December 22, 2010 Service Bulletin #040 Rev. A Turbocharger
Contents
1. Outside North America for units sent to HET there will be no charge for this work and will be returned shipping pre paid less any applicable duties by the same method as received As an alternative HET will provide a labor allowance of 3 hours labor up to US 225 maximum for units sent to nearest of the following facilities PLANE SUPPORT AEROTEST PTY LTD ROEDER PRAEZISION Sunshine Coast Airport Am Flugplatz Mudjimba Qld 4564 Australia Egelsbach ABN 12 079 212 981 E mail ian planesupport com 63329 Germany Ph 61 7 5448 9824 Fax 61 7 5448 9287 Tel 49 6103 4002 0 Fax 49 6103 4002 700 URL www roeder praezision com VORTEX MOTORS Aj Olavo Fontoura 484 San Paulo Brazil 02012 020 Tel 55 11 6221 8566 Fax 55 11 6251 0406 E mail ctm vortexmotores com br E mail vortex vortexmotores com br SHIPPING INFORMATION when returning to HET Turbocharger must be securely packed and packaged so no oil will seep into the shipping container A copy of Attachment A must have Customer Information and Product or Component Information sections filled out completely and included inside the shipping container The turbocharger must be received assembled and undamaged to qualify for repair Address package to Hartzell Engine Technologies LLC Warranty Department 2900 Selma Highway Montgomery AL 36108 USA Also mark WARRANTY DEPT clearly on the outside of the shipping container HET will only pay for return2. commercial assistance this form must be completed as instructed above and will serve as a claim form NO reimbursement will be made without completing this form For further information contact Hartzell Engine Technologies LLC at 2900 Selma Highway Montgomery AL USA or FAX to HET Customer Service 334 386 5450 The complete service bulletin is available to you online via our website at http www HartzellEngine Technologies com
3. 0002 sees oons asesx2 anos aessx2c aeceazoor Table 1b Applicable Original Equipment OE Part Numbers Turbochargers The turbocharger part numbers above or below may appear on the data tag 637374 1 633274 4 635034 2 642518 4 646677 649151 1 649151 2 46C 19836 46019839 46022924 C295001 0301 C295001 0304 LW 10191 LW 13310 LW 16254 IDENTIFICATION WARNING THIS PROCEDURE MUST BE PERFORMED BY COMPETENT AND QUALIFIED PERSONNEL FAMILIAR WITH ENGINE AND AIRFRAME MAINTENANCE THAT IS SPECIFIC TO THE TURBOCHARGING SYSTEM FAILURE TO DO SO MAY RESULT IN ECONOMIC LOSS EQUIPMENT DAMAGE AND OR PHYSICAL INJURY CAUTION DO NOT DEPEND ON THIS SERVICE BULLETIN FOR GAINING ACCESS TO THE AIRCRAFT OR ENGINE THIS WILL REQUIRE THAT YOU USE THE APPLICABLE MANUFACTURER S MAINTENANCE MANUALS OR SERVICE INSTRUCTIONS IN ADDITION ANY PREFLIGHT OR IN FLIGHT OPERATIONAL CHECKS REQUIRE USE OF THE APPROPRIATE AFM OR POH Access the aircraft turbocharger s in accordance with the instructions in the aircraft maintenance manual Some aircraft engines have two turbochargers so check both Do not rely on the aircraft or engine paperwork alone to identify the turbocharger part number Refer to Table to determine if the turbocharger being inspected is an affected part number Observe the part number found on the data plate If the affected part number does not appear go to the Return to Service section step 3 amp 4 If an affected part number do
4. HARTZELL Service Bulletin a MONTGOMERY ALABAMA USA Compliance is Considered Mandatory 2900 Selma Highway Montgomery AL 36108 USA Tel 334 386 5400 Fax 334 386 5450 Bulletin No 040 A Issue Date Dec 22 2010 TURBOCHARGER CHRA CONTAMINATION REASON FOR REVISION To revise Table 2 Cessna 421B TSIO 520 H should be GTSIO 520 H added TIO 541 E1C4 for Beech A60 Duke INTRODUCTION Hartzell Engine Technologies LLC HET has become aware of a condition affecting certain turbocharger center housing rotating assemblies CHRA where debris may not have been removed after the machining operation The debris could enter the normal oil flow to the turbine wheel shaft assembly resulting in seizure of the shaft and or turbine wheel head separation This condition may also lead to a loss of engine oil Either condition may lead to a complete loss of turbocharger function without warning as well as a partial or complete loss of engine power Since this debris is expected to enter the oil stream quickly the effects listed above can also occur quickly The instructions herein identify the two manufacturing sources for the CHRA center housings of which only one is affected This Service Bulletin is being issued to mandate the cleaning of CHRA center housing of turbochargers according to Table 1 below COMPLIANCE For turbochargers having between 0 and 10 hours time in service TIS including field overhauls before further flight perform the
