INSTALLATION OF 2” POWERPLANT INSTRUMENTS · 2017. 12. 11. · 4. Build up 700-7007-3 tee assembly using 3 each AN815-4J unions and NAS617-4 packings. 5. Install 700-1060-5 pressure

SERVICE INSTRUCTION NO. 763-06 Page 1 of 26 Issued Date: May 8, 1987 Revised Date: January 30, 1990

INSTALLATION OF 2” POWERPLANT INSTRUMENTS

Reason: To provide an option to early tri-cluster gauges and to conform with current production configuration.

NOTE: This Service Instruction to be used in conjunction with Soloy Drawings No. 763-

1041, 763-1078 and 763-1048.

MODEL(S)

Soloy/Cessna U206G Soloy/Cessna TU206G

NOTE: If ownership of aircraft has changed, please forward this document to the new owner.

450 PAT KENNEDY WAY, S.W. • OLYMPIA, WA 98501-7298

PHONE (360) 754-7000 • FAX 360-943-7659 • E-MAIL: [email protected] WEB SITE: www.soloy.com

SERVICE INSTRUCTION 763-06 Page 2 of 26


PHONE (360) 754-7000 • FAX 360-943-7659 • E-MAIL: [email protected]

SECTION I

INSTALLATION INSTRUCTIONS Description: The 2” instrument system provides the necessary engine indicators for successful powerplant operation. The torque and engine oil pressure gauges employ “wet lines” rather than transducers to transmit the oil pressure. The TOT indicating system utilizes an adjustable resistance spool to maintain the correct lead resistance. The N1 and Np indicating systems employ three-phase AC generators to transmit power to synchronous motors in the RPM indicators. Separate indicators are now provided for: Torque Pressure N1 RPM Np (Prop RPM) Turbine Outlet Temperature A fifth indicator is installed to provide both: Engine Oil Pressure Engine Oil Temperature Installation (Firewall and Engine Bay): 1. Remove upper and lower cowling assemblies. 2. Remove 763-7005-1 manifolds from left and right side of engine mount frame. 3. Remove and retain for re-use 700-1060-1 and –5 pressure switches from

manifolds. 4. Build up 700-7007-3 tee assembly using 3 each AN815-4J unions and NAS617-4

packings. 5. Install 700-1060-5 pressure switch (identified by a yellow dot) using one AN815-

4J packing on the upper fitting of 700-7007-3 tee assembly. 6. Attach tee assembly to left hand side of engine mount frame using existing rear

scavenge filter mount bolt and hardware. 7. Remove 700-7100-13 hose and 700-7309-5 fitting from engine oil pressure port

(right hand side).

WEB SITE: www.soloy.com




8. Install 700-7309-13 orifice fitting utilizing one NAS617-4 packing in engine oil

pressure port. 9. Install 763-7100-17 hose assembly between 700-7309-13 orifice fitting and

forward fitting of 700-7007-3 tee assembly. 10. Attach electrical connector to engine oil low pressure switch previously installed

on tee assembly. 11. Remove both existing 700-1046-1 tach generators. 12. Install a 22A580 tach generator on each pad using previously removed hardware

and new MS9134-01 gaskets. 13. Remove existing fitting from torque oil pressure port (left hand side). 14. Install 700-7007-1 orifice tee utilizing AN924-3J nut and NAS617-3 packing. 15. Install 700-1060-1 pressure switch with NAS617-4 packing onto upper fitting of

700-7007-1 orifice tee. 16. Attach electrical harness connector to torque pressure switch and elbow end of

763-7100-15 hose assembly to 700-7007-1 orifice tee. 17. Connect forward end of 763-7100-19 hose assembly to 700-7007-3 tee

assembly. 18. Using MS21919DG16 and 18 clamps, attach 763-7100-15 and 763-7100-10

hose assemblies to engine mount frame. 19. Drill one-half inch diameter hole 1.75 inches away from existing hole on right side

of firewall. 20. Secure 763-2880-1 spray shield to firewall with AN832-4J union, AN960-716

washer and AN924-4J nut at lower position and AN784-4J tee, AN960-716 washer and AN924-4J nut at upper position.

21. Install NAS424-4D coupling, two each NAS617-4 packing and AN919-2D reducer

on lower fitting behind firewall. 22. Install NAS424-4D coupling, three each NAS617-4 packing, AN814-4DL plug,

and 700-7309-5 orifice on upper fitting behind firewall.





