THRUSH AIRCRAFT INC. TURBO THRUSH AIRCRAFT MAINTENANCE MANUAL SINGLE COCKPIT AND DUAL COCKPIT

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1 THRUSH AIRCRAFT INC. TURBO THRUSH AIRCRAFT MAINTENANCE MANUAL SINGLE COCKPIT AND DUAL COCKPIT Model S2R T34 Serial Numbers T & Up Manual Number: T34-2 Issued: January 26, 2005 Note: All serial numbers with the DC suffix indicate the dual cockpit configuration. Manufacturer s Serial Number: Registration Number: Thrush Aircraft Inc. 300 Old Pretoria Road Albany, GA Telephone: Fax: Effective: Revision 1 Dated: 2/14/2014 i

2 Rev. No. THRUSH AIRCRAFT INC MODEL S2R-T34 TURBO THRUSH AIRCRAFT MAINTENANCE MANUAL LOG OF REVISIONS Section Pages Description of Revisions FAA Accepted/DATE New All All New Manual Preface Pages Sect 2 Servicing & Inspection i vii 2-1 & Log of Pages and Log of Revisions updated to reflect Revision 1. Section Table of Contents Added P&WC recommended oil levels. Added 100 hour inspection for GCU and associated Relays. Cindy Lorenzen, FAA Program Manager Atlanta Aircraft Certification Office Issue Date 1/26/2005 Approval Date 2/22/2005 Sect 10 Electrical System 10-1 & & thru Updated Table of Contents; Page numbers repaginated after update of TOC Define effectivity for Voltage regulator in General Description of Electrical Sys. Added Generator Control Unit to General Description of Electrical System and defined effectivity. Added Generator Control Unit to Generator System. Updated Generator System to reflect change from voltage regulator and reverse current relay to GCU (Generator Control Unit) power distribution system Added methods of Troubleshooting for GCU. Defined Methods of Control: Voltage Regulation. Defined Method of Control: Generator Control Unit. Define GCU relay removal/install procedures Changed Figure 10-11to be 10-11a: Engine/Pratt &Whitney Power Distribution T thru T Accepted by: Cindy Lorenzen Feb. 14, Added Figure 10-11b: Engine/Pratt &Whitney Power Distribution T & Subsequent Changed Figure 10-13to be 10-13a: Quick Disconnect QDA for T thru T Added Figure 10-13b: Quick Disconnect QDA T & Subsequent Changed Figure to 10.21a: Quick Disconnect QDJ for T thru Added Figure 10.21b: Quick Disconnect QDJ for T & Subsequent NOTE: THIS REVISION HAD INCORRECT PAGE NUMBERS IN THIS LOG OF REVISION AND LOG OF PAGES WHEN ACCEPTED FEB 14, MANUALS DISTRIBUTED AFTER 5/6/2015 CONTAIN THE CORRECT PAGE NUMBERS & REFERENCE. Effective: Revision 1 Dated: 2/14/2014 ii

3 PAGE THRUSH AIRCRAFT INC MODEL S2R-T34 TURBO THRUSH AIRCRAFT MAINTENANCE MANUAL LOG OF PAGES REV DATE i Cover 2/14/14 ii Log of Revisions 2/14/14 iii Log of Effective Pages 2/14/14 iv Log of Effective Pages 2/14/14 v Log of Effective Pages 2/14/14 vi Log of Effective Pages 2/14/14 vii Introduction 2/14/14 SECT 1 GENERAL INFORMATION 1-1 1/26/ /26/ /26/ /26/ /26/ /26/ /26/ /26/ /26/ /26/ /26/05 SECT 2 SERVICING & INSPECTION 2-1 2/14/ /14/ /26/ /26/ /26/ /26/ /26/ /26/ /26/ /26/ /26/ /26/ /26/ /26/ /26/ /26/ /26/ /26/ /26/ /26/ /26/ /26/ /14/ /26/ /26/ /26/ /26/05 Effective: Revision 1 Dated: 2/14/2014 PAGE REV DATE /26/ /26/ /26/ /26/ /26/ /26/ /26/ /14/ /26/ /26/ /26/ /26/ /26/ /26/ /26/ /26/ /26/ /26/ /26/ /26/ /26/ /26/ /26/ /26/ /26/ /26/05 SECT 3 HYDRAULIC SYSTEM 3-1 1/26/ /26/05 SECT 4 POWERPLANT & PROPELLER 4-1 1/26/ /26/ /26/ /26/ /26/ /26/ /26/ /26/ /26/ /26/ /26/ /26/ /26/ /26/ /26/ /26/ /26/05 iii

4 PAGE THRUSH AIRCRAFT INC MODEL S2R-T34 TURBO THRUSH AIRCRAFT MAINTENANCE MANUAL LOG OF PAGES REV DATE PAGE REV DATE /26/ /26/ /26/ /26/ /26/ /26/ /26/ /26/ /26/ /26/ /26/ /26/ /26/ /26/ /26/ /26/ /26/ /26/ /26/ /26/ /26/ /26/ /26/ /26/ /26/ /26/ /26/ /26/ /26/ /26/ /26/ /26/ /26/ /26/ /26/ /26/ /26/ /26/ /26/ /26/ /26/ /26/ /26/05 SECT 5 FUEL SYSTEM 5-1 1/26/ /26/ /26/ /26/ /26/ /26/05 Effective: Revision 1 Dated: 2/14/ /26/ /26/ /26/ /26/ /26/ /26/ /26/ /26/ /26/ /26/ /26/ /26/ /26/ /26/05 SECT 6 LANDING GEAR, WHEELS & BRAKES 6-1 1/26/ /26/ /26/ /26/ /26/ /26/ /26/ /26/ /26/ /26/ /26/ /26/ /26/ /26/ /26/ /26/ /26/ /26/ /26/ /26/ /26/ /26/ /26/ /26/ /26/05 SECT 7 FLIGHT CONTROLS 7-1 1/26/ /26/ /26/ /26/ /26/ /26/ /26/ /26/05 iv

5 PAGE THRUSH AIRCRAFT INC MODEL S2R-T34 TURBO THRUSH AIRCRAFT MAINTENANCE MANUAL LOG OF PAGES REV DATE PAGE REV DATE 7-9 1/26/ /26/ /26/ /26/ /26/ /26/ /26/ /26/ /26/ /26/ /26/ /26/ /26/ /26/ /26/ /26/ /26/ /26/ /26/ /26/ /26/ /26/ /26/ /26/ /26/ /26/ /26/ /26/ /26/ /26/ /26/ /26/ /26/ /26/ /26/05 SECT 8 INSTRUMENTS 8-1 1/26/ /26/ /26/ /26/ /26/ /26/ /26/ /26/ /26/ /26/ /26/ /26/ /26/ /26/ /26/05 Effective: Revision 1 Dated: 2/14/ /26/ /26/ /26/ /26/ /26/ /26/05 SECT 9 DISPERAL SYSTEMS 9-1 1/26/ /26/ /26/ /26/ /26/ /26/ /26/ /26/ /26/ /26/ /26/ /26/05 SECT 10 ELECTRICAL SYSTEM /14/ /14/ /14/ /26/ /14/ /14/ /14/ /14/ /14/ /14/ /26/ /26/ /14/ /26/ /26/ /26/ /26/ /26/ /26/ /26/ /26/ /26/ /26/ /26/ /26/ /14/14 v

6 THRUSH AIRCRAFT INC MODEL S2R-T34 TURBO THRUSH AIRCRAFT MAINTENANCE MANUAL PAGE LOG OF PAGES REV DATE /14/ /26/ /14/ /14/ /26/ /26/ /26/ /26/ /26/ /26/ /26/ /14/ /14/ /26/ /26/ /26/ /26/ /26/ /26/ /26/ /26/ /26/ /26/ /26/ /26/ /26/ /26/ /26/ /26/ /26/ /26/ /26/ /26/ /26/05 SECT 11 AIRWORTHINESS LIMITATIONS /26/ /26/05 PAGE REV DATE Effective: Revision 1 Dated: 2/14/2014 vi

7 THRUSH AIRCRAFT INC MODEL S2R-T34 TURBO THRUSH AIRCRAFT MAINTENANCE MANUAL INTRODUCTION This publication provides information for the Thrush Aircraft, Inc. Model S2R-T34 Turbo Thrush Aircraft. Installations or equipment will vary from model to model due to the wide range of optional equipment. The information contained within this manual is based on data available at the time of publication and will be kept current by changes or service publications. This manual contains information on aircraft systems and operating procedures required for safe and effective maintenance. It shall not be used as a substitute for sound judgment. In this manual: *** WARNING *** -- Indicates a strong possibility of severe personal injury or loss of life if instructions are not followed. ** CAUTION ** -- Indicates a possibility of personal injury or equipment damage if instructions are not followed. * NOTE * -- Gives helpful information. CAUTION: Detailed descriptions of standard workshop procedures, safety principles and service operations are NOT included in this manual. Please note that this manual DOES contain warnings and cautions against some specific service methods which could cause PERSONAL INJURY or could damage an aircraft or MAKE IT UNSAFE. Please understand that these warnings cannot cover all conceivable ways in which service, whether or not recommended by Thrush Aircraft Inc., might be done or of the possible hazardous consequences of each conceivable way, nor could Thrush Aircraft Inc. investigate all such ways. Anyone using service procedures or tools, whether or not recommended by Thrush Aircraft Inc. must satisfy himself thoroughly that either personal safety nor aircraft safety will be jeopardized. All information contained in this manual is based on the latest product information available at the time of printing. We reserve the right to make changes at any time without notice. Effective: Revision 1 Dated: 2/14/2014 vii

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19 SERVICING & INSPECTION THRUSH AIRCRAFT INC S2R-T34 TURBO THRUSH AIRCRAFT MAINTENANCE MANUAL Section 2 TABLE OF CONTENTS SERVICING... 3 GROUND HANDLING... 3 TOWING... 3 TAXIING... 3 PARKING... 3 MOORING... 3 JACKING... 4 LEVELING... 4 COLD WEATHER OPERATION... 4 COLD WEATHER MAINTENANCE HINTS... 5 GROUND EMERGENCY PROCEDURES... 5 ENGINE FIRES... 5 ELECTRICAL FIRES... 6 GROUND OPERATION OF ENGINE... 6 BEFORE STARTING ENGINE... 6 STARTING ENGINE... 7 ENGINE OPERATIONAL CHECK... 8 SYSTEM AND COMPONENT SERVICING... 8 HYDRAULIC SYSTEM... 9 ENGINE OIL SYSTEM... 9 FUEL SYSTEM DEFUELING INDUCTION SYSTEM POWER PLANT INTERNAL CLEANING LANDING GEAR, WHEELS & BRAKES TIRES BRAKE BLEEDING INSPECTION INSPECTION CHECK LIST INSPECTION CHART ENGINE EXTERNALS ENGINE OIL SYSTEM ENGINE FUEL SYSTEM IGNITION SYSTEM PNEUMATIC SYSTEM AIRFRAME FUEL SYSTEM MAIN LANDING GEAR TAIL GEAR FUSELAGE SKINS HOPPER WINGS FUSELAGE FRAME CONTROL SYSTEMS METAL EMPENNAGE AILERONS AND FLAPS COCKPIT ELECTRICAL SYSTEM AIRFRAME MAINTENANCE EFFECTIVE 2/14/ REVISION 1

20 THRUSH AIRCRAFT INC S2R-T34 TURBO THRUSH AIRCRAFT MAINTENANCE MANUAL CORROSION CONTROL WINDSHIELD HOPPER REPAIR FUEL TANK REPAIR BATTERY MAINTENANCE LUBRICATION EFFECTIVE 2/14/ REVISION 1

