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Diamond Diamond Aircraft Industries GmbH DAI MSB 40-074 N. A. Otto-Straße 5 DAI MSB D4-094
AIRCRAFT A-2700 Wiener Neustadt DAI MSB F4-028 Austria Page 1 of 3 10-May-2013
MANDATORY SERVICE BULLETIN MSB 40-074 MSB D4-094 MSB F4-028
TECHNICAL DETAILS I.1 Category Mandatory.
1.2 Airplanes affected Type: DA 40, DA 40 D, DA 40 F Serial numbers: 40.006 through 40.009
40.011 through 40.1071
40.1073 through 40.1077 D4.001 through D4.382
40.DS001 through 40.DS030
40.FC001 through 40.FC029 NOTE Airplanes converted to DA 40 NG via OSB D4-080 are not affected.
1.3 Date of effectivity 10-May-2013
1.4 Time of Compliance Within the next 2000 hrs since new or since the last Major Structural Inspection from the date of effectivity, but not later than 31-Dec-2022.
1.5 Subject Reinforcement of aft main spar.
ATA-Code: 57-00
1.6 Reason By further testing and investigation it was discovered that the fatigue strength of the aft main spar in the cabin area does not ensure unlimited lifetime. This Service Bulletin prescribes the reinforcement of the aft main spar to correct this condition. As an additional benefit the reinforcement is the basis for the Major Structural Inspection interval increase to 6000 hrs since new and every 4000 hrs thereafter.
1.7 Concurrent Documents None.
Diamond Diamond Aircraft Industries GmbH DAI MSB 40-074 N. A. Otto-Straße 5 DAI MSB D4-094 AIRCRAFT A-2700 Wiener Neustadt DAI MSB F4-028 Austria Page 2 of 3 10-May-2013
1.8 Approval The technical information or instructions contained in this document relate to the Design Change Advisories No. MAM 40-398 and MAM 40-475, which have been approved under the authority of EASA Design Organization Approval ref. EASA.21J.052.
The technical content of this document has been approved under the authority of DOA ref.
EASA.21J.052.
1.9 Accomplishments / Instructions Comply with WI-MSB 40-074 / WI-MSB D4-094 / WI-MSB F4-028, latest effective issue.
I.10 Mass (Weight) and CG Not affected.
PLANNING INFORMATION II.1 Material and Availability See WI-MSB 40-074 / WI-MSB D4-094 / WI-MSB F4-028, latest effective issue.
Materials including drawings are available from Diamond Aircraft Industries.
I1.2 Special Tools None.
II.3 Labour Effort Approx. 4 hours.
II.4 Credit None.
11.5 Reference Documents DA 40 Series Airplane Maintenance Manual, Doc. No. 6.02.01, latest effective issue.
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.
›Diamond Diamond Aircraft Industries GmbH DAI MSB 40-074 N. A. Otto-Straße 5 DAI MSB D4-094
AIRCRAFT A-2700 Wiener Neustadt DAI MSB F4-028 Austria Page 3 of 3 10-May-2013
EXECUTION REPORT TO
SERVICE BULLETIN MSB 40-074 MSB D4-094 MSB F4-028
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
Diamond Diamond Aircraft Industries GmbH WI-MSB 40-074 AIRCRAFT N. A. Otto-Straße 5 WI-MSB D4-094 A-2700 Wiener Neustadt WI-MSB F4-028 Austria Revision 0 Page 1 of 3 10-May-2013
WORK INSTRUCTION WI-MSB 40-074 WI-MSB D4-094 WI-MSB F4-028
GENERAL INFORMATION
1.1 Subject Reinforcement of aft main spar.
1.2 Reference Documents DA 40 Series Airplane Maintenance Manual, Doc. No. 6.02.01, latest effective issue.
1.3 Remarks
a) All work must be done by a certified aircraft service station or a certified aircraft maintenance mechanic.
b) All work, in particular if not described in this work instruction, must be done in accordance with the referenced maintenance manual.
c) For conversion factors between Sl units and US/Imperial units refer to AMM Chapter 02.
d) In case of doubt, contact Diamond Aircraft Industries GmbH.
