MODIFICATION KIT. Serial Numbers 300 (LC40-550FG) thru (LC42-550FG) thru (LC41-550FG) thru

Transcription

1 Single Engine MODIFICATION KIT MK TITLE ENGINE OIL COOLER WINTERIZATION MODIFICATION EFFECTIVITY Model Serial Numbers 300 (LC40-550FG) thru (LC42-550FG) thru (LC41-550FG) thru DESCRIPTION This modification kit provides instructions and parts to install an engine oil cooler winterization kit. APPROVAL FAA approval has been obtained on all technical data in this Modification Kit that affects type design. REFERENCE SB CHANGE IN WEIGHT AND BALANCE MODEL /350/400 WEIGHT INCREASE Pounds ARM Inches RESULTANT MOMENT MOMENT/ Page 1 of 24 To obtain satisfactory results, procedures specified in this publication must be accomplished in accordance with accepted methods and prevailing government regulations. Cessna Aircraft Company cannot be responsible for the quality of work performed in accomplishing the requirements of this publication. Cessna Aircraft Company, Customer Service, P.O. Box 7706, Wichita, Kansas 67277, U.S.A. (316) Facsimile (316) COPYRIGHT 2009

2 MATERIAL INFORMATION NOTE: The modification kit listed below will be necessary for all airplanes. All parts are included in MK Use only the parts needed as shown: ITEM PART NUMBER QUANTITY DESCRIPTION NUMBER Model 300/350 Model 400 MK Kit, consisting of the following parts: 1 LA rev LA rev 1 1 Cable, Control, Door, Oil Cooler Winterization Bracket, Cable, Control, Oil Cooler Winterization 3 NAS1149F0332P 9 16 Washer, Flat, #10 4 MS LA rev A AN3-3A 1 3 Nut, Self Locking Flanged All Metal Cable Bolt, Induction Tube, Engine Bolt, Hex Head x 15/32 Bolt, Hex Head x 15/32 7 AN742D3 2 2 Clamp, Loop, Plain 8 LA rev 1 1 Door Assembly, Oil Cooler Winterization 9 LA rev 1 1 Placard, Winterization 10 AN3-5A 4 3 Bolt, Hex Head X 10/16 11 MS Screw, Pan Head, NAS1149FN632P 1 1 Washer #6 13 TYZ 525M GSPC-2 15 RB rev RA rev 6 inches 6 inches 1 1 Tie-Wrap, Fuel Resistant, Hi-Temp. Large Grommet Strip, DIA x 1.6 (ICO Rally) POH Supplement, Winterization Kit* Instructions * For all G1000 equipped model 350 and 400 airplanes, use POH Supplement P/N RB For Avidyne equipped model 350 and 400 airplanes, and all model 300 airplanes, use the POH Supplement P/N RA MK Page 2

3 In addition, the following materials, or equivalent, are necessary: NAME NUMBER MANUFACTURER USE Masking Tape Procure locally To temporarily secure the door hinge Isopropyl Alcohol Procure locally To clean surface for placard Gasket, Silicone, High Temperature, Red Cessna Aircraft Company Cessna Parts Distribution 5800 East Pawnee PO Box1521 Wichita, KS To reseal the intercooler to the baffling EA9309.3NA Adhesive (25 gram kit) U Cessna Aircraft Company Cessna Parts Distribution 5800 East Pawnee PO Box1521 Wichita, KS To secure the Grommet Strip ACCOMPLISHMENT INSTRUCTIONS These instructions are divided into three sections: Section A contains installation instructions for the Model 400 (LC41) Section B contains installation instructions for Models 300 and 350 (LC40 and LC42) Section C contains the Return to Service Instructions for all models. Section A: Installation Instructions, Model If performing this Modification Kit on airplane serial numbers through 41630, make sure that Service Bulletin SB has been accomplished. SB must be performed prior to or concurrently with this Modification Kit. 2. Prepare the airplane for maintenance. a. Remove the Upper and Lower Engine Cowling per Chapter 71 of the Airplane Maintenance Manual (AMM). b. Make sure that all switches are in the OFF position. c. Disconnect electrical power from the airplane. i. Disconnect the airplane batteries. ii. Disconnect external electrical power. d. Attach maintenance warning tags to the batteries and external power receptacle that have DO NOT CONNECT ELECTRICAL POWER MAINTENANCE IN PROGRESS written on them. 3. (Refer to Picture A2). Disconnect the Manifold Pressure Transducer wiring harness from the Manifold Pressure Transducer and temporarily move the harness out of the area where the work will be performed. MK Page 3