21 THRUSH AIRCRAFT INC S2R-T34 TURBO THRUSH AIRCRAFT MAINTENANCE MANUAL SECTION TWO SERVICING & INSPECTION Standard procedure for ground handling, servicing, inspection, airframe maintenance, lubrication, and storage are included in this Section. Adherence to these procedures on a scheduled basis can save many hours of maintenance and aircraft down time. When a system component requires service or maintenance other than that outlined in this Section, refer to the applicable Section of this manual for complete information. GROUND HANDLING TOWING Movement of the aircraft on the ground may be accomplished as follows: A. Pull and guide the aircraft by means of a tow bar with the tail wheel unlocked. B. Attach a rope harness to the main gear when there is a need to tow the aircraft forward through snow or over soft and/or muddy ground. TAXIING Before attempting to taxi the aircraft, maintenance personnel should be checked out by qualified personnel. When it is determined that the propeller area is clear, apply the power to start the taxi roll and perform the following: A. Push the stick full forward to unlock the tail wheel. B. Taxi a few feet and check the brake operation. C. While taxiing, make slight turns to determine that the tail wheel steering is operative. D. Avoid taxiing over ground of loose stones, gravel, or other loose material that may cause foreign object damage to the propeller or to other aircraft in the area. E. You may taxi with the power lever in the Beta region to govern ground speed. Observe all engines operating limits. PARKING Head the aircraft into the wind and set the parking brake. Do not set the parking brake during cold wet weather because the accumulated moisture may freeze in the brakes. Do not set the parking brake if the brakes are overheated. Install the internal control lock. Place the chocks under each main wheel. EFFECTIVE 1/26/05 2-3

22 THRUSH AIRCRAFT INC S2R-T34 TURBO THRUSH AIRCRAFT MAINTENANCE MANUAL MOORING Park aircraft as previously outlined. In winds up to 20 knots, secure the aircraft at the wing tie down rings. For winds above 20 knots, tie the tail and main gear as well as the wings. Install external control surface locks. Be sure to tie the propeller down to prevent it from wind milling with zero oil pressure. The aircraft should be placed in a hangar when wind velocity is predicted to exceed 50 knots. When mooring aircraft, use 3/4-inch manila or nylon rope. A clove hitch or other anti-slip knot should be employed. If a manila rope is used for tie down, allow enough slack to compensate for contraction of the rope fiber without damaging the aircraft. JACKING Jack points are provided on each main spar and located at wing stations 120 & When using the jack points to lift the aircraft, all hopper loads should be removed. (Fig. 2-1) A jack point is also provided on the tail wheel trunnion attach fitting on the lower left longeron. LEVELING The aircraft may be leveled by raising the tail to an approximate level flight position and by supporting the tail on a stable jack or platform. Adjust the height of the tail wheel until the left-hand lower longeron located under the cockpit is level. COLD WEATHER OPERATION Aircraft operation in cold weather creates a need for additional maintenance practices and operating procedures that are not required in moderate temperatures. Whenever possible, shelter the aircraft in a heated hangar to prevent frost, ice, or snow accumulation that requires added maintenance time to remove. These weather elements, if allowed to accumulate only a fraction of an inch in thickness on the critical airfoils and control surfaces, seriously degrade aircraft lift and flight control effectiveness. The possibility of aircraft system failures is increased when the aircraft is parked where wind driven snow or freezing rain can be forced into various openings of the aircraft. If the aircraft is to be moored outside in extreme cold, the battery should be kept fully charged to prevent freezing. Make certain that all vents, air inlets, and so forth are covered. Locating the aircraft inside a heated hanger is the most effective method of preheating the aircraft. The use of an external power unit is recommended to conserve the battery. EFFECTIVE 1/26/05 2-4

23 THRUSH AIRCRAFT INC S2R-T34 TURBO THRUSH AIRCRAFT MAINTENANCE MANUAL COLD WEATHER MAINTENANCE HINTS The information that follows is intended only for the purpose of supplementing the existing information in this manual when operating the aircraft in cold weather. Keeping the aircraft in top maintenance condition during cold weather cannot be over stressed. The battery should be maintained at full charge during cold weather to prevent freezing. After adding water to the battery in freezing temperatures, charge the battery to mix the water and electrolyte. A frozen battery may explode when subjected to a high charge rate. Corrosive damage to the area adjacent to an exploded battery will result if the electrolyte solution is not removed immediately. Instructions for removing spilled electrolyte are provided in this Section. The battery should be removed and stored in a warm place if the aircraft is to remain idle for an extended period of time. In the fuel system, condensation is more likely to occur in cold weather due to a more rapid and positive division of moisture content from other fuel properties. If at all possible, use fueling facilities that filter moisture from the fuel. If fueling facilities with filters are not available, filter the fuel through a good quality chamois. Fill the tanks with correct grade of fuel as soon as possible after landing to reduce the possibility of condensation and ice formation in the tanks. Fuel extracted from fuel header tank drain before starting deserves a closer examination when the aircraft is being operated in cold weather. Cold weather operation demands procedures that are in addition to normal Post Flight Maintenance Procedures. Fill the fuel tanks immediately after flight. If shelter is not available, tie the aircraft down and install covers on all vents, openings, and so forth as required. GROUND EMERGENCY PROCEDURES Emergency procedures must be accomplished as rapidly as possible, should an emergency arise. It is suggested that steps pertaining to each emergency be committed to memory in order to accelerate the procedure and minimize any possible damage. ENGINE FIRES The following Dry Motoring Run procedure is used to clear an engine at any time when deemed necessary to remove internally trapped fuel and vapor or when there is evidence of a fire within the engine. Air that passes through the engine serves to purge fuel, vapor, or fire from the combustion sections, the gas generator turbine, the power turbine, and the exhaust system. EFFECTIVE 1/26/05 2-5

24 A. Fuel Condition Lever - Cut Off B. Ignition Switch - Off C. Master Switch - On D. Fuel Shutoff Valve - On E. Fuel Auxiliary Pump Switch - On THRUSH AIRCRAFT INC S2R-T34 TURBO THRUSH AIRCRAFT MAINTENANCE MANUAL This will provide lubrication for the engine-driven fuel pump. F. Engine Starter Switch On *** WARNING *** If the fire persists as indicated by the sustained interturbine temperature, close the fuel system shutoff valve at this point and continue motoring. G. Maintain the starter operation for the desired duration. The maximum starter duration is 3 minutes. H. Engine Starter Switch - Off I. Fuel Auxiliary Pump Switch - Off J. Fuel Shutoff Valve - Off K. Master Switch - Off L. Allow a 5-minute cooling period for the starter before going any further with the starting operation. ELECTRICAL FIRES Circuit breakers will automatically trip and stop the current flow to a shorted circuit. However, as a safety precaution in the event of an electrical fire, turn the battery switches to off. Use a fire extinguisher approved for electrical fires to extinguish the flame. GROUND OPERATION OF ENGINE BEFORE STARTING ENGINE Visually check the aircraft for general condition. Verify that all camlocs on the skin panels are fastened. Remove all accumulations of frost, ice, or snow in cold weather from the wing, the tail, and the control surfaces. Check that the control surfaces contain no internal accumulations of ice. Remove the inlet and exhaust covers, if fitted. If night flight is planned, check the operation of all lights and have a flashlight available. EFFECTIVE 1/26/05 2-6

25 THRUSH AIRCRAFT INC S2R-T34 TURBO THRUSH AIRCRAFT MAINTENANCE MANUAL After a complete visual inspection has been accomplished, the following checklist may be used for the external prestart check. The aircraft should be headed into the wind and should have the wheel chocks in place. A. A fire extinguisher must be readily available in the event of an engine fire. B. Check the engine oil level. Assure that the oil system has been serviced with the correct grade of oil. C. Verify that the internal control lock has been removed and that the controls operate freely. D. Set the parking brake. E. Check the fuel quantity in both tanks. F. Set the trim tabs for takeoff. G. Clear the area of all personnel. STARTING ENGINE Use the following procedure to start the PT6A engine. A. Battery and Generator Switches - On B. Power Lever - Idle C. Propeller Lever - Feather D. Fuel Condition Lever - Cut Off E. Fuel Shutoff Valve On F. Fuel Auxiliary Pump Switch - On G. Fuel Inlet Pressure Indicator - Check 5 PSI Minimum H. Engine Starter Switch - On The minimum speed to obtain a satisfactory light is 12% Ng. I. After approximately 5 seconds of motoring at the stabilized gas generator speed, turn the Ignition Switch On and move the Condition Lever to the Ground (low) Idle position. J. Observe that the engine accelerates normally to idle RPM and the maximum allowable inter-turbine temperature-starting limit is not exceeded. ** CAUTION ** Whenever the gas generator fails to light up within 10 seconds after moving the fuel condition lever to the ground (low) idle position: fuel condition lever idle cutoff, ignition switch - off, starter off. Allow a 30- second fuel draining period that is followed by a 15-second dry motoring run before attempting another start. If for any reason a starting attempt is discontinued, allow the engine to come to a complete stop and then accomplish a Dry Motoring Run as described on page 2-5 under Engine Fires. That procedure is also referred to as Dry Motoring run. EFFECTIVE 1/26/05 2-7

26 When the engine attains idle rpm: THRUSH AIRCRAFT INC S2R-T34 TURBO THRUSH AIRCRAFT MAINTENANCE MANUAL K. Engine Starter Switch and Ignition Switch - Off L. Oil Pressure - Check 60 PSIG Minimum M. Fuel Auxiliary Pump - Off N. Fuel Pressure from Engine Driven Pump - Check 5 PSI Minimum O. Generator Charging Check ENGINE OPERATIONAL CHECK ** CAUTION ** Fill hopper and hold the elevator control firmly full up during all high power ground operations to keep aircraft from nosing over. Refer to Section Four for specific operational checks and/or Pratt & Whitney Maintenance Manual. Before proceeding with a ground run up, be sure that the propeller system is purged by feathering the propeller once or twice with the power control lever in idle position. The following procedure should be used to check the propeller overspeed governor. A. Place the propeller lever in full increase RPM position (forward). B. Turn prop test switch on. C. Increase RPM with the power lever until governing occurs. This should occur at 2025±20 RPM. (In no case should any engine limitations be exceeded.) D. Reduce power back to idle. E. Turn prop test switch off. *NOTE* If RPM is not governed at 2025 ±20 RPM with the prop test switch on, consult Section IV of this manual for adjustment of the overspeed-governor. SYSTEM AND COMPONENT SERVICING Servicing procedures contained in this Section are confined to those maintenance actions that occur with routine frequency and require a reasonably short period of time to accomplish. Servicing practices and maintenance to aircraft systems and components that require less frequent attention are contained in the appropriate Section of this manual. EFFECTIVE 1/26/05 2-8

27 THRUSH AIRCRAFT INC S2R-T34 TURBO THRUSH AIRCRAFT MAINTENANCE MANUAL HYDRAULIC SYSTEM The hydraulic system consists of two master brake cylinders and the necessary hydraulic lines connecting the master cylinders to the wheel brake cylinders. Applying toe pressure on the rudder pedals actuates the master cylinders, which are located just aft of the pilot s rudder pedals. Refer to Section Six for brake servicing procedures. ENGINE OIL SYSTEM The oils that are specified for the lubrication system are detailed in the Pratt and Whitney Canada Service Bulletin All oils listed in the bulletin are approved for flight operation. It is recommended for all turbo aircraft that the oil should be changed every 400 hours. The oil system contains 13 U.S. quarts. In cases where oils that are approved are not available, an operator must obtain prior approval or recommendations for use of substitution oil from the Service Department, Pratt and Whitney Canada Corp, 1000 Marie-Victorin, Longueuil, Quebec, Canada J4K 1A1. A. OIL LEVEL CHECK To avoid overfilling of oil tank, and high oil consumption, an oil level check is recommended within 30 minutes after shutdown. Ideal interval is 15 to 20 minutes. If more than 30 minutes has passed, and the dipstick indicates that oil is needed, start the engine and run at ground idle (low idle) for five minutes, and recheck oil level. 1. Unlock the filler cap and dipstick from the filler neck at the eleven o'clock position on the accessory gearbox and remove the filler cap. ** CAUTION ** Do not mix different brands, viscosity s, or types of oil since their chemical structures may make them incompatible. If different types of oil become mixed, drain and flush the system. Refill with new oil. 2. Check the oil tank contents against the markings on the dipstick. Service as required. EFFECTIVE 1/26/05 2-9

