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MSB1078-196/1 Page 1 of 9 I GROB 01 December 2014 AIRCRAFT Replaces Issue: 14 July 2014 SERVICE BULLETIN NO. MSB1078-196/1 I. TECHNICAL DETAILS
1.1 Category:
Mandatory Note: GROB issues Service Bulletins of category Mandatory (MSBs), if the information or instructions have a safety intent either related to design or conformity and to publish revisions of manuals (AFM, AMM, IPC). However, according to Article 20
(1) of Regulation (EC) No. 216/2008, only EASA may issue mandatory information, in the form of an Airworthiness Directive (AD), in order to react to a given safety problem. Service Bulletins classified Mandatory issued by GROB's design organisation do not have a legally mandatory character equivalent to an AD, cannot have enforcement implications and, therefore, serve as information or instruction by GROB only. This also applies to cases where a Service Bulletin is Note: This service bulletin is issued in anticipation of an AD. Issue of an AD will not necessarily lead to revision of this service bulletin.
1.2 Airplanes affected:
G 115E all S/N G 115EG all S/N
1.3 Time of Compliance:
Part A: Before next IFR or VFR Night flight, or within next 50FH, whichever comes first, unless already accomplished under MSB 1078-196 at initial issue.
Part B: Within 100 flight hours or next 100 or 200 hours inspection, whichever comes first.
1.4 Subject:
ATA-Code: 80-00 Starting Inspection of starter solenoid and Installation of Starter Relay.
1.5 Reason:
Grob received a report about a total loss of electrical power in IMC. Root cause was found to be a defect starter solenoid. The starter solenoid had an internal defect causing a short circuit. The defect cannot be detected by visual inspection.
This Service Bulletin is intended to prevent an unsafe condition. The configuration of the aircraft is affected by Part B of this Service Bulletin.
1.6 Concurrent documents:
Corresponding AMM 1078-196_1 MSB, Inspection of starter solenoid and Installation of Starter Relay G 115E, EG Grob Aircraft AG, Lettenbachstrasse 9, D-86874 Tussenhausen-Mattsies
Page 2 of 9 MSB1078-196/1 GROB 01 December 2014 AIRCRAFT Replaces Issue: 14 July 2014 Approval Note:
The technical content of this document is approved under the authority of EASA Design Organization Approval No. EASA.21J.030.
These information or instructions relate to change no. MAM 1078-187 which has been approved by the Authority (EASA) under approval no. 10051624.
1.8 Accomplishment/ Instructions Note: The AMM references in this Service Bulletin are for G 115E. For G 115EG use the relevant Job Guide.
Part A One-time Inspection
1.8.1 Disconnect the aircraft battery, refer to AMM Chapter 24-30.
1.8.2 Remove the Engine Cowlings, refer to AMM Chapter 71-10.
1.8.3 Visually inspect the starter. Make sure that the power connection bolts have the same length, refer to Figure 1 for defective item and Figure 2 for correct installation.
OGL Figure 1: Incorrect connection bolts Figure 2: Correct installation
1.8.4 Release the two bolts on the starter solenoid. Carefully pull the solenoid away from the starter housing until the dead stop. Make sure that the solenoid plunger is still attached, refer to Figure 3. Attach the solenoid to the starter with the two bolts.
1078-196_1 MSB, Inspection of starter solenoid and Installation of Starter Relay G 115E, EG Grob Aircraft AG, Lettenbachstrasse 9, D-86874 Tussenhausen-Mattsies
MSB1078-196/1 Page 3 of 9 GROB 01 December 2014 Replaces Issue: 14 July 2014 AIRCRAFT Figure 3: Starter solenoid at dead stop
1.8.5 If the starter is OK, do step 1.8.7.
1.8.6 If the starter is not OK or in case of doubt, replace the Starter.
1.8.7 Install the Engine Cowlings, refer to AMM Chapter 71-10.
1.8.8 Connect the aircraft battery, refer to AMM Chapter 24-30.
1.8.9 For G 115E approved for IFR: Make and install a placard "IFR operation in VMC only", refer to Figure 4.
15 190 G-BTAS н20
399.97
2.4_" 180;
Figure 4: Limitation placard
1.8.10 Release aircraft into service according to national requirements.
1078-196_1 MSB, Inspection of starter solenoid and Installation of Starter Relay G 115E, EG Grob Aircraft AG, Lettenbachstrasse 9, D-86874 Tussenhausen-Mattsies
MSB1078-196/1 Page 4 of 9 GROB 01 December 2014 Replaces Issue: 14 July 2014 AIRCRAFT Part B Installation of Starter Relay (Terminating action)
1.8.1 Disconnect the aircraft battery, refer to AMM Chapter 24-30.
1.8.2 Remove the Engine Cowlings, refer to AMM Chapter 71-10.
1.8.3 Disconnect the spark plug cables from the spark plugs.
1.8.4 Remove the cooling air hose from the oil cooler.
1.8.5 Remove the U-bolts which holds the top and the bottom of the oil cooler to the mounting plate.
1.8.6 Remove the shroud and move the oil cooler to one side.
1.8.7 Remove the screws that attach the Start Control Relay to the mounting plate.
1.8.8 Disconnect the wires from the relay and cut the terminals from the wires. Discard the Start Control Relay.
1.8.9 Drill a 5mm hole in the relay mounting plate, 35mm below forward hole of the old Start Control Relay. Countersink hole for a M5 screw. Refer to Figure 5.
