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Hartzell CD15K Maintenance Manual
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Hartzell CD15K Maintenance Manual

Aircraft combustion heater
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Model:
P/N
S/N
Maintenance Manual
for Hartzell Engine Technologies LLC. Aircraft Combustion Heater
Models CD15K, CD25K, CD35K, CD45K CD50K, CD55K and CD70K
with P/N's ending in –1 (dash one series) (Includes Airworthiness Limitations)
MM10001
January 1, 2008
REV. L dated May 21, 2015
FAA Approval has been obtained on technical data in this publication
that affects product type design
NOTE:
Instructions for Continued Airworthiness" as outlined on page 8 are required.
The Airworthiness Limitations Section (Section 7.2.) is MANDATORY.
Before performing service consult www.hartzell.aero for latest revision to this manual.
Changes to the Instructions for Continued Airworthiness will be distributed by way of service
bulletins and service letters.
The Airworthiness Limitations section is FAA approved and
specifies maintenance required under section 43.16 and 91.403 of the Federal Aviation
Regulations unless an alternative program has been FAA approved.
2900 Selma Highway, Montgomery AL 36108 USA
PH: +1.334.386.5400 (option 2) FAX: +1.334.386.5450 WEB:
www.hartzell.aero
P a g e | ii

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Summary of Contents for Hartzell CD15K

  • Page 1 Instructions for Continued Airworthiness” as outlined on page 8 are required. The Airworthiness Limitations Section (Section 7.2.) is MANDATORY. Before performing service consult www.hartzell.aero for latest revision to this manual. Changes to the Instructions for Continued Airworthiness will be distributed by way of service bulletins and service letters.
  • Page 2 Congratulations! You have purchased the world’s highest quality heating system. Hartzell Engine Technologies LLC (HET) has been servicing heating systems for many years. Using the latest modern technology, Hartzell Engine Technologies has received FAA approval to manufacture new TSO-C20 heaters for general aviation aircraft. Installations are available for most twins and some single engine aircraft.
  • Page 3 TABLE OF REVISIONS ..........4 GENERAL INFORMATION FOR MODEL CD15K, CD25K, CD35K, CD45K, CD50K, CD55K...
  • Page 4 15. PARTS VIEW OF EXPLODED HEATER ASSEMBLY ......56 2900 Selma Highway, Montgomery AL 36108 USA PH: +1.334.386.5400 (option 2) FAX: +1.334.386.5450 WEB: www.hartzell.aero P a g e...
  • Page 5 Added “not” to allow lead wire to twist….. 5/21/15 5/21/15 Reformatted, added more specific info, clarified procedures, added warranty page, removed section ref from ICA’s AL section. 2900 Selma Highway, Montgomery AL 36108 USA PH: +1.334.386.5400 (option 2) FAX: +1.334.386.5450 WEB: www.hartzell.aero P a g e...
  • Page 6 MM10001 Dated 1/1/08 Rev L dated 5/21/15 PAGE INTENTIONALLY LEFT BLANK 2900 Selma Highway, Montgomery AL 36108 USA PH: +1.334.386.5400 (option 2) FAX: +1.334.386.5450 WEB: www.hartzell.aero P a g e...
  • Page 7 Hartzell Engine Technologies LLC a waiver by the purchaser of any right later to assert such a claim will be required. Any cause of action against Hartzell Engine Technologies LLC arising out of or relating to the contract or the performance hereof shall expire unless bought within one year of the time of accrual thereof.
  • Page 8 Heaters are FAA TSO-C20 approved and are designed to use the aircraft fuel (aviation gas or jet) in both pressurized and non-pressurized aircraft. Both 12 and 24 volt applications are available. Designated models are CD15K, CD25K, CD35K, CD45K, CD50K, CD55K & CD70K, with a p/n ending in “-1”.
  • Page 9 The purpose of this manual is to guide its reader to a thorough understanding and working knowledge of the Hartzell Engine Technologies “–1” series combustion heater and subsequent components. While general concepts in operation mentioned herein apply to all aircraft combustion heater makes, the design and operation of a “-1”...
