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Diamond Aircraft Industries GmbH N. A. Otto-Straße 5 2700 Wiener Neustadt, Austria WI-OSB 42-131 Revision 0 Page 1 of 18 20-Dec-2017
WORK INSTRUCTION WI-OSB 42-131
I GENERAL INFORMATION I.1 Subject Re-installation of exhaust pipes with directly attached heat shield as a replacement for exhaust pipes without directly attached heat shield.
Re-qualification of this exhaust pipes with directly attached heat shield previously removed.
Repair of heat shield and heat shield attachment to base pipe.
I.2 Reference Documents DA 42 Series Airplane Maintenance Manual, Doc. No. 7.02.01, latest effective issue.
Design Change Notice: OÄM 42-315 “Alternative Exhaust Clamp Sheet” I.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 SI units and US/Imperial units refer to AMM Chapter 02.
d) In case of doubt, contact Diamond Aircraft Industries GmbH.
II DRAWINGS, SPECIAL TOOLS & MATERIALS II.1 Drawings A01-VR00735-00-0201 II.2 Special Tools No required special tools.
Diamond Aircraft Industries GmbH N. A. Otto-Straße 5 2700 Wiener Neustadt, Austria WI-OSB 42-131 Revision 0 Page 2 of 18 20-Dec-2017
II.3 Material A. Material for Re-Installation of Exhaust Pipe with Directly Attached Heat Shield
Note: Material is for installation on one engine only.
Quantity Part Number Description 1 DAI P/N D60-9078-06- 01 / Technify P/Ns 52- 7810-H0001 02, 52- 7810-H0001 03 or 52- 7810-H0001 04 Exhaust Pipe 1 D60-7806-00-01 Exhaust Clamp 1 (pos. 4) 1 D60-7806-00-02 Exhaust Clamp 2 (pos. 5) 1 D60-7806-00-03 Exhaust Sheet (pos. 6) 2 DIN 912-M5x20-A2 Hexagon Socket Head Screw (pos. 7) 2 LN 9338-M5 K-Nut M5 (pos. 9) 4 DIN 125-A5.3-A2 Washer A2 (pos. 11) 1 LN 9037-06016 Hexagon Screw (pos. 8) 1 LN 9338-M6 K-Nut M6 (pos. 10) 4 BN 806-12x6,2x0,6 Spring Washer (pos. 12) 1 DIN 9021-B10.5-ZP Washer (pos.13) Material is available from Diamond Aircraft Industries.
Diamond Aircraft Industries GmbH N. A. Otto-Straße 5 2700 Wiener Neustadt, Austria WI-OSB 42-131 Revision 0 Page 3 of 18 20-Dec-2017
B. Material for Re-Qualification of Exhaust Pipes Material for Air-Pressure Test:
Quantity Part Number Description 1 VR00735-00-02 01*) Adaptor incl. pressure connection and o-ring 1 VR00735-00-01 01**) Pressure Pad 3 NM-0000-02355 01**) Hexagon Screws M8x40 3 NM-0000-01294 01**) Hexagon Nuts M8 6 NM-0000-00040 01**) Washers M8 Material including drawing is available from Technify Motors GmbH.
*) Adaptor may also be produced locally by a maintenance shop in accordance with the attached drawing A01-VR00735-00-0201 and standard grade fittings and o-rings **) Standard DIN Hardware available may be used for the test.
Material for Hot-Water Test ***):
Quantity Part Number Description 1 D60-9078-06-01ST01 Cap 1 D60-9078-06-01ST02 Rubber 3 DIN 933-M8x30-A2 Bolt 3 DIN 934-M8-A2 Nut 3 DIN 125-M8 Washer Material is available from Diamond Aircraft Industries.
***) Cap an Rubber may also be produced locally by a maintenance shop. Standard DIN Hardware available may be used for the test.
For the Cap use 3 mm thick stainless steel sheet metal.
For the Rubber use 2 mm thick rubber mat of EPDM, FKM, Viton or equivalent.
