Tornado Alley Maintenance Manual
Contents
1. For the MAINTENANCE MANUAL with TROUBLE SHOOTING MANUAL TURBONORMALIZED CIRRUS DESIGN SR22 Series Airplane UPPER DECK REFERENCE L H INTERCOOLER PRESSURE FUEL MANIFOLD VALVE RELIEF VALVE SCAVENGE PUMP MP CONTROLLER FIREWALL 0000000000000 0000000000000 panna FUEL PUMP HEATER BOX 2 VALVE JY D WASTEGATE ACTUATOR TURBO at 5 UH TAILPIPE Tornado Alley Turbo Inc 400 Airport Road Ada OK 74820 FAA APPROVAL HAS BEEN OBTAINED ON THE TECHNICAL DATA IN THIS PUBLICATION THAT AFFECTS AIRPLANE TYPE DESIGN COPYRIGHT 2006 TORNADO ALLEY TURBO INC ADA OKLAHOMA USA P N Report 215 10 ISSUED Nov 2006 TORNADO ALLEY INC Part REPORT 215 10 LOEP REPORT 215 10 LOEP REPORT 215 10 TOC REPORT 215 10 TOC REPORT 215 10 REPORT 215 10 REPORT 215 10 REPORT 215 10 REPORT 215 10 REPORT 215 10 REPORT 215 10 REPORT 215 10 REPORT 215 10 REPORT 215 10 REPORT 215 10 REPORT 215 10 REPORT 215 10 REPORT 215 10 REPORT 215 10 REPORT 215 10 REPORT 215 10 REPORT 215 10 REPORT 215 10 REPORT 215 10 REPORT 215 10 REPORT 215 10 REPORT 215 10 REPORT 215 10 EFFECTIVITY LIST OF EFFECTIVE PAGES Page 00 1 AD A N N PO NM HH H 4 Lo Date 08 NOV 2006 08 NOV 2006 08 NOV 2006 08 NOV 2006 08 NOV 2006 08 NOV 20062. G Functional Inspection Return to Service Flight Perform the following Return to Service Flight after reinstallation of turbonormalizing system during overhaul or maintenance of turbonormalizing system components 1 Pilot should perform normal start up taxi engine parameter checks and any ground operational checks not related to the turbo system Utilizing normal Cirrus before flight checklist perform additional full power performance opera tional check prior to releasing the brakes for take off Take note of engine RPM fuel flow tit manifold pressure and oil temperature Depending on oil temperature the parameters may vary Optimally 2700 RPM 29 6 inches MP 35 GPH at normal operating oil temperature Because of a direct correlation between oil temperature and manifold pressure at lower than nor mal operating oil temperature manifold pressure will indicate higher than redline Because of a direct correlation between manifold pressure and fuel flow higher manifold pres sure will give higher fuel flow TIT should remain relatively the same Utilize normal Cirrus engine break in procedures Keeping in mind the turbo parameters and the addition of more possible fuel and oil leak points E ETE Report 215 10 Page 19 08 Nov 2006 08 Nov 2006 TORNADO ALLEY INC NOTE 1 VIEW LOOKING LEFT INBOARD L H INTERCOOLER UPPER DECK REFERENCE PRESSURE FUEL MANIFOLD VALVE RELIEF VALVE
3. Return to Service Flight EFFECTIVITY 11 13 13 14 14 14 14 15 15 15 15 15 15 15 16 16 1 18 19 19 Report 215 10 TOC Page 1 08 Nov 2006 TORNADO ALLEY INC Intentionally Left Blank Report 215 10 TOC 08 Nov 2006 TORNADO ALLEY INC AIRWORTHINESS LIMITATIONS The Airworthiness Limitations Section is and specifies inspection and maintenance required under para graphs 43 16 and 91 403 of the Federal Aviation Regulations unless an alternative program has been There are no limiting inspections and or maintenance items NOV 08 206 FAA Approved Date Report 215 10 Page 1 08 Nov 2006 EFFECTIVITY All TORNADO ALLEY INC DESCRIPTION AND OPERATION The Tornado Alley Turbonormalizing System See Figure Report 215 10 1 utilizes two Kelly Aerospace turbonormalizers with Kelly absolute manifold pressure controller and Kelly pressure relief valve The turbonormalizers are new generation turbonormalizers designed to provide the same boost as older design turbonormalizers but with lower compressor discharge temperatures This increase in efficiency is due to the improved design of the compressor blades and compressor housing However to further reduce engine induction temperatures two side baffle mounted intercoolers are also installed in the system The absolute controller and wastegates work in conjunction with each other to provide proper boost pres sure to the eng
4. 08 NOV 2006 08 NOV 2006 08 NOV 2006 08 NOV 2006 08 NOV 2006 08 NOV 2006 08 NOV 2006 08 NOV 2006 08 NOV 2006 08 NOV 2006 08 NOV 2006 08 NOV 2006 08 NOV 2006 08 NOV 2006 08 NOV 2006 08 NOV 2006 08 NOV 2006 08 NOV 2006 08 NOV 2006 08 NOV 2006 08 NOV 2006 08 NOV 2006 Report 215 10 LOEP Page 1 08 Nov 2006 TORNADO ALLEY INC Intentionally Left Blank Report 215 1 0 LOEP EL EG UMOR 08 Nov 2006 TORNADO ALLEY INC TABLE OF CONTENTS Subject AIRWORTHINESS LIMITATIONS There are no limiting inspections and or maintenance items DESCRIPTION AND OPERATION Alternate Air Door TROUBLESHOOTING Momentary Overshoot Of Manifold Pressure MAINTENANCE PRACTICES Time Limits And Maintenance Checks Overhaul And Replacement Schedule Scheduled Maintenance Checks Progressive Inspection Program Turbonormalizers Absolute Controller Removal and Installation Absolute Controller Adjustment Absolute Controller Master Waste Gate Actuator Removal and Installation Master Waste Gate Actuator Adjustment Master Waste Gate Actuator Slave Waste Gate Removal And Installation Of Slave Waste Gate Pressure Relief Valve Removal And Installation Of Pressure Relief Valve Engine Removal and Overhaul Engine Installation Engine Inspection Post Engine Overhaul Installation Servicing Post Engine Overhaul Installation Adjustments Post Engine Overhaul Installation Operational Inspection First Flight Run Up Functional Inspection
