CIRRUS AIRPLANE MAINTENANCE MANUAL

Transcription

1 NOISE SUPPRESSOR 1. DESCRIPTION Noise suppression is accomplished through use of a heat exchanger (Serials 0002 thru 019) or a heat exchanger and muffler (Serials 020 & subs) connected to the exhaust header assemblies. The heat exchanger incorporates the use of heat sinks welded to the exterior of a muffler and a shroud with accommodations for ducts to provide cabin heating. Positive ventilation of the heat exchanger is provided at all times by air passing through the outer compartment and entering the cabin, or by venting overboard depending on the cabin heat valve position. Serials 0002 thru 0221: The forward end of the heat exchanger is held in place by a support extending from the engine mount. Ball joints support this portion of the exhaust system, allowing for relative motion between the engine and airframe. A second ball joint connects the heat exchanger to the exhaust tailpipe. Serials 0222 thru 019: The forward end of the heat exchanger is held in place by a support extending from the engine mount. Ball joints support this portion of the exhaust system, allowing for relative motion between the engine and airframe. The exhaust tailpipe is integral to the heat exchanger. Serials 020 & subs: Ball joints support the heat exchanger and muffler, allowing for relative motion between the engine and airframe. Butt joints with clamps and sleeves connect the heat exchanger and muffler to the exhaust tailpipes. All Page 1

2 2. MAINTENANCE PRACTICES A. Heat Exchanger - Serials 0002 thru 019 (See Figure 1) (1) Removal - Heat Exchanger (a) Remove engine cowling. (Refer to 71-10) (b) Remove tailpipe. (Refer to ) (c) Loosen clamps securing air intake and cabin heat hoses. Remove hoses from heat exchanger. (d) Remove cotter pins, nuts, springs, washers, and bolts securing heat exchanger to engine mount bracket. (e) Remove cotter pins, nuts, springs, washers, and bolts from forward ball joint securing heat exchanger to mid-pipe assembly. (f) Remove heat exchanger from airplane. (2) Disassembly - Heat Exchanger (a) Remove screws and nuts securing heat exchanger shroud to heat exchanger. () Assembly - Heat Exchanger CAUTION: Failure to properly align heat exchanger shroud to heat exchanger will result in poor cabin heating. (a) Position heat exchanger shroud on heat exchanger so that shroud baffle is located between duct flanges and secure with screws and nuts. () Installation - Heat Exchanger (a) Acquire necessary tools, equipment, and supplies. Description P/N or Spec. Supplier Purpose Permatex K1 - Any Source Antiseize lubricant. Emery Cloth - Any Source Polishing. (b) (c) Polish both sides of ball joint with emery cloth to ensure surface is smooth and free of burrs. Apply a thin coat of antiseize lubricant to polished ball joint surfaces. Note: Slight adjustment of nuts for cotter pin installation is allowable. (d) Position heat exchanger to mid-pipe assembly and install bolts, washers, springs, nuts, and cotter pins. Tighten nuts to snug, then turn three complete revolutions to compress springs. Install cotter pins. (e) Install tailpipe. (Refer to ) (f) Install bolts, washers, springs, nuts, and cotter pins securing heat exchanger to engine mount bracket. (g) Adjust aft ball joint nuts as required to ensure overall length of each compression spring is 0.0 inch (1.27 cm). (h) Install clamps for air intake and cabin heat hoses, and connect both hoses to heat exchanger. (i) Install engine cowling. (Refer to 71-10) Page 2 Serials 0002 thru 019

