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Operation & Maintenance Manual

CD-135 / CD-155

OM-02-02

Revision no.:
Revision date:

Chapter:
Issue:
Issue date:
Page:
Content:

02-OM-06-02
4
30.07.2014
13
74

7
20.07.2016

Annex 2

Inspecting the Oil and Fuel System for
Leakage

This is a visual inspection. Check all pipes, pipe joints, supply
connections and engine housing separation points (e.g. cylinder
head gasket, cylinder head cover gasket) for leakage, seepage
points and correct routing. Visual inspection of oil for water
contamination and water for oil contamination. For more details
see RM-02-02 Chapter 05-20.03.



WARNING:

No leaks or seepage points are permitted!

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Summary of Contents for CD-135

Page 1: ...ce Manual must be read completely before operating the engine as it contains important safety information and information about the operation of the engine Note Please report any service difficulties...

Page 2: ...This page intentionally left blank...

Page 3: ...tion 1 1 1 Accompanying applicable Document 1 1 2 Engine Identification 2 1 3 Copyright 3 1 4 Safety Recommendations 3 1 5 Validity of this Manual 3 1 6 Abbreviations 3 1 7 Packaging and Transport 4 1...

Page 4: ...olant 4 3 6 Power Curve 8 3 7 Low Temperature Data and Climate Classes of Diesel in Europe 10 4 Operation 1 4 1 Pre start Inspection 1 4 2 Start up 2 4 3 Engine Warm up 3 4 4 Before Takeoff Check 3 4...

Page 5: ...very 300 operating hours 2 5 1 3 Every 600 operating hours 2 5 1 4 Every 900 operating hours 3 5 1 5 Every 1200 operating hours 3 5 1 6 Every 1200 operating hours or every 24 months whichever occurs f...

Page 6: ...4 Every 300 operating hours 5 6 2 5 Every 600 operating hours 6 6 2 6 Every 900 operating hours 7 6 2 7 Every 1200 operating hours only applicable for CD 135 7 6 2 8 Every 1200 operating hours only ap...

Page 7: ...ter 16 Annex 6 Cleaning the Engine 19 Annex 7 Checking the FADEC Sensors 20 Annex 8 Exchanging the gearbox oil filter of the gearbox 25 Annex 9 Checking the level of the gearbox oil of the gearbox 32...

Page 8: ...Malfunction 2 7 3 1 One FADEC light flashing 2 7 3 2 Both FADEC lights flashing 3 7 3 3 Abnormal engine behavior 3 7 4 Restart after Engine Failure 4 7 5 Fire in the Engine Compartment 4 7 6 Air in t...

Page 9: ...Fig 6 8 Crankshaft sensor 1 Fig 6 9 Crankshaft sensor 2 Fig 6 10 Gearbox temperature sensor Fig 6 11 Oil pressure and oil temperature sensor Fig 6 12 Position of the oil filter cap Fig 6 13 Mounting...

Page 10: ...g ring Fig 6 44 Removal of gearbox oil filter Fig 6 45 Mounting direction of the oil filter Fig 6 46 Gearbox oil filter assembling Fig 6 47 Lock wire between the oil drain plug and the filter cap Fig...

Page 11: ...7 Hartung Issue 1 Revision 2 02 OM 00 02 1 2 13 04 2007 Hartung 02 OM 06 02 1 2 13 04 2007 Hartung Issue 1 Revision 3 02 OM 00 02 1 3 01 02 2008 Hartung 02 OM 01 02 1 1 01 02 2008 Hartung 02 OM 03 02...

Page 12: ...03 02 1 4 12 10 2009 Hartung Issue 1 Revision 9 02 OM 00 02 1 9 29 01 2010 Hartung 02 OM 03 02 1 5 29 01 2010 Hartung 02 OM 05 02 1 4 29 01 2010 Hartung Issue 1 Revision 10 02 OM 00 02 1 10 07 04 2010...

Page 13: ...M 05 02 2 2 18 03 2011 Hartung 02 OM 06 02 2 2 18 03 2011 Hartung Issue 2 Revision 3 02 OM 00 02 2 3 12 04 2011 Hartung 02 OM 03 02 2 1 12 04 2011 Hartung Issue 2 Revision 4 02 OM 00 02 2 4 17 06 2011...

Page 14: ...ion 9 02 OM 00 02 2 9 23 07 2012 Hartung 02 OM 03 02 2 6 23 07 2012 Hartung 02 OM 05 02 2 6 23 07 2012 Hartung 02 OM 06 02 2 7 23 07 2012 Hartung Issue 2 Revision 10 02 OM 00 02 2 10 10 07 2013 Hartun...

