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Diamond Aircraft DV 20 KATANA Maintenance Manual

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AIRCRAFT

DV 20 KATANA

AIRPLANE MAINTENANCE MANUAL

Copyright © by DIAMOND AIRCRAFT INDUSTRIES, Wiener Neustadt, Austria

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Page 1 AIRCRAFT DV 20 KATANA AIRPLANE MAINTENANCE MANUAL Copyright © by DIAMOND AIRCRAFT INDUSTRIES, Wiener Neustadt, Austria...
Page 2 Introduction DV 20 KATANA AMM AIRCRAFT This document is protected by copyright. All associated rights, in particular those of translation, reprinting, radio transmission, reproduction by photo-mechanical or similar means and storing in data processing facilities, in whole or part, are reserved.
Page 3 Table of Contents DV 20 KATANA AMM AIRCRAFT TABLE OF CONTENTS Chapter Title GENERAL 01-00 Introduction 02-00 Organization and Handling of the Maintenance Manual 03-00 General Description of the Airplane 04-00 Airworthiness Limitations 05-00 Time Limits / Maintenance Checks (Inspection Intervals)
Page 4 Table of Contents DV 20 KATANA AMM AIRCRAFT Chapter Title PROPELLER 61-00 Propeller ENGINE 71-00 Power Plant (Engine) 75-00 Liquid Cooling 76-00 Engine Controls 77-00 Engine Indicating 78-00 Exhaust 79-00 WIRING DIAGRAMS 92-00 Wiring Diagrams Page ii Doc # 4.02.02...
Page 5 Record of Revision DV 20 KATANA AMM AIRCRAFT Record of Revision 1. Record of Revision Use this check list to record and control all of the revisions which you put in this Airplane Maintenance Manual (AMM). Put the affected pages of the revision into the AMM as soon as you get them. Remove and destroy the pages which are superseded.
Page 6 Record of Revision DV 20 KATANA AMM AIRCRAFT Revision Number Date Affected Pages Original Issue Jun. 1993 Rev. No. 1 Sep. 1993 03-00/4, (SB 20-2) 05-10/1, 61-00/1 Rev. No. 2 Mar. 1994 04/1 thru 04/2 04-00/1 04-10/1 05/2 05-00/1 05-10/1 thru 05-10/2...
Page 7 Record of Revision DV 20 KATANA AMM AIRCRAFT Revision Number Date Affected Pages Rev. No. 4 Dec. 1994 04-10/1 05-10/1 05-20/6b 05-20/7a 05-20/8a 05-20/9a 05-20/11a 05-20/12a 05-20/13a 24/2 24-31/5 thru 24-31/8 Rev. No. 5 Mar. 1995 01/7 (SB 20-17) 05/2...
Page 8 Record of Revision DV 20 KATANA AMM AIRCRAFT Revision Date Affected Affected Pages Number Chapters Rev. No. 7 Jan. 1996 03-00 3 thru 5 04-10 05-10 05-20 6a, 7b, 8a, 10a, 10b, 11b, 12b, 13b, 14a 05-21 6a, 7b, 8a, 10a, 10b, 11b, 12b, 13b, 14a...
Page 9 Record of Revision DV 20 KATANA AMM AIRCRAFT Revision Date Affected Affected Pages Number Chapters Rev. No. 7 57-10 2 thru 4 (continued) 61-00 1 thru 6 71-20 1, 2 76-10 2; wiring diagrams amended as marked on page 2 Rev.
Page 10 Record of Revision DV 20 KATANA AMM AIRCRAFT Revision Date Affected Affected Pages Number Chapters Rev. No. 10 Jul. 1999 03-00 4, 5 05-10 05-20 5, 6a thru 9a, 14b 05-21 5, 6a thru 9a, 14b 11-10 11-11 12-10 2, 2a, 5, 6...
Page 11 Record of Revision DV 20 KATANA AMM AIRCRAFT 2. Record of Incorporated Temporary Revisions The following Temporary Revisions are incorporated into the DV 20 KANTANA AMM by Revision 13: Temporary Revision Number Description of Temporary Revision AMM-TR-MÄM-20-252/a&442 Airframe Life Limit AMM-TR-MÄM-20-259...
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Page 13 DV 20 KATANA AMM Introduction AIRCRAFT CHAPTER 01 INTRODUCTION Doc # 4.02.02 Page 1 01-TITLE Rev. 13 15 Dec 2018...
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Page 15 DV 20 KATANA AMM Introduction AIRCRAFT TABLE OF CONTENTS CHAPTER 01 INTRODUCTION General ............1 Layout of this Manual .
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Page 17 The purpose of this Maintenance Manual is to furnish the maintenance personnel with all data required to maintain the DV 20 KATANA airplane. It comprises a detailed description of its systems, troubleshooting and correction, removal and installation, as well as maintenance information.
Page 18 Introduction DV 20 KATANA AMM AIRCRAFT B. Warning, Cautions and Notes Whenever maintenance work is performed on the airplane, the general safety and maintenance procedures must be observed. In addition, the Maintenance Manual contains safety information which is shown in a specific format...
Page 19 DV 20 KATANA AMM Introduction AIRCRAFT A. Contents (Peculiarities) (1) MAIN GROUP 02, GENERAL Chapter 05 includes maintenance and inspection procedures with reference to respective chapters in this manual. Chapter 12 describes all ground support activities such as refueling and lubrication schedules.
Page 20 Introduction DV 20 KATANA AMM AIRCRAFT B. Chapters Refer to the table of contents in the maintenance manual. C. Arrangement of Chapters (1) STRUCTURE Chapter Section Unit Sample: (Flight Controls) (Rudder) (Pedal assy.) This type of chapter structure in three groups ensures a clear and understandable organization of the Maintenance Manual and guarantees a problem free integration of any new or revised pages.
Page 21 DV 20 KATANA AMM Introduction AIRCRAFT D. Order of Pages (1) PAGES PRECEDING THE ACTUAL MANUAL Page Cover Page ............- Table of Contents .
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Page 23 DV 20 KATANA AMM Manual Organization AIRCRAFT CHAPTER 02 ORGANIZATION AND HANDLING OF THE MAINTENANCE MANUAL Doc # 4.02.02 Page 1 02-TITLE Rev. 13 15 Dec 2018...
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Page 25: Table Of Contents
DV 20 KATANA AMM Manual Organization AIRCRAFT TABLE OF CONTENTS CHAPTER 02 ORGANIZATION AND HANDLING OF THE MAINTENANCE MANUAL General ............1 Revisions .
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Page 27: General
DV 20 KATANA AMM Manual Organization AIRCRAFT CHAPTER 02 ORGANIZATION AND HANDLING OF THE MAINTENANCE MANUAL 1. General To search and gain information regarding a specific system of the airplane, the manual user should refer to the Table of Contents for the correct chapter no.
Page 28: Service Information
Manual Organization DV 20 KATANA AMM AIRCRAFT A. Temporary Revisions Deviating from the regular revision service, in urgent cases Temporary Revisions can be issued. In such cases revised pages are printed on yellow paper and will be considered at the next regular revision of the Maintenance Manual.
Page 29 DV 20 KATANA AMM General Description AIRCRAFT CHAPTER 03 GENERAL DESCRIPTION OF THE AIRPLANE Doc # 4.02.02 Page 1 03-TITLE Rev. 13 15 Dec 2018...
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Page 31 DV 20 KATANA AMM General Description AIRCRAFT TABLE OF CONTENTS CHAPTER 03 GENERAL DESCRIPTION OF THE AIRPLANE General ............1 Description .
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Page 33 DV 20 KATANA. 2. Description The DV 20 KATANA may be operated under VFR conditions. It is approved as a "Normal" airworthiness category airplane. The single engine, two-seated, low wing airplane consists of a self supporting wing structure and a T-tail.
Page 34 General Description DV 20 KATANA AMM AIRCRAFT 10780 1900 7165 2100 1750 2650 Figure 1: Three-view Drawing Dimensions in Millimeters Page 2 Doc # 4.02.02 03-00-00 15 Dec 2018 Rev. 13...
Page 35 The engine of the DV 20 KATANA is a ROTAX 912 A3 or S3. On this four cycle engine, the cylinders are cooled by ram air, while the cylinder heads are cooled by using a liquid cooling system.
Page 36 General Description DV 20 KATANA AMM AIRCRAFT Propeller: Hoffmann HO-V72F/S170DW Supplier: Hoffmann Propeller Küpferlingstr. 9 D-83022 Rosenheim, Germany Phone No. : +49-8031-18780 Fax No. : +49-8031-187878 Available Manuals: Operation & Maintenance Manual No. E243 Overhaul Manual No. E105 Propeller: Hoffmann HO-V352F/170FQ or HO-V352F/C170FQ...
Page 37 DV 20 KATANA AMM Airworthiness Limitations AIRCRAFT CHAPTER 04 AIRWORTHINESS LIMITATIONS Doc # 4.02.02 Page 1 04-TITLE Rev. 13 15 Dec 2018...
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Page 39 DV 20 KATANA AMM Airworthiness Limitations AIRCRAFT TABLE OF CONTENTS CHAPTER 04 AIRWORTHINESS LIMITATIONS Paint Finish ..........3 Registration Markings and Warning Marks .
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Page 41: Airworthiness Limitations
DV 20 KATANA AMM Airworthiness Limitations AIRCRAFT CHAPTER 04 AIRWORTHINESS LIMITATIONS THIS AIRWORTHINESS LIMITATIONS SECTION IS APPROVED BY EUROPEAN AVIATION SAFETY AGENCY (EASA) IN ACCORDANCE WITH THE APPLICABLE CERTIFICATION PROCEDURES AND THE TYPE CERTIFICATION BASIS. IT SPECIFIES THE AIRWORTHINESS LIMITATIONS REQUIRED BY JAR-VLA.
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Page 43: Paint Finish
DV 20 KATANA AMM Airworthiness Limitations AIRCRAFT Note: It is the responsibility of the operator to ensure that time limits or operating limitations for equipment described within this chapter are not exceeded. 1. Paint Finish Since the strength of the fiber composite structure has only been shown up to a temperature of 54 °C (129 °F), the outer surface of the aircraft must be painted white.
Page 44 Airworthiness Limitations DV 20 KATANA AMM AIRCRAFT Zone I Zone II Zone III Figure 1: Paint Color Scheme Page 4 Doc # 4.02.02 04-00-00 15 Dec 2018 Rev. 13...
Page 45: Time Limits
DV 20 KATANA AMM Airworthiness Limitations AIRCRAFT Section 04-10 TIME LIMITS 1. Time Limit for Airframe There is no structural lifetime limit. 2. [Removed.] Doc # 4.02.02 Page 1 04-10-00 15 Dec 2018 Rev. 13...
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Page 47: Major Structural Inspections
DV 20 KATANA AMM Airworthiness Limitations AIRCRAFT Section 04-20 MAJOR STRUCTURAL INSPECTIONS 1. Recurrent Structural Inspection The Major Structural Inspection must be carried out at 6000 hours, 12000 hours, and every 4000 hours thereafter, with a tolerance of ± 100 hours. The inspection is specified in AMM Chapter 05-20.
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Page 49 Time Limits / DV 20 KATANA AMM Maintenance Checks AIRCRAFT CHAPTER 05 TIME LIMITS / MAINTENANCE CHECKS (INSPECTION INTERVALS) Doc # 4.02.02 Page 1 05-TITLE Rev. 13 15 Dec 2018...
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Page 51 Time Limits / DV 20 KATANA AMM Maintenance Checks AIRCRAFT TABLE OF CONTENTS CHAPTER 05 TIME LIMITS / MAINTENANCE CHECKS (INSPECTION INTERVALS) General ............1...
Page 52 Time Limits / DV 20 KATANA AMM Maintenance Checks AIRCRAFT Section 05-30 GENERAL INSPECTIONS General ............1 Preflight Inspection .
Page 53: Time Limits / Maintenance Checks
TIME LIMITS / MAINTENANCE CHECKS (INSPECTION INTERVALS) 1. General During the design of the DV 20 KATANA maintainability of the equipment was one of the prime considerations. Chapters 04 and 05 should be used by the maintenance personnel as reference in the execution of proper maintenance and inspections.
Page 54 Time Limits / DV 20 KATANA AMM Maintenance Checks AIRCRAFT A. Referenced Maintenance Data Use latest revision of referenced maintenance data. Supplier Document Name Document No. Service Bulletin Ignition Switch ACS A510-2 ACS SB 92-01 Artex Installation and Maintenance Manual for the...
Page 55: Time Limits
Time Limits / DV 20 KATANA AMM Maintenance Checks AIRCRAFT Section 05-10 TIME LIMITS 1. Time Limits for Equipment The following components must be overhauled at the specified intervals: Component in accordance with applicable documents of Engine ROTAX 912 A3 or S3 manufacturer (e.g.
Page 56: Time Limits For Parts
Time Limits / DV 20 KATANA AMM Maintenance Checks AIRCRAFT 3. Time Limits for Parts The items listed below are time limited items which must be removed from service at the replacement times shown and discarded (scrapped). Replacement Time Component hrs.
Page 57 Time Limits / DV 20 KATANA AMM Maintenance Checks AIRCRAFT Operating Fluid Replacement Time Coolant EVANS NPG+ on condition (engines without suffix -01) Coolant based on ethylene glycol 2 years (engines with suffix -01) Brake fluid 3 years To ensure correct observation of these times the date of removal and installation of such components as well as the flight hours must be entered in the Service Time Record (filed in the Airplane Maintenance Log).
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Page 59: Scheduled Maintenance Checks
Checklist in this Section. In parallel do the scheduled drain hole checks with reference to the Drain Holes Inspection Checklist. Note: Diamond Aircraft Ind. has replaced the 600 hours inspection. The first 1000 hours inspection has to be done 1000 flight hours after the last 600 hours inspection. Thereafter 1000 hours interval applies.
Page 60 Time Limits / DV 20 KATANA AMM Maintenance Checks AIRCRAFT 2. Drain Holes Inspection Checklist Do a check of the drain holes. The drain holes must not be blocked by dirt or other residues. Make sure to remove all foreign objects and clean the drain holes to their full diameter. Otherwise the drain capacity may not be sufficient under certain conditions like heavy rain etc.
Page 61 Time Limits / DV 20 KATANA AMM Maintenance Checks AIRCRAFT Drain Holes Inspection Checklist Ref. Drain Hole Location Hours Initials % % % HORIZONTAL STABILIZER 3.01 Lower shell, near the outside of the elevator rib, in front of the elevator spar, LH and RH.
Page 62 Time Limits / DV 20 KATANA AMM Maintenance Checks AIRCRAFT 1.14 1.13 1.05 1.02 1.11 1.10 1.09 1.08 1.12 1.07 1.01 1.03 1.06 1.04 100 Hours Check Horizontal Drainage Hole 200 Hours Check Vertical Drainage Hole 1000 Hours Check Exterior Drainage Hole...
Page 63 Time Limits / DV 20 KATANA AMM Maintenance Checks AIRCRAFT 1.02 1.03 1.01 1.06 1.05 1.07 1.08 1.01 1.04 1.06 1.02 100 Hours Check Horizontal Drainage Hole 200 Hours Check Vertical Drainage Hole 1000 Hours Check Exterior Drainage Hole Drainage Hole Inside the Structure Figure 2: Drain Holes Fuselage (Part 2) Doc # 4.02.02...
Page 64 Time Limits / DV 20 KATANA AMM Maintenance Checks AIRCRAFT 2.01 2.02 2.03 2.01 2.02 2.03 2.01 2.02 2.03 100 Hours Check Horizontal Drainage Hole 200 Hours Check Vertical Drainage Hole 1000 Hours Check Exterior Drainage Hole Drainage Hole Inside the Structure...
Page 65 Time Limits / DV 20 KATANA AMM Maintenance Checks AIRCRAFT 3.01 3.01 3.02 3.02 3.03 4.01 4.01 5.01 5.01 100 Hours Check Horizontal Drainage Hole 200 Hours Check Vertical Drainage Hole 1000 Hours Check Exterior Drainage Hole Drainage Hole Inside the Structure Figure 4: Drain Holes Horizontal Stabilizer, Elevator and Elevator Trim Tab Doc # 4.02.02...
Page 66 Time Limits / DV 20 KATANA AMM Maintenance Checks AIRCRAFT View A 6.01 6.01 6.01 100 Hours Check Horizontal Drainage Hole 200 Hours Check Vertical Drainage Hole 1000 Hours Check Exterior Drainage Hole Drainage Hole Inside the Structure Figure 5: Drain Holes Rudder Page 8 Doc # 4.02.02...
Page 67 Time Limits / DV 20 KATANA AMM Maintenance Checks AIRCRAFT 7.02 7.03 7.01 8.01 9.01 Drain Hole in Flap 7.04 Drain Hole in Flap Stop 100 Hours Check Horizontal Drainage Hole 200 Hours Check Vertical Drainage Hole 1000 Hours Check...
Page 68 Time Limits / DV 20 KATANA AMM Maintenance Checks AIRCRAFT 3. 100, 200, and 1000 Hour Inspection Checklist All inspection items listed in Table 2 must be performed within the specified intervals. Note: All items marked with X must be performed at these intervals on any airplane.
Page 69 Time Limits / DV 20 KATANA AMM Maintenance Checks AIRCRAFT A. INSPECTION CHECKLIST DV 20 KATANA Registration _________________ _________________ Engine operating Date _________________ hours, TSN/TSO _________________ Scope Airplane operating (100, 200, 1000) _________________ hours _________________ Flight Hours Inspection Items 1000...
Page 70 Time Limits / DV 20 KATANA AMM Maintenance Checks AIRCRAFT (1) Initial Test-Run INITIAL TEST-RUN Flight Hours Inspection Items 1000 Initials WARNING: DO NOT LET PERSONS GO INTO THE DANGER AREA OF THE PROPELLER. PROPELLERS CAN CAUSE INJURY OR DEATH.
Page 71 Time Limits / DV 20 KATANA AMM Maintenance Checks AIRCRAFT (2) Engine ENGINE Flight Hours Inspection Items 1000 Initials WARNING: MAKE SURE THE EXHAUST SYSTEM IS COOL BEFORE YOU DO MAINTENANCE ON THE ENGINE. THE EXHAUST SYSTEM CAN BE HOT. THIS CAN CAUSE INJURY TO PERSONS.
Page 72 Time Limits / DV 20 KATANA AMM Maintenance Checks AIRCRAFT ENGINE Flight Hours Inspection Items 1000 Initials Clean oil radiator ribs, check for damage and leaks. Check oil radiator for looseness, check radiator mounting for poor condition. Check compensator pipe between the intake manifolds for chafing and leakage.
Page 73 Time Limits / DV 20 KATANA AMM Maintenance Checks AIRCRAFT ENGINE Flight Hours Inspection Items 1000 Initials Check exhaust pipes and mounting brackets for cracks and looseness; check for leakage at the connection to the muffler; check deflector shield for insecure attachment;...
Page 74 Time Limits / DV 20 KATANA AMM Maintenance Checks AIRCRAFT ENGINE Flight Hours Inspection Items 1000 Initials Check all bowden cables for insecure condition, interference, and lack of operating clearance; lubricate. Check clamp straps for looseness. Throttle Carburetor Heat Cabin Heat Choke Prop.
Page 75 Time Limits / DV 20 KATANA AMM Maintenance Checks AIRCRAFT ENGINE Flight Hours Inspection Items 1000 Initials Operating fluids used: (Type and quantity) : ____________________________________ Coolant : ____________________________________ Misc. : ____________________________________ Parts Replaced: ____________________________________________ ___________________________________________ ____________________________________________ ____________________________________________ Remarks: Doc # 4.02.02...
Page 76 Time Limits / DV 20 KATANA AMM Maintenance Checks AIRCRAFT (3) Propeller PROPELLER Flight Hours Inspection Items 1000 Initials WARNING: DO NOT LET PERSONS GO INTO THE DANGER AREA OF THE PROPELLER. PROPELLERS CAN CAUSE INJURY OR DEATH. WARNING: YOU MUST MAKE SURE THAT THE ENGINE IS SAFE BEFORE YOU TURN THE PROPELLER.
Page 77 Time Limits / DV 20 KATANA AMM Maintenance Checks AIRCRAFT (4) Cabin CABIN Flight Hours Inspection Items 1000 Initials Check canopy, sliding windows and seals for damage. Check canopy attachment rods, coil springs, hinges and rubber bumper for damage. Check canopy lock mechanism & emergency release for damage and improper operation in accordance with measure 1 of Service Bulletin MSB20-39/1.
Page 78 Time Limits / DV 20 KATANA AMM Maintenance Checks AIRCRAFT CABIN Flight Hours Inspection Items 1000 Initials Check control sticks for interference; check stops for defects; check zero position; check all fittings and bearings for looseness. Check play of aileron and elevator control system with one stick blocked.
Page 79 Time Limits / DV 20 KATANA AMM Maintenance Checks AIRCRAFT (5) Structure and Control Surfaces STRUCTURE AND CONTROL SURFACES Flight Hours Inspection Items 1000 Initials Check skin of wings, tail surfaces, and fuselage for defects, especially dents, cracks, holes, etc.
Page 80 Time Limits / DV 20 KATANA AMM Maintenance Checks AIRCRAFT STRUCTURE AND CONTROL SURFACES Flight Hours Inspection Items 1000 Initials Check trim tab and trim tab hinges for damage; check trim tab control mechanism for play; check hinge wire and castle nut for improper safetying.
Page 81 Time Limits / DV 20 KATANA AMM Maintenance Checks AIRCRAFT STRUCTURE AND CONTROL SURFACES Flight Hours Inspection Items 1000 Initials Remove panel aft of baggage compartment; check fuselage tube for deformation and cracks; check elevator push rod guidance for insecure mounting;...
Page 82 Time Limits / DV 20 KATANA AMM Maintenance Checks AIRCRAFT STRUCTURE AND CONTROL SURFACES Flight Hours Inspection Items 1000 Initials Check fastening units of B-bolts for improper operation (locking devices must catch perceptibly every 60°). Check pins of flap synchronizing tube assembly for looseness.
Page 83 Time Limits / DV 20 KATANA AMM Maintenance Checks AIRCRAFT (6) Landing Gear LANDING GEAR Flight Hours Inspection Items 1000 Initials Clean main landing gear and nose wheel; remove fairings; check fairing mounts for cracks. Check main landing gear for cracks, unusual deformation, and damage.
