M&D FLUGZEUGBAU MD-TJ Series Operation And Maintenance Manual Download

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Operation and

Maintenance Manual

MD-TJ42

Summary of Contents for MD-TJ Series

Page 1: ...Operation and Maintenance Manual MD TJ42 ...

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Page 3: ...gines Model MD TJ42 Serial number Document number MD02 OMM 70 001 Title Operation and Maintenance Manual MD TJ42 Issue 06 Date of Issue 19 November 2018 Responsible for content Sören Pedersen HoAO Section 5 is approved by the EASA through EASA E 099 Copyright M D Flugzeugbau GmbH Co KG EASA 21J 603P Streeker Straße 5b D 26446 Friedeburg alle Rechte vorbehalten ...

Page 4: ... Operation and Maintenance Manual MD02 OMM 70 001 Issue 06 Rev 00 Rev Date 19 11 2018 Page ii The translation has been done by best knowledge and judgement in any case the German original text is authoritative ...

Page 5: ...iii WARNING Before maintenance or operation of the engine you are required to read this manual completely because it contains safety relevant information Omissions can lead to malfunctions injuries or death The manual does not replace the approved aircraft flight manual of the aircraft manufacturer ...

Page 6: ...MD TJ42 Operation and Maintenance Manual MD02 OMM 70 001 Issue 06 Rev 00 Rev Date 19 11 2018 Page iv Intentionally left blank ...

Page 7: ...o be recorded in the following table and in case of the approved section section 5 be endorsed by the agency The new or amended text on the revised page will be indicated by yellow background colour a black line in the right hand margin The revision number and date will be shown in the footer The issue will be shown in the header Section 5 was approved by the EASA on 29 07 2016 ...

Page 8: ... 11 11 2015 Initial Issue 04 18 05 2016 Amendment of the whole manual 05 29 11 2017 Amendment of entire manual layout Amendment of pages 3 3 4 5 6 4 06 19 11 2018 Amendment of entire manual rearrangement of sections 3 6 3 4 3 6 4 7 6 8 7 rearrangement of headings all sections section 4 3 Ground Run implemented correction of wording all sections ...

Page 9: ...19 11 2018 4 section rearranged headings rearranged table added 3 00 19 11 2018 4 section moved 6 3 section rearranged correction of wording 4 00 19 11 2018 6 section moved 3 subsection added and rearranged correction of wording 5 00 19 11 2018 2 headings rearranged correction of wording 6 00 19 11 2018 8 section moved 4 section rearranged correction of wording ECU V2 7 00 19 11 2018 8 section mov...

Page 10: ...MD TJ42 Operation and Maintenance Manual MD02 OMM 70 001 Issue 06 Rev 00 Rev Date 19 11 2018 Page 0 4 0 3 Record of Amending Date of Issue Date of Insertion Signature ...

Page 11: ... 1 Safety Information 1 1 1 2 Remarks 1 1 1 3 Warnings cautions and notes 1 2 1 4 Abbreviations 1 3 1 5 Conversion Tables 1 4 1 6 Certification Basis 1 6 1 7 Serial Number 1 6 1 8 Technical Data 1 7 1 9 Engine Schematic View 1 8 Operating Limitations 2 1 2 1 Performance Data 2 1 2 2 Rotational Speeds 2 1 2 3 Exhaust Gas Temperature EGT 2 1 2 4 Air Temperature 2 1 2 5 Altitude 2 2 2 6 Battery Limit...

Page 12: ...t 3 2 3 8 Overheat 3 2 3 9 Flame Out 3 2 3 10 No Idle Speed 3 3 3 11 No RPM Signal 3 3 3 12 No Configuration 3 3 3 13 No SD Card 3 3 Normal Operation 4 1 4 1 Ground Maintenance and Pre flight Check 4 1 4 2 Engine Start in Flight 4 1 4 3 Engine Start on the Ground Ground Run 4 2 4 4 Operation in Flight 4 4 4 5 Shut Off of the Engine 4 6 Airworthiness Limitations 5 1 5 1 Approval 5 1 5 2 Life Limite...

