Austria DAI OSB 40NG-007/1 Page 1 of 3 03-Oct-2014 OPTIONAL SERVICE BULLETIN OSB 40NG-007/1 supersedes OSB 40NG-007 I TECHNICAL DETAILS I.1 Category Optional. I.2 Airplanes affected Type: DA 40 NG Serial numbers: 40.N001 through 40.N014 D4.301, D4.326 I.3 Date of effectivity I.4 Time of Compliance At owners discretion. I.5 Subject Installation of a fuel pressure pulsation damper. ATA-Code: 28-00 I.6 Reason For the DA 40 NG Series a fuel pressure pulsation damper upstream of the high pressure pump has been introduced to reduce the amplitude of the fuel pressure oscillations at the high pressure fuel pump. This Service Bulletin describes the retrofit installation on airplanes already in service. I.7 Concurrent Documents None. I.8 Approval The technical information or instructions contained in this document relate to the Design Change Advisory No. MÄM 40-468, which has been approved under the authority of EASA Design Organization Approval ref. EASA.21J.052.
Austria DAI OSB 40NG-007/1 Page 2 of 3 03-Oct-2014 The technical content of this document has been approved under the authority of DOA ref. EASA.21J.052. I.9 Accomplishments / Instructions Comply with, latest effective issue. I.10 Mass (Weight) and CG The change in mass and CG is negligible. II PLANNING INFORMATION II.1 Material and Availability See WI-0SB 40NG-007, latest effective issue. II.2 Special Tools None. II.3 Labour Effort Approx. 1.5 hours. II.4 Credit None. II.5 Reference Documents DA 40 NG Airplane Maintenance Manual, Doc. No. 6.02.15, latest effective issue. III REMARKS 1. All work must be done by a certified aircraft service station or a certified aircraft maintenance mechanic. 2. All work, in particular that which is not especially described in this Service Bulletin, must be done in accordance with the referenced Maintenance Manual. 3. Completion of all work must be recorded in the log book. 4. In case of doubt contact Diamond Aircraft Industries GmbH.
Austria DAI OSB 40NG-007/1 Page 3 of 3 03-Oct-2014 EXECUTION REPORT TO SERVICE BULLETIN OSB 40NG-007/1 AIRPLANE DATA Airplane Serial Number: Airplane Registration: Airplane Operator: Hours of operation of airplane: No. of landings: Hours of operation-engine Typical operation of airplane: private, club, training, other Date, Name, Sign Please fax the completed form to Fax No. +43-2622-26700-1369 or e-mail to airworthiness@diamond-air.at
Page 1 of 7 WORK INSTRUCTION Installation of a fuel pressure pulsation damper I GENERAL INFORMATION I.1 Subject Installation of a fuel pressure pulsation damper in the fuel supply line. I.2 Reference Documents DA 40 NG Airplane Maintenance Manual, Doc. No. 6.02.15, latest effective issue. I.3 Remarks a) All work must be done by a certified aircraft service station or a certified aircraft maintenance mechanic. b) All work, particular that which is not especially described in this work instruction, must be done in accordance with the referenced maintenance manual. c) Completion of all work must be recorded in the log book. d) For conversion factors between SI units and US/Imperial units refer to AMM Chapter 02. e) In case of doubt, contact Diamond Aircraft Industries GmbH. II DRAWINGS, SPECIAL TOOLS & MATERIALS II.1 Drawings None. II.2 Special Tools None.
