings other openings which are covered by removable plates are listed in Figure 3 Access to the interior of the aft fuselage is...

Page 80: ...GRUMMAN A M lr30 SAIftl mffl nWM GA 7 C0UGAR MAINTENANCE MANUAL DETAIL A Servicing Points Figure 1 Sheet 1 of 5 12G72 1 1 12 0 Page2 July 15 77...

Page 81: ...V GRUMMAN MJdl lKg tftj AVOATTBiallN GA 7 COUGAR MAINTENANCE MANUAL DETAIL B DETAIL F Servicing Points Figure 1 Sheet 2 of 5 DETAIL C 12G72 1 2 12 0 Page 3 July 15 77...

Page 82: ...GRUMMAN GMIItsllKg IM WO YOOlfiJ GA 7 COUGAR MAINTENANCE MANUAL Servicing Points Figure I Sheet 3 of 5 DETAIL H 12G72 1 3 12 0 Page 4 July 15 77...

Page 83: ...PRESSURE SYSTEM INLINE FILTER Replace filler every 500 hours or every 12 calendar months whichever occursfirst and whena pressure pump is replaced 8 BRAKE RESERVOIRS Fill to within 1 4 inch of top wit...

Page 84: ...e Figure 2 TIRES MAIN Inflate to 40 2 psi 25 MAIN LANDING GEAR STRUT AND RETRACTION MOVING PARTS Grease all moving parts with MIL G 7711 grease See Figure 2 Refer to Note 3 for cleaning piston Fill ge...

Page 85: ...ny Standard OilCompany Royal Lubricants Company Shell Oil Company Union Carbide MIL L 22851 OIL Note 1 Premium AD 80 Premium AD 120 Texaco Inc Texaco Inc VV P 236 PETROLATUM Note 1 Braycote 236 Parmo...

Page 86: ...ompany Standard Oil Company Chevron Oil Company Chevron Oil Company Mobil Oil Company Mobil Oil Company Mobil Oil Company Mobil Oil Company Mobil Oil Company Texaco Inc Texaco Inc Texaco Inc Continent...

Page 87: ...GRUMMAN a f HP30 g S amfiSHSM GA 7 C0UGAR MAINTENANCE MANUAL Access Openings Figure 3 Sheet I of 2 12G72 2 12 0 Page9 July 15 77...

Page 88: ...er Controls Access 14 Vertical Stabilizer Fairing 15 Horizontal Stabilizer Fairing 16 Elevator Tips 17 Rudder Tip 18 Tail Cone 19 Control Cable And Bellcrank Access 20 Electric Aux Fuel Pump Access 21...

Page 89: ...flushed with water and that all residual fuel and vaporhavedissipated or been neutralized prior to startingaircraft engines Ensure that all fuel is from an approved sourceand that it is free from cont...

Page 90: ...GRUMMAN AMBfWSAM AVOAYOOflM GA 7 COUGAR MAINTENANCE MANUAL 1 Left FuelTank Cap 2 Right FuelTank Cap Fueling Points Figure 1 A12G72 3 12 1 1 Page 2 Dec 10 77 S5...

Page 91: ...filler spout cap D Remove dipstick from engine and wipe oil from dipstick with a clean cloth or paper towel E Return dipstick into filler spout and tighten finger tight F Unscrew and remove dipstick C...

Page 92: ...nstallation 4 Pour oil of proper specification and viscosity into filler spout to achieve desired oil level NOTE When adding engine oil during extremely cold weather the change in viscosity due to ext...

Page 93: ...ing a syringe hand pump or other suitable means add MIL H 5605 brake fluid Refer to Figure 2 Section 12 0 to the reservoirs throughthe filler ports until the level of fluid is 1 4 inch from the top of...

Page 94: ...l B Remove the two wing nuts 1 from the battery box 2 and remove the strap 3 disconnect cooling vent 6 and battery box cover 4 asshown in Figure 3 C Using a clean cloth or paper towel wipe all dirt an...

Page 95: ...jbP grumman AOMngi n j rM mMAnr m GA 7 C0UGAR MAINTENANCE MANUAL Battery Servicing Figure 3 12G72 5 12 1 1 Page 7 July 15 77...

Page 96: ...g strut continue to fill with fluid E Slowly compress strut watching for bubbles at filler hole Repeat extending and compressing strut one time to eliminate bubbles in fluid F Ifno air bubbles are pre...

Page 97: ...Lycoming Operating Manual for further instructions Change engine oil as follows A Remove upper engine cowl Remove lower engine cowl B C D E F G H I J K L Locate engine oil drain plug See Figure 1 and...

Page 98: ...er assembly part number 5500015 501 asa replacement Replace the carburetor airfilter assembly as follows NOTE Never blow off filter with compressed air or attempt to wash element in any liquid or soak...

Page 99: ...GRUMMAN IMiP30 mirai MxmYDoIr GA 7 COUGAR MAINTENANCE MANUAL Carburetor Air Filter Figure 2 12G72 7 12 2 1 Page 3 July 15 77...

Page 100: ...ON SYNTHETIC COMPOUNDS SUCH AS THOSE FOUND IN AIRCRAFT OILS AND GREASES CONTAIN ELEMENTS WHICH CAN SOFTEN PAINT NATURAL RUBBER NEOPRENE AND SOME ELECTRICAL INSULATORS IF THIS TYPE LUBRICANT IS SPILLED...

Page 101: ...j0 T GRUMMAN Z taE 0 CmiM MD YOtPlM GA 7 COUGAR MAINTENANCE MANUAL c i s 1 1 DETAIL A DETAIL B Pressure System Figure3 12G72 8 12 2 1 Page 5 July 15 77...

Page 102: ...el Half 5 Bearing Cup GRUMMAN f E Otg AW0AT0 ftl GA 7 COUGAR MAINTENANCE MANUAL 6 Snap Ring 7 Grease Seal Ring 8 Grease Seal 9 Grease Seal Ring 10 Cone Bearing Nose LandingGearWheel Assembly Figure 4...

Page 103: ...lf Outer 5 Brake Disc Assembly GRUMMAN AMBBNI M AWOATTIKSIFffl GA 7 COUGAR MAINTENANCE MANUAL 6 Snap Ring 7 Grease Seal Ring 8 Grease Seal 9 Grease Seal Ring 10 Cone Bearing Main Landing Gear Wheel As...

Page 104: ...t 4 and gasket 5 NOTE If excessive amounts of foreign material are found in the filter the fuel system should be checked for contamination Refer to Chapter 28 D Reinstall filter element 3 in pump 1 an...

Page 105: ...r GRUMMAN O IE O AV0AYDOR0 GA 7 COUGAR MAINTENANCE MANUAL Auxiliary Fuel Pump Servicing Figure 6 12G72 11 12 2 1 Page 9 July 15 77...

Page 106: ...i PISTON TOP TO END M 2 50 H SERVICED 3 10 REQUIRES SERVICE 1 2 3 4 5 Retainer Rings 8 O Ring 9 BearingHead 10 Housing 11 Seal Washer 12 Pressure Piston RoH Pin Piston Piston Rod Pin 6 7 Bolt 13 Sprin...

Page 107: ...lace piston 10 bottomed out against end of housing 4 opposite open end H Fill housing 4 through open end with MIL H 5606 hydraulic fluid Refer lo Figure 2 Section 12 0 and install bearing head 3 and r...

Page 108: ...hydraulic reservoir for the landing gear system should be checked at each 50 hour inspection and whenever fluid level issuspected to be low Service with MIL H 5606 hydraulic fluid Refer to Figure 2 S...

Page 109: ...WN position and close emergency dump valve F Analyze drained hydraulic fluid If the drained fluid is clean and is not appreciably darker in color than new fluid continue to use the present fluid G If...

Page 110: ...val When ice has accumulated on the aircraft it should be carefully checked to ensure that accumulations have been removed from the following areas A Betweenwingsand ailerons and ailerons and flaps B...

Page 111: ...Clean the interiorregularly witha vacuum cleaner to remove loose dirt from the upholstery and carpet If liquid coffee etc is spilled on upholstery or carpet blot it up promptly with cleansing tissue o...

Page 112: ...Follow directions rub out scratch smooth apply wax and buff 7 Engine Cleaning WARNING USE CLEANING SOLVENT IN A WELL VENTILATED AREA AVOID BREATHING FUMES KEEP AWAY FROM FLAMES CAUTION PARTICULAR CARE...

Page 113: ...rto c nf si...

Page 114: ...d Honeycomb Panel Repairs Riveted Repair of Formed Thermo Plastic Parts Engine Mount Repair Control Surface Repair Bondline Damage and Repair Rivet Substitution Primary Structures Maintenance Practice...

Page 115: ...fixtures can be procured through your authorized Grumman American Dealer or Distributor Materials Structural repairs should be accomplished using identical material to that being repaired i e 0 032 i...

Page 116: ...ncludes an acceptable resin filler Damaged areas greater than 1 0 inch in diameter or including punctures through both face sheets will require removal of the damaged area and insertion of a honeycomb...

Page 117: ...jacent to the wing walkway areas and general damage caused by moving stands etc on other surfaces A typical bondline repair is described in the Approved Repairs section of this chapter V 2 Corrosion D...

Page 118: ...ge andCabin Honeycomb and Bond Joints B Control System 1 All Components C Wing 1 Wing Main Spar and Rear Spar 2 Nacelle Areas 3 Engine Mountsand Extrusions 4 Main LandingGear Areaand Attachments D Emp...

Page 119: ...itable support position nose section and secure to fuselage with rivets 2 Rivet the two splice plates to nose section 3 Rivet the two splice channels to nose section 4 Rivet the two lower splice angle...

Page 120: ...AR MAINTENANCE MANUAL FUSELAGE ASSEMBLY UPPER SPLICE ANGLE FUSELAGE FORWARD BULKHEAD EQUIPMENT SHELF LOWER SPLICE ANGLE Nose Section Removal Installation Figure 201 SUPPORT ANGLE SPUCE CHANNEL LOWER S...

Page 121: ...LES IN WING SKIN COUNTERSINK ALL HOLES IN DOUBLERS REPAIR DOUBLER 2024 T3 ALCLAD 0 040 IN THICKNESS DIMPLE HOLES IN FILLE LEADING EDGE SKIN FILLER SAME MATERIAL AND THICKNESS AS SKIN ORIGINAL PARTS RE...

Page 122: ...amage extending partially through the core of honeycomb panel and equal to or less than I inch diameter Figure 203 can berepaired withan external doubler as follows 1 Trim out damaged area of face she...

Page 123: ...z2i M Mffl V HSM GA 7 C0UGAR MAINTENANCE MANUAL DOUBLER 1 0 IN DIAMAX INHIBITED SEALANT SECTION A A RESIN FILLER SEE SERVICE KIT SK 102 Honeycomb Repair Partial CoreDamage Figure 203 20G72 3 20 1 0 Pa...

Page 124: ...and install through the doubler and repair section both sides such that maximum distance between any two rivets is 1 5 inches f Fair external doubler periphery withepoxy lairing compound to maintain a...

Page 125: ...7 C0UGAR MAINTENANCE MANUAL DOUBLER INHIBITED SEALANT EXTERNAL DOUBLER HONEYCOMB REPAIR SECTION SECTION A A DOUBLER INTERNAL DOUBLER Honeycomb Patch Repair External and Internal Doublers Figure204 COU...

Page 126: ...RIVET SPACING 0 50 IN TYP HONEYCOMB REPAIR SECTION COUNTERSINK DOUBLER INTERNAL DOUBLER SECTION A A Honeycomb Repair Using Spliced In PanelSection Figure 205 0 25 IN TYP EDGE MARGIN DOUBLER INHIBITED...

Page 127: ...produce a flat or hollow sound when tapped directly in the damaged area 3 If the results of Step 2 are questionable insert a 0 004 to 0 006 inch feeler gauge into the bondline to verify that separatio...

Page 128: ...resented in this section The requirements specified in this section shall apply toall polyurethane coated aircraft manufactured by the Grumman American Aviation Corporation Any deviation from ormodifi...

Page 129: ...material wax cleaning agents or other foreign material CAUTION APPLY PROTECTIVE TAPE TIGHTLY TO ENSURE AGAINST SEEPAGE OF STRIPPER g N INTO THE AREAS MENTIONED IN PARAGRAPHS BAND C B Using 2 inch wid...

Page 130: ...n using manufacturer s instructions NOTE Acceptable materialsources for metal conditioners are 1 DuPont 222 Metal Conditioner 2 Magnus No 852 wipe off MetalConditioner Economics Laboratory Incorporate...

Page 131: ...NING Description Operation General 21 2 1 FORWARD FRESH AIR SYSTEM Description Operation General 21 2 2 REAR CABIN PASSENGER VENT SYSTEM Description Operation General 21 4 1 HEATING SYSTEM Description...

Page 132: ...mental control in the flight compartment and passenger cabin areas Louvered ventilators in each side of the instru ment panel beneath the control columns and optional Wemac air vents inthecabin walls...

Page 133: ...shutoff valves immediately beneath the instrument panel on the inside walls and louvered ventilators located on the instrument panel beneath the control columns A flexible duct is used to convey air f...

Page 134: ...ipped with this option ventilation for the rear cabin passenger area is furnished bytwo fresh air vents mounted inthe cabin walls at either side ofthe rear seat The flow ofair into the cabin can be di...

Page 135: ...to a vented duct near the floor at the pilot s station and to the pilot s windshield defogger vent The blower located at the cabin side of the left engine firewall is controlled by the BLOWER ON OFF s...

Page 136: ...connection Air valvedamaged Replace or connect duct Tighten control cable connection Replace air valve Control hard to operate Control cable binding Air valve sticking or binding Check cable for prop...

Page 137: ...Locations and Access Duct from the nacelle to the fuselage is accessible through the two wing access openings beneath the wing inboard of each nacelle All components in the cabin are accessible along...

Page 138: ...GRUMMAN i M lP30 g R WO YOOIRfl GA 7 COUGAR MAINTENANCE MANUAL DETAIL B HeatingSystem Figure 201 Sheet 2 of 2 21G72 4 2 21 4 1 Page 202 July 15 77...

Page 139: ...e Mitchell Century IIB Edo Aire Mitchell Century HI Edo Aire Mitchell Century IV Maintenance Practices General Autopilot Servo Removal Installation Roll Servo Removal Roll Servo Installation Pitch Ser...

Page 140: ...lowing components directional gyro attitude gyro roll servo roll signal filter and command console Aradio coupler can beadded to provide radio navigation and localizer guidance The command console pro...

Page 141: ...FURNISHED WITH AUTOPILOT NAV INPUTS CAN BE SUPPLIED BY THE FOLLOWING NAV UNITS DGO 10 NAV 121 122 Kl 201C Kl 211 Kl 214 IND350 ORIND 351 A 7CA4A20 1TO NAV DIRECTIONAL YRO n CD33 A NAV 1 NAV 2 FUNCTION...

Page 142: ...So fill 55 gS ZOi a r r K C 55 n Z 3 z _ So B5 z S uz o rr Zu ZC 0 GRUMMAN MUPDfg iRJl MD YO M GA 7 COUGAR MAINTENANCE MANUAL Edo Aire Century III Autopilot Simplified Diagram Figure 2 22G72 2 22 1 1...

Page 143: ...met before the glideslope informa tion is coupled to the autopilot system These conditions are localizer modeswitch on radio coupler in the LOC NORM position for at least20 seconds altitude mode switc...

Page 144: ...A20 J p J I L7CA11A20 oLIGHTING i i I 7CA10A70 aPQWFR i NAV 1 NAV 2 FUNCTION SWITCH IS USED WITH DUAL NAV INSTALLATIONS ON SINGLE NAV INSTALLATION SWITCH IS OELETED AND 7CA14A20 7CA13A20 ARE SPLICEO T...

Page 145: ...an air driven gyro and an electrically servo d heading card with VOR Localizer and Glide Slope information The NSD 360 has incorporated a heading warning flag to warnof lossof either airor electric po...

Page 146: ...nted at Fuselage Station 132 80 just to the right of aircraft centeriine Remove necessary furnishings to gain access to this area 2 Loosen the cable guards on the servo and position themaway from serv...

Page 147: ...GRUMMAN AMB lNg M VO YQ GA 7 COUGAR MAINTENANCE MANUAL BL 0 00 FLAP TORQUE TUBE REF FS 12500 Roll Servo Removal Installation Figure 201 22G 2 4 22 1 1 Page202 July 15 77 s3 v s...

Page 148: ...to servo 14 Replace removed interior furnishings C Pitch Servo Removal See Figure 202 1 The pitch servo is mounted in the aft fuselage of the aircraft and forward of Fuselage Station 201 00 Remove af...

Page 149: ...S 20100 GRUMMAN A R Dlil D Ai3fl AWOATDtsJIRfl GA 7 C0UGAR MAINTENANCE MANUAL FS 195 30 Pitch Servo Removal Installation Figure 202 VIEW LOOKING INBD RH SIDE 0 00 22G72 5 22 1 1 Page 204 July 15 77 r...

Page 150: ...h of the capstan O D and tighten the screws 13 Check bridle cable alignment on servo capstan The bridle cable should not rub the sides of the capstan grooves Cable clamps mayberotated slightly to prov...

Page 151: ...VIEW LOOKING INBD LH SIOE GRUMMAN SPO zSiM MM S mm GA 7 C0UGAR MAINTENANCE MANUAL FS 185 30 Pitch Trim Servo Removal Installation Figure 203 22G72 6 22 1 1 Page206 July 15 77 V i MjK N a k...

Page 152: ...ntswith 2 screws 2 spacers 2 washers and2 nuts 5 Attach the servoat the bottom using 2 spacers 2 washers see note and 2 nuts Attach to the two screwsassembled in Step 2 NOTE Use washers as required to...

Page 153: ...GRUMMAN zSiPiHlE OIgzSilM MfflfitfmM GA 7 COUGAR MAINTENANCE MANUAL VIEW LOOKING UP SKIN OMITTED FOR CLARITY Pitch Trim Servo Figure 204 BL 0 00 LH SIDE l 22G72 7 22 1 1 Page 208 July 15 77...

Page 154: ...2 1 VHF COMMUNICATION SYSTEM Description Operation NARCOCOM 120 Transceiver KING KX 175B Transceiver COLLINS VHF 251 Transceiver Troubleshooting Maintenance Practices Removal Installation of VHF Commu...

Page 155: ...T 10 System Components Adjustment Test of NARCO ELT 10 23 5 1 AUDIO INTEGRATING SYSTEM Description Operation General Troubleshooting Maintenance Practices Removal Installation of Audio Panel Removal I...

Page 156: ...variety of makes and models This manual will describe those available from NARCO KING and COLLINS Audio Integrating System The purpose of the audio integrating system is to provide the audio signals f...

Page 157: ...a poweroutput of 8 watts minimum 10 to 12 watts typical The radio can operate on any of 720 independent channels with 25 KHz spacing between channels The unit features 6 digit easy tune frequency rea...

Page 158: ...in 25 KHz steps 5 Frequency Readout Indicates operating frequency of transceiver 6 Transmit Indicator Light Illuminates when transceiver is transmitting KING KX 175B Transceiver See Figure 2 The KX 1...

Page 159: ...ckwise Increases audio volume Counterclockwise Decreases audio volume 7 COLLINS VHF 251 Transceiver See Figure 3 The VHF 251 Communications transceiver operates within the frequency range of 118 000 M...

Page 160: ...Store Stores in memory the frequency selected by select control Recall Recalls frequency stored in memory 3 Transmit Indicator Illuminates when transceiver is transmitting 4 MHz Frequency Control Sele...

Page 161: ...breaker Close tiimit breaker Dirty or corroded antenna Clean or lepboe antenna Faulty audio panel dual system Replace audio panel Faulty transceiver Replace transceiver Weak or no transmission Faulty...

Page 162: ...t If gasket adheres to the aircraft remove it using a phenolic scraper B Installation of VHFAntenna onTurtleback See Figure 201 1 Prepare the aircraft for safe maintenance 2 Place the antenna gasket i...

Page 163: ...GRUMMAN AGMDIil ll AIRfl AVOAYOOIRQ GA 7 COUGAR MAINTENANCE MANUAL DETAIL A VHF COM 1 Antenna Installation Figure 201 COM 1 ANTENNA LBL 1 75 FS 146 67 23G72 4 23 2 1 Page202 July 15 77 x...

Page 164: ...p 0 LBL 12 00 GRUMMAN m H OtS S VOATPOOIRfl GA 7 COUGAR MAINTENANCE MANUAL DOUBLER FS 83 50 COM 2 ANTENNA DETAIL A VHF COM 2 Antenna Installation Figure202 23G72 5 23 2 1 Page203 July 15 77...

Page 165: ...osen the transceiver from mounting case by turning locking screw counterclockwise Use 5 64 inch hex wrench 3 Slide the unit straight forward Avoid bending the connector pins Aslight left to right move...

Page 166: ...ntrol towerfrequency 9 Contact the control tower for a radio check Adjust the volume control as required Contact the toweron several up to five if available frequencies 10 Place transceiver powercontr...

Page 167: ...tion 180 along theright side of the aircraft and a transmitting antenna located on top of the dorsal fin The ELT can be manually activated by removing the back partition of the baggage compartment and...

Page 168: ...ets impact switch and stops transmission 2 Transmission control switch ON Electrically activates transmitter OFF Electrically deactivates transmitter ARM Energizes crash circuit automatically transmit...