Page 84 Time Limits / DV 20 KATANA AMM Maintenance Checks AIRCRAFT LANDING GEAR Flight Hours Inspection Items 1000 Initials Examine main landing gear attachment brackets. If cracks, damages or serious corrosion is detected remove the MLG legs in accordance with Chapter 32-10 Section 6.
Page 85 Time Limits / DV 20 KATANA AMM Maintenance Checks AIRCRAFT LANDING GEAR Flight Hours Inspection Items 1000 Initials Check nose wheel assembly for insecure attachment, cracks, and deformation; check bearings in fuselage bottom for play; check LH and RH journal in rubber spring assembly for play;...
Page 86 Time Limits / DV 20 KATANA AMM Maintenance Checks AIRCRAFT LANDING GEAR Flight Hours Inspection Items 1000 Initials Install 3 wheels and fairings. (7) General GENERAL Flight Hours Inspection Items 1000 Initials Review Airplane Flight Manual Supplements for optional equipment that requires inspection.
Page 87 Time Limits / DV 20 KATANA AMM Maintenance Checks AIRCRAFT GENERAL Flight Hours Inspection Items 1000 Initials REMARKS: The airplane is airworthy with respect to its maintenance condition. Place : ____________________ Date : ____________________ A.M.E. : ____________________ Doc # 4.02.02...
Page 88 Time Limits / DV 20 KATANA AMM Maintenance Checks AIRCRAFT B. CHECK FLIGHT REPORT If an engine with suffix -01 is installed, the items ‘Cylinder head temperature indicator’ and ‘Cylinder head temperature’ are changed to ‘Coolant temperature indicator’ and ‘Coolant temperature’.
Page 89 Time Limits / DV 20 KATANA AMM Maintenance Checks AIRCRAFT DV 20 KATANA CHECK FLIGHT Page 2 of 2 AIRCRAFT Vertical speed indicator Compass Behavior during climb Cylinder head temperature / Coolant temperature Oil temperature Cabin heat / cabin air...
Page 90 "(T)", perform a tap test, if visual inspection reveals evidence of possible delamination and/or disbond. NOTE: If damages are determined which cannot be repaired in accordance with the Airplane Maintenance Manual Diamond Aircraft must be contacted for repair instructions. A. General GENERAL...
Page 91 Time Limits / DV 20 KATANA AMM Maintenance Checks AIRCRAFT GENERAL Inspection Initials Method Inspection Items Remove and inspect the following parts of the flight control system in accordance with AMM Chapter 27. All parts must be examined for wear, corrosion deformation and poor condition.
Page 92 Time Limits / DV 20 KATANA AMM Maintenance Checks AIRCRAFT GENERAL Inspection Initials Method Inspection Items Elevator: S Elevator push rod (item 3). S Elevator push rod in fuselage tube (item 4). S Elevator bell crank (item 5). S Elevator push rod in rudder fin (item 6).
Page 93 Time Limits / DV 20 KATANA AMM Maintenance Checks AIRCRAFT B. Left Wing LEFT WING Inspection Initials Method Inspection Items Left Wing Root Ribs (in front of and behind spar) Bonding with the skins. V (T) Joints with main spar/spar stump.
Page 94 Time Limits / DV 20 KATANA AMM Maintenance Checks AIRCRAFT LEFT WING Inspection Initials Method Inspection Items Left Wing Trailing Edge Spar Laminate (resin erosion, without any resin cover - refer to Chapter 51-10 Section 11). Bonding of trailing edge to skins (cracks, foam strip brittle - V (T) refer to Chapter 51-10 Section 11).
Page 95 Time Limits / DV 20 KATANA AMM Maintenance Checks AIRCRAFT RIGHT WING Inspection Initials Method Inspection Items Right Wing Spar Stump Laminate (cracks, delamination). Main bolt bushing in spar web. V / F Right Wing Main Spar Main spar bonding with wing skins (cracks, delamination)
Page 96 Time Limits / DV 20 KATANA AMM Maintenance Checks AIRCRAFT D. Fuselage FUSELAGE Inspection Initials Method Inspection Items Fuselage Skin, including Vertical Stabilizer Laminate (delamination, cracks, dents, scratches). V (T) Paint (chips, scratches, UV damage, condition of fire-proof paint aft of lower cowl outlet).
Page 97 Time Limits / DV 20 KATANA AMM Maintenance Checks AIRCRAFT FUSELAGE Inspection Initials Method Inspection Items Trailing edge reinforcement rib (delamination from skin, cracks). Main Bulkhead and Wing Connection Main bulkhead laminate and bonding to fuselage (delamination). Fuselage skin outboard of seat fastener through side of main V (T) bulkhead (delamination).
Page 98 Time Limits / DV 20 KATANA AMM Maintenance Checks AIRCRAFT FUSELAGE Inspection Initials Method Inspection Items Rudder lever mounting (located under B-bulkhead, check for security of mounting, elongation of hole, cracks in surrounding laminate). Bronze coated bushings and collar bushings on pedals.
Page 99 Time Limits / DV 20 KATANA AMM Maintenance Checks AIRCRAFT HORIZONTAL STABILIZER Inspection Initials Method Inspection Items Forward mounting bracket (cracks in plate, cracks in bond to V / F plate, delamination in rib around fasteners, condition of spherical bearing, fit of pin in bearing).
Page 100 Time Limits / DV 20 KATANA AMM Maintenance Checks AIRCRAFT CONTROL SURFACES Inspection Initials Method Inspection Items Hinges and control horn (cracks, corrosion, disbond from skin, condition of plain bearing, fit of clevis pin in bearing - refer to Chapter 57).
Page 101 Time Limits / DV 20 KATANA AMM Maintenance Checks AIRCRAFT CONTROL SURFACES Inspection Initials Method Inspection Items Check technical records to ensure mass and static moment V / F are within specified limits (Chapter 06-00). G. After Assembly GENERAL - AFTER ASSEMBLY...
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Page 103 Die Checklisten für die 100, 200 und 1000 Kontrollen in diesem Abschnitt sind abzuarbeiten. Parallel muß die Checkliste zur Überprüfung der Entwässerungsbohrungen durchgeführt werden. ANMERKUNG: Diamond Aircraft Ind. hat die 600 Stunden Kontrolle durch eine 1000 Stunden Kontrolle ersetzt. Die erste 1000 Stunden Kontrolle ist 1000 Flugstunden nach der letzten 600 Stunden Kontrolle durchzuführen.
Page 104 Time Limits / DV 20 KATANA AMM Maintenance Checks AIRCRAFT 2. Checkliste zur Überprüfung der Entwässerungsbohrungen Die Entwässerungsbohrungen sind zu überprüfen. Entwässerungsbohrungen dürfen nicht durch Schmutz oder andere Ablagerungen verstopft sein. Alle Fremdkörper müssen entfernt werden und die Entwässerungsbohrungen sind komplett zu reinigen. Anderenfalls kann die Entwässerungskapazität unter bestimmten Umständen, wie Starkregen, etc., unzureichend sein.
Page 105 Time Limits / DV 20 KATANA AMM Maintenance Checks AIRCRAFT Checkliste zur Überprüfung der Entwässerungsbohrungen Ref. Position der Entwässerungsbohrungen Stunden Initialen % % % HÖHENFLOSSE 3.01 Unterschale, nahe der Außenseite der HF-Rippe, vor HF- Holm, LH und RH. 3.02 Unterschale, hinter HF-Holm, nahe der Aussparung in der Mitte, LH und RH.
Page 106 Time Limits / DV 20 KATANA AMM Maintenance Checks AIRCRAFT 3. Checklisten für die 100, 200 und 1000 h Kontrollen Die in Tabelle 2 angeführten Arbeiten müssen bei der 100, 200 oder 1000 Stunden-Kontrolle erledigt werden. Alle von der ausführenden Person erledigten Arbeiten müssen Punkt für Punkt abgezeichnet werden.
Page 107 Time Limits / DV 20 KATANA AMM Maintenance Checks AIRCRAFT A. CHECKLISTE DV 20 KATANA Werk-Nr _________________ Kennzeichen _________________ Motorbetriebszeit Datum _________________ TSN/TSO _________________ Kontrollumfang Flugzeug- (100, 200, 1000) _________________ Betriebszeit _________________ Flugstunden Wartungsarbeiten 1000 Wart VOR DER KONTROLLE Lufttüchtigkeitsanweisungen beachten.
Page 108 Time Limits / DV 20 KATANA AMM Maintenance Checks AIRCRAFT (1) Eingangsstandlauf EINGANGSSTANDLAUF Flugstunden Wartungsarbeiten 1000 Wart WARNUNG: IM GEFAHRENBEREICH DES PROPELLERS DÜRFEN SICH KEINE PERSONEN BEFINDEN. DER PROPELLER KANN PERSONEN VERLETZEN ODER TÖTEN. WARNUNG: DIE PARKBREMSE MUSS GESETZT WERDEN. WENN DIE PARKBREMSE NICHT GESETZT IST, KANN SICH DAS FLUGZEUG BEWEGEN UND PERSONEN VERLETZEN ODER TÖTEN .
Page 109 Time Limits / DV 20 KATANA AMM Maintenance Checks AIRCRAFT (2) Motor MOTOR Flugstunden Wartungsarbeiten 1000 Wart WARNUNG: VOR BEGINN VON WARTUNGSARBEITEN AM MOTOR MUSS ÜBERPRÜFT WERDEN, OB DIE AUSPUFFANLAGE ABGEKÜHLT IST. EINE HEISSE AUSPUFFANLAGE KANN PERSONEN VERLETZEN. WARNUNG: VERMEIDEN HAUTKONTAKT ÖL.
Page 110 Time Limits / DV 20 KATANA AMM Maintenance Checks AIRCRAFT MOTOR Flugstunden Wartungsarbeiten 1000 Wart Rippen des Kühlers reinigen und auf Beschädigungen und Undichtheit kontrollieren. Kühler auf Festsitz und dessen Befestigung auf mangelhaften Zustand kontrollieren. Vergaservorwärmkasten auf mangelhafte Befestigung, Risse, undichte Stellen, Verformung und Hitzeschäden kontrollieren.
Page 111 Time Limits / DV 20 KATANA AMM Maintenance Checks AIRCRAFT MOTOR Flugstunden Wartungsarbeiten 1000 Wart Elektrische Installation auf Hitzeschäden, Scheuerstellen und Korrosion kontrollieren (siehe MHB). Zentralstecker (falls installiert), Kabelbefestigungen und Verbindungen durch leichtes Ziehen von Hand prüfen. Masseband Starter Öltemperaturgeber Öldruckgeber...
Page 112 Time Limits / DV 20 KATANA AMM Maintenance Checks AIRCRAFT MOTOR Flugstunden Wartungsarbeiten 1000 Wart Wärmetauscher öffnen, Auspufftopf auf Risse, Korrosion und Deformation kontrollieren (Rissgefährdet sind vor allem die Anschlussstutzen). Auspufftopf ausbauen, durch die Stutzen auf innere Beschädigungen kontrollieren. Brandspantdurchführungen und entlang der Kanten des Hitzeschutzblocks auf undichte Stellen und fehlende Isolierung kontrollieren.
Page 113 Time Limits / DV 20 KATANA AMM Maintenance Checks AIRCRAFT MOTOR Flugstunden Wartungsarbeiten 1000 Wart Alle Betätigungszüge auf unsicheren Zustand, Schwergängigkeit und Blockierung kontrollieren und schmieren; Klemmnippel auf losen Sitz kontrollieren. Vergaservorwärmung Heizung Choke Propellerverstellung Motorträger-Befestigungsschrauben nachziehen (Drehmoment siehe Kapitel 20-00).
Page 114 Time Limits / DV 20 KATANA AMM Maintenance Checks AIRCRAFT MOTOR Flugstunden Wartungsarbeiten 1000 Wart Verwendete Betriebsmittel: (Sorte und ggf. Menge) Öl : ____________________________________ Kühlmittel : ___________________________________ Sonstige : ____________________________________ Ausgetauschte Teile: ____________________________________________ ___________________________________________ ____________________________________________ ____________________________________________ Bemerkungen: Page 12 Doc # 4.02.02...
Page 115 Time Limits / DV 20 KATANA AMM Maintenance Checks AIRCRAFT (3) Propeller PROPELLER Flugstunden WARNUNG: IM GEFAHRENBEREICH DES PROPELLERS DÜRFEN SICH KEINE PERSONEN BEFINDEN. DER PROPELLER KANN PERSONEN VERLETZEN ODER TÖTEN. WARNUNG: DER MOTOR MUSS GESICHERT WERDEN; BEVOR DER PROPELLER GEDREHT WIRD.
Page 116 Time Limits / DV 20 KATANA AMM Maintenance Checks AIRCRAFT (4) Kabine KABINE Flugstunden Wartungsarbeiten 1000 Wart Kabinenhaube, Schiebefenster und Abdichtungen auf Beschädigungen kontrollieren. Haubenbefestigungsarme, Ferdern, Lagerungen und Gummipuffer auf Beschädigungen kontrollieren. Haubenverriegelung und -notbetätigung gemäß Technischer Mitteilung Nr. MSB20-39/1 auf Schäden und Fehlfunktionen kontrollieren.
Page 117 Time Limits / DV 20 KATANA AMM Maintenance Checks AIRCRAFT KABINE Flugstunden Wartungsarbeiten 1000 Wart Steuerknüppel auf Schwergängigkeit, defekte Anschläge und übermmäßiges Spiel kontrollieren. Null-Stellung prüfen. Beschläge und Lagerungen auf losen Sitz kontrollieren. Einen Steuerknüppel blockieren; Steuerungsspiel an den Ruderendkanten messen.
Page 118 Time Limits / DV 20 KATANA AMM Maintenance Checks AIRCRAFT (5) Zelle ZELLE Flugstunden Wartungsarbeiten 1000 Wart Schale von Flügel, Leitwerk und Rumpf auf Beschädigungen, insbesondere Beulen, Risse, Löcher oder Ähnliches kontrollieren. Prüfe den Zustand der Faserverbundstruktur im Bereich der Trittstufenbefestigung. Bei Beschädigung gemäß...
Page 119 Time Limits / DV 20 KATANA AMM Maintenance Checks AIRCRAFT ZELLE Flugstunden Wartungsarbeiten 1000 Wart Antriebsreibungsdämpfer abschließen und mit Federwaage auf falsche Reibkraft überprüfen bzw. einstellen. Trimmruder und Lagerung auf Beschädigung kontrollieren; Antrieb auf Spiel kontrollieren; Lagerungsdraht und Kronenmutter auf schadhafte oder fehlende Sicherung kontrollieren.
Page 120 Time Limits / DV 20 KATANA AMM Maintenance Checks AIRCRAFT ZELLE Flugstunden Wartungsarbeiten 1000 Wart Gepäckfachboden ausbauen. Fahrwerksaufhängung auf losen Sitz und schadhafte oder fehlende Sicherungen kontrollieren. Seitenrudersteuerseile, Seitenrudersteuerscheit, Querruderumlenkung, Landeklappenantrieb auf Schäden, Korrosion und Fehlfunktion und auf schadhafte oder fehlende Sicherungen kontrollieren.
Page 121 Time Limits / DV 20 KATANA AMM Maintenance Checks AIRCRAFT ZELLE Flugstunden Wartungsarbeiten 1000 Wart Entwässerungs- und Belüftungsöffnungen in Flügeln, Rumpf und Rudern auf Verstopfung prüfen. Hinweisschilder und Beschriftungen kontrollieren. Hinweisschilder für optionale Ausrüstung: siehe Anhang zum Flughandbuch. Flügel abrüsten;...
Page 122 Time Limits / DV 20 KATANA AMM Maintenance Checks AIRCRAFT (6) Fahrwerk FAHRWERK Flugstunden Wartungsarbeiten 1000 Wart Fahrwerke reinigen, Radverkleidungen demontieren; Halterungen der Verkleidungen auf Risse kontrollieren. Hauptfahrwerk auf Risse, ungewöhnliche Verformungen, Beschädigungen kontrollieren. Maximalen Spalt X der unbelasteten Hauptfahrwerksstrebe messen (geraden Stab [grau] auf...
Page 123 Time Limits / DV 20 KATANA AMM Maintenance Checks AIRCRAFT FAHRWERK Flugstunden Wartungsarbeiten 1000 Wart Die Befestigungsklammern am Hauptfahrwerk auf Risse, Beschädigungen und übermäßige Korrosion prüfen. Bei einem dieser Defekte sind die Hauptfahrwerksbeine gemäß Kapitel 32-10, Abschnitt 6 zu entfernen.
Page 124 Time Limits / DV 20 KATANA AMM Maintenance Checks AIRCRAFT FAHRWERK Flugstunden Wartungsarbeiten 1000 Wart Bremsleitungen und Bremszylinder auf Lecks, Beschädigungen und Korrosion prüfen. Bugradaufhängung auf losen Sitz, Schäden, Risse und Verformungen prüfen; Lagerung im Rumpf auf Spiel, seitliche Lagerzapfen im Federpaket auf Spiel prüfen;...
Page 125 Time Limits / DV 20 KATANA AMM Maintenance Checks AIRCRAFT FAHRWERK Flugstunden Wartungsarbeiten 1000 Wart 3 Räder und Radverkleidungen montieren. (7) Allgemeines ALLGEMEINES Flugstunden Wartungsarbeiten 1000 Wart Optionale Ausrüstung gemäß Anhängen zum Flughandbuch kontrollieren. ELT und dessen Batterie gemäß Herstellerangaben überprüfen.
Page 126 Time Limits / DV 20 KATANA AMM Maintenance Checks AIRCRAFT ALLGEMEINES Flugstunden Wartungsarbeiten 1000 Wart BEMERKUNGEN: Page 24 Doc # 4.02.02 05-21-00 15 Dec 2018 Rev. 13...
Page 127 Time Limits / DV 20 KATANA AMM Maintenance Checks AIRCRAFT ALLGEMEINES Flugstunden Wartungsarbeiten 1000 Wart Das Luftfahrzeug ist in Bezug auf seine Wartung flugklar. : ____________________ Datum : ____________________ Stempel : ____________________ Unterschrift: ____________________ Doc # 4.02.02 Page 25 05-21-00 Rev.
Page 128 Time Limits / DV 20 KATANA AMM Maintenance Checks AIRCRAFT Wenn ein Motor mit dem Suffix -01 eingebaut ist, werden die Punkte ‘Zylinderkopfthermometer’ und ‘Zylinderkopf-Temperatur’ in ‘Kühlmittelthermometer’ and ‘Kühlmittel-Temperatur’ geändert. DV 20 KATANA Seite 1 of 2 WERKSTATTFLUG nach der Wartung...
Page 129 Time Limits / DV 20 KATANA AMM Maintenance Checks AIRCRAFT DV 20 KATANA Seite 2 of 2 WERKSTATTFLUG nach der Wartung AIRCRAFT Verhalten im Steigflug Zylinderkopf-Temperatur / Kühlmittel-Temperatur Öltemperatur Heizung / Lüftung Verhalten im Schnellflug Trimmung / Trimmbereich Verhalten im Langsamflug Überziehwarnung...
Page 130 “(K)” ergänzt ist, soll ein Klopf Test durchgeführt werden, wenn die Sichtprüfung Hinweise auf eine mögliche Delamination und/oder Ablösung gibt. ANMERKUNG: Wenn die festgestellte Beschädigung nicht in Übereinstimmung mit dem Wartungshandbuch repariert werden kann muss Diamond Aircraft für Reparaturanweisungen kontaktiert werden. A. Allgemein ALLGEMEIN...
Page 131 Time Limits / DV 20 KATANA AMM Maintenance Checks AIRCRAFT ALLGEMEIN Inspektions Wart Methode Inspektionsgegenstand Folgende Teile des Steuersystems müssen demontiert und inspiziert werden. (Siehe Kapitel 27) Alle Teile müssen auf Verschleiß, Korrosion, Verformung und schlechten Zustand kontrolliert werden. Querruder: S Die Querruderstoßstangen, die die Steuerknüppel...
Page 132 Time Limits / DV 20 KATANA AMM Maintenance Checks AIRCRAFT ALLGEMEIN Inspektions Wart Methode Inspektionsgegenstand Höhenruder: S Höhenruderstoßstange (Bauteil 3). S Höhenruderstoßstange in der Rumpfröhre (Bauteil 4). S Höhenruderumlenkhebel (Bauteil 5). S Höhenruderstoßstange in der Seitenflossen (Bauteil 6). Höhenrudertrimmung: S Trimmhebel (Bauteil 1).
Page 133 Time Limits / DV 20 KATANA AMM Maintenance Checks AIRCRAFT B. Linker Flügel LINKER FLÜGEL Inspektions Wart Methode Inspektionsgegenstand Linke Flügelwurzelrippen (Vor und hinter Holm) Verklebung mit der Flügelschale. S (K) Verklebung mit dem Hauptholm/Hauptholmstrumpf. Zustand der Faserverbundstruktur (Risse und Delamination).
Page 134 Time Limits / DV 20 KATANA AMM Maintenance Checks AIRCRAFT LINKER FLÜGEL Inspektions Wart Methode Inspektionsgegenstand Linker Hinterkantenholm Zustand der Faserverbundstruktur. (Harzerosion, fehlende Abdeckung durch Harz - siehe Kapitel 51-10). Verklebung zwischen Hinterkante und Flügelschalen (Risse, S (K) brüchiger Schaumstoffstreifen - siehe Kapitel 51-10).
Page 135 Time Limits / DV 20 KATANA AMM Maintenance Checks AIRCRAFT RECHTER FLÜGEL Inspektions Wart Methode Inspektionsgegenstand Rechter Holmstumpf Zustand der Faserverbundstruktur (Risse, Delamination) . Hauptbolzenbuchse im Holm. S / F Rechter Hauptholm Verklebung zwischen Hauptholm und Flügelschale. S (K) Hauptholmflanschverbindung mit Steg von außen durch die Wurzelruppenöffnungen auf Delamination prüfen.
