Supplement Airplane Maintenance Manual

AMM-60-05 1/5 May, 2011 R. van den Bosch AMM-60-06 1/5 May, 2011 R. van den Bosch AMM-60-71 1/5 May, 2011 R. van den Bosch AMM-60-75 1/5 May, 2011 R. van den Bosch Responsibility has been transferred to CEAPR. Please contact CEAPR for further information. Responsibility has been transferred to CEAPR. Please contact CEAPR for further information. Supplement Airplane Maintenance Manual DR400/135CDI / CENTURION 2.0 AMM-60-02 Chapter: Issue no.: Issue Date: Page: Content: AMM-60-00 1 November 16, 2007 6 6 Revision no. : Revision date: 5 May, 2011 This page intentionally blank Responsibility has been transferred to CEAPR. Please contact CEAPR for further information. Supplement Airplane Maintenance Manual DR400/135CDI / CENTURION 2.0 AMM-60-02 Revision no.: Revision date: 5 May, 2011 Chapter: Issue no.: Issue date: Page: Content: AMM-60-01 1 November 16, 2007 1 6 1 Introduction This operating and maintenance manual contains basic information related to the proper operation of the engine in various situations and under different conditions. It also contains instructions for maintenance. The information and descriptions of components and systems in this manual were correct at the time of publication. Any amendments released through the update information service must also be taken into account. Please contact Thielert Aircraft Engines GmbH if you have any questions. We would be glad to assist you further. 1.1 Accompanying applicable documents • Apex Aircraft, DR400 Maintenance Manual (Doc no.1001606 GB ) • Installation Manual IM 02-02 for CENTURION 2.0 • Installation Manual IM 02-02 for CENTURION 2.0 in DR400/140B • Repair Manual RM-02-02 for CENTURION 2.0 • Operation and Maintenance Manual OM 02-02 for CENTURION 2.0 • Operation and Installation Manual E-124 for Propeller MTV-6-A/187-129 • Installation Manual IM-TAE-CED-125 and Operation Manual OM-TAE- CED-125 • Constant Speed Unit Manual CSU CENTURION 2.0 • Component Repair Manual CRM-02-02 1.2 Identification of parts of TAE 125 installation Engine identification Refer to OM-02-02. Supplement Airplane Maintenance Manual DR400/135CDI / CENTURION 2.0 AMM-60-02 Chapter: Issue no.: Issue Date: Page: Content: AMM-60-01 1 November 16, 2007 2 6 Revision no. : Revision date: 5 May, 2011 Engine Mount identification The Engine Mount of the CENTURION 2.0 is indicated by a part number and a serial number as shown in the following picture. Figure 01-1b Identification of Engine Mount Supplement Airplane Maintenance Manual DR400/135CDI / CENTURION 2.0 AMM-60-02 Revision no.: Revision date: 5 May, 2011 Chapter: Issue no.: Issue date: Page: Content: AMM-60-01 1 November 16, 2007 3 6 CED identification The CED is identified by a label. An example of the identification label of a CED is shown below. Figure 01-1c Identification Label CED-125 Propeller identification The serial number of the propeller MTV-6-A/187-129 consists of five digits and is provided at the back side of the propeller flange and on a label at the front side of one propeller blade. 1.3 Copyright © These technical data and the information contained therein are the property of Thielert Aircraft Engines GmbH and may not be reproduced either in full or in part, or passed on to a third party without written consent from Thielert Aircraft Engines GmbH. This text must be included in any full or partial reproduction of this documentation. Copyright © Thielert Aircraft Engines GmbH Supplement Airplane Maintenance Manual DR400/135CDI / CENTURION 2.0 AMM-60-02 Chapter: Issue no.: Issue Date: Page: Content: AMM-60-01 1 November 16, 2007 4 6 Revision no. : Revision date: 5 May, 2011 1.4 Conventions in this manual The following symbols and warning signs are used in the manual. They must be heeded strictly to prevent injury and material damage, to avoid impairment of the operating safety of the aircraft and to rule out any damage to the aircraft as a consequence of improper handling. ▲ WARNING: Disregarding these safety rules can lead to injury or even death. ■ CAUTION: Disregarding these special instructions and safety measures can cause damage to the engine or to the other components.
