# SAIB CE-04-85: - Type: Special airworthiness information bulletin (advisory, not mandatory) - Status: Current - Revision: 0 - Issued: September 10, 2004 - Products: Diamond DA 40 - Product type: Aircraft, Small Airplane - PDF: https://openairdocs.org/files/sha256/a6/68/a6689c9214bf7ca135f112950829df1b1e1c194fd531cd21fb1165a418163737 - FAA DRS: https://drs.faa.gov/browse/excelExternalWindow/4D59C759E97DB7EF8625721F0052ED09.0001 - Page: https://openairdocs.org/saib/CE-04-85 ## Text Some pages are OCR from the scanned FAA bulletin. OCR can misread letters and numbers. **SPECIAL** **AIRWORTHINESS** **INFORMATION** **BULLETIN** Aircraft Certification Service Washington, DC U.S. Department of Transportation Federal Aviation Administration CE-04-85 September 10, 2004 www.faa.gov/certification/aircraft This is information only. Recommendations aren’t mandatory. Introduction This Special Airworthiness Information Bulletin (SAIB) provides you, owners and operators of Diamond Aircraft Model DA 40 airplanes, with safety information regarding inspection/replacement of the fuel selector/fuel valve universal joints. Background Diamond Aircraft has determined a potential safety issue that pertains to abnormal manufacturing in combination with mechanical wear of the universal joint between the fuel selector and the fuel valve, and has developed a Mandatory Service Bulletin, MSB 40-030/1, requiring inspection of the universal joints. If the pins within the universal joint come loose during aircraft operation, the capability of selecting the other fuel tank may not be possible. We are currently considering Airworthiness Directive (AD) action for this safety issue. In the interim, we are sending you copies of Diamond’s MSB and Austria’s AD A-2004-003. Recommendation We highly recommend that you comply with Mandatory Service Bulletin. For Technical Information Concerning These Safety Issues Contact Diamond Aircraft Industries GmbH, N.A. Otto-Straße 5, A-2700 Wiener Neustadt, Austria; phone: 43.2622-26700; fax: 43 2622-26780. For Further Information Contact Mike Kiesov, Aerospace Engineer/Pilot, FAA, Small Airplane Directorate, 901 Locust, Room 301, Kansas City, Missouri, 64106; phone: (816) 329-4144; fax: (816) 329-4090, email: mike.kiesov@faa.gov Diamond Diamond Aircraft Industries GmbH N.A. Otto-Straße 5 DAI MSB 40-030/1 Page 1 of 5 A-2700 Wiener Neustadt 15-Jun-2004 **MANDATORY SERVICE BULLETIN NO. MSB 40-030/1** **SUPERSEDES MANDATORY SERVICE BULLETIN NO. MSB 40-030** **L TECHNICAL DETAILS** 1.1 Category Mandatory. 1.2 Airplanes affected DA 40 Serial numbers 40.006 up to and incl. 40.079, 40.081 up to and incl. 40.083 and 40.201 and subsequent. a): above 200 hours of operation b): up to 200 hours of operation 1.3 Time of Compliance for a): within the next 15 hours of operation and each further inspection thereafter, not exceeding 50 hours of operation for b): at the next scheduled inspection and each further inspection thereafter, not exceeding 50 hours of operation for a) & b): not later than 31-Jul-2004 1.4 Subject Inspection of the universal joints between fuel selector handle and fuel selector valve. ATA-Code: 28-23, Fuel System 1.5 Reason It has been found that the pins of the universal joints may come loose during operation. This can result in loss of capability to select the fuel tank to supply fuel. I Diamond Diamond Aircraft Industries GmbH DAI MSB 40-030/1 N.A. Otto-Straße 5 Page 2 of 5 A-2700 Wiener Neustadt 15-Jun-2004 1.6 Concurrent documents None. 1.7 Approval The technical information or instructions contained in this document relate to the Basic Type Certification. The technical information contained in this document has been approved under the authority of MOT Design Organization Approval No. MOT JA-01. 