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SERVICE M00NEY LOUIS AND MAINTENANCE-MANUAL AIRCRAFT CORPORATION SCHREINER ,ssuED - DECEMBEr, 1998 FIELD, KERI:tVILLE, TEXAS. 78028 MANUAL NUMBER - 123 MOONEY AIRCRAFT CORPORATION M20J SERVICE AND MAINTENANCE MANUAL LDG rlF REI/ISIIINS ALwaysdestroy superseded pQQeswhenyou Insert revtsed paQes, BATE OF REVISION SECTIONS AFFECTEB BATE OF REVISION SECTIONS AFFECTED NDTEI A [is_ o? e??ec±ive pages will Qppe_r Q_ ±he 12-98 beginning o? each ch_p±er, LOG OF REVISIONS PAGE1 SERVICE AND MAINTENANCE MANUAL LOG M20J MOONEY AIRCRAFT CORPORATION OF REVISIONS Alwo, ys DATE OF REVISION des-_Po SECTIONS AFFECTED t supePseded pcLQes when you DATE OF REVISION Inser'_c r-evlsed pages. SECTIONS AFFECTED NOTE, A list oF eFFec±lve p_ges will _ppe&r a± ±he be£1nnln£ o£ e&ch chapter. There will be black, vertical lines on the edge of the pages for data that has been changed or added for the current page revision. The Electrical Equipment List in Section 91 has been updatedto reflectthe current configuration status and there will be added electdcal schematics to cover current model year M20J aircraft_ Each page will be noted with applicable revision date at the bottom-center of the page. LOG OF REVISIONS PAGE 2 12-98 - MOONEY AIRCRAFT CORPORATION M20J SERVICE AND MAINTENANCE MANUAL INTRODUCTION This manual provides servicing and maintenance information for the l_.loeney Model M20J, Serial Numbers 24-0001 and ON. Maintenance actions that refer to a limited numb{_rof aircralt will be designated by sedal number of applicable airplanes. The Part Numbers of replacement or repair parts should be identified using the Illustrated Parts Catalog (IPC) applicable to Model & Serial Number of aircraft being worked on. Part Numbers can be ordered through any Moeney Marketing Center (MMC). See Section 91 for identification of electrical components. The format and content.,;ofthis manual are prepared in accordance with GENERAL AVIATION The variousgroups contain major systems information such as flight controls, landing gear, etc. The systems are arranged numerically per GAMA number assignment, It is suggested, for recommended example, that "Fuel" be identified with the System/Chapter number "28". The sequence of numbers, 28-00-00, refers to General information ofthe Fuel Systems. SUB-SYSTEM/SECTION The major systems of an aircraft are broken down into sub-systems. These sub-systems are identified by the second element of the sequence of numbers, SECTION, ie., 28-20-00. The element -20- indicates the distribution portion of the fuel system. UNIT/SUBJECT MANUFACTURER'S , ASSOCIATION (GAMA) Specification No. 2. Tfu. manual is supplemented with widng schematics for the various model year airplanes, as necessary. These are located in envelopes at the back of the manual text.';pages. The individual units within a sub-system may he identified by a third element of the sequence of numbers, SUBJECT, ie., 28-20-01. This number is assigned by the manufacturer and may or may not be used depending upon the complexity of the maintenance action recommended. APPLICATION OF NUMBERING SYSTEM Mooney Aircraft Corporation is in the process of revising all applicable technical publications to the GAMA format. When this effort is completed any publication concerning maintenance of aircraft will conform to this basic numbering system. Any person wishing information concerning the Fuel Distdbution System would refer to the pages identified as, 28-20-00, in any maintenance odented publication. These pages will be numbered sequentially within each system breakdown in the current Meoney series of aircraft. As Mooney aircraft models become more complex the page numbers may be sequentially numbered within sub-systems. NOTE Revisions of this manual are not automatically provided to manual holders. Holders of these and other Mooney Technical Publications should complete information on YELLOW CARDS located at the front of the Title Page and send to Mooney Aircraft Corporation, Louis SchrienerField, Kerrville, TX., 78028, Attn: Service Parts Department. Notification is sent to known manual holders when any new manual is preparP.d to replace the subscdption manual and advises that no more revisions will be sent out. The new issue manual will require a new subscription service. If additional Technical Publications are desired, contact the Service Parts Department at Mooney Aircraft Corporation at (830) 896-6000, ext 2092 (direct line (830)792-2092). The table of contents in the front of each Chapter will provide a list of sub-systems covered in the Chapter. For example: Correspondence concerning maintenance or part numbers on an airplane should contain the aircraftmodel number and sedal number. The sedal number appears on the identification placsrd located on the aft end, left hand side of the tailcone below the horizontalstabilizer, ASSIGNMENT OF SUBJECT MATERIAL 28-00 28-10 28-20 The content of this publication is organized at four levels: General Storage (Tanks, vents, repair, etc.) Distribution (Boost pumps, fuel lines, etc.) 28-40 ]ndicating (Sender Units, quantity gauges, etc.) If there is a reason to distinguish between LEFT HAND or RIGHT HAND fuel quantity sending units then the number would be expended to 28-40-01 (Left Hand) and 28-40-02 (Right Hand). This concept will apply to any expanded informationthroughout the publications. Group System/Chapter Subsystem/Section Unit,'Subject GROUP These are primary divisions of the manual that enable broad separation of content, ie., Airframe systems VS Powerplant systems. These groups are identified by tabs. 12-98 INTRODUCTION Page 1 SERVICE AND MAINTENANCE MANUAL M20J MOONEY AIRCRAFT CORPORATION SUPPLEMENTARY PUBLICATIONS The following list of M_nufacturem and/or publicationscan provide servicing and maintenance informationon components of the Mooney - 201, 201LM, 205 ATS USE, Allegro (Model M20J). No avionics equpment Manufactummor publicationsare sted due to the manyconfigurationsthat can be installedin the aircraft_These can be obtainedfrom the repairstationsfor e padicularavionicsmanufacturer. Publicationsavailablefrom Mooney Aircraft Corporationare listedin the Parts PAce List and are availablethrough any Mooney Marketing/,_,erviceCenter. As publicationson vado,Jscomponentsbecome available,they willbe added to the listbelow. ENGINE VENDOR ADDRESSES or PUBLICATIONS The followingmaintenance publicationscan be obtainedthroughTEXTRON LycomingDivision,Williamsport,PA., 17701. OverhaulManual for TE_I'RON LycomingAircraftEngines,Direct Drive Models,Manual No. 60294-7. UlustratedPads Catalog _ Manual No. PC-206 for TEXTRON LycomingIO-360, AIO-360, HIO-360, LIO-360 and TIO-360 series aircraftengines. Operators Manuel - N(=. 60297-12, for TEXTRON Lycaming 0-360, HO-360, 10-360, AI0-360, LIO-360 and TI0-360 aircraft:engines, ServiceBulletins- Specify model of engineforwhich maintenancedata is desired. PROPELLER McCauley Propellers - Obtain publicationsfrom McCauley Accessodes Division,Cessna Aircraft Company,3635 McCauleyDAve Vandalis, OH.,45377. ServiceManual- No. 78_630 for McCauley C200 sedes constantspeed propellers. Hartzell Popellers - Obtain publicationsfrom Hadzell Propeller, Inc. 350 WashingtonAvenue, Piqua,OH., 45356. Blade Specification- Manual No. 133-A. OverhaulInstructions- I_lanualNo. 113-B. MAGNETO BendixScintillaMagneto _ Obtain Service data for BendixSedes 2000 or 3000 magnetosfrom Bendix Corporation, ElectricalComponents[:ivision, Jacksonville,FL. 32245-7880. FUEL II_J]ECTOR Fuel 98204 Injector- Obtain sen_icedata for fuel injectorsfrom PrecisionAirmotive,3220-100th Street, S.W. #E, Everett, WA VACUUM PUMP Airborne Division, Parker Hannifin Corporation, 711 Taylor Street, PO Box 4032, Elyda, OH, 44036, USA, Tel. (216) 284-6300, Fax. (216) 322-6094 STAND-BY VACUUM PUMP SYSTEMS AERO-SAFE, 10160 Bufl"aloGrove Rd., Fort Worth, TX 76101, (800) 433-5689 ELECTR0-MECH, 2600 So. Custer, Wichita, KS 67217, (316) 942-3271 SPEED BRAKES PreciseFlight,Inc., 63120 Powell Butte Rd. Bend. OR, 97701, USA, Tel. (800) 547-2558. INTRODUCTION Page 2 12-98 MOONEY AIRCRAFT CORPORATION M20J SERVICE AND MAINTENANCE MANUAL SYSTEM/CHAPTER, SUB-SYSTEM/SECTION INDEX GUIDE SYSTEM/ CHAPTER 1-4 SUB-SYSTEM/ SECTION TITLE RESERVED BY GAMA - MAY BE USED AT LATER DATE 5 TIME LIMITS/MAINTENANCE CHECKS 00 GENERAL 10 20 TIME LIMITS SCHEDULED MAINTENANCE CHECKS 6 DIMENSIONS AND AREAS GENERAL 00 7 LIFTING 10 JACKING 8 LEVELING AND WEIGHING 00 LEVELING 9 TOWING AND TAXIING 00" GROUND HANDLING 10 TOWING 20 TAXIING 10 PARKINGAND MOORING GENERAL 00 10 PARKING 20 MOORING 11 PLACARDSAND MARKINGS GENERAL O0 10 MARKINGS 20 PLACARDS - EXTERIOR/INTERIOR 12 SERVICING 00 SERV]CING 10 REPLENISHING 20 SCHEDULED SERVICING 12-98 INTRODUCTION Page 3 SERVICE AND MAINTENANCE MANUAL SYSTEM/ CHAPTER M20J SUB-SYSTEM/ SECTION TITLE 20 STANDARD PRACTICES - AIRFRAME 00 GENERAL 21 ENVIRONMENTAL SYSTEMS 00 CABIN VENTILATION SYSTEM 40 HEATING 24 25 MOONEY AIRCRAFT"CORPORATION ELECTRICALPOWER 00 GENERAL 30 DC GENERATION 50 ELECTRICALLOAD DISTRIBUTION SEATS CURRENTLY NOT USED 00 GENERAL 10 FLIGHT COMPARTMENT 20 50 PASSENGER COMPARTMENT CARGO COMPARTMENT 27 FLIGHT CONTROLS 00 GENERAL 10 AILERON SYSTEM 20 RUDDER SYSTEM 30 ELEVATOR SYSTEM 40 50 STABILIZERTRIM SYSTEM WING FLAP SYSTEM 90 MISCELLANEOUS 28 FUEL 00 GENERAL 10 STORAGE 20 30 DISTRIBUTION DUMP 40 INDICATING 90 MISCELLANEOUS 30 INTRODUCTION Page 4 ICE AND RAIN PROTECTION 00 GENERAL 30 PITOT AND STATIC 60 PROPELLERS 12-98 MOONEY AIRCRAFT CORPORATION SYSTEM/ CHAPTER M2OJ SERVICE AND MAINTENANCE MANUAL SUB-SYSTEM/ SECTION TITLE 32 LANDING GEAR 00 GENERAL 10 MAIN LANDING GEAR AND DOORS 20 NOSE LANDING GEAR AND DOORS 30 40 EXTENSION AND RETRACTION WHEELS AND BRAKES 50 STEERING 60 POSITION AND WARNING 80 MISCELLANEOUS 33 LIGHTS GENERAL 00 20 INTERIOR LIGHTS MAINTENANCE PRACTICES 40 EXTERIOR LIGHTS MAINTENANCE PRACTICES 34 NAVIGATION 00 GENERAL 10 PITOT & STATIC AIR PRESSURE SYSTEM 20 DIRECTIONAL GYRO COMPASS 35 OXYGEN 00 GENERAL 37 VACUUM 00 GENERAL 10 DISTRIBUTION 20 INDICATING 39 ELECTRICAL PANELS AND COMPONENTS 00 GENERAL 10 INSTRUMENT AND CONTROL PANELS ELECTRICAL AND ELECTRONICS EQUIPMENT RACKS 20 12-98 INTRODUCTION Page 5 SERVICE AND MAINTENANCE MANUAL SYSTEM/ CHAPTER M20J SUB-SYSTEM/ SECTION TITLE 51 STRUCTURES 00 GENERAL 10 STRUCTURAL REPAIR GENERAL 52 DOORS 00 10 GENERAL CABIN DOOR- MAINTENANCE PRACTICE 30 BAGGAGE COMPARTMENT DOOR MAINTENANCE PRACTICE 53 FUSELAGE 00 10 GENERAL MAIN FRAME 20 AUXILIARY STRUCTURE 30 PLATES/SKIN 40 ATTACH FITTINGS 50 FILLETS/FAIRINGS 55 STABILIZERS 00 GENERAL 10 HORIZONTAL STABILIZER 20 ELEVATOR 30 VERTICAL STABILIZER 40 RUDDER 56 WINDOWS 00 20 GENERAL WINDSHIELD & CABIN WINDOWS 50 PLEXIGLASS DRILLING 57 INTRODUCTION Page 6 MOONEY AIRCRAFT CORPORATION WINGS 00 GENERAL 30 PLATES/SKINS 40 ATTACH FITTINGS 50 FLIGHT SURFACES 12-98 MOONEY AIRCRAFT CORPORATION SYSTEM/ CHAPTER M2OJ SERVICE AND MAINTENANCE MANUAL SUB-SYSTEM/ SECTION TITLE 60 STANDARD PRACTICES PROPELLERS [NO TAB DIVIDER] 61 PROPELLERS 00 GENERAL I0 PROPELLER ASSEMBLY 20 CONTROLLING 71 POWERPLANT 00 GENERAL 10 COWLING 72 ENGINE - RECIPROCATING O0 GENERAL 73 ENGINE FUEL SYSTEM GENERAL 00 10 DISTRIBUTION 20 CONTROLLING 30 INDICATING 74 IGNITION 00 GENERAL 10 POWER CONTROL 20 EMERGENCY SHUTDOWN 76 CURRENTLY NOT USED ENGINE CONTROLS 00 GENERAL 10 POWER CONTROL 20 EMERGENCY SHUTDOWN 77 ENGINE INDICATING GENERAL 00 10 POWER 20 TEMPERATURE 12-98 INTRODUCTION Page 7 SERVICE AND MAINTENANCE MANUAL SYSTEM/ CHAPTER M20J SUB-SYSTEM/ SECTION TITLE, 78 EXHAUST GENERAL OO 10 30 INSTALLATION EXHAUST SYSTEM 40 REPLACEMENT COMPONENTS 79 OIL 0O GENERAL 10 STORAGE 20 DISTRIBUTION 30 INDICATING 80 STARTING 00 GENERAL 10 CRANKING 81 CURRENTLY NOT USED TURBINES OO 10 GENERAL POWER RECOVERY 20 TURBOCHARGER 91 SCHEMATICS GENERAL 00 95 MOONEY AIRCRAFT CORPORATION 20 ELECTRICAL SYSTEM HARDWARE CHARTS 30 SCHEMATICS SPECIAL EQUIPMENT CURRENTLY NOT USED INTRODUCTION Page 8 12-98 MOONEY AIRCRAFT CORPORATION M20J SERVICE AND MAINTENANCE MANUAL CHAPTER 5 TIME LIMITS/MAINTENANCE CHECKS SERVICEAND MAINTENANCEMANUAL M20J MOONEY AIRCRAFTCORPORATION CHAPTER5 TIME UMITS/MAINTENANCECHECKS UST OF EFFECTIVEPAGES CHAPTER SECTION SUBJECT ....... 5-Effectivity. 5-Contents .......... 5-00-00 5-1001 ............ 5-20-00 .......... 520-01 ......... 5-20-01 ............ 5-20-01 ............ 5-20-02 ............ 5-20-06 ..... 5-2006 .......... 5-20-06 ......... 5-20-06 ............ 5-20-06 ......... 5-20-06 ........ 5-20-07 ...... 5-20-07 ...... 5-20-07 .......... 5-20-07 ............ 5-20-07 ....... PAGE. ......... 1/2 BLANK ....... 9/4 BLANK ......... 5 ..... 6 ........... 7 ......... 8 ...... 9 ........... 10 ........ 11 .......... 12 ........ 13 ........... 14 15 ...... 16 ........... 17 ........... 18 ........ 19 ........ 20 ......... 21 ........ 22 12-98 DATE 12-98 12-98 12-98 12-98 12-98 12-98 12-98 12-98 12-98 12-98 12-98 12-98 12-98 12-98 12-98 12-98 12-98 12-98 12-98 12-98 5-EFFECTIVITY 1/2BLANK MOONEYAIRCRAFTCORPORATION M20J SERVICEAND MAINTENANCE MANUAL CHAPTER5 TIME UMITS/MAINTENANCECHECKS TABLE OF CONTENTS CHAPTER SECTION SUBJECT 5-00-00 ........ 5-00-01 ....... 5-00-02. 5-00-03 ........ 5-00-04 .......... 5-00-05 ........ 5-00-06 .......... 5-00-07 .......... 5-10-00 5-10-01 ......... 5-20.00 5-20-01 ........ ............. 5-20-02 .......... 5-2003 ......... 5-20-04. 5-20-05 .......... 5-20-06 .......... 5-20-07 .......... ............ ..... ...... SUBJECT ......... General......... Landing Gear System ...... FlightControlSystems Wing FlapSystems .......... ElectricPowerSystem ......... Instruments ....... Cabin Heating & VentilsUngSystems ..... Fuel System .......... Time LimitComponents .......... Overhauland ReplacementSchedule ..... Schedule MaintenanceChecks ........ InspectionCheek Points ......... Torque Values .......... Aircro_FileInspection ...... Engine FunctionalCheck ........ Fimt 25 Hours- Inspection ........ 50 Hour Inspection ......... 100 Hour Inspection(Annual) ....... Access Coverldentif_tion, Lubricationand ServiceGuide ...... 12-98 PAGE 5 5 5 5 5 5 5 5 5 6 7 7 8 11 11 11 11 12 18 5-CONTENTS 3/4BLANK SERVICE AND MAINTENANCE MANUAL M2OJ 54)0-00 - GENERAL AIRCRAFT DESCRIPTION. The M20J series of aircraft are four place high-performancesingle-engine low-wing monoplanes. The all-metal airframe has a tubular-steel cabin frame covered with nonstructursl aluminum skins, a semi-monocoque tailcone, and a full-cantileverlaminar-flowwing. Controlsurfaces have structuralspar constructionwith stressed skins riveted to the spars and dbs. Dual controlwheels accompany the conventional flight controls. The pilot's rudder pedals have toe brakes linked to individual hydraulic cylinders that supply pressure to the hydraulic disc brakes on each main gear wheel. Removable co-pilot rudder pedals are standard equipment. The tdcycle landinggear, havinga steerable nose wheel controlled by rudder pedal action, is fully retractable. The wide-span trailing-edge wing flaps are electrically operated. For stabilizer trim, the entire empennage pivotsverticallyabout its attaching points, 5-00-01 - LANDING GEAR SYSTEM The electriclanding gear system has a steerable nose wheel. Single disc self-adjusting hydraulic brakes are featured on the main gear. Gear position lights, a warning horn and a gear position indicator on the floorboard are standard equipment. Bungee springs that preload the retraction mechanism in an over-center position lock the gear down. An air pressureactuated safety switch in the pitot system or a squat switch in the electricalsystem prevents electric gear retractionon takeoff until a safe flying speed is attained. A gear throttle warning sounds when the manifold pressure is less than a pre-set value with the landing gear up. The electdc gear retraction system has a manual extension system connected to the gear actuatorthat permitsmanuallowering of the gear inthe event of an electricalmalfunction, 5-00-02 - FLIGHT CONTROL SYSTEMS The dual flight control systems can be operated from either the pilot or co-pilot seat. All flight controls are conventionalin operation, using pushpulltubes to link the control surfaces to the control wheels and rudder pedals. Formica guide blocks maintain control tube alignment and dampen vibration. An interconnect springmechanismlinksthe aileron and ruddersystems to assistin controlcoordination.The standard co-pilot's rudder pedals are removable. The trim system sets the stabilizer angle of attack. 5-00-03 - WING FLAP SYSTEM Wing flaps are electdcafiy actuated and are controlled by a spdng loaded =up-off-down"switch on the center console. 5-00-04 -ELECTRIC POWER SYSTEM 1. The master switch and power relay control the electrical power system, comprised of a 60 amp, 14 volt alternator, a voltage regulator and a 12V, 35 AMP HR battery (24-0001 {hru 24-299g), or a 70 amp, 28 volt alternator, a voltage regulator and a 24V, 10 AMP HR battery -- (24-3000 thru 24-TBA). The alternator system has an overvoltage protective relay and an MOONEY AIRCRAFT CORPORATION overvoltageannunciatorlight. Circuitbreakersor circuit breaker switches protect the electrical wiring and equipment from overloads. Standard electrical equipmentincludes: 1-250 watt landing light(24-0001 thru24-3153)(2-100 watt landing, 2-100 watt taxi lights S/N 24-3154 thru 24-TBA), navigation lights, interior lights,gear and stall warning system, an electrical fuel boost pump, an electdc starter, an electric gear retractionsystem with manual extension override, an electrical flap system and an electdc cowl flap actuatingsystem. 5-004)5 -INSTRUMENTS All flight instrumentsare in the shock-mountedflight panel. Engine instrumentsare in the co-pilot'spanel. The pitat system provides air pressure to operate the airspeed indicator. The instrument static pressure system has two static air pickup ports--one on each side of the tailcone--that open to the atmosphere. An alternate static source is provided on lower flight instrumentpanel. The instrumentpanel lightingsystem has manualdimmingmechanisms. 5-00-06 -CABIN HEATING & VENTILATING SYSTEMS The heater muff encasing the exhaust system is the cabin heat source. Hot air from the heater muff mixed with ambientair controlscabintemperature.Air routed from the main heater duct system to nozzles at the windshieldbase defroststhewindshield. An optional defrost blower motor system is available for 24-3000 thru 24-TBA and for retrofit on eadJer aircraft. 5-00-07 - FUEL SYSTEM The fuel systemhas sealed, integralwing tanks in the forward, inboardsectionof each wing. Vents at the aft., outboard top comer of each tank vent through the lowerwing surface. Fuel sump drains are at the lowest point in each tank. The electric fuel pump is in the bottom lefl forward section of the fuselage just aft of the firewall. The engine-driven fuel pump mounts on the enginecrankcase.Two fuel quantity transmittersin each tank are wired to fuel quantity gauges in the engine cluster gauge. The master switch, lefl side of the pilot'spanel, turns on the fuel quantity indicating systems.Optionalvisualsight gauges are availablefor wingtankson aircraft24-0001 thru 24-TBA. NOTE A low fuel warning annunciator light for each tank is activated when usable fuel quantity goes below 2 1/2 gallons. 5-10-00 - TIME LIMIT COMPONENTS It is recommendedthat overhaul or replacement of componentsshouldbe accomplishednot later thanthe specified period of operationfor that componentor in accordance w_h manufactures service data or airworthiness directives, whichever allows longest operation. The specified overhaul time limits, if applicable to a component, do not constitute a guarantee that the component will reach that time limit without requiring maintenance. 12-98 5-OO-OO 5 MOONEY AIRCRAFT CORPORATION M20J SERVICE AND MAINTENANCE MANUAL NOTE "ON CONDITION" itemsare to be repaired,replaced or overhauledwhen inspectionor performance revealsan unserviceablecondition. 5-10-01 - OVERHAUL AND REPLACEMENT SCHEDULE ITEM RECOMMENDED OVERHAUL OR REPLACEMENT TIME LIMITS LANDING GEAR ActuatorNo-Back Spring All other Components 1000 Hours On Condition POWERPLANT Engine Propeller Magneto-Bendix Refer to LycomingSI 1009AJ(or currentrevision) Referto Mfg's. Maintenancedata O/H every4 years or @ EngineO/H - Ref. TCM SB #SB643 & Manual X42003 (currentrevision). @ EngineO/H or on Condition 500 Hours On Condition - Slick InductionAir Filters (Paper) All other Components FUEL & OIL SYSTEM Fuel Selector Valve (Anderson-Brass)* Fuel Selector Valve (otherthan above mfgr.) FlexibleHoses (ALL Except as Below& Teflon) Aemquip 601 Fuel Hoses Teflon Hoses All otherComponents 500 Hours * On Conditionor 500 Hrs. 7 years or Engine O/H, whichever occursfirst. 24 Months On Conditon On Condition INSTRUMENTS Vacuum RegulatorGarter Filter Filters -Vacuum Pump CV1J4 Filter Filters- Gym Instrument Other Components 100 Hours 500 Hours oronce a year On Condition 500 Hours oronce a year On Condition ELECTRICAL COMPONENTS All Components On Condition FLIGHT CONTROLS All Components On Condition MISCELLANEOUS SYSTEMS Vacuum Pump, Primary Stand-byVacuum Pump E.L.T. Battery OxygenCylinders Lt. Wt. Steel Cylinders CompositeCylinders All other Components (excludingAvionics) On Conditionor 500 Hours &@ EngineO/H (TBO Inspect@ 500 Hours 2 years or 1 Hourtotal usetime AVIONICS (General Systems) Refer to ManufacturersPublications 24 yearsor 10,000 recharge cycles 15 years or 10,000 recharge cycles On Condition Bendix-KingSystems KingServiceMemo No. 292 * Applicable on SIN's 24-0084, 24-0378 thru 24-1176 only. 5-10-01 6 12-98 SERVICE AND MAINTENANCE MANUAL M20J NOTE Components should be inspected and serviced at regular intervals perthe servicing, lubrication inspection chart atthe end of thisand SECTION of this Manual 5-20-00 - SCHEDULED MAINTENANCE CHECKS Inspection Intervals. Perform 25, 50, or 100-hour inspectionsof the aircraRand engine at recommended intervalsas outlinedin the followingparagraphs, NOTE Aircraft operated in salt air environment are considered high risk for corrosion damage, and should be cleaned and inspected at more frequent intervals. RefertoAC43-4. 8-20-01 - INSPECTION CHECK POINTS The general points to be covered duringinspection are groupedin accordancewiththe natureand function of the items discussed, 1. Moving Parts shall be inspected and checked as applicablefor. properoperation,securityof attachment, sealing, cleanliness, lubrication, servicing safetying, adjustment, tension, travel, condition of hinges, binding, excessive wear, cracking, corrosion, deformation,and any otherapparent damage, 2. Metal Parts shall be inspected and checked as applicable for: security of attachment, condition of finish and sealant, distortion fatigue cracks, welding cracks,corros on, and any other apparent damage. 3. Fuel, air and hydraulicoil lines and hosesshall be inspected as applicable for: cracks, dents, kinks, deterioration, obstruction, chaffing, improper bend radius, and insecure installation. Hose clamp installationson fuel and hydraulic systems between systemsor between systems and the engine shall be torquedto 25 inch pounds.Hose clamp installationson blast tubes, air ducts, vacuum lines, drain and vent linesshall be torquedto 15 inch pounds, MOONEY AIRCRAFT CORPORATION 4. Pipe Threads - Tightening and Torque procedures. Lubricatepipe threadsasfollows: Oxygen Lines - Use only MiL-T-5542 thread compound or Teflon thread seal tape on threads of valves, connectors,fittings,parts or assemblieswhich might come in contact with oxygen. The thread compoundmust be appliedsparinglyto the first three threads of the male fittingonly.No compoundis to be I used on the couplingsleevesor on the outside of the = tube flares. Extreme care should be exercised to preventthe contaminationof the thread compoundor teflon tape with oil, greaseor otherlubricant. Fuel, Hydraulic,Air,Oil Lines- Use "Parker Thread Lube" or equivalent on male fittings only. Apply lubdoant,omittingthe first two threads, sparingly and carefully. Engine Fittings - Use only aircreR engine oil to lubricater_ings threadeddirectlyto engine. Vacuum Lines- No lubdcaflonis to be used. Check manufacturers instructions when installing components. Refer to Section 37 for maintenance procedureson vacuumsystem. Tapered Threads - Use TeflonThreadsealTape. (1) Continue to tighten until fitting is correctly positionedbut do notoverrunor backoff. (2) If leaks are detected, tighten one full turn more. 3) If leaks persist, the parts should be disconnected and rejected; replace with new components. 5. Electricalwiring shall be checked as applicable for. loose, corroded, or broken terminals; chaffed, broken, or worn insulation;insecure installation;heat deterioration;and any otherapparentdamage. 6. Bolts and nuts in criticalareas shall be checked for: fretting, wear, damage, stretch, proper torque, (Figure 5-2) and safetying. 7. Filtersand screensshall be removed,cleaned and inspected for contaminationor damage that would requirereplacement. Torque Values - See following pages. 12-98 5-20-00 7 MOONEY AIRCRAFT CORPORATION M20J SERVICE AND MAINTENANCE MANUAL TORQUE VALUES FLARE NUT TORQUE VALUES- Tighten to minimum torque valuefor appropriate size as shown (Figure 5-1). I SIZE FITTING ALUMINUM TUBING MINIMUM. -3 .............. -4 .... -5 .... -6 .... -8. -10 -12 -16 -20 . -24 40 60 75 150 200 300 500 600 600 . . .... .... .... .... .... .... .... .... STEEL TUBING TORQUE - IN. LBS, MAXIMUM. MINIMUM. 30 .... 65 .... 50 80 . . . 70 .... 125 . . . 90 .... 250 .... 155 .... 350 300 .... 500 .... 430 .... . 700 .... 550 .... 900 900 I MAXIMUM 70 90 120 150 250 400 575 750 FLARE NUT TORQUE - FIGURE 5-1 BOLT - NUT TORQUE VALUES METRIC BOLTS, SCREWS & NUTS Failure of threaded fasteners due to over-tightening can occur by bolt shank fracture or by stripping of the nut and/or bolts thread. A bolt or screw assembled with a nut of the appropriate class is intended to provide an assemblycapableof beingtightenedto the boltproof loadwithoutthread strippingoccurring. The torquevalue to be set for a particularsize of screw is dependentupon: 1) Materialof the screw. 2) Parent matedal (steel, non-ferrousmetal orplastic). 3) Whetherthe screw is untreatedor plated. 4) Whether the screw isdry or lubricated. 5) The depthof the thread. TIGHTENING TORQUES - Untreated Screw(BlackFinish)- Friction Coeficient 0.14 NOMINAL DIAMETER (CoarseThread) M3 M4 M5 M6 M7 M5 M10 M12 M14 M16 M1a M2O M22 M24 M27 M30 M33 M36 M39 5-20-01 8 PROPERTY_ ._ TORQUE Ma 5.6 8.8 1o.9 0.60/0.44 1.37/1.01 2.70/1.99 4.6/3.3 7.6/5.6 11/9.1 22/16 39/28 62/45 95/70 130195 184/135 2501184 315/232 470/346 6351468 8651637 1111/819 144011052 1.37/1.01 3.10/2.29 6.15/4.54 10.5/7.7 17.5/12.9 26119 51137 89165 141/103 215/158 295/217 420/309 5701420 725/534 1070/789 145011089 197011452 253011865 3290/2426 1.92/1.42 4.40/3.25 8.6516.38 15111 25/18.4 36/26 72/53 125192 198/146 3051224 4201309 5901435 8001590 1020/752 1510/1113 2050/1511 277012042 3560/2625 4620/3407 12-98 2.3011.70 5.2513.87 10.4/7.6 18113 29/21.3 43/31 87164 150/110 2401177 365/269 500/368 710/523 960/708 12201899 1810/1334 245011806 333012455 4260/3156 555014093 f' SERVICE AND MAINTENANCE MANUAL M2OJ MOONEY AIRCRAFT CORPORATION (METRIC TORQUE TABLES CONTINUED) NOMINAL DIAMETER (Fine Thread) PROPERTY CLASS TORQUE Ma M8 x 1 MI0 x 1.25 M12 x 1.25 M 14 x 1.5 M 16 x 1,5 M18 x 1.5 M20 x 1.5 M22 x 1.5 M24 x 2 8.8 Nmlft.lb. 1O.9 NmlftJb. 12.9 NmlftJb. 27/19 52/38 95/70 150/110 2251165 325/239 4601339 6101449 7801575 38128 73153 135199 2101154 315/232 460/339 6401472 8601634 11001811 45/33 88184 1601118 250/184 3801280 5501405 770/587 105O/774 13001958 TIGHTENING TORQUES - ElectricallyZinc Plated - Friction Ceeficient O.125 DIAMETER (Coarse Thread) M3 M4 M5 M6 M7 M8 M10 M12 M 14 M16 M18 M2O M22 M24 M27 M30 M33 M36 M39 TORQUE Ma 5.6 Nm/ft.lb. 8.8 Nm/It.lb. 10.9 Nm/ft.lb. 12.9 Nm/R.ib, 0.5610,41 1.28/0.94 2_50/1,84 4,3/3.1 7.1/5.2 10.5/7.7 21115 36/26 58/42 88/64 121/39 171/126 230/169 295/217 435/320 5901435 8001590 1030/759 13401988 1.28/0,94 2-9012-14 5.7514,24 9.9/7.3 16.5/12_1 24/17.7 46/35 83161 132/97 200/147 25/202 3901287 5301390 6751497 995/733 13501995 183011349 236011740 305012249 1,60/1.33 4.1013.02 8.1015.97 14/10.3 23116.9 34/25 67149 117/86.2 185/136 285/210 3901287 5501405 7,451549 960/708 140011032 190011401 258011902 3310/2441 4290/3163 2-15/1.59 4.95/3.65 9.70/7.15 16.5/12.1 27/19.9 40129 81159 140/103 2201162 340/250 470/346 6601486 8901656 1140_40 168011239 228011651 309012278 3980/2935 515013798 8.8 Nm/R.Ib. 10.9 Nm/ft.lb. 12.9 Nm/ft.lb. 25118 49/35 88/64 140/103 210/154 3051224 425/313 5701420 7201531 35/25 68150 125/92 195/143 2951217 4251313 6001442 800/390 1000/737 42/30 82/60 1501110 2351173 350/258 510/376 7201531 960/708 1200/885 NOMINAL DIAMETER (Fine Thread) M8 x I M1Ox 1,25 M12 x 1,25 M14 x 1.25 M16 x 1.5 M18 x 1.5 M2Ox 1.5 M2.2x 1.5 M24 x 2 OPJ]D_gFJ_,]_ CLASS TORQUE Ma METRIC CONVERSION FACTOR: One Nm(NewtonMeter) = .7375 Foot Pound; One Foot Pound= 1.355818 Nrn 12-98 5-20-01 9 MOONEY AIRCRAFT CORPORATION M20J SERVICE AND MAINTENANCE MANUAL AN/MS STANDARD BOLTS, NUTS TORQUE TABLES TORQUE VALUES (Unitsare Inch-pounds) NUT BOLT SIZE TENSiON-type AN( ) BOLTS; AN-3651AN-310 NUTS SHEAR-type AN( ) BOLTS; AN-364/AN320 NUTS TENSION-type NAS() BOLTS AN-365/AN310 NUTS ! SHEAR-type NAS( ) BOLTS; AN-364/AN320 NUTS FINE - THREAD SERIES 8-36 10-32 114-28 5116-24 318-24 7116-20 112-20 9/16-18 5/8-18 314-16 7/8-14 1-14 1 115-12 1 114-12 12-15 20-25 50-70 100-140 160-190 450-500 480-690 800-1000 1100-1300 2300-2500 2500-3000 3700-5500 5000-7000 9000-11000 7-9 12-15 30-40 60-55 95-110 270-300 290-410 480600 600-780 1300-1500 1500-1800 2200-3300 5000-4200 5400-6600 25-30 80-100 120-145 200-250 520-630 770-950 1100-1300 1250-1550 2650-3200 3550-4350 4500-5500 6000-7300 11000-13000 15-20 50-60 70-90 120-150 300-400 450-550 650-600 750-950 1600-1900 2100-2600 2700-3300 3600-4400 6600-8000 -COARSE - THREAD SERIES 8-32 10-24 114-20 5116-18 3/8-16 7/10-14 1/2-13 9/16-12 5/8-11 3/4-10 7/8-9 12-15 20-25 40-50 80-90 160-185 235-255 400-480 1500-700 700-900 1150-1600 2200-3000 7-6 12-15 25-30 48-55 95-100 140-155 240-290 300-420 420-540 700-950 1300-1800 Figure5-2 Reference: Federal AviationAgencyAdvisoryCircularNo. 43.13-1(*) (*=currentrev.) RecommendedTorqueValues for Nut-Boltcombination 1. Be surenut and/or boltthreads are clean and dry(unlessMfg. states otherwise). 2. Run boltdownnear contact withwasher or beadngsurface and check=frictiondragtorque=requiredto turn bolt/nut. 3. Add"frictiondrag torque"to the recommendedtorque value from Figure 5-2. This value is considered"Final Torque Value". (RRICTION DRAG TORQUE + REC'MD TORQUE = FINAL TORQUE). CAUTION DO NOT REUSE LOCKNUTS IF THEY CAN BE RUN UP FINGER TIGHT, 5-20-01 10 12-98 SERVICE AND MAINTENANCE MANUAL M2OJ MOONEY AIRCRAFT CORPORATION CAUTION These torque values are derived from oil-free cadmium-plated threads. CAUTION DONOTREUSE LOCKNUTS IF THEYCAN BE RUN UP FINGER TIGHT. 5-20-02 8. Check pitotand static systemsfor obstructions. 9. Inspect aircraft exterior for security of bolts, screws, etc. - AIRCRAFT FILE INSPECTION Aircraft 1O0-hour and annual inspections cover, in additionto examining the aircraft proper, a review of the statusof compliancewith current Federal Aviation Regulations. This review includes inspection of the Airplane Flight Manual, Aircraft Log Book, Engine Log Book, Registration Certificate, Airworthiness Certificate, Weight & Balance Record, Lycoming Service Information, Aircraft Radio Station License (if applicable), FAA Airworthiness Directives, and Mooney sedvce documents. 5-20-03 -ENGINE FUNCTIONAL CHECK Pdor to a scheduled 100-hour or annual inspection, and/or 25 hours after installation of new or overhauled engine, wash down the engine and engine components. Then perform an engine runup in accord with procedure recommended in the Airplane Flight Manual. Make a record of all malfunctions and abnormalities. After the engine runup, complete a differential (hot engine) compression check. To verify correction of malfunctions and abnormalities, perform a second engine runup and a flight test after completing the inspection. 5-20-04 - FIRST 25 HOURS - INSPECTION The one time 25-hour inspection consistsof a visual inspection of:.--propeller, engine and aircraft general condition,includinga preflightinspectionas outlined in the Flight Manual. The inspection does not require removal of access panels or disassembly of all components;however it should include completion of all lubdcaton and service requirements. Inspection should be extensive enough to detect any damage or condition which might jeopardize flight safety. Atter the first 25 hours of new or overhauled engine operation, refer to paragraph 5-20-05 for the recommended engine inspection. 1. Visually inspect propeller, spinner, and cowling; remove cowling. . 2. Inspect and clean induction air filter if aircraft has been operating under dusty conditions. Check operation of alternate air door. Check Ram air door operation SIN 24-0001 thru 24-3153. 3. Inspect engine compartment for evidence of fuel, oil or exhaust leaks, 4. Check security and condition of equipment installed on engine. 5. Inspect fuselage wing and empennage for external evidence of damage. Pay particular attention to scratches and dents. 10. Check and service battery. 5-20-05 -50 HOUR INSPECTION The 50-hour inspection includes all requirements for the 25-hour inspection,plus the necessary removal of inspection doors, panels, or faidngs. After the first 25 hours of operating time, a new, remanufactured, or newly overhauled engine should be given a 50-hour inspection including replacement of the lubricating oil. 1. ENGINE A. Drainengineoilsump. B. Remove and clean suction oil strainer; reinstall strainerand plug.Safety wire strainer plug. C. Remove and replace the full-flow oil filter cartridge. D. Drain and clean fuel strainer. E. Remove and clean fuel injector fuel strainer. F. Service engine oil sump with proper type, grade, and amount of lubricating oil. G. Inspect engine intake and exhaust systems for evidence of leakage and looseness. H. Check spark plug elbows and shielding nuts for security. I. Checkcylindersfor evidence of overheating. J. Check baffles for secure anchorage, close fit aroundcylinders,and freedom from cracks. K. Checkengine controlsfor full travel, freedom of movement,and security. L. Visually check fuel and oil lines for secudty of connections and evidence of leakage or damage. M. Visually inspect induction air system; check operation of alternate-air door (refer to paragraph 71-60-01). N. Inspect engine mount & bolts for security and con0iflon. Inspect eng'ne mount tubes (bolt attach tubes), at firewall for moisture accumulation and corrosion. 2. PROPELLER A. Check propeller ano spinner for general condition, looseness, and oil leakage. B. Inspect blades for nicks and cracks. Repair pdor to next flight. 3. CABIN A. Check brake and parking brake control systems for proper operation and fluid level. 6. Inspect windshields and windows for crazing, cracks, and scratches. 7. Check control systems for binding, excessive freeplay, and damage. 12-98 5-20-02 11 MOONEY AIRCRAFT CORPORATION M20J B. Check trim system and indicator for free operationand travel, C. Check cabin and baggage doors for damage, properoperation,and sealing. Check cabin, instrument, position,anticollision, andD. landinglight. E. Check fuel selector valve, gascelator,and boost pumpfor pmperoperation, F. Checkoxygensystem(if installed), 4. LANDING GEAR A. Check tiresfor cuts,blisters,wear, and inflation, B. Check shock discs for proper extension at aircraft,staticweight per Section 32-81-00. C. Check hydraulicbrakes for wear, warpage and properinstallation, 5. WINGS A. Checksurfaces and tips for damage, B. Check ailerons, aileron attachments, and bellcranksfor damage and properoperation, C. Check flaps and attachments for damage and properoperation. D. Lubdcatecontrols if necessary. 6. FUSELAGE and EMPENNAGE A. Check stabilizer, elevators, fin, and rudder for damage and properattachmenL B.Lubdcete controls if necessary. 7. Lights " A. Check operationof extedor and intedorlights, 8. See Section 5-20-07 for repetitive 50 Hour inspectionsand servicingof componentsinformation. 5-20-06 - t00 HOUR INSPECTION (or ANNUAL) (REF, FIG. 6.4) The 100-hour (or annual) inspection is a thorough, searchinginspectionof the entire aircraft. Preparation for the inspection includes the thorough cleaning of exteriorand engine compartment,removalof fuselage, wing, and empennage inspectiondoors, cover plates, and faidngs at all systems attach, hinge, and beadng locations (includingwing and empennage to fuselage matingpoints).Operatinglimitreplacement and special testing of components is to be included at this interval when applicable. Comply with applicable FAA Directives, AD Notes, and applicable Mooney and Vendor mandatory Service Bulletins and Instructions. Check for aircraft conformance to FAA Specification 2A3. Recommended 100-hour and special inspection requirementsare outlined in the followingparagraphs. SERVICE AND MAINTENANCE MANUAL A. Complete a differential (hot engine) compressioncheck: clean and gap or replace spark plugsif necessary.Repairdiscrepanciesfound. B. Inspectenginefor evidence of excessivefuel or oil leakage. Inspect oil cooler and oil hoses for condition.Repairas needed. C. Drain engine oil sump; remove, inspect and clean oil suctionscreens;reinstalland safety. Remove full-flow oil tilter cartridge;replace with new cartridge and safety. Check crank case breather hoses for obstruction.Safety wireoil tilter installation. D. Refill engine oil sump with the proper type, grade, and quantityof lubdcatingoil. E. Inspectfuel injectorand all fuel lineconnections forsecurityand condition. F. Remove, inspect and clean fuel selectorvalve or gascalator strainer, reinstall strainer, lubricatedetent track, ball and spring disc. Inspect fuel lines and connections;pressurecheck fuel system with mixture controlat IDLE CUTOFF and BOOST PUMP ON. G. Inspect all air ducting and connections in the heating and inductionair systems for leaks. Remove and clean inductionair tilter;,replace at 500 Hrs. H. Leak check all exhaust manifold connections, engine exhaust manifolds and muffler connections. Inspectfor properattachment. I. Inspect alternate air door for condition and proper preload.To inspect for praloed remove lower cowlingand PUSH on alternate air door seal bolt with an appropriatespdngscale. A praloadof 3 to 4 pounds should be requiredto start door to open. Add ordelete AN960-416L washersunder belt head to obtainproper tension. Replace all components removed. Coat Seal with TEFLON spray/lubricant. CAUTION CHECK SECURITY of seal to Induction Box Door. If necessary use (3M) EC1403 cement to secure seal to door. J. Check magnetos for grounding and synchmnizalton;check magneto points for condition, clearance,and timing.Inspectdistributorblockfor erosion and cracks.Checkcam followerfelt for properlubrication, and remove excessiveoil from breaker compartment. Repairor mplacs componentsif required,per BendixSB No. 612 at 500 Hrs.for routinemaintenance. K. Check baffles for secure anchorage, cracks, holes, deformation, and for close fit around cylinders. Check cylinders for burned paint and cracked or brokentins. Checkbafflesealant. L. Check engine and propeller controls for free operation, proper security of cable at housingswage, full travel, and securityof attachment. NOTE CaMe Craft control cables are lubricated for the life of the control cable. DO NOT remove seals or lubricate control cable. 1. ENGINE INSPECTION. Prior to the inspection, remove the engine cowling and propeller spinner, Wash downthe engine and enginecompartment.Then perform an engine mnup in accord with the procedure recommendedin the LycomingOperators Manual, To M. Inspect Propeller Governor for security in vadty correction of malfunctions and abnormalities, mounting and unrestricted operation of governor performa second engine runupand flighttest after the control. Check for proper operation dudng post 100-hourinspectionengineset-upcheck, inspectionflight. 5-20-06 12-98 12 SERVICE AND MAINTENANCE MANUAL M20J N. Inspect tubular engine mount for cracks, damage or corrosion; oheck all bolts and robber mountsfor securityand conditlen, O. Check battery cables, electrical wtdng, and ignitionharness for condition,secure anchorage,loose terminals,and burnedorchaffed insulation, P. Inspectbattery,battery box, and vent systemfor condition and corrosion. Check blast tube for obstruction. Flush battery box and battery case if necessary, Q. Inspect accessory case, vacuum pump, hose, flrewalland fittingsfor securityor damage, R. Check alternator and mounting bracket for secodty and ddve belt for conditionand propertension. Checkstarterinstallaticnfor secority.Checkstmter ddve and drivegear condition.Lubricatedriveifnscessary. S. Inspect studs, nuts, belts, etc. for damage & propertmque, T. Inspect Exhaust System for leaks or cracks & proper clearance from other components.Repair any discrepancies.Replace or repair muffler if any intemal damage isfound. Inspectforpreperaifachment, U. Inspect and reinstallcowling. Check cowl flaps for operationcondition,proper opening and cowl flap positionindication(24-3000 thre 24-TBA). V. Inspect landing light for securityand condition (24-0001 thru 24-3153). 2. PROPELLER INSPECTION. A. Remove spinner('dnot already removed). B.Check securityof propellerinstallation, C. Check hubbelts for securityand damage. D. inspect hub parts and blades for craoks and nicks.Repairpdorto nextflight, , E. Q-tip blade inspectionand repair. The tip of the blade is formed at the factory with a bend of 90 degrees toward the blade face (aft). The material thickness in the radius of bend is closely controlled such that the cold bend allowance is not exceeded. A sketchof the "Q"tip is shownbelow (Figure 6-3). F. Checkfor oil leaks, lossof grease,and lubricate as requiredby appropdstemanufacturershandbook. INSPECTION: Inspect =Q-Tip" for stone nicks and scratches using the same procedure as on the completeblade. Inspectfor evidenceof the bend being deformed by assuring that the bend edge is 90 degrees. Also inspect for deformed waviness of the bend. REPAIR: Material in the bend area (.110 plusor minus .010)tomay be removed for repair of nicks and scratches a minimum blade thckness of .065. Correspondingly,reduce the very tip region, when required,to a minimumof .010 less than _e resulting thicknessofthe bend area. The bend may ne reduced in length for repair from the one inch dimension to appreximately.75 inches.The g0 degree bendthat has been deformed by 20 degrees or less may be straightened by using a rubber mallet and block assuring that no waviness or other damage results from the straighteningprocess;inspectfor cracks.The chord length may be reducedfor repair similarto the procedureof a standard blade essudng that all blades are the same so that the aerodynamicbalance of the propellerwillnot be affected. G. DELETED PROCEDURE H. Inspectanti-icingboots for properoperationand for obviousdefects. I. Inspectspinnerandbu_P..adforcracksandcondition. J. Check spinner bulkheadfor correct interference fit with prop cylinder. (Use Teflon Tape to obtain correct fit.) (See Section61-00-20, pare. 10) INSPECTION. 11 0 __ ..L ,,-_ "_'I_ C2_{_"_._ MOONEY AIRCRAFT CORPORATION ) _ A. Check tires for proper inflation,cuts, blisters, slippage,and heavywear. 3. LANDING GEAR and RETRACTION SYSTEM corrosion,boltfailure. Check conditionof felt seals and beadngs;repackbeadngsat 250 hourintervals. C. Checkbrake pads& discs for warpingandwear. D. Checkhydraulicreservoirfor properfluid level. B. Checkwheelsfor oracks,distortion,misalignment, dents,crackschaffing, kbrakelinesand inks,andsecurityof anchorage. E. Check hydraulic hosesfor leakage, F. Check parking brake system for proper engagementand release. G. Check nose gear for cleanliness and damage. I _-----_ _ SH.JK--5--3 NI or broken roll pins.Check shock disc gap per Section 32.81-O0. Check nose gear retractiontube bungeesfor sheared NOTE Maximum allowable towing damage on leg assembly is 1132inch dent. H. Check nose wheel steering mechanismfor adjustment,alignment,corrosion,and lubrication. 12-98 5-20-06 13 MOONEY AIRCRAFT CORPORATION M20J I. Check main gear for cleanliness or damage. Check shock disc gap per Section 32-81-00. J. Jack aircraftas recommendedin pemgmph7-10-00. K. Check landing gear retraction linkage, beUcranks, pivots, and beadngs for wear, damage, distortion, misalignment, corrosion, cleanliness,and lubrication, L. Check the landing gear actuator for secudty of mounting, cleanliness, andinindication of overheating or damage. Inspect brushes motor for wear. SIN 24-0001 - 24-0377 with Dukes Actuator Lubricate actuator ball screw with recommended lubricant for Dukes actuator only per procedures below, (1) After 500 hours of operation and each 200 hoursthereafter. (a) Remove the actuator from the aircraft, (b) Remove the end cap and wipe excess grease from gears, (c) Visually inspect gears for wear as follows: With open end of actuator toward you, rotate jack screw shaft counter clockwise to remove all slack from dng and worm gears. Make an index mark on one gear tooth and on the inside of housing. Turn jack screw shaft clockwise until dng gear contacts worm gear and check index marks. Visible wear or backlash of 1/2 tooth or more requires immediate replacementof gears. Reference SECTION 32-30-04, SIN 24-0001 thru 24-0377, for additional inspection and rigging procedures, ALTERNATE PROCEDURE: (Dukes actuatoCs)Measure backlash by using a .025" diameterwire of .025" thick shim as a feeler gauge. If feeler can be inserted between gear teeth, replace gears, Repeat above procedure after rotating the dng gear thru 90 degrees; 180 degrees; and 270 degrees. (d) Repack gear box with recommended lubdcanL (e) Reinstall end cap and resafety. (f) Refer to Section 32-30-02 for proper actuator adjustment and reinstallation instructions, M. Perform landing gear operational check per Section 32-30-01. 4. FUELSYSTEM INSPECTION. SERVICE AND MAINTENANCE MANUAL G. Check boost pump for leaks, security of mounting, adequate fuel pressure, switch operation, and condition of wiring and electrical connections. H. Check fuel quantity gauges and transmitters for secudty of mounting and condition of widng and electrical connections. I. Check fuel tank filler caps for O'dng condition, cleanliness, secudty and condition of servicing placards (Ref. 28-00-01). 5. EXTERIOR INSPECTION. A. Thoroughlyclean aircraft exterior. B. Inspect fuselage exterior surfacesfor corrosion, damage, loose or popped rivets, dents, cans, scratches,cracks,and deterioratedpaint. C. Inspect windshields and windows for cracks, crazing, scratches, condition of seals, and security of installation. D. Inspect wings, flaps, and ailerons for corrosion, damage, loose or popped dvets, dents, scratches, cracks, condition of attaching points, lubrication, freedom of operation, free-play, travel, and balance weight attachment. . E. Inspect empennage for corrosion,damage, loose or popped dvets, free-play, dents, scratches, cracks, condition and lubdcafion of hinge points, attachment of balanceweights, and freedom of operation. F. Inspect cabin door and door frames for damage, corrosion, nicks, dents, hinge security, and lubrication. O. Inspect cabin door lock mechanism for lubrication and proper engagement. See Section 52-11-00 for rigging procedures. H. Inspect baggage door and baggage compartment for damage, corrosion,warpage, hinge security, condition to door frame and door seals, condition and operation of door locking mechanism, and conditionof cargotiedowns. I. Inspect ventilatingsystemdrain linefor obstruction. J. Inspect the alignment and lubrication of overhead vent push-pull cable for smooth operation (SIN 24-0001 thru 24-0377). K. Inspect Landing/Taxi lights for security, condition and proper adjustment. See Section 33-43-00 for adjustment procedures. 6. INTERIOR INSPECTION. A. Inspect seats, seat tracks, and upholsteryfor cleanliness and mounting security; check seats for conditionand operation of positionlocks; inspect seat structure for cracks, deformation, corrosion, and mechanismlubrication. B. Inspect safety belts, harnesses and attaching bracketsfor cleanliness,condition,latch operation,and securityof attachment. C. Inspect for loose equipment that might restrict controlmovement. D. InspectOxygenSystem(ifinstalled)perChapter35. A. Inspect fuel tank exterior for evidence of fuel seepageand stain. B. Drain tank and inspect tank interior when seepageis evident. C. Check fuel tank drains for leakage, sediment, and water contamination, D. Check fuel-tank vents for obstruction. E. Check fuel selector valve for proper tank selecfion, smooth operation, and leakage in OFF position. F. Check gaseolator for leakage; check sump for sediment, water or other contamination. Inspect fuel filter, clean or replace. 5-20-06 12-98 14 SERVICE AND MAINTENANCE MANUAL M20d 7. INTERNAL INSPECTION. A. Open access panels and inspectiondoom, and removefaidngs as required, B. Inspect wing/fuselage attaching bolts for proper torque and safetying and evidence of damage or corrosion, C. Inspectforward sideof firewallfor damage, D. Inspecttubularstructurefor corrosionor damage (intedorpanelsand insulationmay requireremoval), E. Check wires, lines, and ducts for security, damage, interference,chaffing,and bonding, F. Inspect wing dbs and stringers for cracks and evidenceof damage or corrosion. G. Inspectwingsparsfor damage,distorlion, cracks,or corrosion. H. Inspect wing interior for foreign material, corrosion, and evidence of fuel leakage. I. Inspect Baggage Compartment floorboard assembly, stdngers and doublers, J. Inspect empennage attachment brackets and hardware forcorresion, NOTE Seal all receptacles and plugs outside cabin environment with Dow Coming #4. 8. FLIGHT CONTROL INSPECTION. A. Inspect control column and control wheels for full travel, proper dgging, free-play, binding, security of mounting, proper lubrication, and direction of control surface movement with relation to control movement, CAUTION All flight control components should be checked to are verify all moisture drain holes freethat of obstructions. B. Inspect elevator system for rigging, travel, stop adjustment, condition of all bearings, bellcranks,and hinges, secudty of mounting, damage, corrosion, lubdcation and proper relations to control movement. C. Inspect aileron system for damage corrosion, lubdcation, rigging, travel, stop adjustment, condition of hinges, bellcranks, pivots and rod end bearings, and link bolt security. D. Inspect rudder system linkage for damage, corrosion, lubrication, security of link bolts, rod end beadngs and proper relationship to control movements, Check for free movement of toe-brake pedals and proper rudder and nose wheel travel. MOONEY AIRCRAFT CORPORATION NOTE All control rigging checks should be made with the aircraft jacked and leveled and with the landing gear retracted. NOTE Some elevatortrimtubes have polytape wrapped at bulkhead penetrations. If tape shows signs of wear, rerap (1/2 lap)tube with 2" wide Y9265 polyurethane tape. Trim tubes, without tape, which show signs of abrading grommet should be wrapped. See SB M20-185. Maximum tube wear is .007 in. per wall or.014 in. diameter reduction. 9. INSTRUMENT/AVIONICS INSPECTION. A. Inspect all instrumentwiring and plumbing for conditionand properconnections. B.Cleanand inspect vacuum filter. Replacegarter filter on vacuum regulator. C. Check vacuum regulator at vacuum manifold. Check operation of high-and low-vacuum warning lights or vacuum gauges. D. Inspect all instruments for proper pointer indication, range and limit markings, condition of indicator markings, cracked or loose glass, slippage marks, and secudty of installation. E. Check compass for proper lighting, compensation, secudty of mounting, liquid leakage, and discoloration. Swing compass at annual inspection and after any new equipment has geen Installed. F. Inspect altimeter for scale error, discolored markings, proper pointer readings, setting knob freedom, and syncronization of barometric scale with reference markers. G. Inspect flight panel for security of mounting, condition of shock mounts, freedom from interference with structure,and conditionof groundstraps. H. InspectAvionicsEquipmentfor poper operation& seom_. I. Inspect Avionics antennas, wiring & shielding for obvious damage or defects. J. Inspect pitot head for port obstruction; check lines for cracks, dents, kinks, proper bend radius, and security of attachmenLDrain system and check for leaks. K. Inspect static ports for obstruction and aerodynamic smoothness at port installations. Inspect lines for bends, cracks, dents, kinks, and security of attachment. Drain system and check for leaks. Check alternatestaticpressuresource locatedon le_tflightpanel. 10. ELECTRICAL FUNCTIONAL TEST E. Inspect stabilizertrim controlsystemfor security A. Check operationof navigationlights. and proper adjustment, sha_ and stop nutsfor proper B.Checkoperationof landinglightor landing/taxi lights. dgging, trim control wheel for smooth operation, C. Checkoperationof dome lightsand cigarlighter. universaljoints for free-play and good working order actuator threads for lubrication, linkage for corrosion, D. Check operationof anticollisionlights. and guide blocks for Io(_senessor excessivewear. See E. Check operation of instrument and placard Section27-42-00 for Electric Pitch Trim Inspection. lights.Check rheostat. F. Inspect flap system for rigging,travel, and stop F. Check operationof pitothead heater. adjustment;flap positionindicator for properoperation actuator, push-pull tubes, interconnects, bellcranks & G. Check operation of cluster gauge. bingesfor corrosion,security, and lubrication. 12-98 5-20-06 15 MOONEY AIRCRAFT CORPORATION M2OJ SERVICE AND MAINTENANCE MANUAL H, Chock operation of fuel gauges, 11. MISCELLANEOUS/OPTIONAL EQUIPMENT I. Check operationof annunciatorlight pP.ss-to-test Inspect any installed equipment not covered by switch, previousparagaraphsfor proper operation, attachment J. Check operation of ignition switch, and starter or obvious defects, solenoid. 12. POST INSPECTION FLIGHT TEST K. Flight check operation of landing gear position lights and warning horn. L. Flight check operation of stall warning horn. M. Check operation of "Prop De-Ice" (if installed). Push switch =ON", observe prop de-ice ammeter for:. (1) needle in green arc (8 to 12 AMPS -24-0001 thru 24-2999) and (2) fluctuation every 90 seconds as heating elements are switched. Observe aircraft ammeter on S/N 24-3000 thru 24-TBA for fluctuation as each boot cycles (8 AMPS -24-3000 thru 24-TBA). N. Inspect battery & battery connections for proper installation and cleanliness. 5-20-06 16 Flight test the aircraft to verify correction of all malfunctions and abnormalities. Make proper entdes in aircraft log book. 12-98 r SERVICE AND MAINTENANCE MANUAL M20J MOONEY AIRCRAFT CORPORATION 13 -11 10 15-_ 27 J 19 31 27 19 27 15&16 14 \ G_ _ _24-0001 -- _ 27 - 24-1417 27 .... 24-1418 -thru24-TBA 28 27 _ WING ACCESS CnVERS MAY VARY BETWEEN MFI])EL YEAR AIRCRAFT, ,COMPONENT LnCATII3NS REMAIN BASICALLY UNCHANGED, ACCESS COVER IDENTIFICATION, LUBRICATION & SERVICE GUIDE FIGURE 5-4 NOTE Access covers riveted in place during production need not be removed for routine inspections. 12-98 5-2O-O6 17 MOONEY AIRCRAFT CORPORATION M20J SERVICE AND MAINTENANCE MANUAL 5-20-07 -ACCESS COVER IDENTIFICATION, LUBRICATION AND SERVICE GUIDE ITEM ITEM DESCRIPTION ....... LUBRICATION ..... NO................. SYMBOL * , ....... 1 .... .... .... .... .... .... .... .... Flight Instruments Vacuum Regulator .................. Turn Coordinator ....... Vacuum System Filters--Replace at .............. Control System Adjustments: Control Column Bearing Ball .... Rod End Beadngs ....... Universal Joints ........ Bellcranks ......... 2 Engine Cowling ........ Vacuum Pump ........ AlternateAir Door Seals .... .... 3 .... .... .... .... 4 . .... .... .... .... .... .... 5 .... .... .... .... .... .... .... .... .... 6 .... .... .... .... . . INTERVAL (HRS) 500 ** 100 500 ** Q ........... _ _ _: ]C ........... ........... ........... ........... 100 100 100 100 Q ........... Q ........... _ ........... 100 500 50 Nose Gear Grease Fittings ..... _ ........... RetractionTube Rod End Bearings _ ........... Bellcranks.......... _ ........... Bungees .......... _ ........... Gear Door Rod End Bearings..... _ ........... Main GearGrease Fittings ..... ,Q RetractionTube Rod End Beadngs . . . _ Bellcranks.......... _; ........... Bungees .......... Z ........... Gear Door Rod End Bearings ..... _ ........... ElectricGear Actuator Gear Box .... e/_ ......... ElectricGear ActuatorBall Screw. e ........... ElectricGear ActuatorNo-back Spring ............. Elevator & Rudder Controls: ControlTube Rod End Bearings _ ........... Bellcranks ......... _ ........... Battery,Battery Relay ....... Q ........... Stabilizer Trim ControlShalt: UniversalJoints........ _: ..... Guide Blocks ........ & ........... HydraulicReservoir ....... 13 ........... Oxygen, High Pressure Fittings .... ® ......... 100 100 100 100 50 100 100 100 100 50 AR/AR *** 100 1000 **** ..... ELT Transmitter (14 Volt) ...... Elevator & Rudder Controls: Control Tube Rod End Beadngs Bellcranks ......... Stabilizer Trim Jack Screw/Actuator . Tail Strobe Light Power Supply .... _ ........ _11........... ]C ........... ? ........... u ........... 100 100 100 ...... . . . . . 100 100 50 50 100 100 1gO 100 100 * See last page of section for lubrication symbol legends. ** Change garter tilter on vacuum regulator every 100 hours. Change instrument filters at 500 hours, clean every 100 hrs. *** No pedodic lubricant on Avionics Products #102000-1#2. If necessary to relubdcate, use Aeroshell 22, Mobil 28 or MIL-G-81322 ONLY. **** Replace No-back spring in Avionics Products (Ref. SI M20-52B) & Plessy Actuators (Ref. SI M20-92) 5-20-07 18 12-98 ....... SERVICE AND MAINTENANCE MANUAL , _' M20J ITEM ITEM DESCRIPTION ....... NO................. 7 Empennage Attach Points...... . . . . Stabilizer Trim Attach Point ..... 8 MOONEY AIRCRAFT CORPORATION LUBRICATION ..... SYMBOL * . ....... _ ........... O ............ INTERVAL (HRS) 100 100 .... .... Elevator & Rudder controls: Control Tube Rod End Beadngs Trim Assist Bungee Attach Point _lJ ........... }: ........... 100 100 9 .... .... Elevator & Rudder Controls: Control Tube Rod End Bearings Trim Assist Bungees ...... _F ........... :E ........... 100 100 10 Aileron Control Tube Guide Blocks Z_ ........... 100 11 .... .... Aileron Controls: Control Tube Rod End-Bearings Bell Cranks ......... yl ........... :E ........... 100 100 12 Aileron Control Tube Guide Blocks A ........... 100 13 Main Gear Retraction Spdng/Bellcranks . :_ ........... 100 14 .... Wing Attach Points ....... Control Tube Guide Blocks _ ........... A ........... 100 100 15 .... .... Stabilizer Trim Screw & Stops ..... Indicator Adjustment Point Stabilizer Trim Chain & Gear . (p 100 16 .... .... .... .... .... .... .... .... 17 .... .... 18 .... .... .... .... .... .... Elevator & Rudder Controls: Control Tube Rod End Beadngs Bellcranks ......... Guide Blocks ........ Flap Indicator Cable ....... Electdc Flap Actuator Gear Box .... (Lube gearbox and ballscrew) Electric Flap Actuator Ball Screw .... Baggage Compartment Floorboard Assy. Electric Boost Pump Gascolator .......... Fuel Selector Valve ....... Control Systems: Control Tube Rod End Beadngs Control Yoke (Lower Section) .... Nose Gear Steering Link ...... Rudder Pedal Cross Shall ..... Rudder-Aileron Bungee ...... Hydraulic Brake Cylinder Pedal Linkage . 19 .... Aileron Control Tube Rod End Beadngs . Outboard Flap Stops ....... ..... 12-98 .......... q) ........... 100 W :_ _ :E _ ........... ........... ........... ........... ........... 100 100 100 100 500 8 ........... _ ........... 100 100 _ }: ........... ......... 50 100 _ :_ _ _ :E :E ........... ........... ........... ........... ........... ........... 100 100 100 100 100 100 _ u ........... ........... 100 100 5-20-07 19 MOONEY AIRCRAFT CORPORATION M20J SERVICE AND MAINTENANCE MANUAL ITEM NO.. ITEM DESCRIPTION ....... SYMBOL * .......... 20 .... .... .... .... 21 .... .... .... .... .... Baggage CompartmentDoor:. Hinges .......... Latches .......... Seals .......... Lock........... Cabin Door:. Hinges .......... Latches Seals .......... Hold-OpenAnn ........ Lock........... 22 .... Engine Instruments Radios 23 24 .... .... .... Oil Dip Stick, Oil FillerTube ..... Wheels & Brakes: Wheel Beadngs........ Brake PressurePlates AnchorBolts ShockDiscs. 25 26 .... .... .... Elevator& RudderControlStops .... Nose Wheel: Wheel Beadngs........ Shock Absorber........ Shock Discs......... (] 27 ControlSurface Hinges _: ........... 28 .... .... 29 Propeller .......... Starter Drive ......... Aitemator Drive Bell ....... Cowl Flap Motor and IndicatorCable. =3 . . . ray ........... i] ......... D ........... 30 Remote CompassSender...... O ....... 31 32 Strobe LightPower Supply ..... ELT Transmitter(28 Volt) ...... a a 33 Speedbrake Cartridges SYMBOL MIL. SPEC. NO I; MIL-L-7870 MIL-G-81322 MIL-L-3545 MIL-H-5606 MIL-G-23827 A 5 LUBRICATION (HRS) _ 9 _ 5 . ...... ........... ........... ........... ............ 100 100 100 100 100 100 100 V ........... AR '_ ........... w ........... (I 250 50 50 ........... . . . ........... 250 100 50 ........ 100 : ....... 100 20 Each Flight 100 .... ........... ........ 100 . ...... 0 ........... LUBRICATION SYMBOL LEGEND ........ INTERVAL _; ........... 9 _ ........... q_ ........... 6 _ a 0 . . 100 100 1000 DESCRIPTION ......... ......... ......... ......... ......... LowTemperatureOil (General Purpose) Grease (AvionicsProducts) Grease (High Temperature) HydraulicFluid (Red) Graphite& MIL-G-3278 Grease or MIL-G-23827 PowderedGraphite Teflon Spray (Td-flow) or equivalenL ................ ................ 5-20-07 2O . ..... 12-98 SERVICE AND MAINTENANCE MANUAL SYMBOL MIL. SPEC. NO M2OJ ........ DESCRIPTION .£. ................ e ................ .... ................ fi ................ V ................ r Stick Lubricant (Door Ease or Equivalent) Lubriplate 630AA (10% by Volume Molybdenum Disulfide Mixture Permissible) Seal Dressing Inspect TEXTRON-Lycoming Spec-No. 301F. Mineral Oil per MIL-L-6082 or Compounded Oil per MIL-L-22851 are approved when used per following Viscosity Chart below. (See Lycoming SLL229A, for Mobil AV1 approval) Graphite and Kerosene, Lubdplate 797 ................ ¢P ................ ® ................. MOONEY AIRCRAFT CORPORATION MIL-T-27730 Aeroshell Grease NO. 7 (On jackscrew and inside Actuator Bearing Housing) TAPE, Tetra fiuoroethylene (Permacel Tape Corp) GREASE (Dukes) ......... MIL-G-23827, MOBIL # 27 ..... VISCOSITY CHART Average Ambient Air Temperature MIL-L-6082 or SAEJ 1966 All Temperature MIL-22851 SAE 15W50 or SAE 2gw50 Above 80 Deg. F Above 60 Deg. F 30 Deg. to 90 Deg. F 0 Deg. to 70 Deg. F SAE 60 SAE 50 SAE 40 SAE 30 g Deg. to 90 Deg. F Below 10 Deg. F SAE 20W-50 SAE 20 SAE 60 SAE 40 or SAE 50 SAE 40 SAE 30, SAE 40 or SAE 2gw-40 SAE 20W50 or SAE 15W50 SAE 30 or SAE 20W-30 NOTE Mooney Aircraft are delivered with the proper break-in oil; MIL-L-6082. Oil and filter should be changed after 25 hours. Continue to use mineral oil for 50 operating hours or after oil consumption has stabilized then change to oil conforming to Lycoming Specification 301F. Multi-viscosity oil, both Mineral and Additive, is recommended. NOTE Refer to Textron Lycoming Service instruction No. 1014 ( * ) for lubricating oil recommendations. ( * ) = current revision or subsequent revisions. \ 12-98 5-20-07 21 MOONEY AIRCRAFT CORPORATION M20J BLANK 5-20-07 22 12-98 SERVICE AND MAINTENANCE MANUAL MOONEY AIRCRAFT CORPORATION M20J SERVICE AND MAINTENANCE MANUAL CHAPTER 6 DIMENSIONS AND AREAS SERVICE AND MAINTENANCE MANUAL M20J MOONEY AIRCRAFT CORPORATION CHAPTER 6 DIMENSIONS AND AREAS LIST OF EFFECTIVE PAGES CHAPTER SECTION SUBJECT .......... 6-Effectivity/Contents ....... 6-00-00 ............ 6-00-00 ............ 6-00-02 ............ 6-00-03 ............ 6-00-03 ........... 6-00-03 ............ CHAPTER SECTION SUBJECT ......... 6-00-00 ........ 6-00-01.......... 6-00-02.......... 6-00-03.......... PAGE .......... DATE 1/2BLANK .......... 3 ........... 4 ........... 5 .......... 6 ........... 7 ........... 8 .......... 12-98 12-98 12-98 12-98 12-98 12-98 12-98 TABLE OF CONTENTS SUBJECT ........... Dimensions and Areas .......... Aircraft.Specification .......... Aircraft Dimensions .......... Aircraft Stations ........... 12-98 PAGE 3 3 5 6 6-EFF/CONTENTS 1/2BLANK MOONEY AIRCRAFT CORPORATION M20J SERVICE AND MAINTENANCE MANUAL 6-00-00 . 6-00-01 - AIRCRAFT SPECIFICATIONS EngineMfgr. EngineModel - DIMENSIONS AND AREAS ENGINE No. Cylinders Rated Horsepower RPM Min.Fuel Octane Fuel CapacityTotal TEXTRON-Lycoming IO-360-AIB6D or IO-360-A3B6D or IO-360-A3B6 4 200 @ Sea Level 2700 100/130 or 100 LL. 66.5 U.S. Gal. Useable 64.0 U.S. Gal 1 Oil Specification Oil GradeNiscosity- Above 60 Deg.F 30 to 90 Deg. F, 0 to 70 Deg. F. Oil Grade/Niscosity- Below 10 Deg. F. LycomingSpec. No. 301F Oil Capacity MinimumSafe Oil Level (251.8 Liters) (55.4 IMP Gal.) (242.4 Liters) (53.3 IMP Gal.) SAE 50 SAE 40 SAE 30 SAE 40 or 50 SAE 40 20W-40 SAE 20 W SAE 20W-30 8 qts 7,57 Liters (LEVEL FLIGHT ONLY) NOTE Approved Multiviscosity oil is recommended, especially during cold weather operations. INLET OIL TEMP @ AMBIENT AIR TEMP: 2 qts. _ MAXIMUM Above 60 Deg. F. 30to 90 Deg. F. 0 to 70 Deg. F. Below10 Deg. F. • Oil Pressure NormalOperation Idle,Minimum Max. Allowable (cold oil) Start & Warm up Cylinder Head Temperature (CHT) Max. Allowable Recm'd Cruise 180 Deg. F. 180 Deg, F. 170 Deg. F. 160 Deg. F. 245 245 225 210 Deg. F. Deg. F, Deg. F. Deg, F, 4750 F. 300 to 450° F. 246° C. 149 to 232° C. PROPELLER PropellerMfg. Type Model STANDARD McCauley ConstantSpee_d B2D34C214 _ OPTIONAL Hadzell (Optional) ConstantSpeed HC-C2YK-1BF 60-90 P.S.I. 25 P.S.I. 100 P.S.I. 1 First 50 hours of operation - mineral (non-detergent) oil or equivalent corresponding to MIL-L-6082. 2 REPLACEMENT FOR B2D34C212/78C DA-4 12-98 6-00-00 3 SERVICE AND MAINTENANCE MANUAL M20J MOONEY AIRCRAFT CORPORATION PROPELLER (con't.) STANDARD OPTIONAL Blade Pitch Angle (High) 90DHB-16E 33(+/-)9.5Deg, F7666A-3Q 29.3 Deg. to31.3 Deg. Pitch Angle (Low) Diameter @ 30 IN. STA,{ 13.9(+A) 0.2Dog. 74.0 In. Max/73 In. Min, McCauley(C290D5/T17) High- 27.5 (+/-) 0.2Dog, Low- 14.0(+/-) 0.2Deg. High-2g,5 (+/-) 0.5Deg.(Eft. after C/W S.B. #198) Governor 14.1(+/-) .1 Deg. 73 Inches McCauley AIRFRAME ._ A. Approximate EmptyWeight B. GrossWeight C. Useful Lead D. Wing Loading E. PowerLoading METRIC/OPT/MISC 1700 lb. 2740 Ib./2900 lb. * 1040 lb./1209olb.* 16.4 lb./sq,tl _/16.59 Ib./sq.ft* 13.7 Ib/hp114.5Ib./HP * 771 kg. 1243 kg./1315kg. * 473,.7 kg./544.3,_,g.* 76.58 kg/m=/81.02 Kg/m'* 6.22kg/HP/6.58 kg/HP* WINGS: A. Airfoil At Root B. Airfoil At Tip C. Mean Aerodynamic Chord @ Wing Sta. 93.83 D. CG Range E. Geometdc Twist (DEG) F. Incidence Angle (DEG) From Sta 20. to W_ngTip G. Dihedral angle (DEG) H. Aspect Ratio I. Taper Ratio (CS/CT) NAC632215 NAC641412 59.18 inches 13.4 to 28.7% -1.5 Degree * SIN 24-3201,24-3218 thru 24-TBA & 24-1686 thru 24-3200, 24-3202 thru 24-3217 when CANSL91-2 end MAC drawing 940071 is incorporated. 2.5 Degree 5.5 Degree 7.338 1.935 FUSELAGE: A. Cabin Dimensions: (1) Height (2) Width (3) Length (4) (5) Cabin Cabin Door Door Width Height 44 5" 43.5" 114" 29" 35" 113.03 cm 110.49 cm 289.56 cm 73.66 cm 88.9 cm 3 15,68 Ib/sq 11.(S/N 24-1038 thru 24-3200, 24-3202 thru24-3217) 6-00-00 4 12-98 f MOONEY AIRCRAFT CORPORATION VV'I'S& LOADINGS: (cont.) B. Baggage Compartment: (1) MAX. Loading (2) Baggage Space (3) Baggage Door Width (4) Baggage Door Height (5) Hat Rack Capacity C. Landing Gear. (1) Type (2) Operation (3) Wheel Track (4) Wheel Base (5) Tire Size-- Nose (6-Ply Rating (6) Tire Size-- Main (6-Ply Rating) (7) Tire Pressure,.-(8) Tire Pressure-6-00-02 M20J STANDARD SERVICE AND MAINTENANCE MANUAL . :_., . 120 Ibs 17.0 Cu. Ft. (24-0001 thin 24-3153) 15.3 Cu. Ft. (24-3154 thru 24,TBA) 54.43 kg 0.476 Cu. M. 17" 43.18 cm 20.5" 52.07 cm 10 lbs 4.54 kg Tdcycle Retractable Electrical 9' 2" 5'11 9116" 279.4 cm 181.73 cm 5.00 x 5 (TYPE III) 6.00 x 6 Nose - 49 Ibs/sq.in. Main - 30 Ibs/sq.in. (TYPE Ill) 36'1''4 10.998 meters 24'8" 8'4" 11'9" 7.52 meters 1.321 meters 3.581 meters 174.786 sq. Ft. 11.4 sq. It. 17.9 sq. It. 7.9 sq. It. 6.25 sq. ft. 16.238 sq. meters 1.059 sq. meters 1.663 sq. meters 0.725 sq. meters 0.518 sq. meters 21.5 sq. ft. 13.0 sq. It. 1.900 sq. meters 1.208 sq. meters 0.433 Cu. M - AIRCRAFT DIMENSIONS DIMENSIONS A. Wing Span B. Fuselage Length C. Tail Height D. StabilizerSpan AREAS: A. Wing B. Ailerons C. Flaps D. Vertical Fin E. Rudder F. Hodzontal Stabilizer G. Elevators 4 Prior to SIN 24-1038--35'0" 12-98 6-00-02 5 SERVICE AND MAINTENANCE 6-00-03 - AIRCRAFT MANUAL M20J MOONEY AIRCRAFT CORPORATION STATIONS (751.BcFO 24' 8 ° •= • (18 (254c_) I 5,1,9,16. I1,,,i..I _181'73_ I .-,i.. I h 11'9" (358,1cm) -_ I 36" 1" (1099.8cm) i 24--0001 Thru 24--3153 _I _ I 9' P" _ ( 279.4 cr_ ) PRINCIPAL AIRCRAFT 6-00-03 6 _ = 24-3154 Thru _/INGS TBA I _RAM AIR DELETED ON SIN 24-3154 THRU 24-TBA I DIMENSIONS - FIGURE 6-1 12-98 MOONEY AIRCRAFT CORPORATION STA 210,97 M20J STA 147,75 SERVICE AND MAINTENANCE MANUAL STA 103,50 STA 59,25 STA 24,50 193,50 FIGURE 6- 2 ST A 24-3000 THRU 24-3078 -- 5,3 7 5 STA 3,68 STA 199,50 STA 164,00 STA 130,00 STA 88,00 FUSELAGE STA 53,00 STA STA ;:'1,80 -5,00 STATIONS SMK-6-3 FUSELAGE STATIONS - FIGURE 6-3 NOTE The datum line station e.0 is 5 inches aft of the nose gear trunnion pivot point. (Reference Figure 8-1.) 12-98 6-00-03 7 SERVICE AND MAINTENANCE MANUAL STA G7,75 M20J STA 42,25 MOONEY AIRCRAFT CORPORATION STA 4,43 STA 42,25 STA 70,0 I STA 52,50 STA 25,75 STA 5,25 z_ EMPENNAGE STATIFINS SMK6-4 EMPENNAGE 6-00-03 8 STATIONS -FIGURE 6-4 12-98 MOONEY AIRCRAFT CORPORATION M20J SERVICE AND MAINTENANCE MANUAL CHAPTER 7 LIFTING AND SHORING SERVICEAND MAINTENANCEMANUAL M20J MOONEY AIRCRAFTCORPORATION CHAPTER7 MFTINGAND SHORING LISTOF EFFECTIVEPAGES CHAPTER SECTION SUBJECT ........... 7-Effectivity/Contents ....... 7-10-00 ............ 7-10-00 ....... CHAPTER SECTION SUBJECT ......... 7-10-00 ......... PAGE ......... 1/2BLANK .......... 3 4 DATE ....... ..... 12-98 12-98 12-98 TABLE OF CONTENTS SUBJECT ........ Jacking ....... 12-98 PAGE 3 7-EFF/CONTENTS 1/2BLANK MOONEY AIRCRAFT CORPORATION M20J SERVICE AND MAINTENANCE MANUAL 7-10-00 -JACKING When it is necessary to raise the aircraft off the ground: CAUTION Do not raise the aircraft on jacks out of doors when wind velocity is over 10 MPH. Jacks should be on hard surface, CAUTION Do not place jack directly on propeller de-icing boots. Cushion with a layer of 3/8 inch thick hard rubber or equivalent, 4. Raise aircraft, keeping wings as nearly level as possible. 5. Secure safety lockson eachjack. CAUTION When lowering aircraft on jacks, bleed off pressure on all jacks simultaneously and evenly to keep aircraft level as it is lowered. CAUTION Individual wheels may be raised without raising the entire aircraft. Wheels not being raised should be chocked fore and aft. 1. Install jack points in fiedown mounting holes outboard of each main gear. 2. Use standardaircraft jacks at both wing hoist points (wing tiedown eyebolt receptacles) outboard of the main gears. While holding jack point in place, raise jack to firmlycontactjack point. 3. Use a yoke-flame jack under propeller to lift the nose. NOTE It is not recommendedto use tail-tie down fitting during jacking process to lift nose wheel off ground. CAUTION Do not leave aircraft on jacks for extended periods of time with a tail stand in place. The wing jack may bleed down, putting excessive loads on the front jack point and tail cone. 12-98 7-1O-00 3 SERVICE AND MAINTENANCE MANUAL M20J MOONEY AIRCRAFT CORPORATION / BLANK 7-10-00 4 12-98 MOONEY AIRCRAFT CORPORATION M20J SERVICE AND MAINTENANCE MANUAL CHAPTER 8 LEVELING AND WEIGHING SERVICEAND MAINTENANCEMANUAL M20J MOONEY AIRCRAFTCORPORATION CHAPTER8 LEVELINGAND WEIGHING UST OF EFFECTIVEPAGES CHAPTER SECTION SUBJECT ........... 8-Effectivity/Contents ....... 8-00-00 i • * 8-00-01 PAGE ........ , • i 1/2BLANK ........... 3 • • * 4 ............ DATE • • • • , • , o 12-98 12-98 12-98 TABLEOF CONTENTS CHAPTER SECTION SUBJECT .......... 8-00-00 ....... 8-00-01 ....... SUBJECT Leveling ............ Weight and Balance....... 12-98 PAGE 3 3 8-EFF/CONTENTS 1/2BLANK MOONEY AIRCRAFT CORPORATION 8-00-00 M20J - LEVELING Placea spiritlevel onaccess the skindoor spliceor levelingscrews above the tailcone when leveling the aircraft longitudinally.Level the aircraft by increasingor decreasingair pressurein the nosewheel tire. Level aircraft laterally (wing tip to wing tip by placing Spirit.Level oncenterseattracksin frontofspar, Front seats must be in the full forward position when weighing.(Use skin splice SIN 24-0001 thru 24-0083, 24-0085 thru 24-0900 and leveling screws SIN 24-0084, 24-0901 & ON.) (See FIGURE 8-1) 8-00-81 SERVICE AND MAINTENANCE MANUAL 8. Find reference point by dropping a plumb-bob from center of nosegear trunion(retractingpivotaxis) to the floor. Markthe pointof intersection. 9. Locate centerline of the main wheel axles in the same manner. 10. Measurethe horizontaldistancefrom the reference point to main wheel axle center line. Measure horizontaldistancefrom center line of nose wheel axle to centerlineof mainwheel axles. - WEIGHT AND BALANCE To weigh the aircraft select a level and draft free work area, then: 1. Checkfor installationof all equipmentas listedin the Weightand BalanceRecord. 2. Ground aircraft and drain fuel tanks per Section 12-10-02, 2. 3. Add unusable fuel to each tank, (see applicable P'lot'sOperat ng Handbook for a rcraft be'ng serv=ced for properquantityof unusablefuel). 4. Fill oilto capacity(8 quarts). 5. Position a 2000-pound capacityscale undereach of the three wheels. 6. Level aircraft as described in Section 8-00-00 and centernose wheel. 7. Weigh the aircraft. 12-98 8-00-00 3 SERVICE AND MAINTENANCE MANUAL M20J MOONEY AIRCRAFT CORPORATION 11. Record weights and measurements and compute basic weight and CG as follows: Lc/G = LM/R- 5 - LM _ a. CG Forward of Main Wheels LBS Weight of Nose X (WN) b. CG Aft of Datum (Station0). IN. -Distancefrom Center Nose Gear Tmnion to Center of Main Wheel Axles (Hodzontal) (LM/R) IN. -:DistanceBetween Main and Nose Wheel Axle Centers (LM/N) 5 IN. Distancefrom Nose Gear Trunion to Datum -- LBS. Total Weight of Aircraft N. CG Forwardof Main Wheels (Wr) (LM) IN. Resultof Computation Above (a.) CONSTANT = (LM) = IN. CG (FUS STA) Distance Aft of Datum (Empty Weig.ht CG) (LC/G) NOTE: Empty weight includes unusable fuel and full oil and is computed with gear down and flaps up. REF,PDINT (NOSE GEAR TRUNNION REFERENCE ]]ATUM(STA,0) LEVEL REF, (SKIN SPLICE DR STA,_-5) __ II I"--LCC LM L" -'-'----,." LM/R _ LM/N WN WR _a/L __ _ MEASUREMENTS LM/R INCHES LM/N INCHES WEIGHT AND BALANCE DIAGRAM - FIGURE 8-1 8-00-01 4 12-98 MOONEY AIRCRAFT CORPORATION M20J SERVICE AND MAINTENANCE MANUAL CHAPTER 9 TOWING AND TAXIING SERVICEAND MAINTENANCEMANUAL M20J MOONEY AIRCRAFTCORPORATION CHAPTER9 TOWING AND TAXIING LIST OF EFFECTIVEPAGES CHAPTER SECTION SUBJECT .......... 9-Effestivity/Contents 9-00-00 9-30--00 CHAPTER SECTION SUBJECT ........... 9-00-00 ....... 9-10-00 .......... 9-20-00 .......... 9-30-00 ...... PAGE ....... ....... ...... DATE 1/2BLANK .......... 8 ........ 4 12-98 12-98 12-98 TABLE OF CONTENTS SUBJECT Ground Handling .......... Towing ........... Warmup and Taxiing......... Emergency Procedures ...... 12-98 ...... PAGE 3 3 3 3 9-EFF/CONTENTS I/2BLANK MOONEY AIRCRAFT CORPORATION 9-00-00 - GROUND HANDLING 9-10-00 -TOWING M20J SERVICE AND MAINTENANCE MANUAL 9-30-00 - EMERGENCY PROCEDURES 1. Engine Fire During Starting. Use a towbar for moving the aircraft. The towbar attaches to the nose gear crossbar. One man can move the aircraft providing the ground surface is relatively smooth and the tires are properlyinflated. When no towbar is available, or when assistance in movingthe aircraft is required, push by hand: (1) on the wing leadingedges, and (2) on the inboardportion of propeller blades adjacent to the propeller hub. Towing by tractor or other powered equipmentis not recommended. CAUTION Exercise care nottoturn the nose wheel past its normal swivel angle of 14 degrees either side center. Exceeding thecause turn limits shown onof the turn indicator may structural damage. Maximum allowable damage to nose gear leg assembly is 1132inch dent. 9-20-00 - WARMUP AND TAXIING Before attempting to warmup or taxi the aircraft, ground personnelshould be checked out by qualified pilotsor otherresponsiblepersonnel, 1. Start and warmup engine. (Refer to Pilots OperatingHandbook) 2. Taxi forward a few feet and check brake effectiveness, 3. While taxiing, make shallow turns to test nose gear steering. 4. Check operation of gyro instruments and turn coordinatorduringturns. 5. Checkengineinstrumentsfor sluggishresponseto enginecontrolmovements. A, Continuecrankingenginewith starter, B, Set mixturecontrolat IDLE, CUTOFF. C. Turn fuel selector handleto OFF. D. Open throttleto FULL. E. Turn MASTER switchOFF. F. Pushcabinheat controlto OFF. G. Closecowlflaps. H. If fire is not extinguished,proceed as follows: (1) Turn electricalswitchesOFF. (2) Discharge fire extinguisher into engine compartment throughnose cowlopeningsand through cowlflap openings. (3) Callfor fire-fightingequipment. 2. Fuselage or Wheel Well Fire. In case of fire in wheel well (or in the cabin or fuselage area), turn all fuel, electrical,and ignitioncontrolsto the OFF position beforeevacuatingthe aircraftto extinguishthe flames. 3. Electrical Fire. Circuit breakers (or circuit-breaker switches),that automaticallyinterruptthe flowof power when an overload or short circuit occurs, protect all electrical circuits(exceptthe ignition-startercircuits).In the event of an electricalfire, immediatelyturn off the master/alternator field switch. Make sure that only a fire extinguisherapproved for electricalfires is used. 12-98 9-00-00 3 SERVICE AND MAINTENANCE MANUAL M20J BLANK 9-30-00 4 12-98 MOONEY AIRCRAFT CORPORATION MOONEY AIRCRAFT CORPORATION M20J SERVICE AND MAINTENANCE MANUAL CHAPTER 10 PARKING AND MOORING SERVICEAND MAINTENANCEMANUAL M20J MOONEY AIRCRAFTCORPORATION CHAPTER10 PARKINGAND MOORING UST OF EFFECTIVEPAGES CHAPTER SECTION SUBJECT ......... lO-Effectivity/Contents....... 10-00-00 ............ 10-10-03 ........... PAGE ........... DATE 1/2 BLANK .......... 8 .......... 4 ........... 12-98 12-98 12-98 TABLE OF CONTENTS CHAPTER SECTION SUBJECT ..... 10-00-00 ..... 10-10-00 ..... 10-10-01 ......... 10-10-02 ......... 10-10-03 ......... 10-20-00 ........ SUBJECT ...... General........... Parking............... Storage (Flyable)........... Storage (Prolonged) .......... Returnto Service........... Mooring ............. 12-98 PAGE 3 3 3 3 4 4 IO-EFF/CONTENTS 1/2BLANK MOONEY AIRCRAFT CORPORATION 10-00-00 M20J - GENERAL SERVICE AND MAINTENANCE MANUAL 10-10-02 - STORAGE (PROLONGED) The parkingbrakes are set by applyingthe brakes and pulling out on the parking brake knob. Release the brakes by pushing in on the parking brake control if the aircraftis to be stored for an extended period of time, the following steps are recommended for protection: knob. 1. Refer to paragraph 10-20-00 for mooring instructions. 2. Run engine (minimum of 15 minutes at 1500 RPM) until oil temperature reaches normal operating range, NOTE There is no need to depress the brake pedals to relieve the pressure in the lines during release of parking brake control, There are three tiedown points on the aircraft, one on each wing outboard of main gear (fledown rings are to be threaded into built in receptacles) and the tail skid/Uedownfitting onthe aft end ofthetailcone. 10-10-00 3. Drain engine oil sump and refillthe sump with a preserative oil (Socony Aurex 901 or equivlent) preheated between 200 and 220 degrees F. 4. Start engine and run at 1000 RPM for five minutes. - PARKING 5. Shut engine downand remove spark plugs. When parkingthe aircraft, placewheel chocks fore and aft of the main wheels. The parking brakes may be usedfor short-durationparking. 6. While motodng engine with starter, spray each cylinder(throughspark plug holes)with approximately 2 oz. of hot preservativeoil. CAUTION Do not set parking brakes when they are overheated or slush when accumulation cold weather could moisture and in the freeze brake CAUTION Do not exceed starter operating limits when motoring engine. mechanism. Do not set parking brakes when aircraft down. For maximum protection, hangar is thetied aircraft during severe weather and high winds, 7. When all cylindershave been sprayed, position propellerhorizontallyand resprayeach cylinderwithout movingpropeller. 8. Attach a warningtag to one of the blades stating that propelleris notto be rotated. 10-10-01 - STORAGE (FLYABLE) Outdoor storage requires adequate moodng and tiedown facilities. The following precautionary measures are recommended for keeping the aircraft serviceable and ready-to-fly. 1. Refer to instructions, paragraph 10-20-00 for mooring 2. Maintain an propellerthrough. oil film on internal pads, frequentlypullthe Runengine enginefor 15 minutes at 1500 RPM (or until oil temperature normalizes)once every seven days. 3. After engine run, pressurize the fuel system (turn electric fuel boost pump on) push mixture controlto R CH, and open throttle half way to fill the fuel injector with fuel. 4. Keep fuel tanks filled at least one-half full to minimize moisture condensation. Keep battery fully charged, 9. Installdehydratorplugsin spark plugholes. 10.Cap ignitionharnessleads. 11.Drainpreservativeoilfrom sump. 12.Attach a warning tag to the throttle control in cockpitstatingthat engine has no lubdcatingoil. 13.Drainall fuel from fuel injecto[;then, pumpoil into the fuel injector at five PSI untilinjector is full; do not drain the injectoralter flushing. 14.Lubricate aircra_ in accordancewith instructions givenin the LubricationGuide. 15.Tape or coverallopenings. 16.Remove battery, charge fully, and store in a cool place. 17.Raise aircraft to remove weight from the tires, and block up the wheels. 5. Install protective covers over pitot head, engine cowl openings,staticports,etc. CAUTION If weight is not removed from tires, rotate wheels to a new position at least once each 30 days to prevent fiat-spotting the tires. 6. Maintain a good wax finishon all exterior surfaces, 18. See appropdate TEXTRON-LYCOMING Service Bulletin for engine preservation. Attach warning placards if preservation procedures make engine inoperable. 12-98 10-00-00 3 SERVICE AND MAINTENANCE MANUAL 10-10-03 M20J MOONEY AIRCRAFT CORPORATION -RETURNING TO SERVICE 14. Check fuel tank vents for obstruction,and drain If the aircraft has been storedfor an extended period of time, it is advisable to perform a 50-hour periodic inspectionalter completionof the following preliminary steps: t. Remove blocksfrom wheels. Check tire inflation. 2. Check and install battery. sumpsto removemoistureand sediment. 15. Complete50-hour and preflightinspections. 16. See appropriateTEXTRON-Lycoming Service Bulletinfor servicingof the engine. 10-20-00 - MOORING When mooringthe aircraftout of doors: 3. Remove tape and coversfrom openings. 4. Remove warningplacards (if any). 1. Head aircraftintothe wind. 2. Place chocksfore and alt of each mainwheel. 5. Replace engineei[filter. 6. Clean engine oilsuctionand pressurescreens, 7. Clean and checkoil pressurerelief valve. 3. Driveofstakes ground outboard each inmain gearapproximatelythree and to either sidefeet of tailskid. 4. Installtiedown rings in wing receptaclesoutboard 8. Clean and check oil temperaturebypass valve, 9. Fill engine sump with proper grade of lubricating oil. 10. Clean and reinstall engine air-inlet filter, 11. Check ignition hamess. 12. Remove dehydrator plugs and install spark plugs, 13. Check and clean fuel injector nozzles and screens. Drain oil from fuel injector, 10-10-03 4 of each mainwing gear.tiedown Tie a 600-pound tensiletostrength rope to each ring and anchor ground stake.Allowa littleslackin eachtiedown rope. 5. Tie the center of a rope to tail skid tiedown ring and anchor rope ends to ground stakes at either side oftaU. 6. For additional security, attach a rope to the nose gear and anchor to a ground stake. 7. Lock controls by looping right front seat safety belt through the control wheel and drawing belt snug. 12-98 MOONEY AIRCRAFT CORPORATION M20J SERVICE AND MAINTENANCE MANUAL CHAPTER 11 ! PLACARDS AND MARKINGS SERVICE AND MAINTENANCE MANUAL M20J MOONEY AIRCRAFT CORPORATION CHAPTER 11 PLACARDS AND MARKINGS LIST OF EFFECTIVE PAGES CHAPTER BEC'IION SUBJECT ........... 11-Effect./Contents ........ 11-00-00 ............ 11-20/30-00 ........... PAGE .......... DATE 1/2BLANK .......... 3 ........... 4 ........... 12-98 12-98 12-98 TABLE OF CONTENTS CHAPTER SECTION SUBJECT ........... 11-00-00 ........ 11-10-00 ......... 11-20/30-00 ........ SUBJECT ........ General .............. Markings ............. Placards,Exterior/Interior. 12-98 ........ PAGE 3 3 3 11-EFF/CONTENTS 1/2BLANK MOONEY AIRCRAFT CORPORATION 11-00-00 M20J - GENERAL FAA requiredplacardsand markings. NOTE All placards should be inspected for proper location readability and security during ma ntenance actions, When an airplane has been painted inspect all placards to assure that they are not obscured by paint. SERVICE AND MAINTENANCE MANUAL 11-19-00 - MARKINGS The exteriorpaint schemes for the various model year aircraft are depicted in the M20J Illustrated Parts Catalog. 11-20/30-00 - PLACARDS, EXTERIOR/INTERIOR All requiredplacards and their locations,both interior and exterior, are listed in Section II of the FAA Approved Flight Manual and Pilot's Operating Handbook. 12-98 11-00-00 3 SERVICE AND MAINTENANCE MANUAL M20J BLANK 11-20/30-00 4 12-98 MOONEY AIRCRAFT CORPORATION MOONEY AIRCRAFT CORPORATION M20J CHAPTER 12 SERVICING SERVICE AND MAINTENANCE MANUAL SERVICE AND MAINTENANCE MANUAL M20J MOONEY AIRCRAFT CORPORATION CHAPTER 12 SERVICING LIST OF EFFECTIVE PAGES CHAPTER SECTION SUBJECT ........... 12-Eff./Contents 12-00-00 ............ 12-10-04 ............ 12-20-00 ............ 12-20-05 ............ 12-20-06 ............ 12-20-06 ............ PAGE ........ .......... DATE 1/2BLANK .......... 3............ 4............ 5............ 6 ........... 7 ............ 8............ 12-98 8-93 5-93 5-93 12-98 5-93 5-93 TABLE OF CONTENTS CHAPTER SECTION SUBJECT ........... 12-00-00 ........ 12-00-01 ......... 12-10-00 12-10-01 .......... 12-10-02 .......... 12-10-03 .......... 12-10-04 .......... 12-20-00 ........ 12-20-01 ......... 12-20-02 12-20-03 ......... 12-20-04 ......... 12-20-05 ......... 12-20-06 ......... SUBJECT ...... ...... ........ Servicing .............. Servicing Intervals .......... Replenishing ............ Fuel Tanks ........... Fuel Drains ........... Engine Oil ........... Oxygen System .......... Scheduled Servicing ........... Induction Air Filter .......... Battery ............. Tires & Wheels ........... Brake Reservoir ........... Hydraulic Brake ........... Cleaning ............. 12-98 PAGE 3 3 3 3 3 3 4 5 5 5 5 5 6 6 12-EFF/CONTENTS 1/2BLANK MOONEY AIRCRAFT CORPORATION - 12-00-00 -SERVICING 12-00-01 - SERVICING INTERVALS M20J SERVICE AND MAINTENANCE MANUAL C. After draining, be sure fuel drain valve control is returned to the closed position and the valve is not leaking outsidethe aircraft. The specified intervals (refer to Chapter 5) are considered adequate to meet average requirements under normal operating conditions. It is advisable, however, to shortenserviceand maintenanceintervals when operating under abnormal environmental conditions,suchas extreme temperature ranges, dusty atmospheric conditions, high humidity and moisture, unimproved airport facilities, or unusual operating requirements, 12-10-00 NOTE Isopropyl Alcohol may be added to fuel tanks. It is extremely important to thoroughly BLEND the isopropyl alcohol in with the fuel supply in quantities not to exceed 1% of the total by volume. - REPLENISHING 12-10-01 -FUEL TANKS Keep fuel tanks at least half filled to minimize condensation and moisture accumulation in tanks. (Fuel capacityis given in SECTION 6.) WARNING Ground the aircraft and fuel service vehicle. Groundor servicing nozzle to wing. Permit no smoking open flame within 50 feet of aircraft or vehicle. 2. Dafueling. Fuel tanks may be drained by pumping fuel out with the electric fuel boost pump, siphoning fuel through the filler ports, or removing tank quick drainvalves. WARNING Allow no smoking or open flame within 50 feet of the defueling area. Ground the aircraft and fuel container during all defueling operations. A. To defuelthe aircraftusingfuel boostpump: (1) Disconnectfuel line from electric boost pump outlet atthe f'_ng forward ofthe firewall. WARNING Each fuel tank is vented to the atmosphere at its outboard aft corner; vent openings are on the lower wing surface. Check vents for obstruction before each flight, 12-10-02 WARNING During cold weather operation, frequently check fuel selector drain for ice formation by repeating procedures 1., A, B and C above. (2) Connectto outputfittinga flexible linethatwill reach fuel receptacle. (3) Turn fuel selector valve to the tank to be drained, and remove filler capfrom fuel fillerport. - FUEL DRAINS A fuel-drain valve is located in the aft inboardcomer of each tank to provide for drainage of moisture and sediment. Use the small plasticcup furnishedwith the flyaway kitto drain the fuel sumps. Drainwing tank and selector valvesumpsor gascolatorbeforethe firstflight of the day and after each fuel service to inspect for water and/ororcontamination. free of water contamination.Continue draining until (4) Tum on fuel boost pump untiltank is empty. Repeat steps(3) and (4)to drain other tank. (5) To completelydrain fuel system also drain wing sumps and the fuel gascolator valve sump until fuel stopsrunning. NOTE When defuefing using removable tank quick drains it is only necessary to remove the drains and to operate the gascolator drain. NOTE SIN 24-0378 & ON. The gascolator (fuel drain) is separate from the fuel selector. The fuel selector is located aft of the console on the floor and the gascolator is located to the left of the fuel selector. Separation of the gascolator and the selector does not change fuel drain procedures. WARNING After servicing the aircraft with fuel, wait at least five minutes for moisture and sediment to settle before draining and checking both the fuel tank sumps and the fuel selector valve drain, 1. Fuel Selector Drain. The fuel gascolator is at the lowest point in the fuel system and has a drain valve operated by a controlon the floor in the cabin.To drain the fuel selactorvalve: A. Switch fuel selector valve handleto L and pull fuel drain valve controlringfor 10 seconds, B. Switch fuel selector valve handle to R and pull fuel drain valve controldng for 10 seconds, 12-10-03 -ENGINE OIL Check engine oil level after engine has been stopped long enough for oil to drain back into sump. The oil fillercap accessdoor is locatedin the top cowling.Any lubricating oil, either straight mineral (MIL-L-6082) or compounded(TEXTRON LycomingSpec. No. 301F) or MIL-L-22851are acceptable for use after break-in period. Approved products and engine oil viscosity requirementsare shown in Chapter 5-20-07. 12-98 12-00-00 3 SERVICE AND MAINTENANCE MANUAL M20J CAUTION The terms "detergent", "additive", and "compounded" used in this manual are intended to refer to a class of aviation engine lubricating oils to which certain substances have been added to improve them for aircraft use. These terms do not refer to such materials commonly known as "top cylinder lubricant", "dopes" and "carbon remover" which are sometimes added to fuel or oil. These products may damage the engine and therefore, should not be used. Under no circumstances should automotive oil be used, since such oils could cause engine damage. MOONEY AIRCRAFT CORPORATION When changing from straight mineral oil to additive or compounded oil, after several hundred hours of operation on straight mineral oil, take the following precautionarysteps: 1. Do not mix additive oil and straight mineral oil. Drain straightmineraloilfrom engine, changefilterand fillwith additiveoil. 2. Do not operate engine longer than five hours beforeagainchangingoil. 3. Check oilfilterfor evidence of sludge. Change oil and replace oil filter element every 10 HOURS if sludgeis evident. Resume normal oil drain periodsafter sludgeconditionsimprove. Oil Recommendations for New-Engine or Newly Overhauled Engine Break-In. New or newly overhauledengines should be operated on aviationgrade straight mineral oil during the first 50 hours of operation or until oil consumption has stabilized.The aircraft is delivered from Mooney with • i_roperbreak-in oil (MIL-L-6082) or SAE 20W-50 Type OIL CHANGING RECOMMENDATIONS. The oil sump is equipped with a quick drain fitting.On aircraft equippedwith either an internalor external oil filter, the recommended engine oil change intervals is at 50-HOUR FLIGHT OPERATION INTERVALS• If an enginehas been operating on straight mineral oil for several hundred hours, a change to additive oil shouldbe undertaken with caution. If the engine is in an extremely dirty condition,the switchto additive oil should be deferred until after engine has been overhauled, NOTE During periods of prolonged operation in dusty areas or in cold climates, or when flights have been of short duration with prolonged idling time, change oil and filter element each 25 HOURS, or morewarrant. often when conditions 12-10-04 - OXYGEN SYSTEM (OPTIONAL) The oxygen cylinder, when fully charged, contains approximately 76 cubic feet of aviators breathing oxygen (SpecificationsNo. MIL-O-27210). Recharging of this oxygen cylinder should be accomplished by using the appropriate Scott rechargingfittings to the pressure shown on (Figure 12-1), Pressure vs. Temperature Table. : WARNING Oil, grease or other lubricants in contact with oxygen create a serious fire hazard, and such contact must be avoided when handling oxygen equipment. AMBIENT TEMPERATURE DEGREES F FILLING PRESSURE PSIG AMBIENT TEMPERATURE DEGREES F FILLING PRESSURE PSIG O 10 20 30 40 1650 1700 1725 1775 1825 50 60 70 80 90 1875 1925 1975 2000 2050 OXYGEN PRESSURE VS TEMPERATURE TABLE FIGURE 12-1 12-10-04 4 12-98 MOONEY AIRCRAFT CORPORATION M20J NOTE The oxygen cylinder should not be run down to less than 100 p.s.i. Below this pressure atmospheric contamination of the cylinder may occur, requiring valve removal and cylinder cleaning and inspection at an FAA approved repair stations, 9. Reinstall filler in aircrafl making sure of proper sealingand secodty. t 2-20-02 - BATrERY Service the battery with distilled water to maintain electrolyteabove plates.After adding water in freezing weather, chargebattery long enoughto mix electrolyte and water. Keep battery electrolyte above a specific gravity of 1.225 to avoid freezing. To service the battery: NOTE Refer to Section 35-00-00 for periodic bottle pressure check,Any time fittings are disconnected on the oxygen system the threads should be treated with tetrafluoroethylene tape (MIL-T-17720). Prior to reconnection the system should be checked for leaks with leak testing compound (MIL-L-25567). if no leaks are found wipe the system clean and dry. 12-20-00 SERVICE AND MAINTENANCE MANUAL 1. Remove battery box cover. Check electrolyteand service battery as required. CAUTION Battery gases may be explosive. . SCHEDULED SERVICING 12-20-01 -INDUCTION AIR FILTER The importanceof keeping the inductionair filterclean cannotbe overemphasized. A clean filter promotesfuel economyand longer engine life. The dry-typefilter can usuallybe washed six to eight times within 500 hours or one yearbefore replacement is necessary, To clean the dry-type induction air filter:, 1. Remove filter element, 2. Direct a jet of air against down or clean side of filter (opposite to normal airflow). Keep air nozzle at least two inches from filter element. Cover entire filter area withairjet. CAUTION Do not usa a compressor unit with a nozzle pressure greater than 100 p.s.i. 3. After cleaning, inspect filter and gasket for damage. Discard a rupturedfilter or brokengasket. 2. Check battery box for corrosion and spl[led electrolyte.To cleancables,terminals, and batterybox, use a solutionof bicarbonateof soda and clean water to neutralizecorrosionand spilledelectrolyte. CAUTION When cleaning, do not allow bicarbonate of soda to enter battery cells - permanent damage will result if soda mixes with electrolyte. 3. Rinse battery with clean water, and wipe clean with a dry cloth. 4, To retard corrosion, coat terminals with petroleum jelly a_er cleaning and tightening them. 5. Check battery ram air and vent for obstruction, line kinks, etc. 12-20-03 - TIRES AND WHEELS Keep the tires at recommendedair pressure. (Refer to Chapter6-00-01. 1. Checktires for wear, cuts,and bruises. 2. Checkvalve stems for evidence of tire slippageor pulling. 3. Check wheelsfor damage. NOTE If filter shows an accumulation of carbon, soot, or oil, continue with cleaning steps 4 through 7. 4. Check wheel bearings for condition and lubrication. 12-20-04 - BRAKE RESERVOIR 4. Soak filter in nonsudsing detergent for 15 minutes; then agitate filter back and forth for two to five minutes to free filter element of deposits. 5. Rinse filter element with a stream of clean water until rinse water is clean. Frequently check the brake reservoir for proper fluid level. See Chapter 12-20-05 for locations. CAUTION Do not fill reservoir while parking brake is set. 6. Dry filter thoroughly. Do not use light or air above 180 deg. F. for filter drying, 7. Inspect for damage or ruptures by holding before a light. If damage is evident, replace filter with new one. 8. Check induction air door through lower front cowling opening for good working order, and check alternate air door inside the lower cowling at the induction air box for proper operation, The alternate air should just start to open when a force of 3-4 pounds is applied. Use only hydraulic fluid (red), per specification MIL-H-5606. Do not fill reservoir above two inches belowfiller port. 12-98 : 12-20-00 5 SERVICE AND MAINTENANCE MANUAL M20J 12-20-05 - HYDRAULIC BRAKE (Bleeding) CAUTION Fluid in the wheel cylinders may be under high pressure due to expansion. Therefore, be sure parking brakes are released prior to beginning hydraulic system servicing. For best results, use a hydraulic pressure service unit (pressure pot) to back bleed the system through the wheel cylinderbleedervalves. Allow pressurizedpot to set 10-12 hours to dissapate air from fluid pdor to bleedingbrake lines. 1. Remove hydraulic fluid reservoir filler plug, and installa suitable fittingfor attachinga flexibledrain line to the reservoirfiller port. 2. Immerse open end of drain line in a hydraulicfluid container, 3. Attach pressudzed hydraulic fluid service unit to wheel cylinder bleeder valve and open valve. On aircraft with dual brakes and shuttle valves, depress _ilot's brake pedals to reposition shuttle valve while eing bled. Fluid in hydraulicservice unitshould be free of air pdor to servicingaircraft system. 4. Feed fluid from service unit into brake system, Check for air bubbles at end of drain line immersed in fluid. On aircraft with dual brakes, depress co-pilot's brake pedals to repositionbrake shuttle valve, then proceedwithbleedingthis side. 5. When fluidflow is clear of air bubbles,close wheel cylinderbleedervalve and remove serviceline. NOTE Brake pedal may need to be pulled back in order for fluid to bleed back into reservoir, 6. To bleed oppositebrake, repeat steps3 through 5. 7. Remove drain line from reservoir, 8. Lower fluid level in reservoirto two inches below fillerport. 9. Reinstallfiller plug. 10. Check brake linings for excessive wear and properinstallation.Refer to Section32-40-04 for Brake Removaland inspectionProcedures. 11. Depress brake pedals to check for sponginess, Resistance should be solid and even when brake pedalsare depressed, 12-20-06 B. Flush away loosedirt and mud. C. Wash exterior with a mild aircraft detergent in coolwater, and a soft cleaning cloth or chamois.Rinse away soapfilm. CAUTION Do not use so called "mild" household detergents to wash aircraft exterior. Such detergents may damage finish and corrode aluminum components. CAUTION Do not apply wax or use pre-wax cleaners during initial paint curing period. Use only mild aircraft detergent and cool water when washing exterior during the first 90 days after repainting. D. To remove heavy oxidationfilm, use a pre-wax cleaner. E. Apply an exterior-finishwax recommended for protectionof urethaneenamel. Apply a heavy coating of wax to leading edges of wings, empennage, and nose sectionto reducedrag and abrasion. CAUTION When fuel, hydraulic fluid, or other fluid Containing dye is spilled on painted surfaces, remove it at once to prevent staining. Flush away spilled battery electrolyte immediately with water. Treat the area with bicarbonate of soda solution followed by thorough washing with a mild aircraft detergent solution. 2. WINDSHIELDS, WINDOWS AND DOORS A. Flush windshield and windows with water pdor to wiping. Never wipe while dry. B. Remove grease or oil with a soft clothsaturated in kerosene. CAUTION Never use gasoline, benezene, carbon tetrachloride, acetone, fire extinguisher fluid, de-icer fluid, lacquer thinner, or household window cleaning sprays on windows or windshields. Such solvents will soften or craze the plexiglas surface. C. Clean windows and windshields with an antistaticplexiglascleaner. D. Check door seals for damage that could cause leakage. E. Check cabin and baggage door mechanism for goodworkingorder. - CLEANING NOTE Minor scratches or abrasions may be polished out by using plexiglas resurfacing kits, ie, Micro-Mesh, available from aircraft accessory suppliers. 3. ENGINE COMPARTMENT Cleanliness is a major prerequisite to adequate inspectionand maintenance of an aircraft. Cleanliness enhances the appearance of an aircraft and reduces the probabilityof corrosion. 1. EXTERIOR A. Before washing aircraft exterior, cover brake discs, pitot head, and static ports, 12-20-05 6 MOONEY AIRCRAFT CORPORATION Accumulation of dirt and oil within the engine compartment creates a fire hazard and hampers inspection. 12-98 MOONEY AIRCRAFT CORPORATION M20J A, Wash down engine cowling and engine compartmentusinga nonflammablesolvent. B. Dry engine cowling and engine compartment afterwashing, 4. CABIN INTERIOR Use normal household cleaning practices for routine interiorcare. A. Frequently vacuum seats, rugs, upholstery panels,and headlinersto remove surfacedust and dirt. B. Clean leather or vinyl upholstery and panels with a mild aircraftdetergent. Clean with a slight damp cloth,and dry with a softcloth. NOTE Foam-type shampoos and cleaners for vinyl, leather, and plastic materials can be used to remove stains and to condition the entire interior. Spray-on dry cleaners are also recommended. 12-98 SERVICE AND MAINTENANCE MANUAL CAUTION Never apply furniture polish to interior furnishings. Most poslishes contain solvents harmful to vinyl. Do not use alcohol or strong solvents on interior plastics. When using commercial cleaning and finishing compounds, carefully follow the manufacturer's instructions. Never saturate fabrics with solution which could damage the backing and padding materials. To minimize wetting of carpets, keep foam as dry as possible and rub in circles. Use a vacuum cleaner to remove foam. Do not allow carpets to remain damp; dry them thoroughly. 12-20-06 7 SERVICE AND MAINTENANCE MANUAL M2OJ BLANK 12-20-06 8 12-98 MOONEY AIRCRAFT CORPORATION MOONEY AIRCRAFT CORPORATION M20J SERVICE AND MAINTENANCE MANUAL CHAPTER 20 STANDARD PRACTICES - AIRFRAME SERVICE AND MAINTENANCE MANUAL M20J MOONEY AIRCRAFT CORPORATION CHAPTER 2O STANDARD PRACTICES - AIRFRAME LIST OF EFFECTIVE PAGES CHAPTER SECTION SUBJECT ........... 20-Eft/Contents......... 20-00-00 ............ 20-00-01 ............ 20-00-02 ............ 20-00-02 ............ 20-00-03 ............ 20-00-03 ............ PAGE .......... DATE 1/2BLANK .......... 3 ........... 4 ........... 5 ........... 6 ........... 7 .......... 8 .......... 12-98 12-98 12-98 12-98 12-98 12-98 12-98 TABLE OF CONTENTS CHAPTER SECTION SUBJECT ........... 