Operation & Maintenance Manual - Tmg-service.de - Free Download PDF

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Technify Motors GmbHPlatanenstraße 14D - 09356 St. EgidienTel. 49 37204 696-0Fax 49 37204 ldiesel.deOperation & Maintenance Manual - Issue 4 / Revision 6Operation & MaintenanceManualCD-135CD-155Doc. No.: OM-02-02Version: 4/6CAUTION:The Operation and Maintenance Manualmust be read completely before operating theengine, as it contains important safety informationand information about the operation of the engine. Note:The Operation and Maintenance Manualmust be included at the time of saleof the engine / aircraft. Note:Please report any service difficulties to the TechnicalSupport Center at Technify Motors GmbH.See above for contact information. P/N: 05-7200-H200221

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Operation & Maintenance ManualCD-135 / CD-155OM-02-02Table of ContentsChapter DescriptionRevision no.: 6Revision date: 22.04.2016Page0.10.20.3Table of Contents .3List of Figures .11List of Revisions .1List of applicable Chapters .7Preliminary Remarks .81Introduction .11.1Accompanying applicable Document .11.2Engine Identification .21.3Copyright .31.4Safety Recommendations .31.5Validity of this Manual .31.6Abbreviations .31.7Packaging and Transport .41.8Storage .41.9Scope of Supply .51.10Qualifications of the Operating and MaintenancePersonnel .51.11Update Information Service .51.12Service Life of this Engine .51.13Safety Information .62Description and Dimensions of the Engine .12.1Engine Designation .12.2Description and Standard Production Version .12.3Engine Views .2Chapter:Issue:Issue date:Page:Content:02-OM-00-02430.07.201438

Operation & Maintenance ManualCD-135 / CD-155OM-02-02Chapter:Issue:Issue date:Page:Content:3Technical Data .13.1Dimensions and Weights .13.2Performance Data .13.3Operational Data .23.4Operation Limits .23.5Fuel / Oil / Coolant .43.6Power Curve .83.7Low Temperature Data and Climate Classes of Dieselin Europe .104Operation .14.1Pre-start Inspection .14.2Start-up .24.3Engine Warm-up .34.4Before Takeoff Check .34.4.1 FADEC and propeller pitch functional check .34.4.2 Engine test run for maintenance purposes (Real Time Log File (RTLF), Internal DataLogger (IDL), Event Log (EL)) .54.4.3 FADEC-Reset (from Software 2.7 on andfollowing) .74.5Takeoff and Climb .94.6During Flight .94.7Shutting Down the Engine .902-OM-00-02430.07.201448Revision no.: 6Revision date: 22.04.2016

Operation & Maintenance ManualCD-135 / CD-155OM-02-02Revision no.: 6Revision date: 22.04.20165Airworthiness Limitations .15.1Mandatory Maintenance Actions .15.1.1 Every 100 operating hours .15.1.2 Every 300 operating hours .25.1.3 Every 600 operating hours .25.1.4 Every 900 operating hours .35.1.5 Every 1200 operating hours .35.1.6 Every 1200 operating hours or every 24months, whichever occurs first .35.1.7 Every 12 months .35.1.8 Every 60 months .35.2Claimable Exceeds of Maintenance Actions .45.2.1 Maintenance Actions based on operatinghours .45.2.2 Maintenance Actions based on time .45.2.3 Examples .55.3Log of Revisions to Airworthiness Limitations .6Chapter:Issue:Issue date:Page:Content:02-OM-00-02430.07.201458

Operation & Maintenance ManualCD-135 / CD-155OM-02-02Chapter:Issue:Issue date:Page:Content:6Maintenance Schedules .16.1"Pre-flight Check" .26.2Maintenance Actions based on Operating Hours .26.2.1 After the 3rd - 6th operating hour .36.2.2 Every 100 operating hours .46.2.3 Every 200 operating hours .56.2.4 Every 300 operating hours .56.2.5 Every 600 operating hours .66.2.6 Every 900 operating hours .76.2.7 Every 1200 operating hours (only applicablefor CD-135) .76.2.8 Every 1200 operating hours (only applicablefor CD-155) .76.2.9 Every 1200 operating hours or every 24months, whichever occurs first .86.2.10 Every 1500 operating hours (only applicablefor CD-135) .86.3Maintenance Actions based on Time .96.3.1 Every month .96.3.2 Every 12 months .96.3.3 Every 24 months .106.3.4 Every 60 months .1002-OM-00-02430.07.201468Revision no.: 6Revision date: 22.04.2016