4 4. (Refer to Picture A2). Disconnect the Manifold Pressure Transducer and bracket from the aft baffling and temporarily move the Transducer, bracket, and the Manifold Pressure Transducer tube as an assembly out of the area where the work will be performed. 5. (Refer to Picture A1). Disconnect the Crankcase Breather tube and temporarily move the tube out of the area where the work will be performed. Remove tie wraps that secure the Crankcase Breather tube as needed. 6. (Refer to Picture A1). Disconnect the Fuel Distribution Valve Drain Line and temporarily move the line out of the area where the work will be performed. 7. (Refer to Picture A2). Disconnect the 4 Pin Tachometer Sensor CPC Plug Clamp from the aft baffle. 8. (Refer to Picture A2). Disconnect the 4 pin Tachometer Sensor CPC Plug and temporarily move the plug and wire harness out of the area where the work will be performed. 9. (Refer to Figure A7). Remove and keep the 4 inch bracket (P/N LC ) and hardware that connects the air diverter plate on the top of the oil cooler baffling to the aft baffling. This bracket will be reinstalled later. 10. (Refer to Figure A7). Remove and discard the LC bracket and the two existing bolts, keep the remaining attaching hardware. Install the attaching hardware on the oil cooler baffling and diverter plate with two new MS Nuts and two new NAS1149F0332P Washers. 11. (Refer to Picture A2 and A3). Disconnect the 4 pin Tachometer Sensor CPC plug and reroute the wiring so that it lies inboard or behind the throttle cable. The clamp that holds the CPC connector may have to be re-oriented following reassembly in the later sections of this document. 12. (Refer to Figure A5, Detail View B-B). Install Cable Bolt (p/n LA rev A), Washers (3 ea. p/n NAS1149F0332P), and Self-Locking Nut (p/n MS ) to the Oil Cooler Winterization Door assembly actuator arm. Leave loose for following steps. 13. (Refer to Figure A4). Temporarily install LA Door Assembly between the oil cooler baffling and the oil cooler and use masking tape to temporarily secure the hinge. 14. (Refer to Figure A4 and Picture A4). Locate the door assembly so that it is centered in front of the oil cooler with the top edge laying flush against the left rear baffling. 15. (Refer to Figure A4). Secure the bottom hinge in place with masking tape on the bottom of the oil cooler baffling. Make sure that the door assembly does not touch any surrounding hardware on the oil cooler aft baffling or surrounding structure when in both the open and closed positions. Operate the door several times to make sure that there is no interference during operation. NOTE: It is permissible to enlarge the holes or drill new holes in the door assembly as needed to provide clearance between the door assembly and the oil cooler, aft baffling, and surrounding structure. 16. (Refer to Figures A5 and A6). With the door assembly in position, match drill a #10 ( inch diameter) hole through the center bolt hole of the hinge and the bottom of the oil cooler baffling. MK Page 4