20-00-00 ........ 20-00-01 ......... 20-00-02 ......... 20-00-03 ......... SUBJECT ........ General .............. Skin Specifications .......... CorrosionDetectionand Prevention...... Painting ............. 12-98 PAGE 3 3 5 7 2O-EFF/CONTENTS 1/2BLANK MOONEY AIRCRAFT CORPORATION M20J SERVICE AND MAINTENANCE MANUAL 20-00-00 - GENERAL This chapter of the manual discusses treatment of metal surfaces for corrosion control and the identificationof skin panels for replacement purposes, Those who inspect or repair aircraft should consult FAR 43, Maintenance, Preventive Maintenance, 20-00-01 - SKIN SPECIFICATIONS STA 210,97 STA 193,50 Rebuildingand Alterationand Sub PartsA, D and E of FAR 65, Certification. Advisory Circular 43.13-1(*) outlines inspectionand repair practicesacceptableto the F.A.A. Administrator. Torque valuesare shown in SECTION 5-20-01. NOTE Refer to FAA AC 43.4 for CORROSION TREATMENT. (* = currentrevision) STA 147,75 STA 103,50 STA 59,25 4 3 STA 24.50 2 6" 7 19 13 8 12 17 ii 10 16 14 9 WING SKIN PANELS iNDEX NO.. SKiN THICKNESS 1. 2. 3. 0.063 0.050 0.040 5. 6. 7. 8. 9. 10. 11. 0.025 0.025 0.032 0.040 0.025 0.025 0.025 4. 0.032 MATERIAL ......... ..... $M2o-1 INDEX. NO.. SKiN THICKNI_SS MATERIAL 2024 T-3 CLAD . 2024 T-3 CLAD .... 2024 T-3 CLAD .... 12. 13. 14. 0.025 (o) 0.020 (a) 0.032 __ 2024 T-3 CLAD 2024 T-3 CLAD 2024 T-3 CLAD 2024 T-3 CLAD 2024 "1"-3CLAD 2024 T-3 CLAD 2024 T-3 CLAD 2024 T-3 CLAD 2024 T-3 CLAD 2024 T-3 CLAD 16. 17. 18. 19. 0.040 (d) 2024 T-3 CLAD 0.016 (a) 2024 T-3 CLAD 0.050 (b) _ 2024 T-3 CLAD PolyesterGlass-Fiber Reinforced 2024T-3 cLAo.... 15. .... . . .... (a) Same thioknesson top and bottom (b) Top of wingonly. 0040 ) 2024T-30O (c) Top aft flap skin(hat section) (d) Top inboardflap skin WING SKIN PANELS FIGURE 20-1 12-98 20-00-00 3 SERVICE AND MAINTENANCE MANUAL M20J MOONEY AIRCRAFT CORPORATION 8 5 6 7 3 14 2 12 0 I.... L I J 1 6 10 11 1 5 9 STA 199,50 5 STA 164.00 STA 130,00 STA 88,00 SKIN MATERIAL THICKN_:SS .... 1. 2. 3. 4. 5. 6. 7. 8. 9. 0.025 0.040(d) i 0.025(c)(b) 0.025 0.025(b) i 0.020 0.025 0.032(d)ie) 0.025 ..... ..... 2024T-3CLAD 2024 -0CLAD 2024 T-4 CLAD 2024 T-3 CLAD 2024 T-3 CLAD 2024 "1"-3CLAD 2024 T-3 CLAD 2024-0 CLAD 2024 T-3 CLAD .... .... .... .... .... (a) (b) (c) (d) (e) STA 21,80 SM20-2 SKIN MATERIAL THICKNF:SS" 10.. 11.. 12.. 13.. 14.. 0.032 2024 T-3CLAD O.032(a)i 2024 T-3 CLAD 0.032 2024 T-3 CLAD 0.025(a) i . 2024 T-3 CLAD Polyester Glass-Fiber Reinforced " Left side only Right side only. 0.032 can be used. Heat treated to T-42 condition afterforming. Shell. 12-98 STA -5,00 INDEX. NO.. FUSELAGE SKIN PANELS FIGURE 20-2 20-00-01 4 STA 53,00 SKIN PANELS FUSELAGE INDEX NO.. 1 13 MOONEY AIRCRAFT CORPORATION M20J SKIN PANELS EMPENNAGE INDEX . NO.. SKIN MATERIAL THICKNESS" ......... 1. 2. 3. 4. 5. 6. 7. ................. 0.025 0.025 0.025 0.025 0.025 0.020 0.025 . . 2024 2024 2024 2024 2024 2024 2024 . T-3 CLAD T-3 CLAD T-3 CLAD T-3 CLAD T-3 CLAD T-3 CLAD T-3 CLAD . SERVICE AND MAINTENANCE MANUAL . INDEX NO.. .... .... .... .... .... .... 8. 9. 10. 11. 12. 13. SKIN THICKN;=S8' MATERIAL 0.025 2024 T-3 CLAD 0.020 2024 T-3 CLAD 0.032 2024 T-3 CLAD Polyester Giass-Fiber Reinforced. 0.020 2024 T-3 CLAD 0.025(a) i . 2024 T-3 CLAD (a) Heat treated to T-42 condition. EMPENNAGE SKIN PANELS FIGURE 20-3 20-00-02 - CORROSION DETECTION & PREVENTION Most metallic fabrication materials are susceptibleto corrosion. Corrosion may occur on aircraft in any climate,but itwill be a problemmore often in climates where the aircraft is .exposed to salt air or high humidity,or where there are industrialcontaminantsin the atmosphere. The aircraft should be inspected frequently to detect and correct corrosion before seriousdamage occurs. Any form of corrosion shouldbe removed at once. If it is necessary to remove paint, only an approved aircraft paint remover such as Eldorado PR-3400 (Eldorado Chemca Co., nc., 6700 Lookout Road, P.O. Box 32101, San Antonio, -IX. 78216) shouldbe used. Paintremovingsubstances left in metalcrevices will cause further corrosion.Turco 2662C or 3002 will remove corrosionfrom aluminum and treat the metal surfacein one application. 12-98 20-00-02 5 SERVICE AND MAINTENANCE MANUAL M20J This paragraph discusses corrosion types and their prevention along with suggested procedures for pdming intemalairframe surfaces, 1. Types of Corrosion. Corrosion normally appears in one or more of four forms. Each type of corrosion can be precluded or controlled by a preventative maintenance program, A. Chemical corrosion. Chemical corrosion normally occurs where battery acid or exhaust gases come in contact with metal surfaces. A few simple precautions will prevent chemical corrosion, (1) Be sure battery vent is free from obstruction at all times. (2) Repaint all scratches and worn spots found in areas painted with acid-resistant paint, (3) If acid is spilled on metal surfaces, flush entire area with sodium bicarbonate and water. The solution should be rinsed away at once and the area dried by ddving all water from crevices with an air hose before wiping surface dry with a clean cloth, (4) Frequently clean exhaust gas deposits from metal surfaces. B. Local-Cell Corrosion. On bare metal surfaces, in an early stage development, local-cell corrosion appears as a light, whitish powder deposit. Surface pitswarn of advanced local-cellcorrosion. On painted surfaces, the first indication of corrosion will be evidenced by paint blistering. (1) Intergranular Corrosion - Selective attack along grain boundaries of metal alloys is referred to as intergranular corrosion. Aluminum alloys 2024 and 7075 are vulnerableto this type of attack. Aluminum extrusions may contain nonuniform areas, which in turn may result in galvanic attack along grain boundaries.This type of corrosion is difficult to detect in its original stages. When the attack is well advanced, the metal is usually blistered or delaminated. This is referred to as "exfoliation". It is very dimcultto completelyremove and stopthis type of corrosion, and replacement of the affected part is recommendedwherever possible, C. Concentration Cell Corrosion. Corrosion forming under dvet heads, along laying surfaces, at skin to Iongeron contact surfaces and other similar areas is called concentrationcell corrosion. Detection requiresclose inspection.Rivets must be removed and skin laps must be separated to remove concentration cell corrosion.Use aluminum wool soaked in solvent such as methyl-ethyl-ketone to scour corrosion deposits from the surface before painting both laying surfaces with zinc chromate or eoxy-polymide pdmer and reassembling. D. Galvanic Corrosion- Dissimilarmetals, such as stainless steel and aluminum, in contact with each other sometimes develop galvanic corrosions. To remedy this form of corosion, separate the parts, remove the corrosion_and paint both surfaces with Epoxy-Polymide pdmer or equivalent before reassembling. 2. CorrosionPrevention A. Thoroughlyexamine unpainted metal surfaces at inspections, and check corrosion when found. 20-00-02 12-98 6 MOONEY AIRCRAFT CORPORATION Carefully examine seams, lap joints, and crevices where moisture or dirt can collect. Areas exposed to exhaust gases require frequent inspection and cleaning. B. Corrosion may attack metal even though the surface is painted. Inspect painted areas for a blistered or scaly appearance that warns of corrosion below the paint layer. C. Use only liquid (non-alkaline) soap to wash the extedor airframe. Cover vent scoops when the aircraft is being washed. Rinse aircraft extedor after exposure to salt air or industrial fallout. D. Since moisture promotes corrosion, thoroughly and frequently inspect areas where water is apt to collect. Use an air hose to ddve water from crevices before wiping the exterior surface dry after washdown. E. Hangarthe aircraft when not in use. F. If battery acid is spilled on any part of the aircraft, immediately wash the area with a solution of sodium bicarbonate in water. Rinse with water and dry with clean towels. NOTE ACF-50 or equivalent can be fogged into fuselage empennage or wing skin areas. It is recommended that electrical connections and electrical components be protected during fogging. NOTE FAAAdvisory Circular 43-4addresses corrosion problems and treatment. 3. Surface Protection.Surface protectionof intemal airframe surfaceswill not eliminate the necessity for pedodic inspections. The most likely areas for corrosionto beginare in hidden crevicessuch as skin laps, underrivetheads or any openingwhere moisture can collect. Pedodicinspectionof these areas is most importantso that any corrosionwhich may be present can be detectedand treated in its very earlieststages. When corrosion is detected, it should be treated as follows: A. Remove all corrosionproduct (usually white or grey-white powder on aluminum) from the corroded area downto soundmetal. (1) If the base metal is aluminum,clean off the corrosionproductby scrubbingwith aluminumwool or a nonmetallicscouring pad such as the nylon pads made by the Carborundum Company, P.O. Box 277, Niagara Falls, N.Y. 14302. MOONEY AIRCRAFT CORPORATION M20J (2) If the base metal is steel, remove the corrosionproductwith emery cloth (320 grit or finer) or steel wool. SERVICE AND MAINTENANCE MANUAL B. CleanlngPrucedums. NOTE Fiberglass components are attacked and deteriorated by products containing the following chemicals: Ketone, atiphatic esters, chlorinated hydrocarbons and slightly softened by aromatic hydrocarbons, (3) If the corrosionis too advancedto remove by the light mechanicalcleaning methods of (1) and (2), refer to Advisory Circulars43.13-1(*) and/or 43-4 for alternate methodsof cleanup and repair. (* = current revision) (4) Chemical cleaning solutionsshould be used with extreme caution on both aluminum and steel parts. Such solutionsare not recommended for use in areas where they cannot be easily and completely neutralized, B. Wash all areas to be pdmed with a cleaning solvent such as methylethylketone (MEK), Turco T-657 (Tumo Products,Inc., 6135 SouthCentral Ave., Los Angeles, California), lacquer thinner,#3094 wash thinner (Pratt & Lambert, Inc., 25th and N.Y. Avenue, V_chita,Kansas) or similarsolvents, (1) To get a good clean surfacefor pdminguse a clean cloth or piece of cheesecloth and apply one of the solvents noted above. The surface should be wiped dry with a second piece of clean cloth. Do not allowthe solventto dry on the cleaned area as it will redepositdissolvedsoiland gdme uponevaporation, CAUTION Wipe solvents are generally flammable and toxic and should not be used without adequate ventilation and fire precautions, C. Apply Epoxy-Polymlde pdmer or equivalentto cleaned area by spray or brush. Area needs to be paintedwithin24 hours of pdmer coat. 20-00-03 - PAINTING The extedor is painted with urethane enamel. When exposed to humidsalt air or to an atmospherehaving corrosivefallout,the aircrait should be hangaredwhen not in use. 1. Paint Repairs. A. Matedals. (1) Aluminumwool, nylonscoudngpads,320 grit or fineremery clothor steel wool. (2) Tack rags. (3) Wipe solventssuch as: Methylethyl ketone, T-657 -- Turco Products, Inc., #3094 wash thinner -- Pratt & Lambert, Inc., lacquer thinner or equivalent solvents, (4) Body putty or aerodynamic filler such as: Flex-Bond-- Taylor& Art Plastics,Flex-- 3M Co.,or Cuz polyester body filler #6372 -- NAPA (Martin Senour Paints). NOTE Fuel Servicing Decal Removal: 1. Cover the decal with a hot, wet towel for approximately 2 minutes. 2. Lift one corner of the decal and slowly remove. (1) Remove all old loose paint by one of the followingmethods: (a) On aluminum - for uniformity of finish appearance,the entireskin panel shouldbe prepared for repainting.If the paint is in very bad conditionor if a filler is to be used, remove all of the paint by use of lacquer thinner, MEK or similar solvent. Careful applicationof approved paint stdpper is acceptable. The solventshould be wiped on and wiped off beforeit evaporates. If the solvent is allowed to evaporate it will redeposit the so s and paint that were being can-led.Any scoudng requiredshould be done at this poinLScoudngwith nylonpads or aluminumwool may be done dry or wet with one of the wipe solventslisted above. After the old paint, gdme, etc. has been loosened and removed, the scoured area should be wiped with a tack rag, and again cleaned with fresh wipe solvent. The part should now be ready for pnmmg and painting. (b) On steel - Remove all grease,gdme, loose paint, etc. by wipingwith a wipe solventand rags. Do not allowthe wipe solventto evaporate.Wipe it dryl Steel pads may be cleanedto bare metal by sanding with emery cloth or steel wool. If the pads are removable, they can be cleaned by sandblasting. Regardlessof the scoudngmethod, allparts shouldbe wiped with a tack rag and cleaned with fresh wipe solvent.The part shouldnow be ready for pdmingand painting. C. Pdmingand Painting. (1) On aluminum- Cleaned and driedsurfacesto be painted should be coated with a wash primer conformingto MIL-C-8514 or MIL-P-15328. Read and follow the manufacturer'sinstructionscarefully. The wash primer should be applied to attain a dry film thicknessof 0.3 to 0.4 mils(a transparentfilm). (5) Compatible paints for the item (such as steel tubular structure or extedor skin) and for the year and model being repainted. (Refer to Mooney Pads Manual). (6) Thinnerswhich are compatiblewith the paints being used both for paint thinning and for bum-down thinners. 12-98 20-00-03 7 SERVICE AND MAINTENANCE MANUAL M20J MOONEY AIRCRAFT CORPORATION A good wash primer coating is a must since the top coating can be only as good as the pdmer coat. As a general rule the wash primer should dry from .05 to 1.5 hours but not more than 2 hours before application of the top or epoxy intermediate primer coat. it When intermediate primer coat is applied, should an be mixed very carefully per the manufacturer's instructions. It should be thinned per manufacturer's instructions and applied to a dry film thickness of 0.8 to 1.0 MILS. The intermediate primer should be allowed to dry a minimum of 0.5 to 1.5 hours depending upon the application temperature and relative humidity, Follow manufacturer's instructions. The intermediate primer coat can be dry-scoffed lightly with No. 409 to No. 600 sandpaper pdor to top coat application and give a higher glossfinish. As many coats of paint as desiredmay be applied.A higherglosswill be attained if the surface is scuffed lightly and tack rage cleaned between each coat. D. Painting. (1) Apply three coats of white base and/or color finish allowing three to five minutes between coats depending upon weather conditions. Allow five to ten minutes between coats in cold, dry weather; in humid weather, allow fifteen minutes between coats. (2) Use a small round watercolor brush trimmed to a point for application of undiluted touch-up paint to small scratches and bare spots. Do not thin acid resistant black paint or extedor finish touch-up paint for brush-on application. NOTE M2OJaircraft are painted with Enflex III urethane enamel. Inquiries concerning application of this finish should be directed to: Pratt & Lambert, P.O. Box 2153, Wichita, KS. 67201. (2) On steel - The same general procedure used on aluminum can be applied to steel. However, MIL-P-8585 primer or epoxy primer is recommended for the steel coat. If epoxy primer is use¢ it should have a wash primer(MIL-C-8514) pre-treatment, CAUTION Any flight control surface that is to be repainted should be stripped of all paint prior to repainting. It is required that repainted control surfaces be removed and rebalanced prior to flight per paragraph 27-91-00. NOTE Never use abrasive polish compounds or harsh soaps and detergents on ureathane finishes. Once the surface gloss is damaged it cannot be restored by polishing. 20-00-03 8 12-98 MOONEY AIRCRAFT CORPORATION M20J SERVICE AND MAINTENANCE MANUAL CHAPTER 21 ENVIRONMENTAL SYSTEMS SERVICEAND MAINTENANCEMANUAL M20J MOONEY AIRCRAFTCORPORATION CHAPTER 21 ENVIRONMENTALSYSTEMS UST OF EFFECTIVEPAGES CHAPTER SECTION SUBJECT ..... 21-Effectivity/Contents....... 21-O0-00 ........ 21-40-00 ............ PAGE ........... DATE 1/2BLANK .......... 3 ........... 4 ......... 12-98 12-98 12-98 TABLEOF CONTENTS CHAPTER SECTION SUBJECT ......... 21-00-00 21-40-00 SUBJECT ...... ....... Cabin VentilationSystem .......... Heating ............. 12-98 PAGE 3 3 21-EFF/CONTENTS 1/2BLANK MOONEY AIRCRAFT CORPORATION M20J 21-00-00 -CABIN VENTILATION SYSTEM The cabin environmental system consist of three ventilatingsystemsthat supply heated or fresh air as the pilot or passengers prefer. CABIN AIR, CABIN HEAT and OVERHEAD VENTILATION. The cabin air and heat system controlsand ventsare locatedon the consolebetweenthe pilotand co-pilotseats. Individual fresh air outletsare locatedon each side of the cabin side panels just forward of the pilots and co-pilots knees. The overhead ventilation system consists of individualoutlets (Wemac valves) locatedabove each seat position, S/N 24-0901 & later aircraft have a regulator system with the control located above pilots head. The systems areknob basicallytrouble freethebut inspection should be made at regular intervalsto ensure proper operation, SERVICE AND MAINTENANCE MANUAL S/N 24-0001 thru 24-0757 aircraft have an overhead airscoopoperatedby rotatingthe knobabove the pilots seat to extend or retract as desired, to controlair flow or to preventair-buffetingat high criuse speeds. Small overhead vent deflectors, with inner knob volume controls,distributeincomingair as individuallydesired. 21-40-00 - HEATING Heat is supplied to the cabin through flexible hoses connected to a heat distribution box assembly and shroud assemblieslocated on the exhaustmanifold on the engine. It is recommended that the conditionof these items be checked each time the cowling is removed.This will provide a continuingcheck for the prevention of carbon monoxide in the cabin. Any deteriorated flexible ducts should be replaced. Heat shrouds should be inspected for cracks or other deteriorations and repaired or replaced promptly. Inspectthe exhaustsystemfor any leaksor cracks and replace or repairas needed. 12-98 21-00-00 3 SERVICE AND MAINTENANCE MANUAL M20J BLANK 21-40-00 4 12-98 MOONEY AIRCRAFT CORPORATION MOONEY AIRCRAFT CORPORATION M20J SERVICE AND MAINTENANCE MANUAL CHAPTER 24 ELECTRICAL POWER SERVICE AND MAINTENANCE MANUAL M20J MOONEY AIRCRAFT CORPORATION CHAPTER 24 ELECTRICAL POWER LIST OF EFFECTIVE PAGES CHAPTER SECTION SUBJECT ........... 24-Effectivity ......... 24-Contents.......... 24-00-00. ........... 24-31-02 ............. 24-32-00. ........... 24-34-00 ............ 24-35-00 ............ 24-39-00 ........... 24-39-01 ........... 24-39-02 ........... 24-39-04 ........... 24-39-05 ........... 24-39-05 ........... 24-39-06 ........... 24-39-96 ........... 24-39-06 ........... 24-50-00 ........... 24-51-00 ........... PAGE .......... DATE 1/2BLANK .......... 3/4BLANK .......... 5 ........... 6 ........... 7 ........... 8 ........... 9 ........... 10 ........... 11 ........... 12 ........... 13 ........... 14 ........... 15 ........... 16 ........... 17 ........... 18 ........... 19 ........... 20 ........... 12-98 12-98 12-98 12-98 12-98 12-98 12-98 12-98 12-98 12-98 12-98 12-98 12-98 12-98 12-98 12-98 12-98 12-98 12-98 24-EFFECTIVITY 1/2BLANK MOONEY AIRCRAFT CORPORATION M20J SERVICE AND MAINTENANCE MANUAL CHAPTER24 ELECTRICAL POWER CHAPTER SECTION SUBJECT TABLE OF CONTENTS ........... 24-00-00 ........ 24-30-00 ......... 24-31-01 ............ 24-31-02 ........... 24-31-03 ............ 24-32-00 .......... 24-33-00 .......... 24-34-00 .......... .............. 24-35-00 .......... 24-36-00 .......... 24-37-00 .......... 24-38-00 .......... 24-39-00 .......... 24.39-01 ............ 24-39-02 ............ 24-39-03 ............ 24-39-04 ............ 24-39-05 ............ .............. 24-39-06 ............ .............. 24-50-00 ......... 24-51-00 .......... SUBJECT ........ General .............. D.C. Generation ........... AlternatorChargingSystem Maintenance. Voltage RegulatorMaintenance .... AuxiliaryPowerSystem ...... Battery Maintenance ........ Warning Circuits ......... PowerPlantCircuits ........ --Low BatteryStartingProcedures LightingCircuits.......... LandingGear Circuits ........ Fuel SystemCircuits ........ MiscellaneousCircuits ........ Trouble ShootingCharts . . ..... Alternator Trouble Shooting . RESERVED ...... Battery Trouble Shooting ...... Starter Trouble Shooting ...... Annunciator Trouble Shooting (24-0001 thru 24-3153) ...... Annunciator Trouble Shooting (24-3154thru 24-TBA) ...... Electrical Load Distribution ........ Power Distribution System ..... 12-98 PAGE 5 5 5 5 6 7 7 8 8 9 9 9 9 10 10 12 12 13 14 16 20 20 24-CONTENTS 3/4BLANK SERVICE AND MAINTENANCE MANUAL M20J 24-00-00 - GENERAL (24-0001 thru 24-2999) A 14 volt alternator with a transistorized voltage regulator and an overvoitage relay supplies electric power.A 12 volt, 35 ampere-hour storage battery is installedin the tailcone.The alternator, dudng normal operation, supplies powerswitch in conjunction with the battery when the master is on. The circuit breaker panel is on the right subpanel. The electrical system is capable of supplying current for simultaneous operation of multiple radios, an anticollision beacon, and navigation lights. A shunt type ammeter mounts in the power plant instrument cluster. (Similar systern-24-3079 thru 24-'rBA ,except 28 volts) (24-3000 thru 24-3078) A 28 volt, 70 AMP alternator utilizing a transistodzed voltage regulator/over control electrical power. A 24 volt voltage 10 AMP HR storagesupplies battery is installed n the tailcone. The alternator, during normal operation,will supply power in conjuction with the batterywhen the master switch and alternator field switchis ON. The circuitbreaker panel is on the right subpanel.The electricalsystem is capable of supplying current for simultaneousoperation of multiple radios, anticollisionlights and navigationlights.A shunt type combination gauge gives alternator output and line loadin % of rated capacity plusbus voltage. MOONEY AIRCRAFT CORPORATION D. Do not leave the master switch ON when the aircraftis parked. E. Use an auxiliarygroundpower unitwhen trouble shooting electrical accessory equipment or when performingelectrical landing gear maintenance and retractionsystemtesting. 2. AlternatorSystem Inspection. A. Check alternator circuit breaker on the main circuit breaker panel. Reset breaker If open. B. Check alternator field circuit breaker on main circuit breaker panel. Reset if open. C. Inspect battery for corroded cable connections; remove and Cleancable if corrosion is found. D. Check ddve belt for proper tension and excessiveglazing. E. Checkchargingsystem widng connectorsto be surethey are clean and tight. F. Inspectalternator, voltageregulator,and widng fordamage. CAUTION Do notattemptto polarizealternator. Alternatoris polarizedevery time master switch is turnedon. 3. AlternatorRemovaland Installation. A. Aitemator Removal. 24-30-00 - D.C. GENERATION (1) Turn master switchOFF beforedisconnecting alternatorwiring. 24-31-01 -ALTERNATOR CHARGING SYSTEM MAINTENANCE (2) Remove attaching hardware and slip drive belt from pulley. 1. Alternator System Servicing (24-0001 thru 24-2999, 24-3079 thru 24-TBA) When the ammeter shows a discharge at higher engine speeds, a charging system component (alternator, voltageregulator,drive belt, circuit breaker, orwidng) is malfunctioning, (24-3000 thru 24-3078) When the Ioadmeter shows a higher % than the alternator output at higher RPM, a charging system componentis malfunctioning. On-the-plane testing should indicate which component is faultyand needs to be removed from the aircraft for benchtesting and repair or replacement. The alternator charging system requires no special attention;however, improper maintenance procedures can damage the alternator and widng. There are several precautions that must be observed when servicingthe alternator system: A. Be sure the master switch is OFF when repaidngthe alternatororvoltageregulator, B. When the battery is removed fi'om the aircraft. for charging, be sure that the charger is correctly connected. Use the correct charging rate, refer to battery manufacturers 'procedures. It is possible to reverse the polarity of a battery by connecting a charger backwards. C. Be sure to check battery polarity by using a voltmeterpdor to reinstallationin the aircraft. NOTE Ifblast replacement alternator a cooling fan or a tube housing, they has MUST BE REMOVED prior to installation. Replace cooling fan with Lycoming spacer (LW-15403) which was already on alternator when aircraft was delivered from Mooney. Reinstall pulley after spacer is installed and torque pulley retaining nutto 35-40 ft. Ibs. B. Altematorlnstallation. (1) Be sure master switch is turned OFF. Do not turn master switchON untilall wiringconnectionshave beensecurea. (2) Installattaching hardware;place ddve belt on pulleyand adjust beit tension. (3) Connect alternator wiring and check widng connectorsthroughoutsystam. CAUTION Donot attemptto polarizealternator.Alternatoris polarizedeverytime masterswitch isturnedon. 24-31-02 -VOLTAGE REGULATOR MAINTENANCE The battery charging rate depends upon the battery condition and the voltage regulator setting. With all equipmentturned off and the engine runningat 2000 RPM or faster, the normal batterycharging ratewill be 5 to 35 amperes. 12-98 24-00-00 5 MOONEY AIRCRAFT CORPORATION M20J SERVICE AND MAINTENANCE MANUAL 1. Excessively High Charging Rate. Check the amperes). The regulator should not be considered following: detective because of a low charging rate until: A. Fly aircraft for 15 to 20 minutes; charging rate A. A voltmeter check indicates that voltage at the should slowly drop to 10 amperes or less. A very low bus is below requirements. battery will take longer to show a drop in charging B. A battery hydrometer check indicates that current, battery is not fully charged. B. Measure voltage with a voltmeter connected to 3. Hydrometer Reading. If battery electrolyte the bus. At 80 degree F., voltage should be 13.75 to temperature is below 80 degree F., subtract four points 14.0. An excessively high voltage regulator setting will from hydrometer reading for every 10 degrees F. below cause excessive battery heating and water loss. 80 degrees F. If battery acid temperature is above 80 2. Excessively Low Charging Rate. Check battery degrees F., add four points to hydrometer reading for charging rate (normal rate is not to exceed four everyl0degreesF, above 80 degrees F. Example: Hydrometer reading = 1.260 Battery electrolyte temperature = 30 degree F. 80 degrees - 30 degrees = 50 degrees 5 x 4 = 20 points Corrected reading 1.260 - 20 = 1.240 • . .... .... .... .... . HYDROMETER. READING .... 1.280.......... 1.250 .......... 1.220 .......... 1.190 .......... 1.130 or below PERCENT OF CHARGE 100 75 50 25 Ve_ little useful capacitT--Dtscharcled. "Hi" or Overvolt Adjustment at Regulator - Bench Adjustment. (Electro-Delta) Connect a variable voltage power supply to the regulator,positive (+) to pin "A" or =1" and negative to pin "C" or "3" (24-0001 thru 24- 2999); positiveto pin 5 & negativeto pin 9 for (24-3000 thin 24-TBA). Connect a voltmeterto the regulator (+) to pin "D" or =4" and (-) to pin "C" or "3" (24-0001 thru 24-2999); (pin 6 and pin 9 for 24-3000 thru 24- TBA). Adjust voltageto 16 volts +/- .1 volt (24-0001 thru 24-2999);(28.7 volts for 24-3000 thin 24-TBA). Adjust tnm pot (accessable throughholein case marked "OV'_to relaytrip pointas indicated by voltage indication on test voltmeter. Decrease voltage until relay closes and note voltage, Readjust as necessary until a trip point of 16 +/- .1 volts is attained(24-0001 thin 24-2999); 31.8 (+/-).3 voltsfor 24-3000 thru 24-TBA). Regulator (Electro-Delta) ConnectanAdjustment accurate voltmeterto the aircraft bus. Turn off all electrical equipment and start engine. Run engine at moderate RPM (1500-1800) until ammeter drops to low charge rate. Increase RPM to 2000 and adjust trim pot (accessable through hole in case marked "REG") for a voltage reading of between 13.75 and 14.0 volts (24-0001 thru 24-2999);(28.6 and 28.8 volts for 24-3000 thru 24-TBA). Increase throttle to full RPM and observe that voltage does not exceed 14 volts (24-0001 thru 24-2999);(30 volts for 24-3000 thru 24-TBA). Low Voltage Warning should occur on Annunciator at approximately 12.5/12.75 Volt output from regulator, Electro-Delta Volt. Reg. are adjustable for HI & LOW volts. 24-31-03 6 NOTE Use bushings provided with replacement VR-415F voltage regulator to mount in location of old regulators. NOTE No field adjustment authorized for Mooney Voltage regulators. Max. voltage for 14 volt system is 14.2+.21-0.m 28 volt system is 28.3 +.21-0. 24-31-03 -AUXILIARY POWER SYSTEM An auxiliary power plug and related circuitryis installed to providean outsidesource of electrical power to the aircraft, to charge the battery, or to start the engine. The Auxiliary Power Plug guide pin must have A+ voltage connectedto it in order to activatethe Auxiliary Power Relay. The battery can be charged using the approvedAuxiliary Power Cableconnected to a charge cart capable of regulating the charging current. To prevent battery damage, the charging current should be low (3 - 4 amps) to beginand then increasedas the battery voltage capacity is increased. The MASTER SWITCH is not required to be ON for the auxiliary power source to charge the battery. A. When auxiliary power or a booster battery is used, be sure cables are connected correctly--positive to positive and negative to negative. DO NOT by-pass battery when using an auxiliary power source. B. See paragraph 24-34-00, A for additional information. 12-98 NOTE It is recommended that the approved Auxiliary Power Cable be connected to booster battery, then the plug inserted into auxiliary power receptacle. SERVICE AND MAINTENANCE MANUAL 24-32-00 M20J - BATTERY MAINTENANCE CAUTION Battery gases are explosive, 1. Battery Removal. A. Turn master switch off. B. Remove tailcone access cover and battery box lid. C. Disconnect battery cables, negative lead first, remove battery from aircraft, D. Install battery in reverse sequence of removal. Use a voltmeter to check battery polarity before installation. 2. Battery Cleaning and Corrosion Removal. A, Mix one pound of baking soda in one gallon of water. B. Wash battery box and flush battery with the mixture.Do not allowsoda water to enter battery cells; permanent damage will result if soda mixes with electrolyte, C: Rinse thoroughlywith clear water and dry the area. D. Test each cell with a temperature corrected hydrometer. Specific gravity should be 1.265 to 1.280 for s fullycharged battery, E. Check electrolytelevel and maintainat split ring. F. Clean battery terminals with emery cloth, reinstall and tighten cables. Coat terminals and connectorswithPetroleumjeUyto retardcorrosion, 24-33-00 - WARNING CIRCUITS 1. Landing gear position lights and warning horn. RED and GREEN landinggear positionlightsare in the annunciatorpanel. The gear-down limitswitch controls the GREEN gear-down lighL Both limitswitches control the RED gear unsafe light. The throttle control operates landing gear warning horn (intermittent tone) when the power setting is reduced below 10 IN. Hg. with the gear up. Check gear warning system during flightfor properoperation. 2. PrestallWarning Circuit. The prestallWarning hom has a high frequency continuous tone that sounds when airspeed drops to 5 to 10 MPH IAS (4.3 to 8.7 KIAS) above stalling speed. A vane in the left wing leading edge actuatesthe prestallwaming horn switch. (This vane is made of heat treated steel, and any attempt to adjustswitch operationby bendingthe vane will damage the switch). Refer to Section 27-93-00 for adjustmentprocedures. 3. High and Low Vacuum Warning Circuit.A switch in the vacuum system controls the vacuum warning light on the instrument panel or annunciator panel. Vacuum below 4.25 IN. Hg. causes the vacuum warning light to flash. Vacuum above 5.5 IN. Hg. tdps the high-vacuum switch causing the vacuum warning light to 'llum nate steadily. (S/N 24-0001 thru 24-0083 and 24-0085 thru 24-0377 have a vacuum gauge mounted above the radio panel). MOONEY AIRCRAFT CORPORATION 4. Low Fuel Warning Circuit. The low fuel indicators will illuminatewhen a minimum of 2 1/2 gallons usable fuel remains in either left or right hand tank. When it becomes necessary to replace the annunciator pane[ for any reason other than "low fuel" warning malfunction, the following procedure should be used to set the =low fuel" warning circuits. The calibration transfer standard, I.A.I. PIN 500D0045 (24-0001 thru 24-3153) or I.A.I. PIN 9500324000 (24-3154 thru 24-TBA) is required for this procedure. Adapters can be ordered through Mooney Marketing or Service Centers. A. Calibration Procedures 500D0045 or PIN 9500324000. using I.A.I. PIN (1) Remove glareshield, disconnect plug from rear of annunciator, remove annunciator front panel, and place"Norm-Car switchin "Cal" position. (2) Plug appropriate calibration transfer standard on rear of old annunciatorand reconnectharnessplug. (3) Turn on master switch and turn right hand variable resistor on transfer standard slowly counter clockwise until right "low fuel" light just turns on. (If necessarytam variableresistorclockwiseto extinguish low fuel light).(Do not adjust annunciatorcalibration screws). Repeatfor left "lowfuel". (4) Turn off master switch and remove old annunciator assembly after disconnectionof harness and transfer standardunit. (5) Install new annunciator and connect calibration transfer standard to annunciator panel and harness plug. Remove front plate and legend on new annunciatorpanel to expose the Norm-Cal switch and the Left and Right trim potienometers.(Switchmust be in =Cal"position). (6) Adjust left and right annunciator fuel calibrationscrews clockwise(not the adapter variable resistors) until "low fuel" lights just turn on. (If necessary turn annunciatorcalibration screw counter clockwiseto extinguish=lowfuel" light). (7) Remove calibration panel, transfer standard, reconnect plug to annunciator set switch to =Normal" position,install annunciator front panel and installglareshield. B. Alternate method for calibration without I.A.I. unit. If calibration transfer standard, PIN 500D0045 or 9500324000, is not available use the followingmethod to calibrate =lowfuel" warning: 12-98 24-32-00 7 MOONEY AIRCRAFT CORPORATION M203 (1) Remove glareshield and remove annunciator assembly. CAUTION Do net operate the starter in excess of 15 seconds or re-engage the starter without allowing it time to cool. (2) Install and connectnew annunciator assembly leavingoff front panel. (Set switchto "Cai"). (3) Drainfuel from tanksand replacewith unusable fuel plus2 112gallonsin bothtanks, (4) Turn on master switch and adjust calibration potsto positionwhere "low fuel" lamps just turn on for left and righttanks. (5) Turn OFF master switch, set annunciator"Car switchto =Norm"position, install annunciatorfront and installglareshield, (6) Refuel aircraft. 5. RAM Air Light Warning Circuit - Annunciator Panel. The light illuminateson the annunciatorpanel when the RAM air door is open and the gear is extended, 6. Hi/Low Voltage Warning CircuitAnnunciator Panel. Remove annunciator top cover. Connect a voltmeter to the aircraft bus. Start engine and run at idle. Add load to bus until =Low Volt" light starts to flash.Adjust RPM to obtaina bus voltage of 12.5 volts (24-0001 thru 24-2999); 26.5 volts (24-3000 thru 24-TBA). Adjust trim pot (located at center, rear of circuitboard tillflashinglightjust comes on. NOTE It may be necessary to adjust trim pot to turn out light at 12.5 volts (24-0001 thru 24-2999); 26.5 volts (24-3000 thru 24-TBA) first. Increase RPM until light goes out and note voltage, Decrease RPM until light flashes on and note voltage. at avoltage betweenLight 12.4 should and 12.6come voltson (24-0001 thru 24-2999); 26.4 to 26.6 volts (24-3000 thru 24-TBA). 24-34-00 -POWERPLANTClRCUITS 1: Starter-IgnitionCircuit. The starter-ignitionswitch has five positions:OFF, R (right), L (lefl), BOTH, and START. In the OFF position both magnetos are grounded.At the R positionthe left magneto grounds. At the L position the right magneto grounds. At the BOTH position both magnetos are HOT and the ignitionsystem is ON. to start and pushing in, Turning closes the the ignition starter switch solenoid, engagesthe starter and allowsthe impulse couplingto automatically retard the magneto until the engine is alsoat its retard fidng position.The spring action ofthe impulse couplingis then released to spin the rotating magnetand produce the spark to fire the engine. Alter the engine starts, the impulse couplingflyweights do notengage due to centrifugal action.The couplingthen acts as a straight drive and the magneto fires at the normalfiring positionof the engine. The starter-ignition switch is spring loaded to return from START to the BOTH positionwhen released. 24-34-00 8 SERVICE AND MAINTENANCE MANUAL A. LowBattery startingprocedures. Batteriesthat have been dischargedto the pointwhere they will not turn the engine but have sufficientpower remainingfor other equipment;should NOT be jumped with another powersource for two major reasons: (1) The discharged aireraft battery is not airworthy because it will not have the necessary reserve capacity required to operate the aircraft electricalsystemand avionicsin the eventof the failure of the generatingsystemduringflight. (2) Active material on the positive plate expands when the battery is discharged and the fast recharge from the higher potential source, battery, alternator, generator, rectifier, etc., will severly damage the battery and will result in premature battery failure. A slow charge is recommended priorto flight. WARNING Do not turn the propeller when the magnetos are not grounded. Ground the magneto points before removing switch wires or electrical connectors. All spark plug leads can be removed as an alternate safety measure. 2. Oil and Cylinder Head Temperature Gauge Circuits. Both the oil and cylinder head temperature indicators operate electrically. The oil temperature gauge circuit has a resistance bulb in the oil surnp. Changes in resistance caused by changes in oil temperaturealter current flow rate, thereby varying the magneticfield in the indicatorcoils.The cylinder head temperature indicator connects to a tip sensitive resistance bulb in a cylinder head. Increase or decrease in temperature causes an increase or decrease in bulbresistance,varying the magnetic field in the indicatorcoils. 3. Fuel Pressure Gauge. The Fuel Pressure Gauge is an electricallyoperated gauge located in the cluster. The Manifold Pressure Gauge is a simple direct readinginstrument. 4. Exhaust Gas Temperature Indicator.Exhaust Gas Temperature Gauge is combined with the Outside Air Temperature Gauge in a single instrument. 5. The oil pressure instrument circuit contains an electrical instrument used as a reference, and a transducerwhich vades resistancewith pressure. 6. Fuel Flow (if installed) is indicated on either an electrical instrument usinga pressure transducerwhich varies resistance with pressure or with an electrical instrumentwhich counts electrical pulses produced by a turbine flew transducer. 12-98 SERVICE AND MAINTENANCE MANUAL M20J MOONEY AIRCRAFT CORPORATION 24-3540 -LIGHTING CIRCUITS 1. NavigationLights.A circuit breaker switchon the flight panel controls navigation lights. GEAR DN GREEN, annunciatorlightis dimmed when navigation lightsore ON. 2. Landing Light. A circuit breaker switch on flight panelcontrols landinglightin the lower engine nacelle on SIN 24-0001 thru 24-3153. The rocker switch is connected through MASTER Switch on these aircraft andisaft intedor lights will go OFF when MASTER switch turned OFF if door is Landing/TaxiLights.S/N 24-3154 thin 24-'fBA uses a splitswitchon Flightpanelto controlwingmountedlights, 3. Cabin Lights. A thrse-position (Bdght, Off, Dim) rocker switch adjacent to door, in headliner, controls cabinlights, CAUTION On SIN 24-0001thru 24-3153this lightswitchis connecteddirectlyto battery.The switch MUSTBE TURNED OFFto keepfrom dischargingbattery, i. Limit switchesand relays operatethe landinggear actuator,a reversible motor [14 volt DC (SIN 24-0001 thru 24-2999) or 28 volt DC (SIN 24-3000 thru 24-TBA)]. A landinggear safety system, actuated by a pitot air pressure switch or a squat switch (24-0001 thru 24-0237) prevents landing gear retraction until safe flyingspeed ls attained. The landing gear control switch operates actuator motorthroughone of these safety switchesand relays. When landinggear controlswitch is UP and safe flying speed has been attained, the safety switch closesto activatethe controlrelay, startingthe actuator. As the gear reachesthe up and locked position,a mechanical stop opens limit switch and the actuator stops. When landinggear controlswitch is placed in downposition, the gear motordown-relay closes and actuator starts. When gear reaches down-and-locked position, the mechanicalstopopens limitswitchand actuatorstops. Later modelshave a red lightfor gear unsafe;no lights illuminatewhen gear is up. See Section 32 for squat switchinformation. 2. Gear Safety By-Pass Switch. Gear will not retract if airspeed above set limit has not been attainedwhen gear handle is placed in UP position.Warning hornwill sound and both "GEAR DOWN" and " GEAR UNSFE" lights will illuminate. PUSH and HOLD red button switchbesidelandinggear handle untilgear is UP and bothlightsgo out.Pull circuitbreaker =GEARCON_ or =GEAR RELAY" to stop warning hom. Reset circuit breaker priorto extendinggear. Aircraft 24-3154 thru 24-3200 may have a door switch/timer mechanismthat illuminateforward set of interior lights while cabin door is open. After door is closed,if rocker switchis left ON, forward interiorlights willremainON for approximately2 minutes, The rocker switch is connected through MASTER Switch on these aircraft and forward interior lightswill go OFF when MASTER switchis turnedOFF if door is closed. 4. Anti-Collision Lights. A circutt breaker switch controlsthe white anti-collisionstrobelights, 5. instrument and Radio Lights. Rheostats control the glareshield, and radio lights. The flight panel instrument light rheostat controls the compass light, Lightingloads are controlledby transistorsbiased with manual!y controlledrheostats. The transistorscan be checked bythe followingmethods: A. Connect ohmeter between the emitter and the collector;,shouldbe infinite ohms. B. BhorLbase to collector;shouldbe a direct short, zero ohms. : NOTE If readings are incorrect reverse the loads. CAUTION Care must be exercised to preventshorting light wires when installing or replacinginstruments, Shorted wires will cause blown fuses or burned out transistors in the control box. 6. Baggage Compartment Lights. A three-position (Bright, Off, Dim) rocker switch in headliner controls this dome light, CAUTION On 24-0001thru 24-3153this lightswitch is connecteddirectlyto battery. The switch MUST BE TURNED OFFto keep from dischargingbattery, closed. 7. Map Light.A push buttonswitch on top of control wheel center sectioncontrolsmap light. Co-pilotsmap lightis optional. 24-36-00 - LANDING GEAR CIRCUITS 24-37-00 The fuel system has an electric auxiliary fuel pump. The fuel quantityindicatingsystem is comprisedof two transmittersin each fuel tank and two fuel quantity gaugeson instrumentpanel. 1. Fuel Pump Circuits.A single auxiliary fuel pumpis controlledby a switchlocatedon the instrumentpanel. 2. Fuel QuantityGauge Circuits. Fuel level changes vary fuel quantity transmitter resistance that operates fuel quantity gauges. Master Switch activates fuel quantity indicating system. Refer to Section 28-43-00 for Adjustment Procedures. 24-38-00 Aircraft 24-3154 thru 24-3200 may have a door switch/timer mechanism that illuminate aft set of interior lights while baggage door is open. After door is closed, if rocker switch is left ON, aft interior lights will remain ON for approximately 2 minutes. - FUEL SYSTEM CIRCUITS - MISCELLANEOUS CIRCUITS. 1. Turn CoordinatorCircuit. The turn coordinatoris a flight instrument which operates from an electrical powersource. 2. Heated Pitot Tube. A circuit breaker switch controls the pitot tube heater. 12-98 24-35-00 9 MOONEY AIRCRAFT CORPORATION M20J 3. Hour Meter (Optional). The hour meter operates directly from the alternator =Aux."terminal through a fused wire. SIN 24-1418 and later models hour meter 24-39-00 24-39-01 SERVICE AND MAINTENANCE MANUAL operates from the electric tachometer. A Hobbs meter may be installedas an option. 4. Cigar Lighter. A cigar lighter is mounted in the rightinstrumentpanel. - TROUBLE SHOOTING CHARTS - ALTERNATOR TROUBLE SHOOTING TROUBLE PROBABLECAUSE REMEDY Alternator overchargesbattery; battery uses excessivewater. Regulatorfaulty. ALT FIELD circuitbreakertrips. Circuitshorted in wiring. Checkbus voltagewith enginerunning. Observeaircrattammeter.Ammeter shouldindicatenear zero atterten minutesof engineoperation.Replace voltagemgualtorif defective. Disconnectleadfrom pinA or 1 of regulator,*and resetcircuitbreaker.If circuitbreakertrips,checkwidng.Repair as required.If breakerdoesnottrip, replaceregulator.Reconnectleadto regulator.Set MASTER switchto ON and checkfor 12V at pinA orI of regulator.**Repairwiringif novoltageis present. *(24-0001 thin 24-2999); Pin 5 for 24-3000 THRU 24-TBA. **(24-0001 thru 24-2999); Set alternatorfield & Master switchto ON & checkfor 24 voltsat Pin 5 of regulatorfor SIN (24-3000 thru24-TBA). ALT circuit breaker trips. Short circuit in wiring. Disconnect lead from + postof alternator, and reset ALT circuit breaker. If circuit breaker trips, check wiring between alternator and circuit breaker. Short circuit in alternator. Reconnectleadto + post of alternator. WARNING: ENSURE THAT MAGNETO SWITCH IS OFF WHEN TURNING PROPELLER Rotatepropeller by hand to rotate alternatorthrough360 degrees of travel. Ifcircuitbreakertdps replacealtemator. Alternator will not keep battery charged. Battery malfunction. 1. StarLengine and adjust for 1500 RPM. Ammeter should indicate a heavy charge rate with all electdcal equipment turned off. Rate should taper off in 1 - 3 minutes. A _ge checkatthe busshouldindicatea readingof 13.75to 14.0volts. ***If charge rate tapers off very quickly and voltage is normal, check battery for malfunction. **'24-0001 thru 24-2999; 28.6 to 28.8 volts for 24-3000 thru 24-TBA. If ammeter shows a low charge rate or any discharge rate, and voltage is low, proceed to step 3. 24-39-00 10 12-98 SERVICE AND MAINTENANCE MANUAL TROUBLE (cont.) ! M20J MOONEY AIRCRAFT CORPORATION E_ REMEDY Defective widng. 2. Check voltage at A or 1 terminal of regulator with master switch ON.**** Meter should indicate bus voltage. If voltage is not present, check widng between regulator and bus. ***'24-0001 thin 24-2999; ...@ terminal 5 for 24-3000 thin 24-TBA, with AIt. FId. & Master switch ON. Regulator faulty. 3. Remove connector from regulator and start engine. Momentarily jump A & B or 1 and 2 pins***** together on the _lug. Aircraft ammeter should show eavy rate of charge. If heavy charge rate is observed, replace regulator. If heavy rate is not observed, proceed to step 5. "***'24-0001 thru 24-2999; pins 5 & 7 for 24-3000 & ON CAUTION: Pull alternator field CIB. Start engine; while at idle RPM reset C/B. slowly increase RPM while monitoring bus voltage. DO NOT EXCEED 14 volts for 24-0001 - 24-2999; or 28 volts for 24-3000 thru 24-TBA. Defective wiring regulatorto alternator, 4. Check resistance from F2 terminal + of alternator to pin B or 2 ++of reg. plug. Normal indication is a very low resistance. If reading indicates no, or poor continuity, repair or replace wiring from regulator to alternator. + 24-0001 thru 24-2999, field terminal for 24-3000 thru 24-TBA ++24-0001 thru 24-2999; Pin 7 on 24-3000 thru 24-TBA Defective alternator. +++ 24-0001 thru 24-2999; case to field on 24-3000 thin 24-TBA 5. Check resistance from F2 to F1 term.+++of alternator. Normal indication is 3 - 4 ohms. If rasistance is high or low, repair or replace alternator. 6. Check resistance from F2 terminal of alternator to altemator case. Normal indication is high. If resistance is low, repair or replace alternator. (24-0001 thru 24-2999) 12-98 24-39-00 11 MOONEY AIRCRAFT CORPORATION 24-39-02 24-39-03 M20J SERVICE AND MAINTENANCE MANUAL - RESERVED - BA'n'ERY TROUBLE SHOOTING TROUBLE _ REMEDY Dischargedbattery. Battery worn out. Replace battery. Improperchargingrate setting. Excessive discharging, Reset chargingrate. Turn off some equipmentwhen alternator is notcharging. Decrease starter usage by usingexternalpower whenever possible, Standing too long. Remove and recharge battery. Equipment accidentally lefton. Remove and recharge battery. Impure electrolyte. Replace battery. Short circuit (ground) in widng. Check widng. Low charging rate. Adjust voltage regulator. Loose hold-down bracket. Replace battery and secure firmly. Frozen battery. Charging rate too high. Replace battery. Reduce charging rate by adjusting voltage regulator. Too much water added to battery and charging rate too high. Spillage from overfilling. Drain battery and keep at proper level; adjust voltage regulator. Leaking or clogged vent lines. Repair or clean vent lines. Charging rate too high. Adjust voltage regulator. Discharged battery. Replace battery. Water added and battery not charged Always recharge battery for 1/2 hour following addition of water in freezing weather. Leaking battery case. Frozen electrolyte. Replace battery, Reversed battery polarity. Cables connected backwards on battery or charger, Battery should be slowly discharged completely, then charged correctly and tested. Excessive water consumption in all cells. Charging rate too high. Correct charging rate. Excessive water consumption in one cell only. Cracked jar. Replace battery. Cracked cell jars. Compound on top of battery melts, Electrolyte runs out of vent plugs, Excessive corrosion inside container, Battery freezes, 24-39-02 12 12-98 Flush container with baking soda solution. SERVICE AND MAINTENANCE MANUAL 24-39-04 M20J MOONEY AIRCRAFT CORPORATION - STARTER TROUBLE SHOOTING TROUBLE PROBABLECAUSE REMEDY Motorfails to operate. Lowbattery. Checkand_=charge I_te_yifnecessa_. Defective,improper,or loose wireconnections, Refer to electricalwiring diagram and checkallwiring. Binding,worn,or improperly seated brushes;brusheshave excessive side play. Brushesshouldfitfree in brushboxes withoutexcessivesideplay.Clean brushesand brush boxeswith vareol moistenedcloth. New brushes should be run-inuntilat least 50 percent seated; however,if facilitiesare not available for runningin brushes,seat brush by insertingstrip of No. 00O0sandpaper between brushand commutator with sanded side next to brush. Pull sandpaper indirectionof rotation,being carefulto keep it in same contoursas commutator. Dirty commutator If commutator is rough or dirty, smooth and polish with No. 000Osandpaper. If too rough and pitted, remove commutatorand turn on lathe. Blow out all foreign material. Shorted, grounded, oropen armature, Grounded or open field circuit. Rernoveandreplacewith an armsture knownto bein goodworkJngorder. Test and repair circuit if possible or replace with new parts. Defective master switch or circuit. Defective solenoid switch. Check and repair. Defective starter. Remove and repair or replace. Slow cranking speed. Worn, rough, or improperly lubricated motor or starter, Starter motor runs but will not crank engine, Same causes as listed with "Motor fails to operate." Damaged pinion gear or crankshatl gear. Dirty starter drive. Disassemble, clean, inspect & relubricate components, replace ball bearing if worn. Same remedies. CAUTION: Do not use coarse sand-paper or emery cloth. Alter seating, thoroughly clean brushes and commutator to prevent excessive wear. Keep motor bearing free from sand or metal particles. Starter drags. Excessive motor brush arcing. Check and repair. Remove and replace. Clean and lubdcate with graphite & kerosene. Low battery charge. Check and recharge. Relay or solenoid contacts bumed or dirty. Defective power cable. Worn or dirty commutator. Remove and replace. Binding, worn, or improperly seated brush or brushes have excessive side play. Dirty, rough, pitted, or scored commutator. 12-98 Remove and replace. Turn down commutator. Repair as outlined above. Clean as outlined. 24-39-04 13 MOONEY AIRCRAFT CORPORATION TROUBLE -STARTER TROUBLE SNOOTING (eon't,) _ Excessive motor brush wear / arcing, Noisy starter. M20J SERVICE AND MAINTENANCE MANUAL REMEDY Rough or scored commutator. Remove and turn down commutator on lathe. Armature assembly not concentdc. Worn starter ddve pinion. Reface commutator. Worn or broken teeth on crankshaft,gear. Check teeth and replace gear if damaged. Remove and replace starter drive. 24-39-05 - ANNUNCIATOR TROUBLE SHOOTING (24-0001 thru 24-3153) The followingis a bdef failurecause analysis which pertains to the annunciator(IAI P/N 500D0061) onthe Mooney M20J. Each cause is listed in probable order. All designator references are made from IAI drawings 710D0125A, 900D0134 and 900D0135. 1. The "gear-down" lampwillnot lightduring"TEST butwill lightwiththe gear-down. CR1 (Assy A2) open 2. The "gear-down"lampwillnot lightduring"TEST" or with the landinggear-down. Filamentof DSI (AssyA2) open 3. The "gear-down"lampis dim when the positionlightsare off. CR24 (Assy A1) open 4. The "gear-unsafe"lampwill not lightduring"TEST" but doeslightwhen the gear is in transit. CR3 (AssyA2) open 5. The "gear-unsafe"lampwill lightduring=TEST"but notwhen gear is in transit. CR2 (Assy A2) open 6. The =gear-unsafe"lampwill not lightdudng"TEST" orwhenthe gear is in transit. Filamentof DS2 (AssyA2) open CR2 (Assy A2) and CR3 (AssyA2) open 7. The "left low fuel" lamp will not lightduring =TEST" or in a left low fuel situation. Filament of DS3 (AssyA2) open Q2 (AssyA1) defective U1 (Assy A1) defective Wire fromP1-7 (Assy A1) to leltfuel gauge open 8. The "left low fuel" channel functionsproperly but the lampis alwaysdim. CR22 (Assy A2) open 9. The "lettlow fuel" lampflickerson and off. Switch $1 (AssyA1) is in the "Cal" positioninsteadofthe "NORM" position. Intermittentground on the wirefrom P1-7 (Assy A1) to the left fuel gauge. C2 (Assy A1) defective 10. The "left low fuel" will not light during "TEST only when the left fuel tank is full. R10 (Assy AI) should be replaced with a 47K, 1/4 watt, 5% resistor 11. The "right low fuel" lamp will not light during "TEST" or in a right low fuel situation. Filament of DS4 (Assy A2) open Q6 (Assy A1) defective U1 defective The wire from P1-8 to the right fuel gauge is open 12. The "right low fuel" channel functions properly but the lamp is alwaysdim. CR23 (Assy A2) open 13. The "right low fuel" lamp flickers on and off dudng flight. $1 (Assy A1) is in the "Car position instead of the "Norm" position An intermittent ground on the wire from P1-8 (Assy AI) to the gauge C3 (Assy A1) defective 14. The =dghtIo_; fuel" will not light during "TEST only when the dght fuel tank is full. R10 (Assy A1) should be replaced with a 47K, 1/4 watt, 5% resistor 15. The "right low fuel" orthe "left low fuel" lamps light before a low fuel situation has occured. Recalibrate the appropriate channel CR1 (Assy A1) open. 24-39-05 14 12-98 SERVICE AND MAINTENANCE MANUAL M20J MOONEY AIRCRAFT CORPORATION - ANNUNCIATOR TROUBLE SHOOTING (24-0001 thru 24-3153) (con't.) 16, Both the "let1 low fuel" and the "dght low fuel" channels stay dim when they annunciate a low fuel situationor during "TEST', Q3 (AssyA1) defective Q5 (AssyA1) defective U2 (Assy A1) defective Q4 (AssyA1) defective CR22 (Assy A1) and CR23 (Assy A1) open 17, Neitherthe "left low fuel" northe "rightlow fuel" lightsduring "TEST". CR1 (Assy A1) shorted U1 (Assy A1) defective 18. The "high low vac" lamp will not light during "TEST" but does annunciate a high or low vacuum situation. CR14 (Assy A1) open 19. The =highlow vac" lamp will not lightdudng "TEST" or in a high orlowvacuumsituation. Filament of DS5 (Assy A2) open Q7 (AssyA1) defective 20. The =high low vac" lamp will not light in a low vacuum situation but does light in a high vacuum situation. Q8 (Assy A1) defective CR12 and/or CR13 (Assy A1) open 21. In a low vacuum situation the "high low vac" lamp lights but does not flash. CR16 (Assy A1) open Q8 (Assy A1) defective U2 (Assy A1) defective CR1 (Assy A1) shorted 22. The "high low volts" lamp will not light dudng "TEST" or in a high or low voltage situation. Filament of DS6 (Assy A2) open Q10 (Assy A1) defective Q9 (Assy A1) defective 23. The "high low volts" lamp will not "TEST" but does annunciate a low or high voltage situation. CR20 (Assy A1) open 24. The "high low volts" lamp lights but does not flash in a low voltage situation. CR17 (Assy A1) open Q8 (Assy A1) defective U2 (Assy A1) defective 25. The "high low volts" lamp will not light in a over voltage situation. CR21 (Assy A1) open 26. The "high low volts" lamp flashes before a low voltage situation has occured. RG0(Assy A1) out of calibration U2 (Assy A1) defective CR1 (Assy A1) open 27. The "high low volt" will not light in a low voltage situation. RG0(Assy A1) out of calibration U2 (Assy A1) defective CR19 (Assy A1) open Q8 (Assy A1) defective CR1 (Assy A1) shorted 28. The "RAM air'' will not light dudng "TEST" or in normal operation. Filament of DS8 (Assy A2) open CR6 and CR7 (Assy A2) open 29. The "RAM air" will not light dudng "TEST" but does in normal operation. CR7 (Assy A2) open 30. The "RAM air" will light during "TEST" but not during normal operation. CR6 (Assy A2) open 31. The "START POWER ON" light does not illuminate when "TEST" switch is pushed. This is normal operation; all circuits OK. 32. Once dimmed the "low fuels" cannot be reset to bdght by momentadly depressing the "TEST" switch. CR11 (Assy A1) open. 12-98 24-39-05 15 MOONEY AIRCRAFT CORPORATION M2OJ SERVICE AND MAINTENANCE MANUAL -ANNUNCIATOR TROUBLE SHOOTING (24-0001 THRU 24-3153) (con't.) 33. Neither the "high low vac" orthe "high low volts" will flash when low vacuum and/or low voltage occurs. Q8 (Assy A1) defective U2 (Assy A1) defective CR1 (Assy A1) not suppling +5 VDC C5 (Assy A1) defective 24-39-06 ANNUNCIATOR TROUBLE SHOOTING (24-3154 thru 24-TBA) The following is a brief operational analysiswhich pertains to the I.A.I. annunciator on the Mooney M20J SIN 24-3154 thru 24-TBA.. 1.0 GENERAL 2.0 POWER SUPPLY This document is intended to be a guide to assist a service technician in understanding the theory and operation of International Avionics, Inc. (!AI) Part Numbers, 9500326000 & 9500326001 annunciators.It is not intended to serve as a bench service aid in that reference designators in various Figures are not consistent with those found in actual annunciators, Service literature is available from International Avionics, Incorporated (IAI), 1611 N. 1-35, Suite 428, Carrollton, TX 75006, telephone number (214) 446-1185, to identify location of a particular component and exact manner in which components are interconnected, The following sections address nine (9) basic circuits which, used singulady or in multiple combinations, comprise the annunciators. These sections are as follows: Section 2 Power Supply, with Test and Dim switches Section 3 Flasher Section 4 Landing Gear Indicators Section 5 Let_and Right Low Fuel Section 6 Hi/Lo Vac Section 7 Alternator/Low Volts/Over Volt Section 8 NOT USED Section 9 Typical Positive Apply W/Dim Section 10 Typical Positive Apply W/O/Dim. ,_"',, ;' "; ,,_,'=,, The Power Supply, shown in Figure 1, provides 12 VDC, reverse voltage protectionby means of CR1, spike and overvoltage filtering by means of the low pass network of R1, R2, C1 and C2 with spike clamping provided by CR2. The actual power supply is a 12VDC, integrated circuit regulator. Output filtering is provided by C2. The Test Switch, $1, switches unfiltered aircraft 28 VDC to the internal test line, identified with the mnemonic TEST+. This signal, diode isolated by CR5, is also supplied as OUTTEST+. Additionally TEST+ is applied to the inverter to supply the internal test line, TEST-, and the diode isolated our-FEST-. The dimmer circuit, applicable to certain channels, requires a bias source, DIMBIAS, with a magnitude of 12 VDC to dim the applicable ACTIVE channels, approximately 3 VDC to maintain the dim level of those channels previously dimmed, and near 0 VDC to reset the dimmed channels to a bright condition. The channels having the capability of being dimmed by the above circuitry are channels x, x, x, x, x, x, and x. Channel 1, Landing Gear, dims by means of a separate circuit and is discussed in Section 4.0 below. With both the Dim Switch and Test Switch relaxed, transistor Q3 is in saturation and 02 is off, giving DIMBIAS a value of approximately 9 VDC. When the Dim Switch is depressed Q3 comes out of saturation and DIMBIAS rises to 12 VDC, and when the Test Switch is depressed Q2 saturates and DIMBIAS drops to near O VDC. In the event that both switches are depressed simultaneously, the 0 VDC value of DIMBIAS will prevail and the dimmed c_ ' +'"=_""'' ¢$1_j C :3 " ! L CI=S '_D= bright cond t on channels, with the exception of Channel 1, are reset to l ] zzuDc $1,1 2 n_ 33k r --..,v__ I+1Mm I t,s F'LRSI _ _. 24-39-06 16 2. 2K 12.98 4. ?_t_ _IGURE: 2 - FLftSI.IgI_ SERVICE AND MAINTENANCE MANUAL M20J MOONEY AIRCRAFT CORPORATION 3.0 FLASHER The Flasher, shown in Figure 2, provides the circuit to flash the outputs of the left and right aitemator warnings, the low voltage warning and the low vacuum warning. The flasher consists of an astable oscillator ddving an NPN common emitter connected transistor, Q4. Thistoallows open from collector Q4, amplifiers identified as FLASH, sink the the drive the of output of the appropriate warning channels. bdlliance. The GEAR UNSAFE channel accepts +28 VDC, INPOS2, through isolation diode CR10, illuminates at full brilliance and does not dim. A test signal, TEST+ is applied to both GEAR DOWN and GEAR UNSAFE through CR8 and CRll respectively. 6.0 LEFT AND RIGHT LOW FUEL The Left and Right Low Fuel circuits are shown in Figure 4. The the dght channels are similar, and only the left left and channel will be discussed herein. 4.0 LANDING GEAR INDICATORS The Landing Gear Indicators, shown in Figure 3, provide the status of the landing gear position, that is, whether the landing gear is Down or not and whether the landing gear is safe or unsafe, unsafe being in transit. The circuitshownis the identicalcircuitthat has been used for many years in the IAI annunciators used on Mooney aircraft. The GEAR DOWN channel is dimmed for night operation; however, in the interest of reliability, the dimming circuit is separate from the dimming technique used on the other dimmed channels. The gear down signal, +28 VDC, is applied through isolation diode CR7, to the INPOS1 input and CHIRET is returned to the Nay Light bus. When +28 VDC is applied to INPOS1 and the Nay Lights are off, the impedance of this point is very low due to the low filament resistance of the Nav Light bulbs, and GEAR DOWN illuminates at near full brilliance. When the Nov Lights are on, however, CH1RET is also +28 VDC and DR9 switches this return path off, the return path for the GEAR DOWN lamp being through R15 to Ground and GEAR DOWN now illuminates at reduced Signals from the junction of the le£_ and dght fuel transducers and the left and dght fuel quantity gauges are applied, respectively, to each of the inputs INPOB3 and INPOS4. This signal is an analog signal that indicates the quantity of fuel measured, the typical low fuel point being on the order of 0.1 volt. The low fuel circuits can, however, annunciate an input up to approximately 0.7 volt. The input, INPOS3, is applied through an isolation resistor R55 to the inverting input of open collector comparator U5:C. The input is compared with the set point effected by the setting of R51, accessible through the front of the annunciator, and, when the input is less than the set point, the comparator's output is allowed to rise by means of the pull-up resistor R54 and the network R48, R49, and C9. Feedback resistor R53 provides a small amount of hystedsis to preclude oscillation at the transition point. The exponentially rising output of U5:C is applied to the inverting input of open collector comparator U5:B and is compared with a reference voltage of approximately 6 VDC. When U5:B switches its output to ground Q10 conducts and drives Q8 into saturation to light the L LOW FUEL channel lamp, DS3. The Q10 - Q8 network is required to provide the transition between the internal 12 VDC and aircraft +28 VDC. The delay provided by the charge of C9 through R48 and R49 provides filtering to preclude false annunciation in rough air. When the fuel level dses, c_? _,_oos [_}_ [_Pos t cR8 _,_s ].r_pPos_ psi 7327 _- C_,IRET L,_,B_S I_" cR91 n_s ._._v/_ Posl R_'r / cRle _,_,oes [HPosz TEST':- [_ ca_-i _,,,_o_ _ zsuDc Dsz _2_ the charging rate of the filter C9, thus reducing the delay to approximately 2 seconds. In order to applying through - CR15 to accelerate R49. The TEST+ delaythe time of theR42 charging network provides adjusted with screwdriver adjustment accessible through the front of the annunciator while there is a preset number of fuel gallons in thethe tank. timeR51, delay calibrate the low channel setThe point, is must be removed from the circuit by moving $3, accessible through the front of the annunciator, from This opens the return for capacitor C9 and the the NORMAL position to the CALIBRATE indication on the L LOW FUEL channel willposition. not be [ time delay by moving $3 from the CALIBRATE position the NORMAL position. The position delayed. back After to calibration is accomplished, restore the $3 can be determined without removing the front of the annunciator. When the TEST switch is depressed observe the indication of L LOW FUEL and R LOW FUEL. With 83 in the NORMAL position there is a delay of approximately 2 seconds in Illumination, but with B3 in the CALIBRATE position there is no delay in illumination. LMPPeSz_ _1 _[CURE 3 - LnNDtHC _ low output state, C9 is discharged rapidly through a delay in low fuel annunciation approximately 20 due to sloshing and of U5:C a seconds. A test inofthe thetank functioning of switches the low to fuel channel is accomplished by applying TEST+ through R43 - CR18 to the input of U5:C to switch U5:C and _N_C_TO_S 12-98 24-39-06 17 MOONEY AIRCRAFT CORPORATION M20J SERVICE AND MAINTENANCE MANUAL Up to this point the circuits used to annunciate low fuel are the same circuits that have been used for many _ - F __ ,, _ _---_'- = ,_ _ _>-__ _ _ -° I /1_" I_" _-_"_ _ o The method of dimming, however, has been changed and expanded from what has been used in the past. In the pastonlythe low fuel channelsdimmed, excluding yearn GEAR inDOWN IAI annunciators discussed used above, Mooney whileadditional now aircraft. the5 dimming has been expanded to on include channels. From the perspective of the pilot the switchand operation is the same, depressthe theTEST DIM switch and active channels dim, depress active dimmed channels return to bright. When a dimmed channel is extinguished and then reactivates it will reactivate bright. The method to accomplish this, however, is considerably different from the past. Each , ;,,_>_ /1_ ,,_ IL,. _., _ =_ case Q8 which returnsthe lamp to ground through two parallel paths. The path to provide a dim indication is channel to be dimmed is driven by a transistor, in this through resistor R29 which reduces the brilliance of the lamp. In the bdght mode R29 is shorted by Q6 and CR13 which provide a low impedance path to ground. I Trans stor Q6 s contro ed in conduction by a latch composed of U3 and its associated resistors R22, R23, R24, R25, R26 and R27 as well as the signals DIMBIAS and DIMIN3. If the channel is active DIMIN3 will be near ground and with DIMSIAS near 3 VDC, ._ j__._ == .... =o _ -_-,=_ ° _ E L-_ the output ofWhen U3 will high,Switch thus ddving Q6 into conduction. thebe DIM is depressed momentadly, DIMBIAS goes high to 12 VDC and U3 switchesits outputlow and latches thmugh R26. This _ _. _ _= _ o _ = _ i_ t _== _= "= _ = == _ _, •_ '== ' == __ = _ _,_ -_l-------_-_ o 0" ==_: _._: " _-1- When the TEST Switch is depressed momentarily, DIMBIAS goes low and U3 switches its outputhigh, latches through R26, and drives Q6 into conduction. When the channel deactivates, Q8 opens the retum to ground and DIMIN3 rises which returns latch U3 to a high outputstate. 6.0 HI/LO VAC The High/Low Vacuum circuits are shown in Figure 5. This channel is designed to accept two +28 VDC signals, one from a low vacuum sensor and one from a high vacuum sensor. When low vacuum is detected the annunciator will flash and when high vacuum is detected the annunciator will illuminate steady. A +28 VDC signal applied to LOW VAC INPUT will drive Qll into conduction through the bias network R56, R57, CR17, and thus illuminating DS9. The as signal FLASH will, CR22, however, remove this ddve signal the flasher cycles, thus flashing Dsg. A +28 VDC signal applied to HIGH VAC OVERRIDE will bypass the above network and drive Qll into conduction regardless the state LOW VAC INPUT. Similarly TEST+ willofddve Qll of into conduction regardless of the state of LOW VAC INPUT. The channel High/Low Vac does not dim. 0= _u_ 24-39-06 18 12-98 SERVICE AND MAINTENANCE MANUAL M20J MOONEY AIRCRAFT CORPORATION zeuae DS9 7_27 Rs? Low uAc ,,out ' 6.oR ,vv. [ cRzz _,,4e_5 _., n_ 4._.n_ _L =-. channel flashes, and when detected overvoitage tdpped the annunciator is detected the annunciator channel illuminates steady. Comparator U6 monitors the aircraft 28 VDC by comparing the voltage at the _ _'LASI-I CR19 -_: u_,Bes / cry? L_,,.e_s _., , cR4 _ nso ">,. oK _,_5 _1" elcI_ UACTEST-,. OUEeRIDE _. CRZ_ _,,,4_s / _ Indicates that the aircraft bus voltage is less than 26.5 VDC. When low voltage is detected internally or when low current is _11 ,,,,a_, arm of R68 with the regulated voltage at The the output junction and R65. of of ue,R64 an open collector comparator is normally low. When low Voltage is detected the output of U6 conduction through the bias t rises Q12CR28, into networkand R6O,drives CR24. and thus illuminating DS1O. In a manner similar to the Hi/Lo Vac channel, the signal FLASH will FIGLIRE 5 - HI/LO ut_c remove this ddve signal as the flasher cycles, thus flashing DS10. A +28 VDC signal applied 7.0 ALTERNATOPJLOWVOLTS/OVER VOLT to LOVERRIDE will bypass the above network and The Alternator/Low Volts/Over Volts circuits are shown ddve Q12 into conduction regardless of the state of the in Figure 6. This channel is designed to accept two comparator U6. Similarly TEST+ will ddve Q12 into signals, the +28 VDC signal LOVERRIDE from the conduction regardless of the state of the comparator overvoltage tdpped output on the left alternator U6. A +28 VDC signal applied to LOVERRIDE also regulator, and one signal derived internally that drives Q12 into conduction regardless of the states of either comparator U6 or U7. Similarly TEST+ will drive Q12 into conduction regardless of the states of either cemparator U6 or U7. The channel Left 2evoc _2voc 2BV0C asia Alternator/LowVolts/Over Volt does not dim. , , , 8.0 NOT USED _4.'7K ;15K .21{ , RB2 (FIGURE7 NOTUSED) {:R29 4 TPh LOW VOLT SET g.o TYPICAL POSITIVE APPLY W/DIM _N_05 Re0 CR24 A typical PositiveApply, Dimmable circuit is shownin U6 1OK 1N4005 IN4OQ5 .... Figure 8. This is designed to accept CR20 VDC signal to channel illuminate an indicator channela +28 and ].oo I !R.5 IR., R67 L2K ,R64 ._ , provide for dimming of that channel, as well. Dimming is accomplished in a manner similar to that CR_S L ]VERRIDE "1 ]T_% LASH described isfor low fuel channel Theto input, XlNPUT, applied through CR35above. and R84 drive Q15 into saturation and light DS-X. TEST+ is applied through CR36 and R84 to also ddve Q15 into saturation and light DS-X. These 5 channels may be dimmed by depressing the DIM switch to dim the active channels. Depressing the TEST switch returns the active dimmed channels to bdght. When a dimmed channel is extinguished and then reactivates it will reactivate bdght. Each channel to be dimmed is ddven by a transistor, in this case Q15 which retums the lamp to ground through two parallel paths. The path to provide a dim indication is through resistor lrl_10a5 RB3 CR27 _B_ CR2B _voc RT4 __ ,LTBIA5 H RSg 1.SBO001XXX '_ .C1,_7 _,LTBIASL R75 _)__ _L LSBOOO1XXX R__ ..... _1 I_V= oc _%_' ._.J 1 _i1/_-uC33°_ R85 which reduces the brilliance of the lamp. In the bdght mode R85 is shorted by Q14 and CR34 which providea low impedance path to ground. Transistor Q14 is controlled in conduction by a latch composed of U9 and its associated resistors R86, R87, R88, R89, R9O and R91 as well as the signals DIMBIAS and DIMINPUT. If the channel is active DIMINPUT will be near ground and with DIMBIAS near 3 VDC, INPUT 1.SBO0DIXXXR_72 J FIGURE 5 -- ALTERNATOR, LO'_WOLTS/OVER VOLT 12-98 24-39-06 19 MOONEY AIRCRAFT CORPORATION M20J SERVICE AND MAINTENANCE MANUAL LAMP 3.2 UDC DS--X q14 7a27 DIMOUTPUT ZH6e_9 4 cR3e t Bes 47B _ 90 CR34 RBB 6. DE 12 UDC 47K I{91 qte 47_ c 14 e. et "_ RB6 2 Z_ _le? _ trt4e_ Re4 cR 36 Req 4va _ 12 LIDC up_L u9 -_- ¢3302 2_3a t9 IMBIAS t N4_IB_ %, 'EST+ FIGURE 8 - TYPICAL POSITIVE APPLY W/DIM the output of U9 will be high, thus driving Q14 into conduction. When the DIM Switch is depressed momentarily, DIMBIAS goes high to 12 VDC and U9 switches its output low and latches through R87. This low output removes the ddve from Q14 and DS-X dims. When the TEST Switch is depressed momentarily, DIMBIAS goes low and U9 switchesits outputhigh, latches throughR87, and drives Q14 into conduction.When the channeldeactivates, Q15 opens the returnto ground and DIMINPUT rises which returns latch U9 to a highoutputstate. 10.0 TYPICAL POSITIVE APPLY W/O/DIM 24-50-00 24-51-00 - POWER DISTRIBUTION SYSTEM The power bus distributesdirect current power to the electrical system from the alternator and from the battery throughthe battery relay.The negative battery lead attaches to a structural ground on the airframe. The master switch"ON" closesthe relay and supplies powerto the aircraftelectricalsystem. A typical Positive Apply, Non-Dimmable cimuit is shown in Figure 9. This channel is designed to accept a +28 VDC signal to illuminatean indicatorchannel, but does not providefor dimmingof that channel.The input,YINPUT, is applied through to light DS-Y. TEST+ is appliedthroughCR37 to CR38 also lightDS-Y. CR 38 TEST-,- CR37 tFI400S [_#]] _ tb14005 F '['GURE 7YPICRL 24-50-00 2O POS_T[UE { 9 _ DS-y _ 2322 --_ _PPLY - ELECTRICAL LOAD DISTRIBUTION NO/DI_ 12-98 CAUTION Do not reset a circuit breaker after it has tripped a second time. If necessary to do so to locate the malfunction, be alert for a possible electrical fire. Breakers are "Trip Free" type and cannot be held in the closed position. MOONEY AIRCRAFT CORPORATION M20J CHAPTER 25 SEATS SERVICE AND MAINTENANCE MANUAL MOONEY AIRCRAFT CORPORATION M20J SERVICE AND MAINTENANCE MANUAL CURRENTLY NOT BEING USED 12-98 25-SEATS 1 SERVICE AND MAINTENANCE MANUAL M20J INTENTIONALLY LEFT BLANK 25-SEATS 2 12-98 MOONEY AIRCRAFT CORPORATION MOONEY AIRCRAFT CORPORATION M20J SERVICE AND MAINTENANCE MANUAL CHAPTER 27 FLIGHT CONTROLS SERVICE AND MAINTENANCE MANUAL M20J MOONEY AIRCRAFT CORPORATION CHAPTER 27 FLIGHT CONTROLS LIST OF EFFECTIVEPAGES CHAPTER SECTION SUBJECT ........... 27-EffecUvity ......... 27-Content .......... 27-00-00 ............ 27-20-00 ............ 27-29-00 ............ 27-30-00 ............ 27-30-03 ............ 27-31-00 ........... 27-40-01 ........... 27-50-00 ........... 27-50-00 ........... 27-60-00 ........... 27-93-01 ........... 27-94-00 ........... 27-95-01 ........... 27-96-00 ........... PAGE .......... DATE 1/2BLANK .......... 3/4BLANK .......... 5 ........... 6 ........... 7 ........... 8 ........... 9 ........... 10 ........... 11 ........... 12 ........... 13 ........... 14 ........... 15 ........... 16 ........... 17 ........... 18 ........... 12-98 12-98 12-98 12-98 12-98 12-98 12-98 12-98 12-98 12-98 12-98 12-98 12-98 12-98 12-98 12-98 12-98 27-EFFECTIVITY 1/2BLANK MOONEY AIRCRAFT CORPORATION M20J SERVICE AND MAINTENANCE MANUAL CHAPTER 27 FLIGHT CONTROLS CHAPTER SECTION SUBJECT TABLE OF CONTENTS ........... 27-00-00 ........ 27-10-g0 ......... 27-20-00 ......... 27-30-00 ......... 27-30-03 .......... 27-31-00 .......... 27-40-00 ......... 27-40-01 .......... 27-42-00 ......... 27-50-00 ......... 27-60-00 ......... 27-90-00 ......... 27-91-00 .......... 27-92-00 .......... 27-93-00 .......... 27-93-01 ............ 27-94-00 .......... 27-95-00 .......... 27-95-01 ............ 27-96-00 ......... 27-96-01 .......... SUBJECT ........ General .............. Aileron System ........... Rudder & Steering System ........ Elevator System ........... Empennage Free Play ........ Trim Assist Bungee Rigging ...... StabUizerTdm System ......... Trim System Troubleshooting...... Electric Tdm Pitch Maintenance ...... Wing Flap System .......... Aileron/Rudder Interconnect System ..... Miscellaneous ........... Control Surface Static Balancing ..... Equipment - Static Balancing ...... Balancing Procedures - Static Balancing. Detail Procedures-Static Balancing . Control Surface Trailing Edge ...... StalIWaming Maintenance Practices.. . TroubleShooting- Stall Warning System Speed Brakes System ......... Maintenance - Speed Brakes ...... 12-98 PAGE 5 5 6 8 9 10 10 11 11 12 14 14 14 14 14 14 16 16 17 18 18 27-CONTENTS 3/4BLANK SERVICE AND MAINTENANCE MANUAL M2OJ MOONEY AIRCRAFT CORPORATION 27-00-00 - GENERAL The aircraft,has dual flight controlsand can be flown from eitherthe pilotor co-pilotseat. Dual pairs of foot pedals control the rudder and nose wheel steering mechanisms. The co-pilot pedals are removable if optionaldual brakes are not installed.Push pull tubes actuate the all-metal flight control surfaces. Rod-end beatings are used throughout the flight control systems.These bearings are simple and require little maintenance other than occasional lubdcation. Specially designed aluminum-alloy extrusions, that permit flush skin attachment, form the leading edges of the rudder and elevators. Electrically actuated wing flap systems are installed on all models. Longitudinal pitch trim is achieved through a trim control system that pivots the entire empennage around the tailcone attachmentpoints. at rod end (7) (Figure 27-2) so that aileron (in neutral position) is 0° to -2 ° down (with no additional tolerance) as measured with travel board at wing station indicatedon travel board GSE 030003. NOTE Wing station 147.76 is located at skin splice line between flap outboard end and aileron inboard end. 27-10-00 G. Rotate the left control wheel clockwise until the ailerons contact the aileron stops (8) (Figure 27-2). Adjust control tube (B) at rod ends (1) and (5) (Figure 27-1) by looseningthe lock nut and turning tube clockwise or counterclockwise to attain .020 maximum clearance using feelergauge (N), (Figure 27-1). Secure Iocknuts (1) and (5) and recheck .020 dimension. Repeat the operation on right control wheel by turning wheel counterclockwise until ailerons contact the stops, then proceed as described for the left control wheel. Rigging is now complete. 4. AileronRigging(S/N 24-1426 & ON). A. Level controlwheels - (Reference 27-10-00, 3, B Procedures). B. Install3/15 dia. rig-pinsat: -AILERON SYSTEM 1. Ailerons. The ailerons are of all-metal constructionwith beveled trailing edges. Three hinges of machined, extruded aluminum attach the ailerons to the air wing spar outboard of the wing flaps. The ailerons link to the controlwheel through push-pulltubes and bellcranks, Lead counter-weightsstaticbalancethe ailerons, 2. AileronRemoval and Intallation. A. Remove control tube attaching bolt, nut, and washer at aileronhorn. B. Remove bolts,nuts, and washersfromthe three attachinghinges. C. Remove aileron by pulling it straight air until hinges are clear, rotate inboard portion down and forward to allow aileron balance weights to clear wing tip (if configured). D. Reinstall aileron in reverse sequence of removal. E. Recheckboltsfor securityand safety. 3. Aileron Rigging and Control Adjustment (SIN 24-0001 thru 24-1424). A. Use a straight edge (A), (Figure controlwheels in accordance withstep B.27-1) to align B. Adjust control tube (B) linking control wheel shaft (C) at rod ends (5). Clamp or otherwisesecure controlwheels in the level positionuntil stepsC thru E are completed, F. Remove clamps from control wheels, then adjust aileron stoj0s (8), (Figure 27-2) so the down travel is 8° +/- lU. Aileron up travel may vary from 12-1/2 ° to 17° (with no additionaltolerance), (12-112o to 14-1/2° SIN 24-1038 and ON). NOTE The aboveaUeron rigging and adjustment instructions apply to both the left and right ailerons. (1) Jackshal_(C) (Figure 27-1) (2) Bellcrank(E) (Figure27-1) (3) Bellcranks (9) (Figure 27-2) (Both L.H. and R.H.) C. Adjust controltubes (F) (Figure 27-2) (L.H. and R.H.) to positionailerons at 0 degrees to 2 degrees down. D. Adjust remaining control tubes (F), (B), (D), (Figure 27-1) (L.H. and R.H., if applicable) in order to freely attach to the bellcranksand jackshatt. E. Remove rig-pros. F. Adjust aileronstops (Reference Figure 27-2) per paragraph27-10-00, 3, G. Tolerances are specified in paragraph27-10-00, 3, F. C. Adjust control tube (D) at rod end (2) so that aileron center bellcrank (E) is 1/16 inch left of center facingforward, FIGURE 27-1. D. Adjust aileron control tubes (F) by removing bolt, nut and washer (4) (Figure 27-1) and loosening Iocknut(6) (Figure 27-2). The aileron control tube (F) can then be rotated clockwise or counterclockwiseso that the center of the outboard bolt (K), (Figure 27-2), is 4 3 nches from spar web (M). Replace bolt, nut and washer (4), (Figure 27-1), and recheck 4.3 inch dimension. NOTE Refer to SECTION 27-60-00 for Aileron/Rudder Interconnect System Rigging Procedures E. Adjust aileron push-pull tube (J) (Figure 27-2) 12-98 27-00-00 5 MOONEY AIRCRAFT CORPORATION M20J SERVICE AND MAINTENANCE MANUAL 5 ]3 H SM27-I AILERON & ELEVATOR CONTROL WHEEL RIGGING - FIGURE 27-1 27-20-00 - RUDDER AND STEERING SYSTEM 1. Rudder. The rudderattaches to the aft vertical fin spar at four hinge points. Push-pull tubes and bellcrankslinkthe rudderto the rudderpedals, 2. Rudder Removal and Installation. A. Detach rudderpush-pulltube fromrudder horn. B. Remove attachinghardware at rudderhinges, C. Remove rudder by pullingitstraightaft. D. Install rudder in reverse sequence of removal, Recheckattaching boltsfor security and safety. 3. Rudder Rigging and Adjustment. A. Raise aircraft nose. (A propelleryoke jack may be used.) B. Set stabilizer tdm control in neutral position 27-20-00 6 (stabilizer parallelwith aircraftcenter line). C. Clamp pilotsrudder pedals (A), (Figure 27-3), in neutral position D. Adjust Rod Eng beadng (B)(Fig. 27-3) approximately9-11 turns outto start. E. Adjustrudder control tube (C) at rear tailcone bulkhead bellcrank, (Figure 27-5), approximately 6 turns out at startingpoint. F. Adjust ruddercontroltube (D), (Figure27-6), rod end bearing (at 2) 11 turns outto start. NOTE Rudder bellcrank, aft tailcone, should be modified per SI-M20-44. G. Adjust Rod End Beadng (B) (Fig. 27-3) to positionRudder 1° to the right. 12-98 SERVICE AND MAINTENANCE MANUAL M20J H. Unclamp rudder pedals, I. Adjust rudder stops (paddles) (M), (Figure 27-8), so that rudder travel is 23 degrees (+1,-0 degrees) MOONEY AIRCRAFT CORPORATION dght and left. J. Rudder stop limiter (R), (Fig. 27-8), may be bent to obtain clearances and contact with stops (M). NOTE / between adjustment stop (3) and gear truss assembly (4) (Figure 27-¢) when rudder is at extreme left and right travel position. K. After setting NLG steedng stops, retighten all jam nuts, boltsand secure recheck all travel limits. I On aircraft SIN 24-1464 & ON steedng stops (3) NOTE Measure rudder travel with travel board exists on rivet should be adjusted so .020 clearance line at station indicated on travel board GSE 030005, and with longitudinal trim (stabilizer) set in the 0 degree position. (8ta. 26.50 is located at skin splice on vertical fin). O I L. Adjust nose wheel steedng by removingnut, o steering idter linkage at (2). Bolts, nuts and washers at (5) & (6) must be installed from rear to front. washer & bolt (1), (FigureLimits 27-4), atand adjusting 4. Allowable Free-Play RUDDER VERTICAL MOVEMENT A. Maximum vertioal movement allowable at rudder trailing edge -.08 inches. (1) If excessive free-pray exists check the fallowing areas for wear: (a) Trim screw jackshalt. (b) Trim link connecting empennage to trim screw. AILERON STOP ADJUSTMENT - FIGURE 27-2 TRAVEL BDARD LrlCATIDN _'TA, a_ t/amA_IOVE C/L LEVELINr, SCREWS TRAV'-_ IlrlAp-_ LDCATIrlN BETWEENFLAP & AILERON STA. 147.75 m ( .. RUDDER PEDAL ADJUSTMENTS - FIGURE 27-3 SI427-3A TRAVEL BOARD LOCATIONS - FIGURE 27-3A 12-9B 27-20-00 7 MOONEY AIRCRAFT CORPORATION M20J SERVICE AND MAINTENANCE MANUAL 47 o SMJK_'7-4 NOSE GEAR STEERING LINKAGE ADJUSTMENT - FIGURE 27.4 (c) Bolls and brackels atlach_g empennageto ta#oone. 5. Rudder Torque Tube Removal, The rudder torquetubeshouldbe inspectedthoroughlyand replaced if any damage is found. Remove shield from front of cabin floorboard that covers torque tube. Remove attachinghardware from hingesand rudder pedal control rods.Carefully removetorque tube by slidingout toward the rightside of cabinand throughcabindoor. NOTE Control tube wear allowables. If any portion of the control tube exceeds .007 wear per wall or .014 in reduction in diameter, the tube must be replaced. 27-30-00 -ELEVATOR SYSTEM 1: Elevators. Elevator constructionis essentiallythe same as that of the ailerons. Both elevators attachto SNX27-7 SMP7-9 RUDDER & ELEVATOR TRAVEL ADJUSTMENT FIGURE 27-5 27-30-00 8 RUDDER HORN ADJUSTMENT - FIGURE 27-6 12-98 { SERVICE AND MAINTENANCE MANUAL M2OJ MOONEY AIRCRAFT CORPORATION wa k ng beams and bellcranks link both elevators to the control yoke. Both elevators are connected by control tubes to a common bellcrank in empennage. Lead counterweightsstatic balance both elevators. the stabilizer at four hinge points. Push-pull tubes .,,//1_"_ A. Remove push-pull control tubesbolls, fromnuts, elevator control horns by taking off attaching and 2. Elevator Removal andallInstallation. washer. _/_-_/ _ B. Remove bolls, nuts, and washers from the four attaching hinges. C. Remove elevator to the rear. D. Install elevatorsin reversesequence of removal. Recheck attaching bolls for secudty and safety. 3. Elevator Rigging and Adjustment A. Adjustrodend beating(3), (Figure27-1), at control yoke (G) for controlshaft (H) clearancefrom firewalland controlyoke(G) clearance fromfuselagestructure. B. Level aircraft and set control column in neutral withstabilizer parallelto center lineof aircraft. NOTE Measure elevator travel from O degrees stabilizer thrust line with travel board positioned at stabilizer station indicated on travel board GSE 030004 and with stabilizer at 0 degrees aircraft thrust line. (See Figure 27-3A & 27-11) NOTE Elevator bellcrank, aft tailcone, should be modified per SI-M20-44. C. Adjust rod end bearings of control tube (L), (Figure 27-5), at rear tailcone bulkhead out approximately5 turns to start. D. Adjust elevator horn rod end (9), (Figure 27-7) out 7 or 8 rums to start. y...---- • O \ \ ELEVATOR HORN ADJUSTMENT- FIGURE 27-7 27-30-03 - EMPENNAGE FREE PLAY LIMITS Allowable free-play movement of the empennage assembly on the tailcone of the airplane, with the tailcone fixedat the tailskid: Horizontalstabilizer @ Tip: 0.12 inchma_ -Fore &Art 0.10 inchma_- Up&Down Rudder @ Lower trailingedge: 0.08 inchma_ - Up & Down E. Main spar adjustable rod end bearingis turned out approximately6 turns to start. To obtain additional elevatortravel, adjust as required. F. Set elevator stops (P), (Figure 27-8), in empennage stinger for elevator uptravel 22 +/- 2 degrees and downtravel of 22 +/- 2 degrees, G. After elevator stops (P) are set, rotate elevators thru full range of travel to assure solid contact with stops and that nuts and bolt heads clear stop limiter. Elevator stop limiter (E) may be bent to obtain clearances and positive contactwith (P) (Figure 27-8). H. Rotate stabilizer trim full down to check clearance of bellcrank at wing stub spar. Adjust md end beadng at rear tancone bulkhead (C)(Fig. 27-5), if needed, for clearance. Recheck elevator up and down travel. o o / // 1. Rotate elevator trim _.dL.u_;check that Elevator up stop(P) makes solid,contacton elevator stoplimiter (E). J. Retighten all jam nuts, attach bolts and secure as necessary; recheck all control tube clearances and travel limits. o RUDDER _, ELEVATNR o o TUBE STDP AJ]JUSTMENT FIGURE 27-8 12-98 27-30-03 9 MOONEY AIRCRAFT CORPORATION M20J SERVICE AND MAINTENANCE MANUAL 27-31-00 - TRIM ASSIST BUNGEE RIGGING Bungee units in the elevator control systems assist in stabilizertrim adjustment. NOTE Negative stabilizer (- degrees) settings mean that stabilizer leading edge is moved down relative to the thrust line. [/7 FW9 A, Set stabilizerto -3 degrees position. B. Adjust trim bungees(N), Figure27-9 at rod-end beadng (10) for elevator up angle of 19 degrees + 1 degree. STnp E:- f P SH27-TRIM TRIM ASSIST BUNGEE RIGGING - FIGURE 27-9 nut 27-10), break torque jamor nut/stepped (if installed) and turn stopon(A) jamnut/stepped nut (A&E)ofclockwise alignthread ronsard edge UP stop or or counterclockwise stepped nut, withtofront of tdmscrew (C) (Figure 27-10). Tighten setscrew and %\ 10 N sHJa7-9 TRIM ASSIST BUNGEE RIGGING - FIGURE 27-9 NOTE Rig trim assist bungees before installation of elevator extension springs (P), Figure 27-9. 27-40-00 - STABILIZER TRIM SYSTEM To provide pitch trim control, the entire empennage pivots around its main hinge points. The system consistsof a manuallyoperated actuator that operates a series of torque tubes and universal joints connected to a jack screw on the afl.tailcone bulkhead. NOTE A "stepped stop nut", with a "jam nut" configuration has been incorporated. This can be retrofitted to all M2OJaircraft if desired. This allows trim screw nut (F) to contact stepped portion of these two nuts and not bind. screw nutcontrolwheel (F) against UPtostop stepped (E). (trim turn trim full or NOSE UP nut position (Figure 27-10). Rotate trim screw nut (F') against UP stopor nut(E); full nose up position. B. Disconnecttorque shaft (B) from trim screw (C), C. Tum disconnectedtorquesha_ (B) clockwiseor counterclockwise until horizontal stabilizer as measured,usingthe travel board, PIN 030004-503, as shown by (Figure 27-11), is withinthe following limits. -5.5 degrees leading edge down. (Approx. 4.5 inches measured). NOTE Negative (-degrees)stabilizer degrees mean that stabilizerleadingedge is moved down relative to thrust line. D. Connect torque shaft. (B) to trim screw (C) (Figure 27-10). NOSE UP stabilizer trim control rigging is now complete. 2. Nose Down Stabilizer Trim Control Riggingand Adjustment. A. Loosensetscrew in down stop orjamnut (A) and turn stop(s) on threaded shaft to move it toward AlL Turn trim controlwheel toward NOSE DOWN position until horizontalstabilizer is within the following limits: +.75 degrees leading edge up (Approx. 2.75 inch measurement). NOTE Positive stabilizer (+degree) settings mean that stabilizer leading edge is moved up relative to thrust line. Basic rigging, for either configuration, is identical to procedures below except that stepped nut and jam nut require beingnuttorqued together, withagainst two wrenches, prior to jam set screw tightened threaded trim screw (C). Stepped nuts are required at the nose up and nose down positions, facing trim screw nut (F). 1. Nose Up Stabilizer Trim Control Rigging and Adjustment. A. Loosen setscrew in up stop/jamnut (A) (Figure 27-31-00 12-98 10 MOONEY AIRCRAFT CORPORATION M20J SERVICE AND MAINTENANCE MANUAL WHEEL WHEEL_. I STEPPED _ SMK27-12 1 1 GEAR Brlx ASSEMBLY ........ _ JAM NUT-"_ _m-r--'_v_ II II I I I I ra-.i - I \ ! '--GEAR lID× _q-1 ASSEMBLY S27CHAIN STD. STOP NUTS -- STABILIZERTRIM CHAIN ADJUSTMENT -FIGURE 27-12-- STEPPED STOP NUTS torquetube. D.Remove nuts, washers,bolts/screws fromupper and lowerpitch tdm servobrackets holding brackets to bulkhead. 3. Carder bearing can now be inspected. If carder bearing or torque tube sleeve show evidence of scodng or wear, replace damaged items with new parts. Bendix-King PIN's are:- 047-04143-000 BEARING BLOCK ASSY. TORQUE TUBESLEEVE-076-00971-000 ROLL PIN (for torque tube sleeve) - 090-00052-0022 When scodng orwear is not present, clean any dded grease and/or dirt from beadng and torque tube sleeve, Relubdcate, using MIL-G-23827 or MIL-G-81322 grease. Use a grease needle or other suitable tool to apply grease, 4. Reinstall carder bearing to aft side of electdc pitch tdm servo bracket. Re-tension ddve Chain. 5. Clean any dirt and grease from placard location on forward side of tailcone bulkhead. Install annual service placard (057-05747-0001) on forward, vertical podion of bulkhead, @ fuselage Sta. 142. 6. If bearing block assembly replacement is required, refer to following procedures: E. Carefully lilt torque tube/pitch trim servo assembly up and pull aft end of torque tube from tdm actuator socket on aft tailcone bulkhead. Support aft end of torque tube if needed. F. Pull torque tube/trim servo assembly from tailcone through access cover on left side of tailcone. G. Place torque tube/pitch trim servo assembly on work bench for removal and replacement of beadng block. H. Remove components carefully until access to beadng block is obtained. Install new bearing block and assemble in reverse sequence. 1. Reinstall torque tube/pitch trim servo assembly into taUcone. J. After reinstallation and reconnection of all components, electrical and mechanical, it will be essential to check stabilizer pitch trim system rigging in accordance with Section 27-40-01. 27-50-00 WING FLAP SYSTEM Trim torque tube/pitchtrim servo assembly should be removed from aircraft to replace bearing block, therefore manual tdm wheel and electdc trim switch should be flagged so inadvertent movementwill not occur, Wing Flaps - General Push-pulltubes and beUcranksinterconnectthe flaps. The flaps are operated by an electdcal motor driven actuator (1) connected to a jack shaft (2) (Figure 27-13). The jack shaft is connectedto actuatorbracket (3) (Figure27-13) on each flap just outboardof hinges (4) by a push-pullrod end beadng (5) and hardware. Each flap pivotsaboutfour hinges.Travel is controlled by limitswitches(6) and (7) and stopslocated at O.B. hinges (Figure27-13). Flap position is indicatedin the cockpitthrough a cable link system (B) connectedto the jack sha_.actuator horn (9). A. Disconnect universal joint located between tailcone bulkhead, Sta. 142, and pitch trim servo assemblymountingbrackets. B. Disconnect electrical widng, to servo motor, at connector, C. Disconnect ELT harness from connector and any other widng that may interfere with the removal of torque tube assembly from tailcone. 27-50-00 12 m 12-98 SERVICE AND MAINTENANCE MANUAL M20J B. Rotate stop (A), (Figure 27-10) clockwise or counterclockwise to make contact with trim screw nut (F). Tighten setscrew. NOSE DOWN stabilizer trim control rigging is now complete. 3. Stabilizer Trim Indicator Rigging. The indicator is geared to the tdm control wheel and indicates stabilizer position mlaUve to the aircralt thrust line. Set horizontal stabilizerto an angle of incidence of minus 2 degrees O0 minutes to minus 2 degrees 30 minutes. Adjust tdm indicator cable at (F) (Figure27-10) to set indicator in the cabin to the center of thetakeoff range mank. A. MAXIMUMHORIZONTALSTABILIZER ALLOWABLE FREE PLAY LIMITS- MOONEY AIRCRAFT CORPORATION \\ \ (1) Fore and aft movement at stabilizer tip: 0_ (2) Vertical movement at stabilizer tip: 0_. NOTE When removing trim screw from empennage use a block of wood cut to fit opening between tailcone and empennage to prop empennage up when trim screw is removed. 4. Electric Trim. R A. The clutch torque for the electdc trim system should be checked and adjusted by an Avionics shop SN27-11 for the following settings to operate the autopilot systems properly: STABILIZER TRIM CONTROL RIGGING-FIGURE 27-11 (1) KFC 200 -- 21 +/- 2 inch lbs. (2) KAP 100 --21 +/-2 inch Ibs. (3) KFC 150 --21 +/- 2 inch Ibs. 5. Stabilizer Trim Chain Adjustment. (4) EDO AIRE Systems -- 18 inch Ibs. (Reference Figure 27-12). A. Wuththe four mounting bolts (1) slack, adjust the (5) S-TEC --30 inch Ibs. two NAS428-3-4 bolts (2) to obtain maximum tension on chainwithout causing binding. 27-40-01 - TRIM SYSTEM TROUBLESHOOTING BINDING CHECK controltubes at bulkhead grommets for rub marks, Check Tdm Actuator threads for galling or not lubdcated; lube per Section 5. ELECTRIC CLUTCH SLIPPING' Check BINDING symptoms above. Check for proper clutch settings. Confirm full bus voltage is available at trim motor. 27-42-00 -ELECTRIC PITCH TRIM SYSTEM MAINTENANCE 1. Gain access to area by removing electrical bay access cover from left hand side of tailcone Locate Electdc Pitch Trim servo system,just a_ of Fuselage If installed,the AIliedSignal (Bendix-King)ElectricPitch Sta. 142 bulkhead. Carrier beadng is located around TAm System requires pedodic maintenance at each existing pitch trim torque tube, aft of lower chain annual inspectionfor carrier beadng added to existing sprocket, on aft side of electricpitchtrim servo bracket aimralt pitch trim torque tube. If not already installed, an annual service placard, 057-05747-0001, (available and below electricpitchtrim servo motor. from AIliedSignal)MUST be added to the ElectdcPitch 2. Loosen electric pitch trim servo dave chain. TAm servo bracket area to call attention to the annual Remove four lock nuts which secure carder beadng maintenance requirement. Carder bearing assembly block to al_ side of electric pitch tAm servo bracket. must be inspected and lubricated per the following Slide bearing block aft until it is clear of stainlesssteel procedures: sleeve which is secured to existing airplane pitch trim 12-98 27-40-01 11 SERVICE AND MAINTENANCE MANUAL M2OJ MOONEY AIRCRAFT CORPORATION POSITION ADJUSTMENT SIN 24-0001 thru 24-2999.24-3079 thru 24-:_200, A. Adjust right and left.inboard linkage at rod end beadn.g(1), (Eigure 27-14) to obtaLna flaE deflection of 33= (+g/-2"). Retract flaps to 0u +/- 2_. Set flap outboardtravel stops (not illustrated)so that flaps align withaileronwhilein neutral position. 24--3D00 _ 2.=1---807B _MJ2';'--I_ FLAP ACTUATOR ASSEMBLY & INSTALLATION FIGURE 27-13 SNX27-14 On S/N 24-0001 thru 24-2999 the flap swtch (10) s se f centering from the down position and located on the console adjacent to the flap position indicator. The flaps can be retracted completely by placing the switch in the UP position or to any setting between 0 and 33 degrees by placing in UP position to setting desired and then centeringto stopthe actuator, On SIN 24-3000 thru 24-3078 and 24-3201 and 24-3218 thru 24-TBA, the flap system incorporates a flap preselect feature which allows the flaps to be positionedas desired: UP, TAKEOFF or DOWN. Lubricatethe flap actuatorgear box and ball screw at required intervalsandwithlubricantsprescribed inChapter5. 1. Wing Flap Removal and Installation. A. Remove wing flap hinge faidng to expose flap push-pulltube. B. Remove bolt, nut, and washer from flap-actuating attachment, C. Remove bolts, nuts, and washers at flap hinge points. D. Remove flap by pulling it down and af_ E. Install wing flaps in reverse sequence of removal, Recheck security and safety of attaching bolts. 2. Wing Flap Rigging and Adjustment. ' NOTE Flap deflections areto be measured with travel board GSE 030003 at the station indicated on the travel board. (See SECTION 27-10-00, Fig ure 27-3A) WING FLAP ADJUSTMENT - FIGURE 27-14 B. Retract flapsto 15° (+/-1°), and set flap position indicatorcable (B) at attachment screw (2), (Figure 27-15), to TAKEOFF positionas shownon flap position indicatorin Cabin. This indicates the degree of flap deflectionfrom 0° to 33°, with a 15° takeoffsetting C. The limitswitches,#3, (Figure 27-15) shouldbe adjustedso that under flightloadsthe actuatorover run will not allow the flaps to exceed either up or down positions. NOTE The flaps may be rigged asymetrically (within tolerances) to facilitate aircraft rigging or to compensate forany rolloff during flap operation, POSITION ADJUSTMENT SIN 24-3000 thru 24-3078. 24-3201. 24-3218 thru 24-TBA Before rigging take-off position, verify flap travel is correct for full UP and DOWN. Micro-Switches must strike tang on flap jack properly. Lower switch roller should make contact in the cut-out area; top switch roller should make contact with the non-cut-out area. Adjust switches to accomplishthis. A. Rig flaps per para. 2., A. & B. above. B.Extendflapsto TAKEOFFposition(15° +/-1o) C. Adjust switch stack until bottom Micro-Switch just opens. 12-98 27-50-00 13 MOONEY AIRCRAFT CORPORATION M20J SERVICE AND MAINTENANCE MANUAL applicable) balance weight, control attachment horn and attaching hardware, static wicks (when installed as optional equipment), and rudder taillight and/or strobe light assembly installed. Control surfaces must be rebalanced in accordance with the procedures in Section 27-93-00. CAUTION All control surfaces should be stripped prior to repainting. 3 27-92-00 - BALANCING EQUIPMENT STATIC The design of the balancing fixture is not odtical 2 1. Obtain or otherwise fabricate two (2) knife edge supports approximately one (I) foot in height so that .11 prevent tipping (see Fig. 27-15). The knife edge providingthe requirements of this be sectionLEVEL are met. and nmge supports MUST PERPENDICULAR to the hinge axis of the control surface. "_/_ .,_- 2. Weight Scales: Scales used to recordon weights must accurate within they Ibs can a table andbebe stabilized to 0.02 orbe 1/2placed oz. s_7-_s _ WING FLAP INDICATOR ADJUSTMENT (NON -PRESELECT) - FIGURE 27,15 D. Top switchwill be automaticallyadjusted. E. Cycle flaps UP, TAKEOFF & DOWN; verify propersetting at TAKEOFF while Flapsare goingdown. 27-60-00 - AILERON/RUDDER INTERCONNECT SYSTEM 1. With controls in neutral position, locate 110002-101 bracket, on aileron controltube, so the end of 110002-005 bellcrank assembly will be 2.25 in. AFT of 310020 fuselage former. 2. Holding both, rudder and aileron, controls in neutral position, install two springs, PIN 110003-007, on -005 brackets and position -025 and -027 brackets control tube the bellcrank on andrudder on 110002-025 andso -027 Clamp brackets in place and ddll through brackets and ofinto tube installed length eachcontrol spring is 4.90 for in. AN530-4R6 PK screws. 27-90-00 27-93-00 - BALANCING PROCEDURE 27-93-01 - DETAIL PROCEDURES STATIC BALANCING 1. A line drawn throughthe hinge line support points must be level and perpendicularto the supporting knife edges. 2. The supportingknife edges must be horizontaland parallelto each other within the requirements of Step 1. above. 3. Elevators and rudders are balanced with the "Control Horn" pointing upward. Ailerons are balanced UPSIDE DOWN. (See Fig. 27-18) / t" --KNIFEEDG E/-----..........._ SUPPDRT J "_ _'_ Ill '" J / ./i _" -.. > _" 7 f - MISCELLANEOUS 27-91-00 - CONTROL SURFACE STATIC BALANCING Controlsurface balance must be checked when control surfaces .is repaired, altered or repainted. It is recommended that secure 3. MakesurePKscrewsare all three brackets, control surfaces be stripped npaceto prior to repainting. The control surface balance limits shown in Figure 27-17 apply to a complete painted control surface only. Complete control surfaces include (as 27-60-00 14 Si7 i CONTROL SURFACESTATIC BALANCE SUPPORTS FIGURE27-15 12-98 SERVICE AND MAINTENANCE MANUAL M20J 4. All control surfaces are balanced with the hinge center line and the tip db chord line level. Two tooling holes are located in the tip ribs and are on the rib chord line (rib center line). Chordwise level can be obtained by using a spidt level and pins inserted into these tooling holes, 5. Install a 1/4 inch bolt or pin through the inboard and outboard AILERON hinge bracket. Install a No. 10 bolt or pin through inboard and outboard ELEVATOR hinge bearing, and top and bottom RUDDER hinge bearing. 