N162FA 25 Hour Maintenance Form

Date

3

5

2006

-

Flight Hours

95.0

Engine Hours

123.6

Item to be done	Spec.	Done
Inspect Ballast Weight 1. Inspect the 2 screws on the nose cone for security. 2. Inspect the rear ballast weight mount for conditition and cracks. 3. Inspect the ballast weight lock pin and safety clip. 4. Inspect the righthand skid for security and condition.	-	1.3/5 2.3/5 3.3/5
Service Air Filter 1. Clean of any debris with a soft brush and inspect for damage. 2. Spray it with filter cleaner and let it stand for 10 minutes and then thoroughly flush with water. 3. Spray it with filter oil and allow it to stand for 10 minutes and then if necessary reapply a 2nd coat to any white spots.	-	1.3/5 2.3/5 3.3/5
Check Main Battery 1. Electrolite Level 2. Connections 3. With FADEC UNIT 1# ON ONLY, Record Battery Voltage We found our battery in poor health so we ordered a new one from Skygeek.com on 3/6/06 and installed it on 3/11/06 It is to big and we have a call into Gill Battery for a new one	12.7 Volts with the new battery The old battery still had good readings but with a near empty cell we decided to replace it anyways	1. 3/11 2. 3/11 3. 2/11
Grease Main Drive Pulley Care must be taken to ensure that the 3 shots of grease are pumped in very slowly.  Rapid introduction of grease may cause the bearing seals to blow out.	3 shots of Mystik JT-6 Multi Purpose Hi Temp Grease	3/5
Grease Tail Rotor Hub and Shaft 1. Add grease until it comes out near the pitch horns and wipe off excess. Check to see that the grease escape holes in the tail rotor blade tips are open and that grease hasn't pooled up inside the blades. 2. Lightly Coat the Tail Rotor Shaft with Grease between it and the Slider assembly	Mystik JT-6 Multi Purpose Hi Temp Grease	1. 3/5 2. 3/5
Grease Starter Motor Bendix Gear with a small brush paint the gear and around the base of the gear.	Mystik JT-6 Multi Purpose Hi Temp Grease	3/5
Grease Main Rotor Teeter Hub The grease should come through the bearing until it is visible on the outer race of the bearing.  Wipe off excess grease to prevent it from being thrown onto the blades during operation.	Mystik JT-6 Multi Purpose Hi Temp Grease	3/7
Grease Upper Secondary Unit Bearing Our ship has a Pro-Drive Secondary Unit installed that does't require grease until sometime later on or about the 500/1000 hour mark.	N/A	N/A
Measure & Adjust Valve Lash & Inspect Valve Train Valve train inspection prior to valve lash adjustment 1.  inspect spring retainer for changes 2.  inspect valve stem & spring keeper for excessive wear 3.  inspect valve guide for excessive wear 4.  Adjust Valves Tight = T Loose = L Valve Valve Guide Play Valve Lash Cap Clearance Valve Current Measurement Valve Final Adjusted Measurement Cylinder 1 Intake Valve    = .0K .015 .006T N/A - Exhaust Valve  = .0K .015 .006T N/A Cylinder 2 Intake Valve    = .0K .015 .007 .006T - Exhaust Valve  = .0K .015 .007T .006T Cylinder 3 Intake Valve    = .0K .015 .006T N/A - Exhaust Valve  = .0K .015 .006T N/A Cylinder 4 Intake Valve    = .0K .015 .007 .006T - Exhaust Valve  = .0K .015 .006T N/A If any initial measurement is in excess of .008", inspect the lash cap for wear & repeat valve adjustment at one hour intervals until the lash stabilizes. If repeated excess lash is encountered, all related valve train components should be inspected.	1. Note Depth of keeper set 2. normal gap is .020 to .030 3. no wear or gap between the steam and the guide 4. Adjust valves to .005 or no more than a tight .006	1.   3/5 2.   3/5 3.   3/5 4.   3/5
Inspect Cooling System  1. Check entire system, including engine, for any sign of leakage. 2. Check the security of all hoses. 3. Check to make sure all hose clamps are installed past the bead or flare on the end of the adjoining tube or fitting. 4. Re-tighten all hose clamps. 5. Check the hoses, making sure there is no interference with vibrating or rotating parts or any sign of heat damage. 6. Check Coolant Level. 7. Check Coolant with test strip to make sure it's within specs. The test came out with a 3.0 which means it's ok and has a -30 freeze point Cooling system specifications and limits Miniimum Climb-out water temp = 160F Normal operating temp = 165 190F Caution operating water temp = 190 - 215 Maximum operating temp = 215	-	1. 3/5 2. 3/5 3. 3/5 4. 3/5 5. 3/5 6. 3/5 7. 3/11
Inspect Oil System 1. Check entire system for any sign of leakage. 2. Check the security of all oil line connections. 3. Check the lines for proper clearance from heat sources and other parts. 4. Check oil pressure gauge and line for security and proper operation. Oil Pressure Requirements Minimum at idle = 30 psi Minimum at 4250 RPM = 45 psi Maximum at 4250 RPM = 80 psi Adjust warm (180 to 200 F) @ 4250 RPM to 50 - 55 psi	-	1. 3/5 2. 3/5 3. 3/5 4. 3/5
