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Diamond DA 42 NG, Maintenance Manual

The Diamond DA 42 NG Maintenance Manual is a comprehensive guide that provides detailed instructions and essential information for maintaining and servicing your aircraft. You can conveniently download this user manual for free from our website, ensuring you have the necessary resources to keep your Diamond DA 42 NG in optimal condition.

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AIRCRAFT

DA 42 Series AMM

Record of Revision

Doc # 7.02.15

Rev. 4

ROR

Page v

15 Mar 2018

Record of Revision

1. Record of Revision

Use this check list to record and control all of the revisions which you put in this Airplane Maintenance

Manual (AMM). Put 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and destroy the pages which are superseded.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

Number

Date

Issued

Inserted

On

Inserted

By

Original

18 Feb 2009

1

15 Oct 2009

2

31 Mar 2012

3

16 Aug 2016

4

%

15 Mar 2018

%

Revision

Number

Date

Issued

Inserted

On

Inserted

By

Summary of Contents for DA 42 NG

Page 1: ...AIRCRAFT DA 42 NG AIRPLANE MAINTENANCE MANUAL Copyright by DIAMOND AIRCRAFT INDUSTRIES Wiener Neustadt Austria ...

Page 2: ...ion by photo mechanical or similar means and storing in data processing facilities 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 information contained in this document has been approved under the authority of DOA No EASA 21J 052 ...

Page 3: ...0 Maintenance Checklist Airframe 05 28 90 Maintenance Report 05 28 91 Engine Ground Test Record 05 28 92 Check Flight Report 05 28 93 Major Structural Inspection Check Findings Report 05 50 Unscheduled Maintenance Checks 06 00 Dimensions and Areas 07 00 Lifting and Shoring 07 10 Jacking 07 11 Hoisting 08 00 Leveling and Weighing 08 10 Weighing 08 20 Leveling 09 00 Towing and Taxiing 09 10 Towing 0...

Page 4: ...n 23 15 Satellite Transceiver System if OÄM 42 215 is carried out 23 50 Audio Integration 23 60 Static Discharging 24 00 Electrical Power 24 30 DC Generation 24 31 Battery Systems 24 32 Emergency Power 24 33 Additional Alternator 24 40 External Power 24 60 DC Electrical Load Distribution 25 00 Equipment Furnishings 25 10 Flight Compartment 25 50 Aft Baggage Compartment 25 60 Emergency Equipment 26...

Page 5: ...ension and Retraction 32 40 Wheels and Brakes 32 50 Steering 32 60 Position and Warning 33 00 Lights 33 10 Lights Flight Compartment 33 40 Exterior Lights 34 00 Navigation 34 10 Flight Environment Data 34 20 Attitude and Direction 34 30 Landing and Taxiing Aids 34 40 Independent Position Determining 34 41 Stormscope System 34 42 Traffic Advisory System 34 43 Garmin GWX68 or GWX70 Weather Radar Sys...

Page 6: ...ns 61 00 Propeller 61 10 Propeller Assembly 61 20 Propeller Control 71 00 Power Plant 71 10 Engine Cowlings 71 11 Engine Cowlings if MÄM 42 600 is installed 71 20 Engine Mounting 71 50 Electrical Cables in the Engine Compartment 71 60 Air Intakes 71 61 Air Intakes if MÄM 42 600 is installed 71 70 Engine Drains 71 71 Engine Drains if MÄM 42 600 is installed 72 00 Engine 73 00 Engine Fuel and Contro...

Page 7: ...his Airplane Maintenance Manual AMM Put 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 Number Date Issued Inserted On Inserted By Original 18 Feb 2009 1 15 Oct 2009 2 31 Mar 2012 3 16 Aug 2016 4 15 Mar 2018 Revision Number Date Issued Inserted On In...

Page 8: ...ision AMM TR MÄM 42 319 Main Landing Gear Measurement AMM TR MÄM 42 332 Inspection Intervals Rudder Trim Mechanism AMM TR MÄM 42 334 Improved Maintenance Instructions for the Passenger Door AMM TR MÄM 42 336 Optimized NLG Actuator AMM TR MÄM 42 356 a Rudder Trim Adjustment AMM TR MÄM 42 384 Alternate Air Valve FOD Screen AMM TR MÄM 42 391 Turbo System Aluminium Tube AMM TR MÄM 42 395 Improved Heat...

Page 9: ...ÄM 42 538 Fuel Drain Valve Mounting Torque AMM TR MÄM 42 550 Routing in Center Wing AMM TR MÄM 42 551 Alternator Regulator E4A 91 200 000 AMM TR MÄM 42 570 Large Washer at RH FWD Engine Mounting Arm Bolt AMM TR MÄM 42 594 Alternative Engine Shock Mount AMM TR MÄM 42 600 Performance Enhancement AMM TR MÄM 42 601 Corrections AMM TR MÄM 42 641 Propeller Pitch Information AMM TR OÄM 42 176 171 Retrofi...

Page 10: ...uel System AMM TR MÄM 42 743 Governor Nut Torque AMM TR MÄM 42 745 a Coolant Tank Pressure Relief Valve Test AMM TR MÄM 42 746 Coolant System Pressure Test AMM TR MÄM 42 756 Ground Handling AMM TR MÄM 42 823 Protective Pads for Charged Air Hoses AMM TR MÄM 42 852 Coolant Water Tank with Threaded Cap and Larger Filler Neck AMM TR MÄM 42 875 Replacement of Passenger Door Hinges AMM TR MÄM 42 878 Acc...

Page 11: ...in GSR 56 AMM TR OÄM 42 222 Whelen LED Position Anti Collision Lights AMM TR OÄM 42 224 Removal of Unfeathering Accumulator AMM TR OÄM 42 226 ELT KANNAD 406 AF Compact AMM TR OÄM 42 231 a Trim Weight AMM TR OÄM 42 251 Diesel Operation AMM TR OÄM 42 259 a Front Seats with Adjustable Backrest Hydrolok AMM TR OÄM 42 270 Mid Continent MD302 Standby Attitude Module AMM TR OÄM 42 277 Provisions for MÄM ...

Page 12: ... Handle Improvement AMM TR MÄM 42 995 Engine Oils AMM TR MÄM 42 1001 a Colors other than White AMM TR MÄM 42 1004 SG3 0 Hose between Turbo Charger and Intercooler AMM TR MÄM 42 1008 Turbo Charger Hose Installation AMM TR MÄM 42 1024 New Maplight AMM TR MÄM 42 1041 Rudder Balance Mass Increase AMM TR MÄM 42 1049 Horizontal Stabilizer Torque AMM TR MÄM 42 1052 Rudder and Rudder Trim Adjustment AMM T...

Page 13: ...5 Mar 2018 LOEP 6 15 Mar 2018 LOEP 7 15 Mar 2018 LOEP 8 15 Mar 2018 LOEP 9 15 Mar 2018 Chapter Section Page Revision Date LOEP 10 15 Mar 2018 LOEP 11 15 Mar 2018 LOEP 12 15 Mar 2018 LOEP 13 15 Mar 2018 LOEP 14 15 Mar 2018 LOEP 15 15 Mar 2018 LOEP 16 15 Mar 2018 LOEP 17 15 Mar 2018 LOEP 18 15 Mar 2018 LOEP 19 15 Mar 2018 LOEP 20 15 Mar 2018 LOEP 21 15 Mar 2018 LOEP 22 15 Mar 2018 LOEP 23 15 Mar 201...

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Page 31: ...r 2018 34 43 204 15 Mar 2018 34 50 1 15 Mar 2018 34 50 2 15 Mar 2018 34 50 101 15 Mar 2018 34 50 102 15 Mar 2018 34 50 201 15 Mar 2018 34 50 202 15 Mar 2018 34 50 203 15 Mar 2018 34 50 204 15 Mar 2018 34 50 205 15 Mar 2018 34 50 206 15 Mar 2018 34 50 207 15 Mar 2018 34 50 208 15 Mar 2018 34 50 209 15 Mar 2018 34 50 210 15 Mar 2018 34 50 211 15 Mar 2018 34 50 212 15 Mar 2018 34 56 1 15 Mar 2018 34 ...

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Page 34: ... 56 00 TOC 2 15 Mar 2018 56 00 1 15 Mar 2018 56 00 2 15 Mar 2018 56 10 1 15 Mar 2018 56 10 2 15 Mar 2018 56 10 3 15 Mar 2018 56 10 4 15 Mar 2018 56 10 201 15 Mar 2018 56 10 202 15 Mar 2018 56 10 203 15 Mar 2018 56 10 204 15 Mar 2018 56 10 205 15 Mar 2018 56 10 206 15 Mar 2018 56 10 207 15 Mar 2018 56 10 208 15 Mar 2018 57 00 Title 1 15 Mar 2018 57 00 Title 2 15 Mar 2018 57 00 TOC 1 15 Mar 2018 57 ...

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Page 38: ... 00 TOC 2 15 Mar 2018 78 00 1 15 Mar 2018 78 00 2 15 Mar 2018 78 00 3 15 Mar 2018 78 00 4 15 Mar 2018 78 00 101 15 Mar 2018 78 00 102 15 Mar 2018 78 00 201 15 Mar 2018 78 00 202 15 Mar 2018 79 00 Title 1 15 Mar 2018 79 00 Title 2 15 Mar 2018 79 00 TOC 1 15 Mar 2018 79 00 TOC 2 15 Mar 2018 79 00 1 15 Mar 2018 79 00 2 15 Mar 2018 79 00 101 15 Mar 2018 79 00 102 15 Mar 2018 79 00 201 15 Mar 2018 79 0...

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Page 40: ...AIRCRAFT List of Effective Pages DA 42 NG AMM Page 28 15 Mar 2018 LOEP Doc 7 02 15 Rev 4 Intentionally left blank ...

Page 41: ...AIRCRAFT DA 42 NG AMM Introduction Doc 7 02 15 Rev 4 01 TITLE Page 1 15 Mar 2018 CHAPTER 01 INTRODUCTION ...

Page 42: ...AIRCRAFT Introduction DA 42 NG AMM Page 2 15 Mar 2018 01 TITLE Doc 7 02 15 Rev 4 Intentionally left blank ...

Page 43: ...4 01 CONTENTS Page 1 15 Mar 2018 TABLE OF CONTENTS CHAPTER 01 INTRODUCTION 1 General 1 2 Revision Service 1 3 Warning Cautions and Notes 1 4 Manual Configuration 2 5 Page Numbering System 6 6 Figures 6 7 Record of Revisions 6 8 List of Effective Pages 6 ...

Page 44: ...AIRCRAFT Introduction DA 42 NG AMM Page 2 15 Mar 2018 01 CONTENTS Doc 7 02 15 Rev 4 Intentionally left blank ...

Page 45: ...intenance data is referenced in Chapter 05 00 2 Revision Service The manufacturer provides a revision service for the Airplane Maintenance Manual The revision shows design changes to the airplane or changes in procedures Each page of the manual shows the date of issue If the page has changed it shows the date of the revision 3 Warning Cautions and Notes Obey all the usual safety precautions and ma...

Page 46: ...equirement of the ATA iSpec2200 There are only 3 sources of words available to use in Simplified English SE Approved words from the SE Guide These words have defined meanings and selected parts of speech Technical names as defined in the SE Guide Used only as adjectives or nouns Manufacturing processes as defined in the SE Guide Always used as verbs To obtain a copy of the SE Guide contact ASD STA...

Page 47: ...p Chapter 57 Section 50 contains the data for the trailing edge flaps installation The third pair of numbers shows a unit A unit could be the flap itself Only complex systems use unit numbers For simple systems the main chapter has all of the data and there are no section sub system break downs B Groups of Chapters The chapters are put together in these groups Group A Introduction Chapters 01 02 G...

Page 48: ...ions of the airplane and general procedures such as towing parking and weighing Chapter 11 tells you about the placards and markings which are important for the safe operation of the airplane Chapter 12 contains servicing tasks such as refueling and lubrication It also contains data about cleaning the airplane 3 Group C Airframe Systems Chapter 20 contains the standard practices for airframe maint...

Page 49: ...or maintenance of the engine on the airplane Refer to the engine manufacturer s manual for other data C Chapter Configuration The first page of each chapter shows the number of the chapter and the title The second page shows the contents Where applicable each chapter and section contains the topics that follow Description and Operation Trouble Shooting Maintenance Practices Where applicable the ma...

Page 50: ...o 99 Trouble Shooting Pages 101 to 199 Maintenance Procedures Pages 201 to 299 6 Figures Figures are given numbers in sequence The first figure in a chapter or section is Figure 1 7 Record of Revisions The Airplane Maintenance Manual has a Record of Revisions Use the Record of Revisions to show when changes were included in the Airplane Maintenance Manual 8 List of Effective Pages This Airplane Ma...

Page 51: ...AIRCRAFT DA 42 NG AMM Manual Organization Doc 7 02 15 Rev 4 02 TITLE Page 1 15 Mar 2018 CHAPTER 02 ORGANIZATION AND HANDLING OF THE MANUAL ...

Page 52: ...AIRCRAFT Manual Organization DA 42 NG AMM Page 2 15 Mar 2018 02 TITLE Doc 7 02 15 Rev 4 Intentionally left blank ...

Page 53: ...HANDLING OF THE MANUAL 1 General 1 2 Applicability 1 3 Revisions 1 4 Temporary Revisions 1 5 Service Bulletins and Service Instructions 2 6 Concession Reports and Non Conformance Reports 2 7 Document Notifications 2 8 Abbreviations 3 9 Conversion Factors and Abbreviations 5 10 Torque Conversion Factor 7 11 Supplemental Airplane Manuals 9 ...

Page 54: ...AIRCRAFT Manual Organization DA 42 NG AMM Page 2 15 Mar 2018 02 CONTENTS Doc 7 02 15 Rev 4 Intentionally left blank ...

Page 55: ...sions The manufacturer makes changes to the Airplane Maintenance Manual to show design changes maintenance procedure changes or other changes Each group of changes is called a Revision A manual revision contains these items The changed pages The reason for the revision Instructions for putting the revision into the Airplane Maintenance Manual A new List of Effective Pages LOEP A vertical bar in th...

Page 56: ...mance Reports are tools to approve and document deviations from the standard manufacturing processes during construction and assembly of an individual airplane for example handling of a mis drilled hole in the fuselage In case the operator or the maintenance organization needs to be informed as a consequence of the deviations for that particular airplane for example the use of a special spare part...

Page 57: ...gine Control Unit ELT Emergency Locator Transmitter FRP Fiber Reinforced Plastic GFRP Glass Fiber Reinforced Plastic GPS Global Positioning System G S Glide Slope IAU Integrated Avionics Unit ICS Integrated Cockpit System IFR Instrument Flight Rules HSI Horizontal Situation Indicator LOC Localizer MSI Major Structural Inspection OAT Outside Air Temperature PFD Primary Flight Display RCPI Remote Co...

Page 58: ...on DA 42 NG AMM Page 4 15 Mar 2018 02 00 00 Doc 7 02 15 Rev 4 TTSO Total Time Since Overhaul UHF Ultra High Frequency VFR Visual Flight Rules VHF Very High Frequency VOR VHF Omni Directional Ranging VSI Vertical Speed Indicator ...

Page 59: ... km 1 852 nm km 1 609 sm in x 25 4 mm ft x 0 3048 m nm x 1 852 km sm x 1 609 km Velocity Kilometers per hour km h Meters per second m s Miles per hour mph Knots kts Feet per minute fpm km h 1 852 kts km h 1 609 mph m s x 196 85 fpm mph x 1 609 km h kts x 1 852 km h fpm 196 85 m s Rotational Speed Revolutions per minute RPM RPM min 1 Pressure Bar bar Hectopascal hPa Millibar mbar Pounds per square ...

Page 60: ...S gal US quart US qt Imperial gallon Imp gal Cubic inch in3 l 3 7854 US gal l 0 9464 US qts l 4 5461 Imp gal l 61 024 in3 US gal x 3 7854 l US qt x 0 9464 l Imp gal x 4 5461 l in3 x 61 024 l Torque Newton meter Nm Pound force foot lbf ft Pound force inch lbf in Nm 1 3558 lbf ft Nm x 8 851 lbf in lbf ft x 1 3558 Nm lbf in 8 851 Nm Temperature Degree Celsius C Degree Fahrenheit F C x 1 8 32 F F 32 1...

Page 61: ...torque values Nm lbf ft Use figure 2 for conversion of Nm lbf in Figure 1 Nm lbf ft Find the Nm value on the horizontal axis Move vertically to the solid black diagonal line Then move horizontally to the vertical axis Read the value in lbf ft Example To convert 24 Nm to lbf ft find 24 Nm on the horizontal axis see the dashed line Follow the dashed line vertically to the solid black diagonal line T...

Page 62: ...lbf in 75 80 85 90 Figure 2 Nm lbf in Find the Nm value on the horizontal axis Move vertically to the solid black diagonal line Then move horizontally to the vertical axis Read the value in lbf in Example To convert 4 4 Nm to lbf in find 4 4 Nm on the horizontal axis see the dashed line Follow the dashed line vertically to the solid black diagonal line Then follow the dashed line horizontally to t...

Page 63: ...Airplane Manuals Supplemental Airplane Maintenance Manuals are used to provide maintenance procedures and installation instructions for additional equipment A List of Supplemental AMMs Doc No Title Rev No Date applicable YES NO 7 02 15 O03 O03 Retrofit Installation of Austro Engine E4 B 0 01 Jun 2009 9 9 ...

Page 64: ...AIRCRAFT Manual Organization DA 42 NG AMM Page 10 15 Mar 2018 02 00 00 Doc 7 02 15 Rev 4 Intentionally left blank ...

Page 65: ...AIRCRAFT DA 42 NG AMM General Description Doc 7 02 15 Rev 4 03 TITLE Page 1 15 Mar 2018 CHAPTER 03 GENERAL DESCRIPTION OF THE AIRPLANE ...

Page 66: ...AIRCRAFT General Description DA 42 NG AMM Page 2 15 Mar 2018 03 TITLE Doc 7 02 15 Rev 4 Intentionally left blank ...

Page 67: ...42 NG AMM General Description Doc 7 02 15 Rev 4 03 CONTENTS Page 1 15 Mar 2018 TABLE OF CONTENTS CHAPTER 03 GENERAL DESCRIPTION OF THE AIRPLANE 1 Description 1 2 Equipment Data 4 3 Handling of Identification Data 8 ...

Page 68: ...AIRCRAFT General Description DA 42 NG AMM Page 2 15 Mar 2018 03 CONTENTS Doc 7 02 15 Rev 4 Intentionally left blank ...

Page 69: ...TER 03 GENERAL DESCRIPTION OF THE AIRPLANE 1 Description The DA 42 NG is a twin engine four seat low wing mono plane It has a cantilever wing and a T tail The airplane structure is fiber reinforced plastic composite This gives a very strong but lightweight structure Figure 1 DA 42 NG Airplane ...

Page 70: ... Each wing has top and bottom shells made of carbon fiber reinforced plastic sandwich construction which are bond to the spars Carbon fiber reinforced plastic ribs and webs bond to the spars and shells to complete the structure Electrically operated flaps and mechanical ailerons are attached to the trailing edge of the wings The horizontal stabilizer is a semi monocoque structure It has top and bo...

Page 71: ...are controlled by an EECU system The airplane has aluminum fuel tank assemblies in each wing Each fuel tank has 3 chambers which are mounted between the wing spars The outer fuel chamber of each assembly has a fuel filler Flexible hoses connect the fuel tanks to the fuel distribution system Each tank can feed either engine via a fuel crossfeed system Fuel level sensors are installed in the inner a...

Page 72: ...ers shown in the Equipment List in Chapter 6 of the Airplane Flight Manual Doc No 7 01 15 E or Doc No 7 01 16 E latest revision ATA Chapter Equipment System Manufacturer Address Direct Shipping Approved 12 Anti Corrosion Cleaning Agent Ardrox AV 980 Anti Corrosion Coating Ardrox AV 30 Chemetall GmbH Trakehnerstrasse 3 D 60487 Frankfurt a M Germany Tel 49 69 7165 0 Fax 49 69 7165 3018 Website www c...

Page 73: ...41 2930 Fax 505 341 2927 Website www sandiaaerospace com yes 24 Battery Concorde Battery Corp 2009 San Bernardino Road West Covina CA 91790 USA Tel 626 813 1234 Website www concordebattery com yes 25 Emergency Locator Transmitter ELT Artex Aircraft Supplies 14405 Keil Road NE Aurora Oregon 97002 USA Tel 503 678 7929 Fax 503 678 7930 Website www artex net yes 25 Safety Belts Schroth Safety Products...

Page 74: ...49 6203 75 369 Fax 49 6203 75 265 Website www total feuerschutz de yes Note The airspeed indicator must have the markings specified in Chapter 2 of the Airplane Flight Manual Doc No 7 01 15 E or Doc No 7 01 16 E respective latest revision 31 Airspeed Indicator Altimeter United Instruments Inc 3625 Comotara Avenue Wichita Kansas 67226 USA Tel 316 636 9203 Fax 316 636 9243 Website www unitedinstrume...

Page 75: ...m yes 33 Strobe Lights Whelen Engineering Company Inc Route 145 Winthrop Rd Chester CT 06412 0684 USA Tel 860 526 9504 Fax 860 526 2009 Website www whelen com yes 33 Landing and Taxi Lights Aero Visions International Inc 2497 South 1760 West Ogden UT 84401 USA Tel 801 622 7000 Website www aerovisions com yes Note The propeller must have the pitch settings specified in Chapter 61 of this manual 61 ...

Page 76: ...ller blade or propeller hub without the approval of the competent national Airworthiness Authority If a deviation from the procedure above is necessary any person performing maintenance work may in consultation with the competent national Airworthiness Authority Remove change or place the identification plate on any airplane engine propeller propeller blade or propeller hub Remove an identificatio...

Page 77: ...DA 42 NG AMM Airworthiness Limitations Doc 7 02 15 Rev 4 04 TITLE Page 1 15 Mar 2018 CHAPTER 04 AIRWORTHINESS LIMITATIONS ...

Page 78: ...AIRCRAFT Airworthiness Limitations DA 42 NG AMM Page 2 15 Mar 2018 04 TITLE Doc 7 02 15 Rev 4 Intentionally left blank ...

Page 79: ...DA 42 NG AMM Airworthiness Limitations Doc 7 02 15 Rev 4 04 CONTENTS Page 1 15 Mar 2018 TABLE OF CONTENTS CHAPTER 04 AIRWORTHINESS LIMITATIONS 1 Airworthiness Limitations 3 ...

Page 80: ...AIRCRAFT Airworthiness Limitations DA 42 NG AMM Page 2 15 Mar 2018 04 CONTENTS Doc 7 02 15 Rev 4 Intentionally left blank ...

Page 81: ...RED BY JAR 23 THIS AIRPLANE MAINTENANCE MANUAL CHAPTER 04 AIRWORTHINESS LIMITATIONS IS APPROVED WITH EASA APPROVAL NO EASA A C 09012 AND 10042779 THE AIRWORTHINESS LIMITATIONS SECTION IS FAA APPROVED AND SPECIFIES MAINTENANCE REQUIRED UNDER SECS 43 16 AND 91 403 OF THE FEDERAL AVIATION REGULATIONS UNLESS AN ALTERNATIVE PROGRAM HAS BEEN FAA APPROVED SERVICE BULLETINS OR OTHER DOCUMENTS REVISING THI...

Page 82: ...AIRCRAFT Airworthiness Limitations DA 42 NG AMM Page 2 15 Mar 2018 04 00 00 Doc 7 02 15 Rev 4 Intentionally left blank ...

Page 83: ...he component and system checks under this Paragraph are also included in Section 05 10 The following table lists airplane components and systems which require monitoring through scheduled maintenance Where an interval is given in both flight time and calendar years the limit which is reached first must be applied ATA Ch Component Maintenance Requirement Interval hrs yrs 25 Electronics Module Assem...

Page 84: ...d first must be applied Note The replacement requirements under this Paragraph are also included in Section 05 10 ATA Ch Component Replacement Time hrs yrs 24 Emergency battery package 2 years 30 days or upon reaching the date marked on the package or after use whichever comes first 24 ECU backup batteries LH RH 1 yr 30 days 25 Installation screws for forward inflators if OÄM 42 324 is installed 1...

Page 85: ...efined as total sum of storage life and installation life Return Inflator Assembly to AmSafe for disposal C Paint 1 For S N below 42 N300 42 MN100 It is mandatory to paint the DA 42 NG white with a solar absorptivity not exceeding 0 3 This will prevent the temperature of the structure from becoming too high Examples of approved shades are RAL 9016 Mercedes DB 147 BMW 218 Volvo XG28 Volvo BC76 Saab...

Page 86: ... the DA 42 NG and DA 42 M NG in accordance with the color paint scheme provided in Section 51 20 Before painting the airplane in a different shade than defined in Section 51 20 of this Manual the manufacturer must be contacted D Repairs Repairs which are not described in Chapter 51 of this manual may only be carried out in accordance with a repair scheme which must be approved in accordance with t...

Page 87: ...AIRCRAFT DA 42 NG AMM Time Limits and Maintenance Checks Doc 7 02 15 Rev 4 05 TITLE Page 1 15 Mar 2018 CHAPTER 05 TIME LIMITS AND MAINTENANCE CHECKS ...

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Page 89: ... General 1 2 Regulatory Authorities 1 3 Scheduled Maintenance Time Limits 1 4 Component Time Limits 3 5 Component Time Tracking 7 Section 05 20 Scheduled Maintenance Checks 1 General 1 2 Maintenance Checklist Organization 1 3 Major Structural Inspection 3 Section 05 21 Flight Line Checks 1 General 1 2 Flight Line Checks 1 3 Post Flight Check 1 Section 05 25 Drain Holes Inspection Checklist and Rep...

Page 90: ... Engine Ground Test 2 4 Maintenance Checklist Engines 3 5 Propellers 18 Section 05 28 50 Maintenance Checklist Airframe 1 Exterior of the Fuselage 1 2 Cabin 10 3 Interior of the Rear Fuselage 24 4 Center Wing 30 5 Tail 34 6 Wings 44 7 General 52 Section 05 28 90 Maintenance Report 1 Maintenance Report 1 Section 05 28 91 Engine Ground Test Record 1 Engine Ground Test Record 1 Section 05 28 92 Check...

Page 91: ...ctural Inspection Check Findings Report 1 General 1 Section 05 50 Unscheduled Maintenance Checks 1 General 1 2 Hard Landing Check 1 3 Gear Up Landing Check 6 4 Propeller Strike 7 5 Engine Fire 8 6 Lightning Strike 10 7 Over Temperature 16 8 High Oil Consumption 16 9 Oil Pressure Loss 16 10 Hang Start 16 11 Overweight Landing Check 17 ...

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Page 93: ...If this happens the airplane manufacturer will publish the change as a revision to the Airplane Maintenance Manual Time limits and maintenance checks were established for operation in a moderate climate and on paved runways For operation under rough conditions extreme temperatures saline air wind borne sand operation on grass runways etc it may be necessary to make changes to the maintenance requi...

Page 94: ...ntenance Checklist for the engines Maintenance checks schedule for 100 200 1000 and 2000 hour checks on the engine and propeller 2 Section 05 28 50 DA 42 NG Maintenance Checklist for the airframe Maintenance checks schedule for 100 200 1000 and 2000 hour checks on the airframe 3 Section 05 28 90 DA 42 NG Maintenance Report 4 Section 05 28 91 DA 42 NG Engine Ground Test Reports 5 Section 05 28 92 D...

Page 95: ...tro Engine Maintenance Manual AE300 E4 08 04 Cleveland Parker Cleveland Parker Maintenance Manual AWBCMM0001 8 Cleveland Parker Cleveland Parker Product Catalog AWBPC0001 8 Cleveland Parker Cleveland Parker Technician s Service Guide AWBTSG0001 6 Concorde RG Series Main Aircraft Batteries Component Maintenance Manual 5 0171 Garmin Garmin G1000 System Maintenance Manual 190 00907 00 Goodyear Aircra...

Page 96: ...te Is correctly attached Has no loose parts Shows no signs of leaks Is not cracked or damaged Is not worn S Make sure that The surface protection is not damaged All locking devices are installed correctly S Make sure that items such as pipes and cables Look serviceable Do not rub against other items S For log books and other technical records To find outstanding faults To make sure they are up to ...

Page 97: ...nance Log Replace To remove an item and install a serviceable item in the same location Set To put equipment into a given adjustment condition or mode For example set the altimeter scale to 1013 mbar 1013 hPa Task An assigned work or a procedure For example each step of the task has an identification letter Test That which you do when you operate or examine an item to make sure that it agrees with...

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Page 99: ...that you meet the requirements of the Regulatory Authority of the country where the airplane is registered 3 Scheduled Maintenance Time Limits Refer to Sections 05 20 through 05 28 The following recommended hourly and calendar time limits apply to the scheduled maintenance checks which are necessary to maintain the airplane in a good technical condition Do the scheduled maintenance at the interval...

Page 100: ...ection is carried out earlier than allowed by the specified tolerance all subsequent inspection intervals are counted from that inspection For example If the 100 hour inspection was done at 83 hours the next inspection must be done at 183 10 hours Some inspection items must be done at other intervals than the standard intervals listed in the table above In these cases the maintenance interval for ...

Page 101: ...nterval hrs calendar time Note The mechanical check of the autopilot system is mandatory 22 Autopilot Mechanical check 1 yr 30 days 22 Autopilot if OÄM 42 210 GSM 86 servo mounts is installed Clutch torque check 5 yrs 60 days 24 Main battery Concorde Capacity test Refer to Concorde RG Series Main Aircraft Batteries Component Maintenance Manual latest revision 1000 100 1 yr 30 days 25 Safety harnes...

Page 102: ...e 34 Altimeters G1000 and backup Ensure correct indication 2yrs 30 days 34 Magnetic compass Compensate 1 yr 30 days 34 Transponder G1000 and blind altitude encoder altitude digitizer System check refer to G1000 System Maintenance Manual 190 00907 00 latest revision 1000 50 2 yrs 30 days 35 Oxygen regulator valve if installed Overhaul 5 yrs 60 days 35 Oxygen cylinder if installed Manufacture test d...

Page 103: ...ty harnesses front and rear if OÄM 42 324 is NOT installed Note If OÄM 42 324 is installed refer to the AmSafe Maintenance Documentation for on condition inspection requirements 12 yrs 90 days 25 First aid kit Replace aseptic items Upon reaching the date marked on the kit 27 Rudder cables non stainless steel 3 2 mm 1 8 in diameter 3000 50 5 yrs 60 days 27 Rudder cables stainless steel 3 2 mm 1 8 i...

Page 104: ...he hydraulic control unit 1000 50 30 If the ice protection system is installed Filter cartridges on the LH side 2000 50 32 Brake fluid 3 yrs 60 days 32 Hydraulic fluid in landing gear dampers 2 yrs 30 days 32 Hydraulic fluid in hydraulic system 2 yrs 30 days 35 Oxygen cylinder if installed 15 yrs 90 days 35 Oxygen masks if installed 3 yrs 30 days 35 Oxysaver cannulas if installed 200 of cumulative...

Page 105: ... silicate pouch Co incident with engine TBO 6 yrs 60 days 5 Component Time Tracking To make sure that components overhaul replacement is done at the correct time you must record the data that follows in the Airplane Maintenance Log for each component requiring overhaul replacement Serial Number Flight hours and date at installation Flight hours and date at removal ...

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Page 107: ...e requirements of Paragraphs 2 and 3 of the checklist Do all the applicable tasks on the checklist Note For maintenance of airplanes do the items marked X in the Maintenance Checklist Note The interval columns 100 200 1000 and 2000 are used for maintenance items which must be done at intervals of 100 200 1000 or 2000 flight hours Note The interval column time is used for a Maintenance items which ...

Page 108: ...he aft face of the instrument panel frame to the forward face of the baggage compartment frame It also includes the internal parts of the flight control system the internal pars of the brake system and the canopy and rear door 3 Interior of the Rear Fuselage All items inside the fuselage shell from the aft face of the baggage compartment frame to the vertical tail It includes the control systems a...

Page 109: ... important part of the infinite lifetime concept of the DA 42 NG It is required to prove the structural integrity of the airframe It must be carried out at the intervals shown in Section 05 10 Since the MSI is intended to coincide with a 2000 hour inspection the inspection items are included in the maintenance checklist and are identified by the term MSI in the time column ...

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Page 111: ...irplane log book for problems before doing the pre flight check WARNING DO ALL THE STEPS OF THE PRE FLIGHT CHECK CAREFULLY ACCIDENTS CAN OCCUR IF THE PRE FLIGHT CHECK IS NOT DONE CORRECTLY The schedule for the pilot s pre flight check is furnished in the Airplane Flight Manual for the DA 42 NG 3 Post Flight Check Do the post flight check after the last flight of the day The post flight check inclu...

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Page 113: ...gn objects and clean the drain holes to their full diameter Otherwise the drain capacity may not be sufficient under certain conditions like heavy rain etc All drain holes should be drilled with a diameter of 5 mm 2 mm 0 mm or 0 2 in 0 08 in 0 00 in The holes should be circular deburred not frayed and cleaned At drain holes marked with an asterisk the adhesive bonding is recessed Refer to the corr...

Page 114: ... 100 1 06 Lower fuselage shell aft of baggage compartment frame base 100 1 07 On lowest point of the fin 100 1 08 On the back side of the fin 100 1 09 Bolt in rudder mounting shell on top of the rudder 100 1 10 On lowest point of the cowling LH and RH 100 1 11 On lowest point of the engine nacelle two holes in the LH and RH nacelle 100 1 12 On lowest point of the engine nacelle aft of the front bo...

Page 115: ...rough lower if OÄM 42 119 or OÄM 42 273 is installed and upper end of radar frame 200 1 26 In front of nose baggage compartment floor LH and RH 200 1 27 In rear of nose baggage compartment LH 200 1 28 Through baggage compartment frame center position above lower fuselage shell 200 1 29 Through lower end of ring frame 1 200 1 30 Through lower end of ring frame 2 200 1 31 Through lower end of ring f...

Page 116: ... shell next to the mid inspection hole LH and RH 100 3 02 Lower shell next to the front inspection hole LH and RH 100 3 03 On the lowest point of the horizontal stabilizer tips LH and RH 100 3 04 Elevator end rib next to the rear spar next to lower shell LH and RH 200 3 05 LH and RH rib in front of the rear spar above the lower shell 200 3 06 LH and RH rib aft of the front spar above the lower she...

Page 117: ...ront and rear spar bonding and lower shell LH and RH wing 200 7 04 In flap rib rear spar next to lower shell LH and RH wing 200 7 05 In rear root rib next to rear spar and lower shell LH and RH wing 200 7 06 In aileron rib next to rear spar and lower shell LH and RH wing 200 7 07 Second fuel tank rib next to front and rear spar and lower shell LH and RH wing 200 7 08 Third fuel tank rib next to fr...

Page 118: ...g edge bonding LH and RH 100 8 02 Inner flap root rib next to trailing edge bonding LH and RH 100 8 03 Inner flap root rib at the leading edge LH and RH 100 9 AILERONS 9 01 Inner root rib next to the trailing edge bonding LH and RH 100 9 02 Lower shell aft of mass balance weight LH and RH 100 9 03 Lower shell in front of mass balance hinge line LH and RH 100 9 04 Outer root rib at the leading edge...

Page 119: ...urs Check 2000 Hours Check X X X View from below 1 26 1 25 1 26 1 01 1 02 1 25 1 25 1 27 1 03 Drainage Holes 11mm 1 04 1 05 Drainage Holes 11mm 1 05 1 05 1 03 1 39 1 04 Horizontal Drainage Hole Vertical Drainage Hole Exterior Drainage Hole Drainage Hole Inside the Structure 1 27 1 03 1 25 Figure 1 Drain Holes Fuselage Part 1 ...

Page 120: ...age Part 2 1 30 1 29 1 28 1 06 1 38 1 31 1 31 1 35 1 32 1 33 6 2 6 1 1 08 1 07 To be checked only in production or repair To be checked only in production or repair 1 09 100 Hours Check 200 Hours Check 2000 Hours Check X X X Horizontal Drainage Hole Vertical Drainage Hole Exterior Drainage Hole Drainage Hole Inside the Structure ...

Page 121: ...s Doc 7 02 15 Rev 4 05 25 00 Page 9 15 Mar 2018 100 Hours Check 200 Hours Check 2000 Hours Check X X X Horizontal Drainage Hole Vertical Drainage Hole Exterior Drainage Hole Drainage Hole Inside the Structure 2 01 2 02 2 01 2 02 Figure 3 Drain Holes Canopy ...

Page 122: ...42 NG AMM Page 10 15 Mar 2018 05 25 00 Doc 7 02 15 Rev 4 100 Hours Check 200 Hours Check 2000 Hours Check X X X Horizontal Drainage Hole Vertical Drainage Hole Exterior Drainage Hole Drainage Hole Inside the Structure 2 03 Figure 4 Drain Holes Door ...

Page 123: ...s Check 2000 Hours Check X X X Horizontal Drainage Hole Vertical Drainage Hole Exterior Drainage Hole Drainage Hole Inside the Structure 3 03 3 08 3 07 3 09 3 09 3 08 3 07 3 06 3 05 3 04 3 07 3 06 3 05 3 04 3 01 3 02 4 01 4 02 4 01 4 02 5 01 5 02 5 01 5 02 Figure 5 Drain Holes Horizontal Stabilizer Elevator and Elevator Trim Tab ...

Page 124: ...NG AMM Page 12 15 Mar 2018 05 25 00 Doc 7 02 15 Rev 4 100 Hours Check 200 Hours Check 2000 Hours Check X X X Horizontal Drainage Hole Vertical Drainage Hole Exterior Drainage Hole Drainage Hole Inside the Structure 6 01 6 02 Figure 6 Drain Holes Rudder ...

Page 125: ...2 15 Rev 4 05 25 00 Page 13 15 Mar 2018 100 Hours Check 200 Hours Check 2000 Hours Check X X X Horizontal Drainage Hole Vertical Drainage Hole Exterior Drainage Hole Drainage Hole Inside the Structure 6 01 6 02 Figure 7 Drain Holes Rudder if MÄM 42 600 is installed ...

Page 126: ...ole Inside the Structure 1 24 1 22 8 02 1 20 8 03 1 36 1 37 1 18 1 12 1 14 1 13 1 11 1 10 In Cowling Base 1 15 1 16 1 16 1 18 1 17 1 17 1 19 1 20 1 20 1 22 8 02 8 03 1 21 1 37 1 36 1 14 1 10 1 11 1 12 1 23 To be checked only in Production or Repair To be checked only in Production or Repair To be checked only in Production or Repair To be checked only in Production or Repair In Cowling Base VIEW F...

Page 127: ...0 Hours Check X X X Horizontal Drainage Hole Vertical Drainage Hole Exterior Drainage Hole Drainage Hole Inside the Structure 7 09 to 7 02 9 04 7 01 9 03 9 02 9 01 7 10 7 08 7 07 7 04 7 11 7 12 7 12 7 05 8 01 A A 7 09 7 09 A 7 07 7 08 Maintenance Access Maintenance Access View A 7 06 7 06 7 03 Figure 9 Drain Holes Wings Flaps and Ailerons ...

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Page 129: ...Hours _________________ Engine hours LH RH TTSN _______ _______ Inspection _________________ 100 200 1000 2000 hr Annual Insp LH RH Propeller S N _______ _______ Propeller hours LH RH TTSN _______ _______ 2 Preparation Do the following items before you start the applicable check Inspection Items 100 200 1000 2000 Initials 1 Before you do the inspection S Read the applicable Airworthiness Directive...

Page 130: ...E TO ON IF YOU DO NOT DO THIS THE AIRPLANE CAN MOVE THIS CAN CAUSE INJURY OR DEATH 1 Set the parking brake to ON X X X X 2 Put the chocks against the airplane main wheels X X X X 3 Do an engine ground run Refer to Section 71 00 and AE Maintenance Manual latest revision X X X X 4 Check engine instruments X X X X 5 Do a test of the crossfeed system Refer to Section 28 20 X X X X 6 Do a test of the f...

Page 131: ...AR FUEL FUEL BURNS AND CAN CAUSE INJURY TO PEOPLE AND DAMAGE TO EQUIPMENT 1 Remove the top and bottom cowlings Refer to Section 71 10 Examine the cowlings Make sure that the fasteners are serviceable Look for cracks and areas that have got too hot Check rubber seals X X X X 2 Clean the engine and engine compartment Refer to Section 12 30 and the AE Maintenance Manual latest revision X X X X 3 Do e...

Page 132: ...solenoid and check valves if auxiliary tanks are installed Refer to Section 28 20 X X 10 Examine the exhaust end pipe incl muffler if installed Look specially for cracks and heat damage or incorrect attachment X X X X 11 Examine the mounting bracket pulley assembly and electrical connections of the additional alternator if OÄM 42 204 is carried out S Visual inspection of mounting bracket and pulle...

Page 133: ...oses are correctly attached and that the torque seal on the hose clamps is intact X X X X 14 Examine the cable ties and all electrical connectors in the engine area S Look specially for rub marks and damage S Pull lightly to make sure they are not loose X X X X 15 Examine the bonding cables and their connectors in the engine area S Look specially for rub marks and damage S Pull lightly to make sur...

Page 134: ...ge and damage S Examine the un feathering pressure accumulator Look specially for S Leakage and damage S Insecure attachment S Nitrogen pressure accumulator Refer to mt Propeller Operation and Installation Manual latest revision S Check accumulator nitrogen pressure S Set valve under current open S Remove the cap from the charging valve S Connect a suitable nitrogen supply to the charging valve an...

Page 135: ... filter S Hose from air filter to turbo charger S Turbo charger On the pressure side of the turbo charger S Hoses and hose clamps S Aluminum pipes S Look specially for signs of damage S Make sure the air hoses and ducts are correctly attached and that the torque seal on the hose clamps is intact S Intercooler Do NOT re tighten the worm drive clamps once they have been installed unless they are loo...

Page 136: ...8 00 Doc 7 02 15 Rev 4 Inspect the v clamp on the pressure side of the turbo charger S Inspect for positive clearance between the flanges of the turbo charger aluminum charged air tube and the base of the v clamp on the complete circumference If there is NO positive clearance replace the v clamp S Inspect for signs of cracks in the edges of the ends of the v bands of the v clamp with flashlight an...

Page 137: ... X 20 Examine the coolant radiators S Look specially for leakage damage and insecure attachment S Make sure the cooling fins are not blocked X X X X 21 Examine the coolant tank S Look specially for leakage and damage S Check the attachment for cracks X X X X 22 Perform a coolant tank pressure relief valve test Refer to Section 75 00 X X X X 23 Examine the alternate air valve assembly S Check corre...

Page 138: ...amage No damage allowed S Incorrect torque value Refer to Section 20 10 S Loose or missing lock devices S Damaged shock mounts Replace damaged shock mounts X X X X 25 Check bolts mounting engine mount to firewall Torque to the value given in Section 20 10 S At the first 100 hrs check X X 26 Check the overheat detector for damage loose connectors and insecure attachment X X X X 27 Do a function tes...

Page 139: ...NS AND CAN CAUSE INJURY TO PEOPLE AND DAMAGE TO EQUIPMENT 1 Remove the top and bottom cowlings Refer to Section 71 10 Examine the cowlings Make sure that the fasteners are serviceable Look for cracks and areas that have got too hot Check rubber seals X X X X 2 Clean the engine and engine compartment Refer to Section 12 30 and the AE Maintenance Manual latest revision X X X X 3 Do engine maintenanc...

Page 140: ...28 20 X X 9 Test solenoid and check valves if auxiliary tanks are installed Refer to Section 28 20 X X 10 Examine the exhaust end pipe incl muffler if installed Look specially for cracks and heat damage or incorrect attachment X X X X 11 Examine the air intake hoses S Look specially for signs of damage S Make sure the air hoses are correctly attached and that the torque seal on the hose clamps is ...

Page 141: ...e and hose connection Look specially for leakage and damage S Examine the un feathering pressure accumulator Look specially for S Leakage and damage S Insecure attachment S Nitrogen pressure accumulator Refer to mt Propeller Operation and Installation Manual latest revision S Check accumulator nitrogen pressure S Set valve under current open S Remove the cap from the charging valve S Connect a sui...

Page 142: ...Air filter S Hose from air filter to turbo charger S Turbo charger On the pressure side of the turbo charger S Hoses and hose clamps S Aluminum pipes S Look specially for signs of damage S Make sure the air hoses and ducts are correctly attached and the torque seal on the hose clamps is intact S Intercooler Do NOT re tighten the worm drive clamps once they have been installed unless they are loose...

Page 143: ...00 Page 15 15 Mar 2018 Inspect the v clamp on the pressure side of the turbo charger S Inspect for positive clearance between the flanges of the turbo charger aluminum charged air tube and the base of the v clamp on the complete circumference If there is NO positive clearance replace the v clamp S Inspect for signs of cracks in the edges of the ends of the v bands of the v clamp with flashlight an...

Page 144: ... X 18 Examine the coolant radiators S Look specially for leakage damage and insecure attachment S Make sure the cooling fins are not blocked X X X X 19 Examine the coolant tank S Look specially for leakage and damage S Check the attachment for cracks X X X X 20 Perform a coolant tank pressure relief valve test Refer to Section 75 00 X X X X 21 Examine the alternate air valve assembly S Check corre...

Page 145: ...amage No damage allowed S Incorrect torque value Refer to Section 20 10 S Loose or missing lock devices S Damaged shock mounts Replace damaged shock mounts X X X X 23 Check bolts mounting engine mount to firewall Torque to the value given in Section 20 10 S At the first 100 hrs check X X 24 Check the overheat detector for damage loose connectors and insecure attachment X X X X 25 Do a function tes...

Page 146: ...OU MUST MAKE SURE THAT THE ENGINE IS SAFE BEFORE YOU TURN THE PROPELLER 1 Inspection in accordance with mt Propeller Maintenance Manual latest revision X X X X B RH Propeller 100 hr items marked apply to US registered airplanes only Interval Inspection Items RH Propeller 100 200 10002000Time Initials WARNING DO NOT LET PERSONS GO INTO THE DANGER AREA OF THE PROPELLER PROPELLERS CAN CAUSE INJURY OR...

Page 147: ...nation Examine the surface protection system X X X X 2 Check the static source holes for blockage X X X X 3 Do a coin tap test for delamination of the entire fuselage shell from the nose to the vertical tail Refer to Section 51 10 MSI 4 Do a coin tap test for defects in the entire fuselage tube bonding top and bottom Refer to Section 51 10 MSI 5 Examine all antennas Look specially for damage incor...

Page 148: ...age and corrosion S Damaged surface protection S Incorrect attachment and loose or missing lock devices S Defective bonding strap X X X X 3 Examine the cardan joint bracket Look specially for corrosion cracks and damage X X X X 4 Examine the nose wheel centering device Look specially for damage excessive wear and looseness X X X X 5 Examine the nose landing gear actuator Look specially for leakage...

Page 149: ...nstall the nose landing gear damper assembly S Install the nose landing gear assembly Refer to Section 32 20 X 9 Examine the nose landing gear for damage nose landing gear leg assembly folding stay assembly mounting bracket assembly Look specially for cracks deformation wear corrosion and damaged surface protection X X X X 10 Ensure correct gas pressure in the damper with the wheel off the ground ...

Page 150: ... deformation corrosion and damaged surface protection X X X X 4 Examine the hydraulic lines of the brake system for damage leakage and loose or defective connectors X X X X 5 Examine the main landing gear actuators and hydraulics Look specially for leakage Refer to Chapter 32 X X X X 6 Examine the damper Look specially for leakage X X X X 7 Examine the main landing gear doors S Check for damage to...

Page 151: ...ially for deformation and cracks S Reassemble the dampers Refer to Section 32 10 X 12 Reinstall the dampers trunnions and trailing arms to the legs Refer to Section 32 10 X 13 Ensure correct gas pressure in the dampers 19 bar 276 PSI with the wheel off the ground Refer to Chapter 32 X X X X 14 Apply grease to the actuator bearing Refer to Sections 12 20 and 32 20 X X X X 15 Examine the up lock and...

Page 152: ...the main wheels S 4 7 bar 68 PSI X X X X 2 Examine the main wheel brakes S Check brake linings for excessive wear S Check brake disks for distortion and excessive wear S Check brake cylinders for leaks X X X X 3 Remove all 3 wheels X X X X 4 Examine the wheel axles Look specially for cracks and corrosion X X X X 5 Examine the wheel bearings Look specially for play corrosion and irregular running X...

Page 153: ...ly one nose baggage door and test the lock of the other one by pushing from inside Repeat the procedure for the other side X X X 3 Remove the covers from the rear wall of the nose baggage compartment X X X X 4 Examine the cable ties and all electrical connectors S Look specially for rub marks and damage S Pull lightly to make sure they are not loose X X X X 5 Do a check of the airplane battery Ref...

Page 154: ...X X X 9 If the oxygen system is installed OÄM 42 055 visually inspect the ventilation of the nose baggage compartments oxygen battery and TKS compartment Especially check both ventilation caps installed on the LH and RH side of the nose landing gear X X X X 10 If the oxygen system is installed OÄM 42 055 visually inspect all oxygen tubes installed in the oxygen and battery compartment Check for im...

Page 155: ...heck for structural damage S Check attachment screws 16 pieces S Check lightning protection strips 4 pieces for proper mounting X X X 14 If the GWX 68 or GWX 70 weather radar system OÄM 42 119 or OÄM 42 273 is installed Examine the GWX 68 or GWX 70 installation on the radar bulkhead S Check radar antenna visually S Check bracket attachment screws S Check lightning protection bonding for proper mou...

Page 156: ...G LOADED BACKREST MAY SNAP FORWARD AND CAN CAUSE INJURY 2 If adjustable front seats OÄM 42 067 or OÄM 42 259 are installed S Do a test of the backrest adjustment mechanism on both front seats Refer to Section 25 10 S Do a test of the lumbar support mechanism on both front seats Refer to Section 25 10 X X X X 3 Examine the emergency axe installation if OÄM 42 205 is installed S Check attachments fo...

Page 157: ...sight of the pilots S Examine the bonding between the window and the canopy frame Refer to Section 56 10 S Examine the emergency windows and their hinges for damage S Examine the pop out windows and their hinges for damage Check hinges for improper friction correct if necessary X X X X 2 If OÄM 42 194 carried out Perform release test of canopy jettison system refer to Section 52 10 x 3 If OÄM 42 1...

Page 158: ...ty hook mechanism operate correctly Refer to Section 52 10 S If MÄM 42 097 is installed Do a test of the passenger door handle compression gas spring Refer to Section 52 10 S Examine the carbon hinges for cracks Refer to Section 52 10 S Examine the acrylic glass window for damage Look specially for cracks S Examine the bonding between the window and the door frame Refer to Section 56 10 X X X X 9 ...

Page 159: ...nation and disbonding from the center wing skin X X X 3 Visually inspect the interior structure of the front fuselage from instrument panel frame to baggage compartment frame Use mirror and flashlight where necessary Check for damage cracks delamination and disbonding from the fuselage skin Inspect the following components S Front main spar S Rear main spar S Control bulkhead S Floor element S Top...

Page 160: ...ly to US registered airplanes only Interval Inspection Items Instrument Panel and Electrical System in Cabin 100 200 10002000Time Initials 1 Examine the Pitot static system water traps below the pilot s seat and below the aft baggage compartment X X X X 2 Examine all cable ties and electrical connectors in the cabin Pull lightly to make sure they are not loose X X X X 3 Examine the instrument pane...

Page 161: ...side X X X X 5 Examine the instrument panel for cracks X X X 6 Examine the emergency battery system S Measure the voltage of the emergency battery pack on the EMERGENCY switch Replace emergency battery pack if the voltage is below 30 V X X X X 7 Make sure that the seal on the EMERGENCY switch is intact X X X X 8 Examine the backup instruments Make sure that S The markings are clear if OÄM 42 270 i...

Page 162: ...ed airplanes only Interval Inspection Items Flight Control System in Cabin 100 200 10002000Time Initials 1 Examine the control sticks Make sure that the control stick attachments are not loose and do not catch X X X X 2 If OÄM 42 283 is installed Make sure that the connection of the removable control stick has no play and wear Make sure that the safety pin snaps on the rim of the sleeve nut X X X ...

Page 163: ...aged surface protection Refer to Sections 27 10 and 27 30 X X X X 6 Examine the centering springs for the aileron control system Look specially for damage and looseness X X X X 7 Examine the rudder pedals Look specially for S Incorrect attachment and function S Corrosion and damaged surface protection S Damaged adjustment mechanism S Improper function of adjustment mechanism Refer to Section 27 20...

Page 164: ...pecially for S Incorrect attachment and function Refer to Section 27 20 S Defective cable eyes S Defective rubber sleeves S Corrosion S Rub marks S Defective safety plates S Worn out pulleys S Broken strands X X X 10 Examine the elevator trim control in the center console Make sure that S There is full and free movement S There is no unusual play X X X X 11 Examine the rudder trim control in the c...

Page 165: ...ncorrect attachment and loose or missing lock devices S Defective bonding strap X X X X 13 Examine the push rod guides for the elevator push rod Look specially for incorrect attachment and interference X X X X 14 Examine the flap control mechanism on the rear main spar Look specially for S Damage and corrosion S Damaged surface protection S Incorrect attachment and loose or missing lock devices X ...

Page 166: ... assemblies X X X X F Other Cockpit Controls 100 hr items marked apply to US registered airplanes only Interval Inspection Items Other Cockpit Controls 100 200 10002000Time Initials 1 Examine the brake hoses and components Look specially for leakage X X X X 2 Examine the brake fluid reservoirs on the co pilot s side Make sure the fluid level is correct S The fluid level must be 12 mm to 25 mm 1 2 ...

Page 167: ... restricted movement interference and unusual play X X X X 5 Examine the PARKING BRAKE lever in the center console S Check for damage S Move the lever through its operating range Check for restricted movement interference unusual play and incorrect bounce X X X X 6 Examine the ALTERNATE AIR lever S Check for damage S Move the lever through its operating range Check for restricted movement interfer...

Page 168: ...rplanes only Interval Inspection Items Cabin Miscellaneous 100 200 10002000Time Initials 1 Examine the interior placards Make sure that S They are not damaged S None are missing Refer to Chapter 11 X X X X 2 Examine the fire extinguisher Make sure that S The fire extinguisher will release from the mounting bracket S The fire extinguisher contents are full Do a check of the extinguisher expiry date...

Page 169: ... baggage compartment X X X 6 If the oxygen system is installed OÄM 42 055 check the oxygen push pull knob Bowden cable assembly Check for interference and corrosion X X X CAUTION OIL GREASE OR OTHER LUBRICATIONS IN CONTACT WITH OXYGEN CREATE A SERIOUS HAZARD SUCH CONTACT MUST BE AVOIDED WHEN HANDLING WITH ANY PART OF THE OXYGEN SYSTEM 7 If the oxygen system is installed OÄM 42 055 visually inspect...

Page 170: ... Door to the baggage extension S Lid for the tray on the floor X X X 2 If OÄM 42 203 is carried out Remove the de icing fluid tank Refer to Chapter 30 00 X 3 Visually inspect the inner skin of the rear fuselage aft of baggage compartment frame with mirror and flashlight Check for damage dents cracks delamination and disbonding from the sandwich foam X 4 Visually inspect the interior structure of t...

Page 171: ... air inlet filter for contamination S Two air outlets to the LH and RH side of the upper fuselage Examine the RACC air inlets and outlets if OÄM 42 193 d or later is carried out S One air outlet on the bottom S Check the RACC compartment ventilation filter on the LH side fuselage for contamination S One air inlet on the LH side of fuselage S Check evaporator drain on the bottom for blockage X X X ...

Page 172: ...RACC central unit if OÄM 42 193 is carried out Look specially for S Defective bonding of the side brackets S Incorrect attachment of the mounting panel S Lack of mechanical stability of the mounting panel S Insecure attachment of RACC components to the mounting panel S Insecure attachment of hoses shrouds and cables X X 9 Perform a leakage test Refer to Chapter 21 1 yr 10 If OÄM 42 193 c or earlie...

Page 173: ...r air filter X X 5 Check accumulator for inner leakage and pre fill pressure X X X X C Control System in the Rear Fuselage 100 hr items marked apply to US registered airplanes only Interval Inspection Items Control System in the Rear Fuselage 100 200 10002000Time Initials 1 Examine the push rod guides for the elevator push rod Look specially for S Incorrect attachment S Interference X X X X 2 Exam...

Page 174: ...cially for S Insecure cable connections S Insecure attachment X X X X 3 If OÄM 42 191 is installed Examine the trim weight installation and retighten the attachment screws of the trim weight S Remove trim weight assembly Refer to Section 53 10 S Check the attachment structure in vertical tail for cracks damage and loose or missing anchor nuts S Retighten attachment bolts of lead weight S Reinstall...

Page 175: ...3 is carried out Look specially for S Defective bonding of side brackets S Incorrect attachment of mounting panel S Lack of mechanical stability of mounting panel S Insecure attachment of RACC components to mounting panel S Insecure attachment of hoses shrouds and cables X X X X 6 Check the condenser and evaporator for contamination and remove any accumulation of dust and dirt if OÄM 42 193 is car...

Page 176: ...y for damage dents cracks holes and delamination Examine the surface protection system X X X X 3 Do a coin tap test for delamination of the entire center wing top and bottom shells Refer to Section 51 10 MSI 4 Examine the air inlets for blockage S In the engine nacelles S In the RH center wing nose X X X X 5 Visually inspect the wing main bolts Look specially for play between the bolts and the bus...

Page 177: ... to Section 57 10 S Examine the main bolts Look specially for deformation cracks scratches and corrosion S Examine the main bolt bushes in the center wing spars Look specially for deformation cracks and scratches and looseness S Grease the main bolts S Examine the A bolts Look specially for deformation cracks scratches and corrosion S Grease the A bolts S Examine the B bolts Look specially for def...

Page 178: ...heck for damage cracks delamination and disbonding from the wing skin Inspect the following components S Front spar inner and outer surfaces specially in the area of the bushes for the main bolts S Rear spar inner and outer surfaces specially in the area of the bushes for the main bolts S Firewall LH and RH S Ribs in center wing nose behind firewall 2 LH 2 RH S Root ribs LH and RH middle and rear ...

Page 179: ...only Interval Inspection Items Inner Flaps 100 200 10002000Time Initials 1 Examine the inner flaps Look specially for damage dents cracks holes and delamination Examine the surface protection system X X X X 2 Examine the inner flap hinges and horn Look specially for too much play Refer to Section 27 00 Play allowed S Axial 1 00 mm 0 04 in S Radial 0 25 mm 0 01 in X X X X 3 Examine the inner flap c...

Page 180: ...d X X X X 2 Examine the fuel cooler S Look specially for leakage damage and insecure attachment S Make sure the cooling fins are not blocked X X X X 5 Tail A Tail General 100 hr items marked apply to US registered airplanes only Interval Inspection Items Tail General 100 200 10002000Time Initials 1 If MÄM 42 600 is installed Examine the rudder gap seal X X X 2 Remove the fairing for the horizontal...

Page 181: ... Examine the tail fin lower strake on the bottom side of the fuselage tube Look specially for S Damage to the bottom of the fin S Cracks at the junction to the fuselage X X X X 3 Visually inspect the inner skin of the vertical stabilizer through all access holes with mirror and flashlight Check for damage cracks and delamination MSI 4 Visually inspect the interior structure of the vertical stabili...

Page 182: ...r delamination of the entire top and bottom shell of the horizontal stabilizer Refer to Section 51 10 MSI 3 Examine the mounting brackets for the horizontal stabilizer Look specially for cracks deformation and corrosion Check the attachment bolts for corrosion Refer to Section 55 10 X X X X 4 Examine the horizontal stabilizer tips Look specially for cracks dents and loose or missing attachment scr...

Page 183: ... 15 Mar 2018 7 Visually inspect the interior structure of the horizontal stabilizer through all access holes with mirror and flashlight Look specially for damage cracks delamination and disbonding from the horizontal tail skin Inspect the following components S Front spar S Rear spar S Trailing edge web S Longitudinal ribs LH and RH front middle rear S VT attachment box X 8 Install the tips to the...

Page 184: ...m X X X X 2 Examine the lower bracket on the rudder Look specially for S Cracks and deformation S Excessive wear on brass bushes S Defective stop screws S Insecure attachment S Loose or missing lock devices S Defective powder coating X X X X 3 Check the upper hinge pin on the rudder for deformation cracks and corrosion X X X X 4 Examine the rudder trim tab Look specially for S Damage to the tab st...

Page 185: ...Broken strands S Defective or worn out cable eyes S Corrosion S Poor general condition X X X X 2 Examine the support for the lower rudder hinge Look specially for S Cracks and deformation S Insecure attachment S Cracks deformation or corrosion of stops S Loose or missing lock devices S Defective powder coating X X X X 3 Check the rudder hinges top and bottom for corrosion insecure mounting and poo...

Page 186: ...0002000Time Initials Page 40 15 Mar 2018 05 28 50 Doc 7 02 15 Rev 4 5 Check the friction of the rudder trim mechanism Verify smooth running on trim knob and proper function S Correct friction force at the rudder trim friction rod 3 daN 5 daN 6 7 11 2 lbf S If the friction exceeds 5 daN 11 2 lbf polish the tube S In case of new springs cut up to 1 5 winds of the spring to reach friction value X X X...

Page 187: ...es for corrosion and looseness X 3 Check elevator horn for damage deformation and cracks X X X X 4 Check elevator balancing masses for insecure attachment X X X X 5 Examine the elevator hinges Look specially for S Damage cracks and corrosion S Loose or missing lock devices S Excessive play Play allowed S Axial 1 00 mm 0 04 in S Radial 0 25 mm 0 01 in X X X X 6 Examine the elevator trim tab Look sp...

Page 188: ...k for insecure connection to the bellcrank or elevator horn S Check for loose or missing lock devices X X X X 2 Examine the centering springs for the elevator control system Look specially for damage and looseness X X X X 3 Examine the elevator push rod which was removed from the rear fuselage Look specially for rub marks Refer to Section 27 30 X 4 Examine the elevator bellcrank in the vertical ta...

Page 189: ...he VHF antenna is not actually a part of the major structural inspection MSI It is however carried out at the same time because it can only be done with the horizontal stabilizer removed from the airplane 1 Examine the VHF antenna MSI 2 Install the horizontal stabilizer Refer to Section 55 50 MSI 3 Install the elevator push rod which goes through the rear fuselage Refer to Section 27 30 X 4 Instal...

Page 190: ...ection Items Wings General 100 200 10002000Time Initials 1 Remove the winglets Refer to Section 57 10 X 2 Remove the fuel tanks from the wings Refer to Chapter 28 S Remove the main fuel tanks from the wings S If installed remove the auxiliary fuel tanks from the engine nacelles OÄM 42 056 carried out X 3 Remove the flap and aileron bell crank access panels in the wing Refer to Section 52 40 X X X ...

Page 191: ...cracks dents and loose or missing attachment screws Examine the surface protection system X X X X 3 Do a coin tap test for delamination of the entire top and bottom wing shell Refer to Section 51 10 MSI 4 Visually inspect the inner skin of the LH and RH wing through all access holes with mirror and flashlight or endoscope Check for damage cracks delamination and disbonding from the sandwich foam M...

Page 192: ...v 4 7 Visually inspect the interior structure of the LH and RH wing through all access holes with mirror and flashlight or endoscope Check for damage cracks delamination and disbonding from the wing skin Inspect the following components S Front spar S Rear spar S Rear web S Root rib front middle and rear S End rib on outboard edge S 6 fuel tank attachment ribs S Rib supporting aileron bellcrank S ...

Page 193: ...ne the outer flaps Look specially for damage dents cracks holes and delamination Examine the surface protection system X X X X 3 Examine the aileron mass balance Look specially for cracks X X X X 4 Examine the aileron hinges and horn Look specially for S Damage cracks and corrosion S Loose or missing lock devices S Excessive play Play allowed S Axial 1 00 mm 0 04 in S Radial 0 25 mm 0 01 in X X X ...

Page 194: ...chment and loose or missing lock devices Refer to Sections 27 10 and 27 50 X X X X 7 Examine the aileron push rods S Remove the aileron push rods from the wings S Check for corrosion and damaged surface protection S Look specially for rub marks S Install the aileron push rods Refer to Section 27 10 X 8 Examine the outer flap push rods S Remove the outer flap push rods from the wings S Check for co...

Page 195: ...maged strips X X X X WARNING DO NOT GET FUEL ON YOU FUEL CAN CAUSE SKIN DISEASE DO NOT ALLOW FIRE NEAR FUEL FUEL BURNS AND CAN CAUSE INJURY TO PEOPLE AND DAMAGE TO EQUIPMENT 2 Examine the fuel tank outlets S Clean the finger filters S Look for foreign matter S Look for defective lock wire X 3 Remove the access covers X X X 4 Check condition of tank interconnecting hoses X X X 5 Check for leaks X X...

Page 196: ...s installed Open fuel filler cap and carefully blow through the vent all lines from outside into the tank with compressed air X X X X 10 If the auxiliary fuel tanks are installed OÄM 42 056 Examine the auxiliary fuel tank vents for blockage S Open fuel filler cap and blow through the vent line from outside into the tank with compressed air S Check vent hole in the fuel tank cap for blockage X X X ...

Page 197: ...the fuel tanks to the wings Refer to Chapter 28 S If incorporated OÄM 42 056 install the auxiliary fuel tanks into the engine nacelles S Install the main fuel tanks into the wings X 3 Install the wings Refer to Section 57 10 X 4 Install the winglets Refer to Section 57 10 X 5 Examine the stall warning sensor in the LH wing Do a function test of the sensor X X X X 6 Examine the placards on the wing...

Page 198: ... 00 of the Airplane Maintenance Manual Referenced Maintenance Data X X X X 3 Lubricate the airplane Refer to Section 12 20 X X X X 4 Measure the play in the aileron and elevator controls with the control surfaces locked Refer to Section 27 30 Look specially for too much play Do the test at the top of the control stick S Maximum play allowed 2 5 mm 0 1 in Refer to Section 27 10 X X X X 5 Check flig...

Page 199: ...efer to Section 27 50 Look specially at the pre load With the flaps set to UP S Correct pre load 3 5 daN 6 7 11 2 lbf X 13 Do a function test of the landing gear system Refer to Chapter 32 S Verify proper operation of the pressure accumulator the hydraulic pump must stop operating after the pressure has built up S Verify proper retraction and extension S Verify correct landing gear indication S Do...

Page 200: ...ation of the steering linkage to the rudder control system S Verify the nose wheel returns to the neutral position X X X X 15 Examine the anti corrosion coating of exterior parts Refer to Section 12 30 Replace coating on condition X X X 16 Lower the airplane off jacks Refer to Section 07 10 X X X X 17 Do an operational test of the external lights X X X X 18 Do an operational test of the Pitot heat...

Page 201: ... The engine cowlings Refer to Section 71 10 X X X X WARNING DO NOT LET PERSONS INTO THE DANGER AREA OF THE PROPELLER PROPELLERS CAN CAUSE INJURY OR DEATH WARNING SET THE PARKING BRAKE TO ON IF YOU DO NOT DO THIS THE AIRPLANE CAN MOVE THIS CAN CAUSE INJURY OR DEATH 22 Put chocks against the main airplane wheels X X X X 23 Do the post maintenance engine test S For the engine run procedures refer to ...

Page 202: ...he Airplane Maintenance Log X X X X Note The manufacturer will use the completed Structural Findings Report for the continuous improvement of the Major Structural Inspection MSI 28 Complete the Structural Findings Report Put one copy in the Airplane Maintenance Log Send another copy to the manufacturer i e Diamond Aircraft Industries GmbH Office of Airworthiness N A Otto Str 5 A 2700 Wiener Neusta...

Page 203: ...of the Maintenance Report after all of the applicable maintenance tasks in the Maintenance Checklist have been initialed DA 42 NG Airplane Serial Number Registration Number Check __________ 100 hr 200 hr 1000 hr 2000 hr Annual REMARKS The airplane is airworthy with respect to its maintenance condition _________________ Place _________________ Date _________________ Authorized ...

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Page 205: ...SET TO OFF THE ENGINE MASTER SWITCH IS SET TO OFF THE POWER LEVER IS SET TO IDLE WARNING DO NOT GET OIL ON YOU OIL CAN CAUSE SKIN DISEASE WARNING DO NOT GET FUEL ON YOU FUEL CAN CAUSE SKIN DISEASE DO NOT ALLOW FIRE NEAR FUEL FUEL BURNS AND CAN CAUSE INJURY TO PEOPLE AND DAMAGE TO EQUIPMENT WARNING WHEN YOU COMPLETE AN INSPECTION MAKE SURE THAT YOU REMOVE ALL LOOSE ITEMS TOOLS FROM THAT AREA LOOSE ...

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Page 207: ... NO YES ON GROUND ENGINES OFF Pre flight inspection in accordance with AFM Front baggage doors mechanism key lock open door warning Front canopy locking mechanism key lock general condition optics open door warning Rear door mechanism key lock open door warning Seat belts 4x function locking device general condition Front seats fixed general condition Rear seats locking mechanism general condition...

Page 208: ...cations engine oil pressure temperature gearbox oil temperature coolant temperature Load RPM indications Fuel quantity temperature fuel flow Battery voltage ammeters Alternators Altimeters G1000 and backup Airspeed indicators G1000 and backup Vertical speed indicator Compass G1000 slaved directional gyro magnetic compass Turn indicator Attitude bank G1000 and backup OAT outside air temperature G10...

Page 209: ...lot disconnect Audio panel intercom COM 1 COM 2 ELT Moving map satellite status GPS position terrain information TAXIING in accordance with AFM Compass G1000 and magnetic compass Turn indicator Attitude bank Brakes pilot co pilot side Taxiing behavior BEFORE TAKE OFF CHECK in accordance with AFM ECU test normal behavior and warning sequence ECU VOTER test Available power check Idle RPM TAKE OFF in...

Page 210: ...d RPM indications Fuel quantity temperature fuel flow Airspeed indicator G1000 and backup Altimeter G1000 and backup Alternate static valve Vertical speed indicator Compass G1000 slaved directional gyro magnetic compass Turn indicator Attitude bank G1000 and backup If OÄM 42 224 is NOT installed Propeller feathering engine shut down If OÄM 42 224 is NOT installed Propeller unfeathering engine rest...

Page 211: ...on Autopilot S Wings level mode S HDG mode S FD flight director S YD yaw damper S GA go around mode S NAV mode if required on VLOC and GPS S ALT VS preselect and hold S FLC mode S CWS control wheel steering button S Disconnect red button Cabin ventilation Cabin heating Cabin leaks sounds TKS system if installed TAS system if installed Stormscope if installed Aux fuel transfer indication if install...

Page 212: ... 6 15 Mar 2018 05 28 92 Doc 7 02 15 Rev 4 DESCENT AND LANDING in accordance with AFM Function of flaps Function of landing gear Landing behavior Braking action AFTER LANDING CHECK AND SHUT DOWN in accordance with AFM ELT Engine shut down behavior Engine starting behavior warm LH and RH OUTSIDE INSPECTION Damage Engine oil coolant fuel hydraulic leaks Findings Signature Pilot ______________________...

Page 213: ...llowing Structural defects found during the MSI All structural defects that were detected and repaired since new or since the last MSI STRUCTURAL FINDINGS REPORT DA 42 NG AT MAJOR STRUCTURAL INSPECTION MSI Registration __________________ Date _______________ Airplane S N _________________ Airplane Operating Hours _______________ Maintenance Organization AMM Rev used for check _______________ Signa...

Page 214: ...od remarks at TSN Page 2 15 Mar 2018 05 28 93 Doc 7 02 15 Rev 4 All defects have been repaired The airplane is airworthy with respect to its maintenance condition Place _____________________________________ Date _____________________________________ Authorized _____________________________________ ...

Page 215: ...loads A Equipment Item Quantity Part No Slide sheets 4 Commercial B Procedure Detail Steps Work Items Key Items 1 Remove the access panels for the main and nose landing gear Refer to Section 52 40 2 Examine the landing gear fittings Look specially for cracks Use a mirror and a flashlight 3 Examine the fuselage and center wing structure where the landing gear attaches Look specially for S Disbonds ...

Page 216: ...HE AIRPLANE MANUFACTURER FOR ADVICE 9 Examine the structure in the bottom of the fuselage nose for delamination Look specially in the area of the bearings for the nose gear assembly 10 Examine the control surfaces Look specially for S Correct attachment of the hinges S Correct attachment of the mass balance to the structure 11 Examine the leading edge of the wing for damage 12 Examine the area of ...

Page 217: ...ats OÄM 42 067 or OÄM 42 259 are installed CAUTION DO NOT LOOSEN THE LEVER FOR THE ADJUSTABLE BACKREST OF THE FRONT SEATS UNINTENTIONALLY THE SPRING LOADED BACKREST MAY SNAP FORWARD AND CAN CAUSE INJURY 17 If the adjustable front seats OÄM 42 067 or OÄM 42 259 are installed Do a test of the backrest adjustment mechanism on both front seats Refer to Section 25 10 ...

Page 218: ...018 05 50 00 Doc 7 02 15 Rev 4 Main Landing Gear Rib Front Main Bulkhead Rear Main Bulkhead Folding Stay Pivot Plate Front Mounting Rear Mounting Main Landing Gear Leg Front Closing Rib LH Shown RH Similar Folding Stay Rib Figure 1 Hard Landing Check Areas Main Landing Gear ...

Page 219: ... AMM Time Limits and Maintenance Checks Doc 7 02 15 Rev 4 05 50 00 Page 5 15 Mar 2018 Bulkhead Nose Gear Assembly Folding Stay Mounting Bearings for Nose Gear Assembly Figure 2 Hard Landing Check Areas Nose Landing Gear ...

Page 220: ...ent Refer to Section 52 50 5 Examine the fuselage bonded joints S Between LH and RH fuselage shell for cracks S Between fuselage tube shell and ventral fin S On leading edge of the ventral fin S Between vertical stabilizer front rear web and fuselage shell In case of doubt do a coin tap test Refer to Section 51 10 6 Examine the antennas for damage 7 Examine the engine nacelle structure and bonding...

Page 221: ... propeller Refer to Chapter 61 2 Proceed according to Austro Engine Maintenance Manual latest revision 3 Do an inspection of the engine mount Refer to Section 71 20 4 Do an inspection of the propeller Refer to the Propeller Owner s Manual B Propeller Hit by a Moving Object If a propeller which is not moving is hit by a moving object Detail Steps Work Items Key Items 1 Do an inspection of the prope...

Page 222: ...to Section 24 31 3 Examine the engine cowlings Look specially for signs of fire damage 4 Examine the electrical cables Look specially for signs of fire damage Replace damaged cables 5 Examine the fuel lines Look specially for signs of fire damage to the fire protection sleeves Replace damaged fuel lines 6 Examine the engine oil lines Look specially for signs of fire damage to the fire protection s...

Page 223: ... YOU CLEAN THE ENGINE REFER TO THE FIRE EXTINGUISHER MANUFACTURER S SAFETY INSTRUCTIONS USE SAFETY MASKS AND GLOVES AS RECOMMENDED 9 Clean the engine Make sure you clean all the fire extinguisher particles from the engine Refer to the manufacturer of the fire extinguisher 10 Connect the airplane batteries main battery and ECU backup batteries Refer to Section 24 31 11 Trouble shoot the engine Find...

Page 224: ...s damage you must remove panels or equipment to look for damage on the inside of the airplane Look specially around the area of the external damage You must also examine the airplane lightning protection system Look specially for signs of heat damage or distortion to the conduction tubes and bonding strips Also look for heat damage in the structures around the conduction tubes and bonding strips R...

Page 225: ...es S Engine breather S Canopy handles S Antennas S Static discharge wicks S Vertical fin tip S Rudder S Lower fin If you find any damage you must examine the airplane internally specially in the area of the external damage Make a record of the damage you find and ask Diamond Aircraft for advice before you repair or operate the airplane If you find any sign of a lightning strike on the propellers s...

Page 226: ...examine the airplane internally specially in the area of the external damage Make a record of the damage you find and ask Diamond Aircraft for advice before you repair or operate the airplane 3 Examine the surface of the right wing for lightning damage Look specially in these areas S Winglet S Static discharge wicks S Wing tip light assembly S Wing trailing edge S Aileron trailing edge S Flap trai...

Page 227: ...10 6 Examine the nose landing gear Look specially in these areas S Nose gear attachment points Refer to Section 32 20 7 Operate the flight controls through their complete range of movement Look specially for S Stiff or unusual feel during movement S Restriction of movement S Noisy operation Refer Section 27 00 8 Examine the metal conduction tubes and bonding strips in the fuselage and in the wings...

Page 228: ...Instrument flood lights S Map reading lights Refer to Section 33 40 Refer to Section 33 10 10 Do a test of the Pitot heat system Refer to Section 34 10 11 Do a test of all functions on the G1000 system 12 If OÄM 42 270 is installed Do a test of all functions of the Standby Attitude Module MD302 13 Operate the engine power levers through their range of movement Look specially for S Stiff or unusual...

Page 229: ... movement Look specially for S Stiff or unusual feel during movement S Restriction of movement S Noisy operation Refer to Section 32 40 17 Do an engine run up Look specially for abnormal operation of the following systems S Engine indicating systems S DC generation Refer to Section 71 00 Refer to Section 31 00 Refer to Section 24 30 18 Do an ECU test Refer to Section 76 00 19 Do an ECU VOTER test ...

Page 230: ...umption Detail Steps Work Items Key Items 1 Check engine for oil leakage 2 Check the compression 9 Oil Pressure Loss Detail Steps Work Items Key Items 1 Check the oil quantity 2 Check the indication 3 Check the wiring 4 Check if negative g load flights have been conducted Visual inspection of the breather outlet for oil contamination 10 Hang Start Detail Steps Work Items Key Items 1 Check voltage ...

Page 231: ...ks Use a mirror and a flashlight 2 Examine the fuselage and center wing structure where the landing gear attaches Look specially for S Disbonds S Delamination of the CFRP structure S Damage to the mounting brackets Refer to Section 32 10 3 Examine the landing gear struts Look specially for S Bending S Cracks Refer to Section 32 10 4 Examine the tires Look specially for detoriation on the inner the...

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Page 233: ...AIRCRAFT DA 42 NG AMM Dimensions and Areas Doc 7 02 15 Rev 4 06 TITLE Page 1 15 Mar 2018 CHAPTER 06 DIMENSIONS AND AREAS ...

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Page 235: ...M Dimensions and Areas Doc 7 02 15 Rev 4 06 CONTENTS Page 1 15 Mar 2018 TABLE OF CONTENTS CHAPTER 06 DIMENSIONS AND AREAS 1 General 1 2 Dimensions 3 3 Adjustment Reports 5 4 Weight and Static Moments of Control Surfaces 5 ...

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Page 237: ... Mar 2018 CHAPTER 06 DIMENSIONS AND AREAS 1 General The DA 42 NG uses the System Internationale SI for dimensions and areas Imperial dimensions are also given in brackets For example Wing span 13 42 m 44 03 ft Conversions between SI units and imperial units are given in Chapter 02 ...

Page 238: ... 02 15 Rev 4 Ø 1870 mm 6 ft 2 in 1900 mm 6 ft 3 in If MÄM 42 600 is installed Ø 13 42 m 44 ft 0 in 2 49m 8 ft 2 in 3 50 m 11 ft 6 in 2 95 m 9 ft 8 in 13 55 m 44 ft 5 in 2 205 m 7 ft 3 in 1 95 m 6 ft 5 in 1 735 m 5 ft 8 in Figure 1 DA 42 NG Overall Dimensions Approximate Values ...

Page 239: ... Wing area each wing without winglets flaps and aileron 3 91 m 42 09 ft Winglets each 0 40 m 4 31 ft Dihedral nominal 5 5 Aspect ratio 11 06 Sweep back 1 Wing Center Section Area total without inner flaps 6 16 m 66 31 ft Inner Flaps Span 2 x 1 42 m 2 x 4 ft 8 in Area 2 x 0 43 m 2 x 4 63 ft Horizontal Tail Surfaces Span 3 50 m 11 ft 6 in Area with tips without elevator 1 79 m 19 27 ft Angle of inci...

Page 240: ... 06 m 0 65 ft Area if MÄM 42 600 is installed 0 087 m 0 94 ft Landing Gear typical static normal load Wheel track 2 95 m 9 ft 8 in Wheel base 1 735 m 5 ft 8 in Main Wheel Tire Goodyear 15x6 0 6 6 PR TT 160 mph FS II Only if MÄM 42 659 is installed 15x6 0 6 6 PR TT 160 mph FS II FC III Tire inflation pressure 4 7 bar 68 PSI Damper gas pressure unloaded 19 bar 276 PSI Nose Wheel Tire Goodyear 5 00 5...

Page 241: ...ference to show any deviations 4 Weight and Static Moments of Control Surfaces WARNING IF YOU REPAINT OR DO REPAIRS TO THE CONTROL SURFACES YOU MUST MAKE SURE THAT THE WEIGHT AND STATIC MOMENTS OF THE CONTROL SURFACES ARE IN THE LIMITS GIVEN IN THE CONTROL SURFACE BALANCE REPORT THIS WILL PREVENT CONTROL SURFACE FLUTTER To measure the static moments you must remove the control surface from the air...

Page 242: ...ft left left left Ailerons Take Off Up Neutral 0 1 0 2 0 0 8 0 0 0 32 0 81 16 8 see A 167 12 4 see B 87 7 see E 3 43 0 27 see E 0 3 5 0 0 14 3 10 6 6 22 0 lbf A B C D E F G H R 2 0 0 R 2 3 3 3 5 6 6 11 0 lbf difference LH RH 1 difference LH RH 2 1 Control Surface Adjustment Reports Figure 2 Control Surface Adjustment Report Flaps and Ailerons ...

Page 243: ...oc 7 02 15 Rev 4 06 00 00 Page 7 15 Mar 2018 down up up with variable elevator stop active Elevator R u d d e r A x is right left Rudder C A D B R 240 R 490 R 4 9 0 E F G H Top View Figure 3 Control Surfaces Adjustment Report Elevator and Rudder ...

Page 244: ...G AMM Page 8 15 Mar 2018 06 00 00 Doc 7 02 15 Rev 4 R 9 5 N o s e u p N o s e D o w n N e u tr a l Elevator Trim Elevator 10 Up Elevator Neutral Elevator 10 Down Linear Measurements Figure 4 Control Surfaces Adjustment Report Elevator Trim ...

Page 245: ...Trim RH Trim LH Trim LH Rudder RH Trim RH Trim RH Rudder LH Neutral Neutral 2 40 0 24 0 59 0 16 0 98 0 24 61 6 15 4 25 6 51 4 47 4 47 6 3 4 58 6 2 01 0 16 7 2 1 85 0 16 1 85 0 24 0 12 0 16 2 28 0 24 Angle Limits Angle Actual Travel Actual Travel Limits in Travel Limits mm R 6 7 0 28 0 08 Figure 5 Control Surfaces Adjustment Report Rudder Trim ...

Page 246: ...rim 16 3 26 5 48 3 10 3 36 5 40 5 3 3 Neutral Trim LH Trim RH R65 Trim LH Trim RH Trim LH Trim RH Neutral Neutral Rudder RH Rudder LH Needs only be checked if rudder trim system components are replaced Figure 6 Control Surfaces Adjustment Report Rudder Trim if MÄM 42 600 and MÄM 42 885 are installed ...

Page 247: ...1 4 50 4 4 2 45 4 54 6 8 4 31 5 35 5 1 3 36 5 43 3 3 2 39 5 47 5 7 3 27 5 Neutral Trim LH Trim RH R67 Trim LH Trim RH Linear Measurement on top of Trim Tab Trim LH Trim RH Neutral Rudder RH Rudder LH Figure 7 Control Surfaces Adjustment Report Rudder Trim if MÄM 42 600 is installed and MÄM 42 885 is NOT installed ...

Page 248: ... Dihedral Angle of Incidence Measurement of dihedral with wings supported main bolts unloaded Datum point for wing dihedral Datum point for wing dihedral Baggage hold floor top surface LH 5 5 0 25 3 0 15 1 0 2 0 5 98 15 1 0 3 430 20 D i a g o n a l m e a s u r e m e n t L H D i a g o n a l m e a s u r e m e n t R H 200 200 Plane of reference Wing Angle of setting RH Plane of reference Wing Angle o...

Page 249: ...edral Angle of Incidence Measurement of dihedral with wings supported main bolts unloaded Datum point for wing dihedral Datum point for wing dihedral Baggage hold floor top surface LH 5 5 0 25 3 0 15 1 0 2 0 5 3 86 0 59 1 0 3 16 94 0 79 D i a g o n a l m e a s u r e m e n t L H D i a g o n a l m e a s u r e m e n t R H 7 87 7 87 Plane of reference Wing Angle of setting RH Plane of reference Wing A...

Page 250: ...ty 2 Set airplane MLG wheels on relocatable plates 2 steel plates 250 x 300 x 2 mm use Aeroshell grease between steel plates to reduce friction 3 Use either a track camber fixture or perform the check manually Measure wheel track 4 Track LH wheel dvsl 5 Track RH wheel dvsr 6 Angle between LH and RH wheel dvsl dvsr dvs Measure wheel camber 7 Camber LH wheel gl 8 Camber RH wheel gr Measure track wid...

Page 251: ...15 15 Mar 2018 δ 0 1 VS γ 0 0 5 1 5 0 0 5 Direction of Flight δ 0 δ 0 δ 0 δ 0 MLG loaded with basic weight View from the back End of axle End of axle S 2894 S gets measured to the ends of the axles γ 0 γ 0 γ 0 γ 0 0 0 5 γ 0 0 5 1 5 Figure 11 Main Landing Gear Track and Camber ...

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Page 253: ...AIRCRAFT DA 42 NG AMM Lifting and Shoring General Doc 7 02 15 Rev 4 07 TITLE Page 1 15 Mar 2018 CHAPTER 07 LIFTING AND SHORING GENERAL ...

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Page 255: ...Shoring General Doc 7 02 15 Rev 4 07 CONTENTS Page 1 15 Mar 2018 TABLE OF CONTENTS CHAPTER 07 LIFTING AND SHORING GENERAL 1 General 1 Section 07 10 Jacking 1 General 1 2 Lifting the Airplane on Jacks 1 Section 07 11 Hoisting 1 General 1 ...

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Page 257: ...018 CHAPTER 07 LIFTING AND SHORING GENERAL 1 General The DA 42 NG has no lifting points You must use straps to lift the airplane Two persons can lift the outer wing or the horizontal stabilizer or any of the airplane control surfaces Section 07 10 tells you how to lift the airplane with jacks ...

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Page 259: ... maintenance lift the fuselage with three hydraulic jacks Use a trestle with a special former to hold the front of the fuselage Use standard trestles under the wings at the position where the winglets connect to the wing Refer to Figure 1 2 Lifting the Airplane on Jacks A Equipment Item Quantity Part Number Airplane jacks 1000 kg 2200 lb minimum lifting capacity 3 Commercial Nose trestle 1 Commerc...

Page 260: ...ral DA 42 NG AMM Page 2 15 Mar 2018 07 10 00 Doc 7 02 15 Rev 4 Main Jacking Point LH RH Tail Jacking Point Main Jack Main Jack Wing Trestle Wing Trestle Nose Trestle Nose Trestle Tail Jack Ballast Figure 1 Lifting the Airplane on Jacks ...

Page 261: ...il jacking point Extend the jack until to engage with the lower fin skid plate Tie down the tail section by use of a belt connected to the ballast 4 Extend all the jacks until the airplane wheels are clear of the ground You must operate all the jacks together to keep the airplane level 5 If necessary level the airplane Refer to Section 08 20 CAUTION DO NOT PUT TRESTLES UNDER THE MIDDLE OF THE WING...

Page 262: ... THE AIRPLANE WITH THE JACKS 1 Remove the nose trestle from under the front fuselage 2 Remove the wing trestles from under the wing tips 3 Retract the jacks until the airplane wheels are on the ground Retract the 3 jacks equally to keep the airplane level at all times 4 Apply the parking brake Put chocks under the wheels 5 Retract the 3 jacks fully and move the jacks clear of the airplane 6 Remove...

Page 263: ...in Figure 1 The sling assembly must have a lifting capacity of 2000 kg 4410 lb If you remove any equipment for example an engine or landing gear leg you move the center of gravity of the airplane If you move the center of gravity of the airplane then you must change the lifting position of the lifting sling assembly You can do this by repositioning the sling straps or by repositioning the shackle ...

Page 264: ...IRCRAFT Lifting and Shoring General DA 42 NG AMM Page 2 15 Mar 2018 07 11 00 Doc 7 02 15 Rev 4 Sling Assembly Front Strap Rear Strap Centre of Gravity Shackle Lifting Beam Figure 1 Hoisting the Airplane ...

Page 265: ...AIRCRAFT DA 42 NG AMM Leveling and Weighing Doc 7 02 15 Rev 4 08 TITLE Page 1 15 Mar 2018 CHAPTER 08 LEVELING AND WEIGHING ...

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Page 267: ...v 4 08 CONTENTS Page 1 15 Mar 2018 TABLE OF CONTENTS CHAPTER 08 LEVELING AND WEIGHING 1 General 1 Section 08 10 Weighing 1 General 1 2 Weighing with Mechanical Scales Under the Wheels 4 Section 08 20 Leveling 1 General 1 2 Make the Airplane Level with Jacks 1 ...

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Page 269: ...lso tells you how to level the airplane Use the procedures given in Section 08 10 to weigh the airplane and to calculate the airplane moment Use the procedures in Section 08 20 to level the airplane Note In this Airplane Maintenance Manual masses are referred to as weights The authors accept that this is technically incorrect but have used the expression for simplicity and convenience ...

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Page 271: ...orthiness Authority of the country where the airplane is registered gives approval for persons who can weigh the airplane It also gives the time limits for when the airplane must be weighted Use the Weighing Report when you do the weight and balance calculations refer to Figure 3 You can use mechanical scales or electronic weighing units to weigh the airplane Electronic weighing units give more ac...

Page 272: ...AIRCRAFT Leveling and Weighing DA 42 NG AMM Page 2 15 Mar 2018 08 10 00 Doc 7 02 15 Rev 4 Figure 1 Level the Airplane Laterally for Weighing Spirit Level Horizontal Part of Baggage Compartment Frame ...

Page 273: ...ight as Nose Scale Blocks to Level the Airplane X1 2780 mm 109 45 in 925 mm 36 42 in Legend X1 Arm Reference Plane to center line of main wheels X2 Arm Reference Plane to center line of nose wheel G1 G1LH G1RH Net weight main wheel scales LH and RH G2 Net weight Nose wheel scale G G1LH G1RH G2 Empty Weight XCG Arm Empty Weight center of gravity calculated Figure 2 Weighing Dimensions for Mechanica...

Page 274: ...al Manufacture Optional airplane jacks 1000 kg 2200 lb minimum lifting capacity 3 Commercial Note This procedure uses jacks because the main wheel scales need a number of blocks to bring the airplane level Before you weigh the airplane do these items Make sure that the airplane has all its equipment The equipment must be in the location given in the Airplane Inventory Defuel the airplane to the un...

Page 275: ...part of the ramps under each wheel 7 Lower the airplane onto the ramps with the jacks Remove the jacks Refer to Section 07 10 8 Put a wooden block on the scale in front of each main wheel The blocks should be of the same thickness Figure 2 9 Push the airplane forward onto the scales Make sure that the wheels are above the center of the scales 10 Make the airplane level laterally S Put a spirit lev...

Page 276: ...r passenger seats in the upright position 14 Close the passenger door 15 Read the value from the left main wheel scale Enter the value on the weighing form under MAIN G1LH Gross 16 Read the value from the right main wheel scale Enter the value on the weighing form under MAIN G1RH Gross 17 Read the value from the nose wheel scale Enter the value on the weighing form under NOSE G2 Gross 18 Use the p...

Page 277: ...H Record the value in the Weighing Report 25 Measure the distance X1RH Record the value in the Weighing Report 26 Measure the distance X2 Record the value in the Weighing Report 27 Refer to the calibration records for the weighing scales If necessary correct the Gross and Tare values of MAIN G1LH MAIN G1RH and NOSE G2 28 Subtract each Tare value from the related Gross value Record the result under...

Page 278: ...ndition Include brake fluid hydraulic fluid coolant engine oil unusable fuel main tanks 7 57 liter 2 US gal and unusable fuel auxiliary tanks if installed 5 0 liter 1 32 US gal Support Gross Tare Net Lever Arm MAIN G1LH X1LH mm in MAIN G1RH X1RH mm in NOSE G2 X2 mm in Empty Weight Calculate the Empty Weight G MAIN G1LH MAIN G1RH NOSE G2 G Calculate the Empty Weight Moment M G1LH X1LH G1RH X1RH G2 ...

Page 279: ...h jacks unless you are weighing the airplane If you have to do an asymmetry test use the jacks to make the airplane level If you weigh the airplane change the airplane tire pressures or use blocks to make the airplane level see Section 08 10 2 Make the Airplane Level with Jacks A Equipment Item Quantity Part Number Airplane jacks 1000 kg 2200 lb minimum lifting capacity 3 Commercial Wing trestle 2...

Page 280: ...Mar 2018 08 20 00 Doc 7 02 15 Rev 4 Spirit Level Horizontal Part of Baggage Compartment Frame Spirit Level on the top surface of the front baggage compartment floor left side Figure 1 Level the Airplane Laterally Figure 2 Level the Airplane Longitudinally ...

Page 281: ...allast 3 Make the airplane level laterally S Put a spirit level on the horizontal surface of the baggage compartment frame S Adjust the main jacks to bring the sprit level horizontal Refer to Figure 1 Behind the back seats 4 Make the airplane level longitudinally S Place a spirit level on the top surface of the front baggage compartment floor left side S Adjust the tail jack to bring the spirit le...

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Page 283: ...AIRCRAFT DA 42 NG AMM Towing and Taxiing General Doc 7 02 15 Rev 4 09 TITLE Page 1 15 Mar 2018 CHAPTER 09 TOWING AND TAXIING GENERAL ...

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Page 285: ...ng and Taxiing General Doc 7 02 15 Rev 4 09 CONTENTS Page 1 15 Mar 2018 TABLE OF CONTENTS CHAPTER 09 TOWING AND TAXIING GENERAL 1 General 1 Section 09 10 Towing 1 General 1 2 Towing Procedure 1 Section 09 20 Taxiing 1 General 1 ...

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Page 287: ...move the airplane safely Section 09 10 tells you how to tow the airplane Section 09 20 tells you how to taxi the airplane WARNING YOU MUST NOT TAXI THE AIRPLANE UNLESS YOU HAVE BEEN TRAINED TO TAXI AND HAVE BEEN AUTHORIZED BY YOUR AIRWORTHINESS AUTHORITY CAUTION YOU MUST NOT EXCEED THE WHEEL STEERING ANGLE LIMITS WHEN TOWING THE AIRPLANE WITH A TOW VEHICLE EXCEEDING THE WHEEL STEERING ANGLE LIMITS...

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Page 289: ...ment must always be smooth and slowly to avoid damaging the nose landing gear A qualified person must sit in the cockpit for immediate braking action in the event that the tow vehicle becomes uncoupled 2 Towing Procedure WARNING DO NOT PUSH ON THE SPINNERS IF YOU PUSH ON A SPINNER YOU CAN DAMAGE THE SPINNER WHICH CAN CAUSE VIBRATION WARNING DO NOT DAMAGE THE VORTEX GENERATORS WHEN YOU PUSH ON THE ...

Page 290: ...Do not push on the spinners as you can damage the spinner which may cause vibration and damage to the engine Do not use force on the propeller tips or on the airplane control surfaces and do not push on the de icing nozzles if installed on the propeller blade root as you may damage the propeller the control surfaces or the de icing nozzles It is recommended to use the steering bar or a tow bar whi...

Page 291: ...avoid shock loads on the nose landing gear The maximum steering angle of 40 degrees to either side must not be exceeded If the airplane must be pulled out of soft ground or deep snow towing lines must be used The towing lines should be attached to the main landing gear struts as high as possible without interfering with the brake lines The ropes should be long enough to sufficiently clear the nose...

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Page 293: ...G ONLY YOU MUST USE THE DA 42 NG AIRPLANE FLIGHT MANUAL WHEN YOU TAXI THE AIRPLANE Detail Steps Work Items Key Items References 1 Make sure that the area around the airplane is clear of objects For example Ground equipment and tools 2 Operate the parking brake 3 If necessary remove S The wheel chocks S The tow bar S The mooring ropes S Any other support equipment attached to the airplane WARNING M...

Page 294: ...AIRCRAFT Towing and Taxiing General DA 42 NG AMM Page 2 15 Mar 2018 09 20 00 Doc 7 02 15 Rev 4 3 m 1 0 f t 3 m 10 ft 3 m 10 ft 10 m 30 ft Figure 1 The Safety Area for Taxiing the DA 42 NG Airplane ...

Page 295: ... PERSONS OR EQUIPMENT CAUTION COMPLY WITH THE SAFETY AREA FOR TAXIING SHOWN IN FIGURE 1 CAUTION TAKE CARE IF YOU TAXI ON UNEVEN GROUND THE PROPELLERS MUST NOT TOUCH THE GROUND LOOSE STONES AND GRAVEL CAN DAMAGE THE PROPELLERS USE THE LOWEST POSSIBLE RPM TO REDUCE THE RISK OF FOREIGN OBJECT DAMAGE TO THE PROPELLERS 6 Taxi the airplane to the new position 7 Shut down the engines Refer to the DA 42 N...

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Page 297: ...AIRCRAFT DA 42 NG AMM Parking Mooring and Storage Doc 7 02 15 Rev 4 10 TITLE Page 1 15 Mar 2018 CHAPTER 10 PARKING MOORING STORAGE AND RETURN TO SERVICE ...

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Page 299: ...ge 1 15 Mar 2018 TABLE OF CONTENTS CHAPTER 10 PARKING MOORING STORAGE AND RETURN TO SERVICE 1 General 1 Section 10 10 Parking and Storage 1 General 1 2 Storage 5 Section 10 20 Mooring 1 General 1 2 Mooring 1 Section 10 30 Return to Service 1 General 1 2 Return to Service Procedure 1 ...

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Page 301: ... is not in use Use the procedures given in Section 10 10 for parking the airplane Use the procedures given in Section 10 20 to moor the airplane If the airplane is parked overnight we recommend that you moor the airplane If strong winds are forecast you must always moor the airplane Refer to the AE Operation Manual latest revision for detailed information about engine standstill and storage proced...

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Page 303: ...URE THAT THE AIRPLANE IS CORRECTLY MOORED AND PROTECTED IF STRONG WINDS ARE FORECAST STRONG WINDS CAN CAUSE DAMAGE TO AN UNPROTECTED AIRPLANE A Equipment Item Quantity Part Number Wheel chocks 4 Commercial Gust locks 1 Commercial Pitot cover 1 B Short Term Parking Detail Steps Work Items Key Items References 1 If necessary taxi or tow the airplane to the parking position Refer to Chapter 09 2 Alig...

