SAIB CE-04-74 —

CE-04-74 August 3, 2004 www.faa.gov/certification/aircraft This is information only. Recommendations aren’t mandatory.

Introduction

This Special Airworthiness Information Bulletin alerts you, owners and operators of Cirrus Design Corporation (CDC) SR20 or SR22 airplanes, of possible loss of left or right braking.

Background

In January 2004, an accident occurred involving a CDC SR22 that experienced left brake failure during landing rollout. Examination of the aircraft revealed that the left brake line wall had worn through due to chafing against the retaining hardware for the lower strut fairing. CDC has issued Service Bulletin SB 2X-32-08 to correct the problem.

Recommendation

We recommend that you complete CDC’s SB 2X-32-08 (attached) within the next 30 days.

For Further Information Contact

Wesley Rouse, Aerospace Engineer, FAA Chicago Aircraft Certification, 2300 E. Devon, Des Plaines, IL 60018; phone: (847) 294-8113; email: [email protected]

Cirrus Design Corporation cannot be responsible for the quality of work performed by others while fulfilling the requirements of this service bulletin. Procedures specified in this service bulletin must be accomplished using industry standard maintenance practices and applicable government regulations. Cirrus Design Corporation 4515 Taylor Circle Duluth, Minnesota 55811 PH (218) 727-2737 SB 2X-32-08 1 of 8 Service Bulletin Issued: COMPLIANCE Mandatory: Cirrus Design considers this Service Bulletin to be MANDATORY. Accomplish this Service Bulletin at the next maintenance or within the next 6 calendar months, whichever occurs first. Compliance time begins upon receipt of this Service Bulletin. EFFECTIVITY Cirrus Design SR20 serial numbers 1005 through 1316. Cirrus Design SR22 serial numbers 0002 through 0914. APPROVAL FAA approval has been obtained on all technical data in this Service Bulletin that affects type design. PURPOSE The main landing gear brake line may experience chafing from the lower strut fairing on some affected air- planes. This condition could cause the brake line to fail which would result in diminished or no braking. DESCRIPTION This Service Bulletin contains instructions for brake line inspection and installation of anti-chafe spacers to the upper and lower nutplate clips on the lower strut fairings. WARRANTY INFORMATION Cirrus Design will cover parts and labor costs for this Service Bulletin if the work is accomplished within the next 12 calendar months and the work is accomplished at an authorized Cirrus Design Service Center or at the Cirrus Design factory. The Warranty Claim Form must be properly filled out and submitted with the removed parts to Cirrus Design in order to obtain a warranty credit. ATA 32-10: Main Gear Brake Line Inspection and Anti-Chafe Spacer Installation 2004/04/08 SB 2X-32-08 Model SR20 and SR22

SB 2X-32-08 2 of 8 Issued: 2004/04/08 MANPOWER REQUIREMENTS Inspection Condition - No Chafing Found : 0.25 Manhour Anti-Chafe Spacer Installation: 0.25 Inspection Condition - Chafing Found, Less Than 10% Of Brake Line Wall Thickness: 0.50 Manhour Chafing Depth Measurement: 0.25 Anti-Chafe Spacer Installation: 0.25 Inspection Condition - Chafing Found, Greater Than 10% Of Brake Line Wall Thickness: 4.5 Manhour Chafing Depth Measurement: 0.25 Main Landing Gear Brake Line Replacement: 4.25 OTHER PUBLICATIONS AFFECTED SR20 Airplane Maintenance Manual (p/n 12137-001) SR20 Illustrated Parts Catalog (p/n 12138-001) SR22 Airplane Maintenance Manual (p/n 13773-001) SR22 Illustrated Parts Catalog (p/n 13744-001) WEIGHT AND BALANCE N/A MATERIAL INFORMATION The following parts are required to comply with this Service Bulletin. Parts can be obtained from Cirrus Design Spare Part Sales or an authorized Cirrus Design Service Center. Order Kit P/N 70071-001. ACCOMPLISHMENT INSTRUCTIONS A. Remove key from ignition. B. Ensure BATTERY and AVIONICS master switches are in OFF position. C. Pull ESSENTIAL and NON-ESSENTIAL AVIONICS circuit breakers. D. Remove RH and LH lower strut fairings. (Refer to AMM 32-10) E. Inspect the brake line attached to the main landing gear strut assembly and identify any chafing between the brake assembly and lower strut fairing hardware. Repeat inspection and identify chafing on opposite brake line. F. If no chafing is evident, install anti-chafe spacers. Perform the following steps. (See Figure 01) 1. At upper and lower nutplate clips on the lower strut fairing, slightly pry open clip and insert nar- row end of anti-chafe spacer into clip. 2. Bend nutplate clip back down so that nutplates retain anti-chafe spacer. 3. Verify strut stand-off used to secure lower strut fairing to strut is installed and securely attached. Item No. Description P/N or Spec. Supplier Quantity 1 Service Bulletin SB 2X-32-08 Cirrus Design 1 2 Anti-Chafe Spacer 16108-001 Cirrus Design 4