28 THRUSH AIRCRAFT INC S2R-T34 TURBO THRUSH AIRCRAFT MAINTENANCE MANUAL * NOTE * The graduations on the dipstick indicate the oil level in U.S. quarts below maximum capacity of the oil tank. The normal cold oil level is the Maximum Cold mark on the dipstick. The normal hot level is Maximum Hot mark on the dipstick. A dipstick reading of 3 will indicate that the system requires 2 U.S. quarts to replenish to normal level if the oil is cold. If the oil is hot, it will take 3 U.S. quarts to replenish. 3. If the engine is nose high or nose low, compensation must be made to avoid over or under servicing. B. If the oil level is too low to register on the dipstick due to possible excessive consumption or if low or fluctuating pressures have been recorded, refer to Troubleshooting - Lubrication Problems in the Pratt and Whitney Maintenance Manual for the action to be taken. After that has been accomplished, proceed as follows to check the oil level. 1. Fill the oil tank to the appropriate normal level. Record the quantity of oil added to the system. 2. Install the filler cap and dipstick. Ensure that the cap is locked securely. 3. Run the engine idle for approximately 5 minutes. 4. Check the oil level. 5. Check the oil filter per applicable Pratt & Whitney Maintenance Manual. C. On engines which have remained stationary for a period of 12 hours or more, proceed as follows to check the oil level. 1. Start the engine and run at idle speed for a minimum of 2 minutes. 2. Feather the propeller. 3. Shut down the engine. 4. Check the oil level. D. Recommendations for oil change intervals are based on the performance of specific brands of oil, specific types of oil, specific engine models, and specific operating criteria. General oil change intervals may be extended periodically and will be reflected by revisions to the Pratt and Whitney Engine Service Bulletin Permission for extension of oil drain intervals may be granted to operators through monitoring programs, which are conducted by most EFFECTIVE 1/26/

29 THRUSH AIRCRAFT INC S2R-T34 TURBO THRUSH AIRCRAFT MAINTENANCE MANUAL major oil companies that have been approved by Pratt and Whitney Canada. Service Bulletin 1001 will be revised periodically to include newly approved oils. Refer to Figure 2-8 for the locations called out in the following procedure. 1. Place suitable containers or drip pan under the engine. 2. Remove lockwire from the main oil tank s drain plug #6 from boss on compressor inlet case. Remove drain plug. Discard the preformed packing. Or drain oil at drain port on left shin skin (on aircraft equipped with quick drain). 3. Remove the rear case drain plug #2 from the six o'clock position on the rear face of the accessory gearbox housing. Discard the preformed packing. 4. Remove the chip detector #3 from the six o'clock position on the reduction gearbox front case. Discard the preformed packing. 5. Examine the drained oil for the presence of foreign matter. E. Refill the oil tank by accomplishing the following procedures. 1. Install the chip detector #3 with new preformed packing on the reduction gearbox. Torque chip detector body #3 45 to 55 lb. in. and lockwire. 2. Install rear case drain plug #2 with new preformed packing in the accessory gearbox housing. Tighten and torque to 215 to 240 lb. in. and lockwire. 3. Install the drain plug #6 with the new preformed packing in the bottom of the air inlet case. Or simply install a cap on the drain port on the left shin skin (on aircraft equipped with quick drain) and lockwire. 4. Fill the oil tank with the specified oil to the level of maximum graduation on the dipstick. F. Install the filler cap and dipstick assembly in the oil tank. Ensure that the cap is locked securely. 1. Start the engine and run at idle for approximately 2 minutes to circulate the oil through the system. 2. Feather the propeller. 3. Shut down the engine. 4. Check the oil level in the tank. Replenish, as required, to the normal level on the dipstick. 5. Install the filler cap and dipstick assembly in the oil tank. Ensure that the cap is locked securely. EFFECTIVE 1/26/

30 THRUSH AIRCRAFT INC S2R-T34 TURBO THRUSH AIRCRAFT MAINTENANCE MANUAL G. If an engine is to be operated with an oil brand or type that differs from that on which it previously operated or if the oil system has been contaminated by other than metallic matter, the oil system should be flushed by following the steps below. 1. Place suitable containers or drip pan under the engine. 2. Remove the oil drain plug or chip detector from the reduction gearbox and the plugs from the inlet case and the accessory gearbox housing. ** CAUTION ** Limit the engine rotation to a minimum time which is required to accomplish the complete draining. Also observe the starter operating limitations. 3. With the drains open, place the starting control lever to cutoff and the ignition switch to off. Motor the engine with the starter only to allow the scavenge pumps to clear all lubricating oil. 4. Reinstall all drain plugs and the chip detector. 5. Refill the engine oil tank with new type oil. 6. Start the engine and run at idle speed for a minimum of two minutes. 7. Feather the propeller. 8. Shut down the engine. 9. Repeat Steps 1. through Remove the main oil filter. Clean or replace the filter and reinstall. 11. Remove the reduction gearbox oil strainer and clean. Reinstall the strainer. 12. Reinstall all engine drain plugs and the chip detector. Tighten, torque, and lockwire. 13. Repeat Steps 5. through Check the oil levels and replenish, as necessary. 15. Install the filler cap and dipstick assembly in the filler tube. Ensure that the cap is correctly installed and locked. EFFECTIVE 1/26/

31 THRUSH AIRCRAFT INC S2R-T34 TURBO THRUSH AIRCRAFT MAINTENANCE MANUAL ** CAUTION ** Different formulations of the various oil brands may have varying detergent actions. After an oil brand change, the above may cause the release of carbon particles into the oil system which would result in the clogging of the scavenge screen. After a change of oil brand, the main oil filter should be inspected for carbon particles at 10-hour intervals. There should be 5 inspections for a total of 50 hours, and the filter should be checked at the routine oil filter checks there after up to 500 hours. If an excess of the normal amount of carbon is noted, the following steps should be accomplished. A. Remove the drain plug from the six o'clock position on the accessory gearbox. B. Using a mirror and light, inspect the scavenge screen through the drain hole. C. If there is evidence of carbon, try to dislodge it with a stiff paintbrush. D. Flush out any removed carbon. E. If the carbon cannot be removed by the above method, the accessory gearbox should be removed and the screen cleaned. Refer to the Section Accessory Gearbox in the Pratt and Whitney Maintenance Manual for the removal procedure. FUEL SYSTEM A. Refuel the aircraft with fueling facilities that contain filters for removing the moisture content from the fuel. If the fueling facilities with filters are not available, filter the fuel through a good grade chamois. The fuel tanks should be serviced after the last flight of the day to allow maximum time for the moisture to reach the header tank. Service the aircraft with Jet A, Jet B, JP-4, and JP-5. If jet fuel is not available, aviation gasoline MIL-G-5572 (all grades) may be used for a maximum of 150 hours between overhauls. For the Restricted Category, service the aircraft with Jet A, Jet B, JP-4, JP-5, and automotive diesel number 1D or 2D in accordance with P&WACL Service Bulletin Number 1344 or If the jet fuel or diesel fuel is not available, aviation gasoline MIL-G-5572 (all grades) may be used for a maximum of 150 hours between overhauls. Automotive diesel fuel is approved only for flights when the free air temperature is above +20 degrees Fahrenheit use grade #1D or +40 degrees Fahrenheit use grade #2D. EFFECTIVE 1/26/

32 THRUSH AIRCRAFT INC S2R-T34 TURBO THRUSH AIRCRAFT MAINTENANCE MANUAL *** WARNING *** Ground the aircraft and the fuel servicing equipment to the aircraft. Smoking in or around the aircraft during refueling operations is prohibited. Fire protection equipment must be immediately available. 1. Turn all the switches off. 2. Remove the fuel filler cap. Fill the tank until the fuel level rises to the filler neck. Install the fuel filler cap and service the opposite fuel tank. * NOTE * As the wing tanks are interconnected through the header tank, the fuel can flow from one tank to another. Topping off both wing tanks may be required more than one time to assure that both wing tanks are full. 3. After fueling is complete, check for security of both fill port caps. Wash any spilled fuel from the wing surface with clean water. B. Three fuel drain points are provided to allow fuel draining in order to extract the moisture and sediment entrapped in the system. The drains are located at the bottom of each wing tank (Fig. 2-2), the header tank (Fig. 2-3), and firewall fuel filter (Fig. 2-4). All fuel drains should be drained prior to the first flight of the day. Drain a small quantity of fuel into a transparent container to permit inspection for the presence of moisture or sediment. The fuel should be drained until all evidence of moisture or sediment disappears. Also provided are two fuel vent drains located on each side of fuselage under the wings (Fig. 2-5). The last drain port is provided to drain the residue fuel reservoir. At engine shutdown, fuel from the flow divider/dump valve, located at the 6 o clock position on the engines fuel nozzle manifold, is directed to a residue fuel reservoir EPA tank located on the L/H cowl shin skin. This reservoir holds approximately 3 engine shutdowns worth of fuel before the fuel will exit the reservoirs vent system. EFFECTIVE 1/26/

33 THRUSH AIRCRAFT INC S2R-T34 TURBO THRUSH AIRCRAFT MAINTENANCE MANUAL * NOTE * This reservoir should be emptied after each engine shutdown. * NOTE * It is common and normal after an engine compressor Water Wash or Performance Recovery Wash to have water or soap appear in the reservoirs drained waste fuel. Visually check that all drain valves are closed after draining. C. The airframe is equipped with two fuel filters, a ¼ inch mesh finger strainer is installed in the outlet fitting from the header tank and an airframe supplied, gascolator type, 25-micron main fuel filter located on the forward L/H side of the firewall. Inspect the ¼ inch mesh finger strainer annually or if the fuel system is suspected or has been contaminated with foreign debris: i.e. Main fuel filter red bypass indicator was popped, main fuel filter has contamination, foreign debris noted in drained fuel sample container, known fuel contamination etc. The 25-micron main fuel filter element should be inspected, cleaned or replaced, and reinstalled every 100 hours, when the red fuel bypass indicator button has popped, or any time fuel system contamination is suspected. Refer to chapter 5 for main fuel filter servicing procedures. *** WARNING *** If the red fuel bypass indicator button has popped out, determine and remove the cause of the fuel obstruction before further flight. Remove, inspect, clean or replace, reinstall the filter 25-micron element. You may then reset the red bypass button by pressing it in with finger pressure. DEFUELING During the defueling operation, jet fuel fumes are present; therefore, extreme caution must be exercised to prevent fire hazards. EFFECTIVE 1/26/

34 THRUSH AIRCRAFT INC S2R-T34 TURBO THRUSH AIRCRAFT MAINTENANCE MANUAL *** WARNING *** Smoking on or around the aircraft is not permitted during the defueling procedure. Fire protection equipment must be immediately available. A. Ground aircraft and all defueling equipment or containers to the aircraft. B. Place vented container of adequate capacity under the three drain points. Verify that the containers are properly grounded to the aircraft. C. Open the drain valves and allow all fuel to drain. D. Close the drain valves and move the fuel containers to a safe distance from the aircraft. E. Verify that all the drain valves are closed. INDUCTION SYSTEM The prime difference between the agricultural and a normal installation is the air cleaning system incorporated in the engine air intake system. The air filter is located below the engine air inlet plenum between the center and rear fire seals and is a washable reusable barrier type filter. POWER PLANT INTERNAL CLEANING Refer to Pratt & Whitney Canada Maintenance Manual for the -34 engine for proper internal cleaning. ** CAUTION ** Chemicals should not be allowed to remain in an engine any longer than overnight, and a water wash should not be performed any sooner than 45 minutes after shutdown. It may be more convenient and practical to wash the engine before working the next morning. This is acceptable if extremely corrosive chemicals are not being used. EFFECTIVE 1/26/

35 THRUSH AIRCRAFT INC S2R-T34 TURBO THRUSH AIRCRAFT MAINTENANCE MANUAL LANDING GEAR, WHEELS & BRAKES Check all gear assemblies for general cleanliness, security of mounting, and hydraulic leaks at prescribed inspection intervals. Lubricate all lubrication points on main and tail gear assemblies at prescribed intervals. TIRES Tires should be inspected for proper inflation, breaks, cuts, and foreign objects in tread, flat spots and exposed cord. Replace tire if there is any question of its reliability. Proper inflation is necessary for maximum tire life. Maintain 29x11-10pr main wheel pressure at a minimum of 40 psi to a maximum of 62 psi, depending on the load and runway conditions pr Type III tail wheel tire pressure should be 88 psi maximum. The wheels and tires are balanced assemblies. If tires are suspected of being out of balance, they may be balanced on automotive type balancing equipment. If aircraft is out of service, rotate tires every seven days to prevent flat spots from developing. BRAKE BLEEDING Brake bleeding should be performed when air is suspected of being entrapped in brake lines. See Section Six for brake bleeding procedures. INSPECTION Only the items to be inspected are listed and details as to how to check or what to check for are generally excluded. Those checks can be found in specified Section of this manual. INSPECTION CHECK LIST A. Movable parts are to be checked for lubrication, servicing, security of attachment, binding, excessive wear, Safety, proper operation, proper adjustment, correct travel, cracked fittings, security of hinges, defective bearings, cleanliness, corrosion, deformation, sealing, and tension. B. Fluid lines and hoses are to be checked for leaks, cracks, dents, kinks, chafing, proper radius, security, corrosion, deterioration, obstructions, and foreign matter. C. Metal parts are to be checked for security of attachment, cracks, and metal distortion, broken spot welds, corrosion, condition of paint, and any other apparent damage. D. Wiring is to be checked for security, chafing, burning, defective insulation, and loose or broken terminals, heat deterioration, and corroded terminals. EFFECTIVE 1/26/