Page 304: ... both the brake pedals at least two times 6 Put chocks in front of and behind the main wheels 7 RELEASE the parking brake Lever fully forward 8 Set the airplane controls to neutral Install the control lock 9 Set the flaps to UP position Fully up 10 Make sure that the passenger door and canopy as well as the front baggage doors are closed and locked CAUTION DO NOT INSTALL THE PITOT COVER WHILE THE ...

Page 305: ...the ice protection system several times S Operate the system on HIGH until evidence of de icing fluid on the porous panels is noticed S If the de icing fluid tank is completely empty refill the de icing fluid tank with approx 2 liter 0 5 US gal of de icing fluid Refer to Section 12 10 To deaerate the system Refer to Section 12 10 3 If the airplane can be moved remove the chocks move the airplane t...

Page 306: ...t lock S Move the rudder pedals fully rearward S Engage the control surfaces gust lock with the pedals S Engage the stick wrap straps around stick once S Attach the locks and tighten the straps 7 Do a test for water contamination of the fuel Refer to Section 12 10 Note Do step 6 after each rainy day to prevent water contamination due to leaky fuel tank caps ...

Page 307: ...ible ventilate the airplane in a dry atmosphere 2 Do the procedure for the long term parking Refer to Paragraph 1 3 For engine standstill period and storage refer to AE Operation Manual latest revision 4 Close all engine openings airproof 5 Disconnect the airplane main battery Refer to Section 24 31 6 Completely fill the fuel tanks with fuel Refer to Section 12 10 7 Wipe the tires with a dry cloth...

Page 308: ...ibbed belt Refer to AE Maintenance Manual latest revision 3 Engine ground run S Connect the main battery or connect the airplane to ground power S Start up both engines for at least 20 minutes S Disconnect the main battery or disconnect the airplane from ground power Refer to AFM Chapter 4A CAUTION The engine must not be started after v ribbed belt tension relieve 4 Relieve v ribbed belt tension R...

Page 309: ...ial Rope nylon preferred or hemp A R Commercial B Mooring Procedure Detail Steps Work Items Key Items References 1 Park the airplane Refer to Section 10 10 2 Make sure that the flaps are set to UP Fully up CAUTION MOOR THE AIRPLANE AT THE MOORING POINTS ONLY CAUTION WHEN USING HEMP ROPES DO NOT MAKE THEM TIGHT IF THE ROPES GET WET THEY WILL TIGHTEN AND MAY DAMAGE THE AIRPLANE THIS IS MOST IMPORTAN...

Page 310: ...Parking Mooring and Storage DA 42 NG AMM Page 2 15 Mar 2018 10 20 00 Doc 7 02 15 Rev 4 Rear Tie Down Point Wing Tie Down Point Wing Tie Down Point Mooring Ring Figure 1 Location of Mooring Points on the Airplane ...

Page 311: ... Refer to Section 12 10 4 Do the test for correct air pressure in each tire If necessary inflate the tires Refer to Section 12 10 5 Check the strut extension of each gear damper If necessary charge the damper assemblies of main and nose landing gear Sliding bare piston should be visible Refer to Sections 32 10 and 32 20 6 Check Pitot system and canopy for contamination dirt 7 Open all engine openi...

Page 312: ...torage Time One Year and More Detail Steps Work Items Key Items References 1 Contact the engine manufacturer Austro Engine GmbH 2 If necessary install loose equipment which was removed for storage 3 If the battery has been removed S Install the airplane main battery Refer to Section 24 31 4 Remove the gust lock S Loosen the straps and detach the locks S Disengage the stick from the straps S Diseng...

Page 313: ...AIRCRAFT DA 42 NG AMM Placards and Markings Doc 7 02 15 Rev 4 11 TITLE Page 1 15 Mar 2018 CHAPTER 11 PLACARDS AND MARKINGS ...

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Page 315: ...D MARKINGS 1 General 1 2 Replace Plastic Foil Placards 1 Section 11 20 Exterior Placards and Markings 1 General 1 Maintenance Practices 1 General 201 2 Replace the Safety Walk Adhesive Strips 201 Section 11 30 Interior Placards and Markings 1 General 1 2 Description 1 Maintenance Practices 1 General 201 2 Replace a Placard Panel 201 ...

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Page 317: ...unless approved by the national Airworthiness Authority This Chapter shows you the location of these placards and markings Exterior placards Exterior markings Interior placards Self adhesive foil is used for all the placards except for the aircraft identification plate and the instrument panel labels The aircraft identification plate is made from metal and the instrument panel with integrated ligh...

Page 318: ...fully pull the placard off Do not over heat the composite structure WARNING DO NOT GET SOLVENT ON YOUR SKIN DO NOT BREATHE SOLVENT VAPOR SOLVENT CAN CAUSE DISEASE OR ILLNESS 2 Clean the area where the new placard will go Use a commercial solvent There must be no grease or dirt on the surface Obey the solvent manufacturer s instructions 3 Remove the protective backing from the new placard 4 Put the...

Page 319: ... 30 liters 7 9 US gal Refer to AFM for approved fluids 6 1 bar 88 psi If MÄM 42 659 is installed DO NOT TURN THE NOSE WHEEL MORE THAN 40 EITHER SIDE OF CENTER 40 40 Coolant DE ICING FLUID Refer to AFM for approved fluids LH RH LH RH LH RH If OÄM 42 160 is installed OIL or see Airplane Flight Manual LH RH if OÄM 42 173 is installed or OIL Austro Engine Aero 5W 40 or see Airplane Flight Manual Secti...

Page 320: ...lacards and Markings DA 42 NG AMM Page 2 15 Mar 2018 11 20 00 Doc 7 02 15 Rev 4 AIRCRAFT Diamond LH and RH LH and RH LH and RH LH and RH LH and RH LH and RH LH and RH Figure 2 Design Example for Exterior Markings ...

Page 321: ...erial Item Quantity Part Number Socomore Dienstone DLS Satwipes as required 29003 C86 C10 Acetone as required N000 148 C Replacement Procedure Detail Steps Work Items Key Items References 1 Remove the safety walk adhesive strips S Use a heat gun to warm up the safety walk adhesive strips S Start removing the safety walk adhesive strips by lifting one corner S Carefully pull the safety walk adhesiv...

Page 322: ... solvent to remove grease from the surface The surface must be totally clean from grease or dirt 5 Place the safety walk template on the center wing Refer to Figure 3 6 Make sure that the template orientation is parallel to flight direction 7 Remove the protective layer from the safety walk adhesive strips 8 Place the safety walk adhesive strips into the slots of the safety walk template 9 Use a r...

Page 323: ...15 Mar 2018 Place nose of Safety Walk Template on fuselage wall Place triangular marker to trailing edge SAFETY W ALK T EMPLATE D64 1127 10 52 TRAILING EDGE LEADING EDGE Place nose of Safety Walk Template on fuselage wall No Step Foot Step Figure 3 Safety Walk Template Positioning ...

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Page 325: ... foil placards for the cockpit interior The instrument panel has placard panels which are attached to the instrument panel with screws The placard panels have integral lighting which is controlled by a combined ON OFF dimmer switch The dimmer switch is mounted on the top left of the instrument panel Refer to Section 33 10 for more data about the dimmer switch and refer to Section 31 10 for more da...

Page 326: ... Flight Manual Operating manouvering speed 122 KIAS above 1800 kg 3968 lb 119 KIAS above 1700 kg 3748 lb to 1800 kg 3968 lb 112 KIAS above 1700 kg 3748 lb V V V o o o Limitations for GFC 700 Autopilot System Autopilot Yaw Damper DISC during take off and landing Do not use AP during single engine operation Maximum speed for autopilot operation is 180 KIAS Minimum speed for autopilot operation is 90...

Page 327: ... S W For St eer For St eer DA T E RA DIO S ON P IT OT O F F N 30 60 E S W DO NOT OPERATE SYSTEM BELOW 200 PSI DO NOT OPERATE SYSTEM BELOW 200 PSI Crossfeed with fuel pump ON in emergencies only Crossfeed with fuel pumpON in emergencies only Crossfeed with fuel pumpON in emergencies only Crossfeed withfuel pumpONin em ergenci es only Crossfeed withfuel pum pON in emergenci es only THE AUX POWER SWI...

Page 328: ... TAXI MAP ACL FLOOD OXY PFD ADC AHRS GEAR WRN ELEV LIMIT GEAR XPDR ENG INST GPS NAV1 DE IC E LH RH ECU B ECU B VOTER ECU A VOTER AUTO LH ENGINE RH ENGINE ON OFF ECU TEST ALTERNATOR A U T O A U T O LH ECU BUS RH ECU BUS LH ENG ECU BUS RH ENG ECU BUS LH RH If MÄM 42 403 is installed If OÄM 42 119 or OÄM 42 213 is installed AVIONICS BUS Figure 3 Placard Panels Sheet 1 ...

Page 329: ...AIRCRAFT DA 42 NG AMM Placards and Markings Doc 7 02 15 Rev 4 11 30 00 Page 5 15 Mar 2018 If OÄM 42 270 is installed Figure 4 Placard Panels Sheet 2 ...

Page 330: ...es 5 thru 8 are installed only if the optional oxygen system is installed OÄM 42 055 is incorporated Figure 5 Placard on the Refill Unit on the LH Side of the Nose Baggage Compartment Figure 6 Placard on Each Outlet Manifold Figure 7 Placard on the PUSH PULL Knob Figure 8 Placard on the LH RH Oxygen Compartment Cover ...

Page 331: ...yoto Protocol 1 1 1 2 Tetrafluoroethane Figure 9 RACC Compressor Placard All maintenance and replenishment which requires to open and depressurize the refrigerant circuit must be carried out by authorized personnel according to national and international regulations for refrigerant systems If OÄM 42 193 is carried out the following placard is mounted next to the switch for the map reading light Fi...

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Page 333: ...les form the placard panel that you will replace If necessary at the inline connector 4 Replace the placard panel S Remove the screws that attach the placard panel to the instrument panel S Move the placard panel clear of the instrument panel S Move the new placard panel into position on the instrument panel S Install the screws that attach the placard panel to the instrument panel S Connect the e...

Page 334: ...ation of the placard panel lights S Set the ELECT MASTER to ON S Rotate the INSTRUMENT dimmer switch fully clockwise S Rotate the INSTRUMENT dimmer switch a small amount counter clockwise S Rotate the INSTRUMENT dimmer switch fully counter clockwise S Set the ELECT MASTER to OFF The placard lights must come on The placard lights must dim The placard lights must go out ...

Page 335: ...AIRCRAFT DA 42 NG AMM Servicing General Doc 7 02 15 Rev 4 12 TITLE Page 1 05 May 2016 CHAPTER 12 SERVICING GENERAL ...

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Page 337: ...tamination Test 6 5 Engine Oil System 7 6 Gearbox Oil 9 7 Engine Coolant 12 8 Brake System 15 9 Ice Protection System 16 10 Tires 17 11 Oxygen System 18 Section 12 20 Scheduled Servicing 1 General 1 2 Lubrication Schedule 2 Section 12 30 Unscheduled Servicing 1 General 1 2 Exterior Cleaning 1 3 Canopy and Transparency Cleaning 1 4 Interior Cleaning 1 5 Engine Cleaning 2 6 Snow and Ice Removal 2 7 ...

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Page 339: ...ent procedures for various systems Section 12 20 Lubrication data Section 12 30 Cleaning and snow and ice removal The procedures for preventive and corrective maintenance of systems are given in the related Chapter of this manual Refer to Chapter 05 for the time limits and servicing schedules Note The designation of left and right as well as of forward and afterwards is based on the airplane s dir...

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Page 341: ... B Auxiliary Fuel Tanks Optional Equipment The auxiliary fuel tanks consist of a single fuel chamber in each engine nacelle The auxiliary fuel tanks are installed in the rear section of the engine nacelles above the wing main spars The additional fuel capacity is 13 7 US gal 52 liter per side The total fuel capacity main fuel tanks and auxiliary fuel tanks is 39 7 US gal 150 liter per side Each au...

Page 342: ...GUISHER IS AVAILABLE AT ALL TIMES DURING REFUELING DEFUELING WARNING TURN OFF ALL GROUND EQUIPMENT IN THE REFUELING AREA WARNING DO NOT OPERATE ELECTRICAL SWITCHES IN THE AIRPLANE DURING REFUELING WARNING REFUELING WITH PERSONS ON BOARD IS PROHIBITED CAUTION USE ONLY THE FUEL TYPES GIVEN IN CHAPTER 2 OF THE AIRPLANE FLIGHT MANUAL ...

Page 343: ...ral Doc 7 02 15 Rev 4 12 10 00 Page 3 15 Mar 2018 Fuel Brake Fluid on Co Pilot s Brake Pedals Fuel Tire Air Tire Air LH RH Engine Oil Nitrogen Oil Nitrogen Oil LH RH Coolant Hydraulic Fluid Fuel Fuel Gear Oil Figure 1 Replenishment Points ...

Page 344: ...ically At the refueling connection 5 Ground the refueling vehicle electrically 6 Remove the fuel filler cap 7 Refuel the airplane 8 Install the fuel filler cap Make sure that the filler cap is locked 9 Do steps 4 thru 6 for the other wing 10 Do steps 6 thru 8 for the auxiliary tanks if installed OÄM 42 056 Filler caps are located on the outboard side of the engine nacelles 11 Remove the ground cab...

Page 345: ... you have enough containers to hold all the fuel Each wing can hold approximately 26 US gal 100 liter fuel 3 Open the drain valve 4 When the fuel stops draining close the drain valve Make sure that the drain valve is seated correctly 5 Do steps 2 thru 4 for the auxiliary fuel tank if installed OÄM 42 056 Each auxiliary tank can hold approximately 13 7 US gal 52 liter fuel 6 If necessary do steps 2...

Page 346: ...el container is half full close the drain valve Make sure that the drain valve is seated correctly 4 Let the fuel in the glass container stand for 1 minute 5 Examine the fuel S It must be clear JET A1 S Look specifically for small drops of water in the bottom of the glass container S Look for small particles of solid material If you find any contamination you must do the test again If you still fi...

Page 347: ...oil filler has a dip stick attached A marginal oil consumption is normal Measure the oil quantity before each flight or engine ground run up If necessary replenish the oil system A Replenish the Oil System Detail Steps Work Items Key Items References 1 Open the access panel located at the upper left cowling CAUTION USE ONLY THE CORRECT ENGINE OILS REFER TO THE AE MAINTENANCE MANUAL LATEST REVISION...

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Page 349: ...evision for proper gearbox oil level A Replenish the Gearbox Oil System CAUTION IF THE GEARBOX OIL LEVEL IS LOW THE REASON MUST BE DETERMINED AND THE PROBLEM MUST BE CORRECTED BY AUTHORIZED PERSONNEL Detail Steps Work Items Key Items References 1 Remove the engine top cowling For gearbox oil system replenishment procedures refer to AE Maintenance Manual latest revision 2 Install the top engine cow...

Page 350: ...ervicing General DA 42 NG AMM Page 10 15 Mar 2018 12 10 00 Doc 7 02 15 Rev 4 Filler Cap Coolant Bypass Hose To Thermostat Expansion Tank Pressure Regulating Valve Figure 3 Engine Coolant Expansion Tank Filler Cap ...

Page 351: ...10 00 Page 11 15 Mar 2018 Figure 4 Engine Coolant Expansion Tank Filler Cap if MÄM 42 852 is installed Silicate Pouch Coolant Bypass Hose To Thermostat Expansion Tank Pressure Relief Valve Filler Cap Cartridge Max Coolant Level Marking Plate Coolant Level Sensor ...

Page 352: ...lant to cool the engine and supply heating to the flight cabin The coolant is circulated around the engine in an integral water jacket When the coolant is at normal engine operating temperature a thermostatic valve directs the coolant to flow through a heat exchanger The thermostatic valve controls the flow of coolant through the heat exchanger in order to control the temperature of the coolant A ...

Page 353: ...NOT USE THE CORRECT COOLANT THE ENGINE CAN BE DAMAGED 3 If MÄM 42 852 is NOT installed Add coolant until the fluid level is at the bottom of the tank filler tab If MÄM 42 852 is installed Add coolant until the fluid level is at the max coolant level marking in the filler neck 4 Install the filler cap If MÄM 42 852 is installed S Install the filler cap S Install safety lock wire to secure filler ca...

Page 354: ...12 10 00 Doc 7 02 15 Rev 4 6 Do an engine ground run until the engine reaches normal operating temperature Then shut down the engine Refer to Section 71 00 7 Repeat steps 1 thru 6 until the coolant level remains constant at the correct level B Fill and Bleed an Engine Cooling System Refer to Section 75 00 ...

Page 355: ... IN YOUR MOUTH BRAKE FLUID IS TOXIC AND CAN CAUSE INTERNAL INJURY CAUTION REMOVED SPILLED BRAKE FLUID IMMEDIATELY BRAKE FLUID CAN CAUSE DAMAGE TO PAINT AND OTHER MATERIALS A Fill the Brake System Reservoirs Detail Steps Work Items Key Items References 1 Clean the top of the brake fluid reservoir and filler cap 2 Remove the filler cap 3 Fill the reservoir to the correct level Use only MIL PRF 5606H...

Page 356: ...H side It has a capacity of 30 liter 7 9 US gal The filler is located in the fuselage nose on the right side and is accessible via the nose baggage compartment A Fill the Deicing Fluid Tank Detail Steps Work Items Key Items References 1 Open the right nose baggage compartment 2 Clean the filler cap 3 Remove the filler cap 4 Fill the de icing fluid tank Refer to the AFM for approved deicing fluids ...

Page 357: ...al II Goodyear A Examine the Tires and Measure the Pressure Detail Steps Work Items Key Items References 1 Examine the tires Look specially for S Cuts and friction damage S Correct alignment of the slippage markers Move the airplane as necessary so that each part of each tire can be seen If the slippage markers do not align remove the wheel for shop maintenance 2 Measure the tire pressure If neces...

Page 358: ...T CAUTION OIL GREASE OR OTHER LUBRICATIONS IN CONTACT WITH OXYGEN CREATE A SERIOUS HAZARD SUCH CONTACT MUST BE AVOIDED WHEN HANDLING WITH ANY PART OF THE OXYGEN SYSTEM A Filling the Oxygen Cylinder Detail Steps Work Items Key Items References 1 Open both nose baggage compartment doors 2 Remove all loose items from the baggage compartment 3 Check baggage compartment for oil or oil residue 4 Check d...

Page 359: ...of a fully depleted cylinder will take approximately 3 5 minutes 10 Close the valve of the oxygen filling station when a pressure of 128 bar 1850 PSI is reached 11 Disconnect the filling station outlet port from the filling valve 12 Reinstall the filling valve protection nut 13 Check pressure gauges by comparing pressure indication of the filling block with pressure indication of the gauge install...

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Page 361: ...ives components which MUST NOT be lubricated Most systems and components have maintenance free bearings These can be sealed ball roller bearings or Teflon bushes These bearings MUST NOT be lubricated Table 1 shows the bearings which MUST NOT be lubricated Table 1 Items Which MUST NOT Be Lubricated Rudder pedal sled DO NOT LUBRICATE Flap rod end bearings DO NOT LUBRICATE Aileron rod end bearings DO...

Page 362: ...2 3 4 5 6 7 Hours see Notes 1 2 1 Brake pedal pivot shaft interior 1000 2 Rudder cable S tubes 200 3 Flap actuator extension rod 200 4 Passenger door safety hook button red 100 5 Upper rudder pivot bearing 200 6 Nose wheel bearing see notes 3 5 and 6 200 7 Wing main bolts 2000 8 Stick support pivot pins 1000 9 Battery terminals 1000 10 B bolts 2000 11 B bolt spherical bearings 2000 12 A bolts 2000...

Page 363: ...ot grease on the threads It will reduce the friction of the lock nut CAUTION DO NOT MIX AVIATION WHEEL BEARING GREASES WITH EACH OTHER IF USING OTHER APPROVED GREASES COMPLETE REMOVAL OF CONTAINED GREASE AND BEARING CLEANING IS REQUIRED REPLACEMENT OF PREVIOUSLY LUBRICATED FELT GREASE SEALS IS ALSO REQUIRED 6 The wheel manufacturer lubricates the main wheel bearings with Mobil Aviation Grease SHC ...

Page 364: ...E 2 MIL L 7870 Royco 363 Royal Lubricants Co Inc Brayco 363 Bray Oil Co Warm climates only LPS 2 LPS TYPE 3 Greaseless Lubricant LPS 1 LPS TYPE 4 VV P 236 petrolatum Royco 1 Royal Lubricants Co Inc DC 4 Dow Corning TYPE 5 MIL C 16173 Grade 2 LPS 3 LPS TYPE 6 MIL A 907 Loctite Antiseize 767 Loctite Multi Purpose Lubricant DRI SLIDE LPS Force 842 LPS Lubriplate X 357 Lubriplate Loctite 8191 Loctite ...

Page 365: ...AIRCRAFT DA 42 NG AMM Servicing General Doc 7 02 15 Rev 4 12 20 00 Page 5 15 Mar 2018 2 2 1 1 14 3 15 8 16 6 5 20 17 4 18 Figure 1 Lubrication Points Sheet 1 ...

Page 366: ...AIRCRAFT Servicing General DA 42 NG AMM Page 6 15 Mar 2018 12 20 00 Doc 7 02 15 Rev 4 19 10 12 11 13 9 7 Figure 2 Lubrication Points Sheet 2 ...

Page 367: ...s are very difficult to remove CAUTION DO NOT USE CLEANING OR POLISHING AGENTS WHICH CONTAIN SILICON IF THE AIRPLANE NEEDS REPAIR AT SOME TIME SILICON CAN PREVENT REPAIR MATERIALS FROM BONDING CORRECTLY Approximately once a year apply a silicone free automotive polish to the outer surface of the airplane 3 Canopy and Transparency Cleaning CAUTION DO NOT RUB THE CANOPY OR TRANSPARENCIES WHILE THEY ...

Page 368: ... Protect all electrical components and cables Use polythene bags to seal intakes and other areas that you want to keep dry After washing you can dry the engine using compressed air 8 bar 118 PSI 6 Snow and Ice Removal Remove snow and ice as soon as possible to prevent water from the melting snow or ice re freezing and causing damage CAUTION DO NOT USE SHARP OBJECTS TO REMOVE SNOW OR ICE YOU CAN DA...

Page 369: ... the part shows signs of corrosion you must replace the anti corrosion coating refer to Paragraphs B and C of this Section B Remove the Anti Corrosion Coating CAUTION YOU MUST USE THE APPROVED ANTI CORROSION COATING CLEANING AGENTS IN ORDER TO PREVENT DAMAGE TO OTHER PARTS OF THE AIRPLANE Approved anti corrosion coating cleaning agents are Ardrox AV 980 Diestone DLS Remove the anti corrosion coati...

Page 370: ...n 35 color transparent recommended for visible parts Apply the anti corrosion coating Read the product datasheet carefully Cover the airplane parts and surfaces in your working area which are not subject to the anti corrosion coating Apply the anti corrosion agent to the parts Make sure the surface is covered with a thin film of the anti corrosion coating The anti corrosion coating needs 3 hours t...

Page 371: ...e and folding stay bracket 4 Main landing gear axle bolt heads and nuts 4 4 Main landing gear leg assy trailing arm oversize bolt head and nut 4 Damper upper bolt head and nut 4 Damper lower bolt head and nut 6 Main landing gear bay door hinges 2 bolt heads 6 and nuts 6 6 Main landing gear bay nuts 5 ELEVATOR ELEVATOR CONTROLS AND ELEVATOR TRIM SYSTEM 7 8 Elevator push rod upper eye end fitting 7 ...

Page 372: ... 12 Centering unit guidance plate and bolt heads 3 12 Nose wheel fork bolt heads 4 12 Torque links bolt heads 5 and nuts 5 13 Tension spring 13 Tension spring mounting bolt heads 2 and nuts 2 13 Folding stay latching mechanism 13 Folding stay latch operating arm lower ball joint bolt head and nut 14 Actuator eye end fitting 14 Mounting bracket bolt heads 5 15 Nose landing gear bracket and bolt hea...

Page 373: ...ervicing General Doc 7 02 15 Rev 4 12 30 00 Page 7 15 Mar 2018 Control Rod Flaps LH RH Anti corrosion coating according to Section 12 30 of this AMM LH Shown RH Similar Figure 1 Anti Corrosion Coating Control Rod Flaps LH RH ...

Page 374: ... DA 42 NG AMM Page 8 15 Mar 2018 12 30 00 Doc 7 02 15 Rev 4 Control Rod Ailerons LH RH Anti corrosion coating according to Section 12 30 of this AMM LH Shown RH Similar Figure 2 Anti Corrosion Coating Control Rod Ailerons LH RH ...

Page 375: ...eral Doc 7 02 15 Rev 4 12 30 00 Page 9 15 Mar 2018 Coating with Preventives according to Section 12 30 of this AMM Keep Switch free of Preventives LH Shown RH Similar Reverse Side Figure 3 Anti Corrosion Coating Main Landing Gear LH RH 1 ...

Page 376: ...entives according to Section 12 30 of this AMM Keep Caliper Brake Disc and Tyre free of Preventives LH Shown RH Similar Coating with Preventives according to Section 12 30 of this AMM Coating with Preventives according to Section 12 30 of this AMM Figure 4 Anti Corrosion Coating Main Landing Gear LH RH 2 ...

Page 377: ...according to Section 12 30 of this AMM Apply Preventives on joints of this part not visible on this drawing LH Shown RH Similar Coating with Preventives according to Section 12 30 of this AMM Coating with Preventives according to Section 12 30 of this AMM Figure 5 Anti Corrosion Coating Main Landing Gear LH RH 3 ...

Page 378: ... 4 Coating with Preventives according to Section 12 30 of this AMM LH Shown RH Similar Apply Preventives on all Door Hinges and related Fasteners from both sides Coating with Preventives according to Section 12 30 of this AMM Figure 6 Anti Corrosion Coating Main Landing Gear Bay LH RH ...

Page 379: ... Keep Elevator Trim System free of Preventives Coating with Preventives according to Section 12 30 of this AMM Keep Elevator Trim System free of Preventives Coating with Preventives according to Section 12 30 of this AMM Figure 7 Anti Corrosion Coating Elevator and Elevator Trim System 1 ...

Page 380: ... Servicing General DA 42 NG AMM Page 14 15 Mar 2018 12 30 00 Doc 7 02 15 Rev 4 Coating with Preventives according to Section 12 30 of this AMM Figure 8 Anti Corrosion Coating Elevator and Elevator Trim System 2 ...

Page 381: ...cing General Doc 7 02 15 Rev 4 12 30 00 Page 15 15 Mar 2018 Preventives to be applied on joints not visible as well Coating with Preventives according to Section 12 30 of this AMM Figure 9 Anti Corrosion Coating Elevator Controls ...

Page 382: ...pply Preventives on complete surface of Pedestal Coating with Preventives according to Section 12 30 of this AMM Keep Rudder Trim Damper Rod Friction Damper Bowden Cable Rudder Springs free of Preventives Keep Spring Rods free of Preventives Figure 10 Anti Corrosion Coating Rudder Pedestal ...

Page 383: ...rvicing General Doc 7 02 15 Rev 4 12 30 00 Page 17 15 Mar 2018 Apply Coating with Preventives on both sides of the Bearing Coating with Preventives according to Section 12 30 of this AMM Figure 11 Anti Corrosion Coating Rudder ...

Page 384: ...15 Mar 2018 12 30 00 Doc 7 02 15 Rev 4 Keep Tyre free of Preventives Coating with Preventives according to Section 12 30 of this AMM Coating with Preventives according to Section 12 30 of this AMM Figure 12 Anti Corrosion Coating Nose Landing Gear 1 ...

Page 385: ...15 Rev 4 12 30 00 Page 19 15 Mar 2018 Coating with Preventives according to Section 12 30 of this AMM Keep Switch free of Preventives Coating with Preventives according to Section 12 30 of this AMM Figure 13 Anti Corrosion Coating Nose Landing Gear 2 ...

Page 386: ...ge 20 15 Mar 2018 12 30 00 Doc 7 02 15 Rev 4 Coating with Preventives according to Section 12 30 of this AMM Apply Preventives on Joints of this part not visible as well LH Shown RH Opposite Figure 14 Anti Corrosion Coating Nose Landing Gear 3 ...

Page 387: ...well Apply Preventives to both sides of all Door Hinges LH Shown RH Opposite Apply Preventives to both sides of all Door Hinges Nose Landing Gear Door View from Below Apply Preventives on joints of this part not visible in this picture as well Anti corrosion coating according to Section 12 30 00 of this AMM Figure 15 Anti Corrosion Coating Nose Landing Gear 4 ...

Page 388: ... 42 NG AMM Page 22 15 Mar 2018 12 30 00 Doc 7 02 15 Rev 4 Anti corrosion coating according to Section 12 30 of this AMM Anti corrosion coating according to Section 12 30 of this AMM Figure 16 Anti Corrosion Coating Foot Step Screws ...

Page 389: ...AIRCRAFT DA 42 NG AMM Standard Practices Doc 7 02 15 Rev 4 20 TITLE Page 1 15 Mar 2018 CHAPTER 20 STANDARD PRACTICES ...

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Page 391: ... General 1 2 Bolt and Nut Types Used in the Airplane 2 3 Standard Torque Values 3 4 Special Torque Values 4 5 Torque Measurement 4 Section 20 30 Standard Practices Electrical 1 General 1 2 Thread Locking 1 3 Repair and Maintenance 1 Section 20 70 Standard Practices Engines 1 General 1 2 Torque Values 1 3 Special Torque Procedures 1 4 Installation and Tightening Torques of Worm Drive Clamps 4 ...

Page 392: ...ard Practices DA 42 NG AMM Page 2 15 Mar 2018 20 CONTENTS Doc 7 02 15 Rev 4 Section 20 90 Standard Practices Center Wing 1 General 1 2 Description 1 Trouble Shooting 1 General 101 Maintenance Practices 1 General 201 ...

Page 393: ...r gives you the standard practices for the DA 42 NG airplane Use industry standard practice where no specific practice is given This Chapter has the following Sections Section 20 10 Standard Practices Airframe Section 20 30 Standard Practices Electrical Section 20 70 Standard Practices Engines Section 20 90 Standard Practices Center Wing ...

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Page 395: ...es This Section tells you the procedures used to tighten the fasteners Note Use the standard torque values listed on the subsequent pages of this section where no specific values are given Note Composite structures can have a different thickness for the same component or assembly You must always make sure that you use the correct length of fastener The length of fastener given in the Illustrated P...

Page 396: ...mum strength for the bolts is DIN specification 8 8 Letters and numbers on the head of the bolt identify the bolt type The surface treatment also identifies the bolt A DIN Bolt Bolt Head Identification Surface Treatment Galvanized B LN Bolts Bolt Head Identification Surface Treatment Galvanized and chromated yellow C AN Bolts Bolt Head Identification Surface Treatment Galvanized or chromated yello...

Page 397: ...0 3 8 24 20 7 15 3 7 16 20 37 7 27 8 1 2 20 54 2 40 9 16 18 90 4 66 7 5 8 18 124 3 91 7 B AN Coarse Thread Series Bolt Size Torque Nm Torque lbf ft 10 24 1 6 1 2 1 4 20 5 7 4 2 5 16 18 10 2 7 5 3 8 16 20 9 15 4 7 16 14 28 9 21 3 1 2 13 54 2 40 9 16 12 79 58 3 5 8 11 101 6 75 C DIN and LN Specifications Metric Thread Torque Nm Torque lbf ft M4 1 8 1 3 M5 3 6 2 7 M6 6 4 4 7 M8 16 11 8 M10 32 23 6 M1...

Page 398: ...lic pump motor electric connection bolt 13 9 6 Bolts attaching the main landing gear brake back plates to the caliper Refer to Cleveland Parker Maintenance Manual latest revision or placard on brake cylinder assy Main landing gear axles all bolts M 8 16 11 8 Main landing gear axles all bolts M 12 60 44 3 Trailing arm main landing gear attachment bolts M 12 30 22 1 Upper main landing gear damper at...

Page 399: ...ng can be a source of potential danger and many malfunctions and failures of an electrical system can be traced to this cause The continued proper performance of the electrical systems depends on the knowledge of the personal who do the inspection and repair It is therefore important that maintenance is carried out in accordance with the best available techniques and properly trained maintenance p...

Page 400: ...o CERTI CRIMP P N 91512 1 Commercial M22520 1 01 Commercial M22520 2 01 Commercial M22520 37 01 B Wires and Cables 1 Wires For the purpose of electric and electronic installation an insulated wire consists of a metal conductor covered with a dielectric or insulating material Wires used in the airplane contain stranded conductors for flexibility The insulation may consist of several materials and l...

Page 401: ...wire within a large wiring loom would be extremely difficult without individual identification of each wire or cable To simplify maintenance each interconnecting wire and cable installed in the airplane is marked with a combination of numbers and letters If a wire or cable must be replaced the wire must be marked according to the wiring diagrams in Chapter 92 C Testing After a wire cable or ring t...

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Page 403: ...ecial Torque Procedures When you use self locking nuts add the safety torque friction torque or braking torque to the table values Set this value on the dial of the torque meter before you tighten the nut If a bolt has an additional torque due to shaft friction add this torque value to the table value Set this calculated value on the dial of the torque meter before you tighten the bolt Lubricate t...

Page 404: ...sh Type Asbestos Gaskets THREAD PITCH ANGLE OF TURN THREADS PER INCH ALUMINUM ASBESTOS COPPER ASBESTOS 8 135 67 10 135 67 12 180 90 14 180 90 16 270 135 18 270 135 20 270 135 24 360 180 28 360 180 Note Install all crush type gaskets except the self centering type with the continuous surface against the flange of the plug or against the part which you will tighten against the gasket Turn the part u...

Page 405: ...8 9 16 18 17 22 11 16 10 5 8 7 8 14 41 48 30 36 Table 5 Special Torque Values for the Engine ITEM THREAD TORQUE Nm TORQUE lbf ft Engine oil filter 25 18 5 Gearbox distance bolts if MÄM 42 600 is installed 28 3 20 6 2 2 Coolant silicate pouch cartridge 32 5 2 5 24 0 1 8 Coolant tank filler cap if MÄM 42 852 is installed 12 15 8 85 11 06 Pressure relief valve 12 15 8 85 11 06 Coolant level sensor Lo...

Page 406: ...Tightening Torques of Worm Drive Clamps The Figures and tables show the proper installation and the tightening torques of worm drive clamps A Single Worm Drive Clamp CAUTION DO NOT PLACE A WORM DRIVE CLAMP ON A TUBE BEAD THIS CAN DAMAGE THE HOSE AND MAY IN CASE OF ENGINE CHARGE AIR INSTALLATION CAUSE LOSS OF ENGINE POWER Figure 1 Installation with Single Worm Drive Clamp ...

Page 407: ...uminium Tube Aluminium Tube Beads B Two Worm Drive Clamps 1 Axial Placement CAUTION DO NOT PLACE A WORM DRIVE CLAMP ON A TUBE BEAD THIS CAN DAMAGE THE HOSE AND MAY IN CASE OF ENGINE CHARGE AIR INSTALLATION CAUSE LOSS OF ENGINE POWER Figure 2 Installation with Two Worm Drive Clamps and Single Bead Axial Placement Figure 3 Installation with Two Worm Drive Clamps Two Beads Axial Placement ...

Page 408: ...ring Steel Support Ring Maximum Insertion Expansion Bellows Minimum 90 Connection Tube Silicon Tube Hose Clamps Minimum 2 mm Minimum 4 mm Figure 4 Installation with two Worm Drive Clamps Two Beads Axial Placement and a Hose with flexible Bellows if MÄM 42 1004 is installed 2 Radial Placement Figure 5 Installation with Two Worm Drive Clamps Radial Placement ...

Page 409: ... INSTALLATION ON A HOT ENGINE CAN CAUSE DAMAGE TO THE HOSE AND MAY IN CASE OF ENGINE INSTALLATIONS CAUSE LOSS OF ENGINE POWER CAUTION DO NOT RE TIGHTEN A WORM DRIVE CLAMP ON A SILICONE HOSE PERFORMING AN AIRPLANE INSPECTION UNLESS IT IS LOOSE REFER TO THE TABLE BELOW FOR THE CORRECT TIGHTENING TORQUES OF WORM DRIVE CLAMPS 1 Tightening Torques for Clamp Widths Below 12 mm 0 47 in Clamp Diameter Tor...

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Page 411: ...nstallation positions for the components 2 Description The Figures show the key points of the routing The cables and hoses may be removed for maintenance and repair work Make sure to install components according to the previous setting Note A minimum clearance of 5 mm 0 2 in is required between electrical cables or hoses and moving parts if jamming may occur Note A minimum clearance of 2 mm 0 08 i...

Page 412: ...AIRCRAFT Standard Practices DA 42 NG AMM Page 2 15 Mar 2018 20 90 00 Doc 7 02 15 Rev 4 Figure 1 Routing in Center Wing Overview ...

Page 413: ...AIRCRAFT DA 42 NG AMM Standard Practices Doc 7 02 15 Rev 4 20 90 00 Page 3 15 Mar 2018 Figure 2 Routing in Center Wing Detail 1 ...

Page 414: ...AIRCRAFT Standard Practices DA 42 NG AMM Page 4 15 Mar 2018 20 90 00 Doc 7 02 15 Rev 4 Figure 3 Routing in Center Wing Detail 2 ...

Page 415: ...AIRCRAFT DA 42 NG AMM Standard Practices Doc 7 02 15 Rev 4 20 90 00 Page 5 15 Mar 2018 Figure 4 Routing in Center Wing Detail 3 ...

Page 416: ...AIRCRAFT Standard Practices DA 42 NG AMM Page 6 15 Mar 2018 20 90 00 Doc 7 02 15 Rev 4 Figure 5 Routing in Center Wing Detail 4 ...

Page 417: ...AIRCRAFT DA 42 NG AMM Standard Practices Doc 7 02 15 Rev 4 20 90 00 Page 7 15 Mar 2018 Figure 6 Routing in Center Wing Detail 5 ...

Page 418: ...AIRCRAFT Standard Practices DA 42 NG AMM Page 8 15 Mar 2018 20 90 00 Doc 7 02 15 Rev 4 Figure 7 Routing in Center Wing Detail 6 ...

Page 419: ...CRAFT DA 42 NG AMM Standard Practices Doc 7 02 15 Rev 4 20 90 00 Page 9 15 Mar 2018 Do not connect the Line Section with the Rudder Cable Line Section Rudder Cable Figure 8 Routing in Center Wing Detail 7 ...

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Page 421: ...o the repair given in the Repair column Trouble Possible Cause Repair Clearance less than 5 mm 0 2 in if jamming may occur Electrical cables hoses and Bowden cables position Position and fix the electrical cables hoses and Bowden cables properly Clearance less than 2 mm 0 08 in if chafing may occur Electrical cables hoses and Bowden cables position Position and fix the electrical cables hoses and ...

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Page 423: ...AIRCRAFT DA 42 NG AMM Standard Practices Doc 7 02 15 Rev 4 20 90 00 Page 201 15 Mar 2018 Maintenance Practices 1 General For maintenance of the components refer to the related Chapters of this AMM ...

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Page 425: ...AIRCRAFT DA 42 NG AMM Heating and Ventilation Doc 7 02 15 Rev 4 21 TITLE Page 1 15 Mar 2018 CHAPTER 21 HEATING AND VENTILATION ...

Page 426: ...AIRCRAFT Heating and Ventilation DA 42 NG AMM Page 2 15 Mar 2018 21 TITLE Doc 7 02 15 Rev 4 Intentionally left blank ...

Page 427: ...Trouble Shooting 1 General 101 Maintenance Practices 1 General 201 2 Replace a Heater Control Valve Forward Inner Control Cable 201 3 Replace a Heater Control Valve Control Cable if MÄM 42 739 is installed 209 4 Test Adjust a Heater Valve Control Cable 215 Section 21 40 Heating 1 General 1 2 Description and Operation 3 Trouble Shooting 1 General 101 Maintenance Practices 1 General 201 2 Remove Ins...

Page 428: ...all the Control Panel 207 3 RACC System Test Procedure 208 4 Remove Install Parts of the Refrigerant Circuit 209 Section 21 51 Cooling OÄM 42 193 d or later installed 1 General 1 2 Description 1 3 Operation 4 Trouble Shooting 1 General 101 Maintenance Practices 1 Remove Install the Central Unit 201 2 Remove Install the Control Panel 207 3 RACC System Test Procedure 208 4 Remove Install Parts of th...

Page 429: ...AIRCRAFT DA 42 NG AMM Heating and Ventilation Doc 7 02 15 Rev 4 21 CONTENTS Page 3 15 Mar 2018 Trouble Shooting 1 General 101 Maintenance Practices 1 General 201 ...

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Page 431: ... area Figure 1 shows the schematic for the heating and ventilating cooling systems Refer to Section 21 20 for more data about the air conditioning distribution system Refer to Section 21 40 for more data about the heating system and refer to Section 21 60 for more data about the temperature control system A Cabin Heating and Canopy Defrosting A heat exchanger in each engine nacelle provides the wa...

Page 432: ...of air into the forward cockpit is controlled by outlets located in each side of the instrument panel The flow of air to the rear passenger area is controlled by air outlets located in the cockpit instrument panel and the rear cabin overhead panel The volume and direction of the air flowing from the outlets can be controlled at the outlets Refer to Section 21 50 for more details about the RACC sys...

Page 433: ...AIRCRAFT DA 42 NG AMM Heating and Ventilation Doc 7 02 15 Rev 4 21 00 00 Page 3 15 Mar 2018 Figure 1 Air Conditioning Schematic Diagram ...

Page 434: ...ilation Instrument Panel NACA Air Inlet Cabin Air Controls Rear Overhead Panel Mounted Cabin Air Control LH Heater Control Levers Cabin Air Control RH Cockpit Ventilation Instrument Panel Bowden Cable LH Bowden Cable RH Cabin Air Control Rear Floor LH Cabin Air Control Rear Floor RH To Floor Element Figure 2 Air Conditioning Schematic Diagram if MÄM 42 739 is installed ...

Page 435: ... The ventilation system uses ambient air to ventilate the cabin Warm air for windscreen defrosting and cabin heating is provided by heat exchangers located in the engine nacelles This Section tells you about the air distribution system of the DA 42 NG Refer to Section 21 40 for data about the air heating system and refer to Section 21 60 for data about the temperature control system ...

Page 436: ...AIRCRAFT Heating and Ventilation DA 42 NG AMM Page 2 15 Mar 2018 21 20 00 Doc 7 02 15 Rev 4 Figure 1 Ventilation Air Distribution System Schematic Description and Operation ...

Page 437: ...r flows through sealed compartments in the center wing section to the fuselage At the fuselage the airflow is divided Some of the air is directed into an integral GRP duct that directs the air to the two air outlets on the J panel and to the two air outlets in the rear passenger compartment overhead panel The remaining air flows through flexible hoses to air outlets located at each side of the ins...

Page 438: ...AIRCRAFT Heating and Ventilation DA 42 NG AMM Page 4 15 Mar 2018 21 20 00 Doc 7 02 15 Rev 4 Figure 2 Cabin Heating and Defrost Air Distribution System Schematic ...

Page 439: ...0 Page 5 15 Mar 2018 Heater Radiator Heater Radiator Defrost Heater Valve Heater Valve Cockpit Ventilation Instrument Panel Heater Control Levers Bowden Cable LH Bowden Cable RH Figure 3 Cabin Heating and Defrost Air Distribution System Schematic if MÄM 42 739 is installed ...

Page 440: ...ps in the heater valves via Bowden cables The left lever DEFROST controls the left engine heater valve The right lever CABIN controls the right engine heater valve If MÄM 42 739 is NOT installed a forward Bowden cable from each control lever attaches to the left and right relay levers located under the pilots seats Two aft Bowden cables connect the relay levers to the left and right heater valves ...

Page 441: ...nlet ducts and the fresh air inlet blocked or damaged Open the fresh air outlets Section 21 20 Paragraph 2A Make sure the inlet duct is not blocked Examine the flexible hoses repair or replace the hoses as required No warm air flows through the cockpit defrosting system outlets The DEFROST control lever in the cockpit center console set to OFF Left engine heater valve control cable s out of adjust...

Page 442: ... cable s out of adjustment Right engine heater valve forward aft control cable s broken Flexible hose s between the right engine heater control valve and the fuselage damaged or broken Make sure that the CABIN control lever right lever is set to ON Adjust the right engine heater valve control cable s Refer to Section 21 20 Replace the right engine heater valve forward aft control cable s Refer to ...

Page 443: ...S THE PROPELLER CAN CAUSE DEATH OR INJURY TO PERSONS WARNING YOU MUST MAKE SURE THAT THE ENGINE IS SAFE BEFORE YOU DO WORK ON THE ENGINE CONTROLS IF THE PROPELLER TURNS IT CAN CAUSE INJURY TO PERSONS 1 Make sure that the related engine is safe S Set the ELECT MASTER switch to OFF S Set the ENGINE MASTER switch to OFF S Set the power lever to 0 2 Remove the engine cowlings from the related engine R...

Page 444: ...AIRCRAFT Heating and Ventilation DA 42 NG AMM Page 202 15 Mar 2018 21 20 00 Doc 7 02 15 Rev 4 Figure 4 LH Heater Valve Control Cables ...

Page 445: ... the 4 screws that attach the cover plate to the center console S Slide the cover plate clear of the control levers 6 Disconnect the control cable from the related control lever S Move the related control lever to the OFF position S Loosen the screw that attaches the swivel fitting to the control lever For access 7 Move the broken control cable clear of the cable outer sheath Remove and retain the...

Page 446: ...AIRCRAFT Heating and Ventilation DA 42 NG AMM Page 204 15 Mar 2018 21 20 00 Doc 7 02 15 Rev 4 Figure 5 RH Heater Valve Control Cables ...

Page 447: ...vel fitting into position in the flap lever S Pass the cable through the swivel fitting S Tighten the swivel fitting screw S Connect the control cable to the relay lever under the pilot s co pilot s seat S Move the control lever to a position 3 mm 0 1 in clear of the OFF position S Move the swivel fitting into position in the relay lever S Pass the control cable through the swivel fitting S Tighte...

Page 448: ...sition at the center console S Install the 4 screws that attach the cover to the center console S Tighten the 4 screws S Make sure that both control levers move freely through the full range of movement 11 Install the engine cowlings that you removed in step 2 Refer to Section 71 10 Make sure that there is no servicing equipment left in the engine nacelle 12 Install the pilot s co pilot s seat tha...

Page 449: ...et the power lever to 0 2 Remove the engine cowlings from the related engine Refer to Section 71 10 3 Remove the pilot s co pilot s seat as necessary Pilot s seat for DEFROST cables co pilot s seat for CABIN cables Refer to Section 25 10 4 Disconnect the aft cable at the relay lever S Loosen the screw that attaches the swivel fitting to the control lever and cable S Pull the cable clear of the swi...

Page 450: ...l fitting S Tighten the swivel fitting screw S Connect the control cable to the relay lever under the pilot s co pilot s seat S Move the control lever at the center console to a position 3 mm 0 1 in clear of the OFF position S Move the swivel fitting into position in the relay lever S Pass the control cable through the swivel fitting S Tighten the swivel fitting screw From the relay lever 7 Do a t...

Page 451: ... IF THE PROPELLER TURNS IT CAN CAUSE INJURY TO PERSONS 1 Make sure that the related engine is safe S Set the ELECT MASTER switch to OFF S Set the ENGINE MASTER switch to OFF S Set the power lever to 0 2 Remove the engine cowlings from the related engine Refer to Section 71 10 3 Remove the pilot s co pilot s seat as necessary Pilot s seat for DEFROST cables co pilot s seat for CABIN cables 4 Discon...

Page 452: ... the 4 screws that attach the cover plate to the center console S Slide the cover plate clear of the control levers 6 Disconnect the control cable from the related control lever S Move the related control lever to the OFF position S Loosen the screw that attaches the swivel fitting to the control lever For access 7 Move the broken control cable clear of the cable outer sheath Remove and retain the...

Page 453: ...vel fitting into position in the flap lever S Pass the cable through the swivel fitting S Tighten the swivel fitting screw S Connect the control cable to the relay lever under the pilot s co pilot s seat S Move the control lever to a position 3 mm 0 1 in clear of the OFF position S Move the swivel fitting into position in the relay lever S Pass the control cable through the swivel fitting S Tighte...

Page 454: ...sition at the center console S Install the 4 screws that attach the cover to the center console S Tighten the 4 screws S Make sure that both control levers move freely through the full range of movement 11 Install the engine cowlings that you removed in step 2 Refer to Section 71 10 Make sure that there is no servicing equipment left in the engine nacelle 12 Install the pilot s co pilot s seat tha...

Page 455: ...Page 213 15 Mar 2018 LH Defrost Valve in Engine Nacelle Swivel Fitting Bowden Cable LH Defrost Lever LH Swivel Fitting Control Levers in Center Console Typical Swivel Fitting Detail Defrost Lever Locking Nuts Figure 6 LH Heater Valve Control Cables if MÄM 42 739 is installed ...

Page 456: ... 00 Doc 7 02 15 Rev 4 RH Heater Valve in Engine Nacelle Swivel Fitting Bowden Cable RH Heater Lever RH Swivel Fitting Control Levers in Center Console Typical Swivel Fitting Detail Heater Lever Locking Nuts Figure 7 RH Heater Valve Control Cables if MÄM 42 739 is installed ...

Page 457: ...LLER TURNS IT CAN CAUSE INJURY TO PERSONS 1 Make sure that the related engine is safe S Set the ELECT MASTER switch to OFF S Set the ENGINE MASTER switch to OFF S Set the power lever to 0 2 Remove the engine cowlings for the heater valve control cable that you will test adjust Refer to Section 71 10 3 Test the operation of the heater valve S Set the related control lever in the cockpit to the OFF ...

Page 458: ... ON S Loosen the screw in the swivel fitting and move the flap a small distance towards the closed bypass position S Tighten the screw in the swivel fitting 5 Repeat steps 3 and 4 as necessary to get the correct adjustment It may also be necessary to adjust the cables at the relay lever under the pilot s co pilot s seats 6 Install the engine cowlings that you removed in step 2 Refer to Section 71 ...

Page 459: ...for the windscreen defrosting and the cabin heating systems The left engine supplies warm air for the defrost system The right engine supplies warm air for the cabin heating system This Section tells you about the engine heat exchangers Refer to Section 21 20 for data about the air distribution systems and Section 21 60 for data about the temperature control systems ...

Page 460: ...AIRCRAFT Heating and Ventilation DA 42 NG AMM Page 2 15 Mar 2018 21 40 00 Doc 7 02 15 Rev 4 Figure 1 Heating System ...

Page 461: ... cooling system thermostatic valve The temperature of the ambient air is raised as it flows through the matrix of the heat exchanger A flexible hose connects the outlet of the CFC shroud to the heater valve The heater valve is mounted on the engine firewall and has one air inlet and two air outlets An internal flap divides the air flow from the inlet between the two outlets In the OFF or bypass po...

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Page 463: ...ugh The left engine is not at normal running temperature Air trapped in the left engine heat exchanger or heat exchanger coolant supply Left engine heat exchanger matrix blocked or damaged Allow the engine to warm up to normal operating temperature Bleed the heat exchanger and heat exchanger supply system Replace the heat exchanger The air flowing through the cabin heating vents is cold or not war...

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Page 465: ... DO NOT STAND WITHIN THE DANGER AREA OF THE PROPELLER IF THE ENGINE STARTS THE PROPELLER CAN CAUSE DEATH OR INJURY TO PERSONS WARNING YOU MUST MAKE SURE THAT THE ENGINE IS SAFE BEFORE YOU DO WORK ON THE ENGINE CONTROLS IF THE PROPELLER TURNS IT CAN CAUSE INJURY TO PERSONS 1 Make sure that the related engine is safe S Set the ELECT MASTER switch to OFF S Set the ENGINE MASTER switch to OFF S Set th...

Page 466: ...AIRCRAFT Heating and Ventilation DA 42 NG AMM Page 202 15 Mar 2018 21 40 00 Doc 7 02 15 Rev 4 Airbox Washer Bolt Bolt Washer Washer Bolt Engine Mounting Frame Figure 2 Heat Exchanger Installation 1 ...

Page 467: ...AIRCRAFT DA 42 NG AMM Heating and Ventilation Doc 7 02 15 Rev 4 21 40 00 Page 203 15 Mar 2018 Figure 3 Heat Exchanger Installation 2 ...

Page 468: ... 40 00 Doc 7 02 15 Rev 4 Airbox Engine Mounting Frame Part of Engine Water Hose Water Hose Worm Drive Clamps Worm Drive Clamps Heater Radiator P Clamp Bolt Nut Washer Washer P Clamp Part of Engine Worm Drive Clamps Worm Drive Clamps Figure 4 Heat Exchanger Installation 3 ...

Page 469: ...e the flexible hoses that connect the heat exchanger to the engine cooling system S Remove the worm drive clamp from the heat exchanger coolant supply connection S Remove the worm drive clamp from the heat exchanger coolant return connection S Remove both the flexible hoses from the heat exchanger Make sure that the system is not pressurized At the heat exchanger At the heat exchange Use a suitabl...

Page 470: ...stall S Install the bolts washers and nuts that attach the heat exchanger shroud to the heat exchanger 2 Install the heat exchanger assembly S Move the heat exchanger assembly into position in the engine mount S Install the bolts washers and nuts that attach the heat exchanger assembly to the mounting bracket S Tighten the bolts 3 Install the flexible hoses that connect the coolant supply and retu...

Page 471: ...mp and tighten the worm drive clamp Make sure that the hose is correctly located on the outlet 5 Replenish the coolant supply and then bleed the engine liquid cooling system Refer to Chapter 75 00 6 Install the engine cowlings that you removed in Paragraph 1A step 2 Refer to Section 71 10 7 Do an engine ground test of the related engine and make sure that S The cooling system operates correctly S ...

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Page 473: ... electrical power 28 V DC max 65 A for operation which is provided by an additional alternator The central unit is subdivided into the following components Compressor assembly part of refrigerant circuit Condenser assembly part of refrigerant circuit Evaporator assembly part of refrigerant circuit Condenser fan Evaporator radial fan Cabin radial fan Electrical control system Refer to Figure 1 for ...

Page 474: ...AIRCRAFT Heating and Ventilation DA 42 NG AMM Page 2 15 Mar 2018 21 50 00 Doc 7 02 15 Rev 4 Figure 1 RACC System Schematic ...

Page 475: ...control panel is situated on the LH sidewall in the cabin It is electrically connected to the RACC controller and provides all necessary elements to control the center unit An integrated display shows the preset air temperature Refer to Figure 2 for details about the RACC control panel Figure 2 RACC Control Panel ...

Page 476: ...g circuit is activated An electrically powered compressor takes the low pressure low temperature refrigerant gas and compresses it to a high temperature gas A pressure switch on the compressor assembly regulates the compressor discharge pressure The hot refrigerant gas is cooled down in the condenser and condenses to a high pressure liquid An axial condenser fan forces outside air through the cond...

Page 477: ...stem is a hermetically sealed and pressurized circuit and contains the refrigerant R134a WARNING ALL MAINTENANCE AND REPLENISHMENT WHICH REQUIRES TO OPEN AND DEPRESSURIZE THE REFRIGERANT CIRCUIT MUST BE CARRIED OUT BY AUTHORIZED PERSONNEL ACCORDING TO NATIONALAND INTERNATIONAL REGULATIONS FOR REFRIGERANT SYSTEMS Trouble Possible Cause Repair Blue LED on control panel does not illuminate RACC circu...

Page 478: ...e insufficient Hot air outlet on LH fuselage blocked Leak in refrigerant circuit Condenser faulty Expansion valve faulty Compressor faulty Clean or replace filter Check ground power source respective RACC power supply of airplane Remove blockage Perform a leak test Repair leak Charge the system Check condenser coils for dirt accumulation and remove dirt Replace expansion valve Replace compressor ...

Page 479: ...E DOCUMENTATION A Remove the Central Unit Detail Steps Work Items Key Items References 1 Remove the passenger seats Refer to Section 25 10 2 Remove the seatbelt pulleys of the passenger seats Refer to 25 10 If OÄM 42 324 is installed refer to AmSafe Maintenance Documentation 3 Unplug the electrical connection of the cabin fan S Open the baggage tray S Unplug the electrical connector on the rear wa...

Page 480: ...Key Items References Page 202 15 Mar 2018 21 50 00 Doc 7 02 15 Rev 4 8 Remove the four bolts which connect the mounting panel of the RACC central unit to the mounting panel supports 9 Slide the RACC central unit forward 10 Lift the RACC central unit clear of the airplane ...

Page 481: ...AIRCRAFT DA 42 NG AMM Heating and Ventilation Doc 7 02 15 Rev 4 21 50 00 Page 203 15 Mar 2018 Figure 3 RACC Central Unit Installation ...

Page 482: ...cal connectors of the RACC unit S 3 heavy cables under the passenger seats and at the lightning protection system Verify correct connection Refer to Section 92 00 5 Install the metal air duct tube to the RH air outlet 6 Install the air ducts on the RACC central unit 7 Install the short baggage extension Refer to Section 25 10 8 Connect the cabin fan electrically S Open the baggage tray S Plug in t...

Page 483: ...AIRCRAFT DA 42 NG AMM Heating and Ventilation Doc 7 02 15 Rev 4 21 50 00 Page 205 15 Mar 2018 Figure 4 Central Unit Front and LH Side ...

Page 484: ...AIRCRAFT Heating and Ventilation DA 42 NG AMM Page 206 15 Mar 2018 21 50 00 Doc 7 02 15 Rev 4 Figure 5 Central Unit Back and RH Side ...

Page 485: ...ical connectors of the control panel 3 Unclip the RACC control panel from the LH sidewall B Install the Control Panel Detail Steps Work Items Key Items References 1 Move the RACC control panel in position on the console on the LH sidewall 2 Push the control panel into the console until the clips hold the panel in place on the console 3 Connect the electrical connectors to the control panel 4 Insta...

Page 486: ...C control panel once to switch the RACC system ON The preset temperature display on the RACC control panel must illuminate 5 Push the Preset Temperature DOWN button until the preset temperature shows LO 6 Verify that the cabin outlet air temperature is significantly lower than the cabin air temperature 7 Set the cabin air preset temperature to a convenient temperature level Use the preset temperat...

Page 487: ...graph 1 Make sure to obey the regulations for handling the refrigerant A Discharge Charge the Refrigerant Circuit 1 Equipment One of the following automated discharge and charging stations or equivalent must be used Item Quantity Part Number Silco CS 199 1 Commercial Silco CS 195 1 Commercial Silco CS 150 1 Commercial 2 Discharge the Refrigerant Circuit Detail Steps Work Items Key Items References...

Page 488: ...Use Reniso Triton Oil SE 55 0 019 liter 0 02 quart Follow the instructions of the discharge charging station 3 Print the protocol of the discharge charging station and add it to the RACC system documentation Follow the instructions of the discharge charging station 4 Disconnect the RACC system from the discharge charging station Follow the instructions of the discharge charging station 5 Install t...

Page 489: ...se caps to plug the hose connectors 4 Remove the three screws which attach the compressor to the RACC mounting panel 5 Move the compressor clear of the central unit 2 Install the Compressor Detail Steps Work Items Key Items References 1 Position the compressor on the RACC mounting panel 2 Use the three screws to attach the compressor to the RACC mounting panel 3 Connect the refrigerant circuit hos...

Page 490: ...to plug the hose connectors 4 Remove the two screws which attach the filter drier assembly to the central unit 5 Move the filter drier assembly clear of the central unit 2 Install the Filter Drier Assembly Detail Steps Work Items Key Items References 1 Position the filter drier assembly on the RACC mounting panel 2 Use the two screws to attach the filter drier assembly to the central unit 3 Connec...

Page 491: ...aps to plug the hose connectors 3 Open the pressure line fittings which connect the expansion valve to the evaporator 4 Move the expansion valve clear of the central unit 2 Install the Expansion Valve Detail Steps Work Items Key Items References 1 Position the expansion valve on the central unit 2 Attach the expansion valve to the evaporator with the pressure line fittings Use new O rings 3 Connec...

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Page 493: ... requires electrical power 28 V DC max 65 A for operation which is provided by an additional alternator The central unit is subdivided into the following components Compressor assembly part of refrigerant circuit Condenser assembly part of refrigerant circuit Evaporator assembly part of refrigerant circuit Condenser radial fan Evaporator radial fan Electrical control system Refer to Figure 1 for a...

Page 494: ...ressor Compartment Deventilation via Tail Spar Condenser Condenser Fan Radial Compartment Ventilation 1 x Ø100mm Exhaust 1 x Ø150mm Receiver Drier Expansion Valve Refrigerant Circuit Air Flow Evaporator Cold Air Duct Vents x6 Evaporator Fan Radial Figure 1 RACC System Schematic OÄM 42 193 d or later is installed ...

Page 495: ...re DOWN ON OFF Fresh Air LED B Control Panel The control panel is situated on the center console in the cabin It is electrically connected to the RACC controller and provides all necessary elements to control the center unit An integrated display shows the preset air temperature Refer to Figure 2 for details about the RACC control panel Figure 2 RACC Control Panel if OÄM 42 193 d or later is insta...

Page 496: ...wered compressor takes the low pressure low temperature refrigerant gas and compresses it to a high temperature gas A pressure switch on the compressor assembly regulates the compressor discharge pressure The hot refrigerant gas is cooled down in the condenser and condenses to a high pressure liquid A radial condenser fan forces outside air through the condenser coils and vents the thus heated air...

Page 497: ...en Additional alternator defective Set Check RACC power supply of the airplane Central unit does not power up Control panel defective Electrical control unit defective Replace Replace Insufficient cooling Hot air outlet on fuselage bottom blocked Leak in refrigerant circuit Condenser faulty Expansion valve faulty Compressor faulty Electrical power source insufficient Filter dryer assembly inoperat...

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Page 499: ...EPLOYMENT OF THE SYSTEM REFER TO AMSAFE MAINTENANCE DOCUMENTATION A Remove the Central Unit Detail Steps Work Items Key Items References 1 Remove the passenger seats Refer to Section 25 10 2 Remove the seatbelt pulleys of the passenger seats Refer to Section 25 10 If OÄM 42 324 is installed refer to AmSafe Maintenance Documentation 3 Remove the short baggage extension Refer to Section 25 10 4 Remo...

Page 500: ...Remove the drain hoses from the RACC central unit S Drip tray drain hose S Evaporator drain hose 8 Remove the drip tray 9 Remove the four bolts which connect the base plate of the RACC central unit to the RACC brackets on the LH and RH side of airplane 10 Slide the RACC central unit forward 11 Lift the RACC central unit clear of the airplane ...

Page 501: ... RACC Compartment Ventilation Inlet Drip Tray incl Filter behind Flexible Cold Air Hose Overhead Cold Air Duct C Profile RACC Central Unit Drain Hoses Hot Exhaust Air Duct Flexible Hot Air Hose Hot Exhaust Air Outlet Figure 3 RACC Central Unit Installation if OÄM 42 193 d or later is installed ...

Page 502: ...ip tray 5 Install the drain hoses to the RACC central unit S Drip tray drain hose S Evaporator drain hose 6 Connect the electric cables to the RACC central unit to S 2 heavy connectors of the RACC central unit terminal board LH S 1 plug coming from control panel 7 Install the hot exhaust air duct to the RACC central unit 8 Install the flexible air hoses to the RACC central unit S Flexible cold air...

Page 503: ...ilation Doc 7 02 15 Rev 4 21 51 00 Page 205 15 Mar 2018 Cabin Cold Air Out Condenser Condenser Fan Electric Fan with Control Box behind Evaporator Evaporator Fan Figure 4 Central Unit Front and LH Side if OÄM 42 193 d or later is installed ...

Page 504: ...and Ventilation DA 42 NG AMM Page 206 15 Mar 2018 21 51 00 Doc 7 02 15 Rev 4 Expansion Valve Drier Receiver Bottle Compressor Evaporator Cover Figure 5 Central Unit Back and RH Side if OÄM 42 193 d or later is installed ...

Page 505: ...s of the control panel 3 Unclip the RACC control panel from the center console B Install the Control Panel Detail Steps Work Items Key Items References 1 Move the RACC control panel in position on the center console 2 Push the center console into the center console until the clips hold the panel in place on the center console 3 Connect the electrical connectors to the control panel 4 Install the c...

Page 506: ...ture display on the RACC control panel must illuminate 5 Push the Preset Temperature DOWN button until the preset temperature shows LO and switch the cabin fan speed to the highest stage 3 6 Verify that the cabin air temperature at outlet is significantly lower than the outside air temperature Perform test at ambient temperature of 20 30 C and relative humidity of 20 90 The cabin air temperature a...

Page 507: ...NALREGULATIONS FOR REFRIGERANT SYSTEMS Before you do any maintenance on parts of the refrigerant circuit you must remove the central unit from the airplane Refer to Paragraph 1 Make sure to obey the regulations for handling the refrigerant If the refrigerant circuit is open for more than 30 min and the filter dryer assy is not sealed Diamond Aircraft recommends to replace the filter dryer assy by ...

Page 508: ...igerant circuit are tight 2 Charge the refrigerant circuit with R134a 500 g 25 g if OÄM 42 193 d and subsequent or 450 g 25 g if OÄM42 193 c and earlier is installed and add 15 ccm 5 ccm of oil type PVE 68 cSt acc to ISO 68 If refrigerant circuit and compressor was completely discharged add a total of 290 ccm of oil instead of the amount described above Follow the instructions of the discharge cha...

Page 509: ...he check before charging the air condition system If leakage in the air condition system was detected or the air condition unit lost more than 150 g per year of refrigerant then one of the below described checks must be performed Detail Steps Work Items Key Items References 1 Use a detection spray or soapy water at the suspicious areas and watch for bubbles and foam If a leak is detected repair th...

Page 510: ...4 Remove the three screws which attach the compressor to the RACC mounting panel 5 Move the compressor clear of the central unit 2 Install the Compressor Detail Steps Work Items Key Items References 1 Position the compressor on the RACC mounting panel 2 Use the three screws to attach the compressor to the RACC mounting panel 3 Connect the refrigerant circuit hoses to the compressor Remove the caps...

Page 511: ...e the two screws which attach the filler drier assembly to the central unit 5 Move the filter drier assembly clear of the central unit 2 Install the Filter Dryer Assembly Detail Steps Work Items Key Items References 1 Position the filter drier assembly on the RACC mounting panel 2 Use the two screws to attach the filter drier assembly to the central unit 3 Connect the refrigerant circuit hoses to ...

Page 512: ...nd the second evaporator fixing plate first and then remove the expansion valve from the evaporator Note and mark correct position of the expansion valve 6 Move the expansion valve clear of the central unit 2 Install the Expansion Valve Detail Steps Work Items Key Items References 1 Position the expansion valve on the evaporator Use new O rings on evaporator hoses 2 Install the associated expansio...

Page 513: ...ing supplies for the windscreen defrosting and the cabin heating systems The left engine supplies warm air for the defrost system The right engine supplies warm air for the cabin heating system This Section tells you about the engine heater valves Refer to Section 21 20 for data about the air distribution systems and Section 21 40 for data about the heating systems ...

Page 514: ...AIRCRAFT Heating and Ventilation DA 42 NG AMM Page 2 15 Mar 2018 21 60 00 Doc 7 02 15 Rev 4 Figure 1 Heater Valve Assembly ...

Page 515: ...ater valve can be set to close the outlet to the airplane heating system and allow all the warm air to flow into the engine nacelle Or it can be set to close the outlet to the engine nacelle and allow all the heated air to flow to the airplane heating defrost system Or it can be set to any position between these positions to regulate the flow of air to the airplane heating defrost systems The amou...

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Page 517: ...ontrol Refer to Section 21 20 for troubleshooting data for the air distribution system and see Section 21 40 for trouble shooting data for the heating system If you find the trouble in column 1 do the repair given in column 3 Trouble Possible Cause Repair There is no control of the temperature of the DEFROST or CABIN heating systems The related heater valve is inoperative Replace the heater valve ...

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Page 519: ...INE STARTS THE PROPELLER CAN CAUSE DEATH OR INJURY TO PERSONS WARNING YOU MUST MAKE SURE THAT THE ENGINE IS SAFE BEFORE YOU DO WORK ON THE ENGINE CONTROLS IF THE PROPELLER TURNS IT CAN CAUSE INJURY TO PERSONS 1 Make sure that the related engine is safe S Set the ELECT MASTER switch to OFF S Set the ENGINE MASTER switch to OFF S Set the power lever to 0 2 Remove the engine cowlings from the engine ...

Page 520: ...retain the swivel fitting from the flap lever 5 Remove the flexible hose that attaches the heater valve to the airplane system S Remove the access panel from the under the rear of the engine nacelle S Remove the worm drive clamp that holds the hose to the valve outlet S Remove the hose from the valve outlet Refer to Section 52 40 6 Remove the heater valve assembly S Remove the 2 nuts washers and b...

Page 521: ...AIRCRAFT DA 42 NG AMM Heating and Ventilation Doc 7 02 15 Rev 4 21 60 00 Page 203 15 Mar 2018 Figure 2 Heater Valve Installation ...

Page 522: ...worm drive clamp into position on the flexible hose S Move the flexible hose into position on the heater valve assembly S Tighten the worm drive clamp 4 Connect the heater valve control cable to the heater valve flap lever S Move the swivel fitting into position on the flap lever S Move the cable into position through the swivel fitting S Move the related heater valve control lever to the OFF posi...

Page 523: ... the heat exchanger S Move the worm drive clamp into position on the flexible hose S Connect the flexible hose to the heater valve assembly inlet S Tighten the worm drive clamp 7 Install the engine cowlings that you removed at Paragraph 2A step 2 Refer to Section 71 10 8 Do an engine ground test and do a functional test of the related cabin heating defrost system Refer to the DA 42 NG Airplane Fli...

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Page 525: ...AIRCRAFT DA 42 NG AMM Auto Flight Doc 7 02 15 Rev 4 22 TITLE Page 1 15 Mar 2018 CHAPTER 22 AUTO FLIGHT ...

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Page 527: ... Servo Clutch 206 6 Remove Install the Pitch Trim Servo 209 7 Remove Install the Pitch Trim Servo Clutch 210 8 Remove Install the Yaw Servo and the Yaw Servo Clutch 211 9 Adjust the Bridle Cable Tension of the Roll and Pitch Servos 216 10 Adjust the Bridle Cable Tension of the Yaw Servo 217 11 Adjust Check the Servo Clutch Torques 219 12 Mechanical Check of the Autopilot System if OÄM 42 210 GSM 8...

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Page 529: ...er tells you about the components of the GFC 700 system installed in the airplane This Chapter does not tell you about the workshop maintenance of the equipment For more data about the equipment you must refer to the equipment manufacturer s manuals Refer to Section 22 10 for more data about the autopilot system installed the DA 42 NG airplane Note Refer to Section 20 90 before starting maintenanc...

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Page 531: ...servo GSA 81 pitch trim servo GSA 80 yaw servo The GFC 700 autopilot system is controlled via the MFD of the Garmin G1000 integrated cockpit system ICS The GFC 700 roll axis features includes wing leveler heading select and VOR LOC intercept and tracking The GFC 700 is also coupled to the ICS for navigation information Attitude information is derived from the AHRS Pitch axis features include verti...

Page 532: ...2 15 Rev 4 PFD GDU 10XX MFD GDU 10XX GMU 44 GRS 7X GDC 7X GMA 1347 GSA 81 GSA 81 GSA 81 GSA 80 Roll Servo Pitch Servo Pitch Trim Servo Yaw Servo GIA 63W GIA 63W Reversionary Switch G1000 LRU Digital Communication Discrete I O Figure 1 GFC 700 Autopilot Schematic Diagram ...

Page 533: ...nt frame It is mounted on a mounting plate which is made from sheet aluminum Two aluminum clamps connect a bridle cable to the elevator push rod D GSA 81 Pitch Trim Servo The pitch trim servo is located under the co pilot s seat It is mounted on a mounting plate which is made from sheet aluminum and mounting bracket which is made from GFRP Servo movement is transmitted to the trim wheel through a ...

Page 534: ...AIRCRAFT Auto Flight DA 42 NG AMM Page 4 15 Mar 2018 22 10 00 Doc 7 02 15 Rev 4 Figure 2 Roll Servo Installation ...

Page 535: ... screws 2 or 4 which attach the servo to the clutch Hold the servo 4 Remove the servo clear of the airplane B Install the Roll Servo Detail Steps Work Items Key Items References 1 Put the servo in place on the clutch 2 Install the mounting screws 2 or 4 which attach the servo to the mounting plate and clutch Refer to Figure 2 3 Connect the connector to the servo 4 Do a test of the autopilot system...

Page 536: ...lutch clear of the airplane C Install the Roll Servo Clutch Detail Steps Work Items Key Items References 1 Remove the pilot s seat or the co pilot s seat Refer to Section 25 10 To give access for the rigging pin 2 Put the clutch in place on the mounting plate 3 Install the 4 screws which attach the clutch to the mounting plate 4 Center the aileron control system with a rigging pin at one control s...

Page 537: ...y to allow adjustment see next step 8 Using a small plastic hammer move the clamps along the push rod to adjust the bridle cable tension Adjust tension to 156 9 N 35 2 lbf Measure cable tension with cable tension gauge 9 Tighten the clamps 10 Install the cable guard 11 Remove the rigging pin from the control stick 12 Install the front seat which was removed Refer to Section 25 10 13 Install the ro...

Page 538: ...ervo 4 Remove the servo clear of the airplane B Install the Pitch Servo Detail Steps Work Items Key Items References 1 Put the servo in place on the clutch 2 Install the mounting screws 2 or 4 which attach the servo to the clutch 3 Connect the connector to the servo 4 Do a test of the autopilot system S Set ELECT MASTER switch to ON S Set AV MASTER switch to ON S Observe self test of the flight co...

Page 539: ...AIRCRAFT DA 42 NG AMM Auto Flight Doc 7 02 15 Rev 4 22 10 00 Page 205 15 Mar 2018 Figure 3 Pitch Servo Installation ...

Page 540: ...the airplane C Install the Pitch Servo Clutch Detail Steps Work Items Key Items References 1 Put the clutch in place on the mounting plate 2 Install the 4 screws which attach the clutch to the mounting plate 3 Center the elevator control system with a rigging pin at one control stick Refer to Section 27 30 4 Center the capstan The recess for the ball in the middle of the bridle cable must be in th...

Page 541: ...ove the clamps along the push rod to adjust the bridle cable tension Adjust tension to 156 9 N 35 2 lbf Measure cable tension with cable tension gauge 8 Tighten the clamps 9 Install the cable guard 10 Remove the rigging pin from the control stick 11 Install the front seat which was removed Refer to Section 25 10 12 Install the pitch servo Refer to Paragraph 4 ...

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Page 543: ...move the servo clear of the airplane B Install the Pitch Trim Servo Detail Steps Work Items Key Items References 1 Put the servo in place on the clutch 2 Install the mounting screws 2 or 4 which attach the servo to the clutch 3 Connect the connector to the servo 4 Do a test of the autopilot system S Set ELECT MASTER switch to ON S Set AV MASTER switch to ON S Observe self test of the flight contro...

Page 544: ...e cap from the capstan 4 Release chain tension with chain adjuster On the chain gear next to the servo 5 Remove the chain from the chain gear 6 Remove the 4 screws which attach the clutch and the chain adjuster to the mounting plate Hold the clutch and the chain adjuster B Install the Pitch Trim Servo Clutch Detail Steps Work Items Key Items References 1 Put the clutch and the chain adjuster in pl...

Page 545: ...tems References 1 Remove the passenger seats Refer to Section 25 10 2 Disconnect the connector from the servo 3 Remove 4 screws which attach the rudder cable support 4 Remove 7 screws which attach the yaw servo mounting cradle to the airplane Hold the assembly 5 Remove the bridle cable 6 Remove the yaw servo the yaw servo clutch and the mounting cradle from the airplane 7 Remove the 4 screws witch...

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Page 547: ...nt and secure with Loctite 243 or equivalent 6 Install the yaw damper tension plate on the yaw damper frame 7 Put the rudder cable support in place if installed 8 Pre fit the yaw damper frame assy into the airplane Install but do not tighten the mounting screws to allow axial movement Install the tension screw located on the front of the yaw damper Check before crimping S Rudder in neutral positio...

Page 548: ...light controls in working area for minium 3 mm 0 12 in clearance 13 Check if rudder is in neutral position and the capstan ball cut out is in center up position 14 Do an inspection of the adjusted controls If necessary for the Airworthiness Authority do a second inspection of the controls 15 Install the passenger seats Refer to Section 25 10 ...

Page 549: ...AIRCRAFT DA 42 NG AMM Auto Flight Doc 7 02 15 Rev 4 22 10 00 Page 215 15 Mar 2018 Figure 6 Yaw Damper Cable Installation ...

Page 550: ... Items References 1 Loosen the bolts in the clamps which connect the bridle cable to the push rod Do not remove the bolts Loosen just enough so that the next step can be done 2 Using a small plastic hammer move the clamps along the push rod to adjust the bridle cable tension Adjust tension to 156 9 N 35 2 lbf for the pitch and roll servos Measure cable tension with cable tension gauge 3 Tighten th...

Page 551: ... connection on carabiner using Loctite 243 or equivalent Remove the cable fixing tape CAUTION DO NOT USE THE YAW SERVO ADJUSTMENT SCREW TO ADJUST CABLE TENSION MOVE THE SERVO UNIT WITH GENTLE STROKES AND SECURE POSITION VIA THE ADJUSTMENT SCREW INSTEAD CAUTION DO NOT BEND THE FRAME ASSY DURING ADJUSTMENT 3 Check and adjust the yaw damper cable tension S Pull the yaw damper cable centrally between ...

Page 552: ...arabiners and bridle cable eye ends to thimble eyes with cable ties 6 Do a test of the autopilot system S Set ELECT MASTER switch to ON S Set AV MASTER switch to ON S Observe self test of the flight control computer S Set AV MASTER switch to OFF S Set ELECT MASTER switch to OFF If no error message appears then the system is operative ...

Page 553: ...uantity Part Number Garmin slip clutch adjustment fixture 1 T10 00110 01 B Adjustment Procedure Detail Steps Work Items Key Items References 1 Remove the clutch from the airplane Refer to this Section 2 Clean the servo output gears 3 Install the clutch assembly on the slip clutch test stand Refer to the equipment manufacturers documentation ...

Page 554: ...ment manufacturers documentation The correct clutch torques are Roll servo 5 08 0 68 Nm 45 6 lbf in Pitch servo 6 21 0 79 Nm 55 7 lbf in Pitch trim servo 5 08 0 68 Nm 45 6 lbf in Yaw servo 9 04 1 13 Nm 80 10 lbf in Refer to the equipment manufacturers documentation The correct clutch torques are Roll servo 5 08 0 68 Nm 45 6 lbf in Pitch servo 6 89 1 01 Nm 61 9 lbf in Pitch trim servo 5 08 0 68 Nm ...

Page 555: ... to this Section 5 Check the clutch torque settings for the pitch trim servo adjust if necessary Refer to this Section 6 Check the clutch torque settings for the yaw servo adjust if necessary Refer to this Section 7 Check the bridle cable tension for the yaw servo adjust if necessary Refer to this Section 13 Mechanical Check of the Autopilot System if OÄM 42 210 GSM 86 Servo Mounts is installed Do...

Page 556: ...es 5 Engage the pitch servo S Select the ENG CLCH soft key S Set the DRIVE SERVO speed to zero S Select the DRV SRVO soft key 6 Manually override the servo actuator slip clutch by moving the control stick forward and back through its range of motion The control should move with some resistance through its range of motion 7 Verify the servo motor does not turn by viewing the SPEED in the SERVO DATA...

Page 557: ...AIRCRAFT DA 42 NG AMM Communications Doc 7 02 15 Rev 4 23 TITLE Page 1 15 Mar 2018 CHAPTER 23 COMMUNICATIONS ...

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Page 559: ...eneral 101 Maintenance Practices 1 General 201 2 Remove Install a COM VHF Antenna 201 3 Remove Install a PTT Switch 203 Section 23 15 Satellite Transceiver System if OÄM 42 213 is carried out 1 General 1 2 Description and Operation 1 Trouble Shooting 1 General 101 Maintenance Practices 1 General 201 2 Remove Install the GSR 56 Satellite Transceiver 201 3 Remove Install the Iridium Antenna 202 4 Te...

Page 560: ...ntegration 1 General 1 2 Description and Operation 3 Trouble Shooting 1 General 101 Maintenance Practices 1 General 201 2 Remove Install the GMA 1347 Audio Control Panel 201 Section 23 60 Static Discharging 1 General 1 2 Description 1 Maintenance Practices 1 General 201 2 Replace a Static Discharge Wick 202 ...

Page 561: ...nt Refer to Chapter 92 for the wiring diagrams 2 Description The DA 42 NG communication system has these components GMA 1347 audio panel NAV COM transceivers integral with the Garmin GIA 63 W integrated avionics units COM VHF antennas NAV antenna integral with the horizontal stabilizer or if OÄM 42 112 is carried out externally on the vertical stabilizer Push to talk PTT switches A PTT switch is l...

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Page 563: ...VOR Antenna Speaker Section 23 10 Speech Communication 1 General This Section tells you about the speech communication system in the DA 42 NG It does not tell you about the speech communication equipment Refer to the equipment manufacturers manuals for more data about the equipment Figure 1 shows the main components of speech communication system Figure 1 Speech Communication System Main Component...

Page 564: ...ERG 1 2 COM CRS BARO 121 500 122 650 COM1 COM2 122 650 118 750 6 Active Frequency COM 1 Active Frequency COM 2 Stand by Frequency COM 1 Stand by Frequency COM 2 COM Volume Control Automatic Squelch Frequency Transfer Key Emergency Frequency COM Selector Knob Figure 2 Garmin 1000 Primary Flight Display Panel ...

Page 565: ...dby frequencies are shown for both COM 1 and COM 2 systems Pushing the inner knob of the COM selector will toggle the active COM system between COM 1 and COM 2 Push the COM FREQUENCY TRANSFER key to toggle between the active and standby frequency of the selected communication system A box is displayed around the stand by frequency Pressing and holding the COM FREQUENCY TRANSFER key for approximate...

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Page 567: ...ce the mic Radio check reports readability poor strength poor on COM 1 COM 2 Received audio is poor Coaxial cable connector faulty Examine the coaxial cable and connections for condition and security Faulty related GIA 63 W IAU Replace the related GIA 63 W IAU Faulty antenna Replace the antenna Short range in transmit mode but reception is OK COM 1 COM 2 Faulty related GIA 63 W IAU Replace the rel...

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Page 569: ...M VHF Antenna Use this procedure for both COM 1 and COM 2 antennas Access to both the antennas is through the rear baggage compartment A Remove a COM VHF Antenna Detail Steps Work Items Key Items References 1 Remove the aft baggage compartment Refer to Section 25 10 2 Identify the antenna that you will replace Lower antenna COM 2 top antenna COM 1 3 Disconnect the coaxial cable from the antenna At...

Page 570: ...ition on the fuselage S Make sure that the bonding strip for the antenna is correctly located S Install the 3 screws washers and nuts that attach the antenna to the fuselage 3 Connect the coaxial cable to the antenna At the bayonet connector 4 Do a test for the correct operation of the related speech communications system Refer to the Airplane Flight Manual 5 Install the aft baggage compartment Re...

Page 571: ...IO circuit breaker Instrument panel right side 3 Remove the PTT switch S Leverage the switch with a small screwdriver out of the stick s bar end S Disconnect the electrical cable from the switch and move the switch clear of the pilot s compartment Handle with care You must not damage the bar end 4 Remove the electrical cable if necessary S Remove the appropriate pilot s seat S Unplug the cable S P...

Page 572: ...end of cable Through the hole in the stick At the connector behind the main bulkhead 2 Install the PTT switch S Connect the electrical cable to the switch and move the switch into position at the bar end of the stick S Push the switch in to the cut out of the bar end Put the single cables to the switch Push carefully You must not damage the switch 3 Install the pilot s seat If removed Refer to Sec...

Page 573: ...le to the flight crew through the MFD audio panel and headset The GSR 56 is also used to obtain worldwide weather information from Garmin Flight Data Services GFDS The G1000 displays graphical weather information and associated text on the MFD and the PFD inset map The GSR 56 satellite transceiver is tray mounted and is located under the passenger s seats The antenna of the satellite transceiver s...

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Page 575: ...er Do a test for continuity on each cable Do a test for short circuit to ground and between cables Replace defective cables No or low quality signal Poor antenna performance Ensure the iridium antenna has an unobstructed view of satellite constellation Check the antenna cable and connectors No audio output Faulty cables connectors No subscription with Garmin Iridium Services Check wiring from GSR ...

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Page 577: ...h to OFF 2 Open the IRIDIUM circuit breaker 3 Remove the passengers seat Refer to Section 25 10 4 Loosen the lock nut that attaches the transceiver to its mounting tray 5 Remove the satellite transceiver from the mounting tray B Install the GSR 56 Satellite Transceiver Detail Steps Work Items Key Items References 1 Put the satellite transceiver in position in the mounting tray 2 Tighten the lock n...

Page 578: ...er surface S Move the antenna clear of the airplane Take care not to damage the airplane surface 5 Remove the Iridium antenna from the fuselage nose B Install the Iridium Antenna Detail Steps Work Items Key Items References 1 Move the antenna into position 2 Install the 4 screws washers and nuts that attach the antenna to the airplane 3 Seal the outer edge of the antenna where it contacts the airp...

Page 579: ...the system displays reasonable Iridium signal strength To improve signal strength move airplane out of the hangar 5 Press the TEL button on the GMA 1347 audio panel 6 Press the DIAL softkey on the MFD 7 Enter the test phone number in the ENTER PHONE NUMBER field Using the FMS knobs or the sofkeys on the MFD 8 Press ENT on the MFD To accept the phone number 9 Press ENT on the MFD again To initiate ...

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Page 581: ...instrument panel between the integrated cockpit system ICS display screens Figure 1 shows the audio control panel Push to talk PTT switches are installed in the handles of both control sticks one in the LH side control stick if OÄM 42 281 is installed If OÄM 42 283 is installed the RH control stick including the PTT switch is removable by the pilot The jack sockets for all the headsets are located...

Page 582: ... 15 Mar 2018 23 50 00 Doc 7 02 15 Rev 4 COM1 MIC COM2 MIC COM3 MIC COM 1 2 MKR MUTE COM1 COM2 COM3 TEL SPKR HI SENS PA DME ADF AUX PILOT PILOT DISPLAY BACKUP ICS ISOLATION COPLT COPLT PASS PLAY CREW MAN SQ NAV1 NAV2 Figure 1 Audio Control Panel ...

Page 583: ...tes and the COM 1 caption on the ICS display screen is highlighted COM 2 MIC key Press this key to select COM 2 as the active microphone source and to automatically deselect any COM MIC key that may have been previously selected The COM 2 MIC key annunciator illuminates and the COM 2 caption on the ICS display screen is highlighted COM 3 MIC key This key is not active in the DA 42 NG installation ...

Page 584: ... key Press this key to increase the sensitivity of the marker beacon receiver The annunciator illuminates when the HI SENS key is activated DME ADF NAV 1 NAV 2 keys Press one of these keys to select the related audio source The related annunciator illuminates when the key is activated MAN SQ key Press this key to make the pilot co pilot pass ICS volume control knob a push toggle switch for setting...

Page 585: ... the inner knob counterclockwise to reduce the volume of the pilot s ICS Rotate the outer knob clockwise to increase the volume level of the co pilot s and passengers ICS Rotate the outer knob counterclockwise to reduce the volume level of the co pilot s and passengers ICS MAN SQ key selected When the MAN SQ is selected the ICS squelch levels can set manually and pressing the VOLUME SQ knob toggle...

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Page 587: ...ice modulation when transmitting from pilot s side on headset Co pilot s side OK Faulty headset Open mic audio line Faulty GMA 1347 Replace headset Do a test of the mic audio wiring Refer to Chapter 92 for the wiring diagrams Replace GMA 1347 No intercom audio on pilot s headset Receives radio transmissions correctly ICS mode set incorrectly Faulty GMA 1347 Set mode to required position refer to S...

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Page 589: ...egrating system 2 Remove Install the GMA 1347 Audio Control Panel A Remove the GMA 1347 Audio Control Panel Detail Steps Work Items Key Items References 1 Make sure that the ELECT MASTER switch is set to OFF Instrument panel lower center 2 Remove the audio control unit S Insert a 3 32 hexagonal drive wrench into the access hole in the front of the panel S Rotate the locking mechanism counter clock...

Page 590: ...panel into position at the instrument panel S Carefully slide the panel into position in the instrument panel S Insert a 3 32 hexagonal drive wrench into the access hole in the front of the panel and rotate the locking mechanism clockwise to lock the panel into position Make sure that the audio control panel fully engages with the connectors at the rear of the panel Make sure that you cannot pull ...

Page 591: ...irplane bonding system All the metal components or the airplane and the antenna ground planes connect to the bonding system Refer to Section 51 80 for more data about the airplane bonding system 2 Description The static discharging system removes the electrostatic charge which collects on the airplane surfaces The composite structure of the DA 42 NG does not let electricity flow through it The air...

Page 592: ...018 23 60 00 Doc 7 02 15 Rev 4 Static Discharge Right Wing 2x Static Discharge Right Horizontal Stabilizer Static Discharge Left Horizontal Stabilizer Static Discharge Rudder Static Discharge Left Wing 2x Figure 1 Static Discharge Wick Locations DA 42 NG ...

Page 593: ...4 23 60 00 Page 201 15 Mar 2018 Static Discharger Screw Mounting Plate Maintenance Practices 1 General This Section tells you how to remove install a static discharge wick and how to test a static discharge wick Figure 2 Static Discharge Wick Installation ...

Page 594: ...ems References 1 Remove the 2 screws that attach the discharge wick to the wick mounting Refer to Figure 2 2 Make sure that the mounting is clean and correctly bonded to the airplane structure 3 Move the new static discharge wick into position at the mounting 4 Install the 2 screws that attach the wick to the mounting 5 Do a test for the correct bonding of the static discharge wick to the airplane...

Page 595: ...AIRCRAFT DA 42 NG AMM Electrical Power Doc 7 02 15 Rev 4 24 TITLE Page 1 15 Mar 2018 CHAPTER 24 ELECTRICAL POWER ...

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Page 597: ...on 4 3 Power Supply Control 7 Section 24 30 DC Generation 1 General 1 2 Description and Operation 5 Trouble Shooting 1 General 101 Maintenance Practices 1 General 201 2 Electrical Safety 201 3 Remove Install an Alternator Relay 206 4 Remove Install an ECU Backup Battery 208 Section 24 31 Battery Systems 1 General 1 2 Main Battery Description and Operation 1 Trouble Shooting 1 General 101 ...

Page 598: ... 207 6 Starter Relay Functional Test 209 Section 24 32 Emergency Power 1 General 1 2 Description 1 Trouble Shooting 1 General 101 Maintenance Practices 1 General 201 2 Remove Install the Emergency Battery Pack 201 Section 24 33 Additional Alternator 1 General 1 2 Description and Operation 3 Trouble Shooting 1 General 101 Maintenance Practices 1 General 201 2 Electrical Safety 201 3 Remove Install ...

Page 599: ...1 Maintenance Practices 1 General 201 2 Electrical Safety 201 3 Remove Install the External Power Relay 203 Section 24 60 DC Electrical Load Distribution 1 General 1 Trouble Shooting 1 General 101 Maintenance Practices 1 General 201 2 Electrical Safety 201 3 Remove Install the Avionics Master Relay 203 4 Remove Install a Circuit Breaker 204 5 Remove Install an Instrument Panel Switch 206 ...

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Page 601: ...r this electrical system refer to these Sections Section 24 30 Electrical power generation Section 24 31 Battery installation Section 24 33 Additional alternator if OÄM 42 204 is installed Section 24 40 External power Section 24 60 Power distribution Note Equipment which is certified for installation in the DA 42 NG is listed in Section 6 5 of the Airplane Flight Manual Such equipment may be insta...

Page 602: ...AIRCRAFT Electrical Power DA 42 NG AMM Page 2 15 Mar 2018 24 00 00 Doc 7 02 15 Rev 4 Figure 1 Electrical Schematic Simplified Sheet 1 if MÄM 42 403 is not carried out ...

Page 603: ...AIRCRAFT DA 42 NG AMM Electrical Power Doc 7 02 15 Rev 4 24 00 00 Page 3 15 Mar 2018 Figure 2 Electrical Schematic Simplified Sheet 1 if MÄM 42 403 is carried out ...

Page 604: ... and fuses In the event of a main battery failure the alternators can be excited directly from the related ECU backup batteries which are located below the passengers seat Optionally the RH ECU backup batteries may be installed in the lower tail fin if OÄM 42 247 is installed 3 External Power Connector The external power connector is located below the forward baggage compartment The external power...

Page 605: ...AIRCRAFT DA 42 NG AMM Electrical Power Doc 7 02 15 Rev 4 24 00 00 Page 5 15 Mar 2018 Figure 3 Electrical Schematic Simplified Sheet 2 ...

Page 606: ...AIRCRAFT Electrical Power DA 42 NG AMM Page 6 15 Mar 2018 24 00 00 Doc 7 02 15 Rev 4 Figure 4 Electrical Schematic Simplified Sheet 2 if MÄM 42 551 is carried out ...

Page 607: ...age compartment The relay output connects directly to the RELAY BOX BUS bar If a 28 V external power is connected the 28 V DC on the control pin energizes the relay The relay operates and connects the external power to the RELAY BOX BUS bar 3 Starter Relay The starter relay contacts connect to the RELAY BOX BUS bar Power is applied to the coil of the starter relay when the ELECT MASTER switch is s...

Page 608: ...DA 42 NG AMM Page 8 15 Mar 2018 24 00 00 Doc 7 02 15 Rev 4 LH Alternator Relay RH Alternator Relay Battery Relay External Power Relay Starter Relay Overvoltage Suppressor Terminal Blocks Figure 5 Relay Locations in the Relay Box ...

Page 609: ...BUS supplies power for the PILOT MAP LIGHT and the Emergency Locator Transmitter ELT 7 LH Main Bus The LH MAIN BUS is connected to the RELAY BOX BUS through a 90 Ampere circuit breaker The LH MAIN BUS supplies power for the consumers and the LEFT ECU BUS Each consumer or bus is protected by circuit breakers or fuses The LH MAIN BUS is connected to the LH alternator output through a 60 Ampere circu...

Page 610: ...42 403 is carried out the RH ECU BUS is located on the right side and center for fuel pumps of the instrument panel at the bottom The RH ECU BUS has power when power is applied to the RH MAIN BUS or if the right engine alternator is online The RH ECU BUS provides power for the both ECU A and ECU B functions of the RH engine control unit and to the ECU A and ECU B fuel pumps If MÄM 42 403 is not ca...

Page 611: ...ing to maintain the selected position Setting the START switch to LH or RH with the ELECT MASTER switch set to ON and the related ENGINE MASTER switch set to ON will cause the related engine starter motor to operate 16 Engine Master LH RH The LH and RH ENGINE MASTER switches are located either side of the START switch Each switch is similar and has 4 sets of contacts which operate as follows The r...

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Page 613: ... RH ENGINE MASTER switches LH and RH ELECT MASTER switch Alternator current sensors LH and RH Alternator regulators including current sensors LH and RH if MÄM 42 551 is installed ECU backup batteries LH and RH This Section gives you only the simplified description Trouble Shooting and Maintenance Practices for the DC generating systems for the DA 42 NG Refer to Section 24 00 for a general descript...

Page 614: ...AIRCRAFT Electrical Power DA 42 NG AMM Page 2 15 Mar 2018 24 30 00 Doc 7 02 15 Rev 4 Figure 1 DC Generation Schematic Diagram if MÄM 42 403 is not carried out ...

Page 615: ...AIRCRAFT DA 42 NG AMM Electrical Power Doc 7 02 15 Rev 4 24 30 00 Page 3 15 Mar 2018 Figure 2 DC Generation Schematic Diagram if MÄM 42 403 is carried out ...

Page 616: ...AIRCRAFT Electrical Power DA 42 NG AMM Page 4 15 Mar 2018 24 30 00 Doc 7 02 15 Rev 4 Figure 3 DC Generation Schematic Diagram if MÄM 42 551 is carried out ...

Page 617: ...elay box The relay box is located in the front baggage compartment C Alternator Current Sensors A current sensor monitors the current flowing in the alternator outputs and indicates them on the Garmin G 1000 system This current sensor is located below the pilot s seat and monitors the current flow between the alternator and the related alternator relay D Alternator Regulators Each alternator has a...

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Page 619: ...ation system If you find the trouble in column 1 do the repair given in column 3 Trouble Possible Cause Repair LH or RH alternator warning light illuminated Related alternator defective Refer to the engine manufacturer LH RH alternator output paralleling insufficient Alternator regulators need adjustment if MÄM 42 551 is not installed Refer to the engine manufacturer ...

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Page 621: ...rical equipment Allow only qualified persons to maintain the electrical system CAUTION DISCONNECT THE BATTERIES MAIN AND ECU BACKUP BEFORE YOU DO ANY WORK ON THE ELECTRICAL SYSTEM MAKE SURE THAT YOU DISCONNECT THE NEGATIVE LEAD FIRST CAUTION AFTER DOING ELECTRICAL MAINTENANCE ALWAYS DO A CONFIDENCE TEST OF THE SYSTEM WITH A 24 VOLT POWER SUPPLY THAT HAS OVER CURRENT PROTECTION DO THIS BEFORE CONNE...

Page 622: ... 15 Rev 4 ECU Backup Battery Battery Serial Connection Cable Fuse 32A Foam Insert Battery Box Upper Washer Cable Tie Base Cable Tie Battery Box Lower Foam Insert Foam Insert Seal Foam Insert Foam Insert Foam Insert Foam Insert Screw Figure 4 ECU Backup Batteries Installation RH ...

Page 623: ... Mar 2018 ECU Backup Battery Battery Serial Connection Cable Fuse 32A Foam Insert Battery Box Upper Washer Cable Tie Base Cable Tie Battery Box Lower Foam Insert Foam Insert Seal Foam Insert Foam Insert Foam Insert Foam Insert Screw Figure 5 ECU Backup Batteries Installation LH ...

Page 624: ...trical Power DA 42 NG AMM Page 204 15 Mar 2018 24 30 00 Doc 7 02 15 Rev 4 RH Alternator Relay LH Alternator Relay Bolt Washer Washer Ring Terminal Overvoltage Suppressor Figure 6 LH RH Alternator Relay Installation ...

Page 625: ...ower Doc 7 02 15 Rev 4 24 30 00 Page 205 15 Mar 2018 ECU Backup Battery Battery Serial Connection Cable Fuse 32A Battery Container Cover Washer Screw Lower Tail Fin Figure 7 ECU Backup Battery Installation RH if OÄM 42 247 is installed ...

