PDF Shop Manual Mooney M20M Bravo Aircraft - 2 MB
This is the official shop manual for the Mooney M20M Bravo aircraft.
It provides certified mechanics with the detailed procedures required for inspection, maintenance, and repair.
Adherence to this manual is critical for ensuring the airworthiness and safety of the aircraft.
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OLDWILLWAYNE
O O
SEI~VICE AND MAINTEN ANCE
MANUAL
~I OONEY AIRCR AFT CORPOR ATION
LOUIS SCHREINER FIELD, KERRVILLE, TX 78028
ORIGINAL ISSUE APRIL 1999 MANUAL NUMBER 51
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OLDWILLWAYNE
MOONEY AIRCRAFT CORPORATION M20M SERVICE AND MAINTENANCE MANUAL
CHAPTER 5
TIME LIMITS/MAINTENANCE CHECKS
TABLE OF CONTENTS
CHAPTER
SECTION
SUBJECT SUBJECT PAGE
5-00-00 General 5
5-00-01. Landing Gear System 5
5-00-02. FlightControl Systems 5
5-00-03. Wing Flap Systems 5
5-00-04. Electric Power System 5
5-00-05. Instruments 5
5-00-06. Cabin Heating g Ve~ilating Systems 5
5-00-07. Fuel System 5
5-10-00. Time Limit Components 6
5-10-01 Overhaul and Replacement Schedule 6
5-20-00. Schedule Maintenance Checks 7
5-20-01 Check Points,TorqueValues 7
5-20-02 Aircraft File Inspection. 11
5-20-03 Engine Functional Check 11
5-20-04 First 25 Hour Inspection 11
5-20-05 50 Hour Inspection 11
5-20-06 100 Hour Inspection 12
5-20-07 Access Cover identification,
Lubrication and Service Guide 17
9-CONTENTS
3/48LANK
4-99
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OLDWILLWAYNE
SERVICE AND MAINTENANCE MANUAL M20M MOONEY AIRCRAFT CORPORATION
R. Inspect exhaust system for cracks, looseness and J. Inspect nose wheel steering mechanism for
for evidence of leakage. Replace or repair damaged adjustment, alignment, corrosion, and lubrication.
components. Reference (G) 50 hour inspection. K. Inspect main gear for cleanliness and damage.
S. Inspect exhaust stacks for burned areas, cracks, L. Inspect landing gear retraction linkage, bdlcranks,
distortion and looseness.
pivots, and bearings for wear, damage, distortion,
T. Inspect exhaust couplings, seals, clamps and misalignment, corrosion, cleanliness, and lubrication.
slip-joints for cracks, deformation, leaks and security. M. Inspect landing gear actuator for security of
U. Inspect studs, nuts, bolts, etc. for damage and mounting, deanliness,and indication of overheating,
proper torque. damage, and operation. Inspect motor brushes for wear.
V. Inspect re-install cowling. Check cowl flaps for N. Perform landing gear operational Inspection per
proper operation, condition and proper position indication. Section 32-30-01.
2. PROPELLER INSPECTION. 4. FUEL SYSTEM INSPECTION.
A. Remove spinner (if not already removed). A. Inspect fuel tank exterior for evidence of fuel
B. Inspect security of propeller installation. seepage or stain.
8. Drain tank and inspect tank interior when
C. Inspect hub bolts for proper torque (61-00-20)
seepage is evident.
security and damage.
D. Inspect hub components for damage or leaks and
C. Inspect fuel tank drains for leakage, sediment,
or water contamination.
blades for cracks and nicks. Repair prior to next flight.
D. Inspect fuel-tank vents for obstruction.
E. Inspect Anti-ice boots for security and operation.
E. Inspect fuel selector valve for proper tank
F. Inspect spinner and bulkhead for cracks and
smooth operation, or any leakage when in OFF position.
G. Inspect spinner bulkhead for snug fit be~veen
F. Inspect gascolator for leakage; check sump for
propeller cylinder spinner support. Use shims as sediment, water or other contamination.
necessary to obtain correct snug frt.
G. Inspect electric boost pump for leaks, security of
3. LANDING GEAR and RETRACTION SYSTEM
INSPECTION. mounting, adequate fuel pressure, switch operation,
and condition of wiring and electrical connections.
