Thrush Aircraft S2R-R1340, Maintenance Manual

Page 1: ...COCKPIT Model S2R R1340 Serial Numbers S2R R1340 S N 036 up Issued January 1 2008 Note All serial numbers with the DC suffix indicate the dual cockpit configuration Manufacturer s Serial Number ______...

Page 2: ...ndard workshop procedures safety principles and service operations are NOT included in this manual Please note that this manual DOES contain warnings and cautions against some specific service methods...

Page 3: ...ive 01 01 2008 iii SECTION 3 HYDRAULICS SECTION 4 POWER PLANT AND PROPELLER SECTION 5 FUEL SYSTEM SECTION 6 LANDING GEAR WHEELS BRAKES SECTION 7 FLIGHT CONTROLS SECTION 8 INSTRUMENTS SECTION 9 DISPERS...

Page 4: ...17 01 01 08 18 01 01 08 19 01 01 08 20 01 01 08 21 01 01 08 22 01 01 08 23 01 01 08 24 01 01 08 25 01 01 08 26 01 01 08 SECTION 2 SERVICING INSPECTION Continued Page Date 27 01 01 08 28 01 01 08 29 01...

Page 5: ...01 08 SECTION 6 LANDING GEAR WHEELS BRAKES Page Date 1 01 01 08 2 01 01 08 3 01 01 08 4 01 01 08 5 01 01 08 6 01 01 08 7 01 01 08 8 01 01 08 SECTION 6 LANDING GEAR WHEELS BRAKES Continued Page Date 9...

Page 6: ...S Page Date 1 01 01 08 2 01 01 08 3 01 01 08 4 01 01 08 5 01 01 08 6 01 01 08 7 01 01 08 8 BLANK 01 01 08 SECTION 10 ELECTRICAL SYSTEM Page Date 1 01 01 08 2 01 01 08 3 01 01 08 4 01 01 08 5 01 01 08...

Page 7: ...H AIRCRAFT INC MODEL S2R R1340 AIRCRAFT MAINTENANCE MANUAL Effective 01 01 2008 vii LOG OF REVISIONS Rev No Pages Description of Revisions Eng rg Approval FAA Accepted NC All New Manual 1 1 08 Oct 17...

Page 8: ...THRUSH AIRCRAFT INC MODEL S2R R1340 AIRCRAFT MAINTENANCE MANUAL THIS PAGE INTENTIONALLY LEFT BLANK viii Effective 01 01 2008...

Page 9: ...WING 3 HORIZONTAL STABILIZER AND ELEVATORS 3 VERTICAL STABILIZER AND RUDDER 3 AREAS 3 SUPPLIER FURNISHED COMPONENT MANUALS 4 AIRCRAFT STRUCTURE 4 FUSELAGE 4 WING 4 EMPENNAGE 5 COCKPIT 5 AIRCRAFT SYSTE...

Page 10: ...e features of the design The high strength overturn structure is a proven design The fuselage and overturn structure constructed throughout of chrome moly steel tubing are immensely strong in the cock...

Page 11: ...nches 17 Elevator Travel Up 27 Degrees 1 Degree Down 17 Degrees 1 Degree Trim Tab Travel Up 8 Degrees 1 Degree Down 22 Degrees 1 Degree VERTICAL STABILIZER AND RUDDER Vertical Fin Offset 0 Degrees 1 D...

Page 12: ...ered with heat treated Alclad panels attached with camloc fasteners Side skins can be removed using only a screwdriver thus exposing the fuselage frame for thorough cleaning and inspection All skins a...

Page 13: ...hield is a three piece construction The center section is tempered safety plate glass for better resistance to scratching and bird strikes The windshield side panels are Plexiglas and are curved to pr...

Page 14: ...t and filter systems to remove impurities and water accumulation from the bulk fuel If filtering facilities are not available filter the fuel through a quality high grade chamois Fuel tanks should be...

Page 15: ...ndard flight instrument package ELECTRICAL SYSTEM The standard 24 volts and 50 amp 70 for dual control version electrical system consists of the starting system the wiper washer system the navigation...

Page 16: ...THRUSH AIRCRAFT INC MODEL S2R R1340 AIRCRAFT MAINTENANCE MANUAL 1 8 Effective 01 01 08 Figure 1 1 Aircraft 3 view...

Page 17: ...THRUSH AIRCRAFT INC MODEL S2R R1340 AIRCRAFT MAINTENANCE MANUAL Effective 01 01 08 1 9 Figure 1 2 Aircraft Stations...

Page 18: ...THRUSH AIRCRAFT INC MODEL S2R R1340 AIRCRAFT MAINTENANCE MANUAL 1 10 Effective 01 01 08 THIS PAGE INTENTIONALLY LEFT BLANK...

Page 19: ...ANCE HINTS 6 GROUND EMERGENCY PROCEDURES 6 ENGINE FIRES 6 ELECTRICAL FIRES 6 GROUND OPERATION OF ENGINE 6 EXTERIOR PRE START CHECK 7 PRE START CHECKLIST 7 COCKPIT PRE START CHECK 7 STARTING ENGINE 7 E...

Page 20: ...EL SYSTEM 25 E AIR INDUCTION SYSTEM 25 F AIRFRAME FUEL SYSTEM 26 G IGNITION SYSTEM 27 H MAIN LANDING GEAR 27 J HYDRAULIC SYSTEM 28 K TAIL GEAR 28 L FUSELAGE SKINS 30 M HOPPER 30 N WINGS 30 P FUSELAGE...

Page 21: ...r or to other aircraft in the area PARKING Head the aircraft into the wind and set the parking brake Do not set the parking brake during cold wet weather because the accumulated moisture may freeze in...

Page 22: ...can generally be calculated and logged in the log book To do this you must know the weight change for added for subtracted and its distance in inches from the aircraft datum wing leading edge being a...

Page 23: ...e reading This is not necessary if the scale was between the tailwheel and the stand The new moment is the sum of the main gear scale readings multiplied by 3 10 the distance the MLG axles are behind...

Page 24: ...Fill the tanks with correct grade of fuel as soon as possible after landing to reduce the possibility of condensation and ice formation in the tanks Fuel extracted from fuel header tank drain before s...

