AIRCRAFT MAINTENANCE MANUAL
Diamond DA42 VI · Maintenance Manual
Overview
This Aircraft Maintenance Manual (AMM) is specifically designed for the Diamond DA42 L360 aircraft, featuring the Lycoming IO-360 M1A and LIO-360 M1A engines. It provides comprehensive maintenance instructions, including system descriptions, troubleshooting procedures, and component removal and installation guidelines. The manual is intended for use in conjunction with the original DA42 AMM and other related documents, ensuring that all maintenance tasks are performed safely and effectively. It emphasizes the importance of adhering to safety precautions and includes a revision service to keep the manual up to date with any design changes or procedural updates.
- The manual is specifically for the Diamond DA42 L360 aircraft.
- It includes maintenance instructions for the Lycoming IO-360 M1A and LIO-360 M1A engines.
- Safety warnings and cautions are emphasized throughout the manual.
- Scheduled maintenance checks and time limits are outlined to ensure airworthiness.
- Wiring diagrams are provided for troubleshooting electrical systems.
Document
Source
Originally published by www.pilot18.com. Sprinkle hosts a reference copy with an added summary, specifications and searchable full text.
Document details
- Type
- Maintenance Manual
- Year
- 2012
- Pages
- 648
- File size
- 25 MB
- Publisher
- www.pilot18.com
Common. Rarer than 1% of the aircraft models we track.
Most owners only have the POH. Here's the essential set for the Diamond DA42 VI.
- Pilot's Operating Handbook / AFM
- Checklist
- Maintenance Manual
- Parts Catalog (IPC)
- Systems & Wiring
- Service Bulletins
- Type Certificate (TCDS)
Diamond DA42 VI for sale now
Free — save the DA42 to your watchlist and track it in one place.
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In this document
Introduction
The introduction outlines the purpose of the AMM, which is to provide maintenance instructions specific to the DA42 L360 aircraft. It emphasizes the need to use this manual alongside the original DA42 AMM and other relevant documents. Safety warnings, cautions, and notes are highlighted to ensure safe maintenance practices.
General Description of the Aircraft
This section provides an overview of the DA42 L360, detailing its systems and components. It includes information on the aircraft's engines and the installation of the Supplemental Type Certificate (STC) No. SA09-54.
Time Limits and Maintenance Checks
This section outlines the scheduled maintenance checks and time limits for various components of the DA42 L360. It is crucial for maintaining airworthiness and ensuring that all systems are functioning correctly.
Electrical Power
Details the electrical systems of the DA42 L360, including DC generation and battery systems. This section is essential for understanding the aircraft's power management and troubleshooting electrical issues.
Flight Controls
Covers the maintenance procedures for the flight control systems, including rudder, elevator, and flap controls. This section is vital for ensuring the aircraft's handling characteristics are maintained.
Fuel
Describes the fuel distribution system and maintenance procedures related to fuel management. Proper fuel system maintenance is critical for engine performance and safety.
Engine
Provides detailed maintenance instructions for the engine, including fuel and control systems, ignition, and air management. This section is essential for ensuring the engine operates efficiently and safely.
Wiring Diagrams
Includes wiring diagrams for the electrical systems, which are crucial for troubleshooting and maintenance tasks.
Safety notes
- Follow all safety precautions when performing maintenance tasks.
- Warnings indicate potential injury or death if instructions are not followed.
- Cautions indicate possible damage to equipment if instructions are not adhered to.
Full document text
AIRCRAFT MAINTENANCE MANUAL Initial Issue: 01 Jun 09 Revision 5: 15 Oct 12 DA42 L360 D42L-AMM-001 NOTE: This AMM is a supplement and needs to be used in conjunction with the current DA42 TDI AMM. Complete maintenance instructions for the chapters not affected by TCCA STC No. SA09-54 (FAA STC No. SA02725NY) are available in Diamond Aircraft DA42 AMM, Document Number 7.02.01. 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, London, ON, Canada AIRCRAFT MAINTENANCE MANUAL Initial Issue: 01 Jun 09 Revision 4 : 15 Oct 12 D42L-AMM-001 Rev 5 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 1 Rev 5 ROR Record of Revisions D42L AMM D42L-AMM-001 15 Oct 12 RECORD OF REVISIONS Use this list to record and control all of the revisions which you put in this Aircraft Maintenance Manual (AMM). Put the affected pages of the revision into the AMM as soon as you get them. Remove and destroy the pages that are superseded. Complete the table below when you have put the revised pages into the AMM. A vertical bar in the left margin shows changes on text pages and in drawings. Revision Number Date Issued Date Inserted Inserted By Revision Number Date Issued Date Inserted Inserted By Rev 0 01 Jun 09 01 Jun 09 DAIC Rev 1 02 Nov 09 02 Nov 09 DAIC Rev 2 01 Oct 10 01 Oct 10 DAIC Rev 3 14 Jun 11 14 Jun 11 DAIC Rev 4 16 Apr 12 16 Apr 12 DAIC Rev 5 15 Oct 12 23 Oct 12 DAIC Record of Revisions D42L AMM ROR 16 Apr 12 Page 2 D42L-AMM-001 Rev 4 Intentionally Left Blank Page 1 Rev 5 Highlights Highlights D42L AMM D42L-AMM-001 15 Oct 12 HIGHLIGHTS 1. General The table below highlights the changes that have been incorporated in this Revision 5. CH-SE-SU Page Highlights Front Matter Cover Page, ROR, Highlights, SB List, LOEP, and TOC pages were revised. 05-20-00 217 Corrected the step 5 in Paragraph 4.F. 24-30-00 208 thru 212 Added new removal and installation proceedures for the EMI filter. Added Figures 202 to 204. Renumbered the pages due to pagination shift. 27-50-00 201 and 202 Added new chapter 27-50-00 and added replacement proceedures for the flap indicator lights lamp. 28-20-00 204 thru 216 Revised the installation procedure for Fuel Booster Pump. Added installation procedure for the replacement of gascolator assembly. Revised Figures 201 and 202. Renumbered the pages due to pagination shift. 32-60-00 203 thru 206 Added installation procedure for the replacement of flap and landing gear lights lamp. 80-00-00 5 Revised paragraph 2.C. 92-00-00 3 5 Revised the Table of Contents Revised Paras 1 and 2 and the Wiring Diagrams/Schematics table. 92-10-00 1 thru 24 Revised all of the existing schematics from Rev 4 to be in a standard format and added five schematics. Highlights D42L AMM Highlights 15 Oct 12 Page 2 D42L-AMM-001 Rev 5 Intentionally Left Blank Page 1 Rev 5 List of SB’s List of SBs D42L AMM D42L-AMM-001 15 Oct 12 LIST OF SERVICE BULLETINS SB Number Revision Number Category Title of Service Bulletin Date Issued D42L-25-01 0 Optional DA42 L360 Ballast Installation 02 Dec 09 D42L-27-01 0 Optional Modification of Variable Elevator Stop System 22 Oct 09 D42L-28-01 0 Optional Lighted Fuel Pump Switch 10 Dec 09 D42L-28-02 0 Mandatory Transfer Pump Circuit Breaker Change 30 May 12 D42L-32-01 0 Recommended Implementation of CHECK GEAR Annunciation 18 Jan 12 D42L-34-01 1 Recommended G1000 System Siftware Version 1054.02 15 Aug 11 D42L-34-02 0 Optional Availability of the G1000 Synthetic Vision Pathways Option - Garmin SB 1039A 26 Sep 12 D42L-34-03 2 Optional ADF System Improvements 05 Oct 12 D42L-34-04 1 Optional G1000 System Siftware Version 1054.03 11 Oct 12 D42L-79-01 3 Optional Installation of External Oil Cooler Scoop 07 Feb 12 List of SBs D42L AMM List of SB’s 01 Jun 09 Page 2 D42L-AMM-001 Rev 0 Intentionally Left Blank Page 1 Rev 4 List of TRs D42L AMM D42L-AMM-001 16 Apr 12 LIST OF TEMPORARY REVISIONS Temporary Revision Number Date Issued Inserted Date Inserted By TR 05-01 07 Dec 09 14 Jun 11 DAIC TR 11-01 07 Dec 09 14 Jun 11 DAIC TR 12-01 12 Dec 11 16 Apr 12 DAIC TR 25-01 07 Dec 09 14 Jun 11 DAIC TR 25-02 07 Dec 09 14 Jun 11 DAIC TR 28-01 07 Dec 09 14 Jun 11 DAIC TR 28-02 10 Dec 09 14 Jun 11 DAIC TR 28-03 12 Dec 11 16 Apr 12 DAIC List of TRs D42L AMM 01 Jun 09 Page 2 D42L-AMM-001 Rev 0 Intentionally Left Blank Page 1 Rev 5 LOEP List of Effective Pages D42L AMM D42L-AMM-001 15 Oct 12 Front Matter Page Revision Date ROR 1 15 Oct 12 ROR 2 16 Apr 12 Highlights 1 15 Oct 12 Highlights 2 15 Oct 12 List of SB 1 15 Oct 12 List of SB 2 01 Jun 09 List of TR 1 16 Apr 12 List of TR 2 01 Jun 09 LOEP 1 15 Oct 12 LOEP 2 15 Oct 12 LOEP 3 15 Oct 12 LOEP 4 15 Oct 12 LOEP 5 15 Oct 12 LOEP 6 15 Oct 12 LOEP 7 15 Oct 12 LOEP 8 15 Oct 12 LIST OF EFFECTIVE PAGES 1. General The List of Effective Pages (LOEP) uses the following abbreviations: - TOC = Table of Contents - ROR = Record of Revisions - SB = Service Bulletin - TR = Temporary Revisions. All Chapters have a Title page and Table of Contents. Each revision to the Aircraft Maintenance Manual (AMM) will have a new List of Effective Pages. Revised pages and the revision date will be shown by a revision bar. LOEP 9 15 Oct 12 LOEP 10 15 Oct 12 LOEP 11 15 Oct 12 LOEP 12 15 Oct 12 TOC 1 15 Oct 12 TOC 2 15 Oct 12 Front Matter Page Revision Date List of Effective Pages D42L AMM LOEP 15 Oct 12 Page 2 D42L-AMM-001 Rev 5 CH-SE-SU Page Revision Date 01-TITLE 1 01 Jun 09
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01-TITLE 2 01 Jun 09 01-TOC 3 02 Nov 09 01-TOC 4 02 Nov 09 01-00-00 5 02 Nov 09 01-00-00 6 02 Nov 09 01-00-00 7 02 Nov 09 01-00-00 8 02 Nov 09 01-00-00 9 02 Nov 09 01-00-00 10 02 Nov 09 03-TITLE 1 01 Jun 09 03-TITLE 2 01 Jun 09 03-TOC 3 02 Nov 09 03-TOC 4 02 Nov 09 03-00-00 5 02 Nov 09 03-00-00 6 02 Nov 09 03-00-00 7 02 Nov 09 03-00-00 8 02 Nov 09 04-TITLE 1 01 Jun 09 04-TITLE 2 01 Jun 09 04-TOC 3 02 Nov 09 04-TOC 4 02 Nov 09 04-00-00 5 02 Nov 09 04-00-00 6 02 Nov 09 04-00-00 7 02 Nov 09 04-00-00 8 02 Nov 09 05-TITLE 1 01 Jun 09 05-TITLE 2 01 Jun 09 05-TOC 3 02 Nov 09 05-TOC 4 02 Nov 09 05-10-00 3 02 Nov 09 05-10-00 4 02 Nov 09 05-10-00 5 02 Nov 09 05-10-00 6 02 Nov 09 05-10-00 7 01 Oct 10 05-10-00 8 02 Nov 09 05-20-00 201 02 Nov 09 05-20-00 202 01 Oct 10 05-20-00 203 02 Nov 09 05-20-00 204 02 Nov 09 05-20-00 205 01 Oct 10 05-20-00 206 01 Oct 10 05-20-00 207 01 Oct 10 05-20-00 208 02 Nov 09 05-20-00 209 02 Nov 09 05-20-00 210 16 Apr 12 05-20-00 211 01 Oct 10 05-20-00 212 01 Oct 10 05-20-00 213 01 Oct 10 05-20-00 214 01 Oct 10 05-20-00 215 01 Oct 10 05-20-00 216 01 Oct 10 05-20-00 217 15 Oct 12 05-20-00 218 01 Oct 10 06-TITLE 1 01 Jun 09 06-TITLE 2 01 Jun 09 06-TOC 3 02 Nov 09 06-TOC 4 02 Nov 09 CH-SE-SU Page Revision Date Page 3 Rev 5 LOEP List of Effective Pages D42L AMM D42L-AMM-001 15 Oct 12 06-00-00 5 02 Nov 09 06-00-00 6 02 Nov 09 06-00-00 7 02 Nov 09 06-00-00 8 02 Nov 09 11-TITLE 1 01 Jun 09 11-TITLE 2 01 Jun 09 11-TOC 3 02 Nov 09 11-TOC 4 02 Nov 09 11-00-00 5 02 Nov 09 11-00-00 6 02 Nov 09 11-20-00 1 01 Jun 09 11-20-00 2 01 Jun 09 11-30-00 1 01 Oct 10 11-30-00 2 01 Jun 09 11-30-00 3 01 Jun 09 11-30-00 4 01 Jun 09 11-30-00 5 01 Oct 10 11-30-00 6 01 Oct 10 11-30-00 201 02 Nov 09 11-30-00 202 01 Jun 09 12-TITLE 1 01 Jun 09 12-TITLE 2 01 Jun 09 12-TOC 3 02 Nov 09 12-TOC 4 02 Nov 09 12-00-00 5 02 Nov 09 12-00-00 6 02 Nov 09 12-10-00 1 16 Apr 12 12-10-00 2 02 Nov 09 12-10-00 3 02 Nov 09 CH-SE-SU Page Revision Date 12-10-00 4 02 Nov 09 12-10-00 5 02 Nov 09 12-10-00 6 02 Nov 09 12-10-00 7 02 Nov 09 12-10-00 8 02 Nov 09 12-20-00 1 01 Jun 09 12-20-00 2 02 Nov 09 12-20-00 3 02 Nov 09 12-20-00 4 01 Jun 09 20-TITLE 1 01 Jun 09 20-TITLE 2 01 Jun 09 20-TOC 3 02 Nov 09 20-TOC 4 02 Nov 09 20-10-00 5 02 Nov 09 20-10-00 6 02 Nov 09 20-10-00 7 02 Nov 09 20-10-00 8 02 Nov 09 20-70-00 1 01 Jun 09 20-70-00 2 01 Jun 09 20-70-00 3 01 Jun 09 20-70-00 4 01 Jun 09 24-TITLE 1 01 Jun 09 24-TITLE 2 01 Jun 09 24-TOC 3 02 Nov 09 24-TOC 4 02 Nov 09 24-00-00 5 02 Nov 09 24-00-00 6 02 Nov 09 24-00-00 7 02 Nov 09 24-00-00 8 02 Nov 09 CH-SE-SU Page Revision Date List of Effective Pages D42L AMM LOEP 15 Oct 12 Page 4 D42L-AMM-001 Rev 