A. Inspect tires for proper inflation, cuts, blisters,
(1) Inspect electric boost pump for proper
slippage, and excessive wear. Replace with new,
operation by "T ing" into the line with a calibrated fuel
approved, tire if necessary. pressure gauge. Boost operation should result in a 45-
CAUTION 55 P.S.I. reading (mixture full RICH, throttle-IDLE).
Always run at least 5 Landing Gear Retraction (2) Adjust relief setting on pump if needed.
Cycle checks after any tire has been removed H. Inspect fuel quantity gauges and transmitters for
and/or replaced before flying the aircraft. security of mounting and condition of wiring and
for cracks, distortion, electrical connections.
B. Inspect wheels
misalignment, corrosion or bolt failure.
Inspect I. Inspect fuel tank filler port for cleanliness, cap
condition of felt seals and bearings; repack bearings at security, and condition of servicing placards. Inspect
250 hour intervals, fuel filler cap O’rings for condition and replace if
C. Inspect brake pads discs for warpage or wear needed (Reference SECTION 23-00-01).
(Ref. Section 32-40-04). 5. EXTERIOR INSPECTION.
D. Inspect hydraulic reservoir for proper fluid level. A. Inspect fuselage exterior surfaces for corrosion,
E. Inspect hydraulic brake lines and hoses for damage, loose or popped rivets, dents,
oilcans(stretched skins), scratches, cracks, or
leakage, dents, cracks chafing, kinks, and security.
deteriorated paint.
F. ~lnspect parking brake system for proper
8. Inspect windshields and windows for cracks,
engagement and release.
crazing, scratches, condition of sealant, and security of
G. Check shock disc gap on main 6 nose landing installation.
gear. (See 32-81-00)
C. Inspect wings, flaps, and ailerons for corrosion,
H. Conduct Hard/Overweight Landing Inspection damage, loose or popped rivets, dents, scratches,
per SECTION 32-32-00. cracks, condition of attaching points, lubrication,
Jack aircraft as recommended in paragraph 7-10-00 for freedom of operation, free-play, travel, and balance
the following inspections:. weight attachment. Inspect speedbrake cartridges for
I. Inspect nose gear for cleanliness and damage.
damage or wear. Check for proper operation. Every 200
hours remove speedbrake cartridges per 27-96-01.
Check nose gear retraction tube bungees for sheared
or broken roll pins. D. Inspect empennage for corrosion, damage,
loose or popped rCvets, free-play, dents, scratches,
NOTE
cracks, condition and lubrication of hinge points,
Maximum allowable towing damage on leg attachment of balance weights, and freedom of
assembly is 1/32 inch dent. No repair allowed operation, manually and electrically.
on heat treated landing gear components
4-99 5-20-06
13
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OLDWILLWAYNE
MOONEY AIRCRAFT CORPORATION M20M SERVICE AND MAINTENANCE MANUAL
6-00-00 DIMENSIONS AND AREAS
6-00-01 AIRCRAFT SPECIFICATIONS
ENGINE STANDARD METRIC/OPT/MISC.
Engine Manufacturer TEXTRON-Lycoming
Engine Model TIO-540-AF1A or -AF1B
No. Cylinders 6
Rated Horsepower 270 HP
RPM. 2575
Min. Fuel Octane 100 or 100 LL.
Fuel Capacity
Total 95 U.S. Gal. 359.6 Liters
Useable 89 U.S. Gal. 336.9 Liters
Refer to TCDS for engine configuration
Oil Specification MIL-L-22851
Oil Grade-Above 300 F(-l C)Ambient air SL SAE 40 or 15W-50
Below 300 F(-l" C)Ambient air SL SAE 30 or 20W-30
Oil Capacity 10 qts. 9.5 Liters
Minimum for Flight Oil’Lev~l 6 qts. 5.7 Liters
*X
Break in oil for Lycoming turbocharged engines is required to be ashless dispersant oil per Lycoming
SI 1014(M (or current revision) corresponding to MIL-L-22851 or SAE J1899.
Max Operational Induction Air Temperature 2800 F 1380 C.
