Starship 1 Maintenance Manual

contacted when additional parts or servicing information is required. Additional publications are listed in the current Publications Price List (P/N 118556). Contact your nearest Raytheon Aircraft Service Center for information on these publications or visit the Publications price list web site at http://pubs.raytheonaircraft.com. A. General The Raytheon Aircraft Starship 1 Maintenance Manual is prepared in accordance with the GAMA (General Aviation Manufacturers Association) Specification No. 2 format. It also meets the intent of the requirements of the ATA Specification 2200 (Air Transport Association of America) with respect to the arrangement and content of the System/Chapters within the designated chapter-numbering system. This Starship 1 Maintenance Manual is supplemented by the following publications: • The Raytheon Aircraft Starship 1 Parts Catalog, P/N 122-590013-11 • The Raytheon Aircraft Starship 1 Wiring Diagram Manual, P/N 122-590013-13 • The Raytheon Aircraft Starship 1 Component Maintenance Manual, P/N 122-590013-9 • The Raytheon Aircraft Starship 1 Structural Repair Manual, P/N 122-590013-7 • The Raytheon Aircraft Starship 1 Printed Circuit Board Manual, P/N 122-590013-49 It shall be the responsibility of the owner/operator to ensure that the latest revision of the publications referenced in this manual are utilized during operation, servicing and maintenance of the airplane. Raytheon Aircraft Company expressly reserves the right to supersede, cancel and/or declare obsolete any parts, part numbers, kits or publications that may be referenced in this manual without prior notice. STARSHIP 1 MAINTENANCE MANUAL Page 2 Oct 31/06 INTRODUCTION WARNING: Use only parts obtained from sources approved by Raytheon Aircraft Company, in connection with the maintenance and repair of Raytheon Aircraft Company airplanes. Genuine Raytheon Aircraft Company parts are produced and inspected under rigorous procedures to insure airworthiness and suitability for use in Raytheon Aircraft Company airplane applications. Parts purchased from sources other than those approved by Raytheon Aircraft Company, even though outwardly identical in appearance, may not have the required tests and inspections performed, may be different in fabrication techniques and materials, and may be dangerous when installed in an airplane. Salvaged airplane parts, reworked parts obtained from sources not approved by the Raytheon Aircraft Company or parts, components or structural assemblies, the service history of which is unknown or cannot be authenticated, may have been subjected to unacceptable stresses or temperatures or have other hidden damage, not discernible through routine visual or usual nondestructive testing techniques. This may render the part, component or structural assembly, even though originally manufactured by the Raytheon Aircraft Company, unsuitable and unsafe for airplane use. Raytheon Aircraft Company expressly disclaims any responsibility for malfunctions, failures, damage or injury caused by use of parts not approved by the Raytheon Aircraft Company. Any maintenance requiring the disconnection and reconnection of flight control cables, plumbing, electrical connectors or wiring requires identification of each side of the component being disconnected to facilitate correct reassembly. At or prior to disassembly, components should be color coded, tagged or properly identified in a way that it will be obvious how to correctly reconnect the components. After reconnection of any component, remove all identification tags. Check all associated systems for correct function prior to returning the airplane to service. B. Correspondence If a question should arise concerning the care of your airplane, it is important to include the airplane serial number in any correspondence. The serial number appears on the model designation placard. Refer to Chapter 11 for placard location. C. Publications Change Request (PCR) If an irregularity or missing information is noted, the user of this manual may access a PCR form at http://www.pubs.raytheonaircraft.com., select Forms and Reports and then select Publication Change Request. This form and the information that was entered will be electronically forwarded to Raytheon Aircraft Customer Support. The change request will be researched for any necessary updates to the publication. Assistance is available, at any time, by contacting Raytheon Aircraft Technical Support at 800-429-5372 or 316-676-3140. INTRODUCTION Page 3 Oct 31/06 STARSHIP 1 MAINTENANCE MANUAL D. Normal Revisions Normal Revisions to this manual are issued to provide changes to technical information. 1. Paper Revision That portion of text which has been revised by the addition of, or a change in, information is denoted by a solid revision bar adjacent to the text. The date printed on the bottom of each page can be compared to the “A” page to determine the revision number. Each revised page will ONLY show revision bars for text changed by the revision. There will not be a revision bar if text was deleted from the page. Revised illustrations will be identified by a revision bar printed on the side of the page. E. Temporary Revisions Temporary Revisions to this manual are issued to provide technical information in the interim between normal revisions. Each temporary revision is issued by the chapter number to which it applies, followed by a sequential number in the order of publication (Temporary Revisions 12-1, 12-2, etc.). If relevant, the information in the temporary revision should be included in the next normal revision of the manual. 