Cirrus Component Maintenance Manual - CAPS

4 Exhaust ventilation is recommended if significant dusting occurs or fumes are gen- erated. Otherwise, use general exhaust ventilation. C I R R U S C O M P O N E N T M A I N T E N A N C E M A N U A L - C A P S M O D E L S R 2 0 95-01-01 Page 3 All EFFECTIVITY: C. Approved Parts and Materials Cirrus and/or Cirrus-approved parts and materials shall only be used in the maintenance of this sys- tem. Life limited parts shall not have less than the time/cycles remaining on the removed part and have sufficient time/cycles remaining to reach the scheduled overhaul. Refer to the Illustrated Parts List of this publication for a listing of all approved parts. (Refer to 95-01-01) 01 Feb 2013 95-01-01 Page 4 All EFFECTIVITY: C I R R U S C O M P O N E N T M A I N T E N A N C E M A N U A L - C A P S M O D E L S R 2 0 4 May 2015 2. DESCRIPTION AND OPERATION The Cirrus Airplane Parachute System consists of a parachute, a solid-propellant rocket to deploy the parachute, a rocket activation system, and a harness faired into the fuselage structure. (See Figure 95-01- 011) A composite enclosure containing the parachute and solid-propellant rocket is mounted to the airplane structure immediately aft of the baggage compartment bulkhead. The enclosure is covered and protected from the elements by a thin composite cover. The parachute is enclosed within a deployment bag that stages the deployment and inflation sequence. The deployment bag creates an orderly deployment process by allowing the canopy to inflate only after the rocket motor has pulled the parachute lines taut. The parachute itself is a 2400 sq ft round canopy equipped with a slider, an annular-shaped fabric panel with a diameter significantly less than the open diameter of the canopy. The canopy suspension lines are routed through grommets so that the slider is free to move along the suspension lines. Since the slider is positioned at the top of the suspension lines near the canopy, at the beginning of the deployment sequence, the slider limits the initial diameter of the parachute and the rate at which the parachute inflates. The canopy inflates as the slider moves down the suspension lines. A three-point attachment harness connects the airplane to the parachute. The harness consists of two for- ward straps faired into the fuselage skin and attached to the firewall, and one rear strap attached to FS 222 bulkhead located directly forward of the parachute compartment. The harness system is designed to con- trol the pitch dynamics of the airplane during the deployment cycle by limiting the aft attachment strap’s length until the cycle is complete. This is accomplished by utilizing a variable length strap section. The shorter section, which initially supports the load, employs a mechanical release that is activated by two pyrotechnic cutters which fire when the short section is pulled taut during extraction. The harness strap then lengthens and load is transferred to the longer section. Two separate and deliberate pilot actions are required to deploy the parachute. The first action requires the pilot to remove the access cover from the activation handle enclosure. The second action requires the pilot to pull the activation handle out, and down several inches. Upon pulling the activation handle, the activation cable compresses the igniter’s steel spring, cocks the plunger and the following sequence is initiated: Serials 1005 thru 1267 before SB2X-95-20, Serials 1268 thru 1422 before SB2X-95-17, Serials 1423 & subs w/o Perspective before SB2X-95-18, 2016 thru 2227: When one half-inch of plunger travel is reached, captured ball bearings are released allowing the plunger to strike the firing pins. The fir- ing pins strike two primers which ignite the primary booster. Serials 1005 thru 1267 after SB2X-95-20, Serials 1268 thru 1422 after SB2X-95-17, Serials 1423 & subs w/o Perspective after SB2X-95-18, 2228 & subs: When one half-inch of plunger travel is reached, captured ball bearings are released allowing the plunger to close the electrical contacts. The closed electrical circuit ignites the primary booster. The primary booster ignites a secondary booster ensuring ignition of the larger rocket motor. Once ignited, the rocket propellant’s hot gases are exhausted through the rocket nozzle. The rocket impacts and dis- bonds the parachute compartment cover pulling the deployment bag from the enclosure. The deployment bag then stages the suspension line deployment and inflation of the parachute. As the parachute inflates, the forward harness assembly grows taut, pulls free of the fuselage skin, and stops at the forward attach fitting which supports the forward portion of the airplane. The aft harness is pulled taut, the line cutters are activated, and approximately eight seconds later “fire” and sever the nylon cord. The three-link release mechanism then opens allowing the aft harness to fully extend. The airplane then assumes its touchdown attitude; approximately ten degrees nose down, to opti- mize occupant protection. C I R R U S C O M P O N E N T M A I N T E N A N C E M A N U A L - C A P S M O D E L S R 2 0 95-01-01 Page 5 All EFFECTIVITY: Figure 95-01-011 CAPS System and Deployment SR20_CM95_1318A PARACHUTE ASSEMBLY CAPS COVER ROCKET ASSEMBLY FORWARD HARNESS FORWARD ATTACH POINT ACTIVATION SYSTEM 7 - Snub Line Release 6 - Parachute Disreef 3 - Line Extension 4 - Initial Canopy Inflation 5 - Reefed Parachute 1 - Rocket Extraction 2 - Parachute Extraction CAPSEQUIPPED CAPSEQUIPPED 01 Feb 2013 95-01-01 Page 6 All EFFECTIVITY: C I R R U S C O M P O N E N T M A I N T E N A N C E M A N U A L - C A P S M O D E L S R 2 0 4 May 2015 A. Activation System (See Figure 95-01-012) The rocket motor is activated by pulling an activation handle mounted in a recessed enclosure located in the headliner above the pilot/copilot. This handle is connected to the rocket igniter with a flexible, stainless steel aircraft grade cable routed through a cable housing above the cabin ceiling headliner. The cable routes from the top center of the fuselage to the left side near the baggage door. (See Fig- ure 95-01-0114) A cover with placard is attached to the perimeter of the activation handle enclosure to prevent the han- dle from being pulled accidentally. The placard identifies the system, presents the actions required to deploy it, defines its operating envelope, provides appropriate warnings, and references the airplane Flight Manual. A maintenance safety pin is provided to ensure that the activation handle is not pulled during mainte- nance or other ground operation. The pin is inserted through the handle retainer and barrel locking the handle in the “safe” position. A “Remove Before Flight” streamer is attached to the pin. The handle is the only part of the system accessible to the pilot in flight. B. Rocket Assembly - Serials 1005 thru 1267 before SB2X-95-20, 1268 thru 1422 before SB2X-95- 17, 1423 & subs w/o Perspective before SB2X-95-18, 2016 thru 2227 The rocket assembly consists of the rocket igniter, rocket base, and rocket motor. The rocket igniter consists of a steel spring, a plunger, two firing trains, and a firing pin actuator to which the activation cable is attached. Each firing train consists of a firing pin and primer which ignites a booster. In its nor- mal position the firing pin actuator and plunger are interlocked with two ball bearings held in place by the inner wall of the igniter body. (See Figure 95-01-012) (1) Rocket Igniter Pulling the activation cable compresses the rocket igniter spring and cocks the plunger. One half-inch of plunger travel is required to release the ball bearings and allow the plunger to strike the firing pins. The firing pins then strike the shotgun-type primers which ignite a black powder and magnesium primary booster in the end of the igniter. The igniter is unarmed in its normal configuration since the spring is un-compressed and the plunger is separated from the firing pins by a 0.060-inch gap. (2) Rocket Base The igniter primary booster ignites a secondary black powder and magnesium booster contained in the rocket base. The extra booster material is used to ensure ignition of the larger rocket motor. The rocket base has a conical protrusion which sprays hot particles past the rocket noz- zle and across the surface of the rocket motor's solid propellant. Once ignited, the grains will burn on all exposed surfaces to form hot gases which are exhausted through the rocket nozzle providing thrust. (3) Rocket Motor The rocket motor uses stored chemical energy in the form of a solid propellant to provide the thrust forces necessary to rapidly remove the enclosure