Tiger Aircraft AG-5B Series User manual

T/QEK AIKCKAff AG-5B SERIES
N.UUNTENANCE~AL
Table S-03
INSPECTION PROCEDURE GUIDELINE
TIQEK ~IKtKAfT MODEL AG-SB
ANNUAL
OR 100- HOUR INSPECTION PROCEDURE
ANNUAL OR 100- HOUR INSPECTION PROCEDURE GUIDELINE
FAR 43.15 (c) (1) states: "Each person performing an annual or 100-hour inspection shall use
a check list while performing the inspection. The check list may be of the person's own design,
one provided by the manufacturer of the equipment being inspected, or one obtained from an-
other source. This check list must include the scope and detail of the items contained in appen-
dix D to this part and paragraph (b) of this section." The following pages contain a comprehen-
sive annual or 100 -hour inspection procedure check list.
OWNER'S NAME
STREET ADDRESS
CITY
STATE
ZIP CODE
REGISTRATION NO. SERIAL NO. AIRFRAME HOURS
DATE INSPECTION COMPLETED
SERVICING AGENCY
CITY
REPAIR STATION No. (if applicable)
Check for conformity with FAASpecifications, Airworthiness
Directives
and Tiger Aircraft Service Bulletins and Letters.
NOTE
It is recommended that reference be made to the applicable
maintenance handbook, service bulletins, letters, installation
instructions,
and vendor specifications for torque values,
clearances, settings, tolerances
and other specification data.
STATE
Chapter 5
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T/QER AIKCKAff AG-5B SERIES
MAINTENANCE MANUAL
Table 5-03 (continued)
MODELAG-5B
ANNUAL OR 100- HOUR INSPECTION PROCEDURE
PRE -INSPECTION ENGINE
RUN UP
Prior to beginning the Annual or 100 hour inspection, an engine run up is to be made
to facilitate oil drainage and to observe the following, noting any discrepancies.
1. Fuel Pressure: (0.5 to 8 PSQ
Electric Pump onlyprior to engine start up: __ _
Engine Pump only after engine start up: __ _ Both:
2. Oil Pressure: (60 to 120 PSI @ 1800RPM) (Approx. 25 PSI idling)
Oil Temperature in Green Arc.
Actual@ 1800 RPM: ____ _ Actual@ Idle: ____ _
3. Magneto RPM Drop @1800 RPM: (175 RPM maximum drop
on either Magneto,
no more than 50 RPM difference between magnetos.)
Actual Drop Left:
____ _ Right:
-----
4. Check engine static RPM: (Propeller PitchA, B or C)
A. (61" 2100-2275)
__ . B. (63" 2050-2225) __ . C. (65" 2000-2175) __ .
Prop Pitch: ___ _ Actual RPM:
-----
5. Idling Speed: (550 to 650 RPM) Actual
RPM:-----
6. Check Alternator output:
Check volts, 24 -28V. Actual Voltage:
_____ _
7. Vacuum Gauge: (4.6 to 5.4 In.
Hg@ 1800 RPM)
Actual:
_____ _
8. Fuel Selector: (check operation
at all positions).
MECH. INSP.
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T/QEK AIKCKAFT AG-5B SERIES
MAINTENANCE MANUAL
Table 5-03 (continued)
MODELAG-5B
ANNUAL
OR 100-HOUR INSPECTION PROCEDURE
PRE -INSPECTION ENGINE
RUN UP (continued)
9.
Carburetor Heat Control: (Free movement and slight RPM drop when 'ON')
10. Engine response to smooth change in power: (Should not misfrre, stumble or hesitate)
11. Idle cut-off: (Engine should stop immediately)
A. PROPELLER GROUP
1. Remove spinner and check for cracks, scratches, scoring, dents, nicks and distortion.
2. Inspect spinner back plate, bulkheads and doubler for cracks and secure mounting.
Reference Propeller Installation "Caution" Chapter 61
3. Inspect blades for erosion, scratches, nicks and cracks.
Dress out nicks
as instructed by propeller maintenance manual.