Page 136 Time Limits / DV 20 KATANA AMM Maintenance Checks AIRCRAFT RECHTER FLÜGEL Inspektions Wart Methode Inspektionsgegenstand Innere Rippen - Rechter Flügel Zustand der Faserverbundstruktur (Risse, Delamination). Umlenkhebelhalterung auf Risse, Verschleiß des Befestigungslochs, Korrosion, Delamination und Ablösung zwischen Halterung und Rippe.
Page 137 Time Limits / DV 20 KATANA AMM Maintenance Checks AIRCRAFT RUMPF Inspektions Wart Methode Inspektionsgegenstand Spanten, Stege, Rippen in der Seitenflosse Zustand der Faserverbundstruktur (Delamination und Risse - besonders um die Zugangsöffnungen). Innere Faserverbundstrukturen (Ablösung von der Schale, S (K) Delamination und Risse durch Zugangslöcher in...
Page 138 Time Limits / DV 20 KATANA AMM Maintenance Checks AIRCRAFT RUMPF Inspektions Wart Methode Inspektionsgegenstand Halterung des Hauptfahrwerks und der A Bolzen (Risse, Korrosion, Ablösung von der Faserverbundstruktur und Delamination in der umgebenden Faserverbundstruktur). Brandspant Faserverbundstruktur von der Cockpitseite (Risse, Delamination und Verfärbung - insbesondere um die...
Page 139 Time Limits / DV 20 KATANA AMM Maintenance Checks AIRCRAFT E. Höhenleitwerk HÖHENLEITWERK Inspektions Wart Methode Inspektionsgegenstand Höhenflossenschale Faserverbundstruktur (Delamination, Risse, Dellen und S (K) Kratzer). Lackierung (Abplatzer, Kratzer und UV Schäden). Kern (Delamination zwischen Kern und Decklage, Schäden). S (K) Verklebung der Nasenleiste (Ablösungen, Risse über und...
Page 140 Time Limits / DV 20 KATANA AMM Maintenance Checks AIRCRAFT F. Steuerflächen STEUERFLÄCHEN Inspektions Wart Methode Inspektionsgegenstand Querruder Zustand der Faserverbundstruktur (Delamination, Risse, S (K) Dellen und Kratzer). Lackierung (Abplatzer, Kratzer, UV Schäden). Kern (Ablösung zwischen Kern und Decklage, Schäden).
Page 141 Time Limits / DV 20 KATANA AMM Maintenance Checks AIRCRAFT STEUERFLÄCHEN Inspektions Wart Methode Inspektionsgegenstand Massen und statischen Momente innerhalb der Limits. S / F (siehe Kapitel 06-00). Höhenruder und Trimmruder Zustand der Faserverbundstruktur (Delamination, Risse, S (K) Dellen und Kratzer).
Page 142 Time Limits / DV 20 KATANA AMM Maintenance Checks AIRCRAFT G. Abschließende Arbeitsschritte ABSCHLIEßENDE ARBEITSSCHRITTE Inspektions Wart Methode Wartungsarbeiten Steuerflächeneinstellung überprüfen - Siehe Kapitel 06-00. S / F Einen Test des elektrischen Potentialausgleichsystems durchführen - Siehe Kapitel 51-80. Das Leergewicht und die zugehörige Schwerpunktlage ermitteln.
Page 143 Time Limits / DV 20 KATANA AMM Maintenance Checks AIRCRAFT Section 05-30 GENERAL INSPECTIONS 1. General Preflight as well as postflight inspections are part of the general inspection procedure. In general these inspections are performed on a daily base. These inspections are described in the Airplane Flight Manual and are performed by the pilot.
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Page 145 Time Limits / DV 20 KATANA AMM Maintenance Checks AIRCRAFT Section 05-40 UNSCHEDULED INSPECTIONS 1. General Unscheduled inspections are only performed in the event that during flight operation of the airplane incidents occur which are not part of a normal flight operation, and which could have caused a defect or interfere with the airworthiness of the airplane.
Page 146 Time Limits / DV 20 KATANA AMM Maintenance Checks AIRCRAFT B. Sudden Engine Stoppage (Prop Strike) Refer to the ROTAX Operator's Manual and to Sub-Chapter 71-00 Propeller Flange Check. C. Non-Operation of More Than 30 Days With non-operation of more than 30 days, refer to Chapter 10-30 for correct procedure.
Page 147 DV 20 KATANA AMM Dimensions and Areas AIRCRAFT CHAPTER 06 DIMENSIONS AND AREAS Doc # 4.02.02 Page 1 06-TITLE Rev. 13 15 Dec 2018...
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Page 149 DV 20 KATANA AMM Dimensions and Areas AIRCRAFT TABLE OF CONTENTS CHAPTER 06 DIMENSIONS AND AREAS General ............1 Dimensions .
Page 150: Dimensions And Areas
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Page 151: General
DV 20 KATANA AMM Dimensions and Areas AIRCRAFT CHAPTER 06 DIMENSIONS AND AREAS 1. General Most dimensions in this chapter are metric. The spans are measured parallel to their respective datum plane if not indicated otherwise. Unit Conversions LENGTH ----------- = inch 25.4...
Page 152 Dimensions and Areas DV 20 KATANA AMM AIRCRAFT 10780 1900 7165 2100 1750 2650 Figure 1: Three View Drawing Page 2 Doc # 4.02.02 06-00-00 15 Dec 2018 Rev. 13...
Page 153: Dimensions
DV 20 KATANA AMM Dimensions and Areas AIRCRAFT 2. Dimensions DV 20 KATANA Dimensions Overall Dimensions Wing span 10.78 m (35.4 ft) 10.84 m (35.6 ft) including ACL Length 7.28 m (23.9 ft) Height (nominal) 1.76 m (5.77 ft) Wings...
Page 154: Adjustment Values For Control Surfaces And Trim, Adjustment Report
AIRCRAFT 3. Adjustment Values for Control Surfaces and Trim, Adjustment Report All adjustment values are recorded in the so called Adjustment Report before a DV 20 KATANA is delivered. The completed report is part of the Airplane Maintenance Log. When the adjustment values are checked, the report should be used to determine whether any deviations from the recorded measurements have occurred.
Page 155 DV 20 KATANA AMM Dimensions and Areas AIRCRAFT Doc # 4.02.02 Page 5 06-00-00 Rev. 13 15 Dec 2018...
Page 156: Control Surface Gaps
Dimensions and Areas DV 20 KATANA AMM AIRCRAFT 4. Control Surface Gaps The gaps between control surfaces and wings/fins must be at least 3 mm (0.12") wide. 5. Masses and Residual Moments of Control Surfaces After re-painting or repair of control surfaces special attention must be paid to ensure that the masses (weights) and residual moments of the control surfaces are within the limit values specified on the Adjustment Report (see paragraph 3.
Page 157 DV 20 KATANA AMM Lifting and Shoring AIRCRAFT CHAPTER 07 LIFTING AND SHORING Doc # 4.02.02 Page 1 07-TITLE Rev. 13 15 Dec 2018...
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Page 159 DV 20 KATANA AMM Lifting and Shoring AIRCRAFT TABLE OF CONTENTS CHAPTER 07 LIFTING AND SHORING General ............1 Required Equipment .
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Page 161: Lifting And Shoring
LIFTING AND SHORING 1. General The DV 20 KATANA is a very light airplane and does not have any crane attachment points. Belts are used to lift the airplane. The wings and elevator unit are removed and carried by hand.
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Page 163 DV 20 KATANA AMM Lifting and Shoring AIRCRAFT Section 07-10 LIFTING 1. General No lifting equipment is required for installation and removal of the wings and elevator unit. Belts are used to lift the fuselage. The forward belt should be placed in front of the steps, the rearward belt should be placed in front of the tail fin.
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Page 165: General
SHORING 1. General Two jacking points are provided for jacking and shoring the DV 20 KATANA. They are located at the bottom of the fuselage's root ribs (see Fig. 1). The rear is supported, using the proper support seat, by the third jack in front of the vertical stabilizer.
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Page 167 DV 20 KATANA AMM Leveling and Weighing AIRCRAFT CHAPTER 08 LEVELING AND WEIGHING Doc # 4.02.02 Page 1 08-TITLE Rev. 13 15 Dec 2018...
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Page 169 DV 20 KATANA AMM Leveling and Weighing AIRCRAFT TABLE OF CONTENTS CHAPTER 08 LEVELING AND WEIGHING General ............1 Leveling .
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Page 171 Empty mass (weight) and corresponding center of gravity and useful load must be recorded in the Weighing Report (see DV 20 KATANA Flight Manual). 2. Leveling Prior to weighing the airplane axes must be aligned horizontally and vertically by leveling the airplane.
Page 172 Leveling and Weighing DV 20 KATANA AMM AIRCRAFT 3. Weighing The weighing may be performed using mechanical or electrical scales. The scale manufacturers' guide lines must be observed. Preparations to be made before every weighing: Check that the equipment is complete and installed in the correct positions according to the equipment list.
Page 173 DV 20 KATANA AMM Leveling and Weighing AIRCRAFT Doc # 4.02.02 Page 3 08-00-00 Rev. 13 15 Dec 2018...
Page 174 Leveling and Weighing DV 20 KATANA AMM AIRCRAFT 4. Permissible Empty Mass (Weight) C.G. Range The empty mass center of gravity must be within the limits listed in the table below. On one hand, these limits permit the operation of the airplane by a 55 kg (121 lbs.) pilot with 19 kg (42 lbs.) of fuel without exceeding the rearward CG limit according to the Airplane Flight Manual.
Page 175 DV 20 KATANA AMM Towing and Taxiing AIRCRAFT CHAPTER 09 TOWING AND TAXIING Doc # 4.02.02 Page 1 09-TITLE Rev. 13 15 Dec 2018...
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Page 177 DV 20 KATANA AMM Towing and Taxiing AIRCRAFT TABLE OF CONTENTS CHAPTER 09 TOWING AND TAXIING General ............1 Equipment and Accessories .
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Page 179 2. Equipment and Accessories The DV 20 KATANA is towed using a draw tongue that is part of the optional equipment, and attached to the nose wheel. One person is capable of moving the airplane on a smooth, level surface using this equipment.
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Page 181 On the ground, the airplane can be moved manually or with a tow vehicle. The towing procedures are described below. 2. Towing Procedures A. Towing without Tow Vehicle Normally the DV 20 KATANA is moved manually using the draw tongue. The following procedure should be followed: Detail Steps/Work Items Key Items/References Attach the draw tongue to the nose wheel strut and close.
Page 182 Towing and Taxiing DV 20 KATANA AMM AIRCRAFT B. Towing with a Tow Vehicle When the airplane is moved with a tow vehicle, the following procedure must be followed: Detail Steps/Work Items Key Items/References Attach the draw tongue to the nose wheel strut and close.
Page 183 Towing and Taxiing AIRCRAFT C. Moving without Draw Tongue The airplane may be moved without using the draw tongue. The DV 20 KATANA may be pushed at the wing-tips and at the wing-fuselage connection. CAUTION: NEVER PUSH OR PULL ON THE CONTROL SURFACES! In the case of reduced freedom to maneuver two people can turn the airplane about the main wheels.
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Page 185 Section 09-20 TAXIING 1. General The DV 20 KATANA is controlled with the foot operated brakes during taxiing. In order to achieve very tight turning radii, the brake may be applied to individual wheels. NOTE: The airplane may only be taxied by authorized personnel.
Page 186 Towing and Taxiing DV 20 KATANA AMM AIRCRAFT Detail Steps/Work Items Key Items/References Taxi the airplane to the desired position. Turn off engine. See Airplane Flight Manual DV 20 KATANA. Park the airplane and moor as required. See Chapter 10.
Page 187 DV 20 KATANA AMM Parking and Mooring AIRCRAFT CHAPTER 10 PARKING AND MOORING Doc # 4.02.02 Page 1 10-TITLE Rev. 13 15 Dec 2018...
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Page 189 DV 20 KATANA AMM Parking and Mooring AIRCRAFT TABLE OF CONTENTS CHAPTER 10 PARKING AND MOORING General ............1 Equipment and Accessories .
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Page 191: Parking And Mooring
PARKING AND MOORING 1. General To avoid possible damage to the airplane, the DV 20 KATANA should always be parked or moored while not in use. The pilot and maintenance personnel should thoroughly familiarize themselves with the procedures described in Chapters 10-10 and 10-20.
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Page 193: Parking
DV 20 KATANA AMM Parking and Mooring AIRCRAFT Section 10-10 PARKING 1. General The following parking procedures must be followed to protect the airplane when it is parked outside. The scope of the procedure depends on the parking time and weather conditions.
Page 194: Long Term Parking
Parking and Mooring DV 20 KATANA AMM AIRCRAFT 3. Long Term Parking If the airplane is parked for long periods of time, danger of wheel bearing corrosion exists. To prevent this, the wheels of the lifted airplane (Chapter 07) should be turned three to four revolutions. Parked airplanes should be moved by pushing or towing.
Page 195: Mooring
DV 20 KATANA AMM Parking and Mooring AIRCRAFT Section 10-20 MOORING 1. General Whenever the airplane is parked outside for extended periods of time, it should be moored. Unexpected strong gusts or heavy winds can cause severe damage to an airplane that is not moored.
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Page 197: Parking Duration
DV 20 KATANA AMM Parking and Mooring AIRCRAFT Section 10-30 PARKING DURATION 1. Parking Over 30 Days For parking over 30 days the following maintenance work is required: A. Engine Preservation and De-Preservation See Operator's Manual for the Rotax engine.
Page 198 Parking and Mooring DV 20 KATANA AMM AIRCRAFT G. Loose Equipment Collect loose equipment and store. H. Electronic Equipment No special procedure required. I. Airplane Ventilation Vent the airplane thoroughly before parking. J. Parking and Mooring See Chapter 10-20. Page 2 Doc # 4.02.02...
Page 199 DV 20 KATANA AMM Required Placards AIRCRAFT CHAPTER 11 REQUIRED PLACARDS Doc # 4.02.02 Page 1 11-TITLE Rev. 13 15 Dec 2018...
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Page 201 DV 20 KATANA AMM Required Placards AIRCRAFT TABLE OF CONTENTS CHAPTER 11 REQUIRED PLACARDS General ............1 Material .
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Page 203 DV 20 KATANA AMM Required Placards AIRCRAFT CHAPTER 11 REQUIRED PLACARDS 1. General Placards are used for identification and indication purposes. They should describe the function, operation, and operating limitations of the various systems and equipment. This chapter describes the location of the placards on the interior and exterior surfaces of the airplane.
Page 204 Required Placards DV 20 KATANA AMM AIRCRAFT B. Self Adhesive Plastic Foils Procedure: Detail Steps/Work Items Key Items/References Moisten foil and surface with soap water using a sponge. Press on new placard using plastic spatula. Remove protective film and let the placard dry.
Page 205 DV 20 KATANA AMM Required Placards AIRCRAFT Section 11-10 LOCATION OF PLACARDS 1. General In addition to the fire proof identification plate, the following placards are installed: Easily visible in the cockpit S/N's registered outside of North America: S/N's registered in the U.S.A.:...
Page 206 Required Placards DV 20 KATANA AMM AIRCRAFT Near the pilot's feet, next to the fuel shut-off valve (partly colored red) <-- colored red On the left and right side wall on the air vents Under the instrument panel next to the individual knobs and handles Page 2 Doc # 4.02.02...
Page 207 DV 20 KATANA AMM Required Placards AIRCRAFT On the instrument panel next to the individual breakers, switches, and caution and warning lamps (partly colored red) The area marked gray is red on the actual placard. Doc # 4.02.02 Page 3 11-10-00 Rev.
Page 208 Required Placards DV 20 KATANA AMM AIRCRAFT On the instrument panel next to the individual breakers, switches, and caution and warning lamps (if OÄM 20-244 & OÄM 20-245 are installed): On the instrument panel next to the individual breakers and switches (if OÄM 20-267 is installed): Page 4 Doc # 4.02.02...
Page 209 DV 20 KATANA AMM Required Placards AIRCRAFT On the center console next to the trim lever: Next to the canopy emergency release handles (all colored red) inside, left inside, right 8 last two lines outside, left only if ELT is installed...
Page 210 Required Placards DV 20 KATANA AMM AIRCRAFT On the brake fluid reservoirs Next to main wheels Next to nose wheel On oil filler cap On lid in canopy, inside (colored red) On coolant equalizing reservoir On coolant dispatcher vessel NOT valid on 912 S3...
Page 211 DV 20 KATANA AMM Required Placards AIRCRAFT On the instrument panel or within the pilot's field of vision Next to ELT (if installed) to indicate switch positions On fuselage upper skin behind cockpit (only if ELT is installed), colored yellow Next to GPS (if installed) Doc # 4.02.02...
Page 212 Required Placards DV 20 KATANA AMM AIRCRAFT On power plant instruments A. Engine with Cylinder Temperature Senor If an engine without suffix -01 is installed, use the following placards: for ROTAX 912 A3 only: for ROTAX 912 S3 only: B. Engine with Coolant Temperature Sensor...
Page 213 DV 20 KATANA AMM Required Placards AIRCRAFT Section 11-11 ANBRINGUNGSORTE DER HINWEISSCHILDER UND BESCHRIFTUNGEN (GERMAN VERSION OF CHAPTER 11-10) 1. Allgemeines Es sind außer dem feuerfesten Typenschild noch folgende Schilder angebracht: Gut sichtbar im Cockpit An der Rückwand des Gepäckraums: Auf der Mittelkonsole: Doc # 4.02.02...
Page 214 Required Placards DV 20 KATANA AMM AIRCRAFT Im linken Fußraum neben dem Brandhahn: (teilweise rot) <-- rot An der rechten und linken Bordwand auf der Lüftungsdüse: Unter dem Instrumentenbrett neben den einzelnen Betätigungsgriffen: Page 2 Doc # 4.02.02 11-11-00 15 Dec 2018...
Page 215 DV 20 KATANA AMM Required Placards AIRCRAFT Auf dem Instrumentenbrett neben den Sicherungen, Schaltern und Kontrollampen (teilweise rot): Die grau markierte Fläche ist auf dem Schild rot. Doc # 4.02.02 Page 3 11-11-00 Rev. 13 15 Dec 2018...
Page 216 Required Placards DV 20 KATANA AMM AIRCRAFT Auf dem Instrumentenbrett neben den Sicherungen, Schaltern und Kontrolllampen (wenn OÄM 20-244 & OÄM 20-245 eingebaut sind): Auf dem Instrumentenbrett neben den Sicherungen und Schaltern (wenn OÄM 20-267eingebaut ist): Page 4 Doc # 4.02.02...
Page 217 DV 20 KATANA AMM Required Placards AIRCRAFT Auf der Mittelkonsole neben dem Trimmknopf: Neben den Griffen für den Haubennotabwurf (alle rot): innen links innen rechts 8 untere zwei außen links Zeilen nur falls ELT eingebaut außen rechts Neben dem Zündschalter (rot):...
Page 218 Required Placards DV 20 KATANA AMM AIRCRAFT Neben dem Tankeinfüllstutzen: Auf den Bremsflüssigkeitsbehältern: Neben den Hauptfahrwerksrädern: Neben dem Bugrad: Auf dem Öldeckel: Auf dem Wartungsdeckel für den Öltank (in der oberen Cowling) Auf dem Kühlflüssigkeits-Ausgleichsgefäß: Auf dem Kühlflüssigkeits-Verteilergefäß: nicht für ROTAX 912 S3 oder wenn Sensor für Kühlmittel installiert ist.
Page 219 DV 20 KATANA AMM Required Placards AIRCRAFT Auf dem Instrumentenbrett oder im Sichtfeld des Piloten: Neben dem ELT (falls eingebaut) zur Kennzeichnung der Schalterstellung: Auf der Rumpfoberseite hinter dem Cockpit (falls ELT eingebaut ist, Farbe gelb): Beim GPS (falls eingebaut): Doc # 4.02.02...
Page 220 Required Placards DV 20 KATANA AMM AIRCRAFT Auf den Triebwerksüberwachungsinstrumenten A. Motor mit Zylinderkopftemperatursensor Wenn ein Motor ohne Suffix -01 eingebaut ist, werden die folgenden Placards verwendet: nur für ROTAX 912 A3: nur für ROTAX 912 S3: B. Motor mit Kühlflüssigkeitstemperatursensor Wenn ein Motor mit dem Suffix -01 eingebaut ist, wird das folgende Placard verwendet: Kühlmittel...
Page 221 DV 20 KATANA AMM Servicing AIRCRAFT CHAPTER 12 SERVICING Doc # 4.02.02 Page 1 12-TITLE Rev. 13 15 Dec 2018...
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Page 223 DV 20 KATANA AMM Servicing AIRCRAFT TABLE OF CONTENTS CHAPTER 12 SERVICING General ............1...
Page 224 Servicing DV 20 KATANA AMM AIRCRAFT Section 12-30 UNSCHEDULED SERVICING Cleaning, Exterior ..........1 Cleaning, Interior .
Page 225 DV 20 KATANA AMM Servicing AIRCRAFT CHAPTER 12 SERVICING 1. General Servicing on the ground in general includes replenishing and the periodic lubrication of component groups. Other tasks which are performed during ground services are also described in this chapter.
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Page 227: Replenishing
1. Fuel System A. REFUELING Fuel for the DV 20 KATANA is supplied from a fuselage mounted fuel tank with a capacity of either 55 liters (14.5 US gal.) or 79 liters (20.9 US gal.). The aluminum welded fuel tank is located between the main- and B-bulkhead below the baggage compartment floor.
Page 228: Oil System
2. Oil System The engine installed in the DV 20 KATANA is equipped with a dry sump pressure lubrication system with a capacity of 3 liters (3.2 US quarts). The filler cap of the oil tank is located on the right hand side of the engine behind cylinder No.
Page 229: Brake System
DAMAGES PAINT UPON CONTACT. 4. Tires The DV 20 KATANA main landing gear is equipped with tires of the size 380 x 150/15 x 6.00-5. The tire size used on the nose wheel is 4.00-4. The tire pressure on the landing gear wheels is 2.3 bar (33 psi), on the nose wheel 1.8 bar (26 psi).
Page 230: Battery
Servicing DV 20 KATANA AMM AIRCRAFT 5. Battery The battery mount holding a 12 Volt battery is installed to the front left hand side of the firewall. The battery provides power for the engine starter. Furthermore it allows the electrical consumers to be operated while the engine is off.