Inspect Fuel System 1. Check the security of all fuel hoses. 2. Check for any signs of leakage on the entire system. Fuel pressure on pump 1 and 2 seperately showed 56 psi	Fuel Pressure 40 psi to 60 Psi	1. 3/5 2. 3/5
Inspect Exhaust System 1. Check entire exhaust system for cracks & leaks. Proper fit of each exhaust manifold to its mating port is important. Proper fit can be verified while idling the engine and positioning your finger approximately ½" away from the exhaust ports.  Test all the way around the circumference of each port for any escaping gases.  If no turbulence is felt within the proximity, the system will be sufficiently leak free at full RPM. 2. Inspect security & condition of all exhaust related shielding.	-	1. 3/5 2. 3/5
Inspect Ignition System 1. Check all wiring, including spark plug wires, for proper mounting & condition. 2. Replace any wires that show any sign of damage.	-	1. 3/5 2. 3/5
Re-torque bolts on: 1. The exhaust manifold flanges. 2. The intake manifolds. 3. Water jacket elbows. Note on Item 3:  We Can't actually get to all the bolts to torque them	1. EM = 120 inch lbs. 2. IM = 12 foot lbs. 3. WJ =??????	1. 3/5 2. 3/5 3. 3/5
Inspect Throttle Control 1. Check return spring & linkage for proper adjustment & freedom of movement. 2. Check cable ends & cable for wear. 3. Check and record throttle range on FADEC.	Collective Full Down =  0 % Collective Full Up =   100 %	1. 3/5 2. 3/5 3. 3/11
Change Oil & Filter 1. Change oil 2. Change Filter 3. Record batch number of oil Note: Oil & Filter should be changed every 6 months even if 25 hours of operation has not yet occurred.  To obtain a proper oil level the helicopter must be on a level surface Use a digital protractor and measure the angles of the top of the oil tank Fore and Aft = front height 6.6 Latteral = pass side height 0.4	5 Quarts AeroShell 20W/50 w/filter	1. 3/6 2. 3/6 3. 3/6
Inspect Water Pump 1. For signs of leaking. 2. For rust on shaft. We put a light film of mystic grease on the shaft	Torque flange bolts to 128inch lbs.	1. 3/5 2. 3/5
Inspect Water Pump/Alternator Belt 1. Check for proper tension 2. Check for unusual wear or damage. It was slightly loose so it required adjustment	-	1. 3/5 2. 3/5
Inspect Upper Fan Drive Belt 1. Check for proper tension 2. Check for unusual wear or damage.	-	1. 3/5 2. 3/5
Inspect Lower Fan Drive Belt 1. Check for proper tension 2. Check for unusual wear or damage. It was slightly loose so it required adjustment	-	1. 3/5 2. 3/5
Inspect Tail Rotor Belts 1. Check for unusual wear or damage. 2. Check Tail Rotor Tension Tool for proper calibration with a scale. 3. Check the Tail Rotor belts for proper tension at both the 1st and 3rd bulkheads.	10 lbs pressure @ ambient operating temperature	1. 3/5 2. 3/5 3. 3/5
Inspect Pro-Drive Electric Clutch 1. Check for proper operation, 2. Check for proper tension 3. Check for unusual wear or damage. Belts Tension = 7/16 @10 lbs @ 79F Plunger Rod Tension = 1 & 3/32 @ 79F	Min  7/16 Med  3/8 Max  5/16	1. 3/11 2. 3/11 3. 3/11
Inspect Pro-Drive Main Drive Belts 1. Check for proper tension 2. Check for unusual wear or damage. Belt Tension = 7/16 @10 lbs @ 79F	Min  7/16 Med  3/8 Max  5/16	1. 3/11 2. 3/11
Inspect Pro-Drive Cog Belt 1. Check for proper tension 2. Check for unusual wear or damage. Belt Tension =  7/16 @ 10 lbs @ 80F	Min 7/16 @ 70F Max 1/4 @ 70F	1. 3/7 2. 3/7
Main Rotor Blades 1. Check Blade tip weight bolts for tightness. 2. Check for blade delamination by performing a tap test. 3. Check for signs of blade fatigue by: A.  change in blade droop (while in its static position) from previous inspection. B.  flight response controls seem sluggish and insensitive. C.  during an autorotation flare the blade will develop a shake that will not stop until  collective pitch can be reduced. D. blade tracking seems to keep moving in and out and cannot stabilize.	-	1. 3/5 2. 3/5 3. 3/5 A. X B. X C. X D. X
Inspect Nav Lights 1. Check left side red nav light for security and proper operation. 2. Check right side green nav light for security and proper operation. 3. Check rear tail white nav light for security and proper operation. 4. Check all instrument lights for security and proper operation. 5. Check tail boom strobe light for security and proper operation. 6. Check landing light for security and proper operation.	-	1.3/11 2.3/11 3.3/11 4.3/11 5.3/11 6.3/11
Inspect ELT Unit 1. Check the instrument panel indicator for proper operation. 2. Check that the unit itself is secure 3. Test unit for proper operation. Only check the units operation during the first 5 minutes of any hour. We found that the batterys were leaking acid and replaced them with 6 new ones	125.5 MHz 243.0 MHz	1.3/11 2.3/11 3.3/11

