22-6460004 - Turbo`s For the Flat Land Pilot
Contents
1. N UUUUUUUUDDUUU O y FUEL PUMP HEATER BOX HEATER VALVE y Wi WU ULL ALTERNATE AIR DOOR Bn oe TUBULAR EXHAUST SHOWN HALF STAMP SHOWN VERTICAL SUPPORT L LATERAL SUPPORT BRACKET V NOT SHOWN IN THIS VIEW k _ CURVED TAILPIPE SHOWN Figure 2 STRAIGHT TAILPIPE NOT SHOWN LJH Ta pipe 22 6460004 Continued Airworthiness Rev C Page 132 22 Sept 2011 TORNADO ALLEY TURBO INC L H INTERCOOLER DECK REFERENCE IN i FUEL MANIFOLD VALVE PRESSURE RELIEF VALVE2. CONTROLLER DRIVE IUUUDUDUUUUUUKD ULDDUUUUUUU OD CROSSOVER ALTERNATE AIR DOOR HALF STAMP EXHAUST Joe VERTICAL SUPPORT ROD l LATERAL SUPPORT BRACKET NOT SHOWN IN THIS VIEW Figure 2b 22 6460004 Continued Airworthiness Rev C E j d pA DA WW L H STRAIGHT TAILPIPE FIREWALL HEATER BOX HEATER VALVE Page 133 22 Sept 2011 TORNADO ALLEY TURBO INC GASKET 652458 x6 NUT 520500 428 x24 R H TURBO SUPPORT ETI SR22 2300 d lt AN8C12A x2 X 2 BOLT AN amp C14A i gt _____ NAS1149C0663R x8 FWD EM R H EXHAUST ff a ETI G2 100 1 BOLT AN8C13A R H LATERAL SUPPORT _ EXHAUST ETI G2 600 121 ETl G2 103 1 L
3. OUT H lt 3 am TIl IN A Figure 5b 22 6460004 Continued Airworthiness Rev C Page 137 22 Sept 2011 DO ALLEY TURBO INC SIZE Appendix A Component Specific Torque Specifications FASTENER IN LB FT LB MODELS AFFECTED 2 56 10 32 10028H 10040H 10048H 10016H Miscellaneous Hardware see Note 5 Screw Heatshield MCU 1 4 2 6 All Turbonormalized models Bolt Retaining Inner 36 50 3 0 4 2 All Turbonormalized models AllTurbonormalized models AllTurbonormalized models Clamp Intake tube 45 50 3 7 4 1 Turbonormalized models Clamp Heatshield engine 45 50 3 7 4 1 Turbonormalized models mount Miscellaneous Fuel Injection see Note 5 38 24 25 48 3 38 24 6 5625 18 31 24 90 24 125 27 31 32 All engine models Nut Fuel Drain Line Snug nut finger tight to set seal between nut and male connector then tighten additional 3 4 to 1 turn Nut Aneroid stem jam 25 30 2 1 2 5 All Turbonormalized models Nut B Controller 70 105 5 8 8 7 All Turbonormalized models reference line reference tube to shaft Nut Air reference sleeve Snug nut finger tight to set All Turbonormalized models B nut to air reference line seal between nut and male connector then tighten additio
4. x2 22 6250003 B 22 6150011 NAS1149C0563R x2 sss SEE NOTE 1 n o LEM120D 038 MS21046C5 x2 4 12 2 AN4C11A x2 2 2224229 2 NAS1149C0463R x4 AN4C13A 22 6150018 aa 22 5600003 SEE NOTE 1 NAS1149C0463R x8 p We 7 NAS1149C0463R x2 s AN4C11A NAS 1149C0463R 4 MS210460402 lt x4 22 5600008 FG0120830 x4 NAS1149C0463R x6 NAS1149C0463R x4 I MS21046C4 x4 MS21046C4 x4 22 6150037 9956T 0339 x2 SEE NOTE 22 02 600 109 x2 9 22 6150036 we di SEENOTE 1 NASMMSCO BR MS21046C6 NOTES 22 6150015 6150016 0 02 1 FOR PARTS NOT LISTED PLEASE SEE OUR WEBSITE FOR DETAILED DRAWINGS OF SELECTED PARTS X LIGHTWEIGHT KITS SHIPPED AS OF N 11 19 08 KIT 3534 N N N AFFECTED AS FOLLOWS A NS 22 6150015 BECAME 22 6150024 v 22 6150016 BECAME 22 6150025 22 6150018 BECAME 22 6150041 22 6150019 BECAME 22 6150040 22 6460004 Continued Airworthiness Rev C Page 135 22 Sept 2011 TORNADO ALLEY TURBO INC Em _ 7o EN _ MAIN FUEL SCREEN tS uc HIGH RPM FUEL FLOW ADJUSTMENT CCW INCREASE CC DECREASE 22 6460004 Continued Airworthiness Rev C 136 22 Sept 2011 TORNADO ALLEY TURBO INC
5. 9 Reinstall spark plugs and leads and visually inspect the engine compartment for any oil leaks 10 Conduct a fuel prime operation check by putting the Fuel Selector to either tank and mixture full rich 11 Turn on battery 12 Activate fuel prime switch and observe fuel flow for brief positive indication of fuel flow 13 Turn off battery 14 Inspect engine area for any fuel leaks paying careful attention to the fuel discharge nozzles and fuel lines E Operational Inspection First Flight Run Up Perform the following Run Up Procedure prior to first flight after reinstallation of turbonormalizing system during overhaul or maintenance of turbonormalizing system components With upper and lower cowling removed fireguard observer present Note Make sure turbochargers are pre oiled under Servicing Post Engine Overhaul Installation 1 Start engine using normal starting procedures 2 Keeping RPM below 1700 rpm monitor oil pressure fuel flow manifold pressure and engine temperatures for normal operation 3 Run engine for a short time only long enough to check all indications and ensure no fuel or oil leakage 4 Shut engine down inspect engine and turbo system for any sign of leakage chafing or heat damage 5 Install complete cowling 6 Perform normal engine start and operation to achieve proper operating temperatures 7 Perform magneto operational check 8 Perform high power operation check 22 646
6. Chap Sect Initials Airframe Group Reference 21 Alternate Door X 4 Visually 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 annunciator functions Clean area around jaltermateairdoor C service interval times are to be referenced from initial installation of system or overhaul of turbonormalizing system or after replacement of major exhaust components Chap Sect Interval Initials Engine Group Reference Engine Oil 50 Hrs Drain and change every 50 hours or 6 months whichever occurs first Fuel Injection System Hrs Visually Inspect for leaks security and condition Vent Lines to Fuel Pump and Fuel Discharge Nozzles ee Hrs Visually Inspect for chafing obstruction security and general condition Fuel Discharge Nozzles GAMI On Visually Inspect nozzles and manifold valve for fuel Installation Condition stains security and proper sealing of upper deck Procedure reference manifolds Remove and clean injector No 2001 nozzles every 5 years or 500 hours whichever comes 02 first Remove clean and replace per GAMI Installation Procedure No 2001 02 Spark Plugs TATI Initially RHB32E and RHB32S or equivalents per TCM SIL SB11 05 per TATI 03 2 installed as origina
7. Check movement of linkage by moving control from idle to full throttle Make proper adjustments and replace worn components Service air filter Replace the defective parts Check engine data and verify which cylinders are affected by drop in EGT during single magneto operation Check the spark plug and ignition lead indicated by which cylinder EGT drops on the operating magneto Adjust wastegate per Wastegate Functional Checks and Adjustment document 22 6460007 Disconnect lines from controller to master wastegate and back flush Wastegate and lines with oil compatible solvent at 50 psi Inspect entire exhaust system to turbonormalizers for cracks and leaking connections Tighten connections and replace damaged parts 22 6460004 Continued Airworthiness Rev C Page 111 22 Sept 2011 TORNADO ALLEY TURBO INC Continued Engine lacks power reduction in maximum manifold pressure or critical altitude Loose or damaged intake Inspect entire manifolding system manifolding for possible leakage at connections Replace damaged components tighten all connections and clamps Restricted fuel discharge Look at engine data and check fuel nozzles discharge nozzle that is indicated by higher than usual EGT and CHT at full power and full rich mixture Malfunctioning turbocharger Check for unusual noise in turbochargers If malfunction 1s suspected remove tailpipe and or air inlet connections and check rotor assembly