4. Check front crankshaft seal for oil leaks.
5. Check torque of propeller mounting bolts: (60-65 ft. lbs. I 720-780 in. lbs.)
Re-safety propeller mounting bolts.
6. Reinstall spinner. Check spinner run out ___ inch. Maximum 0.025 inch at tip.
B. ENGINE GROUP
1.
Remove engine cowl. Clean and check for cracks, wear, distortion, loose or.
missing fasteners.
MECH.
MECH.
MECH.
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T/QER AIRCRAfT AG-5B SERIES
MAINTENANCE MANUAL
Table 5-03 (continued)
MODELAG-5B
ANNUAL OR
100- HOURINSPECTION PROCEDURE
B. ENGINE GROUP (continued)
2. Drain oil sump. Remove oil filter and replace with a new filter.
Check and clean suction screen. Reinstall and resafety.
Cut old filter apart and inspect for metal particles.
Check oil pressure transducer for security and signs
of leakage.
3. Check oil temperature sending unit, oil lines, cooler, and fittings for leaks, chafmg,
dents, cracks, and secure mounting.
4. Service engine with oil per manufacturers specifications.
5. Clean engine, using mineral spirits or equivalent.
6. Check engine cylinder compression.
Record cylinder compression: #1.
__ #2. __ #3. __
7. Clean and re-gap or replace sparkplugs as required (See latest revision of
Lycoming Service Instruction No. 1042).
8. Check ignition harnesses.
Clean and inspect insulators.
#4.
9. Check magneto timing and for any oil seal leakage, check distributor block for cracks,
burned areas and/or corrosion.
NOTE: Reference engine data plate for timing.
10. Remove and inspect air filter and replace the air filter if found damaged or defective.
Reinstall carburetor air filter.
NOTE: Do notremove oil coatingfrom airfilter.
MECH. INSP.
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T/QER AIRCRAFT AG-SB SERIES
MAINTENANCE MANUAL
Table 5-03 (continued)
MODELAG-5B
ANNUAL OR
100- HOUR INSPECTION PROCEDURE
B. ENGINE GROUP (continued)
11. Inspect carburetor heat control valve plate, shaft, valve plate to shaft screws and
bearings for signs
of wear and assure proper security. Inspect gasket between
carburetor heat box and carburetor, replace
if defective.
12. Check induction air intake flex ducts for broken
or loose strings, loose or displaced
supporting wire, signs
of wear and/or perforation and general overall condition.
Replace
if required.
13. Drain carburetor bowl. Reinstall drain plug and safety wire. Remove and clean
carburetor fuel inlet screen with acetone. Reinstall screen.
14. Remove and clean electric fuel pump filter. Reinstall and safety.
Check fuel pressure transducer for secure mounting and signs
of leakage.
15. Check fuel pump for proper operation and secure mounting. Pressurize fuel system
with electric pump and inspect fuel system and lines for leaks.
Check fuel primer for operation and line leaks.
16. Check starter for secure mounting.
17. Check security
of throttle arm on carburetor. Check throttle, carburetor heat and
carburetor mixture controls for proper travel, security, operating condition and control
cushion. Check optional manifold pressure transducer for secure mounting and signs
ofleakage
(if installed).
18. Remove exhaust shroud and check muffler tailpipe, risers, clamps, gaskets and
exhaust system for cracks, leaks and secure mounting. Check EGT probes for
damage. Reinstall shroud.
19. Check breather tube for obstructions and secure mountiiig. Breather should
extend below cowl 1.25 inches. Confrrm slit in the aluminum tube is inside
cowl and facing forward.
20. Inspect cylinders for evidence
of excessive heat indicated by discoloration of
cylinder paint. Check for cracks, loose bolts oil leaks and general condition. Check
CHT probes for security and damaged wiring.