5 24-00-00 9 02 Nov 09 24-00-00 10 02 Nov 09 24-30-00 1 01 Jun 09 24-30-00 2 01 Jun 09 24-30-00 101 02 Nov 09 24-30-00 102 01 Jun 09 24-30-00 201 01 Jun 09 24-30-00 202 01 Jun 09 24-30-00 203 01 Jun 09 24-30-00 204 01 Jun 09 24-30-00 205 02 Nov 09 24-30-00 206 01 Jun 09 24-30-00 207 02 Nov 09 24-30-00 208 15 Oct 12 24-30-00 209 15 Oct 12 24-30-00 210 15 Oct 12 24-30-00 211 15 Oct 12 24-30-00 212 15 Oct 12 24-31-00 1 02 Nov 09 24-31-00 2 01 Jun 09 24-31-00 101 02 Nov 09 24-31-00 102 01 Jun 09 25-55-00 1 01 Oct 10 25-55-00 2 01 Oct 10 25-55-00 201 01 Oct 10 25-55-00 202 01 Oct 10 25-55-00 203 01 Oct 10 25-55-00 204 01 Oct 10 27-TITLE 1 01 Jun 09 CH-SE-SU Page Revision Date 27-TITLE 2 01 Jun 09 27-TOC 3 02 Nov 09 27-TOC 4 02 Nov 09 27-20-00 5 02 Nov 09 27-20-00 6 02 Nov 09 27-20-00 7 02 Nov 09 27-20-00 8 02 Nov 09 27-20-00 9 02 Nov 09 27-20-00 10 02 Nov 09 27-20-00 201 02 Nov 09 27-20-00 202 02 Nov 09 27-20-00 203 01 Oct 10 27-20-00 204 01 Oct 10 27-20-00 205 02 Nov 09 27-20-00 206 02 Nov 09 27-20-00 207 02 Nov 09 27-20-00 208 02 Nov 09 27-20-00 209 02 Nov 09 27-20-00 210 02 Nov 09 27-20-00 211 02 Nov 09 27-20-00 212 02 Nov 09 27-20-00 213 02 Nov 09 27-20-00 214 02 Nov 09 27-20-00 215 02 Nov 09 27-20-00 216 02 Nov 09 27-20-00 217 02 Nov 09 27-20-00 218 02 Nov 09 27-20-00 219 01 Oct 10 27-20-00 220 01 Oct 10 CH-SE-SU Page Revision Date Page 5 Rev 5 LOEP List of Effective Pages D42L AMM D42L-AMM-001 15 Oct 12 27-21-00 1 01 Jun 09 27-21-00 2 01 Jun 09 27-21-00 201 16 Apr 12 27-21-00 202 16 Apr 12 27-21-00 203 16 Apr 12 27-21-00 204 16 Apr 12 27-21-00 205 16 Apr 12 27-21-00 206 16 Apr 12 27-21-00 207 16 Apr 12 27-21-00 208 16 Apr 12 27-21-00 209 16 Apr 12 27-21-00 210 16 Apr 12 27-30-00 1 02 Nov 09 27-30-00 2 01 Jun 09 27-30-00 201 02 Nov 09 27-30-00 202 02 Nov 09 27-30-00 203 02 Nov 09 27-30-00 204 02 Nov 09 27-30-00 205 02 Nov 09 27-30-00 206 02 Nov 09 27-30-00 207 02 Nov 09 27-30-00 208 02 Nov 09 27-30-00 209 01 Oct 10 27-30-00 210 01 Oct 10 27-30-00 211 01 Oct 10 27-30-00 212 01 Oct 10 27-30-00 213 01 Oct 10 27-30-00 214 01 Oct 10 27-30-00 215 01 Oct 10 CH-SE-SU Page Revision Date 27-30-00 216 01 Oct 10 27-30-00 217 01 Oct 10 27-30-00 218 01 Oct 10 27-50-00 201 15 Oct 12 27-50-00 202 15 Oct 12 28-TITLE 1 01 Jun 09 28-TITLE 2 01 Jun 09 28-TOC 3 16 Apr 12 28-TOC 4 02 Nov 09 28-00-00 5 16 Apr 12 28-00-00 6 16 Apr 12 28-00-00 7 16 Apr 12 28-00-00 8 16 Apr 12 28-20-00 1 01 Jun 09 28-20-00 2 01 Jun 09 28-20-00 101 01 Oct 10 28-20-00 102 01 Oct 10 28-20-00 201 02 Nov 09 28-20-00 202 01 Jun 09 28-20-00 203 02 Nov 09 28-20-00 204 15 Oct 12 28-20-00 205 15 Oct 12 28-20-00 206 15 Oct 12 28-20-00 207 15 Oct 12 28-20-00 208 15 Oct 12 28-20-00 209 15 Oct 12 28-20-00 210 15 Oct 12 28-20-00 211 15 Oct 12 28-20-00 212 15 Oct 12 CH-SE-SU Page Revision Date List of Effective Pages D42L AMM LOEP 15 Oct 12 Page 6 D42L-AMM-001 Rev 5 28-20-00 213 15 Oct 12 28-20-00 214 15 Oct 12 28-20-00 215 15 Oct 12 28-20-00 216 15 Oct 12 30-TITLE 1 01 Oct 10 30-TITLE 2 01 Oct 10 30-TOC 3 01 Oct 10 30-TOC 4 01 Oct 10 30-00-00 5 01 Oct 10 30-00-00 6 01 Oct 10 30-00-00 7 01 Oct 10 30-00-00 8 01 Oct 10 31-TITLE 1 01 Jun 09 31-TITLE 2 01 Jun 09 31-TOC 3 02 Nov 09 31-TOC 4 02 Nov 09 31-00-00 5 01 Oct 10 31-00-00 6 02 Nov 09 31-10-00 1 02 Nov 09 31-10-00 2 01 Jun 09 31-10-00 3 01 Jun 09 31-10-00 4 01 Jun 09 31-40-00 1 16 Apr 12 31-40-00 2 16 Apr 12 31-40-00 201 02 Nov 09 31-40-00 202 16 Apr 12 31-40-00 203 02 Nov 09 31-40-00 204 02 Nov 09 31-40-00 205 02 Nov 09 CH-SE-SU Page Revision Date 31-40-00 206 02 Nov 09 32-TITLE 1 01 Oct 10 32-TITLE 2 01 Oct 10 32-TOC 3 01 Oct 10 32-TOC 4 01 Oct 10 32-60-00 5 01 Oct 10 32-60-00 6 01 Oct 10 32-60-00 201 01 Oct 10 32-60-00 202 01 Oct 10 32-60-00 203 15 Oct 12 32-60-00 204 15 Oct 12 32-60-00 205 15 Oct 12 32-60-00 206 15 Oct 12 51-TITLE 1 01 Jun 09 51-TITLE 2 01 Jun 09 51-TOC 3 02 Nov 09 51-TOC 4 02 Nov 09 51-80-00 5 02 Nov 09 51-80-00 6 02 Nov 09 51-80-00 201 01 Oct 10 51-80-00 202 01 Oct 10 51-80-00 203 01 Oct 10 51-80-00 204 01 Oct 10 51-80-00 205 01 Oct 10 51-80-00 206 01 Oct 10 55-TITLE 1 16 Apr 12 55-TITLE 2 16 Apr 12 55-TOC 3 16 Apr 12 55-TOC 4 16 Apr 12 CH-SE-SU Page Revision Date Page 7 Rev 5 LOEP List of Effective Pages D42L AMM D42L-AMM-001 15 Oct 12 55-40-00 5 16 Apr 12 55-40-00 6 16 Apr 12 55-40-00 201 16 Apr 12 55-40-00 202 16 Apr 12 61-TITLE 1 01 Jun 09 61-TITLE 2 01 Jun 09 61-TOC 3 01 Oct 10 61-TOC 4 02 Nov 09 61-00-00 5 02 Nov 09 61-00-00 6 02 Nov 09 61-10-00 1 01 Jun 09 61-10-00 2 01 Jun 09 61-10-00 3 01 Jun 09 61-10-00 4 01 Jun 09 61-10-00 101 01 Jun 09 61-10-00 102 01 Jun 09 61-10-00 201 01 Jun 09 61-10-00 202 01 Jun 09 61-10-00 203 01 Jun 09 61-10-00 204 01 Jun 09 61-10-00 205 01 Jun 09 61-10-00 206 01 Jun 09 61-20-00 1 16 Apr 12 61-20-00 2 01 Jun 09 61-20-00 3 01 Oct 10 61-20-00 4 01 Jun 09 61-20-00 101 01 Jun 09 61-20-00 102 01 Jun 09 61-20-00 201 01 Jun 09 CH-SE-SU Page Revision Date 61-20-00 202 01 Jun 09 61-20-00 203 01 Jun 09 61-20-00 204 01 Jun 09 61-20-00 205 01 Jun 09 61-20-00 206 01 Jun 09 61-20-00 207 01 Oct 10 61-20-00 208 01 Oct 10 61-20-00 209 01 Oct 10 61-20-00 210 01 Oct 10 61-20-00 211 01 Oct 10 61-20-00 212 01 Oct 10 61-20-00 213 01 Oct 10 61-20-00 214 01 Oct 10 61-20-00 215 01 Oct 10 61-20-00 216 01 Oct 10 71-TITLE 1 01 Jun 09 71-TITLE 2 01 Jun 09 71-TOC 3 02 Nov 09 71-TOC 4 02 Nov 09 71-00-00 5 02 Nov 09 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09 74-00-00 5 02 Nov 09 74-00-00 6 02 Nov 09 CH-SE-SU Page Revision Date List of Effective Pages D42L AMM LOEP 15 Oct 12 Page 10 D42L-AMM-001 Rev 5 74-00-00 7 02 Nov 09 74-00-00 8 02 Nov 09 74-00-00 9 02 Nov 09 74-00-00 10 02 Nov 09 74-00-00 101 01 Jun 09 74-00-00 102 01 Jun 09 74-00-00 201 01 Jun 09 74-00-00 202 01 Jun 09 74-00-00 203 01 Jun 09 74-00-00 204 01 Jun 09 74-00-00 205 01 Jun 09 74-00-00 206 01 Jun 09 75-TITLE 1 01 Jun 09 75-TITLE 2 01 Jun 09 75-TOC 3 02 Nov 09 75-TOC 4 02 Nov 09 75-00-00 5 02 Nov 09 75-00-00 6 02 Nov 09 75-00-00 201 01 Jun 09 75-00-00 202 01 Jun 09 75-00-00 203 01 Jun 09 75-00-00 204 01 Jun 09 75-00-00 205 01 Jun 09 75-00-00 206 01 Jun 09 75-00-00 207 01 Jun 09 75-00-00 208 01 Jun 09 75-00-00 209 01 Jun 09 75-00-00 210 01 Jun 09 76-TITLE 1 01 Jun 09 CH-SE-SU Page Revision Date 76-TITLE 2 01 Jun 09 76-TOC 3 02 Nov 09 76-TOC 4 02 Nov 09 76-00-00 5 02 Nov 09 76-00-00 6 02 Nov 09 76-00-00 7 02 Nov 09 76-00-00 8 02 Nov 09 76-00-00 9 02 Nov 09 76-00-00 10 02 Nov 09 76-00-00 101 01 Jun 09 76-00-00 102 01 Jun 09 76-00-00 201 01 Jun 09 76-00-00 202 01 Jun 09 76-00-00 203 02 Nov 09 76-00-00 204 01 Jun 09 76-00-00 205 01 Jun 09 76-00-00 206 01 Jun 09 76-00-00 207 01 Jun 09 76-00-00 208 01 Jun 09 76-00-00 209 02 Nov 09 76-00-00 210 01 Jun 09 76-00-00 211 01 Jun 09 76-00-00 212 01 Jun 09 76-00-00 213 01 Jun 09 76-00-00 214 01 Jun 09 76-00-00 215 01 Jun 09 76-00-00 216 01 Jun 09 76-00-00 217 01 Jun 09 76-00-00 218 01 Jun 09 CH-SE-SU Page Revision Date Page 11 Rev 5 LOEP List of Effective Pages D42L AMM D42L-AMM-001 15 Oct 12 77-TITLE 1 01 Jun 09 77-TITLE 2 01 Jun 09 77-TOC 3 02 Nov 09 77-TOC 4 02 Nov 09 77-00-00 5 02 Nov 09 77-00-00 6 02 Nov 09 77-40-00 1 01 Jun 09 77-40-00 2 01 Jun 09 77-40-00 101 01 Jun 09 77-40-00 102 01 Jun 09 77-40-00 201 01 Jun 09 77-40-00 202 01 Jun 09 77-40-00 203 01 Jun 09 77-40-00 204 01 Jun 09 77-40-00 205 01 Jun 09 77-40-00 206 01 Jun 09 77-40-00 207 01 Jun 09 77-40-00 208 01 Jun 09 77-40-00 209 01 Jun 09 77-40-00 210 01 Jun 09 77-40-00 211 01 Jun 09 77-40-00 212 01 Jun 09 77-40-00 213 01 Jun 09 77-40-00 214 01 Jun 09 77-40-00 215 01 Jun 09 77-40-00 216 01 Jun 09 77-40-00 217 01 Jun 09 77-40-00 218 01 Jun 09 77-40-00 219 01 Jun 09 CH-SE-SU Page Revision Date 77-40-00 220 01 Jun 09 78-TITLE 1 01 Jun 09 78-TITLE 2 01 Jun 09 78-TOC 3 02 Nov 09 78-TOC 4 02 Nov 09 78-00-00 5 02 Nov 09 78-00-00 6 02 Nov 09 78-00-00 101 01 Jun 09 78-00-00 102 01 Jun 09 78-00-00 201 01 Jun 09 78-00-00 202 02 Nov 09 78-00-00 203 02 Nov 09 78-00-00 204 02 Nov 09 78-00-00 205 02 Nov 09 78-00-00 206 02 Nov 09 79-TITLE 1 01 Jun 09 79-TITLE 2 01 Jun 09 79-TOC 3 02 Nov 09 79-TOC 4 02 Nov 09 79-00-00 5 02 Nov 09 79-00-00 6 02 Nov 09 79-00-00 101 01 Jun 09 79-00-00 102 01 Jun 09 79-00-00 201 01 Jun 09 79-00-00 202 01 Jun 09 80-TITLE 1 01 Jun 09 80-TITLE 2 01 Jun 09 80-TOC 3 02 Nov 09 80-TOC 4 02 Nov 09 CH-SE-SU Page Revision Date List of Effective Pages D42L AMM LOEP 15 Oct 12 Page 12 D42L-AMM-001 Rev 5 80-00-00 5 15 Oct 12 80-00-00 6 02 Nov 09 80-00-00 7 16 Apr 12 80-00-00 8 02 Nov 09 80-00-00 101 02 Nov 09 80-00-00 102 01 Jun 09 80-00-00 201 02 Nov 09 80-00-00 202 01 Jun 09 80-00-00 203 01 Jun 09 80-00-00 204 16 Apr 12 80-00-00 205 01 Jun 09 80-00-00 206 01 Jun 09 92-TITLE 1 01 Jun 09 92-TITLE 2 01 Jun 09 92-TOC 3 15 Oct 12 92-TOC 4 02 Nov 09 92-00-00 5 15 Oct 12 92-00-00 6 02 Nov 09 92-10-00 1 15 Oct 12 92-10-00 2 15 Oct 12 92-10-00 3 15 Oct 12 92-10-00 4 15 Oct 12 92-10-00 5 15 Oct 12 92-10-00 6 15 Oct 12 92-10-00 7 15 Oct 12 92-10-00 8 15 Oct 12 92-10-00 9 15 Oct 12 92-10-00 10 15 Oct 12 92-10-00 11 15 Oct 12 CH-SE-SU Page Revision Date 92-10-00 12 15 Oct 12 92-10-00 13 15 Oct 12 92-10-00 14 15 Oct 12 92-10-00 15 15 Oct 12 92-10-00 16 15 Oct 12 92-10-00 17 15 Oct 12 92-10-00 18 15 Oct 12 92-10-00 19 15 Oct 12 92-10-00 20 15 Oct 12 92-10-00 21 15 Oct 12 92-10-00 22 15 Oct 12 92-10-00 23 15 Oct 12 92-10-00 24 15 Oct 12 CH-SE-SU Page Revision Date Page 1 Rev 5 TOC Table of Contents D42L AMM D42L-AMM-001 15 Oct 12 TABLE OF CONTENTS Chapter-Section Title 01-00 Introduction 03-00 General Description of the Aircraft 04-00 Airworthiness Limitations 05-00 Time Limits and Maintenance Checks 05-10 - Time Limits 05-20 - Scheduled Maintenance Checks 11-00 Placards and Markings 11-20 - Exterior Placard and Markings 11-30 - Interior Placards and Markings 12-00 Servicing 12-10 - Replenishing 12-20 - Scheduled Servicing 20-00 Standard Practices 20-10 - Standard Practices - Airframe 20-70 - Standard Practices - Engine 24-00 Electrical Power 24-30 - DC Generation 24-31 - Battery Systems 25-00 Equipment and Furnishings 25-55 - Nose Forward Bulkhead Ballast 27-00 Flight Controls 27-20 - Flight Controls - Rudder 27-21 - Flight Controls - Rudder Trim 27-30 - Flight Controls - Elevator 27-50 - Flight Controls - Flaps 28-00 Fuel 28-20 - Fuel Distribution System Table of Contents D42L AMM TOC 15 Oct 12 Page 2 D42L-AMM-001 Rev 5 30-00 Ice Protection System 31-00 Indicating Systems 31-10 - Instrument and Control Panels 31-40 - Central Computers - Integrated Cockpit System (ICS) 32-00 Landing Gear 32-60 - Position and Warning 51-00 Standard Practices and Structure 51-80 - Electrical Bonding 61-00 Propeller 61-10 - Propeller Assembly 61-20 - Propeller Control 71-00 Power Plant 71-10 - Cowling 71-20 - Engine Mounting 71-50 - Electrical Cables in the Engine Compartment 71-60 - Air Intakes 71-70 - Engine Drains 72-00 Engine 73-00 Engine Fuel and Control 74-00 Ignition 75-00 Air 76-00 Engine Controls 77-00 Engine Indicating 77-40 - Engine Indicating 78-00 Exhaust 79-00 Oil Cooling 80-00 Starting 92-00 Wiring Diagrams Chapter-Section Title Page 1 Rev 0 01-TITLE Introduction D42L AMM D42L-AMM-001 01 Jun 09 CHAPTER 01-00 INTRODUCTION Introduction D42L AMM 01-TITLE 01 Jun 09 Page 2 D42L-AMM-001 Rev 0 Intentionally Left Blank Page 3 Rev 1 01-00-00 Introduction D42L AMM D42L-AMM-001 02 Nov 09 TABLE OF CONTENTS CHAPTER 01-00 INTRODUCTION ......................................................................................................... 5 1. General ................................................................................................................................................ 5 2. Revision Service .................................................................................................................................. 5 3. Warning, Cautions and Notes .............................................................................................................. 5 4. Manual Configuration........................................................................................................................... 