Service Bulletin No.: DA L, Rev. 2 Date Issued: July 23, 2009 Title: Use of 50/50 Glycol Coolant types to Comply with EASE AD No.

Transcription

1 ervice Bulletin No.: DA-7-L, Rev. Date Issued: July, 9 with EAE AD No. 7- Page: of. ATA Code: 7. Effectivity: DA-A aircraft equipped with ROTAX 9 series engine.. General: Diamond Aircraft ervice Bulletin DA-7- Rev introduced the use of the EVAN NPG+ waterless coolant as required by ROTAX ervice Bulletin B-9-4. This ervice Bulletin was followed by an EAA Airworthiness Directive (AD 7-) for the 9 F and series engines. Following complaints received from operators of higher operating temperatures, Diamond Aircraft performed additional testing iaw EAA AD 7- and ROTAX B-9-4 Rev to determine if a / Glycol type coolant would meet the limitations in the above listed documents. These tests demonstrated that a new CHT limit of F (.8 C) would meet the intent of ROTAX B-9-4 Rev as an indirect means of monitoring the - Glycol type coolant temperature and maintain it under its 48 F ( C) limit. 4. Compliance: Optional. This service bulletin provides an alternate replacement for the EVAN NPG+ waterless coolant with a / Glycol type coolant as stipulated in EAA AD No. 7-. (ee latest revision of ROTAX I-9-6 for approved Glycol coolants). This B shall be used concurrently with the latest revision of ROTAX B-9-4. Part : Replacing the EVAN NPG+ waterless coolant with a / Glycol type coolant. Part a: A CHT gauge marking to reflect the new specific CHT limit when the - type coolant is used. Part b: Installation of a Temperature witch and an Over Temperature Indication light as an alternative to a. Part : Removing the radiator cap label indicating the use of EVAN NPG+ waterless coolant. Approval: Engineering data referenced or contained in this service bulletin is approved as part of the type design.

2 ervice Bulletin No.: DA-7-L, Rev. Date Issued: July, 9 with EAE AD No. 7- Page: of 6. Labour: Approximately. hours will be required to accomplish Part of this ervice Bulletin. Approximately. hours will be required to accomplish Part a and Part of this ervice Bulletin. Approximately. hours will be required to accomplish Part b and Part of this ervice Bulletin This estimate is for direct labour performed by a technician and it does not include setup, planning, familiarization, cure time, part fabrication or tool acquisition. 7. Material: Description Qty P/N / Glycol type coolant as AR specified in the latest revision of ROTAX ervice Bulletin I-9-6. LH Radiator Pipe -7--X AMP Circuit Breaker WXAG AMP Fuse AGC--R Inline Fuse Holder (with fuse) HRJ Temperature Indicator Light M4- Hose Clamp AR 7-6 Hose Clamp AR M99WDG 4 AWG Jumper AR M AWG Wire AR M Thread ealer AR Temperature witch TT-4A-R/QC 8. pecial Tools: N/A. NOTE: The above Materials may be ordered as KIT DA-7-L. 9. References: DA-A Aircraft Maintenance Manual, Document # DA (AMM). DA-A Flight Manual, Document Number DA. ROTAX ervice Bulletin B-9-4 R, or latest Revision. Installation Manual ROTAX Engine 9 series, Document #

3 ervice Bulletin No.: DA-7-L, Rev. Date Issued: July, 9 with EAE AD No. 7- Page: of. Accomplishment Instructions. Part - Drain engine of current coolant and replenish with new coolant... Remove upper and lower cowlings... Completely drain coolant in accordance with Maintenance Manual. Ensure that a sufficient amount of flushing sequences are carried out with pure Glycol coolant to be assured no EVAN NPG+ coolant is still in the system... Replenish system with - Glycol type coolant as specified in ROTAX (i.e. % distilled water - % Glycol mix by volume)...4 Run engine and ensure no leaks... Install upper / lower cowl.. Part a - Marking the CHT gauge with the Aircraft pecific Cylinder Head Temperature Limit. NOTE: Part b Installation of a Temperature witch and an Over Temperature Indication light can be done as an alternative to a... Refer to the template on page (Figure ) of this service bulletin... Use the template to define a radial line on the face of the CHT gaugeat F (.8 C) and, an arc from F (.8 C) to F ( C)... Mask and carefully etch the surface...4 Wipe clean... Apply PIN AM Aerosol K filler primer red paint or equivalent...6 Allow to dry...7 Inspect and ensure area is properly marked from F (.8 C)...8 Above the CHT gauge apply a Placard stating "MAX CHT = F (.8 C)". NOTE: Care must be taken to ensure that the gauge face is not excessively scratched or damaged.

4 ervice Bulletin No.: DA-7-L, Rev. Date Issued: July, 9 with EAE AD No. 7- Page: 4 of. Accomplishment Instructions (Continued). Part b - Installation of a Temperature witch and an Over Temperature Indication light. NOTE: This installation is an alternative to a... Complete steps.. and.. of Part... Disconnect the battery... Replace the LH radiator pipe (P/N -7--) with LH radiator pipe (P/N -7--X)...4 Install the temperature switch. Use a high temperature thread sealer and torque the temperature switch to. in/lbs. ee Figure... If the circuit breaker panel permits, install a AMP breaker (WXAG) and connect with a 4 AWG jumper as shown in Figure 4. Label the circuit breaker "Coolant Ind."..6 If no circuit breaker location is available then use an inline fuse holder (HRJ) and a A Fuse (AGC--R) off the main bus...7 Drill a /" hole in the instrument panel as indicated in Figure 4. Install indicator light (M4-). Label the indicator COOLANT TEMP....8 Route the wiring along the existing bundles as shown in Figures -. Terminate using applicable ring terminals, fastons and soldering techniques. M or equivalent shall be used. Terminate the wire in accordance with Figure...9 Connect the battery and turn on the system. Press the push to test light and verify correct light function... Complete steps.. to.. of Part.