Page 626: ...age compartment door Refer to Section 52 40 2 Remove the baggage compartment rear cover 3 Disconnect the battery and ECU backup batteries for maintenance Refer to Section 24 31 4 Disconnect the LH RH alternator relay from the RELAY BOX BUS bar S Remove the bolts and washers that attach the relay to the RELAY BOX BUS bar 5 Disconnect the electrical cables from the external relay terminals 6 Remove ...

Page 627: ... Connect the LH RH alternator relay to the RELAY BOX BUS bar S Install the washers and bolts that attach the relay to the RELAY BOX BUS bar 4 Connect the main battery and ECU backup batteries Refer to Section 24 31 5 Install the baggage compartment rear cover 6 Close and secure the front baggage compartment door Refer to Section 52 40 7 Do a test for the correct operation of the LH RH alternator r...

Page 628: ... the positive cable from the batteries that you will remove S Disconnect the serial connection cable from the batteries that you will remove S Release the battery pack hold cover S Move the related batteries clear of the airplane Refer to Figure 4 and 5 Refer to Section 25 10 5 Remove the RH ECU backup batteries if OÄM 42 247 is installed S Remove the 14 screws and washers of the battery container...

Page 629: ...Install the passenger seats Refer to Section 25 10 4 Install the RH ECU backup batteries if OÄM 42 247 is installed S Move the ECU backup batteries slightly into the lower tail fin S Connect the serial connection cable to the batteries S Connect the positive cable to the positive terminal of the batteries S Connect the negative cable to the negative terminal of the batteries S Move the batteries i...

Page 630: ...T Electrical Power DA 42 NG AMM Detail Steps Work Items Key Items References Page 210 15 Mar 2018 24 30 00 Doc 7 02 15 Rev 4 8 Do an engine ground run up Make sure that the electrical system operates correctly ...

Page 631: ...two bolts hold the battery in position The positive and negative cables attach to terminals on the top of the battery at the front The usual rubber caps protect the electrical connections When either or both of the engine alternators are online and the system voltage is greater than the battery voltage the system charges the battery When either or both alternators are on line the integrated cockpi...

Page 632: ...2 NG AMM Page 2 15 Mar 2018 24 31 00 Doc 7 02 15 Rev 4 Battery Mount Battery Battery Retaining Bolt Washer Battery Positive Terminal Battery Negative Terminal Cockpit Forward Bulkhead To Relay Box Figure 1 Main Battery Installation ...

Page 633: ... RELAY BUS Battery relay defective ELECT MASTER switch defective Battery system wiring defective Replace the battery relay Replace the ELECT MASTER switch Do test of the battery system wiring Refer to Chapter 92 for the wiring diagrams Ammeter on ICS display shows zero at all times for LH or RH alternator Defective transducer Alternator regulator needs adjustment if MÄM 42 551 is not installed Rep...

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Page 635: ...ct the terminals and cable lugs with Dow Corning compound 4 DC4 If you do not use the airplane regularly you must remove the battery for charging CAUTION INSTALL ONLY A BATTERY WHICH IS APPROVED BY THE AIRPLANE MANUFACTURER 2 Safety Precautions Obey the instructions of the battery manufacturer Always disconnect the battery before you do work on the airplane electrical system You must disconnect th...

Page 636: ...ber boot from the cable end S Remove the bolt and washer that attaches the negative cable to the battery terminal S Move the negative cable clear of the battery terminal Refer to Figure 1 4 Disconnect the positive cable from the battery S Pull back the rubber boot from the cable end S Remove the bolt and washer that attaches the positive cable to the battery terminal S Move the positive cable clea...

Page 637: ...attery terminal S Install the washer and bolt that attaches the cable to the battery terminal S Move the rubber boot into position over the cable end 4 Connect the negative cable to the negative terminal of the battery S Move the cable end fitting into place over the negative battery terminal S Install the washer and bolt that attaches the cable to the battery terminal S Move the rubber boot into ...

Page 638: ...e compartment rear cover 3 Disconnect the negative cable from the battery S Pull back the rubber boot from the cable end S Remove the bolt and washer that attaches the negative cable to the battery terminal S Move the negative cable clear of the battery terminal Refer to Figure 1 4 Disconnect the positive cable from the battery S Pull back the rubber boot from the cable end S Remove the bolt and w...

Page 639: ...d fitting into place over the positive battery terminal S Install the washer and bolt that attaches the cable to the battery terminal S Move the rubber boot into position over the cable end Refer to Figure 1 2 Connect the negative cable to the negative terminal of the battery S Move the cable end fitting into place over the negative battery terminal S Install the washer and bolt that attaches the ...

Page 640: ...ectrical Power DA 42 NG AMM Page 206 15 Mar 2018 24 31 00 Doc 7 02 15 Rev 4 Overvoltage Suppressor To Battery To Battery Battery Relay Bolt Bolt Washer Washer Ring Terminal Figure 2 Main Battery Relay Installation ...

Page 641: ...tenance Refer to Paragraph 4 A 4 Disconnect the positive cable from the battery relay S Remove the bolt and washer from the terminal of the battery relay S Move the positive cable clear of the relay S Move the 2 smaller cables clear of the relay terminal 5 Disconnect the battery relay from the RELAY BOX BUS bar S Remove the bolt and washer that attaches relay to the RELAY BOX BUS bar Refer to Figu...

Page 642: ...asher and bolt that attaches the relay to the RELAY BOX BUS bar 4 Connect the battery positive cable and the 2 smaller cables to the battery relay coil terminal S Move the 2 smaller cables into position at the battery relay S Move the battery positive cables into position at the battery relay S Install the bolt and washer that attaches the cables to the relay through all 3 cables and into the rela...

Page 643: ...GINE MASTER to ON WARNING MAKE SURE THAT THE AREA OF THE PROPELLERS IS CLEAR BEFORE YOU OPERATE THE STARTER MOTOR PROPELLERS CAN CAUSE INJURY OR DEATH 3 Turn the key of the START switch to the engine for the ENGINE MASTER switch that you set to ON in step 2 The engine starter motor must operate You do not have to start the engine 4 Turn the key of the START switch to OFF 5 Set the ENGINE MASTER sw...

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Page 645: ...ttery pack A sealed HORIZON EMERGENCY switch The emergency battery pack consists of 10 lithium manganese batteries 3 V 1 300 mAh Refer to the Equipment List in Section 6 5 of the Airplane Flight Manual for the approved battery pack type The emergency battery pack is mounted behind the instrument panel on the pilot s side When all other sources of electrical power fail during flight the EMERGENCY H...

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Page 647: ...umn read across to the Possible Cause column Then do the repair given in the Repair column Trouble Possible Cause Repair Batteries leaking Batteries expired Replace battery pack Clean all items that are contaminated Voltage on the back side of the emergency switch less than 30 V Batteries expired Batteries have been used Emergency battery system wiring defective Replace battery pack Replace batter...

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Page 649: ...to Section 25 10 2 Disconnect the electrical plug of the battery pack Refer to Figure 1 3 Remove the GEA 71 of its mounting rack 4 Remove the two screws and nuts of the battery pack Hold the battery pack 5 Remove the battery pack clear of the airplane CAUTION THE BATTERY PACKS CANNOT BE RE CHARGED DO NOT TRY TO RECHARGE THE BATTERY PACKS IF YOU TRY TO RECHARGE THE BATTERY PACKS THEY CAN EXPLODE OR...

Page 650: ...A 42 NG AMM Page 202 15 Mar 2018 24 32 00 Doc 7 02 15 Rev 4 A A Artificial Horizon if OÄM 42 270 is NOT installed Horizon Emergency Switch Emergency Power Pack Dry Cells x10 Safety Cover Washer Nut Figure 1 Emergency Battery Pack ...

Page 651: ...ry pack On the connector for the electrical plug If the voltage is less than 30 V then the batteries are used Use a new battery pack 2 Put the battery pack in place in the instrument panel on the pilot s side 3 Install the two screws and nuts of the battery pack 4 Connect the electrical plug of the battery pack Ensure correct polarity 5 Install the GEA 71 6 Measure the voltage on the back side of ...

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Page 653: ...d on the LH engine The additional alternator generates electrical DC power for optional airplane equipment The additional alternator and its consumers form an additional electrical system which is not connected to the airplanes standard electrical system The additional alternator system has the following components Alternator Alternator fuse Voltage regulator Excitation battery AUX POWER switch ...

Page 654: ...AIRCRAFT Electrical Power DA 42 NG AMM Page 2 15 Mar 2018 24 33 00 Doc 7 02 15 Rev 4 Figure 1 Additional Alternator Electrical System Schematic Diagram ...

Page 655: ... alternator If the additional alternator fails it must be replaced B Additional Alternator Excitation Battery A separately installed small battery is used for the excitation of the additional alternator C Alternator Fuse A 100 A fuse is located in the engine compartment D Additional Alternator Regulator The alternator regulator is located in the engine compartment It measures the alternator output...

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Page 657: ...e detailed in the Trouble column read across to the Possible Cause column Then do the repair in the Repair column Trouble Possible Cause Repair Alternator provides no electrical power Alternator defective Voltage regulator defective Alternator fuse open Alternator control fuse open Alternator v belt loose broken Replace alternator Replace voltage regulator Replace fuse Replace fuse Adjust replace ...

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Page 659: ...n Always follow the usual safety practices for working on electrical equipment Allow only qualified persons to maintain the electrical system Maintenance carried out must be of good workmanship strictly considering the guidelines of AC 43 13 1B It is important that maintenance is carried out in accordance with the best available techniques and properly trained maintenance personnel in order to eli...

Page 660: ...ER switch 3 Remove the nut and washer of the AUX POWER switch Note the orientation of the switch 4 Move the AUX POWER switch clear of the console B Install the AUX POWER Switch Detail Steps Work Items Key Items References 1 Position the AUX POWER switch in place in the console Verify correct orientation of the switch 2 Insert the washer and the nut of the AUX POWER switch Tighten the nut 3 Install...

Page 661: ... ADDITIONAL ALTERNATOR REGULATOR IF THE ENGINE IS TURNED THE PROPELLER CAN CAUSE INJURY OR DEATH 1 Make sure that the engines are safe S Set the ELECT MASTER switch to OFF S Set the ENGINE MASTER switches to OFF S Set the power levers to 0 2 Remove the LH engine upper cowling Refer to Section 71 10 3 Disconnect the voltage regulator wiring harness Refer to Figure 4 4 Remove the two attachment bolt...

Page 662: ...are safe S Set the ELECT MASTER switch to OFF S Set the ENGINE MASTER switches to OFF S Set the power levers to 0 2 Position the alternator regulator on the regulator mounting bracket Refer to Figure 4 3 Install the two bolts with the two bushings which attach the alternator regulator on the regulator mounting bracket 4 Connect the electrical wiring harness to the alternator regulator Refer to Sec...

Page 663: ...t Socket The 28 V DC power socket is located on the lower surface of the fuselage nose section The socket has 3 pins A large negative pin A large positive pin A small positive pin A diode connected between the small positive pin and the external power relay solenoid protects the system from reverse polarity B External Power Relay The external power relay is located in the relay box mounted on the ...

Page 664: ...AIRCRAFT Electrical Power DA 42 NG AMM Page 2 15 Mar 2018 24 40 00 Doc 7 02 15 Rev 4 Figure 1 External Power Supply System Schematic ...

Page 665: ...large negative pin is connected to ground If the polarity of the power supply is incorrect then the diode will prevent current from flowing through the solenoid The solenoid will not operate and current cannot flow through the external power relay to the RELAY BOX BUS CAUTION WHEN OPERATING THE AIRPLANE ELECTRICAL SYSTEM WITH ENGINE MASTER ON LH OR RH AND THE ENGINE IS NOT RUNNING e g EVENT LOG RE...

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Page 667: ... the Trouble column read across to the Possible Cause column Then do the repair given in the Repair column Trouble Possible Cause Repair External power will not come on line No external power External power relay is defective Make sure that the external power plug is securely in the socket Make sure that the external power is operating correctly Do a test of the external power relay if necessary r...

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Page 669: ...qualified persons to maintain the electrical system CAUTION DISCONNECT THE BATTERIES MAIN AND ECU BACKUP BEFORE DOING MAINTENANCE ON THE ELECTRICAL SYSTEM MAKE SURE THAT YOU DISCONNECT THE NEGATIVE CABLE FIRST CAUTION AFTER DOING ELECTRICAL MAINTENANCE ALWAYS DO A CONFIDENCE TEST OF THE SYSTEM WITH A 24 VOLT POWER SUPPLY THAT HAS OVER CURRENT PROTECTION DO THIS BEFORE CONNECTING THE BATTERY CAUTIO...

Page 670: ...AIRCRAFT Electrical Power DA 42 NG AMM Page 202 15 Mar 2018 24 40 00 Doc 7 02 15 Rev 4 External Power Relay Washer Washer Bolt To External Power Socket Ring Terminal Figure 2 External Power Relay ...

Page 671: ...3 Disconnect the battery for maintenance Refer to Section 24 31 4 Disconnect the cable from the external power relay S Remove the bolt and washer from the terminal of the external power relay S Move the cable clear of the relay 5 Disconnect the external power relay from the RELAY BOX BUS bar S Remove the bolt and washer that attaches relay to the RELAY BOX BUS bar 6 Disconnect the electrical cable...

Page 672: ... RELAY BOX BUS bar S Install the washer and bolt that attaches the relay to the RELAY BOX BUS bar 4 Connect the cable to the external power relay terminal S Move the cables into position at the external power relay S Install the bolt and washer that attaches the cable to the relay through he cable and into the relay mounting Refer to the wiring diagrams in Chapter 92 5 Connect the main battery Ref...

Page 673: ...rical power to other systems The DC electrical load distribution system has these components RELAY BUS HOT BUS LH MAIN BUS RH MAIN BUS LH ECU BUS RH ECU BUS AVIONICS BUS Battery relay Starter relay Avionics master relay Switches Circuit breakers Fuses Figure 1 and 2 shows the electrical bus structure for the DA 42 NG Figure 3 shows the layout of the switches and circuit breakers in the instrument ...

Page 674: ...AIRCRAFT Electrical Power DA 42 NG AMM Page 2 15 Mar 2018 24 60 00 Doc 7 02 15 Rev 4 Figure 1 Electrical System Bus Structure Simplified Diagram if MÄM 42 403 is not carried out ...

Page 675: ...AIRCRAFT DA 42 NG AMM Electrical Power Doc 7 02 15 Rev 4 24 60 00 Page 3 15 Mar 2018 Figure 2 Electrical System Bus Structure Simplified Diagram if MÄM 42 403 is carried out ...

Page 676: ...HORIZON EMERGENCY SWITCHES O LH ENG ECU BUS RH ENG ECU BUS LH RH COM1 LH MAIN BUS NO SMOKING RH MAIN BUS AVIONICS BUS PITOT XFER PUMP DE ICE TAXI MAP ACL FLOOD OXY PFD ADC AHRS GEAR WRN ELEV LIMIT GEAR XPDR ENG INST GPS NAV1 D E IC E 5 10 5 5 5 30 20 20 20 20 60 60 30 90 90 5 5 5 3 5 5 10 5 7 3 5 5 5 5 25 3 2 5 10 5 5 5 5 2 3 3 FUEL PUMPS LH ENGINE FUEL PUMP A FUEL PUMP B FUEL PUMPS LH ENGINE FUEL...

Page 677: ...and that the alternators are supplying power If you find the trouble in column 1 do the repair given in column 3 Trouble Possible Cause Repair There is 28 V DC on the RH MAIN BUS but not on the AVIONICS BUS AV MASTER switch set to OFF MASTER CONTROL circuit breaker not set AVIONICS BUS circuit breaker not set Avionics master relay defective A failure of the cables which connect the AVIONICS BUS to...

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Page 679: ...ent Allow only qualified persons to maintain the electrical system CAUTION DISCONNECT THE BATTERIES MAIN AND ECU BACKUP BEFORE YOU DO ANY WORK ON THE ELECTRICAL SYSTEM MAKE SURE THAT YOU DISCONNECT THE NEGATIVE LEAD FIRST CAUTION AFTER DOING ELECTRICAL MAINTENANCE ALWAYS DO A CONFIDENCE TEST OF THE SYSTEM WITH A 24 VOLT POWER SUPPLY THAT HAS OVER CURRENT PROTECTION DO THIS BEFORE CONNECTING THE BA...

Page 680: ...AIRCRAFT Electrical Power DA 42 NG AMM Page 202 15 Mar 2018 24 60 00 Doc 7 02 15 Rev 4 Nut Washer Avionics Master Relay Instrument Panel Shelf Bolt Figure 3 Avionics Master Relay Installation ...

Page 681: ... attaches the relay to the instrument panel floor 8 Move the relay clear of the airplane B Install the Avionics Master Relay Detail Steps Work Items Key Items References 1 Move the new relay into position on the instrument panel shelf 2 Connect the electrical cables to the relay Refer to the wiring diagrams and Paragraph 3 A 6 above 3 Install the bolt washer and nut that attaches the relay to the ...

Page 682: ...battery and the ECU backup batteries for maintenance Refer to Section 24 31 3 Remove the instrument panel cover Refer to Section 25 10 4 Remove the nuts and washers that attach the circuit breakers to the instrument panel Do this for all the circuit breakers that are attached to the same bus bar 5 Remove the screw that connects the circuit breaker that you will replace to the bus bar 6 Disconnect ...

Page 683: ...d nuts that attach the circuit breakers to the instrument panel 6 Install the instrument panel cover Refer to Section 25 10 7 Reconnect the main battery and the ECU backup batteries Refer to Section 24 31 Connect the positive cable first 8 Close and secure the baggage compartment door Refer to Section 52 40 9 Do a test for the correct function of the circuit breaker S Set the ELECT MASTER to ON S ...

Page 684: ...er switches A Remove a Clip Secured Type Instrument Panel Switch Detail Steps Work Items Key Items References 1 Open the front baggage compartment door Refer to Section 52 40 2 Disconnect the main battery and the ECU backup batteries for maintenance Refer to Section 24 31 3 Remove the instrument panel cover Refer to Section 25 10 4 Disconnect the electrical cables for the switch that you will remo...

Page 685: ...tly located 2 Connect the electrical cables to the switch Refer to Chapter 92 for the wiring diagrams 3 Install the instrument panel cover Refer to Section 25 10 4 Reconnect the main battery and the ECU backup batteries Refer to Section 24 31 Connect the positive cable first 5 Close and secure the baggage compartment door Refer to Section 52 40 6 Do a test for the correct function of the switch S ...

Page 686: ...rk Items Key Items References 1 Open the front baggage compartment door Refer to Section 52 40 2 Disconnect the main battery and ECU backup batteries for maintenance Refer to Section 24 31 3 Remove the instrument panel cover Refer to Section 25 10 4 Remove the nut and washer that attaches the switch to the instrument panel 5 Move the switch forward and clear of the instrument panel to give access ...

Page 687: ...ld the switch in position 4 Install the washer and nut that attach the switch to the instrument panel 5 Install the instrument panel cover Refer to Section 25 10 6 Reconnect the main battery and ECU backup batteries Refer to Section 24 31 Connect the positive cable first 7 Close and secure the baggage compartment door Refer to Section 52 40 8 Do a test for the correct function of the switch S Set ...

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Page 689: ...AIRCRAFT DA 42 NG AMM Equipment Furnishings Doc 7 02 15 Rev 4 25 TITLE Page 1 15 Mar 2018 CHAPTER 25 EQUIPMENT FURNISHINGS ...

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Page 691: ...4 4 Remove Install a Pilot s Seat Access Panel 209 5 Disassemble Assemble the Adjustable Backrest Mechanism 213 6 Remove Install the Passenger Seat 220 7 Remove Install a Safety Harness if OÄM 42 324 is NOT installed 222 8 Remove Install the Instrument Panel Cover 224 9 Cleaning 225 10 Remove Install the Short Baggage Extension OÄM 42 207 installed 225 Section 25 50 Aft Baggage Compartment 1 Gener...

Page 692: ...ription of the Kannad 406 AF Compact ELT 4 Trouble Shooting 1 General 101 Maintenance Practices 1 General 201 2 Remove Install the ELT 201 3 Replace the ELT Battery Pack 205 4 Remove Install the Artex ME 406 or Kannad 406 AF Compact ELT 207 5 Replace the ELT Battery Pack of the Artex ME406 212 6 Remove Install the ELT RCPI 214 7 ELT Functional Test 216 8 Kannad 406 AF Compact ELT Functional Test 2...

Page 693: ...25 60 tells you about the emergency location transmitter ELT and the first aid kit Refer to Chapter 26 for data about the hand fire extinguisher Note Equipment which is certified for installation in the DA 42 NG is listed in Section 6 5 of the Airplane Flight manual Such equipment may be installed in accordance with the Airplane Maintenance Manual Note Any equipment which is not listed in Section ...

Page 694: ...ishings DA 42 NG AMM Page 2 15 Mar 2018 25 00 00 Doc 7 02 15 Rev 4 Co Pilot s Seat Pilot s Seat Passengers Seats Safety Belt Carpets Fire Extinguisher First Aid Kit ELT Baggage Compartment Map Storage Figure 1 Cabin Equipment ...

Page 695: ... 067 or OÄM 42 259 is carried out the pilots seats are equipped with adjustable backrests Each seat has a safety harness The fuselage shell is trimmed with fabric wall panels Carpets cover the floor areas and the aft baggage compartment floor Map pockets are located on the cockpit side by each pilot GFRP moldings make the instrument panel cover and the center console Refer to Section 25 60 for dat...

Page 696: ...2 15 Mar 2018 25 10 00 Doc 7 02 15 Rev 4 Bolt Washer Front Main Bulkhead Gaiter for Control Stick Press Studs for Seat Cushion Bolt Washer Rear Face of Floor Panel Inner Crash Element Outer Crash Element Anchor Plate Figure 1 Pilot s Seat Installation ...

Page 697: ...018 Flexible Gaiter Padded Cushion Seat Pan Backrest Lumbar Support Cushion Outboard Hinge Inboard Hinge Lamella Package Friction Adjustment Screw Seat Lever Lumbar Support Lever Lumbar Support Bowden Cable Cover 2 per seat Figure 2 Pilot s Seat Installation if OÄM 42 067 is carried out ...

Page 698: ... 15 Rev 4 Release Button Flexible Gaiter Padded Cushion Lumbar Support Cushion Backrest Seat Pan Lumbar Support Inboard Hinge Lumbar Support Lever Outboard Hinge Bowden Cable Hydraulic Cylinder LH Hydraulic Cylinder RH Figure 3 Pilot s Seat Installation if OÄM 42 259 is carried out ...

Page 699: ...EN THE LEVER FOR THE ADJUSTABLE BACKREST OF THE FRONT SEATS UNINTENTIONALLY THE SPRING LOADED BACKREST MAY SNAP FORWARD AND CAN CAUSE INJURY Figure 2 and Figure 3 show the variants of pilots seats with adjustable backrest installations Each pilots seat consists of a seat pan and a backrest made of GFRP Carbon Kevlar Rivets attach a metal plate to the bottom of the seat pan at the back Two bolts go...

Page 700: ...rtment floor The passenger seat also has two seat backs which attach to the seat pan with hinges A latch at the left side of each seat back locks the seat in the upright position You can lift the latch pin to fold the seat back forward for access to the aft baggage compartment A padded seat cushion covers the seat molding Velcro tapes attach the forward part of the seat cushion to the seat pan Pad...

Page 701: ... NG AMM Equipment Furnishings Doc 7 02 15 Rev 4 25 10 00 Page 7 15 Mar 2018 Crash Element Washer Bolt Rear Main Bulkhead Bolt Bolt Anchor Plate Plate Reinforcing Plate Reinforcing Figure 4 Passenger Seat Installation ...

Page 702: ...NT SAFETY BELT ATTACHMENT FOR INERTIA REEL FRONT SAFETY BELT ATTACHMENT FOR LAP BELT REAR SAFETY BELT ATTACHMENT FOR SHOULDER STRAP Bolt Washer Cover Inertia Reel Fuselage Structure LH Shown RH Opposite Rear Seat Pan Washer Washer Washer Washer Bolt Bolt Nut Nut Metal Plate Bolt Bolt Washer Washer Front Main Frame Front Main Bulkhead Front Seat Pan Bolt Washer Washer Nut Metal Plate Anchor Plate F...

Page 703: ...airplane is accelerated for example in turbulence the latch stops the shoulder strap from pulling out The inertia reel for the pilot s safety harness is located on the fuselage wall behind the pilot s seat The strap passes up through a guide attached to the roll bar just above the pilot s shoulder and down to the tongue on the outboard lap strap The end fitting on the shoulder strap hooks onto a s...

Page 704: ...sole Panel A GFRP panel goes between the rear wall of the floor panel and the front face of the main front bulkhead The center console panel covers the trim mechanism It also seals the gap between the pilot s seats H Baggage Compartment If OÄM 42 207 is carried out a short baggage extension is installed ...

Page 705: ...LECTRICALLY CONNECTED AMSAFE SEATBELT AIRBAG RESTRAINT SYSTEM AND BUCKLED SEAT BELT MAY RESULT IN DAMAGE TO THE EQUIPMENT OR DEPLOYMENT OF THE SYSTEM REFER TO AMSAFE MAINTENANCE DOCUMENTATION Note Some maintenance procedures described in this AMM require the removal of a front seat However if the maintenance hole in the seat gives sufficient access to the system beneath it it is acceptable to leav...

Page 706: ... stick Refer to Figure 1 fixed backrest or Figure 2 and 3 adjustable backrest 3 Release the press studs at the front of the seat cushion Move the cushion to give access to the attaching bolts for the seat 4 Remove the 2 bolts with washer plates which attach the anchor plates to the front main bulkhead From the passenger compartment behind the pilot s seat 5 Remove the 4 bolts with washer plates wh...

Page 707: ...hat the anchor plates go through the large holes in the front main bulkhead Make sure that the stick gaiter locates correctly over the control stick 4 Install the bolts and washer plates which attach the seat to the floor panel Torque 6 4 Nm 4 7 lbf ft 5 Install the bolts and washer plates which attach the anchor plates to the front main bulkhead From the passenger compartment behind the pilot s s...

Page 708: ...ST OF THE FRONT SEATS UNINTENTIONALLY THE SPRING LOADED BACKREST MAY SNAP FORWARD AND CAN CAUSE INJURY Note If the adjustable backrest mechanism does not pass the following test perform a visual inspection Refer to Paragraph 3 1 Sit down in the front seat 2 Lean against the backrest To counteract the spring loaded backrest mechanism 3 Carefully lift the seat lever or press button 4 Move the backre...

Page 709: ...lacard on the roll over bar 6 Pull forward on the backrest to move it forward beyond the designated upright position S Check for limited range of movement and interference S Let the seat lever move to the locking position or release the button at different backrest angles and check for improper fixation Press down the seat lever to ensure proper locking Apply a test load of 90 daN 200 lbf to the t...

Page 710: ... LEVER OR THE BUTTON FOR THE ADJUSTABLE BACKREST OF THE FRONT SEATS UNINTENTIONALLY THE SPRING LOADED BACKREST MAY SNAP FORWARD AND CAN CAUSE INJURY 1 Remove the seat 2 Pull away the lining from the inboard hinge to gain access to the inboard friction adjustment screw Through the access hole in the cover 3 Adjust the friction S Set the locking lever to the unlocked position S Loosen the friction a...

Page 711: ...ew S Remove the lever from the seat 3 Carefully separate the leather lining from the backrest S Remove the cushion from the seat pan attached with velcro S Drill out one blind rivet each attaching the two plastic brackets for the rubber bands to the seat pan S Pull off the rubber bands from the plastic brackets S Untie the knots of the 3 strings which tie the lower edge of the backrest cushion to ...

Page 712: ...e leather lining to the cover using the velcro fasteners S Tie the backrest cushion to the seat pan with the 3 strings S Put the rubber bands into the plastic brackets S Use blind rivets to fasten the plastic brackets to the seat pan S Attach the cushion to the seat pan using the velcro 8 Install the seat lever S Put the lever onto the adjustment mechanism in correct position S Install the lever m...

Page 713: ...anism refer to Maintenance Practices Paragraph 5 Use mirror and flashlight to be able to inspect the mechanism installed in the backrest tunnel 4 Re install the leather lining to the seat 4 Remove Install a Pilot s Seat Access Panel A Remove a Pilot s Seat Access Panel Detail Steps Work Items Key Items References 1 Remove the cloth coating from the seat 2 Remove the 10 bolts which attach the acces...

Page 714: ...al Needle Roller Bearing Hexagon Screw with Stop for Lever Disc Backrest Strong Outer Disc Backrest Strong Inner Clamping Nut Discs Backrest x20 Discs Seat x20 Tension Spring Driver Sheet Fitting Backrest Fitting Seat 1 6mm 1 6mm 0 3mm 0 3mm 0 3mm 0 3mm 0 3mm 0 3mm 0 5mm 0 5mm 0 5mm 0 5mm 0 5mm 0 5mm Figure 6 Adjustable Backrest Assembly if OÄM 42 067 is installed ...

Page 715: ... 10 00 Page 211 15 Mar 2018 Seat Pan Backrest Bracket Seat Side Backrest Bracket Hydraulic Cylinder Release Button PAF Bush Bush Bush PAF Bush Hydrolok Fixing Bracket Side Bracket Seat Side 35 mm 1 38 in Figure 7 Seat Adjustment Mechanism if OÄM 42 259 is installed ...

Page 716: ...18 25 10 00 Doc 7 02 15 Rev 4 Seat Pan Backrest Backrest Bracket Hydraulic Cylinder Hydrolok Fixing Bracket Side Bracket Seat Side Washer x 1 Bolt x 3 Washer x 2 Bolt x 2 Washer x 5 Bolt x 5 Bolt x 1 Figure 8 Adjustable Backrest Assembly if OÄM 42 259 is installed ...

Page 717: ...fully separate the leather lining from the backrest S Remove the cushion from the seat pan attached with velcro S Drill out one blind rivet each attaching the two plastic brackets for the rubber bands to the seat pan S Pull off the rubber bands from the plastic brackets S Untie the knots of the 3 strings which tie the lower edge of the backrest cushion to the seat pan S Carefully remove the leathe...

Page 718: ...agon Screw with Stop for Lever 6 Remove the screw with the distancing bushing and the washer from the torsion bar 7 Remove the nine hexagon screws on both sides of each seat fitting 8 Remove the LH and the RH mechanism 9 Remove the torsion bar from the backrest Figure 9 Arrangement of the Fitting Seat Fitting Backrest and Screws LH side shown if OÄM 42 067 is installed ...

Page 719: ...ne 2 Carefully separate the leather lining from the backrest Turn lining inside out together with the bag while pulling off 3 Disconnect the lumbar actuator bowden cable 4 Remove the 5 outboard and 1 inboard hexagon screws from the backrest brackets as they become accessible on both sides Refer to Figure 8 5 Pull off the backrest shell C Disassemble the Adjustable Backrest Mechanism optional OÄM 4...

Page 720: ...3 Stick the bolt 10 mm through the outer backrest disc 4 Lamella 0 3 mm 4 Washers 0 5 mm 5 4 Washers 0 3 mm Lamella 0 3 mm Repeat steps 5 and 6 four times 6 Lamella 0 3 mm 4 Washers 0 3 mm 7 4 Washers 0 5 mm Lamella 0 3 mm 8 Lamella 0 3 mm 4 Washers 0 5 mm 9 4 Washers 0 3 mm Lamella 0 3 mm Repeat steps 9 and 10 four times 10 Lamella 0 3 mm 4 Washers 0 3 mm 11 4 Washers 2 x 0 3 mm Lamella 0 3 mm 12...

Page 721: ...that 2 stamped points can be seen place a bearing on coil 2 place another coil 1 on the bearing so that 1 stamped point can be seen 28 RH side place coil 1 so that 2 stamped point can be seen place one bearing on the coil 1 place coil 2 onto the bearing so that 1 stamped point can be seen place a bearing on coil 2 place another coil 1 on the bearing so that 2 stamped point can be seen 29 Screw the...

Page 722: ...nces 1 Screw the Hydrolok hydraulic cylinder into the actuating shaft so that the cylinder rod end and the center of the actuating shaft are 35 mm apart Refer to Figure 7 2 Attach the lower end of the hydraulic cylinder to the side bracket seat shell 3 Attach the side bracket seat shell to the seat bracket seat side using 2 hexagon screws 4 Attach the backrest bracket to the actuating shaft using ...

Page 723: ... the torsion bar through the driver blades of the mechanism 5 Fix the outboard mechanism with the 17 hexagon screws 6 Screw the torsion bar screw with the washer and the distance bushing into the inside thread 7 Install cover by moving it over the hinge 8 Reinstall the leather lining to the seat S Attach the leather lining to the cover using the velcro fasteners S Tie the backrest cushion to the s...

Page 724: ...LED SEAT BELT MAY RESULT IN DAMAGE TO THE EQUIPMENT OR DEPLOYMENT OF THE SYSTEM REFER TO AMSAFE MAINTENANCE DOCUMENTATION A Remove the Passenger Seat Detail Steps Work Items Key Items References 1 Release the velcro tapes at the front of the seat cushion Refer to Figure 4 Move the cushion to give access to the attaching bolts for the seat 2 Remove the 6 bolts and washer plates which attach the sea...

Page 725: ...with the seat backs folded forward Lift the latch pins at the left side of each seat back 4 Attach the inertia reels to the through roll over bar 5 Install the 5 bolts and washer plates which attach the rear of the seat pan to the aft baggage compartment frame Torque 6 4 Nm 4 7 lbf ft 6 Install the 6 bolts and washer plates which attach the seat pan to the anchor plates Torque 6 4 Nm 4 7 lbf ft 7 ...

Page 726: ...M AND BUCKLED SEAT BELT MAY RESULT IN DAMAGE TO THE EQUIPMENT OR DEPLOYMENT OF THE SYSTEM REFER TO AMSAFE MAINTENANCE DOCUMENTATION A Remove a Safety Harness Detail Steps Work Items Key Items References 1 Remove the seat Refer to Paragraph 2 or 3 2 Remove the anchor nuts washers and plates which attach the straps to the seat Refer to Figure 5 For the pilots seats only S Make a note of the position...

Page 727: ... the lap straps between the seat pan and the metal plate Install the bolts and washer plates from the top of the seat pan 3 Move the anchor plates into position on the bolts For the pilots seats only 4 Install the seat Refer to Paragraph 2 or 3 5 Install the bolt and washer which attach the guide to the roll bar For the pilots seats only 6 Install the bolt and washer which attach the inertia reel ...

Page 728: ...er clear of the instrument panel and the airplane B Install the Instrument Panel Cover Detail Steps Work Items Key Items References 1 Make sure that the area below the instrument panel cover is free of unwanted objects For example tools 2 Move the instrument panel cover into position near the instrument panel 3 Connect the flexible hoses to the defrost manifold S Move the tie wraps into position o...

Page 729: ...e Short Baggage Extension OÄM 42 207 installed A Remove the Short Baggage Extension Detail Steps Work Items Key Items References 1 Remove access panel Refer to Paragraph 4 2 Release 4 screws with washers which attach the front of the baggage tray to the rear seats 3 Release the 2 screws with washers which attach the rear of the tray to the baggage bulkhead 4 Remove the upholstery pieces which cove...

Page 730: ...the short baggage extension to the baggage bulkhead 4 Install the upholstery pieces which cover the sides of the baggage bulkhead Attached with velcro 5 Put the baggage tray in place on the baggage floor 6 Fasten the 4 screws with washers that attach the front of the baggage tray to the rear seat base Torque 3 6 Nm 2 7 lbf ft 7 Fasten the 2 screws with washers that attach the rear of the baggage t...

Page 731: ...15 Rev 4 25 50 00 Page 1 15 Mar 2018 Section 25 50 Aft Baggage Compartment 1 General This Section tells you about the aft baggage compartment the baggage tie downs and baggage net For data about the forward baggage compartment doors refer to Section 52 00 ...

Page 732: ... Furnishings DA 42 NG AMM Page 2 15 Mar 2018 25 50 00 Doc 7 02 15 Rev 4 Baggage Compartment Frame A Access Panel Rear Door Hinged Floor Panel Quick Release Fastener C A A A A Screw Washer Figure 1 Aft Baggage Compartment ...

Page 733: ...The door is hinged along the lower edge The forward section of the baggage compartment has an access panel in the floor section of the compartment Quick release fasteners attach the access panel to the baggage compartment floor You can remove this access panel to gain access to the aft fuselage Carpet covers the floor of the baggage compartment A cargo net covers the front of the aft baggage compa...

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Page 735: ... Access Panel Detail Steps Work Items Key Items References 1 Fold the passenger seat backs forward into the down position Refer to Section 25 10 2 If necessary remove the cargo net and move any equipment stowed in the baggage compartment clear of the airplane 3 Fold the carpet on the floor of the baggage compartment forward to gain access to the panel 4 Remove the access panel S Remove the 4 quick...

Page 736: ...ess panel S Move the access panel into position at the baggage compartment floor S Install the 4 quick release fasteners and washers that attach the access panel to the baggage compartment 3 Move the floor carpet back into position on the baggage compartment floor 4 If necessary install any equipment that you removed from the baggage compartment and install the cargo net 5 Move the passenger seat ...

Page 737: ...e any equipment stowed in the baggage compartment clear of the airplane 3 Fold the carpet on the floor of the baggage compartment forward and clear of the baggage compartment 4 Open the 4 quick release fasteners of the access panel to remove the access panel with the hinged floor panel Refer to Figure 1 5 Remove the aft baggage compartment S Remove the 4 quick release fasteners that attach the bag...

Page 738: ...rtment is fully into position and install the 4 quick release fasteners that attach the baggage compartment to the fuselage baggage frame Make sure that the aft end of the baggage compartment locates correctly in fuselage ring frame 1 3 Install the hinged floor panel S Move the hinged floor panel into position at the front of the baggage compartment S Align the 4 quick release fasteners from the f...

Page 739: ...he emergency frequencies of 121 5 and 243 0 Megahertz MHz Every 50 seconds the transmitter also transmits a signal on the 406 025 MHz frequency to a satellite The signal to the satellite contains the serial number of the ELT transmitter or the airplane ID a country code and a unique identity code The satellite will also give the emergency services a more accurate location for the airplane The ELT ...

Page 740: ...ment Furnishings DA 42 NG AMM Page 2 15 Mar 2018 25 60 00 Doc 7 02 15 Rev 4 Antenna ELT Antenna Connector Mounting Tray In Line Connector for RCPI A B A B ELT Control Panel Warning Buzzer Figure 1 ELT Main Components ...

Page 741: ...f the ELT transmitter or the airplane ID a country code and a unique identity code The satellite will also give the emergency services a more accurate location for the airplane The ELT has its own battery pack to supply electrical power When the ELT is ON and transmitting the batteries will keep the ELT transmitting until battery power is gone on the 121 5 MHz frequency and for up to 24 hours on t...

Page 742: ...ber of the ELT transmitter or the airplane ID a country code and a unique identity code The satellite will also give the emergency services a more accurate location for the airplane The ELT has its own battery pack to supply electrical power When the ELT is ON and transmitting the batteries will keep the ELT transmitting until battery power is gone on the 121 5 MHz frequency and for up to 48 hours...

Page 743: ...n read across to the Possible Cause column Then do the repair given in the Repair column Trouble Possible Cause Repair ELT does not operate on test ELT batteries discharged ELT defective RCPI cables defective Replace the ELT batteries If the ELT batteries are serviceable then replace the ELT Do a continuity test of the cables between the RCPI and the ELT Replace defective cables If the cables are ...

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Page 745: ...he aft baggage compartment Refer to Section 25 50 2 Remove the ELT protective cover S Loosen the 2 thumbscrews on the ELT end cap S Move the end cap forward and clear of the ELT S Lift the top protective cover at the aft end and pull the cover aft and up from the ELT S Move the top protective cover clear of the ELT 3 Disconnect these cables at the front of the ELT S The coaxial cable S The electri...

Page 746: ...gs DA 42 NG AMM Page 202 15 Mar 2018 25 60 00 Doc 7 02 15 Rev 4 A ELT Assembly Mounting Plate Mounting Tray Top Protective Cover Thumbscrews Electrical Cables End Cap In Line Connector Figure 2 ELT Installation Standard Equipment ...

Page 747: ...the ELT fully into the mounting tray S Install the top protective cover onto the mounting tray Make sure that the slots on the top cover engage over the ears on the ELT 3 Connect the electrical cables At the in line connector Make sure that the cables pass through the end cap before you connect them 4 Connect the coaxial cable At the bayonet connector Make sure that the cable passes through the en...

Page 748: ...shings DA 42 NG AMM Page 204 15 Mar 2018 25 60 00 Doc 7 02 15 Rev 4 A Battery Pack ELT Assembly Screw with O Ring Screw with O Ring Screw with O Ring 8 Pin Connector 2 Pin Connector Seal Figure 3 ELT Battery Pack Installation ...

Page 749: ... Key Items References 1 Remove the ELT from the airplane ELT mounting Refer to Paragraph 2A 2 Remove the battery pack S Remove the 4 screws that attach the battery pack to the ELT S Lay the ELT with battery pack on it s side on a suitable work surface S Carefully move the battery pack a short distance clear of the ELT S Disconnect the wiring harness S Disconnect the 2 smaller cables S Move the bat...

Page 750: ...pack cables to the recessed connector on the ELT S Move the battery pack into position on the ELT S Install the 4 screws that attach the battery pack to the ELT Connecting the 2 pin connector will activate the ELT Reset the ELT by setting the ELT ON OFF switch to ON then to OFF Make sure that none of the electrical cables are trapped between the mating surfaces of the ELT and the battery pack 6 In...

Page 751: ...Remove the access panel in the floor of the aft baggage compartment Refer to Section 25 50 2 Disconnect these cables at the front of the ELT S The coaxial cable S The electrical cables At the bayonet connector At the in line connector 3 Open the velcro strap 4 Remove the ELT from the ELT mounting tray S Lift the ELT from the mounting tray at the forward end S Move the ELT forward and upward clear ...

Page 752: ...AIRCRAFT Equipment Furnishings DA 42 NG AMM Page 208 15 Mar 2018 25 60 00 Doc 7 02 15 Rev 4 ELT Assembly Electric Cables Co Axial Cable Velcro Strap Mounting Tray Figure 4 Artex ME406 ELT Installation ...

Page 753: ...RAFT DA 42 NG AMM Equipment Furnishings Doc 7 02 15 Rev 4 25 60 00 Page 209 15 Mar 2018 Co Axial Cable Mounting Tray ELT Assembly Electric Cables Velcro Strap Figure 5 Kannad 406 AF Compact ELT Installation ...

Page 754: ...switch at the front of the ELT is set to OFF S Lower the aft end of the ELT into the mounting tray so that the locking ears at the aft end of the ELT engage with the slots in the mounting tray S Lower the ELT fully into the mounting tray 3 Fasten the velcro strap around the ELT so that it is firmly held in place 4 Connect the electrical cables At the in line connector 5 Connect the coaxial cable A...

Page 755: ... Equipment Furnishings Doc 7 02 15 Rev 4 25 60 00 Page 211 15 Mar 2018 ELT Unit Coax Wire Battery Pack Seal Mounting Tray Screw Washer Warning Buzzer Washer Nut Mounting Strap Figure 6 Battery Pack Installation Artex ME406 ...

Page 756: ... from the battery side cover S Carefully move the battery pack a short distance clear of the ELT S Disconnect the wiring harness S Move the battery pack clear of the ELT Refer to Figure 6 Hold the battery pack to the ELT with your hand to prevent the battery pack separating from the ELT 3 Do a visual inspection of the underside of the ELT the battery pack side Look specially for corrosion or other...

Page 757: ...stall the ELT in the airplane mounting and attach the battery pack replacement date label to the top surface of the ELT protective cover where it can be easily seen Refer to Paragraph 2 11 Record the details of the ELT battery pack replacement date in the airplane log book 12 Do a functional test of the ELT Refer to Section 25 60 Paragraph 7 ...

Page 758: ...nt panel S Move the RCPI towards the rear of the airplane and clear of the instrument panel S Move the RCPI clear of the airplane Hold the RCPI B Install the ELT Remote Control Panel Indicator RCPI Detail Steps Work Items Key Items References 1 Move the RCPI into position at the instrument panel 2 Install the RCPI S Move the RCPI into position in the instrument pane S Install the 4 screws washers ...

Page 759: ...nt Furnishings Doc 7 02 15 Rev 4 25 60 00 Page 215 15 Mar 2018 ELT Control Panel Screw Washer Nut EMERGENCY USE ONLY ARM TEST RESET PRESS ON WAIT 1 SECOND PRESS ARM ON ARTEX ELT RC 200 ON ELT ARTEX KANNAD Figure 7 RCPI Installation ...

Page 760: ...G DO NOT OPERATE THE ELT FOR MORE THAN 5 SECONDS IF YOU OPERATE THE ELT FOR MORE THAN 5 SECONDS THE ELT WILL TRANSMIT AN EMERGENCY SIGNAL TO THE SATELLITE MONITORING SYSTEM THE SATELLITE MONITORING SYSTEM WILL REACT TO THE ELT SIGNAL AS IT WOULD TO A VALID EMERGENCY SITUATION 4 Set the ELT RCPI to ON for about 3 sweeps of the receiver approximately 1 second The test MUST NOT last longer than 3 aud...

Page 761: ...h to ON 2 Set the AV MASTER switch to ON 3 Set the communications radio to receive 121 50 MHz WARNING DO NOT OPERATE THE ELT FOR MORE THAN 5 SECONDS IF YOU OPERATE THE ELT FOR MORE THAN 5 SECONDS THE ELT WILL TRANSMIT AN EMERGENCY SIGNAL TO THE SATELLITE MONITORING SYSTEM THE SATELLITE MONITORING SYSTEM WILL REACT TO THE ELT SIGNAL AS IT WOULD TO A VALID EMERGENCY SITUATION 4 Switch the RCPI to ON...

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Page 763: ...AIRCRAFT DA 42 NG AMM Fire Protection Doc 7 02 15 Rev 4 26 TITLE Page 1 15 Mar 2018 CHAPTER 26 FIRE PROTECTION ...

Page 764: ...AIRCRAFT Fire Protection DA 42 NG AMM Page 2 15 Mar 2018 26 TITLE Doc 7 02 15 Rev 4 Intentionally left blank ...

Page 765: ... 02 15 Rev 4 26 CONTENTS Page 1 15 Mar 2018 TABLE OF CONTENTS CHAPTER 26 FIRE PROTECTION 1 General 1 Trouble Shooting 1 General 101 Maintenance Practices 1 General 201 2 Remove Install an Engine Overheat Detector 201 3 Overheat Detector Test 202 ...

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Page 767: ... extinguisher and see the overheat detector manufacturer s manual for more data about the overheat detector Note Equipment which is certified for installation in the DA 42 NG is listed in Section 6 5 of the Airplane Flight Manual Such equipment may be installed in accordance with the Airplane Maintenance Manual Note Any equipment which is not listed in Section 6 5 of the Airplane Flight Manual is ...

Page 768: ...tion DA 42 NG AMM Page 2 15 Mar 2018 26 00 00 Doc 7 02 15 Rev 4 Extinguisher Mount Container Carry Handle Safety Guard Release Lever Pressure Gauge Seal Wire Nozzle Washer Nut Screw Figure 1 Fire Extinguisher Installation ...

Page 769: ...residue The only on airplane maintenance is Monitor the pressure indicator It must show in the green sector Make sure that the seal wire is not broken Make sure that the extinguisher is correctly held in the mounting If the seal wire is broken remove the extinguisher for weighing Weight data is given on the label attached to the extinguisher body You must replace the extinguisher or return it to t...

Page 770: ...ion DA 42 NG AMM Page 4 15 Mar 2018 26 00 00 Doc 7 02 15 Rev 4 Thermal Switch Nut Safety Wire Fire Sensor Mounting Bracket Safety Wire Bolt Washer Screw Nuts Ground Wire Washer Figure 2 Engine Overheat Detector Installation ...

Page 771: ...fire detector If the fire detector reaches a temperature of 260 C 500 F the switch closes and a LH RH ENG FIRE warning is displayed on the integrated cockpit system ICS display screen You cannot cancel the LH RH ENG FIRE warning Operating the TEST button for the landing gear will by pass the bi metal switch and will cause the LH RH ENG FIRE warning of ICS to operate This test system will test the ...

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Page 773: ...ir The LH RH ENG FIRE warning fails to display when the landing gear TEST button is operated Wiring defective ICS display defective Do a continuity test of the wiring Repair replace defective wiring Refer to Chapter 92 for the wiring diagrams Refer to Section 31 40 for more data about the ICS An LH RH ENG FIRE warning shows when power is applied to the ICS Defective overheat detector Wiring defect...

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Page 775: ... CAUSE DEATH OR INJURY TO PERSONS WARNING YOU MUST MAKE SURE THAT THE ENGINE IS SAFE BEFORE YOU DO WORK ON THE ENGINE CONTROLS IF THE PROPELLER TURNS IT CAN CAUSE INJURY TO PERSONS 1 Make sure that the related engine is safe S Set the ELECT MASTER switch to OFF S Set the ENGINE MASTER switch to OFF S Set the power lever to 0 2 Remove the engine cowlings from the related engine Refer to Section 71 ...

Page 776: ...e mounting bracket S Secure the overheat detector on the mounting bracket Use a new safety wire 3 Fix the cable with cable ties in the same way as they were before removal 4 Do a test of the related overheat detector Refer to Paragraph 3 5 Install the engine cowlings to the related engine Refer to Section 71 10 3 Overheat Detector Test Detail Steps Work Items Key Items References 1 Set the ELECT M...

Page 777: ...AIRCRAFT DA 42 NG AMM Flight Controls Doc 7 02 15 Rev 4 27 TITLE Page 1 15 Mar 2018 CHAPTER 27 FLIGHT CONTROLS ...

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Page 779: ...nt 201 3 Remove Install Levers or Bellcranks 202 4 Remove Install a Control Stick 204 5 Measure the Play in a Hinge 208 Section 27 10 Flight Controls Aileron and Tabs 1 General 1 2 Description 5 3 Operation 6 Trouble Shooting 1 General 101 Maintenance Practices 1 General 201 2 Aileron Control System Test for Correct Range of Movement 201 3 Aileron Control System Adjustments 204 4 Aileron Pushrod A...

Page 780: ...r Correct Range of Movement 201 3 Rudder Control System Adjustments 203 4 Remove Install the Rudder Control Cables 206 5 Remove Install the Pulleys 214 6 Rudder Control Cable and Yoke Access 216 Section 27 21 Flight Controls Rudder Trim 1 General 1 2 Description 3 3 Operation 4 Trouble Shooting 1 General 101 Maintenance Practices 1 General 201 2 Rudder Trim Tab Control System Test for Correct Rang...

Page 781: ...Remove Install the Variable Elevator Stop Assembly 208 5 Test Adjust the Variable Elevator Stop 210 6 Operational Test of the Variable Elevator Stop 211 7 Operational Test of the STICK LIMIT Caution Message 212 8 Elevator Pushrod Access 213 9 Elevator Bellcrank and Lever Access 213 Section 27 37 Stall Warning System 1 General 1 2 Description and Operation 1 Trouble Shooting 1 General 101 Maintenan...

Page 782: ...ral 101 Maintenance Practices 1 General 201 2 Elevator Mechanical Trim Control System Test for Correct Range of Movement 201 3 Elevator Mechanical Trim Control System Adjustment 204 Section 27 39 Flight Controls Elevator Trim Electrical 1 General 1 2 Description 1 Trouble Shooting 1 General 101 Maintenance Practices 1 General 201 Section 27 50 Flight Controls Flaps 1 General 1 2 Description 3 3 Op...

Page 783: ...NTS Page 5 15 Mar 2018 Trouble Shooting 1 General 101 Maintenance Practices 1 General 201 2 Remove Install the Flap Actuator 201 3 Test the Flap Control System 203 4 Adjust the Flap Control System 206 5 Flap Push Rod Access 212 6 Flap Bellcrank and Lever Access 212 ...

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Page 785: ...standard parts are used to make the flight controls for each system Note Equipment which is certified for use in the DA 42 NG is listed in Section 6 5 of the Airplane Flight Manual Such equipment may be installed in accordance with the Airplane Maintenance Manual Any equipment not listed in Section 6 5 of the Airplane Flight Manual is called Additional Equipment The installation of Additional Equi...

Page 786: ... electrically by using a switch mounted on the pilot s control stick The DA 42 NG is equipped with an electrically operated variable elevator stop that limits the upward elevator deflection as soon as the power setting of both engines exceeds approx 20 The variable elevator stop is controlled by two switches on the throttle quadrant one for each power lever Each pilot has a set of rudder pedals Th...

Page 787: ...G AMM Flight Controls Doc 7 02 15 Rev 4 27 00 00 Page 3 15 Mar 2018 Rudder Trim Rudder Aileron LH Aileron RH Flap Outer LH Flap Inner LH Flap Inner RH Flap Outer RH Elevator Trim Tab Figure 1 DA 42 NG Control Surfaces ...

Page 788: ...th of the pushrod A steel tube makes the rod which connects the end fittings Threaded inserts are welded into the ends of the tube to make the connections for the eye ends Safety holes are drilled into the tube at the end fittings The safety holes shows you if the installation of the eye end into the control rod is correct If you can push safety wire through the hole when the eye end is installed ...

Page 789: ... 15 Mar 2018 Control Rod Safety Test Hole Eye End Fitting with Spherical Bearing Eye End Fitting with Spherical Bearing Bonding Wire Bonding Wire Jam Nut Jam Nut Toothed Washer Toothed Washer Threaded End Fitting Welded into Place Figure 2 DA 42 NG Standard Control Pushrod ...

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Page 791: ...ing to its related lever or bellcrank 2 Loosen the jam nut that locks the adjustable fitting Refer to Figure 1 3 Turn the eye end to adjust the length of the rod Turn the eye end clockwise to make the rod shorter turn the eye end counter clockwise to make the rod longer 4 When you have adjusted the eye end do a test for safety of the eye end S Try to push lock wire through the safety hole The lock...

Page 792: ...ndard attachments for bellcranks and levers in the flight control systems Refer to the tables at the end of each Section for access data Refer to the Figures in the related Section for the correct orientation A Remove a Lever or Bellcrank Detail Steps Work Items Key Items References 1 Release the bolts attaching the pushrods to the lever or bellcrank 2 Remove the pivot bolt assembly from the lever...

Page 793: ... 7 lbf ft 3 Put the lever or bellcrank into position at the mounting bracket Make sure that bushes and spacers are correctly located 4 Install the pivot bolt washer and nut Torque 6 4 Nm 4 7 lbf ft 5 Install the bolts washers and self locking nuts which attach the push rods Torque 6 4 Nm 4 7 lbf ft 6 Do a test of the control system Refer to the related Section 7 Do an inspection of the control tha...

Page 794: ...08 to the AFM A Remove a Control Stick Detail Steps Work Items Key Items References 1 Remove the pilot s seat Refer to Section 25 10 2 Loosen the control stick electrical harness from the airplane structure 3 Disconnect the control stick electrical harness connectors If OÄM 42 283 is installed Disconnect the AP DISC relay from the control stick base harness 4 Remove the nut washer and the bolt att...

Page 795: ... NG AMM Flight Controls Doc 7 02 15 Rev 4 27 00 00 Page 205 15 Mar 2018 Control Bulkhead LH Control Stick RH Stick Lever Control Stick Connector Figure 3 LH Control Stick and RH Stick Lever if OÄM 42 281 is installed ...

Page 796: ...ntrol Bulkhead Removeable Control Stick Assy RH Control Stick LH Control Stick Control Stick Base Assy Safety Pin Control Stick Connector Autopilot Disc Relay Sleeve Nut Dust Cap if Control Stick is removed Sleeve Nut Hood Seat Cover GFRP Figure 4 Control Sticks if OÄM 42 283 is installed ...

Page 797: ...lot bridge connector If OÄM 42 283 is installed Connect the AP DSC relay to the control stick base harness Refer to Chapter 92 for the wiring diagrams 4 Secure the control stick harness to the airplane structure Use cable ties 5 Do an inspection of the control stick stick lever S If necessary for your Airworthiness Authority do a duplicate inspection of the control system that you adjusted S Do a ...

Page 798: ...ction of the hinge line in both directions up and down for the rudder inboard and outboard for the other control surfaces Measure the maximum travel from one limit position to the other C Measure the Radial Play of a Control Surface Hinge Move the control surface by hand perpendicular to the direction of the hinge line in both directions left and right for the rudder up and down for the other cont...

Page 799: ...d Tabs 1 General The DA 42 NG has two control sticks that operate the ailerons If OÄM 42 281 or OÄM 42 283 is installed the RH control stick is removed or removable The aileron control system uses pushrods and bellcranks Figures 1 and 2 show the aileron controls in the fuselage Figure 3 shows the aileron controls in the wing ...

Page 800: ...ulkhead Control Stick Mounting Block Torque Tube Assy Adjustable Aileron Stop Front Bellcrank Push Rod to Left Stick Push Rod to Right Stick Left Stick Push Rod to Idler Lever Idler Lever Rigging Pin Hole Rigging Pin Hole Rigging Pin Hole Rigging Pin Hole To Rear Bellcrank Figure 1 Aileron Controls in the Fuselage Sheet 1 ...

Page 801: ... Rev 4 27 10 00 Page 3 15 Mar 2018 Control Bulkhead Front Bulkhead Rear Bulkhead Rear Bellcrank Push Rod from Idler Lever Push Rod to Left Wing Push Rod to Right Wing Rigging Pin Hole Centering Spring Figure 2 Aileron Controls in the Fuselage Sheet 2 ...

Page 802: ... Push Rod to Left Wing Push Rod to Right Wing Wing Root Rib Flap Control Rib Support Bracket Guide Rollers Guide Rollers Guide Rollers Aileron Control Rib Left Aileron Bellcrank Aileron Horn Aileron Rigging Pin Hole Rigging Pin Hole LH System Shown RH System Opposite Figure 3 Aileron Controls in the Wing ...

Page 803: ...the wing center section The second attaches to the outer flap control rib A small rib holds the third pushrod guide The two long pushrod assemblies attach to the aileron bellcranks which are mounted in each wing at the aileron control rib Short pushrods connect the aileron bellcrank to the aileron horn You can adjust the short pushrods to move the aileron range of movement up or down The aileron s...

Page 804: ...towards the rear The push rod below the center console moves the idler lever and second short pushrod to the rear The second short pushrod moves the rear bellcrank so that the long pushrods in the wing move to the left The left aileron bellcrank in the left wing moves the short pushrod attached to the left aileron horn to the rear The left aileron moves up If you move the control sticks to the rig...

Page 805: ...read across to the Possible Cause column Then do the repair given in the Repair column Trouble Possible Cause Repair Airplane moves about the longitudinal axis in flight with no input from the pilot Aileron pushrods out of adjustment Adjust the aileron pushrods Aileron controls stiff catch Defective bearings in a control rod eye end Control rod guide s defective Pushrod bent Replace the defective ...

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Page 807: ...WORK ON THE AIRPLANE CONTROLS YOU MUST MAKE SURE THAT THE AREA AROUND THE CONTROL SURFACES ARE CLEAR OF PERSONNEL AND EQUIPMENT IF YOU DO NOT DO THIS INJURY TO PERSONNEL AND DAMAGE TO THE CONTROL SURFACES CAN OCCUR WARNING WHEN YOU COMPLETE WORK ON THE CONTROLS MAKE SURE THAT YOU REMOVE ALL LOOSE ITEMS OR TOOLS FROM THAT AREA LOOSE ITEMS OR TOOLS CAN PREVENT FULL AND FREE MOVEMENT OF THE AIRPLANEC...

Page 808: ...each aileron and the trailing edge of the wing tip Record these measurements The left aileron must align with the right aileron 5 Remove the rigging pins from the following S The bottom of the control stick S The left stick mounting bracket WARNING WHEN YOU DO WORK ON THE AIRPLANE CONTROLS YOU MUST MAKE SURE THAT THE AREAS AROUND THE CONTROLS CONTROL SURFACES ARE CLEAR OF PERSONNEL EQUIPMENT IF YO...

Page 809: ...ween the trailing edge of the right aileron and the trailing edge of the wing tip Record the measurement The distance must be as shown in the Control Surface Adjustment Report 11 Measure the distance between the trailing edge of the left aileron and the trailing edge of the wing tip Record the measurement The distance must be as shown in the Control Surface Adjustment Report 12 Install the left pi...

Page 810: ...WARNING IF YOU DO AN ADJUSTMENT OF A PUSHROD YOU MUST MAKE SURE THAT THE PUSHROD IS STILL IN SAFETY IF YOU DO NOT DO THIS THE PUSHROD CAN DISCONNECT THIS CAN CAUSE DEATH OR INJURY TO PERSONS A Equipment Item Quantity Part Number Rigging pins 7 VR D41 2757 3000 Ruler measuring stick 1 Commercial B Aileron Adjustment Procedure Detail Steps Work Items Key Items References 1 Remove these items for acc...

Page 811: ...k each lever or bellcrank in sequence 3 If you cannot put a rigging pin into a lever or bellcrank adjust the pushrod s as necessary Refer to Section 27 00 for the pushrod adjustment procedure 4 Measure the distance between the trailing edge of each aileron and the trailing edge of the wing tip Record these measurements The left aileron must align with the right aileron WARNING ALL RIGGING PINS MUS...

Page 812: ...se the jam nut on the stop bolt S Adjust the stop bolt to give the correct range of movement S Tighten the jam nut on the stop bolt Refer to Figure 1 The aileron positions must be the distances shown in the original Control Surfaces Adjustment Report measured from the neutral position 9 Do an inspection of the controls that you have adjusted If necessary for your Airworthiness Authority do a dupli...

Page 813: ...he center section closing rib Passenger seat Center section access panels Section 25 10 Section 52 40 Between the center section closing rib and the bellcrank in the left right wing Center section access panels Aileron bellcrank access panels under each wing Section 52 40 Between the bellcrank in the left right wing and the ailerons Aileron bellcrank access panels under each wing Section 52 40 5 A...

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Page 815: ...ontrols Rudder 1 General The DA 42 NG has the usual rudder control system Each pilot has a rudder pedal assembly The pilot can adjust the pedal position Control cables connect the pedal assembly to the rudder The rudder has an adjustable trim tab Refer to Section 27 21 for data about the rudder trim system ...

Page 816: ...kles Fuselage Cables with Guide Tubes Rudder Lower Mounting Bracket Co Pilot s Rudder Pedal Assembly Pilot s Rudder Pedal Assembly Control Bulkhead Teflon Tubes which Guide Cockpit Cables Pulley Yoke Inboard Control Cable Outboard Control Cable Centering Springs Figure 1 Rudder Control System ...

Page 817: ...mounting bracket is attached to the rudder leading edge It connects the rudder to the rudder pedestal Cable assemblies Flexible control cables connect the cockpit front bulkhead to the yoke Two long flexible control cables connect the yoke to the rudder Each of the long flexible cables has a turnbuckle assembly for adjusting the length of the cable Six bolts attach each rudder pedal assembly to th...

Page 818: ...ft Attachment to Floor Panel Brake Reservoir Co Pilot only Brake Master Cylinder S Tube for Control Cables S Tube for Control Cables Brake Pedals Right Rudder Pedal Left Rudder Pedal Adjuster Handle Sledge Tubes Adjuster Latch Roll Pins Tension Springs Adjuster Cable Multi Hole Bracket Attachment for Cables Figure 2 Rudder Pedal Assembly ...

Page 819: ...nt to Floor Panel Brake Reservoir Co Pilot only Brake Master Cylinder S Tube for Control Cables S Tube for Control Cables Brake Pedals Right Rudder Pedal Left Rudder Pedal Transmission Mechanism Sledge Tubes Roll Pins Adjuster Rod Multi Hole Bracket Attachment for Cables Figure 3 Rudder Pedal Assembly with Electric Adjustment OÄM 42 070 carried out ...

Page 820: ...f the rudder lower hinge Each rudder stop consists of a nut which is welded to the rudder lower mounting bracket and a bolt which is held tight in the nut by a jam nut 3 Operation If you move the left rudder pedal forward The top of the S shaped tube moves forward The S shaped tube pulls the left cockpit cable The left cockpit cable moves the yoke counterclockwise seen from above The yoke pulls th...

Page 821: ...bly Teflon Tube Pulley Assembly Outboard Control Cable Inboard Control Cable Floor Panel Teflon Tube Plastic Washer Oetiker Clamp Fuselage Cables Yoke Bush Spacer Mounting Bracket Control Bulkhead Right Inboard Cable Left Inboard Cable Left Outboard Cable Right Outboard Cable Control Bulkhead Pulley Safety Plate Rigging Pin Hole Figure 4 Rudder Controls in the Cockpit ...

Page 822: ...f the pedals The latch will lock When you adjust the position of the pedals the control cables move through the S shaped tubes B Electrical Adjustment Optional Equipment OÄM 42 070 Positioning switches are located on the LH and RH side at the rear wall of the leg room The positioning switch causes the rudder pedals on the corresponding side to move along the guide rail To move the pedals towards y...

Page 823: ...s with Guide Tubes Fuselage Cables with Guide Tubes Rudder Lower Mounting Bracket Bush Spacer Teflon Tube Bush Spacer A A A A A A A A Turnbuckles Yoke Assembly on Control Bulkhead Rudder Stop Bolt Plastic Washer Frame Oetiker Clamp Rudder Pedestal Rigging Pin Figure 5 Rudder Controls in the Fuselage ...

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Page 825: ...e column and then do the repair given in the Repair column Trouble Possible Cause Repair Airplane moves about its yaw axis with no input from the pilot Rudder control cable needs adjusting Rudder trim system defective Adjust the rudder control cables Refer to Section 27 21 Rudder controls stiff catch Bearings defective Cables chafing in the guide tubes Replace the defective bearing Replace the cab...

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Page 827: ...ORK ON THE CONTROLS MAKE SURE THAT YOU REMOVE ALL LOOSE ITEMS OR TOOLS FROM THAT AREA LOOSE ITEMS OR TOOLS CAN PREVENT FULL AND FREE MOVEMENT OF THE AIRPLANECONTROLS THIS CAN CAUSE DEATH OR INJURY TO PERSONS 2 Rudder Control System Test for Correct Range of Movement A Equipment Item Quantity Part Number Rigging pins 4 VR D41 2723 5000 Rudder deflection gauge for S N 42 N100 and subsequent and 42 M...

Page 828: ...ition shown in the Control Surfaces Adjustment Report for the airplane 6 Set the rudder pedals to fully left Make sure the rudder deflects to the left at least 24 The maximum left rudder deflection according to the Control Surfaces Adjustment report must be achieved when the rudder is moved directly by hand when hitting the rudder stop 7 Set the rudder pedals to fully right Make sure the rudder de...

Page 829: ...ge for S N 42 N100 and subsequent and 42 MN050 and subsequent 1 D64 5540 00 00 PL Rudder deflection gauge for all other S N 1 D60 5540 00 00 PL Spring scale up to 10 kg 22 lbf 1 Commercial B Rudder Adjustment Procedure Detail Steps Work Items Key Items References 1 Remove these items for access S The pilot s seat S The passengers seat Refer to Section 25 10 2 Set both rudder pedals fully forward 3...

Page 830: ... Tighten the turnbuckles and install the lockwire Refer to Figure 4 Below the passenger seat Use the tensiometer Required value 15 daN 33 72 lbf 17 daN 38 22 lbf 5 Set the rudder pedals to fully left Make sure the rudder deflects to the left at least 24 The maximum left rudder deflection according to the Control Surfaces Adjustment report must be achieved when the rudder is moved directly by hand ...

Page 831: ...ght side of the rudder lower mounting bracket S Release the jam nut on the right stop bolt S Adjust the stop bolt to give the correct range of movement S Tighten the jam nut on the stop bolt The rudder position must be the distance to the right shown in the Control Surfaces Adjustment Report for the airplane measured from the neutral position 9 Do a test for the correct range of rudder movement Re...

Page 832: ...kpit Rudder Control Cables Front Cables Detail Steps Work Items Key Items References 1 Remove these items for access S The pilots seats Refer to Section 25 10 2 Remove the cable between the cockpit front bulkhead and the yoke S Remove the nut washer bolt and spacer that attach the cable to the multihole bracket at the bulkhead S Remove the nut washer bolt bush and spacer that attach the cable to t...

Page 833: ... eye end to the cable before you install it in the airplane S Use cables to specification LN9374 or ISO 2020 or MIL DTL 83420 streched to 60 MBS S Make the eye end using Locoloc thimbles and Nico Press clamps appropriate to the installed 3 2 mm 1 8 diameter steel cables S Inspect the cable eye end for correct assembly S If necessary for your Airworthiness Authority send a sample eye end for proof ...

Page 834: ...that attach the cable to the yoke S Install a washer and new self locking nut onto the bolt Torque to 6 4 Nm 4 7 lbf ft Always use new self locking nuts 7 Install the cable to the bracket at the cockpit front bulkhead S Install the bolt and spacer that attach the cable to the bracket S Install a washer and new self locking nut to the bolt Adjust the position of the bolt in the multihole bracket to...

Page 835: ... Items Key Items References Doc 7 02 15 Rev 4 27 20 00 Page 209 15 Mar 2018 10 Install these items S The passenger seat S The pilots seats Refer to Section 25 10 11 Record type of cables installed stainless or non stainless steel cables in the airplane logs ...

Page 836: ...bush and spacer that attach the cable to the yoke S Cut the eye end from the cable that you will remove at the yoke S Remove the old cable aft S Cut the eye end from the cable that you will remove at the turnbuckle Refer to Figure 4 3 Remove the cable between the turnbuckle and the rudder S Remove the nut washer bolt bush and spacer that attach the cable to the rudder lower mounting bracket S Cut ...

Page 837: ... install it in the airplane 1 Install a new eye end to the front of the cable at the yoke end before you install the cable in the airplane and S Use cables to specification LN9374 or ISO 2020 or MIL DTL 83420 streched to 60 MBS S Make the eye end using Locoloc thimbles and Nico Press clamps appropriate to the installed 3 2 mm 1 8 diameter steel cables S Inspect the cable eye end for correct assemb...

Page 838: ...ess oval sleeve in accordance with FAA AC 43 13 1B Chapter 7 Section 8 4 Install a new eye end to the rear cable before you install the cable into the airplane S Use cables to specification LN9374 or ISO 2020 or MIL DTL 83420 streched to 60 MBS S Make the eye end using Locoloc thimbles and Nico Press clamps appropriate to the installed 3 2 mm 1 8 diameter steel cables S Inspect the cable eye end f...

Page 839: ...ll the able to the rudder lower mounting bracket S Install the bolt bush and spacer that attach the cable to the rudder S Install a washer and new self locking nut Refer to Figure 4 Torque 6 4 Nm 4 7 lbf ft Use a new self locking nut 8 Install the cable to the yoke S Install the bolt bush and spacer that attach he cable to the yoke S Install a washer and a new self locking nut Refer to Figure 4 To...

Page 840: ...non stainless steel cables in the airplane logs 5 Remove Install the Pulleys A Remove the Pulleys Detail Steps Work Items Key Items References 1 Remove these items for access S The pilot s seat Refer to Section 25 10 2 Remove the pulley S Remove the nut washers and bolt that attach the pulley to the mounting link at the control bulkhead S Separate pulley and safety plate from the outer front cable...

Page 841: ...he mounting link at the control bulkhead Refer to Figure 3 Check for correct guidance of the control cable 2 Make sure the cable is in the correct position on the pulley Check friction 3 Do a test for the correct range of rudder movement If necessary adjust the rudder controls Refer to Paragraph 2 Refer to Paragraph 3 4 Do an inspection of all the controls that you have adjusted If necessary for y...

Page 842: ...le and Yoke Access Rudder Cable Yoke Remove Install Access References Cockpit cables between the cockpit front bulkhead and the yoke Pilot s seat Section 25 10 Rear fuselage cables between the yoke and the rudder Pilot s seat Passenger seat Rudder Section 25 10 Section 55 40 Yoke Pilots seats Section 25 10 ...

Page 843: ...ht Controls Rudder Trim 1 General The DA 42 NG has a rudder with a trim tab The pilot uses a trim knob located at the front of the center console to move the rudder trim tab The rudder trim control system is a mechanical control system Figure 1 shows the main components of the rudder trim control system ...

Page 844: ...5 Rev 4 Trim Handwheel Center Console Spindle Flexible Cable Trim Tab Operating Rods Friction Block Assembly Trim Tab Control Horn Cover Plate Trim Indicator Threaded Portion Spindle Block Bellcrank Assembly Bracket Damper Rod Figure 1 Rudder Trim Control System Main Components ...

Page 845: ...th slots that engage with the spindle block spigots and an operating lever that connects to a long flexible cable The two input arms of the bellcrank have a hole drilled through both arms that will align with a hole drilled through the structure of the center console When the holes are aligned the handwheel assembly is in the neutral position You can insert a rigging pin through the holes when you...

Page 846: ... the fork end fitting A friction shoe in the top section of the friction block is held in contact with the friction rod by springs This clamping action on the friction rod dampens the movement of the trim tab actuator should the trim tab control system fail 3 Operation If the pilots rotates the trim control knob clockwise during flight then these events occur The trim control spindle rotates clock...

Page 847: ...trol system If you have the trouble detailed in the Trouble column read across to the Possible Cause column and then do the repair given in the Repair column Trouble Possible Cause Repair Airplane moves about its yaw axis with no input from the pilot Rudder control cables need adjusting Rudder trim system defective Refer to Section 27 20 Adjust the rudder trim tab control system ...

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Page 849: ... and subsequent and 42 MN050 and subsequent 1 D64 5545 00 00 PL Rudder trim deflection gauge for all other S N 1 D60 5545 00 00 PL Rigging pin Ø 4 mm 0 16 in 1 VR D41 2757 3000 B Adjust the Rudder Trim Tab Control System Detail Steps Work Items Key Items References 1 Make a copy of the Control Surfaces Adjustment Report Refer to Section 06 00 Use it to record the measurements 2 Install the rudder ...

Page 850: ...nd the bellcrank The rudder trim tab indicator should indicate neutral 8 The deflection angle of the trim tab must be in accordance with the Control Surfaces Adjustment Report If necessary adjust the lengths of both trim tab control rods Refer to Paragraph 3 Make sure that the trim rudder linkage play is equal to the left and to the right side of neutral position 9 Remove the rigging pin from the ...

Page 851: ...ure that there are no loose articles in the center console S Move the access panel into position at the center console S Install the 3 screws that attach the access panel to the center console For example rags or tools 13 Release the rudder and make sure that both the rudder and the rudder trim tab can move fully and freely throughout their range of movements 14 Remove the rudder and the rudder tr...

Page 852: ...rim Control System Adjustment Procedure Detail Steps Work Items Key Items References 1 Make sure that the rudder is in the neutral position Refer to Section 27 20 Hold the rudder in this position 2 Install the rudder and the rudder trim deflection gauges Make sure the rudder trim gauge axle marker corresponds with the rudder trim tab axle Make sure the rudder trim gauge 0 position is aligned with ...

Page 853: ... mm 0 55 in of thread S Move the lower operating rod back into position at the trim tab lever and install the attaching bolt S Adjust the end fitting of the top operating rod until the end fitting aligns with the trim tab lever S Tighten the lock nuts on the end fittings of both operating both operating rods S Install the bolts that attach the spherical end fittings of the operating rods to the tr...

Page 854: ...le that you removed S Make sure that there are no loose articles in the center console S Move the access panel into position at the center console S Install the 3 screws that attach the access panel to the center console For example rags or tools 10 Release the rudder and make sure that both the rudder and the rudder trim tab can move fully and freely throughout their range of movements 11 Remove ...

Page 855: ...AIRCRAFT DA 42 NG AMM Flight Controls Doc 7 02 15 Rev 4 27 21 00 Page 207 15 Mar 2018 Figure 2 Adjust the Rudder Trim Tab Control System ...

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Page 857: ...l system An elevator attaches to the horizontal stabilizer gives longitudinal control of the airplane Two control sticks operate the elevator The DA 42 NG has an electrically operated elevator trim system and a mechanically operated trim system Refer to Section 27 38 for data about the mechanical trim system and refer to Section 27 39 for data about the electric trim system ...

Page 858: ...2018 27 30 00 Doc 7 02 15 Rev 4 Control Stick Mounting Block Torque Tube Assy Left Stick Push Rod to Idler Lever Idler Lever Rigging Pin Hole Elevator Lever Front Main Bulkhead Variable Elevator Stop Figure 1 Elevator Control Installation in the Cockpit ...

Page 859: ...he stop The elevator stop for the upward movement consists of a bolt bush assembly which is installed in the trim actuator mounting bracket in a transverse direction refer to Section 27 38 When the elevator is deflected fully upwards the forward extension of the elevator horn is deflected fully downward and contacts the stop Figure 3 shows the variable elevator stop The DA 42 NG is equipped with a...

Page 860: ... Collar Bush Distance Bush Large Washer Elevator Push Rod II Elevator Bellcrank Baggage Frame Ring Frame 1 Ring Frame 2 Elevator Push Rod I Idler Lever To Bellcrank Idler Lever Rigging Pin Hole Centering Springs Balance Weight Elevator Lever Rib Additional Elevator Mass optional Figure 2 Elevator Controls in the Rear Fuselage ...

Page 861: ... pushrod aft the short pushrod pushes the long pushrod aft the long pushrod pushes the aft bellcrank rearward The bellcrank pushes the vertical pushrod up The vertical pushrod moves the front of the elevator horn upwards The elevator moves down If you move the control stick aft The torque tube assembly turns The short and long pushrods move forward The bellcrank pulls the vertical pushrod downward...

Page 862: ...T Flight Controls DA 42 NG AMM Page 6 15 Mar 2018 27 30 00 Doc 7 02 15 Rev 4 Stick Limiter Actuator of Variable Elevator Stop Operating Stop Rod Actuator Lever Actuator Bracket Figure 3 Variable Elevator Stop ...

Page 863: ...ed in the Trouble column read across to the Possible Cause column Then do the repair given in the Repair column Trouble Possible Cause Repair Control vibration during flight Too much backlash in the flight controls Examine the flight control system to isolate the problem Replace the defective part Elevator controls stiff catch Bearings defective Pushrod deformed Replace the defective eye end Repla...

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Page 865: ...OLS YOU MUST MAKE SURE THAT THE AREA AROUND THE CONTROL SURFACES ARE CLEAR OF PERSONNEL AND EQUIPMENT IF YOU DO NOT DO THIS INJURY TO PERSONNEL AND DAMAGE TO THE CONTROL SURFACES CAN OCCUR WARNING WHEN YOU COMPLETE WORK ON THE CONTROLS MAKE SURE THAT YOU REMOVE ALL LOOSE ITEMS OR TOOLS FROM THAT AREA LOOSE ITEMS OR TOOLS CAN PREVENT FULL AND FREE MOVEMENTOFTHEAIRPLANE CONTROLS THIS CAN CAUSE DEATH...

Page 866: ...e elevator on the elevator deflection indicator Record the measurement 6 Remove the rigging pin from the stick mounting block WARNING WHEN YOU DO WORK ON THE AIRPLANE CONTROLS YOU MUST MAKE SURE THAT THE AREA AROUND THE CONTROLS CONTROL SURFACES ARE CLEAR OF PERSONS EQUIPMENT IF YOU DO NOT DO THIS INJURY TO PERSONNEL AND DAMAGE TO CONTROL SURFACES CAN OCCUR 7 Move the control stick fully forward a...

Page 867: ...l the rigging pin through the stick mounting block and the torque tube Refer to Figure 1 7 Remove the horizontal stabilizer tips S Remove the 8 screws that attach the tip to the stabilizer Hold the tips 8 Protractor reference S Place the protractor on the edge of the stabilizer onto the rib where the tips were removed before S Reset the protractor This is the 0 reference plane Make sure that the p...

Page 868: ...st the stop 12 Repeat step 9 and keep the bevelled angle 6 5 in mind Record the measurement The angle must be as shown in the Control Surfaces Adjustment Report 13 Move the control stick fully aft and hold it against the stop 14 Repeat step 9 and keep the bevelled angle 6 5 in mind Record the measurement The angle must be as shown in the Control Surfaces Adjustment Report 15 Install the horizontal...

Page 869: ...ity Part Number Protractor electronic deflection gauge or elevator deflection indicator 1 Commercial Rigging pins 3 B Elevator Control Adjustment Procedure Refer to Figure 1 Detail Steps Work Items Key Items References 1 Remove these items for access S The pilots seat S The rudder Refer to Section 25 10 Section 55 40 2 Install rigging pins in the following S Through the stick mounting block and th...

Page 870: ...rear bellcrank On the control bulkhead On the front main bulkhead On the vertical stabilizer rear web 7 Do a test for the correct range of elevator movement Refer to Paragraph 2 8 Do an inspection of all the controls that you have adjusted If necessary for your Airworthiness Authority do a duplicate inspection of the controls 9 Install these items S The pilots seats S The rudder Refer to Section 2...

Page 871: ...207 15 Mar 2018 Reference Plane for Protractor 0 15 5 0 5 Ref Line Horizontal Position Protractor 13 1 6 5 AFT Protractor 15 5 0 5 6 5 Measuring Surface for Protractor 6 5 6 5 UPPER LIMIT Stabilizer with Removed Tips 13 0 5 LOWER LIMIT Figure 4 Elevator Angle Measurement ...

Page 872: ... WRN ELEV LIMIT circuit breaker On the right side of the instrument panel 3 Remove the variable elevator stop assembly S Disconnect the two in line connectors S Release the bolt which attaches the actuator lever adjustable fitting to the torque tube assy S Remove the four bolts washers and nuts that attach the assembly bracket to the control bulkhead S Move the variable elevator stop assembly clea...

Page 873: ...washers and nuts that attach the assembly bracket to the control bulkhead S Install the bolt which attaches the actuator lever adjustable fitting to the torque tube assy S Connect the two in line connectors Refer to Figure 1 and Figure 3 At the variable elevator stop assembly 2 Reset the GEAR WRN ELEV LIMIT circuit breaker On the right side of the instrument panel 3 Do an operational test Refer to...

Page 874: ...t Detail Steps Work Items Key Items References 1 If you will use a deflection gauge put a trestle under the rear fuselage To prevent movement in pitch 2 Switch on the ELECT MASTER Refer to Section 24 00 3 Position both power levers approx beyond the 20 power level 4 Continue according to the elevator control test procedure Refer to Paragraph 2 Required upward deflection 13 0 5 51 mm 2 mm 5 If nece...

Page 875: ...ELECT MASTER Refer to Section 24 00 2 Position both power levers above approx 20 power level To activate the stick limiter 3 Test the system S Pull the control stick rearward to the stop Hold the stick fully rearward S Set both power levers to IDLE S Set both power levers above approx 20 The stick must move rearward The stick must move forward 4 Switch off the ELECT MASTER Refer to Section 24 00 ...

Page 876: ...r 92 for the wiring diagram of the variable elevator stop stick limiter 5 The STICK LIMIT caution message must appear on the G1000 PFD after 6 seconds 6 Remove ground connection from pin A 7 Set both power levers above approx 20 To test the system in the activated configuration 8 Connect pin D on the printed circuit PC board installed on the flap actuator assembly to electrical ground Refer to Cha...

Page 877: ...Between the idler lever at the front main bulkhead and the bellcrank at the vertical stabilizer rear web Pilot s seat Rudder Section 25 10 Section 55 40 Between the bellcrank at the vertical stabilizer rear web and the elevator Rudder Section 55 40 9 Elevator Bellcrank and Lever Access Elevator Pushrod Remove Install Access References Idler lever at the front main bulkhead Pilots seats Section 25 ...

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Page 879: ... A stall warning switch is mounted on the left wing s leading edge The stall warning switch has heater elements to prevent icing A switch on the instrument panel controls the stall warning heat To avoid overheating the heaters are supplied via a resistor if the airplane is on ground A circuit breaker protects the system As the angle of attack increases and the airplane approaches an aerodynamic st...

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Page 881: ... the trouble detailed in the Trouble column read across to the Possible Cause column Then do the repair given in the Repair column Trouble Possible Cause Repair Stall warning horn does not operate Circuit breaker not set Stall warning horn defective Stall warning switch lift detector defective Faulty cables connectors Set the circuit breaker Replace the stall warning horn Replace the stall warning...

Page 882: ...e heater defective RH Weight on Wheel switch defective PITOT switch defective Stall heat control relay defective Faulty cables connectors Replace the stall warning switch Replace the switch refer to Section 32 60 Replace the switch refer to Section 24 60 Replace relay Do a test for continuity on each cable Do a test for short circuit to ground and between cables Replace defective cables ...

Page 883: ...ed firmly and the vane is not bent or damaged S Mark location and angle of the vane on the stall warning switch installation gauge 3 Loosen the screws that attach the stall warning switch to the wing 4 Disconnect the electrical wires At the in line connector 5 Remove the stall warning switch from the wing B Install the Stall Warning Switch Detail Steps Work Items Key Items References 1 Connect the...

Page 884: ...ond S Record stall warning speed and stall speed S If a minimum of 10 kts margin in between stall warning speed and stall speed does not exist or nuisance warnings are experienced during take off or approach adjust the stall warning switch following the scheme S Down if nuisance warnings and a margin of more than 10 kts exists S Up if the stall warning is less than 10 kts S Repeat the flight check...

Page 885: ...ns 4 Remove the nut which attaches the stall warning horn to the instrument panel 5 Remove the stall warning horn from the instrument panel B Install the Stall Warning Horn Detail Steps Work Items Key Items References 1 Put the stall warning horn in position in the instrument panel 2 Install the nut that attaches the stall warning horn to the instrument panel 3 Connect the electrical wires to the ...

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Page 887: ...ith a trim tab The trim tab is mechanically operated The elevator also has an electric trim system which operates on the elevator via flexible cable Refer to Section 27 39 for more data about the electrically operated trim system A handwheel on the center console controls the elevator trim tab An indicator tells the pilot the trim tab setting A flexible cable moves the trim tab ...

Page 888: ... Plate Frame Assembly Handwheel HANDWHEEL AND TRIM INDICATOR INSTALLATION Lock Nut Friction Damper Nut Lock Nut Lock Washer Trim Gear Assembly Gear Segment with Internal Teeth Distance Bush Trim Indicator Mark Bush Bush Flexible Cable Plastic Friction Washer Pivot Bolt Ball Stud Figure 1 Elevator Mechanical Trim Mechanism in the Cockpit ...

Page 889: ...ballstud attaches the eye end of a long flexible cable to the gear segment An extension to the mounting frame at the rear makes the anchor point for the outer sheath of the flexible cable The gear segment is also the trim indicator The top face of the segment has a white line across it midway between the front and back The top face can be seen by the pilot through a slot in the cover plate The sid...

Page 890: ...Doc 7 02 15 Rev 4 Trim Tab Left Actuating Lever Right Actuating lever Flexible Operating Cable Outer Flexible Operating Cable Inner Friction Damper Friction Clamp Block Bolt Washer Castellated Nut Cotter Pin Actuating Lever Fork End Figure 2 Trim Tab Actuator Assembly ...

Page 891: ... top of the gear segment forward The gear segment pulls the inner core of the flexible cable forward The inner core of the flexible cable pulls the left cranked actuating lever forward The left cranked actuating lever pulls the trim tab lever forward to move the trim tab upwards The up movement of the trim tab uses aerodynamic forces to push the elevator down in flight giving nose down trim When y...

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Page 893: ...system If you have the trouble detailed in the Trouble column read across to the Possible Cause column Then do the repair in the Repair column Trouble Possible Cause Repair Too much play in the mechanical trim system Worn bearings or joints Replace the defective items Trim handwheel stiff to move Flexible cable damaged Trim damper incorrectly adjusted Replace the flexible cable Adjust the trim dam...

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Page 895: ...igging pin 1 VR D41 2757 3000 Protractor electronic deflection gauge 1 Commercial Elevator trim deflection indicator 1 D60 5525 00 PL B Elevator Mechanical Trim Control Test Procedure Detail Steps Work Items Key Items References WARNING WHEN YOU DO WORK ON THE AIRPLANE CONTROLS YOU MUST MAKE SURE THAT THE AREA AROUND THE CONTROLS CONTROL SURFACES ARE CLEAR OF PERSONS EQUIPMENT IF YOU DO NOT DO THI...

Page 896: ...m deflection indicator S Record your measurement Check your measurements with the elevator trim angle limits table in this section 9 Set the elevator trim hand wheel to NOSE UP Repeat step 8 10 Set the elevator trim hand wheel to NOSE DOWN Repeat step 8 11 Set the elevator to 10 inclined position Use a protractor or an elevator deflection indicator to measure the inclined position Refer to Figure ...

Page 897: ...rim hand wheel to NOSE UP Repeat step 8 18 Set the elevator trim hand wheel to NOSE DOWN Repeat step 8 19 If your measurements do not comply with the limits in the trim angle limit table then re adjust the trim elevator Refer to Section 27 38 20 Move the wing and rear fuselage trestles clear of the airplane 21 Lower the airplane Refer to Section 07 10 ...

Page 898: ...Key Items References 1 Remove these items for access S The pilot s seat S The center console cover Refer to Section 25 10 2 Put a trestle under the rear fuselage To prevent movement in pitch 3 Hold the trailing edge of the elevator in line with the horizontal stabilizer Use a clamp at the tips 4 Set the trim handwheel to neutral See the trim indicator 5 Adjust the flexible cable S Loosen the nuts ...

Page 899: ...pection of all the controls that you have adjusted If necessary for your Airworthiness Authority do a duplicate inspection of the controls 7 Install these items S The center console cover S The pilot s seat Refer to Section 25 10 8 Remove the clamps from the elevator horizontal stabilizer tips 9 Remove the trestle from under the rear fuselage ...

Page 900: ...S Move the fork end fitting clear of the actuator Refer to Figure 2 3 Measure the force needed to move the damper rod through the clamp Use a spring balance The friction force must be 15 30 N 3 4 6 7 lbf 4 If necessary adjust the friction force S Tighten or loosen the clamping screw a small amount 5 Do steps 3 and 4 again as necessary 6 Connect the right actuating lever to the friction rod S Move ...

Page 901: ...eferences Doc 7 02 15 Rev 4 27 38 00 Page 207 15 Mar 2018 7 Do an inspection of all the controls that you have adjusted If necessary for your Airworthiness Authority do a duplicate inspection of the controls 8 Install the horizontal stabilizer fairing Refer to Section 55 10 ...

Page 902: ...ust the friction damper nut Against the pack of washers and spring washers on the pivot bolt 5 Measure the friction force clamp a spring balance onto the handwheel and measure force The friction force must be 3 2 4 4 Nm This corresponds to a force of 60 10 N on the corded area of the trim handwheel 6 Do step 4 as necessary to set the correct friction force 7 Tighten the locknut for the handwheel f...

Page 903: ...ectrical trim system refer to Chapter 22 The elevator electric trim system has two main components A Pilot s Control Stick Switch A thumb switch on the pilot s control stick operates the elevator electrical trim servo The switch is spring loaded at the neutral position The switch can pushed against the spring in a forward or aft direction When pushed forwards the trim servo will trim the airplane ...

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Page 905: ...ble Possible Cause Repair The elevator electrical trim system does not operate correctly from the switch on the pilot s control stick but the autopilot elevator trim control system operates correctly Defective trim switch on the pilot s control stick Replace the defective trim switch The elevator electrical trim system does not operate correctly from the switch on the pilot s control stick or with...

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Page 907: ...Doc 7 02 15 Rev 4 27 39 00 Page 201 15 Mar 2018 Maintenance Practices 1 General For data about the removal installation of the elevator trim electrical servo and the removal installation of the elevator trim servo clutch refer to Chapter 22 ...

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Page 909: ...d of the inner flap has a tongue which engages with a slot in the inboard end of the outer flap An electric flap actuator moves the flaps See Section 57 50 for data about the flap structure A three position toggle switch controls the flaps The switch is in the right side of the instrument panel Lights located to the left of the flap toggle switch come on when these flap positions are set Green lit...

Page 910: ... Wing Push Rods to Right Wing Rigging Pin Hole Spacer Flap Actuator Rear Main Bulkhead Idler Lever Flap Actuator Rear Closing Rib Push Rods to Left Wing Push Rods to Right Wing Toothed Lockwasher Bonding Wire Bolt Washer Toothed Lockwasher Bonding Wire Washer Nut Spacer Figure 1 Flap Control System in the Fuselage ...

Page 911: ...ndle The spindle operates a pushrod The pushrod connects to an idler lever attaches to the rear main bulkhead A cam attached to the pushrod operates five micro switches The micro switches are part of the flaps electronic control circuit B Push Rods and Bellcranks The idler lever on the rear man bulkhead connects to four pushrods Two of the pushrods connect to the inboard ends of longer pushrods in...

Page 912: ...Rev 4 Guide Rollers Push Rods from Fuselage To RH Wing Push Rods from Fuselage Left Flap Rib Left Inner Flap To Left Outer Flap Rigging Pin Hole Flap Idler Lever in the Fuselage Actuator Control Rod LH Wing Shown RH Wing Similar Figure 2 Flap Push Rods and Bellcranks in the Wings ...

Page 913: ...are in the UP position The middle diode lights when the flaps rare in the APP position The bottom diode lights when the flaps are in the LDG position The switch board attaches to the body of the flap actuator The switch board has five micro switches It also has solid state logic board The logic circuits monitor the outputs from the selector switch and the micro switches on the switch board They co...

Page 914: ...h Mounting Bracket Rear Closing Rib Circuit Board Micro Switches Worm Drive Clamps Cam Micro Switch Base Plate Cam Adjusting Nuts Actuator Control Rod Actuator Swivel Block Base Plate TYPICAL ATTACHMENT OF MICRO SWITCH Micro Switch Cam Toothed Lockwasher Bonding Wire Bolt Washer Figure 3 Flap Actuator Installation ...

Page 915: ...ition reaches the position set by the flap selector The cam on the flap actuator operates the related flap position and indication micro switches The logic circuit switches off the related transistors to de energize the flap motor The flap position indicator shows the new flap position 4 Fail Safe Operation The flap control system has these fail safe properties If the LDG position micro switch fai...

Page 916: ... Position Moving Down Micro Switch UP Indication and APP Position Moving Down Micro Switch LDG Indication and APP Position Moving Up Micro Switch LDG Indication and APP Position Moving Up Micro Switch APP Indication Micro Switch UP Position Micro Switch LDG Position Micro Switch UP POSITION APP POSITION LDG POSITION Closed Closed Closed Closed Closed Closed Closed Open Open Open Open Open Open Ope...

Page 917: ...a micro switch Short to ground in a wire between a closed micro switch and the control unit Do an insulation test between each wire and ground Repair or replace defective wires Replace the electrical control unit Replace the micro switch Do an insulation test between each wire and ground Repair or replace defective wires Flap circuit breaker opens when flap selector switch moved to any down positi...

Page 918: ...ow Flap motor defective Flap actuator defective Do a test of the airplane electrical system voltage Do a test for 24 V at the motor with flaps selected If there is 24 V at the motor replace the actuator Examine the actuator If you find damage then replace the flap actuator Flaps do no not align with the wing trailing edge Flaps extended at too high airspeed Examine the flap system Replace damaged ...

Page 919: ... continuity test of the wiring Repair or replace the defective wire No APP indication when the flaps are in the APP position Flaps move to all positions correctly Micro switch 3 defective Open circuit in the micro switch 3 wiring Replace the micro switch Do a continuity test of the wiring Repair or replace the defective wire Flap circuit breaker opens at the end of down movement Micro switch 4 def...

Page 920: ...ED stays on when the flaps are not in the APP position The other indications operate correctly Micro switch 3 defective Replace the micro switch Flaps move to LDG when APP set from UP Micro switch 2 defective Replace the micro switch Flaps move to UP when APP set from LDG Micro switch 5 defective Replace the micro switch ...

Page 921: ...FROM THAT AREA LOOSE ITEMS OR TOOLS CAN PREVENT FULL AND FREE MOVEMENT OF THE AIRPLANECONTROLS THIS CAN CAUSE DEATH OR INJURY TO PERSONS 2 Remove Install the Flap Actuator Refer to Figures 1 and 3 A Remove the Flap Actuator Detail Steps Work Items Key Items References 1 If possible set the flaps to the APP position 2 Disconnect the airplane main battery Refer to Section 24 31 3 Remove the passenge...

Page 922: ...lock Torque 6 4 Nm 4 7 lbf ft 3 Install the bolt which attaches the actuator push rod to the idler lever At the rear main bulkhead Hold the flaps Torque 6 4 Nm 4 7 lbf ft 4 Connect the control harness plug for the switch board 5 Connect the electrical supply connector to the flap motor 6 Connect the airplane main battery Refer to Section 24 31 7 Do the flap adjustment procedure See Paragraph 4 8 D...

Page 923: ...o ON S Set the flaps to APP S When the flaps stop moving set the flaps to UP S When the flaps stop moving set the ELECT MASTER switch to OFF 3 Do a test for the correct pre load in the flap UP position S Build a loop with strong durable tape and bond both ends side by side on top of the left inner flap S Use the loops of tape for the spring balance until the flap just moves from the lower surface ...

Page 924: ...nclinometer 7 Set the flaps to APP S Set the ELECT MASTER switch to ON S Set the flap selector switch to APP S When the flaps stop moving set the ELECT MASTER switch to OFF 8 Measure the angle of the left outer flap Record the value in the Control Surfaces Adjustment Report Use the inclinometer The value must be as shown in the Control Surfaces Adjustment Report 9 Set the flaps to LDG S Set the EL...

Page 925: ... Steps Work Items Key Items References Doc 7 02 15 Rev 4 27 50 00 Page 205 15 Mar 2018 12 Set the flaps to UP S Set the ELECT MASTER switch to ON S Set the flap selector switch to UP S When the flaps stop moving set the ELECT MASTER switch to OFF ...

Page 926: ...ess panels in both wings Refer to Section 25 10 Refer to Section 53 40 3 Disconnect the airplane main battery Refer to Section 24 31 4 Remove the bolt spacer washer and nut which attach the actuator push rod to the idler lever At the rear main bulkhead Hold the flaps 5 Put a rigging pin in the idler lever Refer to Figure 3 At the rear main bulkhead 6 Put a rigging pin in the left inner bellcrank i...

Page 927: ...of a string through the eye end 11 Measure the extension of the actuator push rod The distance between the center of the eye end of the actuator rod and the center of the actuator swivel block mounting must be 379 7 mm 14 87 in 12 If the actuator pushrod extension is not correct adjust the cam rod S Loosen the nuts which attach the cam rod to the plate at the eye end S Turn the nuts to move the ca...

Page 928: ...deflection Set the flap selector switch to LDG S Set the flap selector switch to APP S Set the flap selector switch to UP Record the value in the Control Surfaces Adjustment Report 21 Make sure that all the flaps hit the stops at the same time If necessary adjust the rod between the bellcrank in the wing and the related flap Refer to Section 27 00 22 Do a test and adjust flap pre load Refer to Par...

Page 929: ... top of the inner flaps Do not place loop ends over the flap stop Refer to Figure 5 7 Put paper slip between inner flap outer end and flap stop 8 Set flaps to 0 9 Connect scale to the reinforced tape loop 10 Pull on scale and paper slip until the paper slip is released Pull vertical downwards 11 If the paper slip release force is out of limits disconnect inner flap push rod and twist rod end half ...