1.8 Measures All works must be done in accordance with the instructions given in the AMM. 2. Remove front seat LH (AMM, Chapter 25-10-00). 3. Inspect universal joints (upper and lower) very carefully for: * any sign of wear, * uneven movement * pins not completely pressed in * loose pins The picture below shows two of the pins separated from the joint. Inspection can be done in assembled condition. For better view rotate fuel selector in steps at least for 360°. Picture 1: Universal joint with two pins separated • Diamond Diamond Aircraft Industries GmbH DAI MSB 40-030/1 AIRCRAFT N.A. Otto-Straße 5 Page 3 of 5 A-2700 Wiener Neustadt 15-Jun-2004 4. In case of one or more of the under 1.8.3 listed defects have been found, replace complete universal joint kit as follows: 4.1 Remove front seat RH (AMM, Chapter 25-10-00) 4.2 Remove handle of fuel selector switch 4.3 Loosen screws of upper center panel (at brake lever) 4.4 Remove lower center panel (at power lever) 4.5 Remove center tunnel cover (between seats), mark forward cable (+) of Hobbs meter 4.6 Remove forward bolts of fuel selector switch plate 4.7 Lift fuel selector switch and pull out bottom of universal joint kit at fuel selector valve Pull out top of universal joint kit at fuel selector switch. If top universal joint shaft is not already assembled: - Set fuel selector valve to OFF position (spline pin in top of valve pointing forward) - Set fuel selector switch to OFF position - Insert top universal joint into selector shaft with cylindrical retaining compound (Loctite 638, 648 or 680). Do not allow retaining compound to cure at this time! - Insert top of selector shaft into selector switch - Insert bottom of selector shaft into selector valve - Allow retaining compound to cure in place - Remove selector shaft - Mark and drill Ø2mm (0.079") hole through shaft and upper universal joint, 6mm from top of shaft - Install roll pin DIN 1481-2x10-A2 with Loctite (as above) Install new universal joint kit by doing items 4.2 to 4.8 in reversed order 5. Perform check for foreign objects 6. Reinstall seat(s) 7. Perform functional check of all three positions of fuel selector with engine running. Inform DAl about result of inspection via e-mail or fax (using enclosed report sheet) 1.9 Mass (Weight) and CG Not affected. we Diamond AIRCRAFT Diamond Aircraft Industries GmbH N.A. Otto-Straße 5 DAI MSB 40-030/1 Page 4 of 5 A-2700 Wiener Neustadt 15-Jun-2004 II. PLANNING INFORMATION 2.1 Material & Availability All necessary parts with specific part numbers can be ordered from Diamond Aircraft Industries GmbH or from your local General Distributor or Diamond Service Center. All other parts shall be procured locally. Qty Description Part Number Universal Joint Kit 42.5141 (D41-2823-20-00) 2.2 Special Tools No special tools are required. 2.3 Labor effort Inspection only: appr. 1.5 hours. Replacement of Universal joint kit: appr. 2.5 hours 2.4 Credit The new universal joint kit can be ordered at Diamond Aircraft or its local distributors free of charge in return of the old ones. 2.4 Reference documents DA 40 Series Airplane Maintenance Manual, Doc. No. 6.02.01. **III. REMARKS** 1. All measures must be carried out by the manufacturer, a certified aircraft service station or a certified aircraft maintenance mechanic. 2. Accomplishment of the measures must be confirmed in the log book. 3. In case of doubt, contact Diamond Aircraft. we Diamond AIRCRAFT Diamond Aircraft Industries GmbH N.A. Otto-Straße 5 DAI MSB 40-030/1 Page 4 of 5 A-2700 Wiener Neustadt 15-Jun-2004 II. PLANNING INFORMATION 2.1 Material & Availability All necessary parts with specific part numbers can be ordered from Diamond Aircraft Industries GmbH or from your local General Distributor or Diamond Service Center. All other parts shall be procured locally. Qty Description Part Number Universal Joint Kit 42.5141 (D41-2823-20-00) 2.2 Special Tools No special tools are required. 