Flight Compartment. 1. General

Size: px

Start display at page:

Download "Flight Compartment. 1. General"

Wilfred Watson
5 years ago
Views:

1 CIRRUS AIRPLANE MAINTENANCE MANUAL Flight Compartment CHAPTER 56-10: FLIGHT COMPARTMENT GENERAL 56-10: FLIGHT COMPARTMENT 1. General The windshield is manufactured of acrylic and is adhesive bonded to the fuselage. Replacement is accomplished by removing the interior trim around the windshield, removing sealant around the windshield, and then removing the windshield from the fuselage. In general, the reverse process is used to install a replacement windshield. This method is literally seamless, and the fuselage will show no marks or evidence of maintenance Dec 2016

2 CHAPTER 56-10: FLIGHT COMPARTMENT 2. Maintenance Practices CIRRUS AIRPLANE MAINTENANCE MANUAL A. Windshield (1) Removal - Windshield (a) Acquire necessary tools, equipment, and supplies. Description P/N or Spec. Supplier Purpose Die Grinder, Cut-Off Wheel, 1-inch diameter - Any Source Cut windshield (if not replacing). Drop Cloth - Any Source Prevent contamination. Masking Tape 2.0 inch (5.1 cm) width Any Source Protect fuselage and secure drop cloth. Duct Tape - Any Source Fabricate handle. Plastic Sheet - Any Source Prevent contamination. Putty Knife - Any Source Remove retainer. Shim Chisel, 1 to 3-inch width - Any Source Remove retainer. Locking Pliers - Any Source Remove retainer. Screwdriver Bit, Phillips #2 Any Source Remove retainer. Flap Wheel, 1 1/4-inch 80 grit Any Source Remove sealant. Isopropyl Alcohol TT-I-735 Grade A or B Fastenal Clean surfaces. Knife, Small Fixed Blade, 1-inch length (Non-Folding) Knife, Large Fixed Blade, 3 to 5-inch length (Non-Folding) - Any Source Remove sealant. - Any Source Remove sealant. Sandpaper, Aluminum Oxide 80 grit Any Source Remove sealant. (b) Remove crew seats. (Refer to 25-10) (c) Remove MFD. (Refer to 31-60) 2 21 Dec 2016

3 CIRRUS AIRPLANE MAINTENANCE MANUAL CHAPTER 56-10: FLIGHT COMPARTMENT (d) Remove PFD. (Refer to 31-60) (e) Remove interior trim from around windshield. (Refer to 25-10) (f) Disconnect and remove interior light harness. (g) Remove attaching hardware securing clips. (h) Cover interior with drop cloth to prevent contamination from debris. Tape drop cloth to fuselage, under windshield bonding flange. (i) At windshield exterior, apply masking tape to fuselage at outer perimeter of sealant and to windshield at inner perimeter of sealant. (j) Remove retainer sections. Due to wet installation of attaching hardware for retainers, apply firm pressure with screwdriver bit at exterior to avoid rounding-off screw heads. Use care to prevent fuselage damage when prying and removing retainer sections from fuselage and windshield. If laminate is damaged, it must be repaired prior to installing new windshield. Removal of retainer attaching hardware requires two technicians. 1 Remove paint from screw heads as required to engage screwdriver bits into slots. There are two windshield retaining clips installed at key locations along interior perimeter of windshield. Note location of clips to facilitate re-installation. 2 Remove nuts, washers, and screws securing sections of retainer to fuselage. 3 Using putty knife at edge of section, carefully remove enough sealant to expose lip of retainer section. 4 Carefully tap shim chisel at edge to further expose lip of retainer section. 5 Using pliers, pry and roll section off fuselage. Dispose of retainer section. 6 Repeat at remaining retainer sections. (k) Remove access panels N1L and N1R. (Refer to 6-00) (l) Remove windshield section. Use care to prevent fuselage damage when cutting and removing sealant from between fuselage and windshield. If 3