  • Page 10 CD14071-1 CD14125-1 CD14045-1 CD14072-1 CD14126-1 CD14046-1* CD14073-1 CD14127-1 CD15000 SERIES CD15010-1 CD15020-1 CD15030-1 CD15011-1 CD15025-1 CD50000 SERIES CD50000-1 CD52000-1 CD52001-1 CD52002-1 2900 Selma Highway, Montgomery AL 36108 USA PH: +1.334.386.5400 (option 2) FAX: +1.334.386.5450 WEB: www.hartzell.aero P a g e...
  • Page 11 Jet Fuel Applications use an electric fuel pump assembly that fuels through a fuel control system providing fuel pressure at 105 +5.-0 PSI. 2900 Selma Highway, Montgomery AL 36108 USA PH: +1.334.386.5400 (option 2) FAX: +1.334.386.5450 WEB: www.hartzell.aero P a g e | 10...
  • Page 12 A combination of mechanical and solid state switches are used to regulate heat and airflow. These switches also provide safety control for shut down of unit in the event of malfunction. 2900 Selma Highway, Montgomery AL 36108 USA PH: +1.334.386.5400 (option 2) FAX: +1.334.386.5450 WEB: www.hartzell.aero P a g e | 11...
  • Page 13 This produces a whirling flame that is stable and sustains combustion under the most adverse conditions. 2900 Selma Highway, Montgomery AL 36108 USA PH: +1.334.386.5400 (option 2) FAX: +1.334.386.5450 WEB: www.hartzell.aero P a g e | 12...
  • Page 14 Ventilating air thus comes in contact with the heated cylindrical surfaces subsequently pushing heated air into the cabin. 2900 Selma Highway, Montgomery AL 36108 USA PH: +1.334.386.5400 (option 2) FAX: +1.334.386.5450 WEB: www.hartzell.aero P a g e | 13...
  • Page 15 7. ICA (INSTRUCTIONS FOR CONTINUED AIRWORTHINESS) Second Edition: Rev E dated 5-21-15 When Hartzell Engine Technologies LLC (HET) heater is installed in an aircraft, the following action is required. A description of its operational principals, controls, servicing, maintenance, troubleshooting and testing can be found in the attached MM10001 maintenance manual in the “Table of Contents.”...
  • Page 16 MM10001 Dated 1/1/08 Rev L dated 5/21/15 7.3. FLIGHT MANUAL SUPPLEMENT SAMPLE SAMPLE 2900 Selma Highway, Montgomery AL 36108 USA PH: +1.334.386.5400 (option 2) FAX: +1.334.386.5450 WEB: www.hartzell.aero P a g e | 15...
  • Page 17 MM10001 Dated 1/1/08 Rev L dated 5/21/15 SAMPLE 2900 Selma Highway, Montgomery AL 36108 USA PH: +1.334.386.5400 (option 2) FAX: +1.334.386.5450 WEB: www.hartzell.aero P a g e | 16...
  • Page 18 MM10001 Dated 1/1/08 Rev L dated 5/21/15 SAMPLE 2900 Selma Highway, Montgomery AL 36108 USA PH: +1.334.386.5400 (option 2) FAX: +1.334.386.5450 WEB: www.hartzell.aero P a g e | 17...
  • Page 19 8.1.2 Where deviation from the original heater controls are required the installation instructions provided with the Hartzell Engine Technologies LLC (HET) heater will address these changes. Refer to appropriate installation instructions. 8.1.3 For new HET TSO-C20 Supplemental Type Certificate (STC’d) heater kits, the installation instructions from HET will contain complete procedures for operation and integrating in the aircraft.
  • Page 20 Verify the torque of the ignition lead both at the igniter plug (15-20 ft. lbs.) and ignition unit (12-15 ft. lbs.).  Complete 100hr/Annual inspection and operational check. 2900 Selma Highway, Montgomery AL 36108 USA PH: +1.334.386.5400 (option 2) FAX: +1.334.386.5450 WEB: www.hartzell.aero P a g e | 19...
  • Page 21 OVERHAUL ANY HEATER THAT DOES NOT PASS THE COMBUSTION TUBE PRESSURE DECAY TEST REQUIRED BY THIS INSPECTION. IT IS RECOMMENDED THAT THE OVERHAUL BE PERFORMED BY THE HARTZELL ENGINE TECHNOLOGIES LLC SERVICE CENTER. 8.5 2000-HOUR OR 10 YEAR OVERHAUL (to be accomplished in accord with MM10001 sections 8-11.)
