Grumman American GA-7 COUGAR User manual
MAINTENANCE
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
CORPORATION
1978
0
Copyright
1978
All
rights
reserved,
including
the
right
to
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
otherwise,
without
prior
written
permission
of
Grumman
American.
'r*\
CHAPTER/
SECTION
Title*
List
of
Effective
Pages*
Record
of
Revisions
Record
of
Temporary
Revisions
Table
of
Contents
Introduction*
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AMERUSAM
/Bm&U'mM
GA-7/C0UGAR
MAINTENANCE
MANUAL
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grumman
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/sm^rmm
GA7/C0UGAR
MAINTENANCE
MANUAL
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^PS\
GRUMMAN
AMBBMS&M
AWOATTOOIfcD
GA-7/C0UGAR
MAINTENANCE
MANUAL
CHAPTER/
CHAPTER/
SECTION
PAGE
DATE
SECTION
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DATE
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GRUMMAN
AtMtdPOISAIfta
AVOATTOIgllRD
GA-7/COUGAR
MAINTENANCE
MANUAL
CHAPTER/ CHAPTER/
SECTION
PAGE
DATE
SECTION
71-2-1
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♦Pages
changed,added, or deleted
by
this revision.
PAGE
1
1
thru
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DATE
July 15/77
July 15/77
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of
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Pages
Page4
July 10/78
^*\
BRUMMAN
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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
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GA-7/COUGAR
MAINTENANCE
MANUAL
RECORD
OF
TEMPORARY
REVISIONS
TEMPORARY
REV.
NO.
PAGE
NUMBER
ISSUE
DATE
BY
DATE
REMOVED
BY
Jf^\
GRUMMAN
/&m:-
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.-.:..
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GA-7/COUGAR
MAINTENANCE
MANUAL
LIST
OF
CHAPTERS
TITLE
AIRCRAFT
GENERAL
Time Limits/Maintenance Checks
Dimensions
and
Areas
Lifting and Shoring
Levelingand
Weighing
Towing and Taxiing
Parking and Mooring
Placards and Markings
Servicing
AIRFRAME
SYSTEMS
Standard
Practices
-
Airframe
Air Conditioning
Auto Flight
Communications
Electrical
Power
Equipment/Furnishings
Flight Controls
Fuel
Ice
and
Rain
Protection
Landing Gear
Lights
Navigation
STRUCTURE
Doors
Fuselage
Stabilizers
Windows
Wings
CHAPTER
NO.
5
6
7
8
9
10
11
12
20
21
22
23
24
25
27
28
30
32
33
34
52
53
55
56
57
Contents
Page I
July 15/77
GRUMMAN
<^[M][SP30(G£i(M
AWOATFOQIRfl
GA-7/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
79
80
91
Contents
Page 2
July 15/77
y^
^
GRUMMAN
AfitfflsmOAIft]
^WO^YOOO^
GA-7/COUGAR
MAINTENANCE
MANUAL
INTRODUCTION
GENERAL
The
function
of
this
Maintenance
Manual
is
to
acquaint
maintenance
personnel
with
the
systems
and
their
components
of
the
GA-7/Cougar
aircraft
and
to
direct
them
in
the
proper
procedures
for
maintaining
the
aircraftin an airworthy condition.
This
manual
contains
information
on
installations
made
in
the
aircraft
during
manufacture
and
optional
equipment
only.
However,
information
derived
from
applicable
Aircraft
Service
Kits,
Service
Bulletins
and
Service
Letters
will
be
included
in
the
manual
as
soon
as
possible
after
the
issuance
of
these
documents.
Changes
or
installations
made
by the
operator
arc
not
included
inthis
manual.
The
ability
of
maintenance
personnel
is
recognized,
and
those
procedures
which
are
considered
common
to
all
aircraft
have
been either briefly referenced or omitted.
FORMAT
The
chapter
identification
in
this
manual
has
been
prepared
in
accordance
with
Air
Transport
Association
(ATA)
Specification
No.
100.