23. Insert 763-7100-15 and 763-7100-19 hose assemblies through S292-28-2 ½ leak

containment sleeve and attach to firewall fittings; 763-7100-15 to upper fitting and 763-7100-19 to lower fitting.

24. Position leak containment sleeve over 763-2880-1 spray shield and secure with

Gates No. 36 clamp. 25. Attach AN6270-4D-0230 hose to upper fitting behind firewall and route to torque

pressure gauge location. 26. Attach AN6270-3D-0220 hose to lower fitting behind firewall and route to engine

oil pressure gauge location. 27. Attach AN5534-2 thermocouple resistance spool block to left side engine mount

upper diagonal strut with MS21919DG18 clamp, AN515-20R8 screw, AN960PD10 washer and MS21042L3 nut.

28. Connect the green lead of the engine thermocouple harness to the forward block

terminal making sure that one resistance spool is connected into the circuit. Connect the white lead of the engine thermocouple harness to the white lead of the airframe thermocouple harness with stainless screw, lockwasher and nut provided. Connect the green lead of the airframe thermocouple harness to the rear terminal of the resistance spool block.

29. Connect a Barfield 2312G instrument tester to the airframe thermocouple leads

at the instrument panel and check lead resistance. Adjust the lead resistance to 8 ohms plus 0 ohms minus .1 ohms. Adjustment is made by altering the length of the resistance spool wire portion of the thermocouple circuit. One inch of the spool wire is equal to .066 ohms.

NOTE

The spool wire is coated with a clear insulating film. This film must be scraped from the wire to achieve circuit continuity.

30. Once adjustment is complete, connect all terminals, covering the lead connection

with the 3/8” insulating heat shrink sleeve. Install and safety the block cover. Installation (Instrument Panel Mods): 1. Remove both instrument panel covers. 2. Remove all radios and instruments that may sustain damage during cutting and

riveting operations.





3. Remove right hand control wheel. 4. Remove right hand instruments. 5. Remove TOT, torque, and Np tri-cluster from left hand panel. 6. For Aircraft Up to S/N 20606439:

a. Locate panel cut out template securing to panel with skin fasteners picking up holes used to secure the fuel quantity cluster and control wheel bearing plate assembly. See Figure 1.

b. Cut out the panel in accordance with the tool and deburr.

c. Install the 700-5001-13 panel, drill rivet holes, deburr and rivet in position.

See Figure 2.

d. Locate, drill, deburr and install 700-2250-3 panel screw nut plates. See Figure 2.

e. Secure 700-2250-3 panel in position.

7. For Aircraft Including and Subsequent to S/N 20606440:

a. Remove screws securing right instrument panel member to panel bulkhead.

b. Remove panel and locate 700-5000-1 panel assembly in its place, drill out

pilot holes, deburr and secure to panel bulkhead using existing screws. 8. Reroute instrument harness from left side of panel to the right side. 9. Unsolder wires from tri-cluster connectors. Cap off unused wires. See wiring

schematic, Figure 3. 10. Solder new connectors to wires in accordance with wiring schematic, Figure 3. 11. Install MS28042-1A instrument clamps (alternate P/N 23906), new instruments

and attach lines and connectors. See Figure 4. 12. Reinstall previously removed instruments, warning lights, and avionic

components. 13. Using tie-wrap straps, make sure harnesses and hoses are secured to prevent

interference with controls.





14. Bleed oil lines at instruments during test run. Secure lines and install panel

covers. Use 700-5257-1 on aircraft up to S/N 20606439. Use 700-5256-1 on aircraft including and subsequent to S/N 20606440.

15. Replace engine cowling. 16. Record incorporation of this service kit in the aircraft logbook. 17. Return redundant material to Soloy Aviation Solutions for exchange credit.

NOTE

The removal of the left tri-cluster gauge leaves a vacant hole in the instrument panel. This may be filled with a relocated nav instrument or a blank plate.





Figure 1. Cut Out Tool Location

Figure 2. Nut Plate Locations





Wiring Modification Details: 1. Transducers

After removal of oil pressure and torque pressure transducers, remove harness connectors and cap wires as follows:

2. TOT Gauge Wiring

1. Install 1-321897-3 terminal end to instrument end thermocouple lead (red or

green) previously disconnected from tri-cluster gauge. 2. Install 1-321897-4 terminal end to instrument end thermocouple lead (yellow or

white) previously removed from tri-cluster gauge. 3. Use amp tool No. 46673 ONLY to correctly install terminal ends on thermocouple

wires.