5 NOTE: Make sure to use a drill stop to prevent damage that may be caused to structure or other engine components that may be below the bottom of the oil cooler baffling. 17. Remove the door assembly, masking tape, and deburr the hole as needed. 18. Temporarily install the door assembly with one AN3-3A Bolt, NAS1149F0332P Washer, and one MS Nut. 19. Operate the door assembly and make sure that it does not contact any hardware or structure. Adjust the position of the door assembly, enlarge holes, and drill additional holes as required in the face plate of the door assembly to provide the best fit of the door assembly and provide clearance. 20. Match drill the remaining #10 (0.193-inch diameter) holes through the hinge and the bottom of the oil cooler baffling. Remove the door assembly and deburr the holes. 21. (Refer to Figure A5). Install the door assembly with Bolts (3 ea. p/n AN3-3A), Self Locking Nuts (3 ea. p/n MS ), and Washers (6 ea. p/n NAS1149F0332P). Adjust the fit of the assembly once again to ensure a flush fit at the top edge of the door assembly and the left rear baffling. Make sure that the door does not contact any hardware. Torque the MS nuts to 30 in-lb. 22. (Refer to Figures A4 and A5). Remove and discard the two existing AN3-3A bolts at the forward edge of the left hand horizontal baffling and attach Control Cable Bracket (p/n LA rev -) with Bolts (2 ea. p/n AN3-5A) and Washers (2 ea. p/n NAS1149F0332P). Torque bolts to 30 in-lb. 23. Temporarily install the LA Control Cable through the LA Cable Bracket and route along the baffling to the door assembly. 24. Mark, remove from the LA Cable Bracket, and cut the LA Control Cable as needed to provide the best fit when installed. Make sure that the cable is approximately 3 inches longer than the cable sheath after it has been cut to length. 25. Install the LA Control Cable onto the Bracket with the lock washer and nut that were provided with the LA Control Cable and torque the nut in-lbs. 26. (Refer to Figures A4 and A5). Install Clamps (2 ea. p/n AN742D3) to secure the LA Rev Control Cable to the left horizontal baffle using Bolt (1 ea. p/n AN3-5A) and Washer (1 ea. p/n NAS1149F0332P) for the forward clamp, and Screw (1 ea. p/n MS ) and Washer (1 ea. p/n NAS1149FN632P) for the aft clamp. Torque hardware to 30 in-lb. Note that the aft cable clamp resides on top of the inboard intercooler flange in the middle position. 27. (Refer to Figure A5, Detail View B-B). Thread the cable through the cable bolt assembly on the actuator arm of the door assembly. 28. (Refer to Figure A5, Detail View B-B). Adjust the cable so that the handle of the cable is positioned all the way in the aft position, and set the door to be in the full aft position (flush against the baffling) at the same time. Tighten the cable bolt lock nut snug to capture the cable end, but still allow for rotation of the cable assembly against the actuator arm of the door. 29. With the bolt snug, operate the cable several times to make sure that the door and cable operates through the full range of travel. Adjust as required. Do not over tighten lock nut as it can break the bolt. Torque to 30 in-lbs. After the cable bolt and nut are tightened, bend the end of the control cable 90 degrees to prevent it from pulling back through the cable bolt. MK Page 5

6 30. Use U Adhesive and secure the GSPC-2 Grommet Strip to the top edge of the door assembly where it contacts the aft baffle. 31. If necessary, reseal the left intercooler to the aft baffling with High Temperature Red Silicone. 32. (Refer to Figure A3). Clean the forward baffling surface with isopropyl alcohol and install Placard (p/n LA rev - ) below Control Cable handle. 33. (Refer to Picture A3). Route the 4 pin Tachometer Sensor CPC plug over the top of the throttle cable so that the wire harness will not interfere with the operation of the door assembly, and connect the plug. 34. (Refer to Picture A2). Secure the 4 pin Tachometer Sensor CPC plug with the removed Clamp and screw to the aft baffle. 35. (Refer to Picture A1). Connect the Fuel Distribution Valve Drain Line. 36. (Refer to Picture A1). Connect the Crankcase Breather tube and secure with TYZ 525M Tie Wraps as necessary. 37. (Refer to Picture A2). Connect the Manifold Pressure Transducer and bracket to the aft baffling. 38. (Refer to Picture A2). Connect the Manifold Pressure Transducer wiring harness from the Manifold Pressure Transducer and secure with TYZ 525M Tie Wraps as necessary. 39. (Refer to Figure A7). Use High Temperature Red Silicone and, with the kept hardware, reinstall the P/N LC bracket, which connects the air diverter plate on the top of the oil cooler baffling to the aft baffling. 40. Use Tie Wraps (p/n TYZ 525M) to re-install heat wrap on fuel drain hose and create standoffs so that no electrical or mechanical chafing occurs against the fuel lines. Make sure that all reattached items are properly fastened and torqued per the AMM and Teledyne Continental Motors (TCM) specifications. 41. Make sure that all items that were reinstalled in Steps are properly secured out of the way of the oil cooler winterization door. 42. Inspect the installation and the items that were removed during the installation, including the connections to the intercooler. 43. Reconnect the airplane batteries and remove the maintenance warning tags from the batteries and the external power receptacle. 44. Perform a Foreign Object Debris (FOD) check and reinstall upper and lower cowls per Chapter 71 of the AMM. 45. Proceed to Section C, Return to Service. MK Page 6