Note: Additional note or instructions for better understanding of an instruction. The indications "right", "left", "front" and "rear" are always relative to the flight direction. The following symbol is used: Example of flight direction right: ► 1.5 Validity of this manual This manual applies only to the engine having the following serial number:_____________________________________ installed in: DR400/135CDI serial number:_____________________________________ Updates and modifications must be taken into account. 1.6 Abbreviations The following abbreviations are used in this manual: • FADEC Full Authority Digital Engine Control • CED Compact Engine Display • CSU Constant Speed Unit Supplement Airplane Maintenance Manual DR400/135CDI / CENTURION 2.0 AMM-60-02 Revision no.: Revision date: 5 May, 2011 Chapter: Issue no.: Issue date: Page: Content: AMM-60-01 1 November 16, 2007 5 6 1.7 Packing and transport According to the Operation and Maintenance Manual OM-02-02 1.8 Storage According to the Operation and Maintenance Manual OM-02-02 1.9 Qualifications of the operating and maintenance personnel Tasks described in this manual may be performed only by trained personnel having necessary certificates and licenses. All locally applicable national and international regulations must be observed. 1.10 Update information service This manual is updated regularly. The engine/ aircraft operator is responsible for keeping up-to-date with all amendment bulletins issued by TAE GmbH and integrating them into this manual. Please inform TAE GmbH if the owner of the engine / aircraft changes. Only is this way can we pass on information about any necessary / recommended changes. A form for this purpose is included in this manual. 1.11 Service life of the engine For Service Life of the engine refer to chapter 4. Supplement Airplane Maintenance Manual DR400/135CDI / CENTURION 2.0 AMM-60-02 Chapter: Issue no.: Issue Date: Page: Content: AMM-60-01 1 November 16, 2007 6 6 Revision no. : Revision date: 5 May, 2011 This page intentionally blank Supplement Airplane Maintenance Manual DR400/135CDI / CENTURION 2.0 AMM-60-02 Revision no.: Revision Date: - - Chapter: Issue no.: Issue Date: Page: Content: AMM-60-04 1 November 16, 2007 1 2 4 Airworthiness Limitations AIRWORTHINESS LIMITATIONS APPROVAL SHEET For airworthiness limitations concerning CENTURION 2.0 engine, refer to OM- 02-02 Operation & maintenance manual, chapter 5. AIRWORTHINESS LIMITATIONS APPROVAL SHEET The airworthiness limitation section is AESA approved and mandatory. It specifies required maintenance unless an alternative program has been EASA approved. 04-1 ENGINE LIFE LIMIT The entire engine CENTURION 2.0 as defined by the Type Design Definition ref. TDD-02-02, issue 1 or later approved revisions has a specific life limit of 1200 hours or 12 years whichever occurs first. This limit calls for replacement of the entire engine after these 1200 hours of operation or after 12 years whichever occurs first. No overhauls are allowed to the core engine. No repairs outside the published ICA’s allowed to the engine. 04-2 MANDATORY MAINTENANCE ACTIONS Mandatory maintenance actions of the engine are listed in chapter 02-OM-05- 02 of the current operation and Maintenance manual OM-02-02. Supplement Airplane Maintenance Manual DR400/135CDI / CENTURION 2.0 AMM-60-01 Chapter Issue no.: Issue Date: Page: Content: AMM-60-04 1 November 16, 2007 2 2 Revision no.: Revision Date: - - This page intentionally blank Supplement Airplane Maintenance Manual DR400/135CDI / CENTURION 2.0 AMM-60-02 Revision no.: Revision date: 5 May, 2011 Chapter: Issue no.: Issue date: Page: Content: AMM-60-05 1 November 16, 2007 1 10 5 TIME LIMITS / MAINTENANCE CHECKS The maintenance work on TAE aircraft engines must be carried out after specific time intervals or on reaching a specific operating hours interval. The pre-flight check must be conducted before each start. Refer to OM-02-02 “Operation & maintenance manual”. Parts that are not included within the scope of supply of the engine must be maintained and checked according to the airplane manufacturer’s specifications (refer to airplane manual). ▲ WARNING: The entire engine has a service life (“time between replacement”); refer to chapter 04 of this manual. ▲ WARNING: It is strongly recommended that the maintenance intervals specified by the manufacturer should be adhered to. Non- compliance with the maintenance schedule can amongst other things lead to lapse of any claims to warranty.
Note: For this engine, an extension program for the service life (time between replacement) is in progress. The up-to-date information is published in service bulletins.
Note: Further information concerning service partners and servicing or parts to be replaced can be obtained from Thielert Aircraft Engines GmbH.
