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Diamond Aircraft DV 20 KATANA, Maintenance Manual

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AIRCRAFT

DV 20 KATANA AMM

Record of Revision

Doc # 4.02.02

Rev. 13

ROR

Page ix

15 Dec 2018

2. Record of Incorporated Temporary Revisions

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The following Temporary Revisions are incorporated into the DV 20 KANTANA AMM by Revision 13:

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Temporary Revision Number

Description of Temporary Revision

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AMM-TR-MÄM-20-252/a&442

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Airframe Life Limit

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AMM-TR-MÄM-20-259

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Alteration of Coolant

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AMM-TR-MÄM-20-323/a

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Drain Holes Inspection Checklist

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AMM-TR-MÄM-20-357

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Life Limited Parts

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AMM-TR-MÄM-20-390

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Spark Plug Replacement

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AMM-TR-MÄM-20-405

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Change from CHT to Coolant Temperature Measurement

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AMM-TR-MÄM-20-422

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Wheel Inflation Pressure

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AMM-TR-OÄM-20-244&245

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Instrument Panel Version D20-3110-00-00 and

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External Alternator 

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AMM-TR-OÄM-20-249

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Garmin SL 30 COM/NAV

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AMM-TR-OÄM-20-253

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Preparation for installation of a portable Garmin

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GPS (GPSMAP 196/296/396/496)

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AMM-TR-OÄM-20-266

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 New Oil Pressure Indicator

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AMM-TR-OÄM-20-267

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Provisions for NVFR

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Summary of Contents for DV 20 KATANA

Page 1: ...AIRCRAFT DV 20 KATANA AIRPLANE MAINTENANCE MANUAL Copyright by DIAMOND AIRCRAFT INDUSTRIES Wiener Neustadt Austria...

Page 2: ...in whole or part are reserved Diamond Aircraft Industries GmbH N A Otto Str 5 A 2700 Wiener Neustadt Austria Phone 43 2622 26700 Fax 43 2622 26780 E mail office diamond air at The technical informati...

Page 3: ...Intervals 06 00 Dimensions and Areas 07 00 Lifting and Shoring 08 00 Leveling and Weighing 09 00 Towing and Taxiing 10 00 Parking and Mooring 11 00 Required Placards 12 00 Servicing EQUIPMENT 20 00 St...

Page 4: ...ge ii 15 Dec 2018 CONTENTS Doc 4 02 02 Rev 13 Chapter Title PROPELLER 61 00 Propeller ENGINE 71 00 Power Plant Engine 75 00 Liquid Cooling 76 00 Engine Controls 77 00 Engine Indicating 78 00 Exhaust 7...

Page 5: ...the affected pages of the revision into the AMM as soon as you get them Remove and destroy the pages which are superseded Complete the table below when you have put the revision in the AMM Revision Nu...

Page 6: ...94 04 1 thru 04 2 04 00 1 04 10 1 05 2 05 00 1 05 10 1 thru 05 10 2 05 20 1 thru 05 20 16b 05 40 1 thru 05 40 3 07 2 07 00 1 07 10 1 07 20 1 27 10 1 thru 27 10 2 27 10 4 thru 27 10 10 27 20 00 1 27 20...

Page 7: ...20 12a 05 20 13a 24 2 24 31 5 thru 24 31 8 Rev No 5 SB 20 17 Mar 1995 01 7 05 2 05 20 9a 05 21 1 thru 05 21 2 05 21 3a b thru 05 21 16a b 11 2 11 11 1 thru 11 11 8 12 2 12 21 1 thru 12 21 2 Rev No 6...

Page 8: ...21 06 00 08 00 09 00 10 30 11 10 11 11 12 10 12 20 12 21 20 00 21 20 24 30 24 31 25 10 27 10 27 20 30 27 50 28 00 28 10 28 20 28 40 32 10 32 20 32 40 34 12 34 50 51 10 55 10 C 3 3 thru 5 1 1 6a 7b 8a...

Page 9: ...0 61 00 71 20 76 10 92 2 thru 4 1 thru 6 1 2 5 2 wiring diagrams amended as marked on page 2 Rev No 8 May 1997 05 20 05 21 10 30 51 10 D 5 6b 12b 13a 14b 1 6b 13a 14b 1 15 Rev No 9 Jan 1999 03 00 05 1...

Page 10: ...ROR Doc 4 02 02 Rev 13 Rev No 10 Jul 1999 03 00 05 10 05 20 05 21 11 10 11 11 12 10 28 00 61 00 71 00 75 10 77 00 D 4 5 1 5 6a thru 9a 14b 5 6a thru 9a 14b 8 8 2 2a 5 6 1 1 6 2 3 3a 5 1 1 2 6 Rev No...

Page 11: ...of Coolant AMM TR M M 20 323 a Drain Holes Inspection Checklist AMM TR M M 20 357 Life Limited Parts AMM TR M M 20 390 Spark Plug Replacement AMM TR M M 20 405 Change from CHT to Coolant Temperature...

Page 12: ...AIRCRAFT Record of Revision DV 20 KATANA AMM Page x 15 Dec 2018 ROR Doc 4 02 02 Rev 13 Intentionally left blank...

Page 13: ...AIRCRAFT DV 20 KATANA AMM Introduction Doc 4 02 02 Rev 13 01 TITLE Page 1 15 Dec 2018 CHAPTER 01 INTRODUCTION...

Page 14: ...AIRCRAFT Introduction DV 20 KATANA AMM Page 2 15 Dec 2018 01 TITLE Doc 4 02 02 Rev 13 Intentionally left blank...

Page 15: ...AIRCRAFT DV 20 KATANA AMM Introduction Doc 4 02 02 Rev 13 01 CONTENTS Page 1 15 Dec 2018 TABLE OF CONTENTS CHAPTER 01 INTRODUCTION 1 General 1 2 Layout of this Manual 2...

Page 16: ...AIRCRAFT Introduction DV 20 KATANA AMM Page 2 15 Dec 2018 01 CONTENTS Doc 4 02 02 Rev 13 Intentionally left blank...

Page 17: ...omponents For the electric system only such diagrams are shown in the manual which are of importance for understanding of the task Maintenance work repairs and inspections must be performed in accorda...

Page 18: ...OT FOLLOW THE INSTRUCTIONS Note A Note tells the person doing the maintenance how to make the task easier 2 Layout of this Manual The layout of the Maintenance Manual in general is in accordance with...

Page 19: ...ly the instrument locations are described A detailed description of each instrument is given with each of the system descriptions e g flaps position indicator in chapter 27 etc 3 MAIN GROUP 04 AIRFRAM...

Page 20: ...zation of the Maintenance Manual and guarantees a problem free integration of any new or revised pages The description of each system is kept straight forward which leaves the third group free for the...

Page 21: ...chapter in which they are presented The numbering will start with 1 for each section and will be continued throughout this section F Record of Revisions A Record of Revisions is located in the front s...

Page 22: ...AIRCRAFT Introduction DV 20 KATANA AMM Page 6 15 Dec 2018 01 00 00 Doc 4 02 02 Rev 13 Intentionally left blank...

Page 23: ...AIRCRAFT DV 20 KATANA AMM Manual Organization Doc 4 02 02 Rev 13 02 TITLE Page 1 15 Dec 2018 CHAPTER 02 ORGANIZATION AND HANDLING OF THE MAINTENANCE MANUAL...

Page 24: ...AIRCRAFT Manual Organization DV 20 KATANA AMM Page 2 15 Dec 2018 02 TITLE Doc 4 02 02 Rev 13 Intentionally left blank...

Page 25: ...c 4 02 02 Rev 13 02 CONTENTS Page 1 15 Dec 2018 TABLE OF CONTENTS CHAPTER 02 ORGANIZATION AND HANDLING OF THE MAINTENANCE MANUAL 1 General 1 2 Revisions 1 3 Service Information 2 4 Concession Reports...

Page 26: ...AIRCRAFT Manual Organization DV 20 KATANA AMM Page 2 15 Dec 2018 02 CONTENTS Doc 4 02 02 Rev 13 Intentionally left blank...

Page 27: ...A Applicability Data applicable to a series of airplane is marked with an applicability note E g valid for S N 20067 to 20090 This shows that such information can be used for serial numbers 20067 thr...

Page 28: ...in the List of Service Bulletins page v vi 3 Service Information A Service Information tells the operator about permitted installations or provided information to installed or additional equipment It...

Page 29: ...AIRCRAFT DV 20 KATANA AMM General Description Doc 4 02 02 Rev 13 03 TITLE Page 1 15 Dec 2018 CHAPTER 03 GENERAL DESCRIPTION OF THE AIRPLANE...

Page 30: ...AIRCRAFT General Description DV 20 KATANA AMM Page 2 15 Dec 2018 03 TITLE Doc 4 02 02 Rev 13 Intentionally left blank...

Page 31: ...T DV 20 KATANA AMM General Description Doc 4 02 02 Rev 13 03 CONTENTS Page 1 15 Dec 2018 TABLE OF CONTENTS CHAPTER 03 GENERAL DESCRIPTION OF THE AIRPLANE 1 General 1 2 Description 1 3 Vendor Documenta...

Page 32: ...AIRCRAFT General Description DV 20 KATANA AMM Page 2 15 Dec 2018 03 CONTENTS Doc 4 02 02 Rev 13 Intentionally left blank...

Page 33: ...sures a generous all around view The cantilever wing is a semimonocoque sandwich construction and has a trapezoidal shape It incorporates an I shaped spar with caps constructed of carbon fiber rovings...

Page 34: ...AIRCRAFT General Description DV 20 KATANA AMM Page 2 15 Dec 2018 03 00 00 Doc 4 02 02 Rev 13 7165 1750 2650 10780 1900 80 2100 Figure 1 Three view Drawing Dimensions in Millimeters...

Page 35: ...o the constant speed two bladed propeller Hoffmann HO V72F S170DW Hoffmann HO V352F 170FQ Hoffmann HO V352F C170FQ or mt Propeller MTV 21 A 175 05 using a reduction transmission The propeller blades a...

Page 36: ...Q Supplier Hoffmann Propeller address see above Available Manuals Operation Maintenance Manual No E540 Overhaul Manual No E569 Propeller mt Propeller MTV 21 A 175 05 Supplier mt Propeller Airport Stra...

Page 37: ...AIRCRAFT DV 20 KATANA AMM Airworthiness Limitations Doc 4 02 02 Rev 13 04 TITLE Page 1 15 Dec 2018 CHAPTER 04 AIRWORTHINESS LIMITATIONS...

Page 38: ...AIRCRAFT Airworthiness Limitations DV 20 KATANA AMM Page 2 15 Dec 2018 04 TITLE Doc 4 02 02 Rev 13 Intentionally left blank...

Page 39: ...S Page 1 15 Dec 2018 TABLE OF CONTENTS CHAPTER 04 AIRWORTHINESS LIMITATIONS 1 Paint Finish 3 2 Registration Markings and Warning Marks 3 Section 04 10 TIME LIMITS 1 Time Limit for Airframe 1 2 Removed...

Page 40: ...AIRCRAFT Airworthiness Limitations DV 20 KATANA AMM Page 2 15 Dec 2018 04 CONTENTS Doc 4 02 02 Rev 13 Intentionally left blank...

Page 41: ...IFIES THE AIRWORTHINESS LIMITATIONS REQUIRED BY JAR VLA THIS AIRPLANE MAINTENANCE MANUAL CHAPTER 04 AIRWORTHINESS LIMITATIONS IS APPROVED WITH EASA APPROVAL NO 0010053079 AND 10065523 AND 10069516 THE...

Page 42: ...AIRCRAFT Airworthiness Limitations DV 20 KATANA AMM Page 2 15 Dec 2018 04 00 00 Doc 4 02 02 Rev 13 Intentionally left blank...

Page 43: ...ation Markings and Warning Marks Registration markings and warning marks are subject to the following restrictions see Fig 1 Zone I No registration markings or warning marks may be applied here Zone I...

Page 44: ...AIRCRAFT Airworthiness Limitations DV 20 KATANA AMM Page 4 15 Dec 2018 04 00 00 Doc 4 02 02 Rev 13 Zone I Zone II Zone III Figure 1 Paint Color Scheme...

Page 45: ...AIRCRAFT DV 20 KATANA AMM Airworthiness Limitations Doc 4 02 02 Rev 13 04 10 00 Page 1 15 Dec 2018 Section 04 10 TIME LIMITS 1 Time Limit for Airframe There is no structural lifetime limit 2 Removed...

Page 46: ...AIRCRAFT Airworthiness Limitations DV 20 KATANA AMM Page 2 15 Dec 2018 04 10 00 Doc 4 02 02 Rev 13 Intentionally left blank...

Page 47: ...ge 1 15 Dec 2018 Section 04 20 MAJOR STRUCTURAL INSPECTIONS 1 Recurrent Structural Inspection The Major Structural Inspection must be carried out at 6000 hours 12000 hours and every 4000 hours thereaf...

Page 48: ...AIRCRAFT Airworthiness Limitations DV 20 KATANA AMM Page 2 15 Dec 2018 04 20 00 Doc 4 02 02 Rev 13 Intentionally left blank...

Page 49: ...AIRCRAFT DV 20 KATANA AMM Time Limits Maintenance Checks Doc 4 02 02 Rev 13 05 TITLE Page 1 15 Dec 2018 CHAPTER 05 TIME LIMITS MAINTENANCE CHECKS INSPECTION INTERVALS...

Page 50: ...AIRCRAFT Time Limits Maintenance Checks DV 20 KATANA AMM Page 2 15 Dec 2018 05 TITLE Doc 4 02 02 Rev 13 Intentionally left blank...

Page 51: ...1 2 Removed 1 3 Time Limits for Parts 2 Section 05 20 Scheduled Maintenance Checks 1 General 1 2 Drain Holes Inspection Checklist 2 3 100 200 and 1000 Hour Inspection Checklist 10 4 Major Structural...

Page 52: ...DV 20 KATANA AMM Page 2 15 Dec 2018 05 CONTENTS Doc 4 02 02 Rev 13 Section 05 30 GENERAL INSPECTIONS 1 General 1 2 Preflight Inspection 1 3 Postflight Inspection 1 Section 05 40 UNSCHEDULED INSPECTIO...

Page 53: ...o time the time intervals could be changed as new experiences are constantly evaluated Information with regard to any such changes will be issued through the revision service In the event that the usa...

Page 54: ...og AWBPC0001 Cleveland Parker Cleveland Parker Technician s Service Guide AWBTSG0001 Goodyear Aircraft Tire Care Maintenance Hoffmann Propeller Instruction Manual No 243 for installing and Operating C...

Page 55: ...ine Governor MT P 850 12 in accordance with applicable documents of manufacturer e g SB Propeller HO V72F S170DW in accordance with applicable documents of manufacturer e g SB Propeller HO V352F C 170...

Page 56: ...hever comes first Coolant hoses 5 years Carburetor membranes 5 years Carburetor vent hoses 5 years Elastomer fittings between intake manifolds and carburetors 5 years Hoses between airbox and carburet...

Page 57: ...uled maintenance checks which are necessary to maintain the airplane in a good technical condition Do the scheduled maintenance at the intervals and within the tolerances shown below Scheduled Mainten...

Page 58: ...AIRCRAFT Time Limits Maintenance Checks DV 20 KATANA AMM Page 4 15 Dec 2018 05 10 00 Doc 4 02 02 Rev 13 Intentionally left blank...

Page 59: ...ue refer to Chapter 20 00 page 2 B Airplanes Serviced in Accordance with FAR 91 The 100 hour inspection checklist shall be accomplished for the 100 Hour and Annual Inspections required by FAR 91 The 2...

Page 60: ...s 1 FUSELAGE 1 01 Front side of fuselage shell in corner of hat profile LH and RH 200 1 02 Footwell LH and RH 200 1 03 Fuselage shell in corner of middle console rear RH 200 1 04 Fuselage shell behind...

Page 61: ...er shell in front of trailing edge near the center LH and RH 100 5 ELEVATOR TRIM TAB 5 01 Lower shell leading edge section near center LH and RH 100 6 RUDDER 6 01 Close to center and lower edge LH and...

Page 62: ...oc 4 02 02 Rev 13 100 Hours Check 200 Hours Check 1000 Hours Check X X X Horizontal Drainage Hole Vertical Drainage Hole Exterior Drainage Hole Drainage Hole Inside the Structure 1 02 1 01 1 03 1 04 1...

Page 63: ...20 00 Page 5 15 Dec 2018 1 02 1 01 1 02 1 01 1 03 1 06 1 07 1 04 1 06 1 08 100 Hours Check 200 Hours Check 1000 Hours Check X X X Horizontal Drainage Hole Vertical Drainage Hole Exterior Drainage Hol...

Page 64: ...c 2018 05 20 00 Doc 4 02 02 Rev 13 2 01 2 02 2 03 2 01 2 02 2 03 2 01 2 02 2 03 100 Hours Check 200 Hours Check 1000 Hours Check X X X Horizontal Drainage Hole Vertical Drainage Hole Exterior Drainage...

Page 65: ...15 Dec 2018 3 01 3 01 3 02 3 02 3 03 4 01 4 01 5 01 5 01 100 Hours Check 200 Hours Check 1000 Hours Check X X X Horizontal Drainage Hole Vertical Drainage Hole Exterior Drainage Hole Drainage Hole Ins...

Page 66: ...age 8 15 Dec 2018 05 20 00 Doc 4 02 02 Rev 13 6 01 A 6 01 6 01 View A 100 Hours Check 200 Hours Check 1000 Hours Check X X X Horizontal Drainage Hole Vertical Drainage Hole Exterior Drainage Hole Drai...

Page 67: ...15 Dec 2018 Figure 6 Drain Holes Wings Flaps and Ailerons 8 01 7 04 Drain Hole in Flap Drain Hole in Flap Stop 7 02 9 01 7 01 100 Hours Check 200 Hours Check 1000 Hours Check X X X Horizontal Drainage...

Page 68: ...asterisk must be performed at these intervals on U S Canadian and Russian registered airplanes All items performed must be signed by the airplane maintenance engineer Completion of the properly perfor...

Page 69: ...ngine operating hours TSN TSO _________________ Scope 100 200 1000 _________________ Airplane operating hours _________________ Flight Hours Inspection Items 100 200 1000 Initials PRIOR TO INSPECTION...

Page 70: ...H 1 Check oil level according to ROTAX Engine Maintenance Manual EMM Chapter 12 00 X X X 2 Run engine until oil temp has reached 40 C check engine instruments for abnormal operation see EMM Chapter 12...

Page 71: ...gine maintenance manual EMM latest revision Refer to Section 05 00 X X X 3 If control light for coolant qty is installed Check for improper operation See Chap 77 00 X X X 4 Check cooling system for lo...