  • Page 22 Pressure in the exhaust seal expansion bulb may be increased to 95 psi to achieve a leak proof seal. 2900 Selma Highway, Montgomery AL 36108 USA PH: +1.334.386.5400 (option 2) FAX: +1.334.386.5450 WEB: www.hartzell.aero P a g e | 21...
  • Page 23 Remove all test fittings, plugs, supply lines, etc., and re-install combustion air supply lines and drain lines which make up the aircraft heater installation. 2900 Selma Highway, Montgomery AL 36108 USA PH: +1.334.386.5400 (option 2) FAX: +1.334.386.5450 WEB: www.hartzell.aero P a g e | 22...
  • Page 24 Inspect and test to ensure that the cabin heater is disabled and that there are no fuel leaks or other aircraft systems affected by this action.  Placard with date near heater control “HEATER DISABLED XX/XX/XX” 2900 Selma Highway, Montgomery AL 36108 USA PH: +1.334.386.5400 (option 2) FAX: +1.334.386.5450 WEB: www.hartzell.aero P a g e | 23...
  • Page 25 This will be accompanied by evidence of extreme oxidation and is cause for replacement of the combustion tube assembly. If detected, replace the combustion tube. 2900 Selma Highway, Montgomery AL 36108 USA PH: +1.334.386.5400 (option 2) FAX: +1.334.386.5450 WEB: www.hartzell.aero P a g e | 24...
  • Page 26 Replace the whole assembly.  If no leaks are detected, dry the assembly carefully with compressed air. 2900 Selma Highway, Montgomery AL 36108 USA PH: +1.334.386.5400 (option 2) FAX: +1.334.386.5450 WEB: www.hartzell.aero P a g e | 25...
  • Page 27 Improper spray pattern is as shown in figure 16. Typically the sheet or funneling action would be distorted or “onioning”, i.e. closing in on itself or atomizing prematurely. Nozzle & Holder FIGURE 16 2900 Selma Highway, Montgomery AL 36108 USA PH: +1.334.386.5400 (option 2) FAX: +1.334.386.5450 WEB: www.hartzell.aero P a g e | 26...
  • Page 28 An overhauled motor will not have as long of a service life as a new motor. CAUTION – Do not touch armature with bare hands – oils will cause premature wear. 2900 Selma Highway, Montgomery AL 36108 USA PH: +1.334.386.5400 (option 2) FAX: +1.334.386.5450 WEB: www.hartzell.aero P a g e | 27...
  • Page 29 9.3.5.4 Inspect inside of ignition unit well area where lead attaches. Any evidence of arching or deterioration of insulator is cause for replacement. Ignition Unit and Lead Assembly FIGURE 8 2900 Selma Highway, Montgomery AL 36108 USA PH: +1.334.386.5400 (option 2) FAX: +1.334.386.5450 WEB: www.hartzell.aero P a g e | 28...
  • Page 30 9.3.6.3 Test ignition by holding lead ¼” away from ground as shown looking for strong blue spark able to jump at least 3/8” to ½” gap. Ignition Lead and Spark Plug FIGURE 10 2900 Selma Highway, Montgomery AL 36108 USA PH: +1.334.386.5400 (option 2) FAX: +1.334.386.5450 WEB: www.hartzell.aero P a g e | 29...
  • Page 31 9.3.7.4 Carefully inspect the porcelain for cracks, erosion or carbon trail. Reject any spark plug if its appearance is questionable. 9.3.7.5 Check the electrode disc for erosion. If found, replace. 2900 Selma Highway, Montgomery AL 36108 USA PH: +1.334.386.5400 (option 2) FAX: +1.334.386.5450 WEB: www.hartzell.aero P a g e | 30...
  • Page 32 NOTE: Do not use solder for heater wiring connections. 9.3.8.3 Reinstall heater controls if they were operating correctly before overhaul. 9.3.8.4 Replace all damaged hardware. 2900 Selma Highway, Montgomery AL 36108 USA PH: +1.334.386.5400 (option 2) FAX: +1.334.386.5450 WEB: www.hartzell.aero P a g e | 31...
