Description
Diamond DA42 L360 Aircraft Maintenance Manual Supplement – D42L-AMM-001 Rev 5 (2012)
File Details
- Manual Type: Aircraft Maintenance Manual (Supplement)
- Document Number: D42L-AMM-001
- Revision: 5
- Publication Date: October 2012
- Language: English
- Page Count: 648 Pages
- Format: PDF
- Applicability: Diamond DA42 L360 aircraft modified under TCCA STC No. SA09-54 (FAA STC No. SA02725NY) with Lycoming IO-360-M1A (LH) and LIO-360-M1A (RH) engines.
The Diamond DA42 L360 Aircraft Maintenance Manual Supplement – D42L-AMM-001 Rev 5 (2012) is the definitive maintenance guide for the Lycoming-powered DA42 L360. This supplement provides all necessary instructions for the systems and components altered by the Supplemental Type Certificate (STC) No. SA09-54. It must be used in conjunction with the original DA42 TDI AMM (Document Number 7.02.01) for complete aircraft coverage.
Chapters Covered
This supplement focuses exclusively on the modifications introduced by the Lycoming STC. The following chapters contain data specific to the DA42 L360:
- Chapter 03-00: General Description of the Aircraft (STC-specific changes)
- Chapter 04-00: Airworthiness Limitations (Mandatory inspections for new components)
- Chapter 05-00: Time Limits and Maintenance Checks (25, 50, 100, 200, 1000, 2000-hour checks)
- Chapter 06-00: Dimensions and Areas (Adjustment report data)
- Chapter 11-00: Placards and Markings (Interior and exterior placards)
- Chapter 12-00: Servicing (Fuel, oil, and lubrication schedules)
- Chapter 20-00: Standard Practices (Torque values for AN, DIN, and LN fasteners)
- Chapter 24-00: Electrical Power (DC Generation, alternator, voltage regulator, battery)
- Chapter 25-00: Equipment and Furnishings (Ballast installation)
- Chapter 27-00: Flight Controls (Rudder, elevator, flaps, variable elevator stop system)
- Chapter 28-00: Fuel (Distribution, gascolator, booster pump, cross-feed)
- Chapter 30-00: Ice Protection System (Propeller de-icing)
- Chapter 31-00: Indicating Systems (G1000 integrated cockpit, GEA 71)
- Chapter 32-00: Landing Gear (Position and warning micro-switch rigging)
- Chapter 51-00: Standard Practices – Structures (Electrical bonding system)
- Chapter 55-00: Stabilizers (Rudder trim seal)
- Chapter 61-00: Propeller (MT three-blade propeller, governor, accumulator)
- Chapter 71-00: Power Plant (Engine removal/installation, cowling, mounts, air intakes, drains)
- Chapter 72-00: Engine (Lycoming IO-360 M1A / LIO-360 M1A description)
- Chapter 73-00: Engine Fuel and Control (Fuel injector, flow divider, nozzles)
- Chapter 74-00: Ignition (Dual magnetos, SlickSTART booster, ignition switch)
- Chapter 75-00: Air (Cooling baffle assembly)
- Chapter 76-00: Engine Controls (Throttle and mixture Bowden cables)
- Chapter 77-00: Engine Indicating (Sensors for EGT, CHT, oil pressure, fuel pressure, etc.)