5. IDENTIFICATION section of this procedure If the CHRA center housing is affected remove the turbocharger in order to proceed to the DISASSEMBLY and CLEANING sections and perform the required actions For turbochargers having between 10 and 50 hours time in service TIS including field overhauls Within the next ten 10 hours time in service perform the IDENTIFICATION section of this procedure If the CHRA center housing is affected remove the turbocharger in order to proceed to the DISASSEMBLY and CLEANING sections and perform the required actions For turbochargers operated beyond 50 hours time in service including field overhauled No action is required EFFECTIVITY Any aircraft or engine utilizing new 0000 series or rebuilt 9000 series turbochargers manufactured before serial number H NJLOO003 new or H NJROOO02 rebuilt with the compliance times above See Table 1a amp 1b for applicable part numbers Applications may include but are not limited to those specified in Table 2 If you have any questions concerning the instructions in this service bulletin please contact Hartzell Engine Technologies Technical Support at 888 461 6077 Questions concerning aircraft service or operation must be forwarded to the applicable manufacturer of that product Rev A Hartzell Engine Technologies Service Bulletin 040 Page 1 of 9 EFFECTIVITY cont d Table 1a Applicable KAES Part Numbers Turbocharger 00042 0002 a86642
6. arger from the engine To avoid the possibility of debris entering the turbocharger system connections cap all open lines and ducts Rev A Hartzell Engine Technologies Service Bulletin 040 Page 3 of 9 DISASSEMBLY AND CLEANING WARNING TO PROPERLY INSPECT DISASSEMBLE ASSEMBLE AND TEST THE TURBO CHARGER THE MOST CURRENT REVISION OF THE KELLY AEROSPACE ENERGY SYSTEMS KAES OVERHAUL AND MAINTENANCE MANUAL P N 400600 0000 MUST BE USED THE PROCEDURES THEREIN MUST BE FOLLOWED PRECISELY FAILURE TO DO SO MAY RESULT IN ECONOMIC LOSS EQUIPMENT DAMAGE AND OR PHYSICAL INJURY NOTE It is required that all turbochargers be removed from the engine and sent to HET or to a properly FAA certificated repair station or the foreign equivalent experienced in servicing turbocharger systems for this disassembly and cleaning Removal must be in accordance with the applicable aircraft and or engine manufacturer s maintenance manuals or service instructions Do not return turbo with fittings oil reservoir or other engine or airframe parts Prepare a clean and suitable work area for the removed turbocharger Utilizing the KAES Overhaul and Maintenance Manual P N 400600 0000 disassemble the turbocharger completely and isolate the CHRA Because of the many different models of turbochargers affected and the differences in disassembly refer to Table 2 to determine model For example P N 407540 9003 turbocharger would be a model T1879 It will be n
7. ecessary to use this model number and select the instructions in Chapter 2 of the Overhaul manual P N 400600 0000 Observe Special Tools pages 2 410 01 amp 2 420 01 for tools required for disassembly or reassembly Using a soft bristle brush paint brush style thoroughly clean the outside of the CHRA prior to disassembly Blow dry with clean oil free shop air This avoids outside contaminates from the CHRA affecting the CHRA center housing cleaning process below Turn to the disassembly section of Chapter 2 and follow the appropriate steps for the specific model turbocharger and disassemble enough to isolate the CHRA center housing from all of it s internal component parts bearings seals wheels etc Be sure to note the orientation of the housings to one another if required by the instructions Once the CHRA center housing has been isolated cover the remaining disassembled turbocharger parts to avoid contamination Proceed to CLEANING CHRA CENTER HOUSING below CLEANING CHRA CENTER HOUSING WARNING CLEANING MUST BE PERFORMED IN A WELL VENTILATED AREA HAND AND EYE PROTECTION IS REQUIRED USE OF HAZARDOUS CHEMICALS REQUIRES A FULL UNDERSTANDING OF EFFECTS OF HANDLING THESE PRODUCTS FOLLOW THE CHEMICAL MANUFACTURER S INSTRUCTIONS FOR USE AND DISPOSAL FAILURE TO DO SO MAY RESULT IN PHYSICAL INJURY OR DEATH 1 Prepare for cleaning the CHRA center housing Obtain the following materials locally Two clean solvent and corrosive