Operation & Maintenance ManualCD-135 / CD-155OM-02-02Annex 1 - Inspecting the V-Ribbed Belt .11Annex 2 - Inspecting the Oil and Fuel System for Leakage .12Annex 3 - Inspecting the Cooling System for Leakage .13Annex 4 - Engine Test Run .14Annex 5 - Exchanging the Engine Oil and Oil Filter .15Annex 6 - Cleaning the Engine .18Annex 7 - Checking the FADEC Sensors .19Annex 8 - Exchanging the gearbox oil filter of the gearbox .24Annex 9 - Checking the level of the gearbox oil of the gearbox31Annex 10 - FADEC Read-out .37Annex 11 - Inspecting the High-Pressure Pump .49Annex 12 - Replacing the Alternator .50Annex 13 - Exchanging the gearbox oil and the gearbox oil filterat the gearbox .51Annex 14 - Exchanging the Coolant .64Annex 15 - Inspecting the Gearbox .65Annex 16 - Replacing the Excitation Battery .66Annex 17 - FADEC Software Update .68Annex 18 - Inspecting the Fuel Feed Pump .73Revision no.: 6Revision date: 22.04.2016Chapter:Issue:Issue date:Page:Content:02-OM-00-02430.07.201478

Operation & Maintenance ManualCD-135 / CD-155OM-02-027Emergency Procedures .17.1Power Loss .17.2FADEC Operation .17.3Engine System Malfunction .27.3.1 One FADEC light flashing .27.3.2 Both FADEC lights flashing .37.3.3 Abnormal engine behavior .37.4Restart after Engine Failure .47.5Fire in the Engine Compartment .47.6Air in the Fuel System (During Flight) .57.7Oil Pressure too Low (During Flight) .5FOBL E8-01 Change of HandsEngine Maintenance Checklist - After the 3rd - 6th operating hourEngine Maintenance Checklist - GeneralChapter:Issue:Issue date:Page:Content:02-OM-00-02430.07.201488Revision no.: 6Revision date: 22.04.2016

Operation & Maintenance ManualCD-135 / CD-155OM-02-02List of FiguresFig. 1.1Fig. 1.1Fig. 1.2Fig. 2.1Fig. 2.2Fig. 2.3Fig. 2.4Fig. 3.5Fig. 3.6Fig. 4.1Fig. 6.1Fig. 6.2Fig. 6.3Fig. 6.4Fig. 6.5Fig. 6.6Fig. 6.7Fig. 6.8Fig. 6.9Fig. 6.10Fig. 6.11Fig. 6.12Fig. 6.13Fig. 6.14Fig. 6.15Fig. 6.16Fig. 6.17Fig. 6.18Fig. 6.19Fig. 6.20Fig. 6.21Fig. 6.22Fig. 6.23Fig. 6.24Fig. 6.25Fig. 6.26Fig. 6.27Revision no.: 6Revision date: 22.04.2016Explanation of the chapter numbering systemEngine identificationPreservation of the engineFront view of CD-135 / CD-155 (dimensions in mm)Overhead view of CD-135 / CD-155 (dimensions inmm)Side view of CD-135 / CD-155, LH (dimensions inmm)Side view of CD-135 / CD-155, RH (dimensions inmm)Power curve of CD-135 (TAE 125-02-99)Power curve of CD-155 (TAE 125-02-114)FADEC and propeller pitch functional checkOil drain plugOil filter assyCoolant temperature sensorRail pressure sensorAir temperarture sensor and MAP connections of the intake manifoldCamshaft sensor 1Camshaft sensor 2Crankshaft sensor 1Crankshaft sensor 2Gearbox temperature sensorOil pressure- and oil temperature sensorPosition of the oil filter capMounting direction of the oil filterGearbox oil filter assemblingLock wiring between oil drain plug and oil filter capPosition of the oil filter capRemoval of gearbox oil filterGearbox oil filter assemblingMounting direction of the oil filterLock wiring the oil filter cap, the proportionalpressure reducing valve and the gearbox housingCheck the oil levelGearbox oil filler screw and inspection glassLock wiring the oil filler screwCheck the oil levelGearbox oil filler screw and inspection glassLock wiring the oil filler screwFADEC read-out - Start Real Time Log FileChapter:Issue:Issue date:Page:Content:02-OM-00-02430.07.20141112

Operation & Maintenance ManualCD-135 / CD-155OM-02-02Fig. 6.28Fig. 6.29Fig. 6.30Fig. 6.31Fig. 6.32Fig. 6.33Fig. 6.34Fig. 6.35Fig. 6.36Fig. 6.37Fig. 6.38Fig. 6.39Fig. 6.40Fig. 6.41Fig. 6.42Fig. 6.43Fig. 6.44Fig. 6.45Fig. 6.46Fig. 6.47Fig. 6.48Fig. 6.49Fig. 6.50Fig. 6.51Fig. 6.52Fig. 6.53Fig. 6.54Fig. 6.55Fig. 6.56Fig. 6.57Fig. 6.58Fig. 6.59Fig. 6.60Fig. 6.61Fig. 6.62Fig. 6.63Fig. 6.64Fig. 6.65Chapter:Issue:Issue date:Page:Content:02-OM-00-02430.07.20141212FADEC read-out - Enter engine specificationsFADEC read-out - Logging function is activeFADEC read-out - Stop Real Time Log FileFADEC read-out - Choice screenFADEC read-out - Maintenance data downloadFADEC read-out - Enter engine specificationsFADEC read-out - Perform engine ground runFADEC read-out - DownloadingFADEC read-out - Choice screenFADEC read-out - Where are my data files?FADEC read-out - Clear warningsFADEC read-out - Enter passwordFADEC read-out - Enter password successfullyFADEC read-out - Hot keysOverview of the gearbox inspection pointsoil drain plug with sealing ringRemoval of gearbox oil filterMounting direction of the oil filterGearbox oil filter assemblingLock wire between the oil drain plug and the filtercapLock wiring the oil filler screwOverview of the gearbox inspection pointsRemoval of gearbox oil filterGearbox oil filter assemblingMounting direction of the oil filterLock wire between oil filter cap, proportionalpressure reducing valve and the gearbox housingLock wiring the oil drain screwLock wiring the oil filler screwExcitation battery holder (28V)Excitation battery holder (14V)Start UpdateInformation displayedUpdate progressUpdate finishedPreviously failed updateForm OneCRC checksumsFADEC Service ToolRevision no.: 6Revision date: 22.04.2016

