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Game Composites GB1 GameBird, Maintenance Manual

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Maintenance Manual GB1 GameBird

Page date: April 24, 2020

51-1

Structure Repair Manual

Inspection for Delamination (Tap Test) ........................................................................................ 51-2

General ......................................................................................................................................... 51-2

Classifying Damage to Composite Parts ....................................................................................... 51-3

Composite Materials ..................................................................................................................... 51-4

Composite Repair Practices .......................................................................................................... 51-6

Repairs to All Composite Structures, General .............................................................................. 51-7

Minor surface damage .................................................................................................................. 51-8

Sandwich Damage....................................................................................................................... 51-10

Stripped threads in composite structures .................................................................................. 51-11

Repairs to Spars .......................................................................................................................... 51-12

Adhesives, Sealants, Coatings ..................................................................................................... 51-12

Tank Sealant PPG P/S 890 Class B ................................................................................................... 51-12

General Adhesive SikaBond ............................................................................................................ 51-12

Clickbond Adhesive ......................................................................................................................... 51-12

Other Sealants ................................................................................................................................ 51-13

Painting ....................................................................................................................................... 51-13

Paint Materials ............................................................................................................................ 51-14

Steel Materials ............................................................................................................................ 51-14

Aluminum Materials ................................................................................................................... 51-14

Titanium Materials ...................................................................................................................... 51-14

Additive Manufacturing Materials .............................................................................................. 51-14

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Summary of Contents for GB1 GameBird

Page 1: ...d Parts Catalog for the GB1 GameBird required to be available by 14 CFR and CS 23 Document No AMM GB1 0000 00 02 Issued to airplane S N ________ Issued by Type Certificate Holder Game Composites LLC 3...

Page 2: ...mended 31 9 additional Accelerometer type 40 12 GMU location 40 17 additional service step Fire Sleeve 51 13 Material Details added April 24 2020 ObtainingRevisions Latest Revisions of Airplane Flight...

Page 3: ...11 1 Tools Servicing Cleaning 12 1 Standard Practices and Shipping 20 1 Air Conditioning 21 1 Autopilot 22 1 Communication 23 1 Electric Power including Switches Breakers 24 1 Equipment and Furnishin...

Page 4: ...s com Magneto booster Installation Instructions for SlickSTART magneto booster SL2 96 http championaerospace com Alternator Technical Manual for Model No BC410 H Spline Drive Alternator BC410 H_Instal...

Page 5: ...ould result in damage or destruction of equipment NOTE An operating procedure inspection repair or maintenance condition etc which is deemed essential to highlight Units andConversions Property Conver...

Page 6: ...al acceleration GDU Garmin Display Unit GPS Global Positioning System hp Horsepower HSI Horizontal Situation Indicator IAS Indicated Airspeed ICAO International Civil Aviation Organization ISA Interna...

Page 7: ...aintenance Manual GB1 GameBird Page date April 24 2020 1 1 Description 01 01 Certification Category 1 2 01 02 Manufacturer 1 2 01 03 Overview Drawing 1 3 01 04 Description 1 4 01 05 Equipment List 1 5...

Page 8: ...ory in accordance with FAR 23 Amendment 64 and CS 23 Amendment 1 FAA TCDS A00073CE and EASA TCDS A 610 Certification is for day VFR non icing conditions Maintenance repairs and changes must be done in...

Page 9: ...Maintenance Manual GB1 GameBird Page date April 24 2020 1 3 OverviewDrawing...

Page 10: ...lizer The rear fuselage incorporates a chamber for removable ballast The seats are integrated fuselage structure composite components Seat cushions are part of the occupant protection system and may n...

Page 11: ...hts O Navigation Compass S S N A Transponder O1 O1 N A Cockpit equipment Airspeed Indicator S S O Altimeter S S O Accelerometer S S N A Annunciator Lights Panel S S N A Garmin G3X multi functional dis...

Page 12: ...Maintenance Manual GB1 GameBird Page date April 24 2020 4 1 Airworthiness Limitations 4 01 General 4 2 4 02 Operating Time 4 2 4 03 Life Limited Parts 4 2 4 04 Structure Temperature Limitation 4 2...

Page 13: ...listed in section 4 03 below are subject to operating time limitations Recommended replacement times for other components are provided in section 5 03 LifeLimitedParts Replacement of the life limited...

Page 14: ...3 Access 5 4 Component Inspections 5 5 25 Hour Inspection Checklist 5 7 50 Hour Inspection Checklist 5 8 100 Hour Inspection Checklist 5 13 1000 Hour Inspection Checklist 5 14 Inspection Log 5 15 In...

Page 15: ...the airworthiness authority are completed as required TimeLimits All scheduled maintenance checks must be done within the time limits specified in this manual All components not listed in the table b...

Page 16: ...ane must be conducted by persons authorized and approved by the Airworthiness Authority of the country of registry All maintenance must be conducted in compliance with this manual The scheduled mainte...

Page 17: ...n correct position located in recess 3 Side panels right and left front and back seat 3 x AN525 832R9 each Engine controls left front rear Electrical parts rear left right Wing main pins front left ri...

Page 18: ...eck for corrosion obvious damage corrosion or damage causes unusual noises or irregular damage or detachment from seat 5 Welded steel components visual surface quality intact surfaces visible surface...

Page 19: ...tion functional more than 2 LEDs per section dysfunctional 18 Fuel Vent and manifold pressure sensor lines visual surface material clear intact surface elastic when compressed with 2 fingers discolori...

Page 20: ...Hour Inspection Checklist NOTE The 25 hour inspection is not required when the engine is equipped with a spin on oil filter Item Reference Initial Ground run in accordance with AFM section 4 4 4 6 4...

Page 21: ...lation 73 Visually check installation condition of engine mount shock mounts 71 03 Visually check Alternator installation and connection to Shunt 24 04 Visually check Magneto P lead connection refer t...

Page 22: ...pers in contact with rails ensure functionality 5 06 27 16 Check function of pedal adjusters over entire range check for play of rollers on rail 27 18 27 29 Check installation and spring force of loca...

Page 23: ...fixing 24 01 Visually check cable routing for chafing visually check connectors 24 09 All circuit breakers and switches OFF Master Switch ON 39 01 Anti collision lights ACL switch circuit breaker ON...

Page 24: ...installation condition and leaks 11 03 Visually check routing and fixing of smoke oil hoses joints and fittings for condition and leaks 85 02 Fuselage and cockpit inside Visually check for damages to...

Page 25: ...28 02 Main landing gear left and right Visually check gear leg retaining bolts for installation and safety wiring 32 04 Visually check installation and condition of fairings 32 02 Visually check slip...

Page 26: ...ange The test should be completed as soon as practical after shut down A differential compression tester is attached to the cylinder via the spark plug hole after the piston is positioned at top dead...

Page 27: ...eel assembly 32 05 Remove and check elevators and trim tab 55 02 55 03 Remove and replace fasteners for rear instrument panel attachment 39 01 Remove and check rudder 55 05 Remove and check ailerons a...

Page 28: ...ectionLog Flight Hours Date Name of Approved Maintenance Organization Name of Certifying Inspector Initials 25 50 75 100 125 150 175 200 225 250 275 300 325 350 375 400 425 450 475 500 525 550 575 600...

