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Tiger Aircraft AA-5 TRAVELER, Maintenance Manual

The Tiger Aircraft AA-5 TRAVELER Maintenance Manual is the essential guide for maintaining your aircraft. Download this manual for free from manualshive.com and ensure your AA-5 TRAVELER is always in top condition. This comprehensive manual covers everything you need to know to keep your aircraft in peak performance.

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Summary of Contents for AA-5 TRAVELER

Page 1: ...L FOR Gulfstream Aerospace Corporation MODELS AA 5 TRAVELER AA 5A CHEETAH AA 5B TIGER ISSUED NOVEMBER 15 1976 REVISION 5 MARCH 1 2004 REVISION 5 CONTENT REVIEWED AND APPROVED BYTYPE DESIGN HOLDER TIGE...

Page 2: ...MS Standard Practices Airframe Air Conditioning Auto Flight Communications Electrical Power Equipment Furnishings Flight Controls Fuel Ice and Rain Protection Landing Gear Lights Navigation Vacuum STR...

Page 3: ...PLANT Power Plant General Engine Fuel and Control Ignition Engine Indicating Exhaust 0iI Starting chajJts Charts A A 5 SERIES MAINTENANCE MANUAL UST OF CHAPTERS CHAPTER NO 57 61 71 73 74 77 78 79 80...

Page 4: ...anddistribution equipment for the electrical system There is not a chapter in this manual specifically designated for instruments Details of individual branch electrical or instrumentsystems will be f...

Page 5: ...first page of each block is placed on a right hand page I FIGURE IDENTIFICATION Figures illustrations are numbered consecutively within eachtopic subject as follows Figures in Description 1 2 3 4 5 e...

Page 6: ...rrent revision CROSS REFERENCE NAME MODEL DESIGNATION AND EFFECTIVE SERIAL RANGES Gulfstream Americanaircraft are certified under model number designations For marketing purposes eachmodel is also giv...

Page 7: ...neral Service Life Limited Components 5 2 1 SCHEDULED MAINTENANCE CHECKS Description Operation General Maintenance Practices Annual or 100 hour Inspection Procedures 5 5 1 UNSCHEDULED MAINTENANCE CHEC...

Page 8: ...TENANCE MANUAL TIME LIMITS MAINTENANCE CHECKS DESCRIPTION OPERATION 1 General This chapter contains the manufacturer s recommended time limits scheduled and unscheduled maintenance checks and inspecti...

Page 9: ...ssociated structure have been shown capable of withstanding the repeated loads of variable magnitude expected in service This was accom plished through a fatigue strength investigation and as a result...

Page 10: ...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 canbe reproduced for ready use by the...

Page 11: ...empennage attachments X X X X X X X X X X X X X X X X X X X X X X X X i LANDING GEAR 1 Strut and upper and lower strut brackets main gear 2 Strut torque tube assy fork and boot assy nose gear 3 Nose...

Page 12: ...and cooler X X X 3 Replaceoil filter if external filter is used X X X 4 Spark plugs X X 5 Ignition harness X X X 6 Magneto timing c 7 Exhaust system X X X 8 Throttle carburetor heat and mixture contr...

Page 13: ...ITY SYSTEMS 1 Master cylinder fluid level X X X f 2 Parking brake operation X X H3 All hoses lines and connections X X 4 Pitot and static systems X X 5 Pitot line drain X X 6 Vacuum regulator and filt...

Page 14: ...e 2000 hours Replace gyros central airfilter each 400 hours Replace vacuum reliefvalve filtereach 1000 hours For opera tion in dusty climates replace filters more frequently g Checkaccuracy of compass...

Page 15: ...901044 1 2 7 250 AA 5B 901044 2 7 250 Wing Spar Assembly AA 5 5A 5201002 501 12 500 AA 5A 5B 5201004 501 12 500 Wing Outboard Spar Assembly AA 5 5A 5201189 501 12 500 AA 5B 5201189 501 12 500 Retirin...

Page 16: ...tters for compliance at the time specified thereon Also appropriate sections of this maintenance manual 2 Check that all aircraft documents are present and In order Aircraft Airworthiness Certificate...

Page 17: ...ail that when the Inspection is completed the mechanic is absolutely sure that he has not over looked any areas even thoughhe may not have previous experience on this parti cular model aircraft Oncea...

Page 18: ...ssure 60 to 90 PSI Approx 25 PSI idling Actual Actual c 3 Magneto RPM Drop 175 RPM maximum drop on either magneto no more than 50 RPM difference between magnetos I 1 Actual Drop Left Right 4 Static RP...

Page 19: ...Clean and check for cracks wear dis tortion loose or missing fasteners and landing light attach 2 Drain oil sump Remove oil screens clean and Inspect for metal particles Reinstall and resafety Replace...

Page 20: ...loose or displaced supporting wire and general overall condition f 12 Drain carburetor bowl Reinstall drain plug Remove and clean carburetor fuel inlet screen with acetone Reinstall screen 13 Remove a...

Page 21: ...on and tension of alternator drive belt fg Replace if required Adjust belt tension toyield a 5 16 in deflection at the center of the belt when applying a pressure equivalent to 14 pounds for new belts...

Page 22: ...and lubricate canopy rails Check canopy 3 Check seat belts and shoulder harnesses for condition and 4 Check elevator trim control for condition secure mounting 5 Check rudder pedal and brake system fo...

Page 23: ...ry 500 hours See fuel system section for details 16 Check gyro system filters if Installed replaceIf necessary 17 Check Instruments for condition secure mounting and legible markings 18 Check electric...

Page 24: ...ps rudder rudder bearings and stops tab hinges and bcllcranks for damage travel and proper operation Maximum allowable torque tube wear limit at bearing supports is 0 030 in reduction in wall thicknes...

Page 25: ...earings and stops tab hinges and bellcranks for damage 1 travel and proper operation Maximum allowable torque tube wear limit at bearing supports Is 0 030 in reduction in wall 7 Check elevator trim me...

Page 26: ...wall thickness Check that aileron flap and drain holes are open Check that aileron balance weight tube arm I D is open corrosion free and zinc coated early aircraft only 4 Check fuel vents and connect...

Page 27: ...ction when tires j 3 Check brake lines for leaks and secure attachment 4 4 Check struts for secure mounting Inspect for cracks delamlnation 5 Inspect the upper main mounting brackets and spar attachin...

Page 28: ...ty repack every 100 hours Perform a complete wheel Inspection when tire Is replaced fr 7 Inspect nose wheel for cracks corrosion and loose or broken bolts J 7 Check tire for approved type wear and pro...

Page 29: ...9 Check engine static RPM 2250 2375 Model AA 5 and AA 5A 2150 2275 Model AA 5B 10 Check carburetor heater for proper operation 12 Checksuction gauge andvacuum system output 4 6 to 5 4 in Hg f 13 Check...

Page 30: ...device for operation 26 Inspect engineafter ground run up Flight test and Inspect for oil leaks and secure mounting of all components 11 GENERAL 1 Aircraft cleaned and serviced 2 Aircraft conforms to...

Page 31: ...aft should beinspected for subsequent damage Applicable groups inFigure 201 5 2 1 should be used as aguideline when performing the unscheduled inspections required as aresult ofunusual circumstances F...

Page 32: ...be submitted to the Customer Service Department for analysis and recommendations 2 Minor imperfections may be repaired Struts with other minor Imperfections must be replaced ORACKS SLIVER STRUT FAIRIN...

Page 33: ...is cause for rejection of the strut On Aircraft1975 model yearand later nose gear struts have a streamlining fairing attached to the aft side This fairing must be removed to perform the visual inspec...

Page 34: ...igure 204 8 Inspectbond fillets in torque tube and yoke assembly as shownin Figure 205 If cracks are noted in paint or in the bond fillets they should be carefully sanded out to determine that they do...

Page 35: ...side lap joint between the tailcone and forward cabin section the jointbetween the tailcone top and side skin and the aft tailcone bulkhead joints 2 Inside edges and Internal joints which have an undi...

Page 36: ...nclude Flanges ofwing andstabilizerrearspars trailingedges ofcontrol surfaces the side lapjoint between the tailcone and forward cabin section the joint between the tailconelop and side skin and the a...

Page 37: ...und when tapped directly in the damaged area 3 Separation If bondline separation cannotbe positively verified by tapping the areawith a coin attempt to inserta 0 004 to 0 006 inch feelergauge into the...

Page 38: ...MENSIONS General Principal Dimensions AA 5 Aircraft Principal Dimensions AA 5A and AA 5B Aircraft 6 1 1 STATION LOCATIONS General Station Locations AA 5 Aircraft Station Locations AA 5A and AA 5B Airc...

Page 39: ...PAL DIMENSIONS General Principal Dimensions AA 5 Aircraft Principal Dimensions AA 5A and AA 5B Aircraft 6 1 1 STATION LOCATIONS General Station Locations AA 5 Aircraft Station Locations AA 5A and AA 5...

Page 40: ...cipal dimensions for the AA 5 AA 5A and AA 5B aircraft 2 Principal Dimensions AA 5 Aircraft Principal dimensions for the AA 5 aircraft are presented in Figure 1 3 Principal Dimensions AA 5A and AA 5B...

Page 41: ...MAINTENANCE MANUAL 8 72 73 7 10 74 75 NOTE DISTANCE BETWEEN TIRES MAY VARY DUE TO LOADING DIMENSION GIVEN IS NOMINAL 8 3 C L TIRES SEE NOTE Principal Dimensions AA 5 Aircraft Figure 1 336 6 0 Page 2...

Page 42: ...CE MANUAL NOTE DISTANCEBETWEENTIRES MAYVARY DUETO LOADING DIMENSIONGIVEN IS NOMINAL 3V 6 U 8 3 C L TIRES SEE NOTE 73 MAX AA 5A 75 MAX AA SB Principal Dimensions AA 5A and AA 5B Aircraft Figure 2 3363...

Page 43: ...ws 1 7 210 WS 129 210 AA 5 SERIES MAINTENANCE MANUAL e u a LEGEND BL BUTT LINE WL WATER LINE WS WING STATION FS FUSELAGE STATION Station Locations AA 5 Aircraft Figure 1 6 1 1 Page 2 July 15 78...

Page 44: ...e stationlocations for the AA 5 AA 5A and AA 5B aircraft 2 Station Locations AA 5 Aircraft I Station locations for the AA 5 aircraft are presented in Figure 1 3 Station Locations AA 5A andAA 5B Aircra...

Page 45: ...AA 5 SERIES MAINTENANCE MANUAL o r i Vj LEGEND BL BUTT LINE WL WATER LINE WS WING STATION FS FUSELAGE STATION lOs l70f Station Locations AA 5A and AA 5B Aircraft Figure 2 6 1 1 Page 3 July 15 78...

Page 46: ...Fixed Pitch Spinner Length Height Wings Span Dihedral Incidence Aileron Travel Up Dn Flap Travel AA 5 A16EA 2200 lbs 1850 lbs 37 gal 8qts Lycoming 0 320 E2G 150 HP 2700 RPM McCauley 73 Dla AA 5A A16E...

Page 47: ...essure Nose Wheel Tire Pressure AA 5 SERIES MAINTENANCE MANUAL AA 5 AA 5A 1 AA 5B 3 0 0 0 0 0 30 db 2 20 2 24 2 IT 2 24 2 17 2 25 A2 25 2 25 2 16 2 19 2 14 3 30 1 14 3 30 lo 6 00 x 6 4 ply rating 6 00...

Page 48: ...CHAPTER 7 LIFTING JACKING TABLE OF CONTENTS NUMBER PAGE 7 0 LIFTING AND JACKING POINTS General X Lifting and Jacking Points 1 7 1 1 LIFTING AND JACKING PROCEDURES General 1 Lifting Procedures 1 Jackin...

Page 49: ...beused when lifting or jacking of the aircraft is required Reference is also made to Paragraph 7 3 to Indicate what special lifting jacking or shoring equipment may be used at each lifting or jacking...

Page 50: ...permanently installed Itis a slip on fitting that can be used only onAA 5 air craft manufactured prior to 1975 2 3 4 Landing Gear Jacking Point On Gear Strut ofAircraft with Jack Fitting Part No DE 0...

Page 51: ...BILIZER 2 Press down on the horizontalstabilizer in the area of the stabilizerfront spar and within six inchesof the fuselage See Figure1 Section 7 0 3 While holding the aircrafttail down slide a stan...

Page 52: ...ENANCE MANUAL Place jacks beneath aft fuselage at Fuselage Station125oneachside of fuselage Place jacks beneath fuselage at Fuselage Station 51 oneach side of fuselage Jacking Arrangement Figure 1 7 1...

Page 53: ...p GE I 8 0 AIRCRAFTPREPARATION FOR WEIGHING General Preparation Procedure 8 1 1 LEVELING General Leveling Procedure 8 2 1 WEIGHING General Weighing Procedure 8 3 1 MEASURING ARM General Measuring Proc...

Page 54: ...or this aircraft can only be found in the appropriate weight and balance records carriedin the aircraft 2 Preparation Procedures Prepare the aircraft for leveling and weighing as follows A Inflate all...

Page 55: ...r main wheels with a 1 inch thick wooden block between each wheel and the scale B Place carpenter s levels on canopytrackasshownin Figure 1 C Level aircraft both laterally andlongitudinally by deflati...

Page 56: ...hould be properly calibrated and of sufficient capacity to support the air cratt 2 Weighing Procedure Weigh the aircraft as follows A Remove the levels close andlock the canopy B With aircraft level a...

Page 57: ...A Nose Landing Gear Arm inInches L Weight of Left Main Landing Gear in Pounds R Weight of RightMain Landing Gear in Pounds N Weight of Nose Landing Gear in Pounds 50 A L R 50 B A l N L K N Net Weight...

Page 58: ...aft from theaxle center of one main landing gear to theaxle center of the other 2 Connecta plumbbob suchthat it hangs fromthe centerline of the engine firewall to the floor 3 Using atape measure thedi...

Page 59: ...Using theweights and measurements previously recorded calculate the C G Arm according to the formula in Section 8 2 1 Figure 1 IC Enter the aircrafts net weight W and C G Arm obtained in Steps Aand B...

Page 60: ...NUMBER 9 0 TOWING General Towing Procedures 9 1 1 TAXIING General Taxiing Technique AA 5 SERIES MAINTENANCE MANUAL CHAPTER 9 TOWING TAXIING TABLE OF CONTENTS PAGE 1 1 1 1 9 Pagel Nov 15 76...

Page 61: ...WHEELPIVOTING ABRUPTLY AND DAMAGINGTHE NOSEWHEEL STOPS Towing of theaircraft should beaccomplished by use of thenose gear towbar Part No 5804052 501 as follows A Extendthe tow bar by pulling the handl...

Page 62: ...HANDLE AA 5 SERIES MAINTENANCE MANUAL TOW BAR ASSEMBLY STOWING POSITION ROLL PIN EXTENDING LATCHING LATCH ARM ATTACHING Tow Bar Usage Figure 1 3012 TOW BOLT SOCKET 9 0 Page 2 July 15 78 3...

Page 63: ...l braking 2 TaxiingTechnique All taxiing should bedone atslow speed and the controls should bepositioned such that the affects of gusty wind areminimized See Taxiing Diagram Figure 1 Taxiing should no...

Page 64: ...OL POSITION 1 FWD WHEEL NEUTRAL BACK 2 PWD RH QUARTER WHEEL RIGHT BACK 3i AFT RH QUARTER WHEEL LEFT FORWARD 4 AFT WHEEL NEUTRAL FORWARD S AFT LH QUARTER WHEEL RIGHT FORWARD 6 FWD LH QUARTER WHEEL LEFT...

Page 65: ...neral Parking Precautions Parking Procedures 10 14 MOORING General Normal Tiedown Severe Weather Precautions AA 5 SERIES MAINTENANCE MANUAL CHAPTER 10 PARKING AND MOORING TABLE OF CONTENTS PAGE 1 1 1...

Page 66: ...ircraft asdescribed in Section 10 1 1 C If heavybraking wasapplied during landing allow the brakes to cool beforesettingthe parking brake D Donot set the parking brakewhen the ambienttemperature isnea...

Page 67: ...ARGE ENOUGH TO COME IN CONTACT WITH THE WHEEL FAIRINGS USE OF CHOCKS THAT ARE TOO LARGE MAY DAMAGE FAIRINGS B Tie sufficientlystrong ropesor chains to thewing and tall tie down fittings and secure eac...

Page 68: ...SERIES MAINTENANCE MANUAL CHAPTER 11 PLACARDS AND MARKINGS TABLE OF CONTENTS PAGE NUMBER 11 0 PLACARDS AND MARKINGS General Placard Locations 11 1 1 EXTERIOR PLACARDS 11 2 1 INTERIOR PLACARDS ii i Dec...

Page 69: ...equired by FAA regulations to beproperty affixed to the aircraft Also shown in this chapter are placards which provide the pilot passengers and maintenance personnel with aircraft oper ational data 2...

Page 70: ...GRUMMAN AifWaSlWCSSAM Ate MODEL MO 1 1 SERIAL MM i i TYPE CERT NO tl PRODCFRTNO LT rfl Located on firewall _ FINISH AND TRIM r O rj Located on firewall 0 CAUTION PRIOR TO STRIPPING EXTERIOR PAINT CONS...

Page 71: ...SW MUST BE OFF Located onwing outer ribs ifstrobe lights are installed WARNING HIGH VOLTAGE WAIT 5 MINUTES AFTER SHUTTING OFF BEFORE STARTING ANY WORK ON THIS UNIT CAUTION THIS UNIT POLARITY SENSITIVE...

Page 72: ...eft and right wing at fuel fillercap Located on right wing leading edge DO NOT PAINT VANE OB SLOT AA 5 SERIES MAINTENANCE MANUAL AA5 0001 thru 0834 AA5A 0001 and Subsequent standard tanks AA5A 0001 an...

Page 73: ...R BCN BY PUSHING THE TOGGLE SWITCH TOWARD THE TOP OF THE FUSELAGE TO THE ON POSITION Located onbracket attached tobattery box H MITER OOME I T CI OCK o Located oneach side of forward fuselage below lo...

Page 74: ...D FUEL GAUGES IN LEVEL FLIGHT ONLY FOR NORMAL OPERATION MAINTAIN FUEL BALANCE Located on left hand rail THIS AIRPLANE MUST BE OPERATED AS A NORMAL OR UTILITY CATEGORY AIRPLANE IN COMPLIANCE WITH THE O...

Page 75: ...NDING INSTRUCTIONS READ FUEL GAUGES IN LEVEL FLIGHT ONLY FOR NORMAL OPERATION MAINTAIN FUEL BALANCE Located on left hand rail THIS AIRPLANE MUST BE OPERATED AS A NORMAL OR UTILITY CATEGORY AIRPLANE IN...

Page 76: ...AIRPLANE NOT APPROVED FOR FLIGHT IN ICING CON D1TIONS THIS AIRPLANE IS CERTIFIED FOR FOR THE FOLLOWING OPERATIONS IFR VFR DAY NIGHT WHEN PROPERLY EQUIPPED PER FAR 91 REFER TO WEIGHT AND BALANCE DATA F...

Page 77: ...ed at static air control Locatedbeneathinstrument panel at cabin walls VENT PULL OPEN Located adjacent to sunvisor ifinstalled CAUTION SWIVEL VISOR AFT AND UP BEFORE OPENING CANOPY On control gust loc...

Page 78: ...ANCE DATA AND OWNERS MANUAL NO PASSENGERS 340 POUNDS MAXIMUM CARGO DISTRIBUTE EVENLY FOR ADDITIONAL LOADING INSTRUCTIONS SEE WEIGHT AND BALANCE DATA AND PILOTS OPERATING HAND BOOK TO OPEN DOORS FROM I...

Page 79: ...5B 0001 and Subsequent Locatedadjacent to flap control UP i 1 3 2 3 AA5 0001 thru 0834 Located adjacent to trim wheel Nr m iy AA5 0001 thru 0834 UP 1 3 2 3 AA5A 0001 and Subsequent AA5B 0001 and Subse...

Page 80: ...SH TO LATCH Located adjacent to canopy latch FLAG INDICATES UNLATCHED CANOPY Located on instrument panel shield NO HOLD I Interior Placards Figure 2 Sheet 7 of 9 AA5 0001 thru 0834 AA5A 0001 and Subse...

Page 81: ...0001 and Subsequent AA5B 0001 and Subsequent AA5B 0001 and Subsequent Located oninstrument panel depending on system installed CAUTION FLASHING BEACON IN CLOUOS MAY CAUSE VISUAL DISORIENTATION Located...

Page 82: ...ed FOR AVIATION EMER GENCY USE ONLY UNLICENSED OPERA TION UNLAWFUL OPERATION IN VIOLA TION OF FCC RULES SUBJECT TO FINE OR LICENSE REVOCATION Interior Placards Figure 2 Sheet 9 of 9 AA5A 0456 and Subs...

Page 83: ...k...

Page 84: ...lenishing 6 Tire Inflation 6 Battery Fluid Replenishing 6 12 2 1 SCHEDULED SERVICING General 1 Engine Oil Servicing 1 Engine Air Filter Servicing AA5 0001 through AA5 0640 2 Engine Air Filter Servicin...

Page 85: ...SERIES MAINTENANCE MANUAL NUMBER PAGE Battery Servicing and Charging 1 External Cleaning 2 Internal Cleaning 2 Windshield and Window Cleaning 2 Engine Cleaning 3 Propeller Care 3 ft 12 Page 2 Nov 15 7...

Page 86: ...points on the AA 5 aircraft Figure 2 lists approved lubricants 3 Access and Inspection Provisions Various openings in the airframe are provided to enable access for Inspection or maintenance In additi...

Page 87: ...aintain safe level NOSE WHEEL BEARINGS Grease with MIL G 25760 Figure 2 grease every 100 hours oras required NOSE WHEEL TIRE Inflate to 21 psi on the AA 5and AA 5A and 25 psi on the AA 5B NOSE FORK SW...

Page 88: ...se with white grease Lubriplate No 501 orequivalent as required 19 FLAP DRIVE JACKSCREW Oil with MIL L 787 HFigure 2 oiLCoat with alight film for corrosion prevention I only tefoshett HviiJ fj R Co j...

Page 89: ...l Oil Company Union Carbide MIL L 22851 OIL Note 1 j Premium AD 80 Premium AD 120 Texaco Inc Texaco Inc VV P 236 PETROLATUM Note1 Braycote 236 Parmo 70 Royco 1 R Bray Oil Company Humble Oil RefiningCo...

Page 90: ...Oil Company Mobil Oil Company Mobil Oil Company Mobil OilCompany Mobil Oil Company Mobil Oil Company Texaco Inc Texaco Inc Texaco Inc Continental Oil Company Continental Oil Company Standard Oil Compa...

Page 91: ...AA 5 SERIES MAINTENANCE MANUAL Access Openings Sheet 1 of 2 Figure 3 3460 12 0 Page 6 Dec 15 77...

Page 92: ...Plate 11 Wing Inboard Forward Access Plate 42 Fuel Tank Access Plates I l3 Landing Gear Root Fairing l4 Wing Root Forward Access Plate 15 Wing Root Aft Access Plate 16 Wing Inboard Aft Access Plate 17...

Page 93: ...Rigging Fixture AA 5 5A 5B 5 DE 5003 501 Aileron Flap Rigging Fixture AA 5 5A 5E 6 DE 5004 501 Trim Tab Rigging Fixture AA 5 7 DE 5004 502 Trim Tab Rigging Fixture AA 5A 5B 8 DE 5005 501 I Control Wh...

Page 94: ...UAL Main Gear Jack Fitting Figure 4 Rudder Rigging Fixture Figure 5 NOTE THE JACK FITTING IS NOT PERMANENTLY INSTALLED IT IS A SLIP ON FITTING THAT CAN BE USED ONLY ON AA 5 AIRCRAFT MANUFACTURED PRIOR...

Page 95: ...AA 5 SERIES MAINTENANCE MANUAL Aileron Flap Rigging Fixture Figure 6 Trim Tab Rigging Fixture AA 5 Figure 7 12 0 Page 10 Nov 15 76...

Page 96: ...AA 5 SERIES MAINTENANCE MANUAL 3025 Trim Tab Rigging Fixture AA 5A AA 5B Figure 8 3026 Control Wheel Elevator Rigging System Figure 9 12 0 Page 11 Nov 15 76...