Page 15: ...sion 3 02 OM 00 02 3 3 07 07 2014 Hartung 02 OM 01 02 3 1 07 07 2014 Hartung 02 OM 02 02 3 1 07 07 2014 Hartung 02 OM 03 02 3 3 07 07 2014 Hartung 02 OM 06 02 3 2 07 07 2014 Hartung Issue 4 Revision 0...

Page 16: ...list After the 3rd 6th operating hour 4 17 04 2015 Hartung Engine Maintenance Checklist General 4 17 04 2015 Hartung Issue 4 Revision 3 02 OM 00 02 4 3 13 08 2015 Steinberg 02 OM 05 02 4 3 13 08 2015...

Page 17: ...Issue 4 Revision 6 02 OM 00 02 4 6 22 04 2016 Hartung 02 OM 05 02 4 5 22 04 2016 Hartung Issue 4 Revision 7 02 OM 00 02 4 7 06 06 2016 Hartung 02 OM 03 02 4 2 06 06 2016 Hartung 02 OM 05 02 4 6 06 06...

Page 18: ...6 06 06 2016 02 OM 06 02 Maintenance Schedules 4 7 20 07 2016 02 OM 07 02 Emergency Procedures 4 30 07 2014 FOBL E8 01 Change of Hands 4 30 07 2014 FOBL E8 06 Inspection of the timing chain 1 20 07 20...

Page 19: ...date Page Content 1 4 30 07 2014 9 10 8 20 07 2016 0 3 Preliminary Remarks 1 The chapter numbering of the footer is different to the chapter numbering of the remaining manual See Fig 1 1 Fig 1 1 Expla...

Page 20: ...Operation Maintenance Manual CD 135 CD 155 OM 02 02 Chapter Issue Issue date Page Content 1 4 30 07 2014 10 10 Revision no Revision date 8 20 07 2016 This page intentionally left blank...

Page 21: ...manual were correct at the time of publication Any amendments released through the update information service must be taken into account Please contact Technify Motors GmbH if you have any questions W...

Page 22: ...The serial number of the engine is provided on the data plate on the crankcase near the starter flange Example Fig 1 1 Engine identification Data plate Note When making inquiries always have the seri...

Page 23: ...nd modifications must be taken into account Effective manuals are announced in the Service Bulletin TM TAE 000 0004 1 6 Abbreviations The following abbreviations are used in this manual FADEC Full Aut...

Page 24: ...must be observed during transport and subsequent storage Store only in workplaces that are suitable for the purpose Never store outside Ambient temperature 25 C to 70 C Rel humidity less than 70 The s...

Page 25: ...icable national and international regulations must be observed 1 11 Update Information Service This manual is covered by a continuous update information service The engine aircraft operator is respons...

Page 26: ...er certain operating conditions it may be necessary to protect the engine from extreme humidity dust or sand using further special equipment Please consult the aircraft manufacturer or distributor Und...

Page 27: ...cooling and oil circuits and operation with non approved fuels or lubricants oils absolves the manufacturer from any liability Any unauthorized modifications made to the engine or the aircraft absolv...

Page 28: ...Operation Maintenance Manual CD 135 CD 155 OM 02 02 Chapter Issue Issue date Page Content 02 OM 01 02 4 30 07 2014 8 8 Revision no Revision date This page intentionally left blank...

Page 29: ...direct diesel injection engine is based on the common rail technique and is turbo charged The engine is controlled by a FADEC system The propeller is driven via an integrated gearbox i 1 69 with a cl...

Page 30: ...02 4 30 07 2014 2 4 Revision no Revision date 2 3 Engine Views Front view CD 135 CD 155 Note The indications right left front and rear are always relative to the flight direction The following symbol...

Page 31: ...n date Chapter Issue Issue date Page Content 02 OM 02 02 4 30 07 2014 3 4 Overhead view CD 135 CD 155 Side view CD 135 CD 155 flight direction to the left Fig 2 2 Overhead view of CD 135 CD 155 dimens...

Page 32: ...CD 135 CD 155 OM 02 02 Chapter Issue Issue date Page Content 02 OM 02 02 4 30 07 2014 4 4 Revision no Revision date Side view CD 135 CD 155 flight direction to the right Fig 2 4 Side view of CD 135 C...

