Maintenance and Rigging Manual 2T-1A-2 MaintenanceManual

 

Maintenance And Rigging Manual Model 2T-1A

Section I - INDEX

 

Great Lakes Model 2T-1A-2

CONGRATULATIONS Welcome to the class of Great Lakes Lakes Owners. Owners. Your Great Lakes has been designed and constructed to give you the most in performance. AIRCRAFT REQUIREMENTS: Fuel Capacit Fuel Capacity: y: Total................. Total............................................... ................................................. ................... 27.4 Ga Gal. l. Oil Cap Capaci acity: ty: Total... Total................................. ............................................................ ................................... ..... 8 Qua Quarts rts Engine Engi ne – Lycoming.... Lycoming........... ............... ............... ............ ..... IO-360-B IO-360-BIF6 IF6 or AEIO-360AEIO-360-BIF6 BIF6 Propellers – Hartzell: Constant Speed Constant Speed ............... ....... ............... ............... ............... ............... ........ HC-C2Y HC-C2YK-4F/FC K-4F/FC 7666A-2 7666A-2 Pitch Settings (30” Station) Low ........................................................ Low ...................................................................................... ................................ ..12.5 12.5 High.............................................. Hi gh............................................................................ .......................................... ............26.8 26.8

Section I - INDEX

 

Section I

Great Lakes Model 2T-1A-2 System Details

Index Page

FUEL FU EL SYSTEM SYSTEM ......................................................... ........................................................................... ..................II-1 1 FUEL SYSTEM ASSEMBLY..........................................I-2 FUEL FU EL GAUG GAUGE E ASSEM ASSEMBL BLY Y ........................................... ...........................................II-3 3 OIL OI L SY SYSTEM. STEM............................... ............................................................ ................................................ ..................II-4 4 ENGI EN GINE NE OIL OIL CHART CHART ..................................................... .....................................................II-5 5 LANDI LA NDING NG GEAR GEAR SYSTEM SYSTEM ........................................................ ........................................................II-6 6 LANDI LA NDING NG GEAR GEAR ASSEMBLY SSEMBLY ...................................... ...................................... II-7 7 SHOCK STRUT STRUT SERVICE SERVICE INSTRU INSTRUCTIONS............. CTIONS.................... ............... .......... .. I-8 SHOCK SHO CK STRUT STRUT AS ASSEM SEMBL BLY Y ......................................... .........................................II-9 9 HYDRAULIC BRAKES.............................................................I-10 BLEED BL EEDING ING INSTRU INSTRUCTIO CTIONS NS ................................................... ................................................... II-10 10 HYDRAUL HY DRAULIC IC BRAKES BRAKES ASSEMBLY......... ASSEMBLY................. ............... .......... ... I-11 BRAK BR AKE E ADJUSTMEN DJUSTMENT T ........................................................... ............................................................. II-12 12 MAIN MA IN WHEEL WHEEL BEARING BEARING SERVICIN SERVICING G ............... ....... ............... ............... ............. ..... I-12 MAIN MA IN WHEEL WHEEL BEARING BEARING ASSEMBL ASSEMBLY Y ............... ........ ............... ........ I-13

Section I - INDEX

 

Great Lakes Model 2T-1A-2 Section Sect ion I

System Deta Details ils

FUEL SYSTEM:  SYSTEM:  Fuel is supplied to the engine by the engine d drive rive pump. Fuel flows from the main tank in the center section through a header tank in the fuselage, through the fuel shut-off valve, the strainer, the fuel boost pump, (which is used for starting and emergency operation) to the engine driven pump. Four lines connect the main tank to the head header er tank, the RH forward line vents air from the header tank to the main tank. The fuel shut-off valve has a control control in each cockpit. It is also important that the holes in the vent on top of the main tank be kept open. A hole is also provided on the aft side of the vent in case the forward hole should become obstructed during flight. The fuel gauge is a simple, trouble free, float indicating type with reading taken on the bottom of the indicator. Drain valves are provided at the fuel gauge. gauge. At the aft left hand corner of the fuel tank, and on RH side of the front cockpit approximately approximat ely 8 inches aft of of the firewall firewa ll for the he head ader er tank. The fuel strainer is provided with a drain operated by a pull control near the oil filler. Use 100/300 100/30 0 Octane fuel.