1. Paper Temporary Revisions Temporary Revisions are printed on yellow paper and are to be inserted in the maintenance manual in accordance with the instructions provided and adjacent to applicable chapter, section, and subject matter in the manual. F. Revised Text That portion of text which has been revised by the addition of, or a change in, punctuation and/or information is denoted by a solid revision bar adjacent to the textual column in the margin of this paragraph. Each page may or may not have revision bars. That date printed on the bottom of each page indicates when the information on that page was changed. Each page will ONLY show revision bars for punctuation and/or text changed by the current revision. G. Revised Illustrations When an illustration is modified or a new illustration is added, it will be noted by a solid line (revision bar) along the outside margin of the illustration. H. Warnings, Cautions, and Notes • WARNING - Brings attention to an operating procedure, inspection or maintenance practice, which if not correctly followed, could result in personal injury or loss of life. • CAUTION - Brings attention to an operating procedure, inspection, repair or maintenance condition, which if not strictly observed, could result in damage or destruction of equipment. • NOTE - Brings attention to an operating procedure, inspection, repair or maintenance condition, which is essential to highlight. STARSHIP 1 MAINTENANCE MANUAL Page 4 Oct 31/06 INTRODUCTION 2. MANUAL LAYOUT A. Title Page A Title page is located at the beginning of the manual and provides the part number of the manual, and lists all aircraft models pertaining to this manual and their respective serial numbers. Information throughout this manual is applicable to all serial numbers listed on the title page except where specifically stated. B. List of Effective Revisions/List of Effective Pages The printed manual will have a List of Effective Revisions/List of Effective Pages, (“A” page) following the title page of the manual. The List of Effective Revisions page lists the revisions currently effective for the manual. The List of Effective Pages section lists the page effectivity for the Title Page(s), “A” page(s) and Introduction chapter. It will also show the effective pages for an entire manual if the manual does not have individual Chapter List of Effective Pages. C. Record of Revisions Page The printed manual will have a Record of Revisions page. The Record of Revisions is provided following the List of Effective Revisions/List of Effective Pages (“A” page). When a revision is inserted, the revision number, the date the revision is inserted into the manual, and the initials of the person(s) inserting the revision should be recorded on this page. D. Log of Temporary Revisions Page The printed manual will have a Log of Temporary Revisions page. The Log of Temporary Revisions Page is located following the Record of Revisions page. The Log of Temporary Revisions page provides a history of each temporary revision, including the revision number which incorporated the temporary revision into the manual. E. Record of Temporary Revisions Page The printed manual will have a Record of Temporary Revisions page. The Record of Temporary Revisions Page is located following the Log of Temporary Revisions page. When a temporary revision is inserted or removed from this manual, the appropriate information should be recorded on this page. F. Chapter List of Effective Page The printed manual may have a Chapter List of Effective Pages. The List of Effective Pages follow the Chapter-Divider-Tab and lists the issue date of each page that is effective for that chapter. G. Chapter Table of Contents Pages The printed manual may have a Chapter Table of Contents Pages. The Chapter Table of Contents Pages follow the Chapter List of Effective Pages and lists the contents of the data for that chapter. 3. HOW TO USE THE MANUAL A. ATA Subject Matter Assignment The contents of this manual are organized into four levels. The four levels are: INTRODUCTION Page 5 Oct 31/06 STARSHIP 1 MAINTENANCE MANUAL (1) Group These are the primary divisions of the manual that enable broad separation of content. Typical of this division is the separation between Airframe Systems and the Power Plant. (2) System/Chapter The various groups are broken down into major systems such as Environmental Systems, Electrical Power, Landing Gear, etc. The systems are arranged more or less alphabetically rather than by precedence or importance. They are assigned a number, which becomes the first element of the standardized numbering system. Thus, the element 28 of the number 28-40-01 refers to the chapter FUEL. Everything concerning the fuel system will be covered in this chapter. (3) Subsystem/Section The major systems/chapters of an airplane are broken down into subsystems. These subsystems are identified by the second element of the standard numbering system. The element 40 of the number 28-40-01 concerns itself with the indicating section of the