MECH.
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T/QEK AIKCKAfT AG-5B SERIES
N.UUNTENANCE~AL
Table 5-03 (continued)
MODELAG-5B
ANNUAL OR
100- HOUR INSPECTION PROCEDURE
B. ENGINE GROUP (continued)
21. Inspect engine mount for cracks and secure mounting. Checkrubber vibration
dampeners for signs
of deterioration. Replace if required.
22. Check all baffles for cracks, loose
or missing screws and deteriorated seal material.
23. Check alternator for secure mounting and lugs and brackets for cracks. Check
condition and tension of alternator drive belt. Replace if required. Adjust the
Alternator Belt as follows:
Apply a torque wrench
to the nut that attaches the pulley to the alternator and apply
force in a clockwise direction, note the torque when the pulley slips. Adjust belt to
the following tension:
Belt Size Condition
Torgue Slippage
3/8" New 11-13
ft. lbs.
3/8" Old 7-9 ft.lbs.
Yl" New 13-15 ft. lbs.
Yz"
Old 9-10 ft. lbs.
24. Check battery electrolyte level and specific gravity. Clean and tighten battery
terminals. Check battery drain for condition and assure drainage is clear
of the
aircraft structure.
Note:
GlOOO equipped aircraft have two batteries (check both). The Back-Up
Battery must be replaced every 24 months. See Chapter 24A
25. Inspect vacuum system components for secure mounting. Check vacuumpump
drive for evidence
of seal leakage. Replace seal and pump if required. Check all
interconnecting lines and fittings for leaks, deterioration and damage.
Replace
if required.
26. Check ground straps for condition and secure attachment.
27. Check electrical wiring for condition and secure connections including shielded
cable ground connection.
28. Check Alternator Control Unit, Starter Relay and Master SwitchRelay for condition,
operation and installation.
MECH.
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T/QER 11/RCRflfT AG-5B SERIES
MAINTENANCE MANUAL
Table 5-03 (continued)
MODELAG-5B
ANNUAL OR I 00- HOUR INSPECTION PROCEDURE
B. ENGINE GROUP (continued)
29. Check fuses for condition and installation.
30. Install cowl, checking for proper engagement of air intake duct and cowl latches.
C. CABIN GROUP
1. Remove front seats, aft. console, rear seat back cushions and fold rear seatbottom
forward, remove cover from rear seat support and remove console side panels.
To
gain access for following inspections and checks.
2. Check windshield, windows and canopy for cracks and secure mounting. Clean
and lubricate canopy rails. Check canopy operation and locking devices.
3. Check seat belts and shoulder harnesses for condition
and secure mounting.
4. Check elevator trim control for condition, secure mounting, proper operation
and indication.
5. Check rudder pedal and brake system for proper operation
and condition.
Check brake fluid level. Replace rudder pedal springs at 1000 hours.
6. Check control "T" column for secure mounting and adequate clearance from
other equipment.
7. Check pitot static system lines and the alternate air source valve. Drain
any
accumulated moisture from system drain. ("T" Fitting under the L/H side of rear
seat).
NOTE: Opening the alternate air source valve will drain static lines behind the
panel.
MECH.
MECH.
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TIOEK 11/:TCK/IFT AG-5B SERIES
MAINT!::\A1\CE MANUAL
TabL.· 5-03 (continued)
- - -
7\'IODEL AG-5B
ANNUAL OR lOll- IlOUR INSPECTION PROCEDURE
C. CABIN GROUP (continued) MECH.
8. Check chains, cables, pulleys,
turnbtt~.:klcs and cable ends for condition, secure
attachment and safeties. Specificall:. check cables at pulleys for fraying while
actuating controls through full travc l.
9. Check all cable tensions.
10. Check all controls for clearance and i)ropcr operation.
11. Check all interior bond lines for any indication
of damage, peeling and/or
cracking.