Page 33: ...TAE 125 02 99 Max takeoff power 99 kw at 2300 rpm Max continuous power 99 kw at 2300 rpm Recommended cruise power 71 kw at 2010 rpm Best Economy 71 kw at 2010 rpm CD 155 TAE 125 02 114 Max takeoff pow...

Page 34: ...starting 32 C Min oil temperature OT opening up 50 C Max oil temperature OT 140 C Min coolant temperature CT starting 32 C Min coolant temperature CT opening up 60 C Max coolant temperature CT 105 C M...

Page 35: ...pressure at takeoff power 2 3 bar Min oil pressure at cruising power 2 3 bar Max oil pressure 6 0 bar Max oil pressure cold start 20 sec 6 5 bar Max oil consumption 0 1 l h Note In the case of an eme...

Page 36: ...in the intended operating environment must be taken into account WARNING The takeoff with Diesel fuel is not permitted if the temperature of the fuel in the tank is below 5 C 10 C if Liqui Moly Diesel...

Page 37: ...G 75W 90 API GL 4 WARNING Prist Hi Flash Anti Icing Fuel Additive is only allowed for the operation with JET A CAUTION If operating the engine with Prist Hi Flash Anti Icing Fuel Additive the specifi...

Page 38: ...pection which has to be carried out by an authorized person Engine damage could result from coolant loss and this could cause engine failure WARNING If the ice flocculation point of the coolant is out...

Page 39: ...n Alu Protect Ready Mix respectively to ensure proper coolant quality Note The ice flocculation point of the coolant is 38 C if mixed 50 50 Glysantin G05 Glysantin G30 and Glysantin G48 are anti corro...

Page 40: ...Revision no Revision date 2 06 06 2016 3 6 Power Curve The values refer to 0 relative humidity Fig 3 5 Power curve of CD 135 TAE 125 02 99 CD 135 Power at Altitude 0 2000 4000 6000 8000 10000 12000 14...

Page 41: ...e Page Content 02 OM 03 02 4 30 07 2014 9 10 2 06 06 2016 Fig 3 6 Power curve of CD 155 TAE 125 02 114 CD 155 Power at Altitude 0 2000 4000 6000 8000 10000 12000 14000 16000 18000 20000 22000 24000 0...

Page 42: ...ate 2 06 06 2016 3 7 Low Temperature Data and Climate Classes of Diesel in Europe Note The officially published figures in EN 590 must be observed Note The minimum opening up fuel temperature in the t...

Page 43: ...the tank is below 5 C 10 C if Liqui Moly Diesel Fliess Fit No 5130 is added according to the manufacturer s specifications If you do not know what fuel grade is in the tank always assume it is additiv...

Page 44: ...ersonnel Any rotating propeller is a potential safety hazard that can cause severe personal injuries or even death CAUTION If external power is used for start up of a 12V Version of the CD 135 CD 155...

Page 45: ...system then automatically switches to the FADEC B only the B light is on e The propeller governor is activated the propeller speed decreases Propeller speed target 800 900PropRPM f The system automati...

Page 46: ...ts start to flash This applies even if the engine seems to run perfectly again after completion of the test procedure Note If the test button is released before the self test is completed the FADEC im...

Page 47: ...ler must accelerate smoothly and steadily to the following propeller speed limits rpm Single engined 2240 rpm to 2300 rpm Twin engined 2240 rpm to 2320 rpm The load indicator must show more than 95 Ma...

Page 48: ...Manifold Pressure MAP Compare MAP to MAP Tar Deviation must be within a tolerance of 75 mbar Propspeed Prop RPM Compare PropRPM to Pr SpdTar Deviation must be within a tolerance of 50 RPM Fuel Pressur...

Page 49: ...s will occur Temporary failure The active warning lamps will extinguish if it is a LOW category warning and a temporary not steady failure In case of a temporary failure the FADEC light will illuminat...

Page 50: ...iled Sensor CAM Broken Sensor FADEC Select Broken Sensor MAP Broken Sensor Mapselect Broken Sensor P Baro Broken Sensor P Fuel Broken Sensor P Oil Broken Sensor P prop Broken Sensor P Rail Broken Sens...

Page 51: ...voltage 4 5 Takeoff and Climb Quickly move the load selector to the full load position 4 6 During Flight Constantly monitor whether the oil pressure oil temperature and coolant temperature is within t...

Page 52: ...Operation Maintenance Manual CD 135 CD 155 OM 02 02 Chapter Issue Issue date Page Content 02 OM 04 02 4 30 07 2014 10 10 Revision no Revision date 2 02 09 2015 This page intentionally left blank...