Figure 3. Wiring Modification Details (Sheet 1 of 2)





After tri-cluster connectors from existing instrument panel harness cap off redundant wires as follows:

Shielded wire cap off detail:

Locate and follow existing instrument and tach generator wires for re-use.

4. Np Indicator and Tach Generator

5. N1 Indicator and tach Generator

6. Engine Oil Temperature Indicator

Figure 3. Wiring Modification Details (Sheet 2 of 2)





Figure 4. Instrument Panel Arrangement





SECTION II MAINTENANCE INSTRUCTIONS

Turbine Outlet Temperature Indicating System (See Figure 5): The temperature measurement system consists of four chromel-alumel single junction thermocouples in the gas producer turbine outlet and associated engine airframe harness, a thermocouple lead resistance spool and a panel mounted indicator. The turbine outlet temperature (TOT) system monitors the critical temperatures present in the turbine section, amplifying the electronically averaged millivolt output of the thermocouples. TOT Indicating System Calibration Check: To provide accurate indications, the TOT system relies on a thermocouple system resistance of 8 ohms +0 - .1. Whenever a new engine or lead is installed, check the resistance as follows: A. Thermocouple Resistance.

1. Make sure all connections are clean and tight at the terminal block on the engine and at the resistance spool block. The resistance spool block is mounted on the left side of the engine mounting bulkhead support structure.

2. With at least one thermocouple lead disconnected from the indicator,

calibrate the system lead resistance to 8 ohms +0 - .1 using a Barfield 2312G tester or equivalent. Adjustment is made by altering the length of the resistance spool section of the thermocouple circuit. One inch of the spool wire is equal to .066 ohms.

3. Reconnect lead to TOT indicator. Replace cover on lead spool and

safety. B. Indicator Test.

1. Make certain that indicator to be tested has stabilized at ambient

temperature at which testing is to be accomplished.





2. Disconnect at least one thermocouple lead from indicator and connect

Barfield type 2312G test set to indicator terminal posts. Using the indicator test function of the test set, compare the indicator and set readings as follows:

NOTE

The calibration check should be accomplished any time a TOT system component is changed. This includes the engine turbine section and thermo-couple. It is no longer necessary to test at each 100 hours of flight time.





Figure 5. TOT Junction





Test Set Reading Indicator Should Be 0° 0° ± 40° 200° 170° - 230° 400° 375° - 425° 600° 580° - 620° 700° 685° - 715° 750° 740° - 760° 800° 795° - 805° 900° 890° - 910° 1000° 980° - 1020° 3. Reconnect leads to TOT indicator. Troubleshooting – TOT System

Trouble Probable Cause Remedy Loose Connection Tighten all thermocouple connections

Defective Indicator Replace indicator

Replace lead

Needle fails to respond

Open in Thermocouple lead Replace resistance spool

Lead not calibrated Calibrate lead

Indicator not adjusted Adjust indicator

High or low reading

Defective indicator Replace indicator Refer to Item 25, Table III-7, Allison 250-C20S Operation and Maintenance Manual for associated troubleshooting procedures.





Figure 6. Propeller (Np) Tachometer System





Description – Propeller (Np) Tachometer System (See Figure 6):

The Np tachometer system is used to indicate propeller RPM. The system incorporates a pad mounted three-phase AC generator driven by the engine’s N2 gear train. It is connected electrically to an indicator mounted on the instrument panel. The generator transmits three-phase power to the synchronous motor in the indicator. The frequency of the transmitted power is proportional to the engine speed. Through use of the magnetic drag principle, the indicator furnishes an accurate indication of engine speed.

Removal – Np Tachometer Signal Generator: Remove the Np tachometer signal generator, located on the engine power and accessories gearbox (left side) as follows: A. Remove the upper nose cowling. B. Unscrew the electrical connector plug from the generator. C. Remove the four nuts and washers mounting the signal generator to the engine.

Withdraw the signal generator and gasket from the engine. D. Using new gasket, install in reverse order of above. Maintenance and Inspection – Propeller (Np) Tachometer System: A. Inspect the generator for security of attachment, wire connections for looseness

and wires for damage. B. Inspect the instrument for loose glass and attachment hardware, chipped scale

markings or loose pointer. C. With engine running, check instrument reading excessive fluctuations. Rectify

defects as required.