Page 29: ...n impact area for invisible damage per 51 01 Classify damage according to 51 03 and advise operator of results Visually inspect propeller blades refer to mt propeller operation and installation manual...

Page 30: ...ually check wiring 51 01 Visually check control cables for damage check for function LightningStrike Item Initial Visually inspect strike area for structural damage tap test surrounding area for damag...

Page 31: ...Maintenance Manual GB1 GameBird Page date April 24 2020 6 1 Dimensions andRiggingInformation For Rigging Information see section 27 For Overview Drawing see section 1 03...

Page 32: ...Maintenance Manual GB1 GameBird Page date April 24 2020 7 1 Liftingand Supporting 7 01 Lifting 7 2 7 02 Supporting 7 2...

Page 33: ...orking underneath The support should be not less than 100 mm x 500 mm 4 inches x 20 inches and should be both smooth edged and padded to protect the airplane from damage The support should be placed u...

Page 34: ...Maintenance Manual GB1 GameBird Page date April 24 2020 8 1 LevellingandWeighing Establish Empty Weight Centre of Gravity 8 2 Moment Arms 8 2...

Page 35: ...t of the windshield frame as reference Place a spirit level in the position as shown in red and adjust tail support to level attitude 8 Fill in below table and follow formula to obtain empty weight an...

Page 36: ...P 1 2 2 6 0 32 12 6 O 1 Gascolator ACS 10585HP 0 1 0 2 0 32 12 6 R 1 Aux Fuel Pump Andair PX375 TC 0 4 0 9 0 23 9 R 1 Engine Data I O unit Garmin GEA 24 0 46 1 0 55 21 6 R 1 Air Data Sensor Unit Garmi...

Page 37: ...ndTowing With its low weight and the free swiveling tail wheel two people can easily move the GB1 by hand The best area to push is the leading edge of the wings while the best place to pull is the pro...

Page 38: ...Maintenance Manual GB1 GameBird Page date April 24 2020 10 1 Parking Mooring Storage Returnto Service Short Term Parking 10 2 Long term storage 10 2...

Page 39: ...nose into wind and chock main wheels For longer outdoor parking or in poor weather use at least engine and canopy covers to reduce the potential for water ingress animal nesting or surface damage dete...

Page 40: ...Maintenance Manual GB1 GameBird Page date April 24 2020 11 1 Placards General 11 2 Exterior Color Schemes and Markings 11 2 Exterior Placards 11 2 Interior Placards 11 5...

Page 41: ...part number and aircraft serial number Exterior ColorSchemesandMarkings No limitations for choice of colors The vertical stabilizer must not be painted with any colors containing metal VHF antenna mou...

Page 42: ...e Manual GB1 GameBird Page date April 24 2020 11 3 1 GB1 1120 00 05 Oil Filler 2 GB1 1120 00 06 Smoke Oil Filler 3 GB1 1120 00 07 Wing Tank Drain 4 GB1 1120 00 08 Wing Tank Vent 5 GB1 1120 00 10 Acrot...

Page 43: ...Page date April 24 2020 11 4 6 GB1 1120 00 11 Wing Tank Filler 7 GB1 1120 00 16 Tire Pressure 8 GB1 1120 00 17 Oil Breather 9 GB1 1120 00 18 Ballast Weight 13 5kg 10 GB1 1120 00 20 Gascolator Drain 1...

Page 44: ...Lock 2 12 GB1 1130 00 06 Placard Baggage Compartment 1 13 GB1 1130 00 08 Placard Headset Sockets 1 14 GB1 1130 00 14 Placard VO 2 15 GB1 1130 00 16 Placard Wing Tank Empty 1 16 GB1 1130 00 20 Placard...

Page 45: ...1 1130 00 05 Canopy Lock 22 GB1 1130 00 06 Baggage Compartment 13 GB1 1130 00 08 Head Set Socket 14 GB1 1130 00 14 Vo 15 GB1 1130 00 16 Fuel Management 16 GB1 1130 00 20 Baggage Door 17 GB1 1130 00 23...

Page 46: ...ain Checks 12 3 Refueling 12 3 Defueling 12 3 Engine Oil Level Check and Top up 12 3 Engine Oil Change Service 12 4 Tires and Tire Pressures 12 4 Brake Fluid Top up and Bleeding 12 4 Cleaning Exterior...

Page 47: ...sed plier 1 Side cutter 1 Mallet 1 Hammer 1 Bearing Press 1 Scalpel razor blade 1 Compression tester 1 Magneto timer 1 Multimeter 1 Tire inflator 1 Allen Key set 1 Allen Key w T handle 8 long 5 32 1 C...

Page 48: ...ard of the windshield Use ignition key grip to open and close fuel caps WARNING Always connect ground cable to either of the exhaust pipes while refueling Do not allow fire sparks heat or smoking with...

Page 49: ...ding When pedals start to feel soft or require pumping to obtain brake action check the fill state of the master brake cylinder reservoirs on the rear rudder pedal assemblies Each reservoir has a clea...

Page 50: ...ed clean the interior prior to the first flight of the day to remove dust and foreign objects CleaningtheMFD screens Clean screen with a clean lint free cloth such as the Garmin cleaning cloth Avoid a...

Page 51: ...actices andShipping General 20 2 Threaded Fasteners Torque Values 20 2 Spherical Bearings 20 3 Adhesive Nutplates 20 3 Adhesives and Sealants 20 4 Flexible Hoses and Hose Fittings 20 5 Disassembly for...

Page 52: ...he specific torque and locking method must be observed The bolts used for the airplane are AN Bolts Army Navy The bolts can be identified by the marking on the bolt head and by the surface treatment S...

Page 53: ...e bearing let the heat sink in for 30 seconds 3 use a plier to pull out the bearing holding on the bolt CAUTION Bearings that have been removed using this method have to be replaced CAUTION Make sure...

Page 54: ...he redeposition of contaminants on the substrate Application Methods Tools Follow the application and mixing instructions printed on the packaging General Adhesive Sika Flex or SikaBond SikaFlex or Si...

Page 55: ...Shipping 1 Drain all fuel refer to section 12 06 2 Remove both front foot well access panels refer to section 5 05 3 Disconnect battery refer to section 24 05 4 Remove all four cockpit side panels ref...

Page 56: ...ird Page date April 24 2020 20 6 Cratingforshipping Wing support box drawing Outer wing support Print this page and use outline as a template Material should be foam of density no less than 20kg m3 Wi...

Page 57: ...ge pins back to elevators and rudder 7 Wrap elevators with bubble wrap then attach and secure them to one of the wings with cling film 8 Wrap rudder with bubble wrap then attach and secure them to one...

Page 58: ...Maintenance Manual GB1 GameBird Page date April 24 2020 20 8...

Page 59: ...Fuel hoses use 9 16 wrench to prevent fitting from turning 11 16 wrench to tighten hose connection c Fuel sensor electrical connector d Wingtip light electrical connector 7 Push right wing in complet...

Page 60: ...ir inlet 2 manually adjustable eyeball air vents are located right and left of each instrument panel No regular maintenance is required for the unit When damaged the unit must be replaced Type AVEO Ba...