Max Continous Operation TIT 17500 F
Normal Operating TIT 1300 17500 F
Oil Pressure
Idle, Minimum- 25 PSI
Normal Operation 55-95 PSI
Max. Allowable (cold oil) 115 PSI
Oil Temperature Max. Allowable 1180_ C 2440 F
Recommended Takeoff-Min 100U.F 380 C
Recommended Flight Operation iCrui’se) 38-1180.C 100 2440 F
Cylinder Head Temperature (CHT)
Max. Allowable. 5000 F 2600 C
Recommended Cruise 250 to 5Q00 F. 121 to 2600 C
Turbocharger
Turbocharger Mfg. Airesearch
Type Exhaust Driven
Turbocharger Model TA0413
PROPELLER
PropellerMfg. McCauley
Type Constant Speed
Model B3D32C41 7/GS2NRD-7
Pitch Angle 30 in.
LOW 15.1 DEG (-e/-)0.2 DEG.
HIGH 43 DEG (+/-)0.5 DEG.
Diameter 75.0 Inches. 190.5 cm
Governor McCauley
4-99 6-00-00
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OLDWILLWAYNE
C H A PT E R
LEVELING AND
VVEIGHING
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OLDWILLWAYNE
MOONEY AIRCRAFT CORPORATION M20M SERVICE AND MAINTENANCE MANUAL
10-00-00 -GENERAL CAUTION
If weight is not removed from tires, rotate
The parking brakes are set by applying the brakes and
wheels to a new position at least once each 30
pulling outon the parking brake knob. Release the
brakes by pushing in on the parking brake control days to prevent flat-spotting the tires.
knob. 5. See appropriate Lycoming Service
NOTE Bulletin/information for engine preservation. Attach
waming placards if preservation procedures make
There is no need to depress the brake pedals to
relieve the pressure in the lines during release e"gine inoperable.
of parking brake control.
10-10-03 RETURNING TO SERVICE
There are three tiedown points on the aircraft, one on If the aircraft has been stored for an extended period of
each wing outboard of main gear (tiedown rings are to time, it is advisable to perform a 50-hour periodic
be threaded into built in receptacles) and the tail inspection after completion of the following preliminary
skid/tiedown fitting on the aft end of the tailcone. steps:
10-10-00 PARKING 1. Remove blocks from wheels. Check tire inflation.
When parking the aircraft, place wheel chocks fore and 2´• Check and install battery.
aft of the main wheels. The parking brakes may be 3. Remove tape and covers from openings.
used for short-duration parking.
4. Remove waming placards (if any).
CAUTION
5. Replace engine oil filter.
Do not set parking brakes when they are
overheated or when cold weather could freeze 6. Clean engine oil suction and pressure screens.
moisture and slush accumulation in the brake 7. Clean and check oil pressure relief valve.
mechanism. Do not set parking brakes when
3. Clean and check oil temperature bypass valve.
aircraft is tied down. For maximum protection,
hangar the aircraft during severe weather and 9. Fill engine sump with proper grade of lubricating oil.
high winds. 10. Clean and reinstall engine air-inlet filter.
lo-lo-ol STORAGE (FLYABLE) 11. Check ignition harness.
Outdoor storage requires adequate mooring and 12. Clean and regap spark plugs.
tiedown facilities. The iollowing 13. Check and clean fuel injector noules and
measures are recommended for keeping Drain oil from fuel injector.
screens.
serviceable and ready-to-fly.
14. Check fuel tank vents for obstruction, and drain
1. Refer to paragraph 10-20-00 for mooring sumps to remove moisture and sediment.
instructions.
15. Complete 50-hour and preffight inspections.
2. Magneto switches..........OfF
16. See appropriate Lycomong Service
3. Throttle....................CLOSED Bulletins/lnformation for servicing of the engine.
4. Mixture...........lDLE CUTOFF
10-20-00 -A1100RING
5. Rotate propeller 6 revolutions every seven days;
STOP propeller 45 to 90 degrees from original position. When mooring the aircraft out of doors:
6. Keep fuel tanks filled at least one-half full to minimize 1´• Head aircraft into the wind.
moisture condensation. Keep batteries fully charged. 2. Place chocks fore and aft of each main wheel.