Page 930: ...oo small bond inserts into the outer flap stop fairing until force is above minimum If release force is too high remove layers from the outer flap stop fairing until force is below maximum 20 Connect the inner flap push rods 21 Do an inspection of all controls that you have adjusted If necessary for your Airworthiness Authority do a duplicate inspection if the controls ...

Page 931: ...AIRCRAFT DA 42 NG AMM Flight Controls Doc 7 02 15 Rev 4 27 50 00 Page 211 15 Mar 2018 Reinforced Tape Loop Paper Slip Scale Figure 5 Flap Preload Adjustment ...

Page 932: ...ection 52 40 Between the center section closing ribs and the outer flap bellcranks Passenger seat Outer flap bellcrank access panels under each wing Section 25 10 Section 52 40 Between the inner flap bellcranks and the inner flap horns Inner flap bellcrank access panels under each wing Section 52 40 Between the outer flap bellcranks and the outer flap horns Outer flap bellcrank access panels under...

Page 933: ...AIRCRAFT DA 42 NG AMM Fuel Doc 7 02 15 Rev 4 28 TITLE Page 1 15 Mar 2018 CHAPTER 28 FUEL ...

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Page 935: ...cription 3 3 Auxiliary Fuel Tank Description 6 4 Auxiliary Fuel Tank Filler 8 Trouble Shooting 1 General 101 Maintenance Practices 1 General 201 2 Remove Disassemble a Main Fuel Tank Assembly 201 3 Assemble Install a Main Fuel Tank Assembly 205 4 Remove Install an Auxiliary Fuel Tank 211 Section 28 20 Fuel Distribution 1 General 1 2 Description 3 3 Fuel Distribution System Components 7 Trouble Sho...

Page 936: ...e Install an Inline Filter 228 12 Test the Auxiliary Fuel Transfer System 230 Section 28 21 Fuel Distribution if MÄM 42 600 is installed 1 General 1 2 Description 3 3 Fuel Distribution System Components 7 Trouble Shooting 1 General 101 Maintenance Practices 1 General 201 2 Remove Install a Fuel Transfer Shut Off Valve 201 3 Remove Install the Fuel Selector Gearbox 205 4 Remove Install the Fuel Fil...

Page 937: ...ting 1 General 1 2 Description 1 3 Operation 1 Trouble Shooting 1 General 101 Maintenance Practices 1 General 201 2 Remove Install a Fuel Quantity Probe 201 3 Remove Install a Fuel Temperature Sensor 203 4 Remove Install a Fuel Low Level Sensor 205 5 Remove Install a Fuel High Level Shut Off Sensor 207 ...

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Page 939: ...ist of a single fuel chamber in each engine nacelle The additional fuel capacity is 13 7 US gal 52 liter per side The total fuel capacity main fuel tank and auxiliary fuel tank is 39 6 US gal 150 liter per side Each auxiliary tank has its own fuel tank filler and an auxiliary electric fuel pump which transfers fuel into the main fuel tank Fuel level sensors in the inboard and outboard chambers of ...

Page 940: ...ve 12 Main Fuel Tank Vent Line 13 Check Valve with Capilare 14 Outboard Fuel Level Sensor 15 Outboard Chamber Main Tank 16 Middle Chamber Main Tank 17 Inboard Fuel Level Sensor 18 Inboard Chamber Main Tank 19 Fuel Temperature Sensor 20 Low Level Fuel Sensor 21 Drain 22 Finger Filter 23 Nacelle 24 Fuel Cooler 25 Fuselage 26 Crossfeed Lines 27 Fuel Selector LH Wing shown RH Wing similar 21 19 20 18 ...

Page 941: ...t Line 13 Check Valve with Capilare 14 Outboard Fuel Level Sensor 15 Outboard Chamber Main Tank 16 Middle Chamber Main Tank 17 Inboard Fuel Level Sensor 18 Inboard Chamber Main Tank 19 Fuel Temperature Sensor 20 Low Level Fuel Sensor 21 Drain 22 Finger Filter 23 Nacelle 24 Fuel Cooler 25 Fuselage 26 Crossfeed Lines 27 Fuel Selector 28 Fuel Bypass Valve LH Wing shown RH Wing similar 22 19 20 18 17 ...

Page 942: ... top to provide a vent system for the fuel tank assembly The inboard chamber has a fuel level sensor fuel temperature sensor low fuel level switch fuel supply and return connections The fuel supply connection attaches to a finger filter mounted on the fuel chamber A fuel drain valve is located at the lowest point of the inner fuel chamber The middle fuel chamber is a plain chamber and has no insta...

Page 943: ...upply connection attaches to a finger filter mounted at the rear of the auxiliary fuel tank A fuel drain valve is located at the lowest point of the auxiliary fuel tank A vent line with check valve and capillary is connected at the forward wall of the auxiliary fuel tank A drain line is connected to the filler drip tray Prior to the auxiliary fuel pump an inline filter protects the connected fuel ...

Page 944: ...e Chamber Main Tank 17 Inboard Fuel Level Sensor 18 Inboard Chamber Main Tank 19 Fuel Temperature Sensor 20 Low Level Fuel Sensor 21 Drain 22 Finger Filter 23 Nacelle 24 Check Valve 25 Inline Filter 26 Auxiliary Pump 27 Solenoid Valve 28 Finger Filter 29 Fuel Cooler 30 Drain 31 Fuel Level Switch 32 Auxiliary Fuel Filter 33 Auxiliary Tank 34 Check Valve with Capillare 35 Auxiliary Fuel Tank Vent Li...

Page 945: ...AIRCRAFT DA 42 NG AMM Fuel Doc 7 02 15 Rev 4 28 00 00 Page 7 15 Mar 2018 Figure 4 Auxiliary Fuel System Schematic Diagram OÄM 42 056 and MÄM 42 600 is installed ...

Page 946: ...e nacelle Fuel from the fuel cooler flows through another flexible hose back into the related main fuel tank If MÄM 42 600 is installed the unused fuel flows back to the main fuel tank through the fuel cooler located in the engine nacelle and the fuel selector shut off valve From the fuel selector shut off valve the fuel flows through another flexible hose back into the related main fuel tank As t...

Page 947: ...engine running and the fuel selector shut off valve set to CROSSFEED the fuel supply and return lines to the related fuel tank are shut off If MÄM 42 600 is NOT installed Before crossfeed operation verify FUEL PUMP LH RH ENGINE switch is OFF Now the low pressure fuel pumps take the fuel from the opposite engine main fuel tank through the related fuel crossfeed line The fuel returning from the engi...

Page 948: ...he engine Thus it is possible for the pilot to keep fuel balance between main fuel tanks D Refueling Add fuel to the tanks through the fuel fillers in the top of each wing Fuel flows through the filler caps into the main fuel tank assembly Air in the tank can escape back past the fuel As the fuel tank becomes full the air can also escape through the vent system E Fuel Drains You can use the fuel d...

Page 949: ...em of the DA 42 NG airplane It talks the following components Main fuel tanks Fuel filler assembly Fuel tank vents Auxiliary fuel tanks optional equipment Refer to Section 28 00 for a general description and schematic of the fuel system Refer to Section 28 20 for data about the fuel distribution system and Section 28 40 for data about the fuel indicating system ...

Page 950: ...ank Filler Flexible Coupling Flexible Coupling Balance Vent Hoses Balance Vent Hoses Outboard Fuel Chamber Middle Fuel Chamber Inboard Fuel Chamber Finger Filter Outlet Hose LH Installation Shown RH Installation Similar Rubber Band Rubber Band Rubber Band Rubber Band Rubber Band Rubber Band Pressure Relief Valve Figure 1 Main Fuel Tank Installation ...

Page 951: ...temperature sensor and a low fuel sensor are also mounted on the inboard end plate of the inner fuel tank chamber The fuel return transfer line also connects to the inboard end plate The outer end plate of the inner chamber has mountings for the flexible connecting hose and a fuel high level switch The end plates of the middle chamber have fittings attached for the flexible connecting hoses that j...

Page 952: ...AIRCRAFT Fuel DA 42 NG AMM Page 4 15 Mar 2018 28 10 00 Doc 7 02 15 Rev 4 Fuel Filler Assembly Fuel Filler Balance Vent Hoses Outboard Fuel Tank Middle Fuel Tank Figure 2 Fuel Filler Assembly LH ...

Page 953: ...ing It also has slots to engage the fuel filler cap The filler cap has a locking lever You pull the locking lever up and turn the filler cap counter clockwise to release it You turn the cap clockwise to install it and push down the locking lever to secure it The area just below the flange has adapters where the flexible hoses of the vent system connect see Figure 2 Bonding strips connect the tank ...

Page 954: ...oard rear corner of the chamber A finger filter at the tank outlet prevents debris from entering the main fuel tank A drain valve is located at the lower surface at the rear end of the chamber You can use this drain valve during pre flight inspection to check fuel contamination and for draining the auxiliary fuel tank assembly A fuel low level sensor is also mounted on the rearward end plate of th...

Page 955: ... AMM Fuel Doc 7 02 15 Rev 4 28 10 00 Page 7 15 Mar 2018 Auxiliary Tank LH Installation Shown RH Installation Similar Fuel Level Sensor Finger Filter Fuel Filler Cap Check Valve Figure 3 Auxiliary Fuel Tank Installation ...

Page 956: ...stallation The auxiliary fuel tank filler has a flange that attaches to a drip tray in the top skin of the nacelle It also has slots that engage the fuel filler cap Turn the filler cap counterclockwise to release it Turn the cap clockwise to install it A drain line is connected to the drip tray Bonding strips connect the tank to the airplane bonding system ...

Page 957: ...DA 42 NG AMM Fuel Doc 7 02 15 Rev 4 28 10 00 Page 9 15 Mar 2018 LH shown RH similar Connecting Pipe Cover Plate O Ring O Rings Filler Cap Drip Tray Auxiliary Tank Figure 4 Auxiliary Fuel Tank Filler Installation ...

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Page 959: ...ble Cause column Then do the repair given in the Repair column Trouble Possible Cause Repair Filler cap leaking Filler cap damaged Filler cap does not have a tight fit Replace filler cap gasket Tighten nut on lower side of cap Fuel drain valve leaking Drain valve damaged Contamination in drain valve Replace fuel drain valve Open and close drain valve to flush contaminant Do this until the drain se...

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Page 961: ...Steps Work Items Key Items References 1 Make sure that the fuel tank that you will remove is empty Defuel and drain the fuel tank 2 Remove the outer wing that has the fuel tank that you will remove and support the wing on trestles Refer to Section 57 10 3 Remove the fuel tank assembly access panels from the lower surface of the wing Refer to Section 52 40 4 Remove the fuel drain valve S Cut the lo...

Page 962: ...old the vent hoses to the adapters on the access panels S Disconnect the vent hoses from the adapters on the access panels Near the outboard end of the lower wing Refer to Section 52 40 9 Disconnect the bonding wire cable from the fuel tank access panel S Remove the nut and washer from the bolt S Remove the bonding strip from the bolt and move it clear of the tank S Remove the bolt 10 Remove the f...

Page 963: ...in Fuel Tank Assembly Detail Steps Work Items Key Items References 1 Remove the fuel tank assembly that you will disassemble and support on a clean workbench Refer to Paragraph 2A 2 Remove the connecting link that attach the inboard fuel chamber to the middle fuel chamber S Remove the nuts washers and bolts that attach each end of the link to the fuel chambers S Move the link clear of the fuel cha...

Page 964: ...fuel chamber S Remove the hose clips from the 2 hoses S Pull the hoses off the fuel chamber connectors and clear of the fuel chambers 6 Remove the flexible coupling that connects the inboard fuel chamber to the middle fuel chamber S Remove the worm drive clamps from the flexible coupling S Pull the flexible coupling off the fuel chamber connectors and clear of the fuel chambers 7 Remove the flexib...

Page 965: ...ch go around the outside of the fuel chambers Use a x 10 magnifying glass 2 Examine all the flexible hoses and couplings which connect the fuel chambers together Look specially for S Cuts or damage specially at the ends where the clips and worm drive clamps locate S Distortion or cracking 3 Examine the fuel filler flange on the outer fuel chamber Look specially for S Corrosion on the mating surfac...

Page 966: ...or engages with the open end of the flexible coupling S Push the fuel chambers together until the flexible coupling is fully located of the fuel chamber connectors S Install the worm drive clamps onto the flexible couplings 3 Install the flexible coupling that connects the inboard fuel chamber to the middle fuel chamber S Push a flexible coupling over the large connector on the middle fuel chamber...

Page 967: ...chamber S Install the other end of the 2 flexible hoses on the vent connectors of the middle fuel chamber S Install the worm drive clamps onto the flexible hoses 5 Install the flexible vent hoses that connect the inboard fuel chamber to the middle fuel chamber S Install 2 flexible hoses over the vent connectors on the middle fuel chamber S Install the other end of the 2 flexible hoses on the vent ...

Page 968: ...mbers together S Move the link into position between the outboard fuel chamber and the middle fuel chamber S Install the bolts washers and nuts that attach the connecting link to the fuel chambers S Move the link into position between the middle fuel chamber and the inboard fuel chamber S Install the bolts washers and nuts that attach the connecting link to the fuel chambers ...

Page 969: ...tall the 6 screws which attach the fuel filler to the outboard fuel chamber S When all 6 screws are installed then tighten the screws If necessary move the tank assembly to give the correct alignment At the position noted in Paragraph 2 A step 10 Finger tight only Tighten opposite screws 3 Install the bolt washer and nut that attaches the bracket at the outboard end of the outboard fuel chamber to...

Page 970: ...er the studs S Install the 11 washers and nuts that attach the panel to the wing root rib 9 Install the fuel drain valve on the lower surface of the inboard fuel chamber S Install a new seal onto the fuel drain S Install the drain valve into the lower surface of the fuel chamber S Secure the drain valve with lock wire Torque 1 3 Nm 0 73 2 21 lbf ft 10 Install the wing assembly onto the airplane Re...

Page 971: ...iliary Fuel Tank A Remove an Auxiliary Fuel Tank Detail Steps Work Items Key Items References 1 Make sure that the auxiliary fuel tank that you will remove is empty Defuel and drain the auxiliary fuel tank 2 Remove the auxiliary fuel tank access panel from the engine nacelle S Remove the 8 screws that attach the access panel to the nacelle S Disconnect the vent line and the drain line coming from ...

Page 972: ...ear attachment rib Hold the tank 8 Disconnect the front bonding cable at the connection point in the chamber below the tank compartment Accessible through the inspection cover below the tank filler 9 Disconnect the 2 vent hoses at the front wall of the auxiliary fuel tank S Gently move the tank rearward a small distance S Pull the vent lines off the connectors on the tank Through the hole for the ...

Page 973: ...h the hole for the drip tray 3 Connect the front bonding cable at the connection point in the chamber below the tank compartment Accessible through the inspection cover below the tank filler 4 Install the bolt washer and nut which closes the metal strap on the rear attachment rib 5 Install the fuel filler assembly S Install the cover plate with the connection pipe S Install the 3 screws that attac...

Page 974: ...el tank access panel to the engine nacelle S Move the access panel in place on the nacelle S Connect the vent line and the drain line coming from the drip tray to the connectors on the access panel S Install the 8 screws that attach the access panel to the nacelle 10 Refuel the auxiliary fuel tank 11 Check auxiliary fuel tank assembly for leakage ...

Page 975: ...lane The fuel distribution system supplies fuel from the fuel tanks to the engines The components of the fuel distribution system are Flexible fuel hoses Fuel transfer shut off valves Fuel filters Low pressure fuel pump assembly Fuel coolers Fuel pressure pulsation damper Refer to Section 28 00 for a general description of the fuel system and for the schematic diagram of the fuel system ...

Page 976: ...Vent Line 13 Check Valve with Capilare 14 Outboard Fuel Level Sensor 15 Outboard Chamber Main Tank 16 Middle Chamber Main Tank 17 Inboard Fuel Level Sensor 18 Inboard Chamber Main Tank 19 Fuel Temperature Sensor 20 Low Level Fuel Sensor 21 Drain 22 Finger Filter 23 Nacelle 24 Fuel Cooler 25 Fuselage 26 Crossfeed Lines 27 Fuel Selector 28 Fuel Pressure Pulsation Damper LH Wing shown RH Wing similar...

Page 977: ...ne fuel system return line to the return bulkhead fitting located on the engine firewall A flexible fuel hose connects on the nacelle side to the return line of the fuel transfer shut off valve Another flexible hose connects the return of the fuel transfer shut off valve to the related main fuel tank return system During normal operation the fuel returning from the left engine will flow through th...

Page 978: ...7 Inboard Fuel Level Sensor 18 Inboard Chamber Main Tank 19 Fuel Temperature Sensor 20 Low Level Fuel Sensor 21 Drain 22 Finger Filter 23 Nacelle 24 Check Valve 25 Inline Filter 26 Auxiliary Pump 27 Solenoid Valve 28 Finger Filter 29 Fuel Cooler 30 Drain 31 Fuel Level Switch 32 Auxiliary Fuel Filter 33 Auxiliary Tank 34 Check Valve with Capillare 35 Auxiliary Fuel Tank Vent Line 36 Fuselage 37 Cro...

Page 979: ...ply system of the right fuel tank Another flexible hose connects the return port of the left fuel transfer shut off valve to the right return system of the right fuel tank The right engine fuel transfer system is designed similar WARNING SWITCHING ON THE FUEL PUMP IN COMBINATION WITH CROSSFEED MAY CAUSE DAMAGE TO THE HIGH PRESSURE PUMP DUE TO THE HIGH FUEL PRESSURE AFTER SWITCHING ON THE FUEL PUMP...

Page 980: ...4 LH Installation Shown RH Installation Similar Vent Line Fuel Feed Line to Main Fuel Tank Drain Line To Exterior Fuel Pump Inline Filter Check Valve Solenoid Valve Fuel Cooler Auxiliary Tank Return Fuel Line from Engine Figure 3 Auxiliary Fuel Supply to the Main Fuel Tank ...

Page 981: ...uel tank 2 CROSSFEED If you set an engine fuel selector lever to the CROSSFEED position the engine will take fuel from the opposite main fuel tank For example if you set the left fuel selector lever to CROSSFEED and the right fuel control lever to ON then both engines will take fuel from the right main fuel tank If you set the right fuel selector lever to CROSSFEED and the left selector lever to O...

Page 982: ...ible through the nacelle inspection panel on the lower outboard side Flexible hoses connect a fuel distribution bridge which leads into two independent pre filters The pre filters prevent the low pressure fuel pumps from contamination Figure 8 shows the pre filter assembly The pre filters are screwed into independent electrically powered low pressure fuel pumps By turning the FUEL PUMP LH RH ENGIN...

Page 983: ...ble detailed in the Trouble column then read across to the Possible Cause column Then do the repair given in the Repair column Trouble Possible Cause Repair The airplane smells of fuel Hose pipe leaking Loose connection Component leaking Examine all hoses and pipes Replace damaged or defective components Examine all connections Tighten loose connections Examine all components Replace defective com...

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Page 985: ... Obey the safety precautions for fuel at all times Detail Steps Work Items Key Items References 1 Defuel the airplane Refer to Section 12 10 2 Remove the access panels from the related engine nacelle aft of the bulkhead that give access to the fuel transfer shut off valve Refer to Section 52 40 3 Remove the engine cowlings for the related engine Refer to Section 71 10 4 Drain the fuel from the fue...

Page 986: ... fuel tank S The fuel return to the related fuel tank S The fuel return to the opposite fuel tank Refer to Figure 4 Put caps on all the open fuel connections 6 Remove the fuel transfer shut off valve from the bulkhead S Remove the cotter pin from the universal joint S Remove the 4 bolts and washers that attach the valve to the mounting bracket S Remove the bonding wire S Move the valve clear of th...

Page 987: ...ils similar Fuel Selector Lever RH Fuel Selector Lever Safety Guards Fuel Selector Lever LH Fuel Selector Gearbox Fuel Transfer Shut Off Valve Connecting Rod Universal Joint Universal Joint Pin Pin Fuel Selector Rod Assy RH Fuel Selector Rod Assy LH Figure 4 Fuel Transfer Shut Off Valve Installation ...

Page 988: ...h the fuel transfer shut off valve to the bracket S Install the bonding wire Seal the connection with bonding lacquer 4 Connect these fuel connections at the fuel transfer shut off valve S The fuel supply to the engine S The fuel return from the engine S The fuel supply from the related fuel tank S The fuel supply from the opposite fuel tank S The fuel return to the related fuel tank S The fuel re...

Page 989: ...Refer to Section 25 10 2 Remove center console between pilot s and co pilot s seat 3 Remove knobs from the fuel selector levers 4 Remove fuel selector cover plate 5 Push LH fuel selector lever into ON position Make sure that the fuel selector valve is engaged in the ON position 6 Mark the ON position on the outer connecting rod splined tube which connects the fuel selector gearbox with the fuel se...

Page 990: ...uel selector gearbox 14 Disconnect the fuel selector push rods rods between fuel selector levers and fuel selector gearbox directly at the fuel selector gear box 15 Disconnect the LH inner connecting rod from the outer connecting rod Open the three bolts at the connection element below the outer crash element 16 Disconnect the RH inner connecting rod from the outer connecting rod Open the three bo...

Page 991: ...ion at the fuel selector gearbox If necessary adjust the length of the push rods at the designated point Old push rods are not adjustable If necessary exchange these push rods with new ones Make sure that the fuel selector valve is engaged in the ON position For reference use marking on the outer push rod directly at the bushing in the fuselage wall 7 Exchange the drilled part of the connection el...

Page 992: ... parts of the connection element with the three bolts 15 Repeat steps 9 to 14 for the RH connection element 16 Do a functional test of the fuel selector valve Pull fuel selector levers into all positions Make sure that the fuel selector valve is engaged in the respective positions using the marking at the bushing in the fuselage wall as reference 17 Bond new crash element onto the fuel selector ge...

Page 993: ...2 15 Rev 4 28 20 00 Page 209 15 Mar 2018 Fitting Fuel Filter Body Fuel Filter Cap Lock Wire Rubber Worm Drive Clamp Fuel Filter Drain Adapter Drain Fitting Screw Sealing Ring Screw Washer Sealing Ring Plug Figure 5 Fuel Filter Assembly ...

Page 994: ... related FUEL SELECTOR lever is set to SHUT OFF In the cockpit 2 Remove the fuel filter element S Drain the fuel from the fuel distribution system S Remove the safety wire from the filter bowl S Unscrew the filter body together with the drain valve assembly from the filter assembly S Unscrew the drain valve and the drain valve adapter from the fuel filter body Refer to Figure 5 From the fuel sedim...

Page 995: ...243 on adapter to fuel filter body connection 2 Install the filter body assembly into the fuel filter cap Make sure that the integral sealings at the new fuel filter body are not damaged 3 Secure the filter body assembly via the drain valve to the filter assembly with lockwire 4 Do a test for leaks of the filter assembly S Make sure that there is fuel in the related fuel tank S Set the FUEL SELECT...

Page 996: ... Fuel Pump Upper Plate LH Fuel Pump Lower Plate LH Lock Nut Fuel Pump Bracket Washer Screw Washer Screw Hollow Bolt Sealing Ring Solid Bridge M14 Electrical Fuel Pump Worm Drive Clamp Worm Drive Clamp Sealing Ring Fuel Pre Filter Sealing Ring Hollow Bolt Solid Bridge M14 Connector Bracket Assy Figure 6 Fuel Pumps Assembly ...

Page 997: ...AIRCRAFT DA 42 NG AMM Fuel Doc 7 02 15 Rev 4 28 20 00 Page 213 15 Mar 2018 Figure 7 Fuel Pumps Assembly if MÄM 42 480 is installed ...

Page 998: ...n the fuel from the fuel distribution system S Disconnect the fuel hose on the pre filter side S Remove the safety wire from the hollow bolts next to the pre filters S Remove the hollow bolts and the solid bridge next to the pre filters S Remove the pre filter assemblies Refer to Figure 6 From the fuel filter drain Use a suitable container to catch spilt fluid The assemblies will contain fuel B Cl...

Page 999: ...AIRCRAFT DA 42 NG AMM Fuel Doc 7 02 15 Rev 4 28 20 00 Page 215 15 Mar 2018 OUT IN Fuel Filter Casing Male Fuel Filter Casing Female Filter Mesh O Ring Figure 8 Fuel Pre Filter Assembly ...

Page 1000: ...er assembly S Install the solid bridge and the hollow bolts S Connect the fuel hose on the pre filter side S Secure the hollow bolts with safety wire Refer to Figure 6 Torque 18 2 Nm 13 3 1 5 lbf ft 2 Do a test for leaks of the filter assembly S Make sure that there is fuel in the related fuel tank S Reset the circuit breaker of the fuel pumps S Set the FUEL SELECTOR lever to the related tank S Ex...

Page 1001: ...s References 1 Make sure that the engine is safe S Set the ELECT MASTER switch to OFF S Set the ENGINE MASTER switch to OFF S Set the power lever to 0 2 Remove the upper cowlings 3 Remove the P clamp which positions the fuel pressure pulsation damper installation 4 Remove the lock wires at the lines on the fuel pressure pulsation damper housing 5 Disconnect the two fuel lines which are connected t...

Page 1002: ...ev 4 Fuel Return Line Fuel Supply Line Pulsating Damper Assy Pulsation Damper Element O Rings O Rings Damper Housing Damper Housing Note Installation Direction as shown Engine Driven High Pressure Fuel Pump Figure 9 Fuel System Components Firewall Forward LH and RH Engine ...

Page 1003: ...n the inside of the fuel pressure pulsation damper housing No contamination allowed Flush with fuel approved for the airplane 5 Install the four new O rings 6 Apply 09 25300 Fuelube EZTurn 1LB to the outside thread and sealing surface of the fuel pressure pulsation damper housing 7 Install the new fuel pressure pulsation damper in the housing Watch out for the installation direction of the fuel pr...

Page 1004: ...ne 4 Install the upper cowlings 5 Conduct an engine ground run 6 Inspect the airplane for fuel leakage 7 Remove Install the Low Pressure Fuel Pumps Obey the safety precautions for fuel at all times A Remove Replace the Low Pressure Fuel Pumps Detail Steps Work Items Key Items References 1 Make sure that the related FUEL SELECTOR lever is set to SHUT OFF In the cockpit 2 Pull the appropriate circui...

Page 1005: ...tric fuel pumps S Remove the fuel pump assembly from the bracket S Remove the two hollow bolts the solid bridge and the two pre filters from the bottom of the fuel pump assembly S Remove safety wire from plug nuts S Remove the two plug nuts the solid bridge and two check valves from the top of the fuel pump assembly Refer to Figure 7 5 Replace fuel pumps and pre filters Refer to Chapter 05 6 Repla...

Page 1006: ...ire Refer to Figure 6 Hollow bolts torque D 08 18 2 Nm 13 3 1 5 lbf ft D 06 18 2 Nm 13 3 1 5 lbf ft 2 If MÄM 42 480 is carried out Install the low pressure fuel pump assembly S Install the aluminum washers the two pre filters the solid bridge and the two hollow bolts S Install the washers the two check valves the solid bridge and the two plug nuts S Secure plug nuts with safety wire S Install the ...

Page 1007: ...alled Obey the safety precautions for fuel at all times CAUTION YOU MUST REPLACE THE CHECK VALVE IF THE TEST FAILS Detail Steps Work Items Key Items References 1 Make sure that there is no fuel in the related main fuel tank 2 Top off the auxiliary fuel tank 3 Disconnect the fuel transfer line from the Tee fitting of the fuel return line Put a cap on the T fitting 4 Check for any leakage from the s...

Page 1008: ... the engine nacelle S Move the access panel clear of the nacelle At the rear of the engine nacelle On the lower surface of the nacelle Support the panel 3 Disconnect the flexible hoses that connect to the fuel cooler Refer to Figure 10 Use a suitable container to catch spilt fuel Put caps on all open connections 4 Remove the fuel cooler S Remove the 4 bolts and washers that attach the fuel cooler ...

Page 1009: ...AIRCRAFT DA 42 NG AMM Fuel Doc 7 02 15 Rev 4 28 20 00 Page 225 15 Mar 2018 LH shown RH similar Flexible Hose Flexible Hose Fuel Cooler Figure 10 Fuel Cooler Installation ...

Page 1010: ...s and washers that attach the fuel cooler to the brackets 2 Connect the flexible hoses to the fuel cooler Make sure that you remove all the blanking caps 3 Bleed the related fuel distribution system Refer to Paragraph 9 4 Do a test for leaks Specially at the flexible hose connections to the fuel cooler Install the fuel cooler access panel S Move the access panel into position at the rear of the en...

Page 1011: ...to Section 71 00 2 Start the related engine On the side of the fuel selector valve that you want to test Refer to Section 71 00 Make sure that the fuel selector valve is in the ON position 3 Set the fuel selector valve that you want to test in the CROSSFEED position 4 Let the engine idle for 1 minute Refer to Section 71 00 5 Set the related power lever to 100 after engine warm up and keep this pos...

Page 1012: ...ty Defuel and drain the auxiliary fuel tank 2 Remove the auxiliary fuel tank access panel from the engine nacelle S Remove the 8 screws that attach the access panel to the nacelle S Disconnect the vent line and the drain line coming from the drip tray from the connectors on the access panel S Move the access panel clear of the nacelle 3 Disconnect the fuel transfer line from the auxiliary fuel pum...

Page 1013: ...ump outlet 3 Refuel the auxiliary fuel tank Fill more than 2 US gal 7 6 l of fuel into the auxiliary tank 4 Perform a test of the auxiliary fuel transfer system Refer to Paragraph 11 5 Check auxiliary fuel tank assembly for leakage 6 Install the auxiliary fuel tank access panel to the engine nacelle S Move the access panel in place on the nacelle S Connect the vent line and the drain line coming f...

Page 1014: ...t you want to test Make sure that the corresponding main tank is empty enough to hold the auxiliary fuel The auxiliary fuel pump must stop due to the auxiliary tank empty switch 3 Fill 2 US gal 7 6 l of fuel into the auxiliary fuel tank 4 Measure transfer time for transferring the 2 US gal 7 6 l of fuel from the auxiliary tank into the main tank The auxiliary fuel pump must stop due to the auxilia...

Page 1015: ...600 installed The fuel distribution system supplies fuel from the main fuel tanks to the engines The components of the fuel distribution system are Flexible fuel hoses Fuel transfer shut off valves Fuel filters Low pressure fuel pump assembly Refer to Section 28 00 for a general description of the fuel system and for the schematic diagram of the fuel system Refer to Chapter 73 00 for information a...

Page 1016: ... Line 13 Check Valve with Capilare 14 Outboard Fuel Level Sensor 15 Outboard Chamber Main Tank 16 Middle Chamber Main Tank 17 Inboard Fuel Level Sensor 18 Inboard Chamber Main Tank 19 Fuel Temperature Sensor 20 Low Level Fuel Sensor 21 Drain 22 Finger Filter 23 Nacelle 24 Fuel Cooler 25 Fuselage 26 Crossfeed Lines 27 Fuel Selector 28 Fuel Bypass Valve LH Wing shown RH Wing similar 22 19 20 18 17 1...

Page 1017: ...iven high pressure fuel pump A flexible hose connects the engine fuel system return line to the return bulkhead fitting located on the engine firewall via the fuel cooler A flexible fuel hose connects on the nacelle side to the return line of the fuel transfer shut off valve Another flexible hose connects the fuel transfer shut off valve to the related main fuel tank return system During normal op...

Page 1018: ...ard Fuel Level Sensor 18 Inboard Chamber Main Tank 19 Fuel Temperature Sensor 20 Low Level Fuel Sensor 21 Drain 22 Finger Filter 23 Nacelle 24 Check Valve 25 Inline Filter 26 Auxiliary Pump 27 Solenoid Valve 28 Finger Filter 29 Fuel Cooler 30 Drain 31 Fuel Level Switch 32 Auxiliary Fuel Filter 33 Auxiliary Tank 34 Check Valve with Capillare 35 Auxiliary Fuel Tank Vent Line 36 Fuselage 37 Crossfeed...

Page 1019: ...l for the left engine is taken from the right main fuel tank A flexible hose from the left fuel transfer shut off valve connects to the supply system of the right main fuel tank Another flexible hose connects the return port of the left fuel transfer shut off valve to the right return system of the right main fuel tank The right engine fuel transfer system is designed similar ...

Page 1020: ...ev 4 Inline Filter LH Installation Shown RH Installation Similar Vent Line Fuel Line to Main Fuel Tank Drain Line To Exterior Fuel Pump Check Valve if installed Solenoid Valve Auxiliary Tank Figure 3 Auxiliary Fuel Supply to the Main Fuel Tank if MÄM 42 600 is installed ...

Page 1021: ...e will take fuel from the right main fuel tank 2 CROSSFEED If you set an engine fuel selector lever to the CROSSFEED position the engine will take fuel from the opposite main fuel tank For example if you set the left fuel selector lever to CROSSFEED and the right fuel control lever to ON then both engines will take fuel from the right main fuel tank If you set the right fuel selector lever to CROS...

Page 1022: ...cessible through the nacelle inspection panel on the lower outboard side Flexible hoses connect a fuel distribution bridge which leads into two independent pre filters The pre filters prevent the low pressure fuel pumps from contamination Figure 6 shows the pre filter assembly The pre filters are screwed into independent electrically powered low pressure fuel pumps By turning the FUEL PUMP LH RH E...

Page 1023: ...ble detailed in the Trouble column then read across to the Possible Cause column Then do the repair given in the Repair column Trouble Possible Cause Repair The airplane smells of fuel Hose pipe leaking Loose connection Component leaking Examine all hoses and pipes Replace damaged or defective components Examine all connections Tighten loose connections Examine all components Replace defective com...

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Page 1025: ... Obey the safety precautions for fuel at all times Detail Steps Work Items Key Items References 1 Defuel the airplane Refer to Section 12 10 2 Remove the access panels from the related engine nacelle aft of the bulkhead that give access to the fuel transfer shut off valve Refer to Section 52 40 3 Remove the engine cowlings for the related engine Refer to Section 71 10 4 Drain the fuel from the fue...

Page 1026: ... fuel tank S The fuel return to the related fuel tank S The fuel return to the opposite fuel tank Refer to Figure 4 Put caps on all the open fuel connections 6 Remove the fuel transfer shut off valve from the bulkhead S Remove the cotter pin from the universal joint S Remove the 4 bolts and washers that attach the valve to the mounting bracket S Remove the bonding wire S Move the valve clear of th...

Page 1027: ...uel Selector Lever RH Fuel Selector Lever Safety Guards Fuel Selector Lever LH Fuel Selector Gearbox Fuel Transfer Shut Off Valve Connecting Rod Universal Joint Universal Joint Pin Pin Fuel Selector Rod Assy RH Fuel Selector Rod Assy LH Figure 4 Fuel Transfer Shut Off Valve Installation if MÄM 42 600 is installed ...

Page 1028: ...h the fuel transfer shut off valve to the bracket S Install the bonding wire Seal the connection with bonding lacquer 4 Connect these fuel connections at the fuel transfer shut off valve S The fuel supply to the engine S The fuel return from the engine S The fuel supply from the related fuel tank S The fuel supply from the opposite fuel tank S The fuel return to the related fuel tank S The fuel re...

Page 1029: ...Refer to Section 25 10 2 Remove center console between pilot s and co pilot s seat 3 Remove knobs from the fuel selector levers 4 Remove fuel selector cover plate 5 Push LH fuel selector lever into ON position Make sure that the fuel selector valve is engaged in the ON position 6 Mark the ON position on the outer connecting rod splined tube which connects the fuel selector gearbox with the fuel se...

Page 1030: ...uel selector gearbox 14 Disconnect the fuel selector push rods rods between fuel selector levers and fuel selector gearbox directly at the fuel selector gear box 15 Disconnect the LH inner connecting rod from the outer connecting rod Open the three bolts at the connection element below the outer crash element 16 Disconnect the RH inner connecting rod from the outer connecting rod Open the three bo...

Page 1031: ...ion at the fuel selector gearbox If necessary adjust the length of the push rods at the designated point Old push rods are not adjustable If necessary exchange these push rods with new ones Make sure that the fuel selector valve is engaged in the ON position For reference use marking on the outer push rod directly at the bushing in the fuselage wall 7 Exchange the drilled part of the connection el...

Page 1032: ... parts of the connection element with the three bolts 15 Repeat steps 9 to 14 for the RH connection element 16 Do a functional test of the fuel selector valve Pull fuel selector levers into all positions Make sure that the fuel selector valve is engaged in the respective positions using the marking at the bushing in the fuselage wall as reference 17 Bond new crash element onto the fuel selector ge...

Page 1033: ... 21 00 Page 209 15 Mar 2018 Fitting Fuel Filter Body Fuel Filter Cap Lock Wire Rubber Worm Drive Clamp Fuel Filter Drain Adapter Drain Fitting Screw Sealing Ring Screw Washer Sealing Ring Plug Figure 5 Fuel Filter Assembly if MÄM 42 600 is installed ...

Page 1034: ...e drain valve assembly from the filter assembly S Unscrew the drain valve and the drain valve adapter from the fuel filter body Refer to Figure 5 From the fuel sediment bowl drain Use a suitable container to catch spilt fluid B Install the Fuel Filter Body Detail Steps Work Items Key Items References 1 Install the fuel filter drain adapter and the drain valve into the new filter body Refer to Figu...

Page 1035: ...etail Steps Work Items Key Items References 1 Make sure that the related FUEL SELECTOR lever is set to SHUT OFF In the cockpit 2 Pull the appropriate circuit breaker of electrically driven fuel pumps 3 Remove the fuel pre filters S Drain the fuel from the fuel distribution system S Disconnect the fuel hose on the pre filter side S Remove the safety wire from the hollow bolts next to the pre filter...

Page 1036: ...aluminium washers of the fuel pump assembly on the pre filter side S Install the pre filter assembly S Install the solid bridge and the hollow bolts S Install the T fitting bypass valve and bypass fuel line S Connect the fuel hose on the pre filter side S Secure the hollow bolts with safety wire Refer to Figure 8 Torque 18 2 Nm 13 3 1 5 lbf ft 2 Do a test for leaks of the filter assembly S Make su...

Page 1037: ...42 NG AMM Fuel Doc 7 02 15 Rev 4 28 21 00 Page 213 15 Mar 2018 IN Fuel Filter Casing Male Fuel Filter Casing Female Filter Mesh O Ring OUT Retaining Ring Figure 6 Fuel Pre Filter Assembly if MÄM 42 600 is installed ...

Page 1038: ...s References 1 Make sure that the engine is safe S Set the ENGINE MASTER switch to OFF S Set the ELECT MASTER switch to OFF S Set the power lever to 0 2 Remove the upper cowlings 3 Remove the P clamp which positions the fuel pressure pulsation damper installation 4 Remove the lock wires at the lines on the fuel pressure pulsation damper housing 5 Disconnect the two fuel lines which are connected t...

Page 1039: ...ine Fuel Supply Line Pulsating Damper Assy Pulsation Damper Element O Rings O Rings Damper Housing Damper Housing Note Installation Direction as shown Engine Driven High Pressure Fuel Pump Firewall Figure 7 Fuel System Components Firewall Forward LH and RH Engine if MÄM 42 600 is installed ...

Page 1040: ...n the inside of the fuel pressure pulsation damper housing No contamination allowed Flush with fuel approved for the airplane 5 Install the four new O rings 6 Apply 09 25300 Fuelube EZTurn 1LB to the outside thread and sealing surface of the fuel pressure pulsation damper housing 7 Install the new fuel pressure pulsation damper in the housing Watch out for the installation direction of the fuel pr...

Page 1041: ...ation damper assy with fuel approved for the airplane No contamination allowed 2 Connect the fuel pressure pulsation damper housing to the fuel supply lines and secure with locking wire Watch out for the flow direction arrow 3 Install the P clamp and mount the fuel pressure pulsation damper assy to the engine 4 Install the upper cowlings 5 Conduct an engine ground run 6 Inspect the airplane for fu...

Page 1042: ...ove the fuel hoses from the fuel filter assembly S Remove the bypass valve the bypass fuel line and the T fitting S Disconnect the electric wires from the electric fuel pumps S Remove the fuel pump assembly from the bracket S Remove the hollow bolts the solid bridge and the two pre filters from the bottom of the fuel pump assembly S Remove the safety wires from plug nuts S Remove the two plug nuts...

Page 1043: ...afety wire S Install the T fitting the bypass valve and the bypass fuel line S Install the fuel pumps assembly to the bracket S Connect the electric wires to the fuel pumps S Connect the fuel hoses to the bypass valve and the T fitting Refer to Figure 8 Hollow bolts torque 18 2 Nm 13 3 1 5 lbf ft Plug nuts torque 18 2 Nm 13 3 1 5 lbf ft 2 Do a test for leaks of the filter assembly S Make sure that...

Page 1044: ...Fuel Pump Bracket Washer Screw Washer Screw Plug Nut Sealing Ring Solid Bridge M12 Electrical Fuel Pump Worm Drive Clamp Worm Drive Clamp Sealing Ring Fuel Filter Sealing Ring Hollow Bolt Solid Bridge M14 Connector Bracket Assy Check Valve Sealing Ring T Fitting Bypass Valve Bypass Hose OUT Fuel Hose Figure 8 Fuel Pumps Assembly if MÄM 42 600 is installed ...

Page 1045: ...References 1 Make sure that there is no fuel in the related main fuel tank 2 Top off the auxiliary fuel tank 3 Disconnect the fuel transfer line from the check valve Put a cap on the fuel line 4 Check for any leakage from the check valve If leakage is observed replace solenoid valve and check valve 5 Disconnect cap from the check valve and reconnect the fuel transfer line to the check valve 6 Chec...

Page 1046: ... the fuel selector valve is in the ON position 3 Set the fuel selector valve that you want to test in the CROSSFEED position 4 Let the engine idle for 1 minute Refer to Section 71 00 5 Set the related power lever to 100 after engine warm up and keep this position for 1 minute Keep the engine temperature in view Do not continue the test if the engine temperature rises too high 6 Make sure that the ...

Page 1047: ... tank is empty Defuel and drain the auxiliary fuel tank 2 Remove the auxiliary fuel tank access panel from the engine nacelle S Remove the 8 screws that attach the access panel to the nacelle S Disconnect the vent line and the drain line coming from the drip tray from the connectors on the access panel S Move the access panel clear of the nacelle 3 Disconnect the fuel transfer line from the inline...

Page 1048: ...y fuel tank Fill more than 2 US gal 7 6 l of fuel into the auxiliary tank 4 Perform a test of the auxiliary fuel transfer system Refer to Paragraph 11 5 Check auxiliary fuel tank assembly for leakage 6 Install the auxiliary fuel tank access panel to the engine nacelle S Move the access panel in place on the nacelle S Connect the vent line and the drain line coming from the drip tray to the connect...

Page 1049: ...t you want to test Make sure that the corresponding main tank is empty enough to hold the auxiliary fuel The auxiliary fuel pump must stop due to the auxiliary tank empty switch 3 Fill 2 US gal 7 6 l of fuel into the auxiliary fuel tank 4 Measure transfer time for transferring the 2 US gal 7 6 l of fuel from the auxiliary tank into the main tank The auxiliary fuel pump must stop due to the auxilia...

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Page 1051: ...re probes are installed on the inboard end of each inboard fuel chamber Fuel low level Fuel low level sensors are installed on the inboard end of each inboard fuel chamber The fuel quantity in the auxiliary fuel tanks optional equipment OÄM 42 056 is not indicated 3 Operation A Fuel Quantity As the fuel level in the fuel tanks decreases the area of the fuel probes which are wetted with fuel also d...

Page 1052: ...s to the ICS The display shows the temperature of the fuel in the left main fuel tank and in the right main fuel tank The temperature is given in C C Fuel Low Level The fuel low level sensors are float type switches When the fuel in the fuel tank falls to 11 to 15 liter 3 to 4 US gal the float operates a micro switch The micro switch operates an electrical circuit which gives a L R FUEL LOW cautio...

Page 1053: ...Fuel Tank Outboard Fuel Tank Fuel Temperature Sensor Low Fuel Switch Fuel Contents Probe Fuel Contents Probe VIEW ON INBOARD END OF LEFT INBOARD FUEL TANK VIEW ON INBOARD END OF LEFT OUTBOARD FUEL TANK A B B A LH Tank Shown RH Tank Similar Figure 1 Fuel Indicating System Components ...

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Page 1055: ...flush the water out of the fuel quantity probe Repeat defueling refueling until the fuel quantity probe indicates correct values If the indication is still incorrect after the third attempt replace the fuel probe s Do a test of the fuel quantity indicating system wiring Refer to Chapter 92 00 for the wiring diagrams Fuel quantity indication on both tanks incorrect Fuel quantity display on ICS defe...

Page 1056: ... tank Fuel low level switch defective Fuel low level warning wiring defective Replace the related fuel low level switch Do a test of the fuel low level warning system wiring Refer to Chapter 92 00 for the wiring diagrams Fuel low level warning fails to operate in both fuel tanks Fuel low level caution on ICS defective Refer to the ICS manufacturer s manual ...

Page 1057: ... EQUIPMENT WARNING DO NOT BREATHE FUEL VAPOR FUEL VAPOR CAN MAKE YOU ILL 2 Remove Install a Fuel Quantity Probe The inboard and outboard chambers of each main fuel tank assembly has a fuel quantity probe Obey the safety precautions for fuel at all times A Remove a Fuel Quantity Probe Detail Steps Work Items Key Items References 1 Remove the outer wing section that has the fuel quantity probe s tha...

Page 1058: ...o the guide tube in the fuel chamber and engage the screw thread S Turn the probe clockwise by hand until the fuel quantity probe is fully engaged in its mount S Tighten the fuel quantity probe until the O ring seals Use Loctite 243 similar Make sure that the fuel quantity probe is correctly located 2 Install the fuel tank assembly into the outer wing section Refer to Section 28 10 3 Install the o...

Page 1059: ...ction that has the fuel temperature sensor that you will remove and support the wing on trestles Refer to Section 57 10 2 Remove the access panel from the wing root rib S Remove the 11 nuts and washers that attach the access panel to the root rib S Move the access panel clear of the root rib 3 Unscrew the temperature sensor from the mounting boss and pull the sensor clear of the tank Install a bla...

Page 1060: ... wing root rib S Install the 11 washers and nuts that attach the access panel to the wing root rib 4 Install the wing onto the airplane Refer to Section 57 10 5 Refuel transfer fuel into the fuel tank assembly for which you installed the temperature sensor 6 Bleed the fuel system Refer to Section 28 20 7 Do a test for fuel leaks at the temperature sensor that you replaced 8 Do a test for the corre...

Page 1061: ...rk Items Key Items References 1 Defuel the main fuel tank related to the fuel low level switch that will be removed Refer to Section 12 10 2 Remove the wing Refer to Section 57 10 3 Remove the access panel from the wing root rib S Remove the 11 nuts and washers that attach the access panel to the root rib S Move the access panel clear of the root rib 4 Unscrew the fuel low level sensor from the in...

Page 1062: ...ach the access panel to the wing root rib 3 Install the wing Refer to Section 57 10 4 Refuel transfer fuel into the fuel tank assembly for which you installed the low level sensor Monitor the ICS alert panel and S Note the fuel level indication at which the related L R FUEL LOW caution goes out S Stop the refuel transfer S Transfer fuel out from the related fuel tank S Note the fuel level indicati...

Page 1063: ...Remove a Fuel High Level Shut Off Sensor Detail Steps Work Items Key Items References 1 Defuel the main fuel tank related to the fuel high level shut off sensor that will be removed Refer to Section 12 10 2 Remove the wing Refer to Section 57 10 3 Remove the main fuel tank assembly Refer to Section 28 10 4 Unscrew the fuel high level shut off sensor from the outer tank chamber ...

Page 1064: ...nstall the wing onto the airplane Refer to Section 57 10 6 Bleed the fuel system If necessary refuel or transfer a small amount of fuel into both fuel tanks Refer to Section 28 20 7 Refuel transfer fuel into the fuel tank assembly for which you installed the low level sensor Monitor the ICS alert panel and S Note the fuel level indication at which the related L R FUEL LOW caution goes out S Stop t...

Page 1065: ...AIRCRAFT DA 42 NG AMM Hydraulic Power Doc 7 02 15 Rev 4 29 TITLE Page 1 15 Mar 2018 CHAPTER 29 HYDRAULIC POWER ...

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Page 1067: ...System 203 3 Depressurize the Hydraulic System 206 4 Bleed the Hydraulic System 207 5 Drain Fluid from the Hydraulic System 209 6 Remove Install the Relay 211 7 Remove Install the Hydraulic Reservoir 212 9 Remove Install Hydraulic Pump 220 10 First Fill Replenishment of the Hydraulic System 222 11 Tests of the Hydraulic System 225 12 Filters 238 13 Valves 241 14 Remove Install Disassemble Assemble...

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Page 1069: ...ral This Chapter tells you about the hydraulic system of the DA 42 NG It gives you the system description It also gives you the trouble shooting data and tells you how to remove and install the main components of the hydraulic system Note Refer to Section 20 90 before starting maintenance work in the center wing area ...

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Page 1071: ...2 NG The Trouble Shooting section provides information about possible causes and repair procedures 2 Description The hydraulic main unit contains all components which are necessary to produce the hydraulic power for the DA 42 NG It consists of the hydraulic pump the hydraulic fluid tank the hydraulic main control block and the hydraulic accumulator The hydraulic main unit is shown in Figure 1 ...

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Page 1073: ...of hydraulic reservoir is too low Pump draws air and runs with high speed Check the fill quantity of the hydraulic reservoir Replenish the hydraulic reservoir with fluid Refer to Section 29 10 check reason of fluid leakage Bottom solenoid valve is not switching S No voltage supply on the solenoid valve S Solenoid valve does not switch power is switched on and off Check fuses power supply and cable...

Page 1074: ...lay Replace landing gear switch Check hydraulic pump and replace if damaged Landing gear is retracting too slow Dump valve is not fully closed high re pump cycles Close dump valve Tighten hexagon socket with 6 10 Nm 4 4 7 4 lbf ft Tighten counter nut with 8 Nm 5 9 lbf ft See Figure 1 Poor motor pump performance S Power supply low Check power supply Top solenoid valve is switched ON i e differentia...

Page 1075: ...h 6 10 Nm 4 4 7 4 lbf ft Tighten counter nut with 8 Nm 5 9 lbf ft See Figure 1 Pressure limitation valve is not working properly Wrong system pressure Check pressure limitation valve Refer to Section 29 10 Replace pressure limitation valve Refer to Section 29 10 Level of hydraulic fluid in the hydraulic reservoir is too low Pump draws air and runs with high speed Check the level of the hydraulic r...

Page 1076: ...ing gear Dump valve is not fully closed high re pump cycles Close dump valve Tighten hexagon socket with 6 10 Nm 4 4 7 4 lbf ft Tighten counter nut with 8 Nm 5 9 lbf ft See Figure 1 Solenoid valves are not fully closing Leakage caused by dirt or low supply voltage High rate of re pump cycles or permanent operation of the pump Check power supply and solenoid valves Replace solenoid valve Refer to S...

Page 1077: ...tor to appropriate pressure Pressure limitation valve is not working properly Wrong system pressure Check pressure limitation valve Refer to Section 29 10 Replace pressure limitation valve Leakage of the emergency extension block Occurs only when retracting the landing gear Check Bowden cables Replace the emergency extension block Refer to Section 29 10 Re pump time of the pump is too short less t...

Page 1078: ...e High rate of re pump cycles or permanent operation of the pump Check power supply and solenoid valves Replace solenoid valve Refer to Section 29 10 Emergency extension slow or not completed High stream resistance in the hydraulic system Check hydraulic hoses for damage Note Emergency extension does not fully extend on the ground because of missing aerodynamic forces Pull the gear backwards to ex...

Page 1079: ...o Section 25 10 Refer to Section 25 60 2 Charge the hydraulic accumulator S Set the ELECT MASTER switch to ON S The hydraulic pump must operate until the system pressure stabilizes S The hydraulic pump must stop operating S Set the ELECT MASTER switch to OFF Approx 16 4 3 sec with a completely empty accumulator 3 Check the fluid level on the hydraulic reservoir S The accumulator must be fully char...

Page 1080: ...AIRCRAFT Hydraulic Power DA 42 NG AMM Page 202 15 Mar 2018 29 10 00 Doc 7 02 15 Rev 4 Figure 1 Hydraulic Supply and Control Assembly ...

Page 1081: ...IDENTALLY WARNING DO NOT GET HYDRAULIC FLUID ON YOU HYDRAULIC FLUID CAN CAUSE SKIN DISEASE IT CAN ALSO DAMAGE CLOTHING CAUTION CLEAN OFF SPILT HYDRAULIC FLUID IMMEDIATELY HYDRAULIC FLUID CAN DAMAGE THE AIRPLANE STRUCTURE IT CAN ALSO REMOVE THE PAINT FROM SOME COMPONENTS CAUTION DO NOT OPERATE THE HYDRAULIC PUMP WITH LOW FLUID LEVEL THE PUMP WILL HEAT UP AND GETS DAMAGED Details Steps Work Items Ke...

Page 1082: ...essure filter Refer to Section 29 10 11 Maintain the hydraulic reservoir filter Refer to Section 29 10 12 First fill replenish the hydraulic system Refer to Section 29 10 13 Bleed the accumulator Refer to Section 29 10 14 Bleed the hydraulic system Refer to Section 29 10 15 Reset the GEAR circuit breaker Right side of instrument panel 16 Do the normal operation test for the hydraulic system Refer ...

Page 1083: ...r to AMM for refilling or fluid change C Fluid Change of the Hydraulic System from Aero Shell Fluid 41 to AMG 10 Detail Steps Work Items Key Items References 1 Repeat the Fluid Change of the Hydraulic System procedure 3 times Refer to Paragraph B 2 Apply the hydraulic fluid placard and mark the used fluid Refer to Figure 2 Mark hydraulic fluid type by punching Figure 2 Position of the Hydraulic Fl...

Page 1084: ... wire from the dump valve S Loosen the counter nut S Loosen the hexagon socket to open the dump valve S After emptying wait 10 to 15 min until the accumulator is thermally balanced Wrench size 19 mm Wrench size 1 4 in 5 Operate the pressure button on the upper solenoid valve Located on the top of the hydraulic control block See Figure 4 Use a little metal pin or ball pen to operate the button 6 Ch...

Page 1085: ...OUND THE AIRPLANE BEFORE YOU PERFORM MAINTENANCE ON THE LANDING GEAR THE LANDING GEAR RETRACTION SYSTEM CAN CAUSE SERIOUS INJURY TO PERSONS IF OPERATED ACCIDENTALLY CAUTION MAKE SURE THAT THE AREA AROUND THE AIRPLANE IS CLEAR IF THE LANDING GEAR HITS AN OBJECT THE LANDING GEAR CAN BE DAMAGED 1 Pull the GEAR circuit breaker Right side of instrument panel 2 Raise the airplane on jacks and move the w...

Page 1086: ...the dump valve should be operated 3 to 4 times to release possible air pockets Refer to Paragraph 7 in Chapter 32 30 Landing Gear Extension and Retraction Test Check the times of extending and retracting the landing gear Refer to Section 29 10 5 Operate the emergency extension of the landing gear repeat this step 1 to 2 times Refer to Section 29 10 6 Move the wing and rear fuselage trestles clear ...

Page 1087: ...ide of instrument panel 2 Getting access to the hydraulic system S Fold the rear passenger seat backs forward S Remove the rear baggage compartment lower access panel Refer to Section 25 10 Refer to Section 25 60 3 Prepare the drain hose S Put a container under the drain hose to collect spilt hydraulic fluid Use a drain hose which can be connected to the MiniMess 1215 plug Refer to Figure 4 4 Inst...

Page 1088: ...ELECT MASTER switch to ON S The hydraulic pump starts pumping and drains hydraulic fluid into the container S Turn the ELECT MASTER switch to OFF For most Maintenance Practices it s the best to drain approx liter of hydraulic fluid from the fully filled hydraulic system 7 Remove the drain hose S Remove the drain hose from the MiniMess 1215 plug S Install the protection cap back onto the plug ...

Page 1089: ... the rear passenger seat backs forward S Remove the rear baggage compartment lower access panel Refer to Section 25 10 Refer to Section 25 60 3 Disconnect all electric connectors from the relay Remember how the cables where connected to the relay 4 Remove the 2 bolts which hold the relay onto the mounting plate 5 Install the new relay with two bolts onto the hydraulic panel 6 Reconnect all electri...

Page 1090: ...lic Reservoir Detail Steps Work Items Key Items References 1 Getting access to the hydraulic system S Fold the rear passenger seat backs forward S Remove the rear baggage compartment lower access panel Refer to Section 25 10 Refer to Section 25 60 2 Depressurize the hydraulic system Refer to Section 29 10 3 Remove the hydraulic supply and control assembly Refer to Section 32 30 4 Draining the hydr...

Page 1091: ... Hydraulic Reservoir Detail Steps Work Items Key Items References 1 Install the hydraulic reservoir S Move the reservoir into position S Install the 4 bolts onto the clamp to secure the hydraulic tank S Install the intake line and the return line onto the reservoir 2 Install the hydraulic supply and control assembly Refer to Section 32 30 3 Replenish the hydraulic reservoir with hydraulic fluid Re...

Page 1092: ...IRCRAFT Hydraulic Power DA 42 NG AMM Page 214 15 Mar 2018 29 10 00 Doc 7 02 15 Rev 4 Fill Port Lid Filter Fitting Drain Hose Drain Port Hydraulic Reservoir Figure 3 DA 42 NG Hydraulic Reservoir Assembly ...

Page 1093: ...etail Steps Work Items Key Items References WARNING TAKE PRECAUTIONS BY SECURING THE AREA AROUND THE AIRPLANE BEFORE YOU PERFORM MAINTENANCE ON THE LANDING GEAR THE LANDING GEAR RETRACTION SYSTEM CAN CAUSE SERIOUS INJURY TO PERSONS IF OPERATED ACCIDENTALLY 1 Pull the GEAR circuit breaker Right side of instrument panel 2 Raise the airplane on jacks and move the wing and rear fuselage trestles into ...

Page 1094: ...he hydraulic pump pressure switch S Disconnect the electrical cables from the hydraulic pump motor At the in line connectors At the in line connectors At the hydraulic pump electric motor 6 Disconnect the flexible cable from the emergency extension valve S Loosen the bolt on the cable swivel fitting S Move the cable clear of the swivel fitting S Release the cable clamp and move the cable clear of ...

Page 1095: ...ttach the bonding strip and earth cable in the location noted in Paragraph 8 B step 7 2 Connect these flexible hydraulic hoses to the hydraulic supply and control assembly S The 3 return hoses to the hydraulic manifold S The supply hose to the hydraulic manifold Make sure that all the blanking caps are removed 3 Connect these electrical cables to the hydraulic supply and control assembly S Connect...

Page 1096: ...old the lever in the cockpit to the EMERGENCY position S Set the lever in the cockpit to the NORMAL position The emergency valve at the supply and control panel must be in the emergency position The hydraulic pump cut out micro switch must be open The emergency valve at the supply and control panel must be in the normal position The hydraulic pump cut out micro switch must be closed 6 If necessary...

Page 1097: ...tail Steps Work Items Key Items References Doc 7 02 15 Rev 4 29 10 00 Page 219 15 Mar 2018 12 Move the wing and fuselage trestles clear of the airplane 13 Lower the airplane with the jacks Make sure that the area around the airplane is clear ...

Page 1098: ...r seat backs forward S Remove the rear baggage compartment lower access panel Refer to Section 25 10 Refer to Section 25 60 3 Depressurize the hydraulic system Refer to Section 29 10 4 Drain fluid from the hydraulic system Refer to Section 29 10 The fluid level should be lower than the hydraulic lines of the motor pump 5 Disconnect the motor pump S Disconnect the two hydraulic connectors from the ...

Page 1099: ...nectors onto the motor S Remove the caps from the hydraulic lines and the pump S Connect the two hydraulic connectors onto the pump M8 nut Torque 13 Nm 9 6 lbf ft 9 If hydraulic fluid was drained replenish the hydraulic reservoir with hydraulic fluid Refer to Section 29 10 10 Bleed the accumulator Refer to Section 29 10 11 Bleed the hydraulic system Refer to Section 29 10 12 Do the normal operatio...

Page 1100: ... The identification placard must be installed if a hydraulic fluid change to another fluid type is carried out Hydraulic fluid As required Aeroshell Fluid 41 MIL PRF 5606 H or AMG 10 GOST 6794 75 Amdt 1 5 see CAUTION above B Fluid Capacity Item Capacity Hydraulic reservoir 0 9 l 0 24 US gal mid leve on the inspection glass Extended landing gear when hydraulic actuators are retracted Both actuators...

Page 1101: ...AR RETRACTION SYSTEM CAN CAUSE SERIOUS INJURY TO PERSONS IF OPERATED ACCIDENTALLY CAUTION MAKE SURE THAT THE AREA AROUND THE AIRPLANE IS CLEAR IF THE LANDING GEAR HITS AN OBJECT THE LANDING GEAR CAN BE DAMAGED 1 Pull the GEAR circuit breaker Right side of instrument panel 2 Raise the airplane on jacks and move the wing and rear fuselage trestles into position to support the airplane Refer to Secti...

Page 1102: ... pump which connects to the FILL port of the hydraulic reservoir See Figure 3 6 Reset the GEAR circuit breaker Right side of instrument panel 7 Charge the hydraulic accumulator S Set the ELECT MASTER switch to ON S The hydraulic pump must operate until the system pressure stabilizes S The hydraulic pump must stop operating S Set the ELECT MASTER switch to OFF Approx 16 4 3 sec with a completely em...

Page 1103: ...ail Steps Work Items Key Items References 1 Pull the GEAR circuit breaker Right side of instrument panel 2 Get access to the hydraulic system S Fold the rear passenger seat backs forward S Remove the rear baggage compartment lower access panel Refer to Section 25 10 Refer to Section 25 60 3 Depressurize the hydraulic system Refer to Section 29 10 4 Reset the GEAR circuit breaker Right side of inst...

Page 1104: ...cting Time of the Landing Gear These values assume that the hydraulic system is fully bled Cycle Set point Retracting 7 2 1 sec Follow up time of the pump 12 3 2 sec respectively 15 sec for control blocks rev D Extending 7 2 1 sec Follow up time of the pump 12 3 2 sec respectively 15 sec for control blocks rev D Note Make sure to raise the airplane according to Section 07 10 and connect an externa...

Page 1105: ...al mode is OFF Refer to Section 25 10 Refer to Section 25 60 A magnetic testing device P NX11 P005 can also be used to test the solenoid valve 3 In case the solenoid valve is not energized check the micro switches in the nose landing gear bay Refer to Section 32 60 4 Internal Leak Tightness High re pump cycles as a result of internal leakage at the fully bled system are usually a maximum of one cy...

Page 1106: ...CTION SYSTEM CAN CAUSE SERIOUS INJURY TO PERSONS IF OPERATED ACCIDENTALLY CAUTION MAKE SURE THAT THE AREA AROUND THE AIRPLANE IS CLEAR IF THE LANDING GEAR HITS AN OBJECT THE LANDING GEAR CAN BE DAMAGED 1 Pull the GEAR circuit breaker Right side of the instrument panel 2 Raise the airplane on jacks and move the wing and rear fuselage trestles into position to support the airplane Refer to Section 0...

Page 1107: ...lve S Tighten the counter nut S Install the lock wire onto the dump valve 6 10 Nm 4 4 7 4 lbf ft wrench size 1 4 in 8 Nm 5 9 lbf ft wrench size 19 mm 7 Reset the GEAR circuit breaker Right side of instrument panel 8 Emergency extension S Operate the emergency extension micro switch Located on the hydraulic main control block This causes the solenoid valves to switch off and the landing gear extend...

Page 1108: ...EAR RETRACTION SYSTEM CAN CAUSE SERIOUS INJURY TO PERSONS IF OPERATED ACCIDENTALLY CAUTION MAKE SURE THAT THE AREA AROUND THE AIRPLANE IS CLEAR IF THE LANDING GEAR HITS AN OBJECT THE LANDING GEAR CAN BE DAMAGED 1 Pull the GEAR circuit breaker Right side of the instrument panel 2 Raise the airplane on jacks and move the wing and rear fuselage trestles into position to support the airplane Refer to ...

Page 1109: ...igure 4 If your hydraulic system is an old revision without the MiniMess 1215 plug contact the vendor to get it installed Note Make sure to use clean hydraulic fluid with the hand pump for testing the hydraulic system Don t overfill the hydraulic reservoir by pumping too much hydraulic fluid with the hand pump into the system 9 Adjust the pressure limitation valve of the hand pump to 190 bar 2775 ...

Page 1110: ...hydraulic system to 180 bar 2610 PSI S The protection valve should open and after the valve closes and the pressure in the hydraulic system is stabilized the pressure is steady at 150 bar 2175 PSI Refer to Figure 4 12 Move the wings and rear fuselage trestles clear of the airplane 13 Lower the airplane with the jacks Make sure that area around the airplane is clear 14 Reset the GEAR circuit breake...

Page 1111: ...allowed Maximum a little amount of dried fluid on the cylinder head respectively on the piston rod end Note After fixing a leakage on the fittings or hose connections a leak tightness test has to be done 1 External Leakage In general you should check if there is any damage of the piston of the hydraulic actuator when the landing gear is retracted Refer to Section 32 30 Landing Gear Extension and R...

Page 1112: ...ycles Max leakage 1 drop of fluid Note If one of the measurements don t comply with these set points send the actuator to the vendor for a repair Otherwise you can continue the operation but observe the situation E Pump Pressure Switch and Pressure Limitation Valve Operation Test 1 Equipment Item Quantity Part Number Airplane jacks 3 Commercial Wing trestle 2 Commercial Rear fuselage trestle 1 Com...

Page 1113: ...ear fuselage trestles into position to support the airplane Refer to Section 07 10 3 Connect an external power supply to the airplane Refer to Section 24 40 4 Get access to the hydraulic system S Fold the rear passenger seat backs forward S Remove the rear baggage compartment lower access panel Refer to Section 25 10 Refer to Section 25 60 5 Remove the protection cap from the test plug MiniMess 12...

Page 1114: ...g properly 8 Check closing point of the pump pressure switch S Retract the landing gear fully S Operate the emergency extension lever just a little bit so that the micro switch on the emergency extension doesn t switch but that the valve is opened a little bit S The pressure on the manometer should decrease S When the pump switches on read the manometer value Refer to Section 32 30 Paragraph 7 See...

Page 1115: ...eases slowly S Now wait approx 20 sec so that the accumulator can charge fully S Slowly close the dump valve completely and check the pressure with the manometer S Tighten the hexagon socket to close the dump valve S Tighten the counter nut S Install the lock wire onto the dump valve Refer to Section 32 30 Adjust the dump valve so that the circulation pressure is at 110 bar 1595 PSI Set point 114 ...

Page 1116: ...ld the rear passenger seat backs forward S Remove the rear baggage compartment lower access panel Refer to Section 25 10 Refer to Section 25 60 3 Remove the vent hose by disconnecting the 90 fitting on the top of the hydraulic reservoir In case you have an old revision without drain hose skip this step Refer to Figure 3 4 Maintain the filter assembly fitting and filter S Remove the lock wire from ...

Page 1117: ...References Doc 7 02 15 Rev 4 29 10 00 Page 239 15 Mar 2018 6 Install the rear baggage compartment lower access panel Refer to Section 25 60 7 Fold the rear passenger seat backs backwards Refer to Section 25 10 8 Reset the GEAR circuit breaker Right side of instrument panel ...

Page 1118: ...0 3 Replace high pressure filter S Remove filter housing S Pull the old filter element clear of the filter body S Push and slightly turn the filter element into the filter body until it s secure S Install filter housing Refer to Figure 1 Put paper towel underneath to avoid spilling of hydraulic fluid Metal paper filter element Tighten the filter housing with your hand approx 5 Nm 3 7 lbf ft 4 Inst...

Page 1119: ...trument panel 2 Getting access to the hydraulic system S Fold the rear passenger seat backs forward S Remove the rear baggage compartment lower access panel Refer to Section 25 10 Refer to Section 25 60 3 Depressurize the hydraulic system Refer to Section 29 10 4 Drain fluid from the hydraulic system Refer to Section 29 10 The fluid level of the reservoir should be lower than the top surface of th...

Page 1120: ...fluid was drained in step 3 replenish the hydraulic reservoir with hydraulic fluid Refer to Section 29 10 7 Bleed the accumulator Refer to Section 29 10 8 Bleed the hydraulic system Refer to Section 29 10 9 Do the normal operation test for the hydraulic system Refer to Section 29 10 10 Reset the GEAR circuit breaker Right side of instrument panel ...

Page 1121: ...e the rear baggage compartment lower access panel Refer to Section 25 10 Refer to Section 25 60 3 Depressurize the hydraulic system Refer to Section 29 10 4 Drain fluid from the hydraulic system Refer to Section 29 10 The fluid level of the reservoir should be lower than the top surface of the main control block 5 Remove the pump pressure switch S Remove the electric connector from the switch S Re...

Page 1122: ...ft 8 Install the pump pressure switch S Install the switch S Install the electric connector back onto the switch Use wrench size 27 mm Apply Rivolta F L A onto the thread and tighten with 18 Nm 13 3 lbf ft 9 If hydraulic fluid was drained in step 3 replenish the hydraulic reservoir with hydraulic fluid Refer to Section 29 10 10 Bleed the accumulator Refer to Section 29 10 11 Bleed the hydraulic sy...

Page 1123: ... instrument panel 2 Remove the electric connector from the solenoid valve 3 Remove the knurled nut on the top of the valve Use special tool to remove the nut 4 Remove the solenoid valve from the shaft Make sure all the O rings are removed from the shaft 5 Install the new solenoid valve onto the shaft Tighten the valve by hand approx 5 Nm 3 7 lbf ft Make sure the valve is installed properly otherwi...

Page 1124: ...ide of instrument panel 2 Getting access to the hydraulic system S Fold the rear passenger seat backs forward S Remove the rear baggage compartment lower access panel Refer to Section 25 10 Refer to Section 25 60 Note Make sure when loosening the counter nut that you don t accidentally loosen the whole accumulator charging valve 3 Releasing the nitrogen from the accumulator S Remove the yellow pro...

Page 1125: ...ody not the counter nut S Install the new accumulator charging valve MS 28889 2 standard valve is used Use wrench size in Apply Rivolta F L A onto the thread and tighten the valve with 25 Nm 18 4 lbf ft 5 Charge the accumulator with nitrogen Refer to Section 29 10 6 Test the accumulator charging valve for leak tightness Apply some leak finder spray onto the valve and look for air bubbles 7 Reset t...

Page 1126: ...the hydraulic system Refer to Section 29 10 3 Drain fluid from the hydraulic system Refer to Section 29 10 The fluid level should be lower than the hydraulic control manifold 4 Remove the flow regulation valves S Remove the valves and two seal rings on each valve S Make sure to catch spilt hydraulic fluid Wrench size 22 mm 5 Install flow regulation valves S Install the M1 7 valve in the middle hol...

Page 1127: ...ROM SOME COMPONENTS A Remove the Hydraulic Control Block Detail Steps Work Items Key Items References 1 Getting access to the hydraulic system S Fold the rear passenger seat backs forward S Remove the rear baggage compartment lower access panel Refer to Section 25 10 Refer to Section 25 60 2 Depressurize the hydraulic system Refer to Section 29 10 3 Remove all seven hydraulic hoses from the hydrau...

Page 1128: ...lock but don t tighten them yet Use hexagon socket size 4 2 Connect the Bowden cable onto the emergency extension module Refer to Figure 4 3 Install the emergency extension micro switch Refer to Figure 4 4 Install all electrical connections onto the hydraulic control block Pump pressure switch connector solenoid valve connections Check polarity of solenoid valve connections 5 Install all seven hyd...

Page 1129: ...ASE IT CAN ALSO DAMAGE CLOTHING CAUTION CLEAN OFF SPILT HYDRAULIC FLUID IMMEDIATELY HYDRAULIC FLUID CAN DAMAGE THE AIRPLANE STRUCTURE IT CAN ALSO REMOVE THE PAINT FROM SOME COMPONENTS Detail Steps Work Items Key Items References 1 Remove hydraulic control block Refer to Section 29 10 2 Remove the four bolts from the control block size 4 hexagon socket head 3 Separate the three main blocks Refer to...

Page 1130: ...vertical so that seal rings can be installed easier S Install the seal rings onto the blocks Refer to Figure 4 So that the plane surface where the seals get installed is horizontal Make sure there is no dirt on the plane surfaces otherwise the control block may be leaking 2 Install the four bolts to secure the three main parts S Apply some Loctite 243 onto each bolt thread to secure it S Install t...

Page 1131: ... Block Protection Valve Pressure Button Top Magnetic Valve Microswitch Emergency Extension Lever Emergency Extension Block O Ring O Ring Hydraulic Supply Manifold Bolt Current Regulation Valve Knurled Nut Bottom Magnetic Valve Electric Connector Bolts Remove Install Control Block Mini Mess 1215 Dump Valve Pump Pressure Switch Figure 4 Hydraulic Control Block ...

Page 1132: ... until the system pressure stabilizes The hydraulic pump must stop operating 6 Set the ELECT MASTER switch to OFF 7 Open the dump valve S Remove the lock wire from the dump valve S Loosen the counter nut S Loosen the hexagon socket to open the dump valve S After emptying wait 10 15 min until the accumulator is thermally balanced Wrench size 19 mm Wrench size 1 4 in 8 Close the dump valve S Tighten...

Page 1133: ...Right side of instrument panel 2 Open the dump valve S Remove the lock wire from the dump valve S Loosen the counter nut S Loosen the hexagon socket to open dump valve S After emptying wait 10 15 min until the accumulator is thermally balanced Wrench size 19 mm Wrench size 1 4 in 3 Operate the pressure button on the upper solenoid valve on the top of the hydraulic control block See Figure 4 Use a ...

Page 1134: ...corrosion protection Tighten with 5 6 Nm 3 7 4 4 lbf ft 3 Check the hydraulic fluid level of the hydraulic reservoir Refer to Section 29 10 4 Bleed the hydraulic system Refer to Section 29 10 5 Bleed the accumulator Refer to Section 29 10 6 Do the normal operation test for the hydraulic system Refer to Section 29 10 16 Check the Accumulator The accumulator should be tested every 200 hours of opera...

Page 1135: ...42 NG AMM Hydraulic Power Doc 7 02 15 Rev 4 29 10 00 Page 257 15 Mar 2018 Protection Cap Screw Washer Clamp Fitting Hydraulic Hose Bolt Accumulator Fitting Charging Valve Figure 5 Hydraulic Accumulator Installation ...

Page 1136: ... pressure valve WARNING IF THE HOSE OF THE MANOMETER IS NOT CONNECTED PROPERLY TO THE HIGH PRESSURE VALVE NITROGEN CAN LEAK FROM THE ACCUMULATOR IF THAT IS THE CASE CLOSE THE COUNTER NUT IMMEDIATELY AND CHECK ALL CONNECTIONS AGAIN THE ACCUMULATOR HASTO BEREFILLED ACCORDING TO SECTION 29 10 PARAGRAPH 17 3 Connecting the test manometer S Remove the yellow protection cap from the high pressure valve ...

Page 1137: ... the counter nut on the valve with 10 Nm 7 4 lbf ft S Remove the manometer from the adapter S Remove the Adapter MS28889 2 MiniMess 1615 from the valve S Put the yellow protection cap back onto the high pressure valve 6 Reset the GEAR circuit breaker Right side of instrument panel 7 Check for correct charging time of the hydraulic accumulator S Set the ELECT MASTER switch to ON S The hydraulic pum...

Page 1138: ...ument panel 2 Get access to the hydraulic system S Fold the rear passenger seat backs forward S Remove the rear baggage compartment lower access panel Refer to Section 25 10 Refer to Section 25 60 3 Depressurize the hydraulic system Refer to Section 29 10 Note Make sure when loosening the counter nut on the accumulator that you don t accidentally loosen the whole high pressure valve WARNING IF THE...

Page 1139: ...e charging hose onto the adapter S Loosen the counter nut on the high pressure valve until it reaches the end face Now slowly continue to loosen the nut this will cause the valve to open 5 Charge the accumulator S Read the pressure on the manometer of the pressure reducer S Charge the accumulator to a pressure of 85 90 bar 1233 1305 PSI S Close the valve on the nitrogen bottle and wait 10 min unti...

Page 1140: ... 4 lbf ft S Close the valve on the nitrogen bottle and release the remaining pressure with the pressure reducer S Remove the nitrogen bottle from the adapter S Remove the Adapter MS28889 2 MiniMess 1615 from the valve S Put the yellow protection cap back onto the high pressure valve 7 Reset the GEAR circuit breaker Right side of instrument panel 8 Check operation of the hydraulic accumulator Refer...

Page 1141: ...AIRCRAFT DA 42 NG Series AMM Ice Protection System Doc 7 02 15 Rev 4 30 TITLE Page 1 15 Mar 2018 CHAPTER 30 ICE PROTECTION SYSTEM ...

Page 1142: ...AIRCRAFT Ice Protection System DA 42 NG Series AMM Page 2 15 Mar 2018 30 TITLE Doc 7 02 15 Rev 4 Intentionally left blank ...

Page 1143: ... 206 5 Remove Install the De Icing Fluid Inlet Strainer 208 6 Remove Install a De Icing Metering Pump 210 7 Replace the Filter Cartridge or Windshield Pump or Solenoid Valve 211 8 Bleed the De Icing System 213 9 Purge the De Icing System 214 10 Remove Install a Proportioning Unit 214 11 Replace an Ice Protection Porous Panel 215 12 Replace De Icing Fluid Nylon Tubing 216 13 Replace Ice Protection ...

Page 1144: ...AIRCRAFT Ice Protection System DA 42 NG Series AMM Page 2 15 Mar 2018 30 CONTENTS Doc 7 02 15 Rev 4 Intentionally left blank ...

Page 1145: ...t gives you general data and the trouble shooting data on the system Refer to CAV Aerospace Ltd for data on the ice protection system The ice protection system prevents accumulation of ice by distributing a thin film of a special de icing fluid on the wings horizontal stabilizer vertical stabilizer propellers and canopy The area on the panels at which de icing fluid weeps out through many fine hol...

Page 1146: ...e Nozzle Spray Nozzle Metering Pumps Filler Neck with Inlet Strainer HP Switch Filters Windshield Pumps Solenoid Valves Inner Wing Panel Proportioning Unit Proportioning Unit Tail Unit for Distribution Vertical Fin Panel Horizontal Tail Panel Horizontal Tail Panel Outer Wing Panel Spraybar T Fitting for Drain Figure 1 Ice Protection System Mechanical Schematic ...

Page 1147: ...if OÄM 42 160 and OÄM 42 203 are carried out HP Switch Filters Windshield Pumps Solenoid Valves Inner Wing Panel Proportioning Unit Proportioning Unit Tail Unit for Distribution Vertical Fin Panel Horizontal Tail Panel Horizontal Tail Panel Outer Wing Panel Spraybar De icing Fluid Tank if OÄM 42 160 and OÄM 42 203 are carried out Figure 2 Ice Protection System Mechanical Schematic if OÄM 42 203 is...

Page 1148: ... 15 Rev 4 Main Pumps De ice Control Panel Low Level Switch High Pressure Switch Windshield Pumps Solenoid Valves Low Pressure Switch De Ice Fluid Level Gauge Low Pressure Switch Low Pressure Switch De Ice Control Box Ice Light Ice Light Figure 3 Ice Protection System Electrical Schematic ...

Page 1149: ...ressure Switch Windshield Pumps Solenoid Valves Low Level Switch if OÄM 42 160 and OÄM 42 203 are carried out Low Pressure Switch De Ice Control Box De Ice Control Panel De icing Fluid Level Gauge Ice Light Low Pressure Switch Low Pressure Switch Figure 4 Ice Protection System Electrical Schematic if OÄM 42 203 is installed ...

Page 1150: ... the outer wings De icing fluid tank with integrated level sensor level switch and inlet strainer De icing fluid main pumps De icing fluid filters Drain hose connector in nose landing gear bay Proportioning units in each engine nacelle Nozzles and slinger rings on the LH and RH propeller Proportioning unit in the vertical tail Low pressure sensors in the vertical tail High pressure sensor Windshie...

Page 1151: ...d tank is installed in the nose baggage compartment of the airplane on the RH side It consists of a single polyamide chamber with a usable capacity of 30 liter 7 9 US gal If OÄM 42 203 is installed the de icing fluid tank is installed behind the baggage compartment and the optional short baggage extension The tank filler is located in the fuselage nose on the RH side aft of the nose baggage door I...

Page 1152: ... the sensor activates a caution message DEIC PRES HI on the Garmin G1000 PFD The system remains operative but the filter cartridges must be replaced at the next scheduled inspection 2 De Icing Fluid Filters Two filters protect the capillaries in the proportioning units from fouling The filters are connected in parallel for redundancy purposes The outlets of the filters are merged with a T fitting ...

Page 1153: ...ection system see Paragraph c b Propeller Ice Protection System A Teflon tube goes from the proportioning unit forward to a nozzle near the propeller where the de icing fluid drops onto a slinger ring In the engine compartment of the nacelle the tube is protected by a fire sleeve The slinger ring has three notches that allow the de icing fluid to be distributed over the propeller blades by centrif...

Page 1154: ...n the LH side Another panel is attached on the RH side The panels discharge the fluid onto the horizontal tail through many fine holes The panels are bonded to the horizontal tail leading edge They cannot be removed without damage c Vertical Tail Ice Protection System One porous panel is attached to the leading edge of the vertical tail The panel discharges the fluid onto the vertical stabilizer t...

Page 1155: ... air is drawn into the system via the spraybar 3 Spraybar A spraybar is located in front of the canopy It is aligned parallel with the center axis of the airplane When activated it sprays de icing fluid onto the canopy A deflector wedge is mounted to the airplane in front of the spraybar for protection and airflow guide purposes E Ice Protection Control System 1 De Ice Control Box The de ice contr...

Page 1156: ... already accumulated Maximum system operating time is approximately 1 0 hour B MAX Push Button The upper push button activates the MAX mode of the ice protection system when the system is presently in the HIGH mode This mode is only active for 2 minutes In this mode both pumps are active simultaneously and provide fluid to the system This mode is selected when icing conditions are severe or if sig...

Page 1157: ...s in icing conditions operation of the ice protection system similar to the HIGH mode is possible F ICE LIGHT ANNUN TEST Switch This switch activates either both ice lights or the annunciation test procedure 1 Ice Lights Operation The ice lights are switched ON by setting the toggle switch to the upper position 2 Test of Annunciations Proper function of the fluid level switch and the low pressure ...

Page 1158: ... DRILLED HOLES MAY BE CLOGGED BY USE OF ANY OTHER MATERIALS LIKE ADHESIVES SEALANTS PAINT OR ANY FINE PARTICLES THIS MAY AFFECT PANEL PERFORMANCE AND IS CAUSE FOR PANEL REJECTION Mask panel active area with low tack tape and plug inlet ports when working with adhesives near panels or in a dusty environment The inlets should be protected with appropriate caps Note The porous panels are not approved...

Page 1159: ...air Cycle time of the WINDSHIELD NORM or and MAX mode is are out of tolerance Internal failure of the de ice control box Replace control box No de icing fluid comes out of the spraybar and porous panels De icing fluid tank empty Replenish De icing fluid pump defective Replace pump De icing fluid filter s clogged Replace filter s De icing fluid tubing leaky Replace the affected part of the tubing D...

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Page 1161: ...CQUER THINNER AND OTHER TYPES OF THINNERS AND SOLVENTS DAMAGE THE INNER MEMBRANE OF THE PANELS MASK ACTIVE AREA OF PANELS WITH A LOW TACK TAPE WHEN USING SOLVENTS OR PAINTING THE AIRPLANE IN THE PROXIMITY OF THE PANELS OR WHEN THE AIRPLANE IS STORED IN A DUSTY ENVIRONMENT REFER TO PARAGRAPH 4 HANDLING OF POROUS PANELS IN THE GENERAL SECTION OF THIS CHAPTER Note It is of particular importance that ...

Page 1162: ...alert window is active Press SYSTEM ENGINE softkey to indicate de ice fluid level Annunciation Checkout 5 Switch to ANNUN TEST mode on the de ice control panel and check that the DEICE LVL LO message appears in the alert window of the PFD The DEICE LVL LO message appears only if less then approx 9 liter 2 4 US gal are in the de icing fluid tank 6 Wait 2 minutes and verify that the DEIC PRES LO mes...

Page 1163: ...cing fluid with pump 1 and pump 2 S Press the WINDSHIELD push button on the de ice control panel for 1 second S Select PUMP2 on the de ice control panel S Press the WINDSHIELD push button on the de ice control panel for 1 second Repeat procedure until de icing fluid emits from all holes in the spraybar Repeat procedure until de icing fluid emits from all holes in the spraybar 16 If the check descr...

Page 1164: ...nd check the middle amber annunciation light if on 23 Verify that both main pumps are running 24 Verify that no DEIC PRES LO warning is now indicated in the alert window on the PFD Cycle Time Test 25 In the NORM Mode the operation of both main pumps is cycled Therefore check runtime of the cycles S Pumps ON 30 s Tolerance 1 s 3 s S Pumps OFF 90 s Tolerance 9 s 1 s 26 Turn the OFF NORM HIGH switch ...

Page 1165: ...tion and check operation of the LH and the RH Ice Light 31 Turn the ICE LIGHT OFF ANNUN TEST back in the OFF position 32 Set the ELECT MASTER switch to OFF 3 Drain the Ice Protection System Detail Steps Work Items Key Items References 1 Open blanking plug on the T fitting in the nose wheel bay Refer to Figure 1 2 Allow the de icing fluid to flow into suitable containers 3 Close blanking plug on th...

Page 1166: ...to the nose baggage compartment 5 Remove the battery cover 6 Move the tank clear of the airplane Twist the tank 90 clockwise inboard for easier removal B Remove the De Icing Fluid Tank if OÄM 42 203 is installed Detail Steps Work Items Key Items References 1 Drain the ice protection system Refer to Paragraph 3 2 Open the passenger door and remove short baggage extension 3 Disconnect all hose and e...

Page 1167: ... compartment 4 Install the battery cover 5 Close the RH door to the nose baggage compartment 6 Replenish the ice protection system Refer to Section 12 10 7 Carry out operational test Refer to Paragraph 2 D Install the De Icing Fluid Tank if OÄM 42 203 is installed Detail Steps Work Items Key Items References 1 Move the tank in position aft of the short baggage extension 2 Install the TKS fluid hos...

Page 1168: ...moval of inlet strainer S Put drive pins of tool into drive slots of lock ring S Unscrew the strainer lock ring counter clockwise S Remove strainer lock and O ring S Take out inlet strainer of filler neck Use drive slot tool 3 Protect filler neck with glycol cap C Remove the De Icing Fluid Inlet Strainer if OÄM 42 203 is installed Detail Steps Work Items Key Items References 1 Remove the de icing ...

Page 1169: ...TILATION 2 Implementation of inlet strainer S Move strainer in place in the filler neck S Apply O ring and strainer lock S Put drive pins of tool into drive slots of lock ring S Fix strainer lock ring by twisting clockwise Use drive slot tool 3 Close the filler cap of the de icing fluid tank E Install the De Icing Fluid Inlet Strainer if OÄM 42 203 is installed Detail Steps Work Items Key Items Re...

Page 1170: ...t all hose connections from the pumps Use caps to protect the loose line connections from contamination 7 Remove the bolts and washers which hold the pump to the lid including the l sections 8 Remove the pump from the lid B Install a De Icing Metering Pump Detail Steps Work Items Key Items References 1 Move the pump in place on the nose floor lid 2 Install the bolts and washers which hold the pump...

Page 1171: ...move locking wire of hose connections downstream of the high pressure switch in 4 Remove locking wire of both hose connections downstream of equal tee 5 16 in 5 Disconnect hose line connections Use caps to protect the loose line connections from contamination 6 Lift up access lid in the nose baggage compartment on the LH side 7 Disconnect all electrical connectors from the windshield pump solenoid...

Page 1172: ... Use new seals 17 Secure all hose connections with locking wire 18 Move the lid in place in the floor 19 Connect all hose connections spray bar filter bleeding hose and manifold block Remove caps Use new seals 20 Secure all hose connections with locking wire 21 Connect all hose connections below small inspection hole High pressure switch and equal tee Remove caps Use new seals 22 Connect all elect...

Page 1173: ...d Refer to Section 12 10 To remove all air Refer to Section 12 10 2 Bleed the filter elements S Move end of bleeding hose to the exterior of the airplane S Remove the blanking plug from the filter bleeding hose S Set ELECT MASTER switch to ON S Set OFF NORM HIGH switch of the de icing control unit to HIGH S Operate system until air free fluid is discharged from the bleeding hose of the filter elem...

Page 1174: ...ing plugs on the proportioning unit LH and RH nacelles 4 Close the small inspection panels on the outboard side of the engine nacelles 10 Remove Install a Proportioning Unit A Remove a Proportioning Unit from the Nacelle Detail Steps Work Items Key Items References 1 Drain the ice protection system Refer to Paragraph 3 CAUTION YOU MUST MARK THE HOSES AND PORTS SO THAT YOU CAN RE CONNECT THE HOSES ...

Page 1175: ...ct all hose connections to the proportioning unit Remove caps 3 Secure all hose connections with wire lock 4 Install the bolts and washers which hold the proportioning unit 5 Close the small inspection panels on the outboard side of the engine nacelles 6 Carry out operational test Refer to Paragraph 2 11 Replace an Ice Protection Porous Panel The porous panels for the ice protection system are bon...

Page 1176: ...ormed T300 112 A 3 16 in 1 25 T300 120 A 5 16 in 3 75 T300 144 A 1 2 in 4 100 13 Replace Ice Protection Control Box Detail Steps Work Items Key Items References 1 Confirm that the XFER PUMP DE ICE circuit breaker is pulled 2 Open the access lid in the nose baggage compartment on the LH side To give access the ice protection control box 3 Unscrew the 2 mounting screws from the upper side of the bag...

Page 1177: ...e bolts and washers which attach the small inspection lid to the floor of LH nose baggage compartment 4 Lift the lid upward 5 Disconnect electrical connectors from high pressure switch 6 Remove locking wire from all hose connections on the high pressure switch 7 Disconnect all hose connections from the high pressure switch Use caps to protect the loose line connections from contamination 8 Remove ...

Page 1178: ... high pressure switch For appropriate range of manometer see table above Prepare collecting container for dissipating fluid 4 Operate ice protection system in HIGH mode 5 Adjust pressure in tubing with the vessel above the activation limit of the high pressure switch See table above for limits 6 Check high pressure caution on PFD of G1000 after 2 minutes tolerance 5 sec delay since pressure adjust...

Page 1179: ...emove caps Use new seals 12 Secure hose line connections of high pressure switch with lock wire 13 Fix high pressure switch with cable ties to the nose cone Replace cable tie base if necessary 14 Move small inspection lid in place 15 Install bolts and washers which attach the lid to the floor of the nose baggage compartment 16 Close LH door of nose baggage compartment 17 Do an operational test Ref...

Page 1180: ...light direction 6 Disconnect the hose connections to the low pressure switches Use caps to protect the loose line connections from contamination 7 Remove bolts and washers which hold the low pressure switch proportioning unit to the vertical stabilizer 8 Pull low pressure switch proportioning unit upward To give access to the feeder line of the fuselage section 9 Remove locking wire from the feede...

Page 1181: ...ow pressure switch proportioning unit to the vertical stabilizer 5 Connect the two hose connections to the proportioning unit labeled as 2 and 3 on the proportioning unit 6 Secure the two hose connections with locking wire CAUTION YOU MUST CONNECT THE HOSES TO THE CORRECT PORTS IF YOU DO NOT CONNECT THE HOSES CORRECTLY THE SYSTEM WILL NOT WORK PROPERLY 7 Connect the hose connections to the low pre...

Page 1182: ...e the maintenance cap horizontal tail outboard Cut sealant 2 Disconnect the electrical connectors from the low pressure switch 3 Remove the locking wire from the hose connections and the screw connections 4 Disconnect the hose connections to the low pressure switch 5 Remove bolts and washers which hold the low pressure switch to the low pressure switch bracket 6 Remove low pressure switch from bra...

Page 1183: ... 3 Move the low pressure switch in position to the low pressure switch bracket bonded to the upper shell of the horizontal tail In flight direction 4 Install bolts and washers which hold the low pressure switch to the bracket 5 Secure the bolts with locking wire 6 Connect the hose connections of the feeding line to panel inlet to the low pressure switch Max length 200 mm 7 Secure the hose connecti...

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Page 1185: ...AIRCRAFT DA 42 NG AMM Indicating Systems Doc 7 02 15 Rev 4 31 TITLE Page 1 15 Mar 2018 CHAPTER 31 INDICATING SYSTEMS ...

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Page 1187: ...ntrol Panels 1 General 1 2 Instrument Panel Description 4 3 Center Console Description 6 4 De Ice Control Panel Description 7 Trouble Shooting 1 General 101 Maintenance Practices 1 General 201 2 Remove Install the Engine Control Assembly 201 Section 31 20 Independent Instruments 1 General 1 Section 31 40 Central Computers 1 General 1 2 Description 3 Trouble Shooting 1 General 101 ...

Page 1188: ...nstall a GIA 63 W Integrated Avionics Unit IAU 208 4 Remove Install the GTX33 335 R Transponder 210 5 Remove Install the GRS 7X Attitude Heading and Reference Unit AHRS 213 6 Remove Install the GDC 7X Air Data Computer ADC 216 7 Remove Install the GEA 71 Processor 218 8 GMU 44 Magnetometer 220 9 G1000 Magnetometer Calibration 223 10 Remove Install the De Ice Control Panel 225 ...

Page 1189: ... part Integrated cockpit system ICS The airplane has an integrated cockpit system with 2 displays which give the airplane flight and navigation displays engine instrument displays and airplane systems indications The ICS has softkeys on the display screens for the option of selecting which indications will be displayed on the screen This Section does not tell you about the indicators that belong t...

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Page 1191: ...ces with a shelf The shelf goes between the panel and the instrument panel frame A control panel in the center console This panel has a forward cover and an aft cover The forward cover has the cabin heat control levers parking brake lever and rudder trim control The aft cover has the engine controls and fuel transfer shut off valve See the related Chapter or Section for data about the controls For...

Page 1192: ...V Master Elect Master Engine Starter Pitot Heat Alternate Static ICS Display Unit ICS Display Unit Altimeter Compass ELT Control Panel Circuit Breakers Fresh Air Vent Fresh Air Vent Artificial Horizon ECU Test Alternator ECU Voter Emergency Switch Artificial Horizon Flood Light Circuit Breakers Fuel Pumps De Ice Panel Oxygen Pressure Indicator Figure 1 Instrument Panel ...

Page 1193: ...AIRCRAFT DA 42 NG AMM Indicating Systems Doc 7 02 15 Rev 4 31 10 00 Page 3 15 Mar 2018 Optional if OÄM 42 270 is installed Figure 2 Instrument Panel with OÄM 42 270 ...

Page 1194: ...fical horizon and altimeter are combined in one unit named Standby Altitude Module These instruments provides the basic data required to fly the airplane in the event of a power failure and the loss of the ICS The artificial horizon or the standby attitude module can be powered from an emergency power pack An emergency switch is located near the artificial horizon or standby attitude module and ha...

Page 1195: ...100 FUEL CONTROL RIGHT ENGINE LEFT ENGINE ON ON OFF OFF CROSS FEED CROSS FEED NOSE DOWN NOSE UP rudder trim R L Rudder Trim Wheel Heater Controls Elevator Trim Wheel Parking Brake Left Engine Power Lever Right Engine Power Lever Left Engine Right Engine Fuel Transfer Shut Off Valve Fuel Transfer Shut Off Valve Cover Plate Fuel Transfer Shut Off Valve Forward Cover Plate Engine Control Cover Plate ...

Page 1196: ...uel transfer shut off valves and the elevator trim wheel The engine control assembly has two aluminum alloy side plates Four brackets attach to the side plates with rivets The front bracket has holes to anchor the outer sheaths of the brake and heat control cables The top bracket has two anchor nuts Bolts engage the anchor nuts to attach the engine control assembly to the top of the floor panel Th...

Page 1197: ...MP 1 ANNUN TEST 4 De Ice Control Panel Description Figure 4 shows the de ice control panel which is installed on the RH side of the instrument panel All functions of the de ice system are operated by the de ice control panel in conjunction with the de ice control box Refer to Chapter 30 for a detailed description of the de icing system Figure 4 DE ICE Control Panel ...

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Page 1199: ...anel in the center console If you have the trouble detailed in the Trouble column read across to the Possible Cause column Then do the repair given in the Repair column Trouble Possible Cause Repair Parking brake or cabin heat control levers do not stay in the set position Friction tension too low Too much wear in the friction washers Adjust the friction Replace the friction washers ...

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Page 1201: ...n the knob S Pull the knob clear of the spindle 2 Remove the knob from the parking brake control lever S Remove the screw that attaches the plain knob to the threaded knob S Remove the knobs and spacer from the lever 3 Remove the knobs from the heater control levers Do this procedure for each lever S Remove the screw that attaches the plain knob to the threaded knob S Remove the knobs and spacer f...

Page 1202: ... Lift the cover plate clear of the engine control assembly 6 Remove the knobs from the fuel transfer shut off control levers Do this procedure for each lever S Remove the screw that attaches the plain knob to the threaded knob S Remove the knobs and spacer from the lever 7 Remove the fuel transfer shut off control assembly cover plate S Remove the 4 screws that attach the cover plate to control as...

Page 1203: ...he center console and release these components as they become accessible S The parking brake control cable S The heater control cables S The electrical cables for the engine power levers S The rudder trim cable S The electrical cables for the engine control assembly micro switches S When all the components are released lift the engine control assembly clear of the center console Refer to Section 3...

Page 1204: ...ected lower the engine control assembly into position in the center console S Install the 2 bolts at the rear of the engine control assembly that attach the engine control assembly to the center console Refer to Section 27 21 At the in line connectors Refer to Section 76 00 Refer to Sections 21 20 and 21 40 Refer to Section 32 40 2 Install the fuel transfer shut off control assembly cover plate S ...

Page 1205: ...tall the 4 screws that attach the cover plate to the engine control assembly 6 Install the knobs onto the heater control levers Do this procedure for each lever S Install the plain knob spacer and threaded knob onto the lever S Install the screw that attaches the plain knob to the threaded knob 7 Install the knobs onto the parking brake lever S Install the plain knob spacer and threaded knob onto ...

Page 1206: ...y for your Airworthiness Authority do a duplicate inspection of the rudder trim system Refer to Section 27 21 10 Do a test for the correct operation of the parking brake system Refer to Section 32 40 11 Do a test for the correct operation of the airplane heating and ventilation system Refer to Sections 21 20 and 21 40 12 Do a test for the correct operation of the engine control system Refer to Sec...