Page 97: ...I AA 5 SERIES MAINTENANCE MANUAL Canopy Track Sizing Tool Figure 10 3467 Spring Scale Chatlllon Gauge R Figure 11 3174 12 0 Page 12 Nov 15 76...

Page 98: ...eratingwithin 100 feet of the aircraft during fueling F If fuel is spilled ensure that the area ofspillage is thoroughly flushed with water and that all residual fuel and ff vapor have dissipated orbe...

Page 99: ...eft Fuel Tank Cap 1 ti FUEL MIN 100 130 OCT 26 3 U S GAL TOTAL CAP 19 0 U S GAL TO TAB FUEL MIN 80 87 OCT 19U S GAL CAP D AA 5 AA 5A STD TANKS ft AA 5BONLY FUEL MIN 80 87 OCT 26 3 U S GAL TOTAL CAP 19...

Page 100: ...complishedby pouringoil into the oil fillerspout See Figure 2 Oil quantity can be conveniently checked by use of the dipstick attached to the oil fillerspout cap Oil quantity is checked as follows A O...

Page 101: ...om the edges of the oil filler spout opening Also wipe oil from the dipstick NOTE When adding engine oil ensure thatnodirt or foreign material isallowed to enterthe oil filler spout and that the cap d...

Page 102: ...AA 5 SERIES MAINTENANCE MANUAL OIL FILLER SPOUT CAP AND DIP STICK Oil Filler Spout Figure 15 12 1 1 Page 5 Dec 15 77...

Page 103: ...USE REGULATED AIR PRESSURETHROUGH VALVE STEMS TIRE PRESSURES ARE AS FOLLOWS MAIN LANDING GEAR TIRES 35 psig AA 5B 24 psig AA 5 AA 5A NOSE LANDING GEAR TIRES 25psig AA 5B 21 psig AA 5 AA 5A 7 BatteryFl...

Page 104: ...AA 5 SERIES MAINTENANCE MANUAL AA5 AND AA5A FILLER PORT AA5B 0945 AND SUBSEQUENT Brake Cylinder Figure 3 12 1 1 Page 7 July 15 78...

Page 105: ...lugs 6 G Install battery boxcover 5 heat shield 4 and tiedown 3 Secure with thewashers 2 and wingnuts 1 H Close and secure cowL NOTE Check that cowl latches are flush with cowl 1 Wmg Nut 2 Washer 3 Ti...

Page 106: ...ttubes B Remove lower engine cowl C Locate engine oildrain plug Figure 5 and cut safetywire securing plug I NOTE On aircraft equipped with aquick oil drain do not cut safetywire at plug Place ahose ov...

Page 107: ...ficiency D Immerse the filter inthe grade oilcalled for onthe filter If none iscalled out useengine preservative oilper MIL L 21260 Section 12 0 Figure 2 E Afterremoving the filter from theoil allow i...

Page 108: ...lower engine cowl 3 Unbolt filteraccess door Figure 7 on bottom of airbox filter assembly 4 Remove old filter and install replacement 5 Close and secure filter access door 6 Install lower engine cowl...

Page 109: ...I FILTER COVER AA 5 SERIES MAINTENANCE MANUAL JL FILTER ELEMENT Air Filter Servicing AA5 0641 and AA 5A Aircraft Figure 6 3472 12 2 1 Page 4 July 15 78 fl8 k...

Page 110: ...I AA 5 SERIES MAINTENANCE MANUAL FILTER COVER PLATE DETAIL A Engine Air Filter Servicing AA 5B Aircraft Figure 7 3473 12 2 1 Page 5 July 15 78...

Page 111: ...replace with new element D Reinstall washer and nut E Reconnect air filter to firewall I Toreplace regulator filter proceed as follows f F Remove screw in top ofregulator Figure 8 and remove regulator...

Page 112: ...AA 5 SERIES MAINTENANCE MANUAL REGULATOR FILTER SYSTEM FILTER WASHER NUT Vacuum System Air Filter Servicing Figure 8 12 2 1 Page 7 July 15 78...

Page 113: ...MANUAL 1 Wheal 2 Bearings 3 Felt Seals Wheel Bearing Lubrication Figure 9 Nose Gear Fork Assembly Servicing Figure 10 3314 1 Fork Assembly 2 Strut 3 Bushings 4 Bellviile Washers 5 Thrust Bearing 6 O...

Page 114: ...CLEANING SOLVENT IN A WELL VENTILATED AREA AVOID BREATHING FUMES KEEP AWAY FROM FLAMES 1 Clean and grease thenose gear fork assembly bushings and Bellville washers every 100 hours Remove nosegear fork...

Page 115: ...tches refer to Chapter 52 3 Lubricate latch parts with alight coating of Lubriplate 50white grease orequivalent before assembly I Flap Position Indicator Cable The flap position indicator cable should...

Page 116: ...pump 1 by pressing slots overlugs androtating cover clockwise into detent F Safety wire bottom cover on pump with 032 inch wire G Energizeauxiliary fuel pump and check for leakage around bottom cover...

Page 117: ...AA 5 AND AA 5A FILTER DRAIN PLUG DETAIL B AA 5 SERIES MAINTENANCE MANUAL TWDj SAFETY WIRE DETAIL A Carburetor Filter Servicing Figure 25 AA 5B DRAIN PLUG 12 2 1 Page 12 Nov 15 76...

Page 118: ...TCH THIS FUEL IN A CONTAINER FOR PROPER DISPOSAL 1 Cut thesafety wire onthe carburetor See Figure 12 between the filter and the bowl drain plug 2 Remove the bowl drain plug and catch the fuel that dra...

Page 119: ...AW 0 i t...

Page 120: ...d snow that could constitute aflight hazard If heated facilities are notavailable ice must be carefully removed with wooden or plastic scrapers or byhand CAUTION DO NOT USE SOLVENTS ALCOHOL ETHYLENE G...

Page 121: ...any solvent read the instructions on the container and test itonan obscure place on the fabric to be cleaned Never saturate the fabric with avolatile solvent itmay damage the padding and backing WARNI...

Page 122: ...ON PARTICULAR CARE SHOULD BE TAKEN TO PROTECT ELECTRICAL EQUIPMENT BEFORE CLEANING SOLVENT SHOULD NOT BE ALLOWED TO ENTER MAGNETOS STARTER OR ALTERNATOR COVER ANY FUEL OIL AND AIR OPENINGS ON THE ENGI...

Page 123: ...IU ii v v v v irv v _ N I M i r I...

Page 124: ...on Repairable Parts Rivet Substitution Primary Structures 20 1 1 AIRFRAME STRUCTURAL REPAIR Approved Repairs Leading Edge Repair Wing Rib Repair Honeycomb Repair Partial Core Damage Honeycomb Repair E...

Page 125: ...AA 5 only 820 Bondline Repair 828 Main Gear Strut Repair 828 Damaged or Delamlnated Spar Collar Repair 829 20 2 0 PREPARATIONS FOR PAINTING Description 1 General 1 Cleaning Painting 701 Stripping and...

Page 126: ...coating des ignatedas Alclad for corrosionprotection Service Kits Service KitNo SK 102A isapotting kit for honeycomb repair and Service KitNo SK 125 isabondline repair kit used for therepair of delam...

Page 127: ...A 5 SERIES MAINTENANCE MANUAL AA5 0406 AND SUB AA5 0001 AND SUB AASB 0CO1 AND SUB 15 14 3 9 Airframe Materials Chart Sheet 1 of 2 Figure 1 1025 AASA 0001 AND SUB AA5B 0001 AND SUB 20 1 0 Page 2 Nov 15...

Page 128: ...s can beachieved with angles riveted over the bonding strap angles across thesplice This isdiscussed in Approved Repairs Paragraph 6 Thelength of the external splice angle can be increased as required...

Page 129: ...38 Elevator Rib 50 Honeycomb 39 Stabilizer Rib 025 2024 T42 Alclad 40 Bottom Skin 025 2024 T3 Alclad 41 Dorsal Fin 025 2024 T3 Alclad 42 Horizontal Fillet 032 2024 T3 Alclad 43 1 Ventral Fin 50 Honey...

Page 130: ...s arenot well protected by paint j This type ofdamage is more likely intropical and subtopical climates particularly where an H aircraft is located close to the coast B Areas Requiring Inspection Emph...

Page 131: ...Main GearAssembly g 9 Aft Fuselage Waterline 49 00 Stiffener Flanges 10 Aft Fuselage Lower Corner Flanges 11 Aft Fuselage Bulkhead Stabilizer Spar Attach 12 Horizontal and Vertical Stabilizer Forward...

Page 132: ...l dimple holes through filler spacing holes 5 8 inch apart from center ofhole to center of adjacent hole G Secure filler Lo doubler with rivets as specified in Step D H Use an epoxy filler as necessar...

Page 133: ...AINTENANCE MANUAL REPAIR DOUBLER 2024 T3ALCLAD 0 040 IN THICKNESS 11 TRIM OUT DAMAGED AREA LEADING EDGE SKIN DIMPLE HOLES IN I FILLER 1 4 F LLER SAMEMATER ALANDTHICKNESS AS SKIN ORIGINALPARTS REPAIR P...

Page 134: ...ANCE MANUAL 0 75 IN RIVET SPACING TYP FLANGE AND WEB CUT LINE SECTION A A SPAR COLLAR FORMED ANGLE SECTION B B SECTION C C ORIGINAL PARTS REPAIR PARTS S Wing Rib Repair Riveted Figure 802 3073 20 1 0...

Page 135: ...rry rivets CR162 CR163 or equivalent in PR1436GB 2 Inhibited Sealant and install to secure doubler to honeycomb panel H Fair external doubler periphery with epoxy filler to maintain asmooth surface I...

Page 136: ...INHIBITED SEALANT AA 5 SERIES MAINTENANCE MANUAL DOUBLER Y 2 00 IN DIA j 1 50IN DIA J RESIN FILLER SEE SERVICE KIT SK 102AI SECTION A A 3075 Honeycomb Repair Partial Core Damage Figure 803 20 1 0 Pag...

Page 137: ...ES MAINTENANCE MANUAL DOUBLER INHIBITED SEALANT EXTERNAL DOUBLER HONEYCOMB REPAIR SECTION INTERNAL D0U8LER SECTION A A Honeycomb Patch Repair External and Internal Doublers Figure 804 COUNTERSINK DOUB...

Page 138: ...CTION COUNTERSINK DOUBLER INTERNAL DOUBLER SECTION A A AA 5 SERIES MAINTENANCE MANUAL 0 25 IN TYP EDGE MARGIN DOUBLER DOUBLER INHIBITED SEALANT 3079 Honeycomb Repair using Spliced In Panel Section Fig...

Page 139: ...gure 804 b rectangular sections ofhoneycomb the length ofthe repair splice similar to Section AA of S Figure 805 or c the sheetmetalpan anddoubler methodas described below The external doublers are re...

Page 140: ...he continuity ofangles from an oribinal panel to a repair panel anglesmust be riveted over the bonding strap anglesacrossthe splice See Figure807 Repairhoneycomb panelusingthe bonding strapangle splic...

Page 141: ...n Figure 807 typical H Coat the repaired area with zinc chromate primer HONEYCOMB REPAIR SECTION PART NO S04001 501 RIVET SPACING 0 60 IN 0 7S IN TYP SPLICE LOCATION RIVET PATTERN IS THE SAME FOR BOTH...

Page 142: ...ice 4 spacer 3 andunderneath side of bottom honeycomb panel SeeSection B B Figure 808 I Slide side block 1 into place between side honeycomb panel and bottom block J Slide reinforcement panel 7 betwee...

Page 143: ...to fit under item 6 6 Splice See Section D D 7 Reinforcement t 08 See Section C C MATERIAL 2014 T6 or 2024 T3 2014 T6 or 2024 T3 2024 T3 Alclad 2024 T3 Alclad 2024 T3 Alclad 2024 T3 Alclad 2024 T3 Alc...

Page 144: ...LOOKING OUTBOARD SECTION D D VIEW LOOKING DOWN 2 00 IN 2 00 IN e7e7 7e7e i i 2 75 IN j 1 S0 IN T i 6 SPLICE THK 0 50 IN FJT 5 SPACER UNDER 6 SPLICE 0 MS426AD4 14 Double Countersunk as shown Section A...

Page 145: ...24694 S59 SCREW 18 REQD AN960 10 WASHER 18 REQD MS 20364 1032 NUT 18 REQD INHIBITED SEALANT I 2 00 IN HONEYCOMB SIDE PANEL REF 102069 1 SUPPORT TOP VIEW RIGHT HANO SIDE 0 38 IN SIDE VIEW RIGHT HAND SI...

Page 146: ...lines with PR1436GB 2 Inhibited Sealant C Coat all parts with zinc chromate primer D Seal all exposed honeycomb core areas with PR1436GB 2 Inhibited Sealant E Place new honeycomb panel into position f...

Page 147: ...1 00 IN VERTICAL SPACING 4 PLACES INHIBITED SEALANT AA 5 SERIES MAINTENANCE MANUAL STATION 50 PANEL I IHEkllll USE EXISTING 102293 3 ANGLE USE CR2248 4 1 RIVETS STAGGERED 1 00 IN VERTICAL SPACING 4 P...

Page 148: ...0410 RIVET AVEX 20 REQD 1 00 IN TYP 1 00 IN TYP 0 50 IN 0 38 IN t t ff 0 19 IN 0 38 IN 1 VIEW A CR2248 4 1 RIVET CHERRY 57 REQD EACH SIDE 1 00 IN TYP 1 00 IN TYP VIEWB Upper Forward Fuselage Assembly...

Page 149: ...selage bulkhead 2 Drillout rivets attaching canopy rail to forward fuselage S 3 Drill out rivets attaching rail to upper aft fuselage skin D Remove rear seat See Chapter 25 E Disconnect flap actuator...

Page 150: ...FS 50 00 o AA 5 SERIES MAINTENANCE MANUAL 190 726 IN FS 116 00 FS 128 00 REPLACEMENT SECTION Overall Fuselage Dimensions Figure 812 24 00 IN FS 240 726 3475 20 1 0 Page 819 Nov 15 76...

Page 151: ...R2249 4 2 RIVET CHERRY 6 REQD EACH SIDE NEW NEW HOLES CR2249 4 2 RIVETS EXISTING HOLES CR2249 4 2 RIVETS EXISTING HOLES MS20470 AD 5 RIVETS EXISTING HOLES 0 062 DIA ROLLPINS Installation of Track Asse...

Page 152: ...INFORCEMENT REF FIG 817 0 187 DIA BOLTS EXISTING CR2248 4 1 RIVETS CHERRY 18 REQD EACH SIDE SIOE SKIN TAILCONE GUSSET REF FIG 816 REMOVE EXISTING GUSSET NEW HOLES EXISTING HOLES AND RIVETSOR BOLT Fuse...

Page 153: ...sset toside skin of aft fuselage section Eight 8 CR2248 4 3 Cherry rivets required for each side of fuselage See Figure 816 for rivet placement 3 Using CR2248 4 4 Cherry rivets dipped in PR1436GB 2 In...

Page 154: ...ES 0 31 IN JTYP VIEW A A AA 5 SERIES MAINTENANCE MANUAL BOTTOM VIEW AIRCRAFT CR2249 4 1 RIVET CHERRY 31 REQD GUSSET REF FIG 816 FOR DETAIL NEWHOLES Bottom Skin Attachment Details Figure 815 3419 20 1...

Page 155: ...N CR2248 4 2 RIVETS CHERRY 39 REQD EACH SIDE CR2248 4 3 RIVETS CHERRY 8 REQD EACH SIDE 5102370 501 GUSSET ASSEMBLY 5102370 502 GUSSET ASSEMBLY STEEL GUSSETS ONLY CR2248 44 RIVETS CHERRY 7 REQD EACH SI...

Page 156: ...2298 13 REINFORCEMENT LH 102236 14 REINFORCEMENT RH SIDE VIEW RH SIDE LOOKING OUTBOARD SKIN TURTLE DECK LONGERON ADDITIONAL HOLES FS 134 2 REF CR2248 4 2 RIVET CHERRY 8 REQD EA SIDE REINFORCEMENT EXIS...

Page 157: ...t section of fuse 4 lage AA Install wingroots andwings See Chapter 57 A B Install canopy See Chapter 52 AC Install forward andaft side panel interiors See Chapter 25 AD Install rear seat See Chapter 2...

Page 158: ...MB FIREWALL 102301 501 BULKHEAD ASSY MODEL AA 5 1601 0410 RIVET AVEX 6 REQD 0 38 IN 0 25 IN i TYP 2 00 IN 2 EQSPACES TYP 1 MS20426AD4 5 RIVET 15 REQD Aft Fuselage Bulkhead Replacement Figure 8 18 FS 2...

Page 159: ...MES If the results of Steps Band Care negative thehairline should bewiped withTrichloroethane and sealed with paint Also any bare bondline edges should be sealed with paint If theresults of either Ste...

Page 160: ...a vacuum cleaner or other suitable means WARNING USE CLEANING SOLVENTS IN A WELL VENTILATED AREA AVOID BREATHING FUMES KEEP AWAY FROM FLAME B Clean area with a lint freecheese cloth dampened with MEK...

Page 161: ...c O TJ D 09 00 53 w o o J WING SPAR WING RIB ADD 4 RIVETS EQUALLY SPACED SPAR COLLAR 0 40 EDGE MARGIN WING SKIN WING RIB J SYM WING SPAR EXISTING RIVETS 2 PLACES J 3 Z z n O rn m so 3 m r...

Page 162: ...this section The requirements specified in this section shall apply to all polyurethane coated aircraft manufactured by the Grumman American Aviation Corporation Any deviation from or modification of...

Page 163: ...Ui r r...

Page 164: ...nose cowl tailcone propeller mainlanding gear drain holes fasteners andallbondlines asshownin the shaded areas of j Figure 701 C Encase antennas lights beacons tires radar domes windows windshield and...

Page 165: ...AINTENANCE MANUAL IF AIRCRAFT HAS PLASTIC DORSAL FIN 1974 AND ON IT MUST BE PROTECTED WITH ALUMINUM FOIL SEAL ALL GAPS BETWEEN SURFACES AS SHOWN PRIOR TO APPLICATION OF STRIPPER Aircraft Stripping She...

Page 166: ...AA 5 SERIES MAINTENANCE MANUAL BOTTOM VIEW 1 ALUMINUM TAPE Y A ALUMINUM FOIL Aircraft Stripping Sheet 2 of 2 Figure 701 3103 20 2 0 Page 703 Nov 15 76...

Page 167: ...nditioner Economics Laboratory Incorporated Magnus Division Osbom Building St Paul Minnesota 55102 B Apply the conditioner bywiping orbrushing the solution on all surfaces tobe painted This conpound i...

Page 168: ...1 VENTILATION SYSTEM Description Operation General 21 4 1 HEATING SYSTEM Description Operation General Troubleshooting Maintenance Practices General AA 5 SERIES MAINTENANCE MANUAL CHAPTER 21 AIR COND...

Page 169: ...All vl l y...

Page 170: ...ed controls used for heating and ventilating the air craft cabin The system is a completely mechanical system and is manually controlled The cabin heat control is a push pull type control located in t...

Page 171: ...f...

Page 172: ...e flow of fresh air in the cabin canbe regulated in the desired direction by movable louvers located in the air vent outlets Ventilation for the rear seat area of the cabin is furnished as an optional...

Page 173: ...R COTTER PINS CONTROL KNOB AA5 0001 THRU AA5 0105 LOUVER SHAFT CONTROL KNOB AA 5 SERIES MAINTENANCE MANUAL 3201 Forward Cabin Area Air Vent System Figure 1 ACTUATOR CHANNEL SCREEN TUBE SLEEVE ACTUATOR...

Page 174: ...REW AA 5 SERIES MAINTENANCE MANUAL FRESH AIR VALVE PLASTIC MESH BALLS AIR SCOOP SCREW OUTSIDE AIR SCOOP AIR FLOW CONTROL 3382 OUTLET VALVE Rear Cabin Area Air Vent System Figure 2 21 2 1 Page 3 July 1...

Page 175: ......

Page 176: ...compartment mixes a stream of cold air with the hot air from the heat exchanger to provide good heat distribution and flow The valve mounted through the firewall is used to regulate the warm air by ei...

Page 177: ...ntrol cable connection Tighten control cable connection Air valve damaged Replace air valve Control hard to operate Control cable binding Check cable for proper routing and free the cable Air valvesti...

Page 178: ...MAINTENANCE PRACTICES 1 General Maintenance ofthe Heating system Figures 201 202 and 203 will probably be confined toreplacement ofducting when damaged Ducts can bereplaced by removing clamp and ducta...

Page 179: ...AFFLE TO HEAT EXCHANGER AA 5 SERIES MAINTENANCE MANUAL HEAT CONTROL TO DEFROSTER OUTLET Vs Heating System AA5 0001 thru 0834 AA5A 0001 thru 0522 Figure 201 TO DEFROSTER OUTLET 21 4 1 Page 202 Dec 15 7...

Page 180: ...I TO OBFROSTER OUTLET AA 5 SERIES MAINTENANCE MANUAL HEAT CONTROL TO DEFROSTER OUTLET Heating System AA 5B 0001 thru 0280 0283 and 0284 Figure 202 21 4 1 Page 203 Dec 15 77...

Page 181: ...AA 5 SERIES MAINTENANCE MANUAL TO OEFROSTER OUTLET V 3197 HEATCONTROL TO DEFROSTER OUTLET Heating System AA5B 0281 0282 and 0285 thru 0399 Figure 203 21 4 1 Page 204 Dec 15 77 s s k v...

Page 182: ...p v AA 5 SERIES MAINTENANCE MANUAL TO DEFROSTER OUTLET HEAT CONTROL TO DEFROSTER OUTLET MUFFLER ASSY 3197 Heating System AA5A 0523 and Subsequent AA5B 0400 and Subsequent Figure 204 21 4 i Page 205 De...

Page 183: ......

Page 184: ...R 22 AUTOPILOT TABLE OF CONTENTS NUMBER 22 0 AUTOPILOT Description General 22 1 1 AUTOPILOT SYSTEM Description Operation Century I Century HB Maintenance Practices Roll Servo Removal Installation I PA...

Page 185: ......

Page 186: ...verride features permit the pilot to override the system at any time without damage to the servo or aircraft controls The Edo Aire Mitchell Century IIB is a light weight automatic flight system utiliz...

Page 187: ...i J J i r i...

Page 188: ...INTENANCE MANUAL AUTOHLOT SYSTEM DESCRIPTION OPERATION For information concerning the description and operation of the Century I and IIB Autopilot refer to the applicable Edo Aire Mitchell manual 22 1...

Page 189: ...INTENANCE MANUAL NOT USED FOR THOSE MOOELS OF THE S2073 THAT 00 NOT CONTAIN A TRACKER BOARD RADIO RAOIO LEFT RIGHT Century I Autopilot Block Diagram Figure 1 TURN 8 BANK INDICATOR 52073 33S4 22 1 1 Pa...

Page 190: ...STAT CONSOLE AMPLIFIER ft uu ROLL SERVO tfnz E22L C B ASSY C TO AIRCRAFT BUS BAR NOTES IP RAOIOCOUPLER IS NOT INSTALLED CO 33 ISTO BE CONNECTED DIRECTLY TO THE S2084 DIRECTIONAL GYRO THE tC388MC RAOIO...

Page 191: ...08S SEE OETAIL A FOR SINGLE NAV INSTALLATION UNUSED PINS NOT SHOWN ON INSTALLATIONS WITHOUT TRACKERS THESE WIRES ARE CAPPEO AND STOWEO CD XX DENOTES WIRE CABLE ASSEMBLY FURNISHEO BY EDO AIRE FOR WIRIN...

Page 192: ...EAKER UNUSEO PINS NOT SHOWN A ON AIRCRAFT WITHOUT TRACKERS THESE WIRES ARE CAPPED AND STOWEO THESE WIRES ARECAPPEO ANO STOWEO s SEE OETAIL AFOR SINGLE NAV INSTALLATION 20GAUGEWIRE PER MIL W 50S6 7 CD...

Page 193: ...TRACKER SWITCH A NOTES FOR WIRING INFORMATION SEE DETAIL B OETAIL AFOR SINGLE NAV INSTALLATION 3 ALL WIRE 20CAUGE 4 WIRE PER MIL W 5086 3392 RADIO COUPLER DETAIL A A h SCA16 SCA1S o 9CA20 5CA19 J TOP...