Page 13: ...tenance and Maintenance Intervals 7 1 7 1 Safety Information 7 1 7 2 Ground Pre flight Daily Check 7 1 7 3 Periodical Maintenance Checks 7 2 7 4 Time Between Overhaul TBO 7 4 7 5 Component Change 7 5 7 5 1 Glow Plug Igniter 7 5 7 5 2 EGT Sensor 7 5 7 5 3 RPM Sensor 7 6 7 5 4 Sensor Board 7 6 7 5 5 Starter 7 7 Contact Information 8 1 8 1 Type Certificate Holder 8 1 8 2 Manufacturer 8 1 8 3 Authoriz...

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Page 15: ...ed maintenance organisation A list of all by M D authorized maintenance organisations can be found on the M D website 1 1 Safety Information It is essential that you have read and understood this manual in its entirety before operation of the engine Omissions of details written in this manual can lead to malfunctions serious injuries or death 1 2 Remarks Maintenance safety and flight information o...

Page 16: ...form shown below Disregarding can lead to malfunctions of the jet engine or serious injuries NOTE Special amendment that can contribute to a better understanding CAUTION Precautions and special instructions the non observance of which may result in damage to the engine or its components WARNING Precautionary rules and measures the non observance of which may result in serious injury or damage ...

Page 17: ...escription EASA European Aviation Safety Agency ECU Engine Control Unit EGT Exhaust Gas Temperature ISA International Standard Atmosphere JDU Jet Display Unit LLP Life Limited Part M D M D Flugzeugbau GmbH Co KG MSL Mean Sea Level RPM Revolutions per Minute SB Service Bulletin TBO Time Between Overhaul TCDS Type Certificate Data Sheet ...

Page 18: ...m mm 0 00328084 ft ft 304 8 mm km 1 852 NM NM 0 539956803 km cm 0 155 sq in inch sq in inch 6 45163 cm m 10 7639 sq ft sq ft 0 092903 m cm 0 06102361 cu in inch cu in 16 3871 cm ltr 0 26419 US gal US gal 3 7852 ltr ltr 0 22009 imp gal imp Gal 4 5435 ltr kg 9 80665 N N 0 101972 kg kg 2 20462 lbs lbs 0 453592909 kg N 0 22481 lbs lbs 4 44816 N mbar 0 02953 in Hg in Hg 33 8653 mbar ...

Page 19: ...Result kW 1 35962162 PS PS 0 73549875 kW PS 1 0139 hp hp 0 7457 kW km h 0 53996 kn kn 1 852 km h km h 0 6214 Stat Mile Stat Mile 1 60935 km h m s 3 281 ft sec ft sec 0 3048 m s m s 196 8 ft min ft min 0 00508 m s kgm 9 80665 Nm Nm 0 101972 kgm Unit Formula Result C 273 15 K K 273 15 C C 5 9 32 F F 32 9 5 C C 10 8 R R 8 10 C ...

Page 20: ...1 Mass of Fuel The density of diesel fuel is stated with minimum 0 820 kg ltr and maximum 0 845 kg ltr at 15 C 1 6 Certification Basis The engine MD TJ42 is certified in accordance with CS 22 subpart H and Special Conditions SC01 to SC19 under the TCDS EASA E 099 1 7 Serial Number For inquiries or spare part orders always quote the serial number S N of the engine as reference You can find the S N ...

Page 21: ...425 mm Diameter 164 mm Mass 3 7 kg RPM Thrust Fuel Consumption Max Thrust1 2 97 000 min 1 350 N 67 l h Max Continous Power 80 000 min 1 205 N 45 l h Max indicated airspeed for engine starting 130 km h Note 1 max thrust corresponds to 97 000 min 1 MSL and ISA Conditions Note 2 max thrust at 97 000 min 1 is limited to 5min Note 3 Fuel consumption data correspond to averaged expercience values ...