fuel system. (4) Unit/Subject The individual units within a subsystem/section may be identified by the third element of the standard numbering system. The element 01 of the number 28-40-01 is a subject designator. This element is assigned at the option of the manufacturer and may or may not be used. B. Application Any publication conforming to the GAMA or ATA format will use the same basic numbering system. Thus, whether the manual is a Starship 1 Maintenance Manual, or a Starship 1 Wiring Diagram Manual, the person wishing information concerning the indication portion of the fuel system, would refer to the System/Chapter Tab 28-FUEL. The table of contents in the front of this chapter will provide a list of subsystems covered in this chapter. For example, the fuel system chapter with a full index would contain: 28-00 - General 28-10 - Storage (Tanks, cells, necks, caps, instruments, etc.). 28-20 - Distribution (Fuel lines, pumps, valves, controls, etc.). 28-30 - Dump (If in-flight dumping system is installed, it would appear here). 28-40 - Indicating (Quantity, temperature, pressure, etc., does not include engine fuel flow or pressure). C. References to Procedures, Figures, Equipment and Materials A system has been developed to provide a method of allowing the user to quickly locate data referred to in the other manuals. This system provides information for both the printed manual as well as a hyperlink in electronic manuals. Here are a few examples: When the user is directed to a procedure in another manual, the text will be as follows: (refer to Chapter 6-50-00, CABIN FLOORBOARD PANELS). The procedure is found in Chapter 6-50-00, of the Maintenance Manual. STARSHIP 1 MAINTENANCE MANUAL Page 6 Oct 31/06 INTRODUCTION When the user is in a procedure and is directed to information about a tool, piece of equipment or material used, the text will be as follows: (1, Chart 2, 27-00-00), which contains a listing of all the special tools and equipment used to maintain the Starship 1 airplane. Item 1 in Chart 2 is Sealant. 4. CHAPTER/SYSTEM INDEX GUIDE TABLE The following System/Chapter, Subsystem/Section Index Guide is prepared in accordance with GAMA Specification No. 2 and ATA Specification No. 100 for use with Maintenance Manuals, Parts Catalogs and Wiring Diagram Manuals. The following chapters are not applicable to this Maintenance Manual: 29, 37, 49, 60, 70, 81, 83, 91 and 95. Table 1 - System/Chapter Subsystem/Section Title INTRODUCTION 4 AIRWORTHINESS LIMITATIONS 00 Airworthiness - Limitations 5 TIME LIMITS/MAINTENANCE CHECKS 10 Time Limits - Maintenance Checks 11 Time Limits - Overhaul and Replacement 20 Scheduled Maintenance Checks 50 Unscheduled Maintenance Checks 6 DIMENSIONS AND AREAS 10 Airplane Dimensions 20 Airplane Areas 30 Airplane Stations 40 Airplane Zones 50 Airplane Access Panels 7 LIFTING AND SHORING 00 General 10 Jacking and Hoisting 8 LEVELING AND WEIGHING 00 General INTRODUCTION Page 7 Oct 31/06 STARSHIP 1 MAINTENANCE MANUAL 8 (Cont’d) 10 Leveling 20 Weighing 9 TOWING AND TAXIING 00 General 10 Towing 20 Taxiing 10 PARKING AND MOORING 00 General 10 Parking 20 Mooring 11 PLACARDS AND MARKINGS 00 General 10 Exterior Color Schemes and Markings 20 Exterior Placards and Markings 12 SERVICING 00 Servicing 10 Replenishing 20 Scheduled Servicing 30 Unscheduled Servicing 20 STANDARD PRACTICES - AIRFRAME 00 Standard Practices 01 Torque Application 02 Electrostatic Discharge Sensitivity 03 Electrical Bonding 04 Control Cables and Pulleys 05 Bearings 06 Tubing, Hoses and Fittings 07 Locking Devices System/Chapter Subsystem/Section Title STARSHIP 1 MAINTENANCE MANUAL Page 8 Oct 31/06 INTRODUCTION 20 (Cont’d) 08 Airplane Finish Care 21 ENVIRONMENTAL SYSTEMS 00 General 10 Air Distribution 21 Nose Avionics Cooling Systems 30 Pressurization 40 Heating 50 Cooling 60 Temperature Control 22 AUTO FLIGHT 10 Autopilot 23 COMMUNICATIONS 00 General 10 Speech Communications 11 VHF Communications 12 Radiophone System 40 Ground Interphone System 50 Audio Intergating 60 Static Discharging 24 ELECTRICAL POWER 00 General 30 DC Generation and Control 31 Battery Power 32 Auxiliary Battery Power 40 External Power 50 Electrical Load Distribution System/Chapter Subsystem/Section Title INTRODUCTION Page 9 Oct 31/06 STARSHIP 1 MAINTENANCE MANUAL 25 EQUIPMENT/FURNISHINGS 00 General 10 Cockpit 20 Passenger Compartment 60 Emergency 26 FIRE PROTECTION 00 General 10 Engine Fire Detection System 11 Engine Bleed Air Warning System 20 Engine Fire Extinguishing 21 Portable Fire Extinguishing 27 FLIGHT CONTROLS 00 General 20 Rudder and Tabs 30 Elevators, Elevons and Tabs 31 Stall Warning System 50 Flap/Forward Wings 70 Control Locks 28 FUEL 00 General 10 Fuel Storage 20 Fuel Distribution 40 Fuel Indicating 30 ICE AND RAIN PROTECTION 00 General 10 Airfoil 20 Engine Air Intakes 40 Windows, Windshields and Doors 70 Water Lines System/Chapter Subsystem/Section Title STARSHIP 1 MAINTENANCE MANUAL Page 10 Oct 31/06 INTRODUCTION 30 (Cont’d) 80 Detection 31 INDICATING/RECORDING SYSTEMS 10 Instrument and Control Panels 20 Independent Instruments 40 Central Computers 41 Integrated Avionics Processor System 50 Central Warning System 32 LANDING GEAR 00 General 10 Main Gear and Doors 20 Nose Gear and Doors 30 Extension and Retraction 40 Wheels and Brakes 50 Nose Landing Gear Steering 60 Landing