8. lt HEATER VALVE _ FIREWALL GASCOLATOR 1 FUEL PUMP _ 3 Ts f 112 E E T m CD cauli J y _ JS H gt ni 7 L Pd H n S 1 V IN y z X f Ell lt n 0 o d TEL OUT LI B ACC PAD S OUT TOUDP OPT a x x IN IN OUT 1 OUT p TJ t T 2 J SDA OIL COOLER TO UDP gam g OUT IN TE i 0 Y V WASTEGATE A Nee C3 J e p IN 3 UHTURBO
9. H TURBO SUPPORT ETI SR22 2200 MS20392 1C19 WASTEGATE 7 BOLT AN8C13A x2 477233 0003 BOLT AN8C12A x2 L H LATERAL SUPPORT ETI G2 600 120 LOWER SUPPORT BRACKET s ETI G2 600 A NUT MS21046C6 x4 N N N WASTEGATE LINKAGE NX ETI SR22 111 1 Se IF d COTTER BACP18BC02A02P x2 1 ver 4 PIN MS20392 1C25 R H TURBO ASSEMBLY N xX ETI SR22 1300 X N BOLT AN4C11A x24 ETI G2 110 106 Aa 77 WASHER NAS1149C0463R x32 w c X N WASTEGATE ASSEMBLY 470842 9004 N GASKET 1550148 2 x4 N X 2 V _ 7 MS21046C4 x16 f NS N R H TAILPIPE WASTEGATE OUTLET NUT MS21046C6 x4 G2 110 ES ETI SR22 109 1 x2 ETI G2 110 R L H TURBO ASSEMBLY ETI SR22 2000 E V BAND CLAMP 2 1 995CS 0339 x2 ANN gt L H WASTEGATE DUMP ETI G2 110 105 L H TAILPIPE z N N ETI G2 110 L N I N N ie Fiqure 3a 22 6460004 Continued Airworthiness Rev C 134 22 2011 TORNADO ALLEY TURBO INC 22 6150019 22 6150012 SEENOTE1 22 6150009 7 ANSC TA x2 ANACTA 2 NAS1149C0563R x2 AN6C12A x8 ce et c NAS1149C0463R 2 ps AN4C12A x4 22 6150010 1
10. fins power lever advanced rapidly replace air filter 22 6460004 Continued Airworthiness Rev C Page 13 22 Sept 2011 TORNADO ALLEY TURBO INC Engine Has Poor Acceleration Runs Rough At Speeds Above Idle Or Lacks Power High manifold pressure Manifold pressure is high and stays high after engine 1s warm Improper fuel air mixture Review downloaded engine data to verify correct operating technique per the AFMS is being used Check intake manifold connections for leaks Check fuel controls and linkage for setting and adjustment Replace worn elements of control linkage Service air filter Turbocharger rotor rubbing Replace Turbocharger Improperly adjusted or defective Adjust or replace Absolute Pressure Absolute Pressure Controller Leak in turbonormalizer induction system Ignition system defective Restricted fuel discharge nozzles Manifold pressure transducer is not functioning properly Manifold pressure overshoot Most likely to occur when engine is accelerated too rapidly Absolute Pressure Controller sensing line broken or loose Controller as required Correct cause of leaks Repair or replace damaged parts Engine oil viscosity too high for Replace oil with proper grade of oil ambient air temperature Exhaust system leakage Inspect and repair excessive exhaust leaks Check engine data and verify which cylinders are affected by drop in EGT
11. flowing out of the wastegate actuator hydraulic control cylinder The aneroid bellows are located inside a housing that is connected to the output air produced by the compressors As compressor outlet pressure increases the normally closed oil control valve opens When open the valve allows metered oil to bypass the wastegate which in turn 15 spring loaded to the open position Oil passing through the absolute controller is returned to the engine oil sump The left hand wastegate 1s a master wastegate connected to a slave wastegate on the right side of the engine The right hand wastegate is the same as the left hand wastegate but 15 slaved to the hydraulic actuator on the left hand wastegate The two wastegates are mechanically synchronized and move in parallel with each other Each wastegate incorporates a typical butterfly exhaust bypass valve The master wastegate 15 spring loaded to the open position Increasing oil pressure from the engine causes the actuator to work against the spring to close the butterfly valve The wastegate is located in the exhaust system parallel with the turbocharger turbine As the butterfly valve opens it allows exhaust gasses to bypass the turbocharger turbine thereby controlling the speed and output of the turbocharger The wastegate helps provide even control of the turbocharger speed and output so that the engine can maintain sea level manifold pressure well into the flight levels As turbocharger compressor outle
12. leaks 5 09 01 1 25 Flat gray gray white or light gray powdering or a Hrs and sooty appearance indicate exhaust leakage Signs of every deterioration include warping deformation thinning 50 Hrs collapse dents cracking tears separation scaling after weld separation discoloration corrosion metal pitting or burn through external joints clamps and couplings for misalignment warpage broken loose or missing fasteners clamps and abnormal wear Visually inspect tailpipe heat exchanger and shields for condition Visually inspect exhaust stack to flange interface for cracks in welds or weld heat affected area blown out or missing gaskets 22 6460004 Continued Airworthiness Rev C Page 117 22 Sept 2011 TORNADO ALLEY TURBO INC Chap Sect Interval Initials Reference MELLE RN U RN weld for cracks or weld separation Hrs Visually inspect tailpipes for erosion thinning OF 1 25 bulging or burn through Hrs Visually inspect bracing supports and support attach lugs on other structures for security Hrs Visually inspect surrounding structures for 5 1 25 NE discoloration heat damage or burning Hrs Visually Inspect for leaks security and condition Engine Baffling and Seals Visual Inspection for cracks tears and rips eae Visually Inspect for security and condition Inspect the crankcase vent dump to the exhaust pipe aM for blockag
13. reading about one inch Hg 4 Operate engine as in step 1 above to ascertain that adjustment has not caused an unacceptable change in manifold pressure 5 After each adjustment the aircraft must be flight tested to check results 6 Repeat this procedure until desired results are obtained 7 Safety wire adjuster TURBOCHARGER A Removal and Installation Turbocharger 1 Loosen clamp and remove induction tubing from the front of the turbochargers 2 Loosen clamp attaching tailpipe to turbine exhaust outlet and work wastegate and manifold from exhaust system 3 Disconnect and tag oil lines from turbochargers and plug or cap open lines and fittings 4 Remove bolts washers and nuts from exhaust flange that connects the turbocharger to the wastegate manifold assembly 5 Remove the turbocharger from aircraft being careful not to drop the unit 6 Installation may be accomplished by reversing the preceding steps and alignment of support rods Caution Pre oil turbocharger before engine operation MASTER WASTEGATE ACTUATOR A Removal and Installation Master Wastegate Actuator 1 Disconnect and tag oil lines from actuator and plug or cap open lines and fittings Disconnect linkage to slave wastegate 2 Remove bolts holding wastegate manifold assembly to exhaust system 22 6460004 Continued Airworthiness Rev C Page 25 22 Sept 2011 TORNADO ALLEY TURBO INC 3 Remove bolts washers and nuts attaching wastega