7. Install protective covers over pitot head, engine 3. Drive stakes in ground approximately three feet
cowl openings, static ports, etc. outboard of each main gear and to either side of
3. Maintain a good wax finish on all exterior surfaces tailskid.
after 90 days. 4. Install tiedown rings in wing receptacles outboard
of each main gear. Tie a 600-pound tensile strength
10-10-02 STORAGE (PROLONGED)
rope to each wing tiedown ring and anchor to ground
If the aircraft is to be stored for an extended period of stake. Allow a little slack in each tiedown rope.
time, the following steps are recommended for protection: 5. Tie the center of a rope to tail skid tiedown ring
1. Refer to paragraph 10-20-00 for mooring and anchor rope ends to ground stakes at either side
instructions. of tail.
2. Tape or cover all openings. 6. For additional security, attach a rope to the nose
3. Remove battery, charge fully, and store in a cool gear and anchor to a ground stake.
place. 7. Lock controls by looping right front seat safety belt
4. Raise aircraft to remove weight from the tires, and
through the control wheel and drawing belt snug.
block up the wheels.
4-99 10-00-00
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OLDWILLWAYNE
MOONEY AIRCRAFT CORPORATION M20M SERVICE AND MAINTENANCE MANUAL
NOTE Use only hydraulic fluid (red), per specification
If filter shows an accumulation of carbon, soot, MIL-H-5606. Do not fill reservoir above two inches
or oil, continue with cleaning steps 3 through 5. below filler port.
3. Soak filter in nonsudsing detergent for 15 minutes; HYDRAULIC BRAKES (Bleeding)
12-20-05
then agitate filter back and forth for two to five minutes
to free filter element of deposits. CAUTION
4. Rinse filter element with FIuid in the wheel cylinders may be under high
a stream of clean water
until rinse water is clean, pressure due to expansion. Therefore, be sure
parking brakes are released prior to beginning
5. Dry filter thoroughly. Do not use light or air above
hydraulic system servicing.
180 deg. F. for filter drying.
6. Check alternate air door for proper operation and
For best results, use a diaphram type hydraulic
sealing, pressure service unit (pressure pot) to back bleed the
system through the wheel cylinder bleeder valves.
7. Reinstall filter in aircraft making sure of proper
SINGLE BRAKE SYSTEM (PILOTS SIDE ONLY)
sealing and security.
1. Remove hydraulic Ruid reservoir filler plug, and
12-20-02 BATTERIES install a suitable fitting for attaching a flexible drain line.
Service batteries with distilled water to maintain 2. Immerse open end of drain line into a hydraulic
electrolyte above plates. After adding water in freezing Ruid container or catch container.
weather, charge battery long enough to mix electrolyte
and water. Keep battery electrolyte above a specific 3´• Attach pressurized hydraulic Ruid service unit to
gravity of 1.225 to avoid freezing. wheel cylinder bleeder valve and open valve. Hydraulic
To service the battery(ies): service unit should be free of air prior to servicing
aircraft system.
1. Remove battery caps. Check electrolyte and
service battery as required. 4. Feed fluid from service unit into brake system. Check
for air bubbles at end of drain line immersed in fluid.
CAUTION
5. When Ruid is Rowing, slowly depress pilot’s brake
Battery gases may be explosive.
pedal by hand and slowly release. Repeat three (3) to
2. Inspect battery mounting area for corrosion and four (4) times.
spilled electrolyte. To clean cables, terminals,
6. Allow fluid to flow until clear of air bubbles.
mounting area and battery case, use a solution of
bicarbonate of soda and clean water to neutralize If shume valve is installed in single brake system
corrosion and spilled electrolyte.
7. Loosen pluglcap on shuttle valve (port is plugged
CAUTION if no cc-pilot’s brake system is installed). Allow air
When cleaning, do not allow bicarbonate of bubbles to purge from back side of shuttle valve;
soda to enter battery cells permanent damage indicated by clear Ruid Rowing from shuttle valve into
will result if soda mixes with electrolyte, catch container.
3. Rinse battery with clean water, and 8´• Close wheel cylinder bleeder valve and remove
wipe clean
with a dry cloth. service line.
4. To retard corrosion, coat terminals with petroleum NOTE
jelly after cleaning and tightening them. Brake pedal may need to be pulled back in
order for fluid to bleed back into reservoir.
5. Inspect battery vent lines for obstruction, line
kinks, etc. 9. To bleed opposite brake, (single brake system
12-20-03 TIRES AND WHEELS only) repeat steps 3 through 8.
