Section TABLE of CONTENTS Pages Introduction 3 Kit Contents 4 Preparation 5 Removal of old exhaust system 5 Installation 5 Installing Collector Box Assembly and Exhaust Assembly 5 Installing Cabin Heat 5 Installing Support Rod 6 Instructions for Continued Airworthiness 8 Installation Overview 11 Pilot Side View 12 Passenger Side View 13 Front View 14 Detail A 15 Detail B 16 Detail C 17 Detail D 18 Detail E 19 STC Letter 20 PFS-14150-00 REV C Page 2 of 20 05/22/07
Introduction Description: The PFS exhaust consists of an exhaust pipe from each cylinder to the collector assembly located beneath the engine. The collector assembly is enclosed in a shroud, which captures ram air to be heated by exhaust gases passing through the tubes of the collector assembly. This heated air is used to heat the aircraft cabin. A separate shroud furnishes heated air for carburetor heat. A detachable tailpipe from the collector assembly routes exhaust gases to a muffler through an opening in the lower cowling. A support rod attached to the lower left engine mount supports the muffler. Carbon Monoxide testing was performed with the muffler positioned as described in these instructions. Repositioning the muffler and/or support rod may cause carbon monoxide to enter the aircraft cabin. Your exhaust muffler has been chemically polished to remove manufacturing marks and provide an attractive finish. The tubular components are manufactured from 321 Stainless Steel and can be further polished for an extremely high shine. After installation and before running engine, we highly recommend wiping clean the exhaust muffler to remove all finger-prints, grease, and other contaminants with Alcohol, MEK, Lacquer thinner, or similar liquid degreaser. After installation and cleaning exhaust muffler, run the engine and let it warm up then run at full power for a short period. This will create a Bluing of the exhaust and a golden yellow color of the muffler. To maintain this Blued finish keep exhaust free from oil, fingerprints, and any other contaminates by normal cleaning or polishing. Note: PFS is the abbreviation for Power Flow Systems. Please read these directions completely before starting installation. Please call us at 386-253-8833 during normal business hours if you have any questions regarding the installation of this kit. Please Note: The Power Flow Systems Exhaust has been designed and FAA certified to be installed in accordance with these instructions. Any modification to the exhaust system or its components, or any deviation from these instructions without express written permission from Power Flow Systems, Inc. invalidates the design and the FAA approval. Any such modifications or deviations will also void the exhaust system warranty. PFS-14150-00 REV C Page 3 of 20 05/22/07
Kit Contents Each Power Flow exhaust kit is shipped with: Quantity Part Description Part Number 1 #1 Header 11080 1 #2 Header 12080 1 #3 Header 13080 1 #4 Header 14080 4 No-blow Header Gasket 77611 8 Exhaust Nut SL-STD-1410 8 Lock Washer MS35333-41 8 Plain Washer AN960-516 1 Shrouded Collector Assembly 41180 1 2 Slider or 3 Slider 4180 or 4181* 1 2.5-3 SCAT Adaptor 4183* 4 Stainless Blind Rivets CCP-32 1 Exhaust Clamp (2 with pin) 7020 1 Exhaust Clamp (2 w/o pin) 7021 1 Exhaust Clamp (1.62 w/o pin) 7030 2 Drilled Bolt AN4C5 1 Drilled Bolt AN4C30A 1 Locking Nut MS21045C4 2 Castle Nut AN310C4 2 Cotter Pin MS24665C153 8 Flat Washer AN960C416 1 2.3x0.375x0.049 Standoff 1 Exhaust Extension Tube 7802 1 Muffler Assembly 80010 1 Support Rod 90180 1 Muffler Clamp (3 1/2 without pin) 8030 1 Adel Clamp size 6 MS21919WH6 1 Adel Clamp size 11 MS21919WH11 1 Locknut MS21044C3 1 Bolt MS51958-63 2 Flat Washer AN960C10 * These are optional methods for installation of the cabin heat outlet. 4180 is for the 2 Cabin Heat, 4181 is for the 3 Cabin Heat. Part Number 4183 is required for 2.5 Air Inlet tubes. SCAT tube and clamps will be supplied for those aircraft requiring PN 4183. PFS-14150-00 REV C Page 4 of 20 05/22/07