Page 231 DV 20 KATANA AMM Servicing AIRCRAFT (2) Engine with Coolant Temperature Sensor If an engine with suffix -01 is installed, ensure that only antifreeze concentrate based on ethylene glycol, designed for aluminum engines is used (e.g. BASF Glysantin Protect Plus/G48).
Page 232 Servicing DV 20 KATANA AMM AIRCRAFT B. Adding of Coolant Prior to adding coolant, the reason for the loss of the liquid must be investigated and corrected (e.g. leaky hose connections). NOTE: Consumption of coolant is very limited under normal circumstances. Therefore topping up is necessary and senseful only if the coolant quantity is below the minimum marking.
Page 233: Scheduled Servicing
DV 20 KATANA AMM Servicing AIRCRAFT Section 12-20 SCHEDULED SERVICING 1. General The complete flight control system and all other mechanical systems are, with a few exceptions, equipped with maintenance free friction bearings and rod end bearings. However, these bearings and joints should be inspected regularly, especially under tough climatic conditions such as airborne sand, saltwater concentrations in the air etc., and if required cleaned and lubricated.
Page 234: Lubrication Schedule
Servicing DV 20 KATANA AMM AIRCRAFT 2. Lubrication Schedule Independent of the lubrication during rigging, lubrication is required at the intervals marked with a X. Prior to lubrication all lubrication points must be cleaned. LUBRICATION SCHEDULE Hours 1000 Clamp straps of engine operating cables (oil).
Page 235: Periodische Kontrollen
DV 20 KATANA AMM Servicing AIRCRAFT Section 12-21 PERIODISCHE KONTROLLEN (GERMAN VERSION OF CHAPTER 12-20) 1. Allgemeines Mit wenigen Ausnahmen sind die gesamte Steuerung und die sonstige Mechanik mit wartungsfreien Gleitlagern und Gelenklagerköpfen ausgerüstet. Trotzdem sollten die Lager (besonders bei härteren klimatischen Bedingungen wie Flugsand, salzwasserfeuchte Luft usw.) ständig beobachtet und bei...
Page 236: Schmierplan
Servicing DV 20 KATANA AMM AIRCRAFT 2. Schmierplan Neben dem Schmieren beim Aufrüsten ist ein Schmieren an den jeweils mit einem X versehenen Zeitpunkten erforderlich. Alle Schmierstellen müssen vor dem Schmieren gereinigt werden. SCHMIERPLAN Hours 1000 Klemmnippel der Triebwerksbedienungs-Bowdenzüge ölen.
Page 237: Unscheduled Servicing
DV 20 KATANA AMM Servicing AIRCRAFT Section 12-30 UNSCHEDULED SERVICING 1. Cleaning, Exterior For the flight characteristics of a composite airplane with a laminar airfoil, a clean external surface is most important. For this reason it is highly recommendable that the airplane, especially the leading edge of the wings are kept clean at all times.
Page 238: Engine Cleaning
Servicing DV 20 KATANA AMM AIRCRAFT 3. Engine Cleaning For cleaning of the engine a cold cleaning agent should be used. CAUTION: ENSURE THAT THE ENGINE CLEANING AGENT DOES NOT GET INTO THE FOLLOWING INSTRUMENTS AND COMPONENTS: IGNITION SYSTEM, GENERATOR, STARTER, AIR INTAKES.
Page 239 Standard Practices DV 20 KATANA AMM - Airframe AIRCRAFT CHAPTER 20 STANDARD PRACTICES - AIRFRAME Doc # 4.02.02 Page 1 20-TITLE Rev. 13 15 Dec 2018...
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Page 241 Standard Practices DV 20 KATANA AMM - Airframe AIRCRAFT TABLE OF CONTENTS CHAPTER 20 STANDARD PRACTICES - AIRFRAME General ............1 Bolt Types .
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Page 243 2. Bolt Types The bolts used in the DV 20 KATANA are of DIN and LN specifications which can be identified by the markings located on the head of the bolts and by the surface treatment.
Page 244 Standard Practices DV 20 KATANA AMM - Airframe AIRCRAFT 4. Special Torques Part Torque (Nm) Torque (lbf.ft.) Propeller lock nuts. see propeller manual Spinner mounting screws. see Chapter 61 or propeller manual Spark plugs. 14.8 Bolts attaching engine mount to firewall.
Page 245 DV 20 KATANA AMM Environmental Systems AIRCRAFT CHAPTER 21 ENVIRONMENTAL SYSTEMS Doc # 4.02.02 Page 1 21-TITLE Rev. 13 15 Dec 2018...
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Page 247 DV 20 KATANA AMM Environmental Systems AIRCRAFT TABLE OF CONTENTS CHAPTER 21 ENVIRONMENTAL SYSTEMS General ............1...
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Page 249 ENVIRONMENTAL SYSTEMS 1. General The heating and ventilation system installed in the DV 20 KATANA permits the independent supply of cold and warm air as well as the supply of warm air to the floor and the canopy. Control of the heating system is located in the center console on the transition piece to the instrument panel.
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Page 251: Distribution
DV 20 KATANA AMM Environmental Systems AIRCRAFT Section 21-20 DISTRIBUTION 1. Functional Description A. Heating System and Canopy Defroster During flight, ram air is directed to the heat exchanger through an air hose installed behind the radiator. After passing the heat exchanger, the warm air is directed by an air hose to the air distributor, which is mounted to the lower half of the firewall.
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Page 253: Heating
DV 20 KATANA AMM Environmental Systems AIRCRAFT Section 21-40 HEATING 1. Heat Exchanger Removal Detail Steps/Work Items Key Items/References Remove engine cowlings. Loosen hose clamps of air intake and cabin heat hose, remove both hoses from the upper half of the heat exchanger.
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Page 255 DV 20 KATANA AMM Communications AIRCRAFT CHAPTER 23 COMMUNICATIONS Doc # 4.02.02 Page 1 23-TITLE Rev. 13 15 Dec 2018...
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Page 257 DV 20 KATANA AMM Communications AIRCRAFT TABLE OF CONTENTS CHAPTER 23 COMMUNICATIONS General ............1 Section 23-10.1...
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Page 259 DV 20 KATANA AMM Communications AIRCRAFT CHAPTER 23 COMMUNICATIONS 1. General The VHF radio system is used for communication between airplane and ground station, and between airplanes. It operates in the frequency band between 118,00 to 136,975 MHz. The system consists of the following components:...
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Page 261 DV 20 KATANA AMM Communications AIRCRAFT Section 23-10.1 SPEECH COMMUNICATION BECKER AR3201 1. General The AR3201-(.) radio system consists of a transmitter/receiver including operator panel, and is designed as a single unit system. The frequency range of 118.000 MHz to 136.975 MHz includes 760 channels in intervals of 25 kHz.
Page 262 Communications DV 20 KATANA AMM AIRCRAFT STORE BECKER 1 ON/OFF Switch, combined with Squelch Switch 2 Transit Mode Indicator 3 Channel Selector Switch 4 Mhz Frequency Selector Switch 5 kHz Frequency Selector Switch 6 LCD for Frequency Selector Switch 7 Memory Switch 8 Volume Control Figure 1: Becker AR3201-(.)
Page 263 DV 20 KATANA AMM Communications AIRCRAFT 2. System Description A. Receiver Description The high frequency signal received by the antenna arrives via a coaxial cable at the antenna input of the radio unit. It is selected, amplified, demodulated, and fed to the speaker or headphones as a low frequency signal.
Page 264 Communications DV 20 KATANA AMM AIRCRAFT C. Unit Operation Switch master switch and avionics master switch ON. (1) SWITCHING ON Switch the VHF unit switch ON. For a few seconds the number 188.88 (display test) as well as an arrow (transmit mode indicator) is displayed on the LC-display. Following that the VHF unit is switched automatically to the last used frequency if the channel selector is in position A.
Page 265 DV 20 KATANA AMM Communications AIRCRAFT (3) TRANSMIT MODE INDICATOR While transmitting, a small arrow is displayed left of the selected frequency on the LC-display. It indicates that the VHF unit is in transmit mode. (4) ON-BOARD INTERCOMMUNICATION The speaker is switched off in this operation mode.
Page 266 Communications DV 20 KATANA AMM AIRCRAFT 3. Troubleshooting The following table contains procedures for general troubleshooting on the radio and intercom system. For the corresponding wiring diagrams refer to Chapter 92 of the Maintenance Manual. Complaint Possible Cause Repair Unable to transmit or receive, Defective power supply.
Page 267 DV 20 KATANA AMM Communications AIRCRAFT Complaint Possible Cause Repair Short range in receive mode, Defective radio unit. Repair. signal noise in reception. Short range in transmit and COMM antenna, coaxial cable Repair or replace. receive mode, signal noise in and plug.
Page 268 Communications DV 20 KATANA AMM AIRCRAFT 4. Maintenance Information A. General The Becker AR3201 radio unit requires no regular maintenance. The built-in buffer battery for the stored frequencies has a lifetime expectancy of approximately four (4) years. We recommend that the AR3201 unit is sent to the manufacturer or an approved Becker representative for replacement of the battery if the stored frequencies are lost.
Page 269 SPEECH COMMUNICATION BENDIX/KING KX125 1. General The KX125 radio system is part of the NAV/COMM system used in the DV 20 KATANA. The COMM frequency range of 118.000 MHz to 136.975 MHz includes 760 channels. The memory can store one frequency.
Page 270 Communications DV 20 KATANA AMM AIRCRAFT Active COMM Frequency COMM Frequency Indicator Transmit COMM Transfer Switch Mode Indicator FLAG KX125 COMM MODE PULL PULL PULL PULL TEST IDENT Unit Lock COMM Volume, COMM Frequency LCD Contrast On/OFF Rotational Selector Buttons...
Page 271 DV 20 KATANA AMM Communications AIRCRAFT 2. System Description A. Receiver Description The high frequency signal received by the antenna arrives via a coaxial cable at the antenna input of the radio unit. It is selected, amplified, demodulated, and fed to the speaker or headphones as a low frequency signal.
Page 272 Communications DV 20 KATANA AMM AIRCRAFT C. Unit Operation Switch master switch and avionics master switch ON. (1) SWITCHING ON The KX125 unit is switched ON by turning the COMM/PULL/TEST rotating switch from the OFF position in clockwise direction. The last selected as well as the pre-selected frequencies are displayed on the LC Display.
Page 273 DV 20 KATANA AMM Communications AIRCRAFT 3. Troubleshooting The following table contains procedures for general troubleshooting on the radio and intercom system. For the corresponding wiring diagrams refer to Chapter 92 of the Maintenance Manual. Complaint Possible Cause Repair Unable to transmit or receive, Defective power supply.
Page 274 Communications DV 20 KATANA AMM AIRCRAFT Complaint Possible Cause Repair Short range in transmit mode, Defective radio unit. Repair. reception without problems. Short range in receive mode, Defective radio unit. Repair. signal noise in reception. Short range in transmit and COMM antenna, coaxial cable Repair or replace.
Page 275 DV 20 KATANA AMM Communications AIRCRAFT 4. Maintenance Information A. General The Bendix/King KX125 radio unit requires no regular maintenance. B. Removal and Installation of Radio Unit The KX125 is held in its place by a retaining claw which can be turned with a hexagon socket screw and catches in the rack.
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Page 277 DV 20 KATANA AMM Communications AIRCRAFT Section 23-10.3 SPEECH COMMUNICATION GARMIN GNS 430 1. General Figure 1 shows the GNS 430 NAV/COM/GPS system. It is located in the avionics rack in the instrument panel, see Chapter 31. Refer to the equipment manufacturers’ manuals for more data about the equipment.
Page 278 Communications DV 20 KATANA AMM AIRCRAFT The GNS 430 display is divided into separate 'windows' (or screen areas), including a COM window, VLOC window and the GPS window (the right 3/4 of the display). Figure 1: Garmin GNS 430 NAV/COM/GPS Page 2 Doc # 4.02.02...
Page 279 DV 20 KATANA AMM Communications AIRCRAFT Section 23-10.4 SPEECH COMMUNICATION GARMIN SL 30 1. General Figure 1 shows the SL 30 COM/NAV. It is located in the avionics rack in the instrument panel, see Chapter 31. Refer to the equipment manufacturers’ manuals for more data about the equipment.
Page 280 Communications DV 20 KATANA AMM AIRCRAFT NAV. Press NAV to select the NAV radio mode. The annunciator above the button will light when you are in NAV mode. Press NAV a second time to monitor the standby frequency. SYS. Press SYS to reach the System mode. The annunciator above the button will light when you are in System mode.
Page 281 DV 20 KATANA AMM Electrical Power AIRCRAFT CHAPTER 24 ELECTRICAL POWER Doc # 4.02.02 Page 1 24-TITLE Rev. 13 15 Dec 2018...
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Page 283 DV 20 KATANA AMM Electrical Power AIRCRAFT TABLE OF CONTENTS CHAPTER 24 ELECTRICAL POWER General ............1 Description .
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Page 285 DV 20 KATANA AMM Electrical Power AIRCRAFT CHAPTER 24 ELECTRICAL POWER 1. General The DV 20 is equipped with a 14 Volt direct current (DC) electrical system. An alternator integrated into the engine and connected to a rectifier/voltage regulator supplies power to the electrical system.
Page 286 Electrical Power DV 20 KATANA AMM AIRCRAFT Figure 1: DV 20 Electrical System, Components in Engine Compartment Page 2 Doc # 4.02.02 24-00-00 15 Dec 2018 Rev. 13...
Page 287 DV 20 KATANA AMM Electrical Power AIRCRAFT Voltage Regulator VR2430-01 Central Ground Overvoltage Connectors Relay K2430-01 Battery Relay K2431-01 Anti-Interference Capacitor C2430-02 (under K2430-01) Capacitor C2430-01 Starting Relay K8010-01 Figure 2: Electrical Shelf in Engine Compartment Doc # 4.02.02 Page 3 24-00-00 Rev.
Page 288 Electrical Power DV 20 KATANA AMM AIRCRAFT Figure 3: Electrical Shelf in Engine Compartment (OÄM 20-245, External Alternator) Page 4 Doc # 4.02.02 24-00-00 15 Dec 2018 Rev. 13...
Page 289 DV 20 KATANA AMM Electrical Power AIRCRAFT 2. Description A. Battery The lead acid battery is located in the engine compartment, supplies power to the starter and is also used as emergency supply when the engine has stopped. B. Battery Relay The battery relay connects the battery to the electrical buses 1 and 2, the starting relay, and the avionics bus.
Page 290 Electrical Power DV 20 KATANA AMM AIRCRAFT H. Ammeter The ammeter is located in the right hand section of the instrument panel and indicates charging (+) and discharging (-) of the battery. I. Low Voltage Caution Light The low voltage caution light is located adjacent to the ammeter in the right hand section of the instrument panel, and illuminates when the on-board voltage drops below the threshold of 12.5 Volts.
Page 291: Troubleshooting
DV 20 KATANA AMM Electrical Power AIRCRAFT 3. Troubleshooting The following table lists defects as they could appear in the electrical system, and their correction. Detailed troubleshooting tables are presented in the respective chapters. The wiring diagrams are located in Chapter 92 of the Maintenance Manual.
Page 292: Maintenance Information
Electrical Power DV 20 KATANA AMM AIRCRAFT 4. Maintenance Information CAUTION: GENERAL SAFETY REGULATIONS SHOULD BE OBSERVED DURING MAINTENANCE PERFORMED ON THE ELECTRICAL SYSTEM, AS WELL AS SAFETY INSTRUCTIONS DESCRIBED IN THE FOLLOWING CHAPTERS. THE BATTERY SHOULD BE DISCONNECTED FOR EXTENSIVE MAINTENANCE OPERATIONS.
Page 293: Dc Generation
DV 20 KATANA AMM Electrical Power AIRCRAFT Section 24-30 DC GENERATION 1. General The generator system consists of the following components: Description Identification Internal alternator GEN2430-01 Voltage regulator VR2430-01 Overvoltage control relay K2430-01 Overvoltage sensor SE2430-01 Generator warning light DS2430-01...
Page 294 Electrical Power DV 20 KATANA AMM AIRCRAFT The generator warning light is located under the battery master switch in the switch panel above the radio rack. If OÄM 20-244 (Instrument Panel Version D20-3110-00-00) is installed, the generator warning light is installed in the top center section of the instrument panel.
Page 295 DV 20 KATANA AMM Electrical Power AIRCRAFT 2. Description The generator is a permanently excited ten-pole monophase alternator. It is connected directly to the engine crankshaft through a flange. The voltage is generated in coils which are arranged in tangential direction and whose windings are crossed by the magnetic flux lines of the rotor magnet.
Page 296 Electrical Power DV 20 KATANA AMM AIRCRAFT In the event that the voltage on the sensing input of the overvoltage sensor (on-board voltage) increases above 16.1 Volts due to malfunction of the voltage regulator, the control output interrupts the supply to the overvoltage control relay, the control relay opens and disconnects the alternator from the voltage regulator.
Page 297: Troubleshooting
DV 20 KATANA AMM Electrical Power AIRCRAFT 3. Troubleshooting The following table lists defects as they could appear on the generator system, and their correction. The wiring diagrams are located in Chapter 92 of the maintenance manual, or this temporary revision to the maintenance manual.
Page 298 Electrical Power DV 20 KATANA AMM AIRCRAFT Trouble Possible Cause Repair No power supplied by Voltage regulator. Replace. Replace alternator if alternator with engine running the external alternator (malfunction even with (OÄM 20-245) is installed. minimum current consumption); low voltage Generator circuit breaker.
Page 299 DV 20 KATANA AMM Electrical Power AIRCRAFT Trouble Possible Cause Repair Generator control or mater Voltage regulator. Replace. Replace alternator if control circuit breaker opens the external alternator with battery master switch on. (OÄM 20-245) is installed. Overvoltage sensor. Replace.
Page 300: Removal And Installation
Electrical Power DV 20 KATANA AMM AIRCRAFT 4. Removal and Installation A. Alternator For removal and installation of the alternator refer to engine operator's manual. (1) Voltage Regulator (a) Removal Detail Steps/Work Items Key Items/References Throw master switch in OFF position.
Page 301 DV 20 KATANA AMM Electrical Power AIRCRAFT (2) Overvoltage Control Relay (a) Removal Detail Steps/Work Items Key Items/References Switch OFF the electric master switch. Remove upper engine cowling. Remove connector (P2430-03) from overvoltage control relay. Remove the front mounting screws on overvoltage control relay;...
Page 302: Maintenance Information
Electrical Power DV 20 KATANA AMM AIRCRAFT (4) Low Voltage Sensor (a) Removal Detail Steps/Work Items Key Items/References Switch OFF the electric master switch. Remove top cover from instrument panel. Disconnect low voltage sensor on terminal board TB1. If OÄM 20-244 (Instrument Panel...
Page 303: Battery System
DV 20 KATANA AMM Electrical Power AIRCRAFT Section 24-31 BATTERY SYSTEM 1. General The DV 20 is equipped with a 12 Volts, 30 amp.hrs. lead acid accumulator located in the engine compartment in a composite trough. The battery is charged by the alternator.
Page 304 Electrical Power DV 20 KATANA AMM AIRCRAFT Engine Flight Compartment Compartment Master Relay Starting Relay B8010-01 Electrical Bus 1 Ammeter M2431-01 K2431-01 K8010-01 Engine Starter Engine Start S7430-01 Battery 12V/30AH Starting Switch CB8010-01 BT2431-01 Part of Ignition Switch Figure 2: DV 20 Battery System, Simplified Schematic Page 2 Doc # 4.02.02...
Page 305 DV 20 KATANA AMM Electrical Power AIRCRAFT 2. Description The battery is connected to the electrical buses, and consequently to the on-board network, via the master relay (K2431-01). With the battery master switch (S2400-01) in the OFF position, the battery voltage is connected to the opened master relay (K2431-01).
Page 306: Troubleshooting
Electrical Power DV 20 KATANA AMM AIRCRAFT 3. Troubleshooting The following table lists defects as they could appear on the battery system, and their correction. The wiring diagrams are located in chapter 92 of the maintenance manual. Complaint Possible Cause...
Page 307: Maintenance Information
DV 20 KATANA AMM Electrical Power AIRCRAFT 4. Maintenance Information The battery has an inspection interval of 100 flight hours. At this interval or after prolonged parking (see Sub-Chapter 10-30), the fluid level should be checked (should be approximately 1 cm or 0.4 inch above the lead plates), as well as the charge condition using a hydrometer.
Page 308: Continuity Check
Electrical Power DV 20 KATANA AMM AIRCRAFT 5. Continuity Check The continuity check is performed to detect eventual defects in parallel routed wires. If OÄM 20-244 (Instrument Panel Version D20-3110-00-00) and OÄM 20-245 (External Alternator) are installed, this check must not be performed. Refer to Wiring Diagram No. 01-2400-14-1 in Chapter 92.
Page 309: Removal And Installation
DV 20 KATANA AMM Electrical Power AIRCRAFT 6. Removal and Installation CAUTION: WHEN DISCONNECTING THE BATTERY, ALWAYS DISCONNECT THE NEGATIVE TERMINAL FIRST. FOR RECONNECTING THE BATTERY, ALWAYS CONNECT THE NEGATIVE TERMINAL LAST. A. Battery (BT2431-01) (1) Removal Detail Steps/Work Items Key Items/References Throw master switch in OFF position.
Page 310 Electrical Power DV 20 KATANA AMM AIRCRAFT B. Master Relay (K2431-01) (1) Removal Detail Steps/Work Items Key Items/References Throw master switch in OFF position. Disconnect negative battery terminal. Disconnect cable from relay. Remove relay by loosening the mounting screws. (2) Installation...
Page 311: Cleaning
DV 20 KATANA AMM Electrical Power AIRCRAFT (2) Installation Detail Steps/Work Items Key Items/References For installation reverse the sequence. Note: Ensure correct re-connection of the connecting wires! Refer to Chapter 92 for wiring diagram. D. Master Switch (S2400-00) (1) Removal...
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Page 313: Electric Load Distribution
DV 20 KATANA AMM Electrical Power AIRCRAFT Section 24-50 ELECTRIC LOAD DISTRIBUTION 1. General The electrical power from the alternator and the battery is supplied via bus 1 and bus 2, the avionics bus, and the respective circuit breakers to the individual electrical equipment.
