2-2. Inspection chart - cabin.
and fittings. Check system operation by moving the controls to make certain they function properly.
Carefully observe that no flammable material is in the vicinity of the heaters and exhaust lines or ports.
Check fuel selector valves for leaks, freedom of movement, positive detents, smooth operation, security of mounting, and placards. Any defects noted should be corrected immediately by a person authorized in FAR 43.
Check engine primer assembly for leaks and operation. Inspect the entire fuel system for general condition, mounting, and freedom from leaks.
Inspect electric wire bundles for general condition, chafing, and routing. Examine connections at terminals, junction boxes, cannon plugs, and clips for looseness and defects.
Check condition of circuit breakers, fuses, switches, voltage regulators, and reverse current relays.
Fuse clips (including spares) must be free from corrosion and hold fuses securely, yet permit easy removal. Replace burned out fuses with fuses of proper type and capacity. Replace any fuses used from the supply of spare fuses.
Inspect the hydraulic system reservoir for general condition, security of attachment, and proper fluid level. Examine the pressure ac- FIGURE 2-3. Operational check - fuel tank cumulator for defects. Check pumps for seselector valve. curity of mounting and condition. Inspect 22
CONTROL LOCK REMOVE BEFORE STARTING ENGINE FULL PAT 000 0 FIGURE 2-4. Circuit breaker and fuse panel.
FIGURE 2-5. Check quantity hydraulic fluid.
bypass valves and relief valves for leaks. Ensure that lines are properly secured and free from leaks, dents, kinks, cracks or chafing.
Check hydraulic brake master cylinder for fluid level and leaks.
Air and dirt in hydraulic systems are the most frequent causes of faulty operation. Air causes faulty release, irregular pressure, and noisy operation. Dirt and grit affect valve operation and produce leakage by cutting the various packings throughout the system.
When replenishing hydraulic fluid, NEVER mix dissimilar hydraulic fluids. This "mixing" can result in complete system failure.
Avoid spilling fluid when servicing hydraulie systems since some of these fluids severely damage paints and electrical insulation material.
Inspect all instruments for security of attachment, cleanliness, legibility of dial markings, security of glass dial covers, proper markings, and general appearance. The magnetic compass should be checked regularly for proper fluid level and accuracy. Check instrument panel indicating and warning lights for operation, condition, and security. Replace inoperative indicator bulbs. Vacuum lines that 23
~~09® 0 FICl.1RE 2-6. lnstnunent panel.
show signs of deterioration should be replaced. check of vacuum operated instruments is recom Inspect the instrument panel for freedom of mended to detect errati c operation . Dirty movement ~nd the shock mount s for signs of filters should be repla ced. Known or suspected deterioration. If the instrument panel is malfunctioning instrum ents should be removed equipped with shock mounts, the panel should and replaced, prior to furt her operation of the nut come in contact with any part of the air aircraft.
craft structure, line, or component , rigidl y Inspect all controls linkages for prope r func attached to the aircraft structure. tioning and general condition. Check cables When suspected of malfunctioning, the flight for fra yed strand s and proper tension . Ex instrum ents should be removed and bench amine pulleys anrl fairl eads for misali gnment, tested by a certified repair station or tested breakage, or looseness. Inspect bellcrank s and with a portable ground test unit . .A periodic torque tubes for alignment, cracks, freedom of movement, and proper safetying. Determine that the pulleys and fairlead s, through which the control cables pass, are clean and that the Fxcuru:; 2-7. Bell crank checkpoints . FxcuR£ 2-8. C able rubbing bulkhead .
surrounding structure does not interfere with their movement. Operate the controls to be sure there is no lost motion, binding, or chafing.
If inspection reveals that cables or control rods have been chafing against some portion of the structure, they should be realigned. If further inspection reveals the cables or control rods to be worn beyond an acceptable limit, they should be replaced.
CONTROL LOCK
REMOVE BEFORE STARTING ENGINE FUSE HE FIGURE 2-9. Gustlock.
Inspect gust locks for condition. Ensure that they release completely and cannot inadvertently engage.
FIGURE 2-11. Safety harness.
Inspect all safety belts and shoulder harnesses for excessive exposure to the deteriorating effects of sunrays, acid and dirt. Make certain the latching devices are in good condition and operating satifactorily. Ensure that all fittings and attachment parts are secure and in good condition.
FIGURE 2-10. Frayed safety belt.
Safety belts and shoulder harnesses that show evidence of cuts or fraying should be removed and replaced with approved-type belts. FIGURE 2-12. Inspection items on seat.
Inspect all seats and seat tracks for security of attachment, condition, and function of ad justing mechanisms. Floor carpets should be removed to permit inspection of the floor and associated structures to which seat and seat tracks are attached. This is the appropriate time to remove floor access covers and inspect floor substructure, controls, etc., below the floor.
Inspect all windows, windshield, and can opies for cracks, cleanliness, freedom of opera tion, and general condition. If your aircraft is pressurized, even minor flaws in windows, their attachment s, and operating mechanisms can be critical. If there is any question, ac quire the services of a certificated mechanic or repair station, 26
Section 3. ENGINE NACELLE FIGURE 3-1. Inspection chart - engine and nacelle.
1. FUEL SYSTEM-Look for signs of fuel dye which indicates a fuel leak. Visually check a small amount of fuel in a clear container, and drain sumps for water.
2. OIL SYSTEM-Check for indication of leaks.
Check oil quantity.
3. EXHAUST SYSTEM-Check for gray-white stains, which are indications of exhaust leaks at the cylinder head or cracks in stacks.
Check condition of heat muffs for cracks or leaks.
