Diamond Aircraft Industries GmbH N. A. Otto-Straße 5 A-2700 Wiener Neustadt Austria DAI RSB 42-089/1 DAI RSB 42NG-017/1 Page 1 of 4 19-Apr-2011 

# RECOMMENDED SERVICE BULLETIN RSB 42-089/1 RSB 42NG-017/1

SUPERSEDES RSB 42-089 / RSB 42NG-017



## I TECHNICAL DETAILS

I.1 Category

Recommended.

I.2 Airplanes affected
Type: DA 42, DA 42 M, DA 42 NG, DA 42 M-NG Serial numbers: 42.004 through 42.321, 42.324 through 42.347, 42.349, 42.351, 42.353 through 42.357, 42.359 through 42.386, 42.388, 42.389, 42.391, 42.394, 42.396, 42.399, 42.405 through 42.409, 42.412 through 42.416, 42.427, 42.AC001 through 42.AC152, 42.M001 through 42.M011, 42.M015 through 42.M019, 42.M021, 42.M022, 42.N001 through 42.N011, 42.N013, 42.N018, 42.N019, 42.N023 through 42.N028, 42MN001 through 42.MN008 provided that a damper D60-3277-10-00_01 has NOT yet been installed

I.3 Date of effectivity

06-Oct-2010

I.4 Time of Compliance

At owner’s discretion.

I.5 Subject
Replacement of seals in main landing gear damper. ATA-Code: 32-10Diamond Aircraft Industries GmbH N. A. Otto-Straße 5 A-2700 Wiener Neustadt Austria DAI RSB 42-089/1 DAI RSB 42NG-017/1 Page 2 of 4 19-Apr-2011

I.6 Reason
The new seal system for the main landing gear damper offers more durability in a greater temperature range.
Note: This Service Bulletin’s instruction, material and labor effort relate to work on one MLG damper only.

I.7 Concurrent Documents

None.

I.8 Approval
The technical information or instructions contained in this document relate to the Design Change Advisory No. MÄM 42-434, which has 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.

I.9 Accomplishments / Instructions
Comply with WI-RSB 42-089 / WI-RSB 42NG-017, latest effective issue. Note: WI-RSB 42-089 / WI-RSB 42NG-017 is attached to this document. Note: This Service Bulletin’s instruction, material and labor effort relate to work on one MLG damper only.

I.10 Mass (Weight) and CG

None.


## II PLANNING INFORMATION

II.1 Material and Availability

See WI-RSB 42-089 / WI-RSB 42NG-017, latest effective issue. Materials including drawings are available from Diamond Aircraft Industries. Note: This Service Bulletin’s instruction, material and labor effort relate to work on one MLG damper only.Diamond Aircraft Industries GmbH N. A. Otto-Straße 5 A-2700 Wiener Neustadt Austria DAI RSB 42-089/1 DAI RSB 42NG-017/1 Page 3 of 4 19-Apr-2011
II.2 Special Tools

See WI-RSB 42-089 / WI-RSB 42NG-017, latest effective issue.

II.3 Labor Effort
Approx. 1.5 hours for upgrade and installation.
Note: This Service Bulletin’s instruction, material and labour effort relate to work on one MLG damper only.

II.4 Credit
For airplanes within warranty per damper: 1.5 hours of labor and material as listed in WI-RSB 42-089 / WI-RSB 42NG-017 II.3.

II.5 Reference Documents
Diamond Aircraft 42 Series Airplane Maintenance Manual, Doc. No. 7.02.01, latest effective issue. Diamond Aircraft 42 NG Airplane Maintenance Manual, Doc. No. 7.02.15, latest effective issue.


## III REMARKS

1. All measures must be carried out by a certified aircraft service station or a certified aircraft maintenance mechanic. 2. All works, in particular those that are not especially described in this Service Bulletin, must be carried out in accordance with the referenced Maintenance Manual. 3. Accomplishment of the measures must be confirmed in the log book. 4. If material and/or labor hours are subject to be credited through Diamond Aircraft Industries, the Service Bulletin must be carried out by an authorized Diamond Service Center and the Warranty Application incl. Work Report must be sent not later than 30 days after the end of time of compliance. 5. In case of doubt contact Diamond Aircraft Industries GmbH.Diamond Aircraft Industries GmbH N. A. Otto-Straße 5 A-2700 Wiener Neustadt Austria DAI RSB 42-089/1 DAI RSB 42NG-017/1 Page 4 of 4 19-Apr-2011



## EXECUTION REPORT TO SERVICE BULLETIN RSB 42-089/1 RSB 42NG-017/1

AIRPLANE DATA
Airplane Serial Number: _________________
Airplane Registration: _________________
Airplane Operator: _________________
Hours of operation of airplane: _________________
No. of landings: _________________
Hours of operation-engine LH _________________
RH _________________
Typical operation of airplane: private, club, training, other ______________

Modified damper □ LH □ RH

__________________________________ Date, Name, Sign

Please fax the completed form to Fax No. +43-2622-26700-1369 or e-mail to airworthiness@diamond-air.atDiamond Aircraft Industries GmbH N. A. Otto-Straße 5 A-2700 Wiener Neustadt WI-RSB 42-089 WI-RSB 42NG-017 Revision 0 Page 1 of 10 06-Oct-2010 

# WORK INSTRUCTION WI-RSB 42-089 WI-RSB 42NG-017 Installation of sealing ring wi th greater temperature range

I GENERAL INFORMATION

I.1 Subject

Replacement of main landing gear damper seals to allow a greater temperature range.