5. SCAVENGE PUMP MP CONTROLLER FIREWALL 0000000000000 0000000000000 FUEL PUMP HEATER BOX HEATER VALVE WASTEGATE ACTUATOR TURBO um UH TAILPIPE Figure Report 215 10 2 port 215 10 Page 20 Turbo System Layout EFFECTIVITY All TORNADO ALLEY INC NOTE COMPLETE RIGHT EXHAUST ASSEMBLY IS P N ETI SR22 100 COMPLETE LEFT EXHAUST ASSEMBLY IS PN ETI SR22 103 R H EXHAUST ETI G2 100 1 BOLT AN8C13A L H EXHAUST ETI G2 103 1 R H LATERAL SUPPORT ETI G2 600 121 L H TURBO SUPPORT ETI SR22 2200 BOLT AN8C13A x2 BOLT AN8C12A x2 gt L H LATERAL SUPPORT ETI G2 600 120 LOWER SUPPORT BRACKET ETI G2 600 A 21046 6 x4 WASTEGATE LINKAGE ETI SR22 111 1 COTTER PIN BACP18BCO2A02P x2 BOLT x24 BOLT AN4C12A x8 WASHER NAS1149C0463R x32 WASTEGATE ASSEMBLY 470842 9004 GASKET 1550148 2 x4 NUT 21046 4 x16 WASTEGATE OUTLET ETI SR22 109 1 x2 NUT 521046 6 x4 L H TURBO ASSEMBLY ETI SR22 2000 V BAND CLAMP 995CS 0339 x2 L H WASTEGATE DUMP ETI G2 110 105 L H TAILPIPE ETI G2 110 L Figure Report 215 10 3 Exhaust System Layout EFFECTIVITY All GASKET 652458 x6 R H TURBO ASSEMBLY PIN ETI SR22 1300 MS20392 1C19 x2 R H WASTEGATE DUMP ETI G2 110 106 R H TURBO SUPPORT ETI
6. Engine Oil Drain and change every 50 hours or 6 months which ever occurs first 1 Cold and Hot Air Hoses Visual Inspection for leaks security and condition Engine Baffling and Seals Visual Inspection for cracks tears and rips 13 Air Intake Ducts Visual Inspection for general condition Fuel Injection System Visual Inspection for leaks security and condition 15 Turbonormalizer Mounting Bracket Visual Inspection for security and condition 16 Vent Lines to Fuel Pump and Discharge Nozzles Visual Inspection for chafing obstruction security and general condition 17 Engine Heat Shields Visual Inspection for security and condition 18 Engine Mount Isolators Visual Inspection for cracking splitting and general condition 19 Turbonormalizer Visual inspection of turbine for coking carbonization oil deposits and turbine impeller damage Visual inspection of compressor wheel for damage interference and free rotation Flexible Turbo System Lines Visual Inspection for chafing obstruction security and general condition Waste Gate and Controller Visual Inspection for security and condition Exhaust Muffler Heat Exchanger Borescopic inspection of tailpipe sections adjacent to heat exchanger for signs of cracking Repair or replace on condition Cabin Heat Mixing Valve Visual Inspection for security and condition Re
7. SR22 2300 BOLT AN8C12A x2 BOLT AN8C14A WASHER NAS1149C0663R x8 WASTEGATE 471233 0003 R H TAILPIPE ETI G2 110 R Report 215 10 Page 21 08 Nov 2006 TORNADO ALLEY INC TO MAIN FUEL SCREEN pe AE6680H0207 180 HOSE HIGH RPM FUEL FLOW ADJUSTMENT CCW INCREASE CC DECREASE Figure Report 215 10 4 Fuel Pump Report 215 10 gd Page 08 Nov 2006 TORNADO ALLEY INC NOTES 1 FITTING IS ON LOWER RIGHT SIDE OF MP CONTROLLER 2 FITTING IS ON LOWER LEFT SIDE OF MP CONTROLLER 3 ORIFICE FITTING 4 RELOCATE FACTORY OIL PRESSURE TRANSDUCER MP CONTROLLER MAIN FUEL SCREEN FIREWALL CONTROLLER BRACKET P N FS 005 FUEL PUMP SEE NOTE 1 N I SEE NOTE 2 SEE NOTE 3 NOTE 4 WASTEGATE CONTROLLER OIL COOLER BULK HEAD FITTING EXISTING REAR BAFFLE fr TO UPPER DECK ASSEM TO UPPER SCAVENGE PUMP TO MAGNETO Bm TO MAGNETO R H INTERCOOLER L H INTERCOOLER TURBO TURBO VIEW LOOKING DOWN Figure Report 215 10 5 Hose Layout EFFECTIVITY Report 215 10 All Page 23 08 Nov 2006 TORNADO ALLEY INC Intentionally Left Blank Re ort 21 5 1 0 EFFECTIVITY dy 08 Nov 2006
8. engine operation Thus any increase or decrease in turbine speed will cause an increase or decrease in manifold pressure and fuel flow If turbine speed increases the manifold pressure increases if the turbine speed decreases the manifold pressure decreases Since the compression ratio approaches 3 to 1 at high alti tude any change in exhaust flow to the turbine or ram induction air pressure will be magnified proportion ally by the compression ratio and the change in flow through the exhaust system A Momentary Overshoot Of Manifold Pressure Under some circumstances such as rapid throttle movement especially with cold oil it is possible that the engine can be overboosted slightly This would most likely be experienced during takeoff roll or during a change to full throttle operation in flight A slight overboost of 2 to 3 inches of manifold pressure is not considered detrimental to the engine as long as it is momentary No corrective action is required when momentary overboost corrects itself and is followed by normal engine operation However if overboosting of this nature persists when oil tem perature is normal or if the amount of overboost tends to exceed 3 inches or more the throttle should be retarded to eliminate the overboost and the controller system including the waste gate and relief valve should be checked for necessary adjustment or replacement of components Heport 215 10 EFEO VI Page 4 08 Nov 2006 TORNADO ALLE
9. gray gray white or light gray powdering sooty appearance indicate exhaust leakage Signs of deterio ration include warping deformation thinning collapse dents cracking tears separation scaling weld sepa ration discoloration corrosion metal pitting or burn thru 2 All external joints clamps and couplings for misalign ment warpage broken loose or missing fasteners clamps and abnormal wear 3 All interior areas for blockage restrictions dents or pro trusions into the exhaust flow path Using a flashlight look in the interior of the tailpipe for 9 loose or displaced baffles cones or diffusers 4 Visually inspect muffler heat exchanger and shrouds O for condition 5 Visually inspect exhaust stack to flange interface for cracks in welds or weld heat affected area blown out or missing gaskets 6 Visually inspect all welds and area adjacent to the weld for cracks or weld separation 7 Visually inspect tailpipes for erosion thinning bulging or burn through 8 Visually inspect bracing supports and support attach lugs on other structures for security Ero Report 215 10 Page 9 08 Nov 2006 TORNADO ALLEY INC Engine Group Continued 25 Hrs 50 Hrs 100 Hrs 200 Hrs or 2 Years Whichever First Visually inspect surrounding structures for discolora tion heat damage or burning