Page 22: ... Maintenance Manual MD02 OMM 70 001 Issue 06 Rev 00 Rev Date 19 11 2018 Page 1 8 1 9 Engine Schematic View 1 Air Intake 2 Starter 3 Radial Compressor 4 Glow Plug 5 Combustion Chamber 6 Turbine 7 Exhaust Nozzle 1 2 7 4 3 6 5 ...

Page 23: ...er be operated Please contact M D in such a case 2 1 Performance Data The performance data are based on ISA conditions at MSL Maximum thrust limited to 5 minutes 350 N Maximum continuous thrust 205 N Idle 0 N 2 2 Rotational Speeds Maximum RPM limited to 5 minutes 97 000 1 Min Maximum continuous RPM 80 000 1 Min Idle 30 000 1 Min 2 3 Exhaust Gas Temperature EGT Operating Range 450 C to 790 C Max wh...

Page 24: ...N 590 For lubrication 2 Vol two stroke engine oil has to be added to the diesel fuel If the engine is to be operated down to 15 C it is recommended to use class F winter diesel The following table provides information on the use of different classes of winter diesel Class A Class B Class C Class D Class E Class F until 5 C until 0 C until 5 C until 10 C until 15 C until 20 C REMARK If it is not kn...

Page 25: ...k of gelling and the associated failure of the engine 2 7 2 Lubricants Only fully synthetic two stroke engine oil which complies with the specification listed below may be used as lubricant The volume fraction of the lubricant within the diesel fuel is 2 Specification Class API American Petroleum Institute TA TSC 1 TB TSC 2 TC TSC 3 JASO Japan Automobile Standards Organisation FC ...

Page 26: ...MD TJ42 Operation and Maintenance Manual MD02 OMM 70 001 Issue 06 Rev 00 Rev Date 19 11 2018 Page 2 4 Intentionally left blank ...

Page 27: ...ercurrent The current consumption of the igniter has exceeded the set maximum value Possibly the igniter is defective or there is a short circuit 3 3 Starter Overcurrent The current consumption of the starter exceeded the set maximum value The starting process has been aborted It must be ensured that there is no short circuit and that the starter and turbine shaft can rotate freely 3 4 No Ignition...

Page 28: ...that the start valve works properly 3 7 Fuel Valve Overcurrent The fuel valve that injects the fuel during operation has drawn too much current It must be ensured that there is no short circuit and that the fuel valve works properly 3 8 Overheat The maximum starting temperature has been exceeded The starting process was aborted due to overheating 3 9 Flame Out The temperature has fallen below the ...

Page 29: ...nced by electromagnetic interference 3 12 No Configuration The Engine Control Unit could not load a valid configuration for the engine It must be ensured that a valid configuration has been stored on the SD card that the SD card can be accessed and that the configuration matches the serial number of the engine WARNING The check whether the SD card is inserted correctly and whether there is a valid...

Page 30: ...ut errors Check that the SD card is inserted correctly and that the file system is error free Without successful access to the SD card no log data will be recorded during operation WARNING The check whether the SD card is inserted correctly may only be performed by M D or a by M D authorized maintenance organisation ...

Page 31: ...Check Before starting the engine a pre flight check daily check or ground start check has to be performed How to perform the check can be found in section 7 2 4 2 Engine Start in Flight Normal engine starts should be performed in the air The maximum indicated airspeed for engine start is 130 km h Engine Start of MD TJ42 1 Main System Switch ON 2 Check Altitude 3 Airspeed for Extracting and Startin...

Page 32: ...the engine on the ground as well The following safety precautions must be executed before starting the engine on ground Precautions for Ground Run 1 Bring the aircraft to a safe area for execution of the ground run secure if necessary 2 Turn the nose of the aircraft into the wind 3 Keep persons and objects out of the engine exhaust gas jet area secure if necessary 4 Secure the main landing gear ag...

Page 33: ...usly secured aircraft starts the engine as follows Engine Start on the Ground First Person 1 Close canopy 2 Put on ear protection 3 Make visiual contact eye contact 4 Wait for Start signal Go OK Signal Abort Stop Signal 5 Main System Switch ON 6 Check Emergency Fuel Shut Off ON 7 Check Battery Voltage 8 Check Fuel quantity 9 Engine switch RUN 10 Engine proceeds through Automatic Start Sequence 11 ...