SB 2X-32-08 3 of 8 Issued: 2004/04/08 4. Repeat on opposite fairing and strut. 5. Install main landing gear fairings. (Refer to AMM 32-10) 6. Complete airplane records by noting compliance with SB 2X-32-08 in Airplane Logbook. G. If chafing is evident, perform the required steps: 1. Acquire necessary tools, equipment, and supplies. Note: Brake line wall thickness is 0.035 inch (0.89 mm). 2. Place straight edge along brake line and use pin feeler gauge to measure chafing depth on brake line(s). 3. If chafing depth is less than 10% of brake line wall thickness (0.0035 inch (0.089 mm)), install anti-chafe spacers. Perform the following steps: (See Figure 01) a. At upper and lower nutplate clips on the lower strut fairing, slightly pry open clip and insert narrow end of anti-chafe spacer into clip. b. Bend nutplate clip back down so that nutplates retain anti-chafe spacer. c. Verify strut stand-off used to secure lower strut fairing to strut is installed and securely attached. d. Repeat on opposite fairing and strut. e. Install main landing gear fairings. (Refer to AMM 32-10) f. Complete airplane records by noting compliance with SB 2X-32-08 in Airplane Logbook. 4. If chafing depth is equal to or greater than 10% of brake line wall thickness (0.0035 inch (0.089 mm)), perform Procedure - Main Landing Gear Brake Line Replacement. H. Main Landing Gear Brake Line Replacement (See Figure 02) 1. Acquire necessary tools, equipment, and supplies. Description P/N or Spec. Supplier Purpose Pin Feeler Gauge 0.0035 inch (0.089 mm) - Any Source Measure Brake Line Chafing. Straight Edge 2 inch (5.1 cm) - Any Source Measure Brake Line Chafing. Description P/N or Spec. Supplier Purpose SR20 serials 1005 thru 1194: SR22 Serials 0002 thru 0005: Brake Line Assembly 11727-001 Cirrus Design Brake line replace- ment. SR20 serials 1195 thru 1316: SR22 Serials 0006 thru 0914: Brake Line Assembly 14445-001 Cirrus Design Brake line replace- ment. Tie Down MS3367-1-9 Cirrus Design Brake line replace- ment. Plastic Dead Blow Hammer 60515A4 McMaster Carr Strut removal. Plastic Wedge 5868A91 McMaster Carr Strut removal.

SB 2X-32-08 4 of 8 Issued: 2004/04/08 2. Remove upper strut fairing. (Refer to AMM 32-10) 3. Raise airplane on jacks. (Refer to AMM 7-10) 4. Cut and remove tie down securing brake line to lower strut. 5. Loosen breeze clamp securing braided grounding strap to brake line. 6. Disconnect and cap flexible brake line at upper end of strut. 7. Disconnect brake line fitting from support bracket at upper end of strut. 8. Disconnect flexible brake line at lower end of strut. 9. Remove nuts and washers securing strut clamp to canted rib. 10. Using the dead blow hammer, squarely strike upper side of strut near clamp fitting to move strut down and away from clamp fitting. 11. Insert and drive plastic wedge into gap between clamp and fitting to free strut from clamp. 12. Slide grommet down strut to brake assembly. WARNING: Verify no fuel leaks or fuel residue are present before applying heat to strut. CAUTION: The adhesive securing the brake line to the strut does not require a high degree of heat to disbond. Heat the adhesive to the point where it is slightly hot to the touch. To protect the composite wing skin from heat damage, place a barrier on the wing skin such as a welding blanket, high temperature mat, or damp cloth before apply- ing heat to the upper section of the strut near the wing skin. 13. With heat gun, apply heat to epoxy bonding brake line to strut channel. As epoxy heats and soft- ens, pull brake line free from strut channel. Discard brake line. CAUTION: Do not use power tools to remove epoxy. Do not cut or gouge strut laminate when removing epoxy. Heat Gun - Any Source Epoxy removal. Putty Knife - Any Source Epoxy removal. Sandpaper 80 Grit Any Source Remove epoxy. Isopropyl Alcohol TT-I-735 Grade A or B Any Source Solvent cleaning. Cotton cloth (clean, white, lint free) - Any Source Solvent cleaning. Neoprene Rubber Gloves - Any Source Hand protection. 5 Minute® Epoxy Gel, 25 ml Syringe Dev-Tube 14240 Devcon Secure brake line. Lead Pencil - Any Source Marking. Applicator (Tongue Depressor) - Any Source Epoxy application. Paper Cup, 1/2 cup - Any Source Epoxy application. Description P/N or Spec. Supplier Purpose

