PISTON PREHEAT SYSTEM ILLUSTRATED INSTALLATION INSTRUCTIONS

Transcription

1 Illustrated Installation Piston Preheat System Rev RCK ENGINE MAKE: Rotax MODEL: 912/914 PISTON PREHEAT SYSTEM ILLUSTRATED INSTALLATION INSTRUCTIONS Page 1 of 6

2 Piston Preheat System Table of Contents Cover Page Page 1 Table of Contents/Packing List Page 2 Installation Overview Page 3 Installation Instructions Page 3-6 System Check Page 6 Instructions for Continued Airworthiness Page 6 Kit Contents Please familiarize yourself with the kit contents and read all enclosed documents before beginning installation. Packing List Documents Wiring Harness 108 Installation Instructions 185 TAS108 Crankcase Heat Element Bonding Instructions 186 4ea TAS Cylinder Head Heat Element Warranty Card 5ea Lock Washer TAS330 Oil Tank Heat Element 20ea Tie Wrap-Black 8 2ea Tie Wrap Black 22 Tube of Bonding Sealant Packet of Anti-Seize Compound Placard (Black) Page 2 of 6

3 Piston Preheat System INSTALLATION OVERVIEW The retrofit of your aircraft with the Tanis Engine Preheat system is complex and must be completed by competent individual appropriately qualified for the project. It is estimated that this retrofit will take approximately 3 man-hours to complete. These instruction procedures are provided as guidance only. Final judgment regarding the proper installation and inspection details is the responsibility of the mechanic and inspection authority releasing the aircraft for service. In many cases, other aircraft modifications may require departure from the suggested installation procedures and harness routing. Figure 1: Remove Manifold Bolt BEFORE STARTING INSTALLATION 1. Read all enclosed documents. 2. Verify kit contents per the packing list. 3. Weigh the kit before installation for weight and balance calculations. 4. Determine heating element locations. 5. Clean installation sites. (see Instruction 186). 6. Make a trial routing of wiring harness without securing the harness or making any connections. DETAILED INSTRUCTIONS Replace Manifold Bolts with Threaded Elements (Refer to Figures 1 and 2) 1. Remove the shorter of the two Allen head cap screws securing the intake manifold to each cylinder. 2. Replace each bolt (4-total) with a Tanis TAS heating element. Use the AntiSeize compound and the lock washer provided with the kit. 3. Torque the bolts according to the most recent Rotax engine manuals. Note: The TAS manifold element shown in figure 2 is shorter than the TAS108 crank case element shown in figure 4. Make sure that the shorter elements are used on the intake manifold and the longer element is installed in the crankcase. Figure 2: Install TAS Element Replace Crankcase Bolt with Threaded Element (Refer to figures 3 and 4) 1. Remove the crankcase bolt on the bottom of the engine located forward of the drain plug beneath the oil pump. 2. Replace the bolt with a Tanis TAS108 heating element. Use the AntiSeize compound and the lock washer provided with the kit. 3. Torque the bolt according to the most recent Rotax engine manuals. Figure 3: Remove Crank Case Bolt Page 3 of 6

4 Piston Preheat System Figure 4: Install TAS108 Element Figure 5: Apply Adhesive to Element Install Pad-Type Element on Oil Tank (Refer to Figures 5 through 10) 1. Read Bonding Instructions 186 included in the kit before attempting to install the Tanis TAS330 element. 2. Determine the area on the tank where the element will be installed. It should be on the lower third of the tank below the oil level with the connector in a position for convenient connection to the wiring harness. It is helpful to lay the wiring harness loosely in place to determine the best position for the element. 3. Clean the area of the tank to be bonded. 4. Apply the bonding sealant included with the kit to the back side of the element and smooth out to a thin even layer with a putty knife. 5. Carefully press the element to the tank and smooth out all excess sealant and air bubbles. 6. Secure the element temporarily in place with the large tie wraps included with the kit. Make sure that the entire element is in contact with the oil tank but do not over tighten the tie wraps. 7. After allowing 8 hours of cure time, carefully remove the large tie wraps holding the element in place. (figure 9) 8. Do not plug in the system or apply heat to the element to hasten bonding. 9. After the large tie wraps are removed, apply a small bead of sealant to seal the edges of the element. (figure 10) Figure 6: Spread Adhesive on Element Figure 7: Install TAS330 Element Figure 8: Secure Element with Tie Wraps Page 4 of 6

5 Piston Preheat System 6. Finish the installation by tightening and trimming all tie wraps. To minimize stress vibration at the element leads, secure the leads as near as possible to the element body. Figure 9: Remove Tie Wraps after Cure Time Figure 11: Lay Out the Harness Figure 10: Seal Edges of Element Install the Wiring Harness (Refer to Figures 11 through 15) 1. Lay the wiring harness on top of the engine and route the cylinder leads along the oil lines and spark plug wires. 2. Route the sump lead to the bottom of the crankcase and the power plug lead to a location near the top of the oil tank. 3. Secure the harness and element leads loosely with the 8 tie wraps included with the kit. 4. Connect the leads from the heating elements to the wiring harness by starting the connectors at approximately a 45 degree angle and then rocking into place. Once the connectors are fully engaged they will be difficult to disconnect. 5. Connect the green ground wire to a suitable grounding location on the engine. It is very important for safety that the system is properly grounded. Figure 12: Loosely Secure the Harness Figure 13: Engage the Connectors Page 5 of 6

6 Piston Preheat System Make a log entry to document the installation. A self sticking label is included for this purpose. Electrical Requirements System Voltage: 115 Volts AC Power Consumption: 230 Watts The installed weight of the system is approximately 15.5 ounces. Figure 14: Ground the System Figure 14: Tighten Tie Wraps Final System Check (Use an Ohmmeter for this test) There should be continuity between the airframe and the ground pin on the power plug (0 ohms). There should be continuity between the two power Blades on the power plug (approx ohms). There should be no continuity between the power pins and the ground pin on the power plug. Plug the system into 115 VAC power. In about 30 minutes the area next to the elements should feel warm. Do not touch the elements as they may burn you. Install the placard supplied with the kit near the flush mount plug. Instructions for Continued Airworthiness Maintenance Inspect the Tanis Preheat System at each annual or 100-hour inspection. Examine the system for security of attachment ensuring the wiring harness is tied securely to the engine. Inspect the harness power plug and leads. Follow this lead to the harness power junctions. In locations where the harness is required to transition from the engine to the airframe make sure there is enough slack to move with the travel of the mount. Inspect all surface areas of harness for chafing. Follow harness leads to each element. If any portion of the wiring shows signs of fatigue due to flexing, airflow, or vibration, repair and re-secure. Secure the harness as it passes over sharp edges with tie wraps or Adel clamps. A lead in a difficult location can also be protected with fire sleeve or appropriate material secured to the lead. Inspect all heat element leads for security and proper installation and bonding. If any portion of a pad heat element comes loose, it may be re-bonded (See Pad Installation Instructions #186). If the pad heat element develops a gray colored area, it is likely due to an air bubble under a poorly bonded element. An element that develops a gray area is in need of replacement. The parts contained in this system are FAA approved and specified inspections and other maintenance requirements are required under 14 CFR AC B Chapter 11 of the Federal Aviations Regulations unless an alternative FAA approved program is in force. End Page 6 of 6