cover and extract the parachute from its enclosure. The rocket motor components consist of the motor case, motor aft bulkhead, propellant, and rocket nozzle. The motor case/aft bulkhead contains the propellant and serves as a pressure chamber when the propellant is burning. The rocket motor uses a composite propellant, consisting of a heterogeneous mixture of ammo- nium perchlorate (AP) and aluminum powder (Al), the oxidizer and fuel. These are the most commonly used ingredients in modern solid propellants. The rocket motor nozzle provides for the expansion and supersonic acceleration of the hot gases. The rocket motor has been designed to specifically meet the extraction requirements of the parachute system. C I R R U S C O M P O N E N T M A I N T E N A N C E M A N U A L - C A P S M O D E L S R 2 0 95-01-01 Page 7 Serials 1005 thru 1267 after SB2X-95-20, 1268 thru 1422 after SB2X-95-17, 1423 & subs w/o Perspective after SB2X-95-18, 2228 & subs EFFECTIVITY: C. Rocket Assembly - Serials 1005 thru 1267 after SB2X-95-20, 1268 thru 1422 after SB2X-95-17, 1423 & subs w/o Perspective after SB2X-95-18, 2228 & subs The rocket assembly consists of the igniter switch, rocket igniter, and rocket motor. The igniter switch consists of a steel spring, a plunger, and two electrical contacts to which the activation cable is attached. A wiring harness connects the switch to an igniter installed at the top of the rocket which via electrical circuit ignites a booster. In its normal position the firing pin actuator and plunger are inter- locked with two ball bearings held in place by the inner wall of the igniter body. (See Figure 95-01-012) (1) Igniter Switch Pulling the activation cable compresses the igniter switch spring and cocks the plunger. One half-inch of plunger travel is required to release the ball bearings and allow the plunger to com- plete an electrical circuit between the contacts. (2) Rocket Igniter The electrical circuit heats the high-resistant wire, igniting a black powder and magnesium pri- mary booster in the end of the igniter. The igniter is unarmed in its normal configuration since the spring is un-compressed and the plunger is separated from the contacts by a 0.060-inch gap. (3) Rocket Motor The rocket motor uses stored chemical energy in the form of a solid propellant to provide the thrust forces necessary to rapidly remove the enclosure cover and extract the parachute from its enclosure. The rocket motor components consist of the motor case, motor aft bulkhead, propellant, and rocket nozzle. The motor case/aft bulkhead contains the propellant and serves as a pressure chamber when the propellant is burning. The rocket motor uses a composite propellant, consisting of a heterogeneous mixture of ammo- nium perchlorate (AP) and aluminum powder (Al), the oxidizer and fuel. These are the most commonly used ingredients in modern solid propellants. The rocket motor nozzle provides for the expansion and supersonic acceleration of the hot gases. The rocket motor has been designed to specifically meet the extraction requirements of the parachute. 4 May 2015 95-01-01 Page 8 Serials w/ Mechanical Ignition EFFECTIVITY: C I R R U S C O M P O N E N T M A I N T E N A N C E M A N U A L - C A P S M O D E L S R 2 0 4 May 2015 Figure 95-01-012 CAPS Handle and Ignition System - Serials w/ Mechanical Ignition (1 of 2) ROCKET BASE SR20_CM95_1321F PLUNGER FIRING PINS (2) MOTOR CASE PROPELLANT GRAINS NOZZLE MOTOR CASE AFT BULKHEAD ROCKET IGNITER ROCKET MOTOR PRIMERS (2) MAGNESIUM/ BLACK POWDER SECONDARY BOOSTER FIRING PIN ACTUATOR ACTIVATION CABLE PRIMARY BOOSTERS (2) SPRING BALL BEARINGS IGNITER BODY NORMAL POSITION ARMED POSITION (Spring in compression) FIRING ROCKET IGNITER HANDLE HOLDER CABLE & HOUSING HANDLE BEARING Serials 1005 thru 1267 before SB2X-95-20, 1268 thru 1422 before SB2X-95-17, 1423 & subs w/o Perspective before SB2X-95-18, 2016 thru 2227. C I R R U S C O M P O N E N T M A I N T E N A N C E M A N U A L - C A P S M O D E L S R 2 0 95-01-01 Page 9 Serials w/ Electronic Ignition EFFECTIVITY: Figure 95-01-012 CAPS Handle and Ignition System - Serials w/ Electronic Ignition (2 of 2) SR20_CM95_3561D Serials 1005 thru 1267 after SB2X-95-20, 1268 thru 1422 after SB2X-95-17, 1423 & subs w/o Perspective after SB2X-95-18, 2228 & subs. FROM WIRING HARNESS ATTACHED TO ANCHOR BLOCK VIA STANDOFF ATTACHED TO TOP OF ROCKET MOTOR VIA STANDOFF MOTOR CASE PROPELLANT GRAINS NOZZLE MOTOR CASE AFT BULKHEAD IGNITER SWITCH ROCKET MOTOR FIRING PIN ACTUATOR NORMAL POSITION ARMED POSITION (Spring in compression) FIRING ROCKET IGNITER PLUNGER IGNITER SWITCH BODY ELECTRICAL CONTACT (2) SPRING ELECTRICAL CONTACT (2) ROCKET IGNITER ROCKET BASE PRIMARY BOOSTERS (2) ROCKET IGNITER NOTE Frangible link breaks at perforated line. FRANGIBLE LINK TO ROCKET IGNITER TO IGNITER SWITCH BALL BEARINGS 4 May 2015 95-01-01 Page 10 All EFFECTIVITY: C I R R U S C O M P O N E N T M A I N T E N A N C E M A N U A L - C A P S M O D E L S R 2 0 01 Feb 2013 D. Incremental Bridle and Deployment Bag (See Figure 95-01-013) The rocket motor is attached to the deployment bag via a set of Teflon sheathed stainless steel cables, or rocket lanyards, and an incremental bridle. The incremental bridle consists a length of nylon web- bing that is folded in half and sewn with a series of bartack stitches. Upon activation these stitches are peeled away to provide proper rocket/bag dynamics by acting as a shock absorber. The incremental bridle, which is connected to the end of the rocket lanyards is protected from the rocket exhaust by a heavy kevlar sheath. A deployment bag is used to contain the packed parachute assembly within the fuselage enclosure and stage its deployment and inflation sequence. The parachute assembly is packed into two compart- ments within the deployment bag. The innermost compartment contains the canopy and is secured by an internal flap that is locked in place with a series of locking loops to ensure that the canopy cannot be extracted from its compartment until the suspension lines, stored in the outer compartment, are pulled taut, and the line stows are extracted from the locking loops that hold the flaps closed. The suspension lines are secured with a hook and loop closure. The four outer flaps are secured with five steel curved release pins attached to the riser. The pins are extracted when the riser is pulled taut during extraction. The deployment bag creates an orderly deployment process by allowing the canopy to inflate only after the rocket motor has pulled the aircraft attachment harness, riser and suspension lines taut and pulled the deployment bag off the canopy. This prevents any slack or uneven tension in the suspension lines during canopy inflation that could result in a malfunction. C I R R U S C O M P O N E N T M A I N T E N A N C E M A N U A L - C A P S M O D E L S R 2 0 95-01-01 Page 11 All EFFECTIVITY: Figure 95-01-013 Incremental Bridle and Deployment Bag INCREMENTAL BRIDLE DEPLOYMENT BAG Aft harness assembly deployed. NOTE CIRRUS AIRFRAME PARACHUTE SYSTEM DEPLOYMENT BAG CLOSURE DEPLOYMENT BAG SUSPENSION LINE STOWS LINE CUTTER SMALL LINK LARGE LINK MEDIUM LINK SUSPENSION LINE STOW FLAPS ACTUATION CABLE SR20_CM95_1319C CAPS ENCLOSURE PARACHUTE RISER SUSPENSION LINE STOWS OUTER FLAPS CURVED RELEASE PINS ROCKET MOTOR PARACHUTE ASSEMBLY 01 Feb 2013 95-01-01 Page 12 All EFFECTIVITY: C I R R U S C O M P O N E N T M A I N T E N A N C E M A N U A L - C A P S M O D E L S R 2 0 26 Jul 2013 E. Parachute Assembly (See Figure 95-01-014) The parachute slows the airplane to a descent speed that is conducive to a safe touchdown. The basic structure of the parachute assembly consists of the canopy, suspension lines, and the slider; a compo- nent used to aerodynamically reef the parachute and limit inflation loads. (1) Canopy and Suspension Lines The canopy, which creates the aerodynamic drag, is made up of a series of fabric panels sewn together to form its desired shape. The canopy has a vent at its center to allow some air to escape in a controlled manner and thus reduce oscillations and provide a stable descent. Vent lines are attached to the perimeter of the vent and routed symmetrically across its center to pro- vide structural support and maintain its shape. The suspension lines are attached to the “skirt” of the canopy and converge to a riser or set of risers at the opposite end. The canopy structural integrity is enhanced by a “skeleton” of tapes and webbings sewn nearly perpendicular to each other to the top surface of the canopy fabric. Radial bands run from opposite suspension line attachment points, across the top of the canopy. The skirt band, vent band, and lateral bands run around the