Page 61: ...Maintenance Manual GB1 GameBird Page date April 24 2020 23 1 Communication General 23 2 VHF Radio 23 2 VHF Antenna 23 4 MIC PHONE Jacks 23 5 VHF Check 23 5...

Page 62: ...ed through the Battery Master essential bus and 10A VHF circuit breaker on the circuit breaker panel located in the RH side console in the rear cockpit Location Centre console of the rear cockpit moun...

Page 63: ...d 4 After update verify the software updates loaded successfully System Display Software Update 1 Turn the outer knob to SYS CONFIGURATION 2 Turn the inner knob to DISPLAY UPDATE 3 Press ENT 4 Press E...

Page 64: ...the retention mechanism it may be necessary to insert the hex drive tool into the access hole and turn the drive tool counterclockwise until it completely stops VHF Antenna Location Bonded inside the...

Page 65: ...MIC PHONE jacks for the rear seat open baggage door 1 Visually check condition of cables and connectors 2 Visually check if connectors touch each other To replace either jack 1 Hold jack by hand use...

Page 66: ...elay 24 23 External Power Socket 24 24 Electrical System Inspection Guide 24 25 Wires wiring harness 24 25 Connectors terminals and splices 24 27 Terminal blocks and studs 24 28 Grounding 24 28 Fuses...

Page 67: ...ting the Master relay providing power from the Battery to Starter Relay and Starter via the Keyed ignition switch with positions for OFF R L BOTH and START In position START the starter is activated a...

Page 68: ...cting power to VHF via the VHF CB Transponder via the XPDR CB MFD2 via the MFD2 CB ADHRS via AHRS CB Landing Lights via Landing Lights CB Switch located on LH side console in the rear cockpit Magnetom...

Page 69: ...tank senor Anti collision lights 7 5A Toggle Switch Circuit Breaker ACL Boost fuel pump 7 5A Toggle Switch Circuit Breaker Boost Pump Trim switch servos and indicators 2A Button Circuit Breaker Trim S...

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Page 85: ...laced To service the alternator 1 Remove connector plug 2 Remove 4 nuts assembly is mounted on 4 studs standing out of engine accessory case 3 Slide alternator off backwards remove from airplane 4 Sli...

Page 86: ...4 With Philips 2 screwdriver remove fasteners and remove battery tiedown 5 Remove battery from airplane 6 Service or replace battery as required For detailed instructions refer to the Odyssey Battery...

Page 87: ...Linear Regulator If required get service conducted by approved maintenance facility as required To service the Voltage Regulator 1 Remove the left hand foot rest panel refer to 5 05 2 Disconnect lead...

Page 88: ...aster check if electric system gets activated For troubleshooting information see section 24 11 below Starter Relay Location Compartment under the left front leg support tank support wall in front of...

Page 89: ...u No regular maintenance is required for the unit When defective unit must be replaced For external power supply the external power socket is accessible from the outside of the airplane To access the...

Page 90: ...Wiring must be replaced with equivalent wire when found to have any of the following defects Wiring that has been subjected to chafing or fraying that has been severely damaged or that primary insulat...

Page 91: ...Maintenance Manual GB1 GameBird Page date April 24 2020 24 26...

Page 92: ...stabilizer and LH elevator Anti Collision Lights connectors located between LH wing and fuselage Aileron trim servo connector located behind RH aft side panel Push To Talk momentary switches connector...

Page 93: ...of damage 3 Inspect battery terminals and quick disconnect charging plug for evidence of corrosion pitting arcing and burns 4 Clean clamps and terminals as required ElectricalSystemTroubleshootingGui...

Page 94: ...put post or B lead and ground It should be battery voltage If not check the wiring between the alternator B lead and the battery positive terminal Look for loose or contaminated connections broken wir...

Page 95: ...not work check connections of the wires on the light 2 If the connection wiring or CB switch are not the cause the light needs to be replaced Smoke System 1 Switch on BAT master switch and circuit br...

Page 96: ...ide pocket rear seat right hand GB1 2520 14 00 25 2 25 06 Side pocket front seat left hand GB1 2520 11 00 25 2 25 07 Side pocket front seat right hand GB1 2520 12 00 25 2 25 08 Side panel rear seat le...

Page 97: ...be removed for cleaning For repair instructions contact Game Composites Sidepocketrear seat left hand GB1 2520 13 00 Installed with Sikaflex the airplane can be safely operated with or without Sidepoc...

Page 98: ...orn cut or fuzzy Minor fraying is permissible B Severe fading or discoloration This is a sign of ultraviolet UV damage If the exposed area of the webbing is more than 2 shades different than unexposed...

Page 99: ...g over retaining tube 6 Install fasteners to keep retaining tube in place Signature 7 Check for correct assembly Lap belt rear seat 1 Through the service panel in the baggage bay floor remove retainer...

Page 100: ...ap 6 mm 2 mm When gap is out of tolerance replace part 5 To reinstall reverse steps 1 to 3 Signature 6 Check for correct assembly FireExtinguisher Installed in the LH footwell of the rear cockpit held...

Page 101: ...or Bellcrank GB1 2733 50 00 27 16 Rudder control system GB1 2723 00 00 27 17 Rudder pedal assembly front seat GB1 2722 00 00 27 18 Rudder pedal adjusters front seat GB1 2723 21 00 27 20 Rudder bellcra...

Page 102: ...ileron is mounted to four hinge points by one hinge pin Aileron movement is limited through two elastomeric stops mounted on the fuselage structure in the front cockpit so as to limit torque tube rota...

Page 103: ...d Torque Tube to Bellcrank 4 GB1 2717 11 00 Torque Tube 5 GB1 2717 30 00 Aileron Bellcrank 6 GB1 2717 40 00 Aileron Control Rod Bellcrank to Aileron 7 GB1 2733 20 00 Elevator Control Rod Torque Tube t...

Page 104: ...ect the PTT connection 3 Remove from the pivot the cotter pin nut washer and bolt 4 Disconnect the elevator rod 5 Remove control stick 6 Clean all components 7 Inspect standard fasteners in accordance...

Page 105: ...pivot the cotter pin nut washer and bolt 4 Disconnect the front elevator rod 5 Disconnect the rear elevator rod 6 Remove control stick 7 Clean all components 8 Inspect standard fasteners in accordance...

Page 106: ...s from the center rudder mount 4 Remove the center rudder mount 5 Disconnect the aileron rods from the torque tube 6 Inside the torque tube remove the nut retaining the torque tube on its front bearin...

Page 107: ...ox 5 Slide torque tube backwards 6 Undo cotter pin in front end of torque tube remove castle nut 7 Remove front torque tube bearing 8 Clean all components 9 Inspect standard fasteners in accordance wi...

Page 108: ...To service the aft torque tube bearing the following items have to be removed 4 Radio and transponder 5 Front seat In the rear cockpit 6 Use 3 8 socket to undo and remove fasteners 7 Remove bearing ho...

Page 109: ...de of the relevant wing 3 Remove the bellcrank access panel 4 Disconnect the rod from the bellcrank 5 Pull the rod out of the wing 6 Clean all components 7 Inspect standard fasteners in accordance wit...

Page 110: ...bellcrank access panel 3 screws each panel 2 Disconnect the rod from the bellcrank and aileron arms 3 Pull the rod out of the wing 4 Inspect standard fasteners in accordance with 5 06 No 1 5 Inspect c...