Page 169: ...CAUSE No transmission Faulty transmitter Faulty wiring to antenna Faulty battery Weak transmission Faulty antenna or wiring to antenna Faulty transmitter Faulty battery REMEDY Replace transmitter Rep...

Page 170: ...THROW IN FIRE 6 Release the battery packwires quick disconnect from the h minals at the transmitter Dispose of battery pack B Installation of Battery Pack 1 Connect the battery pack wires to the tran...

Page 171: ...ovenut cap from antenna 4 Remove washers andseal assembly O ring and washer from the antenna 5 Obtain access to the ELT unit Disconnect antenna 6 Release coax cable from stick clamps 7 Pull the antenn...

Page 172: ...SSY 0 RING AND WASHER WASHER SPRING CO AXIAL CABLE PART OF ANTENNA ASSY FS 247 20 BL 00 00 y FS275 WASHER FLAT WASHER FLAT DETAIL A ELT Antenna Installation Figure 201 9 Depress reset button and place...

Page 173: ...ION MAY LEAD TO AN UNTIMELY DISPERSAL OF EMERGENCY PERSONNEL AND VEHICLES 1 Obtainaccess to the ELT See Figure 201 2 After coordination depress the RESETbutton then place the ON OFF ARM switch to ON A...

Page 174: ...NATION MAY LEAD TO AN UNTIMELY DISPERSAL OF EMERGENCY PERSONNEL AND VEHICLES 1 Obtain accessto the ELT See Figure 201 2 After coordination depress the RESETbutton then place the ON OFF ARM switch to O...

Page 175: ...s a central control point for theoperation and monitoring of installed avionics equipment The audio panel can be one ofthree types NARCO CP 135 KING KMA 20 or COLLINS AMR 350 All three units are very...

Page 176: ...r 10 Marker Beacon Sensitivity Selector 11 Marker Beacon Indicator A Inner O Outer M Middle KING KMA 20 Audio Panel Figure 2 1 COM 1 COM 2 EXT Control 8 DME Control 2 AUTO Control 9 MKR Control 3 COM...

Page 177: ...set audio O K Faulty speaker Replace speaker Faulty audio panel Replace panel Faulty wiringto speaker Repair wiring COM NAV audio not available at the headset Speakeraudio O K Faulty headset Replace h...

Page 178: ...ut the back opening of thespeaker mount B Installation of Speaker 1 Slide thespeaker intotheback opening of thespeaker mount and secure with four screws 2 Attach the twospeaker wires to speaker termin...

Page 179: ...peaker 8 Place COM 1 Speaker Phonecontrol in Phone position 9 Contact control tower for radiocheck Control tower reply is heard over headset 10 Select COM transceiver No 2 if installed asactive transc...

Page 180: ...Wire Identification Circuit Function and Specific Circuit Code Letters Maintenance Practices Diode Test 24 3 0 DCELECTRICALPOWER SYSTEM Description Operation General Operation 24 3 1 BATTERY SYSTEM De...

Page 181: ...ation of Overvoltage Protection Relay Removal Installation of Voltage Regulator Alternator System Operational Check and Adjiistnient 24 4 1 EXTERNAL POWER SYSTEM Description Operation General Operatio...

Page 182: ...ator failure The batteryislocated in the nose section of the aircraft The electrical generating systemconsists of two engine driven 60 ampere alternators two solidstateregulators two overvoltage relay...

Page 183: ...V MAIN DC BUS 9 RADIO BUS ALTERNATOR A ALL CIRCUIT BREAKERS ARE IDENTICAL EXCEPT FOR CURRFNT RATING A All CIRCUIT BREAKERS ARE MOUNTED ON THE IOVVER RIGHT OE INSTRUMENT PANEL AND ARE NORMALLY CLOSEO D...

Page 184: ...ing the general circuit function and assigned in accordance with Paragraph 3 3 An alphabetical character representing the specific circuit within the generalcircuit function and assigned in accordance...

Page 185: ...d as tabled below A Unassignec B Photographic C Control Surface CA Automatic Pilot CB Not Used CC Wing Flaps CD Elevator Trim D Instrument Other than Flight or Engine Instrument DA Ammeter DB Flap Pos...

Page 186: ...Stall Warning Heater FC Stall Warning FD Speed Control System FE Indicator Lights G Landing Gear GA Actuator GB Retraction GC Warning Device Horn GD limit Switches GC Indicator Lights H Heating Ventil...

Page 187: ...Radio LH Deice LJ Fuel Selector M Miscellaneous MA Cowl Flaps MB Electrically Operated Seats N Unassigned 0 Not Used P DC Power PA Battery Circuit PB Generator Circuits PC External Power Source Q Fue...

Page 188: ...Direction Finding RD VHF RE Homing RF Marker Beacon RG Navigation RH High Frequency RK UHF RL Low Frequency RM Frequency Modulation RP AudioSystemand Audio Amplifier RR Distance Measuring Equipment DM...

Page 189: ...22 20 22 22 22 BASE COLOR or solid Red Red Red Red Red Black Black Black Yellow Tan Tan shielded White Green Blue Gray Gray STRIPE COLOR None Black White Green Yellow None White None None None None B...

Page 190: ...dingdiode should be checked NOTE For accurate test diode must be disconnected from circuit A Obtain an ohmmeter and set up on ohms B Position the test leadsacrossthe diode and record the ohmic reading...

Page 191: ...starter solenoids The twovoltage regulators receiving power from the main DC bus via the alternator control switches and the master switch energizes Ihe twoalternator fields With the alternator field...

Page 192: ...m 3 A Q bo e no CA CA J 3 ha M E a w ra jh 4 a W 3 N 6 J J LEFT ALTERNATOR INOPERATIVE...

Page 193: ...battery being charged and discharged will decompose the water from the electrolyte by electrolysis When the water is decomposed hydrogen and oxygen pses are formed which escape into the atmosphere th...

Page 194: ...IRUMMAN A MIIPO S A a AVOATOOIftB GA 7 COUGAR IMAINTENANCE MANUAL Exploded View of Battery Installation Figure 1 24G72 3 24 3 1 Page 2 July 15 77 s s...

Page 195: ...m JffS N GRUMMAN AlMHMlg lFtf VO YDOlPsJ GA 7 C0UGAR MAINTENANCE MANUAL Location of Battery Solenoid Figure 2 Exploded View of Battery Solenoid Figure 3 DETAIL A 24G72 4 24 3 1 Page 3 July 15 77...

Page 196: ...RADIO BUS T RADIO Al S CIRCUIT BREAKERS I IREFI 7PC3A3 FWD WING SPAR MAIN DC BUS G y T ELECTRICAL _ S EQUIPMENT CIRCUIT BRKS TO RIGHT ENGINE STARTER ENG STARTER SOLENOIDS CLOSED BY STARTER BUTTONS Bat...

Page 197: ...ge or replace battery Sulfation due to nonuse Replace battery Level of electrolyte being be low top of plates Maintain correct electrolyte level Battery uses excessive amount of water Charging rate to...

Page 198: ...olution from enteringbattery 3 Wipe down entire battery with a clean cloth dampened with a solution of bicarbonate of soda baking soda and water 4 Wipe battery cableends with samesolution used in Step...

Page 199: ...cover and drain tube for physical damage If damaged they should be replaced Removal Installationof Battery A Battery Removal See Figure 1 1 Open nosebaggage compartment door Removebagpge compartment...

Page 200: ...left engine starter solenoid Disconnect wire 7PA6A10 from battery solenoid 6 Remove the two bolts securingbattery solenoid to mounting panel Remove battery solenoid B Battery Solenoid Installation See...

Page 201: ...al Check 1 Place master switch to ON position Engines OFF 2 Place a moderate drain on the battery This can be accomplished by turning on the naviption and or landinglight NOTE If light is inoperative...

Page 202: ...trol the output of the alternator the following switches circuit breakers must be closed master switch right and left alternator circuit breakers right and left alternator field circuit breakers and l...

Page 203: ...AGE RELAY I pii j i i J 5 P 5 jig p19 bis p 7L PBSC16 fTTTU LEFT JfLD GNoV ALTERNATOR 8ATT JI9 P19 4TFTV 7DA1B10 J 2I2f 7OAIA10 1 1 UK D1S J 9 P19 D 7DAB10 4 3 3 D 7DAAI0 M l 70ABB10 L 7DA A1I J21 P21...

Page 204: ...ge pro Replace relay trips tection relay Circuit shorted in wiring Use ohmmeter to locate short Repair as required Defective circuit breaker Replace circuit breaker Defective voltageregulator Replace...

Page 205: ...or Check resistance from Fl terminal of alternator to alter nator case Normal indi cation is 3 to 4 ohms If resistance is not correct replace alter nator Defective wiring Observeammeter reading and al...

Page 206: ...uld be in accordance with any manuals or bulletins published by the alternator manufacturer B Alternator Installation See Figure 201 CAUTION ENSURE GROUND NEGATIVE CABLE IS DISCONNECTED AND CLEAR OF B...

Page 207: ...GRUMMAN IMdPDIS MO Y0 S RQ GA 7 C0UGAR MAINTENANCE MANUAL DETAIL A Alternator Exploded View Figure 201 24G72 7 24 3 2 Page 202 July 15 77...

Page 208: ...holder bracket with two screws 2 Attach the two leads to the relay 3 Connect the ground negative cable to the battery 4 Replace nose baggage compartment floor panel and close bagpge compartment door...

Page 209: ...GRUMMAN MlUPQIg lftD MO YO ftJ GA 7 C0UGAR MAINTENANCE MANUAL Overvoltage Protection Relay and Voltage Regulator Figure 202 VOLTAGE REGULATOR DETAIL A 24G72 8 24 3 2 Page 204 July 15 77 K...

Page 210: ...lternator indicator light on glare shield is illuminated 5 Observe that right alternator ammeter still indicates some current draw and the right alternator indicator light is out 6 Close Left Alternat...

Page 211: ...n the field terminals of the two voltage regulators Connect positive lead of voltmeter to left regulator field terminal Meter range is30 to 50 volts 12 Place Masterswitch to ON WARNING ENSURE PROPELLE...

Page 212: ...g lFsa M 0 Y0OtRJ GA 7 COUGAR MAINTENANCE MANUAL 21 Shut down left engine in accordance with Pilot s Operating Handbook 22 Replace right engine starter fuse 23 Perform operation checkof alternator sys...

Page 213: ...tactor will not energize This feature protects the diodes in the alternator and other semiconductor devices used in the aircraft from possible damage from reverse polarity Operation See Figure I NOTE...

Page 214: ...r System TROUBLE External power source will not power electrical system PROBABLE CAUSE Defective external power solenoid Defective battery solenoid Defectivediode CR I open Defective Master switch Def...

Page 215: ...Ensure Master switch is OFF 2 From inside the aircraft using the access opening in the floor of thebagpge compartment place the receptacle on the mounting bracket 3 From outsidethe aircraft through th...

Page 216: ...GRUMMAN t M il O ftJ SMOAYOOP i GA 7 COUGAR MAINTENANCE MANUAL DETAIL A ROTATED 180 ExternalPower Receptacle Installation Figure 201 24G72 10 244 1 Page 202 July 15 77 X...

Page 217: ...GRUMMAN AMBSM AM AWOATTOORD GA 7 COUGAR MAINTENANCE MANUAL Location of External Power Solenoid Figure 202 DETAIL A 24G72 11 244 1 Pap 203 July 15 77...

Page 218: ...EFORE INSTALLING SOLENOID NOTE Diode used on solenoid should betested and replaced if necessary before installing solenoid See Section 24 0 1 Paragraph 1 Diode Test 1 Secure external power solenoid to...

Page 219: ...n 24 0 for typical circuit breaker installation Electrical Load Analysis CURRENT DRAIN CONTINUOUS LOAD AMPS Oil Temperature Gauges 16 Battery Solenoid 62 Pitot Heat 6 50 Naviption Lights 3 36 Instrume...

Page 220: ...eceiver 55 NAV 124 Naviption Receiver 92 _ CP 135 Audio Control Panel 41 DME 190 3 00 3 00 AT 150 Transponder 1 60 1 60 ADF 140 1 125 COLLINS VHF 251 Transceiver 84 4 0 VIR 351 Navigation Receiver 80...

Page 221: ...Seat Installation 25 2 0 SAFETY BELTS Description Operation General Maintenance Practices Front Seat Shoulder Harness Removal Front Seat Shoulder Harness Installation Front Seat Lap Belt Removal Front...

Page 222: ...Console Cover Installation 25 5 0 CABIN TRIM PANELING AND MOULDING Description Operation General 25 6 0 MISCELLANEOUS FURNISHINGS Description Carpeting Panel Upholstery and Armrests Hatshelf Glareshi...

Page 223: ...KslBlgj lfcl Vn YO IN GA 7 C0UGAR MAINTENANCE MANUAL V TABLE OF CONTENTS Continued NUMBER 1 AGE 25 8 0 INTERIOR CARE Maintenance Practices 201 Cleaning Precautions 201 Cleaning Procedures 201 25 Page3...

Page 224: ...y spring loaded pins to lock theseat in place The front seat backs are hinged to fold forward Maximum access to the rear seat area can be obtained by moving the right hand seat full forward and foldin...

Page 225: ...the seattracksasshown in Detail A Figure201 B PuU the seat position lever up and move the seat forward enpgingthe forward rollers and retainers on the front of the seattracks Move the seataft to the p...

Page 226: ...GRUMMAN AMBEfflg M MO YDOt GA 7 C0UGAR MAINTENANCE MANUAL ROLLER RETAINER c TRACK HJ DETAIL A SEAT POSITION LEVER Front Seat Installation Figure201 STOP 25G72 1 25 1 0 Page 202 July 15 77 v...

Page 227: ...C0UGAR MAINTENANCE MANUAL 1 2 3 4 5 6 Seat Back Cushion Seat Back Screw Washer Screw Washer 8 9 10 11 12 13 Seat Bottom Screw Washer Screw Washer Collar Assembly 7 Collar Assembly Rear Seat Removal Fi...

Page 228: ...12 and screws 11 3 Install washers 10 and screws 9 4 Inspect well beneath seat bottom and removeany foreign objects 5 Lower seat bottom into proper position B Seat Back Installation 1 Putseatback 2 in...

Page 229: ...leshoulder harness Bothfront seat belt assemblies are controlled by inertia reels The rear seat lap belts are attached to the seat support installations just forward of the bagpge areas The shoulder h...

Page 230: ...GRUMMAN AMSI KSAIft AWOAYOOIRfl GA 7 COUGAR MAINTENANCE MANUAL Lap Belts and Shoulder Harnesses Figure I 25G72 3 25 2 0 Page 2 July 15 77 3...

Page 231: ...Seat Lap Belt Installation A Install washer on bolt head Install spacer in hole in lapbeltend fitting B Installlap belt end fitting and spacerinto proper position Installbolt and washer Rear Seat Shou...

Page 232: ...MB N AM WO YO GA 7 COUGAR i MAINTENANCE MANUAL 8 RearSeat LapBeltInstallation A Install washer and spacer on screw B Install lap belt end fitting intoposition and secure with screws 25 24 h e202 Juiy...

Page 233: ...rner of the aft bagpge compartment The straps in the aft bagpge compartment are normally arranged in a crossed position to secure baggage or cargo Each of the two strapsdirectly behind the rearseat is...

Page 234: ...ontrol console is mounted beneath the instrument panel and contains the throttle propeller pitch and carburetor mixture control levers for each engine Below these controls the rudder trim carburetor h...

Page 235: ...etor mixture control knobs Install knobs on controls C Apply one drop of Loctite No 242 lo threads of seIscrews and install setscrews in control knobs Tighten setscrews securely Aft Console Cover Remo...

Page 236: ...he cabin trim inner paneling and moulding are formed from Ihcrnioplastic material which serves as a covering for insulation and sound deadening nuilerial andalsoharmonizeswilh Ihe cabin furnishings Re...

Page 237: ...ted to the top of the instriimeiil panel and instrument panel braces The glareshield projects forward over Ihe instrument paneland prevents lighting from Ihe instruments from reflecting on the windshi...

Page 238: ...ht front seat and readily accessible by releasing the catch on the mounting strap Operation A Release Ihe catch on the mounting strap to obtain fire extinguisher It Grasp Ihe ringand pullthe safely pi...

Page 239: ...equired remove bolls washers and mounting bracket Inspection Make sure pointer on gage is within normal limits Return unit lo manuracturcr or his autohrized service outlet if pointer is above or below...

Page 240: ...and carpeting wilh a vacuum cleaner Brushes or brooms only remove surface dirt and grit left below Ihe surface will acceleratewear B Periodically remove carpeting and vacuum deck beneath carpeting lo...

Page 241: ...pSystem Gust Lock RiggingFixtures Rig Pins 27 1 1 AILERON TRIM Description Operation Aileron Control System Aileron Trim Control System Maintenance Practices Aileron Removal Aileron Installation Beari...

Page 242: ...nders Brake Lines Rudder BarBearings Rudder BarSupport Brackets Pushrod Assemblies Rudder Bellcrank Linkage Bellcrank Assembly Rudder Cables Rudder Trim Tab Trim Tab Actuator and Drive Assembly Trim C...

Page 243: ...stem Maintenance Practices Elevator Control Column Pushrod Elevator Control Bellcrank Aft Elevator Bellcrank Elevator Pushrods Elevator Cables Trim Tab Trim Tab Actuator and Drive Assembly Trim Contro...

Page 244: ...cription Operation General Flap Structure Flap Drive and Torque Tube Flap PositionIndicatingSystem Flap ElectricalSystem Troubleshooting Troubleshooting Flap Drive System Maintenance Practices Flaps F...

Page 245: ...Rotary motion of the trim wheel positions the trim tab by means of cables chain and sprocket actuator and push rod The rudder trim wheel is located on the center console 4 Longitudinal Control System...

Page 246: ...YCS10401 Flap Rigging Fixture 7YCS10402 Aileron Rigging Fixture 7YCS10403 Elevator Rigging Fixture 7YCS10404 ElevatorTrim Rigging Fixture 7YCS10405 Rudder Rigging Fixture 7YCS10406 Rudder Trim Rigging...

Page 247: ...A 7 C0UGAR MAINTENANCE MANUAL 5 MIN 0 250 DIA FOR AILERON SECTOR 9 MIN 11 IFOR FRONT BELLCRANKS AND SUPPORT BRACKETS 8 MIN 1 IFOR AFT ELEVATOR BELLCRANK Rig Pins Figure 1 10 32 NF 3A THREAD 2 _L T 0 1...

Page 248: ...n The aileron balance weightsarelocatedalongthe aileron leading edgebeneaththe skin and attachedto the rib structure 2 Aileron Trim Control System See Figure 2 The aileron trimcontrol system provides...

Page 249: ...GRUMMAN M iPO g F D Mffl WSB GA 7 COUGAR MAINTENANCE MANUAL Aileron Control System Figure 1 27 1 1 Page 2 July 15 77 Siji...

Page 250: ...r r GRUMMAN lrWS J M MWOATOl GA 7 COUGAR MAINTENANCE MANUAL Aileron Trim Control System Figure 2 27 1 1 Pap 3 July 15 77...

Page 251: ...r aileron onto support CAUTION MAINTAIN ALIGNMENT OF AILERON AND WING TRAILING EDGE DURING RE MOVAL TO AVOID DAMAGE OR MISALIGNMENT OF COMPONENTS f F At center hinge note position and quantity ofwashe...

Page 252: ...DETAIL C DETAIL D 1 Cotter Pin 10 Washer 2 Nut 11 Washer 3 Washer 12 Washer 4 Washer 13 Bolt 5 Bolt 14 Cotter Pin 6 Aileron Assembly 15 Nut 7 Wing 16 Washer 8 Cotter Pin 17 Bolt 9 Nut Aileron Install...

Page 253: ...urs and other costs incurred in throughly inspecting small attaching parts the low frequency of required inspections andthe low costandavailability of the attaching parts it is suggested that the most...

Page 254: ...outboard cable end and pulled into position as the existing cableis removed 7 Remove cotterpin 11 from sector 12 Attach awire orcord to outboard cable end 8 Pull cable into passenger compartment Disc...

Page 255: ...r GRUMMAN AGMHII OISAIFfl rfiMOAYOIsHrV GA 7 COUGAR MAINTENANCE MANUAL DETAIL B Aileron Control Installation Figure 202 Sheet 1 of 3 27 1 1 Page 205 July 15 77...

Page 256: ...DETAIL D GRUMMAN AiMH OISAIftD AWOAYO0M GA 7 C0UGAR MAINTENANCE MANUAL DETAIL E DETAIL F DETAIL G Aileron Control Installation Figure 202 Sheet 2 of 3 27 1 1 Page 206 July 15 77...

Page 257: ...r the area in which the aircraft is usually operated If ambient temperature is above or below normal it is recommended that cable tension be measuredand adjusted as necessary when temperaturereturns t...

Page 258: ...ng cable is removed 13 Attach a wire or cord to outboard cable end and pull cable into passenger compartment Dis connect wire or cord and leave in place D Control Cables Installation NOTE Lubricate ca...

Page 259: ...rees down 25 2 degrees up Refer to Section 274 forrigging fixture partnumbers If necessary rigailerons in accordance with Paragraph 7 13 Installcenter console covers See Chapter25 I 14 Install access...

Page 260: ...tabs must have the tab atneutral 0degree position and the push rodmustbe in place during balancing operation 6 The balancing device must include a means for accurately measuring the distance of the ga...

