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SERVICE AND MAINTENANCE-- MANUAL M00NEY AIRCRAFT

1. JK JK JK JK JK JK JK JK JK JK JK JK JK JK JK JK JK JK JK JK JK JK JK JK JK JK JK JK JK JK JK JK JK JK JK JK JK JK JK JK JK JK JK JK LS117A LS118A LS119A LS120A L5121A LT101A LT102A LT103A LT104A MA101A MA102A MA103A 104 101 MB102A MB103A MB104A MB105A MB106A MB107A MB108A MB109A MB110A MB111A MB112A MB113A MB114A MB115A MB116A MB117A MB118A MB119A MB120A MB121A MB122A MB123A MB124A MB125A MB126A MB127A MB128A MB129A MB130A MB131A MC102A PLUG STROBE LIGHT ASSY SOCKET LIGHT ASSY TAIL STROBE RECEPTACLE 3 PIN PIN RECEPTACLE 3 PIN PIN RECEPTACLE 3 PIN PIN C B TAXI LIGHT SWITCH TAXI LIGHT BULB TAXI R W 28V BULB TAXI LAW 28V RECEPTACLE AUX POWER RELAY AUX POWER AMP AMP MOONEY AMP AMP AMP AMP AMP AMP KLIXON MOONEY GE GE GUTLER HAMMER CUTLER HAMMER SARKES TARZIAN ALT DIODE DIODE ALT ALT GE C B AVIONICS MASTER MOONEY RELAY AVIONICS MASTER KISSLING DIODE ALT ALT GE AVIONICS BUS BAR 1 MOONEY AVIONICS BUS BAR 2 MOONEY AVIONICS BUS BAR 3 MOONEY C B INTERCOM KLIXON C B COM 1 KLIXON C B NAV 1 KLIXON C B AUDIO KLIXON C B PHONE KLIXON C B ADF KLIXON C B COM 2 KLIXON C B NAV 2 KLIXON C B TRANSPONDER KLIXON C B ENCODER KLIXON STERO KLIXON C B DME KLIXON G B R
2. FUNCTION SWITCH ARRANGEMENT 3 84 85 86 57 GALLONS ON OFF OFF NA NA POUNDS OFF ON OFF NA NA LITERS OFF OFF ON NA NA FT 101 TRUTH TABLES FIGURE 73 1 12 98 73 00 00 3 SERVICE AND MAINTENANCE MANUAL 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 automatic dimming through a photo sensor K FACTOR NOT USED UNITS K FACTOR NOT USED UNITS M20J MOONEY AIRCRAFT CORPORATION 2 ELECTRONICS The TRU FLOW 1 amplification system is located in the indicator away from the engine environment The TRU FLOW 1 operates on a low power requirement and is protected against voltage surges 3 MEMORY The TRU FLOW 1 microprocesser continously updates and stores the total fuel used quantity The total fuel used quantity is retained during aircraft shutdown through a low power drain memory circuit connected to the battery 4 INTERNAL CONTACT ARRANGEMENT The configuration selection block located inside the TRU FLOW 1 indicator has several arrangements to change data readout if desired Jumpers should not be changed unless the K factor of the transducer has changed due to replacement See Section 73 31 02 3 for K factor description Refer to Figure 73 3 for Alcor contact arrangement CAUTION Some components in t
3. maaa w a ens ng PE ea s AE dan me Ce am SVD SA SD SMN ant amp gt ED GREP GRE ht am mn fu Mr a eS SO ee OXYGEN FILLING PRESSURES VS TEMPERATURE FIGURE 35 2 12 98 35 00 02 5 MOONEY AIRCRAFT CORPORATION M20J SERVICE AND MAINTENANCE MANUAL BLANK 35 00 02 12 98 6 SERVICE AND MAINTENANCE MANUAL M20J MOONEY AIRCRAFT CORPORATION CHAPTER 37 VACUUM AIRCRAFT CORPORATION M20J SERVICE AND MAINTENANCE MANUAL CHAPTER 37 VACUUM LIST OF EFFECTIVE PAGES CHAPTER SECTION SUBJECT uw uw PAGE a ox x DATE 37 Effectivity V2BLANK 12 08 37 Contents S3M4BLANK 1298 37 00 00 e umo Uk OLI E opo Q a st 7 12298 37 11 04 6 12 98 37 13 00 7 12 98 37 21 05 8 12 98 37 40 00 9 12 98 37 41 00 10 12 98 12 98 37 EFFECTIVITY 1 2BLANK SERVICE AND MAINTENANCE MANUAL M20J 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 02 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 indicating CHAPTER 37 VACUUM LIST OF EFFECTIVE PAGES General Distribution Dry Air Pump Maint
4. 18 5f I TIMER TO BRUSH MODULE BRUSH MODULE FO GROUND 14 15 ft I SHUNT LEADS 2 820 5f i 30 61 02 TROUBLESHOOTING CHART PROPELLER DE ICE TROUBLE PROBABLE CAUSE REMEDY Ammeter reads 0 current all No power from aircraft If no voltage into circuit breaker locate phases of the timer cycle Tripped circuit breaker Circuit breaker or switch faulty Ammeter Faulty Open in ammeter to timer circuit Open in timer to brush assembly ies circuit 12 98 and correct open Locate and correct short before resetting circuit breaker If no voltage at circuit breaker output with voltage at input and circuit breaker does not reset replace circuit breaker If voltage is OK at output check switch in same manner If voltage is OK at switch output go to Ammeter Faulty Test ammeter per Section 30 62 00 Disconnect hamess at timer and check for appropriate voltage at harness Pin B 12V Terminal C 28V to ground If none locate and 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 cont Ammeter reads normal current part of cycle zero current rest of cycle Ammeter reads normal
5. Baggage Compartment Door Latching Mechanism 7 12 98 52 EFF CONTENTS 1 2BLANK SERVICE AND MAINTENANCE MANUAL 52 00 00 GENERAL The cabin door is constructed of an inner and outer aluminum shell fastened together by rivets W is provided with a dual latching mechanism 1 a lock pin extends into a mating receptacle 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 interconnected by adjustable push pull tubes This mechanism is spring loaded to an over center position in the latched position for positive security Adjustment for each push pull tube is provided to accurately rig the latching pin and the jaw type latch Adjustment to the special nut at the top ofthe door frame can be made for proper closure The baggage compartment door is constructed of 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 inside of the baggage door This handle can be operated only from the inside even if the outer handle is locked cam mechanism allows a clevis pin to bypass the outer handle latch groove and open the two latching pins which hold the bag
6. VR 802 JK PA113A RECPT VOLTAGE REG AMP 206705 2 in CLAMP AMP 206966 1 JK PA114A PLUG VOLTAGE REG AMP 206708 2 CLAMP AMP 206966 1 K PA115A ALTERNATOR 2 CONTINENTAL 649283 or 649172 JKL FILTER MOONEY 880014 501 JKL 117 MALLORY CGS302U 050R2C J ALTERNATOR 1 RIGHT LYCOMING LW 14367 ALTERNATOR ALT PRESTOLITE ALU 6421 LS J 42 ALTERNATOR NOT USED AT THIS TIME JK PA120A FUSEHOLDER LITTEL 155020 or 155120 FUSE 5A LITTEL 313005 JK PA121A SWITCH EMERGENCY FIELD SB1DDX492 2 LOCKING RING 29 761 LOCK WASHER C H 16 886 NUT HEX 15 996 6 EE LAMP GE 388 JK PA122A DIODE SARKES TARZIAN 10HaP JK PA123A DIODE SARKES TARZIAN 10HaP JK PA124A SWITCH ALTERNATOR FIELD 880052 503 JK PA125A DIODE SARKES TARZIAN 10H3P JK PA126A DIODE SARKES TARZIAN 10H3P L PAI50A ALTERNATOR LT PORSCHE 933 603 004 00 L 51 ALTERNATOR RT PORSCHE 933 603 004 00 L PAi52A OVERVOLTAGE CONTROL LT ELECTRO DELTA 098 400 L PAi53A PLUG OVERVOLTAGE CONTROL LT AMP 206708 1 CLAMP AMP 206966 1 154 OVERVOLTAGE CONTROL RT ELECTRO DELTA OS 400 L 155 PLUG OVERVOLTAGE CONTROL RT AMP 206708 1 CLAMP AMP 206966 1 L SWITCH OVERVOLTAGE RESET LT C H SB1DDX492 2 LOCKING RING C H 29 761 LOCKING WASHER C H 16 886 m NUT HEX 2 ea C H 15 966 6 LAMP GE 388
7. 12 co 12 98 21 50 00 cho tse G Xe 1208 27 60 00 ic A natum oo ae a SANG de VE deor In 12 98 21 00 01 de ANE x eio nA cx ou NE un 12 908 27 9440 Sp lt 36 AA so vw 12 98 ue EE Age ee NS 12 08 27 96 00 1Bo se su ou vu vo 12 98 12 98 27 EFFECTIVITY 1 2BLANK MOONEY AIRCRAFT CORPORATION M20J SERVIGE AND MAINTENANCE MANUAL CHAPTER 27 FLIGHT CONTROLS TABLE OF CONTENTS CHAPTER SECTION SUBJECT SUBJECT 27 00 00 General 27 10 00 Aieron System Bud 27 20 00 Rudder amp Steering System 27 30 00 Elevator System i 2730 03 Empennage Free Play 27 31 00 Trim Assist Bungee Rigging 27 40 00 Stabilizer Trim System 27 40 01 Trim System Troubleshooting 27 42 00 Electric Trim Pitch Maintenance 27 50 00 Wing Flap System 27 60 00 Alileron Rudder Interconnect System 27 90 00 Miscellaneous 27 91 00 Control Surface Stalic Balancing 27 92 00 Equipment Static Balancing 27 93 00 Balancing Proce
8. 22 91 20 01 13 SERVICE AND MAINTENANCE MANUAL CODE 204 14 VOLT ELECTRICAL EQUIPMENT CHART DESCRIPTION VENDOR MOONEY AIRCRAFT CORPORATION PART NO NOTES gt gt gt _ gt gt m O T y 7Tty r XU SS SS SS 21 21 21 21 91 20 01 14 EG11A EG12A ELO1A ELO2A ELO3A ELO4A ELO6A ELO7A ELOBA ELO9A ELT2A EWO1B JMO1A JMO1B 2 JM02B JMO2C JMO2D JMO2E JMO3A JM03G JM03D JM03E JV01A LBO1A LB01B LB01D LBO2A LCO1A LCO2A LC02B LCO3A LCO3B LCO3C LC03D LCOSE LCO4A LC04B G LCO7A DIODE GEAR UP RELAY DIODE GEAR DN RELAY TRANSISTOR FUSE HOLDER RESISTOR RHEOSTAT SW PLACARD CB PLACARD FUEL SEL PLACARD ANNUN PLACARD CK LIST ELT ALT ELT TRANSMITTER OPT SWITCH REMOTE ELT ALT G B GEAR WARNING 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 G B ROTATING BEACON C B ROTATING BCN SPARES C B ROTATING BEACON LIGHT ROTATING BEACON ADAPTER FUSEHOLDER CLOCK 5AMP FUSE 5A 3AG SLO BLO LIGHT CABIN OVERHEAD BULB LIGHT CABIN OVERHEAD BULB I SWITCH CABIN LIGHT SWITCH CABIN LIGHT FWD SWITCH CABIN LIGHT RE
9. 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 A P TRIM SW RELAY CLAMP AMP 12 98 PART NO 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 1 MS3100A 22 14P M53057 12B 930021 502 206152 1 206070 1 206036 1 206070 1 206841 2 206062 1 206153 1 206062 1 206036 3 206070 1 SERVIGE AND MAINTENANGE MANUAL NOTES 91 20 01 29 SERVICE AND MAINTENANCE MANUAL M20J MOONEY AIRCRAFT CORPORATION 14 VOLT ELECTRICAL EQUIPMENT CHART CODE DESCRIPTION VENDOR PART NO NOTES 21 RC52A RECPT A P PWR AMP 206036 3 CLAMP AMP 206070 1 21 RC53A RECPT A P GRND AMP 206036 3 CLAMP AMP 206070 1 21 RC53B RECPT AVIONICS GRND 1 AMP 206152 1 CLAMP AMP 206070 1 21 RC53G RECPT MAIN CABLE GRND AMP 206036 3 CLAMP AMP 206070 1 21 RC53D AVIONICS GRND 2 AMP 206152 1 CLAMP AMP 206070 1 21 RC54A RECPT INTERFACE PWR AMP 206705 2 CLAMP AMP 206966 1 21 RC55A RECPT COMM NAV PWR AMP 206153 1 CLAMP 206062 1 21 RC57
10. J JKMP105A JKMPOGAT SLIP JKMP15A20 fur JKMP14A20 JKMPO7A1 4 RING PL RCI3A 3 5 WIRING EE JKMP13A20 HARNESS JKMP16A20 8 Su KMPISA20 MODULAR JKMP17A20 4g gs KMP12A20 BRUSH ASSY 1AXFUSECC1A JKMP02A14 MP18A20 IKMPT1A20 RC PLOAA IPM T JKMPO1A14 Eus RC PL33 JUL ASUS BAR 28 VDC AA VOLT SYSTEM EEE S N 24 3000 THRU 24 3153 FIGURE 30 18 PROPELLER DE ICE SCHEMATIC 28 VDC ANNONETA TOR ROP DES ICE CURRENT Moi NITER teser 28 VOLT SYSTEM S N 24 3154 THRU 24 TBA OCK PANEL JK PL206A ERSAULT IK HYTTE JK PL2I2A TETT SIDE PANEL JK RC206A PROP DE ICE TIMER tb 422547 TAILCONE TAILCONE DE ICE JK RC231A 331 M MPIOAT4 POWER i1sA JK MP1014 OB In 45357645 Vo ppt AT JK PB112A MIDI SAOB FIGURE 30 1C PROPELLER DE ICE SCHEMATIC 28 VDC x M 30 61 01 12 98 6 SERVICE AND MAINTENANCE MANUAL M20J MOONEY AIRCRAFT CORPORATION POWER REQUIREMENTS FOR 14 VDC SYSTEM TIME CYCLE ELEMENT HEATED TIME IN SEC S LOAD AMPS D OUTBOARD 90 8 TO 12 F INBD 90 8 TO 12 CYCLE TIME 3 MINUTES POWER REQUIREMENTS FOR 28 VDC SYSTEM TIME CYCLE ELEMENT HEATED TIME IN SEC S LOAD AMPS D 8 ALTERNATING BLADES 90 TOTAL CYCLE TIME 3 MINUTES RECOMMENDED WIRE SIZE CHART I BUSSBARTOTIMER so 15 ft i TIMER TO GROUND
11. ow oi Fiberglass Laminates Repair Procedures 18 STO Vo v 25220 Cracks ln Surface Areas 19 51 1502 eA ek Non Structural Repair 20 51 1503 de e YS AD Common Structural Laminate Repair S C DAR Ge GE Metal Insert 20 91 1504 Common Structural Laminate Repair a dee 221 51 1505 a 3 Fiberglass Delamination Repair 22 51 1600 KD Miscellaneous dan 92 12 98 51 CONTENTS 3 4BLANK SERVICE AND MAINTENANCE MANUAL 51 00 00 GENERAL The Mooney M20J is an all metal low wing airplane The fuselage cabin area is constructed of a welded 4130 chrome molybdenum steel tubular structure The steel tubular structure is covered with non structural aluminum skins fastened to the tubular structure by rivets bolts and screws The tailcone is of semi monocoque type construction nd is fastened to the tubular structure with structural The wing is a tapered iaminar flow one piece wing It is constructed with a one piece full length main spar The spar is constructed from tapered cap strips 7075 aluminum bolted huck bolts to webs 2024 aluminum Aluminum ribs connect the main spar to the aft stub spar and the rear spar Extruded stringers run the full length of the wing spaced chordwise for strength and skin reinforcement The skins are stretch formed wrap around 2024 T3 aluminum ranging in
12. The fuel is contained in wet wing type fuel cells between the main spar and baffles forward of the spar The tanks are sealed during manufacturing with current state of the art technology sealant See Section 28 for fuel system details 57 00 01 WING REMOVAL AND INSTALLATION The major subassemblies of the wing may be removed individually or the wing may be removed as a unit To wing fuselage supporting cradle is needed 1 Wing removal A Remove wing root fairings and bottom fuselage access panels B Drain all fuel from tanks Drain brake lines and reservoir Disconnect hydraulic lines at wing main spar D Remove front and rear seats Remove the two inspection plates under rear seat area E Jack aircraft F Attach A frame hoist to propeller or support with a propeller jack G Disconnect or remove the following 1 Two landing gear assist springs 2 Aileron control tubes at inboard bellcranks 3 Trim control tube at station 59 3 and 94 5 4 Main gear retraction tubes 5 Rudder control tubes 8 Elevator control tube 7 Elevator and rudder push pull tubes 8 Floorboards at rear attach points 8 Belly skin stringer splice angles 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 M20J S
13. gt gt gt gt s s s s JK JK JK JK JK JK JK JK JK JK JK JK JK JK JK JK JK JK C c IN EE e 91 20 03 72 PB115A PB116A PB117A PB120A PB121A PB122A PL201A PL203A PL204A PL205A PL206A PL207A PL208A PL209A PL210A PL211A PL212A PL216A PL217A PL218A PL219A PL220A PL221A PL222A PL222B PL225A PL226A PL227A PL228A BUS BAR 9 BUS BAR 10 BUS BAR 11 GROUND DIMMER BOX PLUG 3 PIN CLAMP RECEPTACLE 3 PIN CLAMP 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 34 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 MOONEY MOONEY MOONEY MOONEY AMP AMP AMP AMP 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 SC
14. 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 balancing procedures 57 50 10 FLAPS Refer to Section 27 50 00 for maintenance and rigging procedures M20J 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 located just inboard of the inboard hinge 2 All four hinges 2 and 3 are faired 4 to reduce drag The internal structure of the flaps consists of a leading edge extrusion 5 trailing edge stiffener 6 ribs 7 and top and bottom skins 8 These components are riveted together into a left hand and right hand assembly 57 50 11 FLAP REMOVAL AND INSTALLATION Refer to Section 27 50 00 for removal and installation procedures FLAP ASSEMBLY FIGURE 57 6 57 40 00 8 12 98 MOONEY AIRCRAFT CORPORATION 57 50 20 AILERONS Refer to Section 27 10 00 for maintenance and rigging procedures The ailerons are of all metal construction The main spar 1 Figure 57 7 is attached to the rear spar 2 through ribs 3 These components are riveted together and a top and bottom skin 4 and 5 riveted to this sub assembly To complete the control surface hinges 6 and balance weights 7 are installed The DETAIL B SMX57 7 M20J SERVICE AND MAINTENANGE MANUAL weights
15. CLAMP AMP 206062 1 JK LC123A SWITCH CABIN DOOR NEWARK B9F5544 JK LC124A RECEPTACLE 2 PIN AMP 1 480319 0 PIN 60620 1 JK LC125A PLUG 2 PIN AMP 1 480318 0 SOCKET AMP 60619 1 JK LC126A SWITCH BAGGAGE DOOR NEWARK 89F5544 JK 1 127 RECEPTACLE 2 PIN AMP 1 480319 0 PIN AMP 60620 1 JK LC128A PLUG 2 PIN AMP 1 480318 0 SOCKET AMP 60619 1 JK LL101A C B LANDING LIGHT KLIXON 7277 2 25 JK LL101A C B LANDING LIGHT MOONEY 930023 215 JK LL102A SWITCH LANDING LIGHT MOONEY 880052 521 JK LL103A LIGHT LANDING RIGHT GE 4596 JK LL104A LIGHT LANDING LEFT GE 4596 JK LL105A LIGHT LANDING COWL GE 4553 JK LN101A C B NAV LIGHT 930023 201 JK LN102A LIGHT ASSY NAV TAIL LT WING MOONEY 800051 501 BULB WHELEN 34 022 8030 85 JK LN103A LIGHT ASSY NAV TAIL RT WING MOONEY 800051 501 BULB WHELEN 34 022 8030 85 JK LN104A PLUG 9 PIN RT WING AMP 206708 1 CLAMP AMP 206062 1 JK LN105A RECEPTACLE 9 PIN RT WING AMP 206705 1 CLAMP AMP 208062 1 MOONEY AIRCRAFT CORPORATION M20J SERVICE AND MAINTENANCE MANUAL 28 VOLT ELECTRICAL EQUIPMENT CHART CODE DESCRIPTION VENDOR PART NO NOTES JK LN106A PLUG 9 PIN LT WING AMP 206708 1 um CLAMP AMP 206062 1 JK LN107A RECEPTACLE 9 PIN LT WING AMP 206705 1 CLAMP AMP 206062 1 JK LP101A C B GLARESHIELD LIGHTS KLIXON 7277 2 5 JK LP102A C B PANEL LIGHTS KLIXON 7277 2 5 JK LP103A DIMMER CONTROL BOX M
16. CLAMP AMP 206070 1 JK PL35A PLUG FLT PNL 3 4 PIN AMP 206060 1 CLAMP AMP 206062 1 JK PL36A PLUG CONSOLE 2 8 PIN AMP 205838 1 CLAMP AMP 206062 1 JK PL37A PLUG LT SIDE PNL 8 PIN AMP 206838 1 206062 1 JK 38 PLUG FLAP RELAY 8 PIN AMP oc 205708 1 CLAMP AMP 206062 1 91 20 02 12 98 54 MOONEY AIRCRAFT CORPORATION M20J SERVICE AND MANUAL 28 VOLT ELECTRICAL EQUIPMENT CHART CODE DESCRIPTION VENDOR PART NO NOTES JK PL39A PLUG FLAP MOTOR 9 PIN 206708 1 CLAMP AMP 206966 1 K PL40A PLUG THROTTLE SWITCH 4 PIN AMP 206060 1 CLAMP AMP 206062 1 JKL PL50A PLUG C B PNL 2 37 PIN AMP 206150 1 FLANGE AMP 207299 4 JKL PL51A RECPT IGNITION SWITCH 26 PIN MOONEY 930021 505 JKL PL52A PLUG ALT STARTER FW CANNON MS3106A2B 22S CLAMP MS3057 16 JKL PLUG EMPENNAGE 9 PIN 206708 1 CLAMP AMP 206966 1 JKL PLUG GRND 4 9 PIN AMP 206708 1 CLAMP AMP 206966 1 JKL PL57A 7 PLUG GRND 5 14 PIN MOONEY 930021 001 JKL PLUG DIM 42 16 PIN AMP 206037 1 CLAMP AMP 206070 1 JKL PLUG GRND 6 26 PIN MOONEY 930021 505 JK PL76A PLUG 9 PIN AMP 206708 1 CLAMP AMP 206966 1 JK PL77A PLUG 28 PIN AMP 205839 3 CLAMP AMP 206070 1 L PL152A PLUG GR STALL WARN HARNESS 4 PIN AMP 206060 1 CLAMP AMP 206062 1 JK PS101A C B IGN TACH CIG LIGHTER KLIXON 7277 2 10 JKL PS102A SOLENO
17. Dimensions and Areas Aircraft Specification Aircraft Dimensions Aircraft Stations 12 98 MOONEY AIRCRAFT CORPORATION DATE 12 98 12 98 12 98 12 98 12 98 12 98 12 98 PAGE 9 C 6 EFFICONTENTS 1 2BLANK MOONEY AIRCRAFT CORPORATION M20J SERVICE AND MAINTENANCE MANUAL 6 00 00 DIMENSIONS AND AREAS 6 00 01 AIRCRAFT SPECIFICATIONS ENGINE METRIC OPT MISC Engine Mfar TEXTRON Lycoming Engine Model 1O 360 A1B6D or 10 360 A3B6D or 10 360 A3B6 No Cylinders 4 Rated Horsepower 200 Sea Level RPM 2700 Min Fuel Octane 100 130 or 100 LL Fuel CapacityTotal 66 5 U S Gal 251 8 Liters 55 4 IMP Gal Useable 64 0 U S Gal 242 4 Liters 53 3 IMP Gal Oil Specification Lycoming Spec No 301F Oil Grade Viscosity Above 60 Deg F SAE 50 SAE 40 or 50 30 io 90 Deg F SAE 40 SAE 40 0 to 70 Deg F SAE 30 20W 40 Oil Grade Viscosity Below 10 Deg F SAE 20 W SAE 20W 30 Oil Capacity 8 qts 7 57 Liters Minimum Safe Oil Level 2 ats LEVEL FLIGHT ONLY NOTE Approved Multiviscosity oil is recommended especially during cold weather operations INLET OIL TEMP STANDARD MAXIMUM AMBIENT AIR TENP Above 60 Deg F 180 Deg F 245 Deg F 30 to 90 Deg F 180 Deg F 245 Deg F 0 to 70 Deg F 170 Deg F 225 Deg F Below 10 Deg F 160 Deg F 210 Deg F Oil Pressure Normal Operation 60 90 P S I Idle Minimum 25 P S I Max Allowable cold oil Start amp Warm up 100 P S I Cylinder Head
18. L 151 RECPT ENGINE HARNESS RT CANNON GERMANY 121006 518 CLAMP CANNON GERMANY 057 8557 000 FERRULE END RING CANNON GERMANY 304 8553 000 L RC151A ENGINE HARNESS RT PORSCHE 933 612 415 00 CLAMP 3 PORSCHE 933 612 417 00 ENDBELL PORSCHE 933 612 425 00 NOTE ALTERNATE HIGH TEMPERATURE COMPONENTS FOR ITEMS L RC152A RECPT GR STALL WARN HARNESS 4 PIN AMP 206153 1 206062 1 JKL SB101A C B SPEED BRAKE KLIXON 7277 2 2 L SPK101A SPEAKER CABIN ARCHER 12 1703 JK WA101A LIGHT OVERVOLTAGE WESTERN IND 501 61K 11K 3RP CLAMP WESTERN IND WI 7049 JK WA102A DIODE 1N2483 JK WA103A DIODE 1N2483 L WD150A FUSEHOLDER STARTER SOLENOID LITTEL 155020 or 155120 WD150A FUSE 1AMP LITTEL 313001 JKL WE101A C B GEAR WARN HORN KLIXON 7277 2 2 JKL WE102A LIGHT GEAR DOWN SLOAN 855S O U BULB GE 327 JK WE103A SWITCH THROTTLE MICRO V3 1 ACTUATOR MICRO JV 1 JK WE104A HORN GEAR WARNING MALLORY SC628P JKL WE105A DIODE 1N2483 JKL WE106A DIODE 1M2483 K WE107A SWITCH THROTTLE MICRO 1SE1 T ACTUATOR MICRO JE 17 L WE150A SWITCH THROTTLE MICRO SWITCH 1SE1 T ACTUATOR MICRO SWITCH JE 5 L WE151A PLUG 4 PIN AMP 206060 1 CLAMP AMP 206062 1 L WE152A RECPT 4 PIN AMP 206153 1 CLAMP AMP 206062 1 JKL WS101A C B STALL WARN HORN KLIXON 7277 2 2 JK WS102A HORN STALL WARNING MALLORY SC628 JKL WS103A SWITCH STALL WAR
19. L MB153A AVIONICS BUS BAR 4 MOONEY 913127 73 L MB154A AVIONICS BUS BAR 5 MOONEY 913127 73 L MB155A AVIONICS BUS BAR 6 MOONEY 913127 73 L MB156A AVIONICS BUS BAR 7 MOONEY 913127 73 L MB157A SHUNT MOONEY 913127 049 L MB158A AVIONICS MASTER RELAY AROMAT HG4 DC24V RECEPTACLE AROMAT HG4 SF MB159A DIODE 1N2483 L MB160A FUSE HOLDER LITTEL 155020 or 155120 FUSE 1A LITTEL 313001 MB162A DIODE STARTER SOLENOID LT 1N2483 L MB163A DIODE STARTER SOLENOID 1N2483 L MB164A ARTIFICIAL HORIZ CASTLEBERRY 800 2BL L MB165A PLUG ART HORIZ AMPHENOL 126 222 L MB166A C B AUTOPILOT ALERT KLIXON 7277 2 XX VARIES JKL CIGAR LIGHTER MOONEY 800336 503 L MC150A C B CIGAR LIGHTER KLIXON 7277 2 10 91 20 02 12 98 48 MOONEY AIRCRAFT CORPORATION M20J SERVICE AND MAINTENANCE MANUAL 28 VOLT ELECTRICAL EQUIPMENT CHART CODE DESCRIPTION VENDOR PART NO NOTES JK ME101A CLOCK ELECTRIC MID CONT MD 88L LIGHT TRAY BA28 24 BW2 JK ME101B CLOCK OPT MID CONT MD 88L ET LIGHT TRAY BA28 24 BW2 L ME150A ALT 950D0312 000 L ME150B CLOCK CONTROLWHEEL PORSCHE 944 641 213 00 L ME151A RECPT CONTROL WHEEL AMP 206705 2 CLAMP AMP 206966 1 af ME152A PLUG CONTROL WHEEL AMP 206708 1 CLAMP AMP 206966 1 JK MIC101A JACK MICROPHONE SWITCHCRAFT C 12B WASHERS SWITCHCRAFT S 1028 or S 1029 L MIC102A JACK MICROPHONE CONSOLE SWITCHCRAFT C 12B
20. MS3106A 32 17S MS3106A 14S 5S MS3106A 28 22S 205838 1 206708 1 126 222 DE 9S 03 06 2092 206485 1 930021 1 930021 513 206043 3 DA15S 206037 1 DBM17WeS 930021 501 DB25S NOTES 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 637847 BSC206 149 RH 10 20 OHM RH 10 5 OHM 919029 501 09F976 RH 50 7 5 OHM RC42 GF102J WA2 G056S502UA 149 11 502 3862C 282 502A 12F9905R 5 0K VC3D 23J N A N A RH 25 1 OHM RH 10 70 OHM N A 071 4037 01 1 480319 0 DEA900020 MS3100 24 9P 91 20 05 89 SERVICE AND MAINTENANCE MANUAL ELECTRICAL EQUIPMENT CHART CODE RC03A RC03B RC03C RC03D RC04A RC04B RC06A RCO9B RC09C RCOSE RC12A RC14A RC14B RC14C 6 RC16B RC20A RC26B RC28A 2 RC34A RC34B RC37A RL1 RL2 RL3 RL4 RL5 RL6 RL7 RL8 RL9 R10 SA101A SA102A SB101A SB102A SB103A SB104A SB105A SB106A 91 20 05 90 DESCRIPTION RECEPTACLE 3 PIN RECEPTACLE 3 PIN RECEPTACLE 3 PIN 3 PIN 4 PIN RECEPTACLE 4 PIN RECEPTACLE 6 PIN RECEPTACLE 8 PIN 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 28
21. 5 Compatible paints for the item such as steel tubular structure or exterior skin and for the year and Mad repainted Refer to Mooney Paris anual 6 Thinners which are compatible with the paints used both for paint thinning for burn down inners 12 98 M20J SERVICE AND MAINTENANCE MANUAL B Cleaning Procedures NOTE Fiberglass components are attacked and deteriorated by products containing the following chemicals Ketone aliphatic esters chlorinated hydrocarbons and slightly softened by aromatic hydrocarbons 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 I remove 1 Remove all old loose paint by one of the following methods a On aluminum for uniformity of finish appearance the entire skin panel should be prepared for repainting If the paint is in very bad condition or if a filler is to be used remove all of the paint by use of lacquer thinner MEK or similar solvent Careful application of approved paint stripper is acceptable The solvent should be wiped on and wiped off before it evaporates If the solvent is allowed to evaporate it will redeposit the soils and paint that were being carried Any scouring required should be done at this point Scouring with nylon pads or aluminum wool may be done dry or wet with one of the wipe solvents listed above After the old pai
22. 7 Remove left and right gear mounting bolts D and E Fig 32 3 from tubular structure and nose gear truss assembly 8 Careful NOSE GEAR RETRACTION TUBE ADJUSTMENT POINTS FIGURE 32 3 9 DO NOT attempt to repair any heat treated component of nose landing gear assembly 32 20 02 NOSE GEAR INSTALLATION 1 Lubricate wheel bearings retraction linkage and left and right mount bearings 2 Install gear in reverse order of removal procedure 12 98 MOONEY AIRCRAFT CORPORATION 32 20 03 NOSE GEAR DOOR RIGGING 1 Raise aircraft on jacks Refer to Section 7 10 00 NOTE Gear system must be properly rigged prior to gear door rigging see Section 32 30 03 2 Adjust gear door link rods H and J Fig 32 3 to obtain proper door fit when closed 3 To increase or decrease nose gear up travel in wheel well adjust both eccentrics on trunnion bearings J Figure 32 4 as required NOSE GEAR RETRACTION TUBE amp DOOR ADJUSTMENT POINTS FIG 32 4 NOTE Eccentrics permit nose sheel to move quicker to clear nose gear doors amp also will allow nose wheel to be positioned further or less further into nose wheel well GAUTION Nose gear overcenter preload must be rechecked after any adjustment to nose wheel eccentrics 4 Readjust nose gear door linkage K as required after eccentrics have been adjusted Fig 32 4 32 30 00 EXTENSION AND RETRACTION 32 30 01 GEAR SYSTEM OPERATIONAL CHECK S N 24 008
23. 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 FUEL ADDITIVES 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 196 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 28 13 00 9 AIRCRAFT CORPORATION 28 20 00 DISTRIBUTION The fuel system includes of two fuel pumps an engine driven pump and an electrically driven auxiliary boost ump The boost pump is connected to a switch on the instrument panel 28 21 00 FUEL BOOST PUMP REMOVAL AND INSTALLATION 1 Auxiliary Electric Boost Pump Removal A Remove electrical leads B Tum fuel selector valve OFF C Disconnect inlet and outlet fuel lines D Remove fuel pump 2 Reverse the removal procedure for 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 CAUTION Mixture control should be in IDLE CUTOFF position to check operating pressure however do not operate the b
24. MOONEY AIRCRAFT CORPORATION REMEDY Check and recharge battery if necessary Refer to electrical wiring diagram and check ali wiring Brushes should fit free in brush boxes without excessive side play Clean brushes and brush boxes with varsol moistened cloth New brushes should be run in until at least 50 percent seated however if facilities are not available for running in brushes seat brush by inserting strip of No 0000 sandpaper between brush and commutator with sanded side next to brush Pull sandpaper in direction of rotation being careful to keep it in same contours as commutator If commutator is rough or dirty smooth and polish with No 0000 sandpaper If too rough and pitted remove commutator and turn on lathe Blow out all foreign material Rernove and replace with an armature known to be in good working order Test and repair circuit if possible or replace with new parts Check and repair Check and repair Remove and repair or replace Disassemble clean inspect amp relubricate components replace ball bearing if worn Same remedies Remove and replace Clean and lubricate with graphite amp kerosene Check and recharge Remove and replace Remove and replace Turn down commutator Repair as outlined above Clean as outlined 24 39 04 13 MOONEY AIRCRAFT CORPORATION M20J SERVICE AND MAINTENANCE MANUAL STARTER TROUBLE SHOOTING con t TROUBLE PROBABLE CAUSE REMEDY
25. Manuai engage arm improperly rigged Sheared female spline in drive connector Drive connector is out of rig Any ofthe above or Brushes in motor worn MOONEY AIRCRAFT CORPORATION REMEDY Refer to landing gear rigging procedure Examine all movable paris for proper lubrication and freedom from binding Check for actuator jackscrew 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 Replace with smaller diameter tire Check pitot tube and line for obstructions Examine pressure switch for proper adjustment and operation Reset circuit breaker I Does gear retract using override check systems operation Gear may have been extended manually amp ball nut is tight against STOPS use wrench on bali nut flat to loosen Adjust and check squat switch operation Ref SB M20 196 Disengage Manual System See Section 32 50 02 Replace burned out lamp Check indicator light circuit and or down limit Switch Same remedies as listed with Incomplete Retraction above Place gear switch in DOWN position Replace burned out lamp Replace spring Rig manual engage arm Replace drive connector assembly if female spline is stripped Adjust control cable tension of drive connector Applicable remedy listed above or rep
26. RC76A RC77A RC78A RC79A WAO1A WA02A WAD3A WA03B WEO1A WEO1B WE02A WEO3A WEOSB WEOSC WE04A WEO5A WEO6A WEO7A WEOBA WEO9A WE10A WE11A WE12A WFO1A WFO3A WFO4A WLO1A WLO2A WLO3A WS01A WS01B WS02A WS03A WTO1A WTO02A WTO3A M20J 14 VOLT ELECTRICAL EQUIPMENT CHART DESCRIPTION RECPT ADF RMI CLAMP RECPT GRND CLAMP RECPT XDCR ENCODER KFC 200 CLAMP RECPT RADIO PKG CABLE CLAMP RECPT 4 2 NAVREC A P CLAMP LIGHT ALT WARN BULB 2 RECTIFIER SWITCH LO VOLT DET SWITCH LO VOLT DET GEAR WARN G B GEAR WARN LIGHT GEAR UNSAFE BULB SWITCH THROTTLE 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 LIGHT LOW FUEL PRESS BULB 2 RECTIFIER PLUG SWITCH FUSEHOLDER FUSE LIGHT LANDING IND BULBS 2 RECTIFIER C B STALL WARN HORN C B STALL WARN HORN HORN STALL WARNING SWITCH PRE STALL WARN SWITCH PRESS TO TEST C B ANNUNCIATOR ANNUNCIATOR LAMPS VENDOR AMP AMP AMP AMP AMP AMP AMP AMP AMP KORRY GE SARKES TARZIAN ELECTRO DELTA ELECTRO DELTA MERIDEN KLIXON KORRY MICRO MICRO C H MICRO MICRO MALLORY SARKES TARZIAN SLOAN GE KORRY SARKES TARZIAN SARKES TARZIAN SARKES TARZIAN SARKES TARZIAN KORRY GE
27. 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 ihe battery to the starter Electrical power is automatically cut off from the radios when the starter current is engaged 80 00 01 STARTER TROUBLESHOOTING 1 Refer to Section 24 39 04 for Starter TroubleShooting Chart 80 00 02 STARTER 1 Inspect and service starter per Lycoming Maintenance Instructions Overhaul Manual 2 Lubrication No lubrication is required on starter or starter drive except at overhaul 3 Check electrical leads for security and condition of wire SZAUTION Do not clean the starter in any degreasing tank or grease dissolving solvents Avoid excessive lubrication Use only kerosene or Varsol 80 00 03 STARTER REMOVAL 1 Remove upper and lower cowling 2 Remove 4 bolis between AIR INTAKE DUCT and fuel Injector pad 3 Remove 2 screws on outer end of air intake duct 4 Remove bolt at front of air intake duct Carefully remove the duct 5 Disconnect electrical wiring from starter terminals and tag wiring for ID REV 10 95 M20J SERVICE AND MAINTENANCE MANUAL 6 Remove 3 nuts and 1 5 16 inch bolt from starter 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
28. 2 8 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 fixed at the tail skid Horizontal stabilizer Tip 0 12 inch max Fore amp Aft 0 10 inch max Up amp Down Rudder amp Lower trailing edge 0 08 inch max Up amp Down RUDDER amp ELEVATOR STOP ADJUSTMENT FIGURE 27 8 27 30 03 9 AIRCRAFT CORPORATION 27 31 00 TRIM ASSIST BUNGEE RIGGING Bungee units in the elevator control systems assist in stabilizer trim adjustment NOTE Negative stabilizer degrees settings mean that stabilizer leading edge is moved down relative to the thrust line Set stabilizer to 3 degrees position B Adjust trim bungees N Figure 27 9 at rod end pown stop bearing 10 for elevator up angle of 19 degrees 1 degree SMJ27 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 consists of a manually operated actuator that operates a series of torque tubes and universal joints connected to a jack screw on the aft tailcone bulkhead NOTE stepped stop nut with a jam nut configuration has been incorporated This c
29. 27 50 00 13 MOONEY AIRCRAFT CORPORATION WING FLAP INDICATOR ADJUSTMENT NON PRESELECT FIGURE 27 15 D Top switch will be automatically adjusted E Cycle flaps UP TAKEOFF amp DOWN verify proper setting at TAKEOFF while Flaps are going down 27 60 00 AILERON RUDDER INTERCONNECT SYSTEM 1 With controls in neutral position locate 110002 101 bracket on aileron control tube 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 P N 110003 007 005 bellcrank and on 110002 025 and 027 brackets and position 025 and 027 brackets on rudder control tube so the installed length of each spring is 4 90 in Clamp brackets in place and drill through brackets and into control tube for AN530 4R6 PK screws 3 Make sure PK screws are in place to secure all three brackets 27 90 00 MISCELLANEOUS CONTROL SURFACE STATIC BALANCING Control surface balance must be checked when control surfaces is repaired altered or repainted It is recommended that control surfaces be stripped prior to repainting The control surface balance limits shown in Figure 27 17 apply to a complete painted control surface only Complete contro surfaces include as 27 60 00 14 27 91 00 M20J SERVICE AND MAINTENANCE MANUAL applicable balance weight control attachment horn and attaching hardw
30. 9 Inspect aircraft exterior for security of boits screws etc 10 Check and service battery 5 20 05 50 HOUR INSPECTION The 50 hour inspection includes all requirements for ihe 25 hour inspection plus the necessary removal of inspection doors panels or fairings 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 Drain engine oil sump B Remove and clean suction oil strainer reinstall strainer and plug Safety wire strainer plug 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 Check cylinders for evidence overheating J Check baffles for secure anchorage close fit around cylinders and freedom from cracks K Check engine controls for full travel freedom of movement and security L Visually check fuel and oil lines for security 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 amp bolts for security an
31. 9 30 00 EMERGENGY PROCEDURES 1 Engine Fire During Starting A Continue cranking engine with starter B Set mixture control at IDLE CUTOFF C Turn fuel selector handle to OFF D Open throttle to FULL E Tum MASTER switch OFF F Push cabin heat control to OFF G Close cowl flaps H If fire is not extinguished proceed as follows 1 Turn electrical switches OFF 2 Discharge fire extinguisher into engine compartment through nose cowl openings and through cowl flap openings 3 Call for fire fighting equipment 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 ignition controls to the OFF position before evacuating the aircraft to extinguish the flames 3 Electrical Fire Circuit breakers or circuit breaker switches that automatically interrupt the flow of power when an overload or short circuit occurs protect ail electrical circuits except the ignition starter circuits In the event of an electrical fire immediately turn off the master alternator field switch Make sure that only a fire extinguisher approved for electrical fires is used 9 00 00 SERVICE AND MAINTENANCE MANUAL M20J MOONEY AIRCRAFT CORPORATION BLANK 9 30 00 12 98 MOONEY AIRCRAFT CORPORATION M20J SERVICE AND MAINTENANCE MANUAL CHAPTER 10 PARKING AND MOORING SERVICE AND MAINTENANCE MANUAL CHAPTER SECTION SUBJECT 10 Effectivity Contents
32. LH amp 4 LH amp RH 24 0001 THRU 24 1417 WING FUSELAGE ATTACH FITTINGS FIGURE 53 4 53 40 00 12 98 6 SERVICE AND MAINTENANCE MANUAL 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 attach point 4 Figure 53 5 on the M20J MOONEY AIRCRAFT CORPORATION empennage assembly secures the stabilizer trim jack screw 5 Figure 53 5 and 4 Figure 53 6 Lateral stability of the empennage assembly is controlled with an articulated hinge assembly 2 Figure 53 6 attached to the rear bulkhead 3 Figure 53 6 of the tailcone The hinge attach pin 6 Figure 53 5 is held in place with a cotter pin at each end EMPENNAGE ASSEMBLY ATTACH FITTINGS FIGURE 53 5 12 98 53 40 02 7 MOONEY AIRCRAFT CORPORATION M20J SERVICE AND MANUAL 55 40 05 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
33. Mid Continent MD 88L Mid Continent MD 88L ET w light tray BA14 24 BW2 Alternate Voltage Regulator Lamar B 00371 6 Alternate Starter 21 P504B TCM 646238 Use buss bars 913127 123 125 as required by installation of Optional Equipment CUT TO SIZE 12 98 MOONEY AIRCRAFT CORPORATION M20J SERVICE AND MAINTENANGE MANUAL 28 VOLT ELECTRICAL EQUIPMENT CHART 91 20 02 ELECTRICAL SYSTEM HARDWARE CHART 28 VOLT SYSTEMS SERIAL NUMBER s 24 3000 THRU 24 3153 MOONEY DRAWING NO 800350 AV 9 CODE DESCRIPTION VENDOR PART NO NOTES JKL CB101A C B DEFROSTER BLOWER KLIXON 7277 2 2 JKL CB102A SWITCH DEFROST BLOWER CHERRY E51 50B JKL CB103A MOTOR DEFROSTER BLOWER MOONEY 640317 501 JKL CB104A RECPT DEFROSTER BLOWER AMP 1 408319 0 PINS AMP 60620 1 JKL CB105A PLUG DEFROSTER BLOWER AMP 1 480318 0 SOCKETS AMP 60619 1 JK CC101A C B COWL FLAP KLIXON 7277 2 5 JK CC102A SWITCH COWL FLAP MICRO 12TW1 1 CAP WHITE MiCRO 15PA90 4W K CC103A ACTUATOR COWL FLAP MOONEY 880050 501 JK CC104A SWITCH OPEN LIMIT MICRO 1SE1 T ACTUATOR MICRO JE 5 JK CC105A SWITCH CLOSE LIMIT MICRO 1SE1 T ACTUATOR MICRO JE 5 JK CC106A RECPT 4 PIN AMP 206153 1 CLAMP AMP 206062 1 JK CC107A PLUG 4 PIN AMP 206060 1 CLAMP AMP 206062 1 JKL CF101A G B FLAP ACT KLIXON 7277 2 5 JKL CF102A SWITCH FLAP C H 8906K3149 JKL CF103A SWITCH UP LIMIT MICRO V3 1 4 JKL CF104A SWITCH DOWN LIMIT MICRO V3 1 4 JK CF106A SWITCH TAKEOFF UP
34. Ref Fig 55 4 riveted to an extruded leading edge 2 and riveted together at the trailing edge The rudder lower skins 3 are drop hammer formed left and right halves riveted to the upper skins a rib assembly 4 and at the leading and trailing edge A stiffener 5 is to support ihe lower rudder ball bearing hinge fitting 6 A weather seal 7 is included in the assembly i The rudder control horn 8 is attached with the cente hinge fitting 9 to the rear flange of the front spar at the junction of the lower rib assembly 10 A brace arm on the horn assembly is attached to a fitting 11 on the lower rib 10 The upper hinge fitting 12 is attached to the rear flange of the front spar just under the top rib assembly 13 and the balance weight 14 refer to Figure 55 4 The balance weight 14 is installed with four iron rivets 15 See section 27 91 00 for balancing procedures on the rudder 55 40 01 RUDDER REMOVAL Remove the AN3 bolt from the control hom and tube bearing then remove the three 3 olts and hardware from each hinge fitting Disconnect connections per paragraph 33 41 03 2 A 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 Nominal torque valves for AN3 bolts are to be used See Section 5 20 01 for torque table 55
35. 1816 1930 9 1816 1930 9 1816 1930 9 1816 1930 9 1816 1930 9 1816 1930 9 1816 1930 9 1816 AHW4 20 930023 15 930023 115 215 28 WB9CQX 2 4522 4509 SA25SCT12 3 SWS3AA2 15 1049 3 930023 001 930023 101 201 28 A1285 R 12 A7512 12 800022 501 W1290 14 W1285 PR NOTES A2064 1777 203529 1777 266P 12 8V A480A A508 14 A1285 G 12 A7512 12 880022 503 W1290 14 W1285 PG 880022 503 AHWA 10 7277 2 10 7277 2 10 AHWA 10 91 20 01 SERVICE AND MANUAL 14 VOLT ELECTRICAL EQUIPMENT CHART CODE 21 LPO3A 21 LP03G 21 LP03B 21 LPO4A 21 LPO5A 21 LPO6A 21 LPO6B C 21 LPO7A 21 LPOBA 21 21 LP10C 21 LP13A 21 LP14A 21 LP15A 21 LP16A 21 LP17A 21 LP18A 21 LP18B 21 LP18C 21 LP18D 21 LP18E 21 LP19A 21 LP20A 21 LP21A 21 LP22A 21 LP22B 21 LP22C 21 LP24A 21 LP24B 21 LP25A 21 LP25B 21 LP25C 21 LP25D 21 LP25E 91 20 01 16 DESCRIPTION XSTR INSTR LIGHTS XSTR RADIO LIGHTS XSTR ALT LPO3A G XSTR RADIO LIGHTS XSTR RADIO LIGHTS RHEOSTAT SWITCH RHEOSTAT SWITCH RADIO RHEOSTAT SWITCH RADIO RHEOSTAT SWITCH RADIO SWITCH RED WHITE LIGHT ROCKER C B INSTR LIGHTS FUSE INSTR LTS M20J VENDOR RCA RCA DELCO RCA RCA ALLEN BRADLEY ALLEN BRADLEY ALLEN BRADLEY ALLEN BRADLEY MICRO MICRO KLIXON McGRAW EDISON HOLDER FUSE INSTR LTS McGRAW EDISON HOLDER FUSE INSTR LTS McGRAW EDISON HOLDER LAMPS RED GE HOLDER 4 EA H H SM
36. 20000 pad seal If the seal shows any signs of oil leakage replace the seal Replace seal if there is any doubt as to its serviceability 37 11 04 INSTALLATION OF NEW PUMP CAUTION Never install a pump that has been dropped 1 Consult the airframe manufacturer s current parts manual Airborne s Application List or the PMA label on the pump box to verify that the pump is the correct model for the engine and or system 2 Place the pump mounting flange in a jaw protected vise with the drive coupling downward dic the pump mounting flange with soft metal or wood xe 7 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 AME DO NOT use teflon tape pipe dope or thread ube 4 Install fittings 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 1 2 turns beyond hand tight position 6 Install new pump mounting gasket supplied with new pump 7 Always replace ALL locking washers when installing a new pump Tighten all four 4 mounting nuts 90 to 110 in Ibs 8 Prior to reconnecting hoses inspect the inside of the hose carefully to make sure it is clean and free of all debris oils or solvents Use vacuum or dir pressure to clean the lines Remove the hoses from the aircraft if
37. 24 3000 thru 24 3078 Gear system must be properly rigged prior to 1 Raise aircraft on jacks gear door rigging see Section 32 30 01 32 10 02 12 98 6 MOONEY AIRCRAFT CORPORATION NOTE Gear system must be properly rigged prior to gear door rigging see Section 32 30 01 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 reinstalling them A Disconnect outboard doors at forward and aft linkages B Fig 32 2A B Disconnect inboard doors at the forward linkage and springs A Fig 32 2B C Raise gear electrically to the full UP position D Forward leading edge and aft trailing edge of Mid Gear Door should be tight against the wing skin Spacers A Figure 32 2A should be added or removed as required to obtain a good fit with no binding or distortion with the gear in ihe 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 binding or distortion where links attach to door Adjust linkage if required Fig 32 2A Extend gear to adjust then retract to check adjustment 4 Check main gear overcenter preload torque for proper values Re rig entire LDG system if necessary bas oji 1 MID GEAR DOOR ADJUSTMEN
38. 32 20 02 Nose Gear Installation 8 32 20 03 Nose Gear Rigging 9 32 30 00 Extension and Retraction 9 32 30 01 Gear System Operational Check LEM 32 30 02 Main Landing Gear System Rigging 10 323501 024 0001 thru 24 2999 24 3079 thru 24 TBA 10 32 34 02 24 0001 thru 24 0377 11 32 34 03 024 3000 thru 24 3078 14 32 30 03 Nose Landing Gear System Rigging Ge qne ET 35 20 4 iE s 24 3000 thru 24 3078 18 32 30 04 Emergency Gear Extension System Rigging 16 32 30 05 Landing Gear Actuator Clutch Spring R amp R 17 32 30 06 Landing Gear Actuator Recoiler Spring R amp R 18 32 90 07 Manual Emergency Gear Extension System 19 32 30 08 FialCheck 19 TABLE OF CONTENTS CONTINUED ON NEXT PAGE 12 98 32 CONTENTS 3 SERVICE AND MANUAL M20J MOONEY AIRCRAFT CORPORATION TABLE OF CONTENTS con t CHAPTER SECTION SUBJECT os SUBJECT PAGE 32 32 00 Trouble Shooting 20 32 40 00 Wheels and Brakes 32 40 01 Main Wheels 32 40 02 Main Wheel Dis
39. 52006 12 5 20 06 _ u ow 1 5 20 06 ov 14 5 20 06 15 52006 16 5 20 06 1 O 20 0Z no U 2 che 8e ow WI 4B x SA 5 20 07 lt 19 52007 more ss ro au ow 20 X oh 5 20 07 22 5 vw Av 52007 22 12 98 DATE 12 98 12 98 12 98 12 98 12 98 19 98 19 98 19 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 MOONEY AIRCRAFT CORPORATION 5 EFFECTIVITY 1 2BLANK AIRCRAFT CORPORATION M20J SERVICE AND MAINTENANCE MANUAL CHAPTER 5 TIME LIMITS MAINTENANCE CHECKS TABLE OF CONTENTS CHAPTER SECTION SUBJECT SUBJECT 5 00 00 General 50001 Landing Gear System 5 00 02 Fight Control Systems 5 00 03 Wing Flap Systems 50004 Electric Power System 5 00 05 Instruments 5 00 06 Cabin Heating Ventilating Systems 5 00 07 so Fuel System 5 10 00 Time Limit Components 5 100010 Overhaul and Replacement Schedule 520 00 Schedule Maintenance Checks 52001 Inspection Check Points p rr ons 0s k s Torque Values 5200
40. 7110 00 22 202 22 Ge ee 002 x om e cr X 42 98 71 41 02 22222 H ee pv 12 98 7124903 l 6o deck de 5 5 sa AS ie ho 112308 12 08 71 EFFECTIVITY 1 2BLANK AIRCRAFT CORPORATION 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 05 71 12 00 71 12 01 71 12 02 71 13 00 71 13 01 74 13 02 71 13 03 71 13 04 71 90 00 71 60 00 71 60 01 71 61 00 M20J SERVICE AND MAINTENANCE MANUAL CHAPTER 71 POWERPLANT TABLE OF CONTENTS SUBJECT PAGE General 5 Engine Data 5 Engine Removal bing 7 6 Engine Inspection amp Repair 6 Engine Installation 6 Engine Ground Checkout 7 Fuel Injection Maintenance 7 Fuel injector Idle amp Mixture Adjustment 8 Starter System Maintenance e 8 Engine Mixture Control Rigging 8 Trouble Shooting A 8 Starter Trouble Shooting 8 Engine Trouble Shooting 8 Engine Cowling 10 Cleaning Inspection and Repair 10 Cowling Removal 10 Top Cowling 10 Bottom Cowling 11 Cowling Installation 11 Bottom Cowling 11 Cowling 11 see Cowl Flap s 11 Engine Cowl Flap Rigging 11 24 0001 thru 24 2999 Engine Cowl Flap Rigging 11 24 3000 thru 24 TBA Cowl Flap Indicator Adjustment 12 24 3000 thru 24 3410 Cowl Flap Indicato
41. ACTUATOR SWITCH LIMIT DOWN ACTUATOR SWITCH LIMIT UP ACTUATOR SWITCH CONTROL SWITCH CONTROL FLAP C B ELECTRIC TRIM C B ELECTRIC TRIM G B ELECTRIC TRIM SHUNT SHUNT SHUNT SHUNT FUSE RETAINER FUSE RETAINER FUSE RETAINER FUSE RETAINER AMMETER BULB C B TURN COORD C B TURN COORD TURN CO ORDINATOR TURN CO ORDINATOR TURN CO ORDINATOR PLUG TURN COORD CLAMP VENDOR KLIXON BRITTIAN MICRO C H MICRO ALCO MERIDEN or EQUIV MAGNECRAFT MAGNECRAFT COMM PROD MOONEY MICRO MICRO MIGRO MICRO MICRO MICRO MICRO MICRO MICRO C H MOONEY MOONEY MOONEY EMPRO or EQUIV STEWART WARNER EMPR0 EMPRO LITTEL LITTEL McGRAW EDISON McGRAW EDISON LITTEL LITTEL McGRAW EDISON McGRAW EDISON MOONEY ROGHESTER MERIDAN OR EQUIV KLIXON BRITTIAN AEROSONIC ALT AEROSONIC 12 98 PART NO il i il A 1 i i I I I I 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 8906K3149 930023 009 930023 109 930023 209 MLA 60 50 SW 813489 MLA 60 100 MLA 70 100 312010 155020 01 FHN42W 311010 155202 FM01 5A FHN42W 640281 509 0153500003 AHW4 2 7277 2 5 604 200 200 ANS50M ANS50ML MS3106A 10SL 3S MS3057 4A or 4B 23 24 23 24 23 24 91 20 01 SERVIGE AND MANUAL 14 VOLT ELECTRICAL EQUIPMENT
42. ALT EMPRO FUSEHOLDER ALT 2 McGRAW EDISON FUSE 5A McGRAW EDISON 12 98 7277 2 3 5 7277 2 5 5 ALLEN BRADLEY 206060 1 206062 1 206153 1 206062 1 930023 245 58112 472 155020 155120 313001 800346 501 830131 511 142483 1 480319 0 60619 1 1 480319 0 60620 1 1 480319 0 60620 1 1 480318 0 60619 1 0326 004 0326 003 640281 509 0105500004 313 PW06B12 10S PTO6A 12 10S SR SAS1SDT12 1 0105500003 0153500003 313 MLA 70A 50MV MLA 55A 50MV FHN42W FM01 5A FHN42W 5 MLB 210A 50MV MLB 165A 50MV MLB 105A 50MV MLA 60A 100MV FHN42W 01 FHN42W FM01 5A MLA 70A 50MV MLA 55A 50MV FHN42W FM01 5A MOONEY AIRCRAFT CORPORATION M20J SERVICE AND MAINTENANCE MANUAL 28 VOLT ELECTRICAL EQUIPMENT CHART CODE DESCRIPTION VENDOR PART NO NOTES JK 2 ALT 2 MoGRAW EDISON FHN42W FUSE 5A MoGRAW EDISON FM01 5A L C BVOLT AMP IND LT KLIXON 7277 2 1 L DAIS1A C BVOLT AMP IND RT KLIXON 7277 2 1 L DA152A INDICATOR VOLT AMP RT PENN AIRBORNE 9A1570 L DA153A PLUG VOLT AMP IND ITT DA15S CLAMP ITT DA51210 LOCK RETAINER ITT DA51220 1 L DA154A INDICATOR VOLT AMP RT PENN AIRBORNE 9A1570 L DA155A PLUG VOLT AMP IND ITT DA15S CLAMP ITT DA51210 LOCK RETAINER ITT DA51220 1 L DA 56A SHUNT LEFT LOAD EMPRO MLA 105A 50M V L DA157A SHUNT LEFT ALTERNATOR MLA 70A 50MV L DA158A SHUNT RIGHT LOAD EMPRO ML
43. 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 CLAMP 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 M20J VENDOR 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 12 98 MOONEY AIRCRAFT CORPORATION PART NO NOTES 206037 1 206070 1 206708 1 206966 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 206708 1 206966 1 206060 1 206062 1 206037 1 206070 1 206037 1 206070 1 206037 2 206070 1 206060 1 206062 1 206708 1 206966 1 206708 1 206966 1 206060 1 206062 1 206705 2 206966 1 206060 1 206062 1
44. CORPORATION CODE SB107A SB108A SPK1 SPK2 SPK3 SW1 swe SW3 SW4 SW5 SW6 SW7 Swe SW9 SW10 SW11 SW12 SW13 SW14 SW15 SW16 SW17 SW18 SW19 SW20 SW21 SW22 SW23 SW25 SW35 SW101A VR1 WM101A WM102A WS101A WS103A FEET SWITCH STALL WARNING M20J ELECTRICAL EQUIPMENT CHART ALERT STALL WARN GEAR WARN 1 MOONEY 12 98 SERVICE AND MAINTENANCE MANUAL DESCRIPTION VENDOR PART NO NOTES SOLENOID CLUTCH PRECISE FLT 01678 INTERFACE SPEEDBRAKE MOONEY 800314 501 SPEAKER ALERT ARCHER 40 1333 SPEAKER CABIN ARGHER 40 1325 SONALERT MALLORY SC628 SWITCH MICRO 1SE1 T SWITCH DEF BLWR CHERRY E51 50B SWITCH LIMIT RUD TRIM MICRO V3 1 SWITCH UP LIMIT LDG MICRO DT 2R 47 SWITCH DN LIMIT LDG OTTO P6 24014 ALT MICRO 1CH116 6 SWITCH CABIN LTS CARLING RC911 VBBOW SWITCH MOONEY 880013 507 SWITCH LDG C H 8906K2875 SWITCH MIC KEY ALCO MPE 106F C 22 9 ALT C H SA1RV20 SWITCH CHT GRAYHILL 71AD30 02 2 AJN SWITCH FLAP C H 8906K4731 SWITCH CABIN LTS MASTER CARLING RA911 VBBOW SWITCH ALT MICRO 12TW1 10 ICAP WHITE MICRO 15PA90 8W ALT MS27753 38 SWITCH F F MEM 7101 SWITCH LDG OVERRIDE NKK DLB241 W01 L3C AT506M AT503MB BUTTON LOCK RING LOCK WASHER HEX NUT 2 EA NKK SWITCH ALT C H SB1DDX492 2 LOCK RING 29 761 JLOCK WASHER C H 16 886 HEX NUT 2 EA C H 15 966 6 SWITCH VAC HI LO MOONEY 880012 501 SWITCH GARLING TILC64 1S WHFN SW ALT TSCHUDI
45. 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 EG GEAR ELECTRIC PA POWER ALTERNATOR EL ELECTROLUMINESCENCE PB POWER BATTERY ET EMERGENCY LOCATOR BEACON PG POWER GENERATOR ROU r amp FA ALT EMER FRENCH PL PLUGS FH FUSE HOLDERS PS POWER START FN PHONES FU FUSES BLOWER RADIO FW ALT EMER FIELD FRENCH RC RECEPTACLES RL RELAYS GD GROUND RS RESISTORS HS HORIZONTAL SITUATION INDICATOR SA STAND BY ALTERNATOR SB SPEEDBRAKE JE IGNITION ELECTONIC SP SPEAKER JM IGNITION MAGNETO SW SWITCHES JV IGNITION VIKBRATOR VB VENT AIR BLOWER LA LIGHT BULBS CONVERTER LB BEACON ROTATING VR VARISTOR LG LIGHT CABIN LE LENS ANNUNCIATOR WA WARNING ALTERNATOR LG LIGHTS LOGO WB WARNING BOOST PUMP LH LAMP HOLDER WC WARNING PROP DE ICE LI LIGHT ICE WD WARNING POWER START LL LIGHT LANDING WE WARNING ELECTRIC GEAR LN LIGHTS NAVIGATION WF WARNING FUEL QUANTITY LP LIGHTS PANEL WG WARNING TACHOMETER LR LIGHTS RECOGNITION WH WARNING CHIP DETECTOR LS LIGHTS STROBE WJ WARNING TRIM FAIL LT LIGHTS TAXI WK WARNING FUEL PRESSURE W WARNING CANOPY LOCK MA AUXILIARY POWER WM WARNING MASTER MB RADIO MASTER WN WARNING PRESSURIZATION MC CIGAR LIGHTER WP WARNING PITOT HEAT ME CLOCK ELECTRIC WS WARNING S
46. ELECTRICAL DB TURN COORDINATOR LENS ANNUNCIATOR LENS RL RELAYS DC CHT LH LAMP HOLDER SP SPEEDBRAKE DD OAT LLLANDING LIGHTS SW SWTCHES DG ENGINE INSTRUMENTS LP PANEL LIGHTS VR VARISTOR DH OIL TEMPERATURE LR RECOGNITION LIGHTS WS STALL WARNING DJ OIL PRESSURE LS STROBE LIGHTS WT STANNUNCIATOR WARNING DK FUEL PRESSURE LT TAXI LIGHTS CODE COMPONENT or SYSTEM CIRCUIT FUNCTION 800383 SCHEMATIC DRAWING AC AIR CONDITIONER AH ARTIFICIAL HORIZON DA INSTRUMENTS AMMETER AT ACTUATOR SWITCH DB INSTRUMENTS TURN COORDINATOR AV AVIONICS DC INSTRUMENTS CYLINDER HEAD TEMPERATURE BR CIRCUIT BREAKERS DD INSTRUMENTS OUTSIDE AIR BS RELAY BASE TEMPERATURE BU BUS BARS DE INSTRUMENTS CARBURETOR AIR TEMPERATURE CA CAPACITORS DF INSTRUMENTS FUEL QUANTITY CB DEFROSTER BLOWER DG INSTRUMENTS ENGINE cc COWL FLAPS DH INSTRUMENTS OIL TEMPERATURE cD PC DUMP Di DIODES CF WING FLAPS DJ INSTRUMENTS OIL PRESSURE CL CLAMPS DK INSTRUMENTS FUEL PRESSURE CR RUDDER TRIM DL INSTRUMENTS TACHOMETER ELECTRIC CT ELEVATOR TRIM DM INSTRUMENTS HOUR METER CV STAND BY VACUUM DN INSTRUMENTS PRESSURIZATION DP INSTRUMENTS PITOT HEAT 12 98 91 00 02 Page 5 MOONEY AIRGRAFT CORPORATION M20J SERVICE AND MAINTENANCE MANUAL CODE COMPONENT or SYSTEM A i SUIT Fe 800383 SCHEMATIC DRAWING con t R INSTRUMENTS TURBINE MO PROP OVERSPEED TEMPERATURE PROP DE ICE DS INSTRUMENTS COMPRESSOR MS MISCELLANEOUS RADIO SPEAKER
47. JK CV106A JK CV107A JK CV108A JK CV109A JK CV110A JK DA101A JK DA101B J DA101D JK DA102A JK DA102A JK DA103A JK DA104A JK DA104B JK DA105A JK DA106A JK DA107A JK DA107B JK DA107C JK DA107D JK DA108A JK DA108A JK DA110A JK DA111A 91 20 02 36 C B ELECTRIC TRIM C B ELECTRIC TRIM KLIXON KLIXON POTENIOMETER TRIM POSITION WA2 G056S502UA PLUG TRIM POSITION 4 PIN CLAMP RECGPT TRIM POSITION 4 PIN GLAMP G B STBY VAG CLUTCH STBY VAC PUMP FUSE HOLDER FUSE ANNUNGIATOR RELAY DIODE PLUG SOGKETS RECPT 2 PIN PINS RECPT 2 PIN PINS PLUG 2 PIN SOCKETS LOADMETER SINGLE LOADMETER DUAL AMMETER LIGHT BULB ASSY BULB CONN AMMETER CONN AMMETER ALT SWITCH PUSH VOLTAGE LIGHT BULB ASSY ALT BULB AMP AMP AMP AMP MOONEY AEROSAFE LITTEL LITTEL MOONEY MOONEY AMP AMP AMP AMP AMP AMP AMP AMP B amp D B amp D MOONEY ROCHESTER GE S E C BENDIX C H ROCHESTER ROCHESTER GE SHUNT AMMETER ALT NR 1 EMPRO SHUNT AMMETER ALT NR FUSEHOLDER ALT 1 FUSE 5A FUSEHOLDER ALT 1 FUSE 5A SHUNT AMMETER LOAD SHUNT AMMETER LOAD SHUNT AMMETER LOAD SHUNT AMMETER LOAD EMPRO McGRAW EDISON McGRAW EDISON McGRAW EDISON McGRAW EDISON EMPRO EMPRO EMPRO EMPRO FUSEHOLDER LOAD McGRAW EDISON FUSE 5A McGRAW EDISON FUSEHOLDER LOAD McGRAW EDISON FUSE 5A McGRAW EDISON AMMETER SHUNT ALT 2 EMPRO AMMETER SHUNT
48. LT PORSCHE N A L 165 IGNITION COIL RT PORSCHE N A L JE168A SENSOR TDC 1 PORSCHE N A L JE169A SENSOR TDC 2 PORSCHE N A L JE170C RECPT 3 PIN CANNON GERMANY 121001 633 RECPT 3 PIN ALT PORSCHE 933 612 411 00 ADAPTER RACHEM TXR18AB000 C1104Al ADAPTER ALT SUNBANK S2900AS0604AI S034 000 ADAPTER ALT SUNBANK 2900AS1004A 8034 000 COUPLING SUNBANK S3292 BOOT RAYCHEM 202S121 25S L JE71C PLUG 3 PIN CANNON GERMANY GAOGEH10SL3PB14 are PLUG 3 PIN ALT PORSCHE 933 612 412 00 ADAPTER RACHEM TXR18AB000 C1104A ADAPTER ALT SUNBANK S2900AS0604AI S034 000 NS ADAPTER ALT SUNBANK S2900AS10044A1 S034 000 COUPLING SUNBANK S3292 RAYCHEM 2028121 256 L JE172B RECEPT IGN COIL LT 4 PIN CANNON MS3100K 14S 2P DEE ADAPTER RAYCHEM TXR18AB000 C1404AI ADAPTER ALT SUNBANK S2900AS1004Al S034 000 RAYCHEM 2025121 255 L 173 PLUG IGN COIL LT 4 CANNON MS3106E 148 28 ics ADAPTER RAYCHEM TXR18ABO00 C1404Al ADAPTER ALT SUNBANK S2900A81004A1 8034 000 erue BOOT RAYCHEM 2028121 258 L JE174C RECPT 3 PIN CANNON GERMANY 121001 633 RECPT 3 PIN ALT PORSCHE 933 612 411 00 ben ADAPTER TXR18AB000 C1104AI ADAPTER ALT SUNBANK S2900AS0804A1 S034 000 ADAPTER ALT SUNBANK 52900A51004Al 5034 000 ape COUPLING SUNBANK 53292 BOOT RAYCHEM 2028121 258 L JE175C PLUG 3 PIN CANNON GERMANY 1051 3 14 PLUG
49. MAIN UNIT ASSY FUSE HOLDER ALT FUSE HOLDER JACK PHONE WASHERS JACK PHONE WASHERS M20J ELECTRICAL EQUIPMENT CHART VENDOR MOONEY MOONEY MOONEY AERO INSTR AERO INSTR MOONEY MOONEY ALCOR ALCOR ALCOR MOONEY ALCOR ALCOR ALCOR KULITE PATRIOT PATRIOT MOONEY MOONEY MOONEY SHADIN MOONEY MOONEY SHADIN MOONEY MOONEY MOONEY MOONEY MOONEY MOONEY MOONEY AMERI KING AMERI KING AMERI KING AMERI KING LITTEL FUSE LITTEL FUSE McGRAW EDISON SWITCHCRAFT SWITCHCRAFT SWITCHCRAFT SWITCHCRAFT 12 98 BES E PART NO 930023 205 930023 305 930023 353 PH502 12 AN5812 PH502 12 AN5812 AN3115 1 AN3116 1 880055 503 880055 505 46361 OEM 46161 OEM 80825 660110 000 86225 41338 41337 APT 231 1000 25A KA21 015 25A SP100 110 25A 880034 501 880034 503 880034 505 912041TD 880030 501 880030 503 680501B 880037 507 560254 503 560254 507 880037 501 560254 501 560254 505 880013 507 110 416 453 0150 4500041 450004 450004 1V 1H AK 450 155020 155120 FHN42W C 11 5 1028 5 1029 112 5 1028 5 1029 SERVICE AND MANUAL NOTES 91 20 06 99 SERVICE AND MANUAL ELECTRICAL EQUIPMENT CHART CODE FU101A FU102A FU103A FU104A FU105A FU106A JE101A JE102A JE103A JE104A JM101A JM101B JM102A JM103A JM104A JM105A JM108A JM107A JM108A JM
50. MOONEY BORG INSTR BORG MITCHELL MOONEY MOONEY MOONEY MOONEY MOONEY DUKES MOONEY DUKES MOONEY MOONEY 12 98 enger mn NC Se Sa DOM Ket PART NO SA25SAT12 3 SW53AA2 15 1049 3 C 11 C 11 7277 2 AHW4 MST215N 7277 2 7277 2 7277 2 7277 2 7277 2 7277 2 7277 2 7277 2 7277 2 930023 023 930023 123 223 930023 021 930023 121 221 800233 000 800233 000 800233 000 930023 125 225 7277 2 KA20 7277 2 7277 2 7277 2 7277 2 7277 2 930023 127 227 7277 2 800336 501 800336 503 CA 7212 or CA 7286 CA7616 98470 1LW 930023 011 930023 117 930023 111 930023 117 217 930023 211 4140 00 19 1499 00 19 610153 501 1499 00 19 610153 501 930023 019 SERVICE AND MANUAL NOTES 11 11 11 11 11 11 11 11 11 11 11 11 28 28 28 11 11 1 1i 11 11 11 28 11 37 37 28 91 20 01 19 SERVICE AND MAINTENANCE MANUAL CODE 21 21 21 21 21 91 20 01 20 NF03B D NF04A NF04B ALT NF05A NFO7A NFOBA NPO2A NPO3A PA01B PA02A PA02B PA02C PA02D PA03A PA03B PA03G PA03D PA04A PA04B PAOSA PA06A B C PA07A PA07B PA08B PBO1A PB01B PBO2A PB02B PBOSA PBO4A PB04B PBOSA PB06A PB06B D PBO7A M20J 14 VOLT ELECTRICAL EQUIPMENT CHART DESCRIPTION VENDOR C B FUEL PUMP HI MOONEY RESISTOR CLARSTAT VO
51. MOONEY MOONEY WHELEN WHELEN LIGHT ANTI COLLISION RED WHELEN LIGHT ANTI COLLISION WHITE WHELEN ANNUNC LENS US ANNUNCIATOR LENS FRAN ANNUNCIATOR LENS US MOONEY MOONEY MOONEY ANNUNCIATOR LENS FRANCE MOONEY ANNUNCIATOR LENS ANNUNCIATOR LENS C B LOGO LIGHT LIGHT LOGO LAMP HOLDER LAMP HOLDER LAMP HOLDER LAMP HOLDER ANASHER LOCK INT TOOTH AWASHER LOCK INT TOOTH MOONEY MOONEY MOONEY WHELEN MOONEY DIALIGHT WHELEN SLOAN ALLEN BRADLEY LAMP HOLDER INSTRUMENTS LAMP HOLDER INSTRUMENTS LAMP HOLDER SIGMA TEC LAMP HOLDER HH SMITH ALT LEECRAFT ALT ALLIED ALT SPC 12 98 MOONEY AIRCRAFT CORPORATION PART NO NOTES 10 382698 6244 6261 6260 10 357240 1 6393 6350 800315 501 S6RN 25 10 CD 4771 CD 4770 4372 Rev C 4370 Rev C 464 T 3 1 4 168 T 3 1 4 385 330 CM7 7330 CM7 7327 370 1816 327 AV RED 327 1818 1495 930023 243 930023 343 WRML 24 WRML 65 90033 19 90033 20 880048 613 880048 615 880048 617 B80048 619 880048 621 880048 623 930023 357 A730 1 28 914083 1 270 1930 0171 702 A 350 CN CL BK SH 28 855S 0 U MS35334 21 M2898 0211 128 BA28 24 BW3 1V 192 971 1930 7 05 931 3103 LSL 11 128U MOONEY AIRCRAFT CORPORATION M20J ELECTRICAL EQUIPMENT CHART SERVICE AND MAINTENANCE MANUAL CODE DESCRIPTION VENDOR PART NO NOTES LH ALT NEWARK 81 2561 LH9 LAMP HOLDER HH SMITH 1925 LH10 LAMP HOLDER WHELEN
52. MOONEY AIRCRAFT CORPORATION M20J SERVICE AND MAINTENANCE MANUAL BLANK 30 70 00 12 98 14 MOONEY AIRCRAFT CORPORATION M20J SERVICE AND MAINTENANCE MANUAL CHAPTER 32 LANDING GEAR SERVICE AND MAINTENANCE MANUAL M20J MOONEY AIRCRAFT CORPORATION CHAPTER 32 LANDING GEAR LIST OF EFFECTIVE PAGES CHAPTER SECTION SUBJECT PAGE DATE 32 Effectivity 12 BLANK 12 98 32 Contents LES NE ec s ws We do e xu ns on 42 98 32 Contents o wow ox 12 98 32 00 00 5 12 98 924002 50 so no vu vw 6 vv 0 5 12 98 32 1005 v box To sv 22 60 lt gt 12 98 8 9 32 10 06 12 98 32 20 03 Ke CR al A X eos or os n 52 cC o5 a 12 98 923002 x ss de a OO o 12 98 32 30 04 MEM 12 98 32 30 04 uu a 12 52 22 12 98 Se UE uox me ue die mox 12 98 92 00 057 EG Ca wa kDa d c M Ree RI LS 12 98 92 30 05 uos Sh wo wow ER 2 oc Bou x us ae 22 2 12 98 32 31 01 4 wo ke OG Gre uk xe BB deca MO 0 2 5 12 98 32 31 02 AT 0 12 98 32 34 03 402 Ec A vem ve WEE unam oum uid 12 98 PEON M M D QM 0205 12 98 32 32 00 7 ECCLE 19 98 32 40 00 e um on BE S x
53. MS3057 16A 930021 002 206036 1 206070 1 930021 002 206060 1 206062 1 206152 1 206070 1 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 AIRCRAFT CORPORATION M20J SERVICE AND MAINTENANCE MANUAL 28 VOLT ELECTRICAL EQUIPMENT CHART CODE DESCRIPTION VENDOR PART NO NOTES JK SB118A RECEPTACLE 8 PIN AMP 205841 2 CLAMP AMP 206082 1 JK SB119A MOTOR RIGHT PRECISE FLT 01532 JK SB120A SWITCH DEPLOY LIMIT PRECISE FLT 01505 JK SB121A SWITCH RETRACT LIMIT PRECISE FLT 01505 JK SB122A SOLENOID CLUTCH PRECISE FLT 01678 JK SB123A PLUG 8 PIN AMP 205838 1 CLAMP AMP 206062 1 JK SB124A 8 PIN AMP 205841 2 CLAMP AMP 206062 1 JK SPK101A SPEAKER CABIN ARCHER 12 1703 JK SPK102A PLUG 2 PIN AMP 1 480318 0 60619 1 JK SPK103A RECEPTACLE 2 PIN AMP 1 480319 0 PIN AMP 60620 1 JK WD101A FUSEHOLDER LITTEL 155020 ALT LITTEL 155120 FUSE 1 LITTEL 313001 JK WE101A C B GEAR WARNING KLIXON 7277 2 1 JK WE102A LIGHT GEAR DOWN SLOAN 8555 0 0 BULB GE 327 J WE103A SWITCH THROTTLE MICRO V3 1 P ACTUATOR MICRO JV 5 K WE103A SWITCH THROTTLE MICRO 1SE1 T ACTUATOR MICRO JE 17 JK WE104A GEAR WARNING MALLORY SC628P JK
54. P N 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 GAUTION 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 installed in reverse sequence of removal 71 13 00 71 13 01 ENGINE COWL FLAPS COWL FLAP RIGGING 24 0001 thru 24 2999 1 Adjust both the feft and right 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 are closed The scissors should be in an overcenter position when 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 12 98 M20J MOONEY AIRCRAFT CORPORATION ADJUSTING ROD B COWL FLAP FLUSH WITH B ENGINE COWLING COWL FLAP RIGGING 24 0001 THRU 24 2999 FIGURE 71 1 71 13 02 COWL FLAP RIGGING 24 3000 thru 24 TBA The cowl flaps are activated UP and DOWN by an idler arm connected by a push pull rod to the actuator arm on a geared motor A cowl flap switch located on the cockpit console directly under the mixture control acti
55. PLO2A PLO2B PLO3A PLO3B PLO4A PL04B PLOSA PLOSB PLOSC DESCRIPTION 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 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 LAMP DIODE ON LIGHT DIODE O V LIGHT RECPTACLE CLAMP PLUG DIODE DIODE RADIO RELAY RECEPTACLE CLAMP CLAMP PLUG C B PANEL CLAMP PLUG FLT PNL 1 CLAMP PLUG FLT PNL 1 PLUG ELEG GEAR CLAMP PLUG ELEC GEAR PLUG L WING CLAMP PLUG L WING PLUG L WG STUB CLAMP PLUG L WG STUB CLAMP PLUG L WG STUB M20J 14 VOLT ELECTRICAL EQUIPMENT CHART VENDOR SARKES TARZIAN MOONEY MOONEY MOONEY MOONEY MOONEY MOONEY MOONEY MOONEY MOONEY ELECTRO MECH LITTEL LITTEL ELECTRO MEC KLIXON LEACH MAGNACRAFT WESTERN IND WESTERN IND SARKES TARZIAN SARKES TARZIAN AMP AMP SAHKES TARZIAN SARKES TARZIAN AMP AMP AMP AMP AMP AMP AMP MOONEY AMP AMP MOONEY MP MOONEY AMP AMP AMP MOONEY 12 98 MOONEY AIRCRAFT CORPORATION PART NO F 4 913127 001 913127 001 913127 003 913127 005 913127 019 913127 035 913127 035 913127 035 913127 037 8012 155020 or 155120 313015 MS3106A 18 1S MS30
56. PROBE OAT SOCKET 4 PIN XMTR FUEL INBD LH RH XMTR FUEL OUTBD LH XMTR FUEL OUTBD RH XMTR FUEL OUTBD LH RH FUEL FLOAT ARM RH I B FLOAT ARM RH O B FLOAT ARM LH I B FLOAT ARM LH O B TRANSDUCER PROCESSOR EMPRO JANCO EMPRO JANCO Ul ASTRONAUTICS ELEC GYRO CORP Ul Ul NORWICH _ MOONEY MOONEY CINCH JONES MOONEY MOONEY MOONEY MOONEY AVAQ 19 98 SERVICE AND MAINTENANGE MANUAL PART NO NOTES MS3420 14 MS3420 16 206138 1 DC19977 3 DC51222 1 800221 505 880052 519 880052 119 880050 503 800242 503 930023 233 800242 519 01165 0 T14 800313 501 800391 501 930023 233 930023 333 820904 2 820904 1 930023 247 930023 347 28G214 CW 2 MLA 70A 100MV 8406 70 MLA 150A 100MV 8406 150 9013 CODE N 5 303990 028MSC 1394T100 3Z 9114 CODE N 21 9112 CODE N 9 MS24482 1 AN5546 1 102 00007 880059 158 880004 501 S 304 CCT 610242 3 610243 3 610243 1 610242 5 9450563001 9400563102 9400563104 9400563101 9400563103 9450563002 9450563303 91 20 06 SERVICE AND MAINTENANCE MANUAL CODE DG101A DG102A DG103A DG104A DG105A DG106A DG107A DG108A DG109A DG110A DG111A DG112A DG113A DG114A DG115A DH101A DH102A Di101A 01102 01104 DI105A DJ101A DJ101B DK101A DK102A DL101A DL102A DL103A DL104A DL104B DL104C DL104D DL105A DL108A DL107A
57. RB102A BLOWER RADIO TRW 19A2790 JK RB102B BLOWER RADIO BENDIX KING KA0033 01 JK RB103A FILTER NOISE ARCHER 273 103 ALT SPRAGUE 5JX5104A JK RB104A PLUG 2 PIN MOLEX 03 06 1023 SOCKET MOLEX 02 06 1103 JK RC201A RECEPTACLE 37 PIN AMP 206151 2 JK RC203A RECEPTACLE 3 PIN AMP 206036 2 CLAMP AMP 206070 1 JK RC204A RECEPTACLE 26 PIN MOONEY 930021 506 JK RC205A RECEPTACLE 28 PIN AMP 206152 1 CLAMP AMP 206070 1 JK RC206A RECEPTACLE 20 MOONEY 930021 502 JK RC207A RECEPTACLE 20 PIN MOONEY 930021 502 JK RC208A RECEPTACLE 14 PIN MOONEY 930021 002 JK RC209A RECEPTACLE 9 PIN AMP 206705 2 CLAMP AMP 206966 1 JK RC210A RECEPTACLE 9 PIN AMP 206705 2 CLAMP AMP 206966 1 JK RC211A RECEPTACLE 34 PIN MOONEY 930021 508 JK 212 RECEPTACLE 14 PIN MOONEY 930021 002 JK RC214A RECEPTACLE 14 PIN AMP 206044 1 CLAMP AMP 206070 1 JK RC215A RECEPTACLE 14 PIN AMP 206044 1 CLAMP AMP 206070 1 JK RC220A RECEPTACLE 4 PIN AMP 206153 1 CLAMP AMP 206062 1 JK RC221A RECEPTACLE 4 PIN AMP 206153 1 CLAMP AMP 206062 1 JK RC222A RECEPTACLE 4 PIN AMP 206708 1 206966 1 JK RC222B RECEPTACLE 9 PIN AMP 206037 1 CLAMP AMP 206070 1 12 98 91 20 03 73 SERVICE AND MAINTENANCE MANUAL JK RC226A JK RC227A JK RC230A JK RC231A JK RC232A JK RC233A JK JK SB101A JK SB102A JK SB103A JK SB104A JK SB105A JK SB106A JK SB107A JK SB10
58. REAR 4 PIN AMP 206153 1 CLAMP AMP 206062 1 JK RC23A RECPT GHND 1 16 PIN AMP 206036 3 CLAMP AMP 206070 1 JK RC24A GRAND 2 16 PIN AMP 206036 3 CLAMP AMP 206070 1 JKL RC26A RECPT COMPASS LT HARNESS AMP 206153 1 CLAMP AMP 206062 1 JK RECPT 2 4 AMP 206153 1 T CLAMP AMP 206062 1 JKL HC27B RECPT FLT PNL 2 20 PIN MOONEY 930021 502 JK RC28A RECPT AVIONICS POWER 20 PIN MOONEY 930021 502 JK DIM GRND 20 PIN 930021 502 91 20 02 12 98 56 MOONEY AIRCRAFT CORPORATION M20J SERVICE AND MAINTENANCE MANUAL 28 VOLT ELECTRICAL EQUIPMENT CHART CODE DESCRIPTION VENDOR PART NO NOTES JK DIM GRND 4 PIN 206153 1 CLAMP AMP 206062 1 JK RC31A RECPT STBY VAC 8 PIN AMP 205841 2 CLAMP AMP 206062 1 JK RC31B RECPT STBY VAC 8 PIN AMP 205841 2 CLAMP AMP 206062 1 JKL HC32A RECPT GEAR RELAY 4 PIN 206153 1 GLAMP AMP 206062 1 JK RC33A RECPT C B PNL 2 9 PIN AMP 206705 2 CLAMP AMP 206966 1 JKL RC34B GRND BUSS 16 PIN AMP 206036 3 CLAMP AMP 206966 1 JK RC35A RECPT FLT PNL 3 4 PIN AMP 206153 1 m CLAMP AMP 206062 1 JK RC36A HECPT CONSOLE 2 8 PIN AMP 205841 2 CLAMP AMP 206062 1 JK RC37A RECPT LT SIDE PNL 8 PIN AMP 205841 2 CLAMP AMP 206062 1 JK RC38A RECPT FLAY RELAY 8 PIN AMP 205841 2 CLAMP AMP 206062 1 JK RC39A RECP
59. SARKES TARZIAN AMPHENOL LITTEL LITTEL KORRY GE SARKES TARZIAN MERIDEN KLIXON MALLORY SAFE FLIGHT ALCO KLIXON IAI CHICAGO MINIATURE 12 98 SERVICE AND MAINTENANCE MANUAL PART NO 206036 3 206070 1 206152 1 206070 1 206036 2 206070 1 206036 3 206070 1 206152 1 206070 1 250 650 5821 003 330 F 4 LV 14 NOTES LV 14F AHW4 2 7277 2 2 250 650 5821 006 330 1SM1 T JS 221 SS12ET10 102L3 V3 1 JV 5 SC628P F 4 855S 0 U 327 250 650 5821 007 GE 330 F 4 F 4 F 4 50 OHM 5 WATT F 4 250 650 5821 004 330 F 4 126 223 1000 155020 311011 250650 5821 005 330 F 4 AHW4 2 7277 2 2 SC628 C46001 MSP205R 7277 2 2 500D0024 CM7 7330 91 20 01 31 SERVICE AND MANUAL 14 VOLT ELECTRICAL EQUIPMENT CHART CODE 21 21 21 21 21 21 91 20 01 32 WT03B WTO3F WT03G WTOSH WTO3J WTOSK WTO4A WV01A WV01B WVO02A WV02B WV02C WVOSA WV04A WV04B WVOSA WVO06A WV07A WWO1A WWo1B DESCRIPTION ANNUNGIATOR LAMPS ANNUNCIATOR LAMPS ANNUNCIATOR LAMPS 8 ANNUNCIATOR ANNUNCIATOR LAMPS ANNUNCIATOR PLUG ANNUNCIATOR PIN C B VACUUM WAHN C B VACUUM WARN SWITCH VACUUM WARN 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 SWITCH RAM AIR ACTUATOR SWITCH ALTERNATE
60. The regulator should not be considered defective because of a low charging rate until A A voltmeter check indicates that voltage at the bus is below requirements B A battery hydrometer check indicates that battery is not fuliy charged 3 Hydrometer Reading If battery electrolyte temperature is below 80 degree F subtract four points from hydrometer reading for every 10 degrees F below 80 degrees F If battery acid temperature is above 80 degrees F add four points to hydrometer reading for every 10 degrees F 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 Hi or Overvolt Adjustment at Regulator Bench Adjustment Electro Delta Connect a variable voltage power supply fo the regulator positive to pin A or 1 and negative to pin C or 3 24 0001 thru 24 2999 positive to pin 5 amp negative to pin 9 for 24 3000 thru 24 TBA Connect a voltmeter to 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 voltage to 16 volts 1 volt 24 0001 thru 24 2999 28 7 volts for 24 3000 thru 24 TBA Adjust trim pot accessable through hole in case marked OV to relay trip point as indicated by voltage indic
61. VENDOR MOONEY AM PROD PRECISE FLT AUXILEC ELECTODELTA SWITCH ALT NTR FIELD DUAL MOONEY SWITCH ALT NTR FIELD SINGLE MOONEY ALTERNATOR ALT ALT RNATOR ALT ALTERNATOR RIGHT ALT GEAR ASSY ALTERNATOR KIT INSTALL REFERENCE 600180 FILTER ALT SENSOR CURRENT REGULATOR VOLTAGE SENSOR CURRENT 110A SENSOR CURRENT 175A ALTERNATOR MONITOR CURRENT ALTERNATOR LEFT ALT BATTERY SWITCH MASTER SWITCH MASTER SWITCH BAT 1 2 SWITCH BAT 1 2 BATTERY 24V BATTERY 24V 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 PIN ALT PLUG 8 PIN LYCOMING PRESTOLITE LYCOMING PRESTOLITE TCM TCM TCM ELECTRO SYSTEMS LYCOMING MOONEY MOONEY MICRO SWITCH MOONEY KLIXON KLIXON TCM MOONEY TCM TCM GILL MOONEY MOONEY MOONEY MOONEY CONCORDE CONCORDE AMP AMP MOLEX DEAN AMP AMP ARRAY CDI CDI AMP AMP ARRAY CONN DEUTSCH MATRIX SCIENT AMP 12 98 SERVICE AND MAINTENANCE MANUAL PART NO 800270 501 DGR 2 VR 802 880052 525 880052 503 LW 14367 ALU 6421 LS LW 15404 ALY 8420 649719 649280 649123 ES 4009 LS 05K 21065 NOTES 880014 501 800307 501 CSLA1GE 800270 503 7235 1 110 7235 1 175 649304 800287 501 6491
62. along grain boundaries of metal alloys is referred to as intergranular corrosion Aluminum alloys 2024 and 7075 are vulnerable to this type of attack Aluminum extrusions may contain nonuniform areas which in tum 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 delaminated This is referred to as exfoliation It is very difficult to completely remove and stop this type of corrosion and replacement of the affected part is recommended wherever possible C Concentration Cell Corrosion Corrosion forming under rivet heads along faying surfaces at skin io longeron contact surfaces and other similar areas is called concentration cell corrosion Detection requires close 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 faying surfaces with zinc chromate or eoxy polymide primer and reassembling D Galvanic Corrosion Dissimilar metals 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 primer or equivalent before reassembling 2 Corrosion Pre
63. bulkhead Access to the cylinder is obtained thru the radio compartment access door or the left side of the aircraft behind left wing post 12 98 SERVICE AND MAINTENANCE MANUAL 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 cylinder through the large radio compartment door C Slowly loosen the supply line fittings at the cylinder valves reference Figure 35 1 to relieve any pressure that may exist in the supply lines After presure is relieved remove the lines D Disconnect the control cable 3 from the arm 4 on reducing valve 5 E Cap all open lines and regulator openings with clean metal caps F Note relative position of regulator valves and control arm prior to removal G Loosen the clamps 11 retaining the cylinder while supporting the cylinder and carefully remove cylinder and regulators from its position 7 Oxygen cylinder installation A Place new oylinder and regulators into position in clamps and secure The new cylinder should bepositioned with regulator valves and control arm in the same position as the removed cylinder assembly components M20J MOONEY AIRCRAFT CORPORATION B Remove caps from lines and carefully inspect all connections for damage or any foreign substance before connection to
64. etc must be operating properly to prevent engine damage It is recommended that all engine indicating components be checked at each 100 hour or annual inspection to verify proper operation Calibrated instruments may be Tee d into the ue systems for a comparison check between hem and the aircraft s instruments 77 00 01 RANGES f Power plant instruments operate electrically through variations in resistance caused by pressure or temperature changes by variations in current output caused by varying engine RPM or alternator output or by pressure from engine induction system 1 Ammeter A Range 60 to 60 AMPS 24 0001 thru 24 2999 B Range 70 to 70 AMPS 24 3000 thru 24 TBA G Tolerance 1 2 AMPS 2 Fuel pressure gauge A Green arc 14 0 PSI to 30 PSI B Red line 14 MIN 30 PSI MAX 3 Oil temperature gauge A Green arc 150 degrees to 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 25 to 60 PSI 2 Starting amp warmup range 90 to 100 PSI C Red line 25 PSI MIN 100 PSI MAX M20J SERVICE AND MAINTENANCE MANUAL NOTE The oil pressure relief valve may be honed to improve low idle oil pressure 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 thru 24 0377 except 24 0084 6 Cylinder head temperature g
65. intensity during flight Seeps considered permissible for flight must be frequently inspected to insure that no increase in intensity has occured 28 12 00 8 M20J SERVICE AND MAINTENANCE MANUAL LI 3 1 2 TB 4 IN 1 1 9 IN 3 4 IN SEEP HEAVY SEEP 4 TO S IN RUNNING LEAK FUEL LEAK CLASSIFICATION FIGURE 28 4 2 A running leak and any leak in a confined area that is not exposed to the airstream should be repaired before the 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 or wing skin to its true source inside the tank the exact point where fuel is escaping from tank must 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 torn 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 exterior 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 interior leak be located The fuel tank is a network of seams and fuel may fiow through or along a seam or from one seam to another Fuel may channel a few inches or several feet to where it app
66. is adjusted with the screwdriver adjustment accessible through the front of the annunciator while there is a preset number of gallons in the tank The time delay must be removed from the circuit by moving S3 accessible through the front of the annunciator from the NORMAL position to the CALIBRATE position This opens the return for capacitor C9 and the indication on the L LOW FUEL channel will not be delayed After calibration is accomplished restore the time delay by moving S3 from the CALIBRATE position back to the NORMAL position The position 53 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 93 in the NORMAL position there is a delay of approximately 2 seconds in illumination but with S3 in the CALIBRATE position there is no delay in illumination 24 39 06 17 AIRCRAFT CORPORATION M20J SERVICE AND MAINTENANCE MANUAL Up to this point the circuits used to annunciate low fuel are the same circuiis that have been used for many years in annunciators used on Mooney aircraft The method of dimming however has been changed and expanded from what has been used in the past In the past only the low fuel channels dimmed excluding DOWN discussed above while now the dimming has been expanded to include additional 5 channels From the perspective of the pilot the operation is the same depress the DIM switch an
67. operation on straight mineral oil take the following precautionary steps 1 Do not mix additive oil and straight mineral oil Drain straight mineral oil from engine change filter and fill with additive oil 2 Do not operate engine longer than five hours before again changing oil 3 Check oil filter for evidence of sludge Change oil and replace oil filter element every 10 HOURS if sludge is evident Resume normal oil drain periods after sludge conditions improve 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 more often when conditions warrant 12 10 04 OXYGEN SYSTEM OPTIONAL The oxygen cylinder when fully charged contains approximately 76 cubic feet of aviators breathing oxygen Specifications No MIL O 27210 Recharging of this oxygen cylinder should be accomplished by using the appropriate Scott recharging fittings 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 FILLING AMBIENT FILLING TEMPERATURE PRESSURE TEMPERATURE PRESSURE DEGREES F PSIG DEGREES F PSIG 0 1650 50 1875 10 1700 60 1925 20 1725 70 1975 30 1775 80 2000 40 1825 90 2050 OXYGEN PRE
68. or to start the engine The Auxiliary Power Plug guide pin must have A voltage connected to it in order to activate the Auxiliary Power Relay The battery can be charged using the approved Auxiliary Power Cable connected to a charge cart capable of regulating the charging current To prevent battery damage the charging current should be low 3 4 amps to begin and then increased as 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 NOTE It is recommended that the approved Auxiliary Power Cable be connected to booster battery then the plug inserted into auxiliary power receptacle 12 98 SERVICE AND MAINTENANCE MANUAL 24 32 00 BATTERY MAINTENANCE CAUTION Battery gases are explosive 1 Battery Removal A Turn master switch off B Remove tailcone access cover and battery box id S 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 o
69. 1 10 101971 8 3 MS3057 6A MS3057 6B MS3057 16A MS3057 16B MS3057 12B 206966 1 P O 126 222 DE 24657 DE 51224 1 D110278 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 AIRCRAFT CORPORATION CODE CL32B CL37A CL37B CM101A CH101A CR101B CH102A GR103A CT101A CT102A CT103A CT104A CT105A CV101A CV101B CV102A CV103A CV104A CV1048 CV105A DA101A DA101B DB101A DB102A DC101A DD101A DD102A DD103A DF101A DF102A DF103A DF104A DF105A DF106A DF107A DF108A DF109A DF110A DF111A M20J ELECTRICAL EQUIPMENT CHART DESCRIPTION CLAMP BOOT ALT CLAMP 37 PIN CLAMP 37 PIN LOCK RETAINER CURRENT MONITOR VENDOR MOONEY SWITCH RUDDER TRIM WHITE MOONEY SWITCH RUDDER TRIM BLACK MOONEY MOTOR RUDDER TRIM INDICATOR RUDDER SWITCH TRIM INDICATOR ELEV TRIM MOTOR ELEV TRIM TRIM INTERFAGE INDIGATOR ELEV TRIM CIRCUIT BREAKER SWITCH CIRCUIT BREAKER SWITCH PUMP STAND BY VAGUUM PUMP STAND BY VACUUM MOONEY MOONEY MIL S 9419 MOONEY S TEC MOONEY MOONEY MOONEY MOONEY AEROSAFE AEROSAFE SWITCH C B STAND BY VACUUM MOONEY SWITCH C B STAND BY VACUUM MOONEY PUMP CLUTCH ASSY STDBY VAC AIRBORNE SHUNT AMMETER ALT SHUNT AMMETER ALT TURN COORDINATOR T TURN COORDINATOR PROBE CHT ALT ALT INDICATOR OAT
70. 10 00 00 10 10 03 CHAPTER SECTION SUBJECT 10 00 00 10 10 00 n 10 10 01 10 10 02 10 10 03 10 20 00 M20J CHAPTER 10 PARKING AND MOORING LIST OF EFFECTIVE PAGES PAGE 1 2 BLANK 3 4 TABLE OF CONTENTS SUBJECT General Parking Storage Flyable Storage Prolonged Return to Service Mooring 12 98 DATE 12 98 12 98 12 98 PAGE P G OCC MOONEY AIRCRAFT CORPORATION 10 EFF CONTENTS 1 2BLANK MOONEY AIRCRAFT CORPORATION 10 00 00 GENERAL The parking brakes are set by applying the brakes and pulling out on the parking brake knob Release the Ra by pushing in on the parking brake control nob i 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 tiedown rings are to be threaded into built in receptacles and the tail skid tiedown fitting on the aft end of the tailcone 10 10 00 PARKING When parking the aircraft place wheel chocks fore and aft of the main wheels The parking brakes may be used for short duration parking CAUTION Do not set parking brakes when they are overheated or when cold weather could freeze moisture and slush accumulation in the brake mechanism Do not set parking brakes when aircraft is tied down For maximum protection hangar the aircr
71. 1049 3 12 98 MOONEY AIRGRAFT CORPORATION CODE 21 MB13A MB14A MB15A MB16A B MB17A MB18A B MB19A MB20A MB21A MB22A MB23A MB24A MB25A MB26A MB27A MB27B D MB28A MB28B MB30A MB31A MB32A B MB33A MB34A MB35A MB36A MB37A MB38A MB39A MB40A D MB41A MCO1A MC01B 1 1 1 1 NF01B NF01G NF01D F NF01E NFO2A NFO2B NFO3A DESGRIPTION KEY GOPILOT GAP FAGE NUT JAGK FONE 1 JAGK FONE 2 C B A P 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 C B WX RADAR COLOR C B RADIO BLOWER RADIO BLOWER ASSY C B STEREO C B ALT SERVO C B 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 FUEL PUMP C B FUEL PUMP HI M20J 14 VOLT ELECTRICAL EQUIPMENT CHART L Sirk VENDOR C H C H C H SWITCHCRAFT SWITCHCRAFT KLIXON MERIDEN ALCO KLIXON KLIXON KLIXON KLIXON KLIXON KLIXON KLIXON KLIXON KLIXON MOONEY MOONEY MOONEY MOONEY MOONEY MOONEY MOONEY MOONEY KLIXON KING KLIXON KLIXON KLIXON KINLIXON KLIXON MOONEY KLIXON MOONEY
72. 13 DIMPLE CRACKS REPAIR FIGURE 51 13 M20J SERVICE MANUAL 3 Repair of Extending Beyond Dimple Radius Cracks that extend through the face of the dimple into the surrounding skin can be repaired as follows see Figure 51 13 A Stop drill crack with No 60 bit B Cut a doubler from the same material as the skin to be repaired Allow for six rivets at four diameter rivet spacings with two diameter edge distances in a circular pattern around the cracked dimple C Round the corners of the doubler and scarf the sandwiched edges to about 010 inch by 250 inch D Drill holes for six rivets same size as those in the originai rivet pattern and drili and countersink 100 degree dimples in doubler E Prime area to be repaired and install doubler with wet primer 4 Repair of Circumferentially Cracked Dimples Circumferentially cracked dimples dimples with cracks that appear as an annular mark around the dimple can be repaired by installing a conical washer A Drill through dimple using a drill large enough to remove the damaged area B install doubler as shown in Figure 51 14 Wet prime prior to assembly C Countersink dimple hole in skin allowing the countersink to extend into substructure D Install conical washer use next oversize rivet size Wet prime washer and adjacent skin and doubler Surfaces prior to assembly E Drill remainder of the hole to allow ins
73. 2 24 CS32004B 4 36 M20J SERVICE AND MAINTENANCE MANUAL C Metal cleaning solvent Turco 657 wipe solvent D Cheese cloth E leak detector or bubble fluid F Methyl ethyl keytone MEK thinner for PR 1005 1 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 Handling and Mixing Sealants A Sealant Material Characteristics 1 Application life is the time that the mixed compound remains suitable for application Application life ratings are always based on standard conditions of 75 degrees F and 50 percent relative humidity For every 10 degree F rise in temperature application life and cure time is reduced by half for every 10 degree F drop in temperature application life and cure time is doubled High humidity at the time of mixing slightly reduces the sealant application life 2 Maximum unopened container life with sealant at 80 degree F is six months 3 Sealant application life tack free curing time and curing rates are as follows Cure Rate HOURS 30 Application Life HOURS 1 2 Application Life HOURS 1 2 Pe is Ne Follow procedures accompaning sealant to properly seal fuel tanks Access Door Sealant except on w
74. 2 Ib air pressure Check for fuel cap leaks by soaping circumference of filler cap assembly and observing bubbles Replace o ring if bubbles are FUEL SYSTEM FIGURE 28 1 adjustment Optional visual fuel quantity gauges are located in each wing tank and are to be used only for partial fuel stop the loading as desired The dial is held in position by RTV eak 108 sealant Occasionally the dial may require changing due to weather fading or other damage After documenting CAUTION dial orientation on wing pry dial from cavity Clean Use only cavity and secure correct new dial into proper position one half with RTV 108 The float assembly which activates the 1 2 magnetic portion of the dial needle as fuel level pound of changes in the tank can be replaced by removing the air access cover that the float assembly is attached to on pressure top side of wing and replace the float assembly in tank 28 00 01 FUEL FILLER CAP ASSEMBLY MAINTENANCE Fuel filler port cap assemblies should be checked periodically for proper sealing and should be serviced occasionally to prevent hard to open or close conditions 1 The o ring seal 1 Figure 28 2 around the cap assembly should be kept clean and free of dirt or grit that might cause abrasive action on seal or mating flange Occasional lubrication with petroleum jelly or Tri Flow will keep the o ring soft and pliable 2 The shaft 2 running through the center of the cap
75. 205060 1 206062 1 Waw a awasi u SA ALITUR T Ede MOONEY AIRCRAFT CORPORATION CODE PL37A PL38A PL39A PL40A PL41A PL42A PL43A PL44A 45 PL46A PL47A PL48A PL50A PL51A PL52A PL53A PL53B PL53C PL53D PL54A PL55A PL57A PL58A PL59A PL60A DESCRIPTION PLUG WARN GLAMP I 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 PLUG AVIONIC PWR PLUG AUDIO INTERCN CLAMP PLUG FLT PNL DIM CLAMP CLAMP PLUG C B DIM CLAMP PLUG A P TRIM SW RELAY CLAMP PLUG A P CLAMP PLUG A P GRND CLAMP PLUG AVIONICS GRND CLAMP PLUG MAIN CABLE GRND CLAMP PLUG AVIONICS GRND 2 CLAMP 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 A P CLAMP M20J VENDOR AMP AMP AMP AMP AMP AMP AMP AMP AMP AMP AMP 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 12 98 PART NO 206060 1 206062 1 205060 1 206062 1 206060 1 206062 1 206060 1 206062 1 206060 1 206062 1 206060 1 206062 1 206708 1 206966 1 206060 1 206062 1 53106 22 145 MS3057 12B 930021 501 205839 1 206070 1 206037 1
76. 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 206708 1 206966 1 206708 1 206966 1 206037 1 206070 1 205839 3 206070 1 wet SERVICE AND MAINTENANCE MANUAL 14 VOLT ELECTRICAL EQUIPMENT CHART NOTES 91 20 01 25 SERVICE AND MANUAL M20J MOONEY AIRCRAFT CORPORATION 14 VOLT ELECTRICAL EQUIPMENT CHART CODE DESCRIPTION VENDOR PART NO NOTES 21 PL61A PLUG K 14 NAV REG A P AMP 205839 3 CLAMP 206070 1 21 PL62A PLUG K 14 NAV REC A P AMP 206037 1 CLAMP 206070 1 21 PL63A PLUG A P XFER AMP 206037 1 a CLAMP 206070 1 21 PL64A PLUG K 2 K 3 REG AP p 205839 3 CLAMP 206070 1 21 PL65A PLUG TRIM RELAY AMP 205838 1 CLAMP 206062 1 21 PL66A PLUG TRIM SW AMP 205838 1 CLAMP 206062 1 21 PL67A PLUG AZIMUTH AMP 206708 1 CLAMP 206966 1 21 PL68A PLUG ADF AMP 205838 1 206062 1 21 PL69A PLUG TRIM RELAY AMP 205838 1 CLAMP 206062 1 21 PL670A PLUG TRIM PWR AMP 206060 1 CLAMP 206062 1 21 PL71A PLUG A P RELAY AMP 205839 3 CLAMP 206070 1 21 PL72A PLUG VOR GS TRANSFER AMP 205838 1 CLAMP 206062 1 21 PL73A PLUG MKR INVERTER AMP 205838 1 CLAMP 206062 1 21 PL74A PLUG NAV REC A P AMP 205839 3 p CLAMP 206070 1 21 PL75A PLUG ADF RMI 206037 1 CLAMP 206070 1 21 PL76A PLUG GRND AMP