3 B. Heat Exchanger - Serials 020 & subs (See Figure 1) (1) Removal - Heat Exchanger (a) Remove engine cowling. (Refer to 71-10) (b) Remove tailpipe. (Refer to ) (c) Loosen clamps securing air intake and cabin heat hoses. Remove hoses from heat exchanger. (d) Remove cotter pins, nuts, springs, washers, and bolts from forward ball joint securing heat exchanger to exhaust header assembly. (e) Remove heat exchanger from airplane. (2) Disassembly - Heat Exchanger (a) Remove screws and nuts securing heat exchanger shroud to heat exchanger. () Assembly - Heat Exchanger CAUTION: Failure to properly align heat exchanger shroud to heat exchanger will result in poor cabin heating. (a) Position heat exchanger shroud on heat exchanger so that shroud baffle is located between duct flanges and secure with screws and nuts. () Installation - Heat Exchanger (a) Acquire necessary tools, equipment, and supplies. Description P/N or Spec. Supplier Purpose Permatex K1 - Any Source Antiseize lubricant. Emery Cloth - Any Source Polishing. (b) Polish both sides of ball joint with emery cloth to ensure surface is smooth and free of burrs. (c) Apply a thin coat of antiseize lubricant to polished ball joint surfaces. (d) Position heat exchanger to header assembly and install bolts, springs, washers, and nuts, so that the overall length of each compression spring is 0.0 inch (1.27 cm). (e) Install hose clamps for air intake and cabin heat hoses, and connect both hoses to heat exchanger. (f) Perform Adjustment/Test - Forward Ball Joints. (Refer to ) (g) Install tailpipe. (Refer to ) (h) Install engine cowling. (Refer to 71-10) Serials 020 & subs Page

4 C. Muffler - Serials 020 & subs (See Figure 1) (1) Removal - Muffler (a) Remove engine cowling. (Refer to 71-10) (b) Remove tailpipe. (Refer to ) (c) Remove cotter pins, nuts, springs, washers, and bolts from forward ball joint securing muffler to exhaust header assembly. (d) Remove muffler from airplane. (2) Installation - Muffler (a) Acquire necessary tools, equipment, and supplies. Description P/N or Spec. Supplier Purpose Permatex K1 - Any Source Antiseize lubricant. Emery Cloth - Any Source Polishing. (b) Polish both sides of ball joint with emery cloth to ensure surface is smooth and free of burrs. (c) Apply a thin coat of antiseize lubricant to polished ball joint surfaces. (d) Position muffler to header assembly and install bolts, springs, washers, and nuts, so that the overall length of each compression spring is 0.0 inch (1.27 cm). (e) Perform Adjustment/Test - Forward Ball Joints (Refer to ) (f) Install tailpipe. (Refer to ) (g) Install engine cowling. (Refer to 71-10) Page Serials 020 & subs

5 D. Tailpipe - Serials 0002 thru 0221 (See Figure 1) (1) Removal - Tailpipe (a) Remove engine cowling. (Refer to 71-10) (b) Remove screws, washers, and grounding strap securing tailpipe to support on firewall. (c) Remove bolts, washers, springs, nuts, and cotter pins securing tailpipe to heat exchanger. (d) Remove tailpipe from airplane. (2) Installation - Tailpipe (a) Acquire necessary tools, equipment, and supplies. Description P/N or Spec. Supplier Purpose Permatex K1 - Any Source Antiseize lubricant. Emery Cloth - Any Source Polishing. (b) Position tailpipe on ball joint flange of heat exchanger and install bolts, washers, springs, and nuts. CAUTION: The aft edge of support bracket can be lower than leading edge of support bracket, however if aft edge of support bracket is higher than the leading edge of the bracket, adjust the ball joint until the hanger is orientated properly. To obtain proper orientation, it s permissible to install washers between support bracket and support (longer mounting bolts may be required for reassembly). (c) (d) (e) Verify support bracket welded onto tailpipe is perpendicular to firewall or that aft edge of support bracket is lower than leading edge. Evenly tighten tailpipe ball joint bolts to ensure overall length of each compression spring is compressed to at least 0.0 inch (1.27 cm). Continue to evenly tighten each ball joint bolt until the flange just starts to bow inward. Install screws, washers and grounding strap securing tailpipe to support on firewall. CAUTION: Verify at aft end of tailpipe there is a minimum of 1. inch (. cm) of clearance between top of tailpipe and to belly of airplane. Ensure tailpipe outlet is pointing downward and away from fuselage. (See Figure 2) (f) Secure balljoint nuts with cotter pins. (g) Install engine cowling. (Refer to 71-10) E. Tailpipe - Serials 0222 thru 019 The tailpipe is integral to the heat exchanger on these airplanes. For maintenance practices pertinent to the tailpipe, refer to Heat Exchanger. (Refer to ) All Page

