CUSTOM KIT No - Thrush Aircraft

CUSTOM KIT No - Thrush Aircraft
THRUSH AIRCRAFT, INC.
P.O. Box 3149
Albany, GA 31706-3149
Phone (229) 883-1440
Fax (229) 439-9790
CUSTOM KIT
No. CK-AG-38
Date: 8/11/06
FIELD CONVERSION OF S2R-T15 AIRCRAFT
TO S2R-T34
MODELS AFFECTED:
S2R-T15: Single cockpit Serial numbers: T15-001 through
T15-009, T15-012 through T15-014, T15-022 through T15-027, T27-028, T27-029, T27-031,
T15-033 through T15-036, T15-038, T15-040 through T15-044 Dual cockpit serial
numbers: T15-010DC, T15-011DC, T15-015DC through T15-018DC, T15-020DC, T15021DC, T15-037DC, T15-039DC.
REASON FOR PUBLICATION: To allow owners to upgrade powerplant for improved
aircraft performance.
COMPLIANCE:
At owner’s discretion.
BY WHOM WORK WILL
BE ACCOMPLISHED:
Inspection accomplished by FAA DAR inspector
or equivalent.
Installation by an A&P Mechanic or equivalent.
Approval:
FAA approved.
Estimated Man-hours:
25
PARTS DATA:
The parts required to comply with this custom kit may be obtained
from your nearest Thrush authorized service center. A parts list is
attached to this publication.
CUSTOM KIT No. CK-AG-38
Page 1 of 9
August 11, 2006
Thrush Aircraft, Inc.
P.O. Box 3149
Albany, GA 31706-3149
Custom Kit No. CK-AG-38
Date: 8/11/06
Page 2 of 9
*NOTE*
If the PT6A-34 or 34AG engine being installed was
manufactured in 1999 or later, it probably has the single line
fuel control unit. Your engine controls may not work with it.
Custom Kit CK-AG-37 allows you to update your engine
controls, if necessary.
ACCOMPLISHMENT INSTRUCTIONS
1.
2.
3.
4.
Remove engine cowling panels.
Place fuel shutoff valve into the OFF position.
Assure all electrical power to the aircraft is disconnected and remove
battery/batteries.
Disconnect all engine control cables/push-pull tubes, rod-ends, and secure.
*NOTE*
Tag and identify all tubes, hoses, electrical leads, and electrical
connector plugs. Upon disassembly, cap all openings, tubing,
hoses, drive pads, fittings, plugs, and connectors to prevent
contamination and/or damage.
5.
6.
7.
8.
9.
10.
11.
12.
13.
14.
Disconnect fuel feed line to the inlet side of engine driven fuel boost pump.
Disconnect oil pressure line from oil pressure port.
Disconnect fuel pressure line from fuel pressure port.
Disconnect engine torque pressure line from torque pressure port.
Disconnect engine torque vent line from torque vent port.
Disconnect engine overboard breather line.
Disconnect fwd. and aft. engine combustor drain lines.
Disconnect F.C.U. or Start Control fuel return line.
Drain engine oil and remove line to engine quick oil drain fitting.
Disconnect battery vent lines.
15.
Disconnect seal drain vent lines at the following locations:
a. Engine driven fuel boost pump.
b. High-pressure fuel pump/fuel control unit.
c. Propeller shaft.
d. Starter/Generator.
Disconnect Air Filter Δp lines on models so equipped.
Disconnect compressor wash feed lines.
Disconnect E.P.A. residue fuel reservoir lines from flow divider/dump valve.
16.
17.
18.
19.
Disconnect engine-wiring harness from engine. Be sure to flag all cannon plugs and
terminal ends. Disconnect the following and secure to prevent damage:
a. Overspeed governor prop test solenoid.
b. Prop beta micro switch.
c. RGB chip detector, if equipped.
Thrush Aircraft, Inc.
P.O. Box 3149
Albany, GA 31706-3149
20.
21.
22.
23.
24.
25.
Custom Kit No. CK-AG-38
Date: 8/11/06
Page 3 of 9
d. Np tachometer generator.
e. Ng tachometer generator.
f. Oil temperature sending unit.
g. Starter/Generator terminal block.
h. Fuel flow transducer, if equipped.
i. Engine ground cable from rear of engine driven boost pump.
j. P3 heat terminal.
k. Ignition exciter box.
Disconnect ITT harness at the T5 terminal block.
Remove propeller.
Using a suitable hoist and sling. Hoist engine at proper C.G. to take weight off of
engine isolators to engine mount attach bolts. (Note: Assure that engine is not
pitched beyond 45° above or below horizontal).
Remove 3 each engine mount isolator attach bolts and hoist engine clear of aircraft.
Preserve and store old engine in accordance with Pratt & Whitney Maintenance
Manual for maximum anticipated storage time.