SB 2X-32-08 5 of 8 Issued: 2004/04/08 14. Using a putty knife and sandpaper, remove epoxy from strut channel. 15. Mark the position where the lower fitting on the newly installed brake line should be positioned: a. At bottom, aft edge of strut, measure 8.9 inches (22.6 cm) up and make a perpendicular reference line across strut face with pencil. (See Figure 02, Note 2) 16. Test fit new brake line: a. Place new brake line into upper support bracket and position to strut assembly. b. At top of strut where brake line enters strut channel and down approximately 6.0 inches (15.2 cm), verify brake line fits completely into strut channel so that top radius of brake line is flush with top of strut channel. (See Figure 02, Note 1) c. Verify flare on lower section of brake line aligns with reference mark on strut. 17. Solvent clean strut channel with isopropyl alcohol. Do not remove reference mark on strut. 18. Solvent clean brake line. 19. Mix approximately half of the syringe, or 12.5 grams, of epoxy. CAUTION: Place a drop cloth over wheel assembly to protect assembly from dripping epoxy. 20. Using wooden applicator, fill strut channel with epoxy until epoxy is flush with top of strut chan- nel. 21. Install new brake line: a. Position brake line into upper support bracket, insert brake line into strut channel, and position brake line so flare on lower section of brake line aligns with reference mark on strut. b. Firmly press brake line into strut channel. c. At top of strut where brake line enters strut channel and down approximately 6.0 inches (15.2 cm), seat brake line completely into strut channel so that top radius of brake line is flush with top of strut channel. Use a wooden applicator to spread epoxy over brake line. d. Where brake line enters and exits strut channel, use a wooden applicator to spread epoxy over and around brake line. e. Wet a clean, lint free cotton cloth in isopropyl alcohol and clean up epoxy. Leave a thin coat of epoxy over top of brake line. f. Apply down pressure over brake line by applying tape over brake line at lower fitting and over bend on upper section of brake line. (See Figure 02, Note 3) g. Allow epoxy to cure for 2 hours. 22. Slide grommet up strut to canted rib strut fitting. 23. Move strut assembly up and towards strut fitting. 24. Position clamp fitting over grommet and install washers and nuts securing clamp fitting to canted rib fitting. Torque to 150.0 in-lb (16.9 Nm). 25. Connect flexible brake line at lower end of strut. 26. Connect brake line fitting to support bracket at upper end of strut. 27. Connect flexible brake line at upper end of strut. 28. Position breeze clamp around braided grounding strap and fasten to brake line. 29. Install tie down securing brake line to lower strut. 30. If required, repeat procedure on opposite side 31. Remove jacks and lower airplane. (Refer to AMM 7-00) 32. Final torque bolts securing strut(s) to canted rib(s) to 160.0-190.0 in-lb (18.1- 21.5 Nm) 33. Fill brake system. (Refer to 12-10) 34. Bleed brake system. (Refer to 32-42) 35. Install anti-chafe spacers. Perform the following steps: (See Figure 01)

SB 2X-32-08 6 of 8 Issued: 2004/04/08 a. At upper and lower nutplate clips on the lower strut fairing, slightly pry open clip and insert narrow end of anti-chafe spacer into clip. b. Bend nutplate clip back down so that nutplates retain anti-chafe spacer. c. Verify strut stand-off used to secure lower strut fairing to strut is installed and securely attached. d. Repeat on opposite fairing and strut. 36. Install main landing gear fairings. (Refer to AMM 32-10) 37. Complete airplane records by noting compliance with SB 2X-32-08 in Airplane Logbook.

SB 2X-32-08 7 of 8 Issued: 2004/04/08 Inspect brake line and check for any chafing between brake assembly and lower strut fairing attachment hardware. Repeat inspection on opposite brake line. NOTE 1 2 Verify strut stand-off used to secure the lower fairing is installed and securely attached. NUTPLATE CLIP ANTI-CHAFE SPACER 2 1 SR2_SB32_1055 Figure 01 - Anti-Chafe Spacer Installation

SB 2X-32-08 8 of 8 Issued: 2004/04/08 6.0" 8.9" At top of strut where brake line enters strut channel and down approximately 6.0 inches (15.2 cm), verify brake line fits completely into strut channel so that top radius of brake line is flush with top of strut channel. NOTE 1 1 2 At bottom, aft edge of strut, measure 8.9 inches (22.6 cm) up and make a perpendicular reference line across strut face with pencil. 2 3 3 4 Apply down pressure over brake line by applying tape over brake line at lower fitting and over bend on upper section of brake line. 3 Verify stand off is installed and securely attached. 4 GROUNDING STRAP BREEZE CLAMP UPPER SUPPORT BRACKET FLEXIBLE FUEL LINE STRUT CLAMP TIEDOWN STRUT GROMMET FLEXIBLE FUEL LINE REFERENCE LINE STRUT CHANNEL SR2_SB32_1049 Figure 02 - Main Landing Gear Brake Line Replacement