Gear Position and Warning 33 LIGHTS 00 General 10 Cockpit Lights 20 Cabin Lights 30 Baggage Compartment Lights 40 Exterior Lights 34 NAVIGATION AND PITOT/STATIC 00 General 10 Flight Environment Data 20 Attitude and Direction 30 Landing Systems 40 Independent Position Determining 50 Dependent Position Determining System/Chapter Subsystem/Section Title INTRODUCTION Page 11 Oct 31/06 STARSHIP 1 MAINTENANCE MANUAL 35 OXYGEN 00 General 36 PNEUMATIC 00 General 10 Distribution 20 Indicating 38 WATER/WASTE 00 General 30 Waste Disposal 39 ELECTRICAL PANELS 10 Instrument And Control Panels 20 Electrical & Electronic Equipment Panels 30 Printed Circuit Boards 51 STRUCTURES 00 General 52 DOORS 00 General 10 Passenger/Crew 20 Emergency Exit 40 Service Doors 70 Door Warning 80 Landing Gear Doors 53 FUSELAGE 00 General 10 Main Frame 20 Auxiliary Structure 30 Access Doors and Skin System/Chapter Subsystem/Section Title STARSHIP 1 MAINTENANCE MANUAL Page 12 Oct 31/06 INTRODUCTION 53 (Cont’d) 40 Attach Fittings 50 Aerodynamic Fairings 54 NACELLES 00 General 55 STABILIZERS 00 General 10 Forward Wing 20 Elevator 30 Tipsails 40 Rudder 60 Ventral Stabilizer 56 WINDOWS 00 General 10 Cockpit 20 Cabin 57 WINGS 00 General 50 Eleven 61 PROPELLERS 00 General 10 Propeller Assembly 20 Controlling 21 Autofeathering 22 Synchrophaser 40 Indicating 71 POWER PLANT 00 General System/Chapter Subsystem/Section Title INTRODUCTION Page 13 Oct 31/06 STARSHIP 1 MAINTENANCE MANUAL 71 (Cont’d) 10 Engine Cowling 20 Engine Mounts 50 Electrical Harness 60 Engine Air Intakes 70 Engine 72 ENGINE 00 General 73 ENGINE FUEL SYSTEMS 00 General 10 Fuel Distribution 74 IGNITION 00 General 76 ENGINE CONTROLS 00 General 77 ENGINE INDICATING 00 General 40 Intergrated Engine Instrument System 78 EXHAUST 00 General 79 OIL 00 General 30 Indicating 80 STARTING 00 General System/Chapter Subsystem/Section Title B10 Page 1 Oct 31/06 5-LOEP STARSHIP 1 MAINTENANCE MANUAL List of Effective Pages CH-SE-SU PAGE DATE 5-LOEP 1 Oct 31/06 5-CONTENTS 1 and 2 Oct 31/06 5-10-00 1 thru 4 Oct 31/06 5-11-00 1 thru 3 Oct 31/06 5-20-00 1 thru 18 Oct 31/06 5-50-00 1 thru 11 Feb 25/94 Page 1 STARSHIP 1 MAINTENANCE MANUAL SUBJECT PAGE CHAPTER 5 - TIME LIMITS/MAINTENANCE CHECKS TABLE OF CONTENTS Oct 31/06 B10 5-CONTENTS 5-10-00 Time Limits - Maintenance Checks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1 Time Limited Inspection Requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1 Special Conditions Cautionary Notice . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1 5-11-00 Time Limits - Overhaul and Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1 Overhaul and Replacement Schedule . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1 Special Conditions Cautionary Notice . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1 5-20-00 Scheduled Maintenance Checks - Maintenance Practices . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1 Scheduled Inspection General Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2 Inspection Interval Tolerance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2 Letter Inspections (Hourly Interval) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2 Special Inspection Items - Calender Date Limited . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2 Inspection Timetable . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3 Starship 1 Inspection Form . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4 A. Left Power Plant (Zone 411) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4 B. Right Power Plant (Zone 421) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6 C. Environmental Systems . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8 D. Nose Section (F.S. 0 to F.S. 95) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8 E. Cockpit (F.S. 95 to F.S. 163) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .10 F. Cabin Section (F.S. 163 to F.S. 357) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .11 G. Aft Fuselage (F.S. 357 and Aft). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .12 H. Aft Wing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .12 I. Left Main Gear and Brakes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .14 J. Right Main Gear and Brakes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .14 K. Nose Gear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .15 L. Landing Gear Retraction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .16 M. Operational Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .16 N. Post Inspection Items . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .18 5-50-00 Unscheduled Maintenance Checks -Maintenance Practices . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1 Operation in Atmospheres of High Salt Content . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1 Operation in Atmospheres of High Industrial Pollution . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1 Operation in Areas of High Dust Content . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1 Operating from Very Soft or Unusual Terrain . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2 Inspection After Hard Landing. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4 Repair of Damage After Hard Landing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6 Page 2 5-CONTENTS Oct 31/06 B10 STARSHIP 1 MAINTENANCE MANUAL SUBJECT PAGE CHAPTER 5 - TIME LIMITS/MAINTENANCE CHECKS TABLE OF CONTENTS (Continued) Log Book Entry After Hard Landing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 Inspection After Encountering Turbulent Air . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 Repair of Damage After Encountering Turbulent Air . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 Log Book Entry After Encountering Turbulent Air . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 Inspection After Lightning Strike . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 Engine Inspection After Sudden Stoppage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 Special Inspections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 STARSHIP 1 MAINTENANCE MANUAL Page 1 B10 Oct 31/06 5-10-00 000 5-10-00 TIME LIMITS - MAINTENANCE CHECKS WARNING: When an airplane has experienced abnormal landing gear procedures of any type, as a safety precaution, place the airplane on jacks prior to performing any inspection or maintenance. Ensure that all three landing gears are down and locked prior to removing the airplane from jacks. CAUTION: Jacking of an airplane for the purpose of landing gear operation inspection, servicing or maintenance, should be accomplished within an enclosed building or hangar. In the interest of safety, should it become necessary to jack the airplane in the open, wind velocity in any direction and terrain variations, must be compensated for prior to jacking the airplane. WARNING: Anytime the airplane is on the ground (whether on jacks or on the wheels), the nose and main landing gear MUST be pinned in the down and locked position. The only exceptions to this would be during landing gear operational checks, during the removal or installation of the landing gear components, and during taxiing operations prior to takeoff or after landing. When any work is being performed in the nose gear wheel well, the nose gear doors MUST be pinned in the open position. Refer to Chapters 32-10-00 and 32-20-00 for the proper lockpin installation procedures. TIME LIMITED INSPECTION REQUIREMENTS This section consists of components that are subject to a thorough inspection based on calendar time, operating hours or cycles. The inspections should be done with reference to this maintenance manual and the Starship 1 Component Maintenance Manual. When disassembly is required to accomplish these inspections, reassembly should be accomplished in accordance with applicable component manuals. Discrepancies noted during these inspections should be noted on work sheets for corrections. The first inspection must be performed not later than the recommended period. The condition of the item at the end of the first period can be used as a criterion for determining subsequent periods applicable to the individual airplane or fleet operation, provided the operator has an approved condition monitoring system. The time periods for inspections noted in this manual are based on average usage and average environmental conditions. NOTE: The recommended periods do not constitute a guarantee the item will reach the period without malfunction as the aforementioned factors cannot be controlled by the manufacturer. SPECIAL CONDITIONS CAUTIONARY NOTICE Airplanes operated for Air Taxi, or other than normal operation, and airplanes operated in humid tropics, cold and damp climates, etc., may need more frequent inspections for wear, corrosion and/or lack of lubrication. In these areas, periodic inspections should be performed until the operator can set his own inspection periods based on experience or an approved condition monitoring system. 5-10-00 STARSHIP 1 MAINTENANCE MANUAL Page 2 Oct 31/06 B10 NOTE: The date on the "ORIGINAL STANDARD AIRWORTHINESS CERTIFICATE", FAA Form No. 8100-2, which is issued with a new airplane, is to be used as the basis for all inspected components listed in the following schedule. Items not listed in Chart 1 do not require specific inspections other than those required under an approved scheduled inspection program. Chart 1 Inspection Requirements ITEM INSPECTION REQUIREMENTS Landing Gear Main and Nose Gear Shock Absorber Assemblies, Main and Nose Gear Drag Brace Assemblies, Axle Assemblies and Torque Knees (Ref. Chapter 32) Inspect for cracks, wear and internal and external corrosion every 4,800 hours or 10 years, whichever occurs first (disassembly required). Landing Gear Cut-Out Relay Inspect landing gear cut-out relay every 1200 hours as detailed in Chapter 32-30-00. Power Plant Engine Inspect in accordance with the Pratt & Whitney PT6A-67A Engine Maintenance Manual. Engine Perform hot section inspection as required. Refer to the Pratt & Whitney PT6A-67A Engine Maintenance Manual. Pedestal Throttle Lever Stop Pin (Ref. Chapter 76) Inspect every 1,200 hours. Maximum wear is 1/3 of pin diameter. Engine vibration isolator mounts (Ref. Chapter 71) Inspect at engine TBO or 4,000 flight hours, which ever occurs first (disassembly required). Replace rubber cushion at engine overhaul. P 3 Air Filter Clean or replace every 1000 hours or less. Refer to Pratt & Whitney PT6A-67A engine maintenance manual. Propellers Dynamically balance every 600 hours as detailed in Chapter 61-10-00. Avionics System Altimeter and Pitot and Static System Every 24 