- Chapter 78-00: Exhaust (Power Flow Systems exhaust, heat exchanger)
- Chapter 79-00: Oil (Oil cooler, NACA duct)
- Chapter 80-00: Starting (Starter relay, Sky-Tech starter)
- Chapter 92-00: Wiring Diagrams (Full schematics for the modified electrical system)
Complete PDF Bookmark Tree
Complete Bookmarks
The complete bookmarks in the “Diamond DA42 L360 Aircraft Maintenance Manual Supplement – D42L-AMM-001 Rev 5 (2012) PDF” are as follows:
+DA42 L360 – AIRCRAFT MAINTENANCE MANUALp. 1
+FRONT MATTERp. 23
Record of Revisionsp. 3
Highlightsp. 5
List of Service Bulletinsp. 7
List of Temporary Revisionsp. 9
List of Effective Pagesp. 11
Table of Contentsp. 23
+CHAPTER 01-00 – INTRODUCTIONp. 25
+Introductionp. 29
1. Generalp. 29
2. Revision Servicep. 29
3. Warning, Cautions and Notesp. 29
+4. Manual Configurationp. 30
A. The ATA iSpec2200 Numbering Systemp. 30
B. Groups of Chaptersp. 31
5. Chapter Configurationp. 32
6. Page Numbering Systemp. 33
7. Figuresp. 33
8. Record of Revisionsp. 33
9. List of Effective Pagesp. 33
+CHAPTER 03-00 – GENERAL DESCRIPTION OF THE AIRCRAFTp. 35
+General Description of the Aircraftp. 39
1. Generalp. 39
2. Descriptionp. 39
3. Equipment Datap. 39
4. Handling of Identification Datap. 41
+CHAPTER 04-00 – AIRWORTHINESS LIMITATIONSp. 43
+Airworthiness Limitationsp. 47
+1. Airworthiness Limitationsp. 49
A. Certification Maintenance Requirementsp. 49
B. Replacement Requirementsp. 50
2. Continued Airworthinessp. 50
+CHAPTER 05-00 – TIME LIMITS AND MAINTENANCE CHECKSp. 51
+05-10 – Time Limitsp. 55
1. Generalp. 55
2. Regulatory Authoritiesp. 55
3. Scheduled Maintenance Time Limitsp. 55
+4. Component Time Limitsp. 56
A. Maintenance Requirementsp. 56
B. Aircraft Life-Limited Componentsp. 58
C. Life-Limited Componentsp. 58
5. Component TIme Trackingp. 56
+05-20 – Scheduled Maintenance Checksp. 59
1. Generalp. 59
2. Maintenance Checklistp. 59
+05-20 – Scheduled Maintenance Checks – Maintenance Practicesp. 61
1. Generalp. 61
2. Preparationp. 61
3. Engine Ground Testp. 62
+4. Maintenance of Checklist Zonesp. 63
A. Engine Compartmentsp. 63
B. Propellerp. 73
C. Fuselage Nosep. 74
D. Flight Control System in Cabinp. 76
E. Miscellaneous Items in Nacellesp. 76
F. Generalp. 76
5. Engine Ground Test Recordp. 77
+CHAPTER 06-00 – DIMENSIONS AND AREASp. 79
+Dimensions and Areasp. 83
1. Generalp. 83
2. Dimensionsp. 83
3. Adjustment Reportp. 83
+CHAPTER 11-00 – PLACARDS AND MARKINGSp. 87
+Description and Operationp. 91
1. Generalp. 91
+2. Replace Plastic Placardsp. 91
A. Materialp. 91
B. Replace a Placardp. 91
+11-20 Exterior Placards and Markingsp. 93
+11-30 Interior Placards and Markingsp. 95
1. Generalp. 95
2. Descriptionp. 95
+Maintenance Practicesp. 101
1. Generalp. 101
2. Replace a Placard Panelp. 101
+CHAPTER 12-00 – SERVICINGp. 103
+servicingp. 107
+12-10 – Replenishingp. 109
1. Generalp. 109
+2. Fuel Systemp. 109
A. Refuelingp. 110
B. Defuelingp. 110
+3. Fuel Contamination Testp. 111
A. Equipmentp. 111
B. Fuel Contamination Test Procedurep. 111
+4. Engine Oil Systemp. 112
A. Replenish the Oil Systemp. 112
B. Change the Engine Oilp. 113
+12-20 – Scheduled Servicingp. 117
1. Generalp. 117
2. Lubrication Schedulep. 118