Page 194: ...W CENTURY 1 AUTOPILOT ROLL SERVO RELAY BOX ROLLSERVO BRIDLE CABLE CENTURY11BAUTOPILOT ROLLSERVO AA 5 SERIES MAINTENANCE MANUAL WASHER PULLEY ASSEMBLY WASHER Roll Servo Removal Installation Figure 6 30...

Page 195: ...r...

Page 196: ...his will bringthe cable forward Attach the bridle cable to the aileron cable with one cable clamp NOTE Move aileron controlto the left stop full travel In this position the aft end of the forward cabl...

Page 197: ...1V i i l i...

Page 198: ...escription Operation General Operation Intercom Switch Troubleshooting General Maintenance Practices Removal and Installation Adjustment Test 23 2 2 KING VHF COMMUNICATION SYSTEM Description Operation...

Page 199: ...Amplifier Switch Troubleshooting Maintenance Practices Removal Installation Adjustment Test 23 5 2 KING KMA 20 AUDIO CONTROL PANEL Description Operation General Troubleshooting Maintenance Practices...

Page 200: ...E MANUAL 23 7 0 NARCO ELT 10 EMERGENCY LOCATOR TRANSMITTER ELT SYSTEM Description Operation 1 General 1 Troubleshooting 101 Maintenance Practices 201 Servicing 201 Removal Installation 202 Adjustment...

Page 201: ...ystem For those aircraft equipped with either dual VHF communications or various navigation systems or both an audio integrating system is necessary An audio integrating panel permits the pilot to sel...

Page 202: ...I j...

Page 203: ...as360 720 channel transceiver The NARCOCOM 11 canbe usedwith a NARCO NAV 11 or 12 to provide navigation the pair would comprise a 1 1 system NOTE NARCO COM 11B 111B has 720 channel 25 KHz spacing cap...

Page 204: ...sed Counterclockwise Required input signal level is increased Tenths Hundreths Mega hertz Frequency Selector Selects frequency for radio In 50 25 KHZ steps I Frequency Indicator Indicates operating fr...

Page 205: ...power to unit TEST Automatic squelch disabled 2 Volume Controls audio volume 3 Course Frequency Control Changes transceiver frequency in one megahertz steps 4 Fine Frequency Control Changes transceive...

Page 206: ......

Page 207: ...Hundredths MHz Frequency Selector 4 Frequency Indicator AA 5 SERIES MAINTENANCE MANUAL 2 7 SQUELCH PUU N feENT 3207 5 Megahertz Frequency Selector 6 Power and Volume Control 7 Ident Squelch Pulled NAR...

Page 208: ...IndicatorLight NARCO COM 11 111 Transceiver Figure 2 Sheet 2 of 2 NARCO COM 120 TSO Volumo o o 1 Power ON OFF TST TST disablesautomatic squelch 2 Volume Control 3 Course Frequency COM1 124 950 orr on...

Page 209: ...UBLE PROBABLE CAUSE REMEDY No reception or transmission Open circuit breaker Close circuit or breaker Dirty or corroded Antenna Clean or replace antenna Faulty audio panel dual system Replace audio pa...

Page 210: ...ii a...

Page 211: ...al cable it H 4 Place the antenna on the rubber gasket and install with three 3 screws 5 Performan operational check for the associated transceiver C Removal and Installation of VHF COMAntenna No 2 Ex...

Page 212: ...locking Allen screw clockwise Use 5 64 inch hex Allen wrench 3 Slide the unit straight out to avoid bending the connector pins A slight left to right movement may help in disconnecting unit from conne...

Page 213: ...COM ANT NO 2 V COAX CONNECTOR impedance e BOX T r fe iy DETAIL B Iff ANTENNA RETAINING U TUBULAR NUT VHF COM Antenna Installation Figure 201 3215 1 NOTE THIS IS NO 2 COM NAV ANTENNA ON AIRCRAFT EQUIPP...

Page 214: ...following procedure can be omitted when Audio Amp switchis installed Place Audio Amp switchto desired position 1 Assure the aircraft battery Is installed and operating 2 Assure the respective radio ci...

Page 215: ...icrophone Speaker s voice isnot heard over speakers 7 Place intercom switch to Phone position Indications are thesame as Steps 5and 6 8 Place the MASTER switch to OFF REAR Location of MIKE GAIN Adjust...

Page 216: ......

Page 217: ...hapter 34 The transceiver operates within the frequency range of118 00 MHz to 135 95 MHz with apower output of five 5 watts The transceiver can operate on any of360 KX 170A or 720 KX 170B KX 175 chann...

Page 218: ...ch OFF Removes power from radio ON Energizes the radio TEST Disables automatic squelch 3 Megahertz Frequency Selector Selects frequency in one 1 megahertz steps 4 Tenths Hundreths Megahertz Frequency...

Page 219: ...BLE PROBABLE CAUSE REMEDY tr No reception or transmission Open circuit breaker Close circuit breaker Dirty or corroded antenna Clean or replace an tenna Faulty audio panel dual system Replace panel Fa...

Page 220: ...K r mjyr M v t r f ifr Vi rr fi Vi K Vi n vir vJ a win...

Page 221: ...eadjustment See I this Section for adjustment procedure ffl 2 Adjustment Test KING Communication System A Mike Gain Adjustment KX 170 KX 175 Transceiver CAUTION THE MINIMUM OF A 2ND CLASS F C C IJCENS...

Page 222: ...ch to ON 6 Set in a tower frequency 7 Rotate theVOLUME control to mld posltlon Contact thetower for a radio check 8 Contact the tower on several up to five 5 KXrl70A orten 10 KXrl70B Ifavailable fre q...

Page 223: ...er outputof 8 12watts 10 watts nominal The transceiver can operate onanyof 720indepen dent channels with 25 KHz spacing between channels The VHF 251 differs from the VHF 250 in that it has the capabil...

Page 224: ...ore Stores in memory the fre quency selected by select control Recall Recall frequency stored in memory 3 Transmit Indicator VHF 251 Only Illuminates when transceiver transmitting 4 1 MHz Frequency Co...

Page 225: ...I AA 5 SERIES MAINTENANCE MANUAL Collins Comm 12i8L2f4 VOL PULL TST VHF 2S0 TSO VHF 250 Transceiver Figure 1 VHF 251 Transceiver Figure 2 23 2 3 Page 3 Dec 15 77...

Page 226: ...uit breaker Close circuit breaker Dirty or corroded antenna Clean or replace antenna Faulty audio panel dual system Replace audio panel Faulty transceiver Replace transceiver Weak or no transmission 1...

Page 227: ...liaU...

Page 228: ...ew clockwise Use 5 64 inch hex wrench 4 Perform operational test of transceiver See test procedurein this chapter I NOTE The mike gain ofthe transceiver is normally set for use with the same type NARC...

Page 229: ...inadjustment Thetransceiver microphone gain isnormally shop adjusted for use with thesame typemicrophone NARCO KING COLLINS as transceiver inuse If themicrophone gain requires adjustment refer to the...

Page 230: ...and or multiple naviga tion systems such asVOR ADF orDME The panel provides acentral control pointfor theoperation and moni toringof installed communication andnavigation equipment The speakers aremo...

Page 231: ...i...

Page 232: ...properly before troubleshooting further TROUBLE PROBABLE CAUSE REMEDY Audio not available on speakers Faulty speaker Replace speaker Faulty wiring Repair wiring Faulty transceiver Replace transceiver...

Page 233: ...yi ij f...

Page 234: ...btain access to the speakers Remember the defrosters are attached to the deck 4 Release the splices from the speaker leads to the aircraft wiring on the pilot s side 5 Unscrew the eight screws holding...

Page 235: ...M rj i 7 0 i iV 1 V Vj V...

Page 236: ...es 1and 3 The NARCO CP 135 is available on 1978 Model AA 5A and AA 5B NOTE TheCP 125 panel requires modifying if onlyoneVHF Com radio isinstalled See NARCO Maintenance Manual for the modification 2 Au...

Page 237: ...Deselects No 1 VHF radio Out Deselects No 2 COM 3 Both COM Control Depressed in Permits simultaneous monitoring of audio from both VHF COM receivers Out I Audio monitoring of VHF radios is selected b...

Page 238: ...e 7 MKR OR MKR DME Control Depressed in Permits monitoring of Marker Beacon audio On those aircraft with DME audio monitoring of DME is also avail able Out Audio monitoring of the Marker Beacon and DM...

Page 239: ...trol 3 Both COM Control 4 NAV 1 Control 5 NAV 2 Control 6 ADF Control 7 Marker or DME Control 8 9 10 Speaker Control Marker Beacon Indicator O Outer M Middle I Inner Power Control NARCO CP 125 Audio C...

Page 240: ...2 Control 6 ADF Control AA 5 SERIES MAINTENANCE MANUAL 7 8 9 10 NARCO CP 135 Audio Panel 1978 Model AA 5A and AA 5B Figures Marker or DME Control Speaker Control Marker Beacon Indicator 0 Outer M Mid...

Page 241: ...air wiring System audio not avail able at the headset Faulty headset Replace headset Faulty jack Replace jack Faulty audio panel Replace panel Faulty wiring to jack Repair wiring HSystem audio availab...

Page 242: ...U f i...

Page 243: ...nsure that the SPKR button is out 6 Foraircraft with Intercom switch place to phone CP 125 only 7 Press the COM 1 button Check thatCOM 1 audio isavailable in the headphones Adjust SQUELCH con trol on...

Page 244: ...case check both headphone and SPKR operation NOTE In order to check Marker Beacon operation It Is necessary to perform a flight test over a beacon If available a beacon ramp generator can be used avoi...

Page 245: ...ication systems and or multiple navigation systems such as VOR ADF DME The panel permits monitoring of audio signals from the radio navigation systems and also permits selec tion of the desired commun...

Page 246: ...SPEAKERS Audio from the No 1 com munication system is sent to the speakers Center OFF Audio routing is controlled by the AUTO selector PHONE No 1 system audio is sent to the headphones 4 COM 2 Audio...

Page 247: ...r OFF Audio from the ADF is not available PHONE Audio from the ADF is routed to the headphones 8 DME Audio Selector SPEAKERS Ident audio from the DME is sent to the speakers Center OFF Audio from the...

Page 248: ...tor 10 4 COM 2 Selector 5 NAV 1 Selector 11 6 NAV 2 Selector 7 ADF Selector 3369 DME Selector Marker Beacon Selector Marker Beacon Sensitivity Selector Marker Beacon Indicator A mner O Outer M Middle...

Page 249: ...ot available on the speakers or head set Faulty audio panel Replace panel System audio available but no transmission IM Faulty microphone Replace microphone This may require a re adjustment of MIKE GA...

Page 250: ...i i f...

Page 251: ...to a different operating frequency b Plugthe microphone andheadset into the appropriatejacks 5 Set all toggle switches to mid position 6 Set microphone selector to COM 1 7 Set Auto selector to Speake...

Page 252: ...v fv J M...

Page 253: ...f the audiocontrolisoptionalandis usedon aircraft with dual com munication systems and or multiple navigation systems such as VOR ADF orDME The panel permits monitoring of audio signals from the radio...

Page 254: ...selector SPEAKERS Audio from the No 1 Com munication system is sent to the speakers Center OFF Audio routing is controlled by the AUTO selector PHONE No 1 system audio is sent to the headphones 4 COM...

Page 255: ...m the ADF is routed to the headphones 8 DME Audio Selector SPEAKERS Ident audio from the DME is sent to the speakers Center OFF Audio from the DME is not available PHONE Audio from the DME is sent to...

Page 256: ...l 5 NAV 1 Control 6 NAV 2 Control AA 5 SERIES MAINTENANCE MANUAL 6 7 a 7 ADF Control 8 DME Control 9 MKR Control 10 MARKER HIGH LOW TEST Select 11 MarkerLight 0 Outer M Middle I Inner Collins AMR 350...

Page 257: ...System audio not available on the speakers or head set Faulty audio panel Replace panel System audio available but no transmission V Faulty microphone Replace microphone This may require a readjustmen...

Page 258: ......

Page 259: ...installed tune each to adifferent operating frequency Plug themi crophone and headset into the appropriate jacks 5 Set all toggle switches to mid position t 6 Set communication selector to COM 1 f 7 S...

Page 260: ...by adeceleration of5g s along the flight axis ofthe air craft Itcan also be activated manually by removing the left side empennage inspection cover and moving the trans mittercontrolswitch tothe ON p...

Page 261: ......

Page 262: ...o antenna Repair wiring Faulty battery Replace battery pack Weak transmission Faulty antenna or wiring to antenna Replace antenna as sembly Repair wiring Faulty transmitter Replace transmitter Faulty...

Page 263: ...OW IN FIRE I f 6 Release the battery pack wires quick disconnect from the terminals at the transmitter Dis H pose ofbattery pack jm B Installation of Battery Pack 1 Connect the battery pack wires to t...

Page 264: ...around the perimeter of transmitter section 3 Fit the two sections together Assure that screwi holes align properly NOTE Do notpress sections together 4 Apply a very small amount of sealant to counter...

Page 265: ...3 Attach the antenna lead to structure using the stick clamps 3 places 4 Slowly slide the dorsal fin rearward while fitting the antenna through the grommet 5 Work the antennathrough the grommet Check...

Page 266: ...SPRING WASHER FLAT WASHER AA 5 SERIES MAINTENANCE MANUAL SEAL ASSEMBLY DETAIL A Removal and Installation of ELT 10 Antenna Figure 201 GROMMET CAP NUT FLAT WASHER 3371 23 7 0 Page 204 July 15 78...

Page 267: ...Electrical Load Analysis Maintenance Practices Diode Test 24 3 0 ELECTRICAL POWER SUPPLY SYSTEM Description Operation Battery Battery Relay Troubleshooting Maintenance Practices Servicing Visual Chec...

Page 268: ...201 i Alternator Removal 201 f Alternator Installation 201 AlternatorOvervoltage Protection Diode Replacement 201 AlternatorOvervoltage Protection Relay Replacement 202 Voltage Regulator Removal Inst...

Page 269: ...he battery battery relay and associated wiring The alternator system consists of the alternator voltage regulator and alternator overvoltage protection diode The external power system consists ofthe e...

Page 270: ...l Function In the case of duplicate circuits performing the same function having the same circuit codes wire sequence numbers are assigned in consecutive order for one of the cir cuits and then begin...

Page 271: ...ion Indicator f DC Clock I DD Voltmeter DE Outside Air Temperature DF Flight Hour Meter E Engine Instrument EA Carburetor Air Temperature EB Fuel Quantity Gage and Transmitter EC Cylinder Head Tempera...

Page 272: ...cing HA Anti icing HB Cabin Heater HC Cigar Lighter HD De ice I Not Used J Ignition JA Magneto K Engine KA Starter L Lightingr LA Cabin LB Instrument LC Landing LD Navigation LE Taxi LF Rotating Beac...

Page 273: ...Pumps y QE Fuel Valves eR Radio Navigation and Communication 6 RA Instrument Landing RB Command RC Radio Direction Finding RD VHF RE Homing RF Marker Beacon RG Navigation RH High Frequency RK UHF RL L...

Page 274: ...lack Black None White Mike Ground 22 Black None Radio Lights Dim 18 Yellow None Mike Audio 22 Tan Tan shielded None None Mike Key 22 White Black Radip Speaker 20 Green None Headphones 22 Blue None Dev...

Page 275: ...y Flashing Beacon Pitot Heat Navigation Lights Instrument Lights Turn and Bank Indicator Hour Meter TOTAL SHORT TERM LOADS Stall WarningSystem Electric Fuel Pump Electric Flap Motor Courtesy Lights 2...

Page 276: ...0 Com lllB 0 76 3 50 Nav 111 0 62 Nav 112 0 62 Nav 114 0 92 PDF 35 0 93 ADF 140 1 12 UGR 2A 0 23 UGR 3 0 23 CP 25 0 41 CP 25B 0 41 CP 125 0 41 AT 50A 1 60 1 60 DME 190 3 00 3 00 Com 120 76 3 50 Nav 12...

Page 277: ...n n V f sViA ii r Oc j...

Page 278: ...d For accurate test the diode must be disconnected from circuit A Check diode as follows 1 Obtain an ohmmeter and set up on OHMS 2 Position the test leads across the diode andrecord the ohmic reading...

Page 279: ......

Page 280: ...roduce an outputto theelectrical system The voltage regulator varies the outputvoltage ofthealternator to meet the require ments of the electrical system loads Anammeter isinstalled into the system to...

Page 281: ...alternator supplies powerto the bus bar through a 60 amp alternator circuit breaker An overvoltagediode in the alternator load protects the alternator against damage due to overload Withalternator pow...

Page 282: ...ATTERY SOLENOID 4 ALTERNATOR 5 BATTERY 6 ALTERNATOR LIGHT AA9A 0S23 ANO SUBSEQUENT 7 OVERVOLTAGE RELAY I AA5B 0693 AND SUBSEQUENT INSIDE FIREWALL J DETAIL A ALT FIELD CIRCUIT BREAKER REAR OF INSTRUMEN...

Page 283: ...T CIRCUIT BREAKERS DETAILA SPARE FUSES AGC 5 AGC 5 AQC 10 AGC 1S AGC ia AGC 1S FUSES O TO rO o IWKAW too U rail tTAUWMM WTOT UK K IT T B IT BCN OASIS CH UM FLAT HT STROM 1 II II II II II 1 V CZDIZZ31...

Page 284: ...n ammeter is incorporated intothebattery system to indicate thecurrent flow either toor from thebattery The ammeter iswired inseries from the battery tothe bus Current will flow from the battery tothe...

Page 285: ...IEDOWN BATTERY HEAT SHIELD COVER TIEDOWN ROD COTTER PIN VENT AA 5 SERIES MAINTENANCE MANUAL BATTERY CABLES BATTERY BOX BATTERY SUPPORT DETAIL A Exploded View of Battery Battery Box Figure 1 24 3 1 Pag...

Page 286: ...5 S I AA 5 SERIES MAINTENANCE MANUAL bli BATTERY RELAY SPACER WASHER NUT WASHER BOLT DIODE ASSEMBLY DETAIL A Exploded View of Battery Relay Figure 2 24 3 1 Page 3 July 15 78...

Page 287: ...4 FF n I MASTER QJ SWITCH o po 5PA3 ON BATTERY X 5PA1 M K AA5 0406 AND SUBSEQUENT AA SA AND AA 5B TOHOURMETER TO DOME LIGHT 4r TO CLOCK 4 AA5 0001 THROUGH AA5 040S TO DOME LIGHT TO CLOCK 4 51DF4 51LA6...

Page 288: ...Level of electrolyte being be low top of plates Charging rate too high Cracked case Shorted cell REMEDY Recharge or replace With master switch OFF check entire DC power sys tem for an open circuit wit...

Page 289: ...ged correctly and tested Battery freezes Undercharged or discharged battery Replace Water added and battery not charged Immediately Always recharge battery for 1 2 hour following addition of water in...

Page 290: ...cableends with samesolution usedin Step 3 5 Rinse areas beingcleaned with clear waterandwipeoff excesswater Allow battery to dry before installation 6 Usea brass wire brushor emery cloth to finish cle...

Page 291: ...AP AND WATER The battery box cover and drain tube should be inspected and cleanedwhen the battery isremoved The battery box cover and drain tube can be cleaned with astrong solution of bicarbonate ofs...

Page 292: ...E CABLE LAST TO PREVENTACCIDENTAL SHORT CIRCUITING DURING INSTALLATION 3 Connect batterycables andcoatterminals with petroleum jellyto reduce corrosion 4 Replace the battery box lid cover 5 Replace th...

Page 293: ...les5PA2 and attachinghardware on battery terminal Slide rubber insulators over the termi nal 5 Connect ground negative cable tobattery see Battery Installation Steps 3 through 6 6 Replace lower cowl a...

Page 294: ...elay The aircraft busvoltage isapplied to theover voltage relay whenthe alternator side of the splitMaster switch is placed to the ON position The relay isdesigned to withstand thenormal busvoltage an...

Page 295: ...BELT ADUSTMENT BOLT ALTERNATOR AA 5 SERIES MAINTENANCE MANUAL 3029 WASHER DETAIL A Alternator Exploded View Figure 1 BRACKET MOUNT 3036 24 3 2 Page 2 July 15 78 iiv e...

Page 296: ...A 0001 thru 0522 AA 5B 0001 thru 0692 S WASHER AA 5 SERIES MAINTENANCE MANUAL Protection Diode Figure 2 DETAIL A 3477 Voltage Regulator Exploded View Figure 3 OVERVOLTAGE PROTECTOR SCREW 24 3 2 Page 3...

Page 297: ...3481 AA5 0001 THROUGH AAS 0491 WIRE NO 5PB6 AA5 0492 AND SUBSEQUENT AA 5A AND AA SB WIRE NO 5PB8 AAS 0001 THROUGH AA5 0491 WIRE NO 5PB7 AA5 0492 AND SUBSEQUENT AA 5A AND AA 5B WIRE NO SPB9 AAS 0001 T...

Page 298: ...T ca ALTERNATOR Locittd oncnittutrwm pniti Locntd enfimvalL t SmFigure 4 fordiagram AA 5 SERIES MAINTENANCE MANUAL OVEHVOLTAQe RELAY Alternator Circuit Wiring Diagram 1978 AA5A 0523 and sub AA5B 0693...

Page 299: ...BUS REOI AA 5 SERIES MAINTENANCE MANUAL LOAO GREEN CROUNO BLACK INDICATOR WHITE Overvoltage Relay Figure 6 24 3 2 Page 6 Dec 15 77 v...

Page 300: ...h Check diode by measuring its resistance in each di rection The front to back resistance shall be 10 to 1 Replace if defective Circuit shorted in wiring Disconnect lead from pin S of regulator and re...

Page 301: ...art See Voltage Regu lator paragraph If charge rate tapers off very quickly and voltage is nor mal check battery for mal function If ammeter shows a low charge rateor any discharge rate andvoltage is...

Page 302: ...MANUAL PROBABLE CAUSE Defective alternator REMEDY 5 Check resistance from ttp terminal of alternator to alternator case Normal indication is 3 4 ohms If resistance Is high or low repair or replace al...

Page 303: ...V...

Page 304: ...AND CLEAR OF BATTERY NOTE When anew belthas beeninstalled recheck the belt tension within 10 to 20 hoursoperation 1 Placealternator near mount and connect leads to alternator 2 Slide alternator into...

Page 305: ...ld adjustments are possible 1 Open right half upper cowl 2 Disconnect ground negative cable from battery terminal Pull cable clear of battery and battery box See Battery Removal 3 Disconnect andidenti...

Page 306: ...ot s Operating Handbook Set engine at 1500 rpm 2 Ammeter should indicate aheavy charge rate positive with all electrical equipment off 3 Observe that charge rate positive tapers off in 1 3 minutes 4 T...

Page 307: ...dO 0i m r j i...

Page 308: ...al maintenance When external powersource isattached powergoes throughthe ammeterto the bus The masterswitch shouldbe placed in the OFF position when external powerisapplied EXTERNAL POWER RECEPTACLE C...

Page 309: ...I lk...

Page 310: ...emoval 3 Remove cableattachinghardware and remove cables 4 Remove receptacle attaching hardware andremove receptacle B External Power Receptacle Installation CAUTION ENSURE GROUND NEGATIVE CABLE IS CL...

Page 311: ...RECEPTACLE AA 5 SERIES MAINTENANCE MANUAL NUT POWER CABLE External Power Receptacle Figure 201 3 84 LOCKWASHER V 4 NUT WASHER 24 4 1 Page 202 July 15 78 B SSk...

Page 312: ...SAFETY BELTS Description Operation General Shoulder Harnesses Lap Belts Maintenance Practices Rear Seat Shoulder Harness Removal Installation Front Seat Shoulder Harness Removal Installation Rear Seat...

Page 313: ...Description General Maintenance Practices Canopy InnerTrim Paneling Removal Installation Aft Fuselage Moulding Removal Installation H Aft Fuselage Inner Trim Paneling Removal Installation 25 6 0 MISCE...

Page 314: ...U P AA 5 SERIES MAINTENANCE MANUAL NUMBER pAGE 25 7 0 INTERIOR CARE Maintenance Practices 201 Cleaning 201 25 Page 3 Dec 15 77...

Page 315: ......

Page 316: ...place Theseat backs pull forward to allow entryto therear seat area orto allow access to bottom cushion snaps which secure the bottom cushion to the seat pan 3 Rear Seat Therear seat in the AA 5 the A...

Page 317: ...1978 CUSHION AA 5 SERIES MAINTENANCE MANUAL RELEASE LATCH 1977 CUSHION Front Seat Figure 1 3172 25 1 0 Page 2 July 15 78 x ak...