A
functional
breakdown
is
employed
whereby
all
data
pertaining
to
a
given
system,
or
component
ofa
system,
may
be
found
in
one
chapter
with
a
minimum
of
crossreferencing
to
other
chapters.
The
Electrical
Power
Chapter
in
this
manual
covers
only
the
power
sources
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
be
found
in
the
applicable
chapter.
IDENTIFICATION
OF
SUBJECT
MATTER
A
three-dash
number
system
is
employed
to
identify
subject
matter.
The
first
dash
number
identifies
the
chapter,
the
second
dash
number
the
section,
and
the
third
dash
number
the
component
or
sub-section
of
the
section.
The
following
example
illustrates
how
the
numbering
system
is
used
in
the
NAVIGATION
Chapter:
•Identifies NAVIGATION
Chapter.
•
Identifies
that
section
(group
of
related
subjects)
which
provides
coverage
for
the
Flight
Environment
Data
portion
of the NAVIGATION
Chapter.
Identifies
a
specific
subject
(component)
of
the
Flight
Environment
Data.
In
this
manual
it is
assigned
to the
Pitot
3*
1 1
and
Static
Pressure
Systems.
The
dash
0
(-0)
is
provided
as
a
means
for
covering
a
complete
system
or
sub-system.
The
chapter
number
followed
by
a
zero
(34-0)
will
segregate
that
material
covering
the
complete
system;
the
chapter-section
numbers
followed
by
a
zero
(34-14))
is
used
for
further
details
covering
the
sub-system,
or
component.
PAGE
NUMBER
IDENTIFICATION
Page
number
blocks
are
used
to
separate
the
subject
matter
into
the
following
categories:
General
Coverage
and
Unit
Description
Pagcs
j
through
100
Troubleshooting
Pages
,
01
through
2QQ
Maintenance
Practices
(See
Be,ow)
Introduction
Page
1
July 15/77
GRUMMAN
^(M[l(^0(g^(M
AMi^^M
GA7/C0UGAR
MAINTENANCE
MANUAL
Maintenance
Practices
include
as
applicable
the
following
sub-topics:
Servicing,
Removal/Installation,
Adjustment/Test,
Inspection/Check,
Cleaning/Painting,
and
Approved
Repairs.
If
all
sub-topics,
under
Maintenance
Practices
are
brief,
they
are
combined
into
one
topic.
All
such
combined
topics
are
numbered
within
page
number
block
201-300.
Whenever
individual
sub-topics
are
so
lengthy
that
a
combination
requires
several
pages,
each
sub-topic
is
treated
as
an
individual
topic.
Page
number
blocks
used
forthis
sub-topic
arrangement
areas
follows:
Servicing
301
- 400
Removal/Installation
401
- 500
Adjustment/Test
501
- 600
Inspection/Check
601
- 700
Cleaning/Painting
701
- 800
Approved
Repairs
801
- 900
Each
new
subject
starts
with
page
1,
101,
201,
etc.,
and
continues
through
the
page
block
assignment
to
the
extent
necessary.
The
first
page
of
each
block
is
placed
on
a
right-hand
page.
FIGURE
IDENTIFICATION
Figures
(illustrations)
are
numbered
consecutively
within
each
topic
(subject)
as
follows:
Figures
in
Description
- 1,2,3,4,
5,
etc.
Figures
in
Troubleshooting
-
101,102,103,
etc.
"^%
Figures
in
Maintenace
Practices
-
When
not sub-divided -201,202,203, etc.
When
sub-divided
-
Servicing
-
301,
302,303, etc.
Removal/Installation
-401,402,403, etc.
Adjustment/Test
-
501,
502,503,
etc.
Inspection/Check
-
601,602,
603,
etc.
Cleaning/Painting
-701,702,
703,
etc.
Approved
Repairs
-
801,
802,803,
etc.
INDEXING
Each
chapter
is
prefaced
with
a
table
of
contents
identifying
the
subject
matter
within
the
chapter
in
the
order
of
presentation.