14. the pressurized air from the induction system from just downstream of the turbochargers In this application timing 15 set at 21 5 0 5 The inlet air filter will need to be changed periodically as shown in the Overhaul and Replacement Schedule listed under Maintenance Practices OXYGEN SYSTEM Some of the turbonormalized SR22 aircraft have an optional oxygen system from Tornado Alley Turbo Inc This paragraph will pertain to only that system and not the Precise Flight system that is installed from the Cirrus factory For oxygen systems installed per other STC s see the Instructions for Continued Airworthiness supplied with the STC This oxygen system consists of a 77 cu Ft bottle installed on the aft baggage compartment bulkhead or in the tail of the aircraft with low pressure oxygen lines routed under the headliner to user ports installed overhead of the passengers It has an on off switch to operate the electric solenoid to turn the flow of oxygen on and off to the user ports This solenoid is a normally closed solenoid so when power is removed the solenoid will shut off the supply of oxygen to the user ports 22 6460004 Continued Airworthiness Rev C Page 23 22 Sept 2011 TORNADO ALLEY TURBO INC All torque values are located in Appendix A ABSOLUTE PRESSURE CONTROLLER APC A Removal and Installation Absolute Pressure Controller 1 2 3 4 5 Disconnect and tag oil lines from controller and p
15. 0004 Continued Airworthiness Rev C Page 28 22 Sept 2011 TORNADO ALLEY TURBO INC 9 Monitor engine operating parameters and make adjustments as described section F 10 After achieving the desired operating parameters inspect the engine compartment for evidence of leaking chafing and heat damage 11 Release aircraft for return to service flight F 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 1 Engine Setup a RPM All adjustments need to be made at 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 Ensure normal operating oil temperature before making RPM adjustments Note Every airplane may not make full RPM during static ground run Make adjustments as close as possible then fly and readjust after flight per pilot information b Fuel Flow For the IO 550 N turbonormalized engine the target full power RPM and MAP fuel flow is 35 GPH 1 0 GPH Normally full power fuel flow will be 36 GPH To achieve these indicated target amounts adjustments may need to be made at the high RPM aneroid adjustment screw Because of the special combination of fuel nozzles and turbonormalized fuel pump the TC
16. 5 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 22 6460004 Continued Airworthiness Rev C Page 26 22 Sept 2011 TORNADO ALLEY TURBO INC ENGINE A Removal and Overhaul Engine If the engine is to be removed the turbochargers and their accessories should be removed in accordance with the following steps before removing engine mount bolts other procedures for engine removal listed in the Cirrus SR22 service manual apply 1 Disconnect hoses to the intercoolers 2 Remove wastegates in accordance with Removal and Installation of Master Wastegate Actuator and Removal and Installation of Slave Wastegate instructions 3 Remove turbochargers in accordance with Turbocharger Removal and Installation instructions Note The replacement normally aspirated IO 550 N engine must be modified before installation as a turbono
17. 6 All Turbonormalized models BN WEM housing SELENE and Hose connection see Note 1 amp 6 8 750 16 Steel fitting 470 550 39 1 45 3 Hose fitting B nut 22 6460004 Continued Airworthiness Rev C Page 139 22 2011 TORNADO ALLEY TURBO INC NOTE Bulkhead fittings consist of fitting with o ring and jam nut To properly install the fitting thread jam nut past first set of threads and to the end of the second set slide o ring over the long end to rest in the groove between threads Thread the fitting into the receiving port until o ring makes contact witht he port seat Turn fitting for alignment while ensuring o ring remains in the groove without contacting threads Tighten jam nut to specified torque above 2 Turbo compressor housing and hot section housing require the application of Locktite 545 be placed on the threads prior to installation of bolts 7 Use locking devices as required after installation and applying the specified torque values The turbo oil inlet valve requires special torque of 105 inch Ibs plus the application of Locktite 545 prior to installation 5 Specific requirements as stated in TCM SB96 7C Torque Limits or later revision will take precedence over this document as it relates to TCM components Utilize accepted procedures and techniques for the installation of all hoses in reguards to alignment and support Back up all fittings when tighteni
18. M 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 complete turn will equal approximately 1 5 GPH To make an adjustment loosen jam nut turn screw snug up jam nut Note Fuel flow is proportional to RPM and Manifold Pressure Given targets are set at engine operating oil temperature engine operating RPM and indicated 29 6 inches of manifold pressure During the run up the oil temperature should be not less than 170 F cooler oil will make higher manifold pressure which will make higher fuel flow Manifold Pressure Maximum manifold pressure in cruise flight 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 The APC pressure set point will vary slightly with engine oil temperature and oil pressure If the oil temperature is cooler the 22 6460004 Continued Airworthiness Rev C Page 29 22 Sept 2011 TORNADO ALLEY TURBO INC manifold pressure may indicate higher Be sure to make adjustments with the engine oil temperature at or above 170 F Pressure Normally there should not be need to make oil pressure adjustments but if the oil pressure is below 20 PSI at idle the oil pressur
19. STEGATE UN 4 O J b aM ACTUATOR e C9 SPRINGLOADED G3 Z Jj m 41 OPENBOTHSIDES DE X LEGEND t t as m I SYSTEM lt RAMAR TO ENGINE lt COVPRESSED AIR OVERBOARD OLSMP FROMENGINE Shy pe TS ABSOLUTE LPP OAE THROUGH TAILPIPE PC EE uj MECHANICAL LINKAGE CONTROLLER REGUATES E OIL THROUGH FROM WASTEGATE ACTUATOR ACTUATOR 22 6460004 Continued Airworthiness Rev C Page 18 22 Sept 2011 TORNADO ALLEY TURBO INC TROUBLESHOOTING To facilitate troubleshooting the following information provides an explanation 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 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 The pressurized induction air then passes through intercoolers then the throttle body and finally induction manifold into the cylinders The air and fuel are burned and exhausted to the turbocharger turbines The 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 6 in Hg In order to