+CHAPTER 20-00 – STANDARD PRACTICESp. 121
+20-10 – Standard Practices – Airframep. 125
1. Generalp. 125
+2. Bolt and Nut Types Used in the Aircraftp. 125
A. DIN Boltp. 125
B. LN Boltsp. 125
C. AN Boltsp. 126
+3. Standard Torque Valuesp. 126
A. AN Fine Threadsp. 126
B. AN Coarse Thread Seriesp. 127
C. DIN and LN Specificationsp. 127
4. Special Torque Valuesp. 127
5. Torque Measurementp. 128
+20-70 – Enginesp. 129
1. Generalp. 129
2. Torque Valuesp. 129
3. Special Torque Proceduresp. 131
+CHAPTER 24-00 – ELECTRICAL POWERp. 133
+Description and Operationp. 137
1. Generalp. 137
+2. Electrical System Description and Operationp. 137
A. Power Suppliesp. 137
B. Power Supply Controlp. 138
+24-30 – DC Generationp. 143
+1. Generalp. 143
+2. Description and Operationp. 143
A. Alternatorsp. 143
B. Alternator Switchesp. 143
C. Alternator Current Sensorsp. 143
D. Voltage Regulatorsp. 143
+Troubleshootingp. 145
+Maintenance Practicesp. 147
1. Generalp. 147
2. Electrical Safetyp. 147
3. Adjust an Alternator Drive Belt Tensionp. 147
+4. Remove/Install an Alternatorp. 149
A. Remove an Alternatorp. 149
B. Install an Alternatorp. 150
+5. Remove/Install a Voltage Regulatorp. 151
A. Remove a Voltage Regulatorp. 151
B. Install a Voltage Regulatorp. 152
6. Test an Alternatorp. 152
7. Voltage Regulator (VR2000) Shunt paralleling Paralleling Procedurep. 153
+8. Removal/Installation of EMI Filterp. 154
A. Remove the EMI Filterp. 154
B. Install the EMI Filterp. 157
+24-31 – Battery Systemsp. 159
1. Generalp. 159
2. Main Battery Description and Operationp. 159
+Troubleshootingp. 161
+CHAPTER 25-00 – EQUIPMENT AND FURNISHINGSp. 163
+Nose Forward ballast – Description and Operationp. 167
+Nose Forward Ballast – Maintenance Practicesp. 169
1. Generalp. 169
+2. Remove/Install the Ballast Plate Assemblies and Clampsp. 169
A. Remove the Ballast Plate Assembly and Clampp. 169
B. Install the Ballast Base Plate Assembly and Clampp. 170
+CHAPTER 27-00 – FLIGHT CONTROLSp. 173
+27-20 – Flight Controls – Rudderp. 177
1. Generalp. 177
2. Descriptionp. 177
3. Operationp. 178
+Maintenance Practicesp. 183
1. Generalp. 183
+2. Rudder Control System Test for Correct Range of Movementp. 183
A. Equipmentp. 183
B. Rudder Control Test Procedurep. 183
+3. Rudder Control System Adjustmentsp. 184
A. Equipmentp. 184
B. Rudder Control Adjustment Procedurep. 185
+4. Remove/Install the Rudder Control Cablesp. 187
A. Equipmentp. 187
B. Remove the Cockpit Rudder Control Cables (Front Cables)p. 187
C. Install the Rudder Control Cables (Front Cables)p. 188
D. Remove the Fuselage Rudder Control Cables (Rear Cables)p. 190
E. Install the Fuselage Rudder Control Cables (Rear Cables)p. 191
+5. Rudder System Control Forces Testp. 193
A. Equipmentp. 193
B. Test Procedurep. 193
6. Rudder Control Cable and Yoke Accessp. 194
+27-21 – Flight Controls – Rudder Trimp. 203
1. Generalp. 203
+Maintenance Practicesp. 205
1. Generalp. 205
2. Rudder Trim Damper Friction Force – Test and Adjustmentp. 205
+3. Rudder Trim Rigging Procedurep. 206
A. Equipmentp. 206
B. Rudder Trim Rigging Procedurep. 206
+27-30 Flight Controls – Elevatorp. 215
1. Generalp. 215
2. Descriptionp. 215
3. Operationp. 215