circumference of the canopy. The parachute is fabricated from woven textiles in the form of fabrics, tapes, webbing, and thread. All of the textile components in CAPS are fabricated from either Kevlar or Nylon and are woven to military specifications that define specific parameters such as yarn count, yarn twist, weave type, and finish. To insure good aging characteristics, the only exception to the use of Kevlar and Nylon is a Teflon cloth buffer on the risers at the suspension line attachment point. A typical deployment load profile begins with a snatch force which occurs when the parachute assembly is initially extracted from its container and pulled to full line stretch. When air begins to fill the canopy, inflation loads result. The parachute is designed to deploy without generating forces high enough to injure the airplane occupants. (2) Slider To limit inflation loads, CAPS uses a slider to aerodynamically reef the parachute. The slider is a flat annular shaped fabric panel with metal grommets attached to its perimeter. The parachute suspension lines are routed through the grommets so that the slider is free to move along the suspension lines. The slider, which has a significantly smaller diameter than the fully inflated parachute, is positioned at the top of the suspension lines, next to the canopy skirt, when the parachute is packed. It therefore limits the initial inflated diameter of the parachute and hence the inflation loads. During inflation, the slider remains next to the skirt for a period of time that is dependent on the dynamic pressure acting on the system. This allows the payload to decelerate to a speed at which the parachute can fully inflate without generating excessive loads. F. Airplane Attachment Harness (See Figure 95-01-014) An aircraft harness system connects the parachute risers to the airplane primary structure. The CAPS aircraft harness consists of two forward harness straps attached to the firewall and a rear harness attached to the FS 222 bulkhead located directly in front of the parachute enclosure. The CAPS har- ness system is designed to control the pitch dynamics of the airplane during the deployment cycle by limiting the aft aircraft attachment harness length until the deployment cycle is complete. The rear harness assembly has two sections of different length. The shorter section has a mechanical release mechanism that is activated by two pyrotechnic reefing line cutters. Fuses on these line cutters are initiated when the line cutter release pin is pulled when the harness is pulled taut during the extraction. After 8 seconds, the line cutters fire, the longer section of the rear harness takes over and the airplane assumes its touchdown attitude, approximately ten degrees nose down, to optimize occupant protection. The release mechanism design is based on a 3-ring release mechanism. This system uses a series of metal rings routed through each other in a manner that provides a significant mechanical advantage. For the mechanism to be released, each link must rotate through its adjacent ring or link. Force neces- sary to hold the small link in its stowed position is considerably smaller than the force that is being applied as a result of the overall load on the mechanism. On the CAPS system the last link is held in place by a mini-ring and short length of nylon cord which is severed by pyrotechnic reefing line cutters. C I R R U S C O M P O N E N T M A I N T E N A N C E M A N U A L - C A P S M O D E L S R 2 0 95-01-01 Page 13 All EFFECTIVITY: Figure 95-01-014 Parachute Assembly and Line Cutters SR20_CM95_1320C FORWARD HARNESS AFT HARNESS RISER SKIRT BAND VENT VENT BANDS LATERAL BANDS RADIAL BANDS SUSPENSION LINES SLIDER REAR HARNESS SLEEVE MINI-RING NYLON CORD LINE CUTTER LINE CUTTER LANYARD REAR HARNESS SMALL LINK MEDIUM LINK LARGE LINK 01 Feb 2013 95-01-01 Page 14 All EFFECTIVITY: C I R R U S C O M P O N E N T M A I N T E N A N C E M A N U A L - C A P S M O D E L S R 2 0 01 Feb 2013 3. MAINTENANCE PRACTICES WARNING: Never activate the system on the ground. The rocket exits the fuselage with a velocity of 150 mph (240 km) in the first tenth of a second and reaches full extension in 2.5 seconds. People near the airplane may be injured and extensive damage to the air- frame will occur. Ground activation will cause the airplane to be out of service until CAPS is replaced and the airframe repaired and inspected. Rocket ignition will occur at temperatures above 500° F (260° C). In the event of ground fire, use necessary precautions to avoid CAPS deployment. A. Servicing - Pyrotechnic Line Cutters Replacement (See Figure 95-01-015) (1) Removal - Pyrotechnic Line Cutters (a) Acquire necessary tools, equipment, and supplies. (b) Remove handle access cover and install safety pin. (c) Remove bulkhead 222 (BH 222) trim panel and carpet. (Refer to AMM 25-10) (d) Remove access panel CB7 from BH 222. (Refer to AMM 6-00) (e) To prevent debris and components from falling into bottom of empennage, place catch cloth below rocket and parachute assembly. (f) Pull open flaps secured with hook and loop to gain access to line cutters. (g) Remove line cutter lanyard from Rapide link and un-thread lanyard routed through line cutter’s ignition loops. WARNING: When cutting nylon cord, ensure three-link release assembly stackup is not altered. (h) Cut and remove nylon cord securing line cutters to link assembly. (i) Remove line cutters from airplane. (j) Discharge line cutters as follows: (See Figure 95-01-016) WARNING: Ensure working area, environmental conditions, and any nearby mate- rials within trajectory of line cutter are non-flammable. Wear leather work gloves, and goggles or full face mask during activa- tion of line cutter. Description P/N or Spec. Supplier Purpose Pyrotechnic Line Cutter Replacement Kit w/ Braided Cord Reference Parts List Cirrus Design Replacement. Vise Clamp - Any Source Secure line cutter. Leather Work Gloves - Any Source Protection. Goggles or Full Face Mask - Any Source Protection. Pliers - Any Source Handling. C I R R U S C O M P O N E N T M A I N T E N A N C E M A N U A L - C A P S M O D E L S R 2 0 95-01-01 Page 15 All EFFECTIVITY: A heat-resistant braided cord is threaded through new line cutters to provide safety during transport. Untie the cord and re-threaded through the removed line cutters prior to discharge to absorb line cut- ter blade energy and minimize discharged debris. 1 Remove braided cord from new line cutter. Retain new line cutter in a safe location until required for installation. 2 Thread braided cord through removed line cutter's installation hole opposite ignition loops. Tie ends of braided cord together securely. CAUTION: Too much pressure in vise clamp could damage line cutter and pre- vent proper activation. Do not crush line cutter in vise clamp. 3 Insert line cutter into vise clamp with ignition loop positioned upward 45º, ensuring line cutter is safely directed away from flammable materials. 4 Using pliers, carefully pull ignition loop from line cutter. 5 After audible “snap” is heard, record seconds between pulling ignition loop and firing of line cutter. Be prepared for delayed activation. Typical activation duration is approximately 8 seconds. WARNING: The line cutter can attain 1,100ºF (590ºC) during activation. Use care when handling hot line cutters. 6 When cool, remove line cutter from vise and shake line cutter vigorously. Verify rat- tle of loose spring can be audibly detected. 7 Verify portion of knife blade can be identified in gap between braided cord and cutter hole edge. 8 Safely discard line cutter. 9 Repeat disposal procedure on remaining line cutter. (2) Installation - Pyrotechnic Line Cutters (a) Ensure safety pin is installed. (b) Verify three-link release assembly is correct. (c) Thread new nylon cord through mini-ring and pull cord ends equal. (d) Thread nylon cord ends through small link. (e) Thread one end of nylon cord through installation hole on first new line cutter. (f) Thread opposite end of nylon cord through installation hole on second new line cutter. Note: Use a short, thin piece of wire wrapped around the nylon cord ends to facili- tate routing the nylon cord through the rear harness sleeve. (g) Wrap wire around nylon cord ends, insert wire into sleeve, and route cord through rear harness sleeve. (h) Pull nylon cord completely through sleeve so mini-ring cinches up against top surface of small link. (i) Position line cutters inside securing flaps and route nylon cord up, between link cutters. (j) With one end of nylon cord make one complete loop around mini-ring. CAUTION: Ensure no slack exists in nylon cord between rear harness sleeve and mini- ring and line cutter installation holes and small link. (k) Cinch nylon cord tight. (l) Tie CAPS knot: (See Figure 95-01-015) 01 Feb 2013 95-01-01 Page 16 All EFFECTIVITY: C I R R U S C O M P O N E N T M A I N T E N A N C E M A N U A L - C A P S M O D E L S R 2 0 01 Feb 2013 1 Cross upper cord end (end looped around mini-ring) over lower cord end twice. i.e. right over left, right over left. 2 Cinch nylon cord tight. 