20. TORNADO ALLEY TURBO INC TORNADO ALLEY TURBO INC Continued Airworthiness Manual For Cirrus Design SR22 Series Airplanes Turbonormalized per STC s SA10588SC and 5 105895 22 6460004 Continued Airworthiness Rev C Page 11 22 Sept 2011 TORNADO ALLEY TURBO INC LOG OF REVISIONS This document supersedes 215 10 release 08 Nov 2006 Revision 10 APR 09 03 NOV 10 22 SEPT 11 1 2 2 1 Revisions Lettered revisions of this document will be issued periodically Each revision will cover the entire document Change to data the previous revisions will be identified by a revision bar in the outer margins of the page Change bars will be shown only against the immediate prior revisions Revision Distribution The latest revision of this document in its entirety will be posted at www taturbo com drawings 22 6460004 Continued Airworthiness Rev C Page 2 22 Sept 2011 TORNADO ALLEY TURBO INC Intentionally Left Blank 22 6460004 Continued Airworthiness Rev C Page 3 22 Sept 2011 TORNADO ALLEY TURBO INC TABLE OF CONTENTS Subject 0 9 O AIRWORTHINESS LIMITATIONS 000000001 6 TURBONORMALIZER SYSTEM DESCRIPTION AND OPERATION 7 Fig 1 SR22 Turbonormalizing System Schematic 08 TROUBLESHOOTING 7 2 _ MAINTENANCEPRACTICES 2 2 Overhaul And Replacement Schedule 17 Scheduled Maintenance Checks 0000 17 Pr
21. Wastegate Functional Check and Adjustment document 22 6460007 for induction leak test Engine Power Increases Slowly Pressure relief valve out of Replace Pressure relief valve if Or Severe Manifold Pressure adjustment or defective defective Fluctuations When Throttle Advanced Wastegate operation is sluggish Lubricate and adjust wastegate Correct cause of sluggish operation Replace Wastegate if defective Engine Power Increases Rapidly Oil temperature not to operating Warm up oil temperature and try And Manifold Pressure standards again Overboosts When Power Lever Wastegate operation is sluggish Lubricate and adjust wastegate Advanced Correct cause of sluggish operation Replace Wastegate if defective Power lever advanced too Advance power lever smoothly rapidly Refer to Cirrus SR22 Service Manual Verify oil pressure is in proper Adjust oil pressure to proper limits operating limits Pressure relief valve out of Factory adjustments required or adjustment or defective replace pressure relief valve if defective Temperature temperature indication properly replace CHT probe or clean as appropriate Engine baffles loose or heat Install baffles or heat shields shields bent or missing properly Repair or replace if defective LOP ops with insufficient Review downloaded engine data to manifold pressure or excessive verify correct operating technique fuel flow per the AFMS 15 being used cooling
22. ating 350 hrs TIS or replace at first annual after 350 hrs TIS whichever occurs first however replacement time not to exceed 450 hrs time in service V band clamps A There are no other limiting inspections and or maintenance items FAA Approved ce 5 Date 22 6460004 Continued Airworthiness Rev C Page 16 22 Sept 2011 TORNADO ALLEY TURBO INC TURBONORMALIZER SYSTEM DESCRIPTION AND OPERATION The Tornado Alley Turbonormalizing System See Figure 1 utilizes two Kelly Aerospace turbochargers with a Kelly Absolute Pressure Controller and a Kelly pressure relief valve The turbochargers are new generation turbochargers designed to provide the same boost as older design turbochargers 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 Pressure Controller and wastegates work in conjunction with each other to provide proper boost pressure to the engine The wastegate is actuated using engine oil pressure to actuate a small hydraulic cylinder which redirects the engine by pass exhaust flow around the turbocharger The absolute pressure controller utilizes an aneroid bellows and spring connected to a valve that regulates the amount of oil
23. d cooler restriction Clean oil cooler Low oil pressure on engine gage or high oil temperature Debris under oil pressure relief Check oil pressure adjuster seat for valve debris Leaking damaged or loose oil Check for restricted lines and loose line connection Restricted connections and cut the oil filter and screen or filter inspect for contaminates or for partially plugged oil filter Clean parts tighten connections and replace defective parts Malfunctioning Turbocharger Turbocharger rotor jammed or Replace turbocharger rubbing See section Engine lacks power reduction in maximum manifold pressure or critical altitude See section Engine lacks power reduction in maximum manifold pressure or critical altitude altitude malfunctioning Controller Wastegate capillary tube Disconnect lines from controller to plugged master wastegate and back flush wastegate and lines with oil compatible solvent at 50 psi Absolute Pressure Controller Remove sense line blockage sensing line blocked Induction system leaking Eliminate any leaks per Induction System Leak and Function Test document 22 6460012 Leak in exhaust system Adjust or repair exhaust system Oil leaking or dripping from Acceptable drip Continue monitoring drip leaking Low manifold pressure at take Absolute Pressure Controller out off of adjustment or defective or replace controller if defective Wastegate capillary tube Disco
24. during single magneto operation Check the spark plug and ignition lead indicated by which cylinder EGT drops on the operating magneto Replace damaged or misfiring plugs Look at engine data and check fuel discharge nozzle that is indicated by higher than usual EGT and CHT at full power and full rich mixture Check that the manifold pressure gage reads the same as field barometric pressure with the engine not operating This is not the altimeter setting Smoothly move throttle about two thirds open Let engine accelerate and stabilize Smoothly move throttle to full open Check upper deck sense line 15 connected and tight or replace if needed 22 6460004 Continued Airworthiness Rev C Page 114 22 Sept 2011 TORNADO ALLEY TURBO INC continued Absolute Pressure Controller out Adjust Absolute Pressure Controller Manifold pressure is high and of adjustment or defective or replace controller if defective Wastegate linkage not Adjust or replace wastegate linkage functioning per document 22 6460007 stays high after engine 15 warm Wastegate Functional Check and Adjustment sensing line blocked Low fuel flow Verify fuel flow is low at rated RPM and MAP fuel pump is installed driven fuel pump Restricted flow to fuel metering Check mixture control for full travel valve Check for restrictions in fuel filters and lines adjust control and clean filters Replace damaged parts Fuel control lever i
25. e and clean at each oil change or not more than 50 hrs erem mem 148 Visually Inspect for security and condition 14 Engine Mount Isolators Visually Inspect for cracking splitting and general condition 15 Turbonormalizer Kelly Aerospace Visually Inspect turbine for oil deposits and turbine Troubleshooting impeller damage Visually Inspect compressor wheel Reference Guide for damage interference and free rotation 400888 0000 Inspection may be accomplished by flexible bore scope or by removal of tailpipe 6 Turbonormalizer System Lines Visually Inspect for chafing obstruction security and 9 Airframe Group Un Un general condition 16 17 Wastegate and Absolute Pressure Controller Visually Inspect for security and condition 18 Tailpipe Heat Exchangers 5108 04 x Pressure test or borescopic Inspection of tailpipe sections adjacent to heat exchanger for signs of cracking Repair or replace on condition 1 Cabin Heat Mixing Valve 200 Visually Inspect for security and condition Hrs 20 Induction System Filter Clean per TATI X Clean and re oil filter at each inspection period or Air Filter when filter is more than 50 covered by foreign Cleaning material Due at annual or on condition not less than Instruction No each annual 5108 05 22 6460004 Continued Airworthiness Rev C Page 18 22 Sept 2011 TORNADO ALLEY TURBO INC