Attach the starter relay (item 1 of List 2.2) so that the terminals point forward, refer to.
Use 2x M5 screw, washers and nuts (Items 2, 3 and 4 of List 2.2).
New Relay New hole Figure 6 Figure 5
1.8.10 Remove the cable KA 01E16-E. Cut the wax strings/ty-wraps and release the P-clips, where necessary. Disconnect the cable at the starter solenoid.
1.8.11 Install the jumper cable (item 5 of List 2.2) on the starter solenoid, refer to wiring diagram.
1.8.12 Cap and stow cable KA 03K16-P near the removed starter control relay (Item 6 of List
2.2).
1.8.13 Disconnect the cable PA 03G06-E at the firewall and the starter motor. Keep the two rubber caps and discard the cable.
1078-196_1 MSB, Inspection of starter solenoid and Installation of Starter Relay G 115E, EG Grob Aircraft AG, Lettenbachstrasse 9, D-86874 Tussenhausen-Mattsies
MSB1078-196/1 Page 5 of 9 I GROB 01 December 2014 AIRCRAFT Replaces Issue: 14 July 2014
1.8.14 Apply one of the rubber caps to the new cable PA 03K06-E (Item 7 of List 2.2) and connect it to the starter motor. Cap the contact and put the cable along the cable loom to the new Starter Relay. Install P-clips and ty-wraps as required
1.8.15 Apply one of the rubber caps to the new cable PA 03G06-E (Item 8 of List 2.2) and connect it to the firewall terminal. Cap the contact and put the cable to the new Starter Relay.
1.8.16 Crimp one new terminal (item 9 of List 2.2) on the two cables KA 02F20-E and KA 02G20-E. Crimp a new terminal (item 10 of List 2.2) on the cable KA 04F20N-P.
1.8.17 Apply two new rubber caps (item 11 of List 2.2) to the cables and connect them to the new starter relay, refer to Figure 7. Cap the contacts.
PA 03K06-E SEE DWG. NO.
PA 03006-E LP 115E-9300/1
BATTERY SYSTEM STABIER. _RELAY 7 KA PA 03K06-E 880 712 88 1PA 03006-F 1 c KA 03K16-P KA 02G20-E <A 02F20-E 85- KA 04F20N-P Figure 7
1.8.18 Safety the cables with cable ties, where necessary.
1.8.19 Put the oil cooler/shroud in position. Install the U-bolts which holds the top and the bottom of the oil cooler to the mounting plate. Use four new nuts (Item 4 of List 2.2) with the original washers
1.8.20 Install the cooling air hose to the oil cooler.
1.8.21 Install the Engine Cowlings, refer to AMM Chapter 71-10
1.8.22 Release the rear equipment compartment panel for access, refer to AMM Chapter 25-10.
1.8.23 Disconnect the External Power Control Relay from its socket (Item 60 of Figure 8).
1.8.24 Remove the bolt that attaches the External Power Control Relay Socket (Item 30 of Figure 8). Remove the bolt that attaches the P-clamp (Item 80 of Figure 8).
1.8.25 Attach the new fuse holder (Item 12 of List 2.2) to the new fuse bracket (Item 13 of List
2.2) with screws, washers and nuts (Items 14 thru 16 of List 2.2).
1.8.26 Install the new fuse bracket with the bolts that attach the External Power Control Relay Socket and the P-clamp. Use a longer bolt for the External Power Control Relay Socket.
(Item 17 of List 2.2)
1.8.27 Disconnect the cable PA 03F06-E from the battery relay.
1.8.28 Apply two new rubber caps (item 11 of List 2.2) to the new cable PA 03L06-E (Item 18 of List 2.2). Connect it to the battery relay and the rear bolt of the new fuse, refer to Figure 9 and Figure 10. Cap the contacts.
1.8.29 Connect the cable PA 03F06-E to front bolt of the new fuse holder, refer to Figure 10.
Install a 150A Fuse (Item 19 of List 2.2) and tighten the attaching nuts.