Page 25: ...rect grade and weight of oil see Section IV d Clear area of personnel and loose objects COCKPIT PRE START CHECK a Verify that the internal control lock has been removed and that the controls operate b...

Page 26: ...y retarding throttle to idle and momentarily switching magneto to OFF and then to BOTH The tachometer should indicate a sudden RPM drop when magneto ceases firing If magneto switch remains OFF for lon...

Page 27: ...sections of this manual HYDRAULIC SYSTEM Reference Section 3 The hydraulic system consists of two master brake cylinders and the necessary hydraulic lines connecting the master cylinders to the wheel...

Page 28: ...ith solvents or cleaned with compressed air The paper filters may be cleaned by lightly tapping on a hard surface If this method does not remove the excess dirt and dust replace the filters with new o...

Page 29: ...fuel draining in order to extract the moisture sediment and other contamination entrapped in the system The drains are located at the low point of each wing tank aft inboard bottom the bottom of the h...

Page 30: ...properly grounded to the aircraft c Open the drain valves and allow all fuel to drain When tanks are empty close the drain valves and move the fuel containers a safe distance from the aircraft d Verif...

Page 31: ...rain plugs and the lower most intake pipes removed to facilitate engine draining On uninstalled engines remove the starter and the oil inlet and outlet shipping covers With the sump drain plugs and th...

Page 32: ...raining Fill the oil tank with enough corrosion preventative mixture to ensure adequate lubrication during the preservation run plus the quantity needed to preserve the induction system Prepare the en...

Page 33: ...the control valve to allow the engine preservation mixture to be introduced into the induction system When the exhaust stacks are smoking profusely move the mixture control to idle cut off position t...

Page 34: ...ed under low temperature or if the alternate method of treating cylinder bores is used must have the rockerbox covers removed and the rockers valve springs washers and valves sprayed with corrosion pr...

Page 35: ...ed the spraying procedure must be repeated NOTE Do not apply excessive amounts of material All that is necessary is a uniform thin coating on all surfaces Excessive amounts of material do not contribu...

Page 36: ...wly from the spark plug opening to the piston but without touching the piston head then back to the spark plug opening where the trigger should be released immediately f Proceed at once to spray each...

Page 37: ...of the packing box X Accessories Drain the fuel from the engine driven fuel pump and the oil from the propeller governor and flush with corrosion preventive mixture while rotating the crankshaft to e...

Page 38: ...line that may have collected in the accelerating pump system After the carburetor has been drained thoroughly place the carburetor on its top flange Install a fitting in the carburetor drain and attac...

Page 39: ...plugs or damaged parts Make certain that the intake pipes are tight at both ends X X Warning Tag Place a warning tag on the propeller shaft and a similar tag in the airplane cockpit stating that the p...

Page 40: ...etal parts are to be checked for security of attachment cracks and metal distortion broken spot welds corrosion condition of paint and any other apparent damage d Wiring is to be checked for security...

Page 41: ...om each blade clamp Using a hand operated grease gun grease each forward fitting slowly Lubrication is complete when grease emerges from the rear in a steady flow with no air pockets or moisture and h...

Page 42: ...leaks X 10 Check engine mount for cracks particularly in welded areas Check rubber isolators for splits cracks and deterioration Check fasteners for security X 11 Check the security of the accessorie...

Page 43: ...rainer X 8 Check the oil level X X X 9 Oil change recommended every 50 hours except for initial ground run See pg 4 10 Refer to Section 4 for applicability of engine pre oiling X D ENGINE FUEL SYSTEM...

Page 44: ...es from wing tanks header tank and firewall fuel filter bowl Check for any debris sediment or water and take corrective action if any is found X X 2 Inspect clean and reinstall firewall fuel filter X...

Page 45: ...12 Check header tank for security leaks and chafing X 13 Check fuel tank vent system for leaks and signs of chafing X 14 Drain fuel vent system drains X X NOTE When a fuel system problem is found refe...

Page 46: ...ck the master cylinders parking brake valves brake lines brake calipers all brake fittings and brake bleeders for leakage general condition and security X 8 Check brake fluid level in each master cyli...

Page 47: ...to prevent collection of potential corrosive material in this area Lubricate 2 ea Trunnion Zerk grease fittings with MIL G 81322 Aeroshell 22 NOTE If the tail gear spring and mount components have bee...

Page 48: ...ect the hopper baffles for security and condition X 2 Check the hopper lid for condition of seal and security of latches X 3 Inspect the hopper for evidence of leaks and for general condition X 4 Chec...

Page 49: ...age attach angles for signs of cracks and corrosion X 10 Inspect aft spar to fuselage attach bolts for condition and torque X 11 Inspect wing attach angle to fuselage bolts 4 per side for condition an...

Page 50: ...ay straightness and paint condition X 4 Check idlers and bell cranks for binding wobble or slack X 5 Inspect the rudder pedals and the support brackets for general condition X 6 Inspect the attachment...

Page 51: ...bearings if needed Lubricate hinges X 5 Check security of all screws and bolts X 6 Check the external skins for general condition X 7 Check the drain holes for obstruction X S AILERONS AND FLAPS Daily...

Page 52: ...g X 3 Check the hopper for leaks and security of mechanism X 4 Check the security and condition of the seat belts shoulder harness and inertia reels X 5 Check the seat for security and proper adjustme...

Page 53: ...exists if there is a reading on the voltmeter A dated service record shall be attached or stamped on the terminal side of the battery to indicate that the battery has been capacity tested AIRFRAME MAI...

Page 54: ...whenever possible b Thoroughly clean area with isopropyl alcohol a solvent or thinner Remove this cleaning agent before it dries with a clean dry cloth so that no oily film remains c Apply one thin sp...

Page 55: ...MS 21044N NAS 1291 MS21044N NAS 1291 MS 21045 MS21045 NAS 1021 NAS 1021 Torque Limits in Torque Limits in NUT BOLT Torque Limits in Torque Limits in Min Max Min Max SIZE Min Max Min Max 5 12 15 7 9 8...