36 THRUSH AIRCRAFT INC S2R-T34 TURBO THRUSH AIRCRAFT MAINTENANCE MANUAL E. Bolts in critical areas are to be checked for correct torque, or when visual inspection indicates the need for a torque check. See (Fig 2-7) Torque Chart. F. Filters, screens, and fluids are to be checked for cleanliness, contamination and/or replacement at specified intervals. This Manual contains information on aircraft systems and operating procedures required for safe and effective maintenance. It shall not be used as a substitute for sound judgment. Clean the aircraft prior to performing any inspections on the airframe or engine. Before removal of detachable skins, fairings, and cowlings wash all exterior surfaces of the aircraft with plain water and any commercial soap or detergent. Soap and detergent are organic chemicals and it is important that all traces be removed by flushing with plain water. *NOTE* Certain chemicals cannot be removed effectively by detergent solutions. Special cleaning agents are available for that purpose. It is suggested that the chemical suppliers be contacted for cleaning agents that are suitable for those special needs. Inspection intervals are greatly influenced by particular operational priorities, operating conditions, environment, and routine inspection results. Due to the anticipated operating environment, servicing and overhaul interval should be in accordance with Pratt & Whitney s recommendations for the PT6A-41AG engine for the PT6A-41, PT6A-41AG, and PT6A- 42. Due to the anticipated operating environment, servicing and overhaul interval should be in accordance with Pratt & Whitney s recommendations for the PT6A-34AG for the PT6A-34 engine. Perform the tasks shown in the following Inspection Chart at the prescribed intervals. EFFECTIVE 1/26/

37 INSPECTION CHART THRUSH AIRCRAFT INC S2R-T34 TURBO THRUSH AIRCRAFT MAINTENANCE MANUAL PROPELLER (Refer to Hartzell Manual #139 Propeller Owner s Manual and Logbook.) Daily 50 HRS 100 HRS 400 HRS 1. Remove the spinner and check for cracks. X 2. Check the back plate for cracks and corrosion. X 3. Check for grease and oil leaks. X 4. Check the pitch rods and lock nuts. X 5. Check the condition of the reverse return springs. X 6. Check the hub bolts and balance screws of the blades for safety. X 7. Inspect the blades for nicks and cracks. Refer to the Hartzell Manual #139. X 8. Inspect the hub parts for cracks and corrosion. X 9. Lubricate the propeller with Aeroshell 6 grease only. Remove the rear Zerk fitting from each blade clamp. Using a hand operated grease gun, grease each forward fitting slowly. Lubrication is complete when grease emerges in a steady flow with no air pockets or moisture, and has the color and texture of the new grease. Reinstalled the rear Zerk fittings. X EFFECTIVE 1/26/

38 THRUSH AIRCRAFT INC S2R-T34 TURBO THRUSH AIRCRAFT MAINTENANCE MANUAL PROPELLER (continued) (Refer to Hartzell Manual #139 Propeller Owner s Manual and Logbook.) Daily 50 HRS 100 HRS 400 HRS 10. Check counterweight bolts for safety. X 11. Check ring rod-end jam nuts. X 13. Re-install spinner. Rotate prop and check alignment of low pitch stop collar. (.010 max. run out) X 14. Check carbon block side clearance. New Block: clearance Used Block:.010 -max allowed 15. Check beta control valve clevis slot end for alignment with face of cap nut. X X 16. Check fuel governor reset arm for hitting stop. X 17. Check prop governor control levers for hitting stop in low and high pitch. X 18. Check reversing cable housing jam nuts and pins for safety and condition of housing. X 19. Inspect overspeed governor. X EFFECTIVE 1/26/

39 THRUSH AIRCRAFT INC S2R-T34 TURBO THRUSH AIRCRAFT MAINTENANCE MANUAL ENGINE EXTERNALS (Refer To The Engines Appropriate Pratt & Whitney Maintenance Manual For Pertinent Details On Engine Inspection) Daily 50 HRS 100 HRS 400 HRS 1. Check the tubing, wiring, control linkages, and hose assemblies for security of all the accessible connections, clamps, and brackets. X 2. Check tubing and hose assemblies for evidence of wear, chafing, cracks, and corrosion. X 3. Check the tubing, wiring, control linkages, and hose assemblies for evidence of fuel and oil leakage. X 4. Lubricate interconnecting rod ball ends, where applicable. X 5. Check the air inlet screen area for cleanliness. X 6. Check the gas generator case for cracks, distortion, and corrosion. X 7. Check the fireseals for cracks and security of brackets and seals. X 8. Check the exhaust duct for cracks and distortion. X 9. Check the propeller shaft seal for oil leaks. X 10. Check security and condition of engine mounts. X EFFECTIVE 1/26/

40 THRUSH AIRCRAFT INC S2R-T34 TURBO THRUSH AIRCRAFT MAINTENANCE MANUAL ENGINE EXTERNALS (continued) Daily 50 HRS 100 HRS 400 HRS 11. Check the security of the accessories. X 12. Check the security of accessory linkages. X 13. Check the security of pneumatic lines. X 14. Check for evidence of oil and fuel leaks in accessory areas. X 16. Check security and mounting of starter/generator. Check brushes for wear. X 17. If starter/generator is equipped with a dry spline drive, remove the starter/generator and check the engine s drive gear splines for wear using special P&W tool. If splines check OK, lubricate starter/generator drive shaft splines with Dow Corning M-77 Molycoat and reinstall starter/generator. 300 HRS *NOTE* As of 1998 all new AG engines will be delivered with a wet spline type starter generator gear shaft that requires no maintenance. You can identify an engine s wet spline (female) gear shaft as follows: From the engine side (female) the splines are recessed approximately ¾ inch. Looking into the center of the gear shaft you can see right through to the AGB diaphragm wall. There will be a 0 ring installed on the starter/generator s drive shaft (male splines). EFFECTIVE 1/26/

41 THRUSH AIRCRAFT INC S2R-T34 TURBO THRUSH AIRCRAFT MAINTENANCE MANUAL ENGINE OIL SYSTEM Daily 50 HRS 100 HRS 400 HRS 1. Check the oil level. Oil change recommended every 400 hours. ** CAUTION ** Do not mix different brands or types of oil when changing oil or when replenishing the oil between oil changes. * NOTE * To avoid overfilling of oil tank, and high oil consumption, an oil level check is recommended within 30 minutes after engine shutdown. Ideal interval is 15 to 20 minutes. If more than 30 minutes has passed, and the dipstick indicates that oil is needed, start the engine and run at ground-idle (low idle) for five minutes, and recheck oil level. NOTE: P&WC recommends Thrush Aircraft Inc. fill the oil level to 2.5 quarts below MAX COLD for PT6A-34AG engines at aircraft delivery. X X X 2. Check condition and security of oil filler cap. X Remove, inspect, clean, and reinstall oil filter in accordance with instructions obtained in the engine s appropriate Pratt & Whitney maintenance manual. NOTE: Do not clean ultrasonically. Elements must be discarded after 1000 hours or after heavy contamination. Check the chip detector for continuity using a suitable ohmmeter. An open circuit condition must exist which indicates no ferrous contamination at pole tips. X X EFFECTIVE: 2/14/ REVISION 1

42 THRUSH AIRCRAFT INC S2R-T34 TURBO THRUSH AIRCRAFT MAINTENANCE MANUAL ENGINE FUEL SYSTEM Daily 50 HRS 100 HRS 400 HRS 1. Check the fuel for presence of water. X X 2. Check the fuel pump for security and fuel leakage. X 3. Inspect, clean and reinstall high pressure fuel pump 74-micron inlet fuel filter. X 4. * NOTE * On new aircraft, check the filter after each flight until there is no evidence of contamination. Check the filter after the first flight or ground run when any upstream component is replaced. At the fuel pump outlet, check the 10-micron filter for foreign matter and/or distortion. Install new filter every 100 hours or as service conditions indicate. X 5. Check the drain valve for security and leakage. X X EFFECTIVE: 1/26/

43 THRUSH AIRCRAFT INC S2R-T34 TURBO THRUSH AIRCRAFT MAINTENANCE MANUAL ENGINE FUEL SYSTEM (continued) Daily 50 HRS 100 HRS 400 HRS *NOTE* When a problem is found, refer to the appropriate section in the Pratt and Whitney Maintenance Manual. 6. Check the fuel control unit for security, linkages, and pneumatic tubes. X Check the fuel control unit bearing for wash-out which is 7. indicated by blue dye - grease and fuel mixed at the FCU X X vent. Check the fuel manifold and nozzle assemblies with a functional test. For improved hot section durability. It is 8. recommended that the fuel nozzle assemblies are inspected X X and functional tested in accordance with time limits set forth in the engines appropriate maintenance manual. IGNITION SYSTEM Daily 50 HRS 100 HRS 400 HRS 1. Check the ignition exciter for security and condition. X 2. Check the ignition cable for chafing, wear, and security. X 3. Check the spark igniters for cleanliness and erosion. Perform an operation test. X PNEUMATIC SYSTEM Daily 50 HRS 100 HRS 400 HRS 1. Clean the air compressor delivery filters (P3) every 100 hours. The maximum interval is 1000 hours for the disposable type. For the metallic cleanable type, return to an approved overhaul shop for ultrasonic cleaning every 1000 hours. After the cleaning, the element may be reused. X EFFECTIVE: 1/26/

44 THRUSH AIRCRAFT INC S2R-T34 TURBO THRUSH AIRCRAFT MAINTENANCE MANUAL AIRFRAME FUEL SYSTEM Daily 50 HRS 100 HRS 400 HRS 1. Remove, inspect, clean, and re-install the airframe main 25- micron fuel strainer. X Drain wing tanks, header tank; vent system (2 ea.), gascolator 2. bowl, and residue fuel reservoir EPA tank. Check for any debris, sediment, or water and take corrective action if any is X X found. 3. Turn the electric fuel pump on and check the fuel lines for leaks. X 4. Inspect the fuel lines and supports for security and signs of chafing. X 5. Check the fuel shutoff valve for leaks in the open and close position. X 6. Check the fuel tank gauges for proper operation. Rock the wings to slosh the fuel to see that the pointers are free. X X *NOTE* When a problem is found, refer to section 5. MAIN LANDING GEAR Daily 50 HRS 100 HRS 400 HRS 1. Remove, clean, and inspect main landing gear bolts, P/N AN10-33 or NAS6610D42, every 800 hours or annually, whichever occurs first, for cracks, wear, damage, corrosion, and general condition. Replace as necessary or, if no defects are noted at time of inspection reinstall. Replace main landing gear attach bolts every 1600 hours or every other annual, which ever occurs first. *NOTE* Prior to installing main landing gear bolts, apply a generously amount of MIL-G (Aeroshell 22) grease to main landing gear knurled bushings as well as to the bolts. Torque hardware I/A/W Torque Chart (Figure 2-7) and install cotter pins. X Inspect 800 hours and annually. Replaced 1600 hours or biannually. EFFECTIVE: 1/26/

45 THRUSH AIRCRAFT INC S2R-T34 TURBO THRUSH AIRCRAFT MAINTENANCE MANUAL MAIN LANDING GEAR (continued) Daily 50 HRS 100 HRS 400 HRS 2. Grease shock struts and shock strut attach to tripod zerk fittings with MIL-G (Aeroshell 22) grease. Inspect rubber shock biscuits for distortion, splits, or deterioration. If replacement of biscuits is required, see chapter 6 for pertinent data. *NOTE* The upper shock strut attach bolt is a close tolerance, heat treated NAS bolt. Do Not replace with an AN bolt. X 3. Check the tires and tubes, wheels, and brake discs and lining for general condition. X X 4. Check the spindle for straightness and tightness. X Check, inspect, lubricate with MIL-G (Aeroshell 22) grease, and reassemble all wheel bearings. (See chapter 6 for pertinent data.) Check the master cylinders, parking brake valves, brake lines, brake calipers, all brake fittings, and brake bleeders for leakage, general condition, and security. X X 7. Check brake fluid level in each master cylinder and top off with fresh MIL-H-5606 aviation hydraulic fluid as required. X 8. Check the operation and holding ability of the pedal and parking brakes. Bleed hydraulic systems if required. X X TAIL GEAR Daily 50 HRS 100 HRS 400 HRS 1. Remove, clean, and inspect leaf spring forward attach bolt P/N NAS D every 100 hours. Upon reassembly lubricate bolt and leaf spring hole with Snap-on General Purpose Antiseize or equivalent or MIL-G (Aeroshell 22) grease. Torque to specifications I/A/W Torque chart (figure 2-7). Replace MS cotter pin each inspection. X EFFECTIVE: 1/26/