Page 318: ...iddlSSy SEAT RELEASE LATCH AA 5 SERIES MAI NTENANCE MANUAL Rear Seat Typical Figure 2 SHOULDER HARNESS COLLAR ASSEMBLIES 3471 25 1 0 Page 3 Dec 15 77...

Page 319: ...ng brackets 2 Install screws attaching mountingbrackets to innerseat tracks Rear Seat Removal Installation A Seat Back Removal 1 Slide front seats as far forward as possible 2 Fold rear seat bottom fo...

Page 320: ...rd andaft several timesto ensure easy movementat hinge points 2 Seat Back Installation a Fold rear seat bottom forward b Align collarassemblieson each side of seat back with hinge holes in support bra...

Page 321: ...aft of the baggage compartment The front seatshoulder harnesses are anchored to mountingplates located on the fuselage side walls justaft of the front seats When not in use theshoulder harness straps...

Page 322: ...AA 5 SERIES MAINTENANCE MANUAL Lap Belts and Shoulder Harnesses Figure 1 25 2 0 Page 2 July 15 78 3Hj...

Page 323: ...Removal Installation See Figure 1 A Rear Seat Outer Lap Belts Removal 1 Locate point atwhich rear seat outer lap belts are attached to brackets mounted to the fuselage floor on the left and right outb...

Page 324: ...ap Belt Removal Installation See Figure 1 A FrontSeat andOuter LapBelt Removal 1 Locate bracketswhich are mounted to the floor to the left and right sides ofeach front seat assembly Locate pointatwhic...

Page 325: ...red to the corner of the baggage compartment floor see Figure 201 The straps are normally arranged in a crossed position for securing baggage Each of the two 2 straps directly behind the rear seat is...

Page 326: ...gain access to washer and nut for particular strap assembly being removed 4 Remove screw securing strap end fitting to baggage floor Note theorder in which the parts are aligned screw washer bushing w...

Page 327: ...arette lighter see Figure 2 Cigarette Lighter Wiring Schematic The console assembly also coversthe control surface pulley groups in the cabin area The console sections can be removed individually or e...

Page 328: ...CONSOLE AA 5 SERIES MAINTENANCE MANUAL SIOE CONSOLE Console Assembly Figure 1 CONNECTOR 51HC2 g JP 1 6 t f 3 Cigarette Lighter Wiring Schematic Figure 2 AFT CONSOLE ASSEMBLY yO 5HC4 LIGHTER 3425 25 4...

Page 329: ...on rear floor carpet around console 2 Remove aft console attach screwsand remove aft console D Side Console Removal NOTE Removal ofconsole side panels provides access for inspection and servicing oft...

Page 330: ...rcarpet to floor G Top Console Installation 1 Aligntop console panel with metal console frame 2 Install screws around side flange of top console H Forward Console Installation 1 Install upper and lowe...

Page 331: ...py inner paneling and aft fuselage mouldings consist of a thermo plastic material and serve as trims around the canopy and aft fuselage windows see Figure 1 The aft fuselage inner paneling consists of...

Page 332: ...AA 5 SERIES MAINTENANCE MANUAL Inner Paneling Figure 1 25 5 0 Page 2 Dec 15 77...

Page 333: ...nel 4 Install rivetssecuring flange of panel to top portionof forward canopy bow 5 Installrivetssecuringside panelto back flange of canopy 6 Install canopy See Chapter 52 Aft Fuselage Moulding Removal...

Page 334: ...screws attaching panel to baggage door B Aft Fuselage Inner Trim Paneling Installation 1 If new panelingis to be used drill out holes needed for screws 2 Fit paneling overshoulderharness mountingbrack...

Page 335: ...fuselage side trim panel The rear seat armrests are I attached to the left and right aft panels 5 Glareshield and Deck Assemblies The glareshield and deck assemblies are mounted to the top of the inst...

Page 336: ...bottom and some are in a bracket attached to the floor of the aircraft 10 Storage Box Approach Plates and Owner s Manual Astoragebox is available asoptional equipment The box is a 6 inch by 10 inch b...

Page 337: ...a dull knife then cleaned up with a spot remover Oily spotsmay be cleaned with household spot removers usedsparingly Beforeusingany solvent read the instruc tions on the container and test it on an o...

Page 338: ...Maintenance Practices Servicing Lubrication of Aileron Bearingsand Control Column Removal Installation Aileron and Torque Tube Removal Installation Aileron Bearing Removal Installation Aileron Bearin...

Page 339: ...on Rudder Pedal Removal Installation f Rudder Cable Removal Installation Rudder Bearing Removal Installation Rudder Bearing Wear Limits I Rudder BellcrankandTorque Tube Repair Adjustment Test Rudder R...

Page 340: ...system consists of a conventional rudder actuated by control cables extending from the rudder pedal linkage 4 Longitudinal Control System The longitudinal control system consists of an anti servo elev...

Page 341: ...Limits Elevator Trim Tab Free Play Reduction Elevator Bellcrankand Torque Tube Repair Adjustment Test Elevator Rigging Elevator Balancing Elevator Trim Tab Free PlayMeasurement Cleaning Painting Gene...

Page 342: ...oting Stall Warning System Aircraft AA5 0001 through 0834 AA5A 0001 through 0054 and AA5B 0001 through 0181 Troubleshooting StallWarning System AircraftAA5A 0055 and Subsequent and AA5B 0182 andSubseq...

Page 343: ...erweight and control stop are mounted on the outboard end of the torque tube The forward channels are riveted to the torque tube and form the contour of the aileron leading edge The skin is bonded to...

Page 344: ...SSEMBLY COUNTER WEIGHT ASSEMBLY CHAIN OUTBOARD HINGE POINT SPROCKET AA 5 SERIES MAINTENANCE MANUAL REAR CHANNEL Aileron Control System Figure 1 3106 TORQUE TU8E TRIM TAB CARRY THROUGH PULLEY 27 1 1 Pa...

Page 345: ...SPROCKET CHAIN AILERON CONTROL CABLE IDLER PULLEY CONTRO COLUMN SUPPORT ASSEMBLY AA 5 SERIES MAINTENANCE MANUAL CONTROL WHEEL Control Column Figure 2 3145 27 1 1 Page 3 July 15 78...

Page 346: ...HING FUMES KEEP AWAY FROM FLAMES 1 Use Stoddard solvent orequivalent to wash all grease from the needle bearings and thrust bearings 2 Inspectbearings forexcessive wear or damage Replace if defective...

Page 347: ......

Page 348: ...their mounting holes align withthose inthe wing 4 Secure with bolts 7 washers 6 and nuts 5 Torque to 50inch pounds 5 Securewith bolt 3 washers 2 and nut 1 6 Install wingtip asdescribed in Chapter57 7...

Page 349: ...2 WASHER 3 BOLT 4 CONTROL HORN 5 NUT 6 WASHER 7 BOLT 8 CONTROL STOP 9 BEARING BRACKET 14 10 SPACERS 11 AILERON TORQUE TUBE 12 PLUG 13 NUT 14 WASHER 15 BOLT 16 AILERON 17 SHIMS Aileron and Torque Tube...

Page 350: ...REMOVAL WOODEN GUIDE AA 5 SERIES MAINTENANCE MANUAL SHANK TURNED FOR FORCE FIT INTO TORQUE TUBE Torque Tube Guide Figure 402 Aileron Bearing Removal Installation Figure 403 TORQUE TUBE 3125 27 1 1 Pag...

Page 351: ...nd bolt 4 from cable clevis end 5 and remove cable clevis H 5 from bellcrank 6 4 Remove nut 7 washer 8 and bolt 9 5 Remove guards 10 from pulleys 11 to dearcables 12 6 Remove nuts 13 and washers 14 an...

Page 352: ...asher 9 Bolt 10 Guard 11 Pulleys 12 Cable AA 5 SERIES MAINTENANCE MANUAL 13 Nut 14 Washer 15 Pulley Bracket 16 Cotter pin 17 Nut 18 Washer 19 Bolt 20 Clevis 21 Control Horn 22 Link 23 Turnbuckle Ailer...

Page 353: ...into clevis 17 and place link and clevis In control hom 5 Secure with bolt 3 washer 2 andnut 1 Torque to standard value perChapter 91 1 5 Install emergency locator transmitter access panel per Chapter...

Page 354: ...N LEFT SIDE IDENTICAL 1 Nut 2 Washer 3 Bolt 4 Link 5 Control Horn 6 Cotter Pin 7 Guard 8 Bracket 9 Nut 10 Washer 11 Bolt 12 Bracket 13 Guard 14 Pulley 15 Cable 16 Pulley Carry Through Cable Removal In...

Page 355: ...ter 91 9 If autopilot is used install perChapter 22 10 Rigcontrols perAdjustment Test Paragraph 1 thischapter 11 Install console trim per Chapter25 Control Column Disassembly Assembly A Control Column...

Page 356: ...lt 10 Control Wheel Shaft 11 Universal 12 Nut AA 5 SERIES MAINTENANCE MANUAL 23 IT 15 V3 4 3 Control Column Removal Installation Figure 406 12 13 13 Washer 14 Support 15 Nut 16 Washer 17 Bolt 18 Guard...

Page 357: ...crank 36 on sprocket 5 such that attachment holes align Secure with bolts 35 washers 34 andnuts 33 Torque to standard value See Chapter 91 6 Place washers 32 andsleeve 31 on bolt 28 7 Place needle bea...

Page 358: ...J I AA 5 SERIES MAINTENANCE MANUAL ControlColumn Disassembly Assembly Sheet 1 of 2 Figure 407 27 1 1 Page 411 Dec 15 77...

Page 359: ...apter 91 20 Installand align chain 2 as follows a Place control wheel shafts 48 onuniversals 11 and secure with bolts 49 washers 50 and nuts 51 b Use astraight piece ofwood 52 and two clamps 53 tohold...

Page 360: ...torque tube Incertain high time in service aircraft this condition has been traced to theenlargement orelongation of theattach holes intheaileron torque tube 11 Figure 401 attheaileron control hom 4...

Page 361: ...C i Li v J U 7 j...

Page 362: ...cribed in Disassembly Assembly Paragraph 9 this chapter 12 Install locking clips on turnbuckles and remove control wheel lock 13 Useriggingfixture to check ailerontravel ascontrol wheel is moved throu...

Page 363: ...I cSoN EURFAC HINGE POINT UNDERBAUNCE MRLml WING fTATlON 140 gure 501 HORIZONTAL DATUM NEUTRAL CONTROL SURFACE 0VERBALANCE SurfaceStaticBaU ee figure 502 3886 27 1 1 Page 50s...

Page 364: ...ment will not be necessary 7 The balancing device must include a means of determining when the chord line of the control surface is horizontally level indicating a balanced condition exists 8 Control...

Page 365: ...FACE MASS BALANCE WEIGHT k HINGE LINE M CONTROL SURFACE HORIZONTAL DATUM EXAMPLE OF AILERON CONTROL SURFACE ON BALANCING DEVICE KNIFE EDGE PARALLEL LEVELING ADJUSTMENT SCREW BOTH SIDES f HORIZONTAL DA...

Page 366: ...ion remove weight from aileron mass balance weight until aileron balances by a shaving away lead material from top and bottom of weight Maximum 0 125 inch or b drilling holes in either side of weight...

Page 367: ...MASS BALANCE WEIGHT S E DETAIL DETAIL A EXAMPLE OF GAGE WEIGHT LOOPED OVER MASS BALANCE WEIGHT SUP PORT TUBE WHEN NECESSARY TO MOVE GAGE WEIGHT FORWARD OF HINGE LINE Typical Aileron Balancing Figure...

Page 368: ...IES MAINTENANCE MANUAL HORIZONTAL DATUM INDICATOR HORIZONTAL DATUM INDICATOR Typical Elevator Balancing Figure 505 MASS BALANCE WEIGHT REMOVE TIP CAP FOR ACCESS DISTANCE X GAGE WEIGHT CHORD LINE ft 38...

Page 369: ...re determining new balance k It is unnecessary to remove the elevator extension and tip cap on AA 5 Models 1 during mass balance weight rework E Rudder Balancing See Figure 503 and 506 NOTE Rudder tip...

Page 370: ...IZONTAL DATUM INDICATOR AA 5 SERIES MAINTENANCE MANUAL CHORD LINE Typical Rudder Balancing Figure 506 MASS BALANCE WEIGHT REMOVETIP CAP FOR ACCESS DISTANCE X GAGE WEIGHT 3890 27 1 1 Page 509 January 4...

Page 371: ...7 If gage weight is forward of the distance limits given in Table 1 underbalance condition the mass balance weight must be replaced with a heavier weight a Remove rudder tip cap to gain access to mass...

Page 372: ...ANUAL MAINTENANCE PRACTICES CLEANING PAINTING CAUTION WHEN CONTROL SURFACES ARE PAINTED THEffi BALANCE IS CHANGED ALWAYS CHECK BALANCE AFTER PAINTING Clean and paint the ailerons in accordance with Ch...

Page 373: ......

Page 374: ...d atip The ribs are bonded toboth the torque tube and theskin to form a rigid struc ture that can be positioned by the torque tube A fixed ground adjustable trim tab is riveted to the lower trailing e...

Page 375: ...CENTERING SPRINGS CONTROL HORN AA 5 SERIES MAINTENANCE MANUAL TURNBUCKLE Rudder System Figure 1 Rudder Assembly Figure 2 BELLCRANK SKIN BOND LINE TRIM TAB SCREW 27 2 1 Page 2 Nov 15 76 3B i i...

Page 376: ...ring Lubrication Apply MIL L 7870 See Chapter 12 oil tothe torque tube and rudder bearings Also apply MIL L 7870 See Chapter 12 oil to the rudder control hom clevis bolts B Rudder Pedal Lubrication Ap...

Page 377: ...l l i l P JA l H...

Page 378: ...ion See Figure401 1 Position ruddersuchthat wirebundle 14 canbe fed through access holein vertical fin Feed wire bun dle through bottom of vertical fin Connect ground strap 2 Place upper spacer 13 on...

Page 379: ...E MANUAL Rudder Removal Installation Figure 401 1 NUT 2 WASHER 3 BOLT 4 BELLCRANK 5 SCREW 6 HINGE 7 CONNECTOR 8 CONNECTOR 9 RUDDER 10 TORQUE TUBE 11 SPACER 12 HINGE 13 SPACER 14 CONTROL STOP 27 2 1 Pa...

Page 380: ...udder Pedal Installation See Figure402 1 Install a bearing assembly 18 in the left end of each rudderbarassembly 21 2 Position the rudder barassemblies 21 such thattheiropenendsslide overthe bearings...

Page 381: ...otter Pin 11 Nut FIREWALL DETAIL C 10 11 12 14 AA 5 SERIES MAINTENANCE MANUAL FLOOR Rudder Pedal Removal Installation Figure 402 DETAIL B 12 Washer 13 Clevis Bolt 14 Rudder Cable 15 Nut 16 Washer 17 B...

Page 382: ...le Select the clevis end 5 of thelong cable andattach it to the rudder bellcrank 6 with clev isbolt 4 washer 3 nut 2 and cotterpin 1 Attach bothrudder cables to thebellcrank 6 2 Feed both cables 7 int...

Page 383: ...9 Guard 10 Pulley Assembly 11 Nuts AA 5 SERIES MAINTENANCE MANUAL 12 Washers 13 Studs t 14 Aircraft Floor 15 Pulley Assembly 16 Cotter Pins 17 Nuts 18 Washers 19 Clevis Bolts 20 Cable Clevis 21 Contro...

Page 384: ...ralpartof the rudder If play is noted determine the largest diameter of the rudder torquetubeandrudder bellcrank bolt holes If thelargest diameter exceeds 0 2505 inch open the existing bolt holes inth...

Page 385: ...00_r I...

Page 386: ...ilcone per Chapter 53 10 Reinstall removed trim per Chapter 25 B Rudder Travel Adjustment See Figure502 1 Remove tailcone per Chapter53 2 Position rudder rigging fixture DE 0002 501 on vertical fin as...

Page 387: ...FIREWALL AA 5 SERIES MAINTENANCE MANUAL 7IN WO00EN BLOCKS BELLCRANK ASSEMBLY PHENOLIC BLOCKS CCLAMPS Rudder Return Tension Adjustment Figure 501 _ i_ i 27 2 1 Page 502 Nov J5 76 flS...

Page 388: ...CONTROL STOP WATER LEVEL 77 fflBSN AA 5 SERIES MAINTENANCE MANUAL BELLCRANK ASSEMBLY Rudder Travel Adjustment Figure 502 RUDDER RIGGING FIXTURE DE C002 501 27 2 1 Page 503 Nov 15 76...

Page 389: ...CH MIN 1 Screws 2 RudderTip 3 Nut 4 Washer 5 Nut 6 Washer 7 Bolt 8 Rib 9 Rudder 10 Shims 11 Hinge AA 5 SERIES MAINTENANCE MANUAL Rudder Tip Fin Clearance Adjustment Figure 503 3167 27 2 1 Page 504 Dec...

Page 390: ...dder Trim Tab Adjustment The rudder trim tab consists of a ground adjustable tab located on the lower end of the rudder trailing edge This tab can be bent to provide rudder trim Bend the tab opposite...

Page 391: ...i n MiJ iV r r i J O WilitK...

Page 392: ...NCE PRACTICES CLEANING PAINTING 1 Cleaning Painting CAUTION WHEN CONTROL SURFACES ARE PAINTED THEm BALANCE IS CHANGED ALWAYS CHECK BALANCE AFTER PAINTING Refer to Chapter 20 for proper cleaning and pa...

Page 393: ...1AW V i t V...

Page 394: ...anels Outboard of the rib is covered by a plastic tip The tab extends the full length of the elevator On AA 5A and AA 5B aircraft the elevator is of similar construction except that it contains more r...

Page 395: ...HINGE AA 5 SERIES MAINTENANCE MANUAL ELEVATOR CONTROL SURFACE Elevator Control System Figure 1 3110 27 3 1 Page 2 Nov 15 76 Htv s...

Page 396: ...ANCE WEIGHT AA 5A AND AA SB RIB AA 5 SERIES MAINTENANCE MANUAL ANTI SERVO TAB Elevator Control Surface Figure 2 TIP AA50200 AND SUBSEQUENT NOTE RIGHT SIDE SHOWN LEFT SIDE MIRROR IMAGE 27 3 1 Page 3 No...

Page 397: ...TRIM TAB CONTROL CABLE TRIM CONTROL AA 5 SERIES MAINTENANCE MANUAL YOKE ASSEMBLY TRIM NOSE UP TRIM NEUTRAL TRIM NOSE DOWN Elevator andTrim Linkage Figure 3 27 3 1 Page 4 July 15 78 H5 Sk...

Page 398: ...n 1 Remove tailcone per Chapter 53 2 Use aclean lint free cloth to wipe excess grease and foreign material from theactuator shaft screw threads 3 Applyacoating of MIL G 7711 See Chapter 12 grease to t...

Page 399: ...in hinge 17 with holein hori zontal stabilizer 14 Install screw 16 3 Holdelevator 15 In fulldown positionand install screw 18 4 Attach ground strap 13 to horizontal stabilizer 14 5 Alignmountingholesi...

Page 400: ...cket 9 Nut 10 Washer AA 5 SERIES MAINTENANCE MANUAL 11 Bolt 12 Bellcrank 13 Ground Strap 14 Horizontal Stabilizer 15 Elevator 16 Screw 17 Hinge 18 Screw 19 Torque Tube 20 Trim Tab Elevator Removal Ins...

Page 401: ...otter pin 1 8 Align forward arm of yoke 13 with hole inelevator 20 9 Place bushing 12 inarm ofyoke 13 and secure toelevator 20 with washer 11 and bolt 10 Torque to standard value and safety wire with...

Page 402: ...r 12 Spacer AA 5 SERIES MAINTENANCE MANUAL 13 Yoke Assembly 14 Nut 15 Washer 16 Bolt 17 Safety Wire 18 Bolt 19 Washer 20 Elevator 21 Torque Tube 22 Bellcrank 23 Horizontal Stabilizer 24 Hinge 25 Thin...

Page 403: ...sher I 23 19 Bolt 20 Bellcrank 21 Torque Tube Elevator Disassembly Assembly AA 5 Aircraft Figure 403 22 Bolt 23 Washer 24 Trim Tab Arm 25 Cotter Pin 26 Nut 27 Washer 28 Bolt 29 Bracket 30 Yoke Assembl...

Page 404: ...ure 403 1 Elevator Linkage Assembly a Position trim arms 24 onright yoke 30 and secure roll pin 49 bolts 47 washers 46 and nuts 45 Torqueto standard value SeeChapter 91 b Assemble two halves ofyoke as...

Page 405: ...e 404 1 Trim Tab Removal a Removescrews 1 and pulltip 2 fromelevator 3 b Remove cotterpin 4 nut 5 washers 6 roller 7 bushing 8 washer 9 and bolt 10 from trim tab arm 11 c Remove cotterpin 12 nut 13 wa...

Page 406: ...inge 20 Trim Tab 21 Nut 22 Washers 23 Bolt 24 BeUcrank 25 Safety Wire 26 Bolt 27 Rasher 28 Bushing 29 Yoke Assembly 30 Torque Tube 31 Cotter Pin 32 Nut 33 Washers 34 Bolt 35 Hinge 36 Nuts 37 Washers 3...

Page 407: ...standardvalue See Chapter91 e Place washer 27 andspacer 28 on bolt 26 f Align hole in front arm of yokeassembly 29 withmounting hole inelevator 3 forward of torque tube 30 g Insert bolt 26 with bushi...

Page 408: ...sembly 33 c Driveroll pin 34 from flexible shaft 25 and pull shaft 32 from flexible shaft 25 d Remove cotter pin 35 nut 36 washers 37 and 38 and bolt 39 from trim wheel 40 e Driveroll pin 41 from trim...

Page 409: ...t 23 Washer 24 Bolt 25 Flexible Cable 26 Bushing 27 Support 28 Bushing 29 Support 30 Roll Pin 31 Pinion Gear 32 Shaft 33 Bracket Assembly 52 34 RoU Pin 53 35 Cotter Pin 54 36 Nut 37 Washer v 38 Washer...

Page 410: ...22 c Place one end ofuniversal 18 in rear end oftorque tube 21 Secure with roll pin 17 and safe ty wire pin with 0 032 wire d Slide afttorque tube 9 through lower elevator cable access hole and throu...

Page 411: ...the three rivetssecuring the trim tab arm to the trim tab Use a soft brush to remove all grindings and other foreign matter from the end of the trim tab 4 Remove the tape from the openings Using a dri...

Page 412: ...at the elevator bellcrank 4 The following isan acceptable repair from astructural standpoint A Remove the tailcone assembly in accordance with Chapter 53 B Hold the elevator bellcrank 4 Figure 406 fir...

Page 413: ...A 5A AA 5B 00 I AA 5 SERIES MAINTENANCE MANUAL Elevator Bellcrank and Torque Tube Repair Figure 406 1 BOLT 2 WASHER 3 NUT 4 BELLCRANK 5 TORQUE TUBE 6 ELEVATOR 7 CONTROLSTOP 27 3 1 Page 415 January 4 8...

Page 414: ......

Page 415: ...ward of the trimtab and in the center of the elevator 9 Hold the elevator at neutral elevator streamlined with horizontalstabilizer and center the bubblein the angle vernier scale Lock the zero adjust...

Page 416: ...AA 5 SERIES MAINTENANCE MANUAL Elevator Rigging Fixture Figure 501 27 3 1 Page 502 Nov 15 76 k...

Page 417: ...jtHflSN ELEVATOR TURNBUCKLES ITWOCENTERTURNBUCKLES AA 5 SERIES MAINTENANCE MANUAL Elevator Turnbuckles Figure 502 27 3 1 Page 503 July 15 78...

Page 418: ...inst thecontrol stop and measure thethrow of the con trol on the angle vernier scale 1 13 Adjust the bottom elevatorstop to obtain 17 2 indication on the angle vernier scale Tighten control k stop loc...

Page 419: ...AA 5 SERIES MAINTENANCE MANUAL Elevator Control Stops Figure 503 27 3 1 Page 505 Nov 15 76...

Page 420: ...e elevator stop to obtain23 i 1 indication on the fixture Tighten lock nut 11 Move the elevator to its full down position against the controlstop and measure the throw of the con trol on the rigging f...