+Maintenance Practicesp. 217
1. Generalp. 217
+2. Elevator Control System Test for Correct Range of Movementp. 217
A. Equipmentp. 217
B. Elevator Control Test Procedurep. 217
+3. Elevator Control System Adjustmentsp. 219
A. Equipmentp. 219
B. Elevator Control Adjustment Procedurep. 219
C. Elevator Angle Limits Tablep. 220
+4. Remove/Install the Variable Elevator Stop Assemblyp. 220
A. Remove the Variable Elevator Stop Assemblyp. 220
B. Install the Variable Elevator Stop Assemblyp. 221
+5. Test/Adjust the Variable Elevator Stopp. 222
A. Equipmentp. 222
B. Variable Elevator Stop Test/Adjustment Procedurep. 222
6. Operational Test of the Variable Elevator Stopp. 223
7. Operational Test of the STICK LIMIT Caution Messagep. 224
8. Rigging Procedure for the Elevator Variable Stop Micro Switchp. 225
9. Elevator Pushrod Accessp. 227
10. Elevator Bellcrank and Lever Accessp. 227
+27-50-00 – Flaps – Maintenance Practicesp. 235
1. Generalp. 235
2. Replacement of Flap and Landing Gear Indication Lights Lampp. 235
+CHAPTER 28-00 – FUELp. 237
+Description and Operationp. 241
1. Generalp. 241
2. Descriptionp. 241
+3. Operationp. 241
A. Electrical Boost Pumpp. 241
+28-20 – Fuel Distribution – Description and Operationp. 245
1. Generalp. 245
+2. Fuel Distribution System Componentsp. 245
A. Fuel Gascolator and Sediment Bowlp. 245
B. Fuel Booster Pumpp. 245
Troubleshootingp. 247
+Maintenance Practicesp. 249
1. Generalp. 249
+2. Clean/Examine a Fuel Sediment Bowlp. 249
A. Remove and Examine the Fuel Sediment Bowlp. 249
B. Install the Fuel Sediment Bowlp. 250
3. Replace a Gascolator Filterp. 251
+4. Remove/Install a Fuel Booster Pumpp. 251
A. Remove a Fuel Booster Pump.p. 251
B. Install the Fuel Booster Pumpp. 253
5. Replace Gascolator Assemblyp. 255
+6. Remove/Install the FUEL PUMP Switch (Pre-SB D42L-28-01)p. 256
A. Remove the FUEL PUMP Switchp. 256
B. Install the FUEL PUMP Switchp. 256
+7. Remove/Install the Illuminated FUEL PUMP Switch and the Current Monitor (Post-SB D42L-28-01 – Optional Installation)p. 257
A. Remove the Illuminated FUEL PUMP Switch and the Current Monitorp. 257
B. Install the Illuminated FUEL PUMP Switch and the Current Monitorp. 257
8. Functional Test of the Fuel Pumps and the Operational Test of the Fuel Indication Failure Switchp. 258
+CHAPTER 30-00 – ICE PROTECTION SYSTEMp. 265
+Description and Operationp. 269
1. Generalp. 269
2. Descriptionp. 269
3. Operationp. 270
+CHAPTER 31-00 – INDICATING SYSTEMSp. 273
+Decription and Operationp. 277
+31-10 – Instrument and Control Panels – Description and Operationp. 279
1. Generalp. 279
2. Instrument Panel Descriptionp. 279
3. Center Console Descriptionp. 280
+31-40 – Central Computers – Description and Operations
+Central Computer – Maintenance Practicesp. 285
1. Generalp. 285
+2. Remove/Install the GEA 71 Processorp. 285
A. Remove the GEA 71 Processorp. 285
B. Install the GEA 71 Processorp. 285
+3. G1000 System Software Load Procedurep. 286
A. G1000 Hardware/Software Compatibility Checkp. 286
B. Software Load Procedurep. 286
+CHAPTER 32-00 – LANDING GEARp. 289
+32-60 – Position and Warning – Description and Operationp. 293
1. Generalp. 293
+Position and Warning – Maintnance Practicesp. 295
