Diamond Aircraft DA 20-C1 Reference manual

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Diamond Aircraft Industries
OPTIONAL SERVICE BULLETIN
Model DA 20-C1
DAC1-61-01 Rev. 5
Page 1 of 9
29 November 2019
OPTIONAL SERVICE BULLETIN NO. DAC1-61-01 REV. 5
SUPERSEDES DAC1-61-01 REV. 4
I TECHNICAL DETAILS
I.1 Category
Recommended.
I.2 Airplanes Affected
Type: DA 20-C1
Serial Numbers: C0001 up to and including C0192
I.3 Time of Compliance
At owner’s discretion.
I.4 Subject
ATA code: 61-00.
I.5 Reason
This service bulletin addresses the Sensenich propeller installation.
This revision adds the use of special extended thread 7/16” attachment bolts (P/N 22-6103-00-03) as
an alternative to the AN7-47A bolts. These extended thread bolts do not require AN960-716 or
AN960-716L shim washers to ensure proper thread engagement. The extended thread bolts are
identified by the “D, A and X” letters on the head. A Part III has been added to this bulletin to provide
the procedure for replacing the AN7-47A bolts with the extended thread bolts.
PART I – Describes the procedure for the replacement of propellers with 3/8” attachment bolts with a
propeller that uses 7/16” diameter attachment bolts (AN7-47A or 22-6103-00-03). This installation
increases the clamping force of the propeller and allows torque inspection without the removal of the
forward spinner dome.
PART II – Describes the replacement of castellated nuts and cotter pins, as fitted to some aircraft,
with self-locking nuts. The installation of self-locking nuts makes torque inspection easier.
PART III – Describes the procedure for the replacement of AN7-47A attachment bolts with the 22-
6103-00-03 extended thread bolts.
I.6 Approval
Engineering data referenced or contained in this service bulletin is approved as part of the type
design.

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OPTIONAL SERVICE BULLETIN
Model DA 20-C1
DAC1-61-01 Rev. 5
Page 2 of 9
29 November 2019
Figure 1. Original configuration, Sensenich W69EK-63, 3/8” diameter attachment bolts.

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OPTIONAL SERVICE BULLETIN
Model DA 20-C1
DAC1-61-01 Rev. 5
Page 3 of 9
29 November 2019
Figure 2. Recommended configuration, Sensenich W69EK-63, W69EK-63G, or W69EK7-63GM,
7/16” diameter attachment bolts.
NOTE: the installation and maintenance procedures for the W69EK7-63G and W69EK7-63GM
propellers are the same as those for the W69EK7-63 propeller.

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OPTIONAL SERVICE BULLETIN
Model DA 20-C1
DAC1-61-01 Rev. 5
Page 4 of 9
29 November 2019
I.7 Accomplishments/Instructions
PART I - Installation of W69EK7-63, W69EK7-63G, or W69EK7-63GM Propeller:
1. Remove the engine cowlings.
2. Remove the W69EK-63 propeller as per AMM Chapter 61.
3. Remove the six bushings in the propeller flange using the removal/installation tool as shown in
Figure 3.
4. Inspect the front spinner bulkhead and engine propeller adapter flange for fretting. If the fretting
is severe and cannot be dressed out with emery cloth and re-alodined, then the parts must be
replaced.
5. Clean the bushings and the bushing bores in the propeller adapter using denatured alcohol.
6. Install the new (7/16” ID) bushings into bores using Loctite 609 and the installation tool. Ensure
the bushings are completely pulled through the propeller flange. Reference Figure 3 for these
instructions.
7. Clean the propeller adapter flange (mating surface for propeller) with de-natured alcohol.
8. Clean the propeller hub faces with de-natured alcohol.
9. Install the W69EK7-63, W69EK7-63G, or W69EK7-63GM propeller in accordance with the
Sensenich Installation Manual (Doc. W69EK7-CF Rev. F, or later). If using AN7-47A bolts, install
AN960-716 or AN960-716L shim washers as necessary under the attachment nut to ensure 1-3
threads are showing above the nut. If using 22-6103-00-03 extended thread bolts, then it is
allowable if more than 3 threads are showing; AN960-716 or AN960-716L shim washers are not
required.
10. Follow the bolt torque check procedure specified in the Sensenich Installation Manual (Doc.
W69EK7-CF Rev. F, or later).
11. Record that this Service Bulletin has been accomplished in the aircraft’s maintenance logbook.
WARNING: The hub of a wooden propeller will shrink or expand to match the ambient conditions.
Excessive hub shrinkage, especially possible during very cold and/or dry ambient conditions, can
result in the loss of propeller bolt torque (pre-load). This can allow slight movement relative to the
drive flange, which may result in damage to the propeller and/or the propeller bolts, and possibly
even the loss of the propeller. To prevent this, proper installation and periodic re-torquing in
accordance with all applicable maintenance instructions is necessary.
Under all circumstances, the inspection interval must never exceed 50 hours. Extreme changes in
ambient conditions (temperature/humidity) may require shorter inspection intervals.

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OPTIONAL SERVICE BULLETIN
Model DA 20-C1
DAC1-61-01 Rev. 5
Page 5 of 9
29 November 2019
Figure 3. Instructions for step 6.