4 CHAPTER 56-10: FLIGHT COMPARTMENT CIRRUS AIRPLANE MAINTENANCE MANUAL (m) laminate is damaged, it must be repaired prior to installing new windshield. If windshield is being replaced, it will be easier to use die grinder and cut-off disk to cut out inner portion of windshield to gain access to bonding flange. Windshield should be cut as close as possible to fuselage. Use care to prevent damage to fuselage and instruments. 1 Use small fixed blade knife to carve sealant out between lower, inboard edge of windshield section and fuselage. Carefully remove enough sealant to expose lip of windshield section. 2 Tap and pry shim chisel into gap between windshield and fuselage to begin separation. As separation permits, increase shim chisel thickness to facilitate improved leverage while prying. 3 Once separation of windshield from fuselage begins, continue to carve sealant with small fixed blade knife. Work upward, carving in-between interfacing contours of windshield sections while prying with shim chisel as more separation occurs. 4 Continue to work along perimeter until windshield section is separated from fuselage. Remove windshield section. 5 Repeat at opposite windshield section. Using large fixed blade knife, flap wheel, isopropyl alcohol and sandpaper, remove all remaining sealant from fuselage bonding flange. (2) Installation - Windshield Windshield sealant is intended to provide a seal between the windshield and fuselage and to prevent the leakage of air through the airframe structure. Window sealant is used in the installation of all windows in the aircraft. Isopropyl alcohol, kerosene, white alptha naptha, mineral spirits, and cotton are acceptable for cleaning acrylic windows. Residue left behind by the Spraylat protective coating may be removed by soaking the area with isopropyl alcohol and rubbing with an alcohol soaked soft flannel cloth. Residue left behind by the adhesive backed paper covering can also be removed by the above method. If, however, the paper covering has been stored on the windshield for an extended period of time, soak paper with kerosene and keep it wet for several hours. Remove any remaining adhesive by using a mixture of equal parts of kerosene and isopropyl alcohol. Soak a soft 4

5 CIRRUS AIRPLANE MAINTENANCE MANUAL CHAPTER 56-10: FLIGHT COMPARTMENT flannel cloth with this mixture and rub the windshield with the cloth. The windshield should be cleaned after this procedure with a dish washing liquid and plenty of water. Never use organic solvents such as Methyl Ethyl Ketone (MEK), acetone, or lacquer thinner. Do not use jewelry cleaner or paper towels to remove any contaminates. Never use ice scrapers on acrylic windows. Do not store any window outdoors while the protective covering is still on the window. The covering will become very difficult, if not impossible, to remove without damaging the windshield. It is very important to keep windshield well supported at all times. Warm temperatures are not required during these operations; however, acrylic will take much more abuse at 80 F (27 C) than at 30 F (-1 C). Before final installation, always inspect the windshield for imperfections. Use care to prevent staining or scratching the windshield. (a) Acquire necessary tools, equipment, and supplies. Description P/N or Spec. Supplier Purpose Padded Cargo Rods - Any Source Secure windshield. Masking Tape 2.0 inch (5.1 cm) width Any Source Protect windshield. Temperature-Resistant Sealing Compound MIL-S-8802 Type II, Class B (Refer to 20-10) Seal windows. Isopropyl Alcohol TT-I-735 Grade A or B Fastenal Clean surfaces. Cotton Gloves (clean, lint free) - Any Source Protect hands. Cotton Cloth (clean, lint free) - Any Source Clean sealing surface. Application Spatula, 1-inch width (non-nylon) - Any Source Smooth adhesive. Primer MC-145 LP Aero Plastics Aid in adhesion. Protective Coating AC-940 Blue AC Products, Inc. Prevent damage to the windshield. Fine Line Masking Tape 0.25 inch width Any Source Provide smooth parting line. Sandpaper, Aluminum Oxide 80 grit or finer Any Source Abrade acrylic surface prior to adhesion. 5