Page 111: ...both pivot bolts and maneuver the bellcrank out of the wing 4 Clean all components 5 Inspect standard fasteners in accordance with 5 06 No 1 6 Inspect control rods in accordance with 5 06 No 5 7 Insp...

Page 112: ...front control stick 3 Pull elevator rod out towards the rear 4 Clean all components 5 Inspect standard fasteners in accordance with 5 06 No 1 6 Inspect control rods in accordance with 5 06 No 5 7 Insp...

Page 113: ...Disconnect the elevator rod from the stick and the idler then lift it out 3 Clean all components 4 Inspect standard fasteners in accordance with 5 06 No 1 5 Inspect control rods in accordance with 5 0...

Page 114: ...ed below 4 Disconnect the elevator rod from the bellcrank and pull it from the fuselage 5 Clean all components 6 Inspect standard fasteners in accordance with 5 06 No 1 7 Inspect carbon fiber control...

Page 115: ...ove Elevator Idler 6 Inspect standard fasteners in accordance with 5 06 No 1 7 Inspect control rods in accordance with 5 06 No 5 8 Inspect spherical bearings in accordance with 5 06 No 3 9 To reinstal...

Page 116: ...omponents 9 Inspect standard fasteners in accordance with 5 06 No 1 10 Inspect center section and outboard parts in accordance with 5 06 No 5 11 Inspect needle bearings in accordance with 5 06 No 4 12...

Page 117: ...djuster aft 7 GB1 2723 31 00 Rudder Bellcrank forward 8 GB1 2723 41 00 Rudder Interconnecting Rod front LH 9 GB1 2723 42 00 Rudder Interconnecting Rod front RH 10 GB1 2723 43 00 Rudder Interconnecting...

Page 118: ...t GB1 2722 00 00 Front seat LH pedal assembly Allowable play of slider on rails No more than 4 mm vertical movement of pedal assembly measured with a ruler between cockpit floor and lowest point of ru...

Page 119: ...06 No 9 9 Inspect welded assemblies in accordance with 5 06 No 5 10 Master brake cylinders have to be replaced in case of malfunction 11 To reinstall reverse steps 1 4 12 Bleed brakes in accordance wi...

Page 120: ...g Replace if less 11 To reinstall reverse steps 1 5 Signature 12 Check for correct installation 13 Reinstall front instrument panel Signature 14 Check for correct installation Rudderbellcrank forward...

Page 121: ...ded assemblies in accordance with 5 06 No 5 9 Inspect spherical bearings in accordance with 5 06 No 3 10 To reinstall reverse steps 1 4 11 Install cotter pins Signature 12 Check for correct installati...

Page 122: ...ove front seat 2 Remove pivot fasteners of center rudder bellcrank 3 Remove locating fasteners 4 Remove bellcrank 5 Clean all components 6 Inspect standard fasteners in accordance with 5 06 No 1 7 Ins...

Page 123: ...rods 3 Remove pivot fastener 4 Remove bellcrank from airplane 5 Clean assembly 6 Remove bellcrank 7 Clean all components 8 Inspect standard fasteners in accordance with 5 06 No 1 9 Inspect welded ass...

Page 124: ...ove bellcrank 5 Clean all components 6 Inspect standard fasteners in accordance with 5 06 No 1 7 Inspect welded assemblies in accordance with 5 06 No 5 8 Inspect spherical bearings in accordance with...

Page 125: ...onnect interconnecting rods to front pedals 3 Remove pivot fastener 4 Slide either side disconnect rudder cables and rear pedal adjusters 5 Remove from airplane 6 Remove bellcrank 7 Clean all componen...

Page 126: ...move locating fasteners 4 slide forward remove from airplane 5 Remove bellcrank 6 Clean all components 7 Inspect standard fasteners in accordance with 5 06 No 1 8 Inspect welded assemblies in accordan...

Page 127: ...ain 10 x 032 THK CPS 9 MS20392 2C17 Pin Clevis 3 16 OD x 17 32 10 MS20392 2C51 Pin Clevis 3 16 OD x 1 19 32 11 NAS1351 3 10P Screw Cap Skt Hd 10 32UNFx0 625CPS 12 MS21044 N3 Nut Nyloc 10 32 UNF CPS 13...

Page 128: ...mblies in accordance with 5 06 No 5 8 Inspect spherical bearings in accordance with 5 06 No 3 9 Inspect rollers in accordance with 5 06 No 9 10 Master brake cylinders have to be replaced in case of ma...

Page 129: ...om airplane 5 Remove spring loaded locating pin 6 Slide components apart 7 Clean all components 8 Inspect standard fasteners in accordance with 5 06 No 1 9 Inspect welded assemblies in accordance with...

Page 130: ...ce with 5 06 No 1 9 Inspect spherical bearings in accordance with 5 06 No 14 10 to install new ones connect the new cable to the old cable and pull the new one in place 11 Connect both ends install co...

Page 131: ...6 Install rear seat panel and cushion RudderCable LH GB1 2723 80 92 To service the LH rudder cable 1 Similar to RH rudder cable see above Signature 2 Check for correct installation 3 Install tail fair...

Page 132: ...ank 1 Remove Rudder 2 Remove fasteners 3 Remove bellcrank from Rudder 4 Clean all components 5 Inspect standard fasteners in accordance with 5 06 No 1 6 Inspect spherical bearings in accordance with 5...

Page 133: ...2020 27 33 UninstallFront SeatFlightControls The front seat flight controls can be uninstalled to conduct flights with passengers or reduce weight for competition flying The dual control configuratio...

Page 134: ...11 Install baggage bay access panel Uninstall Front Rudder Pedals 1 Remove front seat cushion and seat panel 6 screws 2 Remove front instrument panel 3 Remove both bump stop assemblies 4 Reinstall fa...

Page 135: ...ge bay access panel Reinstall Front Rudder Pedals 1 Remove front seat cushion and seat panel 6 screws 2 Remove front instrument panel 3 Remove fasteners for bump stop assemblies 4 Disconnect brake lin...

Page 136: ...sal Joint 28 12 Boost Pump 28 13 Gascolator 28 14 Acrotank Fuel Level Sensor 28 14 Wingtank Fuel Level Sensor 28 15 Warning Observe the following instructions to reduce hazards during all work on the...

Page 137: ...e when the wing is removed from the fuselage The wing tank vent outlets are located on the bottom of the fuselage near the leading edge wing roots The Acrotank vent is located aft of the right hand la...

Page 138: ...Maintenance Manual GB1 GameBird Page date April 24 2020 28 3 System Schematic ACS High Pressure Gascolator 10585HP...

Page 139: ...Maintenance Manual GB1 GameBird Page date April 24 2020 28 4...

Page 140: ...0 01 00 Stratoflex 3175 6 3175003 6CR 0235 418624 6 6CR 418626 6 6CR 600 8 GB1 2830 16 00 5052 O Aluminum tubing Aircraft Spruce 03 39250 N A N A 570 9 GB1 2830 13 00 PVC hose 6 mm ID 8 mm 5 16 OD N A...

Page 141: ...Maintenance Manual GB1 GameBird Page date April 24 2020 28 6 Acrotank GB1 2810 00 00 Overview...

