Description
Diamond DA20-A1 Aircraft Maintenance Manual Revision 15 – The Complete DA201 AMM
This is the full Diamond DA20-A1 Aircraft Maintenance Manual, Revision 15, issued as document DA 201 by Diamond Aircraft Industries Inc. of London, Ontario. The DA20-A1 AMM follows ATA Specification No. 100 and delivers the maintenance, troubleshooting, removal and installation, adjustment and inspection data needed to keep the DA20-A1 composite two-seat light aircraft in airworthy condition. Revision 15 carries the 18 June 2012 issue date and folds in the engineering changes, service bulletins and temporary revisions current at that time.
File Details
- Manual type: Aircraft Maintenance Manual (AMM)
- Manufacturer: Diamond Aircraft Industries Inc., London, Ontario, Canada
- Aircraft model: DA20-A1
- Document number: DA 201
- Revision: Revision 15
- Revision date: 18 June 2012
- Language: English
- File format: PDF
- Page count: Approximately 605 pages
- Layout standard: ATA Specification No. 100
Chapters Covered in This DA20-A1 Maintenance Manual
- 01-00 Introduction
- 02-00 Organization and Handling of the Manual
- 03-00 General Description of the Aircraft
- 04-00 Airworthiness Limitations (04-10 Life Limited Parts, 04-20 Paint Finish)
- 05-00 Time Limits and Maintenance Checks (05-10 Time Limits, 05-20 Scheduled Maintenance Checks, 05-30 General Inspections, 05-40 Unscheduled Inspections)
- 06-00 Dimensions and Areas
- 07-00 Lifting and Shoring (07-10 Lifting, 07-20 Jacking)
- 08-00 Leveling and Weighing
- 09-00 Towing and Taxiing
- 10-00 Parking and Mooring (10-10 Parking, 10-20 Mooring, 10-30 Parking Duration)
- 11-00 Required Placards (11-10 Location of Placards)
- 12-00 Servicing (12-10 Replenishing, 12-20 Scheduled Servicing, 12-30 Unscheduled Servicing)
- 20-00 Standard Practices – Airframe
- 21-00 Environmental Systems (21-20 Distribution, 21-40 Heating)
- 23-00 Communications (23-10 Speech Communication Bendix/King KX125)
- 24-00 Electrical Power (24-30 DC Generation, 24-31 Battery System, 24-50 Electric Load Distribution)
- 25-00 Equipment and Furnishings (25-10 Flight Compartment, 25-50 Baggage Compartment)
- 27-00 Flight Controls (27-10 Aileron Control Systems, 27-11 Main Column, 27-20 Rudder Control Systems, 27-30 Elevator Control System, 27-40 Elevator Trim System, 27-50 Wing Flaps)
- 28-00 Fuel (28-10 Storage Tank, 28-20 Distribution, 28-40 Indicating)
- 31-00 Indicating and Recording Systems (31-10 Instrument Panel)
- 32-00 Landing Gear (32-10 Main Landing Gear, 32-20 Nose Landing Gear, 32-40 Wheels and Brakes)
- 33-00 Lights (33-10 Interior, 33-40 Exterior)
- 34-00 Navigation and Pitot Static (34-10 Pitot Static, 34-12 Stall Warning System, 34-20 Attitude and Direction, 34-50 Position Determining Systems)
- 51-00 Structures (51-10 Repair of Composite Parts, 51-20 Repair of Metal Parts)
- 53-00 Fuselage (53-10 Main Frame, 53-11 Canopy, 53-31 Inspection Holes)
- 55-00 Stabilizers (55-10 Horizontal Stabilizer, 55-20 Elevator, 55-30 Rudder)
- 57-00 Wings (57-10 Wing Structure, 57-50 Wing Flaps, 57-60 Ailerons)
- 61-00 Propeller
- 71-00 Power Plant (71-10 Cowling, 71-20 Mounts, 71-60 Air Intakes and Guides)
- 75-00 Engine Cooling
- 76-00 Engine Controls
- 77-00 Engine Indicating
- 78-00 Exhaust
- 79-00 Oil Systems (79-21 Oil Radiator, 79-30 Indicating)
- 92-00 Wiring Diagrams (92-10 System Schematics, 92-30 Avionics Schematics)
Read as a whole, the DA201 AMM gives a technician a single controlled document for every task on the airplane. Each chapter is split into a description and function section, troubleshooting tables, then a maintenance block covering ground service, removal and installation, adjustment and test, checks and inspections, cleaning and painting, and repairs. Because the DA20-A1 is a fibreglass and carbon composite airframe with a Rotax 912 powerplant, the manual is deliberately explicit about the techniques that matter most on this aircraft – composite layup reference drawings, chamfer ratios for GFRP repairs, coin tap and light test inspection methods, delamination and disbond defect limits, and the specific torque values, service limits and lubrication intervals that keep the airframe and engine within their approved envelopes.