Page 421: ...ontal stabilizer and note reading on fixture 4 Fixture shall indicate 19 2 down throw of trim tab If tab throw isnotwithin tolerance adjust rig ging as follows a Position control wheel to itsneutral 0...

Page 422: ...n streamlined with horizontal stabilizer and note reading p on fixture 4 Fixture shall indicate 29 1 up throw of trim tab If tab throw is not within tolerance adjust rigging as follows a Position cont...

Page 423: ...all partson the can B Measurement of Free Play 1 Using 8 to 10 pounds of hand pressure press down on the elevator trim tab at the inboardend to remove all of the slack from the system 2 Slowly release...

Page 424: ...AA 5 SERIES MAINTENANCE MANUAL SUITABLE WOOD OR PLYWOOD STOCK TRIM TAB TRIM TAB ARM Figure 507 Elevator Trim Tab Free Play Measurement Sheet 1 Of 2 ACTUATOR 27 3 1 Page 510 January 4 80...

Page 425: ...NANCE PRACTICES CLEANING PAINTING 1 General CAUTION WHEN CONTROL SURFACES ARE PAINTED THEIR BALANCE IS CHANGED ALWAYS CHECK BALANCE AFTER PAINTING Referto Chapter 20 for proper cleaning and painting p...

Page 426: ...i...

Page 427: ...the flaps against the aerodynamic load imposed in flight In addition it is a one way mechanismthat effectively locks the flaps in position whenthe motor is stopped Flap position is indicated by means...

Page 428: ...SUPPORT BEARING FLAP AA 5 SERIES MAINTENANCE MANUAL INDICATOR LIMIT SWITCHES Flap System Figure 1 FLAP TORQUE TUBE FLAP ACTUATOR 3142 27 5 1 Page 2 Nov 15 76 Bjv...

Page 429: ...BLER RIB FLAP TORQUE TORQUE TUBE TUBE HORN AILERON TORQUE TUBE HOLE AA 5 SERIES MAINTENANCE MANUAL BUSHING HONEYCOMB RIB TUBES Flap Surface Structure Figure 2 SKIN BOND LINE SKIN 27 5 1 Page 3 Nov 15...

Page 430: ...ACKET AA 5 SERIES MAINTENANCE MANUAL TORQUE TUBE BEARING PUSH PULL LINKAGE Flap Drive Mechanism Figure 3 GEARBOX CENTER TORQUE TUBE BEARING HINGE BOLT MOUNTING BRACKET 27 5 1 Page 4 Nov 15 76 L SfilV...

Page 431: ...ward limit of travel is reached At this point the up limit switch is opened breaking the DC supply to the motor causing the motor to stop The flap switch has a detent in its UP position and the switch...

Page 432: ...AA 5 SERIES MAINTENANCE MANUAL Flap Electrical System Schematic Figure 4 27 5 1 Page 6 Nov 15 76 y v...

Page 433: ...voltage is present check that pin 3 of connector is grounded If not replace switch Disconnect plug P4 from connector J4 Hold flap switch in DOWN position and jumper across down limit switch On plug P...

Page 434: ...not present replace flap switch If voltage is present check that pin 1 of J4 is grounded If not replace flap switch Disconnect plug P4 from connector J4 Hold flap switch in DOWN position and jumper ac...

Page 435: ...ASTER switch to OFF B Torque Tube Oilite BearingLubrication 1 Remove trim perChapter 25 to expose flap torque tube bearings 2 Inject a small amount of MIL L 7870 oil SeeChapter 12 between torque tube...

Page 436: ...j t Xi v 1 I I I 1 il i...

Page 437: ...erChapter91 and safety wire bolts 6 with 0 032 wire 3 Install bolt 3 washer 2 and nut 1 Torque perChapter91 4 Install aileron perSection 27 1 0 this chapter 5 Install trim per Chapter 25 Flap Drive Re...

Page 438: ...4 NUT i ii 15 WASHERS 29 WASHER 16 BOLT 30 BUSHING 17 TORQUE TUBE MOUpSBRACKET 31 BOLT 18 COTTER PIN 32 MOUNTING BRACKET 19 NUT 33 DRIVE MECHANISM 20 WASHERS 34 NUT 21 BOLT 35 WASHER 22 ACTUATOR FITTI...

Page 439: ...bolt 21 washer 20 nut 19 and cotter pin 18 8 Connect electrical connector 24 to its mating connection in the aircraftwiring bundle 9 Placelinkages 42 in horns on torque tube 13 Secure with bolts 12 w...

Page 440: ...IL A SCREW WIRE AA 5 SERIES MAINTENANCE MANUAL 1 Flap Switch Knob 2 Flip Switch 3 MountingNut 4 Screws 5 Microswitch 6 Pad 7 Bracket NUT CLAMP DETAIL B Flap Wiring Removal Installation Figure 402 DETA...

Page 441: ...ign 2 Place microswitch 5 on pad 6 andsecurewith screws 4 3 Reconnect wires 4 Install trim per Chapter 25 5 Wiring Removal InstaUation A Wiring Removal 1 Ensurethat electrical poweris off priorto remo...

Page 442: ...vj k 1 X O V l v...

Page 443: ...provide proper flap position Tighten locknuts 4 whenproper flap position is obtained 7 Check flap position indicator in forward console for correct alignment Ifadjustment isrequired loosen the setscr...

Page 444: ...ained 7 Check flap position mdicator in forward console for correct alignment If adjustment isrequired loosen the setscrew in the indicator andposition asrequired 8 With power on cycle theflaps to the...

Page 445: ...AA 5 SERIES MAINTENANCE MANUAL MAINTENANCE PRACTICES CLEANING PAINTING 1 Cleaning Painting Refer to Chapter 20 for proper cleaning and painting procedures 27 5 1 Page 701 January 4 80...

Page 446: ...ih i...

Page 447: ...re 1 The gust lock Is composed of a formed metal rod attached to a placard tab The lock is installed by positioning the control wheel until the hole in Its shaft is aligned with the hole In its guide...

Page 448: ......

Page 449: ...ompleting the ground to the stallwarning hom The hom then soundsaslongasthe switch remains closed On Aircraft AA5 0001 through 0834 AA5A 0001 through 0054 andAA5B 0001 through 0181 input power is appl...

Page 450: ...U STALL WARNING O VjO 51FC1 X I I 51FC2 SA AND SUBSEQUENT AA5A 0S5 AND SUBSEQUENT AA5B 0182 AND SUBSEQUENT c STALL SENSOR SWITCH ACCESS Z___ JP 13 3 RIGHT WING ROOT JP2 1 5FC3 O 5FC4 AA5 SFC6 IAA5A BI...

Page 451: ...d switch Repair or replace if defective If 12V is present re place stall warning hom If 12V is not present replace time delay controller Horn remains on when sensor switch is open Disconnect the stall...

Page 452: ......

Page 453: ...nection studs 10 3 Remove washers 11 nuts 12 and washers 13 and 14 from studs 10 4 Remove stall warning hom 15 from mounting bracket 16 B Stall Warning Hom Installation See Figure 401 1 Position staU...

Page 454: ...7 Wires 8 Nuts 9 Washers 10 Studs 11 Washers 12 Nuts 13 Washers 14 Washers 15 Stall Warning Horn 16 Bracket 17 Adjustment Screw 18 Wires 19 Screws 20 Controller AA 5 SERIES MAINTENANCE MANUAL 1 5 JO...

Page 455: ...at incorrect speed adjustswitchas follows a Remove stall sensorswitch accesspanel 1 Figure 401 b Loosen screws 2 securing sensor switch c Reposition switchslightly downward to decrease speedat which h...

Page 456: ......

Page 457: ...Vapor Hazards FUEL STORAGE SYSTEM Description Operation General Adjustment Test Testing Fuel Tanks Inspection Check Checking Fuel Tank Leaks Checking Fuel Tank Caps Checking Fuel Tank Drains Approved...

Page 458: ...al Installation Electric Fuel Pump Removal Installation Fuel System Adjustments Tests Approved Repairs 28 3 1 FUEL INDICATING SYSTEM Description Operation General f Troubleshooting Maintenance Practic...

Page 459: ...ides the connection for the fuel primer line Two fuel gauges mountedabove the fuel selector valve are of the electrical type and are connected to fuel sending units in each tank No gascolator or fuel...

Page 460: ...NTENANCE MANUAL FUEL PRESSURE GAUGE FUEL GAUGE TRANSMITTER FINGER STRAINER FUEL SUMP TANK RIGHT HAND PRIMER CARBURETOR MIXTURE CONTROL THROTTLE FUEL GAUGES S n FUEL TANK QUICK DRAIN FUEL TANK CAP FUEL...

Page 461: ...IES MAINTENANCE MANUAL FUEL GAUGE TRANSMITTER FUEL PRESSURE GAUGE FUEL TANK CAP FINGER STRAINER FUEL SUMP TANK RIGHT HAND PRIMER CARBURETOR MIXTURE CONTROL FUEL PRESSURE PICK UP POINT AA SB SHOWN SCUP...

Page 462: ...devices that supply electrical powerto the auxiliary fuel pump and the fuel quantity indicators is shown in Figure 2 f FUEL GAUGES CT P 5EB1 5A JUMPER WIRE ia SA FUEL PUMPSTROBE Fuel System Electrica...

Page 463: ...d clean strainer Fiush tank clean prior to re assembly Obstruction in pressure gauge line Remove all fittings and lines starting at carburetor inlet and inspect and clean as nec essary No or low fuel...

Page 464: ...e fuse in panel Loose connections or open circuit Tighten connections repair or replace wire No fuel quantity indication in one tank Defective gauge or transmitter Check per Fuel Indicating System Cha...

Page 465: ...nga sample of fuel to be taken On Aircraft AA5A 0523 and subsequent and AA5B 0693 and subsequent the quick drains aresimilar to those shown in Figure 201 andinclude a plunger attachedto the fitting Th...

Page 466: ...GHT DRAIN SUMP LEFT TANK SUMP DRAIN a AA 5 SERIES MAINTENANCE MANUAL NOTE LEFT SIDE ONLY SHOWN SUMP FAIRING NOT SHOWN FOR CLARITY Fuel Sump and Fuel Tank Drain Operation Figure 201 28 0 Page202 Dec 15...

Page 467: ...ft is in a hangar ensure that vapors do not accumulate to explosive or toxic levels in the hangar WARNING WHEN FUEL IS BEING DRAINED THERE IS LITTLE CONTROL OVER THE RELEASE OF FUEL VAPOR THIS VAPOR S...

Page 468: ...elector 5 Connect nitrogen supply and pressure gauge or manometer to fittingon fuel line that was disconnected in Step 4 Ilgpf 6 Place suitable containers totaling approximately 26gallon capacity unde...

Page 469: ...similarly constructed the service information in this Sec tionisapplicable to all models Due to theincreased capacity of the optional Model AA 5A andthe Model AA 5B tanks thetankarea extends from the...

Page 470: ...SSURE TO THE TANK WITHOUT A GOOD REGULATOR AND A POSITIVE SHUTOFF IN THE SUPPLY LINE DO NOT PRESSURIZE THE FUEL TANK TO MORE THAN 0 5 PSI OR DAMAGE MAY OCCUR 5 Apply pressure slowly until 0 5 psi is o...

Page 471: ...i t l...

Page 472: ...ot begun causing a flight hazard If a leak causing a flight hazard should occur at a place where there are no facilities available to make an acceptable repair it is recommended that the leaking tank...

Page 473: ...f...

Page 474: ...BLE AND VOLATILE SOLVENTS KEEP SEALANTS AWAY FROM HEAT SPARKS AND FLAME PROPER PRECAUTIONS USED WITH FLAMMABLE MATERIAL MUST BETAKEN WHEN APPLYING SEALANTS COMPLY WITH ALL LOCAL SAFETY REGULATIONS USE...

Page 475: ...not available for use entire contents of kit can be mixed as each kit contains base compound and accelerator in proper proportions a Thoroughly stir the accelerator in its container until an even con...

Page 476: ...OWN IN THIS FIGURE ARE USED WHEN MAKING A STRUCTURAL REPAIR TO THE FUEL TANK AREA AND WHEN REINSTALL ING THE ACCESS COVERS FASTENER SEALING AFT TANK BULKHEAD 1 3 S J s WING SKIN 1 FILLET SEALING 2 RIV...

Page 477: ...3 FAYING SURFACE SEALING FASTENER SEALING WING SKIN NOTE TYPES OF SEALING SHOWN IN THIS FIGURE ARE USED WHEN MAKING A STRUCTURAL REPAIR TO THE FUEL TANK AREA AND WHEN REINSTALL ING THE ACCESS COVERS F...

Page 478: ...ended priorto applyingsealant Check area of leak for defects In bond joints Areas of cracked bondfillets orseparated bond jointsmust be repaired Contactthe Gulfstream Aerospace Corporation customer se...

Page 479: ...ty precautions B Determine source of the leak Fuel can flow along the structure of the wing making the leak source difficult to find A stained area is an indication of the leak source C Drain tank and...

Page 480: ...pe Thread Repairs A The following repair technique may be used for repairing the 1 8 inch pipe threadsat the quick drain valve or vent flange fittings in the AA 5 series sump tanks 1 0 Use a 7 16 inch...

Page 481: ...system is composedof the fuel sump tanks the fuel selector valve the electric fuel pump the engine driven fuel pump and the plumbing associated with these components In addition the electrical circuit...

Page 482: ...j Wi 1...

Page 483: ...r WARNING USE SOLVENT IN A WELL VENTILATED AREA AVOID BREATHING FUMES KEEP AWAY FROM FLAMES 4 Clean the filter by rinsing in Stoddard solvent orequivalent andblowing out cleansing agent with com press...

Page 484: ...lint free cloth towipe all lubricant from dry plugcock and valve body Ensure that the sur faces are clean undamaged and free of corrosion 5 Lubricate dry plug cock with avery light film oflubricant E...

Page 485: ...nuts 3 through bracket 6 and fuel selector valve 2 i g 3 Torque to35 5Inch pounds 4 Install handle 8 on valve stem secure itwith the screw 9 and stick decal 7 overscrew head r 5 Clean the exposed thr...

Page 486: ...Decal 8 Handle 1 Fuel Line 2 Vent Line 3 Supply Line 4 Bolts 5 Washers 1 6 Nipple AA 5 SERIES MAINTENANCE MANUAL Fuel Selector Valve Removal Installation Figure 401 Fuel Sump Tank Removal Installatio...

Page 487: ...9 Reinstall wingrootaccess panel perChapter 57 4 Fuel System Plumbing Removal Installation A Fuel System Plumbing Removal WARNING WHEN DISCONNECTING FUEL LINES FROMTHE MAIN FUEL TANK HOLDTHE BULKHEAD...

Page 488: ...ut Nut Nut Nut Nut Nut Nut Nut Nut AA 5 SERIES MAINTENANCE MANUAL INDEX 1 2 3 4 5 6 7 8 9 10 11 12 Fuel System Fitting Torque Values Figure 403 TORQUE VALUE 25 5 In lb 200 50 In lb 200 50 In lb 100 25...

Page 489: ...irewall and remove the pump B Electric Fuel Pump Installation See Figure 404 1 Position fuel pump on firewall as shown in Figure 404 2 Install washers 5 and nuts 4 3 Torque to 35Ji 5 inch pounds 4 Cle...

Page 490: ...f u v c i r v...

Page 491: ...05 psi tank isacceptable 9 If leaks are found reseal and retest Fuel Storage System Approved Repairs for sealing procedures B Fuel System Plumbing Pressure Test 1 Pressurize the fuel system plumbing...

Page 492: ...to 8 0 psi If required prime engine WARNING ENSURE THAT PROPELLER IS CLEAR PRIOR TO STARTING ENGINE Set MAGNETO switch to LEFT Press STARTER button until engine starts Set MAGNETO switch to BOTH Chec...

Page 493: ...ent in thefuel quantity transmitter Afloat in thefuel tank positions the wiper of the rheostat such that its resistance varies directly with fuel quantity This in turn varies the amount of current app...

Page 494: ...dolph Products Co No 802 sloshcoating orequivalent into the drain plug opening in the sump tank 8 Plugor tape the drain plug opening p 9 Rotate and shake the sump tank such that the coatingentirely co...

Page 495: ...f th i i w i iv rc n Wft i t fV ii i r...

Page 496: ...lace transmitter Transmitter not grounded Check transmitter ground con nections Loose or damaged wiring Check wiring for damage and secure connections Defective fuel gauge Replace gauge Fuel gauge doe...

Page 497: ...1 i...

Page 498: ...und wire 21 through the access opening 22 in the panel 19 2 Attach end of groundwire 21 to ground lug 16 3 Position gauge 20 in panel 19 4 Use screw 15 washer 14 andnut 13 to secure ground lugs 16 to...

Page 499: ...3 Handle 4 Valve Stem 5 Insulator Boot 6 Nuts 7 Washers 8 Washers 9 Wire Lug 10 Terminal Stud 11 Nuts 12 Insulator 13 Nut 14 Washer 15 Grounding Screw 16 Ground Lug 17 Grommet 18 Screws 19 Panel 20 G...

Page 500: ...SOLVENTS IN A WELL VENTILATED AREA AVOID BREATHING FUMES KEEP AWAY FROM FLAMES 2 Onearly AA 5aircraft remove sealant from inner aft fuel tank cover matingsurface and clean with trichloroethane 3 Posit...

Page 501: ...Jo i r...

Page 502: ...5 resistor 6 Check that voltmeter indicates 12 6 1 volt 7 Check fuel gauge indication Gauge shall indicate within one needle width of the full mark Ifnot re place the gauge CAUTION IFTHE GAUGE INDICAT...

Page 503: ...s should be performed using the aircraft fuel gauges No partof the fuel gauge needle should show above the empty mark with the transmitter in the empty position Small adjustments to the transmitter ca...

Page 504: ...AA 5A and AA 5B aircraft as a means of preventing and disposing of ice formation in the carburetor and pitotsystem and the elimination of frost and fog on the windows and windshield This Chapter cont...

Page 505: ......

Page 506: ...BURETOR HEAT CONTROL Description Operation General Troubleshooting Maintenance Practices Removal Installation I Adjustment Operational Test 30 1 3 CARBURETOR HEAT SHUTOFF VALVE Description Operation G...

Page 507: ...AA 5 SERIES MAINTENANCE MANUAL NUMBER pAGE 30 4 1 WINDSHIELD DEFROSTER SYSTEM Description Operation X General 1 30 Page 2 Dec 15 77...

Page 508: ...U f VA 804049 1 522 GAES413 3 1260 Nomenclature 12 3 4 5 6 7 SEALS SEAL FUSELAGE V091441 SEAL AFT CANOPY V09144 SEAL WINDOW V92798 SEAL WINDOW V71015 ALT TAPE VINYL FOAM V26068 SEAL BAGGAGE DOOR SEAL...

Page 509: ...f...

Page 510: ...en the carburetor heat control is in the ON pulled out position the shutoff valve shuts offthe filtered air source and warm unfiltered air from ashroud around the exhaust systemis directed to the carb...

Page 511: ...I CARBURETOR AIRSHUTOFFVALVE AA 5 SERIES MAINTENANCE MANUAL CARBURETOR AIR BOX INSTALLATION Carburetor Air Box Installation AA 5 Serial No 0001 thru 0640 Figure 2 30 1 1 Page 2 Dec 15 77 flS k...

Page 512: ...AA 5 SERIES MAINTENANCE MANUAL BUTTERFLY SHAFT ASSEMBLY DOUBLER BRACKET DETAIL A Carburetor Air Box Installation AA5 0641 and Sub and AA5A 0001 and Sub Figure 3 PLATE PUSH NUT BEARING 30 1 1 Page 3 J...

Page 513: ...ED AIR INLET DETAIL A RAM AIR INLET AA 5 SERIES MAINTENANCE MANUAL SCREEN ASSEMBLY AA5 B 0945 AND SUBSEQUENT Carburetor Air Box Installation AA 5B Figure 4 VALVE CONTROL CABLE FILTER 30 1 1 Page 4 Jul...

Page 514: ...of heat control i NOTE Itisnecessary tooperate the aircraft engine tooperationally test the carburetor heat system WARNING ENSURETHAT PROPELLERAREA IS CLEAR PRIOR TO STARTING ENGINE C Start andrun en...

Page 515: ...IVJ i...

Page 516: ...or during icing conditions It consists of a control knob mounted on the lower instrument panel to the left of the throttle The heat control is connected to a shutoff valve mounted on the carburetor ai...

Page 517: ...V l i 1 T V r i r l r n 1...

Page 518: ...to carbure tor PROBABLE CAUSE Linkage binding broken or crimped Control binding in instru ment panel Air shutoff valve binding or stuck on carburetor air box Control and linkage improperly adjusted R...

Page 519: ...i J...

Page 520: ...nnect cable loosely to the air box control arm 3 On AA 5 and AA 5A aircraft install the clamps that secure the carburetorheat control cableand throt tle cable to the instrument panel support On AA 5Ba...

Page 521: ...tion 3 Attach and bend the carburetorheat control cablewire Figure 202 Tighten clamp and install the cot ter pin B Operational Test Check operation of the carburetor heat control Control should have 1...

Page 522: ...d to the carburetor heat control lever by a control wire assembly When the shutoffvalve is open heated air is diverted to the carburetor air intake Carburetor heat is shut off when the valve is closed...

Page 523: ...T 4 vt x JS iTj f...

Page 524: ...ON switch andassociated wiring The switch andfuse holder are of plastic construction andare mounted on the lower part ofthe instrument panel The heater uses a 15 amp fuse see Figure 2 The purpose of t...

Page 525: ...IES MAINTENANCE MANUAL I JO i O HIiili il O O 0 0 yKKSMJUI 1MWiBilj WA Z PITOT HEATER SWITCH SPARE FUSES PITOT HEATER FUSE 3475 HEATER RECEPTACLE PITOT TUBE Pitot Heater System Figure 2 30 3 1 Page 2...

Page 526: ...MANUAL PITOT HEATER TROUBLESHOOTING TROUBLE PROBABLE CAUSE REMEDY Pitot tube fails to heat Blown fuse Replace with properly rated fuse Defective wiring Check with ohmmeter and repair as neces sary Hea...

Page 527: ...r...

Page 528: ...sition 2 Connect wiring to switch terminals I 3 Position switch in place on instrument panel andpush switch into moimtinghole until switch 1 snaps into panel 3 Operational Test of Pitot Heater A Test...

Page 529: ...j I C Tv J I T vO D f 7 V X...

Page 530: ...ible ducts are connected to the plenum assembly of the heating system and terminated justbelow the sliding doors located on the forward panel deck Oper ation ofthedefroster is accomplished by pulling...

Page 531: ...BAFFLE AA 5 SERIES MAINTENANCE MANUAL DEFROSTER OUTLET Defrosting System AA5 0001 through 0834 and AA5B 0001 through 0522 Sheet 1of4 Figure 1 30 4 1 Page 2 Dec 15 77 flssij...

Page 532: ...i f I BAFFLE DEFROSTER OUTLET WARM AIR INLET DUCT AA 5 SERIES MAINTENANCE MANUAL DEFROSTER OUTLET Defrosting System AA5B 0001 through 0280 0283 and 0284 Sheet 2 of 4 Figure 1 30 4 1 Page 3 Dec 15 77...

Page 533: ...BAFFLE DEFROSTER OUTLET WARM AIR INLET DUCT AA 5 SERIES MAINTENANCE MANUAL DEFROSTER OUTLET Defrosting System AA5B 0281 0282 and 0285 through 0399 Sheet 3of4 Figure 1 30 4 1 Page 4 Dec 15 77...

Page 534: ...BAFFLE Cv AA 5 SERIES MAINTENANCE MANUAL DEFROSTER OUTLET MUFFLER ASSY Heating System AA5A 0523 andSubsequent AA5B 0400 andSubsequent Sheet4 of 4 Figure 1 DETAIL A 30 4 1 Page 5 Dec 15 77...

Page 535: ...i j...

Page 536: ...neral Maintenance Practices Removal Installation of Nose Landing Gear Inspection and Minor Repair of Nose Landing Gear Removal Installation of Shock Absorbers 32 4 1 WHEELS AND TIRES Description Opera...

Page 537: ...ylinder Disassembly Reassembly of Master Cylinder Non Reservoir Type j Disassembly Reassembly of Master Cylinder f Reservoir Type H Removal Installation of Wheel Brake Assemblies Bleeding Hydraulic Br...

