RECOMMENDED SERVICE BULLETIN RSB 42-139 RSB 42NG-081

Material is available from Diamond Aircraft Industries. Diamond Aircraft Industries GmbH Nikolaus-August-Otto-Straße 5 2700 Wiener Neustadt, Austria WI-RSB 42-139 WI-RSB 42NG-081 Revision 1 Page 3 of 9 24-Oct-2019 III INSTRUCTIONS III.1 Replacement of rudder T-yoke axle 1. Remove the pilot and copilot seat in accordance with AMM, Section 25-10. 2. Remove the middle tunnel front cover in accordance with AMM, Section 25-10. 3. Remove the two heating hoses from Y-connector in acc. with AMM, Section 25-10. 4. Disconnect the short elevator push rod from the main spar lever. 5. Remove the passenger seat in accordance with AMM, Section 25-10. 6. Check the clearances while moving the rudder in both directions  between end of T-yoke bolts for copilot’s right rudder cable & pilot’s left rudder cable and nose landing gear (NLG) steering rod (continuous circle in picture 4)  and between head of T-yoke bolts for copilot’s right rudder cable & pilot’s left rudder cable and support plate (dashed circle in picture 4). Record the measured clearances. Each clearance must be greater than 2 mm (0.08 in). Pictures 1 – 4 show the affected area. picture 4picture 3 picture 2 picture 1 Diamond Aircraft Industries GmbH Nikolaus-August-Otto-Straße 5 2700 Wiener Neustadt, Austria WI-RSB 42-139 WI-RSB 42NG-081 Revision 1 Page 4 of 9 24-Oct-2019 7. Remove the bolt from the NLG steering rod end on T-yoke. 8. Release rudder cable turnbuckles. 9. Remove T-yoke axle from the rudder steering bracket. 10. Make sure that the self-locking nut and all washers are removed from the airframe. 11. Verify, if an oblong hole washer was installed to the rudder steering bracket in accordance with MSB 42-087 / MSB 42NG-016. There are 3 different installation variants, which can be found in airplanes in field. Variant 1: No oblong hole washer is installed to the rudder steering bracket. Instead, a standard washer (13 mm outer diameter) is installed between T-yoke and rudder steering bracket. Variant 2: Oblong hole washer D60-5320-00-31 (outer diameter 20 mm) was bonded to the rudder steering bracket, in accordance with MSB 42-087 / MSB 42NG-016. Variant 3: Oblong hole washer D60-5320-00-31_01 (outer diameter 20 mm) was bonded to the rudder steering bracket, in accordance with MSB 42-087 / MSB 42NG-016. Note: The two different designs of oblong hole washers D60-5320-00-31 and D60-5320-00-31_01 can be identified in figure 1. figure 1 12. If an oblong hole washer is installed to the rudder steering bracket (variants 2 or 3), check if the oblong hole washer is well bonded to the rudder steering bracket. additional step spigot D60-5320-00-31_01 D60-5320-00-31 spigot Diamond Aircraft Industries GmbH Nikolaus-August-Otto-Straße 5 2700 Wiener Neustadt, Austria WI-RSB 42-139 WI-RSB 42NG-081 Revision 1 Page 5 of 9 24-Oct-2019 13. Install the T-yoke with new T-yoke axle D60-5320-00-32  in accordance with Section III.2, if no oblong hole washer was installed to the rudder steering bracket (Variant 1),  in accordance with Section III.3, if oblong hole washer D60-5320-00-31 is installed and well bonded to the rudder steering bracket (Variant 2),  in accordance with Section III.4, if oblong hole washer D60-5320-00-31_01 (with additional step) is installed and well bonded to the rudder steering bracket (Variant 3),  in accordance with Section III.5, if oblong hole washer D60-5320-00-31 or D60-5320-00-31_01 is installed to the rudder steering bracket, but the bonding between oblong hole washer and rudder steering bracket had failed and oblong hole washer is found loose (Variant 2 or 3). 14. Install the two heating hoses to the Y-connector in accordance with AMM, Section 25-10. 15. Connect the short elevator push rod to the main spar lever. 16. Check all control cables and push rods in working area for free movement and minimum clearance of 2 mm (0.8 in) in all positions. 17. Do an inspection of all controls that have been adjusted. If required by the National Authority, do a duplicate inspection of the controls. 18. Install the passenger seat in accordance with AMM, Section 25-10. 19. Install the middle tunnel front cover in accordance with AMM, Section 25-10. 20. Install the pilot and copilot seat in accordance with AMM, Section 25-10. 21. Clean working area and check for foreign objects. 22. Perform functional check of altered, repaired and new parts. 23. Test all systems in working area for function. 24. Make necessary entries into aircraft logs. Diamond Aircraft Industries GmbH Nikolaus-August-Otto-Straße 5 2700 Wiener Neustadt, Austria WI-RSB 42-139 WI-RSB 42NG-081 Revision 1 Page 6 of 9 24-Oct-2019 III.2 Installation of T-yoke without oblong hole washer installed to the rudder steering bracket 1. Install the T-yoke with  the new T-yoke bolt D60-5320-00-32,  a DIN 125 washer between support plate and T-yoke,  a DIN 125 washer between the T-yoke and the rudder steering bracket,  a DIN 9021 washer between the self-locking nut and the rudder steering bracket,  a new self-locking nut and  a retaining pin AN416-1 perpendicular to the flight direction in accordance with figure 2. Note: The retaining pin can damage the heating hose if not installed perpendicular to the flight direction. 