26. e must be increased enough to keep adequate oil flow through the turbo at idle speeds The turbo inlet oil pressure check 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 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 Perform normal start up taxi engine parameter checks and any ground operational checks not related to the turbo system 2 Utilizing normal Cirrus before flight checklist perform additional full power performance operational check prior to releasing the brakes for take off Take note of engine RPM fuel flow TIT manifold pressure and oil temperature 3 Depending on oil temperature the parameters may vary Optimally 2700 RPM 29 6 inches MP 35 GPH 1 0 GPH at normal operating oil temperature 4 Because of a direct correlation between oil temperature and manifold pressure at lower than normal operating oil temperature manifold pressure may indicate higher than redline 5 Because of a direct correlation between manifold pressure and fuel flow higher manifold pressure will give higher fuel flow 6 At full power and full rich mixture the TIT will normally be between 1250 1330 F 7 Utilize normal Cirrus engine br
27. e 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 wastegate actuator power cylinder 15 lowered sufficiently the wastegate actuator opening spring forces the mechanical linkage to open the wastegate A portion of the exhaust gases then bypasses the turbonormalizer turbine thus preventing further 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 wastegate closed The PRV will open to prevent any excessive pressure increase from the turbocharger compressor MAGNETOS The magnetos installed on this aircraft are Bendix 25 series These magnetos have been fitted with a magneto pressurization system to enable them to work at higher altitudes without cross firing due to the reduced resistivity of lower pressure atmosphere This pressurization system consists of magneto housing 22 6460004 Continued Airworthiness Rev C Page 122 22 2011 TORNADO ALLEY TURBO INC gaskets a calibrated bleed orifice an inlet air filter and tubing to rout pressurized air to the magnetos The pressurization system gets
28. eak in procedures Keep in mind the turbo parameters and the added system components H Post Return to Service Flight Inspections 1 After first flight recheck torque on V band clamps Use caution to not over torque the V band clamps 2 Inspect engine compartment for evidence of leaking chafing and heat damage I Flooded Engine Start Procedure 1 Mixture to Idle Cut Off 2 Throttle to Full Open 3 Crank engine and once the engine starts move mixture to Full Rich 4 Adjust throttle for engine idle between 800 1000 RPM 22 6460004 Continued Airworthiness Rev C Page 130 22 Sept 2011 TORNADO ALLEY TURBO INC J Hot Engine Start Procedure 1 Mixture to FULL RICH 2 Open throttle slightly to the point of normal engine idle 3 Simultaneously engage electric boost pump to BOOST and the starter switch to START 4 When the engine starts release the starter switch 5 Adjust the throttle to normal idle of 800 1000 RPM 6 On very hot days leave the electric boost pump switch on BOOST during taxi 22 6460004 Continued Airworthiness Rev C Page 22 Sept 2011 TORNADO ALLEY TURBO INC MP CONTROLLER L H INTERCOOLER UPPER DECK REFERENCE 7 IN FUEL MANIFOLD VALVE MD PRESSURE RELIEF VALVE 7 FIREWALL SCAVENGE PUMP
29. ect for security and condition 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 condition 22 6460004 Continued Airworthiness Rev C Page 120 22 Sept 2011 TORNADO ALLEY TURBO INC Engine Group Chap Sect Reference Detailed Inspection Criteria Induction System Hoses and Couplings Refer to AMM 5 20 Visually Inspect for security leaks and condition Tighten hose clamps as required Turbochargers Kelly Aerospace Visually Inspect turbines for carbonization oil deposits and turbine Troubleshooting impeller damage Visually Inspect compressor wheels for damage Reference interference and free rotation Guide 400888 0000 Turbocharger Mounting Brackets Refer to AMM 5 20 Visually Inspect for security and condition Replace any cracked or damaged brackets Flexible Turbo System Lines Refer to AMM 5 20 Visually Inspect for chafing obstruction security and general condition Wastegate and Absolute Pressure Controller Refer to AMM 5 20 Visually Inspect for security and condition Lubricate wastegate butterflies with Mouse Milk Vent Lines to Fuel Pump and Fuel Discharge Nozzles Refer to AMM 5 20 Visually Inspect for chafing obstruction security and general condition Engine Heat Shields Visually Inspect for security and condition Exhaust Muffler Heat Exchanger Refer to AMM 5 20 Borescopic inspection of ta
30. fold pressure Lightly tap the unit after each adjustment to seat internal parts Note When adjusting rotate VERY small increments as this 1s extremely sensitive Approximately 13 degrees rotation will change the manifold pressure reading about one inch Hg Install the bottom plug in absolute pressure controller then operate engine as in step 1 above to ascertain that adjustment has not caused an unacceptable change in manifold pressure 22 6460004 Continued Airworthiness Rev C Page 124 22 Sept 2011 TORNADO ALLEY TURBO INC Note When making adjustment on the ground the hotter the engine gets the lower the manifold pressure will be 5 After each adjustment the aircraft must be flight tested to check results 6 Repeat this procedure until desired results are obtained 7 Safety controller plug 10 Absolute Pressure Controller Adjustment Procedure Adjust the Absolute Pressure Controller so that the engine maintains 29 6 in Hg at full throttle in flight with the oil temperature greater than 170 F Normal in flight oil pressure should be between 42 52 psi 2 Cut safety wire 3 Using a 1 2 wrench rotate metering valve seat clockwise to increase manifold pressure and counterclockwise to decrease manifold pressure Lightly tap the unit after each adjustment to seat internal parts Note When adjusting rotate in VERY small increments Approximately 14 turn will change the manifold pressure
31. for possible rubbing in housing damaged rotor blades or defective bearings Replace turbocharger 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 necessary Absolute Pressure Controller not Check oil pump outlet pressure oil getting enough oil pressure to filter and external lines for close the wastegate obstructions Clean lines and replace if defective Replace oil filter Refer to Wastegate Functional Check and Adjustment document 22 6460007 of adjustment or defective or replace controller if defective Engine smokes white smoke Master wastegate actuator Replace Master wastegate actuator leaking oil Turbo drain line oil return to Clean line and check valve engine sump plugged Replace either if defective Turbocharger jammed Replace turbocharger Turbocharger bearing seals Replace turbocharger leaking RPM idle rise too rich Black smoke only above 1200 Decrease engine driven fuel pump RPM engine driven fuel pump fuel flow set too high 22 6460004 Continued Airworthiness Rev C Page 112 22 Sept 2011 TORNADO ALLEY TURBO INC Engine surges Defective Absolute Pressure Replace Absolute Pressure Controller Controller if defective Wastegate actuator linkage Replace if not adjustable Reference binding document