7 Figure A1 Parts List for A Figure items Model 400 Figure A2 Notes for Figures A2-A4 Figure A3 Installation of Decal (View Looking Aft) MK Page 7

8 Door Assembly LA (REF) Figure A4 Baffling Detail, Model 400 MK Page 8

9 NOTES: DOOR ASSEMBLY IS TO BE CENTERED OVER OIL COOLER WITH TOP EDGE LAYING FLUSH AGAINST THE LEFT REAR BAFFLING. THE DOOR ASSEMBLY MUST ALSO MISS ALL SURROUNDING HARWARE IN BOTH OPEN AND CLOSED POSITIONS. SLOTTING OF HOLES OR DRILLING A NEW CLEARANCE HOLE IS ACEPTABLE TO ACHIEVE PROPER FIT. LOCK WASHER AND JAM NUT ARE SUPPLIED WITH CABLE. TORQUE IN-LB. Figure A5 Winterization Kit Detail, Model 400 MK Page 9

10 Figure A6 Oil Cooler Baffling Modification Detail, Model 400 MK Page 10

11 Figure A7 Oil Cooler Diverter Plate Detail, Model 400 MK Page 11

12 Wastegate Controller Air Reference Tube Wastegate Controller Air Reference Hose Crankcase Breather Tube Fuel Distribution Valve Drain Line Picture A1 Components that penetrate the aft baffling. 4 Pin Tachometer Sensor CPC Plug Wastegate Controller Air Reference Tube 4 Pin Tachometer Sensor CPC Plug Clamp Manifold Pressure Transducer Wiring Harness Wastegate Controller Air Reference Hose Manifold Pressure Transducer Picture A2 Components that penetrate the aft baffling. Manifold Pressure Transducer Tube MK Page 12

13 Tach Sensor Wiring routed over Throttle Cable housing 4 Pin Tachometer Sensor CPC Plug Picture A3 Rerouting of Tachometer Sender Wiring, Model 400 Note: This surface is Carbon Fiber on the Model 400, and is Aluminum on the Model 300 and 350 MK Picture A4 Top edge of the winterization door against the baffling. Page 13

14 Section B: Installation Instructions, Model 300/ Prepare the airplane for maintenance. a. Remove the Upper and Lower Engine Cowling per Chapter 71 of the Airplane Maintenance Manual (AMM). b. Make sure that all switches are in the OFF position. c. Disconnect electrical power from the airplane. i. Disconnect the airplane batteries. ii. Disconnect external electrical power. d. Attach maintenance warning tags to the batteries and external power receptacle that have DO NOT CONNECT ELECTRICAL POWER MAINTENANCE IN PROGRESS written on them. 2. (Refer to Figure B7). Disassemble the components and associated hardware shown by the arrows in the figure to allow for the removal of the oil cooler baffling assembly in the next step. Remove the baffling diverter that is mounted on the front of the oil cooler baffling which wraps around the bottom of the cylinder. Remove the baffling diverter which is mounted below the oil cooler baffling. Remove the screws around the flange face of the oil cooler as required. Remove the bolt that is in the bottom inboard edge of the oil cooler baffling assembly. Loosen and secure the left horizontal baffling out of the way, but only if required to get the oil cooler baffling assembly out of the way. 3. (Refer to Figure B4). Remove the P/N LA Oil Cooler Baffling assembly that is mounted immediately in front of the Oil Cooler assembly and keep the hardware. 4. (Refer to Figure B6). Modify the P/N LA Oil Cooler Baffling assembly by removing the material as indicated in Figure B6. 5. (Refer to Figure B6). Remove the 90 degree bracket that is riveted to the inboard side of the oil cooler baffling assembly. Drill the rivet heads off the bracket, P/N LA , and discard the bracket. File the worked edges smooth. 6. Reinstall the oil cooler baffling assembly using the kept hardware. 7. Reinstall the components that were removed in Step 3. Do not install the two bolts in the bottom center (below where the door hinge will mount) of the oil cooler baffling. They will be installed later. Make sure that the bolts attaching the air diverter baffle to the front of the oil cooler baffling is mounted with the threads of the bolt pointed aft. 8. (Refer to Figure B5, Detail View B). Install Cable Bolt (p/n LA rev A), Washers (3 ea. p/n NAS1149F0332P), and Self Locking Nut (p/n MS ) to the LA Door Assembly actuator arm. Leave loose for the following steps. 9. (Refer to Figures B4 and B5). Temporarily install LA Door Assembly between the oil cooler baffling and the oil cooler and use masking tape to temporarily secure the hinge. 10. (Refer to Figures B4, B5, and Picture B1). Locate the LA Door Assembly so that it is centered in front of the oil cooler with the top edge laying flush against the left rear baffling. 11. (Refer to figure B4). Secure the bottom hinge in place with masking tape on the bottom of the oil cooler baffling. Make sure that the Door Assembly does not touch any surrounding hardware on the oil cooler aft baffling or surrounding structure when in both the open and closed positions. Operate the door several times to make sure that there is no interference during operation. MK Page 14

