Minor Change Approval Letter MCA-50-0001 Installation of … · 2014. 6. 27. · 3 NM-0000-00159 01 Clamp DIN3016-RSGU1-20/15 1 4 NM-0000-00455 01 Edge Protection Profile black, S156.31E

Technify Motors GmbH Platanenstr. 14

D-09356 Sankt Egidien

Doc. MCA-50-0001Issue 05Date 18.06.2014

Page 1/9 © Technify Motors GmbH

Minor Change Approval Letter

MCA-50-0001

Installation of gearbox with oil/water heat exchanger in

DAI DA40 aircraft





1 General

This document describes the installation of gearbox assembly p/n 05-7212-K0360 or p/n 05-7212-K0435 01 into a DAI DA 40 with TAE 125-02-99 engine installation. The installation instruction must be read completely before carrying out the modification as it contains important information concerning safety. Any deviations from the data contained in the installation instruction have to be approved by TAE prior to implementation. Unauthorized deviations will invalidate the approval of the modification.

2 Applicability

The modification described in this document may be installed in DAI DA 40 aircraft with a TAE 125-02-99 engine installation.

3 Preparation

3.1 Special Tools

No special tools required.

3.2 Material, Parts

Item Part Number Description 1 Description 2 Qty.

50-9900-S0001 03 Installation set DA 40 gearbox with oil/water heat

exchanger 1

1 20-3940-H0035 01 Spacer Ø15; Ø6; 10mm long 1

2 40-2140-08215R1 Hose Connector Ø19/Ø19 1

3 NM-0000-00159 01 Clamp DIN3016-RSGU1-20/15 1

4 NM-0000-00455 01 Edge Protection Profile black, S156.31E 1

5 NM-0000-00169 01 Hose Clamp Aba 19-28x12-W1 7

6 NM-0000-00961 01 Hexagon Screw ISO 4017-M5x25-8.8-A2L 1

7 NM-0000-00570 01 Hose Elbow E90.19, blue 1

8 NM-0000-01240 01 Screw with external torx DIN 34801-B M6x10-8.8-

A2E 3

9 NM-0000-01398 01 Hose Elbow E45.19, blue 1

10 NM-0000-02107 01 Coolant Hose SP21MRX-O 18 blue 1

11 52-2140-H0004 01 or 02 Bracket Heating Pipes 1

12 NM-0000-02137 01 Hexagon Nut LN 9338-05 2

13 NM-0000-00040 01 Washer ISO 7089-8-200 HV-A2L 1

14 NM-0000-00504 01 Clamp RSGU1-25/15-W1-Polych. 1

15 NM-0000-00306 01 Cylinder Head Screw ISO 4762-M8x30-8.8-A2J1 1

16 NM-0000-001198 01 Cylinder Head Screw ISO 4762-M8x16-8.8-A2J 1





4 Installation procedure

4.1 Safety Precautions

The relevant accident prevention regulations, as well as the other generally recognized regulations concerning technical safety aspects, industrial health and aviation law must be adhered to. The work described below shall only be performed by trained persons or specialized companies who hold current and valid licenses from the aviation authority to carry out such work The engine should be cold before starting any work. The relevant manufacturer’s instructions concerning the handling of fluids, such as oil and coolant, must be adhered to.

4.2 Instructions

1. Disconnect the battery. 2. Remove propeller in accordance with DAI Airplane Maintenance Manual. 3. Drain gearbox oil and coolant. 4. Disconnect all ground and engine loom connection from the gearbox. 5. Remove the two white clamps from the heating pipes. They are no longer needed. 6. Remove the bracket supporting the heating pipes. 7. Remove the gearbox. Please refer to RM-02-02 for details. 8. Remove the heating pipe and the hose elbow between heat exchanger and intake

manifold. They are no longer needed. 9. Attach the new gearbox. For installation procedures please refer to RM-02-02. 10. Install the new bracket (item 11) for the heating pipes. Use edge protection (item 4). See

Figure 1.

Figure 1 11. Mount the bracket to the gearbox using two screws (item 8). 12. Reattach the bracket to the retaining plate on the engine using the original screw (M5x12)

and a screw (item 6), the original washers (M5) and two nuts (item 12). Additionally, use a spacer (item 1) and a clamp (item 3) to attach the heating pipe to the bracket.





13. Install the coolant hose (item 10) from the oil/water heat exchanger to the intake manifold using two clamps (item 5). The hose p/n 40-2140-08132R1 must be shortened to 350 mm before installation!

14. Secure the hose at the gearbox using a clamp (item 14) and a screw (item 8).

Figure 2

Figure 3 15. Attach the 45° hose elbow (item 9) to the heat exchanger connection using one clamp

(item 5). 16. Attach the hose connector (item 2) and the 90° hose elbow (item 7) to the lower

connection on the oil/water heat exchanger. Secure with three clamps (item 5).





Figure 4 1 45° hose elbow 2 Hose connector 3 90° hose elbow 17. Attach the lower bracket on the oil/water heat exchanger to the intermediate flange using

a screw (item 16) and a washer (item 13). A hole may need to be drilled into the flange to do so.





