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Diamond DA20-C1, Maintenance Manual

The Diamond DA20-C1 Operating Procedures Manual is an essential guide for pilots flying this versatile aircraft. Packed with detailed instructions, safety procedures, and operational guidelines, this comprehensive manual ensures a smooth and efficient flying experience. Download it for free at manualshive.com and make the most of your DA20-C1.

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51-TOC

Standard Practices - Structures

DA20-C1 AMM

Rev 21

DA201-C1

Page 1

14 Jan 13

TABLE OF CONTENTS

Subject

CH-SE-SU

Page

STANDARD PRACTICES - STRUCTURES  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  51-00-00 . . . . . . . . 1

General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

Structural Classification  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

Design, Dimensions, Clearances and Wear Limits  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

The Description and Location of Parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

Repair Limitations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

Inspection Techniques . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5

Approved Materials and Suppliers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7

Resin Handling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9

Resin to Hardner Mixture . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10

Bonding of Fiber Reinforced Plastics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11

Curing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12

CONTROL SURFACE BALANCING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  51-60-00 . . . . . . . . 1

General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

Control Surface Balance. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

Summary of Contents for DA20-C1

Page 1: ...C DA201 C1 DIAMOND AIRCRAFT INDUSTRIES INC 1560 CRUMLIN SIDEROAD LONDON ONTARIO CANADA N5V 1S2 All rights reserved No part of this manual may be reproduced or copied in any form or by any means without written permission of DIAMOND AIRCRAFT INDUSTRIES INC Copyright 2012 by DIAMOND AIRCRAFT INDUSTRIES INC London Ontario ...

Page 2: ...nts and revision status can be found in the TABLE OF CONTENTS and the RECORD OF REVISIONS DIAMOND AIRCRAFT INDUSTRIES INC 1560 CRUMLIN SIDEROAD London Ontario Canada N5V 1S2 http www diamondair com For more information contact DIAMOND AIRCRAFT INDUSTRIES INC Technical Publications 1 519 457 4030 Ext 3173 techpubs diamondair com ...

Page 3: ...Page 1 Rev 16 51 TITLE Standard Practices Structures DA20 C1 AMM DA201 C1 30 Oct 09 CHAPTER 51 00 STANDARD PRACTICES STRUCTURES ...

Page 4: ...Standard Practices Structures DA20 C1 AMM 51 TITLE 30 Oct 09 Page 2 DA201 C1 Rev 16 Intentionally Left Blank ...

Page 5: ...ral 1 Structural Classification 1 Design Dimensions Clearances and Wear Limits 3 The Description and Location of Parts 3 Repair Limitations 3 Inspection Techniques 5 Approved Materials and Suppliers 7 Resin Handling 9 Resin to Hardner Mixture 10 Bonding of Fiber Reinforced Plastics 11 Curing 12 CONTROL SURFACE BALANCING 51 60 00 1 General 1 Control Surface Balance 1 ...

Page 6: ...51 TOC DA20 C1 AMM Standard Practices Structures 14 Jan 13 Page 2 DA201 C1 Rev 21 Intentionally Left Blank ...

Page 7: ...selage structure It has a spar near the rudder hinge line and a full laminate skin The horizontal stabilizer elevator and rudder have GFRP skins with rigid foam cores The ailerons and flaps have GFRP CFRP skins with rigid foam cores The acrylic canopy has a frame made from carbon fiber laminate An epoxy filler with a polyurethane paint protects the aircraft against moisture and ultraviolet rays 2 ...

Page 8: ...d 2 400 200 150 100 300 350 3 0 0 500 300 150 150 80 4 0 0 LIMITED AREA 1 Repairs allowed on external skin damage up to 250mm 10 in diameter LIMITED AREA 2 Repairs allowed on external skin damage up to 50mm 2 in diameter PROHIBITED REPAIR AREA Repairs to be carried out only by the manufacturer or an approved repair facility NOTE All dimensions are mm Section B B ...

Page 9: ...rn clearances The description and location of parts to be examined or inspected A remarks column containing recommendations and where necessary repair details 4 The Description and Location of Parts The Aircraft Maintenance Manual AMM gives the description and location of parts Where a special repair needs more data it is shown on the repair drawing 5 Repair Limitations You cannot do in service re...

Page 10: ...pairs allowed on external skin damage up to 250mm 10 in diameter LIMITED AREA 2 Repairs allowed on external skin damage up to 50mm 2 in diameter PROHIBITED REPAIR AREA Repairs to be carried out only by the manufacturer or an approved repair facility NOTE All dimensions are mm 245 285 100 150 300 300 100 70 150 150 150 VIEW LOOKING DOWN ON BOTTOM SKIN OF FUSELAGE ...

Page 11: ...must be black or black brown If the CFRP has white areas then it may be damaged Look especially at areas where components bond to the CFRP B Light Test A light test can be used to find delamination on components which do not have rigid foam inside CAUTION DO NOT LET THE COMPOSITE GET HOT HEAT CAN CAUSE DAMAGE TO THE COMPOSITE Point a bright light at the surface of the composite and look at the oth...

Page 12: ...30 3 0 00 300 300 400 400 Mass Balance Area on Aileron 150 250 LIMITED AREA 1 Repairs allowed on external skin damage up to 250mm 10 in diameter LIMITED AREA 2 Repairs allowed on external skin damage up to 50mm 2 in diameter PROHIBITED REPAIR AREA Repairs to be carried out only by the manufacturer or an approved repair facility NOTE All dimensions are mm NOTE THE WING DATA IS VALID FOR TOP AND BOT...

Page 13: ...Glass Fiber Cloth Supplier Interglas Textil Gmbh Interglas Technologies AG BenzstraBe 14 D 89155 Erbach Germany C Carbon Fiber Cloth Supplier Interglas Textil Gmbh C Cramer Co Interglas Technologies AG Postfach 1163 48613 Heek Nienborg BenzstraBe 14 D 89155 Erbach Germany Weberstrabe 21 Germany Cloth Mass per Area grams m2 Interglass No Double Twil 2 2 161 92110 Double Twil 2 2 276 92125 Double Tw...

Page 14: ...ll Foundry Quarry Hill Foundry Supplies 1262 Mcdougall Street Windsor ON N8X 3M7 Epoxy Primer Primer EP669 White BASF Hardener PA897 Reducer speed dependant on Application Climate Primer Surfacer High Build Primer DP20 BASF Hardener PH60 Exterior Topcoat UNO S N C0001 to C0383 Paint HS82004 Olympia White BASF Hardener DH46 Reducer speed dependant on Application Climate Exterior Topcoat AF400 S N C...

Page 15: ...xture Material Paint 1109 1240 4 Glasurit Instrument Panel Flat Black UNO HD Paint SC80 BASF Hardener DH46 Reducer type dependant on Application Climate Fire Retardant Paint Paint N56582 T508 PPG Aerospace PRC Desoto International Hein Sass Weg 29 D 21129 Hamburg Finkenwerder Clear Coat 432 0303 Hardener N39 1327 use for clear coat only Desothane HS Buffable Clear Coat 9008B900D Hardner 9008B Deso...

Page 16: ...void dispensing components into different containers prior to mixing Best accuracy is obtained by weighing the resin and the hardener into a single mixing pot Dispensing by weight tends to be more precise than dispensing by volume 7 Large batches of mixed resin should be poured into flat containers so that the surface area to volume ratio is increased This will reduce the risk of an exothermic rea...

Page 17: ...berglass parts Bonding paste or thickened resin is a mixture of three types of fillers and mixed resins Refer to the table below The following combination of thickening fillers shall be used for preparation of bonding paste microballoons aerosil maximum 7 by weight Cotton Fibers minimum 7 by weight Quantity of microballoons and aerosil may be varied to change paste consistency The total mix of fil...

Page 18: ...e trial fit Avoid trapping air by contouring the paste higher in the middle of the joint 7 Fit the parts and remove excess bonding paste as it is squeezed out 8 Immobilize the parts until the pre cure is complete approximately 24 hours at 20 C 68 F 9 Do not disturb the bonded parts until the full pre cured duration has been reached 11 Curing A Introduction The following steps establish the procedu...

Page 19: ...rial Ensure that the nozzle of the heat gun is more than 12 inches away from the area being cured Use a thermocouple probe to measure the surface temperature at the repair Adjust the heat source to maintain 60 o C 5 o C 140 o F 5 Measure and record the temperature every 15 minutes for the first hour and then every hour after that 6 It is not recommended to leave the repair unattended during the po...

Page 20: ...Standard Practices Structures DA20 C1 AMM 51 00 00 14 Jan 13 Page 14 DA201 C1 Rev 21 Intentionally Left Blank ...

Page 21: ...ontrol surface If you use anything to connect the weighing device to the control surface you must weigh it separately Then subtract its weight from the total value For example you use a sling to lift a flap with a spring balance Weight of the flap and the sling 4 3kg Weight of the sling 0 6kg Weight of the flap 4 3 0 6 3 7kg When you balance a control surface the pivot axis must be horizontal We r...

Page 22: ...Standard Practices Structures DA20 C1 AMM 30 Oct 09 Page 2 DA201 C1 Rev 16 51 60 00 Figure 1 Rudder Static Balance ...

Page 23: ...Page 3 Rev 16 51 60 00 Standard Practices Structures DA20 C1 AMM DA201 C1 30 Oct 09 Figure 3 Aileron Static Balance Figure 2 Elevator Static Balance ...

Page 24: ...Standard Practices Structures DA20 C1 AMM 30 Oct 09 Page 4 DA201 C1 Rev 16 51 60 00 Figure 4 Flap Static Balance ...

Page 25: ...Page 1 Rev 16 52 TITLE Doors DA20 C1 AMM DA201 C1 30 Oct 09 CHAPTER 52 00 DOORS ...

Page 26: ...Doors DA20 C1 AMM 52 TITLE 30 Oct 09 Page 2 DA201 C1 Rev 16 Intentionally Left Blank ...

Page 27: ...1 Description 1 Operation 2 CANOPY TROUBLESHOOTING 52 10 00 101 General 101 CANOPY MAINTENANCE PRACTICES 52 10 00 201 General 201 Remove Install the Canopy 201 The Canopy Latch Force Test 202 Adjust the Canopy Latch Force 204 Adjust the Canopy Warning Light Micro Switch 204 Remove Install the Sliding Side Window 205 ACCESS PANELS 52 40 00 1 General 1 ...

Page 28: ...52 TOC DA20 C1 AMM Doors 14 Jan 13 Page 2 DA201 C1 Rev 21 Intentionally Left Blank ...

Page 29: ... Rev 21 52 00 00 Doors DA20 C1 AMM DA201 C1 14 Jan 13 DOORS 1 General The DA20 C1 aircraft has two types of doors The Canopy which gives access to the cockpit Access panels which give access to do maintenance ...

Page 30: ...Doors DA20 C1 AMM 52 00 00 14 Jan 13 Page 2 DA201 C1 Rev 21 Intentionally Left Blank ...

Page 31: ... canopy frame When the canopy is closed the seal touches cockpit sill B Canopy Hinges The canopy attaches to the fuselage with three hinges One hinge at the back of the canopy and one at each side A large spring attaches between each side arm and the rear fuselage The springs help balance the weight of the canopy C Canopy Locking A latch mechanism attaches to each side of the canopy There are two ...

Page 32: ...gages the strike bearing is shaped with a small ramp that ends to make a recess As the grip is pushed forwards the canopy is pulled downwards to compress the canopy seal When the bearing drops into the recess the canopy is locked The force necessary to open the canopy from this position will stop accidental operation If the electrical power is set to on and both latches are not engaged the red war...

Page 33: ...C1 AMM DA201 C1 30 Oct 09 Figure 1 Canopy Left Canopy Latch Shown Un locked Right Canopy Latch Shown Un locked Stabilizing Rod Balance Spring Rear Hinge Sliding Side Window Acrylic Transparency Outside Canopy Handle Later Model Aircraft ...

Page 34: ...Doors DA20 C1 AMM 52 10 00 30 Oct 09 Page 4 DA201 C1 Rev 16 Intentionally Left Blank ...

Page 35: ...CAUSE REPAIR Canopy is difficult to move Canopy frame damaged Replace the canopy Canopy unlock lock grips difficult to move Latch mechanism out of adjustment Adjust the latch mechanism Emergency side windows difficult to move Emergency side window guides dirty or damaged Clean or replace the side window guides Canopy warning light does not operate correctly Canopy warning light out of adjustment A...

Page 36: ...Troubleshooting DA20 C1 AMM 52 10 00 30 Oct 09 Page 102 DA201 C1 Rev 16 Intentionally Left Blank ...

Page 37: ... the rear hinge to the rear of the canopy Hold the canopy 3 Remove the rod end bearings from the stabilizing rods at the canopy frame 4 Lift the canopy clear of the aircraft Detail Steps Work Items Key Items References 1 Lift the canopy into position on the aircraft And hold the canopy open 2 Install the rod end bearings to the stabilizing rods at the canopy frame 3 Install the screws that attach ...

Page 38: ... light goes off Set the GEN BAT switch to OFF 4 Loosen the friction adjusting screw for the canopy handle To completely release the pressure on the conical washers 5 Put a strap around the canopy grip at the top Attach the spring scale to the strap Pull the spring scale straight aft and up at approximately 30 degrees Measure and record the force necessary to move the grip to the unlocked position ...

Page 39: ...r the other grip Detail Steps Work Items Key Items References 1 Close the canopy Make sure both handles are fully forward 2 Set the GEN BAT switch to ON 3 Make sure the canopy warning light goes off Set the GEN BAT switch to OFF 4 Put a strap around the canopy grip at the top Attach the spring scale to the strap Pull the spring scale straight aft and up at approximately 30 degrees Measure and reco...

Page 40: ...e their thickness 3 Lift the strike block assembly into position Do not trap the cable for the canopy lock micro switch 4 Do a latch force test Refer to Paragraph 3 Detail Steps Work Items Key Items References 1 Set the GEN BAT switch to ON 2 Close the canopy Make sure both hooks are engaged past the detent 3 Bend the micro switch actuator in the necessary direction to operate the warning light co...

Page 41: ...ove the air scoop lock 2 Remove the clear and tinted sliding window air scoop as follows Refer to Figure 203 Remove the screw the washer and the nut from the sliding window air scoop hinge Remove the hinge Remove the clear tinted sliding window air scoop 3 Remove the guide rails as follows Refer to Figure 203 Remove the nylon screws Remove the guide rails from the canopy window 4 Remove the slidin...

Page 42: ...ow Install the hinge block using two screws 2 Install the sliding window with the guide rails 3 Secure the guide rails with eight nylon screws 4 If the sliding window installed does not include the clear tinted sliding window air scoop and the air scoop lock install as follows Install the hinge with the screw the washer and the nut Install the clear tinted sliding window air scoop Install the air ...

Page 43: ...01 C1 30 Oct 09 Figure 201 Canopy Latch Installation without Outside Handles Strike Assembly Roller Bearing Pivot Pin Micro Switch Spring Pin Housing Conical Washers Outer Side Plate Inner Side Plate Spacer Stop Hook Assembly Adjusting Screw Strike Block Grip Shim ...

Page 44: ...e 202 Canopy Latch Installation with Outside Handles Hook Assembly Grip Inner Side Plate Bronze Bushing non removable Outside Handle Shim s Spacing Block Guide Plate Cover Plate Travel Limiting Screw Strike Assembly Roller Bearing Pivot Pin Micro Switch Strike Block Strike Plate Shim ...

Page 45: ...Page 209 Rev 16 52 10 00 Maintenance Practices DA20 C1 AMM DA201 C1 30 Oct 09 Figure 203 Sliding Window Assembly ...

Page 46: ...Maintenance Practices DA20 C1 AMM 52 10 00 30 Oct 09 Page 210 DA201 C1 Rev 16 Intentionally Left Blank ...

Page 47: ...anels The panels give access for maintenance Most panels are GFRP moldings Self tapping screws or camlock quick release fasteners hold the panels Refer to Chapter 71 10 for data about the engine cowlings Figure 1 shows the access panel locations on the bottom of the airplane Figure 1 Access Panel Locations on the Bottom of the Aircraft ...

Page 48: ...Doors DA20 C1 AMM 52 40 00 30 Oct 09 Page 2 DA201 C1 Rev 16 Intentionally Left Blank ...

Page 49: ...Page 1 Rev 16 53 TITLE Fuselage DA20 C1 AMM DA201 C1 30 Oct 09 CHAPTER 53 00 FUSELAGE ...

Page 50: ...Fuselage DA20 C1 AMM 53 TITLE 30 Oct 09 Page 2 DA201 C1 Rev 16 Intentionally Left Blank ...

Page 51: ... Page 1 14 Jan 13 TABLE OF CONTENTS Subject CH SE SU Page FUSELAGE 53 00 00 1 General 1 FUSELAGE STRUCTURE 53 10 00 1 General 1 Description 1 FUSELAGE MAINTENANCE PRACTICES 53 10 00 201 General 201 High Temperature Paint Repair of a Cowling 201 ...

Page 52: ...53 TOC DA20 C1 AMM Fuselage 14 Jan 13 Page 2 DA201 C1 Rev 21 Intentionally Left Blank ...

Page 53: ...also makes the vertical stabilizer The fuselage shells have many layers of glass cloth Some areas have more glass cloth than other areas This gives more strength and stiffness where it is needed The frames and webs also have many layers of glass cloth Some areas have layers of carbon fiber cloth to give extra strength Some components also have inserts for attaching brackets or other components Cha...

Page 54: ...Fuselage DA20 C1 AMM 53 00 00 14 Jan 13 Page 2 DA201 C1 Rev 21 Intentionally Left Blank ...

Page 55: ...Two GFRP shells make the outer skin of the fuselage The shells transmit structural loads The shells bond to each other at the top and bottom of the fuselage Each shell has many layers of glass cloth Some areas of the shell have more layers to give more strength and stiffness Thickened resin bonds all other structural components to the shells Many small components bond to the fuselage shells These ...

Page 56: ...Fuselage DA20 C1 AMM 30 Oct 09 Page 2 DA201 C1 Rev 16 53 10 00 Figure 1 Fuselage Shells and Front Fuselage Structure ...

Page 57: ... which holds the front mounting for the flap actuator A rigid GFRP insert holds the locking hook assembly for the main pins The center tunnel bonds to the fuselage shells the bulkhead forward control and the spar bridge G Spar bridge The spar bridge is a rigid GFRP box section molding It has layers of carbon cloth on the top and bottom faces Each end is a strong web Carbon cloth gives strength and...

Page 58: ...Fuselage DA20 C1 AMM 30 Oct 09 Page 4 DA201 C1 Rev 16 53 10 00 Figure 2 Front Fuselage Structure ...

Page 59: ...the fuselage shell just aft of the half bulkhead It has holes for the elevator control pushrod and the rudder control cables It has a cut out on the right side for a cable conduit N Ring Bulkhead 2 The ring bulkhead 2 is a rigid GFRP molding It bonds to the fuselage shell half way along the rear fuselage It has a guide bearing for the elevator control pushrod and holes for the rudder control cable...

Page 60: ...Fuselage DA20 C1 AMM 30 Oct 09 Page 6 DA201 C1 Rev 16 53 10 00 Figure 3 Rear Fuselage Structure ...

Page 61: ...gs for the horizontal stabilizer S Vertical Stabilizer Spar The vertical stabilizer spar is a rigid GFRP molding It bonds to the fuselage shell It also bonds to the upper and vertical stabilizer lower ribs The spar has mounting points for these components The elevator bellcrank The elevator trim actuator The rudder top bearing The rudder bottom bearing Two anti flutter brackets bond to the skin an...

Page 62: ...Fuselage DA20 C1 AMM 30 Oct 09 Page 8 DA201 C1 Rev 16 53 10 00 Figure 4 Vertical Stabilizer Structure ...