6 CHAPTER 56-10: FLIGHT COMPARTMENT CIRRUS AIRPLANE MAINTENANCE MANUAL (b) (c) (d) (e) (f) (g) (h) (i) (j) (k) Use care to protect inner and outer windshield surfaces from damage during installation process. Stepped area on edge of windshield (which is bonded to fuselage) is called bonding flange. Verify sealant is within storage-life requirements. Inspect fuselage bonding flange for any remaining sealant or contaminates, remove and clean as necessary. Remove protective covering from windshield and inspect windshield for damage or defects, never install defective windshield. Install continuous piece of fine line tape on edge of fuselage windshield opening (next to bonding flange). Masking tape will provide smooth and continuous parting line at bonding flange. Working in one direction on fuselage window opening, apply masking tape on top of outer edge (furthest away from bonding flange) of fine line tape. Make directional mark on masking tape to indicate proper direction for removal. Do not apply protective coating on windshield bonding flange. Apply three coats (in opposing directions) of protective coating (AC-940 Blue) on outer windshield surface. Using several pieces of duct tape, make handles on exterior of windshield after protective coating has fully cured. Five or more padded cargo rods may be necessary to hold windshield into proper position. Padded cargo rods may be placed on each corner of windshield and in center of windshield. Additional padded cargo rods may be required to prevent the windshield from sliding down. Place windshield into position and secure windshield into fuselage using padded cargo rods. Inspect windshield for proper fit. The windshield must have equal amounts of space around perimeter of windshield. The exterior surface of windshield should be flush with exterior surface of fuselage skin. 6

7 CIRRUS AIRPLANE MAINTENANCE MANUAL CHAPTER 56-10: FLIGHT COMPARTMENT (l) (m) (n) (o) (p) (q) (r) (s) The windshield bonding flange must never be trimmed to thickness less than inch. The windshield bonding flange must never be less than 0.5 inch wide. The windshield bonding flange should have equal amounts of space around it. If windshield doesn t fit into fuselage with equal amounts of space around it, windshield and/or bonding flange will need to be trimmed accordingly. The windshield should be flush with exterior surface of fuselage skin. If windshield cannot be made flush by adding moderate pressure on padded cargo rods, thickness of windshield bonding flange must be trimmed accordingly. Aluminum oxide sandpaper (80 grit) on sanding board may be used to trim windshield. Mark and trim windshield as required to ensure perfect fit. Five or more padded cargo rods may be necessary to hold windshield into proper position. Padded cargo rods may be placed on each corner of windshield and in center of windshield. Additional padded cargo rods may be required to prevent windshield from sliding down. Prefit and clamp windshield into position using padded cargo rods. Remove small amount (approximately 2 inches wide) of protective coating from around edge of windshield. Install continuous piece of fine line tape around edge of windshield (next to bonding flange). Fine line tape should be adhered to windshield with equal amounts of space between fine line tape on fuselage and fine line tape on windshield. Working in one direction on windshield, apply masking tape on top of inner edge (furthest away from bonding flange) of fine line tape. Alignment marks will be used to ensure windshield will be installed into exact location in which it was during prefit. Using straight edge, make several alignment marks around edges of masking tape on fuselage to masking tape on windshield. Carefully remove windshield from fuselage. Using aluminum oxide sandpaper, abrade bonding flange of windshield in random pattern. Remove all surface gloss. 7

8 CHAPTER 56-10: FLIGHT COMPARTMENT CIRRUS AIRPLANE MAINTENANCE MANUAL (t) (u) (v) (w) (x) (y) (z) (aa) Wax or grease pencil markings on any part are not allowed. Any such markings inadvertently occurring must be removed prior to application of primer. All surfaces must be thoroughly cleaned and dried before application of primer. Immediately prior to applying any primer on windshield bonding flange, solvent clean flange with isopropyl alcohol. When handling cleaned surfaces, wear clean cotton gloves to prevent surface contamination. Surfaces must be re-cleaned in event of contamination. Fold cloth in such a manner to eliminate raw edges to reduce possibility of lint. Always clean area larger than application area. Remove contaminates from windshield bonding flange and immediate work area using vacuum and clean brush attachment. Do not apply primer to composite bonding surface. Ensure all surfaces adjacent to windshield bonding flange are masked to prevent them from coming into contact with any primer or sealant. Using isopropyl alcohol, solvent clean bonding flange in fuselage. (Refer to 20-30) Verify all required materials are present and all parts have been prepared and pre-fit. Wearing clean gloves, lightly dampen cloth with primer. Fold cloth in such a manner to eliminate raw edges to reduce possibility of lint. Apply primer to acrylic bonding flange. Wipe cloth over prepared area. Apply as little primer as possible while still wetting entire surface. Keep primed area clean and free from contaminates while primer is drying. Seal windshield as soon as practical after primer drying period to minimize contamination. Allow primer to dry for thirty to sixty minutes. Mix sealant per manufacturer's instructions. Mix the required quantity in the ratio specified in the adhesive manufacturer's instructions. (Refer to 20-10) Do not apply sealant to windshield bonding flange. Sealant must be applied to fuselage bonding flange. 8