PREPARATION REMOVAL OF OLD EXHAUST SYSTEM 1) Remove lower cowl components in accordance with the latest revision of the Aircraft s Service Manual. 2) Disconnect flexible ducts from muffler assembly. 3) Remove EGT probe(s), if installed. 4) Remove nuts attaching exhaust pipes to exhaust studs. 5) Remove exhaust pipes and gaskets. 6) We recommend that you weigh both the stock system and the Power Flow System for later weight & balance calculations. INSTALLATION A. Installing Collector Box assembly and Exhaust pipes: 1) Insert the exhaust header pipes into the collector assembly as per the numbering on the collector. Be sure to use the alignment marks. A minimum of 1 1/2 penetration is required for proper operation. See Passenger and Pilot Side Views. Put new gaskets into position on each cylinder. It is suggested that you keep them in place temporarily with either a loop of safety wire or a large cotter pin. Lift and hold the assembly into position. Start a nut on each header to hold the entire assembly in place. See Detail A, Passenger and Pilot Side Views. 2) Install a washer, a lock washer and a nut on each stud (there are 8 sets of these). If utilized, remove the loops of safety wire or cotter pins. See Detail A and Pilot Side View. Tighten, but do not torque to value yet. 3) Check clearances all around the collector assembly. If the aircraft has a full-size starter, the outer clamp on the starter may need to be rotated to ensure adequate clearance. Also, if the heat shroud contacts the airbox or intake runners, the shroud may be carefully bent away to ensure positive clearance. See Picture 2. 4) Remove collector endplate. Slide the exhaust extension in place and attach using the two clamps as shown in Detail E. Do not tighten clamps, yet. If the exhaust extension was installed at the factory, skip this step. Picture 1 Clamp rotated for clearance Picture 2 B. Cabin Heat Set-up 1) Align slider over cabin heat cut out on collector, all aircraft with 2 Cabin Heat get the 2 slider, 3 Cabin Heat get the 3 slider. Position the slider to obtain maximum clearances on all sides. Move the throttle to the full open position to ensure proper clearance to the throttle lever. 2) Mark the sides of the sliding assembly so that you can remove the collector and permanently install it. On the slider, transfer hole locations from the 2 existing screws on the collector and mark four holes for rivets. PFS-14150-00 REV C Page 5 of 20 05/22/07
3) Lower the header and collector assembly from the aircraft. 4) Reinstall the sliding heat inlet onto the collector heat shroud align it with the marks you made while it was installed on the aircraft. See Picture 3. WARNING: DO NOT DRILL INTO ANY EXHAUST TUBES THAT ARE UNDER THE COLLECTOR SHROUD. 5) Drill to install 4 rivets (P/N CCP-32) and 2 existing collector screws. WARNING: DO NOT DRILL INTO ANY EXHAUST TUBES THAT ARE UNDER THE COLLECTOR SHROUD. Picture 3 6) Now reinstall the collector body and headers onto the aircraft as outlined above. Torque headers as recommended in the latest approved revision of either the Aircraft Service Manual or AC 43.13. C. Installing Support Rod 1.) Examine the left lower engine mount bolt and nut. If you have one to two threads showing at the nut, it may be necessary to install the next dash number longer AN7 bolt after installing our support rod adapter. See Detail D. a) Loosen and remove the lower left engine Lord mount bolt. Our support rod adapter (the teardrop shaped piece of metal welded to the support rod) goes under the bolt head, on top of the existing large area washer. See Detail D. Ensure that the rod clears all engine compartment parts, and will exit the cowl directly above the muffler assembly. Also make sure that the pointed end of the support rod will clear the bottom of the aircraft cowl. b) Tighten the Lord mount bolt, but DO NOT TORQUE TO VALUE YET. You will fully torque the mount once the position and adjustment of the support rod is complete. Picture 4 c) Attach support rod to engine mount using supplied Adel clamps and hardware. See picture 4. 2.) Position the lower cowl onto the airplane. You will need to attach the cowl with enough screws to ensure the proper angle of the lower cowl. The exhaust extension should pass through the middle of the exhaust outlet. 3.) Slide the muffler assembly over the exhaust extension outlet. It should be pushed up as far it can go, oriented straight back. The support rod should be contacting the unit at the muffler. You may have to make minor adjustments in alignment and rotation of both the muffler assembly and the exhaust extension assembly. PFS-14150-00 REV C Page 6 of 20 05/22/07