Page 63: ...at it will not be damaged 3 Carefully examine the cowling and identify the area s that require s repair At each step of the repair complete all areas of the cowling in need of repair for that sequence 4 Make an estimate of the repair s required and then get the materials and safety equipment satisfactory for the job For approved materials and suppliers refer to AMM Chapter 51 00 WARNING OBEY THE S...

Page 64: ...oth Cover the area s of the cowling that will not be painted Use masking tape to hold the cover s in place WARNING OBEY THE SAFETY PRECAUTIONS THAT FOLLOW WHEN YOU USE PAINTS USE SAFETY GOGGLES USE SAFETY CLOTHING DO NOT LET PAINTS TOUCH YOUR SKIN EYES OR MOUTH PAINTS ARE POISONOUS IF IRRITATION OCCURS GET MEDICAL AID DO THE WORK IN AN AREA THAT HAS A GOOD FLOW OF AIR DO THE WORK IN AN AREA THAT D...

Page 65: ... opened tack cloth 9 After a minimum of four hours apply the second coat of fire resistant paint with a splatter spray gun a brush or a roller to a minimum thickness of 0 010 in 250 microns Make sure that the painting is done in a dust free area 10 Let the fire resistant paint dry in a dust free area for a minimum of 24 hours 11 Before the transparent top coat is applied remove any dust that has c...

Page 66: ... a normal climate of 23 ºC and 50 humidity For product 9008B0900D Dry to Tape 10 to 14 hours Full cure 7days For product CA8720M0900C Dry to Tape 3 to 4 hours Full cure 7days 16 Remove and discard the cover s and masking tape from the cowling Remove any dust that has collected with a fully opened tack cloth 17 Visually inspect the completed high temperature paint repair s Make sure that there are ...

Page 67: ...Page 1 Rev 16 55 TITLE Stabilizers DA20 C1 AMM DA201 C1 30 Oct 09 CHAPTER 55 00 STABILIZERS ...

Page 68: ...Stabilizers DA20 C1 AMM 55 TITLE 30 Oct 09 Page 2 DA201 C1 Rev 16 Intentionally Left Blank ...

Page 69: ...ption 1 HORIZONTAL STABILIZER MAINTENANCE PRACTICES 55 10 00 201 General 201 Remove Install the Horizontal Stabilizer 201 ELEVATOR 55 20 00 1 General 1 Description 1 ELEVATOR MAINTENANCE PRACTICES 55 20 00 201 General 201 Remove Install the Elevator 201 LOWER FIN 55 30 00 1 General 1 Description 1 LOWER FIN MAINTENANCE PRACTICES 55 30 00 201 General 201 Remove Install the Lower Fin 201 ...

Page 70: ...age 2 DA201 C1 Rev 21 TABLE OF CONTENTS Subject CH SE SU Page RUDDER AND TAB 55 40 00 1 General 1 Description 1 RUDDER AND TAB MAINTENANCE PRACTICES 55 40 00 201 General 201 Remove Install the Rudder 201 Remove Install the Top Pivot Bushing 202 ...

Page 71: ... Center ribs fore and aft give strength to the center area A trailing edge web holds 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 lower fin is a GFRP mo...

Page 72: ...Stabilizers DA20 C1 AMM 55 00 00 14 Jan 13 Page 2 DA201 C1 Rev 21 Intentionally Left Blank ...

Page 73: ... from below The mount plate goes down through the large cut out in the bottom shell Four more holes in the bottom part of the mount plate attach to the vertical stabilizer top rib Fore and aft center ribs give strength to the center area Both ribs are rigid GFRP moldings They bond to the other components with bonding paste The front rib has a triangular shape The aft rib has sides with bends and a...

Page 74: ...Stabilizers DA20 C1 AMM 55 10 00 30 Oct 09 Page 2 DA201 C1 Rev 16 Intentionally Left Blank ...

Page 75: ...rsons to remove install the horizontal stabilizer Detail Steps Work Items Key Items References 1 Remove the horizontal stabilizer fairing Remove the four screws 2 Remove the bolt that connects the elevator vertical control rod to the elevator horn 3 Remove the two bolts that connect the lower mounting bracket to the upper mounting bracket 4 Remove the four bolts that attach the horizontal stabiliz...

Page 76: ...ll the two bolts that connect the lower mounting bracket to the upper mounting bracket Torque to 4 6 lbf ft 6 24 Nm 4 Install the bolt which connects the elevator vertical control rod to the elevator horn Torque to 1 2 lbf ft 1 7 Nm Make sure that the fork of the elevator trim actuator engages the spring mount on the control rod 5 Do a test for correct full and free movement of the elevator contro...

Page 77: ...e Upper Mounting Bracket Bottom Shell Rigid Foam Core Forward Rib Mount Plate Rear Web End Rib Aft Rib Center Elevator Hinge Outboard Elevator Hinges Top Shell Lower Mounting Bracket Refer to Chapter 20 00 Special torque values for bracket replacement Cut Out for Elevator Horn Hole For Access To Hinge Nuts Mounting Bolt ...

Page 78: ...Maintenance Practices DA20 C1 AMM 55 10 00 01 Nov 10 Page 204 DA201 C1 Rev 17 Intentionally Left Blank ...

Page 79: ...e of the leading edge spar has a flange which goes forward The shells bond together at this flange and at the trailing edge The hinges attach to the bottom shell Each hinge is a small metal block with a bush A bolt holds the block to the leading edge spar A small hole in the bottom shell near each hinge gives access to the attachment A large horn attaches to the bottom shell at the center The atta...

Page 80: ...Stabilizers DA20 C1 AMM 30 Oct 09 Page 2 DA201 C1 Rev 16 55 20 00 Figure 1 Elevator Structure ...

Page 81: ...izer fairing Remove the four screws 2 Remove the bolt that connects the elevator vertical control rod to the elevator horn 3 Remove the five elevator hinge bolts Hold the elevator There are two bolts outboard at each side and one center bolt through the control horn 5 Lift the elevator clear of the aircraft Detail Steps Work Items Key Items References 1 Put the elevator in position on the horizont...

Page 82: ...DA201 C1 Rev 16 4 Do a test for correct full and free movement of the elevator control If necessary adjust the elevator control Refer to Chapter 27 30 5 Install the horizontal stabilizer fairing Install the four screws Detail Steps Work Items Key Items References ...

Page 83: ...ctional stability It makes a tail bumper It also has a tie down point 2 Description Figure 1 shows the lower fin The lower fin is a rigid GFRP molding Five screws attach the lower fin to the bottom of the fuselage The bottom aft corner has a hole for a tie down rope Some lower fins may be filled with ballast made up of lead shot and epoxy ...

Page 84: ...Stabilizers DA20 C1 AMM 30 Oct 09 Page 2 DA201 C1 Rev 16 55 30 00 Figure 1 Lower Fin Attaching Screw Holes Lower Fin Tie Down Hole ...

Page 85: ...ad balls and epoxy Refer to Chapter 51 2 Remove Install the Lower Fin A Remove the Lower Fin B Install the Lower Fin Detail Steps Work Items Key Items References 1 Remove the adhesive tape that seals the joint between the lower fin and the fuselage 2 Remove the five screws that attach the fin to the fuselage Hold the fin 3 Remove the lower fin from the aircraft Detail Steps Work Items Key Items Re...

Page 86: ...Maintenance Practices DA20 C1 AMM 55 30 00 30 Oct 09 Page 202 DA201 C1 Rev 16 Intentionally Left Blank ...

Page 87: ...ells bond together all around with bonding paste The rudder has two pivots The top pivot pin bonds to the top face of the shells near the leading edge The top pivot has a bushing This bushing is a sacrificial point and will require periodic replacement The bottom pivot is part of the rudder support bracket assembly The rudder lower mounting plate also part of the rudder support bracket assembly at...

Page 88: ...Stabilizers DA20 C1 AMM 09 May 11 Page 2 DA201 C1 Rev 18 55 40 00 Figure 1 Rudder Structure Pivot Bushing ...

Page 89: ...ate Hold the rudder 2 Remove the rudder from the aircraft Move the bottom of the rudder aft then down to release the top pivot 3 Inspect the bushing on the pivot rudder pin Make sure that the bushing is not loose or damage Remove and replace bushing when loose or damaged Apply adhesive Loctite 680 to the replacement bushing and install Make sure that the bushing is free of adhesive on the outside ...

Page 90: ...apter 55 40 00 2 Clean remove all lubrication from the top pivot 3 Apply a small amount of heat using an appropriate heat source i e heat gun to soften the retaining 680 Loctite 4 Apply a torsional force to the pivot bushing to break it feel from the pivot pin Detail Steps Work Items Key Items References 1 Clean the surface of the pivot pin 2 Apply 680 Loctite to the pivot pin 3 Install the pivot ...

Page 91: ...Page 203 Rev 18 55 40 00 Maintenance Practices DA20 C1 AMM DA201 C1 09 May 11 Figure 201 Rudder Installation Pivot Bushing ...

Page 92: ...Maintenance Practices DA20 C1 AMM 55 40 00 09 May 11 Page 204 DA201 C1 Rev 18 Intentionally Left Blank ...

Page 93: ...Page 1 Rev 16 56 TITLE Windows DA20 C1 AMM DA201 C1 30 Oct 09 CHAPTER 56 00 WINDOWS ...

Page 94: ...Windows DA20 C1 AMM 56 TITLE 30 Oct 09 Page 2 DA201 C1 Rev 16 Intentionally Left Blank ...

Page 95: ...moval and Installation 1 REPAIR OF THE CANOPY TRANSPARENCY 56 10 00 1 Damage Limits 1 Tools and Equipment 1 Materials 1 Fillers 1 Temporary Repair to the Canopy Transparency 1 Permanent Repair to the Canopy Transparency 2 REPLACEMENT OF THE REAR WINDOW 56 11 00 1 Damage Limits 1 Tools and Equipment 1 Materials 1 Replacement of the Rear Window 2 ...

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Page 97: ... emergency windows The canopy has a hinge at the back and a stabilizing rod on each side The support arms have counterbalance springs to help operate the canopy A locking system locks the canopy closed Two latch levers operate the locking system One lever is on the inside of the canopy on the left side And one lever is on the inside of the canopy on the right side Later model aircraft are equipped...

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Page 99: ...e repair of the cockpit transparency NOTE A UV light cold is required to cure ACRYFIX 192 4 Fillers To compensate for the shrinkage of the fillers during the cure process the filler must be applied proud of the transparency surface As this is not possible when repairing a vertical crack in situ a strip of masking tape must be rolled up over the repair while simultaneously applying the filler This ...

Page 100: ...t for the repair put protective covers over the inside of the cockpit 3 Mask the area around the crack on the inner and outer surfaces of the canopy 4 Use a high speed grinder to cut a groove along the crack on the outer surface of the transparency Refer to Step 1 of Figure 3 5 On the outer surface countersink the temporary stop drill holes Refer to Step 1 of Figure 4 6 On the inner surface seal o...

Page 101: ...Apply filler to the groove and stop drill holes until the filler is proud of the transparency surface Leave the filler to cure Refer to Step 4 of Figures 3 and 4 11 Remove the masking tape from the surfaces of the canopy Refer to Step 5 of Figures 3 and 4 12 Grind the filler to the contour of the transparency surfaces and polish the repair with the recommended transparency polish 13 If protective ...

Page 102: ...Windows DA20 C1 AMM 30 Oct 09 Page 4 DA201 C1 Rev 16 56 10 00 Figure 2 Crack Limits No Cracks are permitted in the shaded area The maximum crack length is 150 mm 5 9 in ...

Page 103: ...Page 5 Rev 16 56 10 00 Windows DA20 C1 AMM DA201 C1 30 Oct 09 Figure 3 Crack Repairs ...

Page 104: ...Windows DA20 C1 AMM 30 Oct 09 Page 6 DA201 C1 Rev 16 56 10 00 Figure 4 Store Drill Hole Repair ...

Page 105: ...istance 2 Tools and Equipment The following tools and equipment are required for the replacement of the rear window High speed grinder Blade Drill Jigsaw Chisel 3 Materials The following materials are required for the replacement of the rear window Item Quantity Part Number Adhesive Terostat MS9380 Loctite 495 A R Commercial Black paintable acrylic caulking PF224 black sealant A R Commercial Clean...

Page 106: ...he bonding flange on the fuselage Use extreme care not to damage the surrounding composite or the bonding flange CAUTION KEEP BONDING SURFACES CLEAN FROM OIL DIRT AND OTHER CONTAMINANTS CAUTION WEAR GLOVES RESPIRATOR AND EYE PROTECTION WHEN HANDLING RESIN CLEANER AND ADHESIVE 6 Vacuum the frame and surrounding areas to remove any dust and debris 7 Glue small gum rubber shims 5 mm x 5 mm using Loct...

Page 107: ...o align the marks and to make the contour of the acrylic match that of the fuselage as closely as possible Avoid excess local pressure as this can lead to a wavy surface 18 Inspect for voids and for proper bond line 19 Remove excess adhesive from gap between edge of acrylic and fuselage on the outside and at edge of bonding flange on the inside 20 Apply enough flash tape to the exterior to provide...

Page 108: ...nsion on Glass Window 26 Allow the caulk to cure overnight 27 Remove masking or flash tape 28 Mask off fuselage and window in preparation for paint application Paint to original line on fuselage and extend paint line to cover frame line on window Refer to Figure 2 Refer to Chapter 51 00 Detail Steps Work Items Key Items References ...

Page 109: ...Page 1 Rev 16 57 TITLE Wings DA20 C1 AMM DA201 C1 30 Oct 09 CHAPTER 57 00 WINGS ...

Page 110: ...Wings DA20 C1 AMM 57 TITLE 30 Oct 09 Page 2 DA201 C1 Rev 16 Intentionally Left Blank ...

Page 111: ...TENANCE PRACTICES 57 10 00 201 General 201 Remove Install the Wings 201 Install a Wing Spar Bushing to a New Replacement Wing 207 Bolt Play 208 FLAPS 57 50 00 1 General 1 Description 1 FLAPS MAINTENANCE PRACTICES 57 50 00 201 General 201 Remove Install the Flap 201 AILERONS 57 60 00 1 General 1 Description 1 AILERONS MAINTENANCE PRACTICES 57 60 00 201 General 201 Remove Install the Aileron 201 ...

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Page 113: ...There is an aileron on the outboard trailing edge The wings are monocoque structure Each wing has top and bottom shells The shells have GFRP skins and a rigid foam core Each wing has an I section spar Carbon fiber rovings make the spar caps Each wing also has rigid GFRP ribs and webs Refer to Chapter 27 for data on the control systems for the flaps and ailerons Refer to Chapter 51 for general repa...

Page 114: ...Wings DA20 C1 AMM 57 00 00 14 Jan 13 Page 2 DA201 C1 Rev 21 Intentionally Left Blank ...

Page 115: ...al axis The wing has an anti vortex tip The aft end of the wing tip has a mounting for the position light assembly The bottom shell of both wings has holes for access panels below the flap and aileron bellcranks The bottom shell has a hole for an access panel below the B bolt This gives access to the B bolt for removing the wings The outer leading edge of both shells in the left wing has a cut out...

Page 116: ...nge brackets The web goes from the outer end of the flap to the outer end of the aileron F Flap Control Support Rib This small rib is close to the root rib It is a rigid GFRP molding It has a guide bearing for the flap control rod G Flap Control Rib The flap control rib is located half way along the aft inner web It is a rigid GFRP molding with an insert It has the mounting for the flap control be...

Page 117: ...Page 3 Rev 16 57 10 00 Wings DA20 C1 AMM DA201 C1 30 Oct 09 K Tie Down Insert The tie down insert gives strength to the tie down point in the bottom shell ...

Page 118: ...Wings DA20 C1 AMM 30 Oct 09 Page 4 DA201 C1 Rev 16 57 10 00 Figure 1 Wing Structure Shells Spar Root Rib and Webs ...

Page 119: ...Page 5 Rev 16 57 10 00 Wings DA20 C1 AMM DA201 C1 30 Oct 09 Figure 2 Wing Structure Ribs ...

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Page 121: ...hapter 25 10 Access panels below the fuselage for the control connections Refer to Chapter 52 40 Access panels below the wing roots for the B bolts Refer to Chapter 52 40 2 Disconnect the aileron control rods at the bell crank on the bulkhead aft control Refer to Chapter 27 10 Through the panels below the fuselage 3 Disconnect the flap control rods at the bell crank on the bulkhead aft control Ref...

Page 122: ...ll warning hose forward of the spar Left wing only The hose is 3 8 in 10 mm diameter Transparent Color 13 Disconnect the pitot hose forward of the spar Left wing only The hose is 5 16 in 8 mm diameter Green Color 14 Disconnect the static hose forward of the spar Left wing only The hose is 5 16 in 8 mm diameter Purple Color CAUTION DO NOT LIFT ON THE FLAP ONLY LIFT ON THE WING STRUCTURE OTHERWISE Y...

Page 123: ...Page 203 Rev 16 57 10 00 Maintenance Practices DA20 C1 AMM DA201 C1 30 Oct 09 Figure 201 Wing Attachment Bolts ...

Page 124: ...Maintenance Practices DA20 C1 AMM 57 10 00 30 Oct 09 Page 204 DA201 C1 Rev 16 Figure 202 Wing Connections ...

Page 125: ...ard of the spar Left wing only The hose is 5 16 in 8 mm diameter Purple Color 5 Connect the pitot hose forward of the spar Left wing only The hose is 5 16 in 8 mm diameter Green Color 6 Connect the stall warning hose forward of the spar Left wing only The hose is 3 8 in 10 mm diameter Transparent Color 7 Connect the electrical connector forward of the spar CAUTION DO NOT LIFT ON THE FLAP ONLY LIFT...

Page 126: ...ugh the panels below the fuselage Refer to Chapter 20 for standard torque values 18 Do a check of the flap controls for correct connection and operation Obey the instructions of your airworthiness authority for control checks 19 Do a check of the Aileron controls for correct connection and operation Obey the instructions of your airworthiness authority for control checks 20 Do a low range static l...

Page 127: ...an bonding surfaces with bare hands 6 Mix resin Refer to Chapter 51 00 7 Prepare thickened resin paste 8 Wet surfaces to be bonded with a thin coat of mixed resin not paste 9 Apply the paste to the outer surface of the bushing and the spar hole 10 Press the bushing into place 11 Remove any excess paste NOTE Coat the wing pin with mold release wax or equivalent This will aid in release if pin comes...

Page 128: ...dmissible values Spherical bearing for B bolt 0 89 mm 0 035 in To measure axial play the wing tip is to move forward then back the change in the gap between the fuselage and wing root rib directly above the B Bolt must not exceed the values stated in the above table 18 Use a heat source to heat the ambient air around the bushing installation Do not point the heat source directly at the composite m...

Page 129: ...G LEADING EGDE MOLD LINE Spacer Wing Assembly RH Bushing Main Bolt Spar Bushing Main Bolt Spar Filled Resin Spar Bridge Fuselage Bolt Main Spar Assembly Nut Self Locking SECTION B B SECTION C C DETAIL A Wing Assembly LH Wing Assembly RH 4400 ALONG LEADING EGDE MOLD LINE A B B C C 26 26 4400 330 290 4 29 3 77 20 55 0 0 0 72 0 26 0 0 05 Nominal 0 0 SEE DIHEDRAL WING ROOT REF AND SWEEP ...

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Page 131: ...kins The skins bond to a rigid plastic foam core Carbon cloth gives extra strength and stiffness in the outer skin B Bottom Shell The bottom shell has inner and outer GFRP skins The skins bond to a rigid plastic foam core Carbon cloth gives extra strength and stiffness in the outer skin C End Ribs The end ribs are rigid carbon moldings They bond to the top and bottom shells D Flap Horn The flap ho...

Page 132: ...Wings DA20 C1 AMM 30 Oct 09 Page 2 DA201 C1 Rev 16 57 50 00 Figure 1 Flap Structure ...