Page 314: Troubleshooting
Electrical Power DV 20 KATANA AMM AIRCRAFT 3. Troubleshooting The following table lists defects as they could appear on the power distribution system, and their correction. The wiring diagrams are located in Chapter 92 of the maintenance manual, or this temporary revision to the maintenance manual.
Page 315: Maintenance Information
DV 20 KATANA AMM Electrical Power AIRCRAFT 4. Maintenance Information WARNING: TO AVOID BURNS OR FIRE DURING MAINTENANCE TASKS PERFORMED IN THE ENGINE COMPARTMENT, NEAR THE BATTERY, OR DIRECTLY ON THE ELECTRICAL SYSTEM (REPLACING OF COMPONENTS, OR WORKING ON THE CABLING), EXERCISE CAUTION.
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Page 317 DV 20 KATANA AMM Equipment/Furnishings AIRCRAFT CHAPTER 25 EQUIPMENT / FURNISHINGS Doc # 4.02.02 Page 1 25-TITLE Rev. 13 15 Dec 2018...
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Page 319 DV 20 KATANA AMM Equipment/Furnishings AIRCRAFT TABLE OF CONTENTS CHAPTER 25 EQUIPMENT / FURNISHINGS General ............1...
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Page 321 DV 20 KATANA AMM Equipment/Furnishings AIRCRAFT CHAPTER 25 EQUIPMENT / FURNISHINGS 1. General The cabin equipment is subdivided into the two (2) pilot seats, cabin lining, equipment components, and baggage compartment. A description of the individual component groups and equipment can be found in the respective chapters.
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Page 323 DV 20 KATANA AMM Equipment/Furnishings AIRCRAFT Section 25-10 FLIGHT COMPARTMENT 1. General This chapter describes the equipment components located in the cabin. A. Map Pockets Map pockets are installed on the LH and RH cockpit sidewall. Optional extra map pockets are located under the instrument panel.
Page 324 Equipment/Furnishings DV 20 KATANA AMM AIRCRAFT C. Emergency Locator Transmitter (ELT) The DV 20 can be equipped with an Emergency Locator Transmitter. The ELT is installed in a compartment designed for the ELT and located in the rear part of the baggage compartment. The cover of this compartment can easily be removed by loosening the snap screws.
Page 325 DV 20 KATANA AMM Equipment/Furnishings AIRCRAFT 2. Removal and Installation A. ELT (1) Removal Detail Steps/Work Items Key Items/References Loosen wing nuts, remove cover. Slide unit from mounting, disconnect antenna. (2) Installation Detail Steps/Work Items Key Items/References For installation reverse the sequence.
Page 326 Equipment/Furnishings DV 20 KATANA AMM AIRCRAFT B. Instrument Panel Cover (1) Removal Detail Steps/Work Items Key Items/References Remove screws around instrument panel cover. Remove cover by lifting. (2) Installation Detail Steps/Work Items Key Items/References For installation reverse the sequence. C. Seat Shells...
Page 327 DV 20 KATANA AMM Equipment/Furnishings AIRCRAFT D. Safety Belts (1) Removal Detail Steps/Work Items Key Items/References Remove shoulder harnesses by loosening the mounting screws. Remove seat shells. Remove lap belts with central lock by feeding belts through mountings. Remove lap belts without central lock by loosening mounting screw and pulling belts from attachment.
Page 328 Equipment/Furnishings DV 20 KATANA AMM AIRCRAFT 3. Cleaning A. Seats The seat and backrest cushions consist of fire resistant material. For cleaning the cushions are vacuumed. For persistent dirt, the seat covers can be cleaned using a mild soap solution.
Page 329 DV 20 KATANA AMM Equipment/Furnishings AIRCRAFT Section 25-50 BAGGAGE COMPARTMENT 1. General The baggage compartment is used for storage of small baggage and equipment. It is located within the cabin and is within reach of both seats. The baggage compartment has flame resistant floor covering and is approved for loads of up to 20 kg (44 lbs.).
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Page 331 DV 20 KATANA AMM Flight Controls AIRCRAFT CHAPTER 27 FLIGHT CONTROLS Doc # 4.02.02 Page 1 27-TITLE Rev. 13 15 Dec 2018...
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Page 333 DV 20 KATANA AMM Flight Controls AIRCRAFT TABLE OF CONTENTS CHAPTER 27-00 FLIGHT CONTROLS General ............1 Description .
Page 334 Flight Controls DV 20 KATANA AMM AIRCRAFT Section 27-20-10 RUDDER PEDAL ASSEMBLY General ............1 Description .
Page 335 DV 20 KATANA AMM Flight Controls AIRCRAFT Section 27-40 ELEVATOR TRIM SYSTEM General ............1 Description .
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Page 337: Maintenance Information
The DV 20 KATANA is equipped with a manual elevator trim system. The trim lever in the center console is connected to the elevator trim tab. The airplane is trimmed "nose down" when the lever is in a forward position.
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Page 339: Aileron Control System
S/N's 20.005 thru 20.100: refer to Figure 1. S/N's 20.101 and subsequent: refer to Figure 2. The DV 20 KATANA can be operated from either seat. A roll control movement is transmitted from the control sticks to the ailerons through the following parts:...
Page 340 Flight Controls DV 20 KATANA AMM AIRCRAFT LH shown, RH similar Figure 1: Aileron Control System S/N's 20.005 thru 20.100 Page 2 Doc # 4.02.02 27-10-00 15 Dec 2018 Rev. 13...
Page 341 DV 20 KATANA AMM Flight Controls AIRCRAFT LH shown, RH similar Figure 2: Aileron Control System S/N's 20.101 and subsequent Doc # 4.02.02 Page 3 27-10-00 Rev. 13 15 Dec 2018...
Page 342: Troubleshooting
Flight Controls DV 20 KATANA AMM AIRCRAFT 3. Troubleshooting The following table lists defects as they could appear in the aileron control system, and their correction. Complaint Possible Cause Repair Interference. Unclean or detective bearings. Replace bearings. Aircraft moves about Aileron push rods adjusted Re-adjust.
Page 343: Removal And Installation
DV 20 KATANA AMM Flight Controls AIRCRAFT 4. Removal and Installation Refer to Figure 1 or 2. A. Item (1): Control Sticks Refer to Sub-Chapter 27-11. B. Item (2): Aileron Push Rods Connecting Control Sticks (Located under seat shells). (1) Removal...
Page 344 Flight Controls DV 20 KATANA AMM AIRCRAFT C. Item (3): Bellcrank Attached to Rearward Transverse Stiffener Seat shells must be removed. (1) Removal Detail Steps/Work Items Key Items/References Remove 2 mounting bolts of aileron push rods. Remove mounting bolt from pedestal.
Page 345 DV 20 KATANA AMM Flight Controls AIRCRAFT E. Item (5): Bellcrank Attached to Sickle Shaped Bulkhead Baggage compartment floor and fuel tank must be removed. (1) Removal Detail Steps/Work Items Key Items/References Remove 2 mounting bolts of the aileron push rods.
Page 346 Flight Controls DV 20 KATANA AMM AIRCRAFT G. Item (7): Aileron Pockets Only installed in S/N's 20.005 thru 20.100. Wings must be removed. (1) Removal Detail Steps/Work Items Key Items/References Remove mounting bolt of push rod. Remove bolts attaching pocket to fuselage structure;...
Page 347 DV 20 KATANA AMM Flight Controls AIRCRAFT I. Item (9): Push Rod in Wing Wings must be removed (see Chapter 57). (1) Removal Detail Steps/Work Items Key Items/References Open inspection hole on wing bottom side. Remove bolts from rod end bearings at differentiator lever and in wing root rib.
Page 348 Flight Controls DV 20 KATANA AMM AIRCRAFT Cross Section A - A Figure 3: Aileron Bellcrank in Wing NOTE: For reasons of production technique, the aileron bellcrank has holes which must NOT be used. The bellcrank must not be confused with the flap bellcrank (see Chapter 27-50).
Page 349 Refer to Fig. 1 (S/N's 20.005 thru 20.100) or Fig. 2 (S/N's 20.101 and subsequent). The DV 20 KATANA is an airplane with excellent aerodynamic characteristics; any improper adjustment of the ailerons may have a negative effect on the roll stability. After a repair of the aileron control system, a check of the system to verify the correct aileron deflections given in Sub-Chapter 06-00 must be carried out.
Page 350 Flight Controls DV 20 KATANA AMM AIRCRAFT I. Aileron Push Rod in Wing (9) / Aileron Push Rod under Baggage Compartment (6) Applicable only to S/N's 20.101 and subsequent. Wing must be attached, control sticks centered, ailerons at zero deflection.
Page 351: Inspection Of Aileron Control System
DV 20 KATANA AMM Flight Controls AIRCRAFT 6. Inspection of Aileron Control System Detail Steps/Work Items Key Items/References Remove push rod in wing (9). Refer to Figure 1 or 2. Remove aileron bellcrank (10) and (8) if Refer to Figure 1 or 2.
Page 352: Replacement Of Aileron Control System Roller Cages
Flight Controls DV 20 KATANA AMM AIRCRAFT 7. Replacement of Aileron Control System Roller Cages Detail Steps/Work Items Key Items/References Remove the LH and RH wing. Refer to Chapter 57. Remove the roller cages by drilling out the rivets with an angle driller: S Remove the first roller cage through Refer to Figure 4.
Page 353: Main Column
DV 20 KATANA AMM Flight Controls AIRCRAFT Section 27-11 MAIN COLUMN 1. General The main column is located under the seats. It consists of the two control sticks and a torque tube for the transmission of elevator and aileron control inputs.
Page 354 Flight Controls DV 20 KATANA AMM AIRCRAFT B. Elevator Torque Tube Assembly (1) Removal Detail Steps/Work Items Key Items/References Disconnect elevator push rod. Remove LH and RH aluminum mounting ribs. Remove Torque Tube Assembly. (2) Installation Detail Steps/Work Items Key Items/References For installation reverse the sequence.
Page 355: Rudder Control System
2. Description The DV 20 KATANA is equipped with dual control rudder pedals. Any movement of the pedals is transmitted to the rudder through control cables and guide rollers. Either pedal assembly can be adjusted.
Page 356: Troubleshooting
Flight Controls DV 20 KATANA AMM AIRCRAFT 3. Troubleshooting The following table lists defects as they could appear in the rudder control system, and their correction. Complaint Possible Cause Repair Interference. Unclean or detective bearings. Replace or clean bearings. Aircraft moves about yaw axis.
Page 357 RUDDER PEDAL ASSEMBLY 1. General The DV 20 KATANA includes complete pedal assemblies on both sides as standard equipment. These are mounted on the floor group. In addition to the pedals, each assembly consists of an adjustment mechanism and brake cylinders for the left and right wheel brakes. After loosening the mounting bolts, the complete assembly can be removed from the fuselage.
Page 358: Removal And Installation
Flight Controls DV 20 KATANA AMM AIRCRAFT 3. Removal and Installation A. Pedal Assembly (1) Removal It is recommendable to remove the complete pedal assembly. Detail Steps/Work Items Key Items/References Disconnect control cables from firewall. Remove mounting bolts of cradle tube.
Page 359: Rudder Controls In Fuselage
DV 20 KATANA AMM Flight Controls AIRCRAFT Section 27-20-20 RUDDER CONTROLS IN FUSELAGE 1. General Rudder control inputs are transmitted through control cables within the fuselage. Four rollers under the seats and the rudder lever under the B-bulkhead guide the cables through the fuselage structure.
Page 360 Flight Controls DV 20 KATANA AMM AIRCRAFT B. Item (2): Cables Between Rudder Lever and Rudder Lower Mounting Plate (1) Removal and Installation Analogous with removal and installation of forward cables, but with the rudder removed from the airplane. NOTE: Only original material may be used.
Page 361 RUDDER 1. General The DV 20 KATANA is equipped with a conventional rudder which allows control of the airplane about its vertical axis. A fixed trim tab on the rudder allows fine adjustment of the yaw angle. The forward center section of the rudder contains a balancing mass.
Page 362 Flight Controls DV 20 KATANA AMM AIRCRAFT 4. Adjustment A. Rudder Deflection The rudder deflections are limited by stop bolts located in the lower mounting plate. The bolts may be adjusted and locked with lock nuts. For adjustment values, refer to Chapter 06-00.
Page 363: Replacement Of Rudder Upper Hinge Bearing
DV 20 KATANA AMM Flight Controls AIRCRAFT 5. Replacement of Rudder Upper Hinge Bearing Note: Fiber direction reference for all glass fiber plies is the leading edge of the rudder. Detail Steps/Work Items Key Items/References Remove the ball from the bearing.
Page 364 Flight Controls DV 20 KATANA AMM AIRCRAFT Detail Steps/Work Items Key Items/References Manufacture one pre-layer 92110 in accordance Refer to Figure 2. with sketch 2 (cure this layer). Chamfer the cloth around the hole in Refer to Figure 2. accordance with sketch 3.
Page 365 DV 20 KATANA AMM Flight Controls AIRCRAFT CAUTION: ALL LINEAR MEASURES ARE IN MM. Figure 2: Replacement of Rudder Upper Hinge Pin Doc # 4.02.02 Page 5 27-20-30 Rev. 13 15 Dec 2018...
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Page 367: Elevator Control System
DV 20 KATANA AMM Flight Controls AIRCRAFT Section 27-30 ELEVATOR CONTROL SYSTEM 1. General The elevator control system provides control of the airplane about its pitch axis. It consists of the control sticks, the elevator torque tube assembly, push rods, and the elevator. The elevator is equipped with a trim tab consisting of two halves which are connected to each other.
Page 368: Troubleshooting
Flight Controls DV 20 KATANA AMM AIRCRAFT 3. Troubleshooting The following table lists defects as they could appear in the elevator control system, and their correction. Complaint Possible Cause Repair Interference. Unclean or detective bearings. Replace or clean bearings. Excessive play.
Page 369 DV 20 KATANA AMM Flight Controls AIRCRAFT C. Item (4): Elevator Push Rod in Fuselage Tube Rudder must be removed. (1) Removal Detail Steps/Work Items Key Items/References Remove mounting bolts. Remove push rod in rearward direction. (2) Installation Detail Steps/Work Items Key Items/References For installation reverse the sequence.
Page 370 Flight Controls DV 20 KATANA AMM AIRCRAFT E. Elevator Elevator tips and rudder must be removed (see Chapter 27-20). (1) Removal Detail Steps/Work Items Key Items/References Disconnect trim tab control mechanism (see Chapter 27-40). Pull out pins from outboard elevator hinges.
Page 371 DV 20 KATANA AMM Flight Controls AIRCRAFT 5. Adjustment Refer to Figure 1. After a repair of the elevator control system a check of the system to verify the correct elevator deflections given in Sub-Chapter 06-00 must be carried out. To adjust the system, push rod eye-ends must be adjusted to obtain the following: A.
Page 372: Replacement Of Fuselage Roller Cages
Flight Controls DV 20 KATANA AMM AIRCRAFT 6. Replacement of Fuselage Roller Cages Detail Steps/Work Items Key Items/References Remove the elevator control system. Refer to Section 27-30. CAUTION: DO NOT DAMAGE THE COMPOSITE STRUCTURE. Remove the installed roller cage in half frame Refer to Figure 2.
Page 373 DV 20 KATANA AMM Flight Controls AIRCRAFT Figure 3: Example of Auxiliary Tool Doc # 4.02.02 Page 7 27-30-00 Rev. 13 15 Dec 2018...
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Page 375 ELEVATOR TRIM SYSTEM 1. General The DV 20 KATANA is equipped with a manual elevator trim system to allow trimming of the airplane for different center of gravity positions. The trim tab is adjusted with an arresting lever on the center console.
Page 376 Flight Controls DV 20 KATANA AMM AIRCRAFT 2. Description Refer to Figure 1. The trim adjustment lever is connected to the actuating levers through a bowden cable. The actuating levers are connected to each other and drive one half of the tab each. A friction damper prevents flutter in the event of a failure in the trim control system.
Page 377 DV 20 KATANA AMM Flight Controls AIRCRAFT 3. Troubleshooting The following table lists defects as they could appear in the elevator trim system, and their correction. Complaint Possible Cause Repair Excessive play in trim system. Worn bearings or joints. Replace.
Page 378 Flight Controls DV 20 KATANA AMM AIRCRAFT B. Item (2): Trim Bowden Cable Ground straps must be disconnected, holding straps in fuselage must be removed, rudder must be removed. (1) Removal Detail Steps/Work Items Key Items/References Remove mounting bolts for pedestal in center console.
Page 379 DV 20 KATANA AMM Flight Controls AIRCRAFT C. Item (3): Actuating Lever (1) Removal Detail Steps/Work Items Key Items/References Disconnect tab actuating levers from friction damper and bowden cable. Remove safetying of hinge wires; extract hinge wires in outboard direction using nippers.
Page 380 Flight Controls DV 20 KATANA AMM AIRCRAFT 5. Adjustment After a repair of the trim system a check of the system to verify the correct trim tab deflection given in Sub-Chapter 06-00 must be carried out. To adjust the system perform the following: A.
Page 381 WING FLAPS 1. General The DV 20 KATANA has electrically operated wing flaps. They are operated by means of a 3 position toggle switch located in the center section of the instrument panel. The flap position indicator is located next to the switch. It has LED's for the UP, T/O, and LDG positions.
Page 382 Flight Controls DV 20 KATANA AMM AIRCRAFT 2. Description The wing flaps are driven by an electric motor located under the left seat. A reduction gear with a spindle and a push rod is fitted to the motor. The push rod transmits the actuator movement to a bellcrank.
Page 383 DV 20 KATANA AMM Flight Controls AIRCRAFT 3. Troubleshooting The following table lists defects as they could appear in the flap system, and their correction. Complaint Possible Cause Repair Flaps immovable. Defective circuit breaker. Replace. On-board voltage too low. Check battery and generator.
Page 384 Flight Controls DV 20 KATANA AMM AIRCRAFT 4. Removal and Installation A. Wing Flaps The wings must be removed from the fuselage. (1) Removal Detail Steps/Work Items Key Items/References Disconnect push-rod from flap horn. Carefully remove dowel pins from bearing journals.
Page 385 DV 20 KATANA AMM Flight Controls AIRCRAFT (2) Installation Detail Steps/Work Items Key Items/References For installation reverse the sequence. C. Bellcrank in Wing (1) Removal Detail Steps/Work Items Key Items/References Open inspection hole on wing bottom side. Remove mounting bolts of push rods.
Page 386 Flight Controls DV 20 KATANA AMM AIRCRAFT D. Electric Motor The left seat shell must be removed. (1) Removal Detail Steps/Work Items Key Items/References Disconnect push-rod from bellcrank. Disconnect electric wires from motor and micro switch unit. Remove pedestal mounting bolts.
Page 387 DV 20 KATANA AMM Flight Controls AIRCRAFT 5. Adjustment After a repair of the flap system a check of the system to verify the correct flap travel given in Sub-Chapter 06-00 must be carried out. The end positions of the flaps are adjusted with limit stop micro switches. Refer to the sketch below and to Wiring Diagram D20-9227-50-01 in Chapter 92.
Page 388 Flight Controls DV 20 KATANA AMM AIRCRAFT B. Initial Adjustment of Fuselage Mounted Parts S/N's 20.005 thru 20.100: With flap pockets aligned horizontally, align torsion bellcrank parallel to fuselage. Connect actuator to lower arm of torsion bellcrank. With the flap control switch in UP position, adjust pockets to 17° with the limit stop switches.
Page 389 DV 20 KATANA AMM Fuel AIRCRAFT CHAPTER 28 FUEL Doc # 4.02.02 Page 1 28-TITLE Rev. 13 15 Dec 2018...
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Page 391 DV 20 KATANA AMM Fuel AIRCRAFT TABLE OF CONTENTS CHAPTER 28-00 FUEL General ............1 System Description .
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Page 393 DV 20 KATANA AMM Fuel AIRCRAFT CHAPTER 28-00 FUEL 1. General The fuel system of the DV KATANA consists of an aluminum fuel tank with a capacity of 79 liters (20.9 US gal.), a fuel shut off valve, an electrical and a mechanical fuel pump, the carburetors, and the fuel lines.
Page 394 Fuel DV 20 KATANA AMM AIRCRAFT Fuel Shut-Off Valve Center Console Vent Line To Engine Filler Fuel Shut- Off Valve Fuel Tank Main Bulkhead Firewall Water Check Drain Maintenance Drain Electrical Fuel Pump Fuel Return Line Hose Coupling Carburetor Right...
Page 395 STORAGE (TANK) 1. General Fuel in the DV 20 KATANA is supplied from a fuselage mounted tank. The welded aluminum fuel tank is located between the main bulkhead and the B-bulkhead beneath the baggage compartment. The fuel filler cap is located on the left hand side behind the canopy and is connected to the fuel tank via rubber hose.
Page 396 Fuel DV 20 KATANA AMM AIRCRAFT 3. Troubleshooting The following table lists defects which could appear on the fuel tank and corrective measures. Complaint Possible Cause Repair Smell of fuel in airplane. Loose fuel line connectors. Tighten connectors. Cracks in fuel tank welding Weld or replace tank.
Page 397 DV 20 KATANA AMM Fuel AIRCRAFT 4. Removal and Installation (1) Removal Detail Steps/Work Items Key Items/References Drain tank completely using the drain valve; disconnect fuel feed line. Remove baggage compartment floor. Disconnect rubber hose by loosening both hose clamps and pulling hose from connection sleeve.
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Page 399 DV 20 KATANA AMM Fuel AIRCRAFT Section 28-20 DISTRIBUTION 1. General The fuel pump system consists of an electrical and a mechanical fuel pump, fuel filters and the fuel shut off valve. The fuel lines are made out of shielded teflon hoses with screw type connectors.
Page 400 Fuel DV 20 KATANA AMM AIRCRAFT C. Mechanical Fuel Pump The mechanical fuel pump is a diaphragm type pump driven directly by the engine. With the engine running, the pump sucks fuel via the electric fuel pump to deliver it to the carburetors with a pressure of approximately 0.15 to 0.4 bar (2.2 to 5.8 psi).