Page 56: ...oil Wipe off the excess oil to prevent accumulation of dirt and grit Figure 2 4 Lubrication Chart Sheet 1 of 9 The drawings of Figure 2 4 sheets 1 thru 9 are for lubrication reference only They do not...

Page 57: ...THRUSH AIRCRAFT INC MODEL S2R R1340 THRUSH 600 AIRCRAFT MAINTENANCE MANUAL Effective 01 01 08 2 39 Figure 2 4 Lubrication Chart sht 2 of 9...

Page 58: ...THRUSH AIRCRAFT INC MODEL S2R R1340 THRUSH 600 AIRCRAFT MAINTENANCE MANUAL 2 40 Effective 01 01 08 Figure 2 4 Lubrication Chart sht 3 of 9...

Page 59: ...THRUSH AIRCRAFT INC MODEL S2R R1340 THRUSH 600 AIRCRAFT MAINTENANCE MANUAL Effective 01 01 08 2 41 Figure 2 4 Lubrication Chart sht 4 of 9...

Page 60: ...THRUSH AIRCRAFT INC MODEL S2R R1340 THRUSH 600 AIRCRAFT MAINTENANCE MANUAL 2 42 Effective 01 01 08 Figure 2 4 Lubrication Chart sht 5 of 9...

Page 61: ...THRUSH AIRCRAFT INC MODEL S2R R1340 THRUSH 600 AIRCRAFT MAINTENANCE MANUAL Effective 01 01 08 2 43 Figure 2 4 Lubrication Chart sht 6 of 9...

Page 62: ...THRUSH AIRCRAFT INC MODEL S2R R1340 THRUSH 600 AIRCRAFT MAINTENANCE MANUAL 2 44 Effective 01 01 08 Figure 2 4 Lubrication Chart sht 7 of 9 Figure 2 4 Lubrication Chart sht 8 of 9...

Page 63: ...THRUSH AIRCRAFT INC MODEL S2R R1340 THRUSH 600 AIRCRAFT MAINTENANCE MANUAL Effective 01 01 08 2 45 Figure 2 4 Lubrication Chart sht 9 of 9...

Page 64: ...THRUSH AIRCRAFT INC MODEL S2R R1340 THRUSH 600 AIRCRAFT MAINTENANCE MANUAL 2 46 Effective 01 01 08 THIS PAGE INTENTIONALLY LEFT BLANK...

Page 65: ...DRAULICS TABLE OF CONTENTS HYDRAULIC SYSTEM 2 GENERAL DESCRIPTION 2 MASTER CYLINDER 2 FIGURE 3 1 BRAKE MASTER CYLINDER 2 FIGURE 3 2 BRAKE MASTER CYLINDER AND RUDDER PEDAL INSTALLATION 3 BRAKE SYSTEM B...

Page 66: ...the landing gear tripod assembly The master brake cylinder is installed aft of the rudder brake pedals and is actuated by toe pressure on the pedals As toe pressure is applied to the pedals a push ro...

Page 67: ...nto the hydraulic line to the wheel brakes The piston is returned by a spring so that hydraulic pressure is maintained only while the toe brake is depressed Hydraulic fluid reservoirs should be kept a...

Page 68: ...e a clean container of at least a pint capacity a length of 3 16 ID clear plastic tubing clean rags and extra MIL H 5606 hydraulic fluid 3 Put the clear plastic tubing on one of the bleeder valves at...

Page 69: ...bleeder valve 7 Bleed that caliper the same as above It should not take more than two brake pedal strokes 8 Close that bleeder valve and top off the master cylinder hydraulic reservoir 9 Dispose of t...

Page 70: ...to the other bleeder valve 7 Open the bleeder valve and force another few fluid ounces of hydraulic fluid back to the master cylinder 8 Close the bleeder valve and clean off the brake master cylinder...

Page 71: ...iner 10 Figure 4 3 Oil Pressure Screen Assembly 10 Installing Oil Strainer 10 Pre Oiling 10 Pre Oiling Optional 11 CARBURETOR 11 Carburetor Removal 11 Carburetor Installation 11 Cleaning Fuel Strainer...

Page 72: ...21 Initial Engine Ground Run 21 OIL COOLER 22 Oil Cooler Removal 22 Oil Cooler Installation 22 ENGINE MOUNT 22 ENGINE CONTROLS 22 Rigging 22 Figure 4 9 Engine Mount Assembly 23 EXHAUST SYSTEM 23 Exhau...

Page 73: ...o that an equal distribution of voltage will be delivered to the spark plugs through the ignition cable assembly Rubber protectors are installed on all spark plug leads to protect the cables from mois...

Page 74: ...e This will give the correct E gap Permissible limits are 1 32 inch on either side of the timing marks If the timing is correct no further action is necessary however if the timing of either magneto i...

Page 75: ...THRUSH AIRCRAFT INC MODEL S2R R1340 AIRCRAFT MAINTENANCE MANUAL Effective 01 01 2008 4 5 Figure 4 1 Engine Assembly Sht 1 of 2...

Page 76: ...THRUSH AIRCRAFT INC MODEL S2R R1340 AIRCRAFT MAINTENANCE MANUAL 4 6 Effective 01 01 2008 Figure 4 1 Engine Assembly Sht 2 of 2...

Page 77: ...n the direction of normal rotation until the pivot arm pushes the slide pointer to the farthest point E Turn the propeller shaft approximately 90 degrees in the opposite direction This will return the...

Page 78: ...g and synchronizing check should be performed IGNITION CONDUIT LEAD REPLACEMENT Ignition leads showing evidence of chafing or deterioration of insulation should be replaced Replacement of ignition lea...

Page 79: ...the annulus which encircles the left magneto drive gear shaft rear bushing Drilled passages from this annulus carry oil to the left accessory drive gear bushing Here the oil enters the hollow accesso...

Page 80: ...ssure is 80 to 100 PSI C After the desired adjustment has been obtained tighten the locknut reinstall the relief valve cap and lockwire PRESSURE OIL STRAINER The pressure oil strainer see Figure 4 3 i...

Page 81: ...throttle opening After being metered by the carburetor the fuel is discharged into the air stream to the impeller where it is thoroughly mixed with the air vaporized and then delivered to the cylinde...