6 F. Tailpipe - Serials 020 & subs (See Figure 1) (1) Removal - Tailpipe (a) Remove engine cowling. (Refer to 71-10) (b) Remove extension springs securing tailpipe to airframe. (c) Remove nut, washer, and bolt securing grounding strap to tailpipe. (d) Remove nuts, washers, bolts, and clamps securing tailpipe to muffler or heat exchanger. (e) Remove tailpipe from airplane. (2) Installation - Tailpipe (a) Position tailpipe on port of muffler or heat exchanger. (b) Install clamps, bolts, washers, and nuts securing tailpipe to muffler or heat exchanger. (c) Install bolt, washer, and nut securing grounding strap to tailpipe. (d) Install extension springs securing tailpipe to airframe. (e) Serials 020 thru 0820: Adjust tailpipe on muffler or heat exchanger port as required to ensure at aft end of tailpipe there is 2.71 inch (.88 cm) of clearance between top of tailpipe and belly of airplane. (See Figure 2) (f) Serials 0821 & subs: Adjust tailpipe on muffler or heat exchanger port as required to ensure at aft end of tailpipe there is.1 inch (7.9 cm) of clearance between top of tailpipe and belly of airplane. (See Figure 2) (g) Install engine cowling. (Refer to 71-10) Page Serials 020 & subs

7 G. Tailpipe Bracket - Serials 0002 thru 0007, 0012 before SB (See Figure 1) (1) Removal - Tailpipe Bracket (a) Remove silicone sealant from exhaust support bolts. (b) Remove bolt and washer securing ground strap and outboard rear exhaust support to tailpipe. (c) Remove bolt and washer securing inboard rear exhaust support to tailpipe. (d) Remove bolt and washer securing ground strap and outboard rear exhaust support to firewall. (e) Remove bolt and washer securing inboard rear exhaust support to firewall. (2) Installation - Tailpipe Bracket (a) Acquire necessary tools, equipment, and supplies. Description P/N or Spec. Supplier Purpose High Temperature Silicone Sealant 7 Dow Corning Midland, MI Seal firewall. (b) (c) (d) (e) (f) Secure inboard rear exhaust support to firewall with bolt and washer. Secure ground strap and outboard rear exhaust support to firewall with bolt and washer. Secure inboard rear exhaust support to tailpipe with bolt and washer. Secure ground strap and outboard rear exhaust support to tailpipe with bolt and washer. Cover bolt heads with high temperature silicone sealant. Serials 0002 thru 0007, 0012 before SB Page 7

8 H. Tailpipe Bracket - Serials 0008 thru 0011, 001 thru 019, Serials 0002 thru 019 after SB (See Figure 1) (1) Removal - Tailpipe Bracket (a) Remove silicone sealant from exhaust support bolts. (b) Remove bolt and washer securing ground strap and outboard rear exhaust support to tailpipe. (c) Remove bolt and washer securing inboard rear exhaust support to tailpipe. (d) Remove bolt, washers, bushing, and nut securing ground strap and outboard rear exhaust support to firewall. (e) Remove bolt and washer securing inboard rear exhaust support to firewall. (2) Installation - Tailpipe Bracket (a) Acquire necessary tools, equipment, and supplies. Description P/N or Spec. Supplier Purpose High Temperature Silicone Sealant 7 Dow Corning Midland, MI Seal firewall. (b) (c) (d) (e) (f) Secure inboard rear exhaust support to firewall with bolt and washer. Secure ground strap and outboard rear exhaust support to firewall with bolt, washers, bushing, and nut. Secure inboard rear exhaust support to tailpipe with bolt and washer. Secure ground strap and outboard rear exhaust support to tailpipe with bolt and washer. Cover bolt heads with high temperature silicone sealant. Page 8 Serials 0008 thru 0011, 001 thru 019, Serials 0002 thru 019 after SB