Note: Thielert Aircraft Engines GmbH must be informed immediately in case of engine malfunction. Supplement Airplane Maintenance Manual DR400/135CDI / CENTURION 2.0 AMM-60-02 Chapter: Issue no.: Issue Date: Page: Content: AMM-60-05 1 November 16, 2007 2 10 Revision no. : Revision date: 5 May, 2011 5.10 TIME LIMITS INSPECTION REQUIREMENTS The required periodic inspection procedures are listed in § 5.20 Scheduled Maintenance. PREFLIGHT CHECKS Perform a thorough pre-flight and walk-around check in addition to inspection intervals in periodic inspections. Pilot or mechanic must include pre-flight check as normal procedure necessary for safe aircraft operation. Refer to TAE 125 - Supplement of the Pilot’s Operating Handbook for items that must be checked. 5.20 SCHEDULED MAINTENANCE CHECKS A. PROPELLER GROUP Refer to Operation and Installation Manual of MT-Propeller E124 (ATA 61- 01-24) for Inspections and Maintenance of the propeller MTV-6-A/187-129. For Time Between Overhaul (TBO), refer to MT-Propeller Service Bulletin no. 1(latest edition). B. ENGINE GROUP Refer to OM-02-02 “Operation & maintenance manual”, chapter 6. The engine related maintenance tasks according to the OM-02-02 must be accomplished together (simultaneously) with the aircraft maintenance inspections described in § C.
Note: Due to the Diesel principle of the engine CENTURION 2.0, all information of the Airplane Maintenance Manual relating to - Carburator and carburator pre-heating - Ignition magnetos and spark plugs and - Mixture control and priming system are no longer valid. ▲ WARNING: Under extreme conditions such as low usage combined with operation in a salt water environment or in an environment laden with sand and dust, shorter maintenance and inspection intervals are recommended for your own safety. Supplement Airplane Maintenance Manual DR400/135CDI / CENTURION 2.0 AMM-60-02 Revision no.: Revision date: 5 May, 2011 Chapter: Issue no.: Issue date: Page: Content: AMM-60-05 1 November 16, 2007 3 10 C. EASA STC 10014219 INSTALLATION SPECIFIC PARTS Reminder: The engine related maintenance tasks according to the OM-02-02 must be accomplished together (simultaneously) with the aircraft maintenance inspections. 5.20.01 Inspection dependent on engine operating time After initial 3rd - 6th operating hour
Further maintenance action according to Operation and Maintenance Manual OM-02-02. Every 100 operating hours
Check engine mount for signs of corrosion. Visually inspect the engine mount for chafe marks, deformation and any kind of damage. (Refer to Chapter 71).
Check engine shock mounts (cuts, damage...).
Check “coolant low level” warning (Refer to chapter 31).
Check the mixture ratio of the coolant.
Visual inspection, check for coolant leakage.
Visually inspect the joints (e.g. hose connections)
Inspect hoses from turbocharger to engine thru the intercooler radiator, and the intercooler.
Visual inspection of the Wiggins clamp on the turbocharger and the outlet elbow of turbocharger. (Refer to chapter 71)
If Liqui Moly “Diesel Fliess-Fit” is added to Diesel, check all fuel components from fuel cap to engine fuel inlet as well as the return fuel line for leaks.
Replace fuel filter (Refer to chapter 28).
Check airplane fuel electric pump (refer to apex aircraft DR400 maintenance manual Doc. 1001606GB).
Inspect electric pump support.
Check fuel circuit tightness.
Check optional tank, valve, hoses and fittings for leaks.
Check optional tank valve and flexible control for good functioning.
Check optional tank fuel indications for good functioning. Supplement Airplane Maintenance Manual DR400/135CDI / CENTURION 2.0 AMM-60-02 Chapter: Issue no.: Issue Date: Page: Content: AMM-60-05 1 November 16, 2007 4 10 Revision no. : Revision date: 5 May, 2011
Battery: detailed inspection of the battery in order to detect possible leaks. Particularly check around terminals. (Refer to chapter 24)
Check oil lubricating circuit tightness.
Visual inspection of oil radiator. Look for cracks.
Check and clean air filter. (Refer to chapter 71)
Inspect hoses, fittings, turbocharger ducts, for chafing or damage.
Visual inspection of FADEC various sensors
Visual inspection of belt.
Visual inspection of exhaust pipe. (Refer to chapter 78).
Check tightness of the ball joints and of the extension tube assy on the exhaust system. (Refer to chapter 78).
Check the fixing points of the exhaust system on the firewall and on the engine mount. (Refer to chapter 78).
Detailed inspection of the silencer clamp. (Refer to chapter 78).
Replace the 3 loop ceramic cords of the extension tube on the exhaust system. (Refer to chapter 78). Every 200 operating hours
Operations as described for every 100 operating hours.
Check the battery support frame (seek for cracks...). (Refer to chapter 24).
Check and cleaning of reducing union on vacuum circuit.