Page 261: ...ailing edge tends to lea e support C 5 Measure and record the distance X from the hinge centeriine to the gage weight The gage weight must be within the distance limits given in Table 1 6 If the gage...

Page 262: ...GE GRUMMAN Z3 F L 0E 2 AmfiSTmM GA 7 COUGAR MAINTENANCE MANUAL KNIFE EDGE B NUT MOUNTING BOLT KNIFE EDGE NUTS MACHINE THREADS J FROM THIS AREA DETAIL A Aileron Balancing Setup Figure 204A HINGE LINE H...

Page 263: ...r 3RUMMAN A M ll O AlftQ Mffl firwm GA 7 C0UGAR MAINTENANCE MANUAL BALANCE WEIGHT INSIDE TIP CAP HINGE BOLT Elevatoror Rudder Balancing Setup Typical Figure 2041 SUPPORT E WEIGHT 27 1 1 Page213 July 1...

Page 264: ...erage for the area in which the aircraft isusually operated Ifrigging must be done with the ambient temperature above orbelow normal it is recommended that cable tension be measured and adjusted as ne...

Page 265: ...ol wheel through full travel in both directions noting trailing edge position at both extremes of travel Repeat procedure with aileron riggingfixture installed on other wing L Aileron travel limits ar...

Page 266: ...l shaft 12 aft and remove 7 Remove bolt 13 spacers 14 washers 15 and 16 and nut 17 Remove lever 31 8 Remove nut 18 and washer 19 Remove push rod 29 9 Remove cotter pin 20 nut 21 washer 22 and bolt 23...

Page 267: ...E2 S M WO YDOIM GA 7 COUGAR MAINTENANCE MANUAL 18 12 Shaft 13 Bolt 14 Spacer 15 Washer 16 Nut 17 Washer 18 Nut 19 Washer 20 Cotter Pin 21 Nut 22 Washer Aileron Trim Linkage Figure 206 23 24 25 Bolt Co...

Page 268: ...ped so that arm of lever 31 is on LH side of aircraft with lockpin in neutral position If lever arm is on RH side trim control knob will give opposite trim to that desired when turned 11 With lockpin...

Page 269: ...gure 1 Movement ofthe rudder pedals is transmitted by push rods bellcranks and cables resulting inacorresponding displacement ofthe rudder from the neutral position The rudder pedals are held inpositi...

Page 270: ...GRUMMAN AMBSmAM AW0 Y0 ftD GA 7 COUGAR MAINTENANCE MANUAL Rudder System Figure 1 27 2 1 Page 2 July 15 77 y s V r ata...

Page 271: ...Pfes DETAIL A GRUMMAN AIMII lKS IRfl MMAYi M GA 7 C0UGAR MAINTENANCE MANUAL TIP CAP TRIM TAB ROTATED 180 DETAIL B ACTUATOR ASSY SPROCKET TURNBUCKLE Rudder Trim Tab System Figure 2 27 2 1 Page 3 July...

Page 272: ...CAUTION PROVIDE A MEANS OF SUPPORT FOR RUDDER DURING REMOVAL AND INSTALLATION TO AVOID STRESS AND POSSIBLE MISALIGNMENT OR DAMAGE TO HINGE PARTS 5 Note quantity of washers 13 and 14 for use duringinst...

Page 273: ...GRUMMAN IMIIPO SMfl YO GA 7 COUGAR MAINTENANCE MANUAL Rudder Removal and Installation Figure 201 Sheet 1 of 2 18 INCH 27 2 1 Page 202 July 15 77...

Page 274: ...hin washer or substitute a thinwasher fora thick one 4 If clearance is less than 0 18 inch add washers 13 and 14 as required to obtain minimum clearance 5 Install washer 27 on bolt 25 Insert bolt 25 t...

Page 275: ...and cap flexible lines 6 Remove brake cylinder B Installation 1 Connect flexible lines to brake cylinder 2 Install bottom of brake cylinder into mountingbracket on floor and secure with clevis pin 3...

Page 276: ...GRUMMAN Z3 fe4 P30 g 2 lMI AWOATDISIR GA 7 COUGAR i MAINTENANCE MANUAL Rudder Control System Figure 202 Sheet 1 of 3 27 2 1 Page 205 July 15 77...

Page 277: ...GRUMMAN AMBBmAM WD YOOIM GA 7 COUGAR MAINTENANCE MANUAL 25 28 Z V50A Rudder Control System Figure 202 Sheet 2 of 3 DETAIL C 27 2 1 Page 206 July 15 77 r i...

Page 278: ...33 Rudder Bar 50A Bushing 68 Cotter Pin 16 Washer 34 Cotter Pin 51 Clevis Bolt 69 Nut 17 Stud 35 Washer 52 Bungee 70 Washer 18 Bracket 36 Clevis Pin 53 Cotter Pin 71 Clevis Bolt Rudder Control System...

Page 279: ...od assembly 23 2 Release spring tension by unhookingspringassembly 39 at rudder bar 33 3 At rudder bellcrank 24 remove cotter pin 19 nut 20 washer 21 and bolt 22 4 Remove clevis end of push rod assemb...

Page 280: ...proper alignment Rig rudder control system if rudder pedals are not lined up Refer to Paragraph 16 9 Rudder BarSteering Linkage See Figure 202 A Removal 1 Release springtension by unhooking springasse...

Page 281: ...raph 7 4 Disconnect rudder cables 67 Figure 202 by removing cotter pins 68 nuts 69 washers 70 i and clevis bolts 71 5 At left hand bracket 58 remove cotterpin 53 nut 54 washer 55 andbolt 56 6 Slide be...

Page 282: ...dder cable 3 Remove turnbuckles 2 6 At Fuselage Station 266 89 remove nuts 5A washers 5B bolts 5C guards 5 and pulleys 6 7 At rudder bellcrank remove cotter pin 1 Figure 201 nuts 2 washers 3 and 4 and...

Page 283: ...DETAIL A GRUMMAN zS f g 30 g lM Mfl YD IM GA 7 C0UGAR MAINTENANCE MANUAL Rudder Linkage System Figure 203 Sheet 1 of 7 27 2 1 Page 212 July 15 77 V...

Page 284: ...0 DETAIL B 0 DETAIL C GRUMMAN AMBEMSAM AVDATOOIN GA 7 C0UGAR MAINTENANCE MANUAL Rudder Linkage System Figure 203 Sheet 2 of 7 27 2 1 Pap 213 July 15 77...

Page 285: ...GRUMMAN MHI DIS O M0 3Y0 lftO GA 7 COUGAR MAINTENANCE MANUAL Rudder LinkageSystem Figure 203 Sheet 3 of 7 DETAIL D 27 2 1 Page 214 July 15 77 v_...

Page 286: ...ijgfP GRUMMAN GMMI iHg lftQ WO YOOlFsfl GA 7 COUGAR MAINTENANCE MANUAL DETAIL E Rudder Linkage System Figure 203 Sheet 4 of 7 57 j5 56 27 2 1 Page215 July 15 77...

Page 287: ...GRUMMAN A0tfHil30 Alfti MD YOOtMl GA 7 COUGAR MAINTENANCE MANUAL Rudder Linkage System Fiuure 203 Sheet 5 of 7 27 2 1 Page 216 July 15 77 Sv...

Page 288: ...JfP N ghumman Rflisi OiG iRi jsmAsm y m GA 7 COUGAR MAINTENANCE MANUAL DETAIL G Rudder Linkage System Figure 203 Sheet 6 of 7 27 2 1 Pago 217 July 15 77...

Page 289: ...Trim Cable 70 Cotter Pin 71 LH Rudder Trim Cable 72 Cotter Pin 73 Cotter Pin 74 Rudder Trim Wheel 75 Retainer 76 Bolt 77 Washer 78 Spacer Rudder Linkage System Figure 203 Sheet 7 of 7 Installation NOT...

Page 290: ...NG RUDDER TRIM LH ELEVATOR TRIM LH GRUMMAN AlMUPIHg kiRQ AWAYmm GA 7 COUGAR MAINTENANCE MANUAL 11 F S 88 00 Control Cable Routing Figure 204 Sheet I of 2 RUDDERRH ELEVATOR UP AILERON RH WING RUDDER TR...

Page 291: ...7 C0UGAR MAINTENANCE MANUAL FWO I S 181 632 RUDDER LH ELEVATOR DOWN RUDDER TRIM LH ELEVATOR TRIM LH Control Cable Routing Figure 204 Sheet 2 of 2 RUDDER RH ELEVATOR UP RUDDER TRIM RH ELEVATOR TRIM RH...

Page 292: ...udderhinge half 9 and install hinge pin 8 Stake hinge pin NOTE Make sure to install push rod 6 so that adjustable end is aft 2 At left hand side of rudder install push rod 6 inlo rudder and align rod...

Page 293: ...OUGAR MAINTENANCE MANUAL DETAIL A DETAIL B 1 Cotter Pin 2 Nut 3 Washer 4 Washer 5 Bolt Rudder Trim Tab Installation Figure205 6 Push Rod 7 Trim Tab Bellcrank 8 Hinge Pin 9 Rudder Hinge Half 10 Trim Ta...

Page 294: ...udder trimcables 37 from chain 38 B Installation 1 Install drive assembly 43 Figure 203 and secure with nuts 40 washers 42 and screws 41 NOTE If a new chain 38 isinstalled mark corresponding link usin...

Page 295: ...tter pin 34 and cableretainer 35 Pullrudder trim control cables 28 free of pulleys NOTE Remove aileron trim control knob and linkage components as required to pin access to rudder trim wheel Refer to...

Page 296: ...as shown in Figure 204 Install cable retainer 25 and cotter pin 24 9 At Fuselage Station 181 632 route rudder cables as shown in Figure 204 Install cable retainer 15 Figure 203 and cotter pin 14 10 A...

Page 297: ...e measured and adjusted asnecessary when temperature returns to normal Refer to Section 274 for rigging fixture part numbers A Rudder Control System 1 Removeaft fuselage access covers and tailcone per...

Page 298: ...GRUMMAN i t MH 3 M AW10SWBM GA 7 C0UGAR MAINTENANCE MANUAL Rudder and BrakeControl Rigging Figure206 27 2 1 Page227 July 15 77...

Page 299: ...on thatwill limitrudder travel to 40 2 degrees 11 Repeat Steps 9 and 10 above withrudder deflected inopposite direction 12 Install tail cone and aft fuselage access covers per Chapter 53 Rudder Trim S...

Page 300: ...C RUDDER STOP GRUMMAN AMBmSAM AWlA mi GA 7 COUGAR MAINTENANCE MANUAL RudderBellcrank Stops Figure 208 RUDDER BELLCRANK NOTE CLIP MUST FACE AFT Rudder Trim Wheel Neutral Position Figure 209 27 2 1 Page...

Page 301: ...l stabilizer androtate chain andsprocket to obtain an actuator arm measurement of 0 90 inch 7 At aft fuselage access opening hold aft rudder trim cables together and measure offset at cable ends as sh...

Page 302: ...y K GRUMMAN MieP3DO v i Tl TO Jfr GA 7 COUGAR MAINTENANCE MANUAL 1 4 AFT LH Rudder Trim Cables View Looking Up Figure 211 Pq R H 27 2 1 Page 231 July 15 77...

Page 303: ...ould be 15 1 5 degrees 13 Install access covers on vertical stabilizer and aft fuselage Remove rig pin from rudder pedal bellcrank Install cover on rudder trim wheel 17 Cleaningand Painting CAUTION PA...

Page 304: ...wheel is moved fore and aft the displacement is transmitted by a push rod to the elevator control bellcrank located forward of the rudder pedals Theelevator control bellcrank in turn operates the up a...

Page 305: ...GRUMMAN G QIgl OIS INl WOAYOtSHftfl GA 7 COUGAR MAINTENANCE MANUAL ROTATED 180 DETAIL A DETAIL C Elevator Control System Figure 1 DETAIL B 27 3 1 Page 2 July 15 77 B K w...

Page 306: ...DETAIL B GRUMMAN A MI I O gA ftO SMO YOlGJL GA 7 COUGAR MAINTENANCE MANUAL l l 4 DETAIL A DETAIL C Elevator Trim System Figure 2 27 3 1 Page 3 July 15 77...

Page 307: ...sor switcheshi the right wing outboard of the engine a stall warning horn mounted on the cabin wall forward of the instrument panel and a cam actuated flap position detector niicroswilch adjacent lo t...

Page 308: ...0 GRUMMAN i S M i M M lAZ TV J i GA 7 C0UGAR MAINTENANCE MANUAL Control Column Figure 3 27 3 1 PageS July 15 77...

Page 309: ...GRUMMAN AuMi lHi i GA 7 COUGAR MAINTENANCE MANUAL STALL SENSOR SWITCHES ACCESS COVER Stall Warning System Figure 4 STALL WARNING HORN 27 3 1 Page 6 July 15 77 V...

Page 310: ...age access opening install arig pin in the aft elevator bellcrank rig pin hole CAUTION PROVIDE A MEANS OFSUPPORT FOR ELEVATORS DURING REMOVAL AND INSTALLATION TO AVOID STRESS AND POSSIBLE MISALIGNMENT...

Page 311: ...AIL B DETAIL D GRUMMAN AMBRN AM SMO YOOIfcfl GA 7 COUGAR MAINTENANCE MANUAL tAt p A OT DO E D B AC DETAIL C Elevator Removal and Installation D ETAIL E Figure 201 Sheet 1 of 2 27 3 1 Page 202 July 15...

Page 312: ...ENTS 1 Move elevator assembly into position and provide support Install washer 37 Figure 201 on bolt 36 Insert bolt 36 through bearing bracket assembly 38 and washers 39 and into nut plate 41 in eleva...

Page 313: ...Place control column push rod 10 and bob weight push rod 11 into position betweenelevator control bellcrank 9 and control column 12 Install bolts 4 and 8 2 Installwasher 7 nut 6 and cotter pin 5 3 Ins...

Page 314: ...AR MAINTENANCE MANUAL 1 Cotter Pin 2 Nut 3 Washer 4 Bolt 5 Cotter Pin 6 Nut 7 Washer 8 Bolt 9 Elevator Control Bellcrank 10 Control Column Push Rod 11 Bob Weight Push Rod 12 Control Column Control Col...

Page 315: ...n 9 Washer 2 Nut 10 Bolt 3 Washer 11 Elevator Down Cable 4 Bolt 12 Cotter Pin 5 Elevator Control Push Rod 13 Nut 6 Elevator Control Bellcrank 14 Washer 7 Cotter Pin 15 Bolt 8 Nut 16 Elevator Up Cable...

Page 316: ...t bellcranks and support brackets 2 Remove aft fuselage access covers and relieve cable tension at elevatorturnbuckles Install rigpin at aft elevatorbellcrank 6 Figure 204 3 Remove cotter pin 1 nut 2...

Page 317: ...Pin 4 Bolt 18 Nut 5 Up Elevator Cable 19 Washer 6 Aft Elevator Bellcrank 20 Bolt 7 Cotter Pin 21 Right Elevator Push Rod 8 Nut 22 Nut 9 Washer 23 Washer 10 Bolt 24 Bolt 11 Down Elevator Cable 25 Beari...

Page 318: ...s See Figure 205 A Removal 1 Install control wheel lock Install rig pin through front bellcranks and support brackets 2 Remove aft fuselage access covers and install rig pin at aft elevator bellcrank...

Page 319: ...IMI GA 7 COUGAR MAINTENANCE MANUAL 3B43 1 Cotter Pin 7 Nut 2 Nut 8 Washer 3 Washer 9 Bolt 4 Bolt 10 Elevator Hom 5 Aft Elevator Bellcrank 11 Rig Pin 6 Elevator Push Rod Elevator Push Rods Figure205 27...

Page 320: ...ble retainer 5 Pull elevator control cables 3 free of pulleys 6 7 Pull aftend of passenger seat bottom up and forward to gain access to pulley group at Fuselage Station 143 25 Remove cotter pin 12 and...

Page 321: ...GRUMMAN MdPlOIS Gst MMA1WIM GA 7 COUGAR MAINTENANCE MANUAL Elevator Cable System Figure 206 Sheet 1of 2 27 3 1 Page 212 July 15 77 s V...

Page 322: ...Cotter Pin 4 Cotter Pin 16 Cable Retainer 5 Cable Retainer 17 Elevator Trim Wheel 6 Pulley 18 Elevator Trim Control Cable 7 Cotter Pin 19 Aileron Cable 8 Cable Retainer 20 Cotter Pin 9 Pulley 21 Cabl...

Page 323: ...siometer Install locking clips 8 Remove control wheel lock and rig pins Perform a rigging check per Paragraph 11 and rig as necessary 9 Install aft fuselage access covers Install lower panel of aft ca...

Page 324: ...AR MAINTENANCE MANUAL RUDDER LH ELEVATOR DOWN RUDDER TRIM LH ELEVATOR TRIM LH Control CableRouting Figure 207 Sheet 1 of 2 F S 137 50 F S 143 25 s F S 181 632 RUDDER RH ELEVATOR UP RUDDER TRIM RH ELEV...

Page 325: ...RUDDER TRIM LH ELEVATOR TRIM LH GRUMMAN MULrJO ZSMO YOCoM GA 7 COUGAR MAINTENANCE MANUAL Control Cable Routing Figure 207 Sheet 2 of 2 F S 88 00 RUDDER RH ELEVATOR UP AILERON RH WING RUDDER TRIM RH E...

Page 326: ...COP l GA 7 COUGAR MAINTENANCE MANUAL 1 2 3 4 5 Cotter Pin Nut Washer Washer Bolt 6 Elevator Trim Push Rod 7 Elevator Trim Horn 8 Hinge Pin 9 Trim Tab 10 Elevator Elevator Trim Tab Installation Figure2...

Page 327: ...oosen nut 6 slide chain guard 7 aftto free chain and retighten nut NOTE If removal of chain 8 is not required a short piece of wire or cord may be looped around chain and secured to structure to hold...

Page 328: ...LockingClip 2 Elevator Trim Turnbuckle 3 Trim Pulley Bracket 4 Cotter Pin 5 Elevator Trim Cable 6 Nut 7 Chain Guard 12 8 10 11 8 Chain 9 Clip 10 Screw 11 Washer 12 Drive Assembly 13 Sprocket Trim Tab...

Page 329: ...GRUMMAN AMBMSAM AmA mm GA 7 COUGAR MAINTENANCE MANUAL 2 3 m 3 DriveAssembly Prerigging Figure 210 ElevatorTrim CableRouting Figure 211 27 3 1 Page 220 July 15 77 y ttsy...

Page 330: ...ch a wire or cord to end of chain 8 4 Pull remaining elevator trim cable 5 slowly until stop is contacted Remove clip 9 Remove elevator trim cables 5 5 In cabin remove access panels and covers from af...

Page 331: ...A M AWAYmM GA 7 COUGAR MAINTENANCE MANUAL 1 Elevator Trim Wheel 4 Sleeve 2 Cable Retainer 5 Washer 3 Lock Wire 6 Bolt Elevator Trim Wheel Installation View Looking Down Figure 212 3833 27 3 1 Page 222...

Page 332: ...m wheel 1 Install elevator trim wheel placing trim indicator follower into center groove of spiral on trimwheel Install washer 5 and bolt 6 Lock wire bolt 6 Beneath elevator trim control wheel route c...

Page 333: ...emove cotter pin 16 nut 17 washer 18 andbolt 19 Remove crank 15 8 Remove nut 20 and washer 21 In nose baggage compartment slide support assembly 22 outboard and remove from aircraft 9 Loosen lock nut...

Page 334: ...mbly 6 Nut 23 Rod End 7 Washer 24 Locknut 8 Bolt 25 Cotter Pin 9 Bracket 26 Nut 10 Cotter Pin 27 Washer 11 Nut 28 Bolt 12 Washer 29 Clamp 13 Bolt 30 Rivet 14 Bob Weight Push Rod 31 Clamp Plate 15 Cran...

Page 335: ...ll rod end 23 into crank 15 Secure with bolt 13 washer 12 nut 11 and cotter pin 10 12 Hook up lower end of spring 5 NOTE The bob weight weighs approximately 16 pounds and is mounted at an inconvenient...

Page 336: ...easured andadjusted asnecessary when temperature returns to normal Refer to Section 274 for rigging fixture part numbers A Elevator Control System 1 Install control lock or0 250 inch diameter rig pin...

Page 337: ...nd the cable retainer must be at the top of the drum 4 At aft fuselage access opening remove locking clips 1 Figure 209 and elevator trim turnbuckles 2 Tie a cord or wire to free end of each aft eleva...

Page 338: ...GRUMMAN HI 0 S IRJ1 AVOA u 0 RJ GA 7 COUGAR MAINTENANCE MANUAL 1 2 3 Locknut Bolt Arm 4 Bracket 5 Bolt 6 Locknut Elevator Stop Assembly Figure 214 27 3 1 Page 229 July 15 77...

Page 339: ...GRUMMAN fefli PiOS J AmATmM GA 7 COUGAR MAINTENANCE MANUAL LH RH O i I 0 56 INCHES Aft ElevatorTrim Cables View Looking Up Figure 215 I 27 3 1 Pcge 230 July 15 77 S K...

Page 340: ...ning and painting instructions 14 Control Column See Figure 216 A Removal F 1 Installcontrol wheel lock Install a rig pinin bellcranks forward of rudder pedals 2 Removeleft hand nosebaggage compartmen...