6 5. Chapter Configuration...........................................................................................................................8 6. Page Numbering System ..................................................................................................................... 9 7. Figures ................................................................................................................................................. 9 8. Record of Revisions............................................................................................................................. 9 9. List of Effective Pages ......................................................................................................................... 9 Introduction D42L AMM 02 Nov 09 Page 4 D42L-AMM-001 Rev 1 01-00-00 Intentionally Left Blank Page 5 Rev 1 01-00-00 Introduction D42L AMM D42L-AMM-001 02 Nov 09 INTRODUCTION 1. General This Aircraft Maintenance Manual (AMM) contains the chapters necessary to carry out the maintenance that is relative and unique to the DA42 L360 aircraft with the Lycoming IO-360 M1A, left hand (LH) side engine and Lycoming LIO-360 M1A, right hand (RH) side engine installed by Supplemental Type Certificate (STC) No. SA09-54. It contains a full description of the systems, troubleshooting procedures, component removal and installation procedures and maintenance instructions related to the installation of STC No. SA09-54. It does not contain maintenance data for components removed form the aircraft. (Maintenance Shop data). Complete maintenance instructions for the chapters not affected by this STC No. SA09-54 are available in Diamond Aircraft DA42 AMM, Document Number 7.02.01. References made to the original DA42 AMM within this document are made by referencing the document number 7.02.01 followed by the Chapter number. For example: Refer to AMM # 7.02.01 Chapter XX-XX. The AMM contains the wiring diagrams for the electrical system. Use these manuals with the AMM and any related service bulletins: - The DA42 L360 Illustrated Parts Catalog - The DA42 L360 Airplane Flight Manual - The ELT Manufacturer’s Operator’s Manual - The MT Propeller Owner’s Manual - The Lycoming Engine Operator’s Manual. 2. Revision Service The manufacturer provides a revision service for the AMM. The revision shows design changes to the aircraft or changes in procedures. Each page of the manual shows the date of issue. If the page has changed, it shows the date of the revision. 3. Warning, Cautions and Notes Obey all the usual safety precautions and maintenance instructions when doing maintenance. This AMM also contains warnings, cautions and notes before applicable instructions: WARNING: A WARNING TELLS THE PERSON DOING THE MAINTENANCE THAT INJURY OR DEATH IS POSSIBLE IF THEY DO NOT FOLLOW THE INSTRUCTIONS. CAUTION: A CAUTION TELLS THE PERSON DOING THE MAINTENANCE THAT DAMAGE TO EQUIPMENT IS POSSIBLE IF THEY DO NOT FOLLOW THE INSTRUCTIONS. NOTE: A Note tells the person doing the maintenance how to make the task easier. Introduction D42L AMM 02 Nov 09 Page 6 D42L-AMM-001 Rev 1 01-00-00 4. Manual Configuration This manual is written in accordance with the regulations of the Air Transport Association of America (ATA) Specification, iSpec2200. Each system is given a chapter number from the ATA iSpec2200. Where applicable, a chapter contains sections for each sub-system. The European Association of Aerospace Industries specification, AECMA Simplified English has been used to write this AMM. This is a mandatory requirement of the ATA iSpec2200. There are only 3 sources of words available to use in Simplified English (SE). - Approved words from the SE Guide. These words have defined meanings and selected parts of speech. - Technical names as defined in the SE Guide. Used only as adjectives or nouns. - Manufacturing processes as defined in the SE Guide. Always used as verbs. This manual does not use the ATA iSpec2200 Aircraft Maintenance Task Oriented Support System (ATMOSS) or the ATA iSpec2200 Production Management Data Base (PMDB). A. The ATA iSpec2200 Numbering System The ATA iSpec2200 numbering system uses 3 pairs of numbers, for example: The first pair of numbers shows the system. System 57 is the wings. Chapter 57 contains the data for the wings. The second pair of numbers shows the sub-system. Sub-system 50 is the Trailing Edge Flaps. Chapter 57, section 50 contains the data for the trailing edge flaps installation. The third pair of numbers shows a unit. A unit could be the flap itself. Only complex systems use unit numbers. For simple systems, the main chapter has all of the data and there are no section/sub-system break- downs. 57-50-xx Chapter / System (Wings) Section / Subsystem (Flaps) Unit / Subject Number (Not normally used) Page 7 Rev 1 01-00-00 Introduction D42L AMM D42L-AMM-001 02 Nov 09 B. Groups of Chapters The chapters are put together in the following groups: Group A Introduction Chapters 01-02 Group B Aircraft General Chapters 03-12 Group C Airframe Systems Chapters 20-37 Group D Structure Chapters 51-57 Group E Propeller Chapter 61 Group F Power Plant Chapters 71-80 A separation sheet divides each chapter. The separation sheet shows the number of the chapter and the title. The main contents of each group of chapters are given below: (1) Group A - Introduction Chapter 1 describes about the AMM and Chapter 2 describes how to use the AMM. (2) Group B - Aircraft General Chapter 3 describes the general description of the aircraft and its systems. Chapter 4 describes the data about the Airworthiness Limitations and certification of the aircraft. Chapter 5 contains the Scheduled Maintenance Checklist. Some tasks require a maintenance procedure. The scheduled maintenance checklist identifies the chapter in the manual that gives the maintenance procedure for the task. It also tells you where to find general information. Chapters 6 to 10 describe about the dimensions of the aircraft and general procedures such as towing, parking and weighing. Chapter 11 describes about the placards and markings which are important for the safe operation of the aircraft. Chapter 12 contains servicing tasks such as refueling and lubrication. It also contains data about cleaning the aircraft. Introduction D42L AMM 02 Nov 09 Page 8 D42L-AMM-001 Rev 1 01-00-00 (3) Group C - Airframe Systems Chapter 20 contains the standard practices for airframe maintenance. Chapters 21 to 37 describe about the airframe systems. They include the avionics systems (such as communications (23)) and the mechanical systems (such as flight controls (27)). Chapter 31 shows the location of the instruments. The chapter which is applicable to the system gives the details. For example, Chapter 27 gives the details for the flap position indicator. (4) Group D - Structure Chapter 51 contains data about the design of the airframe. It also gives instructions for assessing damage to the airframe and how to do minor repairs. Chapters 52 to 57 describe about each part of the structure. (5) Group E - Propeller Chapter 61 contains the maintenance procedures for the propeller. Refer to the propeller manufacturer’s manual for other data. (6) Group F - Engine This group of chapters describes the engine and its systems. It contains the maintenance procedures for maintenance of the engine on the aircraft. Refer to the engine manufacturer’s manual for other data. 5. Chapter Configuration The first page of each chapter shows the number of the chapter and the title. The second page shows the contents. Where applicable, each chapter and section contains the topics that follow: - Description and Operation - Troubleshooting - Maintenance Practices. Where applicable the Maintenance Practices give data on the following procedures: - Servicing - Removal and Installation - Adjustment/Tests - Checking/Testing - Cleaning/Painting - Repairs. Page 9 Rev 1 01-00-00 Introduction D42L AMM D42L-AMM-001 02 Nov 09 6. Page Numbering System This manual uses the ATA iSpec2200 page block-numbering system. The page number is at the bottom of the page at the outer edge. It is adjacent to the chapter/section number. Each topic in a Chapter has numbers from the following page blocks: - Description and Operation: Pages 1 to 99 - Troubleshooting: Pages 101 to 199 - Maintenance Practices: Pages 201 to 299 7. Figures Figures are given numbers in sequence. The first figure in a chapter or section is figure 1. 8. Record of Revisions The AMM has a Record of Revisions (ROR). Use the ROR to show when changes were included in the AMM. 9. List of Effective Pages This AMM has a List of Effective Pages (LOEP). The LOEP shows you the number and effective date of each page contained in the AMM. Introduction D42L AMM 02 Nov 09 Page 10 D42L-AMM-001 Rev 1 01-00-00 Intentionally Left Blank Page 1 Rev 0 03-TITLE General Description of the Aircraft D42L AMM D42L-AMM-001 01 Jun 09 CHAPTER 03-00 GENERAL DESCRIPTION OF THE AIRCRAFT General Description of the Aircraft D42L AMM 03-TITLE 01 Jun 09 Page 2 D42L-AMM-001 Rev 0 Intentionally Left Blank Page 3 Rev 1 03-00-00 Description and Operation D42L AMM D42L-AMM-001 02 Nov 09 TABLE OF CONTENTS CHAPTER 03-00 GENERAL DESCRIPTION OF THE AIRCRAFT......................................................... 5 1. General ................................................................................................................................................ 5 2. Description ........................................................................................................................................... 5 3. Equipment Data ................................................................................................................................... 5 4. Handling of Identification Data ..............................................................................................................7 Description and Operation D42L AMM 02 Nov 09 Page 4 D42L-AMM-001 Rev 1 03-00-00 Intentionally Left Blank Page 5 Rev 1 03-00-00 Description and Operation D42L AMM D42L-AMM-001 02 Nov 09 GENERAL DESCRIPTION OF THE AIRCRAFT 1. General This chapter describes the configuration of DA42 L360 aircraft with Supplemental Type Certificate (STC) No. SA09-54 installed. Only those areas identified below are changed from the original DA42. All other information about the DA42 is contained in the Aircraft Maintenance Manual (AMM) document number 7.02.01. 2. Description The DA42 L360 aircraft has been modified by the installation of STC No. SA09-54. This STC includes the following changes and is otherwise identical to the Thierlert powered DA42: - Lycoming IO-360 M1A, left hand (LH) side and Lycoming LIO-360 M1A, right hand (RH) side 4-cylinders, horizontally opposed, air cooled engines power the DA42 L360 aircraft. The engines have wet sump oil systems and oil cooling systems. These engines are not Fully Automated Digital Engine Control (FADEC) controlled and therefore, the FADEC units have been removed. The starting system and electrical generation have also been changed to include a high power Sky Tech starter and a Kelly Aerospace 70 amp alternator. - DA42 L360 aircraft has two 3 bladed MT propellers, MTV-12-B-C-F/CF 183-59b (LH) and MTV-12-B-C-F/CFL 183-59b (RH). The propellers are constant speed and fully feathering. A hydraulic accummulator is used for un-feathering the propellers. - The fuel system has been modified to remove the fuel cooler and the fuel return line. A boost pump has also been added behind the firewall. The boost pump is typical of a fuel injected engine installation. - The throttle quadrant has been changed to a standard throttle/propeller control/mixture layout. - The instrument panel has been modified to account for the changes to the starting system, addition to the fuel pumps and removal of the engine control units (ECU). 