Page 53: ...ions Replace gearbox oil filter refer to Chapter 6 Annex 8 Page 23 of this Manual Check the presetting of the proportional pressure reducing valve refer to RM 02 02 Chapter 72 10 05 or Chapter 72 10 1...

Page 54: ...12 Page 49 of this Manual Replace high pressure pump refer to Chapter 6 Annex 11 Page 48 of this Manual Inspect fuel feed pump 05 7312 K0073xx 05 7312 K0133xx refer to Chapter 6 Annex 18 Page 71 of th...

Page 55: ...er s specifications 5 1 7 Every 12 months Replace excitation battery of the alternator refer to Chapter 6 Annex 16 Page 64 of this Manual 5 1 8 Every 60 months Replace all fuel oil and cooling lines C...

Page 56: ...ng hours 5 2 2 Maintenance Actions based on time CAUTION Exceedings must not be cumulated Operating Hours Intervals Claimable Exceeding of the Basic Interval up to and including 100 operating hours 10...

Page 57: ...rmed at the latest at 310 operating hours Assume the basic interval for the next 100 hours check i e 400 operating hours 100 hours check must be performed between 390 and 410 operating hours b Limited...

Page 58: ...f the proportional pressure reducing valve at every 100 operating hours Implementation of high pressure pump inspec tion every 300 operating hours in case of TS 1 jet fuel is being used for clarificat...

Page 59: ...hanges Change of Header 4 1 Implementation of a new fuel feed pump 05 7312 K0177xx 4 2 Increase of proportional pressure reducing valve replacement 1200 hrs 4 3 Update of FAA approval statement Increa...

Page 60: ...Operation Maintenance Manual CD 135 CD 155 OM 02 02 Chapter Issue Issue date Page Content 02 OM 05 02 4 30 07 2014 8 8 Revision no Revision date 6 06 06 2016 This page intentionally left blank...

Page 61: ...pecifications refer also to the aircraft manual WARNING The entire engine has a service life time between replacement recommended by the manufacturer refer to Service Bulletin TM TAE 125 0001 WARNING...

Page 62: ...t a FADEC test run 6 2 Maintenance Actions based on Operating Hours CAUTION When checking the engine oil level screw in the dipstick completely CAUTION Checking the oil level at operating start temper...

Page 63: ...haust system Visual inspection of the v ribbed belt refer to Annex 1 Page 12 of this Chapter Perform an engine test run according to Chapter 4 Section 4 4 2 Page 5 of this Manual read out the FADEC E...

Page 64: ...fuel pump refer to the aircraft manufacturer s specifications Test the cooling system under pressure at 2 0 bar Duration 2 minutes Max 2 0 bar must not be exceeded Afterwards check for leakage refer...

Page 65: ...proportional pressure reducing valve refer to RM 02 02 Chapter 72 10 05 or Chapter 72 10 16 6 2 3 Every 200 operating hours Carry out all steps described in Section 6 2 2 Page 4 of this Chapter Repla...

Page 66: ...fuel feed pump 05 7312 K0073xx 05 7312 K0133xx refer to Annex 18 Page 74 of this Chapter Replace rail pressure control valve refer to RM 02 02 Chapter 73 10 07 Inspect dual mass flywheel refer to RM...

Page 67: ...aircraft manufacturer s specifications Replace coolant hose 05 7523 K0048xx only DA42 installations Visual inspection of the gasket of the turbocharger oil return line replace if necessary Replace pr...

Page 68: ...ifications Replace proportional pressure reducing valve part of the gearbox Inspect gearbox refer to Chapter 6 Annex 15 Page 63 of this Manual Inspect timing chain ONLY applicable for engines Version...

Page 69: ...escribed in Section 6 2 4 Page 5 of this Chapter Inspect timing chain ONLY applicable for engines Version 02 refer to RM 02 02 Chapter 05 20 04 6 2 11 Every 1500 operating hours only applicable for CD...

Page 70: ...ng run analysis The label must show the aircraft serial number registration number engine serial number operation time and date Quantity of oil to be taken for sample 100ml Exchange gearbox oil and ge...

Page 71: ...fuel oil and cooling system lines refer to RM 02 02 Chapter 05 20 03 FADEC maintenance to be carried out by the engine manufacturer Note Flexible hose hose assemblies replacement times are in service...

Page 72: ...06 02 4 30 07 2014 12 74 Revision no Revision date 7 20 07 2016 Annex 1 Inspecting the V Ribbed Belt This is a general visual inspection The v ribbed belt is to be checked for indications of wear such...