Page 341: ...GRUMMAN D l g 0 S IPsa zSMl YOOIRfl GA 7 COUGAR MAINTENANCE MANUAL Control Column Installation Figure 216 Sheet 1 of 4 27G72 42 1 27 3 1 Page 232 July 15 77...

Page 342: ...r r IUMMAN IMML Dtg iW zSMO YOOM GA 7 COUGAR MAINTENANCE MANUAL Control Column Installation Figure 216 Sheet 2 of 4 DETAIL A 3842 27 3 1 Page 233 July 15 77...

Page 343: ...GRUMMAN gP0 z2 A OAYO GA 7 COUGAR MAINTENANCE MANUAL DETAIL B DETAIL C Control Column Installation Figure 216 Sheet 3 of 4 27 3 1 Page 234 July 15 77 s K r rr 7...

Page 344: ...sal Joint 61 Spacer 62 Shim 63 Thrust Plate 64 Nut 65 Washer 66 Bolt 67 Sprocket 68 Thrust Plate 69 Shaft 70 Thrust Bearings 71 Cotter Pin 72 Nut 73 Washer 74 Bolt 75 Bob Weight Push Rod 76 Elevator P...

Page 345: ...moving cotter pin 86 nut 87 washer 88 andbolt 89 21 Remove nuts 90 washers 91 and bolts 92 Remove control column 93 from aircraft 22 Remove nuts 94 and washers 95 Remove support assemblies 96 B Instal...

Page 346: ...r 49 and nut 48 11 Install aileron trim linkage to base of control column with bolt 89 washer 88 nut 87 and cotter pin 86 12 Install top end of push rod 47 to arm of bellcrank 52 with bolt 46 washers...

Page 347: ...sprockets 67 keeping bungee 42 centered and an equal amount of free links at bungee ends 18 Joint turnbuckle eye 30 and end of cable assembly 28 with turnbuckle 26 Tighten turn buckle 26 as required t...

Page 348: ...Removerig pinsfrombellcranks forward of rudder pedals 15 Control Column Rigging Procedure A Opennosebaggage compartment andremove access panels fromaft wall B Place aileron trimcontrol knob in neutral...

Page 349: ...220 NOTE The following procedures apply to either stall sensor switch Refer to Section 27 4 1 for stall sensor selector switch maintenance A Removal NOTE The use of a template to locate switchis reco...

Page 350: ...JP J AILERON CABLE DISCONNECT POINTS GRUMMAN zSxIMISPiOe tM MD YDOIM GA 7 COUGAR MAINTENANCE MANUAL SPROCKET VALLEY Control Column Rigging Figure 219 CONTROL WHEEL 27 3 1 Page 241 July 15 77...

Page 351: ...6 Insulating Strip 7 Wires 8 Nut 9 Washer GA 7 C0UGAR MAINTENANCE MANUAL 10 Terminals 11 Washer 12 Nut 13 Washer 14 Washer 15 Stall WarningHorn 16 Mounting Bracket 17 Adjustment Screw 18 Access Hole S...

Page 352: ...System Adjustment See Figure 221 See Figure 222 for Schematic Diagram A With flaps up flight test aircraft noting speed at which stallwarning system sounds and speedat which stall occurs Stall warning...

Page 353: ...WARNING 5A VANE ADJUST UPWARD TO INCREASE SPEED AT WHICH HORN SOUNDS WING Stall Sensor Switch Adjustment Figure221 STALL WARNING HORN 0 zzx 5 TO 30 OUTBOARD STALL SENSOR SWITCH l STALL SENSOR SELECTOR...

Page 354: ...below 6 degrees F Lift and hold outboard stall sensor switch Stall warninghorn should sound G Release vane and set master switch to OFF 20 Bearing Inspection and Replacement A Remove elevators in acco...

Page 355: ...aps areconnected to the flap torque tube by push rods Flap Drive and Torque Tube Mechanical power to position the flaps is provided by a reversible DCmotor which turns a worm drive in the gearbox The...

Page 356: ...rees down position in increments of 10 degrees The meter is provided with an off scale dot at the top The pointer will go to this dot when poweris off or in the event of a malfunction The flap positio...

Page 357: ...9A20 FLAP SWITCH OP 7CC2A16 7CC4A16 7CC3C16 DOWNq 7CC6A16 7CC7A16 NOTE THE FLAP LIMIT SWITCHES ARE SHOWN IN THE FLAP UP POSITION 7CC9B20 J40 P40 C 1 C 2 C 3 C 4 4 f S 7CC2B16 7CC4B16 7CC3B16 7CC6B16 7...

Page 358: ...e motor if voltage is present Check wiring and flap switch if no voltage is present Flaps drive beyond up or down limit switch Switch improperly rigged or defective Manually actuate limit switch and a...

Page 359: ...of torque tube bellcrank 6 3 At inboard flap hinge remove cotter pin 8 nut 9 washer 10 and bolt 11 Repeat pro cedureat center flap hinge 4 At outboard flap hinge remove cotter pin 14 nut 15 andwasher...

Page 360: ...GRUMMAN AiMHISlOIgAIr SMOAYDOIM GA 7 COUGAR MAINTENANCE MANUAL B C Flap Removal and Installation Figure 201 Sheet 1 of 2 DETAIL A 27 4 1 Page 202 July 15 77...

Page 361: ...5 Flap Push Rod 6 Torque Tube Bellcrank 7 Flap 8 Cotter Pin 9 Nut 10 Washer 11 Bolt 12 Wing Hinge Half 13 Flap Hinge Half 14 Cotter Pin 15 Nut 16 Washer 17 Bolt 18 Washer 19 Wing Hinge Half 20 Torque...

Page 362: ...Indicating System A Removal CAUTION MAKE SURE GROUND NEGATIVE BATTERY CABLE IS DISCONNECTED AND CLEAR OF BATTERY TERMINAL BEFORE REMOVING SYSTEM COMPONENTS 1 Place master switchin OFF position Open b...

Page 363: ...iL V W GA 7 C0UGAP MAINTENANCE MANUAL 1 Connector 2 Nut 3 Washer 4 Bolt 5 Drive Assemblv 6 Torque Tube 7 Nut 8 Washer 9 Bolt 10 Bracket Flap Actuator DriveAssembly Removal and Installation Figure 202...

Page 364: ...9 Wire 2 Washer 10 Nut 3 Roller Arm 11 Washer 4 Torque Tube Cam 12 Wire 5 Flap PositionTransmitter 13 Nut 6 Mounting Bracket 14 Screw 7 Nut 15 Flap Position Indicator 8 Washer 16 Instrument Panel Fla...

Page 365: ...GATIVE BATTERY CABLE IS DISCONNECTED AND CLEAR OF BATTERY TERMINAL BEFORE DISCONNECTING WIRING 1 Pull aft passenger seat bottom up and forward to gain access to flap torque tube Locate landing gear an...

Page 366: ...HKEs IRD WO YDOIW GA 7 COUGAR MAINTENANCE MANUAL 1 Nut 2 Screw 3 Switch 4 Mounting Bracket 5 Nut 6 Washer 7 Washer 8 Cam 9 Bolt 10 Torque Tube Sensor Switch Installation Typical Figure 204 274 1 Page...

Page 367: ...OR OTHER COMPONENTS 5 Beneath the aft wing fairing and forward of the left flap remove nut 1 Figure 205 and washer r 2 Raise flap 10 slightly and remove bolt 3 and washer 4 Move push rod 5 clear of b...

Page 368: ...rank 7 Bolt 8 Washer 9 Washer 10 Flap FLAP POSITION TRANSMITTER SEE FIGURE 203 DUAL STALL VANE AND LANDING GEAR WARNING SWITCH INSTALLATION SEE FIGURE 204 11 Nut 12 Washer 13 Bolt 14 Washer 15 Torque...

Page 369: ...ckness reduction Wear greater than this will require replacement of the bellcrank Bearing Replacement A Remove flap torque tube asdescribed in Paragraph 5 B Collapse bearing asshownin Figure 206and re...

Page 370: ...IRUMMAN AMBRMBAM VDAYO GA 7 COUGAR MAINTENANCE MANUAL Flap Bearing Removal Installation Figure 206 274 1 Page 212 July 15 77 S S...

Page 371: ...conditions Failure to comply will result in shortened flap travel when airborne A Pull therear seat bottomupand forward to gain access to the flap drive assembly NOTE The following procedures require...

Page 372: ...witch With a man at each wing manuallylift both flaps to take up slack in the linkage The flap rigging deviceshouldread 30 2 degrees I Adjust the position if required Move the down limit switch forwar...

Page 373: ...ctor Valves Primer Solenoid Valves Engine Driven Fuel Pumps Fuel Pressure Gauges Fuel Quantity Gauges Fuel System ElectricalCircuitry Troubleshooting Maintenance Practices Refueling Defueling 28 1 1 F...

Page 374: ...tion Fuel Selector Panel and Fuel Selector Valve Description Fuel Selector Valve Removal Fuel Selector Valve Installation Primer Solenoid Valves Removal Installation Fuel System Plumbing Removal Fuel...

Page 375: ...Quantity Gauges Maintenance Practices Removal Installation Fuel Pressure Gauge Removal Fuel Pressure Gauge Installation Fuel Pressure Transmitter Removal Installation Fuel Quantity Gauge Removal Fuel...

Page 376: ...ard ends of the tanks Five ribs inside each fuel tank retard fuel slosh during uncoordinated maneuvers Each wing tank is equipped with a quick drain valve Capacityof the tanks is 120 gallons with 118...

Page 377: ...T LINE PRIMER SOLENOID ELECTRIC FUEL PUMP SUMP TANK PRIMER SOLENOID ELECTRIC FUEL PUMP SUMP TANK ixyywxxgra tvwyyxKwy TvyyyrgyWvvvWvvvvvvvvvtfvvi CROSS FEED LINES GA 7 Cougar Fuel System Schematic Fig...

Page 378: ...are located between the fuel selector valves and the engine driven fuel pumps The valves are operated by a toggle switchlocated on the lower left side of the instrument panel H Engine Driven Fuel Pump...

Page 379: ...attached to a pivoted rod one end of which isa rheostatwiper The vertical motion of the fuel causes angular travel of the float which increases or decreases the amount of resistance in the circuit Thi...

Page 380: ...T0H 3I GA 7 COUGAR MAINTENANCE MANUAL RTENG PRIME SOLENOID J VALVE T 7QC4A20 T GA 7 Cougar Fuel System ElectricalCircuits Figure 3 OUT8D FUEL QUANTITY SENDER INBD FUEL QUANTITY SENDER OUTBD FUEL QUANT...

Page 381: ...lean strainer Flush tank clean prior to reassembly Defectivegauge Temporarily substitute a 72 0 ohm resistance for the fuel pressure trans ducer If fuel pressure gauge does not indicate 10 psi replace...

Page 382: ...tity indication Empty fuel tank Servicewith proper grade of fuel Defective fuel quantity trans mitter Temporarily substitute a 90 0 ohm resistance for the fuel quantity transmitter If fuel quantity ga...

Page 383: ...SURE THAT CONTAINER IS PROPERLY POSITIONED TO CATCH FUEL KEEP ARM ABOVE LOCKNUT TO PREVENT FUEL FLOWING ON BODY A CONTINUOUS SUPPLY OF NITROGEN AT 0 6 PSI MUST BE MAINTAINED TO PERMIT SIPHONING AND I...

Page 384: ...8 usable in all flight attitudes Three position fillers provide a convenient method to limit fuel quantity when aircraft loading restricts the use of the total fuel capacity Each fuel tank is equipped...

Page 385: ...nside threaded portion of union 2 Insert coupling nut over strainer 3 Tighten coupling nut ontoinside threaded portion of union holding wrench onoutside portion of union to keep it from rotating 4 Che...

Page 386: ...n be accomplished simply by inserting threaded end of valve in housing and securing valve to housing Torqueto 100 25 inch pounds The following procedures are for installation of the complete quick dra...

Page 387: ...be repaired before that tank is used for any flight The wet or stained spot on the wing in the area of the tank is an indication of leak intensity Fuel leak classifications are shown in Figure 202 It...

Page 388: ...UGAR MAINTENANCE MANUAL STAIN SIZE WILL VARY WITH LOCATION AND INTENSITY SEEP HEAVY SEEP Classification of Fuel Leaks Figure 202 RUNNING LEAK FUEL Wl LL USUALLY FLOW IN THIS AREA ALONG SKIN CONTOUR AF...

Page 389: ...tanks one mounted in each wing two sump tanks two electric fuel pumps two selector valves two primer solenoid valves two engine driven fuel pumps and associated plumbing In addition the electrical cir...

Page 390: ...h of theelectric fuel pumps also called booster orauxiliary pumps These filters must be serviced periodically every 100 operating hours The following procedures are recommended for fuel pump filter se...

Page 391: ...ked LEFT ENGINE and RIGHT ENGINE and are connected by mechanical linkage to the pivot arm of the respective fuel selector valve The selections provided for these switches are LEFT ENGINE RIGHT ENGINE...

Page 392: ...GRUMMAN MMHriPM PM iW iT GA 7 COUGAR MAINTENANCE MANUAL Fuel Selector Panel and Fuel Selector Valve Removal Installation Figure 202 SELECTOR VALVE FUEL LINES 28G72 7 28 2 1 Page 203 July 15 77...

Page 393: ...Cap allopen lines and fittingsto prevent contamination fromenteringsystem 2 When disconnectinglines first ensure that all residual fuel is drained from the line 3 Exercise the precautionspreviously m...

Page 394: ...osition fuel pump on rib 2 Install washers and screws 3 Clean exposed threads on fuel pump fittings with a stiff bristle brush 4 Connect fuel lines to fuel pump 5 Torque fittings to 100 25 inch pounds...

Page 395: ...ft engine fuel pump check setfuel selector valve to leftengine 3 Set master switch to ON 4 Setauxiliary fuel pumpswitch toON 5 Observe fuel pressure gauge Gauge should indicate 0 5 to8 0psi 6 Set auxi...

Page 396: ...d be indicated within 30 seconds 12 Set auxiliary fuel pump switch to OFF whileobserving fuel pressure gauge Gauge shouldindicate 0 5 to 8 0 psi with auxiliary fuel pump off 13 Run engine at several d...

Page 397: ...ounted on a bracket on the right side of the engine mounts B Fuel Quantity Gauges The two fuel quantity gauges are actuated individually by fuel quantity transmitters installed in the inboard and outb...

Page 398: ...ter B Fuel PressureGauge Installation See Figure 201 1 Insert fuel pressure gauge into centersection of left instrument cluster so studs protrudethrough holes in metal support plate 2 Properly align f...

Page 399: ...Bm AM AWDATTOfr 01 GA 7 COUGAR MAINTENANCE MANUAL INSULATING WASHER FACE PLATE ATTACHING SCREW Fuel Pressure Gauge Fuel Quantity Gauge Removal Installation Figure 201 LOCKNUT 28G72 9 28 3 1 Page202 Ju...

Page 400: ...oved 4 Connect electrical leads to sluds on back of fuel quantity gauge using locknuls provided with gauge Fuel Level Sender Unit Removal See Figure 202 1 Ensure that all power is off WARNING FUEL TAN...

Page 401: ...TANK BULKHEAD BOLT WASHER UNDER HEAD Fuel Level Sender Unit Removal Installation Figure 202 28G72 10 Normally no attempt should be made to calibrate or repair adefective fuel pressure gauge or a fuel...

Page 402: ...nd pitot system and theelimination of frost and fog on the windows and windshield Thischapter contains the following systemsand their related components Carburetor Heat System Pitot Heater System Wind...

Page 403: ...arburetor air boxes by a cable linkage When the carburetor heat control is in the OFF pushed in pdsition filtered air is drawn through ducting into the carburetor When the carburetor heat control is i...

Page 404: ...GRUMMAN IMJUt OISi AWOAITOOIft GA 7 COUGAR MAINTENANCE MANUAL LH CARBURETOR f HEAT CONTROL Carburetor Heat Controls Figure 1 RH CARBURETOR HEAT CONTROL 30G72 1 30 1 0 Page 2 July 15 77 X v...

Page 405: ...MG3 r miM AWiAlwH m GA 7 COUGAR MAINTENANCE MANUAL CARBURETOR REF SHUTOFF VALVE AIR BOX ODZM CARBURETOR HEAT CONTROL CABLE Carburetor Heat System Components Figure 2 Sheet 1 of 2 DETAIL A 30G72 2 1 30...

Page 406: ...TifIIMIM GA 7 COUGAR MAINTENANCE MANUAL CARBURETOR HEAT CONTROL SHUTOFF VALVE CONNECTION Carburetor Heat System Components Figure2 Sheet 2 of 2 AIRBOX BRACKET CARBURETOR HEAT CONTROL CABLE 30G72 2 2 3...

Page 407: ...binding exists throughout travel of heat control NOTE It is necessary to operate the aircraft engines to test the carburetor heat system opera tionally WARNING ENSURE THAT PROPELLER AREAS ARE CLEAR PR...

Page 408: ...ring icingconditions It consists of a control knob for each engine The control knobs are mounted on the control quadrant below the throttles prop control and mixture control levers The heat controls a...

Page 409: ...inadequate to prevent icing PROBABLE CAUSE REMEDY Linkage binding broken or crimped Adjust linkage or replace as required Control binding in control quadrant Clean adjust and lubricate as required Ai...

Page 410: ...ball joint end of the cable to facilitate installation of new cable Slide cable out through console assembly Remove wire or string from old cable Install carburetor heat control cable as follows 1 At...

Page 411: ...justments can be made at the ball joint connection on carburetor air box siiutoff valve If further adjustments are required loosen cable mount clamps and re position cable assembly to obtain the dimen...

Page 412: ...j V GRUMMAN AIMIl D g dR l WD FOOIM GA 7 C0UGAR MAINTENANCE MANUAL Typical Control Knob Rigging Figure 201 0 125 IN SPACER FACE PLATE CONTROL KNOB 30G72 3 30 1 1 Page 203 July 15 77...

Page 413: ...cted to the carburetor heal control lever by a cable assembly When the shutoff valve is open heated air isdiverted to the carburetor air intake Carburetor heat is shut off when the valve is closed Sin...

Page 414: ...associated wiring The switch is of plastic construction andis mounted on the lowerleft sectionof the instrument panel The heater hasa 15amp circuit breaker incorporated See Figure 2 which is located o...

Page 415: ...HEATED PITOT TUBE GRUMMAN EPJOCzSi AmAYmM GA 7 COUGAR MAINTENANCE MANUAL Pitot Heater System Figure 1 FS 3 00 REF 30G72 4 30 3 1 Page 2 July 15 77 s StL...

Page 416: ...lHSAIRi AMmrmM GA 7 COUGAR MAINTENANCE MANUAL FWD BULKHEAD FUSELAGE STATION 50 FWD OFF PITOT HEAT SWITCH 7FBIBI6 J 23 W25 Pitot Heater Circuit Figure 2 P23 W23 7FB2AI6 PITOT TUBE HEATER 7FB3AI6 1 30G7...

Page 417: ...shooting Pitot Heater System TROUBLE PROBABLE CAUSE REMEDY Pitot tube fails to heat Circuit breaker popped Reset circuit breaker If it pops again do not reset Determine cause and correct Defectivewiri...

Page 418: ...rswitch is in OFF position 2 Connect wiring to switch terminals 3 Position switch in place on instrument panel and push switch into mounting hole until switch snaps into panel OperationalTest of Pitot...

Page 419: ...right forward cabin air outlet valves to the left and right windshield defroster vent outlets Operation of the defroster is accomplished by operating the cabin heating system Refer to Chapter 21 and...

Page 420: ...embly Cleaning Inspection and Repairof Trunnion and Oleo Assembly Assemble Trunnion and Oleo Assembly Install Main LandingGearTrunnion and Oleo Assembly Removal Installation of Main Gear Actuator Remo...

Page 421: ...ly Install Main LandingGear Brace Assembly Main LandingGearSide Brace Prerigging Procedures Main LandingGearRiggingProcedures Operational Check NOSE LANDING GEAR Description Operation General Maintena...

Page 422: ...ssors 211 Install NoseGear Scissors 212 Removal Installation of Nose Gear Bracket Assembly 212 RemoveNose Gear Bracket Assembly 212 Install Nose Gear Bracket Assembly 212 Removal Installation of Nose...

Page 423: ...stment Removal Installation of NoseGear Brace Assembly Remove Nose Gear Brace Assembly Disassemble Nose Gear BraceAssembly Cleaning Inspection and Repairof NoseGearBrace Assembly Assemble Nose Gear Br...

Page 424: ...01 Assemble Power Pack Assembly 201 Install Power Pack Assembly 203 Removal Disassembly Assembly Installation of Landing Gear Actuators 203 Removal Installation of Hydraulic Emergency Dump Valve 203 R...

Page 425: ...heel Assembly 201 Cleaning Inspection and Repair ofMain Gear Wheel Assemblies 201 Assemble Main Gear Wheel Assembly 203 Install Main Gear Wheel Assembly 203 Removal Installation of Nose Landing Gear W...

Page 426: ...ype 204 Assemble Master Cylinder Reservoir Type 204 Install Master Cylinder 20s Removal Installation ofParking Brake Valve Assembly 205 Remove Parking Brake Valve Assembly 205 Install Parking Brake Va...

Page 427: ...INTENANCE MANUAL TABLE OF CONTENTS Continued NUMBER PAGE General 1 Maintenance Practices 201 Adjustmentof Landing Gear Up Power Reduced Warning Switch 201 Adjustmentof Landing Gear Up Flaps Extended W...