10. left exhaust so that some of the exhaust from the left bank of cylinders will bypass the left turbine and be vented into the tailpipe A slave wastegate on the right exhaust system is mechanically connected to the master wastegate The right wastegate is used on the right exhaust so that some of the exhaust from the right bank of cylinders will bypass the right turbine and be vented into the tailpipe It can be seen from studying bulleted items above that anything which affects the flow of induction air into the compressors or the flow of exhaust gases into the turbines will increase or decrease the speeds of the turbines This resultant change in flow will have no effect on the engine if the waste gates are still open because the waste gate positions are changed to hold compressor discharge pressure constant A waste gate controller automatically maintains maximum allowable compressor discharge pressure anytime the turbines and compressors are capable of producing that pressure The mechanical linkage between the wastegates is adjustable to ensure both wastegates control both turbonormalizers equally At high altitude part throttle or low RPM the exhaust flow is not capable of turning the turbine and com pressor fast enough to maintain maximum compressor discharge pressure and the waste gate will close to force all of the exhaust flow through the turbine When the waste gate is fully closed any change in turbonormalizer speed will mean a change in
11. turbonormalizer Tur bonormalizer bearings are lubricated with filtered oil supplied from the engine oil system Engine exhaust gas enters the turbine housing to drive the turbine wheel The turbine wheel in turn drives the compressor wheel producing high density air entering the engine induction manifold Exhaust gas is then dumped overboard through the exhaust outlet of the turbine housing and exhaust tailpipe Air is drawn into the compressor through the induction air filter and is forced out of the compressor housing through tangential outlet to the intake manifold The degree of compression is varied by means of waste gate valve which varies the amount of exhaust gas allowed to bypass the turbine 1 Removal And Installation a Disconnect and tag oil lines from controller and plug or cap open lines and fittings b compressor outlet pressure sensing lines from controller and plug or cap open lines and fittings c Remove two bolts attaching controller to mounting bracket on firewall d Remove controller from aircraft being careful not to drop controller unit e Installation of the controller may be accomplished by reversing the preceding steps ABSOLUTE CONTROLLER The waste gate actuator and controller use engine oil for power supply The turbonormalizer is controlled by the waste gate waste gate actuator the absolute pressure controller and overboost control valves The waste gate bypasses engine exhaust
12. NKAGE ENGINE CYLINDERS ENGINE SUMP TO OIL LJ jE je MANIFOLD PRESSURE GAGE FROM ENGINE OIL PUMP TURBINE OVERBOARD THROUGH TAILPIPE Figure Report 215 10 1 System Schematic EFFECTIVITY All WASTEGATE ACTUATOR SPRING LOADED OPEN BOTH SIDES SR22 CM72 2445 Report 215 10 Page 3 08 Nov 2006 TORNADO ALLEY INC TROUBLESHOOTING To facilitate troubleshooting the following information better understanding of how the turbonormalizer System works and points out some of the items that are affected by turbonormalizing The information below follows the induction air as it enters and passes through the engine until it is expelled as exhaust gases e Engine induction air is taken in through an opening in the nose bowl ducted through a filter and into the compressors where it is compressed e pressurized induction air then passes through intercoolers then the throttle body and finally the induction manifold into the cylinders e The air and fuel are burned and exhausted to the turbonormalizer turbines e exhaust gases drive the turbines which in turn drive the compressors thus completing the cycle The compressors have the capability of producing manifold pressures in excess of 29 5 in Hg In order not to exceed 29 5 inches of manifold pressure a master waste gate is used on the
13. Y INC Trouble Probable Cause Remedy Engine Starts But Dies Or Will Not Idle Properly Vaporized fuel in system Most likely to occur in hot weather with hot engine Refer to Airplane Flight Manual Obstructed air intake Remove obstruction service air fil ter Discharge nozzle air vent manifold ing restricted or defective Check for bent lines or loose con nections Tighten loose connections Remove restrictions and replace defective components Defective engine Check compression and listen for unusual engine noises Check oil fil ter for excessive metal Repair engine as required Engine Has Poor Acceleration Runs Rough At Speeds Above Idle Or Lacks Power Idle mixture too lean Refer to Airplane Flight Manual Supplement Malfunctioning turbonormalizer Check operation listen for unusual noise Check operation of waste gate valve and for exhaust system defects Tighten loose connections Engine Lacks Power Reduction In Maximum Manifold Pressure Or Critical Altitude Defective ignition system Improperly adjusted waste gate valve Adjust or replace waste gate valve Waste gate capillary tube plugged Disconnect lines from controller to master waste gate and back flush waste gate and lines Loose or damaged exhaust system Inspect entire exhaust system to turbonormalizers for cracks and leaking connections Tighten con nectio