I.2 Reference Documents

Diamond Aircraft DA 42 Series Airplane Maintenance Manual, Doc. No. 7.02.01, latest effective issue. Diamond Aircraft DA 42 NG Airplane Maintenance Manual, Doc. No. 7.02.15, latest effective issue.

I.3 Remarks

a) The work must be carried out by a certified aircraft service station or a certified aircraft maintenance mechanic. b) All works, particular those that are not especially described in this work instruction, must be carried out in accordance with the referenced maintenance manual. c) For conversion factors between SI and US/Imperial units refer to AMM Chapter 02. d) It is recommended to print this Work Instruction in color. e) This Work Instruction including material and labor effort relate to work on one MLG damper only. f) In case of doubt, contact Diamond Aircraft Industries GmbH.Diamond Aircraft Industries GmbH N. A. Otto-Straße 5 A-2700 Wiener Neustadt WI-RSB 42-089 WI-RSB 42NG-017 Revision 0 Page 2 of 10 06-Oct-2010 

## II DRAWINGS, SPECIAL TOOLS & MATERIALS

II.1 Drawings

D60-3277-10-00_01

II.2 Special Tools

Centering pin: X00-W027-00-00.01 Rev."-" Spacer: X00-W027-00-00.02 Rev."-" Damper Drain Tool: D60-3277-10-00-ST or equivalent Seal pick: D60-3277-10-01-ST or equivalent

II.3 Material

Quantity Part No. Description 1 D60-9032-77-01 Tandem Seal 1 ORAR00227-N7083 O-Ring 1 ORAR00224-N7083 O-Ring 1 MS 28775-010 O-Ring 1 LN9348 M8 Hexagon nut 1 LN9348 M6 Hexagon nut 100ml 1U-9891 or equivalent Additiv 1U-9891 Caterpillar Inc. Materials including special tools are available from Diamond Aircraft Industries.
Note: This list includes material only for one damper.

II.4 Consumables

Quantity Part No. Description 1l 3627020L Aero Shell Fluid 41 a. r. Royoco 81MS Grease Royoco 81MS a. r. N000 148 or equivalent Acetone

Consumables may be procured locally or from Diamond Aircraft IndustriesDiamond Aircraft Industries GmbH N. A. Otto-Straße 5 A-2700 Wiener Neustadt WI-RSB 42-089 WI-RSB 42NG-017 Revision 0 Page 3 of 10 06-Oct-2010


## III INSTRUCTIONS

1 Ensure AMM-TR-MÄM-42-368 is incorporated into the AMM. 2 Remove the Main Landing Gear Damper acc. to AMM section 32-10.

3 Release nitrogen and oil from the damper.
WARNING: Do not spill Fluid 41 on your skin or on your clothes. Fluid 41 is harmful and can cause skin disease and damage to clothes.
WARNING: The damper is gas loaded. Always wear safety glasses. Install the adapter with drain hose onto the charging valve of the damper and release the pressure into the suitable container acc. to picture 1. Wait until the nitrogen is fully released. Push in the damper to minimum position to drain the oil.

Picture1 4 Remove the charging valve from damper.Diamond Aircraft Industries GmbH N. A. Otto-Straße 5 A-2700 Wiener Neustadt WI-RSB 42-089 WI-RSB 42NG-017 Revision 0 Page 4 of 10 06-Oct-2010

5 Remove the bottom cap:

 Remove the bolt holding the bottom cap.

 Pull the bottom cap from the damper assembly.
WARNING: Do not spill Fluid 41 on your skin or on your clothes. Fluid 41 is harmful and can cause skin disease and damage to clothes.

Note: Catch the residual oil into a suitable container.

 Clean the cap with acetone.

 Replace the O-Ring from the cap by new O-Ring ORAR00227-N7083 and apply a coat of Additive 1U-9891 on the new O-Ring. Caution: Do not use steel tools when removing the O-Ring. Do not scratch the surfaces of the groove.

6 Disassemble piston:
Remove the nut on the piston and pull out the piston end plate. 7 Remove the cylinder tube from the piston.