Using Top Drawing number 19000 (S/N’s T15-001 thru T15-020) or Top Drawing
number 19870 (S/N’s T15-021 thru T15-044) complete the following steps:
*NOTE*
Torque all hardware in accordance with Pratt & Whitney
Canada maintenance manual (for engine related components),
Thrush Aircraft Inc. drawings and TORQUE CHART on the
last page.
*NOTE*
Using sound judgement, prep, prime, and paint component
pieces as necessary for corrosion control.
a. Install engine isolator mounts to approved airworthy engine.
*NOTE*
Visually check all Barry engine mount Isolator molded
assemblies for indications of bond failure, separation,
sponginess, swelling, cuts, tears, gouges, or abrasions.
Visually check all Barry Isolator metal parts for nicks,
scratches, cracks, breaks, deformation, dents, thread damage,
corrosion, fretting, galling, chipped plating and wear.
Barry Isolators will provide good service for approved engine
overhaul period (TBO), but will rarely last twice engine TBO.
Therefore, it is suggested that these isolators be removed at
scheduled engine overhaul and replaced with new, rebuilt, or
overhauled isolators.
Thrush Aircraft, Inc.
P.O. Box 3149
Albany, GA 31706-3149
Custom Kit No. CK-AG-38
Date: 8/11/06
Page 4 of 9
b. Using a suitable hoist and sling, carefully position engine in the engine mount
and align the bolt holes of the engine vibration isolators with those of the engine
mounts. Install attaching hardware.
c. Install forward engine mount basket assembly.
d. Install and service propeller according to instructions outlined in Harzell
Propeller Inc. Owner’s manual and logbook No. 139. Use Aeroshell 6 grease
only.
e. Install forward fire seals.
f. Install aft fire seals and cuffs.
g. Seal all mating joints with RTV sealant to assure proper sealing of cannular inlet
and filter area.
h. Install exhaust stacks.
26.
Install the following serviceable engine components from existing PT6A-15AG
engine to new larger engine using new “0”rings, gaskets, and seals as necessary:
(Note: If installing new or overhauled engine, new gaskets will come with engine. If
installing a serviceable previously used engine, obtain necessary consumables listed
under “Additional Parts”)
a. Overspeed governor.
b. Np tachometer/generator.
c. Ng tachometer/generator.
d. Engine driven fuel boost pump.
e. Engine breather fitting.
f. Starter/Generator Q.A.D. mount.
g. Starter/Generator.
*NOTE*
As of 1998 all new AG PT6A engines were delivered with a
wet-spline starter/generator gearshaft that requires no
maintenance. You can identify an engine’s wet spline (female)
gearshaft as follows: From the engine side (female) the splines
are recessed approximately ¾ inch. Looking into the center of
the gearshaft you can see right through to the AGB diaphragm
wall. There will be an “0” ring installed on the
starter/generator’s drive shaft (male spline). The two (2) types
of Starter/generators (dry spline / wet spline) are not
interchangeable. You must purchase a new or serviceable
starter/generator or send old starter/generator to appropriate
maintenance facility for possible rework.
If starter-generator has dry splines, lubricate drive splines
with Dow Corning™ Molycoat M-77. If starter-generator has
wet splines install new “0” ring and lubricate splines with
engine oil.
h. F.C.U. cambox input lever.
i. Oil temperature sending unit.
j. Oil pressure snubber fitting.
Thrush Aircraft, Inc.
P.O. Box 3149
Albany, GA 31706-3149
Custom Kit No. CK-AG-38
Date: 8/11/06
Page 5 of 9
k. Fuel pressure snubber fitting.
l. Δp system, if so equipped.
m. Oil tank quick drain fitting.
27.
Connect the following tube and hose assemblies at the locations noted: Assure that
all hoses and lines are free of anomalies and contamination.
**CAUTION **
If the old engine is being removed because of oil contamination
or of the possibility of oil contamination, scrap the following
items: (a) oil cooler and (b) all oil carrying lines and hoses.
If the old engine has oil contamination, the following items
must be sent to an appropriate maintenance facility for
disassembly and flushing to remove all contaminants or they
must be replaced: (a) propeller, (b) over-speed governor, (c)
any oil wettable components. Failure to comply with the above
will prove to be false economy, as the new engine will be
contaminated by old impurities.
a. Connect Δp system lines.
b. Connect seal drain vent lines at the following locations.
1. Engine driven fuel boost pump.
2. High-pressure fuel pump/fuel control unit.
3. Propeller shaft.
4. Starter/Generator.
c. Connect battery vent lines.
d. Connect smoker oil system lines.
e. Connect F.CU./Start Control purge/return system lines.
f. Connect torque system lines.
g. Connect Oil pressure system lines.
h. Connect Oil quick drain system lines.
i. Connect fwd. and aft. engine combustor drain lines.
j. Connect fuel system lines.
k. Connect compressor wash ring system lines.
l. Connect E.P.A. residue fuel reservoir system lines.