77. 21 DK01E 21 DK01F 21 DK02B 21 DK02D E 21 DKo2F 21 DKO3A 21 DKO3B 21 DKOSC D 21 DKOSE F 21 DKO4A 21 DKO5SA 21 DKOSA 21 DK175A 21 DK176A 21 DK177A 21 DK178A 21 DK179A 21 DK180A 21 DLO1A 21 DLO1B 21 DLOIC 21 DLO1D 21 DLO1E 21 DL01F 21 DLO2A 21 DLO3A 21 04 21 05 21 DMO1A B 91 20 01 12 DESCRIPTION XDCER OIL PRESS AMPLIFIER OIL PRESS PLUG OIL PRESS 4 PIN CLAMP RECPT OIL PRESS 4 PIN CLAMP PLUG 4 PIN CLAMP RECPT 4 PIN CLAMP XDUGR FUEL PRESS XDUCR F F OPT XDUCR FUEL PRESS XDUCR FF XDUCR FUEL FLOW GAUGE FF MP M20J VENDOR DRUCK IA AMP AMP AMP AMP AMP AMP AMP AMP ROCHESTER MOONEY MOONEY MOONEY MOONEY MOONEY 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 ITT CANNON PLUG FF OPT CANNON C B FF KLIXON SWITCH MEMORY FF OPT ALCO PLUG FF XDCR CLAMP XDUCR FUEL PRESS DRUCK AMPLIFIER FUEL PRESS PLUG 4 AMP 4 CLAMP AMP PLUG 4 PIN AMP CLAMP AMP RECPT 4 PIN AMP CLAMP AMP TACH ELEC MOONEY TACH ELEC MOONEY TACH ELEC MOONEY TACH ELEC MOONEY TACH ELEC MOONEY TACH ELEC LIGHTED MOONEY PLUG TACH CLAMP RESISTOR L OHMITE RESISTOR L OHMITE CABLE ASSY MOONEY HOUR METER MOONEY 12 98 MOONEY AIRCRAFT CORPORATION PART NO NOTES PDCR821 0662 100 950D0311 002 206060 1 206
78. 24 0377 Ux mue du dics SC 800200L SA 24 0378 thru 24 0757 includes 240084 275 05 800330 El 24 0758 thru 24 0900 r Dec qd SEES DA xo NA 5 800330 E2 24 0901 thru 24 0942 c k k k k k k k 800330 ES 24 0943 thru 24 1037 k k 800330 E4 24 1038 thru 24 4213 ror k 800330 5 24 1214 thru24 1417 k k se k 800320 24 1418 thru 24 4499 k 800330 E7 24 1500 thru 24 1528 k k k 800530 24 1529 thru 24 1685 Bi swali Et Wo v Sea AIC 800330 E 24 1686 14 thru 24 2999 14 KE SE 20 000069 JP 28 VOLT AIRCRAFT 24 3000 thru 24 3078 57 k 800850 Ji 24 3079 thru 24 3153 S809 0 39 45 5 e 800350 Jo 24 3154 thru 24 3200 24 3202 thru 243217 QT 800283 J1 24 3201 249218 243270 800304 d EHTI REV F hc un T SHT 2 REV H 24 3271 ann 24 8950 k s s k v k s s s s s 800304 jJ REV W JW Tho we lt SHEET 1of2 2of2 24 3351 242878 k s k k k k k k k k k k k k ae lt 800304 J3 REV Ec EE ME 1 of 1 24 3374 thru lt k oe oe k
79. 3 PIN ALT PORSCHE 933 612 412 00 5 ADAPTER RACHEM TXR18AB000 C1104A l ADAPTER ALT SUNBANK S2900AS0604A1 S034 000 ADAPTER ALT SUNBANK S2900AS1004AI S034 000 COUPLING SUNBANK 53292 2028121 258 12 98 91 20 02 43 SERVIGE AND MAINTENANCE MANUAL DESGRIPTION M20J 28 VOLT ELECTRICAL EQUIPMENT CHART VENDOR MOONEY AIRCRAFT CORPORATION PART NO NOTES F s s u CODE L JE176B L JE177B L JE178A L JE179A L JE180A L JE181A L JE182A L JE183A JKL JM101A J JM102A J JM102B K JM103A K JM103B K JM104A K JM104B JK LB101A JK LB101A JK LB102A JKL LB102B JKL LB102B JKL LB103A JKL LB104A JKL LC101A JKL LC102A JKL LC103A JKL LC104A JKL LC105A JKL LC106A JKL LC107A 91 20 02 RECPT IGN COLL RT 4 PIN ADAPTER ADAPTER ALT BOOT PLUG ALT ADAPTER ADAPTER ALT BOOT PLUG 3 PIN RECPT C B 3 PIN PINS PLUG 2 PIN SOCKET RECPT C B 2 PIN PINS PLUG TACH FUEL FLOW SOCKET RECPT TACH FUEL FLOW PINS SWITCH IGNITION PLACARD MAGNETO MAGNETO ALT MAGNETO RIGHT MAGNETO RIGHT MAGNETO LEFT MAGNETO LEFT C B ROTATING BEACON RAYCHEM SUNBANK RAYCHEM HAYCHEM SUNBANK RAYCHEM AMP AMP AMP AMP AMP AMP AMP AMP AMP AMP A
80. 3 S34 LN2 60A 91 20 02 12 98 MOONEY AIRCRAFT CORPORATION DESCRIPTION M20J VENDOR SERVIGE AND MAINTENANGE MANUAL 28 VOLT ELECTRICAL EQUIPMENT CHART PART NO NOTES CODE L PB172A L PB172A L PB173A PB174A L PB175A L PB176A L PB177A L PB178A L PB179A PB180A PB180A L PB181A L PB182A L PB183A L PB184A L PB185A L PB186A PB186A L PB187A PB187A L PB188A L PB189A L 190 L 191 JKL PLO1A JKL PLO2A JKL PLO2B JKL PLO3A JKL PLO4A JKL PL03B JKL PLO4A JKL PLOSA JKL PLOGA JKL PLO7A JKL JKL PLOSA JKL 098 JKL PL10A JKL PL11A JKL PL12B JK PL13A C B LOAD A C RT C B LOAD A C RT ALT BUSS BAR 13 BUSS BAR 14 BUSS BAR 415 BUSS BAR 16 BUSS BAR 17 BUSS BAR 18 BUSS BAR 19 FUSEHOLDER LEFT MASTER FUSE 5AMP MASTER RELAY DIODE MASTER SWITCH RELAY PWR DIODE FUSEHOLDER A H RT FUSE SAMP FUSEHOLDER MASTER RT FUSE SAMP ETA ETA MOONEY MOONEY MOONEY MOONEY MOONEY MOONEY MOONEY LITTEL LITTEL C H C H MOONEY MAGNACRAFT LITTEL LITTEL LITTEL LITTEL MASTER RELAY ENGINE BUS RT C H ALT DIODE MASTER SWITCH OPT GRND DIMMER BOX PLUG C B PANEL 1 37 PIN CLAMP PLUG CONSOLE 1 16 PIN CLAMP PLUG CONSOLE 1 28 PIN CLAMP C H CH MOONEY AMP AMP AMP AMP AMP AMP P
81. 31 93 14 24 39 06 e Annunciator Trouble Shooting Pr XT du Der 2 AM OAS io ma cn 24 3154 thru24 TBA 16 24 50 00 NT Electrical Load Distribution 20 24 51 00 LL Power Distribution System 20 12 98 24 CONTENTS 3 4BLANK SERVICE AND MAINTENANCE MANUAL 24 00 00 GENERAL 24 0001 thru 24 2999 A 14 volt alternator with a transistorized voltage regulator and an overvoltage relay supplies electric power 12 volt 35 ampere hour storage battery is installed in the tailcone The alternator during normal operation supplies power in conjunction with the battery when the master switch 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 shunt type ammeter mounts in the power plant instrument cluster Sika systern 24 3079 thru 24 TBA except 28 volts 24 3000 thru 24 3078 28 volt 70 AMP alternator utilizing a transistorized voltage regulator over voltage control supplies electrical power 24 volt 10 AMP HR storage battery is installed in the tailcone The alternator during normal operation will supply power in conjuction with the battery when the master switch and alternator field switch is ON The circuit breaker panel is on the right subpanel The electrical s
82. 4 1 1 174 786 5 11 4 sq ft 17 9 sq ft T 9 sq tt 8 25 sq ft 21 5 sq ft 13 0 sq ft 1 5 sq 3 0 sq 12 98 SERVICE AND MAINTENANCE MANUAL METRIC OPT MISC 54 43 kg 0 476 Cu M 0 433 Cu M 43 18 cm 52 07 cm 4 54 kg 279 4 cm 181 73 cm TYPE TYPE iil 10 998 meters 7 52 meters 1 321 meters 3 581 meters 16 238 sq meters 1 059 sq meters 1 663 sq meters 0 725 sq meters 0 518 sq meters 1 900 sq meters 1 208 sq meters 6 00 02 SERVICE AND MAINTENANCE MANUAL M20J MOONEY AIRCRAFT CORPORATION 6 00 03 AIRCRAFT STATIONS 24 8 751 Bcm 11 9 3581cm 36 1 lt 1099 8cm 24 3154 Thru TBA L amp R VINGS RAM AlR DELETED ON 84 0001 Thru 84 3153 M g p S N 24 3154 THRU 24 TBA 2794 cm gt PRINCIPAL AIRCRAFT DIMENSIONS FIGURE 6 1 6 00 03 12 98 AIRGRAFT CORPORATION M20J SERVICE AND MAINTENANCE MANUAL STA STA STA STA 147 75 103 50 59 25 24 50 WING STATION RIBS FIGURE 6 2 cr seede GE SES 4a 24 3000 THRU 24 3078 SER DIT M STA STA STA STA STA STA STA 199 50 164 00 130 00 66 00 9506 21 80 3 00 FUSELAGE STATIONS FUSELAGE STATIONS FIGURE 6 3 NOTE The datum line station 0 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 M20J MOONEY AIRCRAFT CORPORATION STA STA STA STA STA 6775 42 25 4 43 42
83. 5 3 to 5 5 volts 4 If correct probable failure in Rochester gauge module 2 If incorrect probable failure in pressure gauge amplifier 2 SIGMA TEK gauge S N 24 3154 thru 24 TBA A Check wiring for continuity between engine compartment connector and Sigma Tek cluster If wiring is correct go to b Probable failure in Sigma Tek gauge module or cluster 12 98 MOONEY AIRCRAFT CORPORATION M20J SERVICE AND MAINTENANGE MANUAL CHAPTER 80 STARTING SERVICE AND MAINTENANCE MANUAL M20J CHAPTER SECTION SUBJECT 80 Effectivity Contents 80 00 00 80 10 00 SECTION SUBJECT 80 00 00 80 00 01 80 00 02 80 00 03 80 00 04 80 00 05 80 10 00 CHAPTER 80 STARTING LIST OF EFFECTIVE PAGES PAGE 1 2BLANK 3 4 TABLE OF CONTENTS SUBJECT General Starter Troubleshooting Starter Maintenance Starter Removal Starter Installation Starter Brushes Cranking MOONEY AIRCRAFT CORPORATION DATE 10 95 10 95 5 93 PAGE C2 ww 80 EFF CONTENTS 1 2BLANK MOONEY AIRCRAFT CORPORATION 80 00 00 GENERAL The airplane is equipped with a 12 volt starter 24 0001 thru 24 2999 24 volt 24 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
84. 503 DT101A IND EGT ALCOR 46361 DT101B IND EGT ALCOR OEM 46161 DT102A SWITCH EGT 4 POSITION ALCOR OEM 80825 DT103A PROBE EGT MOONEY 660110 000 ALTERNATE ALCOR 86255 DT104A TRAY LIGHT 28VDC ALCOR 41338 DT105A TRAY LIGHT 14V ALCOR 41337 DV101A INDICATOR FUEL FLOW MOONEY 880034 501 as INDICATOR FUEL FLOW OPT MOONEY 880034 503 INDICATOR FUEL FLOW OPT MOONEY 880034 505 DV101B INDICATOR F F GALS SHADIN 912021 a INDICATOR F F LBS OPT SHADIN 912023 INDICATOR F F GALS OPT SHADIN 912041 1 INDICATOR F F LBS OPT SHADIN 912043 1 INDICATOR F F LITERS OPT SHADIN 912047 1 INDICATOR F F GALS OPT SHADIN 912081 2 DV102A TRANSDUCER FUEL FLOW MOONEY 880030 501 OPTIONAL MOONEY 880030 503 DV102B TRANSDUCER F F SHADIN 680501B EG101A ACTUATOR LDG GR MOONEY 880037 507 ALT MOONEY 560254 503 EG102A ACTUATOR LDG GR MOONEY 880037 501 ALT MOONEY 560254 501 EG103A ACTUATOR LDG GR MOONEY 560254 505 EG104A SWITCH LDG GR A S SAFETY MOONEY 880013 507 SWITCH ELT PANEL ARTEX 110 416 ELT102A TRANSMITTER ELT ARTEX 453 0150 F1 FUSE 1 AMP LITTEL 818001 F2 FUSE 5 AMP 3AG SLO BLO LITTEL 313005 F3 FUSE 10 AMP SLO BLO LITTEL 313010 F4 FUSE 5 AMP McGRAW EDISON FM01 5A FH1 HOLDER FUSE LITTEL 155020 LITTEL 222 155120 FH2 HOLDER FUSE McGRAW EDISON FHN42W SWITCHCRAFT C 11 SWITCHCRAFT S 1028 WASHER SWITCHCRAFT S 1029 FON2 PHONE
85. 702000 3 MOONEY 880017 501 29 34 P S STROBE R WG MOONEY 880028 505 ALT GABLE P S R WG MOONEY 880017 503 ALT FLASHTUBE R WG WHELEN 429 31 STROBE LITE R WG SDI 702000 2 34 FLASHTUBE MOONEY 880019 501 29 MOONEY 880021 502 34 STROBE LT R WG MOONEY 880038 502 30 P S TAIL STROBE MOONEY 880038 501 29 34 P S TAIL STROBE MOONEY 880028 507 30 CABLE TAIL STROBE MOONEY 880017 505 ALT GABLE TAIL LITE MOONEY 880017 507 29 STROBE TAIL MOONEY 880020 501 29 34 STROBE TAIL MOONEY 880041 501 30 PLUG TAIL STROBE AMP 206708 1 30 RECPT TAIL STROBE P S AMP 1 480305 0 PINS 3 EA AMP 61118 1 OR 60629 1 AUX PWR RECEPTACLE AN2552 3A RELAY AUX PWR C H 6041H105A RELAY C H 6041H105A DIODE AUX PWR RELAY SARKES TARZIAN 10H3P DIODE 1N2483 C B COM 1 MERIDEN AHWA 11 C B COM 1 KLIXON 7277 2 11 NAV 1 MERIDEN AHWA 11 C B NAV 1 KLIXON 7277 2 11 C B COM 2 MERIDEN AHWA 11 C B COM 2 KLIXON 7277 2 11 C B NAV 2 MERIDEN AHWA 11 C B NAV 2 KLIXON 7277 2 11 C B XPN1A MERIDEN AHWA ti KLIXON 7277 2 11 C B AUD 1 MERIDEN AHWA 11 C B AUD KLIXON 7277 2 11 ADF 1 MERIDEN AHWA 11 C B ADF KLIXON 7277 2 11 C B DME 1 MERIDEN AHWA 11 DME KLIXON 7277 2 11 SPEAKER MSO1A MOONEY 810195 SPEAKER ARA 6707001 JAGK MIC 1 SWITCHCRAFT C 128 WASHERS SWITCHCRAFT S 102B S 1029 JACK MIC 2 SWITCHCRAFT C 128 WASHERS SWITCHCRAFT S 102B S 1029 MIC KEY PILOTS C H SA25SAT12 3 CAP C H SWS3AA2 FACE NUT C H 15
86. 81 TURBINES MOONEY AIRCRAFT CORPORATION M20J SERVICE AND MAINTENANCE MANUAL CURRENTLY NOT BEING USED 12 98 81 TURBINES 1 SERVICE AND MAINTENANCE MANUAL M20J MOONEY AIRCRAFT CORPORATION INTENTIONALLY LEFT BLANK 81 TURBINES 12 98 2 MOONEY AIRCRAFT CORPORATION M20J SERVICE AND MAINTENANCE MANUAL CHAPTER 91 ELECTRICAL WIRING DIAGRAMS SERVICE AND MAINTENANCE MANUAL M20J MOONEY AIRCRAFT CORPORATION CHAPTER 91 ELECTRICAL WIRING DIAGRAMS LIST OF EFFECTIVE PAGES CHAPTER SECTION SUBJECT oso os 2 2 PAGE DATE 91 EFFECTIVITY 1 12 98 91 CONTENTS 2 12 98 91 00 00 3 12 98 91 00 02 4 12 98 91 00 02 5 12 98 91 00 03 6 12 98 91 20 00 i 12 98 BIO 2 mou wie 91 20 01 12 98 91 20 02 2 2 2 85tu60 12 98 91 2003 2 6176 5 1298 91 2 4 hus 1298 91 2005 so so 2 sv 12 98 91 20 06 4 Otho 1298 01 9000 o a om oo oe AE we 1208 12 98 91 EFFECTIVITY Page 1 AIRCRAFT CORPORATION M20J SERVICE AND MAINTENANCE MANUAL CHAPTER 91 ELECTRICAL WIRING DIAGRAMS TABLE OF CONTENTS CHAPTER SECTION SUBJECT SUBJECT PAGE 91 00 00 General 3 91 00 01 Electrical
87. 98 33 EFFECTIVITY 1 2BLANK SERVICE AND MAINTENANCE MANUAL M20J MOONEY AIRCRAFT CORPORATION CHAPTER 33 LIGHTS TABLE OF CONTENTS GHAPTER SECTION SUBJECT SUBJECT PAGE 33 00 00 General Description and Operation 5 33 20 00 Interior Lights Maintenance Practices 5 33 21 00 Cabin Lights Overhead Lights 5 33 21 01 Light Bulb Replacement 5 33 21 02 Cabin Light Switch Replacement 2225 6 33 22 00 Instrument Flight Panel Glareshield pol 7 33 22 01 Light Bulb Replacement 7 33 23 00 Gear Down Indicator Light Floorboard 8 33 23 01 Light Bulb Replacement i 8 33 40 00 Exterior Lights Maintenance Practices 8 33 40 01 Trouble shooting Exterior Lights 8 33 41 00 High Intensity Strobe Lights Maintenance 8 33 41 01 Power Supply Unit Removal or Replacement 9 33 41 02 Power Supply Unit Installation ew 33 41 03 Strobe Light Replacement 9 33 42 00 Navigation Position Lights 11 33 42 01 TEM Position Light Replacement Service 11 33 43 00 Landing Taxi Lights 24 1354 thru 24 TBA 11 33 43 01 Landing Taxi Light Adjustment Procedures 11 12 98 33 CONTENTS 3 4BLANK MOONEY AIRCRAFT CORPORATION 33 00 00 GENERAL DESCRIPTION AND OPERATION High intensity strobe 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
88. AMP RECPT TAIL LIGHT RT WING AMP PINS AMP PLUG TAIL NAV LIGHT AMP SOCKETS AMP TAIL NAV LIGHT AMP PINS AMP C B PANEL LIGHTS KLIXON GLARESHIELD LIGHTS KLIXON LAMP COMPASS LIGHT GE 12 98 TILC64 1S WH FN 10 20 OHM 1930 1818 1930 1818 1930 1818 1930 1818 1930 1818 1930 1818 930023 235 4559 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 930023 201 800051 501 34 0228030 B5 800051 501 1 480318 0 60619 1 1 480319 0 60620 1 1 480318 0 60819 1 1 480319 1 60620 1 7277 2 5 7277 2 5 AVIATION RED 327 or 327 91 20 02 45 SERVICE AND MAINTENANCE MANUAL M20J MOONEY AIRCRAFT CORPORATION 28 VOLT ELECTRICAL EQUIPMENT CHART CODE DESCRIPTION VENDOR PART NO NOTES JK 4 RECPT COMPASS LT DEANS DEA90020MALE JKL 10 PLUG COMPASS LIGHT DEANS DEA90020FEMALE JKL LIGHTS GLARESHIELD 14 EACH GE 327 JK LP107A LIGHT HOLDER TRIM FLAP DIALIGHT 270 1930 0171 702 327 LAMP ALT GE 385 JK LP108A LIGHT COWL FLAP DIALIGHT 270 1930 0171 702 LAMP GE 327 JK LP109A LIGHT OXYGEN SLOAN 8558 0 U JK LP109B LIGHT OXYGEN SLOAN 8558 0 U LAMP GE 327 JK LP110A LIGHT CLUSTER GE 327 JK LP111A LIGHT CLUSTER GE 327 JK LP112A LIGHT CLUSTER GE 327 JK LP113A L
89. AMP 60619 1 JK CB105A RECEPTACLE 2 PIN AMP 1 480319 0 PIN AMP 60620 1 JK COWL FLAP KLIXON 7277 2 5 JK CC102A SWITCH COWL FLAP MICRO 12TW1 1 JK 10 ACTUATOR COWL FLAP MOONEY 880050 501 JK CC103B ACTUATOR COWL FLAY MOONEY 880050 505 JK GCI04A SWITCH OPEN LIMIT MICRO 1SE1 T ACTUATOR MICRO JE 5 JK CC105A SWITCH CLOSED LIMIT MICRO 1SE1 T ACTUATOR MICRO JES JK CC106A PLUG 9 PIN AMP 206708 1 CLAMP AMP 206966 1 JK CC107A RECEPTACLE 9 PIN AMP 206705 2 CLAMP AMP 206966 1 JK CC108A 5 GE V47ZA05 JK C B FLAP ACTUATOR KLIXON 7277 2 5 JK CF103A SWITCH UP LIMIT MICRO V3 1 ACTUATOR MICRO JV 5 JK CF104A SWITCH DOWN LIMIT MICRO V3 1 ACTUATOR MICRO JV 5 JK CFIQ5A FLAP MOONEY 750105 501 JK CF108A SWITCH FLAP CUTLER HAMMER 8906K3149 JK STAND BY VACUUM MOONEY 930023 233 JK CVi02A CURRENT MONITOR STD BY VAC MOONEY 800221 505 JK CV103A PLUG 9 PIN AMP 206708 1 CLAMP AMP 206966 1 CV104A PLUG 2 PIN AMP 1 480318 0 SOCKET AMP 60619 1 JK 105 RECEPTACLE 2 PIN AMP 1 480319 0 PIN AMP 60620 1 JK 106 PUMP VACUUM AEROSAFE 820904 2 JK SHUNT LOAD EMPRO gt MLA 70A 100MV JK DAi102A FUSEHOLDER McGRAW EDISON FHN42W JK DA103A FUSEHOLDER McGRAW EDISON JK DB101A C B TURN COORDINATOR KLIXON 7277 2 2 JK D
90. AN MS STANDARD BOLTS NUTS TORQUE TABLES TORQUE VALUES Units are Inch pounds TENSION type AN BOLTS AN BOLTS AN 365 AN 310 AN 364 AN320 NUTS NUTS SHEAR type TENSION type NAS BOLTS AN 365 AN310 NUTS SHEAR type NAS BOLTS AN 364 AN320 NUTS FINE THREAD SERIES 8 36 12 15 7 9 10 32 20 25 12 15 25 30 15 20 1 4 28 50 70 30 40 80 100 50 60 5 16 24 100 140 60 85 120 145 70 90 3 8 24 160 190 95 110 200 250 120 150 716 20 450 500 270 300 520 630 300 400 1 2 20 480 690 290 410 770 950 450 550 9 16 18 800 1000 480 600 1100 1300 650 800 5 8 18 1100 1300 600 780 1250 1550 750 950 3 4 16 718 14 1 14 1 1 8 12 2300 2500 2500 3000 3700 5500 5000 7000 1300 1500 1500 1800 2200 3300 8000 4200 2650 3200 3550 4350 4500 5500 6000 7300 1600 1900 2100 2600 2700 3300 3600 4400 1114 12 9000 11000 5400 6600 11000 13000 COARSE THREAD SERIES 12 15 7 8 20 25 40 50 80 90 160 185 95 100 235 255 140 155 400 480 240 290 500 700 300 420 00 900 420 540 1150 1600 700 950 2200 3000 1300 1800 6600 8000 Figure 5 2 Reference Federal Aviation Agency Advisory Circular No 43 13 1 current rev Recommended Torque Values for Nut Boit combination 1 Be sure nut and or bolt threads are clean and dry unless Mfg states otherwise 2 eu W down near contact with washer or bearing surface and check friction drag torque required to turn nut 3 Add friction drag torque to t
91. B Procedures B Install 3 16 dia rig pins at 1 Jackshaft C Figure 27 1 2 Belicrank E Figure 27 1 Hy Beilcranks 9 Figure 27 2 Both L H and C Adjust control tubes F Figure 27 2 L H and R H to position ailerons 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 bellcranks and jackshaft E Remove rig pins F Adjust aileron stops Reference Figure 27 2 per paragraph 27 10 00 3 G Tolerances are specified in paragraph 27 10 00 3 F i NOTE Refer to SECTION 27 60 00 for Aileron Rudder Interconnect System Rigging Procedures 27 00 00 5 MOONEY AIRCRAFT CORPORATION M20J SERVICE AND MAINTENANCE MANUAL amp ELEVATOR CONTROL WHEEL RIGGING FIGURE 27 1 27 20 00 RUDDER AND STEERING SYSTEM 1 Rudder The rudder attaches to the aft vertical fin spar at four hinge points Push pull tubes and belleranks link the rudder to the rudder pedals 2 Rudder Removal and installation A Detach rudder tube from rudder horn B Remove attaching hardware at rudder hinges C Remove rudder by pulling it straight aft D Install rudder in reverse sequence of removal Recheck attaching bolts for security and safety 3 Rudder Rigging and Adjustment A Raise aircraft nose A propeller yoke jack may be used B Set stabilizer trim control in neutral posi
92. B amp D 0221 128 JK LP126A PLUG 20 PIN MOONEY 930022 501 JK LP127A RECEPTACLE 20 PIN MOONEY 930021 502 JK LP130A RHEOSTAT MAP LIGHT 500 OHM NEWARK 09F981 KNOB NEWARK 57F2368 JK LP133A MAP LIGHT 500 OHM NEWARK O9F981 NEWARK 57F2368 JK LP134A MAP LIGHT SLOAN 8558 0 U 6 JK LP134A LAMP 28V GE 827 LAMP 14V GE 330 12 98 91 20 03 SERVICE AND MAINTENANCE MANUAL M20J MOONEY AIRCRAFT CORPORATION 28 VOLT ELECTRICAL EQUIPMENT CHART PART NO NOTES CODE JK LP135A JK LP136A JK LP137A JK LR101A JK LR102A JK LR103A JK LF104A JK LR105A JK LR106A JK LR107A JK LR108A JK LR109A JK LR110A JK LR111A JK LS101A JK LS102A JK LS103A JK LS104A JK LS105A JK LS106A JK LS107A JK LS108A JK LS109A JK LS110A JK LS111A JK LS112A JK LS113A JK LS114A JK LS115A JK LS116A 91 20 03 DESCRIPTION VENDOR MAP LIGHT SLOAN LAMP 28V GE LAMP 14V GE POST LIGHT WHELEN LAMP 28V GE POST LIGHT WHELEN LAMP 14V GE C B RECOGNITION LIGHTS MOONEY LIGHT RECOGNITION LW MOONEY PLUG 2 PIN AMP DALE 2 PIN AMP PIN AMP PLUG 2 PIN AMP LIGHT RECOGNITION RW MOONEY PLUG 2 PIN AMP DALE RECEPTACLE 2 P
93. COWL FLAP SWITCH COWL FLAP SWITCH COWL FLAP M20J SWITCH COWL FLAP ACTUATOR FLAP INDICATOR TRIM FLAP INDICATOR FLAP SWITCH FLAP CLAMP 3 14 16 28 PIN CLAMP 3 PIN CLAMP 3 PIN ALT CLAMP 4 B PIN CLAMP 5 PIN CLAMP 6 PIN VENDOR MAGNACRAFT MOONEY MOONEY MOONEY MOONEY MOONEY MOONEY MOONEY MOONEY MOONEY MOONEY MOONEY MOONEY MOONEY MOONEY MOONEY MOONEY MOONEY MOONEY MALLORY MICRO SW ALCO SW MATRIX SCIENCE MOONEY MOONEY MOONEY MOONEY MICRO SWITCH MOONEY MOONEY MOONEY MOONEY C H AMP AMP AMP CLAMP 9 PIN LT CONTROL BOX AMP CLAMP 9 PIN CLAMP 9 PIN LOCK RETAINER LOCK RETAINER ALT CLAMP 9 PIN RETAINER CLAMP 15 PIN LOCK RETAINER CLAMP 17 PIN LOCK RETAINER AMP 12 98 PART NO 70 303 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 CGS302V 050R2C 15PA90 8W 22 M83723 60 122RC 640317 503 880050 505 880242 505 880052 517 12TW1 10 880052 117 750105 501 800242 501 800242 505 8906K3149 206070 1 M85049 41 4A MS3057 4A MS3057 4B 206062 1 MS3057 6A B MS3057 16A B 206966 1 P O 126 222 DE 24657 DE 51224 1 D110278 DE 19977 5 DE51224 1 DA51210 i DA51220 1 DB51212 DB51221 1 MOONEY AIRCRAFT CORPORATION NOTES MOONEY AIRCRAFT CORP
94. Check all connections for tightness 3 Reverse the starter removal reinstallation 4 Recheck torque security and safetying 5 Install cowling 80 00 05 STARTER BRUSHES The starter brushes should slide freely in the holder and make full contact on 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 a straight line opposite the force exerted by the spring Read the tension just as the spring leaves the brush 80 10 00 CRANKING 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 should be corrected before the engine is started again procedure for CAUTION Do not operate starter in excess of 30 seconds without allowing cooling time before re engaging 80 00 00 3 SERVICE AND MAINTENANCE MANUAL M20J MOONEY AIRCRAFT CORPORATION BLANK 80 10 00 MOONEY AIRCRAFT CORPORATION M20J SERVICE AND MAINTENANCE MANUAL CHAPTER
95. Check continuity through switch replace if necessary Disconnect synch wires to identify faulty power supply Replace bulb Replace Check for good bonding between fixture and structure Tighten mounting screws Check all connections in circuit Replace fixture LANDING TAXI LIGHTS NAVIGATION LIGHTS AND TAILLIGHT Lamp fails to light Lamp bumed out Loose connection or defective wire Circuit breaker switch defective Circuit breaker switch tripped Check for short circuit Reset circuit breaker Replace lamp Tighten connections and check wire circuit continuity Replace or repair wire if necessary Check continuity through switch Replace if necessary SSS sss ot GE OED EEE os oe EG GE KEKE sees s s 33 41 00 HIGH INTENSITY STROBE LIGHTS MAINTENANCE The strobe light power supply requires a 14 VDC 24 0001 thru 24 2999 28 VDC 24 3000 thru 24 TBA input across the red and black wires Red is positive and 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 potted assembly and cannot be repaired 33 23 00 8 1 35 The power supplies may be synchronized by connecting each yellow wire together between all power supplies Hoskins only 12 98 MOONEY AIRCRAFT CORPORATION TROUBL
96. DL108A DM101A DM102A DM103A DM104A 91 20 06 DESCRIPTION MODULE INSTRUMENT MODULE INSTRUMENT MODULE INSTRUMENT 1 MODULE INSTRUMENT 2 MODULE INSTRUMENT MODULE INSTRUMENT MODULE INSTRUMENT 1 MODULE INSTRUMENT 2 MODULE INSTRUMENT CLUSTER D A CLUSTER D A CLUSTER DIGITAL CLUSTER DIGITAL CLUSTER D A CLUSTER DIGITAL PROBE OIL TEMP PROBE OIL TEMP DIODE ALT DIODE ALT ALT BRIDGE DIODE BRIDGE DIODE XDCR OIL PRESS ALT M20J AL ALT XDCR OIL PRESS M20M XDCR FUEL PRESS ALT XDCR FUEL PRESS TACHOMETER OPTIONAL SENSOR TACH TACHOMETER OPTIONAL SENSOR TACH SLICK SENSOR TACH BENDIX SENSOR TACH BENDIX SENSOR TACH SLICK TACHOMETER TACHOMETER SENSOR TACH SLICK SENSOR TACH BENDIX HOUR METER HOUR METER HOUR METER AUT HOUR METER ALT M20J ELECTRICAL EQUIPMENT CHART VENDOR MOONEY MOONEY MOONEY MOONEY MOONEY MOONEY MOONEY MOONEY MOONEY MOONEY MOONEY MOONEY MOONEY MOONEY MOONEY MOONEY GE ECG NTE FAGOR FAGOR DRUCK KULITE PATRIOT KULITE DRUCK KULITE DRUCK KULITE PATRIOT MOONEY B amp D B amp D MOONEY B amp D B amp D B amp D B amp D B amp D MOONEY MOONEY J P J P INSTR MOONEY MOONEY HOBBS DATCON HOBBS HOBBS 12 98 MOONEY AIRCRAFT CORPORATION PART NO NOTES 880059 507 880059 511 880059 513 880059 515 880059 517 880059 519 880059 523 8800
97. 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 12 98 MOONEY AIRCRAFT CORPORATION M20J SERVICE AND MAINTENANCE MANUAL CHAPTER 25 SEATS MOONEY AIRCRAFT CORPORATION M20J SERVICE AND MAINTENANCE MANUAL CURRENTLY NOT BEING USED 12 98 25 SEATS 1 SERVICE AND MAINTENANCE MANUAL M20J MOONEY AIRCRAFT CORPORATION INTENTIONALLY LEFT BLANK 25 SEATS 12 98 2 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 EFFECTIVE PAGES CHAPTER SECTION SUBJECT 2 PAGE DATE 27 Effectivity 12BLANK 1298 27 Content ABLAK 12 98 27 00 00 oe ME Ghost X A SEE xb x 42 98 27 20 00 e ww 12 98 21 20 00 cus CERT nr de 658 2 30 00 41 A 2 f n de e ue de ue deum ap 12 98 2 30 03 5 65 urat spe NE SANT cda 12 98 24 3120 coa AD er 2 3205 12 98 FAT va EN petu cune a is uut uk N et 588 27 50 00 uc Tou oo
98. Excessive motor brush wear Rough or scored commutator Remove and turn down commutator on arcing lathe Armature assembly not Reface commutator concentric Noisy starter Worn starter drive pinion Remove and replace starter drive Worn or broken teeth on Check teeth and replace gear if crankshaft gear damaged 24 39 05 ANNUNCIATOR TROUBLE SHOOTING 24 0001 thru 24 3153 The following is a brief failure cause analysis which pertains to the annunciator IAI P N 50000061 on the 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 lamp will not light during TEST but will light with the gear down CR1 Assy A2 open 2 The gear down lamp will not light during TEST or with the landing gear down Filament of DSI Assy A2 open 3 The gear down lamp is dim when the position lights are off CR24 Assy A1 open 4 The gear unsafe lamp will not light during TEST but does light when the gear is in transit Assy 2 open 5 The gear unsafe lamp will light during TEST but not when gear is in transit CR2 Assy A2 open 6 The gear unsafe lamp will not light during TEST or when the gear is in transit Filament of DS2 Assy A2 open CR2 Assy A2 and CR3 Assy A2 open 7 The left low fuel lamp will not light dung TEST or in a left OM fuel situation Filament of DS3 Assy A2 open Q2 Assy A1 de
99. FAR 43 M20J 12 98 SERVICE AND MAINTENANCE MANUAL CAUTION Refer to Textron Lycoming maintenance publications for engine inspection procedures after a propeller strike Current issue of AC 43 13 60 00 00 MOONEY AIRCRAFT CORPORATION M20J SERVICE AND MAINTENANCE MANUAL CHAPTER 61 PROPELLERS SERVICE AND MAINTENANCE MANUAL M20J CHAPTER SECTION SUBJECT 61 Effectivity 61 00 00 61 00 20 61 20 90 61 20 90 61 40 00 61 40 00 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 CHAPTER 61 PROPELLERS LIST OF EFFECTIVE PAGES PAGE 1 2BLANK ONDOA TABLE OF CONTENTS SUBJECT General KNR Sul SR P s Spinner Dome and Propeller Removal Propeller Installation Propeller Assembly Minor Propeller Blade Repair Propeiler Controlling TEE Propeller Governor Installation Propeller Governor Rigging Propeller Governor Adjustment Propeller Governor Troubleshooting Propeller Balancing 12 98 DATE 12 98 12 98 12 98 12 98 12 98 12 98 12 98 DATE Q SSS MOONEY AIRCRAFT CORPORATION 61 EFFICONTENTS 1 2BLANK MOONEY AIRCRAFT CORPORATION 61 00 00 GENERAL The propeller is a constant speed type which operates by oil pressure opposing natural centrifugal twisting moment of rotating blades and force of a spring in McCauley propeller
100. FUEL PUMP AMP 206153 1 CLAMP AMP 206062 1 12 98 91 20 02 SERVIGE AND MAINTENANCE MANUAL 28 VOLT ELECTRIGAL EQUIPMENT CHART DESGRIPTION M20J VENDOR MOONEY AIRGRAFT CORPORATION PART NO NOTES gt s s gt a s ne fn om mem me ar EE EE EE EE EE EE gt O nd ond x s s CODE NF105A K NF106A K NF107A K NF108A K NF109A K L 150 L NFI51A L NFI52A L NF158A L 154 L NF155A L L L 158 L 159 L L NFI61A K K NP102A K NP103A L L NSI51A L JK PA101A JKL PA102A JK PA103A JK PA104A JK PA105A JK PA106A K PA107A JKL PA108A JKL PA109A JK PA110A C B HIGH BOOST FUEL PUMP FUEL C B LOW BOOST FUEL REGULATOR FUEL PUMP RECPT CLAMP PLUG CLAMP C B FUEL PUMP MAIN MOONEY WELDON MOONEY ELECTRO DELTA AMP AMP AMP AMP KLIXON C B FUEL PUMP EMERGENCY KLIXON SW FUELPUMP MAIN BOOST C H GUARD SWITCH FUEL PUMP EMER GUARD RECPT FUEL PUMP CLAMP RECPT FUEL PUMP CLAMP C B BOOST PUMP FUEL PUMP BOOST PLUG CLAMP RECPT FUEL PUMP CLAMP FUEL PUMP MAIN FUEL PUMP EMERGENCY FUSEHOLDER PRIMER FUSE 10A SLO BLO SWITCH PRIMER DIFFUSER PRIMER
101. JACK SWITCHCRAFT C 112B WASHER SWITCHCRAFT S 1028 WASHER SWITCHCRAFT S 1029 JE101A IGNITION CONTROL LASAR SLICK CD 1001 02 GABLE LASAR CH1001 XX JM101A SWITCH MAGNETO BENDIX SCINTILLA 10 357210 9 JPLACARD BENDIX SCINTILLA 10 187 468 TERMINAL LUG BENDIX SCINTILLA 10 126656 JM101B SWITCH MAG W CONN JANCO 97 2273 1 JM102A MAGNETO BENDIX SCINTILLA D 4LN2021 Ses ALT BENDIX SCINTILLA D4LN 3000 ALT LYCOMING LW 682555 11 12 98 91 20 05 85 SERVICE AND MANUAL CODE JM103A JM104A JM105A JM106A JM107A JM108A JM109A JM110A JM111A JM112A JM112A JM JM L1 L2 L3 L4 L5 L6 L7 L8 L9 L10 L11 112 LB101A LB101B LB102A LB102B LB102C LENS1 LENS2 LENSS3 LENS4 LENS5 LENS6 LG101A LG102A LH1 LH2 LH3 LH4 LH5 LH6 LH7 LH8 M20J ELECTRIGAL EQUIPMENT CHART DESGRIPTION PLUG MAGNETO MAGNETO MAGNETO LEFT MAGNETO RIGHT SWITCH IGNITION MAGNETO LH MAGNETO RH IGNITION PULSAR MAGNETO L R MAGNETO LH MAGNETO RH MAGNETO LH MAGNETO RH BULB 28V BULB 14V BULB BULB 14V BULB BULB BULB BULB BULB BULB 28V BULB BULB C B BEACON ROTATING C B BEACON ROTATING LIGHT ROTATING BEACON ADAPTER VENDOR BENDIX SCINTILLA SLICK SLICK SLICK TCM SLICK SLICK MOONEY BENDIX SLICK LASAR SLICK LASAR SLICK W O LASAR SLICK W O LASAR GE GE GE GE CHI MINI CHI MINI GE GE GE GE GE GE
102. JKL LRI03A RECOG LIGHT LT WG AMP 1 480318 0 ped SOCKETS AMP 60619 1 91 20 02 12 98 MOONEY AIRCRAFT CORPORATION CODE JKL LR104A JKL LRIO5A JKL JKL LR107A JKL LR108A JKL LR109A JKL LR110A JKL LR111A JKL LS101A JKL LS101A JKL LS102A JKL LS103A JKL LS104A JKL LS105A JKL LS106A JKL LS107A JKL LS108A JKL LS109A JKL LS110A JKL LS111A JKL LS112A JKL LS113A JKL LS114A JKL LS115A JKL LS116A JKL LS117A JKL LS118A JK LS119A JK LS120A JK LS121A JKL MA101A JKL MA102A JKL MA103A JK MA104A JKL MB101A J MB101B JK MB102A J MB102A JKL MB103A JK MB104A DESCRIPTION REGOGNITION LIGHT RT PLUG REGOG LIGHT RT SOCKETS RECPT RECOG LIGHT LEFT PINS PLUG RECOG LIGHT LEFT SOCKETS M20J VENDOR RESISTOR RECOG LIGHT LEFT DALE RECPT HECOG LIGHT RT PINS PLUG RECOG LIGHT RT SOCKETS AMP AMP AMP AMP RESISTOR RECOG LIGHT RT DALE C B STROBE LIGHTS C B STROBE LIGHTS ALT MOONEY MOONEY POWER SUPPLY STROBE LT WG WHELEN RECPT STROBE P S LT WG RECPT STROBE P S LT WG PLUG NAV STROBE LT WG LIGHT NAV STROBE LT WG AMP AMP AMP WHELEN STROBE PWR SUPPLY RT WG WHELEN RECPT STROBE PWR SUPPLY RT AMP RECPT STROBE LIGHT P S RT AMP PLUG STROBE LIGHT RT AMP NAV STROBE LIGHT RT WING WHELEN POWER SUPPLY TAIL STROBEWHELEN RECPT TAIL STROBE PWR SUPPLY AMP RECPT TAIL STROBE PWR SUPPLY AMP PLUG TAIL STROBE AM
103. LEG ASSY MAIN WHEEL CAUTION NOSF WHFF Uneven or improper torque may cause bolt or wheel failure LANDING GEAR WHEEL REMOVAL FIGURE 32 13 12 98 32 40 00 21 SERVICE AND MAINTENANCE MANUAL M20J MOONEY AIRCRAFT CORPORATION C Visually inspect linings for wear and brake disc for warpage Brake linings should be replaced when they are worn to a minimum thickness of 1 8 inch If lining replacement is necessary proceed with steps D thru O Otherwise reassemble in reverse sequence of disassembly CAUTION Brake disc should be replaced if width is 205 inch or less i D Disconnect and cap hydraulic line 4 at brake cylinder assembly Remove nuts from anchor bolts E Remove pressure plate assembly Fig 32 15 5 sliding it off the anchor bolts 6 Note the condition 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 Drill out rivets 9 attaching linings 7 to back lining plate 2 and the pressure plate 5 Remove piston assembly 10 and 1 Aut is iara 28 to use compressed air applied to the brake line fitting MAIN WHEEL ASSY 2 to remove the piston 10 from the brake cylinder G Clean parts in cleaning solvent Federal Specification PS 661 or equivalent and dry with WHEEL AS
104. M E K or equivalent cleaning solvent in the cavity 8 where new windshield will be located Wipe solvent before it dries and redistributes contaminates F SMX56 1 WINDSHIELD INSTALLATION FIGURE 56 1 55 00 00 SERVICE AND MAINTENANCE MANUAL 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 a bead of sealant along the recessed joggle 6 of the cowl deck 3 reference Figure 56 1 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 wipe the excess sealant off with damp clean cloth Prior to riveting the aluminum retainer 1 into position coat retainer with a uniform thickness of either sealant A positive bond will be made as the retainer is riveted into place Use CR3212 5 2 cherry rivets to reattach pie reramor 1 to cowl deck 3 reference Figure After the sealant cures the excess may be removed with a sharp razor knife 2 Check for water leaks 3 Repaint retainer and rivets to match aircraft 56 22 00 CABIN WINDOWS 56 22 01 CABIN WINDOWS REMOVAL 1 Remove interior trim from the window 1 to be replaced Remove the retainers 2 or clips 3 which
105. N 9 ALT ELEC GYRO 1394T100 3Z 14 DG102A INSTUMENT MODULE MOONEY 880059 51 1 14 DM101A HOUR METER HOBBS 15006 HOUR METER ALT DATCON INSTR CO 80 70 14 DP102A HEATED AERO INSTR PH502 12 PITOT HEATED ALT AN5B12 14 DT105A INDICATOR EGT MOONEY 660109 003 tiene WIRE LEAD ALCOR 01 005 78 14 EG105A C B ACTUATOR GEAR KLIXON 7277 2 15 14 EG110A RELAY GEAR UP CUTLER HAMMER 6041 105 14 EG112A RELAY GEAR DOWN CUTLER HAMMER 6041 105 14 EG114A GEAR MOONEY 560254 501 ACTUATOR GEAR ALT MOONEY 880037 501 14 JM102A MAGNETO BENDIX SCINTILLA D 4LN2021 14 LB102A BEACON ROTATING WHELEN WRML 12 ADAPTER WHELEN WRM 65 14 LC103A RESISTOR DIMMING 5 OHM 10W DALE RH 10 5 OHM 14 LC104A LAMP HOLDER HH SMITH 1930 SET LAMP GE 1816 14 LC105A LAMP HOLDER HH SMITH 1930 LAMP GE 1816 14 LC106A LAMP HOLDER HH SMITH 1930 MES LAMP GE 1816 14 LC107A LAMP HOLDER HH SMITH 1930 M LAMP GE 1816 14 LC109A RESISTOR DIMMING 5 OHM 10W DALE RH 10 5 OHM 14 LC110A LAMP HOLDER HH SMITH 1930 SE LAMP GE 1816 14 LC111A LAMP HOLDER HH SMITH 1930 LAMP GE 1816 14 LC112A LAMP HOLDER HH SMITH 1930 LAMP GE 1816 14 LC113A LAMP HOLDER HH SMITH 1930 1816 14 LL101A C B LANDING LIGHT MOONEY 930023 215 14 LL102A LANDING LIGHT GE 4522 14 LN102A LIGHT ASSY NAV TAIL LT WING MOONEY 800051 505 BULB WHELEN 34 021 2030 85 14 LN103A LIGHT ASS
106. PIN REGEPTAGLE 2 PIN RECEPTACLE 3 PIN 3 PIN RECEPTACLE 3 PIN RECEPTACLE 3 PIN RECEPTACLE 4 PIN RECEPTACLE 4 PIN RECEPTACLE 4 PIN RECEPTACLE 4 PIN RECEPTACLE 5 PIN RECEPTACLE 6 PIN RECEPTACLE 8 PIN RECEPTACLE 9 PIN RECEPTACLE 9 PIN RECEPTACLE 9 PIN REGEPTAGLE 9 PIN RECEPTACLE 12 PIN RECEPTACLE 14 PIN M20J VENDOR AMP AMP MOLEX AMP MOONEY MOONEY AMP AMP MOONEY POSITRONICS POSITRONICS AMP MOONEY AMP MOONEY MOONEY AMP MOONEY POSITRONICS KLIXON KLIXON PRESTOLITE LYCOMING TCM TCM B amp C KING GLOBE AMP AMP DEAN MOLEX AMP AMP AMP AMP AMP ARRAY DEUTSCH MATRIX SCIENCE AMP AMP AMP AMP MOLEX MOONEY 12 98 MOONEY AIRGRAFT CORPORATION PART NO NOTES 206708 1 126 222 DE9S 03 06 2092 206485 1 930021 1 930021 513 206043 3 DA15S 206037 1 DBM17W2S 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 DC375 930021 511 GMCT104FOTHO00 7277 2 10 7277 2 5 MHB4016 LW 15572 646275 637847 BSC206 149 071 4037 01 19A2790 1 480351 0 1 480319 0 7022 4 MS3100 24 9P 03 06 2023 1 480305 0 206036 2 206207 1 MS3100 28 65 206153 1 M3100 32 17P 1 480426 0 PWO1F8 04P BVDOAEO205PN 53100 28 22 205841 2 206705 2 206705 1 DE9P 205486 1 03 06 2122 930021 2 MOONEY AIRCRAFT CORPORATION CODE RC14B RC14C
107. RC16A RC16B RC20A RC20B RC26A RC28A RC32A RC34A RC34B RC37A RC104A RC170A RL101A RL102A HL103A RL104A HL105A RL106A RL107A HL108A RL109A RL110A RS101A RS102A RS103A RS104A RS105A RS106A RS107A RS115A RS116A SA101A M20J ELECTRICAL EQUIPMENT CHART DESCRIPTION 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 ALT RECEPTACLE 37 PIN RECEPTACLE 104 PIN RECEPTACLE 170 PIN SOCKETS 22GA SOCKETS 20 18 GA SOCKETS 20 14GA RELAY 28V 200A ALT ALT OBSOLETE RELAY 14V 200A RELAY RELAY RELAY 28V 50A BRACKET 2 REQ D ALT RELAY 28V 100A RELAY 14V 200A RELAY RELAY RELAY SOCKET TERMINAL RESISTOR 20 OHMHOW RESISTOR 5 OHMAOW HESISTOR 500 OHM RESISTOR 100 OHM RESISTOR 7 5 OHM HESISTOR 1K OHM 2W RESISTOR 5K OHM RESISTOR RESISTOR ALTERNATOR STAND BY VENDOR AMP POSITRONIC AMP AMP AMP MOONEY POSITRONICS MOONEY AMP MATRIX SCIENCE MOONEY AMP POSITRONIG AMP POSITRONICS HYPERTRONICS HYPERTRONICS HYPERTRONICS HYPERTRONICS KISSLING KISSLING C H C H KISSLING KISSLING KISSLING MOONEY C H C H C H MAGNAGRAFT KISSLING P amp B P amp B P amp B DALE DALE MOONEY NEWARK DALE ALLEN BRADLEY SPECTROL OHMITE OHMITE B amp C HOUSING PLA
108. RC27A RECPT TRIM POS IND AMP 206153 1 CLAMP AMP 206062 1 21 RECFT PILOT S TRIM AMP 206153 1 CLAMP AMP 206062 1 21 RC29A RECPT TAIL AMP 206153 1 CLAMP AMP 206062 1 21 RC29B RECPT TAIL AMP 206705 2 CLAMP AMP 206966 1 21 RC30A RECPT RADIOS C B PNL AMP 206036 3 CLAMP AMP 206070 1 21 RC30B RECPT C B PNL AMP 206705 2 GLAMP AMP 206966 1 91 20 01 12 98 28 MOONEY AIRCRAFT CORPORATION CODE 21 21 21 21 21 21 21 21 21 21 21 21 21 21 21 Hu 21 21 RC30G RC31A RC32A RC33A RC34B RC34B RC35A RC35B RC35C 5 RC37A RC38A RC39A RC40A RC41A RC42A RC43A RC43C RC44A RC45A RC46A RC47A RC48A RC49A RC50A RC51A M20J 14 VOLT ELECTRICAL EQUIPMENT CHART DESCRIPTION VENDOR RECPT C B PNL OPT AMP CLAMP AMP RECPT RADIO PKG CABLE AMP CLAMP AMP RECPT TRANSISTORS CONSOLE AMP CLAMP AMP RECPT PWR FLT 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 CLAMP AMP RECPT GEAR CONTROL 2 CLAMP AMP REGPT VAC WARN AMP CLAMP AMP RECPT ELT SW AMP CLAMP AMP RECPT O H LIGHT AFT AMP CLAMP AMP HECPT 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
109. RECIPROCATING GENERAL ENGINE FUEL SYSTEM GENERAL DISTRIBUTION CONTROLLING INDICATING IGNITION GENERAL POWER CONTROL EMERGENCY SHUTDOWN ENGINE CONTROLS GENERAL POWER CONTROL EMERGENCY SHUTDOWN ENGINE INDICATING GENERAL POWER TEMPERATURE INTRODUCTION Page 7 SERVICE AND MAINTENANCE MANUAL SYSTEM SUB SYSTEM CHAPTER SECTION 78 00 10 30 40 79 00 10 20 30 80 00 10 81 CURRENTLY NOT USED 10 20 81 00 20 30 CURRENTLY NOT USED INTRODUCTION Page 8 M20J 12 98 MOONEY AIRCRAFT CORPORATION TITLE EXHAUST GENERAL INSTALLATION EXHAUST SYSTEM REPLACEMENT COMPONENTS OIL GENERAL STORAGE DISTRIBUTION INDICATING STARTING GENERAL CRANKING TURBINES GENERAL POWER RECOVERY TURBOCHARGER SCHEMATICS GENERAL ELECTRICAL SYSTEM HARDWARE CHARTS SCHEMATICS SPECIAL EQUIPMENT MOONEY AIRCRAFT CORPORATION M20J SERVICE AND MAINTENANCE MANUAL CHAPTER 5 TIME LIMITS MAINTENANCE CHECKS SERVICE AND MAINTENANCE MANUAL M20J CHAPTER 5 TIME LIMITS MAINTENANCE CHECKS LIST OF EFFECTIVE PAGES CHAPTER SECTION SUBJECT PAGE 5 Effectivity TA BLANK 5 Contents S9 4BLANMK 5 00 00 5 S10 01 uou 25 Q oe ocv 6 5 20 00 7 520 01 5 OK oou GE 52001 9 52001 10 520 02 1i
110. RH engine exhaust flange studs B Place either LH or RH header pipes into position on engine cylinder s exhaust flanges Be careful during this procedure to ensure that exhaust gaskets remain in proper position on each cylinder exhaust flange NOTE Attach new headers with existing exhaust flange stud nuts If nuts have been damaged replace them with new nuts Leave exhaust flange stud nuts loose so header pipes are movable G Lubricate outside of inner and inside of outer slip joints on headers and inside of muffler pipe flanges with Hi temp anti seize compound C5 A Fel Pro or equivalent D Have someone assist with the placement of the muffler assembly into the already installed headers E Assemble muffler assembly into the 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 position 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 left to right with moderate push pull force This insures that 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 a
111. Replace with 940020 501 Cutler Hammer solenoid P N 6041H53 Alternate Turn Coordinators Talley Corp w out lights 1394T 100 72 United Instr w out lights 9100 Gode No 6 Alternate Turn amp Bank Talley Corp w out lights 1234T100 7TZ Talley Corp w out lights 1234T100 3TZ Alternate 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 36 37 38 39 40 41 91 20 01 34 14 VOLT ELECTRICAL EQUIPMENT CHART NOTES con t Aiternate Landing Gear Mooney 880037 501 Use buss bar 913127 029 023 or 013 as required by installation of optional equipment Effective 25 0821 amp ON All are 930023 2xx C B s Effective 24 1464 amp ON also Effective 25 0001 thru 25 0788 or 24 0024 thru 24 1037 Effective 25 0789 amp ON or 24 1426 amp ON S LESE thru 24 0023 24 0024 thru 24 1037 use 21 LS02B 21 LS03B 21 LS04B amp Effective 25 0447 thru 25 0780 or 24 1038 thru 24 1425 Standard on 24 1211 amp ON Effective 25 0613 thru 25 0780 Altemate Turn Coordinator w lights United Instr 9112 Code No 9 Astronautics 303990 113MSC Talley 1394T100 3Z Use 1 ea MS35334 21 or MS2898 Alan Bradley internal tooth lockwasher with each light if not supplied by Sloan Alternate Clock lighted
112. S 1029 SA1RV20 SA1RV20 930023 223 3E1899 1 800221 505 206708 1 206966 1 40521 930023 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 155020 155120 313010 TIGK6B IF WH A 633862 2 1N2483 1N5060 3720 GE 41 3 S34 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 TT AT si C Eagle m adero rue Ae et MOONEY AIRCRAFT CORPORATION M20J SERVICE AND MAINTENANCE MANUAL 28 VOLT ELECTRICAL EQUIPMENT CHART CODE DESCRIPTION VENDOR PART NO NOTES K PA107A ALTERNATOR STD TCM 649280 AL TCM 649172 GEAR ASSY TCM 649123 JK PA108A FILTER MOONEY 880014 501 JK PA109A CAPACITOR MALLORY CGS302U 050R2C ALT MALLORY CGS292U 050R3C K PA110A ETA 41 3 S34 LN2 041800 K PAITIA KLIXON 7277 2 5 K PA112A VOLTAGE REGULATOR DUAL ELECTRODELTA VR 802 10 ALT DUAL AM PROD PREC FLT DGR 2 10 K 112 REGULATOR DUAL ALTERNATOR MOONEY 800270 503 10 K PA113A RECEPTACLE 9 PIN AMP 206708 1 CLAMP AMP 206966 1 K PA114A PLUG 9 PIN AMP 206705 2 CLAMP AMP 206966 1 115 ALTERNATOR OPT TCM 649280 ALT TCM 649172 GEAR ASSY TCM 649123 K PA116A FILTER MOONEY 880014 501 K PA117A CAPACITOR MALLORY CGS302U 050R2C ALT MALLORY CGS292U 050R3C JK PA118A SENSOR CURRENT MICRO CSLA1GE
113. System Notes 3 91 00 02 Writing Identification System Sow Yw 24 91 00 03 Abbreviations Equipment List 6 91 20 00 Electrical System Hardware Charts 7 91 20 04 240001 THRU24 1685 141 9 91 20 02 243000THRU24 3453 28V 35 91 20 03 24 3154 THRU 24 3200 24 3202 THRU 24 3217 WEE ME VG 28V 61 91 20 04 24 1686 14 THRU 24 2999 14 14V ATS 77 91 20 05 4 2 2 24 3201 24 3218 THRU 24 3410 28V 81 91 20 06 2 243411 THRU 24 3431 28V 95 91 30 00 Electrical System Schematics ENVELOPES 111 12 98 91 CONTENTS Page 2 SERVICE AND MAINTENANCE MANUAL M20J MOONEY AIRCRAFT CORPORATION 91 00 00 GENERAL The electrical system hardware lists and related schematics are sequenced in this section by number effectivity The chapter is divided into the following sections Electrical Systems Schematic Notes Wiring Identification System Electrical System Hardware Charts By Effectivity Electrical Schematics By Effectivity 91 00 01 ELECTRICAL SYSTEMS SCHEMATICS NOTES I All electrical wiring assemblies and installtions must be in accord with FAR 43 and AC 43 13 1 All splices must be AMP disconnect or equivalent All circuit breakers are trip free Ali ter
114. Systems RECOMMENDED OVERHAUL OR REPLACEMENT TIME LIMITS 1000 Hours On Condition Refer to Lycoming SI 1009AJ or current revision Refer to Mfg s Maintenance data O H every 4 years or Engine Ref TCM SB SB643 amp Manual X42003 current revision Engine O H or on Condition 00 Hours On Condition 500 Hours On Condition or 500 Hrs 7 years or Engine O H whichever occurs first 24 Months On Conditon On Condition 100 Hours 500 Hours or once a year On Condition 500 Hours or once a year On Condition On Condition On Condition On Condition or 500 Hours amp Engine O H TBO Inspect 500 Hours 2 years or 1 Hour tota use time 24 years or 10 000 recharge cycles 15 years or 10 000 recharge cycles On Condition Refer to Manufacturers Publications King Service Memo No 292 Applicable on S N s 24 0084 24 0378 thru 24 1178 only 5 10 01 6 SERVICE AND MAINTENANCE MANUAL NOTE Components should be inspected and serviced at regular intervals per the servicing lubrication and inspection chart at the end of this SECTION of this Manual 5 20 00 SCHEDULED MAINTENANCE CHECKS Inspection intervals Perform 25 50 or 100 hour inspections of the aircraft and engine at recommended intervals as outlined in the following paragraphs NOTE Aircraft operated in salt air environment are considered high risk for corrosion damage and should be cleaned and inspected at more frequent inte
115. Temperature CHT Max Allowable 475 F 246 C Recm d Cruise 300 to 450 F 149 to 232 C PROPELLER STANDARD OPTIONAL Propeller Mfg McCauley Hartzell Optional Type Constant Speed Constant Speed Model B2D34C214 HC C2YK 1BF 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 SERVICE AND MAINTENANCE MANUAL M20J MOONEY AIRCRAFT CORPORATION PROPELLER con t STANDARD OPTIONAL Blade 90DHB 16E F7868A 3Q Elen Angle High 33 0 5Deg 29 3 Deg to31 3 eg 30 IN 5 Pitch Angle Low 13 9 0 2Deg 14 1 1 Deg Diameter 74 0 In Max 73 In Min 73 Inches Governor McCauley C290D5 T17 McCauley High 27 5 0 2Deg Low 14 0 0 2588 High 29 5 0 5Deg after CAM S B 198 AIRFRAME WIS amp LOADINGS STANDARD METRIC OPT MISC A Approximate Empty Weight 1700 Ib 771 kg B Gross Weight 2740 Ib 2900 Ib 1315kg C Useful Load 1040 Ib 1200 Ib 474 7 544 3 kg D Wing Loading 16 4 Ib sq ft 46 59 Ib Jsq ft 76 58 kg m 81 02 Kg m E Power Loading 13 7 Ib hp 14 5 Ib HP 6 22kg HP 6 58 kg HP A Airfoil At Root B Airfoil At Tip C Mean Aerodynamic Chord Wing Sta 93 83 D CG Range E Geometric Twist DEG F Incidence Angle DEG From Sta 20 to Wing Tip G Dihedral angle DEG H Aspect Ratio I Taper Ratio CS CT A Cabin Dime
116. UP limit switch striker arm H Fig 32 5 so GEAR UP limit switch is just CLOSED and RED GEAR UNSAFE light is OFF Secure striker arm in position 26 Loosen set screw C Figure 32 8 Adjust mechanical up stop A Fig 32 8 for a clearance of 050 to 070 inches at main retraction truss B tighten set screw C 2T Reinstall assist bungee per Section 32 10 06 28 Using emergency gear extension move gear down until GREEN gear down light JUST illuminates 29 Turn Master Switch OFF 30 Place rigging tool T Fig 32 9 P N 030007 100 on retraction truss assembly G Hold tool stationary by pushing at point S toward main gear leg 12 98 M20J SERVICE AND MAINTENANCE MANUAL SA 24 0001 24 0093 DETAIL NOTE The left main gear truss will probably lock over center first Continue to slowly lower the gear 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 Reinstali the modified retraction tube and complete above overcenter 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 rigging tool T as shown in Fig 32 9 and apply an unlo
117. USED AS REQUIRED BY CIRCUIT BREAKER INSTALLATION K PB113A BUSS BAR 7 MOONEY 913127 129 JK PB114A BUSS BAR 8 MOONEY 913127 041 JK PB115A BUSS BAR 9 MOONEY 913127 043 JK PB116A SHUNT KULKA 600RJ 2 L PB150A BATTERY RIGHT GILL G 243 L PB151A RELAY BATTERY RT C H 6041H202 ALT C H 6041H202A f PB152A DIODE BATTERY RELAY RT 1N2483 ES PB153A SWITCH BATTERY LT MOONEY 880052 507 L PB154A SWITCH BATTERY RT MOONEY 880052 509 eL PB155A C B BATTERY RT ETA 41 3 S14 LN2 70A E PB155A C B BATTERY RT ALT ETA 41 3 S34 LN2 70A e PB156A BUSS BAR 1 MOONEY 913127 51 157 BUSS BAR 2 MOONEY 913127 51 PB158A BUSS BAR 3 MOONEY 913127 51 159 BUSS 4 913127 1 L PB160A BUSS BAR 5 MOONEY 913127 19 L PB161A BUSS BAR 6 MOONEY 913127 19 L PB162A BUSS BAR 7 913127 19 PB163A BUSS BAR 8 MOONEY 913127 19 L PB164A BUSS BAR 9 913127 53 L PB165A BUSS BAR 10 MOONEY 913127 53 L PB166A BUSS BAR 11 MOONEY 913127 53 SE PB167A BUSS BAR 12 MOONEY 913127 TBA L PB168A EMERGENCY CROSSOVERETA 41 3 S14 LN2 50A L PB168A C B EMERGENCY CROSSOVER ALT ETA 41 8 S34 LN2 50A COVER PLACARD MOONEY 150080 802 GUARD 800232 503 L PBi69A SHUNT AVIONICS RELAY 913127 047 L PBi70A BATTERY LEFT GILL G 243 L PBi71A LOAD LT ETA 41 3 S14 LN2 60A PBi71A LT ALT ETA 41
118. WASHER XDUCR OIL PRESS XDCR OIL PRESS PLUG XDCR OIL PRESS CLAMP M20J VENDOR 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 STEWART WARNER ROCHESTER MOONEY ROCHESTER MOONEY MOONEY 12 98 PART NO 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 640281 147 640281 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 143 362 CH 3080 37 880009 501 AN900 10 MS35769 11 3080 37 880008 501 880046 501 MS3106A10SL 3S MS3057 4A B SERVICE AND MAINTENANCE MANUAL NOTES 33 32 34 34 91 20 01 11 SERVIGE AND MANUAL 14 VOLT ELECTRICAL EQUIPMENT CHART CODE 21 DJ175A 21 DJ177A 21 DJ178A 21 DJ179A 21 DJ180A 21 DJ181A 21 DK01A 21 DKO1C D 21 DKO1D
119. WE105A DIODE 1N2483 ALT 1N5060 ALT GE 3720 GE JK WE106A DIODE 1N2483 ALT 1N5060 ALT GE 3720 GE JK WE107A RESISTOR ALLEN BRADLEY RC42GF102 1K OHM2W JK WE108A PLUG 4 PIN AMP 206060 1 CLAMP 206062 1 JK WE109A RECEPTACLE 4 PIN AMP 206153 1 CLAMP AMP 206062 1 JK WP101A MONITOR CURRENT PITOT HEAT MOONEY 800221 505 JK WP102A PLUG 9 PIN AMP 206705 2 CLAMP AMP 206966 1 JK WP108A FUSEHOLDER LITTEL 155020 ALT LITTEL 155120 FUSE LITTEL 313005 JK WS101A C B STALL WARNING KLIXON 7277 2 1 JK WS102A STALL WARN MALLORY SC628 JK WS103A RESISTOR ALLEN BRADLEY RC42GF102J1K OHM2W JK WS104A SWITCH STALL WARN SAFE FLIGHT C46001 ALT MICRO SWITCH V3 2451 D8 9 ALT MOONEY 800364 507 JK WT101A KLIXON 7277 2 2 12 98 91 20 03 SERVICE AND MAINTENANCE MANUAL M20J MOONEY AIRGRAFT CORPORATION 28 VOLT ELEGTRICAL EQUIPMENT CHART CODE DESCRIPTION VENDOR PART NO NOTES J WT102A ANNUNCIATOR MOONEY 880048 501 ALT USA MOONEY 880048 601 ALT FRANCE MOONEY 880048 603 K WTi02A ANNUNGIATOR MOONEY 880048 501 ALT LEGEND USA MOONEY 880048 605 ALT LEGEND FRANCE MOONEY 880048 607 JK PLUG 37 PIN DC 37S CLAMP RT ANGLE DC19977 3 LOCK RETAINER DC51222 1 JK WTi04A ANNUNCIATOR ATS MOONEY 880025 521 BULB CHICAGO MINATURE CM 7327 JK WV101A C B VACUUM WARN KLIXON 7277 2 2 JK WV102A SWITCH VACUUM WARN MOONEY 880012 501 J
120. Warning System Alternate Air WD Waring System Starter Power SERVICE AND MAINTENANCE MANUAL M20J MOONEY AIRCRAFT CORPORATION The Mooney Aircraft Corporation wiring electrical equipment identification system used in current production aircraft deletes ihe Model Number annotation The purpose of this is to standardize the identification of a system function component for all model of aircraft The functional groups are basically the same as earlier identification numbers These new functional groups apply to schematic drawing 800304 The new functional groups are as follows Firsttwolthree letes Circuit Function First set of numerals Wire Sequence Configuration Wire size Single letterin seres Last two numerals in series CODE COMPONENT or SYSTEM CIRCUIT FUNCTION 800304 SCHEMATIC DRAWING ACT SWITCH ACTUATOR DL ELECTRIC TACHOMETER MA AUXILIARY POWER BS RELAY BASE DM HOUR METER MB AVIONICS MASTER BUS BUSS BARS DP PITOT HEAT MC CIGAR LIGHTER G GAPACITORS DR TIT ME GLOGK CB DEFROSTER BLOWER DT FUEL FLOW MP PROPELLER DE ICE CC COWL FLAPS DG LANDING GEAR ELEC NF BOOST PUMP CL CLAMPS ELT ELT PA ALTERNATOR POWER CM CURRENT MONITOR F FUSES PB BATTERY POWER CR RUDDER TRIM FH FUSEHOLDER PL PLUGS ELECTRICAL CT STABILIZER TRIM FON PHONE PS START POWER CV STANDBY VACUUM JM IGNITION MAGNETO R RESISTORS D DIODES gt LALIGHT BULBS RB RADIO BLOWER DA AMMETER LB BEACON RC RECEPTACLES
121. aluminum on 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 aft fuselage assembly All air ducts control brackets electrical harnesses and antennas are assembled into the tailcone during this manufacturing stage The forward cabin enclosure and the tailcone are mated and this fuselage assembly advances down the 12 98 M20J 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 S N 24 0901 and ON have had the wishbone subassembly 1 changed to allow this unit to be installed 53 10 02 TAILCONE STRUCTURE The tailcone is of semi monocoque construction The internal structure is shown on Figure 53 2 The forward cabin structure 1 is boited to the tailcone with he tai D j i S SMJKS3 1 TUBULAR STRUCTURE FRAME FIGURE 53 1 53 00 00 MOONEY AIRCRAFT CORPORATION load portion of the assembly The avionics equipment sheif 3 spans the tailcone width to provide rigidity and space for avionics components The battery box 5 and battery are located in this area also The hat rack shelf 4 provides rigidit
122. and directly under the baggage door hinge area B Pull insulation back to clear rivet shanks C Center punch rivet heads holding the hinge half to the fuselage D Carefuily drill rivet heads and punch rivets from oles 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 F Remove hinge and baggage door assembly carefully G Clean hinge and hinge mounting area thoroughly of all sealant or foreign material 2 Repair The baggage door may be repaired per standard repair procedures in accordance with AC 43 13 1 Repairs may be made to the baggage door on the airplane if feasible 52 11 00 MOONEY AIRCRAFT CORPORATION NOTE If repairs are to be made the interior trim panel may require removal 3 Installation OLD HINGE Place repaired baggage door with old hinge into osition and cleco securely to assure fit of door check atching operations B Remove door assure attachment area is clean of old sealant C Apply sealant PR 1403 G B2 or equivalent to attachment area between outer skin and inner me D Reinstall door assembly with old hinge and cleco hinge for proper placement E Install rivets AD4 standard 05 oversize in all oles FABRIC COVER FOLDED BACK Ne I AUX HANDLE RED INSIDE HANDLE lt CAM KE Qe A N e SPRING ADDED PER S J M20 63 LATCH PIN DOO
123. and main gear door links Check gear for binding at pivot points while moving gear legs by hand Lubricate retraction system as indicated in Section 5 20 07 4 Position retraction bellcrank A Fig 32 10B so that center of forward hole in left outboard arm of the bellcrank is 1 56 IN approximately from forward face of truss at Fuselage Station 33 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 Heim bearing aligns with hole in bellcrank at N Install connection bolt NOTE LH amp RH adjustable retraction tubes should be approximately same length to start rigging procedures 6 With bellerank in position and all gears fully extended adjust main and nose gear retraction tubes so that tubes can be slipped in place with zero preload 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 retraction tube rod end G Fig 32 4 IN one 1 full turn then
124. and rudder pedal control 21 30 00 ELEVATOR SYSTEM rods Carefully remove torque tube by sliding out toward 1 Elevators Elevator construction is essentially the the right side of cabin and through cabin door same as that of the ailerons Both elevators attach to RUDDER HORN ADJUSTMENT FIGURE 27 6 RUDDER amp ELEVATOR TRAVEL ADJUSTMENT FIGURE 27 5 27 30 00 12 98 8 SERVICE AND MANUAL the stabilizer at four hinge points Push pull tubes walking beams and bellcranks link both elevators to the control yoke Both elevators are connected by control tubes to a common bellcrank in empennage Lead counterweights static balance both elevators 2 Elevator Removal and Installation A Remove push pull control tubes from elevator horns by taking off all attaching bolts nuts and washer B Remove bolts nuts and washers from the four attaching hinges C Remove elevator to the rear D Install elevators in reverse sequence of removal Recheck attaching bolts for security and safety 3 Elevator Rigging and Adjustment A Adjust rod end bearing 3 Figure 27 1 at control yoke 3 for control shaft H clearance from firewall and control yoke G clearance from fuselage structure B Level aircraft and set control column in neutral with stabilizer parallel to center line of aircraft NOTE Measure elevator travel from 0 degrees stabilizer thrust line with travel board positioned at stabilize
125. and the power supply C Steps B thru D and Warning of paragraph 33 41 01 1 apply for removal of this power supply unit 33 41 02 POWER SUPPLY UNIT INSTALLATION I The installation of any of the power supplies is a reverse sequence of the removal procedures 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 33 41 03 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 from tip rib 33 41 01 9 SERVICE AND MAINTENANCE MANUAL NOTE The Whelen Strobe Nav light assembly is installed slightly different but is removed and replaced in a similar manner TAIL LIGHT TYPICAI WING TIP STROBE LIGHTS FIGURE 33 5 C Remove the two screws 6 from the back side ofthe mounting plate WARNING High voltage is involved in the circuit between the power supply and strobe light assemblies Although a bleed off
126. area to match surrounding surface 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 usually a result of poor bonding of fiberglass layers Generally this condition is localized and can be readily repaired by carefully spreading apart the plys in the delamination and removing loose particles by blowing clean compressed air into damaged area 51 15 05 22 M20J 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 minimum of 8 hours before removing clamps 3 Extensive delamination of a part will be reason for total rejection of the part and shall be scrapped per standard practices 51 16 00 MISCELLANEOUS 1 Protective Coatings A Parts with protective coatings such as Conversion Coated or zinc primer on which the coating is scratched spotfaced drilled or in any way removed must be recoated with zinc chromate primer EXAMPLE Part is Conversion Coated as detail part During replacement the part is spotfaced to receive bolt and washer This part must be primed after spotfacing 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 ca
127. 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 bring deflection within tolerance 32 31 02 EMERGENCY GEAR EXTENSION SYSTEM RIGGING DISENGAGE RIGGING 24 0084 S N 24 0378 amp ON 1 insert cable thru hole in actuator disengage arm B Fig 32 10B 2 With red lever 1 Fig 32 114 in full disengaged position down and latched push actuator disengage arm B to full forward position and apply approximately 5 Ibs pull to cable to remove slack 3 Install D222 wire stop C tighten nut and connect spring E to clevis pin D 4 Lift RED lever and pull T handle 2 Fig 32 11A aside re engage RED lever Check manual extension system to verify that it is fuily disengaged by pulling T handle no resistance should be feit a resistance is felt check cable routing through pulleys 3 and 4 Fig 32 11A to verify if it is cable routing or actuator resistance AVIONICS PRODUCTS ACTUATOR S N 24 0084 24 0378 THRU 24 TBA 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 MOONEY AIRCRAFT CO
128. battery box use a solution of bicarbonate of soda and clean water to neutralize corrosion and spilled electrolyte 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 after cleaning and tightening them 5 Check battery ram air and vent for obstruction line kinks etc I 12 20 03 TIRES AND WHEELS Keep the tires at recommended air pressure Refer to Chapter 6 00 01 1 Check tires for wear cuts and bruises 2 Check valve stems for evidence of tire slippage or pulling I 3 Check wheels for damage 4 Check wheel bearings for lubrication 12 20 04 BRAKE RESERVOIR 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 Use only hydraulic fluid red per specification MIL H 5606 Do not fill reservoir above two inches below filler port condition and 12 20 00 5 SERVICE AND MAINTENANCE MANUAL 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 ble
129. be added to the Electric Pitch Trim servo bracket area to call attention to the annual maintenance requirement Carrier bearing assembly must be inspecied and lubricated per the following procedures 12 98 M20J MOONEY AIRCRAFT CORPORATION 5 27 11 STABILIZER CONTROL RIGGING FIGURE 27 11 5 Stabilizer Trim Chain Adjustment Reference Figure 27 12 A With the four mounting boits 1 stack adjust the iwo NAS428 3 4 bolts 2 to obtain maximum tension on chain without causing binding k K SV EP re CHECK control tubes at bulkhead grommets for rub marks Check Trim Actuator threads for galling or not lubricated lube per Section 5 Check BINDING symptoms above Check for proper clutch settings Confirm full bus voltage is available at trim motor 1 Gain access to area by removing electrical bay access cover from left hand side of tailcone Locate Electric Pitch Trim servo system just aft of Fuselage Sta 142 bulkhead Carrier bearing is located around existing pitch trim torque tube aft of lower chain sprocket on side of electric pitch trim servo bracket and below electric pitch trim servo motor 2 Loosen electric pitch trim servo drive chain Remove four lock nuts which secure carrier bearing block to aft side of electric pitch trim servo bracket Slide bearing block aft until it is clear of stainless steei sleeve which is secured to existing airplane pit
130. be designated by serial number of applicable airplanes The Part Numbers of replacement or repair parts should be identified using the Illustrated Parts Catalog IPC applicable to Model amp Serial Number of aircraft being worked on Part Numbers can be ordered through any Mooney Marketing Center MMC See Section 91 for identification of electrical components The format and contents of this manual are prepared in accordance with GENERAL AVIATION MANUFACTURER S ASSOCIATION GAMA Specification No 2 The manual is supplemented with wiring schematics for 15 various model year airplanes as necessary These are located in envelopes at the back of the manual iexts pages 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 Schriener Field Kerrville TX 78028 Attn Service Parts Department Notification is sent to known manual holders when any hew manual is prepared to replace the subscription manual and advises that no more revisions wilt 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 Correspondence concerning mainten
131. capacity required to operate the aircraft electrical system and avionics in the event of the failure of the generating system during flight 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 prior to 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 sump Changes in resistance caused by changes in oil temperature alter current flow rate thereby varying the magnetic field in the indicator coils 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 bulb resistance varying the magnetic field in the indicator coils 3 Fuel Pressure Gauge The Fuel Pressure Gauge is an electrically operated gauge located in the cluster The Manifold Pressure Gauge is a simple direct reading insirument 4 Exhaust Gas Temperature I
132. contact with oxygen The thread compound must be applied sparingly to the first three threads of the male fitting only No compound is to be used on the coupling sleeves or on the outside of the tube flares Extreme care should be exercised to prevent the contamination of the thread compound or teflon tape with oil grease or other lubricant Fuel Hydraulic Air Oil Lines Use Parker Thread Lube or equivalent on male fittings only Apply lubricant omitting the first two threads sparingly and carefully Engine Fittings Use only aircraft engine oil to lubricate fittings threaded directly to engine Vacuum Lines No lubrication is to be used Check manufacturers instructions when installing components Refer to Section 37 for maintenance procedures on vacuum system Tapered Threads Use Teflon Threadseal Tape 1 Continue to tighten until fitting is correctly positioned but do not overrun or backoff 2 If leaks are detected tighten one full turn more 3 If leaks persist disconnected and components 5 Electrical wiring shall be checked as applicable for loose corroded or broken terminais chaffed broken or worn insulation insecure installation heat deterioration and any other apparent damage 6 Bolts and nuts in critical areas shall be checked for fretting wear damage stretch proper torque Figure 5 2 and safetying T Filters and screens shall be removed cleaned and inspected for contamin
133. container 28 31 00 FUEL SYSTEM DRAINS Fuel drains are installed in the inboard corners of the wing tanks and at the fuel selector valve or gascolator the lowest point in the fuel system The engine manifold and engine driven fuel pump drains join 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 flange seals the valve seat 28 32 00 FUEL VENTS The fuel tanks are vented from the outboard upper edge This vent is routed outboard and is vented overboard through a NACA vent on lower wing surface To check fuel tank vents 1 Block entire fuel tank vent by slipping a short length of rubber hose over tube and projecting below wing lower surface 2 Remove fuel tank filler cap blow gently into rubber hose Air should be felt coming out of filler port 3 If stoppage is found clear vent prior to flight since fuel starvation could result from vent stoppage NOTE It is important that the fuel tank vent tube protrude only enough to be flush with lower wing skins 28 40 00 INDICATING 28 41 00 FUEL QUANTITY INDICATING TRANSMITTERS The fuel quantity indicating system has two fuel quantity transmitters in each wing tank one on wing M20J doubler MOONEY AIRCRAFT CORPORATION 3 Locate amp remove transmitter wires 4 Remove six screws attaching transmitter to rib doubler 5 Remo
134. 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 R60 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 R60 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 fight during TEST or in normal operation Filament of DS8 Assy A2 open I CR6 and CR7 Assy A2 open 29 The RAM air will not light during 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 bright by momentarily depressing the TEST switch CR11 Assy A1 open 12 98 24 39 05 15 MOONEY AIRCRAFT CORPORATION M20J SERVICE AND MAINTENANCE MANUAL ANNUNCIATOR TROUBLE SHOOTING 24 0001 THRU 24 3153 con t 33 Neither the high low vac or the high low volts will flash when low vacuum and or low voltage occurs Q8 Assy A1 defective 12 Assy A1 defective CR1 Assy A1
135. drop fuel level below leaking fasteners E 2 Clean fastener head and adjacent surface with Turco 657 Wipe Solvent or MEK and dry thoroughly Fastener head and adjacent metal must be entirely free from paint dirt and oil 3 Apply a 1 8 inch thick coat of PR1422 or CS3204 B 1 2 or B 2 over head and around fastener 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 procedure shall be to restrike rivet or retorque fastener to maximum permitted torque value ANY ONE RIVET MAY BE RESTRUCK ONLY ONE TIME If leak continues replace the rivet 1 Repair any sealant damage due to restriking or retorqueing a fastener 2 Remove sealant immediate area of leak source using sharp non metallic tool 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 Thoroughiy 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 4 Thoroughly
136. 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 M20J 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 potassium chromate or potassium dichromate B Three and one quarter ounces Thickening Wax Carbo Wax 1500 C Thirteen ounces Alkaryl Sufonate wetting agent D Distilled water 2 Solution Preparation A Mix one of the compounds listed in item A above with one cup distilled water B Mix item B above with one cup distilled water C Mix item C above with four to four and one half gallons distilled water until wetting agent dissolves completely D Mix the three ingredients A B and C together and add enough distilled water to make five gallons of solution NOTE Amount of each ingredient may be reduced for a smaller quantity of solution Solution life is about one week CAUTION Soapless bubble fluid is slightly corrosive and must be completely removed by washing freely with water followed by scrubbing
137. during 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 80 ENGINE MIXTURE CONTROL RIGGING 1 Disconnect mixture control A Remove cotter key B Remove nut bolt and two washers from clevis and mixture control arm 2 Reconnect mixture control A Reverse disconnect procedure to reconnect mixture control 3 Adjustment of mixture control arm A Loosen locknut on control rod end and adjust control arm rod as required B Check for full travel C Check for proper thread grip D Secure locknut 71 00 90 71 00 91 TROUBLE SHOOTING STARTER TROUBLE SHOOTING See Section 24 39 04 for procedure TEXTRON LYCOMING OPERATORS MANUAL should be consulted 71 00 92 ENGINE TROUBLE SHOOTING TROUBLE PROBABLE CAUSE Engine will not start No fuel Incorrect throttle setting Defective spark plugs Defective ignition wire 71 00 61 8 REMEDY Check fuel system for leaks Fill fuel tanks Clean lines strainers and fuel valves Open throttle 1 4 Clean and adjust or replace spark plugs Check with tester and replace defective wires 12 88 SERVICE AND MAINTENANCE MANUAL M20J IROUBLE Engine does not idle properly Low power and uneven running Engine does not develop full power Improper fuel flow R
138. 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 amp 7 for 24 3000 amp ON CAUTION Pull alternator field C B 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 regulator to 4 Check resistance from F2 terminal alternator of alternator to pin 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 aiternator 5 Check resistance from F2 to F1 term of alternator Normal indication is 3 4 ohms If resistance is high or low repair or replace alternator 24 0001 thru 24 2999 case to field on 24 3000 thru 24 TBA 6 Check resistance from F2 terminal of alternator to alternator 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 M20J 24 39 02 RESERVED 24 39 03 TROUBLE Discharged battery Cracked cell jars Eamon on top of battery melts Elecirolyte runs out of vent plugs Excessive corrosion inside conta
139. 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 bellcrank with zero preload NOTE The eccentric bushings may require rotation to a new position in order to meet the zero preload condition 3 Measure nose gear bungees dimension P Fig 32 6 and record for future reference 4 Push landing gear actuator C B IN 5 Place landing gear switch in UP position 6 Turn Master Switch ON 7 Push RED GEAR SAFETY BYPASS SWITCH IN ane hold it to partially retract landing gear release switch 8 Turn Master Switch OFF 9 Puil landing gear actuator C B OUT 32 31 01 10 Screw each nose gear retraction tube F Fig 32 3 IN clockwise looking toward front of aircraft one 1 full turn then re attach to main retraction bellcrank 11 Place landing gear 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 it to its original position Continue this procedure stopping when the gear down light JUST illuminates 32 31 01 16 M20J MOONEY AIRCRAFT CORPORATION 15 Measure nose gear bungee assemblies dimension P
140. eliminate the necessity for periodic inspections The most likely areas for corrosion to begin are in hidden crevices such as skin laps under rivet heads or any opening where moisture can collect Periodic inspection of these areas is most important so that any corrosion which may be present can be detected and treated in its very earliest stages When corrosion is detected it should be treated as follows A Remove all corrosion product usually white or grey white powder on aluminum from the corroded area down to sound metal 1 if the base metal is aluminum clean off the corrosion product by scrubbing with aluminum wool or a nonmetallic scouring pad such as the nylon pads made by the Carborundum Company P O Box 277 Niagara Falls N Y 14302 12 98 AIRCRAFT CORPORATION 2 H the base metal is steel remove the with emery cloth 320 grit finer steel wool 3 If the corrosion is too advanced to remove by the light mechanical cleaning methods of 1 and 2 refer to Advisory Circulars 43 13 1 and or 43 4 for alternate methods of cleanup and repair current revision 4 Chemical cleaning solutions should be used with extreme caution on both aluminum and steel parts Such solutions are not recommended for use in areas Where they cannot be easily and completely neutralized B Wash all areas to be primed with a cleaning solvent such as methylethylketone MEK Tu
141. empennage stinger Figure 33 5 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 from strobe power supply harness and disconnect the connectors for taillight assembly C Remove the connector plug 2 from the strobe light wiring harness leaving the pins connected to individual wires 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 ihe two screws 3 that secure strobe taillight assembly to rudder 4 and pull the light assembly out so it clears the mounting hole The wire harness will be stretched tight at this point F Carefuly begin working the wire harness through the empennage and rudder bulkheads until the wire harness can be pulled through the light mounting hole in the rudder The rubber grommets at each bulkhead will require removal from bulkhead but leave ae la to wire harness See Figure 33 8 for this detail 12 98 MOONEY AIRCRAFT CORPORATION 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 HOLE You will need this to pull the new wire harness back in place during installation Remove cord from wire harness H Replace complete flashtube base assembly 5 if strobe light portion is malfunctioning The flashtube is n
142. engine mounting pad Inability to attain takeoff RPM duringflight RPM fluctuates The RPM can fluctuate 30 RPM High propeller friction Governor function upset by malfunctioning engine 61 20 90 6 M20J PROPELLER GOVERNOR TROUBLE SHOOTING PROBABLE CAUSE Damaged O Ring Damaged head and body gasket Damaged relief valve plug gasket Damaged body and base gasket Damaged governor mounting gasket Loose governor attaching nuts Warped engine mounting pad Wrong high RPM governor setting incorrect system rigging Low engine power Erroneous reading tachometer Sticky pilot valve Sludge in governor pilot valve or relief valve Burrs on pilot valve lands Backlash in governor control System Sticky relief valve Erroneous reading tachometer Excessive oil leakage in pro peller shaft transfer bearing Air trapped in propeller Sticky pilot valve Bent pilot valve Excessive internal ieakage in govemor 12 98 MOONEY AIRGRAFT CORPORATION REMEDY Replace with new O Ring Replace gasket Replace gasket Replace gasket Replace gasket Retighten nuts Consult engine manual Reset governor external high RPM adjustment screw Adjust control system Consult engine manual Calibrate or replace instrument Remove head and clean pilot valve with crocus cloth Maintain sharp pilot valve land corners Check for straightness of pilot
143. equivalent and wiping clean After cleaning inspect iple for dents cracks and loose fasteners Repair efects 1 Remove two 2 screws from top cowling on each inboard side of engine cooling air intakes 2 Remove 1 screw from each side of top cowling forward and outboard Then unlatch cam locks on each side 3 Unlatch cam locks on the aft edge of the top cowling just ahead of windshield 4 Carefully lift top cowling off 71 10 00 12 98 SERVICE AND MANUAL 71 11 02 BOTTOM COWLING 1 Disconnect landing light wiring connectors near firewall 24 0001 thru 24 3153 A Cut ty raps securing insulating tubes over knife disconnects B Slide insulating tubes up wire hamess toward firewall C Disconnect knife disconnects and slide insulating tube back over disconnect 2 Disconnect cowl flap control rod ends at the quick disconnecis located on the cowl fiap brackets See Figure 71 1 NOTE Reach up through the cowl opening to disconnect cowl flap control rods 3 Unlatch cam locks located on bottom of cowling between or around the cowl flaps 4 Unlatch the remaining cam locks on bottom cowling while supporting the cowl 5 Carefully lower cowling clear of spinner and remove from aircraft 71 12 00 COWLING INSTALLATION NOTE Check condition of tape on firewall flange where cowling rests It is recommended that vinyl tape be replaced with polyethylene tape 3M tape
144. forward of the firewall 2 Connect to output fitting a flexible line that will reach fuel receptacle 3 Tum fuel selector valve to the tank to be drained and remove filler cap from fuel filler port 4 Turn on fuel boost pump until tank is empty Repeat steps 3 and 4 to drain other tank 5 To completely drain fuel system also drain wing sumps and the fuel gascolator valve sump until fuel stops running NOTE When defueling using removable tank quick drains it is only necessary to remove the drains and to operate the gascolator drain NOTE S N 24 0378 amp ON The gascolator fuel drain is separate from the fuel selector The fuel selector is located aft of the console on the fioor 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 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 filler cap access door is located in the top cowling Any lubricating oil either straight mineral MIL L 6082 or compounded TEXTRON Lycoming Spec No 301F or MIL L 22851are acceptable for use after break in period Approved products and engine oil viscosity requirements are shown in Chapter 5 20 07 12 00 00 3 SERVICE AND MAINTENANCE MANUAL CAUTION The terms detergent additive and compounded used in this manual are intended to re
145. groups each of which certain specific information The 5th functional group is the wire size of the wire connecting the various components These functional groups are as follows Functional Group No 91 00 02 Page 4 Funcional Description of identifiers roup 21 first two numerals 24 0001 thru 24 1685 Aircraft Type 14V Not ATS JKL first three letters 24 3000 thru 24 TBA Aircraft Type 28V is used if not applicable to a model 14 first two numerals 24 1686 14 228981 Aircraft Type 14V ATS PA first or second two letters Circuit Function 03 or 102 second set of numerals Wire Sequence single letter in the series Configuration 18 last two numerals in the series Wire Size does not appear for components just wires CIRCUIT FUNCTION LEGEND DWG NO s 800330 800350 Defroster Blower LS Lighting Instrument amp Sirobe Navigation Cowl Flap Lights p Wing Flaps Electric Trim Stabilizer Stand by Vacuum Instruments Ammeter Instruments Tum Coordinator Instruments Cylinder Head Temperature Instruments Outside Air Temperature Instruments Carburetor Air Temperature Instruments Fuel Quantity Instruments Cluster Gauge Instruments Oil Temperature Instruments Oil Pressure Instruments Fuel Pressure Instruments Tachometer Instruments Hour Meter instrumenis Pressurization Instruments Pitot Heat Instrument
146. 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 SERVICE AND MANUAL CHAPTER 78 EXHAUST SERVICE AND MAINTENANCE MANUAL M20J CHAPTER SECTION SUBJECT 78 EFF CONTENTS 78 00 00 78 00 00 CHAPTER SECTION SUBJECT 78 00 00 78 10 00 78 30 00 78 40 00 CHAPTER 78 EXHAUST LIST OF EFFECTIVE PAGES PAGE 1 2BLANK 3 4 TABLE OF CONTENTS SUBJECT General SYST n es OG Exhaust System Installation Exhaust System Servicing Periodic Replacement Components 12 98 MOONEY AIRCRAFT CORPORATION DATE 12 98 12 98 12 98 PAGE 4000 78 EFF CONTENTS 1 2BLANK MOONEY AIRCRAFT CORPORATION 78 00 00 GENERAL The exhaust system s headers and exhaust pipes are made from 321 CRES steel They are designed to optimally scavenge the cylinders exhaust gases during normal engine operation Inspections for cracks burns etc are required during each maintenance activity and recommended before each flight 78 10 00 EXHAUST SYSTEM INSTALLATION 1 EXHAUST PIPE HEADERS TO ENGINE A Place new exhaust gaskets in position on the LH amp
147. hold the window in position from the inside reference Figure 56 2 NOTE Some retainers are held in place with screws 4 and some with rivets Drill out rivets carefully The window will be bonded to the outside skin with sealant Considerable effort may be required to break the bond between the acrylic and the outer skin Care should be exercised to keep window from twisting and possibly cracking 1 Remove the window and clean all remaining sealant from the skin Use M E K and a scraper to remove the sealant Aircrat S N 24 1214 thru 24 1417 have an inner 5 and outer window 1 installation on the cabin door window Removal is basically the same procedure as single window installations 56 22 02 CABIN WINDOWS INSTALLATION 1 Remove all old sealant and clean skin area with M E K Place window 1 into position to assure proper fit Trim if necessary 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 M20J MOONEY AIRCRAFT CORPORATION SMJK56 2 WINDOW INSTALLATION FIGURE 56 2 3 Force window 1 into place with retainers 2 or clips 3 and secure with Avex 1601 410 blind rivets or existing screws and hardware 4 The seal
148. inch pounds 5 Reinstall cable support bracket and retaining nuts 6 Retest unit for proper electrical and mechanical operation 7 Install modification plate adjacent to 1 0 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 replacement with the next consecutive number 32 31 04 LANDING GEAR ACTUATOR P N 102000 RECOILER SPRINGS CABLE AND DRUM ASSEMBLY REPLACEMENT 1 Carefully separate pulley housing from recoiler 5 by removing screws 14 Retain pulley on shaft All dash no s applicable for P N 102000 actuator 2 Slide pulley drum and cable off shaft 3 Remove the two 2 recoiler springs and two 2 of the three 3 spring spacers leaving the third spacer in housing Be certain that spacer is in place before installation of two 2 new recoiler springs and previously removed spacers 4 Install new recoiler springs placing a spacer between each spring and over top spring IMPORTANT Recheck proper installation of 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
149. inspected and repaired It is recommended that prior to aircraft engine start the stand by vacuum pump be turned ON to verify that the vacuum gauge if equipped indicates normal operating vacuum and that the gyros 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 indication on the gauge if equipped to be noticeable 37 40 00 9 SERVIGE AND MAINTENANCE MANUAL M20J MOONEY AIRCRAFT CORPORATION BLANK 37 41 00 12 98 10 AIRCRAFT CORPORATION M20J SERVICE AND MAINTANANCE MANUAL CHAPTER 39 ELECTRICAL PANELS AND COMPONENTS SERVICE AND MANUAL 20 MOONEY AIRCRAFT CORPORATION CHAPTER 39 ELECTRICAL PANELS AND COMPONENTS LIST OF EFFECTIVE PAGES CHAPTER SECTION SUBJECT soo so 255 PAGE wo 5 v o vro DATE 39 Effectivity 12BLANK 12 98 39 Contents S3MBLANK 12 98 39 00 00 Td 22 5 de Et ee a 12 98 39 1002 ru lae cR a oe vu om 12 98 38 44 00 2 ue ue s s 2 XC 14 42 98 39 11 01 ue tie Mot ue OG and Heus Al hem vw 12 98 39 11 02 _ x DU Rm 0 u c x 32 98 39 12 00 tat 4e 4 e ETG ER 39 1204 25 ae 40 i
150. instrument Disconnect lines and purge with air r gt SSS SSS SS SS SS SS SS SSS SS SS SS SS SS SSS LS SSS SS SS SS SSS SS SS SS SS SS SS SS SS SS SS SS SS SS SS ee TROUBLE PROBABLE CAUSE Excessive error ai existing Pointer shifted barometric pressure Excessive error when engine Line leaking is running Sluggish or jerky pointer Improper damping adjustment movement Broken or loose cover glass Vibration or excessive pressure Duil or discolored juminous Age markings Incorrect reading Moisture or oil in line 77 10 03 FUEL FLOW INDICATING SYSTEM Refer to Section 73 30 00 for this data 77 20 00 TEMPERATURE INDIGATING 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 ternperature rise 77 10 02 4 Aircraft 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 The cylinder
151. is energized Release of the key after engine starts will return the switch to the BOTH position where both magnetos are operative In the OFF position both magnetos are grounded At the R position the left magneto is grounded and at the L position the right magneto is 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 MAGNETO INSPECTION MAINTENANGE INSTALLATION amp TIMING Refer to engine and magneto manufacturers Service Manual for magneto inspection maintenance installation and timing 74 10 02 IGNITION SYSTEM TROUBLE SHOOTING 1 Hard starting A Assure that the impulse coupling is operating B Check magneto timing to engine 2 Engine Roughness A Install new spark plugs B Check plug leads for deterioration C Check magneto contact points for burning and dirt accumulation 12 98 M20J SERVICE AND MAINTENANCE MANUAL SMJ74 1 ENGINE FIRING ORDER FIGURE 74 1 3 Magneto Drop Out of Limits A Check magneto to engine timing B Inspect contact breaker points for proper clearances C Check spark plugs and leads NOTE Service ignition system per TEXTRON Lycoming Service Manual Section 4 74 20 00 ENGINE FIRING ORDER 74 30 00 SWITCHING The Magneto Starter switch is connected to the magneto grounding wires P leads of both magnetos Turning this switch from BOTH to O
152. light and are located in each wing outboard section mounted on inspection cover and inside the tailcone adjacent to the left rear inspection cover The system is actuated by circuit breaker switch located on the instrument panel in front of the pilot S N 24 0001 thru 24 1037 have combined Nav Strobe light assembly on each wing tip no strobe light on the rudder only a navigation ight 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 fiberglass wing tip trailing edge The lights are activated by a circuit breaker switch located on ihe instrument panel in front of the pilot S N 24 0001 thru 24 3153 The landing light is located in lower engine cowling M20J SERVICE AND MAINTENANGE MANUAL One 290 000 candie power sealed beam bulb is incorporated and mounted in a housing designed to isolate the bulb from engine heat and vibration The light is activated by a circuit breaker switch located on the instrument panel in front of the pilot S N 24 3154 thru 24 TBA Two 110 000 candle power sealed beam bulbs are located in LH amp RH side of wing Two interior lights are located on the overhead panel S N 24 0788 thru 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
153. located at skin splice on vertical fin L Adjust nose wheel steering by removing nut washer amp boit 1 Figure 27 4 and adjusting steering idler linkage at 2 Bolts nuts and washers at 5 amp 6 must be installed from rear to front 4 Allowable Free Play Limits at RUDDER VERTICAL MOVEMENT A Maximum vertical movement allowable at rudder trailing edge 08 inches 1 If excessive free play exists check the following areas for wear a Trim screw jackshafi b Trim link connecting empennage to trim screw AILERON STOP ADJUSTMENT FIGURE 27 2 TRAVEL BOARD LOCATION STA 25 50 TRAVEL BOARD LOCATION 1 2 ABOVE C L DF RIVET ROW LEVELING STA 147 75 TRAVEL BOARD LOCATION BETWEEN FLAP amp AILERON SM27 34 RUDDER PEDAL ADJUSTMENTS FIGURE 27 3 TRAVEL BOARD LOCATIONS FIGURE 27 3A 12 98 27 20 00 7 MOONEY AIRCRAFT CORPORATION M20J SERVICE AND MAINTENANCE MANUAL 4 SMJK27 4 NOSE GEAR STEERING LINKAGE ADJUSTMENT FIGURE 27 4 9 Bolts and brackets attaching empennage to tailcone Control tube wear ae If any pomen of 5 Rudder Torque Tube Removal The rudder the control tube exceeds 007 wear per wall or torque tube should be inspected thoroughly and replaced 014 in reduction in diameter the tube must be if any damage found Remove re from front of replaced cabin floorboa at covers torque tube Remove 2 attaching hardware from hinges