12. Check nose gear torque
tubes, mom:~ing brackets and bondjoints for cracks
and secure mounting. Check torque
') rmounting bolts -center bearing bracket
bolts 185-195 in. lb. and end plate b•lts
~00-350 in. lb.
13. Check flap actuator, push rods, limit ;witches and indicator for proper operation
and secure mounting.
14. Lubricate
per lubrication chart. (Ch<:ptcr
12).
-
15. Check all plumbing in cabin for leak,; and condition.
16. Actuate fuel selector through its
full :angl', check for smooth operation and
position detents.
-
17. Check gyro system filters, replace irnecessary.
18. Check instruments for condition.
se( trc mounting and legible markings.
19. Inspect Transorb Fuse.
If fuse is bl( vn. replace ihse and Transorb.
See Chapter 24A. {GlOOO equipped ,tirnan only)
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T/QEK AIKCKAfT AG-5B SERIES
N.UUNTENANCE~AL
Table 5-03 (continued)
MODELAG-5B
ANNUAL OR
100- HOUR INSPECTION PROCEDURE
C. CABIN GROUP (continued) MECH.
20. Check electrical wiring, switches, lights and electronic equipment for condition
and security. Test the Emergency Buss Dual Diode. (Reference Chapter 24A,
01000 equipped aircraft only.)
21. Inspectbaggage compartment, baggage door and cargo tie downs.
22. Inspect all placards in cabin for condition and legibility.
23. Inspect the emergency locator transmitter (ELT) for security, operation and
battery expiration date.
24. Reinstall items removed in item 1
of this section.
25. Check fresh air vents for proper operation.
D. FUSELAGE AND EMPENNAGE GROUP MECH.
1. Remove tailcone (stinger) and empennage inspection covers.
2. Inspect exterior surfaces for condition and damage. Assure all drain holes in
bottom
of fuselage are unobstructed.
3. Inspect bond lines for any indication
of damage, peeling separation and/or cracks.
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T/QEK AIKCKAff AG-5B SERIES
~NANCE MANUAL
Table 5-03 {continued)
MODELAG-5B
ANNUAL OR 100-HOUR INSPECTION PROCEDURE
D. FUSELAGE AND EMPENNAGE GROUP (continued)
4.
Check, horizontal and vertical stabilizers for damage and secure mounting. Inspect
mounting structure carefully for
any buckling or cracks (see Chapter 55 for details).
Assure
the horizontal stabilizer and elevator drain holes are unobstructed.
5.
Check elevator, elevator bearings and stops, rudder, rudder bearings and stops, tab
hinges and bellcranks for damage, travel and proper operation. Maximum
allowable torque tube wear limit at rudder bearing supports
is 0.030 in. reduction in
wall thickness. Wear beyond 0.030 in. requires replacement of the control surface.
Wear
from 0.005 in. up to and including 0.030 in. require the installation of Tiger
Aircraft Service Kit
121.
6.
Check elevator trimmechanism for damage, secure mounting (safety wire and
cotter pins) and proper operation.
7.
Check rudder and elevator cables and pulleys for damage, proper operation and
safeties. Check bellcrank attaching bolts for wear.
8.
Lubricate per lubrication chart. (Chapter 12)
9.
Inspect antenna mountings, wiring and connectors.
10. Check position and anti-collision light(s) for secure mounting.
11. Check static system lines in the tailcone for security and chafmg.
12. Reinstall inspection covers.
MECH.
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T/QEK AIKCKAff AG-5B SERIES
MAThnENANCEMANUAL
Table 5-03 (continued)
MODELAG-5B
ANNUAL OR 100-HOUR INSPECTION PROCEDURE
E. WING GROUP MECH.
1.
Remove wing tips and access panels, except fuel cell area. Inspect all surfaces,
skins ribs and tips for damage. Check position/strobe and landing lights for secure
mounting. Insure that all drain holes are open.