6. Positon and level the control surface on the knife edge hinge supports. MOONEY AIRCRAFT CORPORATION 7. Accurately measure control surface load at a measured distance from the hinge axis as far from the hinge axis as possible (Figure 27-18). Measuremen_ should be taken in a draft free environment. Calculate the moment (arm times weight) and compare the results with Figure 27-17. 8. Control surfaces MUST BE RECHECKED for balance after any painting, stripping, repair or alteration. SURFACE DESCRIPTION AIRCRAFT EFFECTIVITY BALANCE MOMENT LIMITS * !430026-001 &-002 ELEVATOR 24-0001THRU24-1543 24-1545 THRU 24-1551 24-3000 THRU 24-3038 UNDERBALANCE 16.751N.#TO 14.00 IN, # 24-1544, 24-1552 THRU 24-2999, 24-3039 THRU 24-TBA UNDERBALANCE 16.75 IN. # TO 11.00 IN. # 24-0001THRU24-1543, 24-1545 THRU 24-1551 24-3000 THRU 24-3038 UNDERBALANCE 18.001N.#TO 13.00 IN. # 24-1544, 24-1552 THRU 24-2999 124-3039THRU 24-3200 24-3202 THRU 24-3217 UNDERBALANCE 18.00 IN. # TO 12.50 IN. # 24-3201,24-3218 THRU 24-TBA UNDERSALANCE 15.50 IN. # TO 12.50 IN. # 430043-000 RUDDER NOTE: NC SIN 24-1688 THRU UNDERBALANCE 15.501N. #TO 24-3200, 24-3202 THRU 24-3217 12.50 IN.# MAY BE IN COMPLIANCE WITH KIT DWG 940071 (2900 LB, GROSS WT.) IF SO, USE UNDERBALANCE MOMENT LISTED IN COLUMN TO THE RIGHT. 230015-503 & -504 AILERON 230015-505 & -506 AILERON 230015-507 & -508 AILERON 230015-511 & -512 AILERON 24-0001 THRU 24-0942 UNDERBALANCE 8.00 IN. # TO 5.25 IN. # 24-0943 THRU 24-1037 UNDERBALANCE 7.23 IN. # TO 5.25 IN. # 24-1038 THRU 24-1543 24-1545 THRU 24-1551 UNDERBALANCE 7.10 IN#TO 5.25 IN # 24-1544, 24-1552 THRU 24-1621 24-3000 THRU 24-3038 UNDERBALANCE 6.23 IN. #TO 0.00 IN# 24-1622 THRU 24-2999 24-3039 THRU 24-3110 UNDERBALANCE 6.23 IN. # TO 0.00 IN. # 24-3111 TO 24-TBD UNDERBALANCE 5.30 iN. # TO 0.00 IN. # 24-TBD TO 24-TBA UNDERBALANCE 5.30 IN. # TO 0.00 IN # • UNDERBALANCE = TRAILING EDGE HEAVY M20J FLIGHT CONTROL SURFACE BALANCE LIMITS - FIGURE 27-17 12-98 27-93-01 15 MOONEY AIRCRAFT CORPORATION = M20J DISTANCE (Refer to Figure AFT 27-17 for (NOTE: Aileron is SERVICE AND MAINTENANCE MANUAL OF HINGE dimensions balanced & upside LINE - UNBALANCE down.) FORCE limits) FIGURE 27-18 - DISTANCE FROM HINGE POINT TO UNBALANCE POINT NOTE If specified moments cannot be met (reference Figure 27-17), heavier balance weights can be obtained through a Mooney Service Center. This approach should be examined before reworking any repair or restripping and repainUng the affected control surface. A lighter weight can be produced by shaving existing balance weighL FIGURE 27-19 NOT USED. NOTE The aileron trailing edge MUST NOT BE BENT UP under any circumstance. Any deformed rivets must be replaced after trimming aileron or rudder trailing edge. B. Rudder. The rudder trailing edge may be trimmed right Orlelt as required. 27-94-00 - CONTROL SURFACE TRAILING EDGE NOTE Verify flight control rigging is correct before bending trailing edge. 1. Trimming. A pair of widenose (2.0 - 3.0 in.) ViceGripstyle pliers may to used to bend the trailing edges as necessary (See Figure 27-20). NOTE Glue 1116in. thick rubber strips to inside of jaws of ViceGrip pliers to reduce possibility of damage to trailing edges. 27-95-00 -STALLWARNINGMAINTENANCE PRACTICES A. Aileron. To correct for a left wing-heavy condition, bend right aileron trailing edge down; to correct for a right wing-heavy condition, bend left ailerontrailing edge down. wing leadingedge. C. Disconnecttwowires from the switch. 1. Stall WarningSwitch Removal. A. Remove screws or rivets attachingthe access coveraft of stallswitchon lower wing surface. B. Remove two screws which secure switch to ADJUSTUP TO ACTUATESOONER X "08FFLMEAc_, oANL L_EWAFTB LE R"'°', RUDDER. / q- D DO STALL VANE ADJUSTMENT - FIGURE 27-21A TRAILING EDGE TRIMMING - FIGURE 27-20 27-94-00 16 CT SIN 24-0001 THRU 24-3153 12-98 SERVICE AND MAINTENANCE MANUAL M2OJ 2. StallWarning SwitchInstallation. A. Connect electricalwires to switch connections, B.Positionswitch in opening on lower wing leading edge, install two attach screws. C. Replace the access cover securely. D. Adjust the switch. See STALL WARNING SWITCH ADJUSTMENT (Para. 3 or 4 below), The stallwarning switch is adjustedwhen the airplane is test flown at the factory. Should it require readjusting, proceed asfollows (Para. 3 or4): 3. Stall Warning Switch (Vane) Adjustment SIN 24-0001 thru 24-3153 (Figure 27-21A) Locatethe stall switch on the lower surfaceof the left wing leading edge and loosen the two phillips head screws, one on either side of the vane (See Fig. 27-21A). If the stall warning has been activating too early, pull the vane back and down. if the stall warning has been activating too late, push the vane up and ADJUST UP TOACTUATE SOONER ADJUST [:)OWN TO ACTUATE SCREWS STALL VANE ADJUSTMENT - FIGURE 27-21B SIN 24-3154 THRU 24-TBA 27-95-01 MOONEY AIRCRAFT CORPORATION forward. Moving the vane with the phillips head screws loosened moves the entire unit up or down inside the wing, causing the switchto be closed earlier or later. Retighten the screws JEer making each adjustment. NOTE NEVER TRY TO ADJUST THE SWITCH BY BENDING THEVANE. This part has been heat treated and cannot be bent without damaging or breaking the vane or switch. ¢.StaltWaming Switch (Vane)Adjustment SIN 24-3154 thru 24-TBA (Figure 27-21B) Locate the stall switch on the lower surface of the left wing leading edge and loosen the two screws on both sides of the wing leading edge cutout (See Fig. 27-2tB). If the stall warning has been activating too early, pull the vane back and down. If the stall warning has been activating too late push the vane up and forward. Moving the vane with the ph ps head screws loosened moves the entire unit up or down inside the wing causing the switah to be closed eadier or later. Retighten the screws after mak ng each adjustment. GENERAL As a role of thumb, moving the vane tip 1/4 inch will change the time the stall warning acurates by about 5 MPH of indicated air speed. The only way to test the accuracyo1the settingis to fly the airplane into a stall, noting the speed at whichthe warning horncomes ON and the speed at which the FULL stalloccurs.The stall must be made in various configurations,clean, gear and flaps down and power on and power off. It may be necessary to make several alternate adjustmentsand test flights before the desired setting can be reached. The stall warningshouldactuateat no lessthan 5 KTS. nor more than 10 KTS. preceding the stall and shall continue until the stall occurs in power off configuration.The rate of speed reduction shall not exceed one knot per second with the airplane tdmmed to 1.5 times the stall speed. The switchsetting should be checked and adjusted as necessary whenever a wing or wing leading edge is replaced or extensively repaired, or if a new switch is installed. The switch should require no adjustment in normal service. - TROUBLE SHOOTING - STALL WARNING SYSTEM i TROUBLE Warning system inoperative. Horn continues to blow. PROBABLE CAUSE REMEDY Warning circuit breaker tripped. If circuit breaker persist in tripping, check for grounded circuit. Open circuit. Check for continuity. Defective warning horn switch. Replace switch. Defective warning horn. Replace horn. Defective warning hom switch. Replace switch. 12-98 27-95-01 17 MOONEY AIRCRAFT CORPORATION M20J 27.96-00 - SPEED BRAKE SYSTEM A Speed Brake System Is currentlyoptionalequipment installed on some M20J aircraft. The manufacturer, Precise Flight, Inc. can provide detail parts and maintenanceinformationfor the cartridge assemblies. Some of the electdcal cimuitry, widng, relays, cimuit breakers, etc. are installed by Mooney pmduction drawings.Componentsfor these are available through yourMooney ServiceCenter. The relay for the electric Speed Brake System is locatedunder the rear seat area, on the LH bulkhead, The schematic, located in the envelope, and the electricalpads list, SECTION 91, of this S & M covers the electricalsystemcomponentidentification, 27.96-01 - MAINTENANCE - SPEED BRAKE SYSTEM 1. ELECTRIC OR VACUUM SYSTEMS @ Every1000 hours: A. Remove the speedbrakecartridgesfromwing: (1) Remove access cover from bottom of wing beneaththe Speed Brake cadddge, (2) Remove the single screwfrom bottom of wing whichsecures the strapstrip of the cartridge, (3) Disconnect vacuum or electrical connection fromSpeedbrake cartridge, (.4)Remove Speedbrake cartridge from wing by remo_nngscrews from top of wing from around the Speedbrake carlridge and remove the cartridge throughthe bottom access hole. B. Inspect removed cart_lge, mounting area and relatedcomponents for the following: (1) Visually check doubler and mounting hardwarefor structuralintegrity. (2) Visually inspect for chafing on all moving parts, (3) Manually operate the speedbrake doors and feel fur smooth operation, (4) Inspect cable (on vacuum units) especially aroundpulleysfur fraying. C. Report any deficienciesof cartridge (if any) to PreciseFlight, Inc. D. Repair any defects found. If no deficienciesof the cartridges exist, reinstall spoedbrake cadddges and connections. Cycle to verifyproperoperation, 2. REPLACEMENT OF MALFUNCTIONING CARTRIDGES. A. When replacement of a malfunctioning Speedbrake Cadridge with a new cadddge is necessary, the following proceduresmay be required to installthe new cartridge: NOTE There is no left or right hand configuration on the electrical units. The speedbrake doors are not located in the center oftbe cartridge. The side of the cartridge that has the narrowest flange goes forward. 27-96-00 18 SERVICE AND MAINTENANCE MANUAL Therefore, the motor/gear assembly will be outboard on the left hand wing side and inboard on the right hand wing side. (1)Onsome mplacamentcartddgesadrain hole, (0.27 in.) is required in the aft, inboard comer of Speedbrake cartridge bottom.The drain tube from the old cadddge Is to be securedin place in this hole with siliconeadhesiveused as sealant. On laterconfigurationcadddges, the drain hole already existsin the bottomof each end of the cartridge.Install drain tube in inboard hole. Some drain tubes have a heat formed flange and mountingplates to mountthe tube to the hole which already exists in the new cartridge.These do not requireany siliconesealant to seal the tube, however,the drainholes in the outboard end of the cartddge must be sealed with silicone sealant pdorto installationof cartridgeintowing. Route drain tube through hole in bottom of access cover. (2) The bottom,mountingstrap stripfrom the old cartridgewill require relocatingto the new cartridge. Alter the cartridge is secured in place with the top screws, position the strap strip over the single mounting hole in the wing bottom skin. Mark the locationfur the two holes in the bottom of the cartridge housing. Ddll proper hole (#30 ddll) to install ChenyMax CR3243-4-2 dvets (2 ca.) to attach strap stripto cartridgebottom housing. (3) Door caps may need to be installedon some replacement cadddge doors in accordance with the following: a. Mark dvet locationson flange legs of all cap strips to be installed.One is located 2.0 inches from the angled end of cap stdp and another is located 5.0 inchesfromthe angledend. CAUTION Be certain of which cap strip goes on which door and that the angled end of cap strip matches up with angled edge of each door. (Reference existing cartridge to determine which cap strip is to be installed on a new cartridge door.) b. Place correct door cap stdps on speedbrake doors (while speedbrakes are retracted into cartridge) untilflush with top of wing skin surface. Line angled end of cap strip up with angled end of speedbrake door. c. Cycle spoedbrake doors to verify sufficient clearance exists (0.0625 in.) between cap strip and wing skinand doublers. d. Extend doors to continue with cap strip installation. e. Drill #40 holes in cap strips and door at the locationsmarked in (3) a. Countersinkholes on both sides of cap stdps. Flush dvet in place with AN426A-3-7 rivets. 3. FINAL OPERATIONAL CHECK AND CLOSE-UP A. After vedfication of proper operation, reinstall accesscover plate on each wing. 12-98 MOONEY AIRCRAFT CORPORATION M20J CHAPTER 28 FUEL SERVICE AND MAINTENANCE MANUAL SERVICE AND MAINTENANCE MANUAL M20J MOONEY AIRCRAFT CORPORATION CHAPTER 28 FUEL LIST OF EFFECTIVE PAGES CHAPTER SECTION SUBJECT ........... 28-Effectivity ......... 28-Contents ......... 28-00-00 ............ 28-10-00 ............ 28-11-00 ............ 28-12-00 ............ 28-13-00 ............ 28-20-00 ........... 28-30-00 ........... 28--42-00 ........... 28-91-00 ........... 28-92-00 ........... PAGE .......... DATE 1/2BLANK .......... 3/4BLANK .......... 5 ........... 6 ........... 7 ........... 8 ........... 9 ........... 10 ........... 11 ........... 12 ........... 13 ........... 14 ........... 12-98 12-98 12-98 12-98 12-98 12-98 12-98 12-98 12-98 12-98 12-98 12-98 12-98 28-EFFECTIVITY 1/2BLANK MOONEY AIRCRAFT CORPORATION M20J SERVICE AND MAINTENANCE MANUAL CHAPTER 28 FUEL TABLE OF CONTENTS CHAPTER SECTION SUBJECT ........... 28-00-00 ........ 28-00-01 ......... 28-10-00 ......... 28-11-00 .......... 28-12-00 .......... 28-13-00 .......... 28-14-00 .......... 28-20-00 ......... 28-21-00 .......... 28-22-00 .......... 28-23-00 .......... 28-24-00 .......... 28-25-00 .......... 28-30-00 ......... 28-31-00 .......... 28-32-00 .......... 28-40-00 ......... 28-41-00 .......... 28-42-00 .......... 28-43-00 .......... 28-43-01 ............ 28-43-02 ............ 28-90-00 ......... 28-91-00 .......... 28-92-00 .......... SUBJECT ........ General .............. Filler Cap Maintenance ......... Storage ............. Fuel Tank Field Repair ........ Fuel Tank Leak Repair ........ Soapless Bubble Fluid Formula Preparation for Leak Check ......... Fuel Additives .......... Distribution ............ Fuel Boost Pump Removal and Installation . Selector Valve & Gascolator Screen Cleaning Fuel Injection System ........ Engine Priming ......... Full Selector Valve Removal and Installation. Dump ............. Fuel System Drains ........ Fuel Vents ........... Indicating ............ Fuel Quantity Indicating Transmitters Fuel Quantity Indicator ....... Fuel Quantity Adjustment Procedure. Fuel Tank Transmitter Adjustment . Fuel Quantity Gauge Adjustment Miscellaneous ........... Trouble Shooting ......... Flared Fittings.......... 12-98 PAGE 5 5 6 6 8 9 9 10 10 10 10 10 10 11 11 11 11 11 11 11 11 12 12 12 13 28-CONTENTS 3/4BLANK SERVICE AND MAINTENANCE MANUAL M20J 28-00-00 -GENERAL Internally sealed, integralfuel tanks are in the forward inboardsections of the wings. Fuel feeds from either tank to a selector valve thin a gascolator,(integralwith selectorvalve, 24-0001 thru 24-0377), with a low-point drain, through the emergency pump to the engine-drivenfuel pumpand to the fue/injestor system on the engine. Fuel quantity indicatorsare electrically operated with 2 transmitters located in each tank (1 inboard& 1 outboard). Fuel level indicatortabs, at the 25-.gallonlevel, in each tank, can be seen through the (1 w_ FUEL SYSTEM - FIGURE 28-1 Optional visual fuel quantity gauges are located in each wing tank end are to be used only for padial fuel MOONEY AIRCRAFT CORPORATION to prevent bindingwhile opening or closingthe cap assembly.This should also lubdcatethe o'dng (4) that seatsthisshaft.. WARNING Water can enter the fuel tank through a loose fitting or damaged cap. This should be corrected as soon as possible. 3. The seating capabil_ of each cap assembly should be checked pedodicallyand at each annual inspection. This can be accomplished per the following procedures: A. Remove cap assemblyfrom wing filler pod and inspect o'ring (1) for. any damage or brittleness Removeand replaceif needed. B.Adjusttension of shaft (2) and rotatinglockplate (3) by removingcotter pin (5) from nut (6) on threaded portionof shaft (2). T'q]htennut (6) so cap assembly handle(7) can be opened, fumed and shutwith hand pressure and still providethe necessary seal of cap assemblyto keep water from entedngfeel tank. NOTE Fuel selector should be in the OFF position before proceeding with paragraph C. to pressurize the fuel tanks. C. Connect rubber hose to each tank's vent line. Apptyonly one-half pound (1/2 lb.} air pressure.Check for _el cap leaksby soapingcircumferenceof fillercap assemblyand observingbubbles.Replace o'dng if bubbtesare observed _ and t 7 adjustment _ _ v ofthe nut / U does not I J stopthe I A J 7 ¶ #108 sealant. loadingas desired. The dial is held in positionby RTV leak. ,_ J,__---__ _ _'_ _'_ weather fading or other damage. After documenting dial orientation on wing, pry dial from cavity. Clean cavityand secure correct, new dial into properposition with RTV #108. The float assemblywhich activates the magnetic portion of the dial needle as fuel level Occesionatiythediaimayrequirechangingdueto _i_!__ changes in the tank, can be replaced by removing the access cover that the float assembly is attached to on pressure top side of wing and replace the floatassembly, in tank. 28-00-0t - FUEL FILLER CAP ASSEMBLY MAINTENANCE Fuel filler port cap assembfies should be checked periodicallyfor proper sealing and should be serviced occasionally to prevent bard to open or close conditions. 1. The o'dng seal (1) (Figure 28-2) around the cap assembly should be kept clean and free of did or grit that might cause abrasive action on seal or mating flange. Occasional lubdcationwith petroleumjelly or 2 Td-Flow will keep the o'ringsoit and pliable. 2. The shaft (2) runningthroughthe center of the cap FUEL FILLER CAP ASSEMBLY housing,that actuates the rotatinglockplate (3) should MAINTENANCE - FIGURE 28-2 be lubricatedoccasionallywith Tri-Flow, or equivalent, 12-98 28-00-00 5 =r ; MOONEY AIRCRAFT CORPORATION 28-10-00 28-11-00 M20J -STORAGE - FUEL TANK FIELD REPAIR C. Metal cleaningsolvent- Turco 657 wipe solvent. D. Cheese cloth. This paragraph outlines the procedures recommended for repair of the integral fuel tanks. Tank repairs should not be attempted until these instructions are fully understood. Refer to Service Bulletin M20-230 dudng resealing of the tanks for drain holes to be lett open. 1. Approved Materials. A. Sealants. WARNING Sealants are safe only when handled with reasonable care. Avoid ingestion and all contact with the body, especially with open breaks in the skin. Wash hands before eating or smoking. If accelerator contacts the skin, flush area with warm water, (1) Brush sealant - PR1422-A-1/2 or A-2 or CS3204 A-1/2, A-2 (MIL-S-8802D Class A). (2) Filleting Compound - PR1422 B-1/2, B-2 or CS3204 B-112,B-2 (MIL-S-8802D Class B). (3) Removable PR1403-G-B2, PR1428 oraccess CS3330. panel sealant (4) Protectivesealant - PR1005-L (MIL-S-4383B). B. Gloves-- Polyethylene. a) - BrushableType Sealant ........ CLASS A .... PR1422 A-1/2 .... PR1422 A-2 . . . CS3204 A-1/2 .... CS3204 A-2 . PRO-SEAL 890-Al/2. PRO-SEAL 890-A2 SERVICE AND MAINTENANCE MANUAL E. Turco leak detector or bubblefluid. F. Methylethyl keytone0VIEK)(thinnerfor PR 1005-L). NOTE Approved materials may be obtained from your local Mooney Marketing or Service Center. Sealants may also be obtained from Products Research Co., 5454 San Fernando Road, Glendale, CA 91209; or Chem Seal Corp., 11120 Sherman Way, Sun Valley, CA 91352. 2. Handlingand MixingSealants. A. Sealant Matedal Characteristics. (1) Application life is the time that the mixed compoundremainssuitable for application.Application life ratingsare always based on standard conditionsof 75 degrees F. and 50 percent relative humidity. For every10 degree F. rise in temperature, applicationlife and cure time is reduced by half; for every 10 degree F. drop in temperature,applicationlife and cure time is doubled. High humidityat the time of mixing slightly reducesthe sealant applicationlife. (2) Maximum unopened container life, with sealant at 80 degree F., is six months. (3) Sealant application life, tack-free curing time, and curingrates are as follows: Tack-Free Time .... (HOURS) ...... 10 ....... 36 ....... 8 ........ 24 ....... 10 ....... 36 ....... Cure Rate (HOURS) ...... 30 ....... 72 ....... 30 ....... 72 ....... 30 .... 72 ....... ApplicationLife (HOURS) 1/2 2 1/2 2 1/2 2 (b) FilletingCompound(and on wingwalk access panel) ....... Tack-Free Time .... Cure Rate CLASS B .... (HOURS) ...... (HOURS) ...... PR1422 B-1/2 .... 10 ....... 45 ....... PR1422 B-2 ..... 36 ....... 72 ....... CS3204 B-1/2 .... 8 ........ 30 ....... CS3204 B-2 ..... 24 ....... 72 ....... CS3204 S-4 ..... 36 ....... 76 ....... Followproceduresaccompaningsealantto propedy seal fuel tanks. ApplicationLife (HOURS) 1/2 2 112 2 4 (c) Access Door Sealant (excepton wingwalk access panel) ........ Tack-Free Time .... CLASS B .... (HOURS) ...... CS-3330-B ..... 8 ........ PR1403-G-B2 .... 10 ....... PR1428-B ..... 8 ........ Cure Rate (HOURS) ...... 16 ....... 48 ....... 16 ....... ApplicationLife (HOURS) 2 2 2 (d) Brushable Top Coat Protective Sealant ........ Tack-Free Time .... ........ (HOURS) ...... PR1005L ...... 1/3 ....... CS3600 ...... -....... Cure Rate (HOURS) ...... 4 ........ -....... ApplicationLife (HOURS) -__ Allow 24 hours cure time prior to refueling tanks. 28-10-00 6 12-98 / SERVICE AND MAINTENANCE MANUAL . M20J B. Sealant Mixing (1) For best results, use kits with proper propodions ofbase compound and accelerator, (2) To avoid excessive air entrapment, slowly stir accelerator into base compound. Continue mixing for SEVEN to TEN MINUTES. Scrape sides and bottom of container to include all compound in mixture and to insure uniform blending. Scrape mixing paddle on edge of container to remove unmixed compound. Be sure to use all of the accelerator. MOONEY AIRCRAFT CORPORATION (1) Use a spatula or an extrusion gun with a 1/8 to l/4 - inch nozzle opening for laying fillets at edges of all seams. When using an extrusion gun, hold gun perpendicular to seam so that extruded sealant will pack tightly. (2) Use a spatula to pack sealant firmly in place while working out air pockets. Shape each fillet evenly. (3) Place a small amount of mixture on a clean stdp of aluminumand spread 3/e determine whether accelerator is visible in particleform. If particlesof acceleratorare visible, continuemixing operation.If course particlesof accelerator persistafter mixing thomughiy, rejectthe mixed batch. NOTE Sealant in tube form have mixing instructions on each tube. Read and comply with these mixing instructions prior to sealant ! 3. Cleaning Surfaces to be Sealed. application. A. Clean metal surfacesto be sealed with Turco 657 Wipe Solvent or Methyl Ethyl Ketone. Wipe surface dry with a clean cloth:Do not allow solvent to evaporate. B. Allow cleaned surface to dry five to ten minutes before sealant application. SEAL _/ITH 3/8 TO 1/2 IN, GAPS 8, HnLES FILLETING 3/16 1/,$ _I TO i_Lr IN. prk 2: IN. LI_ APPLY ]BRUSH SEALANT COMPOUND FIRST STEP 3/t6 Tn 1/_ IN, I-'1 THIRD STEP TD 1/4 IN. "1 P" FILLET '_k APPLY FILLETING COMPOUND rL _FILLET SECONDSTEP 1 IN. "1 P" 1/ 1w6 __ - IN. I I '"_J_r*ir "-_IIP PROTECTIVE APPLY SEALANT FOURTH STEP FASTENER SEALING WITH ]BRUSH SEALANT (1132 Tn 1116 IN, THICK) NOTE Apply sealant as soon as possible after cleaning. Store and handle parts in a manner that will prevent finger prints, dust, dirt, or other foreign substances from to be sealed. accumulating on surfaces SHH2EI-3 FUEL TANK SEALING - FIGURE 28-3 NOTE Refer to Mooney SB M20-230 for proper application and drain holes to be left open. 4. Sealant Application. Old sealant must be removed, Use a sharp non-metallic scraper (formica or lexan), When sealant has been removed, clean area thoroughlyand resealtank as foUows: A. FilletSealing. (1) Be certain that the surface to be sealed is totallyclean and free from oil,grime, finger prints,etc. (2) Referto (Figure 28-3) for typicalfilletsize. (3) Join fillets laid on intersection joints to produce a continuousfillet, • (4) Seal all difficult and hard-to-reach areas first to preclude the possibility of their being overlooked or improperly sealed. C. Brush Sealing. (1) Brushsealant (PR1422-A-1/2, A-2 or CS3204 A-1/2, A-(2) over all seams, rivets, nuts, and bolts.A one inch stiffbdstie brush is recommended for sealant application. Force sealant into all gaps with brush strokes parallelto seams. Use a circular brushaction to deposit an even coating of sealant around dvets, nuts, and bolts. Coating should be approximately 1/32-inchthick. Use considerablebrushactionto force sealant into all small crevices and to obtain good adhesion. Air pocketsunder the sealant,that will open up in the form of holes or voids soon after application, will resultfrom improperapplication.To repair holesor voids,presssealant in place usinga spatula. (2) When the edge of a flange protrudes0.040 inch or less, or where the seam cannot be cleady defined, applytwo 1/32-inchbrush coats.Allowthe first coat to cure about four hours or until it becomes rubbery before applying the second coat. The second coat should overlap the edges of the first coat by about 1/4 inch. B. Filleting Compound Application - (PR1422 B-2) 12-98 28-11-00 7 MOONEY AIRCRAFT CORPORATION M2OJ SERVICE AND MAINTENANCE MANUAL £/_ D. Protective Sealant. (1) Using short, even strokes, brush on a smooth and continuouscoat of PR1005-L over sealant. The protectivesealant coat shouldextend one inch beyond edge of the filletingcompound. (2) Allow the first protective coat to cure 20 minutesat 75 degree F., or untiltack-free; then apply a second brush coat of PR1005-L. Make every effort to obtain a completelybubble-free, continuoustop coaL DO NOT REBRUSH over areas, as doing so will only 3-1/2 TD 4 IN, cause dragging and will break coating continuity. E. Upper Wing Tank Access Panel Sealing. (1) Apply a coat of access door sealant (CS3330, PR1428 or PR1403-G-B2) to either laying surface _ HEAVYSEEP using short stiff bristle brush, gun. Ifa an extrusion gun is used,spatula, smoothor theextrusion sealant with a brush or spatula. Cover the entire faying surface with a sealant coat of sufficientthickness (1/32 to 1116 inch)to assure extrusion alongthe edges of the laying surface when the mating parts are assembled. Access panels in wing walk area should be sealed with PR1422, Class [] filleting compound. (2) Assemble parts immediately after application of sealant and tighten screws to obtain as near as possible a metal-to-metal contacL (3) Remove the extruded sealant from the wing surface after installing the fasteners. 28-12-00 1-1/2 IN. -_- ".-:-.--' ..'-':. ..--'...-:---. -_._.I.:-_-_.'._Q.:...:._.I.I-_{.I '._'i-:_:'.(_.._ ..................... _SEEP U STAIN , ,,, u^v i. 4 TD 5 IN. ° "_' '_^ l- _..?_{.-.-.;j," ' """ " ''-_u__ lU 3/4 IN, "" "_'_"':"• ''_ '-'_..... _uM==__ FUEL LEAK CLASSIFICATION - FIGURE 28-4 - FUEL TANK LEAK REPAIR 1. Leak Description. It is necessary to periodically inspect the fuel tanks. Inspection is particularly importantin confined areas of the aircraft that are not exposed to the airstream. Identification and classification of fuel leaks that occur in both confined and necessary differentiate between thoseopen leaksareas that is require repairtobefore flight and those which do not constitute a flight hazard. The size of the wetted area around a leak is an indication of the leak intensity. All fuel leaks must be recorded by descdbing the location and intensity of the leak in the aircraft log book. 2. Classification of leaks as to Intensity and Location. (Referto Figure 28-4). A. Intensity Classification. (1) Stain--A slow fuel leak that tends to evaporate as soon as it is exposed to air. (2) Seep--A fuel leak that reappears shortly after area is wiped clean. (3) Heavy Seep---A fuel leak that reappears immediately after area is wiped clean, (4) Running Leak--A fuel leak that flows steadily, B. Location Classification. (2) A running leak and any leak in a confined area that is not exposed to the airstream should be repaired beforethe next flight. 3. Leak Detection. A. External Leak Detection After Refueling. To be able to trace a leak from where it appears on an outer tank wingwhere skin tofuel its true source inside the tank, exactorpoint is escaping from tank, must the be determined. (1) Use compressed air to blow and evaporate fuel from seams and crevices of leak area. Attempt to define exact point where fuel is escaping from tank. (2) Small seep leaks can be traced with raw edges of tom paper. The fuzzy edge absorbs fluid and gives a good visual indication of fuel presence when brought in contact with suspected leak points. (3) After tracing leak to its extedor source, mark location and drain fuel tank. B. Internal Leak Detection. To make a permanent repair, it is mandatory that the true source of the intedor leak be located. The fuel tank is a network of seams, and fuel may flow through or along a seam or from one seam to another. Fuet may channel a few inches or several feet to where it appears on external skin surface. Slow-to-heavy occuring open areas, (1) Enter tank through inspection access panels such (1) as wing surfaces, seeps exposed to the in airstream, are leaks which do not constitute a flight hazard and need and inspect sealant in general area of outside leak not be repaired prior to flight, providing the condition point. Look first for bare seams, dvets, and bolts in causing the leak cannot result in a leak of greater difficult-to-seal areas. Inspect sealant for blisters, pin intensity during flight. Seeps considered permissible for holes, cracks, splits, and loss of adhesion. Mark all flight must be frequently inspected to insure that no suspected flaws with masking tape. increase in intensity has occured. 28-12-00 12-98 8 f SERVICE AND MAINTENANCE MANUAL M2OJ (2) Test each suspected flaw from inside tank using compressed filtered air at 20 to 30 PSI. Hold air nozzle against flaw and closely check outside leak point for evidence of fuel. (3) After testing each suspected flaw from inside tank as outlined above, and if no leak source can be discovered, apply soapless bubblefluid to exterior and againapplyair pressureto flawsfrom insidetank. (4) If above tests fait to locate leak source, apply air pressure (10 PSI MAX) to external leakpoint after removing all traces of fuel from tank and applying soapless bubble fluid to tank interior seams per Section28-13-00. 4. Leak Repair. A. Temporary Repair of Fastener Leaks. Generally, allleaks in enclosed areas and runningleaks in open areas constitutea flight hazard. Fastener leaks of this category may be temporarily repaired by applying a sealant fillet over fastener head on fuel tank extedor. For a temporary repair to be satisfactory, structural integrity must be retained in leak area. To make a temporaryfastener-leak repair: (1) Remove enough fuel from tank to drop fuel levelbelow leaking fasteners, MOONEY AIRCRAFT CORPORATION (5) Apply sealant as required for repair (See Figure 28-3). Repaired fillets must be blended into existing fillets with a spatula or an appropriate tool. (6) Allow all repaired sealant to cure tack-free and apply two brush coats of PR1005-L to repair area (Refer to paragraph 28-11-00,4.D.). 28-13-00 -SOAPLESS BUBBLE FLUID FORMULA PREPARATION FOR LEAK CHECK 1. Materials. A. Three ounces of either sodium bichromate, potassiumchromate,or potassiumdichromate. B. Three and one-quarterouncesThickeningWax (Carbo Wax 1500). C. Thirteen ouncesAlkaryl Sufonatewettingagent. D. Distilledwater. 2. SolutionPreparation. A. Mix one of the compounds listed in item (A) above withone cup distilledwater. B. Mix item (B) abovewith one cup distilledwater. C. Mix item (C) abovewith fourto four and one half gallons distilled water until wetting agent dissolves (2) Clean fastener head and adjacent surrace with Turco 657 Wipe Solvent or MEK and dry thoroughly.Fastener head and adjacent metal must be entirelyfree from paint, dirt, and oil. completely. D. Mix the three ingredients (A), (B) and (C) together and add enough distilledwater to make five gallons of solution. (3) Apply a 1/8 inch thick coat of PR1422 (or CS3204) B-1/2 or B-2 over head and around fastener. NOTE Amount of each ingredient may he reduced for a smaller quantity of solution. Solution life is about one week. (4) Allow sealant to cure until firm and rubbery, (5) Refill tank and examine repair periodically. If leak recurs, sealant must be removed and area recleaned prior to making another temporary repair. B. Permanent Leak repair. If leak source is found to be around a rivet or threaded fastener the repair procedureshall be to restdke rivet or retorquefastener to maximum permittedtorque value. ANY ONE RIVET MAY BE RESTRUCK ONLY ONE TIME. If leak continues,replacethe rivet, (1) Repair any sealant damage due _.orestdking or retorqueinga fastener, (2) Remove sealant in immediate area of leak source using a sharp, non-metallic tool. A chisel-shaped formica tool is recommended. Scarf or taper ends of existing sealant so that new sealant can form a continuous and smooth overlap. (3) Thoroughly clean repair area using Turco 657 Wipe Solvent or MEK. Wash one small area at a time. To prevent redeposit of oil and dirt on surface, dry with a clean cloth before solvent evaporates. NOTE Always pour solvent onto wash cloth to prevent contamination of solvent supply; do not dip cloth into solvent. CAUTION Soapless bubble fluid is slightly corrosive and must be completely removed by washing freely with water followed by scrubbing. CAUTION S/N 24-1038 and later model aircraft: When removing lower inboard access panels, caution should be exercised during removal so fuel outlet tubes will not be damaged or bent. 28-14-00 -FUELADDITIVES Under certain conditions of temperature and humidity, water can be present in the fuel in sufficient quantities to create ice formations within the fuel system. To prevent this, add ISO-PROPYL Alcohol to the fuel supply in quantities not to exceed 1% of total fuel volume per tank. CAUTION Ethylene glycol monomethyl ether (EGME) or other additives are not recommended due to potential deteriorating effects within the fuel system. (4) Thoroughly dry clean area by flowing filtered air over immediate area until there is no possibility of solvent or fuel entrapment under adjacent sealant. 12-98 28-13-00 9 MOONEY AIRCRAFT CORPORATION M20J 28-20-00 - DISTRIBUTION The fuel system includesof two fuel pumps, an engine driven pump and an electricallydriven auxiliary boost pump.The boostpumpis connectedto a switchon the strumentpanel, 28-21-00 - FUEL BOOST PUMP REMOVAL AND INSTALLATION 1. Auxiliary Electric Boost Pump Removal. A. Remove electrical leads, B. Turn fuel selector valve OFF. C. Disconnect inlet and outletfuel lines, D. Remove fuel pump. 2. Reverse the removal procedurefor reinstallation, CAUTION Do not run pump dry for more than 15 seconds, NOTE Refer to S.B. M20-222 (latest revision) when replacing fuel boost pump. (Ref. A.D. 80-13-03) NOTE When the aircraft will not be flown for a period of time, refer to Section 10-10-01 thru 10-10-03. 28-25-00 - FUEL SELECTOR VALVE REMOVAL & INSTALLATION 1. (For SIN 24-0001 thru 24-0377) The fuel selector valve isbelow the left floorboard just aft of the firewall. A. Disconnect right and left inlet lines at valve body. - SELECTOR VALVE AND GASCOLATOR SCREEN CLEANING 1. Fuel selector and drain valve screen or gascolator screen should be cleaned every 50 hours. Both valves are safety wired, (notice should be taken of exact wiring technique before removal) and upon completion, rewiring should be identical to odginal installation. To clean fuel selector screen, (a) Remove left hand exhaust cavity, (b) Turn selector valve to off position, (c) Remove AN-3 bolt from center of bottom of valve, (d) Remove bowl and clean, (e) Reverse process to re-install taking care not to damage o-rings seal. (Torque AN-3 bolt 15 to 20 inch pounds per Service Bulletin M20-200). 2. SIN 24-0378 & On: Gascolator screen removal and cleaning: Remove belly skin just aft of nose wheelwell; turn selector valve to off position; remove safety wire on bottom nut and remove nut; remove sump and screen by pulling down; clean screen and reverse pmcass to reinstall (take care not to damage O-rings); lubricate O-rings with clean engine oil before installing. Torque 15 to 20 inch pounds per Service Bulletin M20-200. 28-20-00 10 28-23-00 - FUEL INJECTION SYSTEM The Bendix RSA-5AD1 fuel injectionsystem measures airflow and uses an airflow signal In a stem-type regulator to convert the air pressure into a fuel pressure.This fuel pressure (fuel pressuredifferential), when applied across the fuel metering section of the fuel injector (jetting system), makes fuel flow proportional to airflow. The injection system is comprised of the injector, flow divider, air-bleed nozzles, and associated lines and fittings. CAUTION Fluid can easily enter the air section of the injector through the impact tubes or the annular groove around the venturi. For this reason, a protective covering should be installed on the induction air intake when performing engine maintenance, such as washing down the engine and induction air ducts or when injecting preservative oil into the engine and fuel injector prior to storing or shipping. 28-24-00 , ENGINE PRIMING The Lycoming fuel injectioncontrolsdo not include an engine primer. Fuel will be sprayed into the intake manifolds whenever there is pressure in the fuel systemand the mixturecontrol is open. It is necessary, therefore,to exercise cautionwhen operatingthe boost pumpto be sure that the mixture controlis in the IDLE CUTOFF position. CAUTION Mixture control should be in IDLE CUTOFF dPositionto check operating pressure, however o not operate the boost pump for more than a few seconds to prevent excessive flooding of the engine. 28-22-00 SERVICE AND MAINTENANCE MANUAL B. Disconnect outlet line at valve body. C. Remove clevis pin from valve control linkage. D. Loosen set screw on fuel valve drain control. E. Remove bolts from supporting bracket at floorboardand beam. F. Reverse the selector valve removal procedure for reinstallation. Pressure check fuel system for leaks after installation. (For 24-0378 24-TBA) The selector valve is 2. located aft of thethru console below thefuel floorboard. A. Drain both fuel tanks. B. Disconnect dght and left inlet lines at valve body. C. Disconnect outlet line at valve body. D. Remove handle above floorboard in fuel selector pan. E. Remove screws mounting valve to the tubular structure. F. Remove valve. G. Reverse the selector valve removal procedure for reinstaIlation. Pressure check fuel system for leaks after installation. 12-98 SERVICE AND MA NTENANCE MANUAL M20J NOTE It is recommended that the fuel selector valve be replaced each 500 hours of operation or if the valve becomes difficult to operate, (Anderson-Brass Valve only) 28-26-00 - FUEL FILTER MOONEY AIRCRAFT CORPORATION (3) Locate& remove transmitter wires. (4) Removesix screws attachingtransmitter to rib doubler. (5) Removetransmitterfrom rib. B. O/B Transmitterremoval (1) Gain access through lower access cover outsideoftank area. Fuel filter shouldbe inspected,cleaned or replacedat each annual or 100 hour inspection. (See TroubleShootingChart) 28-30-00 - DUMP (2) Locate& removetransmitter wires. (3) Remove six screws attaching transmitterto rib doubler. The fuel tanks can be emptied for maintenance purposesby: (1) removingthe sump drains in the lower panel of each fuel tank and allowingfuel to drain into suitable containeror (2) disconnect the fuel line at outlet of the fuel pump; usa boostpumpto transfer fuel from bothtanks to a suitablestorage container, 28-31-00 - FUEL SYSTEM DRAINS (4) Removetransmitterfromrib. 2. For REINSTALLATION, reverse the fuel quantity transmitterremovalprocedure. A. A calibrated, certifiedtorque applicationdevise 2. Remove fuel tank filler cap; blowgentlyinto rubber hose.Air should be felt comingout of filler port. 3. If Stoppageis found, clear vent priorto flightsince fuel starvationcould resultfrom vent stoppage, NOTE It is important that the fuel tank vent tube protrude only enough to be flush with lower wing skins. mustbe usedto installthe fuel quantitytransmitters. B. Snug each screw, then TORQUE each screw to 20-25 INCH LBS. in a cross flange-random order. C. The torque and screw clamp load will naturally relaxas the gasketflowsto a normal condition. NEVER RETORQUE JUST TO RESTORE THE 20-25 INCH LBS. "DO NOT OVERTORQUE" -- DO NOT RETORQUE UNLESS LEAKING D. Excessive torque or retorquing may warp or distort the transmitter mounting flange and cause a malfunction. E, Make certain wire from outboard transmitter goes under head of insulating sleeve against the inboardtransmitter flange and not under the mounting screw head. F. Systemvoltageshould NOT BE APPLIED to the transmitter terminal. The exicitation from the fuel quantity indicatormust be current and voltage limited and incapable of causing ignition of fuel vapor if transmitterwire is inadvertentlyshortedto ground. G. Care must be taken to insure that the bottom nut on the terminal stud is not disturbed when the electrical connection is made. This bottom terminal stud nut torque is factory set to provide the correct terminal studseal preload. H. Other nuts on the electrical terminalsshould be tightened as follows: #6 - 6 in. Ibs./#6 - 12 in. Lbs./#10 - 14 in. Ibs. 28-40-00 - INDICATING 28-42-00 28-41-00 - FUEL QUANTITY INDICATING TRANSMITTERS Two fuel quantity gauges are in the instrumentcluster gauge. These gauges indicate pounds or gallons of fuel remaining.Each gauge operates by the changein resistanceoftwotransmitters locatedin the fueltanks. Fuel drains are installedin the inboardcomers of the wing tanks and at the fuel selector valve or gascolator, the lowest point in the fuel Thejoin engine manifoldand engine-driven fuel system. pumpdrains at a juncture on the right side of the engine. A single drain line dumps fuel overboard below the cowling. Tank drains are recessed and spring loaded. An O-ring at the lower flangeseals the valveseat. 28-32-00 -FUELVENTS The fuel tanks are vented from the outboard upper edge. This vent is routed outboard and is vented overboardthrougha NACA vent on lowerwing surface, To checkfuel tank vents: 1. Block entire fuel tank vent by slipping a short length of rubber hose over tube and projectingbelow wing lowersurface. The fuel quantity indicating system has two fuel quantitytransmitters in each wing tank, one on lib wing tank fib and one on O/B wing tank rib. The transmitters are electrically connected to the fuel gauges in the clustergauge and work in series witheach other. 1. Fuel QuantityTransmitter Removal. Drain fuel from tank. Reference 28-30-00. - FUEL QUANTITY INDICATOR 28-43-00 - FUEL QUANTITY ADJUSTMENT PROCEDURE 28-43-01 ADJUSTMENT" FUEL TANK TRANSMITTER A. lib Transmitter removal (1) Remove Pilot or Co-Pilot seat as needed. (2) Remove intedor panel, LH or RH as needed. 12-98 AIRCRAFT MUST BE LEVEL TO CALIBRATE FUEL GAUGES NOTE See Section 24-33-00 for low fuel calibration. 28-26-00 11 MOONEY AIRCRAFT CORPORATION M20J (PRIOR TO SIN 24-1050 - approximately) 1. Fueltanks-EMPTY. 2. Add unusable fuel (1.3 Gal.). Indicatorshould read %" to 1/2 needle width below =E". Inboard floats may be adjusted by holding arm near transmitter and bendingouter arm, (do not bend by forcingarm against stops). 3. Add 2 1/2 to 3 gal. (part of additional 8 gal. required for 1/4 gauge reading). Adjust low fuel warning trimmer in annunciator panel so that warning lightjust comes on (see Section24-33-00, 4. A and B). 4. Continue calibration by adding fuel in 8 gal. increments,(-1, +2 gal.) for 1/4, 1/2, and 3/4 gauge readings. Gauge to read within 112 needle width. Outboardfloat may be adjustedif required for 1/2 and 314gauge readings. SERVICE AND MAINTENANCE MANUAL 2843-02 Clustergauges installedon MID 1981 aimraft and any spare units installed on earlier aircraft have this adjustment. 1. Remove plastic plugs from holes in top left of cluster gauge case. With "unusable" fuel in tanks, adjust pot marked "null" so gauge %". as If intermediate or =P"indicationsare out ofreads tolerance tank is filled, adjust pot marked "gain" for correct calibration. 28-90-00 28-91-00 Fuel gauge notindicating Fuel gauge indicatesfull when tanks are not full. No fuel pressure indication (calibratedtest gauges connected. Fuel pressurelow or surging (calibrated test gauges connected.) 28-43-02 12 -MISCELLANEOUS -TROUBLESHOOTING When trouble shooting,checkfrom the powersupplyto the suspect item. If trouble is not located, proceed to check the item itself. If necessary, remove the item and install an identical unit tested and known to be in good operational condition. 5. Finish filling tank and verify total quantity leas unusable fuel. TROUBLE - FUEL QUANTITY GAUGE ADJUSTMENT (Approx. S/N 24-1051 THRU 24-TBA) PROBABLE CAUSE REMEDY Brokenwire. Check and Repair. Faultytransmittingunit. Open circuitbreaker. Replace. Check and reset. Incomplete ground. Check groundconnectionat transmitter. Broken wire. Check and repair. Tank empty. Check and servicetank. Defective fuel pump. Check pump for proper pressure buildup. Checkfor obstructionin boost pump screen. Checkengine fuel pumpand checkvalve. Fuel Filter Clogged Clean or replace Fuel Filter Open fuel line. Repair or replace line. Fuel selector in "OFF" position. Obstructionin inlet side of pump. Select proper position Faulty engine pump. Check fuel lines and connection for leakage or damage. Fuel Filter partially clogged. Clean or replace fuel filter. Fuel selector not in proper position. Air leak in system. Select proper position. 12-98 Check and clear fuel lines. Replace or rebuild pump. Repair leak. SERVICE AND MAINTENANCE MANUAL M2OJ 28-92-00 - FLARED FITTINGS When installing flared fittings and hoses, make sure the threads are properly lubricated with W-P-236 petrolatumper (Figure 28-5). When previouslyinstalled MOONEY AIRCRAFT CORPORATION fittings are removed, they should be wiped clean and relubricated before they are reinstalled. Toque all fittings in accordance with flare fitting torque chart, Chapter5, Figure5-1. TAPERED STRAIGHT--/ TH READS LUBRICATE FEMALE THREADS / / NEVER ALLOW LUBRICANT TO CONTACT THESE SURFACES LUBRICATION OF FLARED FITTINGS - FIGURE 28-5 12-98 28-92.00 13 MOONEY AIRCRAFT CORPORATION M20J BLANK 28-92-00 14 12-98 SERVICE AND MAINTENANCE MANUAL MOONEY AIRCRAFT CORPORATION M20J SERVICE AND MAINTENANCE MANUAL CHAPTER 30 ICE PROTECTION SERVICE AND MAINTENANCE MANUAL M20J MOONEY AIRCRAFT CORPORATION CHAPTER 30 ICE PROTECTION LIST OF EFFECTIVE PAGES CHAPTER SECTION SUBJECT ........... 30-Effectivity ......... 30-Contents.......... 30-00-00 .......... 30-61-01 ........ 30-61-02 ............ 30-61-02 ......... 30-61-02 ............ 30-62-00 ........... 30-63-00 ........... 30-67-00 ........... 30-69-00 ........... 30-70-00 ........... PAGE ._. . .......... DATE 1/2BLANK .......... 3/4BLANK .......... 5 ........... . . 6 ........... 7 ........... 8 ........... 9 ........... 10 ........... 11 ........... 12 ........... 13 ........... 14 ........... 12-98 12-98 12-98 12-98 12-98 12-98 12-98 12-98 12-98 12-98 12-98 12-98 12-98 30-EFFECTIVITY 1/2BLANK MOONEY AIRCRAFT CORPORATION M2CJ SERVICE AND MAINTENANCE MANUAL CHAPTER 30 ICE PROTECTION TABLE OF CONTENTS CHAPTER 8EC'IICN SUBJECT 30-00-00 30-30-00 30-60-00 30-60-01 30-61-00 30-61-01 39-61-02 30-62-00 30-63-00 30-64-00 30-65-00 30-66-00 39-67-00 30-68-00 30-68-01 30-69-00 30-79-00 ........... ........ ......... ......... .......... .......... ............ ............ .......... .......... .......... .......... .......... .......... .......... ............ .......... ......... SUBJECT ........ General .............. Pitot, DescdpUon& Operation ....... Propellers, Description & Operation ...... Schematic - Propeller De-Ice ...... Service Guide .......... Helpful Tips ......... Trouble Shooting Chart ...... Ammeter Test .......... De-Icer Timer Check ........ Heat Test ........... Continuity Test. ......... Brush to Slip Ring Resistance Test Brush Assembly Resistance Check Brush Replacement ........ Brush (Module) Replacement Alignment of Slip Ring ........ Servicing/Cleaning .......... 12-98 PAGE .... .... .... 5 5 5 5 5 5 7 10 11 11 11 11 11 11 12 13 13 "0-CONTENTS 3/4BLANK SERVICE AND MAINTENANCE MANUAL 30-00-00 ( .... M2OJ - GENERAL The M20J aircraft incorporatesan alternate air system that is designed to open automaticallyany time the air intakesystembecomesblocked. A standard heated pitottube is locatedon the left wing at Wing Station No, 145. The pitotheat circuit breaker switch located on the panel in front of the pilots right kneesuppliespowertothe pitottube heatingelement. I ' PROPELLERS, DESCRIPTION AND OPERATION Propeller ice removal is accomplished by optional electrically heated de-ice boots bonded to each propeller blade, The system uses the airplanes electrical power to heat portions of the de-ice boots in cycles controlled by a timer. The ON-OFF switch is located on the switch panel in front of the pilots right knee. A current flow is depicted,(8 to 12 Amps, 24-0001 thru 24-2999) (8 Amps, 24-3000 thru 24-TBA) on the ammeter located in front of the co-pilot at the top of the radio panel. A slight deflection of the ammeter needle may be noticed approximately every 90 seconds; this is due to the cycling action of current flow to the circuits within the boot as controlled by the timer. This is normal operation. The timer is located on the circuit breaker panel side tray above the co-pilots right knee. Deqcer boot replacement should be done per B.F. Goodrich Report No. 59-728J which is supplied with the kits for replacement boots. _ ./-3E1964--3 #_ TIMER '@J, l --O05B I ]('_1 _ --O03B I_ I / AMMETER 30-61-00 - SERVICE GUIDE 30-61-01 - HELPFUL TIPS 1. Normal current isshown as a shaded range onthe ammeter for each propeller De-Icer system with engine running. The ammeter reading will he slightly lower when the system is operated on battery voltage. 2. Use the "heat test" (30-64-00) and "ammeter test" (30-62-00) to determine which De-Icers are not operating. Use wiring schematic to trace circuits. SLIP RING ASSY.-_._ ./_ L - PROPELLER DE-ICE 3. Excess current reading on the ammeter always indicates a power lead is shorted to ground. Thus, when trouble of this nature is found, it is vital that the grounded power lead be located and corrected. 4. A considerable number of timers have been returned for repair which proved, on test, to be fully operable. Before concluding that the timer ls faulty, test it per"De-lcerTimer Check" (30-63-00). 5. For insulation resistance tests, use a "megger" ("Meg" type insulation tester, James G. Biddle Company, Plymouth PROP DE-ICER Meeting, PA.) or 4E2351-3 4E24-06 30-60-01 INTRODUCTION. Whether in flight or during ground testing, the ammeter can be used to determine the general nature of most electdcal nroblems. The TroubleShooting Chart is based, pnmanly, on the use of the ammeter and it is assumed that the user understandsall normaloperatingmodesof the system. (See Section IX of P.O.H.). Read all of the "Trouble" entriesto locatethe one matchingthe conditionsof the system being checked. The "Probable Cause" and =Remedy" entries pertinent to each trouble are arranged in the recommended checking sequence. B.F. Goodrich maintenance Manual Report No. 68-04-712B will be required for complete maintenance actions. This aircraft includesas standard equipmenta heated pitottube assembly and may also include an optional electdcallyoperated propellerde-ice system, 30-30-00 - PITOT, DESCRIPTION AND OPERATION 30-60-00 ._ G-_0" JJ ;o c_[__ 2_IP-L_ " " 2ihtCOgA'- (1A)_,..USE_ J(1 /--002F__L_ SHUNT --'_'-_B" (MS91586-1_J" J having°ther a tester500 _ VDO,megoh m 1000 6. Defective widng in propeller I-°°_ ' e DE-ICE / MOONEY AIRCRAFT CORPORATION ) I I II SWITCH 930023--1 12 VOLT SYSTEM ULAF / "E,_, ,_-,, _ _ _ ASSY. mounted -- I_ \ be indicated by components normal current may readings in ground checkouts (propellers not _, _ E2130 currentprope with --001z_ '_ "IP_GWIRING cmiseHARNESS rotating at RPM. CZZ_ "-q BUS BAR + 14- VDC FIGURE 30-1A - PROPELLER DE-ICE SCHEMATIC (14 VDC) 12-98 3O-0O-0O 5 SERVICE AND MAINTENANCE MANUAL TIME CYCLE D F TIME CYCLE D ..... M20J MOONEY AIRCRAFT CORPORATION POWER REQUIREMENTS FOR 14 VDC SYSTEM ELEMENT HEATED TIME (IN SEC'S.) OUTBOARD 90 INBD 90 TOTAL CYCLE TIME = 3 MINUTES LOAD (AMPS) 8 TO 12 8 TO 12 POWER REQUIREMENTS FOR 28 VDC SYSTEM ELEMENT HEATED TIME (IN SEC'S.) ALTERNATING BLADES 90 TOTAL CYCLE TIME = 3 MINUTES LOAD (AMPS) 8 RECOMMENDED WIRE SIZE CHART ............ AWG SIZE ..... MAZ_.ENG_T_ BUSS BAR TO TIMER ........... #14 ....... 15 t_. TIMER TO GROUND ........... #18 ....... 5 ft. #14 ....... 151_. #20 ....... 5 it. TIMER TO BRUSH MODULE BRUSH MODULE TO GROUND ........ SHUNT LEADS ............. 30-61-02 - TROUBLESHOOTING CHART-PROPELLER DE-ICE TROUBLE PROBABLE CAUSE REMEDY Ammeter reads 0 currentall phasesof the timer cycle, -No powerfrem aimraft. If no voltageintocircuitbreaker, locate and coned open. -Trippedcircuitbreaker. Locate and correctshortbefore resettingcircuitbreaker. -Circuitbreaker or switchfaulty. If novoltageat circuitbreakeroutputwith voltageat inputand circuitbreakerdoes notreset,replacecircuitbreaker.If voltageis OKat output,checkswitchin samemanner.If voltageisOK at switch output,goto =AmmeterFaulty". Test ammeter per Section30-62-00. -Ammeter Faulty. -Open in ammeter to timer circuit, :Open in timer to brush assembly(ies) circuit, 12-98 Disconnectharness at timerand check for appropriatevoltageat harness Pin B,12V,TerminalC,28V to ground.If none, locateand correct open. Disconnect wire harness at brush assembly and check voltage to ground from pins or leads. (See de-icing system wiring schematic for power and ground lead and pin identification.) If low or no voltage,locate and correct open or high resistance in wire harness. 30-61-02 7 MOONEY AIRCRAFT CORPORATION TROUBLE (cant.) Ammeter reads normal current part of cycle, zero current rest af cycle, Ammeter reads normal current part of cycle, low current rest af cycle, Ammeter reads low current over entire cycle, M20J SERVICE AND MAINTENANCE MANUAL PROBABLE CAUSE REMEDY Check continuityfrom appropriate pin or lead to ground; if high resistance is indicated, check ground wire for breakage and ground connections for correctness and tightness. Correct as required -Open circuit ta De-Icer Boot, De-Icer wire harness ar slip ring assembly leads. DisconnectDe-Icer leads and check resistance per B.F. Goodrich Report No. 59-728. If not OK, replace faulty De-Icer. If OK, check for (and fix) open in slip rings leads. See Section 5-4.5, B.P. Gooddch ReportNo. 68-04-712B. Ohmmeter needle must not flicker when leads are stretchedor flexed. Replace as required. See "Open Timer te Brush Assembly" above. -Open circuit in wiring between timer and brush block assembly or brush assembly. -Open in De-Icer boot or slip ring assembly lead circuits. See "Open in De-Icer' above. -Timer faulty. -Inner and outer De-Icer Boot elements heating same phase (in series), should be in parallel., Test timer per Section 30-63-00. Locate and repair incorrect lead connections. See widng schematic.(24-0001 - 24-2999) -Open circuit or high resistance in De-Icer Boats, slip ring assembly leads or wire harness. -High resistance in circuit with low current, See "Open in De-Icer" above. -Worn or dirty brushes and/or slip rings. Inspect & clean brushes or slip ring. Check contact of brushes to slip rings per Section 30-66-00 or B.F. Goodrich Report No. 68-04-714; correct as indicated; check wiring from timer to De-Icers for oose or corroded connections or partially broken wiring. Correct as required. -Aircraft.voltage low under normal operating conditions. Check voltage into switch. 30-61-02 8 -Ammeter, switch,or circuit breaker faulty, Check voltage up to and out of ammeter, switch, and circuit breaker. Test ammeter per Section 30-62-00. Report No. 68-04-712B. If low output and input OK, replace defective component. -High contact resistance up to timer, Check for partially broken wire, or loose or corroded connection in wiring between aircrelt supply and timer input. Correct as required. -High contact resistance in timer. Test timer per Section 3-2.4 B.F. Goodrich Report No. 68-04-712B. 12-98 SERVICE AND MAINTENANCE MANUAL TROUBLE (cont.) Ammeterreads excesscurrent overentirecycle, Ammeter reads normal current part of cycle, excess current rest of cycle.(24-0001 thru 24-2999) (12V) Ammeter does not "cycle" each 90 seconds, Ammeter flicks between 90 second phase periods, M20J MOONEY AIRCRAFT CORPORATION PROBABLE CAUSE REMEDY -One De-Icer Bootelement (or wiringconnectionsto De-Icer) in each cycle open. Performa heat test on each De-Icer. Turn De-Icer switch ON, and, alter locatingthe De-Icer section being heated, followthe heatingcycle, fueling each sectionfor heatingin turn. Replacedefective components. Check power leadsfrom ammeter to timer andthen to De-Icers for evidence of damage or arcing.With de- icing systemswitchOFF and timer harness disconnected,check insulation resistance(use "Megger") to ground fromtimer harnessPin B. 12V, Terminal C, 24V. Disconnectharness at brush assembly and repeat check for applicable brush assembly harness connections. (See widng schematic Section 30-60-01). If ground is indicated, locate and correct it. -Power lead shortedto ground. -Ammeter faulty. Test ammeter per Section 30-62-00. -Short to ground or short between adjacent circuits,timer to brush block, Disconnect leads at brush assembly and timer. With "Megger", check insulation resistance from power leads to ground and between adjacent circuits. Eground or short is indicated, locate and correct. -Short to ground or between adjacent timer circuits in brush block. Electrically isolate brush assembly and test per Section 4-6, B.F. Goodrich Report No. 68-04-712B. -Short to propeller or short between two adjacent circuits slip dngs to De-Icers. Isolate brush assembly. With "Megger", check insulation resistance from one ring of slip ring assembly to bare prop. Reading should be at least .5 megohms after one minute. If not OK, disconnect the slip ring leads one set at a time to trace short. If OK, disconnect slip dng leads and check insulation resistance between slip rings; reading should be at least .5 megohrns after one minute. If not OK, clean assembly thoroughly with standard solvent and wipe clean with MEK and retest. Replace as required. Test timer per Section 30-63-00. Disconnectharnessat timer and check ground connectionwith ohmmeterfrom PinA,12V;TerminalG,24V. -Timer faulty. -Timer ground open; timer not cycling, -Timer contacts welded together (caused by short in electrical system), Test timer per Section30-63-00. Iftirner is faulty, repairor replaceit but insurethat short causingodginalfailure has been locatedand corrected. -Loose connection between aircraft power supply and timer input, Trace wiring from power source to timer input. Insure that good electrical contacts are made at each connection in circuit. 12-98 30-61-02 9 MOONEY AIRCRAFT CORPORATION TROUBLE (cont.) Radionoise or interferencewith Deqcere Boots ON. M20J SERVICE AND MAINTENANCE MANUAL PROBABLE CAUSE -Loose or poor connection; timer to De-Icers. REMEDY If trouble occursonly part of the cycle, determinewhich De-Icer is affected and checkfor roughor dirty sliprings causingbrushto skip. Also, check circuitsfor looseor poorconnections. -Timer cycleserratically. Test timerper Section30-63-00. -Brushes arcing. Checkbrushalignmentper B.F. GooddchReportNo.68-04-714. Check fordirtyor roughsliprings.If so, clean, machineor replaceslipringassembly. (See B.F. GooddchReportNo, 68-04-712B,Section5-4.) Checkslip ringalignmentper Section 4-5, B. F. GoodrichReport No, 68-04-712B. -Loose connection. See 4-3.8.a. and b., B.F. Gooddch Report No. 68-04-712B. -Switch or circuit breakerfaulty. Placejumperwire acrossswitchor circuit breaker,if radionoise disappearsreplace switchor circuitbreaker. -Widng too close to radio equipment or associated widng, Relocate De-Icer wiring at least 8" from radio equipment and wiring. Cycling sequence not correct. -Crossed connections between timer and De-lcars. Check system widng against circuit diagram. Rapid brush wear or frequent breakage. -Brush block out of alignment. Check brush alignment per B. F. Goodrich Report No. 68-04-714. Correct as Required. -Slip ring wobbles. Check slip ring alignment with dial indicator per Section 30-69-00. Refinish per Section 5-4, B.F. Goodrich Report No. 68-04-712B. -Rough slip rings. 30-62-00 -AMMETER TEST At some convenient point between bus bar and ammeter, connect a volt ohmmeter with an ammeter scale or a standard ammeter into the circuit and, with the De-Icer switch ON, check the amperage being used by the De-lcar system. The reading of the standard ammeter should closely agree with the reading obtained from the De-Icer ammeter. Turn De-Icer switch OFF and remove volt-ohmmeter or standard ammeter from circuit. If ammeter readings were significantly different and rest of de-icing system checks out satisfactorily, see Ammeter Checkout, Section 4-7 of B.F. Gooddch Report No. 68-04-712B. 30-63-00 - DE-ICER TIMER CHECK Experience in the field has indicated that often the timer is considered defective when the source of the trouble lies elsewhere. For this reason, the following test should be performed before the timer is removed as defective. ' 1. With the wiring harness disconnected from Terminal B at the timer and the deicer switch in the ON 30-62-00 10 position, check the voltage from Pin B(12V);from wire from shunt (28V) of the harness to ground. If no voltage is present, the timer is NOT at fault; however, if system voltage is present, check the circuit from harness Pin A (12V); from Terminal G (28V)to ground with an ohmmeter. If no circuit is indicated, the fault is in the ground lead rather than the timer. If ground connection is open, the timer step switch will not change position. 2. After the ground and power circuits have been checked, connect a jumper wire between pin B of the timer receptacle and terminal B of the connector plug and from pin A of the timer receptacle to ground. With the de-icing system switch ON, check the voltage to ground from pin B of the timer. The voltmeter should indicate approximately 12 volts (24-0001 thru 24-2999) or 24 volts (24-3000 thru 24-TBA) when the aircraft battery supply is being used. Next, check the DC voltage to ground from Pins D and F (12V); Pin C (24V), the points at which the system voltage is impressed in sequence to cycle power to the propeller de-icers. Each of the plugs should read 12 volts (24-0001 thru 24-2999), 24 volts (24-3000 thru 24-TBA) in sequence of cycle. 12-98 SERVICE AND MAINTENANCE MANUAL M20J MOONEY AIRCRAFT CORPORATION TIMING SEQUENCE Pin O TIME ON 90 sea. AREAS OF PROP DE-ICERS HEATE0 Pin F 90 see. Inboard Section tbru 24-2999) (12 VoltA/C) Pin C 90 see. Both blades ON/OFF(24 Volt NC) Outboard Section- (24-0001 NOTE Timer does not reposition itselfto start at Pin D when systemis turned off, but will begin cycling from same position as it was when turned off. Cycling will then proceed as before (24-0001thru 24-2999). After a voltage reading of 12 volts DC (24-0001 thru 24-2999) or 24 volts (24-3000 thru 24-TBA) is obtained, hold the voltmeter probe on the pin until the voltage drops to zero before moving the probe on to the next pin in the sequence noted above. After the cycling sequence has been established, turn the de-icingsystem switch OFF at the beginningof one of the =on-time"pedods and record the letter of the pin at which the voltage supply is present to facilitate performance of the following test. 30-64-00 -HEATTEBT Before this test can be performed, the jumper wire installed in paragraph 30-63-00, 2, for the timer test must be removed so that the connector plug can be replaced in the timer receptacle. Two men are requiredto perform this test, one in the pilot's compartment to monitor the ammeter while the other checks the De-Icer boots. The man in the pilot's compartment tums the De-Icer system ctmu'rtbreaker switch ON while the man outside feels the De-Icer boots to see if they are heating propedy. The man in the pilot's compartment observesthe ammeter for the proper readings (8 to 12 amps)(24-0001 thru 24-2999), (8 amps)(24-3000thru 24-TBA) throughoutthe timing sequence. The ammeter needle should deflect eve_/90 secondsin responseto the switchingaction of the timer. Each time this occurs,the man in the pilot's compartment must notifythe man inspectingthe propeller De- Icer boots so that the latter can change the position of his hands to check the proper heating sequence of the propeller De-Icer areas. If any irregularitiesare detected, a continuity check should be performed on the widng from the timer to the brush block holders end the propeller De-Icer terminal connections, CAUTION Stand clear of propeller, verify magnetos OFF. Use extreme caution during thistest procedure. 30-65-00 I 3. Pin A of the plug(12V),Terminal G (24V) to the airframeground. 4. Groundterminal of one prop bootto ground. 30.66-00 To check for incorrect resistance or the presence of a short or open circuit at the brush-to-slip ring contact, disconnect the each hamess at the timer check resistance from De-Icer circuit leadand (pins D andtheF of the harness plug) to ground with a low range ohmmeter. If the resultant readings are not 1.55 to 1.78 ohms, disconnect the De-Icer lead straps to measure heater resistance individually. Individual boot resistance should measure between 4.58 and 5.26 ohms. If the readings in the first check are not within the accepted limits but those In the second check are, the trouble is probably in the brush-to-slip ring area. If the readings in the second check are also off, the De-Icer concerned is damaged and must be replaced. 30-67-00 - BRUSH ASSEMBLY RESISTANCE CHECK To checkfor an open circuit,a short, or high resistance in the brush assembly, measure the resistance from the face of the brush to its terminal studs with a low range ohmmeter, if this resistance measures over 0.013 ohms, locate and repair the cause of excessive resistance. If the resistance is infinite, locate and correct the open circuit or ground, or else replace the brush assembly. Check the resistance between the three terminal studs. This resistance should not be less than 5 megobms. 30`08-00 -CONTINUITY TEST After removing the plug from the timer, use an ohmmeterto check continuityfrom: 1. Pin D of the plug'(12V),TerminalC (24V) to the outboardterminal of one prop boot. 2. Pin F of the plug(12V) to the outboard terminal of one prop boot. . BRUSH TO SLIP RING RESISTANCE TEST - BRUSH REPLACEMENT The propeller De-Icer brush module should be replacedwhen a minimumof 1/4 inch of brush matedal remains. It is good practice, however, to replace the modules when 318 inch of the brash material stitt remains. 12-98 30-64-00 11 MOONEY AIRCRAFT CORPORATION M20J SERVICE AND MAINTENANCE MANUAL (24 Volt system has only 2 modules stacked) 30-68-01 - BRUSH (MODULE) REPLACEMENT (See Figure 30-3), X-SIMENSION (JIN_H_) 1. Measure brash wear as shown (Figure 30-2); X-dimension (inches) given indicates when modules MUST be replaced. 2. Brushes are not offered, individually, as replacements. When a brush wears out, the module containing it should be replaced as .__AR IIRUSH ASSE3HIBLIES _u..onu_sHAVING SRLL_HE=VilliRB_ _u__D_.ESHAVZ,6 SRUSHES VITHI]IJT RODS MUST RF.PLACE 17164 1-7164 aircraft by removing attaching hardware, and disconnectenginewire harness. B. Remove assemblyscrews and separate A. Dismountmodular brush assemblyfrom modulesand spacers. C. The part number of each module is ___L._/_ \_ follows: __ etched into the surface of the plastic housing; SuRING ,_ASURB4CNT O_-Y_16InCH _r BRUSHH SH_U_ \ replace with the same part number module. _E TI] PRBTRLll]E FROM BRUSH BLOGI(, "tHIS IR THE ALL£1VF_I) NaP.HAL POSITION BF THE BRUSH ',/HEN INSTALEID D. Restack modules and spacers as shown ONTHE AIRCRAFT. (FIGURE 30-2). Check NB/C (12V),NB (24V) stackingarrangement and location of spacers. If there is interference between adjacent ring terminals, reorient center module as shown (Figure30-4). E. On 3E2042 sedes assemblies, make sure flat washer is positioned between star washer and housing. Make sure that assembly is square,thentighten screws. F. Reconnect aircrafl wire harness to applicable "A","B",or "C" terminals of modules. Insure that adjacentdng terminals are nottouching. G. Install assembly on aircraft with attaching hardware removed. H. Check assemblyfor proper alignment. I. Refer to B.F. Gooddch Report No. 68-04-712(B) forcomplete maintenance information. REFERENCE FIGURE 30-3 SHM30-S MEASURING BRUSH WEAR-FIGURE 30-2 1. BrushAssy. 3E2011-1 2. Brush Assy.3E2011-1 3. BrushAssy. 3E2011-1 6. Spacer 4E2218-3 7. Spacer4E2218-1 10. Screw MS24693-$35 (6-32 x 1-3/8) 12. Washer AN960C6 13. LockwasherM835333-7 14. Nut MS35649-262 1OOJ o_._ ....._. o. RINGS "i_RU 361_ OP SLiP SlHO ROTATION 14-_ .,,/t-10 6 13_: , -, f p(. ( FORE & AFT POSITIONING I i \. .J LS= .-.o°u..,u...,. _3 MEASURING BRUSH WEAR - FIGURE 30-2 30-68-01 12 i 12-98 SERVICE AND MAINTENANCE MANUAL M20J MOONEY AIRCRAFT CORPORATION 30-09-00 - ALIGNMENT OF SLIP RING To check alignment of slip ring assembly, securely attach a dial indicatorto the engine and place the pointer on a slip ring (see Figure 30-5). Grasp the propellerblade and rotateitslowly,notingthe deviation of the slip ring from a true plate as indicated on the gauge. Check that the total run-out does not exceed 0.010 inch (+/- 0.0025 inch) for reciprocatingengines withinany 4 inchesof slipringtravel. CAUTION Due to the loose fit of some propeller thrust bearings, a considerable error may be induced in the readings by pushing in or pulling out on the propeller while rotating it. Care must be taken to exert a uniform push or pull on the propeller to hold this error to a minimum. I l SH30-4 ALTERNATE MODULE STACKING ARRANGEMENT FIGURE30-2 corrective action is required. If it is not within the limits, If the slip withinthe limits specified, no check for ring dirt run-out on the isring gear mounting surfaces, clean, and recheck alignment. If run-out is still out of tolerance, return the slip ring assembly to the B.F. Goodrich Co. 30-70-00 - SERVICING/CLEANING Thoroughly cleaning the slip ring area with MEK or standard engine degreaser on a routine basis is recommeded. Keeping the brushes free of dirt, oil, grease and carbon build-up will prevent those contaminantsfrom beingtransferred to theslip ring. (Only 2 modules for 24 volt systems) ALIGNMENT OF SLIP RING - FIGURE 30-5 12-98 30-69-00 13 MOONEY AIRCRAFT CORPORATION M20J BLANK 30-70-00 14 12-98 SERVICE AND MAINTENANCE MANUAL MOONEY AIRCRAFT CORPORATION M20J SERVICE AND MAINTENANCE MANUAL CHAPTER 32 LANDING GEAR SERVICE AND MAINTENANCE MANUAL M20J MOONEY AIRCRAFT CORPORATION CHAPTER 32 LANDINGGEAR _ LIST OF EFFECTIVE PAGES CHAPTER SECTION SUBJECT ........... 32-Effectivity ......... 32-Contents ........... 32-Contents ........... 32-00-00 ............ 32-10-02 ............ 32-10-05 ............ 32-10-06 ............ 32-20-03 ............ 32-30-02 ........... 32-30-04 ........... 32-30-04 ........... 32-30-04 ........... 32-30-05 ........... 32-30-05 ........... 32-31-01 ........... 32-31-02 ........... 32-31-03 ........... 32-31-05 ........... 32-32-00 ........... 32-40-00 ........... 32-40-03 ........... 32-40-04 ........... 32-40-04 ........... 32-40-04 ........... 32-41-01 ........... 32-50-02 ........... 32-60-00 ........... 32-60-04 ........... 32-82-00 ........... PAGE .......... DATE 1/2BLANK .......... 3 ........... 4 ........... 5 ........... 6 ........... 7 ........... 8 ........... 9 ........... 10 ........... 11 ........... 12 ........... 13 ........... 14 ........... 15 ........... 16 ........... 17 ........... 18 ........... 19 ........... 20 . .......... 21 ........... 22 ........... 23 ........... 24 ........... 25 ........... 26 ........... 27 ........... 28 ........... 29 ........... 30 ........... 12-98 12-98 12-98 12-98 12-98 12-98 12-98 12-98 12-98 12-98 12-98 12-98 12-98 12-98 12-98 12-98 12-98 12-98 12-98 12-98 12-98 12-98 12-98 12-98 12-98 12-98 12-98 12-98 12-98 12-98 32-EFFECTIVITY 1/2BLANK MOONEY AIRCRAFT CORPORATION M2OJ SERVICE AND MAINTENANCE MANUAL CHAPTER 32 LANDING GEAR TABLE OF CONTENTS CHAPTER SECTION SUBJECT ........... 32-00-00 ........ 32-10-00 ......... 32-10-01 .......... 32-10-02 .......... 32-10-03 ........ ............ 32-10-04 ......... 32-10-05 .......... 32-10-06 .......... 32-20-00 ......... 32-20-01 ........ 32-20-02 .......... 32-20-03 .......... 32-30-00 ......... 32-30-01 .......... :32-30-02 .......... 32-31-01 ............ 32-31-02 ............ 32-31-03 ............ 32-30-03 .......... .............. 32-30-04 .......... 32-30-05 .......... 32-30-06 .......... 32-30-07 .......... 32-30-08 .......... SUBJECT ........ PAGE General .............. Main Landing Gear and Doors ....... Main Gear Removal......... Main Gear Installation ........ Main Gear Door Rigging ....... (24-0378 thru 24-2999, 24-3079 thru 24-TBA) Main Gear Door Rigging (24-3000 thru 24-3078) Inboard Door Rigging (24-3000 thru 24-3078) . Assist Bungee Installation ....... Nose Gear and Doors ......... Nose Gear Removal ........ Nose Gear Installation ........ Nose Gear Rigging ......... Extension and Retraction ........ Gear System Operational Check ..... Main Landing Gear System Rigging .... (24-0001 thru 24-2999, 24-3079 thru 24-TBA) (24-0001 thru 24-0377 ...... (24-3000 thru 24-3078) ...... Nose Landing Gear System Rigging (24-3000 thru 24-3078) ...... Emergency Gear Extension System Rigging. Landing Gear Actuator, Clutch Spdng, R & R. Landing Gear Actuator, Recoiler Spdng, R&R Manual Emergency Gear Extension System. Final Check .......... 5 5 5 6 6 6 7 8 8 8 8 9 9 9 10 10 11 14 16 16 17 18 19 19 TABLE OF CONTENTS CONTINUED ON NEXT PAGE! 12-98 32-CONTENTS 3 SERVICE AND MAINTENANCE MANUAL M20J MOONEY AIRCRAFT CORPORATION TABLE OF CONTENTS (con't.) CHAPTER SECTION SUBJECT 32-32-00 32-40-00 32-40-01 32-40-02 32-40-03 32-40-04 32-41-00 32-41-01 32-50-00 32-50-01 32-50-02 32-60-00 32-60-01 32-60-02 32-60-03 32-60-04 32-80-00 32-81-00 32-82-00 ........... ......... ......... .......... .......... .......... .......... ......... .......... ......... .......... .......... ......... .......... .......... .......... .......... ......... .......... .......... 32-CONTENTS 4 SUBJECT ........ Trouble Shooting .......... Wheels and Brakes.......... Main Wheels .......... Main Wheel Disassembly/Assembly .... Nose Wheel Disassembly/Assembly.... Brake Assembly ......... Trouble Shooting- Brake System ...... Shuttle Valve .......... Steering............. Nose Gear SteeringSystem ...... Nose Gear Steering &Tracking ..... Position and Warning ......... ElectricGear Safety Devices ...... Landing Gear Warning System ..... Airspeed Safety SwitchAdjustment .... Squat SwitchAdjustment ....... Miscellaneous ........... Landing Gear ShockDisc Inspection .... Recommended Hard LandingInspections 12-98 PAGE 20 21 21 21 22 22 26 20 26 26 27 28 28 28 28 29 29 29 30 MOONEY AIRCRAFT CORPORATION M20J 32-00-00 -GENERAL The landing gear is operated by an electdcal motor driven actuator. The travel dudng the extend and retract cycle is controlled by down and up limit switches located beneath the floorboard under the pilotsseat. Power is suppliedto the actuatorthrough a set of relays actuatedby the gear selectionswitch. The gear selection switch is located at the top of the instrument panel in front of the pilot. The actuator worm gear ball nut is connectedto the retract bellcrank which is connected to push-pull retract tubes and bellcranksthroughoutthe entire retractionsystem. An airspeed safety switch (24-0084, 24-0238 and on) is mounted to the back of the airspeed indicator and incorporated into the landing gear electricalcircuit to prevent landing gear mtracUon while on the ground untila safe takeoff speed is reached. A squat switch is locatedon the lee main landinggear leg (SIN 24-0001 thru 24-0237, except 24-0084). A by-pass switch is installed adjacentto the gear selectionswitch in order to override not retract.the safety switch circuitryif the gear does The gear legs are constructed of welded chrome-molybdenum tubular steel, heat treated for greater strength and wear resistance. Main gear attaching points have bushings installed in the gear mountingbox attached to the wing spar. The steerable nose gear mountsto the cabintubularsteel frame, NOTE Heat treated components should NOT be repaired; replace them. The main gear wheels have hydraulic disc brakes with a parking brake valve incorporated into the system. Rubber discs in the gear leg assemblies absorb the shock of landing and taxiing. MANUAL-EMERGENCY LANDING GEAR SYSTEM. Emergency gear extension is available through a manual override system. This system is built into the actuatorunit.Refer to Section 32-31-05 and 32-30-03. LANDING GEAR WARNING SYSTEM. The landing gear warning system providesthe pilot with an audible warningthat the landing gear is not down and locked when the throttle is retarded to within 1/4 to 3/8 in. throttle position. When the landing gear is down and locked the electrical circuit is opened and the intermittent horn is stopped. This warning switch is mounted on the throttle housing forward of the instrument panel (24-0378 & ON) and can be adjusted for the proper setting by loosening the screw and repositioning the switch. This switch is located inside the throttleby quadrant (24-0001 thru was 24-0377) and operated a cam when throttle retarded. Adjustment procedures are similar, BRAKE The the brake system is hydraulically operatedSYSTEM. by depressing brake pedals mounted on the pilotsrudder pedals. (Dual brake system is optional for co-pilot). Individual wheel brakes are available by depressingeither left or right pedal. Parking brakes are actuated by depressingboth brake pedals and pulling the parking brake control cable knob. This cable actuates a lever on the parking brake valve and traps the hydraulicfluid from the valveto the wheel cylinders SERVICE AND MAINTENANCE MANUAL thus holding the pucks to the discs. Release the parkingbrakes by pushingthe parking brake knob in. This releaseshydraulicpressureat the wheel cylinders and thereforereleases thebrake discs. 32-10-00 -MAIN LANDING GEARAND DOORS 32-10-01 -MAIN GEAR REMOVAL (SIN 24-0001 thru 24-2999, 24-3079 thru 24-TBA) 1. Raise aircraftonjacks. 2. For SIN 24-0084, 24-0378 and ON partially retract gear as descdbedin Section32-60-01. For SIN 24-0001 thin 24-0377, except 24-0084) Partiallyretract gear by operatingthe emergency gear extensionmechanismin reverse. CAUTION ON SIN 24-0001 THRU 24-0377, except 24-0084 DO NOT fully retract gear using emergency gear extension system. Partial retraction using emergency extension system is permissible only during gear rigging. DO NOT operate gear electrically with emergency extension system engaged. 3. Disconnectgear door links and brake lines. Cap all linesand fittings. 4. Removegear door and mud guard (if desired). 5. Detach main gear retracting tube (V), (Figure 32-9) from retractingtruss (G), and remove bolts (H) from retractingtress mountingblock. NOTE Steps 7 thru 9 apply to 24-0001 thru 24-2999 and 24-3079 thru 24-TBA only. 6. Remove grease fittingsfrom forward gear support trunnion-shaft.bearing. 7. Retractthe gear by hand until a 2 inchthickwood block(C), (Figure 32-1), can be inserted,as shown,to holdgear in retractedposition. A. Remove cotter key and nut at springconnecting link(F), (Figure 32-1). B. Removegear retractionspring (A) at (F), (Figure 32-1), by attachingspringinstallationtool (B), PIN GSE 030012, (old PIN was 8186) using an AN3-12A bolt (E). Remove grease fitting pdorto usingtool. NOTE Apply MIL-G-23827 grease to bolt at (F) for better rotation of Link (D). 8. Extend gear three to four inches from down-lock position and secure. 9. Remove six mounting bolts from rear gear trunnionshatt mounting block assembly at stubspar. 12-98 32-00-00 5 SERVICE AND MAINTENANCE MANUAL M2OJ 2. Check main gear up against bumper pads. 3. Normally once the doors are installed at the factory no further adjustment should be required. However, should the inboard doors be removed for any reason the followingdgging procedureshould be usedwhen reinstallingthem: A. Disconnectoutboard gear doors at the forward and all linkages (B) (Fig. 32-2). APPLY MIL-G-23827 GREASE TO BOLT FOR ROTATION OF LINK =D"AT =F". • 03 IH. t 3 iN. "_" l C._. E - ---... _ | ___S._ • ' F ""-" MOONEY AIRCRAFT CORPORATION D JiJ'_l J" Jk rP skininboard and fairgear witheadng the should aftedge bubble fairing. Spacers (A) the C. Forward be and tight aR trailing the edge wing of B. Raise geardoor electrically to the fullagainst up position. to obtain a good fit with no bindingor distortionwith (Figure32-2)should be added or removedas required be usedas spacers. 4. Reconnect outboard gear doors and check that the forward edge of outboard gear doors are falrea with wing skin/wheel well opening and that there is no binding or distortion where links attach to door. 5. If adjustments are required, adjust outboard gear door rod ends (B)(Fig 32-2) at forward or ett linkages the gear in the UP gear position.AN960-10 washers may as required. Extend to adjust links, then retract to checkadjustment. = _..... GEAR RETRACTION SPRING REMOVAL FIGURE 32-1 10. Slide out aft bearing block. 11. Slide front bearing block aft and remove. 12. Slide gear assembly aft until clear of front beadng, and carefully remove gear assembly from wing. 13. Identify all components removed, and DO NOT intermix right and leRgear components. 14. DO NOT attempt to repair any heat treated component of main landing gear assembly. 32-10-02 ', -MAIN GEAR INSTALLATION 1. Lubricate wheel beatings, retraction linkage, and fore and att trunnion beadngs pdor to installation (refer to Section 5-20-07 for recommended lubdcants). 2. installation of main gear is the exact revereat of the main gear removal procedure. 3. Check fore and aft movement of gear in bearing blocks, Maximum allowable movement is .020. Shim excess by inserting shims at rear block (maximum of any 2 shims). 4. Temporary attach gear door link _odsto gear leg brackets. 5. Retract gear while checking for binding in door linkage and proper contact of gear door edges with wing. DO NOT make final gear door adjustments until gear has been rigged (Ref. 32-30-02). 32-10-O3 - MAIN GEAR DOOR RIGGING • (24-0001 thru 24-2999 and 24-3079 thru 24-TBA) 1. Raise aircraft on jacks. NOTE Gear system must be properly rigged prior to gear door rigging, see Section 32-30-01. 32-10-02 6 MAIN GEAR DOOR ADJUSTMENT POINTS FIGURE 32-2 (SIN 24-0001 THRU 24-2999 8, 24-3079 THRU 24-TBA) 32-10.-04 , MAIN GEAR DOOR RIGGING (24-3000 thru 24-3078) 1. Raise aircraft onjacks. 12-98 MOONEY AIRCRAFT CORPORATION M20J NOTE Gear system must be properly rigged prior to gear door rigging, see Section 32-30-01. SERVICE AND MAINTENANCE MANUAL 3240-05 - INBOARD GEAR DOOR RIGGING (24-3000 thru24-3078) 1, Adjust inboard door link to close doors with =0" gap. Doors must be closed with gear extended and retracted. If door is not closed in both positionsrefer to landinggear dggingprocedures in Section 32-31-03. 2. Normally once the doors are installed at the factory no further adjustment should be required, However, should Mid-Gear doors be removed for any reason the following rigging procedures should be used when reinstallingthem: A. Disconnect outboard doors at forward and aft linkages(El)(Fig. 32-2A). B. Disconnectinboard doors at the forward linkage and springs(A) (Fig. 32-2B). C. Raise gear electricallyto the fullUP position, D. Forward leading edge and aft trailing edge of Mid-Gear Door should be tight againstthe wing skin . Spacers (A) (Figure 32-2A) should be added or removed as required to obtain a good fit with no bindingor distortionwith the gear in the UP position . AN960-10 or AN970-3 washers may be used as spacers. 3. Reconnect outboard and Mid-Gear doors and check that the doors are faired with wing skin/wheel well opening and that there is no bindingor distortion where links attach to door. Adjust linkage if required (Fig. 32-3A), Extend gear to adjust, then retract to check adjustment. 4. Check main gear overcenter preload torque for proper values. Re-dg entire LDG system, if necessary. Any adjustmentto rod end on retract tube (L) Fig 32-5) and rod endon retraction tube (V) (Fig. 32-9) is at a 2 to 1 ratio, respectively; this adjustment will changerigging values,Recheck preloadvalues. EXAMPLE: (1) The door is open a small amountwhen gear is DOWN, but closedwhen gear is UP. Adjust by turningretract tube (V) rod end IN 1/2 turn, and retract tube (L)(Fig. 32-5) rod end OUT 1 turn. EXAMPLE: (2) The door is closed when gear down, but open a small amountwhen gear is UP. Adjust by turning retract tube (V) rod end OUT 1/2 turn, and retracttube (L) (Fig.32-5) md end IN 1 turn. 2. Tightenjamb nuts and connect springs on inboard gear doorbettcranks(A)(Fig. 32-2B). / / V / MAIN GEAR DOOR RIGGING - FIGURE 32-2B I I i . MID-GEAR DOORADJUSTMENT POINTS FIGURE 32-2A (24-3000 THRU 24-3078) this rig may resultshut in higher actuator loads. as DOnot doors more than necessary 3. Adjust outboarddoor link to close gap at leading edge of door. If the dooris rigged too tight, the skinwill be under stress (concave) at the point where the linkageis attachedto the door. It could also causethe midand inboard doors to gap open. 12-98 32-10-05 7 SERVICE AND MAINTENANCE MANUAL M20J 4. Cycle gear manually and electrically while inspecting for clearances Re-check MLG system riggingvalues., 5, Remove aircraftfromjacks. 6. Returnaircraftto service, NOTE To remove INBOARD GEAR DOORS use a sharpened punch less than .093 dia. or a short piece of hinge pin to open the crimped hinge assembly pin hole. 32-10-06 INSTALLING ASSIST BUNGEE (560213-501) (24-3000 THRU 24-3078) 1. Retract gear. 2. Pull gear down with emergency extension until main retract bellcrank and md end bungee line up. InstallAN3 bolt, washers & nut through Helm rod end beadng and AN4 bolt, washers & nut through block. Torque and safety. MOONEY AIRCRAFT CORPORATION 32-20-00 - NOSE GEAR AND DOORS 32-20-01 - NOSE GEAR REMOVAL. 1. Raise aircraftonjacks. 2, Remove exhaustcavityfaidngs, 3. Partially retract gear as described by Section 32-60-10. 4. Remove firewall nose gear box (if needed) to gain accessto bolts. 5. Disconnectlink (A) on nose gear truss assy. (Figure 32-3). 6. Disconnectnosegear steeringhorn link(B) (Figure 32-3). 7. Remove left and rightgear mountingbolts(D) and (E)(Fig 32-3) from tubular structure and nose gear trussassembly. a NOSE GEAR RETRACTION TUBE ADJUSTMENT POINTS - FIGURE 32-3 9. DO NOT attempt to repair any heat treated componentof nose landinggear assembly. 32-20-02 - NOSE GEAR INSTALLATION ASSIST BUNGEE - FIGURE 32-2C (24-3000 THRU 24-3078) CAUTION Bump gear up, CAREFULLY, just to take the load offthe 3/16 in. installation pin at (B). Remove pin from (B) (Fig. 32-2C). 1. Lubricatewheel bearings, retraction linkage and left and rightmountbearings. 2. Installgear in reverse order of removal procedure. 3. With bungee installed recheck pre!oad per steps 30 thru34 of Section 32-31-03. 32-10-06 8 12-98 MOONEY AIRCRAFT CORPORATION M20J 32-20-03 - NOSE GEAR DOOR RIGGING 1. Raise aircraft onjacks. (Refer to Section7-10-00.) NOTE Gear system must be properly rigged prior to gear door rigging, see Section 32-30-03. SERVICE AND MAINTENANCE MANUAL completely. Check for any tire interference as tire enterswheelwell. 3. Closethrottleand confirmgear hornsounds. 2. Adjust gear door link rods (H) and (J) (Fig 32-3) to obtai_pmperdoorfltwhen closed. 3. To increaseor decrease nose gear-uptravel in wheel well, adjustboth eccentricson trunnionbearings 4. Inspectgear doors for proper closing. Referenc Section32-10--03, 3C., 32-10-04, 2,D, or 32-10-05, 1. Lowergear to fullyextendedposition. 5. With zero airspeed place gear switch in UP position.Gear hom shouldsoundregardlessof throttle position,both gear positionlights and safety by-pass switchwill illuminate. (J) (Figure 32-4) as required. 6. Push RED gear safety by-passswitch and holdIN to partiallyretract gear. 7. Pull=GEARACT circuit breaker. F A. Measure nose gear bungees (Figure 32-8). / -'1/ _ "_G,, . , ., _'_ stopping extension the moment the GREEN Gear Extend gear manually (See in Section 32-30-04) 8. B. Checknose gear overcenterpreload as follows: Down Light comes ON. Gearswitch down position. _, "'_'J.'_'7 _ _,/""/ C. Measure nose gear bungee springs. Deflection .070 inches for each bungee (Fig 32-6). (.010 to .030 inch for M20J with Dukes Actuator PIN 1057-00-56). D. If spring deflection is not within prescribed limits, adjust tube rod ends (F) (Fig 32-4) @ (G) in incrementsof 1/2 turns as required. ==.,.,-,-K A Place rigging tool (T) PIN GSE030007 (Fig 32-9)" on retraction truss. Hold tool stationary by placing thumb rear end of tool at (S) and press 9. Check mainon gear overcenter preload asfollows: forward. __ B. Place 10" torque wrench (R) on rigging tool. Place thumb on wing bottom;applyforce untiljoint (4) breaksopen slightly.Insertshim stock(.005 to .008 in. thickness)between link and trussat (P). Release force on wrench. NOSE GEAR RETRACTION TUBE & DOOR ADJUSTMENT POINTS - FIG. 32-4 NOTE Eccentrics permit nose sheel to move quicker to clear nose gear doors & also will allow nose wheel to be positioned further or less further into nose wheel well. CAUTION Nose gear overcenter preload must be rechecked after any adjustment to nose wheel eccentrics. 4. Readjust nose gear door linkage (K) as required after eccentricshave been adjusted. (Fig 32-4). 32-30-00 - EXTENSION AND RETRACTION 32-30-01 - GEAR SYSTEM OPERATIONAL CHECK (S/N 24-0084, 24-0238 thru 24-TBA) 1. Raise aircraft on jacks. (See Section 7-10-00). 2. With Master Switch ON and gear switch in UP position apply pressure to pitot tube (see Section 32-60-01). Verify gear retraction occurs at 69 MPH +/5 MPH (60 +/- 5 KIAS). Allow gear to retract C. With fingers on torque wrench and thumb on wing bottom apply force on wrench while maintaining a pulling force on shim stock. Read torque value on wrench at the exact moment the shim stock pulls loose. Torque valueshouldbe 250 to 280 inchpounds. D. Repeat on other main gear. E. If preload is notwithin prescribedlimitsproceed to applicable SIN main landing gear rigging proceduresin Section32-31-03. F. If main gear preload needs re-adjusting, the nose gear bungees should be re-checked per 8,(C) above. On SIN 24-3000 thru 24-3078 proceed to Section32-30-03 for nosegear riggingprocedures. NOTE When gear overcenter preload check is completed, electrically extend the gear and check the nose gear tube bungee springs to assure they have not compressed completely resulting in no remaining deflection. This would indicate excessive preload or weak bungees. 12-98 32-20-03 9 SERVICE AND MAINTENANCE MANUAL M20J SQUAT SWITCH OPERATIONAL CHECK (24-0001 thru 24-0237,Except 24..0084) A squat switchis above incorporated on theNumbered left main Aimralt. landing gear assemblyof listedSedal The followingoperationalcheckshouldbe made: 1. Raise aircraftonjacks (see Section7-10-00). 2. With master switch ON place gear switch in UP position.Gearshould retract normally. 3. Extendgear to downand locked. 4. Refer to Section 32-60-04 for squat switch adjustmentprocedures, 32-30-02 -MAIN LANDING GEAR SYSTEM RIGGING 32-30-03 - (AVIONICS PRODUCTS - 24-0378 thru 24-2999 & 24-3079 thru 24-TBA) 1. Raise aircraft onjacks and remove 3 belly access panels locatedconsecutivelyjust aft of nose wheel well or the one piece belly access effective 24-1418 and later aircraft. DISCONNECT ALL GEAR DOORS. 2. Disconnect electdcal power from landing gear actuator by pulling actuator circuit breaker. Make sure landinggearwaming lightcircuit breaker is pushedIN. 3. Disconnect main gear retraction tubes (L) (Figure 32-5) at inboard bellcranks (M). Loosen Iocknuts (E). Disconnect nose gear retraction tubes (F) (Fig 32-,3)at main refraction bellcrank (A) (Fig 32-t0B). Loosen Iocknuts (G) (Fig 32-4). Disconnect rod end beadng on barrel nut (D) from bellcrank (A) at N (Fig 32-10B) NOTE Do not loosen Helm rod end bearing from barrel nut (D) on Avionics Products actuator, MOONEY AIRCRAFT CORPORATION Disconnectnose and main gear door links.Check gear for bindingat pivot pointswhile moving gear legs by hand. Lubricate retraction system as indicated in Section 5-20-07. 4. Positionretractionbellcrank(A) (Fig 32-10B) so that center of forward hole in left outboard arm of the bellcrankis 1.56 * IN. (approximately)from forwardface oftruss at FuselageStation33. (See Fig 32- 10B). * NOTE This is a starting point only. This dimension may vary to permit retraction tubes to connect with zero preload. 5. With the bellcrank (A) (Fig 32-10B) in position, turn barrel nut (D) on actuator until Helm bearing aligns with holein bellcrankat (N). Installconnectionbolt NOTE LH & RH adjustable retraction tubes should be approximately same length to start rigging procedures. 6. With bellcrank in position and all gears fully extended, adjust main and nose gear retraction tubes sothattubescanbeslippedinplacewithzeropreload. 7. With bellcrank, retraction tubes, and the gear positioned as indicated in step 4, set down-limit switch striker arm (J) so that gear down light switch is just closed and GREEN gear-down light is ON. Secure striker arm in position. 8. Reset actuator circuit breaker and partially retract gear (use Master Switch to control motor). Screw rod end (E) (Fig. 32-5), on aft end of each main gear retracting tube, OUT two (2) full turns, screw each nose gear retractiontube rod end (G) (Fig. 32-4) IN one (1) full turn, then slip attaching bolts back in place. '- :° MAIN GEAR RETRACTION TUBE ADJUSTMENT POINTS - FIGURE 32-5 32-30-02 10 12-98 MOONEY AIRCRAFT CORPORATION M20J 9. Check nose and main gear overcenter preload described in Section 32-30-01, steps 8 and 9. Adjust as instructed. 10. Complete operational check descdbed in 32-30-01 steps2 3 5 & 6. Reset landinggear system c rcuitbreaker and fullyextend gear. 11. When step 10 is complete,the retractionsystem SERVICE AND MAINTENANCE MANUAL between down-stop and end of barrel nut (C) (Fig 32-7). NOTE Use 1 to4,560252-11 shims with 560252-009 allowance for actuator overrun after cutoff. 12. Disengage manual system. 13. Leave all gear doors disconnected, and run gear-up electrically until main gears are .03 inches minimumfrom bumper pads (.06 in. thk. rubberstrips installedon W.S. 43.50 false rib). Positiongear-up limit switchstrikerarm (H) (Fig. 32-5) so that switch iswith just is rigged for the gear-down-and-locked position D '_ _r__= B'_ strikerarm in position.The gear is nowproperlyrigged in the gear-up position with allowance for actuator overrunafter cutoff. para. 8.C. closed, and RED gear unsafe light is OFF. Secure 14. Electrically extend gear to down-and-locked position.Connectand adjust gear doors (refer to Main Door and Nose Gear Door Rigging Procedures in Section 32-10-03, Main, and 32-20-03, Nose). 15. AdjustNose the mechanical down stop,per on32-30-01, actuator Recheck Gear Bungee Spdngs housing,and up stop, per the followinginstructionsand Fig. 32-7 & 32-5. _..__ g.p --LITBD A"- _[ _r_-_,,_-__..__._ _'_ MECHANICAL DOWN STOP - FIGURE 32-7 y560245 stop to achieve proper clearance as an alternate for 560252-001, -003, -005, or -007. C. Actuatorballnut(C)(Fig. 32-7). (REF) Nose Gear Bungee J VH/_JJ__ _ I_ D. 560252-011 shim (use with 560252-009 only, maximum of 4). Deflection of spring _rom static length to rigged posttton to be . 030 to . 0"/0 In. E. AN515-6R screw* AN936A6 LockWasher Cryp.2 plc.) (usewith 560252-009 only). *Use .063 longer screws with each additional shim. (Securescrew with Blue Locktite#83-31 grade C). NOSE GEAR BUNGEE SPRING - FIGURE 32-6 MECHANICAL DOWN STOPS A. 560252-001 560252-003 560252-005 560252-007 560252-009 Fixed Stops Use one dn/stop Fixed Stops on each side as Fixed Stops --required (Use Fixed Stops existing hdw). Adjustable (use -011 shim) Stop NOTE Tube assemblies are allowed .010 in. per foot bend allowance. MECHANICAL UP STOP With gear fully retracted, adjust stop for .050 - .070 clearance between UP STOP (A) (Figure 32-8) and retracting truss (B), then tighten set screw (C). NOTE B. With gear fully extended, select down stop of proper thickness to give .050 - .100 clearance @ (B) 12-98 The main gear preload torque should not exceed 325 inchprocedure lb. using the torque wrench/shim stock after electrical extension. 32-30-04 (NON-AVIONICS PRODUCTS ACTUATOR) 24-0001 thru 24.0377) 1. Raise aircraft on jacks (refer to Section 7-10-00, and removebellyaccess panels. 32-30-04 11 SERVICE AND MAINTENANCE MANUAL M20J MOONEY AIRCRAFT CORPORATION 2. Partially retract gear (Refer to Section 32-10-01). Disconnectmain gear retractiontubes (L)(Fig 32-5) at F'WD OUTBD _ ,_, _ Disconnect nose gear retraction tubes (F)(Fig 32-,3)at inboardbellcranks (M). Loosen Iocknuts(E). the retraction bellcrank (A) (Fig 32-10A). Disconnect nose gear and main gear door links. Check gear for binding at pivot points while moving gear legs by hand. Lubdcate retractionsystem as indicated in Section5. 3. Adjust Heim end bearing on actuator stud so that the Heimthreaded end at (E) is 7.50 inches +.125 inch from the far end of ball nut (C)(Fig 32-10A). NOTE Helm bearing is locked in position with a set screw extending into a slot in the actuator stud. Set screw must be removed prior to making any adjustment (non-Avionics Prod. or Plessey). CAUTION Adjust Heim end only - Do not loosen actuator set screw or Iocknut and attempt to adjust actuator stud. "_ MECHANICAL UP STOP - FIGURE 32-8 1.56 Checkdistancefrom the Helm bearing centedineto the face of the actuator.Dimensionmust not exceed 2.35 inches, readjust making sure that 7.50 dimension is within the +.125 tolerance. Align slot in actuator stud with setscrew in Heim bearing shank. Loctite Heim beadng setscrew and secure. Tighten Iocknut. Rotate actuator barrel until ball return (or returns) on ball nut ( W Z V R ETRACTI O N LINK NG R RETRACTION TOOL TORQUE TRUSS G 050007-100 WRENCH LEFT MAIN GEAR (VIEW LOOKING FWD) MAIN GEAR RIGGING TOOL APPLICATION - FIGURE 32-9 32-30-04 12 12-98 250 28( INCl LBS. FoR cE MOONEY AIRCRAFT CORPORATION M20J bC) is facing actuator motor. Reattach Helm to ellcrank, NOTE When installing helm bearing end in the bellcrank, position freelyscrew. so there willONE be no lateral bind on theit jack Place AN960-716L washer NEXT TO THE BALL JOINT, (can be placed on either side) and shim remaining space with AN960-616 washers. This installation will prevent helm bearing from twisting too far, yet provide adequate movement, NOTE Previous installation may have contained one large AN960-916 washer next to the balljoint. This washer MUST NOT be reinstalled, the AN960-716L smaller and ththnerwasher described above is used as a replacement, 4. Position (A) outboard (Fig 32-10A) that center ofretraction forward bellcrank hole in left arm so of bellcrank is 1.56 * inches from forward face of tress (B) at FUS. STA. 33.0 (Fig 32-10A). This can be accomplished by engaging the emergency gear extension system hand crank and turning to position the bellcrank, See SI M20-89B for Dukes Actuator Drive Coupling Inspection. • NOTE This is a starting point only. This dimension may vary to permit retraction tubes to convert with zero prelead, II "----" FWD \\-- C Disengat_e I rT,_--._ FL_CC_t" SERVICE AND MAINTENANCE MANUAL 5. With bellcrank in position and gear fully extended and overcenter, adjust main gear retraction tube rod ends (E) (Fig 32-5) and nose gear retraction tube at rod ends (F) (Fig 324) so that tubes can be slipped in place with zero preload. Reattach ends of retraction tubes at the belicrankand slip boltsin place. 6. Disconnect electrical power from landing gear actuator by pullingcircuitbreaker. Make sure landing gear warninglightcircuitbreaker is pushedin. 7. With bellcrank, retraction tubes, and the gear positionedas indicated in step 5, set down-limit switch strikerarm (J) (Fig 32-5) so that gear-downlightswitch is just closedand green gear-down light is on. Secure stdkerarm in position. 8. Use manual crank to padially retractgear. Screw rod end (E) (Fig 32-5) on aft end of each main gear retractingtube, out two full turns, then slip attaching boltsback in place. 9. Manually extend gear; stop extension just as greengear-downlightcomes on. 10. CHECK PRELOAD TORQUE on each main gear per Section 32-30-01, CAUTION Check that bungee springs are not "bottomed" out. Torque difference between each gear should not be more than 25 IN. LBS. If torque is not within limits, repeat steps 8 and 9 to adjust rod ends one-half turn in or out as required. 11. Partiallyretract gear with manual crank, screw in each nose gear retraction tube rod end one full turn, then slipattachingboltsback in place. tube and then extend gear manually, stopping just as 12. Check length of nose gear green gear-down light comes on. bungee spring in each 13. Check length of nose gear bungee spdngs in gear-extended position. Nose gear bungee spdng .030 to .070 inch for each bungee (Fig 32-6). (.010 to .030 inch for M20J with Dukes Actuator, PIN _K.__.-_ deflection fromRecheck zero load main condition 12) must be 1057-00-5G). gear(step preload torque "_==:::'=='==';":'_=_="value. If nose gear bungee spdng deflection and/or ,:._..._.:_.:_main gear preload torque is not within prescribed limits, 7.50 + • i25zN.,ii_ii_iii}i !_ adjust retraction tube rod ends in increments of 1/2 -....'_='_:_"_" turn as required. Use manual crank dudng .ii._ii_i;i_r readjustment, and stop extension just as gear-down light comes on. (When step 15 is complete, the retraction system is dgged for the gear-down-and-locked position with allowance for actuator overrun aftercutoff.) 14. Disengage manual crank and reconnect landing gear system circuit breaker. 15. Leave all gear doors disconnected, and run gear up electdcaily (ref. Section 32-60-01) until main gear each side is .13 to .03 inches from bumper pads (see • Fig 32-1). Position gear-up limit switch stalkerarm (H) ---(Fig 32-5) so that the switch is just closed and the red intransitlight goes out. Secure striker arm in position. The gear is now properlyrigged in the gear-upposition with allowancefor overrun after cutoff. i MAIN GEAR RIGGING - FIGURE 32-10A 12-98 32-30-04 13 SERVICE AND MAINTENANCE MANUAL M20J Extend gear to down-and locked position. Adjust gear doom. (Ref. Section 32-10-03 and 32-20-03 for rigging gear doors.) 16. Cycle the retraction system electrically through at least five trouble-free test operations. Manually extend gear, stop extension just as green light comes on, and check main gear preload torque and nose gear bungee deflection for limits specified in steps 10 and 13. If values are within limits specified, the retraction system is properly rigged and ready for use. If preload and/or deflection is not within limits, readjust retraction tube rod ends as required,and repeat test operations. NOTE Check main gear preload torque and/or nose gear bungee deflection after extending the gear manually and stopping just as the gear-down light comeson. Gearpreload, after electric extension, may vary due to inconsistency in actuator overrun; therefore, the gear must be only manually extended during all rigging checks. Rigging values after electric extension may exceed the values obtained after manual extension, 8. Disconnect nose gear doors, outboard main gear doors, and inboard door links. On outboard main gear doors disconnect springs. On inboard door bellcranks, disconnect spdngs. Loosen jamb nut (X) on retraction tube (V) (Fig 32-9) and back off pressure on spring by loosening adjustment nut (Y). Disconnect retraction tube (V) from bellcrank (C) (Fig. 32-2B) 9. Position main retraction bellcrank (A) so that center of forward hole in the left outboard arm of bellcrank is 1.56 *** inches from forward face of fuselagetmss at F.S. 33 (Fig32-10B, detailA). NOTE This dimension*** may vary to permit connection of the retraction tubes with zero preload at bolt hole. 17. When gear rigging completed, center locks on all gears to is ascertain that check none ofover the down lock bungee springs have compressed to solid heightand have no remainingdeflection. If any bungee has reached solid height, readjust system and/or replace bungee springs, WARNING Lack of compliance with Mooney mandatory Service Bulletin No. M20-177 may result in unsatisfactory electrical extension of the electric gear. 32-30-05 (SIN 24-3000 thru 24-3078) 1. Raise the aircrafton jacks and remove one piece bellyaccess panel. 2. Assist Bungee Assy. Removal. Retract landing gear untilrigging pinhole lines up on bungee assembly and insert 3/16 in. pin. CAREFULLY BUMP the gear UP with the gear safety bypassswitchuntilthere is zero load on bungee assy rod end. Remove AN3 bolt/hardware at rod end and AN4 bolt/hardware at block and remove bungee assy. 3. Pullthe landinggear actuator circuitbreaker OUT. 4. Loosenjam nuts (E) on the main retractiontubes (L) (Fig 32-5); disconnect the tubes at the inboard bellcranks(M). 