32. h turbochargers when the air filter becomes blocked After the air filter blockage 15 removed the alternate air door may be closed by simply retarding the power lever momentarily and the door will re latch automatically In some instances if there is an 22 6460004 Continued Airworthiness Rev C Page 17 22 Sept 2011 TORNADO ALLEY TURBO INC 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 22 2 TURBOSYSTEM PRESSURE SCHEMATIC RELIEF VALVE INDUCTION ALT AR TOFU 4 a AIRFLTER DOR DISCHARGE e N PRESSE SYSTEM A as 21 COMPRESSOR WASTEGATE gt o e gt H PES l _ WA
33. ilpipe sections adjacent to heat exchanger for signs of cracking Repair or replace on condition 22 6460004 Continued Airworthiness Rev C Page 121 22 Sept 2011 TORNADO ALLEY TURBO INC TURBOCHARGERS The turbochargers are exhaust gas driven compressors or air pumps which provide high air mass flow to the engine intake manifold Each turbocharger 15 composed of a 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 turbocharger Turbocharger bearings are lubricated with filtered 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 15 forced out of the compressor housing through a tangential outlet to the intake manifold The degree of compression is varied by means of a wastegate valve which varies the amount of exhaust gas allowed to bypass the turbine ABSOLUTE PRESSURE CONTROLLER APC The Absolute Pressure Controller APC uses engine oil pressure to actuate the wastegate The turbocharger 15 controlled by the wastegate
34. l equipment Replace SBI1 05 RHB32S spark plugs with RHB29E or equivalent heat range massive electrode spark plugs per TATI SBII Thereafter 05 If RHB29E spark plugs are not available RHB32E or equivalent heat range massive electrode spark plugs Condition are acceptable 22 6460004 Continued Airworthiness Rev C Page 19 22 Sept 2011 TORNADO ALLEY TURBO 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 20 of the SR22 AMM Engine Group Chap Sect Reference Routine Inspection Criteria Induction System Hoses and Couplings Refer to AMM 5 20 Visually Inspect for security leaks and condition Turbochargers Refer to AMM 5 20 Visual inspection of turbines for carbonization oil deposits and turbine impeller damage Visually Inspect compressor wheels for damage interference and free rotation Turbocharger Mounting Brackets Refer to AMM 5 20 Visually Inspect for security and condition Flexible Turbo System Lines Refer to AMM 5 20 Visually Inspect for chafing obstruction security and general condition Wastegate and Absolute Pressure Controller Visually Inspect for security and condition Vent Lines to Fuel Pump and Discharge Nozzles Refer to AMM 5 20 Visually Inspect for chafing obstruction security and general condition Engine Heat Shields Refer to AMM 5 20 Visually Insp
35. lug 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 Pressure Controller Caution With engine oil temperature at 170 or greater slowly open throttle and note maximum manifold pressure obtainable 5 Absolute Pressure Controller Adjustment Procedure 1 2 3 4 Adjust the Absolute Pressure Controller so that engine maintains 29 6 in Hg at full throttle in flight with the oil temperature greater than 170 Normal in flight oil pressure should be between 42 52 psi Note Some aircraft have a different absolute pressure controller installed on them This can be identified by a square head on the bottom of the controller instead of a hex head fitting THIS IS THE ADJUSTER DO NOT TURN MORE THAN IS NEEDED FOR THE ADJUSTMENT See the procedure below for the 10 absolute pressure controller Cut safety wire and remove plug from bottom of absolute controller It is normal for a small amount of oil to be encountered upon removal of the plug Using a flat blade screw driver rotate metering valve seat clockwise to increase manifold pressure and counterclockwise to decrease mani
36. maintain 29 6 inches of manifold pressure a master wastegate is used on the 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 the 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 A wastegate 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 15 adjustable to ensure both wastegates control both turbochargers equally At high altitude part throttle or low RPM the exhaust flow 15 not capable of turning the turbine compressor fast enough to maintain maximum compressor discharge pressure and the wastegate will close to force all of the exhaust flow through the turbine In normal operation at full throttle the wastegates will seldom if ever be fully closed When the wastegate is fully closed any change in turbocharger speed will mean a change in engine operation Thus any i
37. nal 3 4 to 1 turn Nozzle Fuel injector with 55 65 4 6 5 4 All Turbonormalized models anti seize compound Nut Fuel injection line 40 45 3 3 3 7 All Turbonormalized models 31 24 31 18 25 20 Crankcase see Note 5 Nut Magneto Flange 100 120 8 3 10 0 All engine models 25 28 38 24 250 28 10 32 8 32 250 20 Bolt Oil sump flange 155 175 12 9 14 6 All engine models Screw Rocker box cover 55 65 4 6 5 4 All engine models flange to cylinder exhaust flange support brackets Bolt Turbo heatshield 36 50 3 0 4 2 All Turbonormalized models Screw Turbo heatshield 17 5 22 5 1 5 4 2 All Turbonormalized models Bolt Turbo support to 75 85 6 3 7 1 Turbonormalized models cylinder head 22 6460004 Continued Airworthiness Rev C Page 138 22 Sept 2011 TORNADO ALLEY TURBO INC Appendix A Component Specific Torque Specifications SIZE FASTENER IN LB FT LB MODELS AFFECTED Exhaust cont d 3125 24 Nut All 312 nuts for turbo 180 220 15 0 18 3 All Turbonormalized models support 3125 24 Nut Spring turbo support Tighten the nut to Turbonormalized models compress the spring to 3 4 of expanded height 25 28 Nut Exhaust coupling V 60 65 5 0 5 4 Turbonormalized models band clamp Turbo see Note 2 3125 18 Bolt Turbo oil inlet adapter 155 175 12 9 14 6 All Turbonormalized models adapter 3125 18 Bolt Turbo compressor 130 140 10 8 11
38. nal Check and Adjustments 22 6460007 TATI Induction System Leak and Function Test 22 6460012 Hartzell Engine Kelly Aerospace Troubleshooting Reference Guide 400888 0000 Technologies formerly Kelly Aerospace GAMI GAMIgjector Installation Procedure IP 2001 02 Permold Series IO 550 A B C G N P R X30634A Aircraft Maintenance Manual 13773 001 TATI Bulletin Letter or Subject Notes Compliance Instruction Number SO Clean crankcase breather tube inlet on tailpipe Recommended _ SI11 03 Turbocharger support system inspection and Highly Recommended maintenance SB11 04 Turbocharger inlet screens Highly Recommended SB11 05 Fine wire spark plugs TATI service bulletins letters and instructions are available at www taturbo com drawings 22 6460004 Continued Airworthiness Rev C Page 15 22 Sept 2011 TORNADO ALLEY TURBO INC AIRWORTHINESS LIMITATIONS The Airworthiness Limitations Section is FAA approved and specifies inspection and maintenance required under paragraphs 43 16 and 91 403 of the Federal Aviation Regulations unless an alternative program has been FAA approved All fluid transfer hoses and the V band clamps are to be replaced per the schedule shown below sy stem are e Teflon lined with integral firesleeve per TSO C53a D Replace with same stvle hoses Flexible Turbo On condition not System Lines to exceed 10 years Replace at 350 hrs TIS if clamp is removed prior to accumul