Any deviation in muffler and/or support rod alignment may cause carbon monoxide to enter the aircraft cabin. The muffler must be pointed down and away from the aircraft not parallel to the fuselage in order to ensure that no exhaust gases enter the aircraft cabin. 4.) Position the large support clamp, P/N 8030, around the muffler so that it will attach to the support rod with a bolt. See Picture 5. If your airplane has a nose wheel pant, turn the nose gear fully to the left and ensure that the muffler assembly does NOT strike the pant. If needed, rotate the muffler outward. The support rod can be carefully bent to assist in assuring that the support rod and muffler clamp stay in alignment. If the end tab does not align flat against the clamp, twist the tab with pliers until it lays flat. 5.) Install the clamp so that the holes will align with the hole in the support rod. See Detail C 6.) Mark the exhaust extension through the hole in the muffler. 7.) Remove the muffler and cowling. 8.) Drill a 0.25 hole at the mark made in step 6 above. Be sure to de-burr the hole or later removal of the muffler will be difficult. 9.) Install the muffler assembly and clamp to the exhaust extension with one of the provided 2 clamps (the one with the pin). See Detail B. 10.) Clamp the muffler assembly to the support rod with the provided 3.5 clamp. See Detail C. 11.) Tighten clamps attached earlier to the exhaust extension. See Detail E. Reattach collector endplate. Now that all of the support mechanism for the muffler is correct, tighten the engine mount to manufacturer s specified torque. Be sure that the support rod doesn t rotate when tightening Picture 5 CAUTION Make sure that you have at least one to two threads showing through the nut on the engine mount. It may be necessary to install a longer bolt. PFS-14150-00 REV C Page 7 of 20 05/22/07
Any deviation in muffler and/or support rod alignment may cause carbon monoxide to enter the aircraft cabin. The muffler must be pointed down and away from the aircraft not parallel to the fuselage in order to ensure that no exhaust gases enter the aircraft cabin. 12.) If your aircraft has a 2.5 Cabin Heat Inlet, cut the existing SCAT tube down to approximately 3-6 inches and install the adapter. Cut the supplied 3 SCAT tube to length and install between the adapter and the cabin heat inlet on the shroud. Attach the carb heat SCAT tubing to the carb heat outlet on the heat shroud. It may be easier to remove the SCAT tube from the carb air box and install on the heat shroud first, then re-attach to the carb air box. The SCAT tube may need to be replaced with a more flexible tube if installation is too difficult. Attach the cabin heat scat tube to the slider that was previously installed. A band clamp may be necessary to ensure proper clearances. 13.) Create a placard and place in clear view of the pilot that reads: The Power Flow Systems, Inc. tuned exhaust system installed on this aircraft may cause the aircraft to burn more fuel at certain power settings. It is the Pilot s responsibility to determine what, if any, change in fuel flow exists and to plan accordingly. 14.) Make appropriate entries in the logbook and on FAA Form 337. The STC is located at the back of this instruction set for easy removal. - Typical Weight and Balance Information: The Power Flow Systems, Inc. tuned exhaust system weighs approximately 20lbs at station 33. To be most accurate, it is recommended that you weigh both the old exhaust system and the new exhaust system to obtain an exact weight differential. INSTRUCTIONS FOR CONTINUED AIRWORTHINESS It is the responsibility of the aircraft owner/technician to ensure that the most recent revision of these instructions is followed. The most recent revision of this report can obtained by calling Power Flow Systems, Inc. at (386) 253-8833 or online at www.powerflowsystems.com 1.0 BASIC OPERATION Basic operation of the airplane remains the same. The pilot must watch to ensure that redline of the RPM is not exceeded. 2.0 AIRWORTHINESS LIMITATIONS The Airworthiness Limitations section is FAA approved and specifies maintenance required under 43.16 and 91.403 of the Federal Aviation Regulations unless an alternative program has been FAA approved. 2.1 Mandatory Replacement Time None 2.2 Structural Inspection Interval At 100 hour or Annual intervals, depending on the service regime of the aircraft. 2.3 Structural Inspection Procedure See Section 5.0 Below. PFS-14150-00 REV C Page 8 of 20 05/22/07