46 THRUSH AIRCRAFT INC S2R-T34 TURBO THRUSH AIRCRAFT MAINTENANCE MANUAL TAIL GEAR (continued) Daily 50 HRS 100 HRS 400 HRS Inspect all bolts holes for elongation. As a general rule, replace components with holes that are out-of-round by or more. (Replacement of the leaf spring forward attach P/N NAS D bolt (Inspect every 100 hours) with a larger diameter is not approved. The leaf spring may not be drilled out for a larger bolt.) Inspect main spring leaf for corrosion and cracks. Check aircraft maintenance records to be sure spring leaf P/N has not exceeded its five thousand (5,000) flight hour life limit. Replace leaf spring as needed. Inspect P/N Acetal (Delrin ) lower support block spacer for wear and cracks. Inspect upper and lower leaf spring support blocks, and attachment hardware for wear, corrosion, and cracks. Ensure that the leaf spring support blocks grips the leaf spring tightly to prevent leaf spring movement fwd. and aft. Ensure flexible sealant around contact edges of support blocks, lower support block spacer and leaf spring is intact to prevent collection of Check locking cable for security and free movement, grease cable and wheel with MIL-G (Aeroshell 22) grease, and assure wheel bearing is completely greased. X X X X X 7. Check for any loose play in tail wheel. X 8. Inspect the tire, wheel body and bearings, spindle, and the fork for general condition. X 9. Check the housing for cracks and corrosion. X Check the taper bearings and spindle-shaft for corrosion for wear. Inspect the lock pin and plate for wear at the ends for correct operation. Check the lock pin cable and spring for corrosion and correct operation. X X EFFECTIVE: 1/26/

47 THRUSH AIRCRAFT INC S2R-T34 TURBO THRUSH AIRCRAFT MAINTENANCE MANUAL *NOTE* After the components have been installed, seal the contact edges where the spring, P/N (replace every 5,000 hours) upper support block P/N , lower support block P/N and spacer P/N come together with a high quality flexible silicone sealant or fuel tank sealant CS3204 BS (AMS-S-8802 formerly MIL-S-8802) to help block the collection of potential corrosive contaminants in this area. FUSELAGE SKINS Daily 50 HRS 100 HRS 400 HRS Inspect all panels and cowlings for cracks, chaffing, and security of fasteners. Check the camloc receptacles for corrosion, wear, and locking action. X X HOPPER Daily 50 HRS 100 HRS 400 HRS 1. Inspect the hopper baffles for security and condition. X 2. Check the hopper lid for condition of seal and security of latches. X 3. Inspect the hopper for evidence of leaks and for general condition. X 4. Check the gate for evidence of leaks and for proper operation. X 5. Check the hopper vent tube for corrosion and security. X 6. Check the gaskets on both the return and outlet lines. X 7. Check the hopper gate handle and the push rod for cracks around the welds. Check the condition of the push rod boot. X 8. Check emergency shut-off valve for leaks and proper operation X X EFFECTIVE: 1/26/

48 THRUSH AIRCRAFT INC S2R-T34 TURBO THRUSH AIRCRAFT MAINTENANCE MANUAL WINGS Daily 50 HRS 100 HRS 400 HRS 1. Inspect the aileron brackets for cracks and security. X 2. Check the boots at the aileron push rod entrance to the wing root for condition and security. X Check for deposits of chemicals around and behind the wing center section and all attachment fittings. Check closely for corrosion. Keep clean. Inspect the wing skins for cracks, loose rivets, general condition of the paint, and corrosion. Inspect the front and rear spar flanges, ribs, and other structures for cracks and corrosion. X X X 6. Check the spray booms attach points for security. X Check the pitot line in the right wing for security and for air leaks. Drain the low spots. Inspect the wing/fuselage attach angles for signs of cracks and corrosion. Annually inspect the lower spar splice blocks (P/N 22508T001 upper half and P/N 22508T002 lower half) as follows: Visually inspect splice blocks with a 10X magnifying glass or dye penetrant. Inspect for external cracks around the ¼ inch and 5/16 inch hole locations. If no cracks are detected this portion of the wing inspection is complete. If cracks are found remove the splice blocks before next flight and inspect the lower spar cap for cracks in accordance with Thrush Aircraft Inc. Service Bulletin SB-AG-39. If cracks are found in spar cap contact Thrush Aircraft Inc for possible repair or replacement. If no cracks are found in spar cap, replace the cracked splice blocks with new units. Refer to Section VIII Wing Removal for splice block removal and installation. X X Annually EFFECTIVE: 1/26/

49 THRUSH AIRCRAFT INC S2R-T34 TURBO THRUSH AIRCRAFT MAINTENANCE MANUAL FUSELAGE FRAME Daily 50 HRS 100 HRS 400 HRS 1. Inspect the fuselage tubing for signs of corrosion or cracks, particularly around welds and in the hopper area. X 2. Check for elongated holes in the engine mount fittings and bellcranks. X 3. Inspect all spring gear attachment fittings, main gear support beam, and beam end plates for security, cracks, and corrosion. X 4. Check the condition of the paint and refinish, if necessary. X CONTROL SYSTEMS Daily 50 HRS 100 HRS 400 HRS 1. Check all turnbuckles for corrosion and for proper lock wiring. X 2. Inspect all cables and end fittings for wear. Check for correct tension. X 3. Check all push rods for loose bearings, endplay, straightness and paint condition. X 4. Check idlers and bellcranks for binding or for slack. X 5. Inspect the rudder pedals and the support brackets for general condition. X Inspect the attachment of the control stick to the main torque tube for slack and bearing wear. Check control stick to main torque tube bolt for proper torque (65 to 70 in. lbs.) Check the aileron control stops for tightness and for condition of fittings. X X X EFFECTIVE: 1/26/

50 THRUSH AIRCRAFT INC S2R-T34 TURBO THRUSH AIRCRAFT MAINTENANCE MANUAL CONTROL SYSTEMS (continued) Daily 50 HRS 100 HRS 400 HRS 9. Inspect all push-pull tubes rod-end jam nuts for security. Inspect all witness/inspection holes with a piece of.032 safety wire to insure that all rod-ends are screwed far enough onto the push-pull tubes. X 10. Inspect the push rods for clearance to the structure. X 11. Inspect the trim systems for correct operation and for general condition. X 12. Remove control stick from main the torque tube bolt, inspect and replace bolt as required. X 500 Hours METAL EMPENNAGE Daily 50 HRS 100 HRS 400 HRS Check the travel of the movable surfaces. Elevator up degrees ±1 degree 1. Elevator down degrees ±1 degree Rudder degrees ±1 degree X Tab up degrees ±1degree Tab down degrees ±1 degree 2. Check for warped contours of the fixed surfaces due to improperly tightened brace struts. X X 3. Inspect horizontal stabilizer V struts, fittings, and hardware for security, cracks and corrosion. X 4 Inspect all hinges for wear. Replace sealed bearings, if needed. X 6. Check security of all bolts. X 7. Check the external skins for general condition. X 8. Check the drain holes for obstruction. X EFFECTIVE: 1/26/

51 THRUSH AIRCRAFT INC S2R-T34 TURBO THRUSH AIRCRAFT MAINTENANCE MANUAL AILERONS AND FLAPS Daily 50 HRS 100 HRS 400 HRS Check the control movements. 1. Aileron up Aileron down 21 degrees ±1 degree 17 degrees ±1 degree X Flap down 15 degrees ±1 degree 2. Check the security of the counterweights, which are installed in the leading edges of the ailerons. X 3. Inspect all the skins and ribs for cracks, loose rivets, general condition, and corrosion. X 4. Inspect the flap push rods, mounting brackets, torque tube, and bearing housings. X X Inspect the flap actuator motor and worm drive for general 5. condition and freedom of travel. Grease Zerk fitting with (MIL- G (Aeroshell 22) on bottom of unit. X Aileron servo tabs 6. a. Check security of hinges b. Check for looseness of rod ends and bolts. X c. Check for freedom of travel. EFFECTIVE: 1/26/

52 THRUSH AIRCRAFT INC S2R-T34 TURBO THRUSH AIRCRAFT MAINTENANCE MANUAL COCKPIT Daily 50 HRS 100 HRS 400 HRS 1. Check the condition of the instrument markings and the placards. X X 2. Check the instrument lines for leaks, security, and chafing. X 3. Check the hopper for leaks and security of mechanism. X 4. Check the security and condition of the seat belts, shoulder harness, and inertia reels. X 5. Check the seat for security and proper adjustment operation. Check the seat fabric for general condition. X 6. Check the windshield and windows for cracks, crazing or scratches, and missing screws. X 7. Check the doors for security of hinges and for correct operation of door locks. X 8. Check operation of flight & engine controls to ensure proper operation and installation. X X EFFECTIVE: 1/26/

53 THRUSH AIRCRAFT INC S2R-T34 TURBO THRUSH AIRCRAFT MAINTENANCE MANUAL ELECTRICAL SYSTEM Daily 50 HRS 100 HRS 400 HRS 1. Check the battery charge and water level. X X 2. Check battery relays, spike diodes, regulator, fuses, and switches for security. X 3. Check all wiring for chafing and clamping. X 4. Check all terminals for security and corrosion X 5. Check the battery s vent hoses for security and deterioration. X 6. Check GCU, GCU Relays, Fuses, Circuit Breakers and switches for security. X 6. Check associated terminals for security and corrosion. X EFFECTIVE: 2/14/ REVISION 1

54 THRUSH AIRCRAFT INC S2R-T34 TURBO THRUSH AIRCRAFT MAINTENANCE MANUAL AIRFRAME MAINTENANCE CORROSION CONTROL The lower part of the aircraft is painted with ultra gloss polyurethane. The forward upper glare shield part is painted with flat black polyurethane. The fuselage frame is painted with a primer, and then painted with a gray ultrathane. All repairs involving refinishing should be painted to the original specifications. The following procedures should be carried out step by step. A. Sand part to bare metal using 180 paper or finer. Avoid removal of cladding with the Alclad parts, whenever possible. B. Thoroughly clean area with isopropyl alcohol, a solvent, or thinner. Allow time to dry. C. Apply one thin spray coat of Epoxy primer with Epoxy hardener. Allow time to dry. D. Mix the required quantity of Polyurethane (use the directions on the can) with the prescribed amount of activator. Spray a smooth and even coat directly onto the primed surfaces. Apply at least two coats and allow time for drying between the coats. A regular and thorough cleaning of both the interior and exterior of the aircraft is a major part of corrosion control. All areas of the aircraft are accessible for cleaning by removal of the panels. The cleaning procedure that follows is recommended for general purposes. * NOTE * Certain chemicals cannot be removed effectively by detergent solutions. Special cleaning agents are available for that purpose. It is suggested that the chemical suppliers be contacted for cleaning agents that are suitable for those special needs. A. Wash all exterior surfaces of the aircraft with plain water and any commercial soap or detergent. Soap and detergent are organic chemicals, and it is important that all traces be removed by flushing with plain water. B. Detach all removable panels from the aircraft. Wash down the rear fuselage aft of the wing trailing edge. Tube joints, skin bends, and so forth should receive particular attention. Remove excess moisture after flushing. EFFECTIVE: 1/26/