1. Generalp. 295
2. Rigging Procedure for the Landing Gear Warning Micro Switchp. 295
+CHAPTER 51-00 – STANDARD PRACTICES – STRUCTURESp. 301
+51-80 – Electrical Bonding – Description and Operationp. 305
1. Generalp. 305
2. Descriptionp. 305
+Electrical Bonding – Maintenance Practicesp. 307
1. Generalp. 307
+2. Test the Electrical Bonding Systemp. 307
A. Very Low Resistance Measurementsp. 307
B. Low Resistance Measurementsp. 311
C. High Resistance Measurementsp. 311
+CHAPTER 55-00 – STABILIZERSp. 313
+55-40-00 – Rudder and Trim Tab – Description and Operationp. 317
1. Generalp. 317
+Maintenance Practicesp. 319
1. Generalp. 319
+2. Remove/Install the Rudder Trim Sealp. 319
A. Remove the Rudder Trim Sealp. 319
B. Install the Rudder Trim Sealp. 319
+CHAPTER 61-00 – PROPELLERp. 321
+Description and Operationp. 325
+61-10 – Propeller Assembly – Description and Operationp. 327
1. Generalp. 327
+2. Description and Operation of MT Propellerp. 327
A. Descriptionp. 327
B. Operationp. 327
+Troubleshootingp. 331
+Maintenance Practicesp. 333
1. Generalp. 333
+2. Remove/Install the MT Propellerp. 333
A. Remove the Propellerp. 333
B. Install the Propellerp. 334
+3. Propeller Blade Tracking Testp. 336
A. Equipmentp. 336
B. Procedurep. 336
+61-20 – Propeller Control – Description and Operationp. 339
1. Generalp. 339
+2. Description and Operationp. 339
A. Propeller Governorp. 339
B. Hydraulic Accumulatorp. 340
+Troubleshootingp. 343
+Propeller Control – Maintenance Practicesp. 345
1. Generalp. 345
+2. Remove/Install the Propeller Governorp. 345
A. Remove the Propeller Governorp. 345
B. Install the Propeller Governorp. 346
+3. Remove/Install the Propeller Un-Feathering Accumulatorp. 348
A. Remove the Propeller Un-Feathering Accumulatorp. 348
B. Install the Propeller Un-Feathering Accumulatorp. 349
C. Charging the Accumulator with Nitrogenp. 350
4. Functional Test of the Propeller Un-Featheringp. 351
5. Rigging Procedure for Propeller Control Micro Switchp. 353
+CHAPTER 71-00 – POWER PLANTp. 361
+Description and Operationp. 367
1. Generalp. 367
+2. Description and Operationp. 368
A. Cowlingsp. 368
B. Engine Mountsp. 368
C. Electrical Harnessp. 368
D. Air Intakesp. 368
E. Drainsp. 369
3. Engine Specificationp. 369
+Troubleshootingp. 373
+Power Plant – Maintenance Practicesp. 375
1. Generalp. 375
+2. Remove the Engine (Without the Engine Mount)p. 375
A. Equipmentp. 375
B. Remove the Engine (Without the Engine Mount)p. 376
+3. Install the Engine (Without the Engine Mount)p. 382
A. Preparationp. 382
B. Install the Enginep. 383
+4. Engine Test – Generalp. 390
A. Equipmentp. 390
B. Preparationp. 390
5. Engine Startingp. 391
+6. Measure/Adjust Engine Parametersp. 393
A. Measure Engine Performancep. 393
B. Adjust an Engine Idle Speedp. 396
C. Adjust the Engine Mixture Controlp. 397
7. Engine Shut Downp. 398
8. After Engine Shut Downp. 398
9. Engine Break-In Procedurep. 399
+71-10-00 – Cowling – Description and Operationp. 405
1. Generalp. 405
2. Descriptionp. 405
+Troubleshootingp. 409
+Cowling – Maintenance Practicesp. 411
1. Generalp. 411
+2. Remove/Install the Engine Cowlingsp. 411
A. Remove the Engine Top Cowlingp. 411
B. Remove the Bottom Cowlingp. 412