Figure 5 18. Reconnect the engine loom and all other connections in accordance with RM-02-02.





Figure 6 19. Fill up the engine with gearbox oil in accordance with RM-02-02. 20. Fill up the engine with coolant. 21. Install propeller in accordance with DAI Airplane Maintenance Manual.

4.3 Functional Test

Do an engine ground test of the related engine (refer to DAI Airplane Maintenance Manual) and make sure that:

- The cooling system operates correctly. - That there are no leaks.

5 Limitations

None

6 Remarks

For questions regarding this modification or to report any service difficulty contact Technify Motors GmbH: Tel: +49 37204 696-0 Fax: +49 37204 696-2912 Email: [email protected]





7 Attachments

- MCA-AMMS-50-0001-03 - MCA-POHS-50-0001-02

8 Associated technical documents

- DAI Doc. # 6.02.01 DA 40 Series Airplane Maintenance Manual - TAE OM-02-02 Operation and Maintenance Manual for the TAE 125-02-99 engine - TAE RM-02-02 Repair Manual for the TAE 125-02-99 engine



Doc. MCA-AMMS-50-001Issue 03Date 19.06.2014


1 System description

The gearbox oil/ water heat exchanger is added to the cooling system. It is installed in the coolant feed line towards the cabin heat heat-exchanger. The flow of coolant and gearbox oil is independent of the coolant or oil temperature. The position of the gearbox temperature sensor is changed from the propeller shaft bearing to the gearbox oil channel close to the gearbox oil pump. The gearbox temperature sensor is now indicating the temperature of the gearbox oil.

2 Regular Checks

The condition of the gearbox oil heat exchanger, oil and coolant hoses and connections must be checked as part of the regular inspection of the engine installation in accordance with the DAI AMM. No damage or leaks are allowed, hoses must be correctly attached. The coolant and oil hoses need to be replaced on condition but not later than 5 years. The gearbox must be maintained in accordance with the engine Operation and Maintenance Manual.

3 Maintenance Instructions

No special maintenance of the gearbox oil heat exchanger is required.

3.1 Removal of gearbox

1. Disconnect the battery. 2. Remove propeller in accordance with DAI Airplane Maintenance Manual. 3. Drain gearbox oil and coolant. 4. Disconnect all ground connections and engine loom connections from the gearbox. 5. Remove the bracket for the heating pipes. 6. Remove the hose between oil/water heat exchanger and intake manifold. 7. Disconnect the 90° hose elbow from the lower connection on the oil/water heat

exchanger. 8. Dispose of all used hose clamps. 9. Remove the gearbox. Please refer to RM-02-02.

3.2 Installation of gearbox

Item Part Number Description 1 Description 2 Qty. 1 NM-0000-00169 01 Clamp Aba 19-28x12-W1 3

1. Install the gearbox. Please refer to RM-02-02. 2. Mount the bracket for the heating pipe to the gearbox using the original screws (M6x12)

and washers (M6). 3. Reattach the hose between oil/water heat exchanger and intake manifold using two

clamps (item 1). Secure the hose to the gearbox using the original clamp (RSGU 25/15) and hexagon screw (M6x12).

4. Reconnect the 90° hose elbow to the lower connection on the oil/water heat exchanger using a clamp (item 1).



Doc. MCA-AMMS-50-001Issue 03Date 19.06.2014


5. Fill up gearbox oil in accordance with RM-02-02. 6. Fill up the engine with coolant. 7. Install propeller in accordance with DAI Airplane Maintenance Manual. Do an engine ground test of the related engine (refer to DAI Airplane Maintenance Manual) and make sure that:

- The cooling system operates correctly. - That there are no leaks.

4 Remarks

Please report any service difficulty to Technify Motors GmbH. Contact Technify Motors GmbH: Tel: +49 37204 696-0 Fax: +49 37204 696-2912 Email: [email protected]

5 Attachments

None



Doc. MCA-POHS-50-0001Issue 02Date 19.06.2014


1 General

No change

2 Limitations

No change

3 Emergency Procedures

No change

4 Normal Procedures

No change

5 Performance

No change

6 Weight and Balance

No change

7 System description

The gearbox oil/ water heat exchanger is added to the cooling system. It is installed in the coolant feed line towards the cabin heat heat-exchanger. The flow of coolant and gearbox oil is independent of the coolant or oil temperature. The position of the gearbox temperature sensor is changed from the propeller shaft bearing to the gearbox oil channel close to the gearbox oil pump. The gearbox temperature sensor is now indicating the temperature of the gearbox oil.

8 Airplane Handling, Care and Maintenance

No change

Remarks

Please report any service difficulty to Technify Motors GmbH. Contact Technify Motors GmbH: Tel: +49 37204 696-0 Fax: +49 37204 696-2912 Email: [email protected]

Documents

Minor Change Approval Letter MCA-50-0001 Installation of … · 2014. 6. 27. · 3 NM-0000-00159 01 Clamp DIN3016-RSGU1-20/15 1 4 NM-0000-00455 01 Edge Protection Profile black, S156.31E