What This Diamond DA20-A1 AMM Lets You Do
- Run the 50, 100, 200, 1000 and 6000 hour inspection checklists with the correct engine, propeller, cabin, structure, landing gear and general inspection steps.
- Service the Rotax 912 engine – oil changes, oil filter replacement, compression tests, spark plug replacement, ignition circuit checks, carburetor heat checks and generator belt checks.
- Remove and install the propeller, spinner and hub assembly using the published torque values and track tolerance.
- Adjust, rig and safety the aileron, elevator, rudder, trim and flap control systems, including push rod eye-end setup and cable pre-tension.
- Repair the composite airframe – GFRP laminate and sandwich repairs, delamination limits, fuselage layup reference, spar repair restrictions and painting.
- Diagnose and fix the landing gear – main and nose gear removal, toe-in, camber and track adjustment, wheel bearings, brake bleeding and the parking brake valve.
- Troubleshoot the electrical system, DC generation, battery system, load distribution, lighting, avionics and instrumentation using the Chapter 92 schematics.
- Perform fuel system checks including the fuel shut off valve and check valve inspection.
- Verify weight and balance, leveling, jacking, towing, mooring and placard requirements.
Why This Revision 15 AMM Matters
Component replacement times, torque values, composite defect limits and rigging tolerances on the DA20-A1 are not guesses. Revision 15 consolidates the latest engineering data, temporary revision TR 05-01 and the incorporated service bulletins – including DA20-32-05, DA20-79-03, DA20-79-08 and DA20-74-01 – so the maintenance you perform is the maintenance the manufacturer actually published. Getting the adjustment report values, cable tensions and control surface travels right is what prevents flutter, premature wear and airworthiness findings down the line.
Complete PDF Bookmark Tree
Complete Bookmarks
The complete bookmarks in the “Diamond DA20-A1 Aircraft Maintenance Manual Revision 15 (DA201 AMM) PDF Download” are as follows:
+AIRCRAFT MAINTENANCE MANUAL – DA20-A1p. 1
+FRONT MATTERp. 23
RECORD OF REVISIONSp. 3
HIGHLIGHTSp. 5
LIST OF TEMPORARY REVISIONSp. 7
LIST OF SERVICE BULLETINSp. 9
LIST OF EFFECTIVE PAGESp. 11
TABLE OF CONTENTSp. 23
+CHAPTER 01-00 – INTRODUCTIONp. 27
+Introductionp. 31
1. Generalp. 31
2. Revision Servicep. 31
3. Warning, Cautions and Notesp. 32
4. Manual Configurationp. 32
+5. Contents (Peculiarities)p. 33
A. MAIN GROUP 01, GENERALp. 33
B. MAIN GROUP 02, EQUIPMENTp. 33
C. MAIN GROUP 03, AIRFRAMEp. 33
D. MAIN GROUP 04, PROPELLERp. 33
E. MAIN GROUP 05, ENGINEp. 33
6. Chaptersp. 33
+7. Arrangement of Chaptersp. 34
A. STRUCTUREp. 34
B. CHAPTER CONTENTSp. 34
+8. Order of Pagesp. 35
A. PAGES PRECEDING THE ACTUAL MANUALp. 35
9. Illustrationsp. 35
+CHAPTER 02-00 – ORGANIZATION AND HANDLING OF THE MANUALp. 37
+Organization and Handling of the Manualp. 41
1. Generalp. 41
2. Validityp. 41
3. Revisionsp. 41
4. Temporary Revisionsp. 41
5. Record of Revisionsp. 42
6. Check Listp. 42
+7. Service Bulletinsp. 42
A. Alert Service Bulletinsp. 42
B. Service Bulletinsp. 42
8. List of Applicable Publicationsp. 42
9. Abbreviationsp. 43
+CHAPTER 03-00 – GENERAL DESCRIPTION OF THE AIRCRAFTp. 45
+General Description of the Aircraftp. 49
1. Generalp. 49
2. Descriptionp. 49
3. Vendor Documentationp. 54
+CHAPTER 04-00 – AIRWORTHINESS LIMITATIONSp. 57
+Airworthiness Limitationsp. 61
+04-10 – Limited Time Partsp. 65
+04-20 – Paint Finishp. 67
+CHAPTER 05-00 – TIME LIMITS AND MAINTENANCE CHECKSp. 69
+Time Limits and Maintenance Checksp. 73
+05-10 – Time Limitsp. 75
1. Time Limits for Equipmentp. 75