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OPTIONAL SERVICE BULLETIN
Model DA 20-C1
DAC1-61-01 Rev. 5
Page 6 of 9
29 November 2019
PART II - Replacement of Castellated Nuts
12. Remove the engine cowlings.
13. Remove cotter pins.
14. Remove AN310-7 nuts and washers.
15. Ensure that bolt threads are clean and free from burrs.
16. Install MS9320-13 washers and MS21044N7 nuts. Install AN960-716 or AN960-716L shim
washers as necessary under the attachment nut to ensure 1-3 threads are showing above the
nut. If these shim washers are required, add the same to all bolts.
NOTE: 22-6103-00-03 extended thread bolts can be installed in place of the AN7-47 bolts. If the
extended thread bolts are sued, then it is allowable to have more than 3 threads showing above the
nut, and AN960-716 or AN960-716L shim washers are not required.
17. Follow the installation and bolt torque check procedure specified in the Sensenich Installation
Manual (Doc. W69EK7-CF Rev. F, or later).
PART III - Replacement of AN7-47A Bolts with Extended Thread Bolts
18. Remove engine cowlings.
19. Remove MS21044N7 self-locking nuts.
20. Remove the AN7-47A attachment bolts, and replace them with 22-6103-00-03 extended thread
bolts. It is allowable to have more than 3 threads showing above the nut, and AN960-716 or
AN960-716L shim washers are not required with the extended thread bolt.
21. Follow the installation and bolt torque check procedure specified in the Sensenich Installation
Manual (Doc. W69EK7-CF Rev. F, or later).
I.8 Mass (Weight) and CG
If Part I of this service bulletin has been accomplished, the aircraft weight increases 0.27 kg (0.6 lbs)
at a lever arm of -60.8 in (-1.54 m) forward of the datum.
Accomplishment of Part II has a negligible effect on the aircraft weight and balance.
Accomplishment of Part III has a negligible effect on the aircraft weight and balance.
I.9 Electrical Load Data
n.a.

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OPTIONAL SERVICE BULLETIN
Model DA 20-C1
DAC1-61-01 Rev. 5
Page 7 of 9
29 November 2019
II PLANNING INFORMATION
II.1 Material and Availability
II.2 Special Tools
Bushing removal/installation tool SPT-01-01.
II.3 Labour Effort
Approximately 2 hours will be required to accomplish Part I of this service bulletin.
This estimate is for direct labor performed by a technician, and it does not include setup, planning,
familiarization, cure time, part fabrication, or tool acquisition.
Material Part Number Description Qty
Part I
Sensenich Supplied
W69EK7-63, W69EK7-
63G, or W69EK7-
63GM
Propeller 1
Diamond Aircraft sup-
plied (kit contents)
Materials may be ordered
as Kit DAC1-61-01
AMK0.
22-6103-01-01
AN7-47A
MS21044N7
MS9320-13
22-6103-00-01
22-6103-60-00
W69EK7-CF
Bushing
Bolts (see NOTE)
Self-locking nuts
Washer
Pressure plate (7/16” bolt holes)
Backing plate (non-painted)
Propeller Installation Manual Rev F, or later
6
6
6
6
1
1
1
Diamond Aircraft, OR
Sensenich SPT-01-01 Bushing removal/installation tool (on loan tool
program). 1
NOTE: the AN7-47A bolts supplied in the materials kit may be replaced with the 22-6103-00-03 extended
thread bolts. The 22-6103-00-03 extended thread bolts are identified by the D, A, and X markings on the
head. Contact Diamond Aircraft Parts Department for these bolts.
Procure locally
Loctite 609
AN960-716
AN960-716L
Retaining compound
Shim washer
Shim washer
A/R
A/R
A/R
Part II
MS21044N7
MS9320-13
Self-locking nuts
Washer
6
6

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Diamond Aircraft Industries
OPTIONAL SERVICE BULLETIN
Model DA 20-C1
DAC1-61-01 Rev. 5
Page 8 of 9
29 November 2019
II.4 Credit
Labour Credit: a labour credit of 2 hours is available until October 31, 2002, for accomplishment of
Part I of this service bulletin.
Replacement Part Credit: contact Diamond Aircraft Customer Support for replacement part credit
information.
II.5 Reference Documents
DA 20-C1 Aircraft Maintenance Manual, document # DA201-C1. Sensenich Manual W69EK7-CF
Rev. F, or later.
III REMARKS
1. All work must be completed by the appropriate authorized personnel.
2. All work, particular that, which is not especially described in this service bulletin, must be done in
accordance with the referenced maintenance manual.
3. Completion of all work must be recorded in the logbook.
4. In case of doubt contact Diamond Aircraft Industries.
To obtain satisfactory results, procedures specified in this service bulletin must be accomplished in accordance with accepted
methods and current government regulations. Diamond Aircraft cannot be responsible for the quality of work performed in
accomplishing the requirements of this service bulletin. Diamond Aircraft reserves the right to void continued warranty
coverage in the area affected by this service bulletin if it is not incorporated.
If you no longer own the aircraft to which this service bulletin applies, please forward it to the current owner, and send the name
of the current owner to Diamond Aircraft at the address below.
Diamond Aircraft Industries Inc. 1560 Crumlin Sideroad, London, Ontario, Canada N5V 1S2
Customer Support: Phone: [phone] Fax: [phone] E-mail: [e-mail]
Technical Publications: E-mail: [e-mail]

© DAI 2019 ALL RIGHTS RESERVED, PROPRIETARY DOCUMENT
Internet: www.diamondair.com
Email: [e-mail]
Diamond Aircraft Industries
OPTIONAL SERVICE BULLETIN
Model DA 20-C1
DAC1-61-01 Rev. 5
Page 9 of 9
29 November 2019
EXECUTION REPORT TO
SERVICE BULLETIN
DAC1-61-01 REV. 5
AIRPLANE INFORMATION
Airplane Serial Number ____________________
Airplane Registration ____________________
Airplane Operator ____________________
Hours of Operation of Airplane ____________________
No. of Landings ____________________
Hours of Operation of Engine ____________________
Typical Operation of Airplane ____________________
(private, club, training, other)
_______________________________________
Date, Name, Signature
Please e-mail the completed form to [e-mail].