8 Remove the upper cap from the piston. Clean the upper cap with fresh acetone. Replace the O-Ring from the upper cap by new O-Ring ORA AR 00224-N7083 and apply a coat of Additive 1U-9891 on the new O-Ring. Caution: Do not use steel tools when removing the O-Ring. Do not scratch the surfaces of the groove.Diamond Aircraft Industries GmbH N. A. Otto-Straße 5 A-2700 Wiener Neustadt WI-RSB 42-089 WI-RSB 42NG-017 Revision 0 Page 5 of 10 06-Oct-2010

9 Remove the quad ring and the two backup rings from the tube: Caution: Do not use steel tools when removing the quad ring. Do not scratch the surfaces of the groove. Use seal pick D60-3277-10-01-ST to remove the quad ring. Clean the cylinder tube with acetone. Examine the grooves of the cylinder tube and the piston tube for scratches and wear. If scratch and wear are discernible, replace the defective part.

Picture 2

10 Description of the new tandem seal kit in the cylinder tube: Support- ring Seal ring Seal base

Picture 3
Pay attention to mounting direction.

11 Install the support ring. Deform the ring carefully acc. to picture 4. CAUTION: Avoid excessive bending of the support ring. Support ring (Step 1)

Seal base (Step 2) Seal ring (Step 3) TOP

Cylinder tubeDiamond Aircraft Industries GmbH N. A. Otto-Straße 5 A-2700 Wiener Neustadt WI-RSB 42-089 WI-RSB 42NG-017 Revision 0 Page 6 of 10 06-Oct-2010

Picture 4

12 Install the seal base below the support ring: Deform the seal base acc. to picture 5 and install it in the cylinder tube. Press the seal base into the groove.

Picture 5 13 Install the seal ring into the seal base. Deform the seal ring acc. to picture 6 and install it into the cylinder tube. CAUTION: Avoid excessive bending of the seal ring. Do not crack the seal ring.
Press the seal ring into the seal base groove.

Picture 6

14 Apply a coat of Additive 1U-9891 on the tandem seal kit and the centering pin. Support- ring (Step 1)

Seal base (Step 2)

Seal ring (Step 3)Diamond Aircraft Industries GmbH N. A. Otto-Straße 5 A-2700 Wiener Neustadt WI-RSB 42-089 WI-RSB 42NG-017 Revision 0 Page 7 of 10 06-Oct-2010

15 Carefully insert the centering pin X00-W027-00-00.01 into the cylinder tube 2 or 3 times to position the tandem seal in the cylinder groove.

Picture 7
16 Examine the connection of the thread rod and upper cap for tight fit. If necessary: Apply Loctite 262 to thread and retighten nut.

17 Install the piston tube on the piston tube end acc. to picture 8. Ensure tight fit.

Picture 8 15mmDiamond Aircraft Industries GmbH N. A. Otto-Straße 5 A-2700 Wiener Neustadt WI-RSB 42-089 WI-RSB 42NG-017 Revision 0 Page 8 of 10 06-Oct-2010

18 Mount the spacer and the centering pin acc. to picture 9.

Picture 9 19 Apply a coat of Additiv 1U-9891 on the piston tube and the centering pin. 20 Put the cylinder tube over the centering pin on the piston tube.

21 Remove the centering pin with a M12 bolt.

Picture 10

22 Examine the piston end plate: Check the thread excess length of 5 mm between bolt head and restriction washer acc. to picture 11.

Picture 11

23 If adjustment is necessary: Remove the bolt and apply a coat of Loctite 262 to the thread and adjust a thread excess length of 5 mm between bolt head and restriction washer acc. to picture 11. Centering pin

SpacerDiamond Aircraft Industries GmbH N. A. Otto-Straße 5 A-2700 Wiener Neustadt WI-RSB 42-089 WI-RSB 42NG-017 Revision 0 Page 9 of 10 06-Oct-2010

24 Secure the bolt after installation with a prick-punch on the bottom side acc. to picture 12.

Picture 12

25 Install the piston end plate in the cylinder tube with a nut LN 9348 M8. Secure the connection with Loctite 262 acc. to drawing D60-3277-10-00_01.

Picture 13 26 Remove the spacer from piston tube. 27 Install the bottom cap with the bolt, washer and nut. 28 Install the charging valve with a new O-Ring MS 28775-010.

29 Adjust the direction of the piston tube to the cylinder tube acc. to picture 14.
Note: The charging valve must be aligned with the nut from the bolt holding the bottom cap. Piston end plate

Nut

SpacerDiamond Aircraft Industries GmbH N. A. Otto-Straße 5 A-2700 Wiener Neustadt WI-RSB 42-089 WI-RSB 42NG-017 Revision 0 Page 10 of 10

06-Oct-2010

Picture 14 30 Fill and charge the Damper acc. to AMM Section 32-10. 31 Install the Damper to the MLG acc. to AMM Section 32-10. 32 Clean working area and check for foreign objects.

33 Mark the damper with a red point for indication of the installed new seal kit with commercial spray paint (or equivalent).

Picture 15
34 Perform a landing gear extension and retraction test and check clearance between MLG wheel and wheel bay acc. to AMM-TR-MÄM-42-447. 35 Apply anti-corrosion coating on damper connections acc. to AMM Section 12-30. 36 Perform functional check of altered, repaired and new parts. 37 Test all systems in working area for function.

38 Make necessary entries into aircraft logs. Note: Record which MLG damper (LH/RH) has been modified.