Dimensions:
Diamond Aircraft Industries GmbH N. A. Otto-Straße 5 2700 Wiener Neustadt, Austria WI-OSB 42-131 Revision 0 Page 4 of 18 20-Dec-2017
III INSTRUCTIONS III.1 Re-Installation of Exhaust Pipes with Directly Attached Heat Shield 1 Remove engine cowlings in accordance with (i.a.w.) AMM section 71-10.
2 Remove Exhaust Pipe DAI P/N D60 -9078-06-01_01 / Te chnify P/N 52 -7810-H0014 01, previously installed under OSB 42-122, i.a.w. AMM Section 78-00.
3 Make sure that the intermediate flange of the engine is installed correctly to the forward engine shock mount. Align a ruler with the straight part of the bottom side of the intermediate flange as shown in the picture below. The distance between screw (pos. 3) and the ruler must be 13mm.
4 Install Exhaust Pipe with directly attached heat shield DAI P/N D60-9078-06-01 / Technify P/Ns 52-7810-H0001 02, 52-7810-H0001 03 or 52-7810-H0001 04 i.a.w. AMM Section 78-
00.
5 Remove the screw (pos. 3) from the front shock engine mount.
pos. 3 intermediate flange
Diamond Aircraft Industries GmbH N. A. Otto-Straße 5 2700 Wiener Neustadt, Austria WI-OSB 42-131 Revision 0 Page 5 of 18 20-Dec-2017
6 Install the exhaust clamp i.a.w. the pictures without tightening the bolts.
13 7 11 9
8,12 6 12 10 4 5 3
Diamond Aircraft Industries GmbH N. A. Otto-Straße 5 2700 Wiener Neustadt, Austria WI-OSB 42-131 Revision 0 Page 6 of 18 20-Dec-2017
7 Make sure that exhaust clamp 1 (pos.4) and exhaust sheet (pos. 6) are arranged as shown in the following pictures:
Note: The correct order of arrangement is:
hexagon screw (pos. 8) – spring washer (pos. 12) – exhaust sheet (pos. 6) – 2 x spring washer (pos. 12 ) – exhaust clamp (pos 4) – spring washer (pos 12) – K-nut M6 (pos 10)
8 Tighten Hexagon Screw (pos. 8) until the spring washer pre -tension is 1.5 mm between the metal sheets.
9 Tighten Hexagon Socket Head Screws (pos. 7) equally on both sides with 5 NM (3.7 lbf.ft.).
correct installation pos. 4 pos. 6
Diamond Aircraft Industries GmbH N. A. Otto-Straße 5 2700 Wiener Neustadt, Austria WI-OSB 42-131 Revision 0 Page 7 of 18 20-Dec-2017
10 Check if the Hexagon Screw (pos. 3) can be installed without applying side force to the exhaust pipe.
If the Hexagom Screw (pos. 3) cannot be installed without applying side force to the exhaust pipe:
- Loosen the exhaust assembly at the manifold an re-align the exhaust pipe with the lower cowling installed in order to keep the pipe centered in the lower cowling cut-out and with adequate clearance to surrounding components. Re -install the exhaust assembly i.a.w. AMM, section 78-00.
- If necessary loosen Hexagon Socket Head Screws (pos. 7), re -align exhaust pipe clamp and tighten Hexagon Socket Head Screws (pos. 7) i.a.w. item 6.
11 Check if the Hexagon Screw (pos. 3) can be installed without applying side force to the exhaust pipe.
If the Hexagon Screw (pos. 3) cannot be installed without applying side force to the exhaust pipe:
- Modify the exhaust pipe bracket by re-working the hole for Hexagon Screw (pos. 3) as shown in the picture below so that the Hexagon Screw (pos. 3) can be installed without applying a side force to the exhaust pipe. Do not remove more material than is needed for tension free installation.
smoothen the edges
Diamond Aircraft Industries GmbH N. A. Otto-Straße 5 2700 Wiener Neustadt, Austria WI-OSB 42-131 Revision 0 Page 8 of 18 20-Dec-2017
12 In case it is not possible to install the exhaust clamp without adequate clearance between exhaust pipe and cowling / surrounding components and without applying tension to the exhaust pipe, install an alternative exhaust sheet i.a.w. DAI OÄM 42-315.
