Single Engine MANDATORY SERVICE LETTER SEL-78-03 TITLE EXHAUST - TRANSMITTAL OF LYCOMING SERVICE BULLETIN NO 627C, EXHAUST SYSTEM INSPECTION EFFECTIVITY REASON MODEL T206H SERIAL NUMBERS T20608001 and On Lycoming model TIO-540-AJIA engines can have exhaust leaks due to cracked welds and have exhaust studs pulling from a cylinder. Continued operation with a cracked exhaust pipe could result in loss of engine power, engine fire, damage to the engine and/or adjacent airplane structure, and/or accumulation of Carbon Monoxide in the cabin. DESCRIPTION This service letter transmits Lycoming Service Bulletin No. 627C, Exhaust System Inspection which provides instructions for completing an exhaust system inspection. Refer to the Lycoming Service Bulletin No. 627C (Revision C or latest revision) for more detailed information. COMPLIANCE MANDATORY. Upon receipt of this service bulletin, complete an exhaust system inspection as follows: 1. Before further flight if one or more of the conditions that follow exist: Cowl Discoloration in the area of the exhaust manifold CO alert Uncommanded or unexplained reduction of Manifold Absolute Pressure (MAP). 2. Within 10 flight hours from the date of this Service Bulletin, complete an initial Exhaust System Inspection in accordance with the Required Action Steps 1 and 3 in Lycoming Service Bulletin No. 627C, Exhaust System Inspection (Revision C or latest revision) 3. After the initial Exhaust System Inspection, subsequent repetitive Exhaust System Inspections are to be completed per Table 1 in Lycoming Service Bulletin No. 627C, Exhaust System Inspection (Revision C or latest revision) NOTE: The Guardian Avionics carbon monoxide detector, that was factory installed on T206H serial numbers T20608594 and ON, meets the requirements of the Lycoming Service Bulletin No. 627C. REFERENCES Lycoming Service Bulletin No. 627C, Exhaust System Inspection (Revision C or latest revision). PUBLICATIONS AFFECTED None SEL-78-03 January 3, 2017 Page 1 of 2 Textron Aviation Customer Service, P.O. Box 7706, Wichita, KS 67277, U.S.A. 1-316-517-5800 This document contains technical data and is subject to U.S. export regulations. This information has been exported from the United States in accordance with export administration regulations. Diversion contrary to U.S. law is prohibited. ECCN: 9E991 COPYRIGHT 2017
Single Engine MANDATORY SERVICE LETTER SEL-78-03 ACCOMPLISHMENT INSTRUCTIONS 1. Prepare the airplane for maintenance. A. Make sure that the airplane is electrically grounded. B. Make sure that all switches are in the OFF/NORM position. C. Disconnect electrical power from the airplane. (1) Disconnect the airplane battery. (2) Disconnect external electrical power. D. Attach maintenance warning tags to the battery and external power receptacle that have "DO NOT CONNECT ELECTRICAL POWER - MAINTENANCE IN PROGRESS" written on them. 2. Complete Lycoming Service Bulletin No. 627C, Exhaust System Inspection. A. Complete the survey for the exhaust system inspection and flange nut torque check and submit to Lycoming Engines. (Refer to Lycoming Service Bulletin No. 627C, Exhaust System Inspection (Revision C or latest revision).) 3. Remove the maintenance warning tags and connect the airplane battery. 4. Make an entry in the airplane logbook that states compliance and method of compliance with this service letter. SEL-78-03 Page 2 January 3, 2017
Single Engine OWNER ADVISORY SEL-78-03 TITLE EXHAUST - TRANSMITTAL OF LYCOMING SERVICE BULLETIN NO 627C, EXHAUST SYSTEM INSPECTION TO: Cessna Model T206H Owner REASON Lycoming model TIO-540-AJIA engines can have exhaust leaks due to cracked welds and have exhaust studs pulling from a cylinder. Continued operation with a cracked exhaust pipe could result in loss of engine power, engine fire, damage to the engine and/or adjacent airplane structure, and/or accumulation of Carbon Monoxide in the cabin. COMPLIANCE MANDATORY. Upon receipt of this service bulletin, complete an exhaust system inspection as follows: 1. Before further flight if one or more of the conditions that follow exist: Cowl Discoloration in the area of the exhaust manifold CO alert Uncommanded or unexplained reduction of Manifold Absolute Pressure (MAP). 