Page 428: ...re all down and locked three green lights illuminate on the instrument panel When all of the gears are not down and locked NOT SAFE an amber light illuminates on the instrument panel An aural sound wa...

Page 429: ...ged trunnion oleo cylinder yoke axle scissors brace assembly actuator assembly and collar The gear is retracted or extended hydraiilically with a single hydraulic actuator Hydraulic pressure issupplie...

Page 430: ...ut 10 washer 11 boll 12 and remove actuator 13 from actuator arm 22 5 Remove access panels beneath wing lo gain access to main gear mounting hardware 6 Remove cotter pin 14 nut 15 and washer 16 From i...

Page 431: ...19 Bolt 20 Pin 21 Bushing 22 Actuator Arm GRUMMAN MHilJlD g Ra MOAYOOEftl GA 7 COUGAR MAINTENANCE MANUAL Main LandingGearInstallation Figure201 23 Nut 24 Washer 25 Bolt 26 Pin 27 Bushing 28 Nut 29 Wa...

Page 432: ...S GRUMMAN ARfflmifdOli lNJ kVD TDl HM GA 7 COUGAR MAINTENANCE MANUAL Trunnion and Oleo Assembly Figure 202 Sheet 1 of 2 32G72 2 32 1 1 Page 203 July 15 77...

Page 433: ...4 Cotter Pin 55 Nut 56 Washer 57 Switch Bracket 58 Bolt 59 Bushings 60 Scissor Half 61 Bushings 62 Trunnion Trunnion and Oleo Assembly Figure 202 Sheet 2 of 2 9 Remove retaining ring 30 spacer 31 scra...

Page 434: ...om of trunnion 6 Install O ring 29 and backup ring 28 on plug 27 Install plug 27 on bottom of piston 41 7 On plug 22 install O ring 25 backupring 24 andbarrel nut 23 8 Place stop plate 26 on top of or...

Page 435: ...B Disassemble Main Gear Actuator Main and nose gear actuators are the same Refer to Section 32 2 1 Paragraph 8B and Figure 206 for disassembly procedures C Cleaning Inspection and Repair of Main GearA...

Page 436: ...tube consists of smoothing out minor nicks scratches and dents replacement of parts and applying new finish C Install Main Landing Gear Support Tube Assembly See Figure 201 1 Slide support tube 43 thr...

Page 437: ...edures SeeFigures 203 and 204 If either main landing gear has been removed from the aircraft the side brace assembly over center adjustment should be made on the bench before the side brace assembly i...

Page 438: ...S fti AVO YO N GA 7 C0UGAR MAINTENANCE MANUAL SWITCH ACTUATING PLUNGER SHOWN IN LOCKED POSITION ACTUATOR DOWN LOCK SWITCH ASSY Main Landing Gear Down and Locked Switch Installation Figure 203 32 1 1...

Page 439: ...Brace 4 Side Brace Over Center Switch 5 Switch Mounting Bracket 6 Upper Side Brace 7 Bolt 8 BraceOver Center Locating Template 9 Upper Locator Hole 10 Lower Locator Hole 11 Locator Pin 12 Pivot Locat...

Page 440: ...tional check to make sure the landing gear isoperating properly A Side Brace Alignment With the landing gear installed on the aircraft it isnecessary to make sure no misalignment orother cause for bin...

Page 441: ...ocate side brace over center switch 4 Figure 204 and trace wiring to connector at upper end of strut Connect an ohmmeter or other continuity tester to pins 4 and 7 2 With side brace in over center pos...

Page 442: ...the gap between the end of the adjustment screw and the side brace The go end should passthrough gap the no go end should not NOTE If feeler gaugesare used the gap tolerance is 0 100 inch to 0 120 inc...

Page 443: ...NCE MANUAL APPLY 20 POUNDS OF PRESSURE AT PIVOT POINT PARALLEL TO ADJUSTMENT SCREW POSITION ADJUSTMENT SCREW TO CONTACT A FLAT SURFACE ADJUST ONLY TO MAKE CONTACT WITH BRACE GO NO GO GAGE Side Brace F...

Page 444: ...MBRN AM AWOAYO0I A GA7 COUGAR MAINTENANCE MANUAL Note The Scissors and Actuator are shown with the Oleo Strut compressed Aircraft on ground for clarity Main Landing Gear Squat Switch Installation Figu...

Page 445: ...ired to match gear Mark position of pad Lower gear Tighten two bolts holding pad in place Swing gearto up position againto check that pad is still positioned correctly 6 While holding gear solid again...

Page 446: ...straight edge against tires at axle height Use a carpenter s square to check wheel alignment 2 Using a force of 10 pounds rock wheel assembly left and right around strut Misalignment toe in and toe ou...

Page 447: ...ll increase free playapproximately 0 050 inch 5 Recheck the drag brace free play Paragraph 6 D above Steps 6 through 10 for main gear and Section 32 2 1 Maintenance Practices Paragraph 12 D Steps 6 th...

Page 448: ...hich protrude from thegear or are routed through the wheel well area 2 Inspect each wheel well interior for deposition of foreign matter chafing orother signs of interference between thegear and wheel...

Page 449: ...install bushings 20 19 and 18 and install pin 17 2 Install switch striker 16 with nut 15 and adjusting screw 14 3 In upper link 13 install bushing 12 4 Installswitch II withjam nut 10 washer 9 and nut...

Page 450: ...ut 3 Washer 4 Spacer 5 Spacer 6 Bolt 7 Retracting Linkage 8 Nut 9 Washer 10 Bushing 11 Spacer 12 Washer 13 Bolt 14 Hinge 15 Nut 16 Washer 17 Washer 18 Spacer 19 Lug 20 Washer 21 Bolt 22 Bracket Nose L...

Page 451: ...ar descends A Remove lockwire 14 Figure 210 loosen locknut 1 and make sure over center stop bolt 2 will turn freely Position the brace over center locating template 7YL10002LT as shown 8 Figure 210 Pl...

Page 452: ...Ril Z5 W0AY0O M GA7 C0UGAR MAINTENANCE MANUAL ACTUATOR DOWN LOCK SWITCH ASSY SWITCH ACTUATING PLUNGER SHOWN IN LOCKED POSITION Nose Landing Gear Down and Locked Switch Installation Figure 209 32 2 1 P...

Page 453: ...ide Brace Over Center Switch 5 Switch Mounting Bracket 6 Upper Side Brace 7 Bolt 8 Brace Over Center Locating Template 9 UpperLocator Hole 10 Lower Locator Hole 11 Locator Pin 12 Pivot Locator Hole 13...

Page 454: ...nthe aircraft itis necessary tomake sure nomisalignment orother cause for binding exists sothatthelanding gear will free fall tothedown and locked position 1 Jack the aircraft in accordance with Chapt...

Page 455: ...n ohmmeter or other continuity tester to pins 4 and 7 2 With side brace in over center position and head of over center stop bolt 2 firmly against switch mounting bracket 5 adjust side brace overcente...

Page 456: ...inch to 0 140 inch 8 If the go end of the gauge will not pass gap less than 0 120 inch or the brace willnot deflect at all investigate for misalignment damage or other causes for binding 9 If the no g...

Page 457: ...TE CLAMPING POINTS DETAIL A ROTATED 90 Nose Gear Brace Free Play Alignment Tool Figure 211 APPLY 20 POUNDS OF PRESSURE AT PIVOT POINT PARALLEL TO ADJUSTMENT SCREW POSITION ADJUSTMENT SCREW TO CONTACT...

Page 458: ...op block Trace wiring to connector adjacent to upper end of strut Connect an ohmmeter or other continuity tester to Pins I and 2 Obtain a piece of rigid tubing 2 inches in diameter and 3 to 4 inches l...

Page 459: ...should be a tight fit but without any evidenceof distortion 8 At the left nose gear door remove nut 2 Figure 208 washer 3 and bolt 4 Disconnect retracting linkage 7 from door 9 RepeatSteps 2 through...

Page 460: ...gear steering through an arc of approximately 20 degrees each side of centeriine and allow swiveling the nose gear through approximately 35 degrees with differential braking When the nose gear retract...

Page 461: ...7 Remove nut 13 washer 14 bolt 15 nut 16 washer 17 and bolt 18 Remove actuator arm 19 8 Remove nut 20 washer 21 and bolt 22 from trunnion 12 9 Working through openings in nose baggage compartment floo...

Page 462: ...GRUMMAN AMBBW AM WO YOOtflU GA 7 C0UGAR MAINTENANCE MANUAL DETAIL C 15 20 Nose Landing Gear Assembly Figure201 Sheet 1 of 2 32G72 3 32 2 1 Page 202 July 15 77...

Page 463: ...op Link Assembly 11 Bolt 39 Not Used 12 Trunnion Assembly 40 Not Used 13 Nut 41 Not Used 14 Washer 42 Cotter Pin 15 Bolt 43 Nut 16 Nut 44 Wheel Assembly 17 Washer 45 Cotter Pin 18 Bolt 46 Nut 19 Actua...

Page 464: ...GRUMMAN AMBBWriAM M Z yyh GA 7 COUGAR MAINTENANCE MANUAL Nose Gear Oleo Assembly Figure 202 Sheet I of 2 32G72 4 32 2 1 Page 204 July 15 77...

Page 465: ...g 24 and O ring 25 8 Remove retaining ring 27 spacer 28 and scraper 29 from inner tube and remove bearing 30 9 Remove backup ring 31 O ring 32 backup ring 33 and O ring 34 from bearing 30 10 From insi...

Page 466: ...Inflate strut to 90 psi E Install Trunnion and Oleo Assembly See Figure 201 1 Place trunnion and oleo assembly in position in wheel well and align mounting holes in trunnion with mount fitting holes i...

Page 467: ...GRUMMAN AGMDIK OOAIft WO YOCg GA 7 COUGAR MAINTENANCE MANUAL H Trunnion and Oleo Assembly Figure 203 Sheet 1 of 2 32G72 5 32 2 1 Page 207 July 15 77...

Page 468: ...t 20 Nut 21 Washer 22 Washer 23 Bolt 24 Shimmy Dampener 25 Cotter Pin 26 Nut 27 Washer 28 Spacer 29 Bolt Trunnion and Oleo Assembly Figure 203 Sheet 2 of 2 30 Bearing Oilite 31 Bearing Oilite 32 Sciss...

Page 469: ...installing bolts 3 washers 2 and nuts 1 D Nose Gear Steering Adjustments Refer to Chapter 27 Flight Controls for information onnose gear steering system adjustments 3 Removal Installation of Nose Gea...

Page 470: ...L Bolt Seal Washer Jam Nut Rod End Retainer Ring Bearing Head Backup Ring O ring Rod Assembly Housing 11 Backup Ring 12 O ring 13 Pin 14 Piston 15 O ring 16 Pin 17 Spring 18 Pressure Piston 19 O ring...

Page 471: ...earingheads 6 5 Install one bearing head 6 on the rodend sideof the housing 10 and install rod end 4 andjam nut 3 on rod assembly NOTE Service shimmy dampener with MIL H 5606 hydraulic oilbeforecontin...

Page 472: ...ove brackets 49 and 50 from nose geartrunnion assembly B Install Nose Gear Bracket Assembly See Figure 203 1 Place nose gear brackets 50 and 49 and pin 48 in position and install bolt 47 washer 46 and...

Page 473: ...I from bellcrank 13 2 Remove cotter pin 2 nut 3 washer 4 washers 5 and bolt 6 and remove turnbuckle assembly 3 Remove cotter pin 7 nut 8 washers 9 10 and 11 and bolt 12 Remove bellcrank assembly 13 4...

Page 474: ...GRUMMAN AIMI iPO Alft M0 Y0 Q1 M GA 7 C0UGAR MAINTENANCE MANUAL DETAIL B Door Closer Mechanism Assembly Figure 205 Sheet I of 2 32G72 7 32 2 1 Page 214 July 15 77 Sik k...

Page 475: ...m 32 33 36 37 40 41 Door CloserMechanism Assembly Figure 205 Sheet 2 of 2 3 Repair of the nose gear door closer mechanism consistsof smoothing out minor scratches nicks and dents and replacement of de...

Page 476: ...springsto eyebolts 35 4 Working through access in nose baggage compartment floor align holes in support tube with holes in mounting block and install bolt 31 washers 30 and nut 29 F Nose Gear DoorClo...

Page 477: ...ator body 32 C Cleaning Inspection and Repair of Nose Landing Gear Actuator 1 Clean actuator components witha suitable drycleaning solvent 2 Inspect components for wear cracks nicks corrosion proper l...

Page 478: ...Switch Retaining Ring Washer Spring Pin Piston Lock Backup Ring O ring Fitting O ring Rod End 17 Jam Nut 8 Retaining Ring 19 Plug 20 Backup Ring 21 O ring 22 Backup Ring 23 O ring 24 Nut 25 Washer 26...

Page 479: ...F Install Nose Gear Actuator See Figure201 1 Position end of actuator 55 in lugs of brace assembly and install bolt 54 washer 53 spacer 52 washer 51 nut 50 and cotter pin 49 2 Install actuator rod end...

Page 480: ...13 Upper Link 3 Washer 14 Adjusting Screw 4 Pin 15 Nut 5 Bolt 16 Switch Striker 6 Washer 17 Pin 7 Switch Bracket 18 Bushing 8 Nut 19 Bushing 9 Washer 20 Bushing 10 Jam Nut 21 Lower Link 11 Switch Disa...

Page 481: ...nut 15 and adjustingscrew 14 3 In upper link 13 installbushing 12 4 Install switch 11 with jam nut 10 washer 9 and nut 8 5 Install switch bracket 7 with washers 6 and bolts 5 6 Assemble upperandlowerl...

Page 482: ...3 Washer 4 Spacer 5 Spacer 6 Bolt 7 Retracting Linkage 8 Nut 9 Washer 10 Bushing 11 Spacer 12 Washer 13 Bolt 14 Hinge 15 Nut 16 Washer 17 Washer 18 Spacer 19 Lug 20 Washer 21 Bolt 22 Bracket Nose Land...

Page 483: ...ee Figure 208 1 Place spacers 18 in lugs 19 and position lugs 19 in brackets 22 2 Install washers 17 and 20 bolts 21 washers 16 and nuts 15 D Install Nose Gear Doors See Figure 208 1 Placedoors in pos...

Page 484: ...licSystem An independent hydraulically actuated brake system is provided for each main wheel Hydraulic master cylinders are connected toeach rudder pedal The master cylinders are connected towheel cyl...

Page 485: ...MMAN AIMUf DO IFiJ AmAfiTmm PUMP MOTOR GA 7 C0UGAR MAINTENANCE MANUAL SELECTOR VALVE CONTROL LEVER DUMP VALVE CONTROL R MAIN GEAR ACTUATOR PRESSURE V A RETURN f H Hydraulic System LandingGearRetractio...

Page 486: ...y squat switch out of adjustment Adjust squat switch Squat switch inoperative Replace switch Pressureswitch inoperative Replace switch Pump solenoid inoperative Replace solenoid Selector switch ground...

Page 487: ...lace or overhaul pump Hydraulic fluid in reservoir below operating level Fill reservoir with hydraulic fluid Battery low Check battery Landinggear retraction extremely slow Hydraulic fluid in reservoi...

Page 488: ...of hydraulic system Pump relief valve onl of adjustment Pump solenoid sticking Gear down liinil swilchles mil of adjustment or failed Pump high pressure relief valve out of adjustment Hydraulic fluid...

Page 489: ...Assembly See Figure 201 1 Remove vent screw 1 washer 2 filler screw 3 and O ring 4 and drain any fluid left in reservoir Do not remove gears unless necessary 2 Remove bolts 5 pump base 6 O rings 7 scr...

Page 490: ...Screw Vent 2 Washer 3 Screw Filler 4 O ring 5 Bolt 4 and Washers 4 6 Pump Base 7 O rings 8 Screw 8 9 Valve and Gear Case 10 Seal 11 Through Bolt 12 Through Bolt 13 Motor Head 14 Brush Spring 15 Brush...

Page 491: ...and gear case 9 Install pump base 6 with bolts and washers 5 Torque bolls to 70 inch pounds E Install Power Pack Assembly 1 Place power pack assembly in position and align mounting holes in power pac...

Page 492: ...rictor Check Valve A Remove Hydraulic Restrictor Check Valve 1 Disconnect hydraulic hose from restrictor check valveand cap hose 2 Remove restrictor check valve from actuator B Disassemble Hydraulic C...

Page 493: ...t hydraulic hose to hydraulic restrictor check valve Hydraulic Fluid Contamination Check A Check Hydraulic Fluid At the first 50 hour and first 100 hour inspection thereafter at each 500 hour inspecti...

Page 494: ...nect aircraft to an external fla powersource if available 2 With landing gear down master switch ON and circuit breaker in place landing gear control handle inthe UP position The hydraulic pump should...

Page 495: ...r The main gear tires should be rotated periodically to obtain maximum tire life All wheels are of the split wheel design for easy servicing and the main wheels have independent disc type brake system...

Page 496: ...alves or tire when breaking tire bead loose from wheel halves WARNING DO NOT ATTEMPT TO SEPARATE WHEEL HALVES WHILE TIRE IS UN DER PRESSURE SERIOUS INJURY COULD RESULT 4 Remove nuts 11 washers 12 and...

Page 497: ...Half 4 Pressure Plate 16 Brake Disc Assembly 5 Cylinder Assembly 17 Snap Ring 6 Screw 18 GreaseSeal Ring 7 Lockwasher 19 Grease Seal 8 Dust Shield 20 Grease Seal Ring 9 Cotter Pin 21 Cone Bearing 10...

Page 498: ...21 grease seal ring 20 grease seal 19 grease seal ring 18 and snap ring 17 6 Inflate tire to 40 2 psi 7 If new tire was installed balance to within 5 inch ounces E Install Main Gear Wheel Assembly Se...

Page 499: ...NTENANCE MANUAL 1 2 3 4 5 6 7 Nut Washer Bolt Wheel Half Wheel Half Snap Ring Grease Seal Ring 8 9 10 II 12 13 Grease Seal Grease Seal Ring Cone Bearing Bearing Cup Tube Tire NoseGear Wheel Assembly F...

Page 500: ...Inspection and Repair of Nose Gear Wheel Assembly 1 Clean bearings 10 grease seal rings 7 and 9 and grease seal 8 with cleaning solvent and dry thoroughly with clean air blasts from an air hose 2 Ins...

Page 501: ...balance wheel and tire to within 5 inch ounces E Install Nose Gear Wheel Assembly See Figure 201 Section 32 2 1 1 Position nose wheel assembly on axle of nose gearand install axle nut 43 and tighten u...

Page 502: ...ng direcl flow of fluid from the two cylinders on the pilot s side The aircraft is also equipped with a parking brake The parking brake system consists of a hydraulic valve mechanically operated by a...

Page 503: ...der pedal 4 Remove cotter pin and withdraw clevis pin which attaches the mounting lug of the master cylinder to the mounting bracket B Disassemble Master Cylinder Assembly Nonreservoir Type See Figure...

Page 504: ...h brake fluid Immerse all seals in hydraulic brake fluid MIL H 5606 and apply a coating of brake fluid to bore of cylinder housing 16 2 Inspect snap rings and springs for cracks and general condition...

Page 505: ...THE CASTING 6 Install fittings in inlet and outlet ports Disassemble MasterCylinder ReservoirType See Figure 202 1 Remove fitting from cylinder housing outlet port 2 Remove clevis I and check nut 2 f...

Page 506: ...rake fluid 2 Inspectspringsand snap ringsfor cracksand general condition 3 Repair of the master cylinder consists of replacement ofO rings and any othercomponents found to be defective AssembleMaster...

Page 507: ...ttings 2 Remove bolt washer nut and cotter pin attachingcontrol cable to parkingbrake valve 3 Remove two screws and washersattaching brake valve to bracket and remove valve B Install ParkingBrakeValve...

Page 508: ...AINTENANCE MANUAL 1 Bolt 2 Washer 3 Backplate 4 Cylinder 5 Pressure Plate 6 Piston 7 O ring Wheel Brake Assembly Figure 203 8 Nut 9 Washer 10 Anchor Bolt 11 Brake Disc 12 Torque Plate 13 Lining 14 Ble...

Page 509: ...damage deterioration and excessive wear d Inspect anchor bolts for nicks or damage e Inspect brake disc for excessive wear minimum thickness of 0 206 inch 3 Repair of the wheel brake assembly consist...

Page 510: ...lines in a suitable container containing enough hydraulic fluid to cover theends of thelines 2 Connect aclean hydraulic source tothe bleeder at the bottom ofthe wheel brake cylinders 3 Fill the hydra...

Page 511: ...ciency of these brakes extremely hard braking could result in lifting the tail from the ground This conditioning procedure will wear off high spots and generate sufficient heat to glaze the linings On...

Page 512: ...nose gear trunnion assembly The nose gear steering system provides nose gear steering through an arc of approximately 18 degrees each side ofcenteriine and iscapable of swiveling the nose gear throug...

Page 513: ...E MANUAL NOSE WHEEL STEERING MAINTENANCE PRACTICES Removal Installation of Nose Wheel Steering Assembly Refer to Section 32 2 1 forremoval and installation of steering arm The steering linkage is cove...

Page 514: ...the amber light should beout and the green lights gear down and locked should beilluminated Ifeither landing gear does notextend and lock the NOT SAFE light will remain illuminated and alert the pilot...