14. d tempera ture indicating system Clogged or dirty fuel injection noz 2165 Clean nozzles and replace if defec tive Engine baffles loose bent or miss ing Install baffles properly Repair or replace if defective Dirt accumulated on cylinder cool ing fins Clean thoroughly Incorrect grade of fuel Drain and refill with proper fuel Advance power lever smoothly Alternate Air Door Opens When Power Lever Advanced Power lever advanced too rapidly Air filter obstructed Remove obstruction Service or replace air filter EFFECTIVITY All Report 215 10 Page 7 08 Nov 2006 TORNADO ALLEY INC Trouble Probable Cause Remedy Engine Has Poor Acceleration Runs Rough At Speeds Above Idle Or Lacks Power Cont Improper fuel air mixture Check intake manifold connections for leaks Check fuel controls and linkage for setting and adjustment Replace worn elements of control linkage Service air filter Tighten loose connections Turbonormalizer wheels rubbing Replace turbonormalizer Improperly adjusted or defective waste gate controller Adjust or replace absolute control ler as required Leak in turbonormalizer discharge pressure system Correct cause of leaks Repair or replace damaged parts Manifold pressure overshoot Most likely to occur when engine is accel erated too rapidly Smoothly move t
15. gas around the turbonormalizer turbine inlet The waste gate actua tor which is physically connected to the waste gate by mechanical linkage controls the position of the waste gate butterfly valve The absolute pressure controller controls the maximum turbonormalizer com pressor discharge pressure The overboost control valve prevents an excessive pressure increase from the turbonormalizer compressor The master waste gate actuator is spring loaded to position the waste gate to the normally open position when there is not adequate oil pressure in the waste gate actuator power cylinder during engine shut down When the engine is started oil pressure is fed into the waste gate actuator power cylinder through the capillary tube This automatically fills the waste gate actuator power cylinder and lines leading to the controller blocking the flow of oil by normally closed metering and or poppet valves As oil pressure builds up in the waste gate actuator power cylinder it overcomes the force of the waste gate open spring closing the waste gate When the waste gate begins to close the exhaust gases causes the turbonormalizer to rotate faster raising the turbonormalizer compressor outlet pressure As the compressor outlet pressure rises the aneroid bellows in the absolute pressure controller senses the increase in pressure When at high engine speed and load and the proper absolute pressure is reached the force on the aneroid bellows opens the normally c
16. hrottle about two thirds open Let engine accelerate and peak Smoothly move throttle to full open Engine oil viscosity too high for ambient air Replace oil with proper grade of oil Exhaust system leakage Refer to Cirrus SR22 Service Man ual for exhaust system inspection procedures Inspect spark plugs for fouled electrodes heavy carbon deposits erosion of electrodes improperly adjusted electrode gaps and cracked porcelains Test plugs for regular firing under pressure Replace damaged or misfiring plugs Report 215 10 Page 08 Nov 2006 EFFECTIVITY All TORNADO ALLEY INC MAINTENANCE PRACTICES TIME LIMITS AND MAINTENANCE CHECKS A Overhaul And Replacement Schedule The following items must be overhauled or replaced at the following intervals unless otherwise noted To ensure correct observation of these times the date of removal installation or overhaul of such components as well as the airplanes flight hours must be entered into the Service Time Record filed in the Airplane Maintenance Log Item Interval O haul Notes 1 Flexible Turbo System Lines 5 Years O 2 Turbonormalizer At Engine Overhaul 3 Waste Gate and Controller At Engine Overhaul Scheduled Maintenance Checks 200 Hrs or 2 Years Whichever First Engine Group 25 Hrs 50 Hrs 100 Hrs 1 All external surfaces for signs of exhaust leaks Flat
17. ine The wastegate is actuated using engine oil pressure to actuate small hydraulic cylin der which redirects the engine by pass exhaust flow around the turbonormalizers The absolute pressure controller utilizes an aneroid bellows and spring connected to valve that regulates the amount of flow ing out of the wastegate actuator hydraulic control cylinder The aneroid bellows are located inside hous ing that is connected to the output air produced by the compressors As compressor outlet pressure increases the bellows are forced down opening the normally closed oil control valve When open the valve allows metered oil to bypass the wastegate which in turn is spring loaded to the open position Oil passing through the absolute controller is returned to the engine oil sump The left hand wastegate 15 master wastegate connected to slave wastegate on the right side of the engine The right hand wastegate is the same as the left hand wastegate but is slaved to the hydraulic actuator on the left hand wastegate The two wastegates are mechanically synchronized and move in par allel with each other Each wastegate incorporates a typical butterfly exhaust bypass valve It is operated hydraulic actuator utilizing engine oil for operation The wastegate is spring loaded to the open position Increasing oil pres sure from the engine causes the actuator to work against the spring to close the butterfly valve The waste gate is loca