9 1 EXHAUST HEADERS 12 Y-PIPE COLLECTOR 1 11 FIREWALL 2 Serials 0002 thru 0007, 0012 before SB , Serials 001 thru BRACKET Serials 017 thru 019, Serials 0002 thru 017 after SB BRACKET FIREWALL Serials 0002 thru 0007, 0012 after SB NOTE One piece header after SB 2X Serials 0002 thru 019. Serials 0002 thru 017 before SB LEGEND 1. Mid-Pipe 2. Cotter Pin. Nut. Washer. Spring. Bolt 7. Heat Exchanger 8. Shroud 9. Ball Joint Flange 10. Tailpipe 11. Screw 12. Grounding Strap 1. Support Assembly 1. Bushing SR22_MM78_172E Serials 0002 thru 019 Figure 1 Exhaust System Installation - Serials 0002 thru 019 (Sheet 1 of ) Page 9

10 CIRRUS AIRPLANE MAINTENANCE MANUAL EXHAUST HEADERS COLLECTOR FIREWALL 9 COLLECTOR LEGEND 2. Cotter Pin. Nut. Washer. Spring. Bolt 7. Heat Exchanger 8. Shroud 9. Ball Joint Flange 10. Tailpipe 11. Screw 12. Grounding Strap 1. Muffler 1. Clamp 1. Bracket Serials 020 thru SR22_MM78_17A Figure 1 Exhaust System Installation - Serials 020 thru 0820 (Sheet 2 of ) Page 10 Serials 020 thru 0820

11 EXHAUST HEADER ASSEMBLY COLLECTOR FIREWALL COLLECTOR LEGEND 2. Cotter Pin. Nut. Washer. Spring. Bolt 7. Heat Exchanger 8. Shroud 9. Ball Joint Flange 10. Tailpipe 11. Screw 12. Grounding Strap 1. Muffler 1. Clamp 1. Bracket SR22_MM78_189 Serials 0821 & subs Figure 1 Exhaust System Installation - Serials 0821 & subs (Sheet of ) Page 11

12 FIREWALL SUPPORT FUSELAGE BELLY 1.0 in. (.0 cm) MIN. Serials 0002 thru 019. TAILPIPE BRACKET FUSELAGE BELLY 2.71 in. (.8 cm) Serials 020 thru NOTE Washers may be added between tailpipe bracket and firewall support to obtain 1.0 in (.0cm) minimum clearance between tailpipe and fuselage belly. At aft end of tailpipe, measure from top of tailpipe to nearest point on fuselage belly. FUSELAGE BELLY in. ( cm) Serials 0821 & subs. SR22_MM78_11B Page 12 Figure 2 Tailpipe Adjustment All

13 I. Adjustment/Test - Forward Ball Joints - Serials 020 & subs (See Figure ) The forward ball joints on the exhaust system must be inspected after installation and at each specified Scheduled Maintenance Check so that the load required to move forward ball joint is - 1 lb ( kg). (1) Adjustment/Test - Forward Ball Joints (a) Acquire necessary tools, equipment, and supplies. Description P/N or Spec. Supplier Purpose Calibrated Spring Scale A Chatillon Kew Gardens, NY 111 Load determination. (b) Remove engine cowling. (Refer to 71-10) (c) Remove tailpipe. (Refer to ) (d) Attach spring scale to aft port of heat exchanger or muffler. Note: The ball joint is torqued correctly if forward ball joint starts to move between a range of - 1 lb ( kg) of pull during both tests. Different length bolts or washers may be necessary to obtain correct ball joint tension. (e) (f) (g) Pull directly down on spring scale and note pull required to move forward ball joint. Pull outboard on spring scale (at right angle from first test) and note pull required to move forward ball joint. Add different length stainless steel bolts or washers as required to adjust ball joint tension so that - 1 lb ( kg) of pull is required to move forward ball joint. Install cotter pins. (h) Install tailpipe. (Refer to ) (i) Install engine cowling. (Refer to 71-10) Serials 020 & subs Page 1