3 Tie standard Square Knot and cinch tight. (m) Using break thread, sew nylon cord ends together just below CAPS knot. (n) Tie CAPS knot with break thread. (See Figure 95-01-015) CAUTION: Ensure trimmed ends of nylon cord do not interfere with line cutter’s ignition loops. (o) Trim nylon cord to 1.0 inch (2.5 cm). (p) Route line cutter lanyard through line cutter’s ignition loops and secure lanyard to Rapide link. (q) Close hook and loop securing flaps. (r) Remove catch cloth from below rocket and parachute assembly. (s) Visually inspect parachute compartment for security, leaks, and general condition. (Refer to AMM 05-20) (t) Install access panel CB7 to BH 222. (Refer to AMM 06-00) (u) Install BH 222 trim panel and carpet. (Refer to AMM 25-10) C I R R U S C O M P O N E N T M A I N T E N A N C E M A N U A L - C A P S M O D E L S R 2 0 95-01-01 Page 17 All EFFECTIVITY: Figure 95-01-015 Pyrotechnic Line Cutters Replacement (1 of 2) LINE CUTTER IGNITION LOOPS NYLON CORD SMALL LINK MINI-RING Tie CAPS knot with nylon cord. Sew nylon cord with break thread here. With one end of nylon cord, make loop around mini-ring. Verify three-link stackup as shown. NOTE Route nylon cords between line cutters. NEEDLE BREAK THREAD SR20_CM95_1534D 4 May 2015 95-01-01 Page 18 All EFFECTIVITY: C I R R U S C O M P O N E N T M A I N T E N A N C E M A N U A L - C A P S M O D E L S R 2 0 01 Feb 2013 Figure 95-01-015 Pyrotechnic Line Cutters Replacement (2 of 2) NYLON CORD SR20_CM95_1535B Loop one end of break thread around nylon cord. Route line cutter lanyard through line cutters and Rapide link. RAPIDE LINK NOTE Tie CAPS knot with break thread. LINE CUTTER LANYARD BREAK THREAD Trim nylon cord to 1.0 inch (2.5 cm). 1.0 inch (2.5 cm) C I R R U S C O M P O N E N T M A I N T E N A N C E M A N U A L - C A P S M O D E L S R 2 0 95-01-01 Page 19 All EFFECTIVITY: Figure 95-01-016 Pyrotechnic Line Cutter Disposal VISE CLAMP (REF) IGNITION LOOP (REF) LIVE LINE CUTTER INERT LINE CUTTER 45° CUTTER HOLE (REF) IGNITION LOOP (REF) FIRING PIN (REF) PROPELLANT BARREL (REF) PROPELLANT GRAINS (REF) KNIFE BLADE (REF) BRAIDED CORD (REF) BRAIDED CORD (REF) SR20_CM95_2960A NOTE Insert line cutter into vice with ignition loop positioned upward 45°. Ensure bottom of line cutter is not directed toward flammable structure or materials. To allow for delayed activation, use stopwatch to measure seconds between pulling ignition loop and firing of line cutter. Using pliers, carefully pull ignition loop from line cutter. To prevent errant blade discharge, carefully thread braided cord through line cutter hole of the removed line cutter. Tie ends of braided cord together securely. To ensure line cutter is inert, verify knife blade has extended. Too much pressure in vise clamp could damage line cutter and prevent proper activation. Do not crush line cutter in vise clamp. 4 May 2015 95-01-01 Page 20 All EFFECTIVITY: C I R R U S C O M P O N E N T M A I N T E N A N C E M A N U A L - C A P S M O D E L S R 2 0 26 Jul 2013 B. Empennage Cover (See Figure 95-01-017) (1) Removal - Empennage Cover (a) Acquire necessary tools, equipment, and supplies. (b) Remove rocket assembly. (Refer to 95-01-01) (c) From aft, exterior edge of rear window and along airplane center line, measure 9.5 inches (24.1 cm) aft and mark. (d) From mark, measure 3.25 inches (8.26 cm) left and mark pilot hole. (e) Using catch cloth, protect parachute assembly from foreign object debris/damage. WARNING: To ensure drill bits do not contact parachute assembly, use stop collar during drilling procedures. (f) At pilot hole mark, use 1/4 inch drill bit with stop collar to drill pilot hole. (g) Through access panel CB7, use inspection mirror to verify that hole is approximately cen- tered within the empennage cover strike plate. (h) At pilot hole, use 5/8 inch drill bit with stop collar to drill hole that facilitates insertion of slide hammer fitting. (i) Position slide hammer to empennage cover and insert slide hammer fitting into drilled hole. (j) At interior of empennage cover, attach anvil to slide hammer fitting. (k) Use sharp, rapid movements with slide hammer until empennage cover is disbonded from fuselage. WARNING: Use utmost care when working around embedded forward harness straps and lightning protection mesh with sharp tools. Failure to fol- low this warning could result in damage to the system and failure to deploy. Note: Empennage cover remnant may be used as an outline template to facilitate cover installation. Avoid unnecessary damage to remnant cover during removal. (l) Continue to work edges away until it is possible to slowly peel empennage cover away from fuselage flange. (m) Remove cover remnant from airplane. (n) Remove catch cloth from parachute assembly. Description P/N or Spec. Supplier Purpose Slide Hammer w/ 5/8 inch Fitting and Anvil Attachment - Any Source Remove empen- nage cover. Inspection Mirror - Any Source Verify hole location. Drill Bit w/ Stop Collar 1/4 inch Any Source Drill pilot hole. Drill Bit w/ Stop Collar 5/8 inch Any Source Drill hole for slide hammer fitting. C I R R U S C O M P O N E N T M A I N T E N A N C E M A N U A L - C A P S M O D E L S R 2 0 95-01-01 Page 21 All EFFECTIVITY: (2) Installation - Empennage Cover (a) Acquire necessary tools, equipment, and supplies. (b) Ensure safety pin is installed. (c) Using plastic sheet and tape, protect parachute assembly from dust and contaminants by lining opening of parachute compartment. CAUTION: Exercise caution when sanding composite surface to prevent sanding into laminate. Control dust migration. WARNING: Use utmost care when working around embedded forward harness straps and lightning protection mesh with sharp tools. Failure to follow this warning could result in damage to the system and failure to deploy. Description P/N or Spec. Supplier Purpose Empennage Cover Reference Parts List Cirrus Design N/A Warning Placard Reference Parts List Cirrus Design Provide warning information. ScotchBrite Conditioning Disc 840332 Standard Abrasives Simi Valley, CA (805) 520-5800 Adhesive removal. Foam Tape 1/8” x 1/4” 93675K11 McMaster-Carr Atlanta, GA (404) 346-7000 Cover installation. Plastic Sheet - Any Source Cover installation. American Tape Masking Tape PG27 Any Source Cover installation. Mixing Cup - Any Source Mix resin system. Tongue Depressor Type Mixing Stick/Applicator - Any Source Mix resin system. Scale 18605T84 McMaster-Carr Atlanta, GA (404) 346-7000 Weighing. Epon 862 a a.Approved adhesive system includes Epon 862/Heloxy 68 blend or Epon 862 and Heloxy 68 as separate components. 50013-101 Cirrus Design Base resin. Epon 862/Heloxy 68 a 50013-401 Cirrus Design Base resin/Modifier. Heloxy 68 a 50013-301 Cirrus Design Modifier. Epicure 3234 50013-201 Cirrus Design Hardener. Aerosil 50009-301 Cirrus Design Filler1. Sil-Cell 50009-401 Cirrus Design Filler2. Scotch® Filament Tape 893 Any Source Cover installation. 01 Feb 2013 95-01-01 Page 22 All EFFECTIVITY: C I R R U S C O M P O N E N T M A I N T E N A N C E M A N U A L - C A P S M O D E L S R 2 0 01 Feb 2013 (d) Using die grinder and sanding disc, remove approximately 70% of remnant adhesive from fuselage flange, and abrade flange surface for adhesive application. (e) Draw an offset line 0.25 inch (0.64 cm) from scribeline on new empennage cover, and trim to offset line to facilitate trimming and fitting. (f) Trim empennage cover to fit, ensuring reinforced section of empennage cover is located above rocket assembly. Maximum gap between empennage cover and fuselage is 0.10 inch (2.5 mm). Note: Empennage cover remnant may be used as an outline template to facilitate cover installation. (g) Position empennage cover to final fit and draw four reference lines across cover/fuselage seam line to facilitate installation. (h) Install warning placard to inside surface of empennage cover. 1 Solvent clean empennage cover surface where placard is to be installed. (Refer to AMM 20-30) 2 Remove protective backing from placard using care not to contaminate adhesive surface. 3 Place one edge of placard on surface and work downward to eliminate wrinkles and air pockets. Avoid stretching decal as poor adhesion will result. 