9 CIRRUS AIRPLANE MAINTENANCE MANUAL CHAPTER 56-10: FLIGHT COMPARTMENT (ab) Apply thin layer of sealant to outer edge of fuselage bonding flange. Spread sealant out using application spatula. (ac) (ad) (ae) (af) When spreading sealant, ensure all air pockets are removed. If more than one bead is required, apply it immediately adjacent to prior bead to form one large bead. Glass beads may be applied in bond line to ensure minimum sealant thickness is maintained. Add up to 2.3 grams of glass beads per 3 fluid ounces of mixed adhesive. (Refer to 51-30) Directly on top of sealant previously spread, apply 1/4 to 3/8 inch bead of sealant down center of bond area. Five or more padded cargo rods may be necessary to hold windshield into proper position. Padded cargo rods may be placed on each corner of windshield and in center of windshield. Additional padded cargo rods may be required to prevent windshield from sliding down. Using padded cargo rods, secure windshield into position ensuring reference marks made earlier are perfectly aligned and contour of windshield matches contour of fuselage. Using application spatula, push sealant into gap between windshield and fuselage. To prevent sealant from becoming damaged, pull tape towards sealant while sealant is still damp. Remove tape from perimeter of windshield and fuselage. Overheating windshield can cause windshield damage. (ag) Allow sealant to air dry. Following manufacturer s instructions, sealant can be heat cured using heat gun. (ah) Remove plastic and tape from perimeter of CAPS bay. (ai) Install CAPS rocket. (Refer to CAPS CMM) (aj) Connect CAPS sequencer. (Refer to CAPS CMM) (ak) Install windshield sprayer. (Refer to 30-40) (al) Install CAPS cover. (Refer to 6-00) 9

10 CHAPTER 56-10: FLIGHT COMPARTMENT CIRRUS AIRPLANE MAINTENANCE MANUAL (am) Install access panels N1L and N1R. (Refer to 6-00) (an) Install retainer sections. Installation of retainer attaching hardware requires two technicians. 1 Apply sealant to bonding flange of windshield and fuselage. 2 Position retainer section to bonding flange. There are windshield retaining clips installed at key locations along interior perimeter of windshield. Position clips at locations noted during removal. 3 Wet install screws, washers, and nuts securing retainer section to fuselage. (Refer to 20-10) 4 Apply and smoothly transition sealant at inner / outer perimeter of retainer. 5 Paint screw heads along perimeter of retainer. (Refer to 51-20) 6 Repeat at remaining retainer sections. (ao) Remove masking tape from perimeter of windshield. (ap) Route and secure the interior light wiring harness. (aq) Using vacuum cleaner, remove all debris from cabin and fuselage. (ar) Remove drop cloth from interior. (as) Install and secure interior trim. (Refer to 25-10) (at) Install crew seats. (Refer to 25-10) (au) Install PFD. (Refer to 31-60) (av) Install MFD. (Refer to 31-60) (aw) Clean windshield. (Refer to 56-10) (3) Inspection/Check - Windshield (a) Acquire necessary tools, equipment, and supplies. Description P/N or Spec. Supplier Purpose Incandescent Lamp 500 or 1000 Watt Any Source Transmit inspection light. 10