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Great Lakes Model 2T-1A-2 Section I

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Great Lakes Model 2T-1A-2 Section Sect ion I

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OIL SYSTEM:  SYSTEM:  During normal flight oil flows from the left fitting in the bottom of the engine through the firewall mounted oil valve, the center hose from the oil valve, the sump screen (on the right rear bottom corner of the engine), the engine driven pump and to the engine lubricating points. During inverted flight oil flows from the breather port at the top rear center of the engine, to thehose “T” fitting (inoil thevalve, line tothe thesump oil separator), to the oil valve, the center from the screen, the engine driven pump and to the engine lubricating lubricat ing points. The right forward hose becomes the breather line during inverted flight. The oil separator allows oil breather exhausted oil to separate and return to the oil system while still providing for a pressure release for the engine. The oil breather overboard overboar d line, connecting to the oil

separator, runs through the firewall on the right top side, through the fuselage to just forward of the tail wheel, where it exhausts overboard. The Great Lakes is the only aircraft made with a factory certified oil breather exhaust extending to the tail, saving much clean up time. The inverted oil system used is approved by Lycoming for indefinite inverted flight, however extreme slipping, skidding and half way maneuvers, such as knife edge flight, vertical climbs and any other zero “G” maneuvers of other than momentary duration, should be avoided, as these maneuvers will cause the oil valve balls to move off their seat allowing the pump to draw air which will cause an immediate loss of oil pressure.

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Engine Oil Chart Engine Oil, Aviation Grade: Ref. Lycoming Service Instructions 1014E

  e   r   u    t   a   r   e   p   m   e    T   g   n    i    t   a   r   e   p    O

  m   u   m    i   x   a    M

   F    °    5    4    2

   5    4    2

   5    2    2

   0    1    2

   d   e   r    i   s   e    D

   F    °    0    8    1

   0    8    1

   0    7    1

   0    6    1

   0

   0    3      W    0

   0    3   -

  y    t    i   s   o

   0    5   r

  c   s    i    V      i    t    l   u    M

  o    0    4    E    A    S

   4    E    A    S

  y    t    i   s   o   c   s    i    V   e    l   g   n    i    S

   0    5    E    A    S

   0    4    E    A    S

   F    °    0    6   e   v   o    b    A

 

   F    °    0    9   o    t    °    0    3

   2   r   o    0    4    E    A    S

   W    0    2    E    A    S

   0    3    E    A    S

   0    2    E    A    S

   F    °    0    7   o    t    0

   F    °    0    1   w   o    l   e    B

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Great Lakes Model 2T-1A-2 Section Sect ion I

System Deta Details ils

Landing Gear System: The Great Lakes has a conventional Gear system and a gear shock system of a combination fluid oleo and internal spring shock strut. The main gear tires are 600 X 6 with an inflation pressure of 29 PSI. the tail gear tire is a 2.8/2.5 4 with with an inflatio inflation n pressure of 25 PSI. the shock strut fluid, in flight, is in the lower strut chamber containing the spring. When a load is applied to the spring, spri ng, flui fluid d is forced through restrictions into the upper chamber dampening the spring action. When the load is removed, the fluid drains again into the lower chamber.

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Great Lakes Model 2T-1A-2 Section I

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Great Lakes Model 2T-1A-2 Section Sect ion I

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SHOCK STRUT SERVICE INSTRUCTIONS:  INSTRUCTIONS:  Very little servicing servici ng is is requir required ed with this type of strut. str ut. If a leak should develop, strut must be removed for repair. To remove strut the spring loading must first be removed by jacking aircraft near top attach point of strut. With spring loading removed, remove bolts at both ends of shock strut. Top cap then will slip off off and lower fairing may be removed by loosening clamps. cla mps. No compression load exist existss on spring with with strut removed removed from airplane. To disassemble strut, remove packing nut at top of lower lower cylinder. Slide nut up piston and using small hook remove packing. Clean packing area and threads as needed. Generally Generall y packing can be turned over and reinstalled reins talled to stop leak, or a new packing acquired from WACO Classic Aircraft (Part number 20102-12, 20102-12 , Packing Rings.) After repacking, install and tighten pack nut. Service strut with with 16 oz. Of MIL0H-5606 MIL0H-560 6 hydraulic hydraulic fluid (red.)