2.3 Labor effort Inspection only: appr. 1.5 hours. Replacement of Universal joint kit: appr. 2.5 hours 2.4 Credit The new universal joint kit can be ordered at Diamond Aircraft or its local distributors free of charge in return of the old ones. 2.4 Reference documents DA 40 Series Airplane Maintenance Manual, Doc. No. 6.02.01. **III. REMARKS** 1. All measures must be carried out by the manufacturer, a certified aircraft service station or a certified aircraft maintenance mechanic. 2. Accomplishment of the measures must be confirmed in the log book. 3. In case of doubt, contact Diamond Aircraft. austro **CONTROL** **AUSTRIAN CIVIL AVERTEN ADMINSTRATION** AIRWORTHINESS DIRECTIVE No. A-2004-003 June 22, 2004 Aeroplane DA40 Inspection/Replacement of the fuel selector/fuel valve universal joints 1. Applicability: DA40, Diamond Aircraft Industries GmbH, Austria (design holder and manufacturer) S/N affected: 40.006 up to 40.079, 40.081 up to 40.083 DA40, Diamond Aircraft Industries Inc, Canada (manufacturer) S/N affected: 40.201 and subsequent 2. Subject: Inspection and replacement of the universal joints between fuel selector handle and fuel selector valve. 3. Reason: Abnormal manufacturing variations of the universal joints in combination with mechanical wear can lead to universal joint failures and subsequent disconnection between the fuel selector and the fuel valve. This condition might remain unrecognized by the pilot and can result in fuel starvation during flight and/or the unavailability of the emergency fuel shut-off function. 4. Action: a) Inspection ofthe universal joints of the fuel selector/fuel valve assembly in accordance with Diamond Aircraft Industries Gmb.H Mandatory Service Bulletin No. MSB 40-030/1 (available under http://www.austrocontrol.at/austro/lta.html) b) Replacement of complete drive assembly in accordance with Diamond Aircraft Industries GmbH Mandatory Service Bulletin No. MSB 40-030/1 5. Compliance: a) For aeroplanes with a time-since-new (TSN) of more than 200 flight hrs: i) Within 15 flight hours after the effective date of this AD but not later than September 30,2004, perform Action 4a). il) If defects are found, prior further flight, perform Action 4b). ili) Repeat Action 4a) at intervals not to exceed 50 hrs of time-in-service (TIS). b) For aeroplanes with a TSN of 200 flight hours or less: i) At next scheduled inspection but not to exceed 50 hours TIS after the effective date of this AD and not later than September 30, 2004, perform Action 4a). ii) If defects are found, prior further flight, perform Action 4b). ii) Repeat Action 4a) at intervals not to exceed 50 hrs TIS. Accomplishment: The required actions have to be accomplished either by the manufacturer, or a licensed/qualified person/organisation, and confirmed in the aircraft log in accordance with national regulations. 6. Effective Date: June 30, 2004. EASA-Approval This Airworthiness Directive has been issued in accordance with Article 10, paragraph 1, of the EU-Regulation No. 1592/2002. ## Registered aircraft it may concern (OpenAirDocs) Registry models matched by make and model, the same way as ADs, most registered aircraft first. - [Diamond Aircraft Ind DA 40](https://openairdocs.org/model/diamond-aircraft-ind-da-40): 688 registered aircraft (airframe model) - [Diamond Aircraft Ind DA40 D](https://openairdocs.org/model/diamond-aircraft-ind-da40-d): 0 registered aircraft (airframe model) --- OpenAirDocs.org is an independent research project of [Contrail Labs](https://contraillabs.com/). It is not affiliated with the FAA or the NTSB. Source documents are U.S. government works in the public domain.