3. Equipment Data The table below gives the names and address of the manufacturers who supply systems and/or equipment for the DA42 L360 aircraft. This will help you get more data on a system and/or equipment. "Yes" in the "Direct Shipping Approved" column means that the part can be ordered directly from the vendor. "No" means that the part must be obtained as a genuine Diamond Aircraft spare part. This is the case when a part needs to be configured for the DA42 L360 aircraft. In any case, the parts must have exactly the part numbers shown in the Equipment List in Chapter 6 of the Airplane Flight Manual (AFM), Doc. No. D42L-AFM-002. Description and Operation D42L AMM 02 Nov 09 Page 6 D42L-AMM-001 Rev 1 03-00-00 ATA Chapter Equipment/System Manufacturer Address Direct Shipping Approved 23, 31, and 34 Integrated Cockpit System (ICS) Garmin International, Inc. 1200 East 151st Street Olathe, Kansas 66062, USA Tel: (913) 397-8200 Fax: (913) 397-8282 Website: www.garmin.com Yes Cooling Fans for Integrated Cockpit System (ICS) SANDIA aerospace 3700 Osuna Road NE, Suite 711 Albuquerque, NM 87109, USA Tel: (505) 341-2930 Fax: (505) 341-2927 Website: www.sandiaaerospace.com Yes NOTE: The airspeed indicator must have the markings specified in Chapter 2 of the Airplane Flight Manual, Doc. No. D42L-AFM-002. 31 Airspeed Indicator, Altimeter United Instruments Inc. 3625 Comotara Avenue Wichita, Kansas 67226, USA Tel: (316) 636-9203 Fax: (316) 636-9243 Yes Attitude Gyro Mid Continent Instrument Co., Inc. 7706 E, Osie, Wichita, Kansas 67207, USA Tel: (316) 683-5619 Fax: (316) 683-1861 Yes NOTE: The propeller must have the pitch settings specified in Chapter 61 of this manual. 61 Propeller MT-Propeller Airport Straubing Wallmühle D-94348 Atting GERMANY Tel: +49-9429-9409-0 E-mail: sales@mt-propeller.com Website: www.mt-propeller.de Yes 72 Engine Textron Lycoming 652 Oliver Street Williamsport, PA 17701, USA Tel: (570) 323-6181 Fax: Website: www.lycoming.textron.com Yes Page 7 Rev 1 03-00-00 Description and Operation D42L AMM D42L-AMM-001 02 Nov 09 4. Handling of Identification Data No person shall remove, change, or place identification information on any aircraft, engine, propeller, propeller blades, or propeller hub, without the approval of the competent national Airworthiness Authority. If a deviation from the procedure above is necessary, any person performing maintenance work may in consultation with a competent national Airworthiness Authority: - Remove, change, or place the identification plate on any aircraft, engine, propeller, propeller blades, or propeller hub. - Remove an identification plate, when necessary during the maintenance operations. - No person shall install an identification plate, removed in accordance with the procedures above, on any aircraft, engine, propeller, propeller blades, or propeller hub other than the one from which it was removed. Description and Operation D42L AMM 02 Nov 09 Page 8 D42L-AMM-001 Rev 1 03-00-00 Intentionally Left Blank Page 1 Rev 0 04-TITLE Airworthiness Limitations D42L AMM D42L-AMM-001 01 Jun 09 CHAPTER 04-00 AIRWORTHINESS LIMITATIONS Airworthiness Limitations D42L AMM 04-TITLE 01 Jun 09 Page 2 D42L-AMM-001 Rev 0 Intentionally Left Blank Page 3 Rev 1 04-00-00 Airworthiness Limitations D42L AMM D42L-AMM-001 02 Nov 09 TABLE OF CONTENTS CHAPTER 04-00 AIRWORTHINESS LIMITATIONS............................................................................... 5 1. Airworthiness Limitations ..................................................................................................................... 7 2. Component Life Tracking......................................................................................................................8 Airworthiness Limitations D42L AMM 04-00-00 02 Nov 09 Page 4 D42L-AMM-001 Rev 1 Intentionally Left Blank Page 5 Rev 1 04-00-00 Airworthiness Limitations D42L AMM D42L-AMM-001 02 Nov 09 AIRWORTHINESS LIMITATIONS THE AIRWORTHINESS LIMITATIONS SECTION IS APPROVED BY TRANSPORT CANADA CIVIL AVIATION (TCCA) IN ACCORDANCE WITH THE APPLICABLE CERTIFICATION PROCEDURES AND THE SUPPLEMENTAL TYPE CERTIFICATION BASIS. IT SPECIFIES THE AIRWORTHINESS LIMITATIONS REQUIRED BY CANADIAN AIR REGULATIONS (CAR) 523, UNLESS AN ALTERNATIVE PROGRAM HAS BEEN APPROVED BY THE COMPETENT AIRWORTHINESS AUTHORITY. THE AIRWORTHINESS LIMITATIONS SECTION IS TCCA/FAA APPROVED AND SPECIFIES MAINTENANCE REQUIRED UNDER SECS. 43.16 AND 91.403 OF THE FEDERAL AVIATION REGULATIONS UNLESS AN ALTERNATIVE PROGRAM HAS BEEN TCCA/FAA APPROVED. SERVICE BULLETINS OR OTHER DOCUMENTS WHICH CONTAIN A STATEMENT THAT THE DOCUMENT IS EUROPIAN AVIATION SAFETY AGENCY (EASA) APPROVED ARE CONSIDERED TCCA/FAA APPROVED AND REVISE THIS SECTION. Signature : ____________________________ Project Certification Manager : ____________________________ Stamp : ___________________________ Date of Approval : ___________________________ Airworthiness Limitations D42L AMM 04-00-00 02 Nov 09 Page 6 D42L-AMM-001 Rev 1 Intentionally Left Blank Page 7 Rev 1 04-00-00 Airworthiness Limitations D42L AMM D42L-AMM-001 02 Nov 09 1. Airworthiness Limitations This chapter describes the airworthiness limitations of the components that are modified with Supplemental Type Certificate (STC) No. SA09-54 installed. Only those areas identified below are changed from the original DA42. All other information about the DA42 is contained in the Aircraft Maintenance Manual (AMM) document number 7.02.01. This chapter is approved and shows the mandatory inspections that were established as a result of the certification process. Personnel must obey the limitations given in this section. A. Certification Maintenance Requirements (1) Component and System Checks The component and system checks under this paragraph are also included in Chapter 05-10. The following table lists aircraft components and systems that require monitoring through scheduled maintenance. Where an interval is given in both flight time and calendar years, the limit that is reached first must be applied. ATA Ch. Component Maintenance Requirement Interval hrs. yrs. 61 MT Propeller For Mandatory Maintenance Actions, refer to MT Propeller Operations and Maintenance Manual ATA 61-01-24, latest revision. See ATA 61-01-24, latest revision. 72 Lycoming IO-360 M1A/ LIO-360 M1A Engines For Mandatory Maintenance Actions, refer to Lycoming Operations and Maintenance Manual, latest revision. See Operations and Maintenance Manual, latest revision. Airworthiness Limitations D42L AMM 02 Nov 09 Page 8 D42L-AMM-001 Rev 1 04-00-00 B. Replacement Requirements The replace requirements under this paragraph are also included in Chapter 05-10. The following table lists life limited aircraft components that must be replaced at a specific time. Where an interval is given in both flight time and calendar years, the limit that is reached first must be applied. 2. Continued Airworthiness Regular inspections of the aircraft including replacement and overhaul of certain components are required to make sure the continued airworthiness of the DA42 L360 aircraft. The time limits given in Chapter 04 must be applied to make sure the continued airworthiness of the DA42 L360 aircraft. The manufacturer recommends that you apply the time limits and maintenance check lists given in Chapter 05. National maintenance requirements must be complied with. ATA Chapter Component Replacement Time hrs. yrs. 61 MT Propeller (for Mandatory Maintenance Actions, refer to MT Propeller Operations and Maintenance Manual ATA 61-01-24, latest revision) See ATA 61-01-24, latest revision. 72 Lycoming Engine (for Mandatory Maintenance Actions, refer to Lycoming Operations and Maintenance Manual, latest revision) See Operations and Maintenance Manual, latest revision. 73 Air Filter 500 74 Ignition System (for Mandstory Maintenance Actions, refer to SlickSTART Installation, Operation, Maintenance and Troubleshooting Manual L-1492 (latest issue) 500 Page 1 Rev 0 05-TITLE Time Limits and Maintenance Checks D42L AMM D42L-AMM-001 01 Jun 09 CHAPTER 05-00 TIME LIMITS AND MAINTENANCE CHECKS Time Limits and Maintenance Checks D42L AMM 05-TITLE 01 Jun 09 Page 2 D42L-AMM-001 Rev 0 Intentionally Left Blank Page 3 Rev 1 05-10-00 Time Limits and Maintenance Checks D42L AMM D42L-AMM-001 02 Nov 09 TABLE OF CONTENTS CHAPTER 05-10 TIME LIMITS ............................................................................................................... 5 1. General ................................................................................................................................................ 5 2. Regulatory Authorities ......................................................................................................................... 5 3. Scheduled Maintenance Time Limits ................................................................................................... 5 4. Component Time Limits ........................................................................................................................6 5. Component Time Tracking ...................................................................................................................8 CHAPTER 05-20 SCHEDULED MAINTENANCE CHECKS ................................................................... 1 1. General ................................................................................................................................................ 1 2. Maintenance Checklist......................................................................................................................... 1 CHAPTER 05-20 MAINTENANCE PRACTICES................................................................................. 201 1. General ............................................................................................................................................ 201 2. Preparation ...................................................................................................................................... 201 3. Engine Ground Test......................................................................................................................... 202 4. Maintenance Checklist Zones...........................................................................................................203 5. Engine Ground Test Record .............................................................................................................215 Time Limits and Maintenance Checks D42L AMM 05-10-00 02 Nov 09 Page 4 D42L-AMM-001 Rev 1 Intentionally Left Blank Page 5 Rev 1 05-10-00 Time Limits and Maintenance Checks D42L AMM D42L-AMM-001 02 Nov 09 TIME LIMITS 1. General All scheduled maintenance checks have time limits. You must do the scheduled maintenance within the time limits. The time limits shown in this chapter pertain only to the components that are changed/modified due to the conversion of DA42 aircraft from TAE-125-01 (1.7 Liters) and TAE-125-02-99 (2.0 Liters) diesel engines to Lycoming IO-360 M1A/LIO-360 M1A gasoline engines by the Supplemental Type Certificate (STC) No. SA09-54. Some components installed in the aircraft have a fixed time between overhaul (TBO), (for example the engine). Refer to Paragraph 4. 2. Regulatory Authorities The recommended time limits given in this chapter were created to meet the requirements of the Canadian Airworthiness Authority, Transport Canada Civil Aviation (TCCA) and US Airworthiness Authority, Federal Aviation Administration (FAA). Other Regulatory Authorities can have different requirements. You must make sure that you meet the requirements of the Regulatory Authority of the country where the aircraft is registered. 