4 Press decal firmly to surface with fingers or rubber roller. Ensure all edges are firmly adhered. WARNING: The empennage cover is secured with a low strength bond which allows the rocket to more easily detach the cover when extracting the parachute. An improper bond could prevent proper parachute extraction and system failure upon deployment. To ensure empennage cover will detach as required, do not prep cover. (i) Solvent clean fuselage flange and empennage cover. (Refer to AMM 20-30) Note: Foam tape should be same height as fuselage. It may be necessary to build up tape in sections where tape to fuselage height is not equal. (j) Offset and apply foam tape 0.50 ±0.13 inches (1.27 ±0.33 cm) around inside perimeter of parachute compartment flange. (k) Mix adhesive components in the following manner: Note: Pot life of adhesive at 70.0° F (21.1° C) is approximately 35 to 45 minutes. CAUTION: Thorough mixing is essential to achieve a proper cure. Mix components until a homogeneous appearance is achieved. Ensure incorporation of all materials along walls and bottom of mixing cup. WARNING: If using standalone modifier, do not mix modifier (Heloxy 68) directly into hardener (Epicure 3234), as violent chemical reaction may occur. Keep adhesive materials away from sources of ignition. Mix and use adhesive materials only in areas with adequate ventilation. Wear protective gloves, goggles, and respirator when handling adhe- sives and solvents. C I R R U S C O M P O N E N T M A I N T E N A N C E M A N U A L - C A P S M O D E L S R 2 0 95-01-01 Page 23 All EFFECTIVITY: 1 Zero scale. 2 Place mixing cup on scale and tare cup weight. 3 If using Epon 862/Heloxy 68 (Base Resin/Modifier) and Epicure 3234 (Hardener) at 100:14.25 ratio, measure and mix adhesive. a. Measure 60.0 g of base resin/modifier (Epon 862/Heloxy 68) into mixing cup. b. Measure 8.6 g of hardener (Epicure 3234) and add to base resin/modifier. c. Mix material thoroughly. 4 If using Epon 862 (Base Resin), Heloxy 68 (Modifier) and Epicure 3234 (Hardener) at 100:11:16 ratio, measure and mix adhesive. a. Measure 55.0 g of base resin (Epon 862) into mixing cup. b. Measure 6.0 g of modifier (Heloxy 68) and add to base resin. c. Mix material thoroughly. d. Measure 8.8 g of hardener (Epicure 3234) and add to resin/modifier mixture. e. Mix material thoroughly. 5 Mix 4.7 g of Filler1 (Aerosil) with 5.3 g Filler2 (Sil-Cell). 6 Add Filler1/Filler2 mixture to resin/modifier/hardener mixture. Mix adhesive thor- oughly. (l) With applicator stick, fill 0.50 inch (1.3 cm) gap between foam tape and perimeter of enclo- sure with adhesive. WARNING: Do not allow any adhesive to contact parachute assembly straps. (m) Squeegee off excess adhesive flush with foam tape and top of fuselage. (n) Position cover over parachute compartment, orient cover using reference lines, and gently press into place. (o) Secure cover to fuselage. Note: To prevent cover deformation and generation of air pockets in adhesive, tape empennage cover to fuselage with two people working on either side of airplane. 1 Cut 20, two-foot strips of filament tape and evenly distribute between LH and RH sides of horizontal stabilizer. Make ready for quick-use by lightly hanging each piece from the leading edge of horizontal stabilizer. WARNING: Apply constant pressure to cover while taping. Do not apply and release pressure as air pockets will develop in adhesive. If addi- tional pressure is necessary, first apply pressure to tape strand on cover, then release tape tension and reset tape. 2 Working from center to aft then center to forward, apply tape to cover and press down slightly on cover while setting tape so that top surface of cover is flush with fuselage. WARNING: Ensure nominal bondline of 0.120 - 0.005 inch (3.05 - 0.13 mm). 3 Ensure adhesive is devoid of air pockets. Inspect bond line for voids or high spots. Clean any adhesive that squeezes out. (p) Through access panel CB7, remove plastic sheet. Inspect and clean enclosure for any spilled adhesive or debris. (q) Perform Heated Air Cure method for 1 hour at 140° F (60° C). (Refer to AMM 51-20) 01 Feb 2013 95-01-01 Page 24 All EFFECTIVITY: C I R R U S C O M P O N E N T M A I N T E N A N C E M A N U A L - C A P S M O D E L S R 2 0 01 Feb 2013 CAUTION: Ensure aft window is properly protected during heat application. (r) Fill, seal, and paint empennage cover enclosure. (Refer to AMM 53-30) (s) Install empennage cover placard. (Refer to AMM 11-20) (t) Install rocket assembly. (Refer to 95-01-01) C I R R U S C O M P O N E N T M A I N T E N A N C E M A N U A L - C A P S M O D E L S R 2 0 95-01-01 Page 25 All EFFECTIVITY: Figure 95-01-017 Empennage Cover Replacement (1 of 2) 3.25 inches (8.26 cm) 9.5 inches (24.1 cm) FUSELAGE (REF) REAR WINDOW (REF) SR20_CM95_2970 LEGEND 1. CAPS Cover NOTE 1 1 ANVIL (REF) SLIDE HAMMER (REF) Reinforced cover section. At pilot hole, use 5/8 inch drill bit with stop collar to drill hole that facilitates insertion of slide hammer fitting. CAPS cover remnant may be used as an outline template to facilitate cover installation. Avoid unnecessary damage to remnant cover during removal. WARNING Use utmost care when working around embedded forward harness straps and lightning protection mesh with sharp tools. Failure to follow this WARNING could result in damage to CAPS system and failure upon deployment. 01 Feb 2013 95-01-01 Page 26 All EFFECTIVITY: C I R R U S C O M P O N E N T M A I N T E N A N C E M A N U A L - C A P S M O D E L S R 2 0 01 Feb 2013 Figure 95-01-017 Empennage Cover Replacement (2 of 2) 0.50 inch (1.27 cm) MIN Reinforced cover section. Wipe away over-squeeze. Feather adhesive to fuselage contour. WARNING Do not allow any adhesive to contact parachute assembly straps. Use utmost care when working around embedded forward harness straps and lightning protection mesh with sharp tools. Failure to follow this WARNING could result in damage to CAPS system and failure upon deployment. To ensure CAPS cover will detach as required, do not prep cover. 3 SR20_CM95_1503C 4 LEGEND 1. CAPS Cover 2. Tape 3. Foam Tape 4. Warning Placard (inside surface) NOTE 2 FUSELAGE (REF) 1 3 Serials 1423 & subs. CAPS ENCLOSURE (REF) 0.10 inch (0.254 cm) MAX 0.50 inch (1.27 cm) MIN FUSELAGE (REF) Serials 1005 thru 1422. TYPICAL CROSS SECTION 0.10 inch (0.254 cm) MAX 1 3 1 C I R R U S C O M P O N E N T M A I N T E N A N C E M A N U A L - C A P S M O D E L S R 2 0 95-01-01 Page 27 All EFFECTIVITY: C. Rocket Assembly (See Figure 95-01-0111) (1) Removal - Rocket Assembly (a) Serials 1005 thru 1267 after SB2X-95-20, Serials 1268 thru 1422 after SB2X-95-17, Serials 1423 & subs w/o Perspective after SB2X-95-18, 2228 & subs: Acquire necessary tools, equipment, and supplies. (b) Remove key from ignition. (c) Set BAT 1, BAT 2, and AVIONICS switches to OFF positions. (d) Serials 1005 thru 1267 after SB2X-95-20: Disconnect battery 1. (Refer to AMM 24-30) (e) Serials 1268 thru 1422 after SB2X-95-17, Serials 1423 & subs w/o Perspective after SB2X-95-18, 2228 & subs: Disconnect battery 1 and battery 2. (Refer to AMM 24-30) CAUTION: Ensure hands are clean while working with interior trim components. (f) Remove handle access cover and install safety pin. (g) Remove bulkhead 222 (BH 222) trim panel and carpet. (Refer to AMM 25-10) (h) Remove access panel CB7 from BH 222. (Refer to AMM 6-00) (i) To prevent debris and components from falling into bottom of empennage, place catch cloth below rocket and parachute assembly. WARNING: Activation of rocket igniter requires 25 lb (11.25 kg) pull force. Use caution during removal, modification, and installation procedures to not introduce any unnecessary pulling force on the activation cable. Always position rocket in a safe direction while handling the rocket assembly. Due to differing tolerances between the rocket assembly shelves, quantities of shims/washers may differ from those depicted in the fig- ures. Ensure the exact stackup of the attaching hardware is noted during disassembly and then replicated during reassembly. Failure to do so may result in an incorrect rocket installation and subsequent deployment failure. CAUTION: Do not snag rocket assembly on parachute or surrounding structure while removing. (j) Serials 1423 & subs w/o Perspective before SB2X-95-18, 2016 thru 2227: Disconnect activation cable from rocket assembly. 1 Remove access hole plug from rocket cone. 2 Remove screw and washer securing activation cable to firing pin actuator. 3 Unscrew activation cable cone adapter from rocket cone. Description P/N or Spec. Supplier Purpose Self-Locking Nut MS21044-08 (or equivalent) Any Source Shunt rocket igniter. Screw, Machine MS35206-245 (or equivalent) Any Source Shunt rocket igniter. 