Page 401 DV 20 KATANA AMM Fuel AIRCRAFT 3. Troubleshooting The following table lists defects which could appear in the fuel supply system and corrective measures. Complaint Possible Cause Repair Smell of fuel in airplane. Loose fuel line connections. Tighten fuel line connections.
Page 402 Fuel DV 20 KATANA AMM AIRCRAFT 4. Removal and Installation A. Fuel Shut-Off Valve (1) Removal Prior to removal, the fuel tank must be drained. Detail Steps/Work Items Key Items/References Remove hand hole cover on the right side of the center console.
Page 403 DV 20 KATANA AMM Fuel AIRCRAFT Hand Hole Cover Center Console Gasket Gasket Fitting Hose Line Fitting Hose Line Operating Lever Fuel Shut Off Valve Operating Lever Mounting Screw Fuel Shut Off Valve Mounting Screws Figure 1: Fuel Shut-Off Valve Doc # 4.02.02...
Page 404 Fuel DV 20 KATANA AMM AIRCRAFT B. Electrical Fuel Pump (1) Removal Prior to removal, the fuel tank must be drained. Detail Steps/Work Items Key Items/References Close fuel shut off valve. Disconnect electrical connections. Disconnect fuel lines (see below). Loosen mounting screws.
Page 405 DV 20 KATANA AMM Fuel AIRCRAFT Figure 2: Electrical Fuel Pump C. Mechanical Fuel Pump (1) Removal and Installation Detail Steps/Work Items Key Items/References Refer to engine Operator's Manual. Doc # 4.02.02 Page 7 28-20-00 Rev. 13 15 Dec 2018...
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Page 407 DV 20 KATANA AMM Fuel AIRCRAFT Section 28-40 INDICATING 1. General A submerging tube sensor is installed in the top side of the fuel tank from which the fuel level is electrically sensed. This signal is sent to the fuel quantity indicator.
Page 408 Fuel DV 20 KATANA AMM AIRCRAFT 3. Troubleshooting The following table lists defects which could appear in the fuel quantity indicating system and corrective measures. Complaint Possible Cause Repair Insufficient fuel pressure. Defective pressure sensor. Check pressure sensor. Voltage supplied to pressure Check electrical supply.
Page 409 DV 20 KATANA AMM Fuel AIRCRAFT 4. Removal and Installation A. Fuel Pressure Sensor (1) Removal Detail Steps/Work Items Key Items/References Disconnect electrical connector. Remove Sensor. (2) Installation Detail Steps/Work Items Key Items/References For installation reverse the sequence. Figure 1: Fuel Pressure Sensor Doc # 4.02.02...
Page 410 Fuel DV 20 KATANA AMM AIRCRAFT B. Fuel Quantity Sensor (1) Removal Detail Steps/Work Items Key Items/References Remove baggage compartment floor. Disconnect electrical connectors. Remove mounting screws around sensor. Remove sensor from tank. (2) Installation Detail Steps/Work Items Key Items/References For installation reverse the sequence.
Page 411 DV 20 KATANA AMM Fuel AIRCRAFT 5. Calibration After replacement of the fuel quantity sensor or indicator, the gauge has to be checked for accurate indication. The fuel quantity indicator is calibrated with an empty tank. Detail Steps/Work Items Key Items/References Drain tank completely.
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Page 413 Indicating/Recording DV 20 KATANA AMM Systems AIRCRAFT CHAPTER 31 INDICATING/RECORDING SYSTEM Doc # 4.02.02 Page 1 31-TITLE Rev. 13 15 Dec 2018...
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Page 415 Indicating/Recording DV 20 KATANA AMM Systems AIRCRAFT TABLE OF CONTENTS CHAPTER 31-00 INDICATING/RECORDING SYSTEMS General ............1...
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Page 417 Indicating/Recording DV 20 KATANA AMM Systems AIRCRAFT CHAPTER 31-00 INDICATING/RECORDING SYSTEMS 1. General This Chapter tells you about the indicating systems installed in the airplane. Refer to these Sections for the related data: Section 31-10. The instrument and control panels for the DV 20.
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Page 419 Indicating/Recording DV 20 KATANA AMM Systems AIRCRAFT Section 31-10 INSTRUMENT PANEL 1. General The instrument panel is divided into five (5) sections: the LH, RH and center section, the instrument panel cover, and the panel on the center console. The instrument panel as installed with OÄM 20-244 is made in one piece with a shelf. The shelf goes between the panel and the firewall.
Page 420 Indicating/Recording DV 20 KATANA AMM Systems AIRCRAFT Figure 1and 2 illustrates the location of each instrument in the Cockpit. System and functional description of each instrument as well as the removal and installation procedures can be found in the corresponding chapters.
Page 421 DV 20 KATANA AMM Systems AIRCRAFT 3. Removal and Installation The DV 20 KATANA was designed with accessibility of the equipment in mind. Consequently, the instruments are easy to reach after removal of the instrument panel cover. (1) Removal Detail Steps/Work Items Key Items/References Remove instrument panel cover.
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Page 423 DV 20 KATANA AMM Landing Gear AIRCRAFT CHAPTER 32 LANDING GEAR Doc # 4.02.02 Page 1 32-TITLE Rev. 13 15 Dec 2018...
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Page 425 DV 20 KATANA AMM Landing Gear AIRCRAFT TABLE OF CONTENTS CHAPTER 32-00 LANDING GEAR General ............1 Troubleshooting .
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Page 427: Landing Gear
CHAPTER 32-00 LANDING GEAR 1. General The DV 20 KATANA is equipped with a fixed tricycle landing gear, including a castering nose wheel. The two main landing gear struts are connected to the main bulkhead with two mounting brackets each.
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Page 429: Main Landing Gear
The struts made of quenched and tempered steel absorb the landing shocks. Brake disks are installed on the aluminum wheels. The disk brakes of the DV 20 KATANA are part of the standard equipment. 2. Description Each strut is mounted to the inner bracket by means of one bolt which must be secured against loosening.
Page 430: Troubleshooting
Landing Gear DV 20 KATANA AMM AIRCRAFT 3. Troubleshooting The following table lists defects as they could appear on the main landing gear system, and their correction. Complaint Possible Cause Repair Strut bent. Hard landing. Replace strut. Negative camber. Strut bent.
Page 431: Removal And Installation
DV 20 KATANA AMM Landing Gear AIRCRAFT 4. Removal and Installation (1) Removal Detail Steps/Work Items Key Items/References Lift airplane or unload wheel. See Chapter 7. Remove wheel fairing by loosening the outer securing bolt (M8) and by removing the two screws on the inside.
Page 432: Adjustment
Landing Gear DV 20 KATANA AMM AIRCRAFT 5. Adjustment A. Play in Wheel Bearing Detail Steps/Work Items Key Items/References Install wheel, install axle nut with spacer washer. Torque nut to 40 Nm (29.5 lbs.ft.). Loosen nut again, tighten to next pinhole with force of hand.
Page 433 After each hard landing and after any repair on the strut or the main bulkhead the wheel alignment has to be checked. For this, the DV 20 KATANA is placed onto slide sheets and alignment checked at empty mass (weight) against the data in the Adjustment Report.
Page 434 Landing Gear DV 20 KATANA AMM AIRCRAFT Wing Root Edge Main Landing Gear Leg Straight Edge Angle Bracket Top View Toe-In Measurements Toe-In Measurements Greased Plates Angle Bracket Note: Ensure that the floor is levelled in the work area Straight Edge...
Page 435: Inspection And Removal Of Main Landing Gear Attachment Brackets
DV 20 KATANA AMM Landing Gear AIRCRAFT 6. Inspection and Removal of Main Landing Gear Attachment Brackets The main landing gear attachment brackets must be replaced, if corrosion, cracks or deformation is detected. Figure 4: Inspection and Removal of Main Landing Gear Attachment Brackets A.
Page 436 Landing Gear DV 20 KATANA AMM AIRCRAFT B. Inspection and Removal of Attachment Fitting 2 Detail Steps/Work Items Key Items/References Examine the inner main landing gear Refer to Figure 4. attachment bracket 2 for cracks and corrosion by visual inspection.
Page 437 Key Items/References Remove paint coat and corrosion from the fitting. Perform dye penetration inspection. If cracks were found, Diamond Aircraft must be contacted and the fitting must be replaced. In case of corrosion use the limit of corrosion depth of inspection item (2). The inner bracket sheet must not be thinner than 2.9 mm.
Page 438 Landing Gear DV 20 KATANA AMM AIRCRAFT Detail Steps/Work Items Key Items/References If corrosion spots in excess of 100 mm² and depth of 0.1 mm are detected at the inspectable surfaces of attachment bracket, remove fittings and repair or replace according to items (3) through (14).
Page 439 AIRCRAFT Detail Steps/Work Items Key Items/References Remove paint coat and corrosion from the fitting. If cracks were found, Diamond Aircraft must be contacted and the fitting must be replaced. In case of corrosion use the limit of corrosion depth of inspection item (2). The inner bracket sheet must not be thinner than 2.9 mm.
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Page 441: Nose Landing Gear
NOSE LANDING GEAR 1. General The DV 20 KATANA is equipped with a fixed nose landing gear with a castering wheel. On its rear end, the leg is attached to the fuselage bottom with a special fitting. An elastomer package connects the leg to the supporting point at the engine mount.
Page 442 Landing Gear DV 20 KATANA AMM AIRCRAFT Fitting Elastomer Package Nose Gear Leg Tubular Strut Castor Stop Nose Wheel Fork Figure 1: Nose Landing Gear Page 2 Doc # 4.02.02 32-20-00 15 Dec 2018 Rev. 13...
Page 443 DV 20 KATANA AMM Landing Gear AIRCRAFT 3. Removal and Installation A. Nose Landing Gear Leg (1) Removal Detail Steps/Work Items Key Items/References Remove engine cowling. Remove cover over nose landing gear fitting. Disconnect elastomer package assembly from engine mount.
Page 444 Landing Gear DV 20 KATANA AMM AIRCRAFT Figure 3: Elastomer Package Figure 4: Elastomer Package Page 4 Doc # 4.02.02 32-20-00 15 Dec 2018 Rev. 13...
Page 445 DV 20 KATANA AMM Landing Gear AIRCRAFT B. Rubber Spring Assembly Airplane must be jacked up or nose wheel unloaded. (1) Removal Detail Steps/Work Items Key Items/References Remove engine cowling. Remove fairing of rubber spring assembly. Disconnect rod end bearing from engine mount.
Page 446: Adjustment
Landing Gear DV 20 KATANA AMM AIRCRAFT C. Elastomer Elements The elastomer elements should be replaced in the event that they are worn (see 4. Adjustment) or cracks are found. (1) Removal Detail Steps/Work Items Key Items/References Remove the adjusting nut.
Page 447: Wheels And Brakes
The parking brake of the DV 20 KATANA is part of the standard equipment. The parking brake valve is located in the center console and is operated via a bowden cable. The operating knob is located between the seats next to the cabin heat and choke knobs.
Page 448 Landing Gear DV 20 KATANA AMM AIRCRAFT Vented Plug Master Master Fluid Level Cylinders Cylinders 15 mm 5/8" Maximum Brake Fluid Reservoir 15 mm 5/8" Pilot's Pedals Co-Pilot's Pedals Minimum LOCK PARKING BRAKE Flexible Hose RELEASE Parking Brake Valve Flexible Hose...
Page 449: Troubleshooting
DV 20 KATANA AMM Landing Gear AIRCRAFT 3. Troubleshooting The following table lists defects as they could appear on the wheels and brakes, and their correction. Complaint Possible Cause Repair Excessive tire wear. Track adjusted improperly. Adjust (see Ch. 32-10).
Page 450: Removal And Installation
Landing Gear DV 20 KATANA AMM AIRCRAFT 4. Removal and Installation Refer to Figure 2 below and to Sub-Chapter 32-10, Figure 1. A. Main Wheels (1) Removal Detail Steps/Work Items Key Items/References Jack-up airplane or unload wheel; remove wheel fairing.
Page 451 DV 20 KATANA AMM Landing Gear AIRCRAFT (3) Disassembly CAUTION: PRIOR TO DISASSEMBLY OF THE WHEEL THE TIRE MUST BE COMPLETELY DEFLATED BY REMOVING THE VALVE INSERT. Detail Steps/Work Items Key Items/References Remove bolts on rim. Remove brake disk and rim halves from tire.
Page 452 Landing Gear DV 20 KATANA AMM AIRCRAFT B. Nose Wheel (1) Removal Detail Steps/Work Items Key Items/References Remove 6 Allen screws securing fairing halves to each other. Remove LH and RH fairing mounting screw. Remove fairing. Unload nose wheel. Remove M10 nut and bolt (serving as axle);...
Page 453 DV 20 KATANA AMM Landing Gear AIRCRAFT C. Brake Master Cylinder (1) Removal Detail Steps/Work Items Key Items/References Remove brake lines on master cylinder. Remove the connecting bolt attaching the cylinder to the pedal. Remove cylinder lower mounting bolt. Remove master cylinder from airplane.
Page 454 Landing Gear DV 20 KATANA AMM AIRCRAFT Pedal Connecting Bolt Pedal Brake Master Cylinder Brake Lines Connecting Bolt Cylinder Lower Mounting Bolt Brake Master Cylinder Brake Lines Figure 3: Brake Master Cylinders Page 8 Doc # 4.02.02 32-40-00 15 Dec 2018...
Page 455 DV 20 KATANA AMM Landing Gear AIRCRAFT D. Caliper (1) Removal Detail Steps/Work Items Key Items/References Disconnect brake line from caliper (1). Disconnect back pressure plate (2) from cylinder. Remove caliper and guide assembly (3) from mount. (2) Installation Detail Steps/Work Items Key Items/References For installation reverse the sequence.
Page 456 Landing Gear DV 20 KATANA AMM AIRCRAFT E. Brake Disk Brake disks should be replaced when their thickness is less than 3.8 mm (0.15 in). (1) Removal Detail Steps/Work Items Key Items/References Remove wheel and caliper. Disassemble wheel. Remove brake disk.
Page 457 DV 20 KATANA AMM Landing Gear AIRCRAFT F. Brake Linings Brake linings should be replaced at scheduled inspections when theis thickness is less than 4 mm (0.16 in) in order to ensure airworthiness until the next scheduled inspection. The wear limit is 3 mm (0.12 in).
Page 458 Landing Gear DV 20 KATANA AMM AIRCRAFT G. Parking Brake (1) Removal Detail Steps/Work Items Key Items/References Disconnect brake lines. Disconnect bowden cable. Remove mounting bolts. NOTE: For repair of the valve refer to the documentation of the manufacturer (Parker).
Page 459: Bleeding Of Brake System
Fill reservoir with brake fluid to maximum level. 6. Adjustment The brakes installed on the DV 20 KATANA are self adjusting. After installation of the calipers or after brake line replacement ensure that the wheels turn freely. If a wheel does not turn freely, the cause must be investigated and corrected.
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Page 461 DV 20 KATANA AMM Lights AIRCRAFT CHAPTER 33 LIGHTS Doc # 4.02.02 Page 1 33-TITLE Rev. 13 15 Dec 2018...
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Page 463 DV 20 KATANA AMM Lights AIRCRAFT TABLE OF CONTENTS Section 33-40 EXTERIOR LIGHTS General ............1 Description .
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Page 465: General
DV 20 KATANA AMM Lights AIRCRAFT Section 33-40 EXTERIOR LIGHTS 1. General The DV 20 KATANA can be equipped with the following exterior lighting: Anti Collision Lights (ACL). Position Lights. Landing Light. Combined Anti Collision and Position Light Anti Collision Light...
Page 466: Description
Lights DV 20 KATANA AMM AIRCRAFT 2. Description The anti collision and position lights are combined in one unit and are located at each wing tip. The anti-collision strobe light power supplies are installed in a location at the wing outboard edge. The landing light is installed in the lower engine cowling.
Page 467: Troubleshooting
DV 20 KATANA AMM Lights AIRCRAFT 3. Troubleshooting The following table lists defects as they could appear on the exterior lighting system, and their correction. Complaint Possible Cause Repair Both ACLs inoperative. Defective switch. Replace. Defective breaker. Replace. Defective wiring in forward Repair.
Page 468: Removal And Installation
Lights DV 20 KATANA AMM AIRCRAFT 4. Removal and Installation WARNING: THE POWER SUPPLIES OF THE ANTI COLLISION STROBE LIGHTS GENERATE HIGH VOLTAGE WHICH IS CONNECTED DIRECTLY TO THE STROBE LIGHTS. PRIOR TO PERFORMING ANY MAINTENANCE ON THE WIRING OR ON THE LIGHT ITSELF, A MINIMUM OF FIVE (5) MINUTES WAITING TIME MUST BE OBSERVED AFTER SWITCHING OFF THE SYSTEM TO ALLOW THE CAPACITORS TO DISCHARGE.
Page 469 DV 20 KATANA AMM Lights AIRCRAFT B. ACL Bulb (1) Removal Detail Steps/Work Items Key Items/References Switch off battery master switch. Wait for five (5) minutes to allow discharge of strobe light capacitors. Remove wing tip. Disconnect power lines and ground connection.
Page 470 Lights DV 20 KATANA AMM AIRCRAFT C. ACL Power Supply (1) Removal Detail Steps/Work Items Key Items/References Switch off battery master switch. Wait for five (5) minutes to allow discharge of strobe light capacitors. Remove wing tip. Disconnect power lines and ground connection.
Page 471 DV 20 KATANA AMM Lights AIRCRAFT D. Landing Light (1) Removal Detail Steps/Work Items Key Items/References Switch off master switch. Remove upper engine cowling. Disconnect the landing light connector (located directly behind the lamp). Remove lower engine cowling. Loosen mounting hardware and remove lamp.
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Page 473 DV 20 KATANA AMM Navigation and Pitot Static AIRCRAFT CHAPTER 34 NAVIGATION AND PITOT STATIC Doc # 4.02.02 Page 1 34-TITLE Rev. 13 15 Dec 2018...
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Page 475 DV 20 KATANA AMM Navigation and Pitot Static AIRCRAFT TABLE OF CONTENTS Section 34-00 NAVIGATION AND PITOT STATIC General ............1...
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Page 477: Navigation And Pitot Static
DV 20 KATANA AMM Navigation and Pitot Static AIRCRAFT Section 34-00 NAVIGATION AND PITOT STATIC 1. General The navigation systems include the instruments that operate on dynamic and static pressure. They indicate the airspeed, altitude, attitude, and direction. The equipment supplied with dynamic and static pressure includes the altimeter, airspeed indicator, and vertical speed indicator.
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Page 479: Pitot Static
DV 20 KATANA AMM Navigation and Pitot Static AIRCRAFT Section 34-10 PITOT STATIC 1. General The Pitot static system is used to measure and deliver dynamic and static pressure to the airspeed indicator, altimeter, and vertical speed indicator. Altimeter Vertical Speed...
Page 480: Description
2. Description A. Pitot Head/Lines The Pitot head of the DV 20 KATANA is designed to measure total head and static pressure. The Pitot head is located below the left wing. Lines running through the left wing and the fuselage connect the Pitot head to the instruments.
Page 481 DV 20 KATANA AMM Navigation and Pitot Static AIRCRAFT C. Altimeter The altimeter measures the change in atmospheric pressure using aneroid chambers. The changes in pressure correspond to changes in altitude. A special mechanism converts the movement of the aneroid chambers into deflections of the pointers. The altimeter is equipped with a scale calibrated in feet (ft).
Page 482 : -30°C to +50°C (-22°F to +122°F) F. Outside Air Temperature Indicator The DV 20 KATANA can be equipped with an optional outside air temperature indicator. The temperature sensor is located in the left NACA type air inlet. The system operates on on-board power.
Page 483: Troubleshooting
DV 20 KATANA AMM Navigation and Pitot Static AIRCRAFT 3. Troubleshooting The following table lists defects as they could appear on the Pitot static system, and their correction. Complaint Possible Cause Repair No or incorrect instrument Leaky pressure lines. Seal.
Page 484: Removal And Installation
Navigation and Pitot Static DV 20 KATANA AMM AIRCRAFT 5. Removal and Installation A. Pitot Head (1) Removal Detail Steps/Work Items Key Items/References Loosen screws from below. Remove Pitot head in downward direction. Disconnect pressure lines. (2) Installation Detail Steps/Work Items Key Items/References For installation reverse the sequence.
Page 485: Pitot Static Test
DV 20 KATANA AMM Navigation and Pitot Static AIRCRAFT 6. Pitot Static Test After working on the Pitot static system, it must be checked in accordance with the table below. A. Airspeed Indicator Leakage At 150 kts max. loss off pressure 10 kts/min.
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Page 487: Stall Warning System
DV 20 KATANA AMM Navigation and Pitot Static AIRCRAFT Section 34-12 STALL WARNING SYSTEM 1. Description The airplane is equipped with a stall warning system as part of the standard equipment. The sensor works pneumatically and is located in the left wing. The stall warning system should warn the pilot acoustically using a horn shortly before reaching the maximum angle of attack.
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Page 489: Attitude And Direction
DV 20 KATANA AMM Navigation and Pitot Static AIRCRAFT Section 34-20 ATTITUDE AND DIRECTION 1. General This section describes the equipment indicating attitude and flight direction. All equipment is gyro driven, with the exception of the magnetic compass. 2. Description A.
Page 490 Navigation and Pitot Static DV 20 KATANA AMM AIRCRAFT D. Attitude Gyro The attitude gyro shows the airplane's attitude in relation to the earth's surface. Any movement about the pitch axis and the roll axis is displayed. The attitude gyro consists of an electrically powered, gimbal mounted gyro. The gyro axis is perpendicular to the earth's surface.
Page 491: Troubleshooting
DV 20 KATANA AMM Navigation and Pitot Static AIRCRAFT 3. Troubleshooting The following table lists defects as they could appear on the attitude and direction indicating system, and their correction. Complaint Possible Cause Repair Compass leaking fluid. Defective seal or membrane.
Page 492: Removal And Installation
Navigation and Pitot Static DV 20 KATANA AMM AIRCRAFT 4. Removal and Installation A. Magnetic Compass (1) Removal Detail Steps/Work Items Key Items/References Remove bolts and nuts from support. Remove compass from support. (2) Installation Detail Steps/Work Items Key Items/References For installation reverse the sequence.