Page 1207: ... 02 15 Rev 4 31 20 00 Page 1 15 Mar 2018 Section 31 20 Independent Instruments 1 General The DA 42 NG airplane has no independent instruments that are not part of the integrated cockpit system ICS For more data about the ICS refer to Section 31 40 ...

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Page 1209: ...d intercom systems Refer to Section 23 50 for more data about the audio control panel Electrical power is supplied to the ICS control and display screens when the ELECT MASTER switch is set to ON Power is supplied to the audio control panel when the AV MASTER switch is set to ON During normal operation the left display screen is referred to as the primary flight display PFD and the right display s...

Page 1210: ...63 W Integrated Avionics Unit No 2 GIA 63 W Integrated Avionics Unit RS 232 RS 232 RS 232 ARINC 429 ARINC 429 RS 232 ARINC 429 RS 232 RS 232 RS 485 RS 485 Engine Airframe Sensors Configuration Module GEA 71 Engine Airframe Unit GTX 3XX Transponder GMU 44 Magnetometer GRS 7X AHRS Configuration Module Configuration Module ARINC 429 ARINC 429 GDC 7X Air Data Computer GPT 59 OAT Probe Digital NAV Audi...

Page 1211: ...ob This control has a large outer knob and a smaller inner knob Rotate these knobs to select the NAV frequency Rotate the large outer knob to select the MHz and the inner knob to select the kHz Pressing the smaller inner knob will toggle the tuning cursor between the NAV1 and NAV2 frequency display HDG knob You can manually select the heading with this control Pressing this knob will cause a headi...

Page 1212: ...PUSH HDG SYNC DFLTMAP PUSH CRS CTR PUSH PUSH SQ PUSH ID VOL VOL EMERG PAN 1 2 HDG ALT NAV FMS 1 2 RANGE COM CRS BARO PROC ENT Garmin Display Unit Left Side Bezel Right Side Bezel NAV Vol Sq NAV Frequency Transfer NAV Frequency Selector Heading Selector Altitude Selector Soft Keys SD Card Slots Figure 2 Garmin G1000 Display Screens and Audio Integrating Unit ...

Page 1213: ...ght plan using the bezel controls and soft keys when this page is displayed PROC key Press this key to display the procedures page If this page is used with a selected flight plan then the procedures page will display the data associated with the flight plan If the page is not used with a flight plan then an airfield and its relate procedures can be selected from a database CLR key Press this key ...

Page 1214: ...12 03 25 REFS OBS CDI PFD OAT KCL 08 INSET NRST WARNING DOOR OPEN ALTERNATOR PITOT OFF R FUEL LOW L FUEL LOW 100 29 68 0 TRAFFIC 120 NORTH UP M ALERTS DOOR OPEN Canopy and or rear door isn t closed and locked ALTERNATOR Alternator failed Battery is only elec source PITOT OFF Pitot heat is off Turn switch on to avoid icing Outside Air Temperature Window Nav Map Transponder Window Horizontal Situati...

Page 1215: ...o shows a altitude bug at the selected altitude or the edge of the tape whichever is closest to the current altitude If the altitude indicator fails the display marks the tape display area with a red X and yellow text spelling out ALTITUDE FAIL if MÄM 42 978 is NOT installed Barometric pressure indicator The barometric pressure indicator is located immediately below the altitude indicator The indi...

Page 1216: ... left of the PFD The window is activated by pressing the INSET softkey and when activated shows a pictorial view of the airplane on a moving map Small windows in the top left corner of the PFD show active and standby NAV frequencies Small windows in the top right of the PFD show active and standby COM frequencies A larger window in the top of the PFD flight planning data when activated and autopil...

Page 1217: ...tem has failed Engine RPM Pointers on each side of a vertical scale move to show the engine rpm If the system fails the display shows a red or yellow cross to the left or right of the RPM indicator to show which engine system has failed Fuel flow Small windows to the left and right of a GPH marking show the engine fuel flow digitally If the system fails a red or yellow cross is displayed in place ...

Page 1218: ...quantity of fuel in the left fuel tank and the pointer below the range bar indicates the quantity of fuel in the right fuel tank If the system fails a red or yellow cross is displayed in place of the digital indication for the failed system s System Display if MÄM 42 978 is NOT installed This display shows graphic and numeric readouts of following critical engine electrical indicators and optional...

Page 1219: ...erature Oil temperature Displays digital readouts of the oil temperature Oil pressure Displays digital readouts of the oil pressure Deice fluid quantity optional Pressing the FUEL softkey at the bottom of the MFD will change the display to the FUEL page in the EIS panel if MÄM 42 978 is NOT installed The display will now give the following indications Engine load and RPM These indications are in t...

Page 1220: ...PROC ENT 100 80 60 40 20 3000 2400 1800 1200 600 LOAD RPM FUEL FLOW GPH OIL TEMP OIL PRES COOLANT TEMP FUEL TEMP FUEL QTY GAL 0 5 10 15 20 25 ENGINE MAP NO TRFC DATA DCLTR SHW CHRT CHKLIST MAP WPT AUX NRST 30NM 110 20 117 80 NAV1 NAV2 COM1 COM2 118 525 122 650 MAP NAVIGATION MAP KT DIS NM TRK GS ETE NO GPS POSITION NORTH UP AP FD NAV YD HDG AFR ALT VS FLC NOSE UP NOSE DN Figure 4 Multi Function Di...

Page 1221: ...AUs via RS 232 digital interface The transponder is installed in the avionics rack in the rear fuselage just aft of the rear baggage frame F GRS 77 79 Attitude Heading and Reference Unit AHRS The GRS 77 79 provides airplane attitude and related flight data to the cockpit displays The GRS 77 79 receives data from the air data computer the GMU 44 magnetometer and GPS signals from the GIA 63 W The GR...

Page 1222: ...eter senses magnetic field information Data is sent to the GRS 77 79 ARHS for processing The magnetometer receives power form the GRS 77 79 and communicates with the GRS 77 79 using RS 485 digital interface The magnetometer is located in the right outer wing and can accessed through a panel in the lower surface of the wing ...

Page 1223: ... 02 15 Rev 4 31 40 00 Page 101 15 Mar 2018 Trouble Shooting 1 General The Garmin ICS has a built in test and trouble shooting facility For more data about troubleshooting the ICS refer to the G1000 Cockpit Reference Guide for the DA 42 NG Airplane ...

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Page 1225: ...Maintenance Manual gives you particular information on Unit related alerts and problems Equipment removal and installation Uploading software configuring and testing Final system checkout Periodic maintenance G1000 system software and configuration GDU lighting setup Refer to the DAI MSB 42NG 003 for data about the approved software configurations The specific DA 42 NG values as to the equipment b...

Page 1226: ...g USA 1200 Aircraft Weight 15 500 lbs Max Airspeed 300 kts Address Type Europe hex id USA us tail Flight ID Type Europe PFD Entry USA same as tail GMA Configuration S Headset Volume Music 1 20 Music 2 20 Unswitched in 1 20 Unswitched in 2 20 Unswitched in 3 20 Altitude Warning 20 GMA Configuration S Speaker Volume Crew Audio 5 GMA Configuration S Master Squelch Threshold Value 16 GMA Configuration...

Page 1227: ...ble TEL set Disable DME specific to airplane Disable ADF specific to airplane Disable AUX set Disable SPEAKER blank Disable PA set Disable PLAY blank Disable MUSIC set Disable REC set Disable CABIN set Note Unlisted items are preset You must not change their values Note Some items are specific to the airplane Note down the settings prior to performing a software upload ...

Page 1228: ...e sure that the ELECT MASTER switch is set to OFF 2 Set the PFD and MFD circuit breakers open Right side of instrument panel 3 Remove the display unit S Rotate the 4 locking studs that attach the display to the instrument panel 90 counter clockwise S Move the display aft and disconnect the electrical cables S Move the display unit clear of the instrument panel Refer to Figure 6 At the in line conn...

Page 1229: ...CRAFT DA 42 NG AMM Indicating Systems Doc 7 02 15 Rev 4 31 40 00 Page 205 15 Mar 2018 Locking Studs GDU 10XX Display Unit In Line Connector Rivet Locking Socket Figure 6 GDU 10XX Display Unit Installation ...

Page 1230: ...e instrument panel S Rotate the 4 locking studs that attach the display unit to the instrument panel 90 clockwise At the in line connector Make sure that you do not trap the electrical cables The locking studs should be oriented with the alignment marks in the vertical position for installation When locked the alignment marks are in the horizontal position 3 Reset the PFD and MFD circuit breakers ...

Page 1231: ... AMM Indicating Systems Doc 7 02 15 Rev 4 31 40 00 Page 207 15 Mar 2018 Garmin GIA 63 W Units GIA 63 Mounting Racks Avionics Enclosure Retainer Locking Screws Figure 7 GIA 63 W Integrated Avionics Unit IAU Installation ...

Page 1232: ...ift the IAU clear of the mounting rack and the airplane Refer to Figure 7 B Install a GIA 63 W Integrated Avionics Unit IAU Detail Steps Work Items Key Items References 1 Install the IAU S Move the GIA IAU into position at the mounting and lower the unit into position in the rack S Move the retainer into position and secure with the locking screw Make sure that the unit is seated correctly Do not ...

Page 1233: ...42 NG AMM Indicating Systems Doc 7 02 15 Rev 4 31 40 00 Page 209 15 Mar 2018 GTX33 335 R Transponder GTX33 335 R Mounting Rack Avionics Enclosure Retainer Locking Screw Figure 8 GTX33 335 R Transponder Installation ...

Page 1234: ...35 R clear of the mounting rack and the airplane Refer to Figure 8 B Install the GTX33 335 R Transponder Detail Steps Work Items Key Items References 1 Install the GTX33 335 R S Move the GTX33 335 R into position at the mounting and lower the unit into position in the rack S Move the retainer into position and secure with the locking screw Make sure that the unit is seated correctly Do not force t...

Page 1235: ...AIRCRAFT DA 42 NG AMM Indicating Systems Doc 7 02 15 Rev 4 31 40 00 Page 211 15 Mar 2018 Connector GRS77 AHRS Unit Figure 9 GRS 77 Attitude Heading and Reference Unit AHRS Installation ...

Page 1236: ...AIRCRAFT Indicating Systems DA 42 NG AMM Page 212 15 Mar 2018 31 40 00 Doc 7 02 15 Rev 4 Connector GRS 79 AHRS Unit Mounting Rack Figure 10 GRS 79 Attitude Heading and Reference Unit AHRS ...

Page 1237: ... GRS 7X S Disconnect the electrical cables S Loosen the 4 or 2 if MÄM 42 978 is installed screws that attach the GRS 7X to the mounting S Move the GRS 7X clear of the airplane Refer to Figure 9 or 10 B Install the GRS 7X Attitude Heading and Reference Unit AHRS Detail Steps Work Items Key Items References 1 Install the GRS 7X unit S Move the unit into position next to the avionics rack S Tighten t...

Page 1238: ...References Page 214 15 Mar 2018 31 40 00 Doc 7 02 15 Rev 4 3 Do a test for the correct operation of the integrated cockpit system ICS S Set the ELECT MASTER switch to ON S Set the ELECT MASTER switch to OFF The ICS must power up and successfully complete its selftest procedure ...

Page 1239: ... 7 02 15 Rev 4 31 40 00 Page 215 15 Mar 2018 Mounting Rack Static Port Pitot Port Garmin GDC 72 Unit In Line Electrical Connector Garmin GDC 74 Unit Mounting Rack Pitot Air Port Static Air Port Figure 11 GDC 7X Air Data Computer ADC Installation ...

Page 1240: ...nect the airplane main battery Refer to Section 24 31 2 Remove the instrument panel cover Refer to Section 25 10 3 Remove the GDC 7X S Locate the GDC 7X on the instrument panel shelf S Disconnect the electrical cables S Disconnect the Pitot static tubes from the unit S Remove the 2 screws of the adapter plate that attaches the GDC 7X to its mounting rack S Move the GDC 7X clear of the airplane Ref...

Page 1241: ... 7X to the mounting rack S Install the Pitot Static tubes to the unit S Connect the electrical cables As noted in 6A At the in line connector 2 Install the instrument panel cover Refer to Section 25 10 3 Connect the airplane main battery Refer to Section 24 31 4 Do a test for the correct operation of the integrated cockpit system ICS S Set the ELECT MASTER switch to ON S Set the ELECT MASTER switc...

Page 1242: ...ear and lift the GEA 71 clear of the mounting Refer to Figure 12 B Install the GEA 71 Processor Detail Steps Work Items Key Items References 1 Install the GEA 71 S Move the GEA 71 into position at its mounting S Lower the GEA 71 into its mounting S Install the retainer and secure the retainer with the retaining screw 2 Install the instrument panel cover Refer to Section 25 50 3 Connect the airplan...

Page 1243: ...AIRCRAFT DA 42 NG AMM Indicating Systems Doc 7 02 15 Rev 4 31 40 00 Page 219 15 Mar 2018 Garmin GEA 71 Unit Mounting Rack Retainer Retainer Screw Figure 12 GEA 71 Processor Installation ...

Page 1244: ... that the ELECT MASTER switch is set to OFF 2 Remove the magnetometer assembly S Remove the 3 screws that attach the magnetometer assembly to the lower surface of the right wing S Lower the magnetometer assembly clear of the structure and disconnect the electrical cables S Move the magnetometer assembly clear of the airplane Support the assembly 3 If necessary remove the magnetometer from the pane...

Page 1245: ... AMM Indicating Systems Doc 7 02 15 Rev 4 31 40 00 Page 221 15 Mar 2018 Magnetometer GMU 44 Screw Mounting Ring Screw Panel Screw Spacer Inspection Panel Electrical Connector Figure 13 Magnetometer Assembly Installation ...

Page 1246: ...netometer assembly S Move the magnetometer assembly fully into position in the lower surface of the right wing S Install the 3 screws that attach the magnetometer assembly to the wing Pay attention on the dedicated mounting direction marked by an arrow At the in line connector 2 Do a test for the correct operation of the integrated cockpit system ICS S Set the ELECT MASTER switch to ON The ICS mus...

Page 1247: ...the airplane to keep the magnetometer from passing within 6 meter 19 7 feet of such objects At the compass rose align the airplane to a heading of magnetic north 5 2 With the airplane stationary initiate the GRS 7X AHRS magnetometer calibration procedure as follows S Enter the GDU configuration mode by holding the ENTER button while applying power Release the ENTER button when the words INITIALIZI...

Page 1248: ...by about 30 each time the GDU displays that it is time to turn rather than attempting to use the GDUs real time indication of how much additional turn is needed Simply turning the airplane by roughly 30 5 increments and dwelling for the time recommended by the GDU is all that is needed for successful calibration 5 Repeat the turn and stop process until the GDU display advises that a successful cal...

Page 1249: ... care that no washer or nut falls into the instrument panel 6 Move the control panel clear from instrument panel B Install the De Ice Control Panel in the Instrument Panel Detail Steps Work Items Key Items References 1 Set the DE ICE XFER circuit breaker open Right side of instrument panel 2 Attach the de ice control panel in the designated cutout on the RH side of the instrument panel Right side ...

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Page 1251: ...AIRCRAFT DA 42 NG AMM Landing Gear Doc 7 02 15 Rev 4 32 TITLE Page 1 15 Mar 2018 CHAPTER 32 LANDING GEAR ...

Page 1252: ...AIRCRAFT Landing Gear DA 42 NG AMM Page 2 15 Mar 2018 32 TITLE Doc 7 02 15 Rev 4 Intentionally left blank ...

Page 1253: ... Leg Completely with Axle and Brake Unit 203 3 Disassemble Assemble a Main Landing Gear Leg 212 4 Fill Charge the Damper Assemblies on the Main Gear Legs 217 5 Required Strut Extension of the Main Gear Damper Assemblies 224 6 Remove Install a Main Landing Gear Damper 225 7 Disassemble Assemble Main Landing Gear Damper 227 8 Remove Install a Main Landing Gear Door 231 9 Remove Install the MLG Foldi...

Page 1254: ...ension of the Nose Landing Gear Damper Assembly 213 6 Fill Charge the Damper Assembly on the Nose Gear Leg 214 7 Disconnect Connect the NLG Folding Stay Assembly 220 8 Remove Install the NLG Actuator 231 9 Remove Install the Nose Landing Gear Mounting Bracket if MÄM 42 659 is installed 239 Section 32 30 Extension and Retraction 1 General 1 2 Description 1 3 Operation 6 Trouble Shooting 1 General 1...

Page 1255: ...ctices 1 General 201 2 Remove Install a Main Wheel 201 3 Remove Install the Nose Wheel 206 4 Disassemble Assemble Main Nose Wheel 209 5 Remove Install Brake System Components General 211 6 Remove Install a Brake Master Cylinder 212 7 Remove Install the Parking Brake Valve 217 8 Remove Install a Brake Caliper 219 9 Bleed the Wheel Brake System 222 10 Replace the Brake Friction Linings 224 Section 3...

Page 1256: ...ion 32 60 Position and Warning 1 General 1 2 Description 1 Trouble Shooting 1 General 101 Maintenance Practices 1 General 201 2 Remove Install an Engine Power Lever Switch 201 3 Replace a Landing Gear Switch Excluding the Nose Gear Folding Stay Switch 205 4 Replace a Nose Gear Folding Stay Switch 208 5 Adjust Landing Gear Indication Micro Switches Excluding Nose Gear Folding Stay Switch 209 6 Test...

Page 1257: ...e gear leg attaches to the fuselage front bulkhead All three legs have CFRP doors that seal the landing gear bays when the landing gear is retracted in flight Each main leg is a tubular steel strut A trailing arm attaches to the bottom of the strut and an axle for the wheel assembly attaches to the trailing arm A damper behind the tubular strut also attaches to the trailing arm and absorbs the lan...

Page 1258: ...The landing gear has a electrically powered hydraulic supply and control system The hydraulic supply and control system is mounted on a bracket located in the rear fuselage near the rear baggage compartment Refer to Chapter 29 and Section 32 30 for more data about the hydraulic system ...

Page 1259: ...SE LANDING GEAR ASSEMBLY MAIN LANDING GEAR ASSEMBLY Tubular Steel Strut Tubular Steel Strut Damper Damper Main Wheel Nose Wheel Hydraulic Supply and Control System Refer to Chpater 29 Hydraulic Actuator Hydraulic Actuator Folding Stay Folding Stay Figure 1 Landing Gear Main Components ...

Page 1260: ... Section 32 10 for more data about the main landing gear components and refer to Section 32 20 for more data about the nose landing gear components 4 Operation in the Air When the airplane is airborne the pilot can retract the landing gear into the landing gear bays The landing gear bays have doors which close when the landing gear is retracted Refer to Section 32 30 for more data about the extens...

Page 1261: ...steel strut and it attaches to the trailing arm The trailing arm carries an axle for the main wheel assembly Four bolts attach the axle to the trailing arm The axle has a steel plate that holds the brake unit Clips and cable binders hold the hydraulic hose for the brake unit and the electrical cables for the micro switches to the leg Each main gear leg has a large hydraulic actuator to retract and...

Page 1262: ...M Page 2 15 Mar 2018 32 10 00 Doc 7 02 15 Rev 4 Longitudinal Pivot Folding Stay Hydraulic Actuator Aft Pivot Bearing Forward Pivot Bearing Tension Spring CFRP Door Axle Trailing Arm Damper Tubular Steel Strut Figure 1 Main Landing Gear ...

Page 1263: ...ding gear position and warning system Refer to Chapter 29 for trouble shooting on the hydraulic power generation If you find the trouble given in Trouble column read across to the possible cause column Then do the repair given in the Repair column Trouble Possible Cause Repair Airplane stands on ground with one wing low Uneven ground Heavy landing Damper pressure low Damper defective Move airplane...

Page 1264: ...AIRCRAFT Landing Gear DA 42 NG AMM Page 102 15 Mar 2018 32 10 00 Doc 7 02 15 Rev 4 Intentionally left blank ...

Page 1265: ...eg components The Maintenance Practices are applicable to both the left and right main gear legs You can remove the main gear leg with the wheel or you can remove the wheel first Refer to Section 32 30 for data on the main gear retraction system Refer to Section 32 40 for data on the main gear wheels brakes Refer to Section 32 60 for data about the landing gear position and warning system ...

Page 1266: ...ng Housing Rear Main Landing Gear Leg Assy LH Trailing Arm LH Spacer Washer Axle Washer Nut Spacer Spacer Joint Damper Unit Bolt Self Locking Nut Bolt Torque Plate Washer Washer Bolt Washer Self Locking Nut Self Locking Nut Bolt Bushing Washer Castle Nut Splint Washer Washer Figure 2 Main Landing Gear Leg Assy ...

Page 1267: ...irplane jacks 3 Commercial Wing trestle 2 Commercial Rear fuselage trestle 1 Commercial Aft bearing centering tool 1 VR D60 3217 12 31 Front bearing centering tool 1 VR D60 3217 12 30 Bearing housing puller 1 VR D60 3217 11 00 B Remove the Main Landing Gear Leg Detail Steps Work Items Key Items References WARNING TAKE PRECAUTIONS BY SECURING THE AREA AROUND THE AIRPLANE BEFORE YOU PERFORM MAINTENA...

Page 1268: ... washer and spacer that attach the door connecting arm to the main gear leg S Pull the connecting arm clear of the main gear leg attachment and secure to the door S Move and hold the main gear door clear of the main gear leg Refer to Figure 2 5 Remove the brake calliper Refer to Section 32 40 6 Remove the main wheel Refer to Section 32 40 7 Remove all cable binders which secure the flexible brake ...

Page 1269: ...ring housing S Use the bearing housing puller to get the bearing housing off the longitudinal pivot Refer to Figures 2 and 3 Support the main gear leg and make sure not to scratch the surface 12 Remove the fuel filter element Refer to Section 28 20 13 Optional Remove the flexible heat pipe from the clamp to gain more space to reach the front bearing housing 14 Optional Remove the front bearing hou...

Page 1270: ... 02 15 Rev 4 15 Remove the main gear leg S Move the leg aft to slide the forward longitudinal pivot clear of its bearing housing S Lower the forward longitudinal pivot clear of the landing gear bay S Move the leg forward until aft longitudinal pivot is clear of the main gear web S Move the leg clear of the airplane ...

Page 1271: ...ring Castle Nut Cotter Pin Forward Pivot Bearing 8 Bolts Washer Sheets 8 Nuts Aft Pivot Bearing Bolt x6 Washer Sheets Nut x6 GFRP Spacer Washer Sheets Tension Spring Bolt Washer Nut Washer Spacer Spacer Sleeve Spacer Spring Lever Bolt Lightning Protection Bonding Wire Washer 8 Washers Washer Washer x6 OR OR Figure 3 Main Landing Gear Installation ...

Page 1272: ... Landing Gear DA 42 NG AMM Page 208 15 Mar 2018 32 10 00 Doc 7 02 15 Rev 4 Puller Spacer Washer Bolt Bolt with Offset Bolt with Offset Bolt Washer Puller AFT FRONT Figure 4 Removal of the Main Landing Gear Leg ...

Page 1273: ...ward longitudinal pivot up and engage it with the front bearing S Move the leg forward until the forward longitudinal pivot is fully engaged in the front main gear bearing Support the main gear leg and make sure not to scratch the surface 2 Install the front bearing housing S Use the front bearing centering tool to pull the longitudinal pivot into the bearing housing If removed previously S Instal...

Page 1274: ... new self locking nuts Required axial clearance max 0 2 mm Tighten by hand 4 Optional Install the flexible heat pipe back onto the worm drive clamp if it was removed 5 Install the fuel filter element Refer to Section 28 20 6 Connect the folding stay assembly of the MLG Refer to Paragraph 10 7 Install the main gear wheel Refer to Section 32 40 8 Install the brake calliper Refer to Section 32 40 9 B...

Page 1275: ...AMM Landing Gear Detail Steps Work Items Key Items References Doc 7 02 15 Rev 4 32 10 00 Page 211 15 Mar 2018 16 Move the wing and rear fuselage trestles clear of the airplane 17 Lower the airplane Refer to Section 07 10 ...

Page 1276: ...ON THE LANDING GEAR THE LANDING GEAR RETRACTION SYSTEM CAN CAUSE SERIOUS INJURY TO PERSONS IF OPERATED ACCIDENTALLY 1 Remove main landing gear leg Refer to Section 32 10 2 Optional If not removed before remove the main gear wheel Refer to Section 32 40 3 Remove the main gear damper Refer to Section 32 10 4 Remove the trailing arm from the main gear leg S Remove the bolt self locking nut washers bu...

Page 1277: ...plate and the axle in position S Install the four bolts washers and self locking nuts which secure the axle and the torque plate Use a new self locking nut 2 Install the top of the damper to the main landing gear leg Refer to Paragraph 6 B 3 Install the trailing arm onto the main gear leg S Slide the outer spacer into the trailing arm S Move the trailing arm into position S Slide the inner spacer ...

Page 1278: ...ANCE ON THE LANDING GEAR THE LANDING GEAR RETRACTION SYSTEM CAN CAUSE SERIOUS INJURY TO PERSONS IF OPERATED ACCIDENTALLY 1 Raise the airplane on jacks and move the wing and rear fuselage trestles into position to support the airplane Refer to Section 07 10 2 Pull the GEAR circuit breaker Right side of instrument panel 3 Support the tire and remove the nut washer lower bolt and bushing from the joi...

Page 1279: ...ering numbers of the LH and RH joint sizes S D64 3217 23 00 Joint x 62 mm z 32 mm S D64 3217 23 01 Joint oversize 1 x 64 mm z 34 mm S D64 3217 23 02 Joint oversize 2 x 66 mm z 36 mm S D64 3217 23 03 Joint oversize 3 x 68 mm z 38 mm Note Different part numbers may be used on LH and RH MLG of the airplane Figure 5 Main Landing Gear Joint Measurement ...

Page 1280: ...ust use the correct joint joint oversize 2 Install joint on damper S Move joint on damper S Verify smooth and easy movement S Install the bolt washer spacer and self locking nut Use new self locking nut 3 Connect joint to main landing gear trailing arm S Move trailing arm into position S Install bushing bolt washer and self locking nut Use new self locking nut 4 Adjust the wheel in retracted posit...

Page 1281: ...you how to fill the main gear damper assemblies with hydraulic fluid and then charge with nitrogen A Equipment Item Quantity Part Number Bottle 1 Commercial Bleed tube 1 Commercial Valve core removal tool 1 Commercial Nitrogen charging equipment 1 Commercial Airplane jacks 3 Commercial Wing trestle 2 Commercial Rear fuselage trestle 1 Commercial Nose trestle 1 Commercial ...

Page 1282: ...ifying the type of hydraulic fluid All airplanes with MÄM 42 495 NOT installed have been manufactured with Aeroshell Fluid 41 MIL PRF 5606 H The identification placard must be installed if a hydraulic fluid change to another fluid type is carried out Hydraulic fluid As required Aeroshell Fluid 41 MIL PRF 5606 H or AMG 10 GOST 6794 75 Amdt 1 5 see CAUTION above Grease for sliding interfaces As requ...

Page 1283: ...RRECTLY THE MAIN LANDING GEAR WILL NOT OPERATE CORRECTLY THIS CAN CAUSE DAMAGE TO THE MAIN LANDING GEAR AND THE AIRPLANE STRUCTURE Detail Steps Work Items Key Items References WARNING TAKE PRECAUTIONS BY SECURING THE AREA AROUND THE AIRPLANE BEFORE YOU PERFORM MAINTENANCE ON THE LANDING GEAR THE LANDING GEAR RETRACTION SYSTEM CAN CAUSE SERIOUS INJURY TO PERSONS IF OPERATED ACCIDENTALLY WARNING THE...

Page 1284: ...Remove the core of the charging valve from the damper assembly 5 Compress the damper assembly WARNING DO NOT GET HYDRAULIC FLUID ON YOUR SKIN HYDRAULIC FLUID CAN CAUSE SKIN DISEASE 6 Connect the tube of the hydraulic fluid filler bottle to the charging valve CAUTION DO NOT MIX OR REPLACE HYDRAULIC FLUIDS OF DIFFERENT TYPES OR MANUFACTURERS Note If MÄM 42 495 is carried out a placard is installed b...

Page 1285: ... into the damper 10 Compress the damper and hold the damper compressed while you close the bottle and remove the tube from the charging valve Keep the damper compressed 11 Install the core of the charging valve 12 Connect the gaseous nitrogen charging equipment to the damper charging valve Allow the damper to extend as it is charged 13 Charge the damper with nitrogen to the correct pressure Refer ...

Page 1286: ...ote If the damper is disassembled clean the inner surface of the damper and fill with AMG 10 Refer to Paragraph C of this Chapter and to item 2 of this table 1 Repeat the Fill Charge the Damper Assemblies on the Main Gear Legs procedure 3 times Refer to Paragraph C 2 Apply the hydraulic fluid placard and mark the used fluid Refer to Figure 6 Mark hydraulic fluid type by punching ...

Page 1287: ...e 223 15 Mar 2018 Placard MLG LH shown RH similar Hydraulic Fluid AeroShell Fluid 41 AMG 10 CAUTION Mixing of different fluid types is not permitted Refer to AMM for refilling or fluid change Figure 6 Position of the Hydraulic Fluid Placard Main Landing Gear Dampers ...

Page 1288: ...f the Main Gear Damper Assemblies The subsequent table tells you about the correct strut extension and pressure of the unloaded fully extended main landing gear dampers MLG Damper Strut Extension unloaded visible length of bare piston Gas Pressure LH 15 cm 6 inches 19 bar 276 PSI RH 15 cm 6 inches 19 bar 276 PSI ...

Page 1289: ...RE CONNECTED TO THE GAS LOADED DAMPER DUE TO THE HIGH FORCES INVOLVED THE ELEMENTS OF THE DAMPING SYSTEM CAN CAUSE SERIOUS INJURY TO PERSONS 1 Pull the GEAR circuit breaker Right side of instrument panel 2 Raise the airplane on jacks and move the wing and rear fuselage trestles into position to support the airplane Refer to Section 07 10 3 Release the nitrogen pressure from the damper S Remove the...

Page 1290: ...E GAS LOADED DAMPER DUE TO THE HIGH FORCES INVOLVED THE ELEMENTS OF THE DAMPING SYSTEM CAN CAUSE SERIOUS INJURY TO PERSONS 1 Move the damper in position at the main gear leg 2 Install the spacer nut washer and bolt that attach the bottom of the damper to the trailing arm Use a new lock nut 3 Install the nut washer and bolt that attach the top of the damper to the main gear leg Use a new lock nut 4...

Page 1291: ... 2 Release nitrogen and oil from the damper S Install a drain hose onto the charging valve of the damper S Wait until the nitrogen is fully released S Compress the damper to drain the oil Use a suitable container to catch the damper oil approx 0 5 l 0 13 US gal 3 Remove the charging valve from the damper Refer to Figure 7 4 Remove the bottom cap S Remove M6 lower cross bolt washer and lock nut S P...

Page 1292: ...2018 32 10 00 Doc 7 02 15 Rev 4 6 Disassemble the inner cylinder S Remove the M8 nut and pull the orifice plate from the damper pipe S Pull the upper cap together with the center bolt from the damper pipe S Remove the O ring from the lid Refer to Figure 7 Make sure not to damage the orifice plate ...

Page 1293: ...se new self locking nut Apply Loctite 262 on thread and tighten with 15 Nm 11 1 lbf ft 2 Assemble damper tube S Install the quad ring and the two backup rings onto the tube S Put inner cylinder onto a tube special tool to raise it S Slide the damper tube onto the inner cylinder Refer to Figure 7 Use new O rings 3 Install the bottom cap S Install the O ring onto the cap S Push the bottom cap onto t...

Page 1294: ...Cylinder Damper Tube Bottom Cap Centre Bolt Orifice Plate Lower Cross Bolt Upper Cap O Ring O Ring Bushings Quad Ring Backup Ring Backup Ring Bushings Charging Valve O Ring Washer Lock Nut Lock Nut Different Orifice Plate If MÄM 42 659 is installed Figure 7 Main Landing Gear Damper Assembly ...

Page 1295: ... the GEAR circuit breaker On the right side of instrument panel 2 Disconnect the door operating rod from the door that will be removed S Remove the nut washers spacers and the bolt from the rod end S Pull the operating rod clear of the angle bracket Refer to Figure 8 At the door end of the rod 3 Remove the door S Remove the two bolts washers and self locking nuts from one of the hinges S Remove th...

Page 1296: ...8 32 10 00 Doc 7 02 15 Rev 4 LH Shown RH similar Main Landing Gear Door Main Landing Gear Leg Door Operating Rod Washer Bolt Washer Nut Washer Screw Angle Bracket Hinge Front Hinge Rear Self Locking Nut Washer Bushing Spacer Figure 8 Main Landing Gear Door ...

Page 1297: ...r bay and align the gear door with the hinge S Install the two bolts washers and self locking nuts Refer to Figure 8 Use new self locking nuts 2 Connect the door operating rod to the door that you installed S Push the door operating rod onto the angle bracket S Install the nut washers spacers and the bolt onto the rod end on the door side Refer to Figure 8 Use a new self locking nut 3 Reset the GE...

Page 1298: ...mmercial B Remove the Folding Stay Hydraulic Actuator Detail Steps Work Items Key Items References WARNING TAKE PRECAUTIONS BY SECURING THE AREA AROUND THE AIRPLANE BEFORE YOU PERFORM MAINTENANCE ON THE LANDING GEAR THE LANDING GEAR RETRACTION SYSTEM CAN CAUSE SERIOUS INJURY TO PERSONS IF OPERATED ACCIDENTALLY 1 Raise the airplane on jacks and move the wing and rear fuselage trestles into position...

Page 1299: ...m the actuator Only if removing the actuator Use a suitable container to catch spilt hydraulic fluid Fit caps on all open connections 10 Measure and record the distance from the actuator safety lock washer to the center of spherical rod end bearing Refer to Figure 9 Note the distance marked x 11 Disassemble the folding stay actuator S Remove the nut 4 spacers washer and bolt from the driver plate ...

Page 1300: ...Stay Bracket Tension Spring Main Landing Gear Leg Spring Lever Actuator Hydraulic Lines Drag Lever Washer Latch Operating Arm Bolt Bearing Shaft Snap Ring Snap Ring Drag Strut Washer Bolt Bolt Washer Nut Spacer Snap Ring Self Locking Nut Self Locking Nut Self Locking Nut Self Locking Nut Washer Bolt Washer Lock Hook Figure 10 Main Landing Gear Folding Stay ...

Page 1301: ... nut 4 spacers washer and bolt onto the driver plate Refer to Figure 10 3 Connect the hydraulic lines with the actuator Remove caps from all open connections 4 Replenish the hydraulic reservoir if necessary Refer to Section 29 10 5 Connect the folding stay assembly of the MLG Refer to Section 32 10 6 Install and adjust the folding stay assembly of the MLG Refer to Section 32 60 7 Reset the GEAR ci...

Page 1302: ...AR THE LANDING GEAR RETRACTION SYSTEM CAN CAUSE SERIOUS INJURY TO PERSONS IF OPERATED ACCIDENTALLY 1 Raise the airplane on jacks and move the wing and rear fuselage trestles into position to support the airplane Refer to Section 07 10 2 Bleed the system S Retract the landing gear to bleed the system S Operate the emergency extension of the landing gear repeat this step one or two times Refer to Se...

Page 1303: ... between the drag strut and the drag lever from the folding stay S Push the drag lever outward to release the stress from the folding stay and slowly remove the bearing shaft from the folding stay S Open the lock hook and slowly release the drag lever S Move the drag strut free from the drag lever S Remove the bolt and the washer which connects the drag strut with the MLG leg S Remove the drag str...

Page 1304: ...g Refer to Figure 10 9 Disconnect the folding stay assembly S Remove the snap ring and the washer from the drag lever were it connects to the folding stay bracket S Pull the drag lever and the actuator off the folding stay bracket S The whole assembly will come off but is still connected to the fuselage through the actuator hydraulic lines and the MLG folding stay switch S Make sure to affix the w...

Page 1305: ...asher and the snap ring onto the drag lever to secure the whole folding stay actuator assembly onto the folding stay bracket Refer to Figure 10 Use new self locking nuts Use a new snap ring 2 Make sure the lock wire for the hydraulic actuator is installed 3 Connect the tension spring S Move the tension spring into position S Push the tension spring into its mounting where it is connected to the ML...

Page 1306: ...g lever Refer to Figure 10 Use a new snap ring 5 Install the nut spacer and bolt which connect the latch operating arm with the folding stay Refer to Figure 10 6 Remove the foam plastic between MLG leg and the GFRP of the airplane fuselage 7 Reset the GEAR circuit breaker Right side of instrument panel 8 Bleed the hydraulic system Refer to Section 29 10 9 Do a test for the correct operation of the...

Page 1307: ...ding gear Make sure the floor is level in the work area Refer to Figure 12 4 Measure the wheel track S Measure from the front wing root edge LH and RH between wing and fuselage perpendicular to the ground S Mark these points on the ground and draw a line or use a straight beam which aligns with both points S Use a metal angle or similar and hold it onto the measured line from the previous step to ...

Page 1308: ...02 15 Rev 4 7 If the Wheel Track and Camber Report does not meet the requirement contact DAI 8 Measure the track width If the track width does not meet the requirement contact DAI Refer to Figure 12 and Section 06 00 Figure 10 9 Move the airplane off the slide sheets 10 Install the main gear door Refer to Paragraph 8 ...

Page 1309: ...34 4 4 1 35 7 7 2 36 1 2 0 37 4 5 1 38 7 8 2 39 1 3 0 40 4 6 1 41 7 9 2 42 1 4 0 43 4 7 1 44 8 2 45 1 5 0 46 4 8 1 47 8 1 2 48 1 6 0 49 4 9 1 50 8 2 2 51 1 7 0 52 5 1 53 8 3 2 54 1 8 0 55 5 1 1 56 8 4 2 57 1 9 0 58 5 2 1 59 8 5 2 61 2 0 61 5 3 1 62 8 6 2 64 2 1 0 64 5 4 1 65 8 7 2 67 2 2 0 67 5 5 1 69 8 8 2 70 2 3 0 70 5 6 1 72 8 9 2 73 2 4 0 74 5 7 1 75 9 2 76 2 5 0 77 5 8 1 78 9 1 2 79 2 6 0 80 ...

Page 1310: ...eel Track Measurement Angle Bracket Greased Plates Straight Edge Angle Bracket Wheel Track Measurements Higher Wheel Track Value Lower Wheel Track Value Final Wheel Track Value Look up in table to convert to degrees Wing Root Edge Main Landing Gear Leg Note Ensure that the floor is levelled in the work area Top View 1 8 5 Figure 12 Main Gear Wheel Track ...

Page 1311: ...age trestles into position to support the airplane Refer to Section 07 10 2 Remove the dust cup from the wheel 3 Verify the tire pressure Refer to the AFM for correct pressure 4 Disconnect the MLG door from the MLG leg Refer to Paragraph 8 5 Set the ELECT MASTER switch to ON 6 Retract the landing gear 7 Check the clearance between the MLG tire and the lower wing shell wheel bay cutout S Put a tres...

Page 1312: ...r Pre Load Detail Steps Work Items Key Items References 1 Connect the MLG door Refer to Paragraph 8 2 Push the emergency landing gear extension lever 3 Set the ELECT MASTER switch to ON 4 Retract the landing gear 5 Measure the distance between the end plane of the wheel axle and the lower wing shell Refer to Figure 14 6 If the measurement does not meet the requirements S Adjust the rod end bearing...

Page 1313: ...the lower wing shell The correct pre load is 5 to 10 kg 11 to 22 lbf Refer to Figure 15 8 If the measurement does not meet the requirements S Adjust the MLG door pre load with the MLG door operating rod 9 Carry out a test of the correct operation of the landing gear retraction and extension system Refer to Section 32 30 10 Extend the landing gear 11 Set the ELECT MASTER switch to OFF 12 Install th...

Page 1314: ...AIRCRAFT Landing Gear DA 42 NG AMM Page 250 15 Mar 2018 32 10 00 Doc 7 02 15 Rev 4 Figure 13 Main Landing Gear Tire Clearance Measurement ...

Page 1315: ...AIRCRAFT DA 42 NG AMM Landing Gear Doc 7 02 15 Rev 4 32 10 00 Page 251 15 Mar 2018 Figure 14 Main Landing Gear Door Measurement ...

Page 1316: ...AIRCRAFT Landing Gear DA 42 NG AMM Page 252 15 Mar 2018 32 10 00 Doc 7 02 15 Rev 4 Figure 15 Main Landing Gear Door Pre Load Measurement ...

Page 1317: ...sing Stops on the tubular steel housing and the tubular steel strut limit the amount that the tubular steel strut can turn The tubular strut carries a universal joint coupling at the top The coupling has three parts A top pivot gimbal a bottom pivot gimbal and a central pivot block The top pivot gimbal has a steering actuator lever Refer to Section 32 50 for more data about the nose wheel steering...

Page 1318: ...g Assembly Nose Wheel Assembly Nose Landing Gear Mounting Bracket Connecting Rod Connecting Rod Hinge Hinge Hinge Hinge Hinge Hinge Left Door Hydraulic Actuator Tension Spring Folding Stay Right Door Steering Arm Bracket Linkage Buffer Steering Linkage Centering Unit Figure 1 Nose Gear Assembly ...

Page 1319: ...r strut This movement compresses the nitrogen in the damper When the load decreases the sliding tube moves out of the tubular strut The sliding tube can move quickly into the tubular strut In the reverse direction the speed of the sliding tube is limited by a damper This prevents the airplane from being pushed up after the landing and it also prevents vibration Refer to Section 32 50 for data abou...

Page 1320: ...02 15 Rev 4 Tubular Steel Housing Tubular Steel Strut Steering Brace Upper Sliding Tube Swivel Mount Swivel Mount Steering Stops Nose Wheel Fork Cardan Joint Bracket Steering Actuator Lever Centering Unit Steering Brace Lower Cardan Joint Figure 2 Nose Gear Leg Assembly ...

Page 1321: ...d across to the Possible Cause column Then do the repair given in the Repair column Trouble Possible Cause Repair Nose gear leg cracked or bent Hard landing Do the hard landing inspection given in Section 05 50 WARNING THE FOLDING STAY AND THE DAMPER ARE SPRING LOADED DUE TO THE HIGH FORCES INVOLVED THE ELEMENTS OF THE DAMPING SYSTEM CAN CAUSE SERIOUS INJURY TO PERSONS Nose gear leg extension too ...

Page 1322: ...AIRCRAFT Landing Gear DA 42 NG AMM Page 102 15 Mar 2018 32 20 00 Doc 7 02 15 Rev 4 Intentionally left blank ...

Page 1323: ...ain nose landing gear components They also tell you how to charge the damper with hydraulic fluid nitrogen You can remove the nose gear leg complete with the nose wheel or you can remove the wheel first Refer to Section 32 30 for data about the nose gear retraction extension system Refer to Section 32 40 for data about the nose wheel Refer to Section 32 60 for data about the landing gear position ...

Page 1324: ...g Brace Upper Spacer Washer Castle Nut Thin Nose Landing Gear Mounting Bracket Bolt Washer Spacer 4 Bolts Washer Bolt Bushing Nut Washer Cotter Pin Cotter Pin Castle Nut Thin Washer Spacer Washer Bolt Castle Nut Thin Cotter Pin Washer Bolt Cardan Joint Cardan Joint Bracket Washer If MÄM 42 659 is installed Plate If MÄM 42 659 is NOT installed Washer Figure 3 Nose Landing Gear Leg ...

Page 1325: ...ERSONS IF OPERATED ACCIDENTALLY WARNING THE FOLDING STAY AND THE DAMPER ARE SPRING LOADED DUE TO THE HIGH FORCES INVOLVED THE ELEMENTS OF THE DAMPING SYSTEM CAN CAUSE SERIOUS INJURY TO PERSONS 1 Raise the airplane on jacks and move the wing and rear fuselage trestles into position to support the airplane Refer to Section 07 10 2 Depressurize the hydraulic system Refer to Section 29 00 3 Pull the G...

Page 1326: ...cket from the pin and the cardan joint Refer to Figure 3 Steer the nose gear by hand so you get better access to the rear joint mount 9 Remove the carpet in the front baggage compartment 10 Airplanes with de icing system S Remove the de icing fluid tank S Remove the de icing metering pump S Remove the filter cartridge Refer to Section 30 00 This step is necessary to get access to the nose gear leg...

Page 1327: ... 3 Airplanes without de icing system S Install the LH and RH aft access panels in the front baggage compartment 4 Install the carpet in the front baggage compartment 5 Install the cardan joint assy S Install the cardan joint bracket onto the pin and move the cardan joint into position S Install the bolt washer and nut onto the rear cardan joint mount S Install the bolt washer and nut onto the fron...

Page 1328: ...ng stay switches and secure the electrical connections with cable binder Refer to Section 32 60 10 Reset the GEAR circuit breaker Right side of instrument panel 11 Do a test for the correct operation of the landing gear retraction and extension system 12 Move the wing and rear fuselage trestles clear of the airplane 13 Lower the airplane Refer to Section 07 10 ...

Page 1329: ...R RETRACTION SYSTEM CAN CAUSE SERIOUS INJURY TO PERSONS IF OPERATED ACCIDENTALLY WARNING THE FOLDING STAY AND THE DAMPER ARE SPRING LOADED DUE TO THE HIGH FORCES INVOLVED THE ELEMENTS OF THE DAMPING SYSTEM CAN CAUSE SERIOUS INJURY TO PERSONS 1 Pull the GEAR circuit breaker Right side of instrument panel 2 Raise the airplane on jacks and move the wing and rear fuselage trestles into position to sup...

Page 1330: ...ear bay S Align the hinges of the door with the hinges at the nose gear bay and install the 4 hinge pins S Install the roll pins into the door hinges Use new roll pins 2 Connect the door operating rod to the door that you installed S Push the rod onto the ball end fitting S Install the safety clip onto the end of the operating rod 3 Reset the GEAR circuit breaker Right side of instrument panel 4 D...

Page 1331: ...NS BY SECURING THE AREA AROUND THE AIRPLANE BEFORE YOU PERFORM MAINTENANCE ON THE LANDING GEAR THE LANDING GEAR RETRACTION SYSTEM CAN CAUSE SERIOUS INJURY TO PERSONS IF OPERATED ACCIDENTALLY 1 Pull the GEAR circuit breaker On the right side of instrument panel 2 Raise the airplane on jacks and move the wing and rear fuselage trestles into position to support the airplane Refer to Section 07 10 3 R...

Page 1332: ...e damper assembly out of the nose gear Support the nose gear Refer to Figure 2 Use the special tool narrow wrench 6 Remove the torque links S Remove the bolts washers spacers and lock nuts from the nose gear S Move the torque links clear from the nose gear Refer to Figure 3 7 Remove the centering guidance plate S Remove the locking wire S Remove the spacers washers and bolts S Move the centering u...

Page 1333: ...ire and check the pressure Refer to Section 32 40 Look specially for scratches and deformation Refer to Section 12 10 2 Inspect the nose wheel fork S Examine the structure Look for cracks 3 Inspect the torque links Look for cracks deformation and play 4 Inspect the nose gear damper S Examine the sliding tube S Check the strut extension S Check for oil leakage Look specially for surface damages and...

Page 1334: ...lled heads are used 2 Install the torque links S Move the torque links into position S Install the four bolts washers and lock nuts onto the nose gear Refer to Figure 3 Use a new self locking nut Apply Loctite onto the thread There must be a play sideways of 0 1 0 3 mm 0 004 0 012 in 3 Install the nose gear damper assembly S Slide the damper assembly into the nose gear S Move the shim slide plate ...

Page 1335: ...nding Gear Damper Assembly The subsequent table tells you about the correct strut extension and pressure of the unloaded fully extended nose landing gear damper Strut Extension unloaded visible length of bare piston Gas Pressure 20 cm 8 inches 16 bar 232 PSI at 20 C 68 F If MÄM 42 659 is installed 10 bar 145 PSI at 20 C 68 F ...

Page 1336: ...edure tells you how to fill the nose gear damper assembly with hydraulic fluid and then charge with nitrogen A Equipment Item Quantity Part Number Bottle 1 Commercial Bleed tube 1 Commercial Valve core removal tool 1 Commercial Nitrogen charging equipment 1 Commercial Airplane jacks 3 Commercial Wing trestle 2 Commercial Rear fuselage trestle 1 Commercial ...

Page 1337: ...ifying the type of hydraulic fluid All airplanes with MÄM 42 495 NOT installed have been manufactured with Aeroshell Fluid 41 MIL PRF 5606 H The identification placard must be installed if a hydraulic fluid change to another fluid type is carried out Hydraulic fluid As required Aeroshell Fluid 41 MIL PRF 5606 H or AMG 10 GOST 6794 75 Amdt 1 5 see CAUTION above Grease for sliding interfaces As requ...

Page 1338: ...ORRECTLY THE NOSE LANDING GEAR WILL NOT OPERATE CORRECTLY THIS CAN CAUSE DAMAGE TO THE NOSE LANDING GEAR AND THE AIRPLANE STRUCTURE Detail Steps Work Items Key Items References WARNING TAKE PRECAUTIONS BY SECURING THE AREA AROUND THE AIRPLANE BEFORE YOU PERFORM MAINTENANCE ON THE LANDING GEAR THE LANDING GEAR RETRACTION SYSTEM CAN CAUSE SERIOUS INJURY TO PERSONS IF OPERATED ACCIDENTALLY 1 Pull the...

Page 1339: ...495 is carried out a placard is installed by the airplane manufacturer identifying the type of hydraulic fluid All airplanes with MÄM 42 495 NOT installed have been manufactured with Aeroshell Fluid 41 MIL PRF 5606 H The identification placard must be installed if a hydraulic fluid change to another fluid type is carried out 7 Turn the bottle to the open position and allow the hydraulic fluid to f...

Page 1340: ...ipment from the damper charging valve 15 Install the dust cap onto the charging valve 16 Reset the GEAR circuit breaker Right side of instrument panel 17 Remove the rear fuselage and wing trestles clear of the airplane 18 Lower the airplane with the jacks Refer to Section 07 10 Make sure that the area around the airplane is clear of equipment D Fluid Change from Aero Shell Fluid 41 to AMG 10 Detai...

Page 1341: ...2 20 00 Page 219 15 Mar 2018 Placard NLG Hydraulic Fluid AeroShell Fluid 41 AMG 10 CAUTION Mixing of different fluid types is not permitted Refer to AMM for refilling or fluid change Figure 4 Position of the Hydraulic Fluid Placard Nose Landing Gear Damper ...

Page 1342: ...RE IT CAN ALSO REMOVE THE PAINT FROM SOME COMPONENTS A Equipment Item Quantity Part Number Airplane jacks 3 Commercial Wing trestle 2 Commercial Rear fuselage trestle 1 Commercial B Disconnect the Nose Landing Gear Folding Stay Assembly Detail Steps Work Items Key Items References WARNING TAKE PRECAUTIONS BY SECURING THE AREA AROUND THE AIRPLANE BEFORE YOU PERFORM MAINTENANCE ON THE LANDING GEAR T...

Page 1343: ...lear of the nose landing gear door Make sure to collect all pins CAUTION WHEN DISCONNECTING THE FOLDING STAY THE NOSE LANDING GEAR LEG SWINGS BACK AND CAN DAMAGE THE DIFFERENTIAL SWITCH HOLD THE NOSE LANDING GEAR LEG FIRMLY 7 Put foam plastic in between the nose landing gear leg and the airplane fuselage for damage protection 8 Disconnect the differential switch located in the nose gear bay S Remo...

Page 1344: ... nose landing gear folding stay tension S Remove the nut and washer from the nose landing gear leg which holds the folding stay S Carefully remove the bolt with spacer while securing the folding stay firmly S Release the nose landing gear folding stay slowly until the tension is fully released Refer to Figure 5 Support the folding stay with your hands and at the same time hold the nose landing gea...

Page 1345: ...ctuator to the nose landing gear brace S Move the nose landing gear actuator clear of the nose gear brace assembly Refer to Figure 5 15 Disconnect the curve part from the fuselage S Remove the bolt bushing washer and nut from both sides of the curve part Refer to Figure 5 16 If MÄM 42 659 is NOT installed Remove the nose landing gear leg Refer to Paragraph 2 B 17 If MÄM 42 659 is NOT installed Dis...

Page 1346: ...special washer on RH side S Pull axle from LH side Refer to Figure 6 Hold the folding stay assembly in place when pulling the axle 20 Move the nose landing gear folding stay assembly if MÄM 42 659 is NOT installed with the nose landing gear mounting bracket clear of the nose gear bay S The nose landing gear actuator is still connected via the hydraulic lines S Secure all parts so that the hydrauli...

Page 1347: ...Leg Bushing Bushing Latch Operating Arm Bolt 6 Washers 6 Nuts Bolt Bolt Nut Washer 6 Washers 6 Nuts 6 Bolts 6 Bolts Circlip Actuator Pin Circlip Curve Part Bushing Bushing Spacer Sleeve View A A Nose Gear Bracket Assy Nose Gear Brace Axle Assy Nose Gear Bracket Assy Washer Actuator Drag Lever Latch Operating Arm Tension Spring Washer Nut Spacer Sleeve Bolt Washer Bolt Figure 5 Nose Landing Gear Ex...

Page 1348: ...h Operating Arm Bolt 6 Washers 6 Nuts Bolt Nut Washer 6 Washers 6 Nuts 6 Bolts 6 Bolts Circlip Actuator Pin Circlip Curve Part Bushing Bushing Spacer Sleeve Special Washer View A A Nose Gear Bracket Assy Nose Gear Brace Axle Nose Gear Bracket Assy Special Washer Nut Nut Bolt Actuator Drag Lever Latch Operating Arm Tension Spring Washer Nut Spacer Sleeve Bolt Washer Figure 6 Nose Landing Gear Exten...

Page 1349: ...stay assembly in position on the nose landing gear frame S Connect the mounting bracket with the 22 bolts washers and nuts to the nose landing gear frame Seal the bonding connections 3 If MÄM 42 659 is NOT installed Connect the nose landing gear brace assembly to the nose landing gear bay S Install the 6 bolts washers and nuts on both sides of the nose landing gear brace Refer to Figure 5 Use new ...

Page 1350: ...all the de icing fluid tank Refer to Section 30 00 9 Install the carpets in the front baggage compartment 10 Install the tension spring S Move the tension spring into position S Install the bolt nut washer spacer and bushing which connects the tension spring to the nose landing gear leg Refer to Figure 5 Make sure to mount the tension spring and the bushing as noted during disassembling 11 Connect...

Page 1351: ...he differential switch Refer to Section 32 60 15 Install the two nose landing gear extension switches Refer to Section 32 60 16 Adjust the nose landing gear extension switches Refer to Section 32 60 17 Connect the nose landing gear door arms to the nose landing gear doors 18 Connect the main battery Refer to Section 24 31 19 Set the GEAR circuit breaker 20 Set the ELECT MASTER switch to ON 21 Perf...

Page 1352: ...Landing Gear DA 42 NG AMM Page 230 15 Mar 2018 32 20 00 Doc 7 02 15 Rev 4 Nose Gear Brace Nose Gear Leg Tube Nose Gear Wheel Landing Gear Door Min 5 mm 0 2 inch 20mm 0 8 inch Figure 7 Nose Landing Gear Actuator ...

Page 1353: ...Steps Work Items Key Items References WARNING TAKE PRECAUTIONS BY SECURING THE AREA AROUND THE AIRPLANE BEFORE YOU PERFORM MAINTENANCE ON THE LANDING GEAR THE LANDING GEAR RETRACTION SYSTEM CAN CAUSE SERIOUS INJURY TO PERSONS IF OPERATED ACCIDENTALLY 1 Raise the airplane on jacks and move the wing and rear fuselage trestles into position to support the airplane Refer to Section 07 10 2 Retract the...

Page 1354: ...GEAR LEG FIRMLY 8 Put foam plastic in between the nose landing gear leg and the airplane fuselage for damage protection CAUTION THE NOSE LANDING GEAR FOLDING STAY IS SPRING LOADED DUE TO THE HIGH FORCES INVOLVED THE ELEMENT OF THE FOLDING STAY CAN CAUSE SERIOUS INJURY TO PERSONS WARNING FOR THE FOLLOWING STEP SIT IN FRONT OF THE NOSE LANDING GEAR LEG FACING THE AFT MAKE SURE TO POSITION YOURSELF S...

Page 1355: ...ur hands and at the same time hold the nose landing gear leg with your feet The nose landing gear leg falls backwards when the bolt is removed 10 Disconnect the hydraulic lines from the actuator Use a suitable container to catch spilt hydraulic fluid Fit caps on all open connections 11 Disconnect the actuator from the nose landing gear S Remove the circlip which secures the ball joint of the actua...

Page 1356: ...AIRCRAFT Landing Gear DA 42 NG AMM Page 234 15 Mar 2018 32 20 00 Doc 7 02 15 Rev 4 Figure 8 Nose Landing Gear Actuator Measurements ...

Page 1357: ...efer to Figure 8 3 Connect the hydraulic lines to the actuator Remove all caps 4 Connect the nose landing gear actuator to the nose landing gear S Move the nose landing gear actuator into position in the nose landing gear brace assembly S Install the bolt washer and nut connecting the actuator to the nose landing gear brace assembly S Install the pin with the two circlips to connect the actuator t...

Page 1358: ...breaker 11 Set the ELECT MASTER switch to ON 12 Retract the landing gear S Set the Landing Gear switch to the UP position and secure against inadvertent operation 13 Pull the emergency landing gear lever to the emergency extension position 14 Measure and record the distance in between the nose landing gear actuator safety lock washer to the cylinder head Refer to Figure 8 Note the distance X 15 Ex...

Page 1359: ...ear actuator counter nut and install the safety lock wire WARNING DUE TO THE HIGH FORCES INVOLVED THE LANDING GEAR RETRACTION SYSTEM CAN CAUSE SERIOUS INJURY TO PERSONS MAKE SURE THAT NO PERSON CAN BE HIT OR CRUSHED WHEN OPERATING THE LANDING GEAR RETRACTION SYSTEM 20 Set the GEAR circuit breaker 21 Set the ELECT MASTER switch to ON 22 Retract the landing gear S Set the Landing Gear Switch to the ...

Page 1360: ...least 5 mm 0 2 in If the clearance does not meet the requirement Contact DAI Refer to Figure 7 25 Set the Landing Gear switch to DOWN 26 Connect the nose landing gear door arms to the nose landing gear doors 27 Perform a test of the correct operation of the landing gear extension and retraction system Refer to Section 32 30 28 Move the wing and rear fuselage trestles clear of the airplane 29 Lower...

Page 1361: ... Gear Mounting Bracket Detail Steps Work Items Key Items References 1 Remove the nose landing gear leg Refer to Paragraph 2 2 Remove the LH and the RH nose gear bracket assy S Remove the 6 mounting bolts washers and nuts from both sides of the baggage compartments and nose gear bay Refer to Figures 5 6 3 Disconnect the nose landing gear mounting bracket S Remove the 22 bolts washers and nuts which...

Page 1362: ...ew self locking nuts 2 Install the LH and RH nose gear bracket assy S Install the 6 mounting bolts washers and nuts on both sides of the baggage compartment and nose gear bay Use new self locking nuts If MÄM 42 659 is installed Install bracket assy with plain bearing on the LH side Orientation of LH side bracket according to Figure 9 Figure 9 LH Nose Gear Mounting Bracket Position if MÄM 42 659 is...

Page 1363: ...s and the surrounding structure unfold to lock the legs in the extended position A spring operated latching mechanism holds the folding stays in a geometrically locked position The initial movement of the gear actuator when moving to retract the landing gear operates the mechanism to unlock the folding stay As the gear retracts the folding stay folds and retracts into the landing gear bay with its...

Page 1364: ...A TEAIR ON EMERGENCY Gear Extension Max 160 KIAS ALT ERNA TEAIR Hydraulic Supply and Control System Extension Retraction Actuator Extension Retraction Actuator Nose Gear Folding Stay Main Gear Folding Stay Selector Handle Emergency Extension Lever Figure 1 Extension and Retraction System Main Components ...

Page 1365: ...y Folding Stay Tubular Steel Strut Tubular Steel Strut Hydraulic Actuator Tension Spring Hydraulic Actuator Latching Mechanism Damper Trailing Arm Longitudinal Pivot EXTENDED VIEW FROM AFT RETRACTED VIEW FROM AFT Left gear leg shown right similar Tension Spring Figure 2 Main Landing Gear Extension and Retraction ...

Page 1366: ...avity are used to extend the legs and a spring loaded mechanism on each leg folding stay locks the leg in the extended position The main component of the emergency extension system is the Emergency extension valve The emergency extension valve is located on the hydraulic control and is operated by the emergency extension lever When the emergency extension valve is operated emergency extension posi...

Page 1367: ...Landing Gear Nose Landing Gear Mounting Bracket Nose Landing Gear Mounting Bracket Hydraulic Actuator Hydraulic Actuator Tension Spring Folding Stay Latching Mechanism Tubular Steel Strut EXTENDED VIEW FROM LEFT RETRACTED VIEW FROM LEFT Figure 3 Nose Landing Gear Extension and Retraction ...

Page 1368: ...ctive surface area on the extend side of the actuator piston Because the same fluid pressure is acting on different effective areas of the actuator pistons the resulting differential pressure acting on the piston causes the actuator to move the landing gear leg towards the retract position The initial movement of the hydraulic actuators towards the retract position releases the folding stay latchi...

Page 1369: ...p Pressure Switch Accumulator Dump Valve Pump Motor 24V Safety Valve Extend Solenoid Valve Level Indicator Tank Closing Valve Breather Filter HP Filter Drain Fitting Filler Cap Retract LG Extend LG Retract LG Extend LG Retract Extend LG R R R E E E NRV NRV NRV NRV NRV 1400 psi ON 1650 psi OFF 1750 1850 psi Relief Valve 2600 psi 14 psi Regulating Valve Flow 1 5 Flow 1 5 Flow 1 7 2 Way Flow Control ...

Page 1370: ... Pump Pressure Switch Accumulator Dump Valve Pump Motor 24V Safety Valve Extend Solenoid Valve Level Indicator Tank Closing Valve Breather Filter HP Filter Drain Fitting Filler Cap Retract LG Extend LG Retract LG Extend LG Retract LG Extend LG R R R E E E NRV NRV NRV NRV NRV 1400 psi ON 1650 psi OFF 1750 1850 psi Relief Valve 2600 psi 14 psi Regulating Valve Flow 1 5 Flow 1 5 Flow 1 7 2 Way Flow C...

Page 1371: ...alve Pump Pressure Switch Accumulator Dump Valve Pump Motor 24V Safety Valve Supply Solenoid Valve Level Indicator Tank Closing Valve Breather Filter HP Filter Drain Fitting Filler Cap Retract LG Extend LG Retract LG Extend LG Retract LG Extend LG R R R E E E NRV NRV NRV NRV NRV 1400 psi ON 1650 psi OFF 1750 1850 psi Relief Valve 2600 psi 14 psi Regulating Valve Flow 1 5 Flow 1 5 Flow 1 7 2 Way Fl...

Page 1372: ...regulating valves and back into the reservoir The pump pressure switch operates the pump as necessary to maintain the system pressure at 96 5 113 8 bar 1400 1650 PSI The pressure acting on the extend side of the actuator piston moves the piston to extend the landing gear legs As the legs reach the fully extended position the latches on the folding stays operate against spring pressure to lock the ...

Page 1373: ...er Gas Valve Pump Pressure Switch Accumulator Dump Valve Pump Motor 24V Safety Valve Extend Solenoid Valve Level Indicator Tank Closing Valve Breather Filter HP Filter Drain Fitting Filler Cap Retract Extend Retract Extend Retract Extend R R R E E E NRV NRV NRV NRV NRV 1400 psi ON 1650 psi OFF 1750 1850 psi Relief Valve 2600 psi 14 psi Regulating Valve Flow 1 5 Flow 1 5 Flow 1 7 2 Way Flow Control...

Page 1374: ...t run Gravity causes the weight of each landing gear leg to move the piston in each actuator inwards The open emergency extension valve allows the fluid on the retract side of the piston in each actuator to flow through the by pass valves The by pass valves allow the hydraulic fluid flowing from the actuators to by pass the regulating valves and return to the reservoir The position of the solenoid...

Page 1375: ...Repair Landing gear does not retract when the selector lever is set to UP Hydraulic pump GEAR circuit breaker pulled Emergency extension lever operated Hydraulic pump defective Hydraulic supply and control assembly defective Wiring from landing gear selector to hydraulic supply and control panel defective Reset GEAR circuit breaker Reset emergency extension lever Replace hydraulic pump Replace hyd...

Page 1376: ...nuously keeps cycling Accumulator pressure low defective Pump pressure switch defective Internal leak in the hydraulic supply and control assembly Recharge replace accumulator Replace pump pressure switch Refer to MAINTENANCE PRACTICES Paragraph 5 Replace hydraulic supply and control assembly Hydraulic system fluid level low Hydraulic fluid leak Do a test for leaks in the hydraulic system Tighten ...

Page 1377: ...n system They also tell you how to do a test for the correct operation of the landing gear extension and retraction system Refer to Section 32 10 for data about the main landing gear Refer to Section 32 20 for data about the nose landing gear Refer to Section 32 40 for data about the wheels and brakes Refer to Section 32 50 for data about the nose wheel steering system Refer to Section 32 60 for d...

Page 1378: ...AIRCRAFT Landing Gear DA 42 NG AMM Page 202 15 Mar 2018 32 30 00 Doc 7 02 15 Rev 4 Figure 8 Main Landing Gear Hydraulic Actuator Installation ...

Page 1379: ...r 2018 Outer Cylinder Cylinder Head Piston Rod Assy Washer Spherical Rod End Bearing Threaded Ring Spherical Bearing Hydraulic Fitting Hydraulic Fitting Counter Nut Figure 9 Landing Gear Hydraulic Actuator Assembly for Correct Alignment of Hydraulic Fittings Refer to Figure 10 ...

Page 1380: ...AIRCRAFT Landing Gear DA 42 NG AMM Page 204 15 Mar 2018 32 30 00 Doc 7 02 15 Rev 4 Main Landing Gear Actuator Nose Landing Gear Actuator Figure 10 Hydraulic Actuator Alignments ...

Page 1381: ...e Actuator Detail Steps Work Items Key Items References 1 Measure and make a note of the distance from the actuator safety lock washer to the center of the rod end bearing Refer to Figure 11 2 Remove spherical rod end bearing S Remove the lock wire from the counter nut S Loosen the counter nut S Remove the spherical rod end bearing counter nut and the washer from the actuator Refer to Figure 9 3 C...

Page 1382: ...S Place the spanner wrench special tool onto the cylinder head S Place the hook wrench onto the threaded ring S Loosen the cylinder head by turning the hook wrench and holding the spanner wrench special tool against it S Remove the cylinder head Refer to Figure 9 5 Remove the hydraulic fitting the threaded ring and the piston rod from the actuator Refer to Figure 9 Figure 11 MLG Actuator Measureme...

Page 1383: ...Refer to Figure 9 4 Install the cylinder head S Install the seal ring protection special tool onto the piston rod S Slide the cylinder head onto the piston rod S Remove the seal ring protection special tool from the piston rod S Apply Rivolta F L A on the cylinder head thread the O ring and the snap ring S Install the spanner wrench special tool onto the cylinder head S Place the hook wrench onto ...

Page 1384: ...t the main landing gear rod end bearing according to the measurement or the base setting of 34 mm 1 34 in from the safety lock washer to the center of the rod end bearing S Tighten the counter nut Install the lock wire not until installing the actuator into the airplane because of correct alignment Refer to Figure 9 Refer to Figure 11 Base settings equals min screw in depth Maximum distance x min ...

Page 1385: ...ARNING DO NOT LET PERSONS NEAR THE LANDING GEAR WHEN YOU DO THE EXTENSION AND RETRACTION TEST THE LANDING GEAR CAN CAUSE INJURY TO PERSONS CAUTION MAKE SURE THAT THE AREA AROUND THE AIRPLANE IS CLEAR IF THE LANDING GEAR HITS AN OBJECT THE LANDING GEAR CAN BE DAMAGED 1 Raise the airplane on jacks and move the wing and rear fuselage trestles into position to support the airplane Refer to Section 07 ...

Page 1386: ... When the gear is fully retracted S The red led UNSAFE switches off S The hydraulic pump stops operating allow 15 sec after gear is fully retracted Refer to Section 32 60 for more data about the landing gear indicating system 6 Do a test for the correct operation of the landing gear warning horn S Move the left engine power lever to IDLE S Move the right engine power lever to IDLE S Move the left ...

Page 1387: ...S The landing gear extends S When all the landing gear legs are fully extended and locked S The red led UNSAFE switches off S The green SAFE leds illuminate S The hydraulic pump stops operating allow 15 sec after gear is fully extended S Set both engine power levers to IDLE 8 Set the ELECT MASTER switch to OFF 9 Disconnect the external power supply from the airplane Refer to Section 24 40 10 Move ...

Page 1388: ... Items References WARNING DO NOT LET PERSONS NEAR THE LANDING GEAR WHEN YOU DO THE EMERGENCY EXTENSION TEST THE LANDING GEAR CAN CAUSE INJURY TO PERSONS CAUTION MAKE SURE THAT THE AREA AROUND THE AIRPLANE IS CLEAR IF THE LANDING GEAR HITS AN OBJECT THE LANDING GEAR CAN BE DAMAGED 1 Raise the airplane on jacks and move the wing and rear fuselage trestles into position to support the airplane Refer ...

Page 1389: ...ly retracted Refer to Section 32 60 for more data about the landing gear indicating system 5 Set the EMERGENCY EXTENSION lever to the EXTEND position these events must occur S The hydraulic pump must not operate S The red UNSAFE led illuminates S The landing gear extends When the landing gear is fully extended and locked S The red UNSAFE led remains on S The 3 green SAFE leds illuminate Pull fully...

Page 1390: ...2018 32 30 00 Doc 7 02 15 Rev 4 7 Do a test of the correct operation of the landing gear normal retraction and extension system Refer to Paragraph 3 8 Move the wing and fuselage trestles clear of the airplane 9 Lower the airplane with the jacks Make sure that the area around the airplane is clear ...

Page 1391: ... wheels are standard Cleveland components The main wheels have brake disks and a Cleveland brake caliper Toe brake pedals operate hydraulic cylinders Hydraulic pipes and hoses connect the cylinders to the brake calipers A parking valve locks the brakes ON Each main wheel has an independent brake system The left pedal of each rudder pedal assembly operates the left wheel brake and the right rudder ...

Page 1392: ...Seal Felt Grease Seal Snap Ring Snap Ring Bolt Brake Disc Tire A B B A A Ring Grease Seal Ring Grease Seal Inner Tube Inner Tube Bearing Bearing Ring Grease Seal Ring Grease Seal Ring Grease Seal Felt Grease Seal Felt Grease Seal Snap Ring Snap Ring Hub Hub Hub Hub Dust Shield Screw Tire Figure 1 Main and Nose Wheel Assemblies ...

Page 1393: ...5x6 00 6 6 PR TT 160 mph FS II tire with a Goodyear 6 00 6 15x6 00 6 G15 6 00 6 inner tube valve type TR 20 If MÄM 42 659 is installed each main wheel may have a Goodyear 15x6 00 6 6 PR TT 160 mph FC III or FS II tire with a Goodyear 6 00 6 15x6 00 6 G15 6 00 6 inner tube valve type TR 20 Two red slip marks one on the tire and the other on the wheel are aligned 3 Description Nose Wheel Figure 1 sh...

Page 1394: ... Co Pilot s Pedals Pilot s Pedals Flexible Hose Parking Brake Valve PARKING BRAKE Brake Disk Brake Caliper Flexible Hose Master Cylinders Master Cylinders Back Plate Pressure Plate Brake Fluid Reservoir Max Level 12 mm 0 5 in Min Level 25 mm 1 in LOCK RELEASE Figure 2 Wheel Brake System Schematic Diagram ...

Page 1395: ...e hoses connect the parking brake valve to each main wheel brake caliper The parking brake valve is mounted on the floor of the fuselage below the seats A flexible cable connects the parking brake valve to an operating lever mounted in the cockpit center console The brake calipers are standard Cleveland components Two pistons in each caliper push a friction lining against the brake disk and a back...

Page 1396: ... Mar 2018 32 40 00 Doc 7 02 15 Rev 4 LH installation shown RH installation similar Back Plate Attaching Bolt Washer Pressure Plate Back Plates Caliper Bleed Nipple Brake Torque Plate Friction Lining Anchor Pins Figure 3 Main Wheel Brake Assembly ...

Page 1397: ...te against the other side of the disk The wheel brake disk is held between the friction linings If you release the pressure on the brake pedal the fluid can go back into the master cylinder and the brake caliper releases the brake disk The wheel is free to turn The right brake pedal of each set of rudder pedals operates the right wheel brake The left brake pedal of each set of rudder pedals operat...

Page 1398: ...AIRCRAFT Landing Gear DA 42 NG AMM Page 8 15 Mar 2018 32 40 00 Doc 7 02 15 Rev 4 Intentionally left blank ...

Page 1399: ...ind the trouble given in Trouble column read across to the Possible Cause column Then do the repair given in the Repair column Trouble Possible Cause Repair Too much wheel run out Wheel bearing s defective Replace the defective wheel bearing s Brake disk damaged Hard landing Excessive braking Replace damaged brake disk Do a hard landing inspection Refer to Section 05 50 Replace brake disk s ...

Page 1400: ...l the brake reservoir s with brake fluid Bleed the brake system Examine the brake system Look specially for leaks Do a test for the correct operation of each master cylinder Replace defective master cylinder s Examine the brake caliper Look specially for leaks and for a piston that is seized Repair replace the caliper Replace the brake friction linings Tighten replace leaking connectors Parking br...

Page 1401: ... 1 Commercial B Remove a Main Wheel WARNING DO NOT LIFT THE AIRPLANE ON JACKS IN THE OPEN IF THE WIND SPEED IS MORE THAN 10 KM H 6 KNOTS Detail Steps Work Items Key Items References 1 Lift the airplane on jacks Refer to Section 07 10 WARNING TAKE PRECAUTIONS BY SECURING THE AREA AROUND THE AIRPLANE BEFORE YOU PERFORM MAINTENANCE ON THE LANDING GEAR THE LANDING GEAR RETRACTION SYSTEM CAN CAUSE SERI...

Page 1402: ... 2018 32 40 00 Doc 7 02 15 Rev 4 Back Plate Attaching Bolt Washer Pressure Plate Back Plates Caliper Brake Torque Plate Axle Wheel Castellated Nut Cotter Pin LH Wheel shown RH Wheel similar Dust Shield Washer Screw Figure 4 Remove Install a Main Wheel ...

Page 1403: ...y 5 Remove the wheel from the axle S Remove the dust shield S Remove the cotter pin from the castle nut S Remove the castle nut that holds the wheel to the axle S Pull the wheel off the axle and clear of the airplane 6 Examine the wheel bearings S Examine the wheel bearings for contamination S Look for damage to the bearings S Turn the bearing slowly and listen for noise that may indicate wear to ...

Page 1404: ...l turns freely and with no noise No perceptible play in the bearings allowed 3 Move the caliper into position at the wheel Make sure that the mounting spigots engage with the locating bushes of the torque plate Make sure that the pressure plate is correctly located within the caliper 4 Install the back plates S Move the back plates into position at the caliper S Install the 4 bolts and Washers tha...

Page 1405: ... 5 Reset the GEAR circuit breaker and make sure that the landing gear selector is set to DOWN 6 If a tire wheel change is performed check minimum clearance between MLG tire and the lower wing shell wheel bay cut out Refer to Section 32 10 Adjustment of the MLG wheel in retracted position 7 Carry out a test of the correct operation of the landing gear retraction and extension system Refer to Sectio...

Page 1406: ...ly and quietly 3 Remove the nose wheel form the airplane S Remove the nut and washer that holds the axle bolt in the wheel fork S Remove the axle bolt and flanged bushes S Move the nose wheel clear of the airplane S Remove and retain the spacers and tubular axle from the wheel Refer to Figure 5 Support the nose wheel 4 Examine the wheel bearings S Examine the wheel bearings for contamination S Loo...

Page 1407: ...T DA 42 NG AMM Landing Gear Doc 7 02 15 Rev 4 32 40 00 Page 207 15 Mar 2018 Bolt Flanged Bush Flanged Bush Axle Washer Nut Spacer Wheel Assembly Wheel Fork Spacer Washer Figure 5 Remove Install the Nose Wheel ...

Page 1408: ... S Move the wheel into position in the fork S Install the flanged bushes S Install the axle bolt with washer through the fork and wheel S Install the washer and nut that holds the axle bolt into the fork Torque 16 Nm 11 8 lbf ft 2 Make sure that the wheel turns freely and with no noise No perceptible play in the bearings allowed 3 Make sure that the nose gear leg is locked down 4 Move the wing tre...

Page 1409: ... the 2 halves of the hub together Refer to Figure 1 4 Remove the brake disk from the wheel Main wheels only 5 Remove the hubs from the tire 6 Remove the inner tube from the tire 7 Remove the bearings from each hub of the wheel S Remove the snap ring S Remove the grease seals from the hub S Remove the bearing cones Note the order of the seals Refer to Cleveland Parker Maintenance Manual latest revi...

Page 1410: ...utside of the inner tube 3 Assemble the main wheel S Move the main wheel hubs into position in the tire S Move the brake disk into position at the inner hub S Install the bolts that attach the brake disk and the 2 hub halves S Install the washers and nuts onto the bolts Torque according to Cleveland Parker Maintenance Manual latest revision or placard on rim 4 Assemble the nose wheel S Move the no...

Page 1411: ...LIC FLUID AT HIGH PRESSURE CAN PENETRATE YOUR SKIN AND CAUSE DISEASE WARNING DO NOT GET HYDRAULIC FLUID ON YOU HYDRAULIC FLUID CAN CAUSE SKIN DISEASE AND IT CAN DAMAGE CLOTHING CAUTION CLEAN OFF SPILT HYDRAULIC FLUID IMMEDIATELY HYDRAULIC FLUID CAN CAUSE DAMAGE TO THE AIRPLANE STRUCTURE AND IT CAN REMOVE PAINT FROM COMPONENTS Note Put caps on all open hydraulic connections to prevent contamination...

Page 1412: ...HYDRAULIC FLUID ON YOU HYDRAULIC FLUID CAN CAUSE SKIN DISEASE AND IT CAN DAMAGE CLOTHING CAUTION CLEAN OFF SPILT HYDRAULIC FLUID IMMEDIATELY HYDRAULIC FLUID CAN CAUSE DAMAGE TO THE AIRPLANE STRUCTURE AND IT CAN REMOVE PAINT FROM COMPONENTS 1 If necessary remove the brake fluid reservoir S Remove the hose from lower hydraulic connection S Remove the reservoir from the top hydraulic connection Co pi...

Page 1413: ...clevis pin S Remove the cotter pin from the clevis pin S Remove the washer S Remove the clevis pin 4 Release the master cylinder from the lower mounting spindle S Remove the cotter pin from the mounting spindle S Remove the washer S Move the master cylinder clear of the pedal assembly S Remove and retrain the spacer from the lower mounting spindle ...

Page 1414: ...4 Brake Fluid Reservoirs Co Pilots Pedals Only Brake Pedals Top Clevis Pin Lower Mounting Spindle Upper Cotter Pin Lower Cotter Pin Washer Washer Brake Master Cylinder Upper Hydraulic Reservoir Connection Lower Hydraulic Connection Spacer Figure 6 Brake Master Cylinder Installation ...

Page 1415: ... the top of the master cylinder with the mounting on the brake pedal S Install the upper clevis pin S Install the washer onto the clevis pin S Install the cotter pin 4 Install the hose onto the lower hydraulic connection on the master cylinder Make sure that all blanking caps are removed 5 Install the hose onto the upper hydraulic connection on the master cylinder Pilot s pedals only Make sure tha...

Page 1416: ...king Brake Lever Swivel Fitting To Right Brake Caliper To Left Brake Caliper Parking Brake Valve Inlet for Left Brake System Inlet for Right Brake System Control Bulkhead Large Washer Self Locking Nut Bowden Cable from Parking Brake Control Lever Cable Adjuster Figure 7 Parking Brake Valve Installation ...

Page 1417: ...OFF SPILT HYDRAULIC FLUID IMMEDIATELY HYDRAULIC FLUID CAN CAUSE DAMAGE TO THE AIRPLANE STRUCTURE AND IT CAN REMOVE PAINT FROM COMPONENTS 2 Disconnect the Bowden cable S Loosen the screw in the swivel fitting S Pull the inner wire of the Bowden cable out of the swivel fitting Refer to Figure 7 3 Disconnect the 4 brake hoses from the parking brake valve Use a suitable container to catch spilt fluid ...

Page 1418: ... brake valve S Move the inner cable of the Bowden cable through the swivel fitting S Make sure that the parking brake control lever in the cockpit is set to RELEASE S Make sure that the operating lever on the parking brake valve is set to the fully open position S Tighten the screw of the swivel fitting 5 Bleed the brake system Refer to Paragraph 9 6 Do a test for the correct operation of the park...

Page 1419: ... FROM COMPONENTS 1 Disconnect the brake hose from the brake caliper Refer to Figure 8 Use a suitable container to catch spilt fluid Put blanking caps on all open connectors CAUTION DO NOT OPERATE THE BRAKES WHILE THE CALIPER BACK PLATES ARE REMOVED OR THE CALIPER IS REMOVED FROM THE AIRPLANE IF YOU DO OPERATE THE BRAKES THE PISTONS BE PUSHED OUT FROM THE CYLINDERS 2 Remove the backing plates from ...

Page 1420: ...220 15 Mar 2018 32 40 00 Doc 7 02 15 Rev 4 LH installation shown RH installation similar Back Plate Attaching Bolt Brake Hose Connector Washer Pressure Plate Back Plates Mounting Spigots Brake Torque Plate Figure 8 Brake Caliper Installation ...

Page 1421: ...spigots engage with the locating bushes of the torque plate Make sure that the pressure plate is correctly located within the caliper 5 Install the back plates S Move the back plates into position at the caliper S Install the 4 bolts and washers that attach the back plates to the caliper finger tight S Make sure that the wheel brake disk can rotate freely between the caliper pressure plate and the...

Page 1422: ...LUID CAN CAUSE SKIN DISEASE IT CAN ALSO DAMAGE CLOTHING CAUTION CLEAN OFF SPILT HYDRAULIC FLUID IMMEDIATELY HYDRAULIC FLUID CAN DAMAGE THE AIRPLANE STRUCTURE IT CAN ALSO REMOVE THE PAINT FROM SOME COMPONENTS Detail Steps Work Items Key Items References 1 Remove the cap from the brake fluid reservoir If necessary remove fluid until the fluid level is at MINIMUM On the co pilot s brake pedals Use a ...

Page 1423: ...ane reservoir S Close the bleed nipple on the brake caliper S Disconnect the outlet hose of the bleeding tool from the nipple of the brake caliper S Install the blanking cap onto the nipple Monitor the level of fluid in the left brake fluid reservoir If necessary use a syringe to remove brake fluid 5 Do steps 3 and 4 for the right wheel brake system 6 Make sure that both brake fluid reservoirs are...

Page 1424: ...leveland 105 00200 C Replace the Brake Friction Linings Note For detailed instructions refer to Cleveland Parker Maintenance Manual latest revision WARNING DO NOT BREATHE THE DUST FROM BRAKE LININGS THE DUST CAN CAUSE DISEASE CAUTION MAKE SURE THAT THE PARKING BRAKE IS SET TO RELEASE BEFORE YOU RELEASE THE BRAKE CALIPER BACK PLATE Note For brake component limits refer to Cleveland Parker Maintenan...

Page 1425: ... linings from the back plates S Drill out the rivets that attach the friction lining to the pressure plate S Use pin punch to remove the rivet stems 5 Install the new friction linings onto the pressure plate and the back plates Use only approved parts Use the Cleveland rivet set to install the new brake friction linings Follow the Cleveland rivet set Instruction Manual 6 Install the pressure plate...

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Page 1427: ...the nose gear leg with a steering rod You can turn the nose wheel up to 9 using the rudder pedals and up to 42 using a wheel brake This Section tells you about the nose wheel steering system form the interface with the rudder controls to the nose wheel leg See Section 27 20 for more data about the rudder control system and see Section 32 20 for more data about the nose gear leg Figure 1 shows the ...

Page 1428: ...02 15 Rev 4 Linkage Buffer Steering Arm Bracket Yolk Assembly on Control Bulkhead Tubular Steel Housing Tubular Steel Strut Centering Unit Steering Actuator Lever Steering Linkage Spring Assembly Clamp Roller Slider Plate Cardan Joint Bracket Figure 1 Nose Wheel Steering ...

Page 1429: ...en a force is applied to one end of the telescopic arm the arm compresses the spring which then exerts a force onto the other end of the telescopic arm This allows the pilot to operate the rudder control system when the nose wheel steering system has reached it s limit of operation C Centering Unit A spring assembly which presses a roll against a slider plate makes the centering unit The spring as...

Page 1430: ... clockwise The steering linkage moves forward and turns the tubular steel strut of the nose gear leg to counter clockwise The airplane will turn to the left When the pilot pushes the right rudder pedal when taxiing the airplane these events occur The rudder cables from the rudder pedal turns the steering arm bracket of the yoke assembly on the control bulkhead clockwise The steering linkage moves ...

Page 1431: ... shooting data on the nose gear leg and refer to Section 27 20 for trouble shooting data on the rudder control system If you find the trouble given in Trouble column read across to the Possible Cause column Then do the repair given in the Repair column Trouble Possible Cause Repair Nose wheel steering ineffective the pilot must give inputs to the rudder pedals to steer the airplane Linkage buffer ...

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Page 1433: ... Key Items References 1 Remove the pilot s seat Refer to Section 25 10 2 Disconnect the steering linkage from the steering arm bracket at the yoke assembly S Remove the nut washer and bolt that attaches the steering linkage to the steering arm bracket S Move the end of the steering linkage clear of the steering arm bracket Refer to Figure 1 3 Disconnect the steering linkage from the steering actua...

Page 1434: ...steering arm bracket S Install the bolt washer and nut that attaches the steering linkage to the steering arm bracket Always use a new self locking nut 3 Connect the steering linkage to the steering actuator at the top of the nose gear leg S Move the end of the steering linkage into position to align with the steering actuator lever S Install the bolt washer and nut that attaches the steering link...

Page 1435: ...NDING GEAR THE LANDING GEAR RETRACTION SYSTEM CAN CAUSE SERIOUS INJURY TO PERSONS IF OPERATED ACCIDENTALLY 1 Pull the GEAR circuit breaker Right side of instrument panel 2 Remove the spring assembly S Remove the 4 bolts and washers which hold the clamp to the leg S Move the clamp and spring assembly clear of the leg 3 Remove the slider plate S Remove the 3 bolts and washers which attach the slider...

Page 1436: ...ring assembly in position at the leg S Install the 4 bolts and washers which hold the clamp to the leg Do not tighten the bolts S Align the spring so that the roller just contacts the lowest point on the slider plate S Turn the nose gear leg in one of its maximum deflected positions S Move the spring assembly towards the slider plate so that 2 5 mm 0 1 inch of bare piston remain visible S Tighten ...

Page 1437: ...lease the nose landing gear Jack the airplane Refer to Section 07 10 2 Check the strut extension of the nose landing gear damper Refer to Section 32 20 If necessary charge the damper assembly 3 Turn the nose wheel to its fully deflected position left hand The counter force of the centering unit must move the nose wheel back into neutral position 4 Turn the nose wheel to its fully deflected positio...

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Page 1439: ... and warning system has these functions Landing gear control Landing gear position Landing gear warning To give position data for the extension and retraction system The system has these components A cockpit selector handle and indicators The cockpit selector handle controls the position of the landing gear The indicators show the position condition of the landing gear legs Switches that sense wei...

Page 1440: ... 16 21 28 22 NOSE LDG GEAR UP 56 55 53 54 SQUAT SWITCH LH 25 24 RH LDG GEAR DOWN LH LDG GEAR DOWN LH LDG GEAR UP RH LDG GEAR UP S4 19 27 23 24 15 40 EMERGENCY RELEASE SWITCH TEST GEAR WARNING 5 2 1 ELEV LIMIT GEAR ANNUN HYDRAULIC PUMP 1 1 21 44 45 NOSE LDG GEAR UP 16 6 6 RELAY NOSE LDG GEAR DOWN THROTTLE SWITCHES L H M A I N B U S Figure 1 Landing Gear Electrical Schematic Diagram ...

Page 1441: ...nd to test the landing gear audible warning horn B Weight on Wheels Switches The LH main landing gear leg has a weight on wheel switch squat switch When the airplane is on the ground the weight of the airplane causes the trailing arm to move up and compress the damper This movement of the trailing arm causes the weight on wheels switch to open With these switches open the electrical power to the s...

Page 1442: ...te F Control Relay and Circuit Breakers The position and warning system has these relays and circuit breakers UNSAFE control relay The UNSAFE control relay is energized when the GEAR selector is set to DOWN When energized the relay gives an electrical ground for the red UNSAFE indicator through the folding stay switch in the OPEN position folding stay not locked When the GEAR selector is set to UP...

Page 1443: ...E indicator stays lit when the landing gear is retracted One of the landing gear retracted switches is defective Replace the related landing gear retracted switch The red UNSAFE indicator stays lit when the landing gear is down All green indicators are lit Control relay defective Replace the control relay The red UNSAFE indicator stays lit when the landing gear is down One of the 3 green indicator...

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Page 1445: ...ng switches 2 Remove Install an Engine Power Lever Switch A Remove an Engine Power Lever Switch Detail Steps Work Items Key Items References 1 Pull the GEAR and GEAR ANNUN ELEV LIMIT circuit breakers Instrument panel Right side 2 Release the engine control quadrant and lift it clear of the center console Refer to Chapter 76 00 3 Remove an engine power lever switch S Move both the engine power leve...

Page 1446: ...ne Connector To In Line Connector To In Line Connector Screw Screw Screw Nut Nut Washer Washer Operating Rod Washer Nut Screw Operating Rod To In Line Connector Microswitch Microswitch Power Lever LH Power Lever RH Washer Nut Washer Screw Washer Figure 2 Engine Power Lever Switch Installation ...

Page 1447: ...ch into position in the engine control quadrant S Install the 2 screws washers and nuts that attach the switch to the structure S Connect the electrical cables for the switch 2 Install the engine control quadrant Refer to Chapter 76 00 3 Reset the GEAR and GEAR ANNUN ELEV LIMIT circuit breakers Instrument panel Right side 4 Do a test of the landing gear position and warning system Refer to Paragra...

Page 1448: ...nding Gear Retract Switch Folding Stay Switch Weight on Wheels Switch Screw Screw Screw Striker Plate To In Line Connector To In Line Connector To In Line Connector Switch Screw Screw Plate Switch Screw Switch Roller Bracket Cover Figure 3 Position and Warning Switches Main Landing Gear ...

Page 1449: ...folding stay switch Main gear retract switch Main gear weight on wheels switch Nose gear differential switch Nose gear retract switch The table will tell you where procedures are different for some switches A Replace a Landing Gear Switch Detail Steps Work Items Key Items References 1 Pull the GEAR and GEAR ANNUN ELEV LIMIT circuit breakers Instrument panel Right side 2 Locate the switch that you ...

Page 1450: ...Plate Washer Landing Gear Retract Switch Switch Washer Washer Washer Screw To In Line Connector Plate Nut Nut Bolt Differential Switch Switch Nut Washer Screw Washer Mounting Bracket Bolt Washer Washer Nut Screw Washer Mounting Plate Washer Mounting Plate Screw Washer To In Line Connector Screw Washer 2nd Folding Stay Switch Figure 4 Position and Warning Switches Nose Landing Gear ...

Page 1451: ...er bracket S Move the old switch clear of the mounting S Move the new switch into position in the mounting S Install the roller bracket S Install the 2 screws and washers that attach the switch S Adjust landing gear switch S Reconnect the electrical cables for the switch S Install the cable ties that attach the electrical cables for the switch to the structure S Install the protective cover for th...

Page 1452: ... cables for the switch to the structure S Disconnect the electrical cables for the switch S Remove the 2 screws and washers that attach the switch S Move the old switch clear of the mounting S Move the new switch into position S Install the 2 screws and washers that attach the switch S Reconnect the electrical cables for the switch S Install the cable ties that attach the electrical cables for the...

Page 1453: ...Nose gear retract switch B Adjust Main Nose Gear Retract Switches and Differential Switch Detail Steps Work Items Key Items References WARNING TAKE PRECAUTIONS BY SECURING THE AREA AROUND THE AIRPLANE BEFORE YOU PERFORM MAINTENANCE ON THE LANDING GEAR THE LANDING GEAR RETRACTION SYSTEM CAN CAUSE SERIOUS INJURY TO PERSONS IF OPERATED ACCIDENTALLY 1 Pull the GEAR circuit breaker Right side of instru...

Page 1454: ...en the two screws on the micro switch Refer to Figure 3 and 4 to see where the micro switches are located The gap of 1 2 mm 0 04 0 08 in ensures that the lever is far enough away from the switch point and that it is not overstretched which can cause the lever to break 9 Extend the landing gear Refer to Section 32 30 10 Set the ELECT MASTER switch to OFF 11 Pull the GEAR circuit breaker 12 Install ...

Page 1455: ... 0 04 0 08 in S Tighten the two screws on the micro switch Refer to Figure 3 and 4 to see where the micro switches are located For the weight on wheels switch remove the protection cover The gap of 1 2 mm 0 04 0 08 in ensures that the lever is far enough away from the switch point and that it is not overstretched which can cause the lever to break 4 Move the wing and rear fuselage trestles clear o...

Page 1456: ...CAUTION MAKE SURE THAT THE AREA AROUND THE AIRPLANE IS CLEAR IF THE LANDING GEAR HITS AN OBJECT THE LANDING GEAR CAN BE DAMAGED 1 Raise the airplane on jacks and move the wing and rear fuselage trestles into position to support the airplane Refer to Section 07 10 2 Connect an external power supply to the airplane Refer to Section 24 40 3 Set the ELECT MASTER switch to ON 4 Set both engine power le...

Page 1457: ... to IDLE S Move the left engine power lever to 100 The landing gear warning horn must operate The landing gear warning horn must operate The landing gear warning horn must operate 7 Extend the landing gear S Set the landing gear selector lever to DOWN and you must have these indications S The red led UNSAFE illuminates S The landing gear extends S When all the landing gear legs are fully extended ...

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Page 1459: ...AIRCRAFT DA 42 NG AMM Lights Doc 7 02 15 Rev 4 33 TITLE Page 1 15 Mar 2018 CHAPTER 33 LIGHTS ...

Page 1460: ...AIRCRAFT Lights DA 42 NG AMM Page 2 15 Mar 2018 33 TITLE Doc 7 02 15 Rev 4 Intentionally left blank ...

Page 1461: ...t installed 201 3 Replace a Filament in a Map Reading Light Assembly if MÄM 42 1024 is not installed 202 4 Remove Install a Map Reading Light Assembly if MÄM 42 1024 is installed 202 5 Replace a Filament in a Map Reading Light Assembly if MÄM 42 1024 is installed 203 6 Remove Install a Dimmer Switch 204 7 Replace the Flood Light Instrument Light Strip 206 8 Remove Install a Solid State Inverter fo...

Page 1462: ... Install the Taxi Light 201 3 Remove Install the Landing Light 203 4 Remove Install an Electronic Controller 205 5 Replace a Filament in the Wing Tip Light Unit OÄM 42 222 is NOT installed 207 6 Remove Install a Wing Tip Light Unit 211 7 Remove Install a Strobe Power Unit in the Wing Tip if OÄM 42 222 is NOT installed 215 ...

Page 1463: ...he equipment in your airplane A combined ON OFF and dimmer switch for the placard lighting is located in the instrument panel top left The DA 42 NG has these exterior lights in one light unit at each wing tip Left and right position lights The front part of the light has a red left or green right lens The light can only be seen from the front and the side If OÄM 42 222 is installed the lenses are ...

Page 1464: ...CRAFT Lights DA 42 NG AMM Page 2 15 Mar 2018 33 00 00 Doc 7 02 15 Rev 4 Right Wing Tip Light Assembly Left Wing Tip Light Assembly Landing Taxi Light Assy Map Reading Lights 3x Figure 1 Flight Compartment ...

Page 1465: ... under the center fuselage next to the taxi light Taxi light The taxi light has a clear lens and a 35 Watt HID Xenon bulb It is located in a recess located under the center fuselage next to the landing light The switches for the landing and taxi lights are in the top left of the instrument panel The landing and taxi lights each have electronic controllers for the Xenon filaments The electronic con...

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Page 1467: ...e front are directed towards the pilots seats and the light at the rear is directed towards the passenger seats Each light assembly has an integral switch and a directional beam The system is protected by a circuit breaker located in the right side of the instrument panel Note Map Reading lights become very hot in service B Instrument Panel Flood Lighting A 115 V AC foil type light strip makes the...

Page 1468: ...8 33 10 00 Doc 7 02 15 Rev 4 B C C A A Map Reading Light Pilot Map Reading Light Co Pilot Reading Light Passengers B Dimmer Switch Instrument Lights placard lights Dimmer Switch Flood Lights Flood Light Foil Strip Figure 1 Flight Compartment Lights ...

Page 1469: ...B C C A A Map Reading Light Pilot Map Reading Light Co Pilot Reading Light Passengers B Dimmer Switch Instrument Lights Placard Lights Dimmer Switch Flood Lights Flood Light Foil Strip Locking Plates Locking Plates Figure 2 Flight Compartment Lights if MÄM 42 1024 is installed ...

Page 1470: ...he placards are illuminated The intensity of the light sources are controlled by a single ON OFF dimmer switch located on the top left of the instrument panel Turn the dimmer switch fully counter clockwise to turn the placard lights off Turn the dimmer switch clockwise to turn the placard lights on and to set the level of lighting that you require All placard panels are attached to the instrument ...

Page 1471: ...rectly Circuit breaker not set Dimmer switch defective Solid state inverter defective Light strip defective Wiring defective Reset the circuit breaker Replace the dimmer switch Replace the solid state inverter Replace the light strip Do a continuity test of the wiring Repair replace defective wiring Refer to Chapter 92 for the wiring diagrams The instrument lights placard lights do not operate cor...

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Page 1473: ...embly in position S Lower the light assembly from the cabin roof and disconnect the electrical cables S Move the light assembly clear of the airplane At the switch end of the assembly At the in line connector B Install a Map Reading Light Assembly Detail Steps Work Items Key Items References 1 Move the light assembly into position in the airplane cabin Hold the light assembly 2 Connect the electri...

Page 1474: ...ly Refer to Paragraph 2B 7 Reset the TAXI MAP ACL circuit breaker 8 Do a test for the correct function of the light assembly 4 Remove Install a Map Reading Light Assembly if MÄM 42 1024 is installed A Remove a Map Reading Light Assembly Detail Steps Work Items Key Items References 1 Pull the TAXI MAP ACL circuit breaker Instrument panel right side 2 Remove the light assembly S Loosen the three scr...