4 May 2015 95-01-01 Page 28 All EFFECTIVITY: C I R R U S C O M P O N E N T M A I N T E N A N C E M A N U A L - C A P S M O D E L S R 2 0 4 May 2015 WARNING: Activation cable and cone adapter should easily separate from the rocket cone allowing removal from the aircraft. If interfer- ence between activation cable and firing pin actuator exists, contact Cirrus Design for disposition. (k) Serials 1005 thru 1267 after SB2X-95-20, Serials 1268 thru 1422 after SB2X-95-17, Serials 1423 & subs after SB2X-95-18, 2228 & subs: Disconnect activation cable from rocket assembly. 1 Remove screw and washer securing activation cable to firing pin actuator. 2 Remove activation cable from cone assembly. WARNING: Activation cable should easily separate from the cone assembly allowing removal from the aircraft. If interference between acti- vation cable and firing pin actuator exists, contact Cirrus Design for disposition. (l) Serials 1886 & subs w/ Aircraft Data Logger: Remove cable ties securing wire harness to anchor blocks on rocket shield. Disconnect plug P1046 from jack J1046. (m) Serials 1005 thru 1267 before SB2X-95-20, 1268 thru 1422 before SB2X-95-17: Remove rocket assembly. 1 Remove grommet securing activation cable to rocket shield slot. 2 While supporting rocket assembly, remove bolts and washers securing shim, back- ing plate, and rocket assembly to BH 222. (n) Serials1005 thru 1267 after SB2X-95-20, 1268 thru 1422 after SB2X-95-17: Remove rocket assembly. 1 While supporting rocket assembly, remove bolts and washers securing shim, back- ing plate, and rocket assembly to BH 222. (o) Serials 1423 thru 1624 before SB2X-95-18: Remove rocket assembly. 1 Remove bolts, washers, and nuts securing rocket assembly bracket to BH 222 cross beam. 2 Remove bolts and washers securing cross beam to BH 222. 3 While supporting rocket assembly, remove bolts and washers securing rocket assembly to parachute compartment. (p) Serials 1423 thru 1624 w/o Perspective after SB2X-95-18, 1625 & subs: Remove rocket assembly. 1 While supporting rocket assembly, remove bolts and washers securing rocket assembly to BH 222 cross beam. (q) To facilitate rocket assembly removal, position aft harness and fuselage harnesses to the side and carefully pull spiral wrap cable from adjustable bushing pass-through hole as required. (r) Carefully slide rocket assembly from behind BH 222 so that top of rocket assembly is exposed. (s) Serials 1005 thru 1267 after SB2X-95-20, Serials 1268 thru 1422 after SB2X-95-17, Serials 1423 & subs w/o Perspective after SB2X-95-18, 2228 & subs: Remove frangible link. 1 Remove wire harness securing frangible link to igniter switch. 2 Remove wire harness securing frangible link to rocket igniter. 3 Shunt rocket igniter by grounding wire terminals using screw and nut. (See Figure 95-01-018) C I R R U S C O M P O N E N T M A I N T E N A N C E M A N U A L - C A P S M O D E L S R 2 0 95-01-01 Page 29 All EFFECTIVITY: 4 Remove screws, washers, and standoffs securing frangible link to rocket assembly. (t) Remove tension screws securing pick-up collar assembly to rocket launch tube. CAUTION: Pick-up collar assembly should slide freely off rocket assembly. If interfer- ence between launch tube and pick-up collar assembly exists, contact Cir- rus Design for disposition. (u) Carefully slide pick-up collar assembly off of rocket assembly. (v) Serials 1005 thru 1267 before SB2X-95-20, 1268 thru 1422 before SB2X-95-17: Discon- nect activation cable from rocket assembly. 1 Remove access hole plug from rocket cone. 2 Remove screw and washer securing activation cable to firing pin actuator. 3 Unscrew activation cable cone adapter from rocket cone. WARNING: Activation cable and cone adapter should easily separate from the rocket cone allowing removal from the aircraft. If interfer- ence between activation cable and firing pin actuator exists, contact Cirrus Design for disposition. (w) Remove rocket assembly from airplane. (2) Disassembly - Rocket Assembly (a) Serials 1005 thru 1267 after SB2X-95-20, Serials 1268 thru 1422 after SB2X-95-17, Serials 1423 & subs w/o Perspective after SB2X-95-18, 2228 & subs: Acquire necessary tools, equipment, and supplies. (b) Serials 1005 thru 1267 before SB2X-95-20, 1268 thru 1422 before SB2X-95-17, Serials 1423 & subs w/o Perspective before SB2X-95-18, 2016 thru 2227: Remove screws securing rocket cone to rocket igniter. Slide rocket cone off of rocket igniter. (c) Cut and remove safety wire from screws securing rocket motor to rocket shelf. (d) Serials 1005 thru 1422: Remove rocket shield and shelf. 1 Remove screws and washers securing rocket motor to rocket shelf. 2 Slide rocket shelf and shield off of rocket motor. (e) Serials 1423 & subs: Remove rocket shelf assembly. 1 Remove screws and washers securing rocket motor to rocket shelf assembly. 2 Slide rocket shelf assembly off of rocket motor. (f) Serials 1005 thru 1267 before SB2X-95-20, Serials 1268 thru 1422 before SB2X-95-17, Serials 1423 & subs w/o Perspective before SB2X-95-18, 2016 thru 2227: Safety the rocket motor by wiring firing pin actuator to rocket igniter. (g) Remove rocket motor. (See Figure 95-01-0113) 1 Remove nylon screws securing rocket motor to rocket base. 2 Carefully slide rocket motor from launch tube. CAUTION: Serials 1005 thru 1267 before SB2X-95-20, 1268 thru 1422 before SB2X- 95-17, Serials 1423 & subs w/o Perspective before SB2X-95-18, 2016 thru 2227: Do not remove rocket igniter from rocket base. Description P/N or Spec. Supplier Purpose Spanner Wrench - Any Source Remove igniter. 4 May 2015 95-01-01 Page 30 All EFFECTIVITY: C I R R U S C O M P O N E N T M A I N T E N A N C E M A N U A L - C A P S M O D E L S R 2 0 4 May 2015 (h) Serials 1005 thru 1267 after SB2X-95-20, Serials 1268 thru 1422 after SB2X-95-17, Serials 1423 & subs w/o Perspective after SB2X-95-18, 2228 & subs: Remove rocket igniter. (See Figure 95-01-0113) 1 Using spanner wrench, rotate rocket igniter counter-clockwise from rocket motor. 2 Carefully slide rocket igniter from rocket motor. (i) Itemize each removed rocket assembly component. Serials 1005 thru 1267 before SB2X-95-20, 1268 thru 1422 before SB2X-95-17, Serials 1423 & subs w/o Perspective before SB2X-95-18, 2016 thru 2227: - rocket motor - rocket igniter/launch tube assembly Serials 1005 thru 1267 after SB2X-95-20, Serials 1268 thru 1422 after SB2X-95-17, Serials 1423 & subs w/o Perspective after SB2X-95-18, 2228 & subs: - rocket motor - rocket igniter - igniter switch (j) Identify each removed rocket assembly component as follows. "Pending Cirrus Design Disposition: Removed from SR20 - ASN#### Date: mm/dd/yyyy" where “####” specifies aircraft serial number, and “mm/dd/yyyy” specifies date of rocket assembly component removal. WARNING: Ensure each removed rocket assembly component is properly identi- fied to prevent any attempt to re-use assemblies pending disposition by Cirrus Design. (k) Store rocket motor and rocket igniter at an approved storage location pending disposition by Cirrus Design. WARNING: Rocket assembly components (rocket motor and rocket igniter) must not be stored assembled to one another, or in the same magazine. To ensure inadvertent re-use, separate removed assemblies from new replacement assemblies. (3) Disassembly - Rocket Motor WARNING: Disassembly of Rocket Motor is prohibited, except when preparing Rocket Motor for return or disposal. If preparing Rocket Motor for return or dis- posal, contact Cirrus technical support for disposition. (4) Assembly - Rocket Motor WARNING: This procedure is hazardous and may only be accomplished by a Cirrus cer- tified technician specifically trained and certified in rocket motor assembly. (a) Acquire necessary tools, equipment, and supplies. Description P/N or Spec. Supplier Purpose General Purpose Industrial Adhesive Silicone Sealant IS808 GE Silicones Waterford, NY 12188 518-237-3330 Seal Ortman key slot. C I R R U S C O M P O N E N T M A I N T E N A N C E M A N U A L - C A P S M O D E L S R 2 0 95-01-01 Page 31 All EFFECTIVITY: (b) Inspect inner diameter of pick-up collar for surface irregularities. If irregularities exist, per- form the following: 1 Acquire necessary tools, equipment, and supplies. 