C. Install the Bottom Cowlingp. 412
D. Install the Engine Top Cowlingp. 413
+3. Remove/Install the Winter Kit bafflesp. 414
A. Install the Winter Kit bafflesp. 414
B. Remove the Winter Kit bafflesp. 414
+4. Cleaning and Paintingp. 415
A. Clean the Cowlingsp. 415
B. Paint the inside of the Cowlingsp. 415
+71-20 – Engine Mounting – Description and Operationp. 417
1. Generalp. 417
+Troubleshootingp. 419
+Maintenance Practicesp. 421
1. Generalp. 421
+2. Remove/Install an Engine Mountp. 421
A. Equipmentp. 421
B. Remove an Engine Mountp. 421
C. Install an Engine Mountp. 422
+71-50 – Electrical Cables in the Engine Compartment – Description and Operationp. 423
1. Generalp. 423
2. Descriptionp. 423
+71-60 – Air Intakes – Description and Opeartionp. 427
1. Generalp. 427
+2. Descriptionp. 427
A. Alternate Air Assemblyp. 427
B. Air Filter Housingp. 427
C. Air Filterp. 427
D. Alternate Air Valve Operating Cablesp. 427
3. Operationp. 428
+Troubleshootingp. 431
+Maintenance Practicesp. 433
1. Generalp. 433
+2. Remove/Install an Air Filterp. 433
A. Remove an Air Filterp. 433
B. Install an Air Filterp. 434
+3. Remove/Install an Alternate Air Valvep. 434
A. Remove an Alternate Air Valvep. 434
B. Install an Alternate Air Valvep. 435
+4. Remove/Install an Alternate Air Control Inner Cablep. 436
A. Remove an Alternate Air Control Forward Inner Cablep. 436
B. Install an Alternate Air Control Forward Inner Cablep. 438
C. Remove an Alternate Air Control Forward Left/Right-Cablep. 439
D. Install an Alternate Air Control Forward Left/Right-Cablep. 440
+5. Adjust an Alternate Air Valve Control Cablep. 441
A. Adjust the Alternate Air Valve Forward Control Cablep. 441
B. Adjust a Left/Right Engine Alternate Air Valve Control Cablep. 442
+71-70 – Engine Drains – Description and Operationp. 445
1. Generalp. 445
+2. Descriptionp. 445
A. Engine Driven Fuel Pumpp. 445
B. Fuel Distributor Drainp. 445
C. Induction Manifold Drainp. 445
+3. Operationp. 446
+A. Engine Driven Fuel Pump Drainp. 446
(1) Fuel Distributor Drainp. 446
(2) Induction Manifold Drainp. 446
+Troubleshootingp. 449
+Maintenance Practicesp. 451
1. Generalp. 451
+2. Remove/Install the Engine Driven Fuel Pump Drainp. 451
A. Remove the Engine Driven Fuel Pump Drainp. 451
B. Install the Engine Driven Fuel Pump Drainp. 451
+3. Remove/Install Fuel Flow Divider Drainp. 452
A. Remove the Fuel Flow Divider Drainp. 452
B. Install the Fuel Flow Divider Drainp. 452
+4. Remove/Install the Induction Manifold Drainp. 453
A. Remove the Induction Manifold Drainp. 453
B. Install the Induction Manifold Drainp. 453
+CHAPTER 72-00 – ENGINEp. 455
+Description and Operationp. 459
1. Generalp. 459
+2. Descriptionp. 459
A. Crankcasep. 459
B. Crankshaftp. 459
C. Camshaftp. 459
D. Connecting Rodsp. 459
E. Flywheelp. 460
F. Cylinder Assemblyp. 460
G. Accessory Housingp. 460
+Troubleshootingp. 463
+Engine – Maintenance Practicesp. 465
1. Generalp. 465
+2. Cylinder Compression Testp. 465
A. Equipmentp. 465
B. Compression Testp. 465
+CHAPTER 73-00 – ENGINE FUEL AND CONTROLp. 469
+Description and Operationp. 473
1. Generalp. 473
+2. Description and Operationp. 473
A. Engine Driven Fuel Pumpp. 473