Page 82: ...d cleaned at periodic intervals To remove strainer proceed as follows A Cut safety wire and remove strainer from carburetor B Wash strainer in approved solvent Clean strainer chamber of any foreign ma...

Page 83: ...er the desired adjustment has been obtained tighten and lockwire the adjusting screw locknut FUEL PUMP REMOVAL To remove fuel pump proceed as follows A Disconnect and cap all fuel lines B Break lockwi...

Page 84: ...he other centrifugal Oil forced into the piston cylinder arrangement is the hydraulic force which moves the cylinder outboard This motion is transmitted to the brackets through the shaft and bearing g...

Page 85: ...ash all parts in kerosene and dry using filtered compressed air Insure that all threaded parts are thoroughly clean and lightly coat all internal surfaces with lubricating oil A Install rear cone spac...

Page 86: ...ston so that the two cotter pin holes in the outboard end of the spider align with two of the eight cotter pin holes in the lock ring Safety the lock ring to the spider with a cotter pin in each of th...

Page 87: ...THRUSH AIRCRAFT INC MODEL S2R R1340 AIRCRAFT MAINTENANCE MANUAL Effective 01 01 2008 4 17 Figure 4 6 Propeller Assembly 12D40 6101 12 or AG 100 2 Blades...

Page 88: ...intain a balanced relationship between the centrifugal force of the flyweights and the speeder spring lowers the RPM necessary to maintain this balance and lowering the rack increases the RPM setting...

Page 89: ...ated within a seven day period comply with storage instructions contained in Section 2 A Close fuel shutoff valve and be sure ignition and battery switches are OFF B Remove propeller see Propeller Rem...

Page 90: ...and new engine be located side by side and a direct transfer of parts be made Observe the following practices during engine buildup CAUTION A Thoroughly clean and inspect removed parts for serviceabi...

Page 91: ...return and drain lines H Connect fuel inlet outlet oil return and vapor lines as required I Connect fuel pressure oil pressure manifold pressure and oil temperature lines as required Connect tachomet...

Page 92: ...truction in the cooler OIL COOLER REMOVAL To remove oil cooler proceed as follows A Disconnect and cap oil inlet and outlet line B Support oil cooler remove nuts and washers from bolts through bolts a...

Page 93: ...e exhaust gases are accumulated by a collector ring and expelled overboard through a single exit The collector ring is made up of seven segments and joined by expansion clamps see Figure 4 11 EXHAUST...

Page 94: ...ting the engine on an excessively rich idle mixture Proper adjustment of the idle mixture will assure longer spark plug life Improper magneto timing faulty magneto points or fouled spark plugs may be...

Page 95: ...THRUSH AIRCRAFT INC MODEL S2R R1340 AIRCRAFT MAINTENANCE MANUAL Effective 01 01 2008 4 25 Figure 4 10 Engine Control Quadrant Figure 4 11 Exhaust Collector Ring...

Page 96: ...ce switch Check starting instruments Replace spark plugs Check battery and starter Time magnetos Replace primer Replace magneto Drain fuel tank until the presence of water is negative Refill with prop...

Page 97: ...fuel runs freely from vent Replace only with a similar pump Wash and replace fuel strainer Inspect and remove obstruction Replace carburetor Drain fuel tank until presence of water is negative Repleni...

Page 98: ...ark plugs or leads Defective breaker points Defective magneto Dead cylinder Faulty ignition switch Pre ignition and detonation Fuel pressure too high Fuel pressure too low Leak in induction system Fue...

Page 99: ...ng Malfunction of internal part Worn thrust bearing Loose thrust nut Loose exhaust collector ring Bent drive shaft Worn engine mounts Trapped air carburetor Preheat or deice depending upon climatic co...

Page 100: ...tomatic mixture control sticking Manual mixture control linkage out of adjustment Defective fuel pump Clogged fuel line or carburetor strainer Low fuel pressure Oil in carburetor air passages Readjust...

Page 101: ...nnection plate for cleanliness Time magnetos Check that air and not fuel is by passed when pressure is on Check high tension lead coil plugs and valve clearance Check valves and piston rings for wear...

Page 102: ...s or replace cylinder Tighten an or replace seals and gaskets Remove restriction Preheat or deice depending upon climatic conditions Replace carburetor if necessary Repair or replace preheat system Re...

Page 103: ...reset Replace engine Replace pump Remove air by bleeding Replace engine Low oil pressure Defective transmitter or gage Inadequate oil supply High oil temperature Oil screen clogged Improper setting o...

Page 104: ...e screens Defective scavenge pump Wrong grade of oil Oil inlet check valve remaining open Internal leaks Disconnect oil line close to oil pump and bleed Inspect oil cooler temperature control Apply he...

Page 105: ...haust valve stem If seepage is present replace cylinder Engine continues operating during ignition switch check Left or Right or Both magnetos may not be grounded properly Check continuity of P lead E...

Page 106: ...r bypass temperature control unit defective Oil foaming bearing malfunction Replace faulty unit Tighten spark plugs Time magnetos Adjust fuel air mixture Repair Reset timing Drain tanks and service wi...

Page 107: ...allowing piston to hang up in combustion chamber Replace engine Detonation Loose spark plugs Spark too far advanced Preignition Wrong grade of fuel Incorrect fuel air ratio High carburetor air temper...

Page 108: ...eplace magneto Both plugs in one cylinder cutting out Fouled spark plugs Faulty wires in ignition cable manifold Cylinder pumping oil Replace spark plugs Replace manifold Replace cylinder Front or rea...

Page 109: ...7 AUXILIARY FUEL PUMP 7 Auxiliary Fuel Pump Removal 7 Auxiliary Fuel Pump Installation 7 FUEL strainer 7 Fuel Strainer Service Instructions 8 FUEL system MAINTENANCE and repair 8 USE OF FUEL PROOF SE...

Page 110: ...ght have gotten in the tank s outboard vent lines The fuel quantity gauge is located on the lower left instrument panel The fuel quantity indicating system consists of two transmitters one indicator g...

Page 111: ...e in an approved work area B Ground aircraft and maintenance stands to a common ground Ground points must not be painted C Remove external power sources and disconnect batteries D Suspend all maintena...