11 CIRRUS AIRPLANE MAINTENANCE MANUAL CHAPTER 56-10: FLIGHT COMPARTMENT (b) (c) (d) (e) Examine window using 500 or 1000 watt incandescent lamp placed on side of window opposing technician. Scan entire window. If necessary, vary sight angle and angle at which the light strikes window to find maximum intensity of scratches, buff marks or minor defects. Look through window toward a dark, uncluttered background for ease of inspection. If identified, verify scratches do not exceed tolerances. For tolerances, contact Cirrus Aircraft for disposition. (Refer to AMM-Intro-00) If identified, verify distortions do not exceed tolerances. 1 Verify no crazing exists in any portion of the window. 2 Verify no haze measuring greater than 5% exists in any portion of the window. 3 Verify no localized hazing exists in any portion of the window. If any measurement exceeds tolerances, contact Cirrus Aircraft for disposition. (4) Optional Leak Check- Windshield (a) Acquire necessary tools, equipment, and supplies. Description P/N or Spec. Supplier Purpose Snoop Liquid Leak Detector - Swagelok Locate leaks. Isopropyl Alcohol TT-I-735 Grade A or B Fastenal Clean winshield. Tape - Any Source Prepare faying surfaces. Sandpaper 180 grit Any Source Prepare faying surfaces. Primer AC-137 Advanced Chemistry and Technology Promote adhesion. Sealant, Epoxy Cured Polythioether PR-1829 Class B-2 PRC-Desoto International Repair leaks. (b) Pressurize cabin per pressure leak test procedure. Do not exceed 2.0 PSI. (Refer to 21-30) Dec 2018

12 CHAPTER 56-10: FLIGHT COMPARTMENT CIRRUS AIRPLANE MAINTENANCE MANUAL (c) (d) (e) (f) (g) (h) (i) (j) (k) Apply leak detector to edges of both RH and LH windshields. 1 Mark any areas that produce bubbles as leak locations. 2 Clean off aircraft exterior when completed. Depressurize cabin. Remove windscreen trim panels installed near leak locations as needed. (Refer to 25-10) Clean interior windscreen with isopropyl alcohol along perimeter of any leak locations. Prepare faying surfaces (outer inch of windscreen and composite flange edge of window frame). 1 Apply tape inch from edge along repair area. 2 Scuff surface with sandpaper. 3 Clean surface with isopropyl alcohol and allow to dry. 4 Apply primer and allow to dry. 5 Fill or inject any openings along the suspected leak areas with sealant. Remove tape and clean windscreen once sealant has cured. Pressurize cabin to 2.0 PSI and check for leaks. 1 If no leaks are found, continue to next step. 2 If any leaks are found, repeat above steps until there are no leaks. Depressurize cabin. Reinstall interior panels and reinstall all components removed during test. (Refer to 25-10) (5) Cleaning - Windshield Acrylic windows should be cleaned using the following chemicals, and by following the manufacturer s instructions for each individual product. (a) Acquire necessary tools, equipment, and supplies Dec 2018

13 CIRRUS AIRPLANE MAINTENANCE MANUAL CHAPTER 56-10: FLIGHT COMPARTMENT Description P/N or Spec. Supplier Purpose Acrylic Polish and Sealant SP-PL16 LP Aero Plastics, Inc. Polish acrylic. Plastic Cleaner and Polish SP-210A LP Aero Plastics, Inc. Clean acrylic. Plastic Scratch Remover SP-210P LP Aero Plastics, Inc. Remove fine scratches in acrylic. (b) For additional information on airplane cleaning practices, see Scheduled Servicing section of Servicing. (Refer to 12-20) Dec 2018

14 CHAPTER 56-10: FLIGHT COMPARTMENT CIRRUS AIRPLANE MAINTENANCE MANUAL Intentionally Left Blank Dec 2018

Flight Compartment. 1. General

Flight Compartment. 1. General CIRRUS AIRPLANE MAINTENANCE MANUAL Flight Compartment CHAPTER 56-10: FLIGHT COMPARTMENT GENERAL 56-10: FLIGHT COMPARTMENT 1. General The windshield is manufactured of acrylic and is adhesive bonded to