154. located on the circuit breaker panel side tray above the co pilots right knee De icer boot replacement should be done per B F Goodrich Report No 59 728J which is supplied with the kits for replacement boots JE1964 3 TIMER 4 2406 SLIP RING ASSY SHUNT MS91586 1 12 98 M20J 4E2551 3 PROP DE ICER 005c 21PLOSAZ MODULAR S QJ T 5 m 003B e AMMETER 21RCOSA om 010 008 1A FUsE 1A 85 002 C B SWITCH 930023 023 12 VOLT SYSTEM FIGURE 30 1A PROPELLER DE ICE SCHEMATIC 14 VDC MOONEY AIRCRAFT CORPORATION 30 60 01 PROPELLER DE ICE 30 61 00 SERVICE GUIDE INTRODUCTION Whether in flight or during ground testing the ammeter can be used to determine the general nature of most electrical problems The Trouble Shooting Chart is based primarily on the use of the ammeter and it is assumed that the user understands all normal operating modes of the system See Section X of P O H Read all of the Trouble entries to locate the one matching the conditions of the system being checked The Probable Cause and Remedy entries pertinent to each trouble are airanged in the recommended checking sequence B F Goodrich maintenance Manual Report No ie will be required for complete maintenance actions 30 61 01 HELPFUL TIPS 1 Normal current is shown as a shaded range on the ammeter for each propelier De Icer s
155. 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 Install inner sleeve in tube to be repaired so that its outer end is one and one half of the original tube diameter from the nearest end of the diagonal cut secure in position with a rosette weld on each side at one half the original 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 G Weld the inner sleeve to the tube stubs through the 1 8 inch gap forming an overlaid bead across the gap H Rosette X weld the REPLACEMENT replacement tube TUBE to the inner sleeve in two or more LEAVE 1 8 IN GAP FOR WELDING places lt amp c2 5 2 s 2 5 INNER SLEEVE SPLICING FIGURE 51 2 12 98 SERVICE AND MANUAL WELD HERE FIRST 4 ROSETTE WELDS M20J MOONEY AIRCRAFT CORPORATION 1 4 IN 1 8 IN GAP FIIR WELDING SPLIT SLEEVE SPLICE FIGURE 51 3 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
156. near the co pilots head The passenger compartment lights are located above the rear seats in the overhead panel and are activated by a similar three position switch located adjacent to the light The rear cabin light is accessible from the baggage compartment door also S N 24 0001 thru 24 0767 A switch in the dome light base controls the overhead dome light CAUTION SIN 24 0001 thru 24 3153 cabin lights connected directly to battery through their switches and WILL ILLUMINATE WITHOUT MASTER SWITCH ON LAMP BULB REPLACEMENT CHART APPLICATIONS BULB PART NUMBER 14 VOLT 28 VOLT Glareshield Lights GE 330 GE 327 Post Lights GE 330 GE 327 Map Light GE 330 GE 327 Cabin Interior Lights GE 1816 GE 1818 Trim amp Flap Indicator S N 24 0084 24 0378 WI 7046 N A thru 24 1168 S N 24 1169 amp ON GE 370 GE 327 Gear Down Light Floorboard Indicator GE 327 GE 327 Tail Position Light Whelen SDI 34 0212030 85 34 0228030 85 Wing Position Light 24 0001 thru 24 1425 Grimes A 7512 12 24 1426 thru 24 1706 Whelen W1290 14 A508 14 24 3000 thru 24 TBA Whelen W1290 28 Landing Light 24 0001 thru 24 3153 GE GE 4522 GE 4553 24 3154 thru 24 TBA GE GE 4596 GE Recognition Light Whelen Use S D I Tool No 203541 to remove lamp 01 0770303 00 Use same light assy but dropping resistor RH 50 7 5 req d 33 20 00 INTERIOR LIGHTS MAINTENANCE PRACTICES 33 21 00 CABIN LIG
157. necessary When hose clearance is tight making it difficult to reinstall onto the pump fitting spray the fitting at the hose end with silicone LET DRY then install hose by pushing it 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 6 M20J MOONEY AIRCRAFT CORPORATION 37 12 00 VACUUM REGULATOR The vacuum regulator 2 Figure 37 1 is a spring controlled diaphragm valve for regulating vacuum for the aircraft pneumatic instrument system The vacuum regulator is located on the left firewall inside the cabin just under glareshield Adjust vacuum regulator valve according to Section 37 12 05 37 12 01 MAINTENANCE PRACTICES Check general condition of regulator to insure it is secure and in airworthy condition 37 12 02 SERVICING No servicing is required to the regulator other than filter replacement per Section 5 See Section 37 13 00 for detail procedures 37 12 03 REMOVAL 1 Underneath the instrument panel remove both instrument lines from vacuum regulator cap to prevent foreign objects from entering them 2 Engine compartment remove hose from vacuum regulator cap to prevent foreign objects from entering 3 Loosen and remove large nut at firewall on vacuum regulator 4 Pull regulator aft to rem
158. 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 analysis which pertains to the 1 A l annunciator on the Mooney M20J S N 24 3154 thru 24 TBA 1 0 GENERAL This document is intended to be a guide to assist a service technician in understanding the theory and operation of international Avionics Inc IAI Part Numbers 9500326000 amp 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 singularly or in multiple combinations the annunciators These sections are as ollows 7 Section 2 Power Supply with Test im switches Section 3 Flasher Section 4 Landing Gear Indicators Section 5 Left and Right Low Fuel Section 6 Hi Lo Vac Section 7 Alternator Low Volts Over Volt Section 8 NOT USED Typical Positive Apply W Dim Typical Positive Apply WO Dim Section 9 Section 10 2 0 POWER SUPPLY The Power Supply shown in Figure 1 provides 12 VDC reverse voltage protectio
159. of the starter ring gear support Fit starter ring gear over propeller fiange bushings on crankshaft NOTE Make sure the bushing hole in the ring gear support that bears the identification 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 aear must be located correctly to assure proper alignment of the timing marks on the ring gear CAUTION Remove all rags or plugs placed in crankshaft or hub during propeller removal 4 Clean propeller hub cavity and mating surfaces of propeller hub and ring gear support 5 Lightly lubricate a new O ring 8 Figure 61 1 and the crankshaft 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 Tighten bolts evenly and work propeller aft on crankshaft flange Tighten bolts to 55 85 FT LBS on McCauley propellers and 60 70 FT LBS on Hartzell propellers 61 00 20 4 M20J MOONEY AIRCRAFT CORPORATION 8 INSTALL SAFETY WIRE THROUGH ROLL PINS SAFETYING BOLTS IN PAIRS 9 Adjust alternator drive beit tension as outlined in Section 24 31 01 10 install spinner dome 5 making sure fiber washers are installed under all screws NOTE The tefl
160. or filters to become saturated with solvent The seals in the front frame of the housing behind the coupling are designed to keep out foreign material such as dirt dust and light fluid However fluid under high pressure can be forced by ihe seals and enter the pump 2 Dry air pump fittings Before washing the engine off check pump fittings for looseness of the threaded fittings Fluid can seep through loose threads and enter the pump 3 Dry air pump discharge hose vacuum instrument system Plug the end of the hose or the fitting and flag it with a red Remove Before Running Engine tag then clean the engine CAUTION Remove plug prior to running engine NOTE Vacuum pump exhaust tube assembly retrofit kit 940064 should be installed if not installed at time of manufacture 4 Replace vacuum relief valve filter after cleaning the engine compartment BEFORE starting engine 37 11 02 SERVICING The dry air pump requires no servicing The internal parts are self lubricating and require NO ADDITIONAL lubricating 37 11 03 REMOVAL 1 Disconnect hoses from dry air pump 37 00 00 5 SERVICE AND MAINTENANCE MANUAL 2 Remove air pump from engine and discard old mounting gasket and locking hardware 3 Remove fittings from pump Retain fittings if they are serviceable and clean thoroughly before reusing Discard twisted fittings and nuts with rounded comers 4 Pad inspection Check the condition of the AND
161. remove and replace defective switch C Reconnect wires and test switch for proper operation D Reinstail glareshield NOTE Other switches located in the ELT placard area of avionics panel can be removed and replaced in similar manner 39 12 03 INSTRUMENT AND RADIO LIGHT CONTROL BOX The control box for the instrument radio glareshield lights consists of iwo variable rheostat switches two transistors two fuses and miscellaneous wiring contained in a metal box assembly The transistors installed in M20J aircraft prior to 24 1214 are P N 2N2016 and no longer being manufactured Check appropriate schematics for proper wiring RHEOSTATS COMPARTMENT BULKHD IN THE TAILCONE S N 24 3201 24 3218 amp ON HAVE THE TRAN p i FUSES UNDER CAP VIEW LOOKING INTO CONTROL BOX COVER REMOVED INSTRUMENT amp RADIO LIGHT CONTROL BOX FIGURE 39 6 S N 24 1214 THRU 24 12 98 SERVICE AND MAINTANANCE MANUAL The replacement transistors are included in a spares modification kit P N 919003 907 which includes a transistor resistor and instruction sheet describing the modification procedures The kit will modify one circuit only two kits are required for both circuits M20J aircraft S N 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 late
162. remove nuts washers and bolts from transducer and bracket Pull transducer and hoses away from engine as far as possible G Disconnect the hose nuts from transducer fittings The transducer should now be free for removal Note position of fittings on old transducer H Cap all lines to prevent contamination 5 Fuel flow transducer replacement installation DASH NO TRU FLOW 1 CONFIGURATION FIGURE 73 5 73 31 02 6 12 98 MOONEY AIRCRAFT CORPORATION us 8 8 M20J U8 s b 80C318H U3 U7 i SERVICE AND MAINTENANCE MANUAL HD3 US s Y1 U10 SE RNI g7CXXX SHADIN FUEL FLOW CIRCUIT FIGURE 73 6 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 paragrapn 3 for detailed explanation A Note the position of fittings on old transducer and place them in similar position on the new transducer B Connect hose nuts to transducer fittings tighten C Connect the new transducer to bracket using bolts 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 secure the transducer E Connect the knife disconnects and slide insulating sleeving over connections Secure sleeving with ty raps B F Leak check all fuel con
163. 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 and before handling either of these units in any way Failure to observe these precautions may result in physical injury from electrical shock D Disconnect the wiring hamess plug and 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 puil 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 fiashtube is soldered in place and is not readily removeable from 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 or cleaning G Install the new strobe light assembly in reverse sequence of removal 33 41 03 10 M20J MOONEY AIRCRAFT CORPORATION 2 TAIL STROBE NAVIGATION LIGHT REMOVAL S N 24 1038 thru 24 2999 S N 24 3000 thru 24 TBA have only a strobe light assembly located on the rudder Removal is same as combination NAV STROBE light assembly A To gain access to the wire harness and connections from the power supply rotate the round access cover 1 on the lower left side of the
164. routine inspections Replace with new current configuration filters The alternate instrument filter installation 6 Figure 37 1 should follow the same cleaning replacement schedule 37 13 03 REMOVAL i Vacuum regulator garter filler is removed by stretching it over and off the regulator frame 2 Individual gyro instrument filters unscrew from the back of the instruments Some installations have one main gyro filter in a manifold line 37 13 04 INSTALLATION 1 Prior to installing a new vacuum regulator filter check the regulator to insure that it is clean from any foreign material 2 Reinstall new gyro filters into instrument boss and tighten securely CAUTION Don t over tighten overtightening will crack the rear housing 37 14 00 HOSES The hoses are of the aircraft MIL H type 37 14 01 MAINTENANCE PRACTICES During engine cleaning protect the discharge hose 1 Plug the end of the hose and flag it with a red Remove Before Running Engine tag then clean the engine CAUTION Remove plug prior to running engine Periodic check of all clamps for security is recommended 37 14 02 SERVICING Inspect the inside of the hose carefully to 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 M20J SERVICE AND MAINTENANCE MANUAL 37 14 03 REMOVAL Replace old hard crack
165. system should be activated manually when low light flashes on regular engine driven system Refer to 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 beiween replacement Replacement is recommended at 500 Hrs amp 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 VACUUM SYSTEM FIGURE 37 1 12 98 M20J SERVICE AND MAINTENANCE MANUAL 37 11 01 MAINTENANGE PRACTIGES Protection of pneumatic dry air pump when cleaning the engine compartment is very important 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 following precautions must be taken for better service life of the pneumatic dry air pump 1 Dry air pump coupling 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 housing by wrapping a protective covering around that area during engine cleaning CAUTION Do not allow protective covering around the coupling
166. the glareshield off B Disconnect the plumbing and or electrical connections from the flight instruments to be removed C Disconnect and remove any post lights D Remove the mounting screws securing the instrument to the panei E Remove the instrument by sliding it aft from the panel DI DH oid of om 11 od off m eS CIRCUIT BKR PANEL ENGINE INSTR PANEL SIL 24 0901 TYPICAL INSTRUMENT AND CONTROL PANEL 12 98 NL PANEL amp ON FIGURE 39 1 MOONEY AIRCRAFT CORPORATION 2 Installation A Place instrument into the proper location on panel B Insert and secure mounting screws to hold instrument to panel C Connect the post lights D Connect all plumbing and or electrical to the instrument perform pitot static leak check E Position the glareshield so connections can be made and secured electrical F Secure glareshield and cover plate with screws 39 10 02 AVIONIGS EQUIPMENT Each avionics package installed is basically customized package to meet the requirements of the customer Wiring harness any associated plumbing or mechanical mechanisms required for a particular avionics installation are welt 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 Mo
167. thickness from 025 at the tip to 050 at the fuel tanks The completed wing assembly is mated to the fuselage tubular structure during final assembly at the Mooney facility Removal of the wing from the fuselage structure is required for most over land type transportation The empennage is of similar construction to the wing A main spar spans the length of the stabilizer Ribs connect the main spar to the stub and rear spar A stretch formed skin wraps around the leading edge ribs and attaches to the rear spar on top and bottom The elevators are constructed of formed aluminum sk ns fastened to a spar extrusion at the leading edge and riveted together at the trailing edge The vertical stabilizer is constructed around a fabricated main spar assembly with ribs connecting the main and rear spar stretch formed aluminum skin wraps around the leading edge ribs and is riveted to the rear spar on both sides The rudder is constructed of formed aluminum skins fastened to a spar extrusion HUCK FASTNER PRE DRILLED SIZE 2LPH T5 No 26 147 IN ALPPH T6 No 18 1695 IN R3001 T6 No 18 1695 IN 2LA426H T5 No 26 147 IN R3007 T6 3 16 187 IN M20J MOONEY AIRCRAFT CORPORATION the leading edge and riveted together at the trailing edge Belly skins are connected to fuselage bulkheads S N 24 0001 thru 24 1417 and are removable for access to various components and controls located between the firewall and the rear spar T
168. to 070 in NOSE GEAR BUNGEE SPRING FIGURE 32 6 MECHANICAL DOWN STOPS A 560252 001 Fixed Stops Use one dn stop 560252 003 Fixed Stops on each side as 560252 005 Fixed Stops required Use 560252 007 Fixed Stops existing hdw 560252 009 Adjustable use 011 shim Stop NOTE Tube assemblies are allowed 010 in per foot bend allowance B With gear fully extended select down stop of proper thickness to give 050 100 clearance B 12 98 M20J SERVICE AND MAINTENANCE MANUAL between down stop and end of barrel nut C Fig 32 7 NOTE Use 1 to 4 560252 11 shims with 560252 009 MECHANICAL DOWN STOP FIGURE 32 7 stop to achieve proper clearance as an alternate for 560252 001 003 005 or 007 C Actuator ball nut C Fig 32 7 D 560252 011 shim use with 560252 009 only maximum of 4 E AN515 6R screw AN936A6 Lock Washer Typ 2 pic use with 560252 009 only Use 063 longer screws with each additional shim Secure screw with Blue Locktite 83 31 grade C 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 The main gear preload torque should not exceed 325 inch Ib using the torque wrench shim stock procedure after electrical extension NON AVIONICS PRODUCTS ACTUATOR 24 0001 thru 24 0377 1 Raise aircraft on jacks refer to Section 7 10
169. together Excessive heat created prior to conditioning will carburize the lining material and prevent the attainment of maximum braking coefficient 2 BRAKES BREAK IN PROCEDURES Proper conditioning may be accomplished as follows 12 98 3 MASTER CYLINDER 24 0001 thru 24 3200 24 3202 thru 24 3217 A Remove left hand exhaust cavity B Disconnect hydraulic cylinder from 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 complete piston rod assembly itern 3 thru 12 3 Remove spacer 11 and O ring packings 10 and 12 from piston and assembly 4 Disassemble piston rod assembly by removing roil pin 4 spring guide 3 will be pushed out by spring 5 when roll pin is removed spring 5 and piston 7 5 Remove O ring packing 6 from piston 8 Remove stat o seal 8 from piston rod 7 Clean all parts with cleaning Solvent Federal Specification No PS 661 8 Inspect cylinder for cracks scoring or grooves in bore 9 Inspect piston 7 for damage check for nicks and scratches 10 Inspect spacer 11 for damage 11 Inspect push rod for scoring grooves nicks and scratches 12 Inspect piston return springs 2 for perma
170. 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 RATE OF CLIMB INDIGATOR TROUBLE SHOOTING VERTICAL SPEED INDICATOR TROUBLE PROBABLE CAUSE REMEDY Pointer does not set on zero Aging of diaphragm Turn setting screw to reset pointer at zero Tap instrument while resetting Pointer fails to respond Obstruction in static line Disconnect static line from instruments Includes water Apply low pressure air 10 25 PSI max to instrument end of static line Check both static ports for air flow Depress static drain valve and check for water Keep depressed until air is free of moisture Reconnect static line to instruments and leak check Pointer osciliates Leaks in static line Disconnect all instruments connected to the static line Check individual and test installation for eaks Defective mechanism Replace instrument 34 13 00 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 barometric pressure This co
171. torque is factory set to provide the correct terminal stud seal preload H Other nuts on the electrical terminals should be tightened as foliows 6 Ibs 8 12 in Lbs 10 14 in Ibs 28 42 00 FUEL QUANTITY INDICATOR Two fuel quantity gauges are in ihe instrument cluster gauge These gauges indicate pounds or gallons of fuel remaining Each gauge operates by the change in resistance of two transmitters located in the fuel tanks tank rib and one on wing tank rib The transmitters 28 43 00 FUEL QUANTITY ADJUSTMENT are electrically connected to the fuel gauges in the PROCEDURE cluster gauge and work in Senes with each other 28 43 01 FUEL TANK TRANSMITTER 1 rue yk eet Removal ADJUSTMENT rain fuel fr 3 30 00 TOT en ee AIRCRAFT MUST BE LEVEL TO CALIBRATE I B Transmitter removal FUEL GAUGES 1 Remove Pilot or Co Pilot seat as needed NOTE 2 Remove interior panel LH or RH as needed See Section 24 33 00 for low fuel calibration 12 98 28 26 00 11 MOONEY AIRCRAFT CORPORATION PRIOR TO S N 24 1050 approximately 1 Fuel tanks EMPTY 2 Add unusable fuel 1 3 Gal Indicator should read E to 1 2 needle width below E Inboard floats may be adjusted by holding arm near transmitter and bending outer arm do not bend by forcing arm 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 tha
172. tube sleeve Relubricate using MIL G 23827 or MIL G 81322 grease Use a grease needle or other suitable tool to apply grease 4 Reinstall carrier bearing to side of electric pitch trim servo bracket Re tension drive 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 portion of bulkhead Q fuselage Sta 142 6 If bearing block assembly replacement is required refer to following procedures Trim torque tube pitch trim servo assembly should be removed from aircraft to replace bearing block therefore manual trim wheel and electric trim switch should be flagged so inadvertent movement will not occur A Disconnect universal joint located between tailcone bulkhead Sta 142 and pitch trim servo assembly mounting brackets B Disconnect electrical wiring to servo motor at connector C Disconnect ELT harness from connector and any other wiring that may interfere with the removal of torque tube assembly from tailcone 27 50 00 12 D Remove nuts washers bolts screws from upper e pitch trim servo brackets holding brackets to ulkhead E Carefully lift torque tube pitch trim servo assembly up and pull aft end of torque tube from trim 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 co
173. valve if bent replace valve Disassemble and clean Disassemble and clean with crocus cloth Rerig or adjust control system Inspect for burrs and clean Calibrate or replace instrument Refer to engine manual Refer to propeller overhaul manual Repair engine for smooth operation 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 Remove head and replace pilot valve Check rigging and make necessary part replacements MOONEY AIRCRAFT CORPORATION M20J TROUBLE CONT PROBABLE CAUSE Excessive over speeding Wrong governor setting Damaged or wrong gasket between governor base and engine mounting pad Sticky governor pilot or relief valve Erroneous reading tachometer inability to attain positive high High RPM screw adjusted RPM too far IN causing restricted arm travel Surging Excessive propeller bladeseat friction SERVICE AND MAINTENANCE MANUAL REMEDY Reset governor Use test rig if available Install correct new gasket Disassemble clean and check for burrs Replace bent pilot valves Calibrate or replace instrument Remove control arm and rotate one serration clockwise Back out high RPM screw to required maximum RPM One turn equals 27 RPM Examine propeiler hub for cause of friction VA PP 61 40 00 PROPELLER BALANCING Balancing of the p
174. wiping the area with a clean cloth saturated with Methyl Ethyl Ketone CAUTION I Methyl Ethyl Ketone M E K is a flammable liquid and should be used with proper ventilation and the prescribed safety equipment CAUTION Fiberglass components are attacked and deteriorated by the following products Ketone aliphatic esters chlorinated hydrocarbons and slightiy softened by aromatic hydrocarbons STOP DRILL CRACK OUTLINE OF CHAMFER AREA CHAMFER 1 5 EACH SIDE OF CRACK LAMINATE MASKING TAPE THICKNESS 5 51 20 NON STRUCTURAL REPAIR FIGURE 51 20 12 98 51 15 01 19 MOONEY AIRCRAFT CORPORATION 51 15 02 NON STRUCTURAL REPAIR t Apply masking tape over crack on finished surface side 2 Apply wet coat of catalyzed epoxy resin to chamfered surface 3 Apply one layer of 181 fiberglass cloth saturated with catalyzed epoxy resin 4 Add additional plys of 4181 fiberglass cloth saturated with epoxy resin to attain original laminate thickness 5 Apply one additional ply of 181 cloth bridging the total repaired area and bond in place M20J SERVICE AND MAINTENANCE MANUAL 51 15 03 COMMON STRUCTURAL LAMINATE REPAIR 1 Cut away laminate per sketch roughen repair area with 240 sandpaper clean repair area with M E K apply a wet coat of catalyzed epoxy resin to surfaces Then IMMEDIATELY perform Steps 2 thru 5 2 Install chemically cleaned 025 T 3 aluminum straps perforated with 40 ho
175. 00 MAIN LANDING GEAR AND DOORS 42 10 01 MAIN GEAR REMOVAL S N 24 0001 thru 24 2999 24 3079 thru 24 TBA 1 Raise aircraft on jacks 2 For S N 24 0084 24 0378 and ON partially retract gear as described in Section 32 60 01 For SIN 24 0001 thru 24 0377 except 24 0084 Partially retract gear by operating the emergency gear extension mechanism in reverse CAUTION ON S N 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 Disconnect gear door links and brake lines Cap all lines and fittings i 4 Remove gear door and mud guard if desired 5 Detach main gear retracting tube V Figure 32 9 from retracting truss G and remove bolts H from retracting truss mounting block NOTE Steps 7 thru 9 apply to 24 0001 thru 24 2999 and 24 3079 thru 24 TBA only 6 Remove grease fittings from forward gear support trunnion shaft bearing 7 Retract the gear by hand until a 2 inch thick wood block C Figure 32 1 can be inserted as shown to hold gear in retracted position A Remove cotter key and nut at spring connecting link F Figure 32 1 B Remove gear retraction spring at F Figure 32 1 by attaching spring installation tool B P N GSE 030012 old P N was 8186 using an AN3 1
176. 00 and remove belly access panels 32 30 04 32 30 04 11 M20J MOONEY AIRCRAFT CORPORATION 2 Partially retract gear Refer to Section 32 10 01 Disconnect main gear retraction tubes L Fig 32 5 at inboard bellcranks M Loosen locknuts E Disconnect nose gear retraction tubes F Fig 32 3 at the retraction bellerank 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 Lubricate retraction system as indicated in Section 5 3 Adjust Heim end bearing on actuator stud so that the Heim threaded end at E is 7 50 inches 4 125 inch from the far end of ball nut C Fig 32 10A NOTE Heim 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 Jocknut and attempt to adjust actuator stud Check distance from the Heim bearing centerline to the face of the actuator Dimension must 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 bearing setscrew and secure Tighten locknut Rotate actuator barrel until ball return or returns on ball nut 250 280 INCH LBS RIGGING RETRACTION Lo TOOL T
177. 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 M20J SERVICE AND MAINTENANCE MANUAL CHAPTER 28 FUEL TABLE OF CONTENTS SUBJECT PAGE General 5 Filler Maintenance 5 Storage 6 Fuel Tank Field Repair 6 Fuel TankLeak Repair 8 Soapless Bubble Fluid Formula Preparation for Leak Check v oe 9 Fuel Additives 9 Distribution 10 Fuel Boost Pump Removal and Installation 10 Selector Valve amp Gascolator Screen Cleaning 10 Fuel Injection System owe Ge 10 Engine Priming 10 Full Selector Vaive Removal and Installation 10 Dump 11 Fuel System Drains 11 Fuel Vents 11 indicating 11 Fuel Quantity Indicating Transmitters 11 Fuel Quantity Indicator 11 Fuel Quantity Adjusiment Procedu re 11 Fuel Tank Transmitter Adjustment 11 Fuel Quantity ore 12 Miscellaneous 12 Trouble Shooting 12 Flared Fittings 13 12 98 28 CONTENTS 3 4BLANK SERVICE AND MAINTENANCE MANUAL 28 00 00 GENERAL Intemally sealed integral fuel tanks are in the forward inboard sections of the wings Fuel feeds from either tank to a selector valve thru a gascolator integral with selector valve 24 0001 thru 24 0377 with low point drain through the emergency pump to the engine driven fuel pump and to the fuel injector syste
178. 00 30 ENGINE INSTALLATION Reverse the engine removal procedure for installation 1 Engine installation torque values are as follows A Spark plugs 360 to 420 Inch Lbs B Hose clamps 10 to 20 Inch Lbs C Engine shock mount bolts 450 to 500 inch Lbs D 1 4 inch upper engine mount to fuselage 5 50 to 70 in Ibs E 10 32 lower engine mount attach block to fuselage 20 to 25 Inch Lbs 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 2 Reinspect to see that Propeiler and spinner are properly torqued B Engine mounting bolis are properiy torqued NOTE Position washers same sequence as when removed C Engine controls are properly rigged and safetied Recheck rod ends for proper threadgrip length D Oil drain plugs are tightened and safetied E Oil sump is filled to eight quarts 12 98 SERVICE AND MAINTENANCE MANUAL F Spark plugs are tight and ignition harness is properly 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 safetied K Cylinder head temperature connection is secure L Tachometer drive is secure if installed M Starter cable connection is secure N Alternator s wiring is secure O Exhaust system is secure P Vacuu
179. 01 LANDING GEAR SYSTEM The electric landing 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 pressure actuated safety switch in the pitot system or a squat switch in the electrical system prevents electric gear retraction on takeoff until a safe flying speed is attained gear throttle warning sounds when the manifold pressure is less than a pre set value with the landing gear up The electric gear retraction system has a manual extension system connected to the gear actuator that permits manual lowering of the gear in the event of an electrical malfunction 5 00 02 FLIGHT CONTROL SYSTEMS The dual flight control systems be operated from either the pilot or co pilot seat All flight controls are conventional in operation using pushpuli tubes to link the control surfaces to the control wheels and rudder pedals Formica guide blocks maintain control tube alignment and dampen vibration An interconnect spring mechanism links the aileron and rudder systems to assist in control coordination 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 electrically act
180. 01 0770437 00 LH11 LAMP HOLDER COCKPIT UTILITY TEK LITE LC 28 5 ss ALT MS1745 51A LH12 LAMP HOLDER BAGGAGE LT WHELEN 01 077 0142 04 LL101A SWITCH LANDING LT MOONEY 880052 521 LL101B SWITCH LANDING LT MOONEY 880052 121 LL102A LIGHT TAXI LANDING LH RH 28V GE 4596 LL103A LIGHT TAXI LANDING LH RH 14V GE 4509 LN101A C B NAV LIGHTS MOONEY 930023 251 LN101B C B NAV LIGHTS MOONEY 930023 351 LN102A LIGHT ASSY WING NAV TAIL MOONEY 800051 501 LP101A DIMMER CONTROL BOX 28V 14v MOONEY ELECT 800299 501 LP102A DIMMER CONTROL BOX 28V MOONEY RHEOSTAT 800299 503 LP103A DIMMER CONTROL BOX 14V MOONEY RHEOSTAT 800299 505 LP104A SWITCH LIGHT ASSY MOONEY 150085 501 LP105A INVERTER PLACARD O H ERG LPS28 3 3P LR101A C B RECOGNITION LIGHT MOONEY 930023 231 LR101B C B RECOGNITION LIGHT MOONEY 930023 331 LR102A RECOGNITION LIGHT MOONEY 880049 501 LS101A C B STROBE LIGHT MOONEY 930023 237 LS101B C B LIGHTS STROBE MOONEY 930023 337 LS102A POWER SUPPLY STROBE WHELEN 01 0770329 00 LS102B POWER SUPPLY STROBE WHELEN 01 0770329 01 LS103A STROBE NAV LIGHT ASSY LH WG WHELEN 01 0770054 12 LS104A STROBE NAV LIGHT ASSY RH WG WHELEN 01 0770054 13 LS105A STROBE TAIL LIGHT ASSY MOONEY 470013 501 LS106A POWER SUPPLY TAIL WHELEN A413A HDA DF 28 LT101A SWITGH TAXI LIGHT MOONEY 880052 523 LT101B SWITCH TAXI LIGHT MOONEY 880052 123 LT102A TAXI LIGHT LT RT GE 4596 MA101A RECEPTACLE AUX POWER AN2552 3A MB101A C B SWITCH AVIONICS MASTER MOONE
181. 04 J3 REV W S N 24 3274 THRU 24 3377 SCHEMATIC NO 800304 44 REV S N 24 3278 THRU 24 3383 SCHEMATIC NO 800304 J5 REV Y S N 24 3284 THRU 24 3392 SCHEMATIC NO 800304 8 REV 2 S N 24 3293 THRU 24 3404 SCHEMATIC NO 800304 27 REV 2 S N 24 3405 THRU 24 3410 SCHEMATIC NO 800304 08 REV CODE DESCRIPTION VENDOR PART NO NOTES ACT1 ACTUATOR MICRO SWITCH JE 5 ACT2 ACTUATOR MICRO SWITCH JV 5 ACT3 ACTUATOR MICRO SWITCH JV 26 ACTUATOR MICRO SWITCH MCD 2711 ACTS ACTUATOR MIGRO SWITCH JE 17 ACT6 ACTUATOR MICRO SWITCH JV 82 AIR101A SWITCH A C MOONEY 880067 501 AIR102A COMPRESSOR A C MOONEY 770028 1 AIR103A EVAP BLWR FAT MOONEY 770002 501 AIR103B EVAP BLWR REAR MOONEY 770002 503 AIR104A CONDENSER BLWR MOONEY 770016 501 AIR105A SWITCH A C PRESS MOONEY 770029 501 BL1 BULB Y GE 1818 HOLDER FOR BL1 HH SMITH 1930 BL2 BULB GE 1816 HOLDER FOR BL2 HH SMITH 1930 BL3 BULB NAV T L WHELEN 84 022 8030 85 BL4 BULB NAV T L WHELEN 34 021 2030 85 BL5 BULB CONSOLE GE 327 ALT GE 385 BL6 BULB COMPASS GE 327 AV RED BL7 BULB POST LIGHT GE 330 BULB ANNUNCIATOR CHI MIN CM7 7730 BL9 BULB ANNUNGIATOR CHI MIN CM7 7327 BR1 CIRCUIT BREAKER 1A KLIXON 7277 2 1 BR2 CIRCUIT BREAKER 2A KLIXON 7277 2 2 BR3 CIRCUIT BREAKER 3A KLIXON 7277 2 3 BR5 CIRCUIT BREAKER 5A KLIXON 7277 2 5 BR7 5 CIRCUIT BREAKER 7 5A KLIXON 7277 2 7 5 BR10 CIRCUIT BREAKER 10A KLIXON 7277 2 10 BR15 CIRCUIT BREAKER
182. 062 1 206153 1 206062 1 206060 1 206062 1 206153 1 206062 1 3060 17 880007 501 880030 501 880045 501 880030 503 880030 505 880031 501 880031 503 880034 501 25 880034 513 PTO06A 10 98S SR PT06A 15 15S SR DE 95 DE 95 7277 2 2 MST215N MS3106A10SL 3S MS30507 4A PDGR821 0662 30 950D031 1 031 206060 1 206062 1 260153 1 206062 1 206060 1 206062 1 260153 1 206062 1 880002 501 3 880039 503 880002 503 880039 501 880039 507 880039 505 MS3106A 148 5S MS3057 6A 011535 011535 880003 501 880035 501 MOONEY AIRCRAFT CORPORATION CODE 21 DP01B DP01D DPO2A DP02B DP03B DR01A DR01B DRO2A DR04A DS01A DTO1A EGO1A EGO1B EGO1C EGO2A EG02B EG04B EGO4C EGO4D EGO4E EGO4F EG04G 5 EG05C EG05D EGOSE EGO5F EGO6A EGO6B EGO6C EG06D EGO7A EGO8C EGO8D EGO8E EGOBF EGO9A EG09B EG10A M20J 14 VOLT ELECTRICAL EQUIPMENT CHART DESCHIPTION C B PITOT HEAT C B PITOT HEAT C B PITOT HEAT HEATED PITOT PITOT HEATED ALT PLUG PITOT HEAT SOCKETS G B TIT CDT GAUGE TIT CDT LIGHTED PLUG TIT CDT INDICATOR PROBE TIT C B TIT CDT PROBE CDT PROBE EGT C B ELEC GEAR C B ELEC GEAR C B ELEC GEAR CONTROL SWITCH CONTROL SWITCH GEAR UP DN SWITGH LIMIT ACTUATOR ACTUATOR GEAR ELEC ACTUATOR GEAH ELEC ACUTATOR GEAR ELEC AGUTATOR GEAR ELEC ACUTATOR GEAR ELEC ACUTATOR GEAR ELEC ACU
183. 10 PITOT amp 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 20 ELECTRICAL AND ELECTRONICS EQUIPMENT RACKS 12 98 INTRODUCTION Page 5 SERVICE AND MAINTENANCE MANUAL M20J MOONEY AIRCRAFT CORPORATION SYSTEM CHAPTER 51 52 53 55 56 57 INTRODUCTION Page 6 SUB SYSTEM TITLE SECTION STRUCTURES 00 GENERAL 10 STRUCTURAL REPAIR GENERAL DOORS 00 GENERAL 10 CABIN DOOR MAINTENANCE PRACTICE 30 BAGGAGE COMPARTMENT DOOR PRACTICE FUSELAGE 00 GENERAL 10 MAIN FRAME 20 AUXILIARY STRUCTURE 30 PLATES SKIN 40 f ATTACH FITTINGS 50 FILLETS FAIRINGS STABILIZERS 00 GENERAL 10 HORIZONTAL STABILIZER 20 ELEVATOR 30 VERTICAL STABILIZER 40 RUDDER WINDOWS 00 GENERAL 20 WINDSHIELD amp CABIN WINDOWS 50 PLEXIGLASS DRILLING WINGS 00 GENERAL 30 PLATES SKINS 40 ATTACH FITTINGS 50 FLIGHT SURFACES 12 98 MOONEY AIRCRAFT CORPORATION SYSTEM CHAPTER NO TAB DIVIDER 61 71 72 73 74 76 CURRENTLY NOT USED 77 SUB SYSTEM SECTION 00 10 20 00 10 00 00 10 20 30 00 10 20 00 10 20 00 10 20 SERVICE AND MANUAL TITLE STANDARD PRACTICES PROPELLERS PROPELLERS GENERAL PROPELLER ASSEMBLY CONTROLLING POWERPLANT GENERAL COWLING ENGINE
184. 109A JM110A JM111A JM113A LA101A LA102A LA103A LA104A LA105A LA106A LA107A LA108A LA109A LA110A LA111A LA112A LA113A LA114A LA115A LB101A LB101B LB102A LB102B LB102C LC101A 91 20 06 100 DESCRIPTION FUSE 1 AMP FUSE 5 AMP 3AG SLO BLO FUSE 10 AMP SLO BLO FUSE 5 AMP FUSE 0 5 AMP FUSE 2 A MP CONTROL IGNITION CABLE MAGNETO LEFT MAGNETO RIGHT SWITCH IGNITION PLACARD LUG TERMINAL M20J VENDOR LITTEL LITTEL LITTEL McGRAW EDISON McGRAW EDISON LITTEL LASAR SLICK LASAR SLICK SLICK LASAR SLICK LAZAR BENDIX SCINTILLA BENDIX SCINTILLA BENDIX SCINTILLA SWITCH IGNITION INCL CONN JANCO MAGNETO ALT ALT PLUG MAGNETO MAGNETO MAGNETO LEFT MAGNETO RIGHT SWITCH IGNITION MAGNETO LEFT MAGNETO RIGHT IGNITION PULSAR MAGNETO L amp R MAGNETO L amp R MAGNETO L amp R OPT LIGHT BULB 28V LIGHT BULB 14V LIGHT BULB LIGHT BULB LIGHT BULB LIGHT BULB LIGHT BULB LIGHT BULB LIGHT BULB LIGHT BULB LIGHT BULB LIGHT BULB LIGHT BULB LIGHT BULB LED C B SW BEACON WHITE G B SW BEACON BLACK BEACON ROTATING ADAPTER BENDIX SCINTILLA BENDIX SCINTILLA LYCOMING BENDIX SCINTILLA SLICK SLICK SLICK BENDIX SCINTILLA SLICK SLICK MOONEY TCM BENDIX TCM BENDIX CHICAGO MINI CHICAGO MINI GE GE GE GE GE GE GE PACIFIC PREC PROD MOUSER MOONEY MOONEY WHELEN WHELEN LIGHT ANTI COLLISION RED WHELE
185. 11 Depress brake pedals to check for sponginess Resistance should be solid and even when brake pedals are depressed 12 20 06 CLEANING Cleanliness is a major prerequisite to adequate inspection and maintenance of an aircraft Cleanliness enhances the appearance of an aircraft and reduces the probability of corrosion 1 EXTERIOR A Before washing aircraft exterior cover brake discs pitot head and static ports 12 20 05 6 M20J MOONEY AIRCRAFT CORPORATION B Flush away loose dirt and mud C Wash exterior with a mild aircraft detergent in cool water and a soft cleaning cloth or chamois Rinse away soap film 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 oxidation film use a pre wax cleaner E Apply an exterior finish wax recommended for protection of urethane enamel Apply a heavy coating of wax to leading edges of wings empennage and nose section to reduce drag and abrasion CAUTION When fuel hydraulic fluid or other fluid containing dye is spilled on painted surfaces remove it at once to prevent staining Fiush away spilled battery electrolyte immediately with water Trea
186. 13 Servicing Cleaning 13 12 98 30 CONTENTS 3 4BLANK SERVICE AND MAINTENANCE MANUAL 30 00 00 GENERAL The M204J aircraft incorporates an alternate air system that is designed to open automatically any time the air intake system becomes blocked This aircraft includes as standard equipment a heated pitot tube assembly and may also include an optional electricaily operated propeller de ice system 30 30 00 PITOT DESCRIPTION AND OPERATION A standard heated pitot tube is located on the left wing at Wing Station No 145 The pitot heat circuit breaker Switch located on the panel in front of the pilots right knee supplies power to the pitot tube heating element 30 60 00 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 ihe de ice boots in cycles controlled by a timer The ON OFF switch is located on the switch panel in front of ihe 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 controled by the timer This is normal operation The timer is
187. 15A KLIXON 7277 2 15 BR20 CIRCUIT BREAKER 20A MECH PROD 4200 002 20 BR25 CIRCUIT BREAKER 25A MECH PROD 4200 002 25 BR30 CIRCUIT BREAKER 30 MECH PROD 700 001 30 BR35 CIRCUIT BREAKER 35A ETA 41 2 814 LN2 35A BR40 CIRCUIT BREAKER 40 ETA 41 3 S34 LN2 40A BR50 CIRCUIT BREAKER 50A ETA 41 2 S34 LN2 50A BR70 CIRCUIT BREAKER 70A ETA 41 3 S14 LN2 70A BRSW3 C B SWITCH KLIXON 7270 5 3 BRSW7 5 C B SWITCH KLIXON 7270 5 7 5 BRSWB C B SWITCH KLIXON 7270 5 8 BRSW10 C B SWITCH KLIXON 7270 5 10 BRSW15 C B SWITCH KLIXON 7270 5 15 BRSW25 C B SWITCH KLIXON 7270 5 25 12 98 91 20 05 81 SERVICE AND MANUAL GODE BS1 BUS2A BUS2B BUS2G BUS3A BUS3B BUS3C BUS4A BUS4B BUS4C BUSSA BUSSB BUSSC BUSSD BUS6A BUS6B BUS7A BUS8A BUSBB C1 CAP1 CAP2 CAP3 CB101A CC101A CC102A CC103A CC103B CC103C CF101A CF102A CF103A CF108A CLO3A CLO3B CLO3C CLO4A CLO6A CLOSA CLOSB CLOSC CLOSD CL15A CL17A 91 20 05 82 M20J ELECTRICAL EQUIPMENT CHAHT DESCRIPTION RELAY BASE BUSS BAR 2 PLC BUSS BAR 2 PLC BUSSBAR BUSS BAR 3 PLC BUSS BAR 3 PLC BUSS BAR 3 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 CAPACITOR CAP WHITE CAP BLACK CAP DUST BLOWER DEFROST MOTOR COWL FLAP INDICATOR
188. 178A DJ179A DJ180A DJ181A DK101A DK102A DK150A DK151A DK152A DK153A DK154A DK155A DK175A DK176A DK177A DK178A DK179A DK180A DL101A DL102A DL102B DL102C M20J 28 VOLT ELECTRICAL EQUIPMENT CHART DESCRIPTION VENDOR PROPE OIL TEMP MOONEY WASHER PROBE OIL TEMP PORSCHE XDUCR OIL PRESS MOONEY PLUG OIL PRESS CLAMP CABLE XDUCER OIL PRESS DRUCK PLUG OIL PRESS 4 PIN AMP CLAMP AMP RECPT OIL PRESS 4 PIN AMP CLAMP AMP XDUCR OIL PRESS DRUCK ALT KULITE AMPLIFIER OIL PRESS AI PLUG 4 PIN AMP CLAMP AMP RECPT 4 PIN AMP CLAMP AMP PLUG 4 PIN AMP CLAMP AMP RECPT 4 PIN AMP CLAMP AMP XDUCR FUEL PRESS MOONEY PLUG FUEL PRESS XDUCR C B FUEL OIL PRESSURE KLIXON INDICATOR FUEL OIL PRESS PENN AIRBORNE PLUG FUEL OIL PRESS ITT CLAMP ITT LOCK RETAINER ITT XDUCER FUEL PRESS DRUCK PLUG FUEL PRESS 4 CLAMP AMP RECPT FUELPRESS 4PIN CLAMP AMP XDUCR FUEL PRESS DRUCK ALT KULITE AMPLIFIER FUEL PRESS PLUG 4 PIN AMP CLAMP AMP RECPT 4 PIN AMP CLAMP AMP PLUG 4 PIN AMP CLAMP AMP RECPT 4 PIN AMP CLAMP AMP TACHOMETER POINTS TACHOMETER MOONEY TACHOMETER MOONEY TACH RPLCMT FOR DL102B MOONEY B amp D 12 98 880009 501 AN900 10 or MS35769 11 933 606 002 00 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 950D031 1 003 206060 1 206062 1 206153 1 20
189. 2 Aircraft File Inspection 5 20 03 EngineFunctional Check 52004 First25 Hours Inspection 5 20 05 50 Hour inspection 5 20 06 100 Hour inspection Annual 5 20 07 Access Cover Identification ad ten QQ cub 21 Lubrication and Service Guide 12 98 PAGE m Q 01 cn 5 CONTENTS 3 4BLANK P PPS SNS Y SERVICE AND MAINTENANCE MANUAL M20J 5 00 00 GENERAL AIRCRAFT DESCRIPTION The M20J series of aircraft are four place high performance single engine low wing monoplanes The all metal airframe has a tubular steef cabin frame covered with nonstructural aluminum skins a semi monocoque tailcone and a full cantilever laminar flow wing Control surfaces have structural spar construction with stressed skins riveted to the spars and ribs Dual control wheels 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 tricycle landing gear having a 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 pivots vertically about its attaching points 5 00
190. 2 2B 9 Position main retraction bellcrank A so that center of forward hole in the left outboard arm of bellerank is 1 56 inches from forward face of fuselage truss at F S 33 Fig 32 10B detail A NOTE This dimension may vary to permit connection of the retraction tubes with zero preload at bolt hole 10 With main reiraction bellcrank A held in position turn actuator barrel nut until rod end bearing aligns with hole in bellcrank install connection bolt at N Fig 32 10B 11 Position bellcrank C Fig 32 2 so center of attach pin D in top leg is 1 35 inches from bottom side of spar cap E This will be the starting position when landing gear is in down and locked over center with out any preload set 12 Adjust retraction tube V Fig 32 9 at rod end wnitl it will connect to bellerank C Fig 32 2B with zero preload install connection boit 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 connection boit hardware 14 Disconnect retraction tube V at bellcrank C 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 landing gear actuator C B IN 16 Turn Master Switch ON 17 Extend main gear actuator to fully extended position Make certain lugs on main retract bellcrank do no contact fus
191. 2 98 M20J MOONEY AIRCRAFT CORPORATION A Adjust right and left inboard linkage at rod end bearing 1 Figure 27 14 to obtain a flap deflection of 33 0 2 Retract flaps to 0 2 Set flap outboard travel stops not illustrated so that flaps align with aileron while in neutral position WING FLAP ADJUSTMENT FIGURE 27 14 B Retract flaps to 15 19 and set flap position indicator cable B at attachment screw 2 Figure 27 15 to TAKEOFF position as shown on flap position indicator in cabin This indicates the degree of flap deflection from 0 to 335 with a 15 takeoff setting C The limit switches 3 Figure 27 15 should be adjusted so that under flight loads the actuator over 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 for any rolloff during flap operation POSITION ADJUSTMENT 24 3218 thru 24 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 accomplish this A Rig flaps per para 2 A amp B above B Extend flaps to TAKEOFF position 15 1 C Adjust switch stack until bottom Micro Switch just opens
192. 2 modules for 24 volt systems M20J MOONEY AIRCRAFT CORPORATION 30 69 00 ALIGNMENT OF SLIP RING To check alignment of slip ring assembly securely attach a dial indicator to the engine and place the pointer on a slip ring see Figure 30 5 Grasp the propeller blade and rotate it slowly noting the 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 reciprocating engines within any 4 inches of slip ring travel 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 uniform push or pull on the propeller to hold this error to a minimum If the slip ring run out is within the limits specified no corrective action is required if it is not within the limits check for dirt on the ring gear mounting surfaces clean and recheck alignment If run out is still out of tolerance return the slip ring assembiy to the 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 ihe brushes free of dirt oil grease and carbon build up will prevent those contaminants from being transferred to the slip ring QP ENG ALIGNMENT SLIP RING FIGURE 30 5 12 98 30 69 00 13
193. 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 systern 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 comes on Gear preload 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 afier electric extension may exceed the values obtained after manual extension 17 When gear rigging is completed check over center locks on all gears to ascertain that none of the down lock bungee springs have compressed to solid height and have no remaining deflection 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 S N 24 3000 thru 24 3078 1 Raise the aircraft on jacks and r
194. 205839 3 CLAMP 206070 1 21 PL77A PLUG XPDR ENCODER AMP 20037 1 KFC 200 CLAMP AMP 206070 1 21 PL78A PLUG RADIO PKG CABLE 206037 1 CLAMP 206070 1 21 PL79A PLUG NAV REC A P K 4 C 2 205839 3 CLAMP 206070 1 21 C B IGN TACH CIG LIGHTER MERIDEN AHWA 10 21 501 C B IGN TACH CIG LIGHTER KLIXON 7977 2 10 21 PS02A SWITCH STARTER MICRO 2D72 HOUSING MICRO 2M1 SCREEN DISPLAY MICRO 2J5 RING GUARD MICRO 2K6 21 PS03AB RELAY C H 6041H105A R B MOONEY 940020 501 22 21 PS04A STARTER PRESTOLITE MZ4206 ALT PRESTOLITE MZ4218 ALT PRESTOLITE MZ4222 21 PS04B STARTER PRESTOLITE MCL 6501 39 ALT LYCOMING LW15572 21 PS05A DIODE SARKES TARZIAN F 4 91 20 01 12 98 MOONEY AIRCRAFT CORPORATION CODE 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 21 506 RCO1A RCO1B 2 RC02B RC03B RCO4A RC04B RC05B RC05C RCOSA RCO7A RC07B RC08B RC10A RC11A RC11B RC12A RC13A RC13B HC14A RC14B RC14C HC15A RC16A DESCRIPTION FUSE HOLDER FUSE RECPT C B PNL CLAMP RECPT C B PNL CLAMP RECPT FLT PNL 1 CLAMP RECPT FLT PNL 1 HECPT ELEC GEAR CLAMP RECPT ELEC GEAR HECPT L WING CLAMP RECPT L WING RECPT L WING CLAMP RECPT L WING STUB CLAMP RECPT L WING STUB HECPT SQUAT SWITCH CLAM
195. 206036 3 CLAMP 206070 1 JKL RCO7A RECPT CLUSTER GAUGE 16 PIN AMP 206036 3 CLAMP 206070 1 JKL FIREWALL 1 19 MS3100A22 14P CLAMP MS3057 12B JKL RC08B RECPT FIREWALL 1 19 PIN MS3100K22 14P ALT MS3100KE22 14P IPM CLAMP MS3057 12B or 12A JKL RECPT RT WG 14 PIN MOONEY 930021 2 JKL RC09B RT WING 20 PIN MOONEY 930021 502 JKL RC10A RECPT RT WING STUB 14 PINMOONEY 930021 2 JKL RC11A RECPT LT WG 14 PIN MOONEY 930021 002 JKL RC12A RECPT FIREWALL 2 19 PIN MS3100A22 14P CLAMP MS3057 12B JKL RC12B RECPT FIREWALL 2 MS3100K22 14P ALT MS3100KE22 14P CLAMP MS3057 12B or 12 JK RC13A RECPT RT RADIO PNL 9 PIN AMP 206705 1 CLAMP AMP 206966 1 JKL RC13B RECPT AVIONICS MASTER 4 PIN AMP 206153 1 mE CLAMP AMP 206062 1 JK RC14A RECPT HOUR METER 4 PIN AMP 206153 1 CLAMP AMP 206062 1 JKL RC15A RECPT LEFT WING STUB 14 PIN MOONEY 930021 002 JKL RC16A RECPT GEAR CONTROL AMP 206705 2 mE CLAMP AMP 206966 1 JKL RC17A RECPT ELECTRIC GEAR MOONEY 930021 002 JK HC18A RECPT DIMMER 16 PIN AMP 206036 3 CLAMP AMP 206070 1 JKL RC18B RECPT PNL LT DIM 1 14 PIN AMP 206044 1 CLAMP AMP 206070 1 JKL RC19A RECPT A S SWITCH 2 4 PIN AMP 206153 1 CLAMP AMP 206062 1 JKL RC20A TAILGONE 16 PIN AMP 206036 3 CLAMP AMP 206070 1 JK RC21A RECPT TAILCONE 16 PIN AMP 206036 3 GLAMP AMP 206062 1 JK 22
196. 206060 1 206062 1 206153 1 206062 1 C 11 S 1028 amp S 1029 7277 2 7 5 7277 2 7 5 933 602 007 07 933 602 007 07 CA3108A 20A 48S B 03 CA3106A 20A 485 B 15 933 612 440 00 TXR18AB45 C2012Al 2900AA1912A 5034 000 202C621 51 164 2028142 25S 106 20 485 15 933 612 440 01 TXR18AB45 C2012AI 52900 1912 5034 000 202 621 51 164 2028142 25S CA3106E 10SL 3P B 14 933 612 409 071 TXR18AB00 C1104A S2900AS06044A1 S034 000 2900AS1004AI S034 000 3292 202S121 25S CA3106E 10SL 3P B 14 933 612 409 01 TXR18ABOO C1104AlI 52900 80504 5034 000 2900AS1004AI S034 000 3292 2028121 25S MOONEY AIRCRAFT CORPORATION M20J SERVICE AND MAINTENANCE MANUAL 28 VOLT ELECTRIGAL EQUIPMENT CHART CODE DESCRIPTION L JE162B VENDOR PART NO NOTES PLUG IGN COIL LT CANNON GERMANY CA3108E 10SL 4S B 14 L JE162B PLUG IGN COIL LT PORSCHE 933 612 407 01 TINEL LOCK ADAPTER RAYCHEM TXR18ABOO C1104AI ADAPTER ALT SUNBANK S2900AS0504Al S034 000 ADAPTER ALT SUNBANK S2900AS1004Al S034 000 oe COUPLING SUNBANK 83292 BOOT 2025121 258 L JEt63B PLUG IGN COIL RT CANNON GERMANY CAS106E 10SL 4S B 14 L JE163B PLUG COIL RT PORSCHE 933 612 407 01 TINEL LOCK ADAPTER RAYCHEM TXR18AB00 C1104Al ADAPTER ALT SUNBANK S2900AS0504A1 S034 000 ADAPTER ALT SUNBANK S2900AS1004Al S034 000 COUPLING SUNBANK S3292 BOOT RAYCHEM 2028121 258 L 164 IGNITION COIL
197. 25 70 0 EMPENNAGE STATIONS EMPENNAGE STATIONS FIGURE 6 4 6 00 03 12 98 8 MOONEY AIRCRAFT CORPORATION M20J SERVICE AND MAINTENANCE MANUAL CHAPTER 7 LIFTING AND SHORING SERVICE AND MAINTENANCE MANUAL CHAPTER SECTION SUBJECT 7 Effectivity Contents 7 10 00 7 10 00 CHAPTER SECTION SUBJECT 7 10 00 M20J CHAPTER 7 LIFTING AND SHORING LIST OF EFFECTIVE PAGES PAGE 1 2BLANK E 0 4 TABLE OF CONTENTS SUBJECT Jacking 12 98 MOONEY AIRCRAFT CORPORATION DATE 12 98 12 98 12 98 PAGE 7 EFF CONTENTS 1 2BLANK MOONEY AIRCRAFT CORPORATION 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 GAUTION Do not place jack directly on propeller de icing boots Cushion with a layer of 3 8 inch thick hard rubber or equivalent 1 Install jack points in tiedown mounting holes outboard of each main gear 2 Use standard aircraft jacks at both wing hoist points wing tiedown eyebolt receptacles outboard of the main gears While holding jack point in place raise jack to firmly contact jack point 3 Use a yoke frame jack under propeller to lift the nose 12 98 M20J SERVICE AND MAINTENANCE MANUAL 4 Raise aircraft keeping wings as nearly level as possible 5 Secure safety locks on each jack CAUTI
198. 250 Shock Absorber 100 Shock Discs 50 Control Surface Hinges E 100 Propeller 100 Starter Drive Thy Es Aiternator Drive Beit Each Flight Cowi Flap Motor and Indicator Cable 100 Remote Compass Sender 100 Strobe Light Power Suppiy 100 ELT Transmitter 28 Volt 0 100 Speedbrake Cartridges 1000 LUBRICATION SYMBOL LEGEND MIL SPEC NO DESCRIPTION MIL L 7870 Low Temperature Oil General Purpose MIL G 81322 Grease Avionics Products MIL L 3545 Grease High Temperature MIL H 5606 Hydraulic Fluid Red MIL G 23827 Graphite amp MIL G 3278 Grease or MIL G 23827 12 98 Powdered Graphite Teflon Spray Tri flow or equivalent SERVICE AND MAINTENANCE MANUAL M20J MOONEY AIRCRAFT CORPORATION SYMBOL MIL SPEC NO DESCRIPTION Stick Lubricant Door Ease or Equivalent Lubriplate 630AA 10 by Volume Molybdenum Disulfide Mixture Permissible Seal Dressing Inspect TEXTRON Lycoming Spec No 301F Mineral 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 r Graphite and Kerosene Lubriplate 797 Aeroshell Grease 7 On jackscrew and inside Actuator Bearing Housing MIL T 27730 Tetra fluoroethylene s 2 k 5 Permacel Tape Corp MIL G 23827 MOBIL 27 GREASE Dukes VISCOSITY C
199. 2A boit E Remove grease fitting prior to using tool 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 trunnion shaft mounting block assembly at stub spar 32 00 00 SERVICE AND MAINTENANCE MANUAL M20J MOONEY AIRCRAFT CORPORATION 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 following rigging procedure should be used when reinstalling them A Disconnect outboard gear doors at the forward and aft linkages B Fig 32 2 B Raise gear electrically to the full up position C Forward leading edge and aft trailing edge of the inboard gear door should be tight against the wing skin and fair with the aft bubble fairing Spacers A Figure 32 2 should be added or removed as required to obtain a good fit with no binding or distortion with the gear in the UP position AN960 10 washers may be used as spacers 4 Reconnect outboard gear doors and check that the forward edge of outboard gear doors are faired 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 aft linkages as requ
200. 30 01 5 MOONEY AIRCRAFT CORPORATION RUDDER ASSEMBLY FIGURE 55 4 55 40 02 12 98 6 AIRCRAFT CORPORATION M20J SERVICE AND MAINTENANCE MANUAL CHAPTER 56 WINDOWS SERVICE AND MAINTENANCE MANUAL M20J MOONEY AIRCRAFT CORPORATION CHAPTER 56 WINDOWS LIST OF EFFECTIVE PAGES CHAPTER SECTION SUBJECT PAGE DATE 56 Eff Contents 4 2BLANK 5 12 98 56 00 00 3 12 98 56 22 00 4 12 98 56 50 00 5 12 98 56 50 00 6 12 98 TABLE OF CONTENTS CHAPTER SECTION SUBJECT SUBJECT 00 lt PAGE 56 00 00 General 3 560001 um Cleaning Acrylic 3 56 20 00 Windshield and Cabin Windows 3 56 21 00 Windshield 3 56 21 01 k k k k Windshield Removal 3 56 21 02 Windshield Installation 3 96 22 00 Cabin Windows x 4 56 22 01 05 5 o5 k K k Cabin Windows Removal 4 56 22 02 Cabin Windows Installation 4 56 28 00 Storm Windows 4 56 50 00 Acrylic Drilling 4 12 98 56 EFF CONTENTS 1 2BLANK MOONEY AIRCRAFT CORPORATION 56 00 00 GENERAL The windshield for the M20J is 187 inch thick acrylic heat formed to contour The pilots side window is also 187 inch thick acrylic with a hole cut out to accommodate the 312 i
201. 33 000 A 8970Bi A 8970B1 A 8970B1 A 8970B1 830 330 AVIATION BLUE 330 AVIATION BLUE 830 AVIATION BLUE 330 AVIATION BLUE 330 AVIATION BLUE DEA 90020 DEA 90020 313001 155020 or 155120 206060 1 206082 1 206153 1 206062 1 930023 231 880044 001 1 480318 0 60619 1 880049 001 1 480318 0 60619 1 930023 007 930023 107 207 A490 T14 701295 3A 880018 501 880028 507 880028 505 ALT 880017 503 ALT A429 701303A 880019 501 702000 1 880021 501 880038 501 702000 3 880017 501 SERVIGE AND MAINTENANGE MANUAL 14 VOLT ELECTRIGAL EQUIPMENT CHART NOTES 28 31 29 32 29 30 31 29 34 30 29 34 91 20 01 17 SERVICE AND MANUAL M20J MOONEY AIRCRAFT CORPORATION CODE 21 21 21 21 21 21 21 21 21 21 21 21 91 20 01 18 LS03E LS04A LS04B LS04C L504D LSO4E LS04F LS05A L505B LSO5C LSO6A LS06B LS06C LS06D LSO7A LS07B LS08A LS09A MAO1A MA02B MA04A MBO1B MBO2A MB02B MBOSB 4 MB04B MBO5A MB05B MBO6B MB07A MB07B MB08B MB10A 11 12 14 VOLT ELECTRICAL EQUIPMENT CHART DESCRIPTION VENDOR PART NO NOTES CABLE ASSY STROBE LWG MOONEY 880017 503 PWR SUPPLY STROBE R WG WHELEN 490 T14 31 P S STROBE R WG SDI 701295 3A MOONEY 880018 501 29 34 P S STROBE R WG MOONEY 880028 507 30 CABLE ASSY R WG SDI
202. 34A LP35A LP36A LP37A LP38A LP39A LP40A LP41A LP42A LP43A LP44A LP45A LRO1A LRO2A LRO3A LRO4A LROSA LS0iA LSO1B D LS02A LSO2B 1502 LS02E LS02F LS03A LS03B LS03B LS03C LS03D DESCRIPTION LIGHT POST M P LAMP LIGHT POST TACH LAMP LIGHT POST CLOCK LAMP LIGHT POST OAT LAMP HOLDER OXYGEN LIGHT LAMP BUSS RADIO LIGHT POST LIGHT POST LIGHT POST LIGHT POST LIGHT LAMP LAMP CLUSTER 41 LAMP CLUSTER 2 LAMP CLUSTER 3 LAMP CLUSTER 4 LAMP CLUSTER 5 CONNECTOR MALE CONNECTOR FEMALE FUSE 1 HOLDER CONNECTOR PLUG CLAMP CONNECTOR CLAMP C B RECOGNITION LIGHTS RECOG LIGHT LT PLUG RECOG LIGHT LT SOCKETS RECOGNITION LIGHT RT PLUG RECOG LIGHT RT SOCKETS C B STROBE LIGHTS C B STROBE LIGHTS ALT PWR SUPPLY STB LWG PWR SUPPLY STB L WG PWR SUPPLY STB L WG PWR SUPPLY STB L WG CABLE PWR SUPPLY L WG STROBE LITE FLASHTUBE STROBE LITE L WG FLASHTUBE STROBE LT LWG STROBE LT L WG CABLE ASSY STROBE L WG M20J VENDOR GRIMES MOONEY GRIMES GRIMES GRIMES GRIMES GE G E G E G E G E G E DEANS DEANS LITTEL LITTEL AMP AMP AMP AMP MOONEY MOONEY AMP AMP MOONEY AMP AMP MOONEY MOONEY WHELEN SDI MOONEY MOONEY MOONEY MOONEY WHELEN SDI MOONEY SDI MOONEY MOONEY SDI MOONEY 12 98 PART NO A 8970B1 330 8970 1 330 8970 1 330 A 8970B1 330 855S 0 U 330 8002
203. 3H 1109 LON NV SONLA 3v3HS 33 38 SHIHS TIVISNI AMVSS3O3N 4i SHISN31 804 335 53015 701941 H9nONHL 318155322 8 LAN 2 lt 01 lt 9 8 N3HSVM 01 096 9NIM dOL SNIAON38 A8 318155302 4 SNIM 3 AB 314155302 6 INN SZP 9ENY c M3HSVMA 9Lv 096NV 1108 VSL tNV 3GJSNI 3181SS355V 53015 HiOH TvatdAL uv M30VdS S MO c L000L1 ANN 29 9 N3HSVM 919 096NV WING ATTACHING HARDWARE FIGURE 57 1 12 98 57 20 02 MOONEY AIRCRAFT CORPORATION M20J SERVICE AND MAINTENANGE MANUAL LEFT WING SHOWN RIGHT WING OPP SKIN LAP STA 103 5 4 20 7 SCREW C BORE STALL AN345 6 STRIP 406 AN960 6 WASHER i STALL STRIP 06 10 DEEP DRILL 189 193 DIA AN515 8R10 SCREW USE USE 6 75 RIVNUT LOCKTITE TYPE CV TYPICAL INSTL WS 103 5 WS 11825 WS 1330 WS 147 75 WS 163 0 WS 178 25 WS 193 5 WS 210 97 a WS B8 75 WS 1035 AES 5 18 25 d P 3 WING STRUCTURE FIGURE 57 3 12 98 57 20 02 5 SERVICE AND MAINTENANCE MANUAL M20J MOONEY AIRCRAFT CORPORATION 24 1038 THRU 24 2999 24 3000 THRU 24 TBA STROBE LIGHTS 7 AND POWER SUPPLY CONNECTORS 8 WILL VARY SMJS7 4 WING TIP ASSEMBLY 24 1038 THRU 24 TBA FIGURE 57 4 B Drill out rivets 4 holding tip to upper and lower 2 Wing tip
204. 4 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 12 98 M20J SERVICE AND MAINTENANCE MANUAL completely Check for any tire interference as tire enters wheelwell 3 Close throttle and confirm gear hom sounds 4 Inspect gear doors for proper closing Referenc Section 32 10 03 3C 32 10 04 2 D or 32 10 05 1 Lower gear to fully extended position 5 With zero airspeed place gear swiich in UP position Gear hom should sound regardless of throttle position both gear position lights and safety by pass switch will illuminate 6 Push RED gear safety by pass switch and hold IN to partially retract gear 7 Pull GEAR circuit breaker 8 Check nose gear overcenter preload as follows A Measure nose gear bungees Figure 32 6 B Extend gear manually See Section 32 30 04 stopping extension the moment the GREEN Gear Down Light comes ON Gear switch in down position C Measure nose gear bungee springs Deflection from zero load condition in A above must be 030 to 070 inches for each bungee Fig 32 5 010 to 030 inch for M20J with Dukes Actuator P N 1057 00 56 D If spring deflection is not within prescribed limits adjust tube rod ends F Fig 32 4 G in increments of 1 2 tu
205. 4 174 80 3302 Bt DIMBIAS FIGURE 8 TYPICAL FOSITIVE 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 drive from Q14 and DS X dims When the TEST Switch is depressed momentarily DIMBIAS goes low and U9 switches its output high latches through R87 and drives Q14 into conduction When the channel deactivates Q15 opens the return to ground and DIMINPUT rises which returns latch U9 to a high output state 10 0 TYPICAL POSITIVE APPLY W O DIM A typical Positive Apply Non Dimmable circuit is shown in Figure 9 This channel is designed to accept a 28 VDC signal to illuminate an indicator channel but does not provide for dimming of that channel The input YINPUT is applied through CR38 to light DS Y TEST is applied through CR37 to also light DS Y CR 38 YINPUT 1 408065 CR37 1 404005 I FIGURE 9 rYPICAL POSITIVE APPLY WO DI 24 50 00 ELECTRIGAL LOAD DISTRIBUTION 24 51 00 POWER DISTRIBUTION SYSTEM The power bus distributes direct current power to the electrical systern from the altemator and from the battery through the battery relay The negative battery lead attaches to a structural ground on the airframe The master switch ON closes the relay and supplies power to the aircraft electrical system CAUTION
206. 4 95 3 65 M5 2 501 84 5 75 4 24 8 10 5 97 9 70 7 15 4 4 3 1 9 9 7 3 1410 3 18 5 12 1 M7 7 1 5 2 16 5 12 1 23 16 9 2719 9 M8 10 5 7 7 2417 7 34 25 40 29 M10 21 15 48 35 67 48 81 59 M12 36 26 83 61 117 86 2 140 103 M14 58 42 132 97 185 136 220 162 M16 88 64 200 147 285 210 340 250 M18 121 89 25 202 390 287 470 346 M20 171126 390 287 550 405 660 486 M22 230 169 530 390 745 549 890 656 M24 295 217 675 497 960 708 1140840 27 435 320 995 733 14001032 1680 1239 M30 590 435 1350 995 1900 1401 2280 1651 M33 800 590 1830 1349 2580 1902 3090 2278 M36 1030 759 2360 1740 3310 2441 3980 2935 M39 1340 988 3050 2249 4290 3163 5150 3798 NOMINAL PROPERTY DIAMETER CLASS Fine Thread TORQUE Ma 8 1 M10 x 1 25 M12 x 1 25 M14 x 1 25 M16 x 1 5 M18 x 1 5 M20 x 1 5 M22x 1 5 M24 x2 xs x gt x gt ss gt gt kaha O q s oah 8 8 10 9 12 9 Nmift Ib Nmift Ib Nmift lb 25 18 35 25 42 30 49 36 68 50 82 60 88 64 125 92 150 110 140 103 195 143 235 173 210 154 295 217 350 258 305 224 4251313 510 376 425 313 600 442 720 531 570 420 800 590 960 708 720 531 1000 737 1200 885 s s s s s s gt gt lt V K M M M A UIEIA Is s METRIC CONVERSION FACTOR One Nm Newton Meter 7375 Foot Pound One Foot Pound 1 355818 Nm 12 98 5 20 01 9 MOONEY AIRCRAFT CORPORATION M20J SERVICE AND MAINTENANCE MANUAL
207. 4 PIN AMP 206153 1 m CLAMP AMP 206062 1 JK DW101A VERTICAL SPEED INDICATOR 7000 CODE C 83 JK EG101A C B GEAR RELAYS KLIXON 7277 2 2 JK EG102A SWITCH GEAR UP DOWN CUTLER HAMMER 8905K2875 JK EG103A SWITCH GEAR OVERRIDE CUTLER HAMMER SB1DDX492 2 RING LOCKING CUTLER HAMMER 29 761 WASHER LOCK CUTLER HAMMER 16 886 MS NUT HEX 2 CUTLER HAMMER 15 966 6 LAMP 28 GE 334 LAMP 14V GE 336 SWITCH ALT NKK CORP DBL2141 3BL BUTTON NKK CORP AT406 LOCKING RING NKK CORP AT406 s LOCK WASHER NKK CORP AT508 NUT 2 EA AT503 LAMP 28V NKK CORP AT604 28 JK EG104A SWITCH AIRSPEED GEAR SAFETY MOONEY 880013 507 JK EG105A C B GEAR ACTUATOR KLIXON 7277 2 7 5 JK EGi06A SWITCH GEAR UP LIMIT MICRO DT 2R A7 MEM ACTUATOR MICRO MCD 2711 JK EG107A SWITCH GEAR DOWN LIMIT MICRO 1CH116 6 JK EG107B SWITCH GEAR DOWN LIMIT ALT SAINT ML1116 JK EG108A PLUG 4 PIN AMP 206060 1 CLAMP AMP 206062 1 JK EG109A RECEPTACLE 4 PIN AMP 206153 1 EN CLAMP AMP 206062 1 91 20 03 12 98 64 OPER SI kuma a MOONEY AIRCRAFT CORPORATION 28 VOLT ELECTRICAL EQUIPMENT CHART M20J SERVICE AND MAINTENANCE MANUAL CODE DESCRIPTION VENDOR PART NO NOTES JK EG110A RELAY GE GEAR UP CUTLER HAMMER 6041 220 JK 111 DIODE 132483 JK EG112A RELAY GEAR DOWN CUTLER HAMMER 6041 220 JK EG113A DIODE 1N2483 JK EG114A ACTUATOR GEAR MOON
208. 4596 4509 930023 251 930023 351 800051 501 800051 509 800299 501 800299 503 800299 505 150085 005 LPS28 3 3P 91 20 06 101 SERVICE AND MAINTENANCE MANUAL CODE LR101A LF101B LR102A LS101A LS101B LS102A LS102B LS103A LS104A LS105A LS106A LT101A LT101B LT102A MA101A MB101A MB101B MC101A MC102A MC103A ME101A ME102A MK101A MP101A MP101B MP102A MP102B MP103A NF101A NF101B NF102A NF103A NF104A NF105A NF106A NF108A NF108B NF109A NF110A 91 20 06 102 DESCRIPTION C B C B LIGHT RECOGNITION CIRCUIT BREAKER CIRCUIT BREAKER POWER SUPPLY STROBE POWER SUPPLY STROBE LIGHT STROBE LT WING LIGHT STROBE RT WING LIGHT STROBE TAIL LIGHT STROBE DUAL SWITCH TAXI LIGHT SWITCH TAX LIGHT BULB LIGHT TAXI LH amp RH RECEPTACLE AUX POWER ALT M20J ELECTRICAL EQUIPMENT CHART VENDOR MOONEY MOONEY MOONEY MOONEY MOONEY WHELEN WHELEN WHELEN WHELEN MOONEY WHELEN MOONEY MOONEY GE C B SWITCH RADIO MASTER WHT MOONEY C B SWITCH RADIO MASTER BLK MOONEY LIGHTER CIGAR CAP amp TETHER LIGHTER SOCKET ALT wWIRE CLOCK ALT CONNECTOR 4 PIN PINS OPT OPT PINS JACK MICROPHONE WASHERS WASHERS MOONEY CASCO CASCO CASCO MID CONT PORSCHE MID CONT MID CONT PORSCHE PORSCHE SWITCHCRAFT SWITCHCRAFT SWITCHCRAFT C B SW PROP DE ICE WHITE MOONEY C B SW PROP DE IGE TIMER PROP DE ICE TIMER PRO
209. 57 10A or 10B 2073 2 7277 2 15 JD1B 50 1049 8309 W67CSX 2 70 303 501 61K 11K3BP WI 7046 501 61K 11K3BP WI 7046 F 4 F 4 206153 1 206062 1 206060 1 F 4 F 4 206705 2 206708 1 206062 1 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 CODE 21 21 21 21 21 21 21 21 21 21 21 21 21 21 PLOGA PLO7A PL07B PLO8A PL08B 09 PL10A PL11A PL11B PL12A PL12B PL13A PL13B PL14A PL14B PL15A PL16A PL16B PL17A PL18A PL18B PL19A PL20A PL21A PL22A PL22B PL23A DESGRIPTION PLUG SQUAT SWITCH CLAMP PLUG CONSOLE t CLAMP PLUG CONSOLE 1 CLAMP PLUG HEADLINER CLAMP PLUG HEADLINER CLAMP PLUG FIREWALL CLAMP M20J VENDOR AMP AMP AMP AMP AMP AMP AMP AMP PLUG L SIDE CABIN MIDDLE AMP CLAMP PLUG FLT PNL 2 CLAMP PLUG FLT PNL 2 CLAMP PLUG GLARESHIELD CLAMP AMP AMP AMP PLUG ANNUNCIATOR PANEL AMP CLAMP PLUG FIREWALL JUNC PNL AMP CLAMP PLUG ACCESS PNL CLAMP PLUG L SIDE CABIN CLAMP PLUG L SIDE PANEL PLUG ELEC FLAPS CLAMP PLUG CONSOLE 2 CLAMP CLAMP PLUG CONSOLE CLAMP PLUG RELAY PANEL CLAMP PLUG CLUSTER GAUGE CLAMP PLUG CLUSTER GAUGE CLAMP PLUG PILOT S WHEEL CLAMP PLUG COPILOTS WHEEL CLAMP PLUG VAC W
210. 59 525 880059 521 880093 501 880093 503 880093 505 880093 507 880093 509 880093 511 880061 501 MS28034 1 1N2483 1N5060 3720 GE 10H3P 5854 5854 FB5001 FB5006 PDCR 821 0662 100 APT 154 1000 100PSIG KA21 014 100G APT 201 1000 100G PDCR 821 0662 30 APT 153 1000 30 PSIG PDCR 920 U143 50 PSID APT 155 1000 50D KA21 016 50D 880039 515 0520 003 0400 004 880039 517 0520 006 0402 102 0402 104 0406 004 0406 003 880039 519 880039 523 420809 420807 880035 507 880035 505 15006 SG 70 85000 15000 gt MOONEY AIRCRAFT CORPORATION CODE DP101A DP101B DP101C DP102A DP103A DP104A DP105A DR101A DR101B DT101A DT101B DT102A DT103A DT104A DT105A DU105A DV101A DV101B DV102A DV102B EG101A EG102A EG103A EG104A ET101A ET102A ET103A ET104A ET105A FH101A FH102A FN101A FN102A DESCRIPTION C B C B C B PITOT HEATED AL PITOT HEATED ALT PLUG SOCKET PROBE TIT PROBE TIT INDICATOR EGT INDICATOR EGT SWITCH EGT 4 POSITION PROBE EGT ALT LIGHT TRAY 28V LIGHT TRAY 14V TRANSDUCER MAP ALT ALT INDICATOR FUEL FLOW OPTIONAL OPTIONAL INDICATOR FUEL FLOW TRANSDUCER FUEL FLOW OPTIONAL TRANSDUCER FUEL FLOW ACTUATOR LDG ALT ALT ACTUATOR LDG ALT ACTUATOR LDG SWITCH AIRSPEED SWITCH ELT PANEL TRANSMITTER ELT CABLE ASSY REMOTE REMOTE UNIT ASSY OPTIONAL
211. 6 Remove gear assembly item 6 from clutch housing item 8 by rotating gear and pulling with slight to moderate pressure 7 Remove two screws item 7 and remove housing item 8 clutch spring item 9 and gear assembly item 10 from actuator body 8 Remove clutch spring item 9 from housing using gear assembly item 6 as removal tool Insert item 6 into spring from flanged end of housing rotate CCW and pull slightly After disassembly clean clutch gear thoroughly Discard removed screws 3 4 CAUTION Use extreme care to prevent ball bearing from dropping out of recoiler assembly avoid damage to gear and do not allow dirt to enter clutch housing bore 9 See 32 30 06 procedure prior to reassembly for additional maintenance if needed ASSEMBLY P N 102000 1 Lubricate gear and new clutch spring thoroughly with lube MIL G 81322 poly lube 2 Using gear to rotate spring insert clutch spring into bore until fully seat d NOTE Be sure spring is all the way in and seated around cam 32 31 03 32 31 03 18 M20J MOONEY AIRCRAFT CORPORATION 3 Reinstall recoiler assembly make sure to fully seat gear bearing and gear tang into manual drive slot of recoiler assembly 4 Apply Loctite Grade A Catalog Number 88 31 not supplied in kit to four new screws supplied and install take care to use the two longest screws in bottom holes of item 5 NOTE Torque to approximately 10 12
212. 6 19 36 26 43 31 M10 22 16 51 37 72 53 87 64 M12 39 28 89 65 125 92 150 110 M14 62 45 141103 198 146 240 177 M16 95 70 215 158 305 224 365 269 M18 130 85 295 217 420 308 500 368 M20 184 135 420 308 590 435 710 523 M22 250 184 570 420 800 590 960 708 M24 315 232 725 534 1020 752 1220 899 M27 470 346 1070 789 1510 1113 1810 1334 M30 635 468 1450 1069 2050 1511 2450 1806 M33 865 637 1970 1452 2770 2042 3330 2455 M36 1111 849 2530 1865 3560 2625 4280 3156 M39 1440 1052 3290 2426 4620 3407 5550 4083 5 20 01 12 98 SERVICE AND MAINTENANCE MANUAL M20J NOMINAL DIAMETER Fine Thread 1 M10 x 1 25 M12 x 1 25 14 1 5 M16x1 5 M18x1 5 M20 x 1 5 M22x1 5 M24x2 s s s sssss s s ss ss x umm T s ss x TIGHTENING TORQUES Electrically Zinc Plated Friction Coeficient 0 125 E ee MOONEY AIRCRAFT CORPORATION METRIC TORQUE TABLES CONTINUED 8 8 Nm ft lb 2719 52 38 95 70 150 110 225 165 325 239 460 339 610 449 780 575 PROPERTY CLASS TORQUE Ma 10 9 Nmift Ib 38 28 73 53 135 99 210 154 315 232 460 339 640 472 860 634 1100 811 12 9 Nmift Ib 45 33 88 54 160 118 250 184 380 280 550 405 770 567 1050 774 1300 958 DIAMETER PROPERTY Coarse Thread CLASS TORQUE Ma 5 6 8 8 10 9 12 9 Nm ft Ib Nm ft ib Nmift Ib Nm ft ib M3 0 56 0 41 1 28 0 94 1 80 1 33 2 15 1 59 M4 1 28 0 94 2 90 2 14 4 10 3 02
213. 6062 1 206060 1 206062 1 206153 1 206062 1 880045 501 MS3106A10SL 3S 7277 2 1 9A1640 DB25S DB51212 1 DB51221 1 PDCR 821 0062 100 PSIG 206060 1 206062 1 206153 1 206062 1 PDCR821 0662 30 APT 153 1000 30PSIG 95000311 001 206060 1 206062 1 260153 1 206062 1 206060 1 206062 1 260153 1 206062 1 880039 511 880039 509 880039 513 880039 517 0520 006 91 20 02 39 SERVICE AND MAINTENANCE MANUAL CODE F JK K JK JK d Ja HEEL c JKL JK JK JK JK JK 91 20 02 40 DL103A DL103A DL104A DL105A DL107A DL108A DL109A DL110A DL150A DL151A DL152A DL153A DL157A DL158A DM101A DM102A DM150A DM151A DM152A DP101A DP101A DP102A DP103A DP104A DP104B DP105A DP108A DP107A DP108A DP150A DP150B DP151A DP152A M20J 28 VOLT ELECTRICAL EQUIPMENT CHART DESCRIPTION VENDOR PLUG TACH TACH SENSOR B amp D TACH SENSOR ALT B amp D RECPT 4 PIN AMP CLAMP AMP PLUG AMP CLAMP AMP TACHOMETER MOONEY TACH GENERATOR MOONEY B amp D CABLE ASSY MOONEY TACHOMETER MOONEY B amp D DIODE RPM FUEL FLOW LT DIODE RPM FUEL FLOW RT INDICATOR RPM FUEL FLOW PENN AIRBORNE PLUG RPM FUEL FLOW ITT CLAMP ITT LOCK RETAINER ITT SENSOR RPM 2 RT PORSCHE SENSOR RPM 1 LT PORSCHE HOUR METER HOUR METER MOONEY HOUR METER AIRPAX RECPT HOUR METER 4 PIN AMP CLAMP AMP PLUG HOUR
214. 6062 1 206153 1 206062 1 G 35 PS6 1 1 R 35 6041H231 6041H105A AHW1 50 700 001 50 41 8 S14 LN2 50 W89CQX 2 MB 4413 6 9811K828 930023 013 930023 113 213 17 28 14 MOONEY AIRCRAFT CORPORATION CODE 21 21 21 PB07B PB07G PB07D PB07E PB07F PB07G PB07H PB07J PB07K PB07L PB09G PB09D PBO9E PBOSF M PB09G PB09J PB09K PBOSL PB10A PB10B PB10G PB11A PB11B PB12A PB12B PB12C PB12D PB12E PB12F PB13A PB13B PB14A PB14B PB14C PB15A PB16A PB20A PB21A PB21B PB21C PB21D 21 PB22A PB23A PB24A PB25A PB26A PB27A DESGRIPTION 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 amp 2 BUSS BAR AUXI 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 ff2 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 F
215. 62C or 3002 will remove corrosion from aluminum and treat the metal surface in one application 20 00 02 SERVICE AND MAINTENANCE MANUAL This paragraph discusses corrosion types and their prevention along with suggested procedures for priming internal airframe 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 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 driving 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 an early stage development local cell corrosion appears as a light whitish powder deposit Surface pits warn of advanced local cell corrosion On painted surfaces the first indication of corrosion will be evidenced by paint blistering 1 Intergranular Corrosion Selective attack
216. 7 are bolted 10 through an outboard rib 8 and bracket 9 on each aileron assembly 57 50 21 AILERON REMOVAL AND INSTALLATION Refer to Section 27 10 00 for removal and installation procedures AILERON ASSEMBLY FIGURE 57 7 12 98 57 50 20 9 SERVICE AND MAINTENANCE MANUAL M20J MOONEY AIRCRAFT CORPORATION BLANK 57 50 21 12 98 10 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 so DATE 60 Eff Contents 12BLANK 12 98 60 00 00 _ ou oo ou eod a as xS C 4 24 12 98 60 00 6060 ee SS xo re 1908 TABLE OF CONTENTS CHAPTER SECTION SUBJECT SUBJECT PAGE 60 0000 General ov o so o v v o ox vo vo o v 3 12 98 60 EFF CONTENTS 1 2BLANK MOONEY AIRCRAFT CORFORATION 60 00 00 GENERAL The standard M20J aircraft has a McCauley Propeller controlled by a governor for constant RPM settings at the pilots discretion An option for the M20J is a Hartzell Propeller with Q Tip blades Each propeller has its own matching spinner assembly Repairs may be made to metal propellers in accordance with AC 43 13 1 and in conjunction with the definitions of
217. 7 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 10 57 50 11 57 50 20 57 50 21 M20J CHAPTER 57 WINGS LIST OF EFFECTIVE PAGES PAGE 1 2BLANK m TABLE OF CONTENTS SUBJECT General Wing Removal and Installation Stall Strip Installation Main Frame hx Auxiliary Structures Jack Points Wing Tips Plates Skin Attach Fittings Flight Surfaces Flaps oo so Flap Removal and Installation Ailerons Aileron Removal and Installation 12 98 DATE 12 98 12 98 12 98 12 98 12 98 12 98 12 98 12 98 12 98 PAGE WWW WW Ww MOONEY AIRCRAFT CORPORATION 57 EFF CONTENTS 1 2BLANK MOONEY AIRCRAFT CORPORATION 57 00 00 GENERAL The all metal wing is a one piece assembly attached to the fuselage at structural hard points with structural hardware See Section 53 40 01 The full span main spar assembly is connected to the stub spar and rear spar assembly by ribs doublers and skins The main landing gear forward attach assembly is an integral part of the main spar and the rear fitting is bolted to the stub spar assembly The spar caps are 7075 T6 aluminum and the webs ribs and doublers are 2024 T3 T4 or T42 aluminum Repair of these components is covered in Section 51 13 00 Moided wing tips S N 24 1038 and ON are fabricated nm composites and house the navigation and strobe ights
218. 72 649283 G 243 880052 501 880052 101 880052 527 880052 127 RG24 11M RG24 15 1 480349 0 1 480318 0 03 06 1023 7021 4 MS3106A 24 9S 1 380303 0 206037 2 MS3106A 10SL 3S MS3106A 28 6P PWFO6F08 33B 01 2020 245 01 2020 244 206060 1 MS3106A 32 17S 1 480424 0 PWO6F8 4S 53106 148 55 BVD06E0205SN MS3106A 28 22S MS3106A 20 15S MS3106R 20 15S 205838 1 97 20 06 103 SERVICE AND MAINTENANCE MANUAL ELECTRICAL EQUIPMENT CHART CODE PLOSA PLOSB PLO9C PL09D PLOSE PL14A PL14B PL14C PL15A 16 PL17A PL20A PL20B PL20C PL25A PL25B PL26A PL28A PL32A PL34A PL34B PL37A PL37B PL50 104 PS101A PS102A PS103A PS104A PS105A HB101A RB102A RG02A RCO2C HCO2D RCO2E RC03B RG03G RC03D RC04A RC04B RC04C RC04D RC05B RC06A RCO9A RC09B 09 09 RC12A HC14A 91 20 06 104 DESCRIPTION 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 C B START POWER C B START POWER STARTER M20J ALT STARTER M20K amp M20R ALT STARTER M20M BLOWER RADIO BLOWER RADIO REGEPTAGLE 1 PIN RECEPTACLE 2 PIN RECEPTACLE 2 PIN MALE RECEPTACLE 2
219. 8 12 98 12 98 PAGE 9 EFF CONTENTS 1 2BLANK MOONEY AIRCRAFT CORPORATION 9 00 00 GROUND HANDLING 9 10 00 TOWING 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 properly inflated When no towbar is available or when assistance in moving the aircraft is required push by hand 1 on the wing leading edges and 2 on the inboard portion of propeller blades adjacent to the propeller hub Towing by tractor or other powered equipment is not recommended CAUTION Exercise care not to turn the nose wheel past its normal swivel angle of 14 degrees either side of center Exceeding the turn limits shown on the turn indicator may cause structural damage Maximum allowable damage to nose gear leg assembly is 1 32 inch dent 9 20 00 WARMUP AND TAXIING Before attempting to warmup or taxi the aircraft ground personnel should be checked out by qualified pilots or other responsible personnel 1 Start and warmup engine Refer to Pilots Operating Handbook 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 coordinator during turns 5 Check engine instruments for sluggish response to engine control movements 12 98 M20J SERVICE AND MAINTENANCE MANUAL
220. 80005 501 660110 000 880005 503 880005 501 680110 000 880005 503 880005 501 660110 000 660109 003 01 005 78 880005 503 880005 501 880005 503 880005 501 880005 503 880005 501 880005 503 880005 501 880005 503 880005 501 880005 503 880005 501 7277 2 1 91 20 03 63 SERVICE AND MAINTENANCE MANUAL M20J MOONEY AIRCHAFT CORPORATION 28 VOLT ELECTRICAL EQUIPMENT CHART CODE DESCRIPTION VENDOR PART NO NOTES JK DV102A INDICATOR FUEL FLOW MOONEY 880034 501 JK DV102A MOONEY 880034 503 ALT MOONEY 880034 505 ALT INDICATOR F F GAL SHADIN 912021 ALT LBS SHADIN 912023 JK DV102B INDICATOR F F OPT GAL SHADIN 912041 4 ALT LBS SHADIN 912043 4 ALT LITER SHADIN 912047 4 ALT GAL SHADIN 912081 5 ALT LBS SHADIN lt 912083 5 ALT LITER SHADIN 912087 5 JK _ DV103A PLUG 9 PIN ITT CANNON DE 9S 2 CLAMP ITT CANNON DE 24657 2 LATCH ASSY 2 ea ITT CANNON DE 51224 1 2 JK DV103B PLUG 9 PIN ITT GANNON 95 3 CLAMP ITT CANNON DE 24657 3 LATCH ASSY 2 ea ITT CANNON D 110278 3 JK DV104A TRANSDUCER FUEL FLOW MOONEY 880030 501 ALT MOONEY 880030 503 JK DV104B TRANSDUCER FUEL FLOW 680501B JK DV105A PLUG 4 PIN AMP 206060 1 CLAMP AMP 206062 1 JK DV108A RECEPTACLE 4 PIN AMP 206153 1 CLAMP AMP 206062 1 JK DV107A SWITCH FUEL FLOW 7101 JK DV108A PLUG 4 PIN AMP 206060 1 CLAMP AMP 206062 1 JK DV109A RECEPTACLE
221. 8A JK SB109A JK SB110A SB111A JK SB112A JK SB113A JK SB114A JK SB115A JK SB116A JK SB1i7A 91 20 03 74 DESCRIPTION RECEPTACLE 32 PIN CLAMP PIN PIN BOOT ALD RECEPTACLE 32 PIN CLAMP PIN PIN BOOT ALT RECEPTACLE 6 PIN ALT CLAMP ALT RECEPTACLE 14 PIN RECEPTACLE 16 PIN CLAMP RECEPTACLE 14 PIN RECEPTACLE 4 PIN CLAMP RECEPTACLE AUDIO CLAMP C B SPEED BRAKE SWITCH SPEED BRAKE PLUG 3 PIN SOCKET RECEPTACLE 3 PIN PIN RELAY SPEED BRAKE DIODE ALT ALT PLUG 4 PIN ALT RECEPTACLE 4 PIN CLAMP PLUG 8 PIN CLAMP RECEPTACLE PIN CLAMP MOTOR LEFT SWITCH DEPLOY LIMIT SWITCH RETRACT LIMIT SOLENOID CLUTCH PLUG 8 PIN CLAMP RECEPTACLE 8 PIN CLAMP PLUG 8 PIN M20J 28 VOLT ELECTRICAL EQUIPMENT CHART VENDOR MATRIX SCIENGE MAT SCI MAT SCI MAT SCI MAT SCI MAT SCI MAT SCI MAT SCI MAT SCI MAT SCI MAT SCI MAT SCI MOONEY AMP AMP MOONEY AMP AMP AMP AMP KLIXON PRECISE FLT AMP AMP AMP AMP PRECISE FLT GE AMP AMP AMP AMP AMPM AMP AMP AMP PRECISE FLT PREGISE FLT PRECISE FLT PREGISE FLT AMP AMP AMP AMP AMP AMP 12 98 MOONEY AIRGRAFT GORPORATION PART NO NOTES 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 M53057 16B
222. 9 25 STA 24 50 INDEX SKIN MATERIAL NO THICKNESS 12 0 025 2024 T 3 CLAD 1 0 020 a 2024 T 3 CLAD 14 0032 2024 T 3 CLAD 15 0 040 b 2024 T 3 CLAD 16 0 040 8 2024 3 CLAD 17 0 016 a 2024 T 3 CLAD 18 0050 2024T 3CLAD 19 Polyester Glass Fiber Reinforced c Top aft flap skin hat section d Top inboard flap skin WING SKIN PANELS FIGURE 20 1 12 98 20 00 00 SERVICE AND MAINTENANCE MANUAL M20J MOONEY AIRCRAFT CORPORATION 14 Je A IC X AN 7 1 E SEDI Fy STA STA STA STA STA STA STA 199 50 164 00 130 00 88 00 53 00 2180 5 00 FUSELAGE SKIN PANELS SM20 2 INDEX SKIN MATERIAL INDEX SKIN MATERIAL THICKNESS NO THICKNESS 1 0 025 2024T 3CLAD 10 0 032 2024T 3CLAD 2 0 040 d 2024 0CLAD 1i 0 032 2024 T 3 CLAD 3 0 025 c b 2024 T 4 CLAD 12 0032 20241 3CLAD 4 0 025 2024T 3CLAD 13 00258 2024T 3CLAD 5 0 025 D 2024T 3CLAD 14 Polyester Glass Fiber Reinforced 6 0 020 2024 T 3 CLAD I 7 0 025 2024 3 CLAD 8 0 032 d e 2024 0 CLAD 9 0 025 2024 3 CLAD a Left side only b Right side only c 0 032 can be used d Heat treated to T 42 condition after forming e Shell FUSELAGE SKIN PANELS FIGURE 20 2 20 00 01 12 98 4 AIRCR
223. 95 KSI 5 Grip in 1 16 ths 8 16 500 MAX HL20 Nominal Dia in 1 32nds 5 32 156 Pin Part Number A REPLACEMENT STANDARD SIZE RIVETS HOLE OVERSIZE This repair applies only to original 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 Head Joint If the edge distance is a minimum of two times the diameter of the original rivet it will be permissible to drill for and install the next standard size larger diameter rivet of the same type and material as the original rivet 3 32 1 8 5 32 ee tr ra ba ag as ee RA 3 Machine Countersink Joint Method II If the edge distance is a minimum of two times the diameter of the original rivet it will be permissible to drill for and install the next standard size larger diameter rivet of the same type and material as the original rivet Do not remachine the countersink After installation mill the excess head height flush with the surface 4 Dimpled Joint If the edge distance is a minimum of two times the diameter of the original rivet it will be permissibie to drill for and install the next 51 10 01 6 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 rivet and the she
224. A Remove two screws 3 Figure 33 6 from the taillight housing that secures the light assembly 5 to the rudder 4 B Remove the clear lens 8 mounting ring 9 and gasket 7 to gain access to position light lamp 6 C Remove lamp 6 with 5 special tool no 203541 or equivalent D Replace with n w lamp and reassemble taillight assembly in reverse sequence 12 98 M20J SERVICE AND MAINTENANCE MANUAL 3 AFT POSITION LIGHT 24 3000 thru 24 TBA A Remove two screws that secure aluminum cover 1 ip 2 Refer to Figure 33 7 5 33 POSITION LIGHT 24 3000 THRU 24 FIGURE 33 7 Remove clear lens 3 8 gasket to gain access to light bulb 4 C Pull light bulb with special puller if needed D Replace with new lamp amp reassemble light assy in reverse sequence of removal 33 43 00 33 43 01 LANDING TAXI LIGHTS LANDING TAXI LIGHT ADJUSTMENT PROCEDURES WING MOUNTED LANDING TAXI LIGHTS ONLY 1 Position aircraft to face a vertical wall with front of nose wheel 7 ft 6 in from wall Position L H and R H main landing gear at exact distance from vertical wall IE parallel to wall 2 Place four target crosses on vertical wall at the following positions A 36 5 inches up vertical wall from same ground plane aircraft is resting on B 9 85 feet left and right of nose wheel center line C 12 375 inches further outboard on both left and right side of St
225. A 105A 50M V L DA159A SHUNT RIGHT ALTERNATOR EMPRO MLA 70A 50MV L DAI60A FUSEHOLDER LT LOAD SHUNT McGRAW EDISON FHN42A FUSE 5A McGRAW EDISON FMO1 5A L DAISIA FUSEHOLDER LT LOAD SHUNT McGRAW EDISON FHN42A FUSE 5A McGRAW EDISON FMO1 5A L DA162A FUSEHOLDER LT ALT SHUNT MoGRAW EDISON FHN42A FUSE 5A McGRAW EDISON 5 L DA163A FUSEHOLDER LT ALT SHUNT MCGRAW EDISON FHN42A FUSE 5 McGRAW EDISON FMO1 5A L DAI64A FUSEHOLDER AT LOAD SHUNT McGRAW EDISON FHN42A FUSE 5A McGRAW EDISON FM01 5A L DAI6SA RT LOAD SHUNT McGRAW EDISON FHN42A FUSE 5A McGRAW EDISON FMO1 5A L DAI66A FUSEHOLDER RT ALT SHUNT McGRAW EDISON FHN42A FUSE 5A McGRAW EDISON 01 L _ FUSEHOLDER RT ALT SHUNT McGRAW EDISON FUSE 5A McGRAW EDISON 1 JKL 101 C B TURN COORD KLIXON 7277 2 2 JK DB102A TURN CO ORDINATOR U l 9013CODE N 5 JK DB102B TURN CO ORDINATOR ASTRONAUTICS 303990 028MSC JKL DB103A PLUG TURN COORD MS3106A 10SL 3S CABLE CLAMP MS3507 4A 4 L DB150A TURN COORDINATOR Ul i 9551B CODE N 541 JK DC101A TEMP PROBE MOONEY 880010 503 L DC150A C BOILTEMP CHT KLIXON 7277 2 1 151 TEMP IND PENN AIRBORNE 9A1630 L DCI52A PLUG CHT OIL TEMP ITT DB258 CLAMP ITT DB51212 LOCK RETAINER ITT DB51221 1 L 0 153 SWIT
226. A RECPT ROLL SERVO CABLE AMP 206705 2 CLAMP 206966 1 21 RC58A RECPT AZIMUTH CABLE AMP 206705 2 CLAMP AMP 206966 1 21 RC59A RECPT AVIONICS DIM AMP 206036 3 CLAMP AMP 206070 1 21 RC59B A P DIM 206153 1 CLAMP AMP 206062 1 21 HC60A RECPT K 4 C 2 NAVREC A P 206152 1 CLAMP AMP 206070 1 21 RC61A RECPT K 14 NAVREG A P 206152 1 CLAMP AMP 206070 1 21 RC62A RECPT K 14 NAVREG A P 206036 3 CLAMP AMP 206070 1 21 RC63A A P TRANSFER 206036 1 CLAMP AMP 206070 1 21 RC64A RECPT K 2 K 3 NAVREC A P 206152 1 CLAMP AMP 206070 1 21 RC65A RECPT TRIM RELAY 205841 2 CLAMP AMP 206062 1 21 RC66A RECPT TRIM SW 205841 2 CLAMP AMP 206062 1 21 RC67A RECPT AZIMUTH 206705 2 CLAMP AMP 206966 1 21 RC68A RECPT ADF RMI 205841 2 CLAMP AMP 206062 1 21 RC69A RECPT TRIM RELAY 205841 2 206062 1 21 RC70A RECPT PWR 206153 1 CLAMP AMP 206062 1 21 RC71A RECPT A P RELAY 206152 1 CLAMP AMP 206070 1 21 RC72A RECPT VOR GS TRANSFER 205841 1 GLAMP AMP 206062 1 21 RC73A RECPT MKR INVERTER 205841 1 CLAMP AMP 206062 1 21 RC74A RECPT NAVREC A P 206152 1 CLAMP AMP 206070 1 91 20 01 12 98 30 MOONEY AIRCRAFT CORPORATION CODE 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 RC75A
227. AFT CORPORATION M20J SERVICE AND MAINTENANCE MANUAL 18 EMPENNAGE SKIN PANELS INDEX SKIN MATERIAL NO THICKNESS 8 0 025 2024 T 3 CLAD 9 0020 2024 T 3 CLAD 10 0032 2024T 3CLAD 11 Polyester Glass Fiber Reinforced 12 0020 2024 T 3 CLAD 13 0 025 2024 T 3 CLAD 8 Heat treated to T 42 condition EMPENNAGE SKIN PANELS FIGURE 20 3 INDEX SKIN MATERIAL NO THICKNESS 1 0025 2024 T 2 CLAD 2 4 60 025 2024 T 3 CLAD 3 0 025 2024 T 3 CLAD 4 0 025 2024 T 3 CLAD 5 0025 2024 T 3 CLAD 6 0 020 2024 T 3 CLAD 7 0 025 2024 T 3 CLAD 20 00 02 CORROSION DETECTION amp PREVENTION Most metallic fabrication materials are susceptible to corrosion Corrosion may occur on aircraft in any climate but it will be a problem more often in climates where the aircraft is exposed to salt air or high humidity or where there are industrial contaminants in the atmosphere The aircraft should be inspected frequently to detect and correct corrosion before serious damage occurs 12 98 Any form of corrosion should be removed at once If it is necessary to remove paint only an approved aircraft paint remover such as Eldorado PR 3400 Eldorado Chemical Co Inc 6700 Lookout Road P O Box 32101 San Antonio TX 78216 should be used Paint removing substances left in metal crevices will cause further corrosion Turco 26
228. AIR LIGHT DIMMER SW BOX RHEOSTAT TRANSISTOR TRANSISTOR ALT FUSE RECEPTACLE M20J VENDOR IAI CHICAGO MINIATURE IAI CHICAGO MINIATURE MOONEY CHICAGO MINIATURE MOONEY MOONEY CHICAGO MINIATURE MOONEY MOLEX MOLEX MERIDEN KLIXON MOONEY WHITMAN GENERAL WHITMAN GENERAL KORRY GE KORRY GE KORRY GE SARKES TARZIAN SARKES TARZIAN ELECTRO DELTA MICRO MICRO CHERRY MOONEY ALLEN BRADLEY RCA RCA McGRAW EDISON AMP 12 98 PART NO 500D0038B CM7 7330 500D0038 007 CM7 7330 880025 501 CM7 7330 880025 515 880025 511 CM7 7330 880025 513 09 50 3121 08 50 106 AHW4 2 7277 2 2 880012 501 P118V IN K5L 1 P118V IN K4L 2 250 650 5821 002 330 250 650 5821 001 330 250 650 5821 009 330 F 4 F 4 FL1 V3 1 JV 5 E51 50B 8800344 JS1N056P02MA 2N3055 2N3773 FM01 5A 206705 2 MOONEY AIRCRAFT CORPORATION NOTES 20 20 21 21 MOONEY AIRCRAFT CORPORATION M20J SERVICE AND MAINTENANCE MANUAL PON 10 11 12 13 14 15 16 17 19 20 21 22 23 24 25 14 VOLT ELECTRICAL EQUIPMENT CHART NOTES Switch 8906k2876 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 replacement for 004 S N 18928 amp UP are modified Or equivalent Sprague HB1535 Dale MFS 1 2 15K TWX 1 2 W 15k Set for 75 MPH 5 0 65 7 4 KIAS increas