Page 133: ... the Flap A Remove the Flap Detail Steps Work Items Key Items References CAUTION MAKE SURE THAT THE AREA UNDER THE FLAPS IS CLEAR BEFORE YOU MOVE THE FLAPS 1 Lower the flaps Set the BAT GEN switch to ON Set the flap selector to LDG When the flaps stop moving Set the BAT GEN switch to OFF 2 Remove the bolt which attaches the control rod to the flap horn Hold the flap 3 Remove the pivot bolts from t...

Page 134: ...hat there is a gap of 0 12 0 20 in 3 5 mm between the flap and the aileron 3 Install the bolt which attaches the control rod to the flap horn 4 Install the bushing Ream the bushing to Ø 9 525 0 010 and 0 050 after installation to fit properly 5 Do a test for correct adjustment of the flaps Refer to AMM Chapter 27 50 6 Do an inspection of the flap controls which you disconnected or adjusted 7 If ne...

Page 135: ...Page 203 Rev 18 57 50 00 Maintenance Practices DA20 C1 AMM DA201 C1 09 May 11 Figure 201 Flap Connections Bushing Hinge ...

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Page 137: ...n B Bottom Shell The bottom shell has inner and outer GFRP skins The skins bond to a rigid plastic foam core Carbon cloth gives extra strength and stiffness in the outer skin C End Ribs The end ribs are rigid carbon moldings They bond to the top and bottom shells The outer end rib has the mounting for the aileron mass balance D Aileron Horn The aileron horn is aluminum alloy Bolts and nuts attach ...

Page 138: ...Wings DA20 C1 AMM 30 Oct 09 Page 2 DA201 C1 Rev 16 57 60 00 Figure 1 Aileron Structure ...

Page 139: ... Key Items References 1 Put the aileron in position on the aircraft Hold the aileron 2 Install the pivot bolts in the hinges and the aileron horn Hold the aileron Make sure that there is a gap of 0 12 0 20 in 3 5 mm between the flap and the aileron Make sure that aileron axial play does not exceed 1 mm If play exceeds 1 mm install a washer P N NAS1149C0432R at the control horn hinge to reduce the ...

Page 140: ...4 Jan 13 Page 202 DA201 C1 Rev 21 Figure 201 Aileron Connections Bushing Plain Bearing Pivot Bolt Aileron Hinge Assembly On The Wing Aileron Hinge Assembly On The Wing Aileron Hinge Aileron Horn Control Rod Bolt Bushing Pivot Bolt Washer Optional ...

Page 141: ...Page 1 Rev 16 61 TITLE Propeller DA20 C1 AMM DA201 C1 30 Oct 09 CHAPTER 61 00 PROPELLER ...

Page 142: ...Propeller DA20 C1 AMM 61 TITLE 30 Oct 09 Page 2 DA201 C1 Rev 16 Intentionally Left Blank ...

Page 143: ...TS Subject CH SE SU Page PROPELLER 61 00 00 1 General 1 PROPELLER ASSEMBLY 61 10 00 1 General 1 Description 1 PROPELLER ASSEMBLY TROUBLESHOOTING 61 10 00 101 General 101 PROPELLER ASSEMBLY MAINTENANCE PRACTICES 61 10 00 201 General 201 Remove Install the Sensenich Propeller 204 ...

Page 144: ...61 TOC DA20 C1 AMM Propeller 14 Jan 13 Page 2 DA201 C1 Rev 21 Intentionally Left Blank ...

Page 145: ...61 00 00 Propeller DA20 C1 AMM DA201 C1 14 Jan 13 PROPELLER 1 General This chapter describes about the propeller installed on the DA20 C1 aircraft For data on the propeller refer to the manufacturer s Owner s Manual ...

Page 146: ...Propeller DA20 C1 AMM 61 00 00 14 Jan 13 Page 2 DA201 C1 Rev 21 Intentionally Left Blank ...

Page 147: ...Deleted B Sensenich W69EK7 63 W69EK7 63G and W69EK 63 Propeller Figures 202 and 203 show the Sensenich propeller It is a Sensenich fixed pitch propeller with two blades The propeller blades are made of wood laminations The W69EK7 63G propeller has a thin composite layer covering the wood laminations A backing plate attaches to the rear of the propeller The backing plate holds a spinner with a 2 pi...

Page 148: ...Propeller DA20 C1 AMM 61 10 00 30 Oct 09 Page 2 DA201 C1 Rev 16 Intentionally Left Blank ...

Page 149: ...LER AND OR THE PROPELLER BOLTS POSSIBLY EVEN LOSS OF THE PROPELLER TO PREVENT THIS PROPER INSTALLATION AND PERIODIC RE TORQUING IN ACCORDANCE WITH ALL APPLICABLE MAINTENANCE INSTRUCTIONS IS NECESSARY WARNING UNDER ALL CIRCUMSTANCES THE INSPECTION INTERVAL MUST NEVER EXCEED 50 HOURS EXTREME CHANGES IN AMBIENT CONDITIONS TEMPERATURE HUMIDITY MAY REQUIRE SHORTER INSPECTION INTERVALS Engine vibration ...

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Page 151: ...OFF 2 Remove the engine cowlings Refer to Chapter 71 10 3 Release the ignition leads from the spark plugs NOTE Mark the propeller spinner forward bulkhead and aft bulkhead with an index mark This will help you install these items in the correct position 4 Remove the spinner front dome Refer to Figure 202 Mark the spinner and backing plate with index marks to aid installation Release the screws hol...

Page 152: ...LICABLE MAINTENANCE INSTRUCTIONS IS NECESSARY WARNING UNDER ALL CIRCUMSTANCES THE INSPECTION INTERVAL MUST NEVER EXCEED 50 HOURS EXTREME CHANGES IN AMBIENT CONDITIONS TEMPERATURE HUMIDITY MAY REQUIRE SHORTER INSPECTION INTERVALS 9 Remove the propeller by pulling forward with a slight rocking motion 10 Lift the propeller clear of the aircraft 11 If necessary remove the backing plate Detail Steps Wo...

Page 153: ...re 203 for W69EK7 63 or W69EK7 63G propeller castellated nuts only 9 Connect the ignition leads to the spark plugs Torque to 110 120 lbf in 12 4 13 5 Nm 10 Install the engine cowlings Refer to AMM Chapter 71 10 11 Do an engine ground run up Look specially for vibration Refer to the DA20 C1 Airplane Flight Manual for engine start stop procedures Following the installation of the propeller Check bol...

Page 154: ...W69EK 63 Sensenich Propeller Assembly Propeller Extension Attaching Bolt Pressure Plate 22 6101 00 01 Spinner Attaching Screw Spinner Attaching Screw Backing Plate C 2397P Spinner Aft Dome Spinner Forward Dome Fibre Washer Fibre Washer Recommended installation in line with 1 TDC compression ...

Page 155: ...Page 205 Rev 21 61 10 00 Maintenance Practices DA20 C1 AMM DA201 C1 14 Jan 13 Figure 202 Sensenich W69EK7 63 and W69EK7 63G Propeller Installation ...

Page 156: ...Maintenance Practices DA20 C1 AMM 61 10 00 14 Jan 13 Page 206 DA201 C1 Rev 21 Intentionally Left Blank ...

Page 157: ...Page 1 Rev 16 71 TITLE Power Plant DA20 C1 AMM DA201 C1 30 Oct 09 CHAPTER 71 00 POWER PLANT ...

Page 158: ...Power Plant DA20 C1 AMM 71 TITLE 30 Oct 09 Page 2 DA201 C1 Rev 16 Intentionally Left Blank ...

Page 159: ...PLANT MAINTENANCE PRACTICES 71 00 00 201 General 201 Remove Install the Engine 201 COWLING 71 10 00 1 General 1 Description 1 COWLING TROUBLESHOOTING 71 10 00 101 General 101 COWLING MAINTENANCE PRACTICES 71 10 00 201 General 201 Remove Install the Cowlings 201 High Temperature Paint Repair of a Cowling 202 MOUNTS 71 20 00 1 General 1 Description 1 MOUNTS MAINTENANCE PRACTICES 71 20 00 201 General...

Page 160: ...ANCE PRACTICES 71 60 00 201 General 201 Remove Install the Air Intake 201 ENGINE DRAINS 71 70 00 1 General 1 Description 1 ENGINE DRAINS TROUBLESHOOTING 71 70 00 101 General 101 ENGINE DRAINS MAINTENANCE PRACTICES 71 70 00 201 General 201 Remove Install the Fuel Distribution Manifold Drain 201 Remove Install The Cylinder Drain 202 Remove Install the Fuel Pump Drain 203 ...

Page 161: ...er to the Continental Motors IO 240 Series Engine and Overhaul Manual Publication M 6 for data on the fuel injection system Chapter 74 00 Ignition system power supply and installation routing and attachment of high tension cables Refer to the Slick Maintenance Manual for other data Refer to the Continental Motors IO 240 Series Engine and Overhaul Manual Publication M 6 for data on the spark plugs ...

Page 162: ...Power Plant DA20 C1 AMM 14 Jan 13 Page 2 DA201 C1 Rev 21 71 00 00 Figure 1 Power Plant ...

Page 163: ...s Rubber and metal bushings make the engine shock mounts C Electrical Harness Electrical cables go through the firewall to connect to the engine They give electrical supply to the engine starter motor and engine sensors Electrical cables from the generator supply electrical power to the aircraft bus D Air Intakes The GFRP air intake attaches below the front of the engine Two flexible hoses from th...

Page 164: ... 9 cu cm Brake Horsepower Rated Maximum Continuous Operation 125 HP 2800 Recommended for Cruise 95 HP 2550 Crankshaft Speed Rated Maximum Continuous Operation 2800 Minimum full power ground static rpm 2100 Idle 1000 25 Intake Manifold Pressure at Idle 18 5 In Hg Max Fuel Control System Continental Continuous Flow Injector Fuel For Fuel grade Refer to the Teledyne Continental Maintenance Manual Oil...

Page 165: ...er Head Temperature Recommended Max at Cruise 380 F 193 C Limit 460 F 237 C Bayonet Thermocouple AS234 with AS236 adapter Ignition Timing Compression stroke breaker opens Right Magneto degrees BTC IO 240B 26 1 Left Magneto degrees BTC IO 240B 26 1 Spark Plugs The following Spark Plugs are approved for use in IO 240B engines Continental Motors 630049 Champion RHM 38E Spark Plug Gap You must use the...

Page 166: ...Power Plant DA20 C1 AMM 71 00 00 14 Jan 13 Page 6 DA201 C1 Rev 21 Intentionally Left Blank ...

Page 167: ... engine system trouble shooting WARNING YOU MUST BE CAREFUL WHEN YOU DO POWER PLANT TROUBLE SHOOTING OPERATION OF A DAMAGED ENGINE CAN CAUSE MORE DAMAGE TO THE ENGINE THIS CAN CAUSE INJURY TO PERSONNEL TROUBLE POSSIBLE CAUSE REPAIR Engine vibration Damaged shock mounts Replace the shock mounts CAUTION YOU MUST LET ALL THE FUEL DRAIN FROM THE INTAKE SYSTEM IF YOU DO NOT DO THIS STARTING AN ENGINE W...

Page 168: ...Troubleshooting DA20 C1 AMM 71 00 00 30 Oct 09 Page 102 DA201 C1 Rev 16 Intentionally Left Blank ...

Page 169: ...IDLE CUT OFF WARNING DO NOT GO BELOW THE ENGINE WHEN YOU LIFT THE ENGINE WITH THE HOIST THE HOIST CAN FAIL THIS CAN CAUSE DEATH OR INJURY TO PERSONS 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 FIRE BURNS AND CAN CAUSE INJURY TO PEOPLE AND DAMAGE TO EQUIPMENT CAUTION YOU MUST ATTACH CAPS TO HOLES PIP...

Page 170: ...Maintenance Practices DA20 C1 AMM 71 00 00 30 Oct 09 Page 202 DA201 C1 Rev 16 Figure 201 Connections at the Rear of the Engine ...

Page 171: ...to LEAN CUT OFF 4 Remove the engine cowlings Refer to Chapter 71 10 5 Disconnect the aircraft battery Refer to Chapter 24 31 6 Disconnect the spark plug leads from the spark plugs and remove the spark plugs 7 Put blanks in the spark plug holes in the cylinder head This will stop contamination going into the cylinders 8 Put the tail trestle under the rear fuselage Put weight attached to straps over...

Page 172: ...ent point Carefully pull the flexible drive clear of the engine WARNING DO NOT GET FUEL ON YOU FUEL CAN CAUSE SKIN DISEASE DO NOT ALLOW FIRE NEAR FUEL FIRE BURNS AND CAN CAUSE INJURY TO PEOPLE AND DAMAGE TO EQUIPMENT 14 Disconnect the inlet and return fuel hoses from the injector fuel pump Put the caps on the two fuel hoses and put the caps on the two injector fuel pump connections This will stop ...

Page 173: ...op contamination going into the vacuum system 19 Remove the shield from the right side of the aft baffle Remove the manifold fuel pressure hose clear of the aft baffle engine 20 Remove the two worm drive clamps from the flexible pipe between the muffler and the cabin heat control valve Remove the flexible pipe 21 Remove the engine exhaust system Refer to Chapter 78 00 Remove the eight nuts from th...

Page 174: ...usting nut from the front of the control cable Move the throttle control cable clear of the bracket Remove the rear adjusting nut from the control cable 25 Move the throttle control cable clear of the engine as follows Release the P clamp holding the cable to the engine mounting frame Carefully pull the throttle control cable through the rubber grommet at the aft baffle 26 Disconnect the mixture c...

Page 175: ... the mixture cable keeper to the bracket Remove the mixture cable keeper Remove the mixture control cable from the front support bracket 28 Move the mixture control cable clear of the engine as follows For aircraft with a standard fuel pump Carefully pull the mixture control cable through the rubber grommet at the aft baffle For aircraft with an altitude compensating fuel pump Remove the rod end a...

Page 176: ... 32 Remove the instrument panel cover Refer to Chapter 25 10 to get access to the engine mounting frame bolts 33 Examine the engine compartment Make sure that all the connections to the engine are clear WARNING DO NOT GO BELOW THE ENGINE WHEN YOU LIFT THE ENGINE WITH THE HOIST THE HOIST CAN FAIL THIS CAN CAUSE DEATH OR INJURY 34 Take up the tension on the hoist 35 Disconnect the engine mounting fr...

Page 177: ...ions on the Left of the Engine 1 Air Intake Pipe Clamp Air Intake Pipe Support Bracket Air Intake Pipe Clamp Oil Cooling Air Pipe Clamp Oil Cooling Air Pipe Clamp Cabin Heating Air Pipe Clamp Air Intake to Heat Exchanger Pipe Clamps Oil Inlet And Return Pipes Exhaust Manifold Nuts Spark Plug Leads ...

Page 178: ...Maintenance Practices DA20 C1 AMM 71 00 00 30 Oct 09 Page 210 DA201 C1 Rev 16 Figure 203 Connections on the Left of the Engine 2 ...

Page 179: ...ight of the Engine Rear Lifting Eye Front Lifting Eye Throttle Cable Bracket Throttle Cable P Clamp Throttle Cable Connection Generator Control Cables Generator Power Cable P Clips Holding Fuel Pipes And Electrical Cables Spark Plug Leads Heat Shield Heat Shield Attaching Screws Vacuum Pipe Starter Power Cable ...

Page 180: ...DA201 C1 Rev 16 Figure 205 Connections on the Top of the Engine Spark Plug Leads Spark Plug Leads Fuel Pressure Hose P Clamp Holding Throttle Cable Fuel Pressure Sensor Throttle Cable Attachment Bracket Generator Cables Throttle Cable Connection to Throttle Lever ...

Page 181: ... the engine compartment Look especially for damage and chafing to the following items Electrical cables Engine mounting studs Firewall Cabin heat control valve Ground connection Oil cooler Engine control cables Fuel Hoses NOTE After you have done the examination of the cabin heat control valve install the flexible hose to the cabin heat control valve This will make the installation of the flexible...

Page 182: ...he grip length of the bolt can be varied to compensate for differences in the composite thickness Install the four plain washers Attach the four self locking nuts Put a wrench on the heads of the bolts Tighten the four nuts Refer to Chapter 20 for torque 8 Install the nose gear elastomer pack to the engine mounting frame Refer to Chapter 32 20 9 Release the tension on the hoist 10 Disconnect the h...

Page 183: ... connector Install the worm drive clamp Tighten the worm drive clamp 18 Attach the engine ground cable to the bottom of the blanking plate on the engine accessory housing Tighten the bolt Refer to the Continental Motors IO 240 Series Engine and Overhaul Manual Publication M 6 for the torque value 19 Install the tachometer drive shaft Put the flexible drive shaft into the engine accessory case at t...

Page 184: ...able The generator two cables Attach the electrical cable to P clips 23 Install the P clip that attaches the fuel pump and cylinder drain pipes to the firewall 24 Cut the locking wire from the oil sump drain plug Remove the oil sump drain plug Drain the preservation oil from the oil sump into a correct oil container 25 Install the oil sump drain plug Tighten the oil sump drain plug Torque to 190 2...

Page 185: ...e aft baffle 29 Install the mixture control cable into the support bracket at the front of the engine as follows For aircraft with a standard fuel pump Install the rear adjusting nut to the control cable Put the control cable in position through the bracket Install the forward adjusting nut to the control cable For aircraft with an altitude compensating fuel pump Insert the end of the mixture cont...

Page 186: ...hten the assembly For aircraft with an altitude compensating fuel pump Install the jam nut and rod end onto the mixture control cable Put the thin washer under the head of the bolt Insert the bolt into the mixture lever from the inboard side Put one washer onto the bolt on the other side of the mixture lever Put the rod end onto the bolt Put one washer onto the bolt Put the large diameter washer o...

Page 187: ... cable to the top right tube of the engine mounting frame 33 Install the eye end of the throttle control cable onto the throttle lever Put one washer under the head of the bolt Put the bolt through the eye end of the control cable Put one washer onto the bolt on the other side of the eye end Attach the bolt to the throttle lever Put one washer on the bolt Attach the nut to the bolt Tighten the ass...

Page 188: ...e propeller to the engine Refer to Chapter 61 00 39 Connect the aircraft battery Refer to Chapter 24 31 40 Do an engine oil level check Refer to Chapter 12 10 41 Install the bottom four spark plugs to the four cylinders Tighten the four spark plugs Torque to 300 360 lbf in 34 40 Nm 42 Do the engine pre oil procedure Refer to the Continental Motors IO 240 Series Engine and Overhaul Manual Publicati...

Page 189: ...er to Chapter 71 10 CAUTION TELEDYNE CONTINENTAL RECOMMEND THAT YOU DO A FLIGHT TEST BEFORE YOU RELEASE THE AIRCRAFT FOR NORMAL USE THIS WILL MAKE SURE THE PISTON RINGS HAVE SEATED AND THAT THERE ARE NO LEAKS FROM THE ENGINE SYSTEMS 49 Do an engine flight test Refer to the Continental Motors IO 240 Series Engine and Overhaul Manual Publication M 6 and the DA20 C1 Airplane Flight Manual for Operati...

Page 190: ...Maintenance Practices DA20 C1 AMM 71 00 00 14 Jan 13 Page 222 DA201 C1 Rev 21 Intentionally Left Blank ...

Page 191: ...r CFRP moldings make the power plant top and bottom cowlings A strip of carbon fiber bonded to the edges of the cowlings makes them strong Camlock fasteners installed around the edge of the cowlings attach them to the airframe A hinge attaches the oil filler access panel to the top cowling and a rotary lock holds it closed Polyurethane paint protects the outside skin from ultraviolet rays and humi...

Page 192: ...Power Plant DA20 C1 AMM 30 Oct 09 Page 2 DA201 C1 Rev 16 71 10 00 Figure 1 Engine Cowlings ...