Page 73: ...m for Leakage This is a visual inspection Check all pipes pipe joints supply connections and engine housing separation points e g cylinder head gasket cylinder head cover gasket for leakage seepage po...

Page 74: ...ecting the Cooling System for Leakage This is a visual inspection The pipes pipe joints and supply connections are inspected for leakage and seepage points WARNING No leakage and seepage points are pe...

Page 75: ...anual 2 Warm up the engine according to Chapter 4 Section 4 3 Page 3 of this Manual 3 Perform the engine test run according to Chapter 4 Section 4 4 2 Page 5 of this Manual 4 Shut down the engine acco...

Page 76: ...nel Any rotating propeller is a potential safety hazard that can cause severe personal injuries or even death CAUTION After the engine has been warmed up shut down the engine Refer to Chapter 4 7 of t...

Page 77: ...with the oil filter cartridge c See Fig 6 2 7 Replace the o ring a and then insert the new oil filter cartridge c into the screw cap b See Fig 6 2 8 Refit the screw cap b and tighten it up to the spec...

Page 78: ...N Only engine oil according to Chapter 3 Section 3 5 Page 4 of this Manual may be used Note Due to differences in the oil cooler installation the oil quantity depends upon the aircraft manufacturer A...

Page 79: ...d The engine must be cleaned only when it is cooled down Generally the use of cold cleaners is recommended e g Eylert cleaner Eylert P N 89226 The engine must be dried after cleaning ideally with comp...

Page 80: ...nspection Check whether the plug connections of the sensors are firmly in place In addition the wiring harness has to be checked for indications of abrasion The sensors which should be checked are lis...

Page 81: ...hapter Issue Issue date Page Content 02 OM 06 02 4 30 07 2014 21 74 7 20 07 2016 Fig 6 5 Air temperarture sensor and MAP connections of the intake manifold a FADEC connection for MAP sensor b Air temp...

Page 82: ...M 02 02 Chapter Issue Issue date Page Content 02 OM 06 02 4 30 07 2014 22 74 Revision no Revision date 7 20 07 2016 Fig 6 7 Camshaft sensor 2 a Camshaft sensor 2 FADEC B 2 of 2 Fig 6 8 Crankshaft sens...

Page 83: ...02 02 Revision no Revision date Chapter Issue Issue date Page Content 02 OM 06 02 4 30 07 2014 23 74 7 20 07 2016 Fig 6 9 Crankshaft sensor 2 a Crankshaft sensor FADEC B 2 of 2 Fig 6 10 Gearbox temper...

Page 84: ...D 135 CD 155 OM 02 02 Chapter Issue Issue date Page Content 02 OM 06 02 4 30 07 2014 24 74 Revision no Revision date 7 20 07 2016 Fig 6 11 Oil pressure and oil temperature sensor a Oil pressure sensor...

Page 85: ...iate container See Fig 6 12 2 Remove the old gearbox oil filter with a M6 screw Item Part Number Description 1 Description 2 Quantity 1 03 7212 K004001 Filter element 1 2 NM 0000 0150401 O Ring DIN 37...

Page 86: ...or mounting direction see Fig 6 13 and Fig 6 14 CAUTION Only use an original Technify Motors GmbH gearbox oil filter Note Make sure that the new o ring is correctly mounted to the new oil filter The o...

Page 87: ...orque Tightening Torque 30 Nm 6 Preset the proportional pressure reducing valve refer to Chapter 72 10 16 of RM 02 02 7 Secure the gearbox oil filter cap with a locking wire See Fig 6 15 8 Do an Engin...

Page 88: ...ove the old gearbox oil filter with a M6 screw See Fig 6 17 Item Part Number Description 1 Description 2 Quantity 1 03 7212 K004001 Filter element 1 2 NM 0000 0121001 Sealing Ring DIN 7603 A30x36 Al 1...

Page 89: ...4 29 74 7 20 07 2016 3 Insert the new gearbox oil filter For mounting direction see Fig 6 18 and Fig 6 19 Fig 6 17 Removal of gearbox oil filter CAUTION Only use an original Technify Motors GmbH gearb...

Page 90: ...e Issue date Page Content 02 OM 06 02 4 30 07 2014 30 74 Revision no Revision date 7 20 07 2016 Fig 6 18 Gearbox oil filter assembling a Filter element with o ring b Sealing ring aluminum c Filter cap...