5. In nose gear well, loosenjam nuts (G) (Fig 32-4) on nose gear retractiontubes (F) (Fig 32-3 & 32-4). 6. At main retraction bellcrank (A) (Fig 32-10B) disconnectactuator barrel nut at (N) (Fig 32-10B) and nose gear retractiontubes (F). 7. On Avionics Products actuator, verify dimension from rod end center to end of barrel nut housing on actuator;,it should be 1;25 +.000/-.010. Adjust rod end bearing, if necessary and secure with set screw and jam nut. Plessey actuatorsare not adjsutable. 32-30-05 14 MOONEY AIRCRAFT CORPORATION 10. With main retraction bellcrank (A) held in position,turn actuator barrel nut until rod end bearing alignswith hole in bellcrank; install connection bolt at (N) (Fig. 32-10B). 11. Position bellcrank(C) (Fig. 32-2B), so centerof attachpin(D) in top leg is 1.35 inchesfrom bottom side of spar cap (E). This will be the startingpositionwhen landing gear is in down and locked over center, with outanypreloadset. 12. Adjust retractiontube (V) (Fig 32-9), at rod end, wnitl it will connectto bellcrank (C) (Fig 32-2B) with zero preload. Install connection bolt/hardware, leave loose. 13. Adjust rod end on retraction tube (L) (Fig 32-5) so attach hole is aligned with inboard bellcrank at (M). Install connectionbolt/hardware. 14. Disconnect retraction tube (V) at bellcrank ((3) rod end; position disconnected gear full down and locked over center. Both LH and RH landing gear should be in this configuration at this time. 15. PUSH landinggear actuator C/B - IN. 16. Turn MasterSwitch- ON. 17. Extend main gear actuator to fully extended position.Make certain lugson main retract belicrankdo no contact fuselagetube, floorboard or actuator barrel nut Ifthere is any contact, runactuator back upslightly. 18. There should be .050 to .100 inch clearance (B) obtained between actuator barrel (C) (Fig 32-7) and mechanicaldown stop (A). Shims (D) (.050 thk.) (Fig 32-7) may be added or deleted to mechanical downstop(A) (4 max). 19. Cycle landinggear UP. Run actuatordown and recheck retraction bellcrank clearance at F.S. 33. Check clearance of bellcranks (M) (Fig 32-5) and center section. 20. Reconnect retractiontubes (V) (Fig 32-9). With main gear fully extended, if necessary, adjust main gear retraction tubes (L)(Fig 32-5) so they can be re-connectedwith zero preload. 21. Adjust nut (Y) (Fig 32-9) until main gear is preloaded.Preload is correctwhen a "CLEAN BREAK" can be felt when pushing up on retraction link at (P) (Fig 32-9). 12-98 MOONEY AIRCRAFT CORPORATION M20J SERVICE AND MAINTENANCE MANUAL 2_7 /- "-"d _"--1.56IN (APPRnX.) ]DETAIL A LANDING GEAR ACTUATOR ADJUSTMENTS 22,NOSE GEAR RETRACTION TUBES ARE TO REMAIN DISCONNECTED at the main retraction bellcrank (A) (Fig 32-10B) dudng remainder of procedure, 23. Place landinggear switchin UP position, 24. Push RED gear safety by-pass switch IN INTERMITTENTLY to =BUMP UP" (retract) landing gear until lelt main tire just contacts bumper bracket which covers bulbstringer in wheel well. Make certain actuator barrel does not contact main retract bellcrank inthe UP position, 25. Set UP limitswitchstdker arm (H) (Fig.32-5) so GEAR UP limit switchis just CLOSED and RED "GEAR UNSAFE"light is- OFF. Securestdker arm in position, 26. Loosen set screw (C)32-8) Figure Adjust mechanical up-stop (A) (Fig. for a 32-8. clearance of .050 to .070 inches at main retractiontruss (B); tighten set screw(C). 27. Reinstallassistbungee per Section32-10-06. 28. Using emergency gear extension, move gear downuntil GREEN, gear down lightJUST illuminates. 29. Turn Master Switch - OFF. 30. Place riggingtool (T) (Fig.32-9), P/N 030007-100, on retractiontruss assembly (G). Hold tool stationaryby pushingat point(S) towardmaingear leg. c :.,'c/_,'cv'u'o, DETAIL B - FIGURE 32-IOB NOTE The left main geartrusswill probably lock over centerfirst. Continuetoslowlylowerthegear manually while monitoring the compression of bungee spring on retraction tubes (V )(Fig.32-9). If the spring coils (W) are fully compressed, retract tube (V) must be removed from aircraft for modification. Dismantle the bungee portion of tube (V); remove one spacer washer (Z) and reassemble. Reinstall the modified retraction tube and complete above overcentar requirement. Removal of additional spacer washers may be required prior to obtaining the final configuration for the retraction tube (V). 31. Place 10 inch torque wrench (R) on riggingtool ('1) as shown in Fig.32-9 and apply an unlockingforce to retractiontruss. 32. When joint at (4) breaks open slightly,insertshim stock (.005 to .008 in. thickness)between retractionlink andtrussat (P), releaseforceon torquewrench. 33. While applyinga pullingforce on the shim stock exertan increasingunlockingforce withtorque wrench. 34. Read torque wrench value at the EXACT momentshimstock pulls loose. 35. Repeat steps 30 through 34 on the other main landinggear leg. 36. Use adjusting nuts (Y) (Fig. 32-9 ) on retract tubes (V) to equalize breakaway torque values within 10.0 inch Ibs. Adjust the torque to 250 to 280 inch pounds. 12-98 32-30-05 15 SERVICE AND MAINTENANCE MANUAL M20J 37. Turn Master Switch ON. 33. RUN GEAR DOWN ELECTRICALLY AND CHECK THAT TORQUE VALUES DO NOT EXCEED 325 INCH POUNDS USING THE TORQUE WRENCH/SHIM STOCK METHOD. MOONEY AIRCRAFT CORPORATION 15. Measure nose gear bungee assemblies, dimension "P", as shown in Fig 32-6. If the springs have deflected less than .030 inches or more than .070 inches from the static dimension (as recorded in Step 2) adjust length of bungee assemblies to bdng deflectionwithintolerance. LANDING GEAR WARNING ADJUSTMENT 32-31-02 1. Check that landing gear warning light circuit breaker is pushedIN. 2. Check pulled OUT.that landing gear actuator circuit breaker is 3. Turn Master Switch - ON. - EMERGENCY GEAR EXTENSION SYSTEM RIGGING. DISENGAGE RIGGING: (24-0084, SIN 24-0378 & ON) 1. Insert cable thru hole in actuator disengage arm, (B) (Fig 32-10B). 4. Set DOWN limit switch striker arm (J) (Fig 32-5) so that gear downlimit switchisjust CLOSED and the GREEN, GEAR DOWN lightis ON. Secure stdker arm in position. 5. Turn Master Switch- OFF. NOTE The main gear preload torque should not exceed 325 inch lb. using the torque wrencWshim stock procedure after electrical extension, 32-31-51 - NOSE LANDING GEAR RIGGING PROCEDURE (24-3000 thru 24-3078) 1. Check eccentric bushings (J) (Fig 32-4) on gear truss assembly to be installed with bolt hole in upper forward position. 2. Adjust nose gear retraction tubes (F) (Fig 32-3), so they can be reconnected to the main retraction bellcrankwithzero preload. 2. With red lever (Fig 32-11A) in full disengaged position(down and(1) latched) push actuator disengage arm (B) to full forwardpositionand applyapproximately 5 Ibs.pullto cableto removeslack. 3. InstallD222 wire stop, (C) tighten nutand connect spdng(E) to clevispin, (D). 4. Lilt RED leverand pull"T" handle (2) (Fig 32-11A) aside; re-engage RED lever. Check manual extension systemto verifythat it is fullydisengagedby pulling=T" handle;no resistanceshould be felt. If a resistance is felt, check cable routingthrough pulleys3 and 4 (Fig 32-11A) to vedfy if it is cable routing or actuator resistance. AVIONICS PRODUCTS ACTUATOR (SIN 24-0084, 24-0378 THRU 24-TBA) The eccentric bushings may require rotation to a new position in order to meet the zero preload condition. NOTE ¢43t'B_ . l . .._._-_ (Fig 32-6) and record for future reference. 4. Pushlandinggear actuator C/B - IN. 5. Place landing gear switchin UP position. 6. Turn Master Switch - ON. 7. Push RED, GEAR SAFETY BYPASS SVVITCH- ,¢n_,=-_¢,_,_-_c _,uE 3. Measure nose gear bungees dimension (P) ____ 8. Turn Master Switch - OFF. IN and hold it to partially retract landing gear;, release 9. Pull landing gear actuator C/B - OUT. switch. 10. Screw each nose gear retractiontube (F) (Fig 32-3) IN (clockwiselookingtoward front of aircmlt) one (1) full turn, then re-attachto main retractionbellcrank. 11. Place landinggear switch in DOWN position. 12. Push latch(5) (Fig 32-11) FORWARD on manual emergency extension controls (on floorboard). 13. Pull RED lever (1) (Fig 32-11) back and upward to engage manual emergency gear extension system, 14. Pull "T" handle (2) UP (slowly until engaged) and return itto its original position. Continue this procedure, stopping when the gear down light JUST illuminates. 32-31-01 16 __' _=.__. _ _-=- • EMERGENCY GEAR SYSTEM - FIGURE 32-11A 5. Move RED lever to full UP position; pull "T" handle slowly to verify manual extension system is engaged. Resistance should be felt at once. 6. Replace "T" handle under RED lever and return RED lever to disengage position, (down and latched). Manual extension system is now rigged. 12-98 II I MOONEY AIRCRAFT CORPORATION M2OJ SERVICE AND MAINTENANCE MANUAL Rigging of Manual Emergency Landing Gear 32-11B): 1. WCLh aircmltonjacks,insurethatdisengage operating handle(1)(Fig 32-11B)in the cabin is in the full forward Disengage positionand that Unit the ascable(2)(Fig32-11B)is Follows (Ref. Fig 32-10A insertedthru and holein existingboltattachedat (K)(Fig32-10A). •7S.._._ _]/_'" _,CTUATOR " _. - _-_. 1 _. "\ 2. V_thbolt unit(K) full engaged position(K full aft)apply and existing (M) in inserted thru disengage arm, _' '/ connect spdng. 3. readjust stops (L) and 4. Tighten Turn crank (3) (Fig 32-11B) to assure full approximately 5nut Ibs.(M), pullto cable to wire removeslack. 3 5. Move disengage operating handle (1) to full aft position and operate hand crank (3) to assure full disengagement.Returnhandle (1)to full forward position. 6. Rigging is nowcomplete. _ (_x_' i (SIN 24-0001 THRU 24-0377, NOTE EXCEPT 24-0084) _"_ _'_ EMERGENCY GEAR SYSTEM - FIGURE 32-11B DISENGAGE RIGGING: (S/N 24-0001tbru 24-0377, Except 240084) (Other than Avionic Productsor PlesseyActuator) PLESSEY SEE SERVICE ACTUATOR INSTRUCTION inspect rubber drive coupling between motor/gearbox and jackshaft/gearbox for signs of During 200 hour gear inspection,5-20-O6,3,L,(1), deterioration, hardness or wear. Loosen and remove 2 nuts/washers/bolts from bracket connecting the two components. Separate motor assy. from jackshaft assy. Remove rubber coupling from which ever shaft it remains on and inspect, Replace if damaged or deteriorated. Reassemble motor assy. to jackshaft assy. and secure all M20-92 9 MOb. IDENT. PLATI 8 ""> i3 EATIqN ACTUATE]R le_ SMbt32-14 3 __" 7 It SEESERVICE INSTR. HaO-52B (P/N IOPO00) LANDING GEAR ACTUATOR(S) [EXPLODED VIEWS] - FIGURE 32-12 12-98 32-31-02 17 SERVICE AND MAINTENANCE MANUAL M20J components. Complete gear inspection per Section 5-20-06,3,L,(1). See SI M20-89B for Dukes Actuator Drive Coupling Inspection. NOTE Plessey Actuators should be lubricated every 2000 cycles w/MIL-G-81322 grease. Run actuator to mechanical "extend", fill tube cavity with grease thru MS15001-1 grease fitting until old grease is purged from screw assy. Remove old grease from & relube exposed screw threads. Run actuator to within approx. 0.5 inch of mechanical "retract" & remove major excess grease extruded from ball nut assembly during this retraction step. 32-31-03 - LANDING GEAR ACTUATOR, PIN 102000(*), CLUTCH SPRING REPLACEMENT, MOONEY AIRCRAFT CORPOFLATION 3. Reinstallrecoiler assemblymake sure to fully seat gear, bearing, and gear tang into manual drive slot of recoilerassembly. 4. ApplyLoctiteGrade A (Catalog Number 88-31, not suppliedin kit) to four new screws suppliedand install; take care to use the two longest screws in bottom holesof item (5). NOTE Torque to approximately 10 - 12 inch pounds. 5. Reinstallcable supportbracketand retainingnuts. 6. Retest unit for proper electrical and mechanical operation. 7. Installmodificationplate adjacentto I.D. plate (first 1000 hours only). Mark the first block of modification plate with the figure "1" using metal stamp or etching tool. Mark plate at each succeeding clutch spring replacementwith the next consecutivenumber. (* currently -1, -2, -3, -4, & ON) KIT No. A10-85. Landing gear actuator clutch spring replacement is mandatoryat each 1000 hoursof aircraft operation. DISSASEMBLY - (P/N 102000(*) 1. Remove two nuts, item (1). Note positionof cable supportbracket, item (2), and remove (Figure 32-12). 2. Remove manual extension system disengage cablefrom actuatordisengage arm. 3. Remove two long screws,item (3). 4. Remove two shortscrews, item (4). 5. Remove recoilerassembly, item (5). 6. Remove gear assembly, item (6), from clutch housing, item (8), by rotating gear and pulling with slightto moderatepressure. 7. Remove two screws, item (7), and remove housing, item (8), clutch spring item (9), and gear assembly,item (10) from actuatorbody. 8. Remove clutchspring, item (9), from housingusing gear assembly,item (6), as removal tool. Insert,item(6), intospring from flangedend of housing;rotateCCW and pull slightly. Alter disassembly, clean clutch gear thoroughly.Discardremovedscrews(3) & (4). CAUTION Use extreme care to prevent ball bearing from dropping out of recoi er assembly, avoid damage to gear and do not allow dirt to enter clutch housing bore. 32-31-04 - LANDING GEAR ACTUATOR, PIN 102000-(*), RECOILER SPRINGS / CABLE AND DRUM ASSEMBLY REPLACEMENT 1. Carefullyseparate pulleyhousingfrom recoiler assembly(5) by removing screws (14). Retain pulley onshaft. * All dash no'sapplicablefor PIN 102000(*) actuator. 2. Slide pulleydrum and cable offshatt. 3. Removethe two (2) recoilersprings, and two (2) of the three (3) springspacers leavingthe thirdspacer in housing. Be certain that spacer is in place before installation of two (2) new recoiler springs and previouslyremovedspacers. 4. Install new recoiler springs placing a spacer betweeneach spring and overtop spring. IMPORTANT - Recheck properinstallationof springs. NOTE When looking at recoiler assembly with shaft end toward you, the spring tabs in the housing slot should curve to the right as shown (Figure 32-12). 5. Inspect cable for sheathing damage. Replace cable if sheathing is cut or stripped. Measure overall cable length prior to reassembly. Cable length should be 31 1/2" +/- 1/2" long. 6. Slide drum ontoshaft; be certain that spring detent on drum engages both recoiler springs by slightly rockingdrum end. 9. See 32-30-06 procedure prior to reassembly for additionalmaintenance if needed, 7. When full engagement is obtained wrap cable arounddrum n a clockwisedirection-leaving2" to 5" of cable free of drum. ASSEMBLY -PIN 102000(*) 1. Lubricate gear and new clutch spring thoroughly withlube(MIL-G-81322) poly-lube. 2. Using gear to rotate spring, insert clutch spring into bore until fully seated, 6. Align slot in pulley housing with cable and slide pulleyhousingover cable and drum assembly. 9. Holding the housings together, pull properly aligned cable several times to ensure the absence of binding conditions. Measure cable length from side of housing. At full extend, the length of cable should be 29" minimum. In retracted position, cable length should be 5" to 8" long. NOTE Be sure spring around is all thecam. way in and seated 32-31-03 18 12-98 MOONEY AIRCRAFT CORPORATION M20J SERVICE AND MAINTENANCE MANUAL NOTE Cable length in retract may be adjusted shorter or longer by position holding clutch with the 1. Pull landing gear circuit breaker. 2. Move landinggear controlswitchto DOWN position. finger of one hand (to prevent shaft rotation), and then with the other hand, rotating pulley housing one full turn CW (to shorten) or CCW (to lengthen). Retention of clutch with finger will not allow pretensioning of springs. Slight spring tension should be noted starting at 8" to 10". 10. Bronze clutch (13) should be inspected for damage or wear at slot where gear assembleengages duringmanualextensionof the landinggear. 11. If damaged or worn, remove pin (11) from disengage arm (12) and slide disengage arm out so bronzeclutch(13) can be pulledfrom itsddveshalt, 12. Replace bronze clutch and reassemble disengagearm into recoiler assembly, 13. Attach clutch recoiler assembly to actuator gear housingwith the four (4) screws removedin 32-30-05 (suppliedin clutchspring kit). 32-31-05 - MANUAL EMERGENCY GEAR EXTENSION SYSTEM (T-HANDLE) (SIN 24-0084, 24-0378 THRU 24-TBA) The manualemergency gear extension systemis used to extend the gear only. The controlsare on floorboard aft and between the front seats. To manually extend the gear: 1. Pull landing gear actuator circuit breaker, 2. Move landinggear control switch to DOWN position. 3. Push latch forward with rightthumb. 4. Pull lever back and upward (engaging manual emergency gear), 5. Pull "T" handle UP, (slowly to engage gears) then RETURN to original position; continue until GREEN GEAR DOWN indicator light is ON and/or the lines on the visual gear position indicator on floorboard att of console are aligned when viewed from directly above the indicator (this will nromally take 12 to 20 pulls). CAUTION DO NOT operate landing gear electrically with manual extension system engaged. Landing gear circuit breaker will trip. CAUTION DO NOT continue to pull T-Handle after GEAR DOWN light is ON. Actuator barrel nut may bind on DOWN STOPS. 3. Push crank engage handle forward to engage drive mechanism. 4. Crank handleclockwiseto lower gear. The gear is down and lockedwhen green down-gear indicatorlight is on and when the lines on the visual gear position indicatoron thefloorboard are aligned. CAUTION DO NOTretractgearmanually; use electrical system to retract gear. DO NOT operate gear electrically with hand crank engaged. CAUTION To prevent partial engagement and subsequent damage to drive spline or flexible shaft, check disengage arm (K), Figure 32-10A. This is covered under disengage rigging. (Section 32-30-04). 32-31-06 FINAL CHECKS ( 24-3000 thru 24-3078) 1. Raise and lower the landing gear through five complete cycles, pausing after each cycle to check re-quired tolerances and dimensions and annunciator lightindications.Make certain that no bungee spdngs are compressed to a solid height and that nose gear tire clearstop of wheel well a minimum of .25 In. when landinggear is retracted. Make adjustments per the above procedures, as required, to correct any discrepancies. 2. Re-torque all jam nuts. 3. Reattach main and nose landing gear door links. Check to see that nose and main landing gear doors are still rigged per paragraph 32-10-04. - MANUAL EMERGENCY GEAR EXTENSION SYSTEM (CRANKDOWN SYSTEM) (SIN 24-0001 thru 24-0377, Except 24-0084) The emergency manual override system may be used to extend the gear. The override systemhas a flexible shaft geared to the landing gear actuator driven by a hand crank on the left side of the cabin panel. To manuallyextend the gear:. 12-98 32-31-05 19 SERVICE AND MAINTENANCE MANUAL 32-32-00 M20J MOONEY AIRCRAFT CORPORATION - TROUBLE SHOOTING - LANDING GEAR SYSTEM TROUBLE Incompleteretraction.Gear retractsto an intermediate positionand stopsshort. Gear will not retract at 70 to 80 MPH IAS. PROBABLE CAUSE REMEDY -Bind in gear retractionsystem becausegear is out of rig. Malfunctionin gear electrical cimuit, inoperativeactuating motor,or weak battery, Referto landinggear riggingprocedure. Examineall movable partsfor proper lubricationand freedomfrom binding. Checkfor actuatorjackscrew binding and lubricate as needed. Any malfunction can cause the landing gear circuit breaker to trip: therefore check electric circuit for loose connection, broken wires, or defective relay switches, Recharge battery if necessary. -Oversize/stretched tire will not go into wheelwell properly. Replace with smaller diameter tire. -Insufficient air-speed, pressure switch inoperative, circuit breaker tdpped or actuator ball nut binding on DOWN STOPS. Check pitot tube and line for obstructions. Examine pressure switch for proper adjustment and operation. Reset circuit breaker. Does gear retract using override; check systems operation. Gear may have been extended manually & ball nut is tight against STOPS; use wrench on ball nut flat to loosen. -Squat switch not properly rigged. Cold weather, -Manual engage handle in engaged position Adjust and check squat switch operation. - Ref.SB-M20-196 Disengage Manual System. Aircraft does not Track or steer properly. -Nose wheel location improper. See Section 32-50-02, Gear will extend; green indicator-light (press-to-test) will notilluminate, Actuating motor extends gear to an intermediate position, -Lamp burned out in green indicator-light circuit. Down-limit switch is inoperative, -Same causes as listed with "In complete Retraction" above. Replace burned out lamp. Check indicator-light circuit and/or down-limit switch. Same remedies as listed with =IncompleteRetraction" above, Gear will extend manually, but green indicator light will not illuminate. -Gear switch is not in DOWN position. -Lamp burned out in green indicator light. Place gear switch in DOWN position. Replace burned out lamp Manual system will not lower gear. -Avionic Products Actuator internal clutch spring broken. -Manual engage arm improperly rigged. -Sheared female spline in drive connector, Replace spring. -Drive connector is out of rig. Adjust control cable tension of ddve connector. -Any of the above or Brushes in motor worn. Applicable remedy listed above or replace motor or brushes. Gear will not retract & Landing Gear Actuator C/B trips, Manual system will not lower gear. (con't.) LDG actuator will not.retract or will not extend gear. 32-32-00 2O 12-98 Rig manual engage arm. Replace drive connector assembly if female spline is stripped. MOONEY AIRCRAFT CORPORATION 3240-00 M20J SERVICE AND MAINTENANCE MANUAL - WHEELS AND BRAKES 14. Inflatetire to 30 PSI. 32-40-01 -MAIN WHEELS The main wheels have standard brand, 6:00 x 6, six-ply ratedtireswithstandard tubes. To remove main wheels fromaimrafl: 15. Install wheel assembly, washer, and axle nut. Tighten axle nut until _adng binds slightly.,back nut offto nearest castellation,and installcotterpin. 1. Remove eitherIB or MID gear door. 2. DetachdtL_tshield.Removethreescowsandwashem. 3. Remove 2 boltsfrom brake caliper, 4. Remove wheel by removing cotter key and nut from axle. (See Fig 32-13). 5. Slide wheal off axle. NOTE Position Spacers as needed to positon Brake Disc .12 inches away from MLG leg assembly. NOTE When properly installed, wheel will turn with a slight resistance. 16. Installdustshieldand IB/MID gear door. 17. Reinstallbrake caliper& safety. CAUTION Conduct a retraction/extension check (6 cycles) to varify tire enters and exits whealwell without interference. [Ref. AC 43.13-1(*) ] (* = current revision). 32-40-02 - MAIN WHEEL DISASSEMBLY ASSEMBLY 1. Remove snap fng, (10) grease seal rings,(8) and feltseals (9), (See Fig 32-14). 2. Remove bearings(7). 3. Completelydeflatetire. Do not loosen wheal WARNING half retaining nuts before tire is completely deflated. Failure to observe this warning may result in bodily injury. /--SCREW ///"_--_ /// | ] (TYP. 3 PLCS.) _NUT / _--SPACER bolts, (5); separate halves, (3, 4) and removetire and tube. NOTE Bearing cups are shrink fated; do not remove them unless necessary for replacement. (Federal Specification PS-661). special care 4. Remove nuts, washers, andExercise wheel half retaining Clean allbeadng wheel parts cleaningfluid in5.cleaning cones_omughly and felt in dngs to insure thoroughcleaning. 6. Inspectal pads f_ crocks,conosion,or evidence wear. 7. Inspect bearing cups and replace if cups are damaged or worn. If necessary to remove bearing cups heat wheel in boiling water for at least 30 minutes.Then remove cup by tapp ng evenly.To insta cup, heat wheel half again; cool cup with dry ice. Positioncup and tap lightlyto insureproperseating. 8. Polish smell burrs or nicks out of wheel halves with No. 400 gdt sandpaper, clean thoroughly, and refinishprotectivecoatingas requital. g. Replsce bearing cones that showsignsof wear or beadng fretting. 10. Repack wheel bearings and lubricateseals with grease. Installbearings, closurerings,and felt seals in wheel halves. Secure with snap 11. Positiontire and tube onrings. one wheel half; then positionotherwheel half on tire. 12. Install brake disc (2) and wheel half retaining bolts,washers, and nutS(Fig. 32-14). 13. T'_htan nutsevenlyand torqueto 150 inchpounds. CAUTION Uneven or improper torque may cause bolt or wheel failure, 12-98 ___//._ COTER MAIN WHEEL e_.= NOSE TIRE NOSE GEAR-J_\\\ LEG ASSY. _//_F "_,// / COTTERPIN -J / WASHERS---' // NUT-J NOSF WHFFI LANDINGGEAR WHEEL REMOVAL - FIGURE 32-13 32-40-00 21 SERVICE AND MAINTENANCE MANUAL M20J MOONEY AIRCRAFT CORPORATION C. Visually inspect linings for wear and brake disc they are wom to a minimum thickness of 1/8 inch. If lining replacement is necessary proceed with steps D thru O. Otherwise reassemble in reve[se sequence of 15 disassembly. CAUTION Brake disc should be replaced if width is ,205 for warpage. Brake linings should be replaced when _4 108 8 "_,_ NOSE WHEE"L-_SSY._ "-- 13 ____ "1_ inch or less. cylinder assembly. Remove nuts from anchor bolts. -GI_ _ MAIN WHEEL ASSY. WHEELASSEMBLIES v - ¢_1_}_.._. - FIGURE 32-14 (5) sliding it offthe anchor (6). Note D. Disconnect and capbolts hydraulic linethe (4) condition at brake of the anchor bolts. If they are nicked or gouged they should be sanded smooth to prevent binding with the pressure plate (5) or torque plate(8). When the anchor bolts are replaced they should be pressed out. New ones can be installed by tapping them in place with a soft hammer. F. Ddll out rivets (9) attaching linings (7) to back lining plate (2) and the pressure plate (5). Remove piston assembly (10) and "O"ring (11). It is permissible E. Remove pressure plate assembly (Fig 32-15) to remove use compressed applied to the brake line fitting to the pistonair (10) from the brake cylinder. G. Clean parts in cleaning solvent (Federal Specification PS-661 or equivalent) and dry with oil-free compressed air. 18. Remove aircraft from jacks. 32-40-03 - NOSE WHEEL DISASSEMBLY-ASSEMBLY The standard brand, tube-type, 5:00 x 5 nose wheel tire is six-plyrated. 1. Nose wheel removal. A. Remove cotter key, nut, and washer from axle. (Figure32-13). B. Remove nose wheel. 2. Installation is in reverse sequence of removal. C8 _ -7 __i _ _\ '--. CI_j 4 A. Completely deflate tire by removing valve core. 3. Nose wheel disassembly. bolts (15) from wheel. (Fig 32-14). B. Remove nuts, washers, and wheel half retaining tire and tube. Refer to Section 32-40-02 steps 5 thru 10 D. Reassemble nose wheel in reverse sequence of for wheel inspection. torque disassembly. to 90 inch-pounds. Tighten retaining Inflate tire bolttonuts 49 PSI. evenly and .._c_ o_ °%o/4_._ 1 0]_ 1 __-"T_ 3 -- 32-40-04 - BRAKE SYSTEM ]3 [_ E F- D V (_ [_ V E--//_ J 1. BRAKE REMOVAL AND INSTALLATION: Lining inspection and/or replacement or cylinder repair. C _ V _-R A. Place aircraft on jacks. B. Remove inboard or mid gear doors. Remove safety wire and two AN4H17A bolts (1) attaching back lining plate assembly (2) to brake cylinder assembly (Fig. 32-15). BRAKE ASSEMBLY - FIGURE 32-15 32-40-03 22 12-98 ] MOONEY AIRCRAFT CORPORATION M20J SERVICE AND MAINTENANCE MANUAL A. Perform a minimum of six (6) light pedal effort braking two Allow (2) hard from 25 to to 40 MPHapplicationsand (21 to 35 KIAS). thestops brake discs ¢_...1..u _.:_... -- '"_;_6 ,.,= n I .=_ partially cool between stops. resins in the lining, but will not cause the material to become carbudzed due to excessive heat. 3. MASTER CYLINDER 24-0001 thru 24-3200, 24-3202 thru 24-3217 REMOVAL. DISASSEMBLY AND REASSEMBLY. ull The procedure will generate sufficient heat to cure the B. Disconnecthydrauliccylinderfrom pedal linkage. C. Disconnect and cap hydraulic lines. D. Disconnect hydraulic cylinder from bracket; remove cylinder. E. To disassemble master cylinder:. (Gerdes or Parker-Hannifin) (Reference Fig 32-17A). (1) Unscrew and remove rod end clevis and nut from piston rod (9). (2) Remove snap ring (13) and lift out compete piston rod assembly, item 3 thru 12. (3) Remove spacer (11) and O-ring packings, (10 and 12) from piston and assembly. TORQUE PLATE ASSY. INSTALLED RELATIVE TO CYL (4) Disassemble piston rod assembly by FIGURE 32-16 removing roll pin (4), (spring guide (3) will be pushed out by spring (5) when roll pin is removed), spdng (5) H. Replace linings with Cleveland 65-30 linings and piston (7). using #561-2 rivets. Rivetsand must be rolled to (5) Remove O-ring packing (6) from piston. obtainCleveland proper fit between dvet shank hole. I. Inspect brake cylinder bore for scodng. A scored (6) Remove stat-o-seal (8) from piston rod. cylinder may _use the "O" dng to leak or cause rapid (7) Clean all parts with cleaning Solvent (Federal wear of the O dng. A scored brake cylinder should be Specification No. PS-661). replaced. (8) Inspect cylinder for cracks, scodng, or J. Replace AN6230-2 "O" dng (11) with a new one. groovesin bore. Do not reusethe old=O"dng. (9) Inspect piston (7) for damage,checkfor nicks K. Lubricatecylinder and piston with MIL-H-5606 and scratches. red hydraulicfluid and assemble componentswith care to preventdamage to the "O" ring. (10) Inspect spacer (11) for damage. (11) Inspectpush rod for scoring,grooves, nicks L. Service and inspectmain wheels as describedin and scratches. Section 32-= . Inspect torque plate assembly making sure the .125 thickness is toward brake (12) Inspectpistonreturnsprings(2) for permanent cylinderassembly (outboard). If thicker 250 protruson set and properlength(3.670 in.min., 4.05 in. max.). is outboard, remove torque plate from axle mounting (13) Replaceall faultyparts and all O-rings. flangeand installas shown (Figure 32-16). (14) Reassemble in reverse sequence of M. Reassembly brake cylinder assemblyand back disassembly. Immerse all parts in hydraulicbrake fluid liningplate assembly onto the airplane in the reverse pdorto reassembly. sequence of disassembly. F. Reinstallmaster cylinder in reverse sequence of N.Beed h_raulicsystemasdesm'bedin 8ec_n 12-20-05. removal. O. Remove aircraft from jacks. NOTE Brake pad conditioning is required to properly cure the resins binding the asbestos lining composition together. Excessive heat created prior to conditioning will carbudze the linin'g matedal and prevent the attainment of maximum braking coefficient. 2. BRAKES - BREAK IN PROCEDURES. Proper conditioning may be accomplished as follows: 12-98 G. Bleed brake system (refer Section 12-20-05). NOTE S/N 24-3201,24-3218 thru 24-TEA have larger capacity Master Cylinders (P/N 10-24D)installed. REMOVAL. DISSASSEMBLY AND ASSEMBLY (24-3201, 24-3218 THRU 24-TBA) A. Remove left. hand, lower fuselage skin aft of firewall and exhaust cavity. 32-40-04 23 SERVICE AND MAINTENANCE MANUAL 112 _- M20J MOONEY AIRCRAFT CORPORATION _0 \_ ,5 _- 3 2 '3_- u _ _- / _ - 4 k'--z7 _--u " _-7 _-7 BRAKE MASTER CYLINDERS - FIGURE 32-17A (7) Clean parts with cleaning solvent (Fed. Specification No.all PS-661). (8) lnspect cylinder for cracks, scodng or grooves In bore. (2) Remove snap dng (11) from cyhlinder housing assembly; lift out complete piston rod assembly, items 2 thin 12. Spring (13) can be removed at this time. _t sMx3,-i_:,01.,,,thru24.TBA '(3) Remove snap ring (2) from end of piston rod assembly. (4) Remove bushing (3) and spdng (4) from end of pistion rod. (5) Remove piston assembly (5) and o'dng (7) from piston assembly and o'ring (6) from piston rod shaft. (6) Remove end cap (8) and o'dngs (9) [ID] and (7) [OD] from end cap assembly. B. Disconnect hydraulic cylinder from pedal linkage. C. Disconnect and cap hydraulic lines, D. Disconnect hydraulic cylinder from bracket and remove cylinder, E. To disassemble master cylinder. (Gerdes or Parker-Hannifin) (Reference Fig 32-17A, 24-3201, 24-3218 thru 24-TBA). (1) Unscrewand remove rod end clevis (17), nut (16) and washers(14 & 15) from pistonrod (12). i s"_-_l_202thru24"3217 [ (9) Inspect piston (5) for damage; check for nicks and scratches. (10) Inspect end cap (8) for damage. NOTE j 1991 single brake systems, with shuttle valve, have to be bled somewhat differently. The plug (that would normally go to ca-pilots side)has to be loosened se fluid can be purged from shuttle valve cavity dudng bleeding to keep shuttle valve from locking up one side lo 9 11 T e • I BRAKE MASTER CYLINDER (PARAMONT) - FIGURE 32'17B 32-40-04 24 12-98 MOONEY AIRCRAFT CORPORATION .... ( M20J SERVICE AND MAINTENANCE MANUAL (11) Inspect push rod for scoring, grooves, nicks and scratches. (12) Inspect spring (4) for free height - .500 in. +/.030. (13) Replace all faulty parts and all c'dngs, (14) Reassemble in reverse sequence of disassembly. Immerse all parts in hydraulic brake fluid pdor to reassembly. 4. PARKING BRAKE VALVE Removal. A. Remove left hand exhaust cavity. B. Disconnect parking brake control at parking brake valve arm. C. Disconnect and cap hydrauliclines. D. Remove parking brake valve. (15) Check piston rod and return spdng (13) for proper compression during stroke (9 Ibs. (@ start of stroke)to 32 Ibs. (@ 3/4 stroke). F. Reinstallmaster cylinder in reverse sequence of removal. G. Bleed brakesystem (refer to Section12-20-05). PARAMOUNT MASTER CYLINDER A. To disassemble Paramount master cylinder (Reference Fig. 32-17B). (1) Unscrew and remove rod end beadng and nut from pistionrod. (2) Remove snap ring (1) and lift out complete pistonrod assembly. (3) Remove piston top (2), o'dng packings (3), and brass washer (4) from pistonrod assembly. (4) Disassemble piston rod assembly .by removing cotter pin (5), valve stop (6), and spnng washer (7). Valve assembly (8) willfall out when cotter pin is removed. NOTE DO NOT attempt to remove O-ring packing (9) under valve head. If valve or packing is faulty, replace the valve assembly, (5) Remove o'dng packing (10) from piston (11). Do not unscrew piston from push rod. Replace entire pistonrod assemblyif faulty. (6) Remove spring (12) from cylinder. (7) Clean all parts with cleaningsolvent(Federal SpecificationNo. PS-661). (8) Inspect cylinder for cracks, scoring, or groovesin bore. (9) Inspect pistonfor damaged valve seat, nicks and scratches. (10) Inspectvalve assemblyfordamage. (11) Inspect push rod for scodng, grooves, nicks and scratches. (12)proper Inspectlength piston (3-3/16 return spring for permanent set and IN. MIN.: 3-5/16 IN. MAX). (13) Replace all faulty parts. (14) Reassemble in reverse sequence of disassembly. Immerse all parts in hydraulic brake fluid pdor to reassembly. B. Reinstall master'cylinder in reverse sequence of removal, C. Bleed brake system (refer Section 12-20-06). Disassembly & assembly parking brake valve: (SIN 24-0758 THRU 24-TBA; Refer Figure 32-18 A). A. Remove bothfittings(1) from valve housing(7), spdngs(8) will comeoutwiththe fittings. B. Remove poppet valves (2) and pins (3), from housingby bumpingontabletop. C. Remove bothfittings(4) from end of housing. D. Remove snap ring (5) from end of camshaft assembly(6). E. Camfullyrsmovecamshaltassembly(6)from housing. F. Inspect all components for damage, nicks, grooves,etc. G. Clean all parts with cleaning solvent (Federal SpecificationNo. PS-561). H. Replace all o'dngs(9). 1. Reassemble parking brake valve in reverse sequenceof disassembly. J. Connectvalve assemblyto the hydrauliclines. K. Bleed system and service hydraulic reservoir with hydraulicfluidas deacdbed in Section12-20-04. Disassembly & assembly parking brake valve. (SIN 24-0001 thru 24-0757; Refer to Figure 32-18 B). A. Remove dvetsor screws (1) attachingvalvearm (2) to valve body (3) and stem (4). B. Remove end plug(5) and square out gasket (6). C. Withdraw valvestem assembly (7) and remove o'dng packings(8 & 9) from valve body. D. Clean all parts with cleaning solvent (Federal SpecificationNo. PS-661). E. Inspect valve stem (4) for nicks, scratches, burrs, and grooves. F. Inspectvalve seat for nicks,scratches, and scodng. G. Inspect all threads for damage. H. Replace o'dng packings. I. Replace end plug gasket (6). J. Reassemble brake valve in reverse sequence of disassembly. K. Install brake valve on hydraulic reservoir, L. Reinstall hydraulic reservoir and connect lines and brake control. M. Bleed system and service hydraulic reservoir with hydraulic fluid as described in Section 12-20-04. 12-98 32-40-04 25 SERVICE AND MAINTENANCE MANUAL M20J MOONEY AIRCRAFT CORPORATION 6 8 PARKING BRAKE VALVE (24-0758 THRU 24-TBA) FIGURE 32-18A 3241-00 PARKING BRAKE VALVE (24-0001 THRU 24-0757 FIGURE 32-18B - TROUBLE SHOOTING - BRAKE SYSTEM TROUBLE " -_ Solid pedal and no brakes. Replace lining. Spongy brake. -Brake lining worn beyond allowable limit. -Air in system. Pressure will not hold. -Leak in brake system. Visually check entire system for evidence of leaks. Parkingbrake willnot hold. -Air insystemor leakin system (downstreamof parkingbrake valve), -Defective parkingbrake valve. See remedies above. -Warped or bentdisc, Replacedisc. -Foreign matter lockingdisc. Cleandisc and lining. -Master cylindershaft or linkage misaligned. Checkthat shaft travels in straightline & not bindingin linkage. Brake grabs. Brake pedalwill not return to neutralposition, .'-I'L :- : - SHUTrLE VALVE SIN 24-0001 thru 24-0763 (If Installed) Shuttle valve removal and testing (optionaldual brake system.) 1, Disconnect inlet lines from master cylinders and cap line ends. 2. Disconnect outlet line leading to brake cylinder and cap lineend, REMEDY 3241-01 3. To test valve operation, seat shuttle valve by applying1500 PSI hydraulic pressure to one inlet port with outletplugged, 4. Apply pressure to opposite port. Shuttle valve shouldunseat at 15 to 50 PSI. 32-41-01 26 Bleed brake system per 12-20-05. Repair or replacethe valve. 5. Repeat step C and D to test oppositeport. 6. Reinstallshuttlevalvein reversesequenceof removal. 7. Bleed brake system per 12-20-05. 32-50-00 -STEERING 32-50-01 - NOSE GEAR STEERING SYSTEM The nose gear steering system consistsof a steedng horn on gear leg linked to the rudder pedals by push-pull tubes and bellcranks. Gear retraction automatically disengages steedng mechanism from nosewheel, 12-98 MOONEY AIRCRAFT CORPORATION M20J SERVICE AND MAINTENANCE MANUAL 3. Check steering ham assembly (5) collars and spacers for looseness. Replace any bushings or spacersthat are worn. 4, Adjust turn limiterstop bolts (7) to contact cross member (8) of trues assembly (.020 gap permissible) when rudder is at its extreme left and right travel position. STRUCTURE 6, 32-50-02 - NOSE GEAR STEERING AND TRACKING 1. Levelaircraft as described in Chapter 8, 2. Center nose wheel. 7 3. Place plumb line over and forward of nose gear trunnion (see Figure 32-20) part number 540001-503. 4. Measure forward from aft edge of plumb line to axle center line. Modification relocating nose wheel should be accomplished if axle position, forward of plumb line, exceeds ,06. 5. Add SB M20-202-3 spacer .under collar to reposition the axle if required. NOTE Some collars have holes drilled off center and may be turned overto change axle position. NOSE LEGASS'(. 6, Run gear through up/down cycle. Check nose gear door and wheel well tire clearances. Re-rig if required. NOSE WHEEL STEERING - FIGURE 32-19 fiSection 27-20-00 outlines the nose gear steering gging.) A centering cam aligns the nose wheel for entry intowheel well. NOTE Check nose gear leg assy. for towing damage. Replace if any dent exceeds 1132inch. NOTE Aircraft SIN 24-1464 & ON have twin limiter pads and adjustable stops (7) (Figure 32-19) installed on the nose gear leg assembly (A) that will prevent turning damage to leg assembly. COLLAR NOSE GEAR TRUNNION SPACER 1. Every 100 hours remove cotter pin (1)(Fig 32-19) and retorque nut (2) to 450-500 inch Ibs. Check holes in leg assembly where pivot bolt (3) is located for any wear. If holes are worn, replace leg assembly. NOTE Shock absorber (6) and related attaching hardware may be removed from all Mooney M20J aircraft if desired. (Ref 940052 Dwg.) CAUTION Bolt, washer, nut (9) and (10) (Figure 32-19) must be installed as shown, from rear to front. PLUMB UNE I SEE ITEM 4I 2. Rod end beadng (4) (Figure 32-19) should be inspected at least every 100 hours for any damage or bending. 12-98 CENTER LINE NOSE WHEEL LOCATION - FIGURE 32-20 32-50-02 27 SERVICE AND MAINTENANCE MANUAL 32-60-00 - POSITION AND WARNING 32-60-01 - ELECTRIC GEAR SAFETY;DEVICES M20J 32-00-03 The gear switch operates the landing gear actuator relays. Pullingwheel-shaped knobout and moving itto upper detentraises gear. However, an airspeed safety switchor a squat switchis incorporatedin the electrical systemto prevent landinggear retractionwhile on the ground. On aircratt equipped with airspeed safety switchto allowgear retractionwith the aircraft on jacks; attach a 12-inchlength of 3/8 inch pliable rubber hose (surgicaltubing) over pitot head, and pinch open end with a larger cotter pin; roll the tubing with the cotter pin until compressed air within the twisted tube actuates airspeed pressure switch. Maintain pressure on the switch until retraction is complete. To adjust airspeed switch refer to Section 32-60,03. To adjust the squatswitchrefer to Section 32-60-04. The up-limitswitch will stop the gear in its retracted position.Moving control knob to its lower detent lowers landing gear. The down limit switch will Stop gear actuating motor when the proper force is exerted to holdlandinggear in down-and-lockedposition.Refer to Section32-30-02,6. for proper limitswitchrig ging. The gear down-and-lockedpositionis indicated by: 1. Illuminationof the GREEN gear downannunciator light. GEAR DOWN annunciator light is dimmed when NAV Lightswitchis ON. 2. The warning horn will not sound with the throttle retarded to within 1/4 - 318 in. of panel, 3. The indicator marks will be aligned on the visual gear-position indicator. CAUTION When running gear up or down electrically DO NOT use circuit breaker as a switch, Partial retraction or extension may be accomplished electricallyas fellows: 1. Place Master Switchin OFF position, 2. Move gear switchto GEAR UP or GEAR DOWN as desired, -AIRSPEED SAFETY SWITCH ADJUSTMENT (24-0084, 24-0238 & ON) The airspeed safety switch, located inside cabin, is mounted behind airspeed indicator.An airspeed safety switch is incorporatedinto electrical system to prevent landing gear retraction while on the ground and at airspeedsbelow69 +/- 5 MPH (60 +/-5 KTS).Additionally the RED gear unsafe lightcomeson and warninghornis soundedwhen gear controlhandleis placed in gear-up positionbelow69 +/- 5 MPH (60 +/-5 KTS). NOTE Whitman-General switches can be adjusted using thefollowing procedures: 1. Using a water manometer to measure pressure, graduallyapplyair pressureto inlet at cap. 2. Connectan ohmmeterbetweenmicroswitchleads. 3. Gradually increase pressure to 2.775 inches of water untildiaphram movement closesmicroswitch. 4. Slowlydecreasepressureuntilmicmswitchopens. 5. Adjust knuded body until switch closes at an increasingpressure of 2.775 +.384/-.359 in. water (69 +/- 5 MPH or 60 +/-5 KTS). 6. Secure set screw and repeat step (5), fivetimes. V.E.P. switches can be adjusted using the following procedures: V.E.P. manufactured switches are field adjustable. They should close at 2.8 +# .4 inches water. Adjust slotted screw head on center of switch to obtain correct settings. CAUTION The airspeed safety switch is designed to operate within a specified range during increasing airspeed only. Due to hysteresis of the switch/diaphram assembly the switch MAY NOT deactivate the landing gear circuitry until approximately 57 MPH (49.5 KTS). This could allow the landing gear to retract if the gear switch is inadvertently placed in the UP position during the landing roll. 3. Momentarilyactuate master switchuntilgear is in desiredposition. 32-60-02 - LANDING GEAR WARNING SYSTEM The landinggear wareing system Consistsof:. 1. Landinggear positionlights:(GEAR DOWN-white indicatorlighton floor and green lighton annunciator;, GEAR IN TRANSIT - up or down - red unsafe on annunciator;GEAR UP - no lights), 2. A warning horn in cabin is actuated by throttle controlwhen gear controlswitch handle is up and the throttleis retarded to within 1/4-3/8 in. of panel. Check warninghornfor volume in flight periodically.Horn will sound if gear is not DOWN and LOCKED even if switch is in DOWN position or if airspeed is below 60 KIAS & gear switch is in UP position, 32-60-00 28 MOONEY AIRCRAFT CORPORATION 12-98 WARNING Do not turn knurled knob on back of switch housing (WhitmaI-General Switches) when disconnecting switch from electrical connections. This is airspeed adjustment knob. NOTE Referto proper electrical schematic when replacing with switches from another manufacturer. CAUTION During Pitot-Static System Inspection, compensating pressure MUST be applied to pitotside ofA/S Safety switch diaphramwhen "static presssure" is applied. Failure to equalize pressure on diaphram could cause it to rupture. MOONEY AIRCRAFT CORPORATION 32-00-04 , ! M20J -SQUATSWITONADJUSTMENT (24-0001 THRU 24-0237 except 24-0084) The squat switch, located on the left main gear, is incorporated into the electrical system to prevent landing gear retraction while aimraft is on ground. Adjustmentof squat switchis accomplishedas follows: 1. Raise aircraft onjacks. 2. Remove safety wire from adjustment nuts on switch. 3. Adjustswitchbodyuntilswitchjust closes, 4. Check switch by slowlyIowedngaircraftto ground. Switch shouldnow be open. 5. Resafety adjustmentnuts. 32-80-00 32-81-00 -MISCELLANEOUS - LANDING GEAR SHOCK DISC INSPECTION SERVICE AND MAINTENANCE MANUAL (3) Careful application of the shock disc replacmanttool is recommendedduringreplacementof main gear shock disc to keep from damaging grease f'rttings. NOTE Shock disc retention collar should be installed with the chamfer facing down and forward. B. Nose Gear Shock Discs.(See Fig 32-22) (1) Check for gap between retainingcollar (D), (Figure 32-22) and top retaining plate (E). Top retainingplate must be in contactwith retainingcollar. (2) Replace shock discs if gap is found. Use shock discreplacementtool (F), P/N GSE 030010, (old PIN ME120), to remove and install nose gear shock discs. Use removable pad from tool as a guide on top of shock link to align discs as they are being compressed. NOTE 1. Aircraft with full fuel load and weight on landing gear. Dimension ('r), (Figure 32-22), is critical to properly locate nose wheel position. The leg A. Main gear shockdiscs. (See Fig 32-21). (1) Check gap between retainingcollar (A) (Fig. 32-21) and top retaining plate (B). Allowable gap is 0.00 to 0.60 inches. assemblies can tolerances.Vary' due to manufacturers The dimension (T) in a no load fully extended position should be approximately 3.0 inches. Add spacer under collar (D) per 8B M20-202, as needed. See (Figure 32-20), paragraph 30-50-02, for proper steering/tracking rigging. (2) Replace discs when gap exceeds tolerance, Use shock disc replacement tool (C), PIN GSE 030011, (old PIN ME 121), to remove and install main gear shock discs. Use removable pad from tool as a guide on top of shock link to align discs as they are beingcompressed. MAIN GEAR SHOCK DISC REPLACEMENT TOOL APPLICATION - FIG 32-21 12-98 NOSE GEAR SHOCK DISC REPLACEMENT/TOOL FIGURE 32-22 32-60-04 29 SERVICE AND MAINTENANCE MANUAL M20J 2. Raise airerafl onjacks - shocksfullyextended. A. Inspectnose and main gear shocksfor evidence of gap between retainingcollarand retainingplate.The disc preload must be great enough to maintain completewheel extensiondudngretraction, B. Replace shock discsthat have lost resilience, C. Inspectretainingcellar and bolt for deformation, wear, and cracks. D. Replace defectiveboltand cellar. CAUTION Both collar and bolt must be replaced when one or the other is defective, E. Inspect nose gear snubber (shock absorber)(if installed) for proper shock absorbing action. Replace snubber when effectiveness is impaired--the unit is sealed and cannot be repaired. NOTE Shock absorbers may be removed if desired. Refer to Drawing 940052. ' NOTE For Nose Gear Steering/Tracking see Section 32-50-02, (Figure 32-20). 32-82-00 3O MOONEY AIRCRAFT CORPORATION 32-82-00 - RECOMMENDED HARD LANDING INSPECTIONS The followingare areas recommendedto be inspected when a "hard landing" has occured. Since a =hard landing"is a relativeterm, it is up to the owner/operator to advise maintenance personnel when the inspectionsare to be accomplished. 1. Mud Shield missingor damaged on eitheror both main landinggear. 2. Main landing gear shock bisquits condition, compressedor extrudedrubber. 3. Tail skid damage or damage to bulkhead that attachestail skid. 4. Propellerstrike/marksor other visualdamage. 5. Engine or engine mount damage. 6. Nose landing gear leg assembly damage near steering lugs. 7. Pilot/Co-Pilot's seat adjustment supports/tubes bentfrom excessiveG-loads. If any evidence of damage or abnormal visual observations are found, it is recommended that a thorough inspectionof all the above areas be done and repairs be made as necessary.Contact FAA personnel for incidentreportrequirements. 12-98 ' SERVICE AND MAINTENANCE MANUAL M20J CHAPTER 33 LIGHTS MOONEY AIRCRAFT CORPORATION MOONEY AIRCRAFT CORPORATION M20J SERVICE AND MAINTENANCE MANUAL CHAPTER 33 LIGHTS LIST OF EFFECTIVE PAGES CHAPTER SECTION SUBJECT ........... 33-Effectivity ......... 33-Contents.......... 33-00-00. ........... 33-21-02. ........... 33-22-00 ............ 33-23-00 ............ 33-41-01. ........... 33-41-03 ........... 33-42-00 ........... 33-43-01 ........... PAGE .......... DATE 1/2BLANK .......... 3/4BLANK .......... 5 ........... 8 ........... 7 ........... 8 ........... 9 ........... 10 ........... 11 ........... 12 ........... 12-98 12-98 12-98 12-98 12-98 12-98 12-98 12-98 12-98 12-98 12-98 33-EFFECTIVITY 1/2BLANK SERVICE AND MAINTENANCE MANUAL M20J MOONEY AIRCRAFT CORPORATION CHAPTER 33 LIGHTS TABLE OF CONTENTS CHAPTER SECTION SUBJECT ........... 33-00-00 ........ 33-20-00 ......... 33-21-00 .......... 33-21-01 .......... 33-21-02 .......... 33-22-00 ......... 33-22-01 .......... 33-23-00 ......... 33-23-01 .......... 33-40-00 ......... 33-40-01 .......... 33-41-00 .......... 33-41-01 ............ 33-41-02 ............ 33-41-03 ............ 33-42-00 ......... 33-42-01 .......... 33-43-00 ........ 33-43-01 ........ SUBJECT ........ PAGE GeneraI-Descdption and Operation ....... Intedor Lights - Maintenance Practices ..... Cabin Lights- Overhead Lights ...... Light Bulb Replacement ....... Cabin Light Switch Replacement ..... Instrument/Right Panel and Glareshield Lights . Light Bulb Replacement ....... Gear Down Indicator Light (Floorboard) ..... Light Bulb Replacement ....... Extedor Lights - Maintenance Practices ..... Trouble shootingExterior Lights ..... High Intensity, Strobe Lights - Maintenance . , Power Supply Unit- Removal or Replacement Power Supply Unit Installation .... Strobe Light Replacement ...... Navigation/Position Lights ........ Position Light - Replacement Service .... Landing/Taxi Lights--24-1354 thru 24-TBA ..... Landing/Taxi Light Adjustment Procedures 12-98 5 5 5 5 6 7 7 8 8 8 8 8 9 9 9 11 11 11 11 33-CONTENTS 3/4BLANK MOONEY AIRCRAFT CORPORATION 33-00-00 M20J -GENERAL-DESCRIPTION AND OPERATION High intensitystrobe lights are standard equipment on M20J aircraft. The lights are located adjacent to the wing tip navigation lights and incorporated in the taillight assembly. Separate power supplies are utilized for each strobe light and are located in each wing outboard section, mounted on inspectioncover, and insidethe tailcone adjacent to the left rear inspection cover. The system is actuated by a circuit breaker/switchlocatedon the instrumentpanel in front of the pilot. SIN 24-0001 thru 24-1037 have a combined Nav-Strebe light assembly on each wing tip and has no strobe lighton the rudder,only a navigation light, Navigation lights are located on each wing tip and rudder trailing edge (24-0001 thru 24-2999). (24-3000 thru 24-TBA) A/C have the aft facing navigation light (clear)located on each fiberglasswingtip trailing edge. The lightsthe areinstrumentpanel activated by a incircuit locatedon front ofbreaker/switch the pilot. S/N 24-0001 thru 24-3153 The landinglightis locatedin lower engine cowling. SERVICE AND MAINTENANCE MANUAL One 290,000 candle power sealed beam bulb is incorporatedand mounted in a housing designed to isolate the bulb from engine heat and vibration.The light is activatedby a circuitbreaker/switch locatedon the instrumentpanelin front of the pilot. S/N 24-3154 thru 24-TBA Two 110,000 candle power sealed beam bulbs are locatedin LH & RH side ofwing. Two intedor lights are located on the overhead panel (SIN 24-0768 thra 24-3373). The forward cabin overhead lights are located between the pilot and co-pilot seats and are actuated by a three position switch, (dim, off, bright)adjacent to the light near the co-pilotshead. The passengercompartment lights are locatedabovethe rear seats in the overhead paneland are activatedby a similar three positionswitch located adjacentto the light.The rear cabin light is accessible from the baggage compartmentdoor also. S/N 24-0001 thru 24-0787 - A switchin the dome light base controlsthe overheaddome light. CAUTION SIN 24-0001 thru 24-3153-cabin lights are connected directly to battery through their switches and WILL ILLUMINATE WITHOUT MASTER SWITCH ON. LAMP BULB REPLACEMENT CHART APPLICATIONS Glareshield Lights Post Lights Map Light Cabin Interior Lights Trim & Flap Indicator Gear Down Light Tail Position Light Wing Tip Position Light -(24-0001 thru 24-1425) -(24-1426 thru 24-1708, 24-3000 thru 24-TBA) LandingLight -(24-0001 thru 24-3153) -(24-3154 thru 24-TBA) RecognitionLight BULB PART NUMBER (SIN 24-0084, 24-0378 thru 24-1168) (SIN 24-1169 & ON) (Floorboard Indicator) (Whelen/SDI) (Grimes) (Whelen) 14 VOLT 28 VOLT GE 330 GE 330 GE 330 GE 1816 W]-7046 GE 327 GE 327 GE 327 GE 1818 N/A GE 370 GE 327 34-0212080-85 * GE 327 GE 327 34-0228030-85 w A-7512-12 W1290-14 A508-14 (Whelen) W1290-28 (GE) (GE) (Whelen) GE 4522 01-0770303-00 • Use S.D.I. Tool No. 203541 to removelamp. 33-20-00 - INTERIOR LIGHTS - MAINTENANCE PRACTICES 33-21-00 - CABIN LIGHTS - OVERHEAD LIGHTS GE 4553 GE 4596 • Use same lightassy. butdroppingresistor RH-50-7.6 req'd. 33-21-01 - LIGHT BULB REPLACEMENT (S/N 24-0768 thru 24-3373) 1. Remove light cover panel (2) (Figure 33-1) from the headlinerassembly(1) by removingscrews(3). NOTE The front and rear light bulbs are replaced in the same manner. 12-98 33-00-00 5 SERVICE AND MAINTENANCE MANUAL M20J MOONEY AIRCRAFT CORPORATION 2. Remove and replace the bulbs and check for properoperation. - LIGHT BULB REPLACEMENT (SIN 24-3374 thru 24-TBA) 1. Carefullyslide smooth,fiat sharp blade underlip of light assembly flange and pop light assembly out of mountinghole. (Ref. Figure 33-1A) 2. Disconnectblade terminals from lightassembly. 3. Hold light assembly body and rotate bulb holder counter-clock-wiseto remove, PILOT'S & REAR SEAT PASSENGER'S LIGHTS 1. Remove cover from arm rest assembly by removing2 screws holding coverto arm rest. 2. Switches are snap-fit and may be removed by pressingsnap tabs and pushingswitchthroughcover. 3. Disconnectwire terminals and replace with new switch.Check for properoperation. 4. Re-assemble switch assembly into cover by snapping in from top side. Re-install cover into arm rest, securewith 2 screws. 4. Pull bulbfrom bulb holder, replacewith new bulb. Reinstallbulbholder. 5. Re-assemblelightassemblyinto mountinghole. 6. Check for properoperation. CO-PILOT'S SWITCH 1. Co-pilot'scabin lightswitch is located in front of cabindoor hingeabove co-pilot'sright knee. 2. Remove 1 screwabove switch.Removedoorframe cap.Pull panelfrom velcmfastnersto accessswitch. 33-21-02 - CABIN LIGHT SWITCH REPLACEMENT (SIN 24-0768 thru 24-3373) 1. Remove cover (4) from headliner assembly(1) by removing screws (3) holding panel in place (Figure 33-1). NOTE SIN 24-0901 and ON have a butterfly shut-off valve for the overhead ventilation that must be freed from the panel prior to removal. 2. Switch (5) is a press and snap in fit and may requirebendingof springtabs to release for removal. 3. Disconnect wire connections and replace with new switch. Check for proper operation. 4. Reassemble panels and ventilation control, if app icable,to headliner. CABIN LIGHT SWITCH REPLACEMENT (24-3374 thru 24-TBA) BAGGAGE COMPARTMENT | BAG.CMPT. UGHT7 3. Press snap tab & pushfrom panelto remove. 4. Re-assemble in reverse swquence when maintenanceactioncompleted. BAGGAGE COMPARTMENT SWITCH 1. Switch is located at rear of baggage door at front, top of hat rack opening (Figure 33-1A) 2. Remove 1 screw inboard of switch. Pull door frame down slightly from velcro fastners to access baggage compartmentlightswitch. 3. Press snaptabs; PUSH switchthrough panel. 4. Disconnectterminals;replaceswitch. 5. Re-assemble in reverse order. 33-22-00 - INSTRUMENT/FLIGHT PANEL AND GLARESHIELD LIGHTS 33-22-01 - LIGHT BULB REPLACEMENT 1. instrumentpanel lights. (UNDER COVER) _ SONALERTS_ _=_=_w_,J_.._,., SWITCH PANEL _, EXERIORUGHTS--_ _, ,_,_ ____ __:_!( REAR SEAT_/"/ /DAFRONTSA'_Tf ...... "-_ PASSENGER'S-EIGHTS / ...... !"rG-_l'_ -" "_" SPEAKERS../ t rp-r _A_ ¢_'AT UNDE_ COVER FINTER]OR UGHTSMASTER SWITCI" * r,_._=_N_._,, \ /r PILOTSOVERHEAD uun. _w,.un \ _ _ _ / UGHTSWITCH RIGHT,REAR SEATPASSENE UGHTSW1TCH ON RIGHTSIDE PANEL.TYPICALTO LEFTSIDE ,OCA O. ........ _p_'_NG_ O_TLSIGEHA. 12-93 _ _._l SWI CA FIGURE 33-1A - INTERIOR LIGHTS (24-3374 THRU 24-TBA) 33-21-02 6 /_ _ /_::1_ --" MOONEY AIRCRAFT CORPORATION M20J SERVICE AND MAINTENANCE MANUAL FWD OUTBD @ .,r...._ / _I \ I t ----_, _" 3-/ I 4 I I TRIM/FLAP INDICATOR LIGHT - FIGURE 33-2 (SIN 24-0084, 24-0378 thru 24-1188) F. Check for proper operation. A. Unscrew the black knurled button (1) (Figure 3-3) to gain access to the bulb. B. Bulb is a friction fit type in button; remove and replace with new bulb. C, Replace knurled button with new bulb installed into console. D. Check for proper operation. INTERIOR LIGHTS FIGURE 33-1 SIN 24-0001 THRU 24-3373 A. Internally lit instruments are not being considered in this information, B. Post light bulbs are replaced by pulling hood straight out from post light base and then pulling bulb from this hooded portion. C. Insert new bulb into hood and push hood back onto post light base. D. Check for proper operation and hood orientaUon. 2. Glareshield lights. A. Remove outer housing by unscrewing from light assembly base. B. Remove bulb and insert new bulb. C. Screw outer housing back onto base. P FWD D. Check for proper operation. 3. Trim/Flap Indicator Light A. Gain access to light assembly (1) (Figure 33-2) by reaching in over console side par (2) from co-pilots side of cabin. B. Disconnect wires at knife disconnects (3) and carefully unscrew socket portion (4) from light assembly lens (5). The lens is glued to trim/flap indicator reflector (6). c. Bulb will come out with socket portion of light assembly; bulb is bayonet type, push, twist and pull to remove. Insert new bulb. D. Carefully screw socket back into lens. E. Connectthe knife connectionsand ty-rap securely. 12-98 O U TB D -LAP S Wl TC H TRIM/FLAP INDICATOR LIGHT - FIGURE 33-3 (24-1169 thin 24-TBA) 33-22-01 7 SERVICE AND MAINTENANCE MANUAL M2OJ 33-23.00 - GEAR DOWN INDICATOR LIGHT (FLOORBOARD) 33-23-01 - LIGHT BULB REPLACEMENT 1. Remove lower belly panel to gain access to light asse-m_-bl.E-_=-..=-========== ......... 33-40-00 33-40-01 MOONEY AIRCRAFT CORPORATION 2. Remove and replace bulb. 3. Check for properoperation. 4. Reinstallbellypanel. - - EXTERIOR LIGHTS - MAINTENANCE PRACTICES - TROUBLE SHOOTING EXTERIOR LIGHTS TROUBLE PROBABLE CAUSE REMEDY STROBE LIGHTS Lightsinoperative. One bulbdoes not light. -Circuitbreaker/switch tripped, Checkfor shortcircuit.Reset circuit breaker. -Loose connection. Check and tighten electrical connections. -Battery defective. Replace battery or use external power. -Circuitbreaker/switch defective, Checkcontinuitythroughswitch; replaceif necessary. -Faulty power supply. Disconnectsynch wiresto identify faulty power supply. -Bulb burned out. Replace bulb. -Power supply inoperative. Replace. -Fixturenot grounded. Checkfor good bondingbetween fixture and structure.Tighten mounting screws. -Loose connection. Check all connections in circuit. -Defective fixture Replace fixture. LANDING/TAXI LIGHTS, NAVIGATION LIGHTS AND TAILLIGHT Lampfails to light. 33-41-00 -Circuit breaker/switch tripped. Check for shortcircuit.Reset circuit breaker. -Lampburned out. Replace lamp. -Looseconnection or defectivewire. Tightenconnectionsand checkwire circuitcontinuity. Replaceor repairwire if necessary. -Circuit breaker/switch defective. Check continuity through switch. Replace if necessary. -HIGH INTENSITY, STROBE LIGHTS-MAINTENANCE The strobe light power supply requires a 14 VDC (24-0001 thru 24-2999); 28 VDC (24-3000 thrc 24-TBA) input across the red and black wires. Red is positiveand black is negative, or common.The voltage for the strobe light is supplied through Pin 1 and 3 of the power supply connector with Pin 2 as the trigger pulse. The strobe light assembly is a pottedassembly and cannot be repaired: 33-23-00 8 ! The power supplies may be synchronized by connecting each yellow wire together between all powersupplies (Hoskins only). 12-98 MOONEY AIRCRAFT CORPORATION M20J SERVICE AND MAINTENANCE MANUAL TROUBLE SHOOTING AIDS When no lights are flashing: 1. Check circuitbreaker/switch. 0 2. To determine powersupplyor flashtubeproblems, first check the input voltageto the power supply. The red and black line should have 14 VDC (24-0001 thru 24-2999); 28 VDC (24-3000 thin 24-TBA). If novoltage is present check for shorted power leads or tripped circuit breaker. If input voltage is present, then disconnect the yellow sync wires. This will allow unaffectedunitsto flash. Determine defectivelight and proceedto =onelightnotflashing"below. When one light not flashing: 1. To determine power supplyor flashtubeproblems, first check the input voltageto the power supply. The red and black line should have 14 VDC (24-0001 thin 24-2999); 28 VDC (24-3000 thru 24-TBA). If no voltage is presentthen check for shorted power leads, blown inline fuses, or circuit breaker. If input voltage is present, then disconnect the connector to the flashtube.400V-500VDC should be presentacross Pin 1 and 3 of the power supply. If not, the power supply has no outputand is defective.Turn off master switch. 2. If voltage is present across Pin 1 and 3 of the power supply, connect a known good flashtube to the power supply. If good flashtube fails to operate power supply is defective. If good flashtube operates, the flashtube is defective. Replace flashtube. L_.I 0 0 LJ 0 2\," '-_ 1 POWER SUPPLY LOOKING UP - LEFT WING INSPECTION COVER - TYPICAL LOCATION - RIGHTWIN(; VIEW STROBE LIGHT POWER SUPPLY- FIGURE 33-4 3. Be sure yellow sync wire is insulated and not grounded, power supply is physically mounted to this inspection cover. 3341-01 B. Disconnectthe widng connectionsbetween the switchand the powersupply. - POWER SUPPLY UNIT - REMOVAL OR REPLACEMENT 1. wing tip strobe power supply. A. Gain access to wing tip power supply through bottominspectioncover (1) near wing tip (See Figure 33-4). Power supply (2) is physically attached to this inspectioncover. B. Disconnect widng connections between switch and power supply: C. Steps B thru D, and Warning of paragraph 33-41-01, 1, applyfor removalofthis powersupplyunit. WARNING High voltage is involved in the circuit between the power supply and strobe light assemblies, Although a bleed-off resistor is incorporated in the power supply circuit, turn the control switch for the strobe lights OFF and allow at least 20 minutes to elapse prior to disconnecting the cables at the power supply or strobe light assemblies before handling either of these units in any way. Failure to observe these precautions may result in physical injury from electrical shock. CAUTION STROBE LIGHT WIRING -An incorrect hook-up of the wires at either the power input or between the strobe light assemblies and the power supply unit will cause a reversal of polarity that results in serious component damage and failure. Care must be taken to ensure that the red wire is connected to positive power and the black wire to ground. 3341-02 , POWER SUPPLY UNIT INSTALLATION The installation of any of the power supplies is a reverse sequenceof the removalprocedures. 33-41-03 C. Disconnect wiring harness between power supply and strobe light. (See warning above). D. Remove the screws secudng the power supply to the inspection panel and remove the unit. 2. Tail strobe light power supply (SIN 24-1038 and on). A. Gain access to this unit through the inspection cover on the aft, let_ hand side of the tailcone. The - STROBE LIGHT REPLACEMENT 1. WING TIP STROBE LIGHT, (24-1038 THRU 24-TBA) A. Remove the wing tip lens (1) (Figure 33-5) to gain access to malfunctioning strobe light. B. Remove the two screws holding the navigation/position light lens (2) and the one screw (3) below the flashtube assembly. This will allow the light assembly (4) and mounting plate (5) to be pulled away fromtip db. 12-98 33-41-01 9 SERVICE AND MAINTENANCE MANUAL M20J MOONEY AIRCRAFT CORPORATION 2. TAIL STROBE/NAVIGATION LIGHT REMOVAL. (S/N 24-1038 thru 24-2999). SIN 24-3000 thin 24-TBA have only a strobe light assembly located on the rudder. Removal is same as combination NAV/STROBE lightassembly. NOTE The Whelen Strobe-Nay light assembly is installed slightly different but is removed and replaced in a similar manner, _. connections from the power supply rotate the round access cover (1) on the lower left side of the empennage stinger (Figure 33-6). %_2 2 7 oPTIoNAL I A. To gain access to the wire harness and 3 I 28 VDC\ (Z_I TYPICAl WING TIP STROBE LIGHTS TAIL LIGHT FIGURE 33-5 C. Remove the two screws (6) from the back side of the mountingplate. WARNING High voltage is involved in the circuit between the power supply and strobe light assemblies. Although a bleed-off resistor is incorporated in the power supply circuit, turn the control switch for the strobe lights OFF and allow st least 20 minutes to elapse prior to disconnecting the cables st the power supply or strobe light assemblies and before handling either of these units in any way. Failure to observe these precautions may result in physical injury from electrical shock. D. Disconnectthe widng harness plugand remove the flashtube assembly, NOTE On some aircraft the plug may not come through the wire routing holes. Remove the pins from the plug and pull individual wires through the holes to allow the flashtube assembly to come free. E. The flashtube assembly must be replaced if determined to be bad; the flashtube is soldered in place and is not readily removeablefrom the assembly, F. If required, the clear lens can be removed from the flashtube assembly by removing the two lens retaining screws (7) and pulling the lens free for replacement orcleaning, G. Installthe new strobe light assembly in reverse sequence of removal. 33-41-03 10 TAILLIGHT ASSEMBLY FIGURE 33-6 (24-1038 thru 24-2999) (24-3000 thru 24-TBA has only strobe light assembly in rudder) B. Disconnect strobe wiring harness connector fromstrobe power supply hamess and disconnectthe connectorsfor taillightassembly. C. Remove the connector plug (2) from the strobe light widng harness leaving the pins connected to individualwires. D: Tie and tape a strong, small diameter cord, 4 to 5 feet long, to the entire wire harness after plug has been removed. E. Remove the two screws (3) that secure strobe/taillightassemblyto rudder (4) and pullthe light assemblyout so it clears the mounting hole. The wire harnesswillbe stretchedtightat this point. F. Carefully begin working the wire harness throughthe empennage and rudder bulkheadsuntilthe wire harness can be pulled through the light mounting hole in the rudder. The rubber grommets at each bulkheadwill require removal from bulkhead but leave attached to wire harness. See (Figure 33-6) for this detail. 12-98 MOONEY AIRCRAFT CORPORATION M20J G. Pull light assembly and entire wire harness through mounting hole in rudder. DO NOT PULL THE STRONG CORD ALL THE WAY THROUGH ACCESS PANEL willduring need installation. this to pull Remove the new cord wire harness HOLE. back inYou place from wire harness. H. Replace complete flashtube/base assembly (5) if strobelight portion is malfunctioning. The flashtube is not a replaceable component. I. Place bulkhead grommets at relative positions on new harness, after plug (2) is removed from new harness. 3. AFT POSITION LIGHT (24-3000thru 24-TBA) A. Remove two screws that secure aluminum cover (1) to wing tip (2). Refer to Figure 33-7. 1_ 4 5 J. Tie and tape cord to new hamess and carefully begin to feed wire and grommets back to their positions. K. Place all grommets in the bulkheads. Reinstall plug (2) on new harness and secure the strobe/navigation light assembly to the rudder. L. Connect the completed harness and plug from the strobe light assembly to the harness socket from the strobe power supply. M. Check for proper operation. N. SIN 24-1418 and LATER aircraft have a new style strobe light installation. There is sufficient wire available, when ty-raps are cut from coiled harness at (1), to pull this strobe light assembly out the rudder light mounting hole. See item (10) (Figure 33-6). Disconnect light assembly pigtail (11) from connector at (12) and replace assembly if needed. Secure light assembly, coil hamess@ (1) and ty-rap harness coils. 3342-00 - NAVIGATION/POSITION LIGHTS 33-42-01 - POSITION LIGHT - SERVICE AND MAINTENANCE MANUAL 2 /-- _M33-AFT AFT POSITION LIGHT (24-3000 THRU 24-TBA) FIGURE 33-7 B. Remove clear lens (3) & gasket to gain access to lightbulb(4). REPLACEMENT/SERVICE 1. WING TIP POSITION LIGHTS (SIN 20-1038 THRU 24-TBA ). A. Remove the wing tip lens (1) (Figure33-5). B. Remove the two screws (2) holdingthe position light lens in place. C. Pull the lens (red or green) from mounting plate (5) and removethe lamp (8). D. Install new lampinto base. E. Reassemble the light assembly in reverse sequence. 2. TAIL POSITION LIGHT (24-0001 thru 24-2999). A. Remove two screws (3) (Figure 33-6) from the taillighthousing that secures the lightassembly (5) to the rudder(4). B. Remove the clear lens (8), mountingdng (9) and gasket (7) to gain accessto positionlightlamp (6). C. Remove lamp (6) with S.D.I. special tool no. 203541 or equivalent. D. Replace with new lamp and reassembletaillight assemblyin reversesequence, C. Pulllight bulb(withspecialpuller if needed) D. Replacewith new lamp & reassemble lightassy. in reversesequenceof removal. 33-43-00 - LANDING/TAXI LIGHTS 33-43-01 - LANDING/TAXI LIGHT ADJUSTMENT PROCEDURES 0NING MOUNTED LANDING/TAXI LIGHTS ONLY) 1. Positionaircraft to face a vertical wall with frontof nosewheel 7 1l.6 in. from wall. PositionL/H and PJH main landinggear at exact distance from vertical wall, IE. parallelto wall. 2. Place four target crosses(+) on verticalwall at the followingpositions: A. 36.5 inches up vertical wall from same ground planeaircraitis restingon. B. 9.85 feet left and right of nosewheel centerline. C. 12.375 inchesfurther outboard on both left and rightside of Step B. target position. 3. Remove access cover behind each landing/taxi light location on with lower surface. 12-98 33-42-00 11 SERVICE AND MAINTENANCE MANUAL M20J 4. Turn taxi lights ON, exit aircralt, turn adjusting screws until light beams are centered on outboard target crosses(+), left and right, 33-43-01 12 MOONEY AIRCRAFT CORPORATION 5. Repeat Step 4 for landing lights, except center light beams on inboard target crosses (+), left and right. 6. Turn lightsOFF, reinstall access covers. 12-98 MOONEY AIRCRAFT CORPORATION M20J SERVICE AND MAINTENANCE MANUAL CHAPTER 34 NAVIGATION AND PITOT STATIC SERVICE AND MAINTENANCE MANUAL M20J MOONEY AIRCRAFT CORPORATION CHAPTER 34 NAVIGATION AND PITOT STATIC LIST OF EFFECTIVE PAGES CHAPTER SECTION SUBJECT ........... 34-Effectivity ......... 34-Corltents.......... 34-00-00 ............ 34-11-O0............ 34-20-00 ............ 34-21-00 ............ 34-23-00 ............ 34-90-00 ........... PAGE .......... DATE 1/2BLANK .......... 3/4BLANK .......... 5 ........... 6 ........... 7 ........... 8 ........... 9 ........... 10 ........... 12-98 12-98 12-98 12-98 12-98 12-98 12-98 12-98 12-98 34-EFFECTIVITY 1/2BLANK MOONEY AIRCRAFT CORPORATION M20J SERVICE AND MAINTENANCE MANUAL CHAPTER 34 NAVIGATION AND PITOT STATIC TABLE OF CONTENTS CHAPTER SECTION SUBJECT 34-00-00 34-10-00 34-10-01 34-11-00 34-11-01 34-12-00 34-12-01 34-13-00 34-13-01 34-20-00 34-20-01 34-21-00 34-21-01 34-22-00 34-22-01 34-23-00 34-23-01 34-90-00 34-90-01 34-90-02 ........... ........ ......... .......... ......... .......... ......... .......... ......... .......... ......... .......... ......... .......... ......... .......... ......... .......... ......... .......... .......... SUBJECT ........ General .............. Pitot & Static Air Pressure System ...... Heated Pitot-Trauble Shooting ...... Airspeed Indicator .......... Airspeed Indicator-Trouble Shooting .... Vertical Speed Indicator ......... Rate-Of-Climb (VSI) Indicator Trouble Shooting Altimeter ............. Altimeter-Trouble Shooting....... Directional Gyro Compass ........ Directional Gyro-Trouble Shooting ..... Turn Coordinator ........... Turn Coordinator-Trouble Shooting .... Magnetic Compass .......... Compass - Trouble Shooting ...... Artificial Hodzon ........... Gyro-Hodzon - Trouble Shooting ..... Miscellaneous Instruments ........ Clock ............ Outside Air Temperature ....... 12-98 PAGE 5 5 5 6 6 6 6 6 7 7 7 8 8 8 8 9 9 10 10 10 34-CONTENTS 3/4BLANK SERVICE AND MAINTENANCE MANUAL M20J 34-08-00 - GENERAL All flight instruments are grouped on the shock mounted panel directly in front of the piloL Flight instrumentsare operated by: (1) barometricpressure or bemmetdc impact air pressure differences (2) vadationsin e ectdc currentdue to mechanicallyvaded resistance,(3) reference to the earths magneticfield or (4) aimralt electricalpower, The glareshisld must be removed and widng or plumbing disconnected on many of the flight mstrumenta before they can be removed. Remove glareshieldattaching screws,center post coverscrews and carefullyliftcanter postcover and glareshieldfrom the panel. Disconnect the glareshield lights. Reinstall the glareshielclin reversesequence, 34-10-00 - PITOT & STATIC AIR PRESSURE SYSTEM Static pressureinstrumentsare extremely sensitive to pressure changes; therefore, the pitot and static system must be kept free from moisture and obstructions.Drain the pitot and static systems after humidor wet weather. If iesthJmentoperation is erratic or inoperativeafter draining,performthe following: 1. Pitotsystem leak test. (Make sure Master switchis OFF and Gear Controlis in DOWN position.) A. Slipendofashortrubberhoseoverpitottube. B. Close open end of hose;slowlyroll up hose until airspeedindicatorreads 150 KIAS. C. Clamp hose and holdfor one minute. D. If airspeed indicatorfalls more than 10 KIAS, within one minute, check system for leaks and tighten linefittings, E. Repeat steps B, C, and D until obtainingless than a 10 KIAS indicatorreadingdrop. 34-10-01 MOONEY AIRCRAFT CORPORATION CAUTION Release the air pressure slowly by unrolling the rubbertubing, a sudden release oftheair pressure may damage the airspeed indicator. 2. Pitot system hose inspections. Alter the pitot system is checked for leaks, inspect the hose sections for signs of detariomtion. Check all tubing for brittleness,checks or cracks particularlyat the bends or connecting points. When new hose is installed, recheck the system for leaks using the PITOT SYSTEM LEAKTEST procedureabove. 3. Static system cleaning. Blow low air pressure (10-25 PSI). through the lines from the disconnected line at the aimpeed indicatorto the static ports. Cover each staticport separatelywhen blowingto insurethat each line is dear. Instrumenterroror possibledamage may result if even one pert is clogged with did or foreignmatter. CAUTION NEVER BLOWAIRthroughthelineTOWARD the INSTRUMENT panel; to do so will seriously damage the instruments. When blowing back through theisinstrument make the sureline thatfrom no air blown intopanel, the instruments. 4. Static system leak test. The static system should be checked for leaks in accordance with the instructionsin Federal AviationRegulation91.411. CAUTION To avoid damaging either the airspeed indicator or the landing gear airspeed safety switch an equal pressure should be applied to the pitot side of the indicator while leak testing the static system. 5. Alternate static source.An alternate static source valve is providedto change the static air source from outside the aimraft to inside the cabin. The valve is located on the lowerpanelimmediatelyto the lett of the pilots control column.Airspeed indicatorand altimeter readings will be slightly affected when using the alternate static source. - HEATED PITOT TROUBLE SHOOTING TROUBLE PROBABLE CAUSE REMEDY Tube does notheat or clear itselfof ice with switchon. Switchcircuitbreakertdpped. Reset cimult breaker. Open circuit. Repair. Excessivevoltagedropbetween batteryand pltot head. Checkvoltageat pltot head. Heatingelement burned out. Replace pitothead. 12-98 34-00-00 5 MOONEY AIRCRAFT CORPORATION M20J 34-11-00 SERVICE AND MAINTENANCE MANUAL - AIRSPEEB INDICATOR Registers airspeed in knots. Air pressure difference between impact air, pitottube, and static air (static ports on each side of the aircraft tailoone) operates the airspeed indicator.An electricallyheated pitot head prevents ice obstructionin flight. The airspeed indicatordial markingsare as follows: Radial Red Line .............. YellowAm ................ Green Arc ................ White Arc ...... NOTE m 34-114) 1 195 KIAS 174-195 KIA8 64-174 KIAS 57-110 KIAS .......... See Section 27-95-00 for stall warning systems. - AIRSPEED INDICATOR TROUBLE SHOOTING TROUBLE PROBABLE CAUSE Instrumentpointerdoes not indicateproperly, -Leak in instrument Checkfor leak and seal case or in staticlines lines. -Obstructionin pitottube. -Leak in instrumentcase or =n pitotlines. Clean outobstruction. Checkfor leak and seal lines. Instrumentpointeroscillates. 34-12-00 REMEDY - VERTICAL SPEED INDICATOR Convertsbarometricpressure changeswithin the static port linesto aircraftascent or descent rate; readingsare in feet per minute. This instrument has a single needle and two adjoining scales that read from 0 to 2000 feet per minute, top side for ascent rate and bottom side for descent rate. The recessed, slotted screw at the lower left of the instrument case is used to "zero" the indicator when the aircraft is on the ground. 34-12-01 TROUBLE - RATE-OF-GMMB INDICATOR TROUBLE SHOOTING. (VERTICAL SPEED INDICATOR). PROBABLE CAUSE REMEDY Pointer does not set on zero. -Aging ofdiaphragrn. Pointerfails to respond. -Obstructionin staticline. (Includeswater) Pointer oscillates. -Leaks in static line. Disconnectall instrumentsconnected to the staticline. Check individual instrumentsand test installationfor leaks. -Defective mechanism. Replace instrument. 34-13-00 Turnsettingscrewto reset pointerat zero.Tap instrumentwhileresetting. Disconnectstatic linefrom instruments. Apply low pressureair (10-25 PSI max.)to instrumentend of static line. Check both staticportsfor air flow. Depress staticdrain valveand check for water. Keep depressed untilair is free of moisture.Reconnectstaticline to instrumentsand leak check. - ALTIMETER The altimeter operates by absolute pressure and converts barometric pressure to altitude;reading is in feet above mean sea level. The altimeter has a fixed dial with three pointers to indicate hundreds, thousands, and tens of thousands of feet. Barometric pressure is sensed through the static vents. A knob adjusts a movable dial behind a small window in the face of the main dial to indicate local barornetdc pressure. This corrects the altimeter reading for prevailing conditions. 34-11-00 6 12-96 SERVICE AND MAINTENANCE MANUAL 34-13-01 M20J MOONEY AIRCRAFT CORPORATION - ALTIMETER TROUBLE SHOOTING TROUBLE PROBABLE CAUSE REMEDY Excessscale error. -Improper calibratio_adjustment. Replaceinstrument. Excessivepointeroscillation, -Defective mechanism. Replace instrument. High reading. Setting knob is hard to turn. -Static pressure system leak. -Wrong lubdcant or lack of lubdcation. -Marker out of engagement. Biminateleakinstaticpressuresystem. Replace instrument. -Excessive vibration. T_hteninstmmontscrewffloose.Replace _stmmentifscrewis missing. Cracked or loose cover glass. -Excessive vibration. Replace instrument. Dull or discolored luminous markings, Barometdc scale and reference markers are out of synchronization with pointers. Barometric scale and reference markers are out of synchronization. -Age. Replace instrument. -Shift in mechanism. Reset pointers. -Slippage of mating parts. Replace instrument. Innerreferencemarkerfailsto mow when setlingknob is misted. Setting knob set-screw is loose or missing. 34-20-00 Replaceinstrument. - DIRECTIONAL GYRO COMPASS This vacuum-operated instrument indicates the heading reference. The directional gym rotor is air ddven and rotates with its spin axis horizontal The _:nobis used to reset basic directional heading. Vacuum pressure for satisfactory operation is 4.25 +/- .2 to 5.5 +0.0/-0.2. The vacuum system filters should be changed each 500 hours or at one year intervals, whichever occurs first. (See Trouble Shooting Chart, for maintenance instructions.) 34-20-01 - DIRECTIONAL GYRO TROUBLE SHOOTING TROUBLE PROBABLE CAUSE Excessivedrift in either direction, -Dirty air filter (high vacuum indication). -Excessive vibration. REMEDY Inspectfilter.Replace if necessary. Testwithvibmmoter.If vibrationamplitudeis morethan.004inch,examineshock mountingsto see ifconneclJons are restifctinginstrument. -Insufficient vacuum. If vacuum indication is below 4.25 IN. Hg. check as follows: 1. Vacuum regulating valve 1. Adjust vacuum regulating valve. improperly adjusted. 2. Pump failure. 2. Repair or replace pump. Instrument is sluggish. Dial spins continuously in one direction, 3. Vacuum line kinked, leaking or too long for its diameter, 3. Locateand if deflective,replace or repairvacuum line. Check for collasped innerwall of flexible hose. -Defective mechanism (worn or dirty pivots and bearings.) -Operating limits have been exceeded Replace instrument. Defective mechanism. Reset the instrument with the aircraft in level flight. Replace instrurnenL 12-98 34-20-00 7 MOONEY AIRCRAFT CORPORATION 34-21-00 M20J SERVICE AND MAINTENANCE MANUAL - TURN COORDINATOR A gyro instrumentthat indicates controlcoordinationand rate oftum. This instrumentis electricallydriven. 34-21-01 - TURN COORDINATOR TROUBLE SHOOTING TROUBLE PROBABLE CAUSE Pointerfails to respond. -Foreign matter lodgedin instrument. -No electric current. Bar does not set level, In lowtemperature, bar fails to respond or responds sluggishly and with insufficient deflection. Bar sluggish in returning to level and does not set on level when stationary. 34-22-00 REMEDY Replace instrument. Check voltageat instrument. -Gimbal and rotorassemblyout of balance. -Pitted orworn pivotsor bearings. Replace instrument. -Oil has become too thick. Replace instrument. -Insufficient beadng clearance. Replace instrument. -Oil or dirt between damping pistons and cylinders. Replace instrument. -Excessive clearance between rotor and rotor pivots. Replace instrument. Replaceinstrument. - MAGNETIC COMPASS The magneticcompassdial, graduatedin five-degree increments,is encased in a liquidfilled glass and metalcase. The unit mountson the stainlesssteel windshieldcenterpost above the glareshield.The compass shouldbe swung and compensatedat each annual inspectionand whenever new equipmentis installed.To compensatefor N-S deviation,adjust leftscrew; to compensatefor E-W deviation,adjustdghtscrew. Degausingof the tubular structuremay be required if compass cannot be compensatedwithin limits.Carefully go over the entire steel structure with degauser to remove residual magnetism. Recommend Armature Growler to degausesteel structure. NOTE Refer to S.B. M20-15OA, Instruction III, for degausing procedures. NOTE Check for outside magnetic influences if excessive compensation is required. 34-22-01 -MAGNETIC COMPASS TROUBLE SHOOTING TROUBLE PROBABLE CAUSE Excessive card error. -Compass not properly compensated. -External magnetic interference. Compensate instrument. -improper instrument mounting. Insufficient liquid. Align Instrument. Replace instrument. Excessive card oscillation. 34-22-00 8 12-98 REMEDY Locate magnetic interference and eliminate if possible. SERVICE AND MAINTENANCE MANUAL TROUBLE (cont.) Sluggish card. Liquid leakage. Discolored luminous markings or discolored damping liquid. Defective light. 34-23-00 M20J MOONEY AIRCRAFT CORPORATION PROBABLE CAUSE -Weak card magnets. REMEDY Replace Instrument. -Excessive pivot friction or broken jewel. -Instrument too heavily compensated. -Loose bezel screws. -Broken cover glass. Replace instrument. Correct excess compensation. Tighten screws. Replace instrument. -Defective sealing gaskets. Replace Instrument. -Age Replace instrument. -Burned out lamp or broken ctmuit. Check lamp or wiring continuity. - ARTIFICIAL HORIZON The vacuum-powered artificial horizon gyro indicates aircraft, attitude relative to straight and level flight, Maintenanceis similarto that requiredfor the directionalgyrocompass. 34-23-01 - GYRO-HORIZON TROUBLE SHOOTING TROUBLE PROBABLE CAUSE REMEDY Horizon bardoes not respond. -Dirty air filter (highvacuum) indication, Examinefilter and clean or replace instrument,if necessary. -Insufficientvacuum resulting from the following: Correctinsufficient vacuumasfollows: 1. Vacuum regulatingvalve impropedyadjusted. 2. Pump failure. 3. Vacuum line kink,lealdngor too long for its diameter, Hodzon bar does not settle. Horizon bar oscillates or vibrates excessively, 1. Dirty air filter. 1. Adjust valve. 2. Repair or replacepump. 3. Locateand repair.Checkfor collapsed innerwaUof flexible hose. -Defective mechanism. Replace instrument. -Excessive vibration. Test with vibrometer. If amplitude is more than .004 inch, examine installation to determine whether connectionsare restrictingmovement of instrument. -Shock mountedpanel is contactingstructure(inadequate clearance). Examineshock mountingsand replace if necessary. -Excessivevacuum resulting from the following: Con_ctfor_ivevacuumasfol[ows: 1. Examine filter and clean or replace if necessary. 2. Adjust valve. 2. Vacuum regulating valve improperly adjusted. 3. Defective mechanism. 4. Excessive vibration. 3. Replace instrument. 4. Test withvibrometer, if amplitudeis morethan .004 inch, examine installation to determinewhether connections are restrictingmovement of instrument. 5. Shock mounted panel is contacting structure (inadequate clearance). 5. Examine shock mountings and replace if necessary. 12-98 34-23-OO 9 MOONEY AIRCRAFT CORPORATION 34-90-00 34-90-01 M20J SERVICE AND MAINTENANCE MANUAL - MISCELLANEOUS 34-90-02 INSTRUMENTS Provides the pilot with the free stream outside air temperaturein degrees centigrade. - CLOCK Variousclockoptions are available.The standardclock ismountedin the left sideof the instrumentpanel, 34-90-00 10 12-98 - OUTSIDE AIR TEMPERATURE SERVICE AND MAINTENANCE MANUAL M20J CHAPTER OXYGEN MOONEY AIRCRAFT CORPORATION 35 MOONEY AIRCRAFT CORPORATION M20J SERVICE AND MAINTENANCE MANUAL CHAPTER 35 OXYGEN UST OF EFFECTIVE PAGES CHAPTER SECTION SUBJECT ........... PAGE 35-Effectivity/Co ntents ....... 35-00-00. • .......... 35-00-02 ............ 35-00-02 ............ 35-00-02 ............ .......... DATE 1/2BLANK .......... 3 ........... 4 ........... 5 ........... 6 ........... 12-98 12-98 12-98 12-98 12-98 CONTENTS CHAPTER SECTION SUBJECT ........... 35-00-00 ........ 35-00-01 35-(:0-02 ......... ......... SUBJECT General ........ ........... Recharging Procedures ......... Maintenance Practices ......... 12-98 PAGE . . . 3 3 4 35-EFF/CONTENTS 1/2BLANK SERVICE AND MAINTENANCE MANUAL M2OJ MOONEY AIRCRAFT CORPORATION 38-00-00 - GENERAL The oxygensystem is an optionalinstallationfor sedal number24-0001 and ON. The system consistsof a 76 (metal),77.1 (composite)or 115.7 (composite)cubic1_. cylinder located in the tailcone immediatelyeR of the baggage compartment bulkhead. A reducing valve and an altitude compensatingvalve are connected to the _iYlinder to regulatethe oxygen flow for a givenaltitude, nes connected to the altitude compensating valve distributeaviatorsoxygento the pilot and passengers, The system is activated by either the control handle being pushed forward (SIN 24-0001 thru 24-1417) or the control knob rotated (24-1418 & ON) to open the reducingvalve. A gauge, located on the pilotsarm rest adjacent to the control, indicates the pressure of the cylinder. When the cylinder is full the pressure will indicate 1850 P.S.I. at 21 degree C. (70 degree F.). The system is serviced through an access opening located aft of the baggage compartment door. Standard refill fittings are required to fill the cylinder WARNING Proper safety measures must be employed while oxygen system maintenance is being performed or a serious fire hazard will be created. Avoid making sparks and keep all burning cigarettes or fire away from the vicinity of oxygen. Make sure that your hands, tools, and clothing are clean, particularly with respect to oil or grease, for these will IGNITE upon contact with pure oxygen under pressure. 35-00-01 - RECHARGING PROCEDURES with aviatorsoxygen. (Spec. No. MIL-O-27210). 1.The oxygen cylinder should not be used to less than 100 P.S.I.; contamination may occur to the cylinder and valve. The valve must be removed and the cylindercleaned and inspected if this happens. 2. Refill the cylinder with aviators oxygen Specification No. MIL-O-27210, through the Oxygen Access WARNING Oil, grease or other lubricants in contact with oxygen create a serious fire hazard, and such contact must be avoided when handling oxygen equipment. WARNING NO SMOKING when refilling oxygen cylinder. ure 9 8 li S/N 24-000] THRU 24-14J7 (2) must be Valve used. Recharging Mooney PIN 870025-501 oxygen recharge hose assembly is recommended. 3. The cylinder contains 1850 P.S.I. at 21 degree C. (70 degree F.) when fully charged. has on the k_ 7 3/ CYLINDER 3 2 i\ \ 10 DUTLETS -TO \ fittings are required for this servicing, -icwever several of standard oxygen fittings are in use and a compatible fitting for the Scott pressure;charging correct See (Figure 35 - 2) for 4 vs. . charging S/N I OXYGEN SYSTEM 24.1418 THRU 24-TBA pressure. FIGURE 35-1 12-98 35-00-00 3 MOONEY AIRCRAFT CORPORATION M20J SERVICE AND MAINTENANCE MANUAL charged to capacity. Conduct high pressuretest using cylinder pressure. Using the su.pplygauge on the pilot's side wall, note cylinder pressure. There shall be no pressure loss alter 30 minutes.If leakage exists apply MIL-L-25567, test solution to ,_ wipe clean and dry. Make necessary repairs and retest. _, 5. Oxygen system purging. Offensive odors may be removed from the oxygen system by purging. The system should also be purged any time the lines are left open and subjectto contamination. Purging is accomplished by connecting a recharging cart into the system and to flow and outlets until any offensive odors have been carded away. (ReEAC 43.13-1 (*) (* = cun'entrevison) 1. The control cable (3) (Fig. 35-1) is attached to an actuating arm (4) on reducingvalve (5). This cable is muted through vadous bulkheads along the leit side panelto the control(6) at pilotsposition.The control is WARNING Avoid making sparks and keep all burning cigarettes or fire away from the vicinity of the airplane when the outlets are in use. Inspect the filler connection for cleanliness before attaching it to the filler valve. Make sure that your hands, tools, and clothing are clean, perticuledy from grease and oil stains, for these contaminants will IGNITE upon contact with oxygen. a posh-pull assembly is activated by a control lever cable assembly for S/Nthat 24-0001 thin 24-1417 and a rotating knob assembly for S/N 24-1418 & ON. The supply gauge (7) located adjacent to this control indicates the pressure of oxygen available in the system; The followingprocedures are recommendedto purge the system: A. Connect a recharge cart to the tiller valve. Set the cart pressure regulator to deliver 50 PSI to the system. OXYGEN SYSTEM FIGURE 35-1A S/N 24-3373 THRU 24-TBA 35-00-02 ' MAINTENANCE PRACTICES 2. The pilots outlet (8) and passenger outlets (9) B. Plug in an oxygen mask at each outlet in the shou_ be inspected for damage and cleanlinessduring cabin. set, crag. C. Open the cabin doorand place the control knob 3. Inspect the individualoxygen masks, and fittings in the halfopen position. fordamage. D. Allow the system to purge for one hour. If an 4. Oxygen system test procedures.Remove oxygen offensiveodorstill lingers,continue purgingthe system line from the regulator and plug the line. Cap open for an additional hour. If such odors still remain, regulator port with a clean plastic cap to prevent replacethe supplycylinder.After the system has been contamination of the regulator. Conduct the low adequatelypurged, removethe masks fromthe outlets, pressure system leak.test using a 70 +1- 10 PSI place the control knob in the closed position and oxygen supply plugged into one of the cabin outlets servicethe systemas describedin 35-00-01. and a test gauge plugged into another outlet.Apply 70 6. Oxygen cylinder removal. The oxygen cylinder is +/- 10 PSI to the system, allow 2 minutes for the locatedin the tailcone aft of the baggage compartment systemto stabilize,remove oxygen supply.The drop in bulkhead.Access to the cylinder is obtainedthru the pressure after 15 minutes shall not exceed five PSIG. radio compartment access door or the left side of the Remove temporary plugand ensurethat the cylinderis aircraftbehind leftwing post. 35-00-02 12-98 4 i SERVICE AND MAINTENANCE MANUAL M20J WARNING Keep fire, cigarettes and sparks away from the vicinity of the oxygen cylinder. Oil and grease will IGNITE upon contact with oxygen under pressure, A. Place pilots control lever/knob in the closed position. B. Gain access to the cylinderthrough the large radiocompartmentdoor. C. Slowly loosen the supply line fittings at the cylindervalves, (reference Figure 35-1), to relieve any pressure that may exist in the supply lines. After presure is relieved,removethe lines. D. Disconnectthe control cable (3) from the arm (4) on reducingvalve (5). E. Cap all open lines and regulatoropenings with cleanmetal cops. F. Note relative position of regulator valves and controlarm priorto removal. G. Loosen the clamps (11) retaining the cylinder, while supporting the cylinder, and carefully remove cylinderand regulatorsfrom its position. 7. Oxygencylinderinstallation. MOONEY AIRCRAFT CORPORATION B. Remove caps from lines and carefully inspect all connections for damage or any foreign substance before connectionto the new cylinderand valves. C. Connect all lines to proper fitting and connect the controlcable (3) to the arm (4) on reducer valve (5)° D. Charge the cylinder, if required, to the correct pressure,see rechargingtable on (Figure 38-2). E. Place the pilotscontol lever/knob to the open positionand plug on oxygenmask intothe pilotsoutlet to checkfor propersystemoperation. F. Repeat this checkoutprocedurefor alloutlets. G. Test the system for leaks per leak test check, paragraph35-00-02, D. H. Reinstallthe radio compartmentaccess door. NOTE Oxygen cylinders must be hydrostatic tested in accordance with DOT Code of Federal Regulations,Title 49,ehap.1,para. 173.34. CAUTION All oxygen cylinders MUST be replaced every 10,000 recharge cycles. NOTE Maximum life for composite oxygen cylinders is 18 years. NOTE Maximum life for light weight steel oxygen cylinders is 24 years. A. Placeand new secure. cylinderand into position in clamps The regulators new cylinder should bepositioned with regulator valves and control arm in the same position as the removed cylinder assembly components. Filling pressures will vary due to ambient temperature in the filling area and the rise of temperature resulting from compression of the oxygen. Because of this merely filling to 1850 PSIG will not result in a propedy filled cylinder. Fill to pressures indicated on FIGURE 35-2 for ambient temperatures. AMBIENT TEMPERATURE -OF FILLING PRESSURE -PSIG AMBIENT TEMPERATURE 2F FILLING PRESSURE -PSIG 0 10 20 30 40 1650 1700 1725 1775 1825 50 60 70 80 90 1875 1925 1975 2000 2050 OXYGEN FILLING PRESSURES VS TEMPERATURE FIGURE 35-2 12-98 35-00-02 5 MOONEY AIRCRAFT CORPORATION M20J BLANK 35-00-02 6 12-98 SERVICE AND MAINTENANCE MANUAL SERVICE AND MAINTENANCE MANUAL M20J CHAPTER 37 VACUUM MOONEY AIRCRAFT CORPORATION MOONEY AIRCRAFT CORPORATION M20J SERVICE AND MAINTENANCE MANUAL CHAPTER 37 VACUUM LIST OF EFFECTIVE PAGES CHAPTER SECTION SUBJECT ........... 37-Effectivity ......... 37-Contents .......... 37-00-00 ............ 37-11-04 ............ 37-13-09 ............ 37-21-95 ............ 37-49-99 ............ 37-41-09 ........... PAGE .......... DATE 1/2BLANK .......... 3/4BLANK .......... 5 ........... 6 ........... 7 ........... . 8 ........... 9 ........... 10 ........... 12-98 12-98 12-98 12-98 12-98 12-98 12-98 12-98 12-98 37-EFFECTIVITY 1/2BLANK SERVICE AND MAINTENANCE MANUAL M20J MOONEY AIRCRAFT CORPORATION CHAPTER 37 VACUUM UST CF EFFECTIVE PAGES 37-00-00 ........ 37-10-00 ......... 37-11-00 .......... 37-11-01 ............ 37-11-02 ............ 37-11-03 ............ 37-11-04 ............ 37-12-00 .......... 37-12-01 ............ 37-12-02 ............ 37-12-03 ............ 37.12-04 ............ 37-12-05 ............ 37-13-00 .......... 37-13-01 .......... 37-13-02 .......... 37-13-03 .......... 37-13-04 .......... 37-14-00 .......... 37-14-01 ............ 37-14-(_2 ......... 37-14-03 ............ 37-14-04 ............ 37-20-00 ......... 37-21-00 .......... 37-21-01 ............ 37-21-02 ............ 37-21-03 ............ 37-21-04 ............ 37-21-05 . . .. 37-30-00 ......... 37-30-01 .......... 37-30-02 .......... 37-40-00 ......... 37-40-01 .......... 37-41-00 .......... ......... General .............. Distribution ............ DryAir Pump .......... MaintenancePractices ...... Servicing .......... Removal .......... Installation-NewPump....... Vacuum Regulator ......... MaintenancePractices ...... Servicing .......... Removal .......... Installation.......... Adjustment.......... Filters ............ MaintenancePractices ........ Servicing ........... Removal ........... Installation ........... Hoses ............ MaintenancePractices ...... - . . . _¢ervicing .......... Removal .......... Installation.......... Indicating............. VacuumSwitch .......... Description.......... MaintenancePractices ...... Removal .......... Installation.......... Adjustment.......... Dry Air PumpRepair.......... CouplingInspection& Replacement .... DryAir Pump Inspection ....... Stand by VacuumSystem (Optional) ..... Servicing ........... OperationalProcedures. ....... 12-98 5 5 5 5 5 5 6 6 6 6 6 6 6 7 7 7 7 7 7 7 7 7 7 7 7 7 7 7 7 8 8 8 8 9 9 9 37-CONTENTS 3/4BLANK MOONEY AIRCRAFT CORPORATION { M20J 37-00-00 - GENERAL An engine driven dry air vacuum pump supplies suction for the vacuum operated gyroscopic flight instruments, Directional Gyro and Artificial Horizon. The air is passedthroughseveral filters before entering the instruments. A vacuum regulator valve is incorporated to maintain the required operating vacuum throughoutthe engine power range. Idle RPM settingswill normally not provide adequate vacuum to satisfactorilyoperate the instruments. A vacuum annunciator light will illuminate and flash when vacuum drops below the setting required to operatethe instruments. A standbyvacuum system kit is availablefor the M20J aircraft.This kitcan be installedby the factory or in the field. The standbyvacuum system should be activated manually whensystem. =low Vac" light on regular engine driven Refer to flashes Vendor Manual for standby vacuum system repair; also refer to Section 37-41-00). 37-10-00 - DISTRIBUTION 37-11-00 - DRY AIR PUMP A dry air pump (1) (Figure 37-1) requires no maintenance between replacement. Replacement is recommendedat 500 Hrs. & engine overhaul. NOTE Always replace inoperative pump with new air pump. NOTE Aircraft with optional radar use vacuum pump (outlet) pressure side to pressurize RTA compartment in right wing. I_L _HU" '_ • " '_=_= _ SERVICE AND MAINTENANCE MANUAL 37-11-01 - MAINTENANCE PRACTICES Protectionof pneumaticdry air pump when cleaning the enginecompartmentis veryimportant. WARNING Failure to protect the dry air pump from contamination by engine cleaning solvents may result in failure of the dry air pump within a short period of operation. Prior to washing down engine compartment, the followingprecautionsmust be taken for better service life of the pneumaticdryair pump. 1. Dry air pumpcoupling. CAUTION Do not blast the air pump coupling area or other pneumatic system components with cleaning solvent under high pressure. Protect coupling area between the pump mounting flange and the pump housingby wrappinga protective coveringaroundthat area dudngenginecleaning. CAUTION Do not allow protective covering around the coupling or filterstobecomesaturatedwith solvent. The seals in the front frame ofthe housingbehindthe coupling are designed to keep out foreign material such as dirt, dust and lightfluid. However, fluid under highpressurecan be forced by the seals and enter the pump. 2. Dry air pumpfittings.Before washingthe engine off, check pump fittings for loosenessof the threaded fittings.Fluid canseep throughloosethreads and enter the pump. I 3. Dry air pump discharge hose _=_'_ _"1,_ with a red =Remove Before Running Engine" tag. then clean the engine. end of theinstrument hose CAUTION or thesystem) fitting and flag it (vacuum Plug the Remove plug prior to running engine. NOTE Vacuum pump exhaust tube should be installed, if not installed at time of manufacture. ¢_:_ _ retrofit kit 940064, 4.assembly, Replace vacuum relief valve filter _,w.,,=,,, _ _ BEFORE engine. 37-11-02 starting - SERVICING The dry air pump requires no servicing. The internal parts are self-lubricating and requirethe NO afler c,eaning engine ADDITIONAL compartment lubricating. 37-11-03 - REMOVAL 1. Disconnect hoses from dry air pump. VACUUM SYSTEM FIGURE 37-1 12-98 37-00-00 5 SERVICE AND MAINTENANCE MANUAL M20J 2. Remove air pump from engine and discard old mountinggasket and lockinghardware. 3. Remove fittingsfrom pump. Retain fittingsif they are serviceable and clean thoroughlybefore reusing, Discardtwistedffitings and nutswith roundedcomers. 4. Pad inspection. Check the conditionof the AND 20000 pad seal, If the seal shows any signs of oil leakage, replace the seal. Replace seal if there is any doubtas to its serviceability. 37-11-04 - INSTALLATION OF NEW PUMP CAUTION Never install a pump that has been dropped. 1. Consultthe airframe manufacturer'scurrent parts manual, Airborae's Application List, or the PMA label on the pump box to vedfy that the pump is the correct modelforthe engineand/orsystem. 2. Place the pump mounting flange in a jaw-protectedvise, with the drive coupling downward Protect the pump mounting flange with soft metal or wood. CAUTION Pump housing should never be placed directly in a vise, since clamping across the center housing will cause an internal failure of the carbon rotor. 3. Spray the fitting threads with silicone and LET DRY. lube. DO NOT use teflon tape, pipe dope or thread 4. Install f_ings in the pump. Hand tighten, 5. Use only a box wrench to tighten fittings to desired Position. DO NOT make more than one and one half (1 /2) turns beyond hand-tight position. 6. Install new pump mountinggasket (suppliedwith new pump). 7. Always replace ALL locking washers when installinga new pump. Tighten all four (4) mounting nuts- 90 to 110 in. Ibs. 8. Prior to reconnecting hoses, inspectthe inside of the hose carefully to make sure it is clean and free of all debds, oils or solvents. Use vacuum or air pressure to cleanthe lines. Remove the hoses fromthe aircraftif necessary. MOONEY AIRCRAFT CORPORATION 37-12-00 -VACUUM REGULATOR The vacuum regulator (2) (Figure 37-1) is a spdng-contrulled diaphragm valve for regulating vacuum for the aircraft pneumatic instrumentsystem. The vacuum regulator is located on the left.firewall insidethe cabin,just under glareshield.Adjustvacuum regulatorvalveaccordingto Section 37-12-05. 37-12-01 - MAINTENANCE PRACTICES Check general condition of regulator to insure it is secure and in airworthycondition. 