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Great Lakes Model 2T-1A-2 Section Sect ion I

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Great Lakes Model 2T-1A-2 Section Sect ion I

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HYDRAULIC BRAKES: The heel operated brakes provided in each cockpit are connected by direct linkage to two m mast aster er cylinders locat located ed below the floor. floor . A hydraulic fluid reservoir is located forward of the rear stick above the floor for accessi accessibility. bility. To insure insure perfect opera operation, tion, keep the system free from fro m bubbles. The reservoir should be complet completely ely filled. See that the lines from the master cylinders to the wheels are free from air by bleeding (see bleeding instructions), after system has been filled from a dry reservoir, or at any time system has been opened for servicing, or there is a spongy response to the brake pedals. BLEEDING INSTRUCTIONS: Remove cap from reservoir, place pan under it to catch overflow. Attach line at bleed port at brake and slowly pump hydraulic fluid (MIL-H-5606, red) through system until no bubbles are visible. visible. A pump type oil can may be used for this purpose. A longer line line also can be attached to a fluid supply held above the level of the reservoir and the system gravity fed.

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BRAKE ADJUSTMENT: Brake pads should be replaced when worn to near rivets. MAIN WHEEL BEARING SERVICING:  SERVICING:  Remove cotter cotter key and nut nut at axle. Remove spacer and wheel. If washers are removed at the inboard side of the wheel, note installation sequence as washer with largest inside diameter must be installed inboard foings for r proper installation installat ion of wheel. wheel . Remove snap rings retaining both bearings bear in wheel. Thoroughly clean both bearings in suitablee solvent and dry be suitabl bearings. arings. Inspect bearings for for damage and regrease with MIL-G-25760 aircraft wheel bearing grease or equivalent. Inspect grease seal for damage and replace if if needed. Install bearings in wheel and install wheel on axle. Torque axle nut to tight, back off

to first cotter pin hole, install cotter pin.

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Great Lakes Model 2T-1A-2 Section Sect ion I

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Section II

Great Lakes Model 2T-1A-2 Lube & Service

Index Page

LUBRICATION LUBRICA TION AND SERVICING SERVICING CHA CHART RT....... ............... ............... ............... ........IIII-1 1 EACH EA CH 50 HOUR HOURS S ........................................................... .......................................................................II............II-2 2 EACH EA CH 100 HOUR HOURS S ......................................................... .....................................................................II............II-5 5

Section II - INDEX

 

Great Lakes Model 2T-1A-2 Section II

Lube & Service

  s    t   n    i   o    P   e   g   n    i    H    3   –    R    E    D    D    U    R  .    6

  s   e    d    i    S    h    t   o    B  ,   s    t   n    i   o    P   e   g   n    i    H    2   –    R    O    T    A    V    E    L    E  .   7

   I    I    I   n   o   n   i   o   t    i   c    t   e   c   e   S    S   m    M    E   t   e   a   t    T   r    S   h   s   y    Y   C   S    l    S   l    i    i    L    O    I    O   e   e    O   i   n   i   n    E   g   g   n   n    N    I    E   E  .    f  .    G   f    N  e   e    E   R   R    .1    

   S   s   D    t   n    i    O   o   R    P   E   e   G   g   n   A    i    H   K    4   N    I   –   L    S   S   t   s    L   L   n    A   A   i   o    D   D   P    E   E   e    P   P   g   n    E   E   i    K   K   H    A   A   4    R   R    B   B  .    2   1    

   K    C    S    O    G    H    N    I    S    R    D    A    N    E    A    B    S    L    T    E    U    E    R    H    T    S   s    W    R    R   t   n    A    A   i   o    E    E   P    G    G  e   g    G  s    G   i   n   e   c    N    N   a    I    H    I    l    D   P    D   2    N   2    N   1    A    A    L    L  .  .    3    4   1     1  

   D    N    A    E    C    I    V    R   N    E   O    S   I    G   R   T    N   O   A    I    C    C   F    I    I    I    V   I    R    R   N   B    E   O   U    L    S   I    T    R   C   R    E    E   E   P    L   S  .    O    L   f    E   e   R    P    P   R    O    R    P  .    5   1    