2. Tighten the T-yoke bolt with a tightening torque of 10 Nm. 3. Adjust left and right rudder cable turnbuckles to give the correct tension to the control cables in accordance with AMM, Section 27-20. 4. Check clearances in accordance with step 6 in Section III.1. 5. If any of the clearances is not greater than 2 mm (0.08 in), reposition the T-yoke in accordance with Work Instruction of MSB 42-087 / MSB 42NG-016, Section III.3, latest effective issue. 6. Continue with step 14 in Section III.1. figure 2 Diamond Aircraft Industries GmbH Nikolaus-August-Otto-Straße 5 2700 Wiener Neustadt, Austria WI-RSB 42-139 WI-RSB 42NG-081 Revision 1 Page 7 of 9 24-Oct-2019 III.3 Installation of T-yoke with oblong hole washer D60-5320-00-31 well bonded to the rudder steering bracket 1. Install the T-yoke with  the new T-yoke bolt D60-5320-00-32,  a DIN 125 washer between support plate and T-yoke,  a DIN 988 shim between the T-yoke and well bonded oblong hole washer,  a DIN 9021 washer between the self-locking nut and the rudder steering bracket,  a new self-locking nut and  a retaining pin AN416-1 perpendicular to the flight direction in accordance with figure 3. Note: The retaining pin can damage the heating hose if not installed perpendicular to the flight direction. 2. Tighten the T-yoke bolt with a tightening torque of 10 Nm. 3. Adjust left and right rudder cable turnbuckles to give the correct tension to the control cables in accordance with AMM, Section 27-20. 4. Check clearances in accordance with step 6 in Section III.1. 5. Continue with step 14 in Section III.1. figure 3 Diamond Aircraft Industries GmbH Nikolaus-August-Otto-Straße 5 2700 Wiener Neustadt, Austria WI-RSB 42-139 WI-RSB 42NG-081 Revision 1 Page 8 of 9 24-Oct-2019 III.4 Installation of T-yoke with oblong hole washer D60-5320-00-31_01 (additional step) well bonded to the rudder steering bracket 1. Install the T-yoke with  the new T-yoke bolt D60-5320-00-32,  a DIN 125 washer between support plate and T-yoke,  a DIN 9021 washer between the self-locking nut and the rudder steering bracket,  a new self-locking nut and  a retaining pin AN416-1 perpendicular to the flight direction in accordance with figure 4. Note: The retaining pin can damage the heating hose if not installed perpendicular to the flight direction. 2. Tighten the T-yoke bolt with a tightening torque of 10 Nm. 3. Adjust left and right rudder cable turnbuckles to give the correct tension to the control cables in accordance with AMM, Section 27-20. 4. Check clearances in accordance with step 6 in Section III.1. 5. Continue with step 14 in Section III.1. figure 4 Diamond Aircraft Industries GmbH Nikolaus-August-Otto-Straße 5 2700 Wiener Neustadt, Austria WI-RSB 42-139 WI-RSB 42NG-081 Revision 1 Page 9 of 9 24-Oct-2019 III.5 Installation of T-yoke and failed bonding between oblong hole washers D60-5320-00-31 or D60-5320-00-31_01 and rudder steering bracket 1. Remove old thickened resin / bonding material from the rudder steering bracket. 2. Make sure, that the oblong hole washer is installed with correct orientation. In case of doubt, do a test installation of the T-yoke and test-fit the new oblong hole washer D60-5320-00-31_01 without bonding it to the rudder steering bracket. Check all clearances in accordance with step 6 in Section III.1. Note: If the clearance between end of T-yoke bolts for copilot’s right rudder cable & pilot’s left rudder cable and NLG steering rod is not greater than 2 mm (0.08 in), install the oblong hole washer with the spigot opposite to flight direction. If the clearance between head of T-yoke bolts for copilot’s right rudder cable & pilot’s left rudder cable and support plate is not greater than 2 mm (0.08 in), install the oblong hole washer with the spigot in flight direction. Note: The spigot must face downwards. 3. Prepare oblong hole washer and rudder steering bracket for bonding in accordance with AMM, Chapter 51. 4. Clean bonding area of oblong hole washer and rudder steering bracket with clean acetone. 5. Bond oblong hole washer D60-5320-00-31_01 to the rudder steering bracket in accordance with adhesive manufacturer instructions:  Apply 3M Scotch-Weld DP 410 adhesive to the mating surfaces.  Move oblong hole washer into correct position.  Make sure the oblong hole washer is correctly aligned (orientation of spigot, plane surface perpendicular to direction of T-yoke bolt axle)  Fix oblong hole washer until further processing is possible (refer to adhesive manufacturer data sheet)  Remove excessive adhesive. 6. Install T-yoke in accordance with Section III.4 7. Continue with step 14 in Section III.1.