39. ncrease or decrease 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 at high altitude any change in exhaust flow to the turbine or ram induction air pressure will be magnified proportionally by the compressor pressure 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 slightly overboost This would most likely be experienced during takeoff roll or during a change to full throttle operation in flight 22 6460004 Continued Airworthiness Rev C Page 19 22 Sept 2011 TORNADO ALLEY TURBO INC A slight overboost to 32 0 inches of manifold pressure is not considered detrimental to the engine as long as it s duration is less than 2 minutes No corrective action is required when momentary overboost corrects itself and is followed by normal engine operation as the engine warms up However if overboosting of this nature persists when oil temperature 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 wastegate and relief valve should be checked for necessa
40. ng hoses 22 6460004 Continued Airworthiness Rev C Page 140 22 Sept 2011
41. nnect lines from controller to plugged master wastegate and back flush wastegate and lines with oil compatible solvent at 50 psi Engine will not deliver rated See Low manifold pressure at take off above power Rotating assembly bearing Free rotating assembly per Induction seizure System Leak and Function Test document 22 6460012 22 6460004 Continued Airworthiness Rev C Page 116 22 Sept 2011 TORNADO ALLEY TURBO 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 airplane s flight hours must be entered into the Service Time Record filed in the Airplane Maintenance Log System Lines to exceed 10 years REE GGTS r ss 1000 hrs not to exceed 2000 hrs ree hc 1000 hrs not to exceed 2000 hrs 4 Absolute Pressure See Note Recommend overhaul Absolute Controller Pressure Controller at 1000 hrs not to exceed 2000 hrs V band clamps 450 hrs time in After 350 hrs if clamp is removed or service first annual after 350 hrs Whichever occurs first Magneto 3 years or 300 Pressurization hours Filter B Scheduled Maintenance Checks Anthea Crome 2 Interval Initials Special All external surfaces for signs of exhaust
42. nterference or Check operation of throttle and out of adjustment mixture control for possible interference with other components Adjust as required to obtain correct operation Incorrect engine driven fuel Check and adjust fuel flow See pump adjustment and operation Engine section part F Replace defective pump Fuel flow transducer or wiring Verify this by determining if EGT s failing fluctuate with fuel flow If EGT s do not fluctuate replace fuel flow transducer or repair wiring Interference from ignition Operate engine on single magneto system and identify which magneto is causing the interference Manifold pressure fluctuating Troubleshoot fluctuating manifold pressure Unsatisfactory engine idle cut Engine getting fuel with mixture Adjust fuel control not in full IDLE off in IDLE CUT OFF CUT OFF position Check auxiliary fuel pump OFF Check for leaking fuel manifold valve Replace defective components Low oil pressure on engine gage Insufficient oil in oil sump or Add oil or change oil to proper or high oil temperature using improper grade oil for viscosity Fluctuating fuel flow prevailing ambient temperature Defective vernatherm valve Check for defective vernatherm valve See TCM X30634A Permold Series 10 550 G N P R Replace valve if defective 22 6460004 Continued Airworthiness Rev C Page 15 22 Sept 2011 TORNADO ALLEY TURBO INC continue
43. ogressive Inspection Program 0 20 Turbochargers 010 2 _ Absolute Controller 0 2 _ Magnets 2 Oxygen System 014 23 i Absolute Controller I I j O Removal and Installation Absolute Controller 04 Adjustment Absolute Controller 0004 RENE uc uw Adjustment Absolute Controller Turbochargers Turbochargers O Master Wastegate Actuator II o Adjustment Master Wastegate Actuator 26 Slave Wastegate Removal And Installation Of Slave Wastegate 206 Pressure Relief Valve T OSO _ Removal And Installation Of Pressure Relief Valve 26 Engine W o Removal and Overhaul Engine 00020 Imsallation Engine Servicing Post Engine Overhaul Installaion 28 Operational Inspection First FlightRun Up 0020 Adjustments Post Engine Overhaul Installation 09 Functional Inspection Return to Service Flight 30 Post Return to Service Flight 8 uM EE EN EN AN Post Return to Service Flight _ E 027 7 K 20 22 22 2 24 24 25 26 26 26 2d 27 28 28 30 30 20 31 32 33 34 36 22 6460004 Continued Airworthiness Rev C Page 14 22 Sept 2011 TORNADO ALLEY TURBO INC Referenced Instructions for Continued Airworthiness and other Publications The latest revision to the following publications should be used in conjunction with this manual TATI Wastegate Functio
44. rictions and replace defective components Defective ignition system Check engine data and verify which cylinders are affected by drop in EGT during single magneto operation Check the spark plug and ignition lead indicated by which cylinder EGT drops on the operating magneto 22 6460004 Continued Airworthiness Rev C Page 110 22 Sept 2011 TORNADO ALLEY TURBO INC continued Engine starts but dies or will not idle properly Engine Has Poor Acceleration Engine lacks power reduction in maximum manifold pressure or critical altitude Defective engine Fouled spark plugs Idle mixture too lean Incorrect fuel air mixture worn control linkage or restricted air filter Incorrectly adjusted throttle control sticky linkage or dirty air filter Defective ignition system Improperly adjusted wastegate Wastegate capillary tube plugged Loose or damaged exhaust system Check compression and listen for unusual engine noises Check oil filter for excessive metal Repair engine as required Check engine data and verify which cylinders are affected by drop in EGT during single magneto operation Check the spark plug and ignition lead indicated by which cylinder EGT drops on the operating magneto Readjust idle setting Tighten adjustment screw to lean mixture and back off adjustment screw to richen mixture Tighten loose connections replace worn elements of linkage Service air filter