2. Within 10 flight hours from the date of this Service Bulletin, complete an initial Exhaust System Inspection in accordance with the Required Action Steps 1 and 3 in Lycoming Service Bulletin No. 627C, Exhaust System Inspection (Revision C or latest revision) 3. After the initial Exhaust System Inspection, subsequent repetitive Exhaust System Inspections are to be completed per Table 1 in Lycoming Service Bulletin No. 627C, Exhaust System Inspection (Revision C or latest revision) NOTE: The Guardian Avionics carbon monoxide detector, that was factory installed on T206H serial numbers T20608594 and ON, meets the requirements of the Lycoming Service Bulletin No. 627C. NOTE: As a convenience, service documents are now available online to all our customers through a simple, free-of-charge registration process. If you would like to sign up, please visit the "Customer Access" link at www.txtavsupport.com to register. SEL-78-03 January 3, 2017 Page 1 of 1 Textron Aviation Customer Service, P.O. Box 7706, Wichita, KS 67277, U.S.A. 1-316-517-5800 This document contains technical data and is subject to U.S. export regulations. This information has been exported from the United States in accordance with export administration regulations. Diversion contrary to U.S. law is prohibited. ECCN: 9E991 COPYRIGHT 2017
652 Oliver Street Williamsport, PA 17701 U.S.A. Telephone +1 (800) 258-3279 (U.S. and Canada) Telephone +1 (570) 323-6181 (International) Facsimile +1 (570) 327-7101 www.lycoming.com DATE: November 17, 2016 Service Bulletin No. 627C (Supersedes Service Bulletin No. 627B) Engineering Aspects are FAA Approved SUBJECT: MODELS AFFECTED: TIME OF COMPLIANCE: Exhaust System Inspection Lycoming Engine Model TIO-540-AJ1A Within 10 flight hours from the date of this Service Bulletin, complete an initial Exhaust System Inspection in accordance with the Required Action Steps 1 and 3 in this Service Bulletin After the initial Exhaust System Inspection, subsequent repetitive Exhaust System Inspections are to be completed per Table 1 in this Service Bulletin REASON FOR REVISION: Changed CO detector lower alarm setting from 35 PPM to 50 PPM; Revised instruction for weld joint examination and included footer on pages 5, 6, and 7 NOTICE: Incomplete review of all the information in this document can cause errors. Read the entire Service Bulletin to make sure you have a complete understanding of the requirements. This Service Bulletin is in response to field reports of exhaust leaks due to cracked welds and exhaust studs pulling from a cylinder on some Lycoming TIO-540-AJ1A engine models. This Service Bulletin contains instructions for the mandatory inspection of the exhaust system for ALL Lycoming TIO-540-AJ1A engine models per the schedule in Table 1. Table 1 Schedule for Exhaust System Inspections Engines installed in aircraft equipped with an operating carbon monoxide detector* After the initial 10-hour Exhaust System Inspection, complete the: Exhaust System Inspection after every 50 hours time in service - complete Required Actions 1 and 3 Torque Check after every 100 hours time in service - complete Required Actions 1, 2, and 3 Engines installed in aircraft not equipped with a carbon monoxide detector or with an inoperative carbon monoxide detector Engines that have accumulated 1000 hours or less time in service since the last Exhaust System Maintenance** After the initial 10-hour Exhaust System Inspection, complete the: Exhaust System Inspection after every 25 hours time in service - complete Required Actions 1 and 3 Torque Check after every 100 hours time in service - complete Required Actions 1, 2, and 3 MANDATORY SERVICE BULLETIN Engines that have accumulated more than 1000 hours time in service since the last Exhaust System Maintenance** After the initial 10-hour Exhaust System Inspection, complete the: Exhaust System Inspection after every 50 hours time in service - complete Required Actions 1 and 3 Torque Check after every 100 hours time in service - complete Required Actions 1, 2, and 3 * An operational carbon monoxide (CO) detector must be an electrochemical CO detector, located on the instrument panel, and set for a lower alarm threshold of 50 parts per million (PPM). ** Since having maintenance that required the removal/reinstallation or the removal and replacement of any exhaust system pipe or turbocharger mounting bracket. 1 of 7 C 2016 Avco Corporation. All Rights Reserved. Lycoming Engines is a division of Avco Corporation