55 THRUSH AIRCRAFT INC S2R-T34 TURBO THRUSH AIRCRAFT MAINTENANCE MANUAL C. The forward fuselage and engine section should not be cleaned with water unless close attention is made to avoid removal of lubricants and to avoid possible rusting of components and hardware. A general purpose, non-corrosive cleaning agent is preferred in those areas. D. Particular attention should be given to the wing center splice fittings and the attachments of the oil cooler, hopper and engine mount. E. Hopper cleaning should be accomplished at the end of each working day. A good commercial detergent should be used and followed by a thorough flush with water. Leave the hopper door and gate open for thorough drying. WINDSHIELD An anti-static type of plastic cleaner, such as Mirror Glaze or equivalent, is recommended for best cleaning. The side windshields are plastic and should not be cleaned with gasoline, alcohol, acetone, and lacquer thinner, or window cleaning spray. Those fluids will soften the plastic and cause crazing. Avoid rubbing the plastic surface with a dry cloth, as that can cause scratches and build up an electrical charge (static) which will attract dust particles. If scratches are visible after removing the dust accumulation, finish the plastic with a quality grade of commercial wax. Apply the wax in a thin, even coat and carefully buff out with a soft cloth. Do not buff or polish in one area for more than a brief period of time. The heat generated by rubbing the surface may soften the plastic and may produce visual distortion. The middle section of the windshield is safety plate glass for better resistance to scratching. It is enclosed in an aluminum frame. HOPPER REPAIR Hopper repair may be accomplished in accordance with the instructions contained in Section IX. FUEL TANK REPAIR Fuel tank repair may be accomplished in accordance with the instructions contained in Section V. BATTERY MAINTENANCE The 24-volt batteries are installed in the engine compartment between the engine and firewall. Access is gained to the batteries by removal of a cowling. Battery servicing involves adding distilled water to maintain electrolyte level of 3/16 inch over the separators, checking the cable connections, and neutralizing or cleaning any spilled electrolyte or any corrosion. Use bicarbonate of soda and clean water to neutralize corrosion. Follow with a thorough flushing of clean water and wipe dry. EFFECTIVE: 1/26/

56 THRUSH AIRCRAFT INC S2R-T34 TURBO THRUSH AIRCRAFT MAINTENANCE MANUAL Clean the cable and terminal connections with a wire brush and coat with petroleum jelly to minimize corrosion. ** CAUTION ** Do not allow the bicarbonate of soda to enter the battery filler openings, as it will neutralize the electrolyte, which could permanently damage the batteries. A hydrometer test of the battery s solution should be made each 50 hours of operation, or more often in hot weather. If the specific gravity tests 1.240, the battery should be removed and recharged. The solution levels should be examined and, when necessary, add distilled water to maintain the level of 3/16 inch over the separators. If distilled water is added, do it just prior to recharging so that the added water mixes with the solution. When the recharging is completed, the specific gravity should be between and The battery should be checked for grounding to the case. A voltmeter can be used to check between the positive cell and the case. A ground fault exists if there is a reading on the voltmeter. A dated service record shall be attached or stamped on the terminal side of the battery to indicate that the battery has been capacity tested. Refer to Section Ten for recharging procedures. LUBRICATION For the lubrication requirements, refer to Figure 2-6 Lubrication Chart (8 sheets). Before adding grease to fittings, wipe the fittings clean. Lubricate the fittings and wipe off the excess lubricant. Lubricate the hinges with a squirt can or a brush moistened with oil. Wipe off the excess oil to prevent accumulation of dirt and grit. EFFECTIVE: 1/26/

57 THRUSH AIRCRAFT INC S2R-T34 TURBO THRUSH AIRCRAFT MAINTENANCE MANUAL FIGURE 2.1 EFFECTIVE: 1/26/

58 THRUSH AIRCRAFT INC S2R-T34 TURBO THRUSH AIRCRAFT MAINTENANCE MANUAL FIGURE 2.2 EFFECTIVE: 1/26/

59 THRUSH AIRCRAFT INC S2R-T34 TURBO THRUSH AIRCRAFT MAINTENANCE MANUAL FIGURE 2.3 EFFECTIVE: 1/26/

60 THRUSH AIRCRAFT INC S2R-T34 TURBO THRUSH AIRCRAFT MAINTENANCE MANUAL FIGURE 2.4 EFFECTIVE: 1/26/

61 THRUSH AIRCRAFT INC S2R-T34 TURBO THRUSH AIRCRAFT MAINTENANCE MANUAL FIGURE 2.5 EFFECTIVE: 1/26/

62 THRUSH AIRCRAFT INC S2R-T34 TURBO THRUSH AIRCRAFT MAINTENANCE MANUAL ** WARNING ** The drawings of Figure 2-6, sheets 1 thru 8, are for lubrication reference only. They do not show proper assembly details and may not be used as assembly reference. Refer to the appropriate parts manual for details concerning parts assembly. APPLICATION SYMBOL SPECIFICATIONS AND TYPE OF LUBRICATION MIL-G (AEROSHELL 22) AIRCRAFT GREASE HAND PACK LUBRICATION GUN OIL CAN MIL-G (AEROSHELL 22) AIRCRAFT GREASE MIL-L (AEROSHELL OIL W 15W50) OR EQUIVALENT LUBRICATING OIL * NOTE* Use only Aeroshell 6 in propeller. FIGURE 2.6 Lubrication Chart Sheet 1 of 8 EFFECTIVE: 1/26/

63 THRUSH AIRCRAFT INC S2R-T34 TURBO THRUSH AIRCRAFT MAINTENANCE MANUAL FIGURE 2.6 Lubrication Chart Sheet 2 of 8 EFFECTIVE: 1/26/

64 THRUSH AIRCRAFT INC S2R-T34 TURBO THRUSH AIRCRAFT MAINTENANCE MANUAL FIGURE 2.6 Lubrication Chart Sheet 3 of 8 EFFECTIVE: 1/26/

65 THRUSH AIRCRAFT INC S2R-T34 TURBO THRUSH AIRCRAFT MAINTENANCE MANUAL FIGURE 2.6 Lubrication Chart Sheet 4 of 8 EFFECTIVE: 1/26/

66 THRUSH AIRCRAFT INC S2R-T34 TURBO THRUSH AIRCRAFT MAINTENANCE MANUAL FIGURE 2.6 Lubrication Chart Sheet 5 of 8 EFFECTIVE: 1/26/

67 THRUSH AIRCRAFT INC S2R-T34 TURBO THRUSH AIRCRAFT MAINTENANCE MANUAL FIGURE 2.6 Lubrication Chart Sheet 6 of 8 EFFECTIVE: 1/26/

68 THRUSH AIRCRAFT INC S2R-T34 TURBO THRUSH AIRCRAFT MAINTENANCE MANUAL FIGURE 2.6 Lubrication Chart Sheet 7 of 8 EFFECTIVE: 1/26/

69 THRUSH AIRCRAFT INC S2R-T34 TURBO THRUSH AIRCRAFT MAINTENANCE MANUAL FIGURE 2.6 Lubrication Chart Sheet 8 of 8 EFFECTIVE: 1/26/

70 THRUSH AIRCRAFT INC S2R-T34 TURBO THRUSH AIRCRAFT MAINTENANCE MANUAL FINE THREAD SERIES BOLTS BOLTS Steel Tension Steel Tension AN 3 thru AN 20 AN 42 thru AN 49 AN 73 thru AN 81 AN 173 thru AN 186 AN thru MS MS MS20074 AN509 NK9 MS AN 525 N K525 MS27039 MS thru MS NAS 144 thru NAS 158 NAS 333 thru NAS 340 NAS 583 thru NAS 590 NAS 624 thru NAS 644 NAS 1103 thru NAS 1120 NAS 1202 thru NAS 1210 NAS 1303 thru NAS 1320 NAS 6203 thru NAS 6220 NAS 6603 thru NAS 6620 NAS 172 NAS 174 NAS 517 Steel Shear NAS 454 NUTS NUTS Steel Tension Steel Shear Steel Tension Steel Shear AN 310 AN 315 AN 363 AN 365 NAS 1021 MS MS AN 320 AN 364 NAS 1022 MS MS MS 21083N MS AN 310 AN 315 AN 363 AN 365 MS MS MS AN 320 AN 364 NAS 1022 MS MS MS 21083N MS MS MS NAS 679 MS MS 21044N MS NAS 1021 NAS 679 NAS 1291 MS MS 21044N MS Nut-bolt size Torque Limits in-lbs Torque Limits in-lbs Nut-bolt size Torque Limits in-lbs Torque Limits in-lbs Min. Max. Min. Max. Min. Max. Min. Max ¼ ¼ / / / / / / ½ ½ / , / ,100 1, /8 18 1,100 1, /8 18 1,250 1, ¾ ,300 2,500 1,300 1,500 ¾ ,650 3,200 1,600 1,900 7/8 14 2,500 3,000 1,500 1,800 7/8 14 3,550 4,350 2,100 2, ,700 4,500 2,200 3, ,500 5,500 2,700 3, /8-12 5,000 7,000 3,000 4, /8-12 6,000 7,300 3,600 4,400 1 ¼ ,000 11,000 5,400 6,600 1 ¼ ,000 13,400 6,600 8,000 FIGURE 2.7 Torque Chart EFFECTIVE: 1/26/

71 THRUSH AIRCRAFT INC S2R-T34 TURBO THRUSH AIRCRAFT MAINTENANCE MANUAL FIGURE 2.8 EFFECTIVE: 1/26/

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118 Figure RPM NP Torque Setting Chart Effective: 1/26/05 And Beta Nut Adjustment 4 45

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127 THRUSH AIRCRAFT INC MODEL S2R-T34 TURBO THRUSH AIRCRAFT MAINTENANCE MANUAL Figure 4-17 Installed Engine Performance Checking Curve Lower Cowl Air Cleaner Panels Effective: 1/26/

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130 THRUSH AIRCRAFT INC MODEL S2R-T34 TURBO THRUSH AIRCRAFT MAINTENANCE MANUAL Figure 4-20 Cockpit Engine Control Quadrant Exploded View Effective: 1/26/

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254 THRUSH AIRCRAFT INC MODEL S2R-T34 TURBO THRUSH AIRCRAFT MAINTENANCE MANUAL Section 10: ELECTRICAL SYSTEM TABLE OF CONTENTS GENERAL DESCRIPTION... 3 POWER DISTRIBUTION... 3 BATTERY AND EXTERNAL POWER... 3 BATTERY SERVICING... 4 SERVICING BATTERY INSTALLED IN AIRCRAFT... 5 GENERATOR SYSTEM... 5 DIAGRAMS... 6 BATTERY OPERATION... 6 BATTERY REMOVAL... 6 BATTERY INSTALLATION... 6 Control Via "VOLTAGE REGULATION"... 7 VOLTAGE REGULATOR REMOVAL/INSTALLATION... 7 Control Via "GENERATOR CONTROL UNIT"... 8 GENERATOR CONTROL UNIT REMOVAL/INSTALLATION... 8 REMOVE/INSTALL RELAYS (BATTERY PLATE)... 9 STARTER/GENERATOR MAINTENANCE... 9 STARTER/GENERATOR - REMOVAL... 9 STARTER/GENERATOR-INSTALLATION TROUBLESHOOTING CHARTS BATTERY SYSTEM STARTER GENERATOR - GENERATOR PHASE GENERATOR CONTROL UNIT STARTER GENERATOR - STARTER PHASE ELECTRICAL DWGS & DIAGRAMS: STANDARD EQUIPMENT: Figure 10-1 Flap System Wiring Figure 10-2 Fuel Quantity Figure 10-3 Hour Meter Figure 10-4 Low Oil Light & Stall Warning Figure 10-5 Windshield Washer/Wiper Figure 10-6 Strobe Lights Figure 10-7a Navigation & Instrument Lighting Figure 10-7b Navigation & Instrument Lighting ENGINE -PRATT & WHITNEY: Figure 10-8 Beta & Chip Detector Figure 10-9 Aux Fuel Pump, Igniters and Prop Test Figure ITT Figure 10-11a Power Distribution (T thru 408) Figure 10-11b Power Distribution (T & subsequent) QUICK DISCONNECTS: Figure Quick Disconnect Figure 10-13a QDA (T thru 408) Figure 10-13b QDA (T & Subsequent) Figure QDB Figure QDC Figure QDD Figure QDE Figure QDF Figure QDG Figure QDH Figure 10-21a QDJ (T thru 408) Figure 10-21b QDJ (T & Subsequent) Figure QDL Figure QDN Figure QDP EFFECTIVE: 2/14/ REVISION 1

255 THRUSH AIRCRAFT INC MODEL S2R-T34 TURBO THRUSH AIRCRAFT MAINTENANCE MANUAL Figure QDR Figure 10-26a Wire Harness Routing Figure 10-26b Wire Harness Routing OPTIONAL Figure Flagger Figure Boom Pressure, Turn & Bank, DG Figure Low Voltage Light, DG & Artificial Horizon Figure Smoker & Map Light Figure Zee Air Conditioner Figure Hopper Rinse & Pitot Heat Figure Micronair Flowmeter, Hopper Light & Agitator Figure Avionics Buss Figure Electric Fan Brake & Crop Hawk Figure Hopper Quantity & Fuel Flow Figure Hi Capacity Windshield Washer Figure Night Working Light Control Figure 10-39a Night Working Lights Figure 10-39b Night Working Lights Figure Standard Oil Cooler Augmentation EFFECTIVE: 2/14/ REVISION 1