The
table
of
contents
is
arranged
with
the
following
headings:
DESCRIPTION,
TROUBLE
SHOOTING,and MAINTENANCE PRACTICES.
PART
NUMBERS
This
manual
must
not
be
used
for
identifying
spare
parts
by
number.
Consult
the
Illustrated
Parts
Catalog
for
this
information.
Part
numbers
are
used
in
this
manual
only
as
a
means
of
identification
when
nomenclature
aloneis inadequate. ^m*.
Introduction
Page 2
July 15/77
/^\
10^
REVISIONS
GRUMMAN
^IMHi^DIg^Q^
M^fi^mm
GA-7/C0UGAR
MAINTENANCE
MANUAL
Revisions
to the
original
text
are
indicated
by
vertical
lines
in the left
margin
of the
page,
adjacent
to the
revised
material.
The
manual
is
provided
with
a
"Log
of
Revisions"
page
for
recording
revisions
by
number
and
the
dates
on
which they wereinsertedin the manual.
Each
page
revised
or
added
tothe
initial
manual
will
be
identified
bythe
date
of
revision
atthe
bottom
of the
page.
Pages
issued
with
the
original
manual
are
identified
with
the
issue
date
ofthe
manual.
Each
revision
also
contains
a"List of
Effective
Pages".
This
list
contains
the
chapter,
page
number
and
date
of
each
page
which
is
effective
since
the
issuance
of
the
initial
manual.
This
list
is
up-dated
for
each
revision,
with
page
changes
indicated
by
asterisks
(*)
placed
adjacent
tothe
page
number
as
shown
below:
*Pages
changed,
added
ordeletedby this
revision.
Introduction
Page
3
July 10/78
IJ$P\
GRUMMAN
AGWDEtm^lry)
^VD^ii'lH-
>*i!
GA-7/COUGAR
MAINTENANCE
MANUAL
CHAPTER
5
TIME
LIMITS
-
MAINTENANCE
CHECKS
TABLE
OF
CONTENTS
NUMBER
5-0 TIME
LIMITS/MAINTENANCE
CHECKS
Description/Operation
General
5-1-1
TIME
LIMITS
Description/Operation
General
Inspection Details
5-2-1
SCHEDULED
MAINTENANCE
CHECKS
Description/Operation
General
Maintenance
Practices
Annual or 100-HourInspection Procedures
5-5-1
UNSCHEDULED
MAINTENANCE
CHECKS
Description/Operation
General
Maintenance
Practices
Inspections Followinga
Hard
or Overweight Landing
Bondline
Damage,
Inspection Procedures, and Repair
PAGE
201
201
201
201
201
5
Page
I
July 15/77
••jl^^x,
GRUMMAN
^IWDIil^li©^D
^MO^TOOIRfl
"~""T^^"
GA-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
checks, and inspections.
5-0
Pagel
July 15/77
ijMl^N
c
GRUMMAN
ARfllll^iK§Al&fl AVOAYOOlftD
GA-7/C0UGAR
MAINTENANCE
MANUAL
TIME LIMITS - DESCRIPTION/OPERATION
General
The Service Guide (Figure 1) contains the manufacturer's recommended time limits for inspection, mainte
nance, and overhaul of the GA-7/Cougaraircraft, its systems and units.
All
wing
and
fuselage
structural
components
are subject to normal inspection, maintenance, repair, and
replacement
procedures.
In addition, if
corrosion
isdetected on
wing
and
inboard
spars,
remove
it as
quickly
as
possible
and protect the
surface
from further
corrosion
in
accordance
with
AC
43.13-1A
and subsequent
revisions, "AcceptableMethods,Techniquesand Practices—Aircraft Inspection Repair."
Service Life Limited Components
Current FederalAviation Regulations require that all newaircraft be certified, for whichapplication for a type
certificate was made after September 14, 1969, have the critical wingstructural components investigated for
fatigue
strength and that,
where
applicable,
these
components be
service
life
limited.