+05-20 – Scheduled Maintenance Checksp. 77
Maintenance Practicesp. 78
1. Generalp. 77
2. 50, 100, 200, and 1000 hour Inspection Checklistp. 77
+Inspection Checklist DA20-A1p. 78
1. Generalp. 78
2. Initial Test Runp. 78
3. Engine:p. 79
4. Propellerp. 83
5. Cabinp. 84
6. Structure and Control Surfacesp. 85
7. Landing Gearp. 88
8. Generalp. 89
9. Maintenance Reportp. 90
10. Maintenance Check Flight Reportp. 91
+11. 6000 Hour Inspectionp. 93
A. Types of Inspectionp. 93
B. Defect Limits for Compositesp. 94
6000 HOUR INSPECTION CHECKLIST DA20-A1 KATANAp. 95
+05-30 – General Inspectionsp. 107
1. Generalp. 107
2. Pre-Flight Inspectionp. 107
3. Post-Flight Inspectionp. 107
+4. Fuel Shut off Valve and Check Valve Inspectionp. 107
(1) Turn fuel shut off valve to CLOSED position.p. 107
(2) Ensure throttle lever is fully in Idle position.p. 107
(3) Turn ignition switch ON, fuel pressure warning light should be illuminated. If not illuminated, crank engine until fuel pressure warning light illuminates.p. 107
(4) To check that the fuel shut off valve is operating properly, switch electric fuel pump ON, fuel pressure warning light should remain illuminated.p. 108
(5) Turn fuel shut off valve to OPEN position, fuel pressure warning light should turn OFF.p. 108
(6) Visually verify, through the filler neck, that fuel is flowing through the return line into the fuel tank.p. 108
(7) To ensure check valve is operating properly, switch electric fuel pump OFF, fuel pressure warning light should not illuminate for at least one minute, visually verify no fuel is returning to the fuel tank.p. 108
+05-40 – Unscheduled Inspectionsp. 109
1. Generalp. 109
+2. Special Inspectionsp. 109
+A. Hard Landingp. 109
(1) The landing gear fittings should be inspected, using a mirror and flashlight, for defects (e.g. cracks), inspect surrounding structure for delamination.p. 109
(2) Condition of the complete nose gear assembly must be checked (cracks, deformation). Special attention must be given to the upper cross bar of the engine mount to which the nose wheel assembly is attached. Check for deformation.p. 109
(3) The top hat profile in the fuselage bottom should be inspected for white spots and delamination in the area around the bearings for the nose gear assembly.p. 109
(4) Check the nose gear assembly in the unloaded condition for excessive play in the bearings due to overloading.p. 109
(5) In addition to the landing gear, all control surfaces (hinges, balancing weights), and the complete engine mounting (engine mount, mounting points to the firewall, shock mounts, etc.) should be inspected.p. 109
B. Sudden Engine Stoppage (Prop Strike)p. 110
C. Non-Operation of more than 30 Daysp. 110
D. Replacement of Engine, Ignition, or Instrumentsp. 110
+E. Tail Impact Damage Inspectionp. 110
(1) Remove the rudder. Reference chapter 27-20-30.p. 110
(2) Examine the areas highlighted in figure 1 for cracking, delamination, dis-bonding or any other damage. Reference figure 1.p. 110
(3) If damage is found to any of the structures contact the manufacturer for repair instructions.p. 110
(4) If there is no damage, the aircraft may be re-assembled.p. 110
+CHAPTER 06-00 – DIMENSIONS AND AREASp. 113
+Dimensions and Areasp. 117
+1. Generalp. 117
A. Unit Conversionsp. 117
2. Dimensionsp. 117
3. Adjustment Values for Control Surfaces and Trimp. 118
4. Control Surface Gapsp. 121
5. Weight And Static Moments Of Control Surfacesp. 121
+CHAPTER 07-00 – LIFTING AND SHORINGp. 123
+Lifting and Shoringp. 127
1. Generalp. 127
2. Required Equipmentp. 127
+07-10 – Liftingp. 129
+07-20 – Jackingp. 131
1. Generalp. 131
2. Jacking the Airplanep. 131
3. Lowering the Airplanep. 131