3. Scheduled Maintenance Time Limits Refer to Chapter 05-20. The following recommended hourly and calendar time limits apply to the scheduled maintenance checks that are necessary to maintain the aircraft in a good technical condition. Do the scheduled maintenance at the intervals and within the tolerances shown below: NOTE: The use of the tolerances specified in the above table may require approval from the civil aviation authority in which the aircraft is registered. Scheduled Maintenance Check (Hourly) Do At These Times Maximum Tolerance 25 Hour Engine Check At 25 hours since new, do a 50 hours engine check of the lycoming engines and re-torque engine mount attachment bolts on the firewall. ± 10% 50 Hour Check At 50 hours since new and every 50 hour intervals. ± 10% 100 Hour Check At 100 hours since new and every 100 hour intervals. ± 10% 200 Hour Check At 200 hours since new and every 200 hour intervals. ± 5% 1000 Hour Check At 1000 hours since new and every 1000 hour intervals or 12 years, whichever comes first. ± 5% 2000 Hour Structural Check At 2000 hours since new and every 2000 hour intervals or 12 years, whichever comes first. ± 2.5% Time Limits and Maintenance Checks D42L AMM 05-10-00 02 Nov 09 Page 6 D42L-AMM-001 Rev 1 The intervals between the inspections must be adhered to within the tolerances shown. These tolerances must not be added up. For example: if the 100 hour inspection was done at 110 hours, the next inspection must be done at 200 ±10 hours, not 210 ±10 hours. If an inspection is carried out earlier than allowed by the specified tolerance, all subsequent inspection intervals are counted from that inspection. For example: If the 100 hour inspection was done at 83 hours, the next inspection must be done at 183 hours. If the aircraft was flown less than 200 hours: 4. Component Time Limits A. Maintenance Requirements The following table lists aircraft components and systems which require overhaul or specific checks. Where an interval is given in both flight time and calendar years, the limit which is reached first must be applied. Visual Flight Route/Rules (VFR) in the "Kind of Operation" column means that this limit applies to day VFR, night VFR and Instrument Flight Route/Rules (IFR) operation. Night Visual Flight Route/ Rules (NVFR) in the "Kind of Operation" column means that this limit applies to night VFR and IFR operation. IFR in the "Kind of Operation" column means that this limit applies to IFR operation. Scheduled Maintenance Check (Hourly) Do At These Times Annual Inspection (for aircraft registered in the USA). At 12 months since new and every 12 month interval, do a 100 Hour Check. Annual Inspection (for aircraft registered in other countries). At 12 months since new and every 12 month interval, do a 200 Hour Check. Page 7 Rev 2 05-10-00 Time Limits and Maintenance Checks D42L AMM D42L-AMM-001 01 Oct 10 ATA Chapter Component Maintenance Requirement Interval Kind of Operation hrs. yrs. 24 Alternator Overhaul 2000 VFR 31 CO Detector Overhaul. Refer to CO Guardian Owners’ Manual 03-452-201 latest version. 7 VFR 61 Propeller, MT-Propeller Overhaul. Refer to mt-Propeller Service Bulletin No. 1AG (latest issue). 1800 6 VFR Propeller Governor Overhaul. Refer to mt-Propeller Service Bulletin No. 1AG (latest issue). 2000 6 VFR Oil Accumulator Overhaul. Refer to mt-Propeller Service Bulletin No. 1AG (latest issue). 2000 6 VFR 71 Air Filter Cartridge, JR filters Replace. Re-use is permitted after washing and servicing the air filter according to the filter manufacturer`s manual. 500 VFR 72 Engine, Lycoming IO-360 M1A/LIO-360 M1A Overhaul. Refer to Lycoming Service Instruction 1009 (latest issue). 2000 12 VFR 74 Ignition Switches Overhaul, lubricate the ignition switches: - see FAA AD 93-05-06 reference ACS/Gerdes Service Bulletin SB 92-01-ACS, ignition switch lubrication/inspection. 2000 VFR Magnetos, Slick Overhaul With the engine VFR 79 Oil Cooler Proof-test at 250 psi (or replace) 2000 12 IFR Time Limits and Maintenance Checks D42L AMM 05-10-00 02 Nov 09 Page 8 D42L-AMM-001 Rev 1 B. Aircraft Life-Limited Components The following table lists life limited aircraft components which must be replaced at a specific time. Where an interval is given in both flight time and calendar years, the limit which is reached first must be applied. VFR in the "Kind of Operation" column means that this limit applies to day VFR, night VFR and IFR operation. NVFR in the "Kind of Operation" column means that this limit applies to night VFR and IFR operation. IFR in the "Kind of Operation" column means that this limit applies to IFR operation. C. Life-Limited Components for the Lycoming Engines Refer to the Lycoming Service Bulletin No. 240 (latest issue) which gives the engine life-limited components. Replace the life-limited components at the times stated. 5. Component Time Tracking To make sure that components overhaul/replacement is done at the correct time you must record the data that follows in the Aircraft Maintenance Log for each component requiring overhaul/replacement: - Serial Number - Flight hours and date at installation - Flight hours and date at removal. ATA Chapter Component Replacement Time Kind of Operation Hours Years 21 CO Detector 7 VFR 71 Engine shock mounts 2000 12 VFR 73 Fuel hoses in the engine compartment 2000 12 NVFR 77 Deleted 79 Oil hoses 2000 12 NVFR Page 1 Rev 0 05-20-00 Time Limits and Maintenance Checks D42L AMM D42L-AMM-001 01 Jun 09 SCHEDULED MAINTENANCE CHECKS 1. General This maintenance check list provided in this section pertains to the engine compartment that is modified with Supplemental Type Certificate (STC) No. SA09-54 installed. Only those areas identified below are changed from the original DA42. All other information about the DA42 is contained in the Aircraft Maintenance Manual (AMM) document number 7.02.01. A. Do the scheduled maintenance checks in this section at the intervals (flight hours and calendar time) stated in Chapter 05-10. NOTE: Only persons authorized by national regulatory authorities of the country where the airplane is registered, (or a JAR-145 approved maintenance organization in Europe), may do these checks. The inspection level for each item is a general visual inspection unless differently specified. NOTE: Only Lycoming authorized maintenance organizations may carry out maintenance and inspection work on the Lycoming engine. Any engine malfunction must be reported to Lycoming. 2. Maintenance Checklist Do the scheduled maintenance checks with reference to the Maintenance Checklist in this Section. Before starting a check, complete the requirements of Paragraphs 2 and 3 of the checklist. Do all the applicable tasks on the checklist. NOTE: For maintenance of aircraft registered in the USA, do the items marked X and the items marked X* in the Maintenance Checklist. For maintenance of aircraft registered in other countries, do only the items marked X in the Maintenance Checklist. NOTE: The interval columns “50”, "100", "200", and "1000", “2000” are used for maintenance items which must be done at intervals of 50, 100, 200, 1000 or 2000 flight hours. The interval column "time" is used for maintenance items which must be done at certain calendar time intervals. These items are marked with the explicit time interval. NOTE: The interval column "time" is used for maintenance items which must be done during a Major Structural Inspection (MSI). These items are marked with the term “MSI”. NOTE: Where an interval is given in both flight time and calendar years, the limit which is reached first must be applied. NOTE: Some inspection items must be done at other intervals than the standard intervals (50, 100, 200, 1000 or 2000 hours). In these cases, the maintenance interval is shown in the column for the next shorter interval instead of an X. For example, an item which must be done every 800 hours is identified by the words "800 hrs." in the 200 hrs. column. All of the applicable items must be signed by authorized maintenance personnel. Record the completion of the check in the airplane log book. Complete a copy of the Maintenance Report. Time Limits and Maintenance Checks D42L AMM 05-20-00 01 Jun 09 Page 2 D42L-AMM-001 Rev 0 Intentionally Left Blank Page 201 Rev 1 05-20-00 Maintenance Practices D42L AMM D42L-AMM-001 02 Nov 09 SCHEDULED MAINTENANCE CHECKS - MAINTENANCE PRACTICES 1. General Enter the applicable data in the blocks below: 2. Preparation Do the following items before you start the applicable check: Registration: _______________________ Date: __________________ LH RH Aircraft S/N: _______________________ Engine S/N: _______ _______ Aircraft Engine Hours, LH RH Operating Hours: _______________________ TTSN: _______ _______ LH RH Inspection: _______________________ Propeller S/N: _______ _______ Propeller Hours, LH RH (50, 100, 200, 1000, 2000 hrs, Annual Inspection) TTSN: _______ _______ Interval Inspection Items 50 100 200 1000 2000 Initials 1. Before you do the inspection: - Read the applicable Airworthiness Directives - Read the applicable Service Bulletins. X X X X 2. Examine the Log Books. Look especially for: - Life limited parts - Reported problems. X X X X 3. Clean the aircraft fully. (Refer to AMM # 7.02.01 Chapter 12-30). X X X Maintenance Practices D42L AMM 05-20-00 01 Oct 10 Page 202 D42L-AMM-001 Rev 2 3. Engine Ground Test Do an engine ground test as follows: NOTE: Complete a copy of the Engine Ground Test Report as part of the engine ground test. Interval Inspection Items 100 200 1000 2000 Time Initials WARNING: DO NOT LET PERSONS GO INTO THE DANGER AREA OF THE PROPELLER. PROPELLERS CAN CAUSE INJURY OR DEATH. WARNING: SET THE PARKING BRAKE TO ON. IF YOU DO NOT DO THIS, THE AIRCRAFT CAN MOVE AND THIS CAN CAUSE INJURY OR DEATH. 1. Do an operational test of the parking brake. X X X X 2. Set the parking brake to ON. X X X X 3. Put the chocks against the aircraft main wheels. X X X X 4. Do an engine operational test. For the engine run procedures refer to DA42 L360 Airplane Flight Manual (AFM). Record the data in the checklist in Chapter 05-20. X X X X 5. Do an operational test of the variable elevator stop with the engines running after the engine operational test. (Refer to Chapter 27-30). X X X X 6. Check engine instruments. X X X X 7. Check for carbon monoxide contamination in the cabin. - Switch cabin heat ON. - Use a carbon monoxide tester (CO tester) X X X 8. Do a test of the cross-feed system. (Refer to Chapter 28-20). X X X X 9. Do an operational test of the fuel shut-off valve for correct operation. (Refer to Chapter 28-20). X X 10. Do a test of the auxiliary fuel transfer system. (Refer to Chapter 28-20). X X X X 11. Do a test of the feathering and unfeathering system. (Refer to Chapter 61-20). X X X X 12. Shut the engine down. X X X X 13. When the propeller stops rotating, set the ignition switches to the OFF position. Set the ALT/BAT switch to the OFF position. Set the Fuel selector to the OFF position. X X X X Page 203 Rev 1 05-20-00 Maintenance Practices D42L AMM D42L-AMM-001 02 Nov 09 4. Maintenance of Checklist Zones Do the applicable checks in each of the zones that follow: A. Engine Compartments (1) LH Engine Interval Inspection Items, LH Engine 50 100 200 1000 Time Initials WARNING: MAKE SURE THAT THE EXHAUST SYSTEM IS COOL BEFORE YOU DO MAINTENANCE ON THE ENGINE. THE EXHAUST SYSTEM CAN BE HOT AND THIS CAN CAUSE INJURY TO PERSONS. 1. Remove the top and bottom cowlings. Examine the cowlings. Make sure that the fasteners are serviceable. Look for cracks and areas that have got too hot. X X X X WARNING: DO NOT GET OIL ON YOU. OIL CAN CAUSE SKIN DISEASE. WARNING: DO NOT GET FUEL ON YOU. FUEL CAN CAUSE SKIN DISEASE. DO NOT ALLOW FIRE NEAR FUEL. FUEL BURNS AND CAN CAUSE INJURY TO PEOPLE AND DAMAGE THE EQUIPMENT. 