Twocritical
areas
of the
GA-7/Cougar wingwere investigated per these requirements, the front spar lower capat
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-goingfatigue testing extends these life-limits,revisionsto this manual will be supplied.
Component
Part
Number
Service
Life
(Airframe Hours)
Lower Cap of Front
Spar at
W.S.
76.50
7W10214-11
7W10214-12
87,157
Lower Cap
of
Front
SparatW.S.
22.415
7W10214-11
7W10214-12
5,705
Service Life Limited Components
Figure 1
Inspection Details
A. Pre-Inspection Procedures
(1) Just prior to beginning the inspection, run up the engines to facilitate oil drainage.
(2) Observethe followingactions and indicators, noting any discrepancies.
Oil and fuel pressures
Magneto rpm
drop
Propeller cycling
Static rpm (dual tachometers)
Idling speed (dual tachometers)
Ammeter
Manifold pressure
Oil temperature
Gyro
pressure gage
Fuel selector (Check operation in all positions.)
Carburetor
heat
control
Engine response to power changes
Idle
cutoff
Post Inspection Procedure
CAUTION:
REPLENISH
OIL
SUPPLY
PRIOR
TO
POST
INSPECTION
RUNUP.
After completion of the inspection, another
engine
runup
should
be performed to
ensure
that all
discrepancies
have
been
eliminated
andno new
discrepancies
have
beenintroduced.
5-1-1
Page 1
Dec 10/77
-"I
p»«^N
GRUMMAN
^[MHI^OS^O^ ^WOATO®^
GA-7/COUGAR
MAINTENANCE
MANUAL
SCHEDULED MAINTENANCE CHECKS- DESCRIPTION/OPERATION
General
The
inspection
procedures
guideline
included
in
this
section
may
be
used
by
the
owner,
inspector,
or
mechanic
to
ensure
complete
and
comprehensive
coverage
of
the
inspection
requirements.
The
format
of
the
procedures
can
be
reproduced
for
ready
use
by the
personnel
performing
the
inspection.
The
checklist
includes
the
minimum
requirements
for
the
100-hour
or
Annual
Inspection.
5-2-1
Page
I
July 15/77
GRUMMAN
^DMKK^Otg^lRfl
^MO^YGlsKN)
GA-7/COUGAR
MAINTENANCE
MANUAL
INSPECTION
MAINTENANCE
Inspection Interval
(Operating Hours)
50
100
1000
NOTE:
AIRFRAME
1.
Clean
aircraft.
2. Aircraftstructure (especially inboardwing
spars
and
fuselage
attachments,
landing
gear
attachments, and empennage attachments).
3.
Windows
and
windshield.
4. Seats, console, interior, and.seat belts.
5. Instrument
panel
instruments and
placards.
6.
Baggage
compartment and
cargo
tiedowns.
7.
Radio
antennas.
8. Control T-Column and bearings.
9.
Cabin
doorand
baggage
door (fwd andaft)
seals
and
latches.
10. Emergency exit window.
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
LANDING
GEAR
1
Main
gear
strut lubrication, strut extension,
and
fluid
level.
2. Nose
gear
strut lubrication, strut
extension
and fluid level.
3. Nose and main wheel bearinglubrication.
4.
Perform
gear
retraction check and
check doors for proper operation.
5. Brakeliningsand discs.
6. Main and nose tires pressure.
7.
Nose
gear
shimmy
dampener
condition,
leakage,
and
fluid
level.
X
X
X
X
X
X
X
X
X
X
X
X
X
a
CONTROL
SYSTEMS
1.
Cables,
turnbuckles, pulleys, guards,
and
terminals.
2. Rudder pedalsand springs.
}.
Flaps,
flap
actuatorjackscrew,
flap
push-pullrods, flap hinges, torque
tube bearings, bearingsupports, and
position indicator.
4. All control stops.
5. Trim wheel assembly.indicator, bungees,
and
actuator
shaft
drive
screw.