Page 538: ...ase for thebrake torque plate assembly The nose gear is the casteringtype andconsists ofa tubularstrut attached to the torque tubeandyoke assembly mounted in thefuselage On AircraftAA 5 SerialNo 0641...

Page 539: ...ii W J iV 5 iO i 1 t J i...

Page 540: ...the right and left hand gear assemblies Each assembly consists of a laminated fiberglass strut forged wheel axle attaching brackets strut fairings andattaching hardware Wheel fairings are a customer...

Page 541: ...f...

Page 542: ...ingplate 20 from strut 21 b Remove nuts 22 bolts 23 washers 24 and separate axle 25 bracket 26 rein forcement plate 27 and shims 28 from strut 21 c Remove nuts 29 bolts 30 andwashers 31 to remove torq...

Page 543: ...AA 5 SERIES MAINTENANCE MANUAL 3313 Main Landing Gear Sheet 1 of 2 Figure 201 32 1 1 Page 202 Nov 15 76 i 8 v ij...

Page 544: ...re McLube 1708 by McGee Chemicals Co Inc Lube Lok 5396 by Allen Aircraft Products Inc 5 Position spar mounting bracket 9 in place on inboard spar and install washers 8 and bolts 7 6 Position shims 6 a...

Page 545: ...ner delaminations slivers are acceptable if they are smaller than 1 16 x 1 16 in in size throughout their length If airworthiness of a damaged fiberglass strut is in question close up photographs of t...

Page 546: ...cation of grease to thenose fork swivel and adjustment of theBelleville washers Aircraft AA5A 0283 and sub sequent and AA5B 0400 and subsequent are equipped with apair ofshock absorbers connected to t...

Page 547: ...f k...

Page 548: ...off strut 28 NOTE Thetorque tube and yokeassembly islocated in the front endof the fuseiage To gain access to the torque tube andyoke assembly some items of equipment must be removed from the cockpit...

Page 549: ...1 AND SUBSEQUENT AA5B OO01 AND SUBSEQUENT AA5 0641 AND SUBSEQUENT AA5A 0001 AND SUBSEQUENT AA5B C001 AND SUBSEQUENT AA50747 AND SUBSEQUENT AA5A 0001 AND SUBSEQUENT AA5B 0025 AND SUBSEQUENT Nose Landin...

Page 550: ...onpilot s side 19 Disconnect one end of the parking brake chain by cutting the wire which attaches it to the link on the master cylinder pilot s side 1 20 Move the left and right master cylinders onth...

Page 551: ...er torque tubebearing support bolts 30 at thefirewall andthe cabin floor to 185 195 inch pounds and torque the bolts 36 that attach the ends ofthe torque tube assembly tothe fuselage sides to 300 350...

Page 552: ...t 28 through cutout in fairing 23 Assemble O ring 17 thrust bearings 16 and fork assembly 15 in place on strut 28 NOTE Properinstallationof nose gearstrut and fork assembly isessential to preventnose...

Page 553: ...e cup to strut fillet with hand abrasive Remove rust and paint from strut 1 5 inch minimum upward from cup stop plate b Apply Loctite 290 Adhesive Sealant wicking Loctite Corporation to any cracks rem...

Page 554: ...ewall area aroundnose gear torque tube and flanges of firewall seal box assembly 5 Install seats 15 on torque tube and yoke assembly 11 with thin edge of seal up and thin seal outboard 6 Coat aft side...

Page 555: ...AA 5 SERIES MAINTENANCE MANUAL Nose Landing Gear Shock Absorber Installation Sheet 1 of 2 Figure 203 32 2 1 Page 208 June 1 83 y 8fe...

Page 556: ...g 6 Nut 7 Washer 8 Bolt 9 Bracket 10 Strut 11 Torque Tube and Yoke Assy 12 Screw 13 Box Cover 14 Box 15 Seal 16 Nut 17 Washer 18 Bolt 19 Bracket 20 Washer 21 Doubler Nose Landing Gear Shock Absorber I...

Page 557: ...f I...

Page 558: ...ted periodically toobtain maximum tire life AU wheels are of the split wheel design for easy servicing and each main wheel has an independent disc type hydraulic brake system For information and instr...

Page 559: ...f L a I J I i i f...

Page 560: ...tating the wheel Back off the nut to the next castellation and install the cotter pin 1 4 Position brake backplate assembly 3 Figure 201 in placeand install washers 2 and bolts 1 Torque mounting bolts...

Page 561: ...Torque Plate Ass y 20 8 Nut 21 9 Washer 22 10 Bolt 23 11 Outer Wheel Half Ass y 24 12 Inner Wheel Half Ass y 25 13 Brake Disc Ass y 3317 Snap Ring Grease Seal Ring Felt Grease Seal Grease Seal Ring Co...

Page 562: ...e sanded smooth a B Reassemble Main Landing Gear Wheel Assembly I 1 Position tube 21 Inside tire 22 andalignthe red dot on the tire with the index mark on the I tube If no mark on tube align dot with...

Page 563: ...el halves 5 and 6 Figure 202 by removing the nuts 1 washers 2 and 4 and bolts 3 5 Remove the snap ring 7 grease seal rings 8 felt grease seals 9 grease seal rings 10 and cone bearings 11 6 Inspect the...

Page 564: ...asher 9 3 Bolt io 4 Washer 11 5 Inner Wheel Half Ass y 12 6 Outer Wheel Half Ass y 13 7 Snap Ring 14 Grease Seal Ring Felt Grease Seal Grease Seal Ring Cone Bearing Bearing Cup Tube Tire Nose Wheel As...

Page 565: ...ircraft having wheel fairing installed is also equipped with a streamlining fairing The streamlining fairing must be removed to gain access to wheel fairing attaching hardware 1 Remove screws 1 washer...

Page 566: ...y within the tolerances specified In Figure 205 and the toe in adjustment should be checked periodically to ensure the wheels are properly aligned Setting toe In within the specified tolerances while...

Page 567: ...heel Fairing Assembly Figure 203 1 Screw 2 Washer 3 Streamlining fairing 4 Plug button 5 Bolt 6 Washer 7 Bearing 8 Bolt 9 Washer 10 Bracket 11 Flex bolt 12 Fairing 13 Nut 14 Washer 15 Scraper Assembly...

Page 568: ...AA 5 SERIES MAINTENANCE MANUAL AA 5 SERIAL NO 0641 AND SUBSEQUENT AA 5A AND AA 5B 1 Plug button 2 Bolt 3 Washer 4 Fairing 5 Scraper Nose Wheel Fairing Assembly Figure 204 33 9 32 4 1 Page 209 Nov 15...

Page 569: ...0 IN SQUARE CARPENTER S SQUARE MEASURE TOE IN AT EDGESOF WHEELFLANGE DIFFERENCE IN MEASUREMENTS IS TOE IN FOR ONEWHEEL HALF OF TOTAL TOE IN FORWARD t BLOCK STRAIGHT EDGE AGAINST TIRES AT AXLE HEIGHT G...

Page 570: ...s 3 and 4 However operation is essentially the same as above except master cylinders 1 and 2 supply hydraulic pressure directly to the wheel brake assemblies Onaircraft AA5 0001 through 0834 AA5A 0001...

Page 571: ...1...

Page 572: ...owever operation isessentially thesame as above except master cylinders 1 and 2 supplyhydraulic pressure directly to the wheel brake assemblies On aircraft AA5 0001 through 0834 AA5A 0001 through 0522...

Page 573: ...YSTEM 0 LH BRAKE ASSEMBLY Lo R H BRAKE ASSEMBLY SCHEMATIC HYDRAULIC BRAKE SYSTEM OUAL TO WHEEL BRAKE CYLINDER R H CO PILOT S RUDDER AND BRAKE PEOALS Hydraulic Brake System AA5 0001 through 0834 AA5A 0...

Page 574: ...NGLE BRAKE SYSTEM n 0 PARKING BRAKE VALVE M3 L H BRAKE ASSEMBLY R H BRAKE ASSEMBLY SCHEMATIC HYDRAULIC BRAKE SYSTEM DUAL TO WHEEL BRAKE CYLINDER R H CO PILOT S RUDDER AND BRAKE PEDALS Hydraulic Brake...

Page 575: ......

Page 576: ...n and cotter H pin Z0 3 Connect the flexible hose assembly to the master cylinder connection 4 Connect parking brake chain to parking brake leveron master cylinder with 0 032 inch stainless steel safe...

Page 577: ...5 O rlng 6 End Cap and Bearing AA 5 SERIES MAINTENANCE MANUAL 7 O rtng 8 Snap Ring 9 Spacer 10 O ring 11 O ring 12 Piston 13 Sprang 14 Snap Ring 15 Spring 16 Housing Master Cylinder Non Reservoir Typ...

Page 578: ...3 Disassembly Reassembly of Master Cylinder Reservoir Type If NOTE Items 3 4 5 and 6ofFigure 202 are not installed in mastercylinders on those aircraft with hydraulic parking brake valve system insta...

Page 579: ...sembly 4 Depress shaft assembly into housing 19 and lock inposition with screw 11 and washer 12 5 Install rubber seal 10 cover plate 9 and lock In place with snap ring 8 6 Install filler plug 7 f 7 Sl...

Page 580: ...cylinder bore and O ring 7 with clean hydraulic fluid 2 Assemble anchor bolts 10 Into cylinder 4 and Install washers 9 and nuts 8 3 Absemble 0 ring 7 on piston 6 and install in cylinder 4 Hold piston...

Page 581: ...oir in the master cylinder 5 Secure the bleeder valve and replace the vent plugs NOTE Donot fill the reservoir higher than 1 4 Inch from the top as this will result In spillage If fluid Is accidentall...

Page 582: ...alve is opening With air still passing through port depress shaft approximately 1 16 inch This should cut off air passing through the assembly and out the top port and show that the check valve is clo...

Page 583: ...ng brake control until all slack isre moved from the actuating chain I 4 Measure the dimension at B This dimension should be0 5 0 13inch If thisdimension isless than specified remove enough chain toob...

Page 584: ...C TYWRAP RETAINING CLAMP CONTROL WIRE WIRE STOP AA 5 SERIES MAINTENANCE MANUAL CONTROL CABLE HOUSING STOP NUT PARKING BRAKE LEVER PARKING BRAKE ON POSITION ParkingBrake Rigging AA5 0001 thru 0834 AA5A...

Page 585: ...m Grumman American Aviation Corporation This kit consists of an anvil and punch 3 Clamp the flat side of the anvil in a vise 4 Align new lining onback plate andplacebrake rivet Inhole withrivet headIn...

Page 586: ...Interior Lights 33 4 1 EXTERIOR LIGHTS Description Operation Landing Light Optional Navigation Lights Flashing Beacon Optional Strobe Lights Optional Troubleshooting Strobe Light System Maintenance P...

Page 587: ......

Page 588: ...1 1 2 N A Quantity BULB CHART INTERIOR LIGHTS Type Light Instrument Lights Map Light FWD AAS 0001 through 0021 Map Light FWD AA5 0022 and Subsequent Dome Light AFT Map Light Optional Fuel Gauge Light...

Page 589: ...VAW ClWA rv f I VZ...

Page 590: ...ed on the instrument panel The rheostat receives its power from the bus through a 10 amp fuse Inst Nav Lts Turning the control knob on the rheostat will vary the brightness of these lights The fuel ga...

Page 591: ...DETAIL A 4 f r DETAIL C AA 5 SERIES MAINTENANCE MANUAL Instrument Lights Figure 2 RIGHT SIDE L NOTE LEFTSIDEIDENTICAL TO RIGHT SIDE DETAILS 53 33 1 1 Page 2 Nov 15 76 r s V sSHjk...

Page 592: ...ndle forward of the firewall On Aircraft AA5 0406 and Subsequent AA5B 0001 and Sub sequent and AA5A 0001 and Subsequent the fuse is located on a plate mounted to the battery support bracket These ligh...

Page 593: ...ii i U...

Page 594: ...this cover Remove the bulb and replace as required 3 Replace the thermoplastic cover 2 Replacement of Dome Lights I A Remove the screws which attach the thermoplastic dome light housing to the forwar...

Page 595: ...Fuel gauge Ughts should go out 2 Dome and Map Lights NOTE Ensure fuses are operational before performing check A Place map and dome Ught switch to forward position The forward map Ught located overhea...

Page 596: ...required On 1975 and later models adjustments are made from the forward side of the cowl by removing the lamp shield 2 Navigation Lights See Figures 3 and 4 The navigation Ughts consist of the two wi...

Page 597: ...LB1 T0 INSTRUMENT LIGHTS 3 3b BLACK 10 S1LD1 INSTRUMENT NAVIGATION FUSE DETAIL A NAVIGATION UGHTS SWITCH O 51LD2 d11p 51L03 4PM JP 3 3 51LD10 RIGHT WING ROOT CJ3 3D 6L012 0J I b RED f JP L r cLLP BLAC...

Page 598: ...ument panel This switch receives power from the bus through a 15 amp fuse Flash Ben FLASHING BEACOfc FUSE FLASHING BEACON FUSE FLASHING BEACON SWITCH f 0 51LF1 IB FLASHING BEACON SWITCH I OJ2 2D SLF3...

Page 599: ...SHIELD LAMP DETAIL A DOME AA 5 SERIES MAINTENANCE MANUAL SPACER OCKET NUT LOAD RESISTOR Flashing Beacon Optional Figure 7 DETAIL B CREW WASHER FLASHER UNIT 33 4 1 Page 4 July 15 78 k a...

Page 600: ...ip cutouts on the wing tips They are located above and behind the navigation Ughts Clear plastic lens are mounted over the Ughts to protect them from the weather On AA5 0001 through 0405 power for the...

Page 601: ...ING ROOT SB V 5CC1 TOFLAP SYSTEM LEFT WING TIP STROBE ASSEMBLY A A A USEO ON AIRCRAFT AA5 001 THROUGH AAS 0405 USE D ON Al RCR AF I AAS 040S AND SUBSEOUE NT USED ON AIRCRAFT AA3A 000J ANO SUBSEQUENT A...

Page 602: ...eck wiring from bus to power supply flasher power unit Only one side fails to flash 61 I Defective flash tube Replace flash tube with known good flash tube opposite wing If operation is normal replace...

Page 603: ......

Page 604: ...See Exterior Lights Operational Check B Replacement of Navigation Lights Wing Tip See Figure 4 1 Remove the screws which attach the protective lens to thewingtip 2 Remove the one screw which holdsthe...

Page 605: ...ingwires 3 Replacethe tallinspection covers 4 Perform operational check See Exterior Lights Operational Check 3 Strobe Light Removal Installation A Light Assembly Removal WARNING REMOVE POWER FOR 5 MI...

Page 606: ...ires goingto flasher unit 5 Removehardware supporting flasher unit to wingrib 6 Remove flasher unit from wing rib B Flasher Assembly Installation 1 Replace flasher unit and supportinghardware CAUTION...

Page 607: ...in access to the adjusting screws On 1975 and later mo dels remove thelamp shield to gain access to the adjusting screws 3 Adjustlightin accordance with Figure 201 NOTE LANDING LIGHT SHOULD NOT BE ADJ...

Page 608: ...wing tipand the one light mounted on the tail cone should come on i 3 Place navigation light switch to OFF position Navigation lights should go out I 4 Place master switch to OFF position C Flashing...

Page 609: ...i f...

Page 610: ...ofPitotand Static Pressure System I Components Pitot and Static Pressure System Leakage Test Pitot Tube Alignment 34 1 2 AIR TEMPERATURE GAUGE Description Operation General Maintenance Practices Remo...

Page 611: ...1 Removal Installation ofAltimeter 34 2 1 DIRECTIONAL GYRO Description Operation General Troubleshooting Troubleshooting Directional Gyro Maintenance Practices Removal Installation of Directional Gyro...

Page 612: ...netic Compass 201 I 34 5 1 TRANSPONDER Description Operation 1 General 1 Maintenance Practices 201 Removal Installation of Transponder 201 Removal Installation of Transponder Antenna 201 34 5 2 ADF SY...

Page 613: ...0B 175B NAV COM Transceiver 2 KING VOR LOCMJS Indicators 2 NARCONAV 14 Navigation Receiver and DGO 10 Display Unit 3 NARCO NAV 10 COM10 System 4 f NARCO NAV 11 NAV12Navigation System Unit 5 I NARCO NA...

Page 614: ...vide minimum requirements to comply with FAA regulations are available on all aircraft More diverse navigational items are installed as a customer option It is the intent of this manual to present pro...

Page 615: ......

Page 616: ...ld be disconnected at the elbow or the plastic connection located inside the wing root in order to drain any moisture accumulation The static system consisting of a static port on each side of the aft...

Page 617: ...IAL NO 0014 AND SUBSEQUENT AA 5A ANDAA 5B PIPE CAP DETAIL E Pitot and Static System Figure 1 J DETAIL D ALTIMETER VERTICAL SPEED INDICATOR AIRSPEED INDICATOR TO STATIC PORTS MOISTURE TRAP DRAIN AA 5 S...

Page 618: ...age is evi dent Defective instrument Replace instrument Instrument leakage Test instrument individually and replace if necessary Altimeter fails to operate 1 Clogged static lines Check all lines and f...

Page 619: ...r g f iJ...

Page 620: ...wing spar and wing rib 4 Remove pitot tube assembly B Install Pitot Tube Assembly 1 Place pitot tube assembly In position and install attaching hardware 2 Connect pitot tube air Inlet tine and wiring...

Page 621: ...d and approved by an appropriately rated repair facility per FAR Part 43 Appendix E prior to aircraft system test 2 Seal off one static portopening with plastic tape This must provide an air tight sea...

Page 622: ...ofparellel lines To check the proper alignment ofthepitot tube make a template conforming to the lines shown in Figure 202 If the pitot tube is properly aligned It should parallel one of the lines WIN...

Page 623: ......

Page 624: ...rature gauge Is located onthe upper center of the windsMeld The gauge is a mechanically operated instrument actuatedby expansion of a metallic element to give the temperature Indication on the face of...

Page 625: ...UK V I iLr v...

Page 626: ...ashers on gauge stem Figure 201 2 Apply one or two drops of Loctitesealant grade EV to the gauge stem threads 3 Insert gauge stem through mounting hole from inside the windshield 4 Assemble tubeadapte...

Page 627: ...v vM v Sili7 1...

Page 628: ...al this in strument will indicate the rate of ascent or descent of the aircraft in feet per minute But due to the lag of the instrument the aircraft will be climbing or descending before the instrumen...

Page 629: ...S V...

Page 630: ...fitting to disconnect tubing from rear of indicator 4 Remove three screws and nuts mounting vertical speed Indicator to instrument panel and remove indicator B Install Vertical Speed Indicator 1 Posi...

Page 631: ...ixs iur 1 SOL 1 I j X...

Page 632: ...ted to the static line Check individual instruments for leaks Reconnect instruments to static line and test installation for leaks Defective mechanism Replace instrument Rate of climb indicates when a...

Page 633: ......

Page 634: ...ir pressure This instrument has its diaphragm vented to the pitotair source andits case ventedto the static air system As the aircraft increases speed the pitot air pressure increases causing the diap...

Page 635: ......

Page 636: ...lates Defective mechanism Replace instrument Instrument reads high Pointer not on zero Replace instrument Leaking static system Find leak and correct Instrument reads low Pointer not on zero Replace i...

Page 637: ...ciu do v 7 i...

Page 638: ...tings to disconnect tubing from the connections on back of indicator 4 Remove four mounting screws securing airspeed indicator to instrument panel and remove indicator B Install Airspeed Indicator 1 P...

Page 639: ...ilVIii 7 i 0 fi...

Page 640: ...ousands of feet A barometric pressure window is located on the right side of the indicator dial The barometric pressure indication is set by the knob located on the lower left corner of the instrument...

Page 641: ...i j f s v...

Page 642: ...trument if screw is missing Cracked or loose cover glass Case gasket hardened Replace instrument Dull or discolored markings Age Replace markings f Barometric scale and refer ence markers out of synch...

Page 643: ...iU t i...

Page 644: ...ittings to disconnect tubing from tee con nection on back of instrument 4 Remove three screws securing altimeter to instrument panel and remove altimeter B Install Altimeter 1 Position altimeter in pl...

Page 645: ......

Page 646: ...Due to gyroscopic inertia the spin axis continues to point in the same direction eventhough the aircraft yaws to the right or left This relative motion between the gyro and the instrument case is sho...

Page 647: ...k...

Page 648: ...um is not correct check for the following a Relief valve improperly ad justed a Adjust b Incorrect gaugereading b Replace gauge c Pump failure c Repair or replace d Vacuum line kinked or leaking d Che...

Page 649: ......

Page 650: ...e reset knob two knobs if aircraft equipped with automatic pilot 6 Remove three mounting screws and slide gyrobackward out of instrument panel B Install Directional Gyro 1 Position directional gyro in...

Page 651: ...yiV i ri P iJ I U...

Page 652: ...continues to point in the vertical direction providing a constant visual reference to the attitude of the aircraft relative to pitch and roll axis A bar across the face of the indicator represents th...

Page 653: ...f...

Page 654: ...ctive instrument Replace Bar oscillates or shimmies continuously Instrument loose in panel Tighten mounting screws Vacuum too high Adjust valve Defective mechanism Replace instrument Instrument does n...

Page 655: ...A...

Page 656: ...automatic pilot disconnect electrical plug from gyro 5 Remove the four mounting screws that secures gyro toinstrument panel and remove gyro B Install Attitude Gyro 1 Position attitude gyro In place o...

Page 657: ...Il C J J A K...

Page 658: ...f this unit The first is the old style with a vertical needle In the center of the dial This instrument reads only the rate of turn and unless the aircraft is turning the needle will not move regardle...

Page 659: ...in instrument Replace instrument Master switch OFF Place master switch ON Blown fuse Replace fuse Incorrect sensitivity Out of calibration Replace instrument Aircraft not in coordinated turn Center b...

Page 660: ......

Page 661: ...ld 3 Disconnect electrical plug from Indicator 4 Remove the four mounting screws and nuts that secure Indicator to Instrument panel and remove Indicator B Install Turn and Bank Indicator 1 Position tu...

Page 662: ...f l JO t...

Page 663: ...n ance is required for the magnetic compass except to swing It on a compass rose Adjustments may be made to the instrument by the two screws located on the front fece using a non magnetic screwdriver...

Page 664: ......

Page 665: ...ard magnet Replace instrument Excessive pivot friction or broken jewel Replace instrument Liquid leakage Loose bezel screws Replace instrument Broken cover glass Replace instrument Defective sealing g...

Page 666: ...i 7 _ 1f...

Page 667: ...gnetic Compass A Remove Magnetic Compass 1 Remove two mounting screws and nuts 2 Disconnect electrical leadand remove compass B Install Magnetic Compass 1 Connect electrical lead to magnetic compass 2...

Page 668: ...lotistransmitted asa Mode A reply Mode C altitude reporting isanadditional capability designed intothe trans ponder However in order to convey altitude information the transponder must beused in conju...

Page 669: ...Function Selector 2 Dim Control 3 Code Selectors AA 5 SERIES MAINTENANCE MANUAL NARCO AT 50A Transponders Figure 1 4 Monitor Light and Ident Button 5 Monitor Light 6 Ident Button 34 5 1 Page 2 Nov 15...

Page 670: ...ntrol Pull for Ident 3 Code Selector 1 2 SBY ON ALT OFF TST AA 5 SERIES MAINTENANCE MANUAL NARCO AT 150 0 E m LH DIM REPLY f S IDENT L Collins Transponder COLLINS TDR 950 950L Transponders Figure 2 TD...

Page 671: ...I J...

Page 672: ...transponder by the sides and carefully slide transponder into avionics panel mount until plug connection is fully engaged 3 Tum locking alien screw counterclockwise to secure transponder unitto itsmo...

Page 673: ...AA 5 SERIES MAINTENANCE MANUAL CABLE ASSY NUT LOCKWASHER DOUBLER ANTENNA 3340 Transponder Antenna Installation Figure 201 34 5 1 Page 202 Nov 15 76 a yS k...

Page 674: ...ADF 141 automatic direction finder Figure 1 is an airborne radio receiver that Indicates the relative direction to thestation to which it istuned The ADF 140 141 receives and detects theradio signal...

Page 675: ...unction Selector KR8B RECEIVER 3333 5 Frequency Selector 6 Frequency Display 7 Volume Control KING KR 85 KI 225 Automatic Direction Finder Figure 2 4 COLLINS ADF 650 IND 650 Automatic Direction Finder...