Troubleshooting – Propeller (Np) Tachometer System:

Trouble Probable Cause Remedy Excessive scale error

Worn magnets in generator Change generator

Pointer moves backwards

Leads reversed at generator Connect leads in accordance with wiring diagram

Break or short circuit Repair or replace lead

Poor connections indicator or generator disconnects

Clean and tighten connection

No reading on indicator either constant or intermittent

Open in unit circuit Replace generator or indicator

High reading on indicator either constant or intermittent

Indicator resistance out of adjustment Replace indicator

Refer to Item 28, Table III-7, Allison 250-C20S Operation and Maintenance Manual for associated troubleshooting instructions.





Figure 7. Gas Producer (N1) Tachometer System





Description – Gas Producer (N1) Tachometer System (See Figure 7): The N1 indicator displays the speed, in percentage RPM, of the gas producer section of the engine. Its primary function is to show the N1 speed required to maintain the Np at full RPM at a particular flight power setting. The components used in the system are the indicator, wiring harness and the generator and the theory of operation is the same as that described in the paragraph for Description – Propeller (Np) Tachometer System. Removal – N1 Tachometer Signal Generator: Refer to instructions provided in paragraph for Removal – Np Tachometer signal Generator.

NOTE

The N1 generator is on the right side of the engine power and accessories gearbox.

Maintenance and inspection – N1 Tachometer System: Refer to instructions provided in paragraph for Maintenance and Inspection – Propeller (Np) Tachometer System. Troubleshooting – N1 Tachometer System: Refer to instructions provided in paragraph for Troubleshooting – Propeller (Np) Tachometer System. Description – Torque Indicating System: The engine torquemeter indicator located on the instrument panel is precalibrated in pounds per square. The indicator provides a reading of engine torquemeter proportional to the shaft horsepower being delivered by the engine. The system includes the indicator, an orifice fitting at the engine torque pressure outlet, plumbing lines and provides direct (wetline) readings. Inspection – Torque Indicating System: A. Inspect fittings and lines for chaffing damage, looseness and leaks. B. Inspect indicator for broken glass, chipped scale markings and loose pointer. C. With engine running, check for excessive fluctuations.





Troubleshooting – Torque Indicating System:

Trouble Probable Cause Remedy Gauge gives sluggish readings

Defective gauge or orifice obstruction

Replace gauge or clean orifice

Low or high reading at all power settings

Defective gauge or orifice obstruction

Replace gauge or clean orifice

Pointer fluctuating Air trapped in line Bleed air from line by disconnecting at indicator while running engine at low torque.

Refer to Item 25, 26, and 27, Table III-7, Allison 250-C20S Operation and Maintenance Manual for associated troubleshooting instructions.





Figure 8. Oil Temperature Bulb





Description – Oil Temperature Indicating System (Refer to Figure 8): The oil temperature indicating system provides oil temperature information, in degrees of Centigrade, from the oil system of the Turbine Pac powerplant. This system is comprised of an oil temperature bulb (located in the inlet oil port of the turbine engine), a combined oil temperature-oil pressure indicator and associated wiring. The temperature bulb is constructed in such a way that, as oil temperature changes, the resistance value across the two terminals of the bulb changes. This varied resistance is supplied to the oil temperature section of the indicator which utilizes the ratiometer principle to provide oil temperature information. Removal – Oil Temperature Bulb: A. Remove the right hand engine nacelle access panels. B. Remove the electrical connector from the temperature bulb. C. Remove the lockwire. Position a suitable container under the temperature bulb

to catch the oil. D. Remove the temperature bulb from the fitting installed in the OIL IN port of the

turbine engine. E. Install a protective plug into the port from which the temperature bulb was

removed to prevent excessive oil loss and to prevent oil system contamination. Installation – Oil Temperature Bulb: A. Remove the protective plug from the temperature bulb port. Catch the oil from

the port with a suitable container. B. Install a new O-ring and apply a light coat of engine oil to the threads of the

temperature bulb. Install the temperature bulb.

NOTE

Do not use a copper crushwasher when installing the oil temperature bulb.

C. Install electrical connector to the temperature bulb. D. Safety the temperature bulb to the engine with .032 lockwire.





E. Safety electrical connector to the temperature bulb with .020 lockwire. F. Install the nacelle access panels. Troubleshooting – Oil Temperature Indicating System:

Trouble Probable Cause Remedy No power to system Check circuit breaker

Check system wiring

Faulty wiring

Check system wiring

Defective temperature bulb

Replace temperature bulb

Indicator fails to operate

Defective indicator

Replace indicator

Description - Engine Oil Pressure System: The engine oil pressure system consists of an orificed fitting at the pressure outlet in the power and accessories gearbox, an oil line and fittings, a low pressure switch and an instrument panel mounted indicator. Inspection – Engine Oil Pressure System: A. Inspect fittings and lines for chaffing damage, looseness and leaks. B. Inspect indicator for broken glass, chipped scale markings and loose pointer. C. With engine running, check for extensive fluctuations.