Close examination of the electric fuel pump: fittings, tightening, electrical connectors, fixing parts, drain.
Replace air filter. Check air conduct leading to turbocharger. (Refer to chapter 71). Every 500 operating hours
Operations as described for every 100 operating hours.
Close examination of the complete fuel line from the tank to the firewall (tubing, hoses, selector, fittings, pump, filter...) and fuel return line. If Liqui Moly “Diesel Fliess-Fit” is added to Diesel, check all fuel components from fuel cap to firewall fitting as well as the return fuel line for material alteration (particles in the sumps...).
Replace the silent blocks (dampers) of the exhaust silencer support. (Refer to chapter 78). Supplement Airplane Maintenance Manual DR400/135CDI / CENTURION 2.0 AMM-60-02 Revision no.: Revision date: 5 May, 2011 Chapter: Issue no.: Issue date: Page: Content: AMM-60-05 1 November 16, 2007 5 10 Every 2000 operating hours
Replace o-rings of the optional tank valve and fittings.
Check optional valve shuttle sliding pads.
Check optional valve shuttle opening travel.
Check optional tank flexible control shaft and housing. Grease as necessary.
Check optional tank fixing elements and adjacent structures. 5.20.02 Inspection dependent on calendar time Every 12 months
Heating: Check tightness of air and water heating installation
Battery: detailed inspection of the battery in order to detect possible leaks. Particularly check around terminals. (Refer to chapter 24).
Remove the battery and check the support frame, the fixing area (seek for defective fixing, glue cracks...). (Refer to chapter 24).
Replace the power supply back-up battery for the FADEC (Refer to chapter 24). (Reminder: alternator excitation battery inspection program is part of OM-02-02).
Detailed examination of the firewall bulkhead.
Replace air filter. Check air conduct leading to turbocharger. (Refer to chapter 71).
Check thightness of the ball joints and of the extension tube assy on the exhaust system. (Refer to chapter 78).
Check the fixing points of the exhaust system on the firewall and on the engine mount. (Refer to chapter 78).
Detailed inspection of the silencer clamp (Refer to chapter 78).
Replace the 3 loop ceramic cords of the extension tube on the exhaust system. (Refer to chapter 78).
Check optional tank, valve, hoses and fittings for leaks.
Check optional tank valve and flexible control for good functioning.
Check optional tank fuel indications for good functioning. Supplement Airplane Maintenance Manual DR400/135CDI / CENTURION 2.0 AMM-60-02 Chapter: Issue no.: Issue Date: Page: Content: AMM-60-05 1 November 16, 2007 6 10 Revision no. : Revision date: 5 May, 2011 Every 36 months
Operations as described for every 12 months.
Check and cleaning of reducing union on vacuum circuit.
Close examination of the electric fuel pump: fittings, tightening, electrical connectors, fixing parts, drain.
Replace the silent blocks (dampers) of the exhaust silencer support. (Refer to chapter 78). Every 60 months
Operations as described for every 12 months.
Replace all fuel, oil, coolant lines and turbocharger ducts. Every 6 years
Replace o-rings of the optional tank valve and fittings.
Check optional valve shuttle sliding pads.
Check optional valve shuttle opening travel.
Check optional tank flexible control shaft and housing. Grease as necessary.
Check optional tank fixing elements and adjacent structures. Every 10 years
Operations as described for every 12 & 60 months.
Inspection of engine electrical circuit. search for corrosion and rubbing wear; replacement of all corroded, worn elements.
Cooling circuit. Replacement of rubber bleeder hoses (P/N 54.81.42.670) from sleeve with permanent bleeder to tee, (P/N 54.81.42.075) from coolant radiator to tee, (P/N 54.81.42.140) from tee to coolant reservoir (expansion tank). Every 25 years
Operations as described for every 12 & 60 months.
Replacement of main battery. (Refer to chapter 24).
Replacement: battery relay; ALT/Battery circuit-breaker; alternator relay; 50A ECU fuse; main bus10A fuse; FADEC ING breaker. Supplement Airplane Maintenance Manual DR400/135CDI / CENTURION 2.0 AMM-60-02 Revision no.: Revision date: 5 May, 2011 Chapter: Issue no.: Issue date: Page: Content: AMM-60-05 1 November 16, 2007 7 10 5.50 UNSCHEDULED MAINTENANCE Engine Events: Over speed, sudden stoppage, loss of oil, over temperature, lightning strike, propeller strike. Refer to
Operation and Maintenance Manual OM 02-02 of the CENTURION 2.0
Repair Manual RM 02-02 of the CENTURION 2.0
Thielert Aircraft Engines GmbH for necessary corrective actions and Repair.