229. ALANCE 18 00 IN TO 24 3039 THRU 24 3200 12 50 IN 24 3202 THRU 24 3217 24 3201 24 3218 THRU 24 TBA UNDERBALANCE 15 50 IN TO 12 50 IN NOTE A C S N 24 1688 THRU UNDERBALANCE 15 50 IN amp 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 amp 504 24 0001 THRU 24 0942 UNDERBALANCE 8 00 IN amp TO lAILERON 5 25 IN 24 0943 THRU 24 1037 UNDERBALANCE 7 23 IN TO 5 25 IN NE 230015 505 amp 506 24 1038 THRU 24 1543 UNDERBALANCE 7 10 IN TO AILERON 24 1545 THRU 24 1551 5 25 24 1544 24 1552 THRU 24 1621 UNDERBALANCE 6 23 IN TO 24 3000 THRU 24 3038 0 00 IN 230015 507 amp 508 24 1622 THRU 24 2999 UNDERBALANCE 6 23 IN TO AILERON 24 3039 THRU 24 3110 0 00 IN 24 3111 TO 24 TBD UNDERBALANCE 5 30 IN TO 0 00 IN 230015 511 amp 512 24 TBD TO 24 TBA UNDERBALANCE 5 30 IN TO AILERON _ e 0 00 IN UNDERBALANCE TRAILING EDGE HEAVY M20J FLIGHT CONTROL SURFACE BALANCE LIMITS FIGURE 27 17 12 98 21 93 01 15 MOONEY AIRCRAFT CORPORATION DISTANCE M20J SERVICE AND MAINTENANCE MANUAL OF HINGE LINE Refer to Figure 27 17 for dimensions amp limits UNBALANCE NOTE is balanced upside down FORCE FIGURE 27 18 DIST
230. AMMETER SHUNT EMPRO MLA 70A 100MV ALT JANCO 8406 70 AMMETER SHUNT EMPRO MLA 150A 100MV ALT JANCO 8406 150 TURN COORDINATOR UNITED INSTRUMENTS 9013 CODE N 5 TURN COORDINATOR ALT ASTRONAUTICS 303990 028MSC TURN COORDINATOR ALT ELECTRO GYRO CORP 1394T100 3Z TURN COORDINATOR ALT UNITED INST 9114 CODE N 21 TURN COORDINATOR UNITED INST 9112 CODE N 9 PROBE CYLINDER 1 924482 1 ALD AN5546 1 USE AN4076 1 ADAPTER INDIGATOR O A T 880059 159 O A T PROBE MOONEY 880004 501 19 98 91 20 05 SERVICE AND MAINTENANCE MANUAL CODE DD103A DF101A DF102A DF103A DF104A DG101A DG102A DG103A DG104A DG105A DG106A DH101A DH102A DJ101A DK101A DK102A PSID DL101A DL102A DL103A DL104A DL104B DL105A DL108A ELECTRICAL EQUIPMENT CHART DESCRIPTION SOCKET 4 PIN FUEL XMTH LH RH VVB FUEL LH O B FUEL XMTR RH O B FUEL XMTR LH RH O B IND INSTRUMENT MODULE M20J VENDOR CINCH JONES MOONEY MOONEY MOONEY MOONEY MOONEY IND INSTRUMENT MODULE MOONEY IND INSTRUMENT MODULE 1 MOONEY IND INSTRUMENT MODULE 2 MOONEY IND INSTRUMENT MODULE MOONEY IND INSTRUMENT MODULE MOONEY PROBE OIL TEMP PROBE OIL TEMP MOONEY TRANSDUCER OIL PRESSURE DRUCK ALT M20M ALT M20J KULITE KULITE TRANSDUCER FUEL PRESSURE DRUCK ALT KULITE TRANSDUCER FUEL PRESSURE ALT IND TACH OPTIONAL SENSOR TACH IND TACH OPTIONAL TACH
231. ANCE 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 repainting the affected control surface A lighter weight can be produced by shaving existing balance weight N poyNaWrs 9s s rr s rr FIGURE 27 19 NOT USED 27 94 00 CONTROL SURFACE TRAILING EDGE NOTE Verify flight control rigging is correct before bending trailing edge 1 Trimming pair of widenose 2 0 3 0 in ViceGrip style pliers may to used to bend the trailing edges as necessary See Figure 27 20 NOTE Glue 1 16 in thick rubber strips to inside of Jaws of ViceGrip pliers to reduce possibility of damage to trailing edges 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 aileron trailing edge down AILERONS DEFLECTION LEFT OR RIGHT ET RUDDER TRAILING EDGE TRIMMING FIGURE 27 20 27 94 00 16 7 070 MAX ALLOWABLE Gee DEFLECTION 08 MAX ALLOWABLE The aileron trailing edge MUST NOT BE BENT UP under any circumstance Any deformed rivets must be replaced after trimming aileron or rudder trailing ed
232. AR SWITCH CABIN LIGHT FWD SWITCH CABIN LIGHT REAR RESISTOR DIM CABIN LT 10 OHM 5W RESISTOR CABIN LT SWITCH MAP LT PILOTS CAP FACE NUT SARKES TARZIAN SARKES TARZIAN RCA McGRAW EDISON OHMITE ALLEN BRADLEY MOONEY MOONEY MOONEY MOONEY DORNE amp MARGOLIN DORNE amp MARGOLIN DORNE amp MARGOLIN C amp K KLIXON BENDIX SCINTILLA BENDIX SCINTILLA BENDIX SCINTILLA BENDIX SCINTILLA BENDIX SCINTILLA BENDIX d SLICK SLICK BENDIX BENDIX SLICK SLICK BENDIX SCINTILLA MOONEY MOONEY MOONEY WHELEN WHELEN LITTEL FUSE LITTEL FUSE LUMINATOR GE GRIMES GE C H CARLING CARLING CARLING CARLING OHMITE DALE C H 12 98 F4 F4 2N2016 FM01 5A FHN42W 4599 181 056 251 150082 009 150082 011 150082 015 150082 013 DM ELT 6 DM ELT 6M DM ELT 8 DM U65 1 7101K 7277 2 2 10 357290 17 10 187 468 10 357210 91 S4LN200 D4LN2021 10 79020 18 6214 6224 S4LN204 10 79020 18 6214 6224 10 176487 121 930023 003 930023 103 28 930023 203 WRML 12 WRM 65 155020 155120 313005 20145 1003 B 3550 89 8144 BK 09 TILC64 1S WH FN TILC64 1S WH FN TILC64 18 WH FN TILC64 1S WH FN 4561 RH 10 5 OHM SA25SCT12 3 SW53AA2 15 1049 3 MOONEY AIRGRAFT CORPORATION GODE 21 21 21 21 21 LCO8A LCOSA LC10A LC11A LC12A LC13A LC14A LC15A LC16A LC17A LC18A LLOIA LLO1B LLO1C D LLO2A LLOSA LLOSB C LL
233. ARATE ALUMINUM BELLY SKINS S N 24 0001 THRU 24 1417 19 19 19 ONE PIECE FIBERGLASS BELLY SKIN S N 24 1418 THRU 84 TOP LEFT WING SMJS7 S 14 BOTTOM LEFT WING WING SKINS AND INSPECTION COVERS FIGURE 57 5 LEGEND FOR FIGURE 57 5 Wing skin 050 thickness fuel tank Wing skin 040 thickness fuel tank Wing skin 040 thickness Wing skin 032 thickness Wing skin 025 thickness Wing skin 025 thickness Fuel tank access Fuel tank filler Control tube guide blocks 10 Wing fuselage attach points 11 OAT probe right wing only 12 Control tube guide blocks and flight timer 13 Pitot post left wing only 14 Strobe light power supply 1 O Qn UN 12 98 15 Aileron beilcrank and control rods 16 Auto pilot servos 17 Gyro compass flux valve one of these depending on installed equipment left wing only 18 Main landing gear retraction spring 19 Elevator and rudder controls rod end bearings bellcranks 20 Retraction Bungee Spring 205 only 21 Speed Brakes if equipped SIN 24 1418 amp ON have a one piece fiberglass belly skin remove for access 57 30 00 SERVICE AND MAINTENANCE MANUAL 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 NOT for routine inspections
234. ARN SW CLAMP PLUG RADIO PWR C B PNL PLUG AUX PWR C B PNL CLAMP 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 PLUG RADIO PWR RELAY PNLAMP CLAMP AMP 12 98 PART NO 206060 1 202062 1 206037 1 202070 1 206060 1 202062 1 206037 1 206070 1 206708 1 206966 1 MS3106A 22 14S MS3057 12B 206060 1 001 206062 1 206037 1 206070 1 206708 1 206966 1 206037 1 206070 1 206060 1 206062 1 206037 1 206070 1 206708 1 206966 1 206037 1 206070 1 930021 001 206037 1 206070 1 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 SERVICE AND MAINTENANCE MANUAL 14 VOLT ELECTRICAL EQUIPMENT CHART NOTES 19 91 20 01 23 SERVICE AND MAINTENANCE MANUAL 14 VOLT ELECTRICAL EQUIPMENT CHART 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 91 20 01 24 CODE PL24A PL24B PL24C PL25A PL25B PL25C PL25D PL26A PL26B PL26C PL27A PL28A PL29A PL29B PL30A PL30B PL30C PL31A PL32A PL33A PL34A PL34B PL35A PL35B PL35C PL35D PL36A DESCRIPTION PLUG CABIN TAIL CONE CLAMP PLUG CABIN TAIL CONE CLAMP PLUG CABIN TAIL CONE CLAMP PLUG R WG CLAMP PLUG R WG
235. ATION T1 13 03 COWL FLAP INDICATOR ADJUSTMENT 24 3000 THRU 24 3410 1 Position the actuator and indicator in the down position 2 Insert cable thru drilled bolt 2 in actuator arm 1 and tighten Reference Fig 71 2 3 Cycle cowl fiaps actuation system a minimum of five times to insure free movement of the indicator 4 Readjust push pull cable wire at actuator arm as required for proper indicator travel and secure COWL FLAP INDICATOR IEW LOOKING INBOARD AT CENTER CONSOLE 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 Position cowl flaps in closed position 2 Adjust cowl flap potentiometer on aircraft to illuminate top bar in display 3 Position cowl flaps to OPEN position 4 Adjust R1 on A D 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 M20J SERVICE AND MAINTENANCE MANUAL 6 Cycle cowl flap system to verify proper movement of indicator 71 30 00 FIRESEALS Firewall fireseals and grommets if removed and replaced for any reason should be sealed after routing the cable or wire assembly rom the engine compartment into the cockpit area After installation cover cable or wire and grommet undemeath the sqan with Coast Pro Seal 700 on engine side of irewall 71 60 00 AI
236. AV 5B M20 239 FIGURE 52 3 12 98 52 31 00 MOONEY AIRCRAFT CORPORATION M20J SERVICE AND MAINTENANCE MANUAL BLANK 52 31 00 12 98 8 SERVICE AND MAINTENANCE MANUAL M20J CHAPTER 53 FUSELAGE MOONEY AIRCRAFT CORPORATION MOONEY AIRCRAFT CORPORATION CHAPTER SECTION SUBJECT 53 Eff Contents 53 00 00 53 30 00 53 30 00 53 40 00 53 40 02 53 40 03 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 M20J SERVICE AND MAINTENANCE MANUAL CHAPTER 53 FUSELAGE LIST OF EFFECTIVE PAGES PAGE DATE 1 2BLAN 12 98 3 12 98 4 12 98 5 12 98 6 12 98 7 12 98 8 12 98 TABLE OF CONTENTS SUBJECT PAGE General E 3 Main Frame g Lr 3 Tubular Structure Frame 3 Tailcone Structure 3 Plates Skins 4 Attach Fittings 6 Wing Attach Fitti 6 Empennage Attach Fittings 7 Main Landing Gear Attach Points 8 Engine Mount Attach Points 8 12 98 53 EFF CONTENTS 1 2BLANK SERVIGE AND MAINTENANCE MANUAL 53 00 00 GENERAL The Mooney M20J forward fuselage is constructed from 4130 chromemolybdenum tubular steel The tubular steel sub assemblies are heliarc welded in fixtures inspected and then assembled into the main cabin fixture and heliarc welded into a cabin enclosure The assembled steel structure is sand blasted and dipped in zinc chromate primer for corrosion protection The tailcone bulkheads formers etc are formed from sheet
237. AVIONICS MOONEY 930023 213 JKL MB109A C B HSI KLIXON 7277 2 XX VARIES JKL MB110A C B COM1 KLIXON 7277 2 XX VARIES JKL MB111A C B NAV1 KLIXON 7277 2 XX VARIES JKL MB112A C B AUDIO KLIXON 7277 2 XX VARIES JKL MB113A C B PHONE KLIXON 7277 2 XX VARIES JKL MB114A C B ADF KLIXON 7277 2 XX VARIES JKL MB115A C B COM2 KLIXON 7277 2 XX VARIES JKL MB116A C B NAV2 KLIXON 7277 2 XX VARIES JKL MB117A C B TRANSPONDER KLIXON 7277 2 XX VARIES JKL MB118A C B ENCODER KLIXON 7277 2 XX VARIES JKL MB119A C B AUTOPILOT TRIM KLIXON 7277 2 XX VARIES JKL MB120A C B RADAR KLIXON 7277 2 XX VARIES JKL MB121A C B DME KLIXON 7277 2 XX VARIES JKL MB122A C B LORAN KLIXON 7277 2 XX VARIES JKL MB123A C B STORMSCOPE KLIXON 7277 2 XX VARIES JKL MB124A C B TELEPHONE KLIXON 7277 2 XX VARIES JKL MB125A C B RMI KLIXON 7277 2 XX VARIES JKL MBi26A C B R NAV KLIXON 7277 2 XX VARIES JKL MB127A C B INVERTER KLIXON 7277 2 XX VARIES JKL MB128A C B STEREO KLIXON 7277 2 XX VARIES JKL MB129A C B PROP DE ICE MOONEY 930023 223 JKL MB131A BUS BAR 10 MOONEY 913127 019 JKL MB132A BUS BAR 11 MOONEY 913127 019 JKL MB133A BUS BAR 12 MOONEY 913127 019 JKL MB134A BUS BAR 13 MOONEY 913127 005 JKL MB135A C B YAW DAMPER KLIXON 7277 2 7 5 JKL MB136A C B RADAR ALTIMETER KLIXON 7277 2 7 5 JKL MB137A C B ARTIFICIAL HORIZON KLIXON 7277 2 5 MB150A AVIONICS BUS BAR 1 MOONEY 913127 73 L MB151A AVIONICS BUS BAR 42 MOONEY 913127 73 MB152A AVIONICS BUS BAR 3 MOONEY 913127 73
238. B 14 PIN MOONEY 930021 001 JKL PL16A PLUG GEAR CONTROL 9 PIN AMP 206708 1 CLAMP AMP 206966 1 JKL PL17A PLUG ELECTRIC GEAR 14 PIN MOONEY 930021 001 JK PL18A PLUG DIMMER 16 PIN AMP 206037 1 CLAMP AMP 206070 1 JKL PL19A PLUG A S SWITCH 2 4 AMP 206060 1 GLAMP AMP 206062 1 JKL PL20A PLUG TAILGONE 16 PIN AMP 206037 1 CLAMP AMP 206070 1 JKL PL21A PLUG HEADLINER 9 PIN AMP 206708 1 DENR CLAMP AMP 206966 1 JKL PL22A PLUG OVERHEAD REAR 4 PIN AMP 206060 1 CLAMP AMP 206062 1 JKL PL23A PLUG GRAND 1 16 PIN AMP 206037 1 CLAMP AMP 27 206070 1 JKL PL24A PLUG 2 16 PIN AMP 206037 1 CLAMP AMP 206070 1 JK PL25A PLUG LIGHT CONTROL 9 PIN AMP 206708 1 CLAMP AMP 206966 1 JK PL26A PLUG G SHIELD HARNESS 4 PIN AMP 206060 1 CLAMP AMP 206062 1 JK PL27A PLUG FLT PNL 2 16 PIN AMP 206037 1 CLAMP AMP 206070 1 JKL PL27B PLUG FLT PNL 2 20 PIN MOONEY 930021 501 JK PL28A PLUG AVIONICS POWER 20 PIN MOONEY 930021 501 JK PL29A PLUG DIM GND 20 PIN MOONEY 930021 501 JK PL30A PLUG DIM GND 4 PIN AMP 206060 1 CLAMP AMP 206062 1 JK PL31A PLUG STANDBY VAC 8 PIN 205838 1 CLAMP 206062 1 JK PL32A PLUG GEAR RELAY 4 PIN AMP 206060 1 CLAMP AMP 206062 1 JKL PL33A PLUG G B PNL 9 PIN AMP f 206708 1 CLAMP 206966 1 JKL PL34A PLUG GRND BUSS 9 PIN AMP 206708 1 TESE 22 CLAMP AMP 206966 1 JKL PL34B PLUG GRND BUSS 16 PIN AMP 206037 1
239. B102A TURN COORDINATOR ULL 9013 CODE N 5 TURN COORDINATOR ALT ASTRONAUTICS 303990 028MSC TURN COORDINATOR ALT ELECTRO GYRO 1394T100 3Z 9114 CODE N 21 TURN COORDINATOR ALT U 12 98 91 20 03 61 SERVICE AND MAINTENANCE MANUAL 28 VOLT ELECTRICAL EQUIPMENT CHART CODE JK JK JK J j J JK 91 20 03 62 DESCRIPTION VENDOR SSS SSS SSS SSS SS SS SS SS SS SS SSS SS SS SLL SSL SSS LS LS SS SS SS SS SS SS SS SS SS SS SSS SS SS SS SSS k DB103A DC101A DD101A DD102A DD102B DD103A DD104A DD105A DD106A DF101A DF102A DF103A DF104A DG101A DG103A DG104A DG105A DH101A DH101A DH102A DJ101A DJ102A DJ103A DK101A DK102A DK103A DL101A DL101A DL102A DL 103A DL103A DL104A DL105A PLUG CABLE CLAMP ALT PROBE CHT CYL 3 ALT C B EGT OAT GAUGE EGT OAT GAUGE 4 PROBE PLUG 8 PIN CLAMP PROBE OAT PLUG 2 PIN SOCKET RECEPTACLE 2 PIN PIN KLIXON MOONEY MOONEY AMP AMP MOONEY AMP AMP AMP AMP TRANSMITTER LT IN BD FUEL MOONEY TRANSMITTER LT OUT BD FUEL MOONEY TRANSMITTER RT IN BD FUELMOONEY TRANSMITTER RT OUT BD FUEL MOONEY C B INSTR MODULE 1 KLIXON MODULE INSTR MOONEY PLUG 28 PIN AMP CLAMP AMP MODULE INSTRUMENT MOONEY PROBE OIL TEMP MOONEY ALT 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 FUEL PR
240. CH CHT GRAY HILL 71AD30 02 2 AJN KNOB RAYTHEON 50 3 1G L DC154A PLUG 16 PIN AMP 206037 1 CLAMP AMP 206070 1 L DC155A RECPT CHT 16 PIN AMP 206036 3 CLAMP AMP 206070 1 12 98 91 20 02 37 SERVIGE AND MANUAL M20J MOONEY AIRCRAFT CORPORATION 28 VOLT ELECTRICAL EQUIPMENT CHART CODE DESCRIPTION VENDOR PART NO NOTES L DCi56A PROBE 1 MS24482 1 L 0 157 PROBE CHT CYL 2 MS24482 1 L DC158A PROBE CHT CYL 3 MS24482 1 L DC159A PROBE CHT CYL 4 MS24482 1 L DC160A PROBE CHT CYL 5 MS24482 1 PROBE CHT CYL 6 MS24482 1 ANS546 1 ALT EITHER REQUIRES AN4076 1 ADAPTER J DD101A OAT EGT KLIXON 7277 2 2 J DD102A GAUGE OAT EGT MOONEY 880001 507 J 001028 GAUGE OAT EGT 4 PROBE OPT B amp D 0230 003 J DD103A PLUG OAT EGT AMP 205838 1 CLAMP CABLE AMP 206062 1 JKL 00104 PROBE OAT 880004 501 L DD150A KLIXON 7277 2 1 L 00151 INDICATOR OAT PENN AIRBORNE 9A1580 L DD152A PLUG OAT ITT DA15S CLAMP ITT DA51210 LOCK RETAINER DA51220 1 J DF101A FUEL QTY LT MOONEY 610242 001 J DFIO3A FUEL QTY I B MOONEY 610242 001 JKL DF102A TRANSMITTER FUEL QTY O B LT MOONEY 610243 003 JKL 4 TRANSMITTER FUEL QTY O B RT MOONEY 610243 001 KL DF105A TRANSMITTE
241. CHART CODE DESCRIPTION 21 21 21 21 21 21 21 21 21 21 21 21 21 21 21 21 21 21 91 20 01 10 DB50A DCO1A DCO1B DC01G DD01A DD01B DDO1C DD01E DD01F DD02A 2 DD02D DDO3A DD03B DD04A DEO2A DEO2B DEO3A DF01A DFO1B DFO2A DFO3A DFO3B DFO4A DGO1A DG01B DG02A T C PROBE CYL HD TEMP PROBE CHT PROBE CHT GAUGE OUTSIDE AIR TEMP GAUGE OAT CAUGE OAT EGT M20J VENDOR MOONEY AIRCRAFT CORPORATION PART NO NOTES i tn i see te te os ee ee UNITED INST STEWART WARNER ROCHESTER MOONEY MOONEY GARWIN INSTR amp FLT RES B amp D INSTRUMENT MOONEY GAUGE OAT EGT LIGHTED MOONEY GAUGE OAT LIGHTED MOONEY PLUG GAUGE CLAMP PLUG OAT EGT AMP CLAMP AMP PLUG OAT CLAMP PROBE OAT PROBE OAT WESTBERG PROBE OAT B amp D INSTR MOONEY C B OAT EGT KLIXON GAUGE CARB AIR TEMP MOONEY GARWIN PLUG GAUGE CLAMP PLUG GAUGE CLAMP PROBE CARB AIR TEMP RICHTER AERO XMTR FUEL QTY LT IB MOONEY XMTR FUEL QTY LT IB MOONEY XMTR FUEL QTY LT OB MOONEY XMTR FUEL QTY RT IB MOONEY XMTR FUEL QTY RT IB MOONEY XMTR FUEL QTY RT OB MOONEY C B CLUSTER GAUGE MERIDEN C B CLUSTER GAUGE KLIXON GAUGE CLUSTER MOONEY FUEL QTY LH MOONEY FUEL QTY RH MOONEY AMMETER MOONEY OIL PRESS MOONEY OIL TEM
242. CONTENTS CHAPTER SECTION SUBJECT SUBJECT lt PAGE 20 00 00 General 3 20 00 01 Skin Specifications 3 20 00 02 Corrosion Detection and Prevention 5 20 0003 o ol Painting 7 12 98 20 EFF CONTENTS 1 2BLANK MOONEY AIRCRAFT CORPORATION 20 00 00 GENERAL This chapter of the manual discusses treatment of metal surfaces for corrosion control and the identification of skin panels for replacement purposes Those who inspect or repair aircraft should consult FAR 43 Maintenance Preventive Maintenance 20 00 01 SKIN SPECIFICATIONS STA 147 75 INDEX SKIN MATERIAL NO THICKNESS 1 0 063 2024 T 3 CLAD 2 0050 2024 T 3CLAD 3 0 040 2024 T 3CLAD 4 0 032 2024 T 3 CLAD 5 0 025 2024 T 3 CLAD 6 0 025 2024 T 3 CLAD 7 0 032 2024 T 3 CLAD B 0 040 2024 T 3 CLAD 9 0 025 2024 T 3 CLAD 10 0 025 2024 T 3 CLAD 11 0 025 2024 T 3 CLAD a Same thickness on top and bottom b Top of wing only M20J STA 103 50 SERVICE AND MAINTENANCE MANUAL Rebuilding and Alteration and Sub Parts A D and E of FAR 65 Certification Advisory Circular 43 13 1 outlines inspection and repair practices acceptable to the F A A Administrator Torque values are shown in SECTION 5 20 01 NOTE Refer to FAA AC 43 4 for CORROSION TREATMENT current revision STA 5
243. CRO SWITCH SWITCH GEAR DN LIMIT MICRO SWITCH SWITCH GEAR DN LIMIT ALT SAINT SWITCH INC RELAY GEAR UP C H RELAY GEAR DOWN C H ACTUATOR LANDING GEAR MOONEY ACTUATOR LDG GR ALT DIODE GEAR UP RELAY LOCK RETAINER ITT DIODE GEAR DOWN RELAY SWITCH REMOTE ELT D amp M SWITCH REMOTE ELT ALT C amp K ELT TRANSMITTER D amp M PLUG ELT AMP CLAMP AMP RECPT ELT AMP CLAMP AMP PHONE JACK SWITCHCRAFT WASHERS SWITCHCRAFT C B IGNITION LT KLIXON C B IGNITION RT KLIXON IGNITION BOX LT PORSCHE IGNITION BOX RT PORSCHE PLUG IGN BOX LT CANNON PLUG IGN BOX LT ALT CANNON GERMANY PLUG IGN BOX LT ALT PORSCHE TINEL LOCK ADAPTER RAYCHEM ADAPTER ALT SUNBANK BOOT RAYCHEM BOOT ALT SUPPLEMENT RAYCHEM PLUG BOX RT ALT CANNON GERMANY PLUG IGN BOX RT ALT PORSCHE TINEL LOCK ADAPTER RAYCHEM ADAPTER ALT SUNBANK BOOT RAYCHEM BOOT ALT SUPPLEMENT RAYCHEM PLUG IGN BOX COIL LT ALT CANNON GERMANY PLUG IGN BOX COIL LT ALT PORSCHE TINEL LOCK ADAPTER RAYCHEM ADAPTER ALT SUNBANK ADAPTER ALT SUNBANK COUPLING SUNBANK BOOT RAYCHEM PLUG IGN BOX COIL RT ALT CANNON GERMANY PLUG IGN BOX COIL RT ALT PORSCHE TINEL LOCK ADAPTER RAYCHEM ADAPTER ALT SUNBANK ADAPTER ALT SUNBANK COUPLING SUNBANK BOOT RAYCHEM 12 98 880013 507 7277 2 15 DT 2R A7 MCD 2711 ICHI 6 ML1116 6041 220 6041H220 560254 503 880037 507 1N2483 DB51221 1 1N2483 DM U65 1 7101K DM ELT 8
244. E MANUAL M20J MOONEY AIRCRAFT CORPORATION ANNUNCIATOR TROUBLE SHOOTING 24 0001 thru 24 3153 con t 16 Both the left low fuel and the right low fuel channels stay dim when they annunciate a low fuel situation or during TEST Q3 Assy A1 defective Q5 Assy A1 defective U2 Assy A1 defective Q4 Assy A1 defective CR22 Assy A1 and CR23 Assy A1 open 17 Neither the left low fuel nor the right low fuel lights during TEST CR1 Assy A1 shorted U1 Assy A1 defective 1 high low vac lamp will not light during TEST but does annunciate a high or low vacuum situation CR14 Assy A1 open 19 The high low vac lamp will not light during TEST or in a high or low vacuum situation Filament of DS5 Assy A2 open Q7 Assy A1 defective 20 Te 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 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 E 22 The high low volts lamp will not light during 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
245. E SHOOTING AIDS When no lights are flashing 1 Check circuit breaker switch 2 To determine power supply or flashtube problems first check the input voltage to the power supply The red and black line should have 14 VDC 24 0001 thru 24 2999 28 VDC 24 3000 thru 24 TBA If no voltage 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 unaffected units to flash Determine defective light and proceed to one light not flashing below When one light not flashing 1 To determine power supply or flashtube problems first check the input voltage to the power supply The red and black line should have 14 VDC 24 0001 thru 24 2999 28 VDC 24 3000 thru 24 TBA If no voltage is present then 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 present across Pin 1 and 3 of ihe power supply If not the power supply has no output and 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 3 Be sure yellow sync wire is insulated and not grounded 33 41 01 POWER SUPPLY UNIT REMOVAL O
246. ECT 79 00 00 79 00 01 79 00 02 79 20 00 79 30 00 79 30 01 79 30 02 79 40 00 CHAPTER 79 OIL LIST OF EFFECTIVE PAGES PAGE 1 2BLANK 3 4 TABLE OF CONTENTS SUBJECT General Oil Filter Removal Oil Filter Installation Distribution Indicating 3 Oil Pressure Oil Temperature Druck Transducer Test Procedure 12 98 DATE 12 98 12 98 12 98 PAGE P O WWW MOONEY AIRCRAFT CORPORATION 79 EFF CONTENTS 1 2BLANK MOONEY AIRCRAFT CORPORATION 79 00 00 GENERAL 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 access door located on top of the engine cowling 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 consumption has stabilized The replacement oil should conform to Lycoming Specification 301F The routine oil change interval is 100 hours however if operating in a dusty environment the interval should be more often NOTE 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 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 in
247. EE SP AB 0 2 5 12 98 24 50 00 M sm 2 98 24 51 00 2 12 08 12 98 24 EFFECTIVITY 1 2BLANK MOONEY AIRCRAFT CORPORATION M20J SERVICE AND MAINTENANCE MANUAL CHAPTER 24 ELECTRICAL POWER TABLE OF CONTENTS CHAPTER SECTION SUBJECT 5 SUBJECT PAGE 2400 00 General 5 24 30 00 222 DC Generation pe 7 5 24 3101 Soo Alternator Charging System Maintenance 5 24 31 02 LL Voltage Regulator Maintenance 5 5 24 31 03 22 5 Auxiliary Power System 6 24 3200 222 Battery Maintenance 7 24 33 00 LL Warming Circuits 7 24 34 00 gt Power Plant Circuits A 8 a Low Battery Starting Procedures 8 24 35 00 Lighting Circuits ar LU g r Og 9 24 36 00 22 Landing Gear Circuits 9 24 37 00 Fuel System Circuits 9 24 38 00 ll Miscellaneous Circuits el dea G 24 39 00 Trouble Shooting Charts 10 24 39 01 NW ap N Altemator Trouble Shooting 10 24 3902 1 RESERVED m wa 742 24 39 03 1 5 Battery Trouble Shooting S x de 24 39 04 Starter Trouble Shooting 18 24 39 05 gt Annunciator Trouble Shooting 7 07 007 ot oco or 24 0001 thru 24
248. ELEMENT SENSOR MICRO SS 37126 K PA119A SENSOR CURRENT MICRO CSLA1GE ELEMENT SENSOR MICRO SS 37126 JK PLUG 9 PIN AMP 206705 2 CLAMP AMP 206966 1 JK PA121A RECEPTACLE 9 PIN AMP 206708 1 CLAMP AMP 206966 1 K PA122A ANALOG CUR SENSOR MOONEY 810088 504 JK PA122A PLUG 16 PIN AMP 206037 1 EAT CLAMP AMP 206070 1 JK PA123A RECEPTACLE 16 PIN AMP 206036 3 CLAMP AMP 206070 1 JK PA124A DIODE 1N2483 ALT 1N5060 ALT GE 3720 GE JK BATTERY GILL G 243 JK PB102A RELAY BATTERY CUTLER HAMMER 6041 202 ALT CUTLER HAMMER 6041 202 JK PB103A DIODE 1N2483 ALT 1N5060 ALT GE 3720 GE JK PB104A SWITCH MASTER MOONEY 880052 501 JK PB105A G B BATTERY ETA 41 3 S34 LN2 041800 JK PB106A C B ETA 41 3 S34 LN2 40A JK PB107A BUS BAR 1 MOONEY 913127 89 JK PB108A BUS BAR 2 MOONEY 913127 75 JK PB109A BUS BAR 3 MOONEY 913127 75 JK PB110A BUS BAR 4 MOONEY 913127 77 JK PB111A BUS BAR 5 MOONEY 913127 77 JK PB112A BUS BAR 6 MOONEY 913127 73 JK PB113A _BUSBAR 7 MOONEY 913127 81 JK PB114A BUS BAR 8 MOONEY 913127 77 12 98 91 20 03 71 SERVICE AND MAINTENANCE MANUAL CODE DESCRIPTION M20J 28 VOLT ELECTRICAL EQUIPMENT CHART VENDOR MOONEY AIRCRAFT CORPORATION PART NO NOTES gt gt gt pk aJa gt gt gt gt
249. EQUIPMENT CHART DESCRIPTION VENDOR BUS BAR 5 PLC MOONEY BUS BAR 6 PLC MOONEY BUS BAR 6 PLC MOONEY BUS BAR 7 PLC MOONEY BUS BAR 8 PLC MOONEY SWITCH C B 3A KLIXON SWITCH C B 7 5 KLIXON SWITCH G B 10A KLIXON SWITCH C B 15 KLIXON SWITCH C B 25A KLIXON CAPACITOR MALLORY CAPACITOR 1000 PF NEWARK BLOWER DEFROSTER MOONEY MOTOR COWL FLAP MOONEY INDICATOR COWL FLAP MOONEY SWITCH COWL FLAP MOONEY SWITCH COWL FLAP J MOONEY SWITCH COWL FLAP MOONEY ACTUATOR FLAP MOONEY INDIGATOR TRIM FLAP MOONEY INDICATOR TRIM FLAP MOONEY INDICATOR TRIM FLAP MOONEY CLAMP 3 14 16 28 PIN AMP CLAMP 3 PIN CLAMP 3 PIN ALT CLAMP 4 8 PIN AMP CLAMP 4 PIN BENDIX CLAMP 5 PIN ALT CLAMP 6 PIN ALT CLAMP 7 PIN CLAMP 9 PIN AMP CLAMP 9 PIN AMP GLAMP 9 PIN RETAINER LOCK ALT 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 LOGK RETAINER CLAMP 25 PIN LOCK RETAINER CLAMP 32 PIN 12 98 PART NO 913127 19 913127 35 913127 79 913127 81 913127 95 7270 5 3 7270 5 7 5 7270 5 10 7270 5 15 7270 5 25 CGS302V050R2C MOONEY AIRCRAFT CORPORATION NOTES 18F2711 TYPE SGAD10 640317 503 880050 505 800242 505 880052 517 12TW1 10 880052 117 750105 501 800242 501 800376 501 800391 502 206070 1 8049 41 4 53057 4 MS3057 4B 206062
250. ER ALERT SPEAKER CABIN ALT SONALERT SWITCH ALT SWITCH DEFROSTER BLWR SWITCH SWITCH UP LIMIT ALT SWITCH DN LIMIT ALT SWITCH SWITCH SWITCH SWITCH ALT SWITCH SWITCH SWITCH SWITCH SWITCH WHITE CAP AKT SWITCH SWITCH MOONEY ARCHER ARCHER BLAUPUNKT MALLORY MICRO SAINT CHERRY MICRO MICRO SAINT MICRO OTTO CONT CARLING MOONEY C H C H ALCO GRAYHILL C H GARLING MICRO MICRO C amp K 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 CARLING SWITCH MOONEY SWITCH CARLING SWITCH SWITCH CROUZET SWITCH CROUZET SWITCH ALCO SWITCH SWITCH NKK SWITCH EATON 12 98 MOONEY AIRCRAFT CORPORATION PART NO BC203 2 880052 531 NOTES 7277 2 3 01265 01384 1N2483 1N5060 3720 GE 01532 01505 01678 800314 501 40 1333C 40 1325 PCx352 SC628 1SE1 T 5 ZS 1009 E51 50B V3 1 DT 2R 47 ML 1409 1 116 6 P6 24014 RC911 VBBOW 880013 507 8906K2875 SA1RV20 MPE 106F C 22 9 71AD30 02 2 AJN 8906K4731 RA911 VBBOW 12TW 10 15PA90 8W MS27753 38 7101K DLB241 W01 L3C AT506M AT503MB SB1DDX492 2 29 761 16 886 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 MOONEY AIRCRAFT CORPORATION CODE S
251. ERNOR CONTROL RIGGING 1 Disconnect propeller governor 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 controi rad from govemor control arm 2 Adjust control arm spring to minimum tension which will return control arm to maximum RPM 3 Push propeller control in cockpit full forward Pull contro back approximately 1 8 inch and lock in this position 12 98 MOONEY AIRCRAFT CORPORATION DRESSED M20J SERVICE AND MAINTENANCE MANUAL SM61 2 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 controi rod end to coincide with ihe governor arm position 6 Attach contro rod end to governor arm and secure 7 Operate the propeller control from cockpit to verify full travel of control arm in both directions high RPM to minimum RPM stop NOTE When propeller control rigging is complete check controls in cockpit to be sure there is 1 8 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 NOTE Vernier controls friction can be adjusted by loosening the lock nut on bac
252. ERVICE AND MAINTENANCE MANUAL 2 Wing installation Installation of the wing assembly is direct reversal of 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 More than 15 degree yaw C More than 30 degree pitch below flight level 2 Place stall strips on leading edge at stations shown on Figure 57 2 attach securely with duct tape for test flights Re position stall strips up or down until aircraft flies to criteria in paragraph 57 00 02 1 A B and C Secure stall strip per installation instructions in Figure 57 2 57 10 00 MAIN FRAME The integral fuel cells shaded area 1 start at wing station 24 5 and continue to the rib at station 74 0 on both wings Reference Figure 57 3 Sealer is applied to all joints on 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 assembly as the skins are 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 splice to the old center section 57 20 00 AUXILIA
253. ERVICE AND MAINTENANCE MANUAL M20J MOONEY AIRCRAFT CORPORATION ELECTRICAL EQUIPMENT CHART RESERVED FOR FUTURE ENTRIES 91 20 06 12 98 108 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 12 98 110 SERVICE AND MAINTENANCE MANUAL M20J MOONEY AIRCRAFT CORPORATION 91 30 00 ELECTRICAL SYSTEM SCHEMATICS SEE ENVELOPES 12 98 91 30 00 111 112BLANK MOONEY AIRCRAFT CORPORATION M20J SERVICE AND MAINTENANCE MANUAL CHAPTER 95 SPECIAL EQUIPMENT MOONEY AIRCRAFT CORPORATION M20J SERVICE AND MAINTENANCE MANUAL CURRENTLY NOT BEING USED 12 98 95 SPECIAL EQUIPMENT 1 SERVICE AND MAINTENANCE MANUAL M20J AIRCRAFT CORPORATION INTENTIONALLY LEFT BLANK 95 SPECIAL EQUIPMENT 12 98 2
254. ESS DRUCK ALT KULITE PLUG 4 PIN AMP CLAMP AMP RECEPTACLE 4 PIN AMP CLAMP AMP TACHOMETER MOONEY ALT B amp D TACHOMETER MOONEY ALT B amp D PLUG 5 PIN CLAMP SENSOR TACH B amp D SENSOR TACH B amp D ALT B amp D PLUG 4 PIN AMP CLAMP AMP RECEPTACLE 4 PIN AMP CLAMP AMP 12 98 MOONEY AIRCRAFT CORPORATION PART NO NOTES MS3106A 10SL 3S MS3507 4A MS3507 4B MS24482 1 1 AN5546 1 1 7277 2 2 880001 507 880001 509 205838 1 206062 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 508 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 PDCHR821 0662 30 APT 153 1000 30PSIG 206060 1 206062 1 206153 1 206062 1 880039 515 0520 003 880039 517 0520 006 MS3106A 14S 5S MS3057 6A B 0400 004 0402 102 0402 104 206060 1 206062 1 206153 1 206062 1 MOONEY AIRCRAFT CORPORATION CODE M20J PART NO SERVICE AND MAINTENANCE MANUAL 28 VOLT ELECTRICAL EQUIPMENT CHART NOTES es Se ees rr emen brer Be dn br are me m a a e Ke SSS SS ee SS SS Rn a ee a SS ee et oe Se Se Se eS Se SSS SS SSS SS SS K JK JK J JK DM101A DM101A DM102A DM103A DM104A DP101A DP102A DP103A DP104A DP105A DR101A DR102A DR102B DR103A DR103B DR104A DT101A DT101A DT102A DT102A D
255. EY 560254 503 ALT MOONEY 880037 507 JK ELT101A TRANSMITTER ELT ARTEX ELT110 4 JK ELT104B TRANSMITTER ELT DORNE amp MARGOLIN DM ELT 8 JK ELT102A RECEPTACLE 12 PIN MOLEX 03 06 2122 PIN MOLEX 02 062103 JK ELT103A SWITCH REMOTE ARTEX 110 416 JK ELT103B SWITCH REMOTE 7101 JK ELT104A PLUG 9 PIN MOLEX 03 06 2092 SOCKET MOLEX 02 06 1103 JK ELT105A PLUG 8 PIN AMP 205838 1 CLAMP AMP 206062 1 JK ELT106A RECEPTACLE 8 PIN AMP 205841 2 CLAMP AMP 206062 1 JK ELT107A PLUG 8 PIN AMP 205838 1 CLAMP AMP 206062 1 JK ELT108A RECEPTACLE 8 PIN AMP 205841 2 CLAMP AMP 206062 1 JK FON101A PHONE JACK SWITCHCRAFT 11 WASHERS SWITCHCRAFT S 1028 WASHERS ALT SWITCHCRAFT 58 1029 JK JM101A SWITCH MAGNETO BENDIX SCINTILLA 10 357210 9 PLACARD BENDIX SCINTILLA 10 187 468 J JM102A MAGNETO BENDIX SCINTILLA D 4LN2021 K JM102A MAGNETO LEFT SLICK 6224 JM102B MAGNETO LEFT BENDIX SCINTILLA 646979 1 CONNECTOR BENDIX SCINTILLA 10 382698 K JM103A MAGNETO RIGHT SLICK 6224 K JM103B MAGNETO RIGHT BENDIX SCINTILLA 646979 1 n CONNECTOR BENDIX SCINTILLA 10 382698 JK LB101A C B BEACON FLASHING MOONEY 930023 243 JK LB102A LIGHT BEACON WHELEN WRLM 24 ADAPTER WHELEN WRM 65 JK LB102A LIGHT ANTI COLLISION WHITEX ALT WHELEN 90033 20 JK LB102B LIGHT ANTI COLLISION RED ALT WHELEN 90033 19 JK LB103A PLUG 3 PIN AMP 1 380303 0 SOCKET AMP 60619 1 JK LB104A RECEPTACLE 3 PIN AM
256. FF or from R to L to OFF will ground out both or either magneto See SECTION 74 00 00 for grounding sequence 74 00 00 3 SERVICE AND MAINTENANCE MANUAL M20J MOONEY AIRCRAFT CORPORATION BLANK 74 30 00 12 98 4 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 M2DJ SERVICE AND MAINTENANCE MANUAL BLANK 76 ENGINE CONTROLS 12 98 2 MOONEY AIRCRAFT CORPORATION M20J SERVICE AND MAINTENANCE MANUAL CHAPTER 77 ENGINE INDICATING SERVICE AND MAINTENANCE MANUAL M20J CHAPTER SECTION SUBJECT 77 Eff Contents 77 00 00 77 10 02 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 71 20 02 CHAPTER 77 ENGINE INDICATING LIST OF EFFECTIVE PAGES PAGE 1 2BLANK s 3 4 TABLE OF CONTENTS SUBJECT General Ranges Power Indicating Tachometer Manifold Pressure Fuel Flow Indicating System Temperature Indicating Exhaust Gas Temperature Cylinder Head Temperature 12 98 DATE 12 98 12 98 12 98 PAGE BARBARA O G MOONEY AIRCRAFT CORPORATION 77 EFF CONTENTS 1 2BLANK MOONEY AIRCRAFT 77 00 00 GENERAL Engine indicating instruments and their sending units transducers probes
257. FFECTIVE PAGES CHAPTER SECTION SUBJECT PAGE DATE 5 5 HM BLANK 12 98 73 00 00 deb Ge BR Ge G 12 98 73 31 01 4 12 98 73 31 01 5 12 98 73 31 02 6 12 98 73 31 03 7 12 98 73 31 04 8 12 98 TABLE CONTENTS CHAPTER SECTION SUBJECT SUBJECT PAGE 73 00 00 General 3 73 30 00 Indicating 3 73 31 00 Fuel Flow System General System Description 3 73 31 01 Panel Mounted Instrument E 3 73 31 02 Fuel Flow Transducer 6 FT 101 SYSTEM ALCOR TRU FLOW SYSTEM s lt Lkw aide Gy L R T ees LIS SHADIN SYSTEM 73 31 03 General Operating Procedures 7 73 91 04 Test Function 8 73 31 05 Troubleshooting FT 401 o 0 c os s 5c 5 5 5 Fuel Management Systems 8 73 31 06 Troubleshooting ALCOR Bock eR Uu Tar uw 24e ud Fuel Management Systems 8 73 50 00 Druck Transducer Test Proedue 8 12 98 73 EFF CONTENTS 1 2BLANK MOONEY AIRCRAFT CORPORATION 73 00 00 GENERAL The engine and its accessories are certificated under TEXTRON Lycoming Type Certificate Refer to Lycoming Operators or Overhaul Manual for specifi
258. GEAR ASSEMBLY ALTERNATOR INSTALL KIT REF 600180 FILTER ALT SENSOR CURRENT REGULATOR VOLTAGE SENSOR CURRENT 110 A SENSOR CURRENT 175 A ALTERNATOR 100A BATTERY SWITCH MASTER SWITGH MASTER SWITCH BATTERY SELECT SWITCH BATTERY SELECT BATTERY 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 4 PIN MOONEY MOONEY AMERICAN PROD ELECTRODELTA MOONEY MOONEY LYCOMING PRESTOLITE LYCOMING PRESTOLITE TCM TCM TCM ELECTRO SYSTEMS LYCOMING MOONEY MOONEY MICRO SW MOONEY KLIXON KLIXON TCM GILL MOONEY MOONEY MOONEY MOONEY CONCORDE AMP MOLEX DEAN AMP AMP AMP 12 98 MOONEY AIRCRAFT CORPORATION PART NO NOTES 930023 245 930023 345 3E1899 1 B 45018 C 40521 930023 211 930023 311 AB163B 8163B 8163A A8163A 10054B A10051D A8152 B VR536 930023 219 800270 501 DGR 2 VR 802 880052 525 880052 503 LW 14367 ALU 6421 LS LW15404 ALY 8420 649280 649172 649123 ES 4009 LS 05 21065 880014 501 800307 501 CSLA1GE 800270 503 7235 1 110 7236 1 175 649304 G 243 880052 501 880052 101 880052 527 880052 127 RG24 11M 1 480318 0 03 06 1023 DEA900020 MS3106A 24 95 1 380303 0 206037 2 MS3106A 10SL 35 53106 28 6 206060 1 MOONEY AIRCRAFT CORPORATION M20J ELECTRICAL EQUIPMENT CHART CODE DESCRIPTION VENDOR PLO4B PLUG 4 PIN PLOSA PLUG 5 PIN PLOSA PLUG 6 PIN
259. H RAM AIR MICRO V3 1 ACTUATOR MICRO JV 5 K WWI102A SWITCH ALTERNATE AR CHERRY E51 508 L WWI150A SWITCH ALTERNATE AR CHERRY E51 508 NOTES 1 Use 1 ea MS35334 21 or MS2898 Alan Bradley internal tooth lockwasher with 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 20 AIRCRAFT CORPORATION 28 VOLT ELECTRICAL EQUIPMENT CHART RESERVED 91 20 02 12 98 MOONEY AIRCRAFT CORPORATION 91 20 03 M20J 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 SERVICE AND MANUAL 28 VOLT ELECTRICAL EQUIPMENT CHART 24 1686 14 thru 24 2999 14 common components 28V amp 14V See 91 20 04 for 14 Volt peculiar components ACTUAL USAGE DETERMINED BY MASTER SCHEMATICS CODE DESCRIPTION VENDOR PART NO NOTES JK CB101A C B DEFROSTER BLOWER gt KLIXON 7277 2 5 JK CB102A SWITCH BLOWER MOTOR CHERRY E51 50B JK CB103A MOTOR BLOWER MOONEY 640317 501 JK CB103B MOTOR BLOWER MOONEY 640317 503 JK CB104A PLUG 2 PIN AMP 14 480318 0 SOCKET
260. HART Average Ambient Air Temperature MIL L 6082 MIL 22851 or SAEJ 1966 All Temperature SAE 15W50 or SAE 20W50 Above 80 Deg F SAE 60 SAE 60 Above 60 Deg F SAE 50 SAE 40 or SAE 50 30 Deg to 90 Deg F SAE 40 SAE 40 0 Deg to 70 Deg F SAE 30 SAE 30 SAE 40 or SAE 20W 40 0 Deg to 90 Deg F SAE 20W 50 SAE 20W50 or SAE 15W50 Below 10 Deg F SAE 20 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 AIRCRAFT CORPORATION 5 20 07 22 M20J BLANK 12 98 SERVICE AND MAINTENANCE MANUAL MOONEY AIRCRAFT CORPORATION M20J SERVICE AND MAINTENANCE MANUAL CHAPTER 6 DIMENSIONS AND AREAS SERVICE AND MAINTENANCE MANUAL M20J 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 CHAPTER 6 DIMENSIONS AND AREAS LIST OF EFFECTIVE PAGES PAGE 1 2BLANK TABLE OF CONTENTS SUBJECT
261. HTS OVERHEAD LIGHTS 12 98 33 21 01 LIGHT BULB REPLACEMENT S N 24 0768 thru 24 3373 1 Remove light cover panel 2 Figure 33 1 from the headliner assembly 1 by removing screws 3 NOTE The front and rear light bulbs are replaced in the same manner 33 00 00 5 SERVICE AND MAINTENANCE MANUAL 2 Remove and replace the bulbs and check for proper operation LIGHT BULB REPLACEMENT S N 24 3374 thru 24 TBA 1 Carefully slide smooth fiat sharp blade under lip of light assembly flange and pop light assembly out of mounting hole Ref Figure 33 1A 2 Disconnect blade terminals from light assembly 3 Hold light assembly body and rotate bulb holder counter clock wise to remove 4 Pull bulb from bulb holder replace with new bulb Reinstall bulb holder 5 Re assemble light assembly into mounting hole 6 Check for proper operation i 33 21 02 CABIN LIGHT SWITCH REPLACEMENT S N 24 0768 thru 24 3373 1 Remove cover 4 from headliner assembly 1 by moving screws 3 holding panel in place Figure NOTE S N 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 require bending of spring tabs to release for removal 3 Disconnect wire connections and replace with new switch Check for proper operation 4 Reassemble panels and ventilation control if applicable to he
262. I MATRIX SCIENCE MAT SCI MAT SCI MAT SCI MAT SCI MOONEY 12 98 913127 75 913127 83 913127 59 800228 501 206037 2 206070 1 206207 1 206070 1 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 86H2232N 8 M85049 52 1 22N 5100 001 0012 5100 001 0020 M83723 86R2232N 8 M85049 52 1 22N 5100 001 0012 5100 001 0020 MS3106A 28 225 8 MS3057 16B MS3057 16A 5100 001 0012 5100 001 0020 930021 501 AIRCRAFT CORPORATION M20J SERVICE AND MAINTENANCE MANUAL 28 VOLT ELECTRICAL EQUIPMENT CHART CODE DESCRIPTION VENDOR PART NO NOTES JK PL229A PLUG 16 PIN AMP 206037 1 CLAMP AMP 206070 1 JK PL230A PLUG 14 PIN MOONEY 930021 001 JK PL231A PLUG 16 PIN AMP 206037 1 CLAMP AMP 206070 1 JK PL232A PLUG 14 PIN MOONEY 930021 001 JK PL233A PLUG 4 PIN AMP 206060 1 CLAMP AMP 206062 1 JK PS101A C B STARTER SOLENOID KLIXON 7277 2 5 JK PS102A SOLENOID STARTER CUTLER HAMMER 6041H202 ALT CUTLER HAMMER 6041H202A JK PS103A DIODE 1N2483 ALT 1N5060 ALT GE 3720 GE j PS104A STARTER PRESTOLITE MHB 4016 ALT LYCOMING LW 15572 K PS104A STARTER TCM 646275 ALT TCM 637847 JK RB101A RADIO BLOWER KLIXON 7277 2 5 JK
263. ICE AND MAINTENANCE MANUAL CHAPTER 55 STABILIZERS LIST OF EFFECTIVE PAGES PAGE DATE 12BLANK 12 98 wd 1 71 12 98 4 12 98 5 12 98 6 12 98 TABLE OF CONTENTS SUBJECT PAGE General Boss 3 Horizontal Stabilizer NE 3 Horizontal Stabilizer Removal 3 Horizontal Stabilizer Installation 3 Elevator AT 4 Elevator Removal 4 Elevator Installation 4 Vertical Stabilizer ELM 4 Vertical Stabilizer Removal 5 Vertical Stabilizer Installation 5 Rudder 5 Rudder Removal 5 Rudder installation 5 12 98 55 EFF CONTENTS 1 2BLANK SERVICE AND MAINTENANCE MANUAL 55 00 00 GENERAL The M20J empennage assembly is a variable 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 horizontal and vertical stabilizer are constructed of formed sheet metal ribs attached to a forward and aft spar assembly covered with stretch formed skins The horizontal stabilizer has a stub spar that spans a portion of the stabilizer The elevator and rudder are constructed from an extruded leading edge spar assembly covered with formed skins The elevators and the rudder have balance weights permanently installed for stabilization during flight HORIZONTAL STABILIZER FIGURE 55 1 55 10 01 E HORIZONTAL STABILIZER REMOVAL The fairing located on the tailcone covering the gap between the tailcone and empennag
264. ID STARTER LT C H 6041H 202 or 202A JK PS103A FUSEHOLDER LITTEL 155020 or 155120 FUSE 1 LITTEL 313001 J PS105A STARTER PRESTOLITE MHB 4016 ALT LYCOMING LW15572 K PS106A STARTER TCM 646275 ALT TCM 637847 JKL PS107A DIODE STARTER SOLENOID LT 1N2483 L PS150A DIODE PWR START LT 1N2483 L PS151A DIODE PWR START RT 1N2483 L PS152A SOLENOID STARTER RT C H 6041H 202 or 202A CER PS153A DIODE STARTER SOLENOID 1N2483 eL PS154A STARTER PORSCHE 933 602 007 03 JKL C B RADIO BLOWER KLIXON 7277 2 2 JKL RB102A RADIO BLOWER TRW 19A2790 JKL 1 FILTER RADIO BLOWER ARCHER 278 103 JKL FILTER RAD BLWR ALT SPRAGUE 5JX5104A JKL C B PNL 1 37 PIN 206151 2 JKL RECPT CONSOLE 1 16 PIN 206036 3 CLAMP AMP 206070 1 JKL RCO2B RECPT CONSOLE 1 28 PIN AMP 206152 1 CLAMP AMP 206070 1 JKL RECPT LEFT SIDE PANEL 20 PIN MOONEY 930021 502 JKL RC03B RECPT LEFT SIDE PANEL 26 PIN MOONEY 930021 506 JKL 4 RECPT FLT PNL 1 26PIN MOONEY 930021 506 JKL RCO5A RECPT A S SWITCH 1 4 PIN 206153 1 CLAMP AMP 206062 1 12 98 91 20 02 55 SERVICE AND MAINTENANCE MANUAL M20J MOONEY AIRCRAFT CORPORATION 28 VOLT ELECTRICAL EQUIPMENT CHART CODE DESCRIPTION VENDOR PART NO NOTES s i JKL RECPT A P POWER 16 PIN AMP
265. IGHT CLUSTER GE 327 JK LP114A LIGHT CLUSTER GE 327 JK LP115A LIGHT TRAY AMMETER B amp D 0221 128 JK LP116A LIGHT TRAY TACHOMETER B amp D 0221 128 JK LP118A LIGHT TRAY AIRSPEED ULL BA28 BW3 JK LP119A LIGHT TRAY TURN CO ORD U l BA28 BW3 JK LP120A LIGHT TRAY ALTIMETER U i BA28 BW3 JK LP121A LIGHT TRAY VERTICAL SPEEDU I BA28 BW3 JK LP122A LIGHT TRAY ARTIFICIAL HORIZON SIGMA TEC IV 192 971 JK LP423A LIGHT TRAY DIRECTIONAL GYRO SIGMA TEC IV 192 971 Je LP125A LIGHT TRAY TIT B amp D 0221 128 JK LP126A LIGHT TRAY EGT OAT B amp D 0221 128 L 5 DIMMER CONTROL BOX JAI 950D0307 000 L LP151A PLUG DIMMER CONTROL BOX ITT DBM17W2S CLAMP ITT DB51212 LOGK RETAINER ITT DB51221 1 RECPT 2 EA ITT DM53744 7 L LPi52A SWITCH PANEL LIGHTS DIMR C amp K 7105 JI Z Q L LP153A SWITCH G SHIELD LIGHTS DIM 7105 J1 Z Q L LP154A LIGHT FLAP SWITCH MOONEY 130285 003 LAMP GE 327 L LP155A LIGHT CONSOLE SWITCH RT MOONEY 130285 003 LAMP GE 327 L LP156A RECPT 9 PIN AMP 206705 2 CLAMP AMP 206966 1 L 1 157 PLUG 9 PIN AMP 206708 1 CLAMP AMP 206966 1 L LP1858A LIGHT CONSOLE SWITCH LT MOONEY 130285 003 LAMP GE 327 L 1 159 PLUG 16 PIN AMP 206037 1 CLAMP AMP 206070 1 L LPi60A RECEPT DIMMER CONTROL BOX AMP 206036 3 CLAMP AMP 206070 1 JKL LR101A C B RECOGNITION LIGHTS MOONEY 930023 231 JKL LR102A RECOGNITION LIGHT LT WG MOONEY 880049 501
266. IGHT BULB REPLACEMENT 1 Instrument panel lights EXTERIOR LIGH SWITCH PANEL INTERIOR LIGHTS MASTER SWITC PILOTS OVERHEAD LIGHT SWITCH RIGHT REAR SEAT PASSENGER S LIGHT SWITCH ON RIGHT SIDE PANEL TYPICAL TO LEFT SIDE PANEL LOCATION FIGURE 33 1A INTERIOR LIGHTS 24 3374 THRU 24 TBA 33 21 02 6 12 98 MOONEY AIRCRAFT CORPORATION INTERIOR LIGHTS FIGURE 33 1 S N 24 0001 THRU 24 3373 A Internally lit instruments 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 orientation 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 D Check for proper operation f 9 Trim Flap Indicator Light Gain access to light assembly 1 Figure 33 2 by reaching in over console side panel 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 fiap 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 i
267. IN AMP PIN AMP PLUG 2 PIN AMP SOCKET AMP C B STROBE LIGHT MOONEY POWER SUPPLY LT WING WHELEN HECEPTACLE POWER SUPPLY AMP PIN AMP RECEPTACLE POWEH SUPPLY AMP PIN PLUG STROBE LIGHT ASSY AMP 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 STROBE NAV LIGHT RT WING WHELEN POWER SUPPLY TAIL WHELEN RECEPTACLE POWER SUPPLY AMP PIN AMP REGEPTAGLE POWER SUPPLY AMP PIN AMP PLUG 4 PIN AMP CLAMP AMP RECEPTACLE 4 PIN AMP CLAMP AMP 12 98 855S 0 U 6 327 330 A350CN1W BK SH28 327 A350CN1W BK SH14 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 60619 1 A650 PR D M 28 01 0770329 00 1 480305 0 60620 1 480305 0 60620 1 1 480303 0 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 MOONEY AIRCRAFT CORPORATION CODE DESCRIPTION M20J VENDOR PART NO SERVICE AND MAINTENANCE MANUAL 28 VOLT ELECTRICAL EQUIPMENT CHART NOTES gt x gt a m a yhN sAH h Oa am s n i
268. INTENANCE MANUAL M20J MOONEY AIRCRAFT CORPORATION CHAPTER 51 STRUCTURES LIST OF EFFECTIVE PAGES CHAPTER SECTION SUBJECT PAGE 0 5 5 DATE S1 Effectivity 42BLAMK 805 5 12 98 S1 Contents 12 98 51 00 00 a x x ko 5 805 c 5 5 ch 1298 S AR ay Or xs Be 5 4 W eo uec 42 98 Zee Xs lul ceo um o0 12 98 BIST 5 A wo OG tw OE UL gt 5 19 98 c And Cu vue GR XD o 4 12 98 51 1202 40 5 t 12 98 54 12 04 hem descr ono A o0 5 5 5 12 98 51 1302 2 42 52 12 98 51 43 03 MMC 5 s 12 98 51 13 03 suc cx M e 5 5 54 12 98 54 13 04 CDM 35 kr 5 52 12 08 51 1307 09 IB or os s 5 12 98 51 1440 gt c 12 98 51 14 03 SG ik ae vv 38 4 o sor o s 12 98 51 1501 5 12 98 511502 vr 20 o0 12 98 ke UR 1 ae 2 eo gt 5 52 0 12 98 51 1505 uA NE x MM sr 5 5 12 98 12 98 51 EFFECTIVITY 1 2BLANK MOONEY AIRCRAFT CORPORATION M20J SERVICE AND MAINTENANCE MANUAL CHA
269. ITH LAMPS RED GE HOLDER 7 EA H H SMITH LAMPS WHITE GE HOLDER 4 EA H H SMITH LAMPS GE HOLDER 10 EA H H SMITH LAMPS GE HOLDER 9 EA H H SMITH LAMPS GE HOLDER 10 EA H H SMITH LIGHTS GLARESHIELD SLOAN MOONEY BULB 7 EA GE LAMPS GE HOLDER 6 EA 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 amp TRIM DIALIGHT LAMP GE FUSE 5 AMP 3AG SLO BLO LITTEL HOLDER LITTEL 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 MOONEY AIRCRAFT CORPORATION PART NO NOTES 2N2016 8 2N2016 8 2N3079 2N2016 8 2N2016 8 JS1N056P251MA JS1N056P251MA 51 056 251 JS1N056P251MA 8H2011 8Z0023 7277 2 5 FMO01 5A FHN42W FM01 5A FHN42W FMO01 5A FHN42W 1836R 1930 1836R 1930 1836 1930 1816 1930 1816 1930 1816 1930 8558 9 1 130285 003 330 1836 1930 9 250 650 5821 008 327 330 501 61K 11K3BP WI 7046 501 61K 11K3BP WI 7046 270 1930 01710702 370 O Oo 313005 155020 319001 155020 or 155120 100 OHM 2W 4599 10 4599 10 RH 10 50 OHM RH 10 50 OHM AIRCRAFT CORPORATION CODE 21 21 21 LP26A LP27A LP28A LP29A LP30A LP31A LP32A LP33A LP
270. K WV103A RECEPTACLE 4 PIN AMP 206153 1 CLAMP AMP 206062 1 JK WV104A 4 PIN AMP 206060 1 CLAMP AMP 206062 1 JK WW101A SWITCH ALTERNATEAIR CHERRY E51 50B 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 SYSTEM SHADIN M NO INTERFACE WITH BENDIX KING KLNBB USE 1 EACH 535334 21 OR 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 M83420 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 9 91 20 03 12 98 76 AIRCRAFT CORPORATION M20J SERVIGE AND MAINTENANGE 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 ATS ONLY MOONEY DRAWING NUMBER 800263 E7 Peculiar 14 volt components listed here See 91 20 03 for common components 28 volt and 14 volt ACTUAL USAGE DETERMINED BY MASTER SCHEMATIC CODE DESCRIPTION VENDOR PART NO NOTES 14 CF105A FLAP ACTUATOR MOONEY 750105 001 14 CVi06A VACUUM PUMP AEROSAFE 820904 1 14 DB102A TURN CO ORDINATOR ULL 9112 CODE
271. L PAI57A SWITCH OVERVOLTAGE RESET RT C H SB1DDX492 2 LOCKING RING C H 29 761 eres LOCKING WASHER C H 16 886 NUT HEX 2 ea C H 15 966 6 LAMP GE 388 L PA158A C B ALTERNATOR LT ETA 41 3 S14 LN2 70A C B ALTERNATOR LT ALT 41 3 S34 LN2 70A L 159 RT ETA 41 3 S14 LN2 70A C B ALTERNATOR RT ALT ETA 41 3 S34 LN2 70A L PAI60A RECPT O VOLTAGE CONTROL LT AMP 206705 2 EN CLAMP AMP 206966 1 12 98 91 20 02 51 SERVICE AND MAINTENANCE MANUAL M20J MOONEY AIRCRAFT CORPORATION 28 VOLT ELECTRICAL EQUIPMENT CHART CODE DESCRIPTION VENDOR PART NO NOTES w L PA161A RECPT OVERVOLTAGE CONT L RT AMP 206705 1 CLAMP AMP 206996 1 JK PB101A BATTERY GILL G 242 JKL RELAY MASTER BATTERY LEFT 6041H202 ALT C H 6041H202A JKL 1 DIODE LEFT BATTERY RELAY 1N2483 JK PB104A SWITCH MASTER C H 880052 501 JKL 1 C B BATTERY LT ALT ETA 41 3 S14 LN2 70A C B BATTERY LT ETA 41 3 S34 LN2 70A JKL PBIOGA C B BUS FLI PNL SWITCH ALT ETA 41 8 S14 LN2 70A C B BUS FLT PNL SW ETA 41 3 S34 LN2 70A JK PB107A BUSS BAR 1 MOONEY 913127 005 JK PB108A BUSS BAR 2 MOONEY 913127 039 JK PB109A BUSS BAR 3 MOONEY 913127 001 JK PB110A BUSS BAR 4 MOONEY 913127 019 JK PB111A BUSS BAR 5 MOONEY 913127 019 JK 112 BUSS 6 913127 239 BUSS BARS 913127 045 213 223 or 227 MAY BE
272. LEX BUSS BAR BUSS BAR DIODE MASTER RELAY DIODE RADIO RELAY SHUNT RADIO RELAY SHUNT RADIO RELAY C B BATTERY POWER BUSS BAR MAIN POWER M20J 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 TARZIAN MOONEY MOONEY MOONEY MOONEY MOONEY SARKES TARZIAN SARKES TARZIAN KULKA KULKA ETA MOONEY 12 98 PART NO 913127 009 913127 003 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 F 4 F 4 600RJ 2 600RJ 2 41 3 814 LN2 70 913127 031 SERVICE AND MAINTENANCE MANUAL 14 VOLT ELECTRICAL EQUIPMENT CHART VENDOR NOTES 14 14 14 40 41 41 91 20 01 21 SERVIGE AND MANUAL CODE 21 21 21 21 21 21 21 21 21 21 21 21 21 21 21 21 21 21 91 20 01 22 PB28A PB29A PB30A PB31A PB32A PB33A PB34A PB35A PB36A PB37A PGO1A PG02A PGO3A PGO4A PGO5A PG07A PG08A PG09A PG10A PG11A PG12A PG13A PG14A PG15A PG16A PLO1A
273. LT REG AUX PUMP ELECTRO DELTA MOONEY HECPT V R AMP CLAMP AMP PLUG V R AMP CLAMP AMP RECPT PUMP AMP CLAMP AMP PLUG PUMP AMP CLAMP AMP SWITCH CARLING SOLENOID CONTINENTAL FUSE HOLDER LITTEL C B ALTERNATOR FIELD MERIDEN C B ALT FIELD KLIXON ALTERNATOR PRESTOLITE ALTERNATOR FORD ALTERNATOR LYCOMING ALTERNATOR CONTINENTAL FILTER ELPAC FILTER SPRAGUE FILTER CAPTOR FILTER CAPTOH C B ALT MECH PROD C B ALT OUTPUT ETA CAPACITOR SANGAMO VOLTAGE REG MOONEY REPLAGES OECO P N 20082 amp ELECTRO DELTA P N s VR414 amp VR415 ADAPTER CABLE MOONEY PLUG VOLT REG CLAMP PLUG VOLT REG AMP CLAMP AMP HECPT VOLT REG AMP CLAMP BATTERY GILL BATTERY PRESTOLITE RELAY BATTERY MASTER C H RELAY MASTER C H C B AUX BUSS MERIDEN ALT MECHANICAL PROD C B AUX POWER ETA RELAY RADIO MAGNECRAFT RELAY RADIO MASTER P amp B SWITCH MASTER C H C B BUS RADIO RELAY MOONEY C B RADIO MASTER MOONEY BUSS BAR MAIN FLEX 12 98 880016 501 AIRCRAFT GORPORATION PART NO 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 T1GK6B 1F WH A 642200 311010 or 312010 NOTES 28 12 AHWA 5 7277 2 5 ALY 8403 or 8420 or ALY6420LS OR ALY8420M DOFF 10300J LW 15404 641669 27 3 99 01021 JN 14 1356A A2637 A2638 1648 001 70 41 3 814 LN2 70 500 1041 01 38 880270 505 SPARES 13 800331 721 MS3106A 18 4S MS3057 10B 206060 1 20
274. LUG 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 PLUG A S SWITCH 1 4 PIN CLAMP MOONEY AMP AMP PLUG AUTOPILOT POWER 16 PIN AMP CLAMP PLUG 16 PIN CLUSTER GAUGE PLUG FIREWALL 1 19 PIN CLAMP PLUG RT WG 14 PIN PLUG RT WING 20 PIN MOONEY 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 CLAMP AMP 12 98 41 3 814 LN2 60A 41 3 S84 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 W8389CX 3 1N2483 155020 or 155120 313005 155020 or 155120 313005 6041H202 6041H202A 1N2483 B133K 21 E13 T52 800228 501 206150 1 206138 1 205837 1 206070 1 205839 3 206070 1 930021 501 930021 505 930021 505 930021 505 206060 1 206062 1 206037 1 202070 1 206037 1 M53106A 22 145 M53057 12B 930021 001 930021 501 930021 001 930021 001 53106 22 145 MS3057 12B 206708 1 206966 1 91 20 02 53 SERVIGE AND MAINTENANCE MANUAL M20J MOONEY AIRGRAFT CORPORATION 28 VOLT ELECTRICAL EQUIPMENT CHART CODE DESGRIPTION VENDOR PART NO NOTES JKL PL13B PLUG AVIONICS MASTER 4 PIN AMP 206060 1 CLAMP AMP 206062 1 JKL PL14A PLUG HOUR 4 PIN AMP 206080 1 GLAMP AMP 206062 1 JKL PL15A PLUG LEFT WING STU
275. MATRIX SCIENCE PLOBA PLUG 8 PIN AMP PLO9A PLUG 9 PIN AMP PL09B PLUG 9 PIN AMPHENOL PLOSC PLUG 9 PIN PLOSD PLUG 9 PIN MOLEX PLOSE PLUG 9 PIN AMP PL14A PLUG 14 PIN MOONEY PL14B PLUG 14 PIN MOONEY PL14C PLUG 14 PIN AMP PL15A PLUG 15 PIN PL16A PLUG 16 PIN AMP PL17A PLUG 17 PIN PL20A PLUG 20 PIN MOONEY PL25A PLUG 25 PIN PL25B PLUT 15 PIN AMP PL26A PLUG 26 PIN MOONEY PL28A PLUG 28 PIN AMP PL32A PLUG 32 PIN MATRIX SCIENCE USE MS3420 14 OR 16 BOOT WITH CONNECTOR PL34A PLUG 34 PIN MOONEY PL34B PLUG 34 PIN MOONEY PL37A PLUG 37 PIN AMP PL37B PLUG 37 PIN PS101A C B STARTER SOLENOID KLIXON PS102A C B STARTER SOLENOID KLIXON PS103A STARTER PRESTOLITE ALT LYCOMING PS104A STARTER TCM ALT TCM PS105A STARTER B amp C SPECIALITY Ri RESISTOR 20 OHM 10W DALE R2 RESISTOR 5 OHM 10W DALE R3 RESISTOR MAPLIGHT 500 OHM NEWARK R4 RESISTOR 100 OHM NEWARK RESISTOR 7 5 OHM DALE R6 RESISTOR 1K OHM 2W ALLEN BRADLEY R7 RESISTOR 5K OHM ALLEN BRADLEY ALT SELECTROL ALT BOURNS ALT NEWARK R8 RESISTOR 150 OHM 3W CLAROSTAT ALT OHMITE R9 RESISTOR 3 9K OHM 1 2W OHMITE R10 RESISTOR 3 0K OHM 1 2W R11 RESISTOR 1 OHM 25W DALE R12 RESISTOR 70 OHM 10W DALE R13 RESISTOR 10 0K OHMAW RB101A BLOWER RADIO KING RCO2A RECEPTACLE 2 PIN AMP RC02C RECEPTACLE 2 PIN MALE DEAN RCO2D RECEPTACLE 2 PIN 12 98 SERVICE AND MAINTENANCE MANUAL PART NO
276. METER 4 PIN CLAMP AMP PITOT HEAT MOONEY C B PITOT HEAT SPARES MOONEY PITOT HEATED AERO INST PLUG PITOT HEAT SOCKETS BOARD ASSY MOONEY CURRENT MONITOR SPARES MOONEY FUSEHOLDER LITTEL FUSE 1A LITTEL PLUG AMP AMP PINS AMP LIGHT ASSY MOONEY RELAY BOX CURRENT DETECTOR MOONEY RELAY BOX CURRENT DETECTOR MOONEY PLUG CUR DECT RELAY AMP CLAMP AMP FUSEHOLDER LITTEL FUSE 5A 3AG SLO BLO LITTEL 12 98 AIRCRAFT CORPORATION PART NO NOTES MS3106A14S 5S 0402 102 0402 104 206153 1 206062 1 206060 1 206062 1 880039 507 880053 501 0400 004 880003 501 880039 515 0520 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 ALT 206153 1 206062 1 206060 1 206062 1 930023 205 930023 241 PH502 24 we ANSB12 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 206060 1 206062 1 155020 155120 313005 MOONEY AIRCRAFT CORPORATION M20J SERVICE AND MAINTENANCE MANUAL 28 VOLT ELECTHICAL EQUIPMENT CHART CODE DESCRIPTION VENDOR PART NO NOTES K DR101A KLIXON 7277 2 2 K DR102A INDICATOR TIT MOONEY 880051 501 K DR102B INDICATOR TIT EGT MOONEY 880051 503 K DRIO3A PLUG TIT AM
277. MICRO V3 1 4 JK CF107A SWITCH TAKEOFF DOWN MICRO V3 1 4 MICRO JV 5 4 JKL CF105A ACTUATOR FLAP MOONEY 750105 501 JK CF108A RELAY UP MAGNACRAFT W67RCSX 3 JK CF109A RELAY DN MAGNACRAFT W67RCSX 3 BASE MAGNAGRAFT 70 303 JK CF110A SWITGH FLAP C H 8906K4064 ALT MICRO 2TL149 12L KNOB MOONEY 917026 501 JK CF111A 112A DIODE 1N2483 J CF113A PLUG 4 PIN AMP 206060 1 CLAMP AMP 206062 1 J CF114A 4 PIN AMP 206153 1 CLAMP AMP 202062 1 L CF150A C B TRIM FLAP IND KLIXON 7277 2 1 L CF151A INDICATOR TRIM FLAP PENN AIRBORNE 9A1590 L CF152A PLUG TRIM FLAP IND ITT DA15S CLAMP ITT DA51210 1 LOCK RETAINER DA51220 1 L CF153A PLUG FLAP POSITION 4 PIN AMP 206060 1 CLAMP AMP 206062 1 CF154A RECPT FLAP POSITION 4 PIN AMP 206153 1 CLAMP AMP 206062 1 12 98 91 20 02 35 SERVIGE AND MANUAL 28 VOLT ELECTRICAL EQUIPMENT CHART CODE DESCRIPTION M20J VENDOR MOONEY AIRCRAFT CORPORATION PART NO NOTES n p kbA POTENTIOMETER FLAP POSITION ALLEN BRADLEY WA2 G056S502UA L CF155A JKL CT101A JKL CT101A L CT150A L CT151A L CT152A JK CV101A JK CV102A JK CV103A JK CV104A JK CV105A
278. MOONEY C H MOONEY AMP AMP AMP AMP KLIXON PORSCHE AMP AMP AMP AMP PORSCHE PORSCHE LITTEL LITTEL CARLING CONTINENTAL SWITCH COLD START ENRICH MOONEY NOZZLE COLD START PORSCHE PLUG PORSCHE CLAMP PORSCHE BOOT PORSCHE CONTACTS PORSCHE DIODE COLD START SW C B ALTERNATOR 1 ETA C B ALTERNATOR FIELD 1 KLIXON SWITCH ALTERNATOR FIELD C H VOLTAGE REGULATOR 1 ELECTRODELTA RECPT VOLTAGE REG AMP CLAMP AMP PLUG VOLTAGE REG AMP CLAMP AMP ALTERNATOR 1 CONTINENTAL GEAR ASSY CONTINENTAL FILTER MOONEY CAPACITOR MALLORY C B ALTERNATOR 2 ETA 12 98 930023 219 10054B 930023 217 VR536 206153 1 206062 1 206060 1 206062 1 7277 2 10 7277 2 10 8162 K22 E13 M50 930028 501 8142 K21 E7 T50 930028 501 206060 1 206062 1 206153 1 206062 1 7277 2 10 933 620 001 00 206060 1 206062 1 206153 1 206062 1 933 620 001 00 933 620 001 00 155020 or 155120 313010 T1GK6B 1F WH A 633862 2 880052 511 933 612 401 00 933 615 032 40 999 615 032 40 944 612 128 00 999 652 456 22 1N2483 41 3 834 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 3 534 LN2 041800 MOONEY AIRCRAFT CORPORATION M20J SERVICE AND MAINTENANCE MANUAL 28 VOLT ELECTRICAL EQUIPMENT CHART CODE DESCRIPTION VENDOR PART NO NOTES JKL PATHA C BALTERNATORFIELD 42 KLIXON 7277 2 5 JK PA112A VOLTAGE REGULATOR 2
279. MOONEY AIRCRAFT CORPORATION LOUIS SCHREINER FIELD KERRVILLE TEXAS 78028 ISSUED DECEMBER 1998 MANUAL NUMBER 123 MOONEY AIRCRAFT CORPORATION M20J SERVICE AND MAINTENANCE MANUAL LUG UF REVISIONS Always destroy superseded pages when you insert revised panes DATE OF SECTIONS DATE SECTIONS REVISION AFFECTED REVISION AFFECTED A list of effective pages will appear at the beginning of each chapter 12 98 LOG OF REVISIONS PAGE 1 SERVICE AND MAINTENANCE MANUAL M20J MOONEY AIRCRAFT CORPORATION LUG REVISIONS Always destroy superseded poges when you Insert revised pages DATE OF SECTIONS DATE OF SECTIONS REVISION AFFECTED REVISION AFFECTED A list of effective pages will appear at the beginning of each 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 updated to reflect the current configuration status and there will be added electrical 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 12 98 PAGE 2 AIRCRAFT CORPORATION M20J INTRODUCTION This manual provides servicing and maintenance information for the Mooney Model M20J Serial Numbers 24 0001 and ON Maintenance actions that refer to a limited number of aircraft will
280. MP AMP BENDIX SCINTILLA BENDIX SCINTILLA BENDIX SCINTILLA BENDIX SCINTILLA BENDIX SCINTILLA TCM SLICK BENDIX SCINTILLA TCM SLICK MOONEY C B ROTATING BCN SPARES MOONEY LIGHT ROTATING BCN ADAPTER WHELEN WHELEN LT ROTATING BCN RED ALT WHELEN LT ROTATING BCN WTE ALT WHELEN PLUG 2 PIN SOCKET RECPT 2 PIN PINS FUSEHOLDER CLOCK 5AMP FUSE 5A 3AG SLO BLO AMP AMP AMP AMP LITTEL LITTEL SWITCH CABIN LIGHT FWD CARLING RESISTOR CABIN LIGHT FWD DALE LIGHT CABIN FWD LT LAMP LIGHT GABIN FWD RT LAMP LIGHT CABIN FWD LT LAMP LIGHT CABIN FWD RT LAMP H H SMITH GE H H SMITH GE H H SMITH GE H H SMITH GE 12 98 MS3100K 14S 2P TXR18AB000 C1404Al S2900AS1004A1 S034 000 2028121 25S MS3108E 148 28 TXR18AB000 C1404Al 2900AS1004A S034 000 2028121 25S 1 480303 0 60619 1 1 480305 0 60620 1 1 480318 0 60619 1 1 480319 0 60620 1 1 480318 0 60619 1 1 480319 0 60620 1 10 357210 9 10 187 468 10 682555 1 10 682555 111 10 79020 120 640896 1 6224 10 79020 120 640896 1 6224 930023 203 930023 243 WRML 24 WRM 65 90033 19 90033 20 1 480318 0 60619 1 1 480319 0 60620 1 155020 155120 313005 TILC64 IS WH FN RH 10 20 OHM 1930 1818 1930 1818 1930 1818 1930 1818 MOONEY AIRCRAFT CORPORATION GODE M20J er eS a ee 28 VOLT ELECTRICAL EQUIPMENT CHART DESCRIPTION VENDOR used ee SERVICE AND MAINTENA
281. N LIGHT ANTI COLLISION WHITE WHELEN CONTROL BOX LIGHT MOONEY 12 98 MOONEY AIRCRAFT CORPORATION PART NO NOTES 313001 313005 313010 01 5 FM01 50A CD 1001 02 CH 1001 XX CD 4771 CD4770 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 120 400 168 T 3 1 4 385 330 CM7 7330 7 7327 370 1816 AVIA RED 327 327 1818 1495 4596 P28028 351 0003 930023 243 930023 343 WRML 28 WRML 65 90033 19 90033 20 800268 509 AIRCRAFT CORPORATION M20J ELECTRICAL EQUIPMENT CHART CODE LE101A LE102A LE103A LE104A LE105A LE106A LE107A LE108A LE109A LE110A LE111A LE112A LE113A LE114A LE115A LE116A LE117A LE119A LG101A LG102A LH101A LH102A LH103A LH104A LH105A LH106A LH107A LH108A LH109A LH110A LH111A LH112A LH113A LL101A LL101B LL102A LL 103A LN101A LN101B LN102A LN102A LP101A LP102A LP103A LP104A LP105A DESCRIPTION VENDOR 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 M20T 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 ANNU
282. N 504202 LENS TSCHUDIN 464415 BULB TSCHUDIN 590002 SWITCH MOONEY 880062 501 SWITCH CARLING TIGM64 1S WHEN 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 78 1009 VARISTOR GE V47ZA05 MASTER WARNING MICRO SWITCH DSK 104 GYR MASTER WARNING MICRO SWITCH DSB 11 RRRR LR2 950D0309 000 800364 507 91 20 05 91 SERVICE AND MAINTENANCE MANUAL M20J MOONEY AIRCRAFT GORPORATION ELECTRICAL EQUIPMENT CHART CODE DESCRIPTION VENDOR PART NO NOTES WT101A ANNUNCIATOR MOONEY 880048 501 WT102A ANNUNCIATOR MOONEY 880048 503 WT103A ANNUNCIATOR MOONEY 880048 507 WT104A ANNUNCIATOR MOONEY 880048 509 NOTES 1 SRM INTERFACE WITH II MORROW APOLLO ARNAV AND NORTHSTAR LORAN 2 SHADIN MODEL NO INTERFACE WITH BENDIX KING KLN 88 OR KLN90 SERIES 3 B amp 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 12 98 MOONEY AIRCRAFT CORPORATION M20J SERVICE AND MAINTENANCE MANUAL i ELECTRICAL EQUIPMENT CHART RESERVED FOR FUTURE ENTRIES 12 98 91 20 05 93 SERVICE AND MAINTENANCE MANUAL M20J MOONEY AIRCRAFT CORPORATION ELECTRICAL EQUIPMENT CHART RESERVED FOR FUTURE ENTRIES 91 20 05 12 98 94 AIRCRAFT CORPORATION 91 20 06 CODE AC101A AC102A AC103A AC103B AC104A AC105A AC108A AT101A A
283. N SAFE FLIGHT C46001 L WS150A ALERT GR STALL WARNING IAI 950D 0309 000 L WS151A PLUG GR STL WRN ALRT 25 PIN ITT DB25S i CLAMP ITT DB51212 E LOCK RETAINER ITT DB1212 1 L WS152A SPEAKER GR STALL WARN ARCHER 40 1333C WS153A PLUG INTER PHONE AMP 206060 1 CLAMP AMP 206062 1 L WS154A PLUG MATE N LOCK 2 PIN 1 480318 0 SOGKETS AMP 60619 1 91 20 02 12 98 58 AIRCRAFT CORPORATION M20J SERVICE AND MAINTENANCE MANUAL 28 VOLT ELECTRICAL EQUIPMENT CHART CODE DESCRIPTION VENDOR PART NO NOTES L WS155A RECPT MATENLOCK 2 PIN AMP 1 480319 0 PINS AMP 60620 1 JK WTi01A C B ANNUNCIATOR KLIXON 7277 2 2 J WTi02A ANNUNCIATOR MOONEY 880025 521 LAMPS CHICAGO MINIATURE 7327 K WT103A ANNUNCIATOR MOONEY 880025 523 LAMPS CHICAGO MINIATURE 7327 JK WT104A PLUG ANNUNCIATOR MOLEX 09 50 3151 SOCKETS MOLEX 08 50 0106 L WT150A C B ANNUNCIATOR LT KLIXON 7277 2 1 L WTi51A C B ANNUNCIATOR RT KLIXON 7277 21 WT153A ANNUNCIATOR IAI 950D0308 000 LAMPS CHICAGO MINATURE CM7327 L WT154A PLUG ANNUNCIATOR ITT DB25S CLAMP ITT DB51212 1 LOCK RETAINER ITT DB51221 1 JK WVi01A C B VACUUM WARNING KLIXON 7277 2 2 JK WVi02A SWITCH VACUUM WARNING MOONEY 880012 501 JK WV103A REGPT VAC WARN 4 PIN AMP 206153 1 CLAMP AMP 206062 1 JK WV104A PLUG VAC WARN 4 PIN AMP 206060 1 CLAMP AMP 206062 1 J WWwi01A SWITC
284. NAV KLIXON STORMSCOPE KLIXON C B LORAN KLIXON C B RMI KLIXON C B AUTOPILOT TRIM KLIXON C B A P ALERT KLIXON C B INVERTER KLIXON C B ART HORIZ KLIXON C B HSI KLIXON C B YAW DAMP KLIXON C B TELEPHONE KLIXON C B VME KLIXON C B RADIO ALT KLIXON CIGAR LIGHTER MOONEY 12 98 1 480303 0 60619 1 470013 501 1 480305 0 60620 1 1 480305 0 60620 1 1 480305 0 60620 1 7277 2 25 880052 523 4596 4596 AN2552 3A 6041H202 6041H202A 10H3P 1N2483 1N5060 3720 GE 930023 213 26 64 01 1N2483 1N5060 3720 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 75 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 10 7277 2 7 5 7277 2 75 7277 2 2 7277 2 2 7277 2 7 5 7277 2 7 5 7277 2 7 5 7277 2 7 5 800336 503 NNNNNNNNNNNNNNNNNNNNNNNNN 91 20 03 69 SERVICE AND MAINTENANCE MANUAL 28 VOLT ELECTRICAL EQUIPMENT CHART CODE JK MC102A JK ME101A JK MIC101A JK MIC102A JK MIC103A JK MP101A JK MP102A JK MP103A JK MP104A JK MP105A J NF101A Ja NF102A K NF102A JK NF103A JK NF104A K NF105A K NF107A K NF108A K NF108B K NF109A K NF110A K NP101A K NP102A K NP103A K NP104A JK PA101A JK PA102A JK PA103A K PA103B JK PA104A JK PA105A JK PA106A J PA107A 91 20 03 70 DESCRIPTION s s s r
285. NC FRANCE M20H MOONEY LENS ANNUNC US M20K MOONEY LENS ANNUNC US M20K MOONEY LENS ANNUNC M20K MOONEY LENS ANNUNC SLOANE LENS ANNUNC M20 MOONEY LENS MASTER WARN MOONEY CIRCUIT BREAKER LOGO LIGHT MOONEY LIGHT LOGO WHELEN LAMP HOLDER MOONEY LAMP HOLDER DIALIGHT LAMP HOLDER WHELEN LAMP HOLDER SLOAN LAMP HOLDER INSTRUMENTS LAMP HOLDER INSTRUMENTS LAMP HOLDER SIGMA TEC LAMP HOLDER HH SMITH ALT LEECRAFT ALT ALLIED ALT SPC ALT NEWARK LAMP HOLDER HH SMITH LAMP HOLDER WHELEN LAMP HOLDER TEK LITE ALT LAMP HOLDER WHELEN LAMP HOLDER MOUSER SWITCH LDG LIGHT MOONEY SWITCH LDG LIGHT MOONEY BULB LIGHT LDG TAXI GE BULB LIGHT LDG TAXI GE CIRCUIT BREAKER MOONEY C B MOONEY LIGHT NAV TAIL MOONEY LIGHT NAV TAIL MOONEY DIMMER BOX MOONEY DIMMER CONTROL BOX MOONEY DIMMER CONTROL BOX MOONEY SWITCH O H LIGHT ASSY MOONEY INVERTER E L PLACARD ERG 12 98 PART NO 880048 613 880048 615 880048 617 880048 619 880048 621 880048 623 880044 633 880044 635 880048 625 880048 627 880048 629 880048 631 880048 605 880048 607 880089 001 855 SE G 880089 003 150080 6097 930023 357 A730 1 28 914083 1 270 1930 0171 702 SERVICE AND MAINTENANCE MANUAL NOTES A 350 CN CL BK SH 28 8555 0 0 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 880052 521 880052 121
286. NCE MANUAL 32 32 00 TROUBLE Incomplete retraction Gear retracts to an intermediate position and stops short Gear will not retract at 70 to 80 MPH IAS Gear will not retract amp Landing Gear Actuator C B trips Aircraft does not Track or steer properiy Gear will extend green indicator light press to test will not illuminate Actuating motor extends gear to an intermediate position Gear will extend manually but green indicator light will not illuminate Manual system will not lower gear Manual system will not lower gear con t LDG actuator will not retract or will not extend gear M20J TROUBLE SHOOTING LANDING GEAR SYSTEM PROBABLE CAUSE Bind in gear retraction system because gear is out of rig Malfunction in gear electrical circuit inoperative actuating motor or weak battery Oversize stretched tire will not go into wheelwell properiy Insufficient air speed pressure switch inoperative circuit breaker tripped or actuator ball nut binding on DOWN STOPS Squat switch not properly rigged Cold weather Manual engage handle in engaged position Nose wheel location improper Lamp burned out in green indicator light circuit Down limit switch is inoperative Same causes as listed with In complete Retraction above Gear switch is not in DOWN position Lamp burned out in green indicator light Avionic Products Actuator internal clutch spring broken
287. NCE MANUAL PART NO NOTES Sr a ri en Qu rer mm mm PpxW s s s SWITCH CABIN LIGHT REAR CARLING JKL LC108A LC109A LC110A LC111A LC112A LC113A LC114A LC115A LL101A LL102A LL103A LL104A LL105A LL106A LL107A LL108A LL109A LL150A LL151A LL152A LL154A LL155A 11 156 LL157A LL158A LN101A LN102A LN103A LN104A LN105A LN106A LN107A LP101A LP102A LP103A RESISTOR GABIN 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 SWITCH LDG LT MOONEY LANDING LIGHT GE RECPT LDG LT AMP CLAMP AMP PLUG LDG LT AMP CLAMP AMP C B LDG LT LEFT KLIXON LIGHT LDG LEFT GE C B LDG LT RIGHT KLIXON LIGHT LDG RIGHT GE SWITCH LDG LT C H C B LANDING LIGHT LEFT KLIXON C B LDG LT LEFT ALT MECHANICAL PROD C B LANDING LIGHT RIGHT C B LDG LT RIGHT ALT PROD SWITCH LANDING LIGHT C H LANDING LIGHT RT WING GE TAXI LIGHT RT WING GE SWITCH TAXI LIGHT C H TAXI LIGHT LEFT WING GE LANDING LIGHT LEFT WING GE C B NAV LIGHTS MOONEY LIGHT TAIL LT WING MOONEY BULB 28V WHELEN LIGHT TAIL RT WING MOONEY PLUG TAIL LIGHT RT WING SOCKETS
288. ND MARKINGS 00 GENERAL 10 MARKINGS 20 PLACARDS EXTERIOR INTERIOR 12 SERVICING 00 SERVICING 10 REPLENISHING 20 SCHEDULED SERVICING 12 98 INTRODUCTION Page 3 SERVICE AND MAINTENANCE MANUAL SYSTEM CHAPTER 20 21 24 CURRENTLY NOT USED 27 28 30 INTRODUCTION Page 4 SUB SYSTEM SECTION 00 00 40 00 30 50 00 10 20 50 00 10 20 30 40 50 90 00 10 20 30 40 90 00 30 60 M20J 12 98 MOONEY AIRCRAFT CORPORATION TITLE STANDARD PRACTICES AIRFRAME GENERAL ENVIRONMENTAL SYSTEMS CABIN VENTILATION SYSTEM HEATING ELECTRICAL POWER GENERAL DC GENERATION ELECTRICAL LOAD DISTRIBUTION SEATS GENERAL FLIGHT COMPARTMENT PASSENGER COMPARTMENT CARGO COMPARTMENT FLIGHT CONTROLS GENERAL AILERON SYSTEM RUDDER SYSTEM ELEVATOR SYSTEM STABILIZER TRIM SYSTEM WING FLAP SYSTEM MISCELLANEOUS FUEL GENERAL STORAGE DISTRIBUTION DUMP INDICATING MISCELLANEOUS ICE AND RAIN PROTECTION GENERAL PITOT AND STATIC PROPELLERS MOONEY AIRCRAFT CORPORATION M20J SERVICE AND MAINTENANCE MANUAL SYSTEM SUB SYSTEM TITLE CHAPTER SECTION 32 LANDING GEAR 00 GENERAL 10 MAIN LANDING GEAR AND DOORS 20 NOSE LANDING GEAR AND DOORS 30 EXTENSION AND RETRACTION 40 WHEELS AND BRAKES 50 STEERING 60 POSITION AND WARNING 80 MISCELLANEOUS 33 LIGHTS 00 GENERAL 20 INTERIOR LIGHTS MAINTENANCE PRACTICES 40 EXTERIOR LIGHTS MAINTENANCE PRACTICES 34 NAVIGATION 00 GENERAL
289. NER ADJUST DOWN TO ACTUATE LATER STALL VANE ADJUSTMENT FIGURE 27 21B S N 24 3154 THRU 24 TBA 27 95 01 TROUBLE Warning system inoperative Open circuit Defective warning horn switch Defective warning hom Defective warning hom switch Horn continues to blow 12 98 M20J PROBABLE CAUSE Warning circuit breaker tripped 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 switch to be closed earlier or later Retighten the screws after making each adjustment NOTE NEVER TRY TO ADJUST THE SWITCH BY BENDING THE VANE This part has been heat treated and cannot be bent without damaging or breaking the vane or switch 4 Stall Warning Switch Vane Adjustment S N 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 21B 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 phillips head screws loosened moves the entire unit up or down inside the wing causing the switch to be closed earlier or later Retighten the screws after making each adjustment GENERAL As a rule of thumb moving the vane tip 1 4 inch will change the time
290. NEY AIRCRAFT CORPORATION 11 Record weights and measurements and compute basic weight and CG as follows Loe LM R 5 LM a CG Forward of Main Wheels LBS X IN LBS IN Weight of Nose Distance Between Total Weight of CG Forward of Main and Nose Wheel Aircraft Main Wheels Axle Centers WN LM N WD LM b CG Aft of Datum Station 0 IN 5 IN IN IN Distance from Center Distance from Result of Computation CG FUS STA Nose Gear Trunion to Nose Gear Above a Distance Aft of Center of Main Wheel Trunion to Datum Datum Empty Axles Horizontal Weight CG LM R CONSTANT LM LC G NOTE Empty weight includes unusable fuel and full oil and is computed with gear down and flaps up REF POINT CNOSE GEAR REFERENCE LEVEL REF TRUNNION DATUMCSTA 0 gt CSKIN SPLICE OR STA 5 LEVELING SCREWS MEASUREMENTS WEIGHT AND BALANCE DIAGRAM FIGURE 8 1 8 00 01 12 98 MOONEY AIRCRAFT CORPORATION M20J SERVICE AND MAINTENANCE MANUAL CHAPTER 9 TOWING AND TAXIING SERVICE AND MAINTENANCE MANUAL CHAPTER SECTION SUBJECT 9 Effactivity Contents 9 00 00 9 30 00 CHAPTER SECTION SUBJECT 9 00 00 9 10 00 9 20 00 9 30 00 M20J CHAPTER 9 TOWING AND TAXIING LIST OF EFFECTIVE PAGES PAGE 1 2BLANK 3 4 TABLE OF CONTENTS SUBJECT Ground Handling Towing Mors Warmup and Taxiing Emergency Procedures 12 98 MOONEY AIRCRAFT CORPORATION DATE 12 9
291. NEY AIRCRAFT CORPORATION 2 Smooth all rough or sharp edges and prime area to be spliced 3 Locate new outboard section and trim splice to fit with a maximum gap of 020 inch 4 Fabricate 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 Prime angles plate and spacer Rivet parts together using wet primer on all rivets 210055 CAP REF SECT B B SECT A A AIRPLANE WS 21 75 B SPAR REF lt a AN 470 405 RIVETS EACH SIDE OF SPLICE PICK UP 15 B P FASTENERS EACH SIDE OF SPLICE amp 503 ANGLE PICK UP 30 B P FASTENERS EACH SIDE OF SPLICE CENTERLINE STUB SPAR REPAIR FIGURE 51 8 12 98 MOONEY AIRCRAFT CORPORATION M20J SERVICE AND MAINTENANCE MANUAL SHSI 10 FORWARD PIECE REPAIR FIGURE 51 10 51 13 03 12 98 14 SERVICE AND MAINTENANCE MANUAL 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 51 13 05 RIB REPAIR Replace ribs that are severely damaged Minor damage may be repaired as shown Figure 51 10 51 13 06 OUTBOARD WING TIP ASSEMBLY REPAIR To repair severe damage to the wing tip outboard of sls 95 it is advisable to replace the entire tip skin and rib 1 Locate the new tip rib in the exact original tip rib position
292. NEY AIRCRAFT CORPORATION 4 All control surfaces are balanced with the hinge 7 Accurately measure control surface load a center line and the tip rib chord line level Two tooling measured distance from the hinge axis as far from the holes are located in the tip ribs and are on the rib chord hinge axis as possible Figure 27 18 Measurements line rib center line Chordwise level can be obtained should be taken in a draft free environment Calculate by using a spirit level and pins inserted into these the moment arm times weight and compare the tooling holes results with Figure 27 17 5 install a 1 4 inch bolt or pin through the inboard 8 Control surfaces MUST BE RECHECKED for and outboard AILERON hinge bracket Install a No 10 balance after any painting stripping repair or bolt or pin through inboard and outboard ELEVATOR alteration hinge bearing and top and bottom RUDDER hinge bearing 6 Positon and level the control surface on the knife edge hinge supports SURFACE DESCRIPTION AIRCRAFT EFFECTIVITY MOMENT LIMITS 430026 001 amp 002 24 0001 THRU 24 1543 UNDERBALANCE 16 75 IN TO ELEVATOR 24 1545 THRU 24 1551 14 00 IN 24 3000 THRU 24 3038 24 1544 24 1552 THRU 24 2999 UNDERBALANCE 16 75 IN TO 24 3039 THRU 24 11 00 IN 430043 000 24 0001 THRU 24 1543 UNDERBALANGE 18 00 IN TO RUDDER 24 1545 24 1551 13 00 IN 24 3000 THRU 24 3038 24 1544 24 1552 THRU 24 2999 UNDERB
293. NGS FIGURE 28 5 12 98 28 92 00 13 MOONEY AIRCRAFT CORPORATION M20J SERVICE AND MAINTENANCE MANUAL BLANK 28 92 00 12 98 14 MOONEY AIRCRAFT CORPORATION M20J SERVICE AND MAINTENANCE MANUAL CHAPTER 30 ICE PROTECTION SERVICE AND MAINTENANCE MANUAL 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 M20J CHAPTER 30 ICE PROTECTION LIST OF EFFECTIVE PAGES PAGE 1 2BLANK 3 4BLANK 5 12 98 MOONEY AIRCRAFT CORPORATION DATE 12 98 12 98 12 98 12 98 12 98 12 98 12 98 12 98 12 98 12 88 12 98 12 98 30 EFFECTIVITY 1 2BLANK AIRCRAFT CORPORATION CHAPTER SECTION SUBJECT 30 00 00 30 30 00 30 60 00 30 60 01 30 61 00 30 61 01 30 61 02 30 62 00 30 63 00 30 64 00 30 65 00 30 66 00 30 67 00 30 68 00 30 68 01 30 69 00 30 70 00 M20J SERVICE AND MAINTENANCE MANUAL CHAPTER 30 ICE PROTECTION TABLE OF CONTENTS SUBJECT PAGE General 5 Pitot Description amp Operation 5 Propellers Description amp Operation 5 Schematic Propeller De ice 5 Service Guide 5 Helpful Tips 5 Trouble Shooting Chart 7 Ammeter Test 10 De Icer Timer Check 11 Heat Test 11 Continuity Test 11 Brush to Slip Ring Resistance Test 11 Brush Assembly Resistance Check 11 Brush Replacement 11 Brush Module Replacement 12 Alignment of Slip Ring
294. NO SMOKING when refilling oxygen cylinder Spec No MILD 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 cylinder cleaned and inspected if this happens 2 Refill the cylinder with aviators oxygen Specification No MIL 0 27210 through the Oxygen Servicing Access Door 1 Figure 35 1 No special fittings are required for this servicing however several types of standard S N 24 0001 oxygen fittings in use and a compatible fitting for the Scott Recharging Valve 2 must be used Mooney P N 870025 501 oxygen recharge hose assembly is recommended 3 The cylinder contains 1850 PSI at 21 degree C 70 degree F when fully charged Temperature has an affect on the correct charging OUTLETS pressure See Figure 35 2 for pressure vs temperature charging S N 24 1418 THRU 24 TBA pressure OXYGEN SYSTEM FIGURE 35 1 12 98 35 00 00 3 MOONEY AIRCRAFT CORPORATION OXYGEN SYSTEM FIGURE 35 1 S N 24 3373 THRU 24 TBA 35 00 02 MAINTENANCE PRACTICES Ref AC 43 13 1 current revison 1 The control cable 3 Fig 35 1 is attached to an actuating arm 4 on reducing valve 5 This cable is routed through various bulkheads along the left side panel to the control 6 at pilots position The contro is a push pull cable assembly that is a
295. O SWITCH MICRO SWITCH MICRO SWITCH MICRO SWITCH MICRO SWITCH MICRO SWITCH MECH PROD KLIXON MECH PROD KLIXON MECH PROD KLIXON MECH PROD KLIXON MECH PROD KLIXON MECH PROD KLIXON MECH PHROD KLIXON MECH PROD MECH PROD MECH PROD ETA ETA MECH PROD ETA ETA MAGNACHAFT MOONEY MOONEY MOONEY MOONEY MOONEY MOONEY MOONEY MOONEY MOONEY MOONEY MOONEY MOONEY MOONEY MOONEY MOONEY 12 98 PAHT NO 880067 501 770028 1 770002 501 770002 503 770016 501 770029 501 CSLT 21PA CB017 55 JE 5 JV 5 JV 26 MCD 2711 JE 17 JV 82 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 2 534 LN2 35A 41 3 534 LN2 40A 700 001 40 41 2 534 LN2 50A 41 3 534 LN2 70A 70 303 913127 33 913127 97 913127 99 913127 75 913127 65 913127 B7 913127 59 913127 73 913127 69 913127 89 913127 5 913127 53 913127 93 913127 77 913127 85 SERVICE AND MAINTENANCE MANUAL NOTES 91 20 06 95 SERVIGE AND MAINTENANCE MANUAL M20J CODE BUSD BUGA BU6B BU7A BUSA BW3 BW7 5 BW10 BW15 BW25 CA101A CA102A CB101A CC101A CC102A CC103A CC103B CC103C CF101A CF102A CF103A CF104A CLO3A CLO3B CLO3C CLO4A CLO4D 05 06 CLO7A CLO9A CL09B CL09C CL09D CL15A CL17A CL25A CL25B CL25C CL32A 91 20 06 96 ELECTRICAL
296. O4A LNO1A LNO1B D LNO2A LN02B LNO3A LNO3B LNO4A LNO4B LPO1A LP01B LP01C D LPO2A M20J DESCRIPTION VENDOR LIGHT MAP PILOTS SLOAN BULB GE SW MAP LT CO PILOT C H CAP FACE NUT LIGHT MAP CO PILOT SLOAN BULB GE LIGHT CABIN F1 R H H SMITH LAMP GE LIGHT CABIN F2 R H H SMITH LAMP GE LIGHT CABIN F1 L H H SMITH LAMP GE LIGHT CABIN F2 L H H SMITH LAMP GE LIGHT CABIN R1 R H H SMITH LAMP GE LIGHT CABIN R2 R H H SMITH LAMP GE LIGHT CABIN R1 L H H SMITH LAMP GE LIGHT CABIN R2 L H H SMITH LAMP GE C B LDG LT MERIDEN C B LDG LT MOONEY C B LDG LT MOONEY RELAY LDG LT MAGNECRAFT LIGHT LDG BULB GE LIGHT LDG BULB GE SWITCH LDG LT C H CAP FACE NUT C B NAV LIGHTS MOONEY C B POSITION LTS MOONEY LIGHT POSITION RED GRIMES BULB POSITION 14V MOONEY BULB POSITION 149 LIGHT POSITION 14V RED WHELEN LIGHT POSITION TAIL WHITE GRIMES BULB 14V TAIL LT BULB 14V TAIL LT GRIMES LIGHT POS TAIL 14V VERT MT WHELEN BULB POS TAIL 14V LIGHT POS GREEN GRIMES BULB POSITION 14V MOONEY BULB POSITION 14V LIGHT POS GREEN WHELEN C B PANEL LIGHTS MERIDEN C B PANEL LIGHTS KLIXON C B INSTR LTS KLIXON C B PANEL LIGHTS MERIDEN 12 98 SERVICE AND MAINTENANCE MANUAL 14 VOLT ELECTRICAL EQUIPMENT CHART PART NO 855 81 0 PE 330 SA25SCT12 3 SW53AA2 15 1049 3 855 51 0 PE 330 1930 9
297. OCK 15 SITIUN BRUSH Wi IS D Restack modules and spacers as shown THE AIRCRAFT SMH30 2 FIGURE 30 2 Check A B C 12V A B 24V stacking arrangement and location of spacers If there is interference between adjacent ring terminals reorient center module as shown Figure 30 4 E On 3E2042 series assemblies make WEAR sure flat washer is positioned between star BRUS washer and housing Make sure that assembly is 1 Brush Assy 3E2011 1 square then tighten screws F Reconnect aircraft wire harness to applicable r BIEN hap SE A B or C terminals of modules Insure that 3 Brush Assy 3E2011 1 adjacent ring terminals are not touching 6 Spacer 4E2218 3 G Install assembly on aircraft with attaching 7 Spacer 4E2218 1 hardware removed i 10 Screw MS24693 535 6 32 x 1 3 8 H Check assembly for proper alignment 12 Washer AN960C6 Refer to Goodrich Report No 68 04 712 B for complete maintenance information REFERENCE FIGURE 30 3 13 Lockwasher MS35333 7 14 Nut MS35649 262 RADIAL ALIGNMENT CERES CENTER BRUSHES ON O RINGS THRU 360 OP Ez SLP RING ROTATION 3E2042 1 FORE amp AFT POSITIONING L 1 6 1 39 5 8 5 042 1 SPRING PRESSURE MODULAR BRUSH ASSY SH K39 3 MEASURING BRUSH WEAR FIGURE 30 2 30 68 01 12 98 SERVICE AND MAINTENANCE MANUAL ALTERNATE MODULE STACKING ARRANGEMENT FIGURE 30 2 Only
298. ON All flight control components should be checked to verify that all moisture drain holes are free of obstructions B Inspect elevator system for rigging travel stop adjustment condition of all bearings bellcranks and hinges security of mounting damage corrosion lubrication and proper relations to control movement C Inspect aileron system for damage corrosion lubrication 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 bearings and proper relationship to control movements Check for free movement of toe brake pedals and proper rudder and nose wheel travel E inspect stabilizer trim control system for security and proper adjustment shaft and stop nuts for proper rigging trim control wheel for smooth operation universal joints for free play and good working order actuator threads for lubrication linkage for corrosion and guide blocks for looseness or excessive wear See Section 27 42 00 for Electric Pitch Trim Inspection F Inspect flap system for rigging travel and stop adjustment flap position indicator for proper operation actuator push pull tubes interconnects belicranks hinges for corrosion security and lubrication 12 98 M20J MOONEY AIRCRAFT CORPORATION NOTE All control rigging checks should be made with the aircraft
299. ON 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 NOTE it is not recommended to 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 7 10 00 SERVICE AND MAINTENANCE MANUAL M20J MOONEY AIRCRAFT CORPORATION BLANK 7 10 00 12 98 MOONEY AIRCRAFT CORPORATION M20J SERVICE AND MAINTENANCE MANUAL CHAPTER 8 LEVELING AND WEIGHING SERVICE AND MAINTENANCE MANUAL CHAPTER SECTION SUBJECT 8 Effectivity Conte 8 00 00 8 00 01 CHAPTER SECTION SUBJECT 8 00 00 8 00 01 nts M20J CHAPTER 8 LEVELING AND WEIGHING LIST OF EFFECTIVE PAGES PAGE 1 2BLANK 4 TABLE OF CONTENTS SUBJECT Leveling Weight and Balance 12 98 MOONEY AIRCRAFT CORPORATION DATE 12 98 12 98 12 98 PAGE 8 EFF CONTENTS 1 2BLANK MOONEY AIRCRAFT CORPORATION 8 00 00 LEVELING Place a spirit level on the skin splice or leveling screws above the tailcone access door when leveling the aircraft longitudinally Level the aircraft by increasing or decreasing air pressure
300. ON AND PITOT STATIC TABLE OF CONTENTS SUBJECT General Pitot amp Static Air Pressure System Heated Pitot Trouble 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 SU Compass Trouble Shooting Artificial Horizon Gyro Horizon Trouble Shooting Miscellaneous Instruments Clock Outside Air Temperature 12 98 uU gt Q m NN J O Q 34 CONTENTS 3 4BLANK SERVICE AND MAINTENANCE MANUAL 34 00 00 GENERAL All flight instruments are grouped on the shock mounted panel directly in front of the pilot Flight instruments are operated by 1 barometric pressure or barometric impact air pressure differences 2 variations in electric current due to mechanically varied resistance 3 reference to the earths magnetic field or 4 aircraft electrical power The glareshield must be removed and wiring or plumbing disconnected on of the fight instruments before they can be removed Remove glareshield attaching screws center post cover screws and carefully lift center post cover and giareshieid from the panel Disconnect the glareshield lights Reinstall the gla
301. ONTROL SYSTEM REPAIR Replace any damaged primary control system component with a new part Repairing primary contro system components is not recommended Use only new hardware when installing new parts After installation of new parts check control system travel and rigging as outlined in Chapter 27 Before returning the aircraft to service flight test the aircraft for proper control system rigging 51 13 00 WING REPAIR 51 13 01 STRINGER REPAIR Stringer splicing may require drilling new holes and adding rivets between existing riveis to obtain the required total number of rivets Add exira rivets where the distance between existing rivets is the greatest The pitch and edge distance must conform to AC 43 13 1 revision requirements see Figure 51 6 750 750 MA pm DIMENSIONS OF EXISTING STRINGERS M20J MOONEY AIRCRAFT CORPORATION 51 13 02 MAIN SPAR REPAIR The spar caps inboard of STA 103 are made of 7075 high strength material Replacement of the spar cap is preferable to repair However if a spar cap repair is thought necessary an exact description of the damage showing location and extent should be sent to the Customer Service Department Mooney Aircraft Corporation to obtain factory recommendations prior to beginning the repair 1 SPAR CAP REPLACEMENT To replace a spar cap remove the skin covering the area to be repaired Before removing a large area of w
302. OONEY 800049 501 JK LP104A PLUG 9 PIN AMP 206708 1 CLAMP AMP 206966 1 JK LP105A LIGHT CONSOLE DIALIGHT 270 1930 0171 702 LAMP 28V GE 327 LAMP ALT GE 385 JK LP106A LIGHT CONSOLE DIALIGHT 270 1930 0171 702 LAMP 28V GE 327 LAMP ALT GE 385 JK LP107A PLUG 4 PIN AMP 206060 1 CLAMP AMP 206062 1 JK LP108A 4 PIN AMP 206153 1 CLAMP AMP 206062 1 JK LP109A RECEPTACLE COMPASS LIGHT DEANS DEA90020MALEHALF JK LP110A PLUG COMPASS LIGHT DEANS DEA90020FEMALEHALF JK LP111A LAMP COMPASS LIGHT 28V GE 327 ALT GE 327 AVIATION RED JK LP112A LAMPS GL SHLD LIGHTS 14 ea GE 327 JK LP113A LIGHT OXYGEN SLOAN B55S 0 U 6 28V GE 327 JK LP114A LIGHT OXYGEN SLOAN 8558 0 U 6 LAMP 28V GE 327 JK LP115A PLUG 2 PIN AMP 1 480318 0 SOCKET AMP 60619 1 JK LP116A 2 PIN AMP 1 480319 0 pm PIN AMP 60620 1 JK LP117A PLUG 2 PIN AMP 1 480318 0 ek SOCKET AMP 60619 1 JK LP118A RECEPTACLE 2 PIN AMP 1 480319 0 a PIN AMP 60620 1 JK LP119A PLUG 2 PIN AMP 1 480318 0 pe 60619 1 JK LP120A RECEPTACLE 2 PIN AMP 1 480319 0 PIN AMP 60620 1 JK LP121A POST LIGHT WHELEN A350CN1W BK SH14 6 LAMP 14 GE 330 JK LP122A POST LIGHT WHELEN A350CN1W BK SH14 LAMP 14V GE 330 JK LP123A LIGHTING TRAY RPM B amp D 0221 128 JK LP124A LIGHTING TRAY M P Ul BA28 24 BW3 JK LP125A LIGHTING TRAP TIT EGT
303. ORATION CODE CL25A CL25B CL25C CL32A CL32B CL37A CL37B CM1 CR101A CR101B CR102A CR103A CT101A CT102A CT103A CT104A CV101A CV101B CV102A CV103A CV104A CV104B CV105A Di D2 D4 D5 DA101A DA101B DB101A DB102A DC101A DD101A DD102A M20J SERVICE AND MAINTENANCE MANUAL ELECTRICAL EQUIPMENT CHART DESCRIPTION VENDOR PART NO NOTES CLAMP 25 PIN DB51212 ILOCK RETAINER DB51221 1 CLAMP 25 PIN DB19977 2 LOCK RETAINER DB51221 1 CLAMP 25 PIN DB 24659 LOCK RETAINER D 20418 2 CLAMP 32 PIN M85049 52 1 22N CLAMP BOOT MS3420 14 ALT MS3420 16 CLAMP 37 PIN 206138 1 CLAMP 37 PIN DC19977 3 LOCK RETAINER DC51222 1 CURRENT MONITOR MOONEY 800221 505 SWITGH RUDDER TRIM MOONEY 880052 519 SWITCH RUDDER TRIM MOONEY BB0052 119 MOTOR RUDDER TRIM MOONEY 880050 503 INDICATOR RUDDER TRIM MOONEY 800242 503 SWITCH ELEV TRIM MOONEY 930023 233 INDICATOR ELEV TRIM MOONEY 800242 519 MOTOR ELEV TRIM S TEC 01165 0 T14 INTERFACE TRIM MOONEY 800313 501 C B SW STAND BY VACUUM MOONEY 930023 233 C B SW STAND BY VAC MOONEY 930023 343 PUMP STAND BY VACUUM AEROSAFE 820904 2 PUMP STAND BY VACUUM 820904 1 C B SW STAND BY VAC MOONEY 930023 247 C B SW STAND BY VAC MOONEY 930023 344 PUMP CLUTCH STAND BY VAC AIRBORNE 28C214CW 2 DIODE 1N2483 ALT 1N5060 ALT 3720GE DIODE SARKES TARZIAN 10H3P ALT ECG 5854 ALT NTE 5854 DIODE BRIDGE FAGOR FB5001 DIODE BRIDGE FAGOR FB5006
304. P CLAMP AMP TAIL STROBE AMP CLAMP AMP PLUG TAIL STROBE AMP STROBE LIGHT TAIL MOONEY RECPT AMP RECPT AMP RECPT AMP AUX PWR RECEPTACLE RELAY AUX PWR C H ALT C H DIODE AUX PWR RELAY SARKES TARZIAN DIODE AVIONICS CONTROL RELAY MAGNACRAFT BASE MAGNACRAFT DIODE DIODE DIODE DIODE RELAY AVIONICS MASTER P B SOCKET P B SPRING P B STANDOFF P B 12 98 SERVICE AND MAINTENANCE MANUAL 28 VOLT ELECTRICAL EQUIPMENT CHART PART NO oe re ee nea om me gt en a a EG re ee SS SS SSS SS SS SS SS SS SSS MH te S Att t rr F F nd 880049 501 1 480318 0 60619 1 1 480319 0 60620 1 1 480318 0 60619 1 50 7 5 OHMS 1 480319 0 60620 1 1 480318 0 60619 1 RH 50 7 5 OHMS 930023 207 930023 237 01 0770329 00 1 480305 0 1 480305 0 1 480303 0 A650 PR D M 01 0770329 00 1 480305 0 1 480305 0 1 480303 0 A650 PG D M 01 0770329 00 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 AN2552 3A 6041H202 6041H202A 10HSP 1N2483 W67CSX 3 70 303 1N2483 1N2483 1N2483 1N2483 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 NOTES JK MB104A RELAY AVIONICS MASTER ALT P B MB4443 1 JKL MB107A SWITCH AVIONICS MASTER C amp K 7101K J MB107B SWITCH MASTER
305. P RECPT CONSOLE 1 CLAMP RECPT CONSOLE 1 CLAMP RECPT HEADLINER CLAMP RECPT HEADLINGER CLAMP RECPT FIREWALL CLAMP L SIDE CABIN MID CLAMP RECPT FLT PNL 2 CLAMP RECPT FLT PNL 2 CLAMP RECPT GLARESHIELD CLAMP M20J VENDOR LITTEL LITTEL 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 RECPT FIREWALL JUNG PNL CLAMP ACCESS PNT CLAMP RECPT L SIDE CABIN LOW CLAMP HECPT SIDE PNL RECPT L SIDE PNL RECPT FLAPS ELEC CLAMP RECPT CONSOLE 2 CLAMP AMP AMP AMP AMP AMP MOONEY MOONEY AMP AMP AMP AMP 12 98 PART NO 155020 or 155120 313001 206036 3 206070 1 206151 1 206138 1 206036 3 206070 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 9206153 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 3 206070 1 206036 3 206070 1 206705 2 206966 1 206036 3 206070 1 930021 002 930021 502 206036 1 206070 1 206036 3 206070 1 SERVIGE AND MAINTENANGE MANUAL 14 VOLT ELEGTRIGAL EQUIPMENT CHART NOTES 19 19 91 20 01 27 SERVICE AND MAN