8. es appear continue with step 3 See Figure 1 for typical turbocharger installation Using Figures 2 3 and 4 identify the foundry mark located on the CHRA center housing as shown Those with a circled JT are not affected and may proceed to the Return to Service section step 3 amp 4 Ifa slanted A appears continue with the DISASSEMBLY and CLEANING sections NOTE For engine or aircraft models reference Table 2 It should be used for identifying turbocharged aircraft as a guide only Not every aircraft or engine combination is listed and not every STC or other field application is included This list is provided to help identify which aircraft may be affected by this service bulletin Page 2 of 9 Hartzell Engine Technologies Service Bulletin 040 Rev A IDENTIFICATION cont d y ae A A Typical Turbocharger ata ijag in this Area Figure 1 Typical Turbo Installation CHRA CENTER usa HOUSING I D Suspect Good Figure 2 Foundry Mark Slanted A Figure 3 Foundry Mark JT Foundry Mark May Also Be An indented Slanted A Suspect 4 Ifit has been determined that the CHRA center housing is affected per Table 1 and IDENTIFICATION section above the turbocharger must be removed and disassembled to isolate the CHRA center housing 5 Utilizing the most current Service Manual or Service Instructions of the applicable engine or airframe manufacturer remove the turboch
9. harger Overhaul amp Maintenance manual P N 400600 0000 Illustrated Parts Catalog as required to comply with this service bulletin Incidental parts may be required for the turbocharger installation These parts must be obtained from the applicable engine or airframe manufacturer PARTS IN INVENTORY Affected unused stock in customers hands must be returned through place of purchase See the Appendix for Commercial Assistance Rev A Hartzell Engine Technologies Service Bulletin 040 Page 7 of 9 TABLE 2 Affected Turbocharger Reference Table Turbocharger Ass y Engine Ass y Aircraft not limited to Turbocharger Model Seen ey Piper Malibu Conversion 466642 0001 649151 1 TSIO 360 MB SB Mooney Encore 466642 9001 TIO 540 AK1A TIO 540 AK1AT ee crea Piper Seneca V eee oe Piper PA46 350P Malibu Mirage is tara SY ew cosa T18 465008 0002 T TIO 540 AG1A Commander 114TC 46601 1 0002 46C19836 TIO 540 AF1A Mooney M20M TLS TA0413 46601 1 9002 TIO 540 AF1B Mooney M20M TLS Bravo TIO 540 AH1A Piper PA32 301T Saratoga 407540 0003 LW 13310 TIO 541 E1D4 Beech A56TC T1879 407540 9003 TIO 541 E1C4 A60 Duke 407800 9003 LW 10191 TIGO 541 E Piper PA31P T18A21 GTSIO 520 F 408590 9012 635034 2 GTSIO 520 K Twin Commander 685 T18A44 406990 9004 633274 4 GTSIO 520 D Cessna 421 421A THO867 408610 0001 632729 1 Ee 408610 9001 GTSIO 520 H Cessna 421B TEO659 NOTE The reference Table 2 should be used as a guide only f
10. ite its screen area and observing the response of any captured particles Observe filter and the bottom of each bucket and record findings on Attachment A at the end of this service bulletin It is normal to see some level of debris as a result of outside contaminant s such as carbon Loctite chips etc Use of paper paint strainer obtained at local hardware store or equivalent is acceptable Treat the center housing with preservative oil immediately after cleaning Use either Castrol 4130GA Castrol 4135 at 100 or Turco 4454 diluted 90 with water Other equivalent products may be used however closely observe dilution and mixing instructions The center housing has multiple cavities inside and out so preservative treatment is more effective when dipped rather than sprayed Submerge the center housing in a solution of preservative oil as called out in step 16 Pour out excess and rotate center housing to assure all excess oil is removed The housing may then be dried in still air or by applying compressed shop air Rev A Hartzell Engine Technologies Service Bulletin 040 Page 5 of 9 REASSEMBLY 1 Once the CHRA center housing has been cleaned reassemble the turbocharger Observe Chapter 2 General Cleaning instructions pages 2 230 01 amp 2 240 01 and General Inspection pages 2 250 01 amp 2 400 01 as required prior to starting reassembly Reassemble the turbocharger referring to the appropriate Reassembly section of Chapter 2 for