TOXIC GASES, SUCH AS CARBON MONOXIDE, FROM LEAKS IN THE EXHAUST SYSTEM CAN POTENTIALLY ENTER THE COCKPIT. NOTICE: The inspections in this Service Bulletin are in addition to the requirements of Service Bulletin No. SB-614A and AD 2015-10-06. Both are to be accomplished as specified in their respective compliance times. Figures in this Service Bulletin are for illustration purposes only; your engine can appear differently. Required Action 1. Exhaust System Inspection THE ENGINE AND EXHAUST SYSTEM CAN BE HOT AND COULD CAUSE BURNS. DO NOT CONDUCT THE EXHAUST SYSTEM INSPECTION WITHIN 1 HOUR OF OPERATING THE ENGINE AND UNTIL THE ENGINE AND EXHAUST ARE COOL. NOTICE: To accurately and efficiently assist those who could be experiencing exhaust leaks due to cracked welds and exhaust studs pulling from a cylinder, Lycoming Engines must collect certain data and information from you each time you complete this inspection. This inspection can be done on an engine installed in an airframe. During this exhaust system inspection and each subsequent inspection thereafter per Table 1, complete the steps in this Service Bulletin. Record and submit the findings to Lycoming Engines on the attached form either online or on hardcopy. NOTICE: It is very important during this inspection to look for and record on the survey any stamped data on the Exhaust No. 2 and 3 pipes. The stamped markings for Exhaust Pipe 2 will have one of the following: Only the part number (P/N) (Figure 1). All pipes will be stamped with at least the P/N. The P/N and the Release ID# (Figure 2) The P/N, Release ID#, and a date code (Figure 3) Figure 1 P/N Only on Exhaust Pipe 2 Figure 2 P/N and Release ID# on Exhaust Pipe 2 Figure 3 P/N, Release ID#, and Date Code on Exhaust Pipe 2 A. Examine Exhaust Pipe 2, identify any stamped markings, and record the data on the survey. 2 of 7 C S.B. 627
The stamped markings for Exhaust Pipe 3 can have: Only the P/N (Figure 4). All pipes will be stamped with at least the P/N. The P/N and the Release ID# (Figure 5) (There is no date code on Exhaust Pipe 3) Figure 4 P/N Only on Exhaust Pipe 3 Figure 5 P/N and Release ID# on Exhaust Pipe 3 B. Examine Exhaust Pipe 3, identify any stamped markings, and record the data on the survey. C. Examine the weld joints of the exhaust pipes for all cylinders (Figures 6 and 7). Closely examine the saddle reinforced weld joints (Figures 8 and 9), especially at Cylinder 3. If any cracks or damage are found, do not operate the aircraft until repairs are made in accordance with existing Lycoming publications. Complete and submit the survey with your findings and corrective action per Required Action 3 in this Service Bulletin. Figure 6 Installed Exhaust System (Cylinders #1, #3, #5 - Right Side of Engine) Figure 7 Installed Exhaust System (Cylinders #2, #4, #6 - Left Side of Engine) Figure 8 Saddle Figure 9 Saddle 3 of 7 C S.B. 627