3.0 TROUBLESHOOTING Problem Possible Cause Solution Exhaust smell in cockpit Exhaust Leak Inspect exhaust system for leaks Excessive vibration Collector not centered on header pipes Propeller not properly balanced Reposition collector -- ensure minimum of 1 ½ Penetration per header into central collector system Have propeller balanced Excessive noise Muffler insert damaged or missing Contact PFS, Inc. for new muffler insert 4.0 MAXIMIZING SERVICE LIFE To get the maximum possible service life from your Power Flow Systems Tuned Exhaust, follow the following steps. 4.1 Dynamically balance your propeller to below 0.2 ips (inches per second) every 2 years or 1000 hours (whichever occurs first). 4.2 Dynamically balance your propeller to below 0.2 ips after modifying, overhauling, dressing, or replacing any rotating component on the engine or propeller. 4.3 Keep slip joints lubricated with a high temperature anti-seize. 4.4 Maintain even engine compressions above 70/80 psi. 4.5 Keep magnetos in good working order and ensure that mag drops are even and less than the maximum recommended by the aircraft manufacture. PLEASE NOTE THAT FAILURE TO COMPLY WITH ONE OR MORE OF THESE STEPS MAY IMPACT THE PRODUCT WARRANTY. PLEASE CONSULT YOUR WARRANTY DOCUMENTATION FOR FURTHER DETAILS. 5.0 REMOVAL 1. Follow the above instructions in reverse order. 6.0 INSPECTION The exhaust system must be thoroughly inspected, especially within the heat exchanger section. A detailed inspection of the exhaust system must be performed in accordance with the latest revision of the Aircraft Service Manual at either 100 hour or annual intervals. All components displaying cracking or general deterioration must be replaced with new parts or repaired in accordance with AC 43.13 or the latest approved revision. A. Exhaust Installed 1. Remove engine cowling 2. Loosen and remove shrouds so that all surfaces of the exhaust system are visible 3. Check for holes, cracks, and burned spots. Especially check areas adjacent to welds. Look for exhaust gas deposits in surrounding areas. This may indicate an exhaust leak. 4. Inspect screen covering carb heat outlet. Screens must be secure with no risk of material breaking off. 5. Inspect pin on clamp. Pin should not indicate excessive wear or cutting. If worn or cut contact Power Flow Systems, Inc. for replacement. 6. Inspect hole that pin is inserted in for elongation. If elongated contact Power Flow Systems, Inc. for replacement. 7. Inspect the packing material in muffler body. If the packing is missing or deteriorated, it will require replacement. New packing inserts are available from Power Flow Systems, Inc. 8. Inspect the ball joint for freedom of movement. A seized ball joint may cause other components to crack. If penetrating lube won t free a seized ball joint, please contact Power Flow Systems, Inc. for a replacement. PFS-14150-00 REV C Page 9 of 20 05/22/07
9. Ensure Placard is visible to pilot that states The Power Flow Systems, Inc. tuned exhaust system installed on this aircraft may cause the aircraft to burn more fuel at certain power settings. It is the Pilot s responsibility to determine what, if any, change in fuel flow exists and to plan accordingly. B. Exhaust Removed If any defects (cracks, burns, etc.) on the collector assembly (other than on the shroud) are noted during the visual inspection, then the collector needs to be pressure tested using the procedure below: 1. Remove exhaust pipes and heat exchanger assembly. 2. All slip joints must be disassembled and lubricated with a high-temperature anti-seize compound. (Only necessary at 500hr or annual intervals, whichever comes first). This should be performed more frequently if headers seize between inspections. While disassembled, inspect for wear or galling. 3. Remove shrouds. 4. Seal openings with expansion rubber plugs. 5. Submerge the collector assembly in water. 6. Using a manometer or pressure gauge, apply 3.0 to 3.5 PSI (approximately 7 Hg) of air pressure. 7. Let the unit sit pressurized for 10 to 30 seconds. The leak rate should be zero. 8. If a leak is found in the collector assembly, replace or repair before further flight. 9. If no leaks are found, dry components and install on airplane. All components displaying cracking or general deterioration must be replaced with new parts or repaired in accordance with AC 43.13 or the latest approved revision. PFS-14150-00 REV C Page 10 of 20 05/22/07
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Power Flow System Extractor Exhaust System Installation Instructions Piper PA28-180/181Aicraft Original Page 17 of 20 08/26/02
Power Flow System Extractor Exhaust System Installation Instructions Piper PA28-180/181Aicraft Original Page 18 of 20 08/26/02
Power Flow System Extractor Exhaust System Installation Instructions Piper PA28-180/181Aicraft Note: Bolt head may be placed on other side for ease of installation. Original Page 19 of 20 08/26/02
NOT VALID WITHOUT LETTER OF AUTHORIZATION FROM POWER FLOW SYSTEMS, INC.