Page 72: ...engine mount for cracks deformation heat damage corrosion missing fasteners and safetying devices check shock mounts for poor condition X X X 15 Check electrical system for heat damage corrosion and...

Page 73: ...h connection sleeves X X 24 Check firewall breaches for leaks and insecure attachment of clamps and missing sealant X X X 25 Check fire resistant hoses for poor condition check fuel lines for improper...

Page 74: ...02 Rev 13 32 Check all bowden cables for insecure condition interference and lack of operating clearance lubricate Check clamp straps for looseness Throttle o Carburetor Heat o Cabin Heat o Choke o Pr...

Page 75: ...rating fluids used Type and quantity Oil ____________________________________ Coolant ____________________________________ Misc ____________________________________ Parts Replaced ____________________...

Page 76: ...AUSE INJURY OR DEATH WARNING YOU MUST MAKE SURE THAT THE ENGINE IS SAFE BEFORE YOU TURN THE PROPELLER 1 Remove spinner check spinner and spinner mount for cracks dents and run out X X X 2 Do inspectio...

Page 77: ...on X X X 7 Remove center console cover check elevator trim system for damage X X X 8 Check rudder control cables for chafing and broken strands in the adjustment range of the S guides and in the area...

Page 78: ...levator X X X 16 Check instrument markings X X X 17 Check flap position indicator for improper operation X X X 18 Check all switches and handles for missing placards in accordance with Maintenance Man...

Page 79: ...rough plexiglass windows for improper connection and improper safetying X X X 6 Check flaps and flap control mechanism in wings and fuselage for improper connection and improper safetying X X X 7 Chec...

Page 80: ...for radial play between spherical surface and wear If necessary replace it in accordance with Chapter 27 20 30 X 18 Examine upper rudder hinge pin If corrosion or grooves are detected or a diameter le...

Page 81: ...cts X X X 24 Check electrical system and ground straps for chafing check cable ties and all connectors by lightly pulling by hand X X X 25 Check Pitot head and antennas for insecure attachment check s...

Page 82: ...ng units of B bolts for improper operation locking devices must catch perceptibly every 60 X X X 33 Check pins of flap synchronizing tube assembly for looseness X X 34 Install wings apply adhesive tap...

Page 83: ...ngs check fairing mounts for cracks X X X 2 Check main landing gear for cracks unusual deformation and damage X X X 3 Measure the maximum deflection X of the unloaded main gear struts Lay a straight r...

Page 84: ...amine outboard main landing gear attachment bolts items 14 16 and replace nuts Examine main landing gear bracket attachment screws items 26 29 for corrosion and poor condition replace if necessary Ret...

Page 85: ...ssy for damage tighten if necessary X X X 15 Check nose wheel fork for play and friction with nose wheel off the ground 3 5 daN 6 75 11 25 lbs at axle X X 16 Remove nose landing gear fork Check vertic...

Page 86: ...4 Drain any water which may have accumulated in the Pitot and static system X X 5 Lubricate in accordance with Lubrication Schedule see Sub Chapter 12 20 X X X 6 Check for foreign objects and tools cl...

Page 87: ...ERAL Flight Hours Inspection Items 100 200 1000 Initials Doc 4 02 02 Rev 13 05 20 00 Page 29 15 Dec 2018 REMARKS The airplane is airworthy with respect to its maintenance condition Place _____________...

Page 88: ...ot Airdrome Date Take Off Landing Functional Check Flight Behavior Findings NO YES Fuel quantity indicator ACL navigation lights Warning and caution lights Altimeter QNH adjustment Radio radio check N...

Page 89: ...ed indicator Compass Behavior during climb Cylinder head temperature Coolant temperature Oil temperature Cabin heat cabin air Behavior during high speed flight Trim trim range Behavior during slow spe...

Page 90: ...airframe Legend T Tap Test V Visual Inspection F Functional or Fit Check NOTE Where the inspection method indicated in the following tables is followed by the symbol T perform a tap test if visual in...

Page 91: ...ank attached to rearward transverse stiffener item 3 S Push rod in center console item 4 S Bell crank attached to sickle shaped bulkhead item 5 S Aileron push rods connected to aileron pockets item 6...

Page 92: ...fin item 6 Elevator trim S Trim lever item 1 S Trim Bowden cable examine for elongation item 2 S Actuating lever Flaps S Flaps actuator S Bell crank assembly S Push rods S Pockets S Synchro tube S For...

Page 93: ...ear of bearing V F Left Wing Spar Stump 6 Laminate cracks delamination V 7 Main bolt bushing in spar web V F Left Wing Main Spar 8 Main spar bonding with wing skins cracks delamination V T 9 Main spar...

Page 94: ...rnal Ribs 20 Laminate cracks delamination V 21 Bellcrank brackets cracks elongation of bellcrank mounting holes corrosion paint and delamination and disbond between bracket and rib V 22 Guide rollers...

Page 95: ...edge bond disbonds cracks above or below overlap seam V T 15 Remove tie down ring and inspect for delamination cracks elongation of hole V Right Wing Trailing Edge Spar 16 Laminate resin erosion witho...

Page 96: ...f T panel to floor panel and fuselage skin V T Bulkheads Webs Ribs in Vertical Stabilizer 6 Laminate delamination cracks particularly around access holes V 7 Internal composite components look through...

Page 97: ...sion of bracket disbond from or delamination in surrounding laminate V Firewall 24 Laminate when viewed from cockpit side cracks and delamination particularly around engine mount fastener holes batter...

Page 98: ...nspection Items HS Skins 1 Delamination cracks dents scratches V T 2 Paint chips scratches UV damage V 3 Damage to core or disbond between skin and core V T 4 Leading edge bond disbonds cracks above o...

Page 99: ...V 3 Core and laminate cracks damage delamination to skin V T 4 Ribs bonding with skins V T 5 Laminate around hinges and control horn fasteners cracks delamination V 6 Replace all bronze coated bushing...

Page 100: ...n T 23 Hinges cracks corrosion disbond from leading edge tightness of fasteners fit of pin condition of sliding surface on plain bearing V F 24 Both intermediate elevator bearings corrosion wear and e...

Page 101: ...ical records to ensure mass and static moment are within specified limits Chapter 06 00 V F G After Assembly GENERAL AFTER ASSEMBLY Inspection Method Initials Inspection Items 1 Control surface adjust...

Page 102: ...AIRCRAFT Time Limits Maintenance Checks DV 20 KATANA AMM Page 44 15 Dec 2018 05 20 00 Doc 4 02 02 Rev 13 Intentionally left blank...

Page 103: ...Betriebshandbuch f r den ROTAX 912 A3 S3 Motor und in den Technischen Mitteilungen enthalten Zus tzliche Hinweise f r die Wartung des Propellers finden sich im Propellerhandbuch Bei jeder Kontrolle si...

Page 104: ...iste zur berpr fung der Entw sserungsbohrungen Ref Position der Entw sserungsbohrungen Stunden Initialen 1 RUMPF 1 01 Vorderseite der Rumpfschale in Ecke des Hutprofils LH und RH 200 1 02 Fu raum LH u...

Page 105: ...R 4 01 In der Unterschale vor der Hinterkante nahe der Mitte LH und RH 100 5 H HENRUDERTRIMMUNG 5 01 In der Unterschale an der Profilnase nahe der Mitte LH und RH 100 6 SEITENRUDER 6 01 Am tiefsten Pu...

Page 106: ...Alle von der ausf hrenden Person erledigten Arbeiten m ssen Punkt f r Punkt abgezeichnet werden Die ordnungsgem e Durchf hrung der Kontrolle ist im Bordbuch zu bescheinigen Beanstandungen und Ma nahme...

Page 107: ...Motorbetriebszeit TSN TSO _________________ Kontrollumfang 100 200 1000 _________________ Flugzeug Betriebszeit _________________ Flugstunden Wartungsarbeiten 100 200 1000 Wart VOR DER KONTROLLE Luftt...

Page 108: ...kontrollieren gem Wartungshandbuch f r Rotax Motor MHB Kapitel 12 00 X X X 2 ltemperatur auf 40 Grad erw rmen lassen Triebwerks instrumente auf abnormales Verhalten kontrollieren siehe MHB Kapitel 12...

Page 109: ...CH DIGEN 1 Obere und untere Cowling abnehmen auf Risse berhitzte Stellen Verformungen lose oder fehlende Verschl sse kontrollieren Verschmutze Cowling reinigen X X X 2 Motorwartung in bereinstimmung m...

Page 110: ...X 9 Vorw rmklappen auf lockeren Sitz und Fehlfunktion kontrollieren X X X 10 Rippen des lk hlers reinigen und auf Besch digung und Leckage kontrollieren X X X 11 lk hler auf mangelhaften Sitz und Halt...

Page 111: ...X X X 16 Starter Relais und Z ndboxen auf mangelhafte Befestigung kontrollieren X X X 17 Durchgangspr fung Continuity Check lt Kapitel 24 31 durchf hren X 18 Kabinenheizungsschlauch Vergaseransaug un...

Page 112: ...Stellen und lose Anschl sse kontrollieren Kraftstoffleitungen auf Verh rtung durch Hitze und Porosit t kontrollieren X X X 26 Filter der elektrischen Kraftstoffpumpe reinigen Pumpendeckel schlie en u...

Page 113: ...Alle Bet tigungsz ge auf unsicheren Zustand Schwerg ngigkeit und Blockierung kontrollieren und schmieren Klemmnippel auf losen Sitz kontrollieren Gas o Vergaservorw rmung o Heizung o Choke o Propeller...

Page 114: ...iebsmittel Sorte und ggf Menge l ____________________________________ K hlmittel ___________________________________ Sonstige ____________________________________ Ausgetauschte Teile _________________...

Page 115: ...R DER PROPELLER GEDREHT WIRD Wartungsarbeiten 100 200 1000 Wart 1 Spinner entfernen Spinner und Spinnertr ger auf Risse Beulen und Schlag kontrollieren X X X 2 Die Inspektion in bereinstimmung mit dem...

Page 116: ...X X 7 Mitteltunneldeckel entfernen und Trimmung im Mitteltunnel auf Sch den kontrollieren X X X 8 Steuerseile im Verstellbereich der S F hrungen und im Bereich der Umlenkrollen und Durchf hrungen auf...

Page 117: ...alsche Markierungen pr fen X X X 17 Klappenanzeige auf fehlerhafte Funktion kontrollieren X X X 18 Bediengriffe auf fehlende oder falsche Beschriftung und Kennzeichnung laut Kapitel 11 11 kontrolliere...

Page 118: ...X X 5 Querruderantrieb im Fl gel durch Plexiglasscheibe auf falschen Anschluss und schadhafte Sicherung kontrollieren X X X 6 Landeklappen und LK Mechanismus in Fl geln und Rumpf auf falschen Anschlu...

Page 119: ...Scheuerstellen an Rollenf hrungen kontrollieren X 15 Heckfinne demontieren Hintere Rumpfspanten auf Besch digung kontrollieren Schmutz entfernen X 16 Aufh ngung des Seitenruders und Anschluss der Steu...

Page 120: ...X 21 Tank ausbauen Auf Besch digung und Korrosion pr fen Kraftstoffsieb ausbauen und reinigen Nach Einbau des Tanks Tankanzeige kalibrieren X 22 Deckel hinter Gep ckfach entfernen Rumpfr hre auf Verf...

Page 121: ...Risse Besch digung und lose Verbindungen pr fen X X 30 Querruder Sto stangen ausbauen auf Scheuerstellen bei Rollenf hrungen berpr fen X 31 Querruderantrieb und Landeklappenantrieb an der Wurzelrippe...

Page 122: ...en auf Risse kontrollieren X X X 2 Hauptfahrwerk auf Risse ungew hnliche Verformungen Besch digungen kontrollieren X X X 3 Maximalen Spalt X der unbelasteten Hauptfahrwerksstrebe messen geraden Stab g...

Page 123: ...g 0 1 mm bersteigt den Bolzen ersetzen Die au enseitigen Befestigungsbolzen des Hauptfahrwerks Bauteile 14 16 kontrollieren und Bolzenmuttern ersetzen Die Befestigungsbolzen an den Klammern des Hauptf...

Page 124: ...ummifederpaket kontrollieren ggf Nachspannen siehe Kapitel 32 20 X X X 15 Bugradgabel auf Spiel und mangelnde Reibung im entlasteten Zustand kontrollieren 3 5 daN 6 75 11 25 lbs bei Achse X X 16 Bugra...

Page 125: ...lieren X 4 Pitot Statik System entw ssern X X 5 Gem Schmierplan schmieren siehe Kapitel 12 21 X X X 6 Fremdk rperkontrolle und Werkzeugkontrolle durchf hren alle ge ffneten Wartungs ffnungen wieder ve...

Page 126: ...AIRCRAFT Time Limits Maintenance Checks DV 20 KATANA AMM ALLGEMEINES Flugstunden Wartungsarbeiten 100 200 1000 Wart Page 24 15 Dec 2018 05 21 00 Doc 4 02 02 Rev 13 BEMERKUNGEN...

Page 127: ...Flugstunden Wartungsarbeiten 100 200 1000 Wart Doc 4 02 02 Rev 13 05 21 00 Page 25 15 Dec 2018 Das Luftfahrzeug ist in Bezug auf seine Wartung flugklar Ort ____________________ Datum ________________...

Page 128: ...gzeugf hrer Flugplatz Datum Startzeit Landezeit Funktionspr fungen Flugverhalten Beanstandungen nein ja Kraftstoffanzeige Zusammensto warnlicht Navigationsbeleuchtung Kontrolllampen H henmesser QNH Ei...

Page 129: ...21 00 Page 27 15 Dec 2018 Verhalten im Steigflug Zylinderkopf Temperatur K hlmittel Temperatur ltemperatur Heizung L ftung Verhalten im Schnellflug Trimmung Trimmbereich Verhalten im Langsamflug berz...

Page 130: ...ng F Funktionalit ts oder Passungspr fung ANMERKUNG Wenn die Inspektionsmethode in den folgenden Tabellen mit dem Symbol K erg nzt ist soll ein Klopf Test durchgef hrt werden wenn die Sichtpr fung Hin...

Page 131: ...o stange in der Mittelkonsole Bauteil 4 S Umlenkhebel am sichelf rmigen Spant Bauteil 5 S Die Querrudersto stangen die mit den Querrudertaschen verbunden sind Bauteil 6 S Querrudertaschen Bauteil 7 S...

Page 132: ...1 S Kabelz ge der Trimmung auf L ngung kontrollieren Bauteil 2 S Bet tigungshebel Landeklappen S Landeklappenbet tigungshebel S Umlenkhebelsystem S Sto stangen S Landeklappentaschen S Synchronisation...

Page 133: ...g des Lagers S F Linker Holmstumpf 6 Zustand der Faserverbundstruktur Risse Delaminaton S 7 Hauptbolzenbuchse im Holm S F Linker Hauptholm 8 Verklebung zwischen Hauptholm und Fl gelschale S K 9 Haupth...

Page 134: ...der Faserverbundstruktur Risse Delamination S 21 Umlenkhebelhalterung Risse Verschlei des Befestigungslochs Korrosion Delamination und Abl sung zwischen Halterung und Rippe S 22 Rollk fige im Fl gel...

Page 135: ...atzer S K 12 Lackierung berpr fen Abplatzer Kratzer und UV Sch den S 13 Zustand des Kerns Sch den Abl sung zwischen Kern und Decklage S K 14 Tragfl chenvorderkanten Verklebung Abl sung oder Risse ober...

Page 136: ...nstand Rumpfh lle inklusive Seitenflosse 1 Zustand der Faserverbundstruktur Delamination Risse Dellen und Kratzer S K 2 Zustand der Lackierung berpr fen Abplatzer Kratzer UV Sch den und feuerfeste Lac...

Page 137: ...hsen und alle Bundbuchsen am Trimmsystem ersetzen N A 13 Buchsen an der hinteren H henflossenbefestigung auf Korrosion Risse Delamination und Risse in der umliegenden Faserverbundstruktur kontrolliere...

Page 138: ...rahmens Risse im Dickharz siehe Kapitel 51 10 S 28 Boden Risse oder Delaminationen um die hinteren Ruderpedalhalterungen und der ffnung f r den Gashebelquadranten S 29 B Spant Risse und Delamination b...

Page 139: ...t fehlende Abdeckung durch Harz siehe Kapitel 51 10 S 7 Verklebung zwischen Hinterkante und Schalen Risse br chiger Schaumstoffstreifen siehe Kapitel 51 10 S K 8 H henruderscharniere Risse Korrosion u...

Page 140: ...rstellen dass die Massen und statischen Momente innerhalb der Limits sind Siehe Kapitel 06 00 S F 9 Scharniere und Steuerhorn Risse Korrosion Abl sung von der Schale lockeren Sitz des Lagerbolzen und...

Page 141: ...Buchsen und alle Bundbuchsen am H henruder und am Trimm Hilfsruder ersetzen N A 26 Steuerhorn Risse Korrosion Abl sung von der Schale lockeren Sitz lockeren Sitz des Lagerbolzen und fehlende Trimmgew...

Page 142: ...BSCHLIE ENDE ARBEITSSCHRITTE Inspektions Methode Wart Wartungsarbeiten 1 Steuerfl cheneinstellung berpr fen Siehe Kapitel 06 00 S F 2 Einen Test des elektrischen Potentialausgleichsystems durchf hren...

Page 143: ...the day to determine the general condition of the airplane and its engine Specific attention should be given to the preflight inspection because many accidents were caused by insufficient preflight in...

Page 144: ...AIRCRAFT Time Limits Maintenance Checks DV 20 KATANA AMM Page 2 15 Dec 2018 05 30 00 Doc 4 02 02 Rev 13 Intentionally left blank...

Page 145: ...eport use gliding sheets Check tires for cuts in side walls check brake system for damage 2 Condition of the complete nose wheel assembly must be checked cracks deformation Special attention must be g...

Page 146: ...8 05 40 00 Doc 4 02 02 Rev 13 B Sudden Engine Stoppage Prop Strike Refer to the ROTAX Operator s Manual and to Sub Chapter 71 00 Propeller Flange Check C Non Operation of More Than 30 Days With non op...

Page 147: ...AIRCRAFT DV 20 KATANA AMM Dimensions and Areas Doc 4 02 02 Rev 13 06 TITLE Page 1 15 Dec 2018 CHAPTER 06 DIMENSIONS AND AREAS...

Page 148: ...AIRCRAFT Dimensions and Areas DV 20 KATANA AMM Page 2 15 Dec 2018 06 TITLE Doc 4 02 02 Rev 13 Intentionally left blank...