Note: The alternative exhaust sheet and corresponding installation instruction (OÄM 42 -315) may be obtained through Diamond Aircraft Industries Austria (support@diamond-air.at).
13 After verification that the Hexagon Screw (pos. 3) can be installed without applying tension to the exhaust pipe and that there is adequate clearance between exhaust pipe and lower cowling cut -out / surrounding components, secure Hexagon Screw (pos. 3) wit h Loctite 272 and torque i.a.w. Technify Motors Repair Manual RM-02-02, Section 71-20.01.
14 Examine heat shielding in the engine compartment. Ensure:
- Installation is compliant with installation requirements in WI-OSB-42-122, Revision 3 or later
- No damage or wear to heat shielding
Note: Heat Shield Installation Requirements:
- Heat shield at the front shock mount:
- Heat protection patch to upper cowling:
heat shield
Diamond Aircraft Industries GmbH N. A. Otto-Straße 5 2700 Wiener Neustadt, Austria WI-OSB 42-131 Revision 0 Page 9 of 18 20-Dec-2017
- Heat protection patch to the air inlet duct of the lower cowling
- Small heat protection patch to lower cowling:
5 mm 5 mm 5 mm
Diamond Aircraft Industries GmbH N. A. Otto-Straße 5 2700 Wiener Neustadt, Austria WI-OSB 42-131 Revision 0 Page 10 of 18 20-Dec-2017
- All patches view:
- Edge sealing of heat protection patches:
cowling composite material heat protection patch Dow Corning 732
Diamond Aircraft Industries GmbH N. A. Otto-Straße 5 2700 Wiener Neustadt, Austria WI-OSB 42-131 Revision 0 Page 11 of 18 20-Dec-2017
- Heat protection shield to the coolant tube:
Note: For detailed installation Procedures refer to in WI-OSB-42-122, Revision 3 or later.
15 Clean working areas, check for foreign objects.
16 Install engine cowlings i.a.w. AMM section 71-10. - Make sure sufficient clearance of the exhaust pipe is provided.
17 Do an engine test i.a.w. AMM section 71-00.
18 Do a post engine test inspection:
- Remove engine cowlings in accordance with (i.a.w.) AMM section 71-10.
- Examine exhaust pipe and cowlings. Ensure no signs of contact and verify sufficient positive clearance of exhaust pipe.
In case of contact, re-align exhaust pipe routing.
- Install engine cowlings i.a.w. AMM section 71-10.
19 Make all necessary entries in the airplane logs.
cowling composite material heat protection patch Dow Corning 732
Diamond Aircraft Industries GmbH N. A. Otto-Straße 5 2700 Wiener Neustadt, Austria WI-OSB 42-131 Revision 0 Page 12 of 18 20-Dec-2017
III.2 Re-Qualification of Exhaust Pipes DAI P/N D60-9078-06-01 / Technify P/Ns 52- 7810-H0001 02, 52-7810-H0001 03 or 52-7810-H0001 04 Note: Either Procedure 1 or 2 may be used for re-qualification of an exhaust pipe.
Note: Re-qualified exhaust pipes are considered having a TSN of 1500 FH.
Procedure 1: Air-Pressure Test
1 Examine Exhaust Pipe visually.
- Clean exhaust pipe.
- Ensure no visible cracks on inner pipe where visually accessible.
- Ensure no visible cracks on heat shield.
- Ensure heat shield is firmly attached to the inner pipe.
Note: On Exhaust pipes Technify P/Ns 52-7810-H0001 03 or 52-7810-H0001 04 the heat shield is welded to the exhaust pipe at the marked points. If a single welding point is cracked the heat shield is considered to be loose.
This defects may be weld-repaired. Refer to Section III.3.
2 Mount the adapter (VR00735 -00-02 01 incl. pressure connection and o -ring) with the exhaust pipe, therefore use 3x M8x40 hexagon screws (NM -0000-02355 01), 3x M8 hexagon nuts (NM-0000-01294 01) and 6x washers (NM-0000-00040 01).