5 ervice Bulletin No.: DA-7-L, Rev. Date Issued: July, 9 with EAE AD No. 7- Page: of Figure - CHT Cockpit Panel Gauge

6 ervice Bulletin No.: DA-7-L, Rev. Date Issued: July, 9 with EAE AD No. 7- Page: 6 of. Accomplishment Instructions (Continued).4 Part - Removing the label from the radiator cap..4. Remove the warning label pin which indicated the use of EVAN NPG+ waterless coolant from the radiator cap..4. Make the appropriate entry into the aircraft records. Figure - Radiator Cap

7 TB4- TB ERVICE BULLETIN ervice Bulletin No.: DA-7-L, Rev. Date Issued: July, 9 with EAE AD No. 7- Page: 7 of TO EXITING HARN TEMP WITCH ROUTE WIRE ALONG COOLANT LINE UING HOE CLAMP (7-6 and M99WDG) AND CONNECT TO EXITING WIRE HARNE ROUTE WIRE THROUGH FIREWALL EE FIGURE 4. 4 Figure - Engine Wire Routing

8 FUEL PUMP Maneuvering speed V = 4kts A TROBE This airplane is classified as a very in non-icing conditions. All aerobatic maneuvres, except light airplane approved for VFR only, only, are prohibited. ee Flight Manual for other limitations. for intentional spinning which is permitted with flaps UP D.C. ELEC. TURN COORDINATOR NO PITCH INFORMATION OFF LIGHT LANDING TAXI POITION J4- O.A.T. AVIONIC MATER U P L CA ON TO OFF L E GEN/BAT mb CALIBRATED TO. FEET FEET PER MINUTE FEET IN.Hg E DIM BRIGHT B Y KX BY OFF ON KING KT 76A TO PULL OFF TET BENDIX/KING NOE UP NEUTRAL NOE DOWN ALT TT B COMM IDENT PULL K MODE PULL IDENT NAV OB PULL B Y Push-On P M Volume 6-8 M AD IO ALL PREURE MANIFOLD in.hg E I N VOLT AMP U A lbs./sq.inch 6 9 P Engineering quelch 6 Hobbs QUARTZ HOUR 8 8 CHT FUEL Usable 77l/. U gal. CHT/OIL PRE. OIL TEMP FUEL QTY AT FUEL PUMP LANDING LIGHT TAXI LIGHT INTERNAL LIGHT POITION LIGHT ACL TART GEN. CONTROL GEN. BATTERY COOLANT IND. COM/NAV ATC IC MATER AVIONIC AVIONIC MATER CONTR. HORIZON D.G. TURN & BANK FLAP TRIM COM/GP DME MARKER ADF ERVICE BULLETIN ervice Bulletin No.: DA-7-L, Rev. Date Issued: July, 9 with EAE AD No. 7- Page: 8 of LABEL INDICATOR "COOLANT TEMP." INTALL INDICATOR LIGHT IN THI AREA (M4-) TRIM GEN FUEL CANOPY EPU LABEL CB "COOLANT IND." Mic L O F 6 4 AIRPEED 4 KNOT 6 8 MIN. R W PUH 4 N 6 G E No smoking! ALT UP VERTICAL PEED DOWN 4 W 4 OB N 6 OB TO FR FLAG 6 B OIL 4 RPM X HOUR F OIL F O F F R BL O T H T A RT 6 + AC Flaps INTALL NEW AMP CB (WXAG) AND ATTACH TO MAIN BU WITH 4AWG JUMPER OR INTALL AMP INLINE FUE FROM MAIN BU INTALL INDICATOR LIGHT IN THI AREA (M4-) TERMINATE GROUND WIRE HERE FIREWALL REF. Figure 4 - Instrument Panel Routing

9 ervice Bulletin No.: DA-7-L, Rev. Date Issued: July, 9 with EAE AD No. 7- Page: 9 of NOTE:. UE AWG I-PANEL ENGINE COMPARTMENT MAIN BU # TEMP WITCH CLOE > F INDICATOR Figure - chematic

10 ervice Bulletin No.: DA-7-L, Rev. Date Issued: July, 9 with EAE AD No. 7- Page: of. Weight and Balance: The weight and balance is not affected by this service Bulletin.. Availability: Contact Diamond Aircraft. To obtain satisfactory results, procedures specified in this service bulletin must be accomplished in accordance with accepted methods and current government regulations. Diamond Aircraft Industries Inc. cannot be responsible for the quality of work performed in accomplishing the requirements of this service bulletin. Diamond Aircraft reserves the right to void continued warranty coverage in the area affected by this service bulletin if it is not incorporated. If you no longer own the aircraft to which this service bulletin applies, please forward it to the current owner and send the name of the current owner to Diamond Aircraft Industries Inc. at the address below. Diamond Aircraft Industries Inc. 6 Crumlin ideroad, London, Ontario, Canada NV Phone: (9) 47-4 Ext. 7 techpubs@diamondair.com COPYRIGHT 8