Page 1475: ...d Caution The locking plates must be in correct position 6 Reset the TAXI MAP ACL circuit breaker 7 Do a test for the correct function of the light assembly 5 Replace a Filament in a Map Reading Light Assembly if MÄM 42 1024 is installed Detail Steps Work Items Key Items References 1 Pull the TAXI MAP ACL circuit breaker Instrument panel right side 2 Remove the light assembly Refer to Paragraph 4A...

Page 1476: ... 31 2 Remove the instrument panel cover Refer to Section 25 10 3 Remove the knob from the dimmer switch that you will remove S Loosen the grub screw that attaches the knob to the switch spindle S Pull the knob off the switch spindle 4 Disconnect the electrical cables from the rear of the dimmer switch Make a note of the connections 5 Remove the placard panel Refer to Section 11 30 6 Remove the nut...

Page 1477: ...t you made at Paragraph 4A step 4 4 Install the placard panel Refer to Section 11 30 5 Install the knob to the front of the dimmer switch S Align the flat on the switch spindle with the flat in the bore of the knob S Push the knob onto the switch spindle S Tighten the grub screw that holds the knob onto the switch spindle 6 Install the instrument panel cover Refer to Section 25 10 7 Connect the ai...

Page 1478: ...rom the inside of the instrument panel cover S Peel the light strip away from the panel cover 4 Install the new flood light instrument light strip to the inside of the instrument panel cover S Make sure that the area where the light strip attaches to the instrument cover is clean S Apply double sided tape to the back of the light strip S Position the flood light instrument light strip and firmly p...

Page 1479: ...Set the ELECT MASTER switch to ON S Rotate the FLOOD light INSTRUMENT light dimmer switch fully clockwise S Rotate the FLOOD light INSTRUMENT light dimmer switch a small amount counter clockwise S Rotate the FLOOD light INSTRUMENT light dimmer switch fully counter clockwise S Set the ELECT MASTER switch to OFF The light strip must come on bright The light strip must go dimmer The light strip must ...

Page 1480: ... 15 Mar 2018 33 10 00 Doc 7 02 15 Rev 4 Solid State Inverter Placards Instruments Solid State Inverter Flood Lights Screw Screw Washer Washer Washer Washer Nut Nut Nut Nut Figure 2 Solid State Inverters for the Instrument and Flood Lights ...

Page 1481: ...eps Work Items Key Items References 1 Disconnect the airplane main battery Refer to Section 24 31 2 Remove the instrument panel cover Refer to Section 25 10 3 Disconnect the electrical cables from the inverter At the in line connector 4 For removal of the instrument light inverter remove the PFD Refer to Section 31 40 5 Remove the inverter S Remove the 2 screws washers and nuts that attach the inv...

Page 1482: ... Section 31 40 3 Connect the electrical cables to the inverter At the in line connector 4 Install the instrument panel cover Refer to Section 25 10 5 Connect the airplane main battery Refer to Section 24 31 6 Do a test for the correct operation of the inverter S Set the ELECT MASTER switch to ON S Rotate the related dimmer switch clockwise S Rotate the related dimmer switch fully clockwise S Rotat...

Page 1483: ...the DA 42 NG The DA 42 NG has these exterior lights Position lights Strobe lights Landing light Taxi light 2 Description The DA 42 NG has the position lights and the strobe lights in a single light unit in each wing tip The taxi and landing lights are located below the fuselage Figure 1 and 2 show the wing tip light unit and Figure 3 shows the landing and taxi lights ...

Page 1484: ...it Rear Position Light Clear Glass Front Position Light Colored Glass Strobe Light Filament Strobe Light Cover Retaining Cover Screws Screw Screw Screw P Clip Washer Nut Lightning Protection Screw In Line Connector 0 Ring Seal Bracket Captive Nut Figure 1 Wing Tip Light Unit and Strobe Power Unit ...

Page 1485: ...AIRCRAFT DA 42 NG AMM Lights Doc 7 02 15 Rev 4 33 40 00 Page 3 15 Mar 2018 Figure 2 Wing Tip Light Unit if OÄM 42 222 is installed ...

Page 1486: ...he airplane A separate power unit for each strobe light is mounted in the wing tip A switch on the top left of the instrument panel controls both the strobe lights and the system is protected by a circuit breaker The power unit generates an electrical impulse of approximately 600 Volts The pulse ionizes the gas in the strobe light which causes a bright flash A second less powerful pulse occurs imm...

Page 1487: ...floor below the pilots seats A switch on the top left of the instrument panel controls the landing light and a circuit breaker protects the system E Taxi Light The taxi light is located in a housing below the center fuselage on the left The taxi light has a clear lens and Xenon filament The taxi light has an electronic controller located on the wing center section floor below the pilots seats A sw...

Page 1488: ...15 Mar 2018 33 40 00 Doc 7 02 15 Rev 4 A A B Rubber Grommet Landing Light Switch Taxi Light Switch B Electronic Controller Transparent Cover Landing Light Landing Light Shown Taxi Light Similar Figure 3 Landing and Taxi Light Installation ...

Page 1489: ... Defective wiring Reset replace circuit breaker Replace the switch Do a continuity test of the wiring Repair replace defective wiring Refer to Chapter 92 for the wiring diagrams One position light does not operate Defective filament Defective wiring Replace the filament Do a continuity test of the wiring Repair replace defective wiring Refer to Chapter 92 for the wiring diagrams Both strobe lights...

Page 1490: ...t does not operate on one side Connector at outer wing to center section disconnected Connect the connector Landing light or taxi light does not operate Defective light unit Defective electronic controller Circuit breaker not set or defective Defective landing light or taxi light switch Loose connector at the light unit Defective wiring Replace the defective light unit Replace the defective electr...

Page 1491: ...E LIGHTS GENERATE HIGH VOLTAGES HIGH VOLTAGES CAN CAUSE INJURY OR DEATH TO PERSONS 2 Remove Install the Taxi Light A Remove the Taxi Light Detail Steps Work Items Key Items References 1 Set the ELECT MASTER switch to OFF Instrument panel 2 Set the TAXI light switch to OFF Top left of instrument panel 3 Set the TAXI MAP ACL circuit breaker open Pull 4 Remove the pilot s seat Refer to Section 25 10 ...

Page 1492: ...re Refer to Figure 3 At the in line connector 2 Install the light cover S Move the light cover into position below the fuselage S Install the 8 screws and washers that attach the light cover to the light housing 3 Reset the TAXI MAP ACL circuit breaker Instrument panel right side 4 Set the ELECT MASTER switch to ON Instrument panel 5 Do a test for the correct operation of the taxi light S Set the ...

Page 1493: ...reaker open Pull 4 Remove the co pilot s seat Refer to Section 25 10 5 Remove the landing light cover from below the center fuselage S Remove the 8 screws and washers that attach the cover to the light housing S Move the light cover clear of the housing Refer to Figure 3 6 Remove the 2 nuts washers and bolts that attach the landing light unit to the structure 7 Hold the landing light and move out ...

Page 1494: ...Figure 3 At the in line connector 2 Install the light cover onto the housing S Move the light cover into position at the housing S Install the 8 screws and washers that attach the light cover to the light housing 3 Reset the LDG LT START circuit breaker Instrument panel right side 4 Set the ELECT MASTER switch to ON Instrument panel 5 Do a test for the correct operation of the landing light S Set ...

Page 1495: ... panel 2 Set LANDING TAXI light switch to OFF Top left of instrument panel 3 Set the LDG LT START or TAXI MAP ACL circuit breaker open as necessary Pull Right side of instrument panel 4 Remove the pilot s co pilot s seat as required Refer to Section 25 10 5 Remove the electronic controller S Disconnect the electrical cables form the controller S Remove the nuts washers bolts and bonding wire lead ...

Page 1496: ...onnect the electrical cables to the controller At the in line connectors 3 Do a test for the correct operation of the LANDING TAXI light S Set the LDG LT START or TAXI MAP ACL circuit breaker as necessary S Set the ELECT MASTER switch to ON S Set the LANDING TAXI light switch to ON S Set the LANDING TAXI light switch to OFF S Set the ELECT MASTER switch to OFF Push the circuit breaker in Right sid...

Page 1497: ... GENERATE HIGH VOLTAGE HIGH VOLTAGE CAN CAUSE DEATH OR INJURY TO PERSONS 2 Set these circuit breakers open S INST LT NAV LT S TAXI MAP ACL 3 Remove the light unit cover and the lamp glasses from the wing tip unit S Remove the 2 screws that attach the cover to the unit S Remove the cover S Remove the glasses and seals Refer to Figure 1 Hold the cover and glasses 4 Replace the defective filament 5 I...

Page 1498: ...e circuit breakers S INST LT NAV LT S TAXI MAP ACL 7 Do a test for the correct operation of the position light S Set the ELECT MASTER switch to ON S Set the POSITION light switch to ON S Set the POSITION light switch to OFF S Set the ELECT MASTER switch to OFF The position lights must all come on The position lights must all go off ...

Page 1499: ... Set these circuit breakers open S INST LT NAV LT S TAXI MAP ACL 3 Remove the light unit cover and the lamp glasses from the wing tip unit S Remove the 2 screws that attach the cover to the unit S Remove the cover S Remove the glasses and seals Refer to Figure 1 Hold the cover and glasses 4 Replace the strobe light filament Disconnect connect the electrical cables at the in line connector 5 Instal...

Page 1500: ... these circuit breakers S INST LT NAV LT S TAXI MAP ACL 7 Do a test for the correct operation of the strobe light S Set the ELECT MASTER switch to ON S Set the STROBE light switch to ON S Set the STROBE light switch to OFF S Set the ELECT MASTER switch to OFF The strobe lights must both operate The strobe lights must all go off ...

Page 1501: ...ONS 2 Set these circuit breakers open S INST LT NAV LT S TAXI MAP ACL 3 Remove the light unit cover and the lamp glasses from the wing tip unit S Remove the 2 screws that attach the cover to the unit S Remove the cover S Remove the glasses and seals Refer to Figures 1 and 2 Hold the cover and glasses 4 Remove the 3 light filaments if OÄM 42 222 is NOT installed Make sure that you disconnect the st...

Page 1502: ...from the wing tip S Remove the nut washer bolt and P clamp that attach the bonding strip to the light unit S Remove the screws that attach the light unit to the wing tip S Carefully move the light unit out from the wing tip S Disconnect the 2 electrical in line connectors from the rear of the light unit S Move the light unit clear of the airplane ...

Page 1503: ...ut that attach the bonding strip to the light unit Refer to Figure 1 2 Install the filaments to the light unit if OÄM 42 222 is NOT installed 3 Install the lamp glasses and light unit cover S Move the glasses into position with the seals S Move the light unit cover into position S Install the 2 screws that attach the cover to the light unit Make sure that the seals are correctly located 4 Install ...

Page 1504: ...ENSITY STROBE LIGHTS CAN CAUSE EYE DAMAGE 6 Do a test for the correct operation of the strobe light S Set the ELECT MASTER switch to ON S Set the STROBE light switch to ON S Set the STROBE light switch to OFF The strobe lights must both operate The strobe lights must all go off 7 Do a test for the correct operation of the position light S Set the POSITION light switch to ON S Set the POSITION ligh...

Page 1505: ...TO THE STROBE LIGHTS GENERATE HIGH VOLTAGE HIGH VOLTAGE CAN CAUSE DEATH OR INJURY TO PERSONS 2 Set these circuit breakers open S INST LT NAV LT S TAXI MAP ACL 3 Remove the wing tip from the wing S Remove the screws that attach the wing tip to the wing S Move the wing tip just clear of the wing and disconnect the electrical connectors S Move the wing tip clear of the airplane 4 Disconnect the elect...

Page 1506: ...to the power unit At the in line connector at the power unit 3 Install the wing tip onto the wing S Move the wing tip into position near the wing S Connect the electrical connections to the wing tip S Move the wing tip fully into position and install the screws that attach the wing tip to the wing At the connector WARNING DO NOT OPERATE THE STROBE LIGHTS WHEN PERSONS ARE CLOSE TO THE AIRPLANE AND ...

Page 1507: ... switch to ON S Set the STROBE light switch to ON S Set the STROBE light switch to OFF The strobe lights must both operate The strobe lights must all go off 6 Do a test for the correct operation of the position light S Set the POSITION light switch to ON S Set the POSITION light switch to OFF S Set the ELECT MASTER switch to OFF The position lights must all come on The position lights must all go ...

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Page 1509: ...AIRCRAFT DA 42 NG AMM Navigation Doc 7 02 15 Rev 4 34 TITLE Page 1 15 Mar 2018 CHAPTER 34 NAVIGATION ...

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Page 1511: ...ng 1 General 101 Maintenance Practices 1 General 201 2 Remove Install an ASI or Altimeter or Standby Attitude Module if OÄM 42 270 is installed 201 3 Remove Install the Pitot Probe 203 4 Remove Install an Altimeter Orifice 206 5 Pitot and Static System Leak Tests 207 6 Clean the Pitot System and the Static System 212 7 Remove Install the OAT Probe 214 Section 34 20 Attitude and Direction 1 General...

Page 1512: ...201 2 Remove Install the Magnetic Compass 201 3 Test Adjust the Magnetic Compass Compass Swing 202 4 Remove Install the Attitude Gyro Artificial Horizon if OÄM 42 270 is NOT installed 204 5 Remove Install the Standby Attitude Module if OÄM 42 270 is installed 205 Section 34 30 Landing and Taxiing Aids 1 General 1 2 Description 1 Section 34 40 Independent Position Determining 1 General 1 Section 34...

Page 1513: ... Traffic Advisory System 1 General 1 Trouble Shooting 1 General 101 Maintenance Practice 1 General 201 2 Remove Install the TAS Processor 201 3 Remove Install the Transponder Coupler 202 4 Remove Install a TAS Antenna 203 Section 34 43 Garmin GWX 68 or GWX 70 Weather Radar System 1 General 1 2 Description and Operation 1 Trouble Shooting 1 General 101 Maintenance Practices 1 General 201 2 Remove I...

Page 1514: ...ning 1 General 1 2 Description 1 Trouble Shooting 1 General 101 Maintenance Practices 1 General 201 2 Replace a Dependent Position Determining System Antenna 201 3 Used Types of Flexible Coaxial Cables 209 4 Sealant Specification 210 5 Post Installation Check of the ADF System 210 Section 34 56 Transponder XPDR 1 General 1 ...

Page 1515: ...igation systems Refer to Section 23 10 for more data about the NAV system which is part of the speech communication system The DA 42 NG has these navigation systems Refer to these Sections for data about the systems Section 34 10 Flight environment data Pitot static OAT flight instruments Section 34 20 Attitude and direction compass artificial horizon Section 34 30 Landing and taxiing aids localiz...

Page 1516: ...ndicator if OÄM 42 270 is NOT installed Standby attitude module if OÄM 42 270 is installed Integrated cockpit system ICS The DA 42 NG also has an electronic outside air temperature OAT indicator The indicator is integral with the ICS Refer to Section 31 40 for more data about the ICS The probe for the OAT is located below the nose baggage compartment B Attitude and Direction The DA 42 NG has a mag...

Page 1517: ... E Dependent Position Determining The DA 42 NG has these dependent position determining systems that are integral with the ICS VOR LOC Global positioning system GPS Transponder DME ADF Marker beacon receiver Refer to Section 31 40 for more data about the integrated cockpit system ...

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Page 1519: ... the alternate static vent by operating a valve lever The Pitot probe has a heater element to prevent icing A switch on the instrument panel controls the Pitot heater and a circuit breaker protects the system The Pitot heater status is shown on the ICS Flexible hoses connect the Pitot probe and the alternate static vent to the air data instruments and the ICS Pitot hoses are green and the static h...

Page 1520: ...8 34 10 00 Doc 7 02 15 Rev 4 To Air Data Instruments ICS Pitot Probe Pitot Hose Green Static Hose Blue Water Traps Static Port Static Port Filter and Orifice Not In Use Water Trap if MÄM 42 462 is installed Figure 1 Pitot Probe and Static System Hoses ...

Page 1521: ...anges speed references and an airspeed trend vector are also displayed on the PFD or SAM Refer to the G1000 system or MD302 SAM installation manual and the airplane flight manual for particular information on the ICS or SAM implemented airspeed indicator D Altimeter The DA 42 NG has the usual mechanical altimeter with an analogue display an altimeter integral of the standby attitude module if OÄM ...

Page 1522: ...ntenna VOR Antenna The altimeter integral with the ICS or standby attitude module displays barometric altitude values on a rolling number gauge using a moving tape Refer to the G1000 system or MD302 SAM installation manual and the airplane flight manual for particular information on the ICS or SAM implemented altimeter Figure 2 Flight Environment Data Component Locations ...

Page 1523: ...ater in static system Replace altimeter Clear straighten the hose Drain the static system Airspeed indication incorrect low Faulty indicator Blocked or kinked Pitot hose Water in the system Leak in Pitot hose Replace ASI Clear straighten the hose Drain the Pitot system Do a Pitot static leak check Pitot heater does not operate Pitot circuit breaker open Pitot circuit breaker defective Pitot heat w...

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Page 1525: ... Module if OÄM 42 270 is installed A Remove an ASI or Altimeter or SAM Detail Steps Work Items Key Items References 1 Make sure that the ELECT MASTER switch is set to OFF 2 Remove the instrument panel cover Refer to Section 25 10 3 Disconnect the Pitot static hose s from the rear of the indicator 4 Disconnect the electrical connector from the rear of the standby attitude module if OÄM 42 270 is in...

Page 1526: ... new indicator Use the connections from the indicator that you removed 3 Move the indicator into position at the instrument panel Hold the indicator 4 Install the screws that attach the indicator to the instrument panel 5 Connect the Pitot static hose s to the rear of the indicator 6 Connect the electrical connector to the rear of the standby attitude module if OÄM 42 270 is installed 7 Do a low r...

Page 1527: ...ot probe access panel with the Pitot probe from the lower surface of the left wing Refer to Section 52 40 4 Disconnect the electrical cables from the Pitot probe At the in line connector 5 Disconnect the Pitot and static hose connections Identify the connections and install dust caps on the hoses 6 Disconnect the bonding wire assembly Note the position of the bonding wire assembly connection 7 Rem...

Page 1528: ...ked at Paragraph 3 A step 5 4 Connect the electrical cables to the probe At the in line connector 5 Install the Pitot probe access panel S Move the panel up into position on the lower surface of the wing S Install the 3 screws and washers that attach the access panel to the wing Refer to Section 52 40 6 Do a test of the Pitot probe heat system S Set the ELECT MASTER switch to ON S Reset the PITOT ...

Page 1529: ...FT DA 42 NG AMM Navigation Doc 7 02 15 Rev 4 34 10 00 Page 205 15 Mar 2018 Pitot Tube Tube Green Tube Blue not in use Thermal Switches Thermal Cut out Bonding Wire Assy Plate Figure 3 Pitot Probe Installation ...

Page 1530: ... of the altimeter 4 Disconnect this part of static hose blue from the next T fitting Hold the T fitting 5 Carefully warm up the section around the orifice Use a heat gun 6 Use an edgeless object to press out the orifice Use a screwdriver B Install an Altimeter Orifice Detail Steps Work Items Key Items References 1 Carefully warm up 50 mm 2 in from one end of the hose Use a heat gun 2 Press the ori...

Page 1531: ... AIR DATA INSTRUMENTS A Precautions The pressure in the Pitot system must always be equal to or greater than the pressure in the static equipment Reversal of the Pitot and static hoses can cause damage to the air data instruments The applied pressure and the rate of change of pressure must not be greater than the design limits of the equipment that you will test After doing the test you must alway...

Page 1532: ...AT ARE CRITICAL TO AIRPLANE OPERATION AND SAFETY THESE PAGES ARE PROTECTED AND CAN NOT BE MODIFIED UNLESS THE TECHNICIAN IS PROPERLY AUTHORIZED AND EQUIPPED HOWEVER MOST PROTECTED PAGES ARE VIEWABLE TO ALLOW SYSTEM AWARENESS FOR TROUBLESHOOTING 1 Remove the blanking cap from the Pitot static probe and connect the Pitot static leak tester to the probe Use the test set adaptor 2 Make sure that the a...

Page 1533: ...D in reversionary mode by pressing the red DISPLAY BACKUP button on the GMA 1347 audio panel Baro settings can then be read from the MFD for the CFR Part 43 Appendix E tests Only required for airplanes for which 14 CFR 91 411 and 14 CFR 91 411 part 43 Appendix E is applicable 6 Apply a partial vacuum to the static port until you get a pressure altitude of 1000 ft above the ambient pressure altitud...

Page 1534: ...tot static probe 13 Remove the blockage of the static line At the filter on top of the fuselage 14 Install the aft baggage compartment Refer to Section 25 50 Table 1 Altimeter Indication Error Altitude Permissible Error 1000 ft 20 ft Sea level 20 ft 4 000 ft 35 ft 8 000 ft 60 ft 12 000 ft 90 ft 16 000 ft 110 ft 20 000 ft 130 ft Only required for airplanes for which 14 CFR 91 411 and 14 CFR 91 411 ...

Page 1535: ... to the probe Use the test set adaptor 2 Slowly apply a pressure to the Pitot port that gives an indication of 150 kts on the ASI 3 Let the pressure stabilize 4 Monitor the system pressure The leak rate must not be more than 10 kts min 5 Compare the test equipment ASI and the airplane ASI The indication error must be less than shown in Table 2 6 Slowly release the system pressure 7 Disconnect the ...

Page 1536: ...ressed air without oil separator Reversal of the Pitot and static hoses can cause damage to the air data instruments After cleaning the system you must always return the system to usual operating conditions B Equipment Item Quantity Part Number Compressed air equipment with oil separator and pressure regulator 1 Commercial C Cleaning Procedure Detail Steps Work Items Key Items References 1 Make su...

Page 1537: ...traps for dirt Replace if necessary 10 Reconnect the Pitot static hoses to the water traps Two under the pilot s seat one below the aft baggage compartment 11 Reconnect the Pitot static hoses to the Pitot probe 12 Reconnect the Pitot static hoses to the air data computer ADC 13 Reconnect the Pitot static hoses to the rear of the backup instruments 14 Do a low range static leak test Refer to Paragr...

Page 1538: ... icing fluid tank 4 Remove the baggage compartment carpeting and the rear access panel on the compartment floor 5 Disconnect the electrical cables from the OAT probe At the in line connector located on the instrument panel frame in the LH corner below the nose baggage compartment 6 Remove the nut and the sealing washer that attach the OAT probe to the airplane surface Located on the lower surface ...

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Page 1540: ...o the airplane surface On the lower surface of the fuselage nose on the RH side of the nose landing gear bay 4 Connect the electrical cables from the OAT probe At the in line connector located on the instrument panel frame in the LH corner below the nose baggage compartment 5 If the de icing system is installed Install the de icing fluid tank 6 Close the rear access hole on the nose baggage compar...

Page 1541: ...on of the compass is 5 A compass deviation card is located next to the compass on the instrument panel You must do a test for the correct operation of the compass compass swing After replacing a major component After replacing the compass After a major modification to the airplane After a lightning strike has been reported If the airplane has been parked for more than 90 days B Attitude Gyro Artif...

Page 1542: ...icator The background of the display consists of the representative white horizon line separating the sky blue and ground brown The roll scale depicted as an arc of graduations representing bank angles of 0 triangle 10 20 30 45 small triangle and 60 The roll scale can be configured during installation to be fixed to the sky horizon or fixed to the top of the display The roll pointer is the triangl...

Page 1543: ...ss to the Possible Cause column Then do the repair given in the Repair column Trouble Possible Cause Repair Magnetic compass damping fluid leaking Defective compass housing Replace the compass Compass deviation more than 10 Residual magnetism of a metal component in the airplane Defective compass Compass out of calibration Do a test for residual magnetism using a hand held compass If necessary deg...

Page 1544: ...view Indication of instrument not reliable AH circuit breaker open or defective Power supply wiring defective Ground connection defective Instrument defective Close or replace the circuit breaker Do a test for the correct voltage at the instrument Repair the power supply wiring connector Do a test for correct ground connection Repair the ground wiring connector Replace the instrument Instrument is...

Page 1545: ... Section 25 10 3 Disconnect electrical cables At the in line connector 4 Remove the 4 screws that attach the compass to the instrument panel Hold the compass 5 Move the compass forward and clear of the instrument panel Remove and discard the compass deviation table B Install the Magnetic Compass Detail Steps Work Items Key Items References 1 Make sure that the ELECT MASTER switch is set to OFF Ins...

Page 1546: ...OMPASS METALLIC OBJECTS NEAR THE COMPASS CAN CAUSE ERRORS Note If possible use a compass swing area that has been tested for magnetic interference In any case you must use a level area that is away from metal structures underground pipes reinforced concrete other airplane and ground servicing equipment A Equipment Item Quantity Part Number Calibrated land compass 1 Commercial B Compass Swing Detai...

Page 1547: ...ading and 180 6 Use the land compass to align the airplane to magnetic west Adjust the E W compensator magnet to remove half of the error between the indicated heading and 270 7 Turn the airplane through 360 record the deviation at each 30 radial Prepare a deviation table that shows the corrections that must be applied to each of the 30 radials If large deviations occur when you operate electrical...

Page 1548: ...f it is removed while running and tilted more than 20 degrees the gyro can develop a gimbal lock The gimbal will tumble and start to spin If gimbal lock occurs while the rotor is turning the gimbal may spin fast enough to damage the gimbal bearings requiring overhaul A malfunctioning gyro should be handled with the same care given a new instrument Most malfunctioning instruments can be repaired an...

Page 1549: ...t Upper instrument panel arranged centrally 2 Install the screws which attach the instrument to the instrument panel 3 Connect the connector at the rear of the instrument 4 Install the instrument panel cover Refer to Section 25 10 5 Set the AH circuit breaker Instrument panel right hand side 5 Remove Install the Standby Attitude Module if OÄM 42 270 is installed Refer to Section 34 10 Maintenance ...

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Page 1551: ...s 2 Description The DA 42 NG has the following landing and taxiing aids Localizer system which is part of the G1000 integrated avionics system Refer to Section 31 40 for more data about the G1000 integrated avionics system Glideslope system which is part of the G1000 integrated avionics system Refer to Section 31 40 for more data about the G1000 integrated avionics system Marker beacon receiver wh...

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Page 1553: ...ing 1 General This Section tells you about the independent position determining systems that can be installed in the DA 42 NG Refer to these Sections for data about the systems Section 34 41 Stormscope system OÄM 42 057 Section 34 42 Traffic advisory system TAS OÄM 42 094 Section 34 43 Enhanced vision system EVS OÄM 42 214 ...

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Page 1555: ...cessor digitizes analyzes and converts the discharge signals into range and bearing data This information is stored in the storm buffer A Stormscope Processor The stormscope processor is tray mounted and is located under the passengers seat The AVIONICS BUS power to the stormscope system The ELECT MASTER switch and the AV MASTER switch must be set to ON to supply power through the WX 500 circuit b...

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Page 1557: ...ou have the trouble detailed in the Trouble column read across to the Possible Cause column Then do the repair given in the Repair column Trouble Possible Cause Repair Stormscope does not operate Circuit breaker not set Faulty cables connectors Set the circuit breaker Do a test for continuity on each cable Do a test for short circuit to ground and between cables Replace defective cables ...

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Page 1559: ...s 1 Remove the passengers seat Refer to Section 25 10 2 Open the WX 500 circuit breaker 3 Loosen the screw that attaches the processor to its mounting tray 4 Remove the stormscope processor from the mounting tray B Install the Stormscope Processor Detail Steps Work Items Key Items References 1 Put the stormscope processor in position in the mounting tray 2 Tighten the screw that attaches the proce...

Page 1560: ... the horizontal stabilizer B Install the Stormscope Antenna Detail Steps Work Items Key Items References 1 Put the stormscope antenna in position on the horizontal stabilizer The arrow must point into flight direction 2 Connect the connector of the stormscope antenna 3 Install the screws which attach the stormscope antenna to the mounting bracket 4 Close the WX 500 circuit breaker 5 Install the ho...

Page 1561: ...nearby transponder equipped airplanes Airplanes with non Mode C transponders can provide range information The TAS does not detect airplanes without an operating transponder A Processor The TAS processor is tray mounted and is located behind the first ring frame The AVIONICS BUS supplies power to the traffic advisory system The ELECT MASTER switch and the AV MASTER switch must be set to ON to supp...

Page 1562: ...Doc 7 02 15 Rev 4 C Antennas The TAS has two directional antennas The top antenna is located on top of the fuselage behind the cabin between the COM and the ELT antennas and the bottom antenna is located on the fuselage bottom between the taxi and landing lights ...

Page 1563: ...s not operate Circuit breaker not set Faulty cables connectors Set the circuit breaker Do a test for continuity on each cable Do a test for short circuit to ground and between cables Replace defective cables The TAS bearing shows opposite to the traffic forward and aft and it shows correctly left and right The antenna co axes for the top antenna are backwards Check antenna connections The TAS bear...

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Page 1565: ...na cables from the TAS processor 5 Loosen the diagonal retaining screws that attaches the processor to its mounting tray 6 Slide the TAS processor out of its mounting tray and clear of the airplane Along the rails B Install the TAS Processor Detail Steps Work Items Key Items References 1 Slide the TAS processor into its mounting tray Along the rails 2 Tighten the diagonal retaining screws that att...

Page 1566: ... the transponder coupler from the remote avionics box and clear of the airplane Fit dust caps to all connections B Install the Transponder Coupler Detail Steps Work Items Key Items References 1 Remove the dust cover s from all connections If necessary install the dust covers from the new transponder coupler onto the transponder coupler that you removed 2 Move the transponder coupler into position ...

Page 1567: ...rtment if you will replace the top mounted antenna Remove both pilots seats if you will replace the bottom mounted antenna Refer to Section 25 50 Refer to Section 25 10 4 Disconnect the coaxial cable from the antenna that you will replace At the antenna 5 Remove the antenna S Remove the 4 screws that attach the antenna to the structure S If necessary use a knife to carefully remove the sealant tha...

Page 1568: ... the antenna where it contacts the airplane surface with sealant Refer to 34 50 Paragraph 4 for an approved sealant 5 Remove the excess sealant that has been forced out of the joint between the antenna and the airplanes surface CAUTION WRONG CONNECTION OF THE ANTENNA CABLES WILL LEAD TO A WRONG INDICATION 6 Connect the coaxial cable to the antenna At the antenna 7 Install the aft baggage compartme...

Page 1569: ...n 4 strips are mounted to the surface and connected to the airplanes lightning protection system with a lightning plate 2 Garmin GWX 68 or GWX 70 Weather Radar System The Garmin GWX 68 or GWX 70 weather radar system provides information about precipitation conditions ahead of the airplane The system consists of a combined microwave transmitter and receiver system in the nose cone mounted to the ra...

Page 1570: ...d GWX 68 GWX 70 Bracket GWX 68 GWX 70 Attachment Screws Lightning Protection Bracket Radar Nose Cone Screws 16 pieces Dimpled Washers 16 pieces Lightning Protection Strips 4 pieces GWX 68 GWX 70 Unit Radar Bulkhead Cover Figure 1 Installation of the Garmin GWX 68 or GWX 70 Weather Radar System ...

Page 1571: ... trouble column read across to the possible cause column Then do the repair given in the repair column Trouble Possible Cause Repair Weather radar does not operate Circuit breaker not set Set the circuit breaker Faulty cables connectors Do a test for continuity test of the weather radar system Repair or replace defective wiring Refer to Chapter 92 for the wiring diagrams Weather radar shows poor i...

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Page 1573: ...ail Steps Work Items Key Items References 1 Make sure that the ELECT MASTER switch is set to OFF Note The inner and outer surface of the radar nose cone radome effects the function and image quality of the weather radar system significantly Make sure to avoid any scratches and contamination of the inner and outer surfaces of the radome and do not touch the antenna face of the GWX 68 or GWX 70 unit...

Page 1574: ...ome effects the function and image quality of the weather radar system significantly Make sure to avoid any scratches and contamination of the inner and outer surfaces of the radome and do not touch the antenna face of the GWX 68 unit 1 Install the GWX 68 or GWX 70 unit S Move the GWX 68 or GWX 70 unit in place in front of the GWX 68 bracket S Install the 4 screws which attach the GWX 68 or GWX 70...

Page 1575: ...sive and masking tapes S Allow the sealant to cure for at least 12 hrs Refer to Figure 2 Use Terostat MS 9380 white sealant Maximum time for sealing process 10 min Use gloves to protect the skin Note Before energizing the equipment make sure microwave radiation safety precautions including both fuel and personnel safety considerations are observed These include clearing all personnel to an area be...

Page 1576: ...AIRCRAFT Navigation DA 42 NG AMM Page 204 15 Mar 2018 34 43 00 Doc 7 02 15 Rev 4 Figure 2 Radar Nose Cone Sealed Joint ...

Page 1577: ...egral with the ICS This Section tells you how to replace the antennas for the dependent position determining systems 2 Description The DA 42 NG has these dependent position determining systems and antennas Transponder DME GPS 2x ADF Marker VOR G S Flexible coaxial cables connect the antennas to their related equipment You can replace the coaxial cables The antennas are all attached to the surface ...

Page 1578: ...AIRCRAFT Navigation DA 42 NG AMM Page 2 15 Mar 2018 34 50 00 Doc 7 02 15 Rev 4 Figure 1 Antenna Locations ...

Page 1579: ...ssible Cause column Then do the repair given in the Repair column Trouble Possible Cause Repair ATC reports no transponder reply Transponder reply symbol operates Low output power Examine and repair replace defective antenna connections Replace antenna ATC reports no transponder reply Transponder reply symbol not operating Poor received signal Examine and repair replace defective antenna connectio...

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Page 1581: ... DME Antenna Detail Steps Work Items Key Items References 1 Make sure that the ELECT MASTER switch is set to OFF Instrument panel left side 2 Open the XPDR DME circuit breaker Instrument panel right side 3 Remove the pilot s seat if you will replace the transponder antenna Remove only the co pilot s seat if you will replace the DME antenna Refer to Section 25 10 4 Disconnect the coaxial cable from...

Page 1582: ... surface with sealant S Install the 2 washers and nuts that attach the antenna to the airplane structure S Remove the excess sealant that has been forced out of the joint between the antenna and the airplane surface Use sealant Refer to Paragraph 4 7 Connect the coaxial cable to the antenna At the antenna 8 Install the seat s that you removed at step 3 Refer to Section 25 10 9 Reset the XPDR DME c...

Page 1583: ...gation Doc 7 02 15 Rev 4 34 50 00 Page 203 15 Mar 2018 A B DME Antenna Transponder Antenna Connector Connector Lightning Protection Lightning Protection Washer Washer Nut Nut A B Figure 2 Transponder and DME Antenna Installation ...

Page 1584: ...AIRCRAFT Navigation DA 42 NG AMM Page 204 15 Mar 2018 34 50 00 Doc 7 02 15 Rev 4 Figure 3 Replace a GPS Antenna GPS Antenna Connector Washer Nut Lightning Protection Ground Plate Washer Nut Screw Screw ...

Page 1585: ...irplane S Remove the ground plate S If necessary use a knife to carefully remove the sealant that seals the antenna to the airplane outer surface S Move the antenna clear of the airplane Hold the antenna Take care not to damage the airplane surface From the outside 6 Install the antenna S Make sure that the contact surfaces of the antenna and the airplane surface where the antenna will be installe...

Page 1586: ...s References 1 Make sure that the ELECT MASTER switch is set to OFF Instrument panel left side 2 Remove the passengers seats Refer to Section 25 10 3 Disconnect the coaxial cable from the antenna that you will replace At the antenna 4 Remove the antenna S Remove the 3 screws nuts and washers that attach the antenna to the airplane S Remove the ground plate S If necessary use a knife to carefully r...

Page 1587: ...eal the outer edge of the antenna where it contacts the airplane surface with sealant S Install the ground plate S Install the 3 screws washers and nuts that attach the antenna to the airplane Use sealant Refer to Paragraph 4 6 Connect the coaxial cable to the antenna At the antenna 7 Install the passenger seats Refer to Section 25 10 8 Do a post installation operational test of the ADF system Onl...

Page 1588: ...AIRCRAFT Navigation DA 42 NG AMM Page 208 15 Mar 2018 34 50 00 Doc 7 02 15 Rev 4 A Marker Antenna Connector Lightning Protection Washer Bolt A ADF Antenna Figure 4 Replace a Marker Antenna ...

Page 1589: ... gain access to the NAV G S antenna via the hole in the stabilizer spar Refer to Section 27 20 4 Disconnect the coaxial cable from the antenna that you will replace At the antenna 5 Remove the antenna S Remove the 4 nuts and washers that attach the antenna to the airplane S If necessary use a knife to carefully remove the sealant that seals the antenna to the airplane outer surface 6 Install the r...

Page 1590: ...ection should be first carried out on the ground then in the air It is also necessary to establish whether any equipment in the airplane electrical system is generating interference B Operational Check Detail Steps Work Items Key Items References 1 Locate the airplane on the correction platform and using the bearing compass point the nose of the airplane to a radio beacon in boundary range 2 Switc...

Page 1591: ...e If the airplane is accurately aligned with the NBD beacon but a relative bearing reading of 0 is not indicated this is an indication that the antenna has been wrongly installed Recheck the antenna for agreement with the centerline of the airplane and correct if necessary Refer to the manufacturer s manual for detailed information on the quadrantal error correction Note It is obliging to proceed ...

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Page 1593: ...Section 34 56 Transponder XPDR 1 General The DA 42 NG has a transponder system which is an integral part of the Garmin G1000 system Refer to the G1000 Maintenance Manual Doc No 190 00907 00 latest revision for more details about the transponder XPDR system of the DA 42 NG airplane ...

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Page 1595: ...AIRCRAFT DA 42 NG AMM Oxygen System Doc 7 02 15 Rev 4 35 TITLE Page 1 15 Mar 2018 CHAPTER 35 OXYGEN SYSTEM ...

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Page 1597: ... Operation 6 Trouble Shooting 1 General 101 Maintenance Practices 1 General 201 2 Operational Test 201 3 Empty the Oxygen System 202 4 Remove Install the Instrument Panel Pressure Gauge 203 5 Remove Install the Oxygen Cylinder 204 6 Remove Install the Oxygen Regulator 206 7 Remove Install the Filling Block Assembly 208 8 Remove Install the Pilot Co Pilot Outlet Manifold 209 9 Remove Install the Pa...

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Page 1599: ...mask or cannula to the oxygen system via four outlet ports The operation of the oxygen system is controlled via a single ON OFF switch installed below the instrument panel on the pilot s side Information concerning the endurance of the system which is in direct relation to the cylinder pressure is indicated on a pressure gauge installed on the upper right side of the instrument panel A pressure ga...

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Page 1601: ...installed on the upper right side of the instrument panel An oxygen system overview is given in Figure 1 The system consists of five main sections Pressure gauge on the instrument panel Oxygen cylinder Regulator valve assembly Filling block Outlet ports To enable proper ventilation the nose baggage compartment is divided into three vented compartments Battery relay box compartment Oxygen compartme...

Page 1602: ... 00 Doc 7 02 15 Rev 4 Passenger Plugs Lit Gauge Plug Battery Relay Box Vented Battery Compartment TKS Fluid Tank Vented Oxygen Compartment Oxygen Regulator Fitting Block with Gauge On Off Cable Batteries T Fitting Plug Push Pull Knob Figure 1 AEROX Oxygen System ...

Page 1603: ... installed on the RH side of the instrument panel The gauge shows the current pressure in the oxygen cylinder The oxygen pressure is directly related to the remaining amount of oxygen The lighting of the instrument panel pressure gauge is the only electrical item of the oxygen system There are no indications and warning lamps of the oxygen system connected to the Garmin G1000 system Figure 2 Oxyge...

Page 1604: ...4 15 Mar 2018 35 10 00 Doc 7 02 15 Rev 4 Screw Instrument Panel Screw Instrument Light Oxygen Indicator Frame Oxygen Indicator O Ring Washer Nut Clamp High Pressure Line Spiral Wrap Figure 3 Pressure Gauge Installation on the Instrument Panel ...

Page 1605: ...ts own adjustable pressure regulator therefore each user can adjust the amount of supplemental oxygen D Filling Block Refilling of the oxygen cylinder which is firmly installed in the airplane is done via the filling block assembly which is installed on the LH side of the oxygen compartment It is accessible via a small cover on the LH side of the oxygen compartment It consists of a damper valve an...

Page 1606: ...ed to the oxygen regulator valve controlling the oxygen system by pulling the green control knob out for ON and pushing the same knob in for system supply OFF The system should be left OFF when not in use The oxygen ports are located one each in the map pocket recess for the pilot and co pilot The passengers oxygen ports are located overhead in the roll over bar next to the cabin speaker The indiv...

Page 1607: ...tailed in the Trouble column read across to the Possible Cause column Then do the repair given in the Repair column Trouble Possible Cause Repair No oxygen comes out of the connected masks and cannulas False adjustment of flow meter needle valve Flow meter needle valve defective Outlet port defective Regulator valve assembly defective Adjust Replace valve Replace outlet port Replace regulator valv...

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Page 1609: ...1850 PSI Do not use oxygen with a lower purity grade than prescribed by MIL PRF 27210 2 Check each plug in outlet port Use the flow meter needle valve assembly open every needle valve completely and make sure the ball floats to the top of the flow meter Make sure that every plug in is fully opened 3 Check pressure gauges by comparing the one attached on the filling block with the pressure gauge in...

Page 1610: ...N OFF knob is in the OFF position 4 Plug in one connection tube in the pilot s outlet port Plug in only the connection tube including the flow meter needle valve assembly 5 Pull ON OFF knob in ON position and adjust the needle valve to maximum flow 6 Confirm that the outlet of the flow meter needle valve assembly does not point not towards oil or grease engine 7 The cylinder is depleted when the f...

Page 1611: ...mp sheet metal and pull the indicator backwards out of its frame 7 Remove the ring from the indicator B Install the Instrument Panel Pressure Gauge Detail Steps Work Items Key Items References 1 Place the oxygen indicator in the frame 2 Attach the ring and the clamp sheet metal to the rear of the indicator 3 Install this assembly in the designated cutout on the RH side of the instrument panel Take...

Page 1612: ...ressure gauges and check the ON OFF knob is in OFF position 3 Open both doors to the nose baggage compartment 4 Remove the LH and RH oxygen compartment cover 5 Remove one PFA tubing 6 Pull ON OFF knob in ON position and confirm that the cylinder is empty 7 Disconnect all other lines and the Bowden cable from the regulator 8 Open the clamp which fixes the oxygen cylinder 9 Remove the LH battery cov...

Page 1613: ... are in or near the oxygen compartment 2 Install the regulator on the cylinder Seal the thread with Teflon tape and a rubber ring 3 Install the cylinder in its designated position Regulator points forward 4 Fix the cylinder by using the silicon protection ring and a clamp 5 Connect all pressure lines and the Bowden cable to the regulator 6 Install the LH battery cover and both oxygen compartment c...

Page 1614: ...hat the ON OFF knob is in the OFF position 3 Open both doors to the nose baggage compartment 4 Remove the LH and RH oxygen compartment cover 5 Remove one PFA tubing 6 Pull ON OFF knob in ON position and confirm that the cylinder is empty 7 Disconnect all other lines and the Bowden cable from the regulator 8 Open the clamp which fixes the oxygen cylinder 9 Remove the LH battery cover For easier rem...

Page 1615: ...nces are in or near the oxygen compartment 2 Install the regulator on the cylinder Seal the thread with Teflon tape and a rubber ring 3 Install the cylinder in its designated position Regulator points forward 4 Fix cylinder with the silicon protection ring and a clamp 5 Connect all pressure lines and the Bowden cable to the regulator 6 Install the LH battery cover and both oxygen compartment cover...

Page 1616: ...Remove one PFA tubing 6 Pull ON OFF knob in ON position and confirm that the cylinder is empty 7 Carefully disconnect the high pressure filling copper line from the regulator 8 Remove filling block assembly screws and pull out the filling block B Install the Filling Block Assembly Detail Steps Work Items Key Items References 1 Thread in the high pressure copper filling line in the grommet installe...

Page 1617: ...anifold 3 Open the threaded ring of the outlet manifold and remove the outlet manifold B Install the Pilot Co Pilot Outlet Manifold Detail Steps Work Items Key Items References 1 Remove the side pocket and install the outlet manifold by using the threaded ring after attaching the placard Confirm that 2 PA rings one between the side pocket and the outlet manifold and the other between the side pock...

Page 1618: ...he outlet manifold do not fall into the roll bar 5 Disconnect the PFA tubing from the dual outlet manifold 6 Protect open end of the PFA tubing against debris with tape B Install the Passengers Dual Outlet Manifold Detail Steps Work Items Key Items References 1 Put the 2 PA rings one at each outlet on the dual outlet manifold Use a small amount of adhesive to fix it 2 Place the dual outlet manifol...

Page 1619: ...AIRCRAFT DA 42 NG AMM Standard Practices Structures Doc 7 02 15 Rev 4 51 TITLE Page 1 15 Mar 2018 CHAPTER 51 STANDARD PRACTICES STRUCTURES ...

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Page 1621: ...ded Components 4 6 Repair Limitations 4 Section 51 10 Investigation 1 General 1 2 Damage Classification 1 3 Types of Damage 2 4 Inspection Techniques 3 5 Further Inspection 4 6 Debris Protection Inspection OÄM 42 088a OÄM 42 089a OÄM 42 090a 4 Section 51 20 Repair Processes 1 General 1 2 Center of Gravity Limits 1 3 Control Surface Balancing 1 4 Drain Vent Holes 1 5 Holding a Component During a Re...

Page 1622: ...210 9 Repairs 224 Section 51 30 Materials 1 General 1 2 Approved Materials 1 Section 51 40 Fasteners 1 General 1 2 Description 1 Maintenance Practices 1 General 201 2 Replace a Quick Release Fastener Stud 201 Section 51 60 Control Surface Balancing 1 General 1 2 Rudder Static Balance 10 3 Rudder Trim Tab Static Balance 11 4 Elevator Static Balance 12 5 Elevator Trim Tab Static Balance 13 6 Aileron...

Page 1623: ...MM Standard Practices Structures Doc 7 02 15 Rev 4 51 CONTENTS Page 3 15 Mar 2018 Section 51 80 Lightning Protection 1 General 1 2 Description 1 Maintenance Practices 1 General 201 2 Test the Electrical Bonding System 201 ...

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Page 1625: ...ers of carbon cloth Rigid foam inserts give stiffness to the fuselage shells where necessary All of the main structural components are CFRP or GFRP rigid moldings Many layers of carbon or glass cloth bond together to make each molding Carbon fiber cloth gives more strength and stiffness The vertical stabilizer is part of the fuselage The aft part of the left and right fuselage shells make the left...

Page 1626: ...bottom shells Each shell has a mixture of CFRP and GFRP cloth The shells have rigid foam cores and bond together The horizontal stabilizer has top and bottom shells Each shell has GFRP skins The horizontal stabilizer has a front spar and a rear spar Three pairs of ribs give strength to the central area The elevator has top and bottom shells Each shell has GFRP skins with a rigid foam core The rudd...

Page 1627: ...ve many layers of cloth bonded together with resin This is called lamination GFRP has very good properties It is strong and flexible It is very resistant to chemical attack and very little maintenance of GFRP laminates is necessary B Carbon Fiber Reinforced Plastic CFRP CFRP is very thin carbon fibers bonded together by resin The carbon gives most of the strength and the resin maintains the shape ...

Page 1628: ...t can fail 5 Bonded Components A number of components can bond together to make a larger component Special thick resin bonds these components together and fills the gap in a joint 6 Repair Limitations Repairs which are categorized as Class 1 in accordance with Section 51 10 Paragraph 2 may only be carried out in accordance with a repair scheme which has been approved by Diamond Aircraft Industries...

Page 1629: ... partial replacing of structural components or extensive repairs is counted among Class 1 Damage that intermits the main flow of forces within the airframe structure as a whole Damage that interrupts transmission and transfer of force to primary structural components fuselage wings empennage and control surfaces rudder elevator ailerons flaps Damage to large areas dimensions for L285 150 mm 5 9 in...

Page 1630: ...ilure of the bonding between two or more components For example between the wing skin and a wing rib Or between a metal component and a composite component Or between a composite skin and a sandwich core material Delamination is the failure of a bond between one or more layers of glass carbon cloth in a laminated component There are also two main types of cracks that can occur in composite structu...

Page 1631: ... and deformation Look specially in the areas where stones can hit the fuselage and wings below the airplane Look specially in the areas of the wing walkways B Light Test Use the light test to find delamination Use this test on components which do not have rigid foam cores CAUTION DO NOT LET THE COMPOSITE GET HOT HEAT CAN CAUSE DAMAGE TO COMPOSITES Point a very bright light at the surface and look ...

Page 1632: ...ke inspection holes then you must contact Diamond Aircraft Industries for advice 6 Debris Protection Inspection OÄM 42 088a OÄM 42 089a OÄM 42 090a A Single and Triple Layer Adhesive Foil Debris Protection OÄM 42 088a OÄM 42 089a Even small holes or buckling deeper than 1 5 mm 0 06 in in this layer have an adverse effect on its tensile strength A proper protection of the fuselage cannot be ensured...

Page 1633: ...ge repair and calculate the center of gravity Refer to Section 08 10 for data about weighing the airplane and calculating the center of gravity 3 Control Surface Balancing When you repair a control surface it becomes heavier Make an estimate of the new weight of the control surface if you were to carry out the repair Weigh the materials that you will use to do the repair and add the weight to the ...

Page 1634: ...USE SKIN DISEASE The resins hardeners and solvents used for composite repairs are poisonous You must not take food or drinks into the work area Use a mask to protect your face and use eye protection WARNING DO NOT GET RESINS HARDENERS OR SOLVENTS IN YOUR MOUTH OR IN YOUR EYES THESE CHEMICALS CAN CAUSE DISEASE When you grind composites you make small particles of composite dust These particles can ...

Page 1635: ... must not be affected by draughts The workshop temperature must be maintained for L285 between 18 C 65 F and 27 C 80 F for RIM 935 between 18 C 65 F and 23 C 73 F The temperature must not fall below 15 C 59 F The relative humidity during mixing applying or curing resins must not be allowed to rise above 80 for L285 or 65 for RIM 935 Maintain the workshop temperature as near to 25 C 77 F as possibl...

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Page 1637: ...igh all the cloth patches that you will use for the repair The ratio for glass cloth to resin mix is 100 70 For example 100 grams of dry cloth require 70 grams of mixed resin The ratio for carbon cloth to mixed resin is 100 85 For example 100 grams of dry carbon cloth requires 85 grams of mixed resin Measure the quantities of resin and hardener accurately 0 5 by weight Mix the resin and hardener t...

Page 1638: ... or scissors to cut the cloth to size Make sure that the fibers in the cut cloth point in the correct relative direction Make sure that the fiber strands are not broken or damaged The cloth must be free of any damage or contamination 4 Core Material You must always use the correct sandwich core for the repair Refer to the lay up drawing of the repair area for data about the core material that you ...

Page 1639: ... the resin You can make the repair neater You do not have to work upside down to make the laminate A Laminating Directly on the Airplane Detail Steps Work Items Key Items References 1 Prepare the damaged area for laminating S Make sure that the repair is clean and free of contamination S Do not touch the area to be repaired Especially particles of skin protecting cream on your hands may act as a s...

Page 1640: ...h to the repair and trim to the correct size Make sure that the fibers in the cloth point in the correct direction 7 Use a roller squeegee and a stipple brush to remove all trapped air Make sure that the cloth is completely impregnated with resin If necessary add more resin 8 When the excess resin has been brought to the surface with the rolling and stippling process Apply the next layer of cloth ...

Page 1641: ...tance 3 Prepare the layers of cloth that you will use for the repair Refer to the lay up drawing 4 Put a layer of clean transparent plastic polythene sheeting over the repair area and hold in place with self adhesive tape 5 Use an indelible ink marker to S Trace onto the plastic sheet the extreme outline of the repair S Trace onto the plastic sheet the contour lines of each layer of cloth in the s...

Page 1642: ...ary add more resin 11 When the excess resin has been brought to the surface with the rolling and stippling process Apply the next layer of cloth Trim the cloth to the correct size Make sure that the fibers in the cloth point in the correct direction 12 Do steps 9 and 10 as necessary until all the layers of cloth are in place 13 Apply a thin coat of resin to the area of the repair on the airplane s...

Page 1643: ...R TO SECTION 51 30 Use bonding paste to bond GFRP CFRP components together and in the repair of sandwich cores Resin and thickening fillers make the bonding paste Table 1 gives you the proportion by weight of resin to thickening fillers Table 1 Bonding Paste Mixing Proportions Material Weight in Grams Mixed Resin 50 100 150 200 250 300 350 400 450 Cotton Flakes 6 1 12 2 18 3 24 4 30 5 36 6 42 7 48...

Page 1644: ...ve an oven or a warming room you can make a temporary enclosure around the repair to trap the heat from a flame proof air heater CAUTION DO NOT ALLOW THE TEMPERATURE TO GET TOO HIGH DURING THE CURE A TEMPERATURE THAT IS TOO HIGH CAN DAMAGE THE COMPOSITE STRUCTURE 2 After 24 hours raise the temperature of the repair to at least 65 C 149 F for a minimum of 6 hours to complete the first stage of the ...

Page 1645: ...TO GET TOO HIGH DURING THE CURE A TEMPERATURE THAT IS TOO HIGH CAN DAMAGE THE COMPOSITE STRUCTURE 2 Gradually raise the temperature of the repair area to 125 to 135 C 257 to 275 F over a minimum of 4 hours 3 Maintain this temperature for a minimum of 14 hours to complete the final post cure Monitor the temperature every 15 minutes for the first hour then hourly The post cure time can be divided in...

Page 1646: ...riping which are subject to the following restrictions refer to Figure 1 Zone 1 No registration markings warning markings trim or striping may be applied here except for the placards in accordance with Section 11 20 Zone 1a This zone has the same restrictions as Zone 1 except that registration markings may be applied here which comply with the restrictions of Zone 2 Zone 2 Registration markings wa...

Page 1647: ...color may be applied in this zone Zone 4 It is mandatory to paint this zone top of vertical stabilizer leading edge in a color with a solar absorptivity not exceeding 0 65 If the Garmin GWX 68 or GWX 70 weather radar system OÄM 42 119 or OÄM 42 273 is installed a special GFRP radar nose cone is installed The radar nose cone is coated with a special paint You must replace the radar nose cone if the...

Page 1648: ...AIRCRAFT Standard Practices Structures DA 42 NG AMM Page 212 15 Mar 2018 51 20 00 Doc 7 02 15 Rev 4 Zone 1a Zone 1 Zone 2 Zone 3 Zone 4 Figure 1 Paint Color Scheme S N below 42 N300 42 MN100 ...

Page 1649: ...t this criterion are Registration markings warning markings trim or striping of any shape provided that colors with a solar absorptivity not exceeding 0 54 are used A stripe of any color on a white background solar absorptivity 0 3 results in a maximum width of the stripe of 50 mm 2 in within the 125 mm x 125 mm 5 in x 5 in square Zone 3 Color paint finish of any color may be applied in this zone ...

Page 1650: ...AIRCRAFT Standard Practices Structures DA 42 NG AMM Page 214 15 Mar 2018 51 20 00 Doc 7 02 15 Rev 4 Zone 4 Zone 3 Figure 2 Paint Color Scheme S N 42 N300 42 MN100 and above Part I ...

Page 1651: ...AIRCRAFT DA 42 NG AMM Standard Practices Structures Doc 7 02 15 Rev 4 51 20 00 Page 215 15 Mar 2018 Figure 3 Paint Color Scheme S N 42 N300 42 MN100 and above Part II ...

Page 1652: ...01 BC A 71061 RUMPF SILBER MET TOY 199 MIPA N001 BC A 71072 RADARNASE SILBER PEARL TOY 199 MIPA A002 BC A 71062 RUMPF ANTHRAZIT TOY 1E5 MIPA N002 BC A 71071 RADARNASE ANTHRAZIT PEARL TOY 1E5 MIPA A003 BC A 3819 RADARNASE ROT PEARL TOY 3L6 MIPA N003 BC A 3819 RADARNASE ROT PEARL TOY 3L6 MIPA A004 BC A 50466 RUMPF BLAU MET FEU MLTC MIPA N004 BC A 50467 RADARNASE BLAU MET FEU MLTC MIPA A005 BC A 1041...

Page 1653: ...E FILLER OR PAINT FUMES ACETONE FILLER AND PAINT FUMES CAN CAUSE DISEASE CAUTION THERE MUST BE NO GREASE OR DUST ON THE REPAIR AREA GREASE AND DUST PREVENT A GOOD BOND 2 Make sure that the area to be repaired is clean and free from any contaminants If necessary use acetone and re sand the area 3 Apply HS filler to the repair area Obey the filler manufacturer s instructions 4 Allow the HS filler to...

Page 1654: ...uctures DA 42 NG AMM Page 218 15 Mar 2018 51 20 00 Doc 7 02 15 Rev 4 Figure 4 Scarfing the Paint Coat Anti static Filler Repair Area Anti static Filler Coating Paint Scarfing 25mm 5mm 1in 0 2in Scarfing 25mm 5mm 1in 0 2in 200mm 8 0in ...

Page 1655: ...R SKIN ACETONE FILLER AND PAINT CAN CAUSE SKIN DISEASE WARNING DO NOT BREATHE ACETONE FILLER OR PAINT FUMES ACETONE FILLER AND PAINT FUMES CAN CAUSE DISEASE CAUTION THERE MUST BE NO GREASE OR DUST ON THE REPAIR AREA GREASE AND DUST PREVENT A GOOD BOND 1 Make sure that the area to be repaired is clean and free from any contaminants If necessary use acetone and re sand the area 2 Apply 2 layers of H...

Page 1656: ...03 3 Repair Procedure Detail Steps Work Items Key Items References WARNING WHEN HANDLING CHEMICALS ALWAYS OBSERVE HEALTH AND SAFETY REGULATIONS GIVEN BY THE MANUFACTURER OF THE CHEMICALS 1 Clean the entire area between fuselage and nacelle Use water to remove dirt from the surface If necessary add a mild cleaning agent Refer to Section 12 30 2 Use a commercial solvent to remove grease from the sur...

Page 1657: ...paint with sandpaper grit 320 for the ends of strips use red Scotch Brite 9 Clean the surface at the safety walk cutouts with a vacuum cleaner and silicon remover 10 Cover the airplane s surface around the safety walk cover 11 Prepare lacquer P N 22101980 in acc with the technical information sheet Shake 2 minutes before and after operating the red button Press red button with the ball of your han...

Page 1658: ...2018 51 20 00 Doc 7 02 15 Rev 4 15 Carefully pull off the safety walk cover starting from one edge Remove the cover in direction of the strips within 15 minutes 16 Let the system dry for 12h in a dry and weather protected area at temperatures from 20 to 30 C 68 to 86 F 17 Remove the cover from the airplane surface ...

Page 1659: ...7 02 15 Rev 4 51 20 00 Page 223 15 Mar 2018 Place front edge of Safety Walk Cover 100mm away from fuselage wall Place rear edge of Safety Walk Cover 175mm away from fuselage wall Place Safety Walk Cover to trailing edge Figure 5 Safety Walk Cover Positioning ...

Page 1660: ...AUSE SKIN DISEASE WARNING DO NOT BREATHE ACETONE FILLER OR PAINT FUMES ACETONE FILLER AND PAINT FUMES CAN CAUSE DISEASE 1 Sand the repair area with 150 grit sanding paper 2 Make sure that the area to be repaired is clean and free from any contaminants If necessary use acetone 3 Apply putty to the repair area to fill any damage Obey the putty manufacturer s instructions Fill to the original contour...

Page 1661: ...the laminates are bonded together and to any core material Refer to Figure 6 Use a sharp knife or grinding disk 4 Scarf the edges of the repair area with a grinding disk or block Scarf glass cloth at 50 1 50x cloth thickness minimum and carbon cloth at 100 1 100x cloth thickness minimum 5 Count the layers of fabric that you will need to replace Refer to the lay up drawing for the related structure...

Page 1662: ...AMM Page 226 15 Mar 2018 51 20 00 Doc 7 02 15 Rev 4 Scarf the Edges of the Repair Area Repair the Laminate Contour the Laminate New Laminate New Laminate Laminate Foam Core Remove Damaged Loose Laminate Laminate Scarf Figure 6 Typical Class 3 Repair ...

Page 1663: ...AN CAUSE DISEASE 7 Repair the laminate Use one of the 2 methods given in Paragraph 5 step 7 8 Pre cure the repair Refer to Paragraph 7 9 Post cure the repair Refer to Paragraph 7 10 When the repair is fully post cured remove the peel ply and sand smooth the surface of the repair 11 Contour the repair so that the final surface level of the repair is slightly lower than the original surrounding area...

Page 1664: ... Remove Damaged Loose Laminate Remove Damaged Foam Core and Scarf Laminate 20 mm 20 mm Scarf Scarf Foam Insert Foam Insert Laminate Laminate Insert the Laminate and Foam Core Into the Repair with Bonding Paste Profile the Foam Core Insert Laminate Laminate Repair the Laminate Contour the Laminate Figure 7 Typical Class 2 Repair ...

Page 1665: ... material Refer to Figure 7 Use a sharp knife or grinding disk 4 Remove the damaged foam core Remove sufficient foam core to give a minimum of 20 mm 0 8 in edge around the outside of the damaged area Refer to Figure 7 5 Scarf the edges of the external laminate repair area with a grinding disk or block Scarf glass cloth at 40 1 40x cloth thickness minimum and carbon cloth at 60 1 60x cloth thicknes...

Page 1666: ...core S Apply a coat of thickened resin to the foam core S Laminate the inner layers of cloth onto the inner surface of the foam core Make sure that the fibers of the cloth point in the correct direction Refer to Paragraph 6 Use one of the 2 methods given in Paragraph 5 10 Apply a thin coat of resin to the area to be repaired 11 Put the foam core and inner laminate into position in the repair 12 Pr...

Page 1667: ... 231 15 Mar 2018 19 Post cure the repair Refer to Paragraph 7 20 When the repair is fully post cured remove any peel ply and sand smooth the surface of the repair 21 Contour the repair so that the final surface level of the repair is lower than the original surrounding area Use 150 grit sanding paper To allow for the paint coat ...

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Page 1669: ...L285 Resin L285 Hardener H286 Mixture 100 parts resin and 40 2 parts of hardener by weight Supplier Hexion Specialty Chemicals Stuttgart GmbH Am Ostkai 21 22 D 70327 Stuttgart Germany Phone 49 711 389800 0 Fax 49 711 389800 11 2 RIM 935 Resin RIM 935 Hardener RIMH937 Mixture 100 parts resin and 38 2 parts of hardener by weight Supplier Hexion Specialty Chemicals Stuttgart GmbH Am Ostkai 21 22 D 70...

Page 1670: ...Hardener H286 Mixture 100 parts resin and 21 2 parts of hardener by weight Supplier Hexion see above C Glass Fiber Cloth 1 L285 WLB No German Aviation Standard Weave Weight per unit area g m Interglas Type Porcher Type 8 4548 60 2 2 twill 163 92110 917 8 4551 60 2 2 twill 280 92125 3063 8 4554 60 2 2 twill 390 92140 1989 8 4520 60 UD 220 92145 8 4525 60 UD 425 92146 All cloth types consist of alka...

Page 1671: ... 390 1989 8 4520 60 UD 220 92145 8 4525 60 UD 425 92146 Plain 49 2037 All cloth types consist of alkali free E glass with K 506 or FK 144 finish and comply with LN9169 German Aviation Standard Supplier for Interglas cloth Interglas P D Interglas Technologies GmbH Benzstraße 14 D 89155 Erbach Germany Phone 49 0 7305955 0 Fax 49 0 7305955 513 Supplier for Porcher cloth Porcher Industrietextilien Gmb...

Page 1672: ...erglas Type ECC Type SGL Type 8 3520 80 2 2 twill 200 98141 CCC 452 2 2 twill with aluminum fibers 220 CCC 459 Al UD tape 380 Sigratex KDU 1034 2 RIM 935 WLB No German Aviation Standard Weave Mass per unit area g m ECC Type SGL Type J H vom Baur Type 2 2 twill 200 CCC 452 2 2 twill with aluminum fibers 220 CCC 459 Al UD tape 380 Sigratex KDU 1034 16563 UD cloth 280 CCC 796 plain 80 CCC 461 ...

Page 1673: ... Heek Nienborg Germany Phone 49 2568 3883 34 Fax 49 2568 3883 97 Supplier for Vom Baur J H vom Baur Sohn GmbH CoKG Marktstraße 34 D 42369 Wuppertal Germany Phone 49 0 20224661 0 Fax 49 0 2024660033 Supplier for SGL tape SGL Technik GmbH Werner von Siemens Str 8 D 86405 Meitingen Germany Phone 49 8271 832152 Fax 49 8271 831427 E Peel Ply Type PA20 63 compliant with LN98690 Supplier Strübel Vertrieb...

Page 1674: ...43 3356 20444 Fax 43 3356 20445 E Mail chemie polychem at G Fillers for Resin Type Cotton flakes FB1 035 Supplier Rudolf Usner GmbH see above Type Silcell 300 Supplier Joh Klinglhuber Söhne Handelsgesellschaft mbH Wallgasse 21 A 1060 Vienna Austria Phone 43 1 5974712 0 Fax 43 1 5974712 16 Type Aerosil 380 Supplier Polychem HandelsgesmbH Markt Allhau Nr 463 A 7411 Markt Allhau Austria Phone 43 3356...

Page 1675: ...ype ICI P551 1052 Manufacturer ICI Paints Berkshire Great Britain Supplier ICI Autocolor der PPG Austria Handels GmbH Siezenheimerstrasse 31 A 5020 Salzburg Austria Phone 43 1 662 420425 0 Fax 43 1 662 435640 2 EP Filler Type ICI P580 2100 Manufacturer ICI Paints Berkshire Great Britain Supplier ICI Autocolor see above Type MIPA EP 103 20 gelb lasierend Manufacturer MIPA Professional Coating Syste...

Page 1676: ...onal Coating System AG Supplier MIPA Professional Coating System AG see above 4 Coating Paint a White Type PPG Turbo Plus 493 Color 6 KVW white Manufacturer PPG Deutschland Supplier Nexa Autocolor der PPG Austria Handels GmbH Siezenheimerstrasse31 A 5020 Salzburg Austria Phone 43 662 420425 0 Fax 43 662 435640 Type MIPA PUR HS Manufacturer MIPA Professional Coating System AG Supplier MIPA Professi...

Page 1677: ...nufacturer E I DUPONT DE NEMOURS CO Supplier E I DUPONT DE NEMOURS CO see above Type BASF UNO Manufacturer BASF Supplier BASF CANADA INC 10 Craig Street Brantfort Ontario Canada b Other Colors Type Refer to Section 51 20 Manufacturer MIPA Professional Coating System AG Supplier MIPA Professional Coating System AG see above ...

Page 1678: ... above Type ICI P551 1052 Manufacturer ICI Paints Berkshire Great Britain Supplier ICI Autocolor der PPG Austria Handels GmbH see above 2 Coating Paint Glare shield Nuvovern DS 10 1 Nuvovern ACR Inst Panel cover Nuvovern DS 10 1 Nuvovern ACR General Nuvovern DS 10 1 Manufacturer Mäder Lacke AG Killwangen Switzerland Supplier Walter Mäder GmbH Wiener Str 99 A 2514 Traiskirchen Austria Phone 43 2252...

Page 1679: ...amburg Germany Phone 49 40 742193 10 Fax 49 40 742139 69 2 Hensel Fire retardant paint Hensotherm 2 KS white Coating paint Hensotop 84f Supplier Rudolf Hensel GmbH Lack und Farbenfabrik Lauenburger Landstrasse 11 D 21039 Börnsen Germany Phone 49 40 72106210 Fax 49 40 72106252 K Acrylic Glass Cement Acrylic glass cement Polymerization Cement Acrifix 92 Manufacturer Röhm D 64275 Darmstadt Germany Ph...

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Page 1681: ... the access panel and a compression spring holds the stud in the stud assembly The T shaped end of the stud locates in the slot of the receptacle When you turn the stud clockwise through 90 it engages the cam track in the receptacle and pulls the access panel into position When the stud is turned fully 90 clockwise the T shaped end of the stud engages in a small indent in the cam track The compres...

Page 1682: ...AIRCRAFT Standard Practices Structures DA 42 NG AMM Page 2 15 Mar 2018 51 40 00 Doc 7 02 15 Rev 4 Receptacle Rivet Spring Ring Access Panel Grommet Stud Figure 1 Quick Release Fastener Assembly ...

Page 1683: ...ers into position under the rim of the stud assembly S Compress the stud assembly with the stud pliers and remove the stud assembly from the grommet If installed Refer to Figure 1 Turn the stud assembly approximately 30 off axis 2 Install the new stud assembly S Select the correct length stud assembly S Put the stud assembly into the U jaw of the stud pliers S Compress the stud assembly and move t...

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Page 1685: ...n or flutter in flight You can use any convenient method to weigh a control surface If you use anything to connect the control surface to the weighing device then you must weigh the device for example a sling separately and deduct its weight from the total value For example you use a rope sling to weigh an aileron with a spring balance Weight of aileron and the rope sling 3 8 kg 8 378 lb Weight of...

Page 1686: ...m 23 0 to 33 1 1 3 to 2 15 1 0 to 7 6 1 0 to 1 5 6 6 to 8 25 0 28 to 0 39 5 3 to 6 35 0 28 to 0 39 Actual kp Actual kp cm Centre Push Rod L R Static Moment Center line horizontal Rudder trim tab and push rod Elevator trim tab and push rod Center line horizontal M P r P in kp r in cm P P P P r r r r Typ 52 4cm Typ 13cm Typ 31cm Typ 10cm Figure 1 Typical Weights and Residual Moments Report DA 42 NG ...

Page 1687: ... cm 53 9 to 69 2 1 5 to 2 4 1 0 to 7 6 1 0 to 1 5 5 62 to 6 54 0 31 to 0 42 5 3 to 6 35 0 28 to 0 39 Actual kp Actual kp cm Centre Push Rod L R Static Moment Center line horizontal Rudder trim tab and push rod Elevator trim tab and push rod Center line horizontal M P r P in kp r in cm P P P P r r r r Typ 52 4cm Typ 13cm Typ 31cm Typ 10cm Figure 2 Typical Weights and Residual Moments Report DA 42 N...

Page 1688: ... 41 to 0 56 0 41 to 0 56 5 3 to 6 35 5 3 to 6 35 0 28 to 0 39 0 28 to 0 39 Actual kp Actual kp cm Centre Push Rod L R Static Moment Center line horizontal Rudder trim tab and push rod Elevator trim tab and push rod Center line horizontal M P r P in kp r in cm P P P P r r r r Typ 52 4cm Typ 13cm Typ 31cm Typ 10cm 6 17 to 7 50 if MÄM 42 1041 is installed if MÄM 42 1041 is installed 53 9 to 75 0 1 3 ...

Page 1689: ... to 28 7 1 13 to 1 87 0 87 to 6 60 0 87 to 1 30 14 6 to 18 2 0 62 to 0 86 11 7 to 14 0 0 62 to 0 86 Actual lbf Actual lbf in Centre Push Rod L R Static Moment Center line horizontal Rudder trim tab and push rod Elevator trim tab and push rod Center line horizontal M P r P lbf r in P P P P r r r r Typ 20 63 in Typ 5 1 in Typ 12 2 in Typ 3 94 in Figure 4 Typical Weights and Residual Moments Report D...

Page 1690: ...8 to 60 1 1 30 to 2 08 0 87 to 6 60 0 87 to 1 30 12 4 to 14 4 0 68 to 0 93 11 7 to 14 0 0 62 to 0 86 Actual lbf Actual lbf in Centre Push Rod L R Static Moment Center line horizontal Elevator trim tab and push rod Elevator trim tab and push rod Center line horizontal M P r P lbf r in P P P P r r r r Typ 20 63 in Typ 5 1 in Typ 12 2 in Typ 3 94 in Figure 5 Typical Weights and Residual Moments Repor...

Page 1691: ... 87 to 1 30 0 87 to 1 30 13 6 to 15 6 13 6 to 16 5 0 90 to 1 24 0 90 to 1 24 11 7 to 14 0 11 7 to 14 0 0 62 to 0 86 0 62 to 0 86 Actual lbf Actual lbf in Centre Push Rod L R Static Moment Center line horizontal Elevator trim tab and push rod Elevator trim tab and push rod Center line horizontal M P r P lbf r in P P P P r r r r Typ 20 63 in Typ 5 1 in Typ 12 2 in Typ 3 94 in if MÄM 42 1041 is insta...

Page 1692: ... Limits kp cm 0 to 2 5 24 5 to 33 1 25 5 to 32 6 2 28 to 2 73 3 4 to 3 9 2 3 to 2 8 Actual kp Actual kp cm Static Moment Upper surface horizontal Upper surface horizontal Upper surface horizontal M P r P in kp r in cm P P P r r r Typ LH 17cm Typ RH 19cm Typ 23cm Typ 30cm Left Left Left Right Right Right Figure 7 Typical Weights and Residual Moments Report DA 42 NG Airplane Sheet 2 Metric Dimension...

Page 1693: ...s lbf in 0 to 2 17 21 3 to 28 7 22 1 to 28 3 5 03 to 6 02 7 50 to 8 60 5 07 to 6 17 Actual lbf Actual lbf in Static Moment Upper surface horizontal Upper surface horizontal Upper surface horizontal M P r P lbf r in P P P r r r Typ LH 6 7 in Typ RH 7 5 in Typ 9 1 in Typ 11 8 in Left Left Left Right Right Right Figure 8 Typical Weights and Residual Moments Report DA 42 NG Airplane Sheet 2 Imperial D...

Page 1694: ...ng Bracket Without Stop Bolts Moment Arm Top Pivot 2 Rudder Static Balance Refer to Figure 1 to 4 for the weight and residual moment Use any suitable method to support the rudder horizontally at the pivot axis The rudder must be able to rotate freely around the pivot axis Remove the stop bolts from the lower mounting bracket before weighing and balancing The residual moment is tail heavy Figure 7 ...

Page 1695: ...ivot Axis Pivot Axis Spring Balance 3 Rudder Trim Tab Static Balance Refer to Figure 1 to 6 for the weight and residual moment Use any suitable method to support the trim horizontally at the pivot axis The trim tab must be able to rotate freely around the pivot axis The residual moment is tail heavy Figure 8 Rudder Trim Tab Static Balance ...

Page 1696: ...Weight Balance Weight Tape Spring Balance 4 Elevator Static Balance Refer to Figure 1 to 6 for the weight and residual moment Use any suitable method to support the elevator horizontally at the pivot axis The elevator must be able to rotate freely around the pivot axis The balance includes the trim tab trim tab control rods and horn Figure 9 Elevator Static Balance ...

Page 1697: ...l Spring Balance Tape 5 Elevator Trim Tab Static Balance Refer to Figure 1 to 6 for the weight and residual moment Use any suitable method to support the elevator trim tab horizontally at the pivot axis The elevator trim tab must be able to rotate freely around the pivot axis The residual moment is tail heavy Figure 10 Elevator Trim Tab Static Balance ...

Page 1698: ... Balance Weight Pivot Axis Moment Arm Horn Trim Plate Hinges 6 Aileron Static Balance Refer to Figure 7 or 8 for the weight and residual moment Use any suitable method to support the aileron horizontally at the pivot axis The aileron must be able to rotate freely around the pivot axis The balance includes the horn trim plate and hinges Figure 11 Aileron Static Balance ...

Page 1699: ...rn Horizontal 7 Wing Outer Flap Static Balance Refer to Figure 7 or 8 for the weight and residual moment Use any suitable method to support the outer flap horizontally at the pivot axis The outer flap must be able to rotate freely around the pivot axis The balance includes the horn and hinges The residual moment is tail heavy Figure 12 Wing Outer Flap Static Balance ...

Page 1700: ...l Hinges Horn 8 Wing Inner Flap Static Balance Refer to Figure 7 or 8 for the weight and residual moment Use any suitable method to support the inner flap horizontally at the pivot axis The inner flap must be able to rotate freely around the pivot axis The balance includes the horn and hinges The residual moment is tail heavy Figure 13 Wing Inner Flap Static Balance ...

Page 1701: ...h capacity aluminum alloy tubes and strips make the basis of the lightning conductor system The lightning conductor system has a longitudinal system and a lateral system The longitudinal system runs from the front rib of the fuselage through both sides and center of the wing center section through the left side of the rear fuselage and up into the vertical stabilizer From the vertical stabilizer a...

Page 1702: ...Tube Relay Box Mounting Bolts Instrument Panel XPDR Ant Engine Mounting Bolts Jumpers Engine Harness Overbraid Engine Mount Aileron Lever Pitot Tube Console Fuel Sel DME Ant GPS Ants Upper Strip MLG Main Bracket Horizontal Stabiliser Vert Tube Lightning Electrode Horizontal Stabiliser Trim System Bracket Bracket Rudder Figure 1 Lightning Protection System Schematic Diagram ...

Page 1703: ... material is conductive and is used to form part of the lightning protection system Carbon fiber material with interwoven aluminum fibers is used on the upper wing skin the fuselage and the engine cowlings Carbon fiber material with interwoven aluminum fibers is conductive A lightning conductor strip is integrated into the horizontal stabilizer The propeller blades are non conductive except for th...

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Page 1705: ... with a milliohmmeter and Kelvin probes The test current must be approximately 2 amps Do the high resistance measurements with a high voltage megaohmmeter Measure the static discharge wicks and the precautions against static charge of the airplane All measurements are referenced to the negative terminal of the airplane main battery The airplane must be serviceable during the tests and the engine c...

Page 1706: ...l tank optional Drain 10 0 Aux fuel tank refill optional Tube 10 0 Nacelle fuel filter Mounting bracket 10 0 FUSELAGE COMPONENTS External power connector Outer large pin 5 0 Instrument panel Above co pilot s left knee 3 0 Taxi light Mounting screw 4 0 Landing light Mounting screw 4 0 Remote avionic box Case 4 0 Hydraulic module Sheet metal 4 0 Nose LDG gear door hinge LH RH front hinge 10 0 Nose b...

Page 1707: ... LDG gear RH Axle mounting screw 10 0 RACC outlet scoop optional Tube 10 0 RACC inlet cap optional Tube 15 0 ANTENNAS COM 1 antenna top Mounting screws 6 0 COM 2 antenna bottom Mounting screws 6 0 ELT antenna Mounting screws 6 0 Top TAS antenna optional Mounting screws 6 0 Bottom TAS antenna optional Mounting screws 5 0 Iridium antenna optional Mounting screws 5 0 STABILIZER Vertical lightning pro...

Page 1708: ...rizontal stabilizer TKS panel optional LH outer panel section 15 0 Horizontal stabilizer TKS panel optional RH inner panel section 15 0 Horizontal stabilizer TKS panel optional RH outer panel section 15 0 Vertical stabilizer TKS panel optional Upper panel section 25 0 Vertical stabilizer TKS panel optional Bottom panel section 25 0 TKS low pressure switches optional Mounting plate 20 0 LH WING Fue...

Page 1709: ...ner panel section 15 0 Outer TKS panel optional Outer panel section 10 0 RH WING Fuel tank drain Drain 5 0 Tank refill Ring 5 0 Tank vent Plate 10 0 Pitot tube base Tube base 6 0 Tip light assembly Base plate 8 0 Aileron push rod attachment Bonding strap connection 50 0 Outer flaps push rod attachment Bonding strap connection 50 0 Inner flap push rod attachment Bonding strap connection 50 0 Inner ...

Page 1710: ...embly 150 0 Co pilot pedal assembly 150 0 Canopy hinge LH Tube tip 100 0 Canopy hinge RH Tube tip 100 0 RACC system optional Bracket 100 0 C High Resistance Measurements Use a wet sponge to get a constant electrical connection to the static dischargers Item Attachment Point Max Allowable MΩ Measured MΩ 500V IN OUT Passed STATIC DISCHARGE WICKS LH wing tip 200 0 RH wing tip 200 0 Rudder 200 0 Horiz...

Page 1711: ...AIRCRAFT DA 42 NG AMM Doors Doc 7 02 15 Rev 4 52 TITLE Page 1 15 Mar 2018 CHAPTER 52 DOORS ...

Page 1712: ...AIRCRAFT Doors DA 42 NG AMM Page 2 15 Mar 2018 52 TITLE Doc 7 02 15 Rev 4 Intentionally left blank ...

Page 1713: ...e Passenger Door 207 6 Remove Install the Passenger Door Locking Mechanism if MÄM 42 687 is installed 209 7 Remove Install the Gas Spring Strut for the Passenger Door 211 8 Test the Canopy and Access Door Warning Lights 212 9 Examine the Carbon Hinges on the Passenger Door 213 10 Inspection of the Door Locking and Safety Hook Mechanisms 217 11 Replace a Passenger Door Carbon Hinge 217 12 Remove In...

Page 1714: ...AIRCRAFT Doors DA 42 NG AMM Page 2 15 Mar 2018 52 CONTENTS Doc 7 02 15 Rev 4 Section 52 40 Access Panels 1 General 1 2 Description 1 ...

Page 1715: ... on the inside of the canopy and red on the outside The locking bolts are at the bottom rear corners of the canopy The passenger door is a CFRP molding with inner and outer frames The frames bond together The door has a acrylic glass window Two hinges attach the door to the top of the fuselage near the center line A gas strut attaches to the rear of the door and the fuselage The gas strut holds th...

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Page 1717: ...le and locking bolts bond to the inside of the frame with thickened resin The canopy has a large one piece acrylic glass window A special flexible adhesive bonds the window to the canopy frame A flexible filler seals the small gap between the edge of the window and the frame The window has a direct vision panels on each side You can open the direct vision panels in flight Refer to Chapter 56 00 fo...

Page 1718: ...AIRCRAFT Doors DA 42 NG AMM Page 2 15 Mar 2018 52 10 00 Doc 7 02 15 Rev 4 Firewall Hinge Frame Hinge Frame Hinges to Firewall Gas Spring Strut A Pedal assy Figure 1 Canopy Installation ...

Page 1719: ...or servicing If you pull the canopy handle away from the canopy frame these things happen The double lever turns to pull the connecting rod and the teleflex cable The connecting rod pulls the left locking bolt forward The teleflex cable pulls the right locking bolt forward The forward movement of the locking bolt operates the door unlocked warning micro switch in the right side fuselage shell The ...

Page 1720: ...me PTFE Bush Locking Bolt Connecting Rod Fork End Fitting PTFE Block Fuselage Shell Teleflex Cable Canopy Handle Canopy Frame Locking Bolt LH Locking Bolt RH Teleflex Cable to Right Locking Bolt Connecting Rod to Left Locking Bolt Countersunk Screw with Internal Hex Head Lock Tab Lock Plate Lock Assy Grub Screw Blanking Plug Figure 2 Canopy Locking Mechanism ...

Page 1721: ...inner handle is red and has a double lever The outer handle is red and attaches to the inner handle with two roll pins A long connecting rod attaches to the rear of the double lever The other end of the long connecting rod attaches to the inside of the rear locking bolt A safety lock is fitted to prevent accidental movement of the handle You must lift the safety handle before you can operate the r...

Page 1722: ... Door Frame Door Frame PTFE Bush PTFE Bush Locking Bolt Long Connecting Rod Locking Clip Fork End Fitting Fork End Fitting PTFE Block Fuselage Shell Short Connecting Rod Hinges Gas Spring Strut Passenger Door Front Locking Bolt Rear Locking Bolt Door Closed Switch Door Closed Microswitch Child Safety Lock Countersunk Screw with Internal Hex Head Figure 3 Passengers Door ...

Page 1723: ... Door Frame PTFE Bush PTFE Bush Locking Bolt Long Connecting Rod Locking Clip Ball Joint Fork End Fitting PTFE Block Fuselage Shell Short Connecting Rod Hinges Gas Spring Strut Passenger Door Front Locking Bolt Rear Locking Bolt Door Closed Switch Door Closed Microswitch Child Safety Lock Countersunk Screw with Internal Hex Head Rear Connecting Rod Fork End Fitting Rod Guide Lever Fork End Fitting...

Page 1724: ...AIRCRAFT Doors DA 42 NG AMM Page 8 15 Mar 2018 52 10 00 Doc 7 02 15 Rev 4 Intentionally left blank ...

Page 1725: ...place the damaged parts Replace the gas spring strut Canopy door handle is difficult to move Locking bolts damaged Handle bushes damaged Replace the damaged bolt Replace the canopy door Canopy handle is difficult to move Teleflex cable defective Replace the teleflex cable Incorrect operation of door warning caption on the ICS display Canopy door micro switch incorrectly adjusted Canopy door micro ...

Page 1726: ...AIRCRAFT Doors DA 42 NG AMM Page 102 15 Mar 2018 52 10 00 Doc 7 02 15 Rev 4 Intentionally left blank ...

Page 1727: ...chanism 2 Remove Install the Canopy A Remove the Canopy Detail Steps Work Items Key Items References 1 Open the canopy S Pull the canopy handle away from the canopy frame S Lift the canopy open Refer to Figure 2 2 Remove the 2 nuts 4 washers and 2 bolts on either side that attach the canopy tubular brackets to the hinge frame Refer to Figure 1 Note the position of the bonding wire cable Hold the c...

Page 1728: ...s 4 washers and 2 bolts on either side that attach the canopy tubular brackets to the canopy frame S Install the bonding wire cable onto the canopy Refer to Figure 1 At the location noted in Paragraph 2 3 Close the canopy 4 Operate the canopy lock S Hold the canopy closed S Push the canopy handle towards the canopy frame S Push up on the rear of the canopy frame When the canopy is locked the canop...

Page 1729: ...3 Remove the outside door handle S Open the inside door handle for access to the spring pin S Push the spring pin through the inside door handle S Pull the outside door handle out Use punch 4 mm 0 16 in 4 Remove the 4 screws from the inside door handle 5 Pull out the handle and disconnect the front fork head from the slide axle Remove the circlip and move the axle out 6 Disconnect the rear fork he...

Page 1730: ...door handle S Connect the rear fork head to the inside lever 2 Connect the front fork head Install the slide axle and secure the axle with circlip 3 Install the inside handle Install the 4 screws 4 Install the outside door handle S Push the outside door handle into the door shell to the inside door handle 5 Install the spring pin through the inside door handle Use punch 4 mm 0 16 in 6 Install the ...

Page 1731: ...Refer to Paragraph 2 2 Remove the nut and washer that attach the strut to the hinge frame Refer to Figure 1 WARNING MAKE SURE THAT THE STRUT IS FULLY EXTENDED BEFORE YOU DISCONNECT IT FROM THE HINGE FRAME 3 Pull the top of the strut away from the hinge frame Remove and retain the bush and second washer 4 Remove these items that attach the bottom of the strut S Nut washer and bolt S Bush S Two spac...

Page 1732: ...2 Install the bolt washer and self locking nut at the bottom attachment to the instrument panel frame Torque 6 4 Nm 4 7 lbf ft Use a new self locking nut 3 Put the washer and bush into position on the hinge frame 4 Move the top eye end of the of the strut over the bush on the hinge frame 5 Install the washer and self locking nut onto the hinge frame Torque 6 4 Nm 4 7 lbf ft Use a new self locking ...

Page 1733: ...S Lift the door open Refer to Figure 3 2 Remove the gas strut S Remove the locking clips from the gas strut top and bottom ball end fittings S Pull the gas strut off the ball end fittings on the fuselage and clear of the airplane Hold the door 3 Remove the passenger reading light assembly from the top of the cockpit For access to the front door hinge Refer to Section 33 10 4 Remove the bolts and w...

Page 1734: ...0 4 Install the gas strut S Push the gas strut ball end fittings onto the fuselage gas strut mounts S Install the locking clips which lock the ball end fittings in place 5 Close the door 6 Operate the door lock S Hold the door closed S Press the safety button next to the door handle and push the door handle towards the door frame S Push outwards on the bottom of the door frame When the door is loc...

Page 1735: ...emove the guide base 5 Pull the long connecting rod and the guide lever with the locking bolt to the door handle cut out B Install the Passenger Door Locking Mechanism Detail Steps Work Items Key Items References 1 Install the long connecting rod and the guide lever into the door handle cutout 2 Install the rear locking bolt into the PTFE bush 3 Connect the guide lever to the guide base 4 Connect ...

Page 1736: ...ng rod S Check the rear locking bolt over length in closed position min 43 mm max 45 mm If necessary adjust the locking bolt thread rod For adjustment remove the guide base and lever S Check the locking mechanism for release Push with 15 kg on the rear locking bolt in the closed position The closing mechanism has to stay locked up to a force of 15 kg S Check the front locking bolt over length in c...

Page 1737: ...e the gas strut S Remove the locking clips from the gas strut top and bottom ball end fittings S Pull the gas strut off the ball end fittings on the fuselage and clear of the airplane Hold the door B Install the Gas Spring Strut for the Passenger Door Detail Steps Work Items Key Items References 1 Open the passenger door S Pull the door handle away from the door frame S Lift the door open Refer to...

Page 1738: ...nger door operating handle towards the open position S Move the door operating handle to the fully closed position S Move the canopy operating handle towards the open position S Move the canopy operating handle to the fully closed position S Set the ELECT MASTER switch to OFF Monitor the integrated cockpit display The DOOR warning caption must be off The DOOR warning caption must come on when the ...

Page 1739: ...ation on the side faces S Hold the passenger door frame with one hand to the left and one hand to the right of the hinge S Apply torsional test force to the hinge by alternately pulling with one hand and pushing with the other hand S If cracks become visible on the side faces of the hinges when test force is applied the hinge is structurally damaged due to delamination Replace the carbon hinges Re...

Page 1740: ...by alternately pulling with one hand and pushing with the other hand check the cracks on the outer face of the hinge S If cracks expand extensively when applying test force the hinges are structurally damaged Replace the carbon hinge If cracks expand extensively when applying test force the hinges are structurally damaged Contact Diamond Aircraft for repair instructions If the cracks do not expand...

Page 1741: ...AIRCRAFT DA 42 NG AMM Doors Doc 7 02 15 Rev 4 52 10 00 Page 215 15 Mar 2018 Cracks on the side faces Figure 5 Passenger Door Torsional Hinge Test ...

Page 1742: ...AIRCRAFT Doors DA 42 NG AMM Page 216 15 Mar 2018 52 10 00 Doc 7 02 15 Rev 4 Cracks on the outer faces Figure 6 Passenger Door Outer Face Hinge Test ...

Page 1743: ...eral times Repeat lubrication procedure until button moves smoothly S Make sure the safety hook engages correctly into the retaining block on the fuselage when the door is closed but unlatched Refer to Section 12 20 11 Replace a Passenger Door Carbon Hinge Detail Steps Work Items Key Items References 1 Remove the passenger door Refer to Paragraph 5 2 Clean the surface around the hinge on fuselage ...

Page 1744: ...ims and positions for later use 9 Remove the passenger door 10 Prepare bonding surfaces Refer to Section 51 20 11 Coat bonding surface with mixed resin Refer to Section 51 20 12 Fill the hole for the carbon hinge with bonding paste completely Refer to Section 51 20 13 Put the passenger door into position Close door lock Make sure there are equal gaps and contour fit 14 Remove excessive bonding pas...

Page 1745: ...ush the spring pin through the inner door handle S Remove the outer door handle Use a 4 mm punch 4 If MÄM 42 687 is installed Remove the rod guide base from the door shell S Remove the 4 screws S Move the guide base free of the door shell 5 If MÄM 42 687 is installed Disconnect the thread rod from the rod guide lever S Remove the cotter pin and the bolt 6 Remove the inner door handle from the pass...

Page 1746: ...ndle into place S Connect the rear fork head to the inner door handle lever 2 Connect the front fork head and install the slide axle and secure the axle with a circlip 3 If MÄM 42 687 is installed S Connect the rear thread rod to the rod guide lever 4 If MÄM 42 687 is installed Install the rod guide base to the door shell S Install the 4 screws 5 Install the inner handle S Install the 4 screws 6 I...

Page 1747: ...mpression Gas Spring Detail Steps Work Items Key Items References 1 Remove the canopy or passenger door handle Refer to Paragraph 12 2 If installed remove the circlip from the gas spring tie bolt Protect the door surface finish 3 Pull the rear end of the door handle frame approximately 4 mm apart and pull out the gas spring tie bolt If MÄM 42 981 is installed pull the tie bolt out axially Caution ...

Page 1748: ... of the door handle frame approximately 4 mm apart and push the gas spring tie bolt in If MÄM 42 981 is installed push the tie bolt in axially 4 If MÄM 42 981 is installed install the circlip on the gas spring tie bolt 5 Install the canopy or passenger door handle Refer to Paragraph 12 14 Test the Passenger Door Handle Compression Gas Spring if MÄM 42 097 is installed Detail Steps Work Items Key I...

Page 1749: ...n system consists of Special canopy hinge with attached canopy jettison mechanism Canopy jettison mechanism with the LH and RH Bowden cables Canopy jettison lever assembly Canopy and Roeger type hooks The standard remove install procedure is valid for the standard canopy and the canopy with the jettison system installed if OÄM 42 194 is installed ...

Page 1750: ... 15 Mar 2018 52 10 00 Doc 7 02 15 Rev 4 Canopy Jettison Lever Canopy Hinge LH and RH Jettison Mechanism Figure 7 The Canopy Jettison System consists of the Canopy Hinge the LH and RH Canopy Jettison Mechanism and the Canopy Jettison Lever ...

Page 1751: ...AIRCRAFT DA 42 NG AMM Doors Doc 7 02 15 Rev 4 52 10 00 Page 225 15 Mar 2018 Washer Screw Canopy Jettison Lever Figure 8 Canopy Jettison Lever Assembly ...

Page 1752: ...rs DA 42 NG AMM Page 226 15 Mar 2018 52 10 00 Doc 7 02 15 Rev 4 Plug Spring Element Locking Pin Jettison Retainer Contraction Ring Spring Conduit Connector Bowden Cable Terminal Figure 9 Canopy Jettison Mechanism I ...

Page 1753: ...DA 42 NG AMM Doors Doc 7 02 15 Rev 4 52 10 00 Page 227 15 Mar 2018 Plug Spring Element Locking Pin Jettison Retainer Contraction Ring Spring Conduit Connector Bowden Cable Figure 10 Canopy Jettison Mechanism II ...

Page 1754: ...AIRCRAFT Doors DA 42 NG AMM Page 228 15 Mar 2018 52 10 00 Doc 7 02 15 Rev 4 1 0 5 0 Figure 11 Configuration of the Canopy and Roeger Type Hooks ...

Page 1755: ...AIRCRAFT DA 42 NG AMM Doors Doc 7 02 15 Rev 4 52 10 00 Page 229 15 Mar 2018 Figure 12 Adjustment of the Bowden Cable Play Terminal Canopy Jettison Lever Bowden Cable Lock Nut ...

Page 1756: ...e lead plumbing on the canopy jettison lever is not broken Refer to Figure 8 2 Make sure that the bowden cables protrude 7 mm 2 mm from the plug on each side Refer to Figures 7 and 10 3 Make sure that torque seal on the bowden cable at the plug is not broken 4 Check clearance between canopy hooks and Roeger type hooks 1 0 0 5 0 mm 0 04 0 02 0 in Refer to Figure 11 ...

Page 1757: ...old the canopy in an almost closed position 2 A third person sitting inside the airplane releases the canopy jettison system S The release force on the lever must not exceed 160 N S If the force exceeds 160 N contact Diamond Aircraft Industries Use spring scale 3 Remove the canopy 4 Report test result to the manufacturer Diamond Aircraft Industries GmbH Office of Airworthiness N A Otto Str 5 A 270...

Page 1758: ...NAP AND CAUSE SERIOUS INJURIES 1 Perform a release test 2 Remove the canopy Refer to Section 52 10 3 Remove the spring element from the canopy 4 Remove the instrument panel cover Refer to Section 25 10 5 Remove the canopy jettison lever assy from the instrument panel Refer to Figure 8 6 Remove the bowden cable from the canopy jettison lever assy 7 Remove the canopy jettison mechanism LH and RH fro...

Page 1759: ...lide the conduit connector the spring and the contraction ring onto the bowden cable Refer to Figure 9 4 Insert the locking pin into the spring element LH RH S Pull at the end of the bowden cable S Make sure that the bowden cable protrudes 7 mm 2 mm 0 28 in 0 08 in from the plug Apply molykote on locking pin Refer to Figure 10 5 Screw the jettison retainer on the bowden cable conduit connector LH ...

Page 1760: ...on nut until following conditions apply S There is no pretension on the bowden cables S The cables do not touch the bracket S The bowden cables can be pushed down approximately 2 diameters of the cable with a small screwdriver 11 Make sure that the bowden cables protrude 7 mm 2 mm 0 28 in 0 08 in from the plug 12 Fix the positions of the bowden cables with the worm screws Secure with Loctite 243 1...

Page 1761: ...ms References Doc 7 02 15 Rev 4 52 10 00 Page 235 15 Mar 2018 17 Make sure that the bowden cables protrude 7 mm 2 mm 0 28 in 0 08 in from the plug 18 Apply torque seal on the bowden cable at the plugs Use Loctite 243 19 Install the canopy Refer to Section 52 10 ...

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Page 1763: ...installed If MÄM 42 600 is installed each door is mounted with two gooseneck hinges supported by a gas spring mounted to the forward gooseneck hinge and the NLG bulkhead A door warning caption is displayed on the integrated cockpit system display when a door is not locked 3 Operation A door locking latch on each lower corner of the door operates two locking bolts A spring loading mechanism holds t...

Page 1764: ... 15 Rev 4 LH Shown RH Similar A B B A A A Door Hinge Assembly Door Seal Locking Door Latch Counter Bearing Gas Strut A Door Latch C B C C Microswitch Screw Door Striker Plate Screw Rivet Screw Washer Screw Washer Door Figure 1 Front Baggage Compartment Access Doors ...

Page 1765: ...rgo Door Assy Door Seal Hinge Arm Assy Hinge Arm with Linkage Assy Gas Spring Assy Gas Spring Mounting Bracket Screw Bushing Bolt Washer Washer Nut Nut Washer Washer Screw Bonded to Fuselage Bonded to Cargo Door Washer Nut Figure 2 Front Baggage Compartment Access Doors if MÄM 42 600 is installed ...

Page 1766: ...AIRCRAFT Doors DA 42 NG AMM Page 4 15 Mar 2018 52 30 00 Doc 7 02 15 Rev 4 Intentionally left blank ...

Page 1767: ... Trouble column read across to the Possible Cause column Then do the repair in the Repair column Trouble Possible Cause Repair Access door is difficult to move Door damaged Door hinges damaged Gas springs defective Replace the door Replace the damaged parts Replace the hinge assembly Door handle is difficult to move Locking bolts damaged Door locking mechanism defective Replace the damaged bolt Re...

Page 1768: ...AIRCRAFT Doors DA 42 NG AMM Page 102 15 Mar 2018 52 30 00 Doc 7 02 15 Rev 4 Intentionally left blank ...

