MSB08-5 - Continental Aerospace Technologies

KIL00632 KIL00633 KIL00634 Rev. New Kelly Aerospace Power Systems Service Bulletin 030 Page 3 of 5 PROCEDURE: CAUTION:: This procedure must be performed by competent and qualified personnel familiar with engine and airframe maintenance activities that are specific to turbocharged aircraft. CAUTION:: Do not depend on this Service Bulletin for gaining access to the aircraft or engine. This will require that you use the applicable manufacturers maintenance manuals or service instructions. In addition, any preflight or in flight operational checks require use of the appropriate AFM or POH. INSPECTION: NOTE:: If the turbocharger installed on the engine(s) can be positively identified as not being affected by this service bulletin using the aircraft log books or other certified aircraft paperwork, no further action is necessary. If it cannot be established positively, then inspection of the data tag will be required. 1. Access the aircraft turbocharger by removing the cowling as required in accordance with the instructions contained in the Cessna Aircraft maintenance manual. Refer to appropriate aircraft in Figure 1. 2. Identify the affected turbocharger by checking data tag for part number and serial number and comparing to the suspect serial number table on page 2. If the turbocharger is affected continue with these instructions, if not, proceed to the “Return to Service” section step 3 and 4. 3. Carefully remove the “V” band clamp from around the turbocharger turbine housing at the turbocharger exhaust outlet taking care not to move the exhaust tube and tail pipe assembly. Figure 2 shows a “V” band clamp improperly installed, notice gap and clamp riding up on flange. 4. Inspect the turbocharger turbine housing at the flange area captured by the “V” band clamp. Use a feeler gauge at the split line between the turbine housing flange and the exhaust tube flange all around the circumference. The maximum gap should not exceed .005 inch at any point. If you suspect or know that the exhaust tube and tail pipe assembly was moved at any point prior to checking for the gap, apply pressure towards the turbine housing flange before taking a measurement. Refer to Figure 3 on page 4. 5. If a gap exceeding tolerance is found, the turbocharger and tail pipe assembly should be removed. To accomplish this, follow the instructions contained in the Cessna Aircraft or STC holder’s maintenance manual or as applicable the appropriate TCM service information. Inspect and clean flange areas using methods recommended by Cessna or TCM. Do not attempt repair of the turbine housing. Connect the cleaned exhaust tube to the turbocharger and re-inspect per step 4 above. If the gap still exceeds tolerance, the turbocharger turbine housing (P/N 441977-23 or 441977-25) must be replaced. Proceed to step 6. If gap tolerance is not exceeded, metal stamp a 1/8” upper case “I” in the area shown in Fig 4 (per step 7) to indicate the instruction was performed then proceed to step 10. Figure 1 - Turbocharger Installation RAM modifications not shown 6. The turbocharger must be sent to a properly certificated part 145 repair station (or foreign equivalent) experienced in turbocharger repair. 7. Once the turbocharger has been repaired, visually inspect for condition and orientation of the turbine housing then, using a 1/8” metal stamp of an upper case “I”, stamp the turbine housing in the area shown in Figure 4. Care must be taken not to extend stamp within 1/8” of the mating edge as it may bulge and distort the mating surface. When stamped, proceed with the installation. 8. Utilizing the applicable aircraft, STC holder and/or engine manufacturers maintenance manuals or service instructions, re-install the turbocharger assembly. Page 4 of 5 Kelly Aerospace Power Systems Service Bulletin 030 Rev. New Figure 4 - Turbine Housing Trouble Area Figure 2 - “V” band Clamp Showing Gap Figure 3 - Gap Inspection Area Typical Turbocharger Exhaust Tube Installation Shown NOTE:: If the existing “V” band clamp is to be used, it should be inspected for damage on the inside of the “V” prior to re-use. If the inside radius of the “V” is flattened or cut it should not be used. Obtain the clamp part number from the appropriate aircraft or engine parts catalog. 9. When connecting the exhaust tube and tail pipe assembly to the repaired turbocharger, it is advisable to re-check the flange fit per step 4 prior to installing the clamp. Carefully, position and install the “V” band clamp to manufacturer specifications and proceed to “Return to Service” below. 10. If gap tolerance was not exceeded and the metal stamp “I” has been applied per step 5, carefully, position and install the “V” band clamp to manufacturer specifications and proceed to “Return to Service” below. RETURN TO SERVICE: 1. When the turbocharger has been replaced, the aircraft may now be prepared for return to service. 2. Refer to Kelly Aerospace Power 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 www.kellyaerospace.com. 3. Utilizing the applicable Cessna Aircraft or STC holder’s maintenance instructions and/or manuals, install the engine cowls removed to gain access. 4. Upon successful completion of this service bulletin per the applicable compliance time listed on page 1, make an appropriate log book entry that includes the affected turbocharger model and serial number, along with an appropriate statement of the inspection and/or repair. MATERIAL REQUIRED: One (1) or two (2) each, turbocharger turbine housing, P/N 441977-23 or 441977-25 as required. All KAPS parts must be obtained through an AVIALL, Inc.. supplier. AVIALL is the sole distributor for KAPS turbocharger parts NOTE: Other incidental parts may be required during the removal and installation of the turbocharger. These parts must be obtained per the aircraft or engine manufacturers parts list from the applicable manufacturer. DISPOSITION OF STOCK: Any turbocharger which appears on the Suspect Serial Number Table(s) on page 2 which remains in stock may be returned for repair or replacement. WARRANTY STATEMENT: Kelly Aerospace Power Systems will supply warranty consideration for each affected KAPS Turbine Housing (up to two per aircraft). Additionally, up to one (1) hour labor per engine or two (2) hours labor per aircraft (at 75.00 USD) will be allowed for the inspection and repair required in this service bulletin. Warranty must be filed through AVIALL Inc. with the affected turbine housing returned. All normal KAPS warranty procedures apply. No other warranty consideration related to this service publication applies. This publication does not imply or state any responsibility for the workmanship of any person or entity performing work or maintenance on the turbocharger, engine, or aircraft. CONTACT INFORMATION: If you have any questions concerning the instructions in this service bulletin, please contact Kelly Aerospace Power Systems Technical Support at (888) 461-6077. Questions concerning aircraft service or operation must be forwarded to the applicable manufacturer of that product. Rev. New Kelly Aerospace Power Systems Service Bulletin 030 Page 5 of 5