Page 193: ...le explains how to troubleshoot the cowling If you find the trouble in column 1 do the repair given in column 3 TROUBLE POSSIBLE CAUSE REPAIR Cowling damaged Not installed correctly Replace repair the damaged cowling Camlock fastener damaged missing Camlock fastener defective Replace the defective camlock fastener ...

Page 194: ...Troubleshooting DA20 C1 AMM 71 10 00 30 Oct 09 Page 102 DA201 C1 Rev 16 Intentionally Left Blank ...

Page 195: ...tems Key Items References 1 Unlock the camlock fasteners from the top cowling 2 Remove the top cowling from the aircraft 3 Unlock the camlock fasteners from the bottom cowling Hold the cowling 4 Remove the bottom cowling from the aircraft Detail Steps Work Items Key Items References 1 Inspect the cowlings for damage Look especially for damage to the camlock fasteners 2 Put the bottom cowling in po...

Page 196: ...ach step of the repair complete all areas of the cowling in need of repair for that sequence 4 Make an estimate of the repair s required and then get the materials and safety equipment satisfactory for the job For approved materials and suppliers refer to AMM Chapter 51 00 WARNING OBEY THE SAFETY PRECAUTIONS THAT FOLLOW WHEN YOU DO WORK WITH COMPOSITE MATERIALS DO THE WORK IN AN AREA THAT HAS A GO...

Page 197: ...ck cloth Cover the area s of the cowling that will not be painted Use masking tape to hold the cover s in place WARNING OBEY THE SAFETY PRECAUTIONS THAT FOLLOW WHEN YOU USE PAINTS USE SAFETY GOGGLES USE SAFETY CLOTHING DO NOT LET PAINTS TOUCH YOUR SKIN EYES OR MOUTH PAINTS ARE POISONOUS IF IRRITATION OCCURS GET MEDICAL AID DO THE WORK IN AN AREA THAT HAS A GOOD FLOW OF AIR DO THE WORK IN AN AREA T...

Page 198: ... that has collected with a fully opened tack cloth 9 After a minimum of four hours apply the second coat of fire resistant paint with a splatter spray gun a brush or a roller to a minimum thickness of 0 010 in 250 microns Make sure that the painting is done in a dust free area 10 Let the fire resistant paint dry in a dust free area for a minimum of 24 hours 11 Before the transparent top coat is ap...

Page 199: ...The following drying times refer to a normal climate of 23 ºC and 50 humidity For product 9008B0900D Dry to Tape 10 to 14 hours Full cure 7days For product CA8720M0900C Dry to Tape 3 to 4 hours Full cure 7days 16 Remove and discard the cover s and masking tape from the cowling Remove any dust that has collected with a fully opened tack cloth 17 Visually inspect the completed high temperature paint...

Page 200: ...Maintenance Practices DA20 C1 AMM 71 10 00 30 Oct 09 Page 206 DA201 C1 Rev 16 Intentionally Left Blank ...

Page 201: ...he engine to the airframe Figure 201 shows the engine mounting frame Refer to the Teledyne Continental Maintenance Manual for data on the engine shock mounts 2 Description The engine mounting frame attaches to the firewall with bolts and self locking nuts Tubular steel makes the mounting frame The mounting frame attaches to the engine with shock mounts Rubber and metal bushings make the engine sho...

Page 202: ...Power Plant DA20 C1 AMM 71 20 00 30 Oct 09 Page 2 DA201 C1 Rev 16 Intentionally Left Blank ...

Page 203: ...a on the shock mounts 2 Remove Install the Engine Mounting Frame A Remove the Engine Mounting Frame Detail Steps Work Items Key Items References NOTE The removal procedure of the engine mounting frame that follows has the engine removed from the aircraft 1 Put a support below the mounting frame before you disconnect it 2 Remove the P clip that attaches the air oil separator vent pipe to the mounti...

Page 204: ...alled correctly Put the two support struts into position Put the two top bolts through the support struts and mounting frame to hold the engine mounts in position Heads aft Put the two shock mounts into position on the two bolts at the forward face of the engine Refer to the Teledyne Continental Motors Maintenance Manual for shock mount assembly data Install the two nuts and the washers 5 Assemble...

Page 205: ...ten the four nuts Torque to 180 190 lbf in 20 4 21 5 Nm 7 Install the P clip that attaches the air oil separator vent pipe to the mounting frame 8 Install the P clip that attaches the fuel pump and cylinder drain pipes to the mounting frame Detail Steps Work Items Key Items References ...

Page 206: ...Maintenance Practices DA20 C1 AMM 71 20 00 30 Oct 09 Page 204 DA201 C1 Rev 16 Figure 201 Engine Mounting Frame ...

Page 207: ...g primary intake supplies air through a filter assembly and large flexible hose to the engine intake manifold The right opening supplies unfiltered air through a duct and large flexible hose to the heat exchanger on the muffler The rear opening alternate intake has a door assembly A bowden cable controls the door position from the cockpit If the filter in the left opening becomes blocked you can s...

Page 208: ...71 60 00 Figure 1 Air Intakes Air Intake Pipe Clamp Air Intake Air Intake Pipe Support Bracket Air Intake Pipe Clamp Oil Cooling Air Pipe Clamp Oil Cooling Air Pipe Clamp Cabin Heating Air Pipe Clamp Air Intake to Heat Exchanger Pipe Clamps Induction Manifold ...

Page 209: ...ail Steps Work Items Key Items References 1 Remove the engine cowlings Refer to Chapter 71 10 2 Disconnect the control cable from the alternate air lever Remove the following items Nut Bolt Two washers Return spring Disconnect the control cable 3 Remove the air intake from the bottom of the engine 4 Remove the four nuts that attach to the mounting frame bolts Remove the two worm drive clamps from ...

Page 210: ...d washers Lock wire the bolts Make sure the two flexible hoses are clear of debris Connect the two flexible hoses to the air intake Install the two worm drive clamps to the flexible hoses at the air intake 3 Install the control cable to the alternate air lever Install the following items Bolt Washer Control cable eye end Return spring Lever arm Washer Nut Tighten the assembly Torque to 1 2 lbf ft ...

Page 211: ... pipes connect from the cylinder heads to a T piece connector below the engine From the T piece connector the drain pipes connect to a single pipe on the left side of the engine The pipe has a check valve installed Rubber hose connects the outlet from the check valve to a fuel drain assembly at the bottom of the firewall When the engine starts the check valve closes At engine start and engine shut...

Page 212: ...ne Engine Cylinder Drain Connection T Piece Injector Pump Gland Drain From Fuel Manifold See Figure 2 Type 2 Drains Rubber Tubes Fuel Drain Outlet Assembly Ty Wrap Hose Clamps Ambient Pressure Line Aft Fuel Pump Drain Line Forward Fuel Pump Drain Line Detail A Aircraft with altitude compensating fuel pump only ...

Page 213: ...Page 3 Rev 16 71 70 00 Power Plant DA20 C1 AMM DA201 C1 30 Oct 09 Figure 2 Drains on the Right Side of the Engine Fuel Manifold Drain Fuel Drain Outlet Assembly See Figure 1 Oil Air Separator Vent Pipe ...

Page 214: ...Power Plant DA20 C1 AMM 71 70 00 30 Oct 09 Page 4 DA201 C1 Rev 16 Intentionally Left Blank ...

Page 215: ... CAUSE REPAIR Fuel leaks from the fuel distribution manifold drain The internal diaphragm of the fuel distribution manifold has failed Replace the fuel distribution manifold Refer to the Continental Motors IO 240 Series Engine and Overhaul Manual Publication M 6 Fuel leaks from the fuel pump drain The internal seal of the fuel pump has failed Replace the fuel pump Refer to the Continental Motors I...

Page 216: ...Troubleshooting DA20 C1 AMM 71 70 00 30 Oct 09 Page 102 DA201 C1 Rev 16 Intentionally Left Blank ...

Page 217: ...NEAR FUEL FIRE BURNS AND CAN CAUSE INJURY TO PEOPLE AND DAMAGE TO EQUIPMENT 2 Remove Install the Fuel Distribution Manifold Drain A Remove the Fuel Distribution Manifold Drain B Install the Fuel Distribution Manifold Drain Detail Steps Work Items Key Items References 1 Remove the engine cowlings Refer to Chapter 71 10 2 Loosen the hose clamp on the fuel drain outlet assembly Pull the hose from the...

Page 218: ...e the engine cowlings Refer to Chapter 71 10 2 Loosen the hose clamp on the fuel drain outlet assembly Pull the cylinder drain hose from the assembly 3 Release the fuel drain bracket below the bottom left shock mount 4 Disconnect the check valve from the T piece connector below the engine Remove the drain pipe and check valve assembly Detail Steps Work Items Key Items References 1 Examine the drai...

Page 219: ...eference line from the fuel pump 5 Remove the drain pipe assembly Detail Steps Work Items Key Items References 1 Examine the drain pipe Make sure that the inner bore of the pipe is clear On aircraft equipped with an altitude compensating fuel pump examine the ambient pressure reference line Make sure the inner bore of the pipe is clear 2 Put the drain pipe and check valve assembly in position belo...

Page 220: ...Maintenance Practices DA20 C1 AMM 71 70 00 30 Oct 09 Page 204 DA201 C1 Rev 16 Intentionally Left Blank ...

Page 221: ...Page 1 Rev 16 72 TITLE Engine DA20 C1 AMM DA201 C1 30 Oct 09 CHAPTER 72 00 ENGINE ...

Page 222: ...Engine DA20 C1 AMM 72 TITLE 30 Oct 09 Page 2 DA201 C1 Rev 16 Intentionally Left Blank ...

Page 223: ...72 TOC Engine DA20 C1 AMM Rev 21 DA201 C1 Page 1 14 Jan 13 TABLE OF CONTENTS Subject CH SE SU Page ENGINE 72 00 00 1 General 1 Description 1 ...

Page 224: ...72 TOC DA20 C1 AMM Engine 14 Jan 13 Page 2 DA201 C1 Rev 21 Intentionally Left Blank ...

Page 225: ... An accessory case closes the rear of the crankcase The accessory case has drive pads for the starter and two magnetos Refer to Chapter 80 00 for data about the starter Refer to Chapter 74 00 for data about the ignition system Four cylinders attach to the crankcase Number 1 cylinder is at the rear on the right Refer to Figure 1 for the cylinder numbering An oil sump attaches to the bottom of the c...

Page 226: ...Engine DA20 C1 AMM 14 Jan 13 Page 2 DA201 C1 Rev 21 72 00 00 Figure 1 Engine ...

Page 227: ...Page 1 Rev 16 73 TITLE Engine Fuel and Control DA20 C1 AMM DA201 C1 30 Oct 09 CHAPTER 73 00 ENGINE FUEL AND CONTROL ...

Page 228: ...Engine Fuel and Control DA20 C1 AMM 73 TITLE 30 Oct 09 Page 2 DA201 C1 Rev 16 Intentionally Left Blank ...

Page 229: ...ription 1 ENGINE FUEL AND CONTROL TROUBLESHOOTING 73 00 00 101 General 101 ENGINE FUEL AND CONTROL MAINTENANCE PRACTICES 73 00 00 201 General 201 Remove Install the Induction Air Filter 201 Remove Install the Fuel Pressure Sensor 202 Remove Install the Fuel Pressure Indicator 204 Fuel Pressure Indicator Functional Test 205 Engine Fuel System Bleeding Procedure 205 ...

Page 230: ...73 TOC DA20 C1 AMM Engine Fuel and Control 14 Jan 13 Page 2 DA201 C1 Rev 21 Intentionally Left Blank ...

Page 231: ...th a down draft induction system The intake manifold supplies air to the air distribution system The air distribution system mounts above the engine cylinders it sends induction air to the cylinder intake ports The cylinder intake ports are cast into the cylinder head assembly The air mixes with fuel from the injector nozzles where it enters the cylinders as a combustible mixture The fuel injectio...

Page 232: ...ld increases the flow to the engine injection nozzles increases The fuel pressure sensor measures the pressure If the pressure increases the indicator shows a higher pressure C Fuel Hoses in the Engine Compartment Figures 2 and 3 show the fuel hoses in the engine compartment Two hoses connect the engine fuel injection pump to the aircraft fuel system The fuel supply hose connects to the through nu...

Page 233: ...Page 3 Rev 21 73 00 00 Engine Fuel and Control DA20 C1 AMM DA201 C1 14 Jan 13 Figure 1 Location and Installation of the Fuel Pressure Sensor ...

Page 234: ...Engine Fuel and Control DA20 C1 AMM 14 Jan 13 Page 4 DA201 C1 Rev 21 73 00 00 Figure 2 Fuel Hoses in the Engine Compartment ...

Page 235: ...Page 5 Rev 21 73 00 00 Engine Fuel and Control DA20 C1 AMM DA201 C1 14 Jan 13 Figure 3 Fuel Hoses in the Engine Compartment with Light Weight Heat Shield ...

Page 236: ...Engine Fuel and Control DA20 C1 AMM 73 00 00 14 Jan 13 Page 6 DA201 C1 Rev 21 Intentionally Left Blank ...

Page 237: ...nduction air filter Engine gives low power Induction air filter blocked Replace the blocked induction air filter Engine difficult to start Air trapped in the fuel hose to the fuel pressure sensor Bleed the fuel system Fuel pressure indication incorrect Fuel pressure sensor defective Replace the pressure sensor Fuel pressure indicator defective Replace the fuel pressure indicator High resistance or...

Page 238: ...Troubleshooting DA20 C1 AMM 73 00 00 30 Oct 09 Page 102 DA201 C1 Rev 16 Intentionally Left Blank ...

Page 239: ...blems 2 Remove Install the Induction Air Filter A Remove the Induction Air Filter B Install the Induction Air Filter 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 1 Remove the engine cowlings Refer to Chapter 71 10 2 Remove the rubber seal from the air intake The rubb...

Page 240: ...from the fuel pressure sensor Refer to Figure 201 WARNING DO NOT ALLOW HEAT OR FIRE NEAR FUEL FUEL BURNS VIOLENTLY THIS CAN CAUSE INJURY TO PERSONS AND DAMAGE TO EQUIPMENT WARNING DO NOT GET FUEL ON YOUR SKIN FUEL CAN CAUSE SKIN DISEASE 4 Set the fuel shut off valve to CLOSED Refer to Chapter 28 00 5 Release the fuel hose from the pressure sensor Put caps on the open connections For aircraft with ...

Page 241: ...EQUIPMENT WARNING DO NOT GET FUEL ON YOUR SKIN FUEL CAN CAUSE SKIN DISEASE 3 Remove the blanking caps from the new sensor and the fuel pipe 4 Connect the fuel pipe to the sensor For aircraft with the fuel pressure sensor installed through the aft baffle refer to Figure 201 Detail C remove the pressure sensor from the tee fitting 5 Set the fuel shut off valve to OPEN Refer to Chapter 28 00 6 Connec...

Page 242: ...cover for access Refer to Chapter 25 10 3 Disconnect the wires from the fuel pressure indicator 4 Release the ring which attaches the fuel pressure indicator 5 Remove the fuel pressure indicator Detail Steps Work Items Key Items References 1 Put the fuel pressure indicator in position in the instrument panel 2 Install the ring that attaches the fuel pressure indicator 3 Connect the wires to the fu...

Page 243: ...onal test 3 Operate the engine through the RPM range Look especially for correct operation of the fuel pressure indication system 4 Stop the engine Refer to the DA20 C1 Airplane Flight Manual for procedures Detail Steps Work Items Key Items References WARNING DO NOT ALLOW HEAT OR FIRE NEAR FUEL FUEL BURNS VIOLENTLY THIS CAN CAUSE INJURY TO PERSONS AND DAMAGE TO EQUIPMENT WARNING DO NOT GET FUEL ON...

Page 244: ... be pulled through 2 turns to remove fuel from the cylinders CAUTION DO NOT ATTEMPT TO START THE ENGINE UNTIL ALL FUEL HAS DRAINED FROM THE ENGINE DRAINS THIS PROCEDURE FLOODS THE INTAKE SYSTEM ATTEMPTING TO START THE ENGINE CAN CAUSE A HYDROSTATIC LOCK AND SUBSEQUENT ENGINE FAILURE 11 Remove the container for the engine drains 12 Do an engine run up test For the engine run procedures refer to the...

Page 245: ...Page 207 Rev 16 73 00 00 Maintenance Practices DA20 C1 AMM DA201 C1 30 Oct 09 Figure 201 Location and Installation of the Fuel Pressure Sensor ...

Page 246: ...Maintenance Practices DA20 C1 AMM 73 00 00 30 Oct 09 Page 208 DA201 C1 Rev 16 Intentionally Left Blank ...

Page 247: ...Page 1 Rev 16 74 TITLE Ignition DA20 C1 AMM DA201 C1 30 Oct 09 CHAPTER 74 00 IGNITION ...

Page 248: ...Ignition DA20 C1 AMM 74 TITLE 30 Oct 09 Page 2 DA201 C1 Rev 16 Intentionally Left Blank ...

Page 249: ...General 101 IGNITION MAINTENANCE PRACTICES 74 00 00 201 General 201 Ignition Switch Test 201 Remove Install the Ignition Switch Pre SB DAC1 74 03 Rev 2 202 Remove Install the Ignition Switch Optional Post SB DAC1 74 03 Rev 2 204 Remove Install the Ignition Switch Cables 205 Remove Install the Spark Plug Leads 207 Starting Vibrator Battery Test 209 Remove Install The Starting Vibrator Battery 209 ...

Page 250: ...74 TOC DA20 C1 AMM Ignition 14 Jan 13 Page 2 DA201 C1 Rev 21 Intentionally Left Blank ...

Page 251: ...al Publication M 6 for data on the other ignition system components and for the trouble shooting of the following items The ignition system has the following components Ignition Switch Ignition cables Two Magnetos Starting vibrator Shower of Sparks system Ignition Harness Spark plug leads Spark Plugs 2 Description and Operation The DA20 C1 aircraft has a dual ignition system Two Slick magnetos sup...

Page 252: ...Ignition DA20 C1 AMM 14 Jan 13 Page 2 DA201 C1 Rev 21 74 00 00 Figure 1 Ignition System Schematic Diagram BOTTOM SPARK PLUGS TOP SPARK PLUGS 1 3 2 2 4 1 3 4 4 3 2 1 ...

Page 253: ...magneto has an additional set of contact points These points are active only when the engine is being started D High Tension Cables Ignition Harness Each magneto supplies high tension pulses to one spark plug in each cylinder High tension leads spark plug leads connect the magnetos to the spark plugs Each lead has a center core which transmits the high tension electricity It also has a layer of in...

Page 254: ...Ignition DA20 C1 AMM 74 00 00 14 Jan 13 Page 4 DA201 C1 Rev 21 Intentionally Left Blank ...

Page 255: ...on components TROUBLE POSSIBLE CAUSE REPAIR Engine does not start not easy to start Ignition switch switch cable defective Do the ignition switch test If necessary replace the ignition switch Refer to the ignition switch remove install procedure Replace the ignition switch cables Refer to the ignition switch cables remove install procedure Defective ignition spark plug leads Replace the spark plug...

Page 256: ...Troubleshooting DA20 C1 AMM 74 00 00 30 Oct 09 Page 102 DA201 C1 Rev 16 Intentionally Left Blank ...

Page 257: ...IS SAFE BEFORE YOU DO WORK ON THE IGNITION SYSTEM DISCONNECT THE SPARK PLUG LEADS MAKE SURE THAT THE IGNITION SWITCH IS IN THE OFF POSITION THE P LEADS ARE GROUNDED THE THROTTLE IS SET TO CLOSED THE MIXTURE CONTROL IS SET TO LEAN CUT OFF 1 Remove the engine cowlings Refer to Chapter 71 10 00 2 Make sure that the spark plug leads are disconnected from the spark plugs and the battery is disconnected...