Page 142: ...ication of leaks If leaks are detected contact Game Composites 14 Check for signs of mechanical damage 15 Check thread of filler neck and fuel cap for damage 16 In the fuselage compartment check for s...

Page 143: ...k 6 Remove sealer residue from both sealing surfaces 7 Reach inside the tank to unscrew the flop tube from its fitting 8 Check bob weight and strainer for cleanliness overall condition and correct ins...

Page 144: ...euver out of the tank 4 Remove sealer residue from both sealing surfaces 5 Check pickup line bulkhead fitting and strainer for correct installation cleanliness and overall condition 6 Check for contam...

Page 145: ...aced To service the selector valve 1 Drain all fuel refer to section 12 06 2 Remove the firewall belly panel 3 Disconnect all fuel hoses at the selector valve 4 Remove the fasteners holding the valve...

Page 146: ...o not require regular maintenance If defective the units must be replaced To service the selector switch 1 Remove the four fasteners on the faceplate pull the selector switch out 2 Service selector sw...

Page 147: ...neuver outside clean and inspect for overall condition 4 Pull universal joint off backwards clean and inspect for overall condition 5 Pull front torque rod backwards maneuver outside clean and inspect...

Page 148: ...isconnect the fuel lines on pump catch spilt fuel into a container of appropriate size 4 Unplug electrical connections 5 Remove fuel pump from its mounting brackets using a 2 5 mm Allen Key 6 If malfu...

Page 149: ...eader tank 5 VDC electrical power is provided from the Engine Data Converter GEA 24 supplied through the Battery Master essential bus and 2A EDC circuit breaker on the circuit breaker panel located in...

Page 150: ...cal power is provided from the Engine Data Converter GEA 24 supplied through the Battery Master essential bus and 2A EDC circuit breaker on the circuit breaker panel located in the RH side console in...

Page 151: ...truments pitot staticsystem General 31 2 Pitot Static System Overview 31 2 Pitot and Static Plumbing 31 3 Pitot Tube Assembly GB1 3690 31 00 31 3 Pitot Static Test 31 3 Troubleshooting 31 5 Airspeed I...

Page 152: ...s pitot tube connected via PVC hoses and connectors to the dynamic pressure ports of both airspeed indicators and the GSU 25 ADHRS unit To drain water a T connector is installed at the lowest point of...

Page 153: ...eversing steps 3 1 Pitot StaticTest The following procedure describes testing of the pitot static system and connected instruments and devices Perform this test any time an instrument pitot tube fitti...

Page 154: ...o Ground b Turn Off the tester c Then disconnect hoses or adapters 16 Only after the Static system is leak tight leak less than 100 feet min proceed to the next step 17 With Pitot and Static systems r...

Page 155: ...pair or replace instrument Obstruction in pitot line Check lines for leaks and or moisture Pointer oscillates Moisture in static line Blow out lines Leak in pitot and or static line Repair or replace...

Page 156: ...nducted by approved maintenance facility as required 6 To reinstall reconnect static and dynamic pressure tubes tubes and instrument ports are marked s static and p pitot 7 Maneuver instrument into po...

Page 157: ...ressure tube 5 Get service conducted by approved maintenance facility as required 6 To reinstall reconnect static pressure tube 7 Maneuver instrument into position 8 Reinstall 4 screws 9 If required r...

Page 158: ...an accelerometer ensure to turn the lock on the backside in unlocked position 6 To reinstall maneuver instrument into position 7 Reinstall 4 screws 8 If required reinstall headrest refer to section 39...

Page 159: ...refer to section 39 03 2 Remove screws on the instrument face 3 Maneuver accelerometer out of instrument panel 4 Disconnect power supply plug 5 If malfunction is detected unit has to be replaced 6 To...

Page 160: ...orrector Key provided into the left hand hole at the front of the compass rotate the key in either direction so that the East point is directly under the Index line 2 Align the aircraft facing West an...

Page 161: ...3 Main Gear Leg left hand GB1 3211 60 01 32 4 32 04 Main Gear Leg right hand GB1 3211 60 02 32 4 32 05 Tailwheel General 32 5 32 06 Tailwheel spring GB1 3220 21 01 32 5 32 07 Tailwheel 32 6 32 08 Brak...

Page 162: ...es are fitted to each wheel The landing gear features non structural composite fairings LandingGearFairings Each main gear leg wheel assembly is covered by a set of non structural composite fairings I...

Page 163: ...wdriver to install fasteners around brake cover Removing either or both Leg Fairings 1 Remove cowling per 71 02 2 Use razor to cut trailing edge sealant open 3 Use 7 16 wrench to remove bottom fastene...

Page 164: ...3 Remove the landing gear fairings wheels and axles as described above 4 To avoid disconnecting the hydraulic brake line slide brake caliper assembly off the torque plate 5 For the right leg detach th...

Page 165: ...bed in 7 02 2 Use 5 8 wrench to remove Tailwheel assembly retaining bolt 3 Remove tail fairing 4 Disconnect linkage chains 5 Remove lock wire 6 Use 9 16 wrench to remove the 3 retaining bolts 7 Remove...

Page 166: ...sistance is felt 9 Loosen the axle nut only enough so that the wheel runs free or with very little drag 10 Install cotter pin 11 Reinstall wheel cap Signature 12 Check for correct installation 13 Lowe...

Page 167: ...sive warpage Straighten or replace press plate if warped in excess of 0 010 3 Rivet new linings onto back plate and press plate using rivet tool 824 or equivalent Refer to Grove parts manual for prope...

Page 168: ...es at a high RPM 4 If brakes hold aircraft stationary break in is complete 5 If brakes don t hold the aircraft stationary repeat steps 1 through 3 Metallic Brake Linings 1 Complete two consecutive ful...

Page 169: ...heel Inspection and Repair 1 Visually inspect cylinder for cracks nick corrosion or other damage Cracks around the torque pins will cause replacement 2 Inspect the caliper torque pins for excessive we...

Page 170: ...AN4H 16A Bolt 3 13 AN960 416L Washer 5 Axle Type 5013 Manufacturer Grove Aircraft 1800 Joe Crosson Drive El Cajon CA 92020 USA www groveaircraft com To service an axle 1 Remove the landing gear fairin...

Page 171: ...6 Remove the retaining snap rings washers felt grease seals and wheel bearings using care to prevent damage to the wheel or bearings Inspection and Repair 1 Inspect the bearing races for scoring corro...

Page 172: ...ting if too much force is applied 4 Press the bearing race into the wheel until it is fully seated 5 Remove the wheel from the press and visually check to see that the race is fully seated and that it...

Page 173: ...nut and hand tighten ensuring that that inboard wheel bearing is fully seated on the axle 4 While slowly rotating the wheel tighten the axle nut until resistance to turning is felt Care must be taken...

Page 174: ...Maintenance Manual GB1 GameBird Page date April 24 2020 33 1 Lights 33 10 Anti Collision Lights 33 2 33 20 Recognition Lights 33 3...

Page 175: ...lectric buffing machine with a lamb s wool cover may be used for deeper cleaning and polishing Do not use petroleum based product to clean the lights The airplane is certified for day VFR only Subject...