11. old side down center bore vertical cold side up oil drain down and oil drain up Reference points shown in Figure 4 Using the large nylon bristle brush insert into center bore and oil outlet cavity Scrub for 3 seconds minimum Using the small nylon bristle brush insert into the oil inlet and drain cavities Work brush around the edges inside the cavity where chips and burrs may be located Submerge center housing in solution allowing it to fill Hold the center housing with center bore axis vertical submerge housing with cold side up Place index finger over the oil feed hole place thumb over the oil drain hole place middle finger of the other hand over the hot side center bore and thumb over the cold side center bore Raise part from bucket and shake for 5 seconds minimum Orient oil drain port down and remove thumb to allow solution to drain into the bucket Repeat this step two times Remove the center housings and place into the other clean metal bucket containing only warm water Agitate center housing and rinse thoroughly After rinsing dry center housings using clean filtered compressed air assuring that all water enters the bucket Set center housing aside in a clean area Using a new conical paint strainer filter or some other easily seen filter media agitate the first and second buckets and pour the the contents of each through the filter Ferrous chips can be identified by passing a magnet along the outside of the filter oppos
12. or turbocharged aircraft Not every aircraft or engine combination is listed and not every STC or other field application is included This list is provided to help identify which aircraft may be affected by this service bulletin Page 8 of 9 Hartzell Engine Technologies Service Bulletin 040 Rev A APPENDIX I COMMERCIAL ASSISTANCE In addition to warranty coverage provided by the KAES or HET Limited Warranty HET will provide additional commercial assistance to comply with SB040 under the terms outlined in this Appendix Commercial Assistance the following will be provided with the submission of a completed PPCR Attachment A Sections and II only along with copies of invoices showing breakdown of labor charges and log book entries This will serve as a claim form when received by HET warranty department If the unit is not sent to HET for disassembly and cleaning a completed PPCR Attachment A with all Sections completed along with copies of invoices showing breakdown of labor charges and log book entries must be submitted This will serve as a claim form when received by HET warranty department Identification up to 1 hour labor up to 75 maximum Removal and Installation if necessary up to 4 hours labor up to 300 maximum Disassembly and Cleaning Reassembly Within North America for units sent to HET there will be no charge for this work and unit will be returned shipping pre paid by the same method as received
13. resistant metal buckets 1 5 gal minimum 5 7 liter A Large Flexible Nylon Bristle Brush 50 inch diameter min 1 in long brush SHB P N 1303 or equivalent A Small Flexible Nylon Bristle Brush 25 inch diameter min 1 in long brush SHB P N 1307 or equivalent Super Strength Greased Lightning Multi Purpose Degreaser or equivalent sufficient amount One graduated beaker 150 ml five ounce Oil Preservative Castrol 4130GA 4135 at 100 or Turco 4454 diluted 90 with water or equivalent Solvent resistant rubber gloves Solo Horton Brushes Inc P O Box 478 Winsted CT 06098 http www solobrushes com Page 4 of 9 Hartzell Engine Technologies Service Bulletin 040 Rev A CLEANING CHRA CENTER HOUSING cont d 2 Mix a solution at a ratio of 3 4 ounces 1 3 ounce 100 ml 10 ml of Degreaser to approximately 4 quarts 3 79 liters of warm water into the first clean bucket The solution in the bucket must be at a level that will completely submerge the entire center housing Oil Inlet Up Cold Side Panicle Wack Figure 4 pierre ns Typical CHRA Oil Drain Down W Center Housing Wearing protective Rubber Gloves place CHRA center housing Figure 4 into the bucket and soak for a minimum of 30 seconds If the housing has coking or other stubborn deposits allow to soak longer After soaking agitate center housing by hand in the bucket for a minimum of 15 seconds in each of the following directions Center bore vertical c