Page 91: ...ing Torque 55 Nm 6 Preset the proportional pressure reducing valve Refer to Chapter 72 10 05 of RM 02 02 7 Secure the gearbox oil filter cap with a locking wire See Fig 6 20 8 Do an Engine Test run ac...

Page 92: ...vel must reach the top of the inspection glass air bubbles must not be visible See Fig 6 21 2 If the oil level is not OK check the gearbox for leaks 3 If leaks were found contact Technify Motors GmbH...

Page 93: ...arking line in Fig 6 21 Air bubbles must not be visible 6 Fill another 150ml of the new gearbox oil to reach the ideal oil level 7 Remount the oil filler screw with a new sealing ring and tighten it t...

Page 94: ...30 07 2014 34 74 Revision no Revision date 7 20 07 2016 9 Secure the oil filler screw with a lock wire See Fig 6 23 10 Do an Engine Test run according to Annex 4 of this Chapter 11 Do a visual inspect...

Page 95: ...isible See Fig 6 24 2 If the oil level is not OK check the gearbox for leaks 3 If leaks were found contact Technify Motors GmbH if no leaks were found do the following work steps 4 If oil needs to be...

Page 96: ...line in Fig 6 24 Air bubbles must not be visible 6 Remount the oil filler screw with a new sealing ring and tighten it to the specified tightening torque Tightening Torque 35 Nm 7 Preset the proporti...

Page 97: ...age Content 02 OM 06 02 4 30 07 2014 37 74 7 20 07 2016 8 Secure the oil filler screw with a lock wire See Fig 6 26 9 Do an Engine Test run according to Annex 4 of this Chapter 10 Do a visual inspecti...

Page 98: ...l as well as other available documentation for instructions and limitations of operation maintenance repair and troubleshooting Routine maintenance must consist of a regular maintenance download and i...

Page 99: ...ote Please use a compressed file format such as zip to send any data This greatly reduces transfer times and facilitates data handling on both sides The tool offers this function automatically for the...

Page 100: ...ad appropriate to the situation should be used Refer to section 4 and 5 of this annex a Establish CAN communication by connecting the computer to the aircraft starting the program and powering up the...

Page 101: ...2014 41 74 7 20 07 2016 c Enter the Engine S N and Engine run time in the fields provided Select OK The window at the bottom right of the screen will indicate that the logging function is active by sh...

Page 102: ...und run the user should verify that engine parameters are to spec Compare the values of Map to MapTar Prop RPM to PrSpdTar and PRail to PRaTar to determine any discrepancy Manifold Pressure MAP Compar...

Page 103: ...e software tool has the ability to generate a single compressed file containing the data necessary during a regular maintenance event This function should be used after a regular maintenance event a M...

Page 104: ...Revision date 7 20 07 2016 b If not already active establish CAN communication with the FADEC by following the steps on the screen Enter the required engine S N and engine run time Select Continue Th...

Page 105: ...l appear Fig 6 34 FADEC read out Perform engine ground run Note During the ground run the user should verify that engine parameters are to spec Compare the values of Map to MapTar Prop RPM to PrSpdTar...

Page 106: ...ision date 7 20 07 2016 d When the download is completed the following screen will appear e Select the action you wish to perform Open Explorer at Logfile s location to locate the file just created Cr...

Page 107: ...accessed through the following Menu FADEC Where are my data files Or by selecting the appropriate icon after the download completes Refer to instructions in your e mail program for attaching files and...

Page 108: ...0 07 2016 6 Clearing Diagnostic Warnings Should the diagnostic warning lights be active they must be cleared after the discrepancy has been diagnosed and resolved before the aircraft can be released f...

Page 109: ...creen will appear c Cycle ECU power and ensure that the lights on the panel have extinguished 7 Selecting Different Screens The tool allows access to various screens to view engine parameters status o...

Page 110: ...ate Page Content 02 OM 06 02 4 30 07 2014 50 74 Revision no Revision date 7 20 07 2016 Annex 11 Inspecting the High Pressure Pump The high pressure pump must be delivered to Technify Motors GmbH for m...

Page 111: ...no Revision date Chapter Issue Issue date Page Content 02 OM 06 02 4 30 07 2014 51 74 7 20 07 2016 Annex 12 Replacing the Alternator The alternator must be delivered to Technify Motors GmbH for mainte...

Page 112: ...x24 Al 1 6 NM 0000 0188601 Sealing Ring 18x24x1 5 Viton 80 1 CAUTION The regulations regarding the disposal of waste oil must be observed Never discharge waste oil into the sewage system or the ground...