Page 1769: ...mpartment Door Detail Steps Work Items Key Items References 1 Open the front baggage compartment door that you will remove 2 Remove the door from the hinges if MÄM 42 600 is NOT installed S Remove the 4 nuts and washers that attach each door hinge to the door S Move the door clear of the airplane Support the door 3 Remove the gas spring if MÄM 42 600 is installed 4 Remove the door from the hinges ...

Page 1770: ...h the attachment brackets on the fuselage nose S Install the bolt nut and washer 3 Install the gas spring if MÄM 42 600 is installed 4 Close the door and lock the door 5 Do a test for the correct operation of the door warning caption S Make sure that the canopy passenger door and both forward baggage compartment doors are closed S Set the ELECT MASTER switch to ON S Move the operating handle of th...

Page 1771: ...have the usual screws The two access panels for the TKS system in the horizontal stabilizer if installed are installed with a sealant Refer to Section 71 20 for data about the engine cowlings 2 Description Figure 1 shows the location of the access panels on the airplane Most panels are CFRP GFRP moldings Screws hold the panels in position There are no special procedures for removing the access pan...

Page 1772: ...rank Flap Bellcrank Flap Bellcrank B Bolt B Bolt Flap Aileron Push Rods Flap Aileron Push Rods Stabilizer Fairing VIEW FROM BELOW Flux Valve Fuel Cooler Fuel Cooler Maintenance Cap 2 RH Nacelle Cap Rear RH Maintenance Cap 1 RH Nacelle Cap ECU RH Fuel Filter Cap RH Nacelle Cap Rear LH Maintenance Cap 1 LH Nacelle Cap ECU LH Fuel Filter Cap LH Maintenance Cap 2 LH Lightning TKS Optional Lightning TK...

Page 1773: ...AIRCRAFT DA 42 NG AMM Fuselage Doc 7 02 15 Rev 4 53 TITLE Page 1 15 Mar 2018 CHAPTER 53 FUSELAGE ...

Page 1774: ...AIRCRAFT Fuselage DA 42 NG AMM Page 2 15 Mar 2018 53 TITLE Doc 7 02 15 Rev 4 Intentionally left blank ...

Page 1775: ...1 General 1 2 Description 3 3 Composite Debris Protection OÄM 42 090 12 4 Adhesive Foil Debris Protection OÄM 42 088 42 089 13 Maintenance Practices 1 General 201 2 Remove Install the Composite Debris Protection OÄM 42 090 201 3 Remove Install the Trim Weight 202 4 Remove Install the Trim Weight if MÄM 42 600 is installed Serial numbers 42 N100 and subsequent 204 ...

Page 1776: ...AIRCRAFT Fuselage DA 42 NG AMM Page 2 15 Mar 2018 53 CONTENTS Doc 7 02 15 Rev 4 Intentionally left blank ...

Page 1777: ... more strength and stiffness where it is needed Rigid foam inserts give stiffness where necessary The frames and webs also have many layers of glass cloth Some areas have layers of carbon fiber cloth or tape to give extra strength Some components also have rigid inserts of GFRP for attaching brackets or other components In order to protect the fuselage from damages caused by ice accumulation which...

Page 1778: ... 4 Roll Over Molding Aft Baggage Compartment Frame Ring Frame 1 Ring Frame 3 Ring Frame 2 Nosewheel Compartment Nose Landing Gear Rib Upper Lower Floor Panel Wing Center Section RH Shell LH Shell LH Engine Nacelle RH Engine Nacelle Figure 1 Fuselage Structure Main Components ...

Page 1779: ...serts give strength and stiffness for attaching other components such as brackets for controls Bonding paste thickened resin bonds components to other components Most of the components in the fuselage are also bond to the fuselage shell To trim the airplane s CG it is possible to install a trim weight in the lower vertical tail It can be varied in 3 0 kg 6 6 lb steps up to 15 kg 33 lb by installin...

Page 1780: ...IRCRAFT Fuselage DA 42 NG AMM Page 2 15 Mar 2018 53 10 00 Doc 7 02 15 Rev 4 Nose Gear Frame Top Nose Gear Frame Nose Gear Leg Compartment Radar Frame Floor Panel Figure 2 Fuselage Structure Nose Section ...

Page 1781: ...d outlet ducts Conduits for electrical wires antenna cables and fuel pipes Mountings for airplane system components B Nose Section The nose section bonds to the front of the fuselage The nose section has a left shell and it has a right shell The shells are made from CFRP with rigid foam inserts Each shell has a hinged door to give access to the nose baggage compartment Refer to Section 52 30 for m...

Page 1782: ... Outer Root Rib Main Landing Gear Rib Control Bellcrank Mounting Bracket Floor Panel Engine Nacelle Engine Firewall Front Inner root Ribs Rear Inner Root Rib RH Rear Inner Root Rib LH Rear Outer Root Rib Flap Rib Rear Inner Rib Middle Root Rib RH Middle Root Rib LH Figure 3 Fuselage Structure Wing Center Section ...

Page 1783: ... moldings which make the inner face of the wing center section Middle and rear closing ribs bond to the box spars at the outer end of the center section to the rear of the outer end of the engine nacelles These ribs close the end of the wing center section The rear inner ribs and flap ribs bond to the aft face of the rear box spar The flap rib has the mountings for the inner flap relay lever and t...

Page 1784: ...AIRCRAFT Fuselage DA 42 NG AMM Page 6 15 Mar 2018 53 10 00 Doc 7 02 15 Rev 4 Roll Over Molding Aft Baggage Compartment Frame Ring Frame 1 Ring Frame 3 Ring Frame 2 Figure 4 Rear Fuselage Structure ...

Page 1785: ...er part of the frame has holes for the rudder cables and trim control It also has a control rod guide for the elevator control rod G Ring Frame 1 The ring frame 1 is a rigid GFRP molding It bonds to the fuselage shells just aft of the baggage compartment frame It has holes for the rudder control cables and trim control It also has a control rod guide for the elevator control rod H Ring Frame 2 The...

Page 1786: ...Mar 2018 53 10 00 Doc 7 02 15 Rev 4 Vertical Stabilizer Front Web Vertical Stabilizer Front Lower Rib Vertical Stabilizer Rear Lower Rib Vertical Stabilizer Rear Web Reinforcing Rib Ring Frame 3 Figure 5 Fuselage Structure Vertical Stabilizer ...

Page 1787: ...to the area where the horizontal stabilizer mounts attach M Vertical Stabilizer Rear Web The vertical stabilizer rear web is a rigid GFRP molding It bonds to the fuselage shell and it bonds to the vertical stabilizer front web The top of the rear web has the top mounting for the rudder It also has a reinforcing rib bonded to the rear face The vertical stabilizer rear web closes the rear of the ver...

Page 1788: ...AIRCRAFT Fuselage DA 42 NG AMM Page 10 15 Mar 2018 53 10 00 Doc 7 02 15 Rev 4 Figure 6 Trim Weight ...

Page 1789: ...15 Rev 4 53 10 00 Page 11 15 Mar 2018 Self Locking Nut Washer Steel Plates max 10 pieces Bolt Bolt Self Locking Nut Washer Steel Plates total max 12 pieces Figure 7 Trim Weight if MÄM 42 600 is installed Serial numbers 42 N100 and subsequent ...

Page 1790: ...tion certified with OÄM 42 090 Refer to Paragraph 4 for information concerning the foil based debris protection certified with OÄM 42 088 and 42 089 The composite debris protections are installed on both sides of the forward fuselage with a silicone based adhesive Refer to Figure 8 Figure 8 Composite Debris Protection OÄM 42 090 RH 160 6 3 in LH 140 5 5 in Flat View RH 290 11 4 in Flat View LH 80 ...

Page 1791: ...n OÄM 42 088 42 089 A Single Layer Debris Protection OÄM 42 089 Figure 9 shows the single layer debris protection material 3M certified with OÄM 42 089 for installation on the DA 42 NG Figure 9 Single Layer Debris Protection OÄM 42 089 RH 160 6 3 in LH 140 5 5 in Flat View RH 290 11 4 in Flat View LH 80 3 1 in ...

Page 1792: ...ction OÄM 42 088 Figure 10 shows the triple layer debris protection material PM certified with OÄM 42 088 for installation on the DA 42 NG Figure 10 Triple Layer Debris Protection OÄM 42 088 RH 160 6 3 in LH 140 5 5 in Flat View RH 290 11 4 in Flat View LH 80 3 1 in 20 0 8 in 40 1 6 in 20 0 8 in 40 1 6 in ...

Page 1793: ...ÄM 42 090 is installed refer to Paragraph 2 for more information If the adhesive foil debris protection OÄM 42 088 OÄM 42 089 is installed refer to Paragraph 3 for more information 2 Remove Install the Composite Debris Protection OÄM 42 090 A Remove the Composite Debris Protection OÄM 42 090 Detail Steps Work Items Key Items References 1 Carefully cut around the debris protection by use of a sharp...

Page 1794: ...rotection using Terostat MS 9380 white adhesive 4 Seal cleave around the composite debris protection with Terostat MS 9380 white 3 Remove Install the Trim Weight A Remove the Trim Weight Detail Steps Work Items Key Items References 1 Remove the rudder Refer to Section 55 40 2 Remove the trim weight assembly S Loosen the outer eleven screws which attach the trim weight assembly to the lower vertica...

Page 1795: ... the seven bolts with adequate length from the attachment plate side in the vertical lead weight s put the washers on the bolts and tighten the trim weight assembly Use 8 mm box wrenches Use new self locking nuts 3 Carefully place the trim weight assembly in the lower vertical tail 4 Tighten all eleven outer screws Use an Allen wrench size 3 5 Install the rudder Refer Section 55 40 6 Verify comple...

Page 1796: ...ghts to the lower vertical tail Hold the trim weights in place 3 Pull the trim weights carefully out of the lower vertical tail B Install the Trim Weight Detail Steps Work Items Key Items References 1 Check the trim weights structure lower vertical tail for S Cracks S Other damages 2 Carefully place the trim weights in the lower vertical tail 3 Put the two bolts with adequate length in the steel w...

Page 1797: ...AIRCRAFT DA 42 NG AMM Stabilizers Doc 7 02 15 Rev 3 55 TITLE Page 1 15 Mar 2018 CHAPTER 55 STABILIZERS ...

Page 1798: ...AIRCRAFT Stabilizers DA 42 NG AMM Page 2 15 Mar 2018 55 TITLE Doc 7 02 15 Rev 4 Intentionally left blank ...

Page 1799: ...ion 55 10 Horizontal Stabilizer 1 General 1 2 Description 1 Maintenance Practices 1 General 201 2 Remove Install the Horizontal Stabilizer 201 Section 55 20 Elevator 1 General 1 2 Description 3 Maintenance Practices 1 General 201 2 Remove Install the Elevator 201 3 Remove Install the Elevator Trim Tab 205 Section 55 30 Lower Fin 1 General 1 ...

Page 1800: ...AMM Page 2 15 Mar 2018 55 CONTENTS Doc 7 02 15 Rev 4 Section 55 40 Rudder and Trim Tab 1 General 1 2 Description 1 Maintenance Practices 1 General 201 2 Remove Install the Rudder Assembly 201 3 Remove Install the Rudder Trim Tab 206 ...

Page 1801: ...s give strength to the center area Two trailing edge webs hold the hinges for the elevator The elevator has top and bottom shells Each shell has GFRP skins with a rigid foam core The bottom shell also makes the leading edge spar The hinges attach to the bottom shell A large horn with the mass balance weight attaches to the bottom shell at the center The trailing edge carries a trim tab The lower f...

Page 1802: ... DA 42 NG AMM Page 2 15 Mar 2018 55 00 00 Doc 7 02 15 Rev 4 Horizontal Stabilizer Horizontal Stabilizer Tip RH Horizontal Stabilizer Tip LH Elevator Trim Tab Lower Fin Tail Skid Rudder Rudder Trim Tab Figure 1 Stabilizers ...

Page 1803: ... to the attachment bolts from below The mounting brackets go down through the cut outs in the bottom shell Four more holes in the bottom part of each mounting bracket attach to the vertical stabilizer front web Three pairs of ribs give strength to the center area on each side of the access holes All are rigid GFRP moldings They bond to the other components with resin The rear box ribs make a box r...

Page 1804: ...00 Doc 7 02 15 Rev 4 Front Mounting Bracket Rear Mounting Bracket Horizontal Stabilizer Tip LH Horizontal Stabilizer Tip RH Front Spar Front Ribs Center Ribs Rear Box Ribs Rear Spar Rear Rib Rear Rib 12 Trailing Edge Web Figure 1 Horizontal Stabilizer Structure ...

Page 1805: ...o the structure Hold the fairing 2 Release the 2 fork end fittings from the trim tab cranked actuating levers Remove the cotter pins from the nuts S Remove the nuts washers and bolts that attach the fork ends to the cranked actuating levers Under the elevator 3 Release the trim tab mechanism from its mounting bracket Refer to Section 27 38 4 Release the lightning protection strip and wire bonding ...

Page 1806: ...age 202 15 Mar 2018 55 10 00 Doc 7 02 15 Rev 4 1 2 Bush Spacer Large Washer Elevator Push Rod Elevator Horn 1 2 Vertical Stabilizer Front Web Horizontal Stabilizer Rear Spar Rear Mounting Plate Figure 2 Horizontal Stabilizer Installation ...

Page 1807: ...elevator vertical push rod to the elevator horn S Remove and retain the large washer bush and spacer from the push rod to elevator horn assembly Refer to Section 55 20 Figure 2 Refer to Figure 2 Note the location of the large washer bush and spacer 7 Remove the 8 lower bolts which attach the horizontal stabilizer and lightning protection strip to the front and rear mounting brackets Hold the horiz...

Page 1808: ... protection strip to the front and rear mounting brackets Use new self locking nuts Torque 45 Nm 33 2 lbf ft 5 Connect the elevator control push rod to the elevator horn S Install the large washer bush and spacer into the push rod to elevator horn assembly S Install the bolt washer and nut that attaches the elevator control push rod to the elevator horn S Tighten the 2 bolts holding the elevator m...

Page 1809: ...ing levers S Install the 2 bolts washers and nuts that attach the fork end fittings to the trim tab actuating levers S Secure the nuts to the bolts with cotter pins Under the elevator 10 Do a test for correct full and free movement of the elevator control If necessary adjust the elevator control Refer to Section 27 30 11 Do a test for correct full and free movement of the trim control If necessary...

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Page 1811: ...Doc 7 02 15 Rev 4 55 20 00 Page 1 15 Mar 2018 Section 55 20 Elevator 1 General The DA 42 NG has the usual elevator The elevator attaches to the rear web of the horizontal stabilizer See Section 27 30 for data about the elevator controls ...

Page 1812: ...AIRCRAFT Stabilizers DA 42 NG AMM Page 2 15 Mar 2018 55 20 00 Doc 7 02 15 Rev 4 Figure 1 Elevator Structure ...

Page 1813: ...nt of the elevator tips Five bearings hold the elevator The elevator horn has a plain bearing A bolt and spacer attach the elevator horn to the trailing edge webs of the horizontal stabilizer A small bearing rib at mid span on each side holds an elevator hinge assembly The hinge assembly has an eye end with a plain shank The eye end has a spherical bearing The shank engages in a bush in the traili...

Page 1814: ... 2018 55 20 00 Doc 7 02 15 Rev 4 Pivot Pin Trailing Edge Web Trailing Edge Web Elevator Rear Rib Removable Tip Bonded Bush Bonded Bush Elevator Horn Elevator Horn Rib Cotter Pin Mass Balance Lever Figure 2 Horizontal Stabilizer Elevator Installation ...

Page 1815: ...the 4 screws that attach the fairing to the structure Refer to Figure 2 2 Remove the horizontal stabilizer tips S Remove the 8 screws that attach the tip to the stabilizer Hold the tips 3 Release the 2 fork end fittings from the trim tab cranked actuating levers Under the elevator 4 Remove 2 bolts nuts and washers which attach the elevator horn rib to the elevator Refer to Figure 2 5 Remove the pi...

Page 1816: ...m Tab Hinge 6x Trim Tab Hinge Trim Tab Hinge Rod Hinge Rod Elevator Trim Tab Attaching Bolt Trim Tab Horn Cranked Actuating Lever RH Cranked Actuating Lever LH Bowden Cable Trim Damper Lightning Protection Strip Lightning Protection Rubber Gaiter Bonding Cable Fork end Fitting Fork end Fitting Figure 3 Trim Tab Installation ...

Page 1817: ...ntal stabilizer Refer to Figure 2 2 Install the pivot pins in the end bearings and lock the pivot pins in position with a roll pin 3 Install the bolts washers and nuts which attach the elevator to the elevator horn Torque 6 4 Nm 4 7 lbf ft Use new self locking nuts 4 Install the 2 fork end fittings for the trim tab cranked actuating levers Under the elevator 5 Install the horizontal stabilizer tip...

Page 1818: ...lizers DA 42 NG AMM Detail Steps Work Items Key Items References Page 204 15 Mar 2018 55 20 00 Doc 7 02 15 Rev 4 9 If necessary for your Airworthiness Authority do a duplicate inspection of the elevator trim control ...

Page 1819: ...e the trim tab from the elevator B Install the Elevator Trim Tab Detail Steps Work Items Key Items References 1 Put the trim tab in position on the elevator Refer to Figure 3 2 Align the hinges 3 Install the hinge rods in each side CAUTION DO NOT USE FORCE TO INSTALL THE LOCK WIRE IN THE TRIM TAB HINGE YOU CAN DAMAGE THE GFRP HINGE 4 Lock the hinge rods in position with wire Use new lock wire 5 Al...

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Page 1821: ... 15 Mar 2018 Section 55 30 Lower Fin 1 General The DA 42 NG has a lower fin The lower fin is a GFRP molding that is bonded to the bottom of the rear fuselage A tail skid is attached to the bottom of the lower fin Refer to Section 32 70 for more data about the tail skid ...

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Page 1823: ...eading edge of each shell has a curve and a flange The shells bond together at the flanges The shells also bond together at the top bottom and at the trailing edge The left shell has a molded fairing for the ruder trim control rods The rudder has a flat face at the bottom of the leading edge The flat face has two bonded bolts The bolts attach the rudder to the rudder lower mounting bracket Refer t...

Page 1824: ...AIRCRAFT Stabilizers DA 42 NG AMM Page 2 15 Mar 2018 55 40 00 Doc 7 02 15 Rev 4 Left Shell Right Shell Bottom Mounting Bolt Top Pivot Pin Insert Mass Balance Figure 1 Rudder Assembly ...

Page 1825: ...m insert strengthens the trim tab at the leading edge The leading edge of each shell has a curve and a flange The leading edge flange has a vertical tube for the trim tab hinge wire The shells bond together at the flanges The shells also bond together at the top bottom and at the trailing edge A GFRP control horn is bonded to the left side of the trim tab Two GFRP shells bonded together make the c...

Page 1826: ...AIRCRAFT Stabilizers DA 42 NG AMM Page 4 15 Mar 2018 55 40 00 Doc 7 02 15 Rev 4 Left Shell Right Shell Figure 2 Rudder Trim Tab ...

Page 1827: ...Remove the 2 nuts washers and bolts that attach the control rods to the trim operating lever S Move the rods clear of the operating lever Refer to Figure 3 Refer to Figure 4 if MÄM 42 600 is installed At the rudder bottom bracket 2 Remove 2 nuts and washers which attach the rudder to the rudder lower mounting bracket Hold the rudder 3 Pull the bottom of the rudder aft to disengage the bottom bolts...

Page 1828: ... levers 4 If MÄM 42 600 is installed and the rudder sealing tape and the sliding tape are worn S Remove the rudder sealing tape and the sliding tape from the fin and the rudder surface S Use solvent to clean the surfaces S Install the self adhesive sliding tape to the rudder surface S Install the self adhesive sealing tape to the rudder fin surface The not adhesive half of the sealing tape must pr...

Page 1829: ...G AMM Stabilizers Doc 7 02 15 Rev 4 55 40 00 Page 203 15 Mar 2018 Bottom Mounting Bolts Top Pivot Pin Rudder Bottom Bracket Rudder Stop Bolt Nut Washer Vertical Stabilizer Rear Web Figure 3 Rudder Assembly Installation ...

Page 1830: ... Page 204 15 Mar 2018 55 40 00 Doc 7 02 15 Rev 4 Top Pivot Pin Rudder Pedestal Nut Washer Vertical Stabilizer Rear Web Rudder Assy Rudder Stop Bolt Bottom Mounting Bolts Figure 4 Rudder Assembly Installation if MÄM 42 600 is installed ...

Page 1831: ... Stabilizers Doc 7 02 15 Rev 4 55 40 00 Page 205 15 Mar 2018 Connecting Rod Eye End Trim Tab Coupling Friction Damper Friction Damper Mounting Bracket Rudder Pedestal Trim Control Horn Figure 5 Rudder Trim Tab Installation ...

Page 1832: ...the 2 control rods for the rudder trim tab S Remove the 2 nuts washers and bolts that attach the trim control rods to the trim control horn S Move the rods clear of the operating lever Refer to Figure 5 At the trim tab control horn 2 Remove the trim tab S Remove the locking wire that secures the hinge pin S Remove the hinge pin from the trim tab S Move the trim tab clear of the airplane Hold the t...

Page 1833: ...der S Install the hinge pin S Secure the hinge pin with lock wire Use new lock wire 2 Connect the control rods for the trim tab S Align the eye ends of the control rods with the trim tab control horn S Install the bolt spacer washers and nut that attaches the control rods to the control horn 3 Do a test for the correct range of movement of the rudder trim tab control system 4 If necessary for your...

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Page 1835: ...AIRCRAFT DA 42 NG AMM Windows Doc 7 02 15 Rev 4 56 TITLE Page 1 15 Mar 2018 CHAPTER 56 WINDOWS ...

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Page 1837: ...v 4 56 CONTENTS Page 1 15 Mar 2018 TABLE OF CONTENTS CHAPTER 56 WINDOWS 1 General 1 Section 56 10 Flight Compartment Windows 1 General 1 2 Description and Operation 3 Maintenance Practices 1 General 201 2 Replace a Window 201 3 Window Repairs 206 ...

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Page 1839: ...xiglass The one piece canopy window covers the pilots cockpit It is also the windscreen The passenger door has a window The right side of the fuselage has a window for the passenger compartment A high performance elastic adhesive bonds each window to the structure Section 56 10 gives the data for all of the windows Refer to Section 52 10 for data about the canopy and door structure ...

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Page 1841: ... 15 Rev 4 56 10 00 Page 1 15 Mar 2018 Section 56 10 Flight Compartment Windows 1 General This Section tells you about the windows in the canopy passenger door and fuselage Refer to Section 52 10 for data about the canopy and door structure ...

Page 1842: ...M Page 2 15 Mar 2018 56 10 00 Doc 7 02 15 Rev 4 Canopy Window Direct Vision Panel Direct Vision Panel Fuselage Window Passenger Door Window Painted Areas Painted Edge Painted Edge Canopy Frame Passenger Door Frame Figure 1 Windows ...

Page 1843: ...one piece canopy window covers the pilots cockpit It is also the windscreen It has a small direct vision panel in each side The direct vision panels have hinges You can open the direct vision panels in flight The passenger door has a window for the left side of the passenger compartment The right side of the fuselage also has a window for the passenger compartment Each window has a band of white p...

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Page 1845: ...s Note Do not use cleaning agents containing alcohol on windows and canopy bubbles 1 Remove the canopy or door Put the canopy or door on a firm working surface If the canopy or door window must be replaced Refer to Section 52 10 2 Put protective covers on the inside of the cockpit If the right fuselage window must be replaced 3 Cut the damaged window from the frame Use the rocker saw with non rota...

Page 1846: ... 10 minutes 10 Apply the sealant and follow the suggested shape and positioning around the entire canopy frame fuselage Refer to Figure 2 Make sure to apply a constant amount of sealant Note It is very important that the Plexiglas is positioned within ten minutes after the sealant has been applied 11 Position the window canopy bubble in place on the canopy frame fuselage by use of the 2 pins 12 Pu...

Page 1847: ...Figure 3 19 Use sealant to fill the joint and the pinholes and smoothen the surface Use plastic spattle 20 Spray the joint with a water cleaning solvent solution and smooth the surface by hand 21 Remove all adhesive and masking tapes 22 Allow the sealant to cure Minimum 24 hrs 23 Install the canopy or door Only if you have replaced the canopy or door window Refer to Section 52 10 ...

Page 1848: ...0 Doc 7 02 15 Rev 4 4mm 0 16 in 10mm 0 39 in 28mm 1 1 in Max 5mm 0 2 in Damtape 6mm high 0 24 in Tesafilm Red Masking Tape Sealant Canopy Frame 8mm 0 31 in Visible Edge End of Paint Tesafilm Red Canopy Bubble Figure 2 Position and Form of the Applied Adhesive ...

Page 1849: ...2 15 Rev 4 56 10 00 Page 205 15 Mar 2018 4mm 0 16 in 25mm 0 98 in Damtape Tesafilm Red Masking Tape Joint Canopy Frame Painting of the Canopy Canopy Bubble Masking Tape 3mm 0 12 in A 1mm 0 04 in A Figure 3 Filling After Placing the Glazing ...

Page 1850: ...0 A R Commercial Masking tape A R Commercial Plastic adhesive tape A R Commercial Cold ultra violet light source only for Acryfix 92 A R Commercial Note Fillers become smaller when they cure Apply enough filler to be above the level of the window surface Cut the filler back when it has cured If you repair a vertical crack keep the filler in place with plastic adhesive tape Apply a second coat of f...

Page 1851: ...AIRCRAFT DA 42 NG AMM Windows Doc 7 02 15 Rev 4 56 10 00 Page 207 15 Mar 2018 Figure 4 Window Repairs ...

Page 1852: ...Use Acryfix 92 or Tensol cement no 70 8 Let the filler cure Refer to the manufacturer s data 9 If possible turn the window so that the inner surface is up Remove any plastic adhesive tape 10 Cut a groove along the crack in the inner surface of the window Refer to Figure 4 step 3 Note This groove is less deep than the outer surface groove It must cut into the outer layer of filler This prevents hol...

Page 1853: ...AIRCRAFT DA 42 NG AMM Wings Doc 7 02 15 Rev 4 57 TITLE Page 1 15 Mar 2018 CHAPTER 57 WINGS ...

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Page 1855: ...ure 1 General 1 2 Description 3 Maintenance Practices 1 General 201 2 Remove Install the Wings 201 3 Remove Install the A or B Bolts 211 4 Remove Install Control Surface Hinge Brackets 215 Section 57 50 Flaps 1 General 1 2 Description 3 Maintenance Practices 1 General 201 2 Remove Install a Flap 204 Section 57 60 Ailerons 1 General 1 2 Description 3 ...

Page 1856: ...AIRCRAFT Wings DA 42 NG AMM Page 2 15 Mar 2018 57 CONTENTS Doc 7 02 15 Rev 4 Maintenance Practices 1 General 201 ...

Page 1857: ...er wing and to the trailing edge of the stub wing An aileron attaches to the outboard trailing edge of each outer wing The wings have a semi monocoque structure Each wing has top and bottom shells The shells have CFRP outer skins a rigid foam core and GFRP inner skins Each wing has two I section spars Uni directional carbon fiber cloth makes the spar caps Each wing also has GFRP ribs and webs The ...

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Page 1859: ... Structure 1 General This Section tells you about the structure of the outer wing Refer to Section 53 10 for data about the structure of the wing center section Refer to Section 57 50 for data about the structure of the flaps Refer to Section 57 60 for data about the structure of the ailerons ...

Page 1860: ...Control Rib Rear Web Inner Fuel Chamber Ribs Mid Fuel Chamber Ribs Front Root Rib Middle Root Rib Rear Root Rib Spar Stub Bush Bottom Shell Removable Wing Tip Rear Spar End Rib Top Shell Left Wing Shown Right Wing Opposite 5x Screws 7x Screws Outer Fuel Chamber Ribs Front Spar Figure 1 Wing Structure ...

Page 1861: ...ass fiber Some areas have more layers of cloth to give more strength For example the area around each access hole has extra layers of carbon fiber cloth The bottom shell of each wing has 8 access holes These give access to the flap and aileron bellcranks and fuel tanks The top shell has a hole for the fuel cap of the outer fuel chamber B Spars Each wing has two I section spars The front spar on on...

Page 1862: ...s a flat inner flange to hold the tank The ribs bond to the top and bottom shells the aft face of the front spar and the front face of the rear spar E Flap and Aileron Control Ribs Each wing has two flap and one aileron control ribs The ribs are GFRP moldings Each rib has a bend with a solid insert The insert gives extra strength where the control bellcrank attaches The ribs bond to the top and bo...

Page 1863: ...ance Practices tell you how to remove and install the outer wings They also tell you how to remove and install the wing tips and other small components 2 Remove Install the Wings A Equipment Item Quantity Part Number Padded wing trestles 4 Commercial Main bolt removal tool 1 Wing stand not essential 1 per wing Commercial ...

Page 1864: ...ar 2018 57 10 00 Doc 7 02 15 Rev 4 Locking Tube Short End Piece Long End Piece Rear Main Bolt Front Main Bolt Front Spar Rear Spar Rear Box Spar Bushes Front Box Spar Bushes Spar Bush Spar Bush Locking Bolt Figure 2 Wing Main Bolt Installation ...

Page 1865: ...efer to Section 12 10 4 Put trestles under both wing tips Under the end rib 5 Disconnect the flap push rod S Remove the nut washer and bolt At the wing root Through the engine nacelle access panels 6 Disconnect the aileron pushrod S Remove the nut washer and bolt At the wing root Through the engine nacelle access panels 7 Disconnect the cable for the fuel probes and the fuel sensor At the fuel tan...

Page 1866: ...ve the tube and the long end piece WARNING USE 3 PERSONS TO LIFT THE WING IF YOU DO NOT YOU CAN CAUSE INJURY CAUTION DO NOT LIFT ON THE FLAP YOU CAN DAMAGE THE FLAP Note For the rest of this procedure one person must lift the wing tip One person must lift the leading edge at the root rib One person must lift the trailing edge at the root rib 14 Remove the main bolts S Take the weight off the wing ...

Page 1867: ...2 NG AMM Wings Detail Steps Work Items Key Items References Doc 7 02 15 Rev 4 57 10 00 Page 205 15 Mar 2018 Note If you use trestles put one trestle under the spar stubs Put the second trestle under the wing end rib ...

Page 1868: ...spars and the shells Refer to the manufacturer if you find damage in any of these areas Clean the bushes 2 Examine the front middle and rear end ribs in the wing center section Look specially for S Damage to the A and B bolt bushes S Looseness between the A and B bolt bushes and the end ribs S Delamination between the end ribs the boxspars and the shells Refer to the manufacturer if you find damag...

Page 1869: ...ches on the bearing surfaces S Deformation S Damage to the threads for the removal tool Clean the main bolt assembly Remove corrosion Repair the surface finish Refer to Section 51 20 No corrosion permitted Maximum depth 0 1 mm 0 004 in No deformation permitted Replace the bolt if you cannot attach the removal tool correctly 6 Measure the radial play of each main bolt in the related main bulkhead b...

Page 1870: ...he wing tip One person must lift the leading edge at the root rib One person must lift the trailing edge at the root rib 2 Lift the wing into position S Install inboard fuel tank access panel S Move the spar stubs part way into the front and rear box spars S Put the electrical cable Pitot static and fuel lines through the conduit in the leading edge of the center section S Align the flap inner rib...

Page 1871: ...e is 8 mm 5 16 in diameter purple color 6 Connect the electrical connector Engine nacelle access panels 7 Connect the bonding connections Engine nacelle access panels 8 Connect the fuel hose At the fuel tank 9 Connect the fuel probe and fuel sensor cables At the fuel tank 10 Connect the flap pushrod S Install the bolt washer and self locking nut Engine nacelle access panels Torque 6 4 Nm 4 7 lbf f...

Page 1872: ...on system Refer to Section 27 10 17 Do an inspection of the aileron controls which you have connected or adjusted S If necessary for your Airworthiness Authority do a second inspection of the controls 18 Do a functional check of these lights S Position lights S Strobe lights ACLs Refer to Section 33 40 19 Do a Pitot and static system leak test Left wing only Refer to Section 34 10 20 Refuel the ai...

Page 1873: ...ey Items References 1 Remove the wing Refer to Paragraph 2 2 Remove the A or B bolt S Hold the flats on the flange of the bolt with a wrench S Remove the self locking nut from the A or B bolt S Remove the A or B bolt Refer to Figure 3 Access for the A bolt through the hole in the front root rib Access for the B bolt through the access panel in the bottom shell ...

Page 1874: ...s DA 42 NG AMM Page 212 15 Mar 2018 57 10 00 Doc 7 02 15 Rev 4 A Bolt B Bolt Rear Root Rib Front Root Rib Bonded Bush Bonded Bush Access Hole Access Panel RIGHT SHOWN LEFT OPPOSITE Figure 3 A and B Bolt Installation ...

Page 1875: ...damage permitted 2 Examine the A or B bolt bush Look specially for S Looseness between the A or B bolt bush and the root rib S Damage to the root rib where the bush attaches S Damage to the bush 3 Install the A or B bolt S Install the bolt in the bush S Hold the flats on the flange of the bolt with a wrench S Install the washer and self locking nut Refer to Figure 3 Access for the A bolt through t...

Page 1876: ... Web Flap Bellcrank Access Panel Aileron Bellcrank Access Panel Flap Control Horn Hinge Aileron Control Horn Hinge Anchor Nut Plate Anchor Nut Plate Aileron Outer Hinge Flap Hinge And Aileron Inner Hinge LEFT SHOWN RIGHT OPPOSITE Figure 4 Control Surface Hinge Bracket Installation ...

Page 1877: ... Sections 57 50 and 57 60 2 For brackets at the control horn hinge S Remove the control bell crank access panel under the wing S Remove the attaching nuts and large washers S Remove the bolts and small washers S Remove the bracket The flap brackets have 3 bolts The aileron brackets have 2 bolts From inside of the wing 3 For brackets not at the control horn hinge S Remove the bolts and small washer...

Page 1878: ...all washers S Install the large washers and self locking nuts S Install the control bellcrank access panel under the wing The flap brackets have 3 bolts The aileron brackets have 2 bolts From inside of the wing Torque 3 6 Nm 2 7 lbf ft 2 For brackets not at the control horn hinge S Put the bracket in position on the rear web S Install the bolts and small washers All brackets have 2 bolts Torque 3 ...

Page 1879: ...u about the flap of the DA 42 NG The DA 42 NG has an inner and an outer flap on each wing The outer flap attaches to the outer wing and the inner flap attaches to the airplane wing center section The flap selector in the cockpit controls both inner and outer flaps Refer to Section 27 50 for data about the flap control system ...

Page 1880: ...AIRCRAFT Wings DA 42 NG AMM Page 2 15 Mar 2018 57 50 00 Doc 7 02 15 Rev 4 Hinge Hinge Hinge Hinge Hinge Inner End Rib Flap Horn Flap Outer LH Figure 1 Outer Flap Assembly ...

Page 1881: ...e The outer layer of the skins are GFRP The inner layers are CFRP The top shell bonds to the bottom shell and the inner end rib The flap has an inner end rib The inner end rib is a CFRP molding The rib has an recess which engages with an extension on the inner flap The end rib bonds to the top and bottom shells A flap horn drives the outer flap The flap horn is an aluminum alloy component Three bo...

Page 1882: ...AIRCRAFT Wings DA 42 NG AMM Page 4 15 Mar 2018 57 50 00 Doc 7 02 15 Rev 4 Hinge Hinge Hinge Flap Horn Flap Inner LH Figure 2 Inner Flap Assembly ...

Page 1883: ...e inner end rib The flap has an outer end rib The outer end rib is a CFRP molding The rib has an extension which engages with a recess on the outer flap The end rib bonds to the top and bottom shells A flap horn drives the inner flap The flap horn is an aluminum alloy component Three bolts attach the horn to the bottom surface of the flap A small hole in the leading edge of the flap gives access t...

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Page 1885: ...G AMM Wings Doc 7 02 15 Rev 4 57 50 00 Page 201 15 Mar 2018 Maintenance Practices 1 General These Maintenance Practices tell you how to remove and install the flaps Refer to Section 27 50 for the flap setting procedure ...

Page 1886: ...Doc 7 02 15 Rev 4 Access Hole Flap Horn Flap Structure A A A A A A Hinge Pin Hinge Pin Roll Pin Roll Pin Flap Hinge Flap Outer LH Brackets attached to Wing Bracket attached to Wing LH installation shown RH installation opposite Figure 3 Outer Flap Installation ...

Page 1887: ...tion shown RH installation opposite C B A Hinge Hinge Pin Blanking Plug Bushing Split Pin Screw Nut Hinge Pin Nut Nut Screw Split Pin Screw Washer Nut Nut Washer Screw Nut Cap Screw Screw Hinge Cover Maintenance Cover Washer Screw Washer Bolt Figure 4 Outer Flap Installation if MÄM 42 600 is installed ...

Page 1888: ... to ON S Set the flap selector to LDG S When the flaps stop moving S Set the ELECT MASTER switch to OFF 2 Open the circuit breaker for the flap control Instrument panel Right side 3 Remove the flap hinge cover if MÄM 42 600 is installed S Remove the bolts and washers which attach the flap hinge cover to the flap horn S Remove the flap hinge cover including the bushings 4 Disconnect the flap push r...

Page 1889: ... 4 57 50 00 Page 205 15 Mar 2018 5 Remove the 6 hinge pins from the flap hinges and the flap horn S Remove the roll pins which locate the flap hinge pins S Move the hinge pins inboard and clear of the hinges Support the flap assembly 6 Carefully move the flap aft and clear of the airplane ...

Page 1890: ...2018 57 50 00 Doc 7 02 15 Rev 4 Flap Inner LH A Hinge Pin Roll Pin Flap Hinge Bracket attached to Wing A A B B A Flap Horn Hinge Pin Roll Pin Bracket attached to Wing LH installation shown RH installation opposite Figure 5 Inner Flap Installation ...

Page 1891: ...n shown RH installation opposite B A Hinge Hinge Pin Bushing Split Pin Screw Nut Hinge Pin Screw Split Pin Nut Washer Screw Nut Screw Bonding Wire Bonding Wire Nut Hinge Cover Maintenance Cover Washer Screw Bushing Washer Screw Washer Screw Figure 6 Inner Flap Installation if MÄM 42 600 is installed ...

Page 1892: ... selector to LDG S When the flaps stop moving S Set the ELECT MASTER switch to OFF 2 Open the circuit breaker for the flap control Instrument panel Right side 3 Remove the flap hinge cover if MÄM 42 600 is installed S Remove the bolts and washers which attach the flap hinge cover to the flap horn S Remove the flap hinge cover including the bushings Refer to Figure 6 4 Disconnect the flap push rod ...

Page 1893: ... 4 57 50 00 Page 209 15 Mar 2018 5 Remove the 4 hinge pins from the flap hinges and the flap horn S Remove the roll pins which locate the flap hinge pins S Move the hinge pins inboard and clear of the hinges Support the flap assembly 6 Carefully move the flap aft and clear of the airplane ...

Page 1894: ... 002 0 010 in between the faces of the hinge at the horn and a gap of 1 3 mm 0 004 0 012 in between the faces at the other hinges 4 Install the bolt which attaches the flap push rod to the flap horn S Install a washer on the bolt S Push the bolt through the horn and the push rod S Install the washer and the nut on the bolt 5 Do a test for correct adjustment of the flaps Refer to Section 27 50 6 In...

Page 1895: ... 002 0 010 in between the faces of the hinge at the horn and a gap of 1 3 mm 0 004 0 012 in between the faces at the other hinges 4 Install the bolt which attaches the flap push rod to the flap horn S Install a washer on the bolt S Push the bolt through the horn and the push rod S Install the washer and the nut on the bolt 5 Do a test for correct adjustment of the flaps Refer to Section 27 50 6 In...

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Page 1897: ...AFT DA 42 NG AMM Wings Doc 7 02 15 Rev 4 57 60 00 Page 1 15 Mar 2018 Section 57 60 Ailerons 1 General This Section tells you about the aileron Refer to Section 27 10 for data about the aileron control system ...

Page 1898: ...AIRCRAFT Wings DA 42 NG AMM Page 2 15 Mar 2018 57 60 00 Doc 7 02 15 Rev 4 LH aileron shown RH aileron opposite Aileron Aileron Horn Hinge Hinge Mass Balance Trim Tab Figure 1 Aileron Assembly ...

Page 1899: ... area where the horn attaches have more carbon fiber cloth to give more strength and stiffness The top shell has inner and outer CFRP skins The outer and inner layers of the skins are GFRP The skins bond to a rigid plastic foam core The aileron horn is an aluminum alloy component Three bolts attach the horn to the bottom surface of the aileron A small hole in the leading edge of the aileron gives ...

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Page 1901: ...ings Doc 7 02 15 Rev 4 57 60 00 Page 201 15 Mar 2018 Maintenance Practices 1 General These Maintenance Practices tell you how to remove and install the ailerons Refer to Section 27 10 for the aileron control setting procedure ...

Page 1902: ...ar 2018 57 60 00 Doc 7 02 15 Rev 4 LH installation shown RH installation opposite Aileron A Hinge Pin Hinge Pin Roll Pin Roll Pin Aileron Hinge Aileron Horn Bracket attached to Wing A A A Brackets attached to Wing Figure 2 Aileron Installation ...

Page 1903: ...on shown RH installation opposite A A B B A Hinge Hinge Pin Blanking Plug Bushing Split Pin Screw Nut Hinge Pin Nut Nut Screw Split Pin Screw Washer Nut Cap Screw Hinge Cover Maintenance Cover Washer Screw A Bushing Screw Washer Bolt Figure 3 Aileron Installation if MÄM 42 600 is installed ...

Page 1904: ...on hinge cover including the bushes 2 Disconnect the aileron push rod from the aileron horn S Remove the nut and washer from the bolt which attaches the push rod to the horn S Remove the attachment bolt and washer from the horn Hold the aileron 3 Remove the 4 hinge pins from the aileron hinges and the aileron horn S Remove the roll pins which locate the aileron hinge pins S Move the hinge pins inb...

Page 1905: ...0 in between the faces of the hinge at the horn and a gap of 1 3 mm 0 004 0 012 in between the faces at the other hinges 4 Install the bolt which attaches the aileron push rod to the aileron horn S Install a washer on the bolt S Push the bolt through the horn and the push rod S Install the washer and the nut on the bolt 5 Do a test for correct adjustment of the aileron Refer to Section 27 60 6 Ins...

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Page 1907: ...AIRCRAFT DA 42 NG AMM Propeller Doc 7 02 15 Rev 4 61 TITLE Page 1 15 Mar 2018 CHAPTER 61 PROPELLER ...

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Page 1909: ...s 1 General 201 2 Remove Install the MTV 6 R C F Propeller 201 3 Propeller Blade Tracking Test 207 4 Check Adjust the V Belt Tension of the Additional Alternator if OÄM 42 204 is installed 208 5 Remove Install the Additional Alternator V Belt if OÄM 42 204 is installed 210 6 Remove Install the Additional Alternator Pulley if OÄM 42 204 is installed 216 Section 61 20 Propeller Control 1 General 1 2...

Page 1910: ... AMM Page 2 15 Mar 2018 61 CONTENTS Doc 7 02 15 Rev 4 Maintenance Practices 1 General 201 2 Remove Install the Propeller Governor 201 3 Remove Install the Propeller Un Feathering Accumulator 205 4 Propeller Un Feathering Test 208 ...

Page 1911: ...e propeller refer to the propeller manufacturer s manuals Note Equipment which is certified for installation in the DA 42 NG is listed in Section 6 5 of the Airplane Flight Manual Such equipment may be installed in accordance with the Airplane Maintenance Manual Any equipment which is not listed in Section 6 5 of the Airplane Flight Manual is called Additional Equipment The installation of Additio...

Page 1912: ...AIRCRAFT Propeller DA 42 NG AMM Page 2 15 Mar 2018 61 00 00 Doc 7 02 15 Rev 4 Spinner Propeller Figure 1 Propeller Assembly ...

Page 1913: ... out an additional alternator gearbox fan with an additional alternator pulley is installed on the gearbox flange of the LH engine using a prop flange pulley support The six propeller attachment nuts mount the gearbox fan assy and the propeller to the gearbox flange Figure 2 A spinner bulkhead spinner backplate attaches to the rear of the hub with six bolts The bolts are locked with wire A front s...

Page 1914: ...0 Doc 7 02 15 Rev 4 Attaching Nut and Washer Spinner Attaching Screws Engine Flange Front Support Plate Spinner Bulkhead Spinner Dome Low Pitch Stop Hub Blade Ferrule Metal Erosion Sheath PU Tape Wood Composite Blade Balance Weights Figure 1 Propeller Assembly ...

Page 1915: ...AIRCRAFT DA 42 NG AMM Propeller Doc 7 02 15 Rev 4 61 10 00 Page 3 15 Mar 2018 Figure 2 Propeller Assembly if OÄM 42 204 is carried out ...

Page 1916: ...ts the oil to the propeller as necessary to control the propeller pitch Hydraulic pressure in the cylinder acts on a piston and the piston moves the propeller blades towards low pitch The propeller pitch control system is integrated into the engine EECS system The pitch is controlled automatically by the EECU Depending on the power setting the propeller pitch is adjusted so that the required RPM w...

Page 1917: ...AIRCRAFT DA 42 NG AMM Propeller Doc 7 02 15 Rev 4 61 10 00 Page 5 15 Mar 2018 Figure 3 Propeller RPM Adjusted by the Engine ECU System ...

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Page 1919: ...balance Propeller mounting loose Spinner attaching screws loose Blade tracking not correct Examine the propeller If you find damage refer to the manufacturer s Owners Manual Replace the spinner Tighten the mounting nuts to the correct torque Refer to the manufacturer s Owners Manual Use new nuts Tighten the attaching screws Refer to the manufacturer s Owners Manual Refer to the manufacturer s Owne...

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Page 1921: ...THE PROPELLER IF THE ENGINE IS TURNED THE PROPELLER CAN CAUSE INJURY OR DEATH 1 Make sure that the engine is safe S Set the ELECT MASTER switch to OFF S Set the related ENGINE MASTER switch to OFF S Set the power lever to 0 2 Disconnect the airplane main battery Refer to Section 24 31 3 Remove the engine cowlings Refer to Section 71 10 or 71 11 Note Mark the propeller spinner front support plate a...

Page 1922: ...s References Page 202 15 Mar 2018 61 10 00 Doc 7 02 15 Rev 4 5 Remove the nuts and washers which attach the propeller to the propeller shaft flange Hold the propeller 6 Pull the propeller forward and clear of the propeller shaft flange 7 Use caps to cover open lines ...

Page 1923: ...ev 4 61 10 00 Page 203 15 Mar 2018 Attaching Bolts Spinner Attaching Screws Spinner Bulkhead Oil Seal Spinner Dome Hub Balance Weights Engine Flange Washer Nut OIL SEAL LOCATION IN THE HUB Hub Engine Flange Oil Seal Figure 4 Propeller Installation ...

Page 1924: ...AIRCRAFT Propeller DA 42 NG AMM Page 204 15 Mar 2018 61 10 00 Doc 7 02 15 Rev 4 Figure 5 Propeller Installation if OÄM 42 204 is installed ...

Page 1925: ...hipping plug is removed and check the inside of the propeller hub area for contamination 4 Make sure that a new O ring oil seal is in place in the propeller hub Lightly oil the seal Refer to Figure 4 Use clean gearbox oil 5 Move the propeller into position on the propeller shaft flange Take care not to damage the propeller O ring seal Note Make sure that the propeller is pushed into the correct po...

Page 1926: ...d plastic washers which attach the spinner to the spinner bulkhead S Tighten all the attaching screws Align the index mark Torque 4 5 Nm 35 44 lbf in 11 Install the engine cowlings Refer to Section 71 10 or 71 11 12 Do an engine run up Do a test for correct operation of the propeller Refer to Section 71 00 13 Check gearbox oil level and refill if necessary Refer to Section 12 10 ...

Page 1927: ...r Doc 7 02 15 Rev 4 61 10 00 Page 207 15 Mar 2018 3 Propeller Blade Tracking Test A Equipment Item Quantity Part Number Tracking stand 1 Commercial B Procedure Refer to mt Propeller Operation and Installation manual latest revision ...

Page 1928: ...CT MASTER switch to OFF S Set the ENGINE MASTER switches to OFF S Set the power levers to 0 2 Disconnect the airplane main battery Refer to Section 24 31 3 Remove the LH engine cowlings Refer to Section 71 10 or 71 11 4 Check the v belt tension by conducting one of the following test methods S Pull the v belt half way between the pulleys down with 25 N 5 6 lbf and measure the deflection S Measure ...

Page 1929: ... bolts S Release the two alternator bracket bolts S Install Diamond tool S Adjust the v belt tension S Tighten the accessible bracket bolt S Check the v belt tension S If the deflection is 4 mm to 5 mm 0 16 in to 0 20 in respectively the natural frequency is 123 Hz 12 0 S Remove Diamond tool S Tighten the remaining bracket bolt S Install the safety wires Use Diamond tool No 044 6116 00 00 SW Refer...

Page 1930: ...STER switch to OFF S Set the ENGINE MASTER switches to OFF S Set the power levers to 0 2 Disconnect the airplane main battery Refer to Section 24 31 3 Remove the LH engine cowlings Refer to Section 71 10 or 71 11 4 Remove the safety wires on the alternator bracket bolts 5 Release the three alternator bracket bolts 6 Lift the v belt from the additional alternator pulley 7 Remove the six bolts which...

Page 1931: ...r to Section 71 10 or 71 11 4 Assemble the LH propeller flange pulley and the fan wheel with six bolts washers and self locking nuts Use new self locking nuts 5 Remove the caps which cover the propeller and the gearbox hub 6 Make sure that a new O ring oil seal is in place in the propeller hub Lightly oil the seal Refer to Figure 5 Use clean gearbox oil 7 Move the v belt the propeller pulley assem...

Page 1932: ...he propeller flange pulley assembly 12 Adjust the additional alternator v belt tension Refer to Paragraph 4 13 Check the gearbox oil level and refill if necessary Refer to Section 12 10 14 Install the engine cowlings Refer to Section 71 10 or 71 11 15 Connect the airplane main battery Refer to Section 24 31 16 Do an engine run up Do a test for correct operation of the propeller Refer to Section 71...

Page 1933: ... Bolt 2nd Alternator Voltage Regulator Bolt Washer Washer Nut Voltage Regulator Support Bolt Washer Fuse Fuse Mounting Washer Screw Nut Washer Washer Bolt P Clamp Alternator Spray Shield Bolt Washer Washer Nut Washer Fan Pulley Lock Washer Nut Washer Nut Washer Bushing Lockwire Lockwire Bushing Bushing Figure 6 Additional Alternator and Regulator Installation if OÄM 42 204 e or earlier is installe...

Page 1934: ...ernator Voltage Regulator Bolt Washer Washer Nut Voltage Regulator Support Bolt Washer Fuse Fuse Mounting Washer Screw Nut Washer Washer Bolt P Clamp Alternator Spray Shield Bolt Washer Washer Nut Washer Fan Pulley Lock Washer Nut Bushing Washer Bushing Lockwire Lockwire Washer Nut Nut Bushing Bushing Figure 7 Additional Alternator and Regulator Installation if OÄM 42 204 g or later and MÄM 42 600...

Page 1935: ...er Nut Voltage Regulator Support Bolt Washer Fuse Fuse Mounting Washer Screw Nut Washer Washer Bolt P Clamp Alternator Spray Shield Bolt Washer Washer Nut Washer Fan Pulley Lock Washer Nut Bushing Lockwire Lockwire Bushing Bushing Engine Mounting Arm RH Mounting Bolt Bushing Washer Nut Nut Figure 8 Additional Alternator and Regulator Installation if OÄM 42 204 o or later is installed and MÄM 42 60...

Page 1936: ... are safe S Set the ELECT MASTER switch to OFF S Set the ENGINE MASTER switches to OFF S Set the power levers to 0 2 Disconnect the airplane main battery Refer to Section 24 31 3 Remove the LH engine cowlings Refer to Section 71 10 or 71 11 4 Remove the safety wires on the additional alternator bracket bolts 5 Release the three alternator bracket bolts Refer to Figure 6 8 6 Lift the v belt from th...

Page 1937: ...E MASTER switches to OFF S Set the power levers to 0 2 Verify that the airplane main battery is disconnected Refer to Section 24 31 3 Install the additional alternator pulley Use new locking washer 4 Position the v belt on the propeller pulley assembly and the additional alternator pulley 5 Adjust the v belt tension Refer to Paragraph 4 6 Check the two safety wires on the additional alternator bra...

Page 1938: ...AIRCRAFT Propeller DA 42 NG AMM Page 218 15 Mar 2018 61 10 00 Doc 7 02 15 Rev 4 Intentionally left blank ...

Page 1939: ...is installed variable pitch and feathering propellers The engines have mounted constant speed governors P 877 16 The constant speed governor is controlled by the engine EECS system The constant speed governor controls the engine speed by changing the propeller blade angle pitch For further information about the constant governor unit refer to mt Propeller Operation and Installation Manual latest r...

Page 1940: ...AIRCRAFT Propeller DA 42 NG AMM Page 2 15 Mar 2018 61 20 00 Doc 7 02 15 Rev 4 Figure 1 Propeller RPM Adjusted by the EECU System ...

Page 1941: ...d RPM will be obtained as shown in Figure 1 Figure 2 shows the propeller control system schematic diagram The oil pressure at the governor is 22 bar 320 PSI If the engine speed is too high the constant speed governor operates the governor so that the oil flows out from the propeller The counterweights on each blade moves the blades to a coarse pitch and increases the blade angle This reduces the R...

Page 1942: ...AIRCRAFT Propeller DA 42 NG AMM Page 4 15 Mar 2018 61 20 00 Doc 7 02 15 Rev 4 Figure 2 Propeller Control System Schematic Diagram ...

Page 1943: ...he oil flowing to the propeller will cause the blades to move into low pitch position The propeller pitch angle in low pitch position is 12 0 2 13 0 2 if MÄM 42 600 is incorporated As soon as the propeller starts turning and the gearbox oil operates the accumulator will be refilled The specified propeller settings are given as follows Low pitch 12 0 2 13 0 2 for MTV 6 R C F CF 190 69 Start lock po...

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Page 1945: ...ir in the Repair column Trouble Possible Cause Repair Propeller RPM fluctuating Engine gearbox oil level low Engine gearbox oil contaminated Electrical connection between related engine EECU system and governor Governor defective Replenish gearbox oil level Refer to Chapter 72 Replace engine gearbox oil Refer to Chapter 72 Do a continuity check of the wiring between the EECU system and the governo...

Page 1946: ...AIRCRAFT Propeller DA 42 NG AMM Page 102 15 Mar 2018 61 20 00 Doc 7 02 15 Rev 4 Intentionally left blank ...

Page 1947: ...ELECT MASTER switch to OFF S Set the related ENGINE MASTER switch to OFF S Set the power lever to 0 2 Disconnect the airplane main battery Refer to Section 24 31 3 Remove the engine cowlings Refer to Section 71 10 or 71 11 4 Disconnect the cable connector GOV from the governor Refer to the AE Maintenance Manual latest revision Chapter 71 50 05 5 Remove the oil hose from the governor If OÄM 42 224 ...

Page 1948: ...n 3 Install the four washers and nuts which attach the governor to the drive pad Torque 28 Nm 20 7 lbf ft Use new self locking nuts 4 Connect the propeller control cable connector GOV to the governor Refer to the AE Maintenance Manual latest revision Chapter 71 50 05 5 Install the oil hose from the unfeathering accumulator to the governor If OÄM 42 224 is performed install the safety cap to the go...

Page 1949: ...4 61 20 00 Page 203 15 Mar 2018 Accumulator Oil Pressure Hose Charging Valve Mounting Clamp Bolt Engine Mounting Frame Rubber Strip Washer Fitting Fitting Accumulator Spray Shield Bolt Washer Figure 4 Propeller Un Feathering Accumulator Installation ...

Page 1950: ...ccumulator Oil Pressure Hose Charging Valve Bolt Engine Mounting Frame Washer Fitting Fitting Accumulator Spray Shield Bolt Washer Mounting Clamp Washer Nut P Clamp Washer Bolt Washer Nut Air Intake Figure 5 Propeller Un Feathering Accumulator Installation if MÄM 42 600 is installed ...

Page 1951: ...itch to OFF S Set the related ENGINE MASTER switch to OFF S Set the power lever to IDLE 2 Disconnect the airplane main battery Refer to Section 24 31 3 Remove the engine cowlings Refer to Section 71 10 or 71 11 WARNING YOU MUST RELEASE ALL THE NITROGEN PRESSURE FROM THE ACCUMULATOR BEFORE YOU REMOVE IT NITROGEN AT HIGH PRESSURE CAN PENETRATE THE SKIN THIS CAN CAUSE DISEASE 4 Drain the propeller un...

Page 1952: ...or at the shut off valve Cut the tie wraps 7 Remove the accumulator S Remove the 2 bolts on engine mount that hold the accumulator S Remove both mounting clamps S Lift the accumulator clear of the mounting bracket Support the accumulator 8 Remove the accu spray shield Remove the bolt and washer 9 Disconnect the oil hose from the accumulator Use a suitable container to collect spilt oil Cap open oi...

Page 1953: ...h nitrogen S Set valve under current open S Remove the cap from the charging valve S Connect a suitable nitrogen supply to the charging valve and charge the accumulator to the correct pressure S Disconnect the nitrogen supply S Install the cap onto the charging valve Follow the manufacturer s instructions for the nitrogen supply 10 4 bar 150 PSI 5 Install the engine cowlings Refer to Section 71 10...

Page 1954: ...ELLERS CAN CAUSE INJURY OR DEATH 1 Position the airplane on level ground Make sure that S There are no loose stones on the ground near the propeller S The safety zone around the airplane is clear S The airplane heads into the wind 2 Put chocks in front of each main wheel 3 Set the parking brake to ON 4 Make sure that the ENGINE FUEL SELECTOR is set to ON for both engines 5 Make sure that the passe...

Page 1955: ...ts S Release the START key switch 14 Leave the power lever at 0 Make sure that there are no warning lights on 15 Monitor the oil pressure The oil pressure must rise to 1 bar minimum within 3 seconds of starting the engine If it does not then you must shut down the engine 16 Let the engine idle at 900 RPM for 4 minutes Monitor the engine instruments for unusual indications 17 Set the power lever to...

Page 1956: ... check reset if necessary If the engine does not start wait 30 seconds and proceed with first item of starting sequence The propeller must un feather within 12 to 15 sec low pitch 12 Check the functional efficiency of the accumulator if the propeller does not un feather 21 Set the ENGINE MASTER switch to OFF The propeller must remain in the un feathered position There is just a small change in pit...

Page 1957: ...AIRCRAFT DA 42 NG AMM Power Plant Doc 7 02 15 Rev 4 71 TITLE Page 1 15 Mar 2018 CHAPTER 71 POWER PLANT ...

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Page 1959: ...e Shooting 1 General 101 Maintenance Practices 1 General 201 2 Remove Install the Engine 202 3 Engine Test General 218 Section 71 10 Engine Cowlings 1 General 1 2 Description 1 Trouble Shooting 1 General 101 Maintenance Practices 1 General 201 2 Remove Install the Engine Cowlings 201 3 Cleaning and Painting 204 Section 71 11 Engine Cowlings if MÄM 42 600 is installed 1 General 1 2 Description 1 ...

Page 1960: ... the Engine Cowlings 201 3 Cleaning and Painting 206 Section 71 20 Engine Mounting 1 General 1 Trouble Shooting 1 General 101 Maintenance Practices 1 General 201 2 Remove Install an Engine Mount 201 Section 71 50 Electrical Cables in the Engine Compartment 1 General 1 Section 71 60 Air Intakes 1 General 1 2 Description 4 3 Operation 5 Trouble Shooting 1 General 101 ...

Page 1961: ...5 Remove Install an Alternate Air Control Cockpit Lever Cable if MÄM 42 933 is installed 212 6 Adjust an Alternate Air Valve Control Cable 216 Section 71 61 Air Intakes if MÄM 42 600 is installed 1 General 1 2 Description 1 3 Operation 2 Trouble Shooting 1 General 101 Section 71 70 Engine Drains 1 General 1 2 Description 1 Maintenance Practices 1 General 201 2 Remove Install a Breather Hose Assemb...

Page 1962: ...AIRCRAFT Power Plant DA 42 NG AMM Page 4 15 Mar 2018 71 CONTENTS Doc 7 02 15 Rev 4 Maintenance Practices 1 General 201 2 Remove Install a Breather Hose Assembly 201 ...

Page 1963: ...ine Chapter 73 Engine fuel and control Refer to the AE Operation Manual latest revision for data on the fuel injection system Chapter 76 Engine controls Chapter 77 Engine indicating Chapter 78 Exhaust system Chapter 79 Oil system components installed in the nacelle Refer to the AE Operation Manual latest revision for data on the engine oil system Chapter 80 Starter system control and installation ...

Page 1964: ...T Power Plant DA 42 NG AMM Page 2 15 Mar 2018 71 00 00 Doc 7 02 15 Rev 4 Engine Mounting Frame Bottom Cowling Engine Cooling Air Intake Top RH Cowling Top LH Cowling New Generation Engine Figure 1 Power Plant ...

Page 1965: ...2 NG AMM Power Plant Doc 7 02 15 Rev 4 71 00 00 Page 3 15 Mar 2018 Engine Mounting Frame Bottom Cowling Engine Cooling Air Intake Top RH Cowling Top LH Cowling Engine Figure 2 Power Plant if MÄM 42 600 is installed ...

Page 1966: ...t has these components installed A Cowlings The power plant has a left side cowling a right side cowling and bottom engine cowling All the cowlings attach to each other and the engine nacelle with Camloc quick release fasteners The bottom cowling has air intakes for the engine cooling the cabin heat exchanger and the engine air intake B Engine Mounts The engine mount attaches to the firewall at fi...

Page 1967: ... 5 kW 165 6 DIN hp at 2300 RPM 114 0 kW 152 9 DIN hp at 2100 RPM 2500 RPM Oil pressure indicated values are corrected for pressure altitude Refer to Airplane Flight Manual Oil temperature Refer to Airplane Flight Manual Oil consumption S Maximum 0 1 liter hr 0 11 US qt hr Oil quantity Refer to Airplane Flight Manual Coolant temperature Refer to Airplane Flight Manual Fuel consumption Refer to Airp...

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Page 1969: ... ENGINE THIS CAN CAUSE INJURY TO PERSONNEL If you have the trouble detailed in the Trouble column read across to the Possible Cause column Then do the repair given in the Repair column Trouble Possible Cause Repair Engine vibration Damaged shock mounts Propeller unbalance Engine operates with only 3 fuel injectors Replace the shock mounts Balance the propeller Refer to the engine manufacturer Engi...

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Page 1971: ...E ENGINE WITH THE HOIST THE HOIST CAN FAIL THIS CAN CAUSE DEATH OR INJURY TO PERSONS WARNING DO NOT GET ENGINE OIL GEAR OIL OR COOLANT ON YOU THESE LIQUIDS CAN CAUSE SKIN DISEASE WARNING DO NOT GET FUEL ON YOU FUEL CAN CAUSE SKIN DISEASE DO NOT ALLOW FIRE OR SPARKS NEAR FUEL FUEL BURNS AND BURNING FUEL CAN CAUSE INJURY TO PEOPLE AND DAMAGE TO EQUIPMENT CAUTION YOU MUST ATTACH CAPS TO HOLES PIPES W...

Page 1972: ...2 15 Mar 2018 71 00 00 Doc 7 02 15 Rev 4 2 Remove Install the Engine A Equipment Item Quantity Part Number Hoist 1 Commercial Engine sling 1 Commercial Engine stand 1 Commercial Tail trestle 1 Commercial Hoisting points 4 Delivered with engine ...

Page 1973: ...Doc 7 02 15 Rev 4 71 00 00 Page 203 15 Mar 2018 Coolant Tank Coolant Temperature Sensor Crankshaft 2 Sensor Oil Case Coolant Radiator Alternator Oil Pressure Sensor Oil Filter Housing Oil Temperature Sensor Figure 3 Left Side of Engine ...

Page 1974: ...8 71 00 00 Doc 7 02 15 Rev 4 Coolant Tank Coolant Temperature Sensor Crankshaft 2 Sensor Oil Case Coolant Radiator Alternator Oil Pressure Sensor Oil Filter Housing Oil Temperature Sensor Fuel Cooler Figure 4 Left Side of Engine if MÄM 42 600 is installed ...

Page 1975: ... safe S Set ELECT MASTER switch to OFF S Set the ENGINE MASTER switch to OFF S Set the power lever to 0 4 Disconnect the airplane main battery Refer to Section 24 31 5 Remove the engine cowlings Refer to Section 71 10 or 71 11 6 Remove the propeller Refer to Section 61 10 7 Drain the coolant system Refer to Section 75 00 8 Remove the hose from the alternate air valve to the turbo charger 9 Remove ...

Page 1976: ... solenoid S Release all clips and ties holding the cables to the engine Do not remove clips and ties on the engine mount 19 Disconnect all electrical connections glow plugs injectors etc Refer to the AE Maintenance Manual latest revision 20 Remove the hose that connects the turbo charger outlet to the inter cooler S Remove the 4 worm drive clamps S Remove the hose Refer to Section 73 00 21 Remove ...

Page 1977: ... revision 30 Take the weight of the engine with the hoist 31 Remove the nuts bolts and washers that attach the engine support brackets to the engine mount 32 Remove the safety rope from the engine 33 Lift the engine a small distance turn it slightly to the right side and move it at the same time forward and clear of the engine mount Make sure that the engine does not hit the engine mount 34 Remove...

Page 1978: ...AMM Detail Steps Work Items Key Items References Page 208 15 Mar 2018 71 00 00 Doc 7 02 15 Rev 4 41 If the engine was removed because of oil system contamination S Remove and discard oil radiator and oil hoses Refer to Section 79 00 ...

Page 1979: ...nt Doc 7 02 15 Rev 4 71 00 00 Page 209 15 Mar 2018 Direction of Flight Air Filter Box Turbocharger Fuel High Pressure Pump Fuel Line Pressure Sensor Propeller Flange Radiator Exhaust Cabin Heat Exchanger Figure 5 Right Side of Engine ...

Page 1980: ... Mar 2018 71 00 00 Doc 7 02 15 Rev 4 Direction of Flight Air Filter Box Turbocharger Fuel High Pressure Pump Fuel Line Pressure Sensor Propeller Flange Radiator Exhaust Cabin Heat Exchanger Figure 6 Right Side of Engine if MÄM 42 600 is installed ...

Page 1981: ...Washer Washer Bolt Washer Bolt Mounting Arm Mounting Arm Bolt Washer Engine Mount Washer Nut Washer Engine Mount Nut Bonding Wire Bonding Wire Bolt Washer Bonding Wire Safety Rope Bonding Wire Safety Rope Spacer Washer Washer Washer Washer Bolt Washer Safety Rope Bolt Bolt Bolt Washer Washer Bolt Nut Washer Bolt Washer Washers Washer Bolt Figure 7 Engine Shock Mounts ...

Page 1982: ... Bolt Bolt Washer Washer Bolt Washer Bolt Mounting Arm Mounting Arm Bolt Washer Washer Engine Mount Nut Bonding Wire Bonding Wire Bolt Washer Safety Rope Bonding Wire Safety Rope Spacer Washer Washer Washer Bolt Washer Safety Rope Bolt Bolt Bolt Engine Mount Washer Nut Bonding Wire Washer Bolt Bushing Figure 8 Engine Shock Mounts if MÄM 42 594 is installed ...

Page 1983: ... Engine Mount Engine Mount Washer Nut Bolt Bolt Washer Washer Bolt Washer Bolt Mounting Arm Mounting Arm Bolt Washer Engine Mount Washer Nut Engine Mount Nut Safety Rope Safety Rope Spacer Washer Washer Washer Bolt Washer Safety Rope Bolt Washer Bolt Spacer Washer Figure 9 Engine Shock Mounts if MÄM 42 600 is installed ...

Page 1984: ...ine mount Front Torque 16 Nm 11 8 lbf ft if MÄM 42 600 is installed 20 Nm 14 75 lbf ft Use Loctite 243 Rear Torque 28 Nm 20 64 lbf ft 4 Install engine support bracket at the engine with safety rope Use Loctite 243 5 Carefully move the engine back into position in the engine mount 6 Install the bolts nuts and washers that attach the engine shock mounts to the engine mounting arms Refer to Chapter 2...

Page 1985: ... bonding cables to these electrical sensors S Fuel rail pressure regulator S Propeller governor S Waste gate valve solenoid S Fuel injectors S Glow plugs At the rear end of the fuel rail At the right side of the reduction gear At the lower crankshaft cover At each fuel injector At the lower crankshaft cover 12 Install clips and ties clamps holding the engine wire harness to the engine 13 Connect t...

Page 1986: ... TURNED THE PROPELLER CAN CAUSE INJURY OR DEATH 23 Install the TKS bracket S Install the three bolts located at the upper right side of the gearbox and engine housing 24 Install the propeller Refer to Section 61 00 25 Fill and bleed the cooling system Refer to Section 75 00 26 Fill the engine with oil Refer to Section 12 10 27 Fill the reduction gear with oil Refer to Section 12 10 28 Connect the ...

Page 1987: ...AIRCRAFT DA 42 NG AMM Power Plant Doc 7 02 15 Rev 4 71 00 00 Page 217 15 Mar 2018 3 m 1 0 f t 3 m 10 ft 3 m 10 ft 10 m 30 ft Figure 10 Engine Testing Safety Zone ...

Page 1988: ...l latest revision and Airplane Flight Manual Note The engine drives the propeller through a speed reducing gear All RPMs are shown as propeller RPMs CAUTION ONLY AUTHORIZED PERSONNEL MAY READ ENGINE DATA WITH THE ECU OPERATOR SOFTWARE A Equipment Item Quantity Part Number Airplane chocks 2 Commercial Fuel sample kit 1 Commercial Laptop computer 1 Commercial Wizard 300 software latest approved revi...

Page 1989: ...sure that S There are no loose stones on the ground near the propeller S The safety zone around the airplane is clear S The airplane heads into the wind Refer to Figure 10 4 Check engine oil level gearbox oil level and coolant level For the engine that you will test 5 Do a test of a sample of fuel for contamination Refer to Section 12 10 6 Put chocks in front of each main wheel 7 Make sure that th...

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Page 1991: ...ction 51 60 for data on the quick release fasteners 2 Description Figure 1 shows the cowlings Camloc quick release fasteners attach the cowlings to each other and to the engine nacelle All the cowlings are very light and one person can hold them easily The bottom cowling has an air intake on the right side of the cowling and a large air intake on the bottom of the cowling at the front The side int...

Page 1992: ...4 Top RH Cowling Top LH Cowling Cooling Air to Oil Cooler Engine Cooling Air Intake Bottom Cowling Rubber Seal Cooling Air Intake Camloc Stud Camloc Receptacle Camloc Receptacle Rivet Ring Grommet Camloc Stud TYPICAL FASTENER ASSEMBLY Cooling Air Intake Figure 1 Engine Cowlings 1 ...

Page 1993: ...AIRCRAFT DA 42 NG AMM Power Plant Doc 7 02 15 Rev 4 71 10 00 Page 3 15 Mar 2018 Top LH Cowling Access Panel Fillister Head Screw Figure 2 Engine Cowlings 2 ...

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Page 1995: ... Repair column Trouble Possible Cause Repair Outer surface of the cowling discolored Paint blistered Black soot on the inner surface Engine overheating Hot gas leak Engine fire Examine the engine for hot gas leaks Examine the exhaust for cracks and leaking gaskets Replaced damage items Repaint the cowlings Oil fuel coolant on the inner surface of the cowling Oil fuel or coolant leak Examine the en...

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Page 1997: ...SET THE POWER LEVER TO 0 DISCONNECT THE AIRPLANE MAIN BATTERY Detail Steps Work Items Key Items References WARNING MAKE SURE THAT THE ENGINE IS SAFE BEFORE YOU DO ANY WORK ON THE COWLINGS IF THE ENGINE IS TURNED THE PROPELLER CAN CAUSE INJURY OR DEATH 1 Make sure that the engine is safe S Set the ELECT MASTER switch to OFF S Set the related ENGINE MASTER switch to OFF S Set the power lever to 0 2 ...

Page 1998: ...e cowling S Move the cowling down and forward S Move the cowling clear of the airplane Take care not to scratch the cowling on the propeller and spinner cone C Install the Bottom Cowling Detail Steps Work Items Key Items References 1 Examine the bottom cowling Make sure that S The cowling is clean S The cowling is not damaged S The quick release fasteners are not missing damaged S Drain holes must...

Page 1999: ...Repair any damage Replace missing damaged fasteners 2 Install the top left cowling S Move the top left cowling into position on the engine nacelle S Move the top right cowling into position on the engine nacelle Make sure that the fasteners engage correctly in the engine nacelle and bottom cowling Make sure that the fasteners engage correctly in the top left cowling the engine nacelle and bottom c...

Page 2000: ...e inside of the engine cowlings with fire protection paint Refer to Section 51 20 for repairs and painting the outside of the cowlings Note If OÄM 40 205 has been carried out cowling made from self extinguishing resin do not apply fire protection paint on the inside of the cowling Use only self extinguishing resin for repair refer to Section 51 30 Detail Steps Work Items Key Items References 1 Cle...

Page 2001: ...to Section 51 60 for data on the quick release fasteners 2 Description Figure 1 shows the cowlings Camloc quick release fasteners attach the cowlings to each other and to the engine nacelle All the cowlings are very light and one person can hold them easily The bottom cowling has three air intakes at the front of the cowling The intake at the front bottom of the lower cooling supplies air to the c...

Page 2002: ...AIRCRAFT Power Plant DA 42 NG AMM Page 2 15 Mar 2018 71 11 00 Doc 7 02 15 Rev 4 Figure 1 Engine Cowlings 1 if MÄM 42 600 installed ...

Page 2003: ...AIRCRAFT DA 42 NG AMM Power Plant Doc 7 02 15 Rev 4 71 11 00 Page 3 15 Mar 2018 Top LH Cowling Access Panel Fillister Head Screw Figure 2 Engine Cowlings 2 if MÄM 42 600 installed ...

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Page 2005: ... Repair column Trouble Possible Cause Repair Outer surface of the cowling discolored Paint blistered Black soot on the inner surface Engine overheating Hot gas leak Engine fire Examine the engine for hot gas leaks Examine the exhaust for cracks and leaking gaskets Replaced damage items Repaint the cowlings Oil fuel coolant on the inner surface of the cowling Oil fuel or coolant leak Examine the en...

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Page 2007: ... TO OFF SET THE POWER LEVER TO 0 DISCONNECT THE AIRPLANE MAIN BATTERY Detail Steps Work Items Key Items References WARNING MAKE SURE THAT THE ENGINE IS SAFE BEFORE YOU DO ANY WORK ON THE COWLINGS IF THE ENGINE IS TURNED THE PROPELLER CAN CAUSE INJURY OR DEATH 1 Make sure that the engine is safe S Set the related ENGINE MASTER switch to OFF S Set the ELECT MASTER switch to OFF S Set the power lever...

Page 2008: ...Bottom Cowling Detail Steps Work Items Key Items References 1 Release the worm drive clamp on the gearbox cooling duct 2 Release the air hose from the gearbox cooling duct 3 Release the quick release fasteners which hold the bottom cowling to them engine nacelle Hold the bottom cowling 4 Remove the bottom cowling S Lower first the left side of the cowling S Move the cowling down S Move the cowling...

Page 2009: ...amage Replace missing damaged fasteners 2 Lift the cowling into position S Move first the cowling upwards S Lift the right side of the cowling fully into position S Tighten the quick release fasteners that attach the cowling to the engine nacelle Take care of the air inlets Engage the respective shrouds Note Make sure that the hose clamp lock at the cooling duct connection is positioned at the top...

Page 2010: ...AIRCRAFT Power Plant DA 42 NG AMM Page 204 15 Mar 2018 71 11 00 Doc 7 02 15 Rev 4 Figure 3 Air Shroud and Clamp Installation if MÄM 42 600 and MÄM 42 660 are installed ...

Page 2011: ...Repair any damage Replace missing damaged fasteners 2 Install the top left cowling S Move the top left cowling into position on the engine nacelle S Move the top right cowling into position on the engine nacelle Make sure that the fasteners engage correctly in the engine nacelle and bottom cowling Make sure that the fasteners engage correctly in the top left cowling the engine nacelle and bottom c...

Page 2012: ... the Cowlings This Paragraph gives the data for painting the inside of the engine cowlings with fire protection paint Refer to Section 51 20 for repairs and painting the outside of the cowlings Detail Steps Work Items Key Items References 1 Clean the inside of the cowling 2 Make the area rough for painting Use 150 320 grade wet and dry paper WARNING DO NOT GET ACETONE ON YOUR SKIN ACETONE CAN CAUS...

Page 2013: ... P clamps and cable ties hold electrical cables and other items of equipment to the engine mount The engine mounting frame has five small mounting pads at the rear of the frame Bolts through the pads attach the engine mount to the engine nacelle The engine attaches to the engine mount at four mounting pads Large gel filled rubber shock mounts go between the engine and the engine mount pads These s...

Page 2014: ... A A Front Engine Mounting LH Rear Engine Mounting LH Front Engine Mounting RH Rear Engine Mounting RH Firewall Mounting Pad Firewall A Alternate Air Valve Mounting Radiator Mounting Accumulator Mounting Radiator Mounting Exhaust Mounting Cabin Heater Radiator Mounting Radiator Mounting Figure 1 Engine Mount Assembly ...

Page 2015: ...Mounting LH Front Engine Mounting RH Rear Engine Mounting RH Firewall Mounting Pad Firewall A Alternate Air Valve Mounting Radiator Mounting Accumulator Mounting Fuel Cooler Mounting Exhaust Mounting Cabin Heater Radiator Mounting Radiator Mounting Front Engine Mounting LH A Figure 2 Engine Mount Assembly if MÄM 42 600 is installed ...

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Page 2017: ...e with the engine mounting If you have the trouble detailed in the Trouble column read across to the Possible Cause column Then do the repair in the Repair column Trouble Possible Cause Repair Engine vibration Defective shock mounts Cracked engine mount Refer to the engine manufacturer Examine the engine mount Look specially for cracks at the welded joints ...

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Page 2019: ... the engine mount are limited to removal installation If the engine mount is damaged it must be repaired by an authorized repair facility 2 Remove Install an Engine Mount A Equipment Item Quantity Part Number Hoist 1 Commercial Engine sling 3 Commercial Engine stand 1 Commercial Tail trestle 1 Commercial Hoisting points 4 Delivered with engine ...

Page 2020: ... 20 4 Remove the cabin heating heat exchanger and shroud Refer to Section 21 40 5 Remove the engine coolant radiator Refer to Section 75 00 6 Remove the inter cooler Refer to Section 81 00 7 Remove the turbo charger inter cooler Refer to Section 81 00 8 Remove the inter cooler mounting bracket Refer to Section 81 00 9 Remove the air filter housing and alternate air valve Refer to Section 71 60 10 ...

Page 2021: ...olts Torque 40 Nm 29 5 lbf ft 3 Install the engine coolant radiator 4 Install the inter cooler mounting bracket Refer to Section 81 00 5 Install the turbo charger inter cooler 6 Install the inter cooler 7 Install the engine air filter housing and alternate air valve 8 Install the cabin heating heat exchanger and shroud 9 Install the propeller un feathering accumulator 10 Install all the clamps cli...

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Page 2023: ...ation The harness has all of the low power cables for the engine control system It is integral with the engine control system Refer to Section 76 00 for data about the main electrical wiring harness There are a small number of separate cables for the alternator and starter See Chapter 24 for data about the battery and alternator wiring See Chapter 80 for more data about the starter cables See Chap...

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Page 2025: ...ssembly make the engine air intake system for the DA 42 NG airplane The air filter box is connected to the intercooler air intake by a flexible hose The same sort of hose feeds the air from the alternate air valve to the turbo charger A lever below the instrument panel right side operates both alternate air valves Figure 1 shows the engine air filter and alternate air valve ...

Page 2026: ...th with Adjuster Alternate Air Valve Worm Drive Clamp Anti Vibration Mount Engine Mounting Frame Air Filter Box Body Air Outlet from Air Intake Air Intake Worm Drive Clamp Worm Drive Clamp Air Filter Box Assy Turbo Charger Worm Drive Clamp Alternate Air Valve Quick Release Fasteners Bolt Washer Nut Nut Locking Washer Figure 1 Air Filter and Alternate Air Assembly ...

Page 2027: ...AIRCRAFT DA 42 NG AMM Power Plant Doc 7 02 15 Rev 4 71 60 00 Page 3 15 Mar 2018 Figure 2 Air Valve Assembly ...

Page 2028: ...e air filter housing is made of sheet aluminum It has a flexible hose which connects the housing to the air intake duct Bolts attach the air filter housing to brackets on the engine mount C Air Filter Refer to Figure 1 The air filter is a K N RU 1620 high flow air filter The air filter located on the air filter housing on the right of the engine compartment just forward of the firewall It is held ...

Page 2029: ...ward Bowden cable The inner cable of the forward Bowden cable turns the relay lever clockwise The relay lever pulls the inner cables of the left and right alternate valves Both engine alternate air valves move to the alternate unfiltered position If MÄM 42 933 is installed Both engine alternate air valves move to the alternate unfiltered position When the pilot moves the alternate air valve contro...

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Page 2031: ...s you could have with the air intake system If you have the trouble detailed in the Trouble column read across to the Possible Cause column Then do the repair given in the Repair column Trouble Possible Cause Repair An engine does not develop full power Air filter blocked defective on related engine Replace air filter For the related engine ...

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Page 2033: ... CAUSE DEATH OR INJURY TO PERSONS WARNING YOU MUST MAKE SURE THAT THE ENGINE IS SAFE BEFORE YOU DO WORK ON THE ENGINE CONTROLS IF THE PROPELLER TURNS IT CAN CAUSE INJURY TO PERSONS 1 Make sure that the engine is safe S Set the ELECT MASTER switch to OFF S Set the related ENGINE MASTER switch to OFF S Set the power lever to 0 2 Disconnect the airplane main battery Refer to Section 24 31 3 Remove th...

Page 2034: ...element Do not use the worm drive clamp provided with K N filter package Use 9 mm 3 8 in wide worm drive clamp instead 2 Place the alternate air valve with the attached filter element 3 Close the 3 camloc bolts of the alternate air valve 4 Connect the alternate air valve Bowden cables 5 Check if position of the alternate air valve is in accordance to the selector handle position 6 Install the engi...

Page 2035: ...the ELECT MASTER switch to OFF S Set the ENGINE MASTER switch to OFF S Set the power lever to 0 2 Disconnect the airplane main battery Refer to Section 24 31 3 Remove the engine top cowlings Refer to Section 71 10 4 Disconnect the airplane main battery Refer to Section 24 31 5 Remove the bolts nuts and washers that hold the alternate air valve to the air filter housing 6 Disconnect the alternate a...

Page 2036: ...ousing Apply fire resistant sealant Dow Corning 736 or equivalent between air filter housing and alternate air valve 3 Move the alternate air valve close to the engine and connect the alternate air control cable to the valve 4 Adjust the alternate air control cable Refer to Paragraph 6 5 Connect the hose that connects the alternate air valve to the turbo charger inlet S Connect the hose to the val...

Page 2037: ...ine is safe S Set the ELECT MASTER switch to OFF S Set the ENGINE MASTER switch to OFF S Set the power lever to 0 2 Disconnect the airplane main battery Refer to Section 24 31 3 Remove the engine top cowlings Refer to Section 71 10 4 Remove the pilot s seat Refer to Section 25 10 5 Disconnect the control cable from the relay lever at the relay bracket S Loosen the screw on the cable swivel fitting...

Page 2038: ... Air Operating Lever Bush Spacer Angle Bracket Bowden Cable LH Bowden Cable RH Bowden Cable from Operating Lever Nipple To RH Alternate Air Valve To LH Alternate Air Valve Swivel Fitting Swivel Fitting Swivel Fitting Relay Lever Relay Bracket Figure 3 Alternate Air Valve Operating Cables ...

Page 2039: ...ol cable form the sheath S Attach a length of suitable cord to the end of the inner cable S Pull the inner cable from the outer sheath and pull the length of cord into the outer sheath and clear of the airplane S Disconnect the inner cable from the length of cord The cord must be longer than the inner cable Leave the length of cord in the outer sheath ...

Page 2040: ...r sheath with the length of cord S When the new inner cable is fully through the outer sheath S Disconnect the length of cord from the inner cable At the cockpit end From the relay lever end 4 Connect the alternate air forward inner cable to the operating lever in the cockpit S Install the swivel fitting into the operating lever S Pass the inner cable through the swivel fitting and tighten the swi...

Page 2041: ...tch to OFF S Set the ENGINE MASTER switch to OFF S Set the power lever to 0 2 Disconnect the airplane main battery Refer to Section 24 31 3 Remove the engine top cowlings Refer to Section 71 10 4 Remove the pilot s seat Refer to Section 25 10 5 Disconnect the control cable from the relay lever at the relay bracket S Loosen the screw on the cable swivel fitting at the relay lever S Pull the inner c...

Page 2042: ...ol cable form the sheath S Attach a length of suitable cord to the end of the inner cable S Pull the inner cable from the outer sheath and pull the length of cord into the outer sheath and clear of the airplane S Disconnect the inner cable from the length of cord The cord must be longer than the inner cable Leave the length of cord in the outer sheath ...

Page 2043: ... the length of cord S When the new inner cable is fully through the outer sheath S Disconnect the length of cord from the inner cable At the related engine end From the relay lever end 4 Connect the alternate air inner cable to the related engine alternate air valve operating lever S Install the swivel fitting into the alternate air valve operating lever S Pass the inner cable through the swivel f...

Page 2044: ...N CAUSE INJURY TO PERSONS 1 Make sure that the engine is safe S Set the ELECT MASTER switch to OFF S Set the ENGINE MASTER switch to OFF S Set the power lever to 0 2 Disconnect the airplane main battery Refer to Section 24 31 3 Remove the engine top cowlings Refer to Section 71 10 4 If necessary remove the pilot s seat Refer to Section 25 10 5 Disconnect the control cable from the related alternat...

Page 2045: ...ol cable from the sheath S Attach a length of suitable cord to the end of the inner cable S Pull the inner cable from the outer sheath and pull the length of cord into the outer sheath and clear of the airplane S Disconnect the inner cable from the length of cord The cord must be longer than the inner cable Leave the length of cord in the outer sheath ...

Page 2046: ... Doc 7 02 15 Rev 4 Cold Air Operating Lever Bush Spacer Angle Bracket Bowden Cable LH Bowden Cable RH Alternate Air Valve RH Swivel Fitting Alternate Air Valve LH Swivel Fitting Swivel Fitting Figure 4 Alternate Air Valve Operating Cables if MÄM 42 933 is installed ...

Page 2047: ...cable outer sheath to the new control cable inner S Pull the new cable into the outer sheath with the length of cord S When the new cable is fully through the outer sheath S Disconnect the length of cord from the cable 4 Connect the alternate air cable to the operating lever in the cockpit Refer to Figure 4 5 Connect the alternate air inner cable to the alternate air valve S Install the swivel fit...

Page 2048: ... sure that the engine is safe S Set the ELECT MASTER switch to OFF S Set the ENGINE MASTER switch to OFF S Set the power lever to 0 2 If necessary disconnect the airplane main battery Refer to Section 24 31 3 If necessary remove the engine top cowlings Refer to Section 71 10 4 Move the alternate air lever in the cockpit from OFF to ON S Make sure the lever moves freely with no restrictions Fully a...

Page 2049: ... it in position S Make sure that both left and right engine alternate air control valves are in the fully open position 7 If necessary adjust the alternate air control cable to get the correct settings at step 5 At the alternate air lever 8 Do steps 5 to 7 again as necessary 9 Connect the airplane battery Refer to Section 24 31 10 Install the engine top cowlings Refer to Section 71 10 ...

Page 2050: ...e ELECT MASTER switch to OFF S Set the ENGINE MASTER switch to OFF S Set the power lever to 0 2 If necessary disconnect the airplane main battery Refer to Section 24 31 3 If necessary remove the engine top cowlings Refer to Section 71 10 4 Remove the pilot s seat Refer to Section 25 10 5 Move the alternate air lever in the cockpit from OFF to ON S Make sure the lever moves freely with no restricti...

Page 2051: ...t the related engine alternate air control valve is in the fully open position 8 If necessary adjust the related engine alternate air control cable to get the correct settings at step 6 At the relay lever 9 Do steps 5 to 8 again as necessary 10 Install the engine cowlings Refer to Section 71 10 11 Install the pilot s seat Refer to Section 25 10 12 If necessary connect the airplane main battery Ref...

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Page 2053: ...parts Alternate air valve assembly Air filter housing Air filter Alternate air valve operating cables A Alternate Air Assembly Refer to Figure 1 The alternate air valve is attached to the aft face of the air filter housing The air filter attaches to the front of the alternate air valve The alternate air valve also has an inlet direct from the engine compartment Rotary motion of the outer ring open...

Page 2054: ...ontrol lever on the right side of the center console below the instrument panel operates the alternate air valves Two Bowden cables connect the control lever connect the relay lever to the left and right engine alternate air valve operating levers 3 Operation When the pilot pulls the alternate air valve control lever aft If MÄM 42 933 is NOT installed The cable turns the relay lever clockwise The ...

Page 2055: ...ath with Adjuster Alternate Air Valve Air Filter Box Body Air Outlet from Air Intake Worm Drive Clamp Worm Drive Clamp Air Filter Box Assy Turbo Charger Worm Drive Clamp Alternate Air Valve Quick Release Fasteners Bolt Washer Nut Locking Washer Air Intake Worm Drive Clamp Worm Drive Clamp A A Figure 1 Air Filter and Alternate Air Assembly if MÄM 42 600 installed ...

Page 2056: ...61 00 Doc 7 02 15 Rev 4 Ring Locking Ring O Ring Alternate Air Valve Body Suction Nozzle Guide Bolt Flange Bowden Cable Guide Bushing Camloc Bolt Lock Washer Locking Ring O Ring Screw Mesh Ring Bonding Wire Figure 2 Air Valve Assembly if MÄM 42 600 installed ...

Page 2057: ...s you could have with the air intake system If you have the trouble detailed in the Trouble column read across to the Possible Cause column Then do the repair given in the Repair column Trouble Possible Cause Repair An engine does not develop full power Air filter blocked defective on related engine Replace air filter For the related engine ...

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Page 2059: ...onnects to the injector cover outlet and to the breather outlet adapter on the other side The breather outlet adaptor is installed to the air filter housing with a P clamp The second breather hose connects the breather outlet adapter to the guide tube which vents the breather gases clear of the cowling To allow for drainage of oil water which accumulates underneath the injector cover a cylinder he...

Page 2060: ...AIRCRAFT Power Plant DA 42 NG AMM Page 2 15 Mar 2018 71 70 00 Doc 7 02 15 Rev 4 Figure 1 Engine Cylinder Head Drain and Breather Hose Assembly ...

Page 2061: ... CAUSE DEATH OR INJURY TO PERSONS WARNING YOU MUST MAKE SURE THAT THE ENGINE IS SAFE BEFORE YOU DO WORK ON THE ENGINE CONTROLS IF THE PROPELLER TURNS IT CAN CAUSE INJURY TO PERSONS 1 Make sure that the engine is safe S Set the ELECT MASTER switch to OFF S Set the ENGINE MASTER switch to OFF S Set the power lever to 0 2 Disconnect the airplane main battery Refer to Section 24 31 3 Remove the engine...

Page 2062: ...rm drive clamp that secures the breather hose assembly to the outlet at the top aft side of the rail cover S Remove worm drive clamp that secures the breather hose assembly to the guide tube S Move the breather hose assembly clear of the engine 6 Disassemble the breather hose assembly S Remove the worm drive clamps which secure the breather outlet adaptor to the breather hoses ...

Page 2063: ... drive clamp Refer to Figure 1 Make sure to install the breather outlet adapter with correct orientation 2 Install the breather hose assembly according to the previously marked attachment points 3 Connect the breather hose assembly to the outlet at the top aft side of the injector cover and guide tube Secure both connections with worm drive clamps 4 Secure the breather hose assembly with cable tie...

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Page 2065: ... connects to the injector cover breather outlet and to the breather drain adapter on the other side The breather drain adaptor is installed to the engine mount with P clamps The second breather hose connects the breather drain adapter to the guide tube which vents the breather gases clear of the cowling To allow for drainage of oil water which accumulates underneath the injector cover a cylinder h...

Page 2066: ...Tube Engine Mounting Frame P Clamp Bolt Nut Washer Washer P Clamp Worm Drive Clamp Hose Clamp Worm Drive Clamp Worm Drive Clamp Drain Adaptor Worm Drive Clamps Crankcase Drain Hose 2 P Clamp Nut Bolt Cylinder Head Drain Hose P Clamp Engine Mounting Frame Figure 1 Engine Cylinder Head Drain and Breather Hose Assembly if MÄM 42 600 installed ...

Page 2067: ... CAUSE DEATH OR INJURY TO PERSONS WARNING YOU MUST MAKE SURE THAT THE ENGINE IS SAFE BEFORE YOU DO WORK ON THE ENGINE CONTROLS IF THE PROPELLER TURNS IT CAN CAUSE INJURY TO PERSONS 1 Make sure that the engine is safe S Set the ENGINE MASTER switch to OFF S Set the ELECT MASTER switch to OFF S Set the power lever to 0 2 Disconnect the airplane main battery Refer to Section 24 31 3 Remove the engine...

Page 2068: ...rm drive clamp that secures the breather hose assembly to the outlet at the top aft side of the rail cover S Remove worm drive clamp that secures the breather hose assembly to the guide tube S Move the breather hose assembly clear of the engine 6 Disassemble the breather hose assembly S Remove the worm drive clamps which secure the breather outlet adaptor to the breather hoses ...

Page 2069: ... drive clamp Refer to Figure 1 Make sure to install the breather outlet adapter with correct orientation 2 Install the breather hose assembly according to the previously marked attachment points 3 Connect the breather hose assembly to the outlet at the top aft side of the injector cover and guide tube Secure both connections with worm drive clamps 4 Secure the breather hose assembly with cable tie...

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Page 2071: ...AIRCRAFT DA 42 NG AMM Engine Doc 7 02 15 Rev 4 72 TITLE Page 1 15 Mar 2018 CHAPTER 72 ENGINE ...

Page 2072: ...AIRCRAFT Engine DA 42 NG AMM Page 2 15 Mar 2018 72 TITLE Doc 7 02 15 Rev 4 Intentionally left blank ...

Page 2073: ... 2018 TABLE OF CONTENTS CHAPTER 72 ENGINE 1 General 1 2 Description 3 3 Engine Oil System 3 Trouble Shooting 1 General 101 Maintenance Practices 1 General 201 2 Change the Engine Oil and Replace the Oil Filter 202 3 Replace the Gearbox Oil 203 4 Read an Engine Event Log 205 ...

Page 2074: ...AIRCRAFT Engine DA 42 NG AMM Page 2 15 Mar 2018 72 CONTENTS Doc 7 02 15 Rev 4 Intentionally left blank ...

Page 2075: ...E E4 C if MÄM 42 600 is installed engine Refer to these Chapters for more data about the engine systems Chapter 73 Engine fuel and control Chapter 75 Liquid cooling system Chapter 76 Engine controls Chapter 77 Engine indicating Chapter 78 Engine exhaust Chapter 79 Oil cooling Chapter 80 Engine starting Chapter 81 Turbo charger Note Only AE authorized maintenance organizations may carry out mainten...

Page 2076: ...MM Page 2 15 Mar 2018 72 00 00 Doc 7 02 15 Rev 4 Engine Oil Filter Housing Engine Oil Filler Gearbox Oil Filler Plug Gearbox Oil Level Window Engine Oil Drain Plug Gearbox Oil Drain Plug Figure 1 Oil System Maintenance Locations ...

Page 2077: ... Airplane Flight Manual Chapter 2 for data about the oil types to use in the engine The internal oil pump supplies oil to all bearings and other components that require oil Oil galleries inside the engine crankcase and cylinder head supply oil to the internal components Figure 1 shows the location of the items that you can maintain on the engine oil system of the AE E4 B engine The engine has thes...

Page 2078: ...AIRCRAFT Engine DA 42 NG AMM Page 4 15 Mar 2018 72 00 00 Doc 7 02 15 Rev 4 Intentionally left blank ...

Page 2079: ...600 is installed repair facility or the engine manufacturer Trouble Possible Cause Repair Engine oil pressure low Oil pressure regulator valve does not operate correctly Defective oil pump Not enough oil in the engine oil sump Refer to the engine manufacturer Refer to the engine manufacturer Fill the engine with oil Gearbox oil temperature high Not enough oil in the gearbox Find the reason for the...

Page 2080: ...AIRCRAFT Engine DA 42 NG AMM Page 102 15 Mar 2018 72 00 00 Doc 7 02 15 Rev 4 Intentionally left blank ...

Page 2081: ...OIL ON YOU OIL CAN CAUSE SKIN DISEASE CAUTION ALWAYS PUT A CAP ON OPEN CONNECTIONS IF YOU DO NOT PUT A CAP ON OPEN CONNECTIONS THEN CONTAMINATION CAN GET INTO THE SYSTEM AND CAUSE DAMAGE CAUTION DO NOT MIX OIL TYPES IF YOU MIX OIL TYPES THE OIL CAN LOSE ITS PROPERTIES AND THE ENGINE WILL WEAR MORE QUICKLY Note A sample of the oil and the used oil filter must be stored in a clean container labeled ...

Page 2082: ... lever to 0 2 Disconnect the airplane main battery Refer to Section 24 34 3 Remove the engine cowlings Refer to Section 71 10 or 71 11 For the engine oil change and the oil filter replacement procedures refer to AE Maintenance Manual latest revision If an engine oil quick drain equipment is available refer to Chapter 79 for more details 4 Install the engine cowlings Refer to Section 71 10 or 71 11...

Page 2083: ...BEFORE YOU DO WORK ON THE ENGINE CONTROLS IF THE PROPELLER TURNS IT CAN CAUSE INJURY TO PERSONS 2 Make sure that the engine is safe S Set the ELECT MASTER switch to OFF S Set the ENGINE MASTER switch to OFF S Set the power lever to 0 3 Remove the engine cowlings Refer to Section 71 10 or 71 11 4 Remove the gearbox oil filler plug Refer to the AE Maintenance Manual latest revision 5 Remove the gear...

Page 2084: ... latest revision 10 Install the gearbox oil filler plug Refer to the AE Maintenance Manual latest revision 11 Install the engine cowlings Refer to Section 71 10 or 71 11 12 Do a ground test of the related engine Refer to Section 71 00 and AE Maintenance Manual latest revision 13 Remove the engine cowlings Refer to Section 71 10 or 71 11 14 If necessary correct gearbox oil level S Remove the gearbo...