2. Examine the engine for oil/fuel leaks. X X X X 3. Clean the engine and engine compartment. (Refer to AMM # 7.02.01 Chapter 12-30). X X X 4. Remove the oil drain plug. Drain the engine oil into an approved container (with the engine warm). (Refer to Chapter 79-00). X X X X 5. Examine the oil suction screen: - Remove the oil suction screen from the oil sump - Look for particles of metal. If the screen contains particles of metal, refer to the Lycoming Maintenance Manual - Replace the gasket - Install the oil suction screen to the oil sump. X X X 6. Install the drain plug. - Tighten the drain plug. Torque to 160 lbf-in (18 Nm) - Lock the drain plug with the safety wire. X X X X 7. Replace the oil filter. (Refer to Chapter 79-00). X X X X Maintenance Practices D42L AMM 05-20-00 02 Nov 09 Page 204 D42L-AMM-001 Rev 1 8. Cut open the used oil filter. Look for particles of metal. If the filter contains particles of metal, refer to the Lycoming Maintenance Manual. X X X X CAUTION: YOU MUST USE THE ENGINE OIL THAT AGREE WITH THE SPECIFICATION IN LYCOMING SERVICE INSTRUCTION NO. 1014. 9. Fill the engine with new oil. X X X X NOTE: Drain the engine oil and fill with straight mineral oil 25 hours after a new engine is installed. Change to an ashless dispersant oil at the next 50 hour check. Refer to Lycoming Service Instruction No. 1014 for details of acceptable oils. 10. Do a compression test with the engine warm and the throttle open. Do the compression test on the four cylinders. Use 5.5 bar (80 psi). Maximum permitted decrease 1.4 bar (20 psi). Record the compression test results: 1 _______ 2 _______ 3 _______ 4 _______ X X X 11. Remove the spark plugs. - Examine the spark plugs. Look specially for damaged electrodes - Clean the spark plugs (refer to spark plug manufacturer's instructions) - Do a spark plug gap test (Refer to the manufacturer's specified spark plug gap). X X X 12. Install the spark plugs. Use a thread lubricant approved by the spark plug manufacturer: - Install the spark plugs - Torque to 35 lbf-ft. (47 Nm) - Refer to Lycoming Service Instruction No. 1042 for approved spark plugs. X X X 13. Examine the ignition harness and cables. Examine the sleeve nut on each spark-plug connector for cracks. X X X X 14. Inspect the ignition system. - Do a 100 hrs/500 hrs check of the SlickSTART system and the magnetos. Refer to the SlickSTART Installation, Operation, Maintenance and Troubleshooting Manual L-1492 (latest issue). X 500 hrs Interval Inspection Items, LH Engine 50 100 200 1000 Time Initials Page 205 Rev 2 05-20-00 Maintenance Practices D42L AMM D42L-AMM-001 01 Oct 10 NOTE: The inspection of ignition system at 500 hrs is indicated under the 200 hrs interval column. 15. Examine each cylinder. Look specially for broken fins and heat damage. X X X 16. Examine the rocker-box covers. Look specially for signs of oil leaks. X X X X 17. Examine the valves and rockers: - Remove the rocker covers - Look specially for abnormal wear and broken parts in the areas of: - Valve tips - Valve keepers - Springs - Spring seats. - Install the rocker covers. Refer to the Lycoming Maintenance Manual. 400 hrs 18. Examine the inlet manifolds. X X X X 19. Examine the fuel injector. Remove and clean the inlet finger filter. X X X 20. Examine the fuel flow-divider. X X X X 21. Deleted. 22. Examine the fuel pump drain pipe. X X X 23. Do a functional test of the fuel emergency pumps to test the operation of the FUEL PUMP switches. (Refer to Chapter 28-20) X X X 24. Do an operational test of the failure indication that will show on the FUEL PUMP switch. (Refer to Chapter 28-20). X X X 25. Deleted. WARNING: MAKE SURE THAT THE EXHAUST SYSTEM IS COOL BEFORE YOU DO MAINTENANCE ON THE EXHAUST SYSTEM. THE EXHAUST SYSTEM CAN BE HOT AND THIS CAN CAUSE INJURY TO PERSONS. Interval Inspection Items, LH Engine 50 100 200 1000 Time Initials Maintenance Practices D42L AMM 05-20-00 01 Oct 10 Page 206 D42L-AMM-001 Rev 2 26. Do a detailed visual inspection of the exhaust system especially within the heat exchanger section. X X X Replace all components displaying cracking or general distortion with new parts or repair in accordance with the latest approved revision of AC 43.13. - Check for holes, cracks, and burned spots. Especially check areas adjacent to welds. Look for unusual tube discoloration. This may indicate an exhaust leak. X X X - Remove the heat shroud to the extent necessary to visually inspect the inside of the heat exchanger section. X X X - Visually inspect the tailpipe insert (baffle) in place by shining a flashlight up the tailpipe. X X X X - Replace the insert if any visible damage or collapse is observed. - Inspect for ball joint freedom of movement by disconnecting the exhaust hangar strap. The tailpipe should be free to move in all directions by applying minimal force. - At 500 hours or annual intervals, in addition to above inspection, lubricate all riser slip joints with high temperature anti-seize compound - While disassembled, inspect for surface abnormalities such as galling or wear marks. X X X 27. Examine the cabin heat system. - Remove the worm drive clamp from the flexible hose at the cabin-heat selector-valve - Examine the flexible hose for damage - Examine the cabin-heat selector-valve - Connect the flexible hose to the cabin-heat selector-valve - Install the worm drive clamp. X X X 28. Examine the engine baffles. Look specially for cracks and incorrect attachment. X X X X 29. Examine the alternator mounting bracket and electrical connections. X X X X Interval Inspection Items, LH Engine 50 100 200 1000 Time Initials Page 207 Rev 2 05-20-00 Maintenance Practices D42L AMM D42L-AMM-001 01 Oct 10 30. Examine the alternator belt. (Refer to Chapter 24-30). - Look for abnormal wear - Do a test for correct adjustment. X X X X 31. Examine the air hoses. Look specially for signs of leakage and damage. Make sure the air hoses are correctly attached. X X X 32. Examine the cable ties and all electrical connectors. Look specially for rub marks and damage. Pull lightly to make sure they are not loose. X X X X 33. Examine the fuel and oil hoses. Look specially for signs of leakage and damage. Make sure the fuel and oil hoses are correctly attached. X X X 34. Examine the oil breather line. Look specially for blockage. X X X 35. Examine the oil cooler. Look specially for leakage and damage. Make sure the cooling fins are not blocked. X X X 36. Examine the air filter. (Refer to Chapter 71-60). Replace the air filter at 500 hours interval. X X X X 37. Examine the alternate air valve assembly. (Refer to Chapter 71-60). X X X X 38. Examine the throttle and mixture controls. - Make sure that the connection to the control lever is tight - Make sure that the end fitting can turn in the control lever - Examine the outer cables. Look specially for wear and for kinks. X X X 39. Examine the engine mounts. Look specially for: - Cracks or corrosion - Incorrect attachment and poor condition of the mounting bolts - Deterioration of the shock mounts - Incorrect torque value. (Refer to Chapter 71-20). X X X Interval Inspection Items, LH Engine 50 100 200 1000 Time Initials Maintenance Practices D42L AMM 05-20-00 02 Nov 09 Page 208 D42L-AMM-001 Rev 1 (2) RH Engine Interval Inspection Items, RH Engine 50 100 200 1000 Time Initials WARNING: MAKE SURE THAT THE EXHAUST SYSTEM IS COOL BEFORE YOU DO MAINTENANCE ON THE ENGINE. THE EXHAUST SYSTEM CAN BE HOT AND THIS CAN CAUSE INJURY TO PERSONS. 1. Remove the top and bottom cowlings. Examine the cowlings. Make sure that the fasteners are serviceable. Look for cracks and areas that have got too hot. X X X X WARNING: DO NOT GET OIL ON YOU. OIL CAN CAUSE SKIN DISEASE. WARNING: DO NOT GET FUEL ON YOU. FUEL CAN CAUSE SKIN DISEASE. DO NOT ALLOW FIRE NEAR FUEL. FUEL BURNS AND CAN CAUSE INJURY TO PEOPLE AND DAMAGE THE EQUIPMENT. 2. Examine the engine for oil/fuel leaks. X X X X 3. Clean the engine and engine compartment. (Refer to AMM # 7.02.01 Chapter 12-30). X X X 4. Remove the oil drain plug. Drain the engine oil into an approved container (with the engine warm). (Refer to Chapter 79-00). X X X X 5. Examine the oil suction screen: - Remove the oil suction screen from the oil sump - Look for particles of metal. If the screen contains particles of metal, refer to the Lycoming Maintenance Manual - Replace the gasket - Install the oil suction screen to the oil sump. X X X 6. Install the drain plug. - Tighten the drain plug. Torque to 160 lbf-in. (18 Nm) - Lock the drain plug with the safety wire. X X X X 7. Replace the oil filter. (Refer to Chapter 79-00). X X X X 8. Cut open the used oil filter. Look for particles of metal. If the filter contains particles of metal, refer to the Lycoming Maintenance Manual. X X X X Page 209 Rev 1 05-20-00 Maintenance Practices D42L AMM D42L-AMM-001 02 Nov 09 CAUTION: YOU MUST USE ENGINE OILS THAT AGREE WITH THE SPECIFICATION IN LYCOMING SERVICE INSTRUCTION NO. 1014. 9. Fill the engine with new oil. X X X X NOTE: Drain the engine oil and fill with straight mineral oil 25 hours after a new engine is installed. Change to an ashless oil at the next 50 hour check. Refer to Lycoming Service Instruction No. 1014 for details of acceptable oils. 10. Do a compression test with the engine warm and the throttle open. Do the compression test on the four cylinders. Use 5.5 bar (80 psi). Maximum permitted decrease 1.4 bar (20 psi). Record the compression test results: 1 _______ 2 _______ 3 _______ 4 _______ X X X 11. Remove the spark plugs. - Examine the spark plugs. Look specially for damaged electrodes - Clean the spark plugs (refer to spark plug manufacturer's instructions) - Do a spark plug gap test (Refer to the manufacturer's specified spark plug gap). X X X 12. Install the spark plugs. Use a thread lubricant approved by the spark plug manufacturer: - Install the spark plugs - Torque to 35 lbf-ft. (47 Nm) - Refer to Lycoming Service Instruction No. 1042 for approved spark plugs. X X X 13. Examine the ignition harness and cables. Examine the sleeve nut on each spark-plug connector for cracks. X X X X 14. Inspect the ignition system. - Do a 100 hrs/500 hrs check of the SlickSTART system and the magnetos. Refer to the SlickSTART Installation, Operation, Maintenance and Troubleshooting Manual L-1492 (latest issue). X 500 hrs 15. Examine each cylinder. Look specially for broken fins and heat damage. X X X Interval Inspection Items, RH Engine 50 100 200 1000 Time Initials Maintenance Practices D42L AMM 05-20-00 14 Jun 11 Page 210 D42L-AMM-001 Rev 3 16. Examine the rocker-box covers. Look specially for signs of oil leaks. X X X X 17. Examine the valves and rockers: - Remove the rocker covers - Look specially for abnormal wear and broken parts in the areas of: - Valve tips - Valve keepers - Springs - Spring seats - Install the rocker covers. Refer to the Lycoming Maintenance Manual. 400 hrs 18. Examine the inlet manifolds. X X X X 19. Examine the fuel injector. Remove and clean the inlet finger filter. X X X 20. Examine the fuel flow-divider. X X X X 21. Deleted. 22. Examine the fuel pump drain pipe. X X X 23. Do a functional test of the fuel emergency pumps to test the operation of the FUEL PUMP switches. (Refer to Chapter 28-20) X X X 24. Do an operational test of the failure indication that will show on the FUEL PUMP switch. (Refer to Chapter 28-20). X X X 25. Deleted. WARNING: MAKE SURE THAT THE EXHAUST SYSTEM IS COOL BEFORE YOU DO MAINTENANCE ON THE EXHAUST SYSTEM. THE EXHAUST SYSTEM CAN BE HOT AND THIS CAN CAUSE INJURY TO PERSONS. 