256 THRUSH AIRCRAFT INC MODEL S2R-T34 TURBO THRUSH AIRCRAFT MAINTENANCE MANUAL SECTION TEN: ELECTRICAL SYSTEM GENERAL DESCRIPTION The aircraft 24-volt DC electrical system is designed to provide the utmost in reliability. Two 24-volt storage batteries provide electric current for engine starting and a reserve source of electrical power in the event of generator failure. A D.C. power receptacle provides a means for connecting external power to the aircraft electrical system. To conserve battery life, external power should always be used for starting engines when temperature is below 40 F or when performing maintenance requiring electrical power. A generator installed on the engine supplies the primary source of electrical power to the main bus. A voltage regulator protects the electrical system on aircraft serial numbers T through T A generator control unit (GCU) protects the electrical system on aircraft T & subsequent providing control of the starter generator, providing voltage regulation, line contactor pull in, and generator disable during engine start. If generator output voltage is below bus voltage, the battery supplies the busloads. The D.C. ammeter, installed in the instrument panel, indicates the discharge or charge on the battery after the engine is started. All electrically operated motors, lighting systems and other electrical component circuits are protected by push button thermal circuit breakers. Switches and instruments required for operation of the aircraft electrical system are installed in the instrument panel and engine control switch panel. POWER DISTRIBUTION The 24-volt D.C. electrical system depends upon electrical power from three different sources: battery, external power and the generator. With the engine operating and the generator on the line, electric power from the generator is provided through a circuit breaker to the main bus. BATTERY AND EXTERNAL POWER Two 24-volt storage batteries provide power to the circuit breaker through relays. A two-position (BAT OFF-ON) switch located on the engine control switch panel controls the relays. Placing the battery switch in the ON position closes the relay to supply power to the circuit breaker bus from the battery or external power. Placing the battery switch in the OFF position de-energizes the battery relay and terminates the supply of power to the electrical system. EFFECTIVE: 2/14/ REVISION 1

257 THRUSH AIRCRAFT INC MODEL S2R-T34 TURBO THRUSH AIRCRAFT MAINTENANCE MANUAL BATTERY SERVICING INITIAL SERVICING OF A DRY CHARGE GE50C BATTERY IS AS FOLLOWS: A. Remove seals (if present) from cells. B. Fill each cell with specific gravity sulfuric acid to bottom of split ring. Use only glass, rubber or plastic materials for containing battery electrolyte fluid during servicing and wear protective clothing and rubber gloves when handling electrolyte to prevent personal injury. Use a solution of baking soda and water to neutralize any acid spilled on clothing, skin or any damageable surface. C. Sway the battery from side to side to release any trapped air. Re-adjust the electrolyte as necessary. C. Let battery sit unused for one hour. E. Check and re-adjust electrolyte level as necessary by adding more electrolytes to obtain proper level as stated in procedure B. F. Install vent plugs tightly into each cell. G. Clean and neutralize any spilled electrolyte on battery. H. Charge battery until all cells are gassing freely and the charge voltage and specific gravity of electrolyte are constant over three successive readings taken at one-hour intervals. (This procedure may take hours with a constant current charger.) During the period of charging, the electrolyte temperatures shall be maintained between 60 F and 110 F (15.6 C and 43.3 C). Charge rate is 3 amps. Reduce rate by 1/2 when cells start gassing. **CAUTION** Gases given off by a battery under charging conditions are flammable. EFFECTIVE: 1/26/

258 THRUSH AIRCRAFT INC MODEL S2R-T34 TURBO THRUSH AIRCRAFT MAINTENANCE MANUAL I. When the battery is completely charged, the specific gravity should read between and At this point, if electrolyte level needs to be adjusted, remove or add electrolyte to proper level and recharge for one hour. * NOTE * For more detailed instructions, see Gill Service Manual. SERVICING BATTERY INSTALLED IN AIRCRAFT The 24-volt battery is installed aft of the engine on the engine mount lower longerons and is accessible through the removable cowling skins. Check the battery electrolyte level frequently, especially during hot weather. If a visual check shows low cell level, add distilled water to bring the cell(s) up to the proper lever. (See battery-servicing instructions) CHARGED Less RECHARGE GENERATOR SYSTEM (T thru T34-408) The generator system consists of a generator; voltage regulator, reverse current relay and circuit breaker. The generator is connected to the circuit breaker bus and will supply the current demands when output voltage exceeds battery voltage. GENERATOR SYSTEM (T & subsequent) The generator system consists of a generator, generator switch/breaker, generator control unit, line connector relay and GCU circuit breaker. The generator is connected to the main bus and will supply the current demands when output voltage exceeds battery voltage. The power distribution diagram is at the end of this section. EFFECTIVE: 2/14/ REVISION 1

259 DIAGRAMS THRUSH AIRCRAFT INC MODEL S2R-T34 TURBO THRUSH AIRCRAFT MAINTENANCE MANUAL The Electrical Diagrams for Model S2R-T34 aircraft are located at the end of this section, beginning on page These diagrams are labeled according to the serial numbers of the aircraft that they apply to when it is necessary to do so. Diagrams without serial numbers apply to serial numbers T thru T and subsequent. BATTERY OPERATION Battery operation is controlled by a battery switch, placarded BATT-ON-OFF, located on the switch panel in the cockpit. The battery is capable of assuming the complete electrical load for a limited time at 70 amps max. The batteries are located on the battery plate assembly on the engine mount aft of the engine. They are installed with two-battery hold down rods through the battery cover. The battery case is vented overboard to dispose of any electrolyte or hydrogen gas fumes discharged during normal charging operation. Air enters the battery compartment from an air scoop located in the left cowl shin skin, circulates throughout the battery compartment, and exists through a vent in the battery and drains overboard through a vent located on the belly skins. BATTERY REMOVAL A. Verify that the BATT-ON-OFF switch is off. Disconnect external power. B. Remove R.H. aft cowl skin. C. Disconnect the quick disconnect from the battery and remove all safety wire. D. Disconnect vent tubes. E. Remove nuts from battery hold down rods and remove batteries from compartment. BATTERY INSTALLATION Reverse battery removal procedure. EFFECTIVE: 2/14/ REVISION 1

260 THRUSH AIRCRAFT INC MODEL S2R-T34 TURBO THRUSH AIRCRAFT MAINTENANCE MANUAL Control Via VOLTAGE REGULATION The generator output voltage is regulated by the voltage regulator circuitry. By using an integrated circuit comparator amplifier with a regulated reference voltage, and difference between the reference voltage and the generator voltage is amplified and supplied to the comparator circuit, which controls the shunt field excitation of the generator. Prior to installation, the voltage regulator is adjusted under NO load condition to maintain volts DC generator output voltage. After installation, the generator over voltage control should be adjusted to 27.5 VDC generator output voltage at the bus with normal systems turned on. VOLTAGE REGULATOR REMOVAL Gain access to the voltage regulator by removing R.H. aft cowl skin. If removal is necessary, proceed as follows: A. Verify that the battery switch is OFF, that the external power is disconnected, and that the batteries are disconnected. B. Disconnect the retaining clips from the voltage regulator and remove voltage regulator from voltage regulator base. VOLTAGE REGULATOR INSTALLATION A. Verify that the battery switch is OFF. B. Brighten up all electrical contacts, both on the voltage regulator and the 6 each fingers on the voltage regulator base, with Scotch-brite Ultra fine abrasive pad or equivalent. Place the voltage regulator into position and snap it to the regulator base with the retaining clips. D. Connect the battery. E. After installing, re-check voltage regulator for 27.5 VDC with engine running and normal systems operating. Adjust as necessary. EFFECTIVE: 2/14/ REVISION 1

261 THRUSH AIRCRAFT INC MODEL S2R-T34 TURBO THRUSH AIRCRAFT MAINTENANCE MANUAL Control Via GENERATOR CONTROL UNIT (GCU) The generator control unit enables the generator to produce current when the engine is running and both the battery switch and the generator switch breaker are ON. If the starter is engaged under these condition, such as when attempting a re-start in the air, the GCU interrupts the generator field circuit so that the pilot need not turn the generator switch breaker OFF. After engine start, with the generator switch breaker on the GCU compares the generator output voltage to main buss voltage and engages the line contact relay when generator voltage exceeds battery voltage. The GCU is factory set to maintain generator voltage at 27.5 VDC. If necessary, generator output voltage can be adjusted by removing the screw plug on the GCU case and turning the potentiometer screw (clockwise increases voltage). The generator voltage control should be adjusted to 27.5 VDC generator output voltage at the main bus with normal systems turned on. If the generator voltage should drop below battery voltage, the GCU will disengage the line contact relay to prevent reverse current to the generator. The GCU will also take the generator off-line if generator voltage exceeds 32 volts by tripping the generator switch breaker. The pilot may cycle the generator switch breaker OFF then back ON to try to reset the generator. If the generator continues to drop off-line, the pilot can assume that the generator is faulty and should terminate the flight. GCU REMOVAL Gain access to the GCU at the left hand or right hand aft engine cowl skin. If removal is necessary, proceed as follows: a. Verify that the battery switch is OFF, that the external power is disconnected, and that the battery is disconnected. b. Disconnect the GCU cannon plug from the unit and remove the GCU by removing the bolts holding it to the battery plate. GCU INSTALLATION a. Verify that the battery switch is OFF. b. Attach the GCU to the battery plate by reinstalling the bolts previously removed. c. Reconnect the GCU cannon plug to the unit. d. With Engine started and generator turned on, Measure the main bus voltage to assure 27.5 VDC. e. Adjust the GCU regulator for 27.5 VDC at the main bus with engine running and normal systems operating. EFFECTIVE: 2/14/ REVISION 1

262 THRUSH AIRCRAFT INC MODEL S2R-T34 TURBO THRUSH AIRCRAFT MAINTENANCE MANUAL Removal of Relays from Battery Plate Assembly Gain access to the Relays at the left hand or right hand aft engine cowl skin. a. Verify that the battery switch is OFF, that the external power is disconnected, and That the battery is disconnected. b. Determine the desired relay(s) to remove. (LCR, Master, or Start Relay) c. Disconnect the applicable wires from the desired relay(s) and identify wire terminations for reconnection later. d. Remove the bolts holding the relay(s) from the battery plate. Installation of Relays on the Battery Plate Assembly a. Verify that the battery switch is OFF. b. Attach the relay(s) to the battery plate by reinstalling the bolts previously removed. c. Reconnect the wires to the applicable relay(s) using the wire terminal identification from above. STARTER - GENERATOR MAINTENANCE * NOTE * Refer to the starter-generator maintenance manual for specific maintenance instructions. STARTER - GENERATOR REMOVAL A. Verify that the battery switch is OFF and that external power is disconnected. Disconnect the batteries. B. Open the upper aft engine cowling to gain access to the starter-generator. D. Loosen the quick-disconnect clamps securing the starter-generator to the mounting adapter and remove the starter-generator. EFFECTIVE: 2/14/ REVISION 1

263 THRUSH AIRCRAFT INC MODEL S2R-T34 TURBO THRUSH AIRCRAFT MAINTENANCE MANUAL ** CAUTION ** It is mandatory that the starter-generator be fully supported from the time the retaining clamp is loosened until the unit is removed from the engine. The startergenerator must never be allowed to support its own weight through the splined shaft engagement. If this precaution is not observed, damage to the shaft shear section or engine internal starter generator drive/breather impeller carbon seal will result. STARTER-GENERATOR INSTALLATION A. Verify that the battery switch is OFF and that external power is disconnected. Disconnect batteries. B. On wet type spline engines (approx and newer) install new 0 ring on startergenerator drive shaft. Lubricate wet-type splines with engine oil. On engines equipped with dry type splines, lubricate splines with Dow Corning M-77 molycoat. C. Position the starter-generator on the mounting adapter and secure it in place with the quickdisconnect clamp. D. Close the clamp hinge over the T-bolt. Check with a mirror to make certain the clamp groove fully captures both the flange on the quick-disconnect adapter and the flange on the starter-generator around its entire circumference. E. When the clamp is properly positioned and the hinge and T-bolt are closed, tighten the T- bolt nut to a torque of 70 inch pounds. Tap circumference of clamp lightly with plastic/rudder mallet. Re-torque T-bolt nut to 70 inch pounds and repeat until you achieve 70 inch pound of torque without nut moving. F. Connect the electrical leads to the starter-generator as previously marked. G. Secure the upper aft engine cowling and connect the batteries. Run the engine at idle speed for at least two minutes. Shut down the engine and recheck the quick-disconnect clamp for proper torque. EFFECTIVE: 2/14/ REVISION 1