2 Serials 1005 thru 1267 before SB2X-95-20, 1268 thru 1422 before SB2X-95-17, Serials 1423 & subs w/o Perspective before SB2X-95-18, 2016 thru 2227: Remove surface irregularities from pick-up collar. a. Remove countersunk screws securing pick-up collar support to pick-up collar. b. Press retaining groove on pick-up collar support toward the rocket lanyard. Use fingers to pry rocket lanyard from opposite retaining groove and pivot the pick-up collar support until lanyard is disengaged from retaining grooves. c. Use half-round file as required to remove bumps. d. Solvent clean with isopropyl alcohol. (Refer to AMM 20-30) e. Apply primer to affected area. WARNING: Position rocket lanyard around top outer diameter of pick-up collar support, NOT over top of the rocket. Failure to comply will absolutely FAIL rocket deployment! f. Position pick-up collar support to upper side of pick-up collar. g. Position retaining groove of pick-up collar support to rocket lanyard. Pivot pick-up collar support until the rocket lanyard engages the opposite retaining groove. Note: It is permissible to re-use countersunk screws. Flourinated Oil Lubricant DuPont Krytox 240AZ DuPont Wilmington, DE 19805 302-774-1000 Lubricate o-ring. Grounded Anti-static Mat and Strap - Any Source Prevent build-up of static electric- ity. Padded Strap Wrench - Any Source Rotate rocket motor onto rocket nozzle bulkhead. Description P/N or Spec. Supplier Purpose Half-Round File - Any Source Remove bumps. Isopropyl Alcohol TT-I-735 Grade A or B Any Source Clean installation area. Cotton Cloth (clean and lint free) - Any Source Clean installation area. Primer (Refer to AMM 51-30) Any Source Seal. Threadlocker, Medium Loctite 242 Any Source Bond screws. Description P/N or Spec. Supplier Purpose 4 May 2015 95-01-01 Page 32 All EFFECTIVITY: C I R R U S C O M P O N E N T M A I N T E N A N C E M A N U A L - C A P S M O D E L S R 2 0 4 May 2015 h. Inspect countersunk screws removed previously from pick-up collar for dam- age. Replace countersunk screws as required. i. Apply medium threadlocker to countersunk screws removed previously from pick-up collar. j. Install countersunk screws securing pick-up collar support to pick-up collar. 3 Serials 1005 thru 1267 after SB2X-95-20, Serials 1268 thru 1422 after SB2X-95-17, Serials 1423 & subs w/o Perspective after SB2X-95-18, 2228 & subs: Remove sur- face irregularities from pick-up collar. a. Use half-round file as required to remove bumps. b. Solvent clean with isopropyl alcohol. (Refer to AMM 20-30) c. Apply primer to affected area. (c) Mount rocket nozzle bulkhead to workbench, or similar flat, stable surface. 1 Acquire necessary tools, equipment, and supplies. 2 Transfer template pattern to workbench and match drill. (See Figure 95-01-019) CAUTION: Do not secure rocket nozzle bulkhead to workbench with nylon screws. 3 Align rocket nozzle bulkhead to workbench hole pattern. 4 Install steel screws securing rocket nozzle bulkhead to workbench. Torque to 3.0 ±0.5 in-lb (33.9 ±5.6 Ncm). (d) Assemble Rocket Motor. (See Figure 95-01-0110) CAUTION: Inspect propellant grains for damage. Do not use if cracks, fractures or other signs of breakage are apparent. 1 Install lubricated o-rings into two upper outer grooves of rocket nozzle bulkhead. WARNING: Fine powder debris could create an explosion danger. Use care not to break propellant during insertion. 2 Slide upper propellant grain into rocket motor case. 3 Slide o-ring into rocket motor case. 4 Orient lower propellant grain so that deep, recessed end of lower propellant grain is visible from open end of rocket motor case. 5 Slide lower propellant grain into rocket motor case. CAUTION: Do not damage O-rings. Insert rocket nozzle bulkhead into rocket motor case slowly. Description P/N or Spec. Supplier Purpose Drill Bit 0.807 inch (2.049 cm Any Source Drill center hole. Drill Bit 0.175 inch (0.445 cm) Any Source Drill attach holes. Screws (3), Steel, 10-32 Thread, Length Variable a a. Length must be 0.375 inch (0.953 cm) longer than workbench thickness. - Any Source Secure rocket nozzle bulkhead. C I R R U S C O M P O N E N T M A I N T E N A N C E M A N U A L - C A P S M O D E L S R 2 0 95-01-01 Page 33 All EFFECTIVITY: 6 Carefully twist rocket motor case right and left while pushing down to engage rocket motor case onto rocket nozzle bulkhead and o-rings. 7 Align hole in bottom groove of rocket nozzle bulkhead with Ortman key slot in rocket motor case. 8 At lower side of rocket motor case, insert pointed tip of Ortman key into right side of slot. Note: To improve strap grip on rocket motor case, position rubber traction mat between rocket motor case and strap. 9 Using large strap wrench at top of rocket motor case, slightly rotate rocket motor case clockwise while observing exposed tip of Ortman key. As tip of key retracts into rocket motor case, continue to rotate rocket motor case until key is completely retracted. CAUTION: Do not over rotate Ortman key into slot. Verify end of key remains vis- ible in slot and is below flush with rocket motor case. Serials 1005 thru 1267 after SB2X-95-20, 1268 thru 1422 after SB2X- 95-17, 1423 & subs w/o Perspective after SB2X-95-18, 2228 & subs: When assembled, verify Ortman key hole in bulkhead is in line with alignment mark in motor case. 10 Serials 1005 thru 1267 after SB2X-95-20, 1268 thru 1422 after SB2X-95-17, 1423 & subs w/o Perspective after SB2X-95-18, 2228 & subs: Verify frangible link hole on rocket motor case aligns with longer anchor block on launch tube. a. Remove and retain steel screws securing rocket nozzle bulkhead to work- bench. b. Position bottom of rocket motor (nozzle end) to launch tube. c. Carefully insert rocket motor into launch tube. d. Temporarily install nylon screws securing rocket base to rocket motor. Install to finger tight only. CAUTION: Do not cross thread or over-tighten nylon screws. Note: Do not apply plastic fastener threadlocker to nylon screws. e. Perform Inspection/Check - Rocket Motor Case Alignment. (Refer to 95-01- 01) f. Remove and retain nylon screws securing rocket base to rocket motor. g. Remove rocket motor from launch tube. 11 At circumference of Ortman key slot, apply silicone sealant to Ortman key slot ensuring slot is sealed and free of air bubbles. 12 Remove and discard steel screws securing rocket nozzle bulkhead to workbench. 4 May 2015 95-01-01 Page 34 Serials 1005 & subs w/o Perspective after SB2X-95-17, SB2X-95-18, or SB2X-95-20, 2228 & subs EFFECTIVITY: C I R R U S C O M P O N E N T M A I N T E N A N C E M A N U A L - C A P S M O D E L S R 2 0 4 May 2015 Figure 95-01-018 Rocket Igniter - Serials 1005 & subs w/o Perspective after SB2X-95-17, SB2X-95-18, or SB2X-95-20, 2228 & subs A DETAIL A 1 2 3 4 5 6 1 NOTE Shunt rocket igniter by grounding wire terminals before removing frangible link. 1 LEGEND 1 . Rocket Motor 2 . Rocket Igniter 3 . Screw 4 . Nut 5. Frangible Link 6 . Launch Tube SR20_CM95_3711 C I R R U S C O M P O N E N T M A I N T E N A N C E M A N U A L - C A P S M O D E L S R 2 0 95-01-01 Page 35 Serials 1005 & subs w/o Perspective after SB2X-95-17, SB2X-95-18, or SB2X-95-20, 2228 & subs EFFECTIVITY: 4 May 2015 Figure 95-01-019 Rocket Nozzle Template 1 1/2 1/4 Scale (inches) 0 2 1 Scale (cm) 0 2.54 Verify template is printed to scale. NOTE SR20_CM95_3572C ROCKET NOZZLE WORKBENCH TEMPLATE 0.658 inch (1.671 cm) 1.316 inch (3.342 cm) 1.140 inch (2.895 cm) 0.380 inch (0.965 cm) Ø 0.807 inch (2.049 cm) 3 × Ø 0.175 inch (0.445 cm) Serials 1005 thru 1267 before SB2X-95-20, 1268 thru 1422 before SB2X-95-17, 1423 & subs w/o Perspective before SB2X-95-18, 2016 thru 2227. Serials 1005 thru 1267 after SB2X-95-20, 1268 thru 1422 after SB2X-95-17, 1423 & subs w/o Perspective after SB2X-95-18, 2228 & subs. 0.888 inch (2.256 cm) 1.775 inch (4.509 cm) 1.538 inch (3.907 cm) 0.513 inch (1.303 cm) 3 × Ø 0.175 inch (0.445 cm) Ø 1.024 inch (2.601 cm) 95-01-01 Page 36 All EFFECTIVITY: C I R R U S C O M P O N E N T M A I N T E N A N C E M A N U A L - C A P S M O D E L S R 2 0 4 May 2015 Figure 95-01-0110 Rocket Motor 4 STRAP WRENCH (REF) 1 5 SR2X_CM95_3306A NOTE Do not use nylon screws to secure rocket nozzle bulkhead to workbench. Using large strap wrench at top of rocket motor case, slightly rotate rocket motor case clockwise while observing exposed tip of Ortman key. As tip of key retracts into rocket motor case, continue to rotate rocket motor case until key is completely retracted. LEGEND 1. Rocket Motor Case 2. Upper Propellant Grain 3. Lower Propellant Grain 4. Rocket Nozzle Bulkhead 5. Ortman Key 6. Screw 7. O-Ring 6 ROCKET NOZZLE WORKBENCH INSTALLATION WORKBENCH WORKBENCH Install steel screws securing rocket nozzle bulkhead to workbench. Torque to 3.0 ±0.5 in-lb (33.9 ±5.6 Ncm). Orient lower propellant grain so that deep, recessed end of lower propellant grain is visible from open end of rocket motor case. RUBBER TRACTION MAT (REF) To improve strap grip on rocket motor case, position rubber traction mat between rocket motor case and strap. WORKBENCH 1 2 3 7 7 4 C I R R U S C O M P O N E N T M A I N T E N A N C E M A N U A L - C A P S M O D E L S R 2 0 95-01-01 Page 37 All EFFECTIVITY: (5) Reassembly - Rocket Assembly (a) Acquire necessary tools, equipment, and supplies. (b) Inspect rocket assembly and attaching parts. (See Figure 95-01-0113) 1 Serials 1005 thru 1267 before SB2X-95-20, 1268 thru 1422 before SB2X-95-17, Serials 1423 & subs w/o Perspective before SB2X-95-18, 2016 thru 2227: Verify rocket igniter condition. a. Verify foil seal on rocket igniter is intact. b. Verify safety wire is installed through firing pin actuator on bottom of rocket igniter. 