  • Page 33 This surface must not distort or be damaged in any way. Nozzle & Holder FIGURE 18 Fuel Feed drain port 2900 Selma Highway, Montgomery AL 36108 USA PH: +1.334.386.5400 (option 2) FAX: +1.334.386.5450 WEB: www.hartzell.aero P a g e | 32...
  • Page 34 Verify and install wiring as specified by P.A.H. (typically same location and connected to the same terminals as before disassembly. ) 2900 Selma Highway, Montgomery AL 36108 USA PH: +1.334.386.5400 (option 2) FAX: +1.334.386.5450 WEB: www.hartzell.aero P a g e | 33...
  • Page 35 0 minimum at rated voltage. (Optional)  The combustion air water manometer should indicate approximately 1-7 inches H 0 at rated voltage. (Optional) 2900 Selma Highway, Montgomery AL 36108 USA PH: +1.334.386.5400 (option 2) FAX: +1.334.386.5450 WEB: www.hartzell.aero P a g e | 34...
  • Page 36 It may have a dab of inspectors lacquer over the screw. Rotation clockwise one turn will increase temperature approx. 20° F. Decrease temperature by turning counterclockwise. 2900 Selma Highway, Montgomery AL 36108 USA PH: +1.334.386.5400 (option 2) FAX: +1.334.386.5450 WEB: www.hartzell.aero P a g e | 35...
  • Page 37 Allow sufficient time for cool down to prevent residual heat from actuating overhead switch.  Shut down heater and recheck all components. 2900 Selma Highway, Montgomery AL 36108 USA PH: +1.334.386.5400 (option 2) FAX: +1.334.386.5450 WEB: www.hartzell.aero P a g e | 36...
  • Page 38 (and many times your marriage) because overall reliability will definitely improve. Most Janitrol B series and Hartzell Engine Technologies LLC heaters require 6.5-8 PSI (turbine aircraft 100+5-0 PSI). South Wind 8240-8472 series must have 22 PSI or above.
  • Page 39 Not On Ground Fuel solenoid on heater stuck open (See 11.4.6). Heater Continues To Heat – Fails To Shut Off. 2900 Selma Highway, Montgomery AL 36108 USA PH: +1.334.386.5400 (option 2) FAX: +1.334.386.5450 WEB: www.hartzell.aero P a g e | 38...
  • Page 40 8 and 10. Heat control is generally controlled by a thermostat wired from terminal 7 to 8. FIGURE 22 2900 Selma Highway, Montgomery AL 36108 USA PH: +1.334.386.5400 (option 2) FAX: +1.334.386.5450 WEB: www.hartzell.aero P a g e | 39...
  • Page 41 Terminal 2 (#7) See 11.4.3: Ignition. YES voltage YES air flow Fuel smell: Terminal 3 (#8) YES voltage YES fuel smell 2900 Selma Highway, Montgomery AL 36108 USA PH: +1.334.386.5400 (option 2) FAX: +1.334.386.5450 WEB: www.hartzell.aero P a g e | 40...
  • Page 42 However, final adjustment can be made upon final installation of the heater. 2900 Selma Highway, Montgomery AL 36108 USA PH: +1.334.386.5400 (option 2) FAX: +1.334.386.5450 WEB: www.hartzell.aero P a g e | 41...
  • Page 43 2900 Selma Highway, Montgomery AL 36108 USA PH: +1.334.386.5400 (option 2) FAX: +1.334.386.5450 WEB: www.hartzell.aero P a g e | 42...
  • Page 44 VDC motor will draw 6-8 amps and 3-5 amps for 24 VDC. Life expectancy is 2000 hrs. minimum under normal operating conditions. 2900 Selma Highway, Montgomery AL 36108 USA PH: +1.334.386.5400 (option 2) FAX: +1.334.386.5450 WEB: www.hartzell.aero P a g e | 43...
  • Page 45 Repair or replace blower assembly. defective. 4. Obstruction in ventilating air Remove obstruction. system. 5. Overheat switch faulty. Replace. Not adjustable. 2900 Selma Highway, Montgomery AL 36108 USA PH: +1.334.386.5400 (option 2) FAX: +1.334.386.5450 WEB: www.hartzell.aero P a g e | 44...