18. let oil pressure valve is preset to 10 PSI If oil pressure is lower than this the turbo will starve for oil Note Make oil pressure adjustment according to TCM maintenance manual instructions Report 215 10 18 08 2006 TORNADO ALLEY INC F Operational Inspection First Flight Run Up Perform the following Run Up Procedure prior to first flight after reinstallation of turbonormalizing sys tem during overhaul or maintenance of turbonormalizing system components With upper and lower cowling removed fireguard and observer present 1 2 PE 10 11 Start engine using normal staring procedures Keeping RPM below 1700 rpm monitor oil pressure fuel flow manifold pressure and engine temperatures for normal operation Run engine for short time only long enough to check all indications and ensure no fuel or oil leakage Shut engine down inspect engine and turbo system for any sign of leakage chafing or heat damage Install complete cowling Perform normal engine start and operation to achieve proper operating temperatures Perform magneto operational check Perform high power operation check Monitor engine operating parameters and make adjustments as necessary After the achievement of desired operating parameters inspect engine compartment for leak age chafing and heat damage Release aircraft for service flight
19. losed metering valve When the oil pressure in the waste gate actuator power cylinder is lowered sufficiently the waste gate actuator open spring forces the mechanical linkage to open the waste gate A portion of the exhaust gases then bypasses the turbonormalizer turbine thus preventing fur ther increase of turbonormalizer speed and holding the compressor discharge absolute pressure to the desired value Conversely at engine idle the turbonormalizer runs slowly with low compressor pressure output therefore the low pressure applied to aneroid bellows is not sufficient to affect the unseating of the normally closed metering valve Consequently engine oil pressure keeps the waste gate closed The over boost control valve acts as a pressure relief valve and will open to prevent any excessive pressure increase from the turbonormalizer compressor E ETE Report 215 10 Page 13 08 Nov 2006 TORNADO ALLEY INC A Removal and Installation Absolute Controller 1 2 3 4 5 Disconnect and tag oil lines from controller and plug or cap open lines and fittings Disconnect compressor outlet pressure sensing lines from controller and plug or cap open lines and fittings Remove two bolts attaching controller to mounting bracket on firewall Remove controller from aircraft being careful not to drop controller unit Installation of the controller may be accomplished by reversing the preceding steps B Adjustment Absolute Contr
20. lso make a fuel prime operation check 8 Activate fuel prime switch and observe fuel flow for positive indication of flow 9 Turn off battery 10 Inspect engine area for any oil leaks and any fuel leaks 11 Reinstall sparkplugs and leads EFFECTIVITY Report 21 5 1 0 All Page 17 08 Nov 2006 TORNADO ALLEY INC E Adjustments Post Engine Overhaul Installation Make the following adjustments as required prior to first flight after reinstallation of turbonormalizing system during overhaul or maintenance of turbonormalizing system components Note All adjustments need to be made with full operating RPM 2700 Fuel Flow Manifold Pressure Turbo Inlet Temperature and Oil Pressure to be measured at full RPM If needed make adjustments at the propeller governor 1 Engine Setup a RPM 1 All adjustments need to be made with full operating RPM 2700 Fuel Flow Mani fold Pressure Turbo Inlet Temperature and Oil Pressure to be measured at full RPM If needed make adjustments at the propeller governor Note Every airplane may not make full RPM on the ground so make adjustments as close as possible then fly and readjust after flight per pilot information b Fuel Flow 1 For the IO 550 N turbonormalized engine the target full RPM fuel flow is 33 5 or 1 5 GPH To achieve these indicated target amounts adjustments may need to be made at the high power aneroid adjustment screw Because of the special c
21. mps and couplings for proper engagement and alignment 3 Induction tubing for current and possible chafe problems 4 Tightness of all exhaust mounting hardware and v band clamps 5 Clearance of exhaust through cowling and below firewall Oo Wiring chafe and heat related problems Engine probe wiring to exhaust clearance 8 Cylinder lower fuel drain plumbing clearance to exhaust and heat shields 0 1 2 3 N 9 Heat shield clearance off of exhaust components Turbo supports for security and safety wire Wastegate linkage clearance and safety wire Turbo air inlet sceet to front cowling clearance Throttle Propeller and mixture control lever full travel 1 Report 215 10 16 08 Nov 2006 TORNADO ALLEY INC D Servicing Post Engine Overhaul Installation After overhaul and reinstallation of the engine and turbonormalizing system pre oil the engine as described below 1 Remove all lower sparkplugs Ground all ignition leads to engine Clear engine and propeller area from obstacles 4 Ensure proper oil level Turn on battery power With security person outside crank engine and monitor indicated oil pressure Crank engine for no more than 30 seconds at a time When a higher than 10 psi is consistently indicated on oil pressure indicator the turbo will be considered to be pre oiled 7 Atthis time a