37-12-02 - SERVICING No servicingis requiredto the regulator otherthanfilter replacement per Section 5. See Section 37-13-00 for detailprocedures. 37-12-03 - REMOVAL 1. Underneath the instrument panel, remove both instrumentlines from vacuumregulator;cap to prevent foreignobjectsfrom entering them. 2. Engine compartment, remove hose from vacuum regulator;,cap to prevent foreign objects from entering. 3. Loosen and remove large nut at firawall on vacuum regulator. 4. Pullregulatoraft to removefrom aircraft. 37-12-04 - INSTALLATION 1. Insideaimratt, insertthe vacuum regulatorthrough the mountinghole in the firewall. 2. Install large nuton regulator and tighten. 3. Engine compartment, install hose from pump to regulator and secure. 4. Inside aircraft, install both instrument lines to regulator and secure. 37-12-05 -ADJUSTMENT 1. Tee a calibratedvacuum gauge into the system upstreamof the regulator,(see Figure 37-1). 2. Operate engine at a minimum of 1700 engine RPM. If the vacuumregulatoris not set at 4.75 +/- 0.25 In. Hg., then bend locking tab away from thumb adjustment screw. Turning screw in, will increase vacuum;turning screw out, will decrease vacuum. Set vacuumto read 4.75 +/- .25 In. Hg. When hose clearance is tight, making it difficult to reinstallonto the pump fitt rig, spray the rriting at the hose end with silicone. LET DRY, then installhose by pushingit straight on. CAUTION Do not wiggle hose from side to side. This could cause particles to be cut from hose ID. These particles WILL damage the pump. CAUTION Change all the filters in the system. This MUST BE DONE or pump warranty may be voided, 37-11-04 12-98 6 NOTE After setting regulator, rebend tab back to lock adjusting screw. MOONEY AIRCRAFT CORPORATION 37-13-00 M20J - FILTERS SERVICE AND MAINTENANCE MANUAL 37-14-03 - REMOVAL All filters, except the vacuum regulator filter are of paper-pleatedmaterial design. The vacuum regulator filteris a foam-gaiter design, Replace old, hard, cracked or brittle hose, particularly on the pump inlet. Sections of the inner layers may separate, causinga pumpfailure. 37-13-01 37.14-04 - MAINTENANCE PRACTICES - INSTALLATION 1.Airfilterreplacement intervals: A.Vacuum regulator,garter filter (2),every 100 hours, B. Instrument filters (5) every 500 hours or at least once a year, Ref. SECTION 5-10-01. Where hose clearance is tight, making it difficultto reinstallit ontothe pumpfitting,spray the fitting at the hose end with silicone.LET DRY then install hose by pushing it straight on. NOTE 2, All filters require routine inspection of condition of elementand securityof filter in system, 3. ALL RLTERS MUST BE CHANGED WHEN A NEW PUMP IS INSTALLED, Do not wiggle hose from side to side. This could cause particles to be cut from hose ID. These particles WILL damage the pump. 37-13-02 - SERVICING All filters require no service except routine inspections. Replaca with new current configurationfilters, The alternate instrument filter installation (6) (Figure 37-1) should follow the same cleaning and replacement schedule, 37-13-03 - REMOVAL Make certain hoses are connected to the correct fittings. Incorrectinstallationwill cause damage to the gyrosystem. Installclamps and secure. 37-20-00 - INDICATING The indicating system contains a low vacuum light which illuminates (flashes) when the vacuum is below 4.25 +/- ,2 In. Hg. and a high vacuum light which illuminates (steady) when the vacuum goes 5.5 (+,2-.0) In, Hg. or above. 37-21-00 - VACUUM SWITCH I. Vacuum regulator garter filter is removed by stretchingit over and offthe regulatorframe, 2. Individual gyro instrument filters unscrew from the back of the instruments. Some installations have one main gyro filter in a manifold line. The vacuum switch (7), Fig. 37-1, is located on either the Artificial Hodzon (3) or Directional Gyro (4). The illuminating low and high light adjustments are done on the switch, not on the annunciator panel. 37-13-04 -INSTALLATION 1. Prior to installing a new vacuum regulatorfilter, checkthe regulatorto insurethat it is clean from any foreign material. The switch is a low and high vacuum sensing adjustableunit. 2 Reinstallnew gyro filters into instrument bossand tightensecurely. CAUTION Don't over tighten; overtightening will crack the rear housing, 37-14-00 - HOSES The hosesare of the aircraf_MIL-H-type. 37-14-01 - MAINTENANCE PRACTICES Dudngenginecleaning, protectthe dischargehose: 1. Plugthe end 0fthe hoseand flag it witha red"Remove BeforeRunningEngine"tag, then cleanthe engine. CAUTION Remove plug prior to running engine. Periodic check of all clamps for security is recommended. 37-14-02 37'21-01 - DESCRIPTION 37-21-02 - MAINTENANCE PRACTICES Check for switch secudty in instrumentand all wires secure at switch. 37-21-03 - REMOVAL Disconnect wires and unscrew from art instrument housing. 37-21-04 - INSTALLATION Installswitchin housingand tighten.Reconnectwires. CAUTION Do not over tighten. Over tightening will cause cracking of the aft instrument housing. - SERVICING Inspect the inside of the hose carefullyto make sure it is clean and free of all debris, oils or solvents. Use vacuum or air pressure to clean the lines. Remove the hoses from the aircraft if necessary. 12-98 37-13-00 7 SERVICE AND MAINTENANCE MANUAL M20J 37-21-05 - ADJUSTMENT 1. Remove switch from instrument.Reinstall wires if removed. Attach poly-vinyl hose, _T_ fitting and calibratedgauge to vacuumswitch. Connect other end of hoseto a vacuumsource. 37-30-00 2. Turn aircrall power on. The "HIGH/LOW VAC" lightshouldflash. 3. App[y vacuumand adjustsourceto 4.25 (+/- .2) ln. Hg. AdjustLow settingscrew (connectorend of switch) to illuminatethe low vacuum circuit on the annunciator panel. 4. Increase vacuum source to 5.5 (+.2-.0) in. Hg. Punch a small jewelers screw driver through the poly-vinyltube and into the fitting where the high setting screw is located and adjust until the =HIGH/LOWVAC" lighton annunciatoris illuminated. 5. After you have completed switchadjustment turn aircral_power off. 6. Remove switchfrom hose and gauge, 7. Reinstallswitchin Gyro. Reconnectwires. CAUTION Crossing the electrical wires on vacuum switch will cause the annunciator lights to act in reverse. MOONEY AIRCRAFT CORPORATION - DRY AIR PUMP REPAIR/ REPLACEMENT 37-30-01 -COUPLING INSPECTION AND REPLACEMENT 1. Remove vacuum pumpfrom engine in accordance with maintenancemanual, Section37-11-03). 2. If coupling (1) has sheared, remove engine couplingdrivegear (2) from engine gear housing and see Section 37-30-20 below. 3. Use a screwdriver or similar tool, remove pump drive coupling (1) from engine couplingdrive gear (2) and pump drive gear (3) being careful not to damage drivepins. 4. Push new drive coupling(1) into place on pump drivegear (3). 5. Push engine couplingdrive gear (2) into place on pumpdrive coupling(I). 6. Turn by hand, checkfor rotationof pump. 7. Reinstall pump on eng'_neand test run, refer to Section37-11-04. 8. Make logbook entry. 37-30-02 - DRY AIR PUMP INSPECTION VACUUM PUMPS ARE A NON-REPAIRABLE UNIT. Remove malfunctioningpump and replace with new pump. VACUUM PUMPS MAY VARY, BUT SHEAR COUPLING WILL BE SIMILAR FOR MOST VACUUM PUMPS. SMX57-2 DRY AIR PUMP COUPLING INSPECTION 37-21-05 8 12-98 FIGURE 37-2 MOONEY"AIRCRAFT CORPORATION M20J NOTE After installation if regulator valve requires adjustment refer to Section 37-124)5. 37-40-00 3740-01 37-414)0 SERVICE AND MAINTENANCE MANUAL - OPERATIONAL PROCEDURES The OptionalStand-by Vacuum pump for the M20J is located in the tailcone. Its location is standard, but can vary slightlydependingon optionalequipmentinstalled on aircraft. - STAND BY VACUUM SYSTEM (OPTIONAL) -SERVICING Refer to manufacturersservice and maintenancedata forthe particularunitinstalled, If no specificmaintenanceinformationis availablefrom the manufacturerthefollowingis recummended: 1. Inspectto verify hoses and wires are clear of any obstructionor interferencawith other componentsthat may chafe hoses orwires, 2. Inspecthose clampson all fittingsto vedfytightand secure. 3. Every 100 hour/annual inspection - inspect set screws in motor/air pump coupling for tightness and security, 4. A dry air pump requires no maintenance between replacement. Replacement is recommended at 500 hoursoperatingtime. It is recommended that stand-by vacuumsystem operatingtime be documented. 5. It is recommended that if the Stand-by Vacuum System is not used regularly, that every g0 days (approximately)the Stand-by Vacuum System should be turned on, in flight, for 20 - 30 minutesto get the pump and drive motor warm enough to dry out any condensation that may have accumulated. The exhaust pert of the dry air pump is routed into the housing of the electric motor to assist in purging moistureand debd from the motorassembly. The Stand-bypumpisto be used only as needed when the main Vacuum pump malfunctions. The VAC annunciatorlight will illuminate (RED) either flashing (low vacuum) or steady (high vacuum) when this situation occurs. If annunciatorlight is flashing RED, push STEY VAC switch ON and annunciator light should extinguishas stand-by vacuum system takes over for all instrumentoperation.s, if annunciator is steady RED, monitor flight instruments with non-vacuumgauges and continuewith flight if feasible, or land and have vacuum sytem inspected and repaired. It is recommendedthat priorto aircraftengine start,the stand*byvacuum pumpbe tumed ON to verifythat the vacuum gauge (if equipped)indicatesnormal operating vacuum and that the gyms spin up and erect. When the engine starts the check valve closes and the stand-by vacuum pump system will not produce enough additional vacuum for any indicationon the gauge (if equipped)to be noticeable. 12-98 37-40-00 9 SERVICE AND MAINTENANCE MANUAL M20J BLAN K 37-41-00 10 12-98 MOONEY AIRCRAFT CORPORATION MOONEY AIRCRAFT CORPORATION M20J SERVICE AND MAINTANANCE MANUAL CHAPTER 39 ELECTRICAL PANELS AND COMPONENTS SERVICE AND MAINTANANCE MANUAL M20J MOONEY AIRCRAFT CORPORATION CHAPTER 39 ELECTRICAL PANELS AND COMPONENTS LIST OF EFFECTIVE PAGES CHAPTER SECTION SUBJECT ........... 39-Effectivity ......... 39-Contents.......... 39-00-00 ............ 39-10-02 ............ 39-11-00 ............ 39-11-01 ............ 39-11-02 ............ 39-12-00 ........... 39-12-04 ........... 39-21-00 ........... PAGE .......... DATE 1/2BLANK .......... 3/4BLANK .......... 5 ........... 6 ........... 7 ........... 8 ........... 9 ........... 10 ........... 11 ........... 12 ........... 12-98 12-98 12-98 12-98 12-98 12-98 12-98 12-98 12-98 12-98 12-98 39-EFFECTIVITY 1/2BLANK MOONEY AIRCRAFT CORPORATION M20J SERVICE AND MAINTANANCE MANUAL CHAPTER 39 ELECTRICAL PANELS AND COMPONENTS TABLE OF CONTENTS CHAPTER SECTION SUBJECT 39-00-00 39-10-00 39-10-01 39-10-02 39-10-03 39-11-00 39-11-01 ............. 39-11-02 39-11-03 39-12-00 39-12-01 39-12-02 39-12-03 39-12-04 39-20-00 39-21-00 39-21-01 ........... ........ ......... .......... .......... .......... ......... .......... .......... .......... ......... .......... .......... .......... .......... ......... ......... .......... SUBJECT ........ General .............. Instrument and Control Panels ....... Flight Instruments ......... Avionics Equipment......... Engine Instruments and Circuit Breakers . Flight Instrument Panel ......... Cluster Gauge .......... -Troubleshooting Guide ....... LandingGear Switch ........ Landing Gear Safety Override Switch .... Avionics/Radio Panel ......... Annunciator Panel ......... Emergency Locator Transmitter (ELT) Switch. Instrument and Radio Light Control Box . Cigar Lighter .......... Electrical/Electronic Equipment Rack ..... Miscellaneous Maintenance ....... Equipment Maintenance ....... 12-98 PAGE 5 5 5 6 6 6 8 8 9 9 10 10 10 10 11 11 12 12 39-CONTENTS 3/4BLANK SERVICE AND MAINTANANCE MANUAL M20J 39-00-00 - GENERAL The instrument panel is divided into three basic groupings: MOONEY AIRCRAFT CORPORATION located steel tubular structurethat will allow the radar indicatorto be installed, The panel illustrationdepicted in Figure 39-1 shows phantom lines for some installations. Model year improvements, technical improvements or vadous avionics installationsdictate which instrumentwill be installedin a givenlocation. See Section91 for ElectricalSystem Hardware Charts and Schematics. l. Flightlnstmments. 2. Avionics/RadioPanel. 3. Engine Instrumentsand CircuitBreaker Panel. The flight instrument panel is shock mounted. The radio/avionicspanel generally, has individual racks for the componentsand are ofthe quick removaltype. The engine instruments and circuit breaker panel are located in a quick removal panel which is slanted toward the pilot. The circuit breaker/switches for theare standard optionalaccessoriesand equipment locatedand/or at the bottom of the flight instrumentpanel on either side of the pilotscontrolcolumn, The clustergauge containingfuel quantity and engine operating gauges is located at the top of the flight instrumentpanel. The annunciatoris located at the top of the avionics panel. 39-10-00 - INSTRUMENT AND CONTROL PANELS 39-10-O1 - FLIGHT INSTRUMENTS 1. Glareshield/InstmmentRemoval: A. Remove the screws attachingthe glareshield and cover plate and carefullylilt glareshieldto expose the disconnectsfor the glareshield lights. Disconnect the wiresand littthe glareshieldoff. B. Disconnect the plumbing and/or electrical connectionsfromthe flightinstrumentsto be removed. The avionics panel has two configurations: Serial Numbers24-0001 thru 24-0900 has a tubular structure configurationthat will not accept the radar installation; Sedal Number24-0901 and ONaircratt have a re- C. Disconnectand remove anypostlights. D. Remove the mounting screws securing the instrumenttothe panel. E. Removethe instrument by slidingit att from the panel. @ _'V I('_)](_-J FLIGH_T INSTRUMENT _-) i PANEL //S/N t I) 24-0001 THRU 24-0900 _ _(SHOCK MOUNTED) I_-_" @ _ E3_l ATS ENGINE CIRCUIT INSTR. BKR. PANEL_, \ II FLIGHT INSTRUMENT I _'1 V _ lr,r-,,_l fT"-. fT'..... _ UUUll d W ,"--"- _ PANEL.. _ _ V _ _ h --''1 oooo ..... [AVUNIU. ( ....... I-'ANLL5 v loB[]a=o F/mmaaam0 onal He- S/N 24--0901 & ON TYPICAL INSTRUMENT AND CONTROL PANEL I OOOOO( _laooooc .11 12-98 PANEL DOG0( FIGURE 39-1 39-00-00 5 MOONEY AIRCRAFT CORPORATION M20J SERVICE AND MAINTANANCE MANUAL A. Place instrument into the proper location on panel. 2.,nste,,ation. I B. Insert and secure mounting screws to hold instrumentto panel. C. Connect the post lights. D. Connect all plumbing and/or electrical connections to the instrument; perform pitot/static leak check. /? /_/ C _ 1] E. Position the glareshield so electdeal connectionscan be madeand secured. F. Secure glareshieldand cover plate withscrews. 39-10-02 (SnNELATERMDDELS MAYHAVERIVETS IN THESELBCATInNS, THEYMUSTBE gRILLE]] nUT,& THENREPLACED,) -AVIONICS EQUIPMENT customized package to meet the requirements of the Each avionics harness, package any installed is basically a customer.Widng associated plumbing or mechanical mechanisms required for a particular avionics installation are well secured to prevent any interference with other components. Removal of these avionics components will require evaluation of each installation to determine the proper procedure or sequence to follow. 1. Removal. Most individual avionics components are mounted in slide out chassis racks. Loosen the screw on the face of the component and slide the unit straight aft to remove. Some components are not mounted in slide out chassis. Removal of these units will require the same sequence as removal of flight instruments in Section 39-10-01. CAUTION Radio panel must be stacked from the bottom to the top. 2. Installation. Install the repaired or new unit in reverse sequenceof removal. 39-10-03 -ENGINE INSTRUMENTS AND CIRCUIT BREAKERS The engine instruments and circuit breaker panel is an assemblythat can be pulled out as a unit for removal of any instrument or circuitbreaker, 1. Removal. A. Remove the glareshield per Section39-10-01. B. Remove two fiat head screws (B) on outside of the airplane (Fig. 39-2). These are located forward of the cabin door hinge and above the cabin air inlet scoopapproximately4 inchesbelow the windshield. C. Remove two screws from the face of the panel at the upper left corner (C)(Figure 39-2). D. Remove two screws (D) from underneath, near the edge of the panelface. 39-10-02 6 L Si IDE AFTF/JRREMBVA SMX39-£ ENGINE AND CIRCUIT BREAKER PANEL FIGURE39-2 E. Remove the NAS21919DG clamp (E) from the steel structure cross brace, underneath the panel, forward section, see (Figure 39-2). F. The panel should now be free to slide aft. approximately 4'5 inches. This will allow access to the plumbing and electrical connections. G. Remove the plumbing or the electrical connections from the instrument or component that will be removed. NOTE In some instances instruments, other than the one to be removed, must be removed or at least some wiring, or plumbing disconnected to gain access to the desired one. H. Remove thin lexan glass insulation strip if requiredwhen removingcomponents. I. Remove the Instrument by removing any post lights and mountingscrewswhich secure instrumentto the panel and pull forward. Remove the circuit breakers by unscrewing nut from stem on each circuit breaker and pushthe breaker throughthe panel. 2. Installation. A. Installationof new instrument or circuit breaker into the panel is accomplishedin reverse sequence of removal. B. Insert the lexan insulator sheet in proper locationto preventany shortcircuits. 39-11-00 - FLIGHT INSTRUMENT PANEL The flight instrument panel is a shock mounted panel containing vadous flight instruments for a particular installationgroup.These instrumentsvaryslightly 12-98 SERVICE AND MAINTANANCE MANUAL M20J MOONEY AIRCRAFT CORPORATION --MASTER SWITCH /-AL_RNATOR ,E_SWOON o o FtFTNoFI VIEW -LOOKING AT FWD SIDE OF PILOT'S PANEL (TYPICAL EXAMPLE OF LAYOUT - LOCATION OF IGNITION OPTIONAL SWITCHES MAY VARY WITH INDIVIDUAL swrrca AIRCRAFT INSTALLATIONS) VIEW -- LOOKING AT BACKSIDE OF PILOT'S PANEL. NOTE: LOCATION OF OPTIONAL SWITCHES MAY VARY WITH INDIVIDUAL AIRCRAFT INSTALLATIONS. LANDING PITOT TAXI SHOOK MOUNT SPARE NAVICATI REOOC" IJNLIGHTS_ :o..om.u::.Y" SPAREALTERNATE STATIC SOURCE VALVE I CIRCUIT BREAKER/SW]TCHES 12-98 SHOCK MOUNT SMX39--3 FIGURE 39-3 39-11-00 7 MOONEY AIRCRAFT CORPORATION M20J depending upon the avionics package installed. The panel containsa row of circuit breaker/switches,along with the master switch, which control most of the systemsofthe airplane. Referto Figure39-3). Access for maintenance of the switches or related widng is obtained by removing the two attachment screws and pushing the switch through the panel, There is a common bus bar on some of the switches that will require loosening or removal for switch replacement, CAUTION Care should be exercised when replacing wiring or switches to ensure proper alignment of terminal connections to prevent shorting between switches, SERVICE AND MAINTANANCE MANUAL 39-1t-01 -CLUSTER GAUGE The cluster gauge is located at the top of the flight panel. Access is obtainedby removingthe glareshield per section 39-10-01. Cluster gauges have the capabilityof individualmodulereplacement. One some configurationsthe entire cluster gauge will require removal from the panel to allow room to pull modules out. The nuts on terminal studs need to be removed so wire terminals can be pulled from studs to remove the modules from the cluster gauge chassis. Remove and replace the defective module. Some configurations have individually removeable gauges. Loosen screw in lower LH corner, remove gauge by pullingfrom pilot'sside of instrumentpanel. Replace by carefully pushinggaugein & securingscrew. LIGHT BULB ACCESS ®®®®®® ? JoJ MODULE TERMINAL STUDS ("f"fP) CONFIGURATION OF CLUSTER GAUGE WILL VARY BETWEEN MODEL YEAR AIRCRAFT. LOOSEN SCREW OF INDIVIDUAL GAUGE AND PULL GAUGE OUT. REPLACE GAUGE INTO CLUSTER, SECURE SCREW. CLUSTER GAUGE FIGURE 39-4 TROUBLE SHOOTING GUIDE FOR CLUSTERS PRESSURE INSTRUMENTS GAUGE CONDITION CHECK FOR THESE POSSIBILITIES Gauge reads full scalewith engineshut down. 39-11-01 8 Wire between sender and gauge disconnected or open. Faulty sender. Faulty gauge. 12-98 SERVICE AND MAINTANANCE MANUAL M20J Gauge reads zero when engine is running. MOONEY AIRCRAFT CORPORATION Wire between sender and gauge grounded. Faulty sender. Faulty gauge TEMPERATURE INSTRUMENTS Gaugereadsfullscalewithenginecoolorcold. Wire between sender and gauge grounded. Defectivegauge. Defectivesender. Gauge readszero when engine is hot. Wire between sender and gauge is open or disconnected. Defective,gauge Defectivesender. FUEL SYSTEM CHECK FOR THESE POSSIBILITIES GAUGE CONDITION Gauge indicates empty in the tank. Grounded wire between sender and gauge. Defective sender. Inoperative gauge. Open sender lead. Open sender (open resistance element). Sender not properly grounded to airframe. Gauge off calibration.Note: Some clusters are equipped with fuel gauges that have trim pots and may need re-calibration. On dual sender systems, the isolated sender may be grounded. The lead between the isolated sender and the grounded sender grounded. Either sender defective. Gauge off calibration. Gauge indicates past full when tank is less than full. Gauge indicates 1/2 when tank is full. 39-11-02 - LANDING GEAR SWITCH The landing gear switch is a two position switch located at the top right side of the flight instrument panel. The wheel shaped knob must be pulledaft pdor to raisingor loweringthe switchto activatethe landing gear actuator. KNURLED NUT FOR REMOVING",.__ SWLTCH -II I_ =_ _ _ / _ I_ Ikl(JL) ([_ __ - _ I, _ _ _ _ /LoG GEAR OVERRIDE SWITCH 39-11-03 . (SOME OVERRIDE X_/A_SWITCHESARE LOCATED ESIOE THE / _ L°G GF'ARsWITCH) _'LDG GEAR SELECTOR SWITCH VIEW-LOOKING ATBACK SIDEOFPILOT'S PANEL SMX3g-5 LDG GR SWITCH &LDG GR SAFETY OVERRIDE FIGURE 39-5 1. The glareshieldwill require removalto gain access to switch for maintenance action (refer to Section 39-10-01). 2. Remove the wire connectionsfrom the back of the landinggear switch,(Figure39-5), 3, Turn the wheel shaped knob counterclockwiseto removefrom stem. 4. Remove the nut and washer from the face of the switch and push switch through the panel. - LANDING GEAR SAFETY OVERRIDE SWITCH (SIN 24-0084, 24-0238 thru 24-TBA) Landing gear safety overdde switch is located to landing gear switch. Proper operation ofadjacent landing 65gear below+7/.4 safety KIAS. system will not allow gear to retract CAUTION Activation of the gear safety override switch while the the aircraft is on the to ground may cause landing gear retract. 1. The landing gear switch or cluster gauge will require removal to gain access for the removal of the overrideswitch. 2. Disconnect wire connectors; approximately 6 inches from the switch, by cutting with wire cutters or opening the knife disconnects. 12-98 39-11-02 9 MOONEY AIRCRAFT CORPORATION M20J 3. Loosen the nut on the stem and hold the nut located inside the mounting bracket. The red lens may need to be removed to fully remove the switch from the panel and bracket. 4. The light bulb (GE 330) can be replaced a_er the glareshield is removed by bending a nail or similar rod (approximately 3/32" diameter) and pushing the red lens off to the front of the panel. Use a small vacuum tube puller or soft nosed instrument to pull the bulb from the socket. 39-12-00 - AVIONICS/RADIO PANEL The avionics/radiopanel containsequipment installed per sales order by Mooney Aircraft and other equipment installed by other sources as the owner desires.The maintenanceinformationcontained in this Service and Maintenance Manual describes the Mooneyfactory installationonly. The avionics/radio components are removed installed acoordingtoSection39-10-02,1 and2, 39-12-01 - ANNUNCIATOR PANEL and The annunciator panel is located at the top of the center-mostavionics/radio panel and is not mounted witha slidein type chassis. Remove this component by removing the two screws holding cover plate in position.Remove the glareshield and disconnect the electricalhamess from back side of the unit. Remove the screws holding unit in place on the panel and removefromthe back side of the panel, SERVICE AND MAINTANANCE MANUAL A. To gain access to the remote switch and widng the glareshield will require removal (refer to section 39-10-01). B. Remove the switch retainilig nut and washer and push switch through face of panel. Disconnect wires, remove and replace defective switch. C. Reconnect wires and test switch for proper operation. D. Reinstall glareshield. NOTE Other switches located in the ELT placard area of avionics panel can be removed and replaced in similarmanner. 39-12-03 -INSTRUMENT AND RADIO LIGHT CONTROL BOX The control box for the instrument, radio and glareshield lights consists of two vadable rheostat switches, two transistors, two fuses and miscellaneous wiring contained in a metal box assembly. The transistors installed in M2OJ aircraft, prior to 24-1214, are P/N 2N2016 and are no longer being manufactured. Check appropriate schematics for proper wiring. LOW FUEL WARNING CIRCUIT CALIBRATION. Refer to Section 24-33-00 paragraph 4. 39-12-02 - EMERGENCY LOCATER TRANSMITTER (ELT) SWITCH The remote ELT switch is located at the top of the avionics panel. The ELT is located in the tailcone and is accessible by removing the radio access panel on the leRside of the aircraft fuselage. The ELT antenna is located on top of the tailcone underneath the fiberglass dorsal fin. The unit has a three position switch "ON", "OFF" and "ARM". The correct position of this switch is "ARM". The remote switch is connected in parallel to the ELT circuit and will operate correctly either in the "ARM" mode or the "ON" mode. Normal operation is in the =ARM" position. Place the remote switch in the "ON" position and tune the communication radio to 121.5 to switch verify back that to a warbling tone is heard. Place the Mhz remote =ARM"positionfor normal operation. CAUTION Testing of ELT should be conducted only during the first five (5) minutes after any hour and no longer than three (3) audible sweeps, "m._NS RHEOSTATS (S//N 24--3201, 24-3218 & ON HAVE THE TRANSISTERSLOCATED THE LWR BAGGAGE COMPARTMENT INTHETAILCONE. .FUSES view- LOOKING INTOCONTROL BOX (UNDER CAP) (COVERREMOVED) 1. If the warbling tone is not heard, replacement of the ELT battery or the unit may be necessary. Follow ELT manufactures instructionsfor battery replacement. 2. If ELT unit is found to be operating properly and the system still will not work correctly through the remoteELT switch, repair or replacementof the switch or wiringwillbe required. 39-12-00 12-98 10 INSTRUMENT & RADIO LIGHT CONTROL BOX FIGURE 39-6 (SIN 24-1214 THRU 24-TBA) SERVICE AND MAINTANANCE MANUAL f /' M20J The replacement transistors are included in a spares modification kit, PiN 919003-907, which includes a transistor,resistor,and instruction sheet describing the modification kit will modify one circuit only,two kitsprocedures. are requiredThe for both circuits. M20J aircraft, SIN 24-1214 thru 24-2999, have a different light control assembly (12V)using a different transistor and circuitry. (See Figure 39-6). NOTE A retrofit kit is available to use the latest light control assemblyonany12Vaircraff (940013-#,11Kit). 39-12-04 - CIGAR LIGHTER The cigar lighter is located at the bottom of the radio panel immediatelyto the dght of the co-pilotscontrol column shaft. It is a standard cigar lighter similar to automotivetype. MOONEY AIRCRAFT CORPORATION 39-20-00 - ELEOTRICAUELECTRONIC EQUIPMENT RACK The electrical equipment rack for the M20 series aircratt is located in the tailcene just aft of the baggage compartment bulkhead. Access is gained through the large access door in the tailcone aft of the left wing trailing edge. The battery and battery box, auxiliary power plug receptacle (if installed), ELT and the various avionics black boxes are mounted on the electrical equipment rack (See Figure 39-7), (12V NC only). 24V A/C have the ELT mounted on an accessory rack further aft in the tailcone. Access is gained through a panel aft of avionics bay access panel. The ELT antenna is [ocated under the dorsal fin. (FIGURE 39-7 REPRESENTS 12 VOLT AIRCRAFT ONLY) ELECTRICAL/ELECTRONICS EQUIPMENT RACK 12-98 FIGURE 39-7 39-12-04 11 MOONEY AIRCRAFT CORPORATION 39-21.00 - MISCELLANEOUS MAINTENANCE 39-21-01 - EQUIPMENT MAINTENANCE M20J Refer to SECTION 27-42-00 for Electric Pitch Trim system Maintenance. 39-21-00 12 12-98 SERVICE AND MAINTANANCE MANUAL MOONEY AIRCRAFT CORPORATION M20J CHAPTER 51 STRUCTURES SERVICE AND MAINTENANCE MANUAL SERVICE AND MAINTENANCE MANUAL M20J MOONEY AIRCRAFT CORPORATION CHAPTER 51 STRUCTURES LIST OF EFFECTIVE PAGES CHAPTER SECTION SUBJECT• 51-Effectivity ......... 51-Contents ........ 51-00-00. 51-10-01 . 51-11-00. ........... 51-12-01 ............ 51-12-01 ............ 51-12-02 ........... 51-12-04 ........... 51-13-02 ........... 51-13-03 51-13-03 ........... 51-13-04 51-13-07 51-14-00 ........... 51-14-03 • , • 51-15-01 51-15-02 ........... 51-15-04 ........... 51-15-05 ........... PAGE DATE 1/2BLANK .......... 3/4BLANK .......... 5 6 7 ........... 8 ........... ........... 9 10 ........... 11 ........... 12 ........... 13 14 ........... 15 16 17 ........... ..... • . • 18 19 20 ........... 21 ........... 22 ........... .... 12-98 • • • ° • • • 12-98 12-98 12-98 12-98 12-98 12-98 12-98 12-98 12-98 12-98 12-98 12-98 12-98 12-98 12-98 12-98 12-98 12-98 12-98 12-98 51-EFFECTIVITY 1/2BLANK MOONEY AIRCRAFT CORPORATION M20J SERVICE AND MAINTENANCE MANUAL CHAPTER 51 STRUCTURES TABLE OF CONTENTS CHAPTER SECTION SUBJECT .......... 51-00-00 ........ 51-10-00 ......... 51-10-01 .......... 51-11-00 .......... 51-12-00 .......... 51-12-01 ............ 51-12-02 ............ 51-12-03 ............ 51-12-04 ............ 51-13-00 .......... 51-13-01 ............ 51-13-02 ............ 51-13-03 ............ 51-13-04 ............ 51-13-05 ............ 51-13-06 ............ 51-13-07 ............ 51-14-00 .......... 51-14-01 ............ 51-14-02 ............ 51-14-03 ............ 51-14-04 ............ 51-15-00 .......... 51-15-01 ............ 51-15-02 ............ 51-15-03 ......... .............. 51-15-04 ............ 51-15-05 ............ 51-16-00 .......... DESCRIPTION ........ PAGE General ............ Structural Repair- General ...... Fastener Replacement ........ Reserved ........ Fuselage Repair ......... Tubular Structure Repair , Taileone Repairs ........ LandingGear & Retraction System Repair . Flight Control System Repair..... Wing Repair .......... 8tdnger Repair ........ Main Spar Repair........ Stub Spar Repair ........ Rear Spar Repair ........ Rib Repair ......... Wing Tip Repair ........ Wing Skin Panel Repair ...... Horizontal Stabilizer & Vertical Fin Repair. Leading Edge Skin Repair ..... Main spar Repair Outboard of STA. 9.00 Rib Repair ......... Remating Horizontal Stabilizer to Stinger Fiberglass Laminates,Repair Procedures . . Cracks, In Surface Areas ...... Non-Structural Repair ...... Common Structural Laminate Repair (Metal Insert) ........ Common Structural Laminate Repair Fiberglass DelaminationRepair .... Miscellaneous .......... 12-98 5 5 5 7 7 7 10 10 11 11 11 11 13 15 15 15 15 17 17 17 18 18 18 19 20 20 21 22 22 51-CONTENTS 3/4BLANK SERVICE AND MAINTENANCE MANUAL M20J MOONEY AIRCRAFT CORPORATION 51-00-00 - GENERAL The Mooney M20J is an all metal, low wing airplane, The fuselage cabin area is constructedof a welded 4130 chreme-melybdenumsteel tubular structure.The steel tubular struutum is covered with non-structural aluminumskins fastened to the tubular structure by rivets,boltsand screws, The tailcone is of semi-monocoque type construction and is fastened to the tubular structurewith structural bolts, at the leadingedge and dvetedtogether at the trailing edge. Belly skins are connectedto fuselage bulkheads (SIN 24-0001 thin 24-1417) and are removablefor access to various componentsand controls located between thefirewalland the rear spar. These skinscontributeto the strengthof the aimmft and secodty of each panel is mandatory.AircraftS/N 24-1418 and later have a one piece composite bellyskin that coversthe undersideof the aircraftfromthe exhaustcavityaftto the tailcone. The wing is a tapered laminarflow one piece wing. It is constructedwith a one piece, full lengthmain spar. The spar is constructed from tapered cap strips(7075 aluminum) bolted (huck bolts) to webs (2024 aluminum).Aluminumribsconnectthe mainspar to the aft stub spar and the rear spar. Extrudedstringers run the full length of the wing, spaced chordwise for strengthand skin reinforcement. The skins are sketch formed, wrap around, 2024-T3 aluminum ranging in thicknessfrom .025 at the tipto .050 at the fuel tanks, The front seats are installed on rails which are attached to the floorboardand structure beneath the floorboard.The rear seat 2 place, is builtinto the top of the w ng center sectionfrom the main spar aft to the rear spar. Aimrsft SIN 24-0001 thru 24-1213 containa bench type seat with a one piece non-recliningback rest. S/N24-1214 and ON contain a split type seat, usingseat cushions in molded wells over the wing spars and individuallyrecliningrearseat backs. TIl.ecompletedwing assemblyis mated to the fuselage tuoular structure duringfinal assembly at the Mooney facility. Removal of the wing from the fuselage structure is required for most over land type transportation. 51-10-00 The empennage is of similarconstructionto the wing. A main spar spans the length of the stabilizer. Ribs connect the main spar to the stub and rear spar. A stretchformed skin wraps aroundthe leadingedge ribs and attachesto the rear spar top and bottom.skins The elevators are constructed of on formed aluminum fastened to a spar extrusionat the leadingedge and dvetadtogetherat the trailingedge. The vertical stabilizer is constructed around a fabdcatad mainspar assemblywith ribs connectingthe main and rear spar. A stretch formed, aluminumskin wraps around the leading edge ribs and is riveted to the rear spar on both sides. The rudder is constructed of formed aluminumskins fastenedto a spar extrusion - STRUCTURAL REPAIR - GENERAL This section outlines structural repair procadures for the M20J airplane. It is intended to supplementFAA Advisory AC 43.13-1( * ) by showing repair methods specificto MooneyAirplanes. (* = currentrevision) All structural repair must be: in compliance with AC 43.13-1( * ), unlessspecificMooney factoryrepairs are recommended, or with the specific approval of a Federal AviationAdministrationrepresentativewhich is the final authority in all repairs. This manual is for general guidance and Support has no Department, authorized approval status. The Customer Mooney Aircraft Corporation,Kerrville,Texas, (830) 792-1904 (830) 896-6000 (switchboard),should be consultedfoi" special repair procedures when repair of damaged structureis notcovered by publishedinstructions. 51-16-01 - FASTENER REPLACEMENT 1. HUCKBOLT INSTALLATION. The Huck LockboRis an interference fit fastener used in a dgid joint structure.A looseor slip fit Huckboft is unacceptable. The recommendedlimitsfor Huckboltholesare: HUCK FASTNER PRE-DRILLED SIZE DRILL SIZE HOLE LIMITS 2LPH-T5 ALPPH-T6 R3001-T6 2LA426H-T5 R3007-T6 No. 26 (.147 IN.) No. 18 (.1695 IN) No. 18 (.1695 IN) No. 26 (.147 IN.) 3/16 (.187 IN.) No. 20 (.161 IN.) No. 13 (.185 IN.) No. 13 (.185) No. 20 (.161 iN.) No. 7 (201 IN) .161 TO .1635 IN .185 TO .187 IN. .185 TO .187 IN. .161TO .1635IN. .2005TO .2025IN H-ilok fastners may be substitited for Huck fastners of same diameter and grip. A. When the Huckbolt is enlarged beyondthe above limits but is straight and round, the hole may be considered acceptable, provided that the Huckboft cannot be pressed into the hole, with normal hand pressure, to a depth thanCheck 50 percent of hole the heaviest matadal beingmore secured. enlarged size at beth ends. Select-fit Huckboitsto the oversize holes. B. Oversize Huckbolt holes may be repaired by replacing 2LPH-T5 Huckboits with ALPPH-T6 Huckboltsor NAS 623-2 screws and NAS 1021 No. 8 Hex-lock nuts (or equivalent), provided the pitch distance is greater than .56 inches and the edge distance is greater than .33 inches. Huckbolis ALPPH-T6 and R3001-T6 may be replaced with R3007-T6 Huckbolts as necessary. Consult the Customer Support Department, Mooney Aircraft uorporetion, Kenville, Texas, (830) 896-6000 for factory recommendations when the preceding instructionsare inadequateto accomplishthe repair. 12-98 51-00-00 5 MOONEY AIRCRAFT CORPORATION M20J To compensate for material thickness tolerances Huckboltlengthmay be ncreased by one dash number from the prescribed length.When a Huckboltpin of the proper length is not available use a pin of the next longer length. To adjust the grip length, install a cadmium-plated steel washer .065 inch thick (or a combinationof not more than two washers .065 inch and .032 inchthick) underthe Huckboit collar. SERVICE AND MAINTENANCE MANUAL The combinedthickness of any two washers shall not exceed .098 inch. Huckboltsor conical KeystoneLock blind rivet heads may be cocked no more than .004 inch. Not more than 20 percentofthe fasteners in any pat-tern, nor more than three fasteners in succession, may be cocked. NOTE Where access is limited orfor replacement/repair the following substitution is permissible. 2. RIVET REMOVAL AND REPLACEMENT. HUCKBOLT PIN SUBSTITUTE P/N (VENDOR) DESCRIPTION NAS1465 or R3001-T5 HL2O-5PIN (HI-LOCK) HL86-5 COLLAR PIN-PROTRUDING TENSION 160 KSI Ftu NAS1466 or R3001-T6 HL2O-6PIN (HI-LOCK) HL86-6 COLLAR PIN-PROTRUDING TENSION 160 KSI Flu NAS1475 or R3014-T5 HL19-5 PIN (HI-LOCK) HL94-5 COLLAR PIN-100 D. FLUSH SHEAR- 95 KSI Fsu NAS1476 or R3014-T6 HL19-6 PIN (HI-LOCK) HL94-6 COLLAR PIN-100 D. FLUSH SHEAR- 95 KSI Fsu [PART NUMBER CODE] Hr0 / " r / " P Gdp in 1/16the" (8/16 = .500)MAX Nominal Dia. in 1/32nds" (5/32 = .156) Pin Part Number A. REPLACEMENT-STANDARD SIZE RIVETS, HOLE OVERSIZE. This repair applies only to odginal aluminum alloy, steel, or monel rivets of 1/16, 3/32, 1/8, and 5/32 inch diameters. Such rivets may be replaced as noted and limited below and in the General Limitations,when the hole only is oversize, (1) Protruding Headthe Joint. If the edge distance is a minimum of two times diameter of the original dvet, it will be permissible to drill for and install the next standard size larger diameter rivet of the same type and material as the odginal rivet. 3/32 1/8 5/32 (2) Machine Countersink Joint, Method I. If the edge distance is a minimum of two times the diameter of the next standard size larger diameter dvet and the sheet thickness involved are within the limits specified for machine countersinking for the next standard size larger diameter dvet, it will be permissible to drill and countersink for and install the next size dvet of the same type and matedal as the original rivet. The following are limits for machine countersinking: .025 .032 .040 (3) Machine Countersink Joint, Method II. If the standard size larger diameter rivet of the same type edge distance is a minimum of two times the diameter and matedal as the odginal rivet. Do not redimple. Alter of the original rivet, it will be permissible to dd]l for and installation, mill the excess head height flush with the install the next standard size larger diameter rivet of surface. This method is subject to the same limitations the same type and material as the original rivet. Do not as paragraph 2, A (3). remachine the countersink. A_er installation, mill the B. REPLACEMENT-STANDARD SIZE RIVETS, excess head height flush with the surface. HOLE AND COUNTERSINK OR DIMPLE OVERSIZE. (4) Dimpled Joint. If the edge distance is a This repair applies only to original countersunk head minimum oftwo times the diameter of the original rivet, aluminum alloy dvets of 1/16, 3/32, 1/8, and 5/32 inch it will be permissible to drill for and install the next diameters. Such dvets may be replaced (as noted and 51-10-01 12-98 6 SERVICE AND MAINTENANCE MANUAL ..... M20J limitedbelow)when the hole and countersinkor dimple is oversize, (1) Machine Countersink Joint. If the edge distanceis a minimumof two timesthe diameterof the next standard size larger diameter dvet and the countersinkdepth is not beyond the thicknessof the countersunk sheet, it will be permissibleto rework accordingto paragraph2, A (3). (2) Dimpled Joint. If the edge distance is a minimumof two timesthe diameterof the next standard size diameterdvetand allthe pads are dimpled,it willbe permissibleto rework the smaller dimplesto a size to matchthe oversizedimpleand installDimples in 75S-T6 mustbe hotformedwhen mworked, (3) Combined Countersink and Dimpled JoinL If the edge distance is a minimum of two times the diameter of the next standard size larger diameter dvet, it will be permissible to rework the smaller countersinkor dimple to a size t;omatch the oversize MOONEY AIRCRAFT CORPORATION dimpleor countersinkand installthe next standardsize larger dvet accordingto paragraph2, A (4). Dimples in 756-T6 mustbe hot formed when reworked. C. RIVET HEAD TOLERANCE. (1) A dvet head will be consideredopen if .001 feeler gauge can be inserted betweenthe head of the flush or protrudinghead dvet end the top skin. The top of a flush head rivet must not be below the skin in whichit is installedby a dimensionof morethan .OO4. D. RIVET HOLE TOLERANCE. (1) An enlarged hole is defined as having an internal diametric dimension in any direction which exceeds the sum of the ddll diameter normally used plusten percentofthe diameterof the dvet shank. (2) The followingtable specifies the maximum acceptable diametricdimensionsfor the vadous dvst sizes that occurin multiplelayer assemblieswhichare "ddlledon assembly=. DIMENSION AN470AD3 orAN426AD3 #40 (.095 dia.) .105 IN. AN470AD4 or AN426AD4 #30 (.1285 die.) .141 IN. I RIVET SIZE NOMINAL DRILL SIZE (3) When a hole becomes enlarged beyond the acceptable diametric limit and the prescribed rivet cannot be used, the next larger diameter rivet may be used if (a) four-diameter (4£)) dvet spacing is maintainedand if (b) two-diameter (2D) edge distance is maintained, 3. BLIND RIVET INSTALLATION. Ordinadly,where dvet bur,king is impossible,ChenyLock (CR-2248 and CR-2249) dvets may be substituted for AD rivets to repair skins and structuralmembers. However, consult the Customer Support Department or a representative of the Federal Aviation Administration before using blind-typeor hollowdvetsin primarystructure. CAUTION The use of blind dvets normally require morefrequent inspection of the area where used. Inspect for evidence of loosening of the rivet(s) or crack developmentthat may cause detedodationof structural integrity. Solid rivet replacement of blind dvets is recommended at eadiast possiblemaintenance. Check existing rivet hole size before installing blind rivets. When hole is marginal, use the next larger size dvet to assurefirm attachmenL 4. AN- BOLT, NUT AND WASHER INSTALLATION. To compensate for matedal thickness tolerances,the lengthof AN bolts may be increased or decreased by one dash numberfrom prescribedlength.AN960 regular washers and AN960L thin washers may be used interchangeabty for properbo|tand nutinstallafion. One regularwasheror one thinwasher may be added to any boltinstallation.Washers may be usedunderthe bolt head and/orunderthe nut.AN365 and AN363 nutsmay be used interchangeably.The AN363 nut is acoeptabie for higheroperatingtemperatureinstallations. 5. HI-SHEAR RIVET INSTALLATION. When a hi-sbear rivet pin of the prescribed length is not AX. ACCEPTABLE DIAMETRIC available,the next longer lengthpin may be used with cadmium-platedsteel washers to adjust the pin grip length. The combined washer thickness shall not exceed .096inch. 6. MS 20470-AD4 of MS20426-AD4 dyers may replace spotwelds,(1) per spot, head side & double flush requirementsdeterminedby form, fit& functionof assemblyunlessaltematefasteners are specified. 51-11-00 -RESERVED 51-12-00 -FUSELAGE REPAIR 51-t2-01 - TUBULAR STRUCTURE REPAIR Check tubular structure annually for corrosion and damage. Intedor panels may require removal to gain accosstoaraaswhicharedifferenttoinspect. Refer to AC 43.13-1(*) ( *= current revision letter of AC43.t3-t) for ALL tubular frame repair procedures. Warped or bent tube memberscan often be straightened;however,all surroundingweldsshould be dye checkedfor cracksalter tube straightening. Use proper material when making weld repairs. Welding rod meeting the requirementof specification MIL-R-5632, class2, is recommendedfor oxyacetylene welding. Electrodes meeting the requirement of specificationMIL-F-5632-A, class2, (MIL-E-23765/1C, (Type MIL-70S-2)or AWS A5.18-69, class E705-2 0Jnde 85, Linde CMS-32 or Page AS-35) are recommended for non-heated area, inert-gas shielded-arcwelding (Hellarc),Use AIS14130 condition N steel for replacement and repair of tubes, and for makingrepairsleeves. Replacing a member or subassembly is often advantageousand more feasiblethan repair. Alldetail 12-98 51-11-00 7 MOONEY AIRCRAFT CORPORATION M20J tubes or assemblies needed for replacement can be purchased from Service Parts Department, Mooney Aircraft Corporation, Louis Schdener Field, Kerrville, Texas, 78028, tele. (830) 792-2092. SERVICE AND MAINTENANCE MANUAL A. Make a 30-degree cut to remove the damaged portion of the tube; then, remove the burr from the remaining end. B. Cut a replacement tube of the same material (AISI 4130 steel, condition N), same diameter and the same wall thickness as the original tube. C. Select a tube with an outer diameter equal to the inner diameter of the tube to be repaired and with the same wall thickness. D. Cut tube to a length five times the outer diameter of the tube to be spliced. E. Installinnersleeve in tubeto be repairedso that its outer end is one and one-half of the original tube diameter from the nearest end of the diagonal cut; secure in positionwith a rosetteweld on each side at one-half the odginal tube diameter from the inner-sleeve end. F. Install replacement tube over the inner sleeve allowing a 1/8 inch gap for welding between the original and replacement tubes. 1. WELDED PATCH REPAIR OF LOCAL DAMAGE. Use a welded patch to repair dents, small holes, and cracks no longer than the outside diameter of the tube and covering a maximum of 1/4 of the tube circum-erence. Drill out the crack, smooth the hole edges, weld the hole or dent, and file the repaired surfacesmooth. Form a patchthat will cover twice the diameter of the tube aroundthe edge ofthe damaged area and twice the circumferential area of damage as shown in (Figure 51-1). Weld patchin place, 2. INNER SLEEVE SPLICING. Use an inner sleeve spliceto partiallyreplace a tube without increasingthe outside diameter (see Figure 51-2). LIF NOT GREATER THAN "A"(DIAH.OF TUBE)) DANA WELDED PATCH-LOCAL DAMAGE REPAIR FIGURE 51-1 o. A innerstubs sleeve to the tube through the 1/8 inch gap, U2A ............... ="=-_ _:_""-----O-"=-i - ,TL. I nRI_NAL EPAIR TUBE TUBE/ INS;mE ='_ /ZL-A RnsErTE VEL_ "_ forming anoveda d bead across the gap \ wel replacement ____ ]/2A _r.].rr._.T_ ........... TL_E RDSE'-rTE WEL_ C REPAIR TUBE INS._E _A IIEA ---_ " LEAVE 1/8 IN, GAP _ = : _5A I/2A - INNER SLEEVE SPLICING - FIGURE 51-2 51-12-01 8 12-98 VELBING 2 to the in the Rosette tube inner t_NO or sleeve more SERVICE AND MAINTENANCE MANUAL WELD HERE M20J MOONEY AIRCRAFT CORPORATION FIRST--_ , I/2A FIR WELI]ING j-1/2A !2-1/2A,I SPLIT-SLEEVE SPLICE , 3. SPLIT-SLEEVE SPLICING. Use the split-sleeve splice to repair a damaged tube when the parts on each side of the damage cannot be separated to insert an inner sleeve (see Figure 51-3). A. Form the split sleeve from steel tube or sheet steel when outside diameter of odginal tube is less than one inch. B. Form the split sleeve from sheet steel when outside diameter of the original tube is one inch or more. C. Form the split sleeve from the same rnatedal (AISI 4130 steel, condition N) with at least the same gauge as the odginal tube. D. Allow a 1/8 inch gap between sleeve halves for welding. E. Weld parallel edges of sleeve to original tube through 1/8 inch gaps. F. Weld center of each sleeve half to odginal tube with two rosette welds spaced one original tube diameter apart, 4. TENSION FI-FFINGREPLACEMENT (see Figure 51-4). A. Cut A and B tubes loose from tension F_ing 340034-7,-8 at welds, B. Cut C tube at a 30 degree angle seven inches from bottom of tension fitting. C. Cut a replacement C tube at a 30 degree angle and at an appmpdate length to position the tension fitting. Weld tension fitting in proper position. D. Drill four 1/4 inch holes for rosette welds 1.9 inches from center of 30 degree cut. E. Make an inner sleeve five inches long from 4130 steel tube, condition N, with outside diameter to match inside diameter of tube (3 and with a .085 inch wall thickness. F. Insert the inner sleeve in C tube and weld in place as shown (Figure 51-4). 5. REPAIRS FOR WELDED ASSEMBLIES General. This section does not apply to any control system tubing or assemblies, engine mounts or heat treated steel components (except as stated below). A. Small holes up to a #20 ddil may be closed by welding with the inert gas shielded arc method. B. Nicks and ddll marks that are no longer than 1/8" and do not exceed four percent of walt thickness in depth after cleanup may be smoothed out and repdmed. Nicks, holes, and cracks that will clean up with a #20 drill may be drilled and repaired per item A. .125IN,_/EL]]GAP ",.... FIGURE 51-3 TUBE == = TUllE7 I INSIDE-J!= _l TENSIONFITTING TENSION FITTING REPLACEMENT - FIGURE 51-4 12-98 51-12-01 9 MOONEY AIRCRAFT CORPORATION M20J C. The repair of weld beads on best-treated assemblies may be accomplished without reheat treatmentwithinthe followinglimits, (1) The repair bead will not exceed .375 in length or 113of total lengthof weld, whichever is the lesser, (2) Onlyone repair perweld bead is allowed. 6. REPAIR OF SPOT WELDS. Failed spot welds' on aluminum may be repaired by installing an AD470`4 rivetthroughtheweld ifthe damaged area willclean up witha #30 drill, 7. DENTS. Smell dents which do not exceed five percentof the diameterof the tube in depthand are no longerthan one-halfthe tubediameter are acceptable. 81-12-02 -TAILCONE REPAIRS 1. LONGERON SPLICING. Use procedure outlined in current AC 43.13-1(*) (*=current revision) for repairingand splicingtailcone Iongerons.(Figure 51-5) shows acceptable methods for splicing Iongerens. ConsultAC 43.13-1(*), figures2.28, 2.29 and 2.30 for fastenerrequirements. 2. TAILCONE STRUCTURAL SKIN REPAIR. Repair minor tailcone skin damage as shown in current AC . : • iooI SERVICE AND MAINTENANCE MANUAL 43 13-1(*), I=igum2.24. The dvet pattern for stressed skin repaim shall be the same as the rivet pattern in the skin joint immediately forward of the damaged area. Replace severely damaged structural skin panels. Install new skin panels to exactly match the originalskininstallation. 3. NON STRUCTURAL SKIN REPAIR. The skin covedngthe M20J aircraft tubular fuselage structureis considerednonstmctural.Patches in nonstructuralskin are not restricted as to size or shape; however, appearance and possiblevibrationdamage should be considered.Either a flush patch, a plate patch, or a plugpatch may be used. 51-12-03 - LANDING GEAR & RETRACTION SYSTEM REPAIR Replace any damaged landing gear or retraction systemcomponentwith a new part. Repairing landing gear or retraction system components is not recommended.After installingnew components,check gear and retraction system rigging as outlined in Section 32-20-02. Before retuming the aircraft to service performa retractiontest and operationalcheck of the landinggear and retracton system per Section 32-30-01. 7.. oooooo', "-1 ',072 "-_ "-,07;= . o o o o io o M51-5 LONGERON SPLICING - FIGURE 51-5 51-12-02 10 12-98 SERVICE AND MAINTENANCE MANUAL M20J MOONEY AIRCRAFT CORPORATION 51-12-04 - FLIGHT CONTROL SYSTEM REPAIR Replace any damaged pdmary control system componentwith a new part. Repairingprimarycontrol system components is not recommended. Use only new hardware when installing new parts. Alter installationof new parts, check control system travel and dggingas outlinedin Chapter 27. Before returning the aircraftto service,flight test the aircraft for proper controlsystemrigging.... 51-13-02 - MAIN SPAR REPAIR The spar caps inboardof STA 103 are made of 7075 high-strengthmaterial.Replacement of the spar cap is preferable to repair. However, if a spar cap repair is thoughtnecessary,an exactdescriptionof the damage showing location and extent should be sent to the Customer Service Department, Mooney Aircraft Corporation,to obtainfactory recommendationsprior to beginningthe repair. 51-13-00 -WING REPAIR S1-13-01 - STRINGER REPAIR 1. SPAR CAP REPLACEMENT. To replace a spar cap, remove the skin covedngthe area to be repaired. Before removing a laq]e area of wing sldn, attach temporaryjigsor holdingfixturesto the wingto prevent wing warpage. When attachinga new spar cap, assure proper interferencEfitof the replacedhuckbolts. Stringer splicing may require drilling new holes and adding rivets between existing rivets to obtain the requiredtotal number of rivets. Add extra dvsts where the distance between existing dvets is the greatest. The p_ch and edge dLstance must conform to AC 43.13-1(*) (*=current revision) requirements (see Figure 51-6). I 06E 0;E LL) ,050 91HENS;IRNSEF EXISTING STRINGERS ._ II I,,of--1 7 I _L..l_ ,0BE Hag SERIES, aO24-T4 H_ SERIESI 20t4-T6 8,0 o^ ¢,u o\o:,* oe ,FUCE .,,E,.,L. a014-T6 SMH51-6 CF _ (6 PER SIgE) STRINGER REPAIR - FIGURE51-6 12-98 _ _.16_! 51-12-04 11 MOONEY AIRCRAFT CORPORATION M20J Dudng Installation of the new spar cap all holes damaged drilling or reaming be reamed toby themproper hole size recommended forshould oversize huckbolt installation. When installing oversize huckbolts, consult the Huck Fastener Standards Manual for proper tolerances. Use proper length huckbolts.If the bolt is too long, the collar will not swage properly;if the bolt is too short, the shank will notcompletelyfill the hole. Repairscratcheson spar caps that are not deeper than .003 inch by sanding with No. 400 abrasive paper, Remove no more than .005 inch of material. Inspect the sandedarea; use dye penetrantto be sure that the scratch is completelyremoved. Clean and prime area where the protectivecoatinghas been removed. SERVICE AND MAINTENANCE MANUAL 2. SPAR CAP REPAIR. Spar cops outboardof 8TA 103 consist of sheet metal angles backed up with aluminumextrusionsfrom STA 103 to near STA 150. Replace or repair damaged extrusions.Do not allow sphces in a repaired extrusion to coincide with a spar-web splice when avoidable. Splice sheet-metal angles with an extrusion of equal area, picking up existing fasteners. Add extra fasteners to bdng the minimum number of fasteners to six AD-5 rivets per side in the vertical flange, and nine AD-4 (or six AD-5) rivets per side in the horizontal flange. (See Figure -_1-7). RIVET CODE FOR STRUCTURAL REPAIRS 4 -_ 5 MS20470AD4-XX MS20470AD5-XX _' 4 MS2046AD4-XX BP 5 CR518-XX MS2046AD5-XX SPLICEANGLE NATERIALI7075-T6 ._CF_ (4 MIN,EACH SIDE) _ ;5 o5e I L_ •7 F •130 __3 ALPPH-TP (4 HIN,EACH SIDE) VIEV LOOKING UP I VIE'_ LOOKINGI)nVN SPAR CAP REPAIR - FIGURE 51-7 51-13-02 12 12-98 SMM51-7 SERVICE AND MAINTENANCE MANUAL ! M20J 3. SPAR WEB REPAIR. Repair all damage to Spar webs in accordance with AC 43.13-1(*). If there is extensivedamage to a web that cannot be repairedas outlined in AC 43.13-1(*) (*=current revision),location consult the CustomerService Departmentgivingexact and extent of damage. 2. Smooth all roughor sharp edges, and pdme area to be spliced. 3. Locate new outboardsectionand trim spliceto witha maximumgap of .020 inch. 4. Fabdcate -501 angles to pick up 30 existing fastener holes (30 recommended, but 22 minimum), -503 angles to pick up 15 existing fastener holes (12 minimum), and -505 plate and -507 spacer. (See Figure 51-8). Pdme angles, plate, and spacer. Rivet partstogetherusingwet pdmeron all rivets. 51-13-03 -STUB SPAR REPAIR (Stubspar spliceat wing STA 34.5 +/- 3.0) (See Figure 51-8). 1. Cut the stub spar halfway between existing rivets as required by the damage incurred. \-r_ 1 Iq-- 98 = --501 FLAT PATrlERN(.091 NSI C 130, ( P_m (_1 _ _ lll./-+' 20.O _ ..( ( MOONEY AIRCRAFT CORPORATION + 82= ._1 (eeO_'_=_ __CkP w._ 4_ w_.21.7s _R_E =.0.-_ =_) --503 FLATPATI_RN ('O40 NSJ 4130, _,--o_o-i I i_" / SKIN AND "503 0°)4- IHRU " +470-AD4 .= + + 4- n.=1 _-m i_1 #ST uaSP. ._- .f (REF) ¢= ...I i , ' I*P" * "t*FI" *" * */** / ' I S:ACttSIOEOFSI:_JCS; + "_° ""/"**'.+**R i...I.I. • .'.. • • J I ] ..... I FI I El/:::1:::::::::, ,:: I i.' i I I..... | PICK UP (15) B/P F/_IENERS EACH Sl0E;OF S_LICE 8= -503 ANGLE PICK UP (30) B/P F/_'IEHERS EACH_DE OF SPLICEc_ n "_ *l i I: i;. I. I S =| L SM51--8 STUB SPAR REPAIR - FIGURE 51-8 12-98 51-13-03 13 MOONEY AIRCRAFT CORPORATION M20J SERVICE AND MAINTENANCE 5,9 ,, ,, ,, Ii I[ 0 O O 0 0 0 0 0 0 ° °: o oo° o 0 Iz ..... O 0 , 0 ooo:lol_ 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 • 0 0 0 L 0 0 0 0 0 0 0 J 7,111 REAR SPAR REPAIR - FIGURE 51-9 _l-|O RIB REPAIR 51-13-03 14 - FIGURE 51-10 12-98 MANUAL SERVICE AND MAINTENANCE MANUAL M20J MOONEY AIRCRAFT CORPORATION 51-13-04 - REAR SPAR REPAIR The rear spar may be spliced between ribs in accordance with AC 43.13-1(*) (*=current revision) (see Figure 51-9). 7. Install cherrylock(CR-2248) blind rivets in places inaccessible for dvet bucking. Add one extra countersunkblind dvet between every other pair of cherrylockdvets. 51-13-05 - RIB REPAIR Replace dbs that are severely damaged. Minor damage may be repairedas shown (Figure 51-10). 51-13-07 -WING SKIN PANEL REPAIR Repairwing skinpanelsas prescribedin AC 43.13-1(*) (*=currantrevision),unlessan entireskinpanel is to be replaced. Install new skinpanels to exactly match the odginalskininstallation.Preformedskinpanels may be obtained _'om the Mooney Service and Marketing Centers. 1. DamagedDimpleRepairAround InspectionHoles. Repair damaged dimples around inspection holes when (a) there are three or more cracked adjacent dimples, (b) the crack in one or more of the dimples extendsbeyondthe radiusof the dimpleinto the skin, and (c) when there are four or more cracked dimples aroundan inspectionhole (see Figure 51-11). To repair damaged dimples(a) cut a doublerfrom the same matedal and gauge as the skin to be repaired, (b) ddll and countersink100-degree fastener holes in the doublerto match dimpled fastener holes in skin, and (c) install doubler around inspectionhole. Use AN426-AD4 dvets when matedal is .040 inch thick or greater. Ddll holes using s No. 30 (.128 IN.) drill as shown in the above illustration.Use AN426-AD3 dvets when matedal is .032 inch thick or less. Ddll holes usinga No. 40 (.098 IN.) ddll. 51-13-06 - OUTBOARD WING TiP ASSEMBLY REPAIR To repair severe damage to the wing tip outboard of STA 193.5, it is advisableto replacethe entiretip skin and db. 1. Locate the new tip db in the exact originaltip db positionto preventwing tip twisting. Use a temporary support position.or Iocator pins to maintain correct wing tip 2. Rivetnew tip db to main and rear spars. 3. Locate new skin, and ddll rivet holesthrough skin to match existingholesin dbs and stdngers. 4. Rivetskinto db at STA 193.5. 5. Roll skin back on lower wing surface to gain access to stringers for dvet bucking. Rivet skin to upperstringers, 6. Rivet skin to tip db starting at leadingedge. Buck dvetsas far back as possible, ACCESS COVER - FIGURE51-11 12-98 51-13-04 15 MOONEY AIRCRAFT CORPORATION EXlSmNG ',_;-"-_ I i M20J - Radius. Cracks extend through Beyond the face Dimple of the 3. Repair of that Cracks Extending dimple into tile surrounding skin can be repaired as follows: (see Figure 51-13 ). CRACKED I/ ADD"_-- ._%..__ "O") ir /_ O_ i ----J RIB STRINGER-_i, B. Cut a doubler from the same matedal as the ddll crack with No.six 60dvets bit. at four-diameter skinA. toStop be repaired. Allowfor DIMPLE circularpatternaroundthe cracked dimple. rivetC.spacingswith two-diameter edge distances in a Round the comers ofthe doubler, and scarfthe ? D. Ddll holes for six rivets (same size as those in sandwiched edges to about .010 inch by .250 inch. degree dimples in doubler. E. Pdme area to be repaired anddvet installdoubler with wet primer. the odginal pattern), and drill and countersink 1O0 --_"__'i-----'_'J _oe_1;"" (_ _}--_EXlSTING SERVICE AND MAINTENANCE MANUAL '_F =" SM51-_2 DIMPLE CRACKS REPAIR - FIGURE 51-12 2. Repair of Cracks Wholly Within Dimple Radius. Surfacecracks on inside (bearing) face of a dimplethat do not extend through the matedal can be repaired by sandingout the crack. Cracks in dimpleswhich do not extend beyond the dimple radius can be repaired by (a) stop drilling the crack with a No. 60 drill and (b) by adding dvets, the same size as those in the original fPoattem,to each side of the cracked dimple. Maintain ur-diameter (4D) spacing and two-diameter (2D) edge distances. When odginal dvet pattern has dvets on only one or two sides of a dimple, only one or two dvets need be added (see Figure 51-12). 4. Repair of cracked Circumferentially Cracked Dimples. Circumferentially dimples (dimples with cracks '.hatappear as an annular mark around the dimple) can _e repaired by installinga conical washer. A. Drill throughdimple usinga ddll large enough to removethe damagedarea. B. Install doubler as shown in Figure 51-14. Wet pdme priorto assembly. C. Countersink dimple hole in skin allowing the countersinkto extendinto substructure. D. Install conical washer, use next oversize rivet size. Wet prime washer and adjacent skin and doubler surfaces priorto assembly. E. Drill remainder of the hole to allow installation of next larger diameter rivet than the rivets in the odgina[ pattern. I/ 6 FASTENERS(SAMESIZE AS ORIGINAL FASTENERWITHCRACKEDDIMPLE) WET PRIMER 100 ° CONICAL WASHER {........ ......... :;T ...... ......... / / CRACKED / DOUBLER(SAMEGAUGE + DIMPLE L_. AS SKIN)--SCARF EDGESTO | APPROX..010 IN. DEEPAND | SCARF EDGES .25 IN. WIDE;ROUNDCORNERS I SM51-13 NEXT OVERSIZE RIVET SM51--1, DIMPLE CRACKS REPAIR - FIGURE51-13 51-13-07 16 DOUBLER SUBSTRUCTURE OVERSIZE HOLE REPAIR - FIGURE 51-14 12-98 SERVICE AND MAINTENANCE MANUAL 51-14-00 M2OJ MOONEY AIRCRAFT CORPORATION - HORIZONTAL STABILIZERFIN VERTICAL & 51-14-01 <4_N.PERS_DD ___ - LEADING EDGE SKIN REPAIR The hodzontai stabilizer and vertical fin leading edge intedom are inaccessiblenear the tailcone. To repair damage in these areas, cut a standard (3.0 inches by 6.5 inches) access hole in the lower side of the stabilizerleading edge 4_0 REPAIR and close the access hole by installing inspection cover PIN 913000-501. ,7s _f j .o402a24T-_ CLAn CHERRY <4Hm._ER StudLDGK £R 2248 SHSt-16 51-14-02 - MAIN SPAR REPAIR SPAR REPAIR (STA. 48.5 Approx.) - FIGURE 51-16 OUTBOARD OF STA. 9.00 Repairdamage to the horizontalstabilizermainspar by 2. Repair main spar cap damage between STA 34 sfrai;]htening the damaged area and inspecting it and STA 48.5 by forminga splice angle from 3/4 inch tullyfor cracks. If cracks are formed, stop ddll or by 3/4 inch.050 2024-T3 sheet aluminum.Pick up five remove cracked area. existing holes and ddll six new dvet holes between 1. Repair damage between S'I:A 9.00 and STA 34.0 existing holes in the skin on each side of damaged on the spar upper flange, and between STA 9.00 and area. Install 11 AD4 dvets through angle and skin and STA 40.0 on the spar lower flange with a splice angle 10 AD4 dvets through angle and web on each side of formed from .070 AISI 4130 steel, condition N. The the damaged area. (See Figure 51-15, ViEW B). splice angle flanges must be as wide as the original 3. Repair main spar damage from STA 48.5 outboard spar flanges. The splice angle must be long enough to by installing splice angles made from .040 2024-T3 install 11 AD4 rivets through the skin and 11 dvets matedal on both side of web using 12 AD4 rivets (6 through the spar web on each side of the damaged through skin and 6 through web on each side of area (see Figure 51-15, VIEWA). damaged area). Pick up three existing holes and drill Prime splice angle before riveting it to spar. Pick up three new holes between existing holes on each side five existingrivet holes and drill six new holesbetween of damaged area. (See Figure 51-16). existing rivet holes in the skin at each side of the 4. Repair main spar web damage outboard of STA damaged area. Install 22 AD4 rivets through splice 34.0, top flange, and STA 48.5, lowerflange by forming angle and skin, and 22 AD4 dvets throughsplice angle a splice angle from .050 2024-T3 aluminum.The splice and sparweb. (See Figure 51-15, VIEWA). angle web flange should be cut to allow sufficient coverage of the damaged area of existing web and long enough to install5 AD4 rivets on the flange on each side of the damaged area. Pick up 3 existing dvet holeson flange of spar and ddll 3 new dvst holes r--.o_o I I .oso splice angle and web on each side of the damauea between existing holes. Drill 10 rivet holes throuon r I • ' SAME LENGTH _S _aUE aB_ SPUCED "/ _ 17_. 35 --t -,--.To .--• SPAR REPAIR (BETWEEN STA. 9.0 & 34.0) FIGURE 51-15 12-98 cracked area priorandtodeburr splice installation. Pdmeremoved splice angle sparangle web and flange before installing spl=-e (see Figure 51-17). 5. Spar webs outboard of STA 48.5 cracked more than 50% The of the web height may be (see web area" damaged web sh°uld be repaired stop ddlled °r aluminum to fit the inside dimensions 0fthe web and Figure at 51-18). Form a splice 2024-T3 flange the damaged area.plate Pick from up 3 .050 existing dvet holes on top and bottom flange on each side of damaged area and drill 2 new AD4 dvet holes between these existing holes. Pick up all dvet holes on web under splice plate and drill new rivet holes on equal spacing around the damaged area similar to that on Figure 51-18 dvets on each side of damaged area. 51-14-00 17 MOONEY AIRCRAFT CORPORATION M2OJ SERVICE AND MAINTENANCE MANUAL d:l_ 4 (10 EACH SIDE OF CRACK) _ (6 EACH SIDE OF HUCKSUMP COLLAR GUN l_-v SWAGE SET oooooooo STOP OLO ov00 CRACKED SPAR WEB AREA) 2024--T3 SM51-17 ET SPAR REPAIR (O/B of STA. 34.0) - FIGURE 51-17 51-14-03 - RIB REPAIR The repair of damaged stabilizer and fin dbs is not feasible in most cases. Damaged dbs should be replacedwith new parts. 51-14-04 ,_/,4(5 EACH SIDE) - FIBERGLASS LAMINATES, REPAIR PROCEDURES .050 2024-T-3 CLAD o J_ o _ ok _ o _ o '",_ I o _ o _o _ o_,j._ o o I o o o =" o o I o o == o 51-15-00 - REMATING HORIZONTAL STABILIZER TO STINGER When stabilizer repair necessitates removal from the stinger, remating can be facilitated by using huckbolt substitutioninformationcontained in Section 51-10-01. When mating stabilizerto stinger use bent rivet swage set #5 (see Figure 51-19). o SM51-19 RP-MATINGHORIZON [AL STABILI/-I::RTO STINGER FIGURE51-19 o I o o I o o o o oLo .,_ • • _,. .,, -,_ .'_ _'. _ o o '_ _'_ ,_1,4(5 Despitethe fact that fiberglasslaminatesare designed to withstand considerable abuse, occasional repairs will be necessary. It is difficult to cover all the various repair techniques due to such limiting factors as accessibilityand the extent of damage. The following stepsoutlinethose procedureswhich are used to make repairs for the more common type damage to a fiberglasslaminate. 1. Materials used for repairs shall be as specified below and compatible with the basic resin used in the fiberglass Resin - Aerospace laminate. Adhesive EA934 Part A HysolDivision The Dexter Corporation Catalyst - AerospaceAdhesive EA934 Part B Hysol Division The Dexter Corporation Alternates: Resin - Epoxical #606 PatchingAdhesive Resin o t_ EACH SIDE) States Catalyst -United Epoxical #606Gypsum Patching Adhesive Hardner United States Gypsum OR Resin- Ren Epoxy CG 1304 Ren Plastics company Lansing, Michigan Catalyst- Ren Hardener CG 1304 Ren Plastics company Lansing, Michigan SM51-1 8, SPARREPAIR 51-14-03 18 - FIGURE51-18 12-98 SERVICE AND MAINTENANCE MANUAL M20J Fire retardation- Antimony Trioxide for fire retardation, 5% minimum, 10% maximum by Weight of Resin Content. Must be added to the base resin (cowling and airintake assembly only). The manufacturer's bulletins shall be followed for all mixing ratios and preparation pdor to application. 2. General. 2. Remove any loose particles and frayed fiberglass strands from the cracked portion. 3. Prepare surface for repair as shown in (Figure 51-20, Figure 51-21, and Figure 51-22). 4. Prior to continuing the repair, all surfaces in the area of the repair must be cleaned of all contaminates by wiping the area with a clean cloth saturated with Methyl-EthYl Ketone. A. The configuration of repairs are shown for fiat surface areas; for simplicity; however, the same techniques can be used for contoured surfaces. Contoured repairs will require additional considerations and the proper shapingof the backupplates used for clamping the laminates together dudng the cudng cycle, B. The degree of laminate chamfer and size will vary based on accessibility, shape of part and the extent of damage, CAUTION Methyl-Ethyl-Ketone (M.E.K.) is a flammable liquid and should be used with proper ventilation andthe prescribed safety equipment. CAUTION Fiberglass components are attacked and deteriorated by the following products: Ketone, aliphatic esters, chlorinated hydrocarbons, and slightly softened by aromatic hydrocarbons. 51-15-01 - CRACKS, IN SURFACE AREAS 1. Stop drill all cracks per standard aircraft procedure. Q MOONEY AIRCRAFT CORPORATION 0.5iiiI_ sToP o.,__ ii:iiii)ii iiiii_ ';ii!:/__>_'- , i:iiiiiiiiiil)iiiiii_.ii)il-,.)))).)I(IIIIIIIIII)IVlIII .,iiiii)iiii: I.VllI I O_OK OOT,,,EO_ C,AMFE, A,_ / CRACK _[-, (_ _ ..... "" 1.5" :-= CHAMFER 1.5" EACH ........ ,:-2: RNBHEBSURFACE ' _ A B SIDE OF CRACK THtCKNESS .02 TO.04 CD o""',N,S.E" _ SURFACE _ ' MASKINGTAPE T i _M_NAT_ THICKNESS SM51-20 NON-STRUCTURAL REPAIR - FIGURE 51-20 12-98 51-15-01 19 MOONEY AIRCRAFT CORPORATION 51-15-02 M20J - NON-STRUCTURAL REPAIR SERVICE AND MAINTENANCE MANUAL 51-15-03 1. Applymaskingtape over crack on finishedsurface side. 2. Apply wet coat of catalyzed epoxy resin to chamferedsurface. 3. Apply one layer of #181 fiberglass cloth saturated withcatalyzedepoxy resin. 4. Add additional plys of #181 fiberglass cloth, saturated with epoxy resin to attain original laminate thickness. 5. Applyone additionalply of #181 cloth bridgingthe totalrepaired area and bond in place, - COMMON STRUCTURAL LAMINATE REPAIR 1. Cut away laminateper sketch, roughenrepair area with 240 sandpaper, clean repair area with M.E.K. apply a wet coat of catalyzed epoxy resin to surfaces. Then IMMEDIATELY performSteps 2. thru 5. 2. Install chemically cleaned .025 T-3 aluminum straps, perforatedwith #40 holesapproximately.35 on centeralldirections. 3. Applywet coat of epoxy resin to aluminumstraps and apply one or more layers of resin saturated#181 fiberglass cloth to equal the thickness of the original laminate. 4. Lay wax paper over both sides of the repaired area while still wet. This prevents adhesion to the pressureclamp application(paragraph5). r........_::::.:::::::::_::::_:::_:.._:_:_:/._:..:.::_.:_:_:_=:::_:_._::_:=_::=_=_i J #181 FIBERGLASS ! •025 T-3 ALUM. (SEE SECTION I , 375" _ • ,rl I 2 O" I = I-] II CLOTH ii I 1 I I I. =i:- /_///////_'_./ _J / ,/../ I / / // ,.,_(/ / / / / _/, 5 i cRAcK __1 ! "1 il 1 51-15-03, 2) 1 / ,, Y//////////'/q"-_"LAMINATE .o3"-J " ! !-I I= 2.75 I I I'.:-:::::::::= ":._ "::=._-::::.':-:: "-:.':::-;,--':::.':: :::::.'.-.-: ::-:::::::-,'= ="::':_":.--._ :::-::_'::":'::=": "":::::""::":l_ I I I ' S F .025 T-3 ALUM (SEE SECTION 51-15-03, 2) # 181 CLOTH BERGLASS OVERLAP(1) LAYER FIBERGLASS ///" //]--- ALUM• PLATES _........._. ................... .... ,............... ;.,.;.;.-:--; ;;i;,,. ,._,,_---,;--_;:;:;--;,.;-/-; ;,,. ........ ,;..,.:.:..:_:_ _/////Z_L_ ,............ ,,......... ,_((_...._::.?./?...-., )rz........... //////_ //_2 .......................... '..................................... '............. " ........................... " ........................... ' F LAMINATE FINISHED SURFACE _ \ X I_ _FIBERGLASS-- BOND _ FLUSH RIVET (TYP.) IN PLACE OVERLAP (1) LAYER RBERGLASS ONLY IF THIS SM51-21 SIDE IS A NON--FINISHED SURFACE. COMMON STRUCTURAL LAMINATE REPAIR(METAL INSERT)-FIGURE 51-21 51-15-02 2O 12-98 SERVICE AND MAINTENANCE MANUAL ( M20J 5. Place rigid aluminum plates on both sides of repair area and clamp into place with "C" clamps. Permit laminated repairtocure. 6. Alter the fiberglass repair has cured, remove the clamps and install #3 AN426A rivets. Flush head to be on the finishedsurface side. The number of rivets and spacing will be determined by the size of the repair. MOONEY AIRCRAFT CORPORATION Permit this surfacing coat to cure pdor to any additional applications or further rework. 11. Using #240 sandpaper, sand and blend the repaired area to match the surrounding surface. Steps 10 and 11 may be repeated to acquire a satisfactory surface finish. 51-15-04 - COMMON STRUCTURAL LAMINATE REPAIR (FIBERGLASS-RESIN COMBINATION) 1. Apply wet coat of catalyzed epoxy resin to chamfered surface. 2. Apply one layer of#181 fiberglass cloth saturated with catalyzed epoxy resin. 3. Add additional plys of #181 fiberglass cloth saturated with epoxy resin to attain original laminate thickness. 4. Apply one layer of #181 fiberglass cloth to the non-finished side of laminate, extending 1/2" each side ofthe chamfer and bond in place. 5. Lay wax paper over both sides of the repaired area while still wet. This prevents adhesion to the pressure clamp application (paragraph 6). 7. Apply one on additional overlapping layerand of #181 fiberglasscloth the non-finished surface bond in place. Should the opposite side be a non-finished sudace, an additional layer of fiberglass should be applied to this side. 8. Upon completion of steps 1 thru 7, permit the repair to cure before attempting further treatment of appearance surfaces, if required. 9. Appearance surfaces will normally require the application of a filler-sealer coating. The appearance area is to be wiped clean, using a clean cloth saturated with M.E.K. prior to applying a filler-sealer coating, 10. Mix epoxy resin and catalyst per manufacturers specifications and apply to the appearance surface area. Care should be taken to assure as smooth as possible surface In this particular operation. 4 r-- 0.5" /1'/ _ STOP DRILL i OUTLINE I_ f ON--FINISHED SURFACE CRACK ........... ................. "---F, ,SHEO SURFACE /y_.LTHICKNESS _ "---q O.AM EI TH,O N LAM'"A .02 TO .04 EACH SIDE ('[YP.) t" ..... _. @-"l F (FIBERGLASS--RESIN COMBINATION) COMMON STRUCTURAL LAMINATE REPAIR 12-98 -q F SM51-22 FIGURE 51-22 51-15-04 21 MOONEY AIRCRAFT CORPORATION M20J 6. Place rigid aluminum plates on both sides of repair area and clamp into place with "C" clamps. Permit laminate repairto cure. 7. After fiberglass repair has cured, remove clamps and install #3 AN426 rivets. Flush head to be on finished surface side. The number of rivets and spacing will be determined bythe size of the repair, 8. Upon completionof steps 1 thru 7, allow the repair to cure before attempting further treatment of the appearancesurface. 9. Appearance surfaces will normally require the applicationof a filler-sealer coating. The appearance area isto be wiped clean, usinga clean cloth saturated with M.E.K. priorto applyinga filler-sealercoating, 10. Mix epoxy resin and catalyst per manufacturer's specificationsand apply to the appearance surface area. Care should be taken to assure as smooth as possiblesurfacein this particularoperation. Permitthis surfacingcoat to cure prior to any additional applicationorfurtherrework, 11. Using#240 sandpaper, sand and blend repaired area to match surroundingsurface. Steps 10 and 11 may be repeated to acquire a satisfactory surface finish. 51-15-05 -FIBERGLASS DELAMINATION REPAIR 1. Delamination or ply separation of a fiberglass product is usuallya result of poorbonding of fiberglass layers. Generally,this conditionis localized and can be readilyrepaired by carefullyspreadingapart the plysin the delamination, and removing loose particles by blowingclean compressedair intodamaged area. 51-15-05 22 SERVICE AND MAINTENANCE MANUAL 2. Proceed by inserting catalyzed epoxy resin into the delamination and then immediately clamp the delamination together. Permit the repair to cure a minimum of 8 hours before removing clamps. 3. Extensive delamination of a part will be reason fortotal rejection of the part and shall be scrapped per standardpractices. 51-16-00 - MISCELLANEOUS 1. ProtectiveCoatings. A. Parts with protective coatings (such as Conversion Coated or zinc pdmer) on which the coatingis scratched, spotfaced, drilled, or in any way removedmust beis recoatedwith chromateprimer. EXAMPLE: Part Conversion zinc Coated as detail part. Dudng replacement the part is spotfaced to receive bolt and washer. This part must be primed after spoffacing. 2. Low Pressure, Plastic, or Rubber Line Splices. Static system lines may be lengthened, shortened, or spliced to allow the replacement of sections of damaged lines. The fittings are called out in the Parts Catalog text pages followingthe illustrationdepicting the assemblyor componentin question. If splices are made, the system must be checked for leaks. 3. Shortening and Lengthening of Tubing, Hoses, and Flexible Ducting. Mooney manufactured assemblies of plumbing, tubing, hoses, and flexible ducting may be modified to allow the use of longer parts of the same size and materialto be cut and used as replacements. When the manufactured ends of flexible ducting are removed the raw edge must be taped with 3M aluminumfoil tape. 12-98 SERVICE AND MAINTENANCE MANUAL M20J CHAPTER 52 DOORS MOONEY AIRCRAFT CORPORATION MOONEY AIRCRAFTCORPORATION M20J SERVICEAND MAINTENANCE MANUAL CHAPTER52 DOORS LIST OF EFFECTIVEPAGES CHAPTER SECTION SUBJECT ......... 52-Effectivity. 52-00-00 ........... 52-10-00 ......... 52-11-00 ........... 52-30-00 ............ 52-31-00 ............ 52-31-00 ............ PAGE ....... 1/2BLANK .......... 3 ........... 4 ........... 5 ........... 6 ........... 7 ........... 8 ........... DATE 12-98 12-98 12-98 12-98 12-98 12-98 12-98 TABLEOF CONTENTS CHAPTER SECTION SUBJECT .......... 52-00-00 52-10-00 52-11-00 52-12-00 52-30-00 52-31-00 . ........... ........ ...... ........... SUBJECT ......... PAGE General.............. • Cabin Door- MaintenancePractices.. , . Cabin Door Rigging/AdjustmentProcedures . . Cabin DoorSeal, • • . . , . . . . Baggage CompartmentDoor-MaintenancePractices . BaggageCompartmentDoor-LatchingMechanism 12-98 3 3 5 5 5 7 52-EFF/CONTENTS I_2BLANK SERVICE AND MAINTENANCE MANUAL 52-00-00 M2OJ -GENERAL The cabin door is constructedof an inner and outer aluminum shell fastened together by rivets. It is providedwith a dual latchingmechanism,1) a lockpin extends into a mating recaptacle in the lower door frame and 2) a jaw type latch clamps a special designed nut in the upper door frame to hold door securely in place. The door is hinged at the forward edge by an extruded aluminum hinge. The inner handle and the outer handle are intemonnected.by adjustablepush pull tubes. This mechanismis spnng loadedto an over center positionin the latchedposition for positive security. Adjustment for each push pull tube is providedto accurately dg the latching pin and the jaw type latch. Adjustmentto the special nut at the top of the door frame can be made for proper closure, The baggage compartment door is constructedof an inner and outer aluminum shell fastened together by rivets. It has dual pin latches that extend into receptacle fittings on both sides of the door frame when the exterior handle is closed properly. The auxiliary exit handle is located on the insideof the baggagedoor. This handle can be operated onlyfrom the inside even if the outer handle is locked. A cam mechanism allows a clevis pin to bypass the outer handle latch groove and open the two latching pins which hold the baggage door closed. (Refer to AFM/POH Section III for specificproceduresto operate auxiliary exit handle.) This door is hinged at the top with an extruded pianotype hinge. A hold open arm is attachedon both doors to assistin holdingthe dooropenwhen desired. A door lockis providedfor bothdoors.A single keywill operate either door lock. The intedor panels require removal if the door locks are to be removed and replaced, 52-10-00 - CABIN DOOR - MAINTENANCE PRACTICES MOONEY AIRCRAFT CORPORATION The original door assembly, with hinge attached, is assembledto the doorframe priorto installationof the outer skin. The door is placed into position and the hinge held in place on its mounting plate by sealant and Iocator rivets or bolts. (The number of Iocator fastners may vary). These fastners will be underneath the outer skin.After removal of the outer rivets and/or screwswork a putty knife or a thin piece of aluminum betweenthe outer skinand the hinge and betweenthe hinge and the mountingplate from the inside in order to break the sealant bond. During this procedure determinationcan be made where the Iocator fastners are positioned.If rivets, locate these rivets from the inside and ddll the bucked head carefully. DO NOT DRILL THROUGH THE OUTER SKIN. Attempt to movethe door and hinge att and away from the attach pointafter each rivet stem is drilled out. The door and hinge should come free when all sealant bond and rivetsare removed. 2. Door Repair. A. The door should be repaired, if applicable, accordingto standard proceduresin AC 43.13-1( * ). B. Remove the intedordoor panel if necessaryto repairthe door assembly. 3. Installation.The old door can be relocated by usingthe existingholes.The mountingplate shouldbe thoroughlycleaned of all sealant and foreign material beforereinstallationof thedoor. A new door or hinge will require proper positioningof the doorto obtain proper sealing. A. Place door, with new hinge installed, into position between the outer skin and the mounting plate. B. When door is properly positionedmark the new hingefor mountingusingexistingholes, eitherfrom the outer skin locationsor from the hinge mountingplate insidethe cabin. C. Drill the new holes in hinge carefullywhile door 1. Removal. The cabin door may be removed to replace or repair the door or to replacea damaged hinge, issecurelyin place. D. Remove the door- deburr holes and clean the shavingsfromthe area. A. Remove the interior panel around the door frame. NOTE The rivets and rivet holes originally used as Iocators do not have to be utilized when B. Remove the hold open arm at the door frame. Remove the cotter pinand washers fromthe holdopen arm shaft. Pull the shaft up from the doubler plate and clear of the doorframe, C. Remove the eight (8) screws from outsidethe airplanethat holdthe front portionofthe hinge in place, There are also three (3) flush dyers that will require removalat this location. D. Carefully drill center of rivet head with a l/8th inch drill bit until head pops off and rivet stem can be punchedout. installing a new door or hinge if proper alignment can be obtained using another method. E. Apply sealant, PRC 1321-B2, or equivalent, betweenouter skin and hinge support plate on tubular structure. F. Reinstalldoor hinge to mountingplate usingthe eight (8) fiat head screws removedearlier and three (3) fiat head AD4 standard (AD5 oversize) dvets. G. Adjustdoor latching mechanismso door closes and seals during flight. (See door dgging procedures paragraph52-11-00). 12-98 52-00-00 3 MOONEY AIRCRAFT CORPORATION M20J SERVICE AND MAINTENANCE MANUAL "6. 9. ADJUSTMEN" 7. SLIDE POINT _ ® LATCH JAWS , ® ® "" ® _COVER PLATE FWD 3. SPRING-_ f i _:_ 4. ,, Z HOUSING ASSEMBLY 8, ADJUSTMENT POINT 5. UPPER// LINK "1 / \ \ ARM VIEW-LOOKING L_ 1. LOWER LINK OUTBOARD AT CABIN DOOR CABIN DOOR- RIGGING/ADJUSTMENT - FIGURE 52-1 52-10-00 4 [:--_q 12-98 SERVICE AND MAINTENANCE MANUAL M20J H. Reinstall the hold open arm with new cotter pin. i A. The seal is held to inner door frame with adhesive. I. Reinstall interior panels and intedor tdm to door and cabin. J. Paint door to match airplane, 52-11-00 MOONEY AIRCRAFT CORPORATION B. Remove the door inner tdrn panel to gain access to the door seal. C. Pull the seal from the door frame. -CABINDOOR RIGGING/ADJUSTMENT PROCEDURES D. Clean the area with lacquer thinner to help solten the remaining adhesive. Remove excess adhesive. The cabin door latching mechanism has several adjustmentpointsthat may be utilizedto obtain proper rigging. (See Figure 52-1.) Removal of the intedor door panel will be required to gain access to the adjustmentpoints, CAUTION Care should be exercised to keep the lacquer thinnerfrom dripping on the wing or any other portion of the airplane. • Adjust cabin door linkage to satisfy requirements listedbelow. A. Latchingpin must contact stdker plate on door frame the full circumferenceof pinwhen mechanism is in fulllatchedposition. B. Latching pin must clear striker plate when openingor closingthe doorwith latchingmechanism in full open position, C. As the lower link (1) and bellcrankarm (2), (Fig. 52-1) travel over center, the spdng (3), is to be compressedto 1.000 +/- .030. E. Coat cleaned door frame with adhesive (St. Clair#4587). F. Coat bond area of new seal with adhesive (St. Clair#4587). G. Let bothapplicationsdry untiltacky. H. Carefully place end of sealthe into position at bottomof door and continuearound door untilthe seal isfirmlyattached.Do not pull tightaround comers. Cut off any excessseal. I. When is propedyattached the door should close with littleseal effort. NOTE Washers may be added between spring and link or 310294-501with housing itemsassembly B and C. (4) to comply NOTE Door contour can be altered slightly to conform with cabin contour, if needed, for proper fit and sealing• D. The lower link (1) and bellcrank arm (2), in full locked position,should be overcenter a minimumof .3 inches,(Figure 52-1). 52-30-00 - BAGGAGE COMPARTMENT DOOR - MAINTENANCE PRACTICES NOTE It is not necessary that the lower link (1) contact the upper link (5), (Figure 52-1). 1. Removal.The baggagecompartmentdoor may be removed replace or repair the door or to replacea damaged to hinge. E. The outside handle is to be flush with outside skin when mechanism is in full latched position, A. Remove the coat hanger anti headliner panel located inside and directly under the baggage door F. In full latched position, the upper latch jaws (6) must be closed and the latch slide cam (7) at the end of its full travel. See adjustment points (8) and (9). G. In full open position the upper latch jaws must be open and slide cam at the end of its full travel. NOTE Slide cam (7) moves 1.13 from the full latched to full open position, hinge area. B. Pull insulation backto clear rivet shanks. C. Center punch rivet heads holding the hinge half to the fuselage. D. Carefully ddll dvet heads and punch dvets from holes. E. Work a putty knife or thin piece of aluminum between outer skin and hinge and inner skin frame and hinge to break sealant bond. 52-12-00 -CABIN DOOR SEAL The cabin door seal is an extruded rubber seal filled with a soft foam. Unless deformed or tom, the sealwill provide adequate sealing around the periphery of the door during flightconditions. F. Remove hinge and baggage door assembly carefully. G. Clean hinge and hinge mounting area thoroughlyof all sealantor foreignmaterial. 1. Cabin doorseal replacement, 2. Repair. The baggage door may be repaired per standard repair procedures in accordance with AC 43.13-1(). Repairsmay be made to the baggage door on the airplaneif feasible. 12-98 52-11-00 5 MOONEY AIRCRAFT CORPORATION M20J SERVICE AND MAINTENANCE NOTE MANUAL NEW HINGE If repairs are to be made the interior trim panel may require removal. A. Place old door assembly with new hinge or new door assembly and new hinge into position and latch the door in place. NOTE 3. Installation. OLD HINGE A. Place repaired baggage door with old hinge into paOSitionand cleco securely to assure fit of door;, check tching operations. B. Remove door - assure attachment area is clean of old sealant, Hinge mounting area should be clean of old sealant and debris. B. Push in on door assembly at top, while door is in the latched position to properly locate the door and seal in the door frame. C. Apply sealant, PR 1403-G-B2 or equivalent, to hinge attachment area between outer skin and inner frame. D. Reinstall door assembly with old hinge and cleco hinge for proper placement. E. Install rivets (AD4 standard, AD5 oversize) in all holes, C. While door is held in place mark holes in new hinge using holes in outerskin as Iocators. D. Verify correct position of door prior to ddlling holes in hinge. E. Center punch all holes and carefully drill the two end holes. Fasten clecoes in these and recheck door assembly fit, if satisfactory continue drilling all holes. FABRFC C 0VF_R_ BACK) LATCH ROD HITCH PIN SPRING--(OVER CENTER TENSION) STIFFENER ANGLE O 3OOR FRAME AUX. (RED) Q INSIDE (CAM SLOT) CLEVIS PIN CAM FOLLOWER y GOES HERE LOCK HANDLE_ CAM SLOT) _" SPRING ADDED PER SJ. M20-63 PIN 0 0 {NOB (WHITE) Q © DOOR SEAL NOT SHOWN EARLY CONFIGURATION LATCH KNOB BAGGAGE DOOR LATCH MECHANISM 52-30-00 6 12-98 - FIGURE 52-2 SERVICE AND MAINTENANCE MANUAL M20J F, Remove door assembly. Deburr and clean the area completely pdor to reinstallation of door assembly, G. Apply sealant, PR 1403-G-B2 or equivalent, to hinge mounting are between outer skin and door frame. H. Reinstall door assembly and cleco securely in place, I. Install rivets, (AD4 standard, AD5 oversize) in all holes. Remove clecoes as rivets are being installed to keep door aligned, 52-31-00 -BAGGAGECOMPAR'rMENT DOOR-LATCHING MECHANISM The baggage compartment door has a direct non-adjustablelatching linkage that inserts two pins into hard points in the door frame. This latching mechanism can be locked from the outside. An auxiliary exit mechanism is inconporatedinto this latching mechanism which allows the door to be opened, in an emergency, from the inside even if outsidehandleis locked. CLIP/PIN A_Y S CR3213-4____===_== RIVET _ _ (2 PLC) LANYARD (ORIENTATION CRITICAL) MOONEY AIRCRAFT CORPORATION The outside handle has to be unlatched arid fully opened to correctly re-engage the latching mechanism alter use of the inside auxiliary exit handle. (See Figure 52-2). S/N 24-0001 thru 24-1381 were manufactured without the spring attached to the clevis pin to actuate the latch pin linkage. Mooney Service Instruction M20-63 dated Apdl, 1953 adds this modification to these aircraft. This ensures a positive reengagement of the clevis pin into the cam slot of outside handle for proper actuation of the outside latching mechanism (see Figure 52-2). See Mooney Service Bulletin M20-239 for retrofit configurationof auxiliary exit handle, inside latching mechanism(See Figure 52-3). NOTE FollowtheproceduresintheAirplane Flight ManuaI-PilotsOperating Handbook(AFM/POH) for reengagement of the mechanism for proper outside handle operation. NITCH PIg/f_HANDLE _ CR32:3-4-3 RIVET AN960-4 WASHER (2) (i UNDER RIVET HEAD 8, 1 ON BACK SIDE OF HANDLE,) NOT HSP0470-4 RIVET (OPT) SH52"2 AUXILIARY EXIT LATCH RETROFIT (CNVSB M20-239)-FIGURE 52-3 12-98 52-31-00 7 MOONEY AIRCRAFT CORPORATION M20J BLANK 52-31-00 8 12-98 SERVICE AND MAINTENANCE MANUAL SERVICE AND MAINTENANCE MANUAL M20J CHAPTER 53 FUSELAGE MOONEY AIRCRAFT CORPORATION MOONEY AIRCRAFT CORPORATION M20J SERVICE AND MAINTENANCE MANUAL CHAPTER 53 FUSELAGE UST OF EFFECTIVE PAGES CHAPTER SECTION SUBJECT ........... 53-Eff/Contents ......... 53-00-00 ............ 53-30-00 ............ 53-30-00 ............ 53-40-00 ............ 53-40-02 ............ 53-40-03 ............ PAGE .......... DATE 1/2BLANK .......... 3 ........... 4 ........... 5 ........... 6 ........... 7 ........... 8 ........... 12-98 12-98 12-98 12-98 12-98 12-98 12-98 TABLE OF CONTENTS CHAPTER SECTION SUBJECT ........... 53-00-00 ........ 53-10-00 ......... 53-10-01 .......... 53-10-02 .......... 53-30-00 ......... 53-40-00 ......... 53-40.01 .......... 53-40-02 .......... 53-40-03 .......... 53-40-04 .......... SUBJECT ........ General .............. Main Frame ............ Tubular Structure Frame ....... Tailcone Structure ......... Plates/Skins ............ Attach Fittings ........... Wing Attach Fittings. ........ Empennage Attach Fittings ....... Main Landing Gear Atta{ h Points ..... Engine Mount Attach Points ...... 12-98 PAGE 3 3 3 3 4 6 6 7 8 8 53-EFF/CONTENTS 1/2BLANK SERVICE AND MAINTENANCE MANUAL ( M20J 53-00-00 -GENERAL The Mooney M20J forward fuselage is constructed from 4130 chromemolybdenum tubular steel. The tubular steel sub-assemblies are hellarc welded in fixtures, inspected and then assembled intothe main cabin fixtureand heliaro welded into a cabin enclosure. The assembled steel structure is sand blasted and dipped in zinc chromate palmerfor corrosionprotection. The tailcone bulkheads,formers, etc., are formed from sheet aluminumon a hydro press or drop hammer at Mooney Aircraft Corporation. These components, along with stringers, clips, brackets, etc., are assembled together on a fixture and built into the all fuselage assembly. All air ducts, control brackets, electricalharnesses and antennas are assembled into the tailconeduring this manufacturingstage. The forward cabin enclosure and the taiicone are mated and this fuselage assembly advances down the MOONEY AIRCRAFT CORPORATION production line to the point of mating with the wing assembly. 53-10-00 -MAIN FRAME 53-10-01 - TUBULAR STRUCTURE FRAME The basic cabin enclosure is shown in (Figure 53-1). Serial No. 24-0001 thru 24-0900 have a windshield frame that will not accept the radar display unit. SIN 24-0901 and ON have had the wishbonesubassembly (1) changed to allow this unit to be installed. 53-10-02 . TAILCONE STRUCTURE The tailcone is of semi-monocoqueconstruction.The internal structure is shown on (Figure 53-2). The forward cabin structure (1) is bolted to the tailcone with TUBULAR STRUCTURE FRAME - FIGURE 53-1 12-98 53-00-00 3 MOONEY AIRCRAFT CORPORATION M20J load beadng portion of the assembly. The avionics equipmentshelf (3) spans the tailcone widthto provide rigidityand space for avionics components.The battery box (5) and battery are located in this area also. The hat rack shelf (4) provides rigidity as well as storage space. SERVICE AND MAINTENANCE MANUAL The empennage attach points(6) are attached to the rear bulkhead (7) with tabs extending forward and attachedto the tailcone structure. NOTE Refer to Mooney Service Instruction M20-76 for sealing of tailcone and smooth belly skin. 8 8 4-, /-8 / .-i / / 0 23 3 _HJK53-2 TAILCONE STRUCTURE - FIGURE 53-2 53-30-00 - PLATES/SKINS The fuselage tubular structure is covered with aluminumskins after mating to the tailcone. The skins are riveted and boltedto support angles, formers and brackets. These skins are non structural coveringsto form the outside contour of the forward fuselage section. The skins covering the tailcone are an integralpart of the structure. Repair or replacement of these skins should be according to AC 43.13-1(*) (*--currentrev.) SECTION 3. The belly skins are removableto provideaccessto all components and control systems located below the floorboard. See (Figure 53-3) and table following for component location and identification.SIN 24-1418 and lateraircrafthave a one piece fiberglassbelly skin. The fuselage assembly and tailcone have panels, coversor doors at various locationsto provideaccess to the interiorfor inspectionor maintenance purposes. (See Figure 53-3). 53-30-00 4 12-98 NOTE PR-1766-B2 sealant should be used on all fuselage skin laps to provide a good electrical ground plane. SERVICE AND MAINTENANCE MANUAL M20J / 3 MOONEY AIRCRAFT CORPORATION 2 21 1713 ' , (24-1418 AND _/N) SMJ53-3 INSPECTION PANEL AND COVERS - FIGURE 5&-3 12-98 53-30-00 5 MOONEY AIRCRAFT CORPORATION M2OJ SERVICE AND MAINTENANCE MANUAL TABLE FOR FIGURE 53-3 - COMPONENT IDENTIFICATION 1. Cabin Door. 12. 2. Engine Compartment ,Oil access 13. 3. Baggage Door. 4. Elevator/Rudder Control Stops. 5. Empennage Attachment. 14. 15. 16, 6. AvionicsBlackboxes, Batteries. 19. 6A. E.L.T. access. 7. StabilizerTrim Jack Screw. 8. EmpennageAttachment. 9. Elevator/RudderControls,Rod End Bearings& Travel Stops. 10. RudderControls,Elevators& Rudder Be,cranks. 20. 21. 22. 23. Landing GearActuator, Gascolator, Fuel Selector Valve. Landing Gear Retract Tubes, Flap Indicator Cable. Electdc Flap Actuator. Stabilizer Trim Screw and Stops. 17, 18. Elevator/Rudder/Aileron Control System, Bellcranks, Rod End Beadngs. Nose Wheel Steering System, Cowl Flap Controls. RudderTorque Tube. LandingGear RetracUonTubes. Tail-LightHarness Connections. EmpennageAttachment, Trim Jack Screw. 24. All components (12-18, 21). 11. Brake Master Cylinders, Rudder Torque Tube, Electdc Fuel Pump. 53-40-00 - ATTACH FITTINGS 53-40-01 - WING ATTACH Frn'INGS The wing assembly (1) is attached to the fuselage assembly (2) using structural hardware (4); (see Figure 53-4 for locations). Vadous type of fittings (3) are used to propedy distribute the load between the wing andthe fuselage. 2 3 (TYP. LH 3 _ 12-98 (TYP. LH & RH) 4 (TYP, LH 8, RH) & RH) (TyP, WING/FUSELAGE ATTACH FII-rINGS 53-40-00 6 (TYP. LH 8, RH) 4 FIGURE 53-4 SERVICE AND MAINTENANCE MANUAL M2OJ 53-40-02 - EMPENNAGE ATTACH FITTINGS The empennage assembly is manufactured as a unit (1), (Figure 53-5) with the vertical fin and the horizontal stabilizer using common components.This unit attaches to the tailcone empennage attach points (1) (Figure 53-6), using two structural bolts (2) (Figure 53-5) passing through two top hinges (3) (Figure 53-5). The bottom attac[n point (4) (Figure 53-5) on the MOONEY AIRCRAFT CORPORATION empennage assembly secures the stabilizer trim jack screw (5) (Figure 53-5) and (4) (Figure 53-6). Lateral stabilityofthe empennageassemblyis controlledwith an articulated hinge assembly (2) (Figure 53-6) attachedto the rear bulkhead (3) (Figure 53-6) of the tailcone. The hinge attach pin (6) (Figure 53-5) is held in place with a coffer pin at each end. / $H53-5 I EMPENNAGE ASSEMBLY ATTACH FiTTiNGS - FIGURE 53-5 12-98 53-40-02 7 MOONEY AIRCRAFT CORPORATION M20J SERVICE AND MAINTENANCE MANUAL 53-40-03 - MAIN LANDING GEAR ATTACH POINTS The main landing gear assembly is a welded heat treated 4130 chromemolybdenum steel assembly. The leg assembly(1) is supported at the forward end by the tension strap fitting (2) attached to the wing main spar assembly (3) (Figure 53-7) and provides one of the hard points for the main landing gear assembly. The leg assembly (1) is supported at the rear by a bracket (4) attached to the stub spar assembly (5), This is the rear hard point. The main landing gear truss assembly (5) also attaches to the tension strap fitting (2) on the main spar, The brass beadng (7) should be inspected at any scheduled maintenance action for wear. Grease fittings (8) are 1 installed at pivot points of the main landing gear assembly for lubrication per Section 5. (Reference Figure 53-7). 3 53-40-04 - ENGINE MOUNT ATTACH POINTS 4 The engine mount is attached to hard points built into 2 the forward portion ofthe tubular structure. The upper hard points (1) (Figure 53-8) are for NAS1304 boiLsinstalled for tension loads. The lower hard points (2) are for fittings outside the firewa[I which allow a clevis on each side of the engine mount to be attached for shear loads. AN4 bolts are used for this application. _4s3--6 TAILCONE-EMPENNAGE ATTACH POINTS FIGURE 53-6 SMX53-7 SNJK53-8 MAIN LANDING GEAR ASSEMBLY ATTACH POINTS FIGURE 53-7 53-40-03 8 12-98 ENGINE MOUNT ATTACH POINT - FIGURE 53-8 SERVICE AND MAINTENANCE MANUAL M20J CHAPTER 55 STABILIZERS MOONEY AIRCRAFT CORPORATION MOONEY AIRCRAFT CORPORATION M20J SERVlCE AND MAINTENANCE MANUAL CHAPTER 55 STABILIZERS LIST OF EFFECTIVE PAGES CHAPTER SECTION SUBJECT ........ 55-Eft/Contents......... 55-00-00 .......... 55-20-00 ............ 55-30-01 ............ 55-40-02 ............ PAGE .......... DATE 1/2BLANK .......... 3 ........... 4 ........... 5 ........... 6 ........... 12-98 12-98 12-98 12-98 12-98 TABLE OF CONTENTS CHAPTER SECTION SUBJECT ........... 55-90-90 ........ 55-10-00 ......... 55-10-01 .......... 55-10-02 .......... 55-20-00 ......... 55-20-01 .......... 55-20-02 .......... 55-30-00 ......... 55-30-01 .......... 55-30-02 .......... 55-40-00 ......... 55-40-01 .......... 55-40-02 .......... SUBJECT ........ General .............. Horizontal Stabilizer ......... Horizontal Stabilizer- Removal ...... Horizontal Stabilizer- Installation ..... Elevator ............. Elevator- Removal ......... Elevator- Installation ........ Vertical Stabilizer. ......... Vertical Stabilizer- Removal ...... Vertical Stabilizer- Installation ..... Rudder ............. Rudder - Removal ........ Rudder- Installation ........ 12-98 PAGE 3 3 3 3 4 4 4 4 5 5 5 5 5 55-EFF/CONTENTS 1/2BLANK SERVICE AND MAINTENANCE MANUAL 55-00-00 ( M20J - GENERAL MOONEY AIRCRAFT CORPORATION 55-10-00 The M20J empennage assembly is a vadable incidence tail-plane consisting of a horizontal and vertical stabilizer built as a unit. (Refer to Chapter 53 for the attachment of the empennage to the fuselage.) The hodzontal and vertical stabilizer are constructed of formed sheet metal ribs attached to a forward and aft spar assembly covered with stretch formed skins. The hodzontal stabilizer has a stub spar that spans a portion of the stabilizer. The elevator and rudder are constructed from an extruded loading edge spar assembly covered with formed skins, The elevators and the rudder have balance weights permanently installedforstabilization during flight. - HORIZONTAL STABILIZER The main sparassembly (1) (Fig. 55-1) is formed from aluminumsheet into a channel. Angle doublers (2, 3 and 4) are formed and riveted to the spar through the web section. The stub spar (5) is a channel formed from aluminum sheet reinforced with a joggled channel (6) at the center section. The rear spar (7) is an extrusion attaching to the aft end of the ribs and containsthehingefittings(8)fortheelevators. The ribs (9) are assembled in sections to the front and rear face of each spar assembly to form the air foil. Stretch formed skins (10) are fastened to the ribs, spars and doublers to form the complete horizontal stabilizer structure. The aft vertical fin spar (11) is attached to the horizontal stabilizer structure through a bracket (12) which is fastened securely to the stabilizer rear spar assembly (7). (Reference Figure 55-1), 11 8 9 _ g s DETAIL A 5 8 3 8 SHX55-1 HORIZONTAL STABILIZER - FIGURE 55-1 55-10-01 - HORIZONTAL STABILIZER REMOVAL The faidng located on the tailcone, covering the gap between the tailcone and empennage assembly, will require removal to gain access to empennage attaching hardware. Section 53-40-02 describes the attaching points for the empennage assembly. Refer to this section for the removal of the empennage assembly from the airplane. 55-10-02 - HORIZONTAL STABILIZER INSTALLATION Referto Section 53-40-02 for installation. 12-98 55-00-00 3 MOONEY AIRCRAFT CORPORATION M20J 55-20-00 -ELEVATOR The elevators on the M20J consist of a left. and fight hand assembly attached through ball bearing fittings (1) to the rear spar of the horizontal stabilizer reference Figure 55-2). SERVICE AND MAINTENANCE MANUAL The elevator control horn (2) is connected to the inboardleadingedge eachconnectedto elevator (R.H. L.H.). Both controlhorns areofthen theand elevator flight controlbellcrank. 6 3 6 2 A ELEVATOR - FIGURE 55-2 55-20-02 The elevator skins (4) are stretch formed for the upper and lower surface of the elevator. There are no ribs in the elevator between the inboard and the outboard fibs. The skins are attached to the leading edge extrusion(5) and the fibs (6) with blind rivets. Each formed corrogationis matchedon top and bottomskins and rivetsare installedfor strength and dgiditythrough each corrogation, A lead balance weight (7) is installed in each elevator tip with iron rivets (8). (Reference Figure 55-2). See Section 27-91-00 for balancing procedures on the elevators, 55-20-01 - ELEVATOR - REMOVAL Remove the AN3 bolts from each control horn and push-pulltube bearing, then remove the AN3 boltsand hardware from each hinge fitting on both elevators. 55-20-00 4 - ELEVATOR - INSTALLATION WARNING Each new, repaired or repainted elevator should be checked for balance per Section 27-91-00. The elevators are installed in reverse order of removal. Nominal torque values for AN3 bolts are to be used (see section 5-20-01 for torque table.) 55-30-00 -VERTICALSTABILIZER The main spar assembly(1) (Ref. Fig. 55-3) is formed from aluminumsheet. Formed angle doublers(2) are nested insidethe main spar channel and dvetedto the web. The rear spar (3) is an extrusionused to attach the art end of the sectioned fibs (4). The stub spar (5) is also formed from sheet aluminum.A doubler channel (6) is attached to the vertical stabilizer stub and the stub spar of the horizontal stabilizer. This attach channel is securely bolted to stinger bulkhead brackets. 