264 THRUSH AIRCRAFT INC MODEL S2R-T34 TURBO THRUSH AIRCRAFT MAINTENANCE MANUAL TROUBLESHOOTING CHART BATTERY SYSTEM TROUBLE PROBABLE CAUSE REMARKS Battery fails to hold charge Battery defective Replace battery Battery will not come up to full charge Battery consumes water rapidly Electrolyte runs out drain tube Battery discharged No power indicated with battery switch on Power on with battery switch in OFF position Charging rate to low Charging rate too high Electrolyte level too high Excessive charging rate Vent caps loose or broken Standing too long Equipment left on Short circuit in wiring Charging rate too high Battery discharged, defective or disconnected Blown C/B in battery control circuit Defective wiring in battery control circuit Defective battery relay Battery switch defective Shorted or sticking contacts Check voltage regulator and adjust to 27.5±.2 VDC Check voltage regulator adjust to 27.5 ±.2 Remove excess electrolyte & adjust specific gravity Check voltage regulator for correct voltage Tighten or replace caps Remove battery and recharge Remove battery and recharge Check wiring and correct Adjust voltage regulator to 27.5 Check battery, recharge or replace battery Check C/B and reset if necessary Continuity. Check circuitry and repair as necessary Check relay for proper operation and replace as necessary Check switch for proper operation. Replace if necessary Check switch and relay for proper operation. Replace if necessary. EFFECTIVE: 1/26/

265 THRUSH AIRCRAFT INC MODEL S2R-T34 TURBO THRUSH AIRCRAFT MAINTENANCE MANUAL STARTER/GENERATOR - GENERATOR PHASE TROUBLE PROBABLE CAUSE REMARKS Zero or low voltage indicated No generator output Loose connection Open or shorted field circuit in generator or defective armature Brushes not contacting commutator Brushes worn Dirty commutator Defective voltage regulator circuit Improper Connections Generator circuit breaker tripped or 100 amp buss limit fuse blown Improper connections Defective generator control switches Continuity. Defective Reverse Current Relay Defective generator Check connections throughout system Test resistance of field. Check field circuit connections. Replace starter-generator if defective. Clean brushes and holders with a clean, dry, lint-free cloth. Replace weak springs. Replace brushes Clean commutator Adjust or replace regulator Check connections against wiring diagram Check for short circuit and reset circuit breaker and / or replace buss limit fuse Check connections against wiring diagram Check switch for proper operation and replace if necessary. With engine running, check for 27.5vdc at both GEN and BATT terminals. If 27.5vdc at GEN and 24vdc at BATT, reverse current relay is faulty. Check generator with an ohmmeter and replace starter-generator if necessary Volt-ammeter does not indicate Defective wiring Continuity. Check wiring and repair as necessary Improper Connections Check connections against wiring diagrams Defective generator control switches continuity. Check switch for proper operation and replace if necessary. EFFECTIVE: 1/26/

266 THRUSH AIRCRAFT INC MODEL S2R-T34 TURBO THRUSH AIRCRAFT MAINTENANCE MANUAL STARTER/GENERATOR GCU TROUBLE PROBABLE CAUSE REMARKS Defective GCU (Generator Control Unit) Defective Generator With Engine running, check for 27.5 VDC at BATT terminal while toggling generator switch. With generator switch in OFF position, there should be a voltage drop to the current BATT voltage. With generator switch in ON position, the voltage should increase to 27.5 volts. If the voltage does not increase to 27.5 VDC, check GCU adjustment to proper voltage. Check generator with and ohmmeter and replace starter-generator if necessary. Defective Meter Replace Meter Generator circuit breaker tripped or 100 amp buss limit fuse blown. Check for short circuit and reset circuit breaker and / or replace buss limit fuse. Defective LCR Relay Check Relay For Operation and replace if necessary. EFFECTIVE: 2/14/ REVISION 1

267 THRUSH AIRCRAFT INC MODEL S2R-T34 TURBO THRUSH AIRCRAFT MAINTENANCE MANUAL STARTER/GENERATOR - STARTER PHASE TROUBLE PROBABLE CAUSE REMARKS Circuit breaker tripped Check for short circuit and reset circuit breaker Low battery Check battery. Service and recharge as necessary Starter relay inoperative Check relay for operation and replace if necessary Starter inoperative Battery relay inoperative Check relay for operation and replace if necessary Loose connection or faulty ground in starter power circuit Defective starter motor Low battery Continuity. Check and repair starter as necessary Check brushes, springs and condition of commutator continuity. Check starter windings for open or short circuit. Repair or replace Check battery. Service and recharge if necessary Starter produces low Ng Starter produces low Ng High resistance starter circuit Defective Starter Motor Check resistance of each connection. Maximum resistance at any connection is ohm. Inspect connections for evidence of heating. Clean and tighten connections as necessary. Check brushes, springs and commutator. Replace brushes and springs and clean commutator as necessary. EFFECTIVE: 1/26/

268 THRUSH AIRCRAFT INC MODEL S2R-T34 TURBO THRUSH AIRCRAFT MAINTENANCE MANUAL FIGURE 10.1 Standard Equipment - Flap System Wiring EFFECTIVE: 1/26/

269 THRUSH AIRCRAFT INC MODEL S2R-T34 TURBO THRUSH AIRCRAFT MAINTENANCE MANUAL FIGURE 10.2 Standard Equipment - Fuel Quantity EFFECTIVE: 1/26/

270 THRUSH AIRCRAFT INC MODEL S2R-T34 TURBO THRUSH AIRCRAFT MAINTENANCE MANUAL FIGURE 10-3 Standard Equipment Hour Meter EFFECTIVE: 1/26/

271 THRUSH AIRCRAFT INC MODEL S2R-T34 TURBO THRUSH AIRCRAFT MAINTENANCE MANUAL FIGURE 10.4 Standard Equipment Low Oil Light & Stall Warning EFFECTIVE: 1/26/

272 THRUSH AIRCRAFT INC MODEL S2R-T34 TURBO THRUSH AIRCRAFT MAINTENANCE MANUAL FIGURE 10.5 Standard Equipment - Windshield Washer/Wiper EFFECTIVE: 1/26/

273 THRUSH AIRCRAFT INC MODEL S2R-T34 TURBO THRUSH AIRCRAFT MAINTENANCE MANUAL FIGURE 10.6 Standard Equipment - Strobe Lights EFFECTIVE: 1/26/

274 THRUSH AIRCRAFT INC MODEL S2R-T34 TURBO THRUSH AIRCRAFT MAINTENANCE MANUAL FIGURE 10.7a Standard Equipment - Navigation & Instrument Lighting EFFECTIVE: 1/26/

275 THRUSH AIRCRAFT INC MODEL S2R-T34 TURBO THRUSH AIRCRAFT MAINTENANCE MANUAL FIGURE 10.7b Standard Equipment - Navigation & Instrument Lighting EFFECTIVE: 1/26/

276 THRUSH AIRCRAFT INC MODEL S2R-T34 TURBO THRUSH AIRCRAFT MAINTENANCE MANUAL FIGURE 10.8 Engine / Pratt & Whitney - Beta & Chip Detector EFFECTIVE: 1/26/

277 THRUSH AIRCRAFT INC MODEL S2R-T34 TURBO THRUSH AIRCRAFT MAINTENANCE MANUAL FIGURE 10.9 Engine / Pratt & Whitney - Aux Fuel Pump, Igniters & Prop Test EFFECTIVE: 1/26/

278 THRUSH AIRCRAFT INC MODEL S2R-T34 TURBO THRUSH AIRCRAFT MAINTENANCE MANUAL FIGURE Engine / Pratt & Whitney - ITT EFFECTIVE: 1/26/

279 THRUSH AIRCRAFT INC MODEL S2R-T34 TURBO THRUSH AIRCRAFT MAINTENANCE MANUAL FIGURE 10.11a Engine / Pratt & Whitney Power Distribution T thru T EFFECTIVE: 2/14/ REVISION 1

280 THRUSH AIRCRAFT INC MODEL S2R-T34 TURBO THRUSH AIRCRAFT MAINTENANCE MANUAL FIGURE 10.11b Engine/Pratt & Whitney Power Distribution T & Subsequent EFFECTIVE: 2/14/ REVISION 1

281 THRUSH AIRCRAFT INC MODEL S2R-T34 TURBO THRUSH AIRCRAFT MAINTENANCE MANUAL FIGURE Quick Disconnect EFFECTIVE: 1/26/

282 THRUSH AIRCRAFT INC MODEL S2R-T34 TURBO THRUSH AIRCRAFT MAINTENANCE MANUAL FIGURE 10.13a Quick Disconnect QDA FOR T THRU 408 EFFECTIVE: 2/14/ REVISON 1

283 THRUSH AIRCRAFT INC MODEL S2R-T34 TURBO THRUSH AIRCRAFT MAINTENANCE MANUAL FIGURE 10.13b Quick Disconnect QDA FOR T & SUBSEQUENT EFFECTIVE: 2/14/ REVISON 1

284 THRUSH AIRCRAFT INC MODEL S2R-T34 TURBO THRUSH AIRCRAFT MAINTENANCE MANUAL FIGURE Quick Disconnect - QDB EFFECTIVE: 1/26/

285 THRUSH AIRCRAFT INC MODEL S2R-T34 TURBO THRUSH AIRCRAFT MAINTENANCE MANUAL FIGURE Quick Disconnect - QDC EFFECTIVE: 1/26/

286 THRUSH AIRCRAFT INC MODEL S2R-T34 TURBO THRUSH AIRCRAFT MAINTENANCE MANUAL FIGURE Quick Disconnect - QDD EFFECTIVE: 1/26/

287 THRUSH AIRCRAFT INC MODEL S2R-T34 TURBO THRUSH AIRCRAFT MAINTENANCE MANUAL FIGURE Quick Disconnect - QDE EFFECTIVE: 1/26/

288 THRUSH AIRCRAFT INC MODEL S2R-T34 TURBO THRUSH AIRCRAFT MAINTENANCE MANUAL FIGURE Quick Disconnect - QDF EFFECTIVE: 1/26/

289 THRUSH AIRCRAFT INC MODEL S2R-T34 TURBO THRUSH AIRCRAFT MAINTENANCE MANUAL FIGURE Quick Disconnect - QDG EFFECTIVE: 1/26/

290 THRUSH AIRCRAFT INC MODEL S2R-T34 TURBO THRUSH AIRCRAFT MAINTENANCE MANUAL FIGURE Quick Disconnect - QDH EFFECTIVE: 1/26/

291 THRUSH AIRCRAFT INC MODEL S2R-T34 TURBO THRUSH AIRCRAFT MAINTENANCE MANUAL FIGURE 10.21a Quick Disconnect - QDJ FOR T THRU 408 EFFECTIVE: 2/14/ REVISION 1

292 THRUSH AIRCRAFT INC MODEL S2R-T34 TURBO THRUSH AIRCRAFT MAINTENANCE MANUAL FIGURE 10.21b Quick Disconnect - QDJ FOR T & SUBSEQUENT EFFECTIVE: 2/14/ REVISION 1

293 THRUSH AIRCRAFT INC MODEL S2R-T34 TURBO THRUSH AIRCRAFT MAINTENANCE MANUAL FIGURE Quick Disconnect - QDL EFFECTIVE: 1/26/

294 THRUSH AIRCRAFT INC MODEL S2R-T34 TURBO THRUSH AIRCRAFT MAINTENANCE MANUAL FIGURE Quick Disconnect - QDN EFFECTIVE: 1/26/

295 THRUSH AIRCRAFT INC MODEL S2R-T34 TURBO THRUSH AIRCRAFT MAINTENANCE MANUAL \ FIGURE Quick Disconnect - QDP EFFECTIVE: 1/26/

296 THRUSH AIRCRAFT INC MODEL S2R-T34 TURBO THRUSH AIRCRAFT MAINTENANCE MANUAL FIGURE Quick Disconnect - QDR EFFECTIVE: 1/26/