   B    S    E    U    B    T    U    K    T    E    N    L    I    K    N    T   s   L    E    B    A    I    B    t    C   n   G    U    C   s   L    E    i    N    t   o    I    T    R    N   n   G    i    N    N    P   T    G    O   o   I    C    P   T    O   e    N    T   g   E    I    A   n   N   e   C    C    i    R    V   g    E    H   n   E    A    E    i    N    L    2   N    O    E    L    H   N    B    8   O    A   –   C    B    E   –   C    C    N   N    N    N    M    M    M    S   S    S    M    U   t    U    t    L   L   t   s   s   U   s   L   s   U    L    A   A  n   A   t   n   n   L   n   O   L   s    L    i    i    i    O    O    O    D   D   i    D   p   o   E   o   C   C  o   C  u   C   o    E   E   P    P    P    P    P   P   e   P   e   L   L   e   L   C   L   T   e   e    C  g   g   O   O  g   O   b    R   R  g   n   n   R  u   O   n   R   R   i   n   R    E   E   i    E   i    R   E   i    D   D   H   D   H   T   T   H   T   L   T   N   H    D   D   4   D   2   N   N   2   N   2   N   N   2    U   U    U    O   O    O    O   O    R   R    R    C   C    C    C   C    .3                        

   F    A    T    H    C    S      E   s   N    W    t    E    i   n   N    R   o   O    C    P    S    t    C   o   M    S    i   v    R    P   A    O    2   E    B    T    A   –   R    U    R   A    T    O   P    C    T   S    A    A   T    N    M    U    T   O    I   s    C    R    R   t   n    T    A   F   i   o    R    R   R   P    E   s   E   E   e    Z    Z    Z   e    I   c   I    I   g   n    L   l    L   i    L   I   a   I    I    B   P   B   B   H    A   2   A   A   2    T    T   T    S    S   S    .4        

   E    L    B    A    C    Y    Y    L    L    B    B    M    M    E    E    S    S    S    S    A    A    N    N    R   t   s   R   s    O  n   O    t   n    i    H   i   o   H   o    R   P   R    P   e    O  e    O   T    C  g    T   g   n   n   T    i    A   i    A   E    H    V   H   V   N    E   4   E   N   2    L    L   O    E    E   C    .5          

   T    S    C    T    E    E    R   s    L    N    O    k    B   r    N    P   e    A    O    P    Z    C    U    C    S    2    L    E    E   –    O    B    B    Y    R    U   t    U    L    T    T   s   n   T    B    N    L   i    O    L   o    M    C    O   J    O    E    R   t   e    S    E    T   k   R    S    K    T    N  c    A    A   o   N  s    O    S   p    L    R    C   d   O    C  u    E    B   n    C    E    G  s    N   a   N  e    H    N  e    O   l   c    O   a    R   l   a   R   b   u    W    I    l    L    B    K   P    E    L    L   4   E    I    R   2    I    L    2    A    A    A    I    A    T    P  .  .  .    0   8   9     1      

   S    E   s    B  e    U   d    i    T   S    E   h    t    V  o    A   B  ,    L   s    S   t   n    S   i   o    N   P    O  e    R  g   n    E   i    L   H    I    A   2    .2  

   S    G  s   e    N    I    d    R   i    S    A   h    E   t   o    B   B    E   r  ,    G  e   p    N    I   p    H   U    S   2   r    N   /    O  e    R  w   o    E   L    L   3    I    A  .    1   1  

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Great Lakes Model 2T-1A-2 Section Sect ion II

Lube & Service

EACH 50 HOURS:  HOURS:  Battery servicing involves adding distilled water to maintain the electrolyte even with the horizontal baffle plate at the bottom of filler holes, checking the battery cable connections, and neutralizing and cleaning off any spilled electrolyte electrolyt e or corrosion. Use bicarbonate bicar bonate of soda (baking soda) and water to neutralize electrolyte or corrosion. Follow with a thorough flushing with water. water. Brighten cables and terminals with a wire brush, then coat with petroleum jelly before connecting. The battery box also should be checked and cleaned if any corrosion corr osion is noticed. Distilled water, not not acid or or “rejuvenators”, should be used to maintain electrolyte electrolyt e level. Check the battery ever ever y 50 hours (or at least every 30 days), oftener in hot weather. Check tires for proper inflation. ENGINE OIL SYSTEM:  SYSTEM:  Engine oil should be checked with the oil dipstick 5 to 10 minutes after stopping the engine to allow the oil to flow back into the sump. Engine oil should be drained while the oil is still hot. On aircraft equipped with an external oil filter, change engine oil and filter element at 50-hour intervals. On aircraft aircra ft NOT equipped equipped with an external oil filter, change engine oil and clean the oil screen EVERY 25 HOURS. Change oil every four months even though less than the specified hours have accumulated. accumulat ed. Reduce these thes e periods perio ds for prolonged operation in dusty areas, in cold climates where sludging conditions exist, or where short flights and long idle periods are encountered, encounter ed, which cause sludging conditions. Always change oil, and replace filter elements or clean the oil screen, whenever oil on dipstick appears dirty.