306. P 1 480305 0 60620 1 JK LC101A FUSEHOLDER LITTEL 155020 ALT LITTEL 155120 FUSE 5A 3AG SLO BLO LITTEL 313005 JK LC102A SWITCH CABIN LIGHT FRONT CARLING TILC64 1S WH FN JK LC103A RESISTOR DIM 20 OHM 10W DALE RH 10 20 OHM JK LC104A LAMP HOLDER H H SMITH 1930 2 LAMP GE 1818 JK LC105A LAMP HOLDER H H SMITH 1930 LAMP GE 1818 JK LC108A LAMP HOLDER HH SMITH 1930 LAMP GE 1818 12 98 91 20 03 65 SERVICE AND MAINTENANCE MANUAL M20J MOONEY AIRCRAFT CORPORATION 28 VOLT ELECTRICAL EQUIPMENT CHART 91 20 03 66 12 98 CODE DESCRIPTION VENDOR PART NO NOTES JK LC107A LAMP HOLDER H H SMITH 1930 LAMP GE 1818 JK LC108A SWITCH CABIN LIGHT REAR CARLING TILC64 1S WH FN JK LC109A RESISTOR DIM 20 OHM 10W DALE RH 10 20 OHM JK LC110A LAMP HOLDER H H SMITH 1930 LAMP GE 1818 JK LC111A LAMP HOLDER H H SMITH 1930 2 LAMP GE 1818 JK LC112A LAMP HOLDER H H SMITH 1930 LAMP GE 1818 JK LC113A LAMP HOLDER H H SMITH 1930 LAMP GE 1818 JK LC117A PLUG 9 PIN ITT CANNON DE 9S CLAMP DE24657 LATCH DE51224 1 JK LC118A MODULE AUTO OFF LIGHT MOONEY 800268 501 JK LC118B RECEPTACLE 9 PIN DE 9P CLAMP DE24657 RING LOCKING 206514 1 JK LC119A DIODE 1N2483 ALT 1N5060 ALT GE 3720 GE JK LC120A DIODE 1N2483 ALT 1N5060 ALT GE 3720 GE JK LC121A PLUG 4 PIN AMP 206060 1 CLAMP AMP 206062 1 JK LC122A 4 PIN AMP 206153 1
307. P 205838 1 CLAMP AMP 206062 1 K DR103B PLUG 28 PIN AMP 205839 3 CLAMP AMP 206070 1 K DR104A PROBE TIT MOONEY 880005 501 K DR104A PROVE TIT ALT MOONEY 880005 503 K DR104B PROBE TIT MOONEY 880055 501 J DT101A PROBE EGT CYL 1 MOONEY 880005 501 PROBE EGT CYL 1 ALT MOONEY 880005 503 PROBE EGT 1 ALT MOONEY 660110 000 DT101A PROBE EGT CYL 1 MOONEY 880005 501 PROBE EGT CYL 1 ALT MOONEY 880005 503 K DT102A PROBE EGT CYL 2 880005 501 PROBE EGT CYL 2 ALT MOONEY 880005 503 K DT103A PROBE EGT CYL 3 MOONEY 880005 501 PROBE EGT CYL 3 ALT MOONEY 880005 503 K DT104A PROBE EGT CYL 4 MOONEY 880005 501 PROBE EGT CYL 4 ALT MOONEY 880005 503 K DT105A PROBE EGT CYL 5 MOONEY 880005 501 PROBE EGT CYL 5 ALT MOONEY 880005 503 K DT106A PROBE EGT CYL 6 MOONEY 880005 501 PROBE EGT CYL 6 ALT MOONEY 880005 503 JK DV101A C B FUEL FLOW KLIXON 7277 2 2 JK DV102A INDICATOR FUEL FLOW MOONEY 880034 501 JK DV102B INDICATOR FUEL FLOW OPT MOONEY 880034 507 JK DV102C INDICATOR FUEL FLOW MOONEY 880034 513 JK DV103A PLUG FUEL FLOW CANNON DE 9S JK DV104A FUEL FLOW MOONEY 880030 501 JK DV104A FUEL FLOW OPT MOONEY 880030 503 JK DV104C XDUGR FUEL FLOW OPT MOONEY 880030 505 JK DV105A SWITCH FURE FLOW MEMORYC amp K 7101K EE DV150A X XDUCER FUEL FLOW PORSCHE 933 110 377 02 FUEL CONTROL D
308. P DE ICE TERMINAL BLOCK MOONEY BF GOODRICH McCAULEY McCAULEY SW C B LOW BOOST FUEL PUMP MOONEY SW C B PUMP FUEL BOOST ALT PUMP FUEL BOOST ALT PUMP FUEL BOOST M20K PUMP FUEL BOOST PUMP FUEL BOOST ALT REGULATOR FUEL PUMP MOONEY WELDON WELDON WELDON WELDON WELDON WELDON WELDON MASSEY MOONEY SW C B HI BOOST FUEL PUMP MOONEY GUARD ASSY HI BOOST SW MOONEY 12 98 MOONEY AIRCRAFT CORPORATION PART NO NOTES 930023 231 930023 331 880049 501 930023 237 930023 337 01 0770329 00 01 0770329 01 01 0770054 12 01 0770054 13 470013 501 A413A HDA CF 880052 523 880052 123 4596 AN2552 3A MS3503 1 930023 213 930023 313 800336 503 216550 216510 200402 MD 89 944 641 213 00 6016177 6016125 944 612 217 00 999 652 351 12 C 12B 5 1028 5 1029 930023 245 930023 345 3E1899 1 B 45018 C 40521 930023 211 930023 311 A8163B 8163B 8163A A8163A 100548 A10051 D A8152 B VR536 800270 523A 930023 219 930028 501 MOONEY AIRCRAFT CORPORATION CODE PA101A PA102A PA103A PA104A PA105A PA108A PA107A PA108A PA109A PA110A PA111A PA111B PA112A PA113A PA114A PB101A PB102A PB102B PB103A PB103B PB105A PB105B PLO1A PLO2A PLO2B PLO2C PLO2D PLOSA PLOSB PL03G PL03D PL03E PLO4A PL04B PL04G PL04D PLOSA PLOSB PLO6A PLO7A 08 M20J ELECTRICAL EQUIPMENT CHART DESCRIPTION REGULATOR VOLTAGE ALT ALT
309. P MOONEY CYL HEAD TEMP MOONEY 12 98 9551B CODE N 541 SW 333 B 3080 00014 880010 501 880010 503 22 295 IFR 11A C203 005 880010 501 880001 505 880023 505 MS3106A 145 25 MS3057 6B 205838 1 206062 1 MS3106A 14S 2S MS3057 6A M52803403 399W 0203 100 880004 501 7277 2 2 660014 005 22 995 04 MS3106A 148 18 MS3057 6B MS3106B 148128 MS3057 6B B 5 610242 001 610242 003 610243 003 610242 001 610242 003 610243 001 AHWA 2 7277 2 2 640281 503 640281 105 640281 107 640281 115 640281 117 640281 149 640281 111 AIRCRAFT CORPORATION 14 VOLT ELECTRICAL EQUIPMENT CHART CODE 21 21 21 21 21 21 21 DG02G DG02G ALT DG02H ALT DG02J DG02K DHO1A DHO1B ALT DJO1A DJO1B DJO2A DESCRIPTION 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 QTY 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 QTY LH FUEL QTY RH AMMETER OIL PRESS OIL TEMP CYL HEAD TEMP PROBE OIL TEMP PROBE OIL TEMP
310. PIN RECEPTACLE 32 PIN RECEPTACLE 34 PIN RECEPTACLE 34 PIN RECEPTACLE 37 PIN RELAY BATT 28V 200A ALT ALT ALT RELAY BATT 14V 200A RELAY RELAY RELAY LDG 28V 50A ALT BRACKET 2 EA RELAY 28V 100A RELAY 14V 200A RELAY RELAY RELAY SOCKET TERMINAL ALTERNATOR STAND BY HOUSING CONNECTOR TERMINAL 1 4 CONTROLLER STBY ALT C B SPEEDBRAKE SWITCH CONTROL WHL HELAY SPEEDBRAKE DIODE ALT ALT MOTOR SPEEDBRAKE SWITCH SPEEDBRAKE M20J MOONEY AIRCRAFT CORPORATION VENDOR PART NO NOTES AMP 1 480305 0 AMP 206036 2 AMP 206207 1 MS3100 28 6S AMP 206153 1 MS3100 32 17P MATRIX SCIENCE MS3100C 28 22P AMP 205841 2 AMP 206705 2 AMP 206705 1 DE9P AMP 205486 1 MOLEX 03 06 2122 MOONEY 930021 2 AMP 203540 1 AMP 206044 1 AMP 206037 1 AMP 206036 1 MOONEY 930021 502 MOONEY 930021 506 AMP 206152 1 MATRIX SCIENCE M83723 83K2232N MOONEY 930021 508 AMP 204814 1 AMP 206151 1 C H 6041H 202 C H 6041H 202A KISSLING 26 57 01 KISSLING 26 57 02 C H 6041H 105A KISSLING 26 64 01 KISSLING 26 64 21 C H 6041H 220 KISSLING 26 72 03 MOONEY 800375 001 C H 6041H 53 C H 6041H 105R MAGNACRAFT WG7RCSX 3 KISSLING 28 08 01 P amp B VF4 15 H11 P amp B VCF4 1002 P amp B 26A1348C B amp C BC410 1 B amp C 12 003 B amp C 14 026 B amp C BC203 2 KLIXON 7277 2 3 PRECISE FLT 01265 PRECISE FLT 01384 1N2483 1N5060 GE 3720 GE PRECISE FLT 01532 PRECISE FLT 01505 12 98 MOONEY
311. PORATION C Set mixture control at IDLE CUTOFF D Turn boost purnp ON E Open throttle 1 4 Push mixture control toward FULL RICH for 3 to 5 seconds then return to IDLE CUTOFF I 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 Ke 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 overtemperature 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 shoul
312. PTE uM Ae 42 98 39 2100 de Sg oe ues cue 6 TAB uolo h tee UAR 21 12 98 12 98 39 EFFECTIVITY 1 2BLANK MOONEY AIRCRAFT CORPORATION M20J SERVICE AND MANUAL CHAPTER 39 ELECTRICAL PANELS AND COMPONENTS 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 TABLE CONTENTS SUBJECT General Instrument and Control Panels Flight Instruments Avionics Equipment Engine Instruments and Circuit Breakers Flight Instrument Panel Cluster Gauge Troubleshooting Guide Landing Gear Switch Landing Gear Safety Override Switch Avionics Radio Panel S oe Annunciator Panel Emergency Locator Transmitter ELT Switch Instrument and Radio Light Control Box Cigar Lighter 55 24 Electrical Electronic Equipment Rack Miscellaneous Maintenance Equipment Maintenance 12 98 PAGE 39 CONTENTS 3 4BLANK SERVICE AND MAINTANANCE MANUAL 39 00 00 GENERAL The instrument panel is divided into three basic groupings 1 Flight Instruments 2 Avionics Radio Panel 3 Engine Instruments and Circuit Breaker Panel The flight instrument panel is shock mounted The radio avionics panel generally has individual racks for the components an
313. PTER 51 STRUCTURES TABLE OF CONTENTS CHAPTER SECTION SUBJECT DESCRIPTION PAGE 91 00 00 General 5 51 10 00 2222 Structural Repair General 5 51 10 01 uw Fastener Replacement 2 DE 51 1100 Reserved 7 51 1200 Fuselage Repair 7 51 4201 4 Tubular Structure Repair 57 51 1202 Tailcone Repairs 10 514203 ue Landing Gear amp Retraction System Repair 10 51 1204 x x vom X Flight Control rm 11 51 1300 x ov os Repair VS ww 4 51 1301 ue ww ue ox Stringer Repair 14 3149 02 uou xo xoi MainSparRepai 11 51 13 03 LL LL Stub Spar Repair 51 13 04 2 LL 42 20 Rear Spar Repair 5 51 1305 LL 2 2 Rib Repair 45 51 1306 wc Wing Tip Repair 45 51 9207 v v Wing Skin Panel Repair sa 15 51 14 00 Horizontal Stabilizer amp Vertical Fin Repair 17 TED Aue Leading Edge Skin Repair 47 dor Main spar Repair Outboard of STA 9 00 17 Yates ME Ex RibRepair 18 51 14 04 LL 2 Remating Horizontal Stabilizer to Stinger 18 9145 00
314. R The engine cooling air intakes and exits are calculated for optimum cooling requirements and minimum drag Normal engine operating temperatures are at the optimum to facilitate engine efficiency The engine induction air intake is an aluminum duct that picks up impact air and routes it through the air filter to the engine injector assernbly The air intake system includes a RAM AIR intake system that is manually operated 24 0001 thru 24 3153 71 60 01 ENGINE INDUCTION SYSTEM Ram air enters through a port in the lower cowling and is ducted to the fuel injector On S N 24 0001 thru 24 3153 a Ram Air control moves a two position door in the ram air duct to permit the selection of filtered or unfiltered direct ram air spring loaded valve in the induction system intake duct permits alternate air to enter the engine from within the engine cowling The alternate air door should be inspected for proper preload and condition per 100 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 seai to door A dry type panel air filter mounts in the 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 filler after 500 hours or once each year whichever occ
315. R FUEL QTY I B LT MOONEY 610242 003 KL DF106A TRANSMITTER FUEL QTY I B RT MOONEY 610242 003 L C B FUEL QTY LH RH KLIXON 7277 2 1 L DF151A FUELQTY IND L R PENN AIRBORNE 9 1620 2 L DF152A PLUG FUEL QTY L R ITT DB25S CLAMP ITT DB51212 LOCK RETAINER HT DB51221 1 JK C B CLUSTER GAUGE KLIXON 7277 2 5 J DG102A GAUGE CLUSTER MOONEY 640281 523 K DG103A GAUGE CLUSTER MOONEY 640281 525 L C BINSTRUMENT DISPLAY KLIXON 7277 2 1 L DG151A INSTRUMENT DISPLAY PENN AIRBORNE 9A1600 2 L 0915224 PLUG INSTR DISPLAY ITT DB25S CLAMP ITT DB51212 LOCK RETAINER ITT DB51221 1 L DG158A C B INSTRUMENT PTT KLIXON 7277 2 1 L DG154A SWITCH INSTRUMENT PTT ALCOSWITCH MPE106F CAP BLACK ALCOSWITCH C 22 L 061554 PLUG 9 PIN PTT AMP 206708 1 CLAMP AMP 206966 1 L DG156A RECPT PTT 9 PIN AMP 206705 2 CLAMP AMP 206966 1 L 0 157 PLUG GRIND 7 28 PIN AMP 205839 3 CLAMP AMP 206070 1 L 091584 RECPT GRND 7 28 PIN AMP 206152 1 CLAMP AMP 206070 1 91 20 02 12 98 MOONEY AIRGRAFT CORPORATION CODE SERVIGE AND MAINTENANGE MANUAL PART NO NOTES gt gt gt Wu To DTW T VT pd x lt a am lt WW JK nm L DH101A DH150A DJ101A DJ102A DJ150A DJ151A DJ152A DJ175A DJ176A DJ
316. R REPLACEMENT 1 Wing tip strobe power supply A Gain access to wing tip power supply through bottom inspection cover 1 near wing tip See Figure 33 4 Power supply 2 is physically attached to this inspection cover B Disconnect wiring connections between switch and power supply WARNING High voltage is involved in the circuit between the power supply and strobe light assemblies Aithough 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 C Disconnect wiring harness between power supply and strobe light See warning above D Remove ihe screws securing the power supply to the inspection panel and remove the unit 2 strobe light power supply S N 24 1038 on A Gain access to this unit through the inspection cover on the aft left hand side of the tailcone The 12 98 M20J SERVICE AND MAINTENANCE MANUAL T POWER SUPPLY VIEW LOOKING UP LEFT WING INSPECTION COVER TYPICAL LOCATION RIGHT WING STROBE LIGHT POWER SUPPLY FIGURE 33 4 power supply is physically mounted to this inspection cover B Disconnect the wiring connections between the switch
317. R SEAL NOT SHOWN M20J SERVICE AND MAINTENANCE MANUAL NEW HINGE A Place old door assembly with new hinge or new door assembly and new hinge into position and latch the door in place NOTE 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 While door is held in place mark holes in new hinge using holes in outer skin as locators D Verify correct position of door prior to drilling 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 SPRING OVER CENTER TENSION DOOR LOCK GOES HERE OUTSIDE HANDL CAM SLOT KNOB WHITE BAGGAGE DOOR LATCH MECHANISM FIGURE 52 2 52 30 00 6 12 98 SERVICE AND MAINTENANCE MANUAL F Remove door assembly Deburr and clean the area completely prior to reinstallation of door assembly G Apply sealant PR 1403 G B2 or equivalent to mounting are between outer skin and door rame 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 BAGGAGE COMPARTMENT DOOR LATCHING MECHANISM The baggage compartment door has a direct non adjustable latching lin
318. RCRAFT CORPORATION 0 24 1418 AND ON INSPECTION PANEL AND COVERS FIGURE 53 3 12 98 53 30 00 5 CORPORATION M20J SERVICE AND MAINTENANCE MANUAL TABLE FOR FIGURE 53 3 COMPONENT IDENTIFICATION Cabin Door Landing Gear Actuator Gascolator Fuel Selector Valve Engine Compartment Oil access Pa Gear Retract Tubes Flap indicator able Baggage Door Electric Flap Actuator Elevator Rudder Control Stops 15 Stabilizer Trim Screw and Stops Empennage Attachment 16 17 18 Elevator Rudder Aileron Control System Belleranks Rod End Bearings Avionics Blackboxes Batteries 19 klag Steering System Cowl Flap ontrols 6A E L T access 20 Rudder Torque Tube 7 Stabilizer Trim Jack Screw 21 Landing Gear Retraction Tubes 8 Empennage Attachment 22 Tail Light Harness Connections 9 Elevator Rudder Controls Rod End 23 Empennage Attachment Trim Jack Screw Bearings amp Travel Stops 10 Rudder Controls Elevators amp Rudder 24 All components 12 18 21 Belleranks 11 Brake Master Cylinders Rudder Torque Tube Electric Fuel Pump 53 40 00 ATTACH FITTINGS Figure 53 4 for locations Various type of fittings 3 are used io properly distribute the load between the 53 40 01 WING ATTACH FITTINGS wing and the fuselage The wing assembly 1 is attached to the fuselage assembly 2 using structurai hardware 4 see 3 TYP LH amp
319. RPORATION EMERGENCY GEAR SYSTEM FIGURE 32 11B DISENGAGE RIGGING SIN 24 0001 thru 24 0377 Except 24 0084 Other than Avionic Products or Plessey Actuator PLESSEY ACTUATOR SEE SERVICE INSTRUCTION M20 92 M20J SERVICE AND MAINTENANCE MANUAL Rigging of Manual Emergency Landing Gear Disengage Unit as Follows Ref Fig 32 10A and 32 11B 1 With aircraft on jacks insure that disengage operating handle 1 Fig 32 11B in the cabin is in the full forward position and that the cable 2 Fig 32 11B is inserted thru hole in existing bolt attached at K Fig 32 10A 2 With unit K in full engaged position K full aft and existing bolt M inserted thru disengage arm apply approximately 5 Ibs pull to cable to remove slack 3 Tighten nut M readjust wire stops L and connect spring 4 Tum crank 3 Fig 32 11B io assure full engagement 5 Move disengage operating handle 1 to full aft position and operate hand crank 3 to assure full disengagement Retum handle 1 to full forward position 6 Rigging is now complete S N 24 0001 THRU 24 0377 EXCEPT 24 0084 NOTE During 200 hour gear inspection 5 20 06 3 L 1 inspect rubber drive coupling between motor gearbox and jackshaft gearbox for signs of 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
320. RUSS 2 020007100 warner VIEW LOOKING FWD MAIN GEAR RIGGING TOOL APPLICATION FIGURE 32 9 32 30 04 12 98 12 MOONEY AIRCRAFT CORPORATION C is facing actuator motor Reattach Heim to bellcrank E NOTE When installing heim bearing end inthe bellcrank position it freely so there will be no lateral bind on the jack screw Place ONE 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 heim bearing from twisting too far yet provide adequate movement NOTE Previous installation may have contained one large AN960 916 washer next to the ball joint This washer MUST NOT be reinstalled the AN960 716L smaller and thinner washer described above is used as a replacement 4 Position retraction bellerank A Fig 32 10A so that center of forward hole in left outboard bellcrank is 1 56 inches from forward face of truss 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 preload NON AVIONICS PRODUCTS ACTUATOR MAIN GEAR RIGGING FIGURE 32 10A 12 98 M20J arm of SERVICE AND MAINTENANCE MANUAL 5 With bellcrank in positio
321. RY STRUCTURES 57 20 01 JACK POINTS The jack points are located on the under side of the wing The threaded wing tie down eyebolt fittings are designed to accept the non threaded jack points These are located outboard of each main gear See Section 7 10 00 for complete jacking procedures 57 20 02 FIBERGLASS WING TIPS S N 24 1038 and on The M20J wing tips are non structural fiberglass components They are riveted to the upper and lower wing skins during final assembly of the wing structure 1 Wing tip removal A Remove the navigation strobe light lens 1 by removing 4 screws and washers 2 ihat retain the lens to wing tip 3 24 0001 thru 24 2999 S N 24 3000 thru 24 TBA Disconnect aft position light connections Refer to Figure 57 4 57 00 00 3 MOONEY AIRCRAFT CORPORATION M20J SERVICE AND MANUAL 53015 TWOldAL M3HSVM 191Z 096NV 344115 GIM UV S INGOVPOV OL OV3H 1708 3MIM Al34VS LVIS N3CNA YIADO 55300 HONOWHL 318155309 1109 VLL HZNV AMVSS3O3N SV WIHS HNvd SS300V ONIM 318155300 Z INN Zy cacNv SIV3S H3UN MiB V9L kNV 901 vV 1 NV 3015 Wld T JASN 3181553297 z INN 8SZb t9tNV c N3HSVM 0L 086NV TIM T33HM NYHL 2181553297 c 1108 VOL NV TASS HiO8 ANN SZPr C9FNY vy N3HSVM 91 096 9 1108 Vr kNY HO AV
322. Road PO Box 32516 San Antonio Tx 78284 telephone 210 349 3771 for further assistance 73 50 00 DRUCK TRANSDUCER TEST PROCEDURE Refer to Section 79 40 00 73 31 06 12 98 MOONEY AIRCRAFT CORPORATION M20J SERVICE AND MAINTENANCE MANUAL CHAPTER 74 IGNITION SERVICE AND MAINTENANCE MANUAL M20J CHAPTER SECTION SUBJECT 74 Effectivity Contents 74 00 00 74 30 00 CHAPTER SECTION SUBJECT 74 00 00 74 10 00 74 10 01 74 10 02 74 20 00 74 30 00 MOONEY AIRCRAFT CORPORATION CHAPTER 74 IGNITION LIST OF EFFECTIVE PAGES PAGE DATE 1 2BLANK 12 98 3 12 98 4 12 98 TABLE OF CONTENTS SUBJECT PAGE General 3 Electrical Power i 3 Magneto inspection Maintenance Installation amp Timing 3 Ignition System Troubleshooting 3 Engine Firing Order 3 Switching 3 12 98 74 EFF CONTENTS 1 2BLANK MOONEY AIRCRAFT CORPORATION 74 00 00 GENERAL The Lycoming O 360 A1B6D or IO 360 A3B6D series engines are equipped with Bendix 2000 or 3000 Series 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 starting functions Turn the key clockwise through R L and BOTH to START position push forward on key while in START and the starter relay
323. S housing that actuates the rotating lock plate 3 should MAINTENANCE AF AST be lubricated occasionally with Tri Flow or equivalent 12 98 28 00 00 5 MOONEY AIRCRAFT CORPORATION 28 10 00 STORAGE 28 11 00 FUEL TANK FIELD REPAIR 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 during resealing of the tanks for drain holes to be left 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 2 MIL S 8802D Class A 2 Filleting Compound PR1422 B 1 2 B 2 or CS3204 B 1 2 B 2 MIL S 8802D Class B 3 Removable access panel sealant PR1403 G B2 PR1428 or CS3330 4 Protective sealant PR1005 L MIL S 4383B B Gloves Polyethylene 8 Brushable Type Sealant 7 Tack Fre Time HOURS 10 36 8 24 10 PRO SEAL890 A2 36 GLASS A PR1422 A 1 2 b Filleting Compound and on wing walk access panel EMEN Tack Free Time CLASS B HOURS PR1422 B 1 2 pod O a PR1422B 2 36 53204 1 2 8 CS3204B
324. S OVER VOLT 12 98 M20J MOONEY AIRCRAFT CORPORATION indicates that the aircraft bus voltage is less than 26 5 VDC When low voltage is detected internally or when low current is detected the annunciator channel flashes and when overvoltage tripped is detected the annunciator channel illuminates steady Comparator monitors the aircraft 28 VDC by comparing the voltage at the arm of R68 with the regulated voltage at the junction of R64 and R65 The output of U6 an open collector comparator is normally low When low voltage is detected the output of U6 rises and drives Q12 into conduction through the bias network R60 CR24 and CR28 thus illuminating 0510 In a manner similar to the Hi Lo Vac channel the signal FLASH will remove this drive signal as the flasher cycles thus flashing DS10 28 VDC signal applied to LOVERRIDE wili bypass the above network and drive Q12 into conduction regardless of the state of the comparator U6 Similarly TEST will drive Q12 into conduction regardless of the state of the comparator U6 A 28 VDC signal applied to LOVERRIDE also 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 comparator U6 or U7 The channel Left Alternator Low Volts Over Volt does not dim 8 0 NOT USED FIGURE 7 NOT USED 9 0 TYPICAL POSITIVE APPLY W DIM A typical Positive Apply Dimmable circ
325. SEMBLIES FIGURE 32 14 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 ply rated 1 Nose wheel removal A Remove cotter key nut and washer from axle Figure 32 13 B Remove nose wheel 2 Installation is in reverse sequence of removal 3 Nose wheel disassembly A Completely deflate tire by removing valve core B Remove nuts washers and wheel half retaining bolts 15 from wheel Fig 32 14 C Separate wheel haives 13 and 14 and remove tire and tube Refer to Section 32 40 02 steps 5 thru 10 for wheel inspection D Reassemble nose wheel in reverse sequence of disassembly Tighten retaining bolt nuts evenly and torque to 90 inch pounds Inflate tire to 49 PSI 3240 04 BRAKE SYSTEM 1 BRAKE REMOVAL AND INSTALLATION Lining inspection and or replacement or cylinder repair 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 12 98 22 MOONEY AIRCRAFT CORPORATION M20J SERVICE AND MAINTENANCE MANUAL A Perform a minimum of six 6 light pedal effort braking applications and two 2 hard stops from 25 to 40 MPH 21 to 35 KIAS Allow the brake discs to partially cool between stops The procedure will g
326. SENSOR TACH SENSOR TACH SENSOR TACH SENSOR INDICATOR TACHOMETER INDICATOR TACHOMETER KULITE MOONEY B amp D B amp D MOONEY B amp D B amp D B amp D B amp D B amp D MOONEY MOONEY MOONEY AIRCRAFT CORPORATION PART NO S 304 CCT NOTES 610242 003 610243 003 610243 001 610242 005 880059 507 880059 511 880059 513 880059 505 880059 517 880059 519 880061 501 MS28034 1 PDCR 821 0662 100 APT 201 1000 100G APT 154 1000 100PSIG PDCR 821 0662 30 APT 153 1000 30PSIG DRUCK 920 0143 50 APT 155 1000 50D 880039 515 0520 003 0400 004 880039 517 0520 006 SLICK MAGS 0402 102 0408 003 NOTE 3 BENDIX MAGS 0402 104 0406 004 NOTE 3 880039 519 880039 523 INSTALLED ON 10 550 ENGINE BY TELEDYNE CONTINENTAL MOTORS DM101A DM102A DM103A DM104A DP101A DP101B DP102A DP103A DP104A DP105A 91 20 05 84 HOUR METER HOUR METER HOUR METER ALT HOUR METER ALT C B PITOT HEAT C B PITOT HEAT HEATED PITOT PITOT HEATED ALT PLUG 2 PIN SOCKET MOONEY MOONEY HOBBS DATCON HOBBS HOBBS MOONEY MOONEY AERO INSTR AERO INSTR 12 98 880035 507 880035 505 15006 SG 70 85000 15000 930023 205 930023 305 PH502 24 AN5812 1 PH502 12 AN5812 AN3115 1 8116 1 MOONEY AIRCRAFT CORPORATION M20J SERVICE AND MAINTENANCE MANUAL ELECTRICAL EQUIPMENT CHART CODE DESCRIPTION VENDOR PART NO NOTES DR101A PROBE TIT MOONEY 880055
327. SITY GRADES GRADES SAE 50 SAE 40 SAE 30 SAE 40 SAE 20 SAE 30 SAE 40 or 50 SAE 40 SAE 20W 40 ALTERNATOR STARTER SPARK PLUG GAP Fine Wire Massive MAX CYLINDER HEAD TEMP SAE 20W 30 PRESTOLITE 24 0001 thru 24 2999 14V 60 AMP 24 3000 thru 24 TBA 28V 70 AMP 24 0001 thru 24 2999 12V 24 3000 thru 24 TBA 24V 015 to 018 018 to 022 475 Degrees F gt Refer to latest edition of Lycoming Service No 101 4 Refer to latest edition of Lycoming Instruction No 1325 Engine Model IO 360 A186D Effective 24 0377 and earlier M20J can be converted to an IO 360 A3B6D engine with SB M20 206 compliance S N 24 3374 thru 24 TBA have IO 360 A3B6 engine configuration installed This configuration utilizes two Slick Magnetos 12 98 71 00 00 5 MOONEY AIRCRAFT CORPORATION M20J 71 00 01 ENGINE DATA CON T START amp WARMUP OIL PRESSURE SERVICE AND MAINTENANCE MANUAL Maximum 100 PSI Minimum 25 PSI NORMAL OIL PRESSURE Maximum 90 PSI Minimum 60 PSI 71 00 10 ENGINE REMOVAL Remove engine mounting bolts To assist in installation identify and tag each part as it is removed Plug or cap all lines hoses and fittings as they are disconnected 1 Make sure that all cockpit switches are OFF 2 Tum fuel selector valve OFF 3 Remove engine cowling and baffles See Section 71 10 4 Disconnect battery ground cable 5 Remo
328. SSURE VS TEMPERATURE TABLE FIGURE 12 1 12 10 04 12 98 MOONEY AIRCRAFT CORPORATION 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 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 SCHEDULED SERVICING 12 20 01 INDUCTION AIR FILTER The importance of keeping the induction air filter clean cannot be overemphasized A clean filter promotes fuel econorny and longer engine life The dry type filter can usually be washed six to eight times within 500 hours or one year before 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 filler opposite to normal airflow Keep air nozzle at least two inches from filter element Cover entire filter area with air jet CAUTION Do not use a compressor unit with a nozzle pressure greater than 100 p s i 3 After cleaning inspect filter and gasket for damage Discard a ruptured filter or broken g
329. STEP 8 After repositioning the jumpers reassemble the indicator in the reverse order of disassembly CAREFULLY LINE UP THE PINS STEP 9 After reassembly power up indicator and check configuration For approximately 2 seconds the right side of the indicator display will depict numbers that indentify the configurations of units Figure 73 5 STEP 10 If fuel flow or quantity used totals do not match aciual values after several hours of flying contact the manufacturer Alcor for trouble shooting procedures M20J SERVICE AND MAINTENANCE MANUAL NOTE Reposition the jumpers by arasping 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 non volatile memory for retaining basic settings and Fuel Remaining and Fuel Used during 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 until corrective action is taken When test routine is completed system will display the following 1 Software basic 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 intern
330. STIC CONNECTOR B amp C TERMINAL 1 4 INCH B amp C 12 98 SERVICE AND MAINTENANCE MANUAL PART NO NOTES 203540 1 G14000H000 1265 0 206044 1 206036 2 206036 1 930021 502 GMCT2M0E100JO 930021 506 206152 1 M83723 83K2232N 930021 508 204814 1 SK2114 206151 1 GMCT104M0000Z0 NEBV23 077 YSK006 011 YSK006 089 YSK015 025AH 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 H11 VCF4 1002 26A1348C RH 10 20 OHM RH 10 5 OHM 919029 501 09F976 RH 50 7 5 OHM RC42 GF102J 7598 80802 3D 1 6K OHM 1 2W 1 0 OHM 1 8W BC410 1 12 003 14 026 91 20 06 105 SERVICE AND MAINTENANCE MANUAL CODE SA102A SA103A SB101A SB102A SB103A SB104A SB105A SB106A SB107A SB108A SP101A SP102A SP103A SW101A SW102A SW103A SW104A SW105A SW106A SW107A SW108A SW109A SW110A SW111A SW112A SW113A SW114A SW115A SW116A SW117A SW118A SW119A SW120A SW121A SW122A SW123A SW124A SW125A SW126A 91 20 06 106 M20J ELECTRICAL EQUIPMENT CHART DESCRIPTION VENDOR CONTROLLER STBY ALTERNATOR B amp C SWITCH STBY ALT EMERG BUS MOONEY C B SPEEDBRAKE KLIXON SWITCH SPEEDBRAKE YOKE PRECISE FLT RELAY SPEEDBRAKE DIODE SPEEDBRAKE ALT MOTOR SPEEDBRAKE SWITCH SPEEDBRAKE PRECISE FLT GE PRECISE FLT PRECISE FLT SOLENOID CLUTCH SPEEDBRK PRECISE FLT S B INTERFACE SPEAK
331. SWITCHES MAY VARY WITH INDIVIDUAL SWITCH AIRCRAFT INSTALLATIONS VIEW LOOKING AT BACKSIDE OF PILOT S PANEL NOTE LOCATION OF OPTIONAL SWITCHES MAY VARY WITH INDIVIDUAL AIRCRAFT INSTALLATIONS PITOT HEAT STAND BY VACUUM 22 7 LF 7 m G JA THATS CIRCUIT BREAKER SWITCHES FIGURE 39 3 12 98 39 11 00 7 MOONEY AIRCRAFT CORPORATION depending upon the avionics package installed The panel contains a row of circuit breaker switches along with the master switch which control most of the systems of the airplane Refer to Figure 39 3 Access for maintenance of the switches or related wiring 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 LIGHT BULB ACCESS VIEW LOOKING AT BACK SIDE OF PILOT S PANEL M20J SERVICE AND MAINTANANCE MANUAL 39 11 01 CLUSTER GAUGE The cluster gauge is located at the top of the flight panel Access is obtained by removing the glareshield per section 39 10 01 Cluster gauges have the capability of individual module replacement One some configurations the entire cluster gauge will require removal from the pane
332. Section 27 93 00 for adjustment procedures 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 trips the high vacuum switch causing the vacuum warning light to illuminate steadily S N 24 0001 thru 24 0083 and 24 0085 thru 24 0377 have a vacuum gauge mounted above the radio panel 12 98 M20J MOONEY AIRCRAFT CORPORATION 4 Low Fuel Warning Circuit The low fuel indicators will illuminate when 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 panel 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 P N 50000045 24 0001 thru 24 3153 or P N 9500324000 24 3154 thru 24 TBA is required for this procedure Adapters can m ordered through Mooney Marketing or Service enters A Calibration Procedures using 500D0045 or P N 9500324000 1 Remove glareshield disconnect plug from rear of annunciator remove annunciator front panel and place Norm Cal switch in Cal position 2 Plug appropriate calibration transfer standard on rear of old annunciator and reconnect harness plug 3 Tum on master switch and t
333. T FLAP MOTOR 9 PIN AMP 206705 2 CLAMP AMP 206966 1 K RC40A RECPT THROTTLE SWITCH 4 PIN AMP 206153 1 CLAMP AMP 206062 1 JKL RC50A RECPT C B PNL 2 AMP 206151 2 CLAMP AMP 206138 1 JKL RC51A RECPT IGNITION SWITCH MOONEY 930021 506 JKL RC52A RECPT ALT STARTER CANNON MS3100K28 2P ALT MS3100KE28 2P JKL RC55A EMPENNAGE AMP 206705 2 CLAMP 206966 1 JKL RC56A RECPT GRND RECPT 4 9 PIN AMP 206705 2 CLAMP 206966 1 JKL HC57A GRND RECPT 5 14 PIN MOONEY 930021 002 JKL RC58A RECPT DIM RECPT 2 16 PIN AMP 206036 3 CLAMP AMP 206070 1 RC58B RECPT PNL LT DIM 2 14 PIN AMP 206044 1 CLAMP AMP 206070 1 JKL RC59A RECPT GRAND RECPT 6 26 PIN MOONEY 930021 506 JK RC76A RECPT 9 PIN AMP 206705 2 CLAMP AMP 206966 1 JK RECPT 28 PIN AMP 206152 1 UNE CLAMP AMP 206070 1 L RC150A RECPT ENGINE HARNESS LT CANNON GERMANY 121006 518 CLAMP CANNON GERMANY 057 8557 000 FERRULE END RING CANNON GERMANY 304 8553 000 RECPT ENGINE LT FAWALL ALT CANNON GERMANY CA121006 600 L RC150A RECPT ENGINE HARNESS LT ALT PORSCHE 933 612 415 00 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 DESCRIPTION VENDOR PART NO NOTES
334. T POINTS FIGURE 32 2A 24 3000 THRU 24 3078 U 1 12 98 M20J 32 10 05 SERVICE AND MAINTENANCE MANUAL INBOARD GEAR DOOR RIGGING 24 3000 thru 24 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 positions refer to landing gear rigging procedures in Section 32 31 03 Any adjustment to rod end on retract tube L Fig 32 5 and rod on retraction tube V Fig 32 9 is ata 2 to 1 ratio respectively this adjustment will change rigging values Recheck preload values EXAMPLE 1 The door is open a small amount when gear is DOWN but closed when gear is UP Adjust by turning retract 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 amount when gear is UP Adjust by turning retract tube V rod end OUT 1 2 tum and retract tube L Fig 32 5 rod end IN 1 turn 2 Tighten jamb nuts and connect springs on inboard gear door bellcranks A Fig 32 2B MAIN GEAR DOOR RIGGING FIGURE 32 2B 24 3000 THRU 24 3078 NOTE Do not rig doors shut more than necessary as this may result in higher actuator loads 3 Adjust outboard door link to close gap at leading edge of door If the door is rigged too tight the skin will be under stress concave at the point where the linkage is attached to the door It could also
335. T and OVERHEAD VENTILATION The cabin air and heat system controls and vents are located on the console between the pilot and co pilot seats Individual fresh air outlets are located on each side of the cabin side panels just forward of the pilots and co pilots knees The overhead ventilation system consists of individual outlets Wemac valves located above each seat position S N 24 0901 amp later aircraft have a regulator system with the control knob located above the pilots head The systems are basically trouble free but inspection should be made at regular intervals to ensure proper operation 12 98 M20J SERVICE AND MAINTENANCE MANUAL S N 24 0001 thru 24 0757 aircraft have an overhead airscoop operated by rotating the knob above the pilots seat to extend or retract as desired to control air flow or to prevent air buffeting at high criuse speeds Small overhead vent deflectors with inner knob volume controls distribute incoming air as individually desired 21 40 00 HEATING Heat is supplied to the cabin through flexible hoses connected to a heat distribution box assembly and shroud assemblies located on the exhaust manifold on the engine It is recommended that the condition of these items be checked each time the cowling is removed This will provide a continuing check for the prevention of carbon monoxide in the cabin Any deteriorated flexible ducts should be replaced Heat shrouds should be inspected for cracks or ot
336. T102A AT103A AT104A AT105A AT106A BH1 BR2 BR3 BR5 BH7 5 BR10 BR15 BR20 BR25 BR30 BR35 BR40 BR50 B270 BS101A BU2A BU2B BU2C BU2D BU2E BU3B BU3C BU4A BU4B BU4C BU4D BUSA BU5B BU5C ELECTRICAL SYSTEM HARDWARE CHART 28 VOLT M20J ELECTRICAL EQUIPMENT CHART 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 SWITCH AIR COND COMPRESSOR AIR COND BLOWER EVAP FRONT BLOWER EVAP REAR BLOWER CONDENSOR SWITCH AIR COND PRESS CONNECTOR AIR COND CONTACTS ACTUATOR SWITCH ACTUATOR SWITCH ACTUATOR SWITCH ACTUATOR SWITCH ACTUATOR SWITCH ACTUATOR SWITCH CIRCUIT BREAKER 1A ALT CIRCUIT BREAKER 2A ALT CIRCUIT BREAKER 3A ALT CIRCUIT BREAKER 5A ALT CIRCUIT BREAKER 7 5 ALT CIRCUIT BREAKER 10 ALT CIRCUIT BREAKER 15A ALT CIRCUIT BREAKER 20A CIRCUIT BREAKER 25A CIRCUIT BREAKER 30A CIRCUIT BREAKER 35 CIRCUIT BREAKER 40 ALT CIRCUIT BREAKER 50A CIRCUIT BREAKER 70 BASE RELAY BUS BAR 2 PLC BUS BAR 2 PLC BUS BAR 2 PLC BUS BAR 2 PLC BUS BAR 2 PLC BUS BAR 3 PLC BUS BAR 3 PLC BUS BAR 3 PLC BUS BAR 4 PLC BUS BAR 4 PLC BUS BAR 4 PLC BUS BAR 4 PLC BUS BAR 5 PLC BUS BAR 5 PLC BUS BAR 5 PLC VENDOR MOONEY MOONEY MOONEY MOONEY MOONEY MOONEY CORY COMP CORY COMP MICR
337. T103A DT103A DT104A DT104A DT105A DT101A DT102A DT103A DT104A DT105A DT106A DV101A DESCRIPTION VENDOR HOUR METER MOONEY HOUR METER MOONEY RECEPTACLE 4 PIN AMP CLAMP AMP PLUG 4 PIN AMP CLAMP AMP FUSEHOLDER LITTEL FUSE ALT LITTEL FUSE 5A 3AG SLO BLO LITTEL C B PITOT HEAT MOONEY PITOT HEATED AERO INSTR ALT PLUG SOCKET PLUG 2 PIN AMP SOCKET AMP RECEPTACLE 2 PIN AMP PIN 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 CYL 1 MOONEY ALT MOONEY ALT MOONEY PROBE EGT CYL 2 MOONEY ALT MOONEY ALT MOONEY PROBE EGT CYL 3 MOONEY ALT MOONEY ALT MOONEY PROBE CYL 4 MOONEY ALT MOONEY ALT MOONEY EGT INDICATOR MOONEY LEAD WIRE ALCOR PROBE EGT CYL 1 MOONEY ALT MOONEY PROBE EGT CYL 2 MOONEY ALT PROBE EGT CYL 3 ALT MOONEY PROBE EGT CYL 4 MOONEY AL MOONEY PROBE EGT CYL 5 MOONEY ALT PROBE CYL 6 MOONEY ALT MOONEY C B FUEL FLOW KLIXON 12 98 880035 507 880035 505 206153 1 206062 1 206060 1 206062 1 155020 155120 313005 930023 205 PH502 24 AN5812 1 AN3115 1 AN3116 1 1 480318 0 60619 1 1 480319 0 60620 1 7277 2 2 880051 501 880051 503 205838 1 206062 1 205839 503 206070 1 880055 501 880005 503 880005 501 6601 10 000 880005 503 8
338. TALL MH MISCELLANEOUS ANTI ICE WT WARNING ANNUNCITOR MJ MISCELLANEOUS JUNCTION BOX WV WARNING VACUUM MK MICROPHONE WW WARNING ALTERNATE AIR MM MISCELLANEOUS MARKER BEACON YAW DAMPER 91 00 03 d RIEREMIATIONS EQUIPMENT The abbreviations to the electrical system hardware charts are necessary due to space limitations in the fields of the computer Airspeed A S Alternate Alin Circuit Breaker Ckt Bkr or C B Console Cnsl Control Cntri Coordinator Coordtr Cylinder Cyl Down Dn 91 00 03 Page 6 12 98 Placard Pied Radio Rad Receptacle Recpt Reguiator Regitr Remote Rem Resistor Res Rheostat Rheo Right R SERVICE AND MAINTENANCE MANUAL M20J MOONEY AIRCRAFT CORPORATION ABBREVIATIONS EQUIPMENT LIST con t Electric Elec Safety S Flight Fit Selector Sel Glareshield Supply Sply Landing Ldg Switch Sw Let L Transducer XDCR Lights Lts Transmitter XMTR Panel Pnl Transistor XSTR Pilot Pit Warning Wrn 91 20 00 ELECTRICAL SYSTEM HARDWARE CHART Refer to the Electrical Schematic located in the envelopes at the back of this manual that depicts the Serial Number configuration of the aircraft being serviced The S N s vs Schematic s are shown below A C SERIAL NUMBER DRAWING SCHEMATIC NUMBER 14 VOLT AIRCRAFT 24 0001 thru 24 0237 except 24 0084 so s 56180026913 24 0238 thru
339. TATOR GEAR ELEC RELAY GEAR RELAY GEAR UP HELAY GEAR UP RELAY GEAR UP RELAY GEAR UP SQUAT SWITCH SWITCH SAFETY AIRSPEED SWITCH SAFETY AIRSPEED VENDOR MOONEY MOONEY MOONEY AEL or EQUIV AERO INST KLIXON MOONEY AMP MOONEY KLIXON MOONEY B amp D INSTR MOONEY MERIDEN or EQUIV KLIXON KLIXON MICRO C H MICRO MICRO HT DUKES DUKES ITT ITT DUKES AVIONICS PROD MOONEY RBM MAGNEGRAFT C H RBM C H COLE HERSEE MICRO MOONEY WHITMAN GENERAL MOONEY SWITCH SAFETY AIRSPEED MOONEY SWITCH DOWN LIMIT MICRO RELAY GEAR DOWN MAGNECRAFT RELAY GEAR DOWN C H RELAY GEAR DOWN RBM RELAY GEAR DOWN C H C B GEAR ACT MECHANICAL PROD C B GEAR KLIXON SWITCH GEAR OVERIDE C H LAMP GE 12 98 PART NO 930023 005 930023 105 930023 205 425936 PH502 24 AN5812 1 AN3115 1 AN3116 1 7277 2 2 880000 503 205838 1 880005 501 7277 2 2 880006 501 0204 100 880005 501 AHWA 15 7277 2 15 7277 2 5 2TL149 3D 8906K2875 DT 2R A7 MCD 2711 LA11C21101 1057 00 1 4196 00 1D LA11C2115 LA11C2114 1057 00 5E 102000 1 560254 501 70 111221 W97CSX 1 6041H50A 70311221 6041H53 24401 1CH1 6 800335 501 SK75 IN K3L 880013 503 880013 505 1CH1 6 W97CSX 1 6041H105A 70 311221 6041H105A 700 01 25 7277 2 15 SBIDDX492 2 388 SERVIGE AND MAINTENANGE MANUAL NOTES SSS SSS SS SS SS SS SSS SSS SSS SS SS SSS SS SS SSS SSeS SSS SSS ss sss se ss sss sss sss 22
340. TS MOONEY AIRCRAFT CORPORATION PART NO NOTES 270 1930 0171 702 370 330 330 AVIATION RED 330 09F976 57F2368 09F976 57F2368 A650 PR D M 14 A650 PR D M 14 CUTLER HAMMER 6041H105A KISSLING 26 64 21 MID CONT MD 89 PORSCHE 944 641 213 00 MID CONT 6016117 MID CONT 6016125 PORSCHE 944 612 217 00 PORSCHE 999 652 351 12 WELDON B163A WELDON A8163A MOONEY 880016 503 AM PROD PREC FLT DGR 1 MOONEY 880270 505 LYCOMING LW 15404 PRESTOLITE ALY 8420 GILL G 35 CUTLER HAMMER 6041 105 MOONEY 930021 001 GUTLER HAMMER 6041 105 PRESTOLITE MZ 4206 PRESTOLITE MZ 4218 PHESTOLITE MZ 4222 MOONEY 810414 501 KING KA0033 00 MOONEY 930021 002 MICRO V3 1 MICRO JV 5 MOONEY 800346 503 iN2483 1N5060 GE 3720 GE 1N2483 1N5060 GE 3720 GE MOONEY 880025 511 CHICAGO MINA CM7 7330 MOLEX 09 50 3151 08 50 0106 MOLEX 12 98 MOONEY AIRGRAFT CORPORATION M20J SERVICE AND MAINTENANCE MANUAL 14 VOLT ELECTRICAL EQUIPMENT CHART RESERVED 12 98 91 20 04 SERVIGE AND MAINTENANCE MANUAL M20J AIRCRAFT CORPORATION 14 VOLT ELECTRICAL EQUIPMENT CHART RESERVED 91 20 04 12 98 80 MOONEY AIRCRAFT CORPORATION M20J SERVICE AND MANUAL ELECTRICAL EQUIPMENT CHART 4 91 20 05 ELECTRICAL EQUIPMENT HARDWARE CHART S N 24 3201 24 3218 THRU 24 3270 NO 800304 J1 REV F S N 24 3271 THRU 24 3350 SCHEMATIG NO 800304 J2 REV S S N 24 3251 THRU 24 3373 SCHEMATIC NO 8003
341. UAL M20J MOONEY AIRCRAFT CORPORATION 14 VOLT ELECTRICAL EQUIPMENT CHART CODE DESCRIPTION VENDOR PART NO NOTES 21 RC16B RECPT CONSOLE AMP 206705 2 CLAMP AMP 206966 1 21 RC17A RECPT RELAY PNL AMP 206036 1 CLAMP AMP 206070 1 21 RC18A RECPT CLUSTER GAUGE AMP 206036 3 CLAMP AMP 206070 1 21 RC18B RECPT CLUSTER GAUGE AMP 206705 2 CLAMP AMP 206966 1 21 RC19A RECPT PILOT S WHEEL AMP 206153 1 GLAMP AMP 206062 1 21 RC20A RECPT COPILOT S WHEEL 206153 1 CLAMP AMP 206062 1 21 RC21A RECPT VAC WARN SW AMP 206153 1 CLAMP AMP 206062 1 21 RC22A RECPT RADIO PWR C B PNL 206207 1 CLAMP AMP 206070 1 21 RC22B RECPT C B PNL AUX PWR AMP 206036 2 CLAMP AMP 206070 1 21 RC23A RECPT RADIO PWR RELAY PNL AMP 206036 1 CLAMP AMP 206070 1 21 RC24A RECPT CABIN TAILCONE AMP 206036 3 CLAMP AMP 206070 1 21 HC24B RECPT CABIN TAILCONE AMP 206705 2 CLAMP AMP 206966 1 21 RC24C RECPT CABIN TAILCONE AMP 206036 3 CLAMP AMP 206070 1 21 RC25A RECPT R WING AMP 206036 3 CLAMP AMP 206070 1 21 RC25B RECPT R WING AMP 206153 1 GLAMP AMP 206062 1 21 RC25C RECPT R WING AMP 206705 1 CLAMP AMP 206070 1 21 RC25D RECPT R WING MOONEY 930021 002 CLAMP AMP 2060966 1 21 RC26A RECPT R WIGN STUB AMP 206153 1 CLAMP AMP 206062 1 21 RC26B R WING STUB AMP 206705 2 E CLAMP AMP 206966 1 21 HC26C RECPT H WING STUB MOONEY 930021 002 CLAMP 206966 1 21
342. V151A PLUG PORSCHE 933 612 403 00 E CLAMP PORSCHE 999 615 032 40 E BOOT PORSCHE 944 612 128 00 CONTACTS PORSCHE 999 652 456 22 ep DW150A INDICATOR VERTICAL SPEED UI 7201 2 CODE C 146 L DW151A PLUG VSI 3 PIN BENDIX 8 35 L DW15iA PLUG V S ALT KPTO6E 8 3S ep DW151A PLUG VSI ALT MS3116 8 3S CLAMP MS3057 3A or 3B JKL C B GEAR RELAY KLIXON 7277 2 5 JKL SWITCH GEAR UP DN C H 8906K2875 JKL EG103A SWITCH GEAR OVERIDE C H SBIDDX492 2 LOCKING RING C H 29 761 1 WASHER 16 886 HEX NUT 2 EA 15 966 6 LAMP 28 V GE 388 SERVICE AND MANUAL CODE M20J 28 VOLT ELECTRICAL EQUIPMENT CHART DESCRIPTION VENDOR MOONEY AIRCRAFT CORPORATION PART NO NOTES gt gt 7 2 4 Pr AR tn a gt dn dar St EE a a ee aS SSS SS SS SS SS SS SS SS SSS SS SSS SS SS SS SS SSS SSS SS SSS SS SS SS SS eS JKL JKL JKL JKL JKL JKL JKL JKL JKL JKL JKL JKL JKL JKL ELS EL 91 20 02 42 EG104A EG105A EG106A EG107A EG107A EG108A EG109A EG110A EG110A EG111A EG112A ELT101A ELT101A ELT102A ELT150A ELT151A FON101A JE150B JE151B JE152B JE153B JE154B JE154B JE154B JE155B JE155B JE156B JE156B JE157B JE157B SWITCH GEAR SAFETY A SPEED MOONEY C B GEAR ACTUATOR KLIXON SWITCH GEAR UP LIMIT MICRO SWITCH ACTUATOR MI
343. W127A SW135A VC101A VR101A WM101A WM102A WS101A WS103A WT101A WT101B WT102A WT103A WT104A M20J ELECTRICAL EQUIPMENT CHART DESCRIPTION VENDOR SWITCH MASTER WARN OMRON SW w LENS OMRON SW w LEGEND OMRON SW w BULB OMRON SWITCH NKK VOLTAGE CONVERTER 28 14 TERRA ALT TERRA VARISTOR GE WARNING MASTER MICRO WARNING MASTER MICRO ALERT STALL GEAR WARN JAI ALT IAI SWITCH STALL WARN MOONEY ANNUNCIATOR MOONEY ANNUNCIATOR MOONEY ANNUNCIATOR MOONEY ANNUNCIATOR MOONEY ANNUNCIATOR MOONEY NOTES SERVICE AND MAINTENANCE MANUAL PART NO NOTES A3BA 7011 1 A3BA 500R 5202 028 MB2085SB1W01 EA MLC28 5 C28 5 V47ZA05 DSK 104 GYR DSB 11 RRRR LR2 950D309 000 950D519 000 800364 509 880048 501 880090 XXX 6 880048 503 880048 507 880048 509 1 ALL P N s ARE ACCEPTABLE SEE VENDOR INFORMATION FOR APPLICABLE CONFIGURATION 2 1 EACH MS35334 21 OR M2898 ALLEN BRADLEY INTERNAL TOOTH LOCKWASHER REQUIRED WITH EAGH LIGHT IF NOT SUPPIED BY SLOAN 3 SEAL BACK OF POTENTIOMETER WITH DOW CORNING 738 ELECTRICAL SEALANT AFTER WIRES ARE SOLDERED TO TERMINALS 4 PLO2C amp RC02C MAY BE PURCHASED FROM DEAN AS P N 7020 5 SEAL BACK OF SWITCH WITH DOW CORNING 738 ELECTRICAL SEALANT AFTER WIRES ARE SOLDERED TO TERMINALS WHEN USED AS THROTTLE SWITCH GEAR WARNING 6 ANNUCIATOR P N WILL BE DETERMINED BY OPTIONS INSTALLED REF DRAWING 880090 12 98 91 20 06 107 S
344. WASHERS SWITCHCRAFT S 1028 or S 1029 JK MJ101A JUNCTION BLOCK GND BEAU 77014 52 JUMPER EDGE ON BEAU 7233 16 JK MJ102A JUNCTION BLOCK GND BEAU 71106 52 JUMPER EDGE ON BEAU 7233 8 JK MJ103A JUNCTION BLOCK DIM BEAU 71106 52 JUMPER EDGE ON BEAU 7233 8 JK MP101A B F GOODRICH 3E1899 1 JK MP102A SHUNT B F GOODRICH MS91586 1 JK MP103A FUSE HOLDER LITTEL 155020 or 155120 FUSE 1 LITTEL 313001 JK MP104A FUSE HOLDER LITTEL 155020 or 155120 FUSE 1 LITTEL 313001 JK MP105A AMMETER B F GOODRICH 3E1872 1 JK MP106A SLIP RING BLOCK B F GOODRICH 3E2062 1 MP150A C B SWITCH PROP DE ICE 15A ETA 930023 223 L MP151A B F GOODRICH 3E2311 4 L MP152A SLIP RING MODULAR BRUSH ASSY GOODRICH 3E2062 1 L MP153 FUSEHOLDER LITTEL 155020 or 155120 FUSE 1 LITTEL 313001 L MP154A RELAY BOX CURRENT MOONEY 800221 505 L MP155A PLUG 4 PIN AMP 206060 1 CLAMP AMP 208082 1 MSxx SPEAKER ARCHER 40 1197 i NE150A C B FUEL ENRICH KLIXON 7277 2 1 NE151A SWITCH ENRICHMENT MICRO SWITCH 18 1 ACTUATOR MICRO SWITCH JE 5 L NE153A VALVE SOLENOID MIXTURE ENRICHMENT PORSCHE 933 606 012 00 L NE154A DIODE ENRICH SW 1N2483 L NE155A DIODE ENRICH SW 1N2483 L NE156A DIODE ENRICH SW 1N2483 JK NF101A C B FUEL PUMP MOONEY 930023 211 J NF102A PUMP FUEL WELDON 8163B JK NF103A PLUG FUEL PUMP AMP 206060 1 CLAMP AMP 206062 1 JK NF104A RECPT
345. Y NAV TAIL RT WING MOONEY 800051 505 BULB WHELEN 34021 2030 85 14 LP103A DIMMER CONTROL BOX MOONEY 800049 503 12 98 91 20 04 77 SERVICE AND MAINTENANCE MANUAL 14 VOLT ELECTRICAL EQUIPMENT CHART CODE DESCRIPTION 14 14 14 14 14 14 14 14 14 14 14 14 14 14 14 14 14 14 LP105A LP111A LP112A LP131A LP132A LS106A LS111A MA102A MB102A ME101A ME102A NF102A PA104A PA107A PB101A PB102A PL204B PS102A PS104A RB102A RB102B RC204B WE103A WP103A WP104A WP105A WT102B WT103B 91 20 04 78 LIGHT CONSOLE LAMP LIGHT COMPASS LIGHT COMPASS ALT M20J VENDOR DIALIGHT GE GE GE GLARESHIELD LIGHTS 14 EA GE RHEOSTAT MAP LIGHT 100 OHM NEWARK KNOB NEWARK RHEOSTAT MAP LIGHT 100 OHM NEWARK KNOB NEWARK LIGHT ASSY STROBE NAV L WG WHELEN LIGHT ASSY STROBE NAV R WG WHELEN RELAY AUX POWER RELAY AVIONICS MASTER CLOCK CLOCK ALT CONNECTOR 4 PIN PINS CONNECTOR 4 PIN ALT PINS PUMP BOOST PUMP BOOST ALT REGULATOR VOLTAGE STD REGULATOR VOLTAGE ALT REGULATOR VOLTAGE ALT ALTERNATOR STD ALTERNATOR ALT BATTERY RELAY BATTERY PLUG 14 PIN SOLENOID STARTER STARTER STARTER ALT STARTER ALT BLOWER RADIO BLOWER RADIO RECEPTACLE SWITCH THROTTLE ACTUATOR ANNUNCIATOR DIODE ALT ALT DIODE ALT ALT ANNUNCIATOR BULB 8 EA PLUG 15 PIN SOCKE
346. Y 930023 213 MB101B C B SWITCH RADIO MASTER MOONEY 930023 313 MC101A CIGAR LIGHTER MOONEY 800336 503 ME101A CLOCK MID CONT MD 89 ALT PORSCHE 944 641 213 00 ME102A CONN 4 PIN ALT MID CONT 6016177 PIN MID CONT 6016125 CONN 4 PIN PORSCHE 944 612 217 00 PIN PORSCHE 999 652 351 12 MIC1 MICROPHONE JACK SWITCHCRAFT C 12B WASHER SWITCHCRAFT S 1028 WASHER SWITCHCRAFT S 1029 19 98 91 20 05 87 SERVICE AND MAINTENANCE MANUAL ELECTRICAL EQUIPMENT CHART CODE MP101A MP101B MP102A MP102B MP103A NF101A NF101B NF102A NF103A NF104A NF105A NF106A NF108A NF109A PA101A PA102A PA103A PA104A PA105A 106 107 PA108A 109 110 111 111 PA112A PB101A PB102A PB102B PB103A PB103B PB105A PLO2A PLO2B PLO2C PLO2D PLO3A PL03B PLO3C PL03D PLO4A 91 20 05 88 DESCRIPTION C B SW PROP DE ICE C B SW PROP DE ICE TIMER PROP DE ICE TIMER PROP DE ICE TERMINAL BLOCK C B SW LOW BOOST PUMP C B SW BOOST PUMP PUMP BOOST ALT PUMP BOOST ALT PUMP BOOST PUMP BOOST PUMP BOOST M20J VENDOR MOONEY MOONEY B F GOODRICH McCAULEY McCAULEY MOONEY MOONEY WELDON WELDON WELDON WELDON WELDON WELDON WELDON REGULATOR FUEL BOOST PUMP MASSEY C B SW Hi BOOST PUMP REGULATOR VOLTAGE ALT ALT SWITCH ALT FLD DUAL SWITCH ALT FLD SINGLE ALTERNATOR ALT ALTERNATOR ALT ALTERNATOR ALT
347. above See Open in De Icer above Test timer per Section 30 63 00 Locate and repair incorrect lead connections See wiring schematic 24 0001 24 2999 See Open in De Icer above 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 loose or corroded connections or partially broken wiring Correct as required Inspect amp clean brushes or slip ring Check voltage into switch 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 Check for partially broken wire or loose or corroded connection in wiring between aircraft supply and timer input Correct as required Test timer per Section 3 2 4 B F Goodrich Report No 68 04 712B SERVICE AND MAINTENANCE MANUAL TROUBLE cont Ammeter reads excess current over entire cycle 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 fiicks between 90 second phase periods M20J PROBABLE CAUSE One De Icer Boot element or wiring connections to De Icer in each cycle open Power lead shorted to ground Ammeter faulty Short to ground or short between adjacent circuits timer to brush block Short t
348. ace if necessary 2 Adjust valve 3 Replace instrument 4 Test with vibrometer If amplitude is more than 004 inch examine installation to determine whether connections are restricting movement of instrument 5 Examine shock mountings and replace if necessary 34 23 00 9 MOONEY AIRCRAFT CORPORATION M20J SERVICE AND MAINTENANCE MANUAL 34 90 00 MISCELLANEOUS 34 90 02 OUTSIDE AIR TEMPERATURE INSTRUMENTS Provides the pilot with the free stream outside air temperature in degrees centigrade 34 90 01 CLOCK Various clock options are available The standard clock is mounted in the left side of the instrument panel 34 90 00 12 98 10 SERVICE AND MANUAL M20J MOONEY AIRCRAFT CORPORATION CHAPTER 35 OXYGEN MOONEY AIRCRAFT CORPORATION CHAPTER SECTION SUBJECT 35 Effectivity Contents 35 00 00 s 35 00 02 35 00 02 35 00 02 CHAPTER SECTION SUBJECT 35 00 00 35 00 01 35 00 02 M20J CHAPTER 35 OXYGEN LIST OF EFFECTIVE PAGES PAGE 1 2BLANK Coo CONTENTS SUBJECT General Recharging Procedures Maintenance Practices 12 98 SERVICE AND MAINTENANCE MANUAL DATE 12 98 12 98 12 98 12 98 12 98 PAGE 0 35 EFF CONTENTS 1 28 SERVICE AND MAINTENANCE MANUAL M20J MOONEY AIRCRAFT CORPORATION 35 00 00 GENERAL WARNING ka The oxygen system is an optional installation for serial Proper safety measures must be employe numb
349. activate the landing gear actuator LDG GEAR OVERRIDE SWITCH KNURLED NUT FOR SOME OVERRIDE SWITCHES ARE LOCATED BESIDE THE LDG GEAR SWITCH LDG GEAR SELECTOR SWITCH VIEW LOOKING AT BACK SIDE OF PILOT S PANEL 5 34 5 LDG GR SWITCH amp LDG GR SAFETY OVERRIDE FIGURE 39 5 12 98 1 The glareshield will require removal to gain access to switch for maintenance action refer to Section 39 10 01 2 Remove connections from the back of the landing gear switch Figure 39 5 3 Turn the wheel shaped knob counterclockwise to remove from stem 4 Remove the nut and washer from the face of the switch and push switch through the panel 39 11 03 LANDING GEAR SAFETY OVERRIDE SWITCH S N 24 0084 24 0238 thru 24 TBA Landing gear safety override switch is located adjacent to landing gear switch Proper operation of landing gear safety system will not allow gear to retract below 65 7 4 KIAS CAUTION Activation of the gear safety override switch while the aircraft is on the ground may cause the landing gear to retract 1 The landing gear switch or cluster gauge will require removal to gain access for the removal of the override switch 2 Disconnect wire connectors approximately 6 inches from the switch by cutting with wire cutters or opening the knife disconnects 39 1 1 02 9 MOONEY AIRCRAFT CORPORATION 3 Loosen the nut on the stem and hold the nut located inside th
350. adliner CABIN LIGHT SWITCH REPLACEMENT 24 3374 thru 24 TBA BAGGAGE COMPARTMENT BAG CMPT LIGHT LIGHT SWTC LEFT REAR SEAT PASSENGER S LIGHT SWITCH M20J MOONEY AIRCRAFT CORPORATION PILOT S amp REAR SEAT PASSENGER S LIGHTS 1 Remove cover from arm rest assembly by removing 2 screws holding cover to arm rest 2 Switches are snap fit and may be removed by pressing snap tabs and pushing switch through cover 3 Disconnect wire terminals and replace with new switch Check for proper operation 4 Re assemble switch assembly into cover by snapping in from top side Re install cover into arm rest secure with 2 screws CO PILOT S SWITCH 1 Co pilot s cabin light switch is located in front of cabin door hinge above co pilot s right knee 2 Remove 1 screw above switch Remove door frame cap Pull panel from velcro fastners to access switch 3 Press snap tab amp push from panel to remove 4 Re assemble in reverse swquence when maintenance action completed BAGGAGE COMPARTMENT SWITCH 1 Switch is located at rear of baggage door at front top of hat rack opening Figure 33 14 2 Remove 1 screw inboard of switch Pull door frame down slightly from velcro fastners to access baggage compartment light switch 3 Press snap tabs PUSH switch through panel 4 Disconnect terminals replace switch 5 Re assemble in reverse order 33 22 00 INSTRUMENT FLIGHT PANEL AND GLARESHIELD LIGHTS 33 22 01 L
351. ads full scale with engine cool or cold Gauge reads zero when engine is hot Wire between sender and gauge grounded Defective gauge Defective sender Wire between sender and gauge is open or disconnected Defective gauge Defective sender te hl em me OE BEE BED VE da me mn VE VEE EA Qu a en a VED EE Ad ud a s a p s s s s ss s s s FUEL SYSTEM GAUGE CONDITION Gauge indicates empty in the tank Gauge indicates past full when tank is less than full Gauge indicates 1 2 when tank is full x s s s nps x x lk f Or a s CHECK FOR THESE POSSIBILITIES 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 s s 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 pulled aft prior to raising or lowering the switch to
352. aft during severe weather and hiqh winds 10 10 01 STORAGE FLYABLE Outdoor storage requires adequate mooring and tiedown facilities The following precautionary measures are recommended for keeping the aircraft serviceable and ready to fly 1 Refer to paragraph 10 20 00 for mooring instructions 2 Maintain an oil film on intemal engine paris frequently pull the propeller through Run engine for 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 control to 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 5 Install protective covers over pitot head engine cowl openings static ports etc 6 Maintain a good wax finish on all exterior surfaces 12 98 M20J SERVICE AND MAINTENANCE MANUAL 10 10 02 STORAGE PROLONGED If the aircraft is to be stored for an extended period of time the following steps are recommended for protection 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 3 Drain engine oil sump and refill the sump with a preserative oil Socony Aurex 901 or equivient preheated between 200 and 220 degrees F 4 Star
353. aft was delivered from Mooney Reinstall pulley after spacer is installed and torque pulley retaining nut to 35 40 ft Ibs B Alternator Installation 1 Be sure master switch is turned OFF Do not turn master switch ON until all wiring connections have been secured 2 Install attaching hardware place drive belt on pulley and adjust belt tension 3 Connect alternator wiring and check wiring connectors throughout system CAUTION Do not attempt to polarize alternator Aiternator is polarized every time master switch is turned on 24 31 02 VOLTAGE REGULATOR MAINTENANCE The battery charging rate depends upon the battery condition and the voltage regulator setting With ail equipment turned off and the engine running at 2000 RPM or faster the normal battery charging rate will be 5 to 35 amperes 24 00 00 5 AIRCRAFT CORPORATION 1 Excessively High Charging Rate Check the following A Fly aircraft for 15 to 20 minutes charging rate should slowly drop to 10 amperes or less very low battery will take longer to show a drop in charging current B Measure voltage with a voltmeter connected to the bus At 80 degree F voltage should be 13 75 to 14 0 An excessively high voltage regulator setting will cause excessive battery heating and water loss 2 Excessively Low Charging Rate Check battery charging rate normal rate is not to exceed four M20J SERVICE AND MAINTENANCE MANUAL amperes
354. age 32 41 01 SHUTTLE VALVE S N 24 0001 thru 24 0763 If Installed Shuttle valve removal and testing optional dual brake system 1 Disconnect inlet lines from master cylinders and cap line ends 2 Disconnect outlet line leading to brake cylinder and cap line end 3 To test valve operation seat shuttle valve by applying 1500 PSI hydraulic pressure to one inlet port with outlet plugged 4 Apply pressure to opposite port Shuttle valve should unseat at 15 to 50 PSI 32 41 01 26 5 Repeat step C and D to test opposite port 6 Reinstall shuttle valve in reverse sequence of 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 consists of steering horn on gear leg linked to the rudder pedals by push pull tubes bellcranks Gear retraction automatically disengages steering mechanism from nose wheel 12 98 MOONEY AIRCRAFT CORPORATION M20J SERVICE AND MAINTENANGE MANUAL 3 Check steering horn assembly 5 collars and spacers for looseness Replace any bushings or spacers that are wom 4 Adjust turn limiter stop bolts 7 to contact cross member 8 of truss assembly 020 gap permissible when rudder is at its extreme left and right travel position 32 50 02 NOSE GEAR STEERING AND TRACKING 1 Level aircraft as described in Chapter 8 2 Center nose wheel 3 Place plumb line over and forward of nose gear trunn
355. air procedures when repair of damaged structure is not covered by published instructions 51 10 01 FASTENER REPLACEMENT 1 HUCKBOLT INSTALLATION The Huck Lockbolt is an interference fit fastener used in a rigid joint structure loose or slip fit Huckbolt is unacceptable The recommended limits for Huckbolt holes are DRILL SIZE HOLE LIMITS No 20 161 IN 161 TO 1635 IN No 13 185 IN 185 TO 187 IN No 13 185 185 TO 187 IN No 20 161 IN 161 TO 1635 IN No 7 201 IN 2005 TO 2025 IN H ilok fastners may be substitited for Huck fastners of same diameter and grip A When the Huckbolt is enlarged beyond the above limits but is straight and round the hole may be considered acceptable provided that the Huckboit cannot be pressed into the hole with normal hand pressure to a depth more than 50 percent of the heaviest material being secured Check enlarged hole at both ends Select fit Huckbolts to the oversize oles 12 98 B Oversize Huckbolt holes may be repaired by replacing 2LPH T5 Huckboits with ALPPH T6 Huckbolts or 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 Huckboits ALPPH T6 and R3001 T6 may be replaced with R3007 T6 Huckbolts as necessary Consult the Customer Support Department Mooney Aircraft Corporation Kenville Texas 830 896 6000 for factory recom
356. al 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 REPLAGEMENT OF SHADIN SYSTEM COMPONENTS Replacement of 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 T Confi ti K Fact indicator Setti Aerosonic Transducer 3 85000 pulses gal 3 or 85000 Fioscan Transducer 82000 M 85000 H 87000 To change K Factor in Shadin Miniflo 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 B 88 0 K 5 6 83 0 1 87 0 K 6 5 82 0 K 2 9 86 0 K 7 4 81 0 K 3 8 85 0 K 8 3 80 0 K 4 7 84 0 K 9 2 79 0 12 98 73 31 01 5 SERVICE AND MAINTENANCE MANUAL DETAIL A URBINE FUEL FLOW TRANSDUCER TURBINE FUEL FLOW TRANSDUGER FIGURE 73 4 73 31 02 FUEL FLOW TRANSDUCER 1 The turbine flow transducer mounted in the engine fuel line measures flow of fuel The transducer is rated for a continuous operation to 60 gallons per hour In addition the transducer is accurate down to 0 6 gallons per hour 2 The transducer supplies the fuel flow indicator with a pulse s
357. an be retrofitted to all M20J aircraft if desired This allows trim screw nut F to contact stepped portion of these two nuts and not bind Basic rigging for either configuration is identical to procedures below except that stepped nut and jam nut require being torqued together with two wrenches prior to jam nut set screw tightened against 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 10 M20J SERVICE AND MAINTENANCE MANUAL D F SM27 TRIM STOP TRIM ASSIST BUNGEE RIGGING FIGURE 27 9 27 10 break torque on jam nut stepped nut if installed and turn stop A or jamnut stepped nut A amp E clockwise or counterclockwise io align forward edge of UP stop or stepped nut with front thread of trimscrew C Figure 27 10 Tighten setscrew and tum trim control wheel to full NOSE UP position trim screw nut F against UP stop or stepped nut E B Disconnect torque shaft B from trim screw C Figure 27 10 Rotate trim screw nut F against UP stop or nut E full nose up position C Tum disconnected torque shaft B clockwise or counterclockwise until horizontal stabilizer as measured using the travel board P N 030004 503 as shown by Figure 27 11 is within the following limits 5 5 degrees leading edge d
358. ance or part numbers on an airplane should contain the aircraft model number and serial number The serial number appears on the identification placard located on the aft end left hand side of the tailcone below the horizontal stabilizer ASSIGNMENT OF SUBJECT MATERIAL The content of this publication is organized at four levels 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 systems These groups are identified by abs SERVICE AND MAINTENANCE MANUAL The various groups contain major systems information such as flight controls landing gear etc The systems are arranged numerically per GAMA recommended number assignment li is suggested for example that Fuel be identified with the System Chapter number 28 The sequence of numbers 28 00 00 refers to General information of the 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 The individual units within a sub system may be 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 co
359. ant will be forced out and seal the window to the outside skin Carefully wipe excess sealant off acrylic before it sets up After sealant cures the excess can be cut off with a sharp razor knife reference Figure 56 2 4 Check replaced window for leaks 5 Reinstall interior trim 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 oe 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 turning drill bit with light pressures is desirable 12 98 MOONEY AIRGRAFT CORPORATION M20J SERVICE AND MAINTENANCE MANUAL 1 NEGATIVE RAKE 03 FLAT WIDTH 5 CLEARANCE STOVE BURNER TYPE BIT FLUTE RELIEF JOBBER FLUTE LENGTH amp JOBBER LENGTH OVERALL DRILL DIAMETER TOLERANCE 9000 TOTAL INDICATED RUNDUT 0002 ACRYLIC PLASTIC DRILL BIT FIGURE 56 3 12 98 56 50 00 5 SERVICE AND MAINTENANCE MANUAL M20J MOONEY AIRCRAFT CORPORATION BLANK 56 50 00 12 98 6 MOONEY AIRCRAFT CORPORATION M20J SERVICE AND MANUAL CHAPTER 57 WINGS SERVICE AND MAINTENANCE MANUAL CHAPTER SECTION SUBJECT 57 Effectivity 57 00 00 57 20 02 57 20 02 57 20 02 57 30 00 57 40 00 57 50 20 57 50 21 SECTION SUBJEGT 57 00 00 57 00 01 5
360. ar outboard of the wing fiaps The ailerons link to the control wheel through push pull tubes and bellcranks Lead counter weights static balance the ailerons AILERON SYSTEM 2 Aileron Removal and Intallation A Remove control tube attaching bolt nut and washer at aileron horn B Remove bolts nuts and washers from the three attaching hinges C Remove aileron by pulling it straight aft until hinges are clear rotate inboard portion down and forward to allow aileron balance weights to clear wing tip if configured D Reinstail removal E Recheck bolts for security and safety 3 Aileron Rigging and Control Adjustment S N 24 0001 thru 24 1424 A Use a straight edge A Figure 27 1 to align control wheels in accordance with step B B Adjust control tube B linking contro wheel shaft C at rod ends 5 Clamp or otherwise secure control wheels in the level position until steps C thru E are completed C Adjust contro tube D at rod end 2 so that aileron center bellcrank E is 1 16 inch left of center facing forward FIGURE 27 1 D Adjust aileron control tubes F by removing bolt nut and washer 4 Figure 27 1 and loosening locknut 6 Figure 27 2 The aileron control tube F can then be rotated cl ckwise or counterclockwise so that the center of the outboard bolt K Figure 27 2 is 4 3 inches from spar web M Replace bolt nut and washer 4 Figure 27 1 and recheck 4 3 inch
361. are 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 27 92 00 BALANCING EQUIPMENT STATIC The design of the balancing fixture is not critical providing the requirements of this section are met 1 Obtain or otherwise fabricate two 2 knife edge supports approximately one 1 foot in height so that they can be placed on a table and be stabilized to revent tipping See Fig 27 16 The knife edge inge supports MUST be LEVEL and to the hinge axis of the control surface 2 Weight Scales Scales used to record weights must be accurate within 0 02 Ibs or 1 2 oz 27 93 00 BALANCING PROCEDURE 27 93 01 DETAIL PROCEDURES STATIC BALANCING 1 A line drawn through the hinge line support points d be level and perpendicular to the supporting knife edges 2 The supporting knife edges must be horizontal and each other within the requirements of Step above 3 Elevators and rudders are balanced with the Control Horn pointing upward Ailerons are balanced UPSIDE DOWN See Fig 27 18 KNIFE EDGE SUPPORT TRAILING EDGE RESTING SUPPORT COPTHINAL SMJ27 16 CONTROL SURFACE STATIC BALANCE SUPPORTS FIGURE 27 16 12 98 SERVICE AND MAINTENANCE MANUAL M20J MOO
362. asket NOTE If filter shows an accumulation of carbon soot or oil continue with cleaning steps 4 through 7 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 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 altemate air eid Just start to open when a force of 3 4 pounds is applied 12 98 M20J SERVICE AND MAINTENANCE MANUAL 9 Reinstall filler in aircraft making sure of proper sealing and security 12 20 02 BATTERY Service the battery with distilled water to maintain electrolyte above plates After adding water in freezing weather charge battery long enough to mix electrolyte and water Keep battery electrolyte above a specific gravity of 1 225 to avoid freezing To service the battery 1 Remove battery box cover Check electrolyte and service battery as required CAUTION Battery gases may be explosive 2 Check battery box for corrosion and spilled electrolyte To clean cables terminals and
363. assembly Assembly ae x 32 40 03 Nose Wheel Disassembly Assembly 22 32 40 04 Brake Assembly 22 32 41 00 Trouble Shooting Brake 2 5 xx cw 9 32 41 01 Shuttle Valve See veda 128 32 50 00 Steering ge 128 325001 Nose Gear Steering System hs de 205 Su ie 28 32 50 02 Nose Gear Steering amp Tracking 27 32 60 00 Position and Warning 40 cw ue 3 48 32 60 01 Electric Gear Safety Devices s Te at 528 32 60 02 Landing Gear Waming System 28 32 60 03 Airspeed Safety Switch Adjustment 28 32 60 04 Squat Switch Adjustment 29 32 80 00 Miscellaneous by osx 32 81 00 Landing Gear Shock Disc Inspection ge 32 82 00 Recommended Hard Landing Inspections 30 32 CONTENTS 12 98 4 MOONEY AIRCRAFT CORPORATION 32 00 00 GENERAL The landing gear is operated by an electrical motor driven actuator The travel during the extend and retract cycle is controlled by down and up limit switches located beneath the floorboard under the pilots seat Power is supplied to the actuator through a set of relays actuated by the gear selection switch The gear selection switch i
364. 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 8 TD 172 IN P i 1 38 IN 3 8 TD 1 2 IN APPLY BRUSH SEAL GAPS amp HOLES WITH FILLETING COMPOUND FIRST STEP SEALANT THIRD STEP 1 IN FILLET APPLY FILLETING COMPOUND 1 IN FILLET 1 16 IN APPLY PROTECTIVE SEALANT FOURTH STEP 8 FASTENER SEALING WITH BRUSH n ste 1 32 TO 1 16 IN THICK SMM2B 3 FUEL TANK SEALING FIGURE 28 3 C Brush Sealing 1 Brush sealant PR1422 A 1 2 A 2 or CS3204 A 1 2 A 2 over all seams rivets nuts and bolts A one inch stiffbristle brush is recommended for sealant application Force sealant into all gaps with brush strokes parallel to seams Use a circular brush action to deposit an even coating of sealant around rivets nuts and bolts Coating should be approximately 1 32 inch thick Use considerable brush action to force sealant into all small crevices and to obtain good adhesion Air pockets under the sealant that will open up in the form of holes or voids soon after application will result from improper application To repair holes or voids press sealant in place using a spatula 2 When the edge of a flange protrudes 0 040 inch or less or where the seam cannot be clea
365. ated in the tailcone and is accessible by removing the radio access panel on the left side 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 Mhz to verify that a warbling tone is heard Place the remote switch back to ARM position for 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 1 If the warbling tone is not heard replacement of the ELT battery or the unit may be necessary Follow ELT manufactures instructions for battery replacement 2 If ELT unit is found to be operating properly and the system still will not work correctly through the remote ELT swiich repair or replacement of the switch or wiring will be required 39 12 00 10 M20J SERVICE AND MAINTANANCE MANUAL A To gain access to the remote switch and wiring the glareshield will require removal refer to section 39 10 01 B Remove the switch retainirig nut and washer and push switch through face of panel Disconnect wires
366. ating elements are switched Observe aircraft ammeter on S N 24 3000 thru 24 TBA ior fluctuation as each boot cycles 8 AMPS 24 3000 thru 24 TBA N inspect battery amp battery connections for proper installation and cleanliness 5 20 06 M20J SERVICE AND MAINTENANCE MANUAL 11 MISCELLANEOUS OPTIONAL EQUIPMENT Inspect any installed equipment not covered by previous paragaraphs for proper operation attachment or obvious defects 12 POST INSPECTION FLIGHT TEST Flight test the aircraft to verify correction of all malfunctions and abnormalities Make proper entries in aircraft log book 12 98 SERVICE AND MAINTENANCE MANUAL M20J MOONEY AIRCRAFT CORPORATION WING ACCESS COVERS MAY VARY BETWEEN MODEL YEAR AIRCRAFT COMPONENT LOCATIONS REMAIN BASICALLY UNCHANGED ACCESS COVER IDENTIFICATION LUBRICATION amp SERVICE GUIDE FIGURE 5 4 NOTE Access covers riveted in place during production need not be removed for routine inspections 12 98 5 20 06 17 MOONEY AIRCRAFT CORPORATION M20J SERVICE AND MAINTENANCE MANUAL 5 20 07 ACCESS COVER IDENTIFICATION LUBRICATION AND SERVICE GUIDE ITEM ITEM DESCRIPTION LUBRICATION INTERVAL NOs 5 w EN w ww Rod x SYMBOL 7522 ee ARS 1 Flight Instruments Vacuum Regulator k k 500 Turn Coordinator Le ow dbz eat ee 100 Vacuum System Filters Replace at de ux 500 Control System Adjustme
367. ation 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 thru 24 2999 31 8 3 volts for 24 3000 thru 24 TBA Regulator Adjustment Electro Delta Connect an accurate voltmeter to the aircraft bus Tum off all electrica 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 HE 01 thru 24 2999 30 volts for 24 3000 thru Low Voltage Warning should occur on Annunciator at approximately 12 5 12 75 Volt output from regulator Dele Volt Reg are adjustable for HI amp LOW volts 24 31 03 6 PERCENT OF CHARGE 25 little useful capacity Dischar 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 2 0 e volt system is 28 3 2 0 24 31 03 AUXILIARY POWER SYSTEM An auxiliary power plug and related circuitry is installed to provide an outside source of electrical power to the aircraft to charge the battery
368. ation or damage that would require replacement the parts should be rejected replace with new Torque Values See following pages 5 20 00 AIRCRAFT CORPORATION M20J SERVICE AND MAINTENANCE MANUAL TORQUE VALUES FLARE NUT TORQUE VALUES Tighten to minimum torque value for appropriate size as shown Figure 5 1 900 FLARE NUT TORQUE FIGURE 5 1 BOLT NUT TORQUE VALUES EE A M RR METRIC BOLTS SCREWS amp 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 bolt or screw assembled with a nut of the appropriate class is intended to provide an assembly capable of being tightened to the bolt proof load without thread stripping occurring The torque value to be set for a particular size of screw is dependent upon 1 Material of the screw 2 Parent material steel non ferrous metal or plastic 3 Whether the screw is untreated or plated 4 Whether the screw is dry or lubricated 5 The depth of the thread TIGHTENING TORQUES Untreated Screw Black Finish Friction Coeficient 0 14 NOMINAL PROPERTY DIAMETER GLASS Coarse Thread TORQUE Ma 56 88 10 9 12 2 Nmift Jb gt Nm flb Nm ft lb 38 0 60 0 44 1 37 1 01 gt 1 92 1 42 2 30 1 70 M4 1 37 1 01 3 10 2 29 4 40 3 25 5 25 3 87 M5 2 70 1 99 6 15 4 54 8 65 6 38 10 4 7 6 M6 4 6 3 3 10 5 7 7 15 11 18 13 M7 7 6 5 6 17 5 12 9 25 18 4 29 21 3 M8 11 8 1 2
369. ator fastners may vary These fastners will be underneath the outer skin After removal of the outer rivets and or screws work a putty knife or a thin piece of aluminum between the outer skin and the hinge and between the hinge and the mounting plate from the inside in order to break the sealant bond During this procedure determination can be made where the locator fastners are positioned If rivets locate these rivets from the inside and drill the bucked head carefully DO NOT DRILL THROUGH THE OUTER SKIN Attempt to move the door and hinge aft and away from the attach point after each rivet stem is drilled out The door and hinge should come free when all sealant bond and rivets are removed 2 Door Repair A The door should be repaired if applicable according to standard procedures in AC 43 13 1 B Remove the interior door panel if necessary to repair the door assembly 3 Installation The old door can be relocated by using the existing holes The mounting plate should be thoroughly cleaned of all sealant and foreign material before reinstallation of the door A new door or hinge will require proper positioning of the door to obtain proper sealing A Place door with new hinge installed into Sn between the outer skin and the mounting plate When door is properly positioned mark the hinge for mounting using existing holes either from the outer skin locations or from the hinge mounting plate inside th
370. auge A Green arc 300 to 450 degrees F B Red line 475 degrees F 7 Manifold Pressure Gauge A Normal operating range 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 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 S N 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 tachometer TACHOMETER TROUBLE SHOOTING s ss s s ssss s s s ah s Q NQnA hP5 a w ss xn s TROUBLE No permanent or intermittent indicator reading Broken shaft C B out IGN CIG LTR Broken wire Faulty instrument Rough spot on or sharp bend Pointer Oscil
371. backwards C Be sure to check battery polarity by using a voltmeter prior to reinstallation in the aircraft 12 98 M20J MOONEY AIRCRAFT CORPORATION D Do not leave the master switch ON when the aircraft is parked E Use an auxiliary ground power unit when trouble shooting electrical accessory equipment or when performing electrical landing gear maintenance and retraction system testing 2 Alternator System 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 clean cable if corrosion is found D Check drive belt for proper tension and excessive glazing E Check charging system wiring connectors to be sure they are clean and tight F Inspect alternator voltage regulator and wiring for damage CAUTION Do not attempt to polarize alternator Alternator is polarized every time master switch is turned on 3 Alternator Removal and Installation A Alternator Removal 1 Tum master switch OFF before disconnecting alternator wiring 2 Remove attaching hardware and slip drive belt from pulley NOTE If replacement alternator has a cooling fan or a blast tube housing they MUST BE REMOVED prior to installation Replace cooling fan with Lycoming spacer LW 15403 which was already on alternator when aircr
372. bearing 4 Figure 32 19 should be elr at least every 100 hours for any damage o ending NOSE WHEEL LOCATION FIGURE 32 20 12 98 32 50 02 27 SERVICE AND MANUAL M20J MOONEY AIRCRAFT CORPORATION 32 60 00 POSITION AND WARNING 32 60 03 AIRSPEED SAFETY SWITCH ADJUSTMENT 24 0084 24 0238 amp ON 32 60 01 ELECTRIC GEAR SAFETY DEVICES The gear switch operates the landing gear actuator relays Pulling wheel shaped knob out and moving it to upper detent raises gear However an airspeed safety switch or a squat switch is incorporated in the electrical system to prevent landing gear retraction while on the ground On aircraft equipped with airspeed safety Switch to allow gear retraction with the aircraft on jacks attach a 12 inch length of 3 8 inch pliable rubber hose surgical tubing 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 squat switch refer to Section 32 60 04 The up limit switch 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 hold landing gear in down and locked position Refer to Section 32 30 02 6
373. by purging The system should also be purged any time the lines are left open and subject to contamination Purging is accomplished by connecting a recharging cart the Syam ermitting oxygen to flow fhrough d Mines and outlets until any offensive odors have been carried away 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 particularly from grease and oil stains for these contaminants will IGNITE upon contact with oxygen The following procedures are recommended to purge the system Connect a recharge cart to the filler valve Set the cart pressure regulator to deliver 50 PSI to the System B Plug in an oxygen mask at each outlet in the cabin C Open the cabin door and place the control knob in the half open position D Allow the system to purge for one hour If an offensive odor still lingers continue purging the system for an additional hour If such odors still remain replace the supply cylinder After the system has been adequately purged remove the masks from the outlets place the control knob in the closed position and service the system as described in 35 00 01 6 Oxygen cylinder removal The oxygen cylinder is located in the tailcone aft of the baggage compartment
374. c instructions 73 30 00 73 31 00 INDICATING FUEL FLOW SYSTEM GENERAL SYSTEM DESCRIPTION The Fuel Flow totalizer system utilizes the latest in microcomputer technology products The fuel flow system is designed to maximize the efficiency of fuel system management by displaying the fuel consumption rate fuel flow of the engine and the precise amount of fuel the engine has consumed This information is displayed in one of the following formats US Gallons Pounds Liters or Imperial Gallons Alcor depending on internal switch arrangement see Figures 73 1 and 73 2 The system consists of a panel mounted instrument and a fuel flow transducer which is installed in the aircraft fuel line The system is designed for use in all single engine fuel injected aircraft having no more than 60 GAL HR continuous consumption or 78 GAL HR Intermittent consumption Take Off power 73 31 01 PANEL MOUNTED INSTRUMENT The panel mounted instrument contains all system electronics and may be divided into four groups M20J SERVICE AND MAINTENANCE MANUAL FT 101 SYMBOLIC DISPLAYS SDI 1 DISPLAY The display uses one mini lamp and four seven segment incandescent digits that are fully sunlight readable and dim automatically during night and low light flight conditions 2 MICROPROCESSOR The microprocessor in the FT 101 contains a crystal controlled oscillator that controls all timing and computing functions for precise fuel
375. cause the mid and inboard doors to gap open 32 10 05 7 SERVIGE AND MAINTENANCE MANUAL 4 Cycle gear manually and electrically while inspecting for clearances Re check MLG system rigging values 5 Remove aircraft from jacks 6 Return aircraft to 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 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 rod end bungee line up install AN3 bolt washers amp nut through Heim rod end bearing and AN4 bolt washers amp nut through block Torque and safety 32 10 06 ASSIST BUNGEE FIGURE 32 2C 24 3000 THRU 24 3078 CAUTION Bump gear up CAREFULLY just to take the load off the 3 16 in installation pin at B Remove pin from B Fig 32 2C 3 With bungee installed recheck preload per steps 30 thru 34 of Section 32 31 03 32 10 06 8 M20J MOONEY AIRCRAFT CORPORATION 32 20 00 NOSE GEAR AND DOORS 32 20 01 NOSE GEAR REMOVAL 1 Raise aircraft on jacks 2 Remove exhaust cavity fairings er retract gear as described by Section 4 Remove firewall nose gear box if needed to gain access to bolts 5 Disconnect link A on nose gear truss assy Figure 32 3 6 Disconnect nose gear steering hom link B Figure 32 3
376. ccomplished not later than the specified period of operation for that component or in accordance with 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 00 00 5 MOONEY AIRCRAFT CORPORATION M20J SERVICE AND MAINTENANCE MANUAL NOTE ON CONDITION items are to be repaired replaced or overhauled when inspection or performance reveals an unserviceable condition 5 10 01 OVERHAUL AND REPLACEMENT SCHEDULE LANDING GEAR Actuator No Back Spring All other Components POWERPLANT Engine Propeller Magneto Bendix Slick Induction Air Filters Paper All other Components FUEL amp OIL SYSTEM Fuel Selector Valve Anderson Brass Fuel Selector Valve other than above m gr Flexible Hoses ALL Except as Below amp Teflon Aeroquip 601 Fuel Hoses Teflon Hoses All other Components INSTRUMENTS Vacuum Regulator Garter Filter Filters Vacuum Pump CV1J4 Filter Filters Gyro Instrument Other Components ELECTRICAL COMPONENTS All Components FLIGHT CONTROLS All Components MISCELLANEOUS SYSTEMS Vacuum Pump Primary Stand by Vacuum Pump E L T Battery Oxygen Cylinders Lt Wt Steel Cylinders Composite Cylinders All other Components excluding Avionics AVIONICS General Systems Bendix King
377. cessive 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 megohms 30 68 00 BRUSH REPLACEMENT The propeller De Icer brush module should be replaced when a minimum of 1 4 inch of brush material remains it is good practice however to replace the modules when 3 8 inch of the brush material still remains 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 DIMENSION INCHES u 1 Measure brush wear as shown Figure MUST REPLACE ALL MODULES HAVING BRUSHES WITH RODS 17 64 30 2 X dimension inches given indicates when modules MUST be replaced MED ALL MODULES HAVING 2 Brushes are not offered individually as BRUSHES WITHOUT RODS replacements When a brush wears out the containing it should be replaced as ollows A Dismount modular brush assembly from aircraft by removing attaching hardware and disconnect engine wire harness B Remove assembly screws and separate modules and spacers G The part number of each module is etched into the surface of the plastic housing DURING HEASUREMENT ONLY 1 16 INCH DF BRUSHH SHOULD replace with the same part number module BE ALLOWED PROTRUDE FROM BRUSH BL
378. ch trim 27 40 01 11 SERVICE AND MAINTENANCE MANUAL 3201 24 2218 thru 24 TBA 4 8078 4 3000 thru 24 SMJ2 7 13 FLAP ACTUATOR ASSEMBLY amp INSTALLATION FIGURE 27 13 On S N 24 0001 thru 24 2999 the flap switch 10 is self 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 centering to stop the actuator I On S N 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 positioned as desired UP TAKEOFF or DOWN Lubricate ihe flap actuator gear box and ball screw at required intervals and with lubricants prescribed in Chapter 5 1 Wing Flap Removal and Installation A Remove wing flap hinge fairing to expose flap push pull tube B Remove bolt nut flap actuating attachment C Remove bolts nuts and washers at flap hinge points D Remove flap by pulling it down and aft 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 are to be measured with travel board GSE 030003 at the station indicated on the travel board See SECTION 27 10 00 Figure 27 3A and washer from 1
379. check clean and gap or replace spark plugs if necessary Repair discrepancies found B Inspect engine for evidence of excessive fuel or oil leakage inspect oil cooler and oil hoses for condition Repair as needed C Drain engine oil sump remove inspect and clean oil suction screens reinstall and safety Remove full flow oil filter cartridge replace with new cartridge and safety Check crank case breather hoses for obstruction Safety wire oil filter instaliation D Refill engine oil sump with the proper type grade and quantity of lubricating oil Inspect fuel injector and ail fuel line connections for security and condition F Remove inspect and clean fue selector valve or gascolator strainer reinstall strainer lubricate detent track ball and spring disc Inspect fuel lines and connections pressure check fuel system with mixture control at IDLE CUTOFF and BOOST PUMP ON G inspect all air ducting and connections in the heating and induction air systems for leaks Remove and clean induction air filter replace at 500 Hrs H Leak check all exhaust manifold connections engine exhaust manifolds and muffler connections Inspect for proper attachment inspect alternate air door for condition and proper preioad To inspect for preload remove lower cowling and PUSH on alternate air door seal bolt with an appropriate spring scale A preload of 3 to 4 pounds should be required to start door to open Add or del
380. cking force to retraction truss 32 When joint at 4 breaks open slightly insert shim stock 005 io 008 in thickness between retraction link and truss at P release force on torque wrench 33 While applying a pulling force on the shim stock exert an increasing unlocking force with torque wrench 34 Read torque wrench value at the EXACT moment shim stock pulls loose 35 Repeat steps 30 through 34 on the other main landing gear leg 38 Use adjusting nuts Y Fig 32 9 on retract tubes V to equalize breakaway torque values within 10 0 nen Ibs Adjust the torque to 250 to 280 inch pounds 32 30 05 15 SERVICE AND MAINTENANCE MANUAL 37 Turn Master Switch ON 33 RUN GEAR DOWN AND CHECK THAT TORQUE VALUES DO NOT EXCEED 325 INCH POUNDS USING THE TORQUE WRENCH SHIM STOCK METHOD LANDING GEAR WARNING ADJUSTMENT 1 Check that landing gear warning light circuit breaker is pushed IN 2 Check that landing gear actuator circuit breaker is pulled OUT 3 Turn Master Switch ON 4 Set DOWN limit switch striker arm J Fig 32 5 so that gear down limit switch is just CLOSED and the GREEN GEAR DOWN light is ON Secure striker arm in position 5 Turn Master Switch OFF NOTE The main gear preload torque should not exceed 325 inch Ib using the torque wrench shim stock procedure after electrical extension NOSE LANDING GEAR RIGGING PROCEDURE 24 3000 thru 24 3078 1 Check