Page 112: ...the tees are connected by hoses to drain valves on the shin skins below the wings The fuel vent manifold is installed forward of the hopper above and forward of the wing spar This position puts the a...

Page 113: ...itter D Remove attaching screws washers and bushings and carefully remove transmitter assembly Installation The transmitter can be installed by reversing the removal procedures Do not damage float or...

Page 114: ...tor I Turn APU on and adjust to 27 5 volts J Turn battery switch ON Readjust APU to 27 5 volts if necessary K Place fuel quantity selector switch to L H fuel tank L With the transmitter float free to...

Page 115: ...efore the servicing is limited to the removal and replacement of the pump Auxiliary Fuel Pump Removal A Close fuel shutoff valve Remove drain plug and drain the aux pump B Disconnect electrical connec...

Page 116: ...8802 formerly MIL S 8802 may be used as a thread seal or to seal minor connection leaks throughout the fuel system Apply sparingly to male fittings only Make sure that any sealing compound or residue...

Page 117: ...until a uniform gray color is achieved There should be no white or black streaks in the properly blended material Blend the components slowly as violent stirring will entrap air in the cured sealant...

Page 118: ...etween the mating surfaces where they are still attached When the fasteners are tightened starting at one end and working to the other the faying sealant is squeezed out along the edges If a small bea...

Page 119: ...ype B sealant to all areas of contact between the skin and ribs spars intercostals and other skins D Wet rivet the wing tank skin in place Smooth out sealant squeezed out to make fillet seals at all j...

Page 120: ...y pressure to the fuel tank very gradually Do not pressurize the tank in excess of 44 0 inches of water or damage may occur When pressure in the tank exceeds 38 start checking the tank for air leaks S...

Page 121: ...The trouble shooting table in this next section Table 5 2 discusses symptoms which can be diagnosed and interprets the results in terms of probable causes and the appropriate corrective action to be...

Page 122: ...g Tighten connections repair or replace wiring Left and right fuel quantity indicator switch defective Check continuity and replace if defective No power to gauge Check power to gauge If no power chec...

Page 123: ...cuit breaker Check visually If not open check continuity Reset Replace if defective Loose connections or open circuit Check connections and wiring Tighten connections repair or replace wiring Defectiv...

Page 124: ...lowed after each refueling the engine may quit when hopper fuel is selected in flight OPERATING INSTRUCTIONS FOR THE P N 60167 FERRY FUEL SYSTEM Operation instructions must be strictly followed to ope...

Page 125: ...THRUSH AIRCRAFT INC MODEL S2R R1340 AIRCRAFT MAINTENANCE MANUAL Effective 01 01 08 5 17 FIGURE 5 6 HOPPER FERRY FUEL SYSTEM...

Page 126: ...THRUSH AIRCRAFT INC MODEL S2R R1340 AIRCRAFT MAINTENANCE MANUAL 5 18 Effective 01 01 08 THIS PAGE INTENTIONALLY LEFT BLANK...

Page 127: ...Installation 9 REASSEMBLY OF ORGANIC LININGS TO CALIPER 10 BRAKE LINING CONDITIONING PROCEDURES 10 Non Asbestos Organic Linings 10 BRAKE REASSEMBLY AND INSTALLATION 11 Figure 6 5 Brake Master Cylinde...

Page 128: ...allows limited fore and aft movement of the spring The spring is supported just forward of the bend by clamping brackets which support it and limit fore and aft motion The housing and spindle is atta...

Page 129: ...are interchangeable according to wheel size The MLG wheels operate on tapered roller bearings that rotate in hardened steel races pressed into each wheel half A brake disc assembly is bolted to the w...

Page 130: ...THRUSH AIRCRAFT INC MODEL S2R R1340 AIRCRAFT MAINTENANCE MANUAL FIGURE 6 1 MAIN LANDING GEAR ASSEMBLY 6 4 Effective 01 01 08...

Page 131: ...he bearing cups are pressed into the wheel halves and should not be removed unless replacement is necessary due to the above conditions If replacement is necessary proceed as follows 1 Insert wheel ha...

Page 132: ...installing the wheels A Reassemble cone bearings grease seals felts and snap ring into the proper wheel halves Lubricate bearings See Inspection of Main Wheel Assembly B Inflate tube sufficiently to...

Page 133: ...s if the self locking feature is damaged or destroyed O Wheels may be repainted if the parts have been repaired and thoroughly cleaned Paint exposed areas with one coat of zinc primer and one coat of...

Page 134: ...sembly from which paint has been removed P Paint exposed areas with one coat of zinc primer and one coat of aluminum lacquer Q Check the wheel brake disc See procedures under Inspection of Main Wheel...

Page 135: ...e crest of the clenched surface 2 No more than two splits shall occur in a 90 area 3 A total of no more than three splits shall be allowed Figure 6 4 D Check to be sure lining is tight and movement fr...

Page 136: ...nylon material embedded in threaded end will required replacement 6 to 8 installations or whenever the bolts can be run in past the locking feature by use of fingers only Bolts with drilled heads req...

Page 137: ...procedure should be performed whenever the rough disc condition is observed Light use such as in taxiing will cause the glaze to be worn rapidly BRAKE REASSEMBLY AND INSTALLATION A Install friction sp...

Page 138: ...into hydraulic system D Apply brake pressure and open bleeder screw approximately 1 3 to turn close bleeder screw before releasing brake pressure to avoid reentry of air into brake system Repeat this...

Page 139: ...bly welds for cracks F Inspect spindle housing assembly for cracks and corrosion G Inspect lock pin and upper and lower lock plates for wear corrosion cracks and proper operation H Inspect centering s...

Page 140: ...indle castellated nut to 20 inch pounds continue rotating spindle and back off to zero inch pounds While manually rotating spindle torque nut to 10 inch pounds If not in locking position advance nut t...

Page 141: ...ock cable turnbuckle D Adjust top plate as required to assure straight travel of aircraft tail wheel when tail gear is locked DISASSEMBLY OF SPINDLE HOUSING ASSEMBLY Ref figure 6 7 A If desired remove...

Page 142: ...CTION OF TAIL LANDING GEAR WHEEL ASSEMBLY A Visually check all parts for cracks corrosion distortion defects and excessive wear B Inspect felt grease seals Replace if surface is hard or contaminated o...