+CHAPTER 08-00 – LEVELING AND WEIGHINGp. 133
+Leveling and Weighingp. 137
1. Generalp. 137
2. Levelingp. 137
3. Weighingp. 137
4. Permissible Empty Weight C.G. Rangep. 139
+CHAPTER 09-00 – TOWING AND TAXIINGp. 141
+Towing and Taxiingp. 145
1. Generalp. 145
2. Equipment and Accessoriesp. 145
+09-10 – Towingp. 147
1. Generalp. 147
+2. Towing Procedurep. 147
A. Towing without tow vehiclep. 147
B. Towing with a tow vehiclep. 147
C. Moving without Tow Barp. 148
+09-20 – Taxiingp. 149
1. Generalp. 149
+2. Taxiing Procedurep. 149
A. Remove all foreign object from the airplane area (tools, tool carts, etc.).p. 149
B. Remove chocks, mooring ropes, and tow bar if required.p. 149
C. Set parking brake by pulling the parking brake lever and operating the toe brakes.p. 149
D. Start engine (see Flight Manual DA 20 KATANA)p. 149
E. Release parking brake.p. 149
F. Check brake operation during taxiing.p. 149
G. Taxi the airplane to the desired position.p. 149
H. Turn off engine (see Flight Manual DA 20 KATANA).p. 149
I. Park the airplane and moor as required (see Chapter 10).p. 149
+CHAPTER 10-00 – PARKING AND MOORINGp. 151
+Parking, Mooring, Storage and Return to Servicep. 155
1. Generalp. 155
2. Equipment and Accessoriesp. 155
+10-10 – Parkingp. 157
1. Generalp. 157
+2. Short Term Parkingp. 157
A. Flight Control Lock Removal and Installationp. 157
3. Long Term Parkingp. 158
+10-20 – Mooringp. 159
1. Generalp. 159
2. Mooringp. 159
+10-30 – Parking Durationp. 161
+1. Parking Over 30 Daysp. 161
A. Engine Preservation and De Preservationp. 161
B. Fuel Supplyp. 161
C. Landing Gear, Wheels and Tiresp. 161
D. Electrical Systemp. 161
E. Lubricationp. 161
F. Instrumentsp. 161
G. Loose Equipmentp. 162
H. Electronic Equipmentp. 162
I. Airplane Ventilationp. 162
J. Parking and Mooringp. 162
+CHAPTER 11-00 – REQUIRED PLACARDSp. 163
+Required Placardsp. 167
1. Generalp. 167
2. Materialsp. 167
3. Removal and Installationp. 167
+11-10 – Location of Placardsp. 169
+CHAPTER 12-00 – SERVICINGp. 177
+Servicingp. 181
+12-10 – Replenishingp. 183
+1. Fuel Systemp. 183
A. Refuelingp. 183
B. Defuelingp. 183
2. Oil Systemp. 183
3. Brake Systemp. 185
4. Tiresp. 185
5. Batteryp. 186
+6. Cooling Systemp. 186
+12-20 – Scheduled Servicingp. 189
1. Fuel Systemp. 189
2. Lubrication Schedulep. 189
+12-30 – Unscheduled Servicingp. 195
1. Cleaning, Exteriorp. 195
2. Cleaning Interiorp. 195
3. Engine Cleaningp. 195
4. Snow and Ice Removalp. 196
+CHAPTER 20-00 – STANDARD PRACTICES – AIR FRAMEp. 197
+Standard Practices – Airframep. 201
1. Generalp. 201
2. Bolt and Nut Types Used in the Aircraftp. 201
+3. Standrad Torquesp. 201
A. AN Fine Thread Seriesp. 202
B. AN Coarse Thread Seriesp. 202
C. DIN Specificationsp. 202
4. Special Torquesp. 203
5. Measuring Torque Detailsp. 204
+CHAPTER 21-00 – ENVIRONMENTAL SYSTEMSp. 205
+Environmental Systemsp. 209
+21-20 – Distributionp. 211
+1. Functional Decriptionp. 211
A. Heating System and Canopy Defroster (Refer to Figure 1)p. 211
B. Ventilationp. 211
+2. Maintenance Informationp. 211
+A. Inspectionsp. 211
100 hour inspectionp. 211
200 hour inspectionp. 211
+21-40 – Heatingp. 213
1. Heat Exchanger Removalp. 213
2. Heat Exchanger Inspectionp. 213
+CHAPTER 23-00 – COMMUNICATIONSp. 215
+Communicationsp. 219
+23-10 – Speech Communication Bendix/King KX125p. 221
1. Generalp. 221
+2. System Descriptionp. 222
A. Receiver Descriptionp. 222
B. Transmitter Descriptionp. 222
C. Unit Operationp. 222
3. Troubleshootingp. 224
+4. Maintenance Informationp. 225
A. Generalp. 225
B. Removal and Installation of the Radio Unitp. 225
+CHAPTER 24-00 – ELECTRICAL POWERp. 227
+Electrical Powerp. 231
1. Generalp. 231