Page 149: ...ev 13 06 CONTENTS Page 1 15 Dec 2018 TABLE OF CONTENTS CHAPTER 06 DIMENSIONS AND AREAS 1 General 1 2 Dimensions 3 3 Adjustment Values for Control Surfaces and Trim Adjustment Report 4 4 Control Surfac...

Page 150: ...AIRCRAFT Dimensions and Areas DV 20 KATANA AMM Page 2 15 Dec 2018 06 CONTENTS Doc 4 02 02 Rev 13 Intentionally left blank...

Page 151: ...06 DIMENSIONS AND AREAS 1 General Most dimensions in this chapter are metric The spans are measured parallel to their respective datum plane if not indicated otherwise Unit Conversions LENGTH mm inch...

Page 152: ...AIRCRAFT Dimensions and Areas DV 20 KATANA AMM Page 2 15 Dec 2018 06 00 00 Doc 4 02 02 Rev 13 7165 1750 2650 10780 1900 80 2100 Figure 1 Three View Drawing...

Page 153: ...mann FX63 137 20 HOAC Wing area 11 6 m 125 ft Mean aerodynamic chord MAC 1 09 m 42 9 in Aspect ratio 10 0 Dihedral 4 Sweep 1 Ailerons Area 0 658 m 7 08 ft Wing Flaps Area 1 236 m 13 3 ft Horizontal Ta...

Page 154: ...d The completed report is part of the Airplane Maintenance Log When the adjustment values are checked the report should be used to determine whether any deviations from the recorded measurements have...

Page 155: ...AIRCRAFT DV 20 KATANA AMM Dimensions and Areas Doc 4 02 02 Rev 13 06 00 00 Page 5 15 Dec 2018...

Page 156: ...FACES AND TRIM ADJUSTMENT REPORT on the previous pages Multiply kilograms kg by 2 2046 to obtain pounds lbs Multiply kg cm by 0 868 to obtain in lbs For the determination of residual moments the surfa...

Page 157: ...AIRCRAFT DV 20 KATANA AMM Lifting and Shoring Doc 4 02 02 Rev 13 07 TITLE Page 1 15 Dec 2018 CHAPTER 07 LIFTING AND SHORING...

Page 158: ...AIRCRAFT Lifting and Shoring DV 20 KATANA AMM Page 2 15 Dec 2018 07 TITLE Doc 4 02 02 Rev 13 Intentionally left blank...

Page 159: ...4 02 02 Rev 13 07 CONTENTS Page 1 15 Dec 2018 TABLE OF CONTENTS CHAPTER 07 LIFTING AND SHORING 1 General 1 2 Required Equipment 1 Section 07 10 LIFTING 1 General 1 Section 07 20 SHORING 1 General 1 2...

Page 160: ...AIRCRAFT Lifting and Shoring DV 20 KATANA AMM Page 2 15 Dec 2018 07 CONTENTS Doc 4 02 02 Rev 13 Intentionally left blank...

Page 161: ...ne The wings and elevator unit are removed and carried by hand The DV 20 KATANA has two jacking points To perform maintenance operations the fuselage may be placed on jacks The rear fuselage is suppor...

Page 162: ...AIRCRAFT Lifting and Shoring DV 20 KATANA AMM Page 2 15 Dec 2018 07 00 00 Doc 4 02 02 Rev 13 Intentionally left blank...

Page 163: ...RH Rearward Jacking Point Section 07 10 LIFTING 1 General No lifting equipment is required for installation and removal of the wings and elevator unit Belts are used to lift the fuselage The forward b...

Page 164: ...AIRCRAFT Lifting and Shoring DV 20 KATANA AMM Page 2 15 Dec 2018 07 10 00 Doc 4 02 02 Rev 13 Intentionally left blank...

Page 165: ...ng the Airplane The following must be observed when shoring the airplane Detail Steps Work Items Key Items References 1 If the airplane is shored outside is must be pointed into the wind CAUTION DO NO...

Page 166: ...AIRCRAFT Lifting and Shoring DV 20 KATANA AMM Page 2 15 Dec 2018 07 20 00 Doc 4 02 02 Rev 13 Intentionally left blank...

Page 167: ...AIRCRAFT DV 20 KATANA AMM Leveling and Weighing Doc 4 02 02 Rev 13 08 TITLE Page 1 15 Dec 2018 CHAPTER 08 LEVELING AND WEIGHING...

Page 168: ...AIRCRAFT Leveling and Weighing DV 20 KATANA AMM Page 2 15 Dec 2018 08 TITLE Doc 4 02 02 Rev 13 Intentionally left blank...

Page 169: ...KATANA AMM Leveling and Weighing Doc 4 02 02 Rev 13 08 CONTENTS Page 1 15 Dec 2018 TABLE OF CONTENTS CHAPTER 08 LEVELING AND WEIGHING 1 General 1 2 Leveling 1 3 Weighing 2 4 Permissible Empty Mass Wei...

Page 170: ...AIRCRAFT Leveling and Weighing DV 20 KATANA AMM Page 2 15 Dec 2018 08 CONTENTS Doc 4 02 02 Rev 13 Intentionally left blank...

Page 171: ...gravity must be re determined every time the airplane or its equipment is modified in a way that might influence its mass weight or center of gravity position Empty mass weight and corresponding cente...

Page 172: ...les When rolling the main wheels onto the scales ensure that the landing gear struts do not distort the scales which would result in inaccurate weighing The nose wheel must be aligned to the rear and...

Page 173: ...AIRCRAFT DV 20 KATANA AMM Leveling and Weighing Doc 4 02 02 Rev 13 08 00 00 Page 3 15 Dec 2018...

Page 174: ...pilot with 19 kg 42 lbs of fuel without exceeding the rearward CG limit according to the Airplane Flight Manual On the other hand two pilots weighing 86 kg 190 lbs each with only the unusable fuel ca...

Page 175: ...AIRCRAFT DV 20 KATANA AMM Towing and Taxiing Doc 4 02 02 Rev 13 09 TITLE Page 1 15 Dec 2018 CHAPTER 09 TOWING AND TAXIING...

Page 176: ...AIRCRAFT Towing and Taxiing DV 20 KATANA AMM Page 2 15 Dec 2018 09 TITLE Doc 4 02 02 Rev 13 Intentionally left blank...

Page 177: ...4 02 02 Rev 13 09 CONTENTS Page 1 15 Dec 2018 TABLE OF CONTENTS CHAPTER 09 TOWING AND TAXIING 1 General 1 2 Equipment and Accessories 1 Section 09 10 TOWING 1 General 1 2 Towing Procedures 1 Section...

Page 178: ...AIRCRAFT Towing and Taxiing DV 20 KATANA AMM Page 2 15 Dec 2018 09 CONTENTS Doc 4 02 02 Rev 13 Intentionally left blank...

Page 179: ...ng with a draw tongue or by taxiing To prevent damage to the airplane it is of great importance to familiarize oneself closely with the towing and taxiing procedures 2 Equipment and Accessories The DV...

Page 180: ...AIRCRAFT Towing and Taxiing DV 20 KATANA AMM Page 2 15 Dec 2018 09 00 00 Doc 4 02 02 Rev 13 Intentionally left blank...

Page 181: ...w 2 Towing Procedures A Towing without Tow Vehicle Normally the DV 20 KATANA is moved manually using the draw tongue The following procedure should be followed Detail Steps Work Items Key Items Refere...

Page 182: ...se parking brake 4 Remove chock blocks 5 Move airplane to desired position 6 Position chock blocks in front of main wheels 7 Remove draw tongue from airplane and tow vehicle 8 Set parking brake NOTE W...

Page 183: ...OL SURFACES In the case of reduced freedom to maneuver two people can turn the airplane about the main wheels One person must push down in front of the vertical stabilizer and turn the airplane while...

Page 184: ...AIRCRAFT Towing and Taxiing DV 20 KATANA AMM Page 4 15 Dec 2018 09 10 00 Doc 4 02 02 Rev 13 Intentionally left blank...

Page 185: ...pes and draw tongue if required 3 Set parking brake by pulling the parking brake lever and operating the foot brakes WARNING ENSURE THAT NO MAINTENANCE PERSONNEL OR OBSTRUCTIONS ARE IN THE IMMEDIATE A...

Page 186: ...tail Steps Work Items Key Items References Page 2 15 Dec 2018 09 20 00 Doc 4 02 02 Rev 13 7 Taxi the airplane to the desired position 8 Turn off engine See Airplane Flight Manual DV 20 KATANA 9 Park t...

Page 187: ...AIRCRAFT DV 20 KATANA AMM Parking and Mooring Doc 4 02 02 Rev 13 10 TITLE Page 1 15 Dec 2018 CHAPTER 10 PARKING AND MOORING...

Page 188: ...AIRCRAFT Parking and Mooring DV 20 KATANA AMM Page 2 15 Dec 2018 10 TITLE Doc 4 02 02 Rev 13 Intentionally left blank...

Page 189: ...15 Dec 2018 TABLE OF CONTENTS CHAPTER 10 PARKING AND MOORING 1 General 1 2 Equipment and Accessories 1 Section 10 10 PARKING 1 General 1 2 Short Term Parking 1 3 Long Term Parking 2 Section 10 20 MOOR...

Page 190: ...AIRCRAFT Parking and Mooring DV 20 KATANA AMM Page 2 15 Dec 2018 10 CONTENTS Doc 4 02 02 Rev 13 Intentionally left blank...

Page 191: ...rked or moored while not in use The pilot and maintenance personnel should thoroughly familiarize themselves with the procedures described in Chapters 10 10 and 10 20 2 Equipment and Accessories The f...

Page 192: ...AIRCRAFT Parking and Mooring DV 20 KATANA AMM Page 2 15 Dec 2018 10 00 00 Doc 4 02 02 Rev 13 Intentionally left blank...

Page 193: ...in headwind direction CAUTION DO NOT END THE TAXI OR TOW OPERATION WITH AN ANGLED NOSE WHEEL THE NOSE WHEEL MUST ALWAYS BE ALIGNED BEFORE THE AIRPLANE COMES TO STOP IN ORDER TO AVOID EXCESSIVE SIDE F...

Page 194: ...ed three to four revolutions Parked airplanes should be moved by pushing or towing To prevent flat spots and other deformations which may lead to irregular running or oscillations the wheels should be...

Page 195: ...each wing and one on the tail fin To moor the airplane proceed as follows Detail Steps Work Items Key Items References 1 Park the airplane See Chapter 10 10 2 Ensure that flaps are retracted 3 Screw m...

Page 196: ...AIRCRAFT Parking and Mooring DV 20 KATANA AMM Page 2 15 Dec 2018 10 20 00 Doc 4 02 02 Rev 13 Intentionally left blank...

Page 197: ...nding Gear No special procedures are required for the main and nose landing gear Wheels The wheels should be turned three to four revolutions to prevent corrosion Tires a Wipe tires with dry cloth and...

Page 198: ...15 Dec 2018 10 30 00 Doc 4 02 02 Rev 13 G Loose Equipment Collect loose equipment and store H Electronic Equipment No special procedure required I Airplane Ventilation Vent the airplane thoroughly be...

Page 199: ...AIRCRAFT DV 20 KATANA AMM Required Placards Doc 4 02 02 Rev 13 11 TITLE Page 1 15 Dec 2018 CHAPTER 11 REQUIRED PLACARDS...

Page 200: ...AIRCRAFT Required Placards DV 20 KATANA AMM Page 2 15 Dec 2018 11 TITLE Doc 4 02 02 Rev 13 Intentionally left blank...

Page 201: ...1 15 Dec 2018 TABLE OF CONTENTS CHAPTER 11 REQUIRED PLACARDS 1 General 1 2 Material 1 3 Removal and Installation 1 Section 11 10 LOCATION OF PLACARDS 1 General 1 Section 11 11 ANBRINGUNGSORTE DER HIN...

Page 202: ...AIRCRAFT Required Placards DV 20 KATANA AMM Page 2 15 Dec 2018 11 CONTENTS Doc 4 02 02 Rev 13 Intentionally left blank...

Page 203: ...nterior placards Placards with poor readability or other damage must be replaced 2 Material The material required to replace placards is listed in the following table Item Manufacturer Purpose Self ad...

Page 204: ...Foils Procedure Detail Steps Work Items Key Items References 1 Moisten foil and surface with soap water using a sponge 2 Press on new placard using plastic spatula 3 Remove protective film and let the...

Page 205: ...TION OF PLACARDS 1 General In addition to the fire proof identification plate the following placards are installed Easily visible in the cockpit S N s registered outside of North America S N s registe...

Page 206: ...ge 2 15 Dec 2018 11 10 00 Doc 4 02 02 Rev 13 Near the pilot s feet next to the fuel shut off valve partly colored red colored red On the left and right side wall on the air vents Under the instrument...

Page 207: ...equired Placards Doc 4 02 02 Rev 13 11 10 00 Page 3 15 Dec 2018 On the instrument panel next to the individual breakers switches and caution and warning lamps partly colored red The area marked gray i...

Page 208: ...18 11 10 00 Doc 4 02 02 Rev 13 On the instrument panel next to the individual breakers switches and caution and warning lamps if O M 20 244 O M 20 245 are installed On the instrument panel next to the...

Page 209: ...he canopy emergency release handles all colored red inside left inside right outside left 8 last two lines only if ELT is installed outside right Next to the ignition switch colored red CHECK before t...

Page 210: ...10 00 Doc 4 02 02 Rev 13 On the brake fluid reservoirs Next to main wheels Next to nose wheel On oil filler cap On lid in canopy inside colored red On coolant equalizing reservoir On coolant dispatche...

Page 211: ...Rev 13 11 10 00 Page 7 15 Dec 2018 On the instrument panel or within the pilot s field of vision Next to ELT if installed to indicate switch positions On fuselage upper skin behind cockpit only if EL...

Page 212: ...ents A Engine with Cylinder Temperature Senor If an engine without suffix 01 is installed use the following placards for ROTAX 912 A3 only for ROTAX 912 S3 only B Engine with Coolant Temperature Senso...

Page 213: ...5 Dec 2018 Section 11 11 ANBRINGUNGSORTE DER HINWEISSCHILDER UND BESCHRIFTUNGEN GERMAN VERSION OF CHAPTER 11 10 1 Allgemeines Es sind au er dem feuerfesten Typenschild noch folgende Schilder angebrach...

Page 214: ...TANA AMM Page 2 15 Dec 2018 11 11 00 Doc 4 02 02 Rev 13 Im linken Fu raum neben dem Brandhahn teilweise rot rot An der rechten und linken Bordwand auf der L ftungsd se Unter dem Instrumentenbrett nebe...

Page 215: ...KATANA AMM Required Placards Doc 4 02 02 Rev 13 11 11 00 Page 3 15 Dec 2018 Auf dem Instrumentenbrett neben den Sicherungen Schaltern und Kontrollampen teilweise rot Die grau markierte Fl che ist auf...

Page 216: ...15 Dec 2018 11 11 00 Doc 4 02 02 Rev 13 Auf dem Instrumentenbrett neben den Sicherungen Schaltern und Kontrolllampen wenn O M 20 244 O M 20 245 eingebaut sind Auf dem Instrumentenbrett neben den Sich...

Page 217: ...018 Auf der Mittelkonsole neben dem Trimmknopf Neben den Griffen f r den Haubennotabwurf alle rot innen links innen rechts au en links 8 untere zwei Zeilen nur falls ELT eingebaut ist au en rechts Neb...

Page 218: ...tutzen Auf den Bremsfl ssigkeitsbeh ltern Neben den Hauptfahrwerksr dern Neben dem Bugrad Auf dem ldeckel Auf dem Wartungsdeckel f r den ltank in der oberen Cowling Auf dem K hlfl ssigkeits Ausgleichs...

Page 219: ...13 11 11 00 Page 7 15 Dec 2018 Auf dem Instrumentenbrett oder im Sichtfeld des Piloten Neben dem ELT falls eingebaut zur Kennzeichnung der Schalterstellung Auf der Rumpfoberseite hinter dem Cockpit f...

Page 220: ...n A Motor mit Zylinderkopftemperatursensor Wenn ein Motor ohne Suffix 01 eingebaut ist werden die folgenden Placards verwendet nur f r ROTAX 912 A3 nur f r ROTAX 912 S3 B Motor mit K hlfl ssigkeitstem...

Page 221: ...AIRCRAFT DV 20 KATANA AMM Servicing Doc 4 02 02 Rev 13 12 TITLE Page 1 15 Dec 2018 CHAPTER 12 SERVICING...

Page 222: ...AIRCRAFT Servicing DV 20 KATANA AMM Page 2 15 Dec 2018 12 TITLE Doc 4 02 02 Rev 13 Intentionally left blank...

Page 223: ...12 SERVICING 1 General 1 Section 12 10 REPLENISHING 1 Fuel System 1 2 Oil System 2 3 Brake System 3 4 Tires 3 5 Battery 4 6 Cooling System 4 Section 12 20 SCHEDULED SERVICING 1 General 1 2 Lubrication...

Page 224: ...AFT Servicing DV 20 KATANA AMM Page 2 15 Dec 2018 12 CONTENTS Doc 4 02 02 Rev 13 Section 12 30 UNSCHEDULED SERVICING 1 Cleaning Exterior 1 2 Cleaning Interior 1 3 Engine Cleaning 2 4 Snow and Ice Remo...

Page 225: ...enishing and the periodic lubrication of component groups Other tasks which are performed during ground services are also described in this chapter Detailed procedures for preventive and corrective ma...

Page 226: ...AIRCRAFT Servicing DV 20 KATANA AMM Page 2 15 Dec 2018 12 00 00 Doc 4 02 02 Rev 13 Intentionally left blank...

Page 227: ...e following must be observed Airplane as well as fuel supply fuel truck filling station etc must be grounded ground connection on engine exhaust pipe Fire extinguisher must available All ground equipm...

Page 228: ...friction modifier additives are unsuitable as this could result in a slipping clutch during normal operation Heavy duty 4 stroke motor cycle oils meet all the requirements These oils are usually no mi...

Page 229: ...ification should be used CAUTION BRAKE FLUID SPILLED MUST BE REMOVED IMMEDIATELY AS IT DAMAGES PAINT UPON CONTACT 4 Tires The DV 20 KATANA main landing gear is equipped with tires of the size 380 x 15...

Page 230: ...ould be cleaned and lubricated In addition the battery cable connector lugs should be inspected NOTE The battery should be removed from the airplane prior to a battery inspection Battery and battery m...

Page 231: ...ratio 50 antifreeze concentrate with additives against corrosion and 50 distilled water shall be used or alternatively an equivalently premixed coolant NOTE If problems are encountered with boiling af...