Page 515: ...8 GRUMMAN AlM BiaO gAIRO AM0AY0 fta GA7 COUGAR MAINTENANCE MANUAL JJ6 tl6 j 9 TTTJ 7GD1C20 SOUAT SWITCH NAV LTSW JpJ noun naV CONTINUED ON IHE FOLLOWING PAGE PM J29 P76 J 7GB1A20 fTTfTi 7GBISTO TIT 7...

Page 516: ...J23 P23 V7GB3B20 Landing Gear Warning System Wiring Diagram Figure 1 Sheet 2 of 2 SWITCHESAND CONTROLSSHOWNWITH AIRCRAFT ON GROUND GEAR DOWN AND LOCKED LANDING GEAR HANDLE IN DOWN POSITION ANDTHROTTL...

Page 517: ...nd shut down the engines 4 Place theaircraft onjacks inaccordance withChapter 7 ApplyDC power to theaircraft 5 Retract the landing gear 6 Position the throttle levers to the markmadein Step 2 7 Remove...

Page 518: ...GRUMMAN AMBRN AM AVOATOOIrcl GA 7 COUGAR MAINTENANCE MANUAL t Landing Gear Up Power Reduced Microswitch Figure 201 ADJUSTING SCREWS 32G72 21 32 6 1 Page 202 July 15 77 S Z...

Page 519: ...PN GRUMMAN F H De OAimOIRQ GA 7 COUGAR MAINTENANCE MANUAL MICROSWITCH UP DOWN Landing Gear Up Flaps Extended Microswitch Figure 202 ADJUSTING SCREWS FS 132 25 32G72 22 32 6 1 Page 203 July 15 77...

Page 520: ...ew on cam mountedon flap torque tube 6 Position cam to the point where warning hom isactivated 7 Tighten set screw on cam 8 Slightly retract flaps Warning homshould silence and landing gear light shou...

Page 521: ...on Operation General Instrument Panel Cabin and Map Lights 33 4 1 EXTERIOR LIGHT SYSTEM Description Operation General Landing Light Navigation Lights Strobe Lights Courtesy Lights Maintenance Practice...

Page 522: ...ts BULB CHART Interior Lights Quantity 5 4 1 2 N A Exterior Lights Type Light Instrument Panel Cabin Baggage Compartment Console Avionics Equipment Type Light Landing Navigation WingTips Navigation Ta...

Page 523: ...ated by five lights in the glareshield panel and by Ihe lights in the individual instruments and avionics equipment The brightness of the lights is controlled by two dimming controls located on the lo...

Page 524: ...T LIGHTS DIMMER A T RADIO LIGHTS DIMMER 7LB1K20 4h4 T 7LB1J20 COMPASS V_ LIGHT 7LB2F20 1 HAL JNC A TO AVIONICS EQUIPMENT A A A Li RADIO LIGHTS RHEOSTAT A LOCATED ON LOWER RIGHT CORNER OF INSTRUMENT PA...

Page 525: ...n GRUMMAN dMl iP3G g RJ MQ YO ftD GA 7 C0UGAR MAINTENANCE MANUAL Cabin Lights Exploded View Figure 2 33G72 2 33 1 1 Page 3 July 15 77...

Page 526: ...EXTERNAL POWER SOURCE S BATTERY y im FS SA TOMOBBSMETER AND ELECTRIC CLOCK F5 SA TO RADIO ANO MAIN DC BUS AFT CABIN LIGHTS ILil OFF 7PA2C20 t 9 b 7PA2O20 7LAIA20 4 4 7LA1B20 r 7PA2K20 TO INSTRUMENT P...

Page 527: ...aft end of the tail cone Tlie courtesy lights step and wingwalk are located on the right side and underneath the fuselage at approximately the trailing edgeof the right wing Landing Light See Figures...

Page 528: ...R MAINTENANCE MANUAL LANDING LIGHT CB OFF l Ml J23 P23 7LCIA16 7LCIB16 1I I 7LCICI8 IT ON L I I LANDING LIGHT J22 P22 nrm NOSE WHEEL DISCONNECT I 0 7LC2B16 1 LANDING LIGHT Landing Light Wiring Diagram...

Page 529: ...h to the strobe light powersupply With the Strobe Lightsswitch in the ON position the power supply supplies energy for the three strobe lights The iodine quartz lamp will produce an extremely high int...

Page 530: ...MAINTENANCE MANUAL IGHTS NAV LIGHTS OFF 7LD1A16 S t 7LOIB70 ON J3J Ml I 3 I 3 I 71UIC20 J J JMJMJ 7LD1C20 i 5 7LOIH20 l l RIGHT I WING ROOT Navigation Lights Wiring Diagram Figure 3 RIGHT WING TIP rG...

Page 531: ...NAVIGATION LIGHT COVER grumman smm si y ys GA 7 COUGAR MAINTENANCE MANUAL PROTECTIVE SHIELD DETAIL A Navigation Liglits ExplodedView Figure4 DETAIL B 33G72 7 334 1 PageS July 15 77...

Page 532: ...NTED INAFI FUSCLAGt BENEATH VCRIICAL STABILISER RIGHT STROBE LIGH ibe w TAILCONE FAIRING red rrrr w j i WHT 22 r RLK 3 3 TAIL STROBE LIGHT RED 2 WHT V 3 BLK LEFT STROBE LIGHT H l_ RED 2_ WHT 3 BLK WIN...

Page 533: ...0 GRUMMAN OMDHL IHg lRfl VDAYOOIRD GA 7 COUGAR MAINTENANCE MANUAL FLASHTUBE PROTECTIVE SHIELD STROBE LIGHT COVER FLASHTUBE Strobe Lights Exploded View Figure 6 DETAIL B 33G72 9 334 1 Page 7 July 15 77...

Page 534: ...TOHOURMETER AND CLOCK INTERNAL 1A BAGGAGE STEP WALKWAY SWITCH c 7PA2R2D Il2 l2 7PA2S20 ll ll 7PA2T28 l TOGGLE SWITCH A PUSHBUTTON SWITCH LOCATED ON OUTSIOE OF AIRCRAFT Baggage Step Walkway Wiring Diag...

Page 535: ...nding light 2 Replacement of Navigation Lights See 334 1 Figure 4 A Replacement of Wing Tip Navigation Lights 1 Remove screws attaching protective shield lo wing tip 2 Remove the screws which hold the...

Page 536: ...tion andstrobelights to plug on end of wing 10 Attach wing tip to wing 11 Perform operational check of strobe lights B Replacement of Tail Strobe Light See 33 4 1 Figure 6 1 Remove tail cone fairing R...

Page 537: ...on each wing tip and on tail are ON 3 Place NAV LTSswitch to OFF 4 Place Master switch to OFF C Operational Test of Strobe Lights 1 Place Master switch to ON 2 Place Strobe light switch to ON Observe...

Page 538: ...GRUMMAN M MP3 gz2 M WO YO GA 7 COUGAR MAINTENANCE MANUAL Landing Light Adjustment Figure 201 A C L OF LIGHT BEAM B 100 FT 33G72 H 33 4 1 Page204 July 15 77...

Page 539: ...em Troubleshooting Maintenance Practices Removal Installation of Pitot Tube Pitot and Static Pressure SystemLeakage Test 34 1 2 VERTICAL SPEED INDICATOR Description Operation General Troubleshooting M...

Page 540: ...TEMPERATURE GAUGE Description Operation General Maintenance Practices Removal Installation of Air Temperature Gauge 34 2 1 PRESSURE SYSTEM Description Operation General Operation Troubleshooting Maint...

Page 541: ...ce Practices Removal Installation of Directional Gyro 34 2 3 ATTITUDE GYRO Description Operation General Troubleshooting Maintenance Practices Removal Installationof Attitude Gyro 34 24 TURN COORDINAT...

Page 542: ...nder Removal Installation of Transponder Antenna 34 5 2 ADF SYSTEM Description Operation General Maintenance Practices Removal Installation of ADF Indicator Removal Installation of ADF Receiver Remova...

Page 543: ...Removal Installation of DME Anleima 201 34 54 VOR SYSTEM Description Operation 1 General 1 KING KX 175B NAV COM Transceiver 1 KING Kl 203 204 VOR LOC Indicator 2 NARCO NAV 124 Navigation Receiver 2 NA...

Page 544: ...More diverse navigational items are available as a customer option It is the intent of this manual to present procedures and instructions adequate for minor inspection and minor flight line iiiainlena...

Page 545: ...ensed by two static ports one on each side of the aft fuselage The pressure is conveyed to the airspeed indicator altimeter vertical speed indicator optional and altitude hold unit optional by a line...

Page 546: ...HEAD GRUMMAN ARsllgPflSAIMI VOz YOlSlFtD GA 7 COUGAR MAINTENANCE MANUAL ALTIMETER ALTERNATE STATIC CONTROL KNOB VERTICAL SPEED INDICATOR Pitot and Static System Figure I 34G72 34 1 1 Page 2 July 15 7...

Page 547: ...Leak in static system Instrument leakage Defective instrument Obstruction in static lines Defective instrument Instrument leakage REMEDY Check all lines and fittings for obstruction and clean as nec e...

Page 548: ...System Leakage Test A Pitot System Leakage Test CAUTION NEVER APPLY SUCTION TO THE PITOT TUBE UNLESS THE AIRSPEED INDICATOR IS DISCONNECTED 1 Place a surgical type rubber hose approximately 24 inches...

Page 549: ...GRUMMAN AlftBlil lH IR MfflAYW H GA 7 COUGAR MAINTENANCE MANUAL PITOT TUBE Pitot Tube Installation Figure 201 DETAIL A 34G72 2 34 1 1 Page 202 July 15 77 V...

Page 550: ...ringe into thestatic porl and slowly withdraw the plunger of Ihe syringe Ensure that thesyringe does not leak and an airtight seal is maintained during lest 4 Slowly apply suction until thealtimeter i...

Page 551: ...instrument will indicate the rate of ascent or descent of the aircraft in feet per minute But due to the lag of the instrument the aircraft will be climbing or descending before the instrument starts...

Page 552: ...con nected to the static line Check individual instruments for leaks Replace if necessary Check lines and connections for leaks Refer lo 34 1 1 Defective mechanism Replace instrument Rate of climb ind...

Page 553: ...cal speed indicator on instrument panel and loosen fitting to disconnect tubing from rear of indicator 3 Remove three screws and nuts securing vertical speed indicator to instrument panel and remove i...

Page 554: ...ween pitot air pressure and sialicair pressure This instrument has its diaphragm vented lo the pitotairsource and its case vented lo the static air system As theaircraft increases speed the pitot air...

Page 555: ...craft is banked PROBABLE CAUSE Leak in instrument case or in pitot lines Defective mechanism Pointer not on zero Leaking static system Pointer not on zero Leaking static system Water in pitot line REM...

Page 556: ...bulkhead at Fuselage Station 50 00 2 Locate airspeed indicator on instruineiit panel and loosen fittings to Ijm niincct tubing from the connections on hack of indicator 3 Remove four mounting screws...

Page 557: ...usands of feet A barometric pressure window islocated on the right side of the indicator dial The barometric pressure indication isset by the knob located onthe lower left cornerof the instrument The...

Page 558: ...f loose Replace instrument if screw is missing Cracked or loose glasscover Case gasket hardened Replace instrument Dull or discolored markings Age Replace markings Barometric scale and reference marke...

Page 559: ...ngin the bulkhead at Fuselage Station 50 00 2 Locate altimeter on instrument panel and loosen fittings to disconnect tubing from tee connection on back of instrument 3 Removethreescrews securing altim...

Page 560: ...air temperature gauge is locateil in the upper center ofthe windshield The gauge is amechanically operated instrument actuated by expansion of a metallic element to give the tenipeiature indication o...

Page 561: ...on gauge stem See Figure 201 2 Applyone or two drops of Loctitesealant gradeEVto the gauge stem threads 3 Insert gauge stem through mounting hole from inside the windshield 4 Assemble tube adapter an...

Page 562: ...ent the flow of air from one inlet sideof the manifold to the other Prior to entering the check valves in the manifold there are porting provisions for outputs to the source indicators on the pressure...

Page 563: ...MAN JM d 0 lftJ Mv O YflOD GA 7 COUGAR MAINTENANCE MANUAL PUMP GYRO PRESSURE GAUGE FRONT Pressure System Figure 1 Differential Pressure Gauge Figure 2 GYROS PRESS VENT R L REAR 34G72 7 34 2 1 Page 2 J...

Page 564: ...latorimproperly set Adjust regulator See procedure in this section Erratic pressure Oil in pump Replace pump Oil in pressure pump Enginedrive sealdefective Replace oil seal High pressure Pressure regu...

Page 565: ...low rpm Pressure O K at high rpm Both source indicators retract on instrument pressure gauge when only one engine is in operation PROBABLE CAUSE Incorrect pressure pump Oil in pump Defective manifold...

Page 566: ...nlet and outlet pressurelines from pump 3 Remove the four nutsand washers which secure pressure pump to engine accessory pad 4 Pull pump from engine 5 Remove gasket and discard 6 Cover opening in acce...

Page 567: ...M GA 7 C0UGAR MAINTENANCE MANUAL PUMP INLET FILTER MOUNTING STUDS 4 CLAMP Location of Pressure Pump Inlet Filter and Pressure Regulator Figure201 NUTS AND WASHER 4 INLET PORT CLAMPS PRESSURE REGULATOR...

Page 568: ...e 201 A Removal 1 One pressure regulator is mounted on the firewall of eachengine nacelle 2 Remove the access panel on the bottom of the engine nacelle and the access panel on top of the engine cowl 3...

Page 569: ...Install nut on forward sideof firewall and torque to standard value Refer to Chapter91 3 Attach hose to filter and secure with hose clamp 4 Replace access panels on engine nacelle and engine cowl 5 In...

Page 570: ...s GRUMMAN IM i 0 ftQ M0z5iY0Offyi GA 7 C0UGAR MAINTENANCE MANUAL CLAMP CLAMP Location of Inline Filter Figure 202 FS 50 00 PRESSURE MANIFOLD 34G72 9 34 2 1 Page205 July 15 77...

Page 571: ...check in this section Pressure System Adjustment Test The pressure regulator can be adjusted in two ways with the engines running or with atest set without the engines running One available test set...

Page 572: ...tes between 4 5 and 6 0 psi and that pressure driven gyro instru ments operate properly Red ballsin source indicatorsare retracted 4 Vary engine speed between2100and2400rpm 5 Check that pressure gauge...

Page 573: ...ir pressure to enter the instrument against the gyro buckets Due to gyroscopic inertia the spin continues to point in the same direction even though the aircraft yaws to the right or left This relativ...

Page 574: ...following a Regulatorimproperly adjusted a Adjust relief valve Refer to 34 2 1 b Incorrect gauge reading b Replace gauge Refer to 34 2 1 c Pump failure c Repair or replace pump Refer to 34 2 1 d Vacuu...

Page 575: ...m outside the aircraft through forward baggage compartment and the opening in bulkhead at Fuselage Station50 00 2 Disconnectlines from fittings on back of gyro 3 Removereset and headingknobs 4 Remove...

Page 576: ...spin axis continues to point in the vertical direction providing a constant visual reference to the attitude of the aircraft relative to pitch and roll axis A bar across the face of the indicator repr...

Page 577: ...ment Replace instrument Bar oscillates or shimmies Instrument loose in panel Tighten mounting screws Pressure too high Adjust regulator Refer to 34 2 1 Defective mechanism Replace instrument Instrumen...

Page 578: ...ent panel or from outside the aircraft through the forward baggage compartment and the opening in the bulkhead at Fuselage Station 50 00 2 Loosen clampsand disconnect lines from gyro 3 Remove the four...

Page 579: ...the instrument is a gyro The turn coordinator Figure 1 consists of a small aircraft silhouette that will indicate whenever the aircraft is rotating about either the yaw or roll axisandan inclinometer...

Page 580: ...ace master switch ON Turn coordinator circuit breaker open Close circuit breaker Incorrect sensitivity Out of calibration Replace instrument Incorrect tum rate Out of calibration Replace instrument Ai...

Page 581: ...nt panel or from outside the aircraft through the forward baggage compartment and the openingin the bulkheadat Fuselage Station 50 00 2 Disconnect electrical plug from indicator 3 Remove the four moun...

Page 582: ...e is the liquid filled compensating type incorporating two adjustable magnets No maintenance is required for the magnetic compass except to swing it on a compass rose Adjustments may be made to the in...

Page 583: ...xternal magnetic interference Insufficient liquid Weakcard magnet Excessive pivot friction or brokenjewel Loose bezel screws Broken coverglass Defective sealing gaskets Age Burned out lamp or broken c...

Page 584: ...MagneticCompass A Removal 1 Remove two mounting screws and nuts 2 Disconnect electrical lead and remove compass B Installation 1 Connect electrical lead to magnetic compass 2 Position magnetic compas...

Page 585: ...ected at the front panel by the pilot is transmitted as a Mode A reply Mode C altitude reporting is an additional capability designed into the transponder However in order to conveyaltitude informatio...

Page 586: ...MANUAL CODE SELECTORS DIM REPLY 5 IDENTl J Collins Transponder REPLY LAMP IDENT BUTTON LAMP DIMMER MONITOR FUNCTION LIGHT SELECTOR TOH 9SO TSO Lg m KING KT 76 KT 78 IDENT BUTTON CODE SELECTORS Transp...

Page 587: ...B Installation 1 Ensure that master power switch isin the OFF position 2 Grasp the transponder by the sides and carefully slide transponder into avionics panel mount until plugconnection is fully enga...

Page 588: ...M GA 7 COUGAR MAINTENANCE MANUAL 3 Install nut securing antenna to the fuselage 4 Connect coax cable to antenna 5 Apply polysulfide sealant aroundattaching nut 6 Replace removed interiorfurnishing 34...

Page 589: ...GRUMMAN z lMEPDO I l Z5 WD S YOO M GA 7 COUGAR MAINTENANCE MANUAL TRANSPONDER ANTENNA CABLE ASSEMBLY ANTENNA Transponder Antenna Installation Figure 201 NUT DOUBLER 34G72 15 34 5 1 Page 203 July 15 77...

Page 590: ...Several different models of ADF equipment are availablefor installation in the aircraft Three different models are described in this section See Figures 1 2 and 3 The receiver operates within the freq...

Page 591: ...GRUMMAN AMBSW AM AWiAYmm GA 7 COUGAR MAINTENANCE MANUAL NARCO ADF 141 TSO VOLUME o IDENT ADF1 J ADF ANT V OFFl BFO 1 0 4 0 NARCO ADF 141 Figure 2 34G72 17 34 5 2 Page 2 July 15 77...

Page 592: ...F GRUMMAN M g CmiM MMAfiWmS GA 7 C0UGAR MAINTENANCE MANUAL BFOANTADF m fO Collins ADF Collins ADF 650 with IND 650 Indicator Figure 3 ADF 650 TSO 34G72 18 34 5 2 Page 3 July 15 77...

Page 593: ...rument panel 3 Loosen ADF receiver unit by turning locking screw counterclockwise Use 5 64 inch hex wrench CAUTION DO NOT PULL ADF RECEIVER FREE FROM INSTRUMENT PANEL BY GRASP ING THE CONTROL KNOBS 4...

Page 594: ...MAN AIMDIglj OOAIRa AWATmM GA 7 COUGAR MAINTENANCE MANUAL LOOP CABLE AND LOOP DOUBLER ASSEMBLY ADF LOOP ANTENNA DETAIL A ADF Loop Antenna Installation Future 201 34G72 19 34 5 2 Page 202 July 15 77 3...

Page 595: ...ure that the arrow on doubler points to the forward end of the aircraft NOTE The loop cable and loop doubler assembly are furnished as one unit The loop cable must not becut Store excess cable underne...

Page 596: ...IFiD OATOP lM GA 7 COUGAR MAINTENANCE MANUAL SENSE ANTENNA STRAIN INSULATOR UNIT FITTING DETAIL A ADF Sense Antenna Installation Figure 202 STAND OFF MAST TENSION UNIT FITTING 34G72 20 34 5 2 Page204...

Page 597: ...ving the four attaching screws for each mast B Installation 1 Attach the three standoff mast to the bottom of the fuselage with four attaching screws on each mast 2 Connect wire antenna toconnector on...

Page 598: ...orground speeds up to 250 knots The transceiver has a maximum slant range of 199 9 nautical miles It is possible to channel DME system from a remote location All operating controls for the DME are mo...

Page 599: ...smitter receiver by the sides and carefully slide transmitler recciver into instrument panel mount until connector plugis fully engaged 3 Turn locking screw clockwise to secure DME unit to its mountin...

Page 600: ...GRUMMAN AMBEMSAM AM LATti m GA 7 C0UGAR MAINTENANCE MANUAL DME ANTENNA CABLE ASSY DETAIL A DME Antenna Installation Figure 201 NUT AND WASHER DME ANTENNA 34G72 22 34 5 3 Page202 July 15 77 V y v rT T...

Page 601: ...echnical data KingKX 175B NAV COM Transceiver The King KX 175B NAV COM combines in a single unit a 720 channel VHF COM transceiver and an independent 200 channel VHF NAV receiver The NAV receiver supp...

Page 602: ...ition it contains a 40 channel glide slope receiver and the visual indicators include an UP DOWN glide slope needle with an OFF warning flag All operating controls for the indicator are mounted on the...