Page 176: ...nnection details refer to section 24 03 No regular maintenance is required for the units If malfunction is detected the defective unit has to be replaced The lenses are polycarbonate only use water an...

Page 177: ...Maintenance Manual GB1 GameBird Page date April 24 2020 34 1 Navigation Dependent Position Determining 34 2 Transponder 34 2 Transponder Antenna 34 5 GPS Antenna 34 5...

Page 178: ...for both the UAT and the 1090 MHz frequency bands The GTX 345 receives ADS B transmissions from other ADS B Out equipped aircraft ADS R and TIS B information from ground stations Traffic information...

Page 179: ...le in country of registration must be conducted In the US refer to Appendix F to Part 43 ATC Transponder Tests and Inspection XPDR Programming A new or overhauled unit requires programming to communic...

Page 180: ...AHRS CALIBRATION OFFSETS UNCALIBRATED PITCH 0 Page 7 ADS B ACFT CATEGORY SMALL ACFT MAX A S 300 KT AIRCRAFT LENGTH 15 mt AIRCRAFT WIDTH 23 mt 1090ES OUT CONTROL PILOT SET UAT OUT RMT CONTROL N A 1090E...

Page 181: ...in country of registration must be conducted In the US refer to Appendix F to Part 43 ATC Transponder Tests and Inspection GPSAntenna Location Inside headrest on top of rear instrument panel Type GAR...

Page 182: ...Manual GB1 GameBird Page date April 24 2020 39 1 Instrument Panels Instrument Panels General 39 2 Rear Instrument Panel GB1 3910 10 00 39 3 Headrest GB1 3910 12 00 39 3 Front Instrument Panel GB1 3920...

Page 183: ...sition indication electronic flight instruments VHF and XPDR interface Garmin GDU 465 2 Airspeed Indicator United 8030B 168 3 Entry Speed limitations placard GB1 1130 00 23 4 Trim switch and indicator...

Page 184: ...l in place remove instrument panel from airplane 5 Conduct service as required For damages to composite structures refer to chapter 51 6 Reinstall reversing steps 1 5 Replace mounting fasteners as req...

Page 185: ...set sockets To service the front instrument panel 1 Remove front instrument panel fasteners 2 Pull instrument panel approximately 10 cm 4 in backwards providing sufficient room to reach the connectors...

Page 186: ...40 5 Engine and Fuel Indication Markings 40 6 System Power Up 40 6 System Annunciations 40 6 Use of System 40 6 MFD 1 40 7 MFD 2 40 8 Magnetometer 40 9 ADAHRS 40 10 Engine Data Converter 40 11 OAT Pro...

Page 187: ...ection 40 06 or the Garmin G3X Touch Installation Manual 190 01115 01 March 2018 Revision AE If a problem cannot be resolved following those procedures replace defective unit or contact Game Composite...

Page 188: ...Maintenance Manual GB1 GameBird Page date April 24 2020 40 3 System Schematic...

Page 189: ...ied to the SD Card NOTE The databases are stored internally on each GDU When updating a system with multiple GDUs each GDU will need to be updated individually using the same SD card Obtain the System...

Page 190: ...ing flight This condition may cause the wire to pull on or vibrate the connector making intermittent connections 4 Ensure that the affected device is mounted securely Use a screwdriver to check the ti...

Page 191: ...low 30 C above 72 C Fuel Pressure 12 to 65 psi 0 to 12 psi 65 psi Volts 12 4 to 15 5 below 12 4 above 15 5 Amperes 3 to 40 Below 3 Carbon Monoxide below 50 ppm above 50 ppm SystemPower Up MFD1 and EDC...

Page 192: ...off plug 4 Remove unit from airplane 5 Service or replace as required 6 To reinstall reverse steps 1 4 Signature 7 Switch ON Battery Avionic Master to check function 8 Switch Avionics and Battery Mast...

Page 193: ...pull connector off plug 4 Remove unit from airplane 5 Service or replace as required 6 To reinstall reverse steps 1 4 Signature 7 Switch ON Battery and Avionic Master to check function 8 Switch Avioni...

Page 194: ...cation RH wing 500mm outboard of aileron bellcrank access panel Type GMU 11 PN 010 01788 00 Manufacturer Garmin International Inc 1200 East 151st Street Olathe Kansas 66062 USA Tel 913 397 8200 Fax 1...

Page 195: ...East 151st Street Olathe Kansas 66062 USA Tel 913 397 8200 Fax 1 913 397 8282 Aircraft on Ground AOG Hotline 1 913 397 0836 www garmin com To service the ADAHRS 1 Remove front instrument panel refer...

Page 196: ...397 8282 Aircraft on Ground AOG Hotline 1 913 397 0836 www garmin com To service the EDC 1 Remove front instrument panel refer to section 39 04 2 Disconnect electrical connection unscrew connector fas...

Page 197: ...t Olathe Kansas 66062 USA Tel 913 397 8200 Fax 1 913 397 8282 Aircraft on Ground AOG Hotline 1 913 397 0836 www garmin com To service the OAT Probe 1 Remove cowling refer to section 71 02 2 Disconnect...

Page 198: ...ments com To service the RPM Sensor 1 Remove cowling refer to section 71 02 2 Disconnect electrical connection 3 Unscrew nut 4 Push sensor backwards 5 Remove unit from airplane 6 Service or replace as...

Page 199: ...91320 USA www kavlico com To service the Fuel Pressure Sensor 1 Remove cowling refer to section 71 02 2 Remove tie wraps slide off fire sleeve 3 Disconnect electrical connection 4 Unscrew sensor remo...

Page 200: ...uel Pressure Sensor 1 Set Fuel Selector Switch to OFF 2 Remove cowling refer to section 71 02 3 Remove open Adel clamps supporting adjacent fuel lines 4 Disconnect electrical connection 5 Remove tie w...

Page 201: ...refer to 5 05 2 Disconnect battery 3 Remove cowling refer to section 71 02 4 Disconnect electrical connections 5 Unscrew fasteners 6 Remove unit from airplane 7 Service or replace as required 8 To rei...

Page 202: ...lcorinc com To service any CHT Sensor 1 Remove cowling refer to section 71 02 2 Disconnect electrical connection 3 Push and turn counter clockwise 4 Pull sensor out 5 Service or replace as required 6...

Page 203: ...ps alcorinc com To service any EGT Sensor 1 Remove cowling refer to section 71 02 2 Disconnect electrical connection 3 Unscrew clamp 4 Pull sensor out 5 Service or replace as required 6 To reinstall r...

Page 204: ...www kavlico com To service the Manifold Pressure Sensor 1 Remove cowling refer to section 71 02 2 Disconnect electrical connection 3 Unscrew sensor remove from airplane 4 Service or replace as requir...

Page 205: ...ive Thousand Oaks CA 91320 USA www kavlico com To service the Oil Pressure Sensor 1 Remove cowling refer to section 71 02 2 Disconnect electrical connection 3 Unscrew sensor remove from airplane 4 Ser...

Page 206: ...A 22821 USA www umainstruments com To service the Oil Temperature Sensor 1 Remove cowling refer to section 71 02 2 Disconnect electrical connection 3 Unscrew sensor remove from airplane 4 Service or r...