45. rmalized Cirrus engine Therefore turbonormalized engines must be overhauled by a facility approved by Tornado Alley Turbo Inc and in accordance with procedures established by TATI Installation of new or overhauled engines in existing turbonormalized aircraft requires installation of components at TATI a facility approved by TATI Overhaul turbochargers MPC wastegates PRV and fuel pump at the same time as engine overhaul Contact TATI for a current list of approved overhaul facilities for engine and components Keep fuel injectors in proper cylinders B Installation Engine Before installing the engine the aft accessories should be installed prior to attaching the engine to the engine mounts per the Cirrus maintenance manual The turbochargers and exhausts can then be installed on the engine 1 Install the turbochargers in accordance with Turbocharger Removal and Installation instructions 2 Install the wastegates per Removal and Installation of Master Wastegate Actuator and Removal and Installation of Slave Wastegate instructions 3 Connect all hoses and induction system C Inspection Post Engine Overhaul Installation After overhaul and reinstallation of the engine and turbonormalizing system a final inspection 15 required Inspect the following for security signs of chaffing leaking and general condition 1 All hose connections routing and security 2 clamps and couplings for p
46. roper 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 6 Wiring chafe and heat related problems 7 Engine probe wiring to exhaust clearance 8 Cylinder lower fuel drain plumbing clearance to exhaust and heat shields 9 Heat shield clearance off of exhaust components 10 Turbo supports for security and safety wire 22 6460004 Continued Airworthiness Rev C Page 127 22 2011 TORNADO ALLEY TURBO INC 11 Wastegate linkage clearance and safety wire 12 Turbo air inlet SCEET to front cowling clearance 13 Throttle propeller and mixture control lever full travel D Servicing Post Engine Overhaul Installation Before First Engine Start After overhaul and reinstallation of the engine and turbonormalizing system pre oil the turbochargers as described below 1 Remove all lower spark plugs 2 Ground all ignition leads to engine 3 Fuel Selector to OFF 4 Clear engine and propeller area from obstacles 5 Ensure proper oil level 6 Turn on battery power 7 With security person outside crank engine and monitor indicated oil pressure Crank engine more than 30 seconds at a time When 12 psi or more is consistently indicated on oil pressure indicator the turbo will be considered to be pre oiled 8 Turn off battery power
47. ry adjustment or replacement of components This troubleshooting section primarily references items covered for the turbonormalizing system If it is not covered in this chart see Cirrus or TCM troubleshooting documents No indication of fuel flow and Check fuel controls for proper no fuel to engine position auxiliary fuel pump BOOST and operating feed Engine will not start valves open mixture full rich throttle open fuel filters open and visually check fuel tank level Positive indication of fuel flow Execute a Flooded Engine Start and engine is flooded Positive indication of fuel flow Check for bent or loose fuel lines but no fuel to engine Check for fuel at a fuel nozzle If no fuel present at nozzle consult TCM X30634A Permold Series I0 550 C G N R Vaporized fuel In system Most Refer to Hot Start Procedure in Hkely to occur In hot weather under Engine section part J with a hot engine Obstructed air intake Remove obstruction service air filter Inadequate fuel to fuel manifold Set fuel control in FULL RICH Engine starts but dies or will not idle properly position turn auxiliary fuel pump BOOST check to be sure feed lines and filters are not restricted Clean or replace defective components Upper deck air supply to fuel Check for bent lines or loose discharge nozzle restricted or connections Tighten loose defective connections Remove rest
48. t 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 wastegate actuator cylinder is lowered sufficiently the wastegate actuator spring forces the mechanical linkage to open the wastegates A portion of the exhaust gases then bypasses the turbocharger turbines thus preventing further increase of turbocharger speed and holding the compressor outlet absolute pressure to the desired value Conversely at engine idle the turbocharger runs slowly with low compressor pressure output therefore the low pressure applied to the aneroid bellows is not sufficient to affect the unseating of the normally closed metering valve Consequently engine oil pressure keeps the wastegates closed and all of the exhaust flows through the turbocharger turbine sections The system 15 equipped with a magnetically latched alternate air door on left side of the induction system When any restriction of the air filter 15 encountered such as from ice or ice crystal formation the alternate air door will open automatically A caution message or light will provide a message alert to 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 bot
49. te manifold assembly to the turbocharger 4 Loosen clamp attaching tailpipe to turbine exhaust outlet and work wastegate and manifold from exhaust system 5 Remove the assembly from aircraft being careful not to drop the unit 6 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 B Adjustment Master Wastegate Actuator If adjustment of wastegate actuator is required remove wastegate actuator in accordance with Removal and Installation of Wastegate Actuator instructions and send to an approved facility for repair or overhaul of wastegate actuators SLAVE WASTEGATE A Removal And Installation Of Slave Wastegate 1 2 3 4 5 Disconnect linkage to master wastegate Remove bolts holding wastegate manifold assembly to exhaust system Remove bolts washers and nuts attaching wastegate manifold assembly to the turbocharger Loosen clamp attaching tailpipe to turbine exhaust outlet and work wastegate and manifold from exhaust system Installation may be accomplished by reversing the preceding steps Note When installing the assembly be sure the gaskets at inlet and outlet of wastegate 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
50. wastegate actuator the absolute pressure controller and pressure relief valve PRV The wastegate bypasses engine exhaust gas around the turbonormalizer turbine inlet The wastegate actuator which is physically connected to the wastegate by mechanical linkage controls the position of the wastegate butterfly valve The absolute pressure controller controls the maximum turbonormalizer compressor discharge pressure The pressure relief valve prevents an excessive pressure increase from the turbocharger compressor The master wastegate actuator is spring loaded to position the wastegate to the normally open position when there is not adequate oil pressure in the wastegate actuator power cylinder during engine shut down When the engine 15 started oil pressure 15 fed into the wastegate actuator power cylinder through internal capillary tube This automatically fills the wastegate 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 wastegate actuator power cylinder it overcomes the force of the wastegate open spring closing the wastegate When the wastegate 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 pressure When at high engin
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