Months Per FAA Regulation. VHF Navigation Receiver Every 30 days perform a VOR equipment check for IFR operations. Refer to the latest revision of the Collins Starship 1 Avionics System Manual P/N 523-0774076- 00111A ATC Transponders Every 2 years perform an ATC transponder test and inspection. Refer to the latest revision of the Collins Starship 1 Avionics System Manual P/N 523-0774076-00111A. STARSHIP 1 MAINTENANCE MANUAL Page 3 B10 Oct 31/06 5-10-00 Air Data Computers Every 2 years recertify the air data computers. Refer to the latest revision of the Collins Starship 1 Avionics System Manual P/N 523-00774076-00111A. Weather Radar Antenna At least once a year, clean and lubricate the mechanical portion of the antenna. Refer to the latest revision of the Collins Starship 1 Avionics System Manual P/N 523- 0774076-00111A. Flight Controls Autopilot Servos and Servo Mounts Inspect the servos and servo mounts as detailed in the latest revision to the Collins Starship 1 Avionics System Manual P/ N 523-0774076-00111 Every 10,000 hours remove each servo mount from the airplane and have the mounts completely tested by a Collins General Aviation Division authorized service agency. Forward Wing Control Actuator and Hydraulic Lock Solenoid Valve Every 200 hours check the control actuator for no-backs and the hydraulic lock solenoid valve for proper operation as detailed in Chapter 27-50-00. Flap Flexible Shaft (Ref. Chapter 27) Inspect every 4,800 hours for wear (remove and lubricate). Trim Monitors Every 100 hours check all three axes of airplane trim (pitch, yaw and roll) as follows: A. With the airplane’s electrical power on, depress and hold the FLAP/TRIM-PUSHER-INTR-AP/YD DISC button located on the pilot’s and co-pilot’s control wheels. B. Operate the pitch trim in both directions, the PITCH TRIM FAIL warning annunciator on the glareshield should illuminate after 2 seconds. C. Operate the roll trim in both directions, the ROLL TRIM FAIL warning annunciator on the glareshield should illuminate after 2 seconds. D. Operate the rudder trim in both directions, the RUD TRIM FAIL warning annunciator on the glareshield should illuminate after 2 seconds. Chart 1 Inspection Requirements (Continued) ITEM INSPECTION REQUIREMENTS 5-10-00 STARSHIP 1 MAINTENANCE MANUAL Page 4 Oct 31/06 B10 Utility Systems Cabin Fire Extinguisher Hydrostatically test every 12 years. (DOT Regulation) Engine Fire Extinguisher Bottle (Ref. Chapter 26) Hydrostatically test bottle at the intervals specified in Chapter 4-00-00. Oxygen Cylinder (Lightweight) DOT 3HT 1850 (Ref. Chapter 35) Hydrostatically test every 3 years (DOT Regulation). Replace after 24 years or 4,380 refills. Cabin Alitiude Warning System Perform the CABIN ALTITUDE WARNING PRESSURE SWITCH CHECK procedure every 12 months (Ref. Chapter 21-30-00). Oxygen System Perform the BAROMETRIC PRESSURE SWITCH CHECK procedure every 12 months (Ref. Chapter 35-00-00). All Weather Systems Surface Deice System Crossfeed Valve Every 600 hours, check the crossfeed valve as follows: A. Start and run engines. B. Set BLEED AIR VALVES switch to L ENG or R ENG. C. Press SURF DEICE - MAIN test switch (make sure minimum engine N 1 speed of 85% is maintained). System is OK if no failure annunciations are present. Pitot/Static Masts Every 100 hours check that both pitot/static mast heaters are operational. Emergency Equipment Underwater Locator Device (ULD) Every 24 months perform operational check per Chapter 25- 60-10 and manufacturers maintenance manual. ULD Battery Every 24 months check battery per Chapter 25-60-10 and manufacturers maintenance manual. ULD Water Switch Clean every 24 months per Chapter 25-60-10 and manufacturers maintenance manual. Electrical Ground Plane Electrical Ground Plane Joints Every 600 hours or 18 months, whichever occurs first, check for evidence of corrosion as detailed in Chapter 20-00-03. Electrical Ground Plane Every 600 hours or 18 months, whichever occurs first, perform a ground plane bond check as detailed in Chapter 20-00-03. Chart 1 Inspection Requirements (Continued) ITEM INSPECTION REQUIREMENTS STARSHIP 1 MAINTENANCE MANUAL Page 1 B10 Oct 31/06 5-11-00 000 5-11-00 TIME LIMITS - OVERHAUL AND REPLACEMENT WARNING: Anytime the airplane is on the ground (whether on jacks or on the wheels), the nose and main landing gear MUST be pinned in the down and locked position. The only exceptions to this would be during landing gear operational checks, during the removal or installation of the landing gear components, and during taxiing operations prior to takeoff or after landing. When any work is being performed in the nose gear wheel well, the nose gear doors MUST be pinned in the open position. Refer to Chapters 32-10-00 and 32-20-00 for the proper lockpin installation procedures. OVERHAUL AND REPLACEMENT SCHEDULE The first overhaul and replacement must be performed not later than the recommended period. The condition of the item at the end of the first period can be used as a criterion for determining subsequent periods applicable to the individual airplane or fleet operation, provided the operator has an approved condition-monitoring system. The time periods for overhaul and replacement noted in this manual are based on average usage and average environmental conditions. NOTE: The recommended periods do not constitute a