D. Examine all cylinder exhaust flanges (Figure 10) for damage, distortion, or signs of exhaust gas leaking past the gasket, especially at Cylinder 2. Indications of a flange gasket leak are burnt paint around the exhaust flange bosses or powdery white to light brown or black residue near the leaks, on the spark plug, and the baffle. If the flange or pipe is distorted, damaged, or there are signs of exhaust leaking past the gasket, do not operate the aircraft until repairs are made in accordance with existing Lycoming publications. Complete and submit the survey with your findings and corrective action per Required Action 3 in this Service Bulletin. Figure 10 Signs of Exhaust Leak DO NOT OPERATE THE AIRCRAFT WITH A LEAKING ENGINE EXHAUST SYSTEM. OPERATION OF THE AIRCRAFT WITH AN EXHAUST SYSTEM LEAK CAN LEAD TO CARBON MONOXIDE POISONING, LOSS OF CONCIOUSNESS, INJURY, OR DEATH. E. Complete a visual inspection on the entire exhaust system (Figures 6 and 7). If any sign of leaks, distortion, or damage is found, do not operate the aircraft until repairs are made in accordance with existing Lycoming publications. Complete and submit the survey with your findings and corrective action per Required Action 3 in this Service Bulletin. 2. Flange Nut Torque Check A. Since loose flange nuts can be an indication of a potential exhaust leak, complete a torque check on exhaust system flange nuts for all six cylinders. B. If a flange, stud, flange nut, or pipe is distorted or visibly damaged, document the issue on the form then replace with serviceable parts. If it is just a leaky gasket, determine root cause, document it on the form, and replace the gasket and hardware with new parts. Do not operate the aircraft until repairs are made in accordance with existing Lycoming publications. Complete and submit the survey with your findings and corrective action per Required Action 3 in this Service Bulletin. C. On the survey, record the fractional amount each flange nut turns to achieve the required 96 in.- lb (11 Nm) torque. If any flange nuts are loose enough to allow movement of the washer, contact Lycoming Engines Product Support. 3. Submit the completed survey after each Exhaust System Inspection and Flange Nut Torque Check to Lycoming Engines either online or by mail. Online Mail Fill out the online form at www.lycoming.com/sb627 Click on the link or cut and paste into your browser. Copy and manually complete the hard copy version of the form in this Service Bulletin and send it by postal service to: Technical Support Lycoming Engines 652 Oliver Street Williamsport, PA 17701 USA 4 of 7 C S.B. 627
Engine Serial Number (Ex. L-12345-61E): Time Since Last Exhaust System Maintenance: Name: OWNER INFORMATION Company: Address: City: State: Postal Code: Country: Telephone Number: Name: MAINTENANCE PROVIDER INFORMATION Company: Address: City: State: Postal Code: Country: Telephone Number: 5 of 7 C S.B. 627
EXHAUST SYSTEM REVIEW Time Since Exhaust System Maintenance Is there an operable carbon monoxide detector installed in the aircraft? Stamped Data on Exhaust Pipe 2 Stamped Data on Exhaust Pipe 3 Were any cracks found on welded joints? If yes, please describe the location of the crack. Were any exhaust leaks found at the cylinder exhaust mounting flange? Yes No Part Number: Released ID #: Date Code: Part Number: Released ID #: Yes No Yes No What cylinder exhaust flange was leaking? (You may select multiple cylinders) Were there any other exhaust discrepancies found? If yes, please describe the discrepancies found. 1 2 3 4 5 6 Yes No 6 of 7 C S.B. 627
Did any exhaust flange nuts require more turning to reach the required torque? (96in/lbs) Yes No If yes, which cylinder exhaust flange nuts did you find loose? Please indicate the amount of movement that you needed to tighten the nuts. Forward Outboard Nut Forward Inboard Nut Aft Outboard Nut Aft Inboard Nut Forward Outboard Nut Forward Inboard Nut Aft Outboard Nut Aft Inboard Nut Forward Outboard Nut Forward Inboard Nut Aft Outboard Nut Aft Inboard Nut Forward Outboard Nut Forward Inboard Nut Aft Outboard Nut Aft Inboard Nut Forward Outboard Nut Forward Inboard Nut Aft Outboard Nut Aft Inboard Nut Forward Outboard Nut Forward Inboard Nut Aft Outboard Nut Aft Inboard Nut CYLINDER 1 N/A <1/8 Turn 1/8 Turn CYLINDER 2 N/A <1/8 Turn 1/8 Turn CYLINDER 3 N/A <1/8 Turn 1/8 Turn CYLINDER 4 N/A <1/8 Turn 1/8 Turn CYLINDER 5 N/A <1/8 Turn 1/8 Turn CYLINDER 6 N/A <1/8 Turn 1/8 Turn 1 / 4 Turn 1 / 4 Turn 1 / 4 Turn 1 / 4 Turn 1 / 4 Turn 1 / 4 Turn 1 / 2 Turn >1/2 Turn 1 / 2 Turn >1/2 Turn 1 / 2 Turn >1/2 Turn 1 / 2 Turn >1/2 Turn 1 / 2 Turn >1/2 Turn 1 / 2 Turn >1/2 Turn 7 of 7 C S.B. 627