Page 232: ...ir must not exceed the maximum marking After the first top up close the pressure cap and let the engine run for approximately 3 minutes at increased idle speed Then fill up dispatcher vessel completel...

Page 233: ...ntrol system and all other mechanical systems are with a few exceptions equipped with maintenance free friction bearings and rod end bearings However these bearings and joints should be inspected regu...

Page 234: ...olts pins of flaps synchronizing tube assembly grease telescopic rods if installed grease X X 5 S N s with removable wings Rollers in the bellcranks for aileron and wing flap control systems in wing r...

Page 235: ...R 12 20 1 Allgemeines Mit wenigen Ausnahmen sind die gesamte Steuerung und die sonstige Mechanik mit wartungsfreien Gleitlagern und Gelenklagerk pfen ausger stet Trotzdem sollten die Lager besonders b...

Page 236: ...lzen B Bolzen und LK Torsionsstangenmitnehmerstifte fetten Teleskopstange fetten wenn vorhanden X X 5 F r WNrn m abnehmbaren Fl geln Querruder und Landeklappenantriebsrollen in der Wurzelrippe fetten...

Page 237: ...imately once a year the surface of the airplane should be treated and buffed using a silicon free automotive polish CAUTION DO NOT USE ANY CLEANING AGENT CONTAINING SILICON BASED MATERIALS Cover all l...

Page 238: ...SYSTEM GENERATOR STARTER AIR INTAKES FURTHERMORE IT MUST BE ENSURED THAT THE ENGINE IS STARTED ONLY AFTER ALL OF THE CLEANING SOLUTION HAS EVAPORATED 4 Snow and Ice Removal After snow has collected on...

Page 239: ...AIRCRAFT DV 20 KATANA AMM Standard Practices Airframe Doc 4 02 02 Rev 13 20 TITLE Page 1 15 Dec 2018 CHAPTER 20 STANDARD PRACTICES AIRFRAME...

Page 240: ...AIRCRAFT Standard Practices Airframe DV 20 KATANA AMM Page 2 15 Dec 2018 20 TITLE Doc 4 02 02 Rev 13 Intentionally left blank...

Page 241: ...dard Practices Airframe Doc 4 02 02 Rev 13 20 CONTENTS Page 1 15 Dec 2018 TABLE OF CONTENTS CHAPTER 20 STANDARD PRACTICES AIRFRAME 1 General 1 2 Bolt Types 1 3 Standard Torques 1 4 Special Torques 2 5...

Page 242: ...AIRCRAFT Standard Practices Airframe DV 20 KATANA AMM Page 2 15 Dec 2018 20 CONTENTS Doc 4 02 02 Rev 13 Intentionally left blank...

Page 243: ...ications which can be identified by the markings located on the head of the bolts and by the surface treatment Bolt type Marking on Head Surface Treatment DIN bolt zinc coated LN bolt zinc coated and...

Page 244: ...fitting 45 33 2 NOTE Observation of the prescribed torque value and installation of the prescribed safetying device must be ensured with each screw connection CAUTION SELF LOCKING NUTS MUST BE REPLACE...

Page 245: ...AIRCRAFT DV 20 KATANA AMM Environmental Systems Doc 4 02 02 Rev 13 21 TITLE Page 1 15 Dec 2018 CHAPTER 21 ENVIRONMENTAL SYSTEMS...

Page 246: ...AIRCRAFT Environmental Systems DV 20 KATANA AMM Page 2 15 Dec 2018 21 TITLE Doc 4 02 02 Rev 13 Intentionally left blank...

Page 247: ...ev 13 21 CONTENTS Page 1 15 Dec 2018 TABLE OF CONTENTS CHAPTER 21 ENVIRONMENTAL SYSTEMS 1 General 1 Section 21 20 DISTRIBUTION 1 Functional Description 1 2 Maintenance Information 1 Section 21 40 HEAT...

Page 248: ...AIRCRAFT Environmental Systems DV 20 KATANA AMM Page 2 15 Dec 2018 21 CONTENTS Doc 4 02 02 Rev 13 Intentionally left blank...

Page 249: ...d and warm air as well as the supply of warm air to the floor and the canopy Control of the heating system is located in the center console on the transition piece to the instrument panel Fresh air ca...

Page 250: ...AIRCRAFT Environmental Systems DV 20 KATANA AMM Page 2 15 Dec 2018 21 00 00 Doc 4 02 02 Rev 13 Intentionally left blank...

Page 251: ...low into the cabin the cabin heat button located in the front part of the center console must be pulled to the stop To regulate the heat any position inbetween can be used B Ventilation Fresh air is d...

Page 252: ...AIRCRAFT Environmental Systems DV 20 KATANA AMM Page 2 15 Dec 2018 21 20 00 Doc 4 02 02 Rev 13 Intentionally left blank...

Page 253: ...pection The heat exchanger must be inspected during each 100 hour inspection for insecure attachment leakage and poor condition In addition the exhaust muffler should be inspected at each 100 hour ins...

Page 254: ...AIRCRAFT Environmental Systems DV 20 KATANA AMM Page 2 15 Dec 2018 21 40 00 Doc 4 02 02 Rev 13 Intentionally left blank...

Page 255: ...AIRCRAFT DV 20 KATANA AMM Communications Doc 4 02 02 Rev 13 23 TITLE Page 1 15 Dec 2018 CHAPTER 23 COMMUNICATIONS...

Page 256: ...AIRCRAFT Communications DV 20 KATANA AMM Page 2 15 Dec 2018 23 TITLE Doc 4 02 02 Rev 13 Intentionally left blank...

Page 257: ...MMUNICATION BECKER AR3201 1 General 1 2 System Description 3 3 Troubleshooting 6 4 Maintenance Information 8 Section 23 10 2 SPEECH COMMUNICATION BENDIX KING KX125 1 General 1 2 System Description 3 3...

Page 258: ...AIRCRAFT Communications DV 20 KATANA AMM Page 2 15 Dec 2018 23 CONTENTS Doc 4 02 02 Rev 13 Intentionally left blank...

Page 259: ...1 VHF COMM transceiver 1 VHF folded top antenna mounted in the rudder fin 1 Swan neck or hand held microphone 1 Speaker 2 Headsets optional Power is supplied by the generator and by the battery via th...

Page 260: ...AIRCRAFT Communications DV 20 KATANA AMM Page 2 15 Dec 2018 23 00 00 Doc 4 02 02 Rev 13 Intentionally left blank...

Page 261: ...s The transmitter is activated with the buttons located in the control sticks The AR3201 can be operated using a swan neck microphone or headsets A breaker located in the instrument panel protects the...

Page 262: ...OM 4 3 2 1 A BECKER SQL ON OFF 1 8 7 2 3 4 5 6 1 ON OFF Switch combined with Squelch Switch 2 Transit Mode Indicator 3 Channel Selector Switch 4 Mhz Frequency Selector Switch 5 kHz Frequency Selector...

Page 263: ...es as a low frequency signal The required volume can be adjusted using the volume control VOL The automatic squelch control is activated with the OFF ON SQL switch and suppresses any signal noise in t...

Page 264: ...frequency other than the displayed one is required the channel selector should be positioned in the A position and the required frequency selected by use of the frequency selectors MHz and kHz 2 STOR...

Page 265: ...cy on the LC display It indicates that the VHF unit is in transmit mode 4 ON BOARD INTERCOMMUNICATION The speaker is switched off in this operation mode Switch the intercom switch ON Communication bet...

Page 266: ...transmit mode indicator on LCD Defective transmit button on pilot s side Defective wiring between pilot s transmit button and radio unit Replace Repair Unable to transmit from the co pilot s side mis...

Page 267: ...n transmit and receive mode signal noise in reception COMM antenna coaxial cable and plug Repair or replace Speaker silent headsets operating normal Defective speaker Defective wiring Defective interc...

Page 268: ...anufacturer or an approved Becker representative for replacement of the battery if the stored frequencies are lost Early replacement prevents possible damage to the radio unit which might occur due a...

Page 269: ...emory can store one frequency The unit can be operated using a speaker and a hand held microphone or headsets It is switched to transmit mode with the transmit button The hand held microphone is conne...

Page 270: ...B Y S B Y TSO KX125 T X PULL OBS PULL 25K PULL IDENT OFF PULL TEST COMM Frequency Indicator Active COMM Frequency COMM Transfer Switch Transmit Mode Indicator COMM Volume On OFF Rotational Switch Tes...

Page 271: ...w frequency signal The required volume can be adjusted using the volume control The automatic squelch control suppresses any signal noise in the speaker or headphone in the event that the HF carrier v...

Page 272: ...y shows the presently active frequency while the lower display shows the pre selected frequency Normally selection of any frequency is performed in the STANDBY window and then by pressing the COMM tra...

Page 273: ...the pilot s side missing transmit mode indicator on LCD Defective transmit button on pilot s side Defective wiring between pilot s transmit button and radio unit Replace Repair Unable to transmit fro...

Page 274: ...reception COMM antenna coaxial cable and plug Repair or replace Speaker silent headsets operating normal Defective speaker Defective wiring Defective intercom switch Replace Repair Replace Transmit mo...

Page 275: ...is located to the left of the MODE button A 3 32 inch wrench is required to remove or install the radio unit 1 Removal Detail Steps Work Items Key Items References 1 Use wrench to turn hexagon socket...

Page 276: ...AIRCRAFT Communications DV 20 KATANA AMM Page 8 15 Dec 2018 23 10 2 Doc 4 02 02 Rev 13 Intentionally left blank...

Page 277: ...t They have these controls The small left knob PUSH C V 1 is used to tune the kilohertz kHz value of the standby frequency for the communications transceiver COM or the VLOC receiver whichever is curr...

Page 278: ...AMM Page 2 15 Dec 2018 23 10 3 Doc 4 02 02 Rev 13 The GNS 430 display is divided into separate windows or screen areas including a COM window VLOC window and the GPS window the right 3 4 of the displa...

Page 279: ...Volume Squelch The knob on the left side of the SL 30 controls power on off volume and squelch test Rotate the knob clockwise CW past the detent to turn the power on Continuing to rotate the knob to t...

Page 280: ...te display will be decoded and displayed on the screen of the SL 30 T F Press T F to toggle between the bearing TO or radial FROM the active VOR The T F button does not operate for Localizer frequenci...

Page 281: ...AIRCRAFT DV 20 KATANA AMM Electrical Power Doc 4 02 02 Rev 13 24 TITLE Page 1 15 Dec 2018 CHAPTER 24 ELECTRICAL POWER...

Page 282: ...AIRCRAFT Electrical Power DV 20 KATANA AMM Page 2 15 Dec 2018 24 TITLE Doc 4 02 02 Rev 13 Intentionally left blank...

Page 283: ...GENERATION 1 General 1 2 Description 3 3 Troubleshooting 5 4 Removal and Installation 8 5 Maintenance Information 10 Section 24 31 BATTERY SYSTEM 1 General 1 2 Description 3 3 Troubleshooting 4 4 Mai...

Page 284: ...AIRCRAFT Electrical Power DV 20 KATANA AMM Page 2 15 Dec 2018 24 CONTENTS Doc 4 02 02 Rev 13 Intentionally left blank...

Page 285: ...f the landing light The electrical circuits of the system are with the exception of the engine start circuit protected by automatic circuit breakers The master switch is used to switch all electrical...

Page 286: ...AIRCRAFT Electrical Power DV 20 KATANA AMM Page 2 15 Dec 2018 24 00 00 Doc 4 02 02 Rev 13 Figure 1 DV 20 Electrical System Components in Engine Compartment...

Page 287: ...00 Page 3 15 Dec 2018 Battery Relay K2431 01 Starting Relay K8010 01 Central Ground Connectors Anti Interference Capacitor C2430 02 under K2430 01 Overvoltage Relay K2430 01 Capacitor C2430 01 Voltage...

Page 288: ...AIRCRAFT Electrical Power DV 20 KATANA AMM Page 4 15 Dec 2018 24 00 00 Doc 4 02 02 Rev 13 Figure 3 Electrical Shelf in Engine Compartment O M 20 245 External Alternator...

Page 289: ...witch is located in the bottom section of the instrument panel on the pilot s side The switch is colored red D Voltage Regulator The voltage regulator rectifies the AC supplied by the alternator to DC...

Page 290: ...Buses 1 and 2 The electrical buses 1 and 2 distribute power to the electrical components via automatic circuit breakers The electrical bus 1 is located in the instrument panel on the right hand side w...

Page 291: ...g lights in instrument panel operating normal during starting Starting relay Starter cabling breaker Ignition switch Starting relay control Replace Replace Replace Repair Starter operates for a short...

Page 292: ...APTERS THE BATTERY SHOULD BE DISCONNECTED FOR EXTENSIVE MAINTENANCE OPERATIONS AFTER COMPLETION OF MAINTENANCE TASKS AND BEFORE RE CONNECTION OF THE BATTERY THE ELECTRICAL SYSTEM SHOULD BE CHECKED USI...

Page 293: ...driven by a flat belt The voltage regulator and the overvoltage control relay are installed on the electrical shelf attached to the engine mount and are accessible after removing the upper cowling If...

Page 294: ...battery master switch in the switch panel above the radio rack If O M 20 244 Instrument Panel Version D20 3110 00 00 is installed the generator warning light is installed in the top center section of...

Page 295: ...ion with voltage regulator and the filter capacitor C2430 10 Power is supplied to the voltage regulator as well as to the generator indicators and the overvoltage protection via the generator control...

Page 296: ...n board electrical voltage in conjunction with the filter capacitor Power is supplied to the internal voltage regulator of the alternator as well as to the overvoltage protection via the master contro...

Page 297: ...Cause Repair No power supplied by alternator with engine running malfunction even with minimum current consumption generator warning light and low voltage caution light illuminated Internal alternato...

Page 298: ...ce Repair No power supplied by alternator with engine running ammeter indicates constant discharging of battery low voltage caution light and generator warning light are not illuminated even when engi...

Page 299: ...y master switch on Voltage regulator Overvoltage sensor Low voltage caution light O M 250 244 not installed Wiring Replace Replace alternator if the external alternator O M 20 245 is installed Replace...

Page 300: ...Steps Work Items Key Items References 1 Throw master switch in OFF position 2 Remove upper engine cowling 3 Remove connector P2430 01 from voltage regulator 4 Remove voltage regulator by loosening th...

Page 301: ...ge control relay remove relay b Installation Detail Steps Work Items Key Items References 1 For installation reverse the sequence 3 Overvoltage Sensor a Removal Detail Steps Work Items Key Items Refer...

Page 302: ...M 20 244 Instrument Panel Version D20 3110 00 00 is installed disconnect the low voltage sensor at connectors P J2440 4 Remove low voltage sensor by loosening both hex nuts on back side If O M 20 244...

Page 303: ...20 is equipped with a 12 Volts 30 amp hrs lead acid accumulator located in the engine compartment in a composite trough The battery is charged by the alternator Venting of the battery cells is accomp...

Page 304: ...ompartment Flight Compartment Ammeter M2431 01 Master Relay H K 10 11 22 Starting Relay B8010 01 M Engine Starter K8010 01 K2431 01 Battery 12V 30AH BT2431 01 Starting Switch Part of Ignition Switch E...

Page 305: ...e battery master switch S2400 01 in the OFF position the battery voltage is connected to the opened master relay K2431 01 By throwing the master switch in the ON position the master relay K2431 01 is...

Page 306: ...nce manual Complaint Possible Cause Repair Battery cannot be connect to the bus Discharged battery Master switch Master relay Cabling Charge Replace Replace Repair Battery uses too much water Voltage...

Page 307: ...AND SHOULD NOT BE USED WARNING TO AVOID BURNS OR FIRE DURING MAINTENANCE TASKS PERFORMED IN THE ENGINE COMPARTMENT NEAR THE BATTERY OR DIRECTLY ON THE ELECTRICAL SYSTEM REPLACING OF COMPONENTS OR WORK...

Page 308: ...spark plugs 4 Disconnect firewall breach plug No P2400 01 See Figure 1 WARNING AFTER DISCONNECTION OF THE FIREWALL BREACH PLUG THE MAGNETOS ARE HOT WHEN THE SPARK PLUGS ARE NOT DEACTIVATED STEP 3 AND...

Page 309: ...ow master switch in OFF position 2 Disconnect negative battery terminal 3 Disconnect positive battery terminal 4 Disconnect battery vent line 5 Loosen mounting clamp and lift battery carefully 2 Insta...

Page 310: ...lay 4 Remove relay by loosening the mounting screws 2 Installation Detail Steps Work Items Key Items References 1 For installation reverse the sequence Note Ensure correct polarization of the diode Re...

Page 311: ...gative battery terminal 3 Remove instrument panel top cover 4 Disconnect wires from master switch 5 Remove master switch 2 Installation Detail Steps Work Items Key Items References 1 For installation...

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Page 313: ...n the bottom left side of the instrument panel For simplified and detailed schematics of electrical load power distribution please refer to Chapter 92 2 Description Electric power os distributed via t...

Page 314: ...he trouble in column 1 do the repair given in column 3 Complaint Possible Cause Repair No electrical power on radio and navigational equipment Defective avionics master switch Defective avionics maste...

Page 315: ...T CIRCUITS During maintenance performed on the power distribution system check all wires and connectors for looseness and poor condition 5 Removal and Installation A Circuit Breakers 1 Removal Detail...

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Page 317: ...AIRCRAFT DV 20 KATANA AMM Equipment Furnishings Doc 4 02 02 Rev 13 25 TITLE Page 1 15 Dec 2018 CHAPTER 25 EQUIPMENT FURNISHINGS...

Page 318: ...AIRCRAFT Equipment Furnishings DV 20 KATANA AMM Page 2 15 Dec 2018 25 TITLE Doc 4 02 02 Rev 13 Intentionally left blank...

Page 319: ...Doc 4 02 02 Rev 13 25 CONTENTS Page 1 15 Dec 2018 TABLE OF CONTENTS CHAPTER 25 EQUIPMENT FURNISHINGS 1 General 1 Section 25 10 FLIGHT COMPARTMENT 1 General 1 2 Removal and Installation 3 3 Cleaning 6...

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Page 321: ...1 15 Dec 2018 CHAPTER 25 EQUIPMENT FURNISHINGS 1 General The cabin equipment is subdivided into the two 2 pilot seats cabin lining equipment components and baggage compartment A description of the in...

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Page 323: ...nguisher agent HALON is with restrictions considered non toxic and leaves no residues Maintenance is limited to checking the pressure indicator and the seal wire and checking the mounting for loosenes...