IF DUAL BRAKES AND SHUTTLE VALVE ARE
Keep the tires at recommended air pressure. (Refer to
CHAPTER 6-00-01. INSTALLED -(See steps 1 8 2, Single Brake System
1. Inspect tires for wear, cuts, and bruises. 1. While pressurized hydraulic fluid service unit is still
attached to either wheel cylinder bleeder valve.
2. Inspect valve stems for evidence of tire slippage or
2. Loosen cc-pilot’s brake line at shuttle valve.
pulling.
Provide another catch container.
3. Inspect wheels for damage.
3. Resbict outflow fnrm reservoir dtai~ hibe to catch
4. Inspect wheel bearings for condition and container.
lubrication.
4. Allow fitting to remain loose until fluid is clear of air
12-20-04 BRAKE RESERVOIR bubbles as it drains from shuttle valve fitting into catch
Co"tainer.
Frequently inspect brake reservoir for proper Ruid level.
See~CHAPTER 12-20-05 for location. See CHAPTER 5. When clear, tighten cc-pilot line fitting and remove
5-20-07 for proper fluid. restriction from reservoir out flow tube.
CAUTION 6. Stroke cc-pilot’s brake pedal several times and
Do not fill reservoir while parking brake is set. allow any purged air to exit through reservoir.
4-99 12-20-02
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OLDWILLWAYNE
C H A PT E R
Al R
CONDITIONING
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OLDWILLWAYNE
MOONEY AIRCRAFT CORPORATION M20M SERVICE AND MAINTENANCE MANUAL
24-34-00 POWER PLANT CIRCUITS temperature causes an increase or decrease in bulb
1. Starter-ignition Circuit. The starter-ignition switch resistance, varying the magnetic field in the indicator
COilS.
has five positions: OFF, R (right), L (left), BOTH, and
START. In the OFF position both magnetos are 3. The oil pressure instrument circuit contains an
grounded. At the R position the left magneto grounds. electrical instrument and a transducer which varies
At the L position the right magneto grounds. At the resistance with pressure.
BOTH position both magnetos are HOT and the
4. Fuel Flow read on the indicator uses an electrical
ignition system is on. Turning the ignition switch to start instrument which counts electrical pulses produced by
and pushing in, closes the starter solenoid, engages
.turbine flow transducer.
the starter and allows the impulse coupling to
automatically retard the magneto until the engine is 24-35-00 LIGHTING CIRCUITS
also at its retard firing position. The spring action of the
1. Navigation Lights. A circuit breaker switch on the
impulse coupling is then released to spin the rotating
magnet and produce the spark to fire the engine. After upper left flight panel controls the navigation lights.
the engine starts, the impulse coupling Ryweights do 2. LandingTTaxi Lights. A pair of circuit breaker split
not engage due to centrifugal action. The coupling then switches on the upper left Right panel controls the landing
acts as a straight drive and the magneto fires at the and taxi lights located in the left and right wings.
normal firing position of the engine. The starter-ignition
3. Cabin Lights. A three-position (Bright, Off, Dim)
switch is spring loaded to return from START to the
rocker switch overhead, between the pilot and cc-pilot
BOTH position when released. in the overhead panel controls the cabin lights.
CAUTION Aircraft S/N 27-0053 thru 27-0107 may have a door
Do not operate the starter in excess of 15 switch and timer mechanism that illuminate forward set
seconds or re-engage the starter without of interior lights while cabin door is open. After door is
allowing it time to cool. closed, if rocker switch is left ON, forward interior lights
will remain ON for approximately 2 minutes.
WARNING
The rocker switch is~connected through the MASTER
Do not turn the propeller when the magnetos
switch on these aircraft and forward interior lights will
are not grounded. Ground the magneto points
when MASTER switch is tumed OFF if door is
before removing rwlhh wires or eloctrloal
connectors. All spark plug leads can be
removed as an alternate safety measure. 4. Strobe Lights. A circuit breaker switch on upper
left flight panel controls the white anti-collision strobe
A. LOW BATTERY STARTING PROCEDURE. A
lights.
battery that has been discharged to the point where it
will not turn the engine over but has sufficient power 5´• Instrument and Radio Lights. Switches are located