Date

3

6

2006

added time for operation

Engine Hours to this point

124.1

Record FADEC Readouts Date: 3/11 - Engine Hours: 124.1 - Flight Hours: N/A - Ship Status During Instrument Readings Instrument and FADEC switch ON, engine not running Engine and all systems running Instrument Readings Readings Outside Temperature (Celcius) 79F in trailer - Barometric Pressure - - Wind Direction - - Wind Speed - - Rotor RPM % 0 - Engine RPM on Rotor Tack % 0 - Engine RPM on Floor Pod 0 - Fuel Pressure - Pump 1 56 - Fuel Pressure - Pump 2 56 - Battery Volts 12.0 - Secondary Bearing Temperature 40 - Manifold Pressure 29 - Water Temperature 0 - Oil Pressure 0 - Oil Temperature 0 - Fuel Level 3/4 - Air Speed 9 - Altitude 0 - VSI 0 - Ship Status During FADEC Readings Instrument and FADEC 1 switch ON, Engine not running Idle after startup FADEC Readings Readings Engine RPM 0 - Manifold Pressure 99.9 - Throttle Position 0 - Water Temperature 19.9 - Air Temperature 22.1 C C /       F Battery Voltage 12.5 - SEC     Tps     Air Temp     Baro 0 - Eman Pressure 99.9 - Baro Pressure 99.9 - Pulse Width 6.8 - Duty Cycle 0 - Spark Advance 14.0 - Fuel Used 0 - Max RPM 0 - Error Codes 0 - - - - Actual Fuel  used from fuel cart reading - - Difference in fuel consumption between FADEC readout and Reality - -

Date

3

11

2006

-

Final Engine Hours

124.1

Log Book Entry and Endorsement