4. COOLING AIR SYSTEM (cowling and baffles) -Check for cracks in cowling and baffles.
Check for proper positioning of baffles, condition of seals, and security of fasteners.
5. INDUCTION AIR SYSTEM (air filter) -Check for proper installation, condition, cleanliness, possible restrictions to airflow, and system air leaks.
6. OTHER SYSTEMS-Check for proper installation and for cleanliness.
Remove and inspect the fuel strainer screens for damage and water or dirt contamination.
Clean screens, replace, and safety.
When reassembling the fuel strainer bowl, care must be exercised when tightening the bale wire. Insufficient tightening may result in leakage; excessive pressure may damage the bowl. Be sure trapped air is eliminated, ensuring unrestricted fuel flow. With fuel 27
A. Cylinder hold-down nuts. G. Accessory section.
B. Crankcase thru-bolts. H. Magnetos.
C. Fuel injection distributor. I. Instrument system pressure filter.
D. Ignition harness. J. Oil lines.
E. Cylinder cooling fins. K. Cowling seals.
F. Firewall.
FICURE 3-2. Inspection chart - engine.
selector and boost pump on, check the fuel strainer for leaks. Inspect fuel lines and connections for leakage, cracks, kinks, chafing. and security of mounting. Examine hoses and clamps for tightness and condition.
that fuel lines do not interfere with adjacent equipment or lines.
FICURE 3-3. Fuel strainer checkpoints.
Examine the primer system for general condition and perform an operational check. Inspect for leakage and security of attachment.
Ensure that all conections are tight. Copper primer lines should be periodically annealed to relieve brittleness, by a person authorized by FAR 43.
Inspect the carburetor for general condition, security of attachment, and defects. Inspect for excessive wear at throttle shaft, link assemblies, and hot air butterfly shaft bearing points. Wear can affect the fuel-air mixture resulting in erratic engine operation. Inspect FIGURE 3-4. Carburetor inspection points.
for leaks due to damaged gaskets, loose fittings.
or damaged fuel lines. Drain carburetor bowl and examine the gasoline for presence of water or other contamination. Remove and clean carburetor screens and inspect for damage.
Flush carburetor by turning fuel supply on momentarily. Replace screens and drain plugs and ensure they are properly safetied.
Remove the carburetor air filter. Clean and inspect for defects. Inspect all air ducts for condition, alignment, and security. Reinstall filter.
Inspect the carburetor air heater for condition and security. Operate the controls through the full travel range. If a questionable condition is found, contact a certificated repair station, mechanic, or the manufacturer for repairs.
The air filter and air heater are critical inspection items. Either can restrict the intake airflow and result in loss of engine power.
Follow manufacturer's instructions at all times.
Examine intake manifolds for general condition, cracks, kinks, and evidence of leakage.
Ensure that upper and lower packing nuts are tight and not leaking.
A. Before cleaning.
B. After cleaning.
FIGURE 3-5. Carburetor air filters.
when replacements are necessary. Replacement must done by persons authorized in FAR 43.
Inspect the oil tank for evidence of cracks or oil leaks, especially around welded seams
DO NOT FILL ABOVE В0TS FIGURF. 3-6. Intake manifold checkpoints.
cannot be corrected by tightening the nut, the If leaks around the intake pipe packing nut packing must be replaced. Use approved parts FIGURE 3-7. Oil tank inspection.
and fittings. Leaks should be traced to their source and corrected.
Check the oil tank retainer straps for evidence of chafing and for security of attachment. If chafing has occurred or the proper security cannot be obtained, antichafe pad replacement is necessary.
NGINE FIGURE 3-9. Satisfactory oil line installation.
FIGURE 3-8. Oil quantity check.
On wet sump engines, inspect the sump for evidence of leaks. Remove oil sump plug and inspect for foreign particles. Remove, inspect, and clean oil sump strainers. Reinstall drain plugs and strainers, and safety immediately The presence of metal particles usually indicates an internal failure. It will be necessary to make a thorough internal inspection of the engine which, in most cases, requires a complete engine disassembly. Fill the system with the type and grade of oil recommended by the manufacturer, for the climatic conditions to be encountered.
Inspect oil lines for leakage and security of attachment, particularly at connections.
hoses should be inspected for exterior checks FIGURE 3-10. Unsatisfactory oil line installation.
and cracks, and proper tension and location of clamps. Any leaks must be repaired immediately.
FIGURE 3-11. Oil-cooler checkpoints.
If the lubrication system incorporates an oil cooler or radiator, examine it very carefully for leaks, defects, and security of mounting.
Any leaks or defects will require replacement of the unit before further service.
Using a torque wrench, check the tightness of the spark plugs to the torque recommended by the manufacturer.
Examine ignition wiring and connections for general condition. Inspect spark plug barrels, elbows, and knurled nuts for proper tightness.
Inspect shielding and bonding for condition and security.
Periodically inspect spark plug "cigarettes" for cleanliness, cracks, and broken spring contacts. Figure 3-13 shows a burned spark plug cigarette. For maximum efficiency of the ignition system, this spark plug cigarette should be replaced.
CAUTION If your engine is a gas-turbine type, its ignition system is entirely different from that used on reciprocating engines.
Work on turbine engine ignition systems can resuit in SEVERE BODILY INJURY OR DEATH due to electrical shock, unless you are fully familiar with recommended procedures.
Figure 3-14 shows the normal condition of a gas turbine igniter plug and illustrates how they differ from spark plugs FIGURE 3-12. Checking sparkplug torque.
FICURE 3-14. Igniter plug - gas turbine engine.
FIGURE 3-13. Unsatisfactory sparkplug cigarette.
FIGURE 3-15. Exhaust manifold checkpoints.