Apex Aircraft DR400 Maintenance schedule (Doc no. 1001586). Supplement Airplane Maintenance Manual DR400/135CDI / CENTURION 2.0 AMM-60-02 Chapter: Issue no.: Issue Date: Page: Content: AMM-60-05 1 November 16, 2007 8 10 Revision no. : Revision date: 5 May, 2011 5.60 TORQUE VALUES For Torque values which are not specific to CENTURION 2.0 installation (not indicated in the following table), refer to DR400 Maintenance manual (Doc. 1001606GB) section 3, §3.3 "Torquing". CENTURION 2.0 installation - specific torque values Description Torque values Remarks Engine mount fixation on bulkhead nr1 0.7 to 0.9 daN.m (62 to 80 lbf.in) 8 bolts. Only for non lubricated nuts 8 PH 135 M Line connectors on electric pump lines 1 to 1.5 daN.m (88.5 to 133 lbf.in) Drawing 52-81-16 Engine vibration damper Front attachment 1 to 1.2 daN.m (88.5 to 106 lbf.in) Drawing 51-81-05 Engine vibration damper Right Hand attachment 1.5 to 2 daN.m (88.5 to 177 lbf.in) Drawing 51-81-05 Engine vibration damper Upper Left Hand attachment 1.5 to 2 daN.m (88.5 to 177 lbf.in) Drawing 51-81-05 Engine vibration damper Lower Left Hand attachment 1 to 1.2 daN.m (88.5 to 106 lbf.in) Drawing 51-81-05 Fuel shut-off attachment to fuselage bottom 0.3 daN.m (27 lbf.in) Drawing 52-81-11 Oil radiator attachment to support 0.3 daN.m (27 lbf.in) Drawing 53-81-25 Heat box plate axle attachement to plate lever 0.15 daN.m (13.3 lbf.in) Drawing 54-81-00 Intercooler to engine mount attaching lug bolt 0.3 daN.m (27 lbf.in) Drawing 56-81-36 Turbo to intercooler to engine hose clamps Torque value 0,5 daN.m with clamp mfg specs tolerances Refer to section 71-60 Supplement Airplane Maintenance Manual DR400/135CDI / CENTURION 2.0 AMM-60-02 Revision no.: Revision date: 5 May, 2011 Chapter: Issue no.: Issue date: Page: Content: AMM-60-05 1 November 16, 2007 9 10 Torque values for tightening flared tube fittings. Extract from: "Standard Aircraft Handbook for Mechanics and Technicians" (1) (1) "Standard Aircraft Handbook for Mechanics and Technicians" 6th Edition, Edited by Larry Reithmaier. ISBN 0-07-134836-0 Supplement Airplane Maintenance Manual DR400/135CDI / CENTURION 2.0 AMM-60-02 Chapter: Issue no.: Issue Date: Page: Content: AMM-60-05 1 November 16, 2007 10 10 Revision no. : Revision date: 5 May, 2011 This page intentionally blank Supplement Airplane Maintenance Manual DR400/135CDI / CENTURION 2.0 AMM-60-02 Revision no.: Revision date: 5 May, 2011 Chapter: Issue no.: Issue date: Page: Content: AMM-60-06 1 November 16, 2007 1 2 6 DIMENSIONS AND AREAS 6.1 MODEL DR400/135CDI with CENTURION 2.0 installation. 6.2 ENGINE Manufacturer ....................................... Thielert Aircraft Engines GmbH Model................................................... TAE 125-02-99 (CENTURION 2.0) TCDSD ................................................ E.055 Takeoff power...................................... 135 HP / 99 kW Rated Speed ....................................... 2300 RPM Gearbox Oil ......................................... Shell EP 75W-90 API GL-4 Shell Spirax GSX 75W-80 SPIRAX S6 GXME75W-80 SPIRAX S4 G 75W-90 Engine Oil............................................ Shell Helix Ultra 5W-30 Shell Helix Ultra 5W-40 AeroShell Oil Diesel 10W-40 AeroShell Oil Diesel Ultra Engine Oil Sump Capacity................... 4.5 to 6.0 liters (1.19 to 1.59 US Gallons) Oil Capacity Gearbox .......................... 1 liter (0.26 US Gallons) Coolant ................................................ Water/Radiator Protection at a ratio of 50:50 Radiator Protection.............................. BASF Glysantin Protect Plus/G48 Valvoline/Zerex Glysantin G48 Gear Reduction ................................... 1.69:1 Supplement Airplane Maintenance Manual DR400/135CDI / CENTURION 2.0 AMM-60-02 Chapter: Issue no.: Issue Date: Page: Content: AMM-60-06 1 November 16, 2007 2 2 Revision no. : Revision date: 5 May, 2011 6.3 PROPELLER Manufacturer ....................................... MT Propeller Entwicklung GmbH Flugplatzstrasse 1 D-94348 Atting Model................................................... MTV-6-A187/129 Number of blades ................................ 3 Diameter.............................................. 1.87 m Type .................................................... Constant Speed 6.4 FUEL SYSTEM DR400/135CDI Main tank: total capacity:............................................. 