Page 324: ...ase the airplane is not in use for a longer time it is recommendable to remove the battery from the unit D Lining of Side Panels The lining of the side panels consists of a fire resistant material and...

Page 325: ...connect antenna 2 Installation Detail Steps Work Items Key Items References 1 For installation reverse the sequence 3 Functional Test Detail Steps Work Items Key Items References 1 Set receiver of the...

Page 326: ...ve cover by lifting 2 Installation Detail Steps Work Items Key Items References 1 For installation reverse the sequence C Seat Shells 1 Removal Detail Steps Work Items Key Items References 1 Remove se...

Page 327: ...al lock by feeding belts through mountings 4 Remove lap belts without central lock by loosening mounting screw and pulling belts from attachment 2 Installation Detail Steps Work Items Key Items Refere...

Page 328: ...02 Rev 13 3 Cleaning A Seats The seat and backrest cushions consist of fire resistant material For cleaning the cushions are vacuumed For persistent dirt the seat covers can be cleaned using a mild s...

Page 329: ...T 1 General The baggage compartment is used for storage of small baggage and equipment It is located within the cabin and is within reach of both seats The baggage compartment has flame resistant floo...

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Page 331: ...AIRCRAFT DV 20 KATANA AMM Flight Controls Doc 4 02 02 Rev 13 27 TITLE Page 1 15 Dec 2018 CHAPTER 27 FLIGHT CONTROLS...

Page 332: ...AIRCRAFT Flight Controls DV 20 KATANA AMM Page 2 15 Dec 2018 27 TITLE Doc 4 02 02 Rev 13 Intentionally left blank...

Page 333: ...27 10 AILERON CONTROL SYSTEM 1 General 1 2 Description 1 3 Troubleshooting 4 4 Removal and Installation 5 5 Adjustment 11 6 Inspection of Aileron Control System 13 7 Replacement of Aileron Control Sys...

Page 334: ...GE 1 General 1 2 Description 1 3 Removal and Installation 1 4 Adjustment 2 Section 27 20 30 RUDDER 1 General 1 2 Description 1 3 Removal and Installation 1 4 Adjustment 2 5 Replacement of Rudder Upper...

Page 335: ...ENTS Page 3 15 Dec 2018 Section 27 40 ELEVATOR TRIM SYSTEM 1 General 1 2 Description 2 3 Troubleshooting 3 4 Removal and Installation 3 5 Adjustment 6 Section 27 50 WING FLAPS 1 General 1 2 Descriptio...

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Page 337: ...vator are deflected with the control stick via push rods The rudder is deflected with the rudder pedals via control cables The DV 20 KATANA is equipped with a manual elevator trim system The trim leve...

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Page 339: ...ass is attached to the aileron horn 2 Description S N s 20 005 thru 20 100 refer to Figure 1 S N s 20 101 and subsequent refer to Figure 2 The DV 20 KATANA can be operated from either seat A roll cont...

Page 340: ...AIRCRAFT Flight Controls DV 20 KATANA AMM Page 2 15 Dec 2018 27 10 00 Doc 4 02 02 Rev 13 8 10 11 12 LH shown RH similar 6 7 5 4 3 2 1 9 2 Figure 1 Aileron Control System S N s 20 005 thru 20 100...

Page 341: ...AIRCRAFT DV 20 KATANA AMM Flight Controls Doc 4 02 02 Rev 13 27 10 00 Page 3 15 Dec 2018 10 11 12 LH shown RH similar 6 5 4 3 2 1 9 2 Figure 2 Aileron Control System S N s 20 101 and subsequent...

Page 342: ...as they could appear in the aileron control system and their correction Complaint Possible Cause Repair Interference Unclean or detective bearings Replace bearings Aircraft moves about longitudinal a...

Page 343: ...b Chapter 27 11 B Item 2 Aileron Push Rods Connecting Control Sticks Located under seat shells 1 Removal Detail Steps Work Items Key Items References 1 Remove mounting bolts from rod end bearings of t...

Page 344: ...rences 1 For installation reverse the sequence D Item 4 Push Rod in Center Console This push rod is located under the center console between the seats In order to gain access to the push rod both seat...

Page 345: ...mounting bolt of bellcrank in upward direction 3 Remove bellcrank together with guide bushing from pedestal 2 Installation Detail Steps Work Items Key Items References 1 For installation reverse the...

Page 346: ...llation Detail Steps Work Items Key Items References 1 For installation reverse the sequence H Item 8 Bellcrank Attached to Wing Root Rib Only installed in S N s 20 005 thru 20 100 Wings must be remov...

Page 347: ...ntiator lever and in wing root rib 3 Remove push rod from wing 2 Installation Detail Steps Work Items Key Items References 1 For installation reverse the sequence J Item 10 Aileron Bellcrank in Wing 1...

Page 348: ...8 27 10 00 Doc 4 02 02 Rev 13 A A Cross Section A A Figure 3 Aileron Bellcrank in Wing NOTE For reasons of production technique the aileron bellcrank has holes which must NOT be used The bellcrank mus...

Page 349: ...nk must be at right angles to aileron push rods in main column C Bellcrank in Rearward Transverse Stiffener 3 Aileron Push Rod in Center Console 4 Transversely oriented arm of bellcrank must be at rig...

Page 350: ...eft aileron must be fitted with a fixed trim tab 20 centimeters 8 inches from the inboard edge Verify that the aileron travel up and down corresponds to prescribed values refer to Sub Chapter 06 00 J...

Page 351: ...fer to Figure 1 or 2 2 Remove aileron bellcrank 10 and 8 if installed Refer to Figure 1 or 2 3 Remove push rod connecting aileron horn 11 Refer to Figure 1 or 2 4 Remove aileron horn 12 Refer to Figur...

Page 352: ...through inspection hole 2 S Remove the second roller cage through the maintenance opening Temporary stop for positioning Refer to Figure 4 Refer to Figure 4 CAUTION THE WASHERS BETWEEN GFRP AND RIVET...

Page 353: ...control sticks 3 Troubleshooting The freedom of movement of the main column must be ensured at all times Interference is in most cases caused by defective bearings Defective bearings must be replaced...

Page 354: ...RH aluminum mounting ribs 3 Remove Torque Tube Assembly 2 Installation Detail Steps Work Items Key Items References 1 For installation reverse the sequence NOTE Ensure proper ground connections 5 Adj...

Page 355: ...Cable Section 27 20 00 RUDDER CONTROL SYSTEM 1 General A deflection of the rudder results in the airplane turning about its vertical axis The operation of the pedals causes the rudder to be deflected...

Page 356: ...llowing table lists defects as they could appear in the rudder control system and their correction Complaint Possible Cause Repair Interference Unclean or detective bearings Replace or clean bearings...

Page 357: ...assembly consists of an adjustment mechanism and brake cylinders for the left and right wheel brakes After loosening the mounting bolts the complete assembly can be removed from the fuselage 2 Descrip...

Page 358: ...t is recommendable to remove the complete pedal assembly Detail Steps Work Items Key Items References 1 Disconnect control cables from firewall 2 Remove mounting bolts of cradle tube 3 Remove brake cy...

Page 359: ...ansferred to the rudder lever via guide rollers From there two cables run back to the rudder lower mounting plate guided by teflon hoses 3 Removal and Installation Refer to Figure 1 in Sub Chapter 27...

Page 360: ...check of the system to verify the correct rudder deflections given in Sub Chapter 06 00 must be carried out To adjust the system the multi hole fittings 3 on the firewall the control cable turnbuckle...

Page 361: ...of the rudder contains a balancing mass The rudder is supported by two hinges at the top and bottom 2 Description On its bottom part rudder is attached to the rudder lower mounting plate A movement o...

Page 362: ...irection of Flight Rudder Pedestal Assy Control Cable Control Cable 4 Adjustment A Rudder Deflection The rudder deflections are limited by stop bolts located in the lower mounting plate The bolts may...

Page 363: ...ure the area of the bearing 6 Replacement of Rudder Upper Hinge Pin Detail Steps Work Items Key Items References 1 Cut two 30 mm 1 2 in holes beside the rudder nose bonding flange S Cut the first hole...

Page 364: ...te for bonding 11 Affix a sheet metal screw in the center of the pre layer and paste the layer from the inside with thickened resin Press the prepared layer against the laminate around the elongated h...

Page 365: ...AIRCRAFT DV 20 KATANA AMM Flight Controls Doc 4 02 02 Rev 13 27 20 30 Page 5 15 Dec 2018 CAUTION ALL LINEAR MEASURES ARE IN MM Figure 2 Replacement of Rudder Upper Hinge Pin...

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Page 367: ...er fin there are two springs connected to the vertical elevator push rod 2 Description Pulling or pushing the control sticks causes the elevator to deflect upward or downward Refer to Figure 1 The ele...

Page 368: ...gs Replace or clean bearings Excessive play Bearing or bolt worn Replace 4 Removal and Installation Refer to Figure 1 A Items 1 and 2 Control Sticks and Torque Tube Assembly Refer to Sub Chapter 27 11...

Page 369: ...rearward direction 2 Installation Detail Steps Work Items Key Items References 1 For installation reverse the sequence D Item 6 Elevator Push Rod in Rudder Fin Rudder must be removed 1 Removal Detail...

Page 370: ...control mechanism see Chapter 27 40 2 Pull out pins from outboard elevator hinges CAUTION BE CAREFUL NOT TO DAMAGE THE CONNECTION BETWEEN THE HINGES AND THE ELEVATOR FIN 3 Remove bearing journals 4 R...

Page 371: ...ks must be centered B Items 3 4 Push Rods in Center Console Fuselage Tube Adjust push rod eye ends so that bellcrank is at right angles to rudder fin web C Item 6 Push Rod in Rudder Fin Adjust push ro...

Page 372: ...roller cage in the Ring Frame 2 with a drill of 5 3 mm 0 17 in by using an extension Refer to Figure 2 3 Drill the holes in the ring frame and the half frame to 5 3 mm 0 17 in 4 Remove drilling chips...

Page 373: ...AIRCRAFT DV 20 KATANA AMM Flight Controls Doc 4 02 02 Rev 13 27 30 00 Page 7 15 Dec 2018 Figure 3 Example of Auxiliary Tool...

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Page 375: ...elevator trim system to allow trimming of the airplane for different center of gravity positions The trim tab is adjusted with an arresting lever on the center console Its movement is transmitted to...

Page 376: ...ction Clamp Block Flexible Operating Cable Inner Flexible Operating Cable Outer Trim Adjustment Lever 2 Description Refer to Figure 1 The trim adjustment lever is connected to the actuating levers thr...

Page 377: ...ings or joints Replace Interference Defective bowden cable Friction damper adjusted in correctly Replace Re adjust 4 Removal and Installation A Item 1 Trim Lever Center console cover must be removed 1...

Page 378: ...ted holding straps in fuselage must be removed rudder must be removed 1 Removal Detail Steps Work Items Key Items References 1 Remove mounting bolts for pedestal in center console 2 Open ball joint co...

Page 379: ...teps Work Items Key Items References 1 Disconnect tab actuating levers from friction damper and bowden cable 2 Remove safetying of hinge wires extract hinge wires in outboard direction using nippers C...

Page 380: ...rts in Rudder Fin The bowden cable must be adjusted to ensure proper tab deflections in accordance with the Adjustment Report The friction damper must be adjusted to a friction force of 15 30 N 3 4 6...

Page 381: ...s electrically operated wing flaps They are operated by means of a 3 position toggle switch located in the center section of the instrument panel The flap position indicator is located next to the swi...

Page 382: ...sh rod actuates 5 micro switches which are part of the electronic control circuit The bellcrank is mounted to the sickle shaped bulkhead From here two push rods run to the LH and RH wing roots The win...

Page 383: ...ctive or loose connector on motor Defective limit stop switch Defective electric motor Replace Check battery and generator Check switch Check connector Check limit stop switch Check motor Flaps moving...

Page 384: ...earing journals 3 Remove bearing journals in inboard direction NOTE To assure an easy re installation mark the bearing journals location and orientation 4 Remove flap 2 Installation Detail Steps Work...

Page 385: ...s Key Items References 1 Open inspection hole on wing bottom side 2 Remove mounting bolts of push rods 3 Remove mounting bolt of bellcrank 4 Remove bellcrank 2 Installation Detail Steps Work Items Key...

Page 386: ...age D Electric Motor The left seat shell must be removed 1 Removal Detail Steps Work Items Key Items References 1 Disconnect push rod from bellcrank 2 Disconnect electric wires from motor and micro sw...

Page 387: ...the sketch below and to Wiring Diagram D20 9227 50 01 in Chapter 92 Figure 5 Micro Switch Designation To move the switches first release the mounting screws After moving the switches to the desired po...

Page 388: ...xtended and fully retracted positions of the actuator This ensures equal travel reserve of the actuator in UP and LDG positions Connect actuator to lower arm of torsion bellcrank Connect stop to lower...

Page 389: ...AIRCRAFT DV 20 KATANA AMM Fuel Doc 4 02 02 Rev 13 28 TITLE Page 1 15 Dec 2018 CHAPTER 28 FUEL...

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Page 391: ...on 28 10 STORAGE TANK 1 General 1 2 System Description 1 3 Troubleshooting 2 4 Removal and Installation 3 5 Leakage Test 3 Section 28 20 DISTRIBUTION 1 General 1 2 System Description 1 3 Troubleshooti...

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Page 393: ...off valve which is located in the center console The fuel shut off valve has two positions OPEN and CLOSED The fuel line continues to the firewall breach from where it runs to the mechanical fuel pump...

Page 394: ...Fuel Pump Cross Shaped Fitting Fuel Pressure Sensor Mechanical Fuel Pump Carburetor Left Carburetor Right Hose Coupling Water Check Drain Electrical Fuel Pump Fuel Tank Filler Vent Line Main Bulkhead...

Page 395: ...at the lowest point of the fuel tank allows draining of condensed water and can be activated using a drainage cup 2 System Description Fuel is taken from the tank through a hollow screw with integrat...

Page 396: ...and corrective measures Complaint Possible Cause Repair Smell of fuel in airplane Loose fuel line connectors Cracks in fuel tank welding seams Leaky fuel lines Tighten connectors Weld or replace tank...

Page 397: ...electric wires 6 Remove tank 2 Installation Detail Steps Work Items Key Items References 1 For installation reverse the sequence 2 Shut hose coupling wrap locking wire around fitting three times betw...

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Page 399: ...tem a capillary valve is installed in the firewall fitting of the return line 2 System Description A Fuel Shut Off Valve The fuel shut off valve is operated with the red lever located on the side of t...

Page 400: ...bar 2 2 to 5 8 psi The pump is driven by a cam via a push rod The motion of the push rod is transferred against the pressure of a spring to the diaphragm which creates suction as well as pressure The...

Page 401: ...rplane Loose fuel line connections Leaky fuel lines Tighten fuel line connections Check fuel lines Insufficient fuel pressure Clogged filter Defective mechanical fuel pump Defective fuel pressure sens...

Page 402: ...fuel tank must be drained Detail Steps Work Items Key Items References 1 Remove hand hole cover on the right side of the center console 2 Disconnect both hose lines 3 Remove operating lever 4 Remove m...

Page 403: ...v 13 28 20 00 Page 5 15 Dec 2018 Hand Hole Cover Center Console Hose Line Hose Line Operating Lever Operating Lever Mounting Screw Fuel Shut Off Valve Mounting Screws Fuel Shut Off Valve Fitting Gaske...

Page 404: ...s Work Items Key Items References 1 For installation reverse the sequence 3 Maintenance of Filter Element Detail Steps Work Items Key Items References 1 Remove locking wire 6 and 7 2 Slide back lockin...

Page 405: ...Fuel Doc 4 02 02 Rev 13 28 20 00 Page 7 15 Dec 2018 2 1 7 4 6 3 5 Figure 2 Electrical Fuel Pump C Mechanical Fuel Pump 1 Removal and Installation Detail Steps Work Items Key Items References 1 Refer t...

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Page 407: ...ected to a resistance wire The changing fuel level changes the resistance which is indicated by the fuel quantity indicator The indicator is calibrated to the highest and lowest position of the float...

Page 408: ...re too low Check pressure sensor Check electrical supply Electrical fuel quantity indication incorrect Defective fuel quantity sensor Defective fuel quantity indicator Fuel quantity indicating system...

Page 409: ...emoval and Installation A Fuel Pressure Sensor 1 Removal Detail Steps Work Items Key Items References 1 Disconnect electrical connector 2 Remove Sensor 2 Installation Detail Steps Work Items Key Items...

Page 410: ...g screws around sensor 4 Remove sensor from tank 2 Installation Detail Steps Work Items Key Items References 1 For installation reverse the sequence NOTE Prior to the installation of a new sensor the...

Page 411: ...etail Steps Work Items Key Items References 1 Drain tank completely 2 Fill tank using a calibrated filler pump 3 Compare fuel quantity indicator reading with amount of fuel filled into tank A Fuel Qua...

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Page 413: ...AIRCRAFT DV 20 KATANA AMM Indicating Recording Systems Doc 4 02 02 Rev 13 31 TITLE Page 1 15 Dec 2018 CHAPTER 31 INDICATING RECORDING SYSTEM...

Page 414: ...AIRCRAFT Indicating Recording Systems DV 20 KATANA AMM Page 2 15 Dec 2018 31 TITLE Doc 4 02 02 Rev 13 Intentionally left blank...

Page 415: ...ing Recording Systems Doc 4 02 02 Rev 13 31 CONTENTS Page 1 15 Dec 2018 TABLE OF CONTENTS CHAPTER 31 00 INDICATING RECORDING SYSTEMS 1 General 1 Section 31 10 INSTRUMENT PANEL 1 General 1 2 Descriptio...

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Page 417: ...alled is made in one piece with a shelf The shelf goes between the panel and the firewall A control panel in the center console This panel has the engine controls fuel controls cabin heat control leve...

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Page 419: ...he center console below the instrument panel there is a panel accommodating the control knobs for the operation of parking brake choke and cabin heating The throttle quadrant consisting of throttle le...

Page 420: ...Figure 1and 2 illustrates the location of each instrument in the Cockpit System and functional description of each instrument as well as the removal and installation procedures can be found in the co...

Page 421: ...equently the instruments are easy to reach after removal of the instrument panel cover 1 Removal Detail Steps Work Items Key Items References 1 Remove instrument panel cover 2 Disconnect instruments 3...

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Page 423: ...AIRCRAFT DV 20 KATANA AMM Landing Gear Doc 4 02 02 Rev 13 32 TITLE Page 1 15 Dec 2018 CHAPTER 32 LANDING GEAR...

Page 424: ...AIRCRAFT Landing Gear DV 20 KATANA AMM Page 2 15 Dec 2018 32 TITLE Doc 4 02 02 Rev 13 Intentionally left blank...