Page 258: ... 5 Connect the spark plug leads to the spark plugs Torque to 110 120 lbf in 12 4 13 5 Nm 6 Install the engine cowlings Refer to Chapter 71 10 00 7 Do an engine run up test Refer to the DA20 C1 Airplane Flight Manual Detail Steps Work Items Key Items References 1 Disconnect the aircraft battery Refer to Chapter 24 31 00 2 Remove the engine cowlings Refer to Chapter 71 10 00 3 Disconnect the spark p...

Page 259: ... Disconnect the ignition cables P leads from the magnetos Do a resistance test between each switch cable and ground for each switch setting Set the ignition switch to OFF Both cables zero ohms Set the ignition switch to R Left zero ohms right open circuit Set the ignition switch to L Left open circuit right zero ohms Set the ignition switch to BOTH Both cables open circuit Set the ignition switch ...

Page 260: ...efer to Chapter 25 10 00 5 Remove the knurled ring from the front of the ignition switch Move the ignition switch clear of the instrument panel 6 Disconnect the electrical cables from the ignition switch Record the cable connections 7 Remove the ignition switch from the aircraft Detail Steps Work Items Key Items References 1 Disconnect the spark plug leads from the spark plugs Refer to Chapter 24 ...

Page 261: ...e ignition switch to OFF Both cables zero ohms Set the ignition switch to R Left zero ohms right open circuit Set the ignition switch to L Left open circuit right zero ohms Set the ignition switch to BOTH Both cables open circuit Set the ignition switch to START Left retard point cable open circuit right and left advance cable zero ohms Set the ignition switch to OFF Connect the ignition switch ca...

Page 262: ...n switch Record the cable connections 9 Disconnect the ground connections at the switch 10 Loosen the bulkhead shield Pull the ignition cables through he shield Remove the ignition switch cables Detail Steps Work Items Key Items References 1 Make sure that the spark plug leads are disconnected from the spark plugs and the battery is disconnected Refer to Chapter 24 31 2 Put the new cables in posit...

Page 263: ... Left retard point cable open circuit right and left advance cable zero ohms Set the ignition switch to OFF 5 Connect the switch cables P leads at the left right magneto Refer to Chapter 92 for wiring diagrams 6 Connect the ground connector at the left right magneto Refer to Chapter 92 for wiring diagrams 7 Install the tie wraps that hold the ignition switch cables 8 Install the instrument panel c...

Page 264: ... shield 6 Carefully pull the four spark plug leads through the aft baffle and remove 7 Remove the four spark plug leads that connect to the bottom spark plugs Detail Steps Work Items Key Items References 1 Before you install the spark plug leads do a test on each cable for a short circuit from the center core to the sheath Use a high voltage tester Megger If you get a short circuit then replace th...

Page 265: ...teps Work Items Key Items References 1 Set Battery switch to OFF 2 Remove the engine cowlings Refer to Chapter 71 10 00 3 Measure voltage between positive and negative terminals of starting vibrator battery Replace starting vibrator battery if voltage below 12V 4 Install the engine cowlings Refer to Chapter 71 10 00 Detail Steps Work Items Key Items References 1 Remove the engine cowlings Refer to...

Page 266: ... with terminals facing forward 2 Tighten gear clamp 3 Connect the battery positive lead to the starting vibrator battery positive terminal 4 Connect the battery negative lead to the starting vibrator battery negative terminal 5 Connect the aircraft battery Refer to Chapter 24 31 00 6 Install the engine cowlings Refer to Chapter 71 10 00 7 Do an engine run up test Refer to the DA20 C1 Airplane Flig...

Page 267: ...Page 211 Rev 18 74 00 00 Maintenance Practices DA20 C1 AMM DA201 C1 09 May 11 Figure 201 Ignition Switch Installation Pre SB DAC1 74 03 Rev 2 ...

Page 268: ...ractices DA20 C1 AMM 74 00 00 09 May 11 Page 212 DA201 C1 Rev 18 Figure 202 Optional Ignition Switch Installation Post SB DAC1 74 03 Rev 2 Wire attachment for new ignition switch Ignition switch with new face plate ...

Page 269: ...Page 1 Rev 16 75 TITLE Air DA20 C1 AMM DA201 C1 30 Oct 09 CHAPTER 75 00 AIR ...

Page 270: ...Air DA20 C1 AMM 75 TITLE 30 Oct 09 Page 2 DA201 C1 Rev 16 Intentionally Left Blank ...

Page 271: ... C1 AMM Rev 21 DA201 C1 Page 1 14 Jan 13 TABLE OF CONTENTS Subject CH SE SU Page AIR COOLING 75 00 00 1 General 1 Description 1 AIR COOLING MAINTENANCE PRACTICES 75 00 00 201 General 201 Remove Install the Baffles 201 ...

Page 272: ...75 TOC DA20 C1 AMM Air 14 Jan 13 Page 2 DA201 C1 Rev 21 Intentionally Left Blank ...

Page 273: ...ont part of the LH and RH baffles attaches to the apron baffle The rear of each baffle bends around the rear cylinder for a short distance Two screws attach each baffle to the aft baffle C LH Aft and RH Aft Baffles Aluminum LH aft and RH aft baffles attach to the related LH and RH baffle They also attach to the bottom of the aft baffle D Aft Baffle The GFRP or CFRP aft baffle attaches to the inter...

Page 274: ...Air DA20 C1 AMM 14 Jan 13 Page 2 DA201 C1 Rev 21 75 00 00 Figure 1 Winter Baffle Kit Installation ...

Page 275: ...AUSE DEATH OR INJURY TO PERSONS WARNING YOU MUST MAKE SURE THAT THE ENGINE IS SAFE BEFORE YOU TURN THE PROPELLER DISCONNECT THE SPARK PLUG LEADS MAKE SURE THAT THE IGNITION SWITCH IS IN THE OFF POSITION THE P LEADS ARE GROUNDED THE THROTTLE IS SET TO IDLE THE MIXTURE CONTROL IS SET TO LEAN CUT OFF 1 Remove the engine cowlings Refer to Chapter 71 10 2 Make the engine safe Disconnect the spark plug ...

Page 276: ...or aircraft with an altitude compensating fuel pump Remove the nut Remove the bolt Remove the three washers 6 For aircraft with a standard fuel pump Remove the mixture control cable and bracket from the apron Remove the screw and the spring washer For aircraft with an altitude compensating fuel pump Remove the mixture control cable from the front support bracket Remove the nuts the washers and the...

Page 277: ... FIRE BURNS AND CAN CAUSE INJURY TO PEOPLE AND DAMAGE TO EQUIPMENT CAUTION YOU MUST ATTACH CAPS TO HOLES PIPES WHEN YOU DISCONNECT THEM IF YOU DO NOT DO THIS CONTAMINATION CAN ENTER THE HOLES PIPES THIS CAN CAUSE BLOCKAGE TO THE AIRCRAFT SYSTEMS 8 Disconnect these items and pull them carefully through the aft baffle The throttle control cable Refer to Chapter 76 00 The mixture control cable Refer ...

Page 278: ... the baffle and one at the front of the baffle 11 Remove the LH and RH aft baffles Remove the three screws and the washers from the LH aft bracket Remove the three screws and the washers from RH aft bracket 12 Remove the aft baffle Remove the two screws and the plain washers that attach the aft baffle to the inter cylinder brackets 13 Disconnect the two electrical connectors from the generator and...

Page 279: ... the screws 2 Connect the two electrical connectors to the generator Carefully put the generator electrical cables through the rubber grommet in the apron Attach the main electrical supply cable to the generator Attach the plain washer spring washer and nut to the stud Tighten the nut and pull the rubber boot over the connection Install the electrical indication connector to the generator 3 Instal...

Page 280: ...s and the plain washers that attach to the LH baffle Tighten the screws 7 Install the RH aft baffle Install the two screws and the plain washers that attach to the RH baffle Tighten the screws 8 Install the aft baffle Attach the two screws and the washers that attach the aft baffle to the inter cylinder brackets Tighten the screws Attach the three screws and the washers to the RH aft baffle that a...

Page 281: ...he oil separator Attach the worm drive clamp and tighten 11 Put the ignition cables through the rear baffle 12 Install the two cable shields to the aft baffle Tighten the nuts and bolts 13 Install the throttle control cable to the support bracket at the top of the plenum assembly Position the throttle control cable correctly in the support bracket Install the two bolts the washers and the nuts Tig...

Page 282: ...t the end of the mixture control cable through the hole in the apron Slide the notch in the control cable into the slot of the support bracket Install the keeper onto the cable and slide it into place Install the screws the washers and the nuts to secure the keeper to the bracket Tighten the assembly 16 Install the mixture control cable to the mixture control lever on the fuel pump Refer to AMM Ch...

Page 283: ...e bolt Put the large diameter washer onto the bolt Attach the nut to the bolt Tighten the assembly 17 For aircraft with a standard fuel pump Put the mixture control cable in the support bracket at the top of the engine Attach the cable to the bracket with a tie wrap For aircraft with an altitude compensating fuel pump Secure the mixture control cable to the 2 cylinder induction tube using a cable ...

Page 284: ...he top and bottom engine cowlings Refer to Chapter 71 10 23 Do an engine operational test For the engine run procedures refer to the DA20 C1 Airplane Flight Manual For the operational test refer to Continental Motors IO 240 Series Engine and Overhaul Manual Publication M 6 Refer to the operational checklist in AMM Chapter 05 20 for difference in static RPM settings 24 Examine the engine for oil fu...

Page 285: ...Page 211 Rev 16 75 00 00 Maintenance Practices DA20 C1 AMM DA201 C1 30 Oct 09 Figure 201 Air Baffles ...

Page 286: ...Maintenance Practices DA20 C1 AMM 75 00 00 30 Oct 09 Page 212 DA201 C1 Rev 16 Intentionally Left Blank ...

Page 287: ...Page 1 Rev 16 76 TITLE Engine Controls DA20 C1 AMM DA201 C1 30 Oct 09 CHAPTER 76 00 ENGINE CONTROLS ...

Page 288: ...Engine Controls DA20 C1 AMM 76 TITLE 30 Oct 09 Page 2 DA201 C1 Rev 16 Intentionally Left Blank ...

Page 289: ...ENGINE CONTROLS TROUBLESHOOTING 76 00 00 101 General 101 ENGINE CONTROLS MAINTENANCE PRACTICES 76 00 00 201 General 201 Remove Install The Throttle Bowden Cable 201 Remove Install the Mixture Control Bowden Cable 207 Remove Install the Alternate Air Control Bowden Cable 214 Throttle Mixture Control Range Of Movement Test 221 Alternate Air Control Range of Movement Test 226 ...

Page 290: ...76 TOC DA20 C1 AMM Engine Controls 14 Jan 13 Page 2 DA201 C1 Rev 21 Intentionally Left Blank ...

Page 291: ...tle controls the engine RPM from IDLE to FULL The throttle lever is the center lever in the control quadrant A bowden cable connects between the throttle lever in the cockpit and the throttle valve at the engine The bowden cable eye end attaches to the throttle lever with a bolt The outer sheath of the bowden cable has a threaded end fitting Two nuts attach the end fitting to a tab bent from the s...

Page 292: ...Engine Controls DA20 C1 AMM 14 Jan 13 Page 2 DA201 C1 Rev 21 76 00 00 Figure 1 Engine Controls In The Cockpit ...

Page 293: ...aded end that attaches to a bracket at the apron with two nuts which can be used to adjust the range of movement of the mixture control lever The bowden cable wire end attaches to the fuel mixture control lever of the fuel pump through a hole in the attachment bolt You can adjust the length of the wire at this point to set the correct fuel mixture control position On aircraft equipped with an alti...

Page 294: ...and a return spring You can adjust the length of the wire at this point to set the correct Alternate air valve position D Friction Adjuster The friction adjuster adjusts the force necessary to move the three control levers in the throttle quadrant The friction adjuster control knob is on the right hand side of the center console Nylon washers and 4 spring washers attached to the lever axis adjust ...

Page 295: ...s not correctly adjusted Do a range of movement check Adjust the mixture controls Cannot control the engine Broken throttle bowden cable Replace the broken bowden cable Throttle control not set correctly Do a range of movement check Adjust the throttle controls Bowden cable not free to move Replace the bowden cable Throttle lever hard to move Friction adjuster incorrectly set Check adjust friction...

Page 296: ...Troubleshooting DA20 C1 AMM 76 00 00 30 Oct 09 Page 102 DA201 C1 Rev 16 Intentionally Left Blank ...

Page 297: ...RE CAN OCCUR IF THE CONTROL INSTALLATION AND ADJUSTMENT ARE NOT DONE CORRECTLY THIS CAN CAUSE DEATH OR INJURY TO PERSONS 2 Remove Install The Throttle Bowden Cable A Remove the Throttle Bowden Cable 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 MAKE SURE THAT ...

Page 298: ...he bowden cable Loosen the adjustment nut and remove the eye end 6 Remove the bowden cable from the support bracket at the top of the engine Remove the forward nut from the bowden cable Move the bowden cable clear of the bracket Remove the rear nut from the bowden cable 7 Remove the P clamp which attaches the bowden cable to the engine mounting frame 8 Carefully pull the bowden cable through the r...

Page 299: ...late Lever the TRIM switch clear 15 Remove the center console cover from the center console Remove the six screws from the two sides of the center console cover 16 Disconnect the eye end of the throttle bowden cable from the throttle lever at the quadrant Remove the bolt and the two washers 17 Disconnect the outer sheath of the throttle bowden cable from the tab at the throttle quadrant frame Remo...

Page 300: ...Maintenance Practices DA20 C1 AMM 76 00 00 30 Oct 09 Page 204 DA201 C1 Rev 16 Figure 201 Throttle Control Installation ...

Page 301: ...een installed correctly 4 Install the eye end to the quadrant throttle lever Refer to Figure 201 Install the bolt the two washers and the nut Torque to 1 2 lbf ft 1 7 Nm 5 Put the bowden cable through the rubber grommet at the aft baffle CAUTION MAKE SURE THAT THE SUPPORT BRACKET IS ATTACHED TO THE INDUCTION HOUSING WITH A FILLISTER HEAD SCREW AND THE SCREW IS LOCK WIRED IF YOU DO NOT DO THIS THE ...

Page 302: ...econd inspection of the controls 12 Do a check for loose items in the cockpit Look especially in the area of the control quadrant 13 Install the instrument panel cover Refer to Chapter 25 10 14 Install the center console cover to the center console 15 Install the TRIM switch to the face plate Push the Trim switch into position in the face plate Connect the connector below the face plate 16 Install...

Page 303: ...HE PROPELLER CAN CAUSE DEATH OR INJURY TO PERSONS WARNING MAKE SURE THAT THE ENGINE IS SAFE BEFORE YOU DO WORK ON THE IGNITION SYSTEM DISCONNECT THE SPARK PLUG LEADS MAKE SURE THAT THE IGNITION SWITCH IS IN THE OFF POSITION THE P LEADS ARE GROUNDED THE THROTTLE IS SET TO CLOSED THE MIXTURE CONTROL IS SET TO LEAN CUT OFF 1 Remove the engine cowlings Refer to Chapter 71 10 2 Disconnect the aircraft ...

Page 304: ... cable from the support bracket at the apron For aircraft with a standard fuel pump Remove the bottom nut from the bowden cable Move the bowden cable clear of the bracket Remove the top nut from the bowden cable For aircraft with an altitude compensating fuel pump Remove the nuts the washers and the screws that fasten the mixture cable to the mixture support bracket Remove the mixture cable keeper...

Page 305: ...h to the firewall Remove the washers and the screws Remove the two angled feed thru halves from the engine side of the firewall 11 Remove the control knobs from the following levers at the center console PARKING BRAKE HEAT control ON OFF HEAT distribution DEFROST FLOOR 12 Remove the two parts of the engine controls face plate from the center console cover Remove the four screws 13 Disconnect and r...

Page 306: ...s 1 Put the mixture control bowden cable through the firewall 2 Put the mixture control bowden cable through the tab at the control quadrant Refer to Figure 202 Sheets 1 and 2 Install the two nuts that hold the bowden cable to the tab 3 Install the cable end to the swivel fitting of the quadrant mixture lever Tighten the attachment screw 4 Put the bowden cable through the rubber grommet at the aft...

Page 307: ... 6 Install the cable end to the mixture control lever at the engine For aircraft with a standard fuel pump Put the cable end through the hole in the swivel bolt Tighten the screw in the swivel bolt For aircraft with an altitude compensating fuel pump Install the jam nut and rod end onto the mixture control cable Put the rod end on the bolt in the mixture control lever Put one washer onto the bolt ...

Page 308: ...ce Adjust cable as necessary Install the engine cowlings Refer to Chapter 71 10 Completely seal the angled split bushing and mixture control cable using firewall sealant Use Product PR 812 MIL S 38249 Type 1 Fire Wall Sealant 9 Do a test for correct range full and free movement of the mixture control system Refer to the Mixture Control Test Procedure in this Chapter 10 Do an inspection of the cont...

Page 309: ...ols freedom of movement check 17 Install the ignition leads to the spark plugs Tighten the B nuts Torque to 110 120 lbf in 12 4 13 5 Nm 18 Connect the aircraft battery Refer to Chapter 24 31 19 Install the engine cowlings Refer to Chapter 71 10 20 Do an operational check of the elevator trim control system 21 Do an engine run up test Refer to the DA20 C1 Airplane Flight Manual Detail Steps Work It...

Page 310: ...CONNECT THE SPARK PLUG LEADS MAKE SURE THAT THE IGNITION SWITCH IS IN THE OFF POSITION THE P LEADS ARE GROUNDED THE THROTTLE IS SET TO CLOSED THE MIXTURE CONTROL IS SET TO LEAN CUT OFF 1 Remove the engine cowlings Refer to Chapter 71 10 2 Disconnect the aircraft battery Refer to Chapter 24 31 3 Make the engine safe Disconnect the spark plug leads Make sure that the ignition switch is set to OFF po...

Page 311: ...e control knobs from the following levers at the center console PARKING BRAKE HEAT control ON OFF HEAT distribution DEFROST FLOOR 10 Remove the two parts of the engine controls face plate from the center console cover Remove the four screws 11 Disconnect and remove the TRIM switch from the face plate Disconnect the connector below the face plate Lever the TRIM switch clear 12 Remove the center con...

Page 312: ...CABLE IS IN SAFETY IF YOU DO NOT DO THIS THE CONTROL CABLE CAN DISCONNECT THIS CAN CAUSE DEATH OR INJURY TO PERSONS 3 Install the cable end to the quadrant alternate air lever Tighten the attachment screw 4 Install the bowden cable to the support bracket at the air intake 5 Install the cable end to the alternate air lever at the air intake 6 Install the feed thru to the engine side of the firewall...

Page 313: ...l the 2 parts of the engine controls face plate to the center console cover 14 Install the control lever knobs to the following items PARKING BRAKE HEAT control ON OFF HEAT distribution DEFROST FLOOR 15 Do an engine controls freedom of movement check 16 Install the ignition leads to the spark plugs Tighten the B nuts Torque to 110 120 lbf in 12 4 13 5 Nm 17 Connect the aircraft battery Refer to Ch...

Page 314: ...Maintenance Practices DA20 C1 AMM 76 00 00 30 Oct 09 Page 218 DA201 C1 Rev 16 Figure 202 Mixture Control Installation Sheet 1 of 2 ...

Page 315: ...Page 219 Rev 16 76 00 00 Maintenance Practices DA20 C1 AMM DA201 C1 30 Oct 09 Figure 202 Mixture Control Installation Altitude Compensating Fuel Pump Sheet 2 of 2 ...

Page 316: ... CONSOLE Swivel Alternate Air Bowden Cable Forward Adjustment Nut Forward Adjustment Nut Aft Adjustment Nut Aft Adjustment Nut Tab On Left Side Of Control Quadrant Alternate Air Control Lever Knob Spacer Screw LEFT SIDE OF ENGINE Mounting Bracket Spring Bolt Washers Self Locking Nut Alternate Air Lever FIREWALL Firewall Feed Thru ...