B. Fuel Injectorp. 473
C. Fuel Flow Dividerp. 474
D. Injector Nozzlesp. 474
E. Fuel Flow Indicatorp. 474
F. Fuel Pressure Indicatorp. 475
G. Manifold Pressure Indicatorp. 475
H. Air Filter Assemblyp. 475
+Troubleshootingp. 477
+Maintenance Practicesp. 479
1. Generalp. 479
+2. Remove/Install the Fuel Injectorp. 479
A. Remove the Fuel Injectorp. 479
B. Install the Fuel Injectorp. 480
+CHAPTER 74-00 – IGNITIONp. 485
+Description and Operationp. 489
1. Generalp. 489
2. Descriptionp. 489
+3. Ignition System Componentsp. 490
A. Ignition Switchp. 490
B. Ignition Switch Cablesp. 490
C. Start Boosterp. 491
D. Magnetosp. 491
E. High-Tension Cables (Ignition Harness)p. 491
+4. Operationp. 492
A. Ignition Switch to OFF:p. 492
B. Ignition Switch to R:p. 492
C. Ignition Switch to L:p. 492
D. Ignition Switch to BOTH:p. 492
E. Ignition Switch is Set to START:p. 493
+Troubleshootingp. 495
+Maintenance Practicesp. 497
1. Generalp. 497
+2. Remove/Install an Engine Ignition Switchp. 497
A. Remove an Engine Ignition Switchp. 497
B. Install an Engine Ignition Switchp. 498
+3. Remove/Install a Start Booster Control Unitp. 499
A. Remove a Start Booster Control Unitp. 499
B. Install a Start Booster Control Unitp. 500
+CHAPTER 75-00 – AIRp. 503
+Description and Operationp. 507
1. Generalp. 507
2. Descriptionp. 507
+Maintenance Practicesp. 509
1. Generalp. 509
+2. Remove/Install a Component of the Baffle Assemblyp. 509
A. Remove the Left Front Bafflep. 509
B. Remove the Left Rear Bafflep. 510
C. Remove the Right Front Bafflep. 512
D. Remove the Right Rear Bafflep. 513
E. Install the Right Rear Bafflep. 514
F. Install the Right Front Bafflep. 516
G. Install the Left Rear Bafflep. 516
H. Install the Left Front Bafflep. 517
+CHAPTER 76-00 – ENGINE CONTROLSp. 519
+Description and Operationp. 523
1. Generalp. 523
+2. Description and Operationp. 523
A. Friction Adjusterp. 523
B. Throttlep. 523
C. Mixture Controlp. 524
+Troubleshootingp. 529
+Maintenance Practicesp. 531
1. Generalp. 531
+2. Remove/Install a Throttle Control Bowden Cablep. 531
A. Remove a Throttle Control Bowden Cablep. 531
B. Install a Throttle Control Bowden Cablep. 534
+3. Remove/Install a Mixture Control Bowden Cablep. 537
A. Remove a Mixture Control Bowden Cablep. 537
B. Install a Mixture Control Bowden Cablep. 540
+4. Throttle/Mixture Control Range of Movement Testp. 543
A. Throttle Control Range of Movement Testp. 543
B. Mixture Control Range of Movement Testp. 545
+CHAPTER 77-00 – ENGINE INDICATING SYSTEMSp. 549
+Description and Operationp. 553
1. Generalp. 553
2. Description and Operationp. 553
+77-40 – Engine Indicating System – Description and Operationp. 555
1. Generalp. 555
+2. Description and Operationp. 555
A. Transducers and Sensorsp. 556
+Troubleshootingp. 557
+Maintenance Practicesp. 559
1. Generalp. 559
2. Replace an Oil Temperature Sensorp. 559
3. Replace the Fuel Flow Sensorp. 561
4. Replace a Cylinder Head Temperature Probep. 563
5. Replace an Exhaust Gas Temperature Probep. 564
6. Replace an Oil Pressure Transducerp. 565
7. Replace a Fuel Pressure Transducerp. 567
8. Replace a Manifold Pressure Transducerp. 569
+CHAPTER 78-00 – EXHAUSTp. 579
+Description and Operationp. 583