110 litres ( 29 US gal) total usable fuel:......................................... 109 litres (28.7 US gal) total unusable fuel:..................................... 1 litre (0.26 US gal) Optional tank: The total fuel capacity can be increased to 160 litres (42.24 US gal) by installing an optional fuel tank of 50 litres (13.2 US gal) which flows into the main tank on command. The total usable fuel is then: 159 litres (42 US gal). Supplement Airplane Maintenance Manual DR400/135CDI / CENTURION 2.0 AMM-60-02 Revision no.: Revision date: 2 May 27, 2008 Chapter: Issue no.: Issue date: Page: Content: AMM-60-12 1 November 16, 2007 1 8 12 SERVICING 12-00 GENERAL The following figures show the service points of the CENTURION 2.0 installation. 1 coolant filler 2 engine oil filler with dip stick 3 engine oil filter 4 gearbox oil filler Figure 12-1a Service Points CENTURION 2.0 1 4 2 3 Supplement Airplane Maintenance Manual DR400/135CDI / CENTURION 2.0 AMM-60-02 Chapter: Issue no.: Issue Date: Page: Content: AMM-60-12 1 November 16, 2007 2 8 Revision no. : Revision date: 2 May 27, 2008 Figure 12-1b Service Points CENTURION 2.0 5 gearbox oil microfilter 6 gearbox oil viewer Figure 12-1c Service Points CENTURION 2.0 7 induction air filter 5 7 6 Supplement Airplane Maintenance Manual DR400/135CDI / CENTURION 2.0 AMM-60-02 Revision no.: Revision date: 2 May 27, 2008 Chapter: Issue no.: Issue date: Page: Content: AMM-60-12 1 November 16, 2007 3 8 Figure 12-1d Service Points CENTURION 2.0 8 fuel filter 9 fuel filter drain Cleaning of the engine compartment Care must be taken when cleaning the engine compartment. If leaks are noticed, determine their location before cleaning. The engine has to be cold before cleaning. The use of cold cleansers is recommended. (for instance Berner Kaltreiniger, Art.no.: 13618.0) „ CAUTION: The use of flammable and acidic cleansers is not allowed. Do not clean the engine electrical system, since it could be damaged. Do not use high pressure cleaning equipment. Dry the engine after cleaning with pressurized air (pressure less than 8 bar). 8 9 Supplement Airplane Maintenance Manual DR400/135CDI / CENTURION 2.0 AMM-60-02 Chapter: Issue no.: Issue Date: Page: Content: AMM-60-12 1 November 16, 2007 4 8 Revision no. : Revision date: 2 May 27, 2008 12-10 REPLENISHING Fuel System Filling  Fuel Tanks ▲ WARNING: Observe all required safety precautions for handling kerosene.  „ CAUTION: Fill tanks with JET-A (ASTM 1655) or Diesel (DIN EN590) fuel only ! For capacity of the tank refer to chapter 6 of this supplement to airplane maintenance manual. Draining Fuel Filter Bowl drain Figure 12.2a Fuel Filter Bowl and Screen Drain at least a cupful of fuel (using sampler cup) from valve to check for water, sediment and proper fuel grade before each flight and after each refueling. If water is observed, take further samples until clear and then gently rock wings and lower tail to the ground to move any additional contaminants to the sampling points. Take repeated samples from all fuel drain points until all contamination has been removed. If contaminants are still present, refer to following WARNING and do not fly the airplane. ▲ WARNING: If, after repeated sampling, evidence of contamination still exists, the airplane should not be flown. Tanks should be drained and system purged by qualified maintenance personnel. All evidence of contamination must be removed before further flight. Supplement Airplane Maintenance Manual DR400/135CDI / CENTURION 2.0 AMM-60-02 Revision no.: Revision date: 2 May 27, 2008 Chapter: Issue no.: Issue date: Page: Content: AMM-60-12 1 November 16, 2007 5 8 Engine Oil System Check engine oil level before each flight according to appropriate POH supplement for CENTURION 2.0 installation. Change engine oil and engine oil filter according to Operation and Maintenance Manual OM 02-02 of the CENTURION 2.0. Gearbox Oil System Check gearbox oil level before each flight according to appropriate POH supplement for CENTURION 2.0 installation. Change gearbox oil and gearbox oil filter according to Operation and Maintenance Manual OM 02-02 of the CENTURION 2.0. Liquid Cooling System ■ CAUTION: Do not drain the coolant if its temperature is above 40°C. ▲ WARNING: Risk of scalding! The cooling