381. ctivated by a contro lever assembly for S N 24 0001 thru 24 1417 and a rotating knob assembly for S N 24 1418 amp ON The supply gauge 7 located adjacent to this control pos the pressure of oxygen available in the system 2 The pilots outlet 8 and passenger outlets 9 should be inspected for damage and cleanliness during servicing 3 inspect the individual oxygen masks and fittings for damage 4 Oxygen system test procedures Remove oxygen line from the regulator and plug the line Cap open regulator port with a clean plastic cap to prevent contamination of the regulator Conduct the low pressure system leak iest using a 70 10 PSI oxygen supply plugged into one of the cabin outlets and a test gauge plugged into another outlet Apply 70 10 PSI to the system allow 2 minutes for the System to stabilize remove oxygen supply The drop in pressure after 15 minutes shall not exceed five PSIG Remove temporary plug and ensure that the cylinder is 35 00 02 4 M20J SERVICE AND MAINTENANCE MANUAL charged to capacity Conduct high pressure test using cylinder pressure Using the supply gauge on the pilot s side wall note cylinder pressure There shall be no pressure loss after 30 minutes If leakage exists apply MIL L 25567 leak test solution to suspected areas After test wipe clean and dry Make necessary repairs and retest 5 Oxygen system purging Offensive odors may be removed from the oxygen system
382. ctuator gear housing with the four 4 screws removed in 32 30 05 supplied in clutch spring kit 32 31 05 MANUAL EMERGENCY GEAR EXTENSION SYSTEM T HANDLE S N 24 0084 24 0378 THRU 24 TBA The manual emergency gear extension system is used to extend the gear only The controls are on floorboard aft and between the front seats To manually extend the gear 1 Pull landing gear actuator circuit breaker 2 Move landing gear control switch to DOWN position 3 Push latch forward with right thumb 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 tight is ON and or the lines on the visual gear position indicator on floorboard aft of console are aligned when viewed from directly above the indicator this will nromaliy 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 MANUAL EMERGENCY GEAR EXTENSION SYSTEM CRANKDOWN SYSTEM S N 24 0001 thru 24 0377 Except 24 0084 The emergency manual override system may be used to exlend the gear The override system has a flexible shaft geared to the landing gear actuator driven by a hand crank on the left side of the cabin panel To
383. current part of cycle low current rest of cycle Ammeter reads low current over entire cycle 30 61 02 8 20 PROBABLE CAUSE Open circuit to De Icer Boot De lcer wire harness or slip ring assembly leads Open circuit in wiring between timer and brush block assembly or brush assembly Open in De Icer boot or slip ring assembly lead circuits Timer faulty Inner and outer De Icer Boot elements heating same phase in series should be in parallel Open circuit or high resistance in De Icer Boots slip ring assembly leads or wire harness High resistance in circuit with low current Worn or dirty brushes and or slip rings Aircraft voltage low under normal operating conditions Ammeter switch or circuit breaker faulty High contact resistance up to timer High contact resistance in timer 12 98 SERVICE AND MAINTENANCE MANUAL REMEDY Check continuity from 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 Disconnect De 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 F Goodrich Report No 68 04 712B Ohmmeter needle must not flicker when leads are stretched or flexed Replace as required See Open Timer to Brush Assembly
384. d Exiend doors to continue with cap strip installation e Drill 40 holes in cap strips and door at the locations marked in 3 a Countersink holes on both sides of cap strips Flush rivet in place with AN426A 3 7 rivets _ 3 FINAL OPERATIONAL CHECK AND CLOSE UP A After verification of proper operation reinstall access cover plate on each wing 12 98 MOONEY AIRCRAFT CORPORATION M20J SERVICE AND MAINTENANCE MANUAL CHAPTER 28 FUEL SERVICE AND MAINTENANCE MANUAL M20J MOONEY AIRGRAFT CORPORATION CHAPTER 28 FUEL LIST OF EFFEGTIVE PAGES CHAPTER SECTION SUBJECT so oo so o d PAGE so cx DATE 28 Effectivity 12BLANK 12 98 28 Contents 3MBLANK 12 98 28 00 00 vb et GENENE ce 08 28 10 00 6 5 d vw gt 12 98 EE EE TE oti OE ee OR NR et esp 28 42 00 bow SE 8 cu 12 98 28 13 00 sor 90 wok ox 12 98 ra 5 gi ke III MIC 283000 ur 4h nem wa 11 os m EG 12 98 20 42 00 4 x dele EE M oc we Woo oy 2 08 28 91 00 ooo co pw ae 1 ETE 12 98 289200 14 ue X Ar 12 98 12 98 28 EFFECTIVITY 1 2BLANK MOONEY AIRCRAFT CORPORATION CHAPTER SECTION SUBJECT 28 00 00 28
385. d active channels dim depress the TEST switch and active dimmed channels return to bright When a dimmed channel is extinguished and then reactivates it will reaciivate bright The method to accomplish this however is considerably different from the past Each channel to be dimmed is driven by a transistor in this case Q8 which retums the lamp to ground through two parallel paths The path to provide a dim indication is through resistor R29 which reduces the brilliance of the lamp In the bright mode R29 is shorted by Q6 and CR13 which provide low impedance path to ground Transistor Q6 is controlled 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 DIMINS If the channel is active DIMIN3 will be near ground and with DIMBIAS near 3 VDC the output of U3 will be high thus driving Q6 into conduction When the DIM Switch is depressed momentarily DIMBIAS goes high to 12 VDC and U3 switches its output low and latches through R26 This low output removes the drive from Q6 and 053 dims When the TEST Switch is depressed momentarily DIMBIAS goes low and U3 switches its output high latches through R26 and drives Q6 into conduction When the channel deactivates Q8 opens the return to ground and DIMIN3 rises which returns latch U3 to a high output state 6 0 HI LO The High Low Vacuum circuits are shown in Figure 5 This channel is designed to accep
386. d condition Inspect engine mount tubes bolt attach tubes at firewall for moisture accumulation and corrosion 2 PROPELLER A Check propeller and spinner for general condition looseness and oil leakage B inspect blades for nicks and cracks Repair prior to next flight 3 CABIN A Check brake and parking brake control systems for proper operation and fluid level 5 20 02 11 AIRCRAFT CORPORATION B Check trim system and indicator for free operation and travel C Check cabin and baggage doors tor damage proper operation and sealing D Check cabin instrument position anticollision and landing light E Check fuel selector valve gascolator and boost pump for proper operation F Check oxygen system if installed 4 LANDING GEAR A Check tires for cuts blisters wear and inflation B Check shock discs for proper extension at airoraft static weight per Section 32 81 00 G Check hydraulic brakes for wear warpage and proper installation 5 MNGS Check surfaces and tips for damage B Check ailerons aileron attachments and bellcranks for damage and proper operation C Check flaps and attachments for damage and proper operation D Lubricate controls if necessary 6 FUSELAGE and EMPENNAGE A Check stabilizer elevators fin and rudder for damage and proper attachment Lubricate controls if necessary T Lights A Check operation of exterior and interior li
387. d for obvious defects I Inspect spinner and bulkhead for cracks and condition J Check spinner bulkhead for correct interference fit with prop cylinder Use Teflon Tape to obtain correct fil See Section 61 00 20 para 10 3 LANDING GEAR and RETRACTION SYSTEM INSPECTION A Check tires for proper inflation cuts blisters slippage and heavy wear B Check wheels for cracks distortion misalignment corrosion bolt failure Check condition of fett seals and bearings repack bearings at 250 hour intervals C Check brake pads amp discs for warping and wear D Check hydraulic reservoir for proper fluid level E Check hydraulic brake lines and hoses for leakage dents cracks chaffing kinks and security of anchorage F Check parking brake system for proper engagement and release G Check nose gear for cleanliness and damage Check nose gear retraction tube bungees for sheared 5 roll pins Check shock disc gap per Section NOTE Maximum aliowable towing damage on leg assembly is 1 32 inch dent H Check nose wheel steering mechanism for adjustment alignment corrosion and lubrication 5 20 06 13 AIRCRAFT CORPORATION I Check main gear for cleanliness or damage Check shock disc gap per Section 32 81 00 J Jack aircraft as recommended in paragraph 7 10 00 K Check landing gear retraction linkage bellcranks pivots and bearings for wear damage distortion misalignment co
388. d are of the quick removal type The engine instruments and circuit breaker panel are located in quick removal panel which is slanted toward the pilot The circuit breaker switches for the standard and or optional accessories and equipment are located at the bottom of the flight instrument panel on either side of the pilots control column The cluster gauge containing fuel quantity and engine operating gauges is located at the top of the flight instrument panel The Waku is located at the top of the avionics panel The avionics panel has two configurations Serial Numbers 24 0001 thru 24 0900 has a tubuiar structure configuration that will not accept the radar installation Serial Number 24 0901 and ON aircraft have a re M20J MOONEY AIRCRAFT CORPORATION located steel tubular structure that will allow the radar indicator to be installed The panel illustration depicted in Figure 39 1 shows phantom lines for some installations Model year improvements technical improvements or various avionics installations dictate which instrument will be installed in a given location See Section 91 for Electrical System Hardware Charts and Schernatics 39 10 00 INSTRUMENT AND CONTROL PANELS 39 10 01 FLIGHT INSTRUMENTS 1 Glareshield Instrument Removal A Remove the screws attaching the glareshield and cover plate and carefully lift giareshield to expose the disconnects for the glareshield lights Disconnect the wires and lift
389. d be within 50 RPM of each other A smooth drop off past normal is usually a sign of too lean or too rich mixture If no drop in RPM check for open or broken P ieads 71 00 60 FUEL INJECTION SYSTEM MAINTENANCE For injection system inspection and overhaul instructions consult engine manufacturer s overhaul manual and service instructions 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 fuei injection system operates by measuring airflow through the throttle body of the servo valve regulator control and using this measurement to operate a servo valve within the control This regulated pressure con trols the distributor valve which schedules fuel flow in proportion to airfiow 71 00 40 7 MOONEY AIRCRAFT CORPORATION 71 00 61 FUEL INJECTOR IDLE SPEED amp MIXTURE ADJUSTMENT 1 For operation in normal or low ambient temperature conditions adjust idle and mixture as follows Start engine and warm up in the usual manner until oil 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 after making idle mixture adjustment during succeeding steps readjust idle speed to desired RPM NOTE id
390. d 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 30 62 00 12 98 10 SERVICE AND MAINTENANCE MANUAL TIMING SEQUENCE Pin D Pin F Pin C M20J MOONEY AIRCRAFT CORPORATION AREAS OF PROP DE ICERS HEATED 24 0001 thru 24 2999 Outboard Section Inboard Section 12 Volt A C Both blades ON OFF 24 Volt A C NOTE Timer does not reposition itself to start at Pin D when system is turned off but will begin cycling from same position as it was when tumed off Cycling will then proceed as before 24 0001 thru 24 2999 x x z x zx x gt gt gt V Tua amami sma m ms ms m nm ue n s 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 icing system switch OFF at the beginning of one of the on time periods and record the
391. d indicator An airspeed safety switch is incorporated into electrical system to prevent landing gear retraction while on the ground and at airspeeds below 69 5 MPH 60 5 KTS Additionally the RED gear unsafe light comes on and warning hom is sounded when gear controi handle is placed in gear up position below 69 5 MPH 60 5 KTS NOTE Whitman General switches can be adjusted using the following procedures 1 Using a water manometer to measure pressure gradually apply air pressure to inlet at cap 2 Connect an ohmmeter between microswitch leads 3 Gradually increase pressure to 2 775 inches of water until diaphram movement closes microswitch 4 Slowly decrease pressure until microswitch opens 5 Adjust knurled body until switch closes at an increasing pressure of 2 775 384 359 in water 69 5 MPH or 60 5 KTS 6 Secure set screw and repeat step 5 five times 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 retrac
392. dicates full Incomplete ground when tanks are not full Broken wire No fuel pressure indication Tank empty calibrated test gauges connected Defective fuel pump ons pump for proper pressure uildu Check I for obstruction in boost pump screen Check engine fuel pump and check valve Ciean or replace Fuel Filter Repair or replace line Select proper position Fuel Filter Clogged Open fuel line Fuel selector in OFF position Fuel pressure low or surging Obstruction in inlet side of Check and clear fuel lines Replace calibrated test gauges pump or rebuild pump connected Faulty engine purnp Check fuel lines and connection for leakage or damage i Fuel Filter partially clogged Clean or replace fuel filter Fuel selector not in proper Select proper position position Air leak system Repair leak 28 43 02 12 98 SERVICE AND MAINTENANCE MANUAL M20J MOONEY AIRCRAFT CORPORATION 28 92 00 FLARED FITTINGS fittings are removed they should be wiped clean and When installing flared fittings and hoses make sure relubricated before they are reinstalled Torque all the threads are properly lubricated with 236 ings in accordance with flare fitting torque chart petrolatum per Figure 28 5 When previously installed Chapter 5 Figure 5 1 LUBRICATE STRAIGHT LUBRICATE THREADS FEMALE THREADS NEVER ALLOW LUBRICANT CONTACT THESE SURFACES LUBRICATION OF FLARED FITTI
393. dimension E Adjust aileron push pull tube J Figure 27 2 aileron in reverse sequence of 12 98 M20J MOONEY AIRCRAFT CORPORATION at rod end 7 Figure 21 2 so that aileron in neutral position is 0 to 2 down with no additional tolerance as measured with travel board at wing station indicated on travel board GSE 030003 NOTE Wing station 147 75 is located at skin splice line between flap outboard end and aileron inboard end F Remove clamps from control wheels then adjust aileron stops 8 Figure 27 2 so the down travel is 8 1 Aileron up travel may vary from 12 1 2 to 17 with no additional tolerance 12 1 2 to 14 1 2 S N 24 1038 and ON NOTE The above aileron rigging and adjustment instructions apply to both the left and right ailerons G Rotate the left control wheel clockwise until the ailerons contact the aileron stops 8 Figure 27 2 Adjust control tube at rod ends 1 and 5 Figure 27 1 by loosening the lock nut and turning tube clockwise or counterclockwise to attain 020 maximum clearance using feeler gauge N Figure 27 1 Secure locknuts 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 Aileron Rigging S N 24 1426 amp ON Level control wheels Reference 27 10 00 3
394. drum onto shaft be certain that spring detent on drum engages both recoiler springs by slightly rocking drum end 7 When full engagement is obtained wrap cable around drum in a clockwise direction leaving 2 to 5 of cable free of drum 8 Align slot in pulley housing with cable and slide pulley housing over cable and drum assembly 9 Holding the housings together puli 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 12 98 AIRCRAFT CORPORATION NOTE Cable length in retract position may be adjusted shorter or longer by holding clutch with the 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 sprinqs Slight spring tension SO noted starting at 8 to 10 Bronze clutch 13 should be inspected for damage or wear at slot where gear assemble engages during manual extension of the landing gear 11 If damaged or wom remove pin 11 from disengage arm 12 and slide disengage arm out so bronze clutch 13 can be pulled from its driveshaft 12 Replace bronze clutch and reassemble disengage arm into recoiler assembly 13 Attach clutch recoiler assembly to a
395. dures Static Balancing 27 93 01 Detail Procedures Static Balancing 27 94 00 Control Surface Trailing Edge 27 95 00 Stall Warning Maintenance Practices 27 95 01 Trouble Shooting Stall EN 27 96 00 Speed Brakes System 27 96 01 0 57 5 c5 oc Maintenance Speed Brakes 12 98 27 CONTENTS 3 4BLANK SERVICE AND MAINTENANCE MANUAL 27 00 00 GENERAL The aircraft has dual flight controls and can be flown from either the pilot or co pilot seat Dual pairs of foot pedals control the rudder and nose wheel steering mechanisms The co pilot pedals are removable if optional dual brakes are not installed Push pull tubes actuate the all metal flight control surfaces Rod end bearings are used throughout the flight control systems These bearings are simple and require little maintenance other than occasional lubrication 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 ail models Longitudinal pitch trim is achieved through a trim control system that pivots the entire empennage around the tailcone attachment points 27 10 00 1 Ailerons The ailerons are of all metal construction with beveled trailing edges Three hinges of machined extruded aluminum attach the ailerons to the aft wing sp
396. e he de S SY s s s a asi ALT CLOCK OPT LIGHT TRAY JACK MICROPHONE WASHERS WASHERS ALT SWITCH MIC KEY PILOT SWITCH MIC KEY CO PILOT M20J VENDOR CASCO MID CONTINENT MID CONT MID CONT SWITCHCRAFT SWITCHCRAFT SWITCHCRAFT CUTLER HAMMER CUTLER HAMMER 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 MoCAULEY C B BOOST PUMP MOONEY PUMP FUEL BOOST WELDON ALT WELDON PUMP BOOST WELDON PLUG 4 PIN AMP CLAMP AMP RECEPTACLE 4 PIN AMP CLAMP AMP C B HI BOOST PUMP MOONEY C B LO BOOST PUMP MOONEY REGULATOR FUEL PUMP ELECTRO DELTA REGULATOR FUEL PUMP AMER PROD RECEPTACLE 4 PIN AMP CLAMP AMP PLUG 4 PIN AMP CLAMP AMP FUSEHOLDER PRIMER DIFFUSER LITTEL ALT LITTEL FUSE 10A SLO BLO LITTEL SWITCH PRIMER CARLING PRIMER DIFFUSER TCM DIODE ALT ALT GE C B ALTERNATOR RT ETA C B FIELD RT ALT KLIXON SWITCH ALT FLD OPT MOONEY SWITCH ALT FLD STD MOONEY VOLTAGE REGULATOR MOONEY ALT AUXILEC ALT AM PROD RECEPTACLE 9 PIN AMP CLAMP AMP PLUG 9 PIN AMP CLAMP AMP ALTERNATOR STD LYCOMING ALT PRESTOLITE 12 98 MOONEY AIRCRAFT CORPORATION PART NO NOTES 208292 MD 88L MD 88L ET BA28 24 BW2 0 128 S 1028
397. e 10 00 00 3 SERVICE AND MAINTENANCE MANUAL 10 10 03 RETURNING TO SERVICE If the aircraft has been stored for an extended period of time it is advisable to perform a 50 hour periodic eo after completion of the following preliminary steps 1 Remove blocks from wheels Check tire inflation 2 Check and install battery 3 Remove tape and covers from openings 4 Remove warning placards if any 5 Replace engine oil filter 6 Clean engine oil suction and pressure screens 7 Clean and check oil pressure relief valve 8 Clean and check oil temperature bypass valve 9 Fill engine sump with proper grade of lubricating oil 10 Clean and reinstall engine air iniet filter 11 Check ignition harness 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 M20J MOONEY AIRCRAFT CORPORATION 14 Check fuel tank vents for obstruction and drain sumps to remove moisture and sediment 15 Complete 50 hour and preflight inspections 16 See appropriate TEXTRON Lycoming Service Bulletin for servicing of the engine 10 20 00 MOORING When mooring the aircraft out of doors 1 Head aircraft into the wind 2 Place chocks fore and aft of each main wheel 3 Drive stakes in ground approximately three feet ou of each main gear and to either side of ailskid 4 Install tiedown rings in wing receptacies outboard of each
398. e Icer system The reading of the standard ammeter should closely agree with the reading obtained from the De Icer ammeter Turn 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 Goodrich 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 hamess disconnected from Terminal B at the timer and the deicer switch in the ON 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 groun
399. e 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 12 98 M20J MOONEY AIRCRAFT CORPORATION 55 10 00 HORIZONTAL STABILIZER The main spar assembly 1 Fig 55 1 is formed from aluminum sheet 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 contains the hinge fittings 8 for the elevators 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 1o 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 55 10 02 HORIZONTAL STABILIZER INSTALLATION Refer to Section 53 40 02 for installation 55 00 00 3 MOONEY AIRCRAFT CORPORATION 55 20 00 ELEVATOR The elevators on the M20J consist of a left and right hand assembly attached through ball bearing fittings 1 to the rear
400. e cabin C Drill the new holes in hinge carefully while door is securely in place D Remove the door deburr holes and clean the shavings from the area NOTE The rivets and rivet holes originally used as locators do not have to be utilized when installing a new door or if proper alignment can be obtained using another method E Apply sealant PRC 1321 B2 or equivalent between outer skin and hinge support plate on tubular structure F Reinstall door hinge to mounting plate using the eight 8 flat head screws removed earlier and three 3 flat head AD4 standard AD5 oversize rivets G Adjust door latching mechanism so door closes and seals during flight See door rigging procedures paragraph 52 11 00 52 00 00 3 MOONEY AIRCRAFT CORPORATION M20J SERVICE AND MAINTENANCE MANUAL 6 LATCH JAWS 9 ADJUSTMEN POINT COVER PLATE 3 SPRING 4 HOUSING ASSEMBLY 3 ADJUSTMENT POINT 5 UPPER LINK 1 LOWER LINK VIEW LOOKING OUTBOARD AT CABIN DOOR CABIN DOOR RIGGING ADJUSTMENT FIGURE 52 1 2 BELLCRANK ARM 52 10 00 12 98 4 SERVICE AND MAINTENANCE MANUAL H Reinstall the hold open arm with new cotter pin l Reinstall interior panels and interior trim to door and cabin J Paint door to match airplane 52 11 00 CABIN DOOR RIGGING ADJUSTMENT PROCEDURES The cabin door latching mechanism has several adjustment poin
401. e factory with a bend of 90 degrees toward the blade face afl The materiai thickness in the radius of bend is closely controlled Such that the cold bend allowance is not exceeded A Sketch of the Q tip is shown below Figure 5 3 F Check for oil leaks loss of grease and lubricate as required by appropriate manufacturers handbook INSPECTION Inspect Q Tip for stone nicks and Scratches using the same procedure as on the complete blade inspect for evidence of 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 plus or minus 010 may be removed for repair of nicks and scratches to a minimum blade thickness of 065 Correspondingly reduce the very tip region when required to a minimum of 010 less than the resuiting thickness of the bend area The bend may be reduced in length for repair from the one inch dimension to approximately 75 inches The 90 degree bend that 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 straightening process inspect for cracks The chord length may be reduced for repair similar to the procedure of a standard blade assuring that ail blades are the same so that the aerodynamic balance of the propeller will not be affected G DELETED PROCEDURE H Inspect anti icing boots for proper operation an
402. e 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 after 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 radio panel contains equipment installed per sales order by Mooney Aircraft and other equipment installed by other sources as the owner desires The maintenance information contained in this Service and Maintenance Manual describes the Mooney factory installation only The avionics radio components are removed and installed according to Section 39 10 02 1 and 2 39 12 01 ANNUNCIATOR PANEL The annunciator panel is located at the top of the center most avionics radio panel and is not mounted with a slide in type chassis Remove this component by removing ihe two screws holding cover plate in position Remove the glareshield and disconnect the electrical harness from back side of the unit Remove ihe screws holding unit in place on the panel and remove from the back side of the panel LOW FUEL WARNING CIRCUIT CALIBRATION Refer to Section 24 33 00 paragraph 4 39 1 2 02 EMERGENCY LOCATOR TRANSMITTER ELT SWITCH The remote ELT switch is located at the top of the avionics panel The ELT is loc
403. e normal household cleaning practices for routine carefully follow the manufacturer s instructions interior care Never saturate fabrics wa could damage the backing and padding A Frequently vacuum seats rugs upholstery materials To minimize wetting of carpets keep panels and headliners to remove surface dust and dirt foam as dry as possible and rub in circles Use B Clean leather or vinyl upholstery and panels a vacuum cleaner to remove foam Do not allow with a mild aircraft detergent Clean with a slight damp carpets to remain damp dry them thoroughly cloth and dry with a soft cloth 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 12 20 06 7 SERVICE AND MAINTENANCE MANUAL M20J MOONEY AIRCRAFT CORPORATION BLANK 12 20 06 12 98 8 MOONEY AIRCRAFT CORPORATION M20J SERVICE AND MAINTENANCE MANUAL CHAPTER 20 STANDARD PRACTICES AIRFRAME SERVICE AND MAINTENANCE MANUAL M20J MOONEY AIRCRAFT CORPORATION CHAPTER 20 STANDARD PRACTICES AIRFRAME LIST OF EFFECTIVE PAGES CHAPTER SECTION SUBJECT PAGE 0 lt DATE 20 Eff Contents 12BLANK lt s 12 98 20 00 00 Se Sa eh ee es ee SO 12 98 20 00 01 4 12 98 20 00 02 5 12 98 20 00 02 6 12 98 20 00 03 7 12 98 20 00 03 8 12 98 TABLE OF
404. ears on external skin surface 1 Enter tank through inspection access panels and inspect sealant in general area of outside leak point Look first for bare seams rivets and bolts in difficult to seal areas Inspect sealant for blisters pin holes cracks splits and loss of adhesion Mark all suspected flaws with masking tape 12 98 SERVICE AND MAINTENANCE MANUAL 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 bubble fluid to exterior and again apply air pressure to flaws from inside tank 4 If above tests fail to locate leak source apply air pressure 10 PSI MAX to external leak point after removing all traces of fuel from tank and applying soapless bubble fluid to tank interior seams per Section 28 13 00 4 Leak Repair A Temporary Repair of Fastener Leaks Generally all leaks in enclosed areas and running leaks in open areas constitute a flight hazard Fastener leaks of this category may be temporarily repaired by applying a sealant fillet over fastener head on fuel tank exterior For a temporary repair to be satisfactory structural integrity must be retained in leak area To make a temporary fastener leak repair 1 Remove enough fuel from tank to
405. ecise Flight Inc D any defects found If no deficiencies of the cartridges exist reinstall speedbrake cartridges and connections Cycle to verify proper operation 2 REPLACEMENT MALFUNCTIONING CARTRIDGES When replacement of malfunctioning Speedbrake Cartridge with a new cartridge is necessary the following procedures may be required to install the new cartridge NOTE There is no left or right hand configuration on the electrical units The speedbrake doors are not located in the center of the cartridge The side of the cartridge that has the narrowest flange goes forward 27 96 00 18 M20J 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 On some replacement cartridges a drain hole 0 27 in is required in the aft inboard corner of Speedbrake cartridge bottom The drain tube from the old cartridge is to be secured in place in this hole with silicone adhesive used as sealant On later configuration cartridges the drain hole already exists in the bottom of each end of the cartridge Install drain tube in inboard hole Some drain tubes have a heat formed flange and mounting plates to mount the tube to the hole which already exists in the new cartridge These do not require any silicone sealant to seal the tube however the drain holes in the outboard end of the cartridge must be sealed w
406. ed or brittle hose particularly on the pump inlet Sections of the inner layers may separate causing a pump failure 37 14 04 INSTALLATION Where hose clearance is tight making it difficult to reinstall it onto the pump fitting spray the fitting at the hose end with silicone LET DRY then install hose by pushing it straight on NOTE Do not wiggle hose from side to side This could cause particles to be cut from hose ID These particles WILL damage the pump Make certain hoses are connected to the correct fittings Incorrect installation will cause damage to the gyro system install clamps 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 Hg or above 37 21 00 VACUUM SWITCH The vacuum switch 7 Fig 37 1 is located on either the Artificial Horizon 3 or Directional Gyro 4 The illuminating low and high light adjustments are done on the switch not on the annunciator panel 37 21 01 DESCRIPTION The switch is a low and high vacuum sensing adjustable unit 37 21 02 MAINTENANCE PRACTICES Check for switch security in instrument and all wires secure at switch 37 21 03 REMOVAL Disconnect wires and unscrew from aft instrument housing 37 21 04 INSTALLATION Install switch in housing and tighten Reconnect
407. ed the system through the wheel cylinder bleeder valves Allow pressurized pot to set 10 12 hours to dissapate air from fluid prior to bleeding brake lines 1 Remove hydraulic fluid reservoir filler plug and install a suitable fitting for attaching a flexible drain line to the reservoir filler port 2 Immerse open end of drain line in a hydraulic fluid container 3 Attach pressurized hydraulic fluid service unit to wheel cylinder bleeder valve and open valve On aircraft with dual brakes and shuttle valves depress p brake pedals to reposition shuttle valve while eing bled Fluid in hydraulic service unit should be free of air prior to servicing aircraft system 4 Feed fluid from service unit into brake system Check for air bubbles at end of drain line immersed in fiuid On aircraft with dual brakes depress co pilot s brake pedals to reposition brake shuttle valve then proceed with bleeding this side 5 When fluid flow is clear of air bubbles close wheel cylinder bleeder valve and remove service line NOTE Brake pedal may need to be pulled back in order for fluid to bleed back into reservoir 6 To bleed opposite brake repeat steps 3 through 5 7 Remove drain line from reservoir 8 Lower fluid level in reservoir to two inches below filler port 9 Reinstall filler plug 10 Check brake linings for excessive wear and proper installation Refer to Section 32 40 04 for Brake Removal and Inspection Procedures
408. el forward section see Figure 39 2 F panel should now be free to slide 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 qain access to the desired one H Remove thin lexan glass insulation strip if required when removing components Remove the instrument by removing any post lights and mounting screws which secure instrument to the panel and pull forward Remove the circuit breakers by unscrewing nut from stem on each circuit breaker and push the breaker through the panel 2 Installation A Installation of new instrument or circuit breaker into the panel is accomplished in reverse sequence of removal B Insert the lexan insulator sheet in proper location to prevent any short circuits 39 11 00 FLIGHT INSTRUMENT PANEL The flight instrument panel is a shock mounted panel containing various flight instruments for a particular installation group These instruments vary slightly 12 98 SERVICE AND MAINTANANCE MANUAL M20J MOONEY AIRCRAFT CORPORATION MASTER SWITCH ALTERNATOR FIELD SWITCH RADIO MASTER SWITCH VIEW LOOKING AT FWD SIDE OF PILOT S PANEL TYPICAL EXAMPLE OF LAYOUT LOCATION OF IGNITION OPTIONAL
409. elage tube floorboard or actuator barrel nut If there is any contact run actuator back up slightly 18 There should be 050 to 100 inch clearance B obtained between actuator barrel C Fig 32 7 and mechanical down stop A Shims D 050 thk Fig 32 7 may be added or deleted to mechanical downstop A 4 max 19 Cycle landing gear UP Run actuator down and recheck retraction bellerank clearance at F S 33 Check clearance of belleranks M Fig 32 5 and center section 20 Reconnect retraction tubes 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 connected with zero preload 21 Adjust nut Y Fig 32 9 until main gear is preloaded Preload is correct when a CLEAN BREAK can be felt when pushing up on retraction link at P Fig 32 9 12 98 MOONEY AIRCRAFT CORPORATION lt 156 APPROX DETAIL A LANDING GEAR ACTUATOR ADJUSTMENTS FIGURE 32 10B 22 NOSE GEAR RETRACTION TUBES ARE TO REMAIN DISCONNECTED at the main retraction bellerank A Fig 32 10B during remainder of procedure 23 Place landing gear switch in UP position 24 Push RED gear safety by pass switch IN INTERMITTENTLY to BUMP UP retract landing gear until left main tire just contacts bumper bracket which covers bulb stringer in wheel well Make certain actuator barrel does not contact main retract bellcrank in the UP position 25 Set
410. electrical system hardware charts that are applicable to the aircraft model and S N being worked on 91 20 01 91 20 02 91 20 03 91 20 04 91 20 05 91 20 05 91 20 05 91 20 05 91 20 05 91 20 05 91 20 05 91 20 05 91 20 06 91 20 06 91 20 00 Page 8 ELECTRICAL SYSTEM HARDWARE CHART 24 0001 thru 24 1685 14 VOLT DRAWING NUMBER SCI 800269L 3 3A amp 800330 ELECTRICAL SYSTEM HARDWARE CHART 24 3000 thru 24 3153 28 VOLT DRAWING NUMBER 800350 5 Py m SYSTEM HARDWARE CHART 24 3154 thru 24 3200 24 3202 thru 24 3217 2B i DRAWING NUMBER 800263 E 24 1686 14 thru 24 2999 14 common components 28V amp 14 V See 91 20 04 for 14 Volt peculiar components ELECTRICAL SYSTEM HARDWARE CHART 24 1686 14 thru 24 2999 14 ATS ONLY 14 VOLT SYSTEMS RAWING NUMBER 800263 E ELECTRICAL EQUIPMENT HARDWARE CHART S N 24 3201 24 3218 THRU 24 3270 DRAWING NO 800304 Jl REV F SHT 1 REV H SHT 2 ELECTRICAL EQUIPMENT HARDWARE CHART S N 24 3271 THRU 24 3350 DRAWING NO 800304 J2 REV W 2 sheets ELECTRICAL EQUIPMENT HARDWARE CHART S N 24 3351 THRU 24 3373 DRAWING NO 800304 J3 REV W 1 sheet ELECTRICAL EQUIPMENT HARDWARE CHART S N 24 3374 thru 24 3377 DRAWING NO 800304 J4 REV W 1 sheet ELECTRICAL EQUIPMENT HARDWARE CHART S N 24 3378 thru 24 3383 DRAWING NO 800304 J5 REV Y 1 sheet ELECTRICAL EQUIPMENT HARDWARE CHART S N 24 3384 t
411. emove one piece belly access panel 2 Assist Bungee Assy Removal Retract landing gear until rigging pin hole lines up on bungee assembly and insert 3 16 in pin CAREFULLY BUMP the gear UP with the gear safety bypass switch until there 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 Pull the landing gear actuator circuit breaker OUT 4 Loosen jam nuts E on the main retraction tubes L Fig 32 5 disconnect the tubes at the inboard belicranks M 5 In nose gear well loosen jam nuts G Fig 32 4 on nose gear retraction tubes F Fig 32 3 amp 32 4 6 At main retraction bellerank A Fig 32 10B disconnect actuator barrel nut at N Fig 32 10B and nose gear retraction tubes 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 actuators are not adjsutable 32 30 05 14 M20J MOONEY AIRCRAFT CORPORATION 8 Disconnect nose gear doors outboard main gear doors and inboard door links On outboard main gear doors disconnect springs On inboard door belicranks disconnect springs 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 3
412. en percent of the diameter of the rivet shank 2 The i specifies the maximum acceptable diametric dimensions for the various rivet sizes that occur in multiple iayer assemblies which are available the next longer length pin may be used with cadmium plated steel washers to adjust the pin grip length The combined washer thickness shall not exceed 096 inch 6 MS 20470 AD4 of MS20426 AD4 rivets may replace spotwelds 1 per spot head side amp double fiush requirements determined by form fit amp function of assembly unless alternate fasteners are specified 51 11 00 RESERVED 51 12 00 FUSELAGE REPAIR 51 12 01 TUBULAR STRUCTURE REPAIR Check tubular structure annually for corrosion and damage Interior panels may require removal to gain access to areas which are different to inspect Refer to AC 43 13 1 current revision letter of AC43 13 1 for A tubular frame repair procedures Warped or bent tube members can often be straightened however all surrounding welds should be dye checked for cracks after tube straightening Use proper material when making weld repairs Welding rod meeting the requirement of specification MIL R 5632 class 2 is recommended for oxyacetylene welding Electrodes meeting the requirement of Specification MIL F 5632 A class 2 MIL E 23765AC MIL 70S 2 or AWS 5 18 69 class E705 2 Linde 65 Linde CMS 32 or Page AS 35 are recommended for non heated area inert gas s
413. enance Practices Servicing Removal Installation New Pump Vacuum Regulator Maintenance Practices Servicing Removal Installation Adjustment Filters Maintenance Practices Servicing Removal Installation Hoses Maintenance Practices Servicing Removal Installation Vacuum Switch Description Maintenance Practices Removal Installation Adjustment Dry Air Pump Repair Coupling Inspection amp Replacement Dry Air Pump Inspection Stand by Vacuum System optional Servicing Operational Procedures 12 98 MOONEY AIRCRAFT CORPORATION VON NNN NN NNN MEM oM M NINO G O Gn Gn 37 CONTENTS 3 4BLANK MOONEY AIRCRAFT CORPORATION 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 passed through several filters before entering the instruments A vacuum regulator valve is incorporated to maintain the required operating vacuum throughout the engine power range Idle RPM settings will normally not provide adequate vacuum to satisfactorily operate the instruments vacuum annunciator light will illuminate and flash when vacuum drops below the setting required to operate the instruments A standby vacuum system kit is available for the M20J aircraft This kit can be installed by the factory or in the field The standby vacuum
414. end of pistion rod 5 Remove piston assembly 5 and o ring 7 from piston assembly and o ring 6 from piston rod shaft 6 Remove end cap 8 and o rings 9 ID and 7 OD from end cap assembly 7 Clean all parts with cleaning solvent Fed Specification No PS 661 8 Inspect cylinder for cracks scoring or grooves in bore 9 inspect piston 5 for damage check for nicks and scratches 1991 single brake systems with shuttle valve have to be bled somewhat differently The plug that would normally go to co pilots side has to be loosened sq fluid can be purged from shuttle valve cavity during bleeding to keep shuttle valve from locking up one side BRAKE MASTER CYLINDER PARAMONT FIGURE 32 17B 12 98 MOONEY AIRCRAFT CORPORATION 11 Inspect push rod for scoring grooves nicks and scratches nen 12 Inspect spring 4 for free height 500 in 13 Replace all faulty parts and all o rings 14 Reassemble in reverse sequence of disassembly Immerse all parts in hydraulic brake fluid prior to reassembly 15 Check piston rod and return spring 13 for proper compression during stroke 9 Ibs start of Stroke to 32 Ibs 3 4 stroke F Reinstall master cylinder in reverse sequence of removal G Bleed brake system refer to Section 12 20 05 PARAMOUNT MASTER CYLINDER A To disassemble Paramount master cylinder Reference Fig 32 17B 1 Unscrew and remove rod
415. end bearing and nut from pistion rod 2 Remove snap ring 1 and lift out complete piston rod assembly 3 Remove piston top 2 o ring packings 3 and brass washer 4 from piston rod assembly 4 Disassemble piston rod assembly by removing cotter pin 5 valve stop 6 and spring washer 7 Valve assembly 8 will fall out when cotter pin is removed 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 ring packing 10 from piston 11 Do not unscrew piston from push rod Replace entire piston rod assembly if faulty 6 Remove spring 12 from cylinder 7 Clean all parts with cleaning solvent Federal Specification No PS 661 8 Inspect cylinder for cracks scoring or grooves in bore 9 Inspect piston for damaged valve seat nicks and scratches 10 Inspect valve assembly for damage 11 Inspect push rod for scoring grooves nicks and scratches 12 Inspect piston return spring for permanent MAX proper length 3 3 16 IN MIN 3 5 16 IN 13 Replace ali faulty parts 14 Reassemble in reverse sequence of disassembly Immerse all parts in hydraulic brake fluid prior to reassembly B Reinstall master cylinder in reverse sequence of removal C Bleed brake system refer Section 12 20 06 12 98 M20J SERVICE AND MAINTENANCE MANUAL 4 PARKING BRAKE VALVE Removal A Remove left hand exha
416. enerate sufficient heat to cure the resins in the lining but will not cause the material to become carburized due to excessive heat Cleveland 75 16 Torque Plate Axle Mounting Flange Brake Cylinder TORQUE PLATE ASSY INSTALLED RELATIVE TO CYL FIGURE 32 16 H Replace linings with Cleveland 66 30 linings using Cleveland 561 2 rivets Rivets must be rolled to obtain proper fit between rivet shank and hole l Inspect brake cylinder bore for scoring A scored cylinder may cause the O ring io leak or cause rapid Mae ed the O ring A scored brake cylinder should be replaced J Replace AN6230 2 O ring 11 with a new one Do not reuse the old O ring K Lubricate cylinder and piston with MIL H 5606 red hydraulic fluid and assemble components with care to prevent damage to the O ring L Service and inspect main wheels as described in Section 32 40 02 Inspect torque plate assembly making sure ihe 125 thickness is toward brake cylinder assembly outboard If thicker 250 protrusion is outboard remove torque plate from axle mounting flange and install as shown Figure 32 16 M Reassembly brake cylinder assembly and back lining plate assembly onto the airplane in the reverse sequence of disassembly N Bleed hydraulic system as described in Section 12 20 05 O Remove aircraft from jacks NOTE Brake pad conditioning is required to properly cure the resins binding the asbestos lining composition
417. ep B target position 3 Remove access cover behind each landing taxi light location on with lower surface 33 42 00 11 SERVICE AND MAINTENANCE MANUAL M20J MOONEY AIRCRAFT CORPORATION 4 Turn taxi lights ON exit aircraft turn adjusting 5 Repeat Step 4 for landing lights except center screws until light beams are centered on outboard light beams on inboard target crosses left and target crosses left and right right 6 Turn lights OFF reinstall access covers 33 43 01 12 98 12 MOONEY AIRCRAFT CORPORATION M20J SERVICE AND MAINTENANCE MANUAL CHAPTER 34 NAVIGATION AND PITOT STATIC SERVICE AND MANUAL M20J MOONEY AIRCRAFT CORPORATION CHAPTER 34 NAVIGATION AND PITOT STATIC LIST OF EFFECTIVE PAGES CHAPTER SECTION SUBJECT so 2 PAGE DATE 34 Effectivity M2BLANK 12 98 34 Contents SAMBLANK 12 98 34 00 00 5 ds ad oh me etu 12 98 34 11 00 6 12 98 34 20 00 7 12 98 34 21 00 S 12 98 34 23 00 9 12 98 34 90 00 10 12 98 12 98 34 EFFECTIVITY 1 2BLANK AIRCRAFT CORPORATION 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 M20J SERVICE AND MAINTENANCE MANUAL CHAPTER 34 NAVIGATI
418. eplace battery Always recharge battery for 1 2 hour following addition of water in freezing weather Replace battery Battery should be slowly discharged Compete then charged correctly and tested Correct charging rate Replace battery SERVICE AND MAINTENANCE MANUAL M20J 24 39 04 TROUBLE Motor fails to operate CAUTION Do not use coarse sand paper or emery cloth After seating thoroughly clean brushes and commutator to prevent excessive wear Keep motor bearing free from sand or metal particles Siow cranking speed Starter motor runs but will not crank engine Starter drags Excessive motor brush arcing STARTER TROUBLE SHOOTING PROBABLE CAUSE Low battery Defective improper or loose wire connections Binding worn or improperly seated brushes brushes have excessive side play Dirty commutator Shorted grounded or open armature Grounded or open field circuit Defective master switch or circuit Defective solenoid switch Defective starter Worn rough or improperly lubricated motor or starter Same causes as listed with Motor fails to operate Damaged pinion gear or crankshaft gear Dirty starter drive Low battery charge Relay or solenoid contacts burned or dirty Defective power cable Worn or dirty commutator Binding worn or improperly seated brush or brushes have excessive side play Dirty rough pitted or scored commutator 42 98
419. er 24 0001 and ON The system consists of a 76 while system metal 77 1 composite or 115 7 composite cubic ft penama Sida so pag di nd ket d cylinder located in the tailcone immediately aft of the b created ett ma fug Spar NOn the dl au baggage compartment bulkhead A reducing valve and perle ar ke viri d ha a an altitude compensating valve are connected to the OF oxygen sure that your nands tools cylinder to regulate the oxygen flow for a given altitude and clothing are respect Lines connected to the altitude compensating valve to oil or or these wi d upon aviators oxygen jo the pilot and passengers contact with pure oxygen under pressure The system is activated by either the control handle E E being pushed forward S N 24 0001 thru 24 1417 or 35 00 01 RECHARGING PROCEDURES the control knob rotated 24 1418 amp ON to open the WARNING reducing valve A gauge located on the pilois arm rest Oil grease or other lubricants in contact with adjacent to the control indicates the pressure of the oxygen create a serious fire hazard and such cylinder When the cylinder is full the pressure will contact must be avoided when handling oxygen indicate 1850 P S 1 at 21 degree C 70 degree F j equipment The system is serviced through an access opening located aft of the baggage compartment door WARNING Standard refill fittings are required to fill ihe cylinder
420. er removing the plug from the timer use an ohmmeter to check continuity from 1 Pin D of the plug 12V Terminal C 24V to the outboard terminal of one prop boot 2 Pin F of the plug 12V to the outboard terminal of one prop boot 12 98 3 Pin A of the plug 12V Terminal G 24V to the airframe ground 4 Ground terminal of one prop boot to ground 30 66 00 BRUSH TO SLIP RING RESISTANCE TEST To check for incorrect resistance or the presence of a short or open circuit at the brush to slip ring contact disconnect the harness at the timer and check the resistance from each De Icer circuit lead pins D and F 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 I To check for 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 ex
421. eration amp security Inspect Avionics antennas wiring amp 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 attachment Drain 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 alternate static pressure source located on left flight panel 10 ELECTRICAL FUNCTIONAL TEST A Check operation of navigation lights B Check operation of landing light or landing taxi lights C Check operation of dome lights and cigar lighter D Check operation of anticollision lights E Check operation of instrument and placard lights Check rheostat F Check operation of pitot head heater G Check operation of cluster gauge 5 20 06 MOONEY AIRCRAFT CORPORATION H Check operation of fuel gauges I Check operation of annunciator light press to test J Check operation of ignition switch and starter solenoid 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 observe prop de ice ammeter for 1 needie in green arc 8 to 12 AMPS 24 0001 thru 24 2999 and 2 fluctuation every 90 seconds as he
422. es Some of the electrical circuitry wiring relays circuit breakers etc are installed by Mooney production drawings Components for these are available through your Mooney Service Center The relay for the electric Speed Brake System is located under the rear seat area on the LH bulkhead The schematic located in the envelope and the electrical paris list SECTION 91 of this S amp M covers the electrical system component identification 27 96 01 MAINTENANGE SPEED BRAKE SYSTEM 1 ELECTRIC OR VACUUM SYSTEMS Every 1000 hours Remove the speedbrake cartridges from wing 1 Remove access cover from bottom of wing beneath the Speed Brake cartridge 2 Remove the single screw from bottom of wing which secures the strap strip of the cartridge 8 Disconnect vacuum or electrical connection from Speedbrake cartridge 4 Remove Speedbrake cartridge from wing by removing screws from top of wing from around the Speedbrake cartridge and remove the cartridge through the bottom access hole B Inspect removed cartridge mounting area and related components for the following 1 Visually check doubler and mounting hardware for structural integrity 2 Visually inspect for chafing on all moving parts 3 Manually operate the speedbrake doors and feel for smooth operation 4 Inspect cable on vacuum units especiaily around pulleys for fraying C Report any deficiencies of cartridge if any to Pr
423. et thickness invoived are within the limits specified for machine countersinking for the next standard size larger diameter rivet it will be permissible to drill and countersink for and install the next size rivet of the same type and material as the original rivet The following are limits for machine countersinking standard size larger diameter rivet of the same type and material as the original rivet Do not redimple After installation mill the excess head height flush with the surface This method is subject to the same limitations as paragraph 2 A 3 B REPLACEMENT STANDARD SIZE RIVETS HOLE AND COUNTERSINK OR DIMPLE OVERSIZE This repair applies only to original countersunk head aluminum alloy rivets of 1 16 3 32 1 8 and 5 32 inch diameters Such rivets may be replaced as noted and 12 98 SERVICE AND MAINTENANCE MANUAL limited below when the hole and countersink or dimple is oversize 1 Machine Countersink Joint If the edge distance is a minimum of two times the diameter of the next standard size larger diameter rivet and the countersink depth is not beyond the thickness of the countersunk sheet it will be permissible to rework according to paragraph 2 A 3 Dimpled Joint If the edge distance is a minimum of two times the diameter of the next standard size diameter rivet and all the parts are dimpled it will be permissible to rework the smaller dimples to a size to match the oversize dimple and insta
424. ete AN960 416L washers under boit head to obtain proper tension Replace ali components removed Coat Seal with TEFLON spray lubricant T 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 synchronization check magneto points for condition clearance and timing Inspect distributor block for erosion and cracks Check cam follower felt for proper lubrication and remove excessive oil from breaker compartment Repair or replace components if required per Bendix SB No 612 at 500 Hrs for routine maintenance K Check baffles for secure anchorage cracks holes deformation and for close fit around cylinders Check cylinders for burned paint and cracked or broken fins Check baffle sealant L Check engine and propeller controls for free operation proper security of cable at housing swage full travel and security of attachment NOTE Cable Craft control cables are lubricated for the life of the control cable DO NOT remove seals or iubricate control cable M inspect Propeller Govemor for security in mounting and unrestricted operation of govemor control Check for proper operation during post inspection flight 12 98 SERVICE AND MANUAL N Inspect tubular engine mount for cracks damage or corrosion check all bolts and rubber mounts for security and condition O Check battery cables elecirica
425. ettle before draining and checking both the fuel tank sumps 2 the fuel selector valve rain 1 Fuel Selector Drain The fuel gascolator is at the lowest point in the fuel system and has a drain valve operated by a control on the floor in the cabin To drain the fuel selector valve A Switch fuel selector valve handle to L and puli fuel drain valve control ring for 10 seconds B Switch fuel selector valve handle to R and pull fuel drain valve control ring for 10 seconds 12 98 M20J SERVICE AND MAINTENANCE MANUAL C After draining be sure fuel drain valve control is returned to the closed position and the vaive is not leaking outside the aircraft WARNING During cold weather operation frequently check fuel selector drain for ice formation by repeating procedures 1 A B and C above 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 2 Defueling 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 drain valves WARNING Allow no smoking or open fiame within 50 feet of the defueling area Ground the aircraft and fuel container during all defueling operations A To defuel the aircraft using fuel boost pump 1 Disconnect fuel line from electric boost pump outlet at the fitting
426. f water B Wash battery box and flush battery with the mixture Do not allow soda water to enter battery cells permanent damage will result if soda mixes with electrolyte C Rinse thoroughly with clear water and dry the area i voe D Test each cell with a temperature corrected hydrometer Specific gravity should be 1 265 to 1 280 for a fully charged battery E Check electrolyte level and maintain at split ring F Clean battery terminals with emery cloth reinstall and tighten cables Coat terminals and connectors with petroleum jelly to retard corrosion 24 33 00 WARNING CIRCUITS 1 Landing gear position lights and warning horn RED and GREEN ianding gear position lights are in the annunciator panel The gear down limit switch controls the GREEN gear down light Both limit switches 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 flight for proper operation 2 Prestall Warning Circuit The prestall warning horn 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 actuates the prestall warning hom switch This vane is made of heat treated steel and any attempt adjust switch operation by bending the vane will damage the switch Refer to
427. f rocker switch is left ON forward interior lights will remain ON for approximately 2 minutes The rocker switch is connected through MASTER Switch on these aircraft and forward interior lights will go oF when MASTER switch is tumed OFF if door is closed 4 Anti Collision Lights A circuit breaker switch controls the white anti collision strobe lights 5 Instrument and Radio Lights Rheostats control ihe glareshield and radio lights The flight panel instrument light rheostat controls the compass light Lighting loads are controlled by transistors biased with manually controlled rheostats The transistors can be checked by the following methods A Connect ohmeter between the emitter and the collector should be infinite onms B Short base to collector should be a direct short zero ohms NOTE If readings are incorrect reverse the loads CAUTION Care must be exercised to prevent shorting light wires when installing or replacing instruments 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 0001 thru 24 3153 this light switch is connected directly to battery The switch MUST BE TURNED OFF to keep from discharging battery Aircraft 24 3154 thru 24 3200 may have a door switch timer mechanism that illuminate aft set of interior lights while baggage door
428. fective U1 Assy A1 defective Wire from P1 7 Assy A1 to left fuel gauge open 8 The left low fuel channel functions properly but the lamp is always dim CR22 Assy A2 open 9 The left low fuel lamp flickers on and off Switch 51 Assy A1 is in the Cal position instead of the NORM position intermittent ground on the wire from 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 A1 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 always dim CR23 Assy A2 open 13 The right low fuel 5m flickers on and off during flight 51 Assy A1 is in the Cal position instead of the Norm position An intermittent ground on the wire from P1 8 Assy A1 to the gauge C3 Assy 1 defective 14 The right low fuel will not light during TEST only when the right fuel tank is full R10 Assy A1 should be replaced with a 47K 1 4 watt 5 resistor 15 The right low fuel or the left low fuel lamps light before a low fuel situation has occured Recalibrate the appropriate channel CR1 Assy A1 open 24 39 05 12 98 14 SERVICE AND MAINTENANC
429. fer 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 sometimes added to fuel or oil These products may damage the engine and therefore should not be used Under no circumstances should automotive oi be used since such oils could cause engine damage Oil Recommendations for New Engine or Newly Overhauled Engine Break In New or newly overhauled engines should be operated on aviation grade straight mineral oil during the first 50 hours of operation or until oil consumption has stabilized The aircraft is delivered from Mooney with ee break in oil MIL L 6082 or SAE 20VV 50 Type OIL CHANGING RECOMMENDATIONS The oil sump is equipped with a quick drain fitting On aircraft equipped with either an internal or external oil filter the recommended engine oil change intervals is at 50 HOUR FLIGHT OPERATION INTERVALS if an engine has been operating on straight mineral oil for several hundred hours a change to additive oil should be undertaken with caution If the engine is in an extremely dirty condition the switch to additive oil should be deferred until after engine has been overhauled M20J MOONEY AIRCRAFT CORPORATION When changing from straight mineral oil to additive or compounded oil after several hundred hours of
430. ffected 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 hysterisis 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 VOC 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 rises due to sloshing in the tank and U5 C switches to a low output state C9 is discharged rapidly through R49 The delay time of the charging network provides a delay in low fuel annunciation of approximately 20 seconds A test of the functioning of the low fuel channel is accomplished by applying through R43 CR18 to the input of U5 C to switch U5 C and applying TEST through R42 CR15 to accelerate the charging rate of the filler C9 thus reducing the delay to approximately 2 seconds In order to calibrate the low fuel channel the set point R51
431. flow and totalizing computations 3 POWER SUPPLY The FT 101 power supply is a high speed switching regulator type for optimum efficiency and the lowest possible power drain on the aircraft electrical system 4 MEMORY The FT 101 microprocessor continuously stores and updates the totalized fuel quantity in a random access memory chip The Total Fuel Used quantity is retained during aircraft shut down by connecting the FT 101 memory wire to the aircraft battery through a memory switch The drain on the aircraft battery is small due to the low power CMOS memory chip which uses only 0 7 milliamps at 12 VDC 5 INTERNAL SWITCH ARRANGEMENT The programming switch block see Figure 73 2 located inside the FT 101 panel mounted unit has several arrangements to change data readout if desired Switches 51 and S2 see Figure 73 1 should not be changed unless the transducer K factor of a replacement transducer differs from the original unit s K factor see Section 73 31 02 3 for K factor description 3 thru S7 can be positioned in various arrangements to change fuel flow readout to gallons pounds or liters as the situation may require see Figure 73 1 FT 101 SWITCH ARRANGEMENT s s s sx sx lt ssn ss rs A_ V S VoV _ ED c s s K FACTOR SWITCH ARRANGEMENT gens s U 51 52 2 ON ON M ON OFF
432. for proper limit switch rig ging The gear down and locked position is indicated by 1 Illumination of the GREEN gear down annunciator light GEAR DOWN annunciator light is dimmed when NAV Light switch is ON 2 The warning horn will not sound with the throttle retarded to within 1 4 3 8 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 electrically as follows 1 Place Master Switch in OFF position 2 Move gear switch to GEAR UP or GEAR DOWN as desired 3 Momentarily actuate master switch until gear is in desired position 32 60 02 LANDING GEAR WARNING SYSTEM The landing gear warning system consists of 1 Landing gear position lights GEAR DOWN white indicator light on floor and green light on 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 control when gear control switch handle is up and the throttle is retarded to within 1 4 3 8 in of panel Check warming horn for 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 amp gear switch is in UP position 32 60 00 The airspeed safety switch located inside cabin is mounted behind airspee
433. formation 79 00 01 OIL FILTER REMOVAL The engine oil filter should be replaced each 50 hours and at every oil change 1 Remove top and bottom cowling see Section 71 10 00 M20J SERVICE AND MAINTENANCE MANUAL 2 Cut and remove safety wire on filter 3 Loosen the spin off oil filter and remove 79 00 02 OIL FILTER INSTALLATION 1 Position new filter on adapter 2 Tighten per instructions on filter 3 Safety wire filter 4 Perform leak check prior to flight 5 Reinstall lower and upper cowling see Section 71 11 00 6 Connect and secure all electrical and mechanical connections 79 20 00 DISTRIBUTION Reference FIGURE 79 1 79 30 00 INDIGATING 79 30 01 OIL PRESSURE Oil pressure indicating is provided through a pressure transducer plumbed into the engine oil system Pressure variations change the resistance within the transducer and this signal drives the oil pressure gauge located within the cluster gauge LUBRICATION DIAGRAM SCHEMATIC FIGURE 79 1 12 98 79 00 00 3 SERVICE AND MAINTENANCE MANUAL 79 30 02 OIL TEMPERATURE The oil temperature gauge is an electric unit receiving its signal from a temperature bulb in the engine case located between the oil cooler and the case The probe resistance changes as the oil temperature changes and this varies the readout on the instrument 79 40 00 DRUCK TRANSDUCER TEST PROCEDURE The Druck Transducer Test Box GSE 030036 can be u
434. gage door closed Refer to AFM POH Section 111 for specific procedures to operate auxiliary exit handle This door is hinged at the top with an extruded piano type hinge A hold open arm is attached on both doors to assist in holding the door open when desired A door lock is provided for both doors A single key will operate either door lock The interior panels require removal if the door locks are to be removed and replaced 52 10 00 CABIN DOOR MAINTENANCE PRACTICES 1 Removal The cabin door may be removed to or repair the door or to replace a damaged inge A Remove the interior panel around the door frame i B Remove the hold open arm at the door frame Remove the cotter pin and washers from the hold open arm shaft Pull the shaft up from the doubler plate and clear of the door frame C Remove the eight 8 screws from outside the airplane that hold the front portion of the hinge in place There are also three 3 flush rivets that will require removal at this location D Carefully drill center of rivet head with a 1 8th inch drill bit until head pops off and rivet stem can be punched out reu 12 98 M20J MOONEY AIRCRAFT CORPORATION The original door assembly with hinge attached is assembled to the door frame prior to installation of the outer skin The door is placed into position and the hinge held in place on its mounting plate by sealant and locator rivets or bolts The number of loc
435. ge B Rudder The rudder trailing edge may be trimmed right or left as required 27 95 00 STALL WARNING MAINTENANCE PRACTICES 1 Stall Warning Switch Removal A Remove screws or rivets attaching the access cover aft of stall switch on lower wing surface B Remove two screws which secure switch to wing leading edge C Disconnect two wires from the switch ADJUST UP TO ACTUATE SOONER ADJUST DOWN TO ACTUATE LATER ADJUSTMENT SCREWS STALL VANE ADJUSTMENT FIGURE 27 21A S N 24 0001 THRU 24 3153 12 98 SERVICE AND MAINTENANCE MANUAL 2 Stall Warning Switch Installation A Connect electrical wires to switch connections B Position switch 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 stall warning switch is adjusted when the airplane is test flown at the factory Should it require readjusting proceed as follows Para 3 or 4 3 Stall Warning Switch Vane Adjustment S N 24 0001 thru 24 3153 Figure 27 21A Locate the stall switch on the lower surface of 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 waming 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 TO ACTUATE SOO
436. ghts 8 See Section 5 20 07 for repetitive 50 Hour inspections and servicing of components information 5 20 06 100 HOUR INSPECTION or ANNUAL REF FIG 5 4 The 100 hour or annual inspection is a thorough searching inspection of the entire aircraft Preparation for the inspection includes the thorough cleaning of exterior and engine compartment removal of fuselage wing and empennage inspection doors cover plates and fairings at all systems attach hinge and bearing locations including wing and empennage to fuselage mating points Operating limit replacement 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 requirements are outlined in the following paragraphs 1 ENGINE INSPECTION Prior to the inspection remove the engine cowling and propeller spinner Wash down the engine and engine compartment Then perform an engine runup in accord with the procedure recommended in the Lycoming Operators Manual To verify correction of malfunctions and abnormalities perform a second engine runup and flight test after the 100 hour inspection engine set up check 5 20 06 12 t M20J SERVICE AND MAINTENANCE MANUAL A Complete a differential hot engine compression
437. gine exhaust system components with a suitable solvent Stoddard Solvent allow to drain and wipe dry with 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 A LOOK FOR LEAKS Examine surfaces adjacent to exhaust system components for signs of exhaust soot Look for gray red or black gas stains at welds clamps flanges etc inspect exhaust system for chaffing by cowling engine mount cables or any airframe components Inspect exhaust stacks for burned areas cracks and looseness I B LOOSE CONNECTIONS Inspect exhaust clamps for cracks looseness and proper security NOTE During inspection particular attention should be qiven to condition and security of flanqes spot welds slip joints and welded areas C INTERNAL EROSION Examine bends and low spots for thinning or pitting 78 00 00 3 SERVICE AND MAINTENANCE MANUAL M20J D STANDOFFS PINS AND HEAT TRANSFER FINS Look for miss
438. he indicator can be damaged by static electricity Dissassemble the indicator at a static controlied workstation DO NOT LEAVE THE INDICATOR UNTIL IT HAS BEEN REASSEMBLED STEP 1 Remove 4 screws 2 on rear of indicator which also removes connector latch and 2 on side Then remove electronlc assembly by simultaneously pushing on rear connector and pulling on front bezel DO NOT BEND THE BOARD CONNEGTOR PINS K FACTOR UNITS TRU FLOW 1 JUMPER ARRANGEMENT FIGURE 73 3 73 31 01 12 98 MOONEY AIRCRAFT CORPORATION 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 boards to the standoff Separate the boards by grasping the edges and puiling them 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 T K3 HH K1 Arrange the jumpers according to Figure 73 3 part A STEP 6 Deiermine the desired unit of measurement Reposition the jumpers according to the examples in Figure 73 3 part B STEP 7 Print the K factor and unit of measurement on the dot label located on the back or the indicator case
439. he recommended torque value from Figure 5 2 This value is considered Final Torque Value FRICTION DRAG TORQUE REC MD TORQUE FINAL TORQUE CAUTION DO NOT REUSE LOCKNUTS IF THEY CAN BE RUN UP FINGER TIGHT 5 20 01 12 98 SERVICE AND MAINTENANCE MANUAL M20J MOONEY AIRCRAFT CORPORATION CAUTION These torque values are derived from oil free cadmium plated threads CAUTION DO NOT REUSE LOCKNUTS IF THEY CAN BE RUN UP FINGER TIGHT 5 20 02 AIRCRAFT FILE INSPECTION Aircraft 100 hour and annual inspections cover in addition to examining the aircraft proper a review of the status of compliance with current Federal Aviation Regulations This review includes inspection of the Airplane Flight Manual Aircraft Log Book Engine Log Book Regisiration Certificate Airworthiness Certificate Weight amp Balance Record Lycoming Service Information Aircraft Radio Station License if applicable FAA Airworthiness Directives and Mooney serivce documents 5 20 03 ENGINE FUNCTIONAL CHECK Prior 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 abnormali
440. her deteriorations and repaired or replaced promptly Inspect the exhaust system for any leaks or cracks and replace or repair as needed 21 00 00 3 SERVICE AND MAINTENANCE MANUAL M20J MOONEY AIRCRAFT CORPORATION BLANK 21 40 00 12 98 4 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 PAGE DATE 24 Effectivity W2BLANK 1298 24 Contents S3A4BLANK 4 2 98 24 00 00 EE JE d 12 98 2 ie dle Cur VB 8 RUE S Yt 2 98 v uo eo e S uo CUN dee xou SP ant e 12 98 24 34200 2 5 a We mo i uS wd 12 98 24 3500 5 Uk 12 98 24 3900 MU de se 22 12 98 24 39 01 NU M MEET MES 12 98 2443902 12 12 98 ue cU Q mo V U e cu ec X unt 4 2 98 24 39 05 tan eade SES lae Mb we ee 12 98 24 39 05 2 50 EE 2 98 24 39 0652 lw xo cae a RS ABE LEY ES 12 98 24 39 06 va odo vv AD 42 98 24 39 4066
441. hese skins contribute to the strength of the aircraft and security of each panel is mandatory Aircraft S N 24 1418 and later have a one piece composite belly skin that covers the underside of the aircraft from the exhaust cavity aft to the tailcone The front seats are installed on rails which are attached to the floorboard and structure beneath the floorboard The rear seat 2 place is built into the top of the wing center section from the main spar aft to the rear spar Aircraft S N 24 0001 thru 24 1213 contain a bench type seat with a one piece non reclining back rest S N 24 1214 and ON contain a split type seat using seat cushions in molded wells over the wing spars and individually reclining rear seat backs 51 10 00 STRUCTURAL REPAIR GENERAL This section outlines structural repair procedures for the M20J airplane it is intended to supplement FAA Advisory AC 43 13 1 by showing repair methods Specific to Mooney Airplanes current revision All structural repair must be in compliance with AC 43 13 1 unless specific Mooney factory repairs are recommended or with the specific approval of a Federal Aviation Administration representative which is the final authority in all repairs This manual is for general guidance and has no authorized approval Status The Customer Support Department Mooney Aircraft Corporation Kenville Texas 830 792 1904 830 896 6000 switchboard should be consulted for special rep
442. hieided arc welding Heliarc Use AISI 4130 condition N steel for replacement and repair of tubes and for making repair sleeves Replacing a member or subassembly is often advantageous and more feasible than repair All detail 51 11 00 7 AIRCRAFT CORPORATION tubes or assemblies needed for replacement can be purchased from Service Parts Department Mooney Aircraft Corporation Louis Schriener Field Kerrville Texas 78028 tele 830 792 2092 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 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 surface smooth 25 Form a patch that will cover twice the diameter of the tube around the edge of the damaged area and twice the circumferential area of damage as shown in Figure 51 1 Weld patch in place 2 INNER SLEEVE SPLICING Use an inner sleeve splice to partially replace a tube eau increasing the outside diameter see Figure 1 4 DF TUBE CIRCUM MAX z c 2 M20J IF NOT GREATER THAN DIAM OF TUBE 2 g e 7 SERVICE AND 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
443. hru 24 3392 DRAWING NO 800304 J6 REV Z 1 sheet ELECTRICAL EQUIPMENT HARDWARE CHART S N 24 3393 thru 24 3404 DRAWING NO 800304 47 REV Z 1 sheet ELECTRICAL EQUIPMENT HARDWARE CHART S N 24 3405 thru 24 3410 DRAWING NO 800304 8 REV AA 1 sheet 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 42 REV H 1 sheet 12 98 MOONEY AIRCRAFT CORPORATION 14 VOLT ELECTRICAL EQUIPMENT CHART M20J ELECTRICAL SYSTEM HARDWARE CHART 14 VOLT SERVIGE AND MAINTENANCE MANUAL S N s 24 0001 THRU 24 1685 MOONEY DRAWING NO S SCI 800268L 3 3A amp 800330 CP FDnh a a a ee 91 20 01 CODE 21 CB101A 21 CDO1A 21 21 CD02B 21 CD03A 21 CF01B 21 CFO2A 21 GFO3A 21 CFO4A 21 CFO5A 21 CFO6A 21 CFO7A 21 CFOBA 21 CFO9A 21 CFO9B 21 CTO1A 21 CT01B 21 CT01D 21 DAO1A 21 DAO1B 21 DAO1C 21 DA01D 21 DA02A 21 DA02B 21 DA03A 21 DA03B 21 DA04A 21 DB01A 21 DB01B 21 DBO2A 21 DB02B 21 DBO3A DESCRIPTION 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 SWITCH LIMIT DOWN ACTUATOR SWITCH LIMIT UP
444. ight Maintenance is similar to that required for the directional gyro compass 34 23 01 GYRO HORIZON TROUBLE SHOOTING Pn _I r F us IUSA A n TROUBLE Horizon bar does not respond 1 Vacuum regulating valve improperiy adjusted 2 Pump failure 3 Vacuum line kink leaking or too long for its diameter Horizon bar does not settle Horizon bar oscillates or vibrates excessively 1 Dirty air filter 2 Vacuum regulating valve improperly adjusted 3 Defective mechanism 4 Excessive vibration 5 Shock mounted panel is contacting structure inadequate clearance PROBABLE CAUSE Dirty air filler high vacuum indication Insufficient vacuum resulting from the following Defective mechanism Excessive vibration Shock mounted panel is contacting structure inadequate clearance Excessive vacuum resulting from the following 12 98 REMEDY Examine filter and clean or replace instrument if necessary Correct insufficient vacuum as follows 1 Adjust valve 2 Repair or replace pump 3 Locate and repair Check for collapsed inner wall of flexible hose Replace instrument Test with vibrometer If amplitude is more than 004 inch examine installation to determine whether connections are restricting movement of instrument Examine shock mountings and replace if necessary Correct for excessive vacuum as follows 1 Examine filter and clean or repl
445. ignal from a self contained opto electronic pickup A neutrally buoyant rotor spins with the liquid between V jewel bearings The rotor movement is sensed when notches in the rotor interrupt an infra red light beam between a light emitting diode and a photo transistor 3 The transducer design is fail safe complete rotor blockage cannot interrupt fuel flow The transducer life expectancy is 1500 hours SOFTWARE VEHSION NO UNIT OF MEASUREMENT UNITS 4 U S GALLONS 3 IMPERIAL GALLONS POUNDS 5 85 X U S GALLONS K FACTORS ARE DISPLAYED AS ACTUAL K FACTOR RANGE ie 1 K1 2 K2 etc M20J MOONEY AIRCRAFT CORPORATION NOTE Transducers are categorized by the number of pulses per second 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 same K factor as the units being replaced Specify K factor code when ordering new transducers 4 Fuel flow transducer removal A Remove top and bottom cowling from aircraft See Section 71 10 00 for procedures B Cut and remove ty raps from insulator sleeves knife disconnects of electrical wires C Slide insulation sleeving up on electrical wire harness D Disconnect the knife disconnects E Remove safety wire from firesleeve around turbine transducer and unwrap firesleeve to expose the transducer F Loosen and
446. ill prevail and the dimmed channels with the exception of Channel 1 are reset to bright condition FLASHER 12 98 SERVICE AND MAINTENANCE MANUAL 3 0 FLASHER The Flasher shown in Figure 2 provides the circuit to flash the outputs of the left and right alternator warnings the low voltage warning and the low vacuum warning The flasher consists of an astable oscillator driving an NPN common emitter connected transistor Q4 This allows the open collector of Q4 identified as FLASH to sink the drive from the output amplifiers of the appropriate warning channels 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 circuit shown is the identical circuit that has been used for many years 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 CH1RET is returned to the Nav Light bus When 28 VDC is applied to INPOS1 and the Nav 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 illu
447. ill six new holes between existing rivet holes in the skin at each side of the damaged area install 22 AD4 rivets through splice angle and skin and 22 AD4 rivets through splice angle and spar web See Figure 51 15 VIEW A SAME LENGTH AS ANGLE BEING SPLICED SPAR REPAIR BETWEEN STA 9 0 amp 34 0 FIGURE 51 15 12 98 M20J 4 3 MIN PER SIDE 040 8084T 3 CLAD MOONEY AIRCRAFT CORPORATION 4 4 HIN PER SIDE lt gt CR 2248 CHERRY LOCK 4 HIN PER SIDE SPAR REPAIR STA 48 5 Approx FIGURE 51 16 2 Repair main spar cap damage between STA 34 and ST 48 5 by forming a splice angle from 3 4 inch by 3 4 inch 050 2024 T3 sheet aluminum Pick up five existing holes and drill six new rivet holes between existing holes in the skin on each side of damaged area Install 11 AD4 rivets through angle and skin and 10 AD4 rivets through angle and web on each side of the damaged area See Figure 51 15 VIEW B 3 Repair main spar damage from STA 48 5 outboard by installing splice angles made from 040 2024 13 material on both side of web using 12 AD4 rivets 6 through skin and 6 through web on each side of damaged area Pick up three existing holes and drill three new holes between existing holes on each side of damaged area See Figure 51 16 4 Repair main spar web damage outboard of STA 34 0 top flange and STA 48 5 lower flange by forming a splice angle from 050 2024 13 aluminum The
448. in the nose wheel tire Level aircraft laterally wing tip to wing tip by placing Spirit Level on center seat tracks in front of spar Front seats must be in the full forward position when weighing Use skin splice S N 24 0001 thru 24 0083 24 0085 thru 24 0900 and leveling screws S N 24 0084 24 0901 amp ON See FIGURE 8 1 8 00 01 WEIGHT AND BALANCE To weigh the aircraft select a level and draft free work area then 1 Check for installation of ali equipment as listed in the Weight and Balance Record 2 Ground aircraft and drain fuel tanks per Section 12 10 02 2 3 Add unusable fuel to each tank see applicable Pilots Operating Handbook for aircraft being serviced for proper quantity of unusable fuel 4 Fill oil to capacity 8 quarts 5 Position a 2000 pound capacity scale under each of the three wheels 6 Level aircraft as described in Section 8 00 00 and center nose wheel 7 Weigh the aircraft 12 98 M20J SERVICE AND MAINTENANCE MANUAL 8 Find reference point by dropping a plumb bob from center of nose gear trunion retracting pivot axis to the floor Mark the point of intersection 9 Locate centerline of the main wheel axles in the same manner 10 Measure the horizontal distance from the reference point to main wheel axle center line Measure horizontal distance from center line of nose wheel axle to center line of main wheel axles 8 00 00 SERVICE AND MAINTENANCE MANUAL M20J MOO
449. incide 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 bring 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 51 7 4 MS20470AD4 XX As MS20470AD5 XX Va MS2046AD4 XX 5 BP MS2046AD5 XX CR516 XX SPLICE ANGLE MATERIAL 7075 6 ALPPH TP 4 MIN EACH SIDE VIEW LOOKING UP VIEW LOOKING DOWN 5 51 7 SPAR FIGURE 51 7 51 13 02 12 12 98 SERVICE AND MANUAL 3 SPAR WEB REPAIR Repair all damage to spar webs in accordance with 43 13 1 If there is extensive damage to a web that cannot be repaired as outlined in AC 43 13 1 current revision consult the Customer Service Depariment giving exact location and extent of damage 51 13 03 STUB SPAR REPAIR Stub spar splice at 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 1 56 7503 REF W S 435 503 FLAT PATTERN 040 AIS 4130 COND M STEEL REAR SPAR REF 18 tis fe PEREZ du am e ftt evi 470 ADB RIVETS REF M20J DETAIL A 10 AN 470 AD4 RIVETS THRU SKIN AND 503 MOO
450. inder Pedal Linkage Aileron Control Tube Rod End md Outboard Flap Stops 12 98 AIRCRAFT CORPORATION LUBRICATION INTERVAL SYMBOL 0 5 HRS a 100 a 100 ur ce a a od uox 300 Lo de 4 Ge w s 2700 MER so URS VS 100 i oue SE 100 A uo lucos Mel av oW 100 We uso ESOS ws CAL wet a O0 Z5 d TGS we 7 71100 Bock y was 75 262 5100 100 100 ee 4 2025 2 es x 100 100 Vo 100 gt 100 A 100 E 100 Q 500 100 a 100 50 100 V 100 gt 100 w 100 21 100 gt 100 X 100 100 100 5 20 07 MOONEY AIRCRAFT CORPORATION M20J ITEM NO 20 21 23 24 25 26 27 28 29 30 31 32 33 SYMBOL 5 OP TA DM 5 20 07 20 SERVICE AND MAINTENANCE MANUAL ITEM DESCRIPTION LUBRICATION INTERVAL SYMBOL HRS Baggage Compartiment Door Hinges 100 Latches 100 Seals 100 Lock 6 Cabin Door Hinges gt 100 Latches 100 Seals 100 Hold Open Arm 100 Lock 8 4 Engine Instruments Radios Oil Dip Stick Oil Filler Tube V AR Wheels amp Brakes Wheel Bearings 250 Brake Pressure Plates Anchor Bolts 3 50 Shock Discs 50 Elevator amp Rudder Snc Nose Wheel Wheel Bearings LAE
451. iner Battery freezes Leaking battery case Reversed battery polarity Excessive water consumption in all cells Excessive water consumption in one ceil only 24 39 02 12 BATTERY TROUBLE SHOOTING PROBABLE CAUSE Battery worn out Improper charging rate setting Excessive discharging Standing too long Equipment accidentally left on Impure electrolyte Short circuit ground in wiring Low charging rate Loose hold down bracket Frozen battery Charging rate too high Too much water added to charging rate too igh Spillage from overfilling Leaking or clogged vent lines Charging rate too high Discharged battery Water added and battery not charged Frozen electrolyte Cables connected backwards on battery or charger Charging rate too high Cracked jar 12 98 SERVICE AND MANUAL REMEDY Replace battery Reset charging rate Turn off some equipment when alternator is not charging Decrease Starter usage by using external power whenever possible Remove and recharge battery Remove and recharge battery Replace battery Check wiring Adjust voltage regulaior Replace battery and secure firmly Replace battery Reduce charging rate by adjusting voltage regulator Drain battery and keep at proper level adjust voltage regulator Flush container with baking soda solution Repair or clean vent lines Adjust voltage regulator R
452. ing actuation 2 775 in H20 0 384 0 358 in Use with socket 27E122 spring 206176 stand off 2 ea 218212 AN515 6R5 screw AN936 A6 washer Alternate L110 1 N K3L or Mooney P N 880013 501 ME RCA KC2B Mounting Hardware Mica Insulating Wafer H H Smith 6291 Nylon Shoulder Washer H H Smith 2666 Solder Lug H H Smith 1410 10 Metal Washer H H Smith 1152 Nut H H Smith 1367 Alternate Holders Leecraft 07 05 Drake 4151 014 Alt Resistors Sprague 243E2015 Drake VC5E 200 Maximum circuit breaker rating is shown amperage of installed circuit breaker is determined by particular unit installed Alternate Ohmite 0561 Mallory 5AV10 Replace 414 amp 20082 with 880016 501 amp 800331 721 cable Manufacture using Alpha Wire Co braid 2172 or 1233 2 2 ea amp AMP terminals as necessary to connect the buss bars as shown on schematic Cover braid with PVC 105 A tubing for insulation Same as 14 except use 1 ea braid Ground tabs 250 series As required AMP 41478 AMP 41480 Alternate Prestolite R35 Replace with MS3106A 22 14P when used in conjunction with MS3450KT22 14S Replace with MS3450KT22 14S receptacle amp MS3417 22 N cable clamp or Matrix 9440KT22 14S MFG Chicago Minature Lamp Co Set switches with room temperature between 60 F and 80 F Set low at 4 25 Hg 0 25 and high at 5 50 Hg 0 20 0 00 increasing vacuum Switches may not vary more than 0 50 Hg between 0 F and 110 F
453. ing in each tube and then extend gear manually stopping just as green gear down light comes on 13 Check length of nose gear bungee springs in gear extended position Nose gear bungee spring deflection from zero load condition step 12 must be 030 to 070 inch for each bungee Fig 32 6 010 to 030 inch for M20J with Dukes Actuator P N 1057 00 5G Recheck main gear preload torque value If nose gear bungee spring deflection and or main gear preload torque is not within prescribed limits adjust retraction tube rod ends in increments of 1 2 tum as required Use manual crank during readjustment and stop extension just as gear down light comes on When step 15 is complete the retraction system is rigged for the gear down and locked position with allowance for actuator overrun after cutoff 14 Disengage manual crank and reconnect landing gear system circuit breaker 15 Leave all gear doors disconnected and run gear up electrically 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 striker arm H Fig 32 5 so that the switch is just closed and the red intransit fight goes out Secure striker arm in position The gear is now properly rigged in the gear up position with allowance for overrun after cutoff 32 30 04 13 SERVICE AND MAINTENANCE MANUAL Extend gear to down and locked position Adjust gear doors Ref Section 32 10 03 and 32