1. Generalp. 583
2. Descriptionp. 583
3. Operationp. 583
+Troubleshootingp. 585
+Maintenance Practicesp. 587
1. Generalp. 587
+2. Remove/Install an Engine Exhaust Systemp. 587
A. Remove an Engine Exhaust Systemp. 587
B. Install an Engine Exhaust Systemp. 588
C. Inspection of the Exhaust Systemp. 590
D. Pressure Test the Engine Exhaust Systemp. 591
+CHAPTER 79-00 – OILp. 593
+Description and Operationp. 597
1. Generalp. 597
2. Engine Oil Systemp. 597
3. Oil Cooler NACA Ductp. 597
+Troubleshootingp. 599
+Maintenance Practicesp. 601
1. Generalp. 601
+2. Remove/Install an Engine Oil Coolerp. 601
A. Remove an Engine Oil Coolerp. 601
B. Install an Oil Coolerp. 602
+CHAPTER 80-00 – STARTINGp. 603
+Description and Operationp. 607
1. Generalp. 607
+2. Descriptionp. 607
A. Elect Master Switchp. 607
B. Ignition Switchesp. 607
C. Start Relaysp. 607
D. Starter Motorp. 608
E. Starter Power ON Captionp. 608
F. Wiresp. 608
3. Operationp. 608
+Troubleshootingp. 611
+Maintenance Practicesp. 613
1. Generalp. 613
+2. Remove/Install an Engine Start Relayp. 613
A. Remove an Engine Start Relayp. 613
B. Install an Engine Starter Relayp. 614
+3. Remove/Install an Engine Starterp. 614
A. Remove an Engine Starterp. 614
B. Install an Engine Starterp. 615
+CHAPTER 92-00 – WIRING DIAGRAMSp. 619
This Diamond DA42 L360 Aircraft Maintenance Manual Supplement gives a licensed A&P mechanic or maintenance organization all the data required to maintain the Lycoming IO-360 engine installation. It includes detailed removal/installation steps for major components like the engine, propeller, fuel pumps, alternator, and starter. Step-by-step procedures cover system adjustments, rigging checks, and functional tests. Comprehensive wiring diagrams (Chapter 92) and electrical schematics support accurate troubleshooting of the G1000 avionics and aircraft systems.
The supplement lists all mandatory Service Bulletins and Temporary Revisions applicable to the DA42 L360, ensuring your maintenance records remain current. It provides torque tables for AN, DIN, and LN fasteners, engine-specific torque values, and the airworthiness limitations required by TCCA and FAA regulations (Secs. 43.16 and 91.403). With this manual, you can confidently perform everything from a 25-hour engine check to a 2000-hour structural inspection.
Why This Manual Is Essential
This Diamond DA42 L360 AMM Supplement is not a generic manual; it is the specific document required to maintain the STC-modified aircraft. Without it, you lack the correct procedures for the Lycoming engines, the MT propellers, the revised fuel and ignition systems, and the unique variable elevator stop. This manual protects your aircraft’s airworthiness, ensures compliance with all mandatory inspections, and provides the precision required for safe aircraft operation.
Instant PDF Delivery
Your purchase provides a single, high-quality PDF file exactly as published by Diamond Aircraft Industries. Download it immediately after payment, view it on any computer, tablet, or smartphone, and print specific sections for use in the hangar or workshop. No physical shipping, no waiting, and no handling fees.
Reviews
There are no reviews yet.