Page 493: Compass Compensation
DV 20 KATANA AMM Navigation and Pitot Static AIRCRAFT B. Turn Indicator, Directional Gyro, Attitude Gyro (1) Removal Detail Steps/Work Items Key Items/References Pull off connectors at rear of instrument. Remove screws on instrument panel. Pull out instrument. (2) Installation...
Page 494 Navigation and Pitot Static DV 20 KATANA AMM AIRCRAFT Detail Steps/Work Items Key Items/References Align the airplane with magnetic north and equalize deviations with compensation magnets. Repeat the procedure for magnetic east. Then, position the airplane to magnetic south and west, and equalize half of the indication error using the compensation magnets.
Page 495: Position Determining Systems
Navigation and Pitot Static AIRCRAFT Section 34-50 POSITION DETERMINING SYSTEMS 1. General The navigation system of the DV 20 KATANA can include the following systems: VOR/Localizer Navigation system Transponder/Altitude Digitizer GPS Navigation system ADF Navigation system The systems and components are installed at the following positions:...
Page 496 Navigation and Pitot Static DV 20 KATANA AMM AIRCRAFT GPS 100 NR3301 Transponder Comm ATC2000 AR3201 Figure 2: VHF NAV Standard Equipment - Becker GPS 100 Transponder NAV/COMM KT76A KX125 Figure 3: VHF NAV Standard Equipment - Bendix/King Page 2 Doc # 4.02.02...
Page 497 DV 20 KATANA AMM Navigation and Pitot Static AIRCRAFT Figure 4: VHF NAV Standard Equipment - Garmin Doc # 4.02.02 Page 3 34-50-00 Rev. 13 15 Dec 2018...
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Page 499 DV 20 KATANA AMM Structures AIRCRAFT CHAPTER 51 STRUCTURES 51-TITLE Doc # 4.02.02 Page 1 Rev. 13 15 Dec 2018...
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Page 501 DV 20 KATANA AMM Structures AIRCRAFT TABLE OF CONTENTS Section 51-00 STRUCTURES General ............1 Identification of Primary Structure .
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Page 503: General
STRUCTURES 1. General The DV 20 KATANA is a low wing airplane in full composite construction. The fuselage consists of a self supporting glass fiber skin in semi-monocoque construction with bulkheads and stiffeners. The single engine cantilever type monoplane is equipped with a T-tail. The DV 20 KATANA has a fixed tricycle landing gear with trailing nose wheel.
Page 504: Identification Of Primary Structure
Structures DV 20 KATANA AMM AIRCRAFT 2. Identification of Primary Structure The primary structure of the DV 20 KATANA consists of the following members: A. Wing Spar. Ribs. Web at hinge line. Skin. Wing-fuselage connection. Ailerons. Wing flaps. B. Fuselage Skin.
Page 505: Structural Inspection Methods For Composite
DV 20 KATANA AMM Structures AIRCRAFT 3. Structural Inspection Methods for Composite A. Types of Inspection In the inspection checklist, three types of inspection are specified: V Visual Inspection T Tap Test F Functional or Fit Check (1) Visual Inspection In glass fibre composite structures, surface damage, e.g.
Page 506 Structures DV 20 KATANA AMM AIRCRAFT The composite structure is protected by paint from exposure to damaging ultraviolet light from the sun. It is important that the paint be in good condition. UV light can also damage the paint. Inspection have shown clear signs of resin erosion at areas where no paintcoat is applied.
Page 507 B. Damage Classifications for Composites Diamond Aircraft has established damage classifications for the inspection of composite airframe components, refer to Section 51-10 for this information.
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Page 509: Approved Materials, Suppliers
DV 20 KATANA AMM Structures AIRCRAFT Section 51-10 REPAIR OF COMPOSITE PARTS 1. Approved Materials, Suppliers A. Resin and Hardener Resin Scheufler L 285 (100 parts of weight) Hardener Scheufler 286 (40 parts of weight) Supplier Hexion Specialty Chemicals Stuttgart GmbH...
Page 510 Structures DV 20 KATANA AMM AIRCRAFT Supplier for Vorwerk fabric: Saertex Wagener GmbH Brochterbecker Damm 52 D-48369 Saerbeck Phone +49/2574/9020 C. Carbon Fiber Cloth Cloth Mass per Area Interglas No. grams/m² Double twill 2/2 98141 Supplier Rudolf Usner GmbH (see above) D.
Page 511 DV 20 KATANA AMM Structures AIRCRAFT F. Resin Fillers Microballoons Q-cell 300 Supplier Polychem GmbH (see above) Aerosil Cotton Flakes Supplier Rudolf Usner GmbH (see above) G. Knifing Filler, Primer (Acrylic Filler), Outside Paint (Color RAL 9016) These products are supplied by Herberts or Sikkens. It is highly recommendable to contact HOAC to inquire about the products used on a specific serial number in order to avoid such problems as bubbles in the paint finish.
Page 512: Damage Classifications
Structures DV 20 KATANA AMM AIRCRAFT 2. Damage Classifications Damages are classified into four categories according to the German Luftfahrt-Bundesamt. NOTE: The primary structure can be identified using the list in Chapter 51-00. A. Damage Category 1 Damage to large areas, requiring partial reconstruction of the part or repair of large areas.
Page 513: Fuselage Layup
DV 20 KATANA AMM Structures AIRCRAFT NOTE: If there is any doubt regarding the damage classification, if it is not possible to clearly asses the damage, or if there are any questions regarding the proper repair of the damage, despite considering the manufacturer's documentation, contact the airplane manufacturer.
Page 514 Structures DV 20 KATANA AMM AIRCRAFT Item Qty. Description Part No. / Supplier Dimensions [mm] 92125 or 95290 X Interglas or Vorwerk 200*200, RH side only 92125 or 95290 # Interglas or Vorwerk 200*200, RH side only 92125 or 95290 X...
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Page 523: Gfrp Repair
DV 20 KATANA AMM Structures AIRCRAFT 4. GFRP Repair When the airplane is damaged, proceed as follows: Carefully visually inspect the surface and damaged area. Often other parts are affected as well. Occasionally the crack continues invisibly under the surface. Classify damage using paragraph 2. DAMAGE CLASSIFICATION.
Page 524: Sandwich Repair
Structures DV 20 KATANA AMM AIRCRAFT 5. Sandwich Repair A. Minor Surface Damage The laminate may have unbonded from the rigid foam around the area of a crack. The affected area is determined by tapping. Remove the loose laminate using a sanding disk, a sanding block, or a sharp knife.
Page 525 DV 20 KATANA AMM Structures AIRCRAFT B. Damage to the Entire Sandwich If the interior laminate is destroyed as well, the exterior laminate that has unbonded from the rigid foam must be removed first. The hole must be enlarged until the exterior laminate is securely bonded to the foam.
Page 526: Laminate Repair
Structures DV 20 KATANA AMM AIRCRAFT 6. Laminate Repair A. Minor Damage Cracks in the paint along a leading edge bonding require careful inspection of the joint. Repair of such delaminations is described below. Crack damage on the leading edge bonding of a control surface is repaired by covering the crack with 1 layer of 92110 cloth.
Page 527 DV 20 KATANA AMM Structures AIRCRAFT B. Major Damage The damaged area must be uncovered down to the basic laminate. A counterpart made of two layers of glass fiber cloth must be constructed. The counterpiece should be approximately 20 mm (0.8 inches) larger than the area to be repaired.
Page 528 Structures DV 20 KATANA AMM AIRCRAFT C. Cracks in Wing Leading Edge Bonding (a) Determine depth of crack. case 1 Crack does not extend under laminate of upper skin: Removal of laminate not required. If crack continues under skin, remove laminate and thickened resin until end of crack is reached.
Page 529: Spar Repair
DV 20 KATANA AMM Structures AIRCRAFT 7. Spar Repair The upper and lower cap of the wing spars consist of carbon fiber rovings. In any case, the repair of a spar is considered to be a major repair. Spar repairs, if at all possible, may only be carried out by the manufacturer.
Page 530 Structures DV 20 KATANA AMM AIRCRAFT Detail Steps/Work Items Key Items/References Prepare surface and paint the reinforced area in accordance with Section 8. B. Repair of Cracks at the Connection Between Backrest and Fuselage If cracks in the thickened resin are detected at the connection between backrest and fuselage in region...
Page 531: Repair Of The Firewall Insulation
DV 20 KATANA AMM Structures AIRCRAFT 10.Repair of the Firewall Insulation NOTE: All parts must be removed from the firewall (screws, cables, etc.). NOTE: All linear measures in the sketches are mm. Detail Steps/Work Items Key Items/References Remove fire resistant resin from the edges of sheet metal to fuselage structure.
Page 532 - 1 ply 8.4554.60 (92140) 0°/90° over all - 1 ply 8.4554.60 (92140) 0°/90° 200x1000 mm (only on horizontal part of firewall) In case of doubt, contact Diamond Aircraft Industries GmbH. Sand all damaged layers. Chamfer each layer with a stagger length of 20 mm.
Page 533 DV 20 KATANA AMM Structures AIRCRAFT Detail Steps/Work Items Key Items/References Adjust both halves of the sheet metal to the firewall bulkhead. CAUTION: THE METAL SHEET MUST NOT WARP. NOTE: The plates should be affixed with screws and screw clamps through the holes which are already in the metal sheet and the firewall bulkhead.
Page 534 Structures DV 20 KATANA AMM AIRCRAFT Detail Steps/Work Items Key Items/References CAUTION: DO NOT DAMAGE THE FIBERFRAX OR THE COMPOSITE STRUCTURE BEHIND BY DRILLING DEEPER THAN 2 MM (0.08 IN). (19) Drill out the prepared drills for the rivets on the right side of the strip.
Page 535: Repair Of Resin Erosion At Trailing Edge Spar
Clean glass fabric structure carefully. Examine structure for cracks or delamination. In case of any finding, report Diamond Aircraft Industries to receive repair instructions. Refill the edge of wing upper shell and trailing edge spar with thickened resin.
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Page 537: Repair Of Metal Parts
DV 20 KATANA AMM Structures AIRCRAFT Section 51-20 REPAIR OF METAL PARTS 1. General A. Steel Fittings Repairs of metal fittings should only be performed after consulting the manufacturer. If welding is required, it must be performed with a TIG (Tungsten Inert Gas) welder.
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Page 539: Electrical Bonding
DV 20 KATANA AMM Structures AIRCRAFT Section 51-80 ELECTRICAL BONDING 1. General This Paragraph tells you how to do a test of the bonding system. The resistance measurements on the DV 20 have to be carried out with milliohmmeter and Kelvin probes.
Page 540: Test Points
Structures DV 20 KATANA AMM AIRCRAFT 2. Test Points Measured Description Permitted Resistance Test Point Resistance Signature (mΩ) (mΩ) % % % TP 01 Engine exhaust % % % TP 02 Engine mount % % % TP 03 LH side of engine firewall...
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Page 543 DV 20 KATANA AMM Fuselage AIRCRAFT CHAPTER 53 FUSELAGE Doc # 4.02.02 Page 1 53-TITLE Rev. 13 15 Dec 2018...
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Page 545 DV 20 KATANA AMM Fuselage AIRCRAFT TABLE OF CONTENTS CHAPTER 53-00 FUSELAGE General ............1...
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Page 547 FUSELAGE 1. General The DV 20 KATANA fuselage is of semi-monocoque construction. The self supporting GFRP-fuselage is reinforced with bulkheads and stiffeners. The number of orientation of the layers corresponds to the loads in the individual sections. Therefore the fuselage skin has different thicknesses and fiber orientations.
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Page 549 DV 20 KATANA AMM Fuselage AIRCRAFT Section 53-10 MAIN FRAME 1. General The DV 20 KATANA consists of a fuselage structure containing bulkheads and stiffeners which are: Firewall Floor Element Transverse Stiffener Main Bulkhead Sickle Shaped Bulkhead B-Bulkhead Roll Bar...
Page 550 The bulkheads and stiffeners are of different shape. They are fabricated from glass fiber laminate. A. Firewall The firewall of the DV 20 KATANA separates the engine compartment from the rest of the fuselage. It is fabricated from glass fiber laminate. For fire protection the front side of the firewall is covered with heat resistant protective texture as well as with stainless sheet steel.
Page 551 DV 20 KATANA AMM Fuselage AIRCRAFT F. B-Bulkhead The B-bulkhead is also fabricated of glass fiber laminate and is, in the rear cabin area, attached to the fuselage skin with resin. Its Z-profile is used to mount the fuel tank. On both sides of the B-bulkhead, the B-bolts for the wing connection are installed.
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Page 553 CANOPY 1. General The DV 20 KATANA is equipped with a single piece lifting canopy with a frame fabricated of glass fiber laminate and rovings. To provide a generous all around view, an acrylic glass window is installed. It is held by screws and a bonding. The canopy is equipped with two emergency windows.
Page 554 Fuselage DV 20 KATANA AMM AIRCRAFT 2. Troubleshooting The following table lists defects as they could appear on the canopy system, and their correction. Complaint Possible Cause Repair Canopy jams. Defective locking pins. Replace. Emergency window hard to Unclean or defective guides.
Page 555 DV 20 KATANA AMM Fuselage AIRCRAFT 3. Removal and Installation A. Canopy, Complete The canopy can be removed and installed easily and fast. (1) Removal Detail Steps/Work Items Key Items/References Open canopy. Remove the screw located on the upper guide lever.
Page 556 Fuselage DV 20 KATANA AMM AIRCRAFT B. Emergency Windows (1) Removal Detail Steps/Work Items Key Items/References Unscrew upper window guide. Lift window from lower window guide. (2) Installation Detail Steps/Work Items Key Items/References For installation reverse the sequence. NOTE: For installation of the window guides, ACRYFIX should be used. The screws should be torqued very carefully.
Page 557 DV 20 KATANA AMM Fuselage AIRCRAFT Canopy Assy Magnetic Compass DV Panel DV Panel Handle, Inner Strut Tension Spring Safety Lock Figure 1: Canopy, Complete Doc # 4.02.02 Page 5 53-11-00 Rev. 13 15 Dec 2018...
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Page 559 INSPECTION HOLES 1. General The DV 20 KATANA fuselage has four inspection holes. Their covers are fitted to the surface of the fuselage and are installed either with self-tapping screws or quick lock fasteners. The openings enable visual inspection and access to components and connections.
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Page 561 DV 20 KATANA AMM Stabilizers AIRCRAFT CHAPTER 55 STABILIZERS Doc # 4.02.02 Page 1 55-TITLE Rev. 13 15 Dec 2018...
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Page 563 DV 20 KATANA AMM Stabilizers AIRCRAFT TABLE OF CONTENTS CHAPTER 55-00 STABILIZERS General ............1...
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Page 565 CHAPTER 55-00 STABILIZERS 1. General The tail plane of the DV 20 KATANA consists of the horizontal stabilizer (elevator fin), elevator including trim tab, vertical stabilizer (rudder fin), and rudder. This chapter describes only the horizontal stabilizer, elevator and rudder.
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Page 567 DV 20 KATANA AMM Stabilizers AIRCRAFT Section 55-10 HORIZONTAL STABILIZERS 1. General Attached to the horizontal stabilizer is the elevator with the trim tab located in the middle. 2. Description The horizontal stabilizer is attached to the rudder fin web with a metal fitting and two times four bolts.
Page 568 Stabilizers DV 20 KATANA AMM AIRCRAFT 3. Removal and Installation A. Horizontal Stabilizer Rudder must be removed (refer to Sub-Chapter 27-20-30), elevator and trim tab must be disconnected from rearward controls (refer to Sub-Chapters 27-30 and 27-40). (1) Removal Detail Steps/Work Items...
Page 569 AIRCRAFT Section 55-40 RUDDER 1. General The conventionally designed DV 20 KATANA rudder allows flight control of the airplane about the vertical axis. For maintenance information refer to Chapter 27-20-30. This chapter describes only the rudder structure. 2. Description The symmetrical half shells of the rudder are manufactured of PVC rigid foam covered on both sides.
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Page 571 DV 20 KATANA AMM Wings AIRCRAFT CHAPTER 57 WINGS Doc # 4.02.02 Page 1 57-TITLE Rev. 13 15 Dec 2018...
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Page 573 DV 20 KATANA AMM Wings AIRCRAFT TABLE OF CONTENTS CHAPTER 57-00 WINGS General ............1...
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Page 575 WINGS 1. General The wing assembly of the DV 20 KATANA is a low wing monoplane design, and consists of two cantilever wings with ailerons and wing flaps. The wings are of semi-monocoque sandwich construction. For removal and installation of the wing flaps refer to Chapter 27. The structure is described in this chapter.
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Page 577 Section 57-10 WING STRUCTURE 1. General The DV 20 KATANA is a low wing monoplane design, using conventional ailerons and wing flaps. 2. Description The cantilever wings of the DV 20 KATANA are of semi-monocoque sandwich construction. An I-spar with caps constructed of carbon fiber is the base of the wing construction. The spar stumps reach to the middle of the fuselage.
Page 578 Wings DV 20 KATANA AMM AIRCRAFT 3. Removal and Installation NOTE: Some S/N's are equipped with the optional wing folding mechanism. Refer to the Supplement to the Airplane Flight Manual for a description. (1) Removal Detail Steps/Work Items Key Items/References S/N's 20.101 and subsequent: remove baggage...
Page 579 DV 20 KATANA AMM Wings AIRCRAFT Figure 1: Connectors and Bolts on LH Wing Root Figure 2: Proper Connection of Bellcrank and Pocket at Wing Root (Ailerons and Flaps) Only S/N's 20.005 thru 20.100 Doc # 4.02.02 Page 3 57-10-00 Rev.
Page 580 Wings DV 20 KATANA AMM AIRCRAFT Figure 3: Properly Secured B-bolt Flight Direction Locking Device Main Bolt Main Bulkhead Figure 4: Properly Secured Main Bolts Drawing does not show wing spar and wing spar bushing. Page 4 Doc # 4.02.02...
Page 581 DV 20 KATANA AMM Wings AIRCRAFT 4. Bolt Play A. Radial Play The wing connection bolts are not sensitive to radial play. However, the radial play should not exceed the values given in the table below. A-bolt in spherical bearing 0.08 mm...
Page 582 Wings DV 20 KATANA AMM AIRCRAFT 5. Replacement of Main Bolt Bushing NOTE: Limits for play are defined in the Paragraph 4. Detail Steps/Work Items Key Items/References CAUTION: DO NOT DAMAGE THE COMPOSITE STRUCTURE. Cut the bushings parallel to the longitudinal axis with a hand-milling machine.
Page 583 AIRCRAFT Section 57-50 WING FLAPS 1. General The DV 20 KATANA is equipped with electrically operated wing flaps which are attached to the wings with hinges. For removal and installation refer to Chapter 27-50. This sub-chapter only describes the structure.
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Page 585 Section 57-60 AILERONS 1. General The DV 20 KATANA is equipped with one aileron on each wing, operated by push rods. For a systems description as well as for removal and installation procedures of the aileron controls refer to Chapter 27-10.
Page 586 Wings DV 20 KATANA AMM AIRCRAFT 3. Removal and Installation Aileron push rod must be removed (refer to Chapter 27-10). (1) Removal Detail Steps/Work Items Key Items/References Remove the dowel pins, extract bearing journals. NOTE: Secure the aileron from falling down! To ensure easy re-installation, mark location and direction of the bearing journals.
Page 587 DV 20 KATANA AMM Propeller AIRCRAFT CHAPTER 61 PROPELLER Doc # 4.02.02 Page 1 61-TITLE Rev. 13 15 Dec 2018...
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Page 589 DV 20 KATANA AMM Propeller AIRCRAFT TABLE OF CONTENTS CHAPTER 61-00 PROPELLER General ............1 Description .
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Page 591 AIRCRAFT CHAPTER 61-00 PROPELLER 1. General The DV 20 KATANA is equipped with one of the following propeller models: Hoffmann HO-V72F/S170DW (with 912 A3 engine only) Hoffmann HO-V352F/170FQ (with 912 A3 or S3 engine) Hoffmann HO-V352F/C170FQ (with 912 A3 or S3 engine)
Page 592 Propeller DV 20 KATANA AMM AIRCRAFT 3. Troubleshooting The following table lists defects as they could appear on the propeller, and their correction. Complaint Possible Cause Repair Blade shake. Loose blade bearing. Hoffmann: Tighten retention nut to 25 - 30 Nm (18.4 to 22.1 lbs.ft.).
Page 593 DV 20 KATANA AMM Propeller AIRCRAFT Complaint Possible Cause Repair Surging RPM. Trapped air in propeller piston. Hoffmann: Move propeller speed control at least 3 times over the entire pitch range to release air. mt-Propeller: Move propeller speed control at least twice...
Page 594 Propeller DV 20 KATANA AMM AIRCRAFT Complaint Possible Cause Repair Differences in RPM during Up to ± 50 RPM are system climb, cruise, and descent inherent. If this value is without propeller speed control exceeded: lever movement. Friction in propeller or Contact propeller governor.
Page 595 DV 20 KATANA AMM Propeller AIRCRAFT Complaint Possible Cause Repair Pitch change extremely Clogged oil lines between Contact repair station to have sluggish after movement of governor and propeller. lines cleaned. propeller speed control lever NOTE: This kind of malfunction and/or RPM changes with does not appear abruptly.
Page 596 Propeller DV 20 KATANA AMM AIRCRAFT 4. Installation Procedure NOTE: Propeller installation may only be carried out by authorized personnel and must be checked immediately after completion. Any maintenance must be performed in accordance with the propeller manufacturer's documentation. Detail Steps/Work Items...
Page 597 DV 20 KATANA AMM Propeller AIRCRAFT Detail Steps/Work Items Key Items/References Install spinner in accordance with the markings. Ensure sufficient guidance on guiding plate. Apply a light coat of motor oil to rubber before installing spinner. Torque of spinner mounting screws: Hoffmann: 2.5 to 3.0 Nm (22.1 to 26.6 in.lbs.),...
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Page 599 DV 20 KATANA AMM Power Plant (Engine) AIRCRAFT CHAPTER 71 POWER PLANT (ENGINE) Doc # 4.02.02 Page 1 71-TITLE Rev. 13 15 Dec 2018...
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Page 601 DV 20 KATANA AMM Power Plant (Engine) AIRCRAFT TABLE OF CONTENTS CHAPTER 71-00 POWER PLANT (ENGINE) General ............1 Description .