Page 143: ...ap gently into place with fiber drift making sure bearing cup is evenly seated against shoulder of wheel half Avoid cocking bearing cup during installation If bearing cup will not seat properly in whe...

Page 144: ...late 12 5x4 5 10pr tire to 55 psi max Assure schrader valve does not leak before replacing valve cap F Repack bearing cones with MIL G 81322 Aeroshell 22 grease or equivalent G On each side of wheel a...

Page 145: ...of adjustment or broken Adjust or replace as required Tail wheel fails to lock or unlock Lock pin or lock pin spring broken or damaged Repair or replace as required Tire imbalance Jack aircraft and r...

Page 146: ...dirt restricting free movement of wheel brake parts Check parts for freedom of movement Clean and repair or replace parts as necessary Dragging brakes Continued Leak in system Check entire hydraulic s...

Page 147: ...7 Aileron Servo Tabs 7 AILERON 7 Figure 7 4 Aileron Assembly 8 WING FLAPS 8 FLAP JACKSCREW REMOVAL 8 FLAP REMOVAL 9 FLAP INSTALLATION 9 Figure 7 5 Flap Operating Mechanism 9 FLAP RIGGING 9 RUDDER 10...

Page 148: ...ATION 20 Figure 7 11 Wing Spar Inboard End and Splice 20 Figure 7 12 Wing Spar Splice 21 Figure 7 13 Attach Angle Mounting to Spar Web 22 Figure 7 14 Attach Angle Mounting to Fuselage Frame 24 WING IN...

Page 149: ...be free of kinks and pulleys must be aligned with the cables Position the cable pulleys and route cables to avoid contact with the aircraft structure and accessories Inspect work areas for mislaid to...

Page 150: ...torque tube C Withdraw controls stick and fork from aircraft D Remove the bolts securing the torque tube to the pillow blocks See Figure 7 1 E Remove the torque tube from aircraft Control Stick Fork...

Page 151: ...e rudder controls by spring loaded cables that enable the ailerons to be activated in conjunction with the rudder Ref Figure 7 2 This provides a safety factor in that if the aileron control system bec...

Page 152: ...d between the left fuselage idler bell crank and the right fuselage bell crank adjusting the length of the rod to fit those items E Install the upper lateral fuselage push rod from right fuselage bell...

Page 153: ...n to prevent flutter Both ailerons have a servo tab to lighten control forces NOTE The left and right ailerons are interchangeable Aileron removal is accomplished as follows A Remove the bolt attachin...

Page 154: ...MOVAL A Remove left side fuselage skin at cockpit and hopper B Remove wing root fairings to gain access to the flap push road and jackscrew attach bolts C Disconnect each flap from the push rod and al...

Page 155: ...rod length has been altered the flap will have to be completely re rigged Figure 7 5 Flap Operating Mechanism FLAP RIGGING A With the master switch ON fully retract the flaps up flaps with the flap s...

Page 156: ...the fuselage side skins and attach to adjustment straps on the rudder horn A spring loaded balance cable is routed between the pedal adjusting channels and forward around pivoted pulleys located on th...

Page 157: ...L CABLES INSTALLATION Ref Figure 7 6 A Install the cables in reverse order of the removal procedures B Check rigging per rigging instructions C Assure all cables cable guards and turnbuckles are insta...

Page 158: ...e neutral position Ensure there is no contact between balance springs ELEVATORS Ref Figure 7 7 7 8 Each elevator is attached to the rear spar of the horizontal stabilizer at two hinge points The contr...

Page 159: ...vel of 17 1 degrees and adjust the aft end of push tube at the elevator horn to match that position Connect push tube to elevator horn NOTE Assure the inspection hole in the rod end is covered by the...

Page 160: ...and the elevators consists of push rods bell cranks and fairleads The push rod leading from the trim tab control lever to the trim tab assembly runs along the left side of the fuselage and is guided...

Page 161: ...as outlined previously in this section of the manual B Remove horizontal struts being sure to mark left and right and top and bottom C Remove the vertical stabilizer by removing the single forward bo...

Page 162: ...adjust fork ends as required to bring the strut as close as possible to lower fuselage attach without touching The strut should be centered fore and aft with fork ends The forks should be shimmed wit...

Page 163: ...chment loosely with NAS6207 68 bolt Using either no shims normal or if a gap exist use one or more of the following P N 21209T001 125 and or P N 21209T002 250 shim s at upper attach and P N 21208T001...

Page 164: ...imately eight feet from the wing tips and under inboard wing ribs to prevent wing movement when the attach bolts are removed NOTE It is highly recommended that mobile wing stands be used for wing remo...

Page 165: ...olt in the upper splice fitting and with a 4X rivet gun drive it flush with the spar cap Proceed in a similar manner with the remainder of the bolts working from the smallest to the largest Under no c...

Page 166: ...landing gear attach points left and right and at the aft jack point B On the left wing install the outboard wing attach angle on the main spar web with NAS1104 16 bolts inch AN960 and MS20002C washers...

Page 167: ...wing tip and under the inboard end rib F Rest the inboard end of the main spar on the lower longeron with a inch temporary spacer between G Install the left wing inboard attach angle on the main spar...

Page 168: ...heads forward and secure with AN960 and MS20002C washers and MS21042 locknuts Bring the nuts up snug but torque only those which will be inaccessible when the splice fittings are installed K Install...

Page 169: ...of lower spar cap Use anti seize the same as for the upper splice blocks but be sure to clean threads before installing nuts Push large bolts through upper splice fitting and lower spar cap until flus...

Page 170: ...s Z Reconnect the batteries Figure 7 14 Attach Angle Mounting to Fuselage Frame WING INSTALLATION WHEN THE WING ATTACH ANGLES ARE REPLACED See Figures 7 13 7 14 A With the wings supported on wing jack...

Page 171: ...e edge distance must be checked H Remove the angle and check to confirm that the mark for the bottom hole is at least 5 8 2X hole diameter inch away from the lower edge of the angle If it is not file...