+2. Descriptionp. 233
A. Batteryp. 233
B. Battery Relayp. 233
C. Master Switch (Split Switch)p. 233
D. Starting Relayp. 234
E. Generator Warning Lightp. 234
F. Ammeterp. 234
G. Voltmeterp. 234
H. Electrical Barsp. 234
I. Avinoics Master Switch and Avionics Busp. 234
3. Troubleshootingp. 234
4. Maintenance Informationp. 235
+24-30 – DC Generationp. 237
1. Generalp. 237
2. Descriptionp. 239
3. Troubleshootingp. 240
+4. Removal Installationp. 240
A. Generatorp. 240
B. Overvoltage Control Relayp. 242
C. Overvoltage Sensorp. 242
5. Maintenance Informationp. 242
+24-31 – Battery Systemp. 243
1. Generalp. 243
2. Descriptionp. 243
3. Troubleshootingp. 243
4. Maintenance Informationp. 244
+5. Removal and Installationp. 245
A. Batteryp. 245
B. Master Relayp. 245
C. Ammeterp. 246
D. Master Switch (Split Switch)p. 246
6. Cleaningp. 247
+24-50 – Electric Load Distributionp. 249
1. Generalp. 249
2. Descriptionp. 251
3. Troubleshootingp. 251
4. Maintenance Informationp. 251
+5. Removal and Installationp. 252
A. Circuit Breakersp. 252
+CHAPTER 25-00 – EQUIPMENT/FURNISHINGSp. 253
+Equipment/Furnishingp. 257
+25-10 – Flight Compartmentp. 259
+1. Functional Descriptionp. 259
A. Map Packetsp. 259
B. Fire Extinguisherp. 259
C. Emergency Locator Transmitterp. 259
D. Lining of Side Panelsp. 260
E. Instrument Panel Coverp. 260
F. Center Console Coverp. 260
G. Seatsp. 260
H. Safety Beltsp. 260
+2. Removal and Installationp. 261
A. ELTp. 261
B. Instrument Panel Coverp. 261
C. Seat Shellsp. 261
D. Seat Beltsp. 262
E. Center Console Coverp. 262
+3. Cleaningp. 262
A. Seatsp. 262
B. Safety Beltsp. 262
+25-50 – Baggage Compartmentp. 263
+CHAPTER 27-00 – FLIGHT CONTROLSp. 265
+Flight Controlsp. 269
1. Generalp. 269
2. Descriptionp. 269
3. Troubleshootingp. 269
+4. Maintenance and Inspection Informationp. 269
100 hour inspectionp. 269
+27-10 – Ailerons Control Systemsp. 271
1. Generalp. 271
2. Descriptionp. 271
3. Troubleshootingp. 272
+4. Removal and Installationp. 272
A. Control Sticksp. 272
B. Aileraon Push Rods Connected to Control Sticksp. 273
C. Bellcrank Attached to the Forward Control Bulkheadp. 273
D. Push Rod in Center Consolep. 273
E. Bellcrank attached to the Aft Control Push Rodsp. 274
F. Push Rod in Wingp. 274
G. Aileron Bellcrank in Wingp. 274
H. Aileronp. 275
5. Adjustmentp. 277
+27-11 – Main Columnp. 279
1. Generalp. 279
2. Descriptionp. 279
3. Troubleshootingp. 279
+4. Removal and Installationp. 279
A. Control Sticksp. 279
B. Elevator Torque Tube Assemblyp. 279
+5. Adjustmentp. 280
+27-20 – Rudder Control Systemp. 281
1. Generalp. 281
2. Descriptionp. 281
3. Troubleshootingp. 284
+27-20-10 – Rudder Pedal Assemblyp. 285
1. Generalp. 285
2. Descriptionp. 285
+3. Removal and Installationp. 286
+27-20-20 – Rudder Controls in Fuselagep. 287
1. Generalp. 287
2. Descriptionp. 287
+3. Removal and Installationp. 287
A. Cables between the Firewall and the Rudder Leverp. 287
B. Cables between the Rudder Lever and the Rudder Lower Mounting Platep. 287
4. Adjustmentp. 288
+27-20-30 – Rudderp. 289
1. Generalp. 289
2. Descriptionp. 289
3. Removal and Installationp. 289
+4. Adjustmentp. 289
A. Rudder Deflectionp. 289
+27-30 – Elevator Control Systemp. 291
1. Generalp. 291
2. Descriptionp. 291
3. Troubleshootingp. 292
+4. Removal and Installationp. 292
A. Items (1) and (2): Control Sticks and Torque Tube Assemblyp. 292
B. Item (3): Elevator Push Rod in Control Consolep. 292
C. Item (4): Elevator Push Rod in Fuselage Tubep. 292
D. Item (6): Elevator Push Rod in Vertical Stabilizerp. 293
E. Elevatorp. 295
+5. Adjustmentp. 297
A. Items (1) + (2): Control Sticks and Torque Tube Assemblyp. 297
B. Item (3) + (4): Push Rods in Control Console and Fuselage Tubep. 297