  • Page 46 Heater fails to shut off. Defective control components Adjust or replace defective controls. in external control circuits. 2900 Selma Highway, Montgomery AL 36108 USA PH: +1.334.386.5400 (option 2) FAX: +1.334.386.5450 WEB: www.hartzell.aero P a g e | 45...
  • Page 47 MM10001 Dated 1/1/08 Rev L dated 5/21/15 12. FIGURES FOR REFERANCE 2900 Selma Highway, Montgomery AL 36108 USA PH: +1.334.386.5400 (option 2) FAX: +1.334.386.5450 WEB: www.hartzell.aero P a g e | 46...
  • Page 48 REGULATOR SUPPLY INFLATED SUPPLY 60-80 PSI OF PRESSURE GAUGE 0-150 PSI FIGURE 26B: TYPICAL TEST SET-UP PRESSURE DECAY TEST 2900 Selma Highway, Montgomery AL 36108 USA PH: +1.334.386.5400 (option 2) FAX: +1.334.386.5450 WEB: www.hartzell.aero P a g e | 47...
  • Page 49 TO CLOSE AT 0.5 + -0.1 INCHES OF WATER FIGURE 27A: COMBUSTION AIR SWITCH TESTING FIGURE 27B: COMBUSTION AIR SWITCH INSTALLATION 2900 Selma Highway, Montgomery AL 36108 USA PH: +1.334.386.5400 (option 2) FAX: +1.334.386.5450 WEB: www.hartzell.aero P a g e | 48...
  • Page 50 SUPPLY LINE, LEFT SIDE PDT FIGURE 28A: TYPICAL EXHAUST TUBE SEAL SHOWN INSTALLED FIGURE 28B: TYPICAL EXHAUST TUBE SEAL SHOWN INSTALLED 2900 Selma Highway, Montgomery AL 36108 USA PH: +1.334.386.5400 (option 2) FAX: +1.334.386.5450 WEB: www.hartzell.aero P a g e | 49...
  • Page 51 15-20 ft. lbs. at plug and 12-15 ft. lbs. at ignition unit. FIGURE 29B FIGURE 29C 2900 Selma Highway, Montgomery AL 36108 USA PH: +1.334.386.5400 (option 2) FAX: +1.334.386.5450 WEB: www.hartzell.aero P a g e | 50...
  • Page 52 MM10001 Dated 1/1/08 Rev L dated 5/21/15 2900 Selma Highway, Montgomery AL 36108 USA PH: +1.334.386.5400 (option 2) FAX: +1.334.386.5450 WEB: www.hartzell.aero P a g e | 51...
  • Page 53 FIGURE 31C: TYPICAL WIRING SCHEMATIC: PRESSURIZED HEATER APPLIES TO S/N 1942 AND UP. FOR EARLIER S/N’S REFER TO FIGURE 31B 2900 Selma Highway, Montgomery AL 36108 USA PH: +1.334.386.5400 (option 2) FAX: +1.334.386.5450 WEB: www.hartzell.aero P a g e | 52...
  • Page 54 THERMOSTAT AIR BLOWER VENT BLOWER OVERHEAT FUEL PUMP (OPT) WARNING &/OR SHUTOFF (OPT) 21528 HEATER HOBBS (OPT) FIGURE 32 2900 Selma Highway, Montgomery AL 36108 USA PH: +1.334.386.5400 (option 2) FAX: +1.334.386.5450 WEB: www.hartzell.aero P a g e | 53...
  • Page 55 FIGURE 36 FIGURE 37 FIGURE 38 FIGURE 39 This thermostat sensor is used with the previous controls. P/N CD21253 Thermostat 2900 Selma Highway, Montgomery AL 36108 USA PH: +1.334.386.5400 (option 2) FAX: +1.334.386.5450 WEB: www.hartzell.aero P a g e | 54...
  • Page 56 P/N CD20800 Series Regulator – Mechanical Bypass Regulator - Electrical FIGURE 42 FIGURE 43 P/N CD29127 - Fuel Train FIGURE 44 2900 Selma Highway, Montgomery AL 36108 USA PH: +1.334.386.5400 (option 2) FAX: +1.334.386.5450 WEB: www.hartzell.aero P a g e | 55...

This manual is also suitable for:

Cd25kCd35kCd45kCd50kCd55kCd70k