Page 317: ...t range of movement You should set the controls to give 0 125 in 3 mm clearance bounce at the face plate A Throttle Control Range Of Movement Test 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 MAKE SURE THAT THE ENGINE IS SAFE BEFORE YOU DO WORK ON THE IGNITIO...

Page 318: ...cessary adjust the bowden cable outer sheath at the engine support bracket With the throttle valve lever on the full stop there must be a minimum of 0 125 in 3 mm clearance bounce between the face plate and the throttle lever in the cockpit 7 Move the throttle control lever between IDLE and FULL Refer to Chapter 25 10 Make sure the lever moves freely with no restriction 8 Do items 5 and 6 again as...

Page 319: ...N THE P LEADS ARE GROUNDED THE THROTTLE IS SET TO CLOSED THE MIXTURE CONTROL IS SET TO LEAN CUT OFF 1 Remove the engine cowlings Refer to Chapter 71 10 2 Disconnect the aircraft battery Refer to Chapter 24 31 3 Make the engine safe Disconnect the spark plug leads Make sure that the ignition switch is set to OFF position Make sure the P leads are grounded Set the throttle to IDLE Set the mixture co...

Page 320: ...ing fuel pump Make sure the mixture valve lever hits the RICH stop at the mixture valve If necessary adjust the bowden cable outer sheath at the throttle quadrant tab With the mixture valve lever on the RICH stop the mixture lever in the cockpit must contact the forward stop in the throttle quadrant 10 Set the mixture control lever to LEAN CUT OFF and hold it in position For aircraft with a standa...

Page 321: ...er console Install the six screws to the two sides of the center console cover 16 Install the TRIM switch to the face plate Push the Trim switch into position in the face plate Connect the connector below the face plate 17 Install the 2 parts of the engine controls face plate to the center console cover 18 Install the control lever knobs to the following items PARKING BRAKE HEAT control ON OFF HEA...

Page 322: ...er to Chapter 71 10 2 Disconnect the aircraft battery Refer to Chapter 24 31 3 Make the engine safe Disconnect the spark plug leads Make sure that the ignition switch is set to OFF position Make sure the P leads are grounded Set the throttle to IDLE Set the mixture control to LEAN CUT OFF 4 Move the alternate air control lever between OFF and ON Make sure the lever moves freely with no restriction...

Page 323: ...ternate air door opens fully at the air intake 8 Move the alternate air control lever between OFF and ON Make sure the lever moves freely with no restriction 9 Do steps 5 and 6 again as necessary to get the correct values 10 Do an inspection of the control connections which you disconnected If necessary for your airworthiness authority do a second inspection of the controls 11 Install the ignition...

Page 324: ...Maintenance Practices DA20 C1 AMM 76 00 00 30 Oct 09 Page 228 DA201 C1 Rev 16 Intentionally Left Blank ...

Page 325: ...Page 1 Rev 16 77 TITLE Engine Indicating DA20 C1 AMM DA201 C1 30 Oct 09 CHAPTER 77 00 ENGINE INDICATING ...

Page 326: ...Engine Indicating DA20 C1 AMM 77 TITLE 30 Oct 09 Page 2 DA201 C1 Rev 16 Intentionally Left Blank ...

Page 327: ...101 ENGINE INDICATING MAINTENANCE PRACTICES 77 00 00 201 General 201 Remove Install the RPM Indicator 201 Remove Install the RPM Indicator Flexible Drive 202 Remove Install the Cylinder Head Temperature CHT Thermocouple Probe 204 Remove Install the Exhaust Gas Temperature EGT Thermocouple Probe 205 Remove Install The Exhaust Gas Temperature EGT Indicator 206 Remove Install the Cylinder Head Temper...

Page 328: ...77 TOC DA20 C1 AMM Engine Indicating 14 Jan 13 Page 2 DA201 C1 Rev 21 Intentionally Left Blank ...

Page 329: ... front of the instrument panel hold the RPM indicator in position A flexible gear shaft that rotates inside a protective cover gives the drive to the RPM indicator The flexible shaft connects from the engine through the engine firewall to the rear of the RPM indicator Gears inside the RPM indicator take the mechanical input from the shaft and turn the indicator needle to give the correct RPM indic...

Page 330: ...nd reduce the problems of engine wear associated with cold starts Tanis engine preheat system applies heat directly to the cylinder heads oil sump and crankcase This makes sure thorough heating of the entire engine in a safe and reliable manner The sump heater element attaches to the aft lower portion of the sump with the power lead to the right The power lead is secured to the oil line that runs ...

Page 331: ...Page 3 Rev 21 77 00 00 Engine Indicating DA20 C1 AMM DA201 C1 14 Jan 13 Figure 1 Locations of Engine Indicating Sensors and Indicators ...

Page 332: ...Engine Indicating DA20 C1 AMM 77 00 00 14 Jan 13 Page 4 DA201 C1 Rev 21 Intentionally Left Blank ...

Page 333: ...rical cable Defective cylinder head temperature indicator Replace the defective cylinder head temperature indicator High cylinder head temperature indication Defective engine Refer to the Continental Motors IO 240 Series Engine and Overhaul Manual Publication M 6 Defective cylinder head temperature indicator Replace the defective cylinder head temperature indicator No exhaust gas temperature indic...

Page 334: ...Troubleshooting DA20 C1 AMM 77 00 00 30 Oct 09 Page 102 DA201 C1 Rev 16 Intentionally Left Blank ...

Page 335: ...K ON THE SYSTEM THE EXHAUST SYSTEM CAN BE HOT THIS CAN CAUSE INJURY TO PERSONS Refer to the Continental Motors IO 240 Series Engine and Overhaul Manual Publication M6 for data on the engine 2 Remove Install the RPM Indicator A Remove the RPM Indicator Detail Steps Work Items Key Items References 1 Remove the instrumental panel cover Refer to Chapter 25 10 2 Remove the flexible drive from the rear ...

Page 336: ...fer to Chapter 25 10 4 Do an engine run up test Make sure that the RPM indication is correct Refer to the DA20 C1 Airplane Flight Manual Detail Steps Work Items Key Items References 1 Remove the instrumental panel cover Refer to Chapter 25 10 2 Remove the flexible drive from the rear of the RPM indicator Disconnect the knurled nut on the end of the flexible drive from the rear of the RPM indicator...

Page 337: ... drive through the firewall 2 Put the flexible drive shaft into the engine accessory case at the attachment point and install the knurled nut to the accessory case housing 3 Put the end of the flexible drive shaft into the rear of the RPM indicator and install the knurled nut of the drive shaft onto the rear of the RPM indicator 4 Install the drive shaft attachment bracket to the firewall and seal...

Page 338: ...u will install a new CHT thermocouple probe Cut the electrical cables close to the CHT thermocouple probe 3 Remove the CHT thermocouple probe from the bottom of the left rear cylinder Detail Steps Work Items Key Items References 1 Install the CHT thermocouple probe into the bottom of the left rear cylinder 2 If necessary connect the electrical cables with in line splices 3 Install the engine cowli...

Page 339: ...Y TO PERSONS 1 Remove the engine cowlings Refer to Chapter 71 10 2 Only do this if you will install a new EGT thermocouple probe Cut the electrical cables close to the EGT thermocouple probe 3 Disconnect the EGT thermocouple probe at the left rear exhaust pipe Detail Steps Work Items Key Items References 1 Install the EGT thermocouple probe onto the left rear exhaust pipe 2 If necessary connect th...

Page 340: ...he EGT indicator from the front of the instrument panel Detail Steps Work Items Key Items References 1 Position the EGT indicator into the instrument panel at the front 2 Install the EGT indicator attachment bracket at the rear of the instrument panel Make sure the EGT indicator is positioned correctly before you attach the bracket Put the bracket onto the two studs Attach the two washers and the ...

Page 341: ...tor from the front of the instrument panel Detail Steps Work Items Key Items References 1 Position the CHT indicator into the instrument panel at the front 2 Install the CHT indicator attachment bracket at the rear of the instrument panel Make sure the EGT indicator is positioned correctly before you attach the bracket Put the locking ring onto the CHT indicator Turn the locking ring clockwise unt...

Page 342: ...he Tanis heating elements from all the cylinder thermocouple wells Detail Steps Work Items Key Items References 1 Clean the cylinder thermocouple wells with compressed air 2 Coat the threads of the TAS 100 cylinder heat elements with anti seize or equivalent 3 Install one cylinder heat element into each cylinder thermocouple well Make sure not to flex the power leads more than that is necessary to...

Page 343: ...Page 1 Rev 16 78 TITLE Exhaust DA20 C1 AMM DA201 C1 30 Oct 09 CHAPTER 78 00 EXHAUST ...

Page 344: ...Exhaust DA20 C1 AMM 78 TITLE 30 Oct 09 Page 2 DA201 C1 Rev 16 Intentionally Left Blank ...

Page 345: ...1 C1 Page 1 14 Jan 13 TABLE OF CONTENTS Subject CH SE SU Page EXHAUST 78 00 00 1 General 1 Description 1 EXHAUST TROUBLESHOOTING 78 00 00 101 General 101 EXHAUST MAINTENANCE PRACTICES 78 00 00 201 General 201 Remove Install the Exhaust 201 ...

Page 346: ...78 TOC DA20 C1 AMM Exhaust 14 Jan 13 Page 2 DA201 C1 Rev 21 Intentionally Left Blank ...

Page 347: ...Expansion brackets further down the exhaust pipes close the exhaust pipe bellows The bellows let the exhaust pipes move And they let the exhaust pipes expand The pipes go underneath the engine where they go into the muffler heat exchanger The exhaust outlet pipe attached to the bottom of the muffler heat exchanger goes through the bottom of the lower cowling This ejects the exhaust gas outside the...

Page 348: ...Exhaust DA20 C1 AMM 14 Jan 13 Page 2 DA201 C1 Rev 21 78 00 00 Figure 1 Exhaust ...

Page 349: ...IS CAN CAUSE INJURY TO PERSONS TROUBLE POSSIBLE CAUSE REPAIR The exhaust system makes too much noise A damaged muffler Replace the exhaust system Cracks in the exhaust pipe Too much vibration Replace the exhaust system weld the crack Exhaust gas leaks into the cockpit Cracks in the muffler Replace the exhaust system Indication on engine cowling of exhaust gas leaks Defective exhaust pipe gaskets R...

Page 350: ...Troubleshooting DA20 C1 AMM 78 00 00 30 Oct 09 Page 102 DA201 C1 Rev 16 Intentionally Left Blank ...

Page 351: ...THIS A DAMAGED COMPONENT CAN CAUSE THE ENGINE TO START THIS CAN CAUSE DEATH OR INJURY TO PERSONS 1 Remove the engine cowlings Refer to Chapter 71 10 2 Disconnect the EGT probe from the left aft exhaust pipe 3 Remove the two worm drive clamps from the heat exchanger shroud Move the air intake flexible hoses clear of the heat exchanger shroud Move the warm air to the cabin heat valve flexible pipe c...

Page 352: ...haust pipes to the muffler Leave the clamping nuts loose 2 Install four new gaskets to the cylinder head exhaust ports 3 Attach the exhaust system to the engine Install the eight nuts Make sure to use new nuts Tighten the eight nuts in sequence across engine in cross pattern Tighten nuts progressively in at least two steps Torque to 16 7 17 5 lbf ft 22 6 23 7 Nm 4 Tighten the expansion joint clamp...

Page 353: ...to the heat exchanger Install the worm drive clamp to the heat exchanger Tighten the worm drive clamp 8 Do an engine ground run Refer to DA20 C1 Airplane Flight Manual Do an exhaust system leak check Do an EGT system indication check 9 Install the cowlings Refer to Chapter 71 10 Detail Steps Work Items Key Items References ...

Page 354: ...Maintenance Practices DA20 C1 AMM 78 00 00 30 Oct 09 Page 204 DA201 C1 Rev 16 Intentionally Left Blank ...

Page 355: ...Page 1 Rev 16 79 TITLE Oil DA20 C1 AMM DA201 C1 30 Oct 09 CHAPTER 79 00 OIL ...

Page 356: ...Oil DA20 C1 AMM 79 TITLE 30 Oct 09 Page 2 DA201 C1 Rev 16 Intentionally Left Blank ...

Page 357: ...9 00 00 201 General 201 Remove Install the Engine Oil Filter 202 Remove Install the Oil Cooler 203 Remove Install the Vernatherm Valve 205 Remove Install the Oil Temperature Sensor 206 Remove Install the Oil Pressure Sensor 207 Remove Install the Events Switch 208 Remove Install the Oil Pressure Indicator 209 Remove Install the Oil Temperature Indicator 210 Remove Install the Air Oil Separator 211...

Page 358: ...79 TOC DA20 C1 AMM Oil 14 Jan 13 Page 2 DA201 C1 Rev 21 Intentionally Left Blank ...

Page 359: ... pass the cooler The oil cooler attaches to two brackets on the front face of the firewall A GFRP plenum chamber above the oil cooler connects to a large flexible air hose The hose supplies cold air from the cooling pressure chamber above the engine Rubber hoses connect the oil cooler to the oil cooler adaptor on the engine As the hot oil flows through the oil cooler matrix ram air from above the ...

Page 360: ... the oil pressure indicator A pressure switch installed at the top of the oil cooler adaptor operates the engine operated hour meter An electrical cable connects the pressure switch to the engine operated hour meter When the engine oil pressure increases to 0 4 0 55 bar 6 8 psi the pressure switch contacts close and when the engine oil pressure decreases below 0 4 0 55 bar 6 8 psi the pressure swi...

Page 361: ...Page 3 Rev 21 79 00 00 Oil DA20 C1 AMM DA201 C1 14 Jan 13 Figure 1 Oil Distribution and Cooling System Schematic Diagram ...

Page 362: ...Oil DA20 C1 AMM 14 Jan 13 Page 4 DA201 C1 Rev 21 79 00 00 Figure 2 Oil Indication Component Locations ...

Page 363: ...Page 5 Rev 21 79 00 00 Oil DA20 C1 AMM DA201 C1 14 Jan 13 Figure 3 Oil Cooler Component Locations ...

Page 364: ...Oil DA20 C1 AMM 79 00 00 14 Jan 13 Page 6 DA201 C1 Rev 21 Intentionally Left Blank ...

Page 365: ...t brush The oil cooler oil passages blocked Replace the oil cooler The vernatherm valve held open by debris Remove the vernatherm valve Clean and reinstall the valve If still not correct replace the valve Low oil temperature indication Vernatherm valve defective Replace the vernatherm valve Low oil pressure indication Blocked oil filter Replace the oil filter High oil temperature indication Defect...

Page 366: ...nental Motors IO 240 Series Engine and Overhaul Manual Publication M 6 No oil pressure indication Defective oil pressure sensor Replace the oil pressure sensor Defective oil pressure indicator Replace the oil pressure indicator Defective electrical cable Replace the defective electrical cable Defective engine Refer to the Continental Motors IO 240 Series Engine and Overhaul Manual Publication M 6 ...

Page 367: ... Events Switch The oil pressure indicator The oil temperature indicator The air oil separator The air oil separator vent Refer to the Continental Motors IO 240 Series Engine and Overhaul Manual Publication M 6 for the procedures on how to remove install the engine gaskets seals WARNING DO NOT GET OIL ON YOU OIL CAN CAUSE SKIN DISEASE CAUTION YOU MUST ATTACH BLANKS CAPS TO HOLES PIPES WHEN YOU REMO...

Page 368: ... 21 5 23 8 Nm Lock the drain plug with safety wire 5 Cut the safety wire from the engine oil filter 6 Remove the engine oil filter 7 Cut open the used oil filter Look for particles of metal If the filter contains particles of metal refer to the Continental Motors IO 240 Series Engine and Overhaul Manual Publication M 6 Detail Steps Work Items Key Items References WARNING DO NOT GET OIL ON YOU OIL ...

Page 369: ...owlings Refer to Chapter 71 10 00 WARNING DO NOT GET OIL ON YOU OIL CAN CAUSE SKIN DISEASE 2 Disconnect the oil hose from the aft connection at the side of the oil cooler Drain the remaining engine oil into an approved container Put a cap on the hose end 3 Disconnect the oil hose from the forward connection at the side of the oil cooler Drain the remaining engine oil into an approved container Put...

Page 370: ...xible air pipe attached in position on the top of the oil cooler 5 Install the oil cooler Tighten the nuts and the bolts 6 Remove the cap from the inlet oil hose Connect the inlet oil hose to the aft connection at the oil cooler Tighten the oil hose connection 7 Remove the cap from the inlet oil hose Connect the outlet oil hose to the forward connection at the oil cooler Tighten the oil hose conne...

Page 371: ...valve 4 Remove the vernatherm valve from the oil cooler adaptor Discard the oil seal Detail Steps Work Items Key Items References 1 Install a new oil seal to the vernatherm valve and install the vernatherm valve to the oil cooler adaptor Tighten the vernatherm valve Torque to 440 460 lbf in 49 6 52 1 Nm Lock the vernatherm valve to the oil cooler adaptor with safety wire WARNING DO NOT GET OIL ON ...

Page 372: ...om the oil cooler adaptor Put a cap in the oil cooler adaptor hole Detail Steps Work Items Key Items References WARNING DO NOT GET OIL ON YOU OIL CAN CAUSE SKIN DISEASE 1 Remove the cap from the oil cooler adapter 2 Install the oil temperature sensor Tighten the oil temperature sensor 3 Connect the electrical connector to the oil tem perature sensor at the oil cooler adaptor 4 Install the top engi...

Page 373: ...ptor 4 Remove the oil pressure sensor from the oil cooler oil filter adaptor Put a cap in the oil cooler oil filter adaptor hole Detail Steps Work Items Key Items References WARNING DO NOT GET OIL ON YOU OIL CAN CAUSE SKIN DISEASE 1 Remove the cap from the oil cooler oil filter adapter 2 Install the oil pressure sensor Tighten the oil pressure sensor 3 Connect the electrical connector to the oil p...

Page 374: ...lter adaptor Put a cap in the oil cooler oil filter adaptor hole Detail Steps Work Items Key Items References WARNING DO NOT GET OIL ON YOU OIL CAN CAUSE SKIN DISEASE 1 Remove the cap from the oil cooler oil filter adapter 2 Install the events switch Tighten the events switch 3 Connect the electrical connector to the events switch at the oil cooler oil filter adaptor 4 Install the top engine cowli...

Page 375: ...ring 5 Remove the oil pressure indicator from the instrument panel into the cockpit Detail Steps Work Items Key Items References 1 Position the oil pressure indicator into the instrument panel from the cockpit 2 Install the oil pressure indicator Make sure that the oil pressure indicator is positioned correctly before you attach the locking ring Put the locking ring onto the oil pressure indicator...

Page 376: ...t panel into the cockpit Detail Steps Work Items Key Items References 1 Position the oil temperature indicator into the instrument panel from the cockpit 2 Install the oil temperature indicator Make sure that the oil temperature indicator is positioned correctly before you attach the locking ring Put the locking ring onto the oil temperature indicator Turn the locking ring clockwise until the oil ...

Page 377: ...the rubber hose breather pipe connection at the air oil separator 5 Carefully pull the air oil separator clear of the rubber hoses Remove the air oil separator Detail Steps Work Items Key Items References WARNING DO NOT GET OIL ON YOU OIL CAN CAUSE SKIN DISEASE 1 Examine the hoses for blockage Remove any blockage 2 Put the air oil separator in position Attach the three hoses Make sure you connect ...

Page 378: ...or 4 Cut the three tie wraps that attach to the fuel distribution manifold drain 5 Carefully pull the vent pipe from the rubber hose at the oil air separator Remove the vent pipe Detail Steps Work Items Key Items References 1 Examine the vent pipe Make sure that the inner bore of the pipe is clear 2 Put the vent pipe in position in the oil air separator 3 Install the worm drive clamp that attaches...