2 Verify surfaces of launch tube, rocket base, and rocket motor are clean and free of any debris. (c) Inspect inner diameter of pick-up collar for surface irregularities. If irregularities exist, per- form the following: 1 Acquire necessary tools, equipment, and supplies. Description P/N or Spec. Supplier Purpose Threadlocker, Light Loctite 222 Any Source Bond screws. Threadlocker, Plastic Fastener Loctite 425 Any Source Bond screws. Serials 1005 thru 1267 after SB2X-95-20, 1268 thru 1422 after SB2X-95-17, 1423 & subs w/o Perspective after SB2X- 95-18, 2228 & subs: Spanner Wrench - Any Source Install igniter. Serials 1005 thru 1267 after SB2X-95-20, 1268 thru 1422 after SB2X-95-17, 1423 & subs w/o Perspective after SB2X- 95-18, 2228 & subs: Torque Wrench Adapter, 3/4” - Any Source Install igniter. Serials 1005 thru 1267 after SB2X-95-20, 1268 thru 1422 after SB2X-95-17, 1423 & subs w/o Perspective after SB2X- 95-18, 2228 & subs: Spanner Wrench Adapter T11849 Cirrus Design Install igniter. Description P/N or Spec. Supplier Purpose Half-Round File - Any Source Remove bumps. Isopropyl Alcohol TT-I-735 Grade A or B Any Source Clean installation area. Cotton Cloth (clean and lint free) - Any Source Clean installation area. Primer (Refer to AMM 51-30) Any Source Seal. 4 May 2015 95-01-01 Page 38 All EFFECTIVITY: C I R R U S C O M P O N E N T M A I N T E N A N C E M A N U A L - C A P S M O D E L S R 2 0 4 May 2015 2 Serials 1005 thru 1267 before SB2X-95-20, 1268 thru 1422 before SB2X-95-17, Serials 1423 & subs w/o Perspective before SB2X-95-18, 2016 thru 2227: Remove surface irregularities from pick-up collar. a. Remove countersunk screws securing pick-up collar support to pick-up collar. b. Press retaining groove on pick-up collar support toward the rocket lanyard. Use fingers to pry rocket lanyard from opposite retaining groove and pivot the pick-up collar support until lanyard is disengaged from retaining grooves. c. Use half-round file as required to remove bumps. d. Solvent clean with isopropyl alcohol. (Refer to AMM 20-30) e. Apply primer to affected area. WARNING: Position rocket lanyard around top outer diameter of pick-up collar support, NOT over top of the rocket. Failure to comply will absolutely FAIL rocket deployment! f. Position pick-up collar support to upper side of pick-up collar. g. Position retaining groove of pick-up collar support to rocket lanyard. Pivot pick-up collar support until the rocket lanyard engages the opposite retaining groove. Note: It is permissible to re-use countersunk screws. h. Inspect countersunk screws removed previously from pick-up collar for dam- age. Replace countersunk screws as required. i. Apply medium threadlocker to countersunk screws removed previously from pick-up collar. j. Install countersunk screws securing pick-up collar support to pick-up collar. 3 Serials 1005 thru 1267 after SB2X-95-20, Serials 1268 thru 1422 after SB2X-95-17, Serials 1423 & subs w/o Perspective after SB2X-95-18, 2228 & subs: Remove sur- face irregularities from pick-up collar. a. Use half-round file as required to remove bumps. b. Solvent clean with isopropyl alcohol. (Refer to AMM 20-30) c. Apply primer to affected area. (d) Serials 1005 & subs w/o Aircraft Data Logger: If plug P1046 is installed to anchor block on launch tube, remove wire harness assembly from launch tube. (e) Serials 1005 thru 1267 after SB2X-95-20, Serials 1268 thru 1422 after SB2X-95-17, Serials 1423 & subs w/o Perspective after SB2X-95-18, 2228 & subs: Install rocket igniter. (See Figure 95-01-0113) 1 Slide o-ring into top of rocket motor case. 2 Carefully slide rocket igniter into rocket motor. 3 Using spanner wrench, rotate rocket igniter clockwise to rocket motor. Using span- ner wrench adapter, torque to 25.0 - 30.0 ft-lb (33.9 - 40.6 Nm). (f) Install rocket motor to rocket base. (See Figure 95-01-0113) Threadlocker, Medium Loctite 242 Any Source Bond screws. Description P/N or Spec. Supplier Purpose C I R R U S C O M P O N E N T M A I N T E N A N C E M A N U A L - C A P S M O D E L S R 2 0 95-01-01 Page 39 All EFFECTIVITY: 1 Position bottom of rocket motor (nozzle end) to launch tube. 2 Carefully insert rocket motor into launch tube. 3 Serials 1005 thru 1267 after SB2X-95-20, Serials 1268 thru 1422 after SB2X-95-17, Serials 1423 & subs w/o Perspective after SB2X-95-18, 2228 & subs: If frangible link hole on rocket motor case does not align with longer anchor block on launch tube, perform Inspection/Check - Rocket Motor Case Alignment. (Refer to 95-01-01) 4 Apply plastic fastener threadlocker to nylon screws. 5 Install nylon screws securing rocket base to rocket motor. Torque to 3.0 ±0.5 in-lb (33.9 ±5.6 Ncm). CAUTION: Do not cross thread or over-tighten nylon screws. (g) Serials 1005 thru 1422: Install rocket shield and shelf. 1 Slide rocket shield over rocket motor and position shield to rocket motor screw holes. 2 Slide rocket shelf over rocket motor and position shelf to rocket motor screw holes. 3 Install screws and washers securing shelf and shield to rocket motor and safety wire. (h) Serials 1423 & subs: Install rocket shelf assembly. 1 Slide rocket shelf assembly over rocket motor and position shelf to rocket motor screw holes. 2 Install screws and washers securing shelf assembly to rocket motor and safety wire. (i) Serials 1005 thru 1267 before SB2X-95-20, 1268 thru 1422 before SB2X-95-17, Serials 1423 & subs w/o Perspective before SB2X-95-18, 2016 thru 2227: Secure firing pin actuator. 1 Carefully remove safety wire from firing pin actuator. 2 Ensure firing pin actuator is rotated so threaded side of actuator is facing aft and screw head attaching activation cable to firing pin actuator will be visible through rocket cone inspection hole when installed. 3 Apply light threadlocker to screws used to secure rocket cone to rocket igniter. 4 Position and secure rocket cone onto rocket igniter with screws. (6) Installation - Rocket Assembly CAUTION: Ensure the exact stackup of the attaching hardware, noted during disassembly, is replicated during reassembly. (a) Acquire necessary tools, equipment, and supplies. Description P/N or Spec. Supplier Purpose Rocket Assembly Reference Parts List Cirrus Design N/A Threadlocker, Light Loctite 222 Any Source Bond screws. Threadlocker, Medium Loctite 242 Any Source Bond screws. Magnetized Screw- driver - Any Source Install screws. 4 May 2015 95-01-01 Page 40 All EFFECTIVITY: C I R R U S C O M P O N E N T M A I N T E N A N C E M A N U A L - C A P S M O D E L S R 2 0 4 May 2015 (b) Ensure safety pin is installed. (c) Record rocket serial number in airplane log book. (d) Slide pick-up collar assembly onto rocket assembly. (e) Verify pick-up collar assembly slides freely on rocket assembly. (f) Verify anchor blocks are perpendicular to pick-up collar assembly. If pick-up collar assem- bly is not fully seated against the anchor blocks, use pliers to gently adjust anchor blocks as required. CAUTION: If anchor blocks require re-alignment, after adjustment, inspect anchor block security. If anchor blocks are loose, contact Cirrus Design for disposi- tion. (g) Apply medium threadlocker to aluminum tension screws. CAUTION: Do not overtighten aluminum tension screws. (h) Install aluminum tension screws securing pick-up collar assembly to rocket launch tube using nut driver. Torque to 1 - 5 in-lb (12 - 56 Ncm). (i) Serials 1005 thru 1267 after SB2X-95-20, Serials 1268 thru 1422 after SB2X-95-17, Serials 1423 & subs w/o Perspective after SB2X-95-18, 2228 & subs: Install frangible link. (See Figure 95-01-0112) 1 Acquire necessary tools, equipment, and supplies. Serials 1005 thru 1267 before SB2X-95-20, 1268 thru 1422 before SB2X-95-17: Grommet Reference Parts List Any Source Replace grommet. Serials 1005 thru 1267 before SB2X-95-20, 1268 thru 1422 before SB2X-95-17: Epoxy Adhesive 5 Minute Epoxy Devcon Danvers, MA 01923 800-933-8266 Seal grommet. Description P/N or Spec. Supplier Purpose Epoxy Adhesive 5 Minute Epoxy Devcon Danvers, MA 01923 800-933-8266 Install cable anchors. Cable Anchors EMS-A-DO Panduit Tinley Park, IL 60487 800-777-3300 Secure wiring. Cable Ties PLT2S-C Expandable Sleeving, 1/8" GRP-120-1/8 Alpha Wire Elizabeth, NJ 07207 800-522-5742 Secure wiring. Heatshrink Tubing, 3/8" M23053/5-107-0 Any Source Secure wiring. Description P/N or Spec. Supplier Purpose