system may be pressurized. Carefully release the pressure before opening the drain plug. 1. Draining the coolant: • Open the clamp on the lower hose of the water radiator, disconnect the hose and allow the coolant to drain into a prepared collecting container. • Open the clamp on the lower hose of the heat exchanger, disconnect the hose and allow the coolant to drain into a prepared collecting container. • Loosen the drain plug of the engine, but do not open it yet. • Attach a suitable length of hose with a diameter of 14-15 mm onto the collar of the plug, and insert the other end of the hose into a collecting container. • Open the drain plug. The coolant can drain off through the plug. • Open the cover of the coolant filler (this allows the coolant to drain faster). • After draining install a new seal and tighten the drain plug - tightening torque: 10 Nm. • Reconnect the lower hoses of the water radiator and the heat exchanger and tighten the clamps. Supplement Airplane Maintenance Manual DR400/135CDI / CENTURION 2.0 AMM-60-02 Chapter: Issue no.: Issue Date: Page: Content: AMM-60-12 1 November 16, 2007 6 8 Revision no. : Revision date: 2 May 27, 2008 2. Filling up new coolant: • Fill up the cooling system by opening the coolant filler (use coolant according to Chapter 4 of Installation Manual IM 02-02). • Close the cover of the coolant filler. • Perform a test run according to Operation and Maintenance Manual OM 02-02. • Check the cooling system for leaks according to Annex 3 of Operation and Maintenance Manual OM-02-02. • Allow the engine to cool down. • Check coolant level. 3. Bleeding of coolant circuit: After every filling of new coolant, bleed the air off the coolant system by means of the maintenance bleeder screw on the thermostat. The bleeder screw must be safetied by means of lockwire. The gasket under bleeder screw must be replaced as necessary (depending on condition). Supplement Airplane Maintenance Manual DR400/135CDI / CENTURION 2.0 AMM-60-02 Revision no.: Revision date: 2 May 27, 2008 Chapter: Issue no.: Issue date: Page: Content: AMM-60-12 1 November 16, 2007 7 8 12-20 SCHEDULED SERVICING ‹ Note: See also Scheduled Maintenance Checks in Chapter AMM-60-05 (Section 5-20). Electrical System Refer to Chapter 5 of this supplement for checks of the electrical system. Fuel System Refer to Chapter 5 of this supplement for checks of the fuel system. Propeller Refer to Operation and Installation Manual of MT-Propeller E124 (ATA 61- 01-24) for Inspections and Maintenance of the propeller MTV-6-A/187-129. Power Plant Regularly check the engine compartment for oil and fuel leaks, chafing of lines, loose wires and tightness of all parts. Be careful when cleaning the engine compartment. Induction Air Filter Regularly check and change the Induction Air Filter (refer to Chapter 5). Coolant System Refer to Chapter 5 Section 5-20 of this supplement for checks of the coolant system. Supplement Airplane Maintenance Manual DR400/135CDI / CENTURION 2.0 AMM-60-02 Chapter: Issue no.: Issue Date: Page: Content: AMM-60-12 1 November 16, 2007 8 8 Revision no. : Revision date: 2 May 27, 2008 This page intentionally blank Supplement Airplane Maintenance Manual DR400/135CDI / CENTURION 2.0 AMM-60-02 Revision no.: Revision date: 4 October 18, 2010 Chapter: Issue no.: Issue date: Page: Content: AMM-60-21 1 November 16, 2007 1 4 21 ENVIRONMENTAL SYSTEMS Cabin Heat and Defroster System The CENTURION 2.0 installation includes a heat exchanger, which is part of the liquid coolant system and is located at the lower left aft section of the engine compartment. Figure 21-1 Location of heat exchanger Hose connections when gearbox without oil cooler Figure 21-2 Location of heat exchanger Hose connections when gearbox with oil cooler Supplement Airplane Maintenance Manual DR400/135CDI / CENTURION 2.0 AMM-60-02 Chapter: Issue no.: Issue Date: Page: Content: AMM-60-21 1 November 16, 2007 2 4 Revision no.: Revision date: 4 October 18, 2010 The heat exchanger for cabin heat is installed inline with the unregulated exit of the cooling system thermostat. According to demand and outside air temperature, warm air is provided to the cabin. Figure 21-2 Heat exchanger Engine coolant passes through the heater core and heats incoming air. The coolant flow through the heater core is always