Page 34: ...ly with the following Engine Start on the Ground Second Person 1 Place oneself in front and sideways of aircraft nose keep visual contact 2 Put on ear protection 3 Make visiual contact eye contact 4 Give Start signal Go OK signal Abort Stop signal 5 Keep portable fire extinguisher at hand 4 4 Operation in Flight The operation of the engine in flight shall be performed according to the aircraft fli...

Page 35: ...possible with the engine REMARK During flight tests the operation of the engine was tested in light to moderate rain On doing so there could be determined no difference compared to dry operation Nevertheless the usage of the engine during rain is not recommended because a climb could be only possible with restrictions or not at all Example of LX JDU EGT in C EGT scale Battery voltage LED retracted...

Page 36: ...nd operation the ECU starts with the cooling of the engine automatically after shutting off the engine This means that the starter spins the engine with approximately 3 000 RPM for forced cooling until an EGT of less than 55 C is reached The engine retracts automatically if the EGT is less than 55 C Engine Shut Off of MD TJ42 1 Engine Switch RET 2 Continue normal Gliding not applicable for ground ...

Page 37: ... changes to each mandatory replacement time inspection interval and related procedure contained in this section must also be approved by the EASA 5 2 Life Limited Parts LLP Critical parts which are subject to low cycle fatigue are listed in the following table with their maximum number of cycles The limitations must be complied with in order to maintain airworthiness LLP Part Number Maximum Cycles...

Page 38: ...MD TJ42 Operation and Maintenance Manual MD02 OMM 70 001 Issue 06 Rev 00 Rev Date 19 11 2018 Page 5 2 Intentionally left blank ...

Page 39: ...d Maintenance Manual MD02 OMM 70 001 Issue 06 Rev 00 Rev Date 19 11 2018 Page 6 1 Engine Systems The following section describes the subsystems of the engine 6 1 Fuel System The fuel system consists of following components ...

Page 40: ...ifferent components can be seen on the wiring diagram below The engine MD TJ42 has no on board generator and is therefore dependent on the operating voltage of the battery For this reason the battery must always be fully charged before operating the engine If the operating voltage of the battery falls below 11 5 V the engine can no longer be started ...

Page 41: ... and monitoring the engine during operation With the help of the JDU the pilot can operate the engine and monitor the relevant engine data In order to start operate and monitor the engine it is necessary to control the applicable modules and that the measured values of the sensors are evaluated Turbinensteuerung Sensorplatine für Temperatur magnetische Drehzahlmessung 09 03 2012 V2 5V GND RXD in T...

Page 42: ...uple for measuring the exhaust gas temperature EGT An inductive speed sensor for measuring the rotational speed of the turbine wheel Furthermore the fuel flow is measured by a fuel flow meter and recorded by the ECU With this information it is possible to display the fuel flow and the remaining fuel quantity on board to the pilot on the JDU In addition the ECU stores important engine parameters th...

Page 43: ...be found on the backside of the ECU ECU P N MD02 73 20 00 which may be exchanged by the engine operator Or in a separate fuse box ECU V2 P N MD02 73 20 50 e g like in the aircraft JS MD 3 with an automatic circuit breaker Starter Valve 3A Igniter 30A Kinematics 10A Fuel Valve 3A Fuel Pump 7 5A Starter 30A Starter Valve 3A Igniter 30A Kinematics 10A Fuel Valve 3A Fuel Pump 7 5A Starter 30A ...

Page 44: ...ce organization 6 2 4 Jet Display Unit JDU REMARK The different operating conditions and functions of the JDU are described and illustrated in the following subsections using an example LX JDU 6 2 5 Engine operating conditions The various primary operating conditions of the engine can be selected with the Engine Switch by the pilot Retracted mode RET Extended mode EXT Run mode RUN System Main Swit...