Page 425: ...EAR 1 General 1 2 Description 1 3 Troubleshooting 2 4 Removal and Installation 3 5 Adjustment 4 6 Inspection and Removal of Main Landing Gear Attachment Brackets 7 Section 32 20 NOSE LANDING GEAR 1 Ge...

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Page 427: ...ed single wheels with low pressure tires Disk brakes are installed on the inside of each of the main wheels The disk brakes can be individually operated by the left or right toe brake pedal 2 Troubles...

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Page 429: ...aluminum wheels The disk brakes of the DV 20 KATANA are part of the standard equipment 2 Description Each strut is mounted to the inner bracket by means of one bolt which must be secured against loos...

Page 430: ...13 3 Troubleshooting The following table lists defects as they could appear on the main landing gear system and their correction Complaint Possible Cause Repair Strut bent Hard landing Replace strut N...

Page 431: ...k pressure plate from caliper 4 Remove wheel axle nut remove caliper 5 Remove wheel 6 Remove brake line from strut 7 Remove axle from strut by removing the four attachment bolts 8 Remove nut and bolt...

Page 432: ...shers Castle Nut Split Pin 5 Adjustment A Play in Wheel Bearing Detail Steps Work Items Key Items References 1 Install wheel install axle nut with spacer washer 2 Torque nut to 40 Nm 29 5 lbs ft 3 Loo...

Page 433: ...placed onto slide sheets and alignment checked at empty mass weight against the data in the Adjustment Report In the event a deviation is found shims should be placed between the strut and the wheel f...

Page 434: ...ents Angle Bracket Greased Plates Wing Root Edge Main Landing Gear Leg Note Ensure that the floor is levelled in the work area Straight Edge Angle Bracket Toe In Measurements Higher Toe In Value Lower...

Page 435: ...of Attachment Fitting 1 and 4 Detail Steps Work Items Key Items References 1 Examine the outer main landing gear attachment brackets 1 and 4 for cracks and corrosion by visual inspection If cracks are...

Page 436: ...If detected remove fittings and follow items 3 through 12 Refer to Figure 4 2 If corrosion spots in excess of 100 mm and depth of 0 1 mm are detected at the inspectable surfaces of attachment bracket...

Page 437: ...Paint the attachment fitting and prepare the area for bonding the fitting 8 Install new attachment fitting with paste 9 Remove excess paste 10 Repair sickle shaped bulkhead with two layers 92140 45 R...

Page 438: ...or replace according to items 3 through 14 Repair small corrosion spots by grinding off rust with sandpaper and repaint Note The maximum corroded area must not exceed 1000 mm 3 Remove screws CAUTION D...

Page 439: ...ction item 2 The inner bracket sheet must not be thinner than 2 9 mm Note Use abrasive fleece for bonding preparation Do not damage or remove the paintcoat 8 Paint the attachment fitting and prepare t...

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Page 441: ...unt 2 Description The nose landing gear has attachment points at the engine mount and in the fuselage bottom A stop on the nose wheel fork limits the deflection of the nose wheel to 30 Steering fricti...

Page 442: ...AIRCRAFT Landing Gear DV 20 KATANA AMM Page 2 15 Dec 2018 32 20 00 Doc 4 02 02 Rev 13 Nose Wheel Fork Castor Stop Nose Gear Leg Tubular Strut Elastomer Package Fitting Figure 1 Nose Landing Gear...

Page 443: ...e engine cowling 2 Remove cover over nose landing gear fitting 3 Disconnect elastomer package assembly from engine mount 4 Remove safety bolt 1 from leg bearing journal unit 5 Compress bearing journal...

Page 444: ...AIRCRAFT Landing Gear DV 20 KATANA AMM Page 4 15 Dec 2018 32 20 00 Doc 4 02 02 Rev 13 11 a Figure 3 Elastomer Package Figure 4 Elastomer Package...

Page 445: ...ing 2 Remove fairing of rubber spring assembly 3 Disconnect rod end bearing from engine mount 4 Support nose gear leg disconnect rubber spring assembly from leg 5 Remove LH and RH safety plate remove...

Page 446: ...Friction The steering friction for the prevention of nose wheel wobble is adjusted with the nose wheel fork mounting bolt The friction should be adjusted to withstand a force of 30 to 50 N 6 75 to 11...

Page 447: ...s calipers and brake disks The brake cylinders on the pilot s side work independently from those on the co pilot s side The brake is applied by pressing the brake pedal which is located on the rudder...

Page 448: ...als Pilot s Pedals Flexible Hose Parking Brake Valve PARKING BRAKE Brake Disk Brake Caliper Hydraulic Tube Master Cylinders Master Cylinders Back Plate Pressure Plate Brake Fluid Reservoir LOCK RELEAS...

Page 449: ...see Ch 32 10 Excessive axial play of wheel Defective wheel bearing Adjust play in bearing or replace bearing Brake disks warped Brake applied too hard Hard landing Replace Replace Brakes inoperative B...

Page 450: ...ter 32 10 Figure 1 A Main Wheels 1 Removal Detail Steps Work Items Key Items References 1 Jack up airplane or unload wheel remove wheel fairing 2 Remove locking wire on caliper remove back pressure pl...

Page 451: ...OVING THE VALVE INSERT Detail Steps Work Items Key Items References 1 Remove bolts on rim 2 Remove brake disk and rim halves from tire 3 Remove inner tube 4 The wheel bearing can be removed if require...

Page 452: ...ting screw 3 Remove fairing 4 Unload nose wheel 5 Remove M10 nut and bolt serving as axle remove nose wheel 2 Installation Detail Steps Work Items Key Items References 1 For installation reverse the s...

Page 453: ...he pedal 3 Remove cylinder lower mounting bolt 4 Remove master cylinder from airplane NOTE As a significant amount of brake will flow out it must be ensured that a container is available for collectio...

Page 454: ...ATANA AMM Page 8 15 Dec 2018 32 40 00 Doc 4 02 02 Rev 13 Brake Master Cylinder Brake Master Cylinder Brake Lines Brake Lines Connecting Bolt Pedal Pedal Connecting Bolt Cylinder Lower Mounting Bolt Fi...

Page 455: ...on D Caliper 1 Removal Detail Steps Work Items Key Items References 1 Disconnect brake line from caliper 1 2 Disconnect back pressure plate 2 from cylinder 3 Remove caliper and guide assembly 3 from m...

Page 456: ...Detail Steps Work Items Key Items References 1 Remove wheel and caliper 2 Disassemble wheel 3 Remove brake disk 2 Installation Detail Steps Work Items Key Items References 1 For installation reverse t...

Page 457: ...ness until the next scheduled inspection The wear limit is 3 mm 0 12 in 1 Removal Detail Steps Work Items Key Items References 1 Remove back pressure plate from caliper 2 Remove pressure plate from ca...

Page 458: ...ke Line Bowden Cable Mounting Bolts Parking Brake Valve G Parking Brake 1 Removal Detail Steps Work Items Key Items References 1 Disconnect brake lines 2 Disconnect bowden cable 3 Remove mounting bolt...

Page 459: ...rns 5 Using the pressure pump fill brake system with brake fluid 6 Check reservoir to prevent overflow In order to avoid overflow it may be useful to connect the brake fluid reservoir to a separate ve...

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Page 461: ...AIRCRAFT DV 20 KATANA AMM Lights Doc 4 02 02 Rev 13 33 TITLE Page 1 15 Dec 2018 CHAPTER 33 LIGHTS...

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Page 463: ...RAFT DV 20 KATANA AMM Lights Doc 4 02 02 Rev 13 33 CONTENTS Page 1 15 Dec 2018 TABLE OF CONTENTS Section 33 40 EXTERIOR LIGHTS 1 General 1 2 Description 2 3 Troubleshooting 3 4 Removal and Installatio...

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Page 465: ...d Position Light Anti Collision Light Power Supply Combined Anti Collision and Position Light Anti Collision Light Power Supply Section 33 40 EXTERIOR LIGHTS 1 General The DV 20 KATANA can be equipped...

Page 466: ...e lamp generating a light flash Immediately after the first discharge a second lower flash is generated increasing the visibility dual flashing principle This procedure is repeated approximately 50 ti...

Page 467: ...e ACL lamp Defective wiring Replace Replace Repair Right ACL inoperative See left ACL Both position lights inoperative Defective switch Defective breaker Defective wiring in forward cockpit area Repla...

Page 468: ...SWITCHING OFF THE SYSTEM TO ALLOW THE CAPACITORS TO DISCHARGE THIS WARNING ALSO APPLIES TO THE POSITION LIGHTS AS THESE ARE INSTALLED UNDER THE SAME CAP CAUTION NEVER TOUCH THE GLASS OF A BULB WITH B...

Page 469: ...Items Key Items References 1 Switch off battery master switch 2 Wait for five 5 minutes to allow discharge of strobe light capacitors 3 Remove wing tip 4 Disconnect power lines and ground connection 5...

Page 470: ...tch 2 Wait for five 5 minutes to allow discharge of strobe light capacitors 3 Remove wing tip 4 Disconnect power lines and ground connection 5 Drill out the four 4 rivets holding the power supply 6 Re...

Page 471: ...Switch off master switch 2 Remove upper engine cowling 3 Disconnect the landing light connector located directly behind the lamp 4 Remove lower engine cowling 5 Loosen mounting hardware and remove la...

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Page 473: ...AIRCRAFT DV 20 KATANA AMM Navigation and Pitot Static Doc 4 02 02 Rev 13 34 TITLE Page 1 15 Dec 2018 CHAPTER 34 NAVIGATION AND PITOT STATIC...

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Page 475: ...STATIC 1 General 1 2 Description 2 3 Troubleshooting 5 4 Maintenance Information 5 5 Removal and Installation 6 6 Pitot Static Test 7 Section 34 12 STALL WARNING SYSTEM 1 Description 1 2 Adjustment 1...

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Page 477: ...ITOT STATIC 1 General The navigation systems include the instruments that operate on dynamic and static pressure They indicate the airspeed altitude attitude and direction The equipment supplied with...

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Page 479: ...2018 Altimeter Vertical Speed Indicator Airspeed Indicator Pitot Head Section 34 10 PITOT STATIC 1 General The Pitot static system is used to measure and deliver dynamic and static pressure to the ai...

Page 480: ...ines for static pressure are blue The lines are attached to the connectors and secured with tie wraps B Drain System A drain system allows dewatering of the pressure lines If Service Bulletin No 20 6...

Page 481: ...t corner Indicator range 1 000 to 35 000 ft Temperature range 30 C to 50 C 22 F to 122 F D Airspeed Indicator The airspeed indicator shows the velocity of the airplane relative to the surrounding air...

Page 482: ...s a differential pressure between membrane and housing resulting in a movement of the membrane which is transferred to the pointer The differential pressure equalizes through a capillary hole allowing...

Page 483: ...ible Cause Repair No or incorrect instrument readings Leaky pressure lines Water in the lines Defective instrument Seal Disconnect lines blow out water Replace 4 Maintenance Information With the excep...

Page 484: ...on 3 Disconnect pressure lines 2 Installation Detail Steps Work Items Key Items References 1 For installation reverse the sequence B Instruments Removal and installation of all air data instruments is...

Page 485: ...t Adjust altimeter to QNH Max tolerance 57 ft Adjust altimeter to QFE Max tolerance 30 ft If tolerances are exceeded the instrument must be replaced C Safety Precautions During the Test The following...

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Page 487: ...slight negative pressure to the sensor 2 Adjustment The stall warning system is designed to warn the pilot approx 5 to 10 knots before the stall in case of slow deceleration see table below Upon slow...

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Page 489: ...o which is suspended in a frame and whose axis is parallel to the airplane s pitch axis The frame is connected to the indicator needle via a system of levers The needle indicates the rotational speed...

Page 490: ...s equipped with a display disk symbolizing the horizon Due to the gyroscopic forces the display disk connected to the gyro remains level at all times regardless of the flight attitude During steep tur...

Page 491: ...Possible Cause Repair Compass leaking fluid Defective seal or membrane Replace parts See Note below Compass deviation exceeding 10 degrees Improperly adjusted compass Defective compass Adjust Replace...

Page 492: ...ion A Magnetic Compass 1 Removal Detail Steps Work Items Key Items References 1 Remove bolts and nuts from support 2 Remove compass from support 2 Installation Detail Steps Work Items Key Items Refere...

Page 493: ...t display accurate information compensation may eliminate or reduce the error The compass compensation is performed as follows Detail Steps Work Items Key Items References 1 Move the airplane to a loc...

Page 494: ...half of the indication error using the compensation magnets The engine must be running during this procedure 7 Rotate the airplane 360 in 30 increments Prepare a compass deviation table that indicate...

Page 495: ...NING SYSTEMS 1 General The navigation system of the DV 20 KATANA can include the following systems VOR Localizer Navigation system Transponder Altitude Digitizer GPS Navigation system ADF Navigation s...

Page 496: ...KATANA AMM Page 2 15 Dec 2018 34 50 00 Doc 4 02 02 Rev 13 Transponder ATC2000 Comm AR3201 Nav NR3301 GPS 100 Transponder KT76A NAV COMM KX125 GPS 100 Figure 2 VHF NAV Standard Equipment Becker Figure...

Page 497: ...AIRCRAFT DV 20 KATANA AMM Navigation and Pitot Static Doc 4 02 02 Rev 13 34 50 00 Page 3 15 Dec 2018 Figure 4 VHF NAV Standard Equipment Garmin...

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Page 499: ...AIRCRAFT DV 20 KATANA AMM Structures Doc 4 02 02 Rev 13 51 TITLE Page 1 15 Dec 2018 CHAPTER 51 STRUCTURES...

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Page 501: ...ection 51 10 REPAIR OF COMPOSITE PARTS 1 Approved Materials Suppliers 1 2 Damage Classifications 4 3 Fuselage Layup 5 4 GFRP Repair 12 5 Sandwich Repair 13 6 Laminate Repair 15 7 Spar Repair 18 8 Pain...

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Page 503: ...trapezoidal cantilever wing has an I spar with caps made of carbon fiber rovings The wing skin is of sandwich construction Each wing is attached to the fuselage with three bolts The DV 20 KATANA is eq...

Page 504: ...ry Structure The primary structure of the DV 20 KATANA consists of the following members A Wing Spar Ribs Web at hinge line Skin Wing fuselage connection Ailerons Wing flaps B Fuselage Skin Bulkheads...

Page 505: ...is easier to see damage on unpainted areas of composite On painted composite surfaces damage is often first visible as waviness that shows up when you illuminate the surface with a bright light at a l...

Page 506: ...the paint due to UV damage If only a small amount of residue is found the paint can be polished smooth If a large amount of residue is found the component should be repainted If visual inspection of a...

Page 507: ...e evaluated by measuring the play between the parts when they are engaged such as the fit of the main bolts in the bushings in the main bulkhead B Damage Classifications for Composites Diamond Aircraf...

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Page 509: ...Mass per Area grams m Interglas No Porcher No Vorwerk No 8 4548 6 Double twill 2 2 161 92110 917 8 4551 6 Double twill 2 2 276 92125 3063 95290 8 4554 6 Double twill 2 2 390 92140 1989 8 4520 6 Warp r...

Page 510: ...as No Double twill 2 2 200 98141 Supplier Rudolf Usner GmbH see above D Glass Silk Rovings EC 9 756 K43 or EC 10 2400 K43 Supplier Rudolf Usner GmbH see above E Rigid Foam PVC foam Divinycell H 60 Sup...

Page 511: ...It is highly recommendable to contact HOAC to inquire about the products used on a specific serial number in order to avoid such problems as bubbles in the paint finish H Paint for the Instrument Pan...

Page 512: ...2 Damage to primary and secondary structures to the following extent Holes and breaks through a sandwich part Repairs may be performed by any qualified aeronautical firm In case of U S registered airp...

Page 513: ...repairs pay special attention to accuracy and cleanliness Item Qty Description Part No Supplier Dimensions mm 1 Filler Sikkens EP all over 2 5 minutes epoxy resin Araldit AW 2104 2934 on edges 3 Thic...

Page 514: ...146 P Interglas 500 100 24 4 if M M 20 291 is installed 92146 P Interglas 600 100 25 5 92146 P Interglas 1200 100 26 4 92146 P Interglas 700 100 27 2 KDU 1034 P 700 100 28 4 92146 P Interglas 600 100...

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Page 522: ...AIRCRAFT Structures DV 20 KATANA AMM Page 14 15 Dec 2018 51 10 00 Doc 4 02 02 Rev 13...

Page 523: ...mportance for the strength of the structure The number of layers required to rebuild the strength of the damaged area can be determined from the layup drawings It is necessary to determine the remaini...

Page 524: ...ng dust with pressurized air b Wash the chamfered area with carbon tetrachloride or acetone if dirt or grease has emerged during chamfering Fill grooves with resin and microballoons Apply resin to rep...

Page 525: ...amfered the protruding rigid foam is sanded down so it is flush with the exterior contour The repair area must then be cleaned as follows a Remove sanding dust with pressurized air b Wash the chamfere...

Page 526: ...er chamfering the area must be cleaned as follows a Remove sanding dust with pressurized air b Wash the chamfered area with carbon tetrachloride or acetone if dirt or grease has emerged during chamfer...

Page 527: ...amfering length should be approx 1 50 After chamfering the area must be cleaned as follows a Remove sanding dust with pressurized air b Wash the chamfered area with carbon tetrachloride or acetone if...

Page 528: ...um chamfer length case 1 15 mm or 0 6 inch case 2 30 mm or 1 2 inch case 2 60 mm or 2 4 inch c Remove sanding dust using compressed air d Wash the chamfered area with carbon tetrachloride or acetone i...

Page 529: ...pply primary coat and paint according to the paint manufacturer s instructions 9 Repair of Cracks A Repair of Cracks Near the Entrance Steps In case of cracks at the entrance step area the structure h...

Page 530: ...st and Fuselage If cracks in the thickened resin are detected at the connection between backrest and fuselage in region of canopy frame Detail Steps Work Items Key Items References CAUTION DO NOT DAMA...

Page 531: ...r measures in the sketches are mm Detail Steps Work Items Key Items References 1 Remove fire resistant resin from the edges of sheet metal to fuselage structure CAUTION DO NOT DAMAGE THE COMPOSITE STR...

Page 532: ...r all 1 ply 8 4554 60 92140 0 90 200x1000 mm only on horizontal part of firewall In case of doubt contact Diamond Aircraft Industries GmbH Sand all damaged layers Chamfer each layer with a stagger len...