open. The warm air supply is regulated by the pilot over the heating valve. In normal operation the control knob “Shut-off Cabin Heat“ must be pulled. With the control knob “Cabin Heat“, the supply of warm air into the cabin can be controlled. In case of certain emergencies (refer to the appropriate Pilot´s Operating Handbook), the control knob “Shut-off Cabin Heat“ has to be closed according to the appropriate procedures. Supplement Airplane Maintenance Manual DR400/135CDI / CENTURION 2.0 AMM-60-02 Revision no.: Revision date: 4 October 18, 2010 Chapter: Issue no.: Issue date: Page: Content: AMM-60-21 1 November 16, 2007 3 4 1 2 3 6 4 5 A B C 1. Engine A flow: Engine cooling circuit 2. Thermostat B flow: Small circuit 3. Radiator C flow: Cabin heating circuit 4. Cabin heat exchanger 5. Coolant reservoir 6. Sleeve with permanent bleeder Figure 75-1 Coolant System of CENTURION 2.0 without gearbox oil cooler (Schematic diagram) Supplement Airplane Maintenance Manual DR400/135CDI / CENTURION 2.0 AMM-60-02 Chapter: Issue no.: Issue Date: Page: Content: AMM-60-21 1 November 16, 2007 4 4 Revision no.: Revision date: 4 October 18, 2010 6 1 2 3 4 7 5 A B C 1. Engine A flow: Engine cooling circuit 2. Thermostat B flow: Small circuit 3. Radiator C flow: Cabin heating circuit 4. Cabin heat exchanger 5. Coolant reservoir 6. Sleeve with permanent bleeder 7. Gearbox oil/coolant heat exchanger Figure 75-2 Coolant System of CENTURION 2.0 with gearbox oil cooler (Schematic diagram) Supplement Airplane Maintenance Manual DR400/135CDI / CENTURION 2.0 AMM-60-02 Revision no.: Revision date: - - Chapter: Issue no.: Issue date: Page: Content: AMM-60-24 1 November 16, 2007 1 14 24 ELECTRICAL POWER 24.00 GENERAL Description and Operation The DR400/135CDI with CENTURION 2.0 installation is fitted with a 14 volts electrical system. The 14 Volts system is equipped with a 90 amp alternator, a 14 V starter, a 12 volts battery, an excitation battery for the alternator and a voltage regulator. The battery is operated by a rocker switch (BAT) located on the lower instrument panel. The alternator is disabled by a circuit breaker mounted below the battery switch on the lower instrument panel. The excitation battery of the alternator is operated with the Engine Master simultaneously. The back-up battery is supplying the FADEC in case of voltage drop. A warning light (ALT) on the annunciator panel will illuminate if the alternator fails to produce current or overproduces. The battery switch (BAT) must be ON before any electrical equipment will operate. For wiring diagrams of the electrical systems of CENTURION 2.0 installations refer to chapter 91, Section 91.10 of this supplement. Supplement Airplane Maintenance Manual DR400/135CDI / CENTURION 2.0 AMM-60-02 Chapter: Issue no.: Issue Date: Page: Content: AMM-60-24 1 November 16, 2007 2 14 Revision no. : Revision date: - - 24.30 DC GENERATION Precautions The following precautions must be observed when testing the electrical system. ▲ WARNING: Failure to observe these precautions will result in serious damage to the electrical equipment. „ CAUTION Refer to wiring diagram in chapter AMM-60-91 (section 91.10) when installing or testing alternator. „ CAUTION Disconnect battery and excitation battery before connecting or disconnecting test instruments (except voltmeter), or before removing or replacing any unit or wiring. Accidental grounding or shorting at alternator with internal regulator (14V version only), excitation battery, ammeter or accessories, will cause severe damage to units and/or wiring. „ CAUTION Disconnect main battery before connecting or disconnecting the excitation battery. The excitation battery wire from the alternator (14V version) may carry electrical power even without connected excitation battery in case the main battery is still connected to the system. „ CAUTION Grounding the alternator output terminal will damage alternator and/or circuit and components. „ CAUTION Reversed battery connections will damage rectifiers, wiring, regulator and other charging system components. Battery polarity must be checked with a voltmeter before connecting battery. The aircraft is negative ground. „ CAUTION If booster battery or fast charger is used, its polarity must be connected correctly to prevent damage to electrical system components.