DRAWINGS, SPECIAL TOOLS & MATERIALS II.1 Drawings D41-5313-03-00_2 Page 3.
I1.2 Special Tools
Diamond Diamond Aircraft Industries GmbH WI-MSB 40-074 AIRCRAFT N. A. Otto-Straße 5 WI-MSB D4-094 A-2700 Wiener Neustadt WI-MSB F4-028 Austria Revision 0 Page 2 of 3 10-May-2013 II.3 Material Quantity Part Number Description 2 m KDU 1034 SGL UD Carbon Fiber Tape а/r LR 285 EPIKOTE ™ Resin MGS® LR285 а/г LH 286 EPIKURE™ Curing Agent MGS® LH286 Material including drawing is available from Diamond Aircraft Industries.
INSTRUCTIONS 1 Remove rear seat bench i.a.w. AMM Section 25-10.
2 Remove carpets in rear floor panel.
3 Prepare bonding area i.a.w. AMM Section 51-20.
CAUTION Do not damage the laminate.
4 Prepare LH and RH reinforcement patch i.a.w. drawing D41-5313-03-00_2:
Place impregnated reinforcement patches (items 101 to 104) on a PE or PP carrier foil.
5 Put LH and RH reinforcement patch in place on aft main spar i.a.w. drawing D41-5313-03- 00_2.
Diamond Diamond Aircraft Industries GmbH WI-MSB 40-074 AIRCRAFT N. A. Otto-Straße 5 WI-MSB D4-094 A-2700 Wiener Neustadt WI-MSB F4-028 Austria Revision 0 Page 3 of 3 10-May-2013 Where the reinforcement patches overlap parts other than the aft main spar, trim the reinforcement patch (max cut off 60 mm).
7 Cover the patches with peel ply.
Cure and post cure i.a.w. AMM Section 51-20.
9 Remove peel ply.
10 Install carpets in rear floor panel.
11 Install rear seat bench i.a.w. AMM Section 25-10.
12 Clean working areas, check for foreign objects.
13 Check all altered, replaced and repaired parts for improper function.
14 Test all systems in working area for function.
15 Record MAM 40-398 as installed.
16 Make all necessary entries in the airplane logs.
DA 40 Series Diamond Time Limits and AMM AIRCRAFT Maintenance Checks
(5) Tail All items of the fuselage aft of the rear fuselage, vertical stabilizer and horizontal stabilizer.
(6) Wings All items on the left and right wings. It includes the ailerons, flaps and Pitot head.
(7) General Those items which include more than one zone at the same time. It includes items such as control checks which need one person in the cockpit and another person at the control surface.
3. Major Structural Inspection The Major Structural Inspection (MSI) is an important part of the infinite lifetime concept of the DA 40 It is required to prove the structural integrity of the airframe. It must be carried out at the intervals shown in Section 05-20.
Since the MSI is intended to coincide with a 2000 hour inspection, the inspection items are included in the maintenance checklist, and are identified by the term 'MSI' in the 'time' column.
Doc # 6.02.01 05-20-00 01 Арг 2013 Page 3 Rev. 7
430 0°, shown on Drawing Fa. Sga 0*, shawn on Daawing Fo. 5 gr Fe. 5ga 0*, shown on Drawing Fo. Signi Supptier Center Part Lower Assy D41-5313-03-00_2 D41-5313-03-00 2.dft medium Drawing Number:
UD Carbon Fiber UD Carbon Fiber UD Cartion Fiber D41-5310-00-00_3 • Diamond DA 40 Diamond Star Saved under:
PA-20-63 LN 90690 KDU 1034 KDU 1034 TOT OTYR Jütte D MAM 10-306 10.1200 5759! Change 105 ITEM 17 TO AVOID STEP IN PATCHE NOTES 104 105