Page 533: ...f the Fiberfrax to the shape of the sheet metal and firewall bulkhead including the drills CAUTION FOLLOW THE ADVICES OF THE FIBERFRAX AND ADHESIVE MANUFACTURER 12 Spread the Fiberfrax adhesive equall...

Page 534: ...en strip and sheet with firewall sealant PR 812 KIT 25 or Dapco 2200 21 Set the rivets at the right side of the strip and the sheet refer to sketch in instruction step 6 22 Cover the edge from sheet m...

Page 535: ...ar Clean glass fabric structure carefully 3 Examine structure for cracks or delamination In case of any finding report Diamond Aircraft Industries to receive repair instructions 4 Refill the edge of w...

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Page 537: ...PARTS 1 General A Steel Fittings Repairs of metal fittings should only be performed after consulting the manufacturer If welding is required it must be performed with a TIG Tungsten Inert Gas welder...

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Page 539: ...em The resistance measurements on the DV 20 have to be carried out with milliohmmeter and Kelvin probes The test current must be approximately 2 amps Measure the resistance between the electrical shel...

Page 540: ...TP 12 LH instrument panel 14 TP 13 Radio mountings 16 TP 14 Copilot stick 30 TP 15 Pilot stick 30 TP 16 Fuel tank filler 40 TP 17 Fuel tank 36 TP 18 ELT antenna 66 TP 19 GPS antenna 80 TP 20 Rudder br...

Page 541: ...AIRCRAFT DV 20 KATANA AMM Structures Doc 4 02 02 Rev 13 51 80 00 Page 3 15 Dec 2018 Figure 1 Test the Electrical Bonding System...

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Page 543: ...AIRCRAFT DV 20 KATANA AMM Fuselage Doc 4 02 02 Rev 13 53 TITLE Page 1 15 Dec 2018 CHAPTER 53 FUSELAGE...

Page 544: ...AIRCRAFT Fuselage DV 20 KATANA AMM Page 2 15 Dec 2018 53 TITLE Doc 4 02 02 Rev 13 Intentionally left blank...

Page 545: ...15 Dec 2018 TABLE OF CONTENTS CHAPTER 53 00 FUSELAGE 1 General 1 Section 53 10 MAIN FRAME 1 General 1 2 Bulkheads and Stiffeners 2 Section 53 11 CANOPY 1 General 1 2 Troubleshooting 2 3 Removal and I...

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Page 547: ...rientation of the layers corresponds to the loads in the individual sections Therefore the fuselage skin has different thicknesses and fiber orientations Figure 1 Fuselage Structure LEGEND 1 Firewall...

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Page 549: ...FRAME 1 General The DV 20 KATANA consists of a fuselage structure containing bulkheads and stiffeners which are Firewall Floor Element Transverse Stiffener Main Bulkhead Sickle Shaped Bulkhead B Bulk...

Page 550: ...r element C Transverse Stiffener The transverse stiffener is attached to the fuselage and the floor element Attached to the transverse stiffener are the control stick mounting ribs as well as the guid...

Page 551: ...ted of laminate including carbon fiber layers H Half Bulkhead The half bulkhead is attached to the fuselage skin and holds the forward guide of the elevator push rod I Ring Frames No 1 2 and 3 For rei...

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Page 553: ...canopy swivel arms are installed which are equipped with springs to counterbalance the weight of the canopy To guide the swivelling motion a third suspension point is provided in the upper rear area...

Page 554: ...could appear on the canopy system and their correction Complaint Possible Cause Repair Canopy jams Defective locking pins Replace Emergency window hard to open Unclean or defective guides Clean or re...

Page 555: ...ily and fast 1 Removal Detail Steps Work Items Key Items References 1 Open canopy 2 Remove the screw located on the upper guide lever 3 Remove rod end bearings on swivel arms from the canopy frame 4 R...

Page 556: ...l Steps Work Items Key Items References 1 Unscrew upper window guide 2 Lift window from lower window guide 2 Installation Detail Steps Work Items Key Items References 1 For installation reverse the se...

Page 557: ...AIRCRAFT DV 20 KATANA AMM Fuselage Doc 4 02 02 Rev 13 53 11 00 Page 5 15 Dec 2018 DV Panel Strut Handle Inner Tension Spring Safety Lock Magnetic Compass Canopy Assy DV Panel Figure 1 Canopy Complete...

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Page 559: ...quick lock fasteners The openings enable visual inspection and access to components and connections 2 Description The covers are made of aluminum or GFRP material The covers are located on the fuselag...

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Page 561: ...AIRCRAFT DV 20 KATANA AMM Stabilizers Doc 4 02 02 Rev 13 55 TITLE Page 1 15 Dec 2018 CHAPTER 55 STABILIZERS...

Page 562: ...AIRCRAFT Stabilizers DV 20 KATANA AMM Page 2 15 Dec 2018 55 TITLE Doc 4 02 02 Rev 13 Intentionally left blank...

Page 563: ...5 CONTENTS Page 1 15 Dec 2018 TABLE OF CONTENTS CHAPTER 55 00 STABILIZERS 1 General 1 Section 55 10 HORIZONTAL STABILIZERS 1 General 1 2 Description 1 3 Removal and Installation 2 Section 55 40 RUDDER...

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Page 565: ...the DV 20 KATANA consists of the horizontal stabilizer elevator fin elevator including trim tab vertical stabilizer rudder fin and rudder This chapter describes only the horizontal stabilizer elevator...

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Page 567: ...a metal fitting and two times four bolts A second mounting point is located near the leading edge of the horizontal stabilizer Here a pivot engages in the eye of the forward horizontal stabilizer fitt...

Page 568: ...0 and 27 40 1 Removal Detail Steps Work Items Key Items References 1 Remove horizontal stabilizer mounting bolts on fuselage side 2 Remove the horizontal stabilizer from the forward fitting by pulling...

Page 569: ...nformation refer to Chapter 27 20 30 This chapter describes only the rudder structure 2 Description The symmetrical half shells of the rudder are manufactured of PVC rigid foam covered on both sides T...

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Page 571: ...AIRCRAFT DV 20 KATANA AMM Wings Doc 4 02 02 Rev 13 57 TITLE Page 1 15 Dec 2018 CHAPTER 57 WINGS...

Page 572: ...AIRCRAFT Wings DV 20 KATANA AMM Page 2 15 Dec 2018 57 TITLE Doc 4 02 02 Rev 13 Intentionally left blank...

Page 573: ...INGS 1 General 1 Section 57 10 WING STRUCTURE 1 General 1 2 Description 1 3 Removal and Installation 2 4 Bolt Play 5 5 Replacement of Main Bolt Bushing 6 Section 57 50 WING FLAPS 1 General 1 2 Descrip...

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Page 575: ...eral The wing assembly of the DV 20 KATANA is a low wing monoplane design and consists of two cantilever wings with ailerons and wing flaps The wings are of semi monocoque sandwich construction For re...

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Page 577: ...root rib and are oriented in cross direction The A bolt is placed in front of the main bulkhead while the B bolt lies near the trailing edge The two main bolts are oriented in flight direction and are...

Page 578: ...device from main bolt support wing 5 Extract main bolt 6 Carefully remove wing from main bulkhead observing and disconnecting the electrical harness located at the root for the lights installed at the...

Page 579: ...NA AMM Wings Doc 4 02 02 Rev 13 57 10 00 Page 3 15 Dec 2018 Figure 1 Connectors and Bolts on LH Wing Root Figure 2 Proper Connection of Bellcrank and Pocket at Wing Root Ailerons and Flaps Only S N s...

Page 580: ...MM Page 4 15 Dec 2018 57 10 00 Doc 4 02 02 Rev 13 Flight Direction Locking Device Main Bolt Main Bulkhead Figure 3 Properly Secured B bolt Figure 4 Properly Secured Main Bolts Drawing does not show wi...

Page 581: ...ceed the values given in the table below A bolt in spherical bearing 0 08 mm 0 003 B bolt in spherical bearing 0 08 mm 0 003 Main bolt in spar stump bush 0 125 mm 0 005 Main bolt in main bulkhead bush...

Page 582: ...to the longitudinal axis with a hand milling machine 2 Remove bushings from the main bulkhead 4x Prepare the area for pasting the new bushings 3 Paste bronze bushings with thickened resin 4 Align the...

Page 583: ...structure 2 Description The wing flaps are of semi monocoque sandwich construction consisting of PVC rigid foam and glass and carbon fiber layers The flap has ribs on its inboard and outboard edges T...

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Page 585: ...er 27 10 This sub chapter only describes the structure and the removal and installation of the ailerons 2 Description The ailerons are of semi monocoque sandwich construction consisting of PVC rigid f...

Page 586: ...to Chapter 27 10 1 Removal Detail Steps Work Items Key Items References 1 Remove the dowel pins extract bearing journals NOTE Secure the aileron from falling down To ensure easy re installation mark...

Page 587: ...AIRCRAFT DV 20 KATANA AMM Propeller Doc 4 02 02 Rev 13 61 TITLE Page 1 15 Dec 2018 CHAPTER 61 PROPELLER...

Page 588: ...AIRCRAFT Propeller DV 20 KATANA AMM Page 2 15 Dec 2018 61 TITLE Doc 4 02 02 Rev 13 Intentionally left blank...

Page 589: ...V 20 KATANA AMM Propeller Doc 4 02 02 Rev 13 61 CONTENTS Page 1 15 Dec 2018 TABLE OF CONTENTS CHAPTER 61 00 PROPELLER 1 General 1 2 Description 1 3 Troubleshooting 2 4 Installation Procedure 6 5 Minor...

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Page 591: ...1 A 175 05 with 912 A3 engine only These propellers have a hydraulic infinitely variable pitch adjustment controlled by a propeller governor When the desired propeller speed is preselected the governo...

Page 592: ...22 1 lbs ft Use new safety plate and sealing mt Propeller Contact manufacturer or approved repair station in case of bladeshake in excess of 3 mm 1 8 Sluggish RPM Cold oil Friction in pitch change me...

Page 593: ...oil lines in engine cylinder propeller and governor Wrong speeder spring in governor Check governor designation with Airplane Type Certification Data Sheet Speeder spring in governor too weak 5 period...

Page 594: ...om outside Replace seals Pitch change due to leakage in internal oil system between governor and propeller Contact engine repair station Oil transfer rings on propeller shaft may be defective or suppl...

Page 595: ...ppear abruptly The quality of the prop speed control function deteriorates slowly over a period of time This condition should be detected during preflight inspections Oil sludge in cylinder of propell...

Page 596: ...ther both O rings are installed in the centering ring Install centering rings to hub mt Propeller Check position of O ring installed in propeller flange 3 Hoffmann Install propeller to centering on en...

Page 597: ...ed The damaged area is cleared from grease with common solvents and sanded with no 220 sanding paper If necessary the repair area should be treated with adequate nitro surfacer Be careful not to apply...

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Page 599: ...AIRCRAFT DV 20 KATANA AMM Power Plant Engine Doc 4 02 02 Rev 13 71 TITLE Page 1 15 Dec 2018 CHAPTER 71 POWER PLANT ENGINE...

Page 600: ...AIRCRAFT Power Plant Engine DV 20 KATANA AMM Page 2 15 Dec 2018 71 TITLE Doc 4 02 02 Rev 13 Intentionally left blank...

Page 601: ...General 1 2 Description 2 3 Troubleshooting 7 4 Removal and Installation 11 5 Maintenance Information 13 CHAPTER 71 10 COWLING 1 General 1 2 Removal and Installation 2 CHAPTER 71 20 ENGINE MOUNT 1 Ge...

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Page 603: ...eduction Gear Mechanical Fuel Pump Oil Filter Intake Air Filter CHAPTER 71 00 POWER PLANT ENGINE 1 General This chapter describes the engine installed in the DV 20 KATANA its external units removal an...

Page 604: ...ds The propeller rotates in clockwise direction Due to the reduction gear the engine turns in opposite direction The engine is equipped with self adjusting valves which are maintenance free The trigge...

Page 605: ...ontinuous RPM 2420 RPM 5500 RPM Idle RPM 950 RPM Bore 79 5 mm Stroke 61 0 mm Displacement 1211 cm3 Compression ratio 9 0 1 Ignition order 1 4 2 3 Min oil pressure up to engine serial no 4 410 226 engi...

Page 606: ...M Max continuous power 69 kW 94 hp Max continuous RPM 2260 RPM 5500 RPM Idle RPM 600 800 RPM Bore 84 mm 3 31 inch Stroke 61 0 mm 2 40 inch Displacement 1352 cm 82 5 inch Compression ratio 10 5 1 Ignit...

Page 607: ...rates totally independent from the electrical on board network Shielded wires are used to connect the spark plugs to the ignition magnetos D Air Distribution Box The air distribution box is of welded...

Page 608: ...ing system using contour clamps with spring washers acting in axial direction The clamp mechanism has a friction dampened backlash which is necessary to achieve a smooth idling Through this backlash a...

Page 609: ...defective or empty battery Recharge or replace battery Loose or defective ignition wire Heck wire connections replace if required Ignition box wet inside Dry thoroughly Spark plugs wet from condensat...

Page 610: ...ry Spark discharge over ignition wires Dry wet wires replace defective wires Defective ignition box Have box repaired or replace Clogged fuel filter Clean Engine runs too hot oil temperature exceeds 1...

Page 611: ...connectors check carburetor connecting piece Defective carburetor diaphragm Replace Low oil pressure Insufficient oil level Check oil level replenish if required Oil remains in engine and does not ret...

Page 612: ...park plugs installed without sealing ring Ensure that there is one sealing ring in each spark plug Excessive residue in combustion chamber Remove cylinder heads remove combustion residue check oil con...

Page 613: ...ork Items Key Items References 1 Install tail support Refer to Chapter 7 2 Remove upper and lower cowling 3 Disconnect nose wheel elastomer package assembly from engine mount 4 Disconnect ignition wir...

Page 614: ...For installation reverse the sequence B Carburetor 1 Installation Detail Steps Work Items Key Items References 1 Remove fuel line from carburetor 2 Disconnect bowden cables from air distribution box...

Page 615: ...ter both carburetors are adjusted to equal flow rates at idling speed The mixture screws can be fine adjusted to achieve equal response to throttle movements on both carburetors Adjustment of the main...

Page 616: ...ith a special testing device with the reduction gear removed from the engine see Repair Manual C Propeller Flange Check The propeller shaft must be removed for this check This check should be carried...

Page 617: ...engine cowling consists of two halves with an inspection cover located on the upper half allowing access to the oil dipstick and the coolant equalizing reservoir The cover is attached to the cowling...

Page 618: ...en fasteners on upper engine cowling 2 Remove upper cowling 3 On lower cowling disconnect electrical connection to landing light located on left hand side 4 Loosen fasteners on lower engine cowling 5...

Page 619: ...5 The shock mounts attached between the engine and the auxiliary engine mounts reduce the vibration transmission from the engine to the airframe 2 Description The engine mount is electrically grounded...

Page 620: ...l and Installation A Removal from the Firewall Detail Steps Work Items Key Items References 1 Remove bolts holding engine mount 2 Remove engine mount from firewall B Installation Detail Steps Work Ite...

Page 621: ...al A ram air guide made of GFRP is installed on the engine to ensure optimal engine cooling 2 Description The air guide is designed to follow the contours of the engine block and cylinders The exact f...

Page 622: ...val Detail Steps Work Items Key Items References 1 Disconnect coolant hoses from cylinder heads upper side remove 2 Remove auxiliary units on engine upper side 3 Disconnect fuel lines from fuel pump r...

Page 623: ...AIRCRAFT DV 20 KATANA AMM Engine Cooling Doc 4 02 02 Rev 13 75 TITLE Page 1 15 Dec 2018 CHAPTER 75 ENGINE COOLING...

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Page 625: ...AIRCRAFT DV 20 KATANA AMM Engine Cooling Doc 4 02 02 Rev 13 75 CONTENTS Page 1 15 Dec 2018 TABLE OF CONTENTS CHAPTER 75 10 ENGINE COOLING 1 General 1 2 Replenishing 4...

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Page 627: ...nt pump radiator dispatcher vessel and an equalizing reservoir The dispatcher vessel may hold the sensor for coolant quantity Also see Chapter 71 00 Figure 1 If an engine with suffix 01 is installed o...

Page 628: ...AIRCRAFT Engine Cooling DV 20 KATANA AMM Page 2 15 Dec 2018 75 10 00 Doc 4 02 02 Rev 13 Coolant Dispatcher Vessel Figure 2 Dispatcher Vessel...

Page 629: ...AIRCRAFT DV 20 KATANA AMM Engine Cooling Doc 4 02 02 Rev 13 75 10 00 Page 3 15 Dec 2018 Equalizing Reservoir Figure 3 Equalizing Reservoir...

Page 630: ...AIRCRAFT Engine Cooling DV 20 KATANA AMM Page 4 15 Dec 2018 75 10 00 Doc 4 02 02 Rev 13 2 Replenishing For replenishing refer to Sub Chapter 12 10...

Page 631: ...AIRCRAFT DV 20 KATANA AMM Engine Controls Doc 4 02 02 Rev 13 76 TITLE Page 1 15 Dec 2018 CHAPTER 76 ENGINE CONTROLS...

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Page 633: ...DV 20 KATANA AMM Engine Controls Doc 4 02 02 Rev 13 76 CONTENTS Page 1 15 Dec 2018 TABLE OF CONTENTS CHAPTER 76 10 ENGINE CONTROLS 1 General 1 2 Description 1 3 Troubleshooting 2 4 Removal and Instal...

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Page 635: ...of a malfunctioning of the throttle valve operating mechanism a spring will position the throttle valve in the fully open position B Choke Operation of the rotary slide valve starting carburetor is c...

Page 636: ...ing the friction washers installed on the lever axis 3 Troubleshooting The following table lists defects as they could appear on the engine controls and their correction Complaint Possible Cause Repai...

Page 637: ...rences 1 Remove engine cowlings 2 Remove instrument panel cover 3 Disconnect bowden cable clamps on carburetors 4 Disconnect bowden cable clamps on shift lever below instrument panel 5 Disconnect bowd...

Page 638: ...Engine Controls DV 20 KATANA AMM Page 4 15 Dec 2018 76 10 00 Doc 4 02 02 Rev 13 Bowden Cable Bowden Cable Clamp Carburetor Carburetor Bowden Cable Clamp Throttle Lever Figure 1 Throttle Control Bowde...

Page 639: ...pter 71 00 For adjustment of the bowden cables move the throttle lever to the idle position Move both levers located on the carburetors to idle position and tighten the bowden cable clamps For fine ad...