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Page 603 POWER PLANT (ENGINE) 1. General This chapter describes the engine installed in the DV 20 KATANA, its external units, removal and installation, as well as the troubleshooting procedures. For maintenance or overhaul of the engine refer to the engine manufacturer's documentation. For operation refer to the Operator's Manual.
Page 604 AIRCRAFT 2. Description The engine installed in the DV 20 KATANA is a ROTAX 912 A3 with a take-off performance of 80 hp at 5800 RPM. Optionally installed may be the ROTAX 912 S3 engine with a take-off performance of 100 hp at 5800 RPM.
Page 605 DV 20 KATANA AMM Power Plant (Engine) AIRCRAFT If an engine with suffix -01 is installed, the item ‘Max. cylinder head temperature’ is changed to ‘Max. coolant temperature’ as shown in the paragraph below. Engine Specification of the ROTAX 912 A3 RPM's are propeller speeds, crankshaft speeds in brackets.
Page 606 Power Plant (Engine) DV 20 KATANA AMM AIRCRAFT If an engine with suffix -01 is installed, the item ‘Max. cylinder head temperature’ is changed to ‘Max. coolant temperature’ as shown in the paragraph below. Engine Specification of the ROTAX 912 S3 RPM's are propeller speeds, crankshaft speeds in brackets.
Page 607 DV 20 KATANA AMM Power Plant (Engine) AIRCRAFT A. Starter The starter is attached to the engine and is located on the right hand side, at the rear of the engine. The starter pinion is pushed forward during the start phase to engage into the ring gear. With the engine running, the starter pinion is retracted by centrifugal force.
Page 608 Power Plant (Engine) DV 20 KATANA AMM AIRCRAFT F. Reduction Gear The step-down ratio between crankshaft and propeller is 2.2727:1 on the 912 A3 engine and 2.43:1 on the 912 S3 engine. The reduction gear contains a dampening unit to reduce torsional vibration.
Page 609 DV 20 KATANA AMM Power Plant (Engine) AIRCRAFT 3. Troubleshooting The following table lists defects as they could appear on the engine, and their correction. Complaint Possible Cause Repair Engine does not start. Spark plug gap to wide. Adjust gap to 0.5 mm (0.02") or replace plugs.
Page 610 Power Plant (Engine) DV 20 KATANA AMM AIRCRAFT Complaint Possible Cause Repair Engine idles unsteadily after Choke activated. Deactivate. warm up, black exhaust gas Carburetors synchronized Adjust carburetors. inadequately. Fuel needle unclean, jammed, Clean or replace. or worn. Intake manifold leaky.
Page 611 DV 20 KATANA AMM Power Plant (Engine) AIRCRAFT Complaint Possible Cause Repair Engine performance Defective ignition system. Check ignition circuits; if defect unsatisfactory. evident, check ignition wires and trigger coil; have ignition box repaired. Too much oil in crankcase. Check return line to oil tank for clogging (seals, covers, etc.).
Page 612 Power Plant (Engine) DV 20 KATANA AMM AIRCRAFT Complaint Possible Cause Repair Excessive oil consumption. Worn, broken, or improperly Engine overhaul required. installed piston rings. Poor oil quality. Change oil, use approved oil type. Worn valve guides, poor Cylinder head repair required.
Page 613 DV 20 KATANA AMM Power Plant (Engine) AIRCRAFT 4. Removal and Installation A. Engine (1) Removal NOTE: In many cases it is better to remove the engine together with the engine mount from the firewall. The following is a description of such task.
Page 614 Power Plant (Engine) DV 20 KATANA AMM AIRCRAFT Detail Steps/Work Items Key Items/References (13) Remove exhaust, radiators, oil tank, ignition box, engine mount, and auxiliary engine mounts. (2) Installation Detail Steps/Work Items Key Items/References For installation reverse the sequence. B. Carburetor...
Page 615 DV 20 KATANA AMM Power Plant (Engine) AIRCRAFT 5. Maintenance Information A. Carburetor Synchronization The throttle valves must open simultaneously for a regular operation of all cylinders. For a complete re-adjustment, both stop screws are turned back until the throttle valves close completely (check by disconnecting bowden cables).
Page 616 Power Plant (Engine) DV 20 KATANA AMM AIRCRAFT (3) OVERLOAD CLUTCH Should only be checked if there is suspicion of clutch malfunction or at the 600 hr. inspection. The overload clutch is adjusted to a torque of 400 to 500 Nm (295 to 369 lbs.ft.) by the manufacturer.
Page 617 DV 20 KATANA AMM Power Plant (Engine) AIRCRAFT CHAPTER 71-10 COWLING 1. General The engine cowling consists of two halves, with an inspection cover located on the upper half allowing access to the oil dipstick and the coolant equalizing reservoir. The cover is attached to the cowling by a hinge and secured by a rotary lock.
Page 618 Power Plant (Engine) DV 20 KATANA AMM AIRCRAFT 2. Removal and Installation A. Removal Detail Steps/Work Items Key Items/References Loosen fasteners on upper engine cowling. Remove upper cowling. On lower cowling, disconnect electrical connection to landing light (located on left hand side).
Page 619 DV 20 KATANA AMM Power Plant (Engine) AIRCRAFT CHAPTER 71-20 ENGINE MOUNT 1. General The engine is mounted to the airframe via the engine mount and the shock mounts (silentblocs). The engine mount consists of a welded steel bar frame which is mounted to the firewall using bolts and self locking nuts.
Page 620 Power Plant (Engine) DV 20 KATANA AMM AIRCRAFT 3. Removal and Installation A. Removal from the Firewall Detail Steps/Work Items Key Items/References Remove bolts holding engine mount. Remove engine mount from firewall. B. Installation Detail Steps/Work Items Key Items/References For installation reverse the sequence.
Page 621 DV 20 KATANA AMM Power Plant (Engine) AIRCRAFT CHAPTER 71-60 AIR INTAKES AND GUIDES 1. General A ram air guide made of GFRP is installed on the engine to ensure optimal engine cooling. 2. Description The air guide is designed to follow the contours of the engine block and cylinders. The exact fitting makes attachment screws unnecessary.
Page 622 Power Plant (Engine) DV 20 KATANA AMM AIRCRAFT 3. Removal and Installation A. Removal Detail Steps/Work Items Key Items/References Disconnect coolant hoses from cylinder heads (upper side); remove. Remove auxiliary units on engine upper side. Disconnect fuel lines from fuel pump; remove.
Page 623 DV 20 KATANA AMM Engine Cooling AIRCRAFT CHAPTER 75 ENGINE COOLING Doc # 4.02.02 Page 1 75-TITLE Rev. 13 15 Dec 2018...
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Page 625 DV 20 KATANA AMM Engine Cooling AIRCRAFT TABLE OF CONTENTS CHAPTER 75-10 ENGINE COOLING General ............1 Replenishing .
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Page 627 DV 20 KATANA AMM Engine Cooling AIRCRAFT CHAPTER 75-10 ENGINE COOLING 1. General The engine cooling is performed using two different systems. Ram air guided by a duct is used to cool the cylinders, while the cylinder heads are liquid cooled.
Page 628 Engine Cooling DV 20 KATANA AMM AIRCRAFT Coolant Dispatcher Vessel Figure 2: Dispatcher Vessel Page 2 Doc # 4.02.02 75-10-00 15 Dec 2018 Rev. 13...
Page 629 DV 20 KATANA AMM Engine Cooling AIRCRAFT Equalizing Reservoir Figure 3: Equalizing Reservoir Doc # 4.02.02 Page 3 75-10-00 Rev. 13 15 Dec 2018...
Page 630 Engine Cooling DV 20 KATANA AMM AIRCRAFT 2. Replenishing For replenishing, refer to Sub-Chapter 12-10. Page 4 Doc # 4.02.02 75-10-00 15 Dec 2018 Rev. 13...
Page 631 DV 20 KATANA AMM Engine Controls AIRCRAFT CHAPTER 76 ENGINE CONTROLS Doc # 4.02.02 Page 1 76-TITLE Rev. 13 15 Dec 2018...
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Page 633 DV 20 KATANA AMM Engine Controls AIRCRAFT TABLE OF CONTENTS CHAPTER 76-10 ENGINE CONTROLS General ............1 Description .
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Page 635: Engine Controls
DV 20 KATANA AMM Engine Controls AIRCRAFT CHAPTER 76-10 ENGINE CONTROLS 1. General The engine is controlled with the carburetor heat lever, propeller speed control lever, as well as by the throttle and the choke control. Bowden cables are used for the transmission of control movements. The bowden cables are sealed with a fire resistant compound as they pass through the firewall.
Page 636: Troubleshooting
E. Throttle Quadrant Friction Control In the DV 20 KATANA, the levers for throttle, propeller speed, and carburetor heat can be arrested by turning the black knob on the right hand side of the center console in clockwise direction. The arresting is performed by clamping the friction washers installed on the lever axis.
Page 637: Removal And Installation
DV 20 KATANA AMM Engine Controls AIRCRAFT 4. Removal and Installation A. Throttle Control Bowden Cables (1) Removal Detail Steps/Work Items Key Items/References Remove engine cowlings. Remove instrument panel cover. Disconnect bowden cable clamps on carburetors. Disconnect bowden cable clamps on shift lever below instrument panel.
Page 638 Engine Controls DV 20 KATANA AMM AIRCRAFT Bowden Cable Clamp Throttle Lever Bowden Cable Carburetor Carburetor Bowden Cable Clamp Figure 1: Throttle Control Bowden Cables Page 4 Doc # 4.02.02 76-10-00 15 Dec 2018 Rev. 13...
Page 639 DV 20 KATANA AMM Engine Controls AIRCRAFT (3) Adjustment To perform the initial idle speed adjustment, the idle speed adjustment screws must be turned back until the throttle valves have reached their limit position within the carburetors. Then the adjustment screws should be turned clockwise until a clearance of 0.1 mm (0.004") has been reached.
Page 640 Engine Controls DV 20 KATANA AMM AIRCRAFT B. Choke Bowden Cables (1) Removal Detail Steps/Work Items Key Items/References Remove engine cowling. Remove instrument panel cover. Disconnect bowden cables from carburetors. Disconnect bowden cables from parallel guide on center console. Remove bowden cables by pulling rearward.
Page 641 DV 20 KATANA AMM Engine Controls AIRCRAFT C. Carburetor Heat Bowden Cable (1) Removal Detail Steps/Work Items Key Items/References Remove engine cowling. Loosen mounting hardware of throttle quadrant on the center console, and remove RH rotary knob. Disconnect bowden cable from flap actuating lever on air distribution box.
Page 642 Engine Controls DV 20 KATANA AMM AIRCRAFT Bowden Cable Clamp Bowden Cable Bowden Cable Tension Spring Carburetor Heat Lever Flap Actuating Lever Air Distribution Box Figure 2: Flap Actuating Lever on Air Distribution Box Page 8 Doc # 4.02.02 76-10-00 15 Dec 2018 Rev.
Page 643 DV 20 KATANA AMM Engine Controls AIRCRAFT D. Propeller Speed Control Bowden Cable (1) Removal Detail Steps/Work Items Key Items/References Remove engine cowling. Disconnect bowden cable from propeller governor. Loosen mounting hardware of throttle quadrant on the center console, and remove RH rotary knob.
Page 644 Engine Controls DV 20 KATANA AMM AIRCRAFT Bowden Cable Clamp Bowden Cable Bowden Cable Propeller Speed Control Lever Governor Lever Propeller Governor Figure 3: Lever on Propeller Governor Page 10 Doc # 4.02.02 76-10-00 15 Dec 2018 Rev. 13...
Page 645 DV 20 KATANA AMM Engine Controls AIRCRAFT E. Throttle Quadrant Friction Control (1) Removal Detail Steps/Work Items Key Items/References Remove rotary knob on RH side of center console. Remove washer springs and replace if required. (2) Installation Detail Steps/Work Items Key Items/References For installation reverse the sequence.
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Page 647 DV 20 KATANA AMM Engine Indicating AIRCRAFT CHAPTER 77 ENGINE INDICATING Doc # 4.02.02 Page 1 77-TITLE Rev. 13 15 Dec 2018...
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Page 649 DV 20 KATANA AMM Engine Indicating AIRCRAFT TABLE OF CONTENTS CHAPTER 77-00 ENGINE INDICATING General ............1 Description .
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Page 651: Engine Indicating
2. Description A. RPM Indicator In the DV 20 KATANA the RPM indication is done by a mechanical system. The RPM indicated on the cockpit instrument is that of the propeller and not that of the engine. B. Fuel Pressure Warning Light The fuel pressure warning light is located in the center section of the instrument panel, and is activated by a pressure sensor located on the firewall.
Page 652 H. Control Light for Coolant Quantity The DV 20 KATANA may be equipped with a control light for coolant quantity. It is preferably located in the center console of the instrument panel and receives its data from a sensor located in the dispatcher vessel especially designed to hold this sensor.
Page 653: Troubleshooting
DV 20 KATANA AMM Engine Indicating AIRCRAFT 3. Troubleshooting The following table lists defects as they could appear on the engine indicating system, and their correction. If an engine with suffix -01 is installed, the item ‘No cylinder head temperature indication’ is changed to ‘No coolant temperature indication’.
Page 654: Removal And Installation
Engine Indicating DV 20 KATANA AMM AIRCRAFT Complaint Possible Cause Repair No or high manifold pressure Defective or leaky manifold Tighten clamps, replace line if indication. pressure line. necessary. Defective indicator. Replace. 4. Removal and Installation If an engine with suffix -01 is installed, the headline ‘Cylinder Head Temperature Indicator’ is changed to ‘Coolant Temperature Indicator’.
Page 655 DV 20 KATANA AMM Engine Indicating AIRCRAFT RPM Indicator Flexible Shaft Figure 1: RPM Indicator Doc # 4.02.02 Page 5 77-00-00 Rev. 13 15 Dec 2018...
Page 656 Engine Indicating DV 20 KATANA AMM AIRCRAFT B. Fuel Pressure Warning Light (1) Removal Detail Steps/Work Items Key Items/References Pull off connectors from rear of warning light. Remove mounting nut. Remove warning light from instrument panel. (2) Installation Detail Steps/Work Items Key Items/References For installation reverse the sequence.
Page 657 DV 20 KATANA AMM Engine Indicating AIRCRAFT D. Oil Pressure Indicator (1) Removal Detail Steps/Work Items Key Items/References Pull off connectors from rear of instrument. Remove nuts from mounting bracket. Remove instrument from panel. (2) Installation Detail Steps/Work Items Key Items/References For installation reverse the sequence.
Page 658 Engine Indicating DV 20 KATANA AMM AIRCRAFT E. Oil Temperature Indicator (1) Removal Detail Steps/Work Items Key Items/References Pull off connectors from rear of instrument. Remove nuts from mounting bracket. Remove instrument from panel. (2) Installation Detail Steps/Work Items Key Items/References For installation reverse the sequence.
Page 659 DV 20 KATANA AMM Engine Indicating AIRCRAFT G. Manifold Pressure Indicator (1) Removal Detail Steps/Work Items Key Items/References Pull off connectors from rear of instrument. Remove mounting bolts and nuts. Remove instrument from panel. (2) Installation Detail Steps/Work Items Key Items/References For installation reverse the sequence.
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Page 661 DV 20 KATANA AMM Exhaust AIRCRAFT CHAPTER 78 EXHAUST Doc # 4.02.02 Page 1 78-TITLE Rev. 13 15 Dec 2018...
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Page 663 DV 20 KATANA AMM Exhaust AIRCRAFT TABLE OF CONTENTS CHAPTER 78-00 EXHAUST General ............1 Description .
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Page 665: General
DV 20 KATANA AMM Exhaust AIRCRAFT CHAPTER 78-00 EXHAUST 1. General Each of the engine cylinders is equipped with its own exhaust pipe leading to the underside of the engine, where they are attached to the muffler. To enable a heat expansion of the exhaust system, the connections between muffler and pipes are movable and secured with two springs each.
Page 666: Description
Exhaust DV 20 KATANA AMM AIRCRAFT 2. Description The exhaust pipes are fabricated of welded high-grade steel. They run from the cylinders to the underside of the engine where they are connected to the muffler. A heat exchanger surrounds the muffler.
Page 667: Removal And Installation
DV 20 KATANA AMM Exhaust AIRCRAFT 4. Removal and Installation (1) Removal Detail Steps/Work Items Key Items/References Disconnect air hoses from heat exchanger. Remove all nuts securing the exhaust pipes to the cylinder heads. Remove complete exhaust system from engine.
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Page 669 DV 20 KATANA AMM Oil Cooling AIRCRAFT CHAPTER 79 79-TITLE Doc # 4.02.02 Page 1 Rev. 13 15 Dec 2018...
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Page 671 DV 20 KATANA AMM Oil Cooling AIRCRAFT TABLE OF CONTENTS CHAPTER 79 OIL COOLING General ............1 Description .
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Page 673 For a detailed description of the engine lubrication system refer to documentation of the engine manufacturer. The DV 20 KATANA is equipped with an oil radiator attached to the engine mount on the right hand engine side and connected to the engine with oil lines. An opening in the lower engine cowling supplies ram air to the oil radiator.
Page 674 Oil Cooling DV 20 KATANA AMM AIRCRAFT 2. Description The hot oil is directed from the crankcase to the oil tank from where it flows to the oil radiator and on to the oil pump. A temperature sensor is installed next to the oil filter. This sensor is connected to the oil temperature indicator.
Page 675 DV 20 KATANA AMM Oil Cooling AIRCRAFT Section 79-21 OIL RADIATOR 1. General The oil radiator is located on the lower right side of the engine, attached to the engine mount. The oil radiator has two threaded connection sleeves to which the oil lines are attached. The sleeves are also used to secure the radiator to the engine mount.
Page 676 Oil Cooling DV 20 KATANA AMM AIRCRAFT 2. Troubleshooting The following table lists defects as they could appear on the oil cooling system, and their correction. Complaint Possible Cause Repair Excessive oil temperature. Damaged radiator fins. Replace radiator. Inhibited air flow.
Page 677 DV 20 KATANA AMM Oil Cooling AIRCRAFT 3. Removal and Installation A. Oil Radiator (1) Removal Detail Steps/Work Items Key Items/References Disconnect hose lines from radiator ports. Straighten locking plates on hose connectors. Remove mounting nuts. Remove oil radiator. (2) Installation...
Page 678 Oil Cooling DV 20 KATANA AMM AIRCRAFT Hose Line Hose Line Locking Plate Radiator Port Locking Plate Oil Radiator Radiator Port Figure 1: Oil Radiator 79-21-00 Page 4 Doc # 4.02.02 15 Dec 2018 Rev. 13...
Page 679 INDICATING 1. General The DV 20 KATANA is equipped with an oil pressure and an oil temperature sensor for monitoring the lubrication system. The oil temperature sensor is attached next to the oil filter, while the oil pressure sensor is located opposite of the oil filter.
Page 680 Oil Cooling DV 20 KATANA AMM AIRCRAFT 2. Troubleshooting The following table lists defects as they could appear on the oil cooling system, and their correction. Complaint Possible Cause Repair No oil temperature indication. Defective wiring or connector. Check wiring and connector.
Page 681 DV 20 KATANA AMM Oil Cooling AIRCRAFT 3. Removal and Installation A. Oil Temperature Sensor (1) Removal Detail Steps/Work Items Key Items/References Disconnect wiring. Remove sensor using suitable tool. (2) Installation Detail Steps/Work Items Key Items/References For installation reverse the sequence. When...
Page 682 Oil Cooling DV 20 KATANA AMM AIRCRAFT Figure 1: Oil Temperature Sensor and Oil Filter 79-30-00 Page 4 Doc # 4.02.02 15 Dec 2018 Rev. 13...
Page 683 DV 20 KATANA AMM Oil Cooling AIRCRAFT B. Oil Pressure Sensor (1) Removal Detail Steps/Work Items Key Items/References Disconnect wiring. Remove sensor. (2) Installation Detail Steps/Work Items Key Items/References For installation reverse the sequence. When installing the sensor, a suitable sealing compound must be used (e.g.
Page 684 Oil Cooling DV 20 KATANA AMM AIRCRAFT Figure 2: Oil Pressure Sensor 79-30-00 Page 6 Doc # 4.02.02 15 Dec 2018 Rev. 13...
Page 685 Wiring Diagrams DV 20 KATANA AMM AIRCRAFT CHAPTER 92 WIRING DIAGRAMS Doc # 4.02.02 Page 1 92-TITLE Rev. 13 15 Dec 2018...
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Page 687 Wiring Diagrams DV 20 KATANA AMM AIRCRAFT TABLE OF CONTENTS CHAPTER 92 WIRING DIAGRAMS General ..........1 Doc # 4.02.02...
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Page 689 Wiring Diagrams DV 20 KATANA AMM AIRCRAFT CHAPTER 92 WIRING DIAGRAMS 1. General This Chapter contains the wiring diagrams for each system. The wiring diagrams use the ATA Chapter/Section numbering system. If an engine with suffix -01 is installed, the items ‘Cylinder head temperature indicator’ and ‘Cylinder head temperature’...
Page 690 Wiring Diagrams DV 20 KATANA AMM AIRCRAFT Title Drawing No. Date Rev. Position and Strobe Lights 01-3340-14-1 30.05.93 ADF KR 87/K1227 01-3431-10 20.02.95 ELT E-01 01-3440-10 25.07.95 NAV Receiver NR3301-(1)/IN3301-(4) 01-3451-14-2.1.1 12.05.93 NAV Receiver NR3301-(2) 01-3451-14-2.2.1 12.05.93 NAV Receiver NR3301-(S) 01-3451-14-2.3.1...
Page 691 Wiring Diagrams DV 20 KATANA AMM AIRCRAFT Title Drawing No. Date Rev. Schematic, Directional Gyro Wiring D20-9234-10-02 18.06.12 Schematic, Turn & Bank Wiring D20-9234-10-03 06.06.12 Schematic, GPSMAP Wiring D20-9234-50-08 07.07.09 Schematic, GNS 430 & GI 106A Wiring D20-9234-50-15 11.06.12 Schematic, GTX 328 Wiring D20-9234-50-18 09.08.11...
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