22. mps holding wastegate manifold assembly to exhaust system Remove bolts washers and nuts attaching wastegate manifold assembly to the turbonormalizer Loosen clamp attaching tailpipe to turbine exhaust outlet and work waste gate and manifold from exhaust system Remove the assembly from aircraft being careful not to drop the unit Installation may be accomplished by reversing the preceding steps Note When installing the assembly be sure the gaskets at inlet and outlet of valve are installed and are in good condition Replace gaskets if damaged Report 215 10 14 08 Nov 2006 TORNADO ALLEY INC B Adjustment Master Waste Gate Actuator If adjustment of waste gate actuator is required remove waste gate actuator in accordance with Removal and Installation of Waste Gate Actuator instructions and send to an approved facility for repair or overhaul of waste gate actuators SLAVE WASTE GATE A Removal And Installation Of Slave Waste Gate 1 2 3 4 5 Disconnect linkage to master waste gate Remove clamps holding wastegate manifold assembly to exhaust system Remove bolts washers and nuts attaching wastegate manifold assembly to the turbonormalizer Loosen clamp attaching tailpipe to turbine exhaust outlet and work waste gate and manifold from exhaust system Installation may be accomplished by reversing the preceding steps Note When installing the assembly be sure the gasket
23. ns and replace damaged parts Loose or damaged intake manifold ing Inspect entire manifolding system for possible leakage at connections Replace damaged components tighten all connections and clamps EFFECTIVITY All Report 215 10 Page 5 08 Nov 2006 TORNADO ALLEY INC Trouble Probable Cause Remedy Engine Lacks Power Reduction In Maximum Manifold Pressure Or Critical Altitude Malfunctioning turbonormalizer Check for unusual noise in turbon ormalizers If malfunction is sus pected remove tailpipe and or air inlet connections and check rotor assembly for possible rubbing in housing damaged rotor blades or defective bearings Replace turbo charger if damage is noted Fuel discharge nozzle defective Inspect fuel discharge nozzle vent manifolding for leaking connections Tighten and repair as required Check for restricted nozzles and lines and clean and replace as nec essary Controller not getting enough oil pressure to close the waste gate Check oil pump outlet pressure oil filter and external lines for obstruc tions Clean lines and replace if defective Replace oil filter Controller out of adjustment or defective Replace controller if defective Defective waste gate actuator Turbo coking oil forced through seal of turbine housing Replace actuator Clean or change turbonormalizer Engine Surges Or Smokes Defective sca
24. oller 1 2 3 4 6 7 8 With engine oil temperature at middle of green arc slowly open throttle and note maximum man ifold pressure obtainable Do not exceed 29 5 in Hg Cut safety wire and remove plug from bottom of absolute controller If small amount of oil is encountered upon removal of the plug there is no need for alarm Using a flat blade screw driver rotate metering valve seat clockwise to increase manifold pres sure and counterclockwise to decrease manifold pressure Lightly tap the unit after each adjust ment to seat internal parts Note When adjusting rotate in VERY small increments as this is an extremely sensitive Approximately 13 degrees rotation will change the manifold pressure reading about one inch Hg Install plug in absolute controller then operate engine as in step a to ascertain that adjustment has not caused radical change in manifold pressure Note When making adjustment on the ground the hotter the engine gets the lower the manifold pressure will be After each adjustment the aircraft must be flight tested to check results Repeat this procedure until desired results are obtained Safety controller plug MASTER WASTE GATE ACTUATOR A Removal and Installation Master Waste Gate Actuator 1 2 RG DU CO X Disconnect and tag oil lines from actuator and plug or cap open lines and fittings Disconnect linkage to slave waste gate Remove cla
25. om bination of fuel nozzles and turbonormalized fuel pump the TCM service bulletin is a guide for adjustments but the target GPH is the desired outcome If an adjustment is necessary the aneroid adjuster screw will need to be turned OUT CCW for an increase in fuel flow or IN CW for a decrease in fuel flow One turn will equal around 1 5 GPH To make and adjustment loosen jam nut turn screw snug up jam nut Note Fuel flow is relative to RPM Manifold Pressure and Temperature Given targets are set at engine operating oil temperature engine operating RPM and indicated 29 6 inches of manifold pressure Cooler oil will make higher manifold pressure which will make higher fuel flow It is suggested that fuel flows be set on the high side of the scale c Manifold Pressure 1 Maximum manifold pressure setting is 29 6 inches at full throttle with normal engine operating oil temperature Make adjustments to manifold pressure according to Absolute Controller Adjustments section above Note Manifold pressure is relative to oil temperature If the oil temp is cooler the manifold pressure may indicate higher Be sure to make adjustments according to engine operating temperature d Oil Pressure 1 There should not be a need to make oil pressure adjustment but if the oil pressure is below red line at idle it is suggested that the oil pressure be increased enough to keep a good oil flow through the turbo at idle speeds The turbo in