C. Item (6): Push Rod in Vertical Stabilizerp. 297
D. Elevator Stopsp. 298
+27-40 – Elevator Trim Systemp. 299
1. Generalp. 299
2. Descriptionp. 299
3. Troubleshootingp. 300
+4. Removal and Installationp. 301
A. Rocker Switchp. 301
B. Actuating Motor (Refer to Figure 7, Item 2)p. 301
C. Spring Mount Assembly (Refer to Figure 7, Item 2)p. 302
D. Anti-Servo Tab Assemblyp. 302
5. Adjustmentp. 303
+27-50 – Wing – Flapsp. 305
1. Generalp. 305
2. Descriptionp. 305
3. Troubleshootingp. 306
+4. Removal and Installationp. 307
A. Wing Flapsp. 307
B. Bellcrank in Fuselagep. 309
C. Bellcrank in Wingp. 309
D. Push-Rodp. 310
E. Flap Actuatorp. 310
F. Current Limiterp. 312
5. Adjustmentp. 314
+CHAPTER 28-00 – FUELp. 317
+Fuelp. 321
1. Generalp. 321
+2. Descriptionp. 321
A. Fuel System Description (S/N 10002 through S/N 10092) (Refer to Fig 1)p. 321
B. Fuel System Description (S/N 10093 and subsequent) (Refer to Fig 2)p. 321
3. Fuel Shut Off Valve And Check Valve Inspection
+28-10 – Storage (Tank)p. 325
1. Generalp. 325
2. Descriptionp. 325
3. Troubleshootingp. 325
+4. Removal and Installation of the Fuel Tankp. 326
A. Removalp. 326
B. Installationp. 326
5. Leakage Testp. 326
6. Repairp. 326
+28-20 – Distributionp. 327
1. Generalp. 327
+2. System Descriptionp. 327
A. Fuel Shut Off Valvep. 327
B. Electrical Fuel Pumpp. 327
C. Mechanical Fuel Pumpp. 328
3. Troubleshootingp. 328
+4. Removal and Installationp. 329
A. Fuel Shut-Off Valvep. 329
B. Electrical Fuel Pumpp. 329
C. Maintenance of the Filter Elementp. 329
D. Mechanical Fuel Pumpp. 330
+28-40 – Indicatingp. 331
1. Generalp. 331
+2. System Descriptionp. 331
A. Fuel Quantity Indicating Systemp. 331
B. Fuel Pressure Sensorp. 331
3. Troubleshootingp. 331
+4. Removal and Installationp. 332
A. Fuel Pressure Sensorp. 332
B. Fuel Quantity Sensorp. 332
+5. Calibrationp. 333
A. Fuel Quantity indicator Adjustmentp. 333
+CHAPTER 31-00 – INDICATING/RECORDING SYSTEMSp. 335
+Indicating/Recording Systemsp. 339
+31-10 – Instrument Panelp. 341
1. Generalp. 341
2. Descriptionp. 341
+3. Removal and Installationp. 344
A. Removalp. 344
B. Installationp. 344
+CHAPTER 32-00 – LANDING GEARp. 345
+Landing Gearp. 349
1. Generalp. 349
2. Troubleshootingp. 349
3. Maintenance Informationp. 349
+32-10 – Main Landing Gearp. 351
1. Generalp. 351
2. Descriptionp. 351
3. Troubleshootingp. 351
+4. Removal and Installationp. 352
A. Main Landing Gearp. 352
+5. Adjustmentp. 354
A. Play in Wheel Bearingp. 354
B. Toe in, Camber, and Trackp. 354
+Main Landing Gearp. 355
1. Generalp. 355
2. Descriptionp. 355
3. Troubleshootingp. 357
+4. Removal and Installationp. 357
A. Generalp. 357
B. Removalp. 357
C. Installationp. 358
+5. Adjustmentp. 359
A. Equipmentp. 359
B. Procedurep. 359
+32-20 – Nose Landing Gearp. 361
1. Generalp. 361
2. Descriptionp. 361
+3. Removal and Installationp. 363
A. Nose Landing Gear Strutp. 363
B. Nose landing Gear Fork Assemblyp. 366
C. Shock Absorber Assemblyp. 367
D. Shock Absorber Assembly Elementsp. 369
+4. Adjustmentp. 374
A. Nose Wheel Steering Frictionp. 374
B. Nose Wheel Balancing
C. Nose Landing Gear Leg Lateral Free Play
+32-40 – Wheels and Brakesp. 375
1. Generalp. 375
2. Descriptionp. 375
3. Troubleshootingp. 377
+4. Removal and Installationp. 377
A. Main Wheelsp. 377
B. Nose Wheelp. 379
C. Brake Master Cylinderp. 380
D. Caliperp. 381
E. Disc Brakep. 382
F. Brake Liningsp. 382
G. Parking Brake Valvep. 383
H. Parking Brake Valvep. 384
I. Remove the Parking Brake Valve.p. 384
J. Install the Parking Brake Valvep. 384
5. Bleeding of Brake Systemp. 387
6. Adjustmentp. 388
+CHAPTER 33-00 – LIGHTSp. 389
+33-10 – Interiorp. 393
1. Generalp. 393
2. Descriptionp. 393