12-98 SERVICE AND MAINTENANCE MANUAL M20J The mainspar doublers and angles 7, 8 and 9 provide attach points for the stinger and the horizontal stabilizerspar. (Refer to Figure 55-3). The skins (1 IN are stretch formed in 2 sections and rivetedto the lbs and spar. The three rudder attachfittings(11) are mountedto the rear spar extrusion. 55-30-01 -VERTICALSTABILIZERREMOVAL The hodzontalstabilizerare removed as a unit verticaland with the stinger assembly. Remove the faidng located on theempennage. tailcone which coversthe gapdescdbes between tailcone and Section 53-40-02 the attaching points for the complete empennage assembly. Refer to this section for removal of the empennage assemblyfrom the airplane, 4 _ J MOONEY AIRCRAFT CORPOP,ATION 55-30-02 - VERTICAL STABILIZER INSTALLATION Refer to Section53-40-02 for installation. 55-40-00 The rudder on the M20J is constructedthe same as the elevator with stretch formed skins (1) (Ref. Fig. 55-4) riveted to an extruded leading edge (2) and rivetedtogether at the trailing edge. The rudder lower skins (3) are drop hammerformed left and right halves rivetedto the upperskins,a rib assembly (4) and at the leadingand trailing edge. A stiffener (5) is to support the lower rudder ball bearing hinge fitting (6). A weather seal (7) is includedin the assembly. The rudder controlhorn (8) is attached with the center hinge fitting (9) to the rear flange of the front spar at the junction of the lower db assembly (10). A brace arm on the horn assemblyis attached to a f_ing (11) on the lower rib (10). The upper hinge fitting (12) is attachedto the rear flange of the frontsparjust under the top rib assembly(13) and the balanceweight (14), (refer to Figure 55-4). The balance weight (14) is installed with four iron dvets (15). See section 27-91-00 for balancing procedures on the rudder. - REMOVAL 55-40-01 - RUDDER Remove the AN3 bolt from the control horn and push-pull tube bearing, then remove the three AN3 bolts and hardware from per eachparagraph hinge fitting. Disconnect electdcal connections 33-41-03,2,A _ 13/f thru E. 55-40-02 - RUDDER INSTALLATION WARNING Each new, repaired or repainted rudder should be checked for balance per section 27-91-00 prior to installation, The rudder is installed in reverse order of removal. Nominaltorque valves for AN3 bolts are to be used. (See Section 5-20-01 for torquetable). 10 VERTICAL STABILIZERASSEMBLY - RUDDER - FIGURE 55-3 12-98 55-30-01 5 MOONEY AIRCRAFT CORPORATION M20J SERVICE AND MAINTENANCE MANUAL 15 , 1 \ \ 11 \ \ 12 \ 1 \ 9 \ I /" 16 \2 3 \ 4 ' _ 3 4 6 5 7 RUDDER ASSEMBLY 55-40-02 6 -/ 12-98 - FIGURE 55-4 5 MOONEY AIRCRAFT CORPORATION M20J CHAPTER 56 WINDOWS SERVICE AND MAINTENANCE MANUAL SERVICE AND MAINTENANCE MANUAL M20J MOONEY AIRCRAFT CORPORATION CHAPTER 56 WINDOWS LIST OF EFFECTIVE PAGES CHAPTER SECTION SUBJECT ........... PAGE 56-Eft/Contents ....... 56-00-00........... 56-22-00 ............ 56-50-00 ............ 58-50-00 ............ .......... DATE 1/2BLANK ........ 3 ........... 4 ........... 5 ......... 6 ......... 12-98 12-98 12-98 12-98 12-98 TABLE OF CONTENTS CHAPTER SECTION SUBJECT ........... 56-90-00 ........ 56-00-01 .......... 56-20-00 ......... 56-21-00 ......... 56-21-01 .......... 56-21-02 .......... 5B-22-00 ......... 56-22-01 .......... 56-22-02 .......... 56-23-00 ......... 56-50-00 ......... SUBJECT General ........ .............. Cleaning Acrylic.......... Windshield and Cabin Windows ....... Windshield ............ Windshield Removal ........ Windshield - Installation........ Cabin Windows ........... Cabin WIndows - Removal ....... Cabin Windows - Installation ..... Storm Windows ........... Acrylic Ddlling . . ; _ . ....... 12-98 PAGE 3 3 3 3 3 3 4 4 4 4 ¢ 56-EFF/CONTENTS 1/2BLANK MOONEY AIRCRAFT CORPORATION 56-00-00 M20J - GENERAL 56-21-01 The windshieldfor the M20J is .187 inch thick acrylic heat formed to contour.The pilotsside windowis also .187 inch thick acrylic with a hole cut out to accommodatethe .312 inch thick storm window. The storm window is milled to fit the hole and to be flush withoutsideof pilotswindowsurface when closed.The other three side windows are .125 inch thick acrylic, Serial Number 24-0001 thru 24-1213 and 24-1418 and ON have single pane side windows installed. Serial Number 24-1214 thru 24-1417 have a double panel cabindoorwindow.The inner pane is a .060 inchthick acrylicfittedto clips and bracketson the doorframe. All the windows are heated in an auto-clave to approximately300 degrees F. and placed on a plaster moldto coolwhile maintainingthe correct shape, The windows are tinted green or gray for visual comfort,ultra-violetfliteration and coolingeffectfor the cabin, The windows are all sealed to the outside skin with PR1403-G-B2 or equivalent sealant. Retainers and clips are used on the frame to hold the windows in place. 56-00-01 SERVICE AND MAINTENANCE MANUAL - WINDSHIELD - REMOVAL 1.The aluminumretainer (1) at bottom of windshield (2) must be removed by drillingout the rivets attaching ittothecowldeck(3), (referenceFigure56-1). A puttyknife or thinaluminumstripwillbe necessaryto work underneaththe top skin (4) and the side post skin (5) to break the sealant bond betweenthe acrylicand the skins. CAUTION Exercise care during this operation to avoid scratching the acrylic. Considerable effort may be required to break the bond. 2. Carefullypullthe windshieldaway from its location startingat the lower portionand work it loose as the sealantbondis brokenaroundthe edge of acrylic. When windshieldis removed, all residualsealant must be removed prior to installation of the replacement windshield. Careful scraping with putty.knife and the application of M,E.K. will assist in remm,qng the excess sealant. 66-21-02 - WINDSHIELD - INSTALLATION When old sealant is removed brush M.E.K. or equivalentcleaningsolventin the cavity(8) where new windshieldwill be located. Wipe solventbefore it dries and redistdbutescontaminates.(Fi£1ure56-1). - CLEANING ACRYLIC A commercial cleaning solution manufactured for acrylic may be used to clean routine grit and grime 7 commercial cleaner used. If no commercial cleaner is available these procedures should be followed: 1. Flush windows with water prior to wiping with clean, soft cloth soaked in kerosene. CAUTION from the windows. the when instructions on the Never wipeFollow windows dry. _ 8 2. Flushwithwater after cleaningwith kerosene. J CAUT,ON Never use gasoline, benezene, carbon tetrachloride, acetone, lacquer thinner, deicer fluid, house hold cleaning fluid or any other questionable fluid to clean acrylic windows. These solvents will soften or craze the surface. _1 f 5 Minor scratches or abrasions may be polished out by using acrylic resuffacing kits, ie., Micro-Mesh, available from aviation accessory suppliers. 56-20-00 The - WINDSHIELD AND CABIN WINDOWS removal and NOTE installation of windshield and __ windows are accomplished in the following paragraphs. 66-21-00 6 --1 WINDSHIELD INSTALLATION - FIGURE 56-1 - WINDSHIELD 12-g8 56-00-00 3 SERVICE AND MAINTENANCE MANUAL M2OJ MOONEY AIRCRAFT CORPORATION NOTE Exercise care with application of these solvents. Damage may result if drops of solvents come in contact with either the exterior paint, interior trim or plexiglass. - 1. Apply sealant, PR1403-G-B2 or PRC1321-B-2, into the cavity (8) until approximately half filled. Apply The new windshield being forced into the cavity between the outer skin (4) and the interior retainer (7) will extrude excess sealant. After the windshield is in place wipe the excess sealant off with a damp clean cloth. Priorto rivetingthe aluminumretainer (1) into position coatretainerwith a uniformthicknessof either sealant. a bead of sealaot along the recessedjoggle (6) of the into place. Use 113212-5-2 cherry rivets to realach the retainer (1) to cowl deck (3), (reference Figure , _' __ - CABIN WINDOWS 56-22-01 - CABIN WINDOWS - REMOVAL = • ' , -2 WINDOW INSTALLATION - FIGURE 56-2 The window will be bonded to the outside skin with sealant. Considerable effort may be requiredto break the bond betweenthe acrylic and the outer skin. Care should be exercisedto keep windowfrom twisting and possiblycracking, 1. Remove the window and clean all remaining sealant from the skin. Use M.E.K. and a scraper to removethe sealant. Aircralt SIN 24-1214 thru 24-1417 have an inner (5) and outer window (1) installation on the cabin door window. Removat is basicaly the same procedure as single window installations, -CABIN WINDOWS- INSTALLATION 1. Removeall old sealantand clean skinareawith M.E.K. Place window (1) into positionto assure proper It. Trim if necessa_/; refer to Figure 56-2. 2. Apply a uniform thickness of PR1403-GB2 or PRC1321-B sealant to' the skin and window area where window (1) will be located. Sufficient sealant should be used so that excess sealant is extruded from all edges of windows, both inside and outside, (approximately 5 tubes (3.5 oz.) for 4 side windows). 56-22-00 4 ,f ' _k, 1. Remove interior trim from the window (1) to be replaced. Remove the retainers (2) or dips (3) which holdthe window in positionfrom the inside, (reference Figure56-2). NOTE Some retainers are held in place with screws (4) and some with rivets. Drill out rivets carefully. 56-22-02 " ' 3. Repaint retainer and rivetsto match aircraft. 56-22.00 __ ' After 56-1).the sealant cures the excess may be removed with a sharp razor knife. 2. Checkfor water leaks. ' 3. Force window (1) into place with retainers (2) or clips (3) and securewith Avex 1601-410 blindrivetsor existingscrews and hardware (4). The sealant will be forced out and seal the window to the outside skin. Carefullywipe excess sealant off acrylic before it sets up.After sealant cures the excess can be cut off with a sharp razorknife, (reference Figure 56-2). 4. Checkreplacedwindowfor leaks. 5. Reinstal interiortrim panels. 56-23-00 -STORM WINDOW The storm window (6) is mounted with two aluminum hinges (7), attaching hardware (8) and held closed by a latch (9). A gasket (10) is bonded to the storm window for seeing purposes when closed, (reference Figure 56-2). 56-50-00 - ACRYLIC DRILLING Drill bits for acrylic should be ground per (Figure 56-3). A slow tuming ddll bit with light pressures is desirable. 12-98 MOONEY AIRCRAFT CORPORATION M20J SERVICE AND MAINTENANCE MANUAL 0 I i" NEGATIVE (,03 FLAT WIDTH) 5 ° CLEARANCE --STOVE BURNER TYPE BIT (NO FLUTE RELIEF) JOBBER FLUTE LENGTH & JOBBER LENGTH OVERALL DRILL DIAMETER TOLERANCE = ! TOTAL +,0000 -,0000 INDICATED RUNr]UT = ,0002 ACRYLIC PLASTIC DRILL BIT - FIGURE 56-3 ( 12-98 56-50-00 5 SERVICE AND MAINTENANCE MANUAL M20J BLANK 56-50-00 6 12-98 MOONEY AIRCRAFT CORPORATION MOONEY AIRCRAFT CORPORATION M20J CHAPTER 57 WINGS SERVICE AND MAINTENANCE MANUAL SERVICE AND MAINTENANCE MANUAL M20J MOONEY AIRCRAFT CORPORATION CHAPTER 57 WINGS LIST CF EFFECTI_E PAGES CHAPTER SECTION SUBJECT ........... PAGE 57-EffectMty ......... 57-00-00 ............ 57-20-02 ............ 57-20-02 ............ 57-20-02 ............ 57-30-00 ............ 57-40-00 ............ 57-50-20 ............ 57-50-21 .......... .......... DATE 1/2BLANK .......... 3 ........... 4 ........... 5 ........... 6 ........... 7 ........... 8 ........... 9 ........... 10 ........... 12-98 12-98 12-98 12-98 12-98 12-98 12-98 12-98 12-98 TABLE OF CONTENTS CHAPTER SECTION SUBJECT ........... 57-00-00 ........ 57-00-01 .......... 57-00-02 .......... 57-10-00 ......... 57-20-00 ........ 57-20-01 .......... 57-20-02 .......... 57-30-00 ........ 57-40-00 ......... 57-50-00 ......... 57-50-1g .......... 57-50-11 ............ 57-50-20 .......... 57-50-21 ............ SUBJECT General ........ .............. Wing Removal and INstallation...... Stall Strip Installation ........ Main Frame ............ Auxiliary Structures .......... Jack Points ........... Wing Tips ........... Plafes - Skin ............ Attach F_ings ........... Flight Surfaces ........... Flaps ............ Flap Removal and Installation ..... Ailerons ............ Aileron Removal and Installation .... 12-98 PAGE 3 3 3 3 3 3 3 7 8 8 8 8 9 9 57-EFF/CONTENTS 1/2BLANK MOONEY AIRCRAFT CORPORATION ( M20J SERVICE AND MAINTENANCE MANUAL 57-00-00 - GENERAL The all metal wing is a one piece assemblyattachedto the fuselage at structural hard points with structural hardware. (SeeisSection 53-40-01). span spar assembly connected to the The stubfull spar andmain rear spar assembly by dbs, doublers and skins. The main landing gear forward attach assembly is an integral part of the main spar and the rear fitting is boltedto the stub spar and assembly. The spar are 7075-T6 aluminum the webs, ribs caps and doublers are 2. Wing installation:Installationof the wing assembly is direct reversalof removal. 57.00-02 -STALL STRIP INSTALLATION 1. Position stall strip on wing leading edge so that during stall recovery normal use of controls would prevent: A. More than 15 degree roll. B. Morethan 15 degree yaw. 2024-T3, T4 or T42 aluminum. Repair of these componentsis covered in Section51-13-00. Moldedwing tips (SIN 24-1038 and ON) are fabricated from compositesand house the navigation and strobe lights, The fuel is contained in wet wing type fuel cells betweenthe main spar and bafflesforward ofthe spar. The tanks are sealed duringmanufacturingwithcurrent state ofthe art technology sealant. (See Section 28 for fuel system details). C. More than 30 degree pitchbelow flight level. 2. Place stall strips on leading edge at stations shown on Figure 57-2, attach securely withduct tape for test flights.Re-positionstall stdps, up ordown, until aircratt flies to criteria in paragraph 57-00-02, 1, A, B and C. Secure stall strip per installationinstructionsin (Figure 57-2). 57-00-01 -WING REMOVAL AND INSTALLATION The major subassembliesof the wing may be removed individually,or the wing may be removed as a unit. To remove a wing, a fuselage supporting cradle is needed, 1. Wing removal: A. Remove wing-root faidngs and bottomfuselage access panels, B. Drain allfuel from tanks, C. Drain brake lines and reservoir. Disconnect hydrauliclinesat wing mainspar. D. Remove front and rear seats. Remove the two inspectionplates under rear seat area. ' E. Jack aircratt. F. AttachA-frame hoistto propeller,or supportwith a propellerjack. G. Disconnector removethe following: (1) Two landinggear assistsprings. (2) Aileron controltubes at inboard bellcranks. (3) Trim controltube at station59.3 and 94.5. (4) Main gear retractiontubes, (5) Rudder controltubes. (6) Elevatorcontroltube. (7) Elevatorand rudder push-pulltubes, (8) Floorboardsat rear attach points. (9) Bellyskin stringersplice angles. 57-10.00 - MAIN FRAME The integral fuel cells, shaded area (1) start at wing station 24.5 and continueto the rib at station74.0 on both wings.(Reference Figure 57-3). Sealer is applied to alljointson ribs,spar and baffle plates. (See section 28 for resealing procedures). The wing is manufactured in three sections;the center section (2), the left outboard section (3) and an opposite right outboard section (not shown) (Figure 57-3). These three sections are then assembled into one full span wing assemblyasthe skinsare installed. A spares, outboard wing tip assembly is available which includes completed section from wing station 118.25 and outboard. The assembly includes the stringers (4) required to complete the spliceto the old centersection. 57-20.00 - AUXILIARY STRUCTURES 57-20.01 - JACK POINTS The jack points are located on the under side of the wing. The threaded wing tie down eyebolt fittingsare designed to accept the non threaded jack points. These are located outboard of each main gear. See Section7-10-00 for completejacking procedures. 57-20-02 - FIBERGLASS WING TIPS (SIN 24-1038 and on) The M20J wing tips are non-structural fiberglass components. They are riveted to the upper and lower wing skinsduringfinalassembly of the wingstructure. 1. W_ngtip removal. A. Remove the navigationstrobe light lens (1) by removing4 screwsand washers (2) that retainthe lens to wing tip (3) (24-0001 tbru 24-2999). SIN 24-3000 thru 24-TBA - Disconnectaft positionlightconnections. Refer to Figure 57-4). (10) Airspeed indicator line, pitot lines, and pitot heater wires (if installed). (11) Hardware shown in (Figure 57-1). CAUTION Have a suitable cradle ready to carry the fuselage before removing all mating hardware. 12-98 57-00-00 3 SERVICE AND MAINTENANCE MANUAL M20J MOONEY AIRCRAFT CORPORATION WING ATTACHING HARDWARE - FIGURE 57-1 57-20-02 4 12-98 MOONEY AIRCRAFT CORPORATION LEFT WING - RIGHT WING - M20J SHOWN OPP. ^/ R,_ KIN LL SERVICE AND MAINTENANCE MANUAL !_!!!-!-_7!27 , SKIN /-_ C BORE STALL .06/.10" DEEP AN515--RR1¢) "_. ST -scREw-UstE LOCKTITE D DRILL /USE .1_]g/'.193 A6-75 _PEcv_ A/_'/_ TYPICAL INSTL. DIA RIVNUT FWD "== STALL STRIP ALTERNATE INSTL STALL STRIP INSTALLATION W_ ( "",,L_/ \ ./_ .// FIGURE 57-2 103,5 W_ 118,25 wS 59,_5 " I SNJ57-3 WING STRUCTURE - FIGURE 57-3 12-98 57-20-02 5 SERVICE AND MAINTENANCE MANUAL 24-1038 M20J MOONEY AIRCRAFT CORPORATION 24-3000 THRU 24-TBA THRU 24-2999 4 7 3 •.. 8 • 6 2 1 STROBE LIGHTS (7) AN]] POWER SUPPLY CONNECTORS (8) WILL VARY, SNJ57-4 WING TIP ASSEMBLY (24-:1038THRU 24-TBA) ..- FIGURE 57-4 B. Drill out rivets (4) holding tip to upper and lower wing skins (5). Remove all rivet shanks with a punch. C. Carefully pull wing tip away from wing db (6) and skins (5). Disconnect the strobe and navigation light harnesses at the quick disconnect plug (8) pdor to completely removing the tip. NOTE The strobe or navigation lights can be removed from wing tip either before or after its removal from wing. 57-2O-O2 6 2. Wing tip installation. A. Place the new or repaired wing tip in place. CAUTION Be sure aileron and aileron balance weights are not restricted in movement either direction. B. Secure wing tip and ddll holes to match wing skins. Cleco as holes are ddlled into tip. When all holes are ddlled remove wing tip assembly and deburr. NOTE Connect strobe and navigation light connectors (8) prior to final attachment of the tip. 12-98 MOONEY AIRCRAFT CORPORATION , I M20J SERVICE AND MAINTENANCE MANUAL C. Use Avex 1604-0412 blind dyers to attach the wing tip to the top and bottom skins, D. Repaintto match the aircraft. 57-30-00 - PLATES - SKIN They are flush mounted covers and when installed continue the aerodynamic contour of the wing. SIN 24-1418 and ON have a one piece fiberglassskin that can be removed to gain access to component located inthat area. The wing access and inspection covers shown in (Figure 57-5) provide maintenance access to components,plumbingand controlbellcranksenclosed withinthewing. NOTE One piece belly skin panel on 24-1418 & ON 7_--_ L_ L7-,___ _ , _ 19-- _= _-- -19 -2 7- -0 8 19--- I] 0-- -19 --_7 9 0---0s--7i2 FIVESEPARATE BELLY SKINS ALUMINUM S/N ;=4-0001 THRU 24-1417 -- 7--0 3 ([]00 3-- _ 7 0__0__9 i9- 17 8-49---ii _4 19 ,-- _ H 4- 17 DNE PIECE L FIBERGLASS J BELLY SKIN S/N 24-1418 THRU £4-T3A 5-- 6 -- l TOP LEFT WING 19-- --13 16 -5 14 15 BOTTOM SMJ57-5 0 --9 LEFT WING O0 =- -6 WING SKINS AND INSPECTION COVERS - FIGURE 57-5 LEGEND FOR FIGURE 57-5. 1. Wing skin - .050 thickness._fueltank) 2. Wing skin - .040 thickness. (fueltank) 3. Wing skin- .040 thickness. 4. Wing skin- .032 thickness, 5. Wing skin - .025 thickness. 6. Wing skin - .025 thickness. 7. Fueltank access, 8. Fueltank filler. 9. Controltube guide blocks. 10. Wing - fuselage attach points. 11. OAT probe, rightwing only. 12. Controltube guide blocksand flighttimer. 13. Pitot post- left wing only. 14. Strobe lightpower supply. 15. Aileronbellcrankand controlrods. 18. Auto pilotservos. 17. Gyro compassflux valve (one of these, depending on installedequipment),(leftwing only). 18. Main landinggear retractionspring. 19. Elevator and rudder controls - rod end bearings, bellcranks. 20. RetractionBungee Spring (205 only) 21. Speed Brakes (if equipped) SIN 24-1418 & ON have a one piece fiberglass belly skin;removefor access. 12-98 57-30-00 7 SERVICE AND MAINTENANCE MANUAL M20J NOTE Access covers on bottom of wing that require removal for inspection intervals are secured with screws. Any access covers that are riveted in place are required for manufacturing only and NOTfor routine inspections, MOONEY AIRCRAFT CORPORATION The flap actuator jack shaft is connected by a push-pull rod end bearing to the actuator bracket (1) (Figure 57-6) locatedjust inboard of the inboardhinge (2). All four hinges(2) and (3) are faired (4) to reducedrag. The intemal structureof the flaps consistsof a leading edge extrusion(5) trailing edge stiffener (6), ribs (7) and top and bottomskins (8). These componentsare riveted together into a leit hand and right hand assembly. 57-50-11 - FLAP REMOVAL AND INSTALLATION Refer to Section27-50-00 for removal and installation procedures. 57-40-00 -ATTACH FITTINGS Refer to Section 57-00-01 for wing fuselage attachment. 57-50-00 - FLIGHT SURFACES Refer to Section 27-90-00 for flight control surfaces balancingprocedures 57-50-10 - FLAPS Refer to Section 27-50-00 for maintenance and rigging procedures. 4 7 4 8 6 1 7 2 4 3 5 3 3 FLAP ASSEMBLY - FIGURE 57-6 57-40-00 8 12'98 3 4 MOONEY AIRCRAFT CORPORATION M20J 57-50-20 -AILERONS Referto Section27-10-00 for maintenanceand rigging procedures. The ailerons are of all metal construction.The main spar (1), (Figure 57-7), is attachedto the rear spar (2) through dbs (3). These components are riveted togetherand a top and bottom skin(4) and (5) dveted to this sub-assembly.To completethe controlsurface, hinges(6) and balance weights (7) are installed.The SERVICE AND MAINTENANCE MANUAL weights (7) are bolted(10) through an outboard rib (8) and bracket(9) on each aileronassembly. 57-50-21 - AILERON REMOVAL AND INSTALLATION Refer to Section 27-10-00 for removal and installation procedures. i6 BEI'AIL I _ _'v'/]]ETAIL 5 2 A I0 B ]]ETAIL C /_'_o_ SMX57-7 AILERON ASSEMBLY - FIGURE 57-7 12-98 57-50-20 9 SERVICE AND MAINTENANCE MANUAL M20J BLANK 57-50-21 10 12-98 MOONEY AIRCRAFT CORPORATION MOONEY AIRCRAFT CORPORATION M20J SERVICE AND MAINTENANCE MANUAL CHAPTER 60 STANDARD PRACTICES - PROPELLER SERVICE AND MAINTENANCE MANUAL M20J MOONEY AIRCRAFT CORPORATION CHAPTER 60 STANDARD PRACTICES - PROPELLER LIST OF EFFECTIVE PAGES CHAPTER SECTION SUBJECT ........... PAGE 60-EIT/Contents......... 60-00-00 ............ 60-00-00 ............ .......... DATE 1/2BLANK .......... 3 ..... 4 ........... ...... 12-98 12-98 12-98 TABLE OF CONTENTS CHAPTER SECTION SUBJECT ........... 60-00-00 ........ SUBJECT Gene_l .............. 1_98 ........ PAGE 3 60-EF_CONTENTS I_BLANK MOONEY AIRCRAFT CORPORATION 60-00-00 + i M20J - GENERAL SERVICE AND MAINTENANCE MANUAL CAUTION The standard M20J aircraft has a McCauley Propeller, controlledby a governor for constantRPM settingsat the pilotsdiscretion, An option for the M20J is a Hartzell Propeller with Q-Tip blades. Each propellerhas its ownmatchingspinnerassembly. Repairs may be made to metal propellers in accordance withAC 43.13-1(*), and in conjunctionwith the definitionsof FAR 43. Refer to Textron-Lycoming maintenance publications for engine inspection procedures after a propeller strike. * Currentissueof AC 43.13 12-98 60-00-00 3 MOONEY AIRCRAFT CORPORATION M20J CHAPTER 61 PROPELLERS SERVICE AND MAINTENANCE MANUAL SERVICE AND MAINTENANCE MANUAL M20J MOONEY AIRCRAFT CORPORATION CHAPTER 61 PROPELLERS LIST OF EFFECTIVE PAGES CHAPTER SECTION SUBJECT ........... 61-Effectivity ......... 61-OO-00 ............ 61-90-20 ............ 61-20-90 ............ 61-20-90 ............ 61-40-00 ............ 61-40-00 ............ PAGE .......... DATE 1/2BLANK .......... 3 ........... 4 ........... 5 ........... 6 ........... 7 ........... 8 ........... 12-98 12-98 12-98 12-98 12-98 12-98 12-98 TABLE OF CONTENTS CHAPTER SECTION SUBJECT 61-00-00 61-00-10 61-00-20 61-10-00 61-10-10 61-20-00 61-20-10 61-20-20 61-20-30 61-20-90 61-40-00 ........... ........ ......... ......... ......... .......... ......... .......... .......... .......... .......... ......... SUBJECT ......... General .............. Spinner Dome and Propeller Removal ..... Propeller Installation .......... Propeller Assembly .......... Minor Propeller Blade Repair ...... Propeller Controlling .......... Propeller Governor Installation ...... Propeller Governor Rigging ....... Propeller Governor Adjustment ...... Propeller Governor Troubleshooting .... Propeller Balancing .......... 12-98 DATE 3 3 4 4 4 4 4 5 5 6 7 61-EFF/CONTENTS 1/2BLANK MOONEY AIRCRAFT CORPORATION 61-00-00 M20J SERVICE AND MAINTENANCE MANUAL " GENERAL NOTE The propelleris a constantspeed type which operates by oil pressure opposing natural centrifugaltwisting moment of rotating blades and rome of a spring (in McCauley propellers) to obtain correct pitch for the selected engine load. Engine lubricatingoil is supplied to a powerpistonin propellerhubthroughthe propeller shall The amountand pressureof oil supplied(0-300 PSI) is controlled by an engine driven governor. Govmor oil pressure acting on a piston (and spring) increase propeller blade pitch, thus decreasingengine RPM. As governor oil pressure is reduced, centrifugal twistingmoments and spring force on propellerblades decrease propellerblade pitchand increaseRPM. Propeller overhaulshall coincide with engine overhaul, but interval between overhauls shall not exceed 1500 hours (McCauley) or 2000 hours (Hartzell). Refer to propeller manufacturers' overhaul manual for complete maintenance action and time limits. Approved propeller shops only are authorized for overhaul or major repairs to these propellers. Referto Federal Aviation Regulations, Part 43, (FAR 43) and Federal Aviation Agency Advisory Circular No. 43.13 (*) for the definition of major or minor repairs or alternations and who may accomplish them. (See Textron LycomingService and Maintenance Instructions). 61-00-10 - SPINNER DOME AND PROPELLER REMOVAL 1. Spinnerdome removal(if necessary).(See Figure 61-1) NOTE It is not necessary to remove spinner when removing propeller assembly. A. Remove screws (1) from spinner (2). B. Remove doubler plates (3). C. Remove spinner dome (2). i I"-- _X \ 7 3 _ l SPINNER DOME & PROPELLER REMOVAL - FIGURE 61-1 12-98 61-00-00 3 SERVICE AND MAINTENANCE MANUAL M20J D. Remove safety wire and loosen bolts (4) attachingpropellerto engine crankshal_,about 114inch and pull propellerforward. NOTE Bolts (4) will have to be backed out evenly so that propeller may be pulled forward (approximately 1/4 inch at a time) until all bolts are disengaged from the engine crankshaft flange. As the propeller is separated from the engine crankshaft, oil will drain from the propeller and engine crankshaft cavities, 8. INSTALL SAFETY WIRE THROUGH ROLL PINS SAFETYING BOLTS IN PAIRS. 9. Adjust alternator drive belt tension as outlined in Section24-31-01. 10. Install spinner dome (5) making sure fiber washersare installedunder all screws. E. Pull propeller from engine crankshaft. F. if necessaryto remove the aft spinnerbulkhead, remove bolts, washers and nuts (5) attaching bulkheads to the starter ring gear support. NOTE After removal of the propeller, the starter ring gear support assembly may be removed from the engine crankshaft to allow easier access of the aft spinner bulkhead attaching bolts, Loosen alternator adjusting arm and disengage alternator drive pulley belt from pulley on aft face of starter ring gear support assembly. 6t-00-20 - PROPELLER INSTALLATION 1. If aft spinner bulkheadwas removed,re-thstallon ring gear supped, using bolts, nuts and washers in the reverse order of removal. 2. If starter ring gear support and aE spinner bulkhead were removed, clean mating surfaces of suppo[tassembly and engine crankshaftflange. 3. Place alternator drive belt in the pulley groove of the starter ring gear support. Fit starter ring gear over propeller flange bushings on cranksha_, NOTE Make sure the bushing hole in the ring gear support, that bears the identification "O", is assembled at the "O" identified crankshaft flange bushing. This bushing is marked "O" by an etching on the crankshaft flange next to the bushing. The starter ring gear must be located correctly to assure proper alignment of the timing marks on the ring gear. NOTE The teflon tape (9) on hub (6) should be checked for smoothness of tape layers and that inner bulkhead (7) fits snug as spinner dome is being installed. 11. Conductoperational and leak check on propeller installationpriorto flight. 6t-10.O9 , PROPELLER ASSEMBLY No externallubricationis required on M2OJpropellers. Preflight inspection should be accomplishedprior to each flightto determine: if bladeshave been damaged, if any abnormal Ioosness is evident between hub and bladesor if there is any evidence ofoil leakage. 6t-t0-10 -MINOR PROPELLER BLADE REPAIR 1. Minor nicks, dents and gouges may be dressed out by approvedpersonnel;Blend any nicksor gouges intothe leading edge with smooth curvesor generous radiias shownin (Figure 61-2). Repaint area to reduce corrosive action. 61-20.00 - PROPELLER CONTROLLING 61-20-10 -GOVERNOR INSTALLATION 1. Clean mountingpad and bottom of governor. 2. Coat new gasket w/ DOW Coming 7 compound release agent or equivalent before installation. 3. Installnewgasketon mountingstuds. Insuregaskethas raisedsurfaceof the gasketscreentowardthe governor. 4. Positiongovernoron mountingstuds, aligningthe governorspttnes andthe splinesof the accessorydrive. 5. Installall mountinghardware. Torgue nuts. 6. Connectgovernor controlto governorand rig. NOTE All dggingto match governorarm Ioction.Do not adjustgovmor high RPMstopto match the dgging. CAUTION Remove all rags or plugs placed in crankshaft or hub during propeller removal. 61-20-20 4. Clean propeller hub cavity and mating surfaces of propellerhub and ring gear support. 5. Lightly lubdoate a new O-ring (8) (Figure 61-1) and the crenkshal_ pilot with clean engine oil and install O-ring in the propeller hub. 6. Align propeller mounting bolts (4) with proper holes in engine crankshaft flange and slide propeller carefully over crankshaft pilot until bolts can be started in crankshaft flange bushing, 7. "l-_Jhtenbotts evenly and work propeller aft on crankshaft flange. Tcjhtsn bolts to 55-65 FT-LBS on McCauley propellers and 60-70 FT-LBS on Hartzell propellers. 61-00-20 4 MOONEY AIRCRAFT CORPORATION - PROPELLER GOVERNOR CONTROL RIGGING 1. Disconnect propeller govemor control rod. A. Remove cotter pin, nut, bolt and washers from rod end at propeller governor control arm. B. Remove bracket installed with propeller governor mounting bolts. C. Disconnect control rcd fromgovemorcontrolarm. 2. Adjust control arm spring to minimum tension which will return control arm to maximum RPM. 3. Push propeller control in cockpit futt forward. Putt control back approximately 1/8 inch and lock in this position, 12-98 _ MOONEY AIRCRAFT CORPORATION M20J SERVICE AND MAINTENANCE MANUAL MINOR PROPELLER BLADE REPAIR - FIGURE 61-2 4. Place governor control arm against high RPM stop screw (325 degrees from governor centerline). 5. Adjust propeller control rod end to coincidewith thegovernor arm position. 6. Attach control rod end to governor arm and secure. 7. Operate the propellercontrolfrom cockpitto verify fulltravel of control arm in both directions,high RPM to minimumRPM stop. NOTE When propeller control rigging is complete, check controls in cockpit to be sure there is 118 inch cushion between control knob and adjustment nut on instrument panel. The control should not bottom out when pushed full forward, CAUTION Recheck safety wire, security and thread engagement on all engine controls after adjustment rigging or assembly. NOTEcan be adjusted by Vernier controls friction loosening the lock nut on back side of panel and either tighten the nut on front of panel to increase friction or loosen the nut to decrease friction. Retighten the lock nut on back side to secure cable to the panel. NOTE Takeoff RPM should not exceed 2700 RPM. (Static RPM may be 50 RPM less than 2700). 61-20-30 - PROPELLER GOVERNOR ADJUSTMENT !. Fly aircraft an drecord max. RPM at T/O or cruise flight atfull power. NOTE No adjustment can be done before a test flight to obtain max. governor RPM. 2. Remove upper engie cowlfor accessto governor. 3. LoosenhighRPM screw jam nut. 4. Turn screw in (CW) or out (CCW) to match RPM recordedduring governortest flight. One (1) fullturn of the screw equalsapproximately25 RPM. 5. Tighten jam nut an make propeller control linkage adjustmentsas necessaryto maintain full travel. 6. Re-dg discennectaed controls and reinstall cowling. 7. Perform propeller and governor operationaltests. Fly aircraft and repeat governor test flight and record max. RPM in flight at max power. Repeat this process untilthe proper max. RPM setting is achieved. NOTE When installing a governor, insure the oil system is purged of all air by cycling the propeller seveal times before flight. 12-98 61-20-30 5 SERVICE AND MAINTENANCE MANUAL 61-20-90 M20J MOONEY AIRCRAFT CORPORATION - PROPELLER GOVERNOR TROUBLE SHOOTING TROUBLE PROBABLE CAUSE REMEDY Leakage: Between controlshaf_ and head. -Damaged O-Ring. Replace with new O-Ring. Betweenhead and body. -Damaged head and body gasket. Replace gasket. Betweenmliefvalveplugand body. -Damaged relief valve plug gasket. Replace gasket. Between body and base. -Damaged body and base gasket. Replace gasket. Between govemor base and engine mounting pad. -Damaged governor mounting gasket. Replace gasket. -Loose governor attaching nuts. Retighten nuts. -Warped engine mounting pad. Consult engine manual. -Wrong high-RPM governer setting, Reset governor external high RPM adjustment screw. -Incorrect system dgging. -Low engine power. Adjust control system. Consult engine manual. -Erroneous reading tachometer. Calibrate or replace instrument. -Sticky pilot valve. Remove head and clean pilot valve with crocus cloth. Maintain sharp pilot valve land corners. Check for straightness of pilot valve; if bent, replace valve. -Sludge in governor pilot valve or relief valve. Disassemble and clean. -Burrs on pilot valve lands. Disassemble and clean with crocus cloth. -Backlash in governor control system. Redg or adjust control system. -Sticky relief valve. Inspect for burrs, and clean. -Erroneous reading tachometer. Calibrate or replace instrument. _Excessive oil leakage in propeller shaft transfer bearing. Refer to engine manual. Inability to attain takeoff RPM dudngflight, RPM fluctuates. The RPM can fluctuate +/-30 RPM. High propeller friction. Refer to propeller overhaul manual. Governor function upset by malfunctioning engine. Repair engine for smooth operation. -Air trapped in propeller. 61-20-90 6 -Sticky oilot valve. Cycle Power Lever from MIN to MAX several times to purge air. Remove head and pilot valve. Clean away sludge and varnish. Check speeder spring ends for proper settings. -Bent pilot valve. Remove head and replace pilot valve. -Excessive intemal leakage in governor, Check rigging and make necessary part replacements, 12-98 MOONEY AIRCRAFT CORPORATION M20J SERVICE AND MAINTENANCE MANUAL TROUBLE (CONT.) PROBABLE CAUSE REMEDY Excessive over-speeding. -Wrong governor setting. Reset governor. Use test rig if available. -Damaged or wrong gasket between governor base and engine mounting pad. Install correct new gasket. -Sticky governor pilot or relief valve, -Erroneous reading tachometer. -High-RPM screw adjusted too far IN, causingrestricted arm travel, Disassemble, clean, and check for burrs.Replace bent pilot valves. Calibrate or replace instrument. Remove control arm and rotate one serratioaclockwise. Back out high-RPM screwto required maximum RPM.(One turn equals 27 RPM.) -Excessivepropeller bladeseatfriction, Examine propellerhub for cause of friction. Inability to attain positive high RPM: Surging. 61-40-00 - PROPELLER BALANCING Balancing of the propeller by means of an approved system is recommended to provide smoother operation. The vendor system used should be an approved system and the procedures followed very carefully.The propeller may have been balanced with another vendor system previoulsy and may require removalof balancing. old balanceweights and/or other means of Log book entdesmust be made when the propeller is dynamicallyor staticallybalanced CAUTION Place weights, washers, or whatever balance weights are specified atthe locations specified bythe balancing procedures. Be careful placing weights on spinner dome. 12-98 61-40-00 7 SERVICE AND MAINTENANCE MANUAL M20J BLANK 61-40-00 8 12-98 MOONEY AIRCRAFT CORPORATION MOONEY AIRCRAFT CORPORATION M20J CHAPTER 71 POWERPLANT SERVICE AND MAINTENANCE MANUAL SERVICE AND MAINTENANCE MANUAL M20J MOONEY AIRCRAFT CORPORATION CHAPTER 71 POWERPLANT LIST OF EFFECTIVE PAGES CHAPTER SECTION SUBJECT ........... 71-Effectivity ......... 71-Contents .......... 71-0O-0O............ 71-00-01 ............ 71-00-40 ............ 71-00-61 ............ 71-00-92 ............ 71-10-00 ........... 71-11-02 ........... 7%13-03 ........... PAGE .......... DATE 1/2BLANK .......... 3/4BLANK .......... 5 ........... 6 ........... 7 ........... 8 ........... 9 ........... 10 ........... 11 ........... 12 ........... 12-98 12-98 12-98 12-98 12-98 12-98 12-98 12-98 12-98 12-98 12-98 71-EFFECTIVITY 1/2BLANK MOONEY AIRCRAFT CORPORATION M2OJ SERVICE AND MAINTENANCE MANUAL CHAPTER 71 POWERPLANT TABLE OF CONTENTS CHAPTER SECTION SUBJECT ........... 71-00-00 ........ 71-00-01 ......... 71-00-10 ......... 71-00-20 ......... 71-00-30 ......... 71-00-40 ......... 71-00-60 ......... 71-00-61 .......... 71-00-70 ......... 71-00-80 ......... 71-00-90 ......... 71-00-91 .......... 71-00-92 .......... 71-10-00 ......... 71-10-01 .......... 71-11-00 .......... 71-11-01 ............ 71-11-02 ............ 71-12-00 .......... 71-12-01 ............ 71-12-02 ............ 71-13-00 .......... 71-13-01 ............ .............. 71-13-02 ............ ........... 71-13-03 ............ .............. 71-13-04 ............ .............. 71-30-00 ......... 71-60-00 ......... 71-60-01 .......... 71-61-00 .......... SUBJECT ........ General .............. Engine Data ............ Engine Removal ........... Engine Inspection & Repair ........ Engine Installation .......... Engine Ground Checkout ........ Fuel Injection Maintenance ........ Fuel Injector Idle & Mixture Adjustment Starter System Maintenance ........ Engine Mixture Control Rigging ....... Trouble Shooting ........... Starter Trouble Shooting ....... Engine Trouble 8hooting ....... Engine Cowling ........... Cleaning,Inspection and Repair ..... Cowling Removal ......... Top Cowling ......... Bottom Cowling ........ Cowling Installation ........ Bottom Cowling ........ Top Cowling ......... Engine Cowl Flap(s) ........ Engine Cowl Flap Rigging ..... (24-0001 thru 24-2999) Engine Cowl Flap Rigging ..... . . . . (24-3000thru24-TBA) Cowl Flap Indicator Adjustment .... (24-3000thru 24-3410) Cowl Flap Indicator Adjustment .... (24-3411thru 24-TBA) Fireseals ............ Air Intakes ............ Engine Induction System Maintenance Air Intake Duct Replacement ...... 12-98 PAGE 5 5 6 6 6 7 7 8 8 8 8 8 8 10 10 10 10 11 11 11 11 11 11 11 12 12 12 12 12 12 71-CONTENTS 3/4BLANK SERVICE AND MAINTENANCE MANUAL M2OJ MOONEY AIRCRAFT CORPORATION 71-00-00 - GENERAL The M20J SIN 24-0001 and ON has either a TEXTRON-Lycoming IO-360-AIB6D, IO-360-A3B6D or IO-360-A3B6 series engineinstalled.These arefour cylinder,200 H.P., fuel injectedengines. 71-00-01 - ENGINE DATA AIRCRAFT MODEL ............. ENGINE MANUFACTURER ............. ENGINE MODEL ................... BHP (rated MAX) ........................ RPM ........................... NO. CYLINDERS ......................... DISPLACEMENT (Cu. In.) ..................... BORE (Inches) ........................ STROKE (Inches) ....................... COMPRESSION RATIO ...................... MAGNETOS Manufacturer ................... Model . . ...................... ........................... ADVANCE BTC** ..................... VALVE ROCKER CLEARANCE (HydraulicTappets Collapsed) ............................ RIGHT MAG FIRES Top Plugs......................... BottomPlugs .................... LEFT MAG FIRES Top Plugs......................... BottomPlugs ........................ R bank FIRING ORDER ........................ FUEL INJECTOR Manufacturer ....................... Model ........................ OIL CAPACITY (QTS) ................. OIL VISCOSITY RECOMMENDATIONS NOTE:Multi-viscosity oil is recommended for all operations. ALTERNATOR ............... ............... ".......... Bendix- Scintilla**** D4LN-2021 D4LN-3021 25 Degrees** 028 to 080 R bank L bank L bank 1-3-2-4 " .... AVERAGE AMBIENT . AIR TEMPERATURE. Above60 Deg. F 30 Deg to 90 Deg. F 0 Deg. to 70 Deg. F Below 10 De_l. F . SINGLE VISCOSITY GRADES *. . .............. . BENDIX RSA-5ADI 8 MULTI-VISCOSITY GRADES * SAE 50 SAE 40 SAE 30,SAE 40 SAE 20, SAE 30 SAE 40 or 50 SAE 40 SAE 20W-40 SAE 20W-30 PRESTOLITE (24-0001 thin 24-2999) 14V, 60 AMP (24-3000 thru24-TBA) 28V, 70 AMP STARTER .............. ................. SPARK PLUG GAP Fine Wire ................ Massive ................ MAX CYLINDER HEAD TEMP M20J TEXTRON LYCOMING IO-360-A3B6D***/**** 200 2700 4 361.0 5.125 4.375 8.7:1 (24-0001 thru 24-2999) 12V (24-3000 thin 24-TBA) 24V 015 to .018 015 to .022 .......... 475 Degrees F • Refer to latest edition of LycomingService Instruction No. 1014. •* Refer to latestedition of LycomingInstructionNo. 1325. •** EngineModelIO-360-AIB6D (Effective24-0377 and earlierM20J) con be convertedto an IO-360-A3B6D enginewithSB M20-206 compliance. •*** S/N 24-3374 thru 24-TBA have IO-360-A3B6 engineconfigurationinstalled.This configurationutilizestwo Slick Magnetos. 12-98 71-00-00 5 MOONEY AIRCRAFT CORPORATION 71-00-0t M20J SERVICE AND MAINTENANCE MANUAL - ENGINE DATA (CON'T.) START & WARMUP OIL PRESSURE Maximum ............... Minimum ................ NORMAL OIL PRESSURE Maximum ................ Minimum ................ 71-00-19 100 PSi 25 PSI 90 PSi 60 PSi - ENGINE REMOVAL -- Remove engine mounting bolts. -- To assistin installation,identifyand tag each part as it is removed.Plug or cap all lines, hoses, and f_ings as the_/are disconnected. 1. Make surethat all cockpitswitches are OFF. 2. Tum fuel selector valve OFF. NOTE IDENTIFY AND MARK SEQUENCE OF WASHERS ON RUBBER BISQUITS AS WELL AS THE ORIENTATION OF THE BISQUITS FOR EACH MOUNTING POSITION. 17. Slowlyraise engine. Be surethat all lines, hoses, and wires are flee. 3. Rerno_ enginecowl'_gandba_es (SeeSection71-10). 4. Disconnect battery ground cable. 71-00-20 - ENGINE INSPECTION & REPAIR For specific engine inspection and overhaul instructions,consult engine manufacturer's overhaul manual and service instructions. Refer to Bendix Maintenanceproceduresfor magnetos. 5. Remove propeller(referto section61-00-10). 6. Drain engine oilsump. 7. Disconnectthefollowing: A. Vacuum line. B. Cabinheat ducts (at engine). C. Fuel vent lines (at firewall). D. Tachometerddve shatl (if installed). E. Oil temperature bulb. F. Oil pressure line. G. Manifold pressure line. H. Cylinder headtemperature bulb. I. Breather hose. 71-00-30 - ENGINE INSTALLATION Reverse the engine removal procedurefor installation. 1. Engineinstallationtorquevalues are as follows: A. Spark plugs-360 to 420 _nchLbs. B. Hose clamps-10 to 29 Inch Lbs. C. Engine shock mount bolts-450 to 500 Inch Lbs. D. 1/4to 70 inch upper engine mount to fuselage bolts---50 in-lbs. E. #10-32 lower engine mount attach block to fusalage-2Oto 25 Inch Lbs. NOTE Make sure the J7763-1 Lord mounts (load bearing) are positioned aft on upper ring and forward on lower. (Gold--load bearing, Silver--non-load bearing). 8. Disconnect the following control linkage: A. Tbruttle control B. Propeller govemor control. C. Mixturecontrol, D. Alternate Air. 9. Disconnect ignition switch wires from magnetos. WARNING Ground magneto breaker points. 10. Disconnect engine ground strap. 11. Disconnectvoltage regulatorwires (opt.). 2. Reinspect to see that: A. Propeller and spinner are properly torqued. B. Engine mounting bolts are properly torqued. NOTE Positionwasherssame sequenceas when removed. 12. Disconnectalternator and starterwires. 13. Disconnectheater muff and exhaust tail pipe. 14. Disconnectfuel line at enginefuel pump. 15. Shore up fuselage at tail skid usingshodngstand to preventtail from dropping. 16. Attach hoist to lifting eye at top of crankcase. S_ightlyli_.engine to relieve weight from engine mounts. 71-00-01 6 C. Enginecontrols are properlydggedand safeUed. (Recheckrod-endsfor properthreadgdplength.) D. Oil drain plugs aretightened and safetied. E. Oil sump is filled to eight quarts. 12-98 SERVICE AND MAINTENANCE MANUAL M20J F. Spark plugs are tight and ignition hamese is propedy installed. G. Magneto ground wires are properly installed and secured• H. Alternator drive belt(s) tight• I. Oil temperature bulb is tight and safetied. J. Oil pressure relief valve plug is safefled. K. Cylinderhead temperature connectionis secure. L. Tachometer drive is secure (if installed), M. Starterceble connection is secure. N. Alternator(s) wiring is secure, O. Exhaust system is secure. P. Vacuum lines and connections are secure. Q. Fuel connections are tight and pressure checked, R. Manifold pressure lines are tight. S. Oil pressure lines are tight and pressure checked, T. Oil pressure transducer is positioned correctly so no interference with any part of engine installation. U. Fuel Injectionlines are fight and pressurechecked, V. Oil filter is installed and secure. W. Induction manifolds are secure, X. All lines, hoses, and wires are pmpedyanchored, Y. Induction air filter; installed and secure, • Z. Ram Air opening between cowling and air induction duct is aligned, AA. Heat shrouds and baffling are installed and secure, BB. Engine area is free of loose objects, tools, etc. CC. Cowling is installed and secure (See Section 71-11). DD. Cowl flap control rods are connected, 71-00-40 - ENGINE GROUND OPERATION CHECKOUT 1. Prestarflngprocedure(withaimraltheadedintowind): A. Turn ignitionswitch OFF. B. Check magnetoground connections, C. Check engine oil level. D. Checkfuel quantity, E. Operate all controlsthrough full range to check for binding, F. Checkbaffles and cowlingfor security, G. Open cowl flaps; check operation, H. Drain fuel sumps, fuel selector drain or gascolator.Check for sediment and water, I. Place wheel chocks and set parkingbrake, 2. Starting procedure_ A. Set propeller governor control: FULL FWD (HIGH RPM). B. Tum fuel valve ON. MOONEY AIRCRAFT CORPORATION C. Set mixture control at: IDLE-CUTOFF. D. Turn boost pump ON. E. Open throttle 1/4. Push mixture control toward FULL RICH for 3 to 5 seconds; then return to IDLE-CUTOFF. F. Boost pump OFF. G. Clear propeller area. H. Engage starter switch. When engine starts, advance mixture to FULL RICH. I. Start engine. Check oil pressure. If no oil pressure is indicated within 30 seconds, shutdown engine and trouble shoot oil system. Refer to AVCO LYCOMING maintenance publications for procedures. J. Set thrOttle for 900 to 1000 RPM for one minute; then, advance throttle slowly to 1200 RPM for engine warmup. 3. Ground run and warmup. Always head the aircraft into the wind during warmup. Always select HIGH RPM blade-angle setting when ground running the engine. NEVER idle for extended periods at LOW RPM (LOW RPM WILL FOUL SPARK PLUGS). Always operate with the mixture control at FULL RICH, and maintain RPM in the 1000 to 1200 RPM range during warmup and ground run. A. Warm up engine until temperature indications are normal. Monitor cylinder head and oil temperature instruments for overtempereture. B. Check magnetos at 1900-2000 RPM with propeller at HIGH RPM blade angle. Switch ignition-starter switch from BOTH to LEFT to check magneto drop. Switch back to BOTH until RPM returns to normal. Switch from BOTH to RIGHT and check magneto drop. Return switch to BOTH. magneto drop should not exceed 175 RPM on either magneto (drop should be within 50 RPM of each other). A smooth drop off past normal is usually a sign of too lean ortoo rich mixture. If no drop in RPM, check for open or broken P-leads. 71-00-60 - FUEL INJECTION SYSTEM MAINTENANCE For injection system inspection and overhaul instructions, consult engine manufacturer's overhaul manualand serviceinstructions. The fuel injection system consists of the following major components: (1) the fuel injector assembly comprised of the servo regulator, fuel control,and airflow sensing system; (2) the flow divider; and (3) the four air bleed nozzles.The fuel injection system operates by measuring airflow through the throttle body of the servo valve regulator controland usingthis measurement to operate a servo valve within the control. This regulated pressure con-troisthe distributorvalvewhich schedules fuelflow in proportionto airflow. 12-98 71-00-40 7 MOONEY AIRCRAFT CORPORATION M20J 71-00-61 - FUEL INJECTOR IDLE SPEED & MIXTURE ADJUSTMENT 1. For operationin normalor low ambienttemperature conditions,adjustidleand mixtureasfollows: A. Start engine and warm up in the usual manner untiloil and cylinder head temperatures are normal. B. Check magnetos; if magneto drop is normal, proceed with idle adjustment, C. Close throttle to IDLE, approximately 600 RPM. If RPM changes appreciably alter making idle mixture adjustment during succeeding steps, readjust idle speed to desired RPM. NOTE Idle mixture must be adjusted with fuel boost pump on. D. When idling speed has stabilized, pull mixture control smoothly and steadily toward idle cutoff, and observetachometer for an RPM changeduring leaning process.Care must be exercisedto return the mixture control to full rich before RPM can drop to where engine cuts out. An increase of more than 50 RPM while leaning indicatesan excessivelyrichmixture.An immediate decrease in RPM (if not preceded by a momentaryincrease) indicatesidlemixture is too lean. E. If above check indicatesthat mixtureistoo lean or too rich, tam idle mixture adjustment in direction required for correction. F. Repeat step D. to check new position. G. Make additionaladjustmentsand checksas required, NOTE Each time idle speed mixture adjustment is changed, Runup to 2000 RPM to clear engine before proceeding with step D. Allowance should be made for weather and field altitude when adjusting idle mixture. 71-00-90 - TROUBLE SHOOTING 71-00-91 - STARTER TROUBLE SNOOTING SERVICE AND MAINTENANCE MANUAL NOTE If above procedures do not result in stabilized idle speed, check idle linkage for looseness. 2. For operation in high ambient temperature conditions,adjustidle and mixture as follows: A. Adjustidleto 700-750 RPM,or as high as practical. B. In the cool of the morning adjust mixture to provide a 50 RPM rise when the mixture contro s slowly pulled to idle cutoff. C. Maintain cooling airflow by keeping engine RPM as high as practicaldudng ground runup. 71-00-70 - STARTER SYSTEM MAINTENANCE Refer to Section 80 for starter system maintenance procedures. CAUTION Do not operate starter in excess of 30 seconds; allow cooling time before re-engaging. 71-00-00 -ENGINE MIXTURE CONTROL RIGGING 1. Disconnectmixture control. A. Remove cotterkey. B. Remove nut, bolt, and two washers from clevis and mixture controlarm. 2. Reconnect mixture control. A. Reverse disconnect procedure to reconnect mixture control. 3. Adjustment of mixture control arm. A. Loosen Iocknut on control rod end and adjust controlarm rod as required. B. Check for full travel. C. Check for properthread grip. D. Secure Iocknut. See Section 24-39-04 for procedure. TEXTRON-LYCOMING OPERATORS MANUAL should be consulted. 71-00-92 - ENGINE TROUBLE SHOOTING TROUBLE Enginewill not start. -: ; : : _-I ; -No fuel. Check fuel system for leaks. Fill fuel tanks. Clean lines, strainers, and fuel valves. -Incorrect throttle setting. Open throttle 1/4. -Defective spark plugs. Clean and adjust or replace spark plugs. Check with tester and replace defective wires. -Defective ignition wire. 71-00-61 8 12-98 SERVICE AND MAINTENANCE MANUAL IEQU_BLE Engine does not idle propedy. Low.power and uneven running, Engine does not develop full power, -- M20J ..: ' EEMEDt -Improper magneto operation. Clean points. Check timing. Internal failure. Check oil screens for metal particles; if found, remove foreign material and overhaulengine. -Incorrect idle mixture. Adjust mixture control. -Incorrect idle speed. Adjust idle speed. -Induction system leak. Tighten all connections and replace any defective parts. Clean injector nozzles. -Mixture too rich as indicated by black exhaust stacks. (Extremely dch mixtures are indicated by black exhaust smoke.) Readjust fuel injector. -Mixture too lean as indicated by overheatingand backfiring. Check fuel lines for restrictions. Readjust mixture. Clean injector nozzles. -Leak in induction system. Tighten all connections and replace defective parts. -Defective spark plugs. -Improper fuel, Clean and gap or replace spark plugs. Drain and fill tanks with recommended grade of fuel. -Magneto breaker points not working properly. Clean points and check timing. -Defective ignition wire. Check with tester and replace defective wires. -Defective spark plug terminal connectors, Check and replace connectors if required. . -Leak in induction system. Tighten all connections and replace defective parts. -Partial clogging of injector nozzle or fuel screens. Clean nozzle or fuel screens. -Throttle lever out of adjustment. Check throttle linkage travel. Check strainers. Check flow at fuel injector. -Restdction in air scoop. Examine air scoop and remove obstruction. -Faulty ignition. Check Ignition system. -Cracked engine mount. -Partial clogging of injector nozzles or fuel screens. Replace or repair mount. Clean nozzles or fuel screens. -Defective mount bushing. Replace bushing. -Uneven compression. Check compression. -Damaged, out of track, or unbalanced propeller. Check propeller, track, and balance. -Insufficient oil. Fill sump with oil and inspect screen and filter for metal particles after running engine. If particles are found, overhaul engine. -Stuck relief valve. Check and replace if necessary. Improper fuel flow. Rough running engine. Low oil pressure. MOONEY AIRCRAFT CORPORATION 12-98 71-00-90 9 MOONEY AIRCRAFT CORPORATION TROUBLE High oil temperature. M20J SERVICE AND MAINTENANCE MANUAL EP_OE&gLE_AU_ BEMED__ -Air lock or dirt in relief valve. Remove and clean oil relief valve. -Dirty oil strainers. Remove and clean strainers, -High oil temperature. See "High Oil Temperature" in Trouble column below. 'Defective pressure gauge, Replace gauge. -Obstruction in oil pump intake passage. Check for obstruction, -Defective pressure transducer, Replace transducer. (Do not over torque fittings). -Insufficient oil supply. Fill sump with oll of recommended grade and inspect engine for metal particles in screen and filter after running engine. If particles found overhaul engine. -Low grade of oil. Drain and fill sump with oil conforming to specifications. -Stuck thermostatic valve: -Clogged oil lines or strainers. Check and replace as necessary. Clean oil lines and strainers. Excessive blow-by. Excessive oil consumption, 71-10-00 Check compression. Check for worn or stuck rings. -Oil cooler restdction. Check and replace, -Failing beadngs. Check oil strainers for metal particles; if found, remove foreign material and overhaul engine. -Defective temperature gauge. Replace gauge. -Low grade of oil. Drain and fill sump with oll conforming to specifications. -Failing bearings. Check sump for metal particles. -Worn rings. Install new rings. -Improper piston dng installation, -Failure of rings to seat. Install new rings. Use mineral-base oil. Climb to cruise altitude at full power; operate at 75 percent power or higher until oil consumption stabilizes. - ENGINE COWLING 71-11-00 - COWLING REMOVAL The engine cowling is in two sections.The lower cowl (SIN 24-0001 thru 24-3153) containsthe ram-air inlet, landing lightand cowl flaps. SIN 24-3154 thru 24-TBA containonlythe cowl flaps. Quick-disconnectfasteners attach the cowlingpanels. The oil filler access door is in the top cowling section, 71-il-01 -TOP COWLING 71-1fi-01 3. Unlatch cam locks on the aE edge of the top cowlingjust ahead of windshield. - ENGINE COWLING CLEANING, INSPECTION & REPAIR 1. Remove two (2) screws from top cowlingon each inboardside of enginecoolingair intakes. 2. Remove (1) screw from each side of top cowling, forwardand outboa_l.Then unlatchcam lockson each side. Clean cowl by spraying with solvent (PS-661 or equivalent) and wiping, clean. At_er cleaning, inspect cowlingfor dents, cracks, and loose fasteners. Repair defects. 71-10-00 10 12-98 4. Carefullylifttop cowlingoff. SERVICE AND MAINTENANCE MANUAL ' 71-11-02 - BOTTOM COWLING 1. Disconnect landing light wiring connectors near firewall. (24-0001 thru i 24--3153) M20J MOONEY AIRCRAFT CORPORATION - ADJUSTING -/" A. Cut ty-raps secudng insulatingtubes over knife disconnects. .._ B- E0_L FLAP ROD FLUSH ENGINE COWLING B _/ITH 11_ J_ towardflrewalL C. Disconnect knife disconnects and 2. Disconnect cowl flap control md ends at the quick disconnects located on the cowl flap brackets. See Figure 71-1. NOTE Reach up through the cowl flap opening tOcontroldisconneCtrods, flap slide insulaflng tube back over cowl disconnect. 3. Unlatch cam lockslocated on bottomof cowlingbetweenor aroundthe cowl flaps. 4. Unlatch the remaining cam locks on bottomcowlingwhilesupportingthe cowl. 5. Carefullylowercowlingclear of spinner and removefrom aircraft. 71-12-00 - COWLING INSTALLATION i '_ F 7_.1____ COWL FLAPRIGGING (24-0001 THRU 24-2999) FIGURE 71-1 71-13-02 NOTE Check condition of tape on firewall flange where cowling rests. It is recommended that vinyl tape be replaced with polyethylene tape,(3M tape, PIN 5421, (UHMW) 1', wide). This will decrease the streaking during wet weather, 71-12-01 -BOTTOM COWLING 1. The bottom cowling is installed ,first" in reverse sequence of removal. CAUTION Be sure landing lights and cowl flaps are connected prior to installation of top cowling, (24-0001 thru 24-3153) 71-12-02 ,TOP COWLING 1. The top cowling is installedin reversesequence of removal, 71-13-00 - ENGINE COWL FLAPS 71-13-01 , COWL FLAP RIGGING (24-0001 thru 24-2999) 1. Adjust both the left and dght cowl flaps so that in the closed position the outboard trailing edges are flush with the lower engine cowling, (Figure 71,1) (B). Maintain .06 - .12 in. "cushion"on cowl flap control at the instrument panel when cowl flaps are closed. The scissorsshould be in an overcenter positionwhen cowl flaps are closed. • NOTE For improved cooling during summer months or above normal temperature operations, cowl flaps may be rigged to have a .25 max inch gap at "B" when at the closed position, - COWL FLAP RIGGING (24-3000 thre 24-TBA) The cowl flapsare activatedUP and DOWN by an idler arm connected, by a push-pullrod, to the actuatorarm on a geared motor.A cowl flap switch, locatedon the cockpit console directly under the mixture control, activates the geared motor. The- switch has three positions: a center (OFF), an up (CLOSED) and a down (OPEN) position. The cowl flaps may be positionedto any angle by selectingthe switcheither UP or DOWN untilthe desired position,as shown on the positionindicator,has been reached. Then return the switch to the center (OFF) position. Limit switches, which are not adjustable, prevent the cowl flaps from exceeding the fullopen or full closed position. A cowl flap positionindicator is located on the cockpit console adjacent to the flap switch. The indicatoris operatedby a cable connectedto the actuatorarm and routed to the indicator on the console (24-0001 thre 24-3410). A potentiometerelectrically controlsthe LED indicatorfor 24-3411 thru 24-TBA). The cowl flaps are riggedfor a flush contourbetween the cowl flaps trailingedges and cowling,when in the closedposition.Adjust per followingprocedures: 1. With the cowl flaps open, adjust the linkage rods from the idler arm to the cowl flaps to their maximum length. 2. Close the cowl flaps and measure the distance betweenthe cowlflaps trailingedges and cowling. 3. Open the cowlflaps and readjust the linkage rods, decreasingthe lengthby the measuredamount. 4. Close the cowl flaps and ensure that cowlflaps are not outside the cowling contour or that the cowl flaps are not preloaded against the nose gear box. Readjust as required. 12-98 71-11-02 11 MOONEY AIRCRAFT CORPORATION 71-13-03 M20J - COWL FLAP INDICATOR ADJUSTMENT 6. Cycle cowl flap system to vedfy proper movement of indicator. (24-3000 THRU 24-3410) 1. Position the actuator and indicator in the down position. 2. Insertcable thru drilled bolt (2) in actuator arm (1) and tighten. Reference Fig. 71-2. 3. Cycle cowl flaps actuation system a minimumof five timesto insurefree movementofthe indicator, 4. Readjust push-pull cable wire at actuator arm, as required,for proper indicatortravel and secure. 71-30-00 Firewall fireseals and grommets, If removed and replacedfor any reason, shouldbe sealed alter routing the cable or wire assembly from the engine compartment into the cockpit area. Alter installation cover cable or wire and grommet undemeath the flreseal with Coast Pro-Seal 700 on engine side of firewall. 71-60-00 - AIR INTAKES 71-60-01 "_ 2 / duct permits alternate air to enter the engine from within the engine valve cowling. door should A spring-loaded in The the alternate induction air system intake be inspected for proper preload and condition per 100 1 hour inspection in SECTION 5-20-06, 1, G. CAUTION Check security of seal to induction box door. Use EC1403 or EC1300L adhesive to secure LOOKING ," AT CENTER CONSOLE FROM RIGHT SIDE { COWl. FLAP INDICATOR RIGGING - FIGURE 71-2 (24-0001 THRU 24-3410) 71-13-04 -COWL FLAP INDICATOR ADJUSTMENT (24-3411 THRU 24-TBA) 1. Positioncowl flaps in closed position. 2. Adjust cowl flap p0tentiometer on aircraft, to illuminatetop bar in display. 3. Positioncowlflaps to OPEN position. 4. AdjustR1 on AID board, if necessary, to illuminate bottom bar on display, 5. Repeat steps 2 'through 4, until no further adjusment is required, 71-13-03 12 - ENGINE INDUCTION SYSTEM MAINTENANCE - is ducteda to theAir fuel injector. On aSIN 24-0001 thru 24-3153 Ram control moves two-positiondoor manually operated 24-3153). filtered or in the ram-air duct (24-0001 to permitthru the selectionof unfiltereddirect ram air. portin the lower cowlingand Ram air entersthrougha /___¢:_ _'/ /_ - FIRESEALS The engine coolingair intakes and exits are calculated for optimumcooling requirements and minimumdrag. Normal engine operating temperatures are at the optimumto facilitateengine efficiency. The engine inductionair intake is an aluminum duct that picks up impact air and routes it through the air filter to the engine injector assembly. The air intake system includes a RAM AIR intake system that is COWL FLAI INDICATOR I SERVICE AND MAINTENANCE MANUAL seal to door. A dry-type,panel, air filter mountsinthe air intake duct. Filter maintenance is directly related to engine wear;, therefore, the filter should be removed and cleaned every 25 hours or more frequently under dry and dusty operating conditions. Replace the filter alter 500 operating hours or once each year, whichever occurs first. 1. Clean the dry-type induction air filter with compressed air. (Ref. to Section 12-20-01). Replace the filter if it has a damaged housing,tom element, or damaged gaskets. 2. Reverse the air filter removal procedure for reinstallation. Make certain that the filter is tightly sealedand securelyfastened in place. 71-61-00 -REPLACEMENT AIR INTAKE DUCT When the air induction duct must be replaced it is essential that the duct be positioned exactly as the odginal installation to prevent any interference with the cowling. 12-98 MOONEY AIRCRAFT CORPORATION M20J CHAPTER 72 ENGINE SERVICE AND MAINTENANCE MANUAL SERVICE AND MAINTENANCE MANUAL M29J MOONEY AIRCRAFT CORPORATION CHAPTER 72 ( ENGINE LIST OF EFFECTIVE PAGES CHAPTER SECTION SUBJECT ........... 72-Eft/Contents......... 72-00-00. ........... 72-50-00. ........... PAGE .......... DATE 1/2BLANK .......... 3 ........... 4 ........... 12-98 12-98 12-98 TABLE OF CONTENTS CHAPTER SECTION SUBJECT ........... 72-00-00 ........ 72-50-00 ......... SUBJECT General .............. Lubrication ............ 12-98 ........ PAGE 3 3 72-EFF/CONTENTS 1/2BLANK MOONEY AIRCRAFT CORPORATION M20J 72-00-00 - GENERAL Refer to TEXTRON-Lycoming Operators Manual No. 60297-12 and Overhaul and Maintenance ManualNo. 60294-T f or detailedinformationon above topics, 72-50-00 - ENGINE LUBRICATION SYSTEM MAINTENANCE. The engine lubrication is a pump. full-pressure, wet-sump system with asystem gear-driven An oil coolerattaches to the firewall on the M20J model.The oil filter is locatedat the rear end of the oil sump. (Oil pressure:60 PSI MIN, 90 PSI MAX, 26 PSI at IDLE, 100 PSI MAX duringenginewarmup), 1. FilterServicing. A. Oil Filter Removal and Installation. SERVICE AND MAINTENANCE MANUAL 2. Oil Pressure Relief Valve. The oil pressure relief valvemaintainsoil pressurewithinspecified limits.The valve is not adjustable; however, the addition of a maximum of three (TEXTRON-LycomIng P/N STD 425) washers under the cap will increase pressure. Using a spacer (LycomingPIN 73629 or 73630) under the cap decreasespressure.The oil relief valve should be disassemblied, inspected, and cleaned when excessivefluctuationsin oil pressure are noted. 3. Oil Cooler Thermostatic Bypass Valve. The oil coolerthermostaticbypass valve or vematherm valve is not adjustable.This valve allowsoil to bypassthe oil coolerwhen the coolerbecomes obstructed or when oil congeals in the cooler due to low ambient temperatures. (1). Remove old filter and replace with new filter after light film of oil has been spread on gasket. Tightento a torqueof 18 - 20 ft. Lbs. 12-98 72-00-00 3 SERVICE AND MAINTENANCE MANUAL M20J BLANK 72-50-00 4 12-98 MOONEY AIRCRAFT CORPORATION MOONEY AIRCRAFT CORPORATION M20J SERVICE AND MAINTENANCE MANUAL CHAPTER 73 ENGINE FUEL SYSTEMS SERVICE AND MAINTENANCE MANUAL M20J MOONEY AIRCRAFT CORPORATION CHAPTER 73 ENGINE FUEL SYSTEMS LIST OF EFFECTIVE PAGES CHAPTER SECTION SUBJECT ........... 73-Effectivity ......... 73-00-00 ............ 73-31-91 ............ 73-81-01 ............ 73-31-02 ............ 73-31-03 ............ 73-31-94 ............ PAGE .......... DATE 1/2BLANK .......... 3 ........... 4 ........... 5 ........... 6 ........... 7 ........... 8 ........... 12-98 12-98 12-98 12-98 12-98 12-98 12-98 TABLE OF CONTENTS CHAPTER SECTION SUBJECT ........... 73-00-00 ........ 73-30-00 ......... 73-31-00 .......... 73-31-01 ............ 73-31-02 ............ .............. .............. .............. 73-31-03 ............ 73-31-04 ............ 73-31-05 ............ .............. 73-31-06 ............ .............. 73-50-00 ......... SUBJECT ........ PAGE General .............. Indicating ............. Fuel Flow System - General System Description Panel Mounted Instrument...... Fuel Flow Transducer ....... FT-101 SYSTEM ALCOR-TRU FLOW SYSTEM SHADIN SYSTEM General Operating Procedures .... Test Function ......... Troubleshooting "FT 101" Fuel Management Systems ..... Troubleshooting ALCOR Fuel Management Systems ..... Druck Transducer Test Procedure ...... 12-98 3 3 3 3 6 7 8 8 8 8 73- EFF/CONTENTS 1/2BLANK MOONEY AIRCRAFT CORPORATION M20J 73-00-00 - GENERAL The engine and its accessories am certificatedunder TEXTRON-Lycoming Type Certificate. Refer to LycomingOperators or Overhaul Manual for specific instmcfions, 73-30-00 - INDICATING 73-31-00 -FUEL FLOW SYSTEMGENERAL SYSTEM DESCRIPTION The Fuel Flow totalizer system utilizes the latest in microcomputer technology products, The fuel flow system is designed to maximize the efficiencyof fuel system management by displaying the fuel consumption rate (fuel flow) of the engine and the preciseamount of fuelthe engine has consumed.This informationis displayedin one of the followingformats US Gallons, Pounds,Litersor Imperial Gallons (Alcor) depending on internal switch arrangement, see (Figures 73-t and 73-2). The system consists of a panel mounted instrument and a fuel flow transducer which is installed in the aircraftfuel line. The systemis designed for use in all single enginefuel injected aircraft having no more than 60 GAL/HR continuous consumption or 78 GAL/HR Intermittent consumption.CTakeOff power), 73-31-O1 -PANEL MOUNTED INSTRUMENT The panel mounted instrument contains all system electronicsand may be divided intofour groups. SERVICE AND MAINTENANCE MANUAL FT-101 (SYMBOLIC DISPLAYS-SDI) 1. DISPLAY- The display uses one minilamp and four seven segment incandescent digits that are fully sunlight readable and dim automatically during night and low lightflight conditions. 2. MICROPROCESSOR - The microprocessorin the FT-101 contains a crystal controlled oscillator that controlsall timing and computingfunctions for precise fuel flowand tutalizingcomputations. 3. POWER SUPPLY - The FT-101 powersupply is a high speed switching regulator type for optimum efficiencyand the lowestpossible power drain on the aircraftelectricalsystem. 4. MEMORY - The FT-101 microprocessor continuouslystores and updates the totalizecl fuel quantity in a random access memory chip. The Total Fuel Used quantityis retainedduring aircraft shutdown by connectingthe FT-101 memory wire to the aircraft battery through a memory switch. The drain on the aircraft battery =ssmall due to the low power CMOS memorychipwhichusesonly 0.7 milliampsat 12 VDC. 5. INTERNAL SWITCH ARRANGEMENT - The programmingswitch block (see Figure 73-2) IocateP inside the FT-101 panel mounted unit has several arrangements to change data readout if desired. Switches $1 and $2 (see Figure 73-1) should not be changed unless the transducer "K" factor of a replacementtransducer differsfrom the original unit's "K" factor (see Section 73-31-02, 3, for "K" factor description). $3 thin $7 can be positionedin vadous arrangements to change fuel flow readoutto galIons, poundsor liters as the situationmay require,(see Figure 73-1). FT-101 SWITCH ARRANGEMENT .... ................ K- FACTOR ........ .... .... .... .... L ........... M .......... H ........... HH ............ .... ................ FUNCTION .... .... .... GALLONS .......... POUNDS .......... LITERS .......... SWITCH ARRANGEMENT $1 $2 ON ON OFF OFF ......... ON OFF ON OFF SWITCH ARRANGEMENT $3 $4 $5 $6 $7 ON OFF OFF OFF ON OFF OFF OFF ON NA NA NA NA NA NA FT-101 TRUTH TABLES FIGURE 73-1 12-98 73-00-00 3 SERVICE AND MAINTENANCE MANUAL M2OJ MOONEY AIRCRAFT CORPORATION 2. ELECTRONICS - The TRU FLOW 1 amplification systemis located in the indicator away from the engine .=nvironment.The TRU FLOW 1 operates on a low )ower requirement and is protected against voltage _urges. 3. MEMORY - The TRU FLOW 1 microprocesser IN_INSULATOR ' luantity. The total fuel usedquantity is retained dudng aircraft shutdown through a low power drain memory ;ircuit connected to the battery. 4. INTERNAL CONTACT ARRANGEMENT - The INSULATOR _S-REWSC _'__joT configuration selection block located the TRU FLOW ;ontinously 1 indicator updates has and several stores arrangements the inside total to fuel change used .ta ..at.......e be changed uness the K-factor of the transducer has changed due to replacement. (See Section 73-31-02, 6 7 Alcor contactarrangement. '\' 1 t-HOUSING _o_ ._,_/_C_K_ FT-101 SWITCH ARRANGEMENT- FIGURE 73-2 TRU FLOW 1 (ALCOR) 1. DISPLAY - The unit features a liquid crystal display(LCD) to indicate fuel flow and total fuel used simultaneously. The display is back lighted and features automaticdimmingthrough a photosensor. K1 K3 STEP 1. Remove 4 screws (2 on rear of indicator, which also removes connector latch, and 2 on side). Then remove electronic assembly by simultaneously pushing on rear connector and pulling on front bezel. DO NOT BEND THE BOARD CONNECTOR PINS. K5 b---Oqo iCL_DJ o K7 b----O] 0 o LO__OJ O Io ol O LQ_QI o o o o o o o o o o o o o o o o o o O O O O O O O O O O O O O O O O O O o o o o o o o o o o o o N N N N K-FACTI]R_ NOT USED_ UNITS CAUT,ON Some components in the indicator can be damaged by static electricity. Dissassemble the at static controlled DOfor 3, indicator for K-fac )r adescrpton). Refer workstation. to Fgure 73-3 NOT LEAVE THE iNDICATOR UNTIL IT HAS BEEN REASSEMBLED. L K L K U,S, GALLONS IMP, GALLONS 0 K-FACTOR_ NFIT US O0 o o o 73-31-01 4 K prlUNDS L K-FACTOR K LITERS JO00 000 000 i,o o o o o o o o o "IZ) o o iooo o o ! o o o ooo o o o o o o oooo o o UNITS O O O O O O O O O UNITS L A _ J_) o -_o o8 I N73-31 TRU-FLOW UM ERARRANGEMENTF,GURE73-3 12-98 MOONEY AIRCRAFT CORPORATION M20J STEP 2. Remove front bezel assembly from main assembly by grasping edges and slowly pulling bezel from main assembly, STEP 3. Remove one of the two screws holding the main assy,boardsto the standoff,Separate the boards by graspingthe edges and pullingthem apart, DO NOT BEND THE PINS, STEP 4. Locate the circuit board and the CONFIGURATION SELECTION BLOCK inside the indicator, STEP 5. Determine the K-factor to be selected to match the K-factor of the Flowscan 201-B transducer. Use one of the following K-factors to match: Flowscan Alcor K-Factor Transducer Code Code L EQUATES TO K7 M K5 H K3 HH K1 Arrangethejumpers according to Figure 73-3, partA, STEP 6. Determine the desired unit of measurement, Reposition the jumpers according to the examples in Figure 73-3, par[ B. STEP 7. Pdnt the K-factor and unit of measurement on the dot label located on the back orthe Indicator case. STEP 8. Atter reposiUoning the jumpers, reassemble the indicator in the reverse order of disassembly, CAREFULLY LINE UP THE PINS. STEP 9. Alter reassembly, power up indicator and check configuration.For approximately 2 seconds the dght side of the indicator display will depict numbers that indentifythe configurationsof units.(Figure73-5). STEP 10. If fuel flow or quantity used totals do not match actual values after several hours of flying contact the manufacturer (Alcor) for trouble shooting procedures, Aeresonic Transducer Floscan Transducer SERVICE AND MAINTENANCE MANUAL NOTE Repnsition the jumpers by grasping with needle nose pliers and pulling straight up to remove them, then reinsert to select the appropriate K-factors and units, SHADIN SYSTEM SHADIN SYSTEM MEMORY System includes a non-volatile memory for retaining basic settings and Fuel Remaining and Fuel Used dudng power shut down. TEST FUNCTIONS AND ERROR MESSAGES Press "TEST" button. Program checks hardware and display. If test is successful, "good" is displayed; if not "bad" is displayed and system is to be considered unserviceable untilcorrective action is taken. When "test routine" is completed, system will display the following: 1. Softwarebasic # and revision level. 2. K factor setting in flow window (pulse count per gallon). This number MUST match pulse count stamped on fuel flow transducer, otherwise errors will occur. 3. Display units (Gal., LB 5.8), part of checking internal settings. 4. Loran-C (GPS) distances as shown on Loran-C (GPS) receiver to check Data Interface Integrity. If system is not capable of reading Loran-C (GPS) data, the word "LbAd" will be displayed. REPLACEMENT OF SHADIN SYSTEM COMPONENTS Replacementof either flow flow transducer or display unit must have new units set to same K- factor as old unit. Transducers are pre-set by manufacturer and display unit must be set to agree with transducer setting.Refer to table below: K-Factor 3 (85000 pulses/gal.) L M H IndicatorSetting 3 or 85000 82000 85000 87000 To change K-Factor in Shadin Minifio display unit: 1. Remove can from indicator 2. Locate switch "0". (Ref. Figure 73-6) 3. Set switch to one of the following positions: K-Factor Sw. # Display will read K-Factor Sw. # Display will read K-0 K-1 K-2 K-3 K-4 B A 9 8 7 88.0 87.0 86.0 85.0 84.0 K-5 K-6 K-7 K-8 K-9 6 5 4 3 2 83.0 82.0 81.0 80.0 79.0 12-98 73-31-01 5 SERVICE AND MAINTENANCE MANUAL M20J MOONEY AIRCRAFT CORPORATION Transducers are categorized by output for a given GPH flow rate ("K Factor)". This will be noted as: L, M, H, or HH scribed on the end of the serial no. For accurate readings, replacement transducers should have the _ cDnjE_'l'_lo_ .n_ A SDUCERi -_ u_ replaced, Specify "K" thebeing number of pulses per second new. factorSame unitScode "K" factor when ordering as the 4. Fuel flow transducer removal. TURBINE FUEL FLOW TRANSDUCER - FIGURE 73-4 73-31-O2 A. Remove top and bottom transducers. cowling from aircraft. See Section 71-10-00 for procedures. B. Cut and remove ty-raps from insulator sleeves on knife disconnectsof electricalwires. C. Slide insulationsleevingup on electdcalw!re harness. - FUEL FLOW TRANSDUCER 1. The turbine flow transducer, mounted in the enginefuel line, measures flow of fuel. The transducer is rated for a continuousoperation to 60 gallons per hour. In addition,the transducer is accurate down to 0.6 gallonsper hour. 2. Thetransducersuppliesthefuelflowindicatorwith a pulse signal from a self contained opte-electronic pickup.A neutrally buoyant rotor spins with the liquid between V-jewel bearings. The rotor movement is sensed when notchesin the rotor interruptan infra-red light beam between a light emitting diode and a photo-transistor. D. Disconnecttheknifediscennects. E. Remove safety wire from flresleeve around turbinetransducer and unwrapfiresleeve to exposethe transducer. F. Loosen and remove nuts, washers and bolts from transducer and bracket. Pull transducer and hoses awayfrom engine as far as possible. G. Disconnect the hose nuts from transducer fittings.The transducershould now be free for removal. Note positionof fittingson oldtransducer. H. Cap all linesto preventcontamination. 3. The transducer design is fail safe; complete rotor blockagecannot interruptfuel flow. The transducerlife expectancyis 1500 hours. 5. Fuel flow transducer(replacement)installation. r_ SOFTWAREVERSIONNO. , t iCO El . _ _ , : K - FA TOR .- FLOW ./ UNIT OF MEASUREMENT TOTAL J UNITS: 4 = U.S. GALLONS 3 = IMPERIALGALLONS 2 = POUNDS'(5.85 X U.S. GALLONS) K-FACTORS ARE DISPLAYEDAS ACTUAL K-FACTOR RANGE, ie., 1 = K1, 2 = K2, etc. TRU-FLOW 1 CONFIGURATION - FIGURE 73-5 73-31-02 6 12-98 MOONEY AIRCRAFT CORPORATION us M20J us SERVICE AND MAINTENANCE MANUAL II [U9 i374HC74II I,-L,'I. I us \ -[E; _) U1 i ]_'l RN, I I J1 L 27cxxx [SN73-SHA SHADIN FUEL PLOW C ROUITFIGURE 73-B NOTE The "K" factor of the replacement transducer should match the "K" factor of the replaced unit. Refer to "NOTE" following Section 73-31-02, paragraph 3 for detaUed explanation, A. Notethe positionof fittingson old transducerand placethem insimilarposiflononthe newtransducer, B. Connect hose nuts to transducer fittings, tighten. C. Connect the new transducer to bracket using belts, washers and nuts. CAUTION Make sure the hoses are not being put into a bind or twist when securing the transducer to the bracket, D. Tighten all nuts on fuel hoses and bolts to securethetransducer, E. Connect the knife disconnects and slide insulatingsleeving over connections. SeciJresleeving withty-raps. F. Leak check all fuel connectionsby pressudzing the fuel lines with boost pump. Correct any leaks or discrepancies, G. Wrap flresleeving over transducer and secure into positionwithsafetywire. NOTE Installation of the newtransducer may affect the engine fuel flow adjustment. It is recommended that the procedures of Section 71-00-00 be followed to assure engine is set up for proper operation, H. When all adjustments have been made and all connections checked for security, install the cowling per Section71-12-00. 73-31-O3 - GENERAL OPERATING PROCEDURES 1. Turn on the aircraft master switch. On activating the aircraft electrical system, the FT-101 display will flash zeros (000.0). This flashingis a reminderfur the pilot to reset or check the fuel used number by pressing either the RESET or USED/TEST buttons. Once the RESET or USED/TEST button is depressed, the display will stop flashing and read fuel flow. The TRU FLOW 1 will display the configuration unit and K-factor on the right side of display window (Refer to Figure 73-5). After starting the aircraft engine, the FT-101 will continuouslydisplayfuel flow. Total Fuel Used may be displayed by pressing and holding the USED/TEST buttonon the rightof the instrument.Total Fuel Used will be displayed as long as the USED/TEST buttonis depressed (or for 2 seconds), whichever comes first. This number may be reset to zero (0.0) by depressing and holdingthe RESET button for at least 1 second. The TRU FLOW 1 displays both functions simuitaneoulsy. 2. The totalizer function in both systemsbe used as a single flighttotalizer or as a long term totalizer.Both methods are explained below. A. SINGLE FLIGHT TOTALIZER. The aircraft should be topped with fuel before each flight so the total usable fuel will be known. Turn on the aircraft master switch. On activating the aircraft electrical system, the FT-101 will flash zero (000.0) fuel flow. Push and hold the reset button, located on the left of either instrument, for at least 1 second. The RESET button has a one half second delay to prevent accidentalreset. On startingthe engine, the FT-101 will begin displaying fuel flow. Total fuel used may be checked by depressingthe USED/TEST button. 12-98 73-31-03 7 SERVICE AND MAINTENANCE MANUAL M20J B. LONG TERM TOTALIZER. Tum on the aircraft master switch. On activating the airoreit electdcal system, the FT-101 will flash zero (000.0) fuel flow. Depress and hold the USED/TEST button the FT-101 willdisplaythe total fuel used from previousflights. DO NOT push the RESET button! On starting the engine, the will fuel flow9999 and continuecounting fuelFT-101 used up todisplay 999.9 gallons, pounds, or 9999 liters depending on the model. The Alcor unit will displayfuel flow and totalused from pastflights, 73-31-04 - TEST FUNCTION A test function is provided in the FT-101, so the pilot may vedfy that all digits are functioning pdor to each flight. To use the test function, depress and hold the USED/TEST button two times within one second and the FT-101 will display all eights (888.8). 73-31-05 -MANAGEMENT TROUBLESHOOTING FT-101 FUEL SYSTEMS Troubleshootingthe FT-101 fuel management system should be approached in a systematic manner. All problemscan be put in one of five categories: - Improper operation due to lack of knowledge about the system, - Inoperativecomputer or main instrument. - Inoperativetransducer. wires. Check BLACK wire for A/F ground. Check RED wire for bus voltage. Check WHITE wire for 2-3 volts with no fuel flow and increasing to near bus voltage at fullflow. (2) If no increase in voltage is seen on WHITE wire as flow increasesor if too high a voltageindication isseen with noflow, change transducer. (3) If RED wire does not have bus voltage, check wiringfrom transducerto Pin 3 of indicator. (4) If BLACK wire is not grounded, check widng from transducerto Pin 6 of indicator. 3. ERRATIC INDICATIONS A. Checkwidng forloose connections. B. Check wiring for intermittent shorts. C. Check transducer for foreign particles, D. If all checks OK, replace transducer. 4. INACCURATE READINGS A. Check transducer K-factor. The letter "L","M","H",or =HH" inscribedafter the serial number. B. Remove indicator from instrument panel and case. Check switch settings and correct to match transducer. NOTE Each switch setting changes reading by approximately 2 %. If settings are OK, replace transducer. CAUTION - Improperwiring, - Impropertransducerinstallation, 1. MEMORY LOSS A. Loses memory when "MASTER" switch is turned OFF. (1) Check =Fuel Flow Memory"switchON. Whenever transducer or indicator is replaced, care must be taken to set indicator switches to match transducer. If after makingthese checksyou still do not isolatethe problemor do not find a problem, contactthe Product SupportDepartment of Mooney AircraR Company for further assistance. (2) If switchis ON, check clockfor operation, (3) If clock inoperative,replacefuse at battery. (4) If no problem found, remove connector from unit,check Pin 9 for buss voltage. (5) If voltage present,replace FT-101. B. Memory scrambles when engine starts. ExchangeFT-10_ for modifiedunit. 2. DOES NOT INDICATE A. No display, (1) Remove connector from indicator.Check Pin 1 of harnessconnector for bus voltage. Check Pin 8 for airframe ground. If OK, changeindicator. B. Displayszeros (withengine running) (1) Remove cowling for access to transducer. Remove insulating sleeving from connections on all 73-31-04 8 MOONEY AIRCRAFT CORPORATION 73-31-06 - TROUBLESHOOTING THE TRU FLOW 1 (ALCOR) FUEL MANAGEMENT SYSTEM If problemis determined to be in the indicatorand all transducerand wiring checks have been made, contact Alcor, Inc., 10130 Jones-MaltsbergerRoad, PC Box 32516, San Antonio, Tx. 78284, telephone (210) 349-3771 for further assistance. 73-50-00 - DRUCK TRANSDUCER TEST PROCEDURE Referto Section 79-40-00 12-98 MOONEY AIRCRAFT CORPORATION M20J CHAPTER 74 ( IGNITION SERVICE AND MAINTENANCE MANUAL SERVICE AND MAINTENANCE MANUAL M20J MOONEY AIRCRAFT CORPORATION CHAPTER 74 _ ! IGNITION LIST OF EFFECTIVE PAGES CHAPTER SECTION SUBJECT ........ PAGE 74-Effectivity/Contents ....... 74-00-00 ............ 74-30-00 ............ .......... DATE 1/2BLANK .......... 3 ........... 4 ........... 12-98 12-98 12-98 TABLE OF CONTENTS CHAPTER SECTION SUBJECT " . 74-00-00 74-10-00 74-10-01 ............. 74-10-02 74-20-00 74-30-00 .......... ........ ......... .......... .......... ......... ......... SUBJECT ........ PAGE General .............. Electrical Power ........... Magneto Inspection, Maintenance, Installation & Timing ........... Ignition System Troubleshooting ..... Engine Firing Order .......... Switching ............. 12-98 3 3 3 3 3 3 74-EFF/CONTENTS 1/2BLANK MOONEY AIRCRAFT CORPORATION 74-00-00 M20J SERVICE AND MAINTENANCE MANUAL - GENERAL engines are equipped with Bendix 2000 or 3000 Sedes magnetos. The magneto incorporates an impulse coupling that retards the spark for starting. When the engine starts, counter weights hold the impulse coupling latch pawls away from stop pins. The magneto then will fire at its advanced firing position. The magneto/starter switch combines both ignition and startingfunctions.Turn the key clockwisethrough R, L and BOTH to START position;push forward on key while in START and the starter relayis energized. Release of the key, after engine starts,will return the switchto the BOTH positionwhere both magnetosare operative. In the OFF positionboth magnetosare grounded.At the R positionthe left magnetois groundedand atthe L positionthe rightmagnetois grounded. NOTE Mooney Service Instruction M20-59A, or later revision, should be complied with for improved starting. 74-10-00 - ELECTRICAL POWER 74-10-01 ENGINE FIRING ORDER - FIGURE 74 -1 - MAGNETO INSPECTION, MAINTENANCE, INSTALLATION & TIMING 3. MagnetoDrop Out of Limits. Refer to engine and magneto manufacturers Service Manual for magneto inspection, maintenance, installation and timing, A. Checkmagneto-to-enginetiming. B. Inspect contact breaker points for proper clearances. 74-10-02 C. Check spark plugs and leads. NOTE Service.ignition system per TEXTRON-Lycommg Service Manual Section 4. 74-20-00 - ENGINE FIRING ORDER 74-30-00 - SWITCHING - IGNITION SYSTEM TROUBLE SHOOTING 1. Hard starting. A. Assure thatthe impulse couplingis operating. B.Check magneto timingto engine. 2. Engine Roughness. A. Install newsparkplugs. B. Check plug leads for detedoretion, C. Check magneto contact points for burning and dirt accumulation. The Magneto/Starter switch is connected to the magneto grounding wires ("P" leads) of both magnetos. Turning this switch from "BOTH" to "OFF" or from =R" to "L" to "OFF" will ground out both or either magneto. (See SECTION 74-00-00 for grounding sequence.) 12-98 74-00-00 3 SERVICE AND MAINTENANCE MANUAL M2OJ BLANK 74-30-00 4 12-98 MOONEY AIRCRAFT CORPORATION MOONEY AIRCRAFT CORPORATION M20J SERVICE AND MAINTENANCE MANUAL CHAPTER 76 ENGINE CONTROLS SERVICE AND MAINTENANCE MANUAL M20J MOONEY AIRCRAFT CORPORATION CURRENTLY NOT BEING USED 12-98 76-ENGINE CONTROLS 1 MOONEY AIRCRAFT CORPORATION M2OJ BLANK 76-ENGINE CONTROLS 2 12-98 SERVICE AND MAINTENANCE MANUAL MOONEY AIRCRAFT CORPORATION M20J SERVICE AND MAINTENANCE MANUAL CHAPTER 77 ENGINE INDICATING SERVICE AND MAINTENANCE MANUAL M20J MOONEY AIRCRAFT CORPORATION CHAPTER 77 ENGINE INDICATING LIST OF EFFECTIVEPAGES CHAPTER SECTION SUBJECT ........... 77-Eft/Contents......... 77-00-00 ............ 77-10-02 ............ PAGE .......... DATE 1/2BLANK .......... 3 ........... 4 ........... 12-98 12-98 12-98 TABLE OF CONTENTS CHAPTER SECTION SUBJECT ........... 77-00-00 ........ 77-00-01 ......... 77-10-00 ......... 77-10-01 .......... 77-10-02 .......... 77-10-03 .......... 77-20-00 ......... 77-20-01 .......... 77-20-02 .......... SUBJECT ........ General .............. Ranges ............. Power Indicating ........... Tachometer ........... Manifold Pressure ......... Fuel Flow Indicating System ...... Temperature Indicating ......... Exhaust Gas Temperature ....... Cylinder Head Temperature ...... 12-98 PAGE 3 3 3 3 4 4 4 4 4 77-EFF/CONTENTS 1/2BLANK MOONEY AIRCRAFT CORPORATION 77-00.00 M20J SERVICE AND MAINTENANCE MANUAL - GENERAL Engine indicatinginstrumentsand their sending units, transducers,probes, etc., must be operatingproperly to preventengine damage. It is recommendedthat all engine indicatingcomponentsbe checkedat each 100 hour or annual inspectionto vedfy proper operation. Calibrated instruments may be "Tee'd" into the J_harticular systems for a compadson check between em and the aircraft'sinstruments. 77.00.01 - RANGES POwer plant instruments operate electrically through variations in resistance caused by pressure or temperature changes, by vadations _n current output caused by varying engine RPM or alternatoroutput, or by pressurefrom engine inductionsystem. 1. Ammeter. A. Range--+60 to 24-2999 -60 AMPS 24-0001 thru B. Range--+70 to -70 AMPS 24-3000 thru 24-TBA C. Tolerance--1.2 AMPS. 5. Tachometer. A. Green arc---1950 to 2700. B. Red line---2700. C. Yellow arc--1500 to 1950 RPM (1600-1950 S/N 24-0001 thru24-0377 except24-0084). 6. Cylinderheadtemperaturegauge. A. Green arc--300 to 450 degrees F. B. Redline---475degreesF. 7. ManifoldPressureGauge A. Normaloperatingrange 10.0 to 35.0 In. Hg. 77-10.00 , POWER INDICATING 77-10.01 - TACHOMETER (S/N 24-0001 thru 24-1417) These aircraft have a mechanical installation. 2. Fuel pressure gauge. tachometer The electric tachometer (24-0001 thru 24-2999) counts ignition pulses from the magneto to indicate engine speed in revolutions per minute (RPM). The tachometer is connected to the "L" and "R" terminals on the Magneto/Starter switch and senses the magneto impulses through this wire connection. Two 15K ohm resistors are in series between the "L" and "R" terminals and the connection of these two wires and the single wire going to the tachometer. These two resistors, located immediately adjacent to the Magneto/Starter switch inside the insulating sleeve, protect the magnetos from grounding out if a short develops in the tachometer. The electric tachometer on SIN 24-3000 thru 24-TBA gets its signal from a second set of breaker points in the magneto. The tachometer counts the impulse and records the correct RPM. A. Green arc--14.0 PSIto 30 PSI. B. Red line---14 MIN, 30 PSI MAX. 3. Oiltemperaturegauge. A. Green arc--150 degreesto 245 degrees F. B. Red line--245 degrees F. C. Tolerance--3 degrees F. 4. Oil pressure gauge. A. Green arc--60 to 90 PSI. B. Yellow arc--(1) Idle range--25to NOTE The oil pressure relief valve may be honed to improve low idle oil pressure. 60 PSI. (2) Starting & warmup range--90 to 100 PSI. C. Red line---25 PSI MIN, 100 PSI MAX. TACHOMETER TROUBLE SHOOTING. TROUBLE PROBABLE CAUSE REMEDY No permanent or intermittent indicator reading. -Broken shaft. Replace shaft. -C/B out (IGN/CIG LTR) Reset C/B. -Broken wire Check & repair wiring. -Faulty instrument. Replace instrument. -Rough spot on, orsharp bend in shalt. Repair or replace shaft. -Excessivefriction in instrument. Replace instrument. -Magnetotimingtoo wide betweenmags. ReUmemagnetos -Isolation resistors at mag. sw. increased in resistance value Replace resistors. Pointer Oscillates excessively. 12-98 77-00-00 3 SERVICE AND MAINTENANCE MANUAL M20J MOONEY AIRCRAFT CORPORATION TROUBLE (con't.) PROBABLE CAUSE REMEDY PointerOscillatesexcessively (con't) -Wiringconnectionsbad. Locateand repair 77-10-02 - MANIFOLD PRESSURE pressure in the induction air manifold. Manifold pressure varies somewhat with pitch attitude in flight and therefore small oscillations may occur in flight, particularly in turbulent air. Manifold pressure is an indication of engine power affected pdmadly by throttlesetting. The instrumentis calibratedin inchesof mercury (Hg) and indicatesthe MANIFOLD PRESSURE TROUBLE SHOOTING. TROUBLE PROBABLE CAUSE REMEDY Excessiveerror at existing barometricpressure. Pointer sh_ed. Replace instrument. Excessiveerror when engine is running. Lineleaking. Tighten line connection. Sluggishor jerky pointer movement. improperdampingadjustment. Adjustdampingscrew. Brokenor loosecover glass. Vibrationor excessivepressure. Replace glass and reseat case. Dull or discolored luminous markings. Incorrect reading. Age. Replace instrument. Moisture or oil in line. Disconnect lines and purge with air. 77-10-03 - FUEL FLOW INDICATING SYSTEM Aircralt with a combination EGT/OAT gauge utilize a non-grounded EGT probe. An ohmmeter connected between either lead and the probe case should indicate high resistance. If zero or low resistance is indicated the probe has shorted and should be replaced. 77-20-02 - CYLINDER HEAD TEMPERATURE Referto Section 73-30-00 forthis data. 77-20-00 -TEMPERATURE INDICATING 77-20-01 - EXHAUST GAS TEMPERATURE (EGT) INSTRUMENT A thermocouple, attached to the exhaust stack or all exhaust stacks (optional) sends an electrical signal to the E.G.T. Instrument. As the exhaust gas temperature rises, the thermocouple sends an electrical current through the field coils of the instrument, moving the pointer to indicate temperature rise. 77-10-02 4 The cylinder head temperature (CHT) instrument provides the operator with an indication of how hot or cool the cylinders are operating during flight. A resistance type temperature probe is installed in the number 3 cylinder (standard configuration). An optional system provides a probe in each cylinder to provide monitoring of each cylinders temperature. 12-98 MOONEY AIRCRAFT CORPORATION M20J CHAPTER 78 EXHAUST SERVICE AND MAINTENANCE MANUAL SERVICE AND MAINTENANCE MANUAL M20J MOONEY AIRCRAFT CORPORATION CHAPTER 78 EXHAUST LIST OF EFFECTIVE PAGES CHAPTER SECTION SUBJECT ........... 78-EFF/CONTENTS 78-00-00 ............ 78-00-00 ............ PAGE ....... .......... DATE 1/2BLANK .......... 8 ........... 4 ........... 12-98 12-98 12-98 TABLE OF CONTENTS CHAPTER SECTION SUBJECT ........... 78-00-00 ........ 78-10-00 ......... 78-30-00 ........ 78-40-00 ........ SUBJECT ........ General .............. Exhaust System Installation........ Exhaust System Servicing ......... Pedodic Replacement Components ....... 12-98 PAGE 3 3 3 4 78-EFF/CONTENTS 1/2BLANK MOONEY AIRCRAFT CORPORATION I M2OJ 78-00-O0 - GENERAL The exhaust system's headers and exhaust pipes are made from 321 CRES steel. They are designed to optimallyscavengethecylinders exhaustgasesdudng normalengineoperation.Inspectionsfor cracks, bums, etc. are requireddudng each maintenanceactivityand recommendedbefore each flight. 78-10-08 - EXHAUST SYSTEM INSTALLATION 1. EXHAUST PIPE HEADERS TO ENGINE. A. Place new exhaust gaskets in position on the LH & RH engine exhaust flange studs, B. Place either LH or RH flanges. header pipes into position on engine cylinder's exhaust Be careful during this procedureto ensure that exhaust gaskets remain in proper positionon each cylinder exhaustflange. NOTE Attach new headers with existing exhaust flange stud nuts. (If nuts have been damaged, replace them with new nuts SERVICE AND MAINTENANCE MANUAL J. Tighten bolts/nutson ball joint flange. Spring will begin to compress pdor to castellation on nuts reaching cotter pin hole in bolt. Continue tightening until any one of the nut castellaUons reach the completehole in bolt. Install cotter pins in all bolts & nuts. K. Hangtailpipewith hanger assemblyattachedto flrewallor exhaustcavitySupports. L. Verify all hardware is secure on header pipes, mufflerand tailpipe. 3. EGT PROBE INSTALLATION/SECURITY A. EGT probe clamp assembly should be safety wired after positioning and tightening of clamp to prevent possible loosening due to engine operation. 78-30-00 - EXHAUST SYSTEM SERVICING 1. CLEANING To properlyinspectexhaust system,componentsmust be cleanand free of oil,grease, etc. Clean as follows: Leave exhaust flange stud nuts looseso header pipes are movable. C. Lubricate outside of inner and inside of outer slipjoints on headers and inside of mufflerpipe flanges with Hi-temp anti-seize compound, C5-A (FeI-Pro) or equivalent. D. Have someone assist withthe placementof the mufflerassemblyintothe already installedheaders, E. Assemble muffler assemblyintothe not installed header pipes; position headers onto the aircraft engine exhaust flanges. Be careful during this procedure to ensure that the exhaust gaskets remain in proper posiflon on each cylinder exhaust flange, F. When muffler and headers are attached to engine, flange nuts snug but not torqued, check that the muffler is free to move laterally, lee to dght, with moderate push/pullforce. This insuresthat header and muffler pipes are aligned properly, NOTE Proper lateral movement may be obtained by loosening cylinder exhaust stud/flange nuts and gently re-positioning header pipes (at the upper flanges)inboard or outboard as the situation requires. The stud/flange nuts can then be re-tightened and the lateral muffler A. Spray engine exhaust system componentswith a suitable solvent (Stoddard Solvent), allow to drain and wipedrywith clean cloth. WARNING Never use highly flammable solvents on engine exhaust systems. WARNING Never use a wire brush or abrasives to clean exhaust systems or mark on system with lead pencils. 2. VISUAL INSPECTION OF COMPLETE SYSTEM A thorough inspection of engine exhaust system will detect any breaks or cracks causing leaks which might result in loss of efficiency, loss of engine power or engine compartment fire. Inspect per following procedures: NOTE This inspection should be conducted when engine is cool. Remove all muffler shrouds/shields to permit full visual inspection. movement checked again, G. When free movement of muffler is obtained, torque exhaust flange stud nuts -- 100 to 110 inch Ibs. Recheck for freedom of movement after nuts have beentorqued, H. Attach tailpipe to exhaust pipe ball joint flange (3 bolts/springs/nutsat balljoint flange) with existingor new hardware. I. Orientate tailpipe'and muffler exhaustpipe so the continuingplane is approximately parallel to the ball joint connection. Verify tailpipe exhaust end is 1.5 +/0.5 inches from nose gear door assembly and the exhaust opening is not pointed toward nose gear door. A. LOOK FOR LEAKS - Examine surfaces adjacent to exhaust system componentsfor signs of exhaustsoot. Look for gray, red or black gas stains at welds, clamps,flanges, etc. Inspect exhaust systemfor chaffing by cowling, engine mount, cables or any airframecomponents. Inspect exhaust stacks for burned areas, cracks and looseness. B. LOOSE CONNECTIONS - Inspect exhaust clampsfor cracks, loosenessand propersecurity. NOTE During inspection, particular attention should be given to condition and security of flanges, spot welds, slip joints, and welded areas. C. INTERNAL EROSION - Examine bends and low spots forthinning or pitting. 12-98 78-00-00 3 SERVICE AND MAINTENANCE MANUAL M20J D. STANDOFFS (PINS) AND HEAT TRANSFER FINS - Look for missing or damaged heat transfer pins or fins. Lookfor holes at these locations, E. METAL FATIQUE - Inspect all surfaces for bulging and distortion, and for groups of small cracks. CAUTION DO NOT mark any surface with lead pencils or any carbon-containing markers. F. BAFFLE BREAKDOWN Lookrestrictthe inside mufflerfor broken bafflesor tubes. These- can outlet, causingpowerloss. G. HIDDEN DAMAGE - Carefully inspect all internal surfaces that lie hidden under external gussets,stiffeners,etc. CAborescopeis recommended) 78-40-00 4 MOONEY AIRCRAFT CORPORATION H. INSTALLATION TIPS - Install only correct parts. DO NOT FORCE FIT any component. Properly align connectingcomponents. Do not reuse gaskets. Insure that attach bolts are propedy torqued. Exhaust flange stud nuts are to be torqued to 100-110 inch Ibs. 78-40-00 - PERIODIC REPLACEMENT COMPONENTS It is recommended that all exhaust system components, pipes, clamps and miscellaneous mounting hardware be replaced at engine overhaul time (2000 Hours).However,thorough inspection of all componentsshould be made any time exhaustsystem is removed from engine for component replacement. The inspection should be made in the interest of preventivemaintenance. 12-98 ---- MOONEY AIRCRAFT CORPORATION M20J CHAPTER 79 OIL SERVICE AND MAINTENANCE MANUAL SERVICE AND MAINTENANCE MANUAL M20J MOONEY AIRCRAFT CORPORATION CHAPTER 79 OIL LIST OF EFFEC'i'IVE PAGES CHAPTER SECTION SUBJECT ........... 79-Effectivity/Contents ....... 79-00-00 ............ 79-30-02 ............ PAGE .......... DATE 1/2BLANK .......... 3 ........... 4 ........... 12-98 12-98 12-98 TABLE OF CONTENTS CHAPTER SECTION SUBJECT ! ........... 79-00-00 ........ 79-0(:}-01 ......... 79-00-92 ......... 79-20-00 ......... 79-30-00 ......... 79-30-01 .......... 79-30-02 .......... 79-40-00 ......... SUBJECT ........ General .............. Oil Filter Removal .......... Oil Filter Installation .......... Distribution ............ indicating ............. Oil Pressure............ Oil Temperature.......... Druck Transducer Test Procedure 12-98 PAGE ...... 3 3 3 3 3 3 4 4 79-EFF/CONTENTS 1/2BLANK MOONEY AIRCRAFT CORPORATION 79-00-00 M20J - GENERAL 2. Cut and remove safety wire on filter. The oil system is a wet sump, pressure type system. The engine sump has an 8 quart (U.S.) capacity. Servicing of the oil quantity is provided through an accessdoorlocated ontop of the enginecowling. The aircraft is delivered with the proper weight, non-detergent,mineral oil (MIL-L-6082). This oil should be replaced at 50 hours or when oil consumptionhas stabilized. The replacement oil should conform to LycomingSpecification301F. The routine oil change interval is 100 hours, however if operating in a dusty environmentthe interval should be more often. NOTE A new, remanufactured or newly overhauled engine should be operated on straight mineral oil for a minimum of 50 hours or until oil consumption has stabilized. Change to a TEXTRON - Lycoming approved additive oil and begin the 100 hour oil change interval. NOTE Refer to Section 5-20-07 or to Lycoming Operator's Manual for approved oil products and servicing information. 79-00-01 SERVICE AND MAINTENANCE MANUAL 3. Loosenthe spinoff oil filterand remove. 79-00-02 - OIL FILTER INSTALLATION 1. Positionnew tilter on adapter. 2. Tighten per instructionsonfilter. 3. Safetywire filter. 4. Perform leak check priorto flight. 5. Reinstall lower and upper cowling (see Sectio_ 71-11-00). 6. Connectand secure all electdcal and mechanical connections. 79-20-00 - DISTRIBUTION Reference - FIGURE 79-1 - OIL FILTER REMOVAL The engine oil filter should be replaced each 50 hours and at evenj oil change. 1. Remove top and bottom cowling (see Section 71-10-00). 79-30-00 - INDICATING 79-30-01 - OIL PRESSURE Oil pressureindicatingis providedthrough a pressure transducer plumbed into the engine oil system. Pressure variations change the resistance within the transducer and this signal ddves the oil pressure gaugelocatedwithin the clustergauge. LUBRICATION DIAGRAM SCHEMATIC - FIGURE 79-1 12-98 79-00-00 3 SERVICE AND MAINTENANCE MANUAL 79-30-02 M20J - OIL TEMPERATURE The oil temperature gauge is an electric unit receiving its signal from a temperature bulb in the engine case, locatedbetweenthe oil coolerand the case. The probe resistance changes as the oil temperature changes and this vadesthe readouton the instrument, 79-40-00 -DRUCKTRANSDUCER TEST PROCEDURE The DruckTransducer Test Box, GSE 030036, can be used to simulatefuel and oil pressure in Mooney M20J models that have the Druck pressure transducer installed, To use the unit for troubleshooting, the box is connected to the aircraft harness in the engine compartment,by disconnectingthe appropriate Druck transducerelectrical connectorand connectingthe test box in its place. Turn aircraft Master Switch ON (insure engine gauge circuit breakers are in) and adjust box to approximate pressure desired. The engine gauge should read this approximate pressure. If pressure reading is.c.or.r_e__: 1. Verify Oil/Fuel pressure to Druck transducer with mechanicalpressure gauge, A. If correct--probable failure is Drucktransducer. B. If incorrect--truubleshootoil/fuelsystem. 