Operation & Maintenance ManualCD-135 / CD-155OM-02-020.1List of RevisionsIssue/RevisionDateApproved ungChapterIssue 1 / Revision 1Issue 1 / Revision 2Issue 1 / Revision 3Issue 1 / Revision 4Issue 1 / Revision 5Issue 1 / Revision 6Revision no.: 6Revision date: 22.04.2016Chapter:Issue:Issue date:Page:Content:1430.07.2014110

Operation & Maintenance ManualCD-135 / CD-155OM-02-02Issue/RevisionDateApproved rtung02-OM-06-022/007.07.2010HartungChapterIssue 1 / Revision 7Issue 1 / Revision 8Issue 1 / Revision 9Issue 1 / Revision 10Issue 1 / Revision 11Issue 2 / Revision 0Chapter:Issue:Issue date:Page:Content:1430.07.2014210Revision no.: 6Revision date: 22.04.2016

Operation & Maintenance ManualCD-135 / CD-155OM-02-02ChapterIssue/RevisionDateApproved 022/407.11.2011Hartung2/719.12.2011HartungIssue 2 / Revision 1Issue 2 / Revision 2Issue 2 / Revision 3Issue 2 / Revision 4Issue 2 / Revision 5Issue 2 / Revision 6Issue 2 / Revision 702-OM-00-02Revision no.: 6Revision date: 22.04.2016Chapter:Issue:Issue date:Page:Content:1430.07.2014310

Operation & Maintenance ManualCD-135 / CD-155OM-02-02ChapterIssue/RevisionDateApproved 0.09.2013HartungIssue 2 / Revision 8Issue 2 / Revision 9Issue 2 / Revision 10Issue 3 / Revision 0Chapter:Issue:Issue date:Page:Content:1430.07.2014410Revision no.: 6Revision date: 22.04.2016

Operation & Maintenance ManualCD-135 / CD-155OM-02-02Issue/RevisionDateApproved .08.2014HartungChapterIssue 3 / Revision 1Issue 3 / Revision 2Issue 3 / Revision 3Issue 4 / Revision 0Issue 4 / Revision 1Revision no.: 6Revision date: 22.04.2016Chapter:Issue:Issue date:Page:Content:1430.07.2014510

Operation & Maintenance ManualCD-135 / CD-155OM-02-02Issue/RevisionDateApproved st - After the3rd - 6th Checklist - st - ungEngineMaintenanceChecklist - General4/202.09.2015HartungChapterIssue 4 / Revision 2Issue 4 / Revision 3Issue 4 / Revision 4Chapter:Issue:Issue date:Page:Content:1430.07.2014610Revision no.: 6Revision date: 22.04.2016

Operation & Maintenance ManualCD-135 / CD-155OM-02-02Issue/RevisionDateApproved 09.2015HartungEngineMaintenanceChecklist - e 4 / Revision 5Issue 4 / Revision 6Revision no.: 6Revision date: 22.04.2016Chapter:Issue:Issue date:Page:Content:1430.07.2014710

Operation & Maintenance ManualCD-135 / CD-155OM-02-020.2List of applicable ChaptersDocument 02Description and Dimensions ofthe Engine4-30.07.201402-OM-03-02Technical -OM-05-02Airworthiness Limitations4522.04.201602-OM-06-02Maintenance Schedules4518.09.201502-OM-07-02Emergency Procedures4-30.07.2014FOBL E8-01FOBL E8-01 Change of Hands4-30.07.2014ChecklistEngine Maintenance Checklist- After the 3rd - 6th operatinghour4-17.04.2015ChecklistEngine Maintenance Checklist- oved:D. DickC. Rudolph, MPID. Hartung, MPLThe technical information contained in t

Please report any service difficulties to the Technical Support Center at Technify Motors GmbH. See above for contact information. Note: The Operation and Maintenance Manual must be included at the time of sale of the engine / aircraft. Operation & Maintenance Manual - Issue 4 / Revision 6 . P/N: 05-7200-H200221