454. ing or damaged heat transfer pins or fins Look for 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 Look inside muffler for broken baffles or tubes These can restrict the outlet causing power loss G HIDDEN DAMAGE Carefully inspect all internal surfaces that lie hidden under extemal gussets stiffeners etc A borescope is recommended 78 40 00 4 MOONEY AIRCRAFT CORPORATION H INSTALLATION TIPS install only correct parts DO NOT FORCE FIT any component Properly align connecting components Do not reuse gaskets Insure that attach bolts are properly torqued Exhaust flange stud nuts are to be torqued to 100 110 inch Ibs 78 40 00 PERIODIC REPLACEMENT COMPONENTS 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 components should be made any time exhaust system is removed from engine for component replacement The inspection should be made in the interest of preventive maintenance 12 98 MOONEY AIRCRAFT CORPORATION M20J SERVICE AND MAINTENANCE MANUAL CHAPTER 79 OIL SERVICE AND MAINTENANCE MANUAL M20J CHAPTER SECTION SUBJECT 79 nr I 79 00 00 79 30 02 CHAPTER SECTION SUBJ
455. ing skin attach temporary jigs or holding fixtures to the wing to prevent wing warpage When attaching a new spar cap assure proper interference fit of the replaced huckbolts 06e SPLICE MATERIAL M80 SERIES 2024 T4 M22 SERIES 2014 76 5 5 PER SIDE f SPLICE MATERIAL 2014 6 5 6 PER SIDE id STRINGER REPAIR FIGURE 51 6 12 98 AIRCRAFT CORPORATION During installation of the new spar cap all holes damaged by improper drilling or reaming should be reamed to the hole size recommended for oversize huckboit 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 not completely fill the hole Repair scratches on 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 sanded area use dye penetrant to be sure that the scratch is completely removed Clean and prime area where the protective coating has been removed th RIVET CODE FOR STRUCTURAL REPAIRS M20J SERVICE AND MAINTENANCE MANUAL 2 SPAR CAP REPAIR Spar caps outboard of STA 103 consist of sheet metal angles backed up with aluminum extrusions from STA 103 to near STA 150 Replace or repair damaged extrusions Do not allow splices in a repaired extrusion to co
456. ing walk access panel Tack Free Time CLASS B HOURS CS 3330 B 8 PR1403 G B2 10 PR1428 B B Cure Rate Application Life HOURS HOURS 16 2 un V ME uncis ux 48 LL oux 1 8 16 2 d Brushable Top Coat Protective Sealant m c Tack Free Time or HOURS PR1003L s x CS3600 ut nie Allow 24 hours cure time prior to refueling tanks 28 10 00 Cure Rate Application Life HOURS HOURS di ox X 12 98 SERVICE AND MAINTENANCE MANUAL B Sealant Mixing 1 For best results use kits with proper proportions of base 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 bottorn 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 3 Place a small amount of mixture on a clean strip of aluminum and spread sealant Visually examine sealant film to determine whether accelerator is visible in particle form If particles of accelerator are visible continue mixing operation If course particles of accelerator persist after mixing thoroughly reject the mixed batch NOTE Sealant in tube form have mixing instructions on each tube Read and comply with these mixing inst
457. inner 2 B Remove doubler plates 3 C Remove spinner dome 2 P 61 00 00 3 SERVICE AND MAINTENANCE MANUAL D Remove safety wire and loosen bolts 4 attaching propeller to engine crankshaft about 1 4 inch and pull propeller forward 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 E Pull propeller from engine crankshaft F if necessary to remove the aft spinner bulkhead 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 61 00 20 PROPELLER INSTALLATION 1 If aft spinner bulkhead was removed re install on ring gear support using bolts nuts and washers in the reverse order of removal 2 If starter ring gear support and aft spinner bulkhead were removed clean mating surfaces of support assembly and engine crankshaft flange 3 Place alternator drive belt in the pulley groove
458. inner sleeve see Figure 51 3 A Form the split sleeve from steel tube or sheet steel when outside diameter of original 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 material AISI 4130 steel condition N with at least the same gauge as the original 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 original tube with two rosette welds spaced one original tube diameter apart 4 TENSION FITTING REPLACEMENT see Figure 51 4 A Cut A and B tubes loose from tension fitting 340034 7 8 at welds 195 IN WELD GAP SLEEVE TUBE INSIDE 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 appropriate 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 C and with 085 inch wall thickness F Insert the inner sleeve in C tube and weld place as shown Figure 51 4 5 REPAIRS FOR WELDED ASSEMBLIES General This sec
459. installation wing skins 5 Remove all rivet shanks with a punch A Place the new or repaired wing tip in place C Carefully pull wing away from wing rib 6 CAUTION and skins 5 Disconnect the strobe and navigation Be sure aileron and aileron balance weights are light san Huk disconnect plug 8 prior to not restricted in movement either direction blad B Secure wing tip and drill holes to match wing NOTE skins Cleco as holes are drilled into tip When all holes The strobe or navigation lights can be removed are drilled remove wing tip assembly and deburr from wing tip either before or after its removal NOTE from wing Connect strobe and navigation light connectors 8 prior to final attachment the 57 20 02 12 98 6 MOONEY AIRCRAFT CORPORATION C Use Avex 1604 0412 blind rivets to attach the wing tip to the top and bottom skins D Repaint to match the aircraft 57 30 00 PLATES SKIN The wing access and inspection covers shown in Figure 57 5 provide maintenance access to components plumbing and control bellcranks enclosed within the wing 2 M20J SERVICE AND MAINTENANCE MANUAL They are flush mounted covers and when installed continue the aerodynamic contour of the wing S N 24 1418 and ON have a one piece fiberglass skin that can be removed to gain access to component located in that area NOTE One piece belly skin panel on 24 1418 amp ON 19 19 3 FIVE SEP
460. instrument panel The instrument panel lighting system has manual dimming mechanisms 5 00 06 CABIN HEATING amp VENTILATING SYSTEMS The heater muff encasing the exhaust system is the cabin heat source Hot air from the heater muff mixed with ambient air controls cabin temperature Air routed from the main heater duct system to nozzles at the windshield base defrosts the windshield An optional defrost blower motor system is available for 24 3000 thru 24 TBA and for retrofit on earlier aircraft 5 00 07 FUEL SYSTEM The fuel system has sealed integral wing tanks in ihe forward inboard section of each wing Vents at the outboard top corner of each tank vent through the lower wing surface Fuel sump drains are at the lowest port in each tank The electric fuel pump is in the ottom left forward section of the fuselage just aft of the firewall The engine driven fuel pump mounts on the engine crankcase Two fuel quantity transmitters in each tank are wired to fuel quantity gauges in the engine cluster gauge The master switch left side of the pilot s panel turns on the fuel quantity indicating systems Optional visual sight gauges are available for wing tanks on aircraft 24 0001 thru 24 NOTE 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 recommended that overhaul or replacement of components should be a
461. instrument that indicates control coordination and rate of turn This instrument is electrically driven 34 21 01 TURN COORDINATOR TROUBLE SHOOTING TROUBLE PROBABLE CAUSE REMEDY Pointer fails to respond Foreign matter lodged in Replace instrument instrument No electric current Check voltage at instrument Bar does not set level Gimbal and rotor assembly out Replace instrument l of balance Pitted or worn pivots or Replace instrument bearings In low temperature bar fails to Oil has become too thick Replace instrument respond or responds sluggishly and with insufficient deflection Insufficient bearing clearance Replace instrument Bar sluggish in returning to or dirt between damping Replace instrument level and does not set on level pistons and cylinders when stationary Excessive clearance between Replace instrument rotor and rotor pivots 34 22 00 MAGNETIC COMPASS The magnetic compass dial graduated in five degree increments is encased in a liquid filled glass and metal case The unit mounts on the stainless steel windshield center post above the glareshield The compass should be swung and compensated at each annual inspection and whenever new equipment is installed To compensate for N S deviation adjust left screw to compensate for E W deviation adjust right screw amp Degausing of the tubular structure may be required if compass cannot be compensated within limits Carefully go over the entire s
462. ion 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 Some collars have holes drilled off center and may be turned over to change axle position NOSE GEAR LEG ASSY 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 Section 27 20 00 outlines the nose gear steering rigging A centering cam aligns the nose wheel fo entry into wheel well NOTE Check nose gear leg assy for towing damage Replace if any dent exceeds 1 32 inch NOTE Aircraft S N 24 1464 amp 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 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 an wear If holes are worn replace leg assembly NOTE Shock absorber 6 and related attaching hardware may be removed from all Mooney 20 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 2 Rod end
463. ion 32 31 05 and 32 30 03 LANDING GEAR WARNING SYSTEM The landing gear warning system provides the pilot with an audible warning that 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 amp ON and can be adjusted for the proper setting by loosening the screw and repositioning ihe switch This switch is located inside ihe throttle quadrant 24 0001 thru 24 0377 and operated by cam when throttie was retarded Adjustment procedures are similar BRAKE SYSTEM The brake system is hydraulically operated by depressing the brake pedals mounted on the pilots rudder pedals Dual brake system is optional for co pilot Individual wheel brakes are available by depressing either left or right pedal Parking brakes are actuated by depressing both brake pedals and pulling the parking brake control cable knob This cable actuates a lever on the parking brake valve and traps the hydraulic fiuid from the valve to the wheel cylinders 12 98 M20J SERVICE AND MAINTENANGE MANUAL thus holding the pucks to the discs Release the parking brakes by pushing the parking brake knob in This releases hydraulic pressure at the wheel cylinders and therefore releases the brake discs 32 10
464. ired Extend gear to adjust links then retract to check adjustment APPLY MIL G 23827 GREASE TO BOLT FOR ROTATION OF LINK D AT F 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 bearing and carefully remove gear assembly from wing 13 Identify all components removed and DO NOT intermix right and left gear 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 bearings retraction linkage and fore and aft trunnion bearings prior to installation refer to Section 5 20 07 for recommended lubricants 2 Installation of main gear is the exact reversal 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 Temporarily attach gear door ink rods io 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 MAIN GEAR DOOR ADJUSTMENT POINTS gear has been rigged Ref 32 30 02 FIGURE 32 2 24 0001 thru 24 2999 and 24 3079 thru 24 TBA 1 Raise aircraft on jacks 32 10 04 MAIN GEAR DOOR RIGGING NOTE
465. is finish should be directed to Pratt amp Lambert 2153 Wichita KS 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 12 98 MOONEY AIRCRAFT CORPORATION M20J SERVICE AND MAINTENANCE MANUAL CHAPTER 21 ENVIRONMENTAL SYSTEMS SERVICE AND MAINTENANCE MANUAL M20J MOONEY AIRCRAFT CORPORATION CHAPTER 21 ENVIRONMENTAL SYSTEMS LIST OF EFFECTIVE PAGES CHAPTER SECTION SUBJECT PAGE DATE 21 Effectivity Contents 1 2BLANK 12 98 21 00 00 4 4 5 5 Ge vh IDEs wc 140 00 es oe Xeock Re a SW 522 des cO a TABLE OF CONTENTS CHAPTER SECTION SUBJECT SUBJECT PAGE 21 00 00 Cabin Ventilation System 8 214000 4 x xc Ue M T 22 222 54 2 EG 12 98 21 EFF CONTENTS 1 2BLANK MOONEY AIRCRAFT CORPORATION 21 00 00 CABIN VENTILATION SYSTEM The cabin environmental system consist of three ventilating systems that supply heated or fresh air as the pilot or passengers prefer CABIN AIR CABIN HEA
466. is open After door is closed if rocker switch is left ON aft interior lights will remain ON for approximately 2 minutes 12 98 M20J MOONEY AIRCRAFT CORPORATION The rocker switch is connected through MASTER Switch on these aircraft and aft interior lights will go OFF when MASTER switch is turned OFF if door is closed 7 Map Light A push button switch on top of control wheel center section controls map light Co pilots map light is optional 24 36 00 LANDING GEAR CIRCUITS 1 Limit switches and relays operate the landing gear actuator a reversible motor 14 volt DC S N 24 0001 ihru 24 2999 or 28 volt DC S N 24 3000 thru 24 A landing gear safety system actuated by a pitot air pressure switch or a squat switch 24 0001 ihru 24 0237 prevents landing gear reiraction until safe flying speed is attained The landing gear control switch operates actuator motor through one of these safety switches and relays When landing gear control switch is UP and safe flying speed has been attained the safety switch closes to activate the control relay starting the actuator As the gear reaches the up and locked position a mechanical Stop opens limit switch and the actuator stops When landing gear controi switch is placed in down position the gear motor down relay closes and actuator starts When gear reaches down and locked position the mechanical stop opens limit switch and actuator stops Later models have a red light f
467. ith silicone sealant prior to installation of cartridge into wing Route drain tube through hole in bottom of access Cover 2 The bottom mounting strap strip from the old cartridge will require relocating to the new cartridge After 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 location for the two holes in the bottom of the cartridge housing proper hole 630 drill to install CherryMax CR3243 4 2 rivets 2 ea to attach strap strip to cartridge bottom housing 3 Door caps may need to be installed on some replacement cartridge doors in accordance with the following a Mark rivet locations on flange legs of all cap strips to be installed One is located 2 0 inches from the angled end of cap strip and another is located 5 0 inches from the angled end 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 strips on speedbrake doors while speedbrakes are retracted into cartridge until flush with top of wing skin surface Line angled pe of cap strip up with angled end of speedbrake oor Cycle speedbrake doors to verify sufficient clearance exists 0 0625 in between cap strip and wing skin and doublers
468. jacked and leveled and with the landing gear retracted NOTE Some elevator trim tubes have poly tape 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 instrument wiring and plumbing for condition and proper connections B Clean and inspect vacuum filter Replace garter 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 security of installation E Check compass for proper lighting compensation security 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 condition of ground straps H Insped Avonics Equipment for proper op
469. k k pr s 00 00 0 sv k 2800904 JA 04 Y a EEE iofd hru 2433838 v k k k 800304 J5 REV Y BS SRA OR as Qa SHEET 1 of 1 24 3384 fru z 24 3392 oo k k k 800304 J6 REV 2 tee Vi oe un roe wc SHEET TON 245309 tru 243404 cay EAS M eas um wc B00304 d7 pees x Q Am Yee She Qu Q INC CAS IB oes une et I SHEET Toti 24 3405 thru 800304 UB REV AA Be ar t ag a a 32 GHEET 1of1 24 8420 v x k k s x x k a B00383 Ji REV G We d r NE te d ur E HY AS SHEET1of1 24 3421 thru 24 3431 so 2 k k k k k 800383 J2 REV E ATIS uhr e e 22 URDU VACCA dee lac im lw lA xs SHEET bel 1 CAUTION These schematics address different serial numbered aircraft Make sure the applicable schematic is being used for the alrcraft being serviced 12 98 91 20 00 Page 7 AIRCRAFT CORPORATION M20J SERVICE AND MAINTENANCE MANUAL The Vendor and Part Number will be depicted where the applicable electrical equipment identifier is shown on the following hardware charts Order replacement or repair part numbers for electrical components from the following
470. k 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 12 98 61 20 30 PROPELLER GOVERNOR ADJUSTMENT 1 Fly aircraft an drecord max RPM at T O or cruise flight at full power NOTE No adjustment can be done before a test flight to obtain max governor RPM 2 Remove upper engie cow for access to governor 3 Loosen high RPM screw jam nut 4 Turn screw in CW or out CCW to match RPM recorded during governor test flight One 1 full turn of the screw equals approximately 25 RPM 5 Tighten jam nut an make propeller control linkage adjustments as necessary to maintain full travel 6 Re ig disconnectaed controls and reinstall cowling 7 Perform propeller and governor operational tests Fly aircraft and repeat governor test flight and record max RPM in flight at max power Repeat this process until the proper max RPM setting is achieved NOTE When installing governor insure the oil system is purged of all air by cycling the propeller seveal times before flight 61 20 30 5 SERVICE AND MAINTENANCE MANUAL 61 20 90 TROUBLE Leakage Between control shaft and head Between head and body Between relief valve plug and body Between body and base Between governor base and
471. kage 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 incorporated into this latching mechanism which allows the door to be opened in an emergency from the inside even if outside handle is locked CLIP PIN ASSY CR3213 4 2 RIVET PLC LANYARD CORIENTATION NOT CRITICAL M20J HITCH PIN MOONEY AIRCRAFT CORPORATION The outside handle has to be unlatched and fully opened to correctly re engage the latching mechanism after 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 April 1983 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 configuration of auxiliary exit handle inside latching mechanism See Figure 52 3 NOTE Follow the procedures in the Airplane Flight Manual Pilots Operating Handbook AFM POH for reengagement of the mechanism for proper outside handle operation HANDLE CR3213 4 3 RIVET AN960 4 WASHER 02 1 UNDER RIVET HEAD amp 1 ON BACK SIDE DF HANDLE MS20470 4 RIVET AUXILIARY EXIT LATCH RETROFIT C
472. l 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 pulling from pilot s side of instrument panel Replace by carefully pushing gauge in amp securing Screw MODULE TERMINAL STUDS TYP CONFIGURATION OF CLUSTER GAUGE WILL VARY BETWEEN MODEL YEAR AIRCRAFT LOOSEN La 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 z s GAUGE CONDITION Gauge reads full scale with engine shut down 39 11 01 Om CHECK FOR THESE POSSIBILITIES Wire between sender and gauge disconnected or open Fauity sender Faulty gauge 12 98 SERVICE AND MAINTANANCE MANUAL Gauge reads zero when engine is running M20J MOONEY AIRCRAFT CORPORATION Wire between sender and gauge grounded Faulty sender Faulty gauge ov EEE EE ne ed Br mm VEE OED re re er OE u n n rs sPs s s s s ss s s TEMPERATURE INSTRUMENTS Gauge re
473. l wiring and ignition harness for condition secure anchorage loose terminals and bumed or chaffed insulation P Inspect battery battery box and vent system for condition and corrosion Check blast tube for obstruction Flush battery box and battery case if necessary I Q Inspect accessory case vacuum pump hose firewall and fittings for security or damage R Check altemator and mounting bracket for security and drive belt for condition and proper tension Check starter installation for security Check starter drive and drive gear condition Lubricate drive if necessary S Inspect studs nuts bolts etc for damage amp proper torque T inspect Exhaust System for leaks or cracks amp proper clearance from other components Repair any discrepancies Replace or repair muffler if any intemal damage is found inspect for proper attachment U inspect and reinstall cowling Check cowl flaps for operation condition proper opening and cowl flap position indication 24 3000 thru 24 V Inspect landing light for security and condition 24 0001 thru 24 3153 2 PROPELLER INSPECTION A Remove spinner if not already removed B Check security of propeller instaliation C Check hub bolts for security and damage D Inspect hub parts and blades for cracks and nicks Repair prior to next flight 12 98 M20J MOONEY AIRCRAFT CORPORATION E Q tip blade inspection and repair The tip of the blade is formed at th
474. lace motor or brushes 32 32 00 12 08 MOONEY AIRGRAFT CORPORATION 32 40 00 WHEELS AND BRAKES 32 40 01 MAIN WHEELS The main wheels have standard brand 6 00 x 6 Six ply rated tires with standard tubes To remove main wheels from aircraft 1 Remove either IB or MID gear door 2 Detach dust shield Remove three screws and washers 3 Remove 2 bolts from brake caliper 4 Remove wheel by removing cotter key and nut from axle See Fig 32 13 5 Slide wheel off axle 32 40 02 MAIN WHEEL DISASSEMBLY ASSEMBLY 1 Remove snap ring 10 grease seal rings 8 and feit seals 9 See Fig 32 14 2 Remove bearings 7 3 Completely deflate tire WARNING Do not loosen wheel half retaining nuts before tire is completely deflated Failure to observe this warning may result in bodily injury 4 Remove nuts washers and wheel half retaining 6 5 separate halves 3 4 and remove tire and tube NOTE Bearing cups are shrink fitted do not remove them unless necessary for replacement 5 Clean all wheel parts thoroughly in cleaning fluid Federal Specification PS 661 Exercise special care in cleaning bearing cones and felt rings to insure thorough cleaning 6 Inspect al parts for cracks or evidence or 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 ta
475. lace spark plugs Drain and fill tanks with recommended grade of fuel Clean points and check timing Check with tester and replace defective wires Check and replace connectors if required P Tighten all connections and replace defective parts Clean nozzle or fuel screens Check throttle linkage travel Check strainers Check flow at fuel injector Examine air scoop and remove obstruction Check ignition system Replace or repair mount Clean nozzles or fuel screens Replace bushing Check compression Check propeller track and balance Fill sump with oil and inspect screen and filter for metal particles after running engine If particles are found overhaul engine Check and replace if necessary 71 00 90 9 MOONEY AIRCRAFT CORPORATION M20J TROUBLE High oil temperature Excessive blow by Excessive oil consumption PROBABLE CAUSE Air lock or dirt in relief valve Dirty oil strainers High oil temperature Defective pressure gauge Obstruction in oil pump intake passage Defective pressure transducer Insufficient oil supply Low grade of oil Stuck thermostatic vaive Clogged oil lines or strainers Oil cooler restriction Failing bearings Defective temperature gauge Low grade of oil Failing bearings Worn rings Improper piston ring installation Failure of rings to seat SERVICE AND MAINTENANCE MANUAL REMEDY Remove a
476. lates excessively in shaft Excessive friction in instrument Magneto timing too wide between mags Isolation resistors at mag sw PROBABLE CAUSE REMEDY Replace shaft Reset C B Check amp repair wiring Replace instrument Repair or replace shaft Replace instrument Retime magnetos Replace resistors increased in resistance value 12 98 77 00 00 SERVICE AND MAINTENANCE MANUAL TROUBLE con t Pointer Oscillates excessively con t M20J PROBABLE CAUSE Wiring connections bad MOONEY AIRCRAFT CORPORATION REMEDY Locate and repair um aum mum SUO r GNE un bn ms it AG BAER mn m Ve Ven m ee m 77 10 02 MANIFOLD PRESSURE Manifold pressure is an indication of engine power affected primarily by throttle setting The instrument is calibrated in inches of mercury Hg and indicates the 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 07 I MANIFOLD PRESSURE TROUBLE SHOOTING REMEDY Replace instrument Tighten line connection Adjust damping screw Replace glass and reseat case Replace
477. le 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 observe tachometer for an RPM change during leaning process Care must be exercised to 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 indicates an excessively rich mixture An immediate decrease in RPM if not preceded by a momentary increase indicates idle mixture is too lean E If above check indicates that mixture is too lean or too rich turn idle mixture adjustment in direction required for correction F Repeat step D to check new position G Make additional adjustments and checks as 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 M20J SERVICE AND MAINTENANCE MANUAL NOTE If above procedures do not resuit in stabilized idle speed check idle linkage for looseness 2 For operation in high ambient temperature conditions adjust idle and mixture as follows A Adjust idle to 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 control is Slowly pulled to idle cutoff C Maintain cooling airflow by keeping engine RPM as high as practical
478. les approximately 35 on center ali directions 3 Apply wet coat of epoxy resin to aluminum straps 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 pressure clamp application paragraph 5 181 FIBERGLASS CLOTH 025 T 3 ALUM SEE SECTION 51 15 03 2 LAMINATE 025 T 3 ALUM SEE SECTION 51 15 03 2 181 FIBERGLASS CLOTH OVERLAP 1 LAYER FIBERGLASS ALUM PLATES 727474 KZ a SURFACE FLUSH RIVET TYP FIBERGLASS BOND IN PLACE OVERLAP 1 LAYER FIBERGLASS ONLY IF THIS SM51 21 SIDE IS A NON FINISHED SURFACE COMMON STRUCTURAL LAMINATE REPAIR METAL INSERT FIGURE 51 21 51 15 02 20 12 98 SERVICE AND MAINTENANCE MANUAL 5 Place rigid aluminum plates on both sides of repair area and clamp into place with C clamps Permit laminated repair to cure 6 After the fiberglass repair has cured remove the clamps and install 3 AN426A rivets Flush head to be on the finished surface side The number of rivets and spacing will be determined by the size of the repair 7 Apply one additional overlapping layer of 181 fiberglass cloth on the non finished surface and bond in place Should the opposite side be a non finished surface an additional layer of fiberglass should be applied to this side 8 Upon com
479. letter of the pin at which the voltage supply is present to facilitate performance of the following test 30 64 00 HEAT TEST 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 required to 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 circuit breaker switch ON while the man outside feels the De lcer boots to see if they are heating properly The man in the pilot s compartment observes the ammeter for the proper readings 8 to 12 amps 24 0001 thru 24 2999 8 amps 24 3000 thru 24 TBA throughout the timing sequence The ammeter needle should deflect every 90 seconds in response to the switching action of the timer Each time this occurs the man in the pilot s compartment must notify the man inspecting the 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 irregularities are detected a continuity check should be performed on the wiring from the timer to the brush block holders and the propeller De Icer terminal connections CAUTION Stand clear of propeller verify magnetos OFF Use extreme caution during this test procedure 30 65 00 CONTINUITY TEST Aft
480. ll Dimples in 75S T6 must be hot formed when reworked 3 Combined Countersink and Dimpled Joint If the edge distance is a minimum of two times the diameter of the next standard size larger diameter rivet it will be permissible to rework the smaller 3 When a hole becomes enlarged beyond the acceptable diametric limit and the prescribed rivet cannot be used the next iarger diameter rivet may be used if a four diameter 4D rivet spacing is maintained and if b two diameter 2D edge distance is maintained 3 BLIND RIVET INSTALLATION Ordinarily where rivet bucking is impossible CherryLock CR 2248 and CR 2249 rivets may be substituted for AD rivets to repair skins and structural members However consult the Customer Support Department or a representative of the Federal Aviation Administration before using blind type or hollow rivets in primary structure CAUTION The use of blind rivets normally require more frequent inspection of the area where used Inspect for evidence of loosening of the rivet s or crack development that may cause deterioriation of structural integrity Solid rivet replacement of blind rivets is recommended at earliest possible maintenance Check existing rivet hole size before installing blind rivets When hole is marginal use the next larger size rivet to assure firm attachment 4 AN BOLT NUT AND WASHER INSTALLATION To compensate for material thickness tolerances the length of AN b
481. lled out in the Parts Catalog text pages following the illustration depicting the assembly or component in question u are made the system must be checked for eaks 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 material to be cut and used as replacements When the manufactured ends of flexible ducting are removed the raw edge must be taped with 3M aluminum foil tape 12 98 SERVICE AND MAINTENANCE MANUAL M20J MOONEY AIRCRAFT CORPORATION CHAPTER 52 DOORS AIRCRAFT CORPORATION M20J SERVICE AND MAINTENANCE MANUAL CHAPTER 52 DOORS LIST OF EFFECTIVE PAGES CHAPTER SECTION SUBJECT os v ov PAGE v 9 9 DATE 09 5 5 5 52 M BLANK 12 98 52 00 00 VOS 40 eus EM ELE 12 98 52 10 00 4 12 98 52 11 00 5 12 98 52 30 00 6 12 98 52 31 00 7 12 98 52 31 00 8 12 98 TABLE OF CONTENTS CHAPTER SECTION SUBJECT SUBJECT PAGE 52 00 00 Gener 3 52 10 00 Cabin Door Maintenance Practices 3 52 11 00 Cabin Door Rigging Adjustment Procedures 5 52 12 00 Cabin Door Seal 5 52 30 00 Baggage Compartment Door Maintenance Practices 5 92 91 00
482. lter is located at the rear end of the oil sump Oil pressure 60 PSI MIN 90 PSI MAX 25 PSI at IDLE 100 PSI MAX during engine warmup M20J SERVICE AND MAINTENANCE MANUAL 2 Oil Pressure Relief Valve The oil pressure relief valve maintains oil pressure within specified 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 Lycoming P N 73629 or 73630 under the cap decreases pressure The oil relief valve should be disassemblied inspected and cleaned when excessive fluctuations in oil pressure are noted 3 Oil Cooler Thermostatic Bypass Valve The oil cooler thermostatic bypass valve or vernatherm valve is not adjustable This valve allows oil to bypass the oil cooler when the cooler becomes obstructed or when oil ae congeals in the cooler due to low ambient 1 Filter Servicing temperatures A Oil Filter Removal and Installation 1 Remove old filter and replace with new filter after light film of oil has been spread on gasket Tighten to a torque of 18 20 ft Lbs 12 98 72 00 00 3 SERVICE AND MAINTENANCE MANUAL M20J MOONEY AIRCRAFT CORPORATION BLANK 72 50 00 12 98 4 MOONEY AIRCRAFT CORPORATION M20J SERVICE AND MAINTENANCE MANUAL CHAPTER 73 ENGINE FUEL SYSTEMS SERVICE AND MANUAL M20J MOONEY CORPORATION CHAPTER 73 ENGINE FUEL SYSTEMS LIST OF E
483. m on the engine Fuel quantity indicators are electrically operated with 2 transmitters located in each tank 1 inboard amp 1 outboard Fuel level indicator tabs at the A ullen level in each tank can be seen through the er ports HH ae 243 B PRESSURE INDICATOR QUmdogp VENT 1 1 EACH TANK DRAN VALVE 1 EACH TANK TSMJ28 1 M20J MOONEY AIRCRAFT CORPORATION to prevent binding while opening or closing the cap assembly This should also lubricate the o ring 4 that seals this shaft WARNING Water can enter the fuel tank through a loose fitting or damaged cap This should be corrected as soon as possible 3 The sealing capability of each cap assembly should be checked periodically and at each annual inspection This can be accomplished per the following procedures A Remove cap assembly from wing filler port and inspect o ring 1 for any damage or brittleness Remove and replace if needed B Adjust tension of shaft 2 and rotating lock plate 3 by removing cotter pin 5 from nut 6 on threaded ponon of shaft 2 Tighten nut 6 so cap assembly andie T can be opened turned and shut with hand pressure and still provide the necessary seal of cap assembly to keep water from entering fuel 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 Apply only one half pound 1
484. m 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 injection lines are tight and pressure checked V Oil filter is installed and secure W Induction manifolds are secure X All lines hoses and wires are properly anchored Y Induction air filter installed and secure Z Ram Air opening between cowling and air induction duct is aligned AA Heat shrouds and baff ng are installed and secure BB Engine area is free of loose objects tools etc 190 Cowling is instaled and secure See Section DD Cowl flap control rods are connected 71 00 40 ENGINE GROUND OPERATION CHECKOUT 1 Prestarting procedure with aircraft headed into wind A Turn ignition switch OFF B Check magneto ground connections C Check engine oil level D Check fuel quantity E Operate all controls through full range to check binding F Check baffles and cowling for 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 parking brake 2 Starting procedure A Set propeller governor control FULL FWD HIGH RPM B Turn fuel valve ON 12 98 M20J MOONEY AIRCRAFT COR
485. m valve contro linkage D Loosen set screw on fuel valve drain control E Remove bolis from supporting bracket at floorboard and beam F Reverse the selector valve removal procedure for reinstallation Pressure check fuel system for leaks after installation 2 For 24 0378 thru 24 TBA The fuel selector valve is located aft of the console below the floorboard A Drain both fuel tanks B Disconnect right 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 reinstallation Pressure check fuel system for leaks after installation 12 98 SERVICE AND MAINTENANCE MANUAL 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 Fuel filter should be inspected cleaned or replaced at each annual or 100 hour inspection See TroubleShooting Chart 28 30 00 DUMP The fuel tanks can be emptied for maintenance purposes by 1 removing the sump drains in the lower panel of each fuel tank and allowing fuel to drain into suitable container or E 2 disconnect the fuel line at outlet of the fuel ump use boost pump to transfer fuel from both tanks into a suitable storage
486. main gear Tie a 600 pound tensile strength rope to each wing tiedown ring and anchor to ground stake Allow a little slack in each tiedown rope 5 Tie the center of a rope to tail skid tiedown ring ds d rope ends to ground stakes at either side of tail 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 CHAPTER SECTION SUBJECT 11 Effect Contents 11 00 00 11 20 30 00 CHAPTER SECTION SUBJECT 11 00 00 11 10 00 11 20 30 00 CHAPTER 11 PLACARDS AND MARKINGS LIST OF EFFECTIVE PAGES PAGE 12BLANK 3 4 TABLE OF CONTENTS SUBJECT General Markings Placards Exterior Interior 12 98 MOONEY AIRCRAFT CORPORATION DATE 12 98 12 98 12 98 PAGE C2 11 EFF CONTENTS 1 2BLANK MOONEY AIRCRAFT CORPORATION 11 00 00 GENERAL FAA required placards and markings NOTE All placards should be inspected for proper location readability and security during maintenance actions When an airplane has been painted inspect all placards to assure that they are not obscured by paint SERVICE AND MAINTENANCE MANUAL 11 10 00 MARKINGS The exterior paint schemes for the various model yea
487. 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 6 also attaches to the tension strap fitting 2 on the main spar The brass bearing 7 should be inspected at any scheduled maintenance action for wear Grease fittings 8 are installed at pivot points of the main landing gear assembly for lubrication per Section 5 Reference Figure 53 7 53 40 04 ENGINE MOUNT ATTACH POINTS The engine mount is attached to hard points built into the forward portion of the tubular structure The upper hard poinis 1 Figure 53 8 are for NAS1304 bolts installed for tension loads The lower hard points 2 are for fittings outside the firewall which allow a clevis on each side of the engine mount TAILCONE EMPENNAGE ATTACH POINTS ior shear loads AN4 bolts are used for FIGURE 53 6 SMX53 7 MAIN LANDING GEAR ASSEMBLY ATTACH POINTS FIGURE 53 7 ENGINE MOUNT ATTACH POINT FIGURE 53 8 53 40 03 12 98 8 SERVICE AND MAINTENANCE MANUAL M20J MOONEY AIRCRAFT CORPORATION CHAPTER 55 STABILIZERS MOONEY AIRGRAFT CORPORATION CHAPTER SECTION SUBJECT 55 Eff Contents 55 00 00 55 20 00 55 30 01 55 40 02 CHAPTER SECTION SUBJECT 55 00 00 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 M20J SERV
488. manually extend the gear 12 98 M20J SERVICE AND MAINTENANCE MANUAL 1 Pull landing gear circuit breaker 2 Move landing gear control switch to DOWN position 3 Push crank engage handle forward to engage drive mechanism 4 Crank handle clockwise to lower gear The gear is down and locked when green down gear indicator light is on and when the lines on the visual gear position indicator on the floorboard are aligned CAUTION DO NOT retract gear manually 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 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 light indications Make certain that no bungee springs are compressed to a solid height and that nose gear tire clears top of wheel well a minimum of 25 in when landing gear 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 32 31 06 32 31 05 SERVICE AND MAINTENA
489. mendations when the preceding instructions are inadequate to accomplish the repair 51 00 00 5 MOONEY AIRCRAFT CORPORATION To compensate for material thickness tolerances Huckbolt length may be increased by one dash number from the prescribed length When a Huckbolt pin 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 combination of not more than two washers 065 inch and 032 inch thick under the Huckbolt collar 2 RIVET REMOVAL AND REPLACEMENT HUCKBOLT P N NAS1465 or R3001 T5 NAS1466 or R3001 T6 NAS1475 or R3014 T5 NAS1476 or R3014 T6 PART NUMBER CODE M20J SUBSTITUTE P N VENDOR HL20 5 PIN HI LOCK HL86 5 COLLAR HL20 6 PIN HI LOCK HL86 8 COLLAR HL19 5 PIN HI LOCK HL94 5 COLLAR HL19 6 PIN HI LOCK HL94 6 COLLAR SERVICE AND MAINTENANCE MANUAL The combined thickness of any two washers shall not exceed 098 inch Huckbolts or conical Keystone Lock blind rivet heads may be cocked no more than 004 inch Not more than 20 percent of the fasteners in any pat tern nor more than three fasteners in succession may be cocked NOTE Where access is limited or for replacement repair the following substitution is permissible DESCRIPTION PIN PROTRUDING TENSION 160 KSI Ftu PIN PROTRUDING TENSION 160 KSI Ftu PIN 100 D FLUSH SHEAR 95 KSI Fsu E 00 D FLUSH SHEAR
490. minals are Spec MS25036 or equivalent or they must be soldered Ali terminals must be preinsulated or must be insulated with Ampsulation or equivalent Wires without dash numbers are furnished by the manufacturer and are included with the equipment The symbol indicates a knife disconnect Optional equipment may be installed as required t oe denoted by symbols to be twisted counter clockwise with a minimum of three 3 wraps per oot 10 F denotes ground through frame no wires 11 All knife disconnect splices to be insulated with PVC 105 and securely string tied with airtex no 417 cord 12 All wire sizes are minimum sizes acceptable 13 Use 913127 bus bars as necessary for various configuration changes and manufacture interconnecting bus using no 2170 tubular braid covered with PVC105 5 16 both Alpha Wire Co and terminated with AMP terminals of appropriate sizes current revision of AC 43 13 1 on IN 35108 Terminal PVC 105 5 16 327218 Ampsula tion 301098 Terminal EXAMPLE FIGURE 91 1 12 98 91 00 00 Page 3 MOONEY AIRCRAFT CORPORATION 91 00 02 identification M20J WIRING IDENTIFICATION SYSTEM SERVICE AND MAINTENANCE MANUAL The Mooney Aircraft Corporation wiring electrical system originally depicted a typical electrical component r JK DJ102A22 number as 21 PA03A18 or JK 7 or 9 character number is cornposed of four functional
491. minates at near full brilliance When the Nav Lights are on however CH1RET is also 28 VDC and CR9 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 CR 184005 INPOS CRB 5 LMPPOS1 CR9 LHABE5 POSARET 2Z8UDC J 252 CR160 LNAGGS LMPPOSZ CR 11 FIGURE 3 LANDING GEAR INDICATORS 12 98 M20J MOONEY AIRCRAFT CORPORATION brilliance The GEAR UNSAFE channel accepts 28 VDC INPOS2 through isolation diode illuminates at full brilliance and does not dim A test signal TEST is applied to both GEAR DOWN and GEAR UNSAFE through CR8 and CR11 respectively 5 0 LEFT AND RIGHT LOW FUEL The Left and Right Low Fuel circuits are shown in Figure 4 The left and the right channels are similar and only the left channel will be discussed herein Signals from the junction of the left and right fuel transducers and the left and right fuel quantity gauges are applied respectively to each of the inputs INPOS3 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 e
492. mplexity of ihe 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 Distribution System would refer to the pages identified as 28 20 00 in any maintenance oriented publication These pages will be numbered sequentially within each system breakdown in the current Mooney series of aircraft As Mooney aircraft models become more complex the page numbers may be sequentially numbered within sub systems The table of contents in the front of each Chapter will provide a list of sub systems covered in the Chapter For example 28 00 General 28 10 Storage Tanks vents repair etc 28 20 Distribution Boost pumps fuel lines etc 28 40 Indicating 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 expanded to 28 40 01 Left Hand and 28 40 02 Right Hand This concept will apply to any expanded information throughout the publications 12 98 INTRODUCTION Page 1 SERVICE AND MAINTENANCE MANUAL M20J MOONEY AIRCRAFT CORPORATION SUPPLEMENTARY PUBLICATIONS The following list of Manufacturers and or publications can pro
493. n 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 32 4 so that tubes can be slipped in place with zero preload Reattach ends of retraction tubes at the bellcrank and slip bolts in place 6 Disconnect electrical power from landing gear actuator by pulling circuit breaker Make sure landing gear warning light circuit breaker is pushed in 7 With bellerank retraction tubes and the gear positioned as indicated in step 5 set down limit switch striker arm J Fig 32 5 so that gear down light switch is just closed and green gear down light is on Secure striker arm in position 8 Use manual crank to partially retract gear Screw rod end E Fig 32 5 on aft end of each main gear retracting tube out two full turns then slip attaching bolts back in place 9 Manually extend gear stop extension just as green gear down light comes 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 Partially retract gear with manual crank screw in each nose gear retraction tube rod end one full turn then slip attaching bolts back in place 12 Check length of nose gear bungee spr
494. n by 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 12 VDC integrated circuit regulator Output filtering is provided by C2 The Test Switch S1 switches unfiliered 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 OUTTEST 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 1o 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 Q2 is off giving DIMBIAS a vaiue 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 0 VDC in the event that both switches are depressed simultaneously the 0 VDC value of DIMBIAS w
495. nch thick storm window The storm window is milled to fit the hole and to be flush with outside of pilots window surface 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 cabin door window The inner pane is a 060 inch thick acrylic fitted to clips and brackets on the door frame All the windows are heated in an auto clave to approximately 300 degrees F and placed on a plaster mold to cool while maintaining the correct shape The windows are tinted green or gray for visual ultra violet filteration and cooling effect for the cabin The windows are all sealed to the outside skin with PR1403 G B2 or equivalent sealant Retainers and SER are used on the frame to hold the windows in place 56 00 01 CLEANING ACRYLIC A commercial cleaning solution manufactured for acrylic may be used to clean routine grit and grime from the windows Follow the instructions on the commercial cleaner used If no commercial cleaner is available these procedures should be followed 1 Flush windows with water prior to wiping with a clean soft cloth soaked in kerosene CAUTION Never wipe windows when dry 2 Flush with water after cleaning with kerosene CAUTION Never use gasoline benezene carbon tetrachloride acetone lacquer thinner deicer fluid house hold cleaning fl
496. nd clean oil relief valve Remove and clean strainers See High Oil Temperature in Trouble column below Replace gauge Check for obstruction Replace transducer Do not over torque fittings Fill sump with oil of recommended grade and inspect engine for metal particles in screen and filter after running engine If particles found overhaul engine Drain and fill sump with oil conforming to specifications Check and replace as necessary Clean oil lines and strainers Check compression Check for worn or stuck rings Check and replace Check oil strainers for metal particles if found remove foreign material and overhaul engine Replace gauge Drain and fill sump with oil conforming to specifications Check sump for metal particles Install new rings Install new rings Use mineral base oil Climb to cruise altitude at full power operate at 75 percent power or higher until oil consumplion stabilizes 71 10 00 ENGINE COWLING The engine cowling is in two sections The lower cowl 71 11 00 71 11 01 COWLING REMOVAL TOP COWLING S N 24 0001 thru 24 3153 contains the ram air inlet landing light and cowl flaps S N 24 3154 thru 24 TBA contain only the cowl flaps Quick disconnect fasteners attach the cowling panels The oil filler access door is in the top cowling section 71 10 01 ENGINE COWLING CLEANING INSPECTION amp REPAIR Clean cowl by spraying with solvent PS 661 or
497. nd gauge as the skin to be repaired b drill and countersink 100 degree fastener holes in the doubler to match dimpled fastener holes in skin and c install doubler around inspection hole Use AN426 AD4 rivets when material is 040 inch thick or greater Drill holes using a No 30 128 IN drill as shown in the above illustration Use AN426 AD3 rivets when material is 032 inch thick or less Drill holes using No 40 098 IN drill ACCESS COVER FIGURE 51 11 12 98 51 13 04 15 MOONEY AIRCRAFT CORPORATION DIMPLE CRACKS REPAIR FIGURE 51 12 2 Repair of Cracks Wholly Within Dimple Radius Surface cracks on inside bearing face of a dimple that do not extend through the material can be repaired by sanding out the crack Cracks in dimples which 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 rivets the same size as those in the original pattern to each side of the cracked dimple Maintain four diameter 4D spacing and two diameter 2D edge distances When original rivet pattern has rivets on only one or two sides of a dimple only one or two rivets need be added see Figure 51 12 6 FASTENERS SAME SIZE AS ORIGINAL FASTENER WITH CRACKED DIMPLE se EA RCE er 5 A OENE Do EA EE OE DOUBLER SAME GAUGE AS SKIN SCARF EDGES TO APPROX 010 IN DEEP AND 25 IN WIDE ROUND CORNERS 5 51
498. nd the lateral muffler 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 been torqued H Attach tailpipe to exhaust pipe ball joint flange 3 bolts springs nuts at ball joint flange with existing or new hardware I Orientate tailpipe and muffler exhaust pipe so the continuing plane 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 12 98 M20J SERVICE AND MAINTENANCE MANUAL J Tighten bolts nuts on ball joint flange Spring will begin to compress prior to castellation on nuts reaching cotter pin hole in bolt Continue tightening until any one of ihe nut castellations reach the complete hole bolt Install cotter pins in all bolts amp nuts K Hang tailpipe with hanger assembly attached to firewall or exhaust cavity supports L Verify all hardware is secure on header pipes muffler and tailpipe 3 EGT PROBE INSTALLATION SECURITY A EGT probe clamp assembiy 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 properly inspect exhaust system components must be clean and free of oil grease etc Clean as follows A Spray en
499. ndicator 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 transducer which varies resistance with pressure 6 Fuel Flow if installed is indicated on either an electrical instrument using a pressure transducer which varies resistance with pressure or with an electrical instrument which counts electrical pulses produced by a turbine flow transducer 12 98 SERVICE AND MAINTENANCE MANUAL 24 35 00 LIGHTING CIRCUITS 1 Navigation Lights A circuit breaker switch on the flight panel controls navigation lights GEAR DN GREEN annunciator light is dimmed when navigation lights ore ON 2 Landing Light circuit breaker switch on flight panel controls landing light in the lower engine nacelle on S N 24 0001 thru 24 3153 Landing Taxi Lights S N 24 3154 thru 24 TBA uses a split switch on Flight panel to control wing mounted lights 3 Cabin Lights A three position Bright Off Dim rocker switch adjacent to door in headliner controls cabin lights CAUTION On S N 24 0001 thru 24 3153 this light switch is connected directly to battery The switch MUST BE TURNED to keep from discharging battery Aircraft 24 3154 thru 24 3200 may have door switch timer mechanism that illuminate forward set of interior lights while cabin door is open After door is closed i
500. nections by pressurizing the fuel lines with boost pump Correct any leaks or discrepancies G Wrap firesleeving over transducer and secure into position with safety wire NOTE installation of the new transducer may affect the engine fuel flow adjustment It is recommended that the procedures of Section T1 00 00 be followed to assure engine is set up for proper operation H When all adjustrhents have been made and all connections checked for security install the cowling per Section 71 12 00 12 98 73 31 03 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 flashing is a reminder for 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 io Figure 73 5 After starting the aircraft engine the FT 101 will continuously display fuel flow Total Fuel Used may be displayed by pressing and holding the USED TEST button on the right of the instrument Total Fuel Used will be displayed as long as the USED TEST button is depressed or for 2 seconds whichever comes first This number may be reset to zero 0 0 by depressing and holding the RESET button for at least 1
501. nent set and proper length 3 670 in min 4 05 in max 13 Replace all faulty parts and all O rings 14 Reassemble in reverse sequence of disassembly immerse all parts in hydraulic brake fluid prior to reassembly F Reinstall master cylinder in reverse sequence of removal G Bleed brake system refer Section 12 20 05 NOTE SIN 24 3201 24 3218 thru 24 TBA 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 M20J MOONEY AIRCRAFT CORPORATION 24 0001 thru 24 3200 52413202 thru 24 3217 24 3201 24 3218 thru 24 TBA SMX32 19A BRAKE MASTER CYLINDERS FIGURE 32 17A 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 1 Unscrew and remove rod end clevis 17 nut 16 and washers 14 amp 15 from piston rod 12 2 Remove snap ring 11 from cyhlinder housing assembly lift out complete piston rod assembly items 2 thru 12 Spring 13 can be removed at this time 3 Remove snap ring 2 from end of piston rod assembly 4 Remove bushing 3 and spring 4 from
502. ng longerons Consult AC 43 13 1 figures 2 28 2 29 and 2 30 for fastener requirements 2 TAILCONE STRUCTURAL SKIN REPAIR Repair minor tailcone skin damage as shown in current AC M20J SERVICE AND MAINTENANCE MANUAL 43 13 1 Figure 2 24 The rivet pattern for stressed skin repairs 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 original skin installation 3 NON STRUCTURAL SKIN REPAIR The skin covering the M20J aircraft tubular fuselage structure is considered nonstruciural Patches in nonstructural skin are not restricted as to size or shape however appearance and possible vibration damage should be considered Either a flush patch a plate patch or a plug patch may be used 51 12 03 LANDING GEAR amp RETRACTION SYSTEM REPAIR Replace any damaged landing gear or retraction system component with a new part Repairing landing gear or retraction system components is not recommended After installing new components check gear and retraction system rigging as outlined in Section 32 20 02 Before retuming the aircraft to service perform a retraction test and operational check a gear and retraction system per Section lt LONGERON SPLICING FIGURE 51 5 51 12 02 10 12 98 SERVICE AND MAINTENANCE MANUAL 51 12 04 FLIGHT C
503. nsions 1 Height 2 Width 3 Length 4 Cabin Door Width 5 Cabin Door Height WINGS NAC632215 NAC641412 59 18 inches 13 4 to 28 7 1 5 Degree Degree Degree 2 5 5 5 7 338 1 935 FUSELAGE 44 5 43 5 114 29 35 15 68 Ib sq ft S N 24 1038 thru 24 3200 24 3202 thru 24 3217 6 00 00 4 12 98 S N 24 3201 24 3218 thru 24 TBA amp 24 1686 thru 24 3200 24 3202 thru 24 3217 when CAN SL91 2 and MAC drawing 940071 is incorporated 113 03 cm 110 49 cm 289 56 cm 73 66 cm 88 9 cm MOONEY AIRCRAFT CORPORATION WIS amp 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 me 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 DIMENSIONS A Wing Span B Fuselage Length C Tail Height AIRCRAFT DIMENSIONS D Stabilizer Span AREAS A Wing B Ailerons C Flaps D Vertical Fin E Rudder F Horizontal Stabilizer G Elevators Prior to S N 24 1038 35 0 M20J STANDARD 120 Ibs 17 0 Cu 24 0001 thru 24 3153 15 3 Cu Ft 24 31 54 thru 24 TBA 17 20 5 10 Ibs Tricycle Retractable Electrical 2 5 11 9 16 5 00 x 5 6 00 x6 Nose 49 Ibs sq in Main 30 Ibs sq in 36 1 uw 4 24 8 8
504. nt grime 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 priming and painting b On steel Remove ail grease grime loose paint etc by wiping with wipe solvent and rags Do not allow the wipe solvent to evaporate Wipe it dry Steel parts may be cleaned to bare metal by sanding with emery cloth or steel wool If the parts are removable they can be cleaned by sandblasting Regardless of the scouring method all parts should be wiped with a tack rag and cleaned with fresh wipe Solvent The part should now be ready for priming and painting C Priming and Painting 1 On aluminum Cleaned and dried surfaces to be painted shouki be coated with a wash primer conforming to MIL C 8514 or MIL P 15328 Read and follow the manufacturer s instructions carefully The wash primer should be applied to attain a dry film thickness of 0 3 to 0 4 mils a transparent film 20 00 03 SERVICE AND MAINTENANCE MANUAL A good wash primer coating is a must since the top coating can be only as good as the primer 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 intermediate primer coat When an intermediate epoxy primer coat is applied it should be mixed very carefully per the manufacturer s instructions It should be thinned per manufacturer s instructi
505. nto lens E Connect the knife connections and ty rap securely being 12 98 M20J SERVICE AND MAINTENANCE MANUAL TRIM FLAP INDICATOR LIGHT FIGURE 33 2 SIN 24 0084 24 0378 thru 24 1168 F Check for proper operation A Unscrew the black knurled button 1 Figure 33 3 to gain access to the bulb B Bulb is a friction fit type in button remove and replace with new bulb Replace knurled button with new bulb installed into console D Check for proper operation TRIM FLAP INDICATOR LIGHT FIGURE 33 3 24 1169 thru 24 TBA 33 22 01 7 SERVICE AND MAINTENANCE MANUAL 33 23 00 GEAR DOWN INDICATOR LIGHT FLOORBOARD 33 23 01 LIGHT BULB REPLACEMENT 1 Remove lower belly panel to gain access to light assembly _ M20J MOONEY AIRCRAFT CORPORATION 2 Remove and replace bulb 3 Check for proper operation 4 Reinstall belly panel 33 40 00 EXTERIOR LIGHTS MAINTENANCE PRACTICES 33 40 01 TROUBLE SHOOTING EXTERIOR LIGHTS TROUBLE PROBABLE CAUSE REMEDY STROBE LIGHTS Lights inoperative Circuit breaker switch Check for short circuit Reset circuit tripped breaker Loose connection Check and tighten electrical connections Battery defective Circuit breaker switch defective Faulty power supply One bulb does not light Bulb burned out Power supply inoperative Fixture not grounded Loose connection Defective fixture Replace battery or use external power
506. nts Control Column Bearing Ball Y 100 Rod End Bearings yY 100 Universal Joints 100 Bellcranks gt 100 2 Engine Cowling 100 i Vacuum Pump 500 Alternate Air Door Seals 50 3 Nose Gear Grease Fittings 100 12 02 0 Retraction Tube Rod End y 100 Bellcranks gt 100 Bungees Vo 100 Gear Door Rod End Bearings y 50 4 Main Gear Grease Fittings 100 Retraction Tube Rod End Bearings WY 100 Bellcranks gt 100 Bungees 100 Gear Door Rod End Bearings 50 Electric Gear Actuator Gear Box e o ARIAR Electric Gear Actuator Ball Screw S uM site dt WV xD tA 100 Electric Gear Actuator No back Spring 1000 5 Elevator amp Rudder Controls A C Control Tube Rod End BRANDS y 100 Belleranks gt 100 Battery Battery Relay 100 Stabilizer Trim Control Shaft Universal Joints 100 Guide Blocks 100 Hydraulic Reservoir B 50 Oxygen High Pressure Fittings e 50 ELT Transmitter 14 Volt e 100 6 Elevator amp Rudder Controls v lC eO e Control Tube Rod End Bearings w 100 Belleranks X 100 Stabilizer Trim Jack Screw Actuator q 100 Tail Strobe Light Power Supply 100 See last page of section for lubrication symbol legends Change spe filter on vacuum regulator every 100 hours Change instrument filters at 500 hours clean every
507. o Chapter 5 are considered adequate to meet average requirements under normal operating conditions It is advisable however to shorten service and maintenance intervals when operating under abnormal environmental conditions such as extreme temperature ranges dusty atmospheric conditions high humidity and moisture unimproved airport facilities or unusual operating requirements 12 10 00 REPLENISHING 12 10 01 FUEL TANKS Keep fuel tanks at least half filed to minimize condensation and moisture accumulation in tanks Fuel capacity is given in SECTION 6 WARNING Ground the aircraft and fuel service vehicle Ground servicing nozzle to wing Permit no smoking or open flame within 50 feet of aircraft or vehicle 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 FUEL DRAINS A fuel drain valve is located in the aft inboard corner of each tank to provide for drainage of moisture and sediment Use the small plastic cup furnished with the flyaway kit to drain the fuel sumps Drain wing tank and selector valve sumps or gascolator before the first flight of the day and after each fuel service to inspect for water and or contamination Continue draining until free of water or contamination WARNING After servicing the aircraft with fuel wait at least five minutes for moisture and sediment to s
508. o ground or between adjacent timer circuits in brush block Short to propeller or short between two adjacent circuits slip rings to De Icers Timer faulty Timer ground open timer not cycling Timer contacts welded together caused by short in electrical systern Loose connection between el power supply and timer nput 12 98 MOONEY AIRCRAFT CORPORATION REMEDY Perform a heat test on each De Icer Turn De Icer switch ON and after locating the De icer section being heated follow the heating cycle feeling each section for heating in turn Replace defective components Check power leads from ammeter to timer and then to De Icers for evidence of damage or arcing With de icing System switch OFF and timer harness disconnected check insulation resistance use Megger to ground from timer harness Pin B 12V Terminal Disconnect hamess at brush assembly and repeat check for applicable brush assembly harness connections See wiring schematic Section 30 60 01 If ground is indicated locate and correct it Test ammeter per Section 30 62 00 Disconnect leads at brush assembly and timer With Megger check insulation resistance from power leads to ground and between adjacent circuits If ground or short is indicated locate and correct Electrically isolate brush assembly and test per Section 4 6 B F Goodrich Report No 68 04 712B isolate brush assembly With Megger check insula
509. olts may be increased or decreased by one dash number from prescribed length AN960 regular washers and ANS60L thin washers may be used interchangeably for proper bolt and nut installation One regular washer or one thin washer may be added to any installation Washers may be used under the bolt head and or under the nut AN365 and AN363 nuts may be used interchangeably The AN363 nut is acceptable for higher operating temperature installations 5 HFSHEAR RIVET INSTALLATION When a hi shear rivet pin of the prescribed length is not 12 98 M20J countersink or dimple to a size to match the oversize on assembly RIVET SIZE NOMINAL DRILL SIZE AX ACCEPTABLE DIAMETRIC DIMENSION AN470AD3 or AN426AD3 40 098 dia 108 IN AN470AD4 or ANA26AD4 30 1285 dia 141 IN MOONEY AIRCRAFT CORPORATION dimple or countersink and install the next standard size larger rivet according to paragraph 2 A 4 Dimples in 75S T6 must be hot formed when reworked C RIVET HEAD TOLERANCE 1 A rivet head will be considered open if 001 feeler gauge can be inserted between the head of the flush or protruding head rivet and the top skin The top of a flush head rivet must not be below the skin in which it is installed by a dimension of more than 004 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 drill diameter normally used plus t
510. on latch operation and Security of attachment C Inspect for loose equipment that might restrict control movement D Inspect Oxygen System if installed per Chapter 35 lights for security See Section 12 98 SERVICE AND MAINTENANCE MANUAL 7 INTERNAL INSPECTION Open access panels and inspection doors and remove fairings as required B Inspect wing fuselage attaching bolts for proper torque and safetying and evidence of damage or corrosion C Inspect forward side of firewall for damage D inspect tubular structure for corrosion or damage interior panels and insulation may require removal E Check wires lines and ducts for security damage interference chaffing and bonding F Inspect wing ribs and stringers for cracks and evidence of damage or corrosion G Inspect wing spars for damage distortion cracks or corrosion H Inspect wing interior for foreign material corrosion and evidence of fuel leakage Inspect Baggage Compartment floorboard assembly stringers and doublers J Inspect empennage attachment brackets and hardware for corrosion NOTE Seal all receptacles and plugs outside cabin environment with Dow Corning 4 8 FLIGHT CONTROL INSPECTION A Inspect control column and control wheels for full travel proper rigging free play binding security of mounting proper lubrication and direction of control Surface movement with relation to control movement CAUTI
511. on 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 Conduct operational and leak check on propeller installation prior to flight 61 10 00 PROPELLER ASSEMBLY No extemal lubrication is required on M20J propellers Preflight inspection should be accomplished prior to each flight to determine if blades have been damaged if any abnormal loosness is evident between hub and blades or if there is any evidence of oil leakage 61 10 10 MINOR PROPELLER BLADE REPAIR 1 Minor nicks dents and gouges may be dressed out by approved personnel Blend any nicks or gouges into the leading edge with smooth curves or generous radii as shown in Figure 61 2 Repaint area to reduce corrosive action 61 20 00 PROPELLER CONTROLLING 61 20 10 GOVERNOR INSTALLATION 1 Clean mounting pad and bottom of governor 2 Coat new gasket w DOW Corning 7 compound release agent or equivalent before installation 3 Install new gasket on mounting studs insure gasket has raised surface of the gasket screen toward the governor 4 Position govemor on mounting studs aligning the governor splines and ihe splines of the accessory drive 5 Install all mounting hardware Torgue nuts 6 Connect governor control to governor and rig NOTE All rigging to match govemor arm loction Do not adjust govmor high RPM stop to match the rigging 61 20 20 PROPELLER GOV
512. onal 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 TROUBLE Excessive drift in either direction DIRECTIONAL GYRO TROUBLE SHOOTING PROBABLE CAUSE Dirty air filter high vacuum indication Excessive vibration Insufficient vacuum REMEDY Inspect filter Replace if necessary Test with vibrometer If vibration amplitude is more than 004 inch examine shock mountings to see if connections are restricting instrument If vacuum indication is below 4 25 IN Hg check as follows Instrument is sluggish Dial spins continuously in one direction Defective mechanism 1 Vacuum regulating valve improperly adjusted 2 Pump failure 3 Vacuum line kinked leaking or too long for its diameter Defective mechanism worn or dirty pivots and bearings Operating limits have been exceeded 12 98 1 Adjust vacuum regulating valve 2 Repair or replace pump 3 Locate and if deffective replace or repair vacuum line Check for collasped inner wall of fiexible hose Replace instrument Reset the instrument with the aircraft in level flight Replace instrument 34 20 00 MOONEY AIRCRAFT CORPORATION M20J SERVICE AND MAINTENANCE MANUAL 34 21 00 TURN COORDINATOR gyro
513. oning prior 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 TROUBLESHOOTING FT 101 FUEL MANAGEMENT SYSTEMS Troubleshooting the FT 101 fuel management system should be approached in a systematic manner All problems can be put in one of five categories Improper operation due to lack of knowledge about the system Inoperative computer or main instrument Inoperative transducer Improper wiring Improper transducer installation 1 MEMORY LOSS A Loses memory when MASTER switch is turned OFF 1 Check Fuel Flow Memory switch ON 2 If switch is ON check clock for operation 3 If clock inoperative replace fuse 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 Exchange FT 101 for modified unit 2 DOES NOT INDICATE A No display 1 Remove connector from indicator Check Pin 1 of harness connector for bus voltage Check Pin 8 for airframe ground If OK change indicator B Displays zeros with engine running 1 Remove cowling for access to transducer Remove insulating sleeving from connections on all 73 31 04 8 M20J MOONEY AIRCRAFT CORPORATION wires Check BLACK wire for A F ground Check RED wire for bus voltage Check WHITE wire for 2 3
514. ons 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 1o 1 5 hours depending upon the application temperature and relative humidity Follow manufacturer s instructions The intermediate primer coat can be dry scuffed lightly with No 400 to No 600 sandpaper prior to top coat application and give a higher gloss finish As many coats of paint as desired may be applied A higher gloss will be attained 20 00 03 8 if the surface is scuffed lightly and tack rage cleaned between each coat 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 stee coat If epoxy primer is used it should have a wash primer MIL C 8514 pre treatment M20J MOONEY AIRCRAFT CORPORATION 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 exterior finish touch up paint for brush on application NOTE M20J aircraft are painted with Enflex III urethane enamel Inquiries concerning application of th
515. oor seal is an extruded rubber seal filled with a soft foam Unless deformed or torn the seal will provide adequate sealing around the periphery of the door during flight conditions 1 Cabin door seal replacement 12 98 M20J MOONEY AIRCRAFT CORPORATION A The seal is held to inner door frame with adhesive B Remove the door inner trim panel to gain access to the door seal C Pull the seal from the door frame D Clean the area with lacquer thinner to help soften the remaining adhesive Remove excess adhesive CAUTION Care should be exercised to keep the lacquer thinner from dripping on the wing or any other portion of the airplane E Coat cleaned door frame with adhesive St Clair 4587 F Coat bond area of new seal with adhesive St Clair 4587 G Let both applications dry until tacky H Carefully place end of seal into position at bottom of door and continue around the door until the seal is firmly attached Do not pull tight around corners Cut off any excess seal I When seal is properly attached the door should close with little effort NOTE Door contour can be altered slightly to conform with cabin contour if needed for proper fit and sealing 52 30 00 BAGGAGE COMPARTMENT DOOR MAINTENANCE PRACTICES 1 Removal The baggage compartment door may be removed to replace or repair the door or to replace a damaged hinge A Remove the coat hanger and headliner panel located inside
516. oost pump for more than a few seconds to prevent excessive flooding of the engine NOTE When the aircraft will not be flown for a period of time refer to Section 10 10 01 thru 10 10 03 28 22 00 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 original installation To clean fuel selector screen 8 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 S N 24 0378 amp 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 process 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 M20J SERVICE AND MAINTENANCE MANUAL 28 23 00 FUEL INJECTION SYSTEM The Bendix RSA 5AD1 fuel injection system measures airflow and uses an airflo
517. or gear unsafe no lights illuminate when gear is up See Section 32 for squat switch information 2 Gear Safety By Pass Switch Gear will not retract if airspeed above set limit has not been attained when gear handle is placed in UP position Warning horn will sound and both GEAR DOWN and GEAR UNSFE lights will illuminate PUSH and HOLD red button switch beside landing gear handle until gear is UP and both lighis go out Pull circuit breaker GEAR CONT or GEAR RELAY to stop warning horn Reset circuit breaker prior to extending gear 24 37 00 FUEL SYSTEM CIRCUITS The fuel system has an electric auxiliary fuel pump The fuel quantity indicating system is comprised of two transmitters in each fuel tank and two fuel quantity gauges on instrument panel 1 Fuel Pump Circuits A single auxiliary fuel pump is controlled by a switch located on the instrument panel 2 Fuel Quantity Gauge 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 MISCELLANEOUS CIRCUITS 1 Tum Coordinator Circuit The turn coordinator is a flight instrument which operates from an electrical power source 2 Heated Pitot Tube A circuit breaker switch controls the pitot tube heater 24 35 00 MOONEY AIRCRAFT CORPORATION M20J SERVICE AND MAINTENANCE MANUAL 3 Hour Meter Op
518. osion damage loose or popped rivets 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 rivets free play dents scratches cracks condition and lubrication of hinge points attachment of balance weights and freedom of operation F Inspect cabin door and door frames for damage corrosion nicks dents hinge security and lubrication G 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 condition of cargo tiedowns I Inspect ventilating system drain line for obstruction J Inspect the alignment and iubrication of overhead vent push pull cable for smooth operation S N 24 0001 thru 24 0377 K Inspect Landing Taxi condition and proper adjustment 33 43 00 for adjustment procedures 6 INTERIOR INSPECTION A Inspect seats seat tracks and upholstery for cleanliness and mounting security check seats for condition and operation of position locks inspect seat Structure for cracks deformation corrosion and mechanism iubrication B Inspect safety beits harnesses and attaching brackets for cleanliness conditi
519. ot a replaceable component I Place bulkhead grommets at relative positions on new harness after plug 2 is removed from new harness J Tie and tape cord to new harness 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 S N 24 1418 and LATER aircraft have a new Style strobe light installation There is sufficient wire available when ty raps are cut from coiled hamess 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 harness 1 and ty rap harness coils 33 42 00 NAVIGATION POSITION LIGHTS 33 42 01 POSITION LIGHT REPLACEMENT SERVICE 1 WING TIP POSITION LIGHTS S N 20 1038 THRU 24 TBA A Remove the wing tip lens 1 Figure 33 5 B Remove the two screws 2 hoiding the position light lens in place C Pull the lens red or green from mounting plate 8 and remove the lamp 8 D Install new lamp into base E Reassemble the light assembly in reverse sequence 2 TAIL POSITION LIGHT 24 0001 thru 24 2999
520. ou 0 12 98 Sede Us 2 de uo DER SEDE Uo Xe d 12 98 32 40 04 un woe 23 0 12 98 EG VEA UR ode ee 12 02 0 12 98 324004 or Bp MEME 0 12 98 32 44 01 ee u ge 26 ue UR 22 2 12 98 929002 2025 2205 ou 0 12 98 S D Ge sm PE ME 202 02 12 98 92 60 04 5 2 52 0 5 12 98 328200 12 98 12 98 32 1 2BLANK MOONEY AIRCRAFT CORPORATION M20J SERVICE AND MAINTENANCE MANUAL CHAPTER 32 LANDING GEAR TABLE OF CONTENTS CHAPTER SECTION SUBJECT 4 me 2 SUBJECT xoxo PAGE 32 00 00 General 5 32 10 00 Main Landing Gear and Doors 5 32 10 0010 Mai Gear Removal 5 32 10 02 24 274 Main Gear Installation 6 32 10 03 4 Main Gear Door Rigging 6 k k s k k k k 24 0378 thru 24 2999 24 3079 thru 24 TBA 32 10 00 Main Gear Door Rigging 24 3000 thru 24 3078 6 32 10 05 Inboard Door Rigging 24 3000 thru 24 DUE 7 32 10 06 Assist Bungee Installation 8 32 20 00 Nose Gear and Doors 8 32 20 01 Nose Gear Removal 8
521. ough running engine Low oil pressure PROBABLE CAUSE improper magneto operation Internal failure Incorrect idle mixture Incorrect idle speed Induction system leak Mixture too rich as indicated by black exhaust stacks Extremely rich mixtures are indicated by black exhaust smoke Mixture too lean as indicated by overheating and backfiring Leak in induction system Defective spark plugs Improper fuel Magneto breaker points not working properly Defective ignition wire Defective spark plug terminal connectors Leak in induction system Partial clogging of injector nozzle or fuel screens Throttle lever out of adjustment Restriction in air scoop Faulty ignition Cracked engine mount Partial clogging of injector nozzles or fuel screens Defective mount bushing Uneven compression Damaged out of track or unbalanced propeller Insufficient oil Stuck relief valve 12 98 MOONEY AIRCRAFT CORPORATION REMEDY Clean points Check timing Check oil screens for metal particles if found remove foreign material and overhaul engine Adjust mixture control Adjust idle speed Tighten all connections and replace any defective parts Clean injector nozzles Readjust fuel injector Check fuel lines for restrictions Readjust mixture Clean injector nozzles Tighten ali connections and replace defective parts Clean and gap or rep
522. ove from aircraft 37 12 04 INSTALLATION 1 Inside aircraft insert the vacuum regulator through the mounting hole in the firewall 2 Install large nut on 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 calibrated vacuum gauge into the system upstream of the regulator see Figure 37 1 2 Operate engine at a minimum of 1700 engine RPM If the vacuum regulator is 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 vacuum to read 4 75 25 In Hg NOTE After setting regulator rebend tab back to lock adjusting screw 12 98 MOONEY AIRCRAFT CORPORATION 37 13 00 FILTERS All filters except the vacuum regulator filter are of paper pleated material design The vacuum regulator filter is a foam garter design 37 13 01 MAINTENANCE PRACTICES 1 Air filter replacement 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 2 All filters require routine inspection of condition of element and security of filter in system 3 ALL FILTERS MUST BE CHANGED WHEN A NEW PUMP IS INSTALLED 37 13 02 SERVIGING All filters require no service except
523. own Approx 4 5 inches measured NOTE Negative degrees stabilizer degrees mean that stabilizer leading edge 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 Rigging and Adjustment A Loosen setscrew in down stop or jamnut A and turn stop s on threaded shaft to move it toward Aft Turn trim control wheel toward NOSE DOWN position until horizontal stabilizer 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 12 98 AIRCRAFT CORPORATION WHEEL ASSEMBLY FLDDRBDARD GEAR BOX ASSEMBLY M20J SERVICE AND MAINTENANCE MANUAL WHEEL ASSEMBLY FLOORBOARD gt GEAR BHX ASSEMBLY S27CHAIN STD STOP NUTS STABILIZER TRIM CHAIN ADJUSTMENT FIGURE 27 12 STEPPED STOP NUTS torque tube 3 Carrier bearing can now be inspected If carrier bearing or torque tube sleeve show evidence of scoring or wear replace damaged items with new parts Bendix King P N s are BEARING BLOCK ASSY 047 04143 000 TORQUE TUBE SLEEVE 076 00971 000 ROLL PIN for torque tube sleeve 090 00052 0022 When scoring or wear is not present clean any dried grease and or dirt from bearing and torque
524. p is 0 00 to 0 60 inches 2 Replace discs when gap exceeds tolerance Use shock disc replacement tool C P N GSE 030011 old P N 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 being compressed MAIN GEAR SHOCK DISC REPLACEMENT TOOL APPLICATION FIG 32 21 12 98 M20J SERVICE AND MAINTENANCE MANUAL 3 Careful application of the shock disc replacment tool is recommended during replacement of main gear shock disc to keep from damaging grease fittings 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 retaining collar D Figure 32 22 and lop retaining plate E Top retaining plate must be in contact with retaining collar 2 Replace shock discs if gap is found Use shock disc replacement tool F P N GSE 030010 old P N 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 Dimension T Figure 32 22 is critical to properly locate nose wheel position The leg assemblies can vary due to manufacturers tolerances The dimension T in no load fully extended position should be approximately 3 0 inches Add spacer under coliar D per SB M20 202 as needed See Figure 32 20 parag
525. pletion 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 M20J AIRCRAFT CORPORATION Permit this surfacing coat to cure prior 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 fibergiass 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 of the 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 a
526. pping evenly To install cup heat wheel half again coo cup with dry ice Position cup and tap lightly to insure proper seating 8 Polish small burrs or nicks out of wheel halves with No 400 grit sandpaper clean thoroughiy and refinish protective coating as required 9 Replace bearing cones that show signs of wear or bearing fretting 10 Repack wheel bearings and lubricate seals with grease Install bearings closure rings and felt seals in wheel halves Secure with snap rings 11 Position tire and tube on one wheel haif then position other wheel half on tire 12 Install brake disc 2 and wheel half retaining bolts washers and nuts Fig 32 14 13 Tighten nuts evenly and torque to 150 inch pounds M20J SERVICE AND MAINTENANCE MANUAL 14 Inflate tire to 30 PSI 15 Install wheel assembly washer and axle nut Tighten axle nut until bearing binds slightly back nut off to nearest castellation and install cotter pin NOTE Position Spacers as needed to positon Brake Disc 12 inches away from MLG leg assembly NOTE When properly installed wheel will tum with a slight resistance 16 Install dust shield and IB MID gear door 17 Reinstall brake caliper amp safety CAUTION Conduct a retraction extension check 5 cycles to verify tire enters and exits wheelwell without interference Ref AC 43 13 1 current revision SCREW TYP 3 PLCS NUT SPACER DS COTTER PIN MAIN GEAR
527. pplication paragraph 6 STOP DRILL CRACK CHAMFERED SURFACE amp GLASS PATCH OUTLINE E ef NON FINISHED SURFACE CRACK FINISHED SURFACE LAMINATE THICKNESS CHAMFER EACH SIDE TYP THICKNESS 02 TO 04 0 50 FIBERGLASS RESIN 0 50 5 51 22 COMMON STRUCTURAL LAMINATE REPAIR FIGURE 51 22 12 98 51 15 04 21 AIRCRAFT CORPORATION 6 Place rigid aluminum plates on both sides of repair area and clamp into place with C clamps Permit laminate repair to 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 by the size of the repair 8 Upon completion of steps 1 thru 7 allow the repair to cure before attempting further treatment of the appearance surface 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 manufacturer s specifications and apply to the appearance surface area Care should be taken to assure as smooth as possible surface in this particular operation Permit this surfacing coat to cure prior to any additional application or further rework 11 Using 240 sandpaper sand and blend repaired
528. pressure 10 25 PSI through the lines from the disconnected line at the airspeed indicator to the static ports Cover each static port separately when blowing to insure ihat each line is clear Instrument error or possible damage may resuit if even one port is clogged with dirt or foreign matter CAUTION NEVER BLOW AIR through the line TOWARD the INSTRUMENT panel to do so will seriously damage the instruments When blowing back through the line from the instrument panel make sure that no air is blown into the instruments 4 Static system leak test The static system should be check for leaks in accordance with the instructions in Federal Aviation Regulation 91 411 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 provided to change the static air source from outside the aircraft to inside the cabin The valve is located on the lower panel immediately to the left of the pilots control column Airspeed indicator and altimeter readings will be slightly affected when using the alternate static source 34 10 01 HEATED PITOT TROUBLE SHOOTING TROUBLE PROBABLE CAUSE REMEDY Tube does not heat or clear Switch circuit breaker tripped Reset circuit breaker itself of ice with switch on Open circuit Repai
529. r Excessive voltage drop between Check voltage at pitot head battery and pitot head Heating element burned out Replace pitot head 12 98 34 00 00 5 MOONEY AIRCRAFT CORPORATION M20J SERVICE AND MAINTENANCE MANUAL 34 11 00 AIRSPEED INDICATOR Registers airspeed in knots Air pressure difference between impact air pitot tube and static air static ports on each side of the aircraft tailcone operates the airspeed indicator An electrically heated pitot head prevents ice obstruction in flight The airspeed indicator dial markings are as follows Radial Red Line 195KIAS Yellow Arc 22 174 195 KIAS Green k k L7 64 174 KIAS White Are 2 2 am 5 57710 NOTE See Section 27 95 00 for stall warning systems 34 11 01 AIRSPEED INDICATOR TROUBLE SHOOTING TROUBLE PROBABLE CAUSE REMEDY Instrument pointer does not Leak in instrument Check for leak and seal case or in indicate properiy static lines lines Obstruction in pitot tube Clean out obstruction Instrument pointer oscillates Leak in instrument case or in Check for leak and seal lines pitot lines 94 12 00 VERTICAL SPEED INDICATOR Converts barometric pressure changes within the static port lines to aircraft ascent or descent rate readings are in feet per minute This instrument has a single needle and two adjoining scales that read from 0 to 2000 feet per minute
530. r aircraft are depicted in the M20J Illustrated Parts Catalog 11 20 30 00 PLACARDS EXTERIOR INTERIOR All required placards and their locations both interior and exterior are listed in Section 11 of the FAA Approved Flight Manual and Pilots Operating Handbook 12 98 11 00 00 3 SERVICE AND MAINTENANCE MANUAL M20J MOONEY AIRCRAFT CORPORATION BLANK 11 20 30 00 12 98 4 MOONEY AIRCRAFT CORPORATION M20J SERVICE AND MANUAL CHAPTER 12 SERVICING SERVICE AND MAINTENANCE MANUAL M20J CHAPTER SECTION SUBJECT 12 Eff Contenis 12 00 00 12 10 04 12 20 00 12 20 05 12 20 06 12 20 06 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 CHAPTER 12 SERVICING LIST OF EFFECTIVE PAGES PAGE 1 2BLANK S ooo TABLE OF CONTENTS SUBJECT Servicing Servicing Intervals Replenishing Fuel Tanks Fuel Drains Engine Oil Oxygen System Scheduled Servicing induction Air Filter Battery Tires amp Wheels Brake Reservoir Hydraulic Brake Cleaning 12 98 MOONEY AIRCRAFT CORPORATION DATE 12 98 8 93 5 93 5 93 12 98 5 93 5 93 PAGE C O1 Ci Oi WW WW ow 12 EFF CONTENTS 1 2BLANK MOONEY AIRGRAFT CORPORATION 12 00 00 SERVICING 12 00 01 SERVICING INTERVALS The specified intervals refer t
531. r Adjustment 12 LU 24 3411 thru 24 TBA Fireseals 12 AirIntakes 12 Engine Induction System Maintenance 12 Air intake Duct Replacement 12 12 98 71 CONTENTS 3 4BLANK SERVICE AND MAINTENANCE MANUAL M20J 71 00 00 MOONEY AIRCRAFT GENERAL The M20J S N 24 0001 and ON has either a TEXTRON Lycoming IO 360 A1B6D IO 360 A3B6D or IO 360 A3B6 series engine installed These are four cylinder 200 H P fuel injected engines 71 00 01 ENGINE DATA AIRCRAFT MODEL ENGINE MANUFACTURER ENGINE MODEL BHP rated MAX RPM CYLINDERS DISPLACEMENT on In BORE Inches STROKE Inches COMPRESSION RATIO MAGNETOS Manufacturer Model ADVANCE BTC VALVE ROCKER CLEARANCE Hydraulic Tappets Collapsed RIGHT MAG FIRES Top Plugs Bottom Plugs LEFT MAG FIRES Plugs Bottom Plugs R bank FIRING ORDER FUEL INJECTOR Manufacturer Mode OIL CAPACITY QTS OiL VISCOSITY RECOMMENDATIONS AVERAGE AMBIENT AIR TEMPERATURE NOTE Multi viscosity oil is recommended for all operations Above 60 Deg F 30 Deg to 90 Deg F 0 Deg to 70 Deg F Below 10 Deg F 22 02 40 M20J TEXTRON LYCOMING lO 360 A3B6D 200 2700 2224 361 0 5 125 4 375 8 7 1 Bendix Scintilla D4LN 2021 D4LN 3021 25 Degrees 028 to 080 R bank L bank L bank 1 3 2 4 _ BENDIX RSA SADI SINGLE VISCOSITY MULTI VISCO