Page 45: ...Issue 06 Rev 00 Rev Date 19 11 2018 Page 6 7 The secondary operating conditions of the engine which cannot be selected directly by the pilot are Starting Extending Retracting Cooling Run mode Extended mode Retracted mode Cooling Retracting Starting Extracting ...

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Page 47: ...pull fuses disconnect battery trip circuit breaker No person is allowed to operate the JDU during the inspection 7 2 Ground Pre flight Daily Check At least once a day before starting the engine a pre flight ground check shall be carried out according to the table below The engine must be cold and the ignition switched off In case of any findings within the check contact M D or a by M D authorized ...

Page 48: ... Check for no water in the fuel 7 3 Periodical Maintenance Checks The periodic maintenance must be performed once a year or after 10 operating hours whichever occurs first according to the following table Yearly Check 10 hrs Check 1 Dismount fairing 2 Wiring Check tight fit condition and strain relief 3 Fuel lines Check tight fit condition no leaks chafe marks or fractures check leak tightness 4 B...

Page 49: ...M D Check sensor board for tight fit and condition Check nozzle for tight fit screw connection 6 Fuel Panel Check all screw connection for tight fit and condition no leaks no chafe marks check leak tightness Check fuel pump for leak tightness Check valves for leak tightness Check flowmeter for leak tightness and function 7 Fuel Filter Clean fuel filter and check condition 8 Shut off Valve Check fo...

Page 50: ...fuel flow indication 7 4 Time Between Overhaul TBO The operating times according to cycles hours and years whichever occurs first listed in the table below must not be exceeded If one of the operating time limits is reached the applicable part assembly has to be sent to M D or a by M D authorized maintenance organisation for overhaul inspection Part Assembly Time Between Overhaul Inspection Time C...

Page 51: ...ug 4 Remove igniter from glow plug retainer 5 Replace O ring within glow plug retainer 6 Insert new glow plug 7 Insert split pin 8 Connect wiring to glow plug 9 Connect battery 10 Perform engine ground test run start engine once to check whether the new glow plug functions correctly according to section 4 3 11 Check glow plug retainer for consistence 7 5 2 EGT Sensor 1 Disconnect battery 2 Disconn...

Page 52: ... RPM sensor 5 Trim and strip the wiring of the new RPM sensor according to the wiring of the old RPM sensor 6 Insert the new RPM sensor into the retainer and adjust the distance between the compressor wheel and the sensor to 0 30 mm with a feeler gauge 7 Tighten the grub screw and recheck the distance 8 Connect the RPM sensor wiring to the sensor board according to subsection 6 2 1 9 Connect batte...

Page 53: ...e sensor board according to subsection 6 2 1 6 Connect battery 12 Perform engine ground test run according to section 4 3 7 Check RPM indication 8 Check EGT indication 7 5 5 Starter 1 Disconnect battery 2 Dismount fairing 3 Disconnect starter wiring at separation point 4 Loosen screw connections of the starter 5 Remove starter move forward 6 Fit new starter straight fit push until stop 7 Tighten s...

Page 54: ...Issue 05 Rev 00 Rev Date 19 11 2018 Page 7 8 13 Check starter does the turbine accelerate properly 14 Check spindle slider does it move out flawlessly 15 Cooling without any complaints spindle slider moves in and out flawlessly during cooling 16 Mount fairing ...

Page 55: ...e 5B 26446 Friedeburg Germany 49 0 4465 97878 11 Mail info md flugzeugbau de 8 2 Manufacturer M D Flugzeugbau GmbH Co KG Streeker Straße 5b 26446 Friedeburg Germany 49 0 4465 97878 11 Mail info md flugzeugbau de 8 3 Authorized Maintenance Organisations 1 M D Flugzeugbau GmbH Co KG DE 145 0397 2 Others A list of all by M D authorized maintenance organisations can be found on the M D website ...

Page 56: ...MD TJ42 Operation and Maintenance Manual MD02 OMM 70 001 Issue 05 Rev 00 Rev Date 19 11 2018 Page 8 2 Intentionally left blank ...

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