79-30-02 4 MOONEY AIRCRAFT CORPORATION If pressure reading is_; zero or pegged condition: 1. ROCHESTER gauge (S/N 24-0001 thin 24-3153) A. Move transducer test box to connector on the input of apprspdate pressure amplifier(located behind instrumentpanel, right side). Check pressure reading on Rochester gauge to see if it approyJmatelyagrees with test box. If it does, repair wire harness from pressure gauge amplifier, to the engine compartment, If pressurereading is incorrectgo to step (b), B. At the appropriateRochestergauge WIPER lug read the following voltages to ground. (digital mulfimeter or 20K ohrns/voitmultimeter) 201/205Fuel 201/205 Oil 14PSI 60 PSI 4.4 to 4.7 volts. 5.3 to 5,5 volts 1. If correct, probable failure in Rochester gauge module. 2. If incorrect, probable failure in pressure gauge amplifier. 2. SIGMA-TEK gauge (SIN 24-3154 thru 24-TBA) A. Check widng for continuity between engine compartment connector and Sigma Tek cluster. If wiring is correctgo to (b). B. Probablefailure in Sigma-Tek gauge module or cluster. 12-98 MOONEY AIRCRAFT CORPORATION M20J CHAPTER 80 STARTING SERVICE AND MAINTENANCE MANUAL SERVICE AND MAINTENANCE MANUAL M20J MOONEY AIRCRAFT CORPORATION CHAPTER 80 ( STARTING LIST OF EFFECTIVE PAGES CHAPTER SECTION SUBJECT ........... 80-Effectivity/Contents 80-00-00 ............ 80-10-00 ............ PAGE ....... .......... DATE 1/2BLANK .......... 3 ........... 4 ............ 10-95 10-95 5-93 TABLE OF CONTENTS CHAPTER SECTION SUBJECT ! ........... 80-00-00 80-00-01 80-00-02 ........ .......... .......... 80-00-03 80-00-04 80-00-05 80-10-00 .......... .......... .......... ......... SUBJECT General ........ .............. Starter Troubleshooting Starter Maintenance PAGE ........ ........ Starter Removal .......... Starter Installation ......... Starter Brushes .......... Cranking ............. 3 3 3 3 3 3 3 8O-EFF/CONTENTS 1/2BLANK MOONEY AIRCRAFT 80-00-00 CORPORATION M20J - GENERAL MANUAL 6. Remove (3) nuts and (1) 5/16 inch bolt from starter The airplane is equipped with a 12 volt starter (24-0001 thru 24-2999), 24 volt C24-3000 thru 24-TBA), supplied with the engine package. (NOTE: Some M20J ATS aircraft may be equipped with 24 volt electrical systems). The starter is located on the front of the engine. The drive ratio of the starter drive pinion to the crankshaft is 16.556:1. When the ignition switch is placed in the "START" position, current is supplied through the main bus to engergize the starter solenoid which in turn connects the battery to the starter. Electrical power is automatically cut off from the radios when the starter current is engaged. 80-00-01 SERVICE AND MAINTENANCE - STARTER TROUBLESHOOTING 1. Refer to Section 24-39-04 for TroubleShooting Chart 80-00-02 -STARTER MAINTENANCE 1. Inspect and ser_,ice starter per Maintenance Instructieiqs Overhaul Manual. mounting pad. 7. Remove starter and starter drive assembly. 80-00-04 -STARTER INSTALLATION 1. Before installation, clean any rust corrosion or dirt from the starter motor. 2. Check all connections for tightness. 3. Reverse reinstallation. Lycoming starter removal procedure for 4. Recheck torque, security and safetying. 5. Install cowling. 80-00-05 Starter the - STARTER BRUSHES The starter brushes shauld slide freely in the holder and make full contact an the commutator. The brushes should be replaced when they have worn to 1/2 of original length. Brush tension should be 32 to 40 ounces as measured with a spring scale hooked under the brush spring and pulled in e straight line opposite the force exerted by the spring. Read the tension just or 2. starter drive except at overhaul. is required on starter Lubrication - No lubrication 80-10-00 - CRANKING as the spring leaves the brush. 3. Check electrical leads for security and condition of wire. CAUTION Do not clean the statler in any degreasing tank or grease dissolvin 9 solvents. Avoid excessive lubrication. Use only kerosene orVarsoL The starter solenoid is located on the cabin side of the firewall. The solenoid is energized by placing the ignition/magneto switch in the start position. Battery current is then directed to the starter. Aircraft serial number 24-1214 and ON are equipped with a "START POWER ON" annunciator light. This light illuminates when the starter switch is in start position or when the starter switch or starter solenoid has malfunctioned and the starter is engaged while the engine is running. This malfunction shauld be corrected before the engine is started again. CAUTION 80-00-03 -STARTER REMOVAL 1. Remove upper and lower cowling. 2. Remove (4) bolts between AIR INTAKE and fuel Injector pad. DUCT 3. Remove (2) screws on outer end of air intake duct. Do not operate starter in excess of 30 seconds 4. Remove bolt at front of air intake duct. Carefully remove the duct. without allowing cooling time before re-engaging. 5. Disconnect electrical wiring from starter terminals and tag wiring for ID. REV. 10-95 80-00-00 3 SERVICE AND MAINTENANCE MANUAL M20J BLANK 80-10-00 4 MOONEY AIRCRAFT CORPORATION MOONEY AIRCRAFT CORPORATION M20J CHAPTER 81 TURBINES SERVICE AND MAINTENANCE MANUAL MOONEY AIRCRAFT CORPORATION M2OJ SERVICE AND MAINTENANCE MANUAL CURRENTLY NOT BEING USED 12-98 81-TURBINES 1 SERVICE AND MAINTENANCE MANUAL M2OJ INTENTIONALLY LEFT BLANK 81-TURBINES 2 12-98 MOONEY AIRCRAFT CORPORATION MOONEY AIRCRAFT CORPORATION M20J SERVICE AND MAINTENANCE MANUAL CHAPTER 91 ELECTRICAL WIRING DIAGRAMS SERVICE AND MAINTENANCE MANUAL M20J MOONEY"AIRCRAFT CORPORATION CHAPTER 91 ELECTRICALWIRING DIAGRAMS LIST OF EFFECTIVE PAGES CHAPTER SECTION SUBJECT ........... 91-EFFECTIVITY .......... 91-CONTENTS .......... 91-00-00 ............ 91-00-02 ............. 91-00-02 ............. 91-00-03 ........ 91-20-00 ...... 91-20-00 ............ 91-20-01 ............ 91-20-02 ........... 91-20-03 ........... 91-20-04 ........... 91-20-05 ........... 91-20-06 ........... 91-30-00 ............ .... ; ..... PAGE .......... DATE 1 ........... 2 ........... 3 ........... 4 ........... 5 ........... 6 ........... 7 ........... 8 ........... 9 thru 34 .......... 35 thru60 ......... 61 thru 76.......... 77 thru80.......... 81 thru94.......... 95 thru 110 ......... 111 .......... 12-98 12-98 12-98 12-98 12-98 12-98 12-98 12-98 12-98 12-98 12-98 12-98 12-98 12-98 12-98 12-98 91- EFFECTIVITY Page I MOONEY AIRCRAFT CORPORATION M20J SERVICE AND MAINTENANCE MANUAL CHAPTER 91 ELECTRICAL WIRING DIAGRAMS ( TABLE OF CONTENTS CHAPTER SECTION SUBJECT ........... SUBJECT 91-00-00 ........ 91-00-01 .......... 91-00-02 .......... 91-00-03 .......... 91-20-00 ......... 91-20-01 .......... 91-20-02 .......... 91-20-03 .......... • . , 91-20-04 91-20-05 91-20-06 91-30-00 • , .......... .......... .......... ......... General • , • • • . , PAGE .............. ElectricalSystemNotes........ WIdng IdentificationSystem ...... Abbreviations- EquipmentList ...... ElectricalSystemHardwareCharts ...... 24-0001 THRU 24-1685 (14V) ...... 24-3000 THRU 24-3153 (28V) ..... 24-3154 THRU 24-3200, 24-3202 THRU 24-3217 • (28V). 24-1686-14 THRU 24-2999-14 (14V) (ATS) . 24-3201, 24-3218 THRU 24-3410 (28V) . 24.-3411THRU 24-3431 (28V) ..... ElectricalSystemSchematics(ENVELOPES) 12-98 Page 2 ........ 3 3 4 6 7 9 35 61 77 81 95 111 91-CONTENTS SERVICE AND MAINTENANCE MANUAL 9140-00 M20J MOONEY AIRCRAFT CORPORATION - GENERAL The electrical system hardware lists and related schematics are sequenced in this section by serial number effectivity.The chapterisdividedintothefollowingsections: -ElectdcalSystems SchematicNotes -Widng IdentificationSystem -ElectdcalSystem Hardware Charts (By Effectivity) -ElectricalSchematics(By Effectivity) 91-00.01 - ELECTRICAL SYSTEMS SCHEMATICS NOTES 1. All electrical widng, assemblies,and instalitionsmust be in accord with FAR 43 and AC 43,13-1(*). 2. All splicesmust be "AMP" disconnector equivalent. 3. All circuitbreakem are trip-free. 4. All terminalsare Spec. MS25036 (or equivalentorthey mustbe soldered.) 5. All terminalsmust be preinsulatedor must be insulatedwith =Ampsulation"(or equivalent), 6. Wireswithoutdash numbersare furnishedby the manufacturerand are includedwith the equipment. 7. The symbol=--" indicatesa knifedisconnect. 8, Optionalequipmentmay be installedas required, 9. Wires denotedby ......... symbolsto be twisted counterclockwisewith a minimumofthree (3) wraps per foot. 10. "F" denotesgroundthroughframe (no wires). 11. All knifedisconnectsplicesto be insulatedwith PVC105 and securelystringtied with airtex no,417 cord. 12. All wiresizes are minimumsizes acceptable. 13. Use 913127 bus bars as necessary for vadousconfigurationchanges and manufacture interconnectingbus using no. 2170 tubular braid coveredwith PVC105/5/16" (bothAlpha Wire Co.) and terminatedwith AMP terminals of appropriatesizes. (* = currentrevisionofAC 43.13-1) 35108 PVC TermlnaL 105/ 5/16 '.170TubuLar 3P7P18 AmpsuLa ;ion ,3P1P98 Terminal EXAMPLE - FIGURE 91-1 12-98 91-00-00 Page 3 MOONEY AIRCRAFT CORPORATION 91-00-02 M20J SERVICE AND MAINTENANCE MANUAL -WIRING IDENTIFICATION SYSTEM The Mooney Aimralt Corporation wiring/electricalsystem, originally depicted a typical electrical component identificationnumber as _ or _. This 7 or 9 character number is composed of four functionalgroups, each of which communicatescertain specificinformation.The 5th functionalgroup is the wire size of the wireconnectingthe variouscomponents.These functionalgmups are as follows: (Functional . GroupNo.) , (1) (1) .... (3) (4) (5) .... Functional .............. Group 21 - first two numerals (24-0001 thru 24-1685)..... JKL- firstthree letters(24-3000 thin 24-TBA) ..... (=-"is used if not applicableto a model) 14- - firsttwo numerals(24-1686-14 thin 24-2999-14). PA - first(or second) two letters ........ 03 or 102- second set of numerals........ A - singleletter in the series ......... Descriptionof identifiers - AircraftType (14V) (Not ATS) - AircraftType (28V) . . -AircraftType (14V) (ATS) - CircuitFunction - V_re Sequence -Configuration 18 - lasttwo numerals in the sedss ........ - Wire Size (does not appear for components;just wires) CIRCUIT FUNCTION LI=GI=ND DV_. NO's 8003301600350 CB DefrosterBlower LS Lighting- Instrument& Strebe/Navigation CC Cowl Flap Lights CD PC Dump LT Lighting- Taxi Lights CF Wing Flaps- Electric CT Trim - Stabilizer MA Miscellaneous- AuxiliaryPowerPlug CV Stand-byVacuum MB Miscellaneous- Radio Cimuits MC Miscellaneous- Cigar Lighter DA Instruments- Ammeter MD Misceflaneous-Clock Light DB Instruments- Turn Coordinator ME Miscellaneous-ElectricClock DC Instruments- CylinderHead MIC Miscellaneous- Microphone Temperature MM Miscellaneous- MadderBeacon DD Instruments- OutsideAir Temperature MP Miscellaneous- Pmpeller De-ico DE Instruments- CarburetorAir Temperature NF Fuel- Fuel Pump DF Instruments- Fuel Quantity NP Fuel- Primer DG Instruments- Cluster Gauge DH Instruments- Oil Temperature PA Power- Aitemator (output& Control) DJ Instruments- Oil Pressure PB Power- Battery (Output & Control) DK Instruments- Fuel Pressure PG Power- Generator (Output& Control) DL Instruments- Tachometer PS Power- Starter (input& Control) DM Instruments- Hour Meter DN Instruments- Pressurization RB Radio Blower DP Instruments- PitotHeat DR Instruments- Turbine Inlet Temperature SPK Speaker DS Instruments- CompressorDischarge Temperature VB Vent Air Blower DT Instruments- E_haust Gas Temperature DU Instruments- ManifoldPressure WA Warning System- Aitemator- Voltage DV Instruments- Fuel Flow Warning DW Instruments- VSI WB Waming - EngineBoost WE Wsming System- Gear Position EG ElectricGear- Gear Contmis Warning (Electric) EL Lighting- Electroluminescence WF WarningSystem - Fuel Pressure ELT Emergency LocatorTransmitter WL WarningSystem- LandingLight WM WarningSystem - Gear Position FON Phones Warning (Manual) WN WarningSystem- Pressurization JM Ignition- Magneto VVS Warning System- Stall Waming LB Lighting- RotatingBeacon WT WarningSystem- Press-to-Test . (AnticollisionLight) WV Waming System- Vacuum Warning LC Lighting- Cabin Lights WW WarningSystem- Aitemate Air LL Lighting- LandingLights WD WarningSystem- StarterPower LN Lighting- NavigationLights LP Lighting- Instrument& Placard Lights LR Lighting- RecognitionLights 91.00-02 Page 4 12-98 SERVICE AND MAINTENANCE MANUAL M20J MOONEY AIRCRAFT CORPORATION dT_e.e.Mooney .Ai.'rc_a..lt Co.q_orationwidng/ele_stdcal equipmentidentification system used in conent productionaircraft letes me MOael P_umeerannotation, i ne purpose of this is to standardizethe identificationof a system function/coroponent for all model of aircraft.The functionalgroups are basicallythe same as earlier identification numbers.These newfunctionalqroupsapplyto schematicdrawinq800304.The newfunctional,qroupsareas follows: 04 .... A .... I 20 CR..... . . --_. -- . . Firstset of numerals . Singleletter in series . numeralsin series . Lasttwo Firsttwo/threeleters ----. -- . . . . I Wire Sequence Configuration . CircuitFunction Wire size | CODE/COMPONENT or SYSTEM (CIRCUIT FUNCTION) - 800304 ( ) SCHEMATIC DRAWING ACT/SWITCH ACTUATOR DL/ELECTRIC TACHOMETER MA/AUXILIARYPOV_ER BS/RELAY BASE DM/HOUR METER ME/AVIONICS MASTER BUS/BUSS BARS DPIPITOT HEAT MC/DIGAR LIGHTER C/CAPACITORS DR/TIT ME/CLOCK CB/DEFROSTER BLOWER DT/FUEL FLOW MP/PROPELLER DE-ICE CC/COWL FLAPS CL/CLAMPS CM/CURRENT MONITOR DG/LANDING GEAR, ELEC. ELT/ELT F/FUSES NF/BOOST PUMP PAJALTERNATORPOWER PB/BATTERY POWER CR/RUDDER TRIM CT/STABILIZER TRIM FHIFUSEHOLDER FON/PHONE PL/PLUGS, ELECTRICAL PSISTART POWER CV/STANDBY VACUUM D/DIODES JMIIGNITION, MAGNETO L/LIGHT BULBS R/RESISTORS RB/RADIO BLOWER DAJAMMETER DB/TURN COORDINATOR LB/BEACON LENS/ANNUNCIATOR LENS RC/RECEPTACLES, ELECTRICAL RL/RELAYS DC/DHT LH/LAMP HOLDER SP/SPEEDBRAKE DD/OAT LL/LANDING LIGHTS SW/SWlTCHES DC-.-dENGINE INSTRUMENTS DH/OIL TEMPERATURE LP/PANEL LIGHTS LR/RECOGNITION LIGHTS VR/VARISTOR WS/STALLWARNING DJ/OIL PRESSURE DK/FUEL PRESSURE LS/STROBE LIGHTS LT/TAXI LIGHTS WT/STANNUNCIATOR WARNING CODE/COMPONENT or SYSTEM (CIRCUIT FUNCTION) - 800383 ( ) SCHEMATIC DRAWING AC AH AT AV AIR CONDITIONER ARTIFICIAL HORIZON ACTUATOR, SWITCH AVIONICS BR BS BU CIRCUIT BREAKERS RELAY BASE BUS BARS CA CB CC CD CF CL CR CT CV CAPACITORS DEFROSTER BLOWER COWL FLAPS PC DUMP WING FLAPS CLAMPS RUDDER TRIM ELEVATOR TRIM STAND-BY VACUUM DA DB DC INSTRUMENTS - AMMETER INSTRUMENTS - TURN COORDINATOR INSTRUMENTS - CYLINDER HEAD TEMPERATURE DD INSTRUMENTS - OUTSIDE AIR TEMPERATURE DE INSTRUMENTS - CARBURETOR AIR TEMPERATURE DF INSTRUMENTS - FUEL QUANTITY DG INSTRUMENTS - ENGINE DH INSTRUMENTS - OIL TEMPERATURE DI DIODES DJ INSTRUMENTS - OIL PRESSURE DK INSTRUMENTS - FUEL PRESSURE DL INSTRUMENTS - TACHOMETER, ELECTRIC DM INSTRUMENTS - HOUR METER DN INSTRUMENTS - PRESSURIZATION DP INSTRUMENTS - PITOT HEAT 12-98 91-00-02 Page 5 MOONEY AIRCRAFT CORPORATION M20J SERVICE AND MAINTENANCE MANUAL CODE/COMPONENT or SYSTEM (CIRCUIT FUNCTION) - 800383 ( ) SCHEMATIC DRAWING (con't.) INSTRUMENTS - TURBINE INLET MO PROP'OVERSPEED TEMPERATURE MP PROP DE-ICE DS INSTRUMENTS - COMPRESSOR MS MISCELLANEOUS, RADIO-SPEAKER DISCHARGE TEMPERATURE MW MISCELLANEOUS, RADIO-WARNING DT INSTRUMENTS - EXHAUST GAS TEMPERATURE NE FURL ENRICHMENT DU iNSTRUMENTS - MANIFOLD PRESSURE NF FUEL PUMP DV INSTRUMENTS - FUEL FLOW NP FUEL PRIMER DW INSTRUMENTS - ENGINE VACUUM NS FUEL COLD START DR EG EL ET GEAR, ELECTRIC ELECTROLUMINESCENCE EMERGENCY LOCATOR BEACON PA PB PG FA FH FN FU FW ALT-EMER (FRENCH) FUSE HOLDERS PHONES FUSES ALT-EMER FIELD (FRENCH) PL PS POWER, ALTERNATOR POWER, BATTERY POWER, GENERATIOR (OUTPUT & CONTROL) PLUGS POWER, START GD GROUND RB RC RL RS BLOWER, RADIO RECEPTACLES RELAYS RESISTORS HS HORIZONTAL SITUATION INDICATOR JE JM JV IGNITION, ELECTONIC IGNITION, MAGNETO IGNITION, VIKBRATOR SA SB SP SW STAND-BY ALTERNATOR SPEEDBRAKE SPEAKER SWITCHES LA LB LC LE LG LH LI LL LN LP LR LS LT LIGHT BULBS BEACON, ROTATING LIGHT, CABIN LENS, ANNUNCIATOR LIGHTS, LOGO LAMP HOLDER LIGHT, ICE LIGHT, LANDING LIGHTS, NAVIGATION LIGHTS, PANEL LIGHTS, RECOGNITION LIGHTS, STROBE LIGHTS, TAXI VB VC VR VENT, AIR BLOWER VOLTAGE CONVERTER VARISTOR WA WB VVC WD WE WF WG WH WJ WK MA MB MC ME MH MJ MK MM AUXILIARY POWER RADIO, MASTER CIGAR LIGHTER CLOCK, ELECTRIC MISCELLANEOUS, ANTI-ICE MISCELLANEOUS, JUNCTION BOX MICROPHONE MISCELLANEOUS, MARKER BEACON WM WN WP WS WT WV VWV WARNING, ALTERNATOR WARNING BOOST PUMP WARNING PROP DE-ICE WARNING POWER START WARNING ELECTRIC GEAR WARNING FUEL QUANTITY WARNING TACHOMETER WARNING CHIP DETECTOR WARNING TRIM FAIL WARNING FUEL PRESSURE WARNING CANOPY LOCK WARNING MASTER WARNING PRESSURIZATION WARNING PITOT HEAT WARNING STALL WARNING, ANNUNCITOR WARNING, VACUUM WARNING, ALTERNATE AIR YD YAW DAMPER 91-004)3 - ABBREVIATIONS - EQUIPMENT LIST The abbreviationsto the electdcal system hardware charts are necessary due to space limitationsin the fields of the computer. Aimpeed - A/S Placard- Plcd Altemate - Altn Radio - Rad Circuit Breaker- Ckt. Bkr. or C/E Receptacle- Recpt Console- Cnsl Regulator- Regltr Control- Cntd Remote - Rein Coordinator- Coordtr Resistor- Res Cylinder- Cyl Rheostat- Rheo Down - Dn Right- R 91-00-03 Page 6 12-98 SERVICEAND MAINTENANCE MANUAL M20J MOONEYAIRCRAFTCORPORATION ABBREVIATIONS. EQUIPMENT UST (con't.) 91-20-00 Electric- Elsc Flight- Fit Glareshield- Glmhld Landing- Ldg Lelt - L Lights- Lts Panel - Pnl Pilot- Pit - ELECTRICAL SYSTEM HARDWARE CHART Safety- Sffy Selector- Sel Supply- Sply Switch- Sw Transducer- XDCR Transmitter- XMTR Transistor- XSTR Warning - Wrn . Refer to the Electrical Schematic (located in the envelopes at the back of this manual) that depicts the Serial Number configurationof the aimrett beingserviced.The SIN's vs. Schemafic's areshown below: A/C SERIALNUMBER. . DRAWING/SCHEMATICNUMBER (14 VOLT AIRCRAFT) 24-0001 thru 24-0237, except 24-0084................ 24-0238 thru 24-0377 ..... 24-0378 thru 24-0757, includes24-0084 ............. 24-0758 thru 24-0900 .................. 24-0901 thru24-0942 ....... -.......... 240943 thru 24--1037 .................... 24-1038 thru24-1213 ......... 24-1214.thru24-1417 ............... 24-1418 thru 24-1499 .................. 24-1500 thru24-1528 .............. 24-1529 thru24-1685 ..................... SCl-800269L-3 SCI-800269L-3A 800330 E1 800330 E2 800330 E3 800330 E4 800330 E5 800330 E6 800330 E7 800330 E8 800330 E9 24-1686-14thru24-2999-14(ATS). .,- 8.VO;.rAIRCRAF.r -. ) 24-3000 thru24-3078 24-3079 thru24-3153 ..... 24-3154 thru24-3200, 24-3202 thru 24-3217 . 800263 800350 800350 800263 24-3201, 24-3218 thru 24-3270 ............. ............... 800304 J1 (SHT1) (REV. F) (SHT 2) (REV. H) 24-3271 thru24-3350 ............ ................. 24-3351 thru 24.,3,373 ....................... 24-3374 thru24-3377 ........................ J2 J1 J,?. J1 ...... . . ............. 800304 J2 (REV.W) (SHEET 1 of 2; 2 of 2) 800304 J3 (FIEV.W) (SHEET 1 of 1) 800304 J4 (REV W) (SHEET 1 of 1) 24-3378 thru 24-3363 ................... .......................... 800304 J5 (REV.Y) (SHEET 1 of 1) 24-3384 thru 24-3392 ................... ......................... 800304 J6 (REV,Z) (SHEET 1 of 1) 24-3393 thru 24-3404 ................. ..................... 800304 J7 (REV,Z) (SHEET 1 of 1) 24-3405 thru 24-3410 ............. ..................... 24-3411 thru 24-3420. ................... 800304 J8 (REV.AA) (SHEET 1 of 1) 24-3421 thru 24-3431 .................... ........................ 800383 J2 (REV.H) (SHEET 1 of 1) 800383 J1 (REV.G) (SHEET 1 of 1) CAUTION These schematics address different serial numbered aircraft. Make sure the applicable schematic Is being used for the alrcralt being serviced. 12-98 91-20-00 Page 7 MOONE'{ AIRCRAFTCORPORATION M20J SERVICE AND MAINTENANCEMANUAL The Vendor and Part Number will be depictedwhere the applicableelectricalequipment identifieris shown on the followinghardwarecharts: Order replacementor repair part numbersfor electricalcomponentsfrom the following electricalsystemhardwarechartsthat are applicableto the aimreftmodel and S/N being worked on. 91-20-01 - ELECTRICAL SYSTEM HARDWARE CHART - 24-0001 thru 24-1685 (14 VOLT), DRAWING NUMBER SCI - 800269L-3,-3A & 800680 91-20-02 - ELECTRICAL SYSTEM HARDWARE CHART - 24-3000 thru 24-3153 (28 VOLT), DRAWING NUMBER - 800350 91-20-03 - ELECTRICAL SYSTEM HARDWARE CHART - 24-3154 thru 24-3200, 24-3202 thru 24-3217 VOL D(_8 . . AWI_i_'NUMBER 800263 (E), 24 1688-14 thru 24-2999-14 common components, ( 28V & 14 V) (See 91 20-04 for 14 Volt peculiar components). 91.2004 - ELECTRICAL SYSTEM HARDWARE CHART - 24-1686-14 thru 24-2999-14 (ATS ONLY) (_4 VOLT SYSTEMS), AWING NUMBER - 800268 (E) 91-20.05 -ELECTRICAL DRAWING NO -ELECTRICAL DRAWING NO -ELECTRICAL DRAWING NO .ELECTRICAL DRAWING NO -ELECTRICAL DRAWING NO -ELECTRICAL DRAWING NO -ELECTRICAL DRAWING NO -ELECTRICAL DRAWING NO 91-20.05 91-20-05 91-20-05 91-20-05 91-20-05 91-20-05 91-20-05 91-20-08 91-20-08 91-20-00 Page 8 EQUIPMENT HARDWARE CHART. - 800304 - (JI) (REV. F Slit 1/REV. EQUIPMENT HARDWARE CHART. - 800304 - (J2) (REV. W) (2 sheets) EQUIPMENT HARDWARE CHART - 800304 - (J3) (REV. W) (1 sheet) EQUIPMENT HARDWARE CHART - 800304 - (J4) (REV. W) (1 sheet) EQUIPMENT HARDWARE CHART - 800304 - (J5) (REV. Y) (1 sheet) EQUIPMENT HARDWARE CHART - 800304 - (J6) (REV. Z) (1 sheet) EQUIPMENT HARDWARE CHART - 800304 - (JT) (REV. Z) (1 sheet) EQUIPMENT HARDWARE CHART - 800304 - (Ja) (REV. AA) (1 sheet) S/N 24-3201, 24-3218 THRU 24-3270, H SliT 2) S/N 24-3271 THRU 24-3350 S/N 24-3351 THRU 24-3373 S/N 24-3374 thru 24-3377 S/N 24-3378 thru 24-3383 S/N 24-3384 thru 24-3392 S/N 24-3393 thru 24-3404 S/N 24-3405 thru 24-3410 -ELECTRICAL EQUIPMENT HARDWARE CHART - S/N 24-3411 thru 24-3420 DRAWING NO - 800383 - (J1) (REV. G) (1 sheet) -ELECTRICAL EQUIPMENT HARDWARE CHART - S/N 24-3421 thru 24-3431 DRAWING NO - 800383 - (J2) (REV. H) (1 sheet) 12-98 MOONEY AIRCRAFT CORPORATION M20J SERVICE AND MAINTENANCE MANUAL 14 VOLT ELECTRICAL EQUIPMENT CHART 9%20-01 - ELECTRICAL SYSTEM HARDWARE CHART - 14 VOLT S/N's 24-0001 THRU 24-1685, MOONEY DRAWING NO.'S SCI-800269L-3, -3A & 800330 (CP) CODE DESCRIPTION VENDOR PART NO. 21 21 21 21 21 CB101A CD01A CD02A CD02B CD03A 21 21 21 21 CF01B CF02A CFO3A CF04A C/B DEFROSTER BLOWER SOLENOID-PC DUMP SW-PILOTS DUMP SW-PILOTS DUMP SW-CO-PILOTS DUMP SW-P.C. ON-OFF (ALT) C/B FLAP ACT RELAY-LEFT RELAY-RT ACTUATOR. FLAP 21 -21 CFO5A 21 -21 CF07A 21 21 CF09A CF09B SWITCH, LIMIT, DOWN ACTUATOR SWITCH, LIMIT, UP ACTUATOR SWITCH, LIMIT, DOWN ACTUATOR SWITCH, LIMIT, UP ACTUATOR SWITCH, CONTROL SWITCH. CONTROL, FLAP KLIXON BRI'I-rlAN MICRO C-H MICRO ALCO MERIDEN or EQUIV. MAGNECRAFT MAGNECRAFT COMM. NC PROD MOONEY MICRO MICRO MICRO MICRO MICRO MICRO MICRO MICRO MICRO C-H 7277-2-2 4085 111SM1-T SA31SDT12-2 111SM1-T MST215-N AHW4-15 W97CSX-1 W97CSX-1 D14500-36 (750105-501) V3-1 JV-5 V3-1 JV-5 V3-1 JV-5 V3-1 JV-5 2TL75-10 6906K3149 21 21 21 CTO1A CT01B CT01D C/S, ELECTRIC TRIM C/S, ELECTRIC TRIM C/B, ELECTRIC TRIM MOONEY MOONEY MOONEY 930023-009 930023-109 930023-209 21 21 21 21 21 DA01A DA01B DA01C DA01D DAO2A 21 DA02B 21 DA03A 21 DAO3B 21 DA04A SHUNT SHUNT SHUNT SHUNT FUSE RETAINER FUSE RETAINER FUSE RETAINER FUSE RETAINER AMMETER BULB EMPRO or EQUIV. STEWART-WARNER EMPR0 EMPRO UI-rEL UI-EEL McGRAW-EDISON McGRAW-EDISON LITTEL LITTEL McGRAW-EDISON McGRAW-EDISON MOONEY ROCHESTER MLA-60-50 SW-813489 MLA-60-100 MLA-70-100 312010 155020 FM01-5A FHN42W 311010 155202 FM01-5A FHN42W 640281-509 0153500003 21 21 21 DB01A DB01B DBO2A 21 21 DB02B DB03A C/B,TURN COORD C/B TURN COORD TURN CO-ORDINATOR TURN CO-ORDINATOR TURN CO-ORDINATOR PLUG, TURN COORD CLAMP MERIDAN OR EQUIV KLIXON BRITTIAN AEROSONIC (ALT) AEROSONIC AHW4-2 7277-2-5 604-200-200 ANS50M ANS50ML MS3106A-10SL-3S MS3057-4A or-4B CF06A CF08A 12-98 NOTES 23/24 23/24 23/24 91-20-01 9 SERVICE AND MAINTENANCE MANUAL M20J MOONEY AIRCRAFT CORPORATION 14 VOLT ELECTRICAL EQUIPMENT CHART CODE DESCRIPTION VENDOR PART NO. --L DB50A T/C UNITED INST 9551B CODE N.541 21 21 DC01A DC01B PROBE, CYL HD TEMP PROBE, CHT 21 DC01C PROBE, GriT STEWART-WARNER ROCHESTER MOONEY MOONEY SW-333-B 8080-00014 (880010-501) 880010-503 21 21 21 DD01A DD01B DDO1C GAUGE, OUTSIDE AIR TEMP GAUGE, OAT CAUGE, OAT/EGT 21 21 DD01E DD01F GAUGE, OAT/EGT(UGHTED) GAUGE, OAT (UGHTED) GARWlN ]NSTR.& FLT RES. B&D INSTRUMENT MOONEY MOONEY MOONEY 22-295 IFR-11A C203-005 880010-501 880001-505 880023-505 21 DD02A 21 DD02C 21 DD02D 21 21 21 DD03A DD03B DD03C PLUG -GAUGE CLAMP PLUG,OAT/EGT CLAMP PLUG,OAT CLAMP PROBE, OAT PROBE, OAT PROBE, OAT 21 DD04A C/B, OAT/EGT 21 DE01A GAUGE, CARB AIR TEMP 21 . DE02A 21 DE02B 21 DE03A PLUG, GAUGE CLAMP PLUG, GAUGE CLAMP PROBE, CARB AIR TEMP RICHTER AERO 660014-005 22-995-04 MS3106A-14S-1S MS3057-6B MS3106B-14S12S MS8057-68 B-5 21 21 21 21 21 21 DF01A DF01B DF02A DF03A DF03B DF04A XMTR, FUEL QIY, LT, IB XMTR, FUEL QTY, LT, IS XMTR, FUEL Q'I'Y, LT, OB XMTR, FUEL QTY, RT, IB XMTR, FUEL QTY, RT, IB XMTR, FUEL QTY', RT, OB MOONEY MOONEY MOONEY MOONEY MOONEY MOONEY 6i0242-001 610242-003 610243-003 610242-001 610242-003 610243-001 21 21 21 DG01A DG01B DG02A C/B, CLUSTER GAUGE C/B, CLUSTER GAUGE GAUGE, CLUSTER FUEL QTY', LH FUEL QFY, RH AMMETER OIL PRESS OIL TEMP CYL HEAD TEMP MERIDEN KLIXON MOONEY MOONEY MOONEY MOONEY MOONEY MOONEY MOONEY AHW4-2 7277-2-2 640281-503 640281-105 640281-107 640281-115 640281-117 640281-149 640261-111 91-20-01 10 AMP AMP WESTBERG B&D INSTR MOONEY KLIXON MOONEY GARWIN 12-98 MS3106A-14S-2S MS3057-6B 205838-1 206062-1 MS3106A-14S-2S MS3057-6A MS2803403 399W 0203-100 880004-501 727%2-2 NOTES MOONEY AIRCRAFT CORPORATION M20J SERVICE AND MAINTENANCE MANUAL 14 VOLT ELECTRICAL EQUIPMENT CHART CODE 21 DG02G 21 DG02G i (ALT) 21 DG02H (ALT) i 21 DG02J 21 DG02K 21 21 DH01A DH01B -- DESCRIPTION VENDOR PART NO. GAUGE, CLUSTER FUEL QTY, LH FUEL QTY, RH FUEL PRESS OIL PRESS OIL TEMP CYL HEAD TEMP GAUGE, CLUSTER FUEL QTY, LH FUEL QTY', RH FUEL PRESS OIL PRESS OIL TEMP OIL TEMP (ALT) CYL HEAD TEMP CYL HEAD TEMP (ALT) GAUGE, CLUSTER FUEL QTY, LH FUEL Q'I-Y, RH AMMETER OIL PRESS OIL TEMP CYL HEAD TEMP GAUGE, CLUSTER FUEL QTY, LH FUEL QTY, RH AMMETER OIL PRESS OIL TEMP OIL TEMP (ALT) CYL HEAD TEMP CYL HEAD TEMP (ALT) GAUGE, CLUSTER FUEL QTY, LH FUEL QTY, RH FUEL PRESS OIL PRESS OIL TEMP CYL HEAD TEMP GAUGE, CLUSTER FUEL Q'P(, LH FUEL QTY, RH AMMETER OIL PRESS OIL TEMP CYL HEAD TEMP MOONEY MOONEY MOONEY MOONEY MOONEY MOONEY MOONEY MOONEY MOONEY MOONEY MOONEY MOONEY MOONEY MOONEY MOONEY MOONEY MOONEY MOONEY MOONEY MOONEY MOONEY MOONEY MOONEY MOONEY MOONEY MOONEY MOONEY MOONEY MOONEY MOONEY MOONEY MOONEY MOONEY MOONEY MOONEY MOONEY MOONEY MOONEY MOONEY MOONEY MOONEY MOONEY MOONEY MOONEY MOONEY MOONEY 640281-507 640281-105 640281-107 640281-119 640281-121 640281-149 640281-511 640281-511 640281-125 640281-127 640281-131 640281-129 640281-133 640281-155 640281-135 640281-157 640281-513 840281-147 840281-145 640281-137 640281-141 640281-139 640281-143 640281-515 640281-153 640281-151 640281-137 640281-141 640281-139 640281-159 640281-143 640281-161 640281-519 640281-163 640281-165 640281-171 640281-133 640281-155 640281-135 640281-521 640281-153 640281-151 640281-137 640281-169 640281-139 40281-143 PROSE, OIL TEMP PROBE, OIL TEMP STEWART-WARNER ROCHESTER MOONEY 362-CR 3080-37 880099-501 AN909-10 MS35769-11 ROCHESTER MOONEY MOONEY 3080-37 880098-501 889046-501 MS3106A10SL-3S MS3057-4NB WASHER (ALl-) 21 DJ01A 21 21 DJ01B DJ02A . XDUCR, OIL PRESS XDCR, OIL PRESS PLUG, XDCR, OIL PRESS CLAMP 12-98 NOTES 33 32 34 34 91.20,01 11 SERVICE AND MAINTENANCE MANUAL M20J MOONEY AIRCRAFT CORPORATION 14 VOLT ELECTRICAL EQUIPMENT CHART CODE DESCRIPTION VENDOR PART NO, 21 21 21 DJ175A DJ177A DJ178A XDCER, OIL PRESS AMPLIFIER, OIL PRESS PLUG, OIL PRESS, 4 PIN CLAMP DRUCK IAI AMP AMP PDCR821-0662-100 950D0311-002 206060-1 206062-1 21 DJ179A 21 -21 DJ180A RECPT, OIL PRESS, 4 PIN CLAMP PLUG, 4 PIN CLAMP RECPT, 4 PIN CLAMP AMP AMP AMP AMP AMP AMP 206153-1 206062-1 206060-1 206082-1 206153-1 206062-1 21 DK01A 21 21 21 21 21 DK01C/D DK01D DK01E DK01F DK02B 21 21 21 21 21 21 21 21 21 DK02D/E DK02F DK03A DK03B DK03C/D DK03E/F DK04A DK05A DK06A 21 21 21 DK175A DK176A DK177A 21 DK178A 21 DK179A 21 DK180A 21 21 21 21 21 21 21 -21 21 21 DL01A DL01B DL01C DL01D DL01E DL01F DL02A 21 91-20-01 12 DJ181A XDUCR, FUEL PRESS ROCHESTER MOONEY XDUCR, F/F(OPr) MOONEY XDUCR, FUEL PRESS MOONEY XDUCR, FF MOONEY XDUCR, FUEL FLOW MOONEY GAUGE, FF/MP MOONEY GAUGE, FF/MP, LIGHTED (OPT)MOONEY GAUGE, FF (OPT) MOONEY GAUGE, (GALS/HR) MOONEY PLUG, FF/MP GAUGE BENDIX PLUG, FF BENDIX PLUG, FF ]l-r CANNON PLUG, FF (OPT) CANNON C/B, FF KLIXON SWITCH, MEMORY, FF (OPT) ALCO PLUG, FF, XDCR CLAMP XDUCR, FUEL PRESS DRUCK AMPUFIER, FUEL PRESS IAI PLUG, 4 PIN AMP CLAMP AMP REOPT, 4 PIN AMP CLAMP AMP PLUG, 4 PIN AMP CLAM P AM P RECPT, 4 PIN AMP CLAMP AMP 3060-17 880007-501 880030-501 880045-501 880030-503 880030-505 880031-501 880031-503 880034-501 880034-513 PT06A-10-98S(SR) PT06A-15-15S(SR) DE-gS DE-9S 7277-2-2 MST215N MS3106A10SL-3S MS30507-4A PDCR821-0662-30 950D0311-031 206060-1 206062-1 260153-1 206062-1 206060-1 206062-1 260153-1 206062-1 MOONEY MOONEY MOONEY MOONEY MOONEY MOONEY DL03A DL04A DL05A TACH, ELEC TACH, ELEC TACH, ELEC TACH, ELEC TACH, ELEC TACH, ELEC, (LIGHTED) PLUG, TACH CLAMP RESISTOR, L RESISTOR, L CABLE ASSY OHMITE OHMITE MOONEY 880002-501 880039-503 880002-503 880039-501 880039-507 880039-505 MS3106A-14S-5S MS3057-6A OL1535 O!_1535 880003-501 DM01NB ' HOUR METER MOONEY 880035-501 12-98 NOTES 25 3 MOONEY AIRCRAFT CORPORATION M20J SERVICE AND MAINTENANCE MANUAL 14 VOLT ELECTRICAL EQUIPMENT CHART CODE DESCRIPTION VENDOR PART NO. C/B, PITOT HEAT C/B, PITOT HEAT C/B, PITOT HEAT HEATED PITOT PITOT, HEATED (ALl) PLUG, PITOT HEAT SOCKETS MOONEY MOONEY MOONEY AEL or EQUIV AERO INST 930023-005 930023-105 930023-205 425936 PH502-24 AN5812-1 AN3115-1 AN3116-1 21 21 21 21 21 DP01A DP01B DP01D DPO2A DP02B 21 DP03S 21 21 21 21 21 DR01A DR01B DR02A DR03A DR04A C/B, TIT/CDT GAUGE, TIT/CDT, LIGHTED PLUG, TIT/CDT INDICATOR PROBE, TIT C/B, TIT/CDT KUXON MOONEY AMP MOONEY KLIXON 7277-2-2 880000-503 205838-1 880005-501 7277-2-2 21 DS01A PROBE, CDT MOONEY 880006-501 21 DTOlA PROBE, EGT B&O INSTR MOONEY 0204-100 880005-501 21 21 21 21 21 21 EG01A EG01B EG01C EG0?-A EG02B EG03A 21 21 21 21 21 21 21 EG04A EG04B EG04C EG04D EG04E EG04F EG04G C/B, ELEC. GEAR C/B, ELEC. GEAR C/B, ELEC. GEAR CONTROL SWITCH, CONTROL SWITCH, GEAR UP/DN SWITCH, LIMIT ACTUATOR ACTUATOR, GEAR, ELEC ACTUATOR, GEAR, ELEC ACUTATOR, GEAR, ELEC ACUTATOR, GEAR, ELEC ACUTATOR, GEAR, ELEC ACUTATOR, GEAR, ELEC ACUTATOR, GEAR, ELEC 21 21 21 21 21 EG05A EG05C EG05D EG05E EG05F 21 EG06A 21 21 21 21 21 21 21 21 21 21 21 EGO6B EG06C EG06D EG07A EGO8C EGO8D EGO8E EGOBF EG09A EG09B EG10A MERIDEN or EQUIV KLIXON KUXON MICRO .... C-H MICRO MICRO I'l-r DUKES DUKES ITr ITT DUKES AVIONICS PROD MOONEY RELAY, GEAR RBM RELAY, GEAR UP MAGNECRAFT RELAY, GEAR UP C-H RELAY, GEAR UP RBM RELAY, GEAR UP C-H COLE-HERSEE SQUAT SWITCH MICRO MOONEY SWITCH SAFETY, AIRSPEED WHITMAN-GENERAL SWITCH SAFETY, AIRSPEED MOONEY SWITCH SAFETY, AIRSPEED MOONEY SWITCE DOWN UMIT MICRO RELAY GEAR DOWN MAGNECRAFT RELAY GEAR DOWN C-H RELAY GEAR DOWN RBM RELA_ GEAR DOWN C.,-H C/B, GEAR ACT MECHANICAL PROD . C/B, GEAR ACT KLIXON SWITCH, GEAR OVERIDE C-H LAMP GE : 12-98 AHW4-15 7277-2-15 7277-2-5 2TL149-3D 8906K2875 DT-2R-A7 MCD-2711 LAllC21101 1057-00-1 4196-00-1D LAllC2115 LAllC2114 1057-00-5E 102000-1 560254-501 70-111221 W97CSX-1 6041H50A 70311221 6041H53 24401 1CH1-6 800335-501 SK75-1N-K3L 880013-503 880013-505 1CH1-6 W97CSX-1 6041H105A 70-311221 6041H105A 700-01-25 7277-2-15 SBIDDX492-2 388 NOTES 26 3 1 1 22 22 5 5 5 22 91-20-01 13 SERVICE AND MAINTENANCE MANUAL M20J MOONEY AIRCRAFT CORPORATION 14 VOLT ELECTRICAL EQUIPMENT CHART CODE 21 21 21 21 EG11A EG12A EL01A EL02A 21 21 21 21 21 21 EL03A ELO4A ELOBA EL07A ELOBA EL09A 21 ELT1A 21 21 ELT1B ELT2A 21 EW01B 21 -21 21 21 21 21 21 21 21 21 21 21 JM01A 21 21 21 21 LB01A LB01B LB01D LB02A 21 LC01A 21 LC02A 21 LC02B 21 21 21 21 21 21 LC03A LC03B LC03C LC03D LC03E LC04A 21 21 LC04B/C LC07A JM01B JM02A JM02B JM02C JM02D JM02E JM03A JM03C JM03D JM03E JV01A DESCRIPTION VENDOR PART NO. DIODE, GEAR UP BELAY DIODE,GEAR DN RELAY TRANSISTOR FUSE HOLDER RESISTOR RHEOSTAT/SW PLACARD, CB PLACARD, FUEL SEL PLACARD, ANNUN PLACARD, CK. LIST SARKES TARZlAN SARKES TARZlAN RCA McGRAW-EDISON 1=4 F4 2N2016 FM01-SA FHN42W 4599 JS1N055P251MA 150082-009 150082-011 150082-015 150082-013 OHMITE ALLEN/BRADLEY MOONEY MOONEY MOONEY MOONEY ELT (ALT) ELT, TRANSMITFER (OPT) SWITCH, REMOTE ELT (ALT) C/B, GEAR WARNING DORNE & MARGOLIN DOBNE & MARGOUN DORNE & MARGOUN C&K KLIXON DM-ELT-6 DM-ELT -6M DM-ELT-8 DM-U65-1 7101K 7277-2-2 SWITCH, MAGNETO PLACARD SWITCH, MAGNETO MAGNETO LEFT MAGNETO DUAL MAGNETO LEFT MAGNETO LEFT MAGNETO LEFT MAGNETO RIGHT MAGNETO RIGHT MAGNETO RIGHT MAGNETO, RIGHT STARTING VIBRATOR BENDIX-SCINTILLA BENDIX- SCINTILLA BENDIX-SCINTILLA BENDIX-SCINTILLA BENDIX-SCINTILLA BENDIX _ SLICK SUCK BENDIX BENDIX SUCK SUCK BENDIX-SCINTILLA 10-857290-17 10-187-468 10-357210-91 S41_N20O D4LN2021 10-79020-18 6214 6224 $4LN204 10-79020-18 6214 6224 10-176487-121 C/B, ROTATING BEACON C/B, ROTATING BCN(SPARES) C/B, ROTATING BEACON LIGHT, ROTATING BEACON ADAPTER MOONEY MOONEY MOONEY WHELEN WHELEN 930023-003 980023-103 980023-203 WRML-12 WRM-65 LITTEL FUSE LI-CFELFUSE LUMINATOR GE GRIMES GE C-H CABLING CABLING CABLING CABLING OHMITE 155020/155120 318005 20145 1003 B-3550 89 8144(BK-09) TILC64-1S-WH-FN TILC64-1S-WH-FN TILC84-1S-WH-FN TILC64-1S-WH-FN 4561 DALE C-H RH-10-5 OHM SA25SCT12-3 FUSEHOLDER, CLOCK, 5AMP FUSE,(5A-SAG-SLO-BLO) LIGHT, CABIN, OVERHEAD BULB UGHT, CABIN, OVERHEAD BULB SWITCH, CABIN LIGHT SWITCH, CABIN LIGHT, FWD SWITCH, CABIN LIGHT, REAR SWITCH, CABIN LIGHT, FWD SWITCH, CABIN LIGHT, REAR RESISTOR, DIM, CABIN LT (10 OHM 5W) . RESISTOR, DIM., CABIN LT SWITCH, MAP LT, PILOTS CAP FACE NUT 91-20-01 14 SW53AA2 15-1049-3 12-98 NOTES 28 MOONEY AIRCRAFT CORPORATION M20J SERVICE AND MAINTENANCE MANUAL 14 VOLT ELECTRICAL EQUIPMENT CHART CODE 21 LC08A 21 LCO9A 21 LC10A 21 LC11A 21 LC12.A 21 LC13A 21 LC14.A 21 LC15A 21 LC16A 21 LC17A 21 LC18A 21 21 21 21 21 21 21 21 21 21 21 21 21 21 = DESCRIPTION VENDOR PART NO. LIGHT, MAP, PILOTS BUlB SW, MAP LT, CO-PILOT CAP FACE NUT UGHT, MAP, CO-PILOT BUlB UGHT, CABIN, (F1-R) LAMP LIGHT, CABIN, (F2-R) LAMP LIGHT, CABIN, (F1-L) LAMP LIGHT, CABIN, (F2-L) LAMP SLOAN GE C-H 855-$1-0-PE 330 SA25SCT12-3 SW53AA2 15-1049-3 855-$1-0-PE 330 1930 1816 1930 t816 1930 1816 1930 =1816 SLOAN GE H.H. SMITH GE H.H. SMITH GE H.H. SMITH GE H.H. SMITH GE LIGHT, CABIN, (R1-R) LAMP LIGHT, CABIN, (R2-R) LAMP LIGHT, CABIN, (R1-L) LAMP LIGHT, CABIN, (R2-L) LAMP H.H. SMITH GE H.H. SMITH GE H.H. SMITH GE H.H. SMITH GE 1930 1816 1930 1816 1930 1816 1930 1816 LL01A LL01B LL01C/D LL02A LL03A LL03B/C LL04A C/B, LDG LT C/B, LDG LT C/B, LDG LT RELAY, LDG LT LIGHT, LDG (BULB) LIGHT, LDG (BULB) SWITCH, LDG LT CAP FACE NUT MERIDEN MOONEY MOONEY MAGNECFIAFT GE GE C-H AHW4-20 930023-15 930023-115/-215 WB9CQX-2 4522 4509 ; SA25SCT12-3 SW53AA2 15-1049-3 LN01A LN01B/D LN02A C/B, NAV LIGHTS C/B, POSITION LTS LIGHT, POSITION (RED) BUlB, POSITION (14V) MOONEY MOONEY GRIMES LN02B LN03A I_NO3B LN04A BUlB, POS TION(14V) UGHT, POSITION,(14V) (RED) LIGHT, POSITION, TAIL _NHITE) BULB, 14V, TAIL LT. BULB, 14V, TAIL LT. LIGHT, POS, TAIL, (14V) CVERT.MT) BUlB, POS., TAIL (14V) UGHT, POS, (GREEN) BUlB, POSITION (14V) 21 I_N04B BULB, POSITION (14V) LIGHT, POS, (GREEN) 21 21 21 21 LP01A LP01B LP01C/D LP02A C/B, PANEL LIGHTS C/B, PANEL LIGHTS C/B, INSTR LTS C/B, PANEL LIGHTS MOONEY WHELEN GRIMES GRIMES WHELEN 930023-001 930023-101/-201 AI285-R-12 A7512-12 800022-501 W1290-14 W1285-PR WHELEN MOONEY MERIDEN KLIXON KLIXON MERIDEN AHW4-10 7277-2-10 7277-2-10 AHW4-10 MOONEY 12-98 9 9 9 9 9 9 9 9 23 28 A2064-1777 203529 1777-266P-12.SV A48OA A506-14 A1295-G-12 A7512-12 880022-503 W1290-14 W1285-PG 880022-503 GRIMES NOTES 91-20-01 15 SERVICE AND MAINTENANCE MANUAL M20J MOONEY AIRCRAFT CORPORATION 14 VOLT ELECTRICAL EQUIPMENT CHART CODE 21 21 21 21 21 21 21 21 21 21 LPO3A LP03C LP03B LP04A LP05A LP08A LP06B/C LP07A LP08A LP09A 21 21 LP10C LP13A 21 LP14A 21 LP15A 21 -21 LP16A 21 LP18A 21 LP18B 21 LP18C 21 LP18D 21 LP18E -21 LP19A 21 LP20A 21 21 LP21A LP22A 21 LP22B 21 LP22C 21 LP24A LP17A 21 LP24B 21 21 21 21 LP25A LP25B LP25C LP25D 21 LP25E 91-20-01 16 DESCRIPTION VENDOR XSTR, INSTR LIGHTS XSTR, RADIO LIGHTS XSTR, (ALT LP03NC) XSTR, RADIO LIGHTS XSTR, RADIO LIGHTS RHEOSTAT/SWITCH RHEOSTAT/SWITCH, RADIO RHEOSTAT/SWITCH, RADIO RHEOSTAT/SWITCH, RADIO SWITCH, RED/WHITE, UGHT ROCKER C/B, INSTR LIGHTS FUSE, INSTR LTS HOLDER FUSE, INSTR LTS HOLDER FUSE, INSTR LTS HOLDER LAMPS (RED) HOLDER (4 EA) LAMPS (RED) HOLDER (7 EA) LAMPS 0NHITE) HOLDER (4 EA) LAMPS HOLDER (10 EA) LAMPS HOLDER (9 EA) LAMPS HOLDER (10 EA) UGHTS, GLARESHIELD RCA RCA DELCO RCA RCA ALLEN/BRADLEY ALLEN/BRADLEY ALLEN/BRADLEY ALLEN/BRADLEY MICRO MICRO KLIXON McGRAW-EDISON McGRAW-EDISON McGRAW-EDISON GE H.H. SMITH GE H.H. SMITH GE H.H. SMITH GE H.H. SMITH GE H.H. SMITH GE H.H. SMITH SLOAN MOONEY BULB (7 EA) GE LAMPS GE HOLDER (6 F_A) H.H. SMITH N# LIGHT (2 EA) KORRY BULBS GE LIGHT, COMPASS GE LIGHT-CONSOLE WESTERN IND CO. LAMP WESTERN IND CO LIGHT-CONSOLE WESTERN IND CO LAMP WESTERN IND CO LIGHT HOLDER, FLAP & TRIM DIALIGHT LAMP GE FUSE (5 AMP)(3AG-SLO-BLO)LFI-TEL HOLDER LI'I-rEL FUSE, MAP LITE LITTEL HOLDER LITTEL RESISTOR RESISTOR, INSTR LITES OHMITE RESISTOR, RADIO LITES OHMITE RESISTOR, INSTR LITES DALE (24-0901THRU 24-0926) RESISTOR, INSTR LITES DALE 12-98 PART NO. 2N2016 2N2016 2N3079 2N2016 2N2016 JS1N056P251MA JSIN056P251MA JS1N056P261MA JSIN056P251MA 8H2011 8Z0023 7277-2-6 FM01-5A FHN42W FM01-5A FHN42W FM01-SA FHN42W 1836R 1930 1836R 1930 1836 1930 1816 1930 1816 1930 1816 1930 8858-9-1 130285-003 330 1836 1930 250-650-5821-008 327 330 501-611<-11K3BP Wl-7046 501-61K-11K3BP Wl-7046 270-1930-01710702 370 NOTES 8 8 8 8 9 9 9 9 9 9 9 9 9 9 313005 155020 313001 155020 or 155120 100 OHM 2W 4599 4599 RH-10-50 OHM RH-10-50 OHM 10 10 / MOONEY AIRCRAFT CORPORATION M20J SERVICE AND MAINTENANCE MANUAL 14 VOLT ELECTRICAL EQUIPMENT CHART CODE 21 LP26A 21 LP27A 21 LP28A 21 LP29A 21 LPSOA 21 21 21 21 21 LP31A LP32A LP33A LP34A LP35A 21 21 21 21 21 21 21 21 LP36A LP37A LP38A LP39A LP40A LP41A LP42A LP43A 21 LP44A 21 LP45A 21 21 21 LR01A LRO2A LRO3A 21 21 -- LRO4A LRO5A 21 21 21 21 LSOIA LS01B/D LS02A LS02B 21 21 21 21 21 LS02C LS02E LSO2F LS03A LS03B 21 LS03B 21 21 LS03C LS03D DESCRIPTION VENDOR PART NO. UGHT, POST, M/P LAMP LIGHT, POST,TACH LAMP UGHT, POST, CLOCK LAMP UGHT, POST,OAT LAMP HOLDER, OXYGEN LIGHT LAMP BUSS, RADIO LIGHT POST LIGHT POST LIGHT POST LIGHT POST LIGHT LAMP LAMP, CLUSTER #1 LAMP, CLUSTER #2 LAMP, CLUSTER #3 LAMP, CLUSTER #4 LAMP, CLUSTER #5 CONNECTOR, MALE CONNECTOR, FEMALE FUSE, (1A) HOLDER CONNECTOR, PLUG CLAMP CONNECTOR, CLAMP GRIMES .... GE GRIMES GE GRIMES GE GRIMES GE SLOAN GE MOONEY GRIMES GRIMES GRIMES GRIMES GE G/E G/E G/E G/E G/E DEANS DEANS LI'I-IEL UTTEL AMP AMP AMP AMP A-8970B1 330 A-8970B1 33O A-897081 330 A-8970S1 330 855S-0-U 330 800233-060 A-897081 A-6970S1 A-8970S1 A-8970B1 330 . 330(AVIATION BLUE) 330(AVIATION BLUE) 330(AVIATION BLUE) 330(AVIATION BLUE) 330(AVIATION BLUE) DEA 90020 DEA 90020 313001 155020 or 155120 206060-1 206062-1 206153-1 206062-1 C/B RECOGNITION LIGHTS RECOG. UGHT, LT PLUG, RECOG. LIGHT, LT SOCKETS RECOGNITION LIGHT, RT PLUG, REGOG. LIGHT, RT SOCKETS MOONEY MOONEY AMP AMP MOONEY AMP AMP C/B, STROBE LIGHTS C/B, STROBE LIGHTS (AL-r) PWR SUPPLY, STB, I_]WG PWR SUPPLY, STB, L,NVG MOONEY MOONEY WHELEN SD| MOONEY PWR SUPPLY, STB, I_/WG MOONEY PWR SUPPLY, STB, LANG MOONEY CABLE, PWR SUPPLY, L/WG MOONEY STROBE LITE(FLASHTUBE) WHELEN STROBE, LITE, L/VVG SDI FLASHTUBE MOONEY STROBE LT, L/WG SDI MOONEY STROBE LT, LANG MOONEY CABLE ASSY, STROBE, LfWG SDI MOONEY NOTES 930023-231 990044-001 1-480318-0 60619-1 880049-001 1-480318-0 60619-1 930023-007 930023-107/-207 A490, T14 701295-3A 880018-501 880023-507 980928-505(ALT) 880017-503(ALT) A429 701303A 880019-501 702000-1 860021-501 880038-501 702000-3 880017-501 28 31 29, 32 29 30 31 29 64 30 29,34 i 12-98 ............................. 91-20-01 17 SERVICE AND MAINTENANCE MANUAL M20J MOONEY AIRCRAFT CORPORATION 14 VOLT ELECTRICAL EQUIPMENT CHART CODE DESCRIPTION VENDOR PART NO. MOONEY WHELEN SDI MOONEY MOONEY SDI MOONEY MOONEY MOONEY WHELEN SDI MOONEY MOONEY MOONEY MOONEY MOONEY MOONEY MOONEY MOONEY MOONEY AMP AMP AMP 880017-503 A490, T14 701295-3A 880018-501 880028-507 702000-3 880017-501 880028-505(ALT) 880017-503(ALT) A429 702000-2 880019-501 880021-502 880038-502 880038-501 880028-507 880017-505(ALT) 880017-507 880020-501 880041-501 206708-1 1-480305-0 61118-1 OR 60629-1 AN2552-3A 6041H105A 6041H105A 10H3P 1N2483 21 21 21 LS03E LS04A LS04B CABLEASSY, STROBE, L/WG PWR SUPPLY, STROBE,R/WG P/S, STROBE, R/WG 21 21 LS04C LS04D P/S, STROBE, R/WG CABLE ASSY, R/WG 21 21 21 21 LB04E LS04F LS05A LS05B P/S, STROBE, R/WG CABLE, P/S, R/WG FLASHTUBE, R/WG STROBE, UTE, R/WG FI..ASHTUBE 21 21 21 21 21 21 21 21 21 LS05C LS06A LS06B LS06C LS06D LS07A LS07B LS08A LS09A 21 21 21 21 21 MA01A MA02A MA02B MA03A MA04A STROBE LT, R/WG P/S, TAIL STROBE P/S,TAIL STROBE CABLE, TAIL STROBE CABLE, TAIL LITE STROBE, TAIL STROBE, TAIL PLUG, TAIL STROBE RECPT, TAIL STROBE P/S PINS (3 EA) AUX. PWR. RECEPTACLE RELAY, AUX. PWR RELAY DIODE, AUX PWR RELAY DIODE 21 21 21 21 21 21 21 21 21 21 21 21 21 21 21 21 21 21 21 MB01A MB01B MB02A MB02B MB03A MB03B MB04A MB04B MB05A MB05B MB06A MB06B MB07A MB07B MB08A MB08B MB09A MB09B MB10A 21 MB11A 21 MB12A 91-20-01 18 C/B, COM 1 C/B, COM 1 C/B, NAV 1 C/B, NAV 1 C/B, COM 2 C/B, COM 2 C/B, NAV 2 C/B, NAV 2 C/B, XPN1A O/B, XPN C/B, AUD 1 C/B, AUD C/B, ADF 1A C/B, ADF C/B, DME 1A C/B, DME SPEAKER, MSO1A SPEAKER JACK, MIC 1 WASHERS JACK, MIC 2 WASHERS MIC KEY, PILOTS 'CAP .FACE NUT C-H C-H SARKES TARZIAN MERIDEN KUXON MERIDEN KLIXON MERIDEN KUXON MERIDEN KLIXON MERIDEN KLIXON MERIDEN KUXON MERIDEN KUXON MERIDEN KUXON MOONEY ARA SWITCHCRAFT SWlTCHCRAFT SWlTCHCRAFT SWITCHCRAFT C-H C-H C-H 12-98 AHW4'7277-2AHW47277-2AHW47277-2AHW47277-2AHW47277-2AHW47277-2AHW47277-2AHW47277-2810195 6707001 C-128 S-102B, S-1029 C-128 S-102B, S-1029 SA25SAT12-3 SW53AA2 15-1049-3 NOTES 31 29, 34 30 29, 34 31 34 29 34 30 29,34 30 29 29, 34 30 30 11 11 11 11 11 11 11 11 11 11 11 11 11 11 11 11 MOONEY AIRCRAFT CORPORATION M20J SERVICE AND MAINTENANCE MANUAL 14 VOLT ELECTRICAL EQUIPMENT CHART CODE DESCRIPTION VENDOR PART NO. C-H C-H C-H SWITCHCRAFT SWITCHCRAFT KUXON MERIDEN ALCO KLIXON KLIXON KUXON KUXON KLIXON KLIXON KUXON KLIXON KUXON MOONEY MOONEY MOONEY MOONEY MOONEY MOONEY MOONEY MOONEY KLIXON KING KLIXON KLIXON KLIXON KI\LIXON KLIXON MOONEY KLIXON MOONEY MOONEY BORG INSTR BORG MITCHELL MOONEY MOONEY MOONEY MOONEY MOONEY DUKES SA2.5SAT12-3 SW53AA2 15-1049-3 C-11 C-11 7277-2AHW4MST215N 7277-27277-27277-27277-27277-27277-27277-27277-27277-2930023-023 930023-123/-223 930023-021 930023-121/-221 800233-000 800233-000 800233-000 930023-125/-225 7277-2KA20 7277-27277-27277-27277-27277-2930023-127/-227 7277-2800336-501 800336-503 CA-7212 or CA-7286 CA7616 98470-1LW 930023-011 930023-117 930023-111 930023-117/-217 930023-211 4140-00-19A (R/B) 1499-00-19 610153-501 1499-00-19 610153-501 930023-019 21 MB13A 21 21 21 MB14A MB15A MB16A/B MIC KEY, COPILOT CAP FACE NUT JACK, FONE 1 JACK, FONE 2 C/B, NP 21 21 21 21 21 21 21 21 21 21 21 21 21 21 21 21 21 21 21 21 21 21 21 21 21 21 21 21 21 21 21 21 21 21 21 21 21 21 MB17A MB18A/B MB19A MB20A MB21A MB22A MB23A MB24A MB25A MB26A MB27A MB27B/D MB28A MB28B MB29A MS30A MB31A MB32A/B MB33A MB34A MB35A MB38A MB37A MB38A MB39A MB40ND MB41A MC01A MC01B ME01A MEOIB MEOlC NF01A NF01 B NFOl C NFOl D/F NF01 E NF02A SWITCH, RADIO MASTER C/B R-NAV C/B HSI C/B ENCODER C/B FUEL FLOW C/B TELEFONE C/B VME C/B TELEPHONE C/B INVERTER C/B, RMI C/B, PROP DE-ICE C/B, PROP DE-ICE C/B,WX RADAR C/B, WX RADAR BUSS, GRD 1 BUSS, GRD 2 BUSS, GRD 3 C/B, WX RADAR, COLOR C/B, RADIO BLOWER RADIO BLOWER ASSY C/B, STEREO C/B, ALT, SERVO C/S, ALT SELECT C/B, CONVERTER C/B, LORAN C/B, STANDBY VACUUM C/B, STORMSCOPE CIGAR LIGHTER CIGAR LIGHTER CLOCK, ELECTRIC CLOCK (OPT) CLOCK,LIGHTED) C/B, FUEL PUMP C/B, FUEL PUMP-LO C/B, FUEL PUMP-LO C/B, FUEL PUMP-LO C/B, BOOST PUMP FUEL PUMP 21 NF02B FUEL PUMP 21 NF03A C/B, FUEL PUMP-HI MOONEY DUKES MOONEY MOONEY 12-98 NOTES 11 11 11 11 11 11 11 11 11 11 11 11, 28 28 28 11 11 11 11 11 11 11,28 11 37 37 28 91-20-01 19 SERVICE AND MAINTENANCE MANUAL M2OJ MOONEY AIRCRAFT CORPORATION 14 VOLT ELECTRICAL EQUIPMENT CHART CODE 21 21 21 DESCRIPTION VENDOR PART NO. C/B, FUEL PUMP-HI RESISTOR VOLT REG, AUX PUMP RECPT, V/R CLAMP PLUG, V/R CLAMP RECPT, PUMP CLAMP PLUG, PUMP CLAMP MOONEY CLARSTAT ELECTRO-DELTA MOONEY AMP AMP AMP AMP AMP AMP AMP AMP 930023-119/-219 VP-50-KA VR-436 880047-505 206153-1 206062-1 206060-1 206062-1 206153-1 206062-1 206060-1 206062-1 NOTES 21 NF03B/D NF04A NFO4B ALT NF05A 21 NF06A 21 NF07A 21 NF08A 21 21 21 NP01A NP02A NP03A SWITCH SOLENOID FUSE/HOLDER CARUNG CONTINENTAL LI'I-FEL T1GK6B-1F-WH-A 642200 311010 or312010 21 21 21 PA01A PA01B PA02A C/B, ALTERNATOR, FIELD C/B, ALT FIELD ALTERNATOR MERIDEN KLIXON PRESTOLITE 21 21 21 21 21 21 21 21 21 21 21 PA02B PA02C PA02D PA03A PA03B PA03C PA03D PA04A PA04B PA05A PA06NB/C 21 PA07A 21 PA07B 21 PA08B ALTERNATOR FORD ALTERNATOR LYCOMING ALTERNATOR CONTINENTAL FILTER ELPAC FILTER SPRAGUE FILTER CAPTOR FILTER CAPTOR C/B, ALT MECH. PROD. C/B, ALT. OUTPUT ETA CAPACITOR SANGAMO VOLTAGE REG. MOONEY REPLACES OECO P/N 20082, & ELECTRO-DELTA P/N's VR414 & VR415 ADAPTER CABLE MOONEY PLUG, VOLT REG CLAMP PLUG, VOLT REG AMP CLAMP AMP RECPT, VOLT REG AMP CLAMP AHW4-5 7277-2-5 ALY-9403 or8420 or ALY6420LS OR ALY8420M DOFP-10300J LW 15404 641669 27-3-99-01021 JN-14-1356A A2637 A2638 1648-001-70 41.-3-$14-LN2-70 500-1041-01 880016-501 38 880270-505 (SPARES) 13 800331-721 MS3106A-18-4S MS3057-10B 206060-1 206062-1 206153-1 206062-1 21 21 21 21 21 PB01A PB01B PB02A PB02B PB03A 21 21 21 21 21 21 21 PB03B PB04A PB04B PB05A PB06A PB06B/D PB07A 91-20-01 20 BATTERY BATTERY RELAY,,BA-[-IERY,MASTER RELAY, MASTER C/B, AUX BUSS (AL'r) C/B, AUX POWER RELAY, RADIO RELAY, RADIO MASTER SWITCH, MASTER C/B BUS, RADIO RELAY C/B, RADIO MASTER BUSS BAR, MAIN FLEX GILL PRESTOLITE C-H C-H MERIDEN MECHANICAL PROD ETA MAGNECRAFT P &B C-H MOONEY MOONEY 12-96 G-35(PS6-11) R-35 6041H231 6041H105A AHW1-50 700-001-50 41-3-$14-LN2-50 W89CQX-2 MB-4413 9811K828 930023-013 930023-113/-213 28 12 17 6 28 14 MOONEY AIRCRAFT CORPORATION M20J SERVICE AND MAINTENANCE MANUAL 14 VOLT ELECTRICAL EQUIPMENT CHART CODE .... ! DESCRIPTION 21 21 21 PB07B PB07C PB07D 21 21 21 21 21 21 21 21 21 21 21 21 21 21 21 21 21 21 21 21 21 21 21 21 21 21 21 21 21 21 21 21 21 21 21 21 21 21 21 21 21 21 21 21 21 21 21 21 21 PB07E PB07F PB07G PB07H PB07J PB07K PB07L PB08A PB09A PB09B PB09C PB09D PB09E PB09F/M PB09G PB09H PB09J PB09K PB09L PB10A PB10B PB10C PB11A PB11B PB12A PB12B PB12C PB12D PB12E PB12F PB13A PB13B PB14A PB14B PB14C PB15A PB16A PB20A PS21A PB21B PB21C PB21D PB21E PB22A PB23A PB24A PB25A PB26A PB27A VENDOR PART NO. BUSS BAR MAIN FLEX BUSS BAR MAIN FLEX, #1 BUSS BAR MAIN FLEX, #2 BUSS BAR MAIN POWER BUSS BAR MAIN POWER BUSS BAR MAIN POWER BUSS BAR MAIN #7 BUSS BAR MAIN POWER BUSS BAR BUSS BAR BUSS BAR RADIO FLEX BUSS BAR AUX BUSS BAR AUX. #1 BUSS BAR AUX. #2 BUSS BAR CONN 1 &2 BUSS BAR AUXl BUSS BAR AUX BUSS BAR AUX. #2 BUSS BAR AUX. #1 BUSS BAR AUX. #2 BUSS BAR AUX. BUSS BAR AUX. #2 BUSS BAR MAIN #1 BUSS BAR MAIN #1 BUSS BAR MAIN #1 BUSS BAR MAIN #2 BUSS BAR MAIN #2 BUSS BAR MAIN #3 BUSS BAR RADIO #3 BUSS BAR MAIN #3 BUSS BAR RADIO #3 BUSS BAR RADIO #3 BUSS BAR RADIO #2 BUSS BAR RADIO #1 BUSS BAR RADIO #2 BUSS BAR RADIO #2 BUSS BAR RADIO #2 BUSS BAR RADIO #3 DIODE, RADIO MASTER BUSS BAR MAIN #1 JUMPER BUSS BAR, RADIO FLEX BUSS BAR, RAD, FLEX #2 BUSS BAR, RAD, FLEX BUSS BAR BUSS BAR DIODE, MASTER RELAY DIODE, RADIO RELAY SHUNT, RADIO RELAY SHUNT, RADIO RELAY C/B, BATTERY POWER . BUSS BAR, MAIN POWER NOTES 14 14 14 MOONEY MOONEY MOONEY MOONEY MOONEY MOONEY MOONEY MOONEY MOONEY MOONEY MOONEY MOONEY MOONEY MOONEY MOONEY MOONEY MOONEY MOONEY MOONEY MOONEY MOONEY MOONEY MOONEY MOONEY MOONEY MOONEY MOONEY MOONEY MOONEY MOONEY MOONEY MOONEY MOONEY MOONEY MOONEY SARKES TARZlAN MOONEY MOONEY MOONEY MOONEY MOONEY SARKES TARZIAN SARKES TARZIAN KULKA KULKA ETA MOONEY 12-98 14 14 14 14 14 14 14 14 913127-009 913127-093 913127-003 913127-011 913127-013 913127-023 913127-025 913127-027 913127-029 913127-113 913127-125 913127-005 913127-017 913127-019 913127-005 913127-019 913127-005 913127-019 913127-001 913127-003 913127-019 913127-019 913127-005 913127-019 913127-005 913127-019 913127-019 F-4 913127-003 40 41 41 15 14 15 15 15 F-4 F-4 600RJ-2 600RJ-2 41-3-S14-LN2-70 913127-031 91-20-01 21 SERVICE AND MAINTENANCE MANUAL M20J MOONEY AIRCRAFT CORPORATION 14 VOLT ELECTRICAL EQUIPMENT CHART CODE DESCRIPTION VENDOR PART NO. 21 21 21 21 21 21 21 21 21 21 PB28A PB29A PB30A PB31A PB32A PB33A PB34A PB35A PB36A PB37A DIODE BUSS BAR,RADIO #5 BUSS BAR, RADIO #4 BUSS BAR, MAIN PWR, #3 BUSS BAR, RADIO #3 BUSS BAR, RADIO #2 BUSS BAR, MAIN PWR#3 BUSS BAR, MAIN PWR #3 BUSS BAR, RADIO #1 BUSS BAR, MAIN #1 SARKEB TARZIAN MOONEY MOONEY MOONEY MOONEY MOONEY MOONEY MOONEY MOONEY MOONEY F-4 918127-001 918127-001 918127-003 913127-005 913127-019 913127-035 913127-035 913127-035 913127-037 21 21 PG01A PGO2A ELECTRO MECH LI'I-FEL LITTEL 21 PG03A 21 21 21 PG04A PGO5A PG06A 21 -21 PG07A GENERATOR, STANDBY FUSE HOLDER FUSE(15A SLO-BLO) PLUG, REGULATOR CLAMP VOLTAGE REGULATOR C/B, STANDBY GEN RELAY, BUSS SWITCHING SOCKET RELAY, CONTROL SOCKET LIGHT, ON LAMP LIGHT, O.V. LAMP DIODE, ON LIGHT DIODE, O.V. LIGHT RECPTACLE CLAMP PLUG DIODE DIODE, RADIO RELAY RECEPTACLE CLAMP CLAMP 8012 155020 or 155120 313015 MS3106A-18-1S MS3057-10A or-10B 2073-2 7277-2-15 JD1B 50-1049-8309 W67CSX-2 70-303 501-61K-11K3BP Wl-7046 501-61K-11K3BP Wl-7046 F-4 F-4 206153-1 206062-1 206060-1 F-4 F-4 206705-2 206708-1 206062-1 PLUG, C/B PANEL CLAMP PLUG, FLT PNL #1 CLAMP PLUG, FLT PNL #1 PLUG, ELEC GEAR CLAMP PLUG, ELEC GEAR PLUG, L/WING CLAMP PLUG, I../WING PLUG, L/WG STUB CLAMP PLUG, L/WG STUB CLAMP PLUG, L/WG STUB AMP AMP AMP AMP MOONEY AMP AMP MOONEY MP PGO8A 21 -21 21 21 PG09A 21 21 21 21 PG13A PG14A PG15A PG16A 21 PLOIA 21 -21 21 PL02A 21 21 PL03B PL04A 21 21 PL04B PL05A 21 PL05B 21 PLO5C 91-20-01 22 PG10A PG11A PG12A PL02B PLO3A ELECTRO MECH KLIXON LEACH MAGNACRAFT WESTERN IND WESTERN IND SARKES TARZlAN SARKES TARZIAN AMP AMP SARKES TAP,ZIAN SARKES TAFIZIAN AMP AMP AMP MOONEY AMP AMP AMP MOONEY 12-98 206037-1 206070-1 206037-1 206070-1 930021-505 206037-1 206070-1 930021-001 206037-1 206070-1 930021-001 206037-1 206070-1 206708-1 206966-1 930021-001 NOTES ..... -- , MOONEY AIRCRAFT CORPORATION M20J SERVICE AND MAINTENANCE MANUAL 14 VOLT ELECTRICAL EQUIPMENT CHART CODE 21 PL06A 21 PL07A 21 PL07B 21 PL08A 21 -21 PL08B 21 -21 PL10A 21 -21 PL11B 21 -21 PL12B 21 PL13B 21 PL14A 21 21 PL14B PL15A 21 PL16A 21 PL16B 21 PL17A 21 PL16A 21 PL16B 21 -21 PL19A 21 P1_21A 21 21 PL22A PL22B 21 -- PL23A PL09A PL11A PL12A PL13A PL20A DESCRIPTION VENDOR PART NO. PLUG, SQUAT SWITCH CLAMP PLUG,CONSOLE #1 CLAMP PLUG,CONSOLE #1 CLAMP PLUG, HEADUNER CLAMP PLUG, HEADLINER CLAMP PLUG, FIREWALL CLAMP PLUG, I_/SIDE CABIN, MIDDLE CLAMP PLUG, FLT PNL #2 CLAMP PLUG, FLT PNL #2 CLAMP PLUG, GLARESHIELD CLAMP PLUG, ANNUNCIATOR PANEL CLAMP PLUG, FIREWALLJUNC. PNL CLAMP PLUG, ACCESS. PNL CLAMP PLUG, I_/SIDE CABIN CLAMP PLUG, L/SIDE PANEL PLUG, ELEC. FLAPS CLAMP AMP AMP AMP AMP AMP AMP AMP 206060-1 202062-1 206037-1 202070-1 206060-1 202062-1 206037-1 206070-1 206708-1 206966-1 MS8106A-22-14S MS3057-12B 206060-1-001 206062-1 206037-1 206070-1 206708-1 206966-1 206087-1 206070-1 206060-1 206062-1 206037-1 206070-1 206708-1 206966-1 206037-1 206070-1 030021-001 206037-1 206070-1 AMP AMP AMP AMP AMP AMP AMP AMP AMP AMP AMP AMP MOONEY AMP AMP PLUG, CONSOLE #2 AMP CLAMP AMP CLAMP AMP PLUG, CONSOLE AMP CLAMP AMP PLUG, RELAY PANEL AMP CLAMP AMP PLUG, CLUSTER GAUGE AMP CLAMP AMP PLUG, CLUSTER GAUGE AMP CLAMP AMP PLUG, PILOT'S WHEEL AMP CLAMP AMP PLUG, COPILOTS WHEEL AMP CLAMP AMP PLUG, VAC WARN SW AMP CLAMP AMP PLUG, RADIO PWR, C./BPNL AMP PLUG, AUX PWR, C/B PNL AMP CLAMP AMP PLUG, RADIO PWR, RELAY PNLAMP ' CLAMP AMP 12-98 NOTES 19 206037-1 206070-1 206966-1 206708-1 206966-1 206037-1 206070-1 206037-1 206070-1 206708-1 206966-1 206060-1 206062-1 206060-1 206062-1 206060-1 206062-1 206070-1 206037-2 206070-1 206037-2 206070-1 91-20-01 23 SERVICE AND MAINTENANCE MANUAL M20J MOONEY AIRCRAFT CORPORATION 14 VOLT ELECTRICAL EQUIPMENT CHART CODE DESCRIPTION VENDOR PART NO. 21 PL24A 21 PL24S 21 PL24C 21 PL25A 21 PI-25B 21 PL2.SC 21 PI.-25D 21 PL26A 21 PL26B 21 PL26C 21 PL2.TA 21 PL28A 21 PL29A 21 PL29B 21 PL30A 21 PL30B 21 PL30C 21 PL31A 21 PL32A 21 PL33A 21 PL34A 21 PL34B 21 PL35A 21 PL35B 21 PL35C 21 PL35D 21 PL36A PLUG, CABIN TAIL CONE CLAMP PLUG, CABIN TAIL CONE CLAMP PLUG, CABIN/TAIL CONE CLAMP PLUG, R/WG CLAMP PLUG, R/WG CLAMP PLUG, R/WG CLAMP PLUG, R/WG CLAMP PLUG, R/WG STUB CLAMP PLUG, R/WG NAV CLAMP PLUG, R/WG STUB CLAMP PLUG, TRIM POS. IND CLAMP PLUG, PILOT'S TRIM CLAMP PLUG, TAIL CLAMP PLUG, EMPENNAGE CLAMP PLUG, RADIO, C/B PNL CLAMP PLUG, C/B PNL(OPT) CLAMP PLUG, C/B PNL(OPT) CLAMP PLUG, RADIO PKG CABLE CLAMP PLUG, XSTRS, CONSOLE CLAMP PLUG, PWR, FLT PNL CLAMP PLUG, PANEL LT CONTROL CLAM P PLUG, LT CONTROL CLAMP PLUG, GEAR CONTROL CLAMP PLUG, GEAR CONTROL CLAMP PLUG, GEAR CONTROL #1 CLAMP PLUG, GEAR CONTROL #2 CLAMP . PLUG, GEAR OVERRIDE . CLAMP AMP AMP AMP AMP AMP AMP AMP AMP AMP AMP AMP AMP MOONEY AMP AMP AMP AMP AMP MOONEY AMP AMP AMP AMP AMP AMP AMP AMP AMP AMP AMP AMP AMP AMP AMP AMP AMP AMP AMP AMP AMP AMP AMP AMP AMP AMP AMP AMP AMP AMP AMP AMP AMP AMP AMP 206037-1 206070-1 206706-1 208966-1 206037-1 206070-1 206037-1 206070-1 206060-1 206062-1 206708-1 206966-1 930021-001 206966-1 206060-1 206062-1 206708-1 206966-1 930021-001 206966-1 206060-1 206062-1 206060-1 206062-1 206060-1 206062-1 206708-1 206966-1 206037-1 206070-1 206706-1 206966-1 206060-1 206062-1 206037-1 206070-1 206037-1 206070-1 206037-2 206070-1 206060-1 206062-1 206706-1 206966-1 206708-1 206966-1 206060-1 206062-1 206705-2 206966-1 206060-1 206062-1 205060-1 206062-1 91-20-01 24 12-96 NOTES MOONEY AIRCRAFT CORPORATION M20J SERVICE AND MAINTENANCE MANUAL 14 VOLT ELECTRICAL EQUIPMENT CHART CODE DESCRIPTION VENDOR PART NO. 21 PL37A 21 PL38A PLUG, VAC WARN CLAMP PLUG, ELT SWITCH CLAMP PLUG, OVERHEAD LITE CLAMP PLUG, EMERG FLD CLAMP PLUG, GLARESHIELD CLAMP PLUG, HOUR METER CLAMP PLUG, FLT PNL CLAMP PLUG, GR SAFETY SW CLAMP PLUG, FIREWALL #2 CLAMP AMP AMP AMP AMP AMP AMP AMP AMP AMP AMP AMP AMP AMP AMP AMP AMP 266060-1 206062-1 205060-1 206062-1 206060-1 206062-1 206060-1 206062-1 206060-1 208062-1 206060-1 206062-1 206708-1 206966-1 206060-1 206062-1 MS3106A-22-14S MS3057-12B PLUG, AVIONIC PWR PLUG, AUDIO INTERCN CLAMP PLUG, FLT PNL DIM CLAMP CLAMP PLUG, C/B DIM CLAMP PLUG, NP TRIM SW RELAY CLAMP PLUG, A/P CLAMP PLUG, NP GRND CLAMP PLUG, AVIONICS GRND CLAMP PLUG MAIN CABLEGRND CLAMP PLUG AVIONICS GRND #2 CLAM P PLUG INT PWR CLAMP PLUG COM/NAV POWER CLAMP PLUG ROLL SERVO CABLE CLAMP PLUG AZIMUTH CABLE CLAMP PLUG AVIONICS DIM CLAMP PLUG K-4/C-2 NAV REC/NP CLAMP MOONEY AMP AMP AMP AMP AMP AMP AMP AMP 930021-501 205839-1 206070-1 206037-1 205838-1 206062-1 206062-1 206062-1 206037-1 206070-1 206037-1 206070-1 206037-1 206070-1 206839-3 206070-1 206037-1 206070-1 2067839-3 206070-1 206708-1 206966-1 206060-1 206062-1 206768-1 286866-1 206708-1 206966-1 206037-1 206070-1 205839-3 206070-1 21 -21 PL39A PL40A 21 -21 PL41A 21 PL43A 21 PL44A 21 PL45A 21 21 PL46A PL47A 21 PL48A 21 -21 -21 PL50A 21 -21 PL53A 21 -21 PL53C 21 PL54A 21 PL55A 21 PL57A 21 PL58A 21 PL59A 21 -- PL60A PL42A PL51A PL52A PL53B PL53D AMP AMP AMP AMP AMP AMP AMP AMP AMP AMP AMP AMP AMP 12-98 NOTES : 91-20-01 25 SERVICE AND MAINTENANCE MANUAL M20J MOONEY AIRCRAFT CORPORATION 14 VOLT ELECTRICAL EQUIPMENT CHART CODE 21 PL61A 21 PL62A 21 PL63A 21 PL64A 21 PL65A 21 PL66A 21 PL67A 21 PL68A 21 PL69A 21 PL670A 21 PL71A 21 PL72A 21 PL73A 21 PL74A 21 PL75A 21 PL76A 21 PL77A 21 PL78A 21 PL79A 21 21 21 PS01A PS01B PS02A 21 PS03NB 21 PS04A 21 PSO4B 21 PS05A 91-20-01 26 DESCRIPTION VENDOR PART NO. PLUG, K-14 NAV REC/NP CLAMP PLUG, K-14 NAV REC/NP CLAMP PLUG, NP XFER CLAMP PLUG, K-2/K-3 NAV REC/NP CLAMP PLUG, TRIM RELAY CLAMP PLUG TRIM SW CLAMP PLUG AZIMUTH CLAMP PLUG ADF RMI CLAMP PLUG TRIM RELAY CLAMP PLUG TRIM PWR CLAMP PLUG NP RELAY CLAMP PLUG, VOR/GS TRANSFER CLAMP PLUG, MKR INVERTER CLAMP PLUG, NAV/REC NP CLAMP AMP 206839-3 206070-1 206037-1 206070-1 206037-1 206070-1 205839-3 206070-1 205838-1 206062-1 205838-1 206062-1 206708-1 206966-1 205838-1 206062-1 205838-1 206062-1 206060-1 206062-1 205839-3 206070-1 205838-1 206062-1 205838-1 206062-1 205839-3 206070-1 PLUG. ADF/RMI CLAMP PLUG, GRND CLAMP PLUG, XPDR/ENCODER (KFC 200) CLAMP PLUG, RADIO PKG CABLE CLAMP PLUG, NAV REC/NP, I<-4/(]-2 CLAMP C/B, IGN/TACH/CIG UGHTER C/B, IGN/TACH/CIG LIGHTER SWITCH, STARTER HOUSING SCREEN, DISPLAY RING, GUARD RELAY STARTER (ALT) (ALT) STARTER • (ALT) DIODE AMP AMP AMP AMP AMP AMP AMP AMP AMP AMP AMP AMP AMP AMP AMP 206037-1 206070-1 205839-3 206070-1 20037-1 AMP 206070-1 206037-1 206070-1 205839-3 206070-1 MERIDEN KLIXON MICRO MICRO MICRO MICRO C-H R/B MOONEY PRESTOLITE PRESTOLITE PRESTOLITE PRESTOLITE LYCOMING SARKES TARZIAN AHW4-10 7277-2-10 2D72 2M1 2J5 2K6 6041H105A 940020-501 MZ4206 MZ4218 MZ4222 MCL-6501 LW15572 F-4 12-98 NOTES 22 39 MOONEY AIRCRAFT CORPORATION M20J SERVICE AND MAINTENANCE MANUAL 14 VOLT ELECTRICAL EQUIPMENT CHART CODE 21 PS06A 21 RC01A 21 RC01B 21 RC02A 21 21 RC02B RC03A 21 21 -21 21 RC03B RC04A RC04B RC05A 21 RC05B 21 21 RC05C RC06A 21 RC07A 21 RC07B 21 RC08A 21 -21 RC09B 21 RC10A 21 -21 RC11A 21 RC12A 21 RC13A 21 RC13B 21 RC14A 21 21 21 RC14B RC14C RC15A 21 RC16A RC09A RC11B DESCRIPTION FUSE HOLDER FUSE RECPT, C/B PNL CLAMP RECPT, C/B PNL CLAMP RECPT, FLT PNL #1 CLAMP RECPT, FLT PNL #1 RECPT, ELEC GEAR CLAMP RECPT, ELEC GEAR RECPT, L/WING CLAMP RECPT, L/WING RECPT, L/WING CLAMP RECPT, L/WING STUB CLAMP RECPT, L/WING STUB RECPT, SQUAT SWITCH CLAMP RECPT, CONSOLE #1 CLAMP RECPT, CONSOLE #1 CLAMP RECPT, HEADLINER CLAMP RECPT, HEADLINGER CLAMP RECPT, FIR_ALL CLAMP RECPT, L/SIDE CABIN, MID CLAMP RECPT, FLT PNL#2 CLAMP RECPT, FLT PNL #2 CLAMP RECPT, GLARESHIELD CLAMP RECPT, FIREWALLJUNC PNL CLAMP RECPT, ACCESS. PNT CLAMP RECPT, L/SIDE CABIN LOW CLAMP RECPT, L,/SIDE PNL RECPT, L/SIDE PNL RECPT, FLAPS, ELEC CLAMP RECPT, CONSOLE #2 CLAMP VENDOR UTTEL LI'I-FEL AMP AMP AMP AMP AMP AMP MOONEY AMP AMP MOONEY AMP AMP MOONEY AMP AMP AMP AMP MOONEY AMP AMP AMP AMP AMP AMP AMP AMP AMP AMP AMP AMP AMP AMP AMP AMP AMP AMP AMP AMP AMP AMP AMP AMP MOONEY MOONEY AMP AMP AMP AMP 12.98 PART NO. 155020 or 155120 313001 206036-3 206070-1 20515%1 206138-1 206036-3 205070-1 930021-506 206036-1 206070-1 930021-002 206036-3 206070-1 930021-002 206036-3 206070-1 206705-2 206966-1 930021-002 ' 206153-1 206070-1 206036-3 206070-1 206153-1 206062-1 206036-3 206070-1 206705-2 206966-1 MS3100A22-14P MS3057-12B 206153-1 206062-1 206036-3 206070-1 206705-2 206966-1 206036-6 206070-1 206066-3 206070-1 206705-2 206966-1 206036-3 206070-1 930021-002 930021-502 206036-1 206070-1 206036-3 206070-1 NOTES 19 19 91-20-01 27 SERVICE AND MAINTENANCE MANUAL M20J MOONEY AIRCRAFT CORPORATION 14 VOLT ELECTRICAL EQUIPMENT CHART CODE DESCRIPTION 21 RC16B 21 RC17A 21 RC18A 21 RC18B 21 RC19A 21 RC20A 21 RC21A 21 RC22A 21 RC22B 21 RC23A 21 RC24A 21 RC24B 21 RC24C 21 RC25A 21 RC25B 21 RC25C 21 RC25D 21 RC26A 21 RC26B 21 RC26C 21 RC27A 21 RC28A 21 RC29A 21 RC29B 21 RC30A 21 RC30B 91-20-01 28 VENDOR RECPT, CONSOLE AMP CLAMP AMP RECPT, RELAY PNL AMP CLAMP AMP RECPT, CLUSTER GAUGE AMP CLAMP AMP RECPT, CLUSTER GAUGE AMP CLAMP AMP RECPT, PILOT'S WHEEL AMP CLAMP AMP RECPT, COPILOT'S WHEEL AMP CLAMP AMP RECPT, MACWARN SW AMP CLAMP AMP RECPT, RADIO PWR C/B PNL AMP CLAMP AMP RECPT, C/B PNL, AUX PWR AMP CLAMP AMP RECPT, RADIO PWR RELAY PNL AMP CLAMP AMP RECP'I" CABIN TAILCONE AMP CLAMP AMP RECP't" CABIN TAILCONE AMP CLAMP AMP RECP'[ , CABIN TAILCONE AMP CLAMP AMP RECP'f , R/WING AMP CLAMP AMP RECPT, R/WING AMP CLAMP AMP RECPT R/WING AMP CLAMP AMP RECPT R/WING MOONEY CLAMP AMP RECPT R/WIGN STUB AMP CLAMP AMP RECPT R/WING STUB AMP CLAMP AMP RECPT R/WING STUB MOONEY CLAMP AMP RECPT TRIM POS IND AMP CLAMP AMP RECPT PILOT'S TRIM AMP CLAMP AMP RECPT, TAIL AMP CLAMP AMP RECPT, TAIL AMP CLAMP AMP RECPT, RADIOS, C/B PNL AMP CLAMP AMP RECPT, C/B PNL AMP CLAMP AMP 12-98 PART NO. 206705-2 206966-1 206036-1 206070-1 206036-8 206070-1 296708-2 206966-1 206153-1 206062-1 206153-1 206062-1 206153-1 206062-1 206207-1 296070-1 206036-2 206070-1 206036-1 206070-1 206036-3 205070-1 206705-2 206966-1 206036-3 206070-1 206036-3 206070-1 206153-1 206062-1 206705-1 206070-1 930021-002 2060966-1 206153-1 206062-1 206705-2 206966-1 930021-002 206966-1 206153-1 206062-1 206153-1 206062-1 206153-1 206062-1 206705-2 206966-1 206036-3 206070-1 206705-2 206966-1 NOTES MOONEY AIRCRAFT CORPORATION M20J SERVICE AND MAINTENANCE MANUAL 14 VOLT ELECTRICAL EQUIPMENT CHART CODE DESCRIPTION 21 RC30C 21 RC31A 21 RC32A 21 RC33A 21 RC34B 21 RC34B 21 RC35A 21 RC35B 21 RC35C 21 RC35D 21 RC37A 21 RC38A 21 -21 RC39A 21 RC41A 21 RC42A 21 RC43A 21 RC43C 21 RC44A 21 RC45A 21 21 RC46A RC47A 21 RC48A 21 RC49A 21 RC5OA 21 RC51A RC40A .... VENDOR RECPT, C/B PNL (OPT) AMP CLAMP AMP RECPT, RADIO PKG CABLE AMP CLAMP AMP RECPT, TRANSISTORS, CONSOLE AMP CLAMP AMP RECPT, F:_NRFLT PNL AMP CLAMP AMP RECPT, PNL LT CONTROL AMP CLAMP AMP RECPT, LIGHT CONTROL AMP CLAMP AMP RECPT, GEAR CONTROL AMP CLAMP AMP RECPT, GEAR CONTROL AMP CLAMP AMP RECPT, GEAR CONTROL #1 AMP CLAMP AMP RECPT, GEAR CONTROL #2 AMP CLAMP AMP RECPT, VAC WARN AMP CLAMP AMP RECPT, ELT, SW AMP CLAMP AMP RECPT, O/H LIGHT, AFT AMP CLAMP AMP RECPT, EMERG FLD AMP CLAMP AMP RECPT, BLARESHIEDL AMP CLAMP AMP RECPT, HOUR METER AMP CLAMP AMP RECPT, FLT PNL AMP CLAMP AMP RECPT, GO AROUND/WX RADAR CLAMP AMP RECPT, GR SAFETY SW AMP CLAMP AMP RECPT, FIREWALL#2 CLAMP RECPT, AVIONICS PWR MOONEY RECPT, AUDIO INTER AMP CLAMP AMP RECPT, FLT PNL GRND/DIM AMP CLAMP AMP RECPT, C/B GRND AMP CLAMP AMP RECPT, C/B DIM AMP CLAMP AMP RECPT, NP TRIM SW RELAY AMP CLAMP AMP 12-96 PART NO. NOTES 206060-1 206062-1 206036-3 206070-1 206036-3 206070-1 206207-1 206070-1 206153-1 206062-1 206705-2 206966-1 206705-2 207008-1 206153-1 206062-1 206705-2 206966-1 206153-1 206062-1 206153-1 206062-1 206153-1 206062-1 206153-1 206062-1 206153-1 206062-1 206153-1 206062-1 206153-1 206062-1 206705-2 206966-1 206705-2 206966-1 206153-1 206062-t MS3100A-22-14P MS3057-12B 930021-502 206152-1 206070-1 206036-1 206070,-1 206841-2 206062-1 206153-1 206062-1 206036-3 206070-1 91-20-01 29 SERVICE AND MAINTENANCE MANUAL M20J MOONEY AIRCRAFT CORPORATION 14 VOLT ELECTRICAL EQUIPMENT CHART CODE 21 RC52A 21 RC53A 21 RC53S 21 RC53C 21 RC53D 21 -21 RC54A 21 RC57A 21 -21 RC58A 21 -21 RC59B 21 RC61A 21 RC62A 21 RC63A 21 -21 RC64A 21 -21 RC66A 21 RC68A 21 RC69A 21 RC70A 21 RC71A 21 -21 -21 RC72A 91-20-01 3O RC55A RC59A RC60A RC65A RC67A RC73A RC74A DESCRIPTION VENDOR PART NO. RECPT, NP PWR CLAMP RECPT, NP GRND CLAMP RECPT, AVIONICS GRND #1 CLAMP RECPT, MAIN CABLE GRND CLAMP RECPT, AVIONICS GRND #2 CLAMP RECPT, INTERFACE PWR CLAMP RECPT, COMM/NAV PWR CLAMP RECPT, ROLL SERVO CABLE CLAMP RECPT, AZIMUTH CABLE CLAMP RECPT, AVIONICS DIM CLAMP NP DIM CLAMP RECPT, K-4/C-2,NAVREC/A/P CLAMP RECPT, K-14, NAVREC/NP CLAMP RECPT, K-14, NAVREC/NP CLAMP RECPT, A/P TRANSFER CLAMP RECPT, K-2/K-3, NAVREC/A/P CLAMP RECPT, TRIM RELAY CLAMP RECPT, TRIM SW CLAMP RECPT, AZIMUTH CLAMP RECPT, ADF/RMI CLAMP RECPT TRIM RELAY CLAMP RECPT TRIM PWR CLAMP RECPT A/P RELAY CLAMP RECPT VOR/GS TRANSFER CLAMP RECPT MKR INVERTER CLAMP RECPT NAVREC/A/P CLAMP AMP AMP AMP AMP AMP AMP AMP AMP AMP AMP AMP AMP AMP 206036-3 206070-1 206036-3 206070-1 206152-1 206070-1 206036-3 206070-1 206152-1 206070-1 206705-2 206966-1 206153-1 206062-1 206705-2 206966-1 206705-2 206966-1 206036-3 206070-1 206153-1 206062-1 206152-1 206070-1 206152-1 206070-1 206036-3 206070-1 206036-1 206070-1 206152-1 206070-1 205841-2 206062-1 205841-2 206062-1 206705-2 206966-1 205841-2 206062-1 205841-2 206062-1 206153-1 206062-1 206152-1 206070-1 205841-1 206062-1 205641-1 206062-1 206152-1 206070-1 AMP AMP AMP AMP AMP AMP AMP AMP AMP AMP AMP AMP AMP AMP AMP AMP AMP AMP AMP AMP AMP 12-98 NOTES MOONEY AIRCRAFT CORPORATION M20J SERVICE AND MAINTENANCE MANUAL 14 VOLT ELECTRICAL EQUIPMENT CHART CODE DESCRIPTION 21 RC75A 21 RC76A 21 RC77A 21 RC78A 21 RC79A 21 WA01A 21 21 21 WA02A WA03A WA03B 21 21 21 WE01A WE01B WE02A 21 WE03A 21 21 -21 21 21 WE03B WE03C 21 WE07A 21 21 21 21 21 WE08A WE09A WE10A WE11A WE12A 21 WF01A 21 21 WF03A WF04A 21 WL01A 21 WL02A 21 VENDOR PART NO. RECPT, ADF/RMI CLAMP AMP RECPT, GRND AMP CLAMP AMP RECPT, XDCR/ENCODER (KFC-200) AMP CLAMP AMP RECPT, RADIO PKG CABLE AMP CLAMP AMP RECPT, K..4/C-2NAVREC/A/P AMP CLAMP AMP 206036-3 206070-1 206152-1 206070-1 206036-2 206070-1 206036-3 206070-1 206152-1 206070-1 LIGHT, ALT WARN BULB (2) RECTIFIER SWITCH, LO VOLT DET SWITCH, LO VOLT DET KORRY GE SARKESTAFIZIAN ELECTRO DELTA ELECTRO DELTA 250-650-5821-003 330 F-4 LV 14 LV-14F C/B, GEAR WARN C/B, GEAR WARN UGHT, GEAR UNSAFE BULB SWITCH, THROI-rLE ACTUATOR SWITCH, THROTTLE SWITCH, THROTTLE ACURATOR HORN, GEAR UP, WARN RECTIFIER LIGHT, GEAR POSITION BULB (1) LIGHT, GEAR DOWN BULB (2) DIODE, GEAR UNSAFE DIODE, GEAR DOWN DIODE, GEAR HORN RESISTOR, DIM DIODE, DIM MERIDEN KLIXON KORRY SARKES TAP,ZIAN AHW4-2 7277-2-2 250-650-5821-006 GE 1SM1-T JS-221 SS12ET10-102L3 V3-1 JV-5 SC628P F-4 855S-0-U 327 250-650-5821-007 GE F-4 F-4 F-4 (50 OHM -5 WAll') F-.4 LIGHT, LOW FUEL PRESS BULB (2) RECTIFIER PLUG-SWITCH KORRY GE SARKES TARZIAN AMPHENOL 250-650-5821-004 330 F-4 126-223-1000 WL03A FUSEHOLDER FUSE LIGHT, LANDING IND BULBS (2) RECTIFIER LITTEL LI'I-['EL KORRY GE SARKES TAP,ZIAN 155020 311011 250650-5821-005 330 F-4 21 21 WS01A WS01B C/B, STALL WARN HORN C/B, STALL WARN HORN MERIDEN KLIXON AHW4-2 7277-2-2 21 21 WS02A WS03A HORN, STALL WARNING SWITCH, PRE-STALL WARN MALLORY SAFE FLIGHT SC628 C46001 21 21 21 WT01A WT02A WT03A SWITCH, PRESS TO TEST C/B, ANNUNCIATOR .ANNUNCIATOR LAMPS ALCO MSP205R KLIXON 7277-2-2 IAI 500D0024 CHICAGO MINIATURE CM7-7330 WE04A WE05A WE06A MICRO MICRO C-H MICRO MICRO MALLORY SARKESTARZIAN SLOAN GE KORRY SARKES TARZIAN SARKES TARZIAN SARKES TARZIAN 12-98 NOTES 330 330 91-20-01 31 SERVICE AND MAINTENANCE MANUAL M20J MOONEY AIRCRAFT CORPORATION 14 VOLT ELECTRICAL EQUIPMENT CHART CODE DESCRIPTION VENDOR PART NO. 500D0038B CM7-7330 21 WT03B ANNUNCIATOR LAMPS IAI CHICAGO MINIATURE 21 WT03F 21 WT03G 21 21 WT03H WT03J 21 WT03K ANNUNCIATOR LAMPS ANNUNCIATOR LAMPS (8) ANNUNCIATOR ANNUNCIATOR LAMPS ANNUNCIATOR IAI 500D0038-007 CHICAGO MINIATURE CM7-7330 MOONEY 880025-501 CHICAGO MINIATURE CM7-7330 MOONEY 880025-515 MOONEY 880025-511 CHICAGO MINIATURE CM7-7330 MOONEY 880025-513 21 WT04A PLUG, ANNUNCIATOR PIN MOLEX MOLEX 09-50-8121 08-50-106 21 21 21 WV01A WV01B WV02A C/B, VACUUM WARN C/B, VACUUM WARN SWITCH, VACUUM WARN MERIDEN KLIXON MOONEY AHW4-2 7277-2-2 880012-501 21 21 21 WV02B WVO2C WV03A 21 WV04A 21 WV04B 21 21 21 WV05A WV06A WV07A SWITCH, VAC. WARN LO SWITCH, VAC. WARN HI LIGHT, LOW VAC BULB (2) LIGHT, HIGH VAC BULB (2) LIGHT, VAC BULB (2) RECTIFIER, LO RECTIFIER, HI SWITCH, VAC LT, FLASHER WHITMAN GENERAL WHITMAN GENERAL KORRY GE KORRY GE KORRY GE SARKES TARZIAN SARKES TARZlAN ELECTRO DELTA P118V-IN-K5L-1 PllSV-IN-K4L-2 250-650-5821-002 330 250-650-5821-001 330 250-650-5821-009 330 F-4 1=-4 FL1 21 WW01A 21 WW01B SWITCH, RAM AIR ACTUATOR SWITCH, ALTERNATE AIR MICRO MICRO CHERRY V3-1 JV-5 E51-50B UGHT DIMMER SW BOX RHEOSTAT TRANSISTOR TRANSISTOR (ALl') FUSE ::IECEPTACLE MOONEY ALLEN-BRADLEY RCA RCA McGRAW-EDISON AMP 8800344 JS1N056P02MA 2N3055 2N3773 FM01-5A 206705-2 91-20-01 32 12-98 NOTES 20 20 21 21 21 MOONEY AIRCRAFT CORPORATION M20J SERVICE AND MAINTENANCE MANUAL 14 VOLT ELECTRICAL EQUIPMENT CHART NOTES 1. 2. 3. 4. Switch8906k2876 may be used by painting black handle with white epoxy paint. Alternate for V3L-3 is V3-1 switch with JV-5 actuator. 0506-505 is replacementfor-004; S/N 18928 & UP are modified. Or equivalent Sprague RB1535 Dale MFS-1/2(15K) TWX 1/2 W (15k) 5. 6. Set for75 MPH (+/-5.0) (65 +7/4 KIAS) increasingactuation.(2.775 in. H20, +0.384/-0.358 in.) Use withsocket,27E122; spring,206176; stand-off,(2 ea) 21B212. (AN515-6R5 screw, AN936-A6 washer). Aitemete L110-1-N-K3L or Mooney P/N 880013-501. MountingHardware RCA KC2B Mica InsulatingWafer H.H. Smith 6291 NylonShoulder Washer H.H. Smith 2666 SolderLug H.H. Smith 1410-10 Metal Washer H.H. Smith 1152 Nut H.H. Smith 1367 7. 8. 9. Altemete Holders Drake Leecraft 4151-014 10. AIt. Resistors 243E2015 VC5E-200 11. Maximum circuitbreakerratingis shown, amperageof installedcircuitbreakerisdetermined by particularunit installed. Aitemate Ohmite 0561 Mallory 5AV10 12. 13. 14. 15. 16. 17. 18. 19. 20. 21. 22. 23. 24. 25. Sprague Drake 07-05 ReplaceVR414 & 20082 with 880016-501 & 800331-721 cable. Manufactureusing"AlphaWire Co." braid #2172 or#1233/2 (2 ea) & AMP terminalsas necessaryto connectthe bussbars as shownon schematic.Cover braidwith PVC 105/A tubingfor insulation. Same as 14 except use (1 ea) braid. Groundtabs ( 250" series) "As required" AMP 41478 AMP 41480 Altemate Prestalite R35 Replacewith MS3106A-22-14P when used in conjunctionwithMS3450KT22-14S. Replace withMS3450K-r22-14S receptacle & MS3417-22-N cableclamp or Matrix#9440KT22-14S. MFG Chicago Minature Lamp Co. Set switcheswithroomtemperature between 60° F and 80° F. Set low at 4.25" Hg. +/-0.25" and highat 5.50" Hg. +0.20/-0.00" increasing vacuum.Switchesmay not vary morethan 0.50" Hg. between 0_ F and 110° F. Replace with 940020-501, (Cutler-Hammer solenoid P/N 6041H53). Alternate Turn Coordinators: Talley Corp. (w/out lights) 1394T100-7Z United Instr.(w/out lights) 9100 Code No. 6 Alternate Turn & Bank: Talley Corp. (w/out lights) 1234T100-7TZ Talley Corp. (w/out lights) 1284T100-3TZ Aitemate Fuel Flow Gauges: Mooney (Gals/hr - lighted) 880034-501 Mooney (liters/hr - lighted) 880034-503/-509 Mooney (Imperial gals/hr - lighted) 880034-511 Mooney (Pounds/hr) 880034-505 12-98 91_20-01 33 SERVICE AND MAINTENANCE MANUAL M20J MOONEY AIRCRAFT CORPORATION 14 VOLT ELECTRICAL EQUIPMENT CHART NOTES (con't,) 26. 27. 28. 29. 30. 31. 32. 33. 34. 35. 36. Alternate Landing Gear: Mooney 880037-501 Use buss bar 913127-029, -023 or -013 as required by installation of optional equipment. Effective 25-0821 & ON (All are 930023-2xx C/B's). Effective 24-1464 & ON also. Effective25-0001 thru 25-0788 or 24-0024 thru 24-1037. Effective25-0789 & ON or 24-1426 & ON. Effective 24-0001 thru 24-0023 (24-0024 thru 24-1037 use 21 LS02B, 21 LS03B, 21 LS04B & 21 LS05B) Effective25-0447 thru 25-0780 or24-1038 thru 24-1425. Standardon 24-1211 & ON. Effective25-0613 thru 25-0780. AltemataTurn Coordinator(w/lights): United Instr 9112-Code No. 9 Astronautics 303990-113MSC Talley 1394T100-3Z 37. Use 1 ea. MS35334-21 or MS2898 (Alan-Bradley)internaltoothIockwasherwith each lightif notsupplied by Sloan. Altemata Clock (lighted): Mid-Continent MD-88L Mid-Continent MD-88L(ET) (w/light tray) BA14-24-BW2 38. AlternateVoltage Regulator: 39. Altamate Starter (21 PS04B): 40. 41. Use bussbars913127-123,-125 as required, by installationof OptionalEquipment. CUT TO SIZE 91-20-01 34 Lamar B-00371-6. TCM 646238 12,98 MOONEY AIRCRAFT CORPORATION M20J SERVICE AND MAINTENANCE MANUAL 28 VOLT ELECTRICAL EQUIPMENT CHART 91-20-02 - ELECTRICAL SYSTEM HARDWARE CHART - 28 VOLT SYSTEMS SERIALNUMBER's 24-3000 THRU 24-3153, MOONEY DRAWING NO. 800350 (AV-9) CODE JKL JKL JKL JKL JKL JKJK-KJKJKJKJKJKL JKL JKL JKL JKJKJKL JKJKJKJKJ--J----L --L --L --L ---L DESCRIPTION VENDOR CB101A CB102A CB103A CB104A C/B DEFROSTER BLOWER KUXON SWITCH, DEFROST BLOWER CHERRY MOTOR, DEFROSTER BLOWER MOONEY RECPT, DEFROSTER BLOWER AMP PINS AMP CB105A PLUG, DEFROSTER BLOWER AMP SOCKETS AMP CCI01A C/B, COWL FLAP KLIXON CC102A SWITCH, COWL FLAP MICRO CAP, WHITE MICRO CC103A ACTUATOR, COWL FLAP MOONEY CC104A SWITCH,OPEN LIMIT MICRO ACTUATOR MICRO CC105A SWITCH, CLOSE LIMIT MICRO ACTUATOR MICRO CC106A RECPT, 4 PIN AMP CLAMP AMP CC107A PLUG, 4 PIN AMP CLAMP AMP CF101A C/B FLAP ACT KLIXON CF102A SWITCH, FLAP C-H CF103A SWITCH, UP LIMIT MICRO CF104A SWITCH, DOWN LIMIT MICRO CF106A SWITCH, TAKEOFF, UP MICRO CF107A SWITCH, TAKEOFF, DOWN MICRO ACTUATOR MICRO CF105A ACTUATOR, FLAP MOONEY CF108A RELAY, UP MAGNACRAFT CF109A RELAY, DN MAGNACRAFT BASE MAGNACRAFT CFI1OA SWITCH, FLAP C-H (ALl') MICRO KNOB MOONEY CF111A/112A DIODE CF113A PLUG, 4 PIN AMP CLAMP AMP CF114A RECPT, 4 PIN AMP CLAMP AMP CF150A C/B TRIM/FLAP IND KUXON CF151A INDICATOR,TRIM/FLAP PENN AIRBORNE CF152A : PLUG, TRIM/FLAP IND 13-1" CLAM P I'IF LOCK RETAINER ITT CF153A PLUG,FLAP POSITION, 4 PIN AMP CLAMP AMP CF154A RECPT,FLAP POSITION, 4 PIN AMP CLAMP AMP 12-98 PART NO. 7277-2-2 E51-50B 640317-501 1-408319-0 60620-1 1-480318-0 60619-1 7277-2-5 12TW1-1 15PAg0-4W 880050-501 1SE1-T JE-5 1SE1-T JE-5 206153-1 206062-1 206060-1 206062-1 7277-2-5 8906K3148 V3-1 V3-1 V3-1 V3-1 JV-5 750105-501 W67RCSX-3 W67RCSX-3 70-303 8906K4064 2TL148-12L 917026-501 1N2483 206060-1 206062-1 206153-1 202062-1 7277-2-1 9A1590 DA15S DA51210-1 DA51220-1 206060-1 206062-1 206153-1 ._ 206062-1 NOTES 4 4 4 4 4 91-20-02 35 SERVICE AND MAINTENANCE MANUAL M20J MOONEY AIRCRAFT CORPORATION 28 VOLT ELECTRICAL EQUIPMENT CHART CODE DESCRIPTION VENDOR --L CF155A JKL JKL CT101A C/B ELECTRIC TRIM KUXON CT101A C/B ELECTRIC TRIM KUXON CT150A POTENIOMEFER, TRIM POSITION WA2-G056S502UA CT151A PLUG, TRIM POSITION, 4 PIN AMP CLAMP AMP CT152A RECPT,TRIM POSITION, 4 PIN AMP CLAMP AMP 7277-2-3 7277-2-5 ALLEN-BRADLEY JKJKJK- CV101A CV102A CV103A JKJKJKJK-JK-JK-JK- CV104A CV105A CV106A CV107A 930023-245 $6112-472 155020 or155120 313001 800846-501 830131-511 1N2483 1-480319-0 60619-1 1-480319-0 60620-1 1-480319-0 60620-1 1-480318-0 --L --L CV108A -CV109A CV110A JKJKJ-- DA101A DA101B DA101D -JKJKJK- DA102A DA102A DA103A JKJKJK- DA104A DA104B DA105A JK- DA106A JKJKJKJKJK- DA107A DA107B DA107C DA107D DA108A JK- DA109A JK- DA110A JK- DA111A 91-20-02 36 POTENTIOMETER,FLAP POSITION C/B, STBY VAC CLUTCH, STBY VAC PUMP FUSE HOLDER FUSE ANNUNCIATOR RELAY DIODE PLUG SOCKETS RECPT, 2 PIN PINS RECPT, 2 PIN PINS PLUG, 2 PIN ALLEN-BRADLEY PART NO. MOONEY AEROSAFE LI'I-rEL LITTEL MOONEY MOONEY -- AMP AMP AMP AMP AMP AMP AMP SOCKETS AMP LOADMETER (SINGLE) B& D LOADMETER (DUAL) B& D AMMETER MOONEY UGHT BULBASSY ROCHESTER BULB GE CONN, AMMETER S.E.C. CONN, AMMETER (ALl') BENDIX SWITCH, PUSH, VOLTAGE C-H LIGHT BULB ASSY ROCHESTER (ALT) ROCHESTER BULB GE SHUNT, AMMETER (ALT'NR #1) EMPRO SHUNT, AMMETER (ALT'NR) EMPRO FUSEHOLDER (+ ALl" # 1) McGRAW-EDISON FUSE, 5A McGRAW-EDISON FUSEHOLDER (- ALE# 1) McGRAW-EDISON FUSE, 5A McGRAW-EDISON SHUNT, AMMETER, LOAD EMPRO SHUNT, AMMETER, LOAD EMPRO SHUNT, AMMETER, LOAD EMPRO SHUNT, AMMETER, LOAD EMPRO FUSEHOLDER (-LOAD) McGRAW-EDISON FUSE, 5A McGRAW-EDISON FUSEHOLDER, (+LOAD) McGRAW-EDISON FUSE, 5A McGRAW-EDISON .AMMETER, SHUNT (ALT #2) EMPRO AMMETER, SHUNT (ALT.) EMPRO FUSEHOLDER (+ ALT. #2) McGRAW-EDISON FUSE, 5A McGRAW-EDISON 12-98 NOTES WA2-G056S502UA 206060-1 206062-1 208153-1 206062-1 60619-1 0326-004 0326-003 640281-509 0105S00004 313 PW06B12-10S PT06A-12-10S-SR SA31SDT12-1 0105S00003 0153500003 313 MLA-70A-50MV MLA-55A-50MV FHN42W FM01-5A FHN42W FM01-5A MLB-210A-50MV MLB-165A-50MV MLB-105A-50MV MLA-60A-100MV FHN42W FM01-5A FHN42W FM01-5A MLA-70A-50MV MLA-55A-50MV FHN42W FM01-5A 5 5 MOONEY AIRCRAFT CORPORATION M20J SERVICE AND MAINTENANCE MANUAL 28 VOLT ELECTRICAL EQUIPMENT CHART CODE DESCRIPTION VENDOR PART NO. JK-- DAl12A FUSEHOLDER (- ALT. #2) FUSE, 5A McGRAW-EDISON McGRAW-EDISON FHN42W FM01-5A --L --L --L --L DA150A DA151A DA152A DA153A ---L DA154A C/B VOLT/AMP IND, LT C/B VOLT/AMP IND, RT INDICATOR, VOLT/AMP, RT PLUG, VOLT/AMP IND CLAMP LOCK RETAINER INDICATOR, VOLT/AMP, RT KLIXON KLIXON PENN AIRBORNE ITT I'1-1" ITT PENN AIRBORNE 7277-2-1 7277-2-1 9A1570 DA15S DA51210 DA51220-1 9A1570 --L DA155A --L --L ---L --L --L DA156A DA157A DA158A DA159A DA160A --L - DA161A --L DA162A --L DA163A DA164A --L ---L DA165A --L DA167A JKL JKJKJKL DB101A DB102A DB102B DB103A --L DB150A JK--L --L --L DC101A DC150A DC151A DC152A --L DC153A --L DC154A --L DC155A DA166A PLUG, VOLT/AMP IND ITT CLAMP ImLOCK RETAINER InSHUNT, LEFT LOAD EMPRO SHUNT, LEFT ALTERNATOR EMPRO SHUNT, RIGHT LOAD EMPRO SHUNT RIGHT ALTERNATOR EMPRO FUSEHOLDER, LT LOAD SHUNT (-) McGRAW-EDISON FUSE 5A McGRAW-EDISON FUSEHOLDER, LT LOAD SHUNT(+) McGRAW-EDISON FUSE 5A McGRAW-EDISON FUSEHOLDER, LT ALT SHUNT (+) McGRAW-EDISON FUSE 5A McGRAW-EDISON FUSEHOLDER, LT ALT SHUNT (-) McGRAW-EDISON FUSE 5A McGRAW-EDISON FUSEHOLDER,RTLOAD SHUNT(+) McGRAW-EDISON FUSE 5A McGRAW-EDISON FUSEHOLDER, RT LOAD SHUNT (-) McGRAW-EDISON FUSE 5A McGRAW-EDISON FUSEHOLDER, RT ALT SHUNT (-) McGRAW-EDISON FUSE 5A McGRAW-EDISON FUSEHOLDER, RT ALT SHUNT (+) McGRAW-EDISON FUSE 5A McGRAW-EDISON DA15S DA51210 DA51220-1 MLA-105A MLA-70A-50MV MLA-105A MLA-70A-50MV FHN42A FM01-5A FHN42A FM01-5A FHN42A FM01-5A FHN42A FM01-SA FHN42A FM01-SA FHN42A FM01-5A FHN42A FM01-5A FHN42A FM01-5A C/B TURN COORD TURN CO-ORDINATOR TURN CO-ORDINATOR PLUG, TURN COORD CABLE CLAMP TURN COORDINATOR KLIXON U.I. ASTRONAUTICS 7277-2-2 9013CODE N.5 303990-028MSC MS3106A-10SL-3S MS3507-4A or-4B 9551B CODE N.541 CYL HD TEMP PROBE C/B OIL TEMP/CHT CHT/OIL TEMP IND PLUG, CHT/OIL TEMP CLAMP LOCK RETAINER -SWITCH, CHT KNOB PLUG, CHT, 16 PIN , CLAMP RECPT, CHT, 16 PIN CLAMP MOONEY KUXON PENN AIRBORNE I1[ ITT I'I-T GRAY HILL RAYTHEON AMP AMP AMP AMP UI 12-98 _ NOTES 50MN 50MN 880010-503 7277-2-1 9A1630 DB25S DB51212 DB51221-1 71AD30-02-2-AJN 50-3-1G 206037-1 206070-1 206036-3 206070-1 91-20-02 37 SERVICE AND MAINTENANCE MANUAL M20J MOONEY AIRCRAFT CORPORATION 28 VOLT ELECTRICAL EQUIPMENT CHART CODE --L --L --L ---L --L -_- DESCRIPTION DC156A DC157A DC158A DC159A DC160A DC161A PROBE, PROBE, PROBE, PROBE, PROBE, PROBE, VENDOR CHT-CYL #1 CHT-CYL #2 CHT-CYL #3 CHT-CYL #4 CHT-CYL #5 CHT-CYL #6 PART NO. MS24482-1 ** MS24482-1 ** MS24482-1 ** MS24482-1 ** MS24482-1 ** MS24482-1 ** ** AN5546-1 (ALT) -EITHER REQUIRES AN4076-1 ADAPTER J-J-J_ J-- DD101A DD102A DD102B DD103A C/B, OAT/EGT KLJXON GAUGE, OAT/EGT MOONEY GAUGE, OAT/EGT, 4 PROBE (OPT) B & D PLUG,, OAT/EGT AMP 7277-2-2 880001-507 0230-003 205838-1 CLAMP, CABLE AMP 206062-1 MOONEY KUXON PENN AIRBORNE ITr ITT I-ri- 880004-501 7277-2-1 9A1580 DA15S OA51210 DA51220-1 JKL --L --L --L DD104A DD150A DD151A DD152A PROBE, OAT C/B OAT IND INDICATOR, OAT PLUG, OAT CLAMP LOCK RETAINER J-J-JKL JKL -KL -KL --L DF101A DF103A DF102A DP104A DF105A DF106A DF150A TRANSMTR, FUEL QTY, LT, I/B MOONEY TRANSMTR, FUEL QTY, RT, I/B MOONEY TRANSMITTER, FUELQTY, O/B, LT MOONIEY TRANSMITTER, FUEL QTY, O/B, RT MOONEY TRANSMI]-rER, FUEL QTY, I/B, LT MOONEY TRANSMI'I-I'ER, FUEL QTY, I/B, RT MOONEY C/B FUEL QTY',LH/RH KLIXON 610242-001 610242-001 610243-003 610243-001 610242-003 610242-003 7277-2-1 --L --L DF151A DP152A FUEL QTY IND, L/R PLUG, FUEL QTY, L/R CLAMP LOCK RETAINER PENN AIRBORNE ITT ITT I'l-l" 9A1620-2 DB25S DB51212 DB51221-1 JKJ--K--L --L --L DG101A DG102A DG103A DG150A DG151A DG152A --L --L DG153A DG154A --L DG155A --L DG156A --L DG157A --L DG158A C]B, CLUSTER GAUGE GAUGE, CLUSTER GAUGE, CLUSTER C./BINSTRUMENT DISPLAY INSTRUMENT DISPLAY PLUG, INSTR. DISPLAY CLAMP LOCK RETAINER C/B INSTRUMENT P]-r SWITCH, INSTRUMENT PTT CAP, BLACK PLUG, 9 PIN, P-I-r CLAMP RECPT, PTT, 9 PIN CLAMP PLUG, GRND #7, 28 PIN CLAMP ' RECPT, GRND #7, 28 PIN •CLAMP KLIXON MOONEY MOONEY KLIXON PENN AIRBORNE 1"17I'IF ITF KUXON ALCOSWlTCH ALCOSWlTCH AMP AMP AMP AMP AMP AMP AMP AMP 7277-2-5 640281-523 640281-525 7277-2-1 9A1600-2 DB25S DB51212 DB51221-1 7277-2-1 MPE106F 0-22 206708-1 206966-1 206705-2 206966-1 205839-3 206070-1 206152-1 206070-1 91-20-02 38 12-93 NOTES MOONEY AIRCRAFT CORPORATION M20J SERVICE AND MAINTENANCE MANUAL 28 VOLT ELECTRICAL EQUIPMENT CHART CODE JK- DH101A --L DH150A JKJK- DJ101A DJ102A --L DJ150A --L DJ151A --L DJ152A JK- DJ175A JKJK- DJ176A DJ178A JK- DJ179A JK- DJ180A JK- DJ181A J-J---L --L --L DK101A DK102A DK150A DK151A DK152A --L DK153A --L ---L DK154A J-- DK175A J-J-- DK176A DK177A J-- DK178A J-- DK179A J-- DK180A J--K-K-K- DL101A DL102A DL102B DL102C DK155A DESCRIPTION VENDOR PART NO. PROPE, OIL TEMP WASHER PROSE, OIL TEMP MOONEY 880009-501 AN900-10 or MS35769-11 938.606.002.00 XDUCR, OIL PRESS PLUG, OIL PRESS CLAMP, CABLE XDUCER, OIL PRESS MOONEY PLUG, OIL PRESS, 4 PIN CLAMP RECPT, OIL PRESS, 4 PIN CLAMP XDUCR, OIL PRESS (ALl') AMPUFIER, OIL PRESS PLUG, 4 PIN CLAMP RECPT, 4 PIN CLAMP PLUG, 4 PIN CLAMP RECPT, 4 PIN CLAMP AMP AMP AMP AMP DRUCK KULITE IAI AMP AMP AMP AMP AMP AMP AMP AMP XDUCR, FUEL PRESS PLUG, FUEL PRESS XDUCR C/B FUEL/OIL PRESSURE INDICATOR, FUEL/OILPRESS PLUG, FUEL/OIL PRESS CLAM P LOCK RETAINER XDUCER, FUEL PRESS MOONEY PLUG, FUEL PRESS, 4 PIN CLAMP RECPT, FUEL PRESS, 4 PIN CLAMP XDUCR, FUEL PRESS (ALl) AMPLIFIER, FUEL PRESS PLUG, 4 PIN CLAMP RECPT, 4 PIN CLAMP PLUG, 4 PIN CLAMP RECPT, 4 PIN CLAMP AMP AMP AMP AMP DRUCK KULITE IAI AMP AMP AMP AMP AMP AMP AMP AMP 880045-501 MS3106A10SL-SS 7277-2-1 9A1640 DB25S DB51212-1 DB51221-1 PDCR 821-0062 (100 PSIG) 206060-1 206062-1 206153-1 205062-1 PDCR821-0662-30 APT-153-1000-30PSIG 950D0311-001 206060-1 206062-1 260163-1 206062-1 206060-1 206062-1 260163-1 206062-1 TACHOMETER (POINTS) TACHOMETER ,TACHOMETER TACH (RPLCMT FOR - DL102B) MOONEY MOONEY MOONEY MOONEY B& D 880039-511 880039-509 880039-513 880039-517 0520-006 PORSCHE DRUCK KLIXON PENN AIRBORNE ITT ITI" I-I-r DRUCK 12-98 NOTES 880046-501 MS3106A10SL-3S MS3057-4A/B PDCR 821-0662 (100 PSIG) 206060-1 206062-1 206153-1 206062-1 PDCR821-0662-100 APT-154-1000-100PSIG 950D0811-003 206060-1 206062-1 206153-1 206062-1 206060-1 206062-1 206158-1 206062-1 91°20-02 39 SERVICE AND MAINTENANCE MANUAL M20J MOONEY AIRCRAFT CORPORATION 28 VOLT ELECTRICAL EQUIPMENT CHART CODE DESCRIPTION VENDOR JK-K-JK- DL103A DL103A JK- DL105A J-J_ DLIO7A DL108A PLUG-TACH TACH SENSOR TACH SENSOR (ALl') RECPT, 4 PIN CLAMP PLUG CLAMP TACHOMETER TACH GENERATOR J-J DL109A DLl10A CABLE ASSY TACHOMETER --L ---L DL150A DL151A DL152A DL153A PENN AIRBORNE ITT I'Cl" 13-1" PORSCHE PORSCHE DL104A B& D B& D AMP AMP AMP AMP MOONEY MOONEY B &D MOONEY MOONEY B&D --L DL157A DL158A DIODE, RPM/FUEL FLOW, LT DIODE, RPM/FUEL FLOW, RT INDICATOR, RPM/FUEL FLOW PLUG, RPM/FUEL FLOW CLAMP LOCK RETAINER SENSOR, RPM #2, RT SENSOR, RPM #1, LT J -KL DM101A DM102A DM150A HOUR METER HOUR METER HOUR METER MOONEY MOONEY AIRPAX --L DM151A --L DM152A RECPT, HOUR METER, 4 PIN CLAMP PLUG, HOUR METER, 4 PIN CLAMP AMP AMP AMP AMP JKL JKJKl. DPIO1A DP101A DP102A C/S, PITOT HEAT C/B, PITOT HEAT (SPARES) PITOT, HEATED MOONEY MOONEY AERO INST JKL DP103A JKJKJK-JK- DP104A DPIO4B DPIO5A JK- DP107A JKL ---L L DP108A DP150A DP150B DP151A L DP152A 91-20-02 40 DP106A PLUG, PITOT HEAT SOCKETS BOARD ASSY MOONEY CURRENT MONITOR (SPARES) MOONEY FUSEHOLDER LITI'EL FUSE, 1A LI]-rEL PLUG AMP SOCKETS AMP RECPT AMP PINS AMP MGHT ASSY MOONEY RELAY BOX, CURRENT DETECTOR MOONEY RELAY BOX, CURRENT DETECTOR MOONEY PLUG, CUR/DECT RELAY AMP CLAMP AMP FUSEHOLDER LI'I-FEL . FUSE, 5A-SAG-SLO-BLO LI'I-I'EL 12-98 PART NO. NOTES MS3106A14S-SS 0402-102 0402-104 206183-1 206662-1 206060-1 206062-1 880039-507 880053-501 0400-004 680003-501 680039-515 0620-003 1N2483 1N2483 9A1610-2 DB25S DB51212 DB51221-1 933.602.002.01 933.602.002.01 880035-507 880035-505 K4205 *** *** K4207 or KF4207 (ALl-) 206153-1 206062-1 206060-1 206062-1 930023-205 930023-241 PH502-24**** **** AN5812-1 (ALT) AN3115-1 AN3116-1 940002-001 800221-501 155020 or 155120 313001 1-480303-0 60619-1 1-480305-0 60620-1 800346-503 800221-501 800221-503 206660-1 206062-1 155020 or 155120 313065 MOONEY AIRCRAFT CORPORATION M20J SERVICE AND MAINTENANCE MANUAL 28 VOLT ELECTRICAL EQUIPMENT CHART CODE DESCRIPTION VENDOR PART NO. C/B, TIT INDICATOR, TIT INDICATOR, T1T/EGT PLUG, TIT CLAMP PLUG, 28 PIN CLAMP PROBE, TIT PROVE, TIT (ALl') PROBE, TIT KLIXON MOONEY MOONEY AMP AMP AMP AMP MOONEY MOONEY MOONEY 7277-2-2 890051-501 880051-503 205838-1 206062-1 205839-3 206070-1 880005-501 680005-503 680055-501 PROBE, EGT - CYL#1 PROBE, EGT - CYL #1 (ALl) PROBE, EGT - CYL #1 (ALl-) PROBE, EGT- CYL #1 PROBE EGT- CYL #1 (ALT) PROBE EGT- CYL #2 PROBE EGT- CYL #2 (ALT) PROBE EGT-CYL #3 PROBE EGT-CYL #3 (ALl') PROBE EGT-CYL #4 PROBE EGT-CYL #4 (ALl') PROBE EGT-CYL #5 PROBE EGT-CYL #5 (ALl') PROBE EGT-CYL #6 PROBE EGT-CYL#6 (ALE) MOONEY MOONEY MOONEY MOONEY MOONEY MOONEY MOONEY MOONEY MOONEY MOONEY MOONEY MOONEY MOONEY MOONEY MOONEY 880005-501 880005-503 660110-000 889005-501 880005-503 880005-501 880005-503 880005-501 680005-503 580005-501 880005-503 880005-501 880005-503 880005-501 880005-503 -K-K-K-K- DR101A DRIO2A DR102B DR103A -K- DR103B -K-K-K- DR104A DRIO4A DRIO4B J-- DT101A -K- DT101A -K- DTIO2A -K- DT103A -K- DT104A -K- DT105A -K- DT106A JKJKJKJKJKJKJKJKJK--L DV101A DV102A DV102B DV102C DV103A DV104A DV104A DV104C DV105A DV150A C/B, FUEL FLOW KLIXON INDICATOR, FUEL FLOW MOONEY INDICATOR, FUEL FLOW(OPT) MOONEY INDICATOR, FUEL FLOW (OPT) MOONEY PLUG, FUEL FLOW CANNON XDUCR, FUEL FLOW MOONEY XDUCR, FUEL FLOW (OPT) MOONEY XDUCR, FUEL FLOW (OPT) MOONEY SWITCH FURE FLOW MEMORY C & K XDUCER, FUEL FLOW PORSCHE --L DV151A PLUG CLAMP BOOT CONTACTS --L --L --L --L DW150A DW151A DW151A DW151A INDICATOR, VERTICAL SPEED UI PLUG, VSI, 3 PIN BENDIX PLUG, V/S (ALT) CANNON PLUG, VSI (ALT) CLAMP 7201-2 CODE C.146 PTO6E-8-SS KPTO6E-8-SS MS3116-8-3S MSS057-3Aor -3B JKL JKL JKL EGIO1A EGIO2A EGI03A C/B GEAR RELAY SWITCH, GEAR UP/DN SWITCH, GEAR OVERIDE LOCKING RING LOCK WASHER HEX NUT (2 EA) LAMP (28 V) 7277-2-5 8906K2875 SBIDDX492-2 29-761 16-886 15-966-6 388 PORSCHE PORSCHE PORSCH E PORSCHE KLIXON C-H C-H C-H C-H C-H GE 12-98 NOTES 7277-2-2 860084-501 880034-507 880034-513 DE-9S 880030-501 880030-503 880030-505 7101K 933-110-377-02 (FUELCONTROL) 933-612-403-00 999-615-032.-40 944-612-128-00 999-652-456-22 91-20-02 41 SERVICE AND MAINTENANCE MANUAL M20J MOONEY AIRCRAFT CORPORATION 28 VOLT ELECTRICAL EQUIPMENT CHART CODE DESCRIPTION JKL JKL JKL EG104A EGIO5A EGIO6A JKL JKL JKL JKL JKL JKL JKL EGIOTA EG1OTA EG106A EG109A EG110A EG110A EG111A JKL EG112A VENDOR PART NO. SWITCH, GEAR SAFETY(NSPEED) MOONEY C/B, GEAR ACTUATOR KLIXON SWITCH, GEAR UP LIMIT MICRO SWITCH ACTUATOR MICRO SWITCH SWITCH, GEAR DN UMIT MICRO SWITCH SWITCH, GEAR DN LIMIT (ALT) SAINT SWlTCH,INC RELAY, GEAR UP C-H RELAY, GEAR DOWN C-H ACTUATOR, LANDING GEAR MOONEY ACTUATOR, LDG. GR (ALT) MOONEY DIODE,GEAR UP RELAY LOCK RETAINER I'IF DIODE, GEAR DOWN RELAY 680013-507 7277-2-15 DT-2R-A7 MCD-2711 ICHI-6 MLl116 6041H220 6041H220 560254-503 880037-507 1N2483 DB51221-1 1N2483 SWITCH, REMOTE ELT SWITCH,REMOTE ELF (ALT) D &M C &K DM-U65-1 7101K ELT TRANSMI'I-I'ER PLUG, ELT CLAMP RECPT, ELT CLAMP D&M AMP AMP AMP AMP DM-ELT-8 206060-1 206062-1 206153-1 206062-1 NOTES JKL JKL ELT101A _ ELT101A JKL L ---L -- ELT102A ELT150A JK- FON101A PHONE-JACK WASHERS SWlTCHCRAFT SWITCHCRAFT C-11 S-1028 & S-1029 --L --L --L --L --L --L --L JE150B JE151B JE152B JE153B JE154B JE154B JE154B C/B IGNITION, LT C./BIGNITION, FIT IGNITION BOX, LT IGNITION BOX, RT PLUG, IGN BOX, LT PLUG, IGN BOX, LT (ALE) PLUG, IGN BOX, LT (ALT) TINEL-LOCK ADAPTER ADAPTER (AL'r) BOOT BOOT (ALT/SUPPLEMENT) PLUG, IGN BOX, RT (ALT) PLUG, IGN BOX, RT (ALT) TINEL-LOCK ADAPTER ADAPTER (ALT) BOOT BOOT (ALT/SUPPLEMENT) PLUG, IGN BOXCOIL LT (ALT) PLUG, IGN BOX COIL, LT (ALT) TINEL-LOCK ADAPTER ADAPTER (ALT) ADAPTER (ALT) COUPLING BOOT PLUG, IGN BOX COIL, RT (ALT) PLUG, IGN BOX COIL, RT (ALT) .TINEL-LOCK ADAPTER ADAPTER (ALT) ADAPTER (ALT) COUPLING BOOT KLIXON KUXON PORSCHE PORSCHE CANNON CANNON-GERMANY PORSCHE RAYCHEM SUNBANK RAYCHEM RAYCHEM CANNON-GERMANY PORSCHE RAYCHEM SUNBANK RAYCHEM RAYCHEM CANNON-GERMANY PORSCHE RAYCHEM SUNBANK SUNBANK SUNBANK RAYCHEM CANNON-GERMANY PORSCHE RAYCHEM SUNBANK SUNBANK SUNBANK RAYCHEM 7277-2-7.5 7277-2-7.5 933.602.007.07 933.602.007.07 CA3106A-20A-48S-B-03 CA3106A-20A-48S-B-15 933.612.440.00 "T'XR18AB45-C2012AI S2900AA1912AI-S034-O00 202C621-51/164 202S142-25S CA3106A-20A_48S-B-15 933.612.440.01 TXR16AB45-C201PAl S2900AA1912AI-SO34-000 202C621-51/164 202S142-25S CA3106E-10SL-3P-B-14 933.612.409.01 TXR18AB00-C1104AI S2900ASO604AI-S034-000 S2909AS1004AI-SO34-000 S3292 202S121-25S CA3106E-1OSL-3P-B-14 933.612.409.01 TXR18ABOO-C1104AI S2900AS0504AI-S034-000 S2900AS1004AI-S034-000 $3292 202S121-25S ELT151A JE155B JE155B --L --L JE156B JE156B --L --L JE157B JE157B 91-20-02 42 12-99 MOONEY AIRCRAFT CORPORATION M20J SERVICE AND MAINTENANCE MANUAL 28 VOLT ELECTRICAL EQUIPMENT CHART CODE --L --L JE162B JE162B --L JE163B JE163B --L --L --L --L --L JE164A JE165A JE168A JE169A JE170C ---L JE171C -- --L JE172B --L JE173B --L JE174C ---L JE175C DESCRIPTION VENDOR PART NO. PLUG, IGN COIL, LT PLUG, IGN COIL, LT TINEL-LOCK ADAPTER ADAPTER (ALT) ADAPTER (ALT) COUPLING BOOT PLUG, IGN COIL, RT PLUG, IGN COIL RT TINEL-LOCK ADAPTER ADAPTER (ALT) ADAPTER (ALl') COUPLING BOOT CANNON-GERMANY PORSCHE RAYCHEM SUNBANK SUNBANK SUNBANK RAYCHEM CANNON-GERMANY PORSCHE RAYCHEM SUNBANK SUNBANK SUNBANK RAYCHEM CA3106E-10SL-4S-B-14 933.612.407.01 TXR18AB00-C1104AI S2900AS0504AI-S034-000 S2900AS1004AI-S034-O00 S3292 202S121-25S CA3106E-10SL-4S-B-14 938.612.407.01 TXR18AB00-C1104AI S2900AS0504AI-S034-O00 S2900AS1004AI-S034-000 $3292 202S121-25S IGNITION COIL, LT IGNITION COIL, RT SENSOR, TDC #1 SENSOR, TDC #2 RECPT, 3 PIN RECPT, 3 PIN (ALT) ADAPTER ADAPTER (ALl") ADAPTER (ALE) COUPLING BOOT PLUG, 3 PIN PLUG, 3 PIN (ALT) ADAPTER ADAPTER (ALT) ADAPTER (ALl') COUPLING BOOT RECEPT, IGN, COIL, LT, 4 PIN ADAPTER ADAPTER (ALT') BOOT PLUG, IGN, COIL, LT,4 PIN ADAPTER ADAPTER (ALT) BOOT RECPT, 3 PIN RECPT, 3 PIN (ALl) ADAPTER ADAPTER (ALE) ADAPTER (ALT) COUPLING BOOT PORSCHE PORSCHE PORSCHE PORSCHE CANNON-GERMANY PORSCHE RACHEM SUNBANK SUNBANK SUNBANK RAYCHEM CANNON-GERMANY PORSCHE RACHEM SUNBANK SUNBANK SUNBANK RAYCHEM CANNON RAYCHEM SUNBANK RAYCHEM CANNON RAYCHEM SUNBANK RAYCHEM CANNON-GERMANY PORSCHE RACHEM SUNBANK SUNBANK SUNBANK RAYCHEM N/A N/A N/A N/A CA121001-633 983-612-411-00 TXR18AB000-C1104AI S2900AS0604AI-S034-O00 S2900AS1004AI-S034-OO0 $3292 202S121-25S CA06EH10Sl-3PB14 983-612-412-00 TXR18AB000-C1104AI S2900AS0804AI-S034-000 S2900AS1004AI-S034-O00 $3292 202S121-25S MS3100K-14S-2P "rXR18AB000-C1404AI $2900AS1004AI-S034-000 202S121-25S MS3106E-14S-2S TXR18AB000-C1404AI S2900AS1004AI-S034-000 202S121-25S CA121001-633 933-612-411-00 TXR18AB000-C1104AI S2900AS0604AI-S034-000 $2900AS1004AI-S034-000 $3292 202S121-25S PLUG, 3 PIN PLUG, 3 PiN (ALT) ADAPTER . ADAPTER (ALE) ADAPTER (ALT) COUPLING BOOT CANNON-GERMANY PORSCHE RACHEM SUNBANK SUNBANK SUNBANK RAYCHEM CA06EH10SL3PB14 933-612-412-00 TXR18AB000-C1104AI S2900AS0604AI-S034-000 S2900AS1004AI-S034-000 $3292 202S121-25S 12-98 NOTES 91-20-02 43 SERVICE AND MAINTENANCE MANUAL M20J MOONEY AIRCRAFT CORPORATION 28 VOLT ELECTRICAL EQUIPMENT CHART CODE DESCRIPTION --L JE176B --L --- JE177B --L JE178A --L JE179A --L JE180A --L JE181A --L JE182A --L -- JE183A JKI_ JM101A J-J--K- VENDOR NOTES RAYCHEM SUNBANK RAYCHEM AMP AMP AMP AMP AMP AMP MS3100K-14S-2P TXR18AB000-C1404AI S2900AS1O04AI-S034-000 202S121-25S MS3106E-14S-2S "FXR18ABO0O-C1404AI S2900AS1004AI-S034-O00 202S121-25S 1-490303-0 60619-1 1-480305-0 60620-1 1-480318-0 60619-1 RECPT, C/B, 2 PIN PINS PLUG, TACH/FUEL FLOW SOCKET RECPT, TACH/FUEL FLOW PINS AMP AMP AMP AMP AMP AMP 1-480319-0 60820-1 1-480318-0 60619-1 1-480319-0 60620-1 JM102A JMIO2B JM103A SWITCH, IGNITION PLACARD MAGNETO MAGNETO (ALl') MAGNETO, RIGHT -K-K- JMIO3B JM104A MAGNETO, RIGHT MAGNETO, LEFT -K- JMIO4B MAGNETO, LEFT BENDIX- SCINTILIJk BENDIX- SCINTILLA BENDIX-SCINTILLA BENDIX-SCINTILLA BENDIX-SCINTILLA TCM SUCK BENDIX-SCiNTILLA TCM SLICK 10-357210-9 10-187-468 10-682555-1 10-682555-111 10-79020-120 640896-1 6224 10-79020-120 640896-1 6224 JKJKJK- LB101A LB101A LB102A JKL JKL JKL LB102B LB102B LB103A JKL LB104A C/B, ROTATING BEACON MOONEY C/B, ROTATING BCN (SPARES) MOONEY LIGHT, ROTATING BCN WHELEN ADAPTER WHELEN LT, ROTATING BCN, RED (ALl') WHELEN LT, ROTATING BCN, WTE (ALT) WHELEN PLUG, 2 PIN AMP SOCKET AMP RECPT, 2 PIN AMP PINS AMP 930023-203 930023-243 WRML-24 WRM-65 90033-19 90033-20 1-480318-0 60619-1 1-480319-0 60820-1 JKL LC101A JKL JKL JKL -JKL -JKL LC102A LC103A LC104A JKL -- LC107A FUSEHOLDER, CLOCK, 5AMP FUSE,(5A-3AG-SLO-BLO) SWITCH, CABIN LIGHT, FWD RESISTOR, CABIN LIGHT, FWD LIGHT, CABIN, FWD, LT LAMP UGHT, CABIN, FWD, RT LAMP LIGHT, CABIN, FWD, LT LAMP 'LIGHT, CABIN, FMVD,RT LAMP 155020/155120 313005 TILC64-1S-WH-FN RH-10-20 OHM 1930 1818 1930 1818 1930 1818 1930 1818 91-20-02 44 LC105A LC106A RECPT, IGN. COIL, RT, 4 PIN ADAPTER ADAPTER (ALT) BOOT PLUG, (ALl-) ADAPTER ADAPTER (ALT) BOOT PLUG, 3 PIN SOCKET RECPT, C/B, 3 PIN PINS PLUG, 2 PIN SOCKET PART NO. RAYCHEM SUNBANK FIAYCHEM UTTEL LI-I-FEL CARLING DALE H.H. SMITH GE H.H. SMITH GE H.H. SMITH GE H.H. SMITH GE 12-98 MOONEY AIRCRAFT CORPORATION M20J SERVICE AND MAINTENANCE MANUAL 28 VOLT ELECTRICAL EQUIPMENT CHART CODE DESCRIPTION JKL JKl. JKL -JKL -JKL -JKL ---L ---L -- LC108A LC109A LC110A J-J-JK- LL101A LL102A LL103A JK- LL104A -K-K-K-K-K--L LL105A LL106A LL107A LL108A LL109A LL150A --L LL151A --L --L --L --L --L --L LL152A LL154A LL155A LL156A LL157A LL158A JKL JKL LN101A LN102A JKL JKL LN103A LN104A JKL LN105A JKL LN106A JKL LN107A JKL JKL JKL LP101A LP102A LP103A LC111A LC112A LC113A LC114A LC115A VENDOR PART NO. SWITCH, CABIN LIGHT, REAR CARLING RESISTOR, CABIN LIGHT SW DALE LIGHT, CABIN, REAR, LT H.H. SMITH LAMP GE LIGHT, CABIN, REAR, RT H.H. SMITH LAMP GE LIGHT, CABIN, REAR, LT H.H. SMITH LAMP GE LIGHT, CABIN, REAR, RT H.H. SMITH LAMP GE LIGHT, CABIN, REAR, LT H.H. SMITH LAMP GE LIGHT, CABIN, REAR, RT H.H. SMITH LAMP GE TILC64-1S-WH-FN RH-10-20 OHM 1930 1818 1930 1818 1930 1818 1930 1818 1930 1818 1930 1818 SWITCH, LDG LT LANDING LIGHT RECPT, LDG LT CLAMP PLUG, LDG LT CLAMP C/B, LDG LT, LEFT LIGHT, LDG, LEFT C/B, LDG LT, RIGHT LIGHT, LDG, RIGHT SWITCH, LDG LT C/B, LANDING LIGHT, LEFT C/B, LDG LT, LEFT (ALl') C/B LANDING UGHT, RIGHT C/B, LDG LT, RIGHT (ALl') SWITCH, LANDING LIGHT LANDING LIGHT-RT WING TAXI LIGHT-RT WING SWITCH, TAXI LIGHT TAXI LIGHT, LEFTWING LANDING UGHT, LEFT WING MOONEY GE AMP AMP AMP AMP KLIXON GE KUXON GE C-H KU×ON MECHANICAL PROD KUXON MECHANICAL PROD C-H GE GE C-H GE GE 930023-235 4553 206153-1 206062-1 206060-1 206062-1 7277-2-10 4596 7277-2-10 4596 8143-K21-E13-M50 7277-2-20 4200-002-25 7277-2-20 4200-002-25 8162-K22-E13-M50 4596 4596 8162-K22-E13-M50 4596 4596 C/B NAV LIGHTS. UGHT, TAIL, LT WING BULB, 28V LIGHT, TAIL RT WING PLUG, TAIL LIGHT, RT WING SOCKETS RECPT, TAILUGHT RTWlNG PINS PLUG, TAIL NAV UGHT SOCKETS RECPT, TAIL NAV LIGHT PINS MOONEY MOONEY WHELEN MOONEY AMP AMP AMP AMP AMP AMP AMP AMP 930023-201 800051-501 34-0228030-85 800051-501 1-480318-0 60619-1 1-480319-0 60620-1 1-480318-0 60619-1 1-480319-1 60620-1 C/B PANEL LIGHTS . C/B GLARESHIELD LIGHTS LAMP, COMPASS LIGHT KLIXON KLIXON GE 7277-2-5 7277-2-5 AVIATION RED 327 or327 12-98 NOTES 91-20-02 45 SERVICE AND MAINTENANCE MANUAL M20J MOONEY AIRCRAFT CORPORATION 28 VOLT ELECTRICAL EQUIPMENT CHART CODE DESCRIPTION JKJKL JKL JK- LP104A LP105A LP106A LP107A JK- LP108A JKJK- LP109A LP109B JKJKJKJKJKJK- LP110A LP111A LP112A LPl13A LP114A LP115A JKJKJKJKJKJKJK-KJK---!---L LP116A LP118A LP119A LP120A LP121A LP122A LP123A LP125A LP126A LP150A LP151A --L LP162A --L --L LP153A LP154A LP155A L --L L LP156A LP157A LP158A --L LP159A --L LP160A JKL JKL JKL LR101A LR102A LR103A 91-20-02 46 VENDOR PART NO. RECPT, COMPASS LT DEANS PLUG, COMPASS LIGHT DEANS LIGHTS, GLARESHIELD (14 EACH) GE LIGHT HOLDER, TRIM/FLAP DIAUGHT LAMP GE LAMP (ALT) GE UGHT, COWL FLAP DIAUGHT LAMP GE LIGHT, OXYGEN SLOAN LIGHT, OXYGEN SLOAN LAMP GE LIGHT, CLUSTER GE LIGHT, CLUSTER GE LIGHT, CLUSTER GE LIGHT, CLUSTER GE LIGHT, CLUSTER GE UGHT TRAY, AMMETER B&D DEAg0020MALE DEAg002OFEMALE 827 270-1930-0171-702 327 385 270-1930-0171-702 327 855S-0-U 865S-0-U 327 327 327 327 327 327 0221-128 UGHTTRAY TACHOMETER B&D UGHT TRAY AIRSPEED U.I. LIGHT TRAY TURN CO-ORD U.I. LIGHT TRAY ALTIMETER U.I. LIGHT TRAY VERTICAL SPEED U.l. UGHT TRAY ARTIFICIAL HORIZON SIGMA-TEC UGHTTRAY DIRECTIONAL GYRO SIGMA-TEC LIGHTTRAY TIT B &D LIGHT TRAY EGT/OAT B &D DIMMER CONTROL BOX IAI PLUG, DIMMER CONTROL BOX ITT CLAMP Ill" LOCK RETAINER I-[-r RECPT (2 EA) ITT SWITCH, PANEL LIGHTS, DIMR C & K 0221-128 BA28-BW3 BA28-BW3 E]A28-BW3 BA28-BW3 IV-192-971 IV-192-971 0221-128 0221-126 950D0307-000 DBM17W2S DB51212 D651221-1 DM53744-7 7105-JI-Z-Q SWITCH, G/SHIELD LIGHTS, DIM C & K LIGHT, FLAP SWITCH MOONEY LAMP GE UGHT, CONSOLE SWITCH, RT MOONEY LAMP GE RECPT, 9 PIN AMP CLAMP AMP PLUG, 9 PIN AMP CLAMP AMP UGHT, CONSOLE SWITCH, LT MOONEY LAMP GE PLUG, 16 PIN AMP CLAMP AMP RECEPT, DIMMER CONTROL BOX AMP CLAMP AMP 7105-J1-Z-Q 130285-003 327 130265-003 827 206706-2 206966-1 206708-1 206966-1 130285-003 327 206037-1 206070-1 206036-3 206070-1 C/B RECOGNITION LIGHTS RECOGNITION LIGHT, LTWG PLUG, RECOG. LIGHT, LT WG SOCKETS 930023-231 660049-501 1-480318-0 60619-1 MOONEY MOONEY AMP AMP 12-98 NOTES MOONEY AIRCRAFT CORPORATION M20J SERVICE AND MAINTENANCE MANUAL 28 VOLT ELECTRICAL EQUIPMENT CHART CODE DESCRIPTION JKL JKL LR104A LR105A JKL. LR106A JKL. LR107A JKL JKL -JKL LR108A LR109A VENDOR PART NO. JKL LR111A RECOGNITION LIGHT, RT MOONEY PLUG, RECOG. LIGHT, RT AMP SOCKETS AMP RECPT, RECOG.LIGHT, LEFT AMP PINS AMP PLUG, RECOG. LIGHT, LEFT AMP SOCKETS AMP RESISTOR, RECOG. LIGHT, LEFT DALE RECPT, RECOG. LIGHT, RT AMP PINS AMP PLUG, RECOG. LIGHT, RT AMP SOCKETS AMP RESISTOR, RECOG. LIGHT, RT DALE JKL JKL JKL JKL JKL LS101A LS101A LS102A LSIO3A LSIO4A C/B STROBE LIGHTS MOONEY O./13STROBE LIGHTS (ALT) MOONEY POWER SUPPLY, STROBE, LT WG WHELEN RECPT, STROBE P/S, LTWG AMP RECPT, STROBE P/S,LT WG AMP 930023-207 930023-287 01-0770329-00 1-480305-0 1-480305-0 JKL JKL JKL JKL JKL JKL JKL JKL LS105A LS106A LS107A LS108A LS109A LS110A LS111A LSl12A PLUG, NAV/STROBE, LTWG AMP LIGHT, NAV/STROBE, LTWG WHELEN STROBE PWR SUPPLY, RT WG WHELEN RECPT, STROBE PWR SUPPLY, RT AMP RECPT,STROBE LIGHT P/S, RT AMP PLUG,STROBE UGHT, FIT AMP NAY/STROBE LIGHT RT. WING WHELEN POWER SUPPLY, TAIL STROBEWHELEN 1-480303-0 A650-PR-D-M 01-07'/0329-00 1-480305-0 1-480305-0 1-480303-0 A650-PG-D-M 01-0770329-00 JKL JKL JKL -JKL LSl13A LS114A LSllSA JKL JKL JKJKJK- LS117A LS118A LSllgA LS120A LS121A RECPT, TAIL STROBE PWR SUPPLY AMP RECPT, TAIL STROBE PWR SUPPLY AMP PLUG, TAIL STROBE AMP CLAMP : AMP RECPT, TAIL STROBE AMP CLAMP AMP PLUG, TAIL STROBE AMP STROBE LIGHT, TAIL MOONEY RECPT AMP RECPT AMP RECPT AMP 1-480305-0 1-480305-0 206060-1 206062-1 206153-1 206062-1 1-480303-0 470013-501 1-480305-0 1-480305-0 1-480305-0 JKL JKL MA101A MA102A JKL JK- MA103A MA104A ALJX.PWR. RECEPTACLE RELAY, AUX. PWR (ALT) DIODE, AUX PWR RELAY DIODE AN2562-3A 6041H202 6041H202A IOH3P 1N2483 JKL MB101A J-JKJ-JKL JK- MB101B MB102A MB102A MBI03A MB104A LR110A - -- LS118A AVIONICS CONTROL RELAY BASE DIODE DIODE DIODE DIODE ' RELAY, AVIONICS MASTER SOCKET SPRING STANDOFF C-H C-H SARKES TARZ.IAN MAGNACRAFT MAGNACRAFT P-B P-B P-B P-B 12-98 880049-501 1-480318-0 60619-1 1-480319-0 60620-1 1-480318-0 60619-1 RH-50-7.5OHMS 1-480319-0 60620-1 1-480318-0 60619-1 RH-50-7.5 OHMS NOTES W67CSX-3 70-303 1N2463 1N2483 1N2483 IN2483 MB4443 27E122 20C176 21B212 91-20-02 47 SERVICE AND MAINTENANCE MANUAL M20J MOONEY AIRCRAFT CORPORATION 28 VOLT ELECTRICAL EQUIPMENT CHART CODE DESCRIPTION VENDOR PART NO. JKJKL J-JKL JKL JKL JKL JKL JKL JKL JKL JKL JKL JKL JKL JKL JKL JKL JKL MB104A MB107A MB107B MBI09A MB110A MB111A MB112A MB113A MB114A MB115A MB116A MB117A MB118A MB119A MB120A MB121A MB122A MB123A MB124A RELAY, AVIONICS MASTER (ALT) P-B SWITCH, AVIONICS MASTER C & K SWITCH, MASTER, AVIONICS MOONEY C/B HSI KLIXON C_ COM1 KUXON C/B NAV1 KUXON C/B AUDIO KUXON C/B PHONE KUXON C/B ADF KUXON C/S COM2 KUXON C/B NAV2 KLIXON C/B TRANSPONDER KLIXON C/B ENCODER KLIXON C/B AUTOPILOT/I"RIM KLIXON C/B RADAR KLIXON C/B DME KLIXON C/B LORAN KUXON C/B STORMSCOPE KLIXON C/B TELEPHONE KLIXON MB4443-1 7101K 930023-213 7277-2-XX(VARIES) 7277-2-XX(VARIES) 7277-2-XX(VARIES) 7277-2-XX(VARIES) 7277-2-XX(VARIES) 7277-2-XX(VARIES) 7277-2-XX(VARIES) 7277-2-XX(VARIES) 7277-2-XX(VARIES) 7277-2-XX(VARIES) 7277-2-_(VARIES) 7277-2-XX(VARIES) 7277-2-XX(VARIES) 7277-2-XX(VARIES) 7277-2-XX(VARIES) 7277-2-XX(VARIES) JKL JKL JKL JKL JKL JKL JKL JKL JKL JKL JKL JKL -_--L --L --L --L --L 1_ --L L MB125A MB126A MB127A MB128A MB129A MB131A MB132A MB133A MB134A MB135A MB136A MB137A MB150A MB151A MB152A MB158A MB154A MB155A MB156A MB157A MB158A C/B RMI C/B P,/NAV C/B INVERTER C/B STEREO C/B PROP DE-ICE BUS BAR #10 BUS BAR #11 BUS BAR #12 BUS BAR #13 C/B, YAW DAMPER C/B, RADAR ALTIMETER C/B, ARTIFICIAL HORIZON AVIONICS BUS BAR #1 AVIONICS BUS BAR #2 AVIONICS BUS BAR #3 AVIONICS BUS BAR #4 AVIONICS BUS BAR #5 AVIONICS BUS BAR #6 AVIONICS BUS BAR #7 SHUNT AVIONICS MASTER RELAY RECEPTACLE DIODE 72T7-2-XX(VARIES) 7277-2-XX(VARIES) 7277-2-XX(VARIES) 7277-2-XX(VARIES) 930023-223 913127-019 913127-019 913127-019 913127-005 7277-2-7.5 7277-2-7.5 7277-2-5 913127-73 913127-73 913127-73 913127-73 913127-73 913127-73 913127-73 913127-049 HG4-DC24V HG4-SF 1N2483 MB159A --L MB160A --L --L L L --L JKL --L 91-20-02 48 KLIXON KLIXON KLIXON KLIXON MOONEY MOONEY MOONEY MOONEY MOONEY KLIXON KLIXON KLIXON MOONEY MOONEY MOONEY MOONEY MOONEY MOONEY MOONEY MOONEY AROMAT AROMAT MB162A MB163A MB164A MB165A MB166A FUSE HOLDER U-i-FEL FUSE 1A LI'I-IEL DIODE, STARTER SOLENOID, LT DIODE, STARTER SOLENOID ARTIFICIAL HORIZ CASTLEBERRY PLUG, ART.HORIZ AMPHENOL C/B, AUTOPILOT ALERT KLIXON 155020 or 155120 313001 1N2483 1N2483 300-2BL 126-222 7277-2-XX(VARIES) MC101A MC150A CIGAR LIGHTER C/B, CIGAR LIGHTER 800336-503 7277-2-10 MOONEY KLIXON 12-98 NOTES MOONEY AIRCRAFT CORPORATION M20J SERVICE AND MAINTENANCE MANUAL 28 VOLT ELECTRICAL EQUIPMENT CHART CODE DESCRIPTION VENDOR PART NO. MID-CONT. MD-88L BA,?.B-24-BW2 MD-88L (ET) BA28-24-BW2 950D0312.000 944.641.213.00 206705-2 206966-1 206708-1 206966-1 NOTES ..................................................................................... ( JK- ME101A JK- ME101B --L --L --L ME150A ME150B ME151A --L ME152A JK---L MIC101A JK- MJ101A JK- MJ102A JK- CLOCK, ELECTRIC LIGHT TRAY CLOCK, (OPT) LIGHT TRAY CLOCK, (ALT) CLOCK, CONTROL WHEEL RECPT, CONTROL WHEEL CLAMP PLUG, CONTROL WHEEL CLAMP MID-CONT. IAI PORSCHE AMP AMP AMP AMP JACK, MICROPHONE SWlTCHCRAFT WASHERS SWlTCHCRAFT JACK, MICROPHONE,CONSOLE SWlTCHCRAFT WASHERS SWITCHCRAFT C-12B S-1028 or S-1029 C-12B S-1028 or S-1029 JUNCTION BLOCK (GND) JUMPER EDGE ON JUNCTION BLOCK (GND) JUMPER EDGE ON BEAU BEAU BEAU BEAU 77014-52 7233-16 71106-52 7233-8 MJ103A JUNCTION BLOCK (DIM) JUMPER EDGE ON BEAU BEAU 71106-52 7233-8 JKJKJK-JK- MP101A MP102A MP103A JKJK--L --L --L --L MP105A MP106A MP150A MP151A MP152A MP153 --L --L MP154A MP155A TIMER B.F. GOODRICH SHUNT B.F. GOODRICH FUSE HOLDER UTTEL FUSE, 1A U'I-I'EL FUSE HOLDER UTTEL FUSE, 1A LITTEL AMMETER B.F. GOODRICH SLIP-RING BLOCK B.F. GOODRICH C/B-SWITCH, PROP DE-ICE (15A) ETA TIMER B.F. GOODRICH SLIP RING, MODULAR BRUSH ASSY FUSEHOLDER U'I-FEL FUSE, 1A U'I-rEL RELAY BOX, CURRENT MOONEY PLUG, 4 PiN AMP CLAMP AMP 3E1899-1 MS91586-1 155020 or 155120 313001 155020 or 155120 313001 3E1872-1 3E2062-1 930023-223 3E2311-4 B.F. GOODRICH 155020 or 155120 313001 600221-505 206060-1 206062-1 MSxxx SPEAKER ARCHER 40-1197 --L --L NE15OA NE151A KLIXON MICRO SWITCH MICRO SWITCH 7277-2-1 1SE1-T JE-5 --L NE153A PORSCHE --L --L --L NE154A NE155A NE156A C/B FUEL ENRICH SWITCH, ENRICHMENT ACTUATOR VALVE, SOLENOID, MIXTURE ENRICHMENT DIODE, ENRICH SW. DIODE, ENRICH SW. DIODE, ENRICH SW. 933.606.012.00 1N2483 1N2483 1N2483 JKJ-JK- NF101A NF102A NF103A JK- NF104A C/B, FUEL PUMP ' PUMP, FUEL PLUG, FUEL PUMP CLAMP RECPT, FUEL PUMP CLAMP MOONEY WELDON AMP AMP AMP AMP 930023-211 8163B 206060-1 206062-1 206153-1 206062-1 MIC102A MP104A 12-98 3E2062-1 91-20-02 49 SERVICE AND MAINTENANCE MANUAL M20J MOONEY AIRCRAFT CORPORATION 28 VOLT ELECTRICAL EQUIPMENT CHART CODE DESCRIPTION -K-K-K-K-K- NF105A NF106A NF107A NF108A NF109A -K- NFl10A --L --L --L ---L NF150A NF151A NF152A NF153A --L NF154A ---L NF155A --L NF156A --L --L NF157A NF158A --L NF159A --L --L NF160A NF161A -K- NP101A -K-K- NP102A NP103A --L --L -- NS150A NS151A --L NS153A JKJK!