Page 2085: ...ICAL SYSTEM WITH ENGINE MASTER ON LH OR RH AND THE ENGINE IS NOT RUNNING ALWAYS CONNECT AN EXTERNAL POWER SUPPLY WITH A PRESET VOLTAGE OF 29V TO THE AIRPLANE OTHERWISE THE ALTERNATORS MAY BE DAMAGED A Equipment Item Quantity Part Number Laptop computer 1 Commercial Wizard 300 software latest approved revision n a n a CAN interface 1 Commercial B Read an Engine Event Log Refer to AE Maintenance Man...

Page 2086: ...AIRCRAFT Engine DA 42 NG AMM Page 206 15 Mar 2018 72 00 00 Doc 7 02 15 Rev 4 Intentionally left blank ...

Page 2087: ...AIRCRAFT DA 42 NG AMM Engine Fuel and Control Doc 7 02 15 Rev 4 73 TITLE Page 1 15 Mar 2018 CHAPTER 73 ENGINE FUEL AND CONTROL ...

Page 2088: ...AIRCRAFT Engine Fuel and Control DA 42 NG AMM Page 2 15 Mar 2018 73 TITLE Doc 7 02 15 Rev 4 Intentionally left blank ...

Page 2089: ...Rev 4 73 CONTENTS Page 1 15 Mar 2018 TABLE OF CONTENTS CHAPTER 73 ENGINE FUEL AND CONTROL 1 General 1 2 Description and Operation 4 Trouble Shooting 1 General 101 Maintenance Practices 1 General 201 2 Remove Install a Fuel Cooler if MÄM 42 600 is installed 201 ...

Page 2090: ...AIRCRAFT Engine Fuel and Control DA 42 NG AMM Page 2 15 Mar 2018 73 CONTENTS Doc 7 02 15 Rev 4 Intentionally left blank ...

Page 2091: ... fuel system of the AE E4 B engines and AE E4 C engines if MÄM 42 600 is installed It provides general data and trouble shooting information of the system Refer to the engine manufacturer s Repair Manual for the AE E4 engines You can replace components in the air intake system and the fuel system Refer to the engine manufacturer for data on the engine fuel system ...

Page 2092: ... Auxiliary Pump Inline Filter Solenoid Valve Fuel Selector Finger Filter Drain Low Level Fuel Sensor Fuel Temperature Sensor Inboard Chamber Main Tank Check Valve with Capilare Fuel Level Switch Fuel Cooler Drain Auxiliary Pump Inline Filter Check Valve Finger Filter Finger Filter Low Level Fuel Sensor Fuel Temperature Sensor Inboard Chamber Main Tank Drain Check Valve Solenoid Valve M M Fuel Pres...

Page 2093: ... 12 Main Fuel Tank Vent Line 13 Check Valve with Capilare 14 Outboard Fuel Level Sensor 15 Outboard Chamber Main Tank 16 Middle Chamber Main Tank 17 Inboard Fuel Level Sensor 18 Inboard Chamber Main Tank 19 Fuel Temperature Sensor 20 Low Level Fuel Sensor 21 Drain 22 Finger Filter 23 Nacelle 24 Fuel Cooler 25 Fuselage 26 Crossfeed Lines 27 Fuel Selector 28 Fuel Bypass Valve LH Wing shown RH Wing s...

Page 2094: ...alve If MÄM 42 600 is installed refer to Section 71 61 for more data on the air filter and alternate air valve The outlet from the alternate air valve connects to the turbo charger The outlet from the turbo charger connects to an intercooler The outlet from the intercooler connects to the engine intake manifold Refer to Section 81 00 for more data on the turbo charger and intercooler If MÄM 42 600...

Page 2095: ...er to the engine manufacturer If you have the trouble detailed in the Trouble column read across to the Possible Cause column Then do the repair given in the Repair column Trouble Possible Cause Repair Loss of engine power Blocked air intake Dirty damaged air filter Dirty damaged fuel filter Examine the air intake Remove any obstructions Refer to Section 71 60 or 71 61 Replace the air filter Refer...

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Page 2097: ... the turbo charging system 2 Remove Install a Fuel Cooler if MÄM 42 600 is installed A Remove a Fuel Cooler Obey the safety precautions for fuel at all times Detail Steps Work Items Key Items References 1 Make sure that the related FUEL SELECTOR lever is set to SHUT OFF In the cockpit 2 Disconnect the flexible hoses that connect to the fuel cooler S Remove the wire locking from the fuel hose conne...

Page 2098: ...02 15 Rev 4 Fuel Cooler Assembly Shock Mount Washer Nut Spray Shield P Clamp Bushing Washer Bolt Engine Mounting Frame Foam Profile Flexible Fuel Hose Flexible Fuel Hose O Ring Fitting O Ring Fitting Wire Locking Wire Locking Figure 3 Fuel Cooler Installation if MÄM 42 600 installed ...

Page 2099: ...pray shield into position on the engine mount S Align the cooler with the mounting hole on the engine mount and install the 2 bolts and washers that attach the fuel cooler to the engine mount 2 Connect the flexible hoses to the fuel cooler Secure fuel line connections with wire locking Make sure that you remove all the blanking caps 3 Do a test for leaks Specially at the flexible hose connections ...

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Page 2101: ...AIRCRAFT DA 42 NG AMM Liquid Cooling System Doc 7 02 15 Rev 4 75 TITLE Page 1 15 Mar 2018 CHAPTER 75 LIQUID COOLING SYSTEM ...

Page 2102: ...AIRCRAFT Liquid Cooling System DA 42 NG AMM Page 2 15 Mar 2018 75 TITLE Doc 7 02 15 Rev 4 Intentionally left blank ...

Page 2103: ...ral 201 2 Remove Install a Coolant Expansion Tank 201 3 Remove Install the Pressure Relief Valve 204 4 Remove Install Silicate Pouch If MÄM 42 852 is installed 206 5 Remove Install Coolant Level Sensor 207 6 Remove Install a Coolant Radiator 208 7 Fill and Bleed an Engine Cooling System 211 8 Drain the Engine Coolant System 214 9 Coolant System Pressure Test 216 10 Pressure Relief Valve Test 218 1...

Page 2104: ...AIRCRAFT Liquid Cooling System DA 42 NG AMM Page 2 15 Mar 2018 75 CONTENTS Doc 7 02 15 Rev 4 Intentionally left blank ...

Page 2105: ...IQUID COOLING SYSTEM 1 General This Section gives you the data for the liquid cooling system for the DA 42 NG airplane It gives you the Maintenance Practices to remove install the system components Figure 1 shows the liquid cooling system schematic diagram Figure 2 shows the installation in the airplane ...

Page 2106: ...System DA 42 NG AMM Page 2 15 Mar 2018 75 00 00 Doc 7 02 15 Rev 4 Radiator Cabin Heat Heat Exchanger Thermostat Bleed Screw Expansion Tank Engine Main Circuit Bypass Bleed Screw Figure 1 Liquid Cooling System Schematic Diagram ...

Page 2107: ... For the main circuit large diameter hoses and pipes connect the thermostat valve to the inlet of a coolant radiator The coolant radiator is located below the engine Large hoses and pipes connect the outlet from the coolant radiator to an inlet on the engine crankcase at the rear top This is the inlet to the engine coolant pump For the bypass circuit large diameter hoses and pipes connect the bypa...

Page 2108: ...rive Clamps Worm Drive Clamps Cool Coolant from Radiator Worm Drive Clamps Silicon Hose Water Pipe Silicon Hose Bleed Nipple B A B C Anti Vibration Mount A Engine Mounting Frame Bleed Nipple Pressure Relief Valve Worm Drive Clamps Radiator Guard Assy Worm Drive Clamps Worm Drive Clamps Worm Drive Clamp Anti Vibration Mount B Engine Mounting Frame Bonding Wire C Bonding Wire Anti Vibration Mount En...

Page 2109: ...ive Clamps Worm Drive Clamps Cool Coolant from Radiator Worm Drive Clamps Worm Drive Clamps Silicon Hose Silicon Hose Bleed Nipple A A Bleed Nipple Worm Drive Clamps A Anti Vibration Mount A Engine Mounting Frame Bonding Wire Aluminium Tube Aluminium Tube Worm Drive Clamps Worm Drive Clamps Pressure Relief Valve Worm Drive Clamps Worm Drive Clamp Worm Drive Clamps Figure 3 Liquid Cooling System In...

Page 2110: ...ool Coolant from Radiator Worm Drive Clamps Silicon Hose Water Pipe Silicon Hose Bleed Nipple B A B C Anti Vibration Mount A Engine Mounting Frame Bleed Nipple Pressure Relief Valve Worm Drive Clamps Radiator Guard Assy Worm Drive Clamps Worm Drive Clamps Worm Drive Clamp Anti Vibration Mount B Engine Mounting Frame Bonding Wire C Bonding Wire Anti Vibration Mount Engine Mounting Frame Worm Drive ...

Page 2111: ...ps Cool Coolant from Radiator Worm Drive Clamps Worm Drive Clamps Silicon Hose Silicon Hose Bleed Nipple A A Bleed Nipple Worm Drive Clamps A Anti Vibration Mount A Engine Mounting Frame Bonding Wire Aluminium Tube Aluminium Tube Worm Drive Clamps Worm Drive Clamps Pressure Relief Valve Worm Drive Clamps Worm Drive Clamp Worm Drive Clamps Silicate Pouch Coolant Level Sensor Figure 5 Liquid Cooling...

Page 2112: ...turns to the inlet of the coolant pump and mixes with the hot coolant from the bypass circulation The thermostat valve adjusts the flow of coolant through the main and bypass circuit to keep the correct temperature It starts opening at 80 C 176 F and fully opens at 95 C 203 F allowing the coolant to flow through the coolant radiator The connection for the cabin heat system supplies coolant at the ...

Page 2113: ... of the cooling system Trouble Possible Cause Repair Engine overheats Flat belt worn or broken Coolant level low Coolant leak Air in cooling system Radiator matrix blocked by foreign objects Thermostat valve defective Coolant pump defective Defective cylinder head gasket Refer to the engine manufacturer Fill the cooling system Refer to Section 12 10 Look for leaks at all system joints Repair or re...

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Page 2115: ...INJURY TO PERSONS WARNING YOU MUST MAKE SURE THAT THE ENGINE IS SAFE BEFORE YOU DO WORK ON THE ENGINE CONTROLS IF THE PROPELLER TURNS IT CAN CAUSE INJURY TO PERSONS Note Use only new worm drive clamps for hose installation of liquid cooling system 1 Make sure that the engine is safe S Set the ELECT MASTER switch to OFF S Set the ENGINE MASTER switch to OFF S Set the power lever to 0 2 Disconnect t...

Page 2116: ...lamp that secures the hose S Pull the hose from the connector at the expansion tank Use a suitable container to collect spilt coolant 6 Disconnect the electrical cables for the coolant level sensor At the inline connector at the sensor 7 Remove the hose from the coolant tank which connects to the thermostat vent S Remove the wire locking from the worm drive clamps S Remove the worm drive clamps an...

Page 2117: ... bypass vent to the expansion tank S Push the hoses onto the connector at the expansion tank S Install the worm drive clamps that secure the hose connections and apply torque seal no red of white torque seal color allowed Use only new worm drive clamps 6 Connect the hose that connects the expansion tank to the supply system S Push the hose onto the connector at the expansion tank S Install and tig...

Page 2118: ...SURE THAT THE ENGINE IS SAFE BEFORE YOU DO WORK ON THE ENGINE CONTROLS IF THE PROPELLER TURNS IT CAN CAUSE INJURY TO PERSONS 1 Make sure that the engine is safe S Set the ELECT MASTER switch to OFF S Set the ENGINE MASTER switch to OFF S Set the power lever to 0 2 Remove the engine cowlings Refer to Section 71 10 or 71 11 WARNING DO NOT REMOVE THE PRESSURE CAP FROM THE COOLANT TANK IF THE ENGINE I...

Page 2119: ...ressure Relief Valve Detail Steps Work Items Key Items References 1 Install the pressure relief valve Torque 12 15 Nm 8 85 11 06 lbf ft Check O ring for deformation and delocation Apply EZ TURN 2 Install locking wire Wire diameter 0 8 mm 0 032 in 3 Install the engine cowlings Refer to Section 71 10 or 71 11 ...

Page 2120: ... be resident in the system S Turn the cap counterclockwise a small distance to release the pressure S When the pressure has fully released turn the cap fully counterclockwise 4 Remove retaining ring inside the filler neck 5 Remove max coolant level plate 6 Remove the used silicate pouch and replace it with the new silicate pouch Remove cartridge and clean it with water Reinstall cartridge 7 Instal...

Page 2121: ...he filler cap on the coolant expansion tank 3 Remove the filler cap from the coolant tank to relief any pressure which may be resident in the system S Turn the cap counterclockwise a small distance to release the pressure S When the pressure has fully released turn the cap fully counterclockwise 4 Drain engine cooling system Refer to Paragraph 8 5 Disconnect the electrical cables for the coolant l...

Page 2122: ...sure that the engine is safe S Set the ELECT MASTER switch to OFF S Set the ENGINE MASTER switch to OFF S Set the power lever to 0 2 Disconnect the airplane main battery Refer to Section 24 34 3 Remove the engine cowlings Refer to Section 71 10 or 71 11 WARNING DO NOT REMOVE THE PRESSURE CAP FROM THE COOLANT TANK IF THE ENGINE IS HOT THE PRESSURE IN THE SYSTEM CAN FORCE HOT COOLANT TO COME OUT AND...

Page 2123: ...ive clamps that secure the hoses S Pull the hoses from the connectors on the radiator Note the position and orientation of the hoses on the radiator 7 Remove the radiator S Remove the nuts washers and bolts that attach the radiator guard assy to the radiator S Remove the nuts washers and bolts that attach the radiator to the engine mounting frame S Move the radiator clear of the engine nacelle ...

Page 2124: ... to the engine mounting frame Refer to Figure 2 2 Install the hoses onto the radiator that you removed in Paragraph 6A step 5 S Install the radiator hoses onto the radiator connections S Secure the hoses with worm drive clamps and apply torque seal no red of white torque seal color allowed In the position and orientation noted in Paragraph 6A step 5 Use new worm drive clamps 3 Fill and bleed the l...

Page 2125: ...E THAT THE ENGINE IS SAFE BEFORE YOU DO WORK ON THE ENGINE CONTROLS IF THE PROPELLER TURNS IT CAN CAUSE INJURY TO PERSONS 1 Make sure that the engine is safe S Set the ELECT MASTER switch to OFF S Set the ENGINE MASTER switch to OFF S Set the power lever to 0 2 Disconnect the airplane main battery Refer to Section 24 31 3 Remove the engine cowlings Refer to Section 71 10 or 71 11 WARNING DO NOT RE...

Page 2126: ...ng for deformation S Install the filler cap to the coolant expansion tank S Install safety lock wire to secure filler cap Allow time for coolant to move through the system Renew if necessary Apply EZ TURN Refer to Section 20 70 Torque 12 15 Nm 8 85 11 06 lbf ft Wire diameter 0 8 mm 0 032 in 5 Do an engine ground run S Let the coolant temperature rise up to the point where the coolant flows from th...

Page 2127: ...ler cap from the coolant tank S Turn the cap counterclockwise a small distance to release the pressure S When the pressure has fully released remove the cap 8 Check coolant level Repeat steps 1 to 4 until the system is completely free of trapped air and the fluid level is at the coolant tank tab 9 Install engine cowlings Refer to Section 71 10 or 71 11 ...

Page 2128: ...NS 1 Make sure that the engine is safe S Set the ELECT MASTER switch to OFF S Set the ENGINE MASTER switch to OFF S Set the power lever to 0 2 Disconnect the airplane main battery Refer to Section 24 31 3 Remove the engine cowlings Refer to Section 71 10 or 71 11 WARNING DO NOT REMOVE THE FILLER CAP FROM THE COOLANT TANK IF THE ENGINE IS HOT THE PRESSURE IN THE SYSTEM CAN FORCE HOT COOLANT TO COME...

Page 2129: ...s Work Items Key Items References Doc 7 02 15 Rev 4 75 00 00 Page 215 15 Mar 2018 5 Drain the coolant system S Remove the safety lock wire from the drain plug at the coolant radiator S Remove the drain plug from the bottom left side of the coolant radiator ...

Page 2130: ...RE YOU DO WORK ON THE ENGINE CONTROLS IF THE PROPELLER TURNS IT CAN CAUSE INJURY TO PERSONS 1 Make sure that the engine is safe S Set the ELECT MASTER switch to OFF S Set the ENGINE MASTER switch to OFF S Set the power lever to 0 2 Disconnect the airplane main battery Refer to Section 24 31 3 Remove the engine cowlings Refer to Section 71 10 or 71 11 WARNING DO NOT REMOVE THE PRESSURE CAP FROM THE...

Page 2131: ...nutes 0 1 bar 1 45 PSI 7 Check the coolant system for leaks 8 Remove the pressure test equipment from the coolant tank S Open the pressure relief valve S Remove the test equipment carefully to relieve the remaining pressure If existent 9 Remove blind plug Install the over pressure valve 10 Install the cap to the coolant tank 11 Install engine cowlings Refer to Section 71 10 or 71 11 12 Connect the...

Page 2132: ...OPELLER CAN CAUSE DEATH OR INJURY TO PERSONS WARNING YOU MUST MAKE SURE THAT THE ENGINE IS SAFE BEFORE YOU DO WORK ON THE ENGINE CONTROLS IF THE PROPELLER TURNS IT CAN CAUSE INJURY TO PERSONS 1 Make sure that the engine is safe S Set the ELECT MASTER switch to OFF S Set the ENGINE MASTER switch to OFF S Set the power lever to 0 2 Disconnect the airplane main battery Refer to Section 24 31 3 Remove...

Page 2133: ...t open depressurize the coolant system by opening the pressure relief valve of the test equipment Mechanically open the PRV by pulling on the outer ring until it moves approx 2 mm 0 08 in outward Remove the PRV S Clean the PRV with water S Install the PRV S Repeat the PRV test If the PRV does not open between 1 8 and 2 3 bar 26 1 and 33 4 PSI Replace the PRV with a new PRV 7 Remove the pressure te...

Page 2134: ...PERSONS 1 Drain the engine cooling system Refer to Paragraph 6 2 Remove the coolant expansion tank Refer to Paragraph 2 3 Remove the lock wire from the cartridge cap 4 Remove the cartridge cap 5 Remove the used silicate pouch and replace it with the new silicate pouch 6 Replace the used O ring with a new O ring Grease O ring with EZ TURN lubricant 7 Install the cartridge cap Torque 32 5 2 5 Nm 24 ...

Page 2135: ...AIRCRAFT DA 42 NG AMM Engine Controls Doc 7 02 15 Rev 4 76 TITLE Page 1 15 Mar 2018 CHAPTER 76 ENGINE CONTROLS ...

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Page 2137: ...CONTENTS CHAPTER 76 ENGINE CONTROLS 1 General 1 2 Description and Operation 1 Trouble Shooting 1 General 101 Maintenance Practices 1 General 201 2 Remove Install a Hall Angle Sensor 201 3 Remove Install an Engine Control Unit ECU 208 4 Remove Install an Engine Control System Electrical Harness 210 ...

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Page 2139: ...n electronic engine control unit EECU Each electronic engine control unit has two independent computers ECU A and ECU B either of which can provide all control functions for the engine and propeller Each engine control system consists of the following componants One EECU located in the engine nacelle An electrical harness that connects the ECUs to the engine the power lever the annunciator panel c...

Page 2140: ...t Pressure Actuator Rail Pressure Control Valve Governor Actuator Fuel Metering Unit Crankshaft 1 Crankshaft 2 Camshaft 1 Camshaft 2 Fuel Rail Pressure Intake Air Temp 1 Intake Air Temp 2 Boost Pressure 1 Boost Pressure 2 Coolant Temp Oil Pressure Oil Temp Gearbox Temp Fuel Pressure Engine Sensors Controlled Components 28 VDC 28 VDC L R ECU A FAIL L R ECU B FAIL L R GLOW ON L R FUEL PRESS L R OIL ...

Page 2141: ...et to AUTO and one ECU controls the engine The ECU TEST buttons on the left of the instrument panel let you test the systems Refer to Section 71 00 for the ECU test procedure B Electrical Harness Each engine has a dedicated engine electrical harness The electrical harness is an engine component The harness connects the power lever and sensors to the ECU A and ECU B It also provides connections for...

Page 2142: ...8 76 00 00 Doc 7 02 15 Rev 4 Push Rod Assy RH Push Rod Assy LH Power Lever RH Power Lever LH 2 Signal Hall Angle Sensors LH Throttle Knob Cover Plate Thumb Switch Washer Nut Screw Connector 2 Pins 2 Signal Hall Angle Sensors RH Figure 2 Engine Power Levers ...

Page 2143: ...ers assemble as a unit to the engine control assembly in the center console Each power lever has two separate and independent electrical systems One system provides signals to the ECU A The other system provides signals to the ECU B Either system can control the engine The levers operate electrical sensors HALL effect that give signals in proportion to the power lever position The signals are used...

Page 2144: ...e Camshaft 1 Front between camshafts Camshaft 2 Aft between camshafts Coolant temperature Beneath the air intake manifold Oil temperature On the top side of the oil sump Oil pressure Behind the oil filter Manifold air temperature 1 and 2 On the air intake manifold Manifold air pressure 1 and 2 On the air intake manifold Fuel rail pressure At the front of the fuel rail Gearbox temperature At the ba...

Page 2145: ... Possible Cause column Then do the repair given in the Repair column For all other engine control trouble refer to the engine manufacturer Trouble Possible Cause Repair An ECU caution light comes ON The related ECU defective Read engine event log refer to Section 72 00 Refer to the engine manufacturer An engine does not respond correctly to power lever movement Run diagnostic routine in ECU Operat...

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Page 2147: ...e Install a Hall Angle Sensor A Remove a Hall Angle Sensor Detail Steps Work Items Key Items References 1 Make sure that the engines are safe S Set the ELECT MASTER switch to OFF S Set both ENGINE MASTER switches to OFF S Set the power lever to 0 2 Lift the power lever control quadrant from the center console S Remove the 4 screws that attach the top covers to the power lever quadrant S Remove the...

Page 2148: ...S Disconnect the electrical cables for the hall angle sensor that you will remove S Remove the 2 bolts and washers that attach the hall angle sensor that you will remove to the power lever quadrant S Pull the hall angle sensor of its drive shaft and clear of the quadrant The flexible cables attached to the other control levers in the quadrant and the electrical cables for the sensor are long enoug...

Page 2149: ...e shaft S Push the sensor onto the quadrant drive shaft S Install the 2 washers and bolts that attach the sensor to the quadrant 2 Connect the electrical cables for the hall angle sensor At the inline connector 3 Install the power lever quadrant into the center console S Lower the quadrant into position in the center console S Install the 2 screws that attach the aft end of the quadrant to the fue...

Page 2150: ...efer to Section 71 00 5 If necessary adjust the power lever alignment S Lift the power lever control quadrant from the center console S Loosen the 2 jam nuts on the sensor link rod for the hall angle sensor that you replaced S Turn the drive rod to adjust the length of the link rod to align the power levers S Tighten the jam nuts on the sensor link rod S Install the power lever control quadrant in...

Page 2151: ...15 Mar 2018 7 Install the top covers on the power lever quadrant S Move the top covers into position on the power lever control quadrant S Install the 4 screws that attach the top covers to the power lever control quadrant 8 Do a full test of the engine for which you replaced the hall angle sensor Refer to Section 71 00 ...

Page 2152: ...trols DA 42 NG AMM Page 206 15 Mar 2018 76 00 00 Doc 7 02 15 Rev 4 Bolt Washer Bolt Washer Bolt Washer Bolt Washer Inner ECU Mounting Bracket Outer ECU Mounting Bracket ECU Electrical Connections Figure 3 ECU Installation ...

Page 2153: ...AIRCRAFT DA 42 NG AMM Engine Controls Doc 7 02 15 Rev 4 76 00 00 Page 207 15 Mar 2018 Inner ECU Mounting Bracket Outer ECU Mounting Bracket ECU Electrical Connections Figure 4 ECU Installation ...

Page 2154: ...es and engine serial number Refer to the AE Maintenance Manual latest revision 2 Make sure that the engine is safe S Set the ELECT MASTER switch to OFF S Set the ENGINE MASTER switch to OFF S Set the power lever to 0 3 Disconnect the airplane main battery Refer to Section 24 31 4 Remove the access panel for the ECU on the related engine nacelle Refer to Section 52 40 5 Release the 3 electrical con...

Page 2155: ...r mounting bracket to the ECU Refer to Figure 3 3 Install the ECU S Move the ECU into position in the related engine nacelle by sliding the ECU into the bracket S Install the 2 washers and bolts that attach the ECU to the mounting bracket and use Loctite 243 to secure the bolts Refer to Figure 4 4 Connect the 3 electrical connectors to the ECU Refer to Figure 4 5 Install the access panel Refer to ...

Page 2156: ...FE BEFORE YOU DO WORK ON THE ENGINE IF THE PROPELLER TURNS IT CAN CAUSE INJURY TO PERSONS 1 Make sure that the engine is safe S Set the ELECT MASTER switch to OFF S Set the ENGINE MASTER switch to OFF S Set the power lever to 0 2 Disconnect the airplane main battery Refer to Section 24 31 3 Remove the access panel for the ECU on the related engine nacelle Refer to Section 52 40 4 Release the 3 ele...

Page 2157: ...oc 7 02 15 Rev 4 76 00 00 Page 211 15 Mar 2018 Direction of Flight Air Filter Box Turbocharger Fuel High Pressure Pump Fuel Line Pressure Sensor Propeller Flange Radiator Exhaust Cabin Heat Exchanger Figure 5 Engine Sensors RH Side of Engine ...

Page 2158: ...rol valve At the front right crank case At the front left crank case On inlet valve cover between cyl 3 and 4 On inlet valve cover between cyl 1 and 2 At the bottom of the oil case At the rear side of the oil filter housing At the rear end of the fuel rail At the front side of the fuel rail At the inlet of the high pressure pump At the backside of the gearbox next to the starter At each fuel injec...

Page 2159: ...ature Sensor Camshaft Sensor Crankshaft Sensor Screw Crankshaft Sensor Coolant Temperature Sensor O Ring Coolant Thermostat Housing Oil Filter Housing Oil Pressure Sensor Fuel Rail Temperature Sensor Gearbox Temperature Sensor Screw Oil Temperature Sensor Figure 6 Engine Sensors LH Side of Engine ...

Page 2160: ... S Propeller governor S Gear temperature S Waste gate valve solenoid S Fuel injectors S Glow plugs S Waste gate control valve At the front right crank case At the front left crank case On inlet valve cover between cyl 3 and 4 On inlet valve cover between cyl 1 and 2 Beneath the air intake manifold At the bottom of the oil case At the rear side of the oil filter housing On the intercooler outlet pi...

Page 2161: ...ring removal for the type and location of each attachment 6 Install the shields for the feed through at the firewall Seal with PR 812 or equivalent 7 Install the engine cowlings Refer to Section 71 10 or 71 11 8 Install the access panels in the engine nacelle Refer to Section 52 40 9 Connect the main airplane battery Refer to Section 24 31 10 Do an engine run up of the engine for which you replace...

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Page 2163: ...AIRCRAFT DA 42 NG AMM Engine Indicating Doc 7 02 15 Rev 4 77 TITLE Page 1 15 Mar 2018 CHAPTER 77 ENGINE INDICATING ...

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Page 2165: ...15 Mar 2018 TABLE OF CONTENTS CHAPTER 77 ENGINE INDICATING 1 General 1 2 Description and Operation 1 Section 77 40 Engine Indicating System 1 General 1 2 Description and Operation 1 Trouble Shooting 1 General 101 Maintenance Practices 1 General 201 2 Replace Install a Sensor 203 ...

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Page 2167: ... shows a schematic diagram of the engine control and indication system Refer to Section 76 00 for data about the engine control system The ICS also shows airframe fuel system data Refer to Section 28 40 for data about the airframe parts of the system 2 Description and Operation The ICS gives all engine indications The ICS displays are located in the left and right sides of the instrument panel Eac...

Page 2168: ...ressure Actuator Rail Pressure Control Valve Governor Actuator Fuel Metering Unit Crankshaft 1 Crankshaft 2 Camshaft 1 Camshaft 2 Fuel Rail Pressure Intake Air Temp 1 Intake Air Temp 2 Boost Pressure 1 Boost Pressure 2 Coolant Temp Oil Pressure Oil Temp Gearbox Temp Fuel Pressure Engine Sensors Controlled Components 28 VDC 28 VDC L R ECU A FAIL L R ECU B FAIL L R GLOW ON L R FUEL PRESS L R OIL PRE...

Page 2169: ...tons Refer to Section 31 40 for more data about the ICS The engine control units EECUs provide most of the indications for the engines Refer to Section 76 00 for data about the engine control system The ICS also shows fuel and systems data Refer to Section 28 40 for data about the airframe parts of the system 2 Description and Operation The ICS displays the engine indications for both engines on t...

Page 2170: ...RS BARO PROC ENT NAV1 GS MAP NAVIGATION MAP 108 00 117 95 136 975 118 000 108 00 117 95 NAV2 WPT AUX MAP ENGINE FUEL QTY GAL FUEL TEMP OIL TEMP LOAD 3000 100 2000 80 1000 60 600 40 20 73 FUEL FLOW GPH RPM NRST 0 0 0 0 120KT XTK 0 09NM ETE 10 11 ESA 3700FT 136 975 COM1 COM2 118 000 75 1800 1800 7 2 8 1 R L OIL PRESS R L R L R L R L 0 5 10 15 20 25 MAP 150NM DCLTR CHKLIST Figure 1 Display Screen Int...

Page 2171: ...on 28 40 LH and RH main fuel tank temperature in C Refer to Section 28 40 LH and RH engine fuel flow in gals hour Refer to Section 28 40 Engine alerts are given on the PFD screen A flashing warning annunciator appears in the PFD when an alert is activated Pressing the WARNING softkey at the bottom of the PFD opens an alert window in the PFD The alerts window gives more details of the alert The ICS...

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Page 2173: ...iled in the Trouble column read across to the Possible Cause column Then do the repair given in the Repair column Trouble Possible Cause Repair One of the indicators in an integrated instrument does not indicate correctly Sensor transducer defective Do a test for continuity of the cables for the relevant sensor If the cables are serviceable then refer to the engine manufacturer Refer to Section 28...

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Page 2175: ...replace the following sensors Crankshaft RPM Gearbox oil temperature Liquid coolant temperature Engine oil temperature Engine oil pressure Refer to the related Chapter for maintenance data on the sensors Where the engine control system provides data for the engine indicating system only the engine manufacturer or a AE approved maintenance shop can replace sensors ...

Page 2176: ...AIRCRAFT Engine Indicating DA 42 NG AMM Page 202 15 Mar 2018 77 40 00 Doc 7 02 15 Rev 4 Screw Screw Crankshaft Sensor Crankshaft Sensor Figure 2 Crankshaft RPM Sensor Installation ...

Page 2177: ...Y TO PERSONS WARNING YOU MUST MAKE SURE THAT THE ENGINE IS SAFE BEFORE YOU DO WORK ON THE ENGINE CONTROLS IF THE PROPELLER TURNS IT CAN CAUSE INJURY TO PERSONS 1 Make sure that the related engine is safe S Set the ELECT MASTER switch to OFF S Set the ENGINE MASTER switch to OFF S Set the power lever to 0 2 Disconnect the airplane main battery Refer to Section 24 31 3 Remove the engine cowlings Ref...

Page 2178: ...AIRCRAFT Engine Indicating DA 42 NG AMM Page 204 15 Mar 2018 77 40 00 Doc 7 02 15 Rev 4 Fuel Metering Valve Figure 3 Fuel Metering Valve Installation ...

Page 2179: ...IRCRAFT DA 42 NG AMM Engine Indicating Doc 7 02 15 Rev 4 77 40 00 Page 205 15 Mar 2018 Coolant Temperature Sensor O Ring Coolant Thermostat Housing Figure 4 Engine Coolant Temperature Sensor Installation ...

Page 2180: ...AIRCRAFT Engine Indicating DA 42 NG AMM Page 206 15 Mar 2018 77 40 00 Doc 7 02 15 Rev 4 Oil Temperature Sensor Figure 5 Engine Oil Temperature Sensor Installation ...

Page 2181: ...AIRCRAFT DA 42 NG AMM Engine Indicating Doc 7 02 15 Rev 4 77 40 00 Page 207 15 Mar 2018 Oil Pressure Sensor Oil Filter Housing Figure 6 Engine Oil Pressure Sensor Installation ...

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Page 2183: ...AIRCRAFT DA 42 NG AMM Exhaust Doc 7 02 15 Rev 4 78 TITLE Page 1 15 Mar 2018 CHAPTER 78 EXHAUST ...

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Page 2185: ...ust Doc 7 02 15 Rev 4 78 CONTENTS Page 1 15 Mar 2018 TABLE OF CONTENTS CHAPTER 78 EXHAUST 1 General 1 2 Description 1 Trouble Shooting 1 General 101 Maintenance Practices 1 General 201 2 Remove Install an Engine Exhaust Pipe 201 ...

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Page 2187: ...a single short exhaust pipe that bolts to the turbo charger outlet and passes through the engine cowling at the bottom 2 Description Figure 1 shows the engine exhaust system You cannot do any maintenance on the exhaust pipe The exhaust pipe does not have a muffler If MÄM 42 600 is installed Figure 2 shows the engine exhaust system The exhaust system has a fixed integral muffler ...

Page 2188: ...0 Doc 7 02 15 Rev 4 Engine Exhaust Manifold Turbocharger Nut Mounting Flange LH engine shown RH engine similar Exhaust Pipe Exhaust Heatshield Gasket Washer Anti Vibration Mount Engine Mounting Frame Nut Nut Washer Washer Figure 1 Exhaust System Installation ...

Page 2189: ...Engine Exhaust Manifold Turbocharger Nut Mounting Flange LH engine shown RH engine similar Exhaust Pipe Gasket Washer Nut Washer Engine Mounting Frame Shock Mount Bolt Washer Heat Shield Muffler Bracket on Muffler Figure 2 Exhaust System Installation if MÄM 42 600 is installed ...

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Page 2191: ...the trouble detailed in the Trouble column read across to the Possible Cause column Then do the repair given in the Repair column Trouble Possible Cause Repair More noise than usual Exhaust pipe cracked Look for signs of exhaust gas leaks Replace cracked pipes Signs of exhaust gas leaks in the engine compartment Exhaust pipe cracked Look for signs of exhaust gas leaks Replace cracked pipes ...

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Page 2193: ...ferences WARNING DO NOT STAND WITHIN THE DANGER AREA OF THE PROPELLER IF THE ENGINE STARTS THE PROPELLER CAN CAUSE DEATH OR INJURY TO PERSONS WARNING YOU MUST MAKE SURE THAT THE ENGINE IS SAFE BEFORE YOU DO WORK ON THE ENGINE CONTROLS IF THE PROPELLER TURNS IT CAN CAUSE INJURY TO PERSONS 1 Make sure that the related engine is safe S Set the ENGINE MASTER switch to OFF S Set the ELECT MASTER switch...

Page 2194: ... Move the exhaust pipe flange over the studs on the turbo charger outlet S Install the 4 special nuts that attach the exhaust pipe to the turbo charger outlet S Install the anti vibration mount to the exhaust Use new nuts 2 Install the engine cowlings Refer to Section 71 10 or 71 11 3 Connect the airplane main battery 4 Do an engine ground run up and then check the exhaust pipe for leaks Specially...

Page 2195: ...AIRCRAFT DA 42 NG AMM Oil Cooling Doc 7 02 15 Rev 4 79 TITLE Page 1 15 Mar 2018 CHAPTER 79 OIL COOLING ...

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Page 2197: ...NG 1 General 1 Trouble Shooting 1 General 101 Maintenance Practices 1 General 201 2 Remove Install the Gearbox Cooling System if MÄM 42 600 is Installed 201 3 Drain the Engine Oil with the Engine Oil Quick Drain 203 4 Refill the Engine Oil with the Engine Oil Quick Drain 204 5 Remove Install the Quick Oil Drain Valve 205 ...

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Page 2199: ...ing oil mist overboard A small hose connects the bottom of the oil separator to the oil sump To protect the breather system from blockage due to icing of the moistured blow by gases an engine integrated over pressure valve is provided below the injector cover An oil pump in the engine takes oil from the sump The oil flows through a filter to the oil water heat exchanger Air passing through the oil...

Page 2200: ...2 15 Mar 2018 79 00 00 Doc 7 02 15 Rev 4 Washer Nut Gearbox Cooler Cap Gearbox Cooling Fins Distance Bolt Bushing Washer Nut Washer Nut Bushing Bushing Distance Bolt Distance Bolt Figure 1 Gearbox Oil Cooling Fins if MÄM 42 600 is installed ...

Page 2201: ...e repair given in the Repair column Trouble Possible Cause Repair An engine oil temperature is too high Oil cooler blocked internally Low oil level Contact engine manufacturer Refill oil Refer to Section 12 10 An engine oil pressure too high Defective oil pressure sensor Refer to AE Maintenance Manual An engine oil pressure too low at normal operating temperatures Low oil level Defective oil press...

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Page 2203: ...SURE THAT THE ENGINE IS SAFE BEFORE YOU DO WORK ON THE ENGINE CONTROLS IF THE PROPELLER TURNS IT CAN CAUSE INJURY TO PERSONS 1 Make sure that the engine is safe S Set the ELECT MASTER switch to OFF S Set the ENGINE MASTER switch to OFF S Set the power lever to 0 2 Disconnect the airplane main battery Refer to Section 24 34 3 Remove the engine cowlings Refer to Section 71 10 4 Remove the 3 nuts and...

Page 2204: ...he gearbox oil inspection window If not rework the cutout on the cooling fin to match the gearbox oil inspection window S Apply heat transfer compound Keratherm KP 98 to the backside of the cooling fins assy S Install the 3 bushings length according to the bolts S Install 3 nuts on the 3 bolts S Remove the excess heat compound S Remove the 3 nuts from the 3 bolts Use a notched spattle 3 Install th...

Page 2205: ...THE ENGINE STARTS THE PROPELLER CAN CAUSE DEATH OR INJURY TO PERSONS WARNING YOU MUST MAKE SURE THAT THE ENGINE IS SAFE BEFORE YOU DO WORK ON THE ENGINE CONTROLS IF THE PROPELLER TURNS IT CAN CAUSE INJURY TO PERSONS 1 Make sure that the engine is safe S Set the ELECT MASTER switch to OFF S Set the ENGINE MASTER switch to OFF S Set the power lever to 0 2 Disconnect the airplane main battery Refer t...

Page 2206: ...OU DO NOT USE APPROVED ENGINE OIL THE ENGINE CAN BE DAMAGED 3 Refill engine oil 4 Install oil dipstick and check oil level 5 Install the engine cowlings Refer to Section 71 10 or 71 11 6 Do a ground test of the related engine allow the engine to reach normal operating temperatures Refer to Section 71 00 and AE Maintenance Manual latest revision 7 Do a test for oil leaks S Remove the engine cowling...

Page 2207: ...ck oil drain valve B Install the Quick Oil Drain Valve Detail Steps Work Items Key Items References 1 Turn in the oil quick drain with new O ring and torque it with 14 Nm 10 3 lbf ft 2 Secure the oil quick drain with safety wire diameter 0 8 mm 0 032 in 3 Refill engine oil 4 Do a test for oil leaks S Remove the engine cowlings S Look for oil leaks specially in the areas where you have done work S ...

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Page 2209: ...AIRCRAFT DA 42 NG AMM Starting Doc 7 02 15 Rev 4 80 TITLE Page 1 15 Mar 2018 CHAPTER 80 STARTING ...

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Page 2211: ...ENTS CHAPTER 80 STARTING 1 General 1 2 Description and Operation 1 Trouble Shooting 1 General 101 Maintenance Practices 1 General 201 2 Remove Install an Engine Master Switch 201 3 Remove Install the Engine Start Switch 204 4 Remove Install an Engine Start Relay 207 5 Replace the Glow Fuse 210 ...

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Page 2213: ...The ELECT MASTER rocker switch is located on the bottom left of the instrument panel Push the rocker to supply power to the main left and right bus bars LEFT ENGINE and RIGHT ENGINE switches located on the bottom left of the instrument panel controls the ground connection for the related engine starter relays This switch must be set to ON for the starter system to operate A key operated START swit...

Page 2214: ...in Battery Battery Relay External Power Relay External Power Connector R E L A Y J U N C T I O N B O X B U S 5 RH Main Bus Starter Relay To ICS To ICS RH Starter LH Starter Engine Master RH Engine Master LH Terminal Block Start Switch Figure 1 Engine Starter System Schematic Diagram ...

Page 2215: ...epair The starter does not operate when the ELECT MASTER switch is set to ON the related ENGINE MASTER and the related engine START key switch is set to START LEFT or START RIGHT The airplane main battery is discharged The related ENGINE MASTER switch is defective The ENGINE START key switch is defective The starter relay is defective The related engine starter motor assembly is defective A cable ...

Page 2216: ...fter the key is released from the START LEFT START RIGHT position The related starter relay is defective The related starter solenoid is defective Replace the related starter relay Refer to the engine manufacturer Difficult cold starting Glow plugs worn Glow fuse defective Replace the glow plugs Refer to the engine manufacturer Replace the fuse ...

Page 2217: ...ences WARNING MAKE SURE THAT THE ENGINE IS SAFE BEFORE YOU DO ANY WORK ON THE STARTER SYSTEM IF THE ENGINE STARTS THE PROPELLER CAN CAUSE INJURY OR DEATH 1 Disconnect the airplane main battery and the ECU backup batteries too Refer to Section 24 30 and 24 31 2 Remove the instrument panel cover Refer to Section 25 10 3 Remove the lower placard panel from the instrument panel Refer to Section 11 30 ...

Page 2218: ...rting DA 42 NG AMM Page 202 15 Mar 2018 80 00 00 Doc 7 02 15 Rev 4 Engine Master Switch RH Engine Master Switch LH Engine Start Switch Placard Panel Screw Figure 2 Engine Master Switch and Start Switch Installation ...

Page 2219: ...ment panel S Install the washer and nut onto the front of the switch Refer to Chapter 92 for the wiring diagrams Make sure that the switch is correctly orientated 2 Install the lower placard panel onto the instrument panel Refer to Section 11 30 3 Install the instrument panel cover and connect the ECU backup batteries too Refer to Section 24 30 and 25 10 4 Connect the airplane main battery Refer t...

Page 2220: ...USE INJURY OR DEATH 1 Disconnect the airplane main battery Refer to Section 24 31 2 Remove the instrument panel cover Refer to Section 25 10 3 Remove the lower placard panel from the instrument panel Refer to Section 11 30 4 Remove the START switch S Remove the nut and washer from the front of the instrument panel S Move the switch forward and clear of the instrument panel S Hold the switch and di...

Page 2221: ...nto position in the instrument panel S Install the washer and nut onto the front of the switch Refer to Chapter 92 for the wiring diagrams Make sure that the switch is correctly orientated 2 Install the lower placard panel onto the instrument panel Refer to Section 11 30 3 Install the instrument panel cover Refer to Section 25 10 4 Connect the airplane main battery Refer to Section 24 31 5 Do an e...

Page 2222: ...AIRCRAFT Starting DA 42 NG AMM Page 206 15 Mar 2018 80 00 00 Doc 7 02 15 Rev 4 Starter Relay Bolt Washer Washer Figure 3 Engine Starter Relay Installation ...

Page 2223: ... SYSTEM IF THE ENGINE STARTS THE PROPELLER CAN CAUSE INJURY OR DEATH 1 Disconnect the airplane main battery Refer to Section 24 31 2 Open the front baggage compartment door left side for access to the relay panel Refer to Figure 3 3 Disconnect the control cables from the starter relay At the terminal block 4 Remove the starter relay S Remove the 2 bolts and washers that attach the relay to the rel...

Page 2224: ... into position in the relay panel S Install the 2 washers and bolts that attach the relay to the relay panel 2 Connect the control cables to the relay At the terminal block 3 Connect the airplane main battery Refer to Section 24 31 4 Close and secure the front baggage compartment door 5 Start the related engine and do a test for the correct operation of the engine starting system Refer to Section ...

Page 2225: ...AIRCRAFT DA 42 NG AMM Starting Doc 7 02 15 Rev 4 80 00 00 Page 209 15 Mar 2018 LH shown RH similar Relay Panel Fuse Holder Fuse Washer Nut Relay Washer Bolt Figure 4 Engine Glow Fuse Installation ...

Page 2226: ...0 3 Remove the fuse S Loosen the nut that attaches the electrical cable and fuse to the fuse holder S Loosen the nut that attaches the bus bar link and fuse to the fuse holder S Pull the fuse clear of the fuse holder Refer to Figure 4 Top side Do not remove the nut Bottom side Do not remove the nut 4 Install a new fuse S Move the new fuse into position at the fuse holder S Tighten the 2 nuts 5 Ins...

Page 2227: ...AIRCRAFT DA 42 NG AMM Turbo Charger Doc 7 02 15 Rev 4 81 TITLE Page 1 15 Mar 2018 CHAPTER 81 TURBO CHARGER ...

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Page 2229: ...Description 1 3 Operation 3 Trouble Shooting 1 General 101 Maintenance Practices 1 General 201 2 Remove Install an Engine Intercooler 201 Section 81 01 Turbo Charger if MÄM 42 600 is installed 1 General 1 2 Description 1 3 Operation 3 Trouble Shooting 1 General 101 Maintenance Practices 1 General 201 2 Remove Install an Engine Intercooler 201 ...

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Page 2231: ...gine nacelle A rotating cage in the alternate air valve can be set to take air into the air inlet system through the filter or it can be set to take unfiltered air directly from the engine nacelle Refer to Section 71 60 for more data about the air filter and the alternate air valve The outlet from the alternate air valve connects to the turbo charger inlet The turbo charger compresses the air This...

Page 2232: ...AIRCRAFT Turbo Charger DA 42 NG AMM Page 2 15 Mar 2018 81 00 00 Doc 7 02 15 Rev 4 Figure 1 Engine Turbo Charger Schematic Diagram ...

Page 2233: ... The waste gate opening is controlled by the engine EECU Ambient air flows through the air filter normal operation or from the engine nacelle alternate air operation into the turbo charger compressor The air gains heat while being compressed in the turbo charger The hot compressed air flows through an aluminum tube and a flexible hose to the intercooler In the intercooler the hot compressed air is...

Page 2234: ...AIRCRAFT Turbo Charger DA 42 NG AMM Page 4 15 Mar 2018 81 00 00 Doc 7 02 15 Rev 4 Note Apply torque seal on all worm drive clamps Figure 2 Intercooler Installation ...

Page 2235: ...lamps Worm Drive Clamps Tube Clamp Outlet Hose Intercooler Anti Vibration Mount Air Intake Engine Inlet Manifold Worm Drive Clamps Worm Drive Clamps Turbocharger Engine Mounting Frame Intercooler Guard Assy Worm Drive Clamps Protective Pads A A A Figure 3 Intercooler Installation if MÄM 42 792 is installed ...

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Page 2237: ...trouble detailed in the Trouble column read across to the Possible Cause column Then do the repair given in the Repair column Trouble Possible Cause Repair An engine inlet manifold pressure is too low too high Waste gate valve defective Refer to the engine manufacturer Inlet air temperature too high Intercooler matrix blocked damaged Clear intercooler matrix of obstructions Replace intercooler if ...

Page 2238: ...AIRCRAFT Turbo Charger DA 42 NG AMM Page 102 15 Mar 2018 81 00 00 Doc 7 02 15 Rev 4 Intentionally left blank ...

Page 2239: ...nnections except such secured with self locking nuts in the charge air system must be secured with lock wire A Remove an Engine Intercooler Detail Steps Work Items Key Items References WARNING DO NOT STAND WITHIN THE DANGER AREA OF THE PROPELLER IF THE ENGINE STARTS THE PROPELLER CAN CAUSE DEATH OR INJURY TO PERSONS WARNING YOU MUST MAKE SURE THAT THE ENGINE IS SAFE BEFORE YOU DO WORK ON THE ENGIN...

Page 2240: ... intercooler guard assy Refer to Figure 2 6 Disconnect the flexible hose that connects the intercooler to the turbo charger and the turbo charger to the engine air intake manifold S Remove the worm drive clamps S Pull the hoses off the intercooler connectors and the turbo charger inlet Refer to Figure 2 At the intercooler 7 Remove the intercooler S Remove the nuts washers and bolts that attach the...

Page 2241: ...bration mounts Refer to Figure 2 2 Connect the flexible hoses that connect the intercooler to the turbo charger and engine air intake manifold S Move the worm drive clamps into position on the flexible hoses S Push the flexible hoses onto the intercooler connectors S Move the worm drive clamps into the correct position and tighten the worm drive clamps and apply torque seal no red of white torque ...

Page 2242: ...81 00 00 Doc 7 02 15 Rev 4 3 If MÄM 42 963 a is installed S Install the nut BN175 M6 PZ on the end of the screw of the new v clamp so that there is no gap S Put the v clamp in position on the flanges Note Do not pull the v clamp over the turbo charger tube since the v clamp will be permanently deformed ...

Page 2243: ...um charged air tube and the turbo charger flange When correctly installed the aluminum charged air tube must fit into the turbo charger flange without tension S Tighten v clamp on turbo charger Make sure the circumferential gap to the turbo charger is equal if not use rubber mallet to tap v clamp into position If tapping with a rubber mallet was required retighten the v clamp Torque 5 5 0 5 Nm 4 0...

Page 2244: ... Key Items References Page 206 15 Mar 2018 81 00 00 Doc 7 02 15 Rev 4 S Make sure that the distance between V flanges on the lock is between 6 and 10 mm 0 24 0 39 in If necessary insert turbo connector shims to obtain the required distance 6 10 mm 0 24 0 39 in ...

Page 2245: ...nges Note Do not pull the v clamp over the turbo charger tube since the v clamp will be permanently deformed S Tighten v clamp on turbo charger S Secure bolt of v clamp with lock wire S Make sure the circumferential gap to the turbo charger is equal if not use rubber mallet to tap v clamp into position If tapping with a rubber mallet was required retighten the v clamp Torque 5 0 0 5 Nm 3 7 0 4 lbf...

Page 2246: ...ke duct on the intercooler S Install the bolts and washers that attach the composite air intake duct to the intercooler 5 Install the intercooler guard assy Refer to Figure 2 6 Install the engine cowlings Refer to Section 71 10 7 Connect the airplane main battery Refer to Section 24 31 8 Do an engine ground run up and do a test for the correct operation of the engine intercooler Refer to Section 7...

Page 2247: ...o the air inlet system through the filter or it can be set to take unfiltered air directly from the engine compartment Refer to Section 71 61 for more data about the air filter and the alternate air valve The outlet from the alternate air valve connects to the turbo charger inlet The turbo charger compresses the air This makes the air hot The outlet from the turbo charger connects to the intercool...

Page 2248: ...ooling Air Out Intercooler Air Intake Duct Turbocharger Nacelle Cooling Air In Waste Gate Engine Exhaust Gases Turbine Compressor Ambient Air In Compressed Air Out Exhaust Gases from Engine Manifold Engine Intake Manifold Figure 1 Engine Turbo Charger Schematic Diagram if MÄM 42 600 installed ...

Page 2249: ...ws through the air filter normal operation or from the engine compartment alternate air operation into the turbo charger compressor The air gains heat while being compressed in the turbo charger The hot compressed air flows through a flexible hose to the intercooler The hot compressed air flows through the matrix of the intercooler Cooling air is guided from the left side of the nacelle to the int...

Page 2250: ...e Inlet Hose Intercooler Turbocharger Air Outlet to Turbo Charger Air Intake Engine Mounting Frame Washer Bolt Washer Nut Hose Clamp Hose Clamp Hose Clamp Hose Clamp Hose Clamp Hose Clamp Note Apply torque seal on all worm drive clamps Figure 2 Intercooler Installation if MÄM 42 600 installed ...

Page 2251: ... Turbocharger Air Outlet to Turbo Charger Air Intake Engine Mounting Frame Washer Bolt Washer Nut Hose Clamp Hose Clamp A A Flexible Charge Air Hose Turbo Connector Assy Worm Drive Clamps A Protective Pads Hose Clamps Hose Clamps Figure 3 Intercooler Installation if MÄM 42 600 and MÄM 42 1004 are installed ...

Page 2252: ...AIRCRAFT Turbo Charger DA 42 NG AMM Page 6 15 Mar 2018 81 01 00 Doc 7 02 15 Rev 4 Intentionally left blank ...

Page 2253: ...rouble detailed in the Trouble column read across to the Possible Cause column Then do the repair given in the Repair column Trouble Possible Cause Repair An engine intake manifold pressure is too low too high Waste gate valve defective Refer to the engine manufacturer Intake air temperature too high Intercooler matrix blocked damaged Clear intercooler matrix of obstructions Replace intercooler if...

Page 2254: ...AIRCRAFT Turbo Charger DA 42 NG AMM Page 102 15 Mar 2018 81 01 00 Doc 7 02 15 Rev 4 Intentionally left blank ...

Page 2255: ...nnections except such secured with self locking nuts in the charge air system must be secured with lock wire A Remove an Engine Intercooler Detail Steps Work Items Key Items References WARNING DO NOT STAND WITHIN THE DANGER AREA OF THE PROPELLER IF THE ENGINE STARTS THE PROPELLER CAN CAUSE DEATH OR INJURY TO PERSONS WARNING YOU MUST MAKE SURE THAT THE ENGINE IS SAFE BEFORE YOU DO WORK ON THE ENGIN...

Page 2256: ... mount S Remove the bolts and washers that attach the composite air intake duct to the intercooler S Move the composite air intake duct clear of the engine B Install the Engine Intercooler Detail Steps Work Items Key Items References CAUTION MAKE SURE THAT TURBO CHARGER HOSES ARE ROUTED CORRECTLY WITHOUT KINKS FALSE INSTALLED HOSES MAY RESULT IN DAMAGE TO THE TURBO CHARGER 1 Install the intercoole...

Page 2257: ...exible hoses onto the intercooler connectors S If MÄM 42 1004 is installed S Make sure that the position of the support rings of the bellows are in front of the aluminum connector and not on it Check that the bellows of the hose are not compressed or stretched If necessary realign charge air hose S Move the worm drive clamps into the correct position S If MÄM 42 1004 is installed bond the protecti...

Page 2258: ...81 01 00 Doc 7 02 15 Rev 4 3 If MÄM 42 963 a is installed S Install the nut BN175 M6 PZ on the end of the screw of the new v clamp so that there is no gap S Put the v clamp in position on the flanges Note Do not pull the v clamp over the turbo charger tube since the v clamp will be permanently deformed ...

Page 2259: ...um charged air tube and the turbo charger flange When correctly installed the aluminum charged air tube must fit into the turbo charger flange without tension S Tighten v clamp on turbo charger Make sure the circumferential gap to the turbo charger is equal if not use rubber mallet to tap v clamp into position If tapping with a rubber mallet was required retighten the v clamp Torque 5 5 0 5 Nm 4 0...

Page 2260: ... Key Items References Page 206 15 Mar 2018 81 01 00 Doc 7 02 15 Rev 4 S Make sure that the distance between V flanges on the lock is between 6 and 10 mm 0 24 0 39 in If necessary insert turbo connector shims to obtain the required distance 6 10 mm 0 24 0 39 in ...

Page 2261: ...nges Note Do not pull the v clamp over the turbo charger tube since the v clamp will be permanently deformed S Tighten v clamp on turbo charger S Secure bolt of v clamp with lock wire S Make sure the circumferential gap to the turbo charger is equal if not use rubber mallet to tap v clamp into position If tapping with a rubber mallet was required retighten the v clamp Torque 5 0 0 5 Nm 3 7 0 4 lbf...

Page 2262: ...tach the intercooler air duct to the engine mount 5 Install the alternate air valve S Tighten the worm drive clamps on the flexible hoses of the intercooler and apply torque seal no red of white torque seal color allowed Torque 5 0 0 5 Nm 3 7 0 4 lbf ft Use only new worm drive clamps 6 Install the engine cowlings Refer to Section 71 11 7 Connect the airplane main battery Refer to Section 24 31 8 D...

Page 2263: ...AIRCRAFT DA 42 NG AMM Wiring Diagrams Doc 7 02 15 Rev 4 92 TITLE Page 1 15 Mar 2018 CHAPTER 92 WIRING DIAGRAMS ...

Page 2264: ...AIRCRAFT Wiring Diagrams DA 42 NG AMM Page 2 15 Mar 2018 92 TITLE Doc 7 02 15 Rev 4 Intentionally left blank ...

Page 2265: ...AIRCRAFT DA 42 NG AMM Wiring Diagrams Doc 7 02 15 Rev 4 92 CONTENTS Page 1 15 Mar 2018 TABLE OF CONTENTS CHAPTER 92 WIRING DIAGRAMS 1 General 1 ...

Page 2266: ...AIRCRAFT Wiring Diagrams DA 42 NG AMM Page 2 15 Mar 2018 92 CONTENTS Doc 7 02 15 Rev 4 Intentionally left blank ...

Page 2267: ...tic Electrical System ECU Split Bus D64 9224 30 01_01 2 Schematic Electrical System D64 9224 30 01_02 2 Schematic RH ECU Backup Battery Tail Fin Installation D64 9224 30 01x01 1 Schematic Second Alternator D64 9224 30 02 1 Schematic Accessory Power Plug D64 9224 60 01 1 Schematic Emergency Power D64 9225 60 01 1 Schematic ELT ME 406 D64 9225 60 02 1 Schematic ELT Kannad 406 Wiring D64 9225 60 03 1...

Page 2268: ...ing Lights LED D64 9233 20 01_02 1 Schematic Map Reading Light Wiring RACC D64 9233 20 01x01 1 Schematic Map Reading Lights Wiring LED RACC D64 9233 20 01x02 1 Schematic Exterior Lighting D64 9233 40 01 C 1 Schematic LED Position Anti Collision Lights D64 9233 40 01x01 1 Schematic Attitude Gyro D64 9234 10 01 1 Schematic MD302 Wiring D64 9234 10 02 1 Schematic Drum Altimeter D64 9234 20 01 1 Schem...

Page 2269: ...AIRCRAFT DA 42 NG AMM Wiring Diagrams Title Drawing No Rev No No of Sheets Doc 7 02 15 Rev 4 92 00 00 Page 3 15 Mar 2018 ...

Page 2270: ...AIRCRAFT Wiring Diagrams DA 42 NG AMM Page 4 15 Mar 2018 92 00 00 Doc 7 02 15 Rev 4 Intentionally left blank ...

Page 2271: ...H N A Weight Calculated Weight N A This Drawing is the Property of Diamond Aircraft Unauthorized Reproduction or Disclosure to Third Parties is Prohibited Diamond Aircraft Industries GmbH REVISIONS Zone Rev Description new drawing all AV CDU FAN 9 J2413 10 P2413 21002A22 21003A22N GS IP 13 21000A22 21001A22N GS IP 4 21002B22 21003B22N 21001B22N 21000B22 J2102 MFD COOLING FAN 1 3 3 1 AVIONICS COOLI...

Page 2272: ... 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 DECIMAL u 1 ANGLE u 1 RAD u 0 5 NTS N A N A N A N A REAR BAGGAGE COMPARTMENT 87A 85 30 86 87 FAN HI RELAY 87A 85 30 86 87 FAN MED RELAY 87A 85 30 86 87 FAN LO RELAY 87A 85 30 86 87 CONDENSER RELAY 87A 85 30 86 87 COMPRESSOR RELAY HI MED LO RED WHITE E...

Page 2273: ...ENSIONS 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 REAR BAGGAGE COMPARTMENT 87A 85 30 86 87 FAN HI RELAY 87A 85 30 86 87 FAN MED RELAY 87A 85 30 86 87 FAN LO RELAY 87A 85 30 86 87 CONDENSER RELAY 87A 85 30 86 87 COMPRESSOR RELAY HI MED LO EVAP FAN J2151 5 3 6 2 9 3 A C DISP 2 n d A L T B U S 50 COMP 20 COND 20 EVAP H L FAN MED...

Page 2274: ... E 22406A24WH RS 485 2 A S SERVO PROGRAM 1 H SERVO PROGRAM 2 G PROGRAM GROUND U 22071D20 SERVO ENABLE P 22036A22 AFCS DISCONNECT IN No 1 GIA 63 INTEGRATED AVIONICS 11 22025A22 DISCRETE IN 5 13 DISCRETE IN 6 14 22035A22 DISCRETE IN 9 19 2J801 3J801 1J801 4J801 1P604 22033A22 DISCRETE IN 3A 39 22034A22 DISCRETE IN 4A 40 1P605 22108A24BL SERVO RS 485 B 6 22108A24WH SERVO RS 485 A 4 1P603 22207A24BL S...

Page 2275: ...SIONS ARE IN MM DIMENSION TOLERANCES 2 DECIMAL u 0 25 1DECIMAL u 0 5 DECIMAL u 1 ANGLE u 1 RAD u 0 5 N A N A N A N A REV ZONE SH DESCRIPTION DATE APPROVAL REVISION OÄM 42 213 FIRST RELEASE ALL 01 20 09 12 SEE TB NTS 23100A24BL GSR 56 5 AUDIO IN LO 1P561 AV BUS GS IP 7 IRIDIUM 1A IRIDIUM ANTENNA J2315 P2315 P2403 35 34 J2403 23100A24WH 4 AUDIO IN HI S 23101A24BL 2 AUDIO OUT LO 23101A24WH 1 AUDIO OU...

Page 2276: ...O N I C B U S 87A 85 24108A10 24105A22 30 86 24107A10 24106A22N AVIONICS MASTER RELAY 25 AVIONIC BUS RH ENGINE MASTER LH ENGINE MASTER 90 BATTERY LDG LT START 5 80102A22N GS RP BATTERY 90 R H M A I N B U S L H M A I N B U S START SWITCH GS IP 15 24012A22N STARTER RELAY 24000A2 BATTERY RELAY B1 5A 24011A22N GS IP 15 24010A22 ALT LH MASTER SWITCH REF D64 9232 00 01 24V 13 6Ah ON OFF AVIONICS MASTER ...

Page 2277: ...4015X22 added pull up resistor all P2404 41 19 P2402 TB1 TB1 24006A4 START RH 80106C22 80109A2 TO LH STARTER P2422 80106B22 2 TO START RELAY ALT RH 3 24006B4 TB1 TB1 24004A4 TO RH STARTER P2421 2 80104B22 TO START RELAY 80108B2 80104C22 LH START 1 ALT LH 19 41 80104D22 28 P2419 REF D64 9231 60 01 28 P2420 80106D22 74002D22 REF D64 9231 60 01 24004B4 REF D64 9231 60 01 REF D64 9231 60 01 50A 24004C...

Page 2278: ...24014A22 ALT RH A V I O N I C B U S 87A 85 24108A10 24105A22 30 86 24107A10 24106A22N AVIONICS MASTER RELAY 25 AVIONIC BUS RH ENGINE MASTER LH ENGINE MASTER 90 BATTERY LDG LT START 5 80102A22N GS RP BATTERY 90 R H M A I N B U S L H M A I N B U S START SWITCH GS IP 15 24012A22N STARTER RELAY 24000A2 BATTERY RELAY B1 5A 24011A22N GS IP 14 24010A22 ALT LH MASTER SWITCH REF D64 9232 00 01 24V 13 6Ah O...

Page 2279: ... STARTER P2422 80106B22 2 TO START RELAY ALT RH 3 24006B4 TB1 TB1 24004A4 TO RH STARTER P2421 2 80104B22 TO START RELAY 80108B2 80104C22 LH START 1 ALT LH 19 41 80104D22 28 P2419 REF D64 9231 60 01 28 P2420 80106D22 74002D22 REF D64 9231 60 01 24004B4 REF D64 9231 60 01 REF D64 9231 60 01 50A 24004C4 50A 24006C4 FUSELAGE LH NACELLE LH ENGINE COMPARTMENT FUSELAGE RH NACELLE RH ENGINE COMPARTMENT AL...

Page 2280: ...24108A10 24105A22 30 86 24107A10 24106A22N AVIONICS MASTER RELAY 25 AVIONIC BUS RH ENGINE MASTER LH ENGINE MASTER 90 BATTERY LDG LT START 5 80102A22N GS RP BATTERY 90 R H M A I N B U S L H M A I N B U S START SWITCH GS IP 18 24012A22N STARTER RELAY 24000A2 BATTERY RELAY B1 5A 24011A22N GS IP 17 24010A22 ALT LH MASTER SWITCH REF D64 9232 00 01 24V 13 6Ah ON OFF AVIONICS MASTER SWITCH GS IP 18 2 AV ...

Page 2281: ...6D22 74002D22 REF D64 9231 60 01 24004B4 REF D64 9231 60 01 REF D64 9231 60 01 50A 24004D4 50A 24006C4 FUSELAGE LH NACELLE LH ENGINE COMPARTMENT FUSELAGE RH NACELLE RH ENGINE COMPARTMENT 18 24016C20 18 24016D20 31004C22 20 20 31004B22 24018A20N 24027A20 4 CPC 2 74000D22 REF D64 9277 40 02 P2404 P2422 24022D20 31006C22 26 24022C20 26 25 31006B22 25 24019A20N 24028A20 4 CPC 2 REF D64 9277 40 03 REF ...

Page 2282: ...ROJECT TITLE DWG ORIG CODE SCALE SH OF DWG NO REV DATE SIGN DEPARTMENT DRAWN CHECKED QA STRESS MANUF SYSTEM APPROVED TL IDENTIFICATION MARKINGS CLASSIFICATION INTERCHANGEABLE PART THIS DRAWING WAS PRODUCED USING SOFTWARE FILENAME DIMENSIONS FIRST ANGLE PROJECTION FORMAT FINISH IN MICRO METER UNLESS OTHERWISE SPECIFIED DIMENSIONS ARE IN MM DIMENSION TOLERANCES 2 DECIMAL u 0 25 1DECIMAL u 0 5 DECIMA...

Page 2283: ... 5 NTS N A N A N A N A REV ZONE SH DESCRIPTION DATE APPROVAL REVISION OÄM 42 204 FIRST RELEASE ALL 01 13 04 11 SEE TB ALT AUX F1 F2 24360A20N 100 3W FIELD ALT REGULATOR J2432 3 2 8 6 1 7 4 AUX GROUND 24357A20 24358A20 24359A20N BROWN BLUE BLACK VOLTAGE SENSE YELLOW ALT CONTROL RED ALT PROTECTION ORANGE ALT OUT GRAY 24353C20 24354C20 24601A22 LH ENGINE COMPARTMENT 2nd EPU RELAY MAIN RELAY 12V 1 3Ah...

Page 2284: ... 8 Confidential PROJECT TITLE DWG ORIG CODE SCALE SH OF DWG NO REV DATE SIGN DEPARTMENT DRAWN CHECKED QA STRESS MANUF SYSTEM APPROVED IDENTIFICATION MARKINGS CLASSIFICATION INTERCHANGEABLE PART THIS DRAWING WAS PRODUCED USING SOFTWARE FILENAME DIMENSIONS FIRST ANGLE PROJECTION FORMAT FINISH IN MICRO METER UNLESS OTHERWISE SPECIFIED DIMENSIONS ARE IN MM DIMENSION TOLERANCES 2 DECIMAL u 0 25 1DECIMA...

Page 2285: ... 05 08 08 DiamondAIRCRAFT Industries GmbH N A Weight Calculated Weight N A This Drawing is the Property of Diamond Aircraft Unauthorized Reproduction or Disclosure to Third Parties is Prohibited Diamond Aircraft Industries GmbH REVISIONS Zone Rev Description new drawing all 1 2 J2430 P2430 24302B20N GS IP 2 EMERGENCY POWER SWITCH 34903B22 33204B22 33204A22 34903A22 24303B20 REF D64 9234 10 01 REF ...

Page 2286: ...operty of Diamond Aircraft Unauthorized Reproduction or Disclosure to Third Parties is Prohibited Diamond Aircraft Industries GmbH REVISIONS Zone Rev Description new drawing all REMOTE SWITCH 28 VDC RESET 2 RESET 1 EXTERNAL ON LIGHT GROUND GROUND 3 2 5 7 8 6 9 P2418 2 22 AWG 22 AWG P2563 1 P2563 2 25601A22 25607A22N GS IP 12 25601B22 1A 25603A22 25604A22 25605A22 25606A22 ELT UNIT G SWITCH LOOP RE...

Page 2287: ... 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 PRODUCED 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 DECIMAL u 1 ANGLE u 1...

Page 2288: ......

Page 2289: ...wing all 27025B22 27024B22 RUDDER 5A R H M A I N B U S 2 2b 1 1a 2a PEDAL MOTOR LH J2722 P2722 1 2 M GS IP 7 J2721 P2721 1 2 27021A20N 27020A20 3A 27023A20 27025A22 27024A22 J2402 P2402 22 23 27021B20N 27020B20 27021C20N 27020C20 PEDAL SWITCH LH 27035B22 27034B22 RUDDER 5A PEDAL MOTOR RH J2724 P2724 1 2 M GS IP 7 J2723 P2723 1 2 27031A20N 27030A20 3A 27033A20 27035A22 27034A22 J2404 P2404 53 54 27...

Page 2290: ...dustries GmbH A VÄM 42 004 Kowarsch 28 11 08 REVISIONS Zone Rev Description new drawing all A removed flaps position logic all 1 WIRING SHOWN WITH STICK LIMITER DEACTIVATED THROTTLE IN IDLE POSITION AND POWERED NOTES REF D64 9232 00 01 5A ELEV LIMIT GEAR ANNUN L H M A I N B U S 4 3 4 3 27300A22 27300B22 27300C22 27303C22N 27301A22 27302A22 black red P2415 P3202 S1 S2 27303B22N 27303A22N GS IP 10 3...

Page 2291: ... 14 AWG GS IP 6 27004A22 27005A22 27006A20N 27001A22 27007A20 27003A22 27002A22 27000A22 SW13 5 6 4 2 3 1 28 19 18 20 21 26 27 29 27008A20 33026A22 L2 L3 L4 27000C22 27003C22 27002C22 27001C22 27007C20 27006C20N 27005C22 27004C22 27006B20N 27000B22 27003B22 27002B22 27005B22 27004B22 P2415 27001B22 27007B20 1 6 7 8 5 3 J2412 4 2 8 5 4 2 6 7 J2700 3 1 x2a_4 x2a_5 x2a_6 x2a_7 x2a_1 x2a_8 x4_2 x4_1 x...

Page 2292: ...ified new standard ALL 01 B 18 11 10 SEE TB FLAG NOTES DEPENDING ON THE INSTALLED OPTIONS THE INSTALLATION OF THE CIRCUIT PROTECTIVE DEVICES IS DIFFERENT AUX FUEL SYSTEM ONLY 7 5A CIRCUIT BREAKER NO FUSE AUX FUEL SYSTEM AND DE ICE SYSTEM 10A CIRCUIT BREAKER AND 7A SLOW BLOW FUSE FOR THE AUX FUEL SYSTEM 1 NTS 87A 85 30 86 87 RELAY 16 7 5 17 14 18 1 2 30 31 7 8 L H M A I N B U S 7 5 10 XFR PUMP DE I...

Page 2293: ...4 18 1 2 12 13 28009C20WH 28009B20WH 28015C22 28015C22 28017B22 28017A22 28015D22 J2420 P2420 J2401 P2401 J3112 J2422 P2422 NOT FULL RIGHT FUEL LEVEL OVER FILL CENTER FUSELAGE RH ENGINE NACELLE RH WING FULL 28017B22 28017C22 28015B22 31034C22 REF D64 9231 60 01 10 31037D22 31037C22 REF D64 9231 60 01 1 2 P2811 3 4 REF D64 9228 10 01 FUEL XFR RH FUEL XFR LH OFF ON 31027C22N 31026C22 REF D64 9231 60...

Page 2294: ...34920C22 34921B22N 34920B22 32 J2400 12 49 J2421 54 34921A22N 49 J2402 54 34920A22 STALL WARNING 3A 30009C22N 30008C22 GS IP 10 30009A22N 12 J2415 11 30008A22 12 J3000 10 30005D14N 30004D14 30005C14N 30004C14 30005B14N 30004B14 15 J2400 22 13 J2427 3 18 Ohm 50W 30007A22 30006A14 87 86 30 85 87A 30005A14N 13 J2417 3 30004A14 30003A14 R H M A I N B U S 10A STALL WRN GS IP 22 REF D64 9231 60 01 L H M...

Page 2295: ...TE 10 30412C20 c 16 30123B20N K Case Ground 30123A20N GS IP 1 30400B20 30402A20 30403A20 30404A20 30405A20 30410A20 30408A20 30124A20N 30125A20N 30126A20N 30422B20 33120F20 33121F20 30412A20 30411B20 30401A20 DE ICE CONTROL PANEL 30107A20N J2418 V P2418 30122A20N GS IP 1 2 3 1 5 6 4 OFF JMPR DA 42 N G D64 9230 40 01a dft A SOLID EDGE V18 01 01 Schematic De Ice Cont rol System D64 9 2 3 0 4 0 0 1 0...

Page 2296: ...is Drawing is the Property of Diamond Aircraft Unauthorized Reproduction or Disclosure to Third Parties is Prohibited Diamond Aircraft Industries GmbH A VÄM 42 004 Kowarsch 12 08 08 REVISIONS Zone Rev Description new drawing all A corrected pinout of P2402 and P2418 D5 DISCRETE IN 19A GEA 71 ENGINE AIRFRAME P702 42 SIGNAL GROUND 37 31028A22 31029A22N D E 1 2 31028B22 31029B22N 1 2 31040A22 31041A2...

Page 2297: ...to Third Parties is Prohibited Diamond Aircraft Industries GmbH A VÄM 42 004 Kowarsch 12 08 08 REVISIONS Zone Rev Description new drawing all A corrected pinout of P2418 E6 DISCRETE IN 1 GEA 71 ENGINE AIRFRAME P701 70 SIGNAL GROUND 4 30110A22 30111A22N F G 30110B22 30111B22N 1 2 30114A22 30115A22N P2418 P3020 DISCRETE IN 2 SIGNAL GROUND DISCRETE IN 3 SIGNAL GROUND 71 19 76 32 DE ICE LEVEL LOW OK M...

Page 2298: ...ECIFIED 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 N A N A N A N A REV ZONE SH DESCRIPTION DATE APPROVAL REVISION VÄM 42 004 FIRST RELEASE ALL 01 06 08 08 SEE REV OÄM 42 214 EVS3 WIRING ADDED ALL 05 A 21 07 11 SEE TB NTS NOTES 1 SYMBOL DESIGNATIONS TWISTED SHIELDED SINGLE CONDUCTOR SHIELD TERMINATED TO GROUND SHIELD FLOATS SHIELD FLOAT...

Page 2299: ...302B24BL 23012B24WH 23012B24BL 34002B24WH 34002B24BL 23210B24WH 23210B24BL 23203B24WH 23203B24BL 23202B24BL 23202B24WH P2413 6 J2413 7 8 44 45 46 52 54 53 15 16 17 18 20 19 INTEGRATED AVIONICS NO 1 GIA63 1P601 4 7 10 9 8 COM MIC AUDIO IN HI COM AUDIO OUT LO COM AUDIO OUT HI COM MIC AUDIO IN LO 41 42 SPKR AUDIO OUT LO SPKR AUDIO OUT HI 14 13 59 61 1P602 VOR LOC DIGI AUDIO OUT SIGNAL GROUND COM DIGI...

Page 2300: ...3003A24BL 23003A24WH 23003A24OR 28 V ANR TIP POWER 28 V ANR 4 55 57 56 5 49 6 7 15 16 22 21 17 40 9 8 23 23014B24WH 23014B24BL 23000B24BL 23000B24OR 23000B24WH 23001B24BL 23001B24OR 23001B24WH 23004B24WH 23004B24BL 23006B24BL 23006B24WH 23005B24BL 23005B24WH 23005B24OR 23007B24BL 23007B24OR 23007B24WH 23002B24WH 23015B24BL 23002B24OR 23002B24BL 23015B24WH 23003B24BL 23003B24WH 23003B24OR PILOT PHO...

Page 2301: ...5 DIGITAL IN 2A 77 76 DIGITAL IN 4A DIGITAL IN 3A 1 2 3 31015A22BL 31015A22WH V 1 2 3 24331A24BL 24331A24WH 24331A24OR 28 12 11 J2413 P2413 74000A22 77010A24BL 77010A24WH ENG INST 5A 77016A22N 77015A22 35 AIRCRAFT POWER 1 20 POWER GROUND P701 J2401 P2401 J2422 P2422 28004D22BL 28004D22OR 28004D22WH 28003D22BL 28003D22WH 28003D22OR FUEL LEVEL RIGHT LONG RANGE 28 25 27 26 28002D22BL 28002D22OR 28002...

Page 2302: ...AIRCRAFT GROUND RS 232 IN 1 ARINC 429 OUT 2 A ARINC 429 OUT 2 B 4 2 3 TEMP PROBE IN LO TEMP PROBE IN HI BLK 1 TEMP PROBE POWER OUT CONFIG MODULE GROUND YEL WHT 60 40 21 CONFIG MODULE CLOCK CONFIG MODULE DATA CONFIG MODULE POWER RED 33000B22 33002B22 31102A24BL 31152B24BL 31152B24WH 31104B24BL 31104B24WH 31153A24BL 31153A24WH 31153A24BL 31153A24WH 22 21 20 J2414 P2414 57 56 55 J2403 P2403 31152A24B...

Page 2303: ...IRCRAFT GROUND 53 54 55 MAIN RS 232 IN 5 SIGNAL GROUND MAIN RS 232 OUT 5 GTX33 P3301 23 51 22 SIGNAL GROUND RS 232 IN 1 RS 232 OUT 1 MODE S XPDR 53 54 55 SIGNAL GROUND MAIN RS 232 IN 5 MAIN RS 232 OUT 5 GIA SYS ID PROGRAM 1 24 DISCRETE IN 12 21008A22 REF D64 9221 20 01 1P604 24 DISCRETE IN 12 21005A22 REF D64 9221 20 01 34202A22 BECKER AC 3504 1 RMI CONVERTER REF D60 9234 50 01 17 ADF COS P1 10 AD...

Page 2304: ...ENSIONS ARE IN MM DIMENSION TOLERANCES 2 DECIMAL u 0 25 1DECIMAL u 0 5 DECIMAL u 1 ANGLE u 1 RAD u 0 5 N A N A N A N A REV ZONE SH DESCRIPTION DATE APPROVAL REVISION MÄM 42 587 FIRST RELEASE ALL 15 11 11 SEE TB ALL NTS NOTES 1 SYMBOL DESIGNATIONS TWISTED SHIELDED SINGLE CONDUCTOR SHIELD TERMINATED TO GROUND SHIELD FLOATS SHIELD FLOATS SHIELD FLOATS SHIELD TERMINATED TO GROUND TWISTED SHIELDED 3 CO...

Page 2305: ...2B24BL 23012B24WH 23012B24BL 34002B24WH 34002B24BL 23210B24WH 23210B24BL 23203B24WH 23203B24BL 23202B24BL 23202B24WH P2413 6 J2413 7 8 44 45 46 52 54 53 15 16 17 18 20 19 INTEGRATED AVIONICS NO 1 GIA63 1P601 4 7 10 9 8 COM MIC AUDIO IN HI COM AUDIO OUT LO COM AUDIO OUT HI COM MIC AUDIO IN LO 41 42 SPKR AUDIO OUT LO SPKR AUDIO OUT HI 14 13 59 61 1P602 VOR LOC DIGI AUDIO OUT SIGNAL GROUND COM DIGITA...

Page 2306: ...003A24BL 23003A24WH 23003A24OR 28 V ANR TIP POWER 28 V ANR 4 55 57 56 5 49 6 7 15 16 22 21 17 40 9 8 23 23014B24WH 23014B24BL 23000B24BL 23000B24OR 23000B24WH 23001B24BL 23001B24OR 23001B24WH 23004B24WH 23004B24BL 23006B24BL 23006B24WH 23005B24BL 23005B24WH 23005B24OR 23007B24BL 23007B24OR 23007B24WH 23002B24WH 23015B24BL 23002B24OR 23002B24BL 23015B24WH 23003B24BL 23003B24WH 23003B24OR PILOT PHON...

Page 2307: ...24OR 28 12 11 J2413 P2413 74000A22 77010A24BL 77010A24WH ENG INST 5A 77016A22N 77015A22 35 AIRCRAFT POWER 1 20 POWER GROUND P701 J2401 P2401 J2422 P2422 28004D22BL 28004D22OR 28004D22WH 28003D22BL 28003D22WH 28003D22OR FUEL LEVEL RIGHT LONG RANGE 28 25 27 26 28002D22BL 28002D22OR 28002D22WH OUT HI FUEL LEVEL RIGHT EXCITATION GROUND FUEL LEVEL LEFT LONG RANGE 8 5 7 6 28001D22BL 28001D22WH 28001D22O...

Page 2308: ...IRCRAFT GROUND RS 232 IN 1 ARINC 429 OUT 2 A ARINC 429 OUT 2 B 4 2 3 TEMP PROBE IN LO TEMP PROBE IN HI BLK 1 TEMP PROBE POWER OUT CONFIG MODULE GROUND YEL WHT 60 40 21 CONFIG MODULE CLOCK CONFIG MODULE DATA CONFIG MODULE POWER RED 33000B22 33002B22 31102A24BL 31152B24BL 31152B24WH 31104B24BL 31104B24WH 31153A24BL 31153A24WH 31153A24BL 31153A24WH 22 21 20 J2414 P2414 57 56 55 J2403 P2403 31152A24BL...

Page 2309: ...CRAFT GROUND 53 54 55 MAIN RS 232 IN 5 SIGNAL GROUND MAIN RS 232 OUT 5 GTX33 P3301 23 51 22 SIGNAL GROUND RS 232 IN 1 RS 232 OUT 1 MODE S XPDR 53 54 55 SIGNAL GROUND MAIN RS 232 IN 5 MAIN RS 232 OUT 5 GIA SYS ID PROGRAM 1 24 DISCRETE IN 12 21008A22 REF D64 9221 20 01 1P604 24 DISCRETE IN 12 21005A22 REF D64 9221 20 01 34202A22 BECKER AC 3504 1 RMI CONVERTER REF D60 9234 50 01 17 ADF COS P1 10 ADF ...

Page 2310: ...NING AND TOLERANCING ACC TO DIMENSIONS IN ISO 2768 mK mm REV ZONE SH DESCRIPTION DATE REVISION MÄM 42 978 NEW DRAWING DOES NOT SUPERSEDE ANOTHER DRAWING ALL 01 09 09 16 NOTES 1 SYMBOL DESIGNATIONS TWISTED SHIELDED SINGLE CONDUCTOR SHIELD TERMINATED TO GROUND SHIELD FLOATS SHIELD FLOATS SHIELD FLOATS SHIELD TERMINATED TO GROUND TWISTED SHIELDED 3 CONDUCTOR TWISTED SHIELDED 3 CONDUCTOR TWISTED SHIEL...

Page 2311: ...23012B24WH 23012B24BL 34002B24WH 34002B24BL 23210B24WH 23210B24BL 23203B24WH 23203B24BL 23202B24BL 23202B24WH P2413 6 J2413 7 8 44 45 46 52 54 53 15 16 17 18 20 19 INTEGRATED AVIONICS NO 1 GIA63 1P601 4 7 10 9 8 COM MIC AUDIO IN HI COM AUDIO OUT LO COM AUDIO OUT HI COM MIC AUDIO IN LO 41 42 SPKR AUDIO OUT LO SPKR AUDIO OUT HI 14 13 59 61 1P602 VOR LOC DIGI AUDIO OUT SIGNAL GROUND COM DIGITAL AUDIO...

Page 2312: ...A24BL 23003A24WH 23003A24OR 28 V ANR TIP POWER 28 V ANR 4 55 57 56 5 49 6 7 15 16 22 21 17 40 9 8 23 23014B24WH 23014B24BL 23000B24BL 23000B24OR 23000B24WH 23001B24BL 23001B24OR 23001B24WH 23004B24WH 23004B24BL 23006B24BL 23006B24WH 23005B24BL 23005B24WH 23005B24OR 23007B24BL 23007B24OR 23007B24WH 23002B24WH 23015B24BL 23002B24OR 23002B24BL 23015B24WH 23003B24BL 23003B24WH 23003B24OR PILOT PHONE 1...

Page 2313: ... 12 11 J2413 P2413 74000A22 77010A24BL 77010A24WH ENG INST 5A 77016A22N 77015A22 35 AIRCRAFT POWER 1 20 POWER GROUND P701 J2401 P2401 J2422 P2422 28004D22BL 28004D22OR 28004D22WH 28003D22BL 28003D22WH 28003D22OR FUEL LEVEL RIGHT LONG RANGE 28 25 27 26 28002D22BL 28002D22OR 28002D22WH OUT HI FUEL LEVEL RIGHT EXCITATION GROUND FUEL LEVEL LEFT LONG RANGE 8 5 7 6 28001D22BL 28001D22WH 28001D22OR J2400...

Page 2314: ...2 A 7 27 2 1 AIR DATA ARINC 429 OUT 1 B ARINC 429 OUT 1 A ARINC 429 OUT 1 A ARINC 429 OUT 1 B GDC72 P721 49 50 70 69 36 RS 232 OUT 1 AIRCRAFT GROUND RS 232 IN 1 ARINC 429 OUT 2 A ARINC 429 OUT 2 B 4 6 5 TEMP PROBE IN LO TEMP PROBE IN HI BLK 74 TEMP PROBE POWER OUT CONFIG MODULE GROUND YEL WHT 55 54 53 CONFIG MODULE CLOCK CONFIG MODULE DATA CONFIG MODULE POWER RED 33000B22 33002B22 31102A24BL 31152...

Page 2315: ... 55 MAIN RS 232 IN 5 SIGNAL GROUND MAIN RS 232 OUT 5 GTX335 P3251 9 52 31 SIGNAL GROUND RS 232 IN 1 RS 232 OUT 1 MODE S XPDR 53 54 55 SIGNAL GROUND MAIN RS 232 IN 5 MAIN RS 232 OUT 5 GIA SYS ID PROGRAM 1 24 DISCRETE IN 12 21008A22 REF D64 9221 20 01 1P604 24 DISCRETE IN 12 21005A22 REF D64 9221 20 01 34202A22 BECKER AC 3504 1 RMI CONVERTER REF D60 9234 50 01 17 ADF COS P1 10 ADF X COS 34203A22 16 ...

Page 2316: ...2026B22 32027B22N 32028B22 32029B22N 32031B22N 32030B22 56 55 53 54 S7 SQUAT SWITCH LH 25 24 S5 RH LDG GEAR DOWN S2 S3 LH LDG GEAR DOWN LH LDG GEAR UP RH LDG GEAR UP S4 S6 32020C22N 32019C22 32025C22 32024C22 32017C22 32018C22N 19 27 23 24 P2412 32029C22N 32028C22 32030C22 32031C22N 32022A22 32006A22 32007A22N 32020A20N 32019A22 32023A22 32018A22N 32017A22 32023A22 32016A22N 32015A22 32023A22 3200...

Page 2317: ... GmbH N A Weight Calculated Weight N A This Drawing is the Property of Diamond Aircraft Unauthorized Reproduction or Disclosure to Third Parties is Prohibited Diamond Aircraft Industries GmbH REVISIONS Zone Rev Description new drawing all ON OFF 5k Ω FLOOD DIMMING CONTROL SWITCHED D C IN ADJ GROUND LAMP LAMP ADJ 1 J3305 33207A22 2 YL 5 WH WH 4 3 6 YL 33208A22N P3305 RED BLK 33204A22 5A FLOOD OXY L...

Page 2318: ... 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 VÄM 42 004 FIRST RELEASE ALL 01 14 07 08 SEE TB OÄM 42 171 corrected J3308 in J3337 changed REF to D64 9231 60 0x E 2 E 3 01 A 18 05 09 SEE TB REF D64 9231 60 0x 33004B22 TERMINAL BLOCK REGULATOR 33032A22 300 ON OFF 33049A22 33050A22 33051A22 33000B22 33011A22 REF D64 9227 50 02 LM 13...

Page 2319: ...ion or Disclosure to Third Parties is Prohibited Diamond Aircraft Industries GmbH A VÄM 42 004 Kowarsch 13 08 08 REVISIONS Zone Rev Description new drawing all A corrected pinout of P2418 E7 REF D64 9233 40 01 33113A20 PASSENGER READING LIGHT J3321 1 2 P3321 CO PILOT MAP LIGHT 33200C22 33202B22 33203B22N 33201B22N 33200C22 33202B22 33203B22N 33201B22N 20 18 11 21 33203A22N 33201A22N GS IP 12 33202...

Page 2320: ......

Page 2321: ...ENTIFICATION MARKINGS 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 DIMENSION TOLERANCES 2 DECIMAL u 0 25 1DECIMAL u 0 5 DECIMAL u 1 ANGLE u 1 RAD u 0 5 N A N A N A N A REV ZONE SH DESCRIPTION DATE APPROVAL REVISION OÄM 42 193 FIRST RELEASE ALL ...

Page 2322: ......

Page 2323: ... 56 57 33104C20WH 33104C20BL 33100C20 L H NACELLE 1 3 4 28 P2400 J2400 P2415 J2415 R H NACELLE 33109B20BL 33109B20WH 33102B20 J2422 P2422 GS IP 17 NAV LIGHT ASSY NAV LIGHT NAV LIGHT ASSY RED WHITE BLACK STROBE LIGHT RED BLACK WHITE 3 1 2 3 1 2 POWER SUPPLY bl rd bl bk 2 3 1 LDG LT START INST LT NAV LT TAXI MAP ACL RIGHT FUSELAGE INSTRUMENT PANEL LEFT FUSELAGE P3312 P3317 2 1 J3317 1 2 J3316 P3316 ...

Page 2324: ...ATION 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 DIMENSION TOLERANCES 2 DECIMAL u 0 25 1DECIMAL u 0 5 DECIMAL u 1 ANGLE u 1 RAD u 0 5 N A N A N A N A REV ZONE SH DESCRIPTION DATE APPROVAL REVISION OÄM 42 222 FIRST RELEASE ALL 01 14 11 13 SEE TB NTS 2 1 2 1 ...

Page 2325: ...hematic Attitude Gyro D64 9234 10 01 M Spanton 14 07 08 DiamondAIRCRAFT Industries GmbH N A Weight Calculated Weight N A This Drawing is the Property of Diamond Aircraft Unauthorized Reproduction or Disclosure to Third Parties is Prohibited Diamond Aircraft Industries GmbH REVISIONS Zone Rev Description new drawing all D64 9225 60 01 REF RH MAIN BUS GS IP 13 34904A22N BACKUP ARTIFICIAL HORIZON D J...

Page 2326: ...ALE SH OF DWG NO REV DATE SIGN DEPARTMENT DRAWN CHECKED QA STRESS MANUF SYSTEM APPROVED N A IDENTIFICATION MARKINGS CLASSIFICATION INTERCHANGEABLE PART THIS DRAWING WAS PRODUCED USING SOFTWARE FILENAME DIMENSIONS FIRST ANGLE PROJECTION FORMAT FINISH IN MICRO METER UNLESS OTHERWISE 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 N ...

Page 2327: ...G Twin Star VÄM 42 004 1 1 Schematic Drum Altimeter D64 9234 20 01 M Spanton 14 07 08 DiamondAIRCRAFT Industries GmbH N A Weight Calculated Weight N A This Drawing is the Property of Diamond Aircraft Unauthorized Reproduction or Disclosure to Third Parties is Prohibited Diamond Aircraft Industries GmbH REVISIONS Zone Rev Description new drawing all GS IP 34906A22N STANDBY DRUM ALTIMETER J3491 C A ...

Page 2328: ...ATION MARKINGS CLASSIFICATION INTERCHANGEABLE PART THIS DRAWING WAS PRODUCED USING SOFTWARE FILENAME DIMENSIONS FIRST ANGLE PROJECTION FORMAT FINISH IN MICRO METER UNLESS OTHERWISE 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 N A N A N A N A REV ZONE SH DESCRIPTION DATE APPROVAL REVISION OÄM 42 119 FIRST RELEASE ALL 01 23 11 12...

Page 2329: ...ICATION MARKINGS CLASSIFICATION INTERCHANGEABLE PART THIS DRAWING WAS PRODUCED USING SOFTWARE FILENAME DIMENSIONS FIRST ANGLE PROJECTION FORMAT FINISH IN MICRO METER UNLESS OTHERWISE 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 N A N A N A N A REV ZONE SH DESCRIPTION DATE APPROVAL REVISION OÄM 42 273 FIRST RELEASE ALL 01 12 09 ...

Page 2330: ...2 004 FIRST RELEASE ALL 01 14 07 08 SEE REV MÄM 42 373 CORRECTED CO AX WIRE NUMBER NEW STANDARD ALL 01 A 11 08 09 SEE TB P2 18 SUPP VOLT 28VDC BECKER RA 3502 01 ADF RECEIVER 36 SUPP VOLT 28VDC 4 GROUND 2 AUDIO OUT HI 3 AUDIO OUT LO 13 RX A 14 RX B 12 TX A 31 TX B 27 GROUND 11 ON 1 OP VOLT 18VDC 23 GROUND 16 ADF 20 18V 34 C CONTROL 37 SUPP VOLT 28VDC SWITCHED 32 AUDIO NAV 33 AUDIO NAV 29 GROUND J9 ...

Page 2331: ...ELEASE ALL 01 15 06 09 SEE TB NTS 2A 61201A22 10 J2402 4 46 J2421 45 19 J2419 18 61201B22 61201D22 61202B22 61202D22 61203A22N 2A 61202A22 2 1 J6121 UNFEATHERING VALVE LH ON OFF 24360A20 ON OFF 24363A20 2A 2A 61207A22 7 7 61207B22 2 1 GOVERNOR LH CPC 2 1 2A 61204A22 47 J2404 46 47 J2422 46 19 J2420 18 61204B22 61204C22 61204D22 61205B22 61205C22 61205D22 61206A22N 2A 61205A22 2 1 J6122 UNFEATHERIN...

Page 2332: ... 24342A20N 24343A20N 24344A20N 24345A20N GS RP GS RP 24004B4 74011A16 74012A16 74013A16 74014A16 24321A22WH 24321A22BL 3 77401B22BL 77401B22WH REF D64 9231 60 01 31005C22 ECU TEST LH 77401A22BL 77401A22WH 77402A22OR 77420A22OR 77420A22BL 77420A22WH 77402A22WH 77402A22BL POWER LEVER SENSOR ECU A 6 1 5 3 4 2 REF D64 9224 30 01 FUSELAGE EMI FILTER OPTIONAL WITH ADF J2402 50A J2427 6 10 7 12 24361C22 ...

Page 2333: ...35A20N GS RP LH FUEL PUMP A LH FUEL PUMP B 3 6 2 1 5 4 24325A22BL 24325A22WH 24322A22WH 24322A22BL VOTER LH 22 AWG EMI FILTER OPTIONAL WITH ADF FUSELAGE 24363A20 J2427 30 17 J2417 30 17 24365B22 24301B14 9 9 16 16 24364B22 24301C14 24365C22 24364C22 29 25 24 29 25 24 24322B22BL 24322C22BL 24322B22WH 24322C22WH 24325B22WH 24325C22WH 24325B22BL 24325C22BL 28039A22 28038A22 28037B22 4 4 28037A22 OFF ...

Page 2334: ... 24350A20N 24351A20N 24352A20N 24353A20N GS RP GS RP 24004B4 74021A16 74022A16 74023A16 74024A16 24323A22WH 24323A22BL 3 77405B22BL 77405B22WH REF D64 9231 60 01 31007C22 77405A22BL 77405A22WH 77406A22OR 77422A22OR 77422A22BL 77422A22WH 77406A22WH 77406A22BL REF D64 9224 30 01 FUSELAGE EMI FILTER OPTIONAL WITH ADF J2404 50A J2428 34 26 35 32 24371C22 24372C22 74020C22 24323C22WH 24323C22BL J2416 3...

Page 2335: ...26A22WH 24324A22WH 24324A22BL VOTER RH 22 AWG EMI FILTER OPTIONAL WITH ADF 24373A20 J2428 30 17 J2416 30 17 24375B22 24303B14 14 14 16 16 24374B22 24303C14 24375C22 24374C22 29 25 24 29 25 24 24324B22BL 24324C22BL 24324B22WH 24324C22WH 24326B22WH 24326C22WH 24326B22BL 24326C22BL 28049A22 28048A22 28047B22 20 20 28047A22 OFF ON 28046A22N FUEL PUMPS RH 27 21 27 21 28042B20 28040B20 28040A20 28042A20...

Page 2336: ...4342A20N 24343A20N 24344A20N 24345A20N GS RP GS RP 24004B4 74011A16 74012A16 74013A16 74014A16 24321A22WH 24321A22BL 3 77401B22BL 77401B22WH REF D64 9231 60 0X 31005C22 ECU TEST LH 77401A22BL 77401A22WH 77402A22OR 77420A22OR 77420A22BL 77420A22WH 77402A22WH 77402A22BL POWER LEVER SENSOR ECU A 6 1 5 3 4 2 REF D64 9224 30 01_01 FUSELAGE EMI FILTER OPTIONAL WITH ADF J2402 50A J2427 6 10 7 12 24361C22...

Page 2337: ...EL PUMP B 3 6 2 1 5 4 24325A22BL 24325A22WH 24322A22WH 24322A22BL VOTER LH 22 AWG EMI FILTER OPTIONAL WITH ADF FUSELAGE 24363A20 J2427 30 17 J2417 30 17 24365B22 24301B14 9 9 16 16 24364B22 24301C14 24365C22 24364C22 29 25 24 29 25 24 24322B22BL 24322C22BL 24322B22WH 24322C22WH 24325B22WH 24325C22WH 24325B22BL 24325C22BL 28039A22 28038A22 28037B22 4 4 28037A22 OFF ON 28036A22N FUEL PUMPS LH 27 21 ...

Page 2338: ...4350A20N 24351A20N 24352A20N 24353A20N GS RP GS RP 24004B4 74021A16 74022A16 74023A16 74024A16 24323A22WH 24323A22BL 3 77405B22BL 77405B22WH REF D64 9231 60 0X 31007C22 77405A22BL 77405A22WH 77406A22OR 77422A22OR 77422A22BL 77422A22WH 77406A22WH 77406A22BL REF D64 9224 30 01_01 FUSELAGE EMI FILTER OPTIONAL WITH ADF J2404 50A J2428 34 26 35 32 24371C22 24372C22 74020C22 24323C22WH 24323C22BL J2416 ...

Page 2339: ...ILTER OPTIONAL WITH ADF 24373A20 J2428 30 17 J2416 30 17 24375B22 24303B14 14 14 16 16 24374B22 24303C14 24375C22 24374C22 29 25 24 29 25 24 24324B22BL 24324C22BL 24324B22WH 24324C22WH 24326B22WH 24326C22WH 24326B22BL 24326C22BL 28049A22 28048A22 28047B22 20 20 28047A22 OFF ON 28046A22N FUEL PUMPS RH 27 21 27 21 28042B20 28040B20 28040A20 28042A20 2 24339A20 24340A20 24341A20 GS IP 11 GS IP 22 22 ...

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