14 NOTE Attach spring scale to aft port of heat exchanger or muffler. Pull directly down on spring scale. The ball joint is torqued correctly if forward ball joint starts to move between a range of -1 lb of pull. Different length bolts or washers may be necessary to obtain correct ball joint tension. Pull outboard at right angle to first test. The ball joint is torqued correctly if forward ball joint starts to move between a range of -1 lb of pull. Different length bolts or washers may be necessary to obtain correct ball joint tension. 90 SR22_MM78_17B Page 1 Figure Adjustment/Test - Forward Ball Joints - Serials 020 & subs Serials 020 & subs

15 J. Inspection/Check - Exhaust System The entire exhaust system including the heat exchanger, shroud, muffler, internal baffling, spark arrestors, stacks, collectors, tailpipes, springs, and exhaust connections must be inspected at each specified Scheduled Maintenance Check. (1) Inspection/Check - Exhaust System (a) Remove engine cowling. (Refer to 71-10) (b) Inspect all exhaust system external surfaces including welds, clamps, supports, brackets, springs, joints, and gaskets, for dents, cracks, missing parts, corrosion, or evidence of exhaust gasses escaping through holes, cracks or around joints. (c) Disassemble heat exchanger. (Refer to ) (d) Inspect heat exchanger for cracks, dents, and evidence of exhaust gasses escaping through holes, cracks, or around joints. WARNING: In addition to performing Inspection/Check - Heat Exchanger at each specified Scheduled Maintenance Check, it must also be performed whenever there is suspicion of exhaust gas leakage. (e) If there is suspicion of exhaust gas leakage, perform Inspection/Check - Heat Exchanger. (Refer to ) (f) Inspect baffle on heat exchanger for cracks. Moderate warping of the baffle is acceptable. (g) Assemble heat exchanger. (Refer to ) (h) Install engine cowling. (Refer to 71-10) All Page 1

16 K. Inspection/Check - Heat Exchanger The heat exchanger must be inspected for secure mounting, leakage, and general condition at each specified Scheduled Maintenance Check and whenever there is suspicion of exhaust gas leakage. Inspect the heat exchanger visually and by pressure check to determine possible leakage which could allow carbon monoxide to enter the heating system. (1) Inspection/Check - Heat Exchanger (a) Acquire necessary tools, equipment, and supplies. Description P/N or Spec. Supplier Purpose Solid Test Plug - Any Source Plug heat exchanger. Ported Test Plug - Any Source Plug heat exchanger. Pressure Source - Any Source Pressurize heat exchanger. Submerging Tank (filled with soap suds solution) - Any Source Leak detection. (b) Visually inspect heat exchanger welds, brackets, and joints for dents, cracks, missing parts, soot, or evidence of exhaust gasses escaping through holes, cracks, or around joints. (c) Remove heat exchanger. (Refer to ) (d) Disassemble heat exchanger. (Refer to ) Note: Up to 10 studs can be missing before replacing heat exchanger. (e) Visually inspect heat exchanger for missing studs, dents, cracks, soot, or evidence of exhaust gasses escaping through holes, cracks, or around welds and joints. (f) To ensure tight seal, wipe soot from inside of heat exchanger pipes with tack cloth. (g) Install solid test plug on one end of heat exchanger. (h) Install ported test plug on other end of heat exchanger. (i) Attach pressure source and pressurize to 2. psi for 1 minute. (j) Submerge pressurized heat exchanger in soap suds solution and inspect for leaks. (k) Repair or replace heat exchanger if leaks are detected. (l) Assemble heat exchanger. (Refer to ) (m) Install heat exchanger. (Refer to ) Page 1 All