CAUTION: DO NOT USE A MAGNETIC SCREWDRIVER TO REMOVE THE
OUTBOARD, FORWARD INSPECTION PANEL ON THE RIGHT WING
OF GlOOO EQUIPPED AIRCRAFT. (MAGNETOMETER LOCATION)
2.
Visually inspect interior and exterior bond lines for any indication of damage,
peeling, separation and/or cracks.
3. Check ailerons, aileron bearings and stops, flaps, and flap bearings for secure
mounting, damage, proper travel and wear. Assure that aileron and flap drain holes
are clear. Maximum allowable aileron torque tube wear limit at bearing supports is
0.030 in. reduction in wall thickness. Wear beyond 0.030 in. requires replacement
of the torque tube or control surface. Wear from 0.005 in. up to and including 0.030
in. requires the installation of Tiger Aircraft Service Kit 121.
4.
Check fuel vents and connecting lines for damage and/or restrictions.
5. Check fuel tanks, sump tanks and lines for evidence of leakage.
Check
sump tanks and lines for secure mounting.
6. Check fuel cap sealing condition.
7.
Check wing and outboard wing section attaching bolts. Torque to 60-85 in. lb.
8.
Inspect fuel tank placards.
9.
Check pitot tube opening and lines for obstruction and condition and heat element
for proper operation.
10. Check for interior corrosion of skin indicated by a white flaking material.
Chapter 5
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T/QEK A/KCKAff AG-5B SERIES
MAINTENANCE MANUAL
Table 5-03 (continued)
MODELAG-5B
ANNUAL OR 100-HOUR INSPECTION PROCEDURE
F. MAIN LANDING GEAR GROUP
MECH.
1.
Remove wheels and check for cracks. Check condition of brake linings, wheel
cylinders, torque plates
and mounting pins. Pack wheel bearings, reinstall wheels
and key axle nuts at frrst 100 hours and each 500 hours thereafter. Inspect wheel
bearing grease for contamination and solidification at each annual or 100 hour
inspection. For operation in dusty areas or areas
of high humidity, repack every
100 hours. Perform a complete wheel inspection at each tire replacement.
2.
Check tires for approved type, acceptable condition and proper inflation.
3. Check brake lines for leaks and secure attachment.
4. Check struts for secure mounting. Inspect for cracks, delamination and/or nicks.
5. Inspect the upper main mounting brackets and spar attaching supports (center spar
to fuselage) for wear, cracks and/or loose bolts.
6. Inspect wheel and strut fairings for damage and secure mounting.
G. NOSE GEAR GROUP
MECH.
1.
2.
3.
Check nose gear strut for secure mounting, deformation, damage and/or cracks.
Remove nose gear strut from torque yoke and inspect for corrosion of the surfaces
every
12 calendar months. Remove corrosion if present and apply McLube 1708
dryfilm lubricant or equivalent to the mating end of the strut and the inside of the
yoke. Allow lubricant to dryand reassemble. Seal strut to yoke connection with
PIS 870 by PRC DeSoto, or equivalent.
Remove and check nose gear fork for deformation, wear and/or cracks. Maximum
fork to strut bearing clearance is 0.035 in.
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T/QfR AIRCRAfT AG-5B SERIES
N.UUNTENANCE~AL
Table S-03 (continued)
MODELAG-5B
ANNUAL OR 100 -HOUR INSPECTION PROCEDURE
G. NOSE GEAR GROUP (continued) MECH.
4.
Grease fork and friction dampener, assemble to strut and tighten to 10-22 lb. drag
to axle. (Reference Chapter 32)
5. Remove nose wheel, clean, check for cracks, inspect and repackbearings,
reinstall wheel and safety axle at frrst 100 hours and each 500 hours thereafter.
Inspect wheel bearing grease for contamination and solidification at each annual
or 100 hour inspection. For operation in dusty areas or areas of high humidity,
repack every 100 hours. Perform a complete wheel inspection at tire replacement.