Page 2 of 7 II.3 Material Quantity Part No. Description 1 A24119-01 Fuel Hose Assembly I 1 A24120-01 Fuel Hose Assembly II 1 D44-7306-30-00_1 Damper Assy (including damping element) 1 RSGU 1.19/15 Clamp, Loop Type, 19 1 RSGU 1.22/15 Clamp, Loop Type, 22 1 LN 9338 06 Nut 1 LN 9037 06 016 Bolt 2 LN 9025 0610K Washer 1 D44-7306-00-13_2 Mounting Bracket 1 E4A-30-100-201 Banjo bolt 2 DIN 7603 Form A12x18x1,5 Sealing Washer Material is available from Diamond Aircraft Industries. III INSTRUCTIONS 1 Removal of the fuel supply line fire wall forward Set the engine master to OFF and pull the circuit breaker of the electrically driven fuel pumps. 2 Remove the upper and lower cowling (refer to AMM Section 71-10). Remove the fuel supply line fire wall forward. 3 Note: Let the engine cool down before working on the engine fuel system. Warning: Contact with a hot engine can cause injury to personnel. Remove cable ties from the fuel supply line fire wall forward. Remove the Loop Type Clamps from the fuel supply line fire wall forward (refer to figure 1). Discard the large Loop Type Clamp (RSGU 1.35/15, Clamp loop Type 35). 4 Figure 1
Page 3 of 7 Disconnect the electrical connector from the fuel pressure sensor of the HPP (high pressure pump) and remove the lock wire of the banjo bolt. Refer to Maintenance Manual AE300 Doc. No. E4.08.04, latest revision. Remove the banjo bolt with fuel pressure sensor. Move fuel supply line clear of the HPP. 5 6 Caution: Keep fuel inlet of the HPP clear of contamination. Any contamination at the HPP fuel inlet may result in damage to the HPP. Remove the fuel pressure sensor from the banjo bolt and discard the banjo bolt. Clean the fuel pressure sensor in the area of the thread with approved fuel grades (Refer to the AFM for approved fuel grades). Remove fuel supply line fire wall forward from the fuel filter. Move the fuel supply line fire wall forward clear of the engine. Discard the fuel feed line. Installation of the fuel supply line assembly fire wall forward Install fuel supply line to the fuel filter connection (A24120-01) according to figure 2. 7 Figure 2
Page 4 of 7 Install damper Mounting Bracket (D44-7306-00-13_2) according to figure 3. Make sure the thermostat is flush in its seat i.a.w figure 4. Fasten thermostat screws (torque 12 Nm). Mounting Bracket 8 Figure 3 9 Figure 4 Install fuel pressure pulsation damper D44-7306-30-00_1 to fuel feed line Note: Make sure that the arrow on the fuel damper points towards the HPP. 10 Install the forward fuel feed line (A24119-01) to fuel damper. 11 Flush the fuel system: Use a suitable container to collect fuel (min. 2 liter). Reset circuit breaker of the electric fuel pumps. Flush the installed fuel feed line assy. (at least 1 liter) prior to connecting it to the HPP.
Page 5 of 7 Note: Install fuel pressure sensor on the new banjo bolt (E4A-30-100-201) with Loctite 243. Install the fuel feed line to the HPP. Install banjo bolt and secure with locking wire (see figure 5). For tightening the banjo bolt and the fuel pressure sensor refer to Maintenance Manual AE300 Doc. No. E4.08.04, latest revision. 12 Figure 5
Page 6 of 7 Position fuel line routing according to figure 6 (avoid tight turns and tension on the fuel lines). 13 Figure 6
Page 7 of 7 Install Loop Type Clamps to fuel supply line assembly and fuel return line according to figure 7. 14 Figure 7 15 Install cable ties to the fuel lines fire wall forward according to figures 6 and 7 16 Reset circuit breaker of the electrically driven fuel pumps. Perform a fuel leakage test. Turn the electric master of the related engine ON 17 Turn the fuel pump switch ON Check for fuel leakage (No leakage allowed) 18 Install the cowling (refer to AMM Section 71-10). 19 Perform a ground run i.a.w. AMM Section 71-00 20 Check the engine fuel system for leakage 21 Clean working areas, check for foreign objects. 22 Check all altered, replaced, repaired parts for proper function. 23 Test all systems in working area for function. 24 Make all necessary entries in the airplane logs.