15 NOTE: It is permissible to enlarge the holes or drill new holes in the door assembly as needed to provide clearance between the door assembly and the oil cooler, aft baffling, and surrounding structure. 12. Remove the door assembly and remove the masking tape. 13. (Refer to Figure B5 and B6). Temporarily install the LA Door Assembly into position. Install the original hardware (2 ea. p/n AN3-3A bolts and 2 ea. p/n NAS1149F0332P washers) into the inboard and center hole locations on the hinge. These two bolts correspond to the same positions on the oil cooler baffling that were left out in Step 8. Install and snug these two bolts into the nut-plates of the diverter bracket that is mounted beneath the oil cooler baffling assembly (this bracket was removed in Step 3). NOTE: It is permissible to enlarge the holes in the door assembly hinge as needed to match existing hardware or oil cooler baffle hole location. 14. (Refer to Figures B5 and B6). With the door assembly mounted in position with the two bolts, match drill a #10 (0.193-inch diameter) hole through the outboard hole of the bottom hinge and the bottom of the oil cooler baffling. NOTE: Make sure to use a drill stop to prevent damage that may be caused to structure or other engine components that may be below the bottom of the oil cooler baffling. 15. Remove the door assembly and deburr the hole as needed. 16. Reinstall the door assembly and fasten the hinge snug with the original hardware (2 ea. p/n AN3-3A bolts and 2 ea. p/n NAS1149F0332P washers) into the inboard and center hole locations on the hinge. Install these two bolts into the nut-plates of the diverter bracket that is mounted beneath the oil cooler baffling assembly. Install Bolt (1 ea. p/n AN3-3A), Washer (2 ea. p/n NAS1149F0332P), and Self Locking Nut (1 ea. p/n MS ) into the outboard hinge position per Figure B5. Adjust the fit of the assembly once again to ensure a flush fit at the top of the door assembly and the left rear baffling. Make sure that the door does not contact any hardware. Torque fasteners to 30 in-lb. 17. (Refer to Figures B4 and B5). Remove the two existing AN3-3A bolts at the forward edge of the left hand horizontal baffling and discard. If installed, remove and discard the P/N LA baffling plate that is mounted underneath the bolt heads. Attach Control Cable Bracket (p/n LA rev -) with Bolt (2 ea. p/n AN3-5A) and Washer (2 ea. p/n NAS1149F0332P). Torque bolts to 30 in-lb. 18. (Refer to Figure B5). Temporarily install the LA Control Cable through the LA Cable Bracket and route along the baffling to the door assembly. 19. Mark, remove, and cut the LA Control Cable as needed to provide the best fit when installed. Make sure that the cable is approximately 3 inches longer than the cable sheath after it has been cut to length. 20. (Refer to Figure B5). Install Control Cable (p/n LA rev -) onto the bracket. The jam nut and washer are supplied with the cable assembly. Torque cable jam nut to in-lb. 21. (Refer to Figures B4 and B5). Clamps (2 ea. p/n AN742D3) using Bolt (1 ea. p/n AN3-5A) and Washer (1 ea. p/n NAS1149F0332P) for the forward clamp, and Screw (1 ea. p/n MS ) and Washer (1 ea. p/n NAS1149FN632P) for the aft clamp. Torque hardware to 30 in-lb. MK Page 15