28.
Connect engine-wiring harness to firewall cannon plug and engine mount. Connect
the following cannon plugs and wire terminals by following flags installed in step 19.
Properly safety wire all cannon plugs upon reinstallation.
a. Overspeed governor prop test solenoid.
b. Prop beta micro switch.
c. RGB chip detector, if equipped.
d. Np tachometer generator.
e. Ng tachometer generator.
f. Oil temperature sending unit.
g. Starter/Generator terminal block.
h. Fuel flow transducer, if equipped.
Thrush Aircraft, Inc.
P.O. Box 3149
Albany, GA 31706-3149
Custom Kit No. CK-AG-38
Date: 8/11/06
Page 6 of 9
i.
j.
k.
l.
29.
30.
31.
32.
33.
34.
35.
36.
37.
38.
39.
40.
41.
42.
Engine ground cable to rear of engine driven boost pump.
Ignition exciter box.
P3 heater.
ITT harness to engines T5 terminal block. Clean all terminals and terminal
hardware with 400 grit Scotch-brite® and contact cleaner immediately before
reassembly.
Connect all engine control rod-ends to the appropriate engine control. Rig engine
controls by using procedures outlined in chapter 4 of the appropriate Thrush
Airplane Maintenance Manual. Refer to the appropriate Pratt & Whitney
Maintenance Manual for depreservation procedures of the engine oil and fuel
systems.
Replace the gauges in the cockpit instrument panels with the following:
a. Oil pressure gauge P/N 21483-018
b. Torque meter P/N 27-3007-3
c. ITT gauge P/N 152C45
Install the following kit placards (P/N 21436-071) on the instrument panels and
throttle quadrant as noted:
“Maximum torque is 58.7 psi at 2200 rpm or 64.5 psi at 2000 rpm
with straight line variation between these points.”
Service engine oil system I/A/W appropriate Pratt & Whitney Maintenance Manual.
Install fully recharged batteries. Using brass safety wire, safety battery connectors.
Assure the engine air inlet plenum is free of all foreign objects and install cannular
inlet skin panels.
Place airframe fuel shutoff valve to ON position. Purge engine fuel system of
preservative compound and air as per appropriate Pratt & Whitney Maintenance
Manual.
Assure engine installation is free of F.O.D. and all hoses, wires, and non-moving
components are secured and ready for run-up operational check.
Check that the engine start and run-up area is clear of F.O.D.
Start engine using start procedures per S2R-T34 Airplane Flight Manual or
Airplane Maintenance Manual. Have safety crew look for any anomalies. Shut
down engine immediately and correct any squawks before continuing run-up.
Perform the engine ground test and checks outlined in chapter 4 of Thrush Aircraft,
Inc. S2R-T34 Airplane Maintenance Manual. Adjust engine and rigging to meet all
specifications.
Install propeller spinner after beta nut adjustment and propeller balancing.
Install cowling.
Install additional data plate identifying the aircraft as being converted to an S2RT34. The data plate shall read as follows:
Modified to S2R-T34
Date: ______________
*NOTE*
The original data plate remains, and the aircraft serial number
does not change.
Thrush Aircraft, Inc.
P.O. Box 3149
Albany, GA 31706-3149
Custom Kit No. CK-AG-38
Date: 8/11/06
Page 7 of 9
The date on the data plate shall be the date on which the aircraft is returned to
service. The data plate shall be made of stainless steel or other equivalent fireproof
material with permanent markings. It shall be attached using six each, CR3212-4-2
Cherrymax rivets adjacent to the existing aircraft data plate.
43.
44.
45.
Issue S2R-T34 Airplane Flight Manual for this S/N aircraft.
Conduct a maintenance test flight of the aircraft and fix any discrepancies found.
Installation is now complete and ready for the applicable 337 (Or foreign aviation
agency approval) and log entry.
RECORD COMPLIANCE: Make appropriate entry in airplane maintenance records as
follows: Field conversion of S2R-T15, serial number
_____________ to S2R-T34 accomplished according to Thrush
Aircraft, Inc. CK-AG-38 by _____(signature)___ _ (date)_ at
airplane total time hours.
Provide a copy of the completed entry to Thrush Aircraft, Inc. so the manufacturer will
have a record of the change of status of the aircraft.
WEIGHT AND BALANCE:
Negligible Change
PUBLICATIONS AFFECTED: Replace the original AFM with the new S2R-T34 AFM
supplied with the kit. Write the aircraft new Model number
and serial number on the new Airplane Flight Manual.
Replace the original AMM with the new S2R-T34 Airplane
Maintenance Manual.
46.