guarantee the item will reach the period without malfunction as the aforementioned factors cannot be controlled by the manufacturer. SPECIAL CONDITIONS CAUTIONARY NOTICE Airplanes operated for Air Taxi, or other than normal operation, and airplanes operated in humid tropics, cold and damp climates, etc., may need more frequent inspections for wear, corrosion and/or lack of lubrication. In these areas, periodic inspections should be performed until the operator can set his own inspection periods based on experience or an approved condition monitoring system. NOTE: The date on the "ORIGINAL AIRWORTHINESS CERTIFICATE", FAA Form No. 8100-2, which is issued with each new airplane, is to be used as the basis for all TBO or replacement components listed in the following schedule. Raytheon Aircraft Company recommends that operators record the number of cycles used on individual components for purposes of complying with inspections based on cycle count. For purposes of establishing the intervals listed in Chart 1, the experience of Raytheon Aircraft Company indicates that each component experiences approximately one cycle per airplane flight hour in normal operation. 5-11-00 STARSHIP 1 MAINTENANCE MANUAL Page 2 Oct 31/06 B10 NOTE: Items not listed in Chart 1 are to be overhauled or replaced "On Condition". If "On Condition" items are worn, inoperative, inaccurate, intermittent and are not repairable through normal maintenance practices, they must be overhauled or replaced. CHART 1 OVERHAUL AND REPLACEMENT SCHEDULE ITEM OVERHAUL OR REPLACE Landing Gear Landing Gear Brake Hoses (Exposed) (Ref. Chapter 32) 10 years of time and service. Landing Gear Retraction and Extension Hoses (Ref. Chapter 32) 10 years of time and service. Electrical System Emergency Locator Transmitter Battery (Ref. Chapter 25) Replace at 50% of useful life as stated on the battery or anytime the transmitter is used more than one cumulative hour. Underwater Locator Device (ULD) Replace at date marked on the device (approx. every 6 years). Power Plant Engine TBO Refer to Pratt & Whitney Service Bulletin Number 14603 or subsequent for TBO. NOTE: A TBO (Time Between Overhaul) recommendation is in no way to be construed as a warranty or engine life proporation basis. The TBO recommendation is based on the projected time for most advantageous initial overhaul. The individual operator’s experience may indicate a departure in either direction from the recommended TBO for the particular operation. Oil Cooler (Ref. Chapter 79) When contaminated.- Flammable-Liquid-Carrying Hoses (Raytheon Aircraft supplied hoses only, which include all hoses between the airframe and the engine or its components, such as torque and oil pressure sensors, and the engine.) 5 years from date of delivery and every 5 years thereafter or at engine overhaul, whichever occurs first. STARSHIP 1 MAINTENANCE MANUAL Page 3 B10 Oct 31/06 5-11-00 Engine-Driven Fuel Pump Refer to Pratt & Whitney Service Bulletin Number 14603 or subsequent. Overspeed Governor Refer to Woodward Service Bulletin 33580 or subsequent. Propeller Governor Refer to Woodward Service Bulletin 33580 or subsequent. Starter/Generator (Ref. Chapter 24) Every 1,200 hours. Propeller Propeller Refer to McCauley Service Bulletin Number 137 or subsequent. Fuel System Firewall Shutoff Valve (Ref. Chapter 28) When the leakage rate reaches 2.0cc per minute. Engine-Driven Fuel Boost Pump (Ref. Chapter 73) Refer to the applicable manual in the Starship Component Maintenance Manual. 9 Utility Systems Windshield Wiper Blade Assembly (Ref. Chapter 30) When the blade does not clear wipe area effectivity. When the blade does not clear wipe area effectivity. Every 24 months. Engine Fire Extinguisher Cartridge (Squib) (Ref. Chapter 26) Total cartridge life is 10 years from the date of manufacture with the exceptions stated in Chapter 26-20-00. Self-Luminous Cabin Signs Inspect 5 years from manufacturer’s date stamped on sign and annually thereafter. Replace when brightness level drops below 160 microlamberts. Refer to Chapter 33-20-00 for the locations of the signs. CHART 1 (Continued) OVERHAUL AND REPLACEMENT SCHEDULE ITEM OVERHAUL OR REPLACE STARSHIP 1 MAINTENANCE MANUAL Page 1 B10 Oct 31/06 5-20-00 000 5-20-00 SCHEDULED MAINTENANCE CHECKS - MAINTENANCE PRACTICES WARNING: Anytime the airplane is on the ground (whether on jacks or on the wheels), the nose and main landing gear MUST be pinned in the down and locked position. The only exceptions to this would be during landing gear operational checks, during the removal or installation of the landing gear components, and during taxiing operations prior to takeoff or after landing. When any work is being performed in the nose gear wheel well, the nose gear doors MUST be pinned in the open position. Refer to Chapters 32-10-00 and 32-20-00 for the proper lock pin installation procedures. The time periods for the inspections noted in this schedule are based on normal usage under average environmental conditions. Airplanes operated in humid tropics, or in cold, damp climates, etc., may need more frequent inspections for wear, corrosion, lubrication, and/or lack of maintenance. Under these adverse conditions, perform periodic inspections in compliance with this guide at more frequent intervals until the owner or operator can set his own