16 22. (Refer to Figure B5, Detail View B-B). Thread the cable through the cable bolt assembly on the actuator arm of the door assembly. 23. (Refer to Figure B5, Detail View B-B). Adjust the cable so that the handle of the cable is positioned all the way in the aft position, and set the door to be in the full aft position (flush against the baffling) at the same time. Tighten the cable bolt lock nut snug to capture the cable end, but still allow for rotation of the cable assembly against the actuator arm of the door. 24. With the bolt snug, operate the cable several times to make sure that the door and cable operates through the full range of travel. Adjust as required. Do not over tighten lock nut as it can break the bolt. Torque to 30 in-lbs. After the cable bolt nut is tightened, bend the end of the control cable 90 degrees to prevent it from pulling back through the cable bolt. 25. Use U Adhesive and secure the GSPC-2 Grommet Strip to the top edge of the door assembly where it contacts the aft baffle. 26. (Refer to Figure B3). Clean the forward baffling surface with isopropyl alcohol and install Placard (p/n LA rev ) below Control Cable handle. 27. (Refer to Figure A7). Use High Temperature Red Silicone and reinstall the P/N LC bracket, which connects the air diverter plate on the top of the oil cooler baffling to the aft baffling. 28. Reconnect the airplane batteries and remove the maintenance warning tags from the batteries and the external power receptacle. 29. Inspect the installation and the items that were removed during the installation. 30. Perform a Foreign Object Debris (FOD) check and reinstall upper and lower cowls per Chapter 71 of the AMM. 31. Proceed to Section C, Return to Service. MK Page 16

17 Figure B1 Parts list for B Figure items Model 300/350 Figure B2 Notes for B Figure items. Figure B3 Decal installation Detail Model 300/350 MK (view looking aft) Page 17

18 Door Assembly Figure B4 - Baffling detail Model 300/350 MK Page 18

19 NOTES: DOOR ASSEMBLY IS TO BE CENTERED OVER OIL COOLER WITH TOP EDGE LAYING FLUSH AGAINST THE LEFT REAR BAFFLING. THE DOOR ASSEMBLY MUST ALSO MISS ALL SURROUNDING HARWARE IN BOTH OPEN AND CLOSED POSITIONS. SLOTTING OF HOLES OR DRILLING A NEW CLEARANCE HOLE IS ACEPTABLE TO ACHIEVE PROPER FIT. LOCK WASHER AND JAM NUT ARE SUPPLIED WITH CABLE. TORQUE IN-LB. Figure B5 Winterization Kit Detail Model 300/350 MK Page 19

20 Part Number LA (REF.) Figure B6 - Oil cooler baffling modification Model 300/350 MK Page 20

21 BEFORE AFTER Figure B6 Continued MK Page 21

22 Remove this piece only if necessary. Figure B7 Removal of Oil Cooler Baffling MK Page 22

23 Note: This surface is Carbon Fiber on the Model 400, and is Aluminum on the Model 300 and 350 Picture B1 Top edge of the winterization door against the baffling. MK Page 23

24 Section C: Return to Service Instructions, Model 300/350/ Insert the appropriate part number POH supplement for the Winterization Kit into the Supplements section at the back of the Pilots Operating Handbook (POH). Make a record in the Supplement revision history page at the beginning of the Supplements section of the POH that this supplement is included. 2. Update the Airplane Weight and Balance Sheet in Section 6 of the POH using the following information: MODEL: 300/350/400 WEIGHT INCREASE: LBS ARM INCHES RESULTANT MOMENT: MOMENT/1000: Make an entry in the airplane logbook stating that this Modification Kit has been installed. MK Page 24