1078-196_1 MSB, Inspection of starter solenoid and Installation of Starter Relay G 115E, EG Grob Aircraft AG, Lettenbachstrasse 9, D-86874 Tussenhausen-Mattsies
MSB1078-196/1 Page 6 of 9 • GROB 01 December 2014
AIRCRAFT Replaces Issue: 14 July 2014
1.8.30 Cut the cable ties on the front edge of the External Power Assy, refer to Figure 10.
Install the edge protection on the front edge (Item 20 of List 2.2).
1.8.31 Safety the cables with cable ties, where necessary.
1.8.32 Connect the External Power Control Relay to its socket.
-60 Figure 8
BAITERY RELAY BATTERY LIMITER 2PA PA 03F06 E 6 0 34PA PA 03L06-E 188 2128806 PA 02122-P PA 02E06-P 150A PA 03E06-E PA 12E22-E 85 7|86+| PA 13E22-E Figure 9 1078-196_1 MSB, Inspection of starter solenoid and Installation of Starter Relay G 115E, EG Grob Aircraft AG, Lettenbachstrasse 9, D-86874 Tussenhausen-Mattsies
MSB1078-196/1 Page 7 of 9 GROB 01 December 2014
AIRCRAFT Replaces Issue: 14 July 2014 PA 03F06-E
• PA 03L06-E New eage protection Figure 10
1.8.33 Connect the aircraft battery, refer to AMM Chapter 24-30.
1.8.34 Install the rear equipment compartment panel for access, refer to AMM Chapter 25-10.
1.8.35 Do an engine run-up, refer to AMM Chapter 71-00.
1.8.36 For G 115E: remove and discard the placard "IFR operation in VMC only".
1.8.37 Release aircraft into service according to national requirements.
1.9 Repetitive Actions none 1078-196_1 MSB, Inspection of starter solenoid and Installation of Starter Relay G 115E, EG Grob Aircraft AG, Lettenbachstrasse 9, D-86874 Tussenhausen-Mattsies
MSB1078-196/1 Page 8 of 9 • GROB 01 December 2014 Replaces Issue: 14 July 2014 AIRCRAFT II. PLANNING INFORMATION
2.1 Weight and CG N/A
2.2 Material and Availability Part B:
Item P/N Description Qty. / A/C 1 GS246001-9 Starter Relay 1 2 DIN965-A2-5x14 Screw 2 DIN 125A-A2-5.3 Washers 2 4 DIN985-A2-5 Nut 6 5 115E-9510.03 Jumper cable 1 6 GS247009-2-32 TC Cap, red 1 115E-9510.02 PA 03K06-E (for 82086/E - 82184/E) PA 03K06-E 1 115E-9510.02/1 (for 82301/E - 82323/E and model G 115EG) 115E-9510.01 PA 03G06-E 8 (for 82086/E - 82184/E and model G 115EG) 1 115E-9510.01/1 PA 03G06-E (for 82301/E - 82323/E) 9 MS 25036-153 Terminal, Blue 1 10 MS 25036-149 Terminal, Red 1 11 MS 25171-3S Rubber Caps 4 12 MS28934-1 Fuse holder 1 13 115E-9332 Fuse Bracket 1 14 DIN 965-A2-5x25 Screw 2 15 DIN9021-A2-5,3 Washer 2 16 DIN985-A2-05 Nut 2 17 DIN933-A2-4x14 Bolt 1 18 115E-9470.01 PA 03L06-E 1 19 MS28936-150 150A Fuse 20 GS510118-1-120 Cellular Rubber Sealing
2.3 Special Tools Part B:
Item P/N Description 1 TYCO 169400-0 (or equivalent) Crimping tool 2 AMP 169404 (or equivalent) Positioner for TYCO 169400-0
2.4 Labor costs N/A
2.5 Reference documents Corresponding AMM and IPC
2.6 N/A 1078-196_1 MSB, Inspection of starter solencid and Installation of Starter Relay G 115E, EG Grob Aircraft AG, Lettenbachstrasse 9, D-86874 Tussenhausen-Mattsies
MSB1078-196/1 Page 9 of 9 _ GROB 01 December 2014 Replaces Issue: 14 July 2014 AIRCRAFT III. REMARKS The instructions in paragraph 1.8 have to be accomplished and certified in the logbook by authorized staff:
- in EASA countries according to Article 5 VO EG 2042/03 (VO EG 1056/2008) Appendix III - Part 66
- in non-EASA countries according to national regulations with respect to maintenance.
If you have sold your aircraft in the meantime, we kindly ask you to forward this information to the new owner and to provide us with the name and address of the new owner as well as with the respective serial number.
For questions and assistance please contact:
Product Support, phone: +49 8268 998105 +49 8268 998200 e-mail: productsupport@grob-aircraft.com 1078-196_1 MSB, Inspection of starter solenoid and Installation of Starter Relay G 115E, EG Grob Aircraft AG, Lettenbachstrasse 9, D-86874 Tussenhausen-Mattsies