3. Troubleshootingp. 393
+4. Removal and Installationp. 394
+33-40 – Exteriorp. 397
1. Generalp. 397
2. Descriptionp. 397
3. Troubleshootingp. 397
+4. Removal and Installationp. 399
A. Position Light Bulbp. 399
B. ACL bulbp. 399
C. ACL Power Supplyp. 400
D. Navigation lightp. 400
E. Taxiing Lightp. 400
+CHAPTER 34-00 – NAVIGATION AND PITOT STATICp. 401
+Navigation and Pitot Staticp. 405
+34-10 – Pitot Staticp. 407
1. Generalp. 407
+2. Descriptionp. 408
A. Pitot Head/Linesp. 408
B. Drain Systemp. 408
C. Altimeterp. 409
D. Airspeed Indicatorp. 409
E. Vertical Speed Indicatorp. 410
F. Outside Air Temperature Indicatorp. 410
3. Troubleshootingp. 410
4. Maintenance Informationp. 411
+5. Removal and Installationp. 411
A. Pitot headp. 411
B. Instrumentsp. 411
C. Pitot Static Testp. 412
D. Airspeed Indicatorp. 412
E. Altimeterp. 412
F. Safety Precautions during the Testp. 412
+34-12 – Stall Warning Systemp. 413
+34-20-00 – Attitude and Directionp. 415
1. Generalp. 415
+2. Descriptionp. 415
A. Magnetic Compassp. 415
B. Turn and Slip Indicatorp. 415
C. Directional Gyrop. 415
D. Attitude Gyrop. 416
3. Troubleshootingp. 416
+4. Removal and Installationp. 417
A. Magnetic Compassp. 417
B. Turn and Slip Indicator, Directional Gyro, Attitude Gyrop. 417
5. Compass Compensationp. 417
+34-50-00 – Position Determining Systemsp. 419
+CHAPTER 51-00 – STRUCTURESp. 421
+Standard Practices and Structuresp. 425
1. Generalp. 425
2. Identification of Primary Structurep. 425
+3. Inspection Techniquesp. 426
A. Examine Visuallyp. 426
B. Light Testp. 426
C. Coin Tap Testp. 427
+51-10 – Repair of Composite Partsp. 429
+1. Approved Material, Suppliersp. 429
A. Resin and Hardnerp. 429
B. Glass Fiber Clothp. 429
C. Carbon Fiber Clothp. 429
2. Damage Classificationsp. 431
+3. Defect Limits for Compositesp. 432
A. Cracks:p. 432
B. Surface scratchesp. 432
C. Delamination and disbond from core:p. 432
D. Surface Dents:p. 433
4. Fuselage Layupp. 433
5. GFRP Repairp. 440
+6. Sandwich Repairp. 441
A. Minor Surface Damagep. 441
B. Damage to the Entire Sandwichp. 441
+7. Laminate Repairp. 442
A. Minor Damagep. 442
B. Major Damagep. 443
8. Spar Repairp. 444
9. Paintingp. 444
+51-20-00 – Repair of Metal Partsp. 445
+CHAPTER 53-00 – FUSELAGEp. 447
+Fuselagep. 451
+53-10-00 – Main Framep. 453
1. Generalp. 453
+2. Bulkheads And Stiffenersp. 453
A. Firewallp. 453
B. Floor Elementp. 453
C. Top Hat Profilep. 453
D. Forward Control Bulkheadp. 453
E. Spar Bridgep. 454
F. Aft Control Bulkheadp. 454
G. B-Bulkheadp. 454
H. Vertical Bulkheadp. 454
I. Lower Tailfin Bulkheadp. 454
J. Tailfin Web and Lower Tailfin Ribp. 454
K. Anti Flutter Bracketp. 454
+3. Paint Application Procedure for the Aircraft Belly and the Cowlingsp. 455
A. High Temperature Paint Repair of Aircraft Belly and Cowlingsp. 455
+53-11-00 – Canopyp. 459
1. Generalp. 459
2. Troubleshootingp. 460
3. Maintenance Informationp. 460
+4. Removal and Installationp. 461
A. Canopy, Completep. 461
B. Emergency Windowsp. 461
+53-31-00 – Inspection Holesp. 463
1. Generalp. 463
2. Descriptionp. 463
+CHAPTER 55-00 – STABILIZERSp. 465
+Stabilizersp. 469
+55-10 – Horizontal Stabilizerp. 471
1. Generalp. 471
2. Descriptionp. 471
+3. Removal and Installationp. 471
A. Horizontal Stabilizerp. 471
+55-20-00 – Elevatorp. 473
1. Generalp. 473
2. Descriptionp. 473
+3. Remove/Install the Elevatorp. 473
A. Remove the Elevatorp. 473
B. Install the Elevatorp. 474
+55-30-00 – Rudderp. 477
1. Generalp. 477
2. Descriptionp. 477
3. Removal and Installationp. 477
+CHAPTER 57-00 – WINGSp. 479
+Wingsp. 483
+57-10 – Wing Structurep. 485
1. Generalp. 485
2. Descriptionp. 485
+3. Removal and Installationp. 485
+4. Bolt Playp. 489