26. on Engine Group Detailed Inspection Criteria 1 Induction System Hoses and Couplings Refer to AMM 5 20 Visual Inspection for security leaks and condition Tighten hose clamps as required 2 Turbochargers Kelly Aerospace Trou Visual inspection of turbines for coking carbonization oil deposits and bleshooting Reference turbine impeller damage Guide 400888 0000 Visual inspection of compressor wheels for damage interference and free rotation 3 Turbocharger Mounting Brackets Refer to AMM 5 20 Visual Inspection for security and condition Replace any cracked or damaged brackets Report 215 10 11 08 Nov 2006 TORNADO ALLEY INC Engine Group Detailed Inspection Criteria Continued Chap Sect Reference Flexible Turbo System Lines Visual Inspection for chafing obstruction security and general condition Refer to AMM 5 20 Waste Gate and Controller Visual Inspection for security and condition Lubricate wastegate butter flies with Mouse Milk Refer to AMM 5 20 Vent Lines to Fuel Pump and Discharge Nozzles Visual Inspection for chafing obstruction security and general condition Refer to AMM 5 20 Engine Heat Shields Visual Inspection for security and condition Refer to AMM 5 20 Exhaust Muffler Heat Exchanger Borescopic inspection of tailpipe sections adjacent to heat exchanger for signs of cracking Repair or replace on condi
27. port 215 10 ELE HNIC Page 10 08 Nov 2006 TORNADO ALLEY INC C Progressive Inspection Program The following inspections are to be performed in addition to the Routine and Detailed Inspection for the Engine Group defined in Chapter 5 Section 21 of the SR22 AMM Engine Group Routine Inspection Criteria gt 1 Induction System Hoses and Couplings Refer to AMM 5 20 Visual Inspection for security leaks and condition 2 Turbochargers Refer to AMM 5 20 Visual inspection of turbines for coking carbonization oil deposits and turbine impeller damage Visual inspection of compressor wheels for damage interference and free rotation 3 Turbocharger Mounting Brackets Refer to AMM 5 20 Visual Inspection for security and condition 4 Flexible Turbo System Lines Refer to AMM 5 20 Visual Inspection for chafing obstruction security and general condition 5 Waste Gate and Controller Refer to AMM 5 20 Visual Inspection for security and condition 6 Vent Lines to Fuel Pump and Discharge Nozzles Refer to AMM 5 20 Visual Inspection for chafing obstruction security and general condition 7 Engine Heat Shields Refer to AMM 5 20 Visual Inspection for security and condition 8 Exhaust Muffler Heat Exchanger Refer to AMM 5 20 Borescopic inspection of tailpipe sections adjacent to heat exchanger for signs of cracking Repair or replace on conditi
28. rs in accordance with Turbonormalizer Removal and Installation instructions Note If the engine is to be sent out for overhaul be sure the overhauler knows that the engine has different fuel injection nozzles a different engine driven fuel pump and a scavenge pump to accommodate the turbonormalizing system The turbon ormalizer scavenge pump fuel pump waste gates waste gate actuator and absolute controller should be overhauled by approved facilities at the same time as the engine overhaul EFFECTNITY Report 215 10 Page 15 08 Nov 2006 TORNADO ALLEY INC B Installation Engine Note After tightening V band clamps fly aircraft Re torque after flight Component Torque Turbine Housing Bolts 160 190 in Ib 18 21 Nm Fuel Injector Nozzle 55 65 6 7 Nm Fuel Injector Nozzle Line Nut 40 50 in Ib 5 6 Nm V band Clamps Compressor Housing 40 60 in Ib 5 7 Nm net torque Exhaust Manifold 30 35 in Ib 3 4 Nm net torque Tailpipe 40 60 5 7 Nm net torque a Net torque torque in addition to torque required to overcome resistance of locknut C Inspection Post Engine Overhaul Installation After overhaul and reinstallation of the engine and turbonormalizing system a final inspection is required Inspect the following for security signs of chaffing leaking and general condition 1 All hose connections routing and security 2 All cla
29. s at inlet and outlet of valve are installed and are in good condition Replace gaskets if damaged PRESSURE RELIEF VALVE A Removal And Installation Of Pressure Relief Valve 1 2 3 4 5 ENGINE Remove bolts washers and nuts holding pressure relief valve to induction manifold assembly Remove pressure relief valve from induction manifold assembly Check condition of O ring on face of pressure relief valve before installation Clean surface of induction manifold assembly verify that the surface is smooth and free from nicks gouges or burrs that may damage the O ring or prevent proper seal of the pressure relief valve Install the pressure relief valve by lining up the holes in the pressure relief valve with the holes in the induction manifold assembly and installing bolts washers and nuts in the same orientation as when removed Tighten nuts to 20 to 25 in Ib 2 3 2 8 Nm net torque A Removal and Overhaul Engine If the engine is to be removed the turbochargers and their accessories should be removed in accor dance with the following steps before removing engine mount bolts All other procedures for engine removal listed in the Cirrus SR22 service manual apply 1 2 3 Disconnect hoses to the intercoolers Remove waste gates in accordance with Removal and Installation of Master Waste Gate Actua tor and Removal and Installation of Slave Waste Gate instructions Remove turbonormalize