Page 172: ...cleanliness Resistance to control stick movement Bent aileron Repair or replace aileron Aileron push rods and tubes out of rig Rig in accordance with aileron rigging procedures Incorrect aileron trav...

Page 173: ...push rod Replace broken parts Flaps on one side fail to operate Disconnected push rod Connect push rod and recheck rigging procedures RUDDER SYSTEM Cables loose Adjust in accordance with rigging proc...

Page 174: ...s Repair or replace elevator horns Resistance to control stick movement Elevator hinges need lubrication Lubricate hinges as required to give free movement Incorrect elevator travel Elevator belcrank...

Page 175: ...SY P N 40226 100 POUND INCHS OF IMBALANCE FROM HINGE LINE TRAILING EDGE HEAVY Note Arm depends on where scale is placed Be sure to measure INCH POUNDS CONDITION MINIMUM MAXIMUM MANUFACTURING 45 100 FI...

Page 176: ...3 16 32 25 30 in lbs 1 4 28 80 100 in lbs 5 16 24 120 145 in lbs 3 8 24 200 250 in lbs 7 16 20 520 630 in lbs 1 2 20 770 950 in lbs 5 8 18 1 250 1 550 in lbs 3 4 16 2 650 3 200 in lbs 1 12 4 500 5 50...

Page 177: ...SYSTEM 7 OIL PRESSURE SYSTEM 7 FUEL PRESSURE SYSTEM 8 MANIFOLD PRESSURE SYSTEM 8 TACHOMETER SYSTEM 8 Figure 8 3 Left Instrument Panel 9 MISCELLANEOUS INSTRUMENTS 9 FUEL QUANTITY INDICATOR 9 VOLTMETER...

Page 178: ...ion of electrical wiring for chafing and electrical connections for security All fluid pressure pitot pressure and static line connections must be tight at all times and lines must be correctly routed...

Page 179: ...air pressure to the pitot and static lines may purge them If not the entire line will have to be inspected to find the blockage Always cap instrument inlets when lines are removed D Adjust the altimet...

Page 180: ...THRUSH AIRCRAFT INC MODEL S2R R1340 AIRCRAFT MAINTENANCE MANUAL 8 4 Effective 01 01 08 Figure 8 1 Pitot Static System...

Page 181: ...atic pressure system and repeat leakage test per steps C through F ALTIMETER The altimeter is equipped with three concentrically arranged pointers with a range of 0 to 20 000 feet One revolution of th...

Page 182: ...west adjustment screw until compass reads exactly east D Position aircraft in a magnetically south direction Notice the resulting south error Adjust north south adjustment screw so that one half of th...

Page 183: ...g properly OIL PRESSURE SYSTEM The oil pressure indicator works on the Bourdon Tube principle whereby a semi circular hollow tube unbends in proportion to internal pressure This unbending motion drive...

Page 184: ...a second s lag indicates a problem with the indicating system If the manifold pressure system is working normally it is an indicator of the power output of the engine The old caution of increasing eng...

Page 185: ...es a minimum resistance through the transducer permitting maximum current flow through the fuel quantity indicator and maximum pointer deflection As the fuel level of the tank is lowered the float rep...

Page 186: ...ide unless there is an aircraft alternator malfunction A discharge indication will show if the alternator is not working or if the electrical load demand exceeds the aircraft alternator output Continu...

Page 187: ...potentiometer until pointer is aligned with 360 marks on gauge NOTE Unit must be on to adjust 360 side of gauge NOTE The small scale on analog control unit Type FA A will move in direct relationship...

Page 188: ...nstrument Incorrect indication or hand oscillates Leaking diaphragm Substitute known good instrument and check reading Replace instrument Excessive vibration Check instrument mounting screws Tighten m...

Page 189: ...compass and compensate Excessive card error External magnetic interference Locate and eliminate interference Insufficient liquid Replace compass Excessive card oscillation Excessive vibration of compa...

Page 190: ...lean line Gauge does not register properly Faulty mechanism Replace instrument ENGINE FUEL PRESSURE GAUGE Gauge inoperative or erratic Low pressure or flow registered Restricted broken or leaking line...

Page 191: ...ute known good indicator Replace indicator Failure to indicate Defective sending unit Replace sending unit Registers either full or empty Float arm stuck Free float arm Defective indicator Substitute...

Page 192: ...ator or wires to indicator are bad No indication and resistance checked good Bad FA A control Check wiring Wiring OK replace FA A control Pins 5 8 11 and 15 are power pins on FA A unit Pin 15 is attac...

Page 193: ...M 70 to 90 Green Arc NORMAL Oil Pressure PSI 90 Red Radial MAXIMUM 3 Red Radial MINIMUM 3 to 6 Green Arc NORMAL Fuel Pressure PSI 6 Red Radial MAXIMUM 1 400 2 200 Green Arc NORMAL 2 200 to 2 250 Yello...

Page 194: ...THRUSH AIRCRAFT INC MODEL S2R R1340 AIRCRAFT MAINTENANCE MANUAL 8 18 Effective 01 01 08 THIS PAGE INTENTIONALLY LEFT BLANK...

Page 195: ...CRIPTION 2 HOPPER 2 HOPPER CARE 2 Figure 9 1 400 Gallon Hopper 3 HOPPER REPAIR 3 Figure 9 2 Hopper Repair 4 HOPPER GATE BOX REMOVAL 4 HOPPER GATE BOX INSTALLATION 4 SPRAY DISPERSAL SYSTEM 5 Figure 9 3...

Page 196: ...to aid in flushing the system The spray pump is located under the fuselage between the main landing gear struts A three way suck back spray valve located at the left underside of the fuselage controls...

Page 197: ...s only of surface cracks excessive abrasion or chemical erosion sand all affected surfaces smooth Extend the prepared surface six inches beyond the damaged area C If damage consists of cracks or holes...

Page 198: ...and nuts Disconnect dump fork spray tube adapter box and vent emergency shut off cable and spray pump Remove the nuts and bolts attaching the gate box to the adapter box and pry off the two apart If...

Page 199: ...airplane back into service Reinstall tubes controls and cables and pump Fill hopper and check for leaks Water should be allowed to stay in hopper for a minimum of two hours with no leaks SPRAY DISPERS...