Page 207: ...Maintenance Manual GB1 GameBird Page date April 24 2020 41 1 Ballast General 41 2 Ballast Installation 41 2 Ballast removal 41 2...

Page 208: ...allastInstallation 1 Insert ballast weight into chamber in the left hand side of the fuselage push until surfaces are flush 2 Spin on and hand tighten wingnut on opposite side of fuselage 3 Insert saf...

Page 209: ...ed baggage compartment is molded into the upper fuselage behind the cockpit It is accessed via an external door on the left side of the fuselage which can be locked and unlocked by moving a lever up a...

Page 210: ...Composite Structures General 51 7 Minor surface damage 51 8 Sandwich Damage 51 10 Stripped threads in composite structures 51 11 Repairs to Spars 51 12 Adhesives Sealants Coatings 51 12 Tank Sealant...

Page 211: ...ad response is considered unacceptable The acoustic response of a good part can vary dramatically with changes in geometry so the entire area of interest must be tapped to establish its responses The...

Page 212: ...mponent less than 300 mm in any direction Subject to review by a suitably qualified person the airplane may be ferried to a repair station WARNING Aerobatics are not permitted Damage class 3 Damage to...

Page 213: ...on Thickness mm Weave pattern Area weight g m2 Cramer CCC 452 C200 0 33 2 2 twill 200 Cramer CCC 469 2 C93 0 14 Plain 93 Cramer AU 030 CU300 0 37 Unidirec 320 Glass fiber Manufacturer P D INTERGLAS TE...

Page 214: ...egebiet Gro h lsberg 42899 Remscheid Germany www bacuplast de Manufacturer Designation Game Composites Designation Fiber details Volume weight g L Milled Cotton Flocks Flox Fiber length app 350 m typi...

Page 215: ...4 Dust respirator mask 5 Protective eye wear 6 Ear defenders Tools Bonding and laminating 1 Scale accuracy of no less than 1gram 2 Mixing stick wooden tongue depressor or similar 3 Cups 100 to 500ml c...

Page 216: ...designations and mix ratios Designation in Work Instruction Resin Hardener mix in grams Flocks in grams Microballoons in grams Aerosil CF Flocks 50 100 150 200 10 20 30 40 N A N A MB Microballoons 50...

Page 217: ...primer and paint below is the composite layup 3 Cross section view of cleaned up area 4 Chamfered repair area Chamfer for 3 layers carbon fiber 0 3 mm thick each 0 9 mm thickness x 80 overlap length...

Page 218: ...act Laminate patch on repair area Apply peel ply over repair area bigger than laminate Cure Wait until material feels dry Build insulating box or tent around repair area or place entire component into...

Page 219: ...ace is covered by a layer of primer and paint below is the composite layup Trim the outer layers and sandwich materials 20 30 mm bigger than the biggest damage to the inner layer Use chisel to remove...

Page 220: ...o smoothen surface Use body filler if needed 8 Cure Wait until material feels dry Build insulating box or tent around repair area or place entire component into oven insulated box Heat up to 90 C 95 C...

Page 221: ...a second clean cloth prior to the solvent evaporating to prevent the redeposition of contaminants on the substrate Application Methods Tools Follow the application and mixing instructions printed on t...

Page 222: ...ners PR812 PPG Aerospace 12780 San Fernando Road Sylmar CA 91342 USA www ppgaerospace com Firewall joints bonds Painting Prepare repaired area using up to 240 grit sandpaper Any small indentations may...

Page 223: ...F3350 or DT895 PPG Hardener DCX61 PPG Interior Paint applied to Cockpit interior Baggage bay Cowling inside Body Filler Spreadable Fiberglass Upol Rage Filler Evercoat Plastik Honey Evercoat Bodyglaze...

Page 224: ...es 52 2 52 02 Remove Windshield GB1 5211 00 00 52 2 52 03 Remove Canopy GB1 5220 00 00 52 3 52 04 Canopy Hinges GB1 5220 79 00 52 3 52 05 Canopy Lock 52 4 52 06 Interconnecting Rod GB1 5220 71 00 52 5...

Page 225: ...move cowling refer to section 71 02 2 Open or remove canopy 3 Remove front instrument panel refer to section 39 04 4 Slide out the two securing pins one each side 5 Remove windshield 6 Clean all compo...

Page 226: ...assemblies in accordance with 5 06 No 5 9 For damages to composite structures refer to chapter 51 10 To reinstall maneuver canopy into position and in open position slide fully back on hinge pins 11...

Page 227: ...GB1 5220 73 00 Assembly Handle Canopy Release 3 GB1 5220 71 00 Assy Rod Canopy Lock 4 AN4 4 Bolt 5 MS35338 44 Washer 6 Igus GFM 1214 07 Closed Linear Plain Bearing 7 MS20392 2C11 Clevis pin 8 NAS1149C...

Page 228: ...in accordance with 5 06 No 1 6 Inspect welded assembly in accordance with 5 06 No 5 7 Exchange or reinstall secure fastener with Loctite 270 8 Reinstall Interconnecting Rod use new cotter pins Signat...

Page 229: ...front LH rudder pedal assembly is provided by removing the LH footrest plate which also secures the LH main wing attachment bolt Access to the smoke pump and lower RH engine mount attachment point lo...

Page 230: ...Stabilizers Horizontal Stabilizer 55 2 Elevators GB1 5520 00 00 55 3 Remove Elevators 55 3 Elevator Deflection 55 3 Allowable free play 55 4 Elevator Weight balance 55 4 Elevator Trim Tab GB1 2743 00...

Page 231: ...e and serve as elevator hinges Skins are carbon fiber with 3 mm Rohacell sandwich cores The inner ribs hold the needle bearings for the elevator connector The middle and outer ribs feature composite b...

Page 232: ...sembly in accordance with 5 06 No 5 7 Inspection of composite structures is described in section 51 01 8 Repair of composite structures is described in sections 51 05 to 51 08 9 To reinstall maneuver...

Page 233: ...ring seats Signature Actual value Elevator Weight balance 1 Remove both elevators refer to Service Elevators above 2 Place each elevator on scale individually allowable weight range 2 3 3 1 kg 5 6 8lb...

Page 234: ...ame Composites ElevatorTrimServo Type T2 10A Manufacturer The Ray Allen Company Inc 1341 Distribution Way Suite 15 Vista CA92081 USA www rayallencompany com No regular maintenance is required for the...

Page 235: ...eutral visual aim use plump bob to mark on the floor 2 Deflect rudder fully right against bump stop use plump bob to mark on the floor 3 Deflect rudder fully left against bump stop use plump bob to ma...

Page 236: ...Maintenance Manual GB1 GameBird Page date April 24 2020 57 1 Wings Wings 57 2 Aileron GB1 5721 00 00 57 3 Aileron Trim Tab GB1 2717 40 00 57 5 Aileron Trim Servo 57 5 Sight Gauges 5700 01 00 57 6...

Page 237: ...e rear cockpit foot wells The wings consist of one main spar assembly each which is bonded inside the composite wing skins Composite ribs do have stiffening purpose and also serve as aileron hinges be...

Page 238: ...01 6 Repair of composite structures is described in sections 51 05 to 51 08 7 When reinstalling reverse steps 1 3 and secure the hinge pin at the threaded end with torque seal Signature 8 Check for co...