After inspection of Aircraft and Records, FAA DAR Inspector will replace the
existing Airworthiness Certificate with an Airworthiness Certificate identifying the
aircraft as being a model S2R-T34. Aircraft shall be re-registered with the FAA
Aircraft Registry as a Model S2R-T34.
KIT PARTS LIST (Parts are available through your Thrush authorized service center).
QTY P/N
DESCRIPTION
1 ea.
Drawing, P&W instl & top dwg- T34 (for T15-001
thruT15-020 aircraft owners)
19000
or
1 ea.
19870
1 ea.
1 ea.
1 ea.
1 ea.
21483-018
27-3007-3
Drawing, P&W instl & top dwg- T34 (forT15-021
thruT15-044 aircraft owners)
S2R-T34 Aircraft Flight Manual
S2R-T34 Aircraft Maintenance Manual
Oil Pressure Gauge
Torque Meter
Thrush Aircraft, Inc.
P.O. Box 3149
Albany, GA 31706-3149
1 ea.
1 ea.
152C45
21436-071
Custom Kit No. CK-AG-38
Date: 8/11/06
Page 8 of 9
ITT Gauge
Placard
If serviceable (not new) engine is being installed, you will also need:
1 ea.
1 ea.
3 ea.
3010818
ST3277-01
ST3276-01
Gasket, over-speed governor
Gasket, starter/generator
Gasket, Np, Ng, & engine driven boost pump
Thrush Aircraft, Inc.
P.O. Box 3149
Albany, GA 31706-3149
Custom Kit No. CK-AG-38
Date: 8/11/06
Page 9 of 9
TORQUE CHART
BOLTS
FINE
THREAD
SERIES
ONLY
STEEL - TENSION
AN 3 thru AN 20
AN 42 thru AN 49
BOLTS
STEEL - TENSION
STEEL - SHEAR
STEEL
MS 20004 thru MS 20024
NAS 333 thru NAS 340
ANY
NAS 144 thru NAS 158
NAS 464
AN 73 thru AN 81
NAS 624 thru NAS 644
NAS 583 thru NAS 590
AN 173 thru AN 186
NAS 1202 thru NAS 1210
NAS 1103 thru
AN 509 NK9
NAS 1303 thru NAS 1320
NAS 1120
AN 525 NK525
NAS 6603 thru NAS 6620
NAS 6203 thru NAS 6220
MS 20033 thru MS 20046
NAS 172
MS 20073
NAS 174
MS 24604
NAS 517
MS 27039
NUTS
NUTS
STEEL - TENSION
STEEL - SHEAR
STEEL - TENSION
STEEL - SHEAR
AN 310
AN 320
AN310
AN320
AN 315
AN 364
AN315
AN364
AN 363
MS 17825
AN363
MS 17825
AN 365
MS 20364
AN365
MS 20364
MS 17829F
MS 21083N
MS18729F
MS 21083N
MS 20365
MS 21245
MS20365
MS 21245
MS 20500
NAS 679
MS20500
NAS 679
MS 21042
NAS 1022N or A
MS21042
NAS 1022N or A
MS 21044N
NAS 1291
MS21044N
NAS 1291
MS 21045
MS21045
NAS 1021
NAS 1021
Torque Limits, in# Torque Limits, in# NUT/BOLT
Min.
Max.
Min.
Max.
SIZE
12
20
50
100
160
450
480
800
1,100
2,300
2,500
3,700
5,000
9,000
15
25
70
140
190
500
690
1,000
1,300
2,500
3,000
4,500
7,000
11,000
7
12
30
60
95
270
290
480
660
1,300
1,500
2,200
3,000
5,400
9
15
40
85
110
300
410
600
780
4,500
4,800
3,300
4,200
6,600
8-36
10-32
1/4-28
5/16-24
3/8/24
7/16-20
1/2-20
9/16-18
5/8-18
3/4-16
7/8-14
1-14
1 1/8-12
1 1/4-12
MS17826
Torque Limits, in#
Min.
Max.
Torque Limits, in#
Min.
Max.
+/- 5%
-25
80
120
200
520
770
1,100
1,250
2,650
3,550
4,500
6,000
11,000
-15
50
70
120
300
450
650
750
1,600
2,100
2,700
3,600
6,600
-30
100
145
250
630
950
1,300
1,550
3,200
4,350
5,500
7,300
13,400
-20
60
90
150
400
550
800
950
1,900
2,600
3,300
4,400
8,000
-16
35
70
100
180
240
320
480
880
1,500
2,400
4,000
5,600
CAUTION: Torques given are for dry threads. Clean bolts/nuts suspected of oil contamination with acetone.
NOTE: Tension nuts may be used on shear bolts, but shear nuts may not be used on tension bolts.
Was this manual useful for you? yes no
Thank you for your participation!

* Your assessment is very important for improving the work of artificial intelligence, which forms the content of this project

Download PDF

advertising