Page 603: ...displays thesame VOR and ILS localizer signals asthe NAV 121 system In addition the NAV 122 system receives and displays the UHF glideslope signals to provide full ILS approach display All operating c...

Page 604: ...GRUMMAN A llI IslOe il VO flTDOlFSfl GA7 COUGAR MAINTENANCE MANUAL NAV 121 UNIT NAV 122 UNIT NARCONAV I21 NAV 122 Navigation System Figure 4 34G72 26 34 54 Page 4 July 15 77 Js...

Page 605: ...olllni Nav i n o j r c i u U J J I TO FREQ FROM o o VIR 3S1TSO VIR 351 VOR LOC RECEIVER MH FREQUENCY CONTROL KH2 FREQUENCY CONTROL COURSE INDEX VOR LOC DEVIATION BAR GS FLAG IND 351 ONLY GLIDESLOPE DE...

Page 606: ...V flag indicates that unreliable information is being supplied to the VOR LOC deviation bar The GS flag IND 351 only indicates an unreliable glide slope signal when tuned to a localizer frequency The...

Page 607: ...27 JaCut4fn ys y Ho c etr e r no s...

Page 608: ...DOOR Description Operation I General I Maintenance Practices 201 Senicing 201 Latch Lubrication 201 Door HingesLubrication 201 Removal lnslallalion 201 Entrance Door Removal 201 Entrance Door Install...

Page 609: ...Aft Baggage Door Remove Door Seal Install Door Seal Remove Aft Baggage Door Lock Assembly Install Aft Baggage Door Lock Assembly 52 3 2 FORWARD BAGGAGE DOOR Description Operation General Maintenance...

Page 610: ...Rfl GA 7 C0UGAR MAINTENANCE MANUAL TABLE OF CONTENTS Continued Install Latch Assemblies Remove Door Lock Install Door Lock Remove Forward Baggage DoorSeal Install Forward Baggage Door Seal PAGE 201 20...

Page 611: ...on the right hand side of the fuselage and provides easy access to Ihe passenger compartment 3 Aft Baggage Compartment Door The aft baggage compartment door isakey operntcd door located on theright ha...

Page 612: ...ht hand side of the fuselage The structure is bonded aluminum with a Plexiglas window The door is attached to the fuselage at the forward end of the door by two hingesand secured by a latch assembly a...

Page 613: ...lation 1 Place door in door frame and align holes in door 5 with holes in door hinges 4 2 Place bolts 3 through door hinges 4 and door 5 and with assistant holding door and bolts in position install w...

Page 614: ...GRUMMAN AMBRN AM VD YDOIf GA 7 COUGAR MAINTENANCE MANUAL DETAIL A 1 2 3 4 5 Nut Washer Bolt Hinge Door Entrance Door Removal Installation Figure 201 52G72 1 52 1 1 Page 202 July 15 77 fi...

Page 615: ...OUGAR MAINTENANCE MANUAL 1 2 3 4 5 6 7 Screw Cover Plate Bolt Washer Bracket Cotter Pin Washer 8 Pin 9 Rod 10 Handle 11 Bolt 12 Washer 13 Channel Entrance Door Lower Latch Removal Installation Figure...

Page 616: ...pper Latch See Figure 203 1 Remove plateassembly 5 spacers 6 bushing 7 andspring 8 2 Remove cotter pin 9 and pin 10 from drive shaft 11 and arm assembly 12 Remove drive shaft 11 3 Remove cotter pin 13...

Page 617: ...ng 4 Screw 16 Pin 5 Plate Assembly 17 Arm Assembly 6 Spacer 18 Hook 7 Bushing 19 Roll Pin 8 Spring 20 Handle 9 Cotter Pin 21 Screws 10 Pin 22 Escutcheon 11 Drive Shaft 23 Bushing 12 Arm Assembly 24 Pl...

Page 618: ...trance DoorUpper Latch Installation See Figure 203 1 Place latchassemblyin positionandtighten screws 4 2 Install interior trim aroundlatchassembly Referto Chapter 25 3 Ontop of fuselage install seal 3...

Page 619: ...ft fuselage between Fuselage Stations 146 and 176 The door is key operated and hinged to the fuselage structure with a strap hinge A restraint chain is attached to Ihe door and fuselage to prevent dam...

Page 620: ...hinge to fuselage structure 4 Remove baggage compartment door from aircraft B Install Aft Baggage Door See Figure 201 1 Position door indoor frame and align holes indoor hinge with holes in fuselage...

Page 621: ...g lfcJ VO YO M GA 7 C0UGAR MAINTENANCE MANUAL DETAIL A Aft Baggage Door Removal Installation Figure 201 Nut Washer Bolt Seal 8 Screw 9 Lockwasher 10 Latch U Washer 12 Camlock 13 Nut 52G72 4 52 3 1 Pag...

Page 622: ...ides of seal would contact surfaces of door 3 Install seal 7 and apply pressure on seal until adhesive has dried 4 Install interior trim in accordance with instructions in Chapter 25 of this manual E...

Page 623: ...vailable asoptionalequipment The door is of bonded aluminum structureand is located on the right hand side of the nose section between Fuselage Stations 17 12 and 40 00 Two hinges attach the door to t...

Page 624: ...with holes inhinge brackets 2 Install washers 4 on bolts 5 Position spacers 3 inside of hinge brackets and install bolt through hinge spacers and brackets 3 Install washers 2 and nuts 1 C Remove Latc...

Page 625: ...ward Baggage Door Removal Installation Figure 201 1 Nut 2 Washer 3 Spacer 4 Washer 5 Bolt 6 Hinge 7 Nut 8 Washer 9 Washer 10 Bolt 11 Latch Assembly 12 Plug 13 Screw 14 Lockwasher 15 Latch 16 Washer 17...

Page 626: ...the seal asthe adhesive softensand remove seal from door H Install Forward Baggage DoorSeal See Figure 201 WARNING METHYL ETHYL KETONE IS TOXIC AND FLAMMABLE USE IN A WELL VENTILATED AREA AVOID BREATH...

Page 627: ...E MANUAL CHAPTER 53 FUSELAGE TABLE OF CONTENTS NUMBER 53 0 FUSELAGE Description Operation General Maintenance Practices General Removal Installation of Fuselage Components Paintingof Fuselage Componen...

Page 628: ...se cap is made of laminated Fiberglas and is secured to the nose section assembly with screws and washers Hie nose section assembly is a bonded aluminum assembly which houses the nose landing gear lan...

Page 629: ...PITOT TUBE ASSEMBLY IS NOT DAMAGED Position nose cap assembly to nose section assembly and secure with screws and washers C Remove Nose Section Assembly See Figure 201 1 Removenose cap assembly Refer...

Page 630: ...MAINTENANCE MANUAL TAIL CONE ASSEMBLY BONDED FUSELAGE ASSEMBLY NOSE SECTION ASSEMBLY AFT FUSELAGE COVER ENTRANCE STEP ASSEMBLY NOSE CAP ASSEMBLY FORWARD WING ROOT FAIRING Fuselage Assembly Figure201...

Page 631: ...ydraulic pump and associated equipment wiring and tubing Refer to Chapter 32 8 Install nose landing gear doors Refer to Chapter 32 9 Connectlanding lightwiring Refer to Chapter 24 10 Install battery b...

Page 632: ...t wiring may beconnected and connect wiring 2 Position tail cone assemblyand secure with screws and washers 3 Install left and right hand aft fuselage covers K Remove Entrance Step Assembly See Figure...

Page 633: ...n Operation General Maintenance Practices Removal Installation Cleaning Painting 55 2 1 VERTICAL STABILIZER Description Operation General Maintenance Practices Removal Installation Cleaning Painting G...

Page 634: ...and vertical stabilizers on the GA 7 Cougar aircraft arc the fixed empennage structures to which Ihe elevators and rudder are connected In addition to providing attachment points for the control surfa...

Page 635: ...rizontal stabilizers on the GA 7 Cougar aircraft are of conventionaldual sparand rib structure with the skin bonded to the ribs and spars The horizontal stabilizers have a tapered chord widerat the ro...

Page 636: ...t 7 and two washers 8 6 Remove and retain for reassembly shim 9 from beneath forward attachment bolts 7 Stabilizer may now be removed from aircraft B Horizontal Stabilizer Installation See Figure 201...

Page 637: ...GRUMMAN AGMfiPiOtS EM V0 fiF0UJLr iJ GA 7 COUGAR MAINTENANCE MANUAL Horizontal Stabilizer Removal Installation Figure 201 55G72 2 55 M Page202 July 15 77 l ij...

Page 638: ...ure 1 The vertical stabilizer on the GA 7 Cougar aircraft is of conventional dual spar and rib construction with its skin bonded to the ribs and spars The stabilizer has a tapered chord with the maxim...

Page 639: ...ch vertical stabilizerrear attachment point to horizontal stabilizer splice plate 4 7 Remove bolt 5 two washers 6 and nut 7 that attaches vertical stabilizer forward spar to fuselage fitting 8 Remove...

Page 640: ...GRUMMAN t lP3a g lili VG YflGi l GA 7 COUGAR MAINTENANCE MANUAL Vertical Stabilizer Removal Installation Figure 201 55G72 4 55 2 1 Page202 July 15 77 y s tfi...

Page 641: ...AM VO TO GA 7 COUGAR MAINTENANCE MANUAL 9 Install tail cone and aft fuselage inspection covers Refer to Chapter53 2 Cleaning Painting Clean and paintvertical stabilizer Refer to Chapter 20 55 2 1 Page...

Page 642: ...WINDOWS Description General Windshield Cabin Windows Maintenance Practices Windshield Removal Installation Window Removal Installation Emergency ExitWindow Removal Installation Emergency Exit Window L...

Page 643: ...is secured by retainers which are riveted to the fuselage assembly Cabin Windows The cabin windows consist of a passenger door window a pilot s window an emergency exit window and three standard cabin...

Page 644: ...UPON PAINTED SURFACES 1 Remove sealant residue and any seal particles from forward fuselage assembly and from retainers 2 and 3 wilh triclilorethylene or methylethyl ketone Wipe surface with aclean d...

Page 645: ...SAIft MfflATmW GA 7 C0UGAR TcNAMCE MANUAL 1 Rivet 6 Nut 2 Retainer 7 Windshield 3 Retainer 8 Seal 4 Screw 9 Seal 5 Washer 10 Seal Windshield Removal Installation Figure 201 DETAIL B 56G72 1 56 1 0 Pag...

Page 646: ...seals 8 and 10 around edge of windshield 10 Mix equal parts of EP 711 and EP 890 sealant Coast ProSeal Co or equivalent until a uniform grey color is achieved 3 to 5 minutes Apply sealant to windshiel...

Page 647: ...grumman Mmmm zm AMiAY mm GA 7 C0UGAR MAINTENANCE MANUAL DETAIL A TYPICAL Window Removal Installation Figure 202 Window Retainer Screw Seal Extruded Sealant 56G72 2 56 1 0 Page 204 July 15 77 Si...

Page 648: ...uded sealant No 579 6 Presstite Engineering Co or equivalent by hand lo fuselage assembly where window is to be mated 5 Position window I and secure by usingretainers 2 and screws 3 6 Clean area of an...

Page 649: ...TENANCE MANUAL DETAIL A DETAIL B TYPICAL TYPICAL 1 Bolt 7 Washer 2 Washer 8 Pin 3 Bushing 9 Latch 4 Washer 10 Handle Assembly 5 Shim 11 Connector 6 Pin Emergency Exit Window Latch Removal Installation...

Page 650: ...The following procedures are recommended A Cleaning CAUTION DO NOT USE GASOLINE ALCOHOL BENZINE ACETONE CARBON TETRACHLO RIDE OR GLASS WINDOW CLEANER THESE FLUIDS CAN DAMAGE THE PLEXI GLAS 1 If large...

Page 651: ...AWOATTOOIfci GA 7 COUGAR MAINTENANCE MANUAL CHAPTER 57 WINGS TABLE OF CONTENTS NUMBER 57 0 WINGS Description General Nacelle Wing Tip Maintenance Practices Removal Installation of WingTip PAGE 201 20...

Page 652: ...pivots Refer to Chapter 27 for information on flight control system Integrated into the outboard wing assembly is an integral fuel tank Refer to Chapter 28 for information on the fuel system The main...

Page 653: ...GRUMMAN i IMflHUW SAIM MMHAW IM GA 7 C0UGAR MAINTENANCE MANUAL Wing Assembly Figure 1 57G72 1 57 0 Page 2 July 15 77...

Page 654: ...GRUMMAN MG iraOC mifJI Mv flAVIii TfJi GA 7 COUGAR MAINTENANCE MANUAL Wing Tip Assembly Figure 201 57G72 2 57 0 Page 202 July 15 77...

Page 655: ...wing 2 Lower the wing tip a few inches away from the wing in order to reach inside anddisconnect the navigation strobe light wires 3 Remove wing tip assembly B Installation of WingTip NOTE Before ins...

Page 656: ...ck Check 61 2 1 PROPELLER CONTROL SYSTEM Description Operation General Maintenance Practices Removal Installation Propeller Pitch Control Cable Assembly Removal Propeller Pitch Control Cable Assembly...

Page 657: ...between the propeller cylinder head and piston changes the blades to the feathered position when the governor oil pressure is relieved Centrifugal responsive pins which engage a shoulderon the propell...

Page 658: ...newconcepts in basic design combining simplicity light weight and rugged construction Aluminum alloy forgings areused throughout and the hub shellis made in two halves bolted together along the plane...

Page 659: ...t up conditions for stressconcentrationswhich can lead to fatigue and cracks Remember the lowest priced maintenance is preventive maintenance Avoid engine run ups and aircraft operation in areas with...

Page 660: ...ut 2 Dome 12 Washer 3 Nut 13 O Ring 4 Screw 14 Propeller Assembly 5 Screw 15 Nut 6 Washer 16 Washer 7 Screw 17 Valve Cap 8 Washer 18 Bulkhead 9 Spinner 19 Mounting Flange 0 Fillet Assembly 20 Shims No...

Page 661: ...ON ENGINE CRANKSHAFT 2 Remove lock wire and loosen all nuts I I a few turns Move propeller assembly 14 forward lo contact nuts II again 3 Repeat procedures in Step 2 until all mils II and washers 12 c...

Page 662: ...ect for evidenceof grease or oil leakage NOTE Record which zerk fitting is used lo lubricite the hub At the next inspection use the other zerk fitting to lubricate the huh Continue to alternate fittin...

Page 663: ...1OX magnifyingglass 4 Crocus cloth 5 Dye penetrant kit 6 Power equipment with suitable grinding and polishing accessories Repair Methods NOTE All methods which will result in moving metal on the blad...

Page 664: ...M W ZA H AiJbAHW K i GA 7 C0UGAR MAINTENANCE MANUAL LOCAL WIDTH OR THICKNESS REPAIR DEPTH MAY NOT EX CEED DIMENSIONS SHOWN DETAIL B Blade Repair Limitations Figure 202 DETAIL C 61G72 2 61 1 1 Page 206...

Page 665: ...st When the cadmium platingis worn off the surface should be cleaned treated and painted with Hartzell Polane paint Replate and bake parts at overhaul Inspect all parts for wearor fretting and lubrica...

Page 666: ...engine power under varying flight conditions The control systemalsoallows the propellerto be feathered The propeller control system consists of a propeller governor mounted on the accessory case and...

Page 667: ...rotective seals from control cable 7 Remove retainer nut and washer securing control cable lobracket and slide cable from bracket 8 Remove remaining retainer nut lhat secures control cable to bracket...

Page 668: ...opeller pitch control to the ball joint at the end of the cable are installed properly and secured Disconnect theball jointat thegovernor control bellcrank NOTE The governor control bellcrank isspring...

Page 669: ...C0UGAR MAINTENANCE MANUAL PROP HIGH RPM HIGH RPM POSITION HIGH RPM POSITION 0 06in too 18in LOW RPM POSITION LOW RPM POSITION Propeller Control System Rigging Figure 201 I EATHER POSITION I I AT III I...

Page 670: ...ire 2 Install elbow 4 and hose 3 3 Charge accumulator to approximately 10 psi and check for leaks Charge accumulator to 90 to 100 psi NOTE Always install cap 1 and tighten securely to avoid contaminat...

Page 671: ...r r r GRUMMAN j GA 7 C0UGAR MAINTENANCE MANUAL 1 Cap 2 Valve 3 Hose 4 Elbow 5 Screw 6 Washer 7 Accumulator Unfeathering Accumulator Figure 202 61G72 4 61 2 I Page 205 July 15 77...

Page 672: ...GAR MAINTENANCE MANUAL 1 Hose 2 Elbow 3 Hose 4 Cotter Pin 5 Washer 6 Connector 7 Cotter Pin 8 Washer 9 Clevis Pin 10 Bolt 11 Washer 12 Unfeathering Valve 13 Governor Unfeathering Valve Figure 203 61G7...

Page 673: ...ARTS BEING EXPELLED WITH CONSIDERABLE FORCE 1 Remove nut 1 and washer 2 Separate balljoint 3 from bellcrank 4 2 If the aircraft is equipped with an unfeathering accumulator bleed offall pressure Remov...

Page 674: ...MAN IMl SilK Q i rRi Xk mYOi OL i GA 7 COUGAR MAINTENANCE MANUAL 1 Nut 2 Washer 3 Ball Joint 4 Bellcrank 5 Nut 6 Washer 7 Propeller Governor Propeller Governor Figure 204 61G 26 61 2 1 Page 208 July 1...

Page 675: ...nance Practices General Cleaning Power Plant Removal Installation of Power Plant 71 1 1 POWER PLANT COWLING Description Operation General Maintenance Practices Removal Installation of Cowling 71 2 1 E...

Page 676: ...SYSTEM Description Operation General Maintenance Practices Removal Installation of AirInduction System 71 6 2 ENGINE BAFFLES Description Operation General Maintenance Practices Removal installation of...

Page 677: ...rced over and around the cylinders by the use of baffles The airis then exhausted to the atmosphere through an exit located in the bottom of the lower cowl assembly 2 Engine Data Engine 0 320 DID Rate...

Page 678: ...wires Water in carburetor Drain carburetor and lines Internal failure Check oil sump for metal particles If found complete overhaulis indicated Enginenot idling properly Incorrect carburetor idle adj...

Page 679: ...ir filter Clean or replace filter Restriction in air scoop Remove restriction Impropergrade of fuel Empty tank and fill with proper grade fuel Faulty ignition system Check ignition leads plugs and mag...

Page 680: ...oil REMEDY Check line for obstruction and clean strainer See High oil temperature in Trouble column Check oil supply and fill as recommended Check cowl inlet and outlet for obstructions Check baffles...

Page 681: ...replace High oil pressure In extreme cold weather readings up to approximately 100 psi do not necessarily indicate malfunctioning Overprinting Open throttle put mixture control in idle cutoff positio...

Page 682: ...hed with a suitable solvent and drying thoroughly Stoddard solvent or equivalent 3 Removal Installation of Power Plant A Remove Power Plant See Figure 201 WARNING PRIOR TO REMOVAL OF THE ENGINE ENSURE...

Page 683: ...15 10 2 GRUMMAN R i P E 0 V VD TOOlrVl GA7 C0UGAR MAINTENANCE MANUAL Power Plant Removal Installation Figure 201 Sheet 1 of 2 71G72 1 1 71 0 Page 202 July 15 77 i H k...

Page 684: ...rive Cable 12 Manifold Pressure Line 13 Heat Duct 14 Power Cable 15 Ground Cable 16 Connector 6 Tachometer GeneratorWiring 17 Connector 7 Propeller Control 8 Pressure Hose 9 Fuel Supply Hose 10 Fuel P...

Page 685: ...om engineand separate from power plant 19 Disconnect the two electrical connectors 16 and 17 at firewall 20 Plugor cap all hosesand lines which havebeen separated prior to engine removal 21 Attach a s...

Page 686: ...to propeller governor Referto Chapter 61 13 Connect tachometer generator wires 6 14 Connect tachometer generatordrive cable 5 to tachometer generator 15 Connect carburetor heat control 4 to air box as...

Page 687: ...ward nacelle The upper cowl assembly is secured to the wing nacelle section and to the lower cowl assembly with quick release fasteners The upper cowl assembly incorporates an oil filler access door T...

Page 688: ...airof Cowling WARNING USE SOLVENTS IN A WELL VENTILATED AREA AVOID BREATHING FUMES KEEP AWAY FROM FLAMES 1 Clean cowling with a suitable cleaningsolvent and wipe dry with a clean cloth 2 Inspect cowli...

Page 689: ...7 C0UGAR MAINTENANCE MANUAL OIL FILLER ACCESS DOOR QUICK RELEASE FASTENERS UPPER COWL ASSEMBLY BALL JOINT AND NUTS COWL FLAP Engine Cowling Removal Installation Figure201 SCREWS LOWER COWL ASSEMBLY 71...

Page 690: ...ed together The purpose of the engine mount is to support the engine and attach the engine to the airframe The engine is attached to the mount at four places using vibration isolator type shock mount...

Page 691: ...engine mount 1 forcracks broken welds and obvious damage 3 Inspectcomponentsof shockmount assemblies forcracks distortion andwear 4 Repairengine mountinstrict accordance with AC43 13 1A of theFederal...

Page 692: ...7 COUGAR MAINTENANCE MANUAL 1 Engine Mount 2 Nut 3 Washer 4 Bolt 5 Spacer 6 Shouldered Mount 7 Gel filled Insert 8 Smooth Mount 9 Shock Mount Washer Engine Mount Removal Installation Figure 201 71G72...