Page 676: ...ntrol 2 100 KHz 1 MKz Frequency Control 3 10 KHz Frequency Control 4 1 KHz Frequency Control 5 Self Test Switch 6 Lubber Line 7 ADF Bearing Pointer 8 Compass Card 9 Heading Selector COLLINS ADF 650 IN...

Page 677: ...i...

Page 678: ...strumentpanel 3 Loosen ADF receiver unitbyturning locking alien screw clockwise Use 5 64 inch hex alien wrench CAUTION DONOT PULLADF RECEIVER FREE FROM INSTRUMENT PANEL BY GRASPING THE CONTROL KNOBS i...

Page 679: ...mbly with holes in fuselage floor at Station 147 1 Make sure arrow on plate points to the forward endof aircraft 3 On outside of fuselage mstall two screws attachingloop cable and plate assembly to fu...

Page 680: ...peration to provide the pilotwith distance to station time to station orground speed readouts The DME isdesigned to operate in altitudes upto amaximum of 50 000feet at ground speeds up to 250knotsand...

Page 681: ...gahertz Selector Knob Frequency Indicator AA 5 SERIES MAINTENANCE MANUAL 6 7 8 9 10 Fractional Megahertz Selector Knobs Ident Volume Indicates Remote Tuning When modified for R NAV operation Tim Push...

Page 682: ...IVER FREE OF MOUNT BY GRASPING THE CONTROL KNOBS 4 Grasp thebody ofthe transmitter receiver and with a slightrocking motion while pulling out ward free receiver from connector plug andslide receiver f...

Page 683: ......

Page 684: ...t of the set Another widely usedunitIs the combination VORreceiver and indicator The AA 5 AA 5A andAA 5Buses equip ment distributed by different manufacturers The NARCO KING and COLLINS VOR receivers...

Page 685: ...ver andthevisual indicators include an UP DOWN glideslope needle with an OFFwarning flag All operating controls for the indicatorare mounted on the front panel andare identified in Figure 2 1 VOR LOC...

Page 686: ...S Control 6 Glideslope Needle KI 204 209 7 Glideslope Warning Flag KI 204 209 8 Heading Indicator KING KI 203 204 208 209 VOR LOC GS Indicator 1978 Model AA 5A and AA 5B Figure 2A NARCO NAV 14 Navigat...

Page 687: ...use the NAV 10 is dependent upon the COM 10 for receiver circuitry The mode of operation is determined by the function selector switch located on the COM 10 unit This section describes the operation o...

Page 688: ...V 12 systems are similar with regard to VOR reception The NAV 12 system has the added capability of receiving and displaying glideslope information to enable fuU ILS approaches rather thanthe localize...

Page 689: ...Indicator 4 VOL ID Control 5 OFF TO FROM Indicator 6 Frequency Selector 7 Frequency Indicator 11 10 8 I 2 3 fffl i M 3329 NAV 12 UNIT 8 OMNI Bearing Selector 9 NAV TO FROM Indicator 10 Glideslope Indi...

Page 690: ...21withthe addition of a glideslope receiver andglideslope display 1 OFF VOL Control Pull for station IDENT 2 NAV TO FROlVfFlag 3 VOR LOC Deviation Needle 4 Frequency Control 5 Frequency Indicator 6 Gl...

Page 691: ...theelectronic display Theheading to the selected VOR station radial 180 degrees may bedisplayed byselecting the TO position no letter appears after thebearing displayed Three dashes will appear in the...

Page 692: ...tor 4 DisplaySelect 5 ON OFF VOL ID Control Pull for IDENT VIR 351 Navigation Receiver Figure 8 1 Course Index 2 VOR LOC Deviation Bar 3 GS Flag IND 351 only 4 NAV Flag 5 Glideslope Deviation Bar IND...

Page 693: ...AA 5 SERIES MAINTENANCE MANUAL Collins OIS 3S0 TSO J 1 Coax Cable Connector 2 Control Cable Connector GLS 350 Glideslope Receiver Figure 10 34 5 4 Page 10 Dec 15 77 4l j k Hfoi...

Page 694: ...onnector pins 2 Turn locking alien screw counterclockwise to secure transceiver unit to its mounting case Use 5 64 inch hex alien wrench a C Removal of Navigation OMNI head Unit 1 Remove screws securi...

Page 695: ...tical stabilizer B Installation of NAV Antenna 1 Ensure the master power switch is OFF 2 Insert antenna rod ends into mounting block 3 Connect cable assembly to antenna rods 4 Replace rudder tip _ pla...

Page 696: ...on General Maintenance Practices Servicing Vacuum Pump Removal Installation Regulator Removal Installation Filter Assembly Removal Installation Adjustment Test Regulator Adjustment 37 2 1 INDICATING D...

Page 697: ...v U J...

Page 698: ...ional gyro horizon gyro and a suctiongauge plus necessary tubing and fittings Since the vacuum pump 1 of the dry type no oil separator is required 1 Engine Driven Vacuum Pump 2 Vacuum Regulator 3 Vacu...

Page 699: ...Oil Seal Defective Improperly Set Regulators Foreign Material on Regulator Seat Regulators Inoperative Plugged Filters Non Differ ential Vac Gauge System Gyros Inoperative Plugged Filters Non Dtffer...

Page 700: ......

Page 701: ...INE 1 Startengine in accordance with Pilot s Operating Handbook 2 Set enginespeedto 2100 rpm 3 Check thatsuction gauge indicates between 4 6and 5 4inch Hg and thatvacuum driven gyro instru ments direc...

Page 702: ...r pump mounting nuts to 40 50 inch pounds even if it means removing an adjacent appliance The larger thepump themore important this function becomes Never usea pumpthat has beendropped f I C Always ve...

Page 703: ......

Page 704: ...d shaft mateswith female spline in engine 3 Slide pump onto itsmounting studs onengine accessory pad Secure pump to engine with four nuts and washers Torque to 40 50 inch pounds 4 Install lineon vacuu...

Page 705: ...AA 5 SERIES MAINTENANCE MANUAL VACUUM PUMP Vacuum Pump Removal Installation Figure 201 ELBOW MOUNTING NUTS AND WASHERS 4 37 1 1 Page 202 July 15 78...

Page 706: ...o operatethe aircraft enginein orderto adjust the regulator WARNING ENSURE THAT PROPELLER AREA IS CLEAR PRIOR TO STARTING ENGINE 1 Start engine in accordance with Pilot s Operating Handbook 2 Adjust e...

Page 707: ...J...

Page 708: ...SERIES MAINTENANCE MANUAL INDICATING SYSTEM DESCRIPTION OPERATION 1 General The indicating system consists of the suction gauge andthe lines attachingit to the othervacuumsystem com ponents 37 2 1 Pa...

Page 709: ......

Page 710: ...ve spring clamp from vacuum line s attached to suction gauge 3 Remove two Phillips screwssecuringsuction gauge 4 Remove suction gauge from aircraft 5 Cap all open lines B Suction Gauge Installation 1...

Page 711: ...I i i l Wr r...

Page 712: ...y Removal Installation Canopy Latch Removal Installation Window Removal Installation Rear Canopy Seal Removal Installation Canopy Front Seal Removal Installation Adjustment Test Cleaning Painting Pain...

Page 713: ...y The canopy isa formed aluminum structure containing side windows of plexiglas and alatching mechanism to lock the canopy in the closed position 3 Baggage Door The baggage door islocated onthe leftsi...

Page 714: ...il L5 v i...

Page 715: ...provides an entry opening approx imately 34 to 40 inches in area This allows entry Into both front and rear seats of the airplane Fixed windows on each side of the canopy provide lateral visibility Th...

Page 716: ......

Page 717: ...oceed as follows On aircraft serial AA5 0230 and subsequent AA 5A and AA 5B canopy attach holes are jig drilled prior to canopy installation on the aircraft Aircraftpriorto this serial number havecano...

Page 718: ...NANCE MANUAL Canopy Removal Installation Figure 201 1 Screw 2 Roll Pin 3 Handle 4 Rivet 5 Screw 6 Shaft 7 Nut 8 Washer 9 Screw 10 Retainer 11 Seal Felt Tape 12 Window 13 Seal 14 Seal 15 Rivet 16 Retai...

Page 719: ...d may be loosened and slightly shifted The ideal condition isachieved when thegap canopy not in locked position between the bows isslightly greater atthe top 3 Canopy Latch Removal Installation A Cano...

Page 720: ...ce lever assembly 16 over spacer 21 and install washer 20 and nut 18 tighten nut 8 Place washers 17 over hole in housing 11 and slide bottom shaft oflever assembly 16 through washers 17 and housing 11...

Page 721: ...s Washers Guide Housing Spring Screw Washer Nyliner Lever Assembly Washers Nut Screw Washers Spacer Hook Nut Screw Washer Spacer Washer Rivet Screw Handle LOCK ASSEMBLY AA5 O001 THRU AA5 0440 AA 5 SER...

Page 722: ...oreign material from the window in an area approxi mately one inchwide around theedge of the window 2 Install seal felttape 11 Part No 7402 around edge of window 3 Position window 12 incanopy and secu...

Page 723: ...r provides an opening measuring approximately 24 by 12 inches for access to the baggage compartment The door is hinged on its forward end and provided with a chain type restraint to prevent damage to...

Page 724: ......

Page 725: ...dclevis pin 6 4 Removecotter pin 2 washer 7 andclevis pin 8 then remove link 9 5 Remove bolt 10 and washer 11 thenpull slide 12 from under clip 3 Remove washer 13 6 Removescrew 14 lockwasher 15 andlin...

Page 726: ...AA 5 SERIES MAINTENANCE MANUAL Baggage Door Removal Installation Figure 203 1 Rivet 2 Cotter Pin 3 Washer 4 Clevis 5 Latch 52 2 1 Page 202 Dec 15 77 v...

Page 727: ...mbly Assembly Figure 204 1 Spring 2 Cotter Pin 3 Clip 4 Cotter Pin 5 Washer 6 Clevis Pin 7 Washer 8 Clevis Pin 9 Link 10 Bolt 11 Washer 12 Slide 13 Washer 14 Screw 15 Lockwashers 16 Link 17 Camlock 18...

Page 728: ...orInstallation See Figure 205 NOTE If the doorisbeingreinstalled omit Step 3 1 Position door sothatitshinge fits between fuselage skin and thebaggage door facing 2 Adjust doorso that it fits within do...

Page 729: ...FUSELAGE SKIN AA 5 SERIES MAINTENANCE MANUAL RIVET HINGE BAGGAGE DOOR DOUBLER DOOR FACING Baggage Door Installation Figure 205 SEAL 3170 52 2 1 Page 205 Nov 15 76...

Page 730: ...ces with isopropyl alcohol and a small brush and then injecting a smallamount of spraylubricant into the I sliding surfaces Production aircraft canopy tracks are lubricated with E Z Free lubricant whi...

Page 731: ...odge excess dirtandmud without scratching the plexiglas 2 Wash with soap and water Use a sponge orheavy wadding of asoftcloth DO NOT rub as theabrasive action In the dirt and mud residue will cause fi...

Page 732: ...0001 thru 0405 Removal Installation of Dorsal Fin AA5 0406 and Subsequent AA 5AandAA 5B Removal Installation of Fillet AA 5 Removal Installation of Horizontal Stabilizer Fairing AA 5A and AA 5B Remova...

Page 733: ...carry through spar extendsthrough the main fuselage structure beneaththe pilotandco pilot s seats and provides attach points for thewings and themain landing gear Thespar isattached to the fuselage st...

Page 734: ...AA 5 SERIES MAINTENANCE MANUAL ACCESS COVERS INBOARD SPAR Fuselage Assembly AA 5 Serial No 0001 Thru 0405 Figure 1 Sheet 1 of 2 53 0 Page 2 Nov 15 76 i a l...

Page 735: ...L NO 0641 AND SUBSEQUENT ANO AA SA INBOARD SPAR AA 5 SERIES MAINTENANCE MANUAL ACCESS COVERS 3284 Fuselage Assembly AA 5 Serial No 0406 and Subsequent AA 5A and AA 5B Figure 1 Sheet 2 of 2 53 0 Page 3...

Page 736: ......

Page 737: ...boltholes inlower sup port brackets 2 Install bolts washers and nutsthatattach lower support brackets to inboard spar but donottighten nuts 3 Position upper support brackets in place and secure to fus...

Page 738: ...Removal Installation of Dorsal Fin AA 5Serial No 0406and Subsequent AA 5A andAA 5B See Figure 202 A Remove Dorsal Fin 1 Remove screws and washers that attach dorsal fin to vertical stabilizer 2 Slide...

Page 739: ...AA 5 SERIAL NO 0406 AND SUBSEQUENT AA SA AND AA 5B CHANNEL AA 5 SERIES MAINTENANCE MANUAL 3285 Dorsal Fin and Horizontal Stabilizer Fairings Figure 202 53 0 Page 203 July 15 78...

Page 740: ...lation ofTailcone See Figure 203 I A Remove Tailcone 1 Remove screws that secure tailcone to aft fuselage 2 Slide tailconeback disconnect tail lightwires and remove tailcone B Install Tailcone 1 Conne...

Page 741: ...ATT FUSE LAGS BULKHEAD AA 5 SERIES MAINTENANCE MANUAL SCREW UPPER TAILCONE HALF LOWER TAILCONE HALF NUT CLIP 3287 DETAIL A Tailcone Installation Figure 203 LIGHT ASSEMBLY 53 0 Page 205 July 15 78...

Page 742: ...S MAINTENANCE MANUAL SKID NUT WASHER AA 5 SERIAL NO 0047 AND SUBSEQUENT CHERRY RIVET DETAIL A Ventral Fin Assembly Figure 204 SKID AA 5 SERIAL NO 0001 THROUGH 0046 BOLT EYE BOLT 3286 53 0 Page 206 Jul...

Page 743: ...terysupportbracketmounted on the lower firewall the instrumentpanel support bracket and the shoulderharness and baggage tiedown attach fittings aresecured to the fuselage structure witheither screws o...

Page 744: ...iption Operation General Maintenance Practices Forward Spar Attach Point Inspection Removal Installation AA 5A and AA 5B Elevator Bearing Removal Installation Removal Installation AA 5 Aircraft 55 2 1...

Page 745: ...ACH POINT AAS SERIES MAINTENANCE MANUAL HINGE Horizontal Stabilizer AA 5 Figure 1 FRONT RIB TENTER rib HINGE REAR SPAR HINGE Horizontal Stabilizer AA 5A and AA 5D Figure 2 REAR SPAR HINGE HINGE 55 1 1...

Page 746: ...d mirrorto performthe following inspections Refer to Figure 3 a Inspect spar support angles 1 and 2 for delamination cracks and buckling above and below stabilizer spar 3 Also inspect the upper flange...

Page 747: ...or intact or by sub assembly removal procedures whichever is required If the trim tabs or elevators are being replaced this can be accomplished without removing the stabilizer For complete stabilizer...

Page 748: ...bracket support assembly to align the aft attach lugsofsupport assembly 7 flush with the external surface of the aft bulkhead 2 Install the aft spar mounting bolts 10 andwashers 11 Torqueto standardv...

Page 749: ...AA 5 Scries Maintenance Manual 5301034 3 SHIM Horizontal Stabilizer Removal Installation Figure 4 Sheet 1 of 2 55 1 1 Page 204 Rev 03 01 04...

Page 750: ...t and Washer 4 AN4 Bolt and Washer 5 5301034 3 Shim 6 5302055 5 Shim 7 Pulley Bracket Support Assembly 8 AN4 Bolts 9 Washers 10 Bolt 11 Washers 12 Stop Elevator 13 Spacer 14 Inboard Hinge Horizontal S...

Page 751: ...into a bearing bracket and considered asingle unit When an elevator hinge bearing requires replacement the complete assembly must be replaced 1 Bolt 2 Washer 3 Hinge Assembly 4 Brace 5 Washer 6 Nut 7...

Page 752: ...ofa new horizontal stabilizer orif the factory shimming setup can notbedetermined then align the hinges by installing shims 12 as necessary between hinge assembly 11 andspar 13 2 Locate hinge assembly...

Page 753: ...ring bearing 4 4 Loosen lock nuts 5 and remove elevator stop bolts 6 n NOTE Before removing horizontal stabilizer mounting bolts plac stands beneath hori zontal stabilizer to prevent its falling 5 Rem...

Page 754: ...cknuts 6 Stop BolU 7 Bolt 8 Washer 9 AtUch BolU 10 Washers 11 Shim 12 Spacers 13 Fltngt 14 RlveU 15 RlveU 16 SUbllizer AA 5 SERIES MAINTENANCE MANUAL Horizonul Stabilizer Removal Installation AA 5 Air...

Page 755: ...nge 13 and fuselage aft bulkhead Align bolt holes and secure with bolts 9 and washers 10 Torque to standard value Refer to Chapter 91 Screw lock nuts 5 on bolts 6 and install bolts 6 Do not tighten bo...

Page 756: ...ertical stabilizer is ofconventional dual sparand ribconstruction with itsskinbonded to theribs and spars Ithas a tapered chord with its maximum chord atthe root and its minimum chord atthe tip RIB SK...

Page 757: ...ation General Maintenance Practices Removal Installation of Horizontal Stabilizer AA 5 Aircraft Removal Installation of Horizontal Stabilizer AA 5A and AA 5B Aircraft I Cleaning Painting I 5 2 l VERTI...

Page 758: ......

Page 759: ...horizontalandvertical stabilizers are the fixed empennage structures to which the elevators and rudder are connected Inaddition to providing attachment points for the control surfaces the stabi lizers...

Page 760: ......

Page 761: ...orizontal stabilizers are ofconventional dual spar and rib structure with the skin bonded to the ribs and spars On the AA 5 aircraft thehorizontal stabilizer has a tapered chord wider at the root than...

Page 762: ...POINT AA 5 SERIES MAINTENANCE MANUAL SKIN HINGE REAR SPAR Horizontal Stabilizer AA 5 Figure 1 FRONT RIB CENTER RI8 HINGE HINGE REAR SPAR HINGE 3512 HINGE 3913 Horizontal Stabilizer AA 5A and AA 5B Fi...

Page 763: ...washers 10 7 Spread stabilizer assemblyapart at forward edge just enough to free forward attaching lugs from fuselage and remove assembly from rear of aircraft 8 When stabilizer is removed note positi...

Page 764: ...Stop Bolts 7 Bolt 8 Washer 9 Attach Bolts 10 Washers 11 Shim 12 Spacers 13 Flange 14 Rivets 15 Rivets 16 Stabilizer AA 5 SERIES MAINTENANCE MANUAL Horizontal Stabilizer Removal Installation AA 5 Aircr...

Page 765: ...8 Torque to standard value Refer 4 to Chapter 91 I f 11 Connectelevator controls and rig CRefer to Chapter 27 12 Install aft fuselage inspection covers and tailcone Refer to Chapter 53 C Horizontal St...

Page 766: ...UAL Horizontal Stabilizer Removal Installation AA 5A and AA 5B Aircraft Figure 202 Forward Mounting Bolts Washers Hinge MountingBolts Washers Spar Attach Bolts Washers ElevatorStop Bolts Spacers Hinge...

Page 767: ...s 5 and washers 6 Torque to standard value fRefer to Chan ter 91 3 Position hinge 9 on aft spar andsecure withbolts 3 and washers 4 4 Install elevator stops 7 and spacers 8 5 Connect elevator and trim...

Page 768: ......

Page 769: ...rtical stabilizer Is of conventional dual spar and rib construction with its skin bondedto the ribs and spars It has a tapered chord with Its maximum chord at the root and its minimum chord at the tip...

Page 770: ...iT r...

Page 771: ...r 2 4 Remove aft attachment bolts 3 and washers 4 5 Disconnect antenna and rotating beacon wiring Refer to Chapter 27 6 Remove vertical stabilizer and rudder from aircraft B Vertical Stabilizer Instal...

Page 772: ...I AA 5 SERIES MAINTENANCE MANUAL 1 Front Attach Bolt 2 Washer 3 Aft Attachment Bolts 4 Washers Vertical Stabilizer Removal Installation Figure 201 55 2 1 Page 202 Dec 15 77 Sfek S t...

Page 773: ...R 56 WINDOWS TABLE OF CONTENTS General Windshield Canopy and Aft Fuselage CabinWindows Maintenance Practices Removal Installation of Windshield Removal Installation of Aft Fuselage Window Removal Inst...

Page 774: ...U i j v y f...

Page 775: ...gether and serviced as asingle unit Thewindshield is attached to the forward fuselage and due to itswrap around design affords excellent visibility Thewindshield is heated by means of twodefroster ven...

Page 776: ...hield Installation See Figure 201 1 Make sure faying surfaces of windshield and upper forward fuselage assembly are clean and dry a The plexiglas faying surface may becleaned with acloth moistenedwith...

Page 777: ...mbly 2 Bolt 3 Washer 4 Nut 5 Screw 6 Screw 7 Rivet AA 5 SERIES MAINTENANCE MANUAL 3 4 1 Windshield Installation Figure 201 8 Support 9 Tape Vinyl Foam 10 Bracket 11 Shim 12 Retainer 13 Rivet 56 0 Page...

Page 778: ...be wipedoff 5 Install aft fuselage moulding Referto Chapter 25 13 Removal Installation of Canopy Window Forcanopywindowremoval andinstallation procedures referto Chapter 52 4 Cleaning A Windshield and...

Page 779: ...E lW j3L if j iSijMji5P...

Page 780: ...CONTENTS 57 0 WINGS Description General Wing Root Wing Tips Wing Interchangeability Maintenance Practices Wing Removal Installation v Wing Root Removal Installation Wing Tip Removal Installation Wing...

Page 781: ...s to the fuel tanks 3 Wing Tips The wing tips are the outermost partof thewing assembly They blend the wing leading edge and trailing I edge into a single unit The wingtips house the aileronbalance we...

Page 782: ......

Page 783: ...N DO NOT DISTURB THE CABLE TURNBUCKLES OR CONTROL SURFACE RIGGING 7 Remove the nut and bolt securing the aileron horn tothe torque tube and remove it from the torque tubeby rotating and sliding from t...

Page 784: ...urpose lubricating oil over the inner wing panel spar mating surface Approved solid film lubricants are a McLube 1708 by McGee Chemical Co Inc b Lube Lok 5396 by Allen Aircraft Products Inc 2 Work the...

Page 785: ...016 inch shim to reduce gap to not morethan0 008inch unshimmed gap less shimthickness asdescribed in Steps b through f below See Figure205 b Sand edgesof the shim s down to remove sharpcomers c Place...

Page 786: ...202 should be centeredon a line drawn 0 31 inch up from the flap surface on the bottom sideof the wingand tapedin place andthe aircraft test flown to fine tune the wing Per form aseries ofstallsat ha...

Page 787: ...Half L H Figure 202 3S20 9 Washer 10 Cover 11 Screw 12 Screw 13 Wing Tip Assembly 14 Outer panel Assembly 15 Stall Strip AILERON HORN ASSEMBLY NOTE WHEN REMOVING AILERONS DO NOT DISTURB AILERON RIGGI...

Page 788: ...E MANUAL 1 Flap Torque Tube Horn 2 Safety Wire AA5 0001ThruAA5 0050 Only 3 Special Drive Bolts 4 Flap Torque Tube Bellcrank Flap Drive Assembly Figure 204 Shim Installation Figure 205 3521 3522 SHIMS...

Page 789: ...ed in the root and holesin the inboard edge ofthe wing root with holes in the fuselage side 3 Install the bolts 6 washers 7 andspacers 8 to secure the supportbrackets with root attached to the fuselag...

Page 790: ...im paneling Refer to Aft Fuselage InnerTrim Paneling Installation Chapter 25 3 Wing Tip Removal Installation A 4 Wing Tip Removal I NOTE Numbers in parentheses refer to Figure 202 1 Remove the screws...

Page 791: ...e and install the bolt in the remaining nut plate toensure properalign ment 4 Drill and ream the mounting holes in the wing and center spar to 0 4375 0 4395 inch Remove the wing from the airplane 5 Mo...

Page 792: ...2 501 SPACER ASSEMBLY MS20426AD4 7 RIVETS NOTE Rotate P7nut plate approximately as shown to allow suffi cient rivet edge clearance Drill 0 128 0 133 holes Counter sink 100 x 0 242 diameter on the oppo...

Page 793: ...ription Operation General AA 5 and AA 5A Propeller AA 5B Propeller 61 1 1 PROPELLER ASSEMBLY Description Operation General Maintenance Practices Servicing Propeller Removal Installation Inspection Che...