Page 200: ...urity and proper operation N Inspect both booms and the support for each boom for security and evidence of corrosion O Inspect all nozzle diaphragms for deterioration P Inspect all fan blades for crac...

Page 201: ...THRUSH AIRCRAFT INC MODEL S2R R1340 AIRCRAFT MAINTENANCE MANUAL Effective 01 01 08 9 7 Figure 9 5 Agitator and Spreader...

Page 202: ...THRUSH AIRCRAFT INC MODEL S2R R1340 AIRCRAFT MAINTENANCE MANUAL 9 8 Effective 01 01 08 THIS PAGE INTENTIONALLY LEFT BLANK...

Page 203: ...E 10 1 ELECTRICAL EQUIPMENT LOCATOR A B 5 FIGURE 10 1 ELECTRICAL EQUIPMENT LOCATOR C D 6 FIGURE 10 1 ELECTRICAL EQUIPMENT LOCATOR E F 7 TABLE 10 1 ELECTRICAL TROUBLESHOOTING CHART 8 BATTERY SYSTEM 8 A...

Page 204: ...ical system can receive electrical power from three different sources battery external power and the alternator With the engine operating and the alternator on the line electric power from the alterna...

Page 205: ...10 1 D Check the battery electrolyte level frequently especially during hot weather If a visual check shows low cell level and no electrolyte is available at this time add distilled water to bring th...

Page 206: ...regulator circuitry see figure 10 1 C By using an integrated circuit comparator amplifier with a regulated reference voltage the alternator s voltage is amplified and supplied to the comparator circu...

Page 207: ...THRUSH AICRAFT INC MODEL S2R R1340 AIRCRAFT MAINTENANCE MANUAL Effective 01 01 08 10 5 FIGURE 10 1 ELECTRICAL EQUIPMENT LOCATOR A B...

Page 208: ...THRUSH AICRAFT INC MODEL S2R R1340 AIRCRAFT MAINTENANCE MANUAL 10 6 Effective 01 01 08 FIGURE 10 1 ELECTRICAL EQUIPMENT LOCATOR C D...

Page 209: ...THRUSH AICRAFT INC MODEL S2R R1340 AIRCRAFT MAINTENANCE MANUAL Effective 01 01 08 10 7 FIGURE 10 1 ELECTRICAL EQUIPMENT LOCATOR E F...

Page 210: ...drain tube Vent caps loose or broken Tighten or replace caps Standing too long Remove battery and recharge Equipment left on Remove battery and recharge Short circuit in wiring Check wiring and correc...

Page 211: ...ntinuity Check switch for proper operation and replace if necessary Volt ammeter does not indicate Defective wiring Continuity Check wiring and repair as necessary Defective meter Replace meter STARTE...

Page 212: ...duces low RPM Low battery Check battery Service and recharge if necessary High resistance starter circuit Check resistance of each connection Maximum resistance at any connection is 0 001 ohm Inspect...

Page 213: ...THRUSH AICRAFT INC MODEL S2R R1340 AIRCRAFT MAINTENANCE MANUAL Effective 01 01 08 10 11 Figure 10 2 WIRING DIAGRAMS Figure 10 2 Windshield Wiper Washer...

Page 214: ...THRUSH AICRAFT INC MODEL S2R R1340 AIRCRAFT MAINTENANCE MANUAL 10 12 Effective 01 01 08 Figure 10 2 Flap Actuation and Control...

Page 215: ...THRUSH AICRAFT INC MODEL S2R R1340 AIRCRAFT MAINTENANCE MANUAL Effective 01 01 08 10 13 Figure 10 2 Fuel Quantity Indication...

Page 216: ...THRUSH AICRAFT INC MODEL S2R R1340 AIRCRAFT MAINTENANCE MANUAL 10 14 Effective 01 01 08 Figure 10 2 Stall Warning System...

Page 217: ...THRUSH AICRAFT INC MODEL S2R R1340 AIRCRAFT MAINTENANCE MANUAL Effective 01 01 08 10 15 Figure 10 2 Tachometer with Hour Meter...

Page 218: ...THRUSH AICRAFT INC MODEL S2R R1340 AIRCRAFT MAINTENANCE MANUAL 10 16 Effective 01 01 08 Figure 10 2 Oil Temperature Indication...

Page 219: ...THRUSH AICRAFT INC MODEL S2R R1340 AIRCRAFT MAINTENANCE MANUAL Effective 01 01 08 10 17 Figure 10 2 Auxiliary Fuel Pump and Primer...

Page 220: ...THRUSH AICRAFT INC MODEL S2R R1340 AIRCRAFT MAINTENANCE MANUAL 10 18 Effective 01 01 08 Figure 10 2 Starting System...

Page 221: ...THRUSH AICRAFT INC MODEL S2R R1340 AIRCRAFT MAINTENANCE MANUAL Effective 01 01 08 10 19 Figure 10 2 Engine Ignition...

Page 222: ...THRUSH AICRAFT INC MODEL S2R R1340 AIRCRAFT MAINTENANCE MANUAL 10 20 Effective 01 01 08 Figure 10 2 Power Distribution...

Page 223: ...UAL Effective 1 1 08 11 1 Section 11 AIRWORTHINESS LIMITATIONS TABLE OF CONTENTS AIRWORTHINESS LIMITATIONS 11 2 MANDATORY INSPECTIONS 11 2 Lower Spar Cap Periodic Inspection 11 2 Lower Splice Block Re...

Page 224: ...7 015 and 20207 016 must be inspected periodically as described below These inspections must first be made when the wings have a total time in service of 6 400 hours The repetitive inspection interval...

Page 225: ...ut touches the splice block A 4X rivet gun may be used for this but place an aluminum block over the bolt end nut to protect it For the largest bolts with the tube nuts place a metal spacer between th...

Page 226: ...he inspection itself must be performed or supervised by a level 2 or level 3 inspector per MIL STD 410E ISO 9712 or SNT TC 1A If Magnetic particle inspection is used ASTM E1444 01 must be followed usi...

Page 227: ...nd thereby assist with bolt installation Extreme care must be taken to avoid damaging the spar cap or the surface finish inside the holes through the spar cap o Position the upper splice block half ov...