Page 379: ...Page 1 Rev 16 80 TITLE Starting DA20 C1 AMM DA201 C1 30 Oct 09 CHAPTER 80 00 STARTING ...

Page 380: ...Starting DA20 C1 AMM 80 TITLE 30 Oct 09 Page 2 DA201 C1 Rev 16 Intentionally Left Blank ...

Page 381: ...TOC Starting DA20 C1 AMM Rev 21 DA201 C1 Page 1 14 Jan 13 TABLE OF CONTENTS Subject CH SE SU Page STARTING 80 00 00 1 General 1 Description and Operation 1 STARTING TROUBLESHOOTING 80 00 00 101 General 101 ...

Page 382: ...80 TOC DA20 C1 AMM Starting 14 Jan 13 Page 2 DA201 C1 Rev 21 Intentionally Left Blank ...

Page 383: ...ument panel The fully clockwise START position of the ignition switch gives a positive supply to the starting vibrator which switches power to the starter relay In all other switch positions there is no supply to the starter relay Heavy cables from the output side of the battery relay supply the electrical power to the starter relay A heavy cable connects the output of the starter relay to the sta...

Page 384: ...Starting DA20 C1 AMM 14 Jan 13 Page 2 DA201 C1 Rev 21 80 00 00 Figure 1 Starter System Component Locations ...

Page 385: ...he battery Starter switch circuit defective Do a continuity test Refer to Chapter 92 for wiring diagram 74 39 00 Ref Vibrator Interlock Starter motor malfunction Refer to the Teledyne Continental Motors Maintenance Manual The starter motor rotates but does not turn the crankshaft Starter motor drive train malfunction Refer to the Teledyne Continental Motors Maintenance Manual The starter motor rot...

Page 386: ...Troubleshooting DA20 C1 AMM 80 00 00 30 Oct 09 Page 102 DA201 C1 Rev 16 Intentionally Left Blank ...

Page 387: ...Page 1 Rev 16 92 TITLE Wiring Diagrams DA20 C1 AMM DA201 C1 30 Oct 09 CHAPTER 92 00 WIRING DIAGRAMS ...

Page 388: ...Wiring Diagrams DA20 C1 AMM 92 TITLE 30 Oct 09 Page 2 DA201 C1 Rev 16 Intentionally Left Blank ...

Page 389: ...stallation Option 2 Trim Display 3 Trim Display Circuit Board 4 Flight Controls Electrical System 5 Flight Controls Electrical System 6 Fuel System 7 2 Speed Electric Fuel Pump 8 Fuel Quantity Timer 9 Pitot Static Heat Installation 10 Digital Clock Hourmeter Outside Air Temperature O A T 11 Canopy Switches 12 Flood Light 13 Internal Lighting 14 Internal Lighting ASPEN 15 Internal Lighting 16 Exter...

Page 390: ...n Communication NAV COMM KX 155 2 Global Positioning System Communication GPS COMM KLX 135A 3 NAV COMM KX 125 4 Audio Panel PMA 6000 5 Navigation Communication Equipment 6 Primary Flight Display PFD Aspen Electronic Flight Display EFD 1000 Fixed Provisions 8 PFD Autopilot Fixed Provisions 9 Backup Artificial Horizon 10 Transponder KT 76C 11 Global Positioning System GPS Receiver KLN 35A 12 Garmin ...

Page 391: ...PAGE Garmin G500 Indegrated Display System 19 Garmin Navigation System GNS 530 430 24 Garmin Navigation Communication GNC 420 25 Garmin Transponder GTX 327 26 GTX 330 27 True Airspeed TAS 600 Option G500 System 28 GNS 530 430 ASPEN Fixed Provisions 29 GNC 420W PM1000 30 ...

Page 392: ...Wiring Diagrams DA20 C1 AMM 92 TOC 14 Jan 13 Page 4 DA201 C1 Rev 21 Intentionally Left Blank ...

Page 393: ...T CONTROLS 22 2732 99 00 1 92 10 00 SCHEMATIC ELECTRICAL SYSTEM FLIGHT CONTROLS 22 2751 99 00 1 92 10 00 SCHEMATIC FUEL SYSTEM 28 00 00 1 92 10 00 SCHEMATIC 2 SPEED ELECTRIC FUEL PUMP 22 2820 99 00 1 92 10 00 SCHEMATIC FUEL QUANTITY TIMER 22 2843 99 00 1 92 10 00 SCHEMATIC HEATER PITOT STATIC 22 3030 99 00 1 92 10 00 SCHEMATIC DIGITAL CLOCK HOUR METER OAT 22 3120 99 00 1 92 10 00 SCHEMATIC CANOPY ...

Page 394: ...1 92 30 00 SCHEMATIC NAVIGATION COMMUNICATION EQUIPMENT 22 3400 99 00 2 92 30 00 SCHEMATIC PFD ASPEN EFD1000 FIXED PROVISIONS 22 3421 99 00 1 92 30 00 SCHEMATIC PFD AUTOPILOT FIXED PROVISIONS 22 3422 99 00 1 92 30 00 SCHEMATIC BACKUP ARTIFICAL HORIZON INDICATOR 22 3424 99 00 1 92 30 00 SCHEMATIC TRANSPONDER KT 76C 22 3450 20 00 1 92 30 00 SCHEMATIC KLN 35A GPS RECEIVER 22 3450 21 00 1 92 30 00 SCH...

Page 395: ...2 1 92 30 00 SCHEMATIC GTX 327 22 9234 50 03 1 92 30 00 SCHEMATIC GTX 330 22 9234 50 04 1 92 30 00 SCHEMATIC TAS600 OPTION G500 SYSTEM 22 9234 50 06X01 1 92 30 00 SCHEMATIC GNS 530 430 ASPEN FXED PROVISIONS 22 9234 50 07 1 92 30 00 SCHEMATIC GNC420W PM1000 22 9234 50 08 1 CH SE SU Title Drawing No No of Pages ...

Page 396: ...Wiring Diagrams DA20 C1 AMM 92 00 00 14 Jan 13 Page 8 DA201 C1 Rev 21 Intentionally Left Blank ...

Page 397: ...6 Ref GS IP 05 D3 24308A20N V 7 0 6 4 24324A20N Generator Control Battery GS IP 09 BB2430 01 GC2430 01 50 24311A8 GS IP 06 24323A18N AM2460 02 Avionics Master Control Avionics Master AM2460 01 2 20 24502A20 24500A12 24501A12 24310A20 24503A20 24301A20 AM2430 01 A GC2430 02 24321A18 24300A8 D7 OV2430 01 AM2450 04 OFF ON 24504A20N GS IP 13 AM2450 03 24316A20 24313A20N GS IP 04 rd 2 VOLTAGE SENSOR OV...

Page 398: ...92 10 00 22 2442 99 00 SCHEMATIC PAGE REV A 1 1 EPU INSTALLATION OPTIONAL EFFECTIVITY C0001 CXXXX BB2430 02 EPU RELAY REFER TO 22 2400 98 00 24404B22 24403A20 D1 BUS BAR REF BUS BAR BUS BAR 24401A4 1 TB1 F1 CONNECTOR EPU ENGINE COMPARTMENT 1A 24405A4N TB2 1 GS FW ...

Page 399: ... R4 LM3914 GND V R LO SIG R HI REF OUT REF ADI MODE 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 511 20K 10K UP DOWN 14VOLT SUPPLY A 7805 TO ACHIEVE CENTRE INDICATION ON THE LED W W W 0 NOTE ACTUATOR POSITION FEEDBACK POTENTIOMETER V OUT GND V IN 1uF C1 DISPLAY ADJUST R1 WHEN TRIM ACTUATOR IS CENTERED GRN 511 R3 W R2 51K R5 W 10KW SIGNAL SW1 C2 0033uF ...

Page 400: ... 4 6 1 J2730 01 SIGNAL GROUND DIM 14V BRIGHT 20K W R1 C1 1uF R4 511 C3 4 7uF W 10K W R2 511 R3 W P2730 01 10 11 12 13 14 16 17 15 CIRCUIT BOARD R 4 LM3914 1 2 GND 3 V LO OUT HI 5 SIG 6 7 R REF ADI MODE 8 9 REF 18 V OUT DOWN 0 UP GND 7805 V IN 22 2731 99 00 8 2K R5 W REF 2 NOTE TO ACHIEVE CENTRE INDICATION ON THE LED CENTERED DISPLAY ADJUST R1 WHEN TRIM ACTUATOR IS ...

Page 401: ...8WH 27301B18BL 27303A24WH 27303A24BL 6 TRIM DISPLAY 27312A22 27310A22 1 5 J2730 01 3 4 2 27508B20 27509B20 J2750 04 27504B20 27505B20 27506B20 27507B20 RELAY B FLAP MOTOR P2750 03 3 J2750 03 2 1 RED BLK 27504B20 27507B20 27509B20 27508B20 27506B20 27505B20 M P2750 04 3 3 5 6 4 5 6 4 1 2 1 2 S3 S1 S2 S4 S5 PILOT STICK CO PILOT STICK 27303B24BL 27303B24WH 27304A18WH 207304A18BL 27301C18BL 27303B24BL...

Page 402: ...3 27303A18Wh 2 FLAP MOTOR FM2750 01 27507B20 27506B20 27505B20 27504B20 J2750 04 27509B20 27508B20 J2750 03 P2750 03 27505B20 27506B20 27508B20 27509B20 27507B20 27504B20 BLK RED M 4 P2750 04 1 2 3 6 5 2 6 4 5 3 1 S3 S1 S2 S4 S5 207304A18Bl 27304A18Wh 12 14 1 2 4 YL Wh M P2730 02 27303B18Wh P2400 02 11 J2730 02 3 TRIM ACTUATOR TA2730 01 Rd FLAP POSITION SWITCH ASSM FP2750 01 TRIM POSITION SWITCH T...

Page 403: ...DA20 C1 AMM Wiring Diagrams DA 201 C1 Rev 21 Page 7 14 Jan 13 92 10 00 22 28 00 SCHEMATIC PAGE REV A 1 1 FUEL SYSTEM EFFECTIVITY C0001 CXXXX ...

Page 404: ...EL PUMP M FUEL SENDER FP2840 01 P2400 01 28401B20 28402B20N 28402A20N J2400 01 5 6 2 FQ2840 03 FUEL S VDO 28400A20 28403A20N GS IP 03 J2400 01 P2400 01 28201A16N 28201B16N 34 FUSELAGE FUEL PUMP FUSELAGE 28402A20N 28401A20 28401A20 FUEL QTY 0 A T Ref 22 3120 99 00 28205A16 10 28206B16 28206A16 GS IP 18 28207A18N 28208A18 1 2 3 ON 28202A16 OFF FUEL PUMP 1 S U B N I A M RED WHT BLK 2 1 R1 P2820 01 J2...

Page 405: ...1 Page 9 14 Jan 13 92 10 00 22 2843 99 00 SCHEMATIC PAGE REV A 1 1 FUEL QUANTITY TIMER EFFECTIVITY C0001 CXXXX SIGNAL PWR PWR 1 7 6 3 2 5 8 4 555 YL WH BL 2 7k 15k 100uF 0 01uF 12v 10 BL GND GND 100uF SIGNAL WHT YL INPUT OUTPUT 15V 1W 100 2W 1k ...

Page 406: ...S 18 30107A20N GS 8 30100A10 30109A22 10A OPENS INSTRUMENT PANEL J3340 01 GS 8 30105A14N 30104A14N 30106A20 3 4 2 J3030 02 30102A10 1 P3030 02 30105B14N 30104B14N 30106B20 30102B10 30116B20 30110A10 FUSELAGE S 2 30104C14N 30105C14N 16 22 19 30106C20 30116A20 20 P3340 01 21 30110B10 H 1 S 1 H 2 L H WING 14 AWG 14 AWG 14 AWG 14 AWG 1 2 30108A22 5A INST C 1 4 3 J3030 03 SYSTEM ...

Page 407: ...203A22 31202A22 METER HOUR GS IP 3 O A T 2 31200A22 FUEL QTY 31201A22N 31200A22 GS IP 3 BLACK RED J3120 01 P3120 01 OAT3120 03 HM3120 02 DC3120 01 31206A22N 31201A22N 2 1 O A T J2400 01 OIL PRESS SWITCH FIREWALL P 2 P2400 01 INSTRUMENT IL3310 01 Ref 22 3310 99 00 Ref 22 2820 99 00 FQ2840 03 24302A2 EPU Charge 25W 10 R1 BB2430 02 D13 3 Hour Meter 1 BATTERY COMPARTMENT BB2430 03 24303A2N 31203C22 EL...

Page 408: ...CANOPY SWITCHES EFFECTIVITY C0001 CXXXX MAIN BUS 2 AN2430 01 2 31602A22N 31605A22 J3160 02 P3160 02 31603A22N 1 2 LEFT 1 J3160 01 P3160 01 2 2 1 RIGHT 1 2 24316A22N 31604A22 CA3160 01 GS IP 18 24325A22 OIL PRESS FUEL PRESS Gen Ref Ref Gen D1 D2 22 2400 99 00 73300A20 73303A20 Ref 22 7930 99 00 Ref 22 7300 99 00 ...

Page 409: ...DA20 C1 AMM Wiring Diagrams DA 201 C1 Rev 21 Page 13 14 Jan 13 92 10 00 22 3310 97 00 SCHEMATIC PAGE REV A1 1 1 FLOOD LIGHT EFFECTIVITY C0001 CXXXX ...

Page 410: ...ENT LIGHT TAXI MAP L1 L3 1 2 2 1 32 P2400 02 J2400 02 36 29 34734A22 51K 1 4 W 34736A22 R3450 01 75 17 27511A22 H J2400 05 2 1 33120A22 33121A22N P3310 04 BLK BLK J3310 04 COMPASS CP3410 01 INSTRUMENT LIGHT MAP LIGHT 33 33107A20N 33107A20N FLAP CONTROL 5 FLAP 27512A22 33104A20 GS IP 11 GS IP 10 33120A22 BRIGHT DIM SWITCH 27312A22 27311A22 27310A22 DIM REF 22 2750 99 00 R3310 01 L2 1 2 FUSELAGE MAP...

Page 411: ...35B22 33706A22 33705A22 P2400 05 17 CHT FUEL QTY 19 23 EGT FUEL PRESS OIL PRESS OIL TEMP AMMETER 33704A22 33708A22 33709A22 33120A22 33707A22 VOLT METER J3120 02 J3370 08 8 1 J3370 07 J3370 04 1 1 J3370 02 1 27300A22 32 36 33 J2400 02 P2400 02 GS IP 11 MAP LIGHT S2 29 2 INSTRUMENT LIGHT TAXI MAP 5 L1 33107B20N INST 33108B20N 33109B20 33114B20 INST MAP 1 2 L2 1 2 1 2 L3 6 4 33105A20 33107A20N 33114...

Page 412: ...5B22 33706A22 33705A22 P2400 05 17 CHT FUEL QTY 19 23 EGT FUEL PRESS OIL PRESS OIL TEMP AMMETER 33704A22 33708A22 33709A22 33120A22 33707A22 VOLT METER J3120 02 J3370 08 J3370 07 8 1 1 J3370 05 J3370 04 J3370 06 1 1 1 J3370 03 J3370 02 1 1 27300A22 32 36 33 J2400 02 P2400 02 GS IP 11 MAP LIGHT S2 29 2 INSTRUMENT LIGHT TAXI MAP 5 L1 33107B20N INST 33108B20N 33109B20 33114B20 INST MAP 1 2 L2 1 2 1 2...

Page 413: ...400B14 33402A18bK 33402A18rd 10 11 33402B18wh 7 8 9 6 5 33401C14N 33402B18rd 33402B18bK 33417C14N 33400C14 J3340 01 33412B14 33415B14N 33410B14 33414B14N 3 4 1 2 33412C14 33415C14N 33410C14 33414C14N P3340 01 L H WING BRAIDED CABLE AILERON BELLCRANK BRAIDED CABLE 33423A14N P3340 05 P3340 06 1 J3340 05 2 bl rd bk GREEN 1 bl J3340 06 3 2 WHITE STROBE TAXI LIGHT WHITE J3340 03 P3340 03 CONDUIT P3340 ...

Page 414: ...414A14N 19 33414B14N 3 PULSE 33422A22 33423A22 PULSE TAXI 20 26 33424A14 33424A14 35 33424B14 2 3 5 1 4 33429A22N 33429B22N P3340 12 J3340 12 33429B22N 33424B14 33430B14 33431B14 BLACK BLUE YELLOW RED WHITE ORANGE GREY P3340 10 J3340 10 2 1 33415C14N 33412C14 33412A16 LANDING 5 33412A16 33413A16 PULSELITE 4 10 4 3 33423A22 33423B22 33423B22 GS IP 01 TAXI GS IP 8 GS IP 08 33412B14 33415B14N 33415B1...

Page 415: ... 201 C1 Rev 21 Page 19 14 Jan 13 92 10 00 22 3420 99 00 SCHEMATIC PAGE REV A 1 1 TURN AND SLIP INDICATOR EFFECTIVITY C0001 CXXXX 3 34103A20 TS3420 01 GS IP 10 MAIN BUS 2 1 2 TURN SLIP TURN SLIP 34103A20 34104A20N TS3420 02 P3420 02 ...

Page 416: ... 99 00 SCHEMATIC PAGE REV B 1 1 FUEL PRESSURE EFFECTIVITY C0001 CXXXX FP7330 02 73301A20 73301A20 6 4 AN2400 01 2 73300A20 73302A20N OIL PRESS FUEL PRESS GS IP 06 FIREWALL CONTINENTAL ENGINE VDO S FUEL PRESS 79303A20 Ref 22 7930 99 00 24325A22 Ref 22 2400 99 00 GS IP 07 73303A20N ...

Page 417: ...MAGNETO 74309A16 BATTERY VIBRATOR 74301A16 S 74304A20N FIREWALL L R 80109A20N 80100A20 24300A8 24306A2 GS IP 07 22 2400 99 00 Ref 74300A16 74301A16 VIBRATOR STARTING 74308B16 D2 L S BAT R L GND 74305A16 GND R SS8010 02 74308A16 74307A18 5 F2 74301B16 74300B16 74300A16 74306A18N D1 F1 3 80106A22 80101A4 CONTINENTAL ENGINE GROUNDING GND GROUNDING RIGHT MAGNETO SS8010 03 22 2400 99 00 Ref START D 801...

Page 418: ...ge 22 14 Jan 13 92 10 00 22 7721 99 00 SCHEMATIC PAGE REV A 1 1 EGT GAUGE EFFECTIVITY C0001 CXXXX FIREWALL 77203A18YW 6 4 CONTINENTAL ENGINE TC7702 EGT 2 77201A20 VDO OT7930 01 EGT S OIL TEMP 1 2 77202A20N 79201A20 79202A20N 79203A18RD GSIP 5 RD YW ...

Page 419: ...iring Diagrams DA 201 C1 Rev 21 Page 23 14 Jan 13 92 10 00 22 7722 99 00 SCHEMATIC PAGE REV A 1 1 CHT GAUGE EFFECTIVITY C0001 CXXXX FIREWALL CONTINENTAL ENGINE TC7701 S 77204A18RD 77204A18WH OT7930 01 VDO CHT RD YW ...

Page 420: ... EFFECTIVITY C0001 CXXXX 6 4 2 AN2430 01 EI7740 01 2 79303A20 79302A20 OT7930 02 OP7930 02 79311A20N 79310A20N 79301A20 79300A20 OIL TEMP OIL PRESS FUEL PRESS Ref 22 2400 99 00 79300A20 79301A20 FIREWALL CONTINENTAL ENGINE GS IP 01 79302A20 79303A20 OT7930 01 S VDO OIL TEMP OIL PSI VDO OP7930 01 S 24325A22 73300A20 Ref 22 7300 99 00 ...