Page 239: ...ble weight range 5 4 6 6 kg 11 9 14 6 lb Signature Actual value LH RH 3 Reinstall hinge pin 4 Suspend aileron on hinge pin one on center one on outer hinge hinge pin horizontal make sure elevator is f...

Page 240: ...which must not exceed 1 mm If play exceeds tolerance contact Game Composites AileronTrimServo Type T3 12A 3 Manufacturer The Ray Allen Company Inc 1341 Distribution Way Suite 15 Vista CA92081 USA www...

Page 241: ...in 2 Slide in place until pin locks in position To uninstall a sight gauge 1 Use a pointed object to depress spring loaded pin through hole in wing sleeve 2 Slide out The sighting devices may be remov...

Page 242: ...Flugplatzstrasse 1 94348 Atting Germany www mt propeller com For inspections installation inspections and repairs refer to manufacturer manuals MT propeller Operation and Installation Manual E124 and...

Page 243: ...ountandCowling General 71 2 Cowling GB1 7110 00 00 71 2 Engine Mount GB1 7120 00 00 71 3 Removing the engine from the Engine Mount 71 4 Re installing the engine 71 4 Removing the engine mount with or...

Page 244: ...se PR812 high temperature sealant for sealing the firewall to the fuselage and for filling any gaps around cable bundles or where the firewall panels meet Cowling GB1 7110 00 00 To service the cowling...

Page 245: ...lage Detail views lower LH and upper LH engine mount attachment points shown with backplate and mounting hardware GB1 7120 00 03 Compression plate upper RH GB1 7120 00 05 Compression plate upper LH GB...

Page 246: ...e rear strap 5 Lift the front end of the engine sufficiently to install the upper bolts washers and shock mounts 6 Torque all four 4 bolts to 51 56 Nm 450 500 in lb Mark nuts with torque seal 7 Referr...

Page 247: ...disassembly engine has to be removed from engine mount Providing access to aft support bracket to lift engine 4 Front Inlets only have to be removed when damaged or engine is shipped away 5 Clean all...

Page 248: ...r NAS1149F0763P Cotter pins MS24665 302 To replace one or more shock mounts 1 Suspend engine by its lift lugs using a hoist 2 Remove cotter pin remove nut 3 Remove large washer and forward facing rubb...

Page 249: ...Maintenance Manual GB1 GameBird Page date April 24 2020 73 1 Engineand PropellerControl System Overview 73 2 Throttle Quadrants 73 3 Throttle Propeller Mixture control cables 73 5...

Page 250: ...n accordance with 5 06 No 1 4 Inspect welded assemblies in accordance with 5 06 No 5 5 Inspect machined components in accordance with 5 06 No 6 6 Inspect handles in accordance with 5 06 No 10 7 Inspec...

Page 251: ...Maintenance Manual GB1 GameBird Page date April 24 2020 73 3 Throttle Quadrants Fig 73 1 Fig 73 2...

Page 252: ...X 12 GB1 7615 13 91 Throttle Grip left X X 13 GB1 7615 13 92 Throttle Grip Right X X 14 GB1 7611 10 71 Propeller Control Grip X X 15 PnHdM3x12 SS Screw M3 Pan Head Stainless Steel X X 16 GB1 7611 10 7...

Page 253: ...th ends 3 GB1 7600 10 01 300 03333 01720 Throttle Cable aft quadrant to Firewall 3 HEFT2 3 Clamp both ends 4 GB1 7600 10 05 300 03233 00700 Mixture Cable front Quadrant to Firewall 3 HEFT2 2 Clamp bot...

Page 254: ...all forward retention of cable 9 as shown on Fig 73 7 below 17 Connect to respective couplings as shown on Fig 73 3 18 Install rod end bearings on front end of cables 7 8 and 9 19 Adjust and connect t...

Page 255: ...Bird Page date April 24 2020 76 7 Fig 73 6 Propeller Control Cable sleeve retention bracket and connection to Governor Fig 73 7 Mixture Control Cable sleeve retention bracket and connection to Fuel Se...

Page 256: ...Maintenance Manual GB1 GameBird Page date April 24 2020 77 1 EngineIndicatingSystem 77 01 Engine Monitor 77 2 77 02 Annunciator Lights Panel 77 2...

Page 257: ...in cables Oil Temp high Red LED triggered when the oil temperature reaches the upper limit 245 F A separate oil temperature sensor JEGS 41326 mounted in the branch port of a T fitting on the upstream...

Page 258: ...section 71 02 2 Uninstall EGT sensors 3 Disconnect Smoke Hoses 4 Remove nuts from cylinder flange 5 Remove exhaust from airplane 6 Get service conducted by approved maintenance facility as required 7...

Page 259: ...eBird Page date April 24 2020 79 1 EngineOil System Oil Cooler 79 2 Oil Lines 79 3 Christen Inverted Oil System 79 5 System Description 79 5 Troubleshooting 79 6 To check or maintain components 79 6 G...

Page 260: ...ect the two hoses from the cooler be prepared to catch spilt oil 3 Remove the four screws and nuts which attach the cooler to the engine mount 4 Remove cooler 5 Clean inspect for cracks or deformation...

Page 261: ...Maintenance Manual GB1 GameBird Page date April 24 2020 79 3 OilLines...

Page 262: ...0041 413524 3 3CR 413524 3 3CR N A 105 4 GB1 7923 06 00 Stratoflex 101 8 101005 8CR 0143 413524 8 8CR 413524 8 8CR N A 364 5 GB1 7923 03 00 Stratoflex 101 10 101001 10CR 0166 413524 10 10CR 413524 10...

Page 263: ...ball valve of the Christen 802 Gravity Valve is closed and the bottom valve is open This permits oil to flow from the sump out to the oil pump and engine lubrication points When the aircraft is invert...

Page 264: ...vgas 5 Check for nicks flat spots surface deterioration or corrosion When surface imperfections cannot be polished out the component should be replaced 6 Reinstall components 7 Reconnect hoses 8 Check...

Page 265: ...24 2020 85 1 SmokeSystem Description 85 2 Smoke Oil Specification and Handling 85 2 Smoke Pump 85 4 Smoke Pump Relay 85 4 Check Valve 85 5 Refill Hose 85 5 Smoke System Operation 85 5 Filling 85 5 Dra...

Page 266: ...g Check wiring and electrical connections Uninstall and bench test pump replace if necessary Check relay replace if required Check CB switch and switch on throttle replace if required System does not...

Page 267: ...16UNF Thread AN824 6D 9 GB1 8513 11 00 Smoke Hose Spar to Pump 3175001 6CR 0247 10 Union 3 8 Tube 9 16UNF 1 4NPT AN816 6D 11 Smoke pump Marco UP2 P 12 Volt 16420212 12 AN Male to Male to swivel Female...

Page 268: ...L switch ON c Battery Master ON d SMOKE switch on throttle ON e check for smoke oil pouring out if the exhaust Signature f All switches OFF NOTE The pump is self priming no bleeding is required SmokeP...

Page 269: ...mokeSystemOperation For troubleshooting information see section 24 11 Filling 1 Click the fitting into the push connector in the fuselage and immerse the other end of the hose in the container of new...

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