A. Radial Playp. 489
B. Axial Playp. 489
+57-50 – Wing Flapsp. 491
1. Generalp. 491
2. Descriptionp. 491
3. Removal and Installationp. 491
+57-60 – Aileronsp. 493
1. Generalp. 493
2. Descriptionp. 493
3. Removal and Installationp. 493
+CHAPTER 61-00 – PROPELLERp. 495
+Propellerp. 499
1. Generalp. 499
+2. Descriptionp. 499
A. Hub Assemblyp. 499
B. Blade Assemblyp. 499
C. Spinner Assemblyp. 500
3. Troubleshootingp. 500
4. Installation Procedurep. 502
5. Minor Repairsp. 503
+CHAPTER 71-00 – POWER PLANT (ENGINE)p. 505
+Power Plantp. 509
1. Generalp. 509
+2. Descriptionp. 510
A. Engine Specificationsp. 510
B. Starterp. 512
C. Generatorp. 512
D. Ignition Systemp. 512
E. Air Distribution Boxp. 512
F. Carburetorsp. 512
G. Reduction Gearp. 512
H. Spark plugsp. 513
3. Troubleshootingp. 513
+4. Removal and Installationp. 518
A. Enginep. 518
B. Carburetorp. 519
+5. Maintenance Informationp. 519
A. Carburetor Synchronizationp. 519
B. Reduction Gear Checksp. 520
C. Propeller Flange Checkp. 521
+71-10 – Cowlingp. 523
1. Generalp. 523
+2. Remove/Install the Cowlingsp. 523
A. Remove the Cowlingsp. 523
B. Install the Cowlingsp. 523
3. High Temperature Paint Repair of a Cowlingp. 524
+71-20 – Mountsp. 529
1. Generalp. 529
2. Descriptionp. 529
+3. Removal and Installationp. 529
A. Removal from the Firewallp. 529
B. Installationp. 529
+71-60 – Air Intakes and Guidesp. 531
1. Generalp. 531
2. Descriptionp. 531
+3. Removal and Installationp. 531
A. Removalp. 531
B. Installationp. 531
+CHAPTER 75-00 – ENGINE COOLINGp. 533
+75-10 – Engine Coolingp. 537
1. Generalp. 537
2. Replenishingp. 539
+3. Removal and Installationp. 539
A. Dispatcher Vesselp. 539
B. Radiatorp. 539
C. Equalizing Reservoirp. 539
D. Water Pumpp. 540
+CHAPTER 76-00 – ENGINE CONTROLSp. 541
+76-10 – Engine Controlsp. 545
1. Generalp. 545
+2. Descriptionp. 545
A. Throttlep. 545
B. Chokep. 545
C. Carburetor Heatp. 546
D. Propeller Speed Controlp. 546
E. Throttle Quadrant Friction Controlp. 546
3. Troubleshootingp. 546
+4. Removal and Installation, Adjustmentp. 547
A. Throttle Control Bowden Cablesp. 547
B. Throttle Control Cablesp. 547
C. Choke Bowden Cablesp. 552
D. Carburetor Heat Bowden Cablep. 553
E. Propeller Speed Control Bowden Cablep. 554
F. Throttle Quadrant Friction Controlp. 555
+CHAPTER 77-00 – ENGINE INDICATINGp. 557
+Engine Indicatingp. 561
1. Generalp. 561
+2. Descriptionp. 561
A. RPM Indicatorp. 561
B. Fuel Pressure Warning Lightp. 561
C. Oil Pressure Indicatorp. 561
D. Oil Temperature Indicatorp. 561
E. Cylinder Head Temperature Indicatorp. 561
F. Manifold Pressure Indicatorp. 562
3. Troubleshootingp. 562
+4. Removal and Installationp. 563
A. RPM Indicatorp. 563
B. Fuel Pressure Warning Lightp. 563
C. Oil Pressure Indicatorp. 564
D. Oil Temperature Indicatorp. 564
E. Cylinder Head Temperature Indicatorp. 564
F. Manifold Pressure Indicator
+CHAPTER 78-00 – EXHAUSTp. 565
+Exhaustp. 569
1. Generalp. 569
2. Descriptionp. 570
3. Troubleshootingp. 570
+4. Removal and Installationp. 570
A. Removalp. 570
B. Installationp. 570
5. Inspection of Exhaust Systemp. 571
6. Inspection of Heat Exchangerp. 571
+CHAPTER 79-00 – OIL SYSTEMSp. 573
+Oil Systemsp. 577
1. Generalp. 577
2. Descriptionp. 577
+79-21 – Oil Radiatorp. 579
1. Generalp. 579
2. Troubleshootingp. 579
+3. Removal and Installationp. 579
+79-30 – Indicatingp. 581
+1. Generalp. 581
A. Oil Temperature Sensorp. 581
B. Oil Pressure Sensorp. 581
2. Troubleshootingp. 581
+3. Removal and Installationp. 582
A. Oil Temperature Sensorp. 582
B. Oil Pressure Sensorp. 583
C. Oil Pressure Sensorp. 584
+CHAPTER 92-00 – WIRING DIAGRAMSp. 587
Untitledp. 53
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