Page 421: ...DA20 C1 AMM Wiring Diagrams DA 201 C1 Rev 21 Page 25 14 Jan 13 92 10 00 33 10 01 SCHEMATIC PAGE REV A 1 1 INSTRUMENT PANEL INTEGRAL LIGHTING EFFECTIVITY C0148 Cxxxx OPTIONAL C0001 C0147 RL 2 ...

Page 422: ...22008A22RD 22008A22BK 22008A22OR 22008A22WH 22008A22YL 22008A22GR 22008A22BL 22022A22 22012A20 22015A20 AUTO PILOT MASTER REF DIMMER SCHEMATIC 5A ELECTRICAL BUS 5A AUTO PILOT AVIONICS BUS 22004B22OR 22004B22WH 22004B22BL 22004B22YL 22004B22GR 22004B22BK 22004B22RD J2202 22023B22BL 22023B22WH SERVO PITCH 7 6 8 3 4 2 1 J2209 1 2 R STICK A P DISC REF GPS SYSTEM REF NAV GPS SYSTEM REF HEADING REFERENC...

Page 423: ...310 02 VOR LOC COMP MIC PTT ILS ENERGIZE GROUND GROUND COMM HI COMM LO NAV HI NAV LO MIC HI 12 M 11 N 34514A20 6 8 15 S H L K 10 2 9 34513A22 23138A24bl 34512A24 23139A18N 23140A18N 23137A24bl 34533A24bl G S FLAG G S FLAG G S UP G S DOWN A C GND KX 155 P2310 51 BOTTOM R U P2310 50 TOP PLUG L T S 34532A22 34531A22 23135A20N 34530A24bl 1 ILS COMMON 34516A20N 23135A20N 23139A18N 23140A18N 34516A20N 2...

Page 424: ...GND LIGHTING LO KLX 135A 28VDC LIGHTING GRN 14VDC LIGHTING MIC HI MIC LO A C GND DBASE OUT RS 232 DBASE IN RS 232 NC2310 01 E 34509A22 23112A24wh 34507A22 34506A22 34505A22 34504A22 34503A22 34502A22 34501A22 23106A24bl 23106A24wh 23112A24or 23112A24bl 34508A22 J BOTTOM 3 4 PLUG P2310 01 PTT K 2 15 B1 B2 A1 A2 A4 18 19 21 22 5 C4 C1 B4 C2 16 13 14 12 17 23110A22N 34735A22 TOP PLUG P2310 02 F D L B...

Page 425: ...DA20 C1 AMM Wiring Diagrams DA 201 C1 Rev 21 Page 4 14 Jan 13 92 30 00 22 2310 23 00 SCHEMATIC PAGE REV B 1 1 NAV COMM KX 125 EFFECTIVITY C0001 CXXXX ...

Page 426: ...25A18 23110A24BL REFERENCE COMM 1 COMM 2 REFERENCE SPEAKER 34804A24BL 23507A24WH 23506A24WH 23504A24WH 23503A24WH 23503A24BL 23110A24BL 31 18 14 22 32 28 27 37 33 26 17 4 23111A24BL 23111A24WH 23127A18N 7 36 6 5 P2400 05 23125A18 P2400 04 23504A24WH 15 PILOT MIC AUDIO PILOT MIC KEY 23503A24BL 23503A24WH 8 Y 23506A24BL 23506A24BL 23506A24WH CO PILOT MIC KEY CO PILOT MIC AUDIO BOTTOM TOP 23137A24BL ...

Page 427: ... 4 6 1 J2730 01 SIGNAL GROUND DIM 14V BRIGHT 20K W R1 C1 1uF R4 511 C3 4 7uF W 10K W R2 511 R3 W P2730 01 10 11 12 13 14 16 17 15 CIRCUIT BOARD R 4 LM3914 1 2 GND 3 V LO OUT HI 5 SIG 6 7 R REF ADI MODE 8 9 REF 18 V OUT DOWN 0 UP GND 7805 V IN 22 2731 99 00 8 2K R5 W REF 2 NOTE TO ACHIEVE CENTRE INDICATION ON THE LED CENTERED DISPLAY ADJUST R1 WHEN TRIM ACTUATOR IS ...

Page 428: ...8WH 27301B18BL 27303A24WH 27303A24BL 6 TRIM DISPLAY 27312A22 27310A22 1 5 J2730 01 3 4 2 27508B20 27509B20 J2750 04 27504B20 27505B20 27506B20 27507B20 RELAY B FLAP MOTOR P2750 03 3 J2750 03 2 1 RED BLK 27504B20 27507B20 27509B20 27508B20 27506B20 27505B20 M P2750 04 3 3 5 6 4 5 6 4 1 2 1 2 S3 S1 S2 S4 S5 PILOT STICK CO PILOT STICK 27303B24BL 27303B24WH 27304A18WH 207304A18BL 27301C18BL 27303B24BL...

Page 429: ...0 23 24 46 47 50 51 P4001 P4006 34902A22WH 34902A22BL 34903A22BL 34903A22WH 34904A22WH 34904A22BL RSM 5 4 1 3 2 RSM_A RSM_D RSM_B RSM_C 33 30 31 32 RSM_F RSM_E RSM_G 36 35 34 6 7 RSM_G RSM_F RSM_E RSM_D RSM_C RSM_B RSM_A 7 5A PFD ELECTRICAL RD BR OR RD OR BR BLK GR BLK GPS ARINC 429 OUT WH GPS ARINC 429 OUT BL IF INSTALLED TO GTX 330 34905A22BL 34905A22WH 34905A22YW 34905A22GR 34905A22BLK 34905A22...

Page 430: ...0 C1 AMM Wiring Diagrams DA 201 C1 Rev 21 Page 9 14 Jan 13 92 30 00 22 3422 99 00 SCHEMATIC PAGE REV A 1 1 PFD AUTOPILOT FIXED PROVISIONS EFFECTIVITY ON ALL AIRCRAFT WITH THE ASPEN EFD1000 SYSTEM INSTALLED ...

Page 431: ...DA20 C1 AMM Wiring Diagrams DA 201 C1 Rev 21 Page 10 14 Jan 13 92 30 00 22 3424 99 00 SCHEMATIC PAGE REV A 1 1 BACKUP ARTIFICIAL HORIZON EFFECTIVITY C0001 CXXXX MAIN BUS ...

Page 432: ...4519A22 34518A22 34528A22 34517A22 34529A22 J3450 02 34524B142 P3450 01 11 13 75VDC GROUND GROUND DIMMER GND A A2 A1 M K 3 1 12 KT 76C 34525A22N 34500A22 34527A22 34526A22 34529A22 34517A22 34528A22 34518A22 34519A22 34533A22 34521A22 P3450 03 J3450 03 TR3450 04 XPDR ANTENNA 16 14 15 13 11 12 10 34525A22N 34526A22 34527A22 34504A22 34502A22 34501A22 34503A22 34508A22 34509A22 34507A22 34506A22 345...

Page 433: ...DA20 C1 AMM Wiring Diagrams DA 201 C1 Rev 21 Page 12 14 Jan 13 92 30 00 22 3450 21 00 SCHEMATIC PAGE REV A 1 1 KLN 35A GPS RECEIVER EFFECTIVITY C0001 CXXXX ...

Page 434: ...24BL 36 22 P2400 05 23111A24OR 23111A24WH 23111A24BL 23137A24WH 23503A24OR 23503A24BL 23503A24WH 7 5 6 J2400 05 14 15 32 23504B24WH 21 23504A24WH 23506A24OR 23506A24BL 23506A24WH 33743A22 23504A24BL 23507A24OR 23507A24BL 23507A24WH 37 28 27 33 23504B24BL 23507B24OR 23507B24BL 23507B24WH 31 36 35 22 19 P2400 04 23400A24OR 23110A22WH 23504A24OR 23110A22BL 23400A24BL 23400A24WH 23400B24OR 12 23110B22...

Page 435: ...V LIGHTING 14V LIGHTING J2 34 33 32 6 7 34 4 2 33 1 3 16 31 14 11 30 5 13 GMA 340H AIRCRAFT PWR AIRCRAFT PWR AIRCRAFT GND 8 10 9 J2 23504A24WH 33743A22 23506A24WH 23506A24BL 23503A24WH 23503A24OR 23507A24WH 23507A24BL 23507A24OR 23504A24BL 23506A24OR 23504A24OR 21 23504B24WH 30 32 14 25 27 28 35 36 33 37 19 22 31 23506B24WH 23506B24BL 23503B24OR 23506B24OR 23507B24WH 23507B24BL 23507B24OR 23504B24...

Page 436: ...P2400 05 16 29 P2400 04 27 23100A18 23101A18 23102A18N 23103A18N 33735A22 33742A22 33735A22 23103A18N 23102A18N 23105A24BL 23106A22WH 23105A24WH 23106A22BL J H 9 14VDC LIGHTING COM AUDIO LO COM GND MIC LO MIC KEY MIC HI COM AUDIO HI 7 15 6 8 B IC A200 P2310 05 J2310 05 P2310 03 J2310 03 23101A18 23100A18 P2310 14 COM 14V PWR COM 14V PWR 14 R COMM 23111A58 23111B58 NC2310 05 COMM ANTENNA 2 N TRANSM...

Page 437: ...NCE 23105A24WH 23105A24BL 23106A22BL 23106A22WH P2400 05 16 P2400 04 27 23100A18 23102A18N 23102A18N 23105A24BL 23106A22WH 23105A24WH 23106A22BL 8 14 7 AUDIO GROUND MIC GROUND MIC 1 HEADPHONE 13 SL40 P2310 05 J2310 05 P2310 03 J2310 03 23100A18 P2310 14 1 COMM 23111A58 23111B58 NC2310 05 COMM ANTENNA 2 4 TRANSMIT INTERLOCK 23144A22 23144A22 9 POWER GROUND 1 1 NOTES 1 WIRE SHIELDS CONNECTED TO REAR...

Page 438: ...7A24BL 23138A24WH 23138A24BL 36 22 P2400 05 23111A24OR 23111A24WH 23111A24BL 23137A24WH 23503A24OR 23503A24BL 23503A24WH 7 5 6 J2400 05 14 15 33 23504B24WH 21 23504A24WH 23506A24OR 23506A24BL 23506A24WH 33743A22 23504A24BL 23507A24OR 23507A24BL 23507A24WH 37 28 27 32 23504B24BL 23507B24OR 23507B24BL 23507B24WH 31 36 35 22 19 P2400 04 23400A24OR 23110A22WH 23504A24OR 23110A22BL 23400A24BL 23400A24W...

Page 439: ...105A24BL SOURCES 23137A24BL 23138A24WH 23138A24BL 36 22 P2400 05 23111A24OR 23111A24WH 23111A24BL 23137A24WH 23503A24OR 23503A24BL 23503A24WH 7 5 6 J2400 05 14 15 33 23504B24WH 21 23504A24WH 23506A24OR 23506A24BL 23506A24WH 33743A22 23504A24BL 23507A24OR 23507A24BL 23507A24WH 37 28 27 32 23504B24BL 23507B24OR 23507B24BL 23507B24WH 31 36 35 22 19 P2400 04 23400A24OR 23110A22WH 23504A24OR 23110A22BL...

Page 440: ... C0001 CXXXX 7 EXT ON OFF EXT ON OFF ANNUNCIATOR 14 VOLT DC 9 1 8 ELT REMOTE SWITCH 3 4 2 1 ELT 200 J2400 01 33 31 P2400 01 25 20 26 EXT ON OFF ANNUNCIATOR EXT ON OFF GROUND GND SW 25601A20RD 25601A20GR 25601A20WH 25601A20BK 25601B20BK 25601B20WH 25601B20GR 25601B20RD HM3120 02 METER HOUR 31203A22 25601A22 J2501 P2502 J2503 P2503 ...

Page 441: ... 4A ARINC 429 IN 4B 24 7 VOR ILS 429 OUT B VOR ILS 429 OUT A P6202 P6201 ETHERNET IN 1B ETHERNET IN 1A 11 12 S 34 ETHERNET OUT 2A S GDL69 OPTIONAL 14 13 ETHERNET OUT 1B ETHERNET OUT 1A 25 24 9 8 26 29 28 27 ETHERNET OUT 2B ETHERNET IN 2A ETHERNET IN 2B P6203 ARINC 429 IN 7A ARINC 429 IN 7B 26 4 S ARINC 429 OUT 1B ARINC 429 OUT 1A GTX330 OPTIONAL P2400 05 TIS TAS STANDBY 26 P6201 TIS CONNECT SELECT...

Page 442: ...WER OUT RS 232 OUT 2 9 10 ARINC 429 IN 1A ARINC 429 IN 1B 30 15 GRS77 AHRS 2 4 3 1 34917B24WH 34917B24BL 34917B24OR ARINC 429 OUT 1B ARINC 429 OUT 1A 42 41 S S AIRCRAFT POWER AIRCRAFT GROUND 22 20 CM CLOCK CM DATA 60 40 3 DATA CLOCK 2 CONFIGURATION GROUND VCC MODULE 1 4 YEL WHT RED BLK CM GROUND CM DATA CM CLOCK CM POWER 1 16 31 17 BLK WHT YEL RED 1 GROUND CLOCK DATA 2 3 MODULE CONFIGURATION 4 VCC...

Page 443: ...33 1 3 24 MUSIC1 R MUSIC1 L SPEAKER OUT SPEAKER LO 44 43 16 31 23 MUSIC1 LO 14 25 11 30 5 13 GMA 340 AIRCRAFT PWR AIRCRAFT PWR AIRCRAFT GND 8 10 9 J2 P2400 04 23504A24WH 33743A22 23506A24WH 23506A24BL 23503A24WH 23503A24OR 23507A24WH 23507A24BL 23507A24OR 23504A24BL 23506A24OR 23400A24WH 23110A22BL 23504A24OR 23110A22WH 23400A24OR 23511A22N 23400A24BL 21 23504B24WH 30 32 14 25 27 28 35 36 33 37 19...

Page 444: ...AV ANTENNA NS3451 11 NC3470 04 GPS ANTENNA 1 NC2310 03 COMM ANTENNA 1 P2400 05 23158A22N 26 23140A18N 23139A18N 33740A22 19 37 33 23157B22 GPS 5A BUSS AV 34516A24WH 34515A24WH 56 57 GPS RS 232 IN 1 GPS RS 232 OUT 1 POWER COMM P2310 14 1 GROUND 9 SL40 P2310 05 J2310 03 23111A400 23100A18 23102A18N P2310 03 23111B400 J2310 05 COMM ANTENNA NC2310 05 2 16 27 P2400 04 P2400 05 P2400 04 5 2 34 TIS CONNE...

Page 445: ... 10 25 50 1 45 42 27 43 21 XPDR ANT 14 VDC DIMMER RS 232 OUT AV MASTER SELECT GTX330 GTX328 OPTIONAL A C POWER GROUND GROUND A C POWER 34524A142 P3450 05 34516A24 J3450 02 P3450 02 P3301 P3281 34525A22N 34500A22 34524B142 P3450 03 XPDR ANTENNA TR3450 04 J3450 03 21 ATC 3A AV BUSS GS IP 16 34500B22 34525B22N 33742A22 34500B22 34525B22N BUSS GS IP 16 3A AV ATC P2400 05 10 21 P2400 04 57 RS 232 IN GN...

Page 446: ...6 35 33 34 21 31 22 ROTOR H STATOR D STATOR E STATOR G STATOR F ROTOR C LEFT RIGHT FLAG 23 COMM PWR 12 23142A18 GTX 327 REF TRANSPONDER 2 4 6 1 34717A22WH 34717A22BL 34718A22WH 34718A22BL 40 LIGHTING GND 39 14 VDC LTG 33740A22 14V ANNUN PWR VLOC ANNUN POWER GROUND RESOLVER H RESOLVER C RESOLVER F RESOLVER G G S DOWN GPS ANNUN G S FLAG G S FLAG LIGHTING LO AUDIO SYSTEM REFERENCE P2400 05 GI106A 19 ...

Page 447: ...N 23102A18N 23105A24BL 23106A22WH 23105A24WH 23106A22BL 6 7 4 GPS GND LIGHTING LO GPS GND GPS PWR GPS PWR 14VDC LIGHTING COM AUDIO LO COM GND COM GND MIC LO MIC KEY MIC HI COM AUDIO HI 19 22 21 18 39 20 19 78 40 77 GNC 420 7 P2310 05 34561A22 J2310 05 P2310 03 J2310 03 23101A18 23100A18 P2310 14 COM 14V PWR COM 14V PWR 11 12 J3470 04 GPS COMM 34715B142 P3470 02 23111A58 GPS ANTENNA P3470 04 34715A...

Page 448: ...ENNA J3450 03 34524B142 P3450 02 P3450 03 34500A22 34525A22N 15 25 13 1 P3450 01 GTX 327 13 75V DC GROUND GROUND 13 75V DC 34518A22 34519A22 34521A22 34533A22 34528A22 34517A22 34529A22 34527A22 34526A22 34524A142 33742A22 10 12 7 4 B1 9 11 6 5 A1 3 C1 B4 C4 C2 A4 B2 A2 P3450 05 24 14 VDC DIMMER XPDR ANT J3450 02 POWER DISTRIBUTION REFERENCE POWER DISTRIBUTION REFERENCE 34516A24 REF GNS 430 DWG 20...

Page 449: ...WER GROUND GROUND A C POWER 34518A22 34519A22 34521A22 34533A22 34528A22 34517A22 34529A22 34527A22 34526A22 34524A142 33742A22 8 10 6 3 B1 7 9 5 4 A1 2 C1 B4 C4 C2 A4 B2 A2 P3450 05 45 14 VDC DIMMER XPDR ANT J3450 02 REF 2 COMM POWER DISTRIBUTION REFERENCE ENCODER REFERENCE REF GNS 530 430 DWG TIS CONNECT SELECT 46 ARINC 429 IN 1 B ARINC 429 IN 1 A ARINC 429 OUT 2 A ARINC 429 OUT 2 B 32 35 30 28 ...

Page 450: ...3271 OPTION 42 41 12 1 P4001 34452A22 34453A22 WW LCM001 AVIONICS BUS J3325 02 J2 J4 J3 COUPLER TAS600 J1 XPDR ANTENNA 34433A400 34434A400 34432A400 34435A400 TCAD XPDR ANT 34436A400 TOP ANTENNA 34590A142 34590B142 BOTTOM ANTENNA REF 22 9234 50 03 11 10 2 8 9 7 5 6 3 4 1 12 13 GDU 620 ARINC 429 OUT 1A ARINC 429 OUT 1B 20 3 S 34455B22WH 34455B22BL 34904A24WH 34904A24BL REF 22 9231 00 00 S S BACKSHE...

Page 451: ... GPS NAV GND 34560A58 34520A58 P3451 12 NAV G S P3451 50 J3470 03 P3470 03 23157A22 23158A22N 23109A58 COMM 78 P2310 52 19 77 20 J2310 15 P2310 15 GPS ANTENNA NC3470 04 34714A142 1 COMM ANTENNA NC2310 03 P3451 13 ANT P3451 21 J3470 05 NAV P3451 20 G S 34520B58 P3470 05 P3451 14 J3451 14 P2310 16 23109B58 J2310 16 1 NS3451 11 NAV ANTENNA 23143A22 14 Tx INTERLOCK 34516A24 57 GPS RS 232 IN 1 34516B24...

Page 452: ...3A22WH 34710A22BL 33740A22 34714A22WH 34716A22WH 34714A22BL 34715A22WH 34715A22BL 34713A22BL 13 14 15 TO FROM FLAG FLAG LEFT 8 7 9 11 10 16 19 23 21 22 OPTIONAL INSTALLATION P3451 16 P4001 5A AVIONICS BUS GPS REF LIGHTING SCHEMATICS 34568B22N 34561B22 ALTITUDE COMMON 60 23100B18 COM 10A AVIONICS BUS 23101B18 23103B18N GS IP 9 23102B18N GS IP 9 33740A22 GPS RS 232 OUT 1 GPS RS 232 IN 1 56 57 34515A...

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