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Great Lakes Model 2T-1A-2 Section Sect ion II

Lube & Service

EACH 50 HOURS:  HOURS:  Induction air filters keep dust and dirt from entering the induction system. Dust induct inducted ed into the intake system is probably probab ly the great greatest est single cause of of early engine wear. wear. The filters should be removed and cleaned every 50 hours maximum when operating under ideal conditions and more frequently if warranted by operating conditions. Under extremely dusty conditions, daily maintenance of filters is recommended. Some opera operators tors prefer to hold hold a spare filter at their home base of operation so that a clean filter is readily available for use. NOTE: Keeping a supply of clean, serviced filters on hand will speed up air filter servicing. To service the dry type filter, proceed as follows: (a)  Remove the filter from the airplane. (b)  Clean the filter by blowing with compressed air (not over 100 psi) from direction opposite of normal air flow. Arrows on filter case indicate direction of normal air flow. NOTE:   Use care to prevent damage to filter element when NOTE: cleaning filter with compressed air. (c) After cleaning as outlined in step “b” filter filter may may be washed, if necessary, with a mild household detergent and warm water solution. NOTE: The dry filter may be cleaned with air a maximum of 30 times or it may be washed a maximum of 20 times. It should be replaced replac ed after 500 hours hours of engine operation or one year, whichever occurs first. NOTE:  Replace filter if damaged. NOTE: 

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Great Lakes Model 2T-1A-2 Section Sect ion II

Lube & Service

EACH 50 HOURS:  HOURS:  CAUTION:  CAUTION: 

Do not use solvent or cleaning fluids to clean filter. Use only a mild household househol d detergent and warm water solution when washing the filter.

(d) After washing, rinse filter in clean water and allow water to drain drain from filter. Dry filter with compressed air (not over 100 psi). (e) Be sure induction air box is cle clean, an, and alternate alternat e air inlet door functions properly. (f) Install filter in air box with gasket gasket on aft face of filter frame and with air flow arrow on filter pointed in the correct direction.

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Great Lakes Model 2T-1A-2 Section Sect ion II

Lube & Service

EACH 100 HOURS:  HOURS:  (1)  Spark Plugs – Clean, test and regap. (2)  Fuel System Drains – Open valves and drain off any water and sediment. Drain valves are provided at the fuel gauge. At the aft left hand corner of the fuel tank, and on RH side of the front cockpit approximately 8 inches aft of firewall for the head header er tank. The fuel strainer stra iner is is provided with with a drain operated by a pull control near the oil filler. Use 100/130 Octane fuel. (3)  Brake Master Cylinder – Check fluid level and refill as required using MIL-H-5606 hydraulic fluid (red). (4)  Fuel Strainer – Disassemble and clean bowl and screen. (5)  Stabilizer Trim Actuator – Check freedom of movement and lube with with WD 40 (Silicone). Check for for proper tension on cord. Forward pulley may may be relocated relocat ed to another ho hole le in bracket to increase tension. (6)  Wheel Bearing Lubrication – It is recommended that main wheel bearings be cleaned and repacked at the first 100-hour inspection and at eeach ach 500-hour inspect inspection ion thereafter. thereaft er. If more than the usual number of take-off and landings are made, extensive taxiing is required, or the airplane is operated in dusty areas or seacoast conditions, it is recommended that cleaning and lubrication of wheel bearings be accomplished acco mplished at each each 100-hour inspecti inspection. on. MIL-G-25760 is recommended. (7)  grease Check tail surface movement for freedom and that no excessive play exists. exists. Lube with WD 40 (Silicone). Use amount only as needed. Wipe off any excess. excess. (8)  Check ailerons ailero ns for freedom of movement, and securit security. y. Lube aileron hinges only with dry lube such as Powdered Graphite. (9)  Make visual inspection of coverings. (10)  Inspect landing gear attach fittings.

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