14. shipping by the same method as received next day ground etc CONTACT INFORMATION All communications regarding this service bulletin must be placed either through Hartzell Engine Technologies Technical Support at 888 461 6077 or via Fax 334 386 5450 For the Warranty department 334 386 5441 Written communications must be placed through Hartzell Engine Technologies Technical Support 2900 Selma Highway Montgomery AL 36108 USA If E mail communication is desired go to our website http www HartzellEngineTechnologies com and select contact and follow the instructions Rev A Hartzell Engine Technologies Service Bulletin 040 Page 9 of 9 ATTACHMENT A HARTZELL PPC R ENGINE TECHNOLOGIES Publication Product Condition Report To validate warranty or commercial assistance all information MUST be filled out SECTION I Customer information Completed by End User Name Date of Report Company Name Address Aircraft Mfg Time in Service Engine as may be applicable SECTION II Product or Component Information Completed by End User Nomenclature TURBOCHARGER Part Number Serial Number Batch Date Code Part Time in Service SECTION Ill Compliance Information Completed by Repair Facility Compliance with SB 040 YES o Debris found YES O NO If yes please describe quantity and size below Eligibility To be eligible for any
15. stem flushing prior to completing engine oil and filter change If no metal particles or ferrous chips are found or upon completion of the above actions complete the engine oil and filter change per engine manufacturer s service instructions Utilizing the applicable aircraft and or engine manufacturer s maintenance manuals or service instructions of the latest revision re install the turbocharger assembly and proceed to Return to Service below RETURN TO SERVICE 1 Once the turbocharger has been properly re installed the aircraft will be ready for return to service 2 Refer to Kelly Aerospace Energy Systems Service Bulletin 23 and perform the recommended turbocharger operational tests This consists of turbocharger pre lubrication ground running tests and and operational flight test Make sure no air exhaust or oil leaks are present Service Bulletin may be viewed or downloaded online via http Awww HarizellEngine Technologies com Utilizing the applicable aircraft and engine manufacturers maintenance manuals of the latest revision install any portion of the aircraft removed to gain access Upon successful completion of this service bulletin per the applicable compliance time listed make an appropriate log book entry If repair accomplished be sure to include the turbo repair records Page 6 of 9 Hartzell Engine Technologies Service Bulletin 040 Rev A PARTS REQUIRED Consult the latest revision of the KAES Turboc
16. your specific model designation Be sure to return the housings to the proper orientation as noted if previously required by the instructions REPAIRED TURBOCHARGER INSTALLATION 1 Upon completion of the turbocharger reassembly the appropriate paperwork must be made indicating that the turbocharger has been repaired This paperwork must be included in the aircraft records Once this is accomplished prepare to re install the turbocharger on the engine If sent to a repair station verify the turbocharger has the correct part number and serial number for your aircraft and that the proper paperwork was delivered with the unit Prior to installation of the turbocharger flush the oil line from the turbo to the oil sump with clean engine oil Utilizing the most current Service Manual or Service Instructions of the applicable engine or airframe manufacturer perform an engine oil and filter change Drain the engine oil completely through a porous white cloth to examine for metal particles and ferrous chips Remove the engine oil filter and completely drain contents through a porous white cloth and examine for metal particles and ferrous chips Cut open the oil filter and examine the pleats for metal particles and ferrous chips If a magnetic oil plug is installed examine it for metal particles and ferrous chips If metal particles and ferrous chips are present consult the engine manufacturers recommendations for engine oil contamination and or oil sy
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