Troubleshooting – Engine Oil Pressure Indicating System:

Trouble Probable Cause Remedy Pressure line clogged Check line for obstructions.

Clear line

Pressure line broken

Replace pressure line

Gauge does not register

Defective instrument

Replace instrument

Foreign matter in line

Inspect line. Clear line Gauge falls to zero


Replace instrument

Leak in pressure line Replace or repair line. Tighten fittings.

Erratic gauge operation


Replace gauge

Refer to Item 14-17, Table III-7, Allison 250-C20S Operation and Maintenance Manual for associated troubleshooting instructions.





SECTION III

PARTS CATALOG

Item Part Number Nomenclature Qty. 1 700-7007-1 Orifice 1 2 700-7007-3 Tee Assembly 1 3 700-7309-13 Orifice 1 4 763-2880-1 Spray Shield 1 5 763-7100-15 Hose 1 6 763-7100-17 Hose 1 7 763-7100-19 Hose 1 8 AN6270-3D-0220 Hose 1 9 AN6270-4D-0230 Hose 1

10 22A580 Tachometer Generator 2 11 AN5534-2 Resistance Spool Block 1 12 700-5211-5 Torque Indicator 1 13 700-5213-1 T.O.T. Indicator 1 14 700-5215-3 N1 Tachometer 1 15 700-5217-3 Np Tachometer 1 16 700-5221-3 Engine Oil Pressure/Temperature Ind 1 17 MS28042-1A Clamp Assembly (Alt. 23906) 5 18 MS3106R-10SL-3S Connector – Np Indicator/N1 Indicator 2 19 MS3116E-10-6S Connector – EOP/EOT Indicator 1 20 AN815-4J Fitting 3 21 NAS424-4D Coupling 2 22 AN784-4J Fitting 1 23 AN814-4DL Cap 1 24 AN816-4D Nipple 1 25 MS3106R-12S-3S Connector – Tach Generators 2 26 MS21059L08 Nut Plate 3 27 MS20426AD3-4 Rivet 8 28 NAS687A08 Nut Plate 1 29 MS20426AD4-5 Rivet 3 30 MS20470AD4-5 Rivet 8 31 AWG #20 (E206A20N) Wire 1 32 AN832-4J Union 1 33 AN960-716 Washer 2 34 AN924-4J Nut 2 35 NAS617-4 Packing 6 36 AN919-2D Reducer 1 37 700-9008-7 Placard 1 38 700-9008-21 Placard 1





Item Part Number Nomenclature Qty. 39 1-321897-3 Terminal 1 40 1-321897-4 Terminal 1 41 S292-28-2 ½ Sleeve – Leak Containment 16” 42 AN515C8-4 Screw 1 43 AN935C8 Washer 1 44 AN340C8 Nut 1 45 MS9134-01 Gasket 2 46 GATES #36 Clamp 1 47 MS21919DG16 Clamp 2 48 MS21919DG18 Clamp 4 49 AN515-10R8 Screw 2 50 AN960PD10 Washer 2 51 MS21042L3 Nut 2 52 NPN Cut Out tool – Right Hand Panel 1 53 NAS617-3 Packing 1 54 763-1041 Drawing – Instrument Panel 1 set 55 763-1078 Drawing – Lube System 1 set

55A 763-1048 Drawing – Instrument Panel Mods 1 set Service Kit 763-06-1 used on aircraft S/N’s up to 20606439 includes items 1 through 38 plus:

56 700-5257-1 Cover Assembly 1 57 700-2250-3 Panel 1 58 700-5001-13 Panel 1

Service Kit 763-06-02 used on aircraft including and subsequent to S/N 20606440 includes items 1 through 38 plus:

59 700-5256-1 Cover Assembly 1 60 MS28042-1 Clamp (Alt. 23906) 1 61 700-5256-5 Plug AR 62 700-5256-7 Plug AR 63 700-5001-1 Panel 1 64 700-3527-1 Panel 1

Weight and Balance: The installation of this service kit imposes a negligible weight and balance change.


Documents

INSTALLATION OF 2” POWERPLANT INSTRUMENTS · 2017. 12. 11. · 4. Build up 700-7007-3 tee assembly using 3 each AN815-4J unions and NAS617-4 packings. 5. Install 700-1060-5 pressure