_ JKJKJK- PA101A PA102A PA103A PAl 04A PAl 05A JK- PA106A -K-JKL JKL JK- PA107A 91-20-02 5O PA108A PA109A PAl 10A VENDOR PART NO. MOONEY WELDON MOONEY ELECTRO-DELTA AMP AMP AMP AMP KLIXON KLIXON C-H MOONEY C-H MOONEY AMP AMP AMP AMP KL[XON 930023-219 10054B 930023-217 VR536 208153-1 206062-1 206060-1 206062-1 7277-2-10 7277-2-10 8162-K22-E13-MS0 930028-501 8142-K21-E7-T50 930028-501 206060-1 206062-1 206153-1 206082-1 7277-2-10 FUEL PUMP, BOOST PLUG CLAMP RECPT, FUEL PUMP CLAMP FUEL PUMP, MAIN FUEL PUMP, EMERGENCY PORSCHE AMP AMP AMP AMP PORSCHE PORSCHE 933.620.001.00 206060-1 206062-1 206153-1 206062-1 933.620.001.00 933.620.001.00 FUSEHOLDER, PRIMER FUSE, 10A,SLO-BLO SWITCH, PRIMER DIFFUSER, PRIMER LI-I-FEL U'I-I'EL CARLING CONTINENTAL 155020 or 155120 313010 T1GK6B-1F-WH-A 633862-2 SWITCH, COLD START/ENRICH NOZZLE, COLD START PLUG CLAMP BOOT CONTACTS DIODE, COLD START SW MOONEY PORSCHE PORSCHE PORSCHE PORSCH E PORSCHE 880052-511 933.612.401.00 933.615.032.40 999.615.032.40 944.612.128.00 999.652.456.22 1N2483 ETA KLIXON C-H ELECTRODELTA AMP AMP AMP AMP CONTINENTAL CONTINENTAL MOONEY MALLORY ETA 41-3-$34-LN2-041800 7277-2-5 8133K-21-E13-T52 VR-802 206705-2 206966-1 206708-2 206966-1 649280 or 646719 649123 880014-501 CGS302U-050R2C 41-3-$34-LN2-041800 C/B, HIGH BOOST, FUEL PUMP, FUEL C/B, LOW BOOST, FUEL REGULATOR, FUEL PUMP RECPT. CLAMP PLUG CLAMP C/S FUEL PUMP, MAIN C/B FUEL PUMP, EMERGENCY SW., FUELPUMP,MAIN/BOOST GUARD SWITCH,FUEL PUMP, EMER. GUARD RECPT, FUEL PUMP CLAMP RECPT, FUEL PUMP CLAMP C/B, BOOST PUMP C/B, ALTERNATOR #1 C/B, ALTERNATOR FIELD, #1 SWITCH, ALTERNATOR FIELD VOLTAGE REGULATOR, #1 RECPT, VOLTAGE REG. CLAMP PLUG, VOLTAGE REG. CLAMP ALTERNATOR #1 GEAR ASSY FILTER . CAPACITOR C/B, ALTERNATOR #2 12-98 NOTES MOONEY AIRCRAFT CORPORATION M20J SERVICE AND MAINTENANCE MANUAL 28 VOLT ELECTRICAL EQUIPMENT CHART CODE { DESCRIPTION VENDOR JKL JKJK- PAl 11A PA112A PAl 13A JK- PAl 14A -KJKL JKL J PAl 15A PAl 16A PAl 17A PAllSA JK- PA119A PA120A JK- PA121A JK- PA122A JKJKJKJKL L --L PA123A PA124A PA125A PA126A PA150A PA151A PA152A DIODE SWITCH, ALTERNATOR FIELD DIODE DIODE ALTERNATOR, LT ALTERNATOR, FIT OVERVOLTAGE CONTROL, LT --L PAl 53A PLUG, OVERVOLTAGE CONTROL, LT AMP CLAMP AMP OVERVOLTAGE CONTROL, RT ELECTRO DELTA PLUG, OVERVOLTAGE CONTROL, RT AMP CLAMP AMP SWITCH, OVERVOLTAGE RESET, LT C-H LOCKING RING C-H LOCKING WASHER C-H NUT, HEX (2 ea) C-H LAMP GE SWITCH, OVERVOLTAGE RESET, RT C-H LOCKING RING C-H LOCKING WASHER C-H NUT, HEX (2 ea) C-H LAMP GE C/B ALTERNATOR, LT ETA C/B ALTERNATOR, LT (ALT) ETA C/B ALTERNATOR, RT ETA C/B ALTERNATOR, RT (ALT) ETA . RECPT, O/VOLTAGE CONTROL, LT AMP CLAMP AMP L --L --L --L PA154A PA155A PA156A PA157A --L PA155A --L PA159A L PA160A C/B ALTERNATOR FIELD, #2 KUXON VOLTAGE REGULATOR, #2 ELECTRODELTA RECPT, VOLTAGE REG. AMP CLAMP AMP PLUG, VOLTAGE REG. AMP CLAMP AMP ALTERNATOR #2 CONTINENTAL FILTER MOONEY CAPACITOR _IALLORY ALTERNATOR #1 (RIGHT) LYCOMING ALTERNATOR (ALT) PRESTOUTE ( #2 ALTERNATOR NOT USED AT THIS TIME) FUSEHOLDER LI'I-I'EL FUSE 5A LI3-FEL SWITCH, EMERGENCY, FIELD C-H LOCKING RING C-H LOCKWASHER C-H NUT, HEX C-H LAMP GE DIODE SARKES-TARZIAN SARKES-TARZIAN C-H SARKES-TARZIAN SARKES-TARZlAN PORSCHE PORSCHE ELECTRO DELTA 12-98 PART NO. NOTES 7277-2-5 VR-802 205705-2 206966-1 205709-2 206966-1 649283 or 649172 660014-501 CGS302U-056R20 LW-14367 ALU-6421-LS 155020 or 155120 313005 SBIDDX492-2 29-761 16-686 15-996-6 388 10H3P 10H3P 880052-503 10H3P 10H3P 933.603.604.00 933.603.004.00 OS-400 206708-1 206966-1 OS-400 206708-1 206966-1 SSl DDX492-2 29-761 16-886 15-966-6 388 SB1DDX492-2 29-761 16-886 15-966-6 368 41-3-S14-LN2-70A 41-3-S34-LN2-70A 41-3-S14-LN2-70A 41-3-S34-LN2-70A 206705-2 206966-'1 91-20-02 51 SERVICE AND MAINTENANCE MANUAL M20J MOONEY AIRCRAFT CORPORATION 28 VOLT ELECTRICAL EQUIPMENT CHART CODE DESCRIPTION VENDOR PART NO. --L PA161A RECPT,OVERVOLTAGE CONT'L, RT AMP CLAMP AMP 206705-1 206996-1 JKJKL PB101A PB102A JKL JKJKL PB103A PB104A PB105A JKL PB106A JKJKJKJKJKJK- PB107A PB108A PB109A PB110A PB111A PB112A BA'I-I'ERY GILL RELAY,MASTER,BA-I-I'ERY,LEFT C-H (ALl') C-H DIODE,LEFT BA'I-rERY RELAY SWITCH, MASTER C-H CiB BA-FI'ERY, LT (ALE) ETA C,tB BATTERY, LT ETA C/B BUS, FLI PNL SWITCH (ALl') ETA C/B BUS, FLT PNL SW ETA BUSS BAR #1 MOONEY BUSS BAR #2 MOONEY BUSS BAR #3 MOONEY BUSS BAR #4 MOONEY BUSS BAR #5 MOONEY BUSS BAR #6 MOONEY G-242 6041H202 6041H202A 1N2483 880052-501 41-3-S14-LN2-70A 41-3-S34-LN2-70A 41-3-S14-LN2-70A 41-3-S34-LN2-70A 913127-005 913127-039 913127-001 913127-019 913127-019 913127-239 * NOTES •BUSS BARS 913127-045,-213,-223 or -227 MAY BE USED, AS REQUIRED, BY CIRCUIT BREAKER INSTALLATION. -KPBl13A BUSS BAR #7 MOONEY 913127-129 JKPB114A BUSS BAR #8 MOONEY 913127-041 JKPB115A BUSS BAR #9 MOONEY 913127-043 JKPB116A SHUNT KULKA 600RJ-2 --L PB150A BATTERY, RIGHT GILL G-243 --L PB151A RELAY, BA'I-rERY, RT C-H 6041H202 (ALT) C-H 6041H202A --L PB152A DIODE, BA3-I-ERY RELAY, RT 1N2483 --L PB153A SWITCH, BATTERY, LT MOONEY 880052-507 --L PB154A SWITCH, BATTERY, RT MOONEY 880052-509 --L PB155A C/B BATTERY, RT .ETA 41-3-S14-LN2-70A --L PB155A C/B BA'I-I'ERY, RT (ALT) ETA 41-3-S34-LN2-70A --L PB156A BUSS BAR #1 MOONEY 913127-51 --L PB157A BUSS BAR #2 MOONEY 913127-51 --L PB158A BUSS BAR #3 MOONEY 913127-51 --L PB159A BUSS BAR #4 MOONEY 913127-51 --L PB160A BUSS BAR #5 MOONEY 913127-19 --L PB161A BUSS BAR #6 MOONEY 913127-19 --L PB162A BUSS BAR #7 MOONEY 913127-19 --L PB163A BUSS BAR #8 MOONEY 913127-19 --L PB164A BUSS BAR #9 MOONEY 913127-53 --L PB165A BUSS BAR #10 MOONEY 913127-53 --L PB166A BUSS BAR #11 MOONEY 913127-53 --L PB167A BUSS BAR #12 MOONEY 913127-TBA --L PB168A C/B EMERGENCY CROSSOVERETA 41-3-S14-LN2-50A --L PB168A C/B EMERGENCY CROSSOVER (ALT) ETA 41-3-S34-LN2-50A C/B COVER PLACARD MOONEY 150080-802 GUARD MOONEY 800232-503 --L PB169A SHUNT, AVIONICS RELAY MOONEY 913127-047 --L PB170A BA'I-I'ERY, LEFT GILL G-243 --L PB171A C/B LOAD, A/C, LT ETA 41-3-S14-LN2-60A --L PB171A 'C/B LOAD, A/C, LT(ALT) ETA 41-3-S34-LN2-6OA 91-20-02 52 12-98 MOONEY AIRCRAFT CORPORATION M20J SERVICE AND MAINTENANCE MANUAL 28 VOLT ELECTRICAL EQUIPMENT CHART CODE --L --L --L ---L --L --L --L --L ---4L i DESCRIPTION VENDOR PART NO. ETA ETA MOONEY MOONEY MOONEY MOONEY MOONEY MOONEY MOONEY Lll-FEL UTTEL C-H C-H 41-3-S14-LN2-60A 41-3-S34-LN2-60A 913127-55 913127-57 913127-57 913127-59 913127-59 913127-61 913127-19 155020 or 155120 313005 6041H202 6041H202A 1N2483 880052-501 W389CX-3 1N2483 155020 or155120 313005 155020 or155120 313005 6041H202 6041H202A 1N2483 --L PB172A PB172A PB173A PB174A PB175A PB176A PB177A PB178A PB179A PB180A PS18OA PB181A --L L L --L L ----L ---L PB182A PB183A PB184A PB185A PB186A PB186A PB187A PB187A PB188A --L PB189A C/B LOAD, A/C. RT C/B LOAD, A/C RT (ALE) BUSS BAR #13 BUSS BAR #14 BUSS BAR#15 BUSS BAR#16 BUSS BAR#17 BUSS BAR#18 BUSS BAR#19 FUSEHOLDER, LEFT MASTER FUSE 5AMP MASTER RELAY (ALl') DIODE MASTER SWITCH RELAY, Nil PWR DIODE FUSEHOLDER, NH, RT FUSE, 5AMP FUSEHOLDER, MASTER, RT FUSE, 5AMP MASTER RELAY, ENGINE BUS, (ALE) DIODE --L PB190A MASTER SWITCH (OPT) C-H 8133K-21-E13-T52 --L PB191A GRND/DIMMER BOX MOONEY 800228-501 JKL PL01A JKL PL02A JKL PL02B JKL JKL JKL JKL JKL PL03A PL04A PL03B PL04A PL05A PLUG, C/B PANEL #1,37 PIN AMP CLAMP AMP PLUG, CONSOLE #1, 16 PIN AMP CLAMP AMP PLUG, CONSOLE #1,28 PIN AMP CLAMP AMP PLUG, LEFT SIDE PANEL, 20 PIN MOONEY PLUG, FLT PNL #1, 26 PIN MOONEY PLUG, LEFT SIDE PANEL, 26 PIN MOONEY PLUG, FLT PNL #1,26 PIN MOONEY PLUG, NS SWITCH #1, 4 PIN AMP CLAMP AMP 206150-1 206138-1 205837-1 206070-1 205839-3 206070-1 930021-501 930021-505 930021-505 930021-505 206060-1 206062-1 JKL PL06A JKL JKL PL07A PLOBA JKL JKL JKL JKL JKL PL09A PL09B PL10A PL11A PL12B JK- PL13A PLUG, AUTOPILOT POWER, 16 PIN AMP CLAMP AMP PLUG, 16 PIN, CLUSTER GAUGE AMP PLUG, FIREWAL.L#1, 19 PIN CLAMP PLUG, RT.WG. 14 PIN MOONEY PLUG, RT. WING, 20 PIN MOONEY PLUG, RT. WING STUB, 14 PIN MOONEY PLUG, LEFT WING, 14 PIN MOONEY PLUG, FIREWALL #2, 19 PIN CLAMP PLUG, RT. RADIO PNL, 9 PIN AMP CLAMP AMP 206037-1 202070-1 206037-1 MS3105A-22-14S MS3057-12B 930021-001 930021-501 930021-001 930021-001 MS3106A-22-14S MS3057-12B 206708-1 206966-1 MOONEY MAGNACRAFT UI-I-EL LII-FEL LITTEL UI-I-EL RT C-H C-H 12-98 NOTES 91-20-02 53 SERVICE AND MAINTENANCE MANUAL M20J MOONEY AIRCRAFT CORRORATION 28 VOLT ELECTRICAL EQUIPMENT CHART CODE DESCRIPTION JKL PL13B JKL PL14A JKL JKL PL15A PL16A JKL JK- PL17A PL18A JKL PL19A JKL PL20A JKL PL21A JKL PL22A JKL PL23A JKL PI-24A JK- PL25A JK- PL26A JK- PL27A JKL JKJKJK- PL27B PL28A PL29A PL30A JK- PL.31A JK- PL32A JKL PI.-33A JKL PL34A JKL PL.34B JK- PL35A JK- PL36A JK- PL37A JK- PL38A 91-20-02 54 VENDOR PART NO. PLUG, AVIONICS MASTER, 4 PIN AMP CLAMP AMP PLUG, HOUR, 4 PIN AMP CLAMP AMP 206060-1 208062-1 205060-1 206062-1 PLUG, LEFTWING STUB, 14 PIN MOONEY PLUG, GEAR CONTROL, 9 PIN AMP CLAMP AMP PLUG, ELECTRIC GEAR, 14 PIN MOONEY PLUG, DIMMER, 16 PIN AMP CLAMP AMP PLUG, A/S SWITCH #2, 4 PIN AMP CLAMP AMP PLUG, TAILCONE, 16 PIN AMP CLAMP AMP PLUG, HEADLINER, 9 PIN AMP CLAMP AMP PLUG, OVERHEAD, REAR, 4 PIN AMP CLAMP AMP PLUG, GRND #1, 16 PIN AMP CLAMP AMP PLUG, GRND #2, 16 PIN AMP CLAMP AMP PLUG, LIGHT CONTROL, 9 PIN AMP CLAMP AMP PLUG, G/SHIELD HARNESS, 4 PIN AMP 930021-001 206708-1 206966-1 930021-001 206037-1 206070-1 206060-1 206062-1 206037-1 206070-1 206708-1 206966-1 206060-1 206062-1 206037-1 206070-1 206037-1 206070-1 206708-1 206966-1 206060-1 CLAMP 206062-1 AMP PLUG, FLT PNL #2, 16 PIN AMP CLAMP AMP PLUG, FLT PNL #2, 20 PIN MOONEY PLUG, AVIONICS POWER, 20 PIN MOONEY PLUG, DIM, GND, 20 PIN MOONEY PLUG, DIM, GND 4 PIN AMP CLAMP AMP PLUG, STANDBY VAC, 6 PIN CLAMP PLUG, GEAR RELAY, 4 PIN CLAMP PLUG, C/B PNL, 9 PIN CLAMP PLUG, GRND BUSS, 9 PIN CLAMP PLUG, GRND BUSS, 16 PIN CLAMP PLUG, FLT PNL #3, 4 PIN CLAMP PLUG, CONSOLE # 2, 8 PIN CLAMP PLUG, LT SIDE PNL, 8 PIN , CLAMP PLUG, FLAP RELAY, 8 PIN "CLAMP AMP AMP AMP AMP AMP AMP AMP AMP AMP AMP AMP AMP AMP AMP AMP AMP AMP AMP 12-98 206037-1 206070-1 930021-501 930021-501 930021-501 206060-1 206062-1 205838-1 206062-1 206060-1 206062-1 206708-1 206966-1 206708-1 206966-1 206037-1 206070-1 206060-1 206062-1 205838-1 206062-1 206838-1 206062-1 205708-1 206062-1 NOTES MOONEY AIRCRAFT CORPORATION M20J SERVICE AND MAINTENANCE MANUAL 28 VOLT ELECTRICAL EQUIPMENT CHART CODE DESCRIPTION JK- PL39A -K- PL40A JK!._ PL50A JKL JKL PL51A PL52A JKL PL55A JKL PL56A JKL JKL PL57A PL58A JKI. JK- PL59A PL76A JK- PL77A --L PL152A VENDOR PART NO. PLUG, FLAP MOTOR, 9 PIN AMP CLAMP AMP PLUG, THROTTLE SWITCH, 4 PIN AMP CLAMP AMP PLUG, C/B PNL #2, 37 PIN AMP FLANGE AMP RECPT, IGNITION SWITCH,26 PIN MOONEY PLUG, ALT/STARTER, F/W CANNON CLAM P PLUG, EMPENNAGE, 9 PIN AMP CLAMP AMP PLUG, GRND #4, 9 PIN AMP CLAMP AMP PLUG,GRND #5, 14 PIN MOONEY PLUG, DIM. #2, 16 PIN AMP CLAMP AMP PLUG, GRND #6, 26 PIN MOONEY PLUG, 9 PIN AMP CLAMP AMP PLUG, 28 PIN AMP CLAMP AMP PLUG, GR/STALL WARN HARNESS, 4 PIN AMP CLAMP AMP 206708-1 206968-1 206060-1 206062-1 208150-1 207299-4 930021-505 MS3106A2.B-22S MS3057-16 206708-1 206966-1 206708-1 206966-1 930021-001 206037-1 206070-1 930021-505 206708-1 206986-1 205839-3 206070-1 7277-2-10 6041H-202 or-202A 155020 or 155120 313001 KLIXON C-H UTTEL LITTEL 206060-1 206062-1 JKJKL JK- PSIO1A PS102A PS103A C/B, IGN/TACH/CIG LIGHTER SOLENOID, STARTER,LT FUSEHOLDER FUSE, 1A J--- PS105A -K- PS106A JKL --L --L --L --L --L PSIOTA PS150A PS151A PS152A PS153A PS154A STARTER PRESTOUTE (ALl') LYCOMING STARTER TCM (ALT) TCM DIODE, STARTER SOLENOID,LT DIODE, PWR START,LT DIODE, PWR START,RT SOLENOID, STARTER, RT C-H DIODE, STARTER SOLENOID STARTER PORSCHE MHB.-4016 LW15572 646275 637847 1N2483 1N2483 1N2483 6041H-202 or -202A 1N2483 933.602.007.03 JKL JKL JKL JKL RB101A RB102A RB103A RB103A C/B RADIO BLOWER RADIO BLOWER FILTER, RADIO BLOWER FILTER, RAD. BLWR, (ALT) 7277-2-2 19A2790 273-103 5JX5104A JKL JKL RCO1A RCO2A JKL RCO2B JKL JKL JKL JKL RC03A RCO3B RC04A RCO5A RECPT, RECPT, CLAMP RECPT, CLAMP .RECPT, RECPT, RECPT, RECPT, CLAMP KLIXON TRW ARCHER SPRAGUE C/B PNL #1, 37 PIN CONSOLE #1, 16 PIN AMP AMP AMP CONSOLE#I, 28 PIN AMP AMP LEFT SIDE PANEL, 20 PIN MOONEY LEFT SIDE PANEL, 26 PIN MOONEY FLT PNL #1, 26 PIN MOONEY NS SWITCH #1, 4 PIN AMP AMP 12-98 NOTES 206151-2 206036-3 206070-1 206152-1 206070-1 930021-502 930021-506 930021-506 205153-1 208082-1 91-20-02 55 SERVICE AND MAINTENANCE MANUAL M20J MOONEY AIRCRAFT CORPORATION 28 VOLT ELECTRICAL EQUIPMENT CHART CODE DESCRIPTION JKL -JKL RC06A JKL RC08A JKL RC08B JKL JKL JKL JKL JKL RC09A RC09B RC10A RC11A RC12A JKL RC12B JK RC13A JKL RC13B JK- RC14A JKL JKL RC16A RC16A RC07A VENDOR RECPT, A/P POWER, 16 PIN AMP CLAMP RECPT, CLUSTER GAUGE, 16 PIN AMP CLAMP RECPT, PIRE'WALL#1, 19 PIN CLAMP RECPT, FIREWALL #1, 19 PIN (ALT) CLAMP RECPT, RT. WG, 14 PIN MOONEY RECPT, RT WING, 20 PIN MOONEY RECPT, RT. WING STUB, 14 PINMOONEY RECPT, LT.WG., 14 PIN MOONEY RECPT, FIREWALL #2, 19 PIN CLAMP RECPT, FIREWALL #2 (ALT) CLAMP RECPT, RT.RADIO PNL, 9 PIN AMP CLAMP AMP RECPT, AVIONICS MASTER, 4 PIN AMP CLAMP AMP RECPT, HOUR METER, 4 PIN AMP CLAMP AMP RECPT, LEFT WING STUB, 14 PIN MOONEY RECPT, GEAR CONTROL AMP PART NO. 206036-3 206070-1 296036-3 206070-1 MS3100A22-14P MS3057-12B MS3100K22-14P MS3100KE22-14P MS3057-12B or 12A 930021-2 930021-502 930021-2 930021-002 MS3100A22-14P MS3057-12B MS3100K22-14P MS3100KE22-14P MS3057-12B or-12A 208705-1 206966-1 206153-1 206062-1 206153-1 206062-1 930021-002 206705-2 CLAMP AMP 206966-1 JKL RC17A RECPT, ELECTRIC GEAR MOONEY 930021-002 JK- RC18A JKL RC18B JKL RC19A JKL RC20A JK- RC21A JK- RC22A JK-JK-- RC23A RECPT, DIMMER, 16 PIN CLAMP RECPT, PNL LT DIM#l, 14 PIN CLAMP RECPT, NS SWITCH #2, 4 PIN CLAMP RECPT, TAILCONE, 16 PIN CLAMP RECPT, TAILCONE, 16 PIN CLAMP RECPT, O/H REAR, 4 PIN CLAMP RECPT, GRND #1, 16 PIN CLAMP RECPT, GRND #2, 16 PIN CLAMP AMP AMP AMP AMP AMP AMP AMP AMP AMP AMP AMP AMP AMP AMP AMP AMP 206036-3 206070-1 206044-1 206070-1 206153-1 206062-1 206036-3 206070-1 206036-3 206062-1 206153-1 206062-1 206036-3 206070-1 206036-3 206070-1 JKL RC26A JK- RC27A JKL JKJK- RC27B RC28A RC29A 91-20-02 56 RC24A RECPT, COMPASS LT HARNESS, AMP CLAMP AMP RECPT, FLT PNL #2,4 PIN AMP CLAMP AMP :RECPT, FLT PNL#2, 20 PIN MOONEY RECPT, AVIONICS POWER, 20 PIN MOONEY RECPT, DIM/GRND, 20 PIN MOONEY 12-98 NOTES 206153-1 206062-1 206153-1 206062-1 930021-502 930021-502 930021-502 : MOONEY AIRCRAFT CORPORATION M20J SERVICE AND MAINTENANCE MANUAL 28 VOLT ELECTRICAL EQUIPMENT CHART CODE JK- RC30A JK- RC81A JK-JKL RC31B JK RC33A JKL RC34B JK- RC35A JK- RC36A JK-JK- RC37A JK RC89A -K- RC40A JKL RCSOA JKL RC51A JKL RC32A DESCRIPTION VENDOR PART NO. RECPT, CLAMP RECPT, CLAMP RECPT, CLAMP RECPT, CLAMP RECPT, CLAMP RECPT, CLAMP AMP AMP AMP AMP AMP AMP AMP AMP AMP AMP AMP AMP 206153-1 206062-1 205841-2 206062-1 205841-2 206062-1 206153-1 206062-1 206705-2 206966-1 206036-3 206966-1 DIM/GRND, 4 PIN STBY VAC, 8 PIN STBY VAC, 8 PIN GEAR RELAY, 4 PiN C/B PNL#2, 9 PIN GRND BUSS, 16 PIN RECPT, FLT PNL #3, 4 PIN AMP CLAMP AMP RECPT, CONSOLE #2, 8 PIN AMP CLAMP AMP RECPT, LT.SIDE PNL, 8 PIN AMP CLAMP AMP RECPT, FLAY RELAY, 8 PIN AMP CLAMP AMP RECPT, FLAP MOTOR, 9 PIN AMP CLAMP AMP RECPT, THRO-I-FLESWITCH, 4 PIN AMP CLAMP AMP RECPT, C/B PNL #2 AMP CLAMP AMP RECPT, IGNITION SWITCH MOONEY 206153-1 206062-1 205841-2 206062-1 205841-2 206062-1 205841-2 206062-1 206705-2 206966-1 206153-1 206062-1 206151-2 206138-1 930021-506 RC52A RECPT, ALT/STARTER (ALT) CANNON MS3160K28-2P MS3100KE28-2P JKL -JKL RC55A AMP JKL JKL RC57A RC58A --L RC58B JKL JK- RC59A RC76A JK- RC77A --L RC150A RECPT, CLAMP RECPT, CLAMP RECPT, RECPT, CLAMP RECPT, CLAMP RECPT, RECPT, CLAMP RECPT, CLAMP RECPT, 206705-2 206966-1 206705-2 206966-1 930021-002 206036-3 206070-1 206044-1 206070-1 930021-506 206705-2 206966-1 206152-1 206070-1 CA121006-518 --L RC38A RC56A RC15OA EMPENNAGE, 9 PIN GRND RECPT. #4, 9 PIN AMP GRND RECPT #5, 14 PIN MOONEY DIM RECPT. #2, 16 PIN AMP AMP PNL LT DIM #2, 14 PIN AMP AMP GRND RECPT #6, 26 PIN MOONEY 9 PIN AMP AMP 28 PIN AMP AMP ENGINE HARNESS, LT CANNON-GERMANY NOTES CLAMP CANNON-GERMANY 057-8557-000 FERRULE END RING CANNON-GERMANY 304-8553-000 RECPT, ENGINE, LT F/WALL (ALT) CANNON-GERMANY CA121006-600 RECPT, ENGINE HARNESS,LT (ALT) PORSCHE 933.612.415.00 . CLAMP * PORSCHE 933.612.417.00 ENDBELL * PORSCHE 933.612.425.00 • NOTE: ALTERNATE HIGH TEMPERATURE COMPONENTS FOR ITEMS: 12-98 91-20-02 57 SERVICE AND MAINTENANCE MANUAL M20J MOONEY AIRCRAFT CORPORATION 28 VOLT ELECTRICAL EQUIPMENT CHART CODE L --L DESCRIPTION RC151A RC151A VENDOR RECPT, ENGINE HARNESS, RT CANNON-GERMANY CLAMP * CANNON-GERMANY FERRULE END RING * CANNON-GERMANY RECPT, ENGINE HARNESS, FiT PORSCHE CLAMP * PORSCHE ENDSELL * PORSCHE PART NO. CA121006-518 057-8557-000 304-8553-000 933.612.415.00 933.612.417.00 933.612.425.00 • NOTE: ALTERNATE HIGH TEMPERATURE COMPONENTS FOR ITEMS: RC152A RECPT, GR/STALL WARN HARNESS, 4 PIN AMP 206153-1 CLAMP AMP 206062-1 JKL SB101A C/B, SPEED BRAKE KUXON 7277-2-2 --L SPK101A SPEAKER, CABIN ARCHER 12-1703 JK- WA101A WESTERN IND WESTERN IND. JKJK- WA102A WA103A UGHT, OVERVOLTAGE CLAMP DIODE DIODE 501-61K-11K-3RP Wl-7049 1N2483 1N2483 --L WD150A -WD150A FUSEHOLDER, STARTER SOLENOID FUSE, 1AMP LI'CI-EL U'I'TEL 155020 or155120 313001 WE101A WE102A C/B, GEAR WARN HORN UGHT, GEAR DOWN KUXON SLOAN 7277-2-2 855S-O-U BULB GE 327 SWITCH, THROI-rLE ACTUATOR HORN, GEAR WARNING DIODE DIODE SWITCH, THROTTLE ACTUATOR SWITCH, THROTTLE ACTUATOR PLUG, 4 PIN CLAMP RECPT, 4 PIN CLAMP MICRO MICRO MALLORY V3-1 JV-1 SC628P 1N2483 1M2483 1SE1-T JE-17 1SE1-T JE-5 206060-1 206062-1 206153-1 206062-1 JKL JKL JK- WE103A JKJKL JKL -K- WE104A WE105A WE106A WE107A --L WE150A L WE151A --L WE152A JKL JKJKL --L L WS101A WS102A WS103A WS150A WS151A --L L WS152A WS153A --L WS154A 01-20-02 58 MICRO MICRO MICRO-SWITCH MICRO-SWITCH AMP AMP AMP AMP C/B STALL WARN HORN KLIXON HORN, STALL WARNING MALLORY SWITCH, STALL WARN SAFE FUGHT ALERT, GR/STALL WARNING IAI PLUG,GR/STLWRN ALRT, 25 PIN ITT CLAMP I1-£ LOCK RETAINER ITT SPEAKER, GR/STALL WARN ARCHER PLUG, INTER PHONE, 4 PIN AMP 'CLAMP AMP PLUG, MATE N LOCK, 2 PIN AMP SOCKETS AMP i2-98 7277-2-2 SC628 C46001 950D-0309-000 DB25S DB51212 DB1212-1 40-1333C 206060-1 206062-1 1-480318-0 60619-1 NOTES MOONEY AIRCRAFT CORPORATION M20J SERVICE AND MAINTENANCE MANUAL 28 VOLT ELECTRICAL EQUIPMENT CHART CODE DESCRIPTION VENDOR PART NO. --L WS155A RECPT, MATE N LOCK, 2 PIN PINS AMP AMP 1-480319-0 60620-1 JKJ-- WTI01A WT102A -K- WT103A C/B, ANNUNCIATOR ANNUNCIATOR LAMPS ANNUNCIATOR LAMPS KLIXON MOONEY CHICAGO MINIATURE MOONEY CHICAGO MINIATURE 7277-2-2 880025-521 CM7327 880025-523 CM7327 JK- W3"104A --L --L WT150A WT151A WT153A --L WT154A PLUG, ANNUNCIATOR SOCKETS C/B, ANNUNCIATOR, LT C/B, ANNUNCIATOR, RT ANNUNCIATOR LAMPS PLUG, ANNUNCIATOR CLAMP LOCK RETAINER MOLEX MOLEX KLIXON KLIXON IAI CHICAGO MINATURE ITT ITT ITT 09-50-3151 08-50-0105 7277-2-1 7277-2-1 950D0308-000 CM7327 DB25S D551212-1 DB51221-1 JKJKJK- WV101A WV102A V¢#103A JK- WVlO4A C/B, VACUUM WARNING SWITCH, VACUUM WARNING RECPT, VAC WARN, 4 PiN CLAMP PLUG, VAC WARN, 4 PIN CLAMP KUXON MOONEY AMP AMP AMP AMP 7277-2-2 880012-501 206153-1 208062-1 208060-1 206082-1 J-- WWlO1A SWITCH, RAM AIR ACTUATOR MICRO MICRO V3-1 JV-5 -K--L _"¢VIO2A WW150A SWITCH, ALTERNATE AIR SWITCH, ALTERNATE AIR CHERRY CHERRY E51-508 E51-508 NOTES NOTES 1. Use 1 ea. MS35334-21 or MS2898 (Alan Bradley) internal tooth Iookwasherwith each light if not supplied by Sloan. 2. Maximum circuit breaker rating is shown, amperage of installed circuit breaker is determined by particular unit installed. 3. Buss bar may be shortened as required by circuit breaker installation. 4. Alternate for V3-1 switch w/JV-5 actuator is V3L-3 assembly. 5. Varies with AutoPilot System installed. 12-98 91-20-02 59 SERVICE AND MAINTENANCE MANUAL M20J MOONEY AIRCRAFT CORPORATION 28 VOLT ELECTRICAL EQUIPMENT CHART RESERVED 91-20-02 60 12-98 MOONEY AIRCRAFT CORPORATION M20J SERVICE AND MAINTENANCE MANUAL 28 VOLT ELECTRICAL EQUIPMENT CHART 91-20-03 ( - ELECTRICAL SYSTEM HARDWARE CHART - 28 VOLT SYSTEMS S/N's 24-3154 THRU 24-3200, 24-3202 THRU 24-3217, MOONEY DRAWING NO. 800263 (E7), 24-1686-14thru 24-2999-14 commoncomponents,28V & 14V - (See 91-20-04 for 14 Volt peculiarcomponents) ** - ACTUAL USAGE DETERMINED BY MASTER SCHEMATICS - ** DESCRIPTION VENDOR PART NO. CODE ( JKJKJKJKJK-JK-JKJKJKJKJK- CB101A CB102A CB103A CB103S CB104A CC101A CC102A CC103A CC103B CC104A JK- CC105A JK- CC106A JK-JKJKJK- CC107A JK- CF104A JKJKJKJKJK- CF105A CF108A CV101A CV102A CV103A JK- CVl04A JK- CV105A JK- CV106A JKJKJKJKJK- DA101A DA102A DA103A DB101A DB102A CB105A CC108A CF101A CF103A C/S, DEFROSTER BLOWER KLIXON SWITCH, BLOWER MOTOR CHERRY MOTOR, BLOWER MOONEY MOTOR, BLOWER MOONEY PLUG, 2 PIN AMP SOCKET AMP RECEPTACLE, 2 PIN AMP PIN AMP C/B, COWL FLAP KLIXON SWITCH, COWL FLAP MICRO ACTUATOR, COWL FLAP MOONEY ACTUATOR, COWL FLAY MOONEY SWITCH, OPEN LIMIT MICRO ACTUATOR MICRO SWITCH, CLOSED LIMIT MICRO ACTUATOR MICRO PLUG, 9 PIN AMP CLAMP AMP RECEPTACLE, 9 PIN AMP CLAMP AMP VARISTOR GE C/B, FLAP ACTUATOR KLIXON SWITCH, UP LIMIT MICRO ACTUATOR MICRO SWITCH, DOWN UMIT MICRO ACTUATOR MICRO ACTUATOR, FLAP MOONEY SWITCH, FLAP CUTLER-HAMMER C/S, STAND-BY VACUUM MOONEY CURRENT MONITOR, STD-BY VAC MOONEY PLUG, 9 PIN AMP CLAMP AMP PLUG, 2 PIN AMP SOCKET AMP RECEPTACLE, 2 PIN AMP PIN AMP PUMP, VACUUM AEROSAFE 7277-2-5 E51-50B 640317-501 640317-503 1-480318-0 60619-1 1-480319-0 60620-1 7277-2-5 12TW1-1 880050-501 880050-505 1SE1-T JE-5 1SE1-T JE-5 206708-1 206966-1 206705-2 206966-1 V47ZA05 7277-2-5 V3-1 JV-5 V3-1 JV-5 750105-501 8906K3149 930023-233 800221-505 206708-1 206966-1 1-480318-0 60619-1 1-480319-0 60620-1 820904-2 SHUNT, LOAD FUSEHOLDER FUSEHOLDER C/B, TURN COORDINATOR TURN COORDINATOR TURN COORDINATOR (ALl') TURN COORDINATOR (ALl') TURN COORDINATOR (ALE) MLA-70A-100MV FHN42W FM01-SA 7277-2-2 9013 CODE N.5 303990-028MSC 1394T100-3Z 9114 CODE N.21 EMPRO McGRAW EDISON McGRAW EDISON KLIXON U.I. ASTRONAUTICS ELECTRO GYRO U.I. !2-98 NOTES 91-20-03 61 SERVICE AND MAINTENANCE MANUAL M20J MOONEY AIRCRAFT CORPORATION 28 VOLT ELECTRICAL EQUIPMENT CHART CODE DESCRIPTION VENDOR PART NO. JK- DB103A PLUG CABLE CLAMP (ALT) MS3106A-10SL-3S MS35074A MS3507-4B JK- DC101A PROBE, CHT, (CYL #3) (ALT) MS24482-1 AN5546-1 JKJ-J-J-- DDIOIA DD102A DD102B DD103A JKJK- DD104A DD105A JK- DD106A JKJKJKJKJKJ-JK- DF101A DF102A DF103A DF104A DG101A DG103A DG104A -KJ-- DG105A DH101A -K-K- DH101A DH102A JK- DJ101A JK- DJ102A JK-JK- DJ103A JK- DK102A JK- DK103A C/B, EGT/OAT KUXON GAUGE, EGT/OAT MOONEY GAUGE (4 PROBE) MOONEY PLUG, 8 PIN AMP CLAMP AMP PROBE, OAT MOONEY PLUG, 2 PIN AMP SOCKET AMP RECEPTACLE, 2 PIN AMP PIN AMP TRANSMI'I-FER, LT IN/BD, FUEL MOONIEY TRANSMll-rER, LT OUT/BD, FUEL MOONEY TRANSMITTER, RT IN/BD, FUELMOONEY TRANSMll-FER, RT OUT/BD, FUEL MOONEY C/B, INSTR. MODULE #1 KUXON MODULE, INSTR. MOONEY PLUG, 28 PIN AMP CLAMP AMP MODULE, INSTRUMENT MOONEY PROBE, OIL TEMP MOONEY (AL'r) LEWIS ENGRG PROBE, OIL TEMP PLUG, 2 PIN CLAMP TRANSDUCER, OIL PRESS DRUCK (ALT) KULITE PLUG, 4 PIN AMP CLAMP AMP RECEPTACLE, 4 PIN AMP CLAMP AMP TRANSDUCER, FUELPRESS DRUCK (ALT) KUIJTE PLUG, 4 PIN AMP CLAMP AMP RECEPTACLE, 4 PIN AMP CLAMP AMP 7277-2-2 880001-507 880001-509 205838-1 206082-1 880004-501 1-480318-0 60619-1 1-480319-0 60620-1 610242-003 610243-003 610242-003 610243-001 7277-2-1 880059-507 205839-3 206070-1 880059-509 880061-501 56B3A9 MS28034-1 MS3108A-12S-3S MS3057-4A PDCR821-0662-100 APT-154-1000-100PSIG 206060-1 206062-1 206153-1 206062-1 PDCR821-0862-30 APT-153-1000-30PSIG 208060-1 206062-1 206153-1 206062-1 J-- DLIOIA -K- DL101A JK- DL102A J--K- DL103A DL103A JK- DLIO4A JK- DLIO5A TACHOMETER (AL'r) TACHOMETER (ALT) PLUG, 5 PIN CLAMP SENSOR, TACH SENSOR, TACH .(ALT) PLUG, 4 PIN CLAMP RECEPTACLE, 4 PIN CLAMP 880039-515 0520-003 880039-517 0520-006 MS3106A-14S-5S MS3057-TA/B 0400-004 0402-102 0402-104 206060-1 206062-1 206153-1 206062-1 91-20-03 62 DK101A MOONEY B &D MOONEY B& D B& D B& D B& D AMP AMP AMP AMP 12-98 NOTES 1 1 MOONEY AIRCRAFT CORPORATION M20J SERVICE AND MAINTENANCE MANUAL 28 VOLT ELECTRICAL EQUIPMENT CHART CODE DESCRIPTION VENDOR PART NO. J--K- DM101A DMIO1A HOUR METER HOUR METER MOONEY MOONEY 880035-507 660035-505 JK- DMIO2A RECEPTACLE, 4 PiN CLAMP AMP AMP 206153-1 206062-1 JK- DM103A J-- DMIO4A PLUG, 4 PIN CLAMP FUSEHOLDER (ALT) AMP AMP LI'I-]'ELFUSE LITTEL 206060-1 206062-1 155020 155120 JKJK- DPIOIA DP102A LITTEL MOONEY AERO INSTR JK- DPIO3A JK- DP104A JK-- DPIO5A FUSE (5A-3AG-SLO-BLO) C/B, PITOT HEAT PITOT, HEATED (ALl) PLUG SOCKET PLUG, 2 PIN SOCKET RECEPTACLE, 2 PIN PIN 313005 930023-205 PH502-24 AN5812-1AN3115-1 AN3116-1 1-480316-0 60619-1 1-480319-0 60620-1 -K-K-K-K--K- DR101A DR102A DR102B DR103A -KJK- DR104A DT101A J-JK- DT101A DT102A J-JK- DT102A DT103A J-JK- DTIO3A DTIO4A J-J-- DT104A DT105A -K- DTIOIA -K- DT102A -K- DT103A -K- DTIO4A -K- DTIOSA -K- DT106A JK- DV101A DR103B AMP AMP AMP AMP C/B, TIT KLIXON TIT INDICATOR MOONEY TIT/EGT INDICATOR (6 PROBE) MOONEY PLUG, 8 PIN AMP CLAMP AMP PLUG, 28 PIN AMP CLAMP AMP PROBE, TIT MOONEY PROBE, EGT, (CYL #1) MOONEY (ALl-) MOONEY (ALT) MOONEY PROBE, EGT (CYL#2) MOONEY (ALT) MOONEY (AL'r) MOONEY PROBE, EGT (CYL#3) MOONEY (ALT) MOONEY (AL'r) MOONEY PROBE, EGT (CYL#4) MOONEY (ALl-) MOONEY (ALl) MOONEY EGT INDICATOR MOONEY LEAD WIRE) ALCOR PROBE, EGT (CYL #1) MOONEY (ALT) MOONEY PROBE, EGT (CYL#2) MOONEY (ALT) MOONEY PROBE, EGT (CYL#3) MOONEY (ALT) MOONEY PROBE, EGT (CYL#4) MOONEY (ALT) MOONEY , PROBE, EGT (CYL#5) MOONEY (ALT) MOONEY ' PROBE, EGT (CYL #6) MOONEY (ALl-) MOONEY C/B, FUEL FLOW KLIXON 12-95 NOTES 7277-2-2 680051-501 880051-503 205838-1 206062-1 205839-503 206070-1 880055-501 850005-503 860005-501 660110-000 880005-503 880005-501 660110-000 680005-503 880005-501 660110-000 880005-503 680005-501 650110-000 660109-003 01-005-78 850005-503 880005-501 880005-503 650005-501 880005-503 880005-501 680005-503 880005-501 880005-503 680005-501 880005-503 550005-501 7277-2-1 91-20-03 63 SERVICE AND MAINTENANCE MANUAL M20J MOONEY AIRCRAFT CORPORATION 29 VOLT ELECTRICAL EQUIPMENT CHART CODE DESCRIPTION VENDOR PART NO. NOTES ! JKJK- DV102A DV102A JK- DV102B JK- DV103A JK- DV103B JK- DV104A JKJK- DV164B DV105A JK- DVIO6A JKJK- DV107A DV108A JK- DV109A JKJKJKJK- DW101A EG101A EG102A EG103A JKJKJK- EG104A EG105A EG106A JKJKJK- EG107A EG107B EG108A JK- EG109A 91-20-03 64 INDICATOR, FUEL FLOW (ALl') (ALl') (ALl') INDICATOR, F/F (GAL) MOONEY MOONEY MOONEY SHADIN 880034-501 680034-503 880034-505 912021 (ALl') (LBS) SHADIN 912023 INDICATOR, F/F (OPT) (GAL) (ALr) (LBS) (ALT) (LITER) (ALT) (GAL) (ALT) (I.BS) (ALE) (LITER) PLUG, 9 PIN CLAMP LATCH ASSY (2 ea) PLUG, 9 PIN CLAMP LATCH ASSY (2 ea) TRANSDUCER, FUEL FLOW (ALT) TRANSDUCER, FUEL FLOW PLUG, 4 PIN CLAMP RECEPTACLE, 4 PIN CLAMP SWITCH, FUEL FLOW PLUG, 4 PIN CLAMP RECEPTACLE, 4 PIN CLAMP SHADIN SHADIN SHADIN SHADIN SHADIN SHADIN Il-r CANNON I1-1"CANNON ITT CANNON II-F CANNON I'FTCANNON Il-r CANNON MOONEY MOONEY FLOSCAN AMP AMP AMP AMP C&K AMP AMP AMP AMP 912041 912043 912047 912081 912083 912087 DE-9S DE-24657 DE-51224-1 DE-gS DE-24657 D-110278 890030-501 880030-503 680501B 206060-1 206062-1 206153-1 206062-1 7101K 206060-1 206062-1 206153-1 205062-1 VERTICAL SPEED INDICATOR U.I. C/B, GEAR RELAYS KLIXON SWITCH, GEAR UP/DOWN CUTLER/HAMMER SWITCH, GEAR OVERRIDE CUTLER/HAMMER RING, LOCKING CUTLER-HAMMER WASHER, LOCK CUTLER-HAMMER NUT, HEX (2 ea) . CUTLER-HAMMER LAMP (28V) GE LAMP (14V) GE SWITCH (ALT) NKK CORP SUTI-ON NKK CORP LOCKING RING NKK CORP LOCKWASHER NKK CORP NUT, HEX (2 EA) NKK CORP LAMP (29V) NKK CORP SWITCH, AIRSPEED, GEAR SAFETY MOONEY C/B, GEAR ACTUATOR KLIXON SWITCH, GEAR UP LIMIT MICRO ACTUATOR MICRO SWITCH, GEAR DOWN LIMIT MICRO . SWITCH, GEAR DOWN LIMIT (ALT) SAINT PLUG, 4 PIN AMP CLAMP AMP RECEPTACLE, 4 PiN AMP CLAMP AMP 12-98 7000 CODE C.83 7277-2-2 8906K2875 SBIDDX492-2 29-761 16-886 15-966-6 334 336 DBL2141-3BL AT406 AT406 AT508 AT503 AT604-28 880013-507 7277-2-7.5 DT-2R-A7 MCD-2711 1CHl16-6 MLl116 206060-1 206062-1 206153-1 206062-1 4 4 4 5 5 5 2 2 2 3 3 3 MOONEY AIRCRAFT CORPORATION M20J SERVICE AND MAINTENANCE MANUAL 28 VOLT ELECTRICAL EQUIPMENT CHART CODE DESCRIPTION VENDOR PART NO. CUTLER-HAMMER 6041H220 1N2483 6041H220 1N2483 560254-503 880037-507 JKJKJKJKJK- EG110A EG111A EG112A EG113A EG114A RELAY, GEAR UP DIODE RELAY, GEAR DOWN DIODE ACTUATOR, GEAR (ALT) JKJKJK- ELT101A ELT101B ELT102A JKJKJK- ELT103A ELT103B ELT104A JK- ELT105A JK- ELT106A JK- ELT107A JK- ELT108A JK- FON101A JK- JM101A J--K-K- JM102A JM102A JM102B -K-K- JM103A JMI03B JK- LB101A TRANSMITTER, ELT TRANSMITTER, ELT RECEPTACLE, 12 PIN PIN SWITCH, REMOTE SWITCH, REMOTE PLUG, 9 PIN SOCKET PLUG, 8 PIN CLAMp RECEPTACLE, 8 PIN CLAMP PLUG, 8 PIN CLAMP RECEPTACLE, 8 PIN CLAMP PHONE JACK WASHERS WASHERS (ALl') SWITCH, MAGNETO PLACARD MAGNETO MAGNETO, LEFT MAGNETO, LEFT CONNECTOR MAGNETO, RIGHT MAGNETO, RIGHT CONNECTOR C./B, BEACON, FLASHING JK-JKJKJK- LB102A JK-JK- LB104A LB102A LB102B LB103A LC101A -JKJKJK- LC102A LC103A LC104A JK- LC105A JK- LC106A CUTLER-HAMMER MOONEY MOONEY NOTES ARTE.X ELT110-4 DORNE & MARGOMN DM-ELT-8 MOLEX 03-06-2122 MOLEX 02-062103 ARTEX 110-416 C &K 7101K MOLEX 03-06-2092 MOLEX 02-06-1103 AMP 205838-1 AMP 206062-1 AMP 205841-2 AMP 206062-1 AMP 205838-1 AMP 206062-1 AMP 205841-2 AMP 206062-1 SWITCHCFIAFT C-11 SWITCHCRAFT S-1028 SWlTCHCRAFT S-1029 BENDIX/SCINTILLA 10-357210-9 BENDIX/SCINTILLA 10-187-468 BENDIX/SCINTILLA D-4LN2021 SLICK 6224 BENDIX/SCINTILLA 646979-1 BENDIX/SCINTILLA 10-382698 SLICK 6224 BENDIX/SCINTILLA 646979-1 BENDIX/SCINTILLA 10-382698 MOONEY 930023-24,3 UGHT, BEACON WHELEN ADAPTER WHELEN LIGHT,ANTI-COLLISION0NHITE) (AL'I-) WHELEN UGHT,ANTI-COLUSION (RED) (ALT) WHELEN PLUG, 3 PiN AMP SOCKET AMP WRLM-24 WRM-65 90038-20 90033-19 1-380303-0 60619-1 RECEPTACLE, 3 PIN PIN FUSEHOLDER (ALT) FUSE, 5A-3AG-SLO-BLO SWITCH, CABIN LIGHT, FRONT RESISTOR, DIM. (20 OHM 10W) LAMP HOLDER .LAMP LAMP HOLDER LAMP LAMP HOLDER LAMP 1-480305-0 60620-1 155020 155120 313005 TILC64-1S-WH-FN RH-10-20 OHM 1930 1818 1930 1818 1930 1818 AMP AMP LITTEL LITFEL LITTEL CARLING DALE H H SMITH GE H H SMITH GE H H SMITH GE 12-98 91-20-03 65 SERVICE AND MAINTENANCE MANUAL M20J MOONEY AIRCRAFT CORPORATION 28 VOLT ELECTRICAL EQUIPMENT CHART CODE DESCRIPTION JK- LC107A JKJKJK- LC108A LC109A LC110A JK- LC111A JK- LC112A JK-JK- LC113A JKJK- LC118A LC118B JK- LC119A JK- LC120A JK- LC121A JK- LC122A JKJK- LC123A LC124A JK-JKJK- LC125A JK- LC128A JKJKJKJKJKJK- LL101A LL101A LL102A LL103A LL104A LL105A JKJK- LN101A LN102A JK- LN103A JK- LN104A • JK- LN105A 91-20-03 66 LC117A LC126A LC127 VENDOR PART NO. LAMP HOLDER H H SMITH LAMP GE SWITCH, CABIN UGHT, REAR CARUNG RESISTOR, DIM. (20 OHM 10W) DALE LAMP HOLDER H H SMITH LAMP GE LAMP HOLDER H H SMITH LAMP GE LAMP HOLDER H H SMITH LAMP GE LAMP HOLDER H H SMITH LAMP GE PLUG, 9 PIN I1-FCANNON CLAMP LATCH MODULE, AUTO OFF LIGHT MOONEY RECEPTACLE, 9 PIN CLAMP RING, LOCKING DIODE (ALl') (ALl') GE DIODE (ALl-) (ALl') GE PLUG, 4 PIN AMP CLAMP AMP RECEPTACLE, 4 PIN AMP CLAMP AMP SWITCH, CABIN DOOR NEWARK RECEPTACLE, 2 PIN AMP PIN AMP PLUG, 2 PIN AMP SOCKET AMP SWITCH, BAGGAGE DOOR NEWARK RECEPTACLE, 2 PIN AMP PIN AMP PLUG, 2 PIN AMP SOCKET AMP 1930 1818 TILC64-1S-WH-FN RH-10-20 OHM 1930 1818 1930 1818 1930 1818 1930 1818 DE-9S DE24657 DE51224-1 800268-501 DE-9P DE24657 206514-1 1N2483 IN5080 3720-GE 1N2483 1N5060 3720-GE 206060-1 206062-1 206153-1 206062-1 89F5544 1-480319-0 60620-1 1-480318-0 60619-1 89F5544 1-480319-0 60620-1 1-480318-0 60619-1 C./B,LANDING LIGHT C/B, LANDING LIGHT SWITCH, LANDING LIGHT LIGHT, LANDING, RIGHT LIGHT, LANDING, LEFT LIGHT, LANDING (COWL) 7277-2-25 930023-215 880052-521 4596 4596 4553 KLIXON MOONEY MOONEY GE GE GE C/B, NAV LIGHT MOONEY UGHT ASSY, NAV, TAIL (LT WING) MOONEY BULB WHELEN UGHT ASSY, NAV, TAIL (RT WING) MOONEY BULB WHELEN . PLUG, 9 PIN (RT WING) AMP CLAMP AMP RECEPTACLE, 9 PIN (RT WING)AMP CLAMP AMP 12-98 930023-201 800051-501 34-022-8030-85 800051-501 34-022-8030-85 206708-1 206062-1 206705-1 206062-1 NOTES MOONEY AIRCRAFT CORPORATION M20J . SERVICE AN D MAINTENANCE MANUAL 28 VOLT ELECTRICAL EQUIPMENT CHART CODE i DESCRIPTION VENDOR PART NO. AMP AMP 206708-1 206062-1 JK- LN106A PLUG, 9 PIN (LT WING) CLAMP JK- LN107A JKJKJKJK- LPIO1A LP102A LP103A LP104A JK- LPIOSA JK- LP106A JK- LP107A JK- LP108A JKJKJK- LP109A LP110A LP111A JKJK- LP112A LP113A JK- LP114A JK- LP115A JK- LP116A JK- LP117A JK- LP118A JK- LP119A JK- LP120A JK- LP121A JK- LP12?-A JKJKJKJKJKJK- LP123A LP124A LP125A LP126A LP127A LP130A JK- LP133A JKJK- LP134A LP134A RECEPTACLE, 9 PIN (LT WING) AMP CLAMP AMP C/B, GLARESHIELD UGHTS KUXON C/B, PANEL LIGHTS KLIXON DIMMER CONTROL BOX MOONEY PLUG, 9 PIN AMP CLAMP AMP UGHT, CONSOLE DIAUGHT LAMP (28V) GE LAMP (ALE) GE LIGHT, CONSOLE DIALIGHT LAMP (28V) GE LAMP (ALT) GE PLUG, 4 PIN AMP CLAMP AMP RECEPTACLE, 4 PiN AMP CLAMP AMP RECEPTACLE, COMPASS LIGHT DEANS PLUG, COMPASS LIGHT DEANS LAMP, COMPASS LIGHT (28V) GE (ALE). GE LAMPS, GL,/SHLDLIGHTS (14 ea) GE LIGHT, OXYGEN SLOAN LAMP (28V) GE UGHT, OXYGEN SLOAN LAMP (28V) GE PLUG, 2 PIN AMP SOCKET AMP RECEPTACLE, 2 PIN AMP PIN AMP PLUG, 2 PIN AMP SOCKET AMP RECEPTACLE, 2 PIN AMP PIN AMP PLUG, 2 PIN AMP SOCKET AMP RECEPTACLE, 2 PIN AMP PIN AMP POST LIGHT WHELEN LAMP (14V) GE POST LIGHT WHELEN LAMP (14V) GE LIGHTING TRAY (RPM) B& D LIGHTING TRAY (M/P) UI LIGHTING TRAP (-I-IT/EGT) B &D PLUG, 20 PIN MOONEY RECEPTACLE, 20 PIN MOONEY RHEOSTAT, MAP LIGHT (500 OHM) NEWARK KNOB NEWARK .RHEOSTAT, MAP LIGHT (500 OHM) NEWARK KNOB N_ARK MAP LIGHT SLOAN LAMP (28V) GE LAMP (14V) GE 12-98 NOTES 206705-1 206062-1 7277-2-5 7277-2-5 800049-501 206708-1 206956-1 270-1930-0171-702 327 385 270-1930-0171-702 327 385 206060-1 206062-1 206153-1 206062-1 DEA90020MALEHALF DEA90020FEMALEHALF 327 327 (AVIATION RED) 327 855S-0-U 327 855S-0-U 327 1-480318-0 60619-1 1-480319-0 60620-1 1-480318-0 60619-1 1-480319-0 60620-1 1-480318-0 60619-1 1-480319-0 60620-1 A350CN1W-BK-SH14 330 A350CN1W-BK-SH14 330 0221-128 BA28-24-BW3 0221-128 930022-501 930021-502 09F981 57F2368 09F981 57F2368 855S-0-U 327 330 6 6 6 91-20-03 67 SERVICE AND MAINTENANCE MANUAL M20J MOONEY AIRCRAFT CORPORATION 28 VOLT ELECTRICAL EQUIPMENT CHART CODE JK- LP135A -JK- LP136A JK- LP137A -JKJKJK- LR101A LR102A LR103A JKJK- LR104A LR105A JK- LR105A JKJK- LR107A LR108A JKJK- LR109A LRllOA JK- LR111A JKJKJK- LSIO1A LSIO2A LS103A JK- LS104A JK- LS105A JKJKJK- LS106A LSIOTA LSIO8A JK-JK- LS109A JKJKJK- LS111A LS112A LS113A JK- LS114A JK-JK-- LS115A 91-20-03 68 LS110A LS116A DESCRIPTION VENDOR PART NO. MAP LIGHT LAMP (28V) LAMP (14V) POST LIGHT LAMP (28V) SLOAN GE GE WHELEN GE 855S-0-U 327 330 A350CN1W-BK-SH28 327 POST LIGHT WHELEN A350CNIW-BK-SH14 LAMP (14V) GE C/B, RECOGNITION LIGHTS MOONEY LIGHT, RECOGNITION, LW MOONEY PLUG, 2 PiN AMP SOCKET AMP RESISTOR DALE RECEPTACLE, 2 PIN AMP PIN AMP PLUG, 2 PIN AMP SOCKET AMP UGHT, RECOGNITION, RW MOONEY PLUG, 2 PIN AMP SOCKET AMP RESISTOR DALE RECEPTACLE, 2 PIN AMP PIN AMP PLUG, 2 PIN AMP SOCKET AMP C/B, STROBE UGHT MOONEY POWER SUPPLY, LT WING WHELEN RECEPTACLE, POWER SUPPLY AMP PIN AMP RECEPTACLE, POWER SUPPLY AMP PIN AMP PLUG, STROBE LIGHT ASSY AMP 330 930023-231 880049-501 1-480318-0 60619-1 RH50-7,5 OHM 1-480319-0 60620-1 1-480318-0 60619-1 880049-501 1-480318-0 60619-1 RH50-7.5 OHM 1-480319-0 60620-1 1-480318-0 60619-1 930023-237 01-0770329-00 1-480305-0 60620-1 1-480305-0 60620-1 1-480303-0 SOCKET AMP STROBE/NAV LIGHT, LT WING WHELEN POWER SUPPLY, LT WING WHELEN RECEPTACLE, POWER SUPPLY AMP PIN AMP RECEPTACLE, POWER SUPPLY AMP PIN AMP PLUG, STROBE LIGHT ASSY AMP 60619-1 A650-PR-D-M-28 01-0770329-00 1-480305-0 60620-1 480305-0 60620-1 1-480303-0 SOCKET AMP STROBE/NAV LIGHT, RT WING WHELEN POWER SUPPLY, TAIL WHELEN RECEPTACLE, POWER SUPPLY AMP PIN AMP RECEPTACLE, POWER SUPPLY AMP PIN AMP PLUG, 4 PIN AMP CLAMP AMP .RECEPTACLE, 4 PIN AMP CLAMP AMP 60619-1 A650-PR-D-M-28 01-0770329-00 1-480305-0 60620-1 1-480305-0 60620-1 206060-1 206062-1 206153-1 206062-1 12-98 NOTES 6 MOONEY AIRCRAFT CORPORATION M20J SERVICE AND MAINTENANCE MANUAL 28 VOLT ELECTRICAL EQUIPMENT CHART CODE JK- LS117A JKJK- LS118A LS119A JK- LS129A JK- LS121A JKJKJKJKJKJK- LTI01A LT102A LT103A LT104A MA101A MA102A JKJK- MA103A MA104A JKJKJK- MB101A MB102A MB103A JKJKJKJKJKJKJKJKJKJKJKJKJKJKJKJKJKJKJKJKJKJKJKJKJKJKJKJKJK- MB104A MB105A MB106A MB107A MB108A MB109A MB110A MB111A MB112A MBl13A MB114A MB115A MB116A MBl17A MB118A MBl19A MB120A MB121A MB122A MB128A MB124A MB125A MB126A MB127A MB128A MB129A MB130A MB131A MC102A DESCRIPTION VENDOR PART NO. PLUG, STROBE LIGHT ASSY SOCKET UGHT ASSY, TAIL STROBE RECEPTACLE, 3 PIN PIN RECEPTACLE, 3 PIN PIN RECEPTACLE, 3 PIN PIN AMP AMP MOONEY AMP AMP AMP AMP AMP AMP 1-480303-0 60619-1 470013-501 1-480305-0 60620-1 1-480305-0 60620-1 1.480305-0 60620-1 C/B, TAXl LIGHT SWITCH, TAXI LIGHT BULB, TAXI, R/W (28V) BULB, TAXI, L/W (28V) RECEPTACLE, AUX POWER RELAY, AUX POWER (ALT) DIODE DIODE (ALl') (ALT) C/B, AVIONICS MASTER RELAY, AVIONICS MASTER DIODE (ALT) (ALT) AVIONICS BUS BAR #1 AVIONICS BUS BAR #2 AVIONICS BUS BAR #3 C/B, INTERCOM C/B, COM 1 C/B, NAV 1 C/B, AUDIO C/B, PHONE C/B, ADF C/B, COM 2 C/B, NAV 2 C/B, TRANSPONDER C/B, ENCODER C./B,STERO C/B, DME C./B,R/NAV C/B, STORMSCOPE C/B, LORAN C/B, RMI C/B, AUTOPILOT/TRIM C/B, NP ALERT C/B, INVERTER C/B, ART. HORIZ. C/B, HSI C/B, YAW DAMP. C./B,TELEPHONE ' C/B, VME C/B, RADIO ALT. CIGAR LIGHTER KLIXON MOONEY GE GE 7277-2-25 880052-523 4596 4596 AN2552-SA 6041H202 6041H202A 10H3P 1N2488 i N5060 8720-GE 930023-213 26.64.01 1N2483 1N5060 8720-GE 913127-67 913127-67 913127-87 7277-2-7.5 7277-2-10 7277-2-7.5 7277-2-7.5 7277-2-7.5 7277-2-7.5 7277-2-10 7277-2-7.5 7277-2-7.5 7277-2-7.5 7277-2-7.5 7277-2-7.5 7277-2-7.5 7277-2-7.5 7277-2-7.5 7277-2-7.5 7277-2-107277-2-7.5 7277-2-7.5 7277-2-2 7277-2-2 7277-2-7.5 7277-2-7.5 7277-2-7.5 7277-2-7.5 800336-503 CUTLER-HAMMER CUTLER-HAMMER SARKES-TARZlAN GE MOONEY KISSLING GE MOONEY MOONEY MOONEY KLIXON KLIXON KUXON KLIXON KLIXON KLIXON KLIXON KUXON KLIXON KLIXON KLIXON KLIXON KLIXON KLIXON KUXON KLIXON KLIXON KLIXON KLIXON KLIXON KLIXON KLIXON KLIXON KUXON KUXON MOONEY 12-98 NOTES 7 7 7 7 7 7 7 7 7 7 7 7 7 7 7 7 7 7 7 7 7 7 7 7 7 91-20-03 69 SERVICE AND MAINTENANCE MANUAL M20J MOONEY AIRCRAFT CORPORATION 28 VOLT ELECTRICAL EQUIPMENT CHART CODE DESCRIPTION VENDOR PART NO. JKJK- MC102A ME101A (ALT) CLOCK (OPT) LIGHT TRAY CASCO MID-CONTINENT MID-CONT. MID-CONT. 208292 MD-88L MD-88L (ET) BA28-24-BW2 JK- MIC101A JKJK- MIC102A MIC103A JACK, MICROPHONE WASHERS WASHERS (ALT) SWITCH, MIC KEY, PILOT SWITCH, MIC KEY, CO-PILOT SWlTCHCRAFT SWlTCHCRAFT SWlTCHCRAFT CUTLER-HAMMER CUTLER-HAMMER C-12B S-1028 S-1029 SAIRV20 SAIRV20 JKJKJKJK- MP101A MP102A MP103A MP104A JK- MP105A J-J-- NF101A NF102A -KJK- NF102A NF103A JK- NF104A -K-K-K-K-K- NF105A NF107A NF108A NF108B NF109A -K- NF110A -K- NP101A -K-K-K- NP102A NP103A NP104A JKJKJK-KJK- PA101A PAl 02A PAl 03A PAl 03B PA104A JK- PA105A JK-J-- PA106A 91-20-03 70. PA107A C/B, PROP DE-ICE MOONEY TIMER, PROP DE-ICE B.F. GOODRICH MONITOR,CURRENT, PROP DE-ICE MOONEY PLUG, 9 PIN AMP CLAMP AMP TERMINAL BLOCK McCAULEY 930023-223 3E1899-1 800221-505 206708-1 206966-1 C-40521 C/B, BOOST PUMP PUMP, FUEL BOOST (ALl') PUMP, BOOST PLUG, 4 PIN CLAMP RECEPTACLE, 4 PIN CLAMP C/B, HI BOOST PUMP C/B, LO BOOST PUMP REGULATOR, FUEL PUMP REGULATOR, FUEL PUMP RECEPTACLE, 4 PIN CLAMP PLUG, 4 PIN CLAMP 980023-211 8163B A8163B 10054B 206060-1 206062-1 206153-1 206062-1 930023-219 930023-217 VR-536 DGB-1 206153-1 206062-1 206060-1 206062-1 MOONEY WELDON WELDON WELDON AMP AMP AMP AMP MOONEY MOONEY ELECTRO-DELTA AMER. PROD AMP AMP AMP AMP FUSEHOLDER, PRIMER, DIFFUSER LI']'TEL (ALT) LITTEL FUSE (10A SLO BLO) LI'I-FEL SWITCH, PRIME R CARLING PRIMER, DIFFUSER TCM DIODE (ALE) (ALl') GE 155020 155120 313010 TIGK6B-IF-WH-A 633862-2 1N2483 1N5060 3720-GE C/B, ALTERNATOR, RT C/B, FIELD, RT. ALT SWITCH, ALT. FLD.(OPT) SWITCH, ALT. FLD. (STD) VOLTAGE REGULATOR (ALT) (ALT) RECEPTACLE, 9 PIN CLAMP 'PLUG, 9 PIN 'CLAMP ALTERNATOR (STD) (ALl) 41-3-$34-LN2-041800 7277-2-5 880052-525 880052-503 880270-501 VR-802 DGR-2 206708-1 206966-1 206705-2 206966-1 LW-14367 ALU-6421-LS ETA KLIXON MOONEY MOONEY MOONEY' AUXILEC AM PROD AMP AMP AMP AMP LYCOMING PRESTOLITE 12-98 NOTES 'MOONEY AIRCRAFT CORPORATION M20J SERVICE AND MAINTENANCE MANUAL 28 VOLT ELECTRICAL EQUIPMENT CHART CODE DESCRIPTION VENDOR PART NO. NOTES ( - -K- PA107A JKJK- PA108A PA109A -K-K-K- PAl 10A PAl 11A PAl12A -K-K--K- PA112A PAl 13A -K- PAl 15A -K-K- PAl 16A PAl 17A JK- PAl 18A -K- PAl 19A JK- PA120A JK--KJK- PA121A JK- PA123A JK-- PA124A JKJK- PB101A PB102A JK- PB103A JKJKJKJKJKJKJKJKJKJKJK- PB104A PB105A PB106A PB107A PB108A PB109A PB110A PB111A PB112A PB113A PB114A PAl 14A PA122A PA122A ALTERNATOR (STD) TCM 649280 (ALl') TCM 649172 GEAR ASSY TCM 649123 FILTER MOONEY 880014-501 CAPACITOR MALLORY CGS302U-05OR2C (ALT) MALLORY CGS292U-050R3C C/B ETA 41-3-$34-LN2-041800 C/B KUXON 7277-2-5 VOLTAGE REGULATOR (DUAL) ELECTRODELTA VR-802 (ALT)(DUAL) AM. PROD/PREC.FLT DGR-2 REGULATOR, DUAL ALTERNATOR MOONEY 800270-503 RECEPTACLE, 9 PIN AMP 206708-1 CLAMP AMP 206966-1 PLUG, 9 PIN AMP 206705-2 CLAMP AMP 206966-1 ALTERNATOR (OPT) TCM 649280 (ALT) TCM 649172 GEAR ASSY TCM 649123 FILTER MOONEY 880014:501 CAPACITOR MALLORY CGS302U-050R2C (ALT) MALLORY CGS292U-050R30 SENSOR, CURRENT MICRO CSLA1GE ELEMENT, SENSOR MICRO SS-37126 SENSOR, CURRENT MICRO CSLA1GE ELEMENT, SENSOR MICRO SS-37126 PLUG, 9 PIN AMP 206705-2 CLAMP AMP 206966-1 RECEPTACLE, 9 PIN AMP 206708-1 CLAMP AMP 206966-1 ADPT'R, ANALOG, CUR. SENSOR MOONEY 810088-504 PLUG, 16 PIN AMP 208037-1 CLAMP AMP 206070-1 RECEPTACLE, 16 PIN AMP 206036-3 CLAMP AMP 206070-1 DIODE 1N2483 (AL-F) 1N5060 (ALT) GE 3720-GE BA'I-I-ERY RELAY, BAI-I-ERY (ALT) DIODE (ALT) (ALT SWITCH, MASTER C/B, BA'I-I'ERY C/B BUS BAR #1 BUS BAR #2 BUS BAR #3 BUS BAR #4 BUS BAR#5 .BUS BAR #6 BUS BAR #7 BUS BAR #8 GILL CUTLER-HAMMER CUTLER-HAMMER GE MOONEY ETA ETA MOONEY MOONEY MOONEY MOONEY MOONEY MOONEY MOONEY MOONEY 12-98 10 10 10 G-243 6041H202 6041H202A 1N2483 1N5060 3720-GE 880052-501 41-3-$34-LN2-041800 41-3-S34-LN2-40A 913127-89 913127-75 913127-75 913127-77 913127-77 913127-73 913127-81 913127-77 91-20-03 71 SERVICE AND MAINTENANCE MANUAL M20J MOONEY AIRCRAFT CORPORATION 28 VOLT ELECTRICAL EQUIPMENT CHART CODE JKJKJKJKJ-- PB115A PB116A PBl17A PB120A PB121A J--- PB122A JK- PL201A JK- PL203A JKJK- PL204A PL205A JKJKJKJK- PL.206A PL207A PL208A PL2.09A JK- PI-210A JKJKJK- PL211A PL212A PL216A JK- PL217A JK- PL218A JK- PL.219A JK- PL220A JK- PL221A JK- PL222A JK- PL2.22S JK- PL225A JK- PI-226A JK- PL227A JK- PL228A 91-20-03 72 DESCRIPTION VENDOR PART NO. BUS BAR #9 BUS BAR #10 BUS BAR #11 GROUND/DIMMER BOX PLUG, 3 PIN CLAMP RECEPTACLE, 3 PIN CLAMP MOONEY MOONEY MOONEY MOONEY AMP AMP AMP AMP 913127-75 913127-83 913127-59 800228-501 206037-2 206070-1 206207-1 206070-1 PLUG, 37 PIN CLAMP PLUG, CLAMP PLUG, 26 PIN PLUG, 28 PIN CLAMP PLUG, 20 PIN PLUG, 20 PIN PLUG, 14 PIN PLUG, 9 PIN CLAMP PLUG, 9 PIN CLAMP PLUG, 84 PIN PLUG, 14 PiN PLUG, 16 PIN CLAMP PLUG, 16 PIN CLAMP PLUG, 16 PIN CLAMP PLUG, 28 PIN CLAMP PLUG, 4 PIN CLAMP PLUG, 4 PIN CLAMP PLUG, 9 PIN CLAMP PLUG, 16 PIN CLAMP PLUG, 32 PIN CLAMP SOCKET SOCKET PLUG, 32 PIN CLAMP SOCKET SOCKET PLUG, 6 PIN CLAMP (ALT) . SOCKET SOCKET PLUG, 20 PIN AMP AMP AMP AMP MOONEY AMP AMP MOONEY MOONEY MOONEY AMP AMP AMP AMP MOONEY MOONEY AMP AMP AMP AMP AMP AMP AMP AMP AMP AMP AMP AMP AMP AMP AMP AMP MATRIX SCIENCE MAT/SCI MAT/SCI MAT/SCI MATRIX SCIENCE MAT/SCI MAT/SCI MAT/SCI MATRIX SCIENCE MAT/SCI MAT/SCI MAT/SCI MAT/SCI MOONEY 206150-1 206138-1 206037-1 206070-1 930021-505 205839-3 206070-1 930021-501 930021-501 930021-001 206708-1 206966-1 206708-1 206966-1 930021-507 930021-001 206037-1 206070-1 206037-1 206070-1 206037-1 206070-1 205839-3 206070-1 206060-1 206062-1 206060-1 206062-1 206708-1 206966-2 206037-1 206070-1 M83723/86R2232N M85049/52-1-22N 5100-001-0012 5100-001-0020 M83723/86R2232N M85049/52-1-22N 5100-001-0012 5100-001-0020 MS3106A-28-22S MS3057-16B MS3057-16A 5100-001-0012 5100-001-0020 930021-501 12-98 NOTES - 8 8 8 MOONEY AIRCRAFT CORPORATION M20J SERVICE AND MAINTENANCE MANUAL 28 VOLT ELECTRICAL EQUIPMENT CHART CODE JK- PL229A JKJK- PL230A PL231A JKJK- PL232A PL233A JKJK- PS101A PS102A JK- PS103A J-- PS104A -K- PS104A JKJKJKJK- RB101A RB102A RB102B RB103A JK- RB104A JKJK- RC201A RC203A JKJK- RC204A RC205A JKJKJKJK- RC206A RC207A RC208A RC209A JK- RC210A JKJKJK- RC211A RC212A RC214A JK- RC215A JK- RC220A JK- RC221A JK- RC222A JK- RC222B DESCRIPTION VENDOR PART NO. PLUG, 16 PIN CLAMP PLUG, 14 PIN PLUG, 16 PIN CLAMP PLUG, 14 PIN PLUG, 4 PIN CLAMP AMP AMP MOONEY AMP AMP MOONEY AMP AMP 206037.-1 206070-1 830021-001 206037-1 206070-1 930021-001 206060-1 206062-1 C/B, STARTER SOLENOID SOLENOID, STARTER (ALT) DIODE (ALT) (ALT) STARTER (ALl') STARTER (ALl) KLIXON CUTLER-HAMMER CUTLER-HAMMER GE PRESTOUTE LYCOMING TCM TCM 7277-2-5 6041H202 6041H202A 1N2483 1N5060 3720-GE MHB-4016 LW-15572 646275 637847 C/B, RADIO BLOWER BLOWER, RADIO BLOWER, RADIO FILTER, NOISE (ALl') PLUG, 2 PIN SOCKET KLIXON TRW BENDIX-KING ARCHER SPRAGUE MOLEX MOLEX 7277-2-5 19A2790 KA0033-01 278-103 5JX5104A 03-06-1023 02-06-1103 RECEPTACLE, 37 PIN RECEPTACLE, 3 PIN CLAMP RECEPTACLE, 26 PIN RECEPTACLE, 28 PiN CLAMP RECEPTACLE, 20 PIN RECEPTACLE, 20 PIN RECEPTACLE, 14 PIN RECEPTACLE, 9 PIN CLAMP RECEPTACLE, 9 PIN CLAMP RECEPTACLE, 34 PIN RECEPTACLE, 14 PIN RECEPTACLE, 14 PIN CLAMP RECEPTACLE, 14 PIN CLAMP RECEPTACLE, 4 PIN CLAMP RECEPTACLE, 4 PiN CLAMP RECEPTACLE, 4 PIN , CLAMP RECEPTACLE, 9 PIN CLAMP AMP AMP AMP MOONEY AMP AMP MOONEY MOONEY MOONEY AMP AMP AMP AMP MOONEY MOONEY AMP AMP AMP AMP AMP AMP AMP AMP AMP AMP AMP AMP 206151-2 206036-2 206070-1 930021-506 206152-1 206070-1 930021-502 930021-502 938021-002 206705-2 206966-1 206705-2 206966-1 930021-508 930021-002 206044-1 206070-1 206044-1 206070-1 206153-1 206062-1 206153-1 206062-1 206706-1 206966-1 206037-1 206070-1 12-98 NOTES 91-20-03 73 SERVICE AND MAINTENANCE MANUAL M20J MOONEY AIRCRAFT CORPORATION 28 VOLT ELECTRICAL EQUIPMENT CHART CODE JK- RC225A --JK-- RC226A JK- RC227A JKJK- RC230A RC231A JKJK-JK- RC232A RC233A JKJKJK- SB101A SB102A SB103A JK- SB104A JKJK- SB105A SB106A JK-JK- SB107A JK- SB109A JK- SB110A JKJKJKJKJK- SB111A SB112A SB113A SB114A SB115A JK- SB116A JK- SB117A 91-20-03 74 RC277A SB108A DESCRIPTION VENDOR PART NO. RECEPTACLE, 32 PIN CLAM P PIN PIN BOOT (ALT) RECEPTACLE, 32 PIN CLAMP PIN PIN BOOT (ALT) RECEPTACLE, 6 PIN (ALT) CLAM P (ALl') RECEPTACLE, 14 PIN RECEPTACLE, 16 PIN CLAMP RECEPTACLE, 14 PIN RECEPTACLE, 4 PIN CLAMP RECEPTACLE, AUDIO CLAMP MATRIX SCIENCE MAT/SCI MAT/SCI MAT/SCI MAT/SCI MAT/SCI MAT/SCI MAT/SCI MAT/SCI MAT/SCI MAT/SCI MAT/SCI M83723/83K2232N M85049/52-1-22N 5000-054-0020 5000-054-0012 MS3420-14 MS3420-16 M83723/83K2232N M85049/52-1-22N 5000-054-0020 5000-054-0012 MS3420-14 MS3420-16 MS3100K-28-2P MS3100KE-28-2P MS3057-16B MS3057-16A 930021-002 206036-1 206070-1 930021-002 206060-1 206062-1 206152-1 206070-1 C/B, SPEED BRAKE SWITCH, SPEED BRAKE PLUG, 3 PIN SOCKET RECEPTACLE, 3 PIN PIN RELAY, SPEED BRAKE DIODE (ALT) (ALl-) PLUG, 4 PIN (ALl-) RECEPTACLE, 4 PiN CLAMP PLUG, 8 PIN CLAMP RECEPTACLE, 8 PIN CLAMP MOTOR, LEFT SWITCH, DEPLOY LIMIT SWITCH, RETRACT LIMIT SOLENOID, CLUTCH PLUG, 8 PiN CLAMP RECEPTACLE, 8 PIN CLAMP PLUG, 8 PIN . CLAMP MOONEY AMP AMP MOONEY AMP AMP AMP AMP KUXON PRECISE FLT AMP AMP AMP AMP PRECISE FLT GE AMP AMP AMP AMP AMPM AMP AMP AMP PRECISE PRECISE PRECISE PRECISE AMP AMP AMP AMP AMP AMP 12-98 FLT FLT FLT FLT 7277-2-3 01265 1-380303-0 60619-1 1-380305-0 60820-1 01384 1N2483 1N5060 3720-GE 206060-1 206062-1 206153-1 206062-1 205838-1 206062-1 205841-2 206062-1 01532 01505 01505 01678 205838-1 206062-1 205841-2 206062-1 205838-1 206062-1 NOTES . MOONEY AIRCRAFT CORPORATION M20J SERVICE AND MAINTENANCE MANUAL 28 VOLT ELECTRICAL EQUIPMENT CHART CODE r' DESCRIPTION VENDOR PART NO. RECEPTACLE, 8 P]N CLAMP MOTOR, RIGHT SWITCH, DEPLOY LIMIT SWITCH, RETRACT UMIT SOLENOID, CLUTCH PLUG, 8 PIN CLAMP RECEPTACLE, 8 PIN CLAMP AMP AMP PRECISE FLT PRECISE FLT PRECISE FLT PRECISE FLT AMP AMP AMP AMP 205841-2 206062-1 01582 01505 01505 01678 205838-1 206062-1 205841-2 206062-1 NOTES JK- SB118A JKJKJKJKJK- SB119A SB120A SB121A SB122A SB123A JK- SB124A JKJK- SPK101A SPK102A SPEAKER, CABIN PLUG, 2 PIN SOCKET ARCHER AMP AMP 12-1703 1-480318-0 60618-1 JK- SPK108A RECEPTACLE, 2 PIN PIN AMP AMP 1-480818-0 60620-1 JK- WD101A FUSEHOLDER (ALT) FUSE, 1A MTTEL LII-rEL LITTEL 155020 155120 313001 JKJK- WE101A WE102A J-- WE103A "K-- WE103A JKJK- WE104A WE105A KLIXON SLOAN GE MICRO MICRO MICRO MICRO MALLORY JK- WE106A JKJK- WE107A WE108A JK- WE109A C/B, GEAR WARNING LIGHT, GEAR DOWN BULB SWITCH, THROI-rLE ACTUATOR SWITCH, THROI-rLE ACTUATOR HORN, GEAR WARNING DIODE (ALT) (ALT) DIODE (ALl-) (ALT) RESISTOR PLUG, 4 PIN CLAMP RECEPTACLE, 4PIN CLAMP 7277-2-1 855S-0-U 327 V3-1 JV'5 lSE1-T JE-17 SC628P 1N2483 1N5060 3720-GE 1N2483 1N5060 3720-GE RC42GF102JIK OHM2W 206060-1 206062-1 206153-1 206062-1 JKJK- WP101A WP102A JK- WP106A JKJKJKJK- WS101A WS102A WS103A WS104A JK- WT101A GE GE ALLEN BRADLEY AMP AMP AMP AMP MONITOR, CURRENT, PITOT HEAT MOONEY PLUG, 9 PIN AMP CLAMP AMP FUSEHOLDER LITI'EL (ALT) Lll-FEL FUSE (5A) Lll-rEL 800221-505 206705-2 206966-1 155020 155120 313005 C/B, STALL WARNING HORN, STALL WARN RESISTOR SWITCH, STALL WARN '(ALl') (ALT) KLIXON MALLORY ALLEN BRADLEY SAFE FLIGHT MICRO SWITCH MOONEY 7277-2-1 SC628 RC42GF102J1K OHM2W C46001 V3-2451-D8 800364-507 C/B KUXON 7277-2-2 12-98 9 91-20-03 75 SERVICE AND MAINTENANCE MANUAL M20J MOONEY AIRCRAFT CORPORATION 28 VOLT ELECTRICAL EQUIPMENT CHART CODE J-- WT102A DESCRIPTION VENDOR PART NO. ANNUNCIATOR MOONEY 880048-501 (ALT)(USA) (ALT')(FRANCE) ANNUNCIATOR (ALT) LEGEND (USA) (AL'r) LEGEND (FRANCE) PLUG, 87 PIN CLAMP, RT ANGLE LOCK RETAINER MOONEY MOONEY MOONEY MOONEY MOONEY 880048-601 880048-603 880048-501 880048-805 880048-607 DC-87S DC19977-3 DC51222-1 ANNUNCIATOR (ATS) BULB C/B, VACUUM WARN SWITCH, VACUUM WARN RECEPTACLE, 4 PIN CLAMP MOONEY 880025-521 CHICAGO MINATURE CM-7327 KLIXON 7277-2-2 MOONEY 880012-501 AMP 206153-1 AMP 206062-1 -K- WT102A JK- WT103A JK- W'I'104A JKJKJK- WV101A WV102A WV103A JK- WV104A PLUG, 4 PIN CLAMP AMP AMP 206060-1 206062-1 JK- WWl01A SWITCH, ALTERNATE AIR CHERRY E51-50B NOTES NOTES: 1. USE AN4076-1 ADAPTER. 2. USE WITH FT101/FT101A FUEL FLOW SYSTEM. 3. USE WITH SHADIN FUEL FLOW SYSTEM. 4. SHADIN MODEL NO. INTERFACE WITH II MORROW APOLLO, ARNAV AND NORTHSTAR LORAN SYSTEMS. 5. SHADIN MODEL NO. INTERFACE WITH BENDIX/KING KLN88. 6. USE 1 EACH M885334--21OR M2898 (ALAN BRADLEY) INTERNAL TOOTH LOCKWASHER WITH EACH LIGHT IF NOT SUPPLIED BY SLOAN. 7. MAXIMUM CIRCUIT BREAKER RATING IS SHOWN. AMPERAGE OF INSTALLED CIRCUIT BREAKER IS DETERMINED BY PARTICULAR UNIT INSTALLED. 8. USE MS3420 OR AN3420-14 OR -16 BOOT WITH CONNECTOR. 9. PART OF 800336-501 INSTALLATION. 10. 800270-503 REPLACES SINGLE UNIT VOLTAGE REGULATORS (2 EA) FOR DUAL ALTERNATOR INSTALLATIONS. 91-20-03 76 12-98 MOONEY AIRCRAFT CORPORATION M20J SERVICE AND MAINTENANCE MANUAL 14 VOLT ELECTRICAL EQUIPMENT CHART 91-20-04 - ELECTRICAL SYSTEM HARDWARE CHART - 14 VOLT SYSTEMS S/N 24-1686-14 THRU 24-2999-14 (ATSONLY), MOONEY DRAWING NUMBER 800263 (E7) (Peculiar14 voltcomponentslistedhere - See 91-20-03 for commoncomponents28 voltand 14 volt) ** -ACTUAL USAGE DETERMINED BY MASTER SCHEMATIC - ** CODE DESCRIPTION VENDOR PART NO. NOTES 1414- CF105A CVl06A FLAP ACTUATOR VACUUM PUMP MOONEY AEROSAFE 750105-001 820904-1 14- DB102A TURN CO-ORDINATOR (ALT) U.I. ELEC GYRO 9112 CODE N.9 1394T100-3Z 14- DG102A INSTUMENT MODULE MOONEY 880059-511 14- DM101A HOUR METER HOUR METER IALT) HOBBS 15006 DATCON INSTR CO SG-70 14- DP102A PITOT, HEATED PITOT, HEATED CALT) AERO INSTR. PH502-12 AN5812 14- DT105A INDICATOR, EGT WIRE, LEAD MOONEY ALCOR 660109-008 01-005-78 14141414- EG105A EG110A EGl12A EG114A C/B,ACTUATOR, GEAR RELAY, GEAR UP RELAY, GEAR DOWN ACTUATOR, GEAR ACTUATOR, GEAR (ALT) KLIXON CUTLER-HAMMER CUTLER-HAMMER MOONEY MOONEY 7277-2-15 6041H105A 6041H105A 560254-501 880037-501 14- JM102A MAGNETO BENDIX/SCINTILLA D-4LN2021 14- LB102A BEACON, ROTATING ADAPTER WHELEN WHELEN WRML-12 WRM-65 1414- LC103A LC104A 14- LC105A 14- LC106A 14- LC107A 1414- LC109A LC110A 14- LC111A 14- LC112A 14- LCl13A RESISTOR, DIMMING C5OHM 10W) DALE LAMP HOLDER HH SMITH LAMP GE LAMP HOLDER HH SMITH LAMP GE LAMP HOLDER HH SMITH LAMP GE LAMP HOLDER HH SMITH LAMP GE RESISTOR, DIMMING (5 OHM 10 W) DALE LAMP HOLDER HH SMITH LAMP GE LAMP HOLDER HH SMITH LAMP GE LAMP HOLDER HH SMITH LAMP GE LAMP HOLDER HH SMITH LAMP GE 141414- LL101A LL102A LN102A 14- LN103A 14- LP103A C/B, LANI_ING LIGHT MOONEY LANDING LIGHT GE . LIGHT ASSY, NAV, TAIL (LT WING) MOONEY BU LB WH ELEN LIGHT ASSY, NAV, TAIL (RT WING) MOONEY BULB WHELEN DIMMER CONTROL BOX MOONEY 12-98 RH-10-5 OHM 1930 1816 1930 1816 1930 1816 1930 1816 RH-10-5 OHM 1930 1816 1930 1816 1930 1816 1930 1816 930023-215 4522 800051-505 34-021-2030-85 800051-505 34021-2030-85 800049-503 91-20-04 77 SERVICE AND MAINTENANCE MANUAL M20J MOONEY AIRCRAFT CORPORATION 14 VOLT ELECTRICAL EQUIPMENT CHART CODE DESCRIPTION : VENDOR PART NO. NOTES ! 14- LP105A UGHT, CONSOLE DIAUGHT LAMP GE LIGHT, COMPASS GE LIGHT, COMPASS (ALE) GE GLARESHIELD UGHTS (14 F_A)GE RHEOSTAT, MAP LIGHT (100 OHM) NEWARK KNOB NEWARK RHEOSTAT, MAP LIGHT (100 OHM) NEWARK KNOB NEWARK LIGHTASSY, STROBE/NAV(LWG) WHELEN LIGHT ASSY, STROBE/NAV(R WG) WHELEN 270-1930-0171-702 370 330 930 AVIATION RED 330 09F976 57F2366 99F976 57F2366 A650-PR-D-M-14 A650-PR-D-M-14 14- LP111A 1414- LPl12A LP131A 14- LP182A 1414- LS106A LS111A 141414- MA102A MB102A ME101A RELAY, AUX POWER RELAY, AVIONICS MASTER CLOCK CLOCK (ALl) CONNECTOR, 4 PIN PINS CONNECTOR, 4 PIN (ALT) PINS CUTLER-HAMMER KISSLING MID-CONT. PORSCHE MID-CONT. MID-CONT. PORSCHE PORSCHE 6041HI05A 26.64.21 MD-89 944.641.213.00 6016117 6016125 944.612.217.00 999.652.351.12 14- ME102A 14- NF102A PUMP, BOOST PUMP, BOOST (ALl') WELDON WELDON 8163A A8163A 14- PA104A 14- PA107A 14.: 1414- PB101A PB102A PL204B REGULATORI VOLTAGE (STD) MOONEY 680016-503 REGULATOR, VOLTAGE (ALT) AM. PROD/PREC.FLT DGR-1 REGULATOR, VOLTAGE (ALT) MOONEY 660270-505 ALTERNATOR, (STD) LYCOMING LW-15404 ALTERNATOR (ALE) PRESTOLITE ALY-8420 BATTERY GILL G-35 RELAY, BA"i-IERY CUTLER-HAMMER 6041H105A PLUG, 14 PIN MOONEY 930021-001 1414- PS102A PS104A 1414- RB102A RB102B SOLENOID, STARTER STARTER STARTER (ALT) STARTER (AL-r) BLOWER, RADIO BLOWER, RADIO CUTLER-HAMMER PRESTOLITE PRESTOLITE PRESTOLITE MOONEY KING 6041H105A MZ-4206 MZ-4218 MZ.-4222 810414-501 KA0033-00 14- RC204B RECEPTACLE MOONEY 930021-002 14- WE103A 1414- WP103A WP104A MICRO MICRO MOONEY 14- WPIO5A 14.- WT102B 14- WT103B SWITCH, THROTTLE ACTUATOR ANNUNCIATOR DIODE (ALE) (ALE) DIODE (ALE) (ALE) ANNUNCIATOR BULB (8 EA) .PLUG, 15 PIN SOCKETS V3-1 JV-5 800346-503 1N2483 1N5050 3720-GE 1N2483 1N5060 3720-GE 880025-511 CM7-7330 09-50-3151 06-50-0106 GE GE MOONEY CHICAGO MINA MOLEX MOLEX i 91-20-04 76 12-98 MOONEY AIRCRAFT CORPORATION M20J SERVICE AND MAINTENANCE 14 VOLT ELECTRICAL EQUIPMENT CHART MANUAL RESERVED 12-98 91-20-04 79 SERVICE AND MAINTENANCE MANUAL M20J MOONEY AIRCRAFT CORPORATION 14 VOLT ELECTRICAL EQUIPMENT CHART RESERVED 91-20-04 80 12-98 MOONEY AIRCRAFT CORPORATION M20J SERVICE AND MAINTENANCE MANUAL ELECTRICAL EQUIPMENT CHART J 91-20-05 - ELECTRICAL EQUIPMENT HARDWARE CHART S/N 24-3201, 24-3218 THRU 24-3270 - SCHEMATIC NO. 800304-(J1) (REV. F) S/N 24-3271 THRU 24-3350 - SCHEMATIC NO. 800304-(J2) (REV. S) S/N 24-3251 THRU 24-3373 - SCHEMATIC NO. 800304 (J3) (REV. W) S/N 24-3274 THRU 24-3377 - SCHEMATIC NO. 800304 (J4) (REV. W) S/N 24-3278 THRU 24-3383 - SCHEMATIC NO. 800304 (,.15)(REV. Y) S/N 24-3284 THRU 24-3392 - SCHEMATIC NO. 800304 (JS) (REV. Z) S/N 24-3293 THRU 24-3404 - SCHEMATIC NO. 800304 (J7) (REV. Z) S/N 24-3405 THRU 24-3410 - SCHEMATIC NO. 800304 (,.18)(RE-V.AA) CODE DESCRIPTION VENDOR PART NO. ACT1 ACT2 ACT3 ACT4 ACT5 ACT6 ACTUATOR ACTUATOR ACTUATOR ACTUATOR ACTUATOR ACTUATOR MICRO SWITCH MICRO SWITCH MICRO SWITCH MICRO SWITCH MICRO SWITCH MICRO SWITCH JE-5 JV-5 JV-26 MCD-2711 JE-17 JV-82 AIR101A AIR102A AIR103A AIR103B AIR104A AIR105A SWITCH, A/C COMPRESSOR, A/C EVAP. BLWR (FRT) EVAP. BLWR, (REAR) CONDENSER BLWR SWITCH, A/C PRESS. MOONEY MOONEY MOONEY MOONEY MOONEY MOONEY 880067-501 770028-1 770002-501 770002-503 770016-501 770029-501 BL1 BL6 BL7 BL8 BL9 BULB HOLDER FOR BL1 BULB HOLDER FOR BL.2 BULB (NAV-T/L) BULB (NAV-T/L) BULB (CONSOLE) (ALl) BULB (COMPASS) BULB (POST LIGHT) BULB (ANNUNCIATOR) BULB (ANNUNCIATOR) GE HH SMITH GE HH SMITH WHELEN WHELEN GE GE GE GE CHI, MIN. CHI. MIN. 1818 1930 1816 1930 84-022-8030-85 34-021-2030-85 327 385 327(AV RED) 330 CM7-7730 CM7-7327 BR1 BR2 BR3 BR5 BR7.5 BR10 BR15 BR20 BR25 BR30 BR35 BR40 BR50 BR70 CIRCUIT BREAKER (1A) CIRCUIT BREAKER (2A) CIRCUIT BREAKER (3A) CIRCUIT BREAKER (5A) CIRCUIT BREAKER (7.5A) CIRCUIT BREAKER (10A) CIRCUIT BREAKER (15A) CIRCUIT BREAKER (20A) CIRCUIT BREAKER (25A) CIRCUIT BREAKER (30) CIRCUIT BREAKER (35A) CIRCUIT BREAKER (40A) CIRCUIT BREAKER (50A) CIRCUIT BREAKER (70A) KUXON KLIXON KLIXON KUXON KLIXON KLIXON KLIXON MECH PROD MECH PROD MECH PROD ETA ETA ETA ETA 7277-2-1 7277-2-2 7277-2-3 7277-2-5 7277-2-7.5 7277-2-10 7277-2-15 4200-002-20 4200-002-25 700-001-30 41-2-S14-LN2-35A 41-3-S34-1_N2-40A 41-2-S34-LN2-50A 41-3-S14-LN2-70A KLIXON KUXON KLIXON KLIXON KLIXON KLIXON 7270-5-3 7270-5-7.5 7270-5-8 7270-5-10 7270-5-15 7270-5-25 BI_2 BL3 BL4 BL5 BRSW3 BRSW7.5 BRSW8 BRSW10 BRSW15 BRSW25 . C/B-SWITCH C/B-SWITCH C/B-SWITCH C/B-SWITCH C/B-SWITCH C/B-SWITCH 12-98 NOTES 91-20-05 81 SERVICE AND MAINTENANCE MANUAL M20J MOONEY AIRCRAFT CORPORATION ELECTRICAL EQUIPMENT CHART CODE DESCRIPTION VENDOR PART NO. BS1 RELAY, BASE MAGNACRAFT 70-803 BUS2A BUS2B BUS2C BUS3A BUS3B BUS3C BUS4A BUS4B BUS4C BUS5A BUS5B BUS5C BUS5D BUS6A BUS6B BUS7A BUSSA BUS8B BUSS BAR (2 PLC) BUSS BAR (2 PLC) BUSS BAR ( ) BUSS BAR (3 PLC) BUSS BAR (3 PLC) BUSS BAR (8 PLC) BUSS BAR (4 PLC) BUSS BAR (4 PLC) BUSS BAR (4 PLC) BUSS BAR (5 PLC) BUSS BAR (5 PLC) BUSS BAR (5 PLC) BUSS BAR (5 PLC) BUSS BAR (6 PLC) BUSS BAR (6 PLC) BUSS BAR (7 PLC) BUSS BAR (8 PLC) BUSS BAR (8 PLC) MOONEY MOONEY MOONEY MOONEY MOONEY MOONEY MOONEY MOONEY MOONEY MOONEY MOONEY MOONEY MOONEY MOONEY MOONEY MOONEY MOONEY MOONEY 913127-033 913127-097 913127-099 913127-087 913127-059 913127-073 913127-069 913127-089 913127-005 913127-093 913127-077 913127-085 913127-019 913127-035 913127-079 913127-081 913127-095 913127-083 C1 CAPACITOR MALLORY CGS302V-050R2C CAP1 CAP2 CAP3 CAP, WHITE CAP, BLACK CAP, DUST MICRO SW ALCO SW MATRIX SCIENCE, 15PA90-8W C-22 M83723/60-122RC CB101A BLOWER, DEFROST MOONEY 640317-503 CC101A CCl02A CC103A CC103B CC103C MOTOR, COWL FLAP INDICATOR, COWL FLAP SWITCH, COWL FLAP SWITCH, COWL FLAP (M20J) SWITCH, COWL FLAP MOONEY MOONEY MOONEY MICRO-SWITCH MOONEY 880050-505 880242-505 880052-517 12TW1-10 880052-117 CF101A CF102A OF103A CF108A ACTUATOR, FLAP INDICATOR, TRIM/FLAP INDICATOR, FLAP SWITCH, FLAP MOONEY MOONEY MOONEY C-H 750105-501 800242-501 800242-505 8906K3149 CL03A CL03B CL03C CLAMP 3/14/16128PIN AMP CLAMP 3 PIN AMP CLAMP 3 PIN (ALl') CLAMP 4/8 PIN AMP CLAMP 5 PIN CLAMP 6 PIN CLAMP 9 PIN, LT. CONTROL BOX AMP CLAMF 9 PIN AMP CLAMF 9 PIN /LOCK RETAINER /LOCK RETAINER (ALE) CLAMP, 9 PIN ./LOCK, RETAINER CLAMP, 15 PIN '/LOCK, RETAINER CLAMP, 17 PIN /LOCK, RETAINER CL04A CL05A CL06A CL09A CL09B CL09C --CL09D -CL15A -CL17A -91-20-05 82 12-98 206070-1 M85049-41-4A MS3057-4A MS3057-4B 206062-1 MS3057-6NB MS3057-16A/B 206966-1 P/O 126-222 DE-24657 DE-51224-1 D110278 DE-19977-5 DE51224-1 DA51210-1 DA51220-1 DB51212 DB51221-1 NOTES MOONEY AIRCRAFT CORPORATION CODE DESCRIPTION CL25A -C1..25B -CL25C -CL32A CL32B CL37A CL37B -- i' M20J SERVICE AND MAINTENANCE MANUAL ELECTRICAL EQUIPMENT CHART VENDOR CLAMP, 25 PIN /LOCK, RETAINER CLAMP, 25 PIN /LOCK, RETAINER CLAMP, 25 PIN /LOCK, RETAINER CLAMP, 32 PIN CLAMP, BOOT (ALl') CLAMP, 37 PIN CLAMP, 37 PIN /LOCK, RETAINER PART NO. DB51212 DB51221-1 DB19977-2 DB51221-1 DB-24659 D-20418-2 M85049/52-1-22N MS3420-14 MS3420-16 206138-1 DC19977-3 DC51222-1 CM1 CURRENT MONITOR MOONEY 800221-505 CR101A CR101B CR102A CR103A SWITCH, RUDDER TRIM SWITCH, RUDDER TRIM MOTOR, RUDDER TRIM INDICATOR, RUDDER TRIM MOONEY MOONEY MOONEY MOONEY 880052-519 880052-119 880050-503 800242-503 CT101A CT102A CT103A CT104A SWITCH, ELEV TRIM INDICATOR, ELEV TRIM MOTOR, ELEV TRIM INTERFACE, TRIM MOONEY MOONEY S-TEC MOONEY 930023-233 800242-519 01165-0-T14 800313-501 CV101A CV101B CV102A CV103A CV104A CV1O4B CV105A C/B-SW, STAND-BYVACUUM MOONEY C/B-SW, STAND-BY VAC MOONEY PUMP, STAND-BY VACUUM AEROSAFE PUMP, STAND-BY VACUUM AEROSAFE C/B-SW, STAND-BY VAC MOONEY C/B-SW, STAND-BY VAC MOONEY PUMP/CLUTCH, STAND-BY VAC AIRBORNE 930023-233 930023-343 820904-2 820904-1 930023-247 930023-344 28C214CW-2 DIODE (AL'r) (AL'r) DIODE (AL'r) (ALT) DIODE BRIDGE DIODE BRIDGE GE SARKES-TARZIAN ECG NTE FAGOR FAGOR 1N2483 1N5O6O 3720GE 10H3P 5854 5854 FB50Ol F85006 AMMETER SHUNT (ALl') AMMETER SHUNT (ALT) EMPRO JANCO EMPRO JANCO MLA-7OA-1OOMV 8406-70 MLA-150A-100MV 8406-150 ---- TURN TURN TURN TURN TURN UNITED INSTRUMENTS 9013 CODE N.5 ASTRONAUTICS 303990-028MSC ELECTRO GYRO CORP 1394"['100-3Z UNITED INST. 9114 CODE N.21 UNITED INST. 9112 CODE N.9 -- . PROBE, CYLINDER #1 (ALT) * USE AN4076-1 ADAPTER. D1 --D2 D4 D5 --- DA101A DA101B --- DB101A DB102A DC101A DD101A DD102A COORDINATOR COORDINATOR (ALT) COORDINATOR (ALT) COORDINATOR (ALT) COORDINATOR INDICATOR, O.A.T. O.A.T. PROBE NOTES MOONEY MOONEY 12-98 MS24482-1 AN5546-1" 880059-159 880004-501 91-20-05 83 SERVICE'AND MAINTENANCE MANUAL M20J MOONEY AIRCRAFT CORPORATION ELECTRICAL EQUIPMENT CHART CODE DESCRIPTION VENDOR PART NO. DDIO3A SOCKET, 4 PIN CINCH-JONES S-894-CCT DF101A DF102A DF1O3A DF104A FUEL XMTR, FUEL XMTR, FUEL XMTR, FUEL XMTR, MOONEY MOONEY MOONEY MOONEY" 610242-003 610243-003 610248-001 610242-005 DG101A DG192A DG103A DG104A DG105A IND, INSTRUMENT MODULE MOONEY IND., INSTRUMENT, MODULE MOONEY IND., INSTRUMENT MODULE #1 MOONEY IND., INSTRUMENT MODULE #2 MOONEY IND., INSTRUMENT MODULE MOONEY 880059-507 880059-511 880059-513 880059-505 880059-517 DG106A IND., INSTRUMENT MODULE MOONEY 880059-519 DH101A DH102A PROBE, OIL TEMP PROBE, OIL TEMP MOONEY 880061-501 MS28034-1 DJ101A LH/RH I/B LH O/13 RH O/B LH/RH O/B NOTES --- TRANSDUCER, OIL PRESSURE DRUCK (ALT) (M20M) KULITE (ALT) (M2OJ) KULITE PDCR 821:0862-100 APT-291-1000-100G APT-154-10O0-100PSIG -- TRANSDUCER, FUEL PRESSURE DRUCK (ALT) KULITE PDCR-821-0662-30 APT-158-1000-,30PSIG TRANSDUCER, FUEL PRESSURE DRUCK (ALT) KULITE APT-155-1O00-50D IND., TACH (OPTIONAL) SENSOR, TACH IND., TACH (OPTIONAL) TACH SENSOR TACH SENSOR TACH SENSOR TACH SENSOR INDICATOR, TACHOMETER INDICATOR, TACHOMETER MOONEY B&D B&D MOONEY B&D B&D B&D B&D B& D MOONEY MOONEY 880039-515 0520-003 0400-004 880039-517 0520-006 (SLICK MAGS) 0402-102 0406-003 * (NOTE 3) (BENDIX MAGS) 0402-104 0406-004 * (NOTE 3) 880039-519 880039-523 DK101A DK102A PSID -- PDCR 920-U143 50 i DL101A -DL102A DL103A -DL104A DL104B DL105A DL106A • INSTALLED ON IO-550 ENGINE BY TELEDYNE CONTINENTAL MOTORS. DM101A DM102A DM103A DM104A --- DP101A DP101B DP102A -DP103A -DP104A DP105A 91-29-05 84 HOUR METER HOUR METER HOUR METER (ALE) HOUR METER (ALT) MOONEY MOONEY HOBBS DATCON HOBBS HOBBS 880035-507 880035-505 15006 SG-70 85000 15000 C/B, PITOT HEAT C./B,PITOT HEAT HEATED PITOT (ALT) ' PITOT, HEATED .(ALl") MOONEY MOONEY AERO INSTR 930023-205 930023-605 PH502-24 AN5812-1 PH502-12 AN5812 AERO INSTR PLUG, 2 PIN SOCKET AN3115-1 AN3116-1 12-98 MOONEY AIRCRAFT CORPORATION CODE DESCRIPTION VENDOR PART NO. DR101A " PROBE, TIT MOONEY 880055-503 DT101A DT101B DT102A DT103A IND., EGT IND., EGT SWITCH, EGT, 4 POSITION PROBE, EGT /ALTERNATE TRAY, LIGHT (28VDC) TRAY, LIGHT (14V) ALCOR ALCOR ALCOR MOONEY ALCOR ALCOR ALCOR 46361 OEM-46161 OEM-80825 660110-000 86255 41338 41337 INDICATOR FUEL FLOW INDICATOR FUEL FLOW (OPT) INDICATOR FUEL FLOW (OPT) INDICATOR F/F (GALS) INDICATOR F/F (LBS) (OPT) INDICATOR F/F (GALS)(OPT) INDICATOR F/F (LBS)(OPT) INDICATOR F/F (LITERS)(OPT) INDICATOR F/F (GALS)(OPT) TRANSDUCER, FUEL FLOW (OPTIONAL) TRANSDUCER, F/F MOONEY MOONEY MOONEY SHADIN SHADIN SHADIN SHADIN SHADIN SHADIN MOONEY MOONEY SHADIN 880034-501 880034-503 880034-505 912021 912023 912041 912043 912047 912081 880030-501 880030-503 680501B EG103A EG104A ACTUATOR, LDG GR (ALT) ACTUATOR, LDG GR (ALT) ACTUATOR, LDG GR SWITCH, LDG GR. NS SAFETY MOONEY MOONEY MOONEY MOONEY MOONEY MOONEY 880037-507 560254-503 880037-501 560254-501 560254-505 880013-507 ELT101A ELT102A SWITCH, ELT PANEL TRANSMII-IER, ELT ARTEX ARTEX 110-416 453-0150 F1 F2 F3 F4 FUSE, 1 AMP FUSE, 5 AMP-3AG-SLO-BLO FUSE, 10 AMP SLO-BLO FUSE, 5 AMP LI3-FEL U'REL UI-IEL McGRAW-EDISON 313001 313005 313010 FM01-5A HOLDER, FUSE (ALT) HOLDER, FUSE U'I-FEL LI'FI'EL McGRAW-EDISON 155020 155120 FHN42W PHONE JACK /WASHER /WASHER PHONE JACK /WASHER /WASHER SWlTCHCRAFT SWITCHCRAFT SWlTCHCRAFT SWITCHCRAFT SWlTCHCRAFT SWITCHCRAFT C-11 S-1028 S-1029 C-112B S-1028 S-1029 IGNITION CONTROL CABLE LASAR (SUCK) LASAR CD-1001-02 CH1001-XX BENDIX SCINTILLA BENDIX SCINTILLA BENDIX SCINTILLA JANCO BENDIX SCINTILLA BENDIX SCINTILLA LYCOMING 10-357210-9 10-187-468 10-126656 97-2273-1 D-4LN2021 D4LN-3000 LW-682555-11 -DT104A DT105A DV101A --DV101B -----DV102A -DV102B EG101A -EG102A -/ M20J SERVICE AND MAINTENANCE MANUAL ELECTRICAL EQUIPMENT CHART FH1 -FH2 FON1 --FON2 --JE101A JM101A --JM101B JM102A --- SWITCH, MAGNETO ./PLACARD /TERMINAL LUG SWITCH, MAC. (W/CONN.) MAGNETO (ALT) (ALT) 12-98 NOTES 1 1 1 2 91-20-05 85 SERVICE AND MAINTENANCE MANUAL M20J MOONEY AIRCRAFT CORPORATION ELECTRICAL EQUIPMENT CHART CODE DESCRIPTION VENDOR PART NO. JM103A PLUG, MAGNETO BENDIX SCINTILLA 10-382698 JM104A JM105A JM106A JM107A JM108A JM109A JM110A JM111A JM112A JM112A JM JM MAGNETO MAGNETO, LEFT MAGNETO, RIGHT SWITCH, IGNITION MAGNETO, LH MAGNETO, RH IGNITION, PULSAR MAGNETO, [JR MAGNETO, LH MAGNETO, RH MAGNETO, LH MAGNETO, RH SLICK SLICK SLICK TCM SUCK SUCK MOONEY BENDIX SLICK (LASAR) SLICK (LASAR) SLICK (W/O LASAR) SLICK (W/O LASAR) 6244 6261 6260 10-357240-1 6393 6350 800315-501 $6RN-25-10 CD-4771 CD-4770 4372 (Rev.C) 4370 (Rev.C) L1 1__2 1_3 L4 1_5 L6 L7 L8 L9 L10 Lll L12 BULB, 28V BULB, 14V BULB BULB, 14V BULB BULB BULB BULB BULB BULB (28V) BULB BULB GE GE GE GE CHI. MINI. CHI. MINI. GE GE GE GE GE GE 464-T-3 1/4 168-T-3 1/4 385 330 CM7-7330 CM7-7327 370 1816 327 (AV RED) 327 1818 1495 LB101A LB101B LB102A LB102B LB102C C/B, BEACON, ROTATING MOONEY C/B, BEACON, ROTATING MOONEY UGHT, ROTATING BEACON WHELEN /ADAPTER WHELEN LIGHT, ANTI-COLLISION (RED) WHELEN LIGHT, ANTI-COLUSION (WHITE) WHELEN 930023-243 930023-343 WRML-24 WRML-65 90033-19 90033-20 LENS1 LENS2 LENS3 ANNUNC. LENS (US) ANNUNCIATOR LENS (FRAN) ANNUNCIATOR LENS (US) 880048-613 880048-615 880048-617 LENS4 LENS5 LENS6 ANNUNCIATOR LENS (FRANCE) MOONEY ANNUNCIATOR LENS MOONEY ANNUNCIATOR LENS MOONEY 880048-619 880048-621 880048-623 LG101A LG102A C/B, LOGO LIGHT LIGHT, LOGO MOONEY WHELEN 930023-357 A730-1-28 MOONEY DIALIGHT WHELEN SLOAN 914083-1 270-1930-0171-702 A-350-CN-CL-BK-SH-28 855S-O-U MS35334-21 M2898 0211-128 BA28-24-BW3 1V-192-971 1930 7-05 931-3103) LSL-11-128U -- LH1 LH2 LH3 LH4 LH5 LH6 LH7 LH8 --- ---91-20-05 86 LAMP HOLDER LAMP, HOLDER LAMP HOLDER LAMP HOLDER /WASHER, LOCK, INT. TOOTH /WASHER, LOCK, INT. TOOTH LAMP HOLDER LAMP HOLDER ' LAMP HOLDER LAMP HOLDER (ALT) (ALT) (ALT) MOONEY MOONEY MOONEY ALLEN BRADLEY INSTRUMENTS INSTRUMENTS SIGMATEC HH SMITH LEECRAFT ALLIED SPC 12-98 NOTES MOONEY AIRCRAFT CORPORATION CODE M20J SERVICE AND MAINTENANCE MANUAL ELECTRICAL EQUIPMENT CHART DESCRIPTION VENDOR PART NO. (ALE) NEWARK 81N2561 1-1-19 LAMP HOLDER HH SMITH 1925 LH10 LH11 LH12 LAMP HOLDER WHELEN LAMP HOLDER, COCKPIT UTILITY) TEK-LITE (ALT) LAMP HOLDER, BAGGAGE LT WHELEN 01-0770437-00 LC-28-5 MS1745-51A 01-077-0142-04 LL101A LL101B LL102A LL103A SWITCH, LANDING LT MOONEY SWITCH, LANDING LT MOONEY UGHT, TAXI/LANDING, LH/RH (28V) GE LIGHT, TAXI/LANDING, LH/RH (14V) GE 880052-521 880052-121 4596 4509 LN101A LN101B LN102A C/B, NAV UGHTS C/B,NAV UGHTS UGHT ASSY, WING, NAV-TAIL 930023-251 930023-351 800051-501 LP101A LP102A LP103A LP104A LP105A DIMMER CONTROL BOX (28V/14v) MOONEY (ELECT.) DIMMER CONTROL BOX (28V) MOONEY (RHEOSTAT) DIMMER CONTROL BOX (14V) MOONEY (RHEOSTAT) SWITCH, UGHT ASSY MOONEY INVERTER, PLACARD (O/H) ERG 800299-501 800299-503 800299-505 150085-501 LPS28-3-SP LR101A LR101B LR102A C/B, RECOGNITION LIGHT C/B, RECOGNITION LIGHT RECOGNITION LIGHT 930023-231 930023-331 880049-501 LS101A LS101B LS102A LS102B LS103A LS104A LS105A LS106A C/B, STROBE LIGHT MOONEY C/B, LIGHTS, STROBE MOONEY POWER SUPPLY, STROBE WHELEN POWER SUPPLY, STROBE WHELEN STROBF_JNAVLIGHTASSY (LH/WG) WHELEN STROBE/NAV LIGHTASSY (RH/WG) WHELEN STROBE/TAIL LIGHT ASSY MOONEY POWER SUPPLY (TAIL) WHELEN 930023-237 930023-337 01-0770329-00 01-0770329-01 01-0770054-12 01-0770054-13 470013-501 A413A,HDA,DF-28 LT101A LT101B LT102A SWITCH, TAXI LIGHT SWITCH, TAXI LIGHT TAXI LIGHT LT/RT 880052-523 880052-128 4596 MA101A RECEPTACLE, AUX POWER AN2552-3A MB101A MB101B C/B-SWITCH, AVIONICS MASTER MOONEY C/B-SWITCH, RADIO MASTER MOONEY 930023-213 930023-313 MC101A CIGAR LIGHTER MOONEY 800336-503 ---- CLOCK (ALT) CONN, 4 PIN (ALT) PIN CONN, 4 PIN PIN MID-CONT PORSCHE MID-CONT MID-CONT PORSCHE PORSCHE MD-89 944.541.213.00 6015177 5016125 944.512.217.00 999.652.351.12 --- MICROPHONE JACK /WASHER /WASHER SWITCHCRAFT SWITCHCRAFT SWlTCHCRAFT C-12B S-1028 S-1029 LH8 -- -- ME101A -ME102A MIC1 MOONEY MOONEY MOONEY MOONEY MOONEY MOONEY MOONEY MOONEY G.E. 12-98 NOTES 91-20-05 87 SERVICE AND MAINTENANCE MANUAL M20J MOONEY AIRCRAFT CORPORATION ELECTRICAL EQUIPMENT CHART CODE DESCRIPTION VENDOR PART NO. MP101A MP101B MP102A MP102B MP103A C/B-SW, PROP DE-ICE C/B-SW., PROP. DE-ICE TIMER, PROP DE-ICE TIMER, PROP DE-ICE TERMINAL BLOCK MOONEY MOONEY B.F. GOODRICH McCAULEY McCAULEY 930023-245 930023-345 3E1899-1 B-45018 C-40521 NF101A NF101B NF102A C/B-SW, LOW-BOOST PUMP MOONEY C/B-SW., BOOST PUMP MOONEY PUMP, BOOST WELDON (ALE) WELDON PUMP, BOOST WELDON (ALE) WELDON PUMP, BOOST WELDON PUMP, BOOST WELDON PUMP, BOOST WELDON REGULATOR, FUEL BOOST PUMP MASSEY C/B-SW, HI-BOOST PUMP MOONEY 930023-211 930023-311 A8163B 8163B 8163A A8163A 10054B A10051D A8152-B VR536 930023-219 REGULATOR, VOLTAGE (ALE) (ALE) SWITCH, ALT FLD (DUAL) SWITCH, ALT FLD (SINGLE) ALTERNATOR (ALl') ALTERNATOR (ALE) ALTERNATOR (ALE) \GEAR ASSEMBLY ALTERNATOR /INSTALL KIT (REF 600180) MOONEY AMERICAN PROD ELECTRODELTA MOONEY MOONEY LYCOMING PRESTOLITE LYCOMING PRESTOUTE TCM TCM TCM ELECTRO SYSTEMS LYCOMING 800270-501 DGR-2 VR-802 880052-525 880052-503 LW-14367 ALU-6421-LS LW15404 ALY-8420 649280 649172 649123 ES 4009-LS 05K-21065 PA109A PAl 10A PAl 11A PAl 11B PAl 12A FILTER (ALE) SENSOR, CURRENT REGULATOR, VOLTAGE SENSOR, CURRENT (110 A) SENSOR, CURRENT (175 A) ALTERNATOR (100A) MOONEY MOONEY MICRO SW MOONEY KLIXON KLIXON TCM 880014-501 800307-501 CSLAIGE 800270-503 7235-1-110 7236-1-175 649304 PB101A PB102A PB102B PB103A PB103B PB105A BATi-ERY SWITCH, MASTER SWITCH, MASTER SWITCH, BATTERY SELECT SWITCH, BATTERY SELECT BATrERY GILL MOONEY MOONEY MOONEY MOONEY CONCORDE G-243 880052-501 880052-101 880052-527 880052-127 RG24-11M PL02A PL02B PL02C PL02D PL03A PLUG, 2 PLUG, 2 PLUG, 2 PLUG, 2 PLUG, 3 AMP MOLEX DEAN 1-480318-0 03-06-1023 DEA900020 MS3106A-24-9S 1-380303-0 PL03B PL03C PLUG, 3 PIN ' PLUG, 3 PIN PL03D PL04A PLUG, 3 PIN PLUG, 4 PIN -NF103A -NF104A NF105A NF106A NF108A NF109A PA101A --PA102A PA103A PA104A -PAl 05A -PA106A --PA107A -PAl 08A -- 91-20-05 88 PIN PIN PIN(FEMALE) PIN PIN AMP AMP AMP 12-98 206037-2 MS3106A-10SL-3S MS3106A-28-6P 206060-1 NOTES MOONEY AIRCRAFT CORPORATION CODE M20J SERVICE AND MAINTENANCE MANUAL ELECTRICAL EQUIPMENT CHART DESCRIPTION VENDOR PL04B PL05A PLO6A PLOBA PL09A PL09S PL09C PLQ9D PL09E PL14A PL14B PL140 PL15A PL16A PL17A PL20A PL25A PL25B PI_26A PL28A PL32A PLUG, 4 PIN PLUG, 5 PIN PLUG, 6 PIN MATRIX SCIENCE PLUG, 8 PIN AMP PLUG, 9 PIN AMP PLUG, 9 PIN AMPRENOL PLUG, 9 PIN PLUG, 9 PIN MOLEX PLUG, 9 PIN AMP PLUG, 14 PIN MOONEY PLUG, 14 PIN MOONEY PLUG, 14 PIN AMP PLUG, 15 PIN PLUG, 16 PIN AMP PLUG, 17 PIN PLUG, 20 PIN MOONEY PLUG, 25 PIN = PLUT, 15 PIN AMP PLUG, 26 PIN MOONEY PLUG, 28 PIN AMP PLUG, 32 PIN**** MATRIX SCIENCE ****USE MS3420-14 OR-16 BOOTWITH CONNECTOR. PL,34A PLUG, 34 PIN MOONEY PL.34B PLUG, 84 PIN MOONEY PL37A PLUG, 37 PIN AMP PI_37B PLUG, 37 PIN PS101A PS102A PS103A -PS104A -PS105A R1 R2 R3 R4 R5 R6 R7 C/B, STARTER SOLENOID C/B, STARTER SOLENOID • STARTER (ALl) STARTER (ALT) STARTER KLIXON KLIXON PRESTOL[TE LYCOMING TOM TCM B & C SPECIALITY PART NO. MS3106A-32-17S MS3106A-14S-5S MS3106A-28-22S 2058,38-1 206708-1 126-222 DE-gS 03-06-2092 206485-1 930021-1 930021-513 206043-3 DA15S 206037-1 DBM17W2S 930021-501 DB25S 205208-1 930021-505 205839-3 M83723/86R2232N 930021-507 930021-515 206150-1 DC37S 7277-2-10 7277-2-5 MHJ-4016 LW-15572 646275 537647 BSO206-149 R9 R10 Rll R12 R13 RESISTOR (20 OHM/10W) DALE RESISTOR (50HM/10W) DALE RESISTOR,MAPLIGHT (500 OHM) NEWARK RESISTOR (100 OHM) NEWARK RESISTOR (7.5 OHM) DALE RESISTOR (1K OHM/2VV) ALLEN-BRADLEY RESISTOR (5K OHM) ALLEN BRADLEY (ALl) SELECTROL (ALT) BOURNS (ALl') NEWARK RESISTOR (150 OHM/3W) CLAROSTAT (ALT) OHMITE RESISTOR (3.9K OHM/1/2W) OHMITE RESISTOR (3.0K OHM/1/2W) OHMITE RESISTOR (10HM/25W) DALE RESISTOR (70 OHM/10W) DALE REStSTOR (10.0K OHM/lW) OHMITE RH-10-20 OHM RH-10-5 OHM 919029-501 09F976 RH-50-7.5 OHM RC42-GF102J WA2-G056S502UA 149-11-502 8862C-282-502A 12F9905R 5.0K VC3D 23J N/A N/A RH-25-1 OHM RH-10-70 OHM N/A RB101A . SLOWER, RADIO KING 071-4037-01 AMP DEAN 1-480319-0 DEAg00020 MS3100-24-9P R8 -- RC02A RCO2C RC02D ..... RECEPTACLE, 2 PIN RECEPTACLE, 2 PIN (MALE-) RECEPTACLE, 2 PIN 12-98 .......... NOTES 91-20-05 89 SERVICE AND MAINTENANCE MANUAL M20J MOONEY AIRCRAFT CORPORATION ELECTRICAL EQUIPMENT CHART CODE DESCRIPTION VENDOR PART NO. RC03A RC03B RC03C RC03D RC04A RC04B RC08A RC08A RC09A RC09B RC09C RC09E RC12A RC14A RC14B RC14C RC16A RC16B RC20A RC26B RC28A RC32A RC34A RC34B RC37A RECEPTACLE, 3 PIN RECEPTACLE, 3 PIN RECEPTACLE, 3 PIN RECEPTACLE, 3 PIN RECEPTACLE, 4 PIN RECEPTACLE, 4 PIN RECEPTACLE, 6 PIN RECEPTACLE, 8 PIN RECEPTACLE, 9 PIN RECEPTACLE, 9 PIN RECEPTACLE, 9 PIN RECEPTACLE, 9 PIN RECEPTACLE, 12 PIN RECEPTACLE, 14 PIN RECEPTACLE, 14 PIN RECEPTACLE, 14 PIN RECEPTACLE, 16 PIN RECEPTACLE, 16 PIN RECEPTACLE, 20 PIN RECEPTACLE, 26 PIN RECEPTACLE, 26 PIN RECEPTACLE, 32 PIN RECEPTACLE, 34 PIN RECEPTACLE, 34 PIN RECEPTACLE, 37 PIN AMP AMP AMP 1.-480305-0 206036-2 206207-1 MS8100-28-6S 206153-1 MS3100-32-17P MS3100C-28-22P 205841-2 206705-2 208705-1 DEgP 205486-1 03-06-2122 930021-2 203540-1 206044-1 206037-1 206036-1 930021-502 930021-506 206152-1 M83723/83K2232N 930021-508 204814-1 206151-1 RL1 ---RL2 RL3 RL4 RL5 --RL6 RL7 RL8 RL9 R10 --SA101A RELAY, BATT. (28V/200A) (ALE) (ALE) (ALE) RELAY, BAN'. (14V/200A) RELAY RELAY RELAY, LDG. (28V/50A) (ALT) /BRACKET (2 E.A) RELAY (28V/100A) RELAY, (14V/200A) RELAY RELAY RELAY SOCKET TERMINAL AMP MATRIX SCIENCE AMP AMP AMP AMP MOLE)( MOONEY AMP AMP AMP AMP MOONEY MOONEY AMP MATRIX SCIENCE MOONEY AMP AMP C-H C-H KISSLING KISSLING C-H KISSLING KISSUNG C-H KISSLING MOONEY C-H C-H MAGNACRAFT . KISSLING P&B P& B P& B SA102A ALTERNATOR, STAND-BY HOUSING, CONNECTOR TERMINAL (1/4") CONTROLLER, STBY. ALT. B& B& B& B& SB101A SB102A SS103A C/B, SPEEDBRAKE SWITCH, CONTROLWHL RELAY, SPEEDBRAKE KLIXON PRECISE FLT PRECISE FLT 72T'/-2-3 01265 01384 GE PRECISE FLT PRECISE FLT 1N2483 1N5060 3720-GE 01532 01505 SB104A --SB105A SB106A 91-20-05 9O . DIODE (ALE) (ALT) MOTOR, SPEEDBRAKE SWITCH, SPEEDBRAKE 12-98 C C C C 6041H-202 6041H-202A 26.57.01 26.57.02 6041H-105A 26.64.01 26.64.21 6041H-220 26.72.03 800375-001 6041H-53 6041H-105R W67RCSX-3 28.08.01 VF4-15-H11 VCF4-1002 26A1348C BC410-1 12-003 14-026 BC203-2 NOTES MOONEY AIRCRAFT CORPORATION M20J SERVICE AND MAINTENANCE MANUAL ELECTRICAL EQUIPMENT CHART CODE DESCRIPTION VENDOR PART NO. SB107A SB108A SOLENOID, CLUTCH INTERFACE, SPEEDBRAKE PRECISE FLT MOONEY 01678 800314-501 SPK1 SPK2 SPK3 SPEAKER, ALERT SPEAKER, CABIN SONALERT ARCHER ARCHER MALLORY 40-1338C 40-1325 SC628 SWl SW2 SW3 SW4 SW5 SWITCH SWITCH, DEF. BLWR. SWITCH, LIMIT, RUD.TRIM SWITCH,UP LIMIT, LDG SWITCH, DN UMIT, LDG (ALT) SWITCH, CABIN LTS SWITCH SWITCH, LOG SWITCH, MIC-KEY (ALT) SWITCH, CHT SWITCH, FLAP SWITCH, CABIN LTS(MASTER MICRO CHERRY MICRO MICRO OTFO MICRO CARLING MOONEY C-H ALCO C-H GRAYHILL C-H CARLING 1SE1-T E51-50B V3-1 DT-2R-47 P6-24014 1CH116-6 RC911-VBBOW 580013-507 8906K2875 MPE-106F-C-22-9 SA1RV20 71AD30-02-2-AJN 8908K4731 RA911-VBBOW MICRO MICRO SW14 SWITCH (ALT) /CAP, WHITE (AL'r) SWITCH, F/F MEM. 12TW1-10 15PAg0-sw MS27753-38 7101K SW15 SWITCH, LDG, OVERRIDE NKK SW18 SW19 SW20 SW21 SW22 SW23 SW25 SW35 SWl01A DLB241-W01-L3C/ ATS06M/AT503MB /BUTFON/LOCK RING/LOCK WASHER/HEX NUT (2 EA) (NKK) /SWITCH (ALT) C-H SB1DDX492-2 /LOCK RING C-H 29-761 /LOCK WASHER C-H 16-885 /HEX NUT (2 EA) C-H 15-966-6 SWITCH, VAC. HI/LO MOONEY 880012-501 SWITCH CARLING TILC64-1S-WHFN SW (ALT) TSCHUDIN 504202 LENS TSCHUOIN 464415 BUlB TSCHUDIN 590002 SWITCH MOONEY 880062-501 SWITCH CARLING TIGM64-1S-WHFN SWITCH MS35058-22 SWITCH, MIKE KEY CROUZET 83-450-001 SWITCH, SPDBRK CROUZET 83-452-504 SWITCH ALCO MPE106F SWITCH NKK MB2085SB1W01-EA SWITCH NKK MB2085SB1W01-EA SWITCH, ALT. AIR DOOR (M20J) SAINT ZS-10O9 VR1 VARISTOR GE V47ZAO5 WM101A WM102A MASTER WARNING MASTER WARNING MICRO SWITCH MICRO SWITCH DSK-104-GYR DSB-11-RRRR-LR2 WS101A WS103A ALERT, STALLWARN/GEAR WARN IAI SWITCH, STALL WARNING MOONEY -SW6 SW7 SW8 SW9 -SWl 0 SWl 1 SW12 SWl 3 --- -----SW16 SW17 C&K NOTES 950D0309-000 800364-507 12-98 ; 91-20-05 91 SERVICE AND MAINTENANCE MANUAL M20J MOONEY AIRCRAFT CORPORATION ELECTRICAL EQUIPMENT CHART CODE DESCRIPTION VENDOR PART NO. WT101A WTIO2A WT103A WTIO4A ANNUNCIATOR ANNUNCIATOR ANNUNCIATOR ANNUNCIATOR MOONEY MOONEY MOONEY MOONEY 880048-501 880048-506 880048-507 880048-509 NOTES NOTES: 1. SHADIN MODEL NO. INTERFACE WITH II MORROW APOLLO, ARNAV AND NORTHSTAR LORAN SYSTEMS. 2. 3. SHADIN MODEL NO. INTERFACE WITH BENDIX/KING KLN-88OR KLN90 SERIES. B & D TACH SENSOR'S P/N 0406-004 IS 9/16" DIAMETER FOR BENDIX MAGNETOS. 0406-003 IS 11/16" DIAMETER FOR SLICK MAGNETOS 91-20-05 92 12-98 MOONEY AIRCRAFT CORPORATION M20J SERVICE AND MAINTENANCE MANUAL ELECTRICAL EQUIPMENT CHART RESERVED FOR FUTURE ENTRIES 12-98 91-20-05 93 SERVICE AND MAINTENANCE MANUAL M20J MOONEY AIRCRAFT CORPORATION ELECTRICAL EQUIPMENT CHART i, RESERVED FOR FUTURE ENTRIES 91-20-05 94 12-98 MOONEY AIRCRAFT CORPORATION 91-20-06 M20J SERVICE AND MAINTENANCE MANUAL ELECTRICAL EQUIPMENT CHART - ELECTRICAL SYSTEM HARDWARE CHART - 28 VOLT S/N 24-3411 THRU 24-3420, SCHEMATIC NO. 800383 (J1) (REV. G) S/N 24-3421 THRU 24-3431, SCHEMATIC NO. 800383 (J2) (REV. H) DESCRIPTION VENDOR PART NO. CODE AC101A AC102A AC103A AC103B AC104A AC105A AC106A -AT101A AT102A AT103A AT104.4, AT105A AT106A BR1 SWITCH, AIR COND. COMPRESSOR, AIR COND. BLOWER, EVAP. (FRON_ BLOWER, EVAP. (REAR) BLOWER, CONDENSOR SWITCH, AIR COND. PRESS CONNECTOR, AIR COND CONTACTS MOONEY MOONEY MOONEY MOONEY MOONEY MOONEY CORY COMP. CORY COMP. 880067-501 770028-1 770002-501 770002-503 770016-501 770029-501 CSLT-21PA CB017-5S ACTUATOR, ACTUATOR, ACTUATOR, ACTUATOR, ACTUATOR, ACTUATOR, MICRO SWITCH MICRO SWITCH MICRO SWITCH MICRO SWITCH MICRO SWITCH MICRO SWITCH JE-5 JV-5 JV-26 MCD-2711 JE-17 JV-82 MECH PROD. KLIXON MECH PROD. KLIXON MECH PROD. KLIXON MECH PROD. KLIXON MECH PROD. KUXON MECH PROD. KUXON MECH PROD. KLIXON MECH PROD. MECH PROD. MECH PROD. ETA ETA MECH. PROD. ETA ETA 4200-002-1 7277-2-1 4200-002-2 7277-2-2 4200-002-3 7277-2-3 4200-002-5 7277-2-5 4200-002-7.5 7277-2-7.5 4200-002-10 7277-2-10 4200-002-15 7277-2-15 4200-002-20 4200-002-25 4200-002-30 41-2-S34-LN2-35A 41-3-S34-LN2-40A 700-001-40 41-2-S34-LN2-50A 41-3-S34-LN2-70A MAGNACRAFT 70-303 SWITCH SWITCH SWITCH SWITCH SWITCH SWITCH BR50 B270 CIRCUIT (ALE) CIRCUIT (ALT) CIRCUIT (ALT) CIRCUIT (ALT) CIRCUIT (ALT) CIRCUIT (ALT) CIRCUIT (ALT) CIRCUIT CIRCUIT CIRCUIT CIRCUIT CIRCUIT (ALT) CIRCUIT CIRCUIT BS101A BASE, RELAY BU2A BU2B BU2C BU2D BU2E BU3A BU3B BU3C BU4A SU4B BU4C BU4D BU5A BU5B BU5C BUS BAR (2 BUS BAR (2 BUS BAR (2 BUS BAR (2 BUS BAR (2 BUS BAR (3 BUS BAR (3 BUS BAR (3 BUS BAR (4 ' BUS BAR (4 BUS BAR (4 BUS BAR (4 BUS BAR (5 BUS BAR (5 BUS BAR (5 -BR2 -BR3 -BR5 -BR7.5 -BR10 -BR15 -BR20 BR25 BR30 BR35 BR40 -- BREAKER (1A) BREAKER (2A) BREAKER (3A) BREAKER (SA) BREAKER (7.5A) BREAKER (10A) BREAKER (15A) BREAKER (20A) BREAKER (25A) BREAKER (30A) BREAKER (35A) BREAKER (40A) BREAKER (50A) BREAKER (70A) PLC) PLC) PLC) PLC) PLC) PLC) PLC) PLC) PLC) PLC) PLC) PLC) PLC) PLC) PLC) MOONEY MOONEY MOONEY MOONEY MOONEY MOONEY MOONEY MOONEY MOONEY MOONEY MOONEY MOONEY MOONEY MOONEY MOONEY 12-98 NOTES 913127-33 913127-97 913127-99 913127-75 913127-65 913127-87 913127-59 913127-73 913127-69 913127-89 913127-5 913127-53 913127-93 913127-77 913127-85 91-20-06 95 SERVICE AND MAINTENANCE MANUAL M20J MOONEY AIRCRAFT CORPORATION ELECTRICAL EQUIPMENT CHART CODE DESCRIPTION VENDOR PART NO. BU5D BU6A BU6B BUTA BUSA BUS BAR (5 PLC) BUS BAR (6 PLC) BUS BAR (6 PLC) BUS BAR (7 PLC) BUS BAR (8 PLC) MOONEY MOONEY MOONEY MOONEY MOONEY 913127-19 913127-35 913127-79 913127-81 913127-95 BW3 BW7.5 BW10 BW15 SW25 SWITCH, SWITCH, SWITCH, SWITCH, SWITCH, KUXON KLIXON KUXON KLIXON KLIXON 7270-5-3 7270-5-7.5 7270-5-10 7270-5-15 7270-5-25 CA101A CA102A CAPACITOR CAPACITOR (1000 PF') MALLORY NEWARK CGS302V050R2C 18F2711 TYPE 5GAD10 CB101A BLOWER, DEFROSTER MOONEY 640317-503 CC101A CC102A CC103A CC103B CC103C MOTOR, COWL FLAP INDICATOR, COWL FLAP SWITCH, COWL FLAP SWITCH, COWL FLAP (J) SWITCH, COWL FLAP MOONEY MOONEY MOONEY MOONEY MOONEY 880050-505 800242-505 880052-517 12TW1-10 880052-117 CF101A CF102A CF103A CF104A ACTUATOR, FLAP INDICATOR, TRIM/FLAP INDICATOR, TRIM/FLAP INDICATOR, TRIM/FLAP MOONEY MOONEY MOONEY MOONEY 750105-501 800242-501 800376-501 800391-502 CL03A CL03B CL03C CLAMP, 3,14,16,28 PIN CLAMP, 3 PIN CLAMP, 3 PIN (ALT) CLAMP, 4, 8 PIN CLAMP, 4 PIN CLAMP, 5 PIN (ALT) CLAMP, 5 PIN (ALT) CLAMP, 7 PIN CLAMP, 9 PIN CLAMP, 9 PIN CLAMP, 9 PIN RETAINER, LOCK (ALE) RET. LOCK (ALT) RET. LOCK CLAMP, 9 PIN RETAINER, LOCK CLAMP, 15 PIN LOCK RETAINER CLAMP, 15 PIN (ALT) CLAMP, 17 PIN LOCK RETAINER CLAMP, 25 PiN • LOCK RETAINER CLAMP, 25 PIN LOCK RETAINER CLAMP, 25 PIN LOCK RETAINER CLAMP, 32 PiN AMP 206070-1 M8049-41-4A MS3057-4A MS3057-4B 206052-1 10-101971-8-3 MS3057-TA MS3057-6B MS3057-16A MS3057-16B MS3057-12B 206966-1 P/O 126-222 DE-24657 DE 51224-1 Dl10278 D-20419-16 DE-19977-5 DE-51224-1 DA51210-1 DA51220-1 DA19977-1 DB51212 DB51221-1 DB51212 DB51221-1 DB19977-2 DB51221-1 DB24659 D-20418-2 M85049/52-1-22N CL04A CL04D CL05A CL06A CL07A CL09A CL09B CL09C ---CL09D CL15A -CL17A CL25A CL25B CL25C CL32A 91-20-06 96 C/B C/B C/B C/B C/B (3A) (7.5A) (10A) (15A) (25A) AMP BENDIX AMP AMP 12-98 NOTES MOONEY AIRCRAFT CORPORATION CODE DESCRIPTION CL32B -CL37A CL37B M20J SERVICE AND MAINTENANCE MANUAL ELECTRICAL EQUIPMENT CHART -- VENDOR CLAMP/BOOT (ALT) CLAMP, 37 PIN CLAMP, 37 PIN LOCK RETAINER PART NO. MS3420-14 MS3420-16 206138-1 DC19977-3 DC51222-1 CM 101A CURRENT MONITOR CR101A CR101B CR102A CR103A SWITCH, RUDDER TRIM (WHITE) MOONEY SWITCH, RUDDER TRIM (BLACK) MOONEY MOTOR, RUDDER TRIM MOONEY INDICATOR, RUDDER MOONEY 880052-519 880052-119 880050-503 800242-503 CT101A CT102A CT103A CT104A CT105A SWITCH, TRIM INDICATOR, ELEV. TRIM MOTOR, ELEV. TRIM TRIM INTERFACE INDICATOR, ELEV. TRIM 930023-233 800242-519 01165-0-T14 800313-501 800391-501 CV101A CV101B CV102A CV103A CV104A CV104B CV105A CIRCUIT BREAKER/SWITCH MOONEY CIRCUIT BREAKER/SWITCH MOONEY PUMP, STAND-BY VACUUM AEROSAFE PUMP, STAND-BY VACUUM AEROSAFE SWITCH/O-B, STAND-BY VACUUM MOONEY SWITCH/C-B, STAND-BY VACUUM MOONEY PUMP/CLUTCH ASSY, STDBY VAC. AIRBORNE 930023-233 930023-333 820904-2 820904-1 930023-247 930023-347 28C214-CW-2 SHUNT, AMMETER (ALT) SHUNT, AMMETER (ALr) EMPRO JANCO EMPRO JANCO MLA-7OA-10OMV 8406-70 MLA-150A-100MV 8406-150 TURN COORDINATOR (ALT) (ALl) (ALT) TURN COORDINATOR UI ASTRONAUTICS ELEC. GYRO CORP. UI UI 9013 CODE N.5 303990-028MSC 1394T100-3Z 9114 CODE N.21 9112 CODE N.9 PROBE, CHT (ALl) (ALl) NORWICH MS24482-1 AN5546-1 102-00007 DD101A DD102A DD103A INDICATOR, OAT PROBE, OAT SOCKET, 4 PIN MOONEY MOONEY CINCH-JONES 880059-159 860004-501 S-304-CCT DF101A DF102A DF103A DF104A DF105A DF106A DF107A DF108A DF109A DF110A DF111A XMTR, FUEL, INBD, LH/RH XMTR, FUEL, OUTBD, LH XMTR, FUEL, OUTBD, RH XMTR, FUEL, OUTBD, LH/RH XMTR, FUEL FLOAT/ARM, RH I/B FLOAT/ARM, RH O/B FLOAT/ARM, LH I/B FLOAT/ARM, LH O/B TRANSDUCER PROCESSOR MOONEY MOONEY MOONEY MOONEY AVAQ AVAQ AVAQ AVAQ AVAQ AVAQ AVAQ 610242-3 610243-3 61024.3-1 610242-5 9450563001 9400563102 9400563104 9400563101 9400563103 9450563002 9450563303 DA101A -DA101B -DB101A DB102A ---- DC101A --- NOTES MOONEY MIL-S-9419 MOONEY S-TEC MOONEY MOONEY 12-98 800221-505 91-20-06 97 SERVICE AND MAINTENANCE MANUAL M20J MOONEY AIRCRAFT CORPORATION ELECTRICAL EQUIPMENT CHART CODE DESCRIPTION VENDOR PART NO. DG101A DG102A DG103A DG104A DG105A DG106A DG107A DG108A DG109A DG110A DG111A DG112A DG113A DG114A DGl15A MODULE INSTRUMENT MODULE INSTRUMENT MODULE INSTRUMENT, #1 MODULE INSTRUMENT, #2 MODULE INSTRUMENT MODULE INSTRUMENT MODULE INSTRUMENT, #1 MODULE INSTRUMENT, #2 MODULE INSTRUMENT CLUSTEF_,-D/A CLUSTEI_, D/A CLUSTEF_ DIGITAL CLUSTEF DIGITAL CLUSTEF , D/A CLUSTEI_ DIGITAL MOONEY MOONEY MOONEY MOONEY MOONEY MOONEY MOONEY MOONEY MOONEY MOONEY MOONEY MOONEY MOONEY MOONEY MOONEY 880059-507 880059-511 880059-513 880059-515 880059-517 880059-519 880059-523 880059-525 880059-521 880093-501 •880093-503 880093-505 880093-507 880093-509 880093-511 DH101A DHIO2A PROBE, OILTEMP PROBE, OIL TEMP MOONEY 880061-501 MS28034-1 DIIOIA DIODE (ALT) DIODE (ALT) (ALT) BRIDGE, DIODE BRIDGE, DIODE DI102A --DI104A DI105A DJIO1A DJIO1B DKIOIA -DK102A -DL101A DL102A DLIO3A DL104A DL104B DLI04C DL104D DL105A DL106A DL107A DL108A DM101A DM102A DM103A DM104A 91-20-06 98 NOTES EGG NTE FAGOR FAGOR 1N2483/1N5060 3720-GE 10H3P 5854 5854 FB5001 FB5006 XDCR, OIL PRESS (ALT) (M2OJ) (ALT) XDCR, OIL PRESS (M2OM) DRUCK KUUTE PATRIOT KULITE PDCR 821-0662-100 APT-154-1000-100PSlG KA21-014-100G APT-201-1000-100G XDCR, FUEL PRESS (ALE) XDCR, FUEL PRESS (ALT) (ALT) DRUCK KULITE DRUCK KULITE PATRIOT PDCR-821-0662-30 APT-153-1000-30 PSIG PDCR-920-U143-50 PSID APT-155-1000-50D KA21-016-50D TACHOMETER (OPTIONAL) SENSOR, TACH TACHOMETER (OPTIONAL) SENSOR, TACH SENSOR, TACH SENSOR, TACH SENSOR, TACH TACHOMETER TACHOMETER SENSOR, TACH SENSOR, TACH MOONEY B&D B&D MOONEY B&D B&D B&D B&D B&D MOONEY MOONEY J-P INSTR. J-P INSTR. 880039-515 0520-003 0400-004 880039-517 0520-006 0402-102 0402-104 0406-004 0406-003 880039-519 880039-523 420809 420807 MOONEY MOONEY HOBBS DATCON HOBBS HOBBS 880035-507 880035-505 15006 SG-70 85000 15000 HOUR . HOUR HOUR (ALT) HOUR (AI_T) METER METER METER METER GE (SLICK) (BENDIX) (BENDIX) (SLICK) (SLICK) (BENDIX) 12-98 MOONEY AIRCRAFT CORPORATION M20J SERVICE AND MAINTENANCE MANUAL ELECTRICAL EQUIPMENT CHART CODE DESCRIPTION VENDOR PART NO. DP101A DP101B DP101C DP102A C/B C/B C/B P]TOT, HEATED (ALT) PITOT, HEATED (ALT) PLUG SOCKET MOONIEY MOONEY MOONEY AERO INSTR 930023-205 930023-305 930023-353 PH502-12 AN5812 PH502-12 AN5812 AN3115-1 AN3116-1 DR101A DR101B PROBE, TIT PROBE, TIT MOONEY MOONEY 880055-503 880055-505 DT101A DT101B DT102A DT103A INDICATOR, EGT INDICATOR, EGT SWITCH, EGT (4 POSITION) PROBE, EGT (AL'F) LIGHT TRAY (28V) UGHT TRAY (14V) ALCOR ALCOR ALCOR MOONEY ALCOR ALCOR ALCOR 46361 OEM-46161 OEM-80825 660110-000 86225 41338 41337 TRANSDUCER, MAP (ALT) (ALE) KULITE PATRIOT PATRIOT APT-231-100O-25A KA21-015-25A SP100-110-25A INDICATOR, FUEL FLOW (OPTIONAL) (OPTIONAL) INDICATOR, FUEL FLOW TRANSDUCER, FUEL FLOW (OPTIONAL) TRANSDUCER, FUEL FLOW MOONEY MOONEY MOONEY SHADIN MOONEY MOONEY SHADIN 880034-501 880034-503 880034-505 912041TD 880030-501 880030-503 680591B ACTUATOR, LDG (ALl') (ALl-) ACTUATOR, LDG (ALl') ACTUATOR, LDG SWITCH, AIRSPEED MOONEY MOONEY MOONEY MOONEY MOONEY MOONEY MOONEY 880037-507 560254-503 560254-507 880037-501 560254-501 560254-505 880013-507 SWITCH, ELT PANEL TRANSMITTER, ELT CABLE ASSY, REMOTE REMOTE UNIT ASSY (OPTIONAL) MAIN UNIT ASSY. ARTEX ARTEX AMERI-KING AMERI-K1NG AMERI-KING AMERI-KING 110-416 453-0150 4500041 450004 450004-1V/-1H AK-450 FUSE HOLDER (ALl') FUSE HOLDER LITTEL FUSE LI'I-rEL FUSE McGRAW EDISON 155020 155129 FHN42W JACK, PHONE WASHERS 'JACK, PHONE WASHERS SWITCHCRAFT SWITCHCRAFT SWlTCHCRAFT SWlTCHCRAFT C-11 S-1028/S-1029 C-112B S-1028/S-1029 -DP103A DP104A DP105A -- -DT104A DT105A DU105A --DV101A --DV101B DV102A -DV102B EG101A --EG102A -EG103A EG104A ET101A ET102A ET103A ET104A ET105A -- FH101A FH102A -- FN101A --FN102A -- AERO INSTR 12-98 NOTES 1 91-20-06 99 SERVICE AND MAINTENANCE MANUAL M20J MOONEY AIRCRAFT CORPORATION ELECTRICAL EQUIPMENT CHART CODE DESCRIPTION VENDOR PART NO. FU101A FU102A FU103A FU104A FU105A FU106A FUSE FUSE FUSE FUSE FUSE FUSE LITTEL LITTEL LI1-FEL McGRAW-EDISON McGRAW-EDISON LITTEL 313001 313005 313010 FM01-5A FM01-.50A JE101A JE102A JE103A JE104A CONTROL, IGNITION CABLE MAGNETO, LEFT MAGNETO, RIGHT LASAR (SLICK) LASAR (SLICK) SLICK (LASAR) SLICK (LAZAR) CD-1001-02 CH-1001-XX CD-4771 CD4770 JM101A (1 AMP) (5 AMP - 3AG-SLO-BLO) (10 AMP, SLO-BLO) (5 AMP) (0.5 AMP) (2 A MP) swITcH, IGNITION BENDIX SCINTILLA /PLACARD BENDIX SCINTILLA /LUG, TERMINAL BENDIX SCINTILLA SWITCH, IGNITION (INCL CONN.) JANCO MAGNETO BENDIX SCINTILLA (ALT) BENDIX SCINTILLA (ALT) LYCOMING PLUG, MAGNETO BENDIX SCINTILLA MAGNETO SLICK MAGNETO, LEFT SLICK MAGNETO, RIGHT SUCK SWITCH, IGNITION BENDIX-SCINTILLA MAGNETO, LEFT SLICK MAGNETO, RIGHT SUCK IGNITION, PULSAR MOONEY MAGNETO, L & R TCM/BENDIX MAGNETO, L & R TCM MAGNETO, L & R (OPT.) BENDIX 10-357210-9 10-187-468 10-126656 97-2273-1 D4LN2021 D4LN3000 LW-682555-11 10-382698 6224 6261 6260 10-357240-1 6393 6350 800315-501 10-79020-10 640896-1 10-79020-120 LA101A LA102A LA103A LA104A LA105A LA106A LA107A LA108A LA109A LA110A LA111A LA112A LA113A LA114A LA115A LIGHT BULB, 28V LIGHT BULB, 14V LIGHT BULB LIGHT BULB UGHT BULB UGHT BULB LIGHT BULB LIGHT BULB LIGHT BULB LIGHT BULB UGHT BULB LIGHT BULB UGHT BULB LIGHT BULB LED 400 168-T-3 1/4 385 330 CM7-7330 CM7-7327 370 1816 AVIA. RED, 327 327 1818 1495 4596 P26028 351-0003 LB101A LB101B LB102A LB102B LB102C C/B-SW, BEACON, WHITE MOONEY C/B-SW, BEACON, BLACK MOONEY BEACON, ROTATING WHELEN /ADAPTER WHELEN LIGHT, ANTI-COLLISION (RED) WHELEN UGHT, ANTI-COLLISION 0NHITE) WHELEN 930023-243 930023-343 WRML-28 WRML-65 90033-19 90033-20 LC101A CONTROL BOX, UGHT 800268-509 --JM101B JM102A --JM103A JM104A JM105A JM106A JM107A JM108A JM109A JM110A JM111A JM113A -- -- 91-20-06 100 GE GE GE GE CHICAGO MINI CHICAGO MINI GE GE GE GE GE GE GE PACIFICPREC.PROD MOUSER MOONEY 12-98 NOTES MOONEY AIRCRAFT CORPORATION M20J SERVICE AND MAINTENANCE MANUAL ELECTRICAL EQUIPMENT CHART CODE DESCRIPTION LE101A LE102A LE103A LE104A LE105A LE106A LE107A LE108A LE109A LEl10A LE111A LE112A LE113A LEl14A LE115A LE116A LE117A LE119A LENS, ANNUNC. (US) (M20J) MOONEY LENS, ANNUNC. (FRANCE) (M20J) MOONEY LENS, ANNUNC. (US) (M20M) MOONEY LENS, ANNUNC. (FRANCE) (M20M) MOONEY LENS, ANNUNC. (M20T) MOONEY LENS, ANNUNC. (M2OT) MOONEY LENS, ANNUNC. (US) (M20J) MOONEY LENS, ANNUNC. (FRANCE) (M20J) MOONEY LENS, ANNUNC. (US) (M20R) MOONEY LENS, ANNUNC. (FRANCE) (M20R) MOONEY LENS, ANNUNC. (US) (M20R) MOONEY LENS, ANNUNC. (FRANCE) (M20R) MOONEY LENS, ANNUNC. (US) (M20K) MOONEY LENS, ANNUNC. (US) (M20K) MOONEY LENS, ANNUNC. (M2OK) MOONEY LENS, ANNUNC. SLOANE LENS, ANNUNC. (M20J) MOONEY LENS, MASTER WARN MOONEY 880048-613 880048-615 880048-617 880048-619 880048-621 880048-523 880044-633 880044-635 880048-625 880048-627 880048-629 880048-631 880048-605 880048-607 880089-001 855-SE-C 880089-003 150080-6097 LG101A LG102A CIRCUIT BREAKER, LOGO LIGHT MOONEY LIGHT, LOGO WHELEN 930023-357 A730-1-28 LH101A LH102A LH103A LH104A LH105A LH106A LH107A LH108A MOONEY DIAUGHT WHELEN SLOAN INSTRUMENTS INSTRUMENTS SIGMA-TEC HH SMITH LEECRAFT ALLIED SPC NEWARK HH SMITH WHELEN TEK-LITE LH112A LH113A LAMP HOLDER LAMP HOLDER LAMP HOLDER LAMP HOLDER LAMP HOLDER LAMP HOLDER LAMP HOLDER LAMP HOLDER (ALl-) (ALr) (ALT) (ALl') LAMP HOLDER LAMP HOLDER LAMP HOLDER (ALE) LAMP HOLDER LAMP HOLDER WHELEN MOUSER 914083-1 270-1930-0171-702 A-350-CN-CL-BK-SH-28 855S-O-U 0211-128 BA28-24-BW3 1V-192-971 1930 7-05 931-3103 LSL-11-128U 81N2561 1925 01-0770437-00 LC-28-5 MS1745-51A 01-077-0142-04 351-0003 LL101A LL101B LL102A LL103A SWITCH, LDG LIGHT SWITCH, LDG LIGHT BULB, LIGHT, LDGfFAXl BULB, LIGHT, LDG/TAXl MOONEY MOONEY GE GE 880052-521 886052-121 4596 4509 LN101A LN101B LN102A LN102A CIRCUIT BREAKER C/B LIGHT, NAV. (TAIL) UGHT, NAV. (TAIL) MOONEY MOONEY MOONEY MOONEY 930023-251 930023-351 800051-501 800051-509 LP101A LP102A LP103A LP104A LP105A DIMMER, BOX DIMMER, CONTROL BOX . DIMMER, CONTROL BOX SWITCH, O/H LIGHT ASSY _INVERTER,E-L PLACARD MOONEY MOONEY MOONEY MOONEY ERG 800299-501 800299-503 800299-505 150085-005 LPS28-3-3P ----LH109A LH11OA LH111A -- VENDOR 12-98 PART NO. NOTES 2 91-20-06 101 SERVICE AND MAINTENANCE MANUAL M20J MOONEY AIRCRAFT CORPORATION ELECTRICAL EQUIPMENT CHART CODE DESCRIPTION VENDOR PART NO. LR101A LR101B LR102A C/B C/B LIGHT, RECOGNITION MOONEY MOONEY MOONEY 930023-231 930023-331 880049-501 LS101A LS101B LS102A LS102B LS103A LS104A LS105A LS106A CIRCUIT BREAKER CIRCUIT BREAKER POWER SUPPLY, STROBE POWER SUPPLY, STROBE LIGHT, STROBE-LT WING LIGHT, STROBE-RT WING LIGHT, STROBE, TAIL LIGHT, STROBE, DUAL MOONEY MOONEY WHELEN WHELEN WHELEN WHELEN MOONEY WHELEN 930023-237 930023-337 01-0770329-00 01-0770329-01 01-0770054-12 01-0770054-13 470013-501 A413A-HDA-CF LT101A LT101B LT102A SWITCH, TAXI LIGHT SWITCH, TAXI LIGHT BULB, LIGHT, TAXI, LH & RH MOONEY MOONEY GE 880052-523 880052-123 4596 MA101A RECEPTACLE, AUX. POWER (ALT) AN2552-3A MS3503-1 MB101A MB101B C]I_SWlTCH, RADIOMASTER(WriT) MOONEY C/B-SWITCH,RADIO MASTER (BLK) MOONEY 930023-213 930023-313 MO101A MC102A MC103A LIGHTER, CIGAR CAP & TETHER LIGHTER, SOCKET (ALT) w/WIRE MOONEY CASCO CASCO CASCO 800336-503 216550 216510 200402 ---- CLOCK (ALT) CONNECTOR, 4 PIN PINS (OPT) (OPT) PINS MID-CONT. PORSCHE MID-CONT MID-CONT PORSCHE PORSCHE MD-89 944.641.213.00 6016177 6016125 944.612.217.00 999.652.351.12 --- JACK, MICROPHONE WASHERS WASHERS SWlTCHCRAFT SWlTCHCRAFT SWlTCHCRAFT C-12B S-1028 S-1029 -- --ME101A -MIE102A MK101A MP101A MP101B MP102A MP102B MP103A C/B-SW, PROP DE-ICE (WHITE) MOONEY C/B-SW, PROP DE-ICE (BLK) MOONEY TIMER, PROP DE-ICE BF GOODRICH TIMER, PROP DE-ICE McCAULEY TERMINAL BLOCK McCAULEY 930023-245 930023-345 3E1899-1 B-45018 C-40521 NF101A NF101B NF102A SW/C-B, LOW BOOST FUEL PUMP MOONEY SW/C-B MOONEY PUMP, FUEL BOOST WELDON (ALT) WELDON PUMP, FUEL BOOST WELDON (ALT) WELDON PUMP, FUEL BOOST (M20K) WELDON PUMP, FUEL BOOST WELDON PUMP, FUEL BOOST WELDON '(ALT) MASSEY REGULATOR, FUEL PUMP MOONEY SW/C-B, HI-BOOST FUEL PUMPMOONEY GUARD ASSY, HI-BOOST SW. MOONEY 930023-211 930023-311 A8163B 8163B 8163A A8163A 10054B A10051-D A8152-B VR536 800270-523A 930023-219 930028-501 -NF103A -NF104A NF105A NF106A NF108A NF108B NF109A NF110A 91-20-06 102 12-98 NOTES MOONEY AIRCRAFT CORPORATION CODE DESCRIPTION PAl 01A --PA102A PA103A PA104A PAl 05A M20J SERVICE AND MAINTENANCE MANUAL ELECTRICAL EQUIPMENT CHART --- PA106A --PA107A -PA108A -PA109A PAl 10A PA111A PAlllB PAl 12A PAl 13A PAl 14A -- VENDOR BATTERY SWITCH, MASTER SWITCH, MASTER SWITCH, BAT 1-2 SWITCH, BAT 1-2 BATTERY, 24V BA3-rERY, 24V GILL MOONEY MOONEY MOONEY MOONEY CONCORDE CONCORDE PL01A PL02A PL02B PL02C PL02D PL03A PL03S PL03C PL03D PL03E PLUG, 1 PIN PLUG, 2 PiN PLUG, 2 PIN PLUG, 2 PIN (FEMALE) PLUG, 2 PIN PLUG, 3 PIN PLUG, 3 PIN PLUG, 3 PIN PLUG, 3 PIN PLUG, 3 PIN SOCKET (ALUMEL) SOCKET (ALUMEL) PLUG 4 PIN PLUG 4 PIN PLUG 4 PIN PLUG 4 PIN PLUG 5 PIN PLUG 5 PIN PLUG 6 PIN .PLUG 7 P|N (ALT) PLUG, 8 PIN AMP AMP MOLEX DEAN PL04A PL04B PLO4C PL04D PL05A PL05B PL06A PL07A -PL08A NOTES REGULATOR, VOLTAGE MOONEY 809270-601 (ALT) AM.PROD,,'PRECISE FiT DGR-2 (ALT) AUX]_ODELTA VR-802 SWITCH, ALT'NTR FIELD (DUAL) MOONEY 880052-525 SWITCH,AL3"NTR.FIELD (SINGLE) MOONEY 680052-508 ALTERNATOR LYCOMING LW-14367 (ALl) PRESTOLITE ALU-6421-LS ALTERNATOR LYCOMING LW-15404 (ALl') PRESTOLITE ALY-8420 ALTERNATOR, RIGHT TCM 649719 (ALT) TCM 649280 GEAR ASSY TCM 649123 ALTERNATOR ELECTRO SYSTEMS ES-4009-LS KIT, INSTALL LYCOMING 05K-21065 (REFERENCE 600160) FILTER MOONEY 880014-501 (ALT) MOONEY 800307-501 SENSOR, CURRENT MICRO SWITCH CSLA1GE REGULATOR, VOLTAGE MOONEY 800270-503 SENSOR, CURRENT (110A) KUXON 7235-1-110 SENSOR, CURRENT (175A) KLIXON 7235-1-175 ALTERNATOR TCM 649304 MONITOR, CURRENT MOONEY 800287-501 ALTERNATOR, LEFT TCM 649172 (ALT) TCM 649283 PB101A PS102A PB102B PB103A PB103B PB105A PS105B --- PART NO. AMP AMP ARRAY CDI CDI AMP AMP ARRAY CONN DEUTSCH MATRIX SCIENT. AMP 12-98 G-243 880052-501 880052-101 880052-527 880052-127 RG24-11M RG24-15 1-480349-0 1-480318-0 03-06-1023 7021 _ MS3106A-24-9S 1-380303-0 206037-2 MS3106A-10SL-3S MS3106A-28-6P PWF06F08-33B 01-2020-245 01-2020-244 206060-1 MS3106A-32-17S 1-480424-0 PW06FS-4S MS3106A-I 4S-5S BVD06E0205SN MS3106A-28-22S MS3106A-20-15S MS3106R-20-15S 205888-1 4 91-20-06 103 SERVICE AND MAINTENANCE MANUAL M20J MOONEY AIRCRAFT CORPORATION ELECTRICAL EQUIPMENT CHART CODE DESCRIPTION VENDOR PART NO. PL09A PL09B PL09C PL09D PL09E PL14A PL14B PL14C PL15A PL16A PL17A PI_20A PL20B PL20C PL25A PL25B PL26A PL28A PL32A PL34A PL34B PL37A PL37B PL50 PL104A PLUG 9 PIN PLUG 9 PIN PLUG 9 PIN PLUG 9 PIN PLUG 9 PIN PLUG 14 PIN PLUG 14 PIN PLUG 14 PIN PLUG 15 PIN PLUG 16 PIN PLUG 17 PIN PLUG 20 PIN PLUG 20 PIN PLUG. 20 PIN PLUG 25 PIN PLUG 25 PIN PLUG 26 PIN PLUG 28 PIN PLUG 32 PIN PLUG 34 PIN PLUG 34 PIN PLUG, 37 PIN PLUG, 37 PIN PLUG, 50 PIN PLUG, 104 PIN AMP AMP MOONEY POSITRONICS 206708-1 126-222 DE9S 03-06-2092 206485-1 930021-1 930021-513 206043-3 DA15S 206037-1 DSM17W2S 930021-501 CC148-003-0.00 CC149-003-0.00 DB25S 205208-1 930021-505 205839-3 M83723/86R2232N 930021-507 930021-515 206150-1 DC37S 930021-511 GMCT104FOTH000 PS101A PS102A PS103A PSI05A C/B, START POWER C/B, START POWER STARTER (M20J) (ALr) STARTER (M20K & M20R (ALT) STARTER (M20M) KLIXON KLIXON PRESTOLITE LYCOMING TCM TCM B &C 7277-2-10 7277-2-5 MHB4016 LW-15572 646275 637847 BSC206-149 RB101A RB102A SLOWER, RADIO SLOWER RADIO KING GLOBE 071-4037-01 19A2790 AMP AMP DEAN 1-480351-0 1-480319-0 7022 MS3100-24-9P 03-06-2023 t-480305-0 206036-2 206207-1 MS3100-28-6S 206153-1 M3100-32-17P 1-480426-0 PW01F8-04P BVD04E0205PN MS3100C-28-22P 205841-2 206705-2 206705-1 DE9P 205486-1 03-06-2122 980021-2 -PS104A -- RC01A RC02A RC02C RC02D RC02E RC03A RC03B RC03C RC03D RC04A RC04B RC04C RC04D RC05B RC06A RC08A RC09A RC09B RC09C RC09E RC12A RC14A 91-20-06 104 RECEPTACLE 1 PIN RECEPTACLE 2 PIN RECEPTACLE 2 PIN (MALE) RECEPTACLE 2 PIN RECEPTACLE 2 PIN RECEPTACLE 3 PIN RECEPTACLE 3 PIN RECEPTACLE 3 PIN RECEPTACLE, 3 PIN RECEPTACLE 4 PIN RECEPTACLE 4 PIN RECEPTACLE 4 PIN RECEPTACLE 4PIN RECEPTACLE 5 PIN RECEPTACLE, 6 PIN RECEPTACLE, 8 PIN . RECEPTACLE, 9 PIN . RECEPTACLE, 9 PIN RECEPTACLE, 9 PIN RECEPTACLE, 9 PIN RECEPTACLE, 12 PIN RECEPTACLE, 14 PIN MOLEX AMP MOONEY MOONEY AMP AMP MOONEY POSITRONICS POSITRONICS AMP MOONEY AMP MOONEY MOONEY AMP MOLEX AMP AMP AMP AMP AMP ARRAY DEUTSCH MATRIX SCIENCE AMP AMP AMP AMP MOLEX MOONEY 12-98 NOTES 4 MOONEY AIRCRAFT CORPORATION CODE RC14B --RC14C RC16A RC16B RC20A RC20B RC26A RC28A RC32A RC34A RC34B RC37A RC104A RC170A -- ----RL101A --RL102A RLIO3A RL104A RL105A .. --RL106A RL107A RL108A RL109A RL110A --RS101A RS102A RS103A RS104A RS105A RS106A RS107A RS115A RS116A DESCRIPTION VENDOR PART NO. RECEPTACLE, 14 PIN (ALT) RECEPTACLE, 14 PIN RECEPTACLE, 16 PIN RECEPTACLE, 16 PIN RECEPTACLE, 20 PIN RECEPTACLE, 20 PIN RECEPTACLE, 26 PIN RECEPTACLE, 28 PIN RECEPTACLE, 32 PIN RECEPTACLE, 34 PIN RECEPTACLE, 34 PIN (AL'I_ RECEPTACLE, 37 PIN RECEPTACLE, 104 PIN RECEPTACLE, 170 PIN SOCKETS (22CA) SOCKETS (20-18 GA) SOCKETS (20-14GA} AMP POSITRONIC AMP AMP AMP MOONEY POSITRONICS MOONEY AMP MATRIX SCIENCE MOONEY AMP POSITRONIC AMP POSITRONICS HYPERTRONICS HYPERTRONICS HYPERTRONICS HYPERTRONICS 203540-1 G14000H000-1265.0 206044-1 206036-2 206036-1 930021-502 GMCT2MOE100J0 930021-506 206152-1 M83723/83K2232N 930021-508 204814-1 SK2114 206151-1 GMCT104M0000Z0 NEBV23-077 YSK006-011 YSK006-089 YSK015-025AH RELAY, 28V/200A (ALT) (ALT) (OBSOLETE) RELAY, 14V/200A RELAY RELAY RELAY, 28V/5OA BRACKET (2 REQ'D.) (AL'r) RELAY, 28V/100A RELAY 14V/200A RELAY RELAY RELAY SOCKET TERMINAL KISSUNG KISSLING C-H C-H KISSLING KISSUNG KISSUNG MOONEY C-H C-H C-H MAGNACRAFT KISSLING P&B P&B P&B 26.57.01 26.57.02 6041H-202/202A 6041H-105A 26.64.01 26.64.21 26.72.03 800375-1 6041H-220 6041H-53 6041H-105R W67RCSX-3 28.08.01 VF4-15-H 11 VCF4-1O02 26A1348C RESISTOR, 20-OHM/10W RESISTOR, 5 OHM/10W RESISTOR, 500 OHM RESISTOR, 100 OHM RESISTOR, 7.5-OHM RESISTOR, 1K OHM/2W RESISTOR, 5K OHM DALE DALE MOONEY NEWARK DALE ALLEN BRADLEY SPECTROL RH-10-20 OHM RH-10-5 OHM 919029-501 09F976 RH-50-7.5 OHM RC42-GF102J 789-B_E_02 OHMITE OHMITE 1.6K OHM/1/2W 1.00HM/1/SW RESISTOR .RESISTOR SA101A --- M20J SERVICE AND MAINTENANCE MANUAL ELECTRICAL EQUIPMENT CHART ALTERNATOR, STAND-BY B&C HOUSING, PLASTIC CONNECTOR B&C TERMINAL, 1/4 INCH B&C 12"90 : NOTES 3D BC410-1 12-003 14-026 .... 91-20-06 105 SERVICE AND MAINTENANCE MANUAL M20J MOONEY AIRCRAFT CORPORATION ELECTRICAL EQUIPMENT CHART CODE DESCRIPTION SA102A SA103A CONTROLLER, 8TBY ALTERNATOR B&C SWITCH, STBYALT./EMERG BUS MOONEY B0203-2 880052-531 SB101A SB102A SB103A SB104A C/B, SPEEDBRAKE KLIXON SWITCH, SPEEDBRAKE, YOKE PRECISE FLT RELAY, SPEEDSRAKE PRECISE FLT DIODE, SPEEDBRAKE (ALl] GE MOTOR, SPEEDBRAKE PRECISE FLT SWITCH, SPEEDBRAKE PRECISE FLT SOLENOID, CLUTCH, SPEEDBRK PRECISE FLT S/B INTERFACE MOONEY 7277-2-3 01255 01384 1N2483/1N5060 3720-GE 01532 01505 01679 900314-501 SPEAKER, ALERT SPEAKER, CABIN (ALl') SONALERT 40-1333C 40-1325 PCx352 SC628 -SB105A SB106A SB107A SB108A SP101A SP102A -SP103A SW101A -SW102A SWIO3A SWIO4A -SWl05A SWl06A SW107A SWl08A SWl08A SW110A SW111A SW112A SW113A SW114A SW115A -- -- --- -- -SWl 16A SW117A SW118A SW119A SW120A SW121A SW122A SW123A SW124A SW125A SW126A 91-20-06 106 VENDOR ARCHER ARCHER BLAUPUNK-r MALLORY SWITCH MICRO (ALT) SAINT SWITCH, DEFROSTER BLWR CHERRY SWITCH MICRO SWITCH, UP-LIMIT MICRO (ALT) SAINT SWITCH, DN-LIMIT MICRO (ALT) O3-i"OCONT. SWITCH CARLING SWITCH MOONEY SWITCH C-H SWITCH C-H (ALl') ALCO SWITCH GRAYHILL SWITCH C-H SWITCH CARUNG SWITCH MICRO SWITCH, WHITE CAP MICRO (AKT) SWITCH C&K SWITCH NKK INCLUDES - BUTTON, LOCKRING, LOCKWASHER, HEX NUT (2) (ALT) C-H LOCK RING C-H LOCK WASHER C-H HEX NUT (2) C-H (ALT) TSCHUDIN LENS TSCHUDIN BULB TSCHUDIN SWITCH MOONEY SWITCH CARUNG SWITCH MOONEY SWITCH CARLING SWITCH , SWITCH CROUZET SWITCH CROUZET SWITCH ALCO SWITCH SWITCH NKK SWITCH EATON 12-98 PART NO. 1SE1-T ZS-1009 E51-50S V3-1 DT-2R-47 ML-1409 1CHl16-5 P6-24014 R0911-VBBOW 880013-507 89061<2375 SA1RV20 MPE-106F-C-22-9 71AD30-02-2-AJN 89061<4731 RA911-VBBOW 12TW-10 15PAg0-8W MS27753-38 7101K DLB241-W01-1-3(3/ AT506M/ATS03MB SB1DDX492-2 29-761 16-856 15-966-6 504102 464415 590002 880012-501 TILC64-1S-WHFN 880062-501 TIGM64-1S-WHEN MS35058-22 83-450-001 83-452-504 MPE106F MB2085SB1W01-EA 1501-11E NOTES 5 MOONEY AIRCRAFT CORPORATION CODE M20J SERVICE AND MAINTENANCE MANUAL ELECTRICAL EQUIPMENT CHART DESCRIPTION VENDOR PART NO. ---- SWITCH, MASTER WARN SW. (w/LENS) SW. (w/LEGEND) SW. (w/BULB) SWITCH OMRON OMRON OMRON OMRON NKK A3BA-7011-1 A3BA-500R A3BA-5202 A3B-028 MB2085SB1W01-EA -- VOLTAGE CONVERTER, 28-14 TERRA (ALT) TERRA MLC28-8 C28-5 VR101A VARISTOR GE V47ZA05 WMIO1A WM102A WARNING, MASTER WARNING, MASTER MICRO MICRO DSK-104-GYR DSB-11-RRRR-LR2 WS103A ALERT, STALL/GEAR WARN (ALT) SWITCH, STALL WARN IAI tAI MOONEY 950D809-000 950D519-000 800364-509 WT101A WT101B WT102A WT103A WT104A ANNUNCIATOR ANNUNCIATOR ANNUNCIATOR ANNUNCIATOR ANNUNCIATOR MOONEY MOONEY MOONEY MOONEY MOONEY 880048-501 880090-XXX 880048-503 880048-507 880048-509 SW127A SW135A VC101A WS101A -- NOTES 6 NOTES: 1. ALL P/N's ARE ACCEPTABLE. SEE VENDOR INFORMATION FOR APPLICABLE CONFIGURATION. 2. 1 EACH MS35334-21 OR M2898 (ALLEN BRADLEY) INTERNALTOOTH LOCKWASHER, REQUIRED WITH EACH LIGHT, IF NOT SUPPLEDBY SLOAN 3. SEAL BACK OF POTENTIOMETER WITH DOW CORNING #738 ELECTRICAL SEALANT AFTER WIRES ARE SOLDERED TO TERMINALS. 4. PL02C & RC02C MAY BE PURCHASED FROM DEAN AS P/N 7020. 6. SEAL BACK OF SWITCH WITH DOW CORNING #738 ELECTRICAL SEALANT AFTER WIRES ARE SOLDERED TO TERMINALS WHEN USED AS "I-HROTFLE SWITCH-GEARWARNING". 6. ANNUCIATOR P/N WILL BE DETERMINED BY OPTIONS INSTALLED. REF. DRAWING # 880090. 12-98 91-20-O6 107 SERVICE AND MAINTENANCE MANUAL M20J MOONEY AIRCRAFT CORPORATION ELECTRICAL EQUIPMENT CHART RESERVED FOR FUTURE ENTRIES 91-20-06 108 12-98 MOONEY AIRCRAFT CORPORATION ( M20J SERVICE AND MAINTENANCE MANUAL ELECTRICAL EQUIPMENT CHART RESERVED FOR FUTURE ENTRIES 12-98 91-20-06 109 SERVICE AND MAINTENANCE MANUAL M20J MOONEY AIRCRAFT CORPORATION ELECTRICAL EQUIPMENT CHART RESERVED FOR FUTURE ENTRIES 91-20-06 110 12-98 SERVICE AND MAINTENANCE MANUAL 91-30-00 M20J MOONE'YAIRCRAFT CORPORATION - ELECTRICAL SYSTEM SCHEMATICS (SEE ENVELOPES) ( 12-98 91-30-00 111/112BLANK MOONEY AIRCRAFT CORPORATION M20J CHAPTER 95 SPECIAL EQUIPMENT SERVICE AND MAINTENANCE MANUAL MOONEY AIRCRAFT CORPORATION M20J SERVICE AND MAINTENANCE MANUAL { ! CURRENTLY NOT BEING USED 12-98 95-SPECIAL EQUIPMENT 1 SERVIGEAND MAINTENANCE MANUAL M20J_ INTENTIONALLY LEFT BLANK 95-SPECIAL EQUIPMENT 2 12-98 MOONEY AIRCRAFT CORPORATION