Page 693: ...E MISMATCH OF 0 200 INCH MAXIMUM REFERENCE BETWEEN PROPELLER SPINNER AND ENGINE COWLING TOTAL QUANTITY OF TWO SHOCK MOUNT WASHERS SHALL NOT BE EXCEEDED AT ANY ONE MOUNT ING LOCATION 9 Check for a maxi...

Page 694: ...c chromate primer from areas to be inspected 4 Inspect attach points inareas shown in Figure 202 for cracks originating from the bolt holes B Upper and Lower Engine Mount Boll Inspection See Figure 20...

Page 695: ...H TYP 4 PLACES DIMENSIONS SHOWN ARE AP PROXIMATE AND FOR REF ONLY ATTACHING POINT MOUNT ENGINE EngineMount Inspection Figure 202 3883 2 70 VIEW LOOKING DOWN VIEW LOOKING UP REMOVE SEALANT FROM SHADED...

Page 696: ...the engine The air box is controlled from the cockpit to allow heated or unheated filtered ram airto be transferred to the carburetor Outside unheated air is transferred to the airbox assembly from th...

Page 697: ...wire four screws 13 four washers 14 and gasket 15 from carburetor and carburetor adapter 16 and remove adapter and airboxassembly 8 Remove the remaining six bolts 11 and washers 12 and separate carbu...

Page 698: ...r Box Assembly 16 Adapter 5 Clamp 17 Seal 6 PropellerControl 18 Door Clamp 7 Throttle Control 19 Door 8 Carburetor Heat Control 20 Filter Assembly 9 Bracket 21 Valves 10 Mixture Control 22 Nutplates 1...

Page 699: ...hers 14 Safety screws with safety wire 4 Position bracket 9 securing mixture control 10 and carburetor heat control 8 to air box assemblyand secure bracket usingremaining two bolts 11 and washers 12 5...

Page 700: ...aluminum with rubber asbestos composition seal at points of contact with the engine cowling The bafflesareattached to the engine and direct the cooling airaround the engineto provide optimum engine c...

Page 701: ...f enginesecuring front and rear baffle assemblies to intercylinder baffle assemblies part of basicengine 7 Remove screwsand bolts as necessary to remove individual baffle assemblies B Cleaning Inspect...

Page 702: ...GRUMMAN M ii 0 A Ra V O YOOIf l GA 7 COUGAR MAINTENANCE MANUAL Engine Baffle AssembliesReinoval lnstallation Figure 201 71G72 5 71 6 2 Page 202 July lS 77...

Page 703: ...ect airduct toaft side of right hand rear baffle assembly 5 Ifremoved install bulkhead connector on left rear baffle assembly Connect manifold pressure line to each side of bulkhead connector 6 Pull s...

Page 704: ...t port in the top of the engine The breather prevents an excessive pressure buildup inside the crankcase The flexible line is extended by a piece of aluminum tubing attached to the flexible line with...

Page 705: ...n of Carburetor 73 1 2 FUEL PRIMER SYSTEM Description Operation General Troubleshooting Maintenance Practices Removal Installation of Fuel Primer System 73 2 1 FUEL CONTROLS Description Operation Gene...

Page 706: ...MOATOOI GA 7 COUGAR MAINTENANCE MANUAL TABLE OF CONTENTS Continued NUMBER PAGE Maintenance Practices 201 Removal Installation of Fuel Pressure Gauge 201 Removal Installation of Fuel PressureTransducer...

Page 707: ...CONTROL DESCRIPTION OPERATION 1 General The engine fuel and control system consists of the units and components which deliver metered fuel to the engine These items include the carburetor fuel priming...

Page 708: ...R DESCRIPTION OPERATION General Each of the engines isequipped with a single barrel float type carburetor which incorporates an idle cutoff mechanism and a manual mixture control The carburetor is mou...

Page 709: ...sket B InstallCarburetor See Figure 201 NOTE Ensure that all mating surfaces of the carburetor engine carburetor adapter and air box assembly are smooth and clean and that all traces ofold seal and ga...

Page 710: ...z i Mi P30e tf i AWOATTOl fyi GA 7 C0UGAR MAINTENANCE MANUAL MIXTURE CONTROL NUT WASHER BOLT Carburetor Removal Installation Figure 201 THROTTLE CONTROL WASHER SCREW WASHER 73G72 1 73 1 1 Page 202 Jul...

Page 711: ...nto the cylinder intake system of each engine by a primer solenoid valve located ineach wing nacelle Both primer solenoid valves are controlled by the same primer switch which is located on the lower...

Page 712: ...aker Defective primerswitch Replace defective switch Defective wiring to switch no voltage Check wiring for security check wiring with ohmmeter and repair as necessary One engine fails to prime Defect...

Page 713: ...ent panel andsecure with knurl nut C Remove Primer Solenoid Valve CAUTION ENSURE THAT MASTER SWITCH IS IN OFF POSITION PRIOR TO REMOVAL OF PRIMER SOLENOID VALVE 1 Disconnect solenoid valve wiring atsp...

Page 714: ...and then air dry G Operational Check of Fuel Primer System WARNING WHEN FUEL LINES ARE DISCONNECTED SOME FUEL SPILLAGE MAY OCCUR TAKE PROPER PRECAUTIONS TO PREVENT FIRE HAZARD DUE TO SPILLAGE 1 Discon...

Page 715: ...jPN N GRUMMAN v r w as GA 7 COUGAR MAINTENANCE MANUAL v Fuel Primer Lines Removal Installation Figure 201 73G72 2 73 1 2 Page 203 July 15 77...

Page 716: ...it Each control handle is connected to the carburetor by means of a flexible control cable assembly The throttle control regulates the power output of the engine by controlling the amount of the fuel...

Page 717: ...rotective seals from control cable 7 Remove retainer nut and washer securing control cable to bracket and slide cable from bracket 8 Remove remaining retainer nut that secures control cableto bracket...

Page 718: ...ng on carburetor end of control fitting 9 Advance control handle forward on control quadrant to within 0 12 1 8 inch minimum from end of slot 10 Position lever arm on carburetor as follows a Position...

Page 719: ...n carburetor so that the engine idles at 600 to 650 rpm 5 With a smooth and steady motion pull mixture control towards the idle cutoff position and observe the tachometer for any change in rpm Return...

Page 720: ...er associated wiring and pressure line for eachengine The fuel pressure gauges are mounted in the instrument cluster assembly on the instrument panel Refer to Chapter28 The fuel pressure transducer is...

Page 721: ...EL SPILL AGE MAY OCCUR TAKE PROPER PRECAUTIONS TO PREVENT FIRE HAZARD DUE TO FUEL SPILLAGE r 3 Disconnect fuel pressureline from fuel pressuretransducer 4 Remove fuel pressure transducerand braided st...

Page 722: ...eral 74 1 1 MAGNETO Description Operation General Maintenance Practices Removal Installation of Magneto 74 2 1 IGNITION DISTRIBUTION Description Operation General Maintenance Practices Inspection of I...

Page 723: ...cylinders The engine dual ignition system consists of the magnetos shielded harness spark plugs and individual magneto switches Tlie magnetos are a sealed lightweight type requiring no internal adjus...

Page 724: ...y adjustment required The GA 7 Cougar engines are designed to start on the left magneto The left magneto only has impulse coupling LCM ENGINE r MAG LIFT INGINE NACtlll UFI WING ROOT PI8 J18 PI4 JM 3 3...

Page 725: ...fthe compression stroke a positive pressure will try toforce the thumb off the port 2 Continue tuming the propeller in the normal direction of rotation until the 25 degree advance timing mark on the f...

Page 726: ...gAlN M 0MY0O GA 7 COUGAR MAINTENANCE MANUAL TIMING HOLE CRANKCASE PARTING LINE 25 MARK FRONT VIEW REAR VIEW Advance Timing Alignment Figure 201 TIMING HOLE MagnetoTiming Hole Figure 202 74G72 2 74 1 1...

Page 727: ...l and the negative leads to any unpainted portion of the engine 10 Remove the pins from the magnetos 11 Rotate the magneto in its mounting flange until the light comes on Slowly turn the magneto in th...

Page 728: ...ge No attempt should be made to repair the magneto in the field since disassembly of the magneto will void its warranty NOTE If the drive shaft nut has been removed from the magneto incorporating the...

Page 729: ...IPTION OPERATION General The ignition distribution is adual system The output of each magneto is applied toall four cylinders The ignition distribution system consists ofthe leads from the magnetos an...

Page 730: ...upper to lower every 100 hours of plugservice or sooner if lead fouling occurs D Check magnetos to engine timing If necessary time the magnetos to the engine The magneto to engine timing check should...

Page 731: ...on harnessas necessary 5 Install clamps securing ignition leads to cylinder heads as necessary 6 Secure ignition harness to engine mount as necessary 7 Remove identification tagsinstalled priorto rem...

Page 732: ...NCE MANUAL n n n Ignition System Schematic Figure 202 2 Install spark plugsand torque to 360 to 420 inch pounds 3 Attach ignition leadsto spark plugs Tighten nut finger tight plus one fourth turn 4 Re...

Page 733: ...tion of Tachometer Removal Installation of Tach Generator 77 1 2 MANIFOLD PRESSURE SYSTEM Description Operation General Troubleshooting Maintenance Practices Removal Installation of Manifold Pressure...

Page 734: ...Troubleshooting Exhaust Gas Temperature EGT Indicator System 101 Maintenance Practices 201 Removal Installation of Cylinder Head Temperature Indicator 201 Removal Installation of Cylinder Head Tempera...

Page 735: ...specifically related system chapters This chapter covers the tachometer cylinder head temperature mamfold pressure and exhaust gas temperature EGT indicating systems The exhaust gas temperature EGT in...

Page 736: ...in rpm and produces electrical impulses that are applied to the tachometer The tachometer is calibrated in hundreds of rpm The tachometer provides the pilot with throttle control information necessary...

Page 737: ...LEFT ENGINE NACELLE J18 7EG3B20 I 7EG4B20 Oil 7EG3C20 JkLfF 12 12 7EG4A20 1 Sj eLEC ENGINE ELECTHICAL tACH GEN RIGHT ENGINE ELECTRICAL f ACH GEN 15 IS 7EG6820 O 7EG6A20 v 12 12 7EGSB20 7EG5C20 __J 7E...

Page 738: ...on from right engine Right engine tach generator defective Replace tach generator Flexible cable from engine to tach generator defective Replace flexible cable Defective electrical wiring Repair wirin...

Page 739: ...fl A Removal of Tach Generator See Figure 201 NOTE A tach generator is mountedon the firewall of each engine nacelle 1 Remove upper engine cowling 2 Disconnect flexible cable from tach generator 3 Di...

Page 740: ...WW v o GRUMMAN AMBBW AM AVDAWg IR9 GA 7 COUGAR MAINTENANCE MANUAL v vv ri VJ J A 0 v DETAIL A Tach Generator and Flexible Cable Removal Installation Figure 201 77G72 3 77 1 1 Page 202 July 15 77...

Page 741: ...N 1 General See Figure 1 The dual manifold pressure gauge is a vapor proof absolutepressure type instmment calibrated from 10 to 35 inchesof mercury The manifold pressure is pickedup from number four...

Page 742: ...error at existing barometric pressure Pointer shifted Replace instrument Excessive error when engine is running Line leaking Tighten line connections Sluggish or jerky pointer movement Defective inst...

Page 743: ...uregauge B Installation of Manifold Pressure Gauge 1 Place manifold pressure gauge in position on instrument paneland secure with four screws NOTE In the following procedure ensure the right and left...

Page 744: ...or located in a cylinderhead The cylinder headused is the hottest head in normal operation The engines in the GA 7 Cougar use cylindernumber three This indicator is electrical and is wired through a c...

Page 745: ...GRUMMAN IM l P30 S ftJ V O YOMRJ GA 7 COUGAR MAINTENANCE MANUAL DETAIL A Exhaust GasTemperature EGT System Figure2 77G72 6 77 2 1 Page 2 July 15 77...

Page 746: ...the way to upper limit Engine not hot Defective wiring grounded between sensor and indicator Repair wiring Defective sensor Replace sensor Left engine indicator shows no indication Engine is operating...

Page 747: ...COUGAR MAINTENANCE MANUAL TROUBLE PROBABLE CAUSE REMEDY No EGT indication from left engine Defective temperature probe Replace probe Defective wiring Repair wiring Defective indicator Replace indicato...

Page 748: ...cknuts and insulating washers that secure cylinder head temperature indicator to instmment cluster case Retain nuts and washers for reuse 7 Disengage andremove indicator from instrument cluster case B...

Page 749: ...position on instrument panel and secure with the four screws and nuts previously removed m 2 Connect the two leads to the rearof the indicator Removal Installation of Exhaust GasTemperature EGT Probe...

Page 750: ...JpN NV GRUMMAN AMBBmAM AmATWfJ GA 7 COUGAR MAINTENANCE MANUAL CylinderHead TemperatureIndicator Removal Installation Figure 201 77G72 7 77 2 1 Page 203 July 15 77...

Page 751: ...ilMIgtsJOO tM AWOAITOOIft GA 7 C0UGAR MAINTENANCE MANUAL v N f i bv V 1 v if r i cy e A v L v i r DETAIL A Cylinder Head Temperature Probe Removal Installation Figure 202 77G72 8 77 2 1 Page 204 July...

Page 752: ...C X GRUMMAN F dP fl sA r MD YD I 1 GA 7 C0UGAR MAINTENANCE MANUAL DETAIL A Exhaust Gas Temperature Probe Removal Installation Figure 203 77G72 9 77 2 1 Page 205 July 15 77...

Page 753: ...7 COUGAR MAINTENANCE MANUAL CHAPTER 78 EXHAUST TABLE OF CONTENTS NUMBER 78 0 ENGINE EXHAUST SYSTEM Description Operation General Maintenance Practices Removal Installation of Engine Exhaust System PA...

Page 754: ...shroud which has provisions for attaching two flexible ducttype tubes One tube transfers heated air to the cabin forcabin heating Thesecond tube transfers heated air to the carburetor for carburetor...

Page 755: ...es and vibration Consequently it is extremely important that the system be inspected every 100 hours or at any time exhaust fumes or carbon monoxide are detected in the cabin To inspect the exhaust sy...

Page 756: ...buretor Heat Tube 4 Shroud s s y 5 Boll 6 Nui jy j 7 Support tS s y 8 Exhaust Gas Temperature Probe M T Jlr 9 Nut 1 y 10 Washer I V Gasket 12 End Plate hr X t s 13 Screw _ 14 Screw v 4 15 Clip Nut i 1...

Page 757: ...r airbubbles 8 If leaks are found around clamp assemblies securing risers lo muffler remove clamp assemblies and swage out the risers for a tight fit I 9 Ifleaks are found in themuffler repair muffler...

Page 758: ...E OF CONTENTS NUMBER PAGE 79 0 ENGINE OIL SYSTEM Description Operation 1 General 1 Troubleshooting 101 Oil Cooler 101 Oil PressureGauge 101 Oil Temperature Gauge 102 Maintenance Practices 201 General...

Page 759: ...ansducer located at the rear of the engine A flexible line connects the oil pressure transducer with the engine The oil temperature gauge is mounted in the instrument cluster assembly on the instrumen...

Page 760: ...l cooler all fittings and lines for leaks Repair or replace as necessary Defective gauge See Note Replace gauge Reset circuit breaker If circuit breaker continues to trip check wiring Tripped circuit...

Page 761: ...ROUBLE PROBABLE CAUSE REMEDY ii indication Defective gauge See Note Replace gauge Tripped circuit breaker Reset circuit breaker If circuit breaker continues to trip check wiring Gauge not grounded Che...

Page 762: ...Q GA 7 COUGAR MAINTENANCE MANUAL PROBABLE CAUSE Defective Sensor REMEDY Temporarily substitute a 36 0 ohm resistance for the oil temperature sensor If oil temperature gaugein dicates 245 red line repl...

Page 763: ...20W 30 Removal Installation of Engine Oil System Externally Mounted Components NOTE For additional information on the engine oil system not covered in this manual refer to Avco Lycoming Operator s Ma...

Page 764: ...YOOtRfl GA 7 COUGAR MAINTENANCE MANUAL 1 Flexible Lines 2 Oil Cooler 3 Bolt 4 Washer 5 Spacer 6 Doubler 7 Screw 8 Washer 9 Nut 10 Doubler 11 Gasket Oil Cooler Removal Installation Figure 201 79G72 1...

Page 765: ...NCAPPED SOME OIL SPILLAGE MAY OCCUR TAKE PROPER PRECAUTIONS TO PREVENT HAZARD DUE TO SPILLAGE 4 Uncap flexible lines and connect to oil cooler Torque flexible linefittings70 to 80 inch pounds 5 Check...

Page 766: ...fifl GA 7 COUGAR MAINTENANCE MANUAL NYLON WASHER BRASS WASHER WIRE LOCKWASHER OIL PRESSURE GAUGE SCREW OIL TEMPERATURE GAUGE Oil Pressure and OilTemperature Gauge Removal Installation Figure 202 NUT N...

Page 767: ...nstrument panel 4 Install attaching screws washers and nuts securing cluster assembly to instmment panel 5 Operate engine for approximately 3 minutes if ambient temperature is above 32 F 10 minutes if...

Page 768: ...ty wire the sensor 2 Connect wire to oil temperature sensor 3 Operate engine for approximately 3 minutes if ambient temperature is above32T 10 minutes if ambient temperature is below 32 F Observe oil...

Page 769: ...ded use 4 During installation avoid twisting flexible lines and provide as large abend radius as possible 5 Route all flexible linesas far as possible fromareas of intense heal 6 If flexible line isbe...

Page 770: ...JAM tfAMMU fs3 aim ln jtitna rAit i i i i i i ir i jr trj y j 0 Tor yris i iMii o j a ii J html i i i cii fn 5 uj i iii hu h srwi it Jiul i ili iM tf i yi i itf ii V l gOt iKi i i i i j f i jjf J i ii...

Page 771: ...M A mm NUMBER 80 1 1 STARTING Description Operation General Troubleshooting Maintenance Practices Removal Installation GA 7 COUGAR MAINTENANCE MANUAL CHAPTER 80 STARTING TABLE OF CONTENTS PAGE 1 1 101...

Page 772: ...arter is mounted on the front of the engine and issecured with one mounting bolt and three mounting studs nuts and washers When power is supplied to the starter the starter drive gears engage the star...

Page 773: ...near Wom or broken leelh on crankshaft ring gear Recharge or replace Replace fuse Check wiringwith ohmmeter and repair as required Replace solenoid CAUTION BF SURE THAT MASTER SWITCH IS OFF BEFORE AT...

Page 774: ...uts and mounting bolt Torque to standard values shown in Chapter 91 2 Position brace from alternator mount in placeand install mounting bolt Safety wire bolt 3 Connect starter cable 4 Install cowl C R...

Page 775: ...vLTERNATOR BRACE MOUNTING DOLT GRUMMAN GMMslOrg lM SMO TOinilfy MOUNTING BOLT GA 7 COUGAR MAINTENANCE MANUAL GA 7 Cougar Starter Removal Installation Figure 201 80G72 2 80 1 1 Page 202 July 15 77...

Page 776: ...RUMMAN MO OS a AWOATDP Dl j GA 7 COUGAR MAINTENANCE MANUAL STARTER RELAY WASHER MOUNTING BOLT DETAIL A GA 7 Cougar Starter Solenoid Removal Installation Figure 202 RIVET NUT PLATE 80G72 3 80 1 1 Page...

Page 777: ...MMAN AIRtiMlg lft AmA mm GA 7 COUGAR MAINTENANCE MANUAL NUMBER 91 1 1 CHARTS General Torque Values Bolts and Nuts Tubing Decimal Conversions CHAPTER 91 CHARTS TABLE OF CONTENTS PAGE 91 Page 1 July 15...

Page 778: ...ue is applied 1 Calibrate the torque wrench periodically toensure accuracy and recheck frequently 2 Ascertain that the bolt and nut threads are clean and dry unless otherwise specified by the manufact...

Page 779: ...S20046 MS20073 MS20074 AN509NK9 MS24694 AN525NKS25 MS27039 AN310 AN315 AN363 AN365 NAS102I MSI7825 MS2I045 MS20365 MS20500 NAS679 AN320 AN364 NASI022 MS17826 MS20364 8 32 10 24 1 4 20 5 16 18 3 8 16 7...

Page 780: ...MS20500 NAS679 NAS679 NAS 1291 Nut bolt Torque Umits Torque Umits Torque Umits Torque Limits Torque Limits Torque Limits size in lbs in lbs in lbs in lbs in lbs in lbs Min Max Min Max Min Max Min Max...

Page 781: ...TUBING FLARE AND10061 HOSE END FITTING AND HOSE ASSEMBLIES MINIMUM MAXIMUM MINIMUM MAXIMUM MINIMUM MAXIMUM 1 8 3 16 1 4 5 16 3 8 1 2 5 8 3 4 1 1 1 4 1 1 2 1 3 4 2 40 60 75 150 200 300 500 600 600 65...

Page 782: ...319 32 21L A22 42 10 716 7 16 64 I c 44 11 112 H P 453 45 11 509 15 64 1 160 47 11 906 32 S 484 48 12 303 64 500 50 12 700 4ths 8ths 16ths 32NDS 64ths TO 3 PLACES TO 2 PLACES MM EQUIV 5 8 9 16 17 32 3...

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