inspection periods based on the contingencies of field experience. Airplanes operated less than 600 hours in 36 months must have a "C" Inspection performed no later than 36 months following the date of the preceding "C" Inspection. NOTE: Ascertain that all placards are in place and legible whenever the airplane has been repainted or touched up after repairs. Replace any placards that have been inadvertently defaced or removed. Raytheon Aircraft Company’s Recommended Inspection Program in accordance with FAR 91.409 (f)(3) consists of, but is not limited to, inspection items listed in this Inspection Guide, any applicable Airworthiness Directives issued against the airframe or any equipment installed therein, conformity to Type Certificate Data Sheet and Maintenance Manual Chapter 4 as applicable. The owner or operator is primarily responsible for maintaining the airplane in an airworthy condition, including compliance with all applicable Airworthiness Directives as specified in Part 39 of the Federal Aviation Regulations. It is further the responsibility of the owner or operator to ensure that the airplane is inspected in conformity with the requirements of Parts 43 and 91 of the Federal Aviation Regulations. Raytheon Aircraft Company has prepared this inspection guide to assist the owner or operator in meeting the foregoing responsibilities. This inspection guide is not intended to be all inclusive, for no such guide can replace the good judgment of a certified airframe and power plant mechanic in the performance of his duties. As the one primarily responsible for the airworthiness of the airplane, the owner or operator should select only qualified personnel to maintain the airplane. While this guide may be used as an outline, detailed information of the many systems and components in the airplane will be found in the various sections/chapters of the maintenance manual and the pertinent vendor publications. It is also recommended that reference be made to the applicable Maintenance Handbooks, Raytheon Aircraft Service Bulletins, applicable FAA Regulations and Publications, Suppliers Bulletins and Specifications for torque values, clearances, settings, tolerances, and other requirements. It is the responsibility of the owner or operator to ensure that the airframe and power plant mechanic inspecting the airplane has access to the previously noted documents as well as to this inspection guide. Raytheon Aircraft Company issues service information for the benefit of owners and operators in the form of two classes of Service Bulletins. MANDATORY (Red Border) Service Bulletins are changes, inspections or modifications that could affect safety. The factory considers compliance with these Service Bulletins mandatory. OPTIONAL (No Border) Service Bulletins cover changes, modifications, improvements or inspections which may benefit the owner. Due to the wide range of information covered by the OPTIONAL Service Bulletin, each owner or operator is responsible for conducting a thorough review of each Optional Service Bulletin to determine if compliance is required based on the applicability of the OPTIONAL Service Bulletin to his particular set of operating conditions. 5-20-00 STARSHIP 1 MAINTENANCE MANUAL Page 2 Oct 31/06 B10 In the final analysis it is the responsibility of the owner or operator to ensure that all previously issued Class I and II Service Bulletins which are pertinent to his particular operation are complied with. NOTE: In addition to the inspections prescribed by this schedule, the altimeter instrument and static system and all ATC transponders MUST be tested and inspected at 24 month intervals in compliance with the requirements specified in FAR Part 91. Owners or Operators wishing to utilize Inspection Intervals less than 100 hours may do so without obtaining Raytheon Aircraft Company’s concurrence. Refer to the latest revision of this form for inspection procedure details to meet FAR 91.409 (f)(3). Inspection timetables are as follows: NOTE: Inspections that are asterisk noted, must also be performed at the first "A" inspection after manufacture. SCHEDULED INSPECTION GENERAL INFORMATION INSPECTION INTERVAL TOLERANCE To facilitate scheduling inspections, Raytheon Aircraft Company authorizes the following inspection interval tolerances: LETTER INSPECTIONS (HOURLY INTERVAL) A tolerance of ± 10 hours is allowed. Each letter inspection must be completed with 10 hours of the prescribed time. EXAMPLE: A “B” CHECK INSPECTION, due at 200 hours, may be accomplished anytime between 190 hours and 210 hours. The subsequent “A” INSPECTION, due at 300 hours may be accomplished anytime between 290 hours and 310 hours, etc. SPECIAL INSPECTION ITEMS - CALENDAR DATE LIMITED A tolerance of ± 12 days per 12 calendar months is allowed, not to exceed a total of 60 calendar days. Inspection A To be performed every 100 hours. Inspection B To be performed every 200 hours concurrent with "A" check. Inspection C To be performed every 600 hours concurrent with "A" and "B" checks. Inspection D To be performed every 2400 hours concurrent with "A", "B" and "C" checks. This inspection is not required at the first 2400 hour interval, the first "D" check is to be performed at 4800 hours. Inspection E Reserved for future use. STARSHIP 1 MAINTENANCE MANUAL Page 3 B10 Oct 31/06 5-20-00