26. Do a detailed visual inspection of the exhaust system especially within the heat exchanger section. X X X Interval Inspection Items, RH Engine 50 100 200 1000 Time Initials Page 211 Rev 2 05-20-00 Maintenance Practices D42L AMM D42L-AMM-001 01 Oct 10 Replace all components displaying cracking or general distortion with new parts or repair in accordance with the latest approved revision of AC 43.13. - Check for holes, cracks, and burned spots. Especially check areas adjacent to welds. Look for unusual tube discoloration. This may indicate an exhaust leak. - Remove the heat shroud to the extent necessary to visually inspect the inside of the heat exchanger section. X X X - Visually inspect the tailpipe insert (baffle) in place by shining a flashlight up the tailpipe. X X X X - Replace the insert if any visible damage or collapse is observed. X X X - Inspect for ball joint freedom of movement by disconnecting the exhaust hangar strap. The tailpipe should be free to move in all directions by applying minimal force. - At 500 hours or annual intervals, in addition to above inspection, lubricate all riser slip joints with high temperature anti-seize compound - While disassembled, inspect for surface abnormalities such as galling or wear marks. X X X 27. Examine the cabin heat system. - Remove the worm drive clamp from the flexible hose at the cabin-heat selector-valve - Examine the flexible hose for damage - Examine the cabin-heat selector-valve - Connect the flexible hose to the cabin-heat selector-valve - Install the worm drive clamp. X X X 28. Examine the engine baffles. Look specially for cracks and incorrect attachment. X X X X 29. Examine the alternator mounting bracket and electrical connections. X X X X 30. Examine the alternator belt. (Refer to Chapter 24-30). - Look for abnormal wear - Do a test for correct adjustment. X X X X Interval Inspection Items, RH Engine 50 100 200 1000 Time Initials Maintenance Practices D42L AMM 05-20-00 01 Oct 10 Page 212 D42L-AMM-001 Rev 2 31. Examine the air hoses. Look specially for signs of leakage and damage. Make sure the air hoses are correctly attached. X X X 32. Examine the cable ties and all electrical connectors. Look specially for rub marks and damage. Pull lightly to make sure they are not loose. X X X X 33. Examine the fuel and oil hoses. Look specially for signs of leakage and damage. Make sure the fuel and oil hoses are correctly attached. X X X 34. Examine the oil breather line. Look specially for blockage. X X X 35. Examine the oil cooler. Look specially for leakage and damage. Make sure the cooling fins are not blocked. X X X 36. Examine the air filter. (Refer to Chapter 71-60). Replace the air filter at 500 hours interval. X X X X 37. Examine the alternate air valve assembly. (Refer to Chapter 71-60). X X X X 38. Examine the throttle and mixture controls. - Make sure that the connection to the control lever is tight - Make sure that the end fitting can turn in the control lever - Examine the outer cables. Look specially for wear and for kinks. X X X 39. Examine the engine mounts. Look specially for: - Cracks or corrosion - Incorrect attachment and poor condition of the mounting bolts - Deterioration of the shock mounts - Incorrect torque value. (Refer to Chapter 71-20). X X X Interval Inspection Items, RH Engine 50 100 200 1000 Time Initials Page 213 Rev 2 05-20-00 Maintenance Practices D42L AMM D42L-AMM-001 01 Oct 10 B. Propeller The maintenance checks for LH propeller are given below and follow the same maintenance checks for the RH propeller. Interval Inspection Items 100 200 1000 2000 Time Initials WARNING: DO NOT LET PERSONS GO INTO THE DANGER AREA OF THE PROPELLER. THE PROPELLER CAN CAUSE DEATH OR INJURY TO PERSONS. WARNING: MAKE SURE THAT THE ENGINE IS SAFE BEFORE YOU TURN THE PROPELLER. 1. Remove and clean the spinner. Examine the spinner for cracks. (Refer to Chapter 61). X X X X 2. Check propeller blades for play: - Blade shake: maximum 1/8 in (3 mm) - Blade angle play: maximum 2°. If you measure more play, then you must contact the propeller manufacturer. X X X X 3. Check outside parts of the propeller hub. Look specially for: - Cracks - Corrosion. X X X X 4. Check nut for low pitch stop for looseness. X X X X 5. Check propeller assembly for loose or missing locking devices. X X X X 6. Check propeller flange nuts for looseness. X X X X 7. Check front and rear spinner plate. Look specially for: - Cracks - Looseness. X X X X 8. Check area of propeller hub and blade root for oil and grease leakage. X X X X 9. Check propeller blades for cracks. Refer to MT propeller manual (E-124) for allowable cracks. X X X X 10. If installed, check de-icing fluid slinger ring and nozzle for damage. X X X X 11. Check the pressure in the propeller unfeathering accumulator. X X X X 12. Install the spinner. (Refer to Chapter 61). X X X X Maintenance Practices D42L AMM 05-20-00 01 Oct 10 Page 214 D42L-AMM-001 Rev 2 C. Fuselage Nose Interval Inspection Items, Fuselage Nose 100 200 1000 2000 Time Initials 1. Examine the nose baggage doors: - Check for damage to the doors - Check for defective hinges - Make sure that the locks operate correctly. X X X X 2. Close only one nose baggage door and test the lock of the other one by pushing from inside. Repeat the procedure for the other side. X X X 3. Remove the covers from the rear wall of the nose baggage compartment. X X X X 4. Examine the cable ties and all electrical connectors. - Look specially for rub marks and damage - Pull lightly to make sure they are not loose. X X X X 5. Do a check of the airplane battery. (Refer to AMM Chapter 24-31). Look specially for: - Low charge and capacity - Incorrect acid level - Corrosion, pitting, burn marks or damage on battery terminals - Incorrect mounting. X X X 11±1 mths since new and then 6±1 mths 6. Examine the battery area. Clean the area. X* X X 7. Visually inspect the interior structure of the front fuselage (forward of instrument panel frame). Use mirror and flashlight where necessary. Check for damage, cracks, delamination and disbonding from the fuselage skin. Inspect the following components: - Instrument panel frame - Nose compartment floor - Nose frame. X 8. If installed, examine the removable nose cone (OÄM 42-077): - Check the nose cone for insecure attachment - Make sure that all screws are properly tightened. X X X X 9. If the ice protection system is installed, replace filter cartridges on the LH side. X 10. If installed, clean the de-icing fluid strainer. 1 yr Page 215 Rev 2 05-20-00 Maintenance Practices D42L AMM D42L-AMM-001 01 Oct 10 11. If installed, check the spraybar for the de-icing fluid for damage. X X X X 12. If the oxygen system is installed (OÄM 42-055), visually inspect the ventilation of the nose baggage compartments (oxygen, battery, and TKS compartment). Especially check both ventilation caps, installed on the LH and RH side of the nose landing gear. X X X X 13. If the oxygen system is installed (OÄM 42-055), visually inspect all oxygen tubes installed in the oxygen and battery compartment. Check for improper fixture, chafing, leakage and improper ventilation of the high pressure tube. X X 14. If the oxygen system is installed (OÄM 42-055), visually inspect the cylinder regulator valve installed on the oxygen cylinder. Check for damage, dust and corrosion. X X 15. If the oxygen system is installed (OÄM 42-055), visually check the front baggage compartment for residues of oil, TKS fluid and grease. X X X X 16. If ballast is installed [Post Diamond Aircraft Service Bulletin (SB) D42L-25-01], remove the cylindrical ballasts and inspect the following: - Dowel pins and ballast base plate for cracks, damage, or excessive wear. - Grease the dowel pins - Ballast mounting bracket for cracks or voids in the fabric and the bond to the nose bulkhead - Ballast clamps for cracks, damage or excessive wear - Make sure that the ballast clamp mechanism is functioning correctly. X X X X Interval Inspection Items, Fuselage Nose 100 200 1000 2000 Time Initials Maintenance Practices D42L AMM 05-20-00 01 Oct 10 Page 216 D42L-AMM-001 Rev 2 D. Flight Control System in Cabin E. Miscellaneous Items in Nacelles F. General Interval Inspection Items, Flight Control System in Cabin 100 200 1000 2000 Time Initials 1. Examine the rudder cables and pulleys. Look specially for: - Incorrect attachment and function. (Refer to Chapter 27-20) - Lubrication at all cable ends - Defective cable eyes - Defective rubber sleeves - Corrosion - Rub marks - Defective safety plates - Worn out pulleys. X X X 2. Do the rudder system control force test. (Refer to Chapter 27-20) X X X Interval Inspection Items, Nacelles 100 200 1000 2000 Time Initials 1. Examine the gascolator: - Remove and clean the fuel filter bowl - Install the filter bowl (Refer to Chapter 28-20) - Do a check for fuel leakage. X X X X Interval Inspection Items, General 100 200 1000 2000 Time Initials 1. Put chocks against the main airplane wheels. X X X X 2. Do the post maintenance engine test. - For the engine run procedures, refer to the DA42 L360 AFM - Record the data (Refer to Paragraph 8, Engine Ground Test Record). X X X X 3. Examine the engines for leakage. X X X X Page 217 Rev 5 05-20-00 Maintenance Practices D42L AMM D42L-AMM-001 15 Oct 12 5. Engine Ground Test Record WARNING: DO NOT STAND WITHIN THE DANGER AREA OF THE PROPELLER. THE PROPELLER CAN CAUSE DEATH OR INJURY TO PERSONS. WARNING: YOU MUST MAKE SURE THAT THE ENGINE IS SAFE BEFORE YOU TURN THE PROPELLER. MAKE SURE THAT: - THE ELECT MASTER SWITCH IS SET TO "OFF". - THE POWER LEVER IS SET TO "IDLE". WARNING: DO NOT GET OIL ON YOU. OIL CAN CAUSE SKIN DISEASE. DO NOT GET FUEL ON YOU. FUEL CAN CAUSE SKIN DISEASE. DO NOT ALLOW FIRE NEAR FUEL. FUEL BURNS AND CAN CAUSE INJURY TO PEOPLE AND DAMAGE TO EQUIPMENT. WARNING: WHEN YOU COMPLETE AN INSPECTION, MAKE SURE THAT YOU REMOVE ALL LOOSE ITEMS/TOOLS FROM THAT AREA. LOOSE ITEMS/TOOLS CAN PREVENT FULL MOVEMENT OF THE AIRCRAFT CONTROLS. THIS CAN CAUSE DEATH OR INJURY TO PERSONS. CAUTION: YOU MUST ATTACH BLANKS/CAPS TO HOLES/PIPES WHEN YOU REMOVE COMPONENTS. IF YOU DO NOT DO THIS, UNWANTED DEBRIS CAN ENTER THE HOLES/PIPES. THIS CAN CAUSE BLOCKAGE TO THE AIRCRAFT SYSTEMS. Do the engine test in accordance with Chapter 71-00. 4. Make sure the engine oil filters are tight (LH and RH engine). (Refer to Chapter 79-00). X X X X 5. Inspect the jacking pad to check: - whether the pad is either loose or has fallen off - if so, then bond jack pad with TEROSTAT M9380 or equivalent adhesive. - Cure for 24 hours at room temperature before the flight or cure for 72 hours at room temperature before using the jacking pads. X X X X 6. Do a maintenance check flight. Put the engine ground test and the maintenance check flight reports in the Aircraft Maintenance Log. X X X X 7. Complete the Maintenance Report and put it in the Aircraft Maintenance Log. X X X X Interval Inspection Items, General 100 200 1000 2000 Time Initials Maintenance Practices D42L AMM 05-20-00 02 Nov 09 Page 218 D42L-AMM-001 Rev 1 Intentionally Left Blank Page 1 Rev 0 06-TITLE Dimensions and Areas D42L AMM D42L-AMM-001 01 Jun 09 CHAPTER 06-00 DIMENSIONS AND AREAS Dimensions and Areas D42L AMM 06-TITLE 01 Jun 09 Page 2 D42L-AMM-001 Rev 0 Intentionally Left Blank Page 3 Rev 1 06-00-00 Dimensions and Areas D42L AMM D42L-AMM-001 02 Nov 09 TABLE OF CONTENTS CHAPTER 06-00 DIMENSIONS AND AREAS ........................................................................................ 5 1. General ................................................................................................................................................ 5 2. Dimensions .......................................................................................................................................... 5 3. Adjustment Report ............................................................................................................................... 5 Dimensions and Areas D42L AMM 02 Nov 09 Page 4 D42L-AMM-001 Rev 1 06-00-00 Intentionally Left Blank Page 5 Rev 1 06-00-00 Dimensions and Areas D42L AMM D42L-AMM-001 02 Nov 09 DIMENSIONS AND AREAS 1. General The DA42 L360 aircraft uses the Imperial dimensions for dimensions and areas. System International (SI) are also given in brackets. For example: Wing Span 39.2 ft (11.94 m). Conversions between SI units and imperial units are given in AMM Chapter 02. 2. Dimensions There are no changes in the dimensions and areas from the DA42 basic aircraft. 