6. Inspect nose wheel for cracks, corrosion and/or loose or broken bolts.
7.
Check tire for approved type, acceptable condition and proper inflation.
8. Check wheel fairing for damage and secure mounting.
H. OPERATIONAL INSPECTION MECH.
1.
2.
3.
4.
5.
Check brake and parking brake operation.
Check fuel primer operation and lines for leaks.
Check electric pump operation.
Check fuel pressure.
Check starter for proper operation.
Chapter 5
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H.
T/QEK AIKCKAfT AG-5B SERIES
MAINTENANCE MANUAL
Table 5-03 (continued)
MODELAG-5B
ANNUAL OR 100 -HOUR INSPECTION PROCEDURE
OPERATIONAL INSPECTION (continued)
6.
Check oil pressure and temperature.
7.
Check engine and throttle controls for proper operation.
8.
Check magneto operation @ 1800 RPM:
Check with both magnetos ON, then
MECH.
with left mag. OFF, then again with both mag's. ON, then with the right mag. OFF,
and once more with both mag's. ON.
(Maximum magneto drop 175 RP/11 on either magneto with 50
RPM maximum difference between magnetos). With engine
at idle, turn switch to OFFposition momentarily to check
magneto grounding. (Reference
AD 76-07-12).
Actual drop:
Left Right
9. Check engine static RPM: (Propeller Pitch A, B or C)
A(61" 2100-2275) .!! (63" 2050-2225)
~ (65" 2000-2175).
Pitch:
RPM:
10. Check carburetor heat for proper operation.
11. Check alternator output.
Record volts:
12. Check vacuum gauge and vacuum system output 4.6 to 5.4 in. Hg@ 1800 RPM.
13. Check fuel selector valve operation and indexing.
14. Check heating, defrosting and ventilating system for proper operation.
15. Check avionics for proper operation. Check the Emergency Battery Switch on
G
1000 equipped aircraft. (Reference Chapter 24A)
Chapter 5
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TJQEK AIKCKAff AG-5B SERIES
MAThiTENANCEMANUAL
Table 5-03 (continued)
MODELAG-5B
ANNUAL OR
100- HOUR INSPECTION PROCEDURE
H. OPERATIONAL INSPECTION (continued)
16. Check engine mixture setting and idle speed:
(550-650 RPM) Actual:
17. Check idle cut
off of carburetor for proper operation.
18. Check ailerons for proper operation.
19. Check elevators and trim tabs for proper operation.
20. Check flaps for proper operation and travel.
21. Check fuel quantity gauges for condition and proper operation.
22. Pitot static systemcheck.
23. Record the certification date
of the following:
Transponder: Altimeter: Encoder:
Air Data LRU: (G1000 equipped aircraft)
24. Complete ELT function test (reference
FAR's for time restrictions) and record
ELT battery replacement date entered inlog book.
25. Check interior lights for proper operation.
MECH.
26. Check navigation and anti-collision lights for proper operation and landing lights
for proper operation and adjustment.
27. Check stall warning device for properoperation.
28. Inspect engine for leaks after ground run-up. Flight test and inspect for oil leaks
and secure mounting
of all components.
Chapter 5
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I.
1.
2.
3.
4.
5.
6.
T/QfK AIKCKAff AG-5B SERIES
N.UUNTENANCE~AL
Table 5-03 (continued)
MODELAG-5B
ANNUAL
OR 100- HOURINSPECTION PROCEDURE
GENERAL
Aircraft cleaned and serviced.
Aircraft conforms to
TC Data Sheet
All FAA Airworthiness Directives complied with.
All Service Letters and Bulletins complied with.
Checked for proper and complete Pilots Operating Handbook (with AFM).
Aircraftpapers in proper order. Make log book entry.
Minimum required documents:
a. Registration
b.Airworthiness Certification
c. POH with AFM (including weight and balance records and equipment list.)
d. Log Books for Aircraft, Engine and Propeller
MECH.
Chapter 5
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