Page 794: ...n Part numbers for the propeller are as follows If an aluminum spacer is used the part number Is 1C172 BTM 7359 If a steel spacer is used the part number is 1C172 SBTM 7359 B AA 5B Propeller The AA 5B...

Page 795: ...a formed aluminum spinner an aluminum support bulkhead assembly to which it issecured byscrews and washers CAUTION DO NOT MOVETHE AIRCRAFT ONTHE GROUND BY PUSHING ON THE SPINNER STORE THE AIRCRAFT WI...

Page 796: ......

Page 797: ...ow 1 Place backplate assembly 10 overdowel pins 11 in spacer 9 NOTE Propeller and spacer are matched during manufacturing Align propeller serial No stamped on spacerwith No 1 propellerblade for best b...

Page 798: ...9 SPACER 10 BACKPLATE ASSY 11 DOWEL PIN AA5A 0830 AND SUBSEQUENT AA5B 1048 AND SUBSEQUENT AA5 0001 AND SUBSEQUENT WITH SERVICE KIT 143 AA5A 0001 THROUGH 0829 WITH SERVICE KIT 143 AA5B 0001 THROUGH 104...

Page 799: ...9 down 5 Using a fiber orsoft metal 3 8inchdrift punch drive the dowel pins 8 from the propeller 7 Remove spacer 9 and aft bulkhead assembly 10 D Propeller Installation AA5A 0830 andsubsequent AA5B 10...

Page 800: ...e A small thin sectionof metalextendingbeyond aregular surface usually located at a comer or on the edge of a bore or hole Loss of metal from the surfaceby chemical or electrochemical action The corro...

Page 801: ...143 AA5B 0001 THROUGH 1047 WITHOUT SERVICE KIT 143 5 I 13 14 I 10 AA5A 0830 AND SUBSEQUENT AA5B 1048 AND SUBSEQUENT AA5 0001 AND SUBSEQUENT WITH SERVICE KIT 143 AA5A 0001 THROUGH 0829 WITH SERVICE KIT...

Page 802: ...hour inspection Visually inspect thebulkheads and doubler for security f o f mounting cracks missing ordamaged plate nuts Inspect thespinner items listed insub paragraphs 2 3 and 4 above On early mode...

Page 803: ...ublishedby the propeller manufacturer B SpinnerAssembly Repair 1 Spinner and components repair consists ofreplacement ofmissing or loose attachment hardware screws and nutplates If thespinner iswarped...

Page 804: ...l t C j vi i...

Page 805: ...air pressure that is forced over and around the cylinders by the use of baffles The air is then exhausted to the atmosphere through exit ducts located in the bottom of the lower cowl 2 Engine Data f A...

Page 806: ......

Page 807: ...Power Plant 201 i Power Plant Removal Installation 201 171 1 1 POWER PLANT COWLING f Description Operation 1 General 1 Maintenance Practices 201 I Removal Installation AA 5 Serial No 0001 through 064...

Page 808: ...MAINTENANCE MANUAL NUMBER PAGE 71 6 2 ENGINE BAFFLES Description Operation 1 General 1 Maintenance Practices 201 Removal Installation r 201 71 7 1 ENGINE DRAINS Description 1 General 1 I 71 Page 2 Ju...

Page 809: ...ive ignition wire Check with electric tester and replace any defective wires Water in carburetor Drain carburetor and lines Internal failure Check oil sump for metal particles if found com plete overh...

Page 810: ...f fuel Empty tank and fill with proper grade fuel failure ofengine todevelop full power Throttle not properly adjusted Adjust throttle lever Leak in the induction system Tighten all connections and re...

Page 811: ...nt oil supply Check oil supply and fill as recommended Insufficient cooling air Check cowl inlet and out let for obstructions Check baffles Low grade of oil Replace with oil conform ing to specificati...

Page 812: ...stabilizes Engine does not stop Mixture control not correctly adjusted Adjust mixture control Faulty ignition system Check ground wires Cold weather difficulties Cold oil Heat oil Weak battery Rechar...

Page 813: ...d openings in the engine Keep the amount of solvent contacting wiring to a mini mum Removal Installation of Power Plant A Remove Power Plant CAUTION PRIOR TO REMOVAL OF THE ENGINE PLACE A SUPPORT UNDE...

Page 814: ...uum pump hose at the pump 6 Connect the tachometer cable 7 Connect the main fuel line at the inlet to the engine driven fuel pump 8 Connect the fuel and oil pressure lines 9 Connect the throttle mixtu...

Page 815: ...o the lower cowl on each side The upper cowl can be raised to gain access to the engine for inspection service or minor repair The lower cowl assembly encloses the lower engine components and must be...

Page 816: ......

Page 817: ...wl assembly 8 on front ofengine and connect landing light wires 4 2 Install spacer propeller and propeUer spinner refer toChapter 61 3 Position lower cowl assembly 7 in place onengine and install wash...

Page 818: ...MAINTENANCE MANUAL 1 Cowl Latch 2 Screw 3 Upper Cowl Ass y 4 Screw 3256 5 Screw 6 Washer 7 Lower Cowl Ass y 8 Forward Cowl Ass y Cowl Assembly AA 5 Serial No 0001 thru 0640 Figure 201 71 1 1 Page 202...

Page 819: ...11 and inside diameter of guide bushing 13 with lubricant I McLube 1708 by McGee Chemicals Company Inc J 1 Position forward cowl assembly 10 on front of engine and connectlanding lightwires NOTE For...

Page 820: ...ANUAL 3257 1 Latch 6 Screw 11 Latch Pin 2 Nut 7 Screw 12 Clevis Pin 3 Bolt 8 Screw 13 Guide Bushing 4 Washer 9 Lower Cowl Ass y 5 Upper Cowl Ass y 10 Forward Cowl Ass y Cowl Assembly AA 5 Serial No 06...

Page 821: ...f the engine mount is to support the engine and attach the engine to the airframe The engine is attached to the mount at four places using vibration Isolator type shock mount assemblies bolts and self...

Page 822: ...oval 2 Disconnectall wiring ties and clamps attachedto engine mount 3 Remove nuts washers and bolts securing mount to engine mount supports and remove mount B Install Engine Mount See Figures 201 and...

Page 823: ...AA 5 SERIES MAINTENANCE MANUAL BOLT WASHER Engine Mount Installation AA 5 and AA 5A Figure 201 71 2 1 Page 202 July 15 78...

Page 824: ...AA 5 SERIES MAINTENANCE MANUAL Engine Mount Installation AA 5B Figure 202 71 2 1 Page 203 July 15 78...

Page 825: ......

Page 826: ...n the AA 5 and AA 5A an opening in the lower front of the forward cowl provides ram air directly to the carburetor air filter and then to the carburetor On the AA 5B ram air enters the openings in the...

Page 827: ...AA 5 SERIES MAINTENANCE MANUAL AA 5 SERIAL NO 0641 AND SUBSEQUENT AND AA SA AA 6 SERIAL NO 0001 THROUGH 0840 AA SB Engine Air Intake Systems Figure 1 71 6 1 Page 2 Nov 15 76 t j...

Page 828: ...ttached to the engine and direct the cooling air around the engine to provide optimum engine cooling The complete baffles are composed of several segments which provides for easy removal and replaceme...

Page 829: ......

Page 830: ...d bolts that secure baffles to engine 7 Remove screws that secure baffle segments togetherwhere necessary to remove Individual segments and remove baffles B Install Engine Baffles See Figures 201 and...

Page 831: ...TER AA 5 SERIES MAINTENANCE MANUAL SPRING STIFFENER BAFFLE AND SEAL ASSEMBLY REAR RH Engine Baffles AA 5 and AA 5A Figure 201 BRACKET BAFFLE AND SEAL ASSEMBLY REAR LH BAFFLE AND SEAL 6L ASSEMBLY LEFT...

Page 832: ...GHT SIDE AA 5 SERIES MAINTENANCE MANUAL STIFFENER FRONT BAFFLE AND SEAL ASSEMBLY Engine Baffles AA 5B Figure 202 BAFFLE AND SEAL ASSEMBLY REAR 3262 BRACKET BAFFLE AND SEAL ASSEMBLY LETT SIDE CLOSEOUT...

Page 833: ......

Page 834: ...ex tendedby a piece of aluminum tubingattached to the flexible line with a spring clamp The fuel pump drain line may be either a clear plastic line attached to the pump vent by a spring type clamp or...

Page 835: ...I T Ki y yii...

Page 836: ...tem AA 5 Serial No 0641 and Subsequent and AA 5A 201 Removal Installation of Air InductionSystem AA 5B 204 Filter Servicing AA 5 Serial No 0001 through 0640 204 Filter Servicing AA 5 Serial No 0641 an...

Page 837: ...01 73 2 2 MIXTURE CONTROL Description Operation 1 General 1 Maintenance Practices 201 Removal Installation of Mixture Control 201 Idle Speed and Mixture Adjustment 204 73 3 1 FUEL PRESSURE GAGE Descri...

Page 838: ...controls fuel primer and fuel pressure indicator The induction system consists of the air box assembly flexible ducts and air filters The air portion includes the air induction system and associated c...

Page 839: ...the inductioninlet duct AA 5 aircraft Serial No 0641 and subsequent and AA 5A has apolyurethane type filter that isalso located in the induction inlet duct The AA5B 0001 through 0950 filter is apolyur...

Page 840: ...he air duct is properly fitted over the scoop in the forward cowl Failure to do this could result in an inadequate air supply to the carburetor 2 Removal Installation of Air Induction System AA 5 Seri...

Page 841: ...AIR BOX ASSEMBLY CARBURET R CARBURETOR HEAT CONTROL AA SSERIES MNMMMKSMANUAL AIR FILTER AlrinductionSystem AA 5 INTAKE DUCT 73 1 1 page 202 Nov 15 16 BV...

Page 842: ...CARBURETOR V MISERIES MA1NTENANCEMANUAL A RB X CARBURETOR ASSENIBLV HEAT CONTROL SSSS AIR INTAKE AA 5A 73 1 1 page 203 ovl5 16...

Page 843: ...e carburetor heat and induction air hoses and clamp to the air box filter housing 5 Install the lower cowl 4 Filter Servicing AA 5 Serial No 0001 through 0640 A Remove Service and Install Filter 1 Rem...

Page 844: ...Service and Install Filter 1 Remove the lower cowl assembly 2 Unbolt filter access doow on the bottomof theair box filter housing 3 On aircraft with foam type filter installed replace filter if filter...

Page 845: ...EAT CONTROL AIR BOX FILTER HOUSING SCREEN AA 5 SERIES MAINTENANCE MANUAL DETAIL A CARBURETOR CARBURETOR HEAT DUCT Air Induction System AA 5B Figure 203 THROTTLE CONTROL FILTER ACCESS DOOR 73 1 1 Page...

Page 846: ...ith a single barrel float type carburetor which incorporates an Idle cut off mechanism and a manual mixture control On AA 5 and AA 5A aircraft the carburetor is mounted on the bottom of the engine On...

Page 847: ...Remove four nuts and washers and remove carburetor B Install Carburetor 1 Using anew gasket position carburetor toengine and install washers nuts and Pal nuts 2 On AA 5 and AA 5A use a new gasket and...

Page 848: ...CARBURETOR THROTTLE CONTROL SUPPORT BRACKET GASKET AA 5 SERIES MAINTENANCE MANUAL CARBURETOR S Sn Carburetor Installation AA 5 AA 5A Figure 201 3225 73 1 2 Page 202 Nov 15 76 liSC Sk y S v...

Page 849: ...AIR INDUCTION SYSTEM AA 5 SERIES MAINTENANCE MANUAL CARBURETOR Carburetor Installation AA 5B Figure 202 73 1 2 Page 203 Nov 15 76...

Page 850: ...J...

Page 851: ...t panel Fuel to the primer is obtained from a tee connection In the fuel line from the left sump The primer knob can be locked In the closed position by pushing fully in and rotating either left or ri...

Page 852: ...o i vfr Hv i...

Page 853: ...gthe primer 5 Remove primer knob plunger spacer and knurled nut as an assembly from the front of the instrument panel 6 Remove primer body from rear of instrument panel it _ B Install Primer System 1...

Page 854: ...TEE CONNECTOR AA 5 SERIES MAINTENANCE MANUAL 3330 Primer Lines Installation Figure 201 ENGINE PRIMER LINES 73 1 3 Page 202 Nov 15 76...

Page 855: ...FUEL INLET LINE FUEL OUTLET LINE AA 5 SERIES MAINTENANCE MANUAL 7 KNURLED NUT INSTRUMENTPANEL Engine Primer Figure 202 PRIMER KNOB ASSEMBLY 3231 73 1 3 Page 203 Nov 15 76...

Page 856: ......

Page 857: ...engine by controlling the amount of the fuel air mixture that moves into the engine cylinders The throttle control is located in the lower center of the Instrument panel and is connected to the carbu...

Page 858: ...retor I f 3 Install and tighten the nut 11 on the throttle housing behind the instrument panel 4 Position the throttle plunger sleeve 4 in the slotin the supportbracket 5 andinstall the lock plate 3 I...

Page 859: ...LUNGER 8 BOOT TORQUE NUT TO 30 48 IN LBS INSTALL COTTER PIN 9 800T 10 CLAMP 11 THROTTLE HOUSING RETAINER NUT 12 THROTTLE CABLE 13 THROTTLE KNOB 14 FRICTION LOCK 15 JAM NUT 16 THROTTLE ARM CLAMP SCREW...

Page 860: ...instrument paneland slidethe housing retainer nut 9 over the end of the cable 2 Route cable through the firewall to the carburetor 3 Install and tighten the nut 9 on the throttle housing behind the i...

Page 861: ...may be threaded out to 3 16 inch minimum thread engagement and Step 9 above repeated 11 Space between throttle knob jam nut 11 and friction jock 10 with throttle fully open friction lock slightly loos...

Page 862: ...JOINT 2 THROTTLE ARM 3 JAM NUT 4 THROTTLE PLUNGER SLEEVE 5 BOOT 6 CLAMP 7 AIRBOXASSFMBLY 8 THROTTLE CABLE 9 THROTTLE HOUSING RETAINER NUT 10 FRICTION LOCK 11 JAM NUT 12 THROTTLE KNOB 13 BOOT 14 SUPPO...

Page 863: ...ontrol is located on the lower center of the instrument panel adjacent to the throttle con trol The mixture control meters the amount of fuel that passes through the carburetor mainjet and Is used to...

Page 864: ...MDCTURE CONTROL CABLE DURING INSTALLATION 1 Pass the end of the control cable through the Instrument panel opening andslide the nut over the end of the cableandsecure housing to instrument panel I 2 C...

Page 865: ...n nut washers bearing and bolt from mixture control arm 3 Straighten mbcture control wire and remove wire from swivel assembly 4 Loosen clamp atbracket oncarburetor sufficiently toallow the cable to s...

Page 866: ...50 IN MIN BEND RADIUS AA 5 SERIES MAINTENANCE MANUAL CARBURETOR HEAT CONTROL CABLE TIE WRAP MIXTURE CONTROL CABLE CARBURETOR MIXTURE CONTROL ARM AIR BOX Mixture Control Cable Installation AA 5B Figur...

Page 867: ...Seal 700 Firewall sealant 13 Install cowl refer to Chapter 71 2 Idle Speed and Mbcture Adjustment A I Adjust Idle Speed and Mbcture Setting 1 Perform anormal engine warmup until oil temperature has s...

Page 868: ...instrument cluster assembly The instrument cluster assembly is locatedon the right hand side of the instrument panel The gage Is connected to the fuel inletonthe carburetor by an aluminum tube from t...

Page 869: ...r mounting screws andremove cluster assembly from instrument panel 5 Remove nut from shell of inlet nipple on backof pressure gageandremove gage from cluster case B Install Fuel Pressure Gage I WARNIN...

Page 870: ...FACE PLATE AA 5 SERIES MAINTENANCE MANUAL NUT NSTRUMENT CLUSTER 3232 Fuel Pressure Gage Installation Figure 201 INDICATOR ATTACHING NUT FUEL PRESSURE GAGE 73 3 1 Page 202 Nov 15 76...

Page 871: ...L CHAPTER 74 IGNITION TABLE OF CONTENTS IGNITION SYSTEM Description Operation General Maintenance Practices Inspection of Ignition System Components Removal Installation of Ignition System Components...

Page 872: ...dual ignition system consists of the magnetos shielded harness spark plugs and the ignition switch The magnetos are a sealed lightweight type requiring no internal adjustments Timing the magneto to th...

Page 873: ...g If necessary time the magnetos tothe engine The magneto to engine timing check should be made every 100 hours 2 Removal Installation of Ignition System Components A Remove Ignition Harness 1 Remove...

Page 874: ...AA 5 SERIES MAINTENANCE MANUAL No OISASSEMBUED ASSEMBLED Magneto Lead Arrangement Figure 201 74 0 Page 202 Dec 15 77 v HShfk...

Page 875: ...f the spark plug 2 Install spark plugs andtorque to 360 420 inch pounds 3 Install ignition harness leads tospark plugs Tighten nut finger tight plus one fourth turn 4 Install cowl Remove Magneto WARNI...

Page 876: ...ke a positive pressure will try to force the thumb off the port 2 The ring gear flywheel maybemarked at 20 or25 Consult Engine Specifications for correct timing mark for your installation 2 Continue t...

Page 877: ...Position the magneto into the crankcase at the approximate angle noted on removal Be sure gasket is installed behind the magneto mounting flange 7 Install the attach clip over the magneto mounting fl...

Page 878: ...um tolerance of 2 is allowable 14 Tighten themagneto mounting nuts and torque to 150 inch pounds and installmagneto ground wire and shielding terminal 15 When the magneto shows an excessive rpm loss o...

Page 879: ...the simplicity of the engine installed in AA 5 AA 5A and AA 5B aircraft a limited number of engine indicating instruments are required Most of the engine indicating instruments are discussed in their...

Page 880: ...ING TABLE OF CONTENTS NUMBER PAGE 77 0 ENGINE INDICATING SYSTEM Description Operation 1 General 1 77 1 1 TACHOMETER Description Operation 1 General 1 Maintenance Practices 201 Removal Installation of...

Page 881: ...formation necessary inmaking required power settings and adjustments for takeoff climb cruise and descent The tachometer is also used when making magneto checks andfor maintenance checks of the engine...

Page 882: ...r i SAi i i S It ir i...

Page 883: ...achometer and from engine 4 Cover connections on engine and tachometer with masking tape or plastic caps 5 Pull cable and housing through firewall 6 Pull cable out of housing D Install Tachometer Cabl...

Page 884: ...SHAFT AA 5 SERIES MAINTENANCE MANUAL Tachometer Figure 201 TACHOMETER MOUNTING SCREW 3191 77 1 1 Page 202 Nov 15 76...

Page 885: ...MANUAL CHAPTER 78 EXHAUST TABLE OF CONTENTS ENGINE EXHAUST SYSTEM Description Operation General Maintenance Practices Removal Installation of Engine Exhaust System Inspection of Exhaust System PAGE 1...

Page 886: ...for cabin heating Inlet airis picked up through an opening in the front of the shroud which ex tends slightly through an opening in the front baffle On Model AA 5 and AA 5A aircraft the carburetorhea...

Page 887: ...Position the muffler assembly on the risers apply approved sealant Walker Acousti Seal 5160 around riser to muffler joints and install bead clamps 3 Position support braces tobead clamps and install b...

Page 888: ...SHROUD SHELL ASSEMBLY AA 5 SERIES MAINTENANCE MANUAL GASKET Exhaust System Assembly AA 5 and AA 5A Figure 201 RISER BEAD CLAMP 3191 78 0 Page 202 Nov 15 76...

Page 889: ...SHROUD AA 5 SERIES MAINTENANCE MANUAL BEAD CLAMP Exhaust System Assembly AA 5B Figure 202 GASKET RISER 3192 78 0 Page 203 November 15 76...

Page 890: ...WAY FROM FLAMES WARNING DO NOT USE HIGHLY FLAMMABLE SOLVENTS ON ENGINE EXHAUST SYSTEM NEVER USE A WIRE BRUSH OR ABRASIVES TO CLEAN EXHAUST SYSTEMS OR MARK THE SYSTEM WITH LEAD PENCILS Inspect Exhaust...

Page 891: ...ric pressure to the tail pipe opening using a rubber plug or other suitable means of effecting a suitable seal NOTE The inside of the vacuum cleaner hose should be free of any contamination that might...

Page 892: ...ENGINE OIL SYSTEM Description Operation General Trouble Shooting Maintenance Practices Oil Cooler Removal Installation Oil Cooler Inspection Indicating Gages Removal Installation Inspection and Mainte...

Page 893: ...Anoptional item is the oil filler access door for servicing located on the right hand side of the upper cowl The oil cooler is mounted on the left rear engine baffle The cooler is connectedto the eng...

Page 894: ...unded Defective wiring Defective gage Defective probe Defective gage Low voltage REMEDY Inspect oil cooler core for dirt or obstructions and clean as necessary REMEDY Check oil supply and fill as reco...

Page 895: ...age 2 Oil Cooler Inspection A Inspect Oil Cooler 1 Inspect oil cooler air passages for dirt and obstructions 2 Inspect cooler core for cracks damage and evidence of leakage 3 Check flexible lines for...

Page 896: ...DOUBLER SPACER ATTACHING BOLTS OIL COOLER CORE AA 5 SERIES MAINTENANCE MANUAL Oil Cooler Installation Figure 201 ATTACHING SCREW INLET OUTLET FLEXIBLE LINES 3202 79 0 Page 202 Dec 15 77 k...

Page 897: ...FACE PLATE ATTACHING SCREW AA 5 SERIES MAINTENANCE MANUAL ATTACHING NUT CASE ASSEMBLY Instrument Cluster Assembly Figure 202 79 0 Page 203 Nov 15 76...

Page 898: ...exible oil hoses ateach 50 hour inspection 2 Examine flexible hose exterior for evidence ofleakage CAUTION AVOTD EXCESSIVE FLEXING AND SHARP BENDS WHEN EXAMINING HOSES FOR STIFFNESS 3 Check flexible o...

Page 899: ...ERIES MAINTENANCE MANUAL CHAPTER 80 STARTING TABLE OF CONTENTS STARTING SYSTEM Description Operation General Troubleshooting Maintenance Practices Removal Installation of Starting System Components PA...

Page 900: ...orner of theinstrument panel The same fuse also protects twoother circuits and isdecaled FUEL PUMP STROBE STARTER The starter relay Is located onthefront of the firewall and isconnected directly tothe...

Page 901: ...AA 5 SERIES MAINTENANCE MANUAL K S r S3 I J HI to 30 ft 3 I 5 5 u Starter Circuit Figure 1 80 1 1 Page 2 Nov 15 76 y E 8...

Page 902: ...duct continuity test across starter switch If circuit is open when button is depressed replace switch Defective starter motor Repair or replace S 1 Starter motor sluggish I Low battery Recharge or rep...

Page 903: ...BRACE MOUNTING BOLT STARTER MOUNTING BOLT AA 5 SERIES MAINTENANCE MANUAL ENGINE Starter Removal Installation Figure 201 GROUND WIRE 80 1 1 Page 202 July 15 78...

Page 904: ...lace and install mounting bolt 3 Connect starter cable and ground wire 4 Install cowl C Remove Starter Relay See Figure 202 NOTE Ensure that master switch is in OFF position 1 Raise right hand side of...

Page 905: ...AL F Install Starter Switch 1 Connect wiring to starter switch 2 Position switch in instrument panel and install hex nut on switch shell FIREWALL WASHER Starter Relay Removal Installation Figure 202 N...

Page 906: ...AA 5 SERIES MAINTENANCE MANUAL CHAPTER 91 CHARTS TABLE OF CONTENTS NUMBER PAGE 91 0 CHARTS Recommended Nut Torques 1 91 Page 3 Nov 15 76...

Page 907: ...ymW tt C A...

Page 908: ...00 270 390 1 2 20 480 690 480 730 290 410 290 500 9 16 18 00 1000 800 1070 480 600 480 750 5 8 18 1100 1300 1100 1600 660 780 660 1060 3 4 16 2300 2500 2300 3350 1300 1500 1300 2200 7 8 14 2500 3000 2...

Page 909: ...normal torquevalues use alternate torquevalues or replace nut 3 Covers AN316 AN320 AN7502and MS20364 4 Covers AN310 AN340 AN366 MS20365 and other self locking anchor nuts 5 Covers AN316 AN320 and MS20...

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