Page 640: ...ent panel cover 3 Disconnect bowden cables from carburetors 4 Disconnect bowden cables from parallel guide on center console 5 Remove bowden cables by pulling rearward 2 Installation Detail Steps Work...

Page 641: ...e from flap actuating lever on air distribution box 4 Remove throttle quadrant from center console in upward direction 5 Disconnect bowden cable from carburetor heat lever 6 Remove bowden cable by pul...

Page 642: ...TANA AMM Page 8 15 Dec 2018 76 10 00 Doc 4 02 02 Rev 13 Bowden Cable Bowden Cable Clamp Carburetor Heat Lever Flap Actuating Lever Air Distribution Box Tension Spring Bowden Cable Figure 2 Flap Actuat...

Page 643: ...hrottle quadrant on the center console and remove RH rotary knob 4 Remove throttle quadrant from center console in upward direction 5 Disconnect bowden cable from propeller speed control lever 6 Remov...

Page 644: ...ntrols DV 20 KATANA AMM Page 10 15 Dec 2018 76 10 00 Doc 4 02 02 Rev 13 Bowden Cable Bowden Cable Clamp Propeller Speed Control Lever Bowden Cable Propeller Governor Governor Lever Figure 3 Lever on P...

Page 645: ...Quadrant E Throttle Quadrant Friction Control 1 Removal Detail Steps Work Items Key Items References 1 Remove rotary knob on RH side of center console 2 Remove washer springs and replace if required 2...

Page 646: ...AIRCRAFT Engine Controls DV 20 KATANA AMM Page 12 15 Dec 2018 76 10 00 Doc 4 02 02 Rev 13 Intentionally left blank...

Page 647: ...AIRCRAFT DV 20 KATANA AMM Engine Indicating Doc 4 02 02 Rev 13 77 TITLE Page 1 15 Dec 2018 CHAPTER 77 ENGINE INDICATING...

Page 648: ...AIRCRAFT Engine Indicating DV 20 KATANA AMM Page 2 15 Dec 2018 77 TITLE Doc 4 02 02 Rev 13 Intentionally left blank...

Page 649: ...V 20 KATANA AMM Engine Indicating Doc 4 02 02 Rev 13 77 CONTENTS Page 1 15 Dec 2018 TABLE OF CONTENTS CHAPTER 77 00 ENGINE INDICATING 1 General 1 2 Description 1 3 Troubleshooting 3 4 Removal and Inst...

Page 650: ...AIRCRAFT Engine Indicating DV 20 KATANA AMM Page 2 15 Dec 2018 77 CONTENTS Doc 4 02 02 Rev 13 Intentionally left blank...

Page 651: ...ropeller and not that of the engine B Fuel Pressure Warning Light The fuel pressure warning light is located in the center section of the instrument panel and is activated by a pressure sensor located...

Page 652: ...led on cylinder no 3 right rear G Manifold Pressure Indicator The indicator is located in the right hand section of the instrument panel A hose is attached to the equalizing pipe connecting the intake...

Page 653: ...Defective RPM indicator Replace No oil pressure indication Defective sensor Defective indicator Replace Replace Low oil pressure indication Low oil pressure Clogged bore in sensor Check oil pressure u...

Page 654: ...ary Replace 4 Removal and Installation If an engine with suffix 01 is installed the headline Cylinder Head Temperature Indicator is changed to Coolant Temperature Indicator A RPM Indicator 1 Removal D...

Page 655: ...AIRCRAFT DV 20 KATANA AMM Engine Indicating Doc 4 02 02 Rev 13 77 00 00 Page 5 15 Dec 2018 RPM Indicator Flexible Shaft Nut Figure 1 RPM Indicator...

Page 656: ...ove warning light from instrument panel 2 Installation Detail Steps Work Items Key Items References 1 For installation reverse the sequence C Control Light for Coolant Quantity 1 Removal Detail Steps...

Page 657: ...s D Oil Pressure Indicator 1 Removal Detail Steps Work Items Key Items References 1 Pull off connectors from rear of instrument 2 Remove nuts from mounting bracket 3 Remove instrument from panel 2 Ins...

Page 658: ...ove instrument from panel 2 Installation Detail Steps Work Items Key Items References 1 For installation reverse the sequence F Cylinder Head Temperature Indicator Coolant Temperature Indicator 1 Remo...

Page 659: ...Bolt G Manifold Pressure Indicator 1 Removal Detail Steps Work Items Key Items References 1 Pull off connectors from rear of instrument 2 Remove mounting bolts and nuts 3 Remove instrument from panel...

Page 660: ...AIRCRAFT Engine Indicating DV 20 KATANA AMM Page 10 15 Dec 2018 77 00 00 Doc 4 02 02 Rev 13 Intentionally left blank...

Page 661: ...AIRCRAFT DV 20 KATANA AMM Exhaust Doc 4 02 02 Rev 13 78 TITLE Page 1 15 Dec 2018 CHAPTER 78 EXHAUST...

Page 662: ...AIRCRAFT Exhaust DV 20 KATANA AMM Page 2 15 Dec 2018 78 TITLE Doc 4 02 02 Rev 13 Intentionally left blank...

Page 663: ...DV 20 KATANA AMM Exhaust Doc 4 02 02 Rev 13 78 CONTENTS Page 1 15 Dec 2018 TABLE OF CONTENTS CHAPTER 78 00 EXHAUST 1 General 1 2 Description 2 3 Troubleshooting 2 4 Removal and Installation 3 5 Inspe...

Page 664: ...AIRCRAFT Exhaust DV 20 KATANA AMM Page 2 15 Dec 2018 78 CONTENTS Doc 4 02 02 Rev 13 Intentionally left blank...

Page 665: ...th its own exhaust pipe leading to the underside of the engine where they are attached to the muffler To enable a heat expansion of the exhaust system the connections between muffler and pipes are mov...

Page 666: ...irected to the cockpit by a hose Another section of the heat exchanger provides hot air that is guided to the air distribution box 3 Troubleshooting The following table lists defects as they could app...

Page 667: ...To perform this test loosen the mounting screws of the heat exchanger and inspect the muffler for cracks and corrosion The weld seams are especially susceptible to cracks through which dangerous carb...

Page 668: ...AIRCRAFT Exhaust DV 20 KATANA AMM Page 4 15 Dec 2018 78 00 00 Doc 4 02 02 Rev 13 Intentionally left blank...

Page 669: ...AIRCRAFT DV 20 KATANA AMM Oil Cooling Doc 4 02 02 Rev 13 79 TITLE Page 1 15 Dec 2018 CHAPTER 79 OIL...

Page 670: ...AIRCRAFT Oil Cooling DV 20 KATANA AMM Page 2 15 Dec 2018 79 TITLE Doc 4 02 02 Rev 13 Intentionally left blank...

Page 671: ...NTS Page 1 15 Dec 2018 TABLE OF CONTENTS CHAPTER 79 OIL COOLING 1 General 1 2 Description 2 Section 79 21 OIL RADIATOR 1 General 1 2 Troubleshooting 2 3 Removal and Installation 3 Section 79 30 INDICA...

Page 672: ...AIRCRAFT Oil Cooling DV 20 KATANA AMM Page 2 15 Dec 2018 79 CONTENTS Doc 4 02 02 Rev 13 Intentionally left blank...

Page 673: ...ith an oil radiator attached to the engine mount on the right hand engine side and connected to the engine with oil lines An opening in the lower engine cowling supplies ram air to the oil radiator Th...

Page 674: ...the oil pump A temperature sensor is installed next to the oil filter This sensor is connected to the oil temperature indicator An oil pressure sensor is installed opposite to the oil filter It is con...

Page 675: ...or is located on the lower right side of the engine attached to the engine mount The oil radiator has two threaded connection sleeves to which the oil lines are attached The sleeves are also used to s...

Page 676: ...lists defects as they could appear on the oil cooling system and their correction Complaint Possible Cause Repair Excessive oil temperature Damaged radiator fins Inhibited air flow Replace radiator C...

Page 677: ...e lines from radiator ports 2 Straighten locking plates on hose connectors 3 Remove mounting nuts 4 Remove oil radiator 2 Installation Detail Steps Work Items Key Items References 1 For installation r...

Page 678: ...AIRCRAFT Oil Cooling DV 20 KATANA AMM Page 4 15 Dec 2018 79 21 00 Doc 4 02 02 Rev 13 Oil Radiator Hose Line Hose Line Radiator Port Locking Plate Locking Plate Radiator Port Figure 1 Oil Radiator...

Page 679: ...site of the oil filter Both sensors operate electrically and transmit their data to the instruments located in the instrument panel A Oil Temperature Sensor The oil temperature sensor uses a resistor...

Page 680: ...system and their correction Complaint Possible Cause Repair No oil temperature indication Defective wiring or connector Defective sensor Check wiring and connector Replace sensor No oil pressure indi...

Page 681: ...Key Items References 1 Disconnect wiring 2 Remove sensor using suitable tool 2 Installation Detail Steps Work Items Key Items References 1 For installation reverse the sequence When installing a new s...

Page 682: ...AIRCRAFT Oil Cooling DV 20 KATANA AMM Page 4 15 Dec 2018 79 30 00 Doc 4 02 02 Rev 13 Figure 1 Oil Temperature Sensor and Oil Filter...

Page 683: ...n installing the sensor a suitable sealing compound must be used e g Crane pac Plastic Lead Seal No 2 Max torque of sensor in engine block 30 Nm 22 1 lbs ft Proper torque of cable connector 1 Nm 0 74...

Page 684: ...AIRCRAFT Oil Cooling DV 20 KATANA AMM Page 6 15 Dec 2018 79 30 00 Doc 4 02 02 Rev 13 Figure 2 Oil Pressure Sensor...

Page 685: ...AIRCRAFT DV 20 KATANA AMM Wiring Diagrams Doc 4 02 02 Rev 13 92 TITLE Page 1 15 Dec 2018 CHAPTER 92 WIRING DIAGRAMS...

Page 686: ...AIRCRAFT Wiring Diagrams DV 20 KATANA AMM Page 2 15 Dec 2018 92 TITLE Doc 4 02 02 Rev 13 Intentionally left blank...

Page 687: ...AIRCRAFT DV 20 KATANA AMM Wiring Diagrams Doc 4 02 02 Rev 13 92 CONTENTS Page 1 15 Dec 2018 TABLE OF CONTENTS CHAPTER 92 WIRING DIAGRAMS 1 General 1...

Page 688: ...AIRCRAFT Wiring Diagrams DV 20 KATANA AMM Page 2 15 Dec 2018 92 CONTENTS Doc 4 02 02 Rev 13 Intentionally left blank...

Page 689: ...AA80 01 2310 14 1 2 3 19 05 93 0 VHF COMM AR3201 COMM TRANSCEIVER 01 2310 14 2 1 21 05 93 0 VHF COMM AR3201 ICS Switching 01 2310 14 2 2 21 05 93 0 Audio Integration Cabin Audio General 01 2350 14 1...

Page 690: ...Electrical Wiring Diag Engine Compartm 820 2400 00 00 sheet 1 19 10 99 0 Electrical Wiring Diag Flight Compartm 820 2400 00 00 sheet 2 17 10 99 0 Schematic Avionics Cooling D20 9221 20 01 22 06 12 A S...

Page 691: ...Directional Gyro Wiring D20 9234 10 02 18 06 12 A Schematic Turn Bank Wiring D20 9234 10 03 06 06 12 A Schematic GPSMAP Wiring D20 9234 50 08 07 07 09 Schematic GNS 430 GI 106A Wiring D20 9234 50 15...

Page 692: ...AIRCRAFT Wiring Diagrams DV 20 KATANA AMM Page 4 15 Dec 2018 92 00 00 Doc 4 02 02 Rev 13 Intentionally left blank...

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Page 722: ...MAINTENANCE MANUAL DV 20 KATANA...

Page 723: ...MAINTENANCE MANUAL DV 20 KATANA...

Page 724: ...ALE SH OF DW G NO REV DATE SIGN DEPARTMENT DRAW N CHECKED QA STRESS MANUF SYSTEM APPROVED TL IDENTIFICATION MARKINGS CLASSIFICATION INTERCHANGEABLE PART THIS DRAW ING W AS PRODUCED USING SOFTW ARE FIL...

Page 725: ...26A24BL HAND MIC PILOT PM 1000 II GS IP 23202A24WH MIC AUDIO LO MIC AUDIO HI 13 25 A C RADIO AUDIO LO A C RADIO AUDIO HI 23202A24BL 23203A24WH MIC KEY 12 4 17 COM 5A SL 30 23204A24WH 23 NAV AUDIO AUDI...

Page 726: ...SPECIFIED DIMENSIONS ARE IN MM DIMENSION TOLERANCES 2 DECIMAL u 0 25 1DECIMAL u 0 5 DECIMAL u 1 ANGLE u 1 RAD u 0 5 NTS N A N A N A N A 23000B24BL 23000B24WH 23014B24WH 23001B24WH 23002B24WH 23002B24B...

Page 727: ...NDING LIGHT P3341 J3341 7722B22 7932B22 7332B22 23 24 22 19 20 10 7 4 2 1 BAT GRD R S L 7432B16 7431B16 741A16N 8014A22 8013A16 X A B L 50 2405A6 BATT 2437A22 245A22N 2404B22 2 50 3342A16 2406A10 10 5...

Page 728: ...CLASSIFICATION INTERCHANGEABLE PART THIS DRAW ING W AS PRODUCED USING SOFTW ARE FILENAME DIMENSIONS FIRST ANGLE PROJECTION FORMAT FINISH IN MICRO METER UNLESS OTHERW ISE SPECIFIED DIMENSIONS ARE IN MM...

Page 729: ...FORMAT FINISH IN MICRO METER UNLESS OTHERW ISE SPECIFIED DIMENSIONS ARE IN MM DIMENSION TOLERANCES 2 DECIMAL u 0 25 1DECIMAL u 0 5 DECIMAL u 1 ANGLE u 1 RAD u 0 5 NTS N A N A N A N A REV ZONE SH DESCR...

Page 730: ...onfidential PROJECT TITLE DWG ORIG CODE SCALE SH OF DWG NO REV DATE SIGN DEPARTMENT DRAWN CHECKED QA STRESS MANUF SYSTEM APPROVED J tte IDENTIFICATION MARKINGS CLASSIFICATION INTERCHANGEABLE PART THIS...

Page 731: ...LE SH OF DW G NO REV DATE SIGN DEPARTMENT DRAW N CHECKED QA STRESS MANUF SYSTEM APPROVED TL IDENTIFICATION MARKINGS CLASSIFICATION INTERCHANGEABLE PART THIS DRAW ING W AS PRODUCED USING SOFTW ARE FILE...

Page 732: ...UF SYSTEM APPROVED TL IDENTIFICATION MARKINGS CLASSIFICATION INTERCHANGEABLE PART THIS DRAW ING W AS PRODUCED USING SOFTW ARE FILENAME DIMENSIONS FIRST ANGLE PROJECTION FORMAT FINISH IN MICRO METER UN...

Page 733: ...DRAW N CHECKED QA STRESS MANUF SYSTEM APPROVED TL IDENTIFICATION MARKINGS CLASSIFICATION INTERCHANGEABLE PART THIS DRAW ING W AS PRODUCED USING SOFTW ARE FILENAME DIMENSIONS FIRST ANGLE PROJECTION FOR...

Page 734: ...G NO REV DATE SIGN DEPARTMENT DRAW N CHECKED QA STRESS MANUF SYSTEM APPROVED TL IDENTIFICATION MARKINGS CLASSIFICATION INTERCHANGEABLE PART THIS DRAW ING W AS PRODUCED USING SOFTW ARE FILENAME DIMENSI...

Page 735: ...ghting for Flap Switch and other Switches added ALL 01 A 03 12 12 SEE TB NTS 33014A22 GS IP 10 33020A22N 33021A22 5k 33022A22 2 1 J3302 33025A22 ASI ALT 2 J3303 1 2 33024A22 HOR J3422 D 33027A22 FLAP...

Page 736: ...RODUCED USING SOFTW ARE FILENAME DIMENSIONS FIRST ANGLE PROJECTION FORMAT FINISH IN MICRO METER UNLESS OTHERW ISE SPECIFIED DIMENSIONS ARE IN MM DIMENSION TOLERANCES 2 DECIMAL u 0 25 1DECIMAL u 0 5 DE...

Page 737: ...TITLE DW G ORIG CODE SCALE SH OF DW G NO REV DATE SIGN DEPARTMENT DRAW N CHECKED QA STRESS MANUF SYSTEM APPROVED TL IDENTIFICATION MARKINGS CLASSIFICATION INTERCHANGEABLE PART THIS DRAW ING W AS PRODU...

Page 738: ...SCALE SH OF DW G NO REV DATE SIGN DEPARTMENT DRAW N CHECKED QA STRESS MANUF SYSTEM APPROVED TL IDENTIFICATION MARKINGS CLASSIFICATION INTERCHANGEABLE PART THIS DRAW ING W AS PRODUCED USING SOFTW ARE...

Page 739: ...tial PROJECT TITLE DW G ORIG CODE SCALE SH OF DW G NO REV DATE SIGN DEPARTMENT DRAW N CHECKED QA STRESS MANUF SYSTEM APPROVED TL IDENTIFICATION MARKINGS CLASSIFICATION INTERCHANGEABLE PART THIS DRAW I...

Page 740: ...A 1 2 3 4 5 6 7 8 Confidential PROJECT TITLE DW G ORIG CODE SCALE SH OF DW G NO REV DATE SIGN DEPARTMENT DRAW N CHECKED QA STRESS MANUF SYSTEM APPROVED J tte IDENTIFICATION MARKINGS CLASSIFICATION INT...

Page 741: ...34001A24BL 34013A24BL 34013A24WH 34014A24BL 34014A24WH 35 36 27 29 GS FLAG GS FLAG 30 28 33 STATOR D STATOR E 34 STATOR G STATOR F 22 RIGHT 24 VOR FLAG VOR FLAG 23 TO 25 FROM 26 LEFT 21 34614A20N 346...

Page 742: ...DECIMAL u 0 25 1DECIMAL u 0 5 DECIMAL u 1 ANGLE u 1 RAD u 0 5 NTS N A N A N A N A REV ZONE SH DESCRIPTION DATE APPROVAL REVISION O M 20 244 FIRST RELEASE ALL 01 28 05 09 SEE TB O M 20 267 Wire 33014A...

Page 743: ...RTMENT DRAW N CHECKED QA STRESS MANUF SYSTEM APPROVED TL IDENTIFICATION MARKINGS CLASSIFICATION INTERCHANGEABLE PART THIS DRAW ING W AS PRODUCED USING SOFTW ARE FILENAME DIMENSIONS FIRST ANGLE PROJECT...

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