6. All control surface hinges.
X
X
X
X
X
X
X
X
X
X
X
X
i
h
Service
Guide
Figure
1 (Sheet 1 of 4)
5-2-1
Page
2
July 15/77
/pN
j^k\ I
/^P^
GRUMMAN
AR«!E[^flOAIRD AVO^TFOOIftfl
GA-7/COUGAR
MAINTENANCE
MANUAL
INSPECTION
MAINTENANCE
Inspection Interval
(Operating Hours)
50
100
1000
NOTE:
POWER
PLANT
1. Oil change.
2.
Oil
screens
and
cooler.
3. Replace oil filter
if
external filter is
installed.
4. Spark plugs.
5. Ignition harness.
6. Magneto timing.
7. Exhaust
system.
8.
Throttle,
carburetor
heat,
mixture,
and
propeller controls operation.
9. Enginebaffles and seals.
10.
Air
filter.
11.
Engine
shock mounts (both engines).
12.
Oil
breather
vents.
13. All lines, flex
ducts,
and
connections.
14. Oil and fuel pressure lines, fittings and wiring.
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
crankshaft
seal.
20. Engineoverhaul.
21. Engineupper and lower mount attachments
and mounting hardware.(Refer to Chapter71.)
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
b
j
c
d
FUEL
SYSTEM
1. Electric fuel pump filters.
2. Fuel cap gaskets.
3.
Fuel
overboard
vents.
4. Fuel tanks and quick drains (4).
5. Fuel gauges,fuel tank selectors, and
placards.
6.
Fuel
tank
outlet
screens.
7.
All
hoses
and
lines.
8. Fuel primers.
9.
Transmitters
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
g
c
Service
Guide
Figure
1(Sheet 2
of
4)
5-2-1
Page
3
July 10/78
GRUMMAN
AIMDIgl^OSAIftg
zSMOATO©^
GA-7/COUGAR
MAINTENANCE
MANUAL
INSPECTION
MAINTENANCE
Inspection Interval
(Operating Hours)
50
100
1000
NOTE:
UTILITY
SYSTEMS
1. Mastercylinder fluid level. XXX
2.
Parking
brake operation. X X
3. All hoses, lines, and
connections.
XX
4. Pitot and static systems. X X
5.
Pitot
and
static
line
drain.
XX
6. Gyro pressuresystem, pressure X X e
pump regulator,and filters.
7. Flexible ducts for heating system. XX
8. Cabin heat control operation. X X
9. Fresh air ventilation
system.
XX
10. Compasscheck. Xf
11. Hydraulicsystem, lines, pump. XX X k
and
fluid
level.
ELECTRICAL
SYSTEM
1. Battery fluid level. XX X
2. Battery hydrometer check. XX
3.
All
connections.
XX
4. All lights for operation. XXX
5. All wiring harnesses and wires. X X
6. Stall warning. XX X
7. Electric flap motor. X X
RADIO
AND
ELECTRONIC
EQUIPMENT
1. Communication Equipment Xh
2. Navigation Equipment Xh
3.
Antennas
X1
4.
Wiring,
bonding, and shielding Xm
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 wheel miles between repacking
intervals.
Maximum
time between magneto timing checks is 100 hours.
Magneto
replacement recommended after 900
hours
of
service.
Recommendreplacement
of
all flexiblelinesat
engine
overhaul
orevery 5 years,whicheveroccurs
first.
Engine overhaul time recommended by engine manufacturer is 2000 hours
Replace
gyro
pressure
air system inline filter every 500 hours or annually,whicheveroccurs first,and when a
pressure
pump is replaced. For operationin dusty climates,
replace
filters more frequently. Replace
pressure
pump inlet filter when clogged or dirty as required.
Check accuracy
of
compass every 1000 hours or at each time that an item
of
equipment is installed or
removed
that
could
affect
the
accuracy
of
the unit.
Remove
and clean fuel
tank
outlet
screens every 1000 hours.
Check for improper installation and insecuremounting.
Service
Guide
Figure 1 (Sheet 3
of
4)
5-2-1
Page4
July
10/78
>*«K
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