30. s equipped with a magnet latched alternate air door on the left side of the induction sys tem When any restriction of the air filter is encountered such as from ice or ice crystal formation the alternate air door will open automatically The MFD and PFD will provide a message alerting the pilot that the alternate air door is open The alternate air door provides an alternate path for warm air from the lower side of the engine compartment to go to both turbonormalizers when the air filter becomes blocked After the air filter blockage is removed the alternate air door may be closed by simply retard ing the power lever momentarily and the door will re latch automatically In some instances if there is an unusual surge in engine power especially at high altitude the alternate air door may become unlatched In that event again simply retarding the throttle momentarily will re latch the alternate air door Heport 215 10 Pd Page 08 Nov 2006 TORNADO ALLEY INC ALT AIR DOOR INDUCTION AIR FILTER b V J 4 RAM AIR N N PRESSURE RELIEF VALVE TO FUEL DISCHARGE INDUCTION NOZZLES SYSTEM WASTEGATE INTERCOOLER COMPRESSOR THROTTLE BODY gt EXHAUST SYSTEM OVERBOARD THROUGH TAILPIPE ABSOLUTE PRESSURE CONTROLLER REGULATES OIL THROUGH WASTEGATE ACTUATOR COMPRESSED AIR 2 EXHAUST AIR MECHANICAL LI
31. ted in the exhaust system ahead of the turbonormalizer turbine As the butterfly valve opens it allows exhaust gasses to bypass the turbonormalizer turbine thereby controlling the speed and output of the turbonormalizer The wastegate helps provide even control of the turbonormalizer speed and output so that the engine can maintain sea level manifold pressure well into the flight levels As turbonormalizer com pressor outlet pressure rises the aneroid bellows in the absolute pressure controller senses the increase in pressure When at high engine speed and load and the proper absolute pressure is reached the force on the aneroid bellows opens the normally closed metering valve When the oil pressure in the waste gate actuator cylinder is lowered sufficiently the waste gate actuator spring forces the mechanical linkage to open the waste gates A portion of the exhaust gases then bypasses the turbonormalizer turbines thus preventing further increase of turbonormalizer speed and holding the compressor outlet absolute pressure to the desired value Conversely at engine idle the turbonormalizer runs slowly with low compressor pres sure output therefore the low pressure applied to the aneroid bellows is not sufficient to affect the unseat ing of the normally closed metering valve Consequently engine oil pressure keeps the waste gates closed and all of the exhaust flows through the turbonormalizer turbine sections A Alternate Air Door The system i
32. tion Refer to AMM 5 20 Induction System Filter Clean and re oil filter at each inspection period or when filter is more than 50 covered by foreign material Clean per K amp N Air Filter Service Instruction 18627 K amp N Air Filter Service Instruction 18627 10 Alternate Air Door Visual Inspect for secure closing Check for loose fasteners or rivets that may enter turbocharger Verify that alternate air door indicator circuit is working by opening alternate air door and checking that alternate air door light is ON on MFD Clean area around alternate air door Refer to AMM 5 20 11 Fuel Injection Nozzles Visual inspect nozzles and manifold valve for fuel stains security and proper sealing of upper deck reference manifolds Remove and clean injector nozzles every 5 years or 500 hours which ever comes first Remove clean and replace per GAMI Installation Pro cedure No IP 2001 02 GAMI Installation Pro cedure No 2001 02 Report Page 12 08 Nov 2006 21 5 1 0 E EIE TORNADO ALLEY INC TURBONORMALIZERS The turbonormalizers are exhaust gas driven compressors or air pumps which provide high air mass flow to the engine intake manifold Each turbonormalizer is composed of turbine wheel compressor wheel turbine housing and compressor housing The turbine compressor wheel and interconnecting drive shaft comprise one complete assembly and are the only moving parts in the
33. venge pump Replace if defective Defective controller Replace if defective Waste gate actuator linkage bind ing Replace if not adjustable Waste gate actuator leaking oil Replace actuator Turbonormalizer Noisy With Plenty Of Power Turbonormalizer overspeeding from defective or improperly adjusted controller Replace controller if defective Waste gate sticking closed Correct cause of sticking Replace defective parts Turbo drain line oil return to engine sump plugged Clean line and check valve Replace if defective Report 215 10 Page 08 Nov 2006 EFFECTIVITY All TORNADO ALLEY INC Trouble Probable Cause Remedy Engine Power Increases Slowly Or Severe Manifold Pressure Fluctua tions When Throttle Advanced Engine Power Increases Rapidly And Manifold Pressure Overboosts When Power Lever Advanced Overboost control valve out of adjustment or defective Replace if defective Waste gate operation is sluggish Replace if defective Correct cause of sluggish operation Overboost control valve out of adjustment or defective Replace if defective Waste gate operation is sluggish Replace if defective Correct cause of sluggish operation Power lever advanced too rapidly Advance power lever smoothly Refer to Cirrus SR22 Service Man High Cylinder Head Temperature Defective cylinder hea
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