532. r station indicated on travel board GSE 030004 and with stabilizer at 0 degrees aircraft thrust line See Figure 27 3A amp 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 approximately 5 turns to start D Adjust elevator horn rod end 9 Figure 27 7 out 7 or 8 turns to start E Main spar adjustable rod end bearing is tumed out approximately 6 turns to start To obtain additional elevator travel 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 contact with P Figure 27 8 H Rotate stabilizer trim full down to check clearance of bellcrank at wing stub spar Adjust rod end bearing at rear tailcone bulkhead C Fig 27 5 if pe for clearance Recheck elevator up and down ravel I Rotate elevator trim full up check that Elevator oO P makes solid contact on elevator stop limiter J Retighten ail jam nuts attach bolts and secure as necessary recheck all contro tube clearances and travel limits 12 98 M20J MOONEY AIRCRAFT CORPORATION 5
533. raph 30 50 02 for proper steering tracking rigging NOSE GEAR SHOCK DISC REPLACEMENT TOOL FIGURE 32 22 32 60 04 29 SERVICE AND MANUAL 2 Raise aircraft on jacks shocks fully extended A Inspect nose and main gear shocks for evidence of gap between retaining collar and retaining plate The disc preload must be great enough to maintain complete wheel extension during retraction B Replace shock discs that have lost resilience C Inspect retaining collar and bolt for deformation wear and cracks D Replace defective bolt and collar 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 se NOTE For Nose Gear Steering Tracking see Section 32 50 02 Figure 32 20 32 82 00 30 M20J MOONEY AIRCRAFT CORPORATION 32 82 00 RECOMMENDED HARD LANDING INSPECTIONS The following are areas recommended to be inspected when a hard landing has occured Since a hard landing is a relative term it is up to the owner operator to advise maintenance personnel when the inspections are to be accomplished 1 Mud Shield missing or damaged on either or both main landing gear 2 Main landing gear shock bisq
534. rco T 657 Turco Products inc 6135 South Central Ave Los Angeles California lacquer thinner 3094 wash thinner Pratt amp Lambert Inc 25th and N Y Avenue Wichita Kansas or similar solvents 1 To get a good clean surface for priming use a clean cloth or piece of cheesecioth and apply one of the solvents noted above The surface should be wiped dry with a second piece of clean cloth Do not allow the solvent to dry on the cleaned area as it will redeposit dissolved soil and grime upon evaporation CAUTION Wipe solvents are generally flammable and toxic and shouid not be used without adequate ventilation and fire precautions C Apply Epoxy Polymide primer or equivalent to cleaned area by spray or brush Area needs to be painted within 24 hours of primer coat 20 00 03 PAINTING The exterior is painted with urethane enamel When exposed to humid salt air or to an atmosphere having oe fallout the aircraft should be hangared when not in use 1 Paint Repairs A Materials 1 Aluminum wool nylon scouring pads 320 grit or finer emery cloth or steel wool 2 Tack rags 3 Wipe solvents such as Methyl ethyl ketone T 857 Turco Products inc 3094 wash thinner oF Pratt amp Lambert inc lacquer thinner or equivalent solvents 4 Body putty or aerodynamic filler such as Flex Bond Taylor amp Art Plastics Flex 3M Co or Cuz polyester body filler 6372 NAPA Martin Senour Paints
535. reaker Short circuit in alternator Reconnect lead to post of alternator WARNING ENSURE THAT MAGNETO SWITCH IS OFF WHEN TURNING PR PELLER Rotate propeller by hand to rotate alternator through 360 degrees of travel If circuit breaker trips replace altemator Alternator will not keep battery Battery malfunction 4 Start engine and adjust for 1500 charged RPM Ammeter should indicate heavy charge rate with all electrical equipment turned off Rate should taper off in 1 3 minutes A voltage check at the bus should indicate a reading of 13 75 to 14 0 volts 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 12 98 10 SERVICE AND MAINTENANCE MANUAL M20J MOONEY AIRCRAFT CORPORATION TROUBLE cont PROBABLE CAUSE REMEDY Defective wiring 2 Check voltage at or 1 terminal of regulator with master switch ON Meter should indicate bus voltage If voltage is not present check wiring between regulator and bus 24 0001 thru 24 2999 terminal 5 for 24 3000 thru 24 TBA with Alt Fid amp Master switch ON Regulator faulty 3 Remove connector from regulator and start engine Momentarily jump A amp B or 1 and 2 pins together on the plug Aircraft ammeter should show
536. remains on and inspect Replace if damaged or deteriorated Reassemble motor assy to jackshaft assy and secure all EATON ACTUATOR lt P N 108000 SEE SERVICE INSTR M20 52B LANDING GEAR ACTUATOR S EXPLODED VIEWS FIGURE 32 12 12 98 32 31 02 17 SERVICE AND MAINTENANCE MANUAL components Complete gear inspection per Section 20 06 3 L 1 See S 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 amp relube exposed screw threads Run actuator to within approx 0 5 inch of mechanical retract amp remove major excess grease extruded from ball nut assembly during this retraction step LANDING GEAR ACTUATOR P N 102000 CLUTCH SPRING REPLACEMENT currently 1 2 3 4 amp ON KIT No A10 85 Landing gear actuator clutch spring replacement is mandaiory at each 1000 hours of aircraft operation DISSASEMBLY P N 102000 1 Remove two nuts item 1 Note position of cable support bracket item 2 and remove Figure 32 12 2 Remove manual extension system disengage cable from actuator disengage arm 3 Remove two long screws item 3 4 Remove two short screws itern 4 5 Remove recoiler assembly item 5
537. replaced with new parts 51 14 04 REMATING HORIZONTAL STABILIZER TO STINGER When stabilizer repair necessitates removal from the stinger remating can be facilitated by using huckbolt substitution information contained in Section 51 10 01 When mating stabilizer to stinger use bent rivet swage set 5 see Figure 51 19 v 5 EACH SIDE 050 20241 3 CLAD x B EACH SIDE SM51 18 SPARREPAIR FIGURE 51 18 51 14 03 18 M20J SERVICE AND MAINTENANCE MANUAL HUCK SUMP COLLAR SWAGE SET INSTALL HUCK COLLAR BUCKING BAR BENT 5 5 amp 6 SWAGE SET WAGE SET SM51 19 N AB STINGER FIGURE 51 19 51 15 00 FIBERGLASS LAMINATES REPAIR PROCEDURES Despite the fact that fiberglass laminates are 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 accessibility and the extent of damage The following steps outline those procedures which are used to make repairs for the more common type damage to a fiberglass laminate 1 Materials used for repairs shall be as specified below and compatible with the basic resin used in the fiberglass laminate Resin Aerospace Adhesive EA934 Part A Hysol Division The Dexter Corporation Catalyst Aerospace Adhesive EA934 Part B Hysol Division The Dexter Corporation Alternates Resin Epoxical 606 Patching Adhesive Resin United Sta
538. reshield in reverse sequence 34 10 00 PITOT amp STATIC AIR PRESSURE SYSTEM Static pressure instruments are 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 humid or wet weather If instrument operation is erratic or inoperative after draining perform the following 1 Pitot system leak test Make sure Master switch is OFF and Gear Control is in DOWN position A Slip end of a short rubber hose over pitot tube B Close open end of hose slowly roll up hose until airspeed indicator reads 150 KIAS C Clamp hose and hold for one minute D If airspeed indicator falls more than 10 KIAS within one minute check system for leaks and tighten line fittings E steps until obtaining less than a 10 5 indicator reading drop M20J MOONEY AIRCRAFT CORPORATION CAUTION Release the air pressure slowly by unrolling the rubber tubing a sudden release of the air pressure may damage the airspeed indicator 2 Pitot system hose inspections After the pitot system is checked for leaks inspect the hose sections for signs of deterioration Check all tubing for brittleness checks or cracks particularly at the bends or connecting points When new hose is installed recheck the system for leaks using the PITOT SYSTEM LEAK TEST procedure above 3 Static system cleaning Blow low air
539. rim control wheel and indicates stabilizer position relative to the aircraft thrust line Set horizontal stabilizer to an angle of incidence of minus 2 degrees 00 minutes to minus 2 degrees 30 minutes Adjust trim indicator cable at F Figure 27 10 to set indicator in the cabin to the center of the takeoff range mark A MAXIMUM HORIZONTAL STABILIZER ALLOWABLE FREE PLAY LIMITS 1 Fore and aft movement at stabilizer tip 0 12 inches 2 Vertical movement at stabilizer tip 0 10 inches NOTE When removing trim screw from empennage use a biock of wood cut to fit opening between tailcone and empennage to prop empennage up when trim screw is removed 4 Electric Trim A The clutch torque for the electric trim system Should be checked and adjusted by an Avionics shop for the following settings to operate the autopilot systems properly 1 KFC 200 21 2 inch Ibs 2 KAP 100 21 2 inch 165 3 KFC 150 21 2 inch Ibs 4 EDO AIRE Systems 18 inch Ibs 5 S TEC i 30 inch Ibs 27 40 01 TRIM SYSTEM TROUBLESHOOTING BINDING ELECTRIC CLUTCH SLIPPING 27 42 00 ELECTRIC PITCH TRIM SYSTEM MAINTENANCE If installed the AlliedSignal Bendix King Electric Pitch Trim System requires periodic maintenance at each annual inspection for carrier bearing added to existing aircraft pitch trim torque tube If not already installed an annual service placard 057 05747 0001 available from AlliedSignal MUST
540. rly defined apply two 1 32 inch brush coats Allow the first coat to cure about four hours or until it becomes rubbery before applying the second coat The second St overlap the edges of the first coat by about inch 28 11 00 7 MOONEY AIRCRAFT CORPORATION D Protective Sealant 1 Using short even strokes brush on a smooth and continuous coat of PR1005 L over sealant The protective sealant coat should extend one inch beyond edge of the filleting compound 2 Allow the first protective coat to cure 20 minutes at 75 degree F or until tack free then apply second brush coat of PR1005 L Make every effort to obtain a completely bubble free continuous top coat DO NOT REBRUSH over areas as doing so will only cause dragging and will break coating continuity E Upper Wing Tank Access Panel Sealing 1 Apply a coat of access door sealant 053590 PR1428 or PR1403 G B2 to either faying surface using a short stiff bristle brush spatula or extrusion gun If an extrusion gun is used smooth the sealant with a brush or spatula Cover the entire faying surface with a sealant coat of sufficient thickness 1 32 to 1 16 inch to assure extrusion along the edges of the faying surface when the mating parts are assembled Access panels in wing walk area should be sealed with PR1422 Class B filleting compound 2 Assemble parts immediately after application of sealant and tighten screws to obtain as near as possible a me
541. rns as required 9 Check main gear overcenter preioad as follows A Place rigging tool T P N GSE030007 Fig 32 9 on retraction truss Hold tool stationary by pong thumb on rear end of tool at S and press orward B Place 10 torque wrench R on rigging tool Place thumb on wing bottom apply force until joint 4 breaks open slightly Insert shim stock 005 to 008 in thickness between link and truss at P Release force on wrench 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 value should be 250 to 280 inch pounds D Repeat on other main gear E If preload is not within prescribed limits proceed to applicable S N main landing gear rigging procedures in Section 32 31 03 F If main gear preload needs re adjusting the nose gear bungees should be re checked per 8 C above On S N 24 3000 thru 24 3078 proceed to Section 32 30 03 for nose gear rigging procedures 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 32 20 03 9 SERVICE AND MAINTENANCE MANUAL SQUAT SWITCH OPERATIONAL CHECK 24 0001 thru 24 0237 Except 24 0084 A sq
542. rom Hartzell Propeller Inc 350 Washington Avenue Piqua OH 45356 Blade Specification Manual No 133 A Overhaul Instructions Manual No 113 B MAGNETO Bendix Scintilla Magneto Obtain Service data for Bendix Series 2000 or 3000 magnetos from Bendix Corporation Electrical Components Civision Jacksonville FL 32245 7880 FUEL INJECTOR we Obtain service data for fuel injectors from Precision Airmotive 3220 100th Street S W E Everett VACUUM PUMP Airbome Division Parker Hannifin Corporation 711 Taylor Street PO Box 4032 Elyria OH 44038 USA Tel 216 284 6300 Fax 216 322 6094 i STAND BY VACUUM PUMP SYSTEMS AERO SAFE 10160 Buffalo Grove Rd Fort Worth TX 76101 800 433 5689 ELECTRO MECH 2600 50 Custer Wichita KS 67217 316 942 3271 SPEED BRAKES Precise Flight Inc 63120 Powell Butte Rd Bend OR 97701 USA Tel 800 547 2558 INTRODUCTION 12 98 Page 2 MOONEY AIRCRAFT CORPORATION M20J SERVICE AND MAINTENANCE MANUAL SYSTEM CHAPTER SUB SYSTEM SECTION INDEX GUIDE SYSTEM SUB SYSTEM TITLE CHAPTER SECTION 1 4 RESERVED BY GAMA MAY BE USED AT LATER DATE 5 TIME LIMITS MAINTENANCE CHECKS 00 GENERAL 10 TIME LIMITS 20 SCHEDULED MAINTENANCE CHECKS 6 DIMENSIONS AND AREAS 00 GENERAL 7 LIFTING 10 JACKING 8 LEVELING AND WEIGHING 00 LEVELING 9 TOWING AND TAXIING 00 GROUND HANDLING 10 TOWING 20 TAXIING 10 PARKING AND MOORING 00 GENERAL 10 PARKING 20 MOORING 11 PLACARDS A
543. ropeller by means of an approved Log book entries must be made when the propeller is system is recommended to provide smoother dynamically or statically balanced operation The vendor system used should be an CAUTION approved system and the procedures followed very Place weights washers or whatever balance carefully The propeller may have been balanced with weights are specified at the locations specified another vendor system previoulsy and may require by the balancing procedures Be careful placing removal of old baiance weights and or other means of balancing 12 98 weights on spinner dome 61 40 00 7 SERVICE AND MAINTENANCE MANUAL M20J MOONEY AIRCRAFT GORPORATION BLANK 61 40 00 12 98 8 MOONEY AIRCRAFT CORPORATION M20J SERVICE AND MAINTENANCE MANUAL CHAPTER 71 POWERPLANT SERVICE AND MAINTENANCE MANUAL M20J MOONEY AIRCRAFT CORPORATION CHAPTER 71 POWERPLANT LIST OF EFFECTIVE PAGES CHAPTER SECTION SUBJECT PAGE DATE 71 Effectivity 12BLANK 1298 71 Contents 3MBLANK 12 98 71 00 00 B k k 12 98 71 00 01 12 98 71 00 40 f se pm k k 12 98 71 00 01 sa Kor OK lt K KR we Kr S oux Cw Gee lt 12 08 71 0062 ro M 90 ocv 12 98
544. rrects the aitimeter reading for prevailing conditions 34 11 00 12 98 6 SERVICE AND MANUAL 34 13 01 TROUBLE Excess scale error Excessive pointer oscillation High reading Setting knob is hard to turn Inner reference marker fails to move when setting knob is rotated Setting knob set screw is loose or missing Cracked or loose cover glass Dull or discolored luminous markings Barometric scale and reference markers are out of synchronization with pointers Barometric scale and reference markers are out of synchronization 34 20 00 M20J ALTIMETER TROUBLE SHOOTING PROBABLE CAUSE Improper calibration adjustment Defective mechanism Static pressure system leak Wrong lubricant or lack of lubrication Marker out of engagement Excessive vibration Excessive vibration Age Shift in mechanism Slippage of mating parts DIRECTIONAL GYRO COMPASS MOONEY AIRCRAFT CORPORATION REMEDY Replace instrument Replace instrument Eliminate leak in static pressure system Replace instrument Replace instrument Tighten instrument screw if loose Replace instrument if screw is missing Replace instrument Replace instrument Reset pointers Replace instrument This vacuum operated instrument indicates the heading reference The directional gyro rotor is air driven and rotates with its spin axis horizontal The knob is used to reset basic directi
545. rrosion cleanliness and lubrication L Check the landing gear actuator for security of mounting cleanliness and indication of overheating or damage Inspect brushes in motor for wear S N 24 0001 24 0377 with Dukes Actuator Lubricate actuator ball screw with recommended ORGAN for Dukes actuator only per procedures elow 1 After 500 hours of operation and each 200 hours thereafter 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 ring and worm gears Make an index mark on one gear tooth and on the inside of housing Tum jack screw shaft clockwise until ring gear contacts worn gear and check index marks Visible wear or backlash of 1 2 tooth or more requires immediate replacement of gears Reference SECTION 32 30 04 S N 24 0001 thru 24 0377 for additional inspection and rigging procedures ALTERNATE PROCEDURE Dukes actuator s Measure backlash by using a 025 diameter wire of 025 thick shim as a feeler gauge If feeler can be inserted between gear teeth replace gears Repeat above procedure after rotating the ring gear thru 90 degrees 180 degrees and 270 degrees d Repack gear box with recommended lubricant e Reinstall end cap and resafety f Refer to Section 32 30 02 for proper actuator adj
546. rs No periodic lubricant on Avionics Products 102000 1 2 If necessary to relubricate use Aeroshell 22 Mobil 28 or MIL G 81322 ONLY Replace No back spring in Avionics Products Ref SI M20 52B amp Plessy Actuators Ref SI M20 92 5 20 07 12 98 18 SERVICE AND MAINTENANCE MANUAL M20J ITEM NO 7 10 11 12 13 14 15 16 17 18 19 ITEM DESCRIPTION Empennage Attach Points Stabilizer Trim Attach Point Elevator amp Rudder controls Control Tube Rod End Bearings Trim Assist Bungee Attach Point Elevator amp Rudder Controls Control Tube Rod End Beans Trim Assist Bungees Aileron Control Tube Guide Blocks Aileron Controls Control Tube Rod End Bell Cranks Aileron Control Tube Guide Blocks Main Gear Retraction Spring Belleranks Wing Attach Points Control Tube Guide Blocks Stabilizer trim Screw amp Stops Indicator Adjustment Point Stabilizer Trim Chain amp Gear Elevator amp Rudder Controls Control Tube Rod End peng Bellcranks i Guide Blocks Flap Indicator Cable i Electric 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 Bearings Control Yoke Lower Section Nose Gear Steering Link Rudder Pedal Cross Shaft Rudder Aileron Bungee Hydraulic Brake Cyl
547. rt of the cycle determine which De lcer is affected and check for rough or dirty slip rings causing brush to skip Also check circuits for loose or poor connections Test timer per Section 30 63 00 Check brush alignment per B F Goodrich Report No 68 04 714 Check for dirty or rough slip rings If so clean machine or replace slip ring assembly See B F Goodrich Report No 68 04 712B Section 5 4 Check slip ring alignment per Section 4 5 B F Goodrich Report No 68 04 712B See 4 3 8 a and b B F Goodrich Report No 68 04 7128 Place jumper wire across switch or circuit breaker if radio noise disappears replace _ Switch or circuit breaker Relocate De Icer wiring at least 8 from radio equipment and wiring Check system wiring against circuit diagram Check brush alignment per B F breakage Slip ring wobbles Rough slip rings Goodrich Report No 68 04 714 Correct as Required 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 ee a rr a xx q T e une m s ma c s x r a e ss se u ws m st s e SSS SS SS SS yxa aHrUoAn m n s s s sn s s 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 D
548. ructions prior to sealant application 3 Cleaning Surfaces to be Sealed A Clean metal surfaces to 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 3 16 TH 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 accumulating on surfaces to be sealed 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 thoroughly and reseal tank as follows Fillet Sealing 1 Be certain that the surface to be sealed is totally clean and free from oil grime finger prints etc 2 Refer to Figure 28 3 for typical fillet size 8 Join fillets laid on intersection joints to produce a continuous fillet 4 Seal all difficult and hard to reach areas first to preclude the possibility of their being overlooked or improperly sealed B Filleting Compound Application PR1422 B 2 12 98 M20J 3 16 TO 1 4 IN EE SECOND STEP MOONEY AIRCRAFT CORPORATION 1 Use a spatula or an extrusion gun with a 1 8 to 1 4 inch nozzle opening for laying fillets
549. rvals Refer to AC 43 4 5 20 01 INSPECTION CHECK POINTS The general points to be covered during inspection are grouped in accordance with the nature and function ofthe items discussed 1 Moving Parts shall be inspected and checked as applicable for proper operation security of attachment sealing cleanliness lubrication servicing safetying adjustment tension travel condition of hinges binding excessive wear cracking corrosion deformation and any other apparent 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 corrosion and any other apparent damage 3 Fuel air and hydraulic oil lines and hoses shall be inspected as applicable for cracks dents kinks deterioration obstruction chaffing improper bend radius and insecure installation Hose clamp installations on fuel and hydraulic systems between systems or between systems and the engine shall be torqued to 25 inch pounds Hose clamp installations on blast tubes air ducts vacuum lines drain and vent lines shall be torqued to 15 inch pounds 12 98 M20J MOONEY AIRCRAFT CORPORATION 4 Pipe Threads Tightening and Torque procedures Lubricate pipe threads as follows Oxygen Lines Use only MIL T 5542 thread compound or Teflon thread seal tape on threads of valves connectors fittings parts or assemblies which might come in
550. s Turbine Inlet Temperature Instruments Compressor Discharge Temperature Instruments Exhaust Gas Temperature Instruments Manifold Pressure Instruments Fuel Flow Instruments VSI Electric Gear Gear Controls Lighting Electroluminescence Emergency Locator Transmitter Phones Ignition Magneto Lighting Rotating Beacon Light Lighting Cabin Lights Lighting Landing Lights Lighting Navigation Lights Lighting Instrument amp Placard Lights Lighting Recognition Lights 12 98 LT Lighting Taxi Lights MA Miscellaneous Auxiliary Power Plug MB Miscellaneous Radio Circuits MC Miscellaneous Cigar Lighter MD Miscellaneous Clock Light ME Miscellaneous Electric Clock MIC Miscellaneous Microphone MM Miscellaneous Marker Beacon MP Miscellaneous Propeller De Ice NF Fuel Fuel Pump NP Fuel Primer PA Power Altemator output amp Control PB Power Battery Output amp Control PG Power Generator Output amp Control PS Power Starter input amp Control RB Radio Blower Speaker VB Vent Air Blower Warning System Alternator Voltage Warning Warning Engine Boost Warning System Gear Position Waming Electric Waming System Fuel Pressure Warning System Landing Light Warning System Gear Position Waming Manual Warning System Pressurization Warning System Stall Warning Waming System Press to Test Warning System Vacuum Warning
551. s to obtain correct pitch for the selected engine load Engine lubricating oil is supplied to a power piston in propeller hub through the propeller shaft The amount and pressure of oil supplied 0 300 PSI is controlled by an engine driven governor Govrnor oil pressure acting on a piston and spring increase propeller blade pitch thus decreasing engine RPM As governor oil pressure is reduced centrifugal twisting moments and spring force on propeller blades decrease propeller blade pitch and increase RPM Propeller overhaul shall 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 12 98 M20J SPINNER DOME amp PROPELLER REMOVAL FIGURE 61 1 SERVICE AND MAINTENANCE MANUAL NOTE Approved propeller shops only are authorized for overhaul or major repairs to these propellers Refer to 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 Lycoming Service and Maintenance Instructions SPINNER DOME AND PROPELLER REMOVAL 1 Spinner dome removal if necessary See Figure 61 1 61 00 10 NOTE It is not necessary to remove spinner when removing propeller assembly A Remove screws 1 from sp
552. s located at the top of the instrument panel in front of the pilot The actuator worm gear ball nut is connected to the retract bellcrank which is connected to push pull retract tubes and bellcranks throughout the entire retraction system 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 electrical circuit to prevent landing gear retraction while on the ground until a safe takeoff speed is reached A squat switch is located on the left main landing gear leg S N 24 0001 thru 24 0237 except 24 0084 A by pass switch is installed adjacent to the gear selection switch in order to override the safety switch circuitry if the gear does not retract 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 mounting box attached to the wing spar The steerable nose gear mounts to the cabin tubular steel 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 assembiies 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 actuator unit Refer to Sect
553. seat for nicks scratches and scoring G Inspect all threads for damage H Replace o ring 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 32 40 04 25 SERVICE AND MAINTENANCE MANUAL PARKING BRAKE VALVE 24 0758 THRU 24 TBA FIGURE 32 18A 32 41 00 TROUBLE Solid pedal and no brakes allowable limit Spongy brake Air in system Pressure will not hold Parking brake will not hold M20J Leak in brake system Air in system or leak in system MOONEY AIRCRAFT CORPORATION PARKING BRAKE VALVE 24 0001 THRU 24 0757 FIGURE 32 18B TROUBLE SHOOTING BRAKE SYSTEM PROBABLE CAUSE Brake lining worn beyond REMEDY Replace lining Bleed brake system 12 20 05 Visually check entire system for evidence of leaks See remedies above downstream of parking brake valve Defective parking brake valve Warped or bent disc Foreign matter locking disc Master cylinder shaft or linkage Brake grabs Brake pedal will not return to neutral position misaligned Repair or replace the valve Replace disc Clean disc and lining Check that shaft travels in straight line amp not binding in link
554. second The TRU FLOW 1 displays both functions simultaneoulsy 2 The totalizer function in both systems be used as a single flight totalizer 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 i second The RESET button has a one half second delay to prevent accidental reset On starting the engine the FT 101 will begin displaying fuel flow Total fuel used may be checked by depressing the USED TEST button 73 31 03 7 SERVICE AND MAINTENANCE MANUAL B LONG TERM TOTALIZER Turn on the aircraft master switch On activating the aircraft electrical system the FT 101 will flash zero 000 0 fuel flow Depress and hold the USED TEST button the FT 101 will display the total fuel used from previous flights DO NOT push the RESET button On starting the engine the FT 101 will display fuel flow and continue counting fuel used up to 999 9 gallons 9999 pounds or 9999 liters depending on the model The Alcor unit will display fuel flow and total used from past flights 73 31 04 TEST FUNCTION A test function is provided in the FT 101 so the pilot may verify that all digits are functi
555. sed to simulate fuel and oil pressure in Mooney M20J modas 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 disconnecting the appropriate Druck transducer electrical connector and connecting the 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 correct 1 Verify Oil Fuel pressure to Druck transducer with mechanical pressure gauge A If correct probable failure is Druck transducer B If incorrect troubleshoot oil fuel system 79 30 02 4 M20J MOONEY AIRCRAFT CORPORATION If pressure reading is incorrect zero or pegged condition 1 ROCHESTER gauge S N 24 0001 thru 24 3153 A Move transducer test box to connector on the input of appropriate pressure amplifier located behind instrument panel right side Check pressure reading on Rochester gauge to see if it approximately agrees with test box If it does repair wire harness from pressure gauge amplifier to the engine compartment If pressure reading is incorrect go to step b B At the appropriate Rochester gauge WIPER lug read the following voltages to ground digital multimeter or 20K ohms volt multimeter 201 205 Fuel 14 PSI 4 4 to 4 7 volts 201 205 Oil 60 PSI
556. see Section 37 30 20 below 3 Use a screwdriver or similar tool remove pump drive coupling 1 from engine coupling drive gear 2 and pump drive gear 3 being careful not to damage drive pins 4 Push new drive coupling 1 into place on pump drive gear 3 5 Push engine coupling drive gear 2 into place on pump drive coupling 1 6 Turn by hand check for rotation of pump 7 Reinstall pump on engine and test run refer to Section 37 11 04 8 Make log book entry 37 30 02 DRY AIR PUMP INSPECTION VACUUM PUMPS ARE NON REPAIRABLE UNIT Remove malfunctioning pump and replace with new pump VACUUM PUMPS MAY VARY BUT SHEAR COUPLING WILL BE SIMILAR FOR MOST VACUUM PUMPS DRY AIR PUMP COUPLING INSPECTION 37 21 05 SMX37 2 FIGURE 37 2 12 98 MOONEY AIRCRAFT CORPORATION NOTE After installation if regulator valve requires adjustment refer to Section 37 12 05 37 40 00 STAND BY VACUUM SYSTEM OPTIONAL 37 40 01 SERVICING Refer to manufacturers service and maintenance data for the particular unit installed If no specific maintenance information is available from the manufacturer the following is recommended 1 Inspect to verify hoses and wires are clear of any obstruction or interference with other components that may chafe hoses or wires 2 Inspect hose clamps on all fittings to verify tight and secure 3 Every 100 hour annual inspection inspect set 1 motor air pump co
557. slip attaching bolts back in place 12 98 MOONEY AIRCRAFT CORPORATION 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 described in 32 30 01 steps 2 3 5 amp 6 Reset landing gear system circuit breaker and fully extend gear 11 When step 10 is complete the retraction system is rigged for the gear down and locked position with allowance for actuator overrun after cutoff 12 Disengage manual system 13 Leave ail gear doors disconnected and run gear up electrically until main gears are 03 inches minimum from bumper pads 06 in thk rubber strips installed on W S 43 50 false rib Posilion gear up limit Switch striker arm H Fig 32 5 so that switch is just closed and RED gear unsafe light is OFF Secure striker arm in position The gear is now properly rigged in the gear up position with allowance for actuator overrun after cutoff Recheck Nose Gear Bungee Springs 32 30 01 para 8 C 14 Electrically extend gear to down and locked position Connect and 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 Adjust the mechanical down stop on actuator housing and up stop per the following instructions and Fig 32 7 amp 32 8 560245 REF Nose Gear Bungee Deflection of spring from static length to rigged position to be 030
558. spar of the horizontal stabilizer reference Figure 55 2 M20J SERVICE AND MAINTENANCE MANUAL The elevator control horn 2 is connected to the inboard leading edge of each elevator R H and L H Both control horns are then connected to the elevator flight control bellcrank ELEVATOR FIGURE 55 2 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 ribs The skins are attached to the leading edge extrusion 5 and the ribs 6 with blind rivets Each formed corrogation is matched on top and bottom skins and rivets are installed for strength and rigidity through 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 pull tube bearing then remove the AN3 bolts and hardware from each hinge fitting on both elevators 55 20 00 4 55 20 02 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 E 5 20 01 for torque table 55 30 00 VERTICAL STABILIZER The main spar assembly 1 Ref Fig 55 3 is formed from al
559. splice angle web flange should be cut to allow sufficient coverage of the damaged area of existing web and long enough to install 6 AD4 rivets on the flange on each side of the damaged area Pick up 3 existing rivet holes on flange of spar and drill 3 new rivet holes between existing holes Drill 10 rivet holes through splice angle and web on each side of the damaged web area The damaged web should be stop drilled or cracked area removed prior to splice angle installation Prime splice angle and deburr spar web and flange before installing spl e see Figure 51 17 5 Spar webs outboard of STA 48 5 cracked more than 5096 of the web height may be repaired see Figure 51 18 Form a splice plate from 050 2024 13 aluminum to fit the inside dimensions of the web and flange at the damaged area Pick up 3 existing rivet holes on top and bottom flange on each side of damaged area and drill 2 new AD4 rivet holes between these existing holes Pick up all rivet 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 rivets on each side of damaged area 51 14 00 MOONEY AIRCRAFT CORPORATION 4 10 EACH SIDE OF CRACK 6 EACH SIDE OF CRACK 4 amp STOP DRILL OR REMOVE CRACKED SPAR WEB AREA SPAR REPAIR 0 B of STA 94 0 FIGURE 51 17 51 1403 RIB REPAIR The repair of damaged stabilizer and fin ribs is not feasible in most cases Damaged ribs should be
560. st 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 io remove Some components are not mounted in slide out chassis Removal of these units will require the same SY 160 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 Sequence of removal ENGINE INSTRUMENTS AND CIRCUIT BREAKERS The engine instruments and circuit breaker panel is an assembly that can be pulled out as a unit for removal of any instrument or circuit breaker 39 10 03 1 Removal A Remove the glareshield per Section 39 10 01 B Remove two flat 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 scoop approximately 4 inches below the windshield C Remove two screws from the face of the panel at the upper left corner C Figure 39 2 D Remove iwo screws D from undemeath near the edge of the panel face 39 10 02 6 M20J SERVICE AND MAINTANANCE MANUAL NI SOME LATER MODELS MAY HAVE RIVETS IN THESE LOCATIONS THEY MUST BE DRILLED DUT amp THEN REPLACED SLIDE AFT FOR REMOVAL SMX39 2 ENGINE AND CIRCUIT BREAKER PANEL FIGURE 39 2 E Remove the NAS21919DG clamp E from the steel structure cross brace underneath the pan
561. st light control assembly on any 12V aircraft 940013 511 Kit 39 12 04 CIGAR LIGHTER The cigar lighter is located at the bottom of the radio panel immediately to the right of the co pilots control column shaft It is standard cigar lighter similar to automotive type ELECTRICAL ELECTRONICS EQUIPMENT RACK 12 98 M20J MOONEY AIRCRAFT CORPORATION 39 20 00 ELECTRICAL ELECTRONIC EQUIPMENT RACK The electrical equipment rack for the M20 series aircraft is located in the talicone 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 12 A C only 24V A G have the ELT mounted on an accessory rack further in the tailcone Access is gained through a panel aft of avionics bay access panel The ELT antenna is located under the dorsal fin ONLY 39 7 REPRESENTS 12 VOLT AIRCRAFT ON FIGURE 39 7 39 12 04 11 AIRCRAFT CORPORATION M20J 39 21 00 MISCELLANEOUS MAINTENANCE 39 21 01 EQUIPMENT MAINTENANCE Refer to SECTION 27 42 00 for Electric Pitch Trim System Maintenance 39 21 00 12 98 SERVICE AND MAINTANANCE MANUAL MOONEY AIRCRAFT CORPORATION M20J SERVICE AND MAINTENANCE MANUAL CHAPTER 51 STRUCTURES SERVICE AND MA
562. t engine and run at 1000 RPM for five minutes 5 Shut engine down and remove spark plugs 6 While motoring engine with starter Spray each cylinder through spark plug holes with approximately 2 oz of hot preservative oil CAUTION Do not exceed starter operating limits when motoring engine j 7 When all cylinders have been sprayed position propeller horizontally and respray each cylinder without moving propeller 8 Attach a warning tag to one of the blades stating that propeller is not to be rotated 9 Install dehydrator plugs in spark plug holes 10 Cap ignition harness leads 11 Drain preservative oil from sump 12 Attach a warning tag to the throttle control in cockpit stating that engine has no lubricating oil 13 Drain all fuel from fuel injector then pump oil into the fuel injector at five PSI until injector is full do not drain the injector after fiushing 14 Lubricate aircraft in accordance with instructions given in the Lubrication Guide 15 Tape or cover all openings battery charge fully store cool place 17 Raise aircraft to remove weight from the tires and block up the wheels CAUTION If weiqht is not removed from tires rotate wheels to a new position at least once each 30 days to prevent flat spotting the tires 18 See appropriate TEXTRON LYCOMING Service Bulletin for engine preservation Attach warning placards if preservation procedures make engine inoperabl
563. t if the gear switch is inadvertently placed in the UP position during the landing roll WARNING Do not turn knurled knob on back of switch housing Whitmal General Switches when disconnecting switch from electrical connections This is airspeed adjustment knob NOTE Refer to proper electrical schematic when replacing with switches from another manufacturer CAUTION During Pitot Static System Inspection compensating pressure MUST be applied to pitot side of A S Safety switch diaphram when static presssure is applied Failure to equalize pressure on diaphram could cause it to rupture 12 98 MOONEY AIRCRAFT CORPORATION 32 60 04 SQUAT SWITCH ADJUSTMENT 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 aircraft is on ground Adjustment of squat switch is accomplished as follows 1 Raise aircraft on jacks 2 Remove safety wire from adjustment nuts on Switch 3 Adjust switch body until switch just closes 4 Check switch by slowly lowering aircraft to ground Switch should now be open 5 Resafety adjustment nuts 32 80 00 MISCELLANEOUS 32 81 00 LANDING GEAR SHOCK DISC INSPECTION 1 Aircraft with full fuel load and weight on landing gear A Main gear shock discs See Fig 32 21 1 Check gap between retaining collar A Fig 32 21 and top retaining plate B Allowable ga
564. t 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 prior to wiping Never wipe while dry B Remove grease or oil with a soft cloth saturated in kerosene CAUTION Never use gasoline benezene carbon tetrachloride acetone fire extinguisher fluid de icer fiuid 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 antistatic plexiglas cleaner D Check door seals for damage that could cause leakage E Check cabin and baggage door mechanism for good working order 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 Accumulation of dirt and within the engine compartment creates a fire hazard and hampers inspection 12 98 AIRCRAFT CORPORATION M20J SERVICE AND MAINTENANCE MANUAL A Wash down engine cowling and engine CAUTION compariment using nonflammable solvent Never apply furniture polish to interior ane DA engine and engine compartment furnishings Most poslishes contain solvents solvents on interior plastics When using 4 CABIN INTERIOR commercial cleaning and finishing compounds Us
565. t 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 Q11 into conduction through the bias network R56 R57 CR17 and CR22 thus illuminating DS9 The signal FLASH wiil however remove this drive signal as the flasher cycles thus flashing DS9 A 28 VDC signal applied to HIGH VAC OVERRIDE will bypass the above network and drive Q11 into conduction regardless of the state of LOW VAC INPUT Similarly TEST will drive Q11 into conduction regardiess of the state of LOW VAC INPUT The channel High Low Vac does not dim 4 MC3302 22 H27 NIKLAS DS4 LMPPOS 4 7327 DIMOUT 4 2 i t o i 24 39 06 12 98 18 SERVICE AND MAINTENANCE MANUAL FLASH CR19 VMA4GG5 CRI CR22 1446565 114605 CR4 IET HIGH VAC GUERRIDE b TEST CRZ1 1H4685 FIGURE 5 0 VAC 7 0 ALTERNATOR LOW VOLTS OVER VOLT The Alternator Low Volts Over Volts circuits are shown in Figure 6 This channel is designed to accept two signals the 28 VDC signal LOVERRIDE from the overvoltage tripped output on the left alternator regulator and signal derived internally that LOW VOLT SET R60 24 40K 194005 1 680001XXX 3 680001Xxx FIGURE 6 ALTERNATOR LOWVOLT
566. t warning light just comes on see Section 24 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 1 2 needle width Outboard float may be adjusted if required for 1 2 and 3 4 gauge readings 5 Finish filling tank and verify total quantity less unusable fuel M20J SERVICE AND MAINTENANCE MANUAL 28 43 02 FUEL QUANTITY GAUGE ADJUSTMENT Approx S N 24 1051 THRU 24 TBA Cluster gauges installed on MID 1981 aircraft 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 reads if intermediate F indications are out of tolerance as tank is filled adjust pot marked gain for correct calibration 28 90 00 MISCELLANEOUS 28 91 00 TROUBLE SHOOTING When trouble shooting check from the power supply to 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 TROUBLE PROBABLE CAUSE REMEDY Fuel gauge not indicating Broken wire Check and Repair Faulty transmitting unit Replace Check and reset Check ground connection at transmitter Check and repair Open circuit breaker Check and service tank Fuel gauge in
567. tal to metal contact 3 Remove the extruded sealant from the wing surface after instailing the fasteners 28 12 00 FUEL TANK LEAK REPAIR 1 Leak Description It is necessary to periodically inspect the fuel tanks Inspection is particularly important in confined areas of the aircraft that are not exposed to the airstream Identification classification of fuel leaks that occur in both confined and open areas is necessary to differentiate between those leaks that require repair before flight and those which do not constitute a fiight hazard The size of the wetted area around a leak is an indication of the leak intensity All fuel leaks must be recorded by describing he and intensity the leak in the aircraft log ook 2 Classification of leaks as to Intensity and Location Refer to 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 1 Slow to heavy seeps occuring in open areas such as wing surfaces exposed to the airstream are leaks which do not constitute a flight hazard and need not be repaired prior to flight providing the condition causing the leak cannot result in a leak of greater
568. tallation of next larger diameter rivet than the rivets in the original pattern 100 CONICAL WASHER WET PRIMER SUBSTRUCTURE NEXT OVERSIZE RIVET 5 51 14 SCARF EDGES OVERSIZE HOLE REPAIR FIGURE 51 14 12 98 SERVICE AND MAINTENANCE MANUAL 51 14 00 HORIZONTAL STABILIZER amp VERTICAL FIN REPAIR LEADING EDGE SKIN REPAIR The horizontal stabilizer vertical fin leading edge interiors are inaccessible near the tailcone To repair damage in these areas cut standard 3 0 inches by 6 5 inches access hole in the lower side of the stabilizer leading edge and close the access hole by installing inspection cover P N 913000 501 51 14 02 51 14 01 MAIN SPAR REPAIR OUTBOARD OF STA 9 00 Repair damage to the horizontal stabilizer main spar by straightening the damaged area and inspecting it carefully for cracks If cracks are formed stop drill or remove cracked area 1 Repair damage between STA 9 00 and STA 34 0 on the spar upper flange and between STA 9 00 and STA 40 0 on the spar lower flange with a splice angle formed from 070 AISI 4130 steel condition N The splice angle flanges must be as wide as the original spar fianges The splice angle must be long enough to install 11 AD4 rivets through the skin and 11 rivets through the spar web on each side of the damaged area see Figure 51 15 VIEW A Prime splice angle before riveting it to spar Pick up five existing rivet holes and dr
569. teel structure with degauser to remove residual magnetism Recommend Armature Growler to degause steel structure NOTE Refer to S B M20 150A Instruction for degausing procedures NOTE Check for outside magnetic influences if excessive compensation is required 34 22 01 MAGNETIC COMPASS TROUBLE SHOOTING TROUBLE PROBABLE CAUSE REMEDY Excessive card error Compass not properly Compensate instrument compensated External magnetic interference Locate magnetic interference and eliminate if possible Excessive card oscillation Improper instrument mounting Align instrument Insufficient liquid Replace instrument 34 22 00 12 98 8 SERVICE AND MAINTENANCE MANUAL TROUBLE cont Sluggish card Liquid leakage Discolored luminous markings or discolored damping liquid Defective light 34 23 00 M20J PROBABLE CAUSE Weak card magnets Excessive pivot friction or broken jewel Instrument too heavily compensated Loose bezel screws Broken cover glass Defective sealing gaskets Age Burned out lamp or broken circuit ARTIFICIAL HORIZON MOONEY AIRCRAFT CORPORATION REMEDY Replace instrument Replace instrument Correct excess compensation Tighten screws Replace instrument Replace instrument Replace instrument Check lamp or wiring continuity ave The vacuum powered artificial horizon gyro indicates aircraft attitude relative to straight and level fl
570. tes Gypsum Catalyst Epoxicai 606 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 12 98 SERVICE AND MAINTENANCE MANUAL 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 air intake assembly The manufacturer s bulletins shall be followed for all mixing ratios and preparation prior to apptication 2 General A The configuration of repairs are shown for flat surface areas for simplicity however the same techniques can be used for contoured surfaces Contoured repairs will require additional considerations and the proper shaping of the backup plates used for camping the laminates together during the curing cycle B The degree of laminate chamfer and size will vary based on accessibility shape of part and the extent of damage 51 15 01 CRACKS IN SURFACE AREAS 1 Stop dril all cracks per standard aircraft procedure FINISHED SURFACE M20J MOONEY AIRCRAFT CORPORATION 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
571. the new cylinder and valves C Connect all lines io proper fitting and connect control cable 3 to the arm 4 on reducer valve D Charge the cylinder if required to the correct pressure see recharging table on Figure 35 2 E Place the pilots contol lever knob to the open position and plug on oxygen mask into the pilots outlet to check for proper system operation F Repeat this checkout procedure for all outlets G Test the system for leaks per leak test check paragraph 35 00 02 D H Reinstall the radio compartment access door NOTE Oxygen cylinders must be hydrostatic tested in accordance with DOT Code of Federal Regulations Title 49 chap 1 para 173 34 CAUTION All oxygen cylinders MUST be replaced every 10 000 recharge cycles NOTE Maximum life for composite oxygen cylinders is 15 years NOTE Maximum life for light weight steel oxygen cylinders is 24 years Filling pressures will vary due to ambient temperature in the filing 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 properly filled cylinder Fill to pressures indicated on FIGURE 35 2 for ambient temperatures AMBIENT FILLING PRESSURE TEMPERATURE PSIG 0 1650 10 1700 20 1725 30 1775 40 1825 F s AMBIENT FILLING PRESSURE TEMPERATURE PSIG 50 1875 60 1925 70 1975 80 2000 90 2050 ED a OP AE
572. the stall warning acurates by about 5 MPH of indicated air speed The only way to test the accuracy of the setting is to fly the airplane into a stall noting the speed at which the warning horn comes ON and the speed at which the FULL stall occurs 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 altemate adjustments and test flights before the desired setting can be reached The stali warning should actuate at no less than 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 trimmed to 1 5 times the stall speed The switch setting 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 REMEDY If circuit breaker persist in tripping check for grounded circuit Check for continuity Replace switch Replace horn Replace switch 27 95 01 17 MOONEY AIRCRAFT CORPORATION 27 96 00 SPEED BRAKE SYSTEM A Speed Brake System is currently optional equipment installed on some M20J aircraft The manufacturer Precise Flight Inc can provide detail paris and maintenance information for the carirkige assembli
573. ties 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 consists of a visual inspection of propeller engine and aircraft general condition including a preflight inspection as 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 lubrication and service requirements Inspection should be extensive enough to detect any damage or condition which might jeopardize flight safety After 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 S N 24 0001 thru 24 3153 3 Inspect engine compartment for evidence of fuel ail or exhaust leaks 4 Check securiy 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 6 inspect windshields and windows for crazing cracks and scratches 7 Check contro systems for binding excessive freeplay and damage 12 98 8 Check pitot and static systems for obstructions
574. tion 27 20 00 6 stabilizer parallel with aircraft center line C Clamp pilots rudder pedals A Figure 27 3 in neutral position D Adjust Rod Eng bearing B Fig 27 3 approximately 9 11 turns out to start E Adjust rudder control tube C at rear tailcone bulkhead bellcrank Figure 27 5 approximately 6 turns out at starting point F Adjust rudder control tube D Figure 27 6 rod end bearing at 2 11 turns out to start NOTE Rudder bellcrank aft tailcone should be modified per 51 20 44 G Adjust Rod End Bearing B Fig 27 3 to position Rudder 1 to the right 12 98 SERVICE AND MAINTENANCE MANUAL M20J MOONEY AIRCRAFT CORPORATION H Unclamp rudder pedals right and left I Adjust rudder stops paddles M Figure 27 8 J Rudder stop limiter R Fig 27 8 may be bent so that rudder travel is 23 degrees 1 0 degrees to obtain clearances and contact with stops M NOTE On aircraft S N 24 1464 amp ON steering stops 3 should be adjusted so 020 clearance exists between adjustment stop 3 and gear truss assembly 4 Figure 27 4 when rudder is at extreme left and right travel position K After setting NLG steering stops retighten all jam nuts bolts and secure recheck ali travel limits NOTE Measure rudder travel with travel board on rivet line at station indicated on travel board GSE 030005 and with longitudinal trim stabilizer set in the 0 degree position Sta 26 50 is
575. tion 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 drill may be closed by welding with the inert gas shielded arc method B Nicks and drill marks that are no longer than 1 8 and do not exceed four percent of wall thickness in depth after cleanup may be smoothed out and reprimed Nicks holes and cracks that will clean up with a 20 drill may be drilled and repaired per item A 340034 7 TENSIDN FITTING TENSION FITTING REPLACEMENT FIGURE 51 4 12 98 51 12 01 MOONEY AIRCRAFT CORPORATION C The repair of weld beads on heat treated assemblies may be accomplished without reheat treatment within the following limits 1 The repair bead will not exceed 375 in length or 1 3 of total length of weld whichever is the lesser 2 Only one repair per weld bead is allowed 6 REPAIR OF SPOT WELDS Failed spot welds on aluminum may be repaired by installing an AD470 4 rivet through the weld if the damaged area will clean up with a 30 drill 7 DENTS Small dents which do not exceed five percent of the diameter of the tube in depth and are no longer than one half the tube diameter are acceptable 51 12 02 TAILCONE REPAIRS 1 LONGERON SPLICING Use procedure outlined in curent 43 13 1 curent revision for repairing and splicing tailcone longerons Figure 51 5 shows acceptable methods for splici
576. tion 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 ring leads and check insulation resistance between slip rings reading should be at least 5 megohms 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 Disconnect hamess at timer and check ground connection with ohmmeter from Pin A 12V Terminal G 24V Test timer per Section 30 63 00 If timer is faulty repair or replace it but insure that short causing original failure has been located and corrected Trace wiring from power source to timer input Insure that good electrical contacts are made at each connection in circuit 30 61 02 9 MOONEY AIRCRAFT CORPORATION M20J TROUBLE cont Radio noise or interference with De Icers Boots ON Cycling sequence not correct Rapid brush wear or frequent PROBABLE CAUSE Loose or poor connection timer to De Icers Timer cycles erratically Brushes arcing Loose connection Switch or circuit breaker faulty Wiring too close to radio equipment or associated wiring Crossed connections between timer and De Icers Brush block out of alignment SERVICE AND MAINTENANCE MANUAL REMEDY If trouble occurs only pa
577. tional The hour meter operates operates from the electric tachometer Hobbs meter directly from the alternator Aux terminal through a may be installed as an option fused wire S N 24 1418 and later models hour meter 4 Cigar Lighter A cigar lighter is mounted in the right instrument panel 24 39 00 TROUBLE SHOOTING CHARTS 24 39 01 ALTERNATOR TROUBLE SHOOTING TROUBLE OBA USE REMEDY Alternator overcharges battery Regulator faulty Check bus voltage with engine running battery uses excessive water Observe aircraft ammeter Ammeter should indicate near zero after ten minutes of engine operation Replace voltage regualtor if defective ALT FIELD circuit breaker trips Circuit shorted in wiring Disconnect lead from pin A or 1 of regulator and reset circuit breaker If circuit breaker trips check wiring Repair as required if breaker does not trip replace regulator Reconnect lead to regulator Set MASTER switch to ON and check for 12V at pin A or 1 of regulator Repair wiring if no voltage is present 24 0001 thru 24 2999 Pin 5 for 24 3000 THRU 24 24 0001 thru 24 2999 Set alternator field Master switch to ON amp check for 24 volts at Pin 5 of regulator for S N 24 3000 thru 24 TBA ALT circuit breaker trips Short circuit in wiring Disconnect lead from 4 post of f alternator and reset ALT circuit breaker If circuit breaker trips check wiring between alternator and circuit b
578. to prevent wing tip twisting Use a temporary support or locator pins to maintain correct wing tip position 2 Rivet new tip rib to main and rear spars 3 Locate new skin and drill rivet holes through skin to match existing holes in ribs and stringers 4 Rivet skin to rib at STA 193 5 5 Roll skin back on lower wing surface to gain access to stringers for rivet bucking Rivet skin to upper siringers RU 6 Rivet skin to tip rib starting at leading edge Buck rivets as far back as possible M20J MOONEY AIRCRAFT CORPORATION 7 Install cherrylock CR 2248 blind rivets in places inaccessible for rivet bucking Add one extra countersunk blind rivet between every other pair of cherrylock rivets 51 13 07 WING SKIN PANEL REPAIR Repair wing skin panels as prescribed in AC 43 13 1 current revision unless an entire skin panel is to be replaced Install new skin panels to exactly match the original skin installation Preformed skin panels may be obtained from the Mooney Service and Marketing Centers 1 Damaged Dimple Repair Around Inspection Holes 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 extends beyond the radius of the dimple into the skin and c when there are four or more cracked dimples around an inspection hole see Figure 51 11 To repair damaged dimples a cut a doubler from the same material a
579. ts that may be utilized to obtain proper rigging See Figure 52 1 Removal of the interior door panel will be required to gain access to the adjustment points Adjust cabin door linkage to satisfy requirements listed below A Latching pin must contact striker plate on door frame the full circumference of pin when mechanism is in full latched position B Laiching pin must clear striker plate when opening or closing the door with latching mechanism in full open position C As the lower link 1 and bellcrank arm 2 Fig 52 1 travel over center the spring 3 is to be compressed to 1 000 030 Washers be added between spring and link or 310294 501 housing assembly 4 to comply with items B and C D The lower link 1 and bellcrank arm 2 in full locked position should be overcenter a minimum of 3 inches Figure 52 1 NOTE It is not necessary that the lower link 1 contact the upper link 5 Figure 52 1 E The outside handle is to be flush with outside skin when mechanism is in full latched position 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 52 12 00 CABIN DOOR SEAL The cabin d
580. uat switch is incorporated on the left main landing gear assembly of above listed Serial Numbered Aircraft The following operational check should be made 1 Raise aircraft on jacks see Section 7 10 00 2 With master switch ON place gear switch in UP position Gear should retract normally 3 Extend gear to down and locked 4 Refer to Section 32 60 04 for squat switch adjustment procedures 32 30 02 MAIN LANDING GEAR SYSTEM RIGGING 32 30 03 AVIONICS PRODUCTS 24 0378 thru 24 2999 amp 24 3079 thru 24 TBA 1 Raise aircraft on jacks and remove 3 beily access panels located consecutively just aft of nose wheel well or the one piece belly access effective 24 1418 and later aircraft DISCONNECT ALL GEAR DOORS 2 Disconnect electrical power from landing gear actuator by pulling actuator circuit breaker Make sure landing gear warning light circuit breaker is pushed IN 3 Disconnect main gear retraction tubes L Figure 32 5 at inboard bellcranks M Loosen locknuts E Disconnect nose gear retraction tubes F Fig 32 3 at main retraction bellcrank A Fig 32 10B Loosen locknuts G Fig aan Disconnect rod end bearing on barrel nut D from bellcrank A at N Fig 32 10B NOTE Do not loosen Heim rod end bearing from barrel nut D on Avionics Products actuator 32 30 02 10 M20J M MAIN GEAR RETRACTION TUBE ADJUSTMENT POINTS FIGURE 32 5 MOONEY AIRCRAFT CORPORATION Disconnect nose
581. uated and are controlled by a spring 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 thru 24 2999 or a 70 amp 28 volt altemator a voltage regulator and a 24V 10 AMP HR battery 24 3000 thru 24 TBA The aiternator system has an overvoltage protective relay and an MOONEY AIRCRAFT CORPORATION overvoltage annunciator light Circuit breakers or circuit breaker switches protect the electrical wiring and equipment from overloads Standard electrical equipment includes 1 250 watt landing light 24 0001 thru 24 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 electric starter an electric gear retraction system with manual extension override an electrical flap system and an electric cowl flap actuating system f 5 00 05 INSTRUMENTS All flight instruments are in the shock mounted flight panel Engine instruments are in the co pilot s panel The pitot 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
582. uid or any other questionable fluid to clean acrylic windows These solvents will soften or craze the surface NOTE Minor scratches or abrasions may be polished out by using acrylic resurfacing kits ie Micro Mesh available from aviation accessory suppliers WINDSHIELD AND CABIN WINDOWS The removal and installation of windshield and windows are accomplished in the following paragraphs 56 20 00 56 21 00 WINDSHIELD 12 98 M20J SERVICE AND MAINTENANCE MANUAL 56 21 01 WINDSHIELD REMOVAL 1 The aluminum retainer 1 at bottom of windshield 2 must be removed by drilling out the rivets attaching it to the cowl deck 3 reference Figure 56 1 A putty knife or thin aluminum strip will be necessary to work underneath the top skin 4 and the side post skin 5 break the sealant bond between the acrylic and the skins CAUTION Exercise care during this operation to avoid scratching the acrylic Considerable effort be required to break the bond 2 Carefully pull the windshield away from its location starting at the lower portion and work it loose as the sealant bond is broken around the edge of acrylic When windshield is removed all residual sealant 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 removing the excess sealant 56 21 02 WINDSHIELD INSTALLATION When old sealant is removed brush
583. uit is shown in Figure 8 This channel is designed to accept a 28 VDC signal to illuminate an indicator channel and provide for dimming of that channel as well Dimming is accomplished in a manner similar to that described for low fuel channel above The input XINPUT is applied through CR35 and R84 to drive Q15 into saturation and light DS X TEST is applied through CR36 and R84 to also drive 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 bright When a dimmed channel is extinguished and then reactivates it will reactivate bright Each channel to be dimmed is driven by a transistor in this case Q15 which returns the lamp to ground through two parallel paths The path to provide a dim indication is through resistor R85 which reduces the brilliance of the lamp In the bright mode R85 is shorted by Q14 and CR34 which provide a 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 R90 and R91 as well as the signais DIMBIAS and DIMINPUT if the channel is active DIMINPUT will be near ground and with DIMBIAS near 3 VDC 24 39 06 18 MOONEY AIRCRAFT CORPORATION Q14 DIMOUTPUT K 286839 CR 34 iN488BS 915 6 8 K A INPUT DIMINPUT 242819 M20J SERVICE AND MAINTENANCE MANUAL C1
584. uits condition compressed or extruded rubber 3 Tail skid damage or damage to bulkhead that attaches tail skid 4 Propeller strike marks or other visual damage 5 Engine or engine mount damage 6 Nose landing gear leg assembly damage near steering lugs 7 Pilot Co Pilots seat adjustment supports tubes bent from excessive G loads If any evidence of damage or abnormal visual observations are found it is recommended that a thorough inspection of all the above areas be done and repairs be made as necessary Contact FAA personnel for incident report requirements 12 98 SERVICE AND MAINTENANCE MANUAL M20J MOONEY AIRCRAFT CORPORATION CHAPTER 33 LIGHTS MOONEY AIRCRAFT CORPORATION M20J SERVICE AND MAINTENANCE MANUAL CHAPTER 33 LIGHTS LIST OF EFFECTIVE PAGES CHAPTER SECTION SUBJECT dco PAGE 2 2 DATE 33 Effectivity 12BLANK 12 98 33 Contents 3 4BLANK 12 98 93 00 0055 i i uc ox Be a Bg ue 22 0 5 12 98 33 21 02 2 ak 4 EE SS m 0 lt 12 98 33 22006 cw To i d 0 a 12 08 93 23 00 de ar ueca ue uc E la 222 lt 12 98 93 41 01 Ios EN gt Q 5 12 98 EE x oe AOS 1298 33 42 00 fi 12 98 334301 S oso oo vv 32 soe 12 98 12
585. uminum sheet Formed angle doublers 2 are nested inside the main spar channel and riveted to the web The rear spar 3 is an extrusion used to attach the aft end of the sectioned ribs 4 The stub spar 5 is also formed from sheet aluminum 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 The main spar doublers and angies 7 8 and 9 provide attach points for the stinger and the horizontal stabilizer spar Refer to Figure 55 3 The skins 10 are stretch formed in 2 sections and riveted to the ribs and spar The three rudder attach fittings 11 are mounted to the rear spar extrusion 55 30 01 VERTICAL STABILIZER REMOVAL The vertical and horizontal stabilizer are removed as a unit with the stinger assembly Remove the fairing located on the tailcone which covers the gap between tailcone and empennage Section 53 40 02 describes the attaching points for the complete empennage assembly Refer to this section for removal of ihe empennage assembly from the airplane VERTICAL STABILIZER ASSEMBLY FIGURE 55 3 12 98 M20J MOONEY AIRCRAFT CORPORATION 55 30 02 VERTICAL STABILIZER INSTALLATION Refer to Section 53 40 02 for installation 55 40 00 RUDDER The rudder on the M20J is constructed the same as the elevator with stretch formed skins 1
586. upling for tighiness and security 4 dry air pump requires no maintenance between replacement Replacement is recommended at 500 hours operating time It is recommended that stand by vacuum system operating time be documented 5 It is recommended that if the Stand by Vacuum System is not used regularly that every 90 days approximately the Stand by Vacuum System should be tumed on in flight for 20 30 minutes to get the pump and drive motor warm enough to dry out any condensation that may have accumulated The exhaust port of the dry air pump is routed into the housing of the electric motor to assist in purging moisture and debri from the motor assembly 12 98 M20J SERVICE AND MAINTENANCE MANUAL 37 41 00 OPERATIONAL PROCEDURES The Optional Stand by Vacuum pump for the M20 is located in the tailcone Its location is standard but can RUN depending on optional equipment installed on aircraft The Stand by pump is to be used only as needed when the main Vacuum pump malfunctions The VAC annunciator light will illuminate RED either flashing low vacuum or steady high vacuum when this situation occurs If annunciator light is flashing RED push STBY VAC switch ON and annunciator light Should extinguish as stand by vacuum system takes over for all instrument operation s if annunciator is steady RED monitor flight instruments with non vacuum gauges and continue with flight if feasible or land and have vacuum sytem
587. urn right hand variable resistor on transfer standard slowly counter clockwise until right low fuel light just turns on If necessary turn variable resistor clockwise to extinguish low fuel light Do not adjust annunciator calibration screws Repeat for left low fuel 4 Tum off master switch and remove old annunciator assembly after disconnection of harness and transfer standard unit 5 Install new annunciator and connect calibration transfer standard to annunciator panel and harness plug Remove front plate and legend on new annunciator panel to expose the Norm Cal switch and the Left and Right trim potienometers Switch must be in Cal position 6 Adjust left and right annunciator fuel calibration screws clockwise not the adapter variable resistors until low fuel lights just turn on if necessary turn annunciator calibration screw counter clockwise to extinguish low fuel light 7 Remove calibration transfer standard reconnect plug to annunciator panel set switch to Normal position install annunciator front panel and install glareshield B Alternate method for calibration without L A I unit If calibration transfer standard P N 500D0045 or 9500324000 is not available use the following method to calibrate low fuei warning P N 24 32 00 7 MOONEY AIRCRAFT CORPORATION 1 Remove glareshield and remove annunciator assembly 2 Install and connect new annunciator assembly lea
588. urs irst 1 Clean the dry type induction air fiter with compressed air Ref to Section 12 20 01 Replace the filter if it has a damaged housing torn element or damaged gaskets 2 Reverse the air f ter removal procedure for reinstallation Make certain that the filter is tightly sealed and securely fastened in place 71 61 00 AIR INTAKE DUCT REPLACEMENT Wnen the air induction duct must be replaced it is essential that the duct be positioned exactly as the installation to prevent interference with the cowling 12 98 MOONEY AIRCRAFT CORPORATION M20J SERVICE AND MAINTENANCE MANUAL CHAPTER 72 ENGINE SERVICE AND MAINTENANCE MANUAL M20J CHAPTER SECTION SUBJECT 72 Eff Contents 72 00 00 72 50 00 CHAPTER SECTION SUBJECT 72 00 00 72 50 00 CHAPTER 72 ENGINE LIST OF EFFECTIVE PAGES PAGE 12BLANK 3 4 TABLE OF CONTENTS SUBJECT General Lubrication 12 98 MOONEY AIRCRAFT CORP DATE 12 98 12 98 12 98 PAGE ORATION 72 EFF CONTENTS 1 2BLANK MOONEY AIRCRAFT CORPORATION 72 00 00 GENERAL Refer to TEXTRON Lycoming Operators Manual No 60297 12 and Overhaul and Maintenance Manual No 60294 7 for detailed information on above topics 72 50 00 ENGINE LUBRICATION SYSTEM MAINTENANCE The engine lubrication system is a full pressure wet sump system with a gear driven pump An oil cooler attaches to the firewall on the M20J model The oil fi
589. ust cavity B Disconnect parking brake control at parking brake valve arm C Disconnect and cap hydraulic lines D Remove parking brake valve S N 24 0758 THRU 24 TBA Refer Figure 32 18 A A Remove both fittings 1 from valve housing 7 springs 8 will come out with the fittings B Remove poppet valves 2 and pins 3 from housing by bumping on table top C Remove both fittings 4 from end of housing D Remove snap ring 5 from end of camshaft assembly 6 E Carefully remove camshaft assembly 6 from housing F Inspect all components for damage nicks grooves etc G Clean all parts with cleaning solvent Federal Specification No PS 661 H Replace all o rings 9 I Reassemble parking brake valve in reverse sequence of disassembly J Connect valve assembly to the hydraulic lines K Bleed system and service hydraulic reservoir with hydraulic fluid as described in Section 12 20 04 Disassembly amp assembly parking brake valve S N 24 0001 thru 24 0757 Refer to Figure 32 18 B A Remove rivets or screws 1 attaching valve arm 2 to valve body 3 and stem 4 B Remove end plug 5 and square out gasket 6 C Withdraw valve stem assembly 7 and remove o ring packings 8 amp 9 from valve body D Clean all parts with cleaning solvent Federal Specification No PS 661 E inspect valve stem 4 for nicks scratches burrs and grooves F Inspect valve
590. ustment and reinstallation instructions E M Perform landing gear operational check per Section 32 30 01 4 FUEL SYSTEM INSPECTION A Inspect fuel tank exterior for evidence of fuel seepage and stain B Drain tank and inspect tank interior when seepage is 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 selection smooth operation and leakage in OFF position F Check gascolator for leakage check sump for sediment water or other contamination Inspect fuel filter clean or replace 5 20 06 14 M20J 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 security of mounting and condition of wiring and electrical connections I Check fuel tank filler caps for O ring condition cleanliness security and condition of servicing placards Ref 28 00 01 5 EXTERIOR INSPECTION A Thoroughly clean aircraft exterior B Inspect fuselage exterior surfaces for corrosion damage loose or popped rivets dents cans scratches cracks and deteriorated paint C Inspect windshields and windows for cracks crazing scratches condition of seals and security of installation D Inspect wings flaps and ailerons for corr
591. vates the geared motor The switch has three positions a center OFF an up CLOSED and a down OPEN position The may be ositioned to any angle by selecting the switch either P or DOWN until the desired position as shown on the position indicator 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 full open or full closed position A cowl fiap position indicator is located on the cockpit console adjacent to the flap switch The indicator is operated by a cable connected to the actuator arm and routed to the indicator on the console 24 0001 thru 24 3410 A potentiometer electrically controls the LED indicator for 24 3411 thru 24 TBA The cowl flaps are rigged for a flush contour between the cowl flaps trailing edges and cowling when in the closed position Adjust per following procedures 1 With the cowl flaps open adjust the linkage rods from the idler arm to the cowi flaps to their maximum length 2 Close the cow flaps and measure the distance between the cowl flaps trailing edges and cowling 3 Open the cowl flaps and readjust the linkage rods decreasing the length by the measured amount 4 Close the cowl flaps and ensure that cowl flaps are not outside the cowling contour or that the cowl flaps are not preloaded against the nose gear box Readjust as required 71 11 02 11 MOONEY AIRCRAFT CORPOR
592. ve propeller refer to section 61 00 10 6 Drain engine oil sump 7 Disconnect the following Vacuum line B Cabin heat ducts at engine C Fuel vent lines at firewall D Tachometer drive shaft if installed E Oil temperature bulb F Oil pressure line G Manifold pressure line H Cylinder head temperature bulb I Breather hose 8 Disconnect the following control linkage A Throttle control B Propeller govemor control C Mixture control D Alternate Air 9 Disconnect ignition switch wires from magnetos WARNING Ground magneto breaker points 10 Disconnect engine ground strap 11 Disconnect voltage regulator wires opt 12 Disconnect alternator and starter wires 13 Disconnect heater muff and exhaust tail pipe 14 Disconnect fuel line at engine fuel pump 15 Shore up fuselage at tail skid using shoring stand to prevent tail from dropping 16 Attach hoist to lifting eye at top of crankcase Slightiy lift engine to relieve weight from engine mounts 71 00 01 6 NOTE IDENTIFY AND MARK SEQUENCE OF WASHERS ON RUBBER BISQUITS AS WELL AS THE ORIENTATION OF THE BISQUITS FOR EACH MOUNTING POSITION 17 Slowly raise engine Be sure that all lines hoses and wires are free 71 00 20 ENGINE INSPECTION amp REPAIR For specific engine inspection and overhaul instructions consult engine manufacturers overhaul manual and service instructions Refer to Bendix Maintenance procedures for magnetos 71
593. ve transmitter from rib B O B Transmitter removal 1 Gain access through lower access cover outside of tank area 2 Locate amp remove transmitter wires 3 Remove six screws attaching transmitter to rib 4 Remove transmitter from rib 2 For REINSTALLATION reverse the fuel quantity transmitter removal procedure A A calibrated certified torque application devise must be used to install the fuel quantity transmitters 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 relax as the gasket flows to a normal condition RETORQUE JUST RESTORE THE 20 25 INCH LBS DO NOT OVER TORQUE 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 inboard transmitter flange and not under the mounting screw head F System voltage should NOT BE APPLIED to the transmitter terminal The exicitation the fuel quantity indicator must be current and voltage limited and incapable of causing ignition of fuel vapor if transmitter wire is inadvertenily shorted to 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
594. vention A Thoroughly examine unpainted metal surfaces at inspections and check corrosion when found 20 00 02 6 M20J 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 wams of corrosion below the paint layer C Use only liquid non alkaline soap to wash the exterior airframe Cover vent scoops when the aircraft is being washed Rinse aircraft exterior 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 drive water from crevices before wiping the exterior surface dry after washdown E Hangar the 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 FAA Advisory Circular 43 4 addresses corrosion problems and treatment 3 Surface Protection Surface protection of intemal air rame surfaces will not
595. ver on left side of tailcone G Place torque tube pitch trim servo assembly on work bench for removal and replacement of bearing block H Remove components carefully until access to bearing block is obtained install new bearing block and assemble in reverse sequence Reinstall torque tube pitch trim servo assembly into tailcone 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 Wing Flaps General Push pull tubes and bellcranks interconnect the flaps The flaps are operated by an electrical motor driven actuator 1 connected to a jack shaft 2 Figure 21 13 The jack shaft is connected to actuator bracket 3 Figure 27 13 on each flap just outboard of hinges 4 by a push pull rod end bearing 5 and hardware Each flap pivots about four hinges Travel is controlled by limit switches 6 and 7 and stops located at O B hinges Figure 27 13 Flap position is indicated in the cockpit through a cable link system 8 connected to the jack shaft actuator hom 9 12 98 SERVICE AND MAINTENANCE MANUAL 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 t
596. vide servicing and maintenance information on components of the Mooney 201 201LM 205 ATS MSE Allegro Model M20J No avionics equipment Manufacturers or publications are listed due to the many configurations that can be installed in the aircraft These can be obtained from tha repair stations for a particular avionics manufacturer Publications available from Mooney Aircraft Corporation are listed in the Parts Price List and are available ihrough any Mooney Marketing Hervice Center As publications on various components become available they will be added to the list below VENDOR ADDRESSES or PUBLICATIONS ENGINE maintenance publications can be obtained through TEXTRON Lycoming Division Williamsport Overhaul Manual for TEXTRON Lycoming Aircraft Engines Direct Drive Models Manual No 60294 7 Illustrated Paris Catalog Manual No PC 206 for TEXTRON Lycoming 10 360 AIO 360 HIO 360 LIO 360 and TIO 360 series aircraft engines Operators Manual No 60297 12 for TEXTRON Lycoming 360 HO 360 10 360 AIO 360 L1O 380 and TIO 360 aircraft engines Service Bulletins Specify model of engine for which maintenance data is desired PROPELLER McCauley Propellers Obiain publications from McCauley Accessories Division Cessna Aircraft Company 3535 McCauley Drive Vandalia OH 45377 Service Manual No 783630 for McCauley C200 series constant speed propellers Hartzell Popellers Obtain publications f
597. ving off front panel Set switch to Cal 3 Drain fuel from tanks and replace with unusable fuel plus 2 1 2 gallons in both tanks 4 Turn on master switch and adjust calibration pots to position where low fuel lamps just turn on for left and right tanks 5 Turn OFF master switch set annunciator Cal switch to Norm position install annunciator front and install glareshield 6 aircraft 5 RAM Air Light Warning Circuit Annunciator Panel The light illuminates on the annunciator panel when the RAM air door is open and the gear is extended 6 Hi Low Voltage Warning Circuit Annunciator 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 obtain a 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 circuit board till flashing light just 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 first Increase RPM until light goes out and note voltage Decrease RPM until light flashes on and note voltage Light should come on at a voltage between 12 4 and 12 6 volts 24 0001 thru 24 2999 26 4 to 26 6 volts 24 3000 thru 24 TBA 24 34 00 POWER PLANT CIRCUITS 1 Starter Ignition Circuit The starter Ignition s
598. volts with no fuel flow and increasing to near bus voltage at fuil flow 2 If no increase in voltage is seen on WHITE wire as flow increases or if too high a voltage indication is seen with no flow change transducer 3 If RED wire does not have bus voltage check wiring from transducer to Pin 3 of indicator 4 If BLACK wire is not grounded check wiring from transducer to Pin 6 of indicator 3 ERRATIC INDICATIONS A Check wiring for loose 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 inscribed after the serial number 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 Whenever transducer or indicator is replaced care must be taken to set indicator switches to match transducer If after making these checks you still do not isolate the problem or do not find a problem contact the Product Support Department of Mooney Aircraft Company for further assistance 5 TROUBLESHOOTING THE TRU FLOW 1 ALCOR FUEL MANAGEMENT SYSTEM If problem is determined to be in the indicator and all transducer and wiring checks have been made contact Alcor Inc 10130 Jones Maltsberger
599. w signal in a stem type regulator to convert the air pressure into a fuel pressure This fuel pressure fuel pressure differential 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 injection controls do not include an engine primer Fuel will be sprayed into the intake manifolds whenever there is pressure in the fuel system and ihe mixture control is open It is necessary therefore to exercise caution when operating the boost pump to be sure that the mixture control is in the IDLE CUTOFF position 28 25 00 FUEL SELECTOR VALVE REMOVAL amp INSTALLATION 1 For S N 24 0001 thru 24 0377 The fuel selector valve is below the left floorboard just aft of the firewall A Disconnect right and left inlet lines at valve body B Disconnect outlet line at valve body C Remove clevis pin fro
600. wires GAUTION Do not over tighten Over tightening will cause cracking of the aft instrument housing 37 13 00 7 SERVICE AND MAINTENANCE MANUAL 37 21 05 ADJUSTMENT 1 Remove switch from instrument Reinstall wires if removed Attach poly vinyl hose T fitting and calibrated gauge to vacuum switch Connect other end of hose to a vacuum source 2 Turn aircraft power on The HIGH LOW VAC light should flash 3 Apply vacuum and adjust source to 4 25 2 In Hg Adjust Low setting screw connector end of switch to Minds the 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 vinyl tube and into ihe fitting where the high setting screw is located and adjust until the HIGH LOW VAC light on annunciator is illuminated 5 After you have completed switch adjustment turn aircraft power off 6 Remove switch from hose and gauge T Reinstall switch in Gyro Reconnect wires CAUTION Crossing the electrical wires on vacuum switch will cause the annunciator lights to act in reverse M20J im MOONEY AIRCRAFT CORPORATION 37 30 00 DRY AIR PUMP REPAIR REPLACEMENT 37 30 01 COUPLING INSPECTION AND REPLACEMENT 1 Remove vacuum pump from engine in accordance with maintenance manual Section 37 11 03 2 If coupling 1 has sheared remove engine coupling drive gear N 2 from engine gear housing and
601. witch has five positions OFF R right L left BOTH and START In the OFF position both magnetos are grounded At the R position the left magneto grounds At the L position the right magneto grounds At the BOTH position both magnetos are HOT and the ignition system is ON Turning the ignition switch to start and pushing in closes the starter solenoid engages the starter and allows the impulse coupling to automatically retard the magneto until the engine is also at its retard firing position The spring action of the impulse coupling is then released to spin the rotating magnet and produce the spark to fire the engine After the engine starts the impulse coupling flyweights do not engage due to centrifugal action The coupling then acts as a straight drive and the magneto fires at the normal firing position of the engine The starter ignition switch is spring loaded to return from START to the BOTH position when released 24 34 00 M20J SERVICE AND MAINTENANCE MANUAL CAUTION Do not operate the starter in excess of 15 seconds or re engage the starter without allowing it time to cool A Low Battery starting procedures Batteries that have been discharged to the point where they will not turn the engine but have sufficient power remaining for other equipment should NOT be jumped with another power source for two major reasons 1 The discharged aircraft battery is not airworthy because it will not have the necessary reserve
602. y as well as storage space M20J SERVICE AND MAINTENANCE MANUAL The empennage attach points 6 are attached to the rear bulkhead 7 with tabs extending forward and attached to the tailcone struciure NOTE Refer to Mooney Service Instruction M20 76 for sealing of tailcone and smooth beliy skin SMJK53 2 TAILCONE STRUCTURE FIGURE 53 2 53 30 00 PLATES SKINS The fuselage tubular structure is covered with aluminum skins after mating to the tailcone The skins are riveted and bolted io support angles formers and brackets These skins are non structural coverings to form the outside contour of the forward fuselage section The skins covering the tailcone are an integral part of the structure Repair or replacement of these skins should be according to AC 43 13 1 current rev SECTION 3 The fuselage assembly and tailcone have panels covers or doors at various locations to provide access to the interior for inspection or maintenance purposes See Figure 53 3 53 30 00 4 The belly skins are removable to provide access to all components and control systems located below the floorboard See Figure 53 3 and table following for component location and identification S N 24 1418 and later aircraft have a one piece fiberglass belly skin NOTE PR 1766 B2 sealant should be used on ail fuselage skin laps to provide a good electrical ground plane 12 98 SERVICE AND MAINTENANCE MANUAL M20J AI
603. ystem is capable of supplying current for simultaneous operation of multiple radios anticoilision lights and navigation lights A shunt type combination gauge gives alternator output and line load in of rated capacity plus bus voltage 24 30 00 D C GENERATION 24 31 01 ALTERNATOR CHARGING SYSTEM MAINTENANCE 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 voltage regulator drive belt circuit breaker or wiring is malfunctioning 24 3000 thru 24 3078 When the loadmeter shows a higher than the alternator output at higher RPM a charging system component is malfunctioning On the plane testing should indicate which component is faulty and needs to be removed from the aircraft for bench testing and repair or replacement The altemator charging system requires no special attention however improper maintenance procedures can damage the altemator and wiring There are Several precautions that must be observed when servicing the alternator system A Be sure the master switch is OFF when repairing the alternator or voltage regulator B When the battery is removed from 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
604. ystem with engine running The ammeter reading will be 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 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 is faulty test it per Timer Check 30 63 00 5 For insulation resistance tests use a megger Meg type insulation tester James G Biddle Company Plymouth Meeting PA or other tester having a 500 VDC 1000 megohm y capacity 6 Defective wiring in propeller mounted components may be indicated by normal current readings in usaq ground checkouts propellers not 001 rotating but low pt with 21 2 E2130 propellers HRL SLIP RING WIRING rotating at cruise E HARNESS RPM BUS BAR 14 VDC 30 00 00 MOONEY AIRCRAFT CORPORATION M20J SERVICE AND MANUAL SLIP RING ASSY PROP DE ICER RC PLSAA A pre GND JKMD10A14 5 5 GND JKMPOSA14 GND JKMP19A14 RC PL12A KMP08A14 B JKMPTO1 A TIMER

SERVICE AND MAINTENANCE-- MANUAL M00NEY AIRCRAFT

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