3. Adjustment Report The measurements of the DA42 L360 aircraft are recorded on an Adjustment Report at the factory when the aircraft is built. This report becomes part of the aircraft records. When you measure the dimensions, use the Adjustment Report as reference to show any deviations. Dimensions and Areas D42L AMM 02 Nov 09 Page 6 D42L-AMM-001 Rev 1 06-00-00 Figure 1 - DA42 L360 Overall Dimensions (Approximate Values) Page 7 Rev 1 06-00-00 Dimensions and Areas D42L AMM D42L-AMM-001 02 Nov 09 Figure 2 - Control Surfaces Adjustment Report - Rudder Trim Rudder Trim Rudder 20 o LH Rudder Neutral Rudder 20 o RH Trim RH Trim Neutral Trim LH Trim RH Trim Neutral Trim LH Trim RH Trim Neutral Trim LH Travel Limits (in.) 1.5 ±0.23 0.31 ±0.16 0.82 ±0.23 1.34 +0.2/-0 0.16 ±0.08 1.38 +0.2/-0.0 0.94 +0.23/-0.08 0.31 ±0.16 1.69 ±0.19 Travel Limits (mm) 39±6 8±4 21±6 35+5/-0 4±2 34+5/-0 24+6/-2 8±4 43±5 Travel Actual Angle Limits (o ) 34±5 7±3 18+5/-1 30+5/-0 3±2 29+5/-0 21+5/-1 7±3 37±5 Angle Actual (o) Dimensions and Areas D42L AMM 02 Nov 09 Page 8 D42L-AMM-001 Rev 1 06-00-00 Intentionally Left Blank Page 1 Rev 0 11-TITLE Placards and Markings D42L AMM D42L-AMM-001 01 Jun 09 CHAPTER 11-00 PLACARDS AND MARKINGS Placards and Markings D42L AMM 11-TITLE 01 Jun 09 Page 2 D42L-AMM-001 Rev 0 Intentionally Left Blank Page 3 Rev 1 11-00-00 Description and Operation D42L AMM D42L-AMM-001 02 Nov 09 TABLE OF CONTENTS CHAPTER 11-00 PLACARDS AND MARKINGS .................................................................................... 5 1. General ................................................................................................................................................ 5 2. Replace Plastic Placards ......................................................................................................................5 CHAPTER 11-20 EXTERIOR PLACARDS AND MARKINGS ................................................................. 1 1. General ................................................................................................................................................ 1 CHAPTER 11-30 INTERIOR PLACARDS AND MARKINGS .................................................................. 1 1. General ................................................................................................................................................ 1 2. Replace Plastic Placards ......................................................................................................................1 Description and Operation D42L AMM 11-00-00 02 Nov 09 Page 4 D42L-AMM-001 Rev 1 Intentionally Left Blank Page 5 Rev 1 11-00-00 Description and Operation D42L AMM D42L-AMM-001 02 Nov 09 PLACARDS AND MARKINGS - DESCRIPTION AND OPERATION 1. General Placards are used for identification and indication. They show the function, operation and operating limitations of systems and equipment. This chapter shows you the location of these placards and markings: - Exterior placards - Exterior markings - Interior placards. 2. Replace Plastic Placards A. Material B. Replace a Placard Use this procedure for both internal and external placards. Item Quantity Part Number Solvent A/R Commercial Detail Steps/Work Items Key Items/References 1. Remove the old placard: - Warm the placard with a hot air blower. - Lift one corner of the placard. - Carefully pull the placard off. WARNING: DO NOT GET SOLVENT ON YOUR SKIN. DO NOT BREATHE SOLVENT VAPOR. SOLVENT CAN CAUSE DISEASE OR ILLNESS. 2. Clean the area where the new placard will go. Use a commercial solvent. There must be no grease or dirt on the surface. Obey the solvent manufacturer’s instructions. 3. Remove the protective backing from the new placard. 4. Put the new placard into the correct position. Make the placard smooth with a clean cloth. Refer to the related Figure in this Chapter. Description and Operation D42L AMM 11-00-00 02 Nov 09 Page 6 D42L-AMM-001 Rev 1 Intentionally Left Blank Page 1 Rev 0 11-20-00 Description and Operation D42L AMM D42L-AMM-001 01 Jun 09 EXTERIOR PLACARDS AND MARKINGS 1. General Figure 1 shows the exterior placards for the DA42 L360 aircraft. Description and Operation D42L AMM 11-20-00 01 Jun 09 Page 2 D42L-AMM-001 Rev 0 Figure 1 - Exterior Placards Page 1 Rev 2 11-30-00 Description and Operation D42L AMM D42L-AMM-001 01 Oct 10 INTERIOR PLACARDS AND MARKINGS 1. General Figure 1 shows the instrument and control panel placards. Figure 2 shows the instrument panel placard panels. Figures 3 and 4 show the Cylindrical Ballast Assembly and Nose Forward Bulkhead Ballast installation placards. 2. Description The DA42 L360 aircraft has self-adhesive placards for the cockpit interior. The instrument panel has placard panels that attach to the instrument panel with screws. The placard panels have integral lighting that is controlled by a combined ON/OFF Dimmer switch. The dimmer switch is mounted on the top left of the instrument panel. Refer to AMM # 7.02.01 Chapter 33-10 for more data about the dimmer switch and refer to Chapter 31-10 for more data about the inverter for the placard panels. There are 8 placard panels and you can replace each of the placard panels. Description and Operation D42L AMM 11-30-00 01 Jun 09 Page 2 D42L-AMM-001 Rev 0 Figure 1 - Interior Placards - Instrument Control Panels Page 3 Rev 0 11-30-00 Description and Operation D42L AMM D42L-AMM-001 01 Jun 09 Figure 2 - Placards Panels (Sheet 1 of 2) Description and Operation D42L AMM 11-30-00 01 Jun 09 Page 4 D42L-AMM-001 Rev 0 Figure 2 - Placards Panels (Sheet 2 of 2) Page 5 Rev 2 11-30-00 Description and Operation D42L AMM D42L-AMM-001 01 Oct 10 Figure 3 - Nose Forward Bulkhead Ballast Placards Ballast Mass=5.08 kg (11.2 lbs) Max. Ballast Mass: 6 x 5.08 kg = 30.5 kg [67.2 lb] Description and Operation D42L AMM 11-30-00 01 Oct 10 Page 6 D42L-AMM-001 Rev 2 Intentionally Left Blank Page 201 Rev 1 11-30-00 Maintenance Practices D42L AMM D42L-AMM-001 02 Nov 09 INTERNAL PLACARDS AND MARKINGS - MAINTENANCE PRACTICES 1. General This chapter describes how to replace a placard panel. You can not repair a placard panel. 2. Replace a Placard Panel Use this procedure for all of the placard panels Detail Steps/Work Items Key Items/References 1. Disconnect the aircraft main battery. Refer to Chapter 24-31. 2. Remove the instrument panel cover. Refer to AMM # 7.02.01 Chapter 25-10. 3. Disconnect the electrical cables from the placard panel that you will replace. If necessary, at the in-line connector. 4. Remove the placard panel: - Remove the screws that attach the placard panel to the instrument panel Make sure that you remove all of the screws. - Move the placard panel clear of the instrument panel - Move the new placard panel into position on the instrument panel Make sure that you route the electrical cables correctly. - Install the screws that attach the placard panel to the instrument panel - Connect the electrical cables for the placard panel. At the in-line connector. 5. Install the instrument panel cover. Refer to AMM # 7.02.01 Chapter 25-10. 6. Connect the aircraft main battery. Refer to Chapter 24-31. 7. Do a test for the correct operation of the placard panel lights: - Set the ELECT MASTER to ON - Rotate the INSTRUMENT dimmer switch fully clockwise The placard lights must come on. - Rotate the INSTRUMENT dimmer switch a small amount counter- clockwise The placard lights must dim. - Rotate the INSTRUMENT dimmer switch fully counter-clockwise The placard lights must go out. - Set the ELECT MASTER to OFF. Maintenance Practices D42L AMM 11-30-00 01 Jun 09 Page 202 D42L-AMM-001 Rev 0 Intentionally Left Blank Page 1 Rev 0 12-TITLE Servicing D42L AMM D42L-AMM-001 01 Jun 09 CHAPTER 12-00 SERVICING Servicing D42L AMM 12-TITLE 01 Jun 09 Page 2 D42L-AMM-001 Rev 0 Intentionally Left Blank Page 3 Rev 1 12-00-00 Servicing D42L AMM D42L-AMM-001 02 Nov 09 TABLE OF CONTENTS CHAPTER 12-00 SERVICING................................................................................................................. 5 1. General ................................................................................................................................................ 5 CHAPTER 12-10 REPLENISHING.......................................................................................................... 1 1. General ................................................................................................................................................ 1 2. Fuel System ..........................................................................................................................................1 3. Fuel Contamination Test.......................................................................................................................3 4. Engine Oil System ................................................................................................................................4 CHAPTER 12-20 SCHEDULED SERVICING.......................................................................................... 1 1. General ................................................................................................................................................ 1 2. Lubrication Schedule ............................................................................................................................2 Servicing D42L AMM 12-00-00 02 Nov 09 Page 4 D42L-AMM-001 Rev 1 Intentionally Left Blank Page 5 Rev 1 12-00-00 Servicing D42L AMM D42L-AMM-001 02 Nov 09 SERVICING 1. General This chapter describes the servicing tasks that apply to the whole aircraft: - Section 12-10 Replenishing procedure for fuel systems - Section 12-20 Lubrication data - Section 12-30 Cleaning and snow and ice removal. The procedures for preventive and corrective maintenance of systems are given in the related chapter of this manual. Refer to Chapter 05 for the time limits and servicing schedules. Servicing D42L AMM 12-00-00 02 Nov 09 Page 6 D42L-AMM-001 Rev 1 Intentionally Left Blank Page 1 Rev 4 12-10-00 Servicing D42L AMM D42L-AMM-001 16 Apr 12 REPLENISHING 1. General Use the procedures in this section to replenish the fuel and engine oil system on the aircraft. 2. Fuel System Three interconnected fuel tanks in each wing hold the fuel for the DA42 L360 aircraft. The aircraft can hold 26 US gallons (98.4 liters) of AVGAS 100 or 100LL in each wing main fuel tank. The tanks are located in the wing outboard of the engine nacelles, between the main spars. The aircraft can also hold 13.7 US gallons (52 liters) of AVGAS 100 or 100LL in each wing auxiliary fuel tank. The auxiliary fuel tanks are located in the rear of each engine nacelle. NOTE: Although AVGAS 100LL is a better choice of fuel because the lower lead content reduces both the combustion chamber deposits as well as the spark plug deposits, the Lycoming (L) IO-360-M1A engine is approved by Lycoming to run on AVGAS 100 meeting ASTM D910 specifications. Each wing main fuel tank has a filler cap located on the top surface of the wing. The filler cap connects to the outboard end of the outer fuel tanks. A fuel tank drain is located on the lower surface of each wing. The drain connects to the inboard end of the inner fuel tank. Each wing auxiliary fuel tank has a filler cap located in the aft engine nacelle. The filler cap connects directly to the auxiliary tank. A fuel drain is located in the rear lower surface of each engine nacelle. The drain connects to the lowest point at the rear of the auxiliary fuel tank. WARNING: DO NOT ALLOW FIRE, SPARKS OR HEAT NEAR FUEL. FUEL BURNS VIOLENTLY AND CAN CAUSE INJURY TO PERSONS AND DAMAGE TO THE AIRCRAFT. WARNING: DO NOT GET FUEL ON YOUR SKIN. FUEL CAN CAUSE SKIN DISEASE. WARNING: CONNECT THE AIRCRAFT AND THE FUEL SUPPLY VEHICLE TO ELECTRICAL GROUND BEFORE REFUELING. IF YOU DO NOT GROUND THE AIRCRAFT, STATIC ELECTRICITY CAN CAUSE FIRE DURING REFUELING. WARNING: MAKE SURE THAT A SUITABLE FIRE EXTINGUISHER IS AVAILABLE AT ALL TIMES DURING REFUELING/DEFUELING. WARNING: TURN OFF ALL GROUND EQUIPMENT IN THE REFUELING AREA. WARNING: DO NOT OPERATE ELECTRICAL SWITCHES IN THE AIRCRAFT DURING REFUELING. CAUTION: USE ONLY THE FUEL TYPES GIVEN IN CHAPTER 2 OF THE DA42 L360 AIRPLANE FLIGHT MANUAL (AFM). Servicing D42L AMM 12-10-00 02 Nov 09 Page 2 D42L-AMM-001 Re
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