Page 113: ...ge Content 02 OM 06 02 4 30 07 2014 53 74 7 20 07 2016 3 Check the magnet of the oil drain plug for chips Fig 6 42 Overview of the gearbox inspection points a Oil filler screw b Oil level inspection g...

Page 114: ...e oil filter with a M6 screw See Fig 6 44 CAUTION The sealing ring has 2 different sealing surfaces The plane surface of the sealing ring must face the magnet Fig 6 43 oil drain plug with sealing ring...

Page 115: ...4 55 74 7 20 07 2016 7 Insert the new gearbox oil filter For mounting direction see Fig 6 45 and Fig 6 46 Fig 6 44 Removal of gearbox oil filter CAUTION Only use an original Technify Motors GmbH gearb...

Page 116: ...4 56 74 Revision no Revision date 7 20 07 2016 8 Attach the new o ring to the filter cap See Fig 6 46 Fig 6 45 Mounting direction of the oil filter Fig 6 46 Gearbox oil filter assembling a Filter elem...

Page 117: ...1 2 liters 12 Remount the oil filler screw with a new sealing ring and tighten it to the specified tightening torque Tightening Torque 35 Nm 13 Preset the proportional pressure reducing valve Refer to...

Page 118: ...4 Revision no Revision date 7 20 07 2016 15 Secure the oil filler screw with a lock wire See Fig 6 48 16 Do an Engine Test run according Annex 4 of this Chapter 17 Do a visual inspection and a check f...

Page 119: ...ng 18x24x1 5 Viton 80 1 CAUTION The regulations regarding the disposal of waste oil must be observed Never discharge waste oil into the sewage system or the ground CAUTION Only use an original Technif...

Page 120: ...gearbox oil filter an remove it See Fig 6 49 6 Remove the oil filter with a M6 screw See Fig 6 50 Fig 6 49 Overview of the gearbox inspection points a Oil filler screw b Oil level inspection glass c F...

Page 121: ...ing direction see Fig 6 51 and Fig 6 52 Fig 6 50 Removal of gearbox oil filter CAUTION Only use an original Technify Motors GmbH gearbox oil filter Note Make sure that the new o ring is correctly moun...

Page 122: ...m a 11 Fill in 1 liter new gearbox oil 12 Remount the oil filler screw with a new sealing ring and tighten it to the specified tightening torque Tightening Torque 35 Nm 13 Preset the proportional pres...

Page 123: ...02 OM 06 02 4 30 07 2014 63 74 7 20 07 2016 14 Secure the gearbox oil filter cap with a locking wire See Fig 6 53 15 Secure the oil drain plug with a lock wire See Fig 6 54 Fig 6 53 Lock wire between...

Page 124: ...Revision no Revision date 7 20 07 2016 16 Secure the oil filler screw with a lock wire See Fig 6 55 17 Do an Engine Test run according to Annex 4 of this Chapter 18 Do a visual inspection and a check...

Page 125: ...a collection container After draining reinstall and tighten the drain plug Tightening Torque 30 Nm Reconnect the lower hoses of the water radiator and the heat exchanger Tighten the clamps 2 Filling u...

Page 126: ...ter Issue Issue date Page Content 02 OM 06 02 4 30 07 2014 66 74 Revision no Revision date 7 20 07 2016 Annex 15 Inspecting the Gearbox The gearbox must be delivered to Technify Motors GmbH for inspec...

Page 127: ...y The short connection line connects both excitation batteries series connection The red cable lug is pushed onto the red connection of the second excitation battery Afterwards connect the wiring harn...

Page 128: ...g four screws c eight washers d and four stop nuts e Tightening torque 3 5 Nm 5 Connect the wiring harness to the excitation battery The blue cable lug is pushed onto the black connection of the excit...

Page 129: ...structions given to you during the process Afterwards you can start the program by using the link on your computer s desktop Update Process 1 For updating FADEC software please attach the USB CAN inte...

Page 130: ...out the aircraft type is displayed Also for each FADEC an update status is displayed See Fig 6 59 7 If all information is correct proceed to the next step by pressing Update Fig 6 58 Start Update CAUT...

Page 131: ...e EASA Form 1 Please compare the CRC checksum on the EASA Form 1 see Fig 6 63 with the checksum on the information screen see Fig 6 64 Fig 6 60 Update progress Fig 6 61 Update finished Note In case th...

Page 132: ...D 135 CD 155 OM 02 02 Chapter Issue Issue date Page Content 02 OM 06 02 4 30 07 2014 72 74 Revision no Revision date 7 20 07 2016 11 Please save the Form 1 Fig 6 62 Previously failed update Fig 6 63 F...

Page 133: ...Perform a Diagnostic Reset Refer to Section 7 Clearing Diagnostic Warnings in Annex 10 of this Chapter 15 Start the FADEC Service Tool 16 Compare the CRC checksums with those found on the Form 1 s see...

Page 134: ...ssue date Page Content 02 OM 06 02 4 30 07 2014 74 74 Revision no Revision date 7 20 07 2016 Annex 18 Inspecting the Fuel Feed Pump The fuel feed pump must be delivered to Technify Motors GmbH for ins...

Page 135: ...es over to FADEC B If the FADEC system detects a problem with channel B the FADEC B light begins to flash and the system automatically switches to whichever channel is the healthiest If the Force B sw...

Page 136: ...ntinue flight normally b Inform service center after landing The lights will illuminate after the ignition has been switched off and on 3 FADEC lights steady illuminated steady failure or high categor...

Page 137: ...e next airfield or landing strip be prepared for an emergency landing d Inform service center after landing 7 3 3 Abnormal engine behavior If abnormal engine behavior should occur during flight and th...

Page 138: ...itionally Starter ON 7 Check the engine power Load Selector 100 engine parameters check altitude and airspeed The propeller will normally continue to turn as long as the airspeed is above 65 KIAS Shou...

Page 139: ...power setting which keeps the oil pressure in the green if possible b If the oil pressure remains too low expect engine failure and prepare for an emergency landing WARNING If there is air in the fuel...

Page 140: ...Operation Maintenance Manual CD 135 CD 155 OM 02 02 Chapter Issue Issue date Page Content 02 OM 07 02 4 30 07 2014 6 6 Revision no Revision date This page intentionally left blank...

Page 141: ...rthiness we kindly request you to fill out this form when you sell your engine or aircraft Please send this form by e mail fax or post to Technify Motors GmbH Technify Motors GmbH Platanenstra e 14 D...

Page 142: ...u perform an inspection of the timing chain according RM 02 02 Chapter 05 20 04 Please send this form preferentially by e mail also possible by fax or post to Technify Motors GmbH Technify Motors GmbH...

Page 143: ...Hours Check Engine Maintenance Check After the 3rd 6th operating hour Date 2 Engine Maintenance Checklist Inspection Items Initials Check the oil system for leakage refer to Chapter 6 Annex 2 of this...

Page 144: ...0 of this Manual Exchange the gearbox oil filter refer to Chapter 6 Annex 8 of this Manual The used gearbox oil filter should be labeled stored in a clean container and made available to Technify Moto...

Page 145: ...nterval Engine operation hours Initials 100 200 300 600 900 1200 1500 1800 Time Protect engine against corrosion Start up the engine for at least 20 minutes refer to Chapter 4 Section 4 2 Page 2 of th...

Page 146: ...oil system refer to Chapter 6 Annex 2 of this Manual x x x x x x x x Visual inspection of the fuel system refer to Chapter 6 Annex 2 of this Manual x x x x x x x x Replace the fuel filter refer to th...

Page 147: ...Annex 13 of this Manual A sample of the oil and the used gearbox oil filter should be labeled stored in a clean container and made available to Technify Motors GmbH on request for the complete engine...

Page 148: ...this Manual every 12 month Replace alternator 14V 28V refer to Chapter 6 Annex 12 of this Manual x x x Replace rail pressure control valve refer to RM 02 02 Chapter 73 10 07 x x x Replace proportional...

Page 149: ...flywheel and the use of gearbox oil Shell Spirax S6 ATF ZM or CENTURION Gearbox Oil N1 In all other cases the interval remains at 300 or 600 hrs The 600 hrs gearbox inspection interval is only valid i...

Page 150: ...2015 6 8 Revision no Revision date 5 20 07 2016 Engine Maintenance Checklist General FADEC maintenance to be carried out by the engine manufacturer every 60 month FINAL INSPECTOR in block letters date...

Page 151: ...nance Manual CD 135 CD 155 OM 02 02 Revision no Revision date Chapter Issue Issue date Page Content Checklist 4 17 04 2015 7 8 5 20 07 2016 Engine Maintenance Checklist General 3 this page is intentio...

Page 152: ...Operation Maintenance Manual CD 135 CD 